Download - Service TOTAL
Chapter 1 Februar 2009
Chapter 1: Association the company Aspöck
Chapter 1 Februar 2009
Aspöck Systems – we bring light tot he road
At Aspöck Systems we have made i tour business to design, develop and build the best possible total soluations for Europe’s vehicle manufactures. And here we mean the complete range of vehicles. Individual systems – Satisfied customers. Since their inception in 1977, Aspöck Systems GmbH has focused on a philosophy that has made i tone of today’s leading producers of lighting systems fort he vehicle industry: developing custom-tailored solutions for each individual customer. Thos ist he flexibility that has become the successful trademark of Aspöck Systems. Innovative products. We see it as our obligation to make our entire range of cable and light systems compaible with the sate-of-the-art, and play a pioneering role in setting new standards. We apply waterproof cables, connection systems and LED lighting to every field of application. Continous growth. Our headquarters in Peuerbach, Upper Austria has undergone continuous expansion in the production, storage and management sectors. Every year we invest in new production facilities, testing equipment and development systems to remain at the cutting edge of technology. At the same time we promote the further education and training of our employees, so that they alwys have the right answer when confronted with difficult questions, such as specific legislation issues.
Chapter 1 Februar 2009
Subsidiaries.
A perfectly organised sales and service network throughout Europe guarantees short delivery times and ahigh degree of technical expertise. Many of the sales and service centres are our own subsidiaries, or those of sales partners.
Chapter 1 Februar 2009
Milestones
1977 – Aspöck company founded as manufacturer of lieghting systems for agricultural vehicles.
1981 – First production workshop opens in Peuerbach
1982 – First Aspöck connector system developed; car trailer manufactures
1988 - Aspöck Germany opens
1991 – New customers: caravsn manufactuers
1992 – New customers: truck trailer manufacurers
1996 – First Aspöck „Multipoint“ light prduced
1997 – New customers: bicycle carrier rack manufacturers
1999 – Aspöck Iberica opens, Trailer Lite opens
2001 - Aspöck Uk opens, Aspöck France opens, Aspöck do Brasil opens
2003 – Partnership PAGG Aspöck
2004 – Introduce moulding technology to connector systems
2005 – Aspöck Norden opens, New customers: truck manufacturers
2006 – Aspöck Hungary opens New customers: car manufacturers
2007 – New customers: motorcycle manufacturers
2008 – Renaming Fabrilicar as Aspöck Portugal
Chapter 2
Chapter 2: Bayonet System
Chapter 2
2 pin bayonet with socket case
1. Cut away max. 30mm the cover at the end of the cable and thread the pipe onto the cable (picture 1) 2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1) 3. Put the bayonet nut onto the socket case with the ohring , and plug the single cores into the correct pin
at the socket casing (picture 1) shown in the drawing right. NOTE: they must engage in the socket casing
4. Screw the Nut on the pipe over the case and fix the cable strip back of the pipe (picture 2) Picture 1
Picture 2
Stipulate working time to change a complete 2 pin c onnector: max. 15 min
socket case
contacts
Cable strip
pipe
Here must be a sealing, please check.
Ansicht Aview Avue A
2 1
1 = white common return 2 = current-carring
Chapter 2
Chapter 2
2 pin bayonet with pin case 1. The end of the cable max. 35mm cut away the cover and thread the pipe onto the cable (picture 1) 2. aufcrimpen (Bild 1) 3. About 6mm cut away from the single cores and fix the contacts onto the cable (picture 1) 4. Put the contacts into the plug case, so that they engage in the plug case (picture 1) 5. Screw the nut on the pipe over the case and fix the cable strip at the back of the pipe (picture 2) Picture 1
Stipulate working time to change a complete 2 pin c onnector: max. 15 min
21
1 = white common return 2 = current-carring
Plug case
contacts pipe
Cable strip
Screw the nut until tot he block (picture)
Chapter 2
8 pin bayonet with socket case 1. Cut away max. 30mm the cover at the end of the cable and thread the pipe onto the cable 2. (picture 1) 3. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1) 4. Put the bayonet nut onto the socket case with the ohring, and plug the single cores into the
correct 5. pin at the socket casing (picture 1) shown in the drawing right. NOTE: they must engage in the 6. socket casing 7. Screw the Nut on the pipe over the case and fix the cable strip back of the pipe (picture 2)
Picture 1 Picture 2
Vorgeschriebene Arbeitszeit zum Tausch eines 8 pol. Verbinders: max. 20 min
Bayonet nut Pipe
8
2
6
5
7
4
3
1
1 = ye / flasher left 4 = gn / flasher right 2 = bl / rear fog lamp 3 = wt / common return
7 = bk / rear light left 5 = Br / rear light right 6 = rd / brake light 8 = gr / reverse light
Socket case contacts
Cable strips
Here must be a sealing,
please check
Chapter 2
Chapter 2
8 pin bayonet with pin case 1. The end of the cable max. 35mm cut away the cover and thread the pipe onto the cable (picture 1)
2. About 6mm cut away from the single cores and fix the contacts onto the cable (picture 1) 3. Put the contacts into the plug case, so that they engage in the plug case (picture 1) 4. Screw the nut on the pipe over the case and fix the cable strip at the back of the pipe (picture 2)
Picture 1
Picture 2
Stipulate working time to change a complete 8 pin c onnector: max. 20 min
pipe
6
7
2
8
4
1
5
3
1 = ye / flasher left 4 = gn / flasher right 2 = bl / rear fog lamp 3 = wt / common return
7 = bk / rear light left 5 = Br / rear light right 6 = rd / brake light 8 = gr / reverse light
plug case contacts cable strip
Chapter 2
15 pin bayonet with socket case
1. Cut away max. 30mm the cover at the end of the cable and thread the pipe onto the cable (picture 1)
2. Cut away ca. 4mm the cover of the single cores and fix the contacts onto these cores (picture 1)
3. Put the bayonet nut onto the cable, and plug the single cores into the correct pin at the socket 4. casing (picture 1) (shown in the drawing right). NOTE: they must engage in the socket casing
5. Put the pipe over the case and fix the metal clamp at the front and the back of the pipe (picture 2) Picture 1 Picture 2
Stipulate working time to change a complete 15 pin connector: max. 0,5 h
View A
Metal clamp
Here must be a sealing,
please check Bayonet nut pipe
Ansicht Aview Avue A
2
4
11
3
12
1
13
5
715
14 6
1089
1 = ye / flasher left 2 = gn / flasher right 3 = bl / rear fog lamp 4 = wt / common return 5 = bk / rear light left 6 = Br / rear light right
7 = rd / brake light 8 = gr / reverse light 9 = br-bl / feed current 10= Br-rd/interior light 11= Ye-bk / free 12= rs / steering axle
13 = Wt-bk / free 14 = vi / drive up help 15 = or / bogie lift
Metal clamp
socket case contacts
Chapter 2
15 pin bayonet with pin case 1. The end of the cable max. 35mm cut away the cover and thread the pipe onto the cable (picture 1) 2. About 4mm cut away from the single cores and fix the contacts onto the cable (picture 1) 3. Put the pipe over the case and fix the metal clamp at the front and the back of the pipe (picture 2) Picture 1
Picture 2
Stipulate working time to change a complete 15 pin connector: max. 0,5 h
Metal clamp
pipe
1 = ye / flasher left 2 = gn / flasher right 3 = bl / rear fog lamp 4 = wt / common return 5 = bk / rear light left 6 = Br / rear light right
7 = rd / brake light 8 = gr / reverse light 9 = br-bl / feed current 10= Br-rd/interior light 11= Ye-bk / free 12= rs / steering axle
13 = Wt-bk / free 14 = vi / drive up help 15 = or / bogie lift
15
5
14
7
6
8
4
1
2
3
13
10
12
9
11
Ansicht Aview Avue A
Metal clamp
contacts
View A
Chapter 2
Montageanleitung für Aspöck Verbinder Mounting instruction for Aspöck connectors System Bayonet
2.
15 pin female 15 pin male
1. Look that this “anti twists” fit correct together
Anti-twist
Chapter 2
2. Put the two connectors together so that they engage
3. Put the plastic screw in the correct position
correct position
Chapter 2
4. Turn the plastic screw, until it locks. If it´s correct, you will hear “click”
Turn the plastic screw, until it locks. If it´s correct, you will hear “click”
Chapter 2
Spare parts SYSTEM BAYONET
Order-Nr. left (yellow) right (green) reversible describtion
13-0230-031 X Bayonet 2-pin male yellow
13-0232-031 X Bayonet 2-pin male green
13-0236-031 X Bayonet 2-pin male black
13-0220-031 X Bayonet 2-pin female yellow
13-0222-031 X Bayonet 2-pin female green
13-0226-041 X Bayonet 2-pin female black
13-0831-031 X Bayonet 8-pin male yellow
13-0833-031 X Bayonet 8-pin male green
13-0834-021 X Bayonet 7-pin male white
13-0836-021 X Bayonet 7-pin male grey
13-0838-061 X Bayonet 8-pin male black
13-0821-051 X Bayonet 8-pin female yellow
13-0823-041 X Bayonet 8-pin female green
13-0824-031 X Bayonet 7-pin female white
13-0826-031 X Bayonet 7-pin female grey
13-0828-061 X Bayonet 8-pin female black
13-1530-101 Bayonet 15-pin male
13-1520-051 Bayonet 15-pin female
Chapter 3 Februar 2009
Chapter 3: ASS1 System
Chapter 3 Februar 2009
7 pin ASS1 connector white and black
1. Cut away max. 35mm of the cover at the end of the cable, thread the gland, pipe and the ring onto
the cable (picture 1) 2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1) 3. Put the contacts into the plug case, so that they engage in the plug case (picture 1) 4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2) picture 1
gland
ring contacts
Gleitring
1 = wh / common return 2 = bk / rear light left 3 = ye / flasher left 4 = rd / brake light 5 = Gr / flasher right 6 = Br / rear light right 7 = Ye/bl free
1 = wh / common return 2 = bk / rear light left 3 = gr / reverse light 4 = Br/bl feed current 5 = or / free 6 = Rs / bogie lift 7 = bl / rear fog lamp
1
5
7
6
3
4
2
ASS1 7 pin black ASS1 7 pin. white
plug case
Chapter 3 Februar 2009
picture 2 Stipulate working time to change a complete 7 pin connector: max. 0,35 h
Cable tie
Chapter 3 Februar 2009
7 pin ASS1 connector with socket case green
1. Cut away max. 35mm of the cover at the end of the cable, thread the gland, pipe and the ring onto the cable (picture 1)
2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)
3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)
4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)
picture 1
gland
ring contacts
Gleitringringbague
1/4 = gn / flasher ri 2 = bl / rear fog lamp 3 = wh / common return 5 = br / rear light right 6 = rd / brake light 7 = Bk / rear light left 8 = gr / reverse light
8 1/4
2 63
57
plug case
Chapter 3 Februar 2009
picture 2 Stipulate working time to change a complete 7 pin connector: max. 0,35 h
Cable tie
Chapter 3 Februar 2009
7 pin ASS1 connector yellow
1. Cut away max. 35mm of the cover at the end of the cable, thread the gland, pipe and the ring onto the cable (picture 1)
2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)
3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)
4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)
picture 1
ring
contacts
gland
pip
Gleitring
1/4
6
8
2
7 5
3
1/4 = ye / flasher ri 2 = Bl / rear fog lamp 3 = Wh / common return 5 = Br / rear light right 6 = Rd / brake light 7 = Bk / rear light left 8 = gr / reverse light
plug case
Chapter 3 Februar 2009
picture 2 Stipulate working time to change a complete 7 pin connector: max. 0,35 h
Cable tie
Chapter 3 Februar 2009
7 pin ASS1 connector green and yellow
1. Cut away max. 35mm of the cover at the end of the cable, thread the gland and the pipe onto the cable (picture 1)
2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)
3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)
4. sie den Kabelbinder am Tüllenende (Bild 2)
picture 1
plug case contacts nut
pipe
gland ring
1/4
2 3
8
7 5
6
1/4 = gr or ye / flasher 2 = bl / rear fog lamp 3 = wh / common return 5 = br / rear light right 6 = rd / brake light 7 = bk / rear light left 8 = gr / reverse light
Chapter 3 Februar 2009
picture 2 Stipulate working time to change a complete 7 pin connector: max. 0,35 h
Cable tie
Chapter 3 Februar 2009
2 pin ASS1 connector black
1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe and the ring onto the cable (picture 1)
2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)
3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)
4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)
picture 1 picture 2 Stipulate working time to change a complete 2 pin connector: max. 0,25 h
contacts pipe nut
pipe
ring
plug case
1 2
1 = wh / common return 2 = current carring
Cable tie
Chapter 3 Februar 2009
2 pin ASS1 connector black
1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe and the ring onto the cable (picture 1)
2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)
3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)
4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)
picture 2 picture 2 Stipulate working time to change a complete 2 pin connector: max. 0,25 h
contacts pipe nut
pipe
ring plug case
1 2
1 = wh / common return 2 = current carring
Cable tie
Chapter 3 Februar 2009
1. the connector has an “anti twist” (flattening)
“anti twist”
System ASS1 – 2 pin connector explanation: the yellow connectors are for the left side, and the green ones are for the right side (in driving direction)
Chapter 3
2. put t
3. the p
he connecto
plastic screw
rs correct tog
w has to be
gether, and m
tighten only
mount the pl
y by hand
astic screw
Feebruar 2009
s
Chapter 3
Syste explanatdriving d
connector oside of the
em ASS1
tion: the yellodirection)
on the backrear lamp
– 7 pin c
ow connecto
k
1. check connec
togeth
connecto
ors are for the
that both “actors her
“anti tw
or
e left side, an
anti twists” f
wist”
nd the green
“anligh
fit together,
ones are for
ti twist of thht
Fe
than put th
r the right sid
he rear
ebruar 2009
he
de (in
2
Chapter 3
2. put the co light. The
onnectors togplastic screw
gether and mw has to tigh
mount the platen only by h
stic screw onhand !
nto the back
Feebruar 2009
Chapter 3 Februar 2009
mounting instructions ASS1 connector - Strip the Isolation 150 mm. Mount the screwing nut, slide-ring and rubber (look picture 1).
Depending tot he diameter oft he cable use the right rubber (different colours). As a strain-bearing element fit a plastic strip and tighten him.
Rubber black for cable diameter 5-6 mm Rubber brown for cable diameter 2x5-6 mm Rubber white for cable diameter 7-8 mm Rubber blue for cable diameter 9-10 mm Rubber red for cable diameter 11-13 mm Rubber grey for the flat cable P&R 2x1,5 [] Rubber green sealing rubber for 2 pin. Outside connector - Crimp the 6,3 fastons onto the conductors, pass the cable through the entrance on the junction box
and connect them corresponding DIN ISO. (look description – insde of the cover) - Close all screwing devices on the junction box as far as it will go - Close the cover with the housing from the junction-box with the 4 thermoplast screws 5x30 as far
as it will go. Torque 3,0 Nm.
