MUNICIPAL VEHICLES AND VEHICLES WITH ... - Hella

MUNICIPAL VEHICLES AND VEHICLES WITH SPECIAL BODYWORK

www.hella.com/municipal

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You can find exciting illumination comparisons in the work lights section (from page 50)

Road sweeper with halogen lighting. The same road sweeper, with HELLA LED work lights fitted.

INTRODUCTION

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Beacons from page 24

Optical warning systems (OWS)from page 42

Content

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2HELLA is quality – you can count on that . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Thermal management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8ECE-R10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Lux, lumens, candela – what are the differences? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Target Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Waste collection vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Street cleaning vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Winter service vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Maintenance vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Baggage tug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Aircra� tugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Towing vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Escort vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Construction machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Agriculture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Sewer cleaning vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Beacons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Beacons – overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Which beacons are approved for use on roads? – Directive ECE-R65 . . . . . . . . . . . . . . . . . . . . 26LED beacons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Xenon beacons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Halogen beacons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Accessories for LED and Xenon beacons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Accessories for halogen beacons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Optical warning systems (OWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42OWS7 Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Fully modular from the basic version to maximum features. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Optical warning systems (OWS) – overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44OWS7 technical details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45OWS7 accessories and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Configuration examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47LED warning lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Worklightsfrom page 50

Worklights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50HELLA quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Garbage / waste collection vehicle – halogen lighting vs. LED lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Road sweeper – halogen lighting vs. LED lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Road sweeper conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56LED worklights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58ZEROGLARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Thermo Pro series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Worklights – Isolux diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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Rear lightingFrom page 116

INTRODUCTION

Shapelinefrom page 84

Front lightingfrom page 66

Side lightingfrom page 112

Front lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6690 mm modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Range overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Configuration tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68LED accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

50 mm Premium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Headlamps and auxiliary driving lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Unimog – halogen vs. LED lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Daytime running lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Legal regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Daytime running lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Daytime running lights, direction indicators, and position lights . . . . . . . . . . . . . . . . . . . . . . . . . 80Position lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Shapeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Front lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

LED position lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85LED direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87LED reflex reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Side lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90LED direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90LED direction indicators and reflex reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Clearance light and LED side marker lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92LED side marker lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Shapeline online configuration tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Rear lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

LED position lights and LED tail stop light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98LED tail stop lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99LED tail stop lights and LED tail/stop/direction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 100LED direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102LED reverse lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105LED rear fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107LED rear fog/reverse lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Reflex reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Warning lights and design elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Side lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Direction indicators and position lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Side marker lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Rear lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116LED reversing spotlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Single-function lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

55 mm LED modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Single-function lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Single and multi-function lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

66 mm modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Multi-function lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122Licence plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Clearance lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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Interior lightingfrom page 136

Electronic systemfrom page 144

Electrical systemfrom page 160

Additional informationfrom page 166


Lighting electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130LED lighting Failure monitor and electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136Ceiling lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Orientation lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

LED step lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Reading lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Product ranges, Special OE Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Intelligent battery sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146Accelerator pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148Rain light sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Radio-controlled systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Angular Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156Switch series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Plug connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Cable Ties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Municipal fleet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166ROAD SWEEPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Waste collection vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Find the right product with ease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Online tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

IP protection category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Overview of icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Look out for information boxes: Our rotating beacons provide you with important information and tips.

6 | 7INTRODUCTION

HELLA has set itself the ambitious standard of guaranteeing consistently high product quality in every respect. This is achieved by defining quality criteria and checking every detail using carefully-selected methods throughout the entire manufacturing process. Production quality is ensured by parallel quality monitoring and testing.

Quality products from HELLA are subject to different test procedures in accordance with HELLA norm 67101. These test procedures are conducted by the HELLA test laboratory in Lippstadt.

HELLA is quality – you can count on that

Freezing conditions down to - 40°C and at full power up to + 100°C, also rapid temperature fluctuations, condensation and decondensation tests at air humidities up to max. 95%.

HELLA LED products withstand rapid temperature fluctuations and changes in air humidity.

Environmental conditions such as rain, splash water, hose water and spray are simulated in splash water booths.

HELLA LED products are splash-proof.

Heat, moisture and cold test

Splash water test

First-class quality by convictionHELLA guarantees the perfect, long-term functioning of its products and stands for satisfied customers in the spare parts, accessories and light sources areas.

As the long-established company from Lippstadt is an efficient partner to the automotive industry, HELLA products are manufactured to meet the respective precision, tolerance specifications. Combined with the use of sophisticated test procedures in the product development, you can depend on HELLA products in any situation.

You will find further information on the HELLA quality criteria at: www.hella.com/quality

Before HELLA products are brought onto the market, they undergo rigorous testing:

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Simulation of cleaning in a car wash with extremely high water pressure of up to 120 bar and water temperatures up to + 85°C.

HELLA LED products can be cleaned using a high-pressure cleaner without a problem.

Intensive tests guarantee dust tightness, even with the tiniest of dust particles.

HELLA LED products are exceptionally tight to protect sensitive components from dust.

During this test, our products are exposed to powerful vibrations and impacts.

HELLA LED products offer guaranteed high resistance to vibrations.

Underwater pressure testing at depths of up to 6 m guarantees the leak tightness of our products.

HELLA LED products are tight.

High-pressure cleaner test

Vibration test

Immersion and pressure tightness test

Dust test

DID YOU KNOW?

ª The heat and cold tests last up to 48 hours. ª The leak tightness of products is tested by carrying out

intermittent and splash water tests at pressures up to 5 bar, and a spray water test at a pressure of up to 10 bar.

ª During the vibration test, all products are tested for up to 24 hours when in operation.

ª An overpressure test up to 1.6 bar is performed in an immersion tank.

8 | 9

Thermal management

The service life of an LED heavily depends on its temperature and the applied current. If the LEDs overheat (usually because the input currents are too high), their service life will be drastically reduced. Effective thermal management is therefore extremely important.

HELLA uses state-of-the-art simulation programs to precisely calculate the heat flow. The task of the developer is to protect the LED from overheating and to safely and efficiently dissipate the heat into the environment.

Why use thermal management? ª The basis for effective uniform lighting ª Keeps the LEDs within the optimum temperature range ª Increases the service life of the product ª Reduces the risk of failure

Most important components ª Cooling fins incorporated into headlamp casing ª High-quality LEDs (automotive standard) ª Thermosensors for temperature monitoring ª Heat-dissipating substances (film, paste, etc.)

INSUFFICIENT THERMAL MANAGEMENT

Hot spots cause the components to expand at different rates, which normally leads to failure.

Disadvantages: ª Mechanical stress on the circuit board ª The adhesive bond on components breaks ª Breaks in soldering points ª Cracks in the circuit board ª Result: Short circuit

The heat on the PCB is not sufficiently dissipated by the heat sink, i.e. the heat transfer is poor, meaning there is a risk of the LEDs overheating. If they are damaged, they could cause a failure.

Disadvantages: ª Low light output ª Accelerated wear ª Reduced service life ª Overheating = downtimes and repair time

INTRODUCTION

8 | 9

Many LED products stand out due to their powerful light outputs. Many manufacturers push LEDs to their limits and also far beyond in order to maximise the light outputs. If the operating temperature of LEDs is too high, this has a direct effect on the service life and luminous efficiency of the product. The full potential of the LEDs can then only be exploited if the heat generated is deflected outwards to prevent the LEDs from overheating.

If you want to get the best out of LED technology, thermal management is essential!

LEDs

Example of optimum thermal management by HELLA using a beacon

Thermosensors for greater safetyHELLA LED products are equipped with thermal management which, assisted by temperature sensors, can actively intervene in the system. These sensors monitor the temperature of the LED and respond immediately. If the system identifies excessively high temperatures, it automatically reduces the input current. During this process, the light output of the headlamp is dimmed until the temperature of the LEDs is once again within the optimum range. The LEDs are therefore always operated under perfect conditions. This is the only way to achieve a service life of up to 60,000 hours.

The thermal imaging camera clearly shows how HELLA thermal management works: The high temperatures of the LEDs are distributed uniformly across a large surface area which then transfers this heat to the surroundings. The heat dissipation, and therefore the thermal conductivity of the housing in headlamps, for example, can be improved by using cooling fins.

HELLA selects heat-conductive materials and arranges components to ensure effective heat flow. Thermal management dissipates heat from the LED. This is why we can guarantee a long service life for our products!

Advantages: ª Effective heat flow ª Optimum temperature distribution ª Long service life ª Reliability

10 | 11INTRODUCTION

ECE-R10

What is EMC (ECE-R10)?

Electromagnetic compatibility (EMC) is a major quality feature for optical signalling systems and describes two factors:

ª Emitted interference: Limitation of radiated electromagnetic interference to a level that guarantees the interference-free operation of other devices in the environment.

ª Interference immunity: Guarantees sufficiently high resistance to external electromagnetic interference.

The legal foundations for this are the CISPR 25 as well as the ISO 7637 and 11452.

Electromagnetic interactions

Protective categories standard CISPR 25:

CISPR 25 is the standard for emitted interference which applies a classification of 1 - 5. In doing so, category 5 products must satisfy the most demanding requirements and are even suitable for installation situations directly next to an aerial. The statutory standards are met by category 3, which guarantees adequate protection in standard practice. (HELLA lighting systems fulfil at least category 3, many even category 5, and guarantee absolute functional safety in all application situations).

Radio / TV

Mobile telephone Sat radio Navigation Telematics fee collection

Entire electrical system

Distance warning radar

Only beacons, which can have both of these test numbers, possess the authorisation for use on public roads.

1 2 1 ECE-R65

2 ECE-R10

10 | 11

Lux, lumens, candela – what are the differences?

These three terms are often confused. However, they deal with various factors relating to lighting technology. We would like to "shed some light" on a few things:

LUMEN (lm)A lumen is the unit of the luminous flux and describes the overall light that is emitted by a light source such as an LED headlamp. However, the lumen value does not provide a statement on how the light is distributed in the room.

CANDELA (cd) Candela is the unit that describes the strength of the light emission that is sent from a light source in a specific direction. Candela, like a lumen, is also a transmission value. Traditionally, 1 candela corresponds to the luminous intensity of a household candle. A candela is also used as the unit of luminance, i.e. of the subjective brightness perceived by the human eye from an illuminated surface. This also describes what is called "glare".

A lumen value is frequently specified for work lights. As an example, our Ultra Beam LED Gen. II work light achieves a powerful measured output of 4,000 lumens. Here, the difference between measured and calculated lumens is enormously important. Only measured lumens yield the correct, precise value. Calculated lumens merely provide a theoretical value. Calculated lumens do not provide useful information and are always higher than the measured lumens because energy losses from heat and light losses through the reflector and cover lens are not taken into account.

HELLA only specifies real measured lumen values for this reason! When comparing or purchasing headlamps, always check if the lumen specifications are a measured or calculated value!

Another value is relevant for auxiliary (high-beam) headlamps. This is the reference number (ref.). This value tells you the maximum luminous intensity the headlamp can produce. The reference number enables you to see at a glance how powerful a headlamp is. The reference number is obtained by converting the maximum luminous intensity in candelas. It is a dimensionless number so it has no associated unit of measurement. Please note the national regulations related to the reference value that apply in your country and check whether you are subject to the ECE Regulation in force since 2009. In some countries, a total reference value (the sum of the reference values of all high-beam headlamps on the vehicle) exceeding 100 is not permitted.

LUX (lx)Lux is the unit used to measure illuminance. The lux value specifies the light emanating from the light source that strikes a specific surface. Unlike lumens and candelas, lux is a "receiver value". This means that it measures the amount of light arriving in a specified area. This is crucial in achieving optimum work conditions.

Target Groups

Waste collection vehicles

Garbage / Waste collection vehicles have evolved into highly specialised technological showcases over the past few years. Equipped with state-of-the-art safety systems, they ensure that waste generated is disposed of as quickly as possible, in an environmentally friendly and quiet manner, and with the utmost efficiency every day.

Through the development of innovative and high-quality technology in the areas of light, electronics and electrics, HELLA has made a small but significant contribution to this. Highly modern LED work lights ensure an optimum view during manoeuvring and turn darkness into daylight for the disposal team. HELLA LED rotating beacons achieve the best possible safety for workers and warn road users from a distance to ensure smooth conditions.

K-LED 2.0Page 28

Ultra Beam LED Gen. IPage 60

Coluna full LED rear combination lamp Page 124

Product recommendation

TARGET GROUPS

Q90 Compact LEDPage 58

Shapeline tail stop light, wingPage 99

Street cleaning vehicles

Their range of applications is versatile. They are used for cleaning pavements, pedestrian zones, roads, runways or even industrial halls. They often appear from nowhere on the road, clean at lightening speed and disappear again just as quickly. They ensure inner cities are kept clean and sweep all sorts of road surfaces from narrow little alleyways to large public spaces or airports.

HELLA lighting technology helps ensure that no piece of waste is missed and the drivers always have optimum visibility, regardless of where they are sweeping. HELLA sensors allow precise measurement of vehicle properties, so that problems can be detected early on and HELLA switches facilitate all functions being quick and easy to operate.

Rota LEDPage 31

Intelligent battery sensorsPage 146



90 mm LED modulesfrom page 68

12 | 13

Module 70 LED Generation 4 Page 59

Winter service vehicles

They don't usually get to enjoy idyllic winter landscapes. When they are on the move, they need to take great care as usually the temperature is below freezing, visibility is poor, there is a high risk of black ice and heavy snowfall. They often start work in the early hours before dawn and often work until late in the evening or night. There is no question that winter service vehicles play an important role in keeping the roads, footpaths and airports safe, as well as many other public and private spaces.

Such situations not only put a great strain on people, but also on the materials used. HELLA has been a partner of leading winter maintenance vehicle manufacturers for years and tries to support the work in this sector as much as possible with high-quality and innovative products. This is because reliability, safety, and durability are more important for winter maintenance vehicles than in virtually any other sector. HELLA products are checked down to the last detail throughout the entire manufacturing process, and are subject to the highest requirements so that drivers can be confident in relying on the HELLA lighting system.

Q90 compact LED, redPage 58

C140 LED headlampPage 75

Coluna full LED rear combination lamp Page 124


TARGET GROUPS

Front flashers BSTPage 48

K-LED 1.2Page 29

Maintenance vehicles

They carry out safety checks, appraise roads, guard railings or paths. Wherever they stop, something needs to be done urgently. Despite usually being painted in a conspicuous vehicle colour, drivers approaching too quickly often overlook them. The only way to improve safety here is to use the best warning systems. HELLA has been a reliable partner for roof bars, rotating beacons and other warning systems for many years now. HELLA worklights ensure optimum visibility, even in the darkest hours.

OWS7

from page 44



14 | 15

K-LED 1.2Page 29

Ultra Beam LED Gen. IIPage 60


K-LED 2.0 AirportPage 28


Baggage tug

Compact, robust, and special. This is how you can describe luggage trucks that are used in large numbers at airports around the world, which ensure that luggage gets on the right aircraft or to the right passenger every day while always keeping to a tight schedule. Safety at the airport is also the top priority. HELLA warning systems ensure the highest level of warning effectiveness so that vehicles can be seen at all times. Front headlamps and work lights ensure an optimum view when driving and working around the vehicle.

90 mm LED modulesPage 68

TARGET GROUPS

Shapeline tail stop lightPage 99


Module 70 LED Gen. 3.2Page 59

K-LED 2.0 AirportPage 28


Intelligent battery sensorsPage 146


Aircraft tugs

They are powerhouses, moving unimaginable masses with great precision and yet often remain undetected. They are operational for thousands of hours per year, which is only possible with top quality products. HELLA lighting technology on airport vehicles makes an important contribution towards safety. It stands for top quality, a high signal effect and minimum energy consumption. HELLA lighting systems mean working at the highest safety level with a reliable partner.

16 | 17





Towing vehicles

They mostly work on roads with fast-moving traffic and where other road users might not notice them. They rescue vehicles on motorways, blind corners, or country roads with fast-moving traffic. It's a job that can only be done by people with nerves of steel, a lot of expertise, and optimum equipment. HELLA products help to achieve maximum safety for people and materials, where it is important to be 100 % reliant upon the lighting equipment used.


TARGET GROUPS

K-LED 1.2Page 29

Module 70 LED Generation 4 Page 59


Trucks

Wider than others, longer, higher, heavier, more powerful, slower. Prescribed routes and driving times. Heavy and wide loads present drivers with a special challenge – often underestimated by other road users. For this reason, the same rules apply for those responsible for equipping the vehicles with warning systems and worklights as for those responsible for the vehicle condition and load securing measures: Only perfect will do. HELLA is happy with this attitude. Because we work according to the very same principle.

18 | 19

K-LED BlizzardPage 30K-LED Blizzard

Full LED truck rear combination lampPage 124

LED Light Bar 350Page 75

Repulse UltraPage 117


TARGET GROUPS

Escort vehicles

This job is one of the most dangerous in the transport business. A relatively small, light vehicle drives along, right on the tail of a heavy truck as though attached by a rope. The vehicle’s driver has to look forwards and in the rear view mirror at the same time. He receives instructions by radio to block the lanes before road works to prevent other vehicles attempting to overtake. His sole purpose: To secure the area behind him, prevent accident risks before they even happen. His best life insurance: State-of-the-art warning systems on the vehicle. Ideally combined with daytime running lights and worklights. These turn the escort vehicle into a mobile light source for work on the transporter and its load.


OWS7

from page 44

K-LED 1.2Page 29



Rota LEDPage 31


DuraLED CombiPage 125

Power Beam 1500 Page 58


Construction machinery

Construction sites are really tough tests for all kinds of material. But this doesn’t frighten HELLA lighting systems. Because they have had to undergo tough tests of their own in the testing laboratory and in field trials. This includes series of tests against water and dust penetration, checks on electromagnetic compatibility, thermal tests, endurance tests, electronic tests and vibration tests, of course. Once they’ve been through all that, they feel at home on any construction site in the world.

20 | 21


Rota LEDPage 31

Oval 100 LED Thermo ProPage 61


Agriculture

Tractors and combine harvesters with beacons are a familiar sight on country roads. But tractors are getting larger and larger and combine harvesters faster and faster all the time. So the output and reliability of the beacons has to be right. And what about worklights? In agriculture in particular, selective use of special worklights allows productivity to be increased significantly. This allows modern owner-operators to work at full capacity both at night and at dusk – older machines can be used more efficiently through light optimisation.

90 mm LED modulesfrom page 68

TARGET GROUPS

Shapeline tail stop lightPage 99

Module 70 LED Gen. 3.2Page 59


Sewer cleaning vehicles

Equipped with the latest technology, sewer cleaning vehicles are used to clean and inspect sewers. They are deployed in particular when sewers become blocked due to deposits or contamination. Various cleaning devices are used to eliminate smaller materials in liquid, paste-like or solid form.

HELLA supports this work in the best possible way with its high-quality, innovative products: Work lights achieve a better view for workers – not only around the vehicle, but also within the sewers. State-of-the-art warning systems on the vehicle increase safety and warn other road users from a distance about the cleaning work being carried out.

22 | 23

K-LED 1.2Page 29

MODULE 50 LEDPage 60

Coluna full LED rear combination lampPage 124



24 | 25

HELLA beacons with powerful warning effect signal to the other road users: please take care – work is going on around this vehicle.

They enable maximum own- and third-party safety by means of an intensive warning effect. This safety is achieved by the optimum light bundling and distribution, the resulting high range as well as the very high light intensity.

You can rely 100 % on our beacons: HELLA beacons are characterised by outstanding quality in terms of processing and stability – the long service life proves this!

BEACONS

24 | 25

Beacons – overview

Product line F(Fixed attachment)

FL(Flexible pipe-socket

mounting)

R(Pipe socket mounting)

M(Magnetic attachment)

LED

K-LED 2.0Page 28 –

K-LED 1.2Page 29 – –

K-LED BlizzardPage 30 –

Rota LEDPage 31 –

RotaLED CompactPage 32 –

KL 7000 LEDPage 33 –

Xenon

KLX 7000Page 34 –

Halogen

KL 7000Page 35

KL Rotaflex / RotafixPage 36 –

KL Rota CompactPage 37

Other domes (blue, red and green) are available on request.

BEACONS

Which beacons are approved for use on roads? – Directive ECE-R65

A beacon may only be used on public roads if it meets Directive ECE-R65.

ECE-R65 is the European directive for beacons. It specifies the required light values, light distribution and fitting specifications, etc. Can also be viewed at www.unece.org (United Nations Economic Commission for Europe)

MountingThe beacon [warning light] shall be designed in such a way that it cannot be adjusted after it has been fitted correctly to the vehicle (ECE-R65 5.2). The design and fixing method must conform to DIN14620. The beacon itself can have the following designs: A, B1, B2 or C.

The large E-approval mark (here ) shows whether the beacon meets the ECE-R65 directive and therefore has approval.

Design A Design B1 Design B2 Design C

EMC test number TA1 ECE-R65

Type approval T 360°

CE CE marking A Amber; B = Blue

Pmax. 9 W = 9 watt power consumption 1 1 = night; 2 = day and night

10 03 6194 ECE-R10 approval TA1 Amber beacon with night level according to ECE-R65

65 00 3397 ECE-R65 approval TA2 Amber beacon with day and night level according to ECE-R65

Positive example:The warning signal can be seen from all directions in a 25 m radius.

Correct

Negative example: In a 25 m radius, the warning signal cannot be seen from all directions – this is interrupted in the area of the towing hook. In this case, another warning light needs to be attached to the rear of the vehicle or two beacons attached to the driver's cab.

Incorrect

26 | 27

28 | 29

ª Two warning signal types The first HELLA beacons where you can choose between rotating or flashing warning signals.

ª Two brightness levels An integrated light sensor enables automatic switching between day and night mode. This guarantees you the greatest warning effectiveness.

ª Functional safety The IP 67-protected beacon is dust-tight and can be immersed in water for a short period.

ª Vibration resistance The beacon is protected against strong vibrations and shocks without any moving parts.

ª Compact design Extremely flat design and impact-resistant dome.

ª Low life-cycle costs Maintenance-free beacon with very long service life. Maintenance costs and standstill times are reduced to a minimum.

ª ECE-R65 Approved in accordance with ECE-R 65.

K-LED 2.0 beacon

Technical specifications

Rated voltage (UN) MultivoltOperating voltage (UB) 10 – 32 VInterference suppression (CISPR25) Power-controlled class 5Total current consumption 0.45 A to 2.5 APower consumption max. 30 WOperating temperature range - 40°C up to + 60°CDome PolycarbonateMounting from the bottomReverse polarity protection YesPosition of use UprightProtection category IP 67

Type approval

Approval GGVSE / ADRSAE 7845, class 1

Technical light homologationTR1 003468TA2 003555TB2 003555

SAE W3-11)

EMC protection 036816ECE-R10: 036816

BEACONS

Beacon K-LED 2.0 F*(Rotating and flashing)

Multi-voltage, amber 2XD 011 557-1011)

Multi-voltage, blue 2XD 011 557-111Multi-voltage, red 2XD 011 557-121Multi-voltage, yellow, black base 2RL 011 557-841

These LED products have the following features:

ECE R65

+8°

-8°

Beacon K-LED 2.0 R *(Flashing)


Multi-voltage, blue 2XD 011 557-211Multi-voltage, red 2XD 011 557-221Multi-voltage, yellow, black base 2RL 011 557-811

Beacon K-LED 2.0 M *(Flashing)


Multi-voltage, blue 2XD 011 557-311 Multi-voltage, red 2XD 011 557-321

K-LED 2.0 Airport **

Multi-voltage, amber (fixed attachment) 2XD 011 557-701Pipe-socket attachment (to be ordered separately) 8HG 005 436-041

** tested according to ICAO Annex 14 (Low Intensity, Type C)

* Other colours available on request.

28 | 29

K-LED 1.2 Beacon

Low current consumption, high level of efficiency and large light exit area

ª Dual lighting system The dual lighting system provides a larger light exit area, making it especially effective at providing a warning function.

ª Very robust and vibration-proof Developed without any moving parts. This beacon is thus optimally protected against strong vibrations and shocks. The polycarbonate dome is impact-resistant.

ª Extremely long service life Due to the innovative LED technology.

ª EMC resistance Wireless signals are not disrupted by the K-LED 1.2 since it has a high resistance to EMC.

ª Mounting The three attachment options enable the beacon to be optimally adapted to its areas of application: pipe-socket mounting, fixed mounting in accordance with DIN 14620 Form B1 (Ø 130 mm) and SAE (Ø 150 mm), magnetic attachment in accordance with DIN 14620.


Rated voltage (UN) MultivoltOperating voltage (UB) 10 – 30 VInterference suppression Tested according to CISPR 25Total current consumption

Rotating Approx. 1.6 A (12 V), approx. 0.8 A (24 V)

Flashing Approx. 1.8 A (12 V), approx. 0.9 A (24 V)

Power consumptionRotating Approx. 20 WFlashing Approx. 22 WOperating temperature range - 40°C up to + 60°CDome PolycarbonateReverse polarity protection YesPosition of use UprightProtection category IP 6K7, IP 6K9K

Type approval

Approval SAE J845 class 1EMC protection ECE-R10, RCMRotating light function

Homologation, yellow 10 00 5796365 00 4439TA1

Homologation, blue 10 00 5796365 00 4440TB1

Homologation, red 10 00 5796365 00 4441TR1

Flashing light function



Homologation, red 10 00 5796265 00 4444TR1

1600

±10

21

Ø146 ±0,5

85 ±1

115,

5 ±1

,5

123

±1,5

Ø6 ±0,1

Ø164,7 ±1

Ø169,3 ±1

Ø6

120°

(x3)

Ø150 ±0,5

Ø130 ±0,5

20°

42,8°

1600

±10

21

Ø146 ±0,5

85 ±1

115,

5 ±1

,5

123

±1,5

Ø6 ±0,1

Ø164,7 ±1

Ø169,3 ±1

Ø6

120°

(x3)

Ø150 ±0,5

Ø130 ±0,5

20°

42,8°

Ø 169,5 ±0,5

196,

5 ±1

146 ±1

115,

5 ±1

,5

85 ±1

125,

5 ±1

,5


K-LED 1.2 F* beacon

Multi-voltage, yellow, rotating 2RL 012 983-301Multi-voltage, blue, rotating 2RL 012 983-311Multi-voltage, red, rotating On requestMulti-voltage, yellow, flashing 2XD 012 984-301Multi-voltage, blue, flashing 2XD 012 984-311Multi-voltage, red, flashing On request

K-LED 1.2 R* beacon

Multi-voltage, yellow, rotating 2RL 012 983-401Multi-voltage, blue, rotating On requestMulti-voltage, red, rotating On requestMulti-voltage, yellow, flashing 2XD 012 984-401Multi-voltage, blue, flashing On requestMulti-voltage, red, flashing On request


ECE R65

+8°

-8°

30 | 31BEACONS

ª Flashing light function Intensive perception due to dual flashing signal, 360° warning function, sharp increase of the light values, signal immediately perceptible.

ª Functional safety Meets the requirements of IP 67 and IP 9K. The beacon is dust-tight, resistant to high-pressure cleaners, and even able to withstand brief immersion in water to a depth of up to 1 m.

ª Ideal for continuous use Due to its low total power consumption and high-quality, durable LEDs.



ª Intelligent and high-performance electronics This makes multi-voltage function, protection against voltage peaks and polarity reversal protection possible.

ª High-quality corrosion protection The housing is passivated and then powder-coated. This provides a considerable degree of protection against aggressive media like salt and lyes.

ª Compact and modern design Extremely flat design and impact-resistant, crystal-clear polycarbonate dome.

ª Approvals Approved in accordance with ECE-R65 and ECE-R10.

K-LED Blizzard

K-LED Blizzard F

Amber 2XD 012 980-001

K-LED Blizzard FL

Amber 2XD 012 980-011

K-LED Blizzard M

Amber 2XD 012 980-021


Rated voltage (UN) MultivoltOperating voltage (UB) 10 - 30 V

Total current consumption Approx. 1.3 A (12 V)

Approx. 0.7 A (24 V)

Power consumption 16WDome PolycarbonateHousing AluminumPosition of use UprightTemperature range -40 °C to +60 °CReverse polarity protection YesProtection category IP 6K7, IP 6K9K

Type approval

Homologation, yellow 65 Certification from 3rd quarter 2017TA1

Interference suppression CISPR25 conducted class 5Approval GGVSE / ADR

EMC protection ECE-R10: Certification from 3rd quarter 2017

Ø 4,1 (3X)

120° (3X)

20°

39 ±1

88 ±1

,5

83,6

±1

132

±1,5

149 ±1

83,6

±1,5

95,5

±1,5

148,3 ±1


ECE R65

+8°

-8°

Ø 4,1 (3X)

120° (3X)

20°

39 ±1

88 ±1

,5

30 | 31

Rota LED beacon

ª Long service life No moving parts, no wear and maximum reliability.

ª Cost saving Since LEDs are maintenance-free, they do not cause any additional costs for spare parts or maintenance. Downtime is reduced to a minimum.

ª Vibration resistance Particularly resistant to vibrations and shocks as a result of the LED technology, without any moving parts.

ª Rotating light function The innovative electronics concept makes a rotating function possible without moving parts.

ª Compact and robust design Flat, compact design and impact-resistant polycarbonate dome protect against impacts, e.g. branches.

