ELECTRICAL VEHICLE INSTALLATION

Transcription

1 ELECTRICAL VEHICLE INSTALLATION

2 BUSINESS. SIMPLIFIED. Everything we do revolves around our customers. In order to ensure that business runs smoothly, HELLA supports wholesalers as your daily business is already complicated enough. That's why we see it as our job to make this as simple as possible for you. For the aftermarket, we offer outstanding availability of goods using sophisticated logistics and first-class data management as well as targeted sales support. This speeds up and simplifies the wholesale business for greater efficiency. We support workshops throughout the entire repair process. We search proactively for new solutions to help independent workshops successfully master the growing complexity of the different models so that customer cars can "hit the road" that much faster. This is how we make your daily business run faster and more profitable.

3 CONTENTS Fuses / Circuit-breakers / Fuse holders / Fuse boxes 4. Fuses 4.. Blade fuses 4..2 Strip and screw fuses 9..3 Cartridge fuses (PAL fuses) 2..4 Other fuses 4.2 Circuit-breakers 6.3 Fuse holders 8.3. Inline fuse holders Other fuse holders 20.4 Fuse boxes 23 2 Plug-type connections Cigarette lighters and power sockets Universal plug-type connections / 2-pole plug system compliant with ISO Universal plugs, sockets, adapters and couplings pole plug system compliant with ISO pole plug system in accordance with DIN pole plug systems pin connector system i.a.w. DIN Plug-type connections 2 V pole plug system compliant with ISO pin plug system i.a.w. ISO 724 (N-type) pin plug system i.a.w. ISO 3732 (S-type) pin plug system i.a.w. ISO pole plug system compliant with NEN Plug-type connections 24 V pole plug system compliant with ISO 85 (N-type) pole plug system compliant with ISO 37 3 (S-type) pole plug system compliant with ISO ABS/EBS plug system in accordance with ISO (24 V) and ISO (2 V) Plug connectors for special vehicles in accordance with VG 96923, VG 9697 and ISO Adapter 2 V / 24 V Test plug 2 V / 24 V 87

4 CONTENTS 3. Cables Helical cables Cables (running meter) Single-wire PVC vehicle cables Multi-wire PVC vehicle cables PVC flat cables Cables Weld cables Cable connectors Crimp connector Uninsulated crimp connectors Insulated crimp connectors with shrink-on insulation (Duraseal) Insulated crimp connectors Cable end ferrules Solder connectors CWT solder connectors Solder connectors i.a.w. DIN Cable junction boxes Other cable connectors "SUPERSEAL" plug connectors DEUTSCH "DT series" plug connectors Female and male connector housings Insulation/bundling Cable straps with edge clips Cable Ties Driller Chassis cable clips Corrugated pipes Spiral bands Insulating tapes Heat shrink hoses 56

5 6 Installation accessories Battery terminals Grounding straps Hose/pipe clamps Spring band clamps Connector /pin base for bulbs Trailer connection units/voltage transformers Charge compensation device 75 7 Product range case/accessories Assortment case Product range accessories Tools Basic crimping and release tool Professional crimping and release tool Heavy Duty tool system Squeezing and crimping pliers 98 overview 200

6 Fuses / Circuit-breakers / Fuse holders / Fuse boxes. Fuses.. Blade fuses Application Blade fuses are primarily used in automotive electrical fuse systems. A distinction is made between the following:. The very common ATO standard version (up to max. 40 A) 2. The large-sized MAXI blade terminal fuse for the high-current range (up to max. 80 A) 3. The small-sized MINI blade terminal fuse for individual consumer protection (up to max. 30 A) 4. The even more space-saving low-profile MINI variant (also up to 30 A) Range advantages OEM quality in accordance with ISO requirements Compact design Easy to use Complete product range, including special variants for electric vehicles and LED fuses for expedited replacement (in the night as well) 4

7 .. Blade fuses Ampere Colour Contents Short designation ATO BLADE FUSES MINI BLADE FUSE A 5 D 3 8JS A 5 D 32 8JS A 5 D 6 8JS A 5 D 90 8JS A 5 D 7 8JS A 5 D 8 8JS A 5 D 9 8JS A 5 D 20 8JS A 5 D 2 8JS A 5 D 22 8JS A 5 D 23 8JS A 5 D 9 8JS A 5 D 33 8JS A D 28 8JS A D 29 8JS A D 69 8JS A D 88 8JS A D 70 8JS A D 7 8JS A D 72 8JS A D 73 8JS A D 74 8JS A D 75 8JS A D 76 8JS A D 89 8JS A D 30 8JS A 5 D 34 8JS A 5 D 35 8JS A 5 D 30 8JS A 5 D 3 8JS A 5 D 36 8JS A 5 D 32 8JS A 5 D 33 8JS A 5 D 34 8JS A 5 D 37 8JS A 5 D 35 8JS A D 38 8JS A D 39 8JS A D 40 8JS A D 4 8JS A D 42 8JS A D 43 8JS A D 44 8JS A D 45 8JS A D 46 8JS A D 47 8JS

8 .. Blade fuses Ampere Colour Contents Short designation 2A 3A 4A 5A 7.5 A 0 A 5 A 20 A 25 A 30 A D 233 D 234 D 235 D 236 D 237 D 238 D 239 D 240 D 24 D 242 8JS JS JS JS JS JS JS JS JS JS A 30 A 40 A A 60 A 70 A 80 A D 48 D 49 D D 5 D 52 D 53 D 54 8JS JS JS JS JS JS JS A 25 A 30 A 40 A A 60 A 70 A 80 A D 56 D 249 D 57 D 58 D 59 D 60 D 6 D 62 8JS JS JS JS JS JS JS JS A 5A 7.5 A 0 A 5 A 20 A 25 A 30 A D 94 D 95 D 96 D 97 D 98 D 99 D 200 D 20 8JS JS JS JS JS JS JS JS A 5A 7.5 A 0 A 5 A 20 A 25 A 30 A D 203 D 204 D 205 D 206 D 207 D 208 D 209 D 20 8JS JS JS JS JS JS JS JS LOW PROFILE MINI BLADE FUSES MAXI BLADE FUSES ATO BLADE FUSES WITH LED, UP TO 32 V MINI BLADE FUSES WITH LED, UP TO 32 V 6

9 .. Blade fuses Ampere Colour Contents Short designation MICRO 2 MICRO 3 5A 5 D269 8JS ,5A 5 D275 8JS A 5 D270 8JS A 5 D27 8JS A 5 D272 8JS A 5 D273 8JS A 5 D274 8JS BLADE FUSES FOR ELECTRIC VEHICLES UP TO 80 V 5A 5 D276 8JS ,5A 5 D279 8JS A 5 D277 8JS A 5 D278 8JS A 0 D 262 8JS A 0 D 26 8JS A 0 D 260 8JS A 0 D 259 8JS A 0 D 258 8JS A 0 D 257 8JS A 0 D 256 8JS A 0 D 255 8JS Description Contents Short designation FUSE GRIPPER/TESTER ATO/MINI blade terminal fuse gripper with integrated function check A 96 8PE MAXI blade fuse gripper D 225 8PE

10 .. Blade fuses Description Ampere Contents Short designation FUSE ASSORTMENT Product range with ATO fuses and 4 fuse holders (page 20) 8KV ATO product range ATO product range MINI product range MAXI product range ATO product range with LED MINI product range with LED 5 pcs. each, 5 A / 7.5 A / 0 A / 5 A / 20 A / 25 A / 30 A pc. each, 3 A / 5 A / 7.5 A / 5 A, 25 A / 30 A; 2 pcs. each, 0 A / 20 A 5 pcs. each, 2 A / 5 A / 7.5 A / 5 A, 20 A / 30 A 3 pcs. each, 4 A / 5 A / 30 A / 5 pcs. each 0 A / 5 A / 20 A x 20 A, 3 pcs. each, 30 A / 40 A / A / 60 A pc. each, 5 A / 7.5 A / 0 A / 5 A / 20 A pc. each, 5 A / 7.5 A / 0 A / 5 A / 20 A 05 D 99 8JS D 49 8JS D 263 8JS D 44 8JS D 43 8JS D 202 8JS D 2 8JS Description FUSE ASSORTMENT CASE Comprising: ATO (25 pcs. each per rated current), MINI blade terminal fuses (20 pcs. each per rated current) and a MINI/ATO blade terminal fuse tester/gripper. 8JS (quantity in reorder does not correspond with the number in the set) Description Ampere Colour Quantity in the assortment Short designation Fuses CONTENT, PRODUCT RANGE CASE, FUSES SPARE PARTS FOR REFILLING ATO blade terminal fuse MINI blade fuse 2 A 25 D 29 8JS A 25 D 69 8JS A 25 D 88 8JS A 25 D 70 8JS A 25 D 7 8JS A 25 D 72 8JS A 25 D 73 8JS A 25 D 74 8JS A 25 D 75 8JS A 25 D 76 8JS A 25 D 30 8JS A 20 D 38 8JS A 20 D 39 8JS A 20 D 40 8JS A 20 D 4 8JS A 20 D 42 8JS A 20 D 43 8JS A 20 D 44 8JS A 20 D 45 8JS A 20 D 46 8JS A 20 D 47 8JS

11 ..2 Strip and screw fuses Application Strip fuses or leaf fuses primarily comprise a punched out locking plate. In addition to the open variant without jacket material, closed types with a plastic insulating body or ceramic housing are also common. Due to the more robust design, these fuse types are mainly used to provide fuse protection for electrical systems operating at higher currents and voltages. Range advantages OEM quality to standard Various versions for a wide range of applications The CF8 main fuse is specially designed for applications at the battery terminal. Accompanying insulating nuts and terminals are included in the range. 9

12 ..2 Strip and screw fuses Ampere Colour Contents Short designation MIDI HIGH-VOLTAGE FUSES MEGA HIGH-VOLTAGE FUSES FUSE STRIP, 4.0 X.0 MM HSB FUSE STRIP, 42.0 X 2.0 MM FUSE STRIP FOR TRACKLESS BATTERY VEHICLES, 82.0 X 20.0 MM (DIN 43560, PART ) 30 A D 64 8JS A D 65 8JS A D 66 8JS A D 67 8JS A D 68 8JS A D 69 8JS A D 70 8JS A D 7 8JS A D 72 8JS A D 267 8JS A D 268 8JS A D 73 8JS A D 74 8JS A D 75 8JS A D 76 8JS A D 77 8JS A D 78 8JS A D 79 8JS A D 80 8JS A D 243 8JS A D 244 8JS A D 245 8JS A D 246 8JS A 00 8JS A 00 8JS A 00 8JS A 00 8JS A 00 8JS A 00 8JS A 00 8JS A 0 8JS A 0 8JS A 0 8JS A 0 8JS A 0 8JS A 0 8JS A 0 8JS A 0 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS

13 ..2 Strip and screw fuses Ampere Colour Contents Short designation CF 8 MAIN FUSES UP TO 58 V A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS A 8JS Ampere Contents ACCESSORIES, CF 8 MAIN FUSES Insulating nut 9MJ Battery terminal, -pin + terminal Ø 7.5 mm pin Ø 8.0 mm 8KX Battery terminal, 2-pin + terminal Ø 7.5 mm pin Ø 8.0 mm 8KX

14 ..3 Cartridge fuses (PAL fuses) Application PAL fuses (up to a maximum of 20 A) have a similar range of application to MAXI blade fuses, but unlike these they are installed primarily in Japanese vehicles. Range advantages Compact design Easy to use Complete assortment for all vehicle generations These fuse types are also available in different sizes and designs. Late-model vehicles in particular have JCASE or even the particularly space-saving, low-profile JCASE fuses fitted. 2

15 ..3 Cartridge fuses (PAL fuses) Ampere Colour Contents Short designation FEMALE AS FEMALE SMALL F 20 A D 00 8JS A D 0 8JS A D 02 8JS A D 03 8JS A D 04 8JS A D 05 8JS A D 06 8JS MALE B BENT C BENT SHORT CS FEMALE SLOT D 30 A D 07 8JS A D 2 8JS A D 3 8JS A D 08 8JS A D 4 8JS A D 09 8JS A D 0 8JS A D 5 8JS A D 6 8JS A D 7 8JS A D 8 8JS A D 9 8JS A D 20 8JS A D 8JS A D 2 8JS A D 22 8JS A D 22 8JS A D 23 8JS A D 24 8JS A D 25 8JS A D 26 8JS A D 27 8JS A D 28 8JS A D 29 8JS A D 220 8JS A D 22 8JS FEMALE SLOT E 45 A D 222 8JS A D 223 8JS A D 224 8JS

16 ..3 Cartridge fuses (PAL fuses) Ampere Colour Contents Short designation 20 A 30 A 40 A A 60 A D 23 D 24 D 25 D 26 D 27 8JS JS JS JS JS A 25 A 30 A 40 A A 60 A D 227 D 228 D 229 D 230 D 23 D 232 8JS JS JS JS JS JS A 20A 25A 30A 40A A 60A D280 D28 D282 D283 D284 D285 D286 2JS JS JS JS JS JS JS Contents Short designation 5A 8A 6 A 25 A 5A 8A 6 A 25 A 40 A D D 2 D 3 D 4 D 64 D 65 D 66 D 67 D 68 8JS JS JS JS JS JS JS JS JS A 00 D 8JS A 00 D 5 8JS A 00 D 52 8JS A 0 A 5 A 20 A 25 A 30 A D 53 D 54 D 55 D 57 D 58 D 59 8JS JS JS JS JS JS JCASE LOW PROFILE JCASE MCASE+..4 Other fuses Ampere Colour TORPEDO FUSES 6.0 X 25.0 MM (DIN 7258, PART ) GLASS TUBE FUSES, 5.0 X 20.0 MM, FAST GLASS TUBE FUSES, 6.3 X 32.0 MM, FAST 4

17 ..4 Other fuses Ampere Colour Contents Short designation GLASS TUBE AND TORPEDO FUSE PRODUCT RANGE 5.0 x 20.0 mm x 2.5 A 6.3 x 32 mm GLASS TUBE FUSE PRODUCT RANGE 3 x 0 A 3 x 20 A x 25 A 5.0 x 20.0 mm x 2.5 A Torpedo x 5 A 4 x 8 A 3 x 6 A x 25 A 8 D 48 8JS D 47 8JS

18 .2 Circuit-breakers Application Automatic fuses as well as conventional fuses provide protection from overloads and short circuits by interrupting the electrical circuit of the application. The advantage they have over a standard fuse is that they can carry out this action many times without having to be replaced every time they are tripped. An automatic or manual reset facility allows the automatic fuse to be reverted to its initial state this saves both time and money. The variant with a hand release allows the user to quickly and conveniently interrupt an electrical circuit and subsequently close it with a manual reset optimal for a large number of electrical tests as are carried out in car workshops, for example. Range advantages Compact design Easy and reliable to use Available in all common blade fuse sizes Circuit-breakers are able to distinguish between brief start-up surges and genuine overloads, so they can guarantee optimal protection without triggering unnecessarily or wasting power. 6

19 .2 Circuit-breakers Ampere Colour Contents Short designation C 0 C 02 C 03 C 04 C 05 C 06 C 07 C 08 8JS JS JS JS JS JS JS JS C 09 C 0 C C 2 C 3 C 4 C 5 C 6 C 7 8JS JS JS JS JS JS JS JS JS A C 8 8JS A C 9 8JS A C 20 8JS A C 2 8JS RESETTABLE, CONNECTIONS I.A.W. ATO FUSES 5A 7.5 A 0 A 5 A 20 A 25 A 30 A 40 A WITH HAND RELEASE, CONNECTIONS I.A.W. ATO FUSES 5A 7.5 A 0 A 5 A 20 A 25 A 30 A 35 A 40 A SELF-RESETTING, 2 BLADE TERMINAL CONNECTIONS, 6.3 X 0.8 MM 7

20 .3 Fuse holders Application The fuse holder acts as a connector between the cable and fuse link whenever setting up or converting an electrical system requires additional fuse protection against overloads (e.g. when integrating an additional consumer). Range advantages Wide assortment of products for numerous applications Practical safeguarding solutions for minor upgrades and conversions Here the range of products is at least as wide as the range of possible applications. Depending on requirements, variants can be fitted for many different fuse types including with an integrated line, cover cap or even a rubberised full seal for maximum protection against moisture. 8

21 .3. Inline fuse holders Description Load-carrying capacity Contents Short designation With cables.3 mm², splash waterprotected max. 20 A D 8 8JD With cables 3.3 mm², splash waterprotected max. 30 A D 82 8JD with.3 mm² cables max. 20 A D 83 8JD with cables 3.3 mm² max. 30 A D 84 8JD With cables 2.0 mm², splash waterprotected max. 20 A D 8 8JD With cables 3.0 mm², splash waterprotected max. 30 A D 82 8JD With protective cap, with lines 2.5 mm², splash waterprotected, butt-mounting several holders possible max. 20 A D 264 8JD With cables.5 mm², splash waterprotected max. 5 A D 265 8JD With cables 2.5 mm², splash waterprotected max. 20 A D 266 8JD With cables 0.75 mm², splash waterprotected max. 0 A D 247 8JD With cables 3.0 mm², splash waterprotected max. 30 A D 248 8JD ATO INLINE FUSE HOLDER MINI INLINE FUSE HOLDER MINI INLINE FUSE HOLDER LOW-PROFILE MINI INLINE FUSE HOLDER LOW-PROFILE MINI INLINE FUSE HOLDER 9

22 .3. Inline fuse holders Description Load-carrying capacity Contents Short designation max. 60 A D 2 8JD max. 60 A D 25 8JD For 5.0 x 20.0 mm glass tube fuses, without fuse max. 0 A at 32 V D 252 8JD For 6.3 x 32.0 mm glass tube fuses, without fuse max. 20 A at 32 V D 253 8JD JCASE INLINE FUSE HOLDERS With cables 8.3 mm², splash waterprotected LOW-PROFILE JCASE INLINE FUSE HOLDER With cables 8.3 mm², splash waterprotected INLINE FUSE HOLDER FOR GLASS TUBE FUSES.3.2 Other fuse holders Description Contents Short designation 0 I 59 8KV I 09 8KV for direct clamping to the cable 0 I 60 8KV With 2 double-spring contacts 8KW (page 0), butt-mounting several holders possible, compatible with socket housing 8JA for mini relay (see HELLA main electrics catalogue) 8JA Load-carrying capacity MAXI FUSE HOLDERS with blade terminal connections (6.3 x 0.8 mm) 20

23 .3.2 Other fuse holders Description Load-carrying capacity Contents Short designation MAXI FUSE HOLDERS MINI FUSE HOLDER MAXI FUSE HOLDERS With 2 double-spring contacts 8KW (page 0) and cover, for lines up to 2.5 mm² For lines mm², use double-spring contacts 8KW (page 0) Butt-mounting several holders possible. With protective cap, accommodates up to 4 MINI blade terminal fuses Matching JPT contacts not included (product family 8KW xxx, page 02) max. 30 A 6 D 77 8JD max. 30 A 2 D 24 8JD JD Splash water-protected, with cover, 2 screws each, contacts for cables from mm² and mm² 20 A - 60 A D 83 8JD Water-tight, with cover, seals and contacts, for cables mm² 20 A - 80 A D 84 8JD For cables mm² D 85 8JD AUXILIARY FUSE HOLDER MINI fuse holder with 4 blade fuses each of 3 A, 5 A, 7.5 A, 0 A D 92 8JD ATO fuse holder with 4 blade fuses each of 3 A, 5 A, 7.5 A, 0 A D 93 8JD

24 .3.2 Other fuse holders Description Load-carrying capacity Contents Short designation MIDI AND MEGA FUSE HOLDERS MIDI fuse holder 30 A - A D 87 8JD MEGA fuse holder 00 A - 2 A D 86 8JD MEGA fuse holder with flexible cover that permits cable feed from all directions Max. 0 A D 254 8JD JD MIDI / MEGA COMBO-FUSE HOLDERS With protective cap, for 4 x MIDI and x MEGA fuse, housing construction with additional attachment points and recesses for cable feeding FUSE HOLDER FOR TRACKLESS BATTERY VEHICLES For fuses 8JS up to -3 (page 0) D 226 8JD with fuse insert 8 A 2 0 I 04 I 55 8KV KV with fuse insert 5 A 0 8KV With fuse link 6 A 0 8KV with fuse link 25 A 0 8KV Without fuse link 0 8KV TORPEDO FUSE HOLDER FOR CABLE CROSS SECTION MM² 22