- Mount the junction-box only in vertical position. Follow description „TOP“ (=at the top). Fix the cables from the junction-box down (waternoxe) together with several cable clips.
screwing nut
slide ringrubber
/ Picture 1
Ru
Chapter 3
- While
- Not u
Fitting
Gu
Detail
ubber /
The ventlowest prubber whdirection After fittinplastic pa
e connection
used outside
g and ch
12 mm Lo
ummitülle
Plastikstop
/ Detail
12 mm h
ed gland mupoint oft he hole must beoft he traffic
ng the rubbeart into the slo
either the 2-
connectors
hanging o
och an der t
pfen
V
/ plast
hole at the lo
ust be positijunction-bo
e positioned c. Blean the rer, look detaot as far as i
-pin or 7-pin
must be clos
of bayon
iefsten Stel
Gehäuseb
Ventil
tic part / g
box‐hous
owest point
oned at the ox and the
against the rilled whole. il, press the t goes.
connector fo
sed with a sc
net-insert
le
boden
vented land
sing
Put34xbayas spa
ollow the cor
crewing devic
ts in the
t the O-ring-sx2,5 for the byonet-insert it goes, turn
anner 23 and
rect position
ce + the gree
junction
sealing (30x2big one) intointo whole atot he right.
d fort he big o
Fe
(code).
en sealing ru
n-box AS
2,5 for the smo the deepenand make 1/Fort he sma
one use a sp
ebruar 2009
bber
SS1
mall insert anning. Insert th/8 turn, as fall insert usepanner 30.
ns he far e a
Chapter 3 Februar 2009
Spare parts: Junction-box ASS1 with rubbers, slide-rings and screwing nuts assembled 76-5100-007 Bayonet housing black fort he rubber with whole and O-ring 13-5621-004 Bayonet housing black fort he rubber without whole and O-ring 13-5621-014 Bayonet housing yellow for 2 pins outside connector with O-ring and faston 6,3 13-5627-204 Bayonet housing green for 2 pin outside connector with =-ring and faston 6,3 13-5627-224 Bayonet housing black for 2 pin outside connector with O-ring and faston 6,3 13-5627-284 Bayonet housing yellow for 7 pin outside connector with O-ring and faston 6,3 13-5627-704 Bayonet housing green for 7 pin outside connector with O-ring and faston 6,3 13-5627-724 Bayonet housing black for 7 pin outside connector with =-ring and faston 6,3 13-5627-784 Bayonet housing 17 pin. ASS3 male, O-Ring with spring and contacts 13-1750-004 Bayonet housing 17 pin. ASS3 female, with 2x O-Ring and contacts 13-1740-004 5 pcs. Black rubbers 6mm open 15-5623-00V 5 pcs. Black rubbers 6mm closed 15-5623-10V 5 pcs. Brown rubbers 2x6mm open 15-5623-01V 5 pcs. Brown rubbers 2x6 mm closed 15-5623-11V 5 pcs. White rubbers 8mm open 15-5623-02V 5 pcs. White rubbers 8mm closed 15-5623-12V 5 pcs. Blue rubbers 10mm open 15-5623-03V 5 pcs. Blue rubbers 10mm closed 15-5623-13V 5 pcs. Red rubbers 12mm open 15-5623-04V 5 pcs. Red rubbers 12mm closed 15-5623-14V 5 pcs. Grey rubber fort he flat-cable P&R [] 15-5623-18V 5 pcs. Sealing rubber for 2 pin outside connect 15-5623-30V
Chapter 3 Februar 2009
Mounting instruction (detail) vented gland picture 1
picture 2
picture 3
Step 1:
• Open the junction box Drill a 12 mm dia hole at the thickest point in the bottom of the junction box
• ATTENTION: care must be taken not to drill into existing cables or contacts, ensure tht the 12 mm dia hole is drille asclose tot he rubber seal as possible
• Ensure the mark „TOP“ is upright • Ensure all waste particles are removed from the box
Step 2:
• Insert the rubber part into the drilled hole, so that the hole of the vented gland is AGAINST the direction fot he traffic. Push the plastic gland firmly into the rubber part. ATTENTION: both items have a locating rail.
Step 3:
• Close the juntion box • Ensure that the vented gland is mounted correctly. If the
junction box mounted in the center oft eh rear bumber bar, the vented gland must point towards the rear oft he trailer (i.e. against the direction of travel), see pucture 3.
• If the junction box is mounted tot he trailer main rail, the vented gland should point towards the mounting face.
Chapter 3 Februar 2009
System ASS1 Selection oft he correct sealing glands for additional outputs on the jucntion box cover:
• All sealing glands for cable glands are marked with a different colour (please refer tot he fitting instructions „junction box ASS1)
• Different diamters for cables are mentioned on the junction box cover (please refer tot he drawing below)
• Measure the diameter oft he required cable • Select the correct rubber (diameter oft he cable) • Thread the rubber, the slide ring fort he connector and the seal nut in the cable • Unwind the cable ca. 130 mm • Crimp the cables • Fit on the required terminal oft he junction box (refer to chapter 15 – electrical circuit plan) • Tightly fix the seal nut on the housing • Close the junction box (be careful not the jam any cables) and tightly fix the screws
Chapter 3 Februar 2009
SYSTEM ASS1
Order Nr. left (yellow) right (green) reversible describtion
13-5625-211 X ASS1 2 pin male yellow
13-5625-231 X ASS1 2 pin male green
13-5625-361 X ASS1 2 pin male black
13-5626-261 X ASS1 2 pin female yellow
13-5626-271 X ASS1 2 pin female green
13-5626-331 X ASS1 2 pin female black
SYSTEM ASS1
Order Nr. left (yellow) right (green) reversible describtion
13-5625-751 X ASS1 7 pin male yellow
13-5625-811 X ASS1 7 pin male green
13-5625-771 X ASS1 7 pin male white
13-5625-821 X ASS1 7 pin male black
13-5626-931 X ASS1 7 pin female yellow
13-5626-921 X ASS1 7 pin female green
13-5626-901 X ASS1 7 pin female white
13-5626-911 X ASS1 7 pin female black
Chapter 3a Februar 2009
Chapter 3a System ASS2
Chapter 3a Februar 2009
7 pin ASS1 connector white and black Types:
2- and 7 pin Female terminal and connector / housing AMP (6,3 mm) male flat terminals
Difference to ASS1 System: As shown on the drawings below, bayonet ducts are implemented in the male parts with external thread. The screwcap has only bayonet nobs without a thread. Measurements according to the drawing (diameter a little larger than ASS1 system). Advantages of the ASS2 to ASS1 system: On closing the connector the bayonet snaps in (click). The ASS1 system allows to adjust the tightness of the seal depending on the strain applied. Protective evaluation ( www.aspoeck.at ): IP69K, ADR approved for Zone 2
Colours: yellow, green, black, white (please refer to chapter 16 – colours)
Diameter of the individual connectors:
28,9
040
,90
2 pol. ASS2 / 2 pin ASS2
7 pol. ASS2 / 7 pin ASS2
37,40
28,8
0
Chapter 3a Februar 2009
2pin ASS2 connector 1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe and the ring onto the cable (picture 1) 2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1) 3. Put the contacts into the plug case, so that they engage in the plug case (picture 1) 4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)
picture 1
picture 2
Stipulate working time to change a complete 2 pin connector: max. 0,25 h
plug case
contacts
pipe nut
pipe
ring
1 = wh / common return 2 = Current carring
12
Chapter 3a Februar 2009
2pin. ASS2 connector 1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe onto the cable (picture 1) 2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1) 3. Put the contacts into the plug case, so that they engage in the plug case (picture 1) 4. Put the pipe over the case, fix the metal clamp and the cable strip at the end of the pipe (picture 2)
picture 1
picture 2
Stipulate working time to change a complete 2 pin connector: max. 0,25 h
metal clamp
plug case contacts metal clamp
pipe 1 2
1 = wh / common return 2 = Current carring
metal clamp
cable strip
Chapter 3a
7 pin. 1. Cut a
cable 2. Cut a 3. Put th 4. Put th picture
picture 2
Stipula
7
a
ASS2 co
away max. 35e (picture 1)
away ca. 6mm
he contacts i
he pipe close
1
2
ate workin
1
6
5
onnector
5mm of the c
m the cover o
nto the plug
e to the plug
ng time to
pipe
2
3
4
m
r with pin
cover at the e
of the single
case, so tha
case and fix
change a
1 = wh / c2 = Bk / r3 = Ye / f4 = Rd / b5 = Gn / f6 = Br / re7 = Ye-sw
A
etal clamp
n case b
end of the ca
cores and fi
at they engag
x both metal
complete
contac
common returear light leftflasher left brake light flasher rightear light rightw / trailer bra
ASS2 7 pin
black and
able, thread t
x the contac
ge in the plug
clamps. (pict
e 7 pin con
cts
urn
t ake control
black
meta
d white
the gland an
cts onto these
g case (pictu
ture 2)
nnector: m
plug case
1 = w2 = B3 = g4 = B5 = o6 = rs7 = B
al clamp
Fe
d the pipe on
e cores (pictu
ure 1)
max. 0,35 h
e
wh / commonBk / free
n / reverse liBr-bl / feed cuor / free s / bogie lift
Bl / rear fog la
ASS2 7
ebruar 2009
nto the
ure 1)
h
return
ight urrent
amp
pin white
Chapter 3a
7 pin. 1. Cut
cab
2. Cut
3. Put
4. Put picture
2
a
ASS2 co
t away max. ble (picture 1)
t away ca. 6m
the contacts
the pipe clo
1
pip
1/4
3
5 7
8
onnector
35mm of the)
mm the cove
s into the plu
se to the plu
pe
6
1235678
r with pin
e cover at the
er of the singl
g case, so th
g case and f
/4 = Gn or ye = Bl / rear fo = Wh / com = Br / rear li = Rd / brake = Bk / rear l = Gr /revers
n case g
e end of the c
le cores and
hat they enga
fix both meta
cont
e / flasher og lamp mon returnight right e light light left se light
green and
cable, thread
fix the conta
age in the pl
al clamps (p
tacts
d yellow
d the gland a
acts onto the
ug case (pic
icture 2)
plu
Fe
and the pipe
ese cores (pic
cture 1)
ug case
ebruar 2009
onto the
cture 1)
Chapter 3a
picture 2
Stipula
me
a
2
ate workin
etal clamp
ng time to
change a complete
metal clam
e 7 pin con
mp
nnector: m
Fe
max. 0,35 h
ebruar 2009
h
Chapter 3a
7 1. Cut
onto 2. Cut 3. Put 4. Put picture
pi
7
2
8
a
pin. ASS
t away max. o the cable (
t away ca. 6m
the contacts
the pipe clo
1
pe
1/4
3
5
6
S2 conne
35mm of thepicture 1)
mm the cove
s into the plu
se to the plu
conta
gland
p
1235
ector yel
e cover at the
er of the singl
g case, so th
g case and f
acts
pipe nut
ring
1/4 = ye / flas2 = Bl / rear f3 = Wh / com5 = Br / rear l
llow/gree
e end of the c
le cores and
hat they enga
fix the cable
plug
g
sher fog lamp
mmon returnlight right
en
cable, thread
fix the conta
age in the pl
strip at the e
g case
6 7 8
d the gland, p
acts onto the
ug case (pic
end of the pip
= Rd / brake= Bk / rear li= Gr /revers
Fe
pipe and the
ese cores (pic
cture 1)
pe (picture 2
ring
e light ght left e light
ebruar 2009
ring
cture 1)
)
Chapter 3a
picture 2
Stipula
a
2
ate workin
cable strip
ng time to
pe
change a complete
e 7 pin con
nnector: m
Fe
max. 0,35 h
ebruar 2009
h
Chapter 3a
7pin. A 1. Cut
onto 2. Cut 3. Put 4. Put picture
7
a
ASS2 co
t away max. o the cable (
t away ca. 6m
the contacts
the pipe clo
1
pipe
5
1 7
6
onnector
35mm of thepicture 1)
mm the cove
s into the plu
se to the plu
glan
3
4
2
r white a
e cover at the
er of the singl
g case, so th
g case and f
nd
pipe nut
contact
1 =2 =3 =4 =
and black
e end of the c
le cores and
hat they enga
fix the cable
ring
= Wh / comm= Bk / rear li= Ye / flashe= Rd/ break
k
cable, thread
fix the conta
age in the pl
strip at the e
mon return ight le er left light
d the gland, p
acts onto the
ug case (pic
end of the pip
plug
5 = Gn6 = Br7 = Y
Fe
pipe and the
ese cores (pic
cture 1)
pe (picture 2
g case
ring
n / flasher rigr /rear light ri
Ye/bl free
ebruar 2009
ring
cture 1)
)
g
ght ght
Chapter 3a
picture 2
Stipula
7
a
2
ate workin
7
cable s
ng time to
strip
change a complete
e 7 pin connnector: m
Fe
max. 0,35 h
ebruar 2009
h
Chapter 3a Februar 2009
SYSTEM ASS2
Order Nr. left (yellow) right (green) reversible describtion
15-5624-041 side marker light connector ASS2
13-5625-871 X ASS2 2 pin male yellow
13-5625-881 X ASS2 2 pin male green
15-0281-021 X ASS2 2 pin male black
13-5626-341 X ASS2 2 pin female yellow
13-5626-351 X ASS2 2 pin female green
15-5624-031 X ASS2 2 pin female black
13-5625-831 X ASS2 7 pin male yellow
13-5625-841 X ASS2 7 pin male green
13-5625-851 X ASS2 7 pin male white
13-5625-861 X ASS2 7 pin male black
13-5626-941 X ASS2 7 pin female yellow
13-5626-951 X ASS2 7 pin female green
13-5626-961 X ASS2 7 pin female white
13-5626-971 X ASS2 7 pin female black
Chapter 3a Februar 2009
1. check that both “anti twists” fit together (same “anti twists” like at ASS1) than put the connectors together
2 pin. ASS2 connector explanation: the yellow connectors are for the left side, and the green ones are for the right side (in driving direction)
7 pin female connector 7 pin male connector
ASS2 nut
O-Ring
Chapter 3a
2. put
3. l
a
the connecto
ock the nut b
ors together
by hand, unt
and turn the
il you hear a
C
nut until it s
gro
click !
CLICK !
naps into the
oove
e groove.
Feebruar 2009
Chapter 3a Februar 2009
1. check that both “anti twists” fit together (same “anti twists” like at ASS1) than put the connectors together
7 pin. ASS2 connector explanation: the yellow connectors are for the left side, and the green ones are for the right side (in driving direction)
7 pin female connector 7 pin male connector
nut
Chapter 3a Februar 2009
2. put the connectors together, turn the nut until it moves into the groove
groove
3. lock the nut by hand, until you hear a click !
CLICK !
Chapter 3b Februar 2009
Chapter 3b ASS3 Systems
Chapter 3b Februar 2009
System ASS3 Types:
15 pin Female and male housing Connector mounted inside the housing (divider ASS1) or loose on the cable with rubber sealing or
hotmelt Tyco Mate N Lok pins and sockets
Protective evaluation ( www.aspoeck.at ): IP69K, ADR approved for Zone 2
Colour: black
Diameter of the individual connectors:
in mm:
Ansicht A
Ansicht A
Ansicht A
Ansicht A
max
. 33,
5 m
m
max
. 37,
3 m
m
ATTENTION: Pin 4, 7, 8 and 17 are assembled with large Mate N Lok contacts
Female housing Male housing
Chapter 3b Februar 2009
Electrical circuit:
rs / steering axle
br-bl / Stromvers. 24V
rs / Lenkachse12ws-sw / frei13
1415
vi / Anfahrhilfe
or / Achslift
br / Standlicht rechts6
gr RFS
ge-sw / frei
7891011
rt / Bremse
bl / NES
2345
1 ge / Blinker links
gn / Blinker rechts
ws / Masse
sw / Standlicht links
br-bl / feed current
wt-bk / free
vi / drive up help
or / bogie lift
br / rear light right
gr / reverse light
yw-bk / free
rd / brake light
bl / rear fog lamp
ye / flasher left
gn / flasher right
wt / common return
bk / rear light left
br-rd / interior lightbr-rt / Innenbeleuchtung
rose / essien de direction
brun-bleu / alimentatien en courant
blanc-noir / libre
violet / aide de depart
orange / léve essieu
brun / feux de position droite
gris / recul
jaune-noir / libre
rouge / stop
bleu / brouillard arriere
jaune / clignotant gauche
vert / clignotant droite
blanc / masse
noir / feux de position gauche
brun-rouge / éclairage intérieur
1617
frei
frei
free
free
ouvert
ouvert
Chapter 3b Februar 2009
Installation instructions for repair purposes with rubber pipe
Tüllepipedouille
metal clampcollier de serrage métallique
Metallschelle
Ansicht Aview Avue A
Bild / picture / photo 1
O - Ring DichtungO - ring sealingO - Ring
Gehäusesocket caseconnecteur
Bild / picture / photo 2
Metallschelle
collier de serrage métalliquemetal clamp
Chapter 3b Februar 2009
1. The end of the cable max. 35mm cut away the cover and thread the pipe onto the cable (picture 1) 2. About 4mm cut away from the single cores and fix the contacts onto the cable (picture 1) 3. Put the pipe over the case and fix the metal clamps at the front and the back of the pipe (picture 2) 4. Put the contact-grease onto the contacts ! ATTENTION: Before activating you vehicle check all electrical functions according to their proper functionality. All warranties are void in case of non-compliance with this mounting instruction.
