service total

Chapter 1 Februar 2009

Chapter 1: Association the company Aspöck


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.


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.


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


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


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


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


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


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: ASS1 System


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


picture 2 Stipulate working time to change a complete 7 pin connector: max. 0,35 h

Cable tie


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)


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



Cable tie


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)




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



Cable tie


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)



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



Cable tie


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)




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


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)




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


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


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


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


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.


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


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




13-5625-771 X ASS1 7 pin male white




13-5626-901 X ASS1 7 pin female white


Chapter 3a Februar 2009

Chapter 3a System ASS2


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


37,40

28,8

0


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


plug case

contacts

pipe nut

pipe

ring

1 = wh / common return 2 = Current carring

12


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


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


SYSTEM ASS2


15-5624-041 side marker light connector ASS2









13-5625-851 X ASS2 7 pin male white




13-5626-961 X ASS2 7 pin female white



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


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


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


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


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


Installation instructions for repair purposes with rubber pipe

Tüllepipedouille

metal clampcollier de serrage métallique

Metallschelle


Bild / picture / photo 1

O - Ring DichtungO - ring sealingO - Ring

Gehäusesocket caseconnecteur


Metallschelle

collier de serrage métalliquemetal clamp


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.


Siftgehäuseplug caseconnecteur

Tüllepipedouille


Metallschelle

Feder muss eingerastet sein !


the spring must be engagedle ressort doit être enclanché



Metallschelle

collier de serrage métallique


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


contacts

pipe

connector

2 3 1

1 = wh / common return 2 = Current carring 3 = free

cable strip

o‐ring


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)



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


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


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 P&R System


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!


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


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


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


picture 2 picture 3

contacts

ATTENTION !!! this side is only for these contacts!!!

cable strips


P&R System

Flatcable

P&R connector

put the connector onto the flatcable (see photos)


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 Aspöck Lights


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


Monopoint white/red Rückstrahler red/white

Europoint Europoint II

Ecopoint mit URL Ecopoint mit LED

Ecopoint with triangle and/or outlinemarker Earpoint


Regpoint red Regpoint white

Regpoint white LED

Posipoint red Posipoint white


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


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.


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


picture 2 picture 3 Stipulate working time to change a complete side marker light : max. 0,15 hours

Isolate hose

Cable tie


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


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)


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: 3-Socket Junction Box


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).


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).


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:


special wiring: company PAGG (Italy)

company Schwarzmüller


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: Examples of lighting system


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.


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

,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

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

fart

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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

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

31-3

406-

067

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 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


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

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Buc

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ASS3

Buc

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ASS3

Buc

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SYSTEMASPÖCK

TOP

festziehen !

500

mm

2x1

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Reg

poin

t

36-3

007-

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0,

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Teile

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T II

31-2

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0

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1

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1250

mm

2x1

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31-3

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RT

/ WS

31-3

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RT

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31-3

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127

RT

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1250

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1250

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2x1

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2x1

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2x1

200

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200

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200

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5500

mm

3700

mm

3700

mm

3700

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3700

mm

3500

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2x1

qmm

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mm

3700

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3700

mm

3700

mm

3700

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500

mm

2x1

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1500

mm

2x1

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DIN

ISO

1185

DIN

ISO

3731

15 P

ol S

teck

er

12x1

+ 3

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5

ASS3

Buc

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Buc

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12x1

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1 50

0 m

m7x

113

00 m

m

76-6

431-

007

ASS3

Buc

hse

7x1

1300

mm





ASPÖCKSYSTEM

TOP

festziehen !

LED

Uni

poin

t

2x1

LED

Uni

poin

t

2x1

87-1

286-

007

0

,2m

65-6

499-

007

0

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65-1

499-

007

0

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65-1

499-

017

1

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2x1,

5 qm

m P

&R

1,65

m

2,5

m

7x1

2x1,

5 qm

m P

&R1,

65 m

2,5

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4-00

7

ASS3

Buc

hse

87-1

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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

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31-7

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117

1

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31-7

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127

3

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o. S

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31-6

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0

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1

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3

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2x1

31-2

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0

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31-2

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017

1

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31-2

367-

027

0

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31-2

367-

037

1

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2x1

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047

0

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1

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LED

Fla

t II

LED

Fla

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65-1

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9

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017

12,

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15,

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65-1

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15,

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65-1

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12,

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65-1

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9

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65-1

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9

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017

12,

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027

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DIN

ISO

1185

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15,

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9

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520

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66-8

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Stop

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SYSTEMASPÖCK

TOP

festziehen !

Stan

dard

Teile

AD

R / P

VC fü

r Zon

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Prü

fart

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007

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mm





ASPÖCKSYSTEM

TOP

festziehen !

2x1,

5 qm

m P

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m

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Uni

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ISO

3731

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15 pol. ISO 12098

DAF

DIN

ISO

3731

24V

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24V

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ISO

1185

6x1

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12,

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65-1

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15,

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65-1

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9

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2x2,51000 mm

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520

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66-8

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007

Stop

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SYSTEMASPÖCK

TOP

festziehen !

Stan

dard

Teile

Ve

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CP

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Prü

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.

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D

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m7x

113

00 m

m

76-6

431-

007

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Buc

hse

7x1

1300

mm





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

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1185

DIN

ISO

3731

7x1

4800

mm

4800

mm

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Buc

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dose

12x1

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007

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poin

t 2x

1

2x1

2x1

2x1

31-2

064-

407

0,

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017

0

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004-

027

1

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31-2

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037

1

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31-2

064-

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0,

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31-2

064-

017

0

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31-2

064-

027

1

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31-2

064-

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1

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31-2

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0

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poin

t

31-2

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31-2

104-

037

1

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13,

0m

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017

15,

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68-7

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027

17,

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68-7

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16,

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31-6

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1

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Pos.

Leu

chte

n LE

D-V

ersi

on

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017

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Pos.

Leu

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IPO

INT

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31-7

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037

1

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2x1

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mm

2x1

qmm

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007

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/ WS

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404-

027

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S

1250

mm

2x1

qmm

31-3

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2x1

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0,5m

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0,5m

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027

1

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Pos.

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chte

n G

lühl

ampe

nver

sion

2x1


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: ADR Equipment


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.


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)


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


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).


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


- 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.


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.


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.


If you have any further questions please contact th e sales department of Aspöck Systems.


Chapter 10: BBVA II – Brake Pad Wear Indicator

Chapter 10

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ebruar 2009

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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


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

Bremse bl

+ 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: Ramp-Distance-Control


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.


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).


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)


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°)


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.



Superpoint LED

operating voltage 24 V


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.


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.


The maximum detectable distance is 3m from the sensor.

And is Graduated into five phases, Please study the sketch below.

ERROR &


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


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


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 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


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


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 13: Detection of errors


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: Legal Installation Instructions for Lamps


Chapter 15: Installation of single components


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 3 connector 17-pin - mind. 40 mm

Bayonet connector 15-pin - mind. 40 mm


• 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



39,1

0

33,8

0

40,0

8

21,6

0

28,2

0

28,2

0



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 16: Labelling of spare parts


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: Electrical circuit plan


Chapter 18: General terms and conditions of warranty


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.


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.


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.


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


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.


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.


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: Claims


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: 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


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

service total

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