ª Mounting Three different attachment variants guarantee a mounting solution for every application.

ª ECE-R65 Approved in accordance with ECE-R 65.

Beacon Rota LED F*

Multi-voltage 10 – 32 V, yellow, rotating 2RL 010 979-001Multi-voltage 10–32 V, blue, rotating 2RL 010 979-101Multi-voltage 10 – 32 V, yellow, flashing 2XD 012 878-001Multi-voltage 10-32 V, blue, flashing 2XD 012 878-101

Beacon Rota LED FL*


Beacon Rota LED M*



Rated voltage (UN) MultivoltOperating voltage (UB) 10 – 32 VTotal current consumption Approx. 0.8 A (12 V), ca. 0.4 A (24 V)Power consumption Approx. 10 WDome PolycarbonatePosition of use UprightProtection category IP 5KX, IP X4K and IP X9K

Type approvalInterference suppression (CISPR25) Power-controlled class 5

Approval GGVSE / ADRSAE 9845, class 2

EMC protection 035517ECE-R10

Rotating light function



Flashing light function


Homologation, blue

10 05 769665 00 4155TB1

10 05 769665 00 4255TR1

ECE R65

+8°

-8°



32 | 33BEACONS

RotaLED Compact

ª Flashing light function Intensive perception due to dual flashing signal, 360° warning function, sharp increase of the light values, signal immediately perceptible.


ª Halogen can be replaced 1:1 with LED The RotaLED Compact is the LED successor to the existing Rotafix, Rotaflex and Rota Compact halogen beacon series. These can be replaced 1:1.


ª Flexible version Flexible base protects against branch impact – the beacon bends and always returns to its original position.

ª Approval ECE and SAE-approved.

RotaLED Compact F*

Multi-voltage 10-30 V, yellow 2XD 013 979-001

RotaLED Compact FL*


RotaLED Compact M*


ECE R65

+8°

-8°

84,8

±0,

5

Ø165,2 ±1

Ø138,8 ±1

118

±1

Ø5,5 (3x)

Ø150 ±0,5

Ø5,5 (3x)

Ø10 min Ø130 ±0,5

20°

120°

(3x)

120° (3x)

118

±1

164

±1

165 ±1

84,8

±0,

5

Ø165 ±1

Ø138,8 ±0,513

0 ±1



Rated voltage (UN) MultivoltOperating voltage (UB) 10 – 30 V

Total current consumption Approx. 1.3 A (10 V)

Approx. 0.7 A (30 V)

Power consumption 10 WDome PolycarbonatePosition of use UprightProtection category IP X9K, IP 67

Type approval

Homologation, yellow 65 004636TA1

Interference suppression (CISPR25) Power-controlled class 5

Approval GGVSE / ADRSAE 7 845, class 2

EMC protection ECE-R10: 058156


32 | 33

KL 7000 LED beacon

ª Long service life The latest LED technology provides an optimum signal pattern with low power consumption.

ª Rotating light function The innovative electronics concept makes a rotating function possible without moving parts.

ª Mounting Three different attachment variants in accordance with DIN 14620 guarantee a mounting solution for every application. It is possible to mount the fixed installation variant from above and below.

ª Cost saving Since LEDs are maintenance-free, they do not cause any additional costs for spare parts or maintenance. Downtime is reduced to a minimum.

ª Compact design The module connection, consisting of thermal management and optics, enables a noticeably compact design.

ª Low design height Even trucks with top-mounted sleeping cabs will still be below the maximum vehicle height of 4 m permitted on public roads.

ª ECE-R65 approval ª Thermal management

The thermal management guides the heat away from the LED.

ª Scratch-proof, smooth dome The scratch-proof, dirt-resistant, and smooth dome ensures an optimal warning effect.

KL 7000 LED F *

Multi-voltage 10 – 32 V, amber 2RL 011 484-001Multi-voltage 10 – 32 V, blue 2RL 011 484-101

KL 7000 LED R *


KL 7000 LED M *



Rated voltage (UN) MultivoltOperating voltage (UB) 10 – 32 VTotal current consumption 0.8 A 0.4 APower consumption 10 WDome PMMAPosition of use UprightProtection category IP 5K4K, IP X9K

Type approval

Homologation, yellow 65 00 3397TA1

Interference suppression (CISPR25) Power-controlled class 5

Approval GGVSE / ADRSAE 7 845, class 2

EMC protection 036194

ECE-R10: 036194ECE-R65: 003397

ECE R65

+8°

-8°



34 | 35BEACONS

KLX 7000 beacon

Beacon KLX 7000 FL *

12 V, amber 2RL 008 183-10124 V, amber 2RL 008 183-11112 V, blue 2RL 008 183-00124 V, blue 2RL 008 183-011

Beacon KLX 7000 F *



Beacon KLX 7000 M *


ECE R65

+8°

-8°

High quality double flash technology – extremely high warning effect

ª Excellent lighting values on account of high-quality electronics and efficient internal lens system

ª Integrated personal protection cut-off of the live components guarantees safe handling

ª Powerful electronics with self-diagnosis function, polarity reversal protection, undervoltage cut-off and function control output (e.g. for relays or bulbs)

ª Replaceable standard flash tube X1 with practical pin base and replaceable electronics with a holder make servicing really easy

ª Highest EMC protection class ª Excellent cooling system ª Smooth, easy-to-clean dome made of polycarbonate ª Bayonet closure system with waterproof pressure

mechanism ª Approved according to ECE-R65


Rated voltage (UN) 12 V 24 VOperating voltage (UB) 10 – 15 V 20 – 30 V

Interference suppression Conducted class 5 (CISPR 25)

Total current consumption 3.3 A 1.6 AUndervoltage cut-off 8 V 12 VFunction control output Capable of bearing loads up to 0.5 AOperating temperature range - 40°C up to + 60°CInstallation (KLX 7000 F) From above and belowPosition of use UprightReverse polarity protection Fuses

Protection category IP 5K4K, IP X9K (resistant to dust and high-pressure jet cleaners)

Type approvalHomologation, yellow 001399 (ECE-R65)Homologation, blue 001399 (ECE-R65)EMC protection 031889


34 | 35

KL 7000 beacon

ECE R65

+8°

-8°

Beacon KL 7000 F *

12 V, amber 2RL 008 061-10124 V, amber 2RL 008 061-111230 V, amber 2RL 008 064-101*12 V, blue 2RL 008 061-00124 V, blue 2RL 008 061-011

Beacon KL 7000 R *


Beacon KL 7000 FL *


Beacon KL 7000 M *



Maximum light values – optimal signal effect

ª Extremely high light values for optimum warning effectiveness

ª Full light power, focusing and distribution through the rotating unit made up of a high-sheen metallised parabolic reflector and bulb

ª Maximum running smoothness by means of maintenance-free drive bearings and double-belt technology

ª Electronic motor control with multi-voltage function for a constant rotating frequency even in the event of fluctuations in the vehicle electric system

ª Excellent EMC protection, integrated polarity reversal protection

ª Operation with 12 or 24 V possible by replacing the bulbs ª Smooth, easy-to-clean dome with a handy pressure point

closure ª Approved according to ECE-R65 ª LED successor is the KL 7000 LED


Rated voltage (UN) 12 V 24 V 230 VOperating voltage (UB) 10.8 – 13.8 V 21.6 – 27.6 V –

Interference suppression Power-controlled class 5 (CISPR 25)

Power consumption of bulb 55 W 70 W 25 WTotal current consumption 5.5 A 3.5 A 0.2 A

Operating temperature range - 40°C up to + 60°C - 30°C up to + 60°C

Installation (KL 7000 F) From above or below

From above

or belowPosition of use Upright


Type approvalHomologation, yellow 001241 (ECE-R65)Homologation, blue 001240, (ECE-R65)EMC protection 031740

230 V protective mark


36 | 37


Rated voltage (UN) 12 V 24 VOperating voltage (UB) 10.8 – 13.8 V 21.6 – 27.6 V

Interference suppression Power-controlled class 3 (CISPR 25)

Engine speed 160 U/minPower consumption of bulb 55 W 70 WTotal current consumption 5.5 A 3.5 AOperating temperature range - 40°C up to + 60°CMounting From above and belowPosition of use Upright


Type approvalHomologation, yellow 006509, (ECE-R65)Homologation, blue 006513, (ECE-R65)Approval SAE 7845, class 2

EMC protection 032181

BEACONS

Beacon KL Rotaflex / Rotafix

ECE R65

+8°

-8°


Standard solution for robust applications

ª Tough rotary beacons ª Optimum light power, focusing and distribution through the

rotating unit made up of a high-sheen metallised parabolic reflector and bulb

ª Compact design shape and unmistakeable look ª Drive from motor with plastic worm gear ª Sturdy domes with smooth, easy-to-clean surface ª Approved according to ECE-R65 ª The RotaLED Compact is the LED successor

Beacon KL Rotafix M *


Beacon KL Rotaflex FL *


Beacon KL Rotafix F*

12 V, amber 2RL 007 337-00124 V, amber 2RL 007 337-01112 V / 24 V, amber (twin-belt drive) 2RL 007 337-04112 V, blue 2RL 007 337-10124 V, blue 2RL 007 337-111


36 | 37

KL Rota compact beacon

Compact Beacon for tough applications

ª Specially impact-resistant ª Low-noise belt drive ª Polycarbonate dome is impact and shock-resistant ª Different attachment versions for every application

Rota Compact FL: ª Elastic, shock-absorbing base minimises the risk of

damage; the light is always returned to the optimal position ª At the same time, the elastic base serves as a vibration

damper ª Approved according to ECE-R65 ª The RotaLED Compact is the LED successor

Beacon KL Rota Compact F *

12 V, amber 2RL 009 506-20124 V, amber 2RL 009 506-211

Beacon KL Rota Compact R *



Rated voltage (UN) 12 V 24 VOperating voltage (UB) 10.8 – 13.8 V 21.6 – 27.6 VEngine speed 180 U/minPower consumption of bulb 55 W 70 WTotal current consumption 5 A 3 AOperating temperature range - 40°C up to + 60°CDome PolycarbonatePosition of use Upright


EMC interference immunity VDE 0879 Part 3 Class 3

Type approvalHomologation, yellow 002076, (ECE-R65)EMC protection 034277

Beacon KL Rota Compact M *


ECE R65

+8°

-8°


Beacon KL Rota Compact FL *



38 | 39BEACONS

Accessories

Product photo Description Part number PU

Socket pipe to weld on, straight, 100 mm long, with rubber stopper and socket according to DIN 14620

1-pin8HG 002 365-001

2-pole8HG 006 294-101

1

Socket pipe with base to screw on, total height 126 mm long, with rubber stopper and socket according to DIN 14620

1-pin8HG 006 294-011

2-polepossible on request

1

Angled socket pipe with base to screw on side, clearance 90 mm, height 100 mm incl rubber stopper, socket , 2 x hexagon screws M8 x 35, 2 x hexagon nuts M8, 2 x spring washers according to DIN 14620

1-pin8HG 006 294-021


1

Angled socket pipe with base to screw on side, clearance 50 mm, height 100 mm incl rubber stopper, socket , 2 x hexagon screws M8 x 35, 2 x hexagon nuts M8, 2 x spring washers according to DIN 14620

1-pin8HG 006 294-111


1

Rotatable socket pipe, height approx. 105 mm incl rubber stopper, socket , 2 x hexagon screws M8 x 35, 2 x hexagon nuts M8, 2 x spring washers according to DIN 14620

1-pin8HG 006 294-031

2-pole8HG 006 294-141

1

Socket pipe with screw attachment, height approx. 100 mm, with rubber stopper and socket according to DIN 14620

1-pin8HG 006 294-051

2-pole8HG 006 294-091

1

Socket pipe with 2 screw holes for attaching it to the rear of the cab, with telescope holder, total height approx. 1000 mm, Can be shifted up to 700 mm, with rubber stopper and socket according to DIN 14620

1-pin8HG 006 294-041


1

Socket pipe to weld on, straight, height 100 mmCompatible with 8HG 002 365-001 / -8HG 006 294-101 8HG 096 531-007 2

Socket pipe, straight, black with M8 thread, approx. 220 mm longCompatible with 8HG 990 368-001 / -007 8HG 331 470-007 2

Socket pipe, straight with base, to screw on, total height 126 mmCompatible with 8HG 006 294-011 / -121 8HG 096 531-107 2

Angled socket pipe, with base to screw on side, clearance 90 mm Compatible with 8HG 006 294-021 and -221 8HG 096 531-117 2

Angled socket pipe, with base to screw on side, clearance 50 mmCompatible with 8HG 006 294-111 and -211 8HG 096 531-127 2

Rotatable socket pipe, height approx. 105 mm Compatible with 8HG 06 294-031 / -141 8HG 096 531-137 2

38 | 39

Installation examples

Bracket to screw on Angle bracket Variable bracketBracket with thread

Product photo Description Part number PU

2-pin socket with cap, with 2 blade terminal connections 6.3 mm

9JB 004 777-001*9JB 004 777-002*

51

2-pin round socket with ground contact, with 2 blade terminal connections 6.3 mm

8JB 862 757-001*8JB 862 757-007*

124

2-pin 6-edge SW20 socket with ground contact,with 2 blade terminal connections 6.3 mm

8JB 862 757-021*8JB 862 757-027*

124

2-pin socket with cap, with 300 mm cable 2.5 mm² and 2 male spade connectors 6.3 mm 8JB 001 946-101* 1

2-pin aluminum alloy socket with cap and 1 screw connection ground on housing 8JB 001 946-021* 10

2-pin socket with cap and 2 male spade connectors 6.3 mm 8JB 004 123-031* 1

1-pin round socket with fillister head screw M4 x 8 8JB 850 434-011* 10

1-pin socket with cap 8JB 001 946-011* 10

12 V, test equipment to monitor the function of rotating beacons and flashing beacons, indicates the failure of a beacon. 5KG 011 630-101 1

24 V, test equipment to monitor the function of rotating beacons and flashing beacons, indicates the failure of a beacon. 5KG 011 630-111 1

Rubber stopper /cap according to DIN 14620

9GH 096 532-0019GH 096 532-007

10200

* Sockets comply with DIN ISO 4165; installation opening: ø 18.5 mm, control panel thickness max. 7 mm

Accessories

40 | 41BEACONS

Accessories for LED and Xenon beacons

KLX 7000 beacon

Dome, amber (polycarbonate) 9EL 862 140-031Dome, blue (polycarbonate) 9EL 862 140-021Dome, red (polycarbonate) 9EL 862 140-041*Fresnel lens on the inside 9EL 862 678-001PCB with socket, 12 V 9MK 862 863-001PCB with socket, 24 V 9MK 862 862-001Dome seal 9GD 862 679-001Flash tube 8GS 859 634-001EMC shield cage for flash tube 9HB 862 864-001Xenon standard flash tube X1 with pin base 8GS 859 634-001Rubber base, flat, for KLX 7000 F (5 units) 9GD 862 164-001Rubber base, wedge-shaped, for KLX 7000 F (1 unit) 9GD 863 033-001Wing nut (with screw and washer as a fixing option for KLX 7000 FL) 9NM 863 332-001

¼ Page 74

Rota LED beacon

Dome, amber (polycarbonate) 9EL 181 506-001Dome, blue (polycarbonate) 9EL 181 506-011

¼ Page 31

KL 7000 LED beacon

Dome, amber (polycarbonate) 9EL 190 025-001Dome, blue (polycarbonate) 9EL 190 025-011Dome, red (polycarbonate) 9EL 190 025-021Rubber base, wedge-shaped 9GD 856 863-001Rubber base, flat 9GD 856 562-001

¼ Page 33

K-LED 2.0 beacon

Rubber base, wedge-shaped 9GD 856 863-001Pipe socket adapter 8HG 005 436-041

K-LED 2.1 beacon

Pipe socket adapter 8HG 005 436-041

RotaLED Compact beacon


K-LED beacon, flashing


¼ Page 28

¼ Page 29

¼ Page 32

¼ Page 30

40 | 41

KL 7000 beacon

Dome, amber (polycarbonate) 9EL 862 141-021Dome, amber (PMMA) 9EL 862 141-001Dome, blue (PMMA) 9EL 862 140-001Dome, red (PMMA) 9EL 862 141-011*Drive belt, 2 pcs. 9XR 854 840-001Motor (inc. PCB) 9MN 862 741-001Reflector (inc. base plate and drive belt) 9DX 862 740-001

Bulb 12 V / 55 W 8GH 002 089-133Bulb 24 V / 70 W 8GH 002 089-251Rubber base, flat (5 pcs.) 9GD 862 164-001Rubber base, wedge-shaped (1 pce.) 9GD 863 033-001Wing nut (with screw and washer as a fixing option for KL 7000 R and FL)

9NM 863 332-001

¼ Page 35

Accessories for halogen beacons

KL Rotaflex FL beacon

Dome, amber (PMMA) 9EL 859 020-001Dome, blue (PMMA) 9EL 859 020-101Motor 12 V (inc. worm gear) 9MN 858 114-001Motor 24 V (inc. worm gear) 9MN 858 114-011Reflector (inc. worm wheel) 9DX 860 438-001Bulb 12 V / 55 W 8GH 002 089-133Bulb 24 V / 70 W 8GH 002 089-251Rubber housing with integrated plug socket 9GP 859 115-001

KL Rotafix F and M beacon

Dome, amber (polycarbonate) 9EL 859 020-001Dome, blue (PMMA) 9EL 859 020-101Drive belts (2 pcs) 9XR 854 840-001Motor 12 V (inc. worm gear) 9MN 858 114-001Motor 24 V (inc. worm gear) 9MN 858 114-011Motor 12 / 24 V (inc. PCB) 9MN 862 741-001Bulb 12 V / 55 W 8GH 002 089-133Bulb 24 V / 70 W 8GH 002 089-251Reflector (inc. worm wheel) 9DX 860 271-001Reflector assembly (inc. drive belt) 9DX 862 844-001Rubber base, wedge-shaped 9GD 860 396-001

KL Rota compact beacon

Dome, amber 9EL 864 074-001Drive belts (2 pcs) 9XR 855 975-001Motor assembly 9MN 863 026-001Bulb 12 V / 55 W 8GH 002 089-133Bulb 24 V / 70 W 8GH 002 089-251

¼ Page 37

¼ Page 36

¼ Page 36

42 | 43

Sometimes, single beacons do not provide sufficient optical warning. By positioning two or four beacons on the outside edges of the vehicle roof, HELLA OWS can offer optimum signalling.

When professionals have to rely on technology, they choose warning systems from HELLA. Our OWS guarantee maximum safety. You can rely on them. Always!

Choose from different roof beams in a variety of heights and widths. The lighting technology can be selected from four different optical systems. Furthermore, various additional lighting systems such as work lights, additional direction indicators, or alley lights are available to you depending on the system.

The OWS7 is our highlightThe modular based system concept provides individual configuration options; from the basic through to the high-end version - all requirements are covered!

OPTICAL WARNING SYSTEMS (OWS)

42 | 43

OWS7 ModulesFully modular from the basic version to maximum features.

Main beacons ª LED KL-LM 2: 360° module, flashing warning signal, high-power LEDs arranged in a semi-circle ª LED KL-LM 4: Like the LED KL-LM 2 module, rotating warning signal ª LED KL-LR 2: Flash module, groove-type reflector, option to switch signal separately at front and rear ª KL-ER: Classic halogen rotating mirror module

Alley lights ª With 4 LEDs ª Intensive close-range illumination along the side

Worklights (ASW) ª 12 V-Version with H9 light sources ª 24 V-Version with H3 light sources ª Also available in LED technology ª Multiple light assembly possible

Hazard warning lights ª To the front, to the front and rear, or to the rear ª LED module with powerful light intensity ª Synchronisation with the vehicle indicators is possible if a central processing unit (CPU) is used ª For installation under the light dome

Chaser signal: LED Signal Bar (LSB) ª Integrated amber chaser signal for rearward warning and security ª Traffic control possible thanks to different signal directions ª Daytime / night-time mode switchable via control unit ª Please observe country-specific regulations during use

Domes (depending on LED module) ª Transparent ª Amber

Panels ª Milky white ª Transparent amber ª Transparent clear

For widths greater than 1,200 mm, partitions are installed to cascade the panels.

Configure your own OWS7 here: www.hella.com/ows7

44 | 45

Optical warning systems (OWS) – overview


Product photos Description Lengths Rated voltage

OWS7

Single reflector(KL-ER)

from 900 mm to 2,000 mm(in steps of 100) 12 / 24 V

360° LED module KL-LM2, flash function


360° LED module KL-LM4, Rotating light function


OWS

OWSSingle reflector

540 mm1,000 mm1,400 mm1,600 mm

12 / 24 V

OWS-MRMultiple reflector 1,424 mm 12 / 24 V

OWS-XXenon double flash

1,000 mm1,400 mm1,600 mm

12 / 24 V

RAPTOR +

Raptor + 598 mm1,118 mm1,248 mm

12 V

Further information about the OWS and Raptor + product lines can be found on our website at www.hella.com/municipal

44 | 45

OWS7 technical details

Description Abbreviation

Halogen single-reflector system KL-ER

360° LED module, Flash function, High-power LEDs arranged in a semi-circle

KL-LM2

360° LED module, Rotating light function,High-power LEDs arranged in a semi-circle

KL-LM4

Lighting technologies:

Technical specifications KL-ER KL-LM2 KL-LM4

Operating temperature range - 40°C up to + 60°C - 40°C up to + 60°C - 40°C up to + 60°C

Interference suppression Conducted class 5 (CISPR 25)

Conducted class 5 (CISPR 25)

Conducted class 5 (CISPR 25)

Light source H1 / 55 W LED LED

Rated voltage (UN) 12 / 24 V 12 / 24 V 12 / 24 V

Current consumption 2 x 5 A / 2 x 3 A 2 x 3 A / 2 x 1.5 A 2 A / 1 A

Approvals DIN 14620 035717 DIN 14620 035717 DIN 14620 035717

Type approval

Technical light homologation TA1 002 380 (ECE-R65)

TA1 003232 (ECE-R65)

TA1 003232 (ECE-R65)

EMC compatibility 035 717 035717 035717

46 | 47OPTICAL WARNING SYSTEMS (OWS)

OWS7 accessories and spare parts

Spare parts for... Description Part number

ER module Dome, amber without cut-out 9EL 172 563-221

ER module Dome, amber with cut out 9EL 172 563-321

LED modules Dome, amber without cut-out 9EL 172 563-351

LED modules Dome, amber with cut out 9EL 172 563-251

KL-ER Halogen module 2RL 864 233-001

12 V. alley lights, white 2XD 176 235-001

12 V, worklights (halogen) 1GA 010 467-001

Rubber base 900 mm, cambered 9GD 175 947-001

Rubber base 1,000 mm, cambered 9GD 175 947-011







Rubber base, flat 9GD 176 514-871

LSB operating unit for OWS 7 (incl. cable) 9SX 178 258-001

KL-ER H1 bulb, 12 V / 55 W 8GH 002 089-131

46 | 47

Configuration examples

OWS7 with KL-ER single-reflector system, 24 V

Part number Width Illuminated panel

2RL 010 710-741 1,400 mm –2RL 010 710-791 1,600 mm –

OWS7 with KL-ER single-reflector system, 12 V

2RL 010 710-101 900 mm –2RL 010 710-471 900 mm front / rear2RL 010 710-111 1,000 mm –2RL 010 710-121 1,100 mm –2RL 010 710-131 1,400 mm –2RL 010 710-141 1,600 mm –

OWS7 with KL-LM2 module, 24 V

Part number Width Alley lights Halogen work lights

2RL 010 711-291 1,400 mm – 2 rear2RL 010 711-271 1,600 mm – –2RL 010 711-201 1,800 mm – –2RL 010 711-211 1,800 mm X 2 rear2RL 010 711-351 2,000 mm – –

OWS7 with KL-LM2 module, 12 V

Part number Width Alley lights

WorklightsHalogen LSB Warning lights Backlighting module

2RL 010 710-951 900 mm – – – – –2RL 010 710-971 1,000 mm – – – – –2RL 010 710-981 1,000 mm X – – – –2RL 010 710-991 1,000 mm X – 5 modules, amber – –2RL 010 711-001 1,100 mm – – – – –2RL 010 711-011 1,100 mm X – – – –2RL 010 711-021 1,100 mm X – 6 modules, amber – –2RL 010 711-381 1,100 mm – – – – front / rear2RL 010 711-641 1,100 mm X 2 rear, 2 front 6 modules, amber – –2RL 010 711-031 1,200 mm – – – – –2RL 010 711-061 1,200 mm X 2 rear – – –2RL 010 711-081 1,200 mm X 2 rear, 2 front – – –2RL 010 711-601 1,300 mm – – – – –2RL 010 711-101 1,400 mm – 2 rear – – –2RL 010 711-111 1,400 mm X – – – –2RL 010 711-121 1,400 mm X 2 rear – – –2RL 010 711-301 1,400 mm – – – – –2RL 010 711-611 1,400 mm – – – – front / rear2RL 010 711-621 1,400 mm – 2 rear 8 modules, amber rear –2RL 010 711-161 1,600 mm X 2 rear – – –2RL 010 711-181 1,600 mm X 2 rear, 2 front – – –

Further versions available on request.

48 | 49

Warning light: BST and BST-V front flashers

Front flasher, fixed attachment

BST, multi-voltage 11 – 30 V, yellow 2XD 012 160-8511) BST, multi-voltage 11 – 30 V, blue 2XD 012 160-801BST-V, multi-voltage 11 – 30 V, yellow 2XD 012 160-9512)

BST-V, multi-voltage 11 – 30 V, blue 2XD 012 160-901


Powerful BST and BST-V front flashers

ª Intensive warning signal Optimum signaling effect through the combination of 6 power LEDs and a high-grade precision lens.

ª Various flashing sequences and patterns The flashing sequences can be adjusted as a synchronous or alternating signal. BST: There are five flash patterns for you to choose from – single flash / double flash / triple flash (ECE-R65-approved) / quadruple flash or continuous flash. BST-V: There are four flash patterns for you to choose from – single flash / double flash / triple flash (ECE-R65-approved) or continuous flash.

ª Simple assembly The strobe headlights make an impression thanks to their flat and compact design. The 2 different housing variants allow straightforward and flexible mounting in almost any installation situation.

ª ECE-R65 type tested, incl. approved 3x flash ª ECE-R10-tested. ª BST and BST-V can be synchronized with 2 or more units. ª Approved as a rear warning light system

(K-approval in Germany)


Rated voltage (UN) MultivoltOperating voltage (UB) 11 – 30 VOperating temperature -40 °C to +60 °CProtection category IP 5K4K, IP 9KOvervoltage protection YesPower consumption 7 – 14 W

Current consumption BST BST-VAmber 0.39 A at 12 V 0.78 A at 12 VAmber 0.20 A at 24 V 0.40 A at 24 VBlue 0.43 A at 12 V 0.87 A at 12 VBlue 0.29 A at 24 V 0.58 A at 24 V

Type approval BST BST-V

Technical light homologation XA1 000078 XA1 000100

XB1 000079 XB1 000101

EMC protection ECE-10R: 040471

ECE-R10: 040471

K-approval (§53a, German Road Traffic Licensing Regulations - StVZO) K 1039 K 1129*

* only applicable for yellow (012 160-951 and -961)

Front flasher, bracket mounting

BST, multi-voltage 11 – 30 V, yellow 2XD 012 160-8611)

BST, multi-voltage 11 – 30 V, blue 2XD 012 160-811BST-V, multi-voltage 11 – 30 V, yellow 2XD 012 160-9612)

BST-V, multi-voltage 11 – 30 V, blue 2XD 012 160-911

ECE R65

+8°

-8°


42

24

107

42

24

107

42

24

107

127,5

17,2

27,8

127,5

17,2

27,8

127,5

17,2

27,81)

1)

2)

2)

48 | 49

Warning light: DuraLED and WL-LED

ª 36 high-power LEDs each ª A total of ten flash sequences can be coded ª Synchronisation of 2, 3 or 4 warning lights is possible ª Vibration and impact-resistant ª Extremely long design life ª Very low current consumption ª Flat design, compact dimensions ª Simple to install with concealed screw attachment

Front flasher DuraLED

Multivolt 9 – 33 V, amber 2XD 965 429-021Multivolt 9 – 33 V, blue 2XD 965 429-001

Front flasher WL-LED

12 V, amber, without installation frame 2XD 008 997-01112 V, amber, with installation frame 2XD 008 997-21124 V, amber, without installation frame 2XD 009 048-01124 V, amber, with installation frame 2XD 009 048-211

AccessoriesAngled brackets, 2 pieces, incl. 4 screws optional for mounting at the side or rear 9XD 863 533-001

Installation frame made of black coated aluminum, angle can be adjusted, incl. 4 screws 9XD 863 828-001


Rated voltage (UN) MultivoltOperating voltage (UB) 9 – 33 VOperating temperature -30 °C to +50 °CProtection category IP 6K6, IP 6K7

Current consumptionAmber 500 mA (12 V), 265 mA (24 V)Blue 580 mA (12 V), 310 mA (24 V)

Type approvalEMC protection 035517

ª 12 high-power LEDs each ª Eight flashing frequencies can be coded ª Synchronisation of up to 4 lights ª Vibration-proof ª Resistant to high-pressure jet cleaners ª Extremely low current consumption, high efficiency ª Available in amber or red as well as in 12 V or 24 V ª Extremely compact dimensions and low weight ª Multitude of mounting possibilities


Rated voltage (UN) 12 V 24 VOperating voltage (UB) 10 – 15 V 24 – 30 VCurrent consumption 0.70 A 0.35 AInterference suppression Conducted class 5 (CISPR 25)Flashing frequency 2 HzOperating temperature -40 °C to +60 °CReverse polarity protection FusesProtection category IP 5K4K, IP 9K

Type approvalEMC protection 023686

This LED product has the following features:


50 | 51

Working at night or in the early morning in the dark is no problem, providing you have the right headlamp to work with!