Ansicht Aview Avue A
Siftgehäuseplug caseconnecteur
Tüllepipedouille
metal clampcollier de serrage métallique
Metallschelle
Feder muss eingerastet sein !
Bild / picture / photo 1
the spring must be engagedle ressort doit être enclanché
Bild / picture / photo 2
metal clampcollier de serrage métallique
Metallschelle
collier de serrage métallique
Chapter 3b Februar 2009
3 pin. ASS3 female connector 1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe and the ring onto the
cable (picture 1) 2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1) 3. Put the contacts into the plug case, so that they engage in the plug case (picture 1) 4. Put the pipe over the case, fix the cable strips at both ends of the pipe as well the o-ring on the
casing (picture 2) picture 1
picture 2
Stipulate working time to change a complete 3 pin connector: max. 0,25 h
contacts
pipe
connector
2 3 1
1 = wh / common return 2 = Current carring 3 = free
cable strip
o‐ring
Chapter 3b Februar 2009
3 pin. ASS3 male connector
1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe onto the cable
(picture 1)
2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)
3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)
4. Put the pipe over the case, fix the cable strips at both ends of the pipe (picture 2) picture 1 picture 2 Stipulate working time to change a complete 3 pin connector: max. 0,25 h
contacts pipe
connector
1 3 4
1 = wh / common return 2 = Current carring 3 = free
cable strip
Chapter 3b Februar 2009
17 pin. ASS3 connector
close the connector
female connector male connector
1. check that the O-ring sealing and the spring is mounted
/O-Ring sealing
/metal spring
2. Put the connectors together, the locking mechanism must engage in the correct position
Locking mechanism/position
Chapter 3b
open t
3. th
1. you h
b
he connec
he connector
have to lift u
ctor
r is correct c
p the spring
lift up
losed, after y
g with a scr
the spring
you hear two
CLICK !!
rewdriver, th
only at this
o clicks !
!
han you can
position !
n open the c
Fe
connector
ebruar 2009
Chapter 3b Februar 2009
2. lift the spring until it is in the catch “open” on the left and right side !
open closed
3. now you can disconnect the connectors, put the spring down, until it engages in the catches “closed”.
put the spring down
Chapter 3b
1
2. Put corr
3 pin.
close t
K
b
. Check, th
the connecrect position
ASS3 co
the conne
fema
Kabelbinder
hat the O-rin
ctors togethen.
onnector
ctor
le connecto
O-Ring sea
rTo fix the c
ng is mounte
er, the locki
r
or
aling
connector o
ed.
ing device m
L
n the chass
must engag
male con
Locking dev
sis, use a ca
ge in the
nnector
vice, correct
able tie in th
Fe
t position
his guide ra
ebruar 2009
ail
3.
4.
Chapter 3b
. The conn
. Mounting
C
b
nector is co
g Instruction
a.100 mm
rrect closed
ns for the ca
d, after you
able ties.
can see the
e two lockin
Lock
ng devices a
ca. 100 m
king device
Fe
are fixed
mm
ebruar 2009
Chapter 4 Februar 2009
Chapter 4 P&R System
Chapter 4 Februar 2009
P & R System (Press and ready)
Types: � 2 pin � Connector on the cable with single conductor sealing Protective evaluation (www.aspoeck.at): IP69K, ADR approved for Zone 2
Diameter of the individual connectors: In mm:
Information: � Quick, easy and flexible installation. � Useable for all type of one-function-lights. � All lights are already function-tested as well as pre-assembled. � Absolutely water tight through silicon seal � Useable for the transport of dangerous goods (ADR).
ATTENTION: There is already a copy of our product on the marke t, which can optically not be distinguished
from our system. The only difference can be seen at the back of the connector. On our connectors (black part) you can see the Aspöck Logo ! ! Please be aware of this!
Chapter 4 Februar 2009
Repairing instructions
Change of a 2-pin P&R connection on a flat cable
1) Turn off the voltage supply oft he truck before teh repair. 2) The defective P&R connection on the flat cable hast o remain fixed, this is necessary for
preventing water to pour in when the holes on the flat cable are open on the outer side. (please refer to picture 1).
3) Cut the cable (dimensions: 2x1) ca. 10-20 cm after the P&R connection (please refer to picture 1)
4) The cut end hast o be sealed water tight by the means of an appropriate rubber flat terminal (order no.: 15-5983-024) (pleae refer to picture 1).
5) The new P&R connection now hast o be fixed on a different place oft he flat calbe (please refer to picture 1)
6) The further procedure is described in picture 2,3 and 4.
visual control • Please check all electrical functions for the funct ional ability before starting the vehicle.
BILD 2/picture 2
BILD 3/picture
BILD 4/
picture 4
RICHTIG/
right FALSCH/
wrong
FALSCH/
wrong
Chapter 4 Februar 2009
Repairing instructions P&R flatcable / round cables
All cables (round or flat) can be repaired and sealed watertight after a mechanical damage (drilled, scrubbed and so on…)
� Connecting Set 2pin: Order Nr.: 13-5625-284 / complete connecting component (male and female) For Flat cables 2x1,5 and round cables 2x1 qmm, in a PE bag.
Repairing instructions:
1) Cut the cable at the defective end. 2) Cut the cable 25 mm at both ends. 3) Thread the seal nuts and the slide rings on the rubber (please refer tot he drawing below) and
then put them on the cable ends. 4) crimp the terminals on the flex (male flat terminals and terminals) 5) Put all terminals in the housing and fix it
ATTENTION: Please nitice the electrical wiring on the inner side, otherwise the electronics might be damaged. CLAMP 1 – mass (White) CLAMP 2 – electrical circuit (e.g.: BROWN)
6) Move the rubbers tightly tot he connecting component. 7) Put the 2-pin main connecotr (female flat terminals) into the conterpart
ATTENTION: The housing is protected against pinning - do not use force. 8) Tightly foix both seal nuts 9) Fox both cable clips on the intended place – READY
Chapter 4 Februar 2009
Repairing set for the side marker cable
1. Cut away max. 30mm the cover at the end of the cable, and thread the pipes and the rings onto the cable (picture 1, 2)
2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1, 2) 3. Put the correct contacts into "case 1" and the other contacts into "case 2" they must engage in the
cases ! 4. Put the pipes close to the cases, close the pipe nuts, and fix the cable strips at the end of each
pipe (picture 3) picture 1
contacts contacts
ring
Pipe nut
Case 2 Case 1 Rubber pipe
Chapter 4 Februar 2009
picture 2 picture 3
contacts
ATTENTION !!! this side is only for these contacts!!!
cable strips
Chapter 4 Februar 2009
P&R System
Flatcable
P&R connector
put the connector onto the flatcable (see photos)
Chapter 4 Februar 2009
put the plastic cover onto the connector + flatcable, like in the photo below
Click the plastic cover and the P&R connector with the P&R tool together.
Chapter 5 Februar 2009
Chapter 5 Aspöck Lights
Chapter 5 Februar 2009
Aspöck Lights
Unipoint SML Unipoint red Unipoint white
Sidepoint SML Sidepoint white Flatpoint II
Flatpoint II white Flatpoint II red
Superpoint URL Superpoint II
Superpoint LED Superpoint III LED
Chapter 5 Februar 2009
Monopoint white/red Rückstrahler red/white
Europoint Europoint II
Ecopoint mit URL Ecopoint mit LED
Ecopoint with triangle and/or outlinemarker Earpoint
Chapter 5 Februar 2009
Regpoint red Regpoint white
Regpoint white LED
Posipoint red Posipoint white
Chapter 5 Februar 2009
Posipoint white II LED Posipoint II red LED
Monopoint red II LED Monopoint white II LED
3- Chamberlight LED 3-Chamberlight
fog lamp fog lamp LED
Chapter 5 Februar 2009
reverseing lamp reversing lamp LED
• You will receive detailed information concerning order numbers, replacement parts, types
and possible wiring on our homepage www.aspoeck.at.
Chapter 5 Februar 2009
Side marker lamp „Flatpoint II“ with ASS2 connector 1. Cut away max. 25mm the cover, thread the nut, ring and the pipe onto the cable (picture 1) 2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1) 3. Put the contacts onto the light, it doesn´t matter which contact on the light you choose. Put the
isolate hose onto on of the contacts (picture 2) 4. Put the pipe close to the light and fix the cable strip (see picture 2) and mount the ASS 2 nut onto
the light. The nut must be screwed onto the light, as long as the pipe can´t be turned (picture 3) picture 1
isolate hose cable tie
contacts ring
pipe ASS2 nut
Chapter 5 Februar 2009
picture 2 picture 3 Stipulate working time to change a complete side marker light : max. 0,15 hours
Isolate hose
Cable tie
Chapter 5 Februar 2009
Side marker lamp „Unipoint“ with ASS2 connector 1. Cut away max. 25mm the cover, thread the nut, ring and the pipe onto the cable (picture 1) 2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1) 3. Put the contacts onto the light, it doesn´t matter which contact on the light you choose. Put the isolate hose
onto on of the contacts (picture 2) 4. Put the pipe close to the light and fix the cable strip (see picture 2) and mount the nut onto the light. The ASS2
nut must be screwed onto the light, as long as the pipe can´t be turned (picture 3) picture 1
isolate hose cable tie
contacts ring
pipe ASS2 nut
Chapter 5
picture 2 picture 3
Stipula
2
3
te working
Isolate hos
g time to ch
e
hange a complete sid
Cable tie
e marker li
ight : max.
Fe
0,15 hours
ebruar 2009
s
Chapter 5 Februar 2009
Side marker lamp „Unipoint“ with ASS2 connector
1. Cut away max. 25mm the cover, thread the nut, ring and the pipe onto the cable (picture 1)
2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)
3. Put the contacts onto the light, it doesn´t matter which contact on the light you choose. Put the isolate hose onto on of the contacts (picture 1)
4. Put the pipe close to the light and fix the cable strip (see picture 2) and mount the nut onto the light. 5. The nut must be screwed onto the light, as long as the pipe can´t be turned picutre 1 picture 2
Stipulate working time to change a complete SML+holder: max. 0,15 hours
contacts ring
pipe nut
Isolate hose pipe
Chapter 6 Februar 2009
Chapter 6: 3-Socket Junction Box
Chapter 6 Februar 2009
Installation instructions
Installation instruction on the vehicle:
The installation on the vehicle has to be done at a gradient of 5 degree (towards the road level).
Cable ends down. It has to be fixed on the vehicle by nuts
(8x90). Torque: 8-10 Nm. Dimension of the hole: 124 x 224 mm
Subsequent installation of additional fittings:
Step 1:
Unscrew the plastic screws (5x30/15) at the back of the junction box.
Cut the cable at roughly 150mm, thread the seal nuts, slide rings and the rubber according to drawing 1. Please use the appropriate sealing glands for the diameter of the cable. Please fix a cable clip and tighten it.
Fix male flat terminals (6,3mm).
Chapter 6 Februar 2009
Step 2:
Thread the cable on the desired place and fix it according to DIN/ISO (please refer to the explanation on the next page) on the free contacts of the terminal.
Tightly fix the seal nut on the housing.
Unused cable terminals have to be closed with a seal nut (green colour).
Step 3:
Please appropriately fix the loose wires inside the junction box or fix them on the other wires by means of cable clips.
Close the back of the housing as well as the plastic screws (at torque 2,5 Nm).
Chapter 6 Februar 2009
wiring schematic: PIN color Function
1 yellow flasher left
2 green flasher right
3 blue fog light
4 white 2,5 ground
5 black tail light left
6 brown tail light right
7 red 2,5 brake
8 grey reverse light
9 brown/blue 2,5 feed current+
10 brown/red wear control
11 yellow/black trailer brake control
12 pink axle lift
13 white/black ground electronic
14 violett data
15 orange data
standard-wiring:
Chapter 6 Februar 2009
special wiring: company PAGG (Italy)
company Schwarzmüller
Chapter 6 Februar 2009
spare parts:
standard wiring N, S and 15pin for 3 socket junction box 58-3008-007
3fach Steckdosen Verteiler (vorverkabelt - zur Selbstmontage) 76-7001-007
Front – housing with sockets (empty) 15-5660-004
Rear – housing with screws 15-5661-004
socket ISO 12098 (15pin) incl. O – Ring 69-0001-004
socket ISO 1185 incl. O – Ring 69-0002-004
socket ISO 3731 incl. O – Ring 69-0003-004
5 pieces sealing glands / black for cable diameter 5-6mm 15-5623-10V
5 pieces sealing glands / brown for cable diameter 2 x 5-6mm 15-5623-11V
5 pieces sealing glands / white for cable diameter 7-8mm 15-5623-12V
5 pieces sealing glands / blue for cable diameter 9-10mm 15-5623-13V
5 pieces sealing glands / red for cable diameter 11-13mm 15-5623-14V
5 pieces sealing glands / grey for flat cables P&R System 15-5623-18V
5 pieces sealing glands / green 15-5623-30V
• Please check all electrical functions before you start your vehicle ! • In case of non-compliance with these installation instructions all warranties
are void!
Chapter 7 Februar 2009
Chapter 7: Examples of lighting system
Chapter 7 Februar 2009
All lighting systems of Aspöck Systems are designed to fulfil the specific customers requirements. All lighting systems are planned in cooperation with our customers. Hereby we are strongly following the requirements of our customers concerning design and packaging. Our aim is to provide our customers cost saving solutions which are easy to assemble. On the following pages you will find a clear overview of our 24 V standard parts. Our customers may chose out of these components and put together a lighting systems up to their requirements. All parts are in stock and are available on short term. Special requests will have to be produces separately and therefore have a longer lead time. Please find more details on our lighting equipment on our homepage www.aspoeck.at.
Chapter 7 Februar 2009
31-2
007-
237
0
,5m
31-2
007-
247
1
,5m
LED
Uni
poin
t
OA-
7000
-04565
-100
3-00
7
9,0
m
65-1
003-
017
12,
5m
65-1
003-
027
15,
0m
DIN
ISO
1185
24V
DIN
ISO
3731
DAF
NATO
24V
15 pol. ISO 12098
DAF
DIN
ISO
3731
24V
NATO
24V
DIN
ISO
1185
6x1
+ 2x
2,5
12x1
+ 3
x2,5
7x1
600
mm
600
mm
5x1+
2x2,
55x1+
2x2,
5
600
mm
600
mm
7x1
0,8m
0,8m
600
mm
12x1
+ 3
x2,5
65-1
005-
027
15,
0m7x
1 +
1x1,
5 +
2x2,
5
65-1
005-
017
12,
5m
65-1
007-
007
9
,0m
65-1
007-
017
12,
5m
65-1
007-
027
15,
0m
65-1
005-
007
9
,0m
2x1
31-2
067-
097
0
,5m
31-2
067-
107
1
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2x1
Pos.