25 .4 Fuse boxes Application If a single fuse holder is not sufficient to integrate an additional device into the electrical system or several functions are to be added at the same time, it's a good idea to install a fuse box. Range advantages Wide assortment of products for numerous applications The modular set system for ATO offers a highly customisable solution Bundling the safety functions at one central point makes this clearer and easier to maintain. As for the fuse holders, there are numerous variants for every type of fuse, in different shapes, colours. sizes, contacts and protection classes. 23

26 .4 Fuse boxes The fuse box sets are modular by design, whereby the fuse box assembly can be configured individually for the application at hand. The new fin contact system allows the box to also be used for high currents: With the accompanying individual contacts rated up to 60 A and the contact busbars that are available separately, 25 A is also possible. The order set includes the housing, the insert, 6 individual contacts and, depending on the set in question, a matching cover for standard ATO fuses or the 8JS xxx or 8JS xxx automatic fuse (page 7). One coding set and contact busbars of different sizes are available as accessories. Fuse box sets from HELLA:. 8JD With standard cover 2. 8JD With tall cover 3. 8JD With open cover Fuse box set with high cover for circuit-breakers 8JS xxx. Fuse box set with open cover for circuit-breakers 8JS xxx. This is how it's done: The empty housing is fitted with contact busbars or individual contacts. The housing insert is inserted... and clicked into place. Next step: insert fuses. Put cover in place. Finished. 24

27 .4 Fuse boxes Description Pins Contents Fuse box set for ATO blade terminal fuses, each comprising a housing, insert and cover as well as 6 individual contacts 8-pin Fuse box set for 8JS xxx automatic fuse, each comprising a housing, insert and cover as well as 6 individual contacts Fuse box set for 8JS xxx automatic fuses, each comprising a housing, insert and cover as well as 6 individual contacts Short designation set 8JD pin set 8JD pin set 8JD pin 0 9MK pin 0 9MK pin 0 9MK pole 0 9MK pin 0 9MK pole 0 9MK pin 0 9MK ATO FUSE BOXES Contact rails for currents up to 25 A 25

28 .4 Fuse boxes Description Pins Contents Short designation ATO FUSE BOXES with 8 axial outputs, (6.3 x 0.8 mm), transparent cover and contact parts 4-pin 0 8JD With 8 lateral outputs (6.3 x 0.8 mm), transparent cover and contact parts 4-pin 0 8JD With 0 axial outputs (6.3 x 0.8 mm), transparent cover, for max. 5 x 30 A flat blade inserts, with 2 angle brackets 5-pole 0 8JD D 95 8JD With 0 axial solder connections (2.2 mm), transparent cover, for max. 5 x 5 A flat blade fuse inserts 5-pole 0 8JD With 0 lateral outputs (6.3 x 0.8 mm), transparent cover, for max. 5 x 30 A flat blade fuse inserts 5-pole 0 8JD with 2 axial outputs (6.3 x 0.8 mm), transparent cover and contact parts 6-pin 0 8JD With 2 lateral outputs (6.3 x 0.8 mm), transparent cover and contact parts 6-pin 0 8JD

29 .4 Fuse boxes Description Pins Contents With 24 axial connections (6.3 x 0.8 mm), transparent cover 6-pin Short designation 0 8JD MK ATO FUSE BOXES Bridge (width 5.8 mm) with 6 axial outputs (6.3 x 0.8 mm), transparent cover and contact parts 8-pin 0 8JD With 6 lateral outputs (6.3 x 0.8 mm), transparent cover and contact parts 8-pin 0 8JD with either 32 axial connections (6.3 x 0.8 mm) or 64 axial connections (2.8 x 0.8 mm), transparent cover 8-pin 0 8JD Bridge (width.5 mm) 80 9MK Coding set 4 8JB Coding set 4 8JB

30 .4 Fuse boxes Description Cover color Pins Contents Short designation. TORPEDO FUSE BOXES WITH 8 A FUSE INSERTS Screw connections for cables up to 6.0 mm² 2-pin 8JD transparent 2-pin 8JD Blade terminal connection, 6.3 x 0.8 mm² transparent 2-pin 0 8JD Screw connections for cables up to 6.0 mm² 4-pin 8JD transparent 4-pin 8JD Blade terminal connection, 6.3 x 0.8 mm² transparent 4-pin 0 8JD Screw connections for cables up to 6.0 mm² 6-pin 8JD transparent 6-pin 8JD Blade terminal connection, 6.3 x 0.8 mm² transparent 6-pin 0 8JD Screw connections for cables up to 6.0 mm² 8-pin 8JD transparent 8-pin 8JD Blade terminal connection, 6.3 x 0.8 mm² transparent 8-pin 0 8JD male blade connections 6.3 x 0.8 mm transparent 2-pin 0 8JD

31 2 Plug-type connections 2. Cigarette lighters and power sockets 2 Application Cigarette lighters and/or power sockets are absolute basic equipment in today's vehicles. In addition to conventional cigarette lighters, power sockets provide a further connection option to supply a large number of small consumers such as lamps, fans, cooler boxes, phones, laptops, portable refrigerators and coffee machines, for example. The HELLA product range offers the right socket for every application. Range advantages Easy to assemble Screw thread and clamping sleeve Optionally with light 2 V and 24 V versions available Proven technology for OEMs 29

32 2. Cigarette lighters and power sockets Description 2 Voltage max. load-carrying capacity as socket 2 V 0 A 8EZ V 5A 8EZ V 0 A 8EZ V 5A 8EZ V 8EZ V 8EZ V 8EZ V 8EZ UNIVERSAL CIGARETTE LIGHTER WITH LIGHTING Connection type: Blade terminal connection 6.3 mm, attachment via green split sleeve, installation opening: Ø 28.0 mm, control panel thickness: max. 2.5 mm ø 29 ø 23,3 47, UNIVERSAL CIGARETTE LIGHTER WITHOUT LIGHTING Connection type: Blade terminal connection 6.3 mm, attachment via spring washer, installation opening: Ø 23.5 mm, control panel thickness: max. 2.5 mm UNIVERSAL CIGARETTE LIGHTER, SAE STANDARD WITH LIGHTING Connection type: Blade terminal connection 6.3 mm, attachment via red split sleeve, installation opening: Ø 28.0 mm, control panel thickness: max. 2.0 mm Ø 27.8 UNIVERSAL CIGARETTE LIGHTER, SAE STANDARD WITHOUT LIGHTING Connection type: Blade terminal connection 6.3 mm, attachment via hexagon nut, installation opening: Ø 28.0 mm, control panel thickness: mm 53 Ø

33 2. Cigarette lighters and power sockets Description Voltage max. load-carrying capacity as socket 2 V 5 A 8JB V / 24 V 5 A 8JB V 20 A 8JB V 20 A 8JB POWER SOCKET WITH LIGHTING AND COVER Ø 22,9 Connection type: Blade terminal connection 6.3 mm, attachment via green split sleeve, installation opening: Ø 28.0 mm, control panel thickness: max. 2.5 mm with 2 V bulb installed, an additional bulb must be ordered for 24 V application. 37,5 53,3 POWER SOCKET, UNLIT, WITH COVER Ø 23,2 Connection type: Blade terminal connection 6.3 mm, attachment via green split sleeve, installation opening: Ø 28.0 mm, control panel thickness: max. 2.5 mm 37,5 53,3 POWER SOCKET WITH LIGHTING AND COVER Connection type: Blade terminal connection 6.3 mm, attachment via red split sleeve, installation opening: Ø 28.0 mm, inner diameter: 2.0 mm Ø 27,8 3

34 2. Cigarette lighters and power sockets Description 2 Voltage max. load-carrying capacity as socket 2 / 24 V 20 A 8JB / 24 V 20 A 8JB POWER SOCKET, UNLIT, WITH COVER Connection type: Blade terminal connection 6.3 mm, attachment via hexagon nut, red sleeve, installation opening: Ø 28.0 mm, inner diameter: 2.0 mm control panel thickness: mm POWER SOCKET, UNLIT Connection type: 2 blade terminal connections 6.3 mm, attachment via black hexagon nut, black sleeve, installation opening: Ø 28.0 mm, inner diameter: 2.0 mm, cover blank control panel thickness: mm

35 2.2 Universal plug-type connections / 2-pole plug system compliant with ISO Application Similar to power sockets, the proven connector system in accordance with ISO 465 provides an additional connection option to supply a large number of small consumers such as lamps, fans, cooler boxes, phones, laptops, portable refrigerators and coffee machines. Depending on the version, the connector systems can be installed inside or outside the vehicle. Universal connectors, thanks to their red front adapter, allow both systems to be used with the same connector. Here, too, the diverse HELLA product range offers the right version for almost every application. Range advantages Easy to assemble A number of different connection options (screw terminals and blade couplings) Sockets with and without cover Alloy and plastic designs available Sockets in accordance with ISO 465 available with inversepolarity protection in the form of a T-plug connection Extensions, battery monitors and adapters for final consumers in the product range 33

36 2.2. Universal plugs, sockets, adapters and couplings Description 2 Connection 2 blade terminal connections 6.3 mm 8JB JB screw terminals up to 2.5 mm² 8JA screw terminals up to 2.5 mm² 8JA screw terminals up to 2.5 mm² 8JA screw terminals up to 2.5 mm² 8JA MOUNTED SOCKET 2-pin, without cover, plastic housing Inner diameter: 2.0 mm, for universal connector Load-carrying capacity: Max. 20 A at 24 V (cable cross section 2.5 mm²) max. 5 A at 24 V (cable cross section.5 mm²) MOUNTED TRIPLE POWER SOCKET 2-pin, plastic housing Inner diameter: 2.0 mm, for universal connector Load-carrying capacity: Max. 20 A at 24 V (cable cross section 2.5 mm²) max. 5 A at 24 V (cable cross section.5 mm²) In PE bag Ø 2 SAFETY UNIVERSAL CONNECTOR WITH POSITIVELY-DRIVEN STRAIN RELIEF With integrated, replaceable 8A fuse and pulling tool Opening for 7.0 mm cable feed, load-carrying capacity: max. 8 A at 6-24 V, cable cross section at 0.75 mm² 83 In Pro-fit packaging SAFETY UNIVERSAL CONNECTOR WITH LED AND SCREWED-ON STRAIN RELIEF With integrated, replaceable 8A fuse and pulling tool 83 Opening for 7.0 mm cable feed Load-carrying capacity: max. 8 A at 6-24 V In Pro-fit packaging 34

37 2.2. Universal plugs, sockets, adapters and couplings Description Connection Load-carrying capacity: 8 A at 24 V 2 screw terminals up to 2.5 mm² 8JA Load-carrying capacity: 6 A at 24 V in folding box 2 screw terminals up to 2.5 mm² 8JA screw terminals up to 2.5 mm² 8JA screw terminals up to 2.5 mm² 8JA screw terminals up to.5 mm² 8JA screw terminals up to.5 mm² 8JA SAFETY UNIVERSAL CONNECTOR WITH SCREWED-ON STRAIN RELIEF Without fuse, with pulling tool Opening for 7.0 mm cable feed 83 UNIVERSAL ANGLE PLUG With screwed-on strain relief, with integrated, replaceable 8A fuse, continuously adjustable through 80 degrees, with sufficient space for electronics (dimensions for circuit board: 28.5 x 26.5 x.5 mm) 24 In Pro-fit packaging With screwed-on strain relief, with printed-on rocker O-I and integrated, replaceable 8 A fuse, continuously adjustable through 80 degrees With screwed-on strain relief, with integrated 7.5 A ATO blade terminal fuse and function check via LED

38 2.2. Universal plugs, sockets, adapters and couplings Description 2 Connection 4.0 m 8KA m 8KA m 8KA m 8KA mm 8KA EXTENSION CABLES For adapting standard or cigarette lighter sockets to cigarette lighter connectors Cable: 2 x 0.75 mm² Safety universal connector with integrated 8 A fuse Load-carrying capacity: max. 8 A at 24 V In PE bag FILAMENT EXTENSION CABLE For adapting standard or cigarette lighter sockets to cigarette lighter connectors Cable: 2 x 0.75 mm² Safety universal connector with integrated 8 A fuse Load-carrying capacity: max. 8 A at 24 V In PE bag ADAPTER CABLE For adapting standard sockets to cigarette lighter socket Cable: 2 x 0.75 mm² Load-carrying capacity: max. 8 A at 24 V In PE bag In Pro-fit packaging ADAPTER For adapting standard sockets to cigarette lighter socket Load-carrying capacity: max. 6 A at 2 V / 24 V In PE bag 36

39 2.2. Universal plugs, sockets, adapters and couplings Description Connection 0.2 m 8JB m 8JA m 8JA mm 8JA m 8ES ADAPTER CABLE For adapting standard or cigarette lighter sockets to 2 standard sockets Cable: 2 x 0.75 mm² Safety universal connector with integrated 8 A fuse Load-carrying capacity: max. 8 A at 24 V In PE bag TWIN COUPLING For adapting standard or cigarette lighter sockets to 2 cigarette lighter connectors Cable: 2 x 0.75 mm² Safety universal connector with integrated 6 A fuse Load-carrying capacity: max. 2 x 8 A at 24 V In PE bag In Pro-fit packaging For adapting standard or cigarette lighter sockets to 2 cigarette lighter connectors Load-carrying capacity: max. 6 A at 2 V / 24 V In PE bag BATTERY MONITOR Protects the battery from deep discharging by switching off consumers in good time for low voltage. Consumers include: Cooler boxes, seat heaters, fans and other mobile 2 V devices. Automatic activation when operating voltage reinstated Cable: 2 x 0.75 mm², suitable for standard and cigarette lighter sockets, LED function check and short circuit protection Load-carrying capacity: max. 8 A at 2 V In PE bag 37

40 pole plug system compliant with ISO 4 65 Description 2 Connection screw terminal, ground at the housing 8JB blade terminal connections 6.3 mm 8JB screw terminal, ground at the housing 8JB screw terminal, ground at the housing 8JB blade terminal connection 6.3 mm, ground to housing 8JB blade terminal connections 6.3 mm 8JB SOCKETS I.A.W. ISO 465, ALLOY HOUSING Installation opening: Ø 8.5 mm Control panel thickness: max. 7.0 mm Load-carrying capacity: max. 8 A at 24 V Standard socket 2-pin Standard socket 2-pin, with additional ground connector Standard socket 2-pin, with cover 48 In Pro-fit packaging 22 Socket 2-pin, with cover Socket 2-pin, with cover, with additional ground connector

41 pole plug system compliant with ISO 4 65 Description Connection 8JB JB JB blade terminal connections 6.3 mm 8JB Blade contact and earth sleeve 8JB SOCKETS I.A.W. ISO 465, PLASTIC HOUSING Inverse-polarity protection via T-plug connection, recommended female connector housings 8JD (0 pcs.), recommended flat receptacles 8KW (00 pcs.), installation opening: Ø 8.5 mm, control panel thickness: max. 7.0 mm, load-carrying capacity: max. 6 A at 6-24 V Socket 2-pin, without cover 2 blade terminal connections 6.3 mm 38,5 Socket 2-pin, with snap-on cover, cover does not engage 44.5 Load-carrying capacity: max. 6 A at 6-24 V 2 blade terminal connections 6.3 mm 2V 20W 44.5 Socket 2-pin, with snap-on cover (the cover remains in the open position; the engaging mechanism is released when a connection is made so that the cover automatically closes when the connector is pulled.) Load-carrying capacity: max. 6 A at 6-24 V 44.5 Socket 2-pin, waterproof i.a.w. IP 67, with captive cover mm cable 2.5 mm², exceptionally well suited to applications in boats and in engine areas Temperature range: -40 C up to +05 C 39

42 pole plug system compliant with ISO 4 65 Description 2 Socket 2-pin, with cover Connection 2 blade terminal connections 6.3 mm 8JB blade terminal connections 6.3 mm 8JB screw terminals 8JB blade terminal connections 6.3 mm 8JA blade terminal connections 6.3 mm 8JB In Pro-fit packaging 35 Socket 2-pin, with cover Clutch For realising individual extensions for supplying power to electrical devices and lamps. Load-carrying capacity: max. 6 A at 24 V 70 2 Socket 2-pin, without cover Control panel thickness: max. 3.0 mm Installation opening: Ø 23.0 mm Load-carrying capacity: max. 8 A at 6-24 V

43 pole plug system compliant with ISO 4 65 Description Connection 2 blade terminal connections 6.3 mm 8JB screw terminals 8JB screw terminals 8JB screw terminals 8JB blade terminal connections 6.3 mm 8JB blade terminal connections 6.3 mm 8JB Socket 2-pin, with cover Control panel thickness: max. 2.0 mm Installation opening: Ø 23.0 mm Load-carrying capacity: max. 8 A at 6-24 V Mounted socket 2-pin, without cover, plastic housing CuZn contacts In Pro-fit packaging 25 Mounted socket 2-pin, without cover, plastic housing, marinecompatible version 34.2 CuZn contacts nickel-plated Mounted socket 2-pin, with cover, plastic housing In Pro-fit packaging 4

44 pole plug system compliant with ISO 4 65 Description 2 Connection 2 screw terminals up to 2.5 mm² 8JA screw terminals up to 2.5 mm² 8JA screw terminals up to 2.5 mm² 8JA solder contacts 8JA PLUG COMPLIANT WITH ISO 465, PLASTIC DESIGN Connector, without strain relief Opening for cable feed: Ø 9.2 mm Load-carrying capacity: max. 8 A at 24 V In Pro-fit packaging Connector, with screwed-on strain relief Opening for cable feed: Ø 9.2 mm Load-carrying capacity: max. 8 A at 24 V Connector, with solder contacts and positively-driven strain relief Opening for cable feed: Ø 6.5 mm Load-carrying capacity: max. 8 A at 24 V 42

45 2.3 2-pole plug system in accordance with DIN Application This plug system is mainly used for charging batteries on a fire engine. Range advantages Entire range consisting of connector, socket and coupling socket Socket and coupling box with captive cover Technical data Operating temperature: -40 C to C Operating voltage: 6-42 V Amperage: max. 6 A 43

46 2.3 2-pole plug system in accordance with DIN Description 2 Connection 2 screw terminals 8JB screw terminals 8JB screw terminals 8JB screw terminals 8JA GD MK SOCKET, ALLOY, WITH CAPTIVE SCREW CAP, FORM A With seal in screw cap, with rubber base for cables Ø mm In Pro-fit packaging COUPLING SOCKET, ALLOY, WITH CAPTIVE SCREW CAP, FORM B 2 With seal in screw cap, with protective cable cover for cable Ø mm 80 ø 36 ø 40 CONNECTOR, ALLOY, FORM C With union nut, for cable Ø mm RUBBER BASE For cables Ø mm ø6 40 ø 30 ø 67 CONTACT INSERT For 2-pin connector i.a.w. DIN (HELLA : 8JA ) In PE bag 44 2 screw terminals

47 2.4 3-pole plug systems 2 Application The 3-pin connector system in accordance with DIN 9680 is used on tractors and agricultural machinery to electrically connect continuous consumers such as mowers, built-on excavators and sweepers with a max. current consumption of 25 A. This standard does not apply to electrical connections for supplying lighting equipment (see ISO 724). The 3-pin connector system without standard is used to transfer auxiliary functions between the tractor and trailer. Range advantages Easy to assemble Various different connection options (screw-on and blade terminal connection) Robust plastic housing with high mechanical rigidity Technical data Operating voltage: 6-24 V Amperage: max. 6 A 45

48 2.4 3-pole plug systems Description 2 Connection 4 x 6.3 mm / x 4.8 mm blade terminal connections 8JB x 6.3 mm / x 4.8 mm blade terminal connections 8JB x 6.3 mm / x 4.8 mm blade terminal connections 9MK x 6.3 mm / x 4.8 mm Blade terminal connections 8JA SOCKET WITH RUBBER GROMMET Black plastic version, DIN 9680, with rubber grommet Installation opening: Ø 30.0 mm Temperature range: -25 C to +75 C Waterproof in accordance with IP 54 SOCKET WITH SCREW CAP DIN 9680, with screw cap Temperature range -25 C to +75 C Waterproof i.a.w. IP 54 FEMALE CONNECTOR HOUSING For 8JB and -042 MALE CONNECTOR Black plastic version, DIN 9680, with rubber seals for cables Ø mm