HELLA worklights illuminate the working area appropriately for all applications. Their development has been specifically aimed at illuminating as large an area as possible with a soft transition area at the edge.

Worklights can be installed in all sorts of areas and environments. Whether in agriculture, on construction vehicles, hazardous goods transporters, towing or municipal vehicles.

So that every move counts, even in the dark: see more, work more precisely and safely – HELLA Worklights.

WORKLIGHTS

50 | 51

HELLA quality

Where others are cutting back, HELLA is investing in outstanding quality. Attempting to save in the wrong place costs more in the end as inferior headlamps provide less power and fail more often. Here you can see why you can rely on worklights from HELLA.

Surface coating High-quality coatings protect against salt and chemicals, and therefore against corrosion.

Thermal management The heat of the LEDs is evenly distributed and deflected via the housing. If there is a risk of overheating, individual LEDs are automatically dimmed.

Electromagnetic compatibility (EMC) The LED arrangement in HELLA's worklights and the construction of the reflector ensure that no interference occurs from magnetic fields.

Electro-static discharge (ESD) Before HELLA employees are allowed to enter the LED production, they have to be statically discharged to ensure that no components can be damaged by charging.

Reverse polarity HELLA worklights are protected against reverse polarity. If they are wrongly connected, they will not be damaged.

Light distribution via the reflector system The reflectors are calculated in such a way to ensure that the working area is evenly illuminated and the light optimally used.

Lens material The cover lens consists of a high-quality, impact and scratch-proof plastic, which makes it 100% suitable for daily use. The light exit remains homogenous, even after colliding with a branch or anything similar.

AdhesionThe worklights at HELLA are hermetically sealed by high-accuracy glue-dispensing robots. This guarantees that the lens is glued at an optimal angle for the optimum luminous efficiency which has been precisely calculated.

Quality of the LEDs Only LEDs that have been subjected to strict tests are used in HELLA's worklights. The selection guarantees the extremely long design life of the LEDs of up to 60,000 hours.

Halogen lighting

Garbage / waste collection vehicle with halogen lighting. The vehicle is equipped with three Ultra Beam H3 worklights which illuminate the area to the right side of the vehicle. This illumination helps the driver and the passengers identify obstacles and hazardous places in the work area. In addition, two Ultra Beam H3 worklights are mounted on a telescopic pole (see accessories) at the rear of the vehicle to illuminate the tipping area.

5 x halogen worklights Ultra Beam H3

WORKLIGHTS

5

Tip:On YouTube you can watch the product video

for the Ultra Beam H3 halogen worklights.

LED lighting

The same garbage / waste collection vehicle, but equipped with HELLA LED worklights. During the conversion, a total of five Power Beam 1500 work lights were installed; three to illuminate the side and two more to illuminate the tipping area. The worklight is pressure-cleaner proof (IP 6K9K / IP 67), has an extremely robust housing and features innovative thermal management. This ensures that the LEDs do not overheat, thus allowing a longer service life to be attained.

5 x LED worklights Power Beam 1500 | Page 58

52 | 53

5 x

Tip:On YouTube you can watch the product video

for the Power Beam 1500 LED worklights.

Halogen lighting

Road sweeper with halogen lighting. The vehicle is fitted with two halogen worklights. Both 70 H3 modules are used for illumination in front of the vehicle. The halogen worklights are characterised by a high degree of robustness, high light output, and homogenous illumination. Halogen bulbs tend to generate less bright light with an obvious yellow cast. With a halogen light, it is quite difficult to detect the cut-off line due to the colour temperature (2,500° Kelvin). The energy consumption of a halogen work light is up to 70 watts. This is 22 watts with a comparable LED worklight.

WORKLIGHTS

2 x halogen worklights module 70 H32 x

Tip:On YouTube you can see how a road sweeper is converted to LEDs.

Tip:On YouTube you can watch the product video for the module 70 LED Generation 3 worklights.

LED lighting

A comparable road sweeper, but equipped with HELLA LED work lights. For the conversion, a total of three LED worklights were installed for the illumination of the work area.

You can clearly distinguish between the brightness of halogen and LED. Due to the daylight-like colour temperature of LED light of up to 6,500° Kelvin, it is significantly more pleasant for the human eye and therefore leads to better quality work at night. Furthermore, the image perfectly demonstrates the greatly optimised illumination of the work area thanks to HELLA LED worklights.

3 x LED worklight 2 x module 70 LED Generation 3 | Page 59 1 x Q90 compact LED | Page 58

54 | 55

3

56 | 57WORKLIGHTS

Road sweeper conversion

The road sweeper is fitted with the K-LED 2.0 beacon as well as the 3rd generation and 4th generation module 70 LED worklights. Prior to conversion work on the vehicle, the system voltage needs to be switched off. Please also pay attention to the assembly manuals.

We are replacing the old halogen beacon on the road sweeper with the K-LED 2.0. This stands out due to its extremely high warning effect.

Make sure that the wiring and insulation have been carefully installed to avoid any defects.

The compatible pipe-socket mounting allows for replacement in a matter of seconds.

The 4th Generation Module 70 LED is installed on the cab roof on the front passenger side. It stands out with its high light output associated with extremely homogenous illumination.

To replace the worklight, the cover on the cab roof needs to be opened, the module 70 halogen worklights that are already installed need to be removed and the electrical connections need to be disconnected.

The 3rd generation Module 70 LED with wide illumination is installed on the driver's side. This ensures daylight-like illumination in the vicinity of the road sweeper.

The plug connection is shown here as an example with a DEUTSCH connector. In many cases, HELLA work lights are available with DEUTSCH connectors.

The open cable ends on the new worklight Module 70 LED are crimped with blade terminals in contact with the connecting lines.

1 2 3

4 5 6

7 8 9

56 | 57

After installing the worklight and beacon, a functional test is carried out.

Afterwards, the wiring can be arranged in the correct place and the cover on the cab roof can be closed again.

When doing so, ensure that the worklight is aligned correctly

Perfectly converted with HELLA LED products Here, a comparison againBefore the conversion (halogen) …

… and after the conversion (LED).

10 11 12

13 14 15

Road sweeper video:On YouTube you can see how a road sweeper is converted to LEDs.

Unimog video:On YouTube you can see how a Unimog

is converted to LEDs.

58 | 59WORKLIGHTS

LED worklights

Power Beam 1500

Light output (measured): 1,300 lumens, power requirement: 22 watts, colour temperature: 6,500° Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, high-quality aluminium housing, ADR-tested.

Also available with an orange lens - optimal for use in areas where normal LED worklights could dazzle.

Recommended tilt angle: close-range: 12° long range: 5°

1GA 996 488-... -001 -011

Supply voltage 10.5 – 32 V 10.5 – 32 V

Close-range illumination ■ –

Long-range illumination – ■

Connection DT connector DT connector

Power Beam 1800 Compact

Light output (measured): 1,850 lumens, power requirement: 32 watts, colour temperature: 6,500°Kelvin, must only be operated with 24 V operating voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, heat-conducting plastic housing.


1GA 996 288- … -001 -011 -041

Supply voltage 9 – 33 V 9 – 33 V 9 – 33 V

Close-range illumination – ■ –

Long-range illumination ■ – ■

Connection DT connector DT connector DT connector

More features – – orange cover lens

1GA 996 284-… -001 -011 -081 -137

Supply voltage 9 – 33 V 9 – 33 V 9 – 33 V 9 – 33 V

Close-range illumination ■ – ■ ■

Long-range illumination – ■ – –

Connection 500 mm cable 500 mm cable150 mm cable

and DT connector

2,000 mm cable

More features – – ADR / GGVSEB tested Red lens

Also available as a tail light on page 117.

Q90 compact LED

Light output (measured): 1,200 lumens, power requirement: 15 watts, colour temperature: 6,500°Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, heat-conducting plastic housing (Thermo Pro).

You can find more information about "Thermo Pro" on page 63.


58 | 59

LED worklights

Module 70 LED Generation 4

Light output (measured): 2,500 lumens, power requirement: 30 watts, colour temperature: 6,500° Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, high-quality aluminium housing.


1G0 996 476-… -001 -011 -031


Close-range illumination ■ – ■

Long-range illumination – ■ –

Connection 2,000 mm cable 2,000 mm cable 2,000 mm cable

More features – – Ultra-broad illumination


Light output (measured): 800 lumens, power requirement: 13 watts, colour temperature: 6,500° Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 67 (pressure cleaner-proof/ submersible), ECE-R10-approved, high-quality aluminium housing.

Now also available as a reversing light (ECE-R23).

Recommended inclination angle: close-range: 12°

1G0 996 276-… -451 -481 1G0 996 376-501 2ZR 996 376-091


Close-range illumination ■ ■ ■ –

Reversing spotlight – – – ■

Connection 2,000 mm cable

190 mm cable + DT plug 2,000 mm cable 2,000 mm cable

More features – Ultra-broad illumination Plastic housing ECE-R23 approval

Module 70 LED Generation 3.2



1G0 996 576-… -001 -011 -031 -041


Close-range illumination – – ■ ■

Long-range illumination ■ ■ – –

Connection 2,000 mm cable DT connector 2,000 mm

cable DT connector

60 | 61WORKLIGHTS

LED worklights

1G0 995 050-… -001 -021

Supply voltage 9 – 33 V 9 – 33 V




Different light colours available upon request.

1GA 995 506-… -001 -031





MODULE 50 LED

Light output (measured): 800 lumens, power requirement: 15 watts, colour temperature: 6,500°Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, high-quality aluminium housing, ADR/GGVSEB-tested


Ultra Beam LED Generation II



1GA 995 606-… -001 -011 -071 -081


Close-range illumination ■ – ■ –

Long-range illumination – ■ – ■

Connection DT connector DT connector DT connector DT connector

More features – –Heavy duty surrounding

bracket

Heavy duty surrounding

bracket

Ultra Beam LED Generation I

Light output (measured): 2,200 lumens, power requirement: 30 watts, colour temperature: 6,500° Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, high-quality aluminium housing, ADR/GGVS-tested.


60 | 61

1GA 996 661-… -031 -041 -501


Close-range illumination ■ ■ ■

Mounting, upright – ■ ■

Mounting, pendant – ■ ■

Mounting, lateral ■ – –

Swivel joint ■ – ■


1GA 996 661-... -001 -011





Oval 100 LED

Light output (measured): 1,700 lumens, power requirement: 25 watts, colour temperature: 6,500° Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, high-quality aluminium housing, ADR/GGVSEB-tested.


1GA 996 761-… -001 -011





Oval 100 LED Thermo Pro

Light output (measured): 1,700 lumens, power requirement: 25 watts, colour temperature: 6,500°Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, heat-conducting plastic housing.

Oval 100 LED Generation II

Light output (measured): 4,000 lumens, power requirement: 56 W (12 V), 54 W (24 V), colour temperature: 6,500° Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, high-quality aluminium housing.



LED worklights

62 | 63WORKLIGHTS

LED worklights

RokLUME 280 N

Light output (measured): 4,400 lumens, power requirement: 55 watts, colour temperature: 5,000° Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), ECE-R10-approved, aluminium die-cast housing "NanoSafe non-stick easy to clean" – surface coating. Version with ZEROGLARE technology available.


1GA 995 606-… -501 -511 -541


ZEROGLARE – – ■

Close-range illumination ■ – –

Long-range illumination – ■ –


More featuresHeavy duty surrounding

bracket


bracket


bracket


1GJ 958 040-… -501

Supply voltage 9 – 33 V

Close-range illumination ■

Long-range illumination –

Connection 2,500 mm cable

More features Flexible bracket width

1GA 995 193-... -001 -021


Close-range illumination ■ ■

Long-range illumination – –

Connection 2,000 mm cable 2,000 mm cable

More features Standard bracket Wall-mounted

Flat Beam 500

Light output (measured): 550 lumens, power requirement: 7 watts, colour temperature: 6,500°Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K8 (pressure cleaner-proof/ submersible), overheating protection, impact-resistant plastic housing, ECE approval, 45° illumination as standard.

Good close-range illumination possible even mounted flat to the wall.

Recommended tilt angle: 0°

LED Light Bar 350

Light output (measured): 2,200 lumens, power requirement: 25 watts, colour temperature: 5,000°Kelvin, multi-voltage, polarity reversal protection, overvoltage protection, thermal management, IP 6K9K / IP 6K7 (pressure cleaner-proof/ submersible), ECE-R10-approved, Thermo Pro plastic housing.

62 | 63

ZEROGLARE

In order to guarantee and support the same safety and comfort as experienced on the road, HELLA has developed a new optical system for worklights. The innovative, glare-free illumination variant ZEROGLARE is a special illumination solution with lens optics.

The ZEROGLARE system specifically aims light from the LEDs towards the ground in front of the vehicle, creating a very clear cut-off line between light and dark. This means that drivers of oncoming vehicles are not dazzled, thus increasing safety and operator comfort enormously.

The new technology is already used in the HELLA LED work lights RokLUME 280 N and 380 N. Developed for applications with particularly high light requirements, the robust work lights provide outstanding luminous efficiency.

Thermo Pro seriesA HELLA innovation

The innovative plastic material of the THERMO PRO series boasts thermal conductivity properties similar to aluminium. This means that the LEDs can operate using the full power supply even if the ambient temperatures are high.

In addition, the THERMO PRO series impresses with its considerably reduced weight and improved vibration characteristics. Even in the toughest conditions, the omission of vulnerable aluminium and the use of synthetic material housings ensure a long service life and prevent corrosion.

Advantages: ª Especially suitable when corrosion risk is high,

e. g. corrosion of worklights caused by salts ª Optimal vibration behaviour thanks to reduced weight ª Plastic material is resistant to external factors such as dust,

dirt and water (IP 6K9K / IP 6K8 protection classes)

Looks dazzling but doesn't dazzle – the RokLUME 280 N ZEROGLARE

Special thermally conductive plastics ensure optimum heat dissipation from the LEDs.

64 | 65WORKLIGHTS

Power Beam 1500

Close-range

ª Page 58

Worklights – Isolux diagrams

Power Beam 1800 Compact

Close-range

ª Page 58

MODULE 50 LED

Close-range

ª Page 60


Close-range

ª Page 59

Ultra Beam LED Generation 2

Close-range

ª Page 60


Close-range

ª Page 59

Q90 compact LED Thermo Pro

Close-range

ª Page 58

Module 70 LED Generation 3.2

Close-range

ª Page 59

Ultra Beam LED

Close-range

ª Page 60

64 | 65

LED Light Bar 350

Close-range

ª Page 62

Oval 100 LED

Close-range

ª Page 61

RokLUME 280 N

Close-range

ª Page 62

Oval 100 LED Thermo Pro

Close-range

ª Page 61

Oval 100 LED Generation 2

Close-range

ª Page 61

Flat Beam 500

Close-range

ª Page 62

66 | 67

LED daytime running light: safe and economical

Daytime running light make driving on the roads safer and are becoming mandatory in more and more European countries. Save money now by converting your municipal commercial vehicles, thus ensuring you have the advantage when it comes to safety.

In comparison to low beam lights, the daytime running light reduces the risk of accidents as these can be detected much more easily. The visibility of your own vehicle in road traffic is immediately and permanently increased – other road users can see you in good time. In dangerous situations, daytime running light can ensure the crucial additional seconds of response time. Furthermore, using daytime running lights means that you no longer have to drive with low beam. This enables you to significantly reduce fuel consumption without compromising safety.

Daytime running light does the job: Safe, efficient, and switches on and off automatically.

FRONT LIGHTING

66 | 67

90 mm modulesRange overview

ª For diverse applications and the highest demands ª Maximum design and technological freedom thanks to modular system ª More illumination and safety with innovative LED technology

LEDHalogen(conventional lighting technology)

Mai

n lig

ht fu

nctio

ns

ª Low beam and high beam (bi-modules) ª Low beam ª Low beam with daytime running and position light ª High beam ª High beam with daytime running and position light ª Dipped beam and indicator

ª Low beam and high beam (bi-modules) ª Low beam ª High beam ª High beam and position light

Auxi

liary

ligh

t fun

ctio

ns ª Fog light ª Fog light and cornering light ª Fog light, daytime running light and position light ª Daytime running lights ª Daytime running light and position light ª Indicator, daytime running light and position light

ª Fog light ª Fog light and cornering light ª Fog and daytime running light ª Daytime running light and position light ª Position light ª Indicator and position light ª Direction indicator

90 mm modulesConfiguration tool

In our 90 mm configurator, you can design and put together your own front lighting. This process is aided by a simple menu guide. This results in a parts list, which you can then send to HELLA directly from the tool.www.hella.com/90mm-modules

68 | 69FRONT LIGHTING

* In areas where the ECE-R48 regulation applies, vehicles registered in accordance with ECE-R48, series 05 must incorporate suitable measures to safeguard active failure monitoring of an LED headlamp in the vehicle electrical system. For vehicles that are registered in accordance with ECE-R48, series 06, the failure monitor is no longer mandatory.

90 mm modulesL 4060 LED low beam

Uniform illumination similar to daylight. Low beam, daytime running light and position light in one module or as a separate low beam. 40 x 60 mm polycarbonate lens for a new design. Mounting points as for Performance module for 1:1 exchange. FEP or DEUTSCH connection. Hardened plastic cover lens. Integrated electronics, robust die-cast aluminium housing, multi-volt 9 - 32 V. Perfectly fitting adjustment screws for Premium and Performance attachment included in the scope of supply.

a) LED low-beam headlamp L 4060*

Module headlamp with 40 x 60 mm polycarbonate lens, robust aluminium die-cast housing, silver design cover, (black design cover upon request), multi-voltage 9 – 32 V.Right-hand traffic/USA version, FEP connector 1BL 012 488-001Left-hand traffic, FEP connector 1ML 012 488-011Right-hand traffic/USA version, DEUTSCH connector 1BL 012 488-101Left-hand traffic, DEUTSCH connector 1ML 012 488-111

b) LED low-beam headlamp L 4060 with daytime running /position light*Right-hand traffic/USA version, FEP connector 1BL 012 488-021Left-hand traffic, FEP connector 1ML 012 488-031Right-hand traffic/USA version, DEUTSCH connector 1BL 012 488-121Left-hand traffic, DEUTSCH connector 1ML 012 488-131

Type approval: 1BL 012 488-001 /-021: ECE 3831, 1ML 012 488-011 /-031 /-111 /-131 : ECE 4090, 1BL 012 488-101 /-121: ECE 3881

Performance module mount for 1:1 conversion of existing halogen versions

143

22,4

14,733,9

Ø90

3

114,2

114,2143

22,4

14,733,9

Ø90

3

114,2

114,2143

22,4

14,733,9

Ø90

3

114,2

114,2

90 mm modulesL 5570 low beam and high beam

Low beam and high beam from a single headlamp module. Uniform illumination similar to daylight. Hardened plastic cover lens, no moving parts, passive cooling. FEP and DEUTSCH connector, USA version available. Integrated function output for failure monitor. Multi-voltage 9- 32 V.

2nd generation (since 2016)L 5570 bi-LED low-beam and high-beam headlamp

Module headlamp with 55 x 70 mm polycarbonate lens and further developed lighting/electronics, robust aluminium die-cast housing, hardened plastic cover lens, no moving parts, multi-voltage 9 – 32 V.Right-hand traffic, FEP connector 1AL 012 758-001Left-hand traffic, FEP connector 1LL 012 758-011USA version, FEP connector 1AL 012 758-021Right-hand traffic, DEUTSCH connector 1AL 012 758-101Left-hand traffic, DEUTSCH connector 1LL 012 758-111USA version, DEUTSCH connector 1AL 012 758-121

Type approval: right-hand traffic: ECE 4208, left-hand traffic: ECE 4209, USA versions: SAE


179,2

134,4

120

85

179,2

134,4

120

85

a) b)

68 | 69

90 mm modulesL 4060 LED high beam

High-end illumination. High beam, daytime running and position lights in one module, one high-beam/direction indicator combination or high beam as a separate module. 40 x 60 mm polycarbonate lens for a new design. Pattern-free and hardened plastic cover lens. High-beam headlamp with either pre-mounted carrier frame or as a 90 mm Performance module mount for 1:1 conversion. Integrated FEP plug and control electronics. Sturdy die-cast aluminium housing, multi-volt 9 - 32 V.

LED spotlight L 4060

Module headlamp with 40 x 60 mm polycarbonate lens, robust aluminium die-cast housing, silver design cover, (black design cover upon request), multi-voltage 9 – 32 V.Pre-mounted carrier frame 1F0 011 988-021Performance mount 1F0 011 988-121

Type approval: ECE 3831

LED spotlight L 4060 with daytime running light / position light

Module headlamp with 40 x 60 mm polycarbonate lens, robust aluminium die-cast housing, silver design cover, (black design cover upon request), multi-voltage 9 – 32 V.Pre-mounted carrier frame 1F0 011 988-031Performance mount 1F0 011 988-131


LED spotlight L 4060 with indicator light

Module headlamp with 40 x 60 mm polycarbonate lens, robust aluminium die-cast housing, silver design cover, (black design cover upon request), multi-voltage 9 – 32 V.Preassembled carrier frame, with pulse generator 1F0 011 988-081Preassembled carrier frame, without pulse generator 1F0 011 988-071Performance attachment, with pulse generator 1F0 011 988-181Performance attachment, without pulse generator 1F0 011 988-171



85

85

Ø14(4x)

Ø6.5(6x)

52

51

52

50 314.8

33.4

With pre-mounted carrier frame

Performance module mount for 1:1 conversion of existing halogen versions

85

85

Ø14(4x)

Ø6.5(6x)

52

51

52

50 314.8

33.4

85

85

Ø14(4x)

Ø6.5(6x)

52

51

52

50 314.8

33.4

Pulse generatorsMalfunctions of the high beam with direction indicator module can usually be detected with the vehicle control unit. The stages of detection are as follows: DI: < 400 mA | HB: < 800 mA

If your control unit cannot detect stage < 400 mA for DI, the pulse generator will increase the amperage in an interval of 100 to 120 ms to simulate the level consistent with a standard 12 V (21 W) bulb.


Bi-halogen low-beam and high-beam headlamp

Halogen, low beam, and high beam in one headlamp, metal reflectors with clear DE lens. Ideal in combination with the coordinated high-beam headlamps and fog lamps, incl. light source.12 V, right-hand traffic, H7, ECE 1AL 009 998-00112 V, left-hand traffic, H7, ECE 1LL 009 998-01112 V, right-hand traffic, H9, SAE 1AL 009 998-02124 V, right-hand traffic, H7, ECE 1AL 009 998-04124 V, left-hand traffic, H7, ECE 1LL 009 998-051

Type approval: ECE 2484 and ECE 2485

Halogen low-beam headlamp

Metal reflectors with clear DE lens. Ideal in combination with the coordinated high-beam headlamps and fog lamps, incl. light source.12 V, right-hand traffic, H7, ECE 1BL 009 999-00112 V, left-hand traffic, H7, ECE 1ML 009 999-01112 V, right-hand traffic, H7, SAE 1BL 009 999-02124 V, right-hand traffic, H7, ECE 1BL 009 999-04124 V, left-hand traffic, H7, ECE 1ML 009 999-051


90 mm modulesPremium low beam and high beam

Low beam and high beam from a single headlamp module with 70 mm DE lens. Pattern-free and hardened glass cover lens. High-quality aluminium reflector. Preassembled adjusting screws. Including light source. Connection using 0.5 m shielded supply cable with detachable plug connection.

Bi-halogen low-beam and high-beam headlamps and halogen low-beam headlamps

70 | 71

90 mm modulesPerformance low beam and high beam

Proven illumination. Modules in enhanced quality for use on long hauls. Pattern-free and hardened glass cover lens. High-quality aluminium reflector. With splash-proof plug connection. Perfectly fitting adjusting screws included in the scope of supply. Including light source. 24 V versions incl. heavy-duty long-life bulbs. Low beam with 50 mm DE lens, high beam with free-form reflector.

Halogen low-beam headlamp

Module headlamp with an aluminium reflector and clear DE lens behind a non-patterned glass cover lens, incl. light source.12 V, right-hand traffic, H1, for Performance fixing 1BL 247 042-00712 V, left-hand traffic, H1, for Performance fixing 1ML 247 042-02712 V, right-hand traffic, H1, for Premium fixing 1BL 247 042-17712 V, left-hand traffic, H1, for Premium fixing 1ML 247 042-187

Type approval: ECE 2397 and ECE 23981) With technical solution for the "tourist solution" for occasional use in countries

that drive on the left, or for the left-hand drive versions in countries that drive on the right.