Leu
chte
UN
IPO
INT
- LED
1250
mm
2x1
qmm
2x2,51000 mm
6x1+
2x2,
520
0mm 31 / 54
66-8
892-
007
Stop
/ Mas
se
NES
RFS
9x1
200m
m
1000 mm2x1
2x11000 mm
NES
/ Mas
seRF
S / M
asse
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Stif
t
ASS3
Stif
t
ASS3
Stif
tAS
S3 S
tift
ASS3
Stif
t
ASS3
Stif
t
ASS3
Stif
tAS
S3 S
tift
76-5
123-
007
ASS3
Stif
t
66-8
893-
007
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Buc
hse
DICHTMUTTERN bis zum Anschlag
Dichtstopfen rot 11 - 13mm
Dichtstopfen braun 2x5 - 6mmDichtstopfen weiß 7 - 8mmDichtstopfen blau 9 - 10mm
Dichtstopfen schwarz 5 - 6mm
Klemmbereiche f. Kabeldurchmesser:
SYSTEMASPÖCK
TOP
festziehen !
36-3
007-
397
0,
5m
Stan
dard
Teile
AD
R / P
VC fü
r Zon
e 2
Prü
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atum
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STEM
S
Sta
ndar
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unde
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Kun
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pez.
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Pos.
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chte
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POIN
T II
31-2
067-
687
0
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31-2
067-
697
1
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LED
Fla
t II
2x1
31-2
307-
007
0
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307-
017
1
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31-2
367-
027
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057
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LED
Fla
t II
LED
Fla
t II
31-3
406-
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RT
/ WS
31-3
405-
077
RT
/ WS
1250
mm
2x1
qmm
200
mm
2x1
200
mm
2x1
200
mm
200
mm
200
mm
5500
mm
3700
mm
3700
mm
3700
mm
3700
mm
3500
mm
2x1
qmm
3700
mm
3700
mm
3700
mm
3700
mm
3700
mm
2x1
qmm
500
mm
2x1
qmm
1500
mm
2x1
qmm
15 P
ol S
teck
er
12x1
+ 3
x2,5
4800
mm
ASS3
Buc
hse
12x1
+ 3
x2,5
1 50
0 m
m7x
113
00 m
m
76-6
430-
007
ASS3
Buc
hse
7x1
1300
mm
Dichtstopfen schwarz 5 - 6mm
Klemmbereiche f. Kabeldurchmesser:
DICHTMUTTERN bis zum Anschlag
Dichtstopfen rot 11 - 13mmDichtstopfen blau 9 - 10mmDichtstopfen weiß 7 - 8mmDichtstopfen braun 2x5 - 6mm
ASPÖCKSYSTEM
TOP
festziehen !
LED
Uni
poin
t
2x1
LED
Uni
poin
t
2x1
87-1
286-
007
0
,2m
65-6
499-
007
0
,2m
65-1
499-
007
0
,5m
65-1
499-
017
1
,5m
2x1,
5 qm
m P
&R
1,65
m
2,5
m
7x1
2x1,
5 qm
m P
&R1,
65 m
2,5
m68
-498
3-00
7
ASS3
Buc
hse
87-1
285-
007
87-1
284-
007
53-1
667-
037
58-6
647-
007
58-6
649-
007
76-7
037-
007
31-7
707-
107
0
,5m
31-7
707-
117
1
,5m
31-7
707-
127
3
,5m
o. S
trahl
er
31-6
907-
027
0
,5m
31-6
907-
037
1
,5m
31-6
907-
047
3
,5m
o. S
trahl
erDI
N IS
O 11
85
DIN
ISO
3731
7x1
4800
mm
4800
mm
5x1+
2x2,
5
ASS3
Buc
hse
58-6
024-
017
15 P
ol S
teck
dose
12x1
+ 3
x2,5
600
mm
ASS3
Buc
hse
53-6
768-
007
500
mm
2x1
KZ -
Reg
poin
t
31-3
305-
127
RT
/ WS
1250
mm
2x1
qmm
LED
31-3
305-
167
SW
/ W
S
1250
mm
2x1
qmm
LED
31-3
306-
127
RT
/ WS
31-3
306-
167
SW
/ W
S
0802
12
TM
Chapter 7 Februar 2009
31-2
007-
237
0
,5m
31-2
007-
247
1
,5m
LED
Uni
poin
t
OA-
7000
-046
0802
12
TM
DIN
ISO
1185
24V
DIN
ISO
3731
DAF
NATO
24V
15 pol. ISO 12098
DAF
DIN
ISO
3731
24V
NATO
24V
DIN
ISO
1185
6x1
+ 2x
2,5
12x1
+ 3
x2,5
7x1
600
mm
600
mm
5x1+
2x2,
55x1+
2x2,
5
600
mm
600
mm
7x1
0,8m
0,8m
600
mm
12x1
+ 3
x2,5
7x1
+ 1x
1,5
+ 2x
2,52x
1
31-2
067-
097
0
,5m
31-2
067-
107
1
,5m
2x1
Pos.
Leu
chte
UN
IPO
INT
- LED
1250
mm
2x1
qmm
2x2,51000 mm
6x1+
2x2,
520
0mm 31 / 54
66-8
892-
007
Stop
/ Mas
se
NES
RFS
9x1
200m
m
1000 mm2x1
2x1
1000 mm
NES
/ Mas
seRF
S / M
asse
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Stif
t
ASS3
Stif
t
ASS3
Stif
tAS
S3 S
tift
ASS3
Stif
t
ASS3
Stif
t
ASS3
Stif
tAS
S3 S
tift
76-5
123-
007
ASS3
Stif
t
66-8
893-
007
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Buc
hse
DICHTMUTTERN bis zum Anschlag
Dichtstopfen rot 11 - 13mm
Dichtstopfen braun 2x5 - 6mmDichtstopfen weiß 7 - 8mmDichtstopfen blau 9 - 10mm
Dichtstopfen schwarz 5 - 6mm
Klemmbereiche f. Kabeldurchmesser:
SYSTEMASPÖCK
TOP
festziehen !
500
mm
2x1
KZ -
Reg
poin
t
36-3
007-
397
0,
5m
Stan
dard
Teile
P
VC
Prü
fart
.P
rüfa
rt.
IND
EX
D
atum
N
ame
Änd
erun
g
gez.
gepr
.
IND
EX
D
atum
N
ame
Änd
erun
g
Bes
tell-
Nr.
gez.
gepr
.
SY
STEM
S
Sta
ndar
dK
unde
nNr.:
Kun
dens
pez.
2x1
Pos.
Leu
chte
FLAT
POIN
T II
31-2
067-
687
0
,5m
31-2
067-
697
1
,5m
1250
mm
2x1
qmm
31-3
406-
067
RT
/ WS
31-3
405-
077
RT
/ WS
31-3
305-
127
RT
/ WS
1250
mm
2x1
qmm
1250
mm
2x1
qmm
200
mm
2x1
200
mm
2x1
200
mm
200
mm
200
mm
5500
mm
3700
mm
3700
mm
3700
mm
3700
mm
3500
mm
2x1
qmm
3700
mm
3700
mm
3700
mm
3700
mm
3700
mm
2x1
qmm
500
mm
2x1
qmm
1500
mm
2x1
qmm
DIN
ISO
1185
DIN
ISO
3731
15 P
ol S
teck
er
12x1
+ 3
x2,5
4800
mm
7x1
4800
mm
4800
mm
5x1+
2x2,
5
ASS3
Buc
hse
ASS3
Buc
hse
12x1
+ 3
x2,5
1 50
0 m
m7x
113
00 m
m
76-6
431-
007
ASS3
Buc
hse
7x1
1300
mm
Dichtstopfen schwarz 5 - 6mm
Klemmbereiche f. Kabeldurchmesser:
DICHTMUTTERN bis zum Anschlag
Dichtstopfen rot 11 - 13mmDichtstopfen blau 9 - 10mmDichtstopfen weiß 7 - 8mmDichtstopfen braun 2x5 - 6mm
ASPÖCKSYSTEM
TOP
festziehen !
LED
Uni
poin
t
2x1
LED
Uni
poin
t
2x1
87-1
286-
007
0
,2m
65-6
499-
007
0
,2m
65-1
499-
007
0
,5m
65-1
499-
017
1
,5m
2x1,
5 qm
m P
&R
1,65
m
2,5
m
7x1
2x1,
5 qm
m P
&R1,
65 m
2,5
m68
-498
4-00
7
ASS3
Buc
hse
87-1
288-
007
87-1
287-
007
53-1
666-
047
58-6
020-
057
58-6
648-
007
58-6
650-
007
76-7
037-
007
31-7
707-
107
0
,5m
31-7
707-
117
1
,5m
31-7
707-
127
3
,5m
o. S
trahl
er
31-6
907-
027
0
,5m
31-6
907-
037
1
,5m
31-6
907-
047
3
,5m
o. S
trahl
er
15 P
ol S
teck
dose
12x1
+ 3
x2,5
600
mm
ASS3
Buc
hse
53-6
769-
007
LED
LED
LED
Fla
t II
2x1
31-2
307-
007
0
,5m
31-2
307-
017
1
,5m
31-2
367-
027
0
,5m
31-2
367-
037
1
,5m
2x1
2x1
31-2
367-
047
0
,5m
31-2
367-
057
1
,5m
LED
Fla
t II
LED
Fla
t II
65-1
006-
007
9
,0m
65-1
006-
017
12,
5m
65-1
006-
027
15,
0m
65-1
008-
027
15,
0m
65-1
008-
017
12,
5m
65-1
008-
007
9
,0m
65-1
004-
007
9
,0m
65-1
004-
017
12,
5m
65-1
004-
027
15,
0m
31-3
305-
167
SW
/ W
S
31-3
306-
127
RT
/ WS
31-3
306-
167
SW
/ W
S
Chapter 7 Februar 2009
OS-
7000
-118
neu
0706
13
TM
65-1
003-
007
9
,0m
65-1
003-
017
12,
5m
65-1
003-
027
15,
0m
DIN
ISO
1185
24V
DIN
ISO
3731
DAF
NATO
24V
15 pol. ISO 12098
DAF
DIN
ISO
3731
24V
NATO
24V
DIN
ISO
1185
6x1
+ 2x
2,5
12x1
+ 3
x2,5
7x1
600
mm
600
mm
5x1+
2x2,
55x1+
2x2,
5
600
mm
600
mm
7x1
0,8m
0,8m
600
mm
12x1
+ 3
x2,5
65-1
005-
027
15,
0m7x
1 +
1x1,
5 +
2x2,
5
65-1
005-
017
12,
5m
65-1
007-
007
9
,0m
65-1
007-
017
12,
5m
65-1
007-
027
15,
0m
65-1
005-
007
9
,0m
2x2,51000 mm
6x1+
2x2,
520
0mm 31 / 54
66-8
892-
007
Stop
/ Mas
se
NES
RFS
9x1
200m
m
1000 mm2x1
2x1
1000 mm
NES
/ Mas
seRF
S / M
asse
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Stif
t
ASS3
Stif
t
ASS3
Stif
tAS
S3 S
tift
ASS3
Stif
t
ASS3
Stif
t
ASS3
Stif
tAS
S3 S
tift
76-5
123-
007
ASS3
Stif
t
66-8
893-
007
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Buc
hse
DICHTMUTTERN bis zum Anschlag
Dichtstopfen rot 11 - 13mm
Dichtstopfen braun 2x5 - 6mmDichtstopfen weiß 7 - 8mmDichtstopfen blau 9 - 10mm
Dichtstopfen schwarz 5 - 6mm
Klemmbereiche f. Kabeldurchmesser:
SYSTEMASPÖCK
TOP
festziehen !
Stan
dard
Teile
AD
R / P
VC fü
r Zon
e 2
Prü
fart
.P
rüfa
rt.
IND
EX
D
atum
N
ame
Änd
erun
g
gez.
gepr
.
IND
EX
D
atum
N
ame
Änd
erun
g
Bes
tell-
Nr.
gez.
gepr
.
SY
STEM
S
Sta
ndar
dK
unde
nNr.:
Kun
dens
pez.
15 P
ol S
teck
er
12x1
+ 3
x2,5
4800
mm
ASS3
Buc
hse
12x1
+ 3
x2,5
1 50
0 m
m7x
113
00 m
m
76-6
430-
007
ASS3
Buc
hse
7x1
1300
mm
Dichtstopfen schwarz 5 - 6mm
Klemmbereiche f. Kabeldurchmesser:
DICHTMUTTERN bis zum Anschlag
Dichtstopfen rot 11 - 13mmDichtstopfen blau 9 - 10mmDichtstopfen weiß 7 - 8mmDichtstopfen braun 2x5 - 6mm
ASPÖCKSYSTEM
TOP
festziehen !
2x1,
5 qm
m P
&R
1,65
m
2,5
m
7x1
2x1,
5 qm
m P
&R1,
65 m
2,5
m68
-498
3-00
7
ASS3
Buc
hse
53-1
667-
037
58-6
647-
007
58-6
649-
007
76-7
037-
007
DIN
ISO
1185
DIN
ISO
3731
7x1
4800
mm
4800
mm
5x1+
2x2,
5
ASS3
Buc
hse
58-6
024-
017
15 P
ol S
teck
dose
12x1
+ 3
x2,5
600
mm
ASS3
Buc
hse
53-6
768-
007
LED
Uni
poin
t 2x
1
2x1
2x1
2x1
31-2
064-
407
0,
25m
2x1
31-2
004-
017
0
,5m
31-2
004-
027
1
,0m
31-2
004-
037
1
,5m
31-2
064-
007
0,
25m
31-2
064-
017
0
,5m
31-2
064-
027
1
,0m
31-2
064-
037
1
,5m
31-2
064-
707
0,
25m
31-2
064-
717
0
,5m
31-2
064-
727
1
,0m
31-2
064-
737
1
,5m
LED
Uni
poin
t
31-2
104-
017
0,
5m
31-2
104-
037
1
,5m
Kabe
ldire
ktab
gang
2x
1
31-2
064-
227
1,
0m
31-2
064-
237
1,
5m
2x 1
,5 q
mm
2x 1
,5 q
mm
68-7
503-
007
13,
0m
68-7
503-
017
15,
0m
68-7
503-
027
17,
0m
68-7
503-
177
16,
0m
31-6
614-
037
1
,5m
Pos.
Leu
chte
n LE
D-V
ersi
on
2x1
31-7
704-
017
0
,5m
Pos.
Leu
chte
UN
IPO
INT
- LED
31-7
704-
037
1
,5m
2x1
1250
mm
2x1
qmm
31-3
404-
007
RT
/ WS
31-3
404-
027
SW
/ W
S
1250
mm
2x1
qmm
31-3
404-
017
RT
/ WS
31-3
404-
037
SW
/ W
S
2x1
KZ -
Reg
poin
t 36
-300
4-01
7
0,5m
2x1
KZ -
Reg
poin
t 36
-300
4-01
7
0,5m
31-5
004-
027
1
,0m
Pos.