49 2.4 3-pole plug systems Description Connection Black plastic version, with rubber seal in cover, base: Ø 65.0 mm (round housing) 3 screw terminals 8JB screw terminals 8JA screw terminals 8JA GD SOCKET WITH RUBBER SEAL IN COVER CONNECTOR WITH UNION NUT AND RUBBER GROMMET Black plastic version, for cable Ø mm, with union nut and rubber grommet CONNECTOR WITH CABLE GROMMET Black plastic version, for cable Ø mm, with cable grommet RUBBER BASE For cables Ø 6.8 mm 40 ø6 ø 30 ø 67 47

50 2.5 4-pin connector system i.a.w. DIN Application The 4-pole plug system compliant with DIN is use for the transfer of auxiliary functions between the tractor and the trailer. Range advantages Easy to assemble Robust plastic housing with high mechanical rigidity Load-carrying capacity Max. 6 A at 6-24 V (cable cross section.5 mm²) Max. 25 A at 6-24 V (cable cross section 2.5 mm²) 48

51 2.5 4-pin connector system i.a.w. DIN Description Connection 4 screw terminals 8JB screw terminals 8JA SOCKET 40 6 With rubber seal in cover, 90-degree cable branch-off point for cable Ø mm Operating temperature: -40 C to +85 C 59.5 MALE CONNECTOR With screwed-on strain relief, for cable Ø mm

52 2.6 Plug-type connections 2 V pole plug system compliant with ISO Application The 5-pin connector system in accordance with ISO 724 is used to transfer auxiliary functions between the tractor and the trailer. Range advantages Easy to assemble Robust plastic housing with high mechanical rigidity Load-carrying capacity Max. 6 A at 6-24 V (cable cross section.5 mm²) Max. 25 A at 6-24 V (cable cross section 2.5 mm²)

53 pole plug system compliant with ISO 7 24 Description Connection 5 screw terminals 8JB screw terminals 8JA SOCKET WITH COVER Base: Ø max mm, temperature range: -25 C to +75 C MALE CONNECTOR Screwed-on strain relief and union nut for cables up to Ø 8.0 mm,temperature range: -25 C to +75 C 5

54 pin plug system i.a.w. ISO 724 (N-type) 2 Application The 7-pin, 2 V connector system in accordance with ISO 724/ ISO 3732 is the most popular system for establishing electrical connections between the towing vehicle and trailer using the 2 V on-board electrical system. The system is primarily used for applications with average requirements. It includes a standard plug connector, type N, in accordance with ISO 724 and an auxiliary plug connector, type S, in accordance with ISO The auxiliary system is distinguished from the standard system by its white housing, contact inserts and non-interchangeable contact arrangement. Range advantages Economical system for simple applications Easy to assemble Various different connection options (screw-on and blade terminal connection) Coupling sockets available Sockets with rear fog light switch-off available Load-carrying capacity Max. 5 A at 2 V Cable cross section: max. x 2.5 mm², max. 2 x.5 mm² Permissible temperature range: -25 C to 70 C Ambient temperature 52

55 pin plug system i.a.w. ISO 724 (N-type) Assignment diagram Trailer plug fitting, 2 V/ 7-pin N-version, ISO Direction indicator, left Stop lights /L Left tail light, clearance light, marker light and licence plate light¹) 6/54 5/58R 7/58L 2/54 g 3/3 Rear fog light Earth Right tail light, clearance light, marker light and licence plate light¹) 4/R Indicator, right Contact assignment for normal plug-type connectors compliant with ISO 724, 2 V, 7-pole N Contact no. Function Cable cross section in mm² Colour of wire insulation / L Direction indicator, left.5 2 / 54g Rear fog light.5 3/3 Earth / R Indicator, right.5 5/58R¹) Right taillight, clearance light, sidelight and licence plate lights.5 6/54 Stop lights.5 7/58L¹) Left taillight, clearance light, sidelight and licence plate lights.5 ¹) The licence plate lights must be connected in such a way that none of its lamps are connected to the two contacts 5 and 7. 53

56 pin plug system i.a.w. ISO 724 (N-type) 2 Socket: Centre contact 7/58L as pin Connector: Centre contact 7/58L as sleeve Base: Ø max mm SOCKET Description Connection With cover, solid metal version, removable contact insert 7 screw terminals 8JB In Pro-fit packaging 7 screw terminals 8JB With switch-off contact for the rear fog light on the motor vehicle 7 screw terminals with auxiliary terminal 8JB With cover, solid metal version, removable contact insert 7 blade terminal connections 6.3 mm 8JB With cover, black plastic version, removable contact insert 7 blade terminal connections 6.3 mm 8JB With cover, black plastic version, removable contact insert 7 screw terminals 8JB In Pro-fit packaging 7 screw terminals 8JB With switch-off contact for the rear fog light on the motor vehicle 7 screw terminals 8JB

57 pin plug system i.a.w. ISO 724 (N-type) Description Connection 9GD GD GD screw terminals 8JA blade terminal connections 6.3 mm 8JA screw terminals 8JA screw terminals 8JA screw terminals 8JA blade terminal connections 6.3 mm 8JA SOCKET BASE For cable Ø mm, with 80 line branch-off point, suitable for the following sockets: 8JB JB JB JB JB JB For cable Ø mm, with 80 line branch-off point, suitable for the following sockets: 8JB JB RUBBER BASE For cable Ø mm, with 90 line branch-off point, suitable for the following sockets: 8JB JB JB MALE CONNECTOR Metal version, with screwed-on strain relief and rubber grommet Metal version, with screwed-on strain relief and rubber grommet, robust version Black plastic version, with screwed-on strain relief and rubber grommet In Pro-fit packaging 55

58 pin plug system i.a.w. ISO 724 (N-type) 2 COUPLING SOCKET Description Connection With cover, black plastic version, with screwed-on strain relief, suspension device and rubber grommet for 7-wire extension cables 7 screw terminals 8JB MALE CONNECTOR Black plastic version, folding version with strain relief, contact insert and union nut, included individually 7 screw terminals 8JA Industrial packaging 7 screw terminals 8JA GROMMET FOR 7-PIN CONNECTOR Compatible with , and In PE bag Ø 0.2 mm 9GD In PE bag Ø 6.2 mm 9GD In PE bag Ø 3.2 mm 9GD In PE bag Ø 2 x 6.5 mm 9GD In PE bag Ø 8.5 mm 9GD

59 pin plug system i.a.w. ISO 3732 (S-type) 2 Application The 7-pin, 2 V connector system in accordance with ISO 724/ ISO 3732 is the most popular system for establishing electrical connections between the towing vehicle and trailer using the 2 V on-board electrical system. The system is primarily used for applications with average requirements. It includes a standard plug connector, type N, in accordance with ISO 724 and an auxiliary plug connector, type S, in accordance with ISO The auxiliary system is distinguished from the standard system by its white housing, contact inserts and non-interchangeable contact arrangement. Range advantages Economical system for simple applications Easy to assemble Various different connection options (screw-on and blade terminal connection) Coupling sockets available Sockets with rear fog light switch-off available Load-carrying capacity Max. 5 A at 2 V Cable cross section: max. x 2.5 mm², max. 2 x.5 mm² Permissible temperature range: -25 C to 70 C ambient temperature 57

60 pin plug system i.a.w. ISO 3732 (S-type) 2 Pin-out trailer plug fitting 2 V/7-pole S type ISO 3732 Backup lamp¹) Power supply controlled by ignition switch Ground for circuit contact no. 6 Reserved for future applications Reserved for future applications Ground for circuit contact no. 4 Power supply (permanent plus) Contact assignment for auxiliary plug-type connectors compliant with ISO 3732, 2 V, 7-pole S Contact no. Function Cable cross section in mm² Colour of wire insulation Backup lamp¹).5 2 Reserved for future applications not prescribed No cable or blue 3 Ground for circuit contact no Power supply (permanent plus) Reserved for future applications.5 6 Power supply via the ignition switch Earth for circuit contact no ¹) The ground for this contact is traditionally contact no. 3 of the 2 V, 7-pin N plug connector in accordance with ISO

61 pin plug system i.a.w. ISO 3732 (S-type) Description Connection 7 screw terminals 8JB screw terminals 8JA screw terminals 8JB GD GD Socket: Centre contact 7/58L as sleeve Connector: Centre contact 7/ 58L as pin, base: Ø max mm SOCKET Black plastic version with light gray cover, removable contact insert Light gray plastic version, with screwed-on strain relief and rubber grommet COUPLING SOCKET 08 Black plastic version with light gray cover, with screwed-on strain relief, suspension device and rubber grommet for 7-wire extension cables 6 SOCKET BASE For cable Ø mm, with 80 branch-off point RUBBER BASE For cable Ø mm, with 90 branch-off point 59

62 pin plug system i.a.w. ISO Application The 3-pin connector system in accordance with ISO 446 was developed as the 980s drew to a close. Unlike the 7-pin system, the high number of pins makes it possible to transfer all lighting and auxiliary functions using just one connector. The system is also replacing older plug connector generations due to the benefits it offers, including with respect to water tightness, stability, contact security and ease of handling thanks to the bayonet closure. Range advantages Easy handling thanks to the bayonet closure Easy to assemble Tightness compliant with protection class IP 54K Sockets with rear fog light switch-off available Load-carrying capacity Max. 6 A at 6-24 V (cable cross section.5 mm²) Max. 25 A at 6-24 V (cable cross section 2.5 mm²) Permissible temperature range: -40 C to 85 C 60

63 pin plug system i.a.w. ISO 446 Assignment diagram Trailer plug fitting, 3-pin, ISO Power supply (permanent plus) Direction indicator, left Power supply (switched on with ignition switch) 0 Reversing light Left tail light, clearance light, marker light and licence plate light²) Stop lights Rear fog light 2 4 Indicator, right Ground (for circuit contact no. 0)¹) Right tail light, clearance light, marker light and licence plate light²) Reserved for future applications Ground (for circuit contact no. 9)¹) Ground (for circuit contact no. to 8)¹) Contact assignment for plug-type connectors compliant with ISO 446, 2 V, 3-pole Contact no. Function Cable cross section in mm² Colour of wire insulation Direction indicator, left.5 2 Rear fog light.5 3¹) Earth for contacts no. to Indicator, right.5 5²) Right taillight, clearance light, sidelight and licence plate lighting.5 6 Stop lights.5 7²) Left taillight, clearance light, sidelight and licence plate lighting.5 8 Reversing light.5 9 Power supply (permanent plus) Power supply via the ignition switch 2.5 ¹) Earth for contact no Reserved for future applications not prescribed not prescribed 3¹) Earth for contact no ¹) The 3 ground wires may not be connected to conduct electricity in the trailer. 2) The licence plate lights must be connected in such a way that none of its lamps are connected to the two contacts 5 and 7. 6

64 pin plug system i.a.w. ISO Description Connection SOCKET WITH COVER Black plastic version, with removable contact insert, rubber base and rubber seal in cover 3 screw terminals 8JB With switch-off contact for the rear fog light on the motor vehicle 49 MALE CONNECTOR screw terminals with auxiliary screw terminal 8JB In Pro-fit packaging 3 screw terminals with auxiliary screw terminal 8JB With microswitch, three-way switch left 8JB Black plastic version, with rubber seal, union nut and bayonet lock 3 screw terminals 8JA screw terminals 8JA In Pro-fit packaging 3 screw terminals 8JA Black plastic version, click version, connector cannot be re-opened after installation; includes parking socket 3 screw terminals 8JA In PE bag PARK SOCKET Black plastic version with blue cover; protects the 3-pin connector when trailer is parked 8HG

65 pole plug system compliant with NEN Application The 7+6-pole plug system for the electrical connection of traction and trailer vehicles can be used for both 7 and 3-pole applications. Range advantages Compatible with standard ISO 724 Simple and rational fitting The socket contains microswitches with a changeover function to activate the rear fog light, parking aid and/or trailer detection. Load-carrying capacity Max. 20 A (for 2.5 mm² cable) Operating temperature: -25 C to + 75 C 63

66 pole plug system compliant with NEN SOCKET Description Connection pin, black plastic version, rubber seal in cover, with microswitch Compatible with MULTICON and WeSt connectors 3 screw terminals 8JB MALE CONNECTOR 7+6-pin, black plastic version, with rubber seal and union nut for cable Ø mm Compatible with WeSt sockets. Not suitable for MULTICON sockets. 3 screw terminals 8JA

67 2.7 Plug-type connections 24 V pole plug system compliant with ISO 85 (N-type) 2 Application The 7-pin, 24 V connector system in accordance with ISO 85/ ISO 373 is currently the most popular system for establishing electrical connections between the towing vehicle and trailer or tractor and trailer in the commercial vehicle sector. The system is primarily used for applications with average requirements. It includes a standard plug connector, type N, in accordance with ISO 85 and an auxiliary plug connector, type S, in accordance with ISO 373. The auxiliary system is distinguished from the standard system by its white housing, contact inserts and non-interchangeable contact arrangement. Range advantages Economical system for simple applications Easy to assemble Various different connection options (screw-on and blade terminal connection) Housing parts in robust materials (aluminum, break-proof plastic) Load-carrying capacity Max. 20 A (for 2.5 mm² cable) Max. 5 A (for.5 mm² cable) Permissible temperature range: -25 C to 75 C 65

68 pole plug system compliant with ISO 85 (N-type) 2 Pin-out trailer plug fitting 24 V / 7-pole N-type ISO 85 3st contact /socket pin; 3st contact /plug sleeve Earth Right tail light, clearance light, marker light and licence plate light¹) Brake control for trailer 6/58R /3 7/54g 2/58L Left tail light, clearance light, marker light and licence plate light¹) 5/R 3/L Direction indicator, left 4/54 Indicator, right Stop lights Contact assignment for normal plug-type connectors compliant with ISO 85, 24 V, 7-pole N Contact no. Function Cable cross section in mm² Colour of wire insulation /3 Earth 2.5 2/58L¹) Left taillight, clearance light, sidelight and licence plate lighting.5 3/L Direction indicator, left.5 4/54 Stop lights.5 5/R Indicator, right.5 6/58R¹) Right taillight, clearance light, sidelight and licence plate lighting.5 7/54g Control trailer brake.5 ¹) The licence plate lights must be connected in such a way that none of its lamps are connected to the two contacts 2 and 6. 66

69 pole plug system compliant with ISO 85 (N-type) Description Connection 7 screw terminals 8JB blade terminal connections 6.3 mm 8JB blade terminal connections 6.3 mm (5 x 2x/2 x 3x) 8JB screw terminals 8JB blade terminal connections 6.3 mm 8JB blade terminal connections 6.3 mm (5 x 2x/2 x 3x) 8JB GD screw terminals 8JA blade terminal connections 6.3 mm 8JA screw terminals 8JA blade terminal connections 6.3 mm 8JA SOCKET, METAL VERSION With cable grommet for cable Ø mm SOCKET, PLASTIC VERSION With cable grommet for cable Ø mm CABLE GROMMET For cable Ø mm CONNECTOR, METAL VERSION, WITH HIGH-STRENGTH CABLE GLAND Inner seal for cable Ø mm SOCKET, PLASTIC VERSION With cable grommet for cable Ø mm DIN ISO SAE 3 WHT 58L 2 BLK L 3 YEL 54 4 RED R 5 GRN 58R 6 BRN ZEN 7 BLU 67

70 pole plug system compliant with ISO 37 3 (S-type) 2 Application The 7-pin, 24 V connector system in accordance with ISO 85/ ISO 373 is currently the most popular system for establishing electrical connections between the towing vehicle and trailer or tractor and trailer in the commercial vehicle sector. The system is primarily used for applications with average requirements. It includes a standard plug connector, type N, in accordance with ISO 85 and an auxiliary plug connector, type S, in accordance with ISO 373. The auxiliary system is distinguished from the standard system by its white housing, contact inserts and non-interchangeable contact arrangement. Range advantages Economical system for simple applications Easy to assemble Various different connection options (screw-on and blade terminal connection) Housing parts in robust materials (aluminum, break-proof plastic) Load-carrying capacity Max. 20 A (for 2.5 mm² cable) Max. 5 A (for.5 mm² cable) Permissible temperature range: -25 C to 75 C 68

71 pole plug system compliant with ISO 37 3 (S-type) Pin-out trailer plug fitting 24 V / 7-pole S-type ISO 373 3st contact /socket sleeve; 3st contact /plug pin 2 Earth Power supply (switched on with ignition switch) 6 2 Not assigned Rear fog light Reversing light 4 Control via earth Power supply (permanent plus) Contact assignment for auxiliary plug-type connectors compliant with ISO 373, 24 V, 7-pole S Contact no. Function Cable cross section in mm² Colour of wire insulation Earth Reserved for future applications.5 3 Reversing light.5 4 Power supply (permanent plus) Control via earth.5 6 Power supply via the ignition switch Rear fog light.5 69

72 pole plug system compliant with ISO 37 3 (S-type) Description 2 Connection 7 screw terminals 8JB blade terminal connections 6.3 mm 8JB blade terminal connections 6.3 mm (5 x 2x/2 x 3x) 8JB screw terminals 8JB blade terminal connections 6.3 mm 8JB blade terminal connections 6.3 mm (5 x 2x/2 x 3x) 8JB GD screw terminals 8JA blade terminal connections 6.3 mm 8JA screw terminals 8JA blade terminal connections 6.3 mm 8JA SOCKET, METAL VERSION With cable grommet for cable Ø mm SOCKET, PLASTIC VERSION With cable grommet for cable Ø mm CABLE GROMMET For cable Ø mm CONNECTOR, METAL VERSION WITH HIGH-STRENGTH CABLE GLAND Inner seal for cable Ø mm CONNECTOR, PLASTIC VERSION With cable grommet for cable Ø mm

73 pole plug system compliant with ISO Application The 5-pin plug system in accordance with ISO 2098 is the modern system for the transfer of lighting and auxiliary functions in 24 V vehicle electrical systems. On account of its technical advantages, such as reliable contacting and water tightness, the system is used by many leading commercial vehicle manufacturers for original equipment applications. The system is increasingly replacing the older 7-pin plug connector generations. The plug connectors are suitable for ADR/ GGVS applications. Range advantages The system meets the strict requirements for modern trailer plug connectors in accordance with ISO 409 High-grade lamella contacts with crimp connection Easy to assemble Crimp connection for OE applications Screw-type connection for spare part applications Load-carrying capacity Max. 6 A at 6-24 V (cable cross section.5 mm²) Max. 25 A at 6-24 V (cable cross section 2.5 mm²) 7

74 pole plug system compliant with ISO Pin-out trailer plug fitting 5-pole compliant with ISO Data communication CAN L Power supply (+24 V) Brake pad wear sensor Display for spring-loaded brake Reverse light, reverse lock 9 0 Direction indicator, left Brake light Data communication CAN H Right tail light, clearance light, marker light and licence plate light ¹) Indicator, right Axle lift fitting Rear fog light Left taillight, clearance light, sidelight and licence plate light¹) Ground (for circuit contacts 4 and 5) Earth (for circuit contact 3 and 5 2) Contact assignment for 5-pin plug connector in accordance with ISO Contact no. Function Cable cross section in mm² Colour of wire insulation Direction indicator, left.5 2 Indicator, right.5 3 Rear fog light.5 4 Earth for contacts 3 and ¹) Left tail light, clearance light, marker light and licence plate lights.5 6 ¹) Right tail light, clearance light, marker light and licence plate lights.5 7 Stop lights.5 8 Reversing light.5 9 Permanent power supply (+ 24 V) Sensor for brake pad wear indication.5 Display for spring-loaded brake.5 2 Axle lift.5 3 Earth for data cables 4 and CAN H.5 5 CAN L.5 ¹) The licence plate lights must be connected in such a way that none of its lamps are connected to the two contacts 5 and 6. 72

75 pole plug system compliant with ISO Description Connection Sturdy plastic design with cover, ADR/GGVS tested, with rubber seals and nickelplated contact pins, made of glass-fiber reinforced polyamide, high-strength cable gland for the cable outlet 5 screw terminals 8JB crimped/solder connections 8JB screw terminals 8JA crimped/solder connections 8JA HG MK MK SOCKET Installation opening: Ø 54.0 mm, for cable diameter: mm Contact pins: 2 x.5 mm² + 3 x 2.5 mm² MALE CONNECTOR ADR / GGVS tested, with rubber seals and nickel-plated contact bushings, made of glass fibre reinforced polyamide, mechanical strain relief, safe latching in place through non-rusting metal hoop For cable diameter: mm Contact bushings: 2 x.5 mm² + 3 x 2.5 mm² PARK SOCKET For 5-pin, 24 V connectors 8JA and -03 Installation opening: Ø 54.0 mm CRIMPED/SOLDER CONTACT PIN SET* 2 x.5 mm² + 3 x 2.5 mm², for 8JB socket CRIMPED/SOLDER CONTACT BUSHINGS SET* 2 x.5 mm² + 3 x 2.5 mm², for 8JA connector * The appropriate tool can be found on page