Halogen high-beam headlamp

Module headlamp with an aluminium free-form reflector and a non-patterned glass cover lens, incl. light source.12 V, with position light, H1, for Performance mounting 1K0 247 043-007

12 V, without position light, H1, for Performance mounting 1K0 247 043-017

12 V, with position light, H1, for Premium mounting 1K0 247 043-117

12 V, without position light, H1, for Premium mounting 1K0 247 043-127


24 V, with position light, H1 heavy-duty, long-life,for Performance mounting 1K0 247 043-027

24 V, without position light, H1,for Performance mounting 1K0 247 043-037

12 V, with position light, H1,for Classic mounting 1K0 247 043-157

12 V, H1,for Classic mounting 1K0 247 043-167


Halogen low-beam headlamp Halogen high-beam headlamp


90 mm modulesLED accessories

Legend•) Accessory for proper connection, or mandatory accessory••) Optional accessory

L 4060 L 5570 L 70

Low

bea

m01

2 48

8-00

1 / -0

11

Low

bea

m01

2 48

8-10

1 / -1

11

Low

bea

m, d

aytim

e ru

nnin

g lig

ht a

nd

posi

tion

light

01

2 48

8-02

1 / -0

31

Low

bea

m, d

aytim

e ru

nnin

g lig

ht a

nd

posi

tion

light

01

2 48

8-12

1/-1

31

High

bea

m01

1 98

8-02

1

High

bea

m01

1 98

8-12

1

High

bea

m, d

aytim

e ru

nnin

g lig

ht a

nd

posi

tion

light

011

988-

031

High

bea

m, d

aytim

e ru

nnin

g lig

ht a

nd

posi

tion

light

011

988-

131

High

bea

m a

nd d

irect

ion

indi

cato

r (w

ith p

ulse

) 01

1 98

8-08

1

High

bea

m a

nd d

irect

ion

indi

cato

r (w

ith p

ulse

) 01

1 98

8-18

1

High

bea

m a

nd d

irect

ion

indi

cato

r (w

ithou

t pul

se)

011

988-

071

High

bea

m a

nd d

irect

ion

indi

cato

r (w

ithou

t pul

se)

011

988-

171

Fog

light

011

988-

001

Fog

light

, day

time

runn

ing

light

and

po

sitio

n lig

ht

011

988-

011

Fog

light

and

corn

erin

g lig

ht

011

988-

051 /

-061

Bi-L

ED lo

w b

eam

and

hig

h be

am

012

758-

001 /

-011

/ -0

21

Bi-L

ED lo

w b

eam

and

hig

h be

am

012

758-

101 /

-111

/ -1

21

Bi-L

ED lo

w b

eam

and

hig

h be

am

010

820-

021 /

-031

Low

bea

m01

0 82

0-00

1 / -0

11

Accessory components Part number Features

Carrier frame

Premium carrier frame 9AH 169 580-011 black •• •• •• •• •• •• •• •• •• ••

Performance carrier frame 9AH 254 228-012 black •• •• •• •• •• •• •• ••

Performance carrier frame for agricultural and truck applications 9AH 185 978-011 black •• ••

Premium carrier frame 9AH 205 652-011 black •• ••

Performance carrier frame 9AH 205 652-111 black •• ••

Adapter for 1:1 exchange from 009 999 bi-halogen modules to bi-LED 9AH 213 181-001 black •• ••

Adapter for 1:1 exchange from bi-LED to 009 999 bi-halogen modules 9AH 205 653-001 black •• ••

Surplus supply LED: AMP SUPERSEAL connector, 3-pin

Housing 8JA 746 184-032 10 parts • •

Socket connector 8KW 744 837-002 50 parts • •

Strand insulation 9GD 746 185-002 50 parts • •

Surplus supply LED: FEP 4-pin connector

Housing 8JA 202 231-002 10 parts • • • • • • • • • • • • • •

Flat contact 8KW 863 933-013 50 parts • • • • • • • • • • • • • •

Strand sealing 0.35 - 0.5 mm2 or 9GD 863 952-022 50 parts • • • • • • • • • • • • • •

Strand sealing 0.75 mm2 9GD 863 952-012 50 parts • • • • • • • • • • • • • •

Blind plug 9GD 863 952-002 50 parts • • • • • • • • • •

Surplus supply LED: DEUTSCH connector, 4-pin (together with adapter cable, see 1), except for 012 488-1xx and 012 758-1xx)

Connector housing 8JA 201 022-042 10 pcs. (**1 pc. in set) • • • • • • • • • • • • • •

Lock/wedge lock 9NB 201 024-042 10 pcs. (**1 pc. in set) • • • • • • • • • • • • • •

Contact sleeve 0.5 - 1.5 mm2 8KW 201 025-112 50 pcs. (**5 pcs. in set) • • • • • • • • • • • • • •

Blind plug 9NB 201 026-012 50 pcs. (**3 pcs. in set) • • • • • • • • • •

Set packaging 8JA 201 022-821 Number, see ** • • • • • • • • • • • • • •

Illumination range adjustment systems

Headlamp leveling system, 12 V 6NM 007 282-221 • • • • • • • •


Bracket for right-side mounting of actuator 8HG 138 619-007 • • • • • • • •

Bracket for left-side mounting of actuator 8HG 138 620-007 • • • • • • • •

Mounting set for headlamp leveling actuators (bracket and articulated element) 8HG 183 586-001 • • • • • • • •

Left bracket/interface for headlamp levelling actuator for connecting to the module 8HG 208 791-011 • •

Right bracket/interface for headlamp leveling actuator for connecting to the module 8HG 208 791-001 • •

Bend lighting accessories

LED module connection cable - cornering light control unit 8KB 163-160-811 1 part ••

Bend lighting control unit 5DF 009 244-007 24 parts ••

Adapter cable1) Adapter from FEP connector to DEUTSCH connector (4-pin) 8KA 202 117-001 1 part •• •• •• •• •• •• •• •• •• •• •• •• •• ••

Adapter from FEP connector to Performance module (247 043) or DynaView (009 295) 8KA 202 117-011 1 part •• •• •• ••

Other accessories (only if the vehicle was registered i.a.w. ECE-R48, series 05. As of ECE-R48, series 06, no more mandatory accessories)

Function monitoring device, 12 V 5DS 011 630-001 1 part • • • • • •

Function monitoring device, 24 V 5DS 011 630-011 1 part • •


72 | 73

Legend•) Accessory for proper connection, or mandatory accessory••) Optional accessory

L 4060 L 5570 L 70

Low

bea

m01

2 48

8-00

1 / -0

11

Low

bea

m01

2 48

8-10

1 / -1

11

Low

bea

m, d

aytim

e ru

nnin

g lig

ht a

nd

posi

tion

light

01

2 48

8-02

1 / -0

31

Low

bea

m, d

aytim

e ru

nnin

g lig

ht a

nd

posi

tion

light

01

2 48

8-12

1/-1

31

High

bea

m01

1 98

8-02

1

High

bea

m01

1 98

8-12

1

High

bea

m, d

aytim

e ru

nnin

g lig

ht a

nd

posi

tion

light

011

988-

031

High

bea

m, d

aytim

e ru

nnin

g lig

ht a

nd

posi

tion

light

011

988-

131

High

bea

m a

nd d

irect

ion

indi

cato

r (w

ith p

ulse

) 01

1 98

8-08

1

High

bea

m a

nd d

irect

ion

indi

cato

r (w

ith p

ulse

) 01

1 98

8-18

1

High

bea

m a

nd d

irect

ion

indi

cato

r (w

ithou

t pul

se)

011

988-

071

High

bea

m a

nd d

irect

ion

indi

cato

r (w

ithou

t pul

se)

011

988-

171

Fog

light

011

988-

001

Fog

light

, day

time

runn

ing

light

and

po

sitio

n lig

ht

011

988-

011

Fog

light

and

corn

erin

g lig

ht

011

988-

051 /

-061

Bi-L

ED lo

w b

eam

and

hig

h be

am

012

758-

001 /

-011

/ -0

21

Bi-L

ED lo

w b

eam

and

hig

h be

am

012

758-

101 /

-111

/ -1

21

Bi-L

ED lo

w b

eam

and

hig

h be

am

010

820-

021 /

-031

Low

bea

m01

0 82

0-00

1 / -0

11

Accessory components Part number Features

Carrier frame

Premium carrier frame 9AH 169 580-011 black •• •• •• •• •• •• •• •• •• ••

Performance carrier frame 9AH 254 228-012 black •• •• •• •• •• •• •• ••

Performance carrier frame for agricultural and truck applications 9AH 185 978-011 black •• ••

Premium carrier frame 9AH 205 652-011 black •• ••

Performance carrier frame 9AH 205 652-111 black •• ••

Adapter for 1:1 exchange from 009 999 bi-halogen modules to bi-LED 9AH 213 181-001 black •• ••

Adapter for 1:1 exchange from bi-LED to 009 999 bi-halogen modules 9AH 205 653-001 black •• ••

Surplus supply LED: AMP SUPERSEAL connector, 3-pin

Housing 8JA 746 184-032 10 parts • •

Socket connector 8KW 744 837-002 50 parts • •

Strand insulation 9GD 746 185-002 50 parts • •

Surplus supply LED: FEP 4-pin connector

Housing 8JA 202 231-002 10 parts • • • • • • • • • • • • • •

Flat contact 8KW 863 933-013 50 parts • • • • • • • • • • • • • •

Strand sealing 0.35 - 0.5 mm2 or 9GD 863 952-022 50 parts • • • • • • • • • • • • • •

Strand sealing 0.75 mm2 9GD 863 952-012 50 parts • • • • • • • • • • • • • •

Blind plug 9GD 863 952-002 50 parts • • • • • • • • • •

Surplus supply LED: DEUTSCH connector, 4-pin (together with adapter cable, see 1), except for 012 488-1xx and 012 758-1xx)

Connector housing 8JA 201 022-042 10 pcs. (**1 pc. in set) • • • • • • • • • • • • • •

Lock/wedge lock 9NB 201 024-042 10 pcs. (**1 pc. in set) • • • • • • • • • • • • • •

Contact sleeve 0.5 - 1.5 mm2 8KW 201 025-112 50 pcs. (**5 pcs. in set) • • • • • • • • • • • • • •

Blind plug 9NB 201 026-012 50 pcs. (**3 pcs. in set) • • • • • • • • • •

Set packaging 8JA 201 022-821 Number, see ** • • • • • • • • • • • • • •

Illumination range adjustment systems



Bracket for right-side mounting of actuator 8HG 138 619-007 • • • • • • • •

Bracket for left-side mounting of actuator 8HG 138 620-007 • • • • • • • •

Mounting set for headlamp leveling actuators (bracket and articulated element) 8HG 183 586-001 • • • • • • • •

Left bracket/interface for headlamp levelling actuator for connecting to the module 8HG 208 791-011 • •

Right bracket/interface for headlamp leveling actuator for connecting to the module 8HG 208 791-001 • •

Bend lighting accessories

LED module connection cable - cornering light control unit 8KB 163-160-811 1 part ••

Bend lighting control unit 5DF 009 244-007 24 parts ••

Adapter cable1) Adapter from FEP connector to DEUTSCH connector (4-pin) 8KA 202 117-001 1 part •• •• •• •• •• •• •• •• •• •• •• •• •• ••

Adapter from FEP connector to Performance module (247 043) or DynaView (009 295) 8KA 202 117-011 1 part •• •• •• ••

Other accessories (only if the vehicle was registered i.a.w. ECE-R48, series 05. As of ECE-R48, series 06, no more mandatory accessories)


Function monitoring device, 24 V 5DS 011 630-011 1 part • •



50 mm Premium

Low beam headlamp, 12 V

Installation frame for 3-point attachment, adjustable from the front and rear.XenonTraffic driving on the right D2Sincluding D2S xenon bulb and separate xenon electronic ballast

1BL 009 071-047

HalogenTraffic driving on the right, H7Traffic driving on the left, H7

1BL 009 071-0071ML 009 071-017


Spotlight, 12 V

3-point holder, adjusted via adjusting screw.Xenonincluding D2S xenon bulb and separate xenon electronic ballast

Rear carrier frame is not included in the scope of supply (see accessories), D2S

1F0 008 390-317


HalogenH9 1KL 009 486-001


Fog light, 12 V

3-point holder, adjusted via adjusting screw, rear carrier frame not included in scope of supply (see accessories).H7 1NL 008 090-317

Type approval: ECE 877, ECE-R19 B series 02, B series 03

147.6

95.2

Accessories

Carrier frame (not for H9 halogen spotlights)

a) without headlamp leveling system holder 9AH 161 786-017

b) with headlamp leveling system holder 9AH 161 784-017

Stepping motors for headlamp beam adjustment

for 12 V xenon 6NM 007 282-231

74 | 75

Headlamps and auxiliary driving lamps



C140 LED headlamp

The C140 is the first combination headlamp on the market in which all the light functions are realised in LED technology: low beam, high beam, direction indicator, and position light (implemented as LED light guide).

ª Combination headlight with 100% LED technology ª Excellent light distribution ª For extreme and highly demanding applications ª For horizontal or vertical mounting ª With aluminium die-cast housing ª Light lens made from scratch-resistant polycarbonate ª With 6-pin DEUTSCH connector ª Light functions: low beam, high beam, position light and direction indicator

Vertical mounting 1EE 996 374-001Horizontal mounting on the left 1EE 996 374-011Horizontal mounting on the right 1EE 996 374-021

Type approval: ECE 4079 / 4080, ECE-R112, R6, R7, ECE-R10

Headlamp C220

For mounting, with H7 low beam, H3 high beam, position light with integrated direction indicator to front and rear (category 1, 1a and 5), with 6-pin DEUTSCH connector, light exit 120 mm x 120 mm.Upright mounted12 V, left 1EE 996 174-25112 V, right 1EE 996 174-26124 V On request

Mounted in the centre12 V, left 1LE 996 174-21112 V, right 1EE 996 174-221

Type approval: ECE 6556, 11372 and 11373

LED Light Bar 350

Multi-voltage 12 / 24 V, 25 W, single headlamp with 2-pin connection cable 2,500 mm (with open ends), incl. bracket set, fixed LED light source, continuously adjustable for all mounting positions, suitable for upright, pendant mounting and mounting on surfaces of any inclination, compact size and diverse attachment options.With plastic holderLED high-beam headlamp (ECE Ref. 20) 1FJ 958 040-001LED high-beam headlamp (ECE Ref. 30) 1FJ 958 040-051

With universal holderLED high-beam headlamp (ECE Ref. 20) 1FJ 958 040-072LED high-beam headlamp (ECE Ref. 30) 1FJ 958 040-082

Type approval: 1FJ 958 040-001 /-072: ECE 0008, 1FJ 958 040-051 / -082: ECE 0009; ECE 2909

350

68

56

81

53

40

5744

408

42

67

5744

408

42

67

With plastic holder

With universal holder

Unimog with halogen lighting: The vehicle is equipped with two halogen headlamps for illumination of the area in front of the vehicle. Halogen bulbs tend to generate less bright light with an obvious yellow cast. With a halogen light, it is quite difficult to detect the cut-off line.

Halogen lighting

2 x halogen headlamp module 120

FRONT LIGHTING

The same Unimog, however outfitted with HELLA LED work lights: For the conversion, a total of two C140 LED headlamps and two LED light bar 350 LED auxiliary driving lamps were installed. These feature extremely high light output, are extremely robust, and have a long service life. The LED Light Bar 350 auxiliary driving lamps increase the light output in the high-beam range and are impressive with their low power consumption, light weight and compact design.

LED lighting

2 x LED headlamps C140 | Page 75

2 x LED auxiliary driving lamps LED light bar 350 | Page 75

76 | 77

Tip:On YouTube you can see how a Unimog

is converted to LEDs.


Daytime running lightsLegal regulations

Advantages: ª Daytime running lights provide a decisive safety advantage

on the roads and help prevent approx. 58% of accidents which result in serious injuries.

ª It is significantly easier to detect than normal low beam. ª A vehicle’s own visibility is significantly increased. ª The vehicle can be seen earlier on, which provides a few

more seconds of vital reaction time. ª Fuel consumption is significantly reduced compared to

driving with low beam

Required by law:Lawmakers have recognised the benefits of the daytime running light: As of 2012, a daytime running light is compulsory for all newly approved commercial vehicles in EU states. Different attachment variants are permitted. However, there are predefined distances and beam angles that must be adhered to.

ª When using daytime running light as a position light, the standard position light must be permanently decommissioned in accordance with ECE-R48.

ª For more information on legal stipulations and attachment regulations, please refer to the Internet or a qualified garage.

ª See the relevant assembly instructions for more detailed information.

max. 1,500 mm

min. 600 mm**

min. 250 mm*

max. 1,500 mm

min. 600 mm**

min. 250 mm*

min. = minimum distance | max. = maximum distance

* When used as a position light, the minimum permitted installation height is 350 mm and the lights must not be more than 400 mm from the outer edge of the vehicle.** For vehicles with a width of < 1,300 mm, the spacing distance must be at least 400 mm.


LEDayLine Zero

For horizontal installation, 8 high-power LEDs per daytime running light, suitable for vehicles without sweep angle, power consumption 2 W, high vibration resistance, polarity reversal protection.12 V, daytime running light set 2PT 980 970-82124 V, daytime running light set 2PT 980 970-871


78 | 79

Daytime running lights

LEDayFlex II rectangular

Light source: High-power LEDs for best light output, power consumption approx. 3.6 W (6 modules), cable length: approx. 80 mm between the individual modules, mounting: using separate brackets (1 bracket per light module, each bracket is mounted with 2 attachment screws, individual modules are locked in place).Module chain with 5 light modules12 V, daytime running light / position light 2PT 980 789-051

24 V, daytime running light / position light 2PT 980 789-051*2PT 980 789-061*

Module chain with 6 light modules12 V, daytime running light / position light 2PT 980 789-251

24 V, daytime running light / position light 2PT 980 789-251*2PT 980 789-261*

Accessories12 V, control unit with connecting cables 8KA 959 186-90124 V, control unit with connecting cables 8KA 959 186-911

Type approval: ECE / SAE


* For 24 V operation, please observe instructions in installation guide: The lamps are series-connected. You must order both items for this!

LED DAYTIME RUNNING LIGHT SET LEDayFlex

Set consisting of two pre-wired module chains with 5 – 8 round LED modules as well as two electronics boxes for controlling the daytime running lights, available with or without position light. The system is connected to the vehicle electrical system via a 3-pin AMP-SUPERSEAL connector. 12 / 24 V multi-voltage.5x LED module daytime running light 2PT 010 458-7015x LED module daytime running light with position light 2PT 010 458-7116x LED module daytime running light 2PT 010 458-7216x LED module daytime running light with position light 2PT 010 458-7317x LED module daytime running light 2PT 010 458-7417x LED module daytime running light with position light 2PT 010 458-7518x LED module daytime running light 2PT 010 458-7618x LED module daytime running light with position light 2PT 010 458-771

Type approval: ECE 5852 and SAE

Accessories12 / 24 V, control unit for daytime running light with position light 5DS 010 668-701

12 / 24 V, control unit for position light 5DS 010 668-711Harness (not included) 8KA 165 959-001

Type approval: ECE 1152 – R10 and SAE




LEDayLine 15 and LEDayLine 30 with position light

For horizontal installation, 8 LEDs per daytime running light, power consumption: 2 W, 2 versions for horizontal installation in various vehicle fronts.LEDayLine 15Suitable for vehicles with a 15° angle at the installation location12 V, light module daytime running light/position light 2PT 980 860-00124 V, light module daytime running light/position light 2PT 980 860-501Brackets (set right/left) 8HG 980 864-101

LEDayLine 30Suitable for vehicles with a 30° angle at the installation location12 V, light module daytime running light/position light 2PT 980 850-00124 V, light module daytime running light/position light 2PT 980 850-501Brackets (set right/left) 8HG 980 854-101

Control units 12 V, with connecting cables 8KA 959 186-80124 V, with connecting cables 8KA 959 186-811

Type approval: 2PT 980 850: ECE 5862, 2PT 980 860: ECE 5863 and SAE


LED signal light

Low power consumption, lens made from impact-resistant Grilamid, extremely durable, mounting variant, high vibration resistance, polarity reversal protection.Front direction indicatorWithout pulse for direction indicator failure monitor12 V, horizontal mounting: ± 45° to light and vehicle axis, 2,500 mm cable 2BA 980 888-311

24 V, horizontal mounting: ± 45° to light and vehicle axis, 2,500 mm cable 2BA 980 888-411

12 V, vertical mounting: ± 45° to light and vehicle axis, 2,500 mm cable 2BA 980 888-511

24 V, vertical mounting: ± 45° to light and vehicle axis, 2,500 mm cable 2BA 980 888-611

Daytime running light/position light12 V, horizontal mounting, 2,500 mm cable 2PT 980 880-81124 V, horizontal mounting, 2,500 mm cable 2PT 980 880-861

Type approval: ECE

15°

30°

Daytime running lights, direction indicators, and position lights

80 | 81

Daytime running lights, direction indicators, and position lights



LED direction indicator and position light Ø 66 mm

For installation, with 12 LEDs.Direction indicator 2BA 009 001-411Position light 2PF 009 001-421


LED direction indicator and position light, modular, Ø 55 mm

For front installation, clear lens with optics and a 500 mm connecting cable.Direction indicator, without pulse, 12 V 2BA 011 172-001Direction indicator, without pulse, 24 V 2BA 011 172-401Direction indicator, with pulse1), 12 V 2BA 011 172-011Direction indicator, with pulse1), 24 V 2BA 011 172-411

Type approval: ECE 3284 and CCC (BL)

ECE: distance < 40 mm to the low-beam headlamp/fog lamp

1)

LED multi-function light

83 mm LED 3 functional luminaire: direction indicator, position light, daytime running light. The integrated electronics are integrated such that the daytime running light switches off during flashing, pre-wired with 2.5 m sheathed four-core cable, individual lights.12 V, 83 mm-LED-3 functional luminaire 2BE 980 691-10124 V, 83 mm-LED-3 functional luminaire 2BE 980 690-101

Type approval: ECE 5854, 2907

Optional accessoriesAdapter ring 90 mm 9GD 980 696-001Type approval: ECE




DuraLED marker light/position light

For horizontal mounting, 2 LEDs, power consumption < 1 W, simple installation: Plug & Play, highly impact-resistant lens made from UV-resistant Grilamid, surface mounting, high vibration resistance, polarity reversal protection.DEUTSCH connector 2PF 980 990-221


Position lamps


2914

Pin 1 (+)Pin 2 (-)

60

46

35

2 x 2.8 22.5

DuraLED position light

For horizontal/vertical mounting, 2 LEDs, power consumption 0.5 W, lens made from impact-resistant Grilamid, extremely durable, slim design - 9 mm profile, mounting variant, high vibration resistance, reverse polarity protection.500 mm cable, black end caps 2PF 959 855-2012,500 mm cable, black end caps 2PF 959 855-241500 mm cable, white end caps 2PF 959 855-251


Accessories and spare partsWheel cover, polished stainless steel (ECE engraving) 9AB 959 685-201Contour seal 9GD 958 028-001Flat, rectangular seal (x8) 9GD 980 867-507Cap for screw top, black (x4) 9HD 980 858-008Cap for screw top, white (x4) 9HD 980 858-018

Ø10

84

29

9

10

86

31

9

57.6

2 x Ø3.5 Ø10

This LED product has the following characteristics

LED position light without reflector

For installation, clear lens, black plastic housing with adhesive film for attaching to the body. 2-pin cable, 150 mm, open cable ends, with 2 white LEDs.12 V/0.6 W, current consumption = approx. 0.05 A 2PF 340 825-041


82 | 83

Position lamps

LED position light, installation

For horizontal or vertical installation, with 0.5 m cable12 V/0.5 W, current consumption = approx. 0.04 A10 –33 V 2PF 959 590-401

Type approval: ECE 7597 and 031721



LED position light

for surface mounting, self-adhesive with 6.3 mm contacts and counterplug grommet. Current consumption = 0.04 A12 V 2PF 009 226-097Counterplug grommet (order separately) 9GT 186 597-007



with cable

LED position light

For horizontal surface mounting, with 500 mm cable, modern night-time design and high level of safety thanks to maximum illumination area.12 V 2PG 344 690-307



LED position light with reflex reflector

For horizontal mounting, with 2 LEDs.12 V/0.3 W, current consumption = approx. 0.03 A 2PG 964 295-121


84 | 85

Customised light designThe variety and range of shapes and the various combination options paired with a technically optimised product design make the new Shapeline lamp series a true innovation in vehicle lighting.

Whether on the front, side or rear end of a vehicle, every vehicle series – whether big or small – can have a unique and, above all, consistent look using a customised configuration and arrangement of lamps. This allows us to meet the demands of vehicle manufacturers with lower numbers of manufactured vehicles.

Along with innovative technology and the familiar high quality of HELLA's products, the variety of shapes of Shapeline lamps provide you with nearly infinite design freedom.

The modular HELLA Shapeline product range provides a variety of different light functions that can be combined with each other individually. Here, all lamps are available in two different designs: The classic straight-line Shapeline Tech design and the dynamic curved Shapeline Style design.

Tech or Style: The HELLA Shapeline series provides design freedom for nearly any application and vehicle, and achieves a consistent light signature for your vehicle at the same time.

Design your light – with HELLA Shapeline!

SHAPELINE

84 | 85

Front lightingLED position lights

Shapeline position light, small

1 LED, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 26 mA at 13.5 V / 32 mA at 28 VPower consumption 0.35 W at 13.5 V / 0.9 W at 28 VDimensions (length/width/height) 62 /40 /18 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)

HELLA specification HN 67101 class 6.3 + 7.2Reverse polarity protection YesCurrent detection 1 LED off = all offFailure protection ISO 13207Integrated short-circuit protection Yes

6.3 mm receptacles 2,100 mm 2PF 013 323-211open ends 250 mm 2PF 013 323-221open ends 5,000 mm 2PF 013 323-201Homologation: ECE /SAE

62 187.1

40


1 LED, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 26 mA at 13.5 V / 32 mA at 28 VPower consumption 0.35 W at 13.5 V / 0.9 W at 28 VDimensions (length/width/height) 136.9 /40 /18 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

6°(0°)


left, AMP SS 250 mm 2PF 013 324-011left, open ends 250 mm 2PF 013 324-031left, Amphenol 250 mm 2PF 013 324-051right, AMP SS 250 mm 2PF 013 324-021right, open ends 250 mm 2PF 013 324-041right, Amphenol 250 mm 2PF 013 324-061Homologation: ECE /SAE

Shapeline position light, wing

30 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 315 mA at 13.5 V / 340 mA at 28 VPower consumption 5.5 W at 13.5 V / 5.5 W at 28 VDimensions (length/width/height) 384.4 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

6°(0°)

HELLA specification HN 67101 class 6.3 + 7.2Reverse polarity protection YesIntegrated short-circuit protection Yes

left, horizontal, integrated 2-pin AMP SS 2PF 013 325-011right, horizontal, integrated 2-pin AMP SS 2PF 013 325-021Homologation: ECE /SAE

136.9

40

187.1

384.4

40 12

19.1

25

64

104104

* Other fastening options available upon request.

86 | 87

Front lightingLED position lights

SHAPELINE

Shapeline position light, wing


0°(0°)


left, vertical, integrated 2-pin AMP SS 2PF 013 325-031right, vertical, integrated 2-pin AMP SS 2PF 013 325-041Homologation: ECE /SAE

Shapeline position light, slim

6 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 65 mA at 13.5 V / 75 mA at 28 VPower consumption 0.88 W at 13.5 V / 2.1 W at 28 VDimensions (length/width/height) 198.1 /40 /25 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

6°(0°)


left, horizontal, integrated 2-pin AMP SS 2PF 013 326-011right, horizontal, integrated 2-pin AMP SS 2PF 013 326-021Homologation: ECE /SAE

Shapeline position light, slim


0°(0°)


left, vertical, integrated 2-pin AMP SS 2PF 013 326-031right, vertical, integrated 2-pin AMP SS 2PF 013 326-041Homologation: ECE /SAE

384.4

40

12 19.125

64104

198.1

40

2516.4

198.1

40

25

16.4


86 | 87

Front lightingLED direction indicators


Shapeline direction indicator, wing


6°(0°)

HELLA specification HN 67101 class 6.3 + 7.2Reverse polarity protection YesFailure protection ISO 13207Integrated short-circuit protection Yes

left, horizontal, integrated 2-pin AMP SS 2BA 013 334-011right, horizontal, integrated 2-pin AMP SS 2BA 013 334-021Homologation: ECE /SAE

left, horizontal, integrated 2-pin AMP SSWiping L→R 2BA 013 334-051

right, horizontal, integrated 2-pin AMP SSWiping R→L 2BA 013 334-061

right, horizontal, integrated 2-pin AMP SSWiping L→R 2BA 013 334-071

left, horizontal, integrated 2-pin AMP SSWiping R→L 2BA 013 334-081

Homologation: ECE

Shapeline direction indicator, slim

6 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 217 mA at 13.5 V / 105 mA at 28 VPower consumption 2.93 W at 13.5 V / 2.93 W at 28 VDimensions (length/width/height) 198.1/40 /25 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


left, vertical, integrated 2-pin AMP SS 2BA 013 335-051right, vertical, integrated 2-pin AMP SS 2BA 013 335-061Homologation: ECE /SAE >2032

384.4

40 12

19.1

25

64

104104



0°(0°)


left, vertical, integrated 2-pin AMP SS 2BA 013 334-031right, vertical, integrated 2-pin AMP SS 2BA 013 334-041Homologation: ECE /SAE

198.1

40

25

16.4

384.4

40

12 19.125

64104

88 | 89

Front lightingLED direction indicators

SHAPELINE

Shapeline direction indicator, clear

12 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 408 mA at 13.5 V / 240 mA at 28 VPower consumption 5.5 W at 13.5 V / 6.7 W at 28 VDimensions (length/width/height) 149.1/104 /25Operating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


Integrated 2-pin AMP SS 2BA 013 330-011Homologation: SAE >2032

Shapeline direction indicator

6 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 217 mA at 13.5 V / 105 mA at 28 VPower consumption 2.93 W at 13.5 V / 2.93 W at 28 VDimensions (length/width/height) 128 /40 /25 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


Without wiping function, integrated 2-pin AMP SS 2BA 013 398-001Homologation: ECE /SAE

With wiping function, integrated 2-pin AMP SS 2BA 013 398-011Homologation: ECE

149.1 2512

19.1

104

128 255.4

40

198.1

40

2516.4Shapeline direction indicator, slim


6°(0°)


left, horizontal, integrated 2-pin AMP SS 2BA 013 335-031right, horizontal, integrated 2-pin AMP SS 2BA 013 335-041Homologation: ECE /SAE >2032



Homologation: ECE


88 | 89

Front lightingLED reflex reflector

Shapeline reflex reflector

Style DesignDimensions (length/width/height) 161.8 /40/12 mmOperating temperature -40 °C to +60 °CFixing system TapeAssembly homologation(Tolerance +/- angle [°])

6°(0°)

HELLA specification HN 67101 class 6.3 + 7.2Left 2RA 013 347-011Right 2RA 013 347-021Homologation: ECE /SAE


Tech DesignDimensions (length/width/height) 113 /40 /12 mmOperating temperature -40 °C to +60 °CFixing system TapeAssembly homologation(Tolerance +/- angle [°])

0°(0°)

HELLA specification HN 67101 class 6.3 + 7.28RA 013 403-011

Homologation: ECE /SAE

161.8 12

40

113

40

12


90 | 91SHAPELINE

Side lightingLED direction indicators

Shapeline direction indicator, cat. 6


0°(0°)

HELLA specification HN 67101 class 6.3 + 7.2Reverse polarity protection YesCurrent detection 1 LED off = all offIntegrated short-circuit protection Yes

horizontal, open ends 500 mm 2BM 013 337-011horizontal, integrated 2-pin AMP 2BM 013 337-001vertical, left, open ends 500 mm 2BM 013 337-031vertical, right, open ends 500 mm 2BM 013 337-041vertical, left, integrated 2-pin AMP 2BM 013 337-051vertical, right, integrated 2-pin AMP 2BM 013 337-061Homologation: ECE



0°(0°)


open ends 500 mm 2BM 013 336-001Homologation: ECE

128 255.4

40

62 187.1

40



0°(0°)


left, open ends 500 mm 2BM 013 338-011right, open ends 500 mm 2BM 013 338-021Homologation: ECE /SAE

136.9

40

187.1

128

25

16.4

40


90 | 91

Side lightingLED direction indicators and reflex reflectors



0°(0°)


left, open ends 500 mm 2BM 013 339-011left, integrated 2-pin AMP 2BM 013 339-031right, open ends 500 mm 2BM 013 339-021right, integrated 2-pin AMP 2BM 013 339-041Homologation: ECE


Style DesignDimensions (length/width/height) 163.5 /40 /12 mmFixing system TapeHELLA specification HN 67101 class 6.3 + 7.2

Left 8RA 013 347-031Right 8RA 013 347-041Homologation: ECE /SAE


Tech DesignDimensions (length/width/height) 113 /40 /12 mmFixing system TapeHELLA specification HN 67101 class 6.3 + 7.2

8RA 013 403-021Homologation: ECE /SAE

198.1

40

2516.4

161.8 12

40

113

40

12


92 | 93SHAPELINE

Side lightingClearance light and LED side marker lights

Shapeline clearance light front and rear

Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VDimensions (length/width/height) 91/40.5 /21 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