Leu
chte
n G
lühl
ampe
nver
sion
2x1
Chapter 7 Februar 2009
12
x1 +
3x2
,5
5x1+
2x2,
5
OS-
7000
-119
neu
0706
13
TM
65-1
004-
007
9
,0m
65-1
004-
017
12,
5m
65-1
004-
027
15,
0m
DIN
ISO
1185
24V
DIN
ISO
3731
DAF
NATO
24V
15 pol. ISO 12098
DAF
DIN
ISO
3731
24V
NATO
24V
DIN
ISO
1185
6x1
+ 2x
2,5
12x1
+ 3
x2,5
7x1
600
mm
600
mm
5x1+
2x2,
55x1+
2x2,
5
600
mm
600
mm
7x1
0,8m
0,8m
600
mm
12x1
+ 3
x2,5
65-1
006-
027
15,
0m7x
1 +
1x1,
5 +
2x2,
5
65-1
006-
017
12,
5m
65-1
008-
007
9
,0m
65-1
008-
017
12,
5m
65-1
008-
027
15,
0m
65-1
006-
007
9
,0m
2x2,51000 mm
6x1+
2x2,
520
0mm 31 / 54
66-8
892-
007
Stop
/ Mas
se
NES
RFS
9x1
200m
m
1000 mm2x1
2x1
1000 mm
NES
/ Mas
seRF
S / M
asse
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Stif
t
ASS3
Stif
t
ASS3
Stif
tAS
S3 S
tift
ASS3
Stif
t
ASS3
Stif
t
ASS3
Stif
tAS
S3 S
tift
76-5
123-
007
ASS3
Stif
t
66-8
893-
007
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Buc
hse
ASS3
Buc
hse
DICHTMUTTERN bis zum Anschlag
Dichtstopfen rot 11 - 13mm
Dichtstopfen braun 2x5 - 6mmDichtstopfen weiß 7 - 8mmDichtstopfen blau 9 - 10mm
Dichtstopfen schwarz 5 - 6mm
Klemmbereiche f. Kabeldurchmesser:
SYSTEMASPÖCK
TOP
festziehen !
Stan
dard
Teile
Ve
rsio
n PV
CP
rüfa
rt.
Prü
fart
.
IND
EX
D
atum
N
ame
Änd
erun
g
gez.
gepr
.
IND
EX
D
atum
N
ame
Änd
erun
g
Bes
tell-
Nr.
gez.
gepr
.
SY
STEM
S
Sta
ndar
dK
unde
nNr.:
Kun
dens
pez.
15 P
ol S
teck
er48
00 m
m
ASS3
Buc
hse
12x1
+ 3
x2,5
1 50
0 m
m7x
113
00 m
m
76-6
431-
007
ASS3
Buc
hse
7x1
1300
mm
Dichtstopfen schwarz 5 - 6mm
Klemmbereiche f. Kabeldurchmesser:
DICHTMUTTERN bis zum Anschlag
Dichtstopfen rot 11 - 13mmDichtstopfen blau 9 - 10mmDichtstopfen weiß 7 - 8mmDichtstopfen braun 2x5 - 6mm
ASPÖCKSYSTEM
TOP
festziehen !
2x1,
5 qm
m P
&R
1,65
m
2,5
m
7x1
2x1,
5 qm
m P
&R1,
65 m
2,5
m68
-498
4-00
7
ASS3
Buc
hse
53-1
666-
047
58-6
648-
007
58-6
650-
007
76-7
037-
007
DIN
ISO
1185
DIN
ISO
3731
7x1
4800
mm
4800
mm
ASS3
Buc
hse
58-6
020-
057
15 P
ol S
teck
dose
12x1
+ 3
x2,5
600
mm
ASS3
Buc
hse
53-6
769-
007
LED
Uni
poin
t 2x
1
2x1
2x1
2x1
31-2
064-
407
0,
25m
2x1
31-2
004-
017
0
,5m
31-2
004-
027
1
,0m
31-2
004-
037
1
,5m
31-2
064-
007
0,
25m
31-2
064-
017
0
,5m
31-2
064-
027
1
,0m
31-2
064-
037
1
,5m
31-2
064-
707
0,
25m
31-2
064-
717
0
,5m
31-2
064-
727
1
,0m
31-2
064-
737
1
,5m
LED
Uni
poin
t
31-2
104-
017
0,
5m
31-2
104-
037
1
,5m
Kabe
ldire
ktab
gang
2x
1
31-2
064-
227
1,
0m
31-2
064-
237
1,
5m
2x 1
,5 q
mm
2x 1
,5 q
mm
68-7
502-
007
13,
0m
68-7
502-
017
15,
0m
68-7
502-
027
17,
0m
68-7
502-
167
16,
0m
31-6
614-
037
1
,5m
Pos.
Leu
chte
n LE
D-V
ersi
on
2x1
31-7
704-
017
0
,5m
Pos.
Leu
chte
UN
IPO
INT
- LED
31-7
704-
037
1
,5m
2x1
1250
mm
2x1
qmm
31-3
404-
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Chapter 8 Februar 2009
Chapter 8: Spare Parts For detailed information on our spare parts and accessories as well as drawings please refer tot he respective product on our website www.aspoeck.at.
Chapter 9 Februar 2009
Chapter 9: ADR Equipment
Chapter 9 Februar 2009
ADR regulations concerning Aspöck lighting systems Abbreviation “ADR”: Accord europeènne relatif en transport des marchandises dangerauses per route. European arrangement for transportation of hazardous goods on the road Meaning of the expression “GGVSE”: This abbreviation only expresses that the ADR regulations are superior to any other except national regulations Excerpt of VdTÜV instructions 5205 edition 12.03 ATTENTION: The following guidelines refer to the current “ADR frame guidelines 94/55/EC” and may be re-enacted any time in the ADR handbook.
Range of validity The following regulations do not repeat all appropriated regulations of ADR, but only serve for explanation of the partly indefinite terms for the “electrical” equipment of transport units mentioned in passage 9.2.1.
Note: The electrical equipment of tanks (for ex.: electrical installations in the instrument panel, appliances for reference dimension measuring, pumps, heat installations) will be tested by tank experts.
2 Zone division (9.7.8.2) EX/II, EX/III AT, FL, OX General explanation of the zones: The following zones may also come into effect in case of temporary stops (e.g. loading and unloading) in dangerous areas as e.g. in warehouses containing explosives etc.
2.1.1 Zone 0: Zone 0 covers areas where explosive atmospheres exist often, on a long-term basis or constantly.
For tank vehicles, vehicles with tanks and battery vehicles these are i.e.:
• interior of the tanks, fittings and pipes for dispensing or filling and gas recirculation
ATTENTION: Aspöck Systems GmbH does not deliver par ts for lighting systems for Zone 0.
Chapter 9 Februar 2009
2.1.2 Zone 1 Zone 1 covers areas, in which you have to expect that dangerous explosive atmospheres can occasionally arise.
For tank vehicles, vehicles with tanks and battery vehicles these are i.e.:
• interior of locked instrument panels • within a radius of 0,5 m around stop fittings • within a radius of 0,5 m around ventilation systems that cannot be locked but
are open under normal operating conditions (i.e. tipping valve) • within a radius of 0,5 m around security valves
Requirements concerning installed equipment:
- lamps: CE – label, added by the lamps manufacturer - plug and socket connector: CE – label, added by the manufacturer - housing (for ex. junction box ...): CE – label, added by the manufacturer - cable: the wire and cover isolation meet the requirements 3.1.3,
verification of norm (for ex. ISO 6722),
verification of a component label TÜ.EGG
- mounting place has to be defined EXACTLY by the vehicle manufacturer
Explanation to CE – label:
In order to obtain a CE label the manufacturer of the equipment has to provide an approved IP inspection and a shock test in order to verify compliance with the requirements. Afterwards ONLY official test institutes are authorized to grant the release for a vehicle.
2.1.3 Zone 2 Zone 2 covers areas, in which one does not expect a dangerous explosive atmosphere, but in case they arise are rare and of short duration.
• Zone 2 is not covered by ADR. • Zone 2 is not to be expected for tank vehicles, vehicles with tanks and battery
vehicles: - in front of the operator’s cab back wall - within the vehicle frame - with a bigger distance of 1,5m around Zone 1 and around leak- and
drainage drains (e.g. drains of instrument panel, blank hose box, chapter pan)
- within a bigger distance of 0,2m in the distance around the whole tank contour by tanks, which have the open installation in the parting (e.g. chapter top, air-bleed valve)
Chapter 9 Februar 2009
Requirements for the installed equipment:
- lamps: CE – label, added by the lamp manufacturer - connector: CE – label, added by the manufacturer - housing(e.g. junction box ...): CE – label, added by the manufacturer - cables: the wire and cover isolation meet the requirements 3.1.3,
verification of norm (e.g. ISO 6722),
verification of component label TÜ.EGG
- mounting place requires no exact definition.
Explanation to CE label:
In order to obtain a CE label the manufacturer of the equipment has to provide an approved IP inspection and a shock test in order to verify compliance with the requirements. Afterwards the manufacturer is entitled to place the CE label on the respective part which is then valid ARD-checked for Zone 2.
3.1 Electrical pipes and cables (9.2.2.2) EX/ II, EX/III AT, FL, OX
3.1.1 Electrical pipe (conductor) If we speak of „conductor“ we mean of course both, the positive as well as the negative poled conductor. A so-called mass return over structural parts like the vehicle frame, contradicts all rules of technology of the explosion protection.
3.1.2 „sufficiently measured“ Is given when the pipe is corresponding to the conductor cross-section (e.g. ISO 6722-2002³ or ISO 4141:1998)
For mechanical reasons we recommend that the pipe cross-section of fine-wiry conductors which are not coated, should be no smaller than:
- 1,0 mm² for one-wire pipes - 0,75 mm² for multi-wire pipes up to 5 wires - 0,5 mm² for multi-wire pipes with more than 5 wires or pipes in cable
channels
3.1.3 „suitably isolated“ Is given if the pipe corresponds with the wire isolation (e.g. ISO 6722-2002² or ISO 4141:1998)
Examples for usual isolation materials for wire and coating:
- PVC (special mixture of raw material) - PU - rubber
Chapter 9 Februar 2009
3.1.4 „well fixed“ Is given if the pipe (regarding to the pipe coating) is fixed for example by clamps, bands or other fixture so that it cannot sag, scrub or loosen itself. Because of the possibility of mechanical damage you should not lay the pipes in touch with the plastic brake air pipes.
3.1.5 „protected against mechanical and thermal stress“ Is fulfilled if the pipe (corresponding to the pipe coat) is layed as for example in EN 60079-14:1997 No. 9.1.1 protected
- through laying in conduits, plastic tube, metal tube or - through covers (e.g. vehicle frame).
The connecting cables between tractor and trailer vehicle meet the requirements if they are corresponding to e.g. ISO 4141:1998.
3.2 Battery switch (9.2.2.3) EX/II, EX/III A T, FL, OX
3.2.1 “as close as possible to the battery” Fulfilled if the switch is fitted as close to the battery as constructively possible.
The connecting cables must have a wire and coat isolation.
3.2.2 „operating device in the operators’s cab, easily accessible and clearly marked” Must be easily accessible without the aid of auxiliaries and clearly marked. Following the norms of other regulations the marking shall be red.
Note: Further activity facilities are allowed only if they are marked and protected against unintentional operating.
3.2.3 „IEC-norm“ is corresponding to DIN EN 40 050 (IP – kinds of protection).
3.3 Batteries (9.2.2.4) EX/II, EX/III AT , FL, OX
The battery connection clamp must be
- isolated electrically - covered by an isolated cap of the battery box
If the batteries are not situated under the bonnet (a tiltable operator’s cab is regarded as a bonnet), they must be fixed in an aerated battery box.
3.4 Continuous Circuit (9.2.2.5.1, 9.7.8.3) EX/II, EX/III AT, FL, OX
3.4.1 „is suited for using within a danger zone (except inside the operator’s cab)” The parts (appliances, accessory pipes and connections) of the electrical installation, which stay under current while the battery switch is open must be suited for use in zone 1 (certificate 94/9/EG, see“requirements on the installed appliances” item 2.1.2).
Chapter 9 Februar 2009
The parameters of the correct danger zone are defined by:
- temperature class T6 - explosion group IIC
This means a max. surface temperature of 85°C!
At use in an external environment where the temperature caused by the electrical equipment installed in this area is higher than 85° C (T6) the electrical equipment has to correspond to temperature class T4 (135° C)
Examples for continuous circuits:
- securing for EG-control appliance - circuits for appliances to measure the reference dimension - circuits for QSS - parts of a GPS-installation - alarm system
3.4.2 „is suited for use within a danger zone (in the operator’s cab) The parts (appliances, accessory pipes and connections) of the electrical installation, which stay under current while the battery switch is open must be suited for use in zone 2 (certificate 94/9/EG, see“requirements on the installed appliances” item 2.1.3).
Examples for continuous circuits:
- EG-control appliances - toll measuring appliances - alarm systems - parts of a GPS-installation
3.5 Regulations for the parts of electrical install ation fixed behind the operator’s cab (9.2.2.6) EX/II, EX/III AT, FL, OX
Information: Not valid for installations in zone 0, 1 and 2!!!
3.5.1 „in such a state, installed and protected, that....“ Fulfilled, if e.g. a CE-label according to explosion protection regulation exists and the operating instructions allow the use, or the following regulations concerning the requirements for the construction are adhered to:
- suited for Zone 0, 1, 2 or
- manufacturing equipment does not cause sparks, arcs or inadmissible temperatures (≤ 200°C) during the undisturbed running. (to be conf irmed by the producer or EX-n), or
Chapter 9 Februar 2009
- housing of manufacturing equipment, which causes sparks and/or arcs are “waft-safe” or simply overpressure-capsuled (tight). (to be confirmed by the producer or EX-n), and
- junction boxes have to comply with safety class IP54 (to be confirmed by the producer), as well as
- electrical connections protected by soldering, welding, screws or against self-loosening and
- lamps which comply at minimum with safety class IP 54 (to be confirmed by the producer),
- lamps (light bulb) must be protected by a housing against mechanical damage (EN 50014 table 4, low mechanical stress); (to be confirmed by the producer).
- the surface temperature of the pre-finished lamp must at no place be higher than 195°C (to be confirmed by the producer, pls. note i tem 3.4.1!)
- bulb lamps must not exceed the maximum surface temperature of 250° C on the lamp (light bulb) (usually fulfilled by vehicle lamps up to 21 W; in case of higher output a verification by the producer is necessary)
- metal steam, glow discharge and halogen lamps must noch exceed the maximum surface temperature of 200° C on the lamp (light bu lb); (to be confirmed by the producer).
3.5.2 „normal operating“ This is the accident-free operating of a vehicle.
3.5.3 „the danger is minimized by shock or deformation“ lights (light bulbs) in lamps, except on the vehicle, must be protected by
- a breakproof housing (to be confirmed by the producer) or
- a housing protecting against mechanical damage (EN 50 014 table 4, high mechanical stress) or
- installed in a protected area (e.g. the vehicle outline).
examples for protected installation:
- rear lights are integrated in the rear bumper - SML do not limit the contour of the vehicle.
Chapter 9 Februar 2009
examples for non-protected installation:
- end outline marker lights on the rubber arms - end outline marker lights on the front of the semi-trailer in the front
exposed to cantilever arm.
3.5.4 „connections protected against shock, wear, scrub“ Fulfilled if the laying of the connections corresponds to e.g. EN 60 079-17:1997 no 9.1.1:
- by laying in conduits, plastic tubes or
- protected by a cover (e.g. vehicle frame)
- by laying in protected areas.
For connection cables between the towing vehicle and the trailer this requirement is fulfilled if they comply with e.g. ISO 4141:1998.
Nevertheless, it is recommended not to lay cables and pipes in gas-tight pipe systems. In order to avoid liquid aggregation or dangerous atmospheres in protection tube systems,
the protection tube connection on appliances do not need to be insulated particularly. A drainage hole should be included at the lowest point of the protection tube system.