76 2.8 ABS/EBS plug system in accordance with ISO (24 V) and ISO (2 V) 2 Application The plug systems in accordance with ISO / ISO are used in almost all commercial vehicles with ABS / EBS systems. The plug connectors are suitable for ADR / GGVS applications. Range advantages The system meets the strict requirements for modern trailer plug connectors in accordance with ISO 409 High-grade lamella contacts with crimp connection Easy to assemble Crimp connection for OE applications Screw-type connection for spare part applications Both 2 V and 24 V versions of this plug system are available Load-carrying capacity Max. 6 A at 24 V (cable cross section.5 mm²) Max. 25 A at 24 V (cable cross section 2.5 mm²) Max. 30 A at 24 V (cable cross section mm²) 74

77 2.8 ABS/EBS plug system in accordance with ISO (24 V) and ISO (2 V) Pin-out trailer plug fitting ABS/EBS 24 V / 5/7-pole ISO Data communication, CAN L ²) 7 Solenoid control valves plus Data communication, CAN H ²) 6 2 Electronics plus Electronics minus Warning device ¹) Solenoid control valves minus Contact assignment for plug-type connectors compliant with ISO 7638-, ABS/EBS 24 V Contact no. Function Cable cross section in mm² Colour of wire insulation Solenoid valve plus 4 2 Electronics plus.5 3 Electronics minus.5 4 Solenoid valve minus 4 5 ¹) Warning device.5 6 ²) Data communication CAN H.5 7 ²) Data communication CAN L.5 ) The warning device is triggered via contact no. 5. Under normal operating conditions, this contact s circuit in the trailer is open. 2) According to ISO 992- and ISO

78 2.8 ABS/EBS plug system in accordance with ISO (24 V) and ISO (2 V) Description 2 Connection Screw connections 8JB Crimp/solder connections 8JB Screw connections 8JB Screw connections 8JA Crimp/solder connections 8JA Screw connections 8JA HG SOCKET With cover, ADR/GGVS tested, with rubber seals and nickelplated contact pins, made of glass-fiber reinforced polyamide, high-strength cable gland for the cable outlet Installation opening: Ø 54.0 mm for cable diameter: mm Contact pins: 5 x.5 mm² + 2 x 4.0 mm² + 2 x 6.0 mm² and 2 blind plugs V variant With screw connections according to ISO MALE CONNECTOR ADR /GGVS tested, with rubber seals and nickel-plated contact bushings, made of glass fiber reinforced polyamide, mechanical strain relief, safe locking in place through non-rusting metal hoop For cable diameter: mm Contact bushings: 5 x.5 mm² + 2 x 4.0 mm² + 2 x 6.0 mm² and 2 blind plugs 2 V variant With screw connections according to ISO PARK SOCKET For ABS /EBS 24 V connectors 8JA and -05 Installation opening: Ø 54.0 mm made of glass-fiber reinforced polyamide

79 2.8 ABS/EBS plug system in accordance with ISO (24 V) and ISO (2 V) Description Connection 9MK MK CRIMPED/SOLDER CONTACT PIN SET* 5 x.5 mm² + 2 x 4.0 mm² + 2 x 6.0 mm² and 2 blind plugs for 8JB socket CRIMPED/SOLDER CONTACT BUSHINGS SET* 5 x.5 mm² + 2 x 4.0 mm² + 2 x 6.0 mm² and 2 blind plugs for 8JA connector * The appropriate tool can be found on page

80 2.9 Plug connectors for special vehicles in accordance with VG 96923, VG 9697 and ISO Application This product group includes various plug connectors for special applications that are found primarily in the military sector but also increasingly in applications that involve high levels of current, safety and reliability, and ease of use. The 2-pin, 24 V system in accordance with VG is characterised by meeting very high requirements in military operations, particularly with respect to dirt and impact resistance. The 2-pin, 24 V system in accordance with VG 9697 meets similar requirements and is used for battery charging at currents of up to 0 A (short-term loads up to 0 s). The connector system in accordance with ISO 465 is used to electrically connect different consumers. Range advantages High-grade crimped/solder contacts Easy to assemble Suitable for high current loads Load-carrying capacity Rated currents: Max. 5 A (cable cross section.5 mm²) Max. 00 A (cable cross section 25.0 mm²) Max. 60 A (cable cross section 35.0 mm²) Max. 200 A (cable cross section.0 mm²) Short-term currents to 0 s: Max. 35 A (cable cross section.5 mm²) Max. 2 A (cable cross section 25.0 mm²) Max. 400 A (cable cross section 35.0 mm²) Max. 0 A (cable cross section.0 mm²) 78

81 2.9 Plug connectors for special vehicles in accordance with VG 96923, VG 9697 and ISO 465 Description Connection screw terminal, ground at the housing 8JB crimped/solder bushing contacts for cables up to.0 mm² 8JB crimped/solder bushing contacts for cables up to 35.0 mm² 8JB crimped/solder bushing contacts for cables up to 35.0 mm² 8JB crimped/solder bushing contacts for cables up to.0 mm² 8JB GD SOCKET With green cover (ISO 465 / VGV 9692), compact flush-fit version, cover color: RAL Installation opening: Ø 8.5 mm Control panel thickness: max. 7.0 mm 22 SOCKET, ALUMINUM 2-pin with green screw cap (VG , form A), seal in screw cap, additional sealing ring between thread and screw cap Permissible operating temperature: -40 C to +85 C Protection class: IP X4 (connection in plugged-in state) Contacts: CuZn, silver-plated SOCKET, PLASTIC 2-pin with black rubber cap (plug compatible with VG 9697) Permissible operating temperature: -40 C to +85 C Protection class: IP X6 with closed cap Contacts: CuZn, silver-plated In black folding box In yellow folding box Accessory grommet for 2-pin sockets: 8JB JB JB JB

82 2.9 Plug connectors for special vehicles in accordance with VG 96923, VG 9697 and ISO SOCKET, METAL Description Connection yellow, 2-pole with black rubber cap (insertion compatible with VT 96 97) 2 crimped/solder bushing contacts for cables up to.0 mm² 8JB MALE CONNECTOR 2-pin (plug compatible with VG 9697), black Permissible operating temperature: -40 C to +85 C Contacts: CuZn, silver-plated Metal design Plastic design 2 crimped/solder pin contacts for cables up to 35.0 mm² 2 crimped/solder pin contacts for cables up to 35.0 mm² 8JA JA CONNECTOR, METAL 2-pin with green threaded ring (VG 9697, form E) Permissible operating temperature: -40 C to +85 C Protection class: IP X4 (connection in plugged-in state) Contacts: CuZn, silver-plated 2 crimped/solder pin contacts for cables up to 35 mm² 2 crimped/solder pin contacts for cables up to.0 mm² 8JA JA pin with black, plastic-sheathed threaded ring (VG 9697, form E) Permissible operating temperature: -40 C to +85 C Protection class: IP X4 (connection in plugged-in state) Contacts: CuZn, silver-plated 2 crimped/solder pin contacts for cables up to 35.0 mm² 8JA

83 2.9 Plug connectors for special vehicles in accordance with VG 96923, VG 9697 and ISO 465 Description Connection 8KA solder contact sleeves 8JB solder male contacts 8JA solder contact sleeves 8JA HELICAL CONNECTION CABLE 2-pin, max. working length 4.0 m, cross section 2 x 35.0 mm², with 2 mounted connectors with threaded ring (VG 9697) Permissible operating temperature: -40 C to +85 C Rated current: 300 A (at ambient temperature of 20 C) SOCKET 2-pin with green cover (VG A - 2 S), with connection set and screw cap Permissible operating temperature: -40 C to +85 C Protection class: IP 68 Connectable cross sections: 2 x.5 mm², for cable diameter mm Contacts: CuZn, silver-plated MALE CONNECTOR 2-pin, with green cover (VG96 923) Permissible operating temperature: -40 C to +85 C Protection class: IP 54 (in plugged-in state) Connectable cross sections: 2 x.5 mm², for cable diameter 24.0 mm Contacts: CuZn, silver-plated 8

84 2.9 Plug connectors for special vehicles in accordance with VG , VG and ISO CRIMPED CONTACT BUSHING Description Connection For cables up to.0 mm², for articles: 8JB JB Crimped contact bushing.0 mm² 9MK For cables up to 35.0 mm², for articles: 8JB JB Crimped contact bushing 35.0 mm² 9MK CRIMP CONTACT PIN For cables up to.0 mm², for articles: 8JA Crimped contact pin.0 mm² 9MK For cables up to 35.0 mm², for articles: 8JA JA JA JA Crimped contact pin 35.0 mm² 9MK

85 2.0 Adapter 2 V / 24 V 2 Application Adapter from 3-pin socket (ISO 446) on towing vehicle to a 7-pin connector (ISO 724) on the trailer cable Adapter from 7-pin socket (ISO 724) on towing vehicle to a 3-pin connector (ISO 446) on the trailer cable Cable connection 7-pole (ISO 724) UK short adapter from 3-pin socket (ISO 446) on towing vehicle to two 7-pin connectors (ISO ISO 3732) on the trailer cables 24 V adapter cable from 5-pin socket (ISO 2098) on towing vehicle to two 2-pin sockets (ISO 85 and ISO 373) on the trailer Adapter cable available in two lengths, other lengths are available upon request 83

86 2.0 Adapter 2 V / 24 V 2 Description Length in mm SUPER SHORT ADAPTER From 3-pin socket (ISO 446) on towing vehicle to a 7-pin connector (ISO 724) on the trailer cable SHORT ADAPTERS Round cover in accordance with ISO 446 protects against dirt and damage, insertion aid for single-hand operation, splash water protected in accordance with IP 54, nickel-plated contacts (corrosion protection and continuously low insertion forces), low weight load of the 3-pin socket (only 99 g), load-carrying capacity: max. 6 A at 2 V JA From 3-pin socket (ISO 446) on towing vehicle to a 7-pin connector (ISO 724) on the trailer cable Load-carrying capacity: max. 6 A at 2 V 9.0 8JA In Pro-fit packaging 9.0 8JA ADAPTER From 3-pin socket (ISO 446) on towing vehicle to a 7-pin connector (ISO 724) on the trailer cable, with suspension gear to 7-pin coupling socket JA "UK" SHORT ADAPTER From 3-pin socket (ISO 446) to 2 x 7-pin connectors (ISO ISO 3732) JA

87 2.0 Adapter 2 V / 24 V Description Length in mm JA JA JA JA SHORT ADAPTERS Ø 4,2 63,3 From 3-pin socket (ISO 446) on towing vehicle to a 3-pin WeSt connector or 7-pin connector (ISO 724) on the trailer cable 06, SUPER SHORT ADAPTER From 7-pin socket (ISO 724) on towing vehicle to a 3-pin connector (ISO 446) on the trailer cable MINI SHORT ADAPTER From 7-pin socket (ISO 724) on towing vehicle to a 3-pin connector (ISO 446) on the trailer cable 00 SHORT ADAPTERS From 5-pin socket (ISO 2098) on towing vehicle to two 7-pin connectors (ISO 85 + ISO 373) on trailer made from glass fibrereinforced polyamide 85

88 2.0 Adapter 2 V / 24 V Description 2 Length in m max. 3.5 m 8JA Max. 4.0 m 8JA max. 3.5 m 8JA Max. 4.0 m 8JA ADAPTER CABLE From 5-pin socket (ISO 2098) on towing vehicle to two 7-pin sockets (ISO 85 + ISO 373) on trailer, with 5-pin plastic connector and 7-pin metal connectors Cable diameter: 8.7 mm Outside filament: Ø.0 mm Jacket: Polyurethane Folding box ADAPTER CABLE From 5-pin socket (ISO 2098) on towing vehicle to two 7-pin sockets (ISO 85 + ISO 373) on trailer, with 5-pin plastic connector and molded-on 7-pin plastic connectors 00% waterproof! (Protection class: IPX9K for the cable outlet) ø Cable diameter: 8.8 mm Outside filament: Ø 48.0 mm Jacket: Polyurethane Folding box 86

89 2. Test plug 2 V / 24 V 2 Application Test plug for 7-pin sockets (ISO 724) and 3-pin sockets (ISO 446) Test plugs for helical cables (ISO 85) Test plugs for testing ABS sockets 87

90 2. Test plug 2 V / 24 V Description 2 Length in mm 8PD PD PD PD PD TEST PLUG For testing 7-pin sockets 2 V (ISO 724), function display with LEDs, 7-pin For testing 3-pin sockets 2 V (ISO 446), function display with LEDs, 3-pin For testing 7-pin sockets in accordance with ISO 85, standard version For testing filament connection cables in accordance with ISO 85, standard version For testing ABS sockets 88

91 3. Cables 3. Helical cables 3 Application Helical cables are used for the electrical connection between traction vehicles and semi-trailers in the commercial vehicles field. Range advantages Wide range of products for all common applications Cable jacket made from polyurethane or Hytrel Extremely resistant to cold, heat and influence of the weather High resistance to oils and chemicals Very good reversed bending properties Excellent reset behaviour 7-pole connector in a choice of metal or plastic 89

92 3. Helical cables Description ISO Cable cross-section in mm² Material HELICAL CONNECTION CABLE 2 V, 7-pin, max. working length 4.0 m, with 2 screwed-on metal connectors 724, x.0 + x.5 Polyurethane 8KA Description Length in m CONNECTING CABLE 2 V "N", 7-pin, (ISO 724), jacket: PVC, cable cross sections: 6 x.0 mm² + x.5 mm², with 2 screwed-on plastic connectors 3.0 8KA In PE bag Description ISO Cable cross-section in mm² Material HELICAL CONNECTION CABLE 24 V, 7-pin, with 2 screwed-on plastic connectors With anti-kink sleeves, 4.0 m 85 N, x.0 + x.5 Polyurethane 8KA with anti-kink sleeves, 3.5 m 85 N, x.0 + x.5 Polyurethane 8KA With anti-kink sleeves, 4.0 m 373 S, x.0 + x.5 Polyurethane 8KA with anti-kink sleeves, 3.5 m 373 S, x.0 + x.5 Polyurethane 8KA V, 7-pin, max. working length 4.0 m, with 2 molded-on plastic connectors and anti-kink guard, cable outlet waterproof (IP X9K) 85 N, S, x.0 + x.5 6 x.0 + x.5 Polyurethane 8KA Polyurethane 8KA

93 3. Helical cables Description ISO Cable cross-section in mm² Material HELICAL CONNECTION CABLE 24 V 7-pin, max. working length 4.0 m, with 2 molded-on metal connectors 85 N, S, x.0 + x.5 6 x.0 + x.5 Polyurethane 8KA Polyurethane 8KA pin, max. working length 4.0 m, with 2 molded-on metal connectors, anti-kink guard in metal and suspension bracket 85 N, S, x.0 + x.5 6 x.0 + x.5 Polyurethane 8KA Polyurethane 8KA ABS HELICAL CONNECTION CABLE 24 V, 5-pin,with 2 mounted ABS connectors and anti-kink sleeves ,000 bending cycles guaranteed!* 4.0 m x x x x 4.0 Hytrel 8KA Polyurethane 8KA ,000 reversed bending operations guaranteed!* 3.5 m x x 4.0 Polyurethan 8KA EBS HELICAL CONNECTION CABLE 7-pin, with 2 mounted EBS connectors and anti-kink sleeves ,000 bending cycles guaranteed!* 4.0 m x x x x 4.0 Hytrel 8KA Polyurethane 8KA ,000 reversed 25 bending operations guaranteed!* 3.5 m * In accordance with ISO 44, at least 0,000 bending cycles are required x x 4.0 Polyurethane 8KA

94 3. Helical cables Description ISO Cable cross-section in mm² Material HELICAL CONNECTION CABLE 24 V, 5-pin, with 2 mounted plastic connectors with blue anti-kink sleeves ,000 bending cycles guaranteed!* 4.0 m x x x x 2.5 Hytrel 8KA Polyurethane 8KA ,000 reversed bending operations guaranteed!* 3.5 m x x 2.5 Polyurethane 8KA HELICAL CONNECTION CABLE 2/24 V "N", 7-pin Standard version for German road traffic regulation functions, with 2 screwed-on metal connectors 85 N, 724, x.0 + x.5 Polyurethane 8KA Cable diameter: 8.8 mm filament outer diameter: 48.0 mm * In accordance with ISO 44, at least 0,000 bending cycles are required. 92

95 3. Helical cables Description Length in m Max JA ADAPTER CABLE ø From 5-pin socket (ISO 2098) on towing vehicle to two 7-pin sockets (ISO 85 + ISO 373) on trailer, with 5-pin plastic connector and molded-on 7-pin plastic connectors 00% waterproof! (Protection class: IPX9K for the cable outlet) Cable diameter: 8.8 mm Coil outer diameter: 48.0 mm Jacket: Polyurethane 3 Max JA Max JA Max JA From 5-pin socket (ISO 2098) on towing vehicle to two 7-pin sockets (ISO 85 + ISO 373) on trailer, with 5-pin plastic connector and 7-pin metal connectors Cable diameter: 8.7 mm Filament outer diameter:.0 mm Jacket: Polyurethane 93

96 3.2 Cables (running meter) 3 Application Wherever in a vehicle electrical current has to flow from A to B you will need cables. Their precise design, size, material and implementation will depend on the voltage, current and frequency required and the environmental conditions to which the cable will be exposed. Range advantages Vehicle cables compliant with ISO 6722 Wide assortment of products for numerous applications 94

97 3.2 Cables (running meter) Codes for vehicle cables Representation of the code structure compliant with DIN : Basic code: FL⁷⁹ Special constructional features (e.g. F = flat cable) No. of wires and nominal cross-section (e.g. 2 x 0.75) Sheathing material (see insulating material) 3 Insulating material (e.g. Y = PVC) Non-extruded cladding (e.g. C = copper wire braiding) st block (basic code) 2nd block (constructional features) 3rd block (insulating material and sheathing material) FL Vehicle cable F Flat cable Y PVC R Reduced wall thickness X PVC-X (X = cross-linked) Z Multi-wire separable cable Y PUR Classification with standards (e.g. H = agreement with harmonised standards) Rated voltage (e.g. 05 = 300/0 V) Insulating material (e.g. V = PVC, soft) No. of wires and nominal cross-section of the conductors (e.g. 2 x.0) Conductor form (e.g.: F = fine-wire conductor) Constructive design elements (e.g.: H = flat version, separable cables) Sheathing materials (e.g. Q = polyurethane) st block (standard assignment) 2nd block (rated voltage) 3rd block (insulating material and sheathing material) 4th block (type of conductor) H harmonised 00/00 V V PVC, soft A non-harmonised, national 3 300/300 V 5 300/0 V R Ethylene propylene rubber or equivalent synthetic elastomer F Fine-wire conductor of a flexible cable (flexibility in accordance with EN class 5) 7 4/7 V N2 Special polychloroprene rubber mixture for jackets of weld cables i.a.w. HD 22.6 D Fine-wire conductor for weld cables i.a.w. HD

98 3.2. Single-wire PVC vehicle cables Description Cable cross-section in mm² Wire colour Metres per coil Metres per ring SINGLE-WIRE PVC VEHICLE CABLES KL KL KL KL KL KL FLY KL KL KL KL KL KL KL KL KL KL KL KL KL KL KL FLY KL KL KL KL KL KL KL KL KL KL KL KL KL KL KL KL KL KL KL KL FLY KL KL KL KL / 8KL / 8KL / 8KL / 8KL / 8KL KL KL KL KL KL FLY 2.5 8KL KL KL KL KL KL KL KL KL FLY KL KL KL KL KL FLY 6.0 8KL KL FLY 0.0 8KL KL FLY 6.0 8KL FLY KL FLY KL FLY.0 8KL