Open ends 500 mm 2SX 013 327-011Integrated 2-pin AMP 2SX 013 327-001Homologation: ECE

Open ends 500 mm 2SX 013 327-111

Integrated 2-pin AMP 2SX 013 327-101

Homologation: SAE

Shapeline side marker light with reflex reflector

3 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 41 mA at 13.5 V / 47 mA at 28 VPower consumption 0.55 W at 13.5 V / 1.3 W at 28 VDimensions (length/width/height) 168 /34 /15.5 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


horizontal, EC angled, 1,000 mm 2PS 013 300-011horizontal, AMP SS 450 mm 2PS 013 300-021horizontal, EC straight 1,300 mm 2PS 013 300-031horizontal, QL 1,300 mm 2PS 013 300-041horizontal, 6.3 mm receptacles 2,100 mm 2PS 013 300-051horizontal, open ends 500 mm 2PS 013 300-001horizontal, open ends 1,500 mm 2PS 013 300-061horizontal, Amphenol 500 mm 2PS 013 300-071vertical, EC angled 1,000 mm 2PS 013 301-011vertical, AMP SS 450 mm 2PS 013 301-021vertical, EC straight 1,300 mm 2PS 013 301-031vertical, QL 1,300 mm 2PS 013 301-041vertical, 6.3 mm receptacles 2,100 mm 2PS 013 301-051vertical, open ends 500 mm 2PS 013 301-001vertical, open ends 1,500 mm 2PS 013 301-061vertical, Amphenol 500 mm 2PS 013 301-071Homologation: ECE SM1/SAE

168

34

15.510

168

34

15.5

10


92 | 93

Side lightingLED side marker lights


1 LED, Tech DesignVoltage range 9 – 16 VRated voltage 12 VCurrent flow 38 mA at 13.5 VPower consumption 0.5 W at 13.5 VDimensions (length/width/height) 168 /34 /15.5 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


horizontal, AMP SS 250 mm, not overmolded 2PS 013 302-011horizontal, 6.3 mm receptacles 250 mm 2PS 013 302-021horizontal, open ends 250 mm 2PS 013 302-001vertical, AMP SS 250 mm, not overmolded 2PS 013 302-111vertical, 6.3 mm receptacles 250 mm 2PS 013 302-121vertical, open ends 250 mm 2PS 013 302-101Homologation: ECE SM2

168

34

15.510

Shapeline side marker light with reflex reflector and rubber housing

3 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 41 mA at 13.5 V / 47 mA at 28 VPower consumption 0.55 W at 13.5 V / 1.3 W at 28 VDimensions (length/width/height) 171.8 /37.8 /17.1 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


horizontal, EC angled, 1,000 mm 2PS 013 300-251horizontal, AMP SS 450 mm 2PS 013 300-261horizontal, EC straight 1,300 mm 2PS 013 300-271horizontal, QL 1,300 mm 2PS 013 300-281horizontal, 6.3 mm receptacles 2,100 mm 2PS 013 300-291horizontal, open ends 500 mm 2PS 013 300-241horizontal, open ends 1,500 mm 2PS 013 300-301horizontal, Amphenol 500 mm 2PS 013 300-311vertical, EC angled 1,000 mm 2PS 013 301-251vertical, AMP SS 450 mm 2PS 013 301-261vertical, EC straight 1,300 mm 2PS 013 301-271vertical, QL 1,300 mm 2PS 013 301-281vertical, 6.3 mm receptacles 2,100 mm 2PS 013 301-291vertical, open ends 500 mm 2PS 013 301-241vertical, open ends 1,500 mm 2PS 013 301-301vertical, Amphenol 500 mm 2PS 013 301-311Homologation: ECE SM1/SAE

168

34

15.5

10

171.8

37.8

17.1

10

171.8

37.8

17.110


94 | 95


SHAPELINE

Shapeline side marker light

3 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 41 mA at 13.5 V / 47 mA at 28 VPower consumption 0.55 W at 13.5 V / 1.3 W at 28 VDimensions (length/width/height) 205 /34 /15.5 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


left, AMP SS 250 mm, overmolded 2PS 013 305-011left, 6.3 mm receptacles 250 mm 2PS 013 305-031left, open ends 250 mm 2PS 013 305-051left, Amphenol 500 mm 2PS 013 305-071right, AMP SS 250 mm, overmolded 2PS 013 305-021right, 6.3 mm receptacles 250 mm 2PS 013 305-041right, open ends 250 mm 2PS 013 305-061right, Amphenol 500 mm 2PS 013 305-081Homologation: ECE SM1/SAE

205 15.510

34

Shapeline side marker light with rubber housing


0°(0°)


left, AMP SS 250 mm, overmolded 2PS 013 305-251left, 6.3 mm receptacles 250 mm 2PS 013 305-271left, open ends 250 mm 2PS 013 305-291left, Amphenol 500 mm 2PS 013 305-311right, AMP SS 250 mm, overmolded 2PS 013 305-261right, 6.3 mm receptacles 250 mm 2PS 013 305-281right, open ends 250 mm 2PS 013 305-301right, Amphenol 500 mm 2PS 013 305-321Homologation: ECE SM1/SAE

205 15.510

34


94 | 95



3 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 41 mA at 13.5 V / 47 mA at 28 VPower consumption 0.55 W at 13.5 V / 1.3 W at 28 VDimensions (length/width/height) 168 /34 /15.5 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


horizontal, EC angled, 1,000 mm 2PS 013 303-011horizontal, AMP SS 450 mm 2PS 013 303-021horizontal, EC straight 1,300 mm 2PS 013 303-031horizontal, QL 1,300 mm 2PS 013 303-041horizontal, 6.3 mm receptacles 2,100 mm 2PS 013 303-051horizontal, open ends 500 mm 2PS 013 303-001horizontal, open ends 1,500 mm 2PS 013 303-061horizontal, Amphenol 500 mm 2PS 013 303-071vertical, EC angled 1,000 mm 2PS 013 304-011vertical, AMP SS 450 mm 2PS 013 304-021vertical, EC straight 1,300 mm 2PS 013 304-031vertical, QL 1,300 mm 2PS 013 304-041vertical, 6.3 mm receptacles 2,100 mm 2PS 013 304-051vertical, open ends 500 mm 2PS 013 304-001vertical, open ends 1,500 mm 2PS 013 304-061vertical, Amphenol 500 mm 2PS 013 304-071Homologation: SAE

168

34

15.510

Shapeline side marker light

1 LED, Style DesignVoltage range 9 – 16 VRated voltage 12 VCurrent flow 38 mA at 13.5 VPower consumption 0.5 W at 13.5 VDimensions (length/width/height) 205 /34 /15.5 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


left, AMP SS 250 mm, not overmolded 2PS 013 306-011left, 6.3 mm receptacles 250 mm 2PS 013 306-031left, open ends 250 mm 2PS 013 306-051right, AMP SS 250 mm, not overmolded 2PS 013 306-021right, 6.3 mm receptacles 250 mm 2PS 013 306-041right, open ends 250 mm 2PS 013 306-061Homologation: ECE SM2/SAE

205 15.510

34

168

34

15.5

10


96 | 97


SHAPELINE

Shapeline side marker light with reflex reflector and rubber housing

3 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 41 mA at 13.5 V / 47 mA at 28 VPower consumption 0.55 W at 13.5 V / 1.3 W at 28 VDimensions (length/width/height) 171.8 /37.8 /17.1 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


horizontal, EC angled, 1,000 mm 2PS 013 303-251horizontal, AMP SS 450 mm 2PS 013 303-261horizontal, EC straight 1,300 mm 2PS 013 303-271horizontal, QL 1,300 mm 2PS 013 303-281horizontal, 6.3 mm receptacles 2,100 mm 2PS 013 303-291horizontal, open ends 500 mm 2PS 013 303-241horizontal, open ends 1,500 mm 2PS 013 303-301horizontal, Amphenol 500 mm 2PS 013 303-311vertical, EC angled 1,000 mm 2PS 013 304-251vertical, AMP SS 450 mm 2PS 013 304-261vertical, EC straight 1,300 mm 2PS 013 304-271vertical, QL 1,300 mm 2PS 013 304-281vertical, 6.3 mm receptacles 2,100 mm 2PS 013 304-291vertical, open ends 500 mm 2PS 013 304-241vertical, open ends 1,500 mm 2PS 013 304-301vertical, Amphenol 500 mm 2PS 013 304-311Homologation: SAE

205 15.510

34Shapeline side marker light


0°(0°)


left, AMP SS 250 mm, overmolded 2PS 013 307-011left, 6.3 mm receptacles 250 mm 2PS 013 307-031left, open ends 250 mm 2PS 013 307-051left, Amphenol 500 mm 2PS 013 307-071right, AMP SS 250 mm, overmolded 2PS 013 307-021right, 6.3 mm receptacles 250 mm 2PS 013 307-041right, open ends 250 mm 2PS 013 307-061right, Amphenol 500 mm 2PS 013 307-081Homologation: SAE

171.8

37.8

17.1

10

171.8

37.8

17.110


96 | 97

The HELLA Shapeline online configuration tool turns you into a lighting designer: With a few clicks, make your own vehicle light design for the front, sides, and rear end – and see the result directly after, as applied convincingly to a car outline.

www.hella.com/shapeline


Shapeline online configuration toolDesign freedom at the click of a mouse

205 15.510

34Shapeline side marker light with rubber housing


0°(0°)


left, AMP SS 250 mm, overmolded 2PS 013 307-251left, 6.3 mm receptacles 250 mm 2PS 013 307-271left, open ends 250 mm 2PS 013 307-291left, Amphenol 500 mm 2PS 013 307-311right, AMP SS 250 mm, overmolded 2PS 013 307-261right, 6.3 mm receptacles 250 mm 2PS 013 307-281right, open ends 250 mm 2PS 013 307-301right, Amphenol 500 mm 2PS 013 307-321Homologation: SAE

lighting designer: With a few clicks, make your own vehicle light design for the front, sides, and rear end – and see the result

ww

w.h

ella

.com

/sha

pelin

e

98 | 99SHAPELINE

Rear lightingLED position lights and LED tail stop light


1 LED, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 48 mA at 13.5 V / 54 mA at 28 VPower consumption 0.65 W at 13.5 V / 1.5 W at 28 VDimensions (length/width/height) 62 /40 /18 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


6.3 mm receptacles 2,100 mm 2SA 013 323-011open ends 250 mm 2SA 013 323-021open ends 5,000 mm 2SA 013 323-001Homologation: ECE /SAE


1 LED, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 48 mA at 13.5 V / 54 mA at 28 VPower consumption 0.65 W at 13.5 V / 1.5 W at 28 VDimensions (length/width/height) 139.6 /40 /18 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

6°(0°)


left, AMP SS 250 mm 2SA 013 324-211left, open ends 250 mm 2SA 013 324-231left, Amphenol 250 mm 2SA 013 324-251right, AMP SS 250 mm 2SA 013 324-221right, open ends 250 mm 2SA 013 324-241right, Amphenol 250 mm 2SA 013 324-261Homologation: ECE /SAE

Shapeline tail stop light

24/12 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V

Current flow Stop: 260 mA at 13.5 V / 272 mA at 28 VTail: 52 mA at 13.5 V / 54 mA at 28 V

Power consumption Stop: 3.5 W at 13.5 V / 7.6 W at 28 VTail: 0.7 W at 13.5 V / 1.5 W at 28 V

Dimensions (length/width/height) 149.1/104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


Integrated 3-pin AMP SS 2SB 013 341-001Homologation: ECE /SAE

136.9

40

187.1

62 187.1

40

149.1 2512

19.1

104


98 | 99

Rear lightingLED tail stop lights


24/12 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V

Current flow Stop: 260 mA at 13.5 V / 272 mA at 28 VStop: 52 mA at 13.5 V / 54 mA at 28 V


Dimensions (length/width/height) 270.8/104/25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


left, vertical, integrated 3-pin AMP SS 2SB 013 342-031right, vertical, integrated 3-pin AMP SS 2SB 013 342-041Homologation: ECE /SAE

Shapeline tail stop light, wing

30 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V



Dimensions (length/width/height) 384.4 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

6°(0°)


left, integrated 3-pin AMP SS 2SB 013 399-011right, integrated 3-pin AMP SS 2SB 013 399-021Homologation: ECE /SAE


24/ 12 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V

Current flow Stop: 260 mA at 13.5 V / 272 mA at 28 VStop: 52 mA at 13.5 V / 54 mA at 28 V


Dimensions (length/width/height) 270.8/104/25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

2.5°(6°)


left, horizontal, integrated 3-pin AMP SS 2SB 013 342-011right, horizontal, integrated 3-pin AMP SS 2SB 013 342-021Homologation: ECE /SAE

270.8 2512

19.1104

104

270.8

2512

19.1

104

104

384.4

40 12

19.1

25104104

64


100 | 101

Rear lightingLED tail stop lights and LED tail/stop/direction indicator

SHAPELINE

Shapeline tail stop light, wing

30 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V




6°(0°)


left, integrated 3-pin AMP SS 2SB 013 399-031right, integrated 3-pin AMP SS 2SB 013 399-041Homologation: ECE /SAE

Shapeline tail/stop/direction indicator

4/12/4 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V

Current flowStop: 82 mA at 13.5 V / 118 mA at 28 VTail: 45 mA at 13.5 V / 50 mA at 28 VDI: 304 mA at 13.5 V / 190 mA at 28 V

Power consumptionStop: 1.1 W at 13.5 V / 3.3 W at 28 VTail: 0.6 W at 13.5 V / 1.4 W at 28 VDI: 4.1 W at 13.5 V / 5.3 W at 28 V


0°(0°)


Integrated 4-pin AMP SS 2SD 013 341-011Homologation: ECE


4/12/4 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V




2.5°(6°)


left, integrated 4-pin AMP SS 2SD 013 342-111right, integrated 4-pin AMP SS 2SD 013 342-121Homologation: ECE

384.4

40

12 19.125

64104

149.1 2512

19.1

104

270.8 2512

19.1104

104


100 | 101

Rear lightingLED tail/stop/direction indicator and LED direction indicators


12 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 171 mA at 13.5 V / 183 mA at 28 VPower consumption 2.3 W at 13.5 V / 5.1 W at 28 VDimensions (length/width/height) 149.1/104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


Integrated 2-pin AMP SS 2BA 013 330-021Homologation: ECE


12 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 171 mA at 13.5 V / 183 mA at 28 VPower consumption 2.3 W at 13.5 V / 5.1 W at 28 VDimensions (length/width/height) 149.1 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


Integrated 2-pin AMP SS 2BA 013 330-001Homologation: ECE


4/12/4 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V




0°(0°)


left, vertical, integrated 4-pin AMP SS 2SD 013 342-131right, vertical, integrated 4-pin AMP SS 2SD 013 342-141Homologation: ECE

270.8

2512

19.1

104

104

149.1 2512

19.1

104

149.1 2512

19.1

104


102 | 103

Rear lightingLED direction indicators

SHAPELINE


12 LED, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 171 mA at 13.5 V / 183 mA at 28 VPower consumption 2.3 W at 13.5 V / 5.1 W at 28 VDimensions (length/width/height) 270.8 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

2.5°(6°)


left, horizontal, integrated 2-pin AMP SS 2BA 013 331-051right, horizontal, integrated 2-pin AMP SS 2BA 013 331-061Homologation: ECE



2.5°(6°)


left, horizontal, integrated 2-pin AMP SS 2BA 013 331-011right, horizontal, integrated 2-pin AMP SS 2BA 013 331-021Homologation: ECE



0°(0°)


left, vertical, integrated 2-pin AMP SS 2BA 013 331-071right, vertical, integrated 2-pin AMP SS 2BA 013 331-081Homologation: ECE

270.8 2512

19.1104

104

270.8 2512

19.1104

104

270.8

2512

19.1

104

104


102 | 103



30 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 285 mA at 13.5 V / 315 mA at 28 VPower consumption 3.9 W at 13.5 V / 8 W at 28 VDimensions (length/width/height) 384.4 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(0°)


left, horizontal, integrated 2-pin AMP SS 2BA 013 333-011right, horizontal, integrated 2-pin AMP SS 2BA 013 333-021left, horizontal, integrated 2-pin AMP SSWiping L→R 2BA 013 333-051



right, horizontal, integrated 2-pin AMP SSWiping R→L 2BA 013 333-081

Homologation: ECE



0°(0°)



384.4

40 12

19.1

25

64

104104

270.8

2512

19.1

104

104


104 | 105


SHAPELINE


30 LEDs, Style DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 VCurrent flow 285 mA at 13.5 V / 315 mA at 28 VPower consumption 3.9 W at 13.5 V / 8 W at 28 VDimensions (length/width/height) 384.4 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(0°)





0°(6°)


left, horizontal, integrated 2-pin AMP SS 2BA 013 332-031right, horizontal, integrated 2-pin AMP SS 2BA 013 332-041left, horizontal, integrated 2-pin AMP SSWiping 2BA 013 332-011

right, horizontal, integrated 2-pin AMP SSWiping 2BA 013 332-021

Homologation: ECE



0°(0°)



384.4

40

12 19.125

64104

198.1

40

2516.4

198.1

40

25

16.4


104 | 105

Rear lightingLED reverse lights

Shapeline reverse light


0°(0°)


Integrated 3-pin AMP SS 2ZR 013 344-101Homologation: ECE /SAE



2.5°(6°)


left, horizontal, integrated 3-pin AMP SS 2ZR 013 345-111right, horizontal, integrated 3-pin AMP SS 2ZR 013 345-121Homologation: ECE /SAE



2.5°(6°)


left, vertical, integrated 3-pin AMP SS 2ZR 013 345-131right, vertical, integrated 3-pin AMP SS 2ZR 013 345-141Homologation: ECE /SAE

270.8 2512

19.1104

104

270.8

2512

19.1

104

104

149.1 2512

19.1

104


106 | 107

Rear lightingLED reverse lights

SHAPELINE

Shapeline reverse light, slim


0°(6°)


left, horizontal, integrated 2-pin AMP SS 2ZR 013 401-011right, horizontal, integrated 2-pin AMP SS 2ZR 013 401-021Homologation: ECE /SAE, (only with 2 lamps)



0°(0°)


left, diagonal, integrated 2-pin AMP SS 2ZR 013 401-051right, diagonal, integrated 2-pin AMP SS 2ZR 013 401-061Homologation: ECE /SAE



0°(6°)


left, vertical, integrated 2-pin AMP SS 2ZR 013 401-031right, vertical, integrated 2-pin AMP SS 2ZR 013 401-041Homologation: ECE /SAE, (only with 2 lamps)

198.1

40

2516.4

198.1

40

25

16.4

198.1

40

25

16.4


106 | 107

Rear lightingLED rear fog lights

Shapeline rear fog light


0°(0°)


Integrated 3-pin AMP SS 2NE 013 344-001Homologation: ECE /SAE



2.5°(6°)


left, horizontal, integrated 3-pin AMP SS 2NE 013 345-011right, horizontal, integrated 3-pin AMP SS 2NE 013 345-021Homologation: ECE /SAE



2.5°(6°)


left, vertical, integrated 3-pin AMP SS 2NE 013 345-031right, vertical, integrated 3-pin AMP SS 2NE 013 345-041Homologation: ECE /SAE

149.1 2512

19.1

104

270.8 2512

19.1104

104

270.8

2512

19.1

104

104


108 | 109

Rear lightingLED rear fog lights

SHAPELINE

Shapeline rear fog light. slim


0°(6°)


left, horizontal, integrated 2-pin AMP SS 2NE 013 343-011right, horizontal, integrated 2-pin AMP SS 2NE 013 343-021Homologation: ECE /SAE



0°(0°)


left, diagonal, integrated 2-pin AMP SS 2NE 013 343-051right, diagonal, integrated 2-pin AMP SS 2NE 013 343-061Homologation: ECE /SAE



0°(0°)


left, vertical, integrated 2-pin AMP SS 2NE 013 343-031right, vertical, integrated 2-pin AMP SS 2NE 013 343-041Homologation: ECE /SAE

198.1

40

2516.4

198.1

40

25

16.4

198.1

40

25

16.4


108 | 109

Rear lightingLED rear fog/reverse lights

Shapeline rear fog/reverse light

12/4 LEDs, Tech DesignVoltage range 9 – 16 V, 18 – 32 VRated voltage 12 / 24 V

Current flowRF: 171 mA at 13.5 V /

100 mA at 28 VRev.: 230 mA at 13.5 V / 130 mA at 28 V

Power consumption RF: 2.3 W at 13.5 V / 2.8 W at 28 VRev.: 3.1 W at 13.5 V / 3.6 W at 28 V


0°(0°)


Integrated 3-pin AMP SS 2NR 013 344-201Homologation: ECE /SAE







2.5°(6°)


left, horizontal, integrated 3-pin AMP SS 2NR 013 345-211right, horizontal, integrated 3-pin AMP SS 2NR 013 345-221Homologation: ECE /SAE







2.5°(6°)


left, vertical, integrated 3-pin AMP SS 2NR 013 345-231right, vertical, integrated 3-pin AMP SS 2NR 013 345-241Homologation: ECE /SAE

149.1 2512

19.1

104

270.8 2512

19.1104

104

270.8

2512

19.1

104

104


110 | 111

Rear lightingReflex reflector

SHAPELINE


Tech DesignDimensions (length/width/height) 113 /10 /12 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(0°)

HELLA specification HN 67101 class 6.3 + 7.2

8RA 013 403-001Homologation: ECE /SAE


Style DesignDimensions (length/width/height) 161.8 /40 /12 mmOperating temperature -40 °C to +60 °CFixing system Tape*Assembly homologation(Tolerance +/- angle [°])

0°(6°)



Shapeline reflex reflector, wing

Style DesignDimensions (length/width/height) 384.4 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(6°)



384.4

40 12

19.1

25

64

104

161.8 12

40

113

40

12

104


110 | 111

Rear lightingWarning lights and design elements

Shapeline warning light

Style DesignVoltage range 9 – 16 V, 18 – 32 VDimensions (length/width/height) 384.4 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(6°)


left, integrated 2-pin AMP SS 2XW 013 493-011right, integrated 2-pin AMP SS 2XW 013 493-021Homologation: SAE

Shapeline design element

Style DesignCurrent flow 407 mA at 13.5 V / 197 mA at 28 VPower consumption 5.5 W at 13.5 V / 5.5 W at 28 VDimensions (length/width/height) 384.4 /104 /25 mmOperating temperature -40 °C to +60 °CFixing system Screw*Assembly homologation(Tolerance +/- angle [°])

0°(6°)


left, no connector 2XX 013 349-011right, no connector 2XX 013 349-021

384.4

40 12

19.1

25104

384.4

40 12

19.1

25

64

104

64

104

104


112 | 113

Side marker lamps in LED technology

Every day, side marker lights contribute towards road safety. After all, it is these markings that make the entire vehicle easy to detect, even in darkness.

The side marker lights from HELLA offer durability, a high illuminating power, and quick mounting.

SIDE LIGHTING

112 | 113


24 ±

0,2

35 ±

0,2

166 ±0,2

147,2 ±0,2

24,1

±0,

2

184 ±0,2

29 ±

0,2

18,9

±0,

2

23,7

±0,

2

LED direction indicator and position light in striped look

400 mm cable with open endsPosition light12 V, horizontal 2PF 012 846-40112 V, vertical 2PF 012 846-41124 V, horizontal 2PF 012 846-60124 V, vertical 2PF 012 846-611

Direction indicator with pulse for direction indicator failure monitor12 V, horizontal 2BA 012 846-00112 V, vertical 2BA 012 846-01124 V, horizontal 2BA 012 846-21124 V, vertical 2BA 012 846-201

Direction indicator12 V, horizontal 2BA 012 846-02112 V, vertical 2BA 012 846-03124 V, horizontal 2BA 012 846-23124 V, vertical 2BA 012 846-221

Type approval: ECE 6R-015896, 6R-015897, 6R-015898

Direction indicators and position lights

LED auxiliary indicator, cat. 5

12 V, power consumption 0.7 W, operating temperature -40°C to +60°C, screwed, 2-pin EasyConn, rubber housing, AMP-SUPERSEAL, rubber housing, 6.3 mm receptacles, and plastic housing.Screwed, 2-pin EasyConnWith rubber housing 2BM 340 825-201/7

AMP-SUPERSEAL (AMP 282080-1)With rubber housing 2BM 340 825-211/7

6.3 mm receptaclesWith plastic housing 2BM 340 825-301/7

AMP-SUPERSEAL (AMP 282080-1)With plastic housing 2BM 340 825-311/7

Type approval: ECE 01 0066


114 | 115SIDE LIGHTING

a)

b)

a)

b)


LED side marker light

For horizontal installation, with 4 yellow LEDs, yellow lens, yellow lights, without reflex reflector, ADR / GGVS-tested.a) Without bracket24 V/1.0 W, current consumption = approx. 0.04 A(can be combined with reflector 9EL 154 637-001)

2PS 008 382-001*

2PS 008 382-007*

b) Side marker lamp set without bracket, with separate reflex reflector

2PS 008 382-801*

2PS 008 382-807*

Side marker lamp set with angled bracket, angled forwards, mounting

2PS 008 382-811*

2PS 008 382-817*

Type approval: ECE 3169 / 9111


LED side marker light with reflex reflector

for horizontal mounting, with 2 amber LEDs, amber lens and amber light. 24 V/1.3 W, current consumption = approx. 0.05 Aa) mounted on a bracket, with clip angle across towards front 2PS 340 001-001*

b) mounted on a universal holder, angled towards the rear 2PS 340 001-011*

Accessories (please order separately)Suitable cables and connection sets2-pin connection set 9XX 340 220-011*2-pin connection set fittings (for 10 lights) 9XX 340 220-801*


Further versions available upon request.

* Please see the note on pages 130 to 131 regarding LED direction indicators and LED light failure monitor.

Side marker lights


DuraLED side marker light

For horizontal mounting, 2 LEDs, power consumption 0.5 W, lens made from impact-resistant Grilamid, extremely durable, slim design - 9 mm profile, mounting variant, high vibration resistance, reverse polarity protection500 mm cable, black end caps 2PS 980 868-2012,500 mm cable, black end caps 2PS 980 868-211


Ø10

84

29

9

10

86

31

9

57.6

2 x Ø3.5 Ø10

114 | 115


DuraLED marker light

For horizontal mounting, 2 LEDs, power consumption < 1 W, simple installation: Plug & Play, highly impact-resistant lens made from UV-resistant Grilamid, surface mounting, high vibration resistance, polarity reversal protection.Side marker light (cat. SM1), DEUTSCH connector 2PS 980 990-301Additional side direction indicator (cat. 5), DEUTSCH connector 2BM 980 990-121


2914

Pin 1 (+)Pin 2 (-)

60

46

35

2 x 2.8 22.5


Innovative side marker lights

a) With 6.3 mm contacts for horizontal and vertical mounting12 V, white housing 2PS 344 690-00712 V, grey housing 2PS 344 690-02712 V, black housing 2PS 344 690-06724 V, black housing 2PS 344 690-037

b) With AMP-SUPERSEAL for horizontal and vertical mounting12 V, white housing 2PS 344 690-60712 V, black housing 2PS 344 690-61724 V, orange housing 2PS 344 690-68724 V, black housing 2PS 344 690-627

AccessoriesRubber seal 9GD 343 697-007Grommet 9GT 343 367-002Type approval: ECE 5853 and 03 0227


LED side marker light with reflex reflector

With 1 yellow LED, for vertical assembly, yellow lens, black housing, ADR-tested.12 V, 1,500 mm cable 2PS 008 645-981*24 V, 1,500 mm cable 2PS 008 645-991*

Type approval: 1395


a) b)

Side marker lights

116 | 117

When it comes to municipal vehicles and special vehicles, you can be sure that these will be deployed smoothly time and time again. Rear combination lamps from HELLA impress with their clear design and top quality, and guarantee optimal visibility of your vehicle. In this area in particular, manufacturers are making ever greater use of of the many options available when LEDs are combined with optical systems. In addition, our rear combination lamps contribute towards the branding and visual appearance of a vehicle.

You will make the perfect choice with our highlight products. We ensure this through our many years of development experience in this area. The result is innovative products and sophisticated services, from professionals for professionals.