The wear resistance of wire insulation of single layed wires and the abrasion resistance of coat insulation of coat pipes respectively has to be determined independently from the nominal wire size in compliance with the test method documented in ISO 6722:2002 item 9.2
providing that the number of cycles must be 1000 and the remaining wall thickness of the wire /coat insulation has to be at least 60 % of the nominal wall thickness.
3.5.5 „ABV (ABS) – sensor pipes are not additionally insulated“ Only one wire may carry wire insulation (i.e. without coat insulation or protection tube). Due to the mechanical stress an insulation of the quality PUR or equivalent is recommended.
3.5.6 “Electrical plug connection” (e.g. between motor tractor and trailer) IEC norm 529 complies with EN 40 050.
Both ISO 12098 (15 pin socket) and ISO 7638:1985 (ABS connection) demand test to ensure these requirements and are therefore suitable for these demands.
Chapter 9 Februar 2009
3.6 Grounding (9.7.4, 6.8.2.1.27) and grounding con nection (6.8.2.1.27) of the vehicles FL and AT which are allowed to carry UN120 2 diesel, gasoline or heating oil light each complying with the norms EN 590:1993 as well as UN 1361 coal or soot of the packing group II
3.6.1 “Grounding” Due to mechanical reasons the ground cable between tank and chassis should have min. 6 mm². The matching bolted connection should have min. 1 x M10 or 2 x M 8 and be protected against self-loosening. The resistor between the touching parts must not exceed 10 Ohm.
3.6.2 “Grounding Connection” The tag for the marking may be depicted either negatively or positively.
3.7. Information on electrical equipment of thermal superstructures for parceled goods of class 4.1. and 5.2 (7.2., special regulation V8, par. 3, R3 and R5)
3.7.1 “Explosion-proof electrical equipment Eex IIB T3” Concerning the required verifications please refer to item 2.2
3.7.2 “Explosion-proof electrical connections Eex IIB T3” Concerning the required verifications please refer to item 2.2
3.8 Electrical equipment EX/II and EX/III (9.2.2.5. 2, 9.3.7)
3.8.1 “Nominal voltage” The nominal voltage of the electrical installation must not exceed 24 V.
3.8.2 “Electrical installation in a fold” IP54 or IP65 (for compatibility group J) or equivalent have to be verified (to be confirmed by the manufacturer). All safety classes with a higher digit than demanded count as equivalent, whereas each digit counts for itself. Letters following this digit have no restrictive effect in this case.
3.8.3 “Continuous circuits protected against overheating” The continuous circuits have to be protected by suitable means as e.g. fuses, circuit interrupters or circuit limiters.
ATTENTION:
If you need further information on ADR please refer to ADR manual chapter 9. We kindly ask for your understanding that we cannot state all details in this document.
Chapter 9 Februar 2009
If you have any further questions please contact th e sales department of Aspöck Systems.
Chapter 10 Februar 2009
Chapter 10: BBVA II – Brake Pad Wear Indicator
Chapter 10
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Chapter 10 Februar 2009
2. Mount the SPIDER at a place where it is protected against direct impact of
water and stones above the first or last axle by means of the two mounting straps. The place has to be as vibration poor as possible. High vibrations and shocks may damage the SPIDER.
3. Mount the sensor cables with the 2-pole plugs to the brakes. Avoid any tension
at the SPIDER as this may lead to damages due to the changes of temperature. Furthermore, it is important that the cables do not stretch, even if the axle is completely released.
4. Connect the 2-pole plugs to the wear contacts, fix them on the trailer and fasten them in such a way to the vehicle that no tension at the patch cord can occur. Assemble the brake lining wear sensors in accordance with the enclosed fitting instructions. The provided wear contacts are suitable for the axles of the following manufacturers:
a) BPW b) Gigant c) Mercedes d) Sauer
e) Lecinena f) Raba g) SMB
5. Mount the OPTI-Control to a place where it can be seen easily and where it is protected against damage. The mounting place has to be as free from vibration
OPTI-Control
7pin connector
SPIDER
wiring schematic:
Sensor cables with 2-pin plugs for the wear contacts
2pin connector
connection junction box
cable harness
Chapter 10 Februar 2009
and shocks as possible. To ensure this, the OPTI-Control has to be mounted on the main carrier of the towed vehicle. High vibration and shocks may damage the OPTI-Control.
6. The cable harness has 3 connections. One 7-pin for the connection to OPTI-
Control, one 2-pin for the connection to the SPIDER and one 3-pin (connector or “open end”) for the connection in the junction box.
cable function white = ground (white)
brown = tail light left (brown) or tail light right (black)
blue = brake (red)
Masse ws
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+ 24 V br
3 pol. Stecker Spider
7 pol. ASS2 (schwarz)
If the cable is too long, do not mount it in round loops.
7. After finishing the assembly of the system, it has to be tested according to the following steps:
a) tail light on OPTI-control has to signal black b) tail light off OPTI-control has to stay black c) plug off one wear contact and switch tail light on OPTI-Control has to
signal red d) plug on the wear contact again OPTI-Control has to signal black after
switching on tail light
8. Due to extraordinary circumstances the brake pad wear indicator may fail or react inappropriately. The test and maintenance requirements that are necessary if there is no brake pad wear indicator must not be reduced in any way if such a brake pad wear indicator is used. Any and all liabilities for damages that will arise – the liability according to PHG included – due to the use, especially due to a failure of the brake pad wear indicator is excluded, to the extent as permitted by law.
junction box
SPIDER
Opti-Control
Chapter 11 Februar 2009
Chapter 11: Ramp-Distance-Control
Chapter 11 Februar 2009
Description of the system:
Components:
Pos 1: RDC junction box incl. Electronics
Pos 2a, 2b: Optional power supply
Pos 3: Adjustable sensor in the metal bumper
Pos 4: Reversing alarm (Audible warning system)
Pos 5: ‘’Superpoint’’ LED outline marker (Visual warning system)
The Ramp Distance Control is an innovative new technology to support the driver
when reversing a trailer up to a loading bay.
Before using the system please read the description and the operation instructions
carefully.
The system can not replace the driver’s responsibility to ensure a clear passage when
manoeuvring.
Chapter 11 Februar 2009
Mounting instructions
Preparation:
• Ensure you have all the parts necessary to complete the installation. • Remove existing outline markers. • Determine a suitable mounting point for :
� RDC junction box (Pos 1) � Reversing buzzer (Pos 4)
• We recommend a minimum spatial requirement of approx. 500 x 500 mm.
Installation: • General information: All cables must be installed suitably protected by
the trailer chassis. Fix all cables every 10-15 cm with a cable strip/tie. Do not fit the cables onto surfaces that can become hot. Hydraulic Fluid pipe lines are not allowed!! Unnecessary cables should be fixed coiled up. Ensure that the junction box bayonets are closed correctly.
o Installation of RDC junction box (Pos 1)
The position of the junction box should be in a suitably protected position in the rear part of the trailer. The box should be fixed on to the Chassis. Position in a rigid location unsuseptable to large vibration and ensure cables are safely installed.
o Installation of new Led-outline marker (Pos 5)
The new LED-outline marker should be assembled in the same location as the old lamp, (Ensure that from within the tractor unit mirrors you can see the LED-lamps clearly). Refer to drawing (page 1) the connectors should be plugged into the RDC junction box. Please seal the existing connectors for old outline marker (2 pin. central plug or junction box exit) seal with a connector sealing gland. It is essential that you only use LED Outline markers not bulbed, they are clearer in daylight and require less power.
o Installation of reversing buzzer (Pos 4)
Fit the reversing alarm in a protected position unsuseptable to vibration. Normally on the front panel or near the rear axle. When assembling pay attention to the location of the alarm, the cable entry must be at the top. (observe “TOP” on the alarm). Plug the cable into the RDC junction box referring to drawing (page 1)
o Installation of sensor onto rear bumper (Pos 3)
Drill a hole with ∅ 45 mm, pass the sensor lead through with the 7pin ASS2 connector from the sensor, Fix the sensor with four fixing screw
Chapter 11
onto the rear bumper. Plug the cable into the connectojunction box referring to drawing (page 1)
o Installation of power supply with an adapter cable (Pos 2 a)
Disconnect the connector between main cable and the rear junction box cable.Plug the adapter for the power supply (Pos 2a) betweenconnectors (main cable and rear junction cable).
o Installation of power supply into an existing junction box (Pos 2b)
Open the junction box. Insert and connect the power supply cable through a spare entry in the existing junction box, connect theand ensure a waterproof installation.Contact allocation: Close the junction box.fixed correctly!
Functional test: After the installation is completed you should test the system thoroughly.
For this test you require a test sample (preferred material is a cardboard box approx. 500 x 500 mm, if there is no box available, you can use a similar object material with a smooth surface). Please ensure that there are no obstacles situated within the range of 4m x 4m behind the vehicle. The test procedure must carried out in the following steps:
step 1: ignition on / tail light on
step 2: Engage reverse gear
step 3: Place the test sample in perpendicular to a sensor within a range of 3 m behind the vehicle (see picture 1).
step 4: Remove the test sample from the vehicle until the beeping and led outline are extinguished.
step 5: Slowly Move the test sample inwards towards the 1)
step 6: Repeat step 4 with the second sensor
onto the rear bumper. Plug the cable into the connectojunction box referring to drawing (page 1)
of power supply with an adapter cable (Pos 2 a)
Disconnect the connector between main cable and the rear junction box cable. Plug the adapter for the power supply (Pos 2a) betweenconnectors (main cable and rear junction cable).
Installation of power supply into an existing junction box (Pos 2b)
Open the junction box. Insert and connect the power supply cable through a spare entry in the existing junction box, connect theand ensure a waterproof installation. Contact allocation:
black – tail light left grey– reverse lightbrown – tail light rights white –earth connection
Close the junction box. IMPORTANT: Ensure the junction box gasket is fixed correctly!
After the installation is completed you should test the system thoroughly.
For this test you require a test sample (preferred material is a cardboard box approx. 500 x 500 mm, if there is no box available, you can use a similar object
rial with a smooth surface). Please ensure that there are no obstacles situated within the range of 4m x 4m behind the vehicle. The test procedure must carried out in the following steps:
activity result
ignition on / tail light on LED-outline marker
Engage reverse gear LED-outline markerseconds
Place the test sample in perpendicular to a sensor within a range of 3 m behind the vehicle (see picture 1).
LED-outline markerfrequency
Reverse alarm: slow beep
Remove the test sample from the vehicle until the beeping and led outline are extinguished.
Completed phase I (see picture 2)
(area greater than 3m)
Slowly Move the test sample inwards towards the trailer sensor (see picture
run through the complete range of phases as shown within diagram (picture 2).
Repeat step 4 with the second sensor see step 4
Februar 2009
onto the rear bumper. Plug the cable into the connector from the RDC
Disconnect the connector between main cable and the rear junction
Plug the adapter for the power supply (Pos 2a) between these two
Installation of power supply into an existing junction box (Pos 2b)
Open the junction box. Insert and connect the power supply cable through a spare entry in the existing junction box, connect the terminals
reverse light earth connection
Ensure the junction box gasket is
After the installation is completed you should test the system thoroughly.
For this test you require a test sample (preferred material is a cardboard box approx. 500 x 500 mm, if there is no box available, you can use a similar object
rial with a smooth surface). Please ensure that there are no obstacles situated within the range of 4m x 4m behind the vehicle. The test procedure
result
marker has to shine
outline marker is deactivated after 2
outline marker: slow flashing
Reverse alarm: slow beep
Completed phase I (see picture 2)
(area greater than 3m)
run through the complete range of phases as shown within diagram (picture 2).
Chapter 11 Februar 2009
step 7: Repeat step 5 with the second sensor
see step 5
testing of the silent mode (night silent switch off)
step 8: place the test sample in the distance as in step 3.
step 9: Engage the reverse gear twice
(within 2 seconds)
LED-outline marker: slow flashing frequency
Reverse alarm: no signal
step 10: let the system work for min. 10 seconds. After this, disengage the reverse gear.
step 11: Engage reverse gear once only,
LED-outline marker: slow flashing frequency
Reverse alarm: returns to slow beep frequency
picture 1 picture 2
Please note during the function test that the test sample will be moved always perpendicular to the respective sensor axis (see picture 1)
Chapter 11 Februar 2009
Adjusting the sensors: If you cannot assemble the steel ram buffer on the outermost area of the rear panel, you can adjust the detection of the sensors with a special tool.
The available adjustable area of the sensor is 10° horizontal and vertical
Adjust the sensor by rotating 3 fixing nuts (DIN 546)
To adjust these slotted nuts you require a special key tool (see above).
By rotating the nut clockwise, the housing will be inclined in the direction of the rotated nut. Due to the order of the screws (3 x 120°) you have the possibility to incline the sensor in any direction (maximum adjusting area is 10°)
Chapter 11 Februar 2009
The adjustment should only be made with an obstacle in place
Technical data:
ATTENTION: The RDC is protected against an AC voltage supply, but will not function. It will function again correctly when reconnected with DC supply.
nominal voltage 24 V
operating voltage 19 to 32 V
operating temperature -30 to +65 °C
current consumption (total system) < 300 mA
Ultrasonic Sensors
Max Range 2500 mm
Min Range 350 mm
Detection Angle 15 °
operating voltage 12-30 V
Max current consumption < 35 mA
Frequency 180 kHz
Reversing alarm
Operating voltage 12-30 V
obstacle.
Chapter 11 Februar 2009
Max current consumption < 35 mA
Superpoint LED
operating voltage 24 V
Max current consumption < 35 mA
The sensor has an area (<350mm), within which the measurement result might not be 100% accurate.
Liability exclusion
The system is not 100% accurate under all circumstances. You must observe the same care when manoeuvring with the RDC up to the ramp.
We cannot be held responsible for any damage that may occur when using the system.
It is the drivers responsibility to manoeuvre safely.
Operating instructions: The complete system is assembled on the last third of the trailer. Thus the RDC is independent of the truck and also very well suited for changes of the truck and trailer combination. Engage the reverse gear and you activate the system. Both sensors detect the distance to an obstacle to the system electronics. Depending on the distance to an object, the system electronics will give out a warning signal (from the reversing alarm and LED-outline marker), which varies dependent to the object distance.
System check 1 (De activation of the system by switching on the tail lights):
If the tail light is on while engaging the reverse gear, the tail light function in the outline marker is deactivated for about 2 seconds.
As soon as the obstacle is more than 3m away, the lamp is switch to normal – permanent operation. The buzzer is not activated.
Chapter 11 Februar 2009
If you get nearer than 3m to the obstacle, the system switches to the 5 test phases (please see below).
System check 2 (activation of the system during the day with tail lights switched on):
After engaging the reverse gear the outline marker is turned on.
Distance to the obstacle > 3m: Outline marker is on, buzzer is silent !
Distance to the obstacle < 3m: System switches to the five test phases.
If the reverse gear is engaged twice (within 2 seconds) the acoustic warning installation (buzzer) will be ‘’night silent’’. The outline marker is however active.
The ‘’night silent’’ option is to prevent audible nuisance at night in residential areas.
Chapter 11 Februar 2009
The maximum detectable distance is 3m from the sensor.
And is Graduated into five phases, Please study the sketch below.
ERROR &
Chapter 11 Februar 2009
Error repair / Sensor diagnosis:
Error possible reason repair
Display an obstacle, when no present A sensor is Obscured Adjust Sensor
RDC doesn’t work
reversing light, tail light L/R and Earth connection is defective
Establish or check all the connections
one of the fuses (tail light L/R or reversing light) defective
change one of the fuses
supply voltage is too small (< 19V) check the light control unit is the truck
URL doesn’t shine
LED defective change the URL
When activating the system and error occurs
activate the system once again
Reverse alarm doesn’t work
Defective alarm change the alarm
Silent mode is active engage the reverse gear
The sensor diagnosis is shown by the 6 leds inside the RDC junction box.