99 3.2.2 Multi-wire PVC vehicle cables Description Cable cross-section in mm² Wire colour Jacket colour Metres per coil Metres per ring MULTI-WIRE PVC VEHICLE CABLES FLYY.0 x.5 8KL KL x 2.5 8KL x x 8KL KL x 0.75 / 200 8KL x.0 / 8KL x.5 2x 25 8KL KL x.5 / 8KL x 2.5 2x 8KL x.5 / / 8KL Description Cable cross-section in mm² Wire colour Jacket colour Metres per ring MULTI-WIRE PVC VEHICLE CABLES FLYY 4.0 x 0.75 / / / 200 8KL x 0.75 / / / 200 8KL x.0 / / / 8KL x.5 / / / 8KL x.0 / / / / 8KL x.5 / / / / 8KL x 0.75 / / / / / 200 8KL x 0.75 / / / / / / 200 8KL x.0 / / / / / / 8KL x.5 / / / / / / 8KL x 0.75 / / / / / / / 00 8KL x.5 / / / / / / / 8KL x x x x x x x x 2.5 (.5) / / / / / / (2.5) (.5) / / / / / / / (2.5) / / / - / - (.5) 7x / / / (2.5) 2x / / (.5) / / / / / / / / - / - / - / - / (2.5) 3x - / / 8KL KL KL KL

100 3.2.3 PVC flat cables Description Cable cross-section in mm² Wire colour Sheath colour Metres per coil Metres per ring 3 FLAT CONDUCTOR FOR LOUDSPEAKER AND STEREOS VEHICLE FLAT CONDUCTOR XYFAZ 2.0 x 0.5 / 00 8KL XYFAZ 2.0 x 0.75 / - / 00 8KL KL XYFAZ 2.0 x 0.75 / 00 8KL XYFAZ 2.0 x.5 / - 8KL FLFYY 2.0 x 0.75 / 8KL FLFYY 2.0 x.5 / 8KL FLFYY 2.0 x.5 / 8KL FLFYY 2.0 x 2.5 / 8KL Cables Description Cable cross-section in mm² Wire colour Jacket colour Metres per ring RUBBER ELECTRIC CABLE H05 RR-F 2.0 x 0.75 / 00 8KL H05 RR-F 2.0 x.0 / 8KL H05 RR-F 2.0 x.5 / 8KL A05 RR-F 3.0 x 0.75 / / 8KL A05 RR-F 3.0 x.0 / / 8KL A05 RR-F 3.0 x.5 / / 8KL RR-F 4.0 x.5 / / / / 8KL RR-F 5.0 x.5 / / / / 8KL RR-F 7.0 x.5 / / / / / / 8KL Weld cables Description Cable cross-section in mm² Wire colour Jacket colour Metres per ring SPECIAL WELD CABLES FOR CONNECTING MECHANISED AND HAND-HELD WELDERS H0N2-D 6.0 8KL H0N2-D KL H0N2-D KL H0N2-D.0 8KL H0N2-D KL H0N2-D KL

101 4. Cable connectors 4. Crimp connector 4.. Uninsulated crimp connectors 4 Application Uninsulated crimp connectors are typically used in splash waterprotected areas of a vehicle and serve primarily as detachable system elements for electrical and mechanical connections/ branches of cables. As the years have gone by, a number of different contact systems have become established, depending on the application area and vehicle age. Range advantages OEM quality Wide assortment of products for numerous applications 99

102 4.. Uninsulated crimp connectors Materials and surface finishes Short designation Material Corrosion resistance (in air) Electrical conductivity MATERIAL OVERVIEW CuZn Brass good, better with surface treatment medium CuSn Tin bronze good, better with surface treatment low CuFe Copper-iron good, better with surface treatment good CuNi Copper-nickel good low Short designation Material Remark 4 SURFACE TREATMENT bk (bright) no surface coating, no special protection Sn Tin corrosion protection, easy to solder, provides electrical contact frsn Galvanised tin-plated lead-free corrosion protection, easy to solder, provides electrical contact Ag Silver high conductivity, provides good electrical contact Au Gold resistant to tarnishing, best contact making at low current 00

103 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation MICRO TIMER II Flat receptacle x 0.8 CuFe/Sn B 92 8KW For individual conductor seal x 0.8 CuFe/Sn B 93 8KW Blade terminals x 0.8 CuFe/Sn B 90 8KW For individual conductor seal x 0.8 CuSn/Sn B 9 8KW

104 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation MICRO TIMER II Strand insulation Silicone red 9GD Strand insulation 0.75 Silicone grey B 20 9GD Dummy plug Silicone white B 202 9GD JUNIOR TIMER x 0.8 CuZn/Sn B 75 8KW Flat receptacle with a catch spring x 0.8 CuZn/Sn B 76 8KW JUNIOR POWER TIMER Flat receptacle x 0.8 CuSn/Sn B 94 8KW For individual conductor seal x 0.8 CuSn/Sn B 95 8KW Flat receptacle x 0.8 CuSn/Sn B 26 8KW

105 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation JUNIOR POWER TIMER Blade terminal with asymmetrical steel overspring x 0.8 CuSn/Sn B 89 8KW With symmetrical steel overspring x 0.8 CuSn/Sn B 87 8KW With symmetrical steel overspring for strand insulation x 0.8 CuSn/Sn B 88 8KW Strand insulation.2-2. mm Silicone blue B 204 9GD Dummy plug Silicone natural B 203 9GD

106 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation STANDARD TIMER /5.8/ 6.8 x 0.8 CuZn/Sn B 73 8KW Flat receptacle with a catch spring /5.8/ 6.8 x 0.8 CuSn/Sn B 74 8KW STANDARD POWER TIMER /5.8/ 6.8 x 0.8 CuFe/Sn B 77 8KW Flat receptacle /5.8/ 6.8 x 0.8 CuFe/Sn B 78 8KW /5.8/ 6.8 x 0.8 CuFe/Sn B 79 8KW For individual conductor seal /5.8/ 6.8 x 0.8 CuFe/Sn B 80 8KW x 0.8 CuFe/Sn B 8 8KW Blade terminal with symmetrical steel overspring x 0.8 CuFe/Sn B 82 8KW x 0.8 CuFe/Sn B 83 8KW With symmetrical steel overspring for strand insulation x 0.8 CuFe/Sn B 84 8KW

107 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation STANDARD POWER TIMER Strand insulation Silicone white B 205 9GD Dummy plug Silicone black B 206 9GD MAXI POWER TIMER x.2 CuNi/Sn B 98 8KW Flat receptacle for strand insulation x.2 CuNi/Sn B 99 8KW x.2 CuNi/Sn B 200 8KW MAXI POWER TIMER Strand insulation mm Silicone blue B 208 9GD Strand insulation mm Silicone light blue B 209 9GD

108 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation MALE CONNECTOR-TYPE CONNECTION CIC CuZn/Sn B 59 8KW Female contact CuSn/Sn B 60 8KW CuZn/Sn B 6 8KW Male pin contact CuZn/Sn B 62 8KW PLUG CONNECTION, TYPE III FOR M SERIES CuZn/Sn B 96 8KW Female contact CuSn/Sn B 97 8KW CuZn/Sn B 85 8KW Male pin contact CuSn/Sn B 86 8KW

109 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation MALE CONNECTOR-TYPE CONNECTION CI 2 Female contact CuSn/Sn B 57 8KW Male pin contact CuZn/Sn B 7 8KW PLUG CONNECTION, MATE N LOCK Female contact CuZn/Sn B 55 8KW Male pin contact CuZn/Sn B 207 8KW

110 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation PLUG CONNECTION, UNIVERSAL, MATE N LOCK CuSn/Sn B 69 8KW Female contact CuZn/Sn B 70 8KW CuZn/Sn B 67 8KW Male pin contact CuZn/Sn B 68 8KW CABLE LUG FOR CONI ROUND MALE CONNECTOR SYSTEM Ø.6 CuZn/frSn B 70 8KW Sleeve Ø.6 CuZn/frSn B 6 8KW Ø.6 CuSn/frSn B 7 8KW Male connector Ø.6 CuZn/frSn B 7 8KW

111 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation RAM ROUND MALE CONNECTOR SYSTEM Ø 3.5 CuZn/frSn B 72 8KW Sleeve Ø 3.5 CuSn/frSn B 25 8KW Ø 3.5 CuSn/frSn B 73 8KW Male connector Ø 3.5 CuSn/frSn B 24 8KW MDK5 FLAT RECEPTACLE /4.8 x 0.8 CuSn/frSn B 76 8KW Sleeve /4.8 x 0.8 CuSn/frSn B 77 8KW

112 4.. Uninsulated crimp connectors Description Cable cross-section in mm² Connector dimensions in mm Material/ surface finish Short designation DFK 2 FLAT RECEPTACLE x 0.8 CuSn/frSn B 78 8KW Sleeve x 0.8 CuSn/frSn B 79 8KW AFK 4.8 FLAT RECEPTACLE (CLAW ROTATED 90 TO DFK) Sleeve x 0.8 CuFe/frSn B 27 8KW METRI PACK FLAT RECEPTACLE x 0.8 CuZn/Sn B 24 8KW Sleeve x 0.8 CuZn/Sn B 242 8KW

113 4.. Uninsulated crimp connectors Cable cross section in mm² Eyelet hole Ø mm Nominal size acc. to DIN Contents Short designation 3.2 (M3) B 8 8KW (M4) B 9 8KW (M5) B 20 8KW (M6) B 2 8KW (M4) B 22 8KW (M5) B 23 8KW (M6) B 24 8KW (M8) 8-6 B 25 8KW (M5) 5-0 B 26 8KW (M6) 6-0 B 27 8KW (M8) 8-0 B 28 8KW (M0) 0-0 B 29 8KW (M5) 5-6 B 30 8KW (M6) 6-6 B 3 8KW (M8) 8-6 B 32 8KW (M0) 0-6 B 33 8KW (M6) B 34 8KW (M8) B 35 8KW (M0) B 36 8KW (M6) B 37 8KW (M8) B 38 8KW (M0) B 39 8KW (M8) 8-0 B 40 8KW (M0) 0-0 B 4 8KW (M2) 2-0 B 42 8KW (M8) B 48 8KW (M0) B 49 8KW (M2) B 53 8KW (M0) B 8KW (M2) B 5 8KW (M2) B 52 8KW SOLDER-FREE TUBE CABLE LUGS, DIN > > > > > > > > > >

114 4.. Uninsulated crimp connectors Cable cross section in mm² Connector dimensions in mm Material/ surface finish Contents Short designation FLAT RECEPTACLE x 0.8 CuZn/bk 00 B 94 8KW x 0.8 CuZn/bk 00 B 5 8KW x 0.8 CuZn/Ag 00 B 92 8KW x 0.8 CuZn/bk 00 B 52 8KW x 0.8 CuZn/bk 0 8KW , x.2 CuZn/bk B 95 8KW x 0.8 CuSn/Sn 00 B 93 8KW FLAT RECEPTACLE, WITH LOCK Cable cross section in mm² Connector dimensions in mm Material/ surface finish Short designation x 0.8 CuSn/Sn B 00 8KW x 0.8 CuZn/Sn B 64 8KW x 0.8 CuZn/bk B 03 8KW x 0.8 CuZn/Ag B 243 8KW x 0.8 CuZn/Sn B 54 8KW x 0.8 CuZn/Sn 8KW ,0 6.3 x 0.8 CuZn/Ag B 04 8KW Solder pin 6.3 x 0.8 CuSn/frSn 8KW , x 0.8 CuSn/Ag B 05 8KW BLADE TERMINALS x 0.8 CuZn/bk B 85 8KW x 0.8 CuZn/Sn B 56 8KW x 0.8 CuZn/bk B 86 8KW

115 4.. Uninsulated crimp connectors Cable cross section in mm² Connector dimensions in mm Material/ surface finish Short designation BLADE TERMINAL, WITH LOCK x 0.8 CuZn/Sn B 90 8KW x 0.8 CuZn/frSn B 88 8KW x 0.8 CuZn/frSn B 57 8KW x 0.8 CuZn/Ag B 89 8KW PIGGY BACK SPADE CONNECTOR x 0.8 CuZn/bk B 58 8KW x 0.8 CuZn/Sn B 82 8KW MALE CONNECTOR DISTRIBUTOR, DOUBLE 6.3 x 0.8 CuZn/bk B 59 8KW MALE CONNECTOR DISTRIBUTOR, TRIPLE 6.3 x 0.8 CuZn/Sn B 60 8KW COUPLING x 0.8 Ø 4.2 CuZn/Sn B 23 8KW

116 4.. Uninsulated crimp connectors Description PRODUCT RANGE CASE, CRIMP CONNECTOR PRODUCT RANGE, UNINSULATED for Case Comprising: Different uninsulated connectors (quantity in reorder does not correspond with the number in the set; not all articles can be replenished) 8KW Description Cable cross section in mm² Male connector dimensions mm Quantity in the assortment Short designation 4 CONTENT, PRODUCT RANGE CASE UNINSULATED CRIMP CONNECTORS Flat receptacle with locking tag SPARE PARTS FOR REFILLING 2.8 x 0.8 B 00 8KW x 0.8 B 64 8KW x 0.8 B 03 8KW x 0.8 B 54 8KW Female spade connector with locking tag, claw across x B 05 8KW x 0.8 B 90 8KW Blade terminal with lock 6.3 x 0.8 B 88 8KW x 0.8 B 57 8KW Flat receptacle x 0.8 B 94 8KW x 0.8 B 5 8KW Flat receptacle, transverse claw x B 93 8KW Flat receptacle x 0.8 B 52 8KW x.2 B 95 8KW Blade terminals x 0.8 B 86 8KW Male connector distributor, double 6.3 x B 59 8KW Male connector distributor, triple 6.3 x B 60 8KW Piggy back spade connector x B 82 8KW Coupling, 2x 6.3 x Male spade connector, x Blade terminal, Ø 5.3 mm 6.3 x

117 4..2 Insulated crimp connectors with shrink-on insulation (Duraseal) 4 Application The insulated "Duraseal" crimp connectors have a shrinkable nylon cap with adhesive that can be used to make a waterproof connection between the cable and contact. To this end, the nylon cap is heated using a hot-air gun (or other heat source) to approx. 35 C. At this temperature, the cap material encompasses the cable with fixed handle. Other insulation solutions (e.g. heat-shrinkable plastic tubing or insulating tape) are therefore not required. Range advantages Cable connection and sealed insulation in a single integrated product Diverse product range with all common contact versions Identification colour red: Crimp connector for cable cross section mm² Identification colour blue: Crimp connector for cable cross section mm² Identification colour yellow: Crimp connector for cable cross section 4-6 mm² 5

118 4..2 Insulated crimp connectors with shrink-on insulation (Duraseal) Colour Cable cross section in mm² Connector dimensions in mm/eyelet hole Insulation material Short designation FLAT RECEPTACLE, FULLY INSULATED 2.8 x 0.5 Nylon A 6 8KW x 0.5 Nylon A 62 8KW x 0.8 Nylon A 00 8KW x 0.8 Nylon A 0 8KW x 0.8 Nylon A 63 8KW BLADE TERMINALS x 0.8 Nylon A 02 8KW x 0.8 Nylon A 03 8KW RING CONNECTOR (M4) Nylon A 04 8KW (M5) Nylon A 06 8KW (M4) Nylon A 05 8KW (M5) Nylon A 07 8KW (M6) Nylon A 09 8KW (M8) Nylon A 8KW (M0) Nylon A 54 8KW (M5) Nylon A 08 8KW (M6) Nylon A 0 8KW (M8) Nylon A 2 8KW (M0) Nylon A 55 8KW FORK CONNECTOR 4.3 (M4) Nylon A 57 8KW (M5) Nylon A 58 8KW MALE BULLET CONNECTOR Ø 4 Nylon A 65 8KW Ø 5 Nylon A 66 8KW ROUND RECEPTACLES, FULLY INSULATED Ø 4 Nylon A 67 8KW Ø 5 Nylon A 68 8KW INSULATING SPLICE Nylon A 3 8KW Nylon A 4 8KW Nylon A 5 8KW

119 4..2 Insulated crimp connectors with shrink-on insulation (Duraseal) PRODUCT RANGE CASE, CRIMP CONNECTOR PRODUCT RANGE (DURASEAL) Description for Case Comprising: Different Duraseal crimp connectors (quantity in reorder does not correspond with the number in the set) 8KW Description Cable cross section in mm² Insertion width in mm/ eyelet hole Quantity in the assortment Short designation CONTENTS OF ASSORTMENT CASE ASSORTMENT OF DURASEAL CRIMP CONNECTORS SPARE PARTS FOR REFILLING A 3 8KW Insulating splice A 4 8KW A 5 8KW Flat receptacle x A 00 8KW x A 0 8KW Blade terminals x A 02 8KW x A 03 8KW Female bullet connector Ø A 68 8KW Male bullet connector Ø A 66 8KW M5 5 A 07 8KW M6 5 A 09 8KW Ring connector M8 5 A 8KW M5 5 A 08 8KW M6 5 A 0 8KW Fork connector M4 5 A 57 8KW M5 5 A 58 8KW

120 4..3 Insulated crimp connectors 4 Application Insulated crimp connectors are crimped using a corresponding tool at the colored end to create a safe, rigid contact to the cable. The insulation material comprises either PVC (max. temperature resistance of 80 C) or nylon (max. 05 C). The insulating sleeve has a special "easy-entry" funnel shape to ensure better guidance of the cable. Range advantages Cable connection and insulation in a single integrated product Diverse product range with all common contact versions Identification colour red: Crimp connector for cable cross section mm² Identification colour blue: Crimp connector for cable cross section mm² Identification colour yellow: Crimp connector for cable cross section mm² 8

121 4..3 Insulated crimp connectors Colour Cable cross section in mm² Connector dimensions in mm Insulating material Contents in pieces Short designation FLAT RECEPTACLES x 0.5 PVC 0 A 0 8KW x 0.5 PVC 00 A 8KW x 0.5 PVC 00 A 5 8KW x 0.8 PVC 5 A 03 8KW x 0.8 PVC 00 A 52 8KW x 0.8 PVC 000 8KW x 0.5 PVC 00 A 36 8KW x 0.8 PVC 00 A 37 8KW x 0.8 PVC 5 A 04 8KW x 0.8 PVC 00 A 53 8KW x 0.8 PVC 000 8KW x 0.8 PVC A 55 8KW x 0.8 PVC A 54 8KW x 0.8 PVC 000 8KW FLAT RECEPTACLES, FULLY INSULATED BLADE TERMINALS BLADE TERMINALS, FULLY INSULATED PIGGY BACK SPADE CONNECTOR 9.5 x.2 PVC A 56 8KW x 0.8 PVC A 82 8KW x 0.8 PVC 000 8KW x 0.8 PVC 8 A 9 8KW x 0.8 PVC A 83 8KW x 0.8 PVC 000 8KW x 0.8 PVC A 73 8KW x 0.8 PVC 00 A 38 8KW x 0.8 PVC 00 A 59 8KW x 0.8 PVC 5 A 07 8KW x 0.8 PVC 00 A 60 8KW x 0.8 PVC A 39 8KW x 0.8 PVC A 40 8KW x 0.8 PVC A 4 8KW x 0.8 PVC 25 A 42 8KW For 8KV to 8KV (page 30) x 0.8 PVC A 57 8KW x 0.8 PVC A 58 8KW MALE BULLET CONNECTOR Ø 4.0 PVC 00 A 6 8KW Ø 4.0 PVC 000 8KW Ø 5.0 PVC 00 A 62 8KW Ø 5.0 PVC A 43 8KW FEMALE BULLET CONNECTORS Ø 4.0 PVC 0 A 0 8KW Ø 4.0 PVC A 63 8KW Ø 5.0 PVC A 64 8KW Ø 5.0 PVC A 44 8KW

122 4..3 Insulated crimp connectors Colour Cable cross section in mm² Eyelet in mm Insulating material Contents Short designation 3.2 (M3) 4.3 (M4) 5.3 (M5) 6.5 (M6) 8.4 (M8) 0.5 (M0) (M4) 5.3 (M5) 6.5 (M6) 6.5 (M6) 8.4 (M8) 0.5 (M0) 4.3 (M4) 5.3 (M5) 6.5 (M6) 8.4 (M8) 0.5 (M0) PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC PVC A 65 A 67 A 69 A 6 A 7 A 8 A 66 A 68 A 70 A 5 A 72 A 74 A 9 A 20 A 7 A 73 A 75 A 76 8KW KW KW KW KW KW KW KW KW KW KW KW KW KW KW KW KW KW (M3) 4.3 (M4) 5.3 (M5) 6.5 (M6) PVC PVC PVC PVC A 2 A 22 A 23 A 24 8KW KW KW KW RING CONNECTOR OPEN CONNECTOR (M4) PVC 00 A 25 8KW (M5) PVC A 77 8KW (M6) PVC 00 A 26 8KW (M5) PVC A 27 8KW (M6) PVC A 28 8KW (M8) PVC A 29 8KW (M5) PVC 00 A 78 8KW Cable cross section in mm² Connector dimensions in mm Insulating material Contents in pieces Short designation PVC PVC PVC PVC PVC PVC A 79 A 7 A 80 A 8 8KW KW KW KW KW KW ,000 00,000 PVC 0 I 8KV Colour INSULATING SPLICE CABLE CONNECTOR PRODUCT RANGE Comprising: 5 x branch cable connectors 8KV (page 30) and 5 x blade terminals, fully insulated 8KW (page 9) x 0.8