REAR LIGHTING

116 | 117

LED reversing spotlight


Q90 Compact LED Reversing Light

1,000 lumens, power requirement: 15 W, colour temperature: 6,500° Kelvin, heat-conducting plastic housing, total corrosion protection thanks to Thermo Pro technology, mounting upright/pendant.2,000 mm cable 2ZR 996 284-501500 mm cable and DT connector, ADR / GGVSEB-tested 2ZR 996 284-511

Type approval: ECE-R23, ECE-R10


Repulse Pro

870 lumens, power requirement: 11 W, colour temperature: 5,500° Kelvin, heat-conducting plastic housing, total corrosion protection thanks to Thermo Pro technology, mounting upright/pendant.2-pin AMP-SUPERSEAL connector, with 2,000 mm connecting lead 2ZR 012 456-201

6.3 mm flat receptacles, with 3,500 mm connecting lead 2ZR 012 456-221

Type approval: ECE-R23, ECE-R10


Repulse Ultra

1,100 lumens, power requirement: 11 W, colour temperature: 5,500° Kelvin, heat-conducting plastic housing, total corrosion protection thanks to Thermo Pro technology, mounting upright/pendant.6.3 mm flat receptacle with 3,500 mm connecting lead 2ZR 012 456-117Type approval: ECE-R23, ECE-R10

118 | 119REAR LIGHTING

Single-function lights55 mm LED modules

LED rear light/stop light/direction indicator Ø 55 mm

For rear installation, clear lens with optics and 500 mm connecting cable, 12 V / 1.1 W. 12 V, tail light 2SA 011 172-04112 V, stop light 2DA 011 172-06112 V, direction indicator, without pulse 2BA 011 172-02124 V, direction indicator, without pulse 2BA 011 172-42112 V, direction indicator, with pulse 2BA 011 172-03124 V, direction indicator, with pulse 2BA 011 172-431

Type approval: ECE 3283 / 3284, ECE 10R-036317 and CCC

LED rear fog and reverse light Ø 55 mm

For rear installation, clear lens with optics and 500 mm connecting cable, 12 V / 2.5 W, current consumption = 0.21 A, 24 V / 1.9 W, current consumption = 0.08 A.12 V, rear fog lamp 2NE 011 172-08124 V, rear fog lamp 2NE 011 172-481

Type approval: ECE 3286, 10R-036317 and CCC

12 V, reverse light 2ZR 011 172-10124 V, reverse light 2ZR 011 172-501

Type approval: ECE 3285, 10R-036317 and CCC

LED ring modules Ø 98 mm

12 V, for installation, ideal for combination with light series 011 172 (Ø 55 mm), optionally available with clear or red cover lens.LED tail clearance lamp, with 12 red LEDs, clear lens1) 12 V / 1.8 W, current consumption = approx. 0.15 A 2SA 008 405-0211) 24 V / 1.8 W, current consumption = approx. 0.08 A 2SA 008 405-017

LED tail stop light, with 12 red LEDs, clear lens, with passive thermal management1) 12 V / 2.1 W, current consumption = approx. 0.15 A 2SB 008 405-1011) 24 V / 1.8 W, current consumption = approx. 0.08 A 2SB 008 405-091

1) LED position light 12 V / 1.8 W, current consumption = approx. 0.15 A 2PF 008 405-061

2) Chromium-plated cover 8XU 008 405-0313) Reflex reflector 8RA 008 405-001

Type approval: ECE 1196 / 1197 / 1892




1)2)

3)

118 | 119

Single-function lights55 mm modules

Tail stop light and rear fog light Ø 55 mm

12 V and 24 V, for installation, with red lens.Tail light 2XA 008 221-021Tail light with mounted 12 V / 5 W bulb 2SA 008 221-127Stop light 2XA 008 221-021Stop light with mounted 12 V / 21 W bulb 2DA 008 221-167


Rear fog light 2NE 008 221-031Rear fog light with mounted 12 V / 21 W bulb 2NE 008 221-137


AccessoriesHarness with grommet 8KA 152 134-007Grommet separate 9GT 137 236-007

Direction indicator and reverse light Ø 55 mm

12 / 24 V, for installation with grey lens.Direction indicator 2BA 008 221-041Direction indicator with mounted yellow 12 V / 21 W bulb 2BA 008 221-147

Type approval: ECE 878, 879 and 1051

Back-up lamp 2ZR 008 221-051Reverse light with mounted 12 V / 21 W bulb 2ZR 008 221-157

Type approval: ECE 1052 and SAE type approval for vehicles with width < 2,032 mm and > 2,031 mm

AccessoriesHarness with grommet 8KA 152 134-007Grommet separate 9GT 137 236-007

Examples of combination possibilities

Rear lighting

1) Tail light and direction indicator2BA 008 221-041

and2SA 008 405-021

2) Stop light and reverse light2XA 008 221-021

and8RA 008 405-001

Heat conducting shield (necessary at > 50°C ambient temperature) 9XB 161 749-007

1)

2)



LED combination rear light

Low power consumption, lens made from impact-resistant Grilamid, extremely durable, mounting variant, high vibration resistance, polarity reversal protection.Rear direction indicatorWithout pulse for direction indicator failure monitor12 V, horizontal/vertical mounting: 360° to light and vehicle axis, 2,500 mm cable 2BA 980 888-011

24 V, horizontal/vertical mounting: 360° to light and vehicle axis, 2,500 mm cable 2BA 980 888-211

Stop light/tail light12 V, horizontal/vertical mounting: 360° to light and vehicle axis, 300 mm cable 2SB 980 887-011

24 V, horizontal/vertical mounting: 360° to light and vehicle axis, 300 mm cable 2SB 980 887-211

Additional stop lamp12 V, horizontal/vertical mounting, 2,500 mm cable 2DA 980 887-31124 V, horizontal/vertical mounting, 2,500 mm cable 2DA 980 887-411

Rear fog light12 V, horizontal/vertical mounting, 2,500 mm cable 2NE 980 889-50124 V, horizontal/vertical mounting, 2,500 mm cable 2NE 980 889-601

Reversing spotlight12 V, horizontal mounting: ± 10° to light and vehicle axis, 2,500 mm cable 2ZR 980 889-011

12 V, vertical mounting: ± 15° to light and vehicle axis, 2,500 mm cable 2ZR 980 889-111

24 V, horizontal mounting: ± 10° to light and vehicle axis, 2,500 mm cable 2ZR 980 889-211

24 V, vertical mounting: ± 15° to light and vehicle axis, 2,500 mm cable 2ZR 980 889-311

Type approval: ECE ,

Single-function lights

Single and multi-function lights66 mm modules

LED tail stop light and direction indicator Ø 66 mm

With clear lens, 12 LEDs and AMP connector.12 V, tail stop light 2SB 009 001-40124 V, tail stop light 2SB 009 001-50112 V, direction indicator, without pulse 2BA 009 001-41124 V, direction indicator, without pulse 2BA 009 001-51112 V, direction indicator, with pulse 2BA 009 001-4311)

24 V, direction indicator, with pulse 2BA 009 001-5311)


This LED product has the following features:1)

120 | 121

Single and multi-function lights66 mm modules

Rear combination lamps Ø 66 mm

With mounted bulbs 12 V or 24 V, incl. design ring.Red lens24 V, direction indicator with ECE approval for double lights 2NE 009 001-127

12 V, stop light with ECE approval for double lights 2DA 009 001-057

12 V, tail stop light with ECE approval for double lights 2SB 009 001-067

12 V, rear fog lamp with SAE type approval for vehicles < 2,032 mm and > 2,031 mm wide 2NE 009 001-027

12 V, macro reflex reflector with SAE type approval for vehicles < 2,032 mm and > 2,031 mm wide 8RA 009 001-037

Grey lens12 V, direction indicator with ECE approval for double lights 2BA 009 001-007

24 V, direction indicator with ECE approval for double lights 2BA 009 001-107

24 V, tail light with ECE approval for double lights 2SA 009 001-137

24 V, stop light with ECE approval for double lights 2DA 009 001-147

24 V, tail stop light with ECE approval for double lights 2SB 009 001-157

12 V, reverse light with SAE type approval for vehicles < 2,032 mm and > 2,031 mm wide 2ZR 009 001-017

24 V, reverse light with SAE type approval for vehicles < 2,032 mm and > 2,031 mm wide 2ZR 009 001-117

with Silvervision bulb12 V, direction indicator with ECE approval for double lights 2BA 009 001-191

Type approval: ECE 3917 / 6546 / 7613, ECE 23255, ECE 3189 (reflex reflector)

Accessories for rear combination lamps Ø 66 mm

Mating connector, 2-pole 2JD 156 150-807Mating connector, 3-pole 2JD 162 581-802Adapter ring screw connection, frontal for rear combination lamps Ø 66 mm, direct mounting as well as mounting in ring module, black 9XD 161 119-007Adapter ring, for installing LED lamps or the reflex reflector in the ring module series … 009 362-..., black 9XD 161 119-017

Rear combination lamps design rings Ø 66 mm

Suitable for 66 mm light modules with Ø 71.6 mm (article number ...009 -001-... except LED versions), perfect high-gloss finish with one "click".High-gloss chromium plated 9HB 161 122-012silver 9HB 161 122-007Premium silver 9HB 164 168-002Assembly stop ring (no image) 8HG 162 530-002


Multi-function lights112 mm ring modules

Design rings Ø 118 mm

Suitable for light series 009 362, perfect high-gloss finish with one "click"High-gloss chromium plated 9HB 163 085-012Silver 9HB 163 085-001

LED tail/stop/direction indicator Ø 112 mm

For rear installation, clear lens, with 24 red LEDs, suitable for light series 009 362 and 009 001.12 V / 4.8 W current consumption approx. 0.4 A 2SD 009 362-201Type approval: SAE type approval for vehicles with width > 2,031 mm


LED ring modules Ø 112 mm

Tail stop light, ideal for combination with light series 009 001 (Ø 66 mm), optionally available with clear or red cover lens.24 V, tail stop light, red lens with ECE approval for double lights 2SB 009 362-011

12 V, tail stop light, clear lens with ECE approval for double lights 2SB 009 362-021

12 V, tail stop light, red lens with ECE approval for double lights 2SB 009 362-041

12 V, reflex reflector, red lens (no image) 8RA 009 362-001



LED ring modules, edge, Ø 112 mm

12 or 24 V, tail stop light in innovative LED edge light technology, ideal for combination with light series 009 001 (Ø 66 mm), optionally available with clear or red cover lens.12 V, red lens 2SB 009 362-30124 V, red lens 2SB 009 362-32112 V, clear lens 2SB 009 362-31124 V, clear lens 2SB 009 362-331

Type approval: ECE 7R-025889


122 | 123


LED hybrid trailer light

Modular multi-function rear combination lamp 24 V for horizontal mounting, clear lens, 7-pin EasyConn plug connection and 4 x 2-pin connector for the connection of various functions, with pulse for direction indicator failure monitor. Tail light/stop light = 7 red LEDs, direction indicator = 7 yellow LEDs, reverse light = 6 white LEDs, rear fog light = 7 red LEDs. Light: IP 5K4K, LED modules: IP 6K9K.Full-LED tail lamp/triangular reflex reflector/stop light, indicator, rear fog light, reversing lightLeft 2VP 340 960-011*Right 2VP 340 960-021*

Full-LED rear light/triangular light/reflex reflector/stop light, indicator, rear fog light, reversing light, clearance light in the rubber armLeft 2VP 340 960-111*Right 2VP 340 960-121*


Multi-function lights


LED multi-function light

for installation, with 2,500 cable and pulse for indicator failure check, protection class IP 6K6, IP 6K7.a) LED tail light/stop light/indicatorwith clear cover lens, 16 LEDs. 2SD 959 010-401*


b) LED tail light/stop lightwith red lens, 12 LEDs 2SB 959 010-301*


c) LED reversing lightwith clear lens, 24 LEDs 2ZR 959 010-501*


d) LED rear fog lampwith clear lens, 24 LEDs 2NE 959 011-501*


e) LED indicatorwith amber lens, 12 LEDs 2BA 959 011-301*

Type approval: ECE 12373 / EMC

a) b) c)

d) e)


124 | 125


REAR LIGHTING


Coluna full LED rear combination lamp

Tail light, stop light, direction indicator, rear fog lamp, reverse light with rectangular reflex reflector Innovative and patented flat LED light guide, combined with reflex reflector For horizontal and vertical mounting, with impact-resistant lens and high vibration resistance, mounting from front through mounting screws or from rear through fastening bolts, with and without pulse for direction indicator failure monitor. Long service life, low life cycle costs, as well as very robust. Upon request, the rear combination lamp is also available in other frame colors as well as with a triangular reflex reflector.with pulse, front attachment, 500 mm cable12 V 2VP 345 900-40124 V 2VP 345 900-201without pulse, front attachment, 500 mm cable12 V 2VP 345 900-41124 V 2VP 345 900-211with pulse, rear attachment, 500 mm cable12 V 2VP 345 900-42124 V 2VP 345 900-221with pulse, rear attachment, 500 mm cable12 V 2VP 345 900-43124 V 2VP 345 900-231with pulse, front attachment, 3,000 mm cable with 6.3 mm female spade connectors12 V 2VP 345 900-44124 V 2VP 345 900-241without pulse, front attachment, 3,000 mm cable with 6.3 mm female spade connectors12 V 2VP 345 900-45124 V 2VP 345 900-251with pulse, rear attachment, 3,000 mm cable with 6.3 mm female spade connectors12 V 2VP 345 900-46124 V 2VP 345 900-261without pulse, rear attachment, 3,000 mm cable with 6.3 mm female spade connectors12 V 2VP 345 900-47124 V 2VP 345 900-271

Type approval: ECE 5879, 10R 04 0071, EMC

300

130

40

Full LED truck rear combination lamp

Hole pattern 152 mm, DIN (bayonet) at side, inner lens with optics, replaceable non-patterned lens, fully metallised reflector, innovative direction indicator through dynamic flashers. All functions in LED for heavy-duty requirements.Left, integrated licence plate light 2VD 012 381-352Right 2VP 012 381-362Right, integrated backup alarm 2VP 012 381-382


Spare partsLens 9EL 208 551-002


268,9400

403,5

160 ± 0,5

158,

9

91,9

25, 5

124 | 125




LED DuraLED Combi multi-function light

Dual volt 12 / 24 V, tail light/stop light/direction indicator, for horizontal mounting, with 2,500 mm cable, stop light = 8 red LEDs (4 LEDs with reduced light output for tail light), direction indicator = 8 yellow LEDs, with reflex reflector, red/yellow lens, ends decorated metallic grey.12/24 V DC, with pulse for direction indicator failure monitor 2VA 980 710-061*

24 V DC 2VA 980 710-301

Type approval: ECE 5882, GGVS / ADR

LED DuraLED Combi multi-function light

Dual volt 12 / 24 V, tail light/stop light/direction indicator, for horizontal/vertical mounting, with pulse for direction indicator failure monitor, stop light = 18 red LEDs (6 LEDs with reduced light output for tail light), direction indicator = 12 yellow LEDs, lens colour clear, ends decorated red.12 / 24 V DC, with 2,500 mm cable 2SD 980 613-211*12 / 24 V DC, with integrated 6-pin DEUTSCH connector (mating connector to be used DT 06-6S) 2SD 980 602-211*

Type approval: ECE 5883, GGVS / ADR

25223

96

193

25223

96

193


LeanLED combination rear light

Flush-mounted and compact tail light, stop light, and direction indicator in LED for horizontal or vertical mounting, with 24 LEDs, clear lens, with pulse for direction indicator failure monitor, multi-voltage 9 – 32 V, long service life, partially metallised, other frame colors available upon request.Silver, with 500 mm cable and exposed ends 2SD 343 910-001*Silver, with integrated 4-pin AMP plug 2SD 343 910-027*Silver, with 100 mm cable and 4-pin DEUTSCH connector 2SD 343 910-057*


Without type approval and without pulse for indicator failure checkwith 500 mm cable and exposed ends 2SD 343 910-037




"Oval" LED combination rear light

For horizontal and vertical surface mounting, clear lens, 24 LEDs, can be used on the right and left, can be turned through 180°, 2 bodywork fastening screws (diagonal arrangement) with 100 mm harness, multivolt 9–32 V.Stop light, tail light, and direction indicator 2SD 343 390-0111)

12 red LEDs for brake light: 12 V/1 W, current consumption = approx. 0.08 A12 red LEDs for tail lamp (reduced output): 12 V/0.2 W, current consumption = approx. 0.02 A12 amber LEDs for indicator light: 12 V/1.5 W, current consumption = approx. 0.13 A

Direction indicator 2BA 343 390-0711)

24 amber LEDs for indicator light: 12 V/1.5 W, current consumption = approx. 0.13 A

Stop light and tail light 2SB 343 390-091Stop light: 12 V / 1 W, current consumption = approx. 0.08 ATail lamp: 12 V/0.2 W, current consumption = approx. 0.02 A (reduced power)


1)

"Oval" LED combination rear light

Only for vertical surface mounting, with 24 LEDs, 12 red LEDs for stop light, with 4-pole DT connector integrated in the housing.

Stop light, tail light, and direction indicator2SD 343 390-401

and2SD 343 390-407

12 red LEDs for stop light:12 V/1 W, current consumption = approx. 0.08 A12 red LEDs for stop light (reduced power):12 V/0.2 W, current consumption = approx. 0.02 A12 amber LEDs for indicator light 12 V/1.5 W, current consumption = approx. 0.13 A


126 | 127


LED licence plate light

For surface-mounting on the right or left next to the licence plate, only 1 light needed for illumination. Clear lens, with 4 LEDs, black plastic housing.Licence plate 520 x 120 mm12 V, with blade terminal 6.3 x 0.8 mm 2KA 010 278-321*12 V, with blade terminal 6.3 x 0.8 mm 2KA 010 278-327*24 V, with blade terminal 6.3 x 0.8 mm 2KA 010 278-021*24 V, with blade terminal 6.3 x 0.8 mm 2KA 010 278-027*24 V, with 500 mm cable and 2-pin EasyConn plug 2KA 010 278-051*

24 V, with 500 mm cable and Quick Link connector 2KA 010 278-041*

24 V, with 2,000 mm cable and blade terminal 6.3 x 0.8 mm 2KA 010 278-031*

Licence plate 340 x 240 mm or 280 x 200 mm12 V, with blade terminal 6.3 x 0.8 mm 2KA 010 278-421*24 V, with blade terminal 6.3 x 0.8 mm 2KA 010 278-121*Type approval: ECE 2609


LED licence plate light

For installation above the licence plate, 2 lights required to illuminate the licence plate.Licence plate 520 x 120 mm, with blade terminal 6.3 x 0.8 mm12 V 2KA 010 278-311*24 V 2KA 010 278-011*

Licence plate 520 x 120 mm, light contacts sealed and potted, with 1,000 mm cable with open cable ends12 V 2KA 010 278-617*24 V 2KA 010 278-607*

Licence plate 340 x 240 mm or 280 x 200 mm, with blade terminal 6.3 x 0.8 mm1 light required for illuminating the licence plate12 V 2KA 010 278-411*24 V 2KA 010 278-111*



Licence plate lights


The products feature the following properties:

LED end-outline marker with integrated side marker light

24 V, verticalEasyConn 2-pin connector housing, angled, left, with 500 mm cable 2XS 011 744-011

EasyConn 2-pin connector housing, angled, right, with 500 mm cable 2XS 011 744-021

EasyConn 2-pin female connector housing, right, with 500 mm cable 2XS 011 744-101

EasyConn 2-pin female connector housing, left, with 500 mm cable 2XS 011 744-111

Quicklink connector, left, with 500 mm cable 2XS 011 744-071

Quicklink connector, right, with 500 mm cable 2XS 011 744-081

Quicklink connector, right, with 1,000 mm cable 2XS 011 744-181

Quicklink connector, left, with 1,000 mm cable 2XS 011 744-191

AMP-SUPERSEAL connector, left, with 2,000 mm cable 2XS 011 744-051

AMP-SUPERSEAL connector, right, with 2,000 mm cable 2XS 011 744-061

AMP-SUPERSEAL connector, right, with 800 mm cable 2XS 011 744-201

AMP-SUPERSEAL connector, left, with 800 mm cable 2XS 011 744-211

Flat receptacle 6.3 mm, left, with 3,000 mm cable 2XS 011 744-031

Flat receptacle 6.3 mm, right, with 3,000 mm cable 2XS 011 744-041

Flat receptacle 6.3 mm, right, with 150 mm cable 2XS 011 744-161

Flat receptacle 6.3 mm, left, with 300 mm cable 2XS 011 744-171

Type approval: ECE 7R-02 11392, 91R-00 11392, ECE 057951


24 V, horizontalEasyConn 2-pin female connector housing, left, with 500 mm cable 2XS 011 769-011

EasyConn 2-pin female connector housing, right, with 500 mm cable 2XS 011 769-021

Quicklink connector, left, with 670 mm cable 2XS 011 769-091

Quicklink connector, right, with 670 mm cable 2XS 011 769-101



24 V, shortEasyConn 2-pin connector housing, angled, with 500 mm cable 2XS 011 768-011

EasyConn 2-pin female connector housing, with 500 mm cable 2XS 011 768-021

Quicklink connector, with 500 mm cable 2XS 011 768-001

AMP-SUPERSEAL connector, with 2,000 mm cable 2XS 011 768-031

Flat receptacle 6.3 mm, right, with 3,000 mm cable 2XS 011 768-061

Flat receptacle 6.3 mm, left, with 2,000 mm cable 2XS 011 768-071

DEUTSCH connector, 2-pin, with 485 mm cable 2XS 011 768-117


Clearance lights

128 | 129

LED clearance light

Clear lines and no visible mounting from the outside, red/clear lens, black frame for direct screw connection. Universal attachment frame – same light can be installed left and right. Error-free contacting thanks to bipolarity (+ / – can be inverted). Theft protection thanks to the "fit and forget" system. 1:1 replacement with bulb version 2XS 008 497 and 2XS 005 020.With AMP SS black12 V 2XS 205 020-00124 V 2XS 205 020-011Type approval: ECE E11 07R-023011 / CCC

With 500 mm cable, welded, without connector housing12 V 2XS 205 020-04124 V 2XS 205 020-051Type approval: ECE E11 07R-023011 / CCC


Clearance lights


DuraLED clearance light

For horizontal/vertical mounting, 2 LEDs, power consumption 0.5 W, lens made from impact-resistant Grilamid, extremely durable, slim design - 9 mm profile, mounting variant, high vibration resistance, reverse polarity protection.500 mm cable, black end caps 2XS 959 855-4012,500 mm cable, black end caps 2XS 959 855-441500 mm cable, white end caps 2XS 959 855-451


Ø10

84

29

9

10

86

31

9

57.6

2 x Ø3.5 Ø10


DuraLED marker light/clearance light

For horizontal mounting, 2 LEDs, power consumption < 1 W, simple installation: Plug & Play, highly impact-resistant lens made from UV-resistant Grilamid, surface mounting, high vibration resistance, polarity reversal protection.DEUTSCH connector 2XS 980 990-621


Pin 1 (+)Pin 2 (-)

60

46

35

2 x 2.8 22.5

130 | 131LIGHTING ELECTRONICS

LED lighting Failure monitor and electrical connection

Functional diagram

Representation of the power consumption of a bulb and of an LED lamp with integrated pulse

Single pulse

The flasher unit or the light control unit checks the output over 100 – 130 ms with an amplitude of ~ 21 W. At this point the measurement is performed.

At this time, LED and bulb have the same amperage so that a failure can be unambiguously recognised.

Pow

er (W

)

Time (t)

LED light failure monitor A defined standard such as for bulbs cannot be used for the monitoring of LED lamps. Every LED lamp is different in its technical design and its energy consumption:

ª Due to the number of LEDs ª The intensity with which they are driven ª Due to the electronic ballast necessary for their operation

Monitoring of the lamp failure is therefore no longer as simple as it once was with bulbs. HELLA has various approaches as solutions to this problem that are summarised here under the heading "Lighting Electronics".

BulbLED

130 | 131

Flasher units ISO 13207-conformant LED direction indicators can "communicate" with the flasher unit. The flasher unit checks for a defined energy consumption at a defined point in time: Exactly 21 W for 100-130 ms after each switch-on of the direction indicator. The energy consumption or "pulse" corresponds here to that of a bulb, so that the flasher unit notices no difference between a bulb and an ISO 13207-conformant LED light.

If the intelligent ISO 13207-conformant LED lamp detects a defect or only a partial defect, this "pulse" is switched off and the flasher unit can interpret this as a failure. ISO 13207-conformant LED lamps and ISO 13207-conformant flasher units are required for this method.

Advantage: Bulbs and ISO LED lamps can be operated in any combination on an ISO 13207-conformant flasher unit. This is relevant both for vehicles that are frequently operated with different trailers and for manufacturers who wish to offer several variants of the lighting system without having to modify the underlying electronics.

LED lamp control units for use with third-party electronicsIf the vehicle electronics have already been dictated by third parties, HELLA offers LED control units that on the one hand monitor the LED lamps, and on the other hand simulate to the vehicle that bulbs are connected. This allows LED lamps to be used without any problems.

Current monitoringAnother possibility is to measure the average energy consumption of the headlight or the LED lamp.

Disadvantage:In most cases, however, partial defects cannot be detected in this way. With very efficient LED lamps it is possible that their energy consumption is so low that they are detected as defective even when functioning correctly. Or in the worst case: The electronic ballast of the LED lamp requires so much energy that a failure cannot be detected even if all the LEDs are defective.

What is demanded by law?ECE R48 defines that flashers as direction indicators have to be monitored and that their failure has to be signaled optically or visually.

There are two possibilities: ª The LED lamp either has to be able to "communicate" with the vehicle or it is monitored via its energy consumption. ª The "communication" is the better approach here, but is not always possible, e.g. between towing vehicle and trailer.

Solutions: The optimum solution is to match the lighting electronics or the flasher unit to the connected lighting. This is only possible in the most seldom of cases, however, as either a towing vehicle or trailer is involved or the vehicle electronics have already been dictated by third parties.


LED lightingFailure check and electrical connectionLED flasher unit: towing vehicle

12 V

Operating voltage 10 – 15 VFunctional voltage 11 – 14 VOperating temperature -40 to +85°CProtection category IP 53 (contacts underneath)

24 V

Operating voltage 18 – 32 VFunctional voltage 20 – 28 VOperating temperature -40 to +85°CProtection category IP 53 (contacts underneath)

12 V, LED flasher unit 3+1

3 Indicators on the vehicle / tractor vehicle1 Indicator on optional trailerMinimum switching power 18 WMaximum switching power 171 WError threshold towing vehicle 58 WError threshold towing vehicle + trailer 77 W4DW 009 492-111


3 Indicators on the vehicle / tractor vehicle1 Indicator on optional trailerMinimum switching power 18 WMaximum switching power 171 WError threshold towing vehicle 59 WError threshold towing vehicle + trailer 82 W4DW 009 492-011

12 V, LED flasher unit 2+1+1

2 Indicators on the vehicle / traction vehicle1 direction indicator at max. 2 optional trailersMinimum switching power 18 WMaximum switching power 171 WError threshold towing vehicle 39 WError threshold towing vehicle + trailer 59 WError threshold towing vehicle + 2 trailers 80 W4DN 009 492-101


2 Indicators on the vehicle / traction vehicle1 Indicator on optional trailerMinimum switching power 18 WMaximum switching power 129 WError threshold towing vehicle 33 WError threshold towing vehicle + trailer 59 W4DM 009 492-001

3 + 1

2 + 1 + 1

3 + 1

2 + 1

ISO 13207-conformant LED direction indicators can "communicate" with the flasher unit. The flasher unit checks for a defined energy consumption at a defined point in time: Exactly 21 W for 100-130 ms after each switch-on of the direction indicator. The energy consumption or "pulse" corresponds here to that of a bulb, so that the flasher unit notices no difference between a bulb and an ISO 13207-conformant LED light.

Benefit: Bulbs and ISO LED lamps can be operated in any combination on an ISO 13207-conformant flasher unit. This is relevant both for vehicles that are frequently operated with different trailers and for manufacturers who wish to offer several variants of the lighting system without having to modify the underlying electronics.

132 | 133

BASIC CONTROL UNIT

12 V Basis 5DS 227 488-00124 V Basis 5DS 227 488-101

System representation: PremiumControl unit is responsible for monitoring the whole rear lighting (tail lights, brake lights, direction indicators, reversing light and rear fog light).

System representation: BasicControl unit is responsible only for monitoring the direction indicators.

PREMIUM CONTROL UNIT

12 V Premium (1 stop light channel) 5DS 227 489-001

12 V Premium (2 stop light channels) 5DS 227 489-011

24 V Premium (1 stop light channel) 5DS 227 489-101

LED lightingFailure check and electrical connectionLED lamp control unit

1 32 4 1 32 44 43 32 21 1

5

5

5

55

5

5

5 5

5

5

55

5

5

5

Legend

1 – Direction indicator2 – Stop/tail light3 – Reverse light4 – Rear fog light5 – Side marker light

Legend

1 – Direction indicator2 – Stop/tail light3 – Reverse light4 – Rear fog light5 – Side marker light

Electronic control unit

Electronic control unit


Control unit for flashing side marker lights

ECE-R48 category 5, 24 V On request

Variant 2:This control unit can be connected to any side marker light and allows it to flash, if necessary.

Variant 1:This control unit has been specially developed for CAT 5 side marker lights with integrated direction indicators and functions only in combination with these.

Control unit for flashing side marker lights

ECE-R48 category 6, 24 V On request

LED lightingControl unit for flashing side marker lights

1 32 4 1 32 44 43 32 21 1

5

5

5

55

5

5

5 5

5

5

55

5

5

5

Legend

– Control unit 1 – Direction indicator 2 – Stop/tail light 3 – Reverse light 4 – Rear fog light 5 – Side marker /

indicator light

Legend

– Control unit 1 – Direction indicator 2 – Stop/tail light 3 – Reverse light 4 – Rear fog light 5 – Side marker /

indicator light

In order to increase the safety of trailers, the side marker lights can flash synchronously with the direction indicators.

