Installation material

Flat connector fuses are primarily used in automotive electrical fuse systems.

Strip fuses or leaf fuses primarily comprise a punched out locking plate strip. In addition to the open variant without jacket material, closed types with a plastic insulating body or ceramic housing are also common. Because of the more robust design, these fuse types are mainly used to provide fuse protection for electrical systems operating at higher currents and voltages.

AL fuses (up to max. 120 A) have a similar range of applications as the MAXI flat connector fuse, but unlike the latter they are mainly installed in Japanese vehicles.

Circuit breakers, just like 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 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). The product variety here is definitely more than wide enough to cover all the possible applications.

If a single fuse holder is not sufficient to integrate an additional device into the electrical system or if several functions are to be added at the same time, it is a good idea to install a fuse box. The bundling of backup features at a central point creates an overview and, at the same time, ease of maintenance.

Cigarette lighters and/or power sockets are absolutely 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. The HELLA product portfolio, thanks to its huge variety, offers the right socket for every application.

Similar to power sockets, the proven plug connector system in accordance with ISO 4165 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 plug connector systems can be installed either inside or outside the vehicle. Universal connectors, thanks to their red front adapter, allow both systems to be used with the same connector.

This plug connector system is mainly used by fire-fighting vehicles for charging batteries. Technical data: ➔ Operating temperature: -40°C to +100°C ➔ Operating voltage: 6 - 42 V ➔ Current: max. 16 A

The 3-pin plug 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 the supplying of lighting equipment (see ISO 1724). The 3-pin plug connector system without a standard is used to transfer auxiliary functions between tractor and trailer.

The 4-pin plug connector system in accordance with DIN 72 575 is used to transfer auxiliary functions between tractor and trailer. Load-carrying capacity: ➔ max. 16 A at 6 - 24 V (cable cross-section 1.5 mm²) ➔ max. 25 A at 6 - 24 V (cable cross-section 2.5 mm²)

The 5-pin plug connector system in accordance with ISO 1724 is used to transfer auxiliary functions between tractor and trailer. Load-carrying capacity: ➔ max. 16 A at 6 - 24 V (cable cross-section 1.5 mm²) ➔ max. 25 A at 6 - 24 V (cable cross-section 2.5 mm²)

The 7-pin, 12 V plug connector system in accordance with ISO 1724 / ISO 3732 is the most popular system for establishing electrical connections between the towing vehicle and trailer using the 12 V vehicle electrical system. The system is primarily used for applications with average requirements. It includes a standard plug connector, type N, in accordance with ISO 1724 and an auxiliary plug connector, type S, in accordance with ISO 3732. The auxiliary system is differentiated from the standard system by its white housing, contact inserts and non-interchangeable contact arrangement.

The 13-pin plug connector system in accordance with ISO 11446 was developed as the 1980s 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 increasingly replacing the older plug connector generations on account of its benefits, particularly with regard to water tightness, stability, contact reliability and easy handling thanks to the bayonet closure.

The 7 + 6-pin plug connector system for the electrical connection of towing and trailer vehicles can be used with both 7 pins and 13 pins.

The 7-pin, 24 V plug connector system in accordance with ISO 1185 / ISO 3731 is currently the most popular system for establishing electrical connections between 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 1185 and an auxiliary plug connector, type S, in accordance with ISO 3731. The auxiliary system is differentiated from the standard system by its white housing, contact inserts and non-interchangeable contact arrangement.

The 15-pin plug connector system in accordance with ISO 12098 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.

The plug connector systems in accordance with ISO 7638-1 / ISO 7638-2 are used in almost all commercial vehicles with ABS / EBS systems. The plug connectors are suitable for ADR / GGVS applications.

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 and where importance is attached to high levels of safety and ease of use. The 12-pin, 24 V system in accordance with VG 96923 stands out 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 96917 meets similar requirements and is used for battery charging at currents of up to 500 A (short-term loads up to 10 s). The plug connector system in accordance with ISO 4165 is used to electrically connect different consumers.

➔Adapter from 13-pin socket (ISO 11 446) on the towing vehicle to a 7-pin connector (ISO 1724) on the trailer cable ➔ Adapter from 7-pin socket (ISO 1724) on the towing vehicle to a 13-pin connector (ISO 11 446) on the trailer cable ➔ Connecting cable 7-pin (ISO 1724) ➔ UK short adapter from 13-pin socket (ISO 11 446) on the towing vehicle to two 7-pin plugs (ISO 1724 + ISO 3732) on the trailer cables ➔ Adapter cable 24 V from 15-pin socket (ISO 12098) on the towing vehicle to two 2-pin sockets (ISO 1185 and ISO 3731) on the trailer ➔ Adapter cable available in two lengths, other lengths on request

➔ Test connector for 7-pin sockets (ISO 1724) and 13-pin sockets (ISO 11446) ➔ Test connector for spiral connecting cables (ISO 1185) ➔ Test connector for testing ABS sockets

Spiral connecting cables are used for the electrical connection between towing vehicles and trailers in the commercial vehicle sector.

Cables are needed everywhere in the vehicle where electrical current flows from A to B. The design, size, material and type are determined by the requirements to be met with regard to voltage, current and frequency and also to the environmental conditions to which the cable is exposed.

Non-insulated crimp connectors are typically used in splash water-protected areas of a vehicle and serve primarily as detachable system elements for electrical and mechanical connections/branches of cables. In the course of time, a number of different contact systems have become established, depending on the application area and vehicle age.