123 4..3 Insulated crimp connectors Colour Eyelet in mm Insulating material Contents in pieces Short designation 3.2 (M3) 4.3 (M4) 5.3 (M5) 6.5 (M6) 8.4 (M8) 0.5 (M0) (M4) 5.3 (M5) 6.5 (M6) 8.4 (M8) 0.5 (M0) 4.3 (M4) 5.3 (M5) 6.5 (M6) 8.4 (M8) 0.5 (M0) Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon Nylon A78 A79 A80 A8 A82 A83 A84 A85 A86 A87 A88 A89 A90 A9 A92 A93 A94 8KW KW KW KW KW KW KW KW KW KW KW KW KW KW KW KW KW (M3) 5.3 (M5) 5.3 (M5) 6.5 (M6) 5.3 (M5) 6.5 (M6) 8.4 (M8) Nylon Nylon Nylon Nylon Nylon Nylon Nylon A20 A202 A203 A204 A205 A206 A207 8KW KW KW KW KW KW KW Cable cross section in mm² Connector dimensions in mm Insulating material Contents in pieces Short designation Ø.9 Nylon 00 A98 8KW Ø.9 Nylon 00 A99 8KW Ø 2.7 Nylon A200 8KW Nylon 00 A95 8KW Nylon A96 8KW Nylon A97 8KW Cable cross section in mm² OPEN CONNECTOR Colour PIN CONNECTOR INSULATING SPLICE 2

124 4..3 Insulated crimp connectors Description for Case PRODUCT RANGE CASE, INSULATED CRIMP CONNECTORS Comprising: Different crimp connectors, one branch connector, one coupling and one pair of crimping pliers (quantity in reorder does not correspond with the number in the set) 8KW Description Cable cross section in mm² Insertion width in mm/ eyelet hole Quantity in product range Short designation 4 CONTENTS OF ASSORTMENT CASE OF INSULATED CRIMP CONNECTORS SPARE PARTS FOR REFILLING Female bullet connector Ø A 63 8KW Male bullet connector Ø A 6 8KW Flat receptacle x A 8KW x A 52 8KW Flat receptacle, fully insulated x A 82 8KW Flat receptacle x A 53 8KW Blade terminals x A 59 8KW x A 60 8KW M4 20 A 67 8KW M5 20 A 69 8KW M4 20 A 68 8KW Ring connector M5 20 A 70 8KW M6 20 A 72 8KW M5 20 A 7 8KW M6 20 A 73 8KW Insulating splice A 80 8KW Open connector M5 20 A 78 8KW Piggy back spade connector x A 58 8KW Branch cable connector 20 I 8KW Clutch 6.3 x A 84 8KW Crimping pliers 8PE

125 4..4 Cable end ferrules 4 Application Cable end sleeves avoid the need to fan out single strands of multi-wired copper cables and facilitate the process of guiding them into terminals. For this purpose, the end sleeve is pressed onto the stripped part of the cable. Depending on the tool, the pressed-on sleeve can take many different shapes. Range advantages Precise and well-fitting bundling of wire ends With insulating insertion guide Covers all standard cross-sections The range corresponds with DIN in terms of design and dimensions. The material comprises copper with a nickel-plated surface and a plastic sleeve. 23

126 4..4 Cable end ferrules Colour Cable cross section in mm² Entire length/ length of metal sleeve Contents Short designation CABLE END FERRULES /8.0 mm 00 A 45 8KW /8.0 mm 00 A 46 8KW /8.2 mm 00 A 47 8KW /8.2 mm 00 A 48 8KW /8.2 mm 00 A 49 8KW /9.0 mm A 8KW /2.0 mm 00 A 5 8KW /2.0 mm 00 A 52 8KW /2.0 mm A 53 8KW

127 4.2 Solder connectors 4.2. CWT solder connectors 4 Application In addition to the crimp connections, the solder connectors present an additional option for connecting cables. To this end, the stripped cable end is guided into the connector and then treated with preheated solder fluid. After the soldering material has cooled down, a secure, positive material connection is established. Range advantages Broad range of products for all common cable cross sections Reliable connection solutions for temperature-sensitive applications as well For temperature-sensitive applications for which traditional soldering does not represent an alternative, a shrink solder connector can be the answer. This can be heated using a hot-air gun, whereby the integrated tin solder ring melts and two lateral sealing rings coated with adhesive shrink. The connection is soldered, fully insulated and relieved from mechanical strain after the heat exposure. Suitable as a high-quality connection for individual cables or to ground coaxial cable shields. 25

128 4.2. CWT solder connectors Colour Cable cross section in mm² Ø max. insulation in mm Contents Short designation 2 x A 77 8KW x x x A 74 A 75 A 76 8KW KW KW CWT SOLDER CONNECTORS Transparent Solder connectors i.a.w. DIN 462 Cable cross section in mm² Eyelet Ø in mm Nominal size i.a.w. DIN Contents Short designation 5.3 (M5) B 29 8KW (M6) B 220 8KW (M6) 6-6 B 22 8KW (M8) 8-6 B 222 8KW (M0) 0-6 B 223 8KW (M6) B 224 8KW (M8) B 225 8KW (M0) B 226 8KW (M6) B 227 8KW (M8) B 228 8KW (M0) B 229 8KW (M2) B 230 8KW (M8) B 23 8KW (M0) B 232 8KW (M2) B 233 8KW (M8) B 234 8KW (M0) B 235 8KW (M2) B 236 8KW (M0) 0-5 B 237 8KW (M2) 2-5 B 238 8KW (M0) B 239 8KW (M2) B 240 8KW SOLDER CONNECTORS I.A.W. DIN > > > > > > > >

129 4.3 Cable junction boxes 4 Application When you have to join up a number of different multi-wire cables it is all too easy to lose track of them. In situations like this, HELLA s cable junction boxes offer a secure and easy bundling solution to keep them tidy. Its lockable fireproof design gives the individual wires the necessary protection. Range advantages Compact design Easy and reliable to use Various sizes and contact solutions 27

130 4.3 Cable junction boxes Description Protective class Dimensions in mm Pins Contents CABLE JUNCTION BOXES Cable junction box with screw connection for cables up to 6 mm² = Ø 4.3 mm IP x 73.0 x pin 8KV Cable junction box with screw connection for cables up to 6 mm² = Ø 3.5 mm IP x 73.0 x pin 8KV Cable junction box with 8 x 2 blade terminal connections (6.3 x 0.8 mm) IP x 73.0 x pin 8KV Cable junction box with 8 x 4 blade terminal connections (6.3 x 0.8 mm) IP x 73.0 x pin 8KV

131 4.3 Cable junction boxes Description Protective class Dimensions in mm Pins Contents CABLE JUNCTION BOXES Cable junction box with screw connection for cables up to 6 mm² = Ø 3.5 mm IP x 90.0 x pole 8KV Cable junction box with 8 x 4 blade terminal connections (6.3 x 0.8 mm) IP x 90.0 x pin 8KV ADR CABLE JUNCTION BOXES Cable junction box ADR-suitable with 6 x 8 and 8 x 4 blade terminal connections (6.3 x 0.8 mm) with 2 metric connections x M25, 3 x M20 and 8 x M6 IP 69K 58 x 99 x 63 6-pole 20 8KV ADR-suitable cable junction box with 6 x 8 and 8 x 4 blade terminal connections (6.3 x 0.8 mm) with 4 metric threaded connections 4 x M20 IP 69K 58 x 99 x 63 8-pin 30 8KV

132 4.4 Other cable connectors Colour Cable crosssection in mm² Contents Short designation BRANCH CABLE CONNECTOR I 52 8KV I 0 8KV I 8KV KV , I 5 8KV I 6 8KV I 62 8KV I 63 8KV PVC MALE SPADE BRANCH CONNECTOR Description/ color Dimensions Connector dimensions in mm Pins Contents Short designation Transparent 54 x 2 x x I 57 8KV CABLE CONNECTORS Transparent 28 x.5 x x 0.8 -pole 25 A 84 8KW Transparent x 20 x x pin KW Transparent With 8 x 4 blade terminal connections (6.3 x 0.8 mm) 47.8 x 28 x x pin 0 8KV x 42 x x pin 0 8KV x 40 x x 0.8 8KV Description Pins Contents Short designation INSULATING SCREW JOINTS, WITH SOLID BRASS TERMINALS For cables up to 2.5 mm² 2-pin 0 8KV For cables up to 4 mm² 2-pin 0 8KV For cables up to 0 mm² 2-pin 0 8KV For cables up to 6 mm² 2-pin 0 8KV

133 4.5 "SUPERSEAL" plug connectors 4 Application "SUPERSEAL" plug connectors comply with IEC 529 and DIN ISO 400 regulations and come with IP class 67, which offers the maximum level of water and dust proofing protection. The quality of the "SUPERSEALS" has made them popular wherever other interconnection systems reach their limits due to adverse pressure or humidity conditions. Range advantages OEM quality Reliable electrical connection Maximum protection against outside influences The appropriate tool for "SUPERSEAL" plug connectors can be found on page 95. 3

134 4.5 "SUPERSEAL" plug connectors Description Pins Contents Short designation "SUPERSEAL" PLUG HOUSING SETS 2 pin contacts each mm², socket contacts mm², 2 strand insulations each -pole 0 B 03 8KW pin contacts each mm², socket contacts mm², 4 strand insulations each, 2 blind plugs 2-pin 8 B 04 8KW pin contacts each mm², socket contacts mm², 6 strand insulations each, 4 blind plugs 3-pin 26 B 05 8KW pin contacts each mm², socket contacts mm², 8 strand insulations each, 6 blind plugs 4-pin 34 B 06 8KW

135 4.5 "SUPERSEAL" plug connectors Description Pins Contents Short designation "SUPERSEAL" PLUG HOUSING SETS 6 pin contacts each mm², socket contacts mm², 0 strand insulations each, 8 blind plugs 5-pole 42 B 07 8KW pin contacts each mm², socket contacts mm², 2 strand insulations each, 0 blind plugs 6-pin B 08 8KW "SUPERSEAL" PLUG HOUSING Male pin housing -pole 0 8JA Female connector housing -pole 0 8JA Male pin housing 2-pin 0 8JA Female connector housing 2-pin 0 8JA

136 4.5 "SUPERSEAL" plug connectors Description Pins Contents Short designation Male pin housing 3-pin 0 8JA Female connector housing 3-pin 0 8JA Male pin housing 4-pin 0 8JA Female connector housing 4-pin 0 8JA Male pin housing 5-pole 0 8JA Female connector housing 5-pole 0 8JA Male pin housing 6-pin 0 8JA Female connector housing 6-pin 0 8JA

137 4.5 "SUPERSEAL" plug connectors Cable cross-section in mm² Connector dimensions in mm Contents Short designation MALE PIN CONTACT B 43 8KW FEMALE CONTACT B 44 8KW STRAND INSULATION Ø B 45 9GD Ø B 46 9GD DUMMY PLUG B 47 9GD

138 4.5 "SUPERSEAL" plug connectors PLUG HOUSING PRODUCT RANGE CASE, "SUPERSEAL" PRODUCT RANGE Description for Case Comprising: Various "SUPERSEAL" plug housings, pin/socket contacts, strand insulations and blind plugs (quantity in reorder does not correspond with the number in the set) 8JA Description Cable cross-section in mm² Quantity in the assortment Short designation 4 CONTENTS OF ASSORTMENT CASE SUPERSEAL PLUG HOUSING ASSORTMENT SPARE PARTS FOR REFILLING Individual wire seal B 45 9GD Dummy plug 00 B 47 9GD Male pin contact B 43 8KW Female contact B 44 8KW Pin housing, -pin 5 8JA Female socket housing, -pole 5 8JA Pin housing, 2-pin 5 8JA Female socket housing, 2-pole 5 8JA Pin housing, 3-pin 5 8JA Female socket housing, 3-pole 5 8JA Pin housing, 4-pin 5 8JA Female socket housing, 4-pole 5 8JA Pin housing, 5-pin 5 8JA Female socket housing, 5-pole 5 8JA Pin housing, 6-pin 5 8JA Female socket housing, 6-pole 5 8JA

139 4.6 DEUTSCH "DT series" plug connectors 4 Application The concept of the DEUTSCH "DT series" plug connectors combines high quality materials with a connecting system characterised by both reliability and easy handling. Thanks to these properties, the product range is particularly suited to applications where maximum performance is required with a minimum number of disruptions, despite tough environmental conditions. Range advantages Environmental sealing maximum protection from external influences High impact and vibration resistance High flexibility, even under extreme temperatures Compatible with a range of cable cross-sections Housing locking mechanism with integrated click-in function 37

140 4.6 DEUTSCH "DT series" plug connectors DEUTSCH "DT" PLUG HOUSING SETS Description/colour Pins Contents DT housing each, 2-pin, DT "wedgelock" for housing, 2-pin 3 contact pins, mm² blind plug 2-pin 6 8JA DT connector each, 2-pin, DT "wedgelock" for connector, 2-pin 3 contact sleeves, mm² blind plug 2-pin 6 8JA DT housing each, 3-pin, DT "wedgelock" for housing, 3-pin 4 contact pins, mm², 2 blind plugs 3-pin 8 8JA DT connector each, 3-pin, DT "wedgelock" for connector, 3-pin 4 contact sleeves, mm², 2 blind plugs 3-pin 8 8JA DT housing each, 4-pin, DT "wedgelock" for housing, 4-pin; 5 contact pins, mm², 3 blind plugs 4-pin 0 8JA DT connector each, 4-pin, DT "wedgelock" for connector, 4-pin 5 contact sleeves, mm², 3 blind plugs 4-pin 0 8JA

141 4.6 DEUTSCH "DT series" plug connectors DEUTSCH "DT" PLUG HOUSING SETS Description/colour Pins Contents DT housing each, 6-pin, DT "wedgelock" for housing, 6-pin, 7 contact pins, mm², 5 blind plugs 6-pin 4 8JA DT connector each, 6-pin, DT "wedgelock" for connector, 6-pin 7 contact sleeves, mm² 5 blind plugs 6-pin 4 8JA DT housing each, 8-pin, coding "A", DT "wedgelock" for housing, 8-pin, 9 contact pins, mm², 7 blind plugs 8-pin 8 8JA DT connector each, 8 pin, coding "A", DT "wedgelock" for connector, 8-pin, 9 contact sleeves, mm², 7 blind plugs 8-pin 8 8JA DT housing each, 2-pin, coding "A", DT "wedgelock" for housing, 2-pin, 3 contact pins, mm², blind plugs 2-pin 26 8JA DT connector each, 2-pin, coding "A", DT "wedgelock" for connector, 2-pin, 3 contact sleeves, mm², blind plugs 2-pin 26 8JA

142 4.6 DEUTSCH "DT series" plug connectors DEUTSCH "DT" CONNECTORS AND HOUSINGS Description/colour Pins Contents DT housing 2-pin 0 8JA DT connector 2-pin 0 8JA DT "wedgelock" for housing 2-pin 0 9NB DT "wedgelock" for plug 2-pin 0 9NB DT housing 3-pin 0 8JA DT connector 3-pin 0 8JA DT "wedgelock" for housing 3-pin 0 9NB DT "wedgelock" for plug 3-pin 0 9NB DT housing 4-pin 0 8JA DT connector 4-pin 0 8JA DT "wedgelock" for housing 4-pin 0 9NB DT "wedgelock" for plug 4-pin 0 9NB DT housing 6-pin 0 8JA DT connector 6-pin 0 8JA DT "wedgelock" for housing 6-pin 0 9NB

143 4.6 DEUTSCH "DT series" plug connectors Description/colour Pins Contents DT "wedgelock" for plug 6-pin 0 9NB DT housing 8-pin, coding: "A" 0 8JA DT connector 8-pin, coding: "A" 0 8JA DT "wedgelock" for housing 8-pin 0 9NB DT "wedgelock" for plug 8-pin 0 9NB DT housing 2-pin, coding: "A" 0 8JA DT connector 2-pin, coding: "A" 0 8JA DT "wedgelock" for housing 2-pin 0 9NB DT "wedgelock" for plug 2-pin 0 9NB Description/colour Cable cross section Contents Contact sleeve 2 mm² 8KW Contact pin 2 mm² 8KW Contact sleeve mm² 8KW Contact pin mm² 8KW Dummy plug 0.5 mm² - 2 mm² 9NB

144 4.7 Female and male connector housings 4 Application Socket and connector housings offer an easy way to protect uninsulated cable connectors from external influences. The product range encompasses housings for standardised, uninsulated crimp connectors with interlock and for the CONI and Mate N lock round male connector systems. Range advantages Simple protection solution for contact systems Easy and reliable to use 42

145 4.7 Female and male connector housings FEMALE CONNECTOR HOUSING FOR HOLDING FLAT RECEPTACLES Connection Pins Contents Flat receptacle 6.3 mm -pole 0 8JD female spade connectors 6.3 mm 2-pin 0 8JD female spade connectors 6.3 mm 2-pin 0 8JD FEMALE CONNECTOR HOUSING FOR HOLDING FLAT RECEPTACLES 3 flat receptacles 6.3 mm 3-pin 0 8JD flat receptacles 6.3 mm 4-pin 0 8JD flat receptacles 6.3 mm 6-pin 0 8JD flat receptacles 6.3 mm 8-pin 0 8JD CONNECTOR HOUSING FOR HOLDING BLADE TERMINALS male spade connector 6.3 mm -pole 0 8JD male spade connectors 6.3 mm 2-pin 0 8JD male spade connectors 6.3 mm 2-pin 0 8JD

146 4.7 Female and male connector housings CONNECTOR HOUSING FOR HOLDING BLADE TERMINALS Connection Pins Contents 3 male spade connectors 6.3 mm 3-pin 0 8JD male spade connectors 6.3 mm 4-pin 0 8JD male spade connectors 6.3 mm 6-pin 0 8JD male spade connectors 6.3 mm 8-pin 0 8JD CONI ROUND MALE CONNECTOR SYSTEMS, PIN HOUSINGS 3-pin 0 8KW pin 0 8KW pin 0 8KW pole 0 8KW

147 4.7 Female and male connector housings CONI ROUND MALE CONNECTOR SYSTEMS, SOCKET HOUSINGS Connection Pins Contents 3-pin 0 8KW pin 0 8KW pin 0 8KW pole 0 8KW MATE N LOCK CONNECTOR SYSTEMS, PIN HOUSINGS 3-pin 0 8JA pin 0 8JA pin 0 8JA pole 0 8JA

148 4.7 Female and male connector housings MATE N LOCK CONNECTOR SYSTEMS, SOCKET HOUSINGS Connection Pins Contents 3-pin 0 8JA pin 0 8JA pin 0 8JA pole 0 8JA

149 5. Insulation/bundling 5. Cable straps with edge clips Sample applications: 5 Application Oftentimes more than one cable tie is required to properly fasten a bundled subharness. Our cable ties with integrated edge clips offer a quick and easy complete solution that provide a strong holding force. Range advantages Complete fastening in a single product Suitable for numerous positionings and edge thicknesses Powerful specification with OEM references They are weatherproof, flame-resistant and resistant to diluted organic acids, oils, gasoline, salt water, solvents and greases. They even offer perfect support for extremely small bundled diameters meaning that no cable lining or other attachment aids are required. 47

150 5. Cable straps with edge clips L x W in mm Profile thicknesses in mm Colour Capacity in mm Contents CABLE STRAPS WITH EDGE CLIPS x Ø HL x Ø HL x Ø HL x Ø HL x Ø HL x Ø HL x Ø HL x Ø HL

151 5.2 Cable Ties 5 Application Cable ties make it possible to quickly fasten and bundle cables, wiring harnesses and a large number of other component parts. The system, which has been around for decades and undergone little change, is just as simple as it is affordable and cost effective. Range advantages Comprehensive assortment including numerous lengths and widths In each case choose between either black or natural Additional fastening elements round off the application range 49