134 | 135

12 V

Operating voltage 9 – 16 VRated current 1.5 AOperating temperature -40 to +85°C

Protection category IP 54(contacts below)

Part number 5DS 009 602-011

24 V

Operating voltage 18 – 32 VRated current 1.5 AOperating temperature -40 to +85°C

Protection category IP 54(contacts below)

Part number 5DS 009 602-001

LED lightingFailure check and electrical connectionSimulation device for cold checking

If the existing vehicle electrical system is programmed to monitor the lighting even when it is not in operation, we speak of a cold check. During a cold check, a small test pulse is transmitted to the lamp while switched off to see whether this pulse is discharged via the bulb to ground. The energy here is so low that the bulb does not light up.

As LED lamps are essentially not suitable for this form of monitoring, HELLA offers an electronic system for "simulation of the cold check" to ensure operation.

136 | 137

HELLA offers a comprehensive range of interior lighting for various vehicle applications and vehicle types.

The product range includes ambient lighting in the form of light guides and LED modules, continuous lighting systems/modules for ceiling systems, service sets (control units), and step lighting.

If you have any questions, please contact our field sales staff or our Customer Service Centre.

INTERIOR LIGHTING

136 | 137




Ceiling lights

EuroLED ceiling light

Number of LEDs 1 white Power LED

Connection electrical connection through a 2,500 mm cable

Lens White

Power consumption 4 W (0.33 A at 12 V), white< 2.5 W (0.20 A at 12 V), red

Mounting Surface-mounting, permanently bonded with base plate

Multi-voltage 9 – 33 V 2JA 959 820-501

EuroLED Touch ceiling light

Number of LEDs 1 white and 8 red

Connection electrical connection through a2,500 mm cable

Functionwith sensitive switch, for ON/OFF and dimming as well as switching between red and white light

Lens White

Power consumption 4 W (0.33 A at 12 V), white< 2.5 W (0.20 A at 12 V), red


Housing, black 2JA 959 950-031Housing, white 2JA 959 950-041

LED ceiling light, structure

Number of LEDs 24 LEDsIlluminance at 1 m Approx. 200 lux (24 LEDs)Length 355 mmLight colour 4,000 K (neutral white)Nominal output 4.8 W

Current consumption Approx. 0.40 A at 12 VApprox. 0.20 A at 24 V

12 V with switch 2JA 007 373-30112 V without switch 2JA 007 373-32124 V with switch 2JA 007 373-31124 V without switch 2JA 007 373-331

138 | 139INTERIOR LIGHTING



Ceiling lights

LED ceiling light with switch

Number of LEDs 12 or 24 LEDs

Illuminance at 1 m Approx. 100 lux (12 LEDs)Approx. 200 lux (24 LEDs)

Length 355 mmLight colour 4,000 K (neutral white)

Material description Lens and frame made of impact-resistant material

Mounting MountingNominal output 3.5 W (12 LEDs)Current consumption 7 W (24 LEDs)

12 LEDs 2JA 007 373-15124 LEDs 2JA 007 373-161

Mini Oval LED

Number of LEDs 4 white LEDs, 1 ambient LEDIllumination angle 50°Illumination Side driver or instrument range

Illuminance at 1 m Standard = 14.5 lux, Power = 54 lux

Function Switchable ambient lighting

IP Class (Protection) 6K9K (without frame/switch), 40 (with frame/switch)

Power consumption Standard = 1.7 Watt (0.14 A at 12 V) Power = 3.6 Watt (0.30 A at 12 V)

Lens Brilliant and clearMounting Installation

Current consumption 3.6 W = approx. 0.30 A (12 V)3.6 W = approx. 0.15 A (24 V)

Voltage 12 V or 24 VTemperature range -40° to +60°C

LED equipment Without frameand switch

With frameand switch

4 white power LEDs, 12 V, blue 2JA 343 570-117 2JA 343 570-157

4 white power LEDs, 24 V, blue 2JA 343 570-101 2JA 343 570-141

4 white power LEDs, 12 V, red 2JA 343 570-011 2JA 343 570-051

4 white power LEDs, 24 V, red 2JA 343 570-001 2JA 343 570-041

4 white standard LEDs, 12 V, red 2JA 343 570-031 –

4 white standard LEDs, 24 V, red – 2JA 343 570-061

Other versions are available on request

138 | 139




Ceiling lights

CargoLED ceiling light

Number of LEDs 4 white Power LEDs

Connection Electrical connection through a 310 mm cable

Illumination angle 44° (wide illumination at close range)Illuminance at 1 m 180 luxPower consumption 6 W (0.5 A at 12 V)Lens Clear

Mounting Flush-mounting (aluminium installation frame)

Temperature range -40 °C to +60 °C

Cold white 2JB 343 227-001Warm white 2JB 343 227-041

AccessoriesInstallation frame, grey 9XD 344 118-101

CargoLED ceiling light

Number of LEDs 36 white LEDs

Connection Electrical connection through a 2,500 mm cable

Illumination angle 70°, wide horizontal and narrow vertical illumination

Illuminance 720 luxPower consumption 9 W (0.75 A at 12 V)Lens Clear

Material description Impact-resistant plastic, UV-resistant

MountingSurface-mounting, permanently bonded with white base plate

Multi-voltage 9 – 33 V 2JA 959 037-511

DuraLED oval ceiling light

Number of LEDs 4 white LEDsLED angle of radiation 120°Illuminance at 1 m 60 luxIP Class (Protection) 6K6 6K7Power consumption 3 W (0.25 A at 12 V)

Voltage Dualvolt 12 and 24 V

12 V 2JA 959 700-102





Orientation lightingLED step lights

Mini thin LED orientation light


Connection Electrical connection through a cable 170 mm long

Illumination angle 34°Illuminance at 1 m 7.2 luxIP Class (Protection) 6K9K

Power consumption 2.8 W (0.23 A at 12 V)2.8 W (0.11 A at 24 V)

Voltage 12 V or 24 V

12 V 2JA 343 660-10124 V 2JA 343 660-117

LED step light

Number of LEDs 1 LEDFeature With polished steel frameMounting Installation

1 blue LED 2XT 959 680-6121 white LED 2XT 959 680-812

LED step light

Number of LEDs 4 white LEDsFeature With square white framePower consumption 0.5 W (0.04 A at 12 V)Lens WhiteMounting Installation

12 V, passive electronics 2XT 980 580-05212 V, active electronics 2XT 980 596-002

140 | 141




84 9

29 Ø10

84 9

29 Ø10


LED step light

Number of LEDs 2 LEDs

Connection Electrical, using a cable 120 mm long

Illumination angle 30°Illuminance at 1 m 15 lxFeature With polarity reversal protectionIP Class (Protection) 5K9KPower consumption 0.5 W (0.04 A at 12 V)Lens ClearScope of delivery Seal, fixing screws and screw capsMounting Installation

White LEDs 2XT 959 510-427Blue LEDs 2XT 959 510-657

LED step light

Number of LEDs 2 LEDsConnection Electrical, using a cable 500 mm longConnecting bracket 30°Illuminance at 1 m 15 lxFeature With polarity reversal protectionPower consumption 0.5 W (0.04 A at 12 V)IP Class (Protection) 6K9KLens ClearScope of delivery Seal, fixing screws and screw capsMounting Installation

White LEDs 2XT 980 855-117Blue LEDs 2XT 980 855-417

LED step light

Number of LEDs 1 LED

Connection Electrical connection through a 100 mm potted cable

Illumination Wide in close range areasIlluminance at 1 m < 10 luxColoring White cover capPower consumption 0.5 W (0.04 A at 12 V)Lens ClearScope of delivery with seal

Mounting Flush-mounting, choice with 2 screws or with snap-on fastening

White LEDs 2JA 998 560-017Blue LEDs 2JA 998 560-057






LED orientation light, structure, flat


Connection Electrical connection via a cable 500 mm long

Illumination angle 38°Illuminance at 1 m 32 luxPower consumption 1.8 W (0.15 A at 12 V)Lens Clear


Temperature range -40 °C to +60 °C

12 V, white LEDs 2JA 343 606-001/-00712 V, blue LEDs 2JA 343 606-201

LED step light

Number of LEDs 10 white LEDsConnection 2,500 mm cableIllumination angle 24°Illuminance at 1 m 130 luxFeature Cast in one piecePower consumption 2 W (0.16 A at 12 V)Lens Clear

Scope of delivery With screws, screw caps, seal, and cable connector

Mounting Installation

12 V 2JA 959 073-001

LED step light


Connection Electrical connection through blade terminal and grommet

Feature With prism rod as a light aperture bodyColoring Grey housingPower consumption 0.7 W (0.05 A at 12 V)Lens Clear

Mounting Surface-mounted (horizontally or vertically)

12 V 2JA 008 078-031

142 | 143

Reading lights

a)

b)


LED reading light, flexibly adjustable arm

Number of LEDs 1 white Power LED

Connection Electrical, using a cable 150 mm long

Illumination Optimal for map-readingIllumination angle 38°Illuminance at 0.7 m 110 luxIP Class (Protection) 53Power consumption 2.5 W (0.20 A at 12 V)Lens PatternedMounting Mounting

150 mm 2JA 343 720-011400 mm 2JA 343 720-111

Finish colour black150 mm 2JA 343 720-021400 mm 2JA 343 720-121

Trim colour silver400 mm 2JA 343 720-191

With plug for cigarette lighter (150 mm)Finisher colour black 2JA 343 720-081

Xenon reading light, flexibly adjustable arm

Number of light sources 1 xenon bulb 12 V/6 WFeature With flexible metal armLight source Strong and glare-freePower consumption 6 W (0.50 A at 12 V)Lens Clear

Scope of delivery With bracket for permanent surface-mounting

Mounting MountingVoltage 12 V

a) For fixed installation500 mm 2AB 004 532-001195 mm 2AB 004 532-011

b) With plug for cigarette lighter160 mm 2AB 004 532-021

AccessoriesLens, red 9EL 128 922-011

Spare partsXenon bulb, 12 V 8GP 007 676-121Brackets 9XB 136 202-005

144 | 145

Electronic components – benefit from our unique experience and innovative power.

HELLA is one of the first ports of call for the international supplier industry not just in lighting technology but also in electronic components.

One thing all our products have in common is that their quality and output are carefully optimised to meet the special requirements of our customers.

For more information visit www.hella.de/sensors-actuators

ELECTRONIC SYSTEM

144 | 145

Energy management Drive train Components

Careful use of energy by appropriately influencing the consumer:

These electronic systems make it possible to monitor and plan the energy budget and maintain the power supply.

Increasing safety and efficiency of the overall system and preventing failures:

These electronic systems make it possible to precisely measure and record measured value in the engine compartment and drive train.

Provide added convenience with compact solutions in a variety of areas:

These electronic systems are generally invisible little helpers for the various automatic processes within the vehicle.

Product ranges, Special OE Electronics

Voltage stabilisersIntelligent battery sensors Oil level switches Oil pressure sensors Angular Position

Sensors Air quality sensors

Oil level sensors Pedal sensors Remote controls Rain light sensors

Pedal sensors Actuators Temperature sensors

146 | 147ELECTRONIC SYSTEM

Intelligent battery sensors

Design and functionThe IBS is attached directly to the negative terminal of the battery via the pole terminal (4).

In addition to the terminal, the mechanical portion of the battery sensor consists of shunt (1) and ground bolt (5) components. The shunt is attached to the vehicle’s load path and is used as a measuring resistor for indirect current measurement. On the ground bolt (5), the existing ground cable can be conveniently attached, for example, to the optionally available battery pole adapter.

The electronics are located in a molded housing (3) with plug connector (2), functioning as the interface to the energy management system. The communication interface to the higher-level control unit is the LIN protocol. The supply voltage, used simultaneously as the reference voltage for voltage measurement, is provided by the connection to the positive pole of the battery.

The ASIC is the main electronics component used to record and process measured values. Measured value acquisition in the ASIC, as a precision sensor, is the core function of the intelligent battery sensor and is used to record the physical parameters of current, voltage and temperature.

ApplicationThe intelligent battery sensor (IBS) from HELLA is the key element of vehicle energy management.

The IBS reliably and accurately measures the battery parameters: voltage, current, and temperature. Information about the battery’s state of charge (SOC), state of health (SOH) and state of function (SOF) is calculated algorithmically from the measured values. The IBS is designed for use in starter, gel and AGM batteries to monitor in-vehicle starter or consumer batteries. The IBS can be directly integrated into the vehicle electrical system with the standardised LIN protocol.

5 1

4

2 3

Product features

ª High-accuracy measurement of battery voltage, current and temperature parameters

ª Determining the battery condition parameters State of Charge (SOC), State of Health (SOH) and State of Function (SOF)

ª Simple electrical and mechanical integration

146 | 147

Monitoring of different battery states

Ageing condition (SoH):• "Real" capacity• Changed charging and discharging capability

Avai

labl

e ca

pacit

y (SO

H)

= no

min

al ca

pacit

y

Star

ting

abilit

y (So

F)

Redu

ced

st

artin

g ab

ility (

SoF)

Capa

city l

oss

due

to

agei

ng p

roce

sses

Avai

labl

e ca

pacit

y (So

H)

Disc

harg

able

ca

pacit

y

Disc

harg

able

ca

pacit

y

Ageing process

Charge state (SoC)

Nominal capacity Capacity loss

Available capacity

Charge state (SoC)

Starting capability (SoF):• Ability of the battery to deliver high levels of current• Change in the starting capability throughout the design life

Battery condition algorithmsThe intelligent battery sensor calculates and monitors the following battery conditions

State of charge (SOC): Describes the current charge status of the battery.The SOC is defined as: SOC [%] = dischargeable capacity/nominal capacity

State of health (SOH): Indicates the ageing status of the battery.The (SOH) is defined as: SOH [%] = available capacity/nominal capacity

The available capacity of the battery typically decreases as the battery ages and through lengthy use.

State of Function (SOF): Describes the future starting ability of the motor based on the actual measured current and the voltage

Summary of versions

There are four variants of the intelligent battery sensor available. Sensor 1 is the basic version. When monitoring a second battery, sensor 2 is used in the same communication network. The third variant is used when two 12 V batteries are series-connected (24 V vehicle electrical system). The fourth variant is intended for vehicles with high starting currents (e.g. agricultural and construction vehicles) as well as those with higher ground cable cross sections (> 70 mm2).

Operating voltage Type Mating connector Part number

6 – 16.5 V Sensor 1 Hirschmann 872-858-565 6PK 010 842-0016 – 16.5 V Sensor 2 Hirschmann 872-858-565 6PK 010 842-0117.5 – 32 V – Hirschmann 872-858-546 6PK 011 700-0016 – 16.5 V For motorhomes Hirschmann 872-857-561 6PK 013 824-001 6 – 16.5 V For agricultural and construction machinery Hirschmann 872-858-546 On request


Upright/pendant accelerator pedals

ApplicationThe accelerator pedals are suitable for driver's cabs in agricultural and construction machinery. Thanks to the wear-free measuring principle of HELLA’s in-house developed CIPOS ® sensors (see description of the design and function of the turning angle sensors) and their extremely low level of mechanical wear, this version is particularly suitable for contact-type accelerator pedals that effect frequent small movements.

Summary of versions

Description Pedal material Part number

Floor-mounted accelerator pedal Plastic 6PV 312 010-107

Suspended accelerator pedal Plastic 6PV 009 591-011

Product features

ª Contact-free measuring principle ª Slim and sturdy design ª Simple mechanical connection ª Redundant output signal ª High degree of measurement accuracy; programming

in the vehicle is not necessary ª High interference immunity against electrical and

magnetic fields

Design and functionHousing and operating lever or pedal plate are made from fully reusable, glass-fibre reinforced plastic. The sensor is inserted into a slot of the device, fully waterproof, and does not protrude from the package space. The actuation force is generated by two springs, which both return separately. The electric output signal is extracted using the CIPOS® measuring principle. For this, a cursor plate is guided from the pedal arm to the measuring board via sensor conducting paths. There, two galvanically separated sensors each generate an output signal. Different output signals can be generated depending on the measuring board used. Furthermore, it is possible to program individual characteristic curves upon request.

148 | 149

Rain light sensorsRecording environmental properties

ApplicationThe full range of functions of the rain/light sensor (five functions: rain sensor, light sensor, solar sensor, humidity measurement, and head-up display) can only be used for passenger vehicle applications. This sensor can only be used to a limited extent in vehicles with special windshields (thick, slanted, transmission).

The optics of the second sensor are specially designed for vehicles with steep windshields and combine the functions of rain and light detection (ambient and tunnel detection).

Summary of versions

The sensors must be specially applied for each vehicle. For that reason all part numbers are customer-specific provided.

Areas of use Permitted windshield thickness Permitted windshield angle Part number

Passenger vehicles 4 – 6 mm 22° – 32° On request

Vehicles with special windshields 6 – 9 mm 80° – 90° On request

Product features

ª Fourth generation of the long-established rain sensors from HELLA

ª Up to five functions in one product: Rain, light, solar, and humidity measurement as well as adjustment of the light intensity on the head-up display

ª Optimised design – extremely compact package space


Radio-controlled systemsSwitching on and off or opening and locking

Design and functionIn terms of its electronic function, the radio transmitter consists of the "radio transmitter electronics" and the "transponder." The transponder responsible for the immobiliser function is independent from the radio transmitter electronics and can be customised.

The radio transmitter electronics are mounted on a double-sided printed circuit board. In addition to the radio transmitter electronics themselves, the printed circuit board also contains the "Lock/Unlock" button and, depending on the variant, another button (additional function). Spring contact elements are used to provide the electrical connection between the printed circuit board and the battery. When a button is pressed, the radio remote control sends data packages with a rolling code and updated 128 bit encryption. If the receiver control unit of the radio remote control positively decrypts the data, it activates the output signals of the control unit.

The radio control system can be used in every European country and also in North America (USA + Canada) and India without limitations. System radio approvals outside Europe can be carried out in consultation with HELLA.

The radio remote control is equipped with a holder for a mechanical key bit. The mechanical key bit is not included in the scope of delivery for the radio transmitter electronics. The key bit is usually mounted (by using a special mounting device) either at the customer's premises or at the manufacturer's.

Two radio transmitter keys are "taught-in" and assigned to the device during production of the radio receiver. Teaching additional radio transmitter keys in the field requires at least one functioning, taught-in key. Up to 7 radio transmitter keys can be taught in. If the maximum number of radio transmitter keys has already been taught in, the last key place is overwritten when teaching in another key.

ApplicationThe radio control system has been specially developed for use in tough operating conditions (agricultural and construction machinery, trucks). The system enables the vehicle operator to comfortably unlock the cab door. The remote control can be equipped with one or two buttons, depending on the customer’s requirements. The robust design has been specially developed for use in agricultural and construction vehicles. An additional control unit which sends up to four output signals enables lamps to be activated, e.g. work lights or beacons. HELLA’s radio control system can easily be used to activate direction indicators and to release or lock covers to engine compartments or toolboxes, for example. The design can be customised on request, such as by incorporating customised emblems.

Product features

Electronic radio transmitter key: ª Unlocking cab doors /covers ª Controlling lamps/work lights ª Activation/deactivation of an electronic immobiliser

via transponder ª Robust design

150 | 151

Summary of versions

There are two variants of the receiver control unit available: The basic variant and the enhanced variant. Customer-specific output signal characteristics are available upon request. If a customer-specific emblem is to be included, a new part number is created for this. Each device variant includes two blind plugs made from hard plastic. This enables the radio transmitters to also be operated without a key bit.

Variants Part number

2 radio transmitters and receivers, basic version On request

2 radio transmitters and receivers, enhanced variant 5FA 012 485-817

Further variants and configurations available upon request.

Functional diagram

Central locking

Actuators

WorklightsRelease of immobiliser

Assignment of rights (personalisation)

Transponder signal

Radio signal

Radio receiver Radio remote control

HELLA radio control system

Additional function

Engine control unit

Central control unit

Immobiliser

Electronic immobiliserRelays


Electromotive actuators Electric locking / unlocking, space-saving, with or without micro-switchLow Force

ApplicationAs a result of the very space-saving design, this actuator is well suited to locking and unlocking applications in dry and humid areas (e.g. including via remote actuation) in which only minimal package space is available.

Examples include: ª Tank modules ª Service flaps ª Glove compartments ª Locking of the charging plug (e-mobility)

FunctionWhen a voltage is applied, the motor integrated in the electromotive actuator moves the locking lever attached to the motor shaft.

Summary of versions

Function Voltage Actuating force Manual adjustment Protection category Part number

Forward and reverse rotation electrical

12 V - Yes IP 5K4 6NW 011 122-017

With micro-switch 12 V - Yes IP 5K4 6NW 011 122-027

Electrical forward rotation and reverse rotation via return spring, with soft touch button

12 V - Yes IP 5K4 6NW 011 122-047

Product features

ª Compact, space-saving design ª Electrical resetting or automatic resetting

(without current) ª Easy to fix in place thanks to snap-fit mounting ª Spray water protected ª With or without micro-switch ª Explosion report for tank modules

152 | 153

Electromotive actuatorsElectrical locking / unlocking and closing (medium force)

ApplicationThe motorised actuator electrically locks, unlocks or shuts locking and flap systems in automotive and industrial areas.

Examples of applications in mechanisms include: ª Electrical locking and unlocking ª Electrical shutting ª Power opening and closing of all doors (locking systems),

flaps, roof windows, seats, covers, hoods, glove compartments, etc.

AccessoriesThe wide range of accessories for the electromotive actuator consists of diverse connecting elements. These enable the actuator to be integrated easily in the application without the need for additional development work.

Summary of versions

Function Voltage Positioning force* Manual adjustment Protection category Part number

Power extension and retraction

12 V 30 – 130 N Yes IP 5K0 6NW 009 203-401

12 V 30 – 140 N No IP 5K0 6NW 009 203-411

12 V 30 – 130 N Yes IP 5K4 6NW 009 203-421

12 V 30 – 140 N No IP 5K4 6NW 009 203-431

24 V 30 – 130 N Yes IP 5K4 6NW 009 203-441

24 V 30 – 140 N No IP 5K4 6NW 009 203-451

12 V 30 – 140 N No IP 5K4 6NW 009 203-557

Electrical retraction, extension with clockwork spring

12 V 30 – 170 N No IP 5K0 6NW 009 203-461

12 V 30 – 170 N No IP 5K4 6NW 009 203-471

24 V 30 – 170 N Yes IP 5K4 6NW 009 203-541

Electrical extension, retraction with clockwork spring

12 V 30 –130 N No IP 5K0 6NW 009 203-491

12 V 30 –130 N No IP 5K4 6NW 009 203-501

24 V 40 – 150 N No IP 5K4 6NW 009 203-521

* Dependent on the operating voltage and ambient temperature

Product features

ª High actuating force ª High-accuracy, laser-welded housing ª Three versions ª Dust- and waterproof ª With or without manual adjustment ª Thermal overload protection through PTC (PolySwitch) ª Multifunctional ª Various connection elements available


Electromotive actuatorsElectrical locking / unlocking and pull / push (high force)

ApplicationThe actuator is particularly well-suited for locking and pull/push applications requiring high forces.

Examples include: ª Large locks ª Large flaps ª Seat release

When a Bowden cable is used, the actuator can also operate without being attached to the body as it is attached to the application via the Bowden cable sheath and can be embedded in a foam body for noise dampening.

FunctionThis electromotive actuator is an actuator with rotary output driven by a DC motor. The actuator is operated by applying a voltage via a 2-pin connector with contacts "+" and "ground". The return action is carried out by simply reversing the polarity or automatically via a spring. The direction of rotation and runtime are defined by the control unit. The actuator can be attached to three connecting points.

Summary of versions

Function Voltage Torque Manual adjustment Protection category Part number

Retraction via spring, power extension 12 V 150 Ncm No IP 5K0 6NW 009 424-781

Power extension and retraction 12 V 300 Ncm No IP 5K0 6NW 009 424-791

Product features

ª Very high positioning forces ª Sturdy and compact design ª Interference suppression class 3 ª Universal interface for Bowden cable ª For universal use

154 | 155

Electromotive actuatorsElectrical locking / unlocking and closingPart number 6NW 011 303-011

ApplicationThe URA can be used in a broad range of applications involving harsh environmental conditions, and can perform precise and reliable positioning. The insensitivity to magnetic fields and the high level of temperature stability, in particular, are the characteristic qualities of the CIPOS technology employed in the URA. Angles are measured inductively using a non-contact and hence wear-free method, thus guaranteeing a high measuring precision over the whole service life. An error memory records errors and the actuator is able to react differently to different errors.

Application examples ª Seed metering/singling ª Delivery air/exhaust air flaps

FunctionThe URA monitors the position of the output gear wheel and the integrated electronics continually calculate the position using an ASIC (Application Specific Integrated Circuit). The actuator offers the "true power on" function for angles under 180°; i.e. it enables commissioning without calibration. In operation, the actuator carries out controlled movement to the programmable "soft stops". The self-locking transmission minimizes current consumption (< 25 mA), which is required to maintain a defined position.

Product features

ª Flexible operating angle range ª Fast response time ª Precise position control ª CIPOS position sensor integrated directly at

driven gear ª "True power on" function for angular ranges < 180° ª Controlled motion up to limit stop ª Self-blocking gearbox; low current consumption

(< 25 mA) for holding the position ª Internal fault memory

Summary of versions

Function Voltage Torque Manual adjustment Protection category Part number

Power locking/unlocking & closing, power rotational movement to right and left, with position feedback via CIPOS technology

12 V Up to 300 Ncm NoIP 6K9K or IP 6K71 ( 1 depends on the connector classification)

6NW 011 303-701


Angular Position Sensors Single and double sensors

Function

Inside the laser-welded polyamide housing (PA66), the rotation of the lever arm is transferred to the rotor and measured by induction. An ASIC (Application Specific Integrated Circuit) accurately computes the rotor position. Various mounting positions are possible thanks to the repeating characteristic curve of the output signal (which depends on the structure of the sensor that is used), which increases the flexibility of the sensor.

ApplicationThese CIPOS ® angular position sensors (contactless inductive position sensors) can be used in many different applications to return accurate and reliable angular measurements even in tough environments. In particular, insensitivity to magnetic fields and a high degree of thermal stability are characteristic of the CIPOS ® technology used in all these angular position sensors. Angles are measured inductively using a contact-free and hence wear-free method. This guarantees a high degree of precision throughout the entire life of the sensor. The redundant sensors (double sensors) are especially designed for failure detection, thus improving the reliability of the overall system.

Rotor

Stator Elektronik

Induktion

Transmitter SpuleEmpfängerspule

Rotor

Induction

Excitation coilReceiver coil

Stator Electronic system

Product features

ª Single or redundant sensors ª High precision due to internal 14 bit resolution ª High thermal stability and linearity ª High insensitivity to magnetic fields ª Zero position can be individually programmed ª Various connection elements available

156 | 157

Summary of versions

Mechanical connection Angle range Supply voltage Output signal Zero position Lever arm Part number

Single sensors

Socket - 30° to + 30° 5 V 0.5 – 4.5 V ratiometric and PWM 0° / 120° / 240° 50 mm 6PM 008 161-241

Socket - 51° to + 51° 5 V 0.5 – 4.5 V ratiometric and PWM 0° / 120° / 240° 50 mm 6PM 008 161-251

Socket - 54° to + 54° 5 V 0.25 - 4.75 V ratiometric and PWM 0° / 120° / 240° 70 mm 6PM 008 161-121




Basic sensors – Compact design

Ball, top - 54° to + 54° 5 V 0.5 - 4.5 V ratiometric 0° / 120° / 240° 39 mm 6PM 010 200-501

Ball, bottom - 54° to + 54° 5 V 0.5 - 4.5 V ratiometric 0° / 120° / 240° 39 mm 6PM 010 200-511

Ball, bottom - 54° to + 54° 5 V 0.5 - 4.5 V ratiometric 0° / 120° / 240° 51 mm 6PM 010 200-521

Ball, top - 54° to + 54° 5 V 0.5 - 4.5 V ratiometric 0° / 120° / 240° 64 mm 6PM 010 200-531

Double sensors

Socket - 30° to + 30° 5 V or 9 - 32 V 0.5 – 4.5 V ratiometric/ absolute 0° / 120° / 240° 50 mm 6PD 009 583-001

Socket - 54 to + 54° 5 V or 9 - 32 V 0.5 – 4.5 V ratiometric/ absolute 0° / 120° / 240° 50 mm 6PD 009 583-011

Socket - 54 to + 54° 5 V 0.5 - 4.5 V ratiometric 0° / 120° / 240° 70 mm 6PD 009 580-017

Ball, top - 54 to + 54° 5 V or 9 - 32 V 0.5 – 4.5 V ratiometric/ absolute 0° / 120° / 240° 90 mm 6PD 009 584-017

ANALOGUE OUTPUTAt a supply voltage of 5 V DC, the measured angle is reflected through the ratio of the output voltage (Uout) to the operating voltage (US) (ratiometrically to the supply voltage). This signal is output via a high side driver (HSD). At a supply voltage of 9 V to 32 V (multi-voltage), the measured angle is reflected through a voltage of 0.5 V to 4.5 V.

PWM OUTPUT (DIGITAL)

When using the PWM signal, the angular position of the turning angle sensor results from the ratio between the low time (Tlow) of the PWM signal and the period time (Tperiod). The absolute time of the high or low level is not a measure of the angle. The PWM signal is output via a low side driver (LSD). Of course, it is also possible to evaluate the ratio of high time (Thigh) to period time (Tperiod). This results in a characteristic curve that is inverse to the analog signal.