1) One green LED: indicates, that the voltage supply is in order.
2) Two red LEDs: indicate in which of the sensors a fault has occurred.
3) Three yellow LEDs: indicate an error code, which describes the type of default.
Circuit board
in the RDC-
junction box
Chapter 11 Februar 2009
ERROR CODE
2 1 0 possible reasons repair
cable break of a sensor cable change the sensor
defect on the head of the sensor change the sensor
cable break of a sensor cable change the sensor
In the case of an “error” the Led outline marker will permanently illuminate and the Reverse alarm will permanently sound for about 5-7 sec.!!!
Afterwards the alarm switches off automatically, The Led outline marker continues to operate.
Except a complete failure of the system the following situations can lead to an erroneous signal on the display. The reason for this is that in these cases, the physical limits of the ultrasonic sound are exceeded.
If you drive at an angle to the ramp it can occur that the reflected sound will be to small for the sensor to detect.
Ramps with floors that jut out from the main body. Caution !
ramps with curtains require special attention:
a) The material of the curtains can absorb the ultrasonic, this means that the reflected sound is too weak for the sensor to detect.
b) If the curtain is deformed, so that the ultrasonic signal could be absorbed.
Some materials like textiles weaken the ultrasonic signals, significantly reducing the sensing distance !
ATTENTION: It is the driver’s responsibility to manoeuvre safely.
permanent tone 5-7 sec.
a b
Chapter 11 Februar 2009
Abbreviations: RDC Ramp Distance Control URL LED outline marker
RFL Reverse lamp
StdL Tail light GND Earth
LED Light Emitting Diode TRIG Trigger VDD + supply
Chapter 11 Februar 2009
Chapter 12 Februar 2009
Chapter 12: LED Control Gear Gear LCG ATTENTION: Due to technical attributes this device is not suit able for motor tractors and must not be used unless released for various types by Aspöck Systems
Chapter 12
Description of the system: This control device enables the connection of modern LED rear lamps of conventional motor tractors equipped with electronical light control devices and onboard computers. Advantages:
• Adapts the electrical features of LED lamps to the requirements of a modern motor tractor.
• Checks the function of a LED direction consumption if the direction indicator function exists according to statuory regulations.
• Easy retrofitting by using lamp mounting screws to fix the LCG.• If the LCG adapter is mounted with a respective 7
possible without having to interfere in the lamp or the cabling of Aspöck systems.
• By installing additional components the power consumption for parking and stop light is increased so that modern motor tractors with electronic light control devices do not put out error messages anymore.
• Compact construction style
Mounting instructions LED Control Gear (LCG) from A spöck
The LED Control Gear is needed for the adjustment o f the electrical characteristics of the LED lights to the requirements of the LCG can become very hot! Therefore the housing of the LCG must be always mounted on a larger metallic part for the purpose o f cooling!
IT IS FORBIDDEN (disclaimer):
o to assemble the LCG within the ra
o connect and disconnect under power
o current and voltage measurements with conventional measurement
instruments
ATTENTION: As truck manufacturers constantly adjust the elec tronic systems on their trucks we cannot grant any warranty on the LCG concerning functional ity. Therefore, Aspöck Systems GmbH will not accept any claims for this LCG.
Description of the system:
This control device enables the connection of modern LED rear lamps of conventional motor tractors equipped with electronical light control devices and on
Adapts the electrical features of LED lamps to the requirements of a modern
Checks the function of a LED direction indicator and increases the power consumption if the direction indicator function exists according to statuory
Easy retrofitting by using lamp mounting screws to fix the LCG.If the LCG adapter is mounted with a respective 7-pin plug retrofittpossible without having to interfere in the lamp or the cabling of Aspöck
By installing additional components the power consumption for parking and stop light is increased so that modern motor tractors with electronic light
do not put out error messages anymore. Compact construction style
Mounting instructions LED Control Gear (LCG) from A spöck
The LED Control Gear is needed for the adjustment o f the electrical characteristics of the LED lights to the requirements of the tractors. Due to the necessary power consumptio n the LCG can become very hot! Therefore the housing of the LCG must be always mounted on a larger metallic part for the purpose o f cooling!
IT IS FORBIDDEN (disclaimer):
to assemble the LCG within the range of temperature sensitive components
connect and disconnect under power
current and voltage measurements with conventional measurement
: As truck manufacturers constantly adjust the elec tronic systems on their grant any warranty on the LCG concerning functional ity. Therefore,
Aspöck Systems GmbH will not accept any claims for this LCG.
Februar 2009
This control device enables the connection of modern LED rear lamps of trailers to conventional motor tractors equipped with electronical light control devices and on-
Adapts the electrical features of LED lamps to the requirements of a modern
indicator and increases the power consumption if the direction indicator function exists according to statuory
Easy retrofitting by using lamp mounting screws to fix the LCG. pin plug retrofitting is
possible without having to interfere in the lamp or the cabling of Aspöck
By installing additional components the power consumption for parking and stop light is increased so that modern motor tractors with electronic light
Mounting instructions LED Control Gear (LCG) from A spöck
The LED Control Gear is needed for the adjustment o f the electrical characteristics of the the tractors. Due to the necessary power consumptio n
the LCG can become very hot! Therefore the housing of the LCG must be always
nge of temperature sensitive components
current and voltage measurements with conventional measurement
: As truck manufacturers constantly adjust the elec tronic systems on their grant any warranty on the LCG concerning functional ity. Therefore,
Chapter 12
75-0300-00, 75-0301
75-0302-00, 75-0303
„a“ � LCG – Electronic housing
„b“ � Connector to the rear lamp
„c“ � Power supply (cable rear light supply)
1. Remove protection cap if mounted and disconnect the cable from the lamp
Description:
0301-00
0303-00 75-0304-00
IN / OUT is interchanged
Electronic housing „a“ � LCG – Electronic housing
Connector to the rear lamp „b“ � Connector to the rear lamp
Power supply (cable rear light „c“ � Power supply (cable rear light supply)
Remove protection cap if mounted and disconnect the cable from the lamp
Februar 2009
00
IN / OUT is interchanged
Electronic housing
Connector to the rear lamp
Power supply (cable rear light supply)
Remove protection cap if mounted and disconnect the cable from the lamp
Chapter 12
2. LCG connection:
75-0300-00, 75-
75-0302-00, 75-
1. Fix LCG to the mounting bolt of the lamp2. Connector angular � to the lamp3. Connector straight � cable rear light supply
3. Mounting without protection cover:1. fix the lamp + LCG + protection cover with
the nuts 2. fix the cable with cable ties
4. Mounting of the protection cap:1. Put the connection above the lamp connector (see
pictures) 2. The 3 cables must go downwards3. Fix the protection cap 4. Put cable ties into the holes of the protection cap and fix
the cables 5. Mount the lamp + LCG + protection cap with the nuts from
the lamp
* WARNING: The LCG must have full contact to the bumper surface! If it’s not possible to mount on the bumper with the lamp fixation nuts, it must be mounted on a place with low vibration. This place must have a metal ground to aid cooling of the LCG !Don’t mount the LCG next to temperature sensitive components! (fuel tanks, etc…)
„a“
„b“
-0301-00
-0303-00 75-0304
Fix LCG to the mounting bolt of the lamp to the lamp cable rear light supply
1. Mount the LCG on an appropriate* place
2. Connector angular box
3. Connector straight
Mounting without protection cover: fix the lamp + LCG + protection cover with
fix the cable with cable ties
Mounting of the protection cap: Put the connection above the lamp connector (see
The 3 cables must go downwards
Put cable ties into the holes of the protection cap and fix
Mount the lamp + LCG + protection cap with the nuts from
The LCG must have full contact to the bumper If it’s not possible to mount on the bumper with the lamp
fixation nuts, it must be mounted on a place with low vibration. This place must have a metal ground to aid cooling of the LCG ! Don’t mount the LCG next to temperature sensitive components!
„c“
Februar 2009
0304-00
Mount the LCG on an appropriate*
Connector angular � to the connector
Connector straight � to the lamp
Chapter 12 Februar 2009
Chapter 13 Februar 2009
Chapter 13: Detection of errors
Chapter 13 Februar 2009
Detection of errors In most cases errors occur due to incoming (salt) water into not properly closed connectors or lamps. However, it is also possible that defects in the lighting system occur due to mechanically damaged cables (chafing on sharp edges and so on.). In both cases a short circuit will occur and as a result a fuse in the traction engine will be damaged. As such errors are sometimes not easy to detect for the mechanic, we suggest the following procedure for such repairs: For example: 1. Remove the conductor cable of the trailer from the traction engine. 2. Insert a new fuse. 3. Measure the required function of the sockets of the truck with a proper inspection
device. (please refer to chapter 15 – electrical circuit plan). 4. Separate all main connectors from the lamps. The error usually lies with functions
such as side marker lamps and so on. 5. Reconnect the conductor cable of the trailer with the truck. 6. Press the desired function in the truck. 7. Reconnect the main connectors beginning from the front. A mechanic is supposed
to control the fuses in the truck. 8. Once the fuses is again failing when connecting the connector, the error is found. 9. Repair according to our repair instructions. Usually the error detection is supposed to be done from FRONT to BACK in electrical circuit direction.
Chapter 14 Februar 2009
Chapter 14: Legal Installation Instructions for Lamps
Chapter 14 Februar 2009
Chapter 14 Februar 2009
Chapter 14 Februar 2009
Chapter 14 Februar 2009
Chapter 14 Februar 2009
Chapter 14 Februar 2009
Chapter 15 Februar 2009
Chapter 15: Installation of single components
Chapter 15 Februar 2009
Installation of single components
Precautions • Installation work on the lighting equipment
� All installation work on the lighting equipment has to be done with voltage turned off .
� Please follow all mentioned torques of the screws. � The electrical circuits have to be free of dust, grease, lye or acids. � All sealing material has to be fitted on the intended place. � The cables on all electrical fittings have to be fixed in such a way, that water
can drip by building a water drip nose. � Only lamps or electrical fitting with separated mass return travel can be
used. � The installation of the triple socket junction box has to be done according to
the regulations. Please notice the colour coding of the pre assembled connection components please refer to section „colour coding“.
• Colour coding:
All plug connectors of Aspöck Systems lighting equipment are marked by colours. We distinguish 5 colours and their functions: YELLOW: LEFT side of the vehicle seen from facing the front (indicator,
sidelights) GREEN: RIGHT side of the vehicle seen from facing the front (indicator,
sidelights) BLACK: Can be used for BOTH sides or for functions, which can not be
applied to aspezial side (axle lift, NES, RFS and so o.)BLACK – for functions of socket ISO 1185
WHITE: for functions of socket ISO 3731 • Dimensions of the pass holes on the frame of our plug connectors: •
P&R System in a non-pressed condition
(without P&R cover) - min. 20 mm
ASS 1 connector 2-pin (mit Dichtmutter) - mind. 30 mm
ASS 1 connector 7-pin (mit Dichtmutter) - mind. 40 mm
ASS 2 connector 2-pin (mit Dichtmutter) - mind. 30 mm
ASS 2 connector 7-pin (mit Dichtmutter) - mind. 42 mm
ASS 3 connector 17-pin - mind. 40 mm
Bayonet connector 15-pin - mind. 40 mm
Chapter 15 Februar 2009
• Diameter of the various connectors:
28,9
0
15pol. Bajonett / 15pin bajonett
38,1
0
34,0
07 odern 8pol. Bajonett / 7 or 8pin bajonett
2pol. Bajonett / 2pin bajonett
28,0
0
30,7
0
17,0
0
20,0
0
16,6
41,5
35,5
16
P&R System
2 pol. ASS1 / 2 pin ASS1
7 pol. ASS1 / 7 pin ASS1
39,1
0
33,8
0
40,0
8
21,6
0
28,2
0
28,2
0
2 pol. ASS2 / 2 pin ASS2
7 pol. ASS2 / 7 pin ASS2
37,4
028
,80
33,5
mm
Buchsengehäuse Syst. ASS3
17 polig
37,3
mm
Stiftgehäuse Syst. ASS3
17 polig
ASS3 3pol.Stift SW
17,5 mm
ASS3 3pol.Buchse SW
• Correct assembly of the flat cable or other cables: � Both P&R flat cables may either be assembled on the outer frame or between
the longitudinal supports backwards up to the last connector. � The cables must be protected against mechanical influences (for example:
stone throws, sharp edges, heat etc.). � The cables must not be drilled or assembled in loops. � It is not permitted to varnish the cables before contacting the individual
connectors. � The fixing material of the cables may be chosen freely. However, the cable
has to be fixed every 10 – 15 cm on the frame. No “free cables” are allowed. � All pass holes (on the frame) must covered by rubber so that the cables
cannot be chafed. � Furthermore, please ensure that no ice clumps may be formed during winter
due to the cabling. This may lead to mechanical damage of the cables or the connectors.
Chapter 15 Februar 2009
Chapter 16 Februar 2009
Chapter 16: Labelling of spare parts
Chapter 16 Februar 2009
Recognizing spare parts numbers of Aspöck Systems i n case of repair
The labelling of spare parts of Aspöck Systems is being done by adhesive labels on the cables or on the housing.
On these labels you will find the number of the spare part without the packaging code. Furthermore, the year and month of production, the controlling code as well as the production number is written on the labels.
Please indicate all the below mentioned data in case of warranty. Please only indicate the 8-digit order number in case of reordering spare parts.
The labels are waterproof and can be read even after years!
Chapter 17 Februar 2009
Chapter 17: Electrical circuit plan
Chapter 17 Februar 2009
Chapter 18 Februar 2009
Chapter 18: General terms and conditions of warranty
Chapter 18 Februar 2009
General Terms and Conditions of Aspöck Systems GesmbH
1. In general, we accept - in accordance with the following terms and conditions - justified warranty claims of our contracting party regarding all parts of our range of products of products notified to us in writing within two years of delivery of our products to our contracting party, not later than within one year of first registration of the vehicle. Any claims raised after the said period shall be excluded, also claim of a recourse according § 933 ABGB. Prerequisite for any claim shall be that assembly war carried out properly or according to the assembly instructions of Aspöck Systems GesmbH through a special business, respectively.
2. Any kind of mechanical destruction (e.g. breakage of luminescent glass) shall exclude a claim against us. Claims related to defects of wearing parts, such as defective bulbs, and the cost of repair of the same or claims which are attributable to such defects as well as claims in connection with defects due to material defects or material fatigue or put down to our product or separates of its parts are unusual or in material data sheet or product information called, unreliably physically, chemically, mechanically or were other influences exposure ( e.g. acid or alcoholics, temperatures beyond the range of minus 30° - plus 65°, leaking cargo, chemical cleaning agent or their results, UV - radiation, outside the UV - regulation ISO 4892T2) shall be executed.
3. Claims related to defective parts which we have purchased ourselves, such as plugs, sockets ISO 1185/3731,… may only be raised against us to extent to which we have a justified claims against our suppliers, than raise a claim to our suppliers. In such an event we shall be entitled to finally defend ourselves against being held liable by assigning the claims we have against our suppliers.
4. In addition, no claims may be raised if our components are combined with third - party parts, if the assembling is done self of their completion, particularly sealing, or if our system is tested by third parties. If our system is also interfered by third parties, all claims are deleted as well.
5. Aspöck Systems GesmbH shall decide on whether the replacement or an improvement will be carried out. Any repair work must be done in garages authorized by us; otherwise any warranty claims and other claims shall expire in general. The cost of labour incurred if a decision is made in favour or repair, shall be reimbursed to the extent it is absolutely necessary but in no case in an amount exceeding that which is usually paid.