152 5.2 Cable Ties L x W in mm Colour Capacity in mm Contents Short designation CABLE TIES 00.0 x 2.5 Ø E 0 8HL Ø E 02 8HL x 4.8 Ø E 03 8HL Ø E 04 8HL x 3.6 Ø E 05 8HL Ø E 06 8HL x 4.8 Ø E 07 8HL Ø E 08 8HL x 2.5 Ø E 09 8HL Ø E 0 8HL x 7.6 Ø.0 00 E 8HL x 3.6 Ø E 2 8HL Ø E 3 8HL x 7.6 Ø E 4 8HL Ø E 5 8HL x 3.6 Ø E 6 8HL x 4.8 Ø E 7 8HL Ø E 8 8HL x 4.8 Ø E 9 8HL Ø E 20 8HL x 7.6 Ø E 2 8HL Ø E 22 8HL x 4.8 Ø E 23 8HL Ø E 24 8HL x 3.0 Ø 52.0 E 25 8HL x 9.0 Ø 94.0 E 26 8HL

153 5.2 Cable Ties Description Contents Short designation Cable clip for cables up to Ø 7. mm, size 25.4 x 25.4 x 0.4 mm 00 E 27 8HL Natural colour adhesive pad for sticking wiring harnesses to level, smooth, grease-free body parts and walls; for additional fixing you can use an M5 bolt; (without cable ties), size 27.7 x 27.7 x 5.7 mm 00 E 29 8HL Expansion anchor for cable ties up to 4.8 mm, hole diameter 6.5 mm, sheet thickness mm 00 E 52 8HL Expansion anchor for cable ties up to 4.8 mm, hole diameter 6.5 mm, sheet thickness mm 00 ACCESSORIES 5 E 53 8HL

154 5.3 Driller Probably the fastest way to bundle and fasten cables. Max. diameter Contents HL HL HL Description Contents Cable clip, 43 mm long 00 8HS Cable clip, 52.5 mm long 00 8HS DRILLER 5.4 Chassis cable clips For frame thicknesses of 3 to 6 mm, length of clamping foot: 2 mm, chrome-6 free CHASSIS CABLE CLIPS 5 52

155 5.5 Corrugated pipes Corrugated pipes are used to bundle cables and protect them from dynamic loads and other external influences. The slotted variant makes it easier to thread in the cable, while the closed variant offers better protection. The polyamide variant also meets ADR requirements. Usage temperature: 40 C to +40 C (briefly +60 C) Flame-resistant Halogen-free UV-resistant Nominal diameter in mm Inner diameter in mm Outer diameter in mm Material Length in m PP PP PP PP PP PP PP JR JR JR JR JR JR JR PP PP PP PP PP PP PP JR JR JR JR JR JR JR PA PA PA PA PA PA JR JR JR JR JR JR CORRUGATED PIPES, SLOTTED CORRUGATED PIPES, UNSLOTTED CORRUGATED PIPES, UNSLOTTED, ADR-SUITABLE Spiral bands Spiral strips are used for the bundling of cables, wires or hoses. The advantage over corrugated pipes is their greater flexibility, allowing cables to be routed in and out of anywhere with no difficulty. Bundle area in mm Inner diameter in mm Outer diameter in mm Filament width in mm Length in m 0, JR JR JR JR SPIRAL BANDS 53

156 5.7 Insulating tapes 5 Application Electrically insulating adhesive tape comprises non-conducting material and is compatible with a wide range of vehicle repair applications without negatively impacting the on-board electronics. Be it bundling, fastening, temporarily insulating or colour coding the tried-and-true all-purpose system always provides reliable results. Now, numerous special variants are available that target a very specific application area by design. Range advantages Diverse product range of various lengths, widths and materials Robust and reliable For numerous applications 54

157 5.7 Insulating tapes Description/ Material Colour Length in m Width in mm Thickness in mm Temperature range in C Contents to to to to to to to MJ MJ MJ MJ MJ MJ MJ to MJ to MJ to MJ PVC to MJ Self-adhering adhesive tape, tearing resistance: > 20.0 N/cm; for repairing damaged cable sheathings to +05 9MJ Thread sealing strip (Teflon tape) to XX to +25 9MJ to +05 9MJ to +05 9MJ to +80 9MJ INSULATING TAPES PVC PVC Dirt-repellent, good resistance to substances 5 Polyester fabric Rattle/chafing protection for bandaging wiring harnesses Polyester fleece Especially well-suited for repair and insulation work under unfavorable weather conditions PVC High-quality, all-purpose adhesive fitting tape for masking off, fastening and sealing PE fabric 55

158 5.8 Heat shrink hoses 5 Application Heat-shrinkable tubing are an excellent way of sealing and insulating connections and crimp contacts or repairing damaged cable harnesses. Their wide range of colours means that they are also suitable for bundling and marking purposes. A variety of shrinkage factors are available, with or without adhesive pre-applied to the inner surface. Range advantages Different lengths, diameters and shrink ratios Wide range of applications Self-extinguishing 56

159 5.8 Heat shrink hoses Shrink rate Colour Length in m Diameter in mm Minimum shrinkage temperature in C Temperature range in C Contents Ø 25.4 Ø 9. Ø 9.5 Ø 2.7 Ø 6.4 Ø 4.8 Ø 3.2 Ø to to to to to to to to +25 9MJ MJ MJ MJ MJ MJ MJ MJ to to to to to to to MJ MJ MJ MJ MJ MJ MJ HEAT-SHRINKABLE PLASTIC TUBING, ON ROLL 2: HEAT-SHRINKABLE PLASTIC TUBING SECTIONS, WITH INSIDE ADHESIVE : Colour Ø 3.0 Ø 4.8 Ø 6.0 Ø 9.0 Ø 2.0 Ø 9.0 Ø 24.0 Length in mm Diameter in mm Temperature range in C Contents HEAT-SHRINKABLE PLASTIC TUBING SETS, SHRINK RATE 2 : 20x each / / to MJ x each /transparent to MJ x each / / to MJ x each /transparent to MJ x each / / to MJ x each /transparent to MJ x each / / to MJ x each /transparent to MJ x each / / / /transparent to MJ x each / / / /transparent to MJ x each /transparent to MJ x each to MJ x each, 9., to MJ x / / / /transparent 5 57

160 5.8 Heat shrink hoses Description for Case PRODUCT RANGE CASE, HEAT-SHRINKABLE PLASTIC TUBING Comprising: Various heat-shrinkable plastic tubes, shrink rate 2 :, operating temperature -55 C to +25 C, flame-retardant and self-extinguishing, UL224, shrinkage temperature min. 70 C 9MJ Colour Length in mm Diameter in mm Quantity in the assortment CONTENTS OF PRODUCT RANGE CASE FOR HEAT-SHRINKABLE PLASTIC TUBING SPARE PARTS FOR REFILLING 20x each / / MJ x each /transparent MJ x each / / MJ x each /transparent MJ x each / / MJ x each /transparent MJ x each / / MJ x each /transparent MJ x each / / / /transparent MJ x each / / / /transparent MJ x each /transparent MJ x each / / / /transparent MJ x x each, 9., MJ

161 6 Installation accessories 6. Battery terminals Application Whether as a replacement or an OEM original component - the high material hardness and corrosion resistance of HELLA s universal terminals will give you optimum service. The programme is strictly geared to the agreed standards for battery terminals. Range advantages Assortment closely based on DIN 7233 Wide variety of variants permit them to be used in almost any installation space 6 59

162 6. Battery terminals Description +/ DIN + left Based on DIN 7233 Contents 8KX KX KX KX KX KX KX KX BATTERY TERMINALS Form A, for cables up to 70.0 mm², pin Ø 7.5 mm 6 Form B, for cables up to 70.0 mm², pin Ø 5.9 mm right Form C, for cables up to 70.0 mm², pin Ø 7.5 mm + right Form D, for cables up to 70.0 mm², pin Ø 5.9 mm left Form E, for cables from mm² with light cable connection, pin Ø 7.5 mm + left DIN KX Form E, for cables from mm² without light cable connection, pin Ø 7.5 mm + left DIN KX Form F, for cables from mm² without light cable connection, pin Ø 5.9 mm right DIN KX Based on DIN 7233 Based on DIN 7233 Based on DIN 7233 For cables from mm² Pole Ø 7.5 mm + terminal 0 8KX Pole Ø 5.9 mm - terminal 0 8KX terminal 0 8KX terminal 0 8KX With screw M 2 x.75, pin Ø 7.5 mm + terminal 0 8KX With screw M 0 x.5, pin Ø 5.9 mm - terminal 0 8KX For cables from mm² Pin Ø 7.5 mm with light cable connection Pin Ø 5.9 mm without light cable connection For cables from mm² 60

163 6. Battery terminals Description +/ DIN Contents + terminal 0 8KX terminal 0 8KX terminal 0 8KX KX FORD BATTERY TERMINAL QUICKLOCK BATTERY POLE CLAMP STARTER CABLE WITH BATTERY TERMINAL AND M8 RING TONGUE Cable cross section: 25.0 mm², mm long, pin Ø 7.5 mm + terminal 6 6

164 6.2 Grounding straps 6 Application The highly flexible electrical conductors have already been used for decades in a range of electrical vehicle applications. As the name implies, applications such as terminating/grounding EMC disturbances or static charges are involved. In this context, the ground strap must reliably withstand high amperages such as those that can occur between the starter and battery. If the electrical system is malfunctioning, a defective or nonexistent ground strap can be the cause. Range advantages Designs optimised for the respective application area Dense woven structure enables reliable discharging of currents Sustainable specification with lead-free dip soldering process 62

165 6.2 Grounding straps Description Cable cross-section in mm² Loadcarrying capacity Length in mm Contents ENGINE EARTHING STRAPS 5 8KX A KX Made from highly flexible copper braiding, punch Ø 0.5 mm 2 5 8KX KX A 2 5 8KX KX SUPPRESSOR EARTHING STRAPS Made from highly flexible copper braiding, punch Ø 8.5 mm A KX KX KX KX BATTERY EARTHING STRAPS KX KX Made from highly flexible copper braiding, punch Ø.0 mm, terminal post 5.9 mm A KX KX KX KX KX

166 6.3 Hose/pipe clamps 6 Application Hose and pipe clamps are typical fastening elements for liquid line mechanisms. Our universal hose clamps are particularly well suited for applications that involve high mechanical loads due to their high tensile strength, high breaking torque and uniform force distribution. All configurations are available in different alloy variants. Range advantages Strong, durable attachment solution for fluid systems Wide ranging assortment including all the usual sizes for automobiles Hose clamps compliant with DIN

167 6.3 Hose/pipe clamps Description Clamping range for Ø in mm Band width in mm Contents HOSE CLAMPS HK In insert magazine, band and housing in stainless steel, zinc-coated steel screw The insert magazine system is a flexible and compact storage solution. The individual elements can be combined as required HK HK HK HK HK For gasoline lines, band and housing in stainless steel, zinc-coated steel screw HK Band and housing in stainless steel, zinc-coated steel screw All parts in zinc-coated steel HK HK HK HK HK HK HK HK HK HK HK HK HK HK HK HK HK HK HK HK HK HK Band and housing in stainless steel, zinc-coated steel screw All parts in zinc-coated steel HK HK HK HK HK HK HK HK HK HK HK HK HK HK

168 6.3 Hose/pipe clamps Description Inner diameter for Ø in mm Band width in mm Surface finish Contents galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 00 8HS galvanised 8HS galvanised 8HS galvanised 8HS galvanised 8HS galvanised 25 8HS galvanised 25 8HS PIPE CLAMPS 2 W 5 W 6 20 W 66

169 6.4 Spring band clamps Application Unlike standard hose clamps, spring bracket clamps (SBCs) have a flexible holding mechanism. This greatly increases their service life for frequent temperature fluctuations in the application area (e.g. for air or fuel circuits). When the fluid system expands in diameter as a result of elevated temperatures, the SBCs adapt accordingly as they also do for a temperature-induced reduction in cross-section diameter. This, in turn, ensures optimal fixation. Range advantages Strong, durable attachment solution for fluid systems Optimal support at all times thanks to dynamic spring properties Broad product range with all common vehicle dimensions as per DIN

170 6.4 Spring band clamps Nominal diameter in mm Band width in mm Contents SPRING BAND CLAMPS HK R HK HK R HK HK HK R HK HK HK HK Depicted example spring band clamp, type FBS HK HK HK HK HK HK HK HK R HK HK HK HK R HK HK Depicted example: spring band clamp, type FBSR HK HK HK HK HK

171 6.5 Connector /pin base for bulbs Application Pin bases for bulbs are used in special applications such as auxiliary lamps in agricultural and construction machinery. They are also employed to carry out fair-value repair work on headlamps whose base has fused with the bulb or for which corrosion has formed and led to contact resistance. Range advantages Time-saving repair for the workshop or the final consumer H and H7 pin bases with high-quality, prefabricated cables with butt-joint connectors 69 6

172 6.5 Connector /pin base for bulbs Description Connection without earth cable up to max JA with earth cable (30 mm) up to max JA up to max..0 8KB up to max JA up to max..0 8KB up to max..0 8KB up to max..0 8KB MALE CONNECTOR For H4 or RL bulbs, 3-pin, cable connection clamp can be released via pushbuttons PIN BASE FOR HEADLAMPS Connector with prefabricated cables and butt-joint connectors for H bulbs Cable length, brown (ground): 60.0 mm Cable length, white: 40.0 mm Cable connection with crimp MALE CONNECTOR For H4 or RL bulbs, 3-pin, can be released via pushbuttons, with ground cable (30.0 mm) 6 0 MALE CONNECTOR With prefabricated cables and butt-joint connectors for H7 bulbs Cable length, brown (ground): 20.0 mm Cable length, white: 00 mm Cable connection with crimp MALE CONNECTOR With prefabricated and incised cable ends Cable length, black:.0 mm Cable length, brown (ground): 30.0 mm 70

173 6.6 Trailer connection units/voltage transformers Application Trailer connection units allow the use of 2 V trailers on vehicles with 24 V operating voltage. The integrated voltage transformer permits operation without a separate charge compensation device. The trailer connection unit has 7 channels for the light function of the trailer. A 2 V trailer indicator lamp malfunction is indicated by the series C2 indicator lamp. Known vehicle limitations: Not for Mercedes-Benz Atego model series MP2, not for DAF CF Load-carrying capacity Rated voltage: 24 V/2 V Output per switch channel: 2 x 2 W Output per direction indicator: x 2 W Operating temperature: -30 C to C Polarity reversal protection: Continuously reverse-polarity protected Protection class: IP 5K9K in accordance with DIN Type approvals: e/ce 6 7

174 6.6 Trailer connection units/voltage transformers Cable colour TRAILER CONNECTING UNITS 24 V towing vehicle, ISO 2098 yellow = direction indicator, left 2 green = direction indicator, right 3 blue = rear fog light 4 white = ground 5 black = tail light, left 6 brown = tail light, right 7 red = stop light 8 grey = reverse light 2 V trailer, ISO 446 or ISO 724 yellow = direction indicator, left 2 blue = rear fog light 3 white = ground 4 green = direction indicator, right 5 brown = tail light, right 6 red = stop light 7 black = tail light, left 8 grey = reverse light 5DS Voltage converter, 24 V/2 V 6 72

175 6.6 Trailer connection units/voltage transformers Application Trailer connection units allow the use of 2 V trailers on vehicles with 24 V operating voltage. The trailer connection unit requires a separate charge compensation device or a separate voltage transformer with 8 A/2 V. The following devices can be used for this purpose: 8ES Load-carrying capacity Rated voltage: 24 V/2 V Quiescent current: 8 ma Control current of switch channels: 2.5 ma Output per switch channel: 2 x 2 W Output per direction indicator: 2 W Voltage drop of switch channels: 200 mv Operating temperature: -30 C to C Polarity reversal protection: Continuously reverse-polarity protected Protection class: IP 5K9K in accordance with DIN Type approvals: e/ce 6 73

176 6.6 Trailer connection units/voltage transformers Cable colour TRAILER CONNECTING UNITS 24 V towing vehicle, ISO 2098 yellow = direction indicator, left 2 green = direction indicator, right 3 blue = rear fog light 5 black = tail light, left 6 brown = tail light, right 7 red = stop light 8 grey = reverse light 2 V trailer, ISO 446 or ISO 724 yellow = direction indicator, left 2 blue = rear fog light 3 white = ground 4 green = direction indicator, right 5 brown = tail light, right 6 red = stop light 7 black = tail light, left 8 grey = reverse light 5DS Voltage converter, 24 V/2 V 6 74

177 6.7 Charge compensation device Application The charge compensation device detects the voltages of the two 2 V batteries. Should the ground-side battery have less voltage, the charge compensation device provides a compensating current. An LED indicates when the device is working. 2 V consumers can therefore be connected to the ground-side battery. The configuration of the charge compensation device depends on the average current drain of all 2 V consumers. For a conventional voltage transformer, the device configuration must correspond with the maximum current drain of all 2 V consumers. Load-carrying capacity Rated voltage: 24 V Equalizing current: 8 A Quiescent current: 5 ma Turn-on voltage: 27 V Turn-off differential voltage: 0.5 V Operating temperature: -25 C to C Polarity reversal protection and short-circuit proof Protection class: IP 5K9K 6 Therefore add up the average current drain of all 2 V consumers. 75

178 6.7 Charge compensation device Description CHARGE COMPENSATION DEVICE For vehicles with 24 V operating voltage The connection is made using 3 cables: One cable to 24 V, one to ground and one to the center tap of the batteries (see diagram). 8ES "Plus" charge compensation device 6 76

179 7 Product range case/accessories 7. Assortment case Application HELLA product ranges include a selection of the most common products in a particular topic area well laid out and compact in a high-quality, fully mobile concept. Four cases can be integrated in the practical Handy Box that offers not only a transport handle, but also many fastening options (further information: page 84). Range advantages All important dimensions/amperages are well organised in a single location The modular case concept offers many options for expanding and resorting/reorganising (further information: page 84) 7 77

180 7. Assortment case Description FUSE ASSORTMENT CASE Comprising: ATO (25 pcs. each per rated current), MINI blade terminal fuses (20 pcs. each per rated current) and a MINI/ATO blade terminal fuse tester/gripper. 8JS (quantity in reorder does not correspond with the number in the set) Description Ampere Colour Quantity in the assortment Short designation for Fuses CONTENT, PRODUCT RANGE CASE, FUSES SPARE PARTS FOR REFILLING ATO blade terminal fuse MINI blade fuse 2 A 25 D 29 8JS A 25 D 69 8JS A 25 D 88 8JS A 25 D 70 8JS A 25 D 7 8JS A 25 D 72 8JS A 25 D 73 8JS A 25 D 74 8JS A 25 D 75 8JS A 25 D 76 8JS A 25 D 30 8JS A 20 D 38 8JS A 20 D 39 8JS A 20 D 40 8JS A 20 D 4 8JS A 20 D 42 8JS A 20 D 43 8JS A 20 D 44 8JS A 20 D 45 8JS A 20 D 46 8JS A 20 D 47 8JS

181 7. Assortment case Description PRODUCT RANGE CASE, CRIMP CONNECTOR PRODUCT RANGE, UNINSULATED for Case Comprising: Different uninsulated connectors (quantity in reorder does not correspond with the number in the set; not all articles can be replenished) 8KW Description Cable cross section in mm² Male connector dimensions mm Quantity in the assortment Short designation CONTENT, PRODUCT RANGE CASE UNINSULATED CRIMP CONNECTORS SPARE PARTS FOR REFILLING Flat receptacle with locking tag x 0.8 B 00 8KW x 0.8 B 64 8KW x 0.8 B 03 8KW x 0.8 B 54 8KW Female spade connector with locking tag, claw across x B 05 8KW x 0.8 B 90 8KW Blade terminal with lock 6.3 x 0.8 B 88 8KW x 0.8 B 57 8KW Flat receptacle x 0.8 B 94 8KW x 0.8 B 5 8KW Flat receptacle, transverse claw x B 93 8KW Flat receptacle x 0.8 B 52 8KW x.2 B 95 8KW Blade terminals x 0.8 B 86 8KW Male connector distributor, double 6.3 x B 59 8KW Male connector distributor, triple 6.3 x B 60 8KW Piggy back spade connector x B 82 8KW Coupling, 2x 6.3 x Male spade connector, x Blade terminal, Ø 5.3 mm 6.3 x