T

T t

U

U

variabel zum Winkel

0V

Tlow

period

pull-up

high

variable to the angle


3100 switch series

The new waterproof series of rocker switches for electrical systems. It meets the requirements of protection class IP 68. The lasered symbols are lit by integrated LEDs.

Variety of lasered symbol discs ª IP 68 according to test standard IEC EN 60529 ª Extremely reliable in extreme conditions ª Ideal for use in agricultural and construction machinery ª Most diverse switch functions in 12/24 V

• Normally open contact/ changeover contact • Button/grid • Locking functions • Hazard warning light switch

ª Wide range of standard and customer-specific laser symbols

ª Up to two LED light sources enable direct symbol illumination

ª Simple to install, directly in the mounting hole or using a modular mounting frame

ª Display lights in the same design for safety-related feedback

Accessories

Frame

End piece left, right 9AR 169 209-102 / -107

Center piece 9AR 169 208-102 / -107

Dummy panel 9HB 172 229-102 / -107

Receptacle housing

Type I 8JD 010 076-102 / -107

Type II 8JD 010 076-112 / -117

Type III 8JD 010 076-122 / -127

Female spade connector, 6.3 mm

0.5 mm² – 1 mm² 8KW 744 882-003

1.5 mm² – 2.5 mm² 8KW 744 820-003

Dismantling tool 8PE 197 631-001


Mounting opening 21.1 mm x 37.0 mm

Material rocker PC transparent, painted

Base plate material PBT

Connecting contacts 6.3 mm x 0.8 mm

Coating of switch contacts CuZn silver-plated

Light source

Max. 2 LEDs1 x orientation lighting, green1 x function light, redWarning lights available in amber and green

Symbol type Lasered

Design life 6 A / 24 V at 150,000 switching cycles

Leak tightness IP 66 terminal side, IP 68

Operating temperature -40 °C to +85 °C

Storage temperature -40 °C to +85 °C

Dashboard thickness 2 mm switch for direct installation

The HELLA switch configuratorConfigure your custom switch at www.hella.com/switch.

Select switching functions, symbol combinations and accessories with just a few clicks.

158 | 159

4100 switch series

The modular switch series with self-cleaning microswitches is suitable for modern electrical and electronic systems. This ensures reliable switching of small currents as well without contaminating the contacts. The series features a timeless design, with lasered symbols lit by integrated LEDs.

The strength of the product range: ª Modular design of the switch ª Realisation of a wide variety of 12 V and 24 V switching

functions: • Normally open contact/ changeover contact • Button/grid • Locking function • Hazard warning light switch

ª Wide range of standard and customer-specific symbols ª Selective, reliable and durable illumination of the symbols

by using up to 4 LED light sources ª Simple to install, directly in the mounting hole or using a

modular mounting frame ª Display lights in the same design for safety-related

feedback ª Modern and timeless design ª Pleasant to the touch

Accessories

Frame

Single frame 9AR 168 396-002 / -007

End piece, left 9AR 169 209-002 / -007

End piece, right 9AR 169 210-002 / -007

Centre piece 9AR 169 208-002 / -007

Dummy panel 9HB 172 229-002 / -007

Cable sachet housing, 10-pin 8JD 010 076-002 / -007

Female spade connector, 2.8 mm

Junior Power Timer 0.5 mm² – 1 mm² 8KW 863 934-003

Junior Power Timer 1.5 mm² – 2.5 mm² 8KW 863 934-023 / -024


Mounting opening 19.8 mm x 41.8 mm

Material rocker PC transparent, painted

Base plate material PA white, housing PA black

Connecting contacts 3 mm Junior Power Timer

Coating of switch contacts AgNi

Light source

Max. 4 LEDs2 x orientation lighting, green2 x function lighting, redWarning lights also available in blue and amber

Symbol type Lasered

Design life5 mA / 450,000 cycles5 A / 24 V inductive / 270,000 cycles4 A / 24 V lamp (75 W) / 90,000 cycles10 A / 24 V resistive/80,000 cycles

Leak tightness IP 54

Operating temperature -40 °C to +85 °C

Storage temperature -40 °C to +100 °C

Dashboard thickness 2 mm switch for direct installation

The HELLA switch configuratorYou can configure your own switches individually at www.hella.com/switch.

Select switching functions, symbol combinations and accessories with just a few clicks.

160 | 161

Wide electrics range that has grown over the years

As a worldwide partner to the automotive industry, HELLA offers system know-how, experience with large volume production and also process know-how for fast implementation of innovative concepts in efficient and reliable serial products.

This is why the HELLA electrics range is particularly broad: from A as in "Acoustic signal unit" to W as in "Washer pumps". By continuously expanding and optimising, we offer a wide range of electrical plug connectors.

At HELLA you will find everything that connects: short or super-short, made of plastic or metal. HELLA makes something special even out of standard parts, simple to install or retrofit, in certified quality, in all variations, and suited to almost every special case.

ELECTRICAL SYSTEM

160 | 161

Plug connectors

2-pin socket according to VG 96 917The 2-pin sockets in accordance with VG 96 917 are designed to withstand large currents and ensure a high degree of safety while being easy to use. The system is used to charge batteries and as a starting aid. This involves the transfer of high to very high currents. The 2-pin 24 V system can be used for temporary currents up to a maximum of 2,500 A (temporary load up to 10 s).

Product photo Description Part number PU in units

Socket, aluminum2-pin with green screw cap (VG 96 917-3 Form A). Seal in screw cap, additional sealing ring between thread and screw cap.

2 crimped/solder socket contacts for cables up to 50 mm² 8JB 001 935-031 1

2 crimped/solder socket contacts for cables up to 35 mm² 8JB 001 935-051 1

Socket, metalYellow, 2-pole with black rubber cap (insertion compatible with VT 96 917)2 crimped/solder socket contacts for cables up to 50 mm²

8JB 010 806-001 1

Socket, plastic2-pin with rubber cap (insertion compatible with VT 96 917)2 crimped/solder socket contacts for cables up to 35 mm²

Black 8JB 001 935-041 1

Amber 8JB 001 935-061 1

Accessory grommetFor 2-pin sockets:8JB 001 935-0318JB 001 935-0418JB 001 935-0518JB 001 935-061

9GD 735 641-062 1

Range advantages ª Permissible operating temperature: - 40°C to + 85°C ª Protection class: IP X4 ª Contacts: CuZn, silver-plated

162 | 163ELECTRICAL SYSTEM

Plug connectors


Socket, light alloyWith captive screw-on cap Form AWith seal in the screw-on capWith rubber base for cables Ø 6...8 mm

8JB 002 281-001 1

Coupling box, light alloyWith screw-on cap Form BSeal in the screw-on cap with cable protection sleeveFor cables Ø 6 – 10 mm

8JB 002 281-011 1

Connector, light alloyWith union nut, Form CFor cables Ø 6 – 10 mm

8JA 001 925-001 1

2-pole plug system in accordance with DIN 14 690This plug system is mainly used for charging batteries.

ª Permissible operating temperature: -40°C to +100°C ª Rated power: 6 – 42 V ª Amperage: max. 16 A

Range advantages: ª Complete range comprising connector, socket and coupling box ª Socket and coupling box with captive cap


Socket13 Screw connections with rubber base 8JB 005 949-001 1

Socket13 Screw connections with rubber base,with switch-off contact for the rear fog light on the motor vehicle

8JB 005 949-011 1

Socket13 Screw connections with rubber base, with microswitch, changeover contact left

8JB 005 949-041 1

13-pin plug system in accordance with ISO 11446The 13-pin socket systems according to ISO 11446 allow all the lighting and auxiliary functions to be transferred using only one plug. The system is continually replacing the older generation of plug-type connectors on account of its advantages, particularly with regard to waterproofness, stability, contact reliability and easy handling thanks to the bayonet closure.

ª Permissible operating temperature: - 40°C to + 85°C ª Tightness in accordance with protection class IP 54K ª Sockets with rear fog light switch-off available

162 | 163

DEUTSCH "DT series" plug connectors

The concept combines high quality materials with a connecting system characterised by both reliability and easy handling. Thanks to these properties, the product range is particularly suited to applications where maximum performance is required with a minimum number of disruptions, despite tough environmental conditions. The symmetrical star crimp process allows a gas-tight connection which is characterised by high resistance to temperature and oxidation-based fluctuations in resistance. The housing locking mechanism with integrated click-in function guarantees a quick and secure connection with a strong grip. The "wedgelocks" used for secondary locking facilitate precise, strain-resistant alignment of the contacts and are "clicked" into position on the contact side of the DT housing.

Description Pin Part number PU in units

DT housing 2-pole 8JA 201 021-022 10

DT connector 2-pole 8JA 201 022-022 10

DT "wedgelock" for housing 2-pole 9NB 201 023-022 10

DT "wedgelock" for plug 2-pole 9NB 201 024-022 10

DT housing 3-pin 8JA 201 021-032 10

DT connector 3-pin 8JA 201 022-032 10

DT "wedgelock" for housing 3-pin 9NB 201 023-032 10

DT "wedgelock" for plug 3-pin 9NB 201 024-032 10









DT housing, coding "A" 8-pin 8JA 201 021-082 10

DT plug, coding "A" 8-pin 8JA 201 022-082 10

DT "wedgelock" for housing 8-pin 8JA 201 023-082 10

DT "wedgelock" for plug 8-pin 8JA 201 024-082 10

DT housing, coding "A" 12-pin 8JA 201 021-122 10

DT plug, coding "A" 12-pin 8JA 201 022-122 10

DT "wedgelock" for housing 12-pin 8JA 201 023-122 10

DT "wedgelock" for plug 12-pin 8JA 201 024-122 10

Contact sleeve 2 mm2 9NB 201 025-012 50

Contact pin 2 mm2 9NB 201 025-022 50

Contact sleeve 0.5 – 1.5 mm2 9NB 201 025-112 50

Contact pin 0.5 – 1.5 mm2 9NB 201 025-122 50

Blind plug – 9NB 201 026-012 50

Range advantages ª Environmental sealing – maximum protection from external

influences ª High quality housing material ª Strong, gas-tight crimp connections

164 | 165ELECTRICAL SYSTEM

SUPERSEAL connectors

Comply with the guidelines in IEC 529 as well as DIN ISO 40050 and have been given protection rating IP class 67, which guarantees maximum protection from water and dust penetration. The quality of the SUPERSEALS makes them ideal wherever other interconnection systems reach their limits due to adverse pressure or humidity conditions.

Range advantages ª OEM quality ª Reliable electrical connection ª Maximum protection from external influences

Description Pin Part number PU in units

SUPERSEAL pin housing 1-pin 8JA 746 183-012 10

SUPERSEAL socket housing 1-pin 8JA 746 184-012 10

SUPERSEAL pin housing 2-pole 8JA 746 183-022 10

SUPERSEAL socket housing 2-pole 8JA 746 184-022 10









Male pin contact, B 143 1.0 – 1.5 mm² 8KW 744 836-002 50

Female contact, B 144 1.0 – 1.5 mm² 8KW 744 837-002 50

Strand insulation, B 145 Ø 1.8–2.4 mm 9GD 746 185-002 50

Strand insulation, B 146 Ø 2.6 – 3.3 mm 9GD 746 186-002 50

Blind plug, B 147 – 9GD 746 187-002 50

164 | 165

Cable straps with edge clips

To cleanly attach a cable bundle, this often requires more than the cable strap itself. Our cable straps with integrated edge clips offer a quick and easy to use complete solution with strong holding power. They are weatherproof, flame retardant and resistant to dilute organic acids, oils, petrol, salt water, solvents and greases. They offer perfect purchase even for bundles with the tiniest cross-section, so there is no need for additional padding.

Range advantages ª Complete attachment solution in a single product ª Suitable for numerous different positions and edge

thicknesses ª High-performance specification with original equipment

references

Description Profile thickness Capacity Part number PU in units

Cable strap, black200 x 4.8 mm 0.7 – 3.0 mm ø 48 mm 8HL 185 549-001 100








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Good product ideas are the answer to real problems that occur in practice. Quality, practicability, safety and cost effectiveness are the aims of every new development. These are criteria HELLA's comprehensive range of products already meets today.

You can save costs on a reliable and long-term basis with LED products from HELLA. Fleet managers and drivers expect functional safety at all times - with no buts. In other words, vehicle components with a high quality standard and long design life. HELLA LED lights meet these requirements. They have been developed and produced according to the strictest quality standards.

Using sample calculations drawn from practice, on the following pages we would like to demonstrate the the vast potential for achieving cost savings in your vehicle fleet in respect of material costs, labour costs, and repair hours spent on maintenance work through the systematic and

consistent use of LED lighting units from HELLA. For design reasons, the light sources installed are specified with their max. expected design life. Malfunctions of light sources are therefore correspondingly low when you change over to LED lighting and this in turn means that maintenance work can be reduced to a minimum. The use of LED products from HELLA also considerably reduces energy consumption: Consequently, fuel consumption and exhaust emissions drop.

MUNICIPAL FLEET

166 | 167

ROAD SWEEPERS

Enjoy the benefits of HELLA LED technology in your vehicle fleet! Save time and money, and be ahead of the pack in CO₂ reduction. See for yourself:

1. Sample calculation

The sample calculations are based on the following data: ª Garage labour costs per hour: € 50 ª Repair times worklights and beacons:

Replacement time worklights / beacons: 30 minutes (0.5 h), Changing light source on worklights/beacons: 15 minutes (0.25 h)

ª Average replacement rates worklights/beacons per vehicle (p.a.)

Experience has shown that light sources and products have the following replacement rates on an annual basis:Light sources: 2 x per year Work lights: 1 x per year, beacon lights: 1 x per year(assuming an average duration of use of 6 hours per day and without mechanical damage)

ª Number of work lights /beacons per vehicle: work lights: 2, beacons: 2

ª Average product costs:

The sample calculations below show the potential savings that can be achieved for the worklight and beacon product groups over various time periods. You'll be amazed by the savings available even to small fleets!

Halogen LED

Worklights 20 € 80 €

Beacon lights 60 € 120 €

Bulb 3 € –

168 | 169MUNICIPAL FLEET

2. Sample calculation (halogen)

For 1 vehicle with halogen worklights/beacons

A) Labour costs (per vehicle)Replacement costs worklight(1 work light x 0.5h x €50/h) 25 €

Replacement costs beacons(1 beacon x 0.5h x €50 /h) 25 €

Light source change on worklights (2 work lights x 0.25h x 2 changes per year x €50/h) 50 €

Light source change on beacons(1 beacon x 0.25 h x 2 changes per year x 50 €/h) 25 €

Total annual labor costs (per vehicle) 125 €

B) Material costs (per vehicle)Worklight costs(€ 20 product costs + € 12 light source costs) 32 €

Beacons costs(€ 60 product costs + € 6 light source costs) 66 €

Total annual material costs (per vehicle) 98 €

Total costs:

A) Labour costs 125 €

B) Material costs 98 €

Halogen worklights/beacons

Important:Recurring, annual costs per vehicle!

223 €

3. Sample calculation (LED)

For 1 vehicle with LED worklights/beacons

A) Labour costs (per vehicle)In the case of LED worklights and beacons, labour costs are incurred only when converting the existing vehicle fleet. You should specify the direct installation of HELLA LED products in new vehicles in order to benefit from the potential savings in full from the outset.

Replacement costs worklight(2 work lights x 0.5 h x €50/h) 50 €

Replacement costs beacons(1 beacon x 0.5 h x €50/h) 25 €

One-off total labour costs (per vehicle) 75 €

B) Procurement costs (per vehicle)LED worklights(2 work lights x € 80) 160 €

LED beacons(1 beacon x € 120) 120 €

One off procurement costs (per vehicle) 280 €

Total costs:


B) Procurement costs 280 €

LED worklights/beacons

Important: One-off costs per vehicle!

355 €

1. 2. 3. 4. 5. 6. 7. 8. Total

Halogen costs (€) per year 223 223 223 223 223 223 223 223 1.784 (€)

LED costs (€) per year 355 0 0 0 0 0 0 0 355 (€)

Maintenance cost savings per vehicle (€) per year

-132 223 223 223 223 223 223 223 1.429 (€)

The higher acquisition costs for LED products have paid dividends after just 24 months.

Comparison of total costs for halogen compared to LED over a vehicle service life of 8 years.

168 | 169

4. Fuel savings through the use of LED technology

Savings per vehicle per yearLight functions are activated on 200 days a year, 5 hours a day.

Halogen(12 V / 24 V)

LED

1 x beacons consumption 55 / 70 Watt 15 Watt

2 x work lights consumption 110 / 140 Watt 26 Watt

Total consumption 165 / 210 Watt 41 Watt

kWh per vehicle per year – savings(165 W - 41 W) x 5 hours x 200 days/1,000 (210 W - 41 W) x 5 hours x 200 days/1,000

124 / 169 kWh

Possible savings with a diesel engine

Degree of efficiency of a diesel engine 45 %

Degree of efficiency of generator (alternator) 80 %

Fuel value diesel1 litre of diesel generates 3.6 kWh electrical energy 10 kWh / liter

Diesel in litres – savings potential124 kWh/3.6 kWh169 kWh/3.6 kWh

34 litres (12 V)46 litres (24 V)

5. Savings potential for a fleet of 10 vehicles over 8 years

The following table applies the potential savings calculated above to a fleet of 10 vehicles over an 8 year period and shows just how much can be saved by choosing the right lighting from the right manufacturer.

The average vehicle is assumed to be driven for 200 days.

1. 2. 3. 4. 5. 6. 7. 8. Total

Costs for halogen (€) 2.230 2.230 2.230 2.230 2.230 2.230 2.230 2.230 17.840 (€)

Costs for LED (€) 3.550 0 0 0 0 0 0 0 3.500 (€)

Maintenance cost savings (€) -1.320 2.230 2.230 2.230 2.230 2.230 2.230 2.230 14.290 (€)

Fuel savings (l)340 340 340 340 340 340 340 340 2.720 (l / 12 V)420 420 420 420 420 420 420 420 3.360 (l / 24 V)

CO2 savings (kg)889 889 889 889 889 889 889 889 7.112 (kg /12 V)

1092 1092 1092 1092 1092 1092 1092 1092 8.736 (kg /24 V)

These non-binding figures are based on average values and general technical assumptions; they are provided purely as information for your support. We accept no liability for the accuracy of this data.

Conclusion:The results speak for LED by HELLA: Maintenance cost savings = € 14,290Fuel savings = 2,720 (litres/12 V) and 3,360 (litres/24 V) Reduction of CO2 emissions by 7.1 t (12 V) and 8.7 t (24 V)

These calculations can, of course, be applied to fleets of other sizes. If you are not convinced by these figures, just carry out the test and see for yourself, or contact us directly.

170 | 171MUNICIPAL FLEET

170 | 171

Waste collection vehicles

Enjoy the benefits of HELLA LED technology in your vehicle fleet! Save time and money, and be ahead of the pack in CO₂ reduction. See for yourself:

1. Sample calculation

The sample calculations are based on the following data: ª Garage labour costs per hour: € 50 ª Repair times worklights and beacons:

Replacement time worklights / beacons: 30 minutes (0.5 h), Changing light source on worklights/beacons: 15 minutes (0.25 h)

ª Average replacement rates worklights/beacons per vehicle (p.a.)

Experience has shown that light sources and products have the following replacement rates on an annual basis:Light sources: 2 x per year Work lights: 1 x per year, beacon lights: 1 x per year(assuming an average duration of use of 6 hours per day and without mechanical damage)

ª Number of work lights /beacons per vehicle: work lights: 2, beacons: 2

ª Average product costs:

The sample calculations below show the potential savings that can be achieved for the worklight and beacon product groups over various time periods. You'll be amazed by the savings available even to small fleets!

Halogen LED

Worklights 20 € 80 €

Beacon lights 60 € 120 €

Bulb 3 € –

172 | 173

2. Sample calculation (halogen)

For 1 vehicle with halogen worklights/beacons

A) Labour costs (per vehicle)Replacement costs worklight(1 work light x 0.5h x €50/h) 25 €

Replacement costs beacons(1 beacon x 0.5h x €50 /h) 25 €

Light source change on worklights (2 work lights x 0.25h x 2 changes per year x €50/h) 50 €

Light source change on beacons (2 beacons x 0.25h x 2 changes per year x € 50 / h) 50 €

Total annual labour costs (per vehicle) 150 €

B) Material costs (per vehicle)Worklight costs(€ 20 product costs + € 12 light source costs) 32 €

Beacons costs(€ 60 product costs + € 12 light source costs) 72 €

Total annual material costs (per vehicle) 104 €

Total costs:


B) Material costs 104 €

Halogen worklights/beacons

Important:Recurring, annual costs per vehicle!

254 €

3. Sample calculation (LED)

For 1 vehicle with LED worklights/beacons

A) Labour costs (per vehicle)In the case of LED worklights and beacons, labour costs are incurred only when converting the existing vehicle fleet. You should specify the direct installation of HELLA LED products in new vehicles in order to benefit from the potential savings in full from the outset.

Replacement costs worklight(2 work lights x 0.5 h x €50/h) 50 €

Replacement costs beacons(2 beacons x 0.5h x € 50 / h) 50 €

Total labour costs (per vehicle) 100 €

B) Procurement costs (per vehicle)LED worklights(2 work lights x € 80) 160 €

LED beacons(2 beacons x € 120) 240 €

One off procurement costs (per vehicle) 400 €

Total costs:


B) Procurement costs 400 €

LED worklights/beacons

Important: One-off costs per vehicle!

500 €

1. 2. 3. 4. 5. 6. 7. 8. Total

Halogen costs (€) per year 254 254 254 254 254 254 254 254 2.032

LED costs (€) per year 500 0 0 0 0 0 0 0 500

Maintenance cost savings per vehicle (€) per year

-246 254 254 254 254 254 254 254 1.532

The higher acquisition costs for LED products have paid dividends after just 24 months.

Comparison of total costs for halogen compared to LED over a vehicle service life of 8 years.

MUNICIPAL FLEET

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5. Savings potential for a fleet of 10 vehicles over 8 years

The following table applies the potential savings calculated above to a fleet of 10 vehicles over an 8 year period and shows just how much can be saved by choosing the right lighting from the right manufacturer.

The average vehicle is assumed to be driven for 200 days.

1. 2. 3. 4. 5. 6. 7. 8. Total

Costs for halogen (€) 2.540 2.540 2.540 2.540 2.540 2.540 2.540 2.540 20.320 (€)

Costs for LED (€) 5.000 0 0 0 0 0 0 0 5.000 (€)

Maintenance cost savings (€) -2.460 2.540 2.540 2.540 2.540 2.540 2.540 2.540 15.320 (€)

Fuel savings (l) 620 620 620 620 620 620 620 620 4.960 (l)

CO2 savings (kg) 1612 1612 1612 1612 1612 1612 1612 1612 12.896 (kg)

These non-binding figures are based on average values and general technical assumptions; they are provided purely as information for your support. We accept no liability for the correctness of this data.

Conclusion:The results speak for LED by HELLA: Maintenance cost savings = € 15,320 Fuel savings = 4,960 litresReduction of CO2 emissions by 12.8 t

These calculations can, of course, be applied to fleets of other sizes. If you are not convinced by these figures, just carry out the test and see for yourself, or contact us directly.

4. Fuel savings through the use of LED technology

Savings per vehicle per yearLight functions are activated on 200 days a year, 5 hours a day. Halogen (24 V) LED

2 x beacons consumption 140 Watt 30 Watt

2 x work lights consumption 140 Watt 26 Watt

Total consumption 280 Watt 56 Watt

kWh per vehicle per year – savings(280 W - 56 W) x 5 x 200 / 1.000 224 kWh

Possible savings with a diesel engine

Degree of efficiency of a diesel engine 45 %

Degree of efficiency of generator (alternator) 80 %

Fuel value diesel1 litre of diesel generates 3.6 kWh electrical energy 10 kWh / litre

Diesel in litres224 kWh / 3.6 kWh 62 litres (24 V)

ONLINE TOOLS

Website for municipal vehicles and special vehiclesInformative, compact, interactive. Here, you can find everything you need to know about products and technologies for municipal use.


Find the right product with ease

The purpose of our online information is to give you more ways to efficiently and conveniently identify the latest HELLA products and obtain important information about them. No matter what you are looking for, we are sure to have the right part in our range.

ª Brief information product sheets ª Product videos ª 3D animations ª Configuration tools for many applications ª Interactive apps for smartphones and tablets ª Comparisons of lighting technology ª Fitting recommendations ª Online catalogues

ELIVER – the light comparison toolThis online tool allows you to compare many HELLA work lights and beacons on the basis of their illumination in a realistic environment.

www.hella.com/eliver

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Installation video for BST LED front flasherFrom the functional test to the correct installation and wiring: In this video, you learn in a few minutes what is involved in the assembly of the HELLA BST front flasher. Our experts guide you step-by-step to success using clear and easy-to-understand descriptions.


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Shapeline configuration toolThe HELLA Shapeline online configuration tool turns you into a lighting designer: With a few clicks, make your own vehicle light design for the front, sides, and rear end – and see the result directly after, as applied convincingly to a car outline

www.hella.com/shapeline

HELLA YouTube channelIn addition to informative product and application videos, you can also find many helpful tips and advice on our comprehensive HELLA product range on the HELLA YouTube channel.

www.youtube.com/hellagroup

HELLA online catalogueHelps you in your search for vehicle-specific products. Regardless of where you are beginning your search, the search system helps you find the right solution very quickly.

www.hella.com/catalogue

The online universal parts catalogue also offers a quick and up-to-date overview of products in the categories of lighting, electrics and thermal management for a wide range of vehicles.

www.hella.com/upc

IP protection category

What does IP protection category mean?IP stands for International Protection. The IP protection categories are determined according to DIN 40 050, Part 9. The purpose of the standard is the exact definition of electrical vehicle equipment against the penetration of solid materials including dust and against water penetration. The different degrees of protection important for signalling systems are explained below.

Protective category IP 5K4KDust may only penetrate to such an extent that function and safety are not impaired. Water that is sprayed from any direction at increased pressure against the housing must not have any damaging effect: water pressure approx. 4 bar.

Features Description

Power consumption of LED lights Advantages of the LED:Generally, LED lamps need less power than bulb lighting. Savings of up to 90 % are possible, which also helps to reduce CO2.

Vehicle electrical system voltageDefines the power supply for the light. This can be 12 V, 24 V or a flexible voltage range for multi-voltage (8 – 33 V). Multi-voltage for the most flexibility: Requires fewer versions, but has more electronic components and is therefore more expensive.

Dust and water protection IPResistant to high-pressure jet cleaners.

International Protection (IP) gemäß DIN 40050 Teil 9. Specific definition for road vehicles. 5K = Dust protected.6K = Dustproof. 9K = Water resistance during high-pressure/steam cleaning.

Electronic circuitActive Basically, two different circuits are possible for LED lamps:

Active:LED current regulation by means of active electronics

Passive:Adjustment of a specific voltage range for the LED by means of a series resistor.Passive

Thermal managementActive Active:

Electronic power control of the LED in case of impermissible high ambient temperatures. This ensures the LEDs are protected against destruction caused by overheating.

Passive:Optimised layout of the components for even temperature distribution and spread.

Passive

Protection class IP 9KWater that is directed from high-pressure/steam-cleaning equipment onto the housing must not have any damaging effect: water pressure approx. 80 – 100 bar.

Protection class IP 6K7Dust must not penetrate. No water may penetrate, even if the device is submersed for some time. HELLA products meet the highest requirements and are ideally protected against all kinds of weather conditions.

Features Description

Indicator failure check according to ECE-R48Regulation according to ECE-R48:The driver must be informed if the indicator function fails. To remain legally compliant, this requirement must also be met for LED lights. This requirement is met by an integrated self-diagnostic unit on the PCB of the LED and an electrical pulse. Since the end of 2011, this HELLA failure check with a pulse has been ISO Standard: ISO 13207.

Bi-polarity of the lampEven if the connecting cable is attached with reverse polarity, the LED is still fully functional.

Reverse polarity protectionEven if the connecting cable is connected the wrong way round, there is still no danger for the electronics.

Overvoltage protectionSupplement to the electronics for protecting the LED against high voltage / current in the vehicle's electric system as per ISO 7637-2.

Approval for transport of dangerous goodsLight approved for transport of dangerous goods according to Hazardous Waste Road Directive (GGVS).

Beacon failure check (DIN 14630 – Blue)Beacons for preferential road use.

Automotive Electronic CouncilComponents qualified according to automotive standard.

Electromagnetic compatibilityElectromagnetic compatibility (EMC) tested and EC type approval issued.

ECE-R65ECE R65

+8°

-8°

Defines the light values, light distribution, and color location of beacons that are to be achieved. Only beacons that fulfill ECE-R65 can be used on public roads.

ECEProduct is licensed according to ECE guidelines.

HELLA KGaA Hueck & Co.Rixbecker Straße 7559552 Lippstadt, GermanyTel.: +49 2941 38-0Fax: +49 2941 38-7133Internet: www.hella.com

KG Knutsson AB19181 SollentunaTel. 08-923000Fax 08-923032Internet: www.kgk.se

HELLA, Inc.201 Kelly Drive P.O. Box 2665Peachtree City, GA 30269Toll Free: 1-877-224-3552Fax: 1-800-631-7575www.hellausa.com

© HELLA KGaA Hueck & Co., Lippstadt 9Z2 999 139-682 J01318/SCH/05.17/0.67Subject to technical and price modifications Printed in Germany


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