The insulated "Duraseal" crimp connectors have a shrinkable nylon cap with adhesive that can be used to make a waterproof connection between cable and contact. To this end, the nylon cap is heated using a hot-air gun (or other heat source) to approx. 135°C . At this temperature, the cap material firmly encompasses the cable. Other insulation solutions (e.g. heat-shrink tubing or insulating tape) are therefore not required.

Insulated crimp connectors are crimped using an appropriate tool at the coloured end in order to create a safe, rigid contact to the cable. The insulation material is made up either of PVC (max. temperature resistance of 80°C) or of nylon (max. 105°C). The insulating sleeve has a special "easy-entry" funnel shape to ensure better guidance of the cable.

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 used, the pressed-on sleeve can have many different shapes. The range corresponds to DIN 46228-4 in terms of design and dimensions. The material is made of copper with a nickel-plated surface and a plastic sleeve in PVC.

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, firmly-bonded connection is established.

If different, multi-core cables are to be linked together, it can be difficult to maintain the overview. For such cases, the HELLA cable connector boxes offer a safe and easy-to-use bundling solution that keeps everything neat and tidy and clear. This lockable, fire-resistant box provides the necessary protection for the individual wires.

"SUPERSEAL" plug connectors comply with IEC 529 regulations and also with DIN ISO 40050, and come with protection class IP 67, which offers the maximum level of water and dust proofing. The quality of the "SUPERSEALS" makes them ideal wherever other connecting systems reach their limits because of adverse pressure or humidity conditions.

The concept of the DEUTSCH "DT series" plug connections combines high-quality materials with a connecting system characterized by both reliability and easy handling. Thanks to these qualities, the range is particularly suited to applications where maximum output is required but with a low failure rate despite tough environmental conditions.

Female and male connector housings offer an easy way to protect non-insulated cable connections from external influences. The product range encompasses housings for standardized, non-insulated crimp connectors with locking mechanism and for the CONI and Mate-N-Lock round plug connector systems.

Properly fastening a cable bundle often requires more than the cable tie itself. Our cable ties are weatherproof, flame-resistant and also resistant to diluted organic acids, oils, petrol, salt water, solvents and all kinds of grease. They even offer perfect support for extremely small bundled diameters such that no cable lining or other attachment aids are required.

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 universal.

Bundling and fastening cables.

Electrically insulating adhesive tape is made of non-conductive material and is suitable for a wide range of applications in the field of vehicle repairs without negatively impacting the vehicle electrical system. Whether it’s a case of bundling, fastening, temporary insulating or colour coding ─ the tried-and-tested all-purpose system always provides reliable results. In the meantime numerous special variants are available that have shown themselves to be particularly suitable for a specific area of application.

Shrink sleeves are an excellent tool for achieving the sealed insulation of cable connections and crimp contacts or for the repairing of damaged wiring harnesses. Their variety of colours also makes them very suitable for tasks that require bundling and marking. Depending on the application in question, various shrink ratios are available, with or without adhesive on the inside.

Whether as a spare part or as an original equipment component – HELLA universal clamps provide the best service with their high level of hardness of material and their corrosion resistance. The range is strictly oriented towards the common standards in place for battery terminals.

The highly flexible electrical conductors have been used in a range of electrical vehicle applications for decades. As the name implies, it is all about applications such as discharging/grounding of EMC interference or static charges. In this context, the ground strap must reliably withstand high currents such as those that can occur between the starter and battery. If the electrical system is malfunctioning, a defective or non-existent ground strap can often be the cause.

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 because of their high tensile strength, high breaking torque and uniform force distribution. All measurements/configurations are available in a selection of alloy variants.

Unlike standard hose clamps, spring band clamps (SBCs) have a flexible holding mechanism. This greatly increases their lifetime if there are 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.

Plug-in bases for bulbs are used in special applications such as auxiliary headlamps in agricultural and construction machinery. They are also used to carry out fair-value repair work on headlamps whose base has fused with the bulb or where corrosion has formed and led to contact resistance.

Trailer connection units allow the use of 12 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. Malfunction of a 12 V trailer’s direction indicator is indicated by the C2 series control lamp.

The charge compensation device detects the voltages of the two 12 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. 12 V consumers can therefore be connected to the ground-side battery.

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 handle for easy transporting, but also many options for safe securing of the item.

The HELLA Handy Box is a practical way of transporting up to 4 product range cases.

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 thus offer a time, space and cost-saving alternative to the need for several individual tools. The matching release tool set is the appropriate counterpart for the removal of existing connections.

Thanks to its special profile geometries, the "Professional" crimping tool enables very precise radial contacts to be set up. The fixing concept of the patented crimping tool set ensures that the tool inserts are perfectly positioned. Furthermore, the pliers have an extra cutting and stripping unit in the handle which makes the tool set especially versatile. The whole set is rounded off by a modular set of unlocking blades.

The linear crimping technology of the HELLA "Heavy Duty" tool system offers the highest level of precision finishing. Unlike conventional radial pliers, this concept proves its worth because of the uniform distribution of force during the crimping process. This feature allows it to produce consistently high-quality work results. The system’s modular design allows you to put together your own individual combinations and also to separately exchange basic handles and crimping or release tools.

Each of the application-specific hand-held tools is designed for a particular area of application. All models feature solid workmanship and guarantee excellent work results.

➔ For petrol engines < 7,500 ccm, diesel engines: < 4,000 cm ➔ Reinforced pliers sheath for less wear ➔ CCA cable made of copper-coated aluminium, cable cross-section: 50 mm² ➔ Includes practical storage bag Programme advantages ➔ Various lengths available ➔ With overvoltage protection