6. Claims exceeding those stated in these General Terms and conditions of Warranty, in particular claims for damages (e.g. loss of use, lost, profit, consequential damage to property of any kind, shall in no event be reimbursed.
Chapter 18 Februar 2009
7. Rights of recourse pursuant to sections § 933 ABGB (Austrian General Civil Code) shall
be excluded.
8. In any event claims of any kind may only be raised, if the defective old parts are present, a warranty protocol is filled out completely and signed. Only upon receipt and examination of those parts a relevant decision will be taken by us.
I. General 1. These General Terms and Conditions of Sale and Delivery (GTCS&D) shall constitute an
integral part of all of our offers, sales and deliveries. Deviations from these Terms and Conditions shall only be valid on a case-by-case basis if we have confirmed them in writing. Customer's terms and conditions of purchase shall only be binding on us if we have recognised applicability of the same in writing.
2. If a separate agreement was entered into with the Customer, the terms and conditions stated therein shall apply primarily. Subsidiary, the GTCS&D shall be applicable to the extent reference is made to them or if the relevant facts and circumstances are only regulated in the GTCS&D.
II. Acceptance of order/Seller's right of rescission 1. Customer shall be bound by his order for a period of four weeks as of receipt of the same
by Aspöck. If Aspöck issues an acceptance of order (AO) on such order, the order shall be effective upon receipt of the AO and deemed concluded in a way, which is binding on both parties. Customer shall immediately examine acceptances of orders with respect to correctness of their contents. Any deviations from the order shall be notified in writing within 2 (two) days; otherwise the delivery and the services described in the AO shall be considered approved by the party conclusively.
2. If upon acceptance of the order it turns out that Customer's financial situation is so bad that our claims are at risk or if facts become known which reduce Customer's creditworthiness sustainable, we shall be entitled to withhold our services until the consideration has been obtained or secured. In addition, we shall be entitled to rescind the contract and claim damages.
III. Prices 1. Our services shall be charged according to the current price list subject to deductions
according to the agreed terms. Provided that the order is accepted, the price list shall be used which is valid at the time of receipt of the proper order. The order is proper if it is made in a form commercially and technically clears to Aspöck.
2. Unless otherwise agreed our prices are exclusive of value-added tax, assembly, insurance and other ancillary charges ex our distributing warehouse.
Chapter 18 Februar 2009
IV. Information of the Customer/plans 1. In any case the Customer shall be solely responsible for correctness and usefulness of
his order details (e.g. details on units, measurements and quantities; order numbers stated; details on colour, form and other specifications, etc.); likewise he shall be solely responsible for a technically faultless solution for the plans and drawings provided by customer.
2. If in the course of placing of an offer Customer requires us to provide plans, extensive sketches, etc., we shall retain the right to charge the cost incurred in connection therewith separately.
3. In connection with offers, sales or deliveries, copyrights or other industrial property rights shall be transferred or made available by us.
V. Terms of payment 1. Unless any other payment date or arrangement on cash discounts was agreed, our
deliveries and services shall be due for payment within 10 days in the event of a cash discount of 2 %, otherwise within 30 days without deduction, in each case as of the date of the invoice. In case of a delay in payment we shall be entitled to demand bank default interest of 10 % p.a. in each case. In case of a default, in addition, all dunning charges, collection charges and legal costs shall be reimbursed, including those incurred in connection with collection measures out of court. In case of default Customer already at this point acknowledges his duty to pay both as to the merits and the amount in the amount that is calculated on the basis of the Autonomous Fee Guidelines for Lawyers (AHR 1976) as amended.
2. If customer is in delay of payment for deliveries and services properly provided by us and if these arrears exceed an amount of EUR 10,000 exclusive of VAT (in words: ten thousand euros) on a case by case basis or from several orders together, Aspöck shall, in addition, be entitled to demand immediate payment of all other outstanding accounts receivable. Furthermore, Aspöck may refuse performance of any purchase agreements, contracts for work and service contracts not fully discharged until total payment of the arrears. Apart from that Aspöck shall also be entitled to rescind any and all contracts not performed at that time with immediate effect.
3. Customer shall not be entitled to set off its own accounts receivable from Aspöck against claims of Aspöck for payment of outstanding accounts receivable under individual purchase agreements, contracts for work and supply contracts or to withhold or reduce services owed for whatsoever reason. This waiver of setoff shall not apply to those counterclaims, which Aspöck recognised in writing, or which were ascertained towards Aspöck by court.
4. Bills of exchange shall only be accepted if expressly agreed. Discount charges and bill charges shall always be borne by the Customer. Bills shall only be accepted on account of payment and, in addition, only if our banks will discount the bills. Such payments shall only be considered made upon payment of the bill.
Chapter 18 Februar 2009
VI. Retention of title 1. All goods shall be delivered subject to retention of title. They shall remain our property
until full payment of all our accounts receivable including those that will arise under our business relation with the Customer in future. In case of an open account the goods to which title is retained shall be deemed a security for our account receivable. Customer shall not receive title to the item delivered through installation of the same either, and all removable parts (lamps, etc.) shall remain the property of the seller as an independent part unless items are inseparably connected. An act of returning and securing shall not be deemed a rescission of the contract and shall not lift Customer's duties, in particular that of payment of the purchase price.
2. Customer shall be entitled to process and sell the goods. In that case the reselling price received shall not become the property of the reselling Customer up to the amount of the purchase price still outstanding in case of a cash transaction. The reselling Customer shall rather keep the reselling price separately and transfer the same to us without delay in the amount of the purchase price still outstanding. In the event of a sale on credit, Customer already at this point assigns the account receivable to which he is entitled under the resale vis-à-vis his customer to us as security. Customer shall be authorised to collect the assigned account receivable as long as he fulfils his payment obligation towards us in accordance with the contract. Upon request Customer shall immediately advise the name and address of the buyer as well as the amount of his account receivable and surrender all documents for enforcement of our claims. Customer shall furthermore be obliged to immediately inform us about attachments or seizures of the goods by third parties. Customer shall be obliged to bear the cost of measures for the purpose of removing seizure of goods being subject to retention of title by third parties, in particular the cost of intervention procedures to the extent it cannot be obtained from the opposing party.
3. In the event that we assert our title retained, Customer already at this point authorises us to seize our goods without judicial assistance. Likewise we shall be entitled to either sell the object of the purchase at the best possible price and credit the revenue achieved to liabilities of the Customer still outstanding or to take the object of the purchase back for the invoice price and charge Customer an amount of rent at the customary rate for the term during which he possessed the products delivered; assertion of further claims for damages reserved.
VII. Delivery/cancellation 1. The delivery dates announced by us shall be non-binding. Mere announcing or agreeing
on delivery dates concludes no fixed transaction. The delivery period, which shall always be considered an approximate period, shall commence not earlier than upon acceptance of the order and in no case before clarification of the technical details.
2. If the delivery dates stated by us are exceeded by 14 days, the Customer shall, upon an additional grace period of 14 days having been granted by him, be entitled to rescind the contract through written declaration. All other claims, in particular claims for damages of any kind, shall be excluded. If in case of an overall order delivery dates announced are only exceeded with respect to a part of the delivery, the foregoing provision shall apply provided that rescission shall only be admissible with respect to the partial delivery that has not been made within the grace period. Plant interruptions and events of force
Chapter 18 Februar 2009
majeure shall entitle us to extend delivery periods or lift the delivery obligation and any claims for damages shall be excluded.
3. In principle we shall be entitled to make partial or advance delivery and to issue partial invoices thereon.
4. If we receive a written cancellation of an order from Customer before delivery of the goods, we shall be entitled to demand a cancellation fee of 30 % of the list price or the higher loss actually incurred plus lost profit without being obliged to prove the concrete loss. The cancelled transaction shall not be performed.
5. After delivery of the goods an order may only be cancelled with Aspöck's approval. Also in that case Customer shall pay at least 30 % of the list price as cancellation fee (see handling of returns).
6. Unless otherwise explicitly agreed transport shall be at the cost and risk of Customer, also in case of partial deliveries. The goods shall only be insured on the account and upon express instruction of Customer.
VIII. General Terms and Conditions of Warranty of Aspöck Systems GesmbH 1. In general, we accept - in accordance with the following terms and conditions - justified
warranty claims of our contracting party regarding all parts of our range of products notified to us in writing within two years of delivery of our product to our contracting party, however, not later than within one year of first registration of the vehicle. Any claims raised after the said period shall be excluded. Prerequisite for any claim shall be that assembly was carried out properly or according to the assembly instructions of Messrs. Aspöck through a specialised business, respectively.
2. Any kind of mechanical destruction (e.g. breakage of luminescent glass) shall exclude a claim vis-à-vis us. Claims related to defects of wearing parts, such as defective bulbs, and the cost of repair of the same or claims which are attributable to such defects as well as claims in connection with defects due to material defects or material fatigue, e.g. due to impact of hazardous substances (acids or alkalis, etc.), temperatures beyond the range of minus 30° Celsius and plus 65° Celsius, leaking cargo and the consequences resulting there from, etc. shall be excluded.
3. Claims related to defective parts, which we have purchased ourselves, such as plugs/sockets ISO 1185/3731, .... may only be raised vis-à-vis us to the extent to which we have a justified claim vis-à-vis our suppliers. In such an event we shall be entitled to finally defend ourselves against being held liable by assigning the claims we have towards our suppliers.
4. In addition, no claims may be raised if our components are combined with third-party parts or if third parties interfere with our system.
5. Aspöck Systems GesmbH shall decide on whether a replacement or an improvement (repair) will be carried out. Any repair work must be done in garages authorised by us; otherwise any warranty claims and other claims shall expire in general. The cost of labour incurred if a decision is made in favour of repair shall be reimbursed to the extent it is absolutely necessary but in no case in an amount exceeding that which is usually paid.
Chapter 18 Februar 2009
6. Claims exceeding those stated in these General Terms and Conditions of Warranty, in
particular claims for damages, e.g. loss of use, lost profit, consequential damage or damage to property of any kind, shall in no event be reimbursed. Rights of recourse pursuant to Section 933b ABGB [Austrian General Civil Code] shall be excluded.
7. In any event claims of any kind may only be raised if the defective old parts are presented. Only upon receipt and examination of those parts will we make a relevant decision.
IX. Product Liability Statute 1. Customer undertakes to observe all our warnings, instructions for use and other product
declarations, etc. and notify the same to the end user in a complete and up-to-date version. Notification shall, if possible, be made in writing and, to the extent possible, by using relevant information material (product description, etc.).
2. If Customer is held liable within the scope of the Product Liability Statute, he already at this point explicitly waives recourse to us as laid down in Section 12 Product Liability Statute. In the event that such a transfer should not be made, Customer undertakes to indemnify and hold us harmless and to reimburse all costs arising in connection with strict liability. If Customer is held liable within the scope of the Product Liability Statute, he already at this point waives recourse to us.
Chapter 18 Februar 2009
X. Severability clause If any of the provisions of these General Terms and Conditions of Sale and Delivery should be or become ineffective, the validity of the remaining provisions shall not be affected thereby. XI. Place of performance and place of jurisdiction 1. The place of performance for all deliveries and payments shall be Peuerbach also
if delivery is made at a different place agreed.
2. The court in A-4600 Wels having jurisdiction over the subject matter shall have jurisdiction over all legal disputes arising between us and Customer. The supplier may also call upon a different court that has jurisdiction over the buyer.
3. In all cases between Customer Austrian and us law shall be applicable. Applicability of the Vienna Sales Law Convention of 1980 shall be explicitly excluded.
XII. These General Terms and Conditions of Sale and Delivery shall also apply to consumer transactions unless mandatory statutory provisions provide otherwise.
Place/Date Signature
Chapter 19 Februar 2009
Chapter 19: Claims
Chapter 19 Februar 2009
Procedure of Service Partners (factory): 1 Determine the damage. 2 Check whether the claim is justified by reviewing the licensing papers ( please
refer to chapter 16 – warranty terms). 3 Repair. 4. Fill out the „Warranty protocol of Aspöck Systems“ (only the first section in capital
letters). � All questions have to be answered � Should there not be enough space, please use the warranty attachment.
Please do not forget to fill in the serial number. � The forwarding agent is supposed to receive the original � Our service partner is supposed to receive a copy
5. Please send the rest of the protocol and the damaged parts to your Service Total partner (regional representatives of Aspöck Systems).
• Item 5 may be ignored by direct customers of Aspöck Systems. Please send
damaged parts and the protocol directly to Aspöck Systems, Enzing 4, A-4722 Peuerbach; Austria.
Procedure of the regional representatives of Aspöck Systems: 1. Check of the damaged parts and statements. 2. Once the claims is clearly not justified by reviewing the parts or statements, the
claims can immediately be declined. However, this can only be done by a written (please always fill in the serial number).
3. Once the claim is justified, the protocol has to be filled out (only section 2). If necessary, you can also use the attachment (please fill in the serial number).
4. Our regional representative is supposed to receive a copy. 5. Please send both, the parts and the protocol to Aspöck Systems. Procedure of Aspöck Systems: 1. Check of the parts and statements by our quality assurance department. 2. Decision by our quality assurance department. 3. The whole correspondence is forwarded to our sales department. 4. Invoice is paid or a credit note is issued. 5. The whole correspondence will be filed. General issues: � Please always fill in the serial number and the address of our service shop, no
matter whether the claim is made in written form or by phone. � Warranty protocols of Aspöck Systems can be ordered directly and free of charge
at Aspöck Systems. Order Numbers: Protocol (1 piece DIN A4 with 50 application forms) 10-V702-007 Attachment (1 piece DIN A4 with pages) 10-V702-107
Chapter 20 Februar 2009
Chapter 20: Price list of changed or repaired parts • Aspöck Systems generally pays an hourly rate of Euro 60 €uro netto for the
service work.
• Cancellation costs will not be paid by Aspöck Systems (please refer to chapter 15 – Warranty Terms).
• Preparatory works are also included in the following list
Chapter 20 Februar 2009
overview time – repair list:
change / rework product: max repair time per part (in hours):
side marker light (SML)
•incl. P&R 0,25 h•incl. ASS2 and ASS3 0,15 h •only SML lense 0,10 h
position lights
•incl. P&R 0,25 h•incl. ASS2 and ASS3 0,15 h•only Lense white / red 0,10 h
outline marker
•change rear outline marker (per unit) incl. P&R 0,25 h•incl. ASS2 and ASS3 0,15 h
number plate lights and number plate holder LED
•number plate light incl. P&R 0,25 h•only number plate light 0,25 h•number plate with ASS2 0,15 h•number plate holder LED P&R 0,25 h•number plate holder LED ASS2 0,15 h
rear lights
•with 7 pin connector 0,15 h•with 7 pin and 2 pin connector 0,25 h•with PG ‐ connector 0,40 h•3‐chamber light with PG 0,40 h•3‐chamber light with Bayonet 0,15 h
plugs and sockets
•7 pin ISO 3731 or 1185 0,15 h•15 pin ISO 12098 0,35 h
P&R flatcable and ASS3 3pin loom
•P&R flatcable total 2 pcs (left and right) 2,00 h•repair of P&R flatcable with repair set 0,25 h•change of one ASS3 3pin loom 1,50 h
change connectors on cables
•Bayonet‐ or system ASS1 + ASS2 + ASS3 (2 pin) 0,25 h•Bayonet‐ or system ASS1 (7 pin) 0,35 h•Bayonet (15 pin) ‐ or ASS3 (17 pin) 0,50 h
junction boxes
•3socket front junction box 0,50 h•rear junction box 0,50 h
change of complete lightning set
•semi trailer 5‐6 h•trailer 4‐5 h
special / options
•LED interiour light with P&R 0,10 h•reverse light with ASS2 0,15 h•LCG 0,15 h•change main cable 1,50 h