182 7. Assortment case PRODUCT RANGE CASE, CRIMP CONNECTOR PRODUCT RANGE (DURASEAL) Description for Case Comprising: Different Duraseal crimp connectors (quantity in reorder does not correspond with the number in the set) 8KW Description Cable cross section in mm² Insertion width in mm/ eyelet hole Quantity in the assortment Short designation CONTENTS OF ASSORTMENT CASE ASSORTMENT OF DURASEAL CRIMP CONNECTORS SPARE PARTS FOR REFILLING A 3 8KW Insulating splice A 4 8KW A 5 8KW Flat receptacle x A 00 8KW x A 0 8KW Blade terminals x A 02 8KW x A 03 8KW Female bullet connector Ø A 68 8KW Male bullet connector Ø A 66 8KW M5 5 A 07 8KW M6 5 A 09 8KW Ring connector M8 5 A 8KW M5 5 A 08 8KW M6 5 A 0 8KW Fork connector M4 5 A 57 8KW M5 5 A 58 8KW

183 7. Assortment case Description for Case PRODUCT RANGE CASE, INSULATED CRIMP CONNECTORS Comprising: Different crimp connectors, one branch connector, one coupling and one pair of crimping pliers (quantity in reorder does not correspond with the number in the set) 8KW Description Cable cross section in mm² Insertion width in mm/ eyelet hole Quantity in the assortment Short designation CONTENTS OF ASSORTMENT CASE OF INSULATED CRIMP CONNECTORS SPARE PARTS FOR REFILLING Female bullet connector Ø A 63 8KW Male bullet connector Ø A 6 8KW Flat receptacle x A 8KW x A 52 8KW Flat receptacle, fully insulated x A 82 8KW Flat receptacle x A 53 8KW Blade terminals x A 59 8KW x A 60 8KW M4 20 A 67 8KW M5 20 A 69 8KW M4 20 A 68 8KW Ring connector M5 20 A 70 8KW M6 20 A 72 8KW M5 20 A 7 8KW M6 20 A 73 8KW Insulating splice A 80 8KW Open connector M5 20 A 78 8KW Piggy back spade connector x A 58 8KW Branch cable connector 20 I 8KW Clutch 6.3 x A 84 8KW Crimping pliers 8PE

184 7. Assortment case PLUG HOUSING PRODUCT RANGE CASE, "SUPERSEAL" PRODUCT RANGE Description for Case Comprising: Various "SUPERSEAL" plug housings, pin/socket contacts, strand insulations and blind plugs (quantity in reorder does not correspond with the number in the set) 8JA Description Cable cross-section in mm² Quantity in the assortment Short designation CONTENTS OF ASSORTMENT CASE SUPERSEAL PLUG HOUSING ASSORTMENT SPARE PARTS FOR REFILLING Individual wire seal B 45 9GD Dummy plug 00 B 47 9GD Male pin contact B 43 8KW Female contact B 44 8KW Pin housing, -pin 5 8JA Female socket housing, -pole 5 8JA Pin housing, 2-pin 5 8JA Female socket housing, 2-pole 5 8JA Pin housing, 3-pin 5 8JA Female socket housing, 3-pole 5 8JA Pin housing, 4-pin 5 8JA Female socket housing, 4-pole 5 8JA Pin housing, 5-pin 5 8JA Female socket housing, 5-pole 5 8JA Pin housing, 6-pin 5 8JA Female socket housing, 6-pole 5 8JA

185 7. Assortment case Description for Case PRODUCT RANGE CASE, HEAT-SHRINKABLE PLASTIC TUBING Comprising: Various heat-shrinkable plastic tubes, shrink rate 2 :, operating temperature -55 C to +25 C, flame-retardant and self-extinguishing, UL224, shrinkage temperature min. 70 C 9MJ Colour Length in mm Diameter in mm Quantity in product range CONTENTS OF PRODUCT RANGE CASE FOR HEAT-SHRINKABLE PLASTIC TUBING SPARE PARTS FOR REFILLING 20x each / / MJ x each /transparent MJ x each / / MJ x each /transparent MJ x each / / MJ x each /transparent MJ x each / / MJ x each /transparent MJ x each / / / /transparent MJ x each / / / /transparent MJ x each /transparent MJ x each / / / /transparent MJ x x each, 9., MJ

186 7.2 Product range accessories Application The HELLA Handy Box is a practical transport frame for up to 4 product range cases. 7 Ergonomic handle Assortment case latches securely into the retaining system Handy boxes can be combined together in a number of ways It can also be attached to walls (e.g. for arranging/ fixing for vehicle equipment or workshop use). 84

187 7.2 Product range accessories Description ASSORTMENT CASE The product range case can be subdivided individually with inserts in different sizes, including slide closures and an ergonomic handle; the grid system at the bottom prevents the contents from sliding around Description HANDY BOX For product range case (without case) Dimensions: (H x W x D in mm): 30.0 x x XX ASSORTMENT CASE Empty, without inserts Dimensions: (H x W x D, in mm): 57.0 x x XX INSERT FOR PRODUCT RANGE CASE Insert 7- Max. 8 inserts fit per case Dimensions: (H x W x D, in mm): 47.0 x 79.0 x XX Insert 8- Max. 6 inserts fit per case Dimensions: (H x W x D, in mm): 47.0 x 45.0 x XX Insert 9- Max. 32 inserts fit per case Dimensions: (H x W x D, in mm): 47.0 x 39.0 x XX

188 8. Tools 8. Basic crimping and release tool Application The "Basic" crimping tool set allows many different kinds of crimp connections to be created safely. The inserts can be changed quickly and easily and offer a time, space and costsaving alternative to several individual tools. Range advantages Strong basic solution Broad coverage with 6 different crimping tool heads, 9 release tools and 3 extension sleeves The matching release set is here an appropriate counterpart for releasing existing connections. 8 86

189 8. Basic crimping and release tool BASIC CRIMPING TOOL SET Description Comprising: One pair of pliers and 6 inserts 8PE Description BASIC CRIMPING TOOL SET INSERTS FOR REORDERING Insert A for insulated crimp connectors mm² 8PE Insert B for uninsulated crimp connectors mm² 8PE Insert C for uninsulated flat receptacles mm² 8PE Insert D for wire nail receptacles, mm² 8PE Insert F for cable end sleeves mm² 8PE Insert H for pin contacts mm² 8PE

190 8. Basic crimping and release tool BASIC RELEASE SET Description for Case Comprising: 9 release tools and 3 extension sleeves 8PE CONTENTS OF BASIC RELEASE SET* Description Vehicle manufacturer Marking Release tool for contacts with a cable cross section of.5 mm² + extension sleeve BMW, DaimlerChrysler, Fiat, MAN, Opel, Porsche, Seat, Skoda, VW/Audi HE0 Release tool for contacts with a cable cross section of 3.5 mm² + extension sleeve BMW, DaimlerChrysler, Fiat, MAN, Opel, Porsche, Seat, Skoda, VW/Audi HE02 Release tool for contacts with a cable cross section of 3.5 mm² + extension sleeve Ford, Opel, PSA, Renault HE05 Release tool for connectors with a "release channel" of 2.8 and 5.8 mm² BMW, DaimlerChrysler, Ford, MAN, Opel, Porsche, PSA, Renault, Seat, Skoda, VW/Audi HE53 Release tool for Micro Timer II and III with a cable cross section of.6 mm² DaimlerChrysler, VW/Audi HE56 Release tool for Maxi-Power Timer with a cable cross section of 9.5 mm² All vehicle makes/ specifications HE59 Release tool for pit-pod contacts Fiat, Ford, Mazda, Opel, PSA, Renault, Saab, VW/Audi HE62 Release tool for Micro Timer I and ABS "plug-in housing" with a cable cross section of.6 mm² Fiat, Ford, Mazda, Opel, PSA, Renault, Saab, VW/Audi HE53 Release tool for connector with two "release channels" of 2.8 and 5.8 mm² * Content cannot be ordered separately BMW, DaimlerChrysler, Fiat, Ford, MAN, Opel, PSA, Renault, Saab, VW/Audi HE9 8 88

191 8.2 Professional crimping and release tool Application Thanks to its special profile geometries, the professional crimping tool forms very precise radial contacts The patented crimping tool set fixing concept ensures that the tool inserts are positioned perfectly. Furthermore, the pliers have an extra cutting and stripping unit in the handle which makes the tool set especially versatile. It is completed by a modular set of release blades on the back of the case. Range advantages High-quality all-in solution Broad application coverage with 5 different crimping tool heads, 4 release blades and the "Clip & Strip" cutting and stripping unit 3 different, individually expandable assembly variants Ergonomic, soft handle with slip guard Optimised mechanical power transmission facilitates longterm, unfatiguing use Made of hardened tool steel with special surface finish on elements subject to particularly high loads 89 8

192 8.2 Professional crimping and release tool CRIMPING TOOL AND RELEASE SET Description for Case Crimping tool and release set Profi type I 8PE CONTENTS OF PROFESSIONAL TYPE I CRIMPING TOOL AND RELEASE SET Description Basic pliers without inserts 8PE "Clip & Strip" stripping unit 8PE Insert 44 Cable cross section of mm²for DIN cable lugs and insulated crimp connectors 8PE Insert red/yellow/blue Cable cross section of mm² for fully insulated butt-joint connectors 8PE Insert JPT/TAB 2.8/MCP 2.8 Cable cross section of mm² 8PE Universal insert Cable cross section of mm² for uninsulated blade terminals and flat receptacles 8PE Basic grip for release 8PE

193 8.2 Professional crimping and release tool CONTENTS OF PROFESSIONAL TYPE I CRIMPING TOOL AND RELEASE SET Description Blade MCP 2.8/FL 2.8/JPT/SPT 8PE Blade MDK 5, DFK 2, AFK 8PE Blade FSH 6.3 8PE Blade F2.8 FS/H.58 8PE

194 8.2 Professional crimping and release tool CRIMPING TOOL AND RELEASE SET Description for Case Professional type II crimping tool and release set 8PE CONTENTS OF PROFESSIONAL TYPE II CRIMPING TOOL AND RELEASE SET Description Basic pliers without inserts 8PE "Clip & Strip" stripping unit 8PE Insert 44 Cable cross section of mm² for DIN cable lugs and insulated crimp connectors 8PE Insert red/yellow/blue Cable cross section of mm² for fully insulated butt-joint connectors 8PE Insert AE 2 Cable cross section of mm² for insulated and uninsulated wire end ferrules 8PE

195 8.2 Professional crimping and release tool CRIMPING TOOL AND RELEASE SET Description for Case Professional type III crimping tool and release set 8PE CONTENTS OF PROFESSIONAL TYPE III CRIMPING TOOL AND RELEASE SET Description Basic pliers without inserts 8PE "Clip & Strip" stripping unit 8PE Insert 44 Cable cross section of mm² for DIN cable lugs and insulated crimp connectors 8PE Insert red/yellow/blue Cable cross section of mm² for fully insulated butt-joint connectors 8PE Universal insert Cable cross section of mm² for uninsulated blade terminals and flat receptacles 8PE

196 8.2 Professional crimping and release tool CONTENTS OF PROFESSIONAL TYPE III CRIMPING TOOL AND RELEASE SET Description Basic grip for release 8PE Blade MCP 2.8/FL 2.8/JPT/SPT 8PE Blade FSH 6.3 8PE

197 8.3 Heavy Duty tool system Application The HELLA "Heavy Duty" tool system offers maximum machining precision thanks to its linear crimping technology. Unlike conventional radial pliers, this design is remarkable for the uniform distribution of force during the crimping process. which allows it to produce consistently high-quality work results. The system s modular design allows you to put together your own individual combinations and separately exchange basic handles and crimping or release tools. Range advantages High-quality, modular tool concept Linear/parallel crimping technology enables maximum machining precision Ergonomic, soft handle with slip guard Optimised mechanical power transmission facilitates longterm, unfatiguing use Made of hardened tool steel with special surface finish on elements subject to particularly high loads 95 8

198 8.3 Heavy Duty tool system Description TOOL CASE Heavy Duty Tool Case Front accommodates complete pliers and 4 tool heads Rear accommodates release handle and 2 blades 8PE Tool handle for crimping pliers 8PE SUPERSEAL tool The "SUPERSEAL" tool head offers all the advantages of the "Heavy Duty" system. It also has a built-in positioning aid on the rear, which makes it much easier to position the contact correctly within the tool. 8PE The specialised design concept allows crimping and insulation to be performed in one integrated work step. This saves valuable time. Tool head Deutsch DT 8PE Tool head ABS-G 8PE Releasing tool handle 8PE

199 Description SUPERSEAL extraction blade 8PE Releasing blade, Deutsch DT 8PE Releasing blade ABS-G 8PE

200 8.4 Squeezing and crimping pliers Application Each of the application-specific hand-held tools is designed for a targeted application area. All models feature solid workmanship and ensure excellent work results. Range advantages Specialised tool types for a range of applications 8 98

201 8.4 Squeezing and crimping pliers Description Contents PROFESSIONAL I SPECIAL CRIMPING PLIERS For insulated crimp connectors, cable cross section of mm² (red/blue/yellow) 8PE PROFESSIONAL II SPECIAL CRIMPING PLIERS For uninsulated crimp connectors, cable cross section of mm². Not suited for crimping butt-joint connectors with insulation. 8PE EXPERT SPECIAL CRIMPING PLIERS For insulated crimp connectors, cable cross section of mm² (red/blue/yellow) Suited for cutting bolts with threads in accordance with ISO of M2.6 - M3.5 and for shortening and stripping cables from mm² 8PE QUICK LINK HAND GRIP PLIERS For the two-pin, "click-in" contact system (common e.g. in trailer and semi-truck trailer constructions) 8PE

202 overview Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page 2JS Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 4 5DS Folding box Folding box 72 8ES PE bag Folding box 76 8EZ Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box 30 8HG Folding box Folding box 73, 76 8HK Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Plastic insert magazine Plastic insert magazine Plastic insert magazine Plastic insert magazine Plastic insert magazine Plastic insert magazine Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box HL PE bag, with Euro hole PE bag, with Euro hole PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag

203 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole PE bag, with Euro hole HS PE bag, with Euro hole Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box JA Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Industrial packaging Folding box Folding box Pro-fit packaging Folding box PE bag Folding box Folding box Folding box Pro-fit packaging Folding box 86, Folding box Folding box 86, Folding box Folding box 86, Folding box 86, PE bag Folding box Folding box Folding box Pro-fit packaging Folding box Folding box Pro-fit packaging 34 20

204 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Folding box Pro-fit packaging Folding box Folding box Folding box PE bag Pro-fit packaging PE bag Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box PE film 36, Folding box Folding box PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging PE bag PE bag PE bag PE bag PE bag PE bag Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging PE bag 0 33, 36, PE bag 0 33, 36, PE bag 0 34, 36, PE bag 0 34, 36, PE bag PE bag PE bag 0 33, 36, PE bag 0 33, 36, PE bag 0 34, 36, PE bag 0 34, 36, PE bag 0 34, 36, PE bag 0 34, 36, 82 8JB Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Pro-fit packaging Folding box Folding box Folding box Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Pro-fit packaging Folding box

205 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Pro-fit packaging Folding box Folding box PE bag Folding box Pro-fit packaging Folding box Folding box Folding box Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box 3, Folding box PE bag, with Euro hole Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box PE bag PE bag 27 8JD PE bag PE bag Folding box PE bag PE bag Folding box PE bag PE bag Folding box PE bag PE bag PE bag PE bag Folding box Pro-fit packaging Pro-fit packaging Folding box Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Pro-fit packaging Pro-fit packaging Pro-fit packaging Folding box Folding box Pro-fit packaging PE bag Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging PE bag PE bag Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 2 8JR PE bag PE bag PE bag PE bag PE bag

206 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag JS Pro-fit packaging Pro-fit packaging PE film 8, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging

207 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Pro-fit packaging Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging 5, 8, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 3 205

208 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag 8KA Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box PE bag PE bag PE bag Pro-fit packaging PE bag Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box 8 8KB Folding box Folding box Folding box Folding box 70 8KL Coils Coils Coils Coils Coils Coils Coils Coils Coils Coils Coils Coils Coils Ring Ring

209 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Coils Ring Coils Ring Coils Ring Coils Ring Coils Ring Coils Ring Coils Ring Coils Ring Coils Ring Coils Coils Ring Coils Coils Ring Coils Ring Coils Ring Coils Ring Coils Ring Coils Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Coils Ring Ring Coils Ring Ring Coils Coils Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring Ring

210 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Ring Ring Ring Coils Ring 97 8KV PE bag PE bag Pro-fit packaging Folding box Folding box Pro-fit packaging PE bag PE bag Folding box Folding box Folding box Folding box PE bag PE bag PE bag PE bag Folding box Folding box Folding box Pro-fit packaging Pro-fit packaging Industrial packaging Industrial packaging Pro-fit packaging Industrial packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging KW PE film 7; PE film 22; PE film 4; Pro-fit packaging 00 2; 4; Industrial packaging Pro-fit packaging Pro-fit packaging 00 3; 4; Pro-fit packaging 00 9; 22; Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 00 20, 22, Pro-fit packaging 00 20, 22, Pro-fit packaging 20, 22, Pro-fit packaging 20, 22, Pro-fit packaging Pro-fit packaging 9, 22, Pro-fit packaging 00 20, 22, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 25 22, 30, Pro-fit packaging 00 9, 22, Pro-fit packaging Pro-fit packaging Pro-fit packaging 00 20, 22, Pro-fit packaging Pro-fit packaging 00 20, 22, Pro-fit packaging Pro-fit packaging Pro-fit packaging 00 9, 22, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 00 20, 22, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 00 9, 22, Pro-fit packaging Pro-fit packaging 00 20, 22, Pro-fit packaging 9, 22, Pro-fit packaging Pro-fit packaging 00 3, 4, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging

211 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 3, 4, Pro-fit packaging 00 2, 4, Industrial packaging Pro-fit packaging Pro-fit packaging 00 9, 22, Pro-fit packaging 25 22, Pro-fit packaging Pro-fit packaging 00 9, 22, Pro-fit packaging Pro-fit packaging 9, 22, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Industrial packaging Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging 00 2, 4, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging

212 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 25 6, 7, Pro-fit packaging 25 6, 7, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 25 6, 7, Pro-fit packaging Pro-fit packaging 25 6, 7, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 2, 4, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 00 2, 4, Pro-fit packaging 00 2, 4, Pro-fit packaging Pro-fit packaging 00 2, 4, Pro-fit packaging 00 2, 4, Pro-fit packaging Pro-fit packaging 00 2, 4, Pro-fit packaging 00 2, 4, Pro-fit packaging 00 3, 4, Pro-fit packaging Pro-fit packaging 00 3, 4, Pro-fit packaging 35, 36, Pro-fit packaging 35, 36, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging PE bag PE bag PE bag PE bag PE bag PE bag PE bag Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 00 3, 4, PE bag Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging 06 20

213 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging KX Folding box Folding box Folding box Folding box Folding box Pro-fit packaging Folding box Pro-fit packaging Folding box Pro-fit packaging Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box PE bag PE bag 8PD Folding box Folding box Folding box Folding box 88 8PE Plastic box Plastic box Plastic box Pro-fit packaging Pro-fit packaging PE bag 90, 92, Folding box Folding box Folding box Folding box PE bag 90, 92, PE bag 90, 92, PE bag 90, 92, Folding box PE bag PE bag 90, PE bag 90, 94, Plastic box 9, Plastic box Plastic box 9, Plastic box Folding box Folding box Folding box Plastic box PE bag PE bag PE bag PE bag PE bag PE bag PE bag Folding box Folding box Folding box Folding box 93 9GD PE bag PE bag PE bag PE bag Folding box 0 55, Folding box 0 67, Folding box 0 44, Folding box 0 55, Folding box PE bag Pro-fit packaging 35, 36, 82 2

214 Part number Content in pcs. Type of packaging in pcs. Page Part number Content in pcs. Type of packaging in pcs. Page Pro-fit packaging Pro-fit packaging 35, 36, Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging Pro-fit packaging MJ Cardboard roll Cardboard roll Cardboard roll Cardboard roll Cardboard roll Cardboard roll Cardboard roll PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE bag 57, 58, PE film 58, PE film PE film PE film PE film Pro-fit packaging PE film PE film PE film PE film PE film PE film PE film Pro-fit packaging PE bag 9MK PE bag PE bag PE bag PE bag Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box Folding box PE bag PE bag PE bag PE bag PE bag 44 9NB PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag PE bag Pro-fit packaging 4 9XX Folding box Folding box Folding box PE bag PE bag 85 22

215 HELLA KGaA Hueck & Co. Rixbecker Straße Lippstadt, Germany Tel.: Fax: Internet: HELLA KGaA Hueck & Co., Lippstadt J0267/05.7 Subject to technical and price modifications.