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Hella
Mining Catalogue
4th Edition

Hella Australia Pty Ltd
ABN 77 006 256 524
54 – 76 Southern Road
Mentone Victoria
Australia 3194
PO Box 89
Mentone Victoria
Australia 3194
P 03 9581 9333
F 03 9585 2654
E mining@ha.hella.com
W www.hella.com/mining
Customer Service:
P 03 9581 9299
F 03 9583 1838
P Techline 1800 061729
E custservice@ha.hella.com
Expert professional
advice from our
technical department
staffed with qualified
personnel
Product availability
and new product
updates
Customer-specific
lighting applications
engineering service
www.hella.com/mining
International Regions
Africa
Hella Automotive
South Africa (Pty) Ltd
1 Fitzpatrick Street
Uitenhage
South Africa 6232
Phone: +27 (0)11-538-7530
Asia
Hella Asia Singapore Pte Ltd
Regional Headquarters
Asia Pacific
Independent Aftermarket
2 International Business Park
#02 – 15
The Strategy
Singapore 609930
DID: +65 6854 7343
USA
Hella Mining LLC
1250 Lamollie Hwy
Suite 414
Elko Nevada 89801
Fax: (775) 738-7450
Phone: (775) 738-7441
Canada
Hella, Inc.
201 Kelly Drive
Peachtree City, GA 30269
Phone: (770) 626-2209
Fax: (770) 631-7575
Mexico & South America
Hellamex, S.A. de C.V.
Proten No. 50
Parque Industrial Naucalpan
Estado de Mexico, Mexico
C.P. 53489
Phone: (52) 55-5321-1300
New Zealand
Hella-New Zealand Limited
PO Box 51427
81–83 Ben Lomond Crescent
Pakuranga, Auckland 1706
Telephone: (09) 577 0000
Fax: (09) 576 2476
Internet: www.hella.co.nz
Europe
Hella KGaA Hueck & Co.
Rixbecker Straße 75
59552 Lippstadt/Germany
Internet: www.hella.com
Telephone: +49 (0) 29 41/38-0
Fax: +49 (0) 29 41/38-71 33
The illustrations, information and specifications presented and referred to in this catalogue were correct at the date of
printing. However Hella reserves the right, subject to all applicable laws, at any time, at its discretion and without notice,
to discontinue or change the specifications or design of any product referred to herein.
The data and suggested applications are given as a general guide only and users should independently evaluate the
suitability of each product for any particular application.
© 2010 Hella Australia Pty Ltd. All rights reserved. Release Date November 2010

Hella Centre of Excellence – Mining 3
Mining Centre of Excellence
Hella Australia manufactures automotive
lighting equipment, and plastic
mouldings and accessories, and employs
approximately 500 people. Its facility in
Mentone, Victoria, designs, develops and
manufactures a range of lighting products
including headlamps, reflectors, lenses,
signal lamps, interior and exterior lighting,
and auxiliary lamps and mouldings.
Hella products are developed and built using
state-of-the-art technology and are used on some
of the most advanced cars in the world.
The Hella manufacturing plant employs injection
moulding machines, polycarbonate lens moulding
machines, thermoset moulding machines,
automated paint processes, hot foil stamping,
aluminium metallising and lacquering facilities.
The Hella Centre of Excellence – Mining, at Hella Australia
head office in Mentone Victoria, was launched in 2002 to
drive a global mine lighting program focussed on the unique
requirements of mining. The key factors in the Australian location
of this important business are:
Over 1280 mines operate under the most stringent safety
requirements, so Australia is the best place to develop and
prove products for the global mining industry
Hella Australia is equipped with highly advanced production
and distribution facilities
Hella Australia has its own full design and development
facilities that include: NATA registered Photometric
Laboratory, Chemical Analysis Laboratory Facilities,
and some of the most advanced environmental and
physical test simulation facilities available anywhere.
Hella continues to develop, prove and market innovative
products based on worldwide leadership in advanced lighting
technology – to demonstrably improve end user profitability in
mining applications. This is achieved through products that offer:
Greater safety
Lower operating cost
Greater productivity
Predictable service
Better value
Hella mining products are backed by the renowned global Hella
quality guarantee, and service and distribution network.
Project Argon charts the extremes
Developing lighting equipment that will go the distance in
mines requires a very clear understanding of their operating
systems and specific environmental conditions.
At Hella, we don’t guess, we measure.
Hella Australia initiated
ARGON, a research
project to collect
detailed data from a
diverse range of mines
and machines.
A suite of robust
sensors with
integrated data
loggers is mounted on
mining plant and machines to record operating conditions, with
the equipment working as normal.
After the sensors are recovered from the machines, their
data is downloaded for analysis and used as the basis of
product design and test specifications able to match extreme
mining environments.
Statement of Warranty
Hella Mining products are covered by a one year warranty which
covers faults in material or workmanship only and provided that
the product is used for its intended purpose.
Important Note
Only products specifically identified as ECE or SAE compliant
are approved for use on public roads, when installed and
operated as required by local regulation on approved vehicles.
The responsibility for correct selection, fitment and operation to
meet local regulations is that of the vehicle operator.

4 How to read this catalogue
Key to symbols: Hella Product Features Configuration: Electrical: Protection/Hazard Ratings: Standards Compliance:
MULTI
VOLT
Multivolt
H3
Lamp type
24V
Rated voltage
IP6K
IP rating
Electrical Compliance
MUSTADD
MustADD ®
DT
Connection type
3W
Power consumption/load
Transient spike protection
ECE
APPROVED
Public road traffic
compliance type
DRACO
DRACO ®
1.4Kg
Mass
200G
Rated shock resistance
MULTI
FLASH
MultiFLASH ®
Hella Mining Part Numbers
12V H3
24V H3
Wide Beam HM1524WB HM1526WB
Narrow Beam HM1524NB HM1526NB
Long Range HM1524LR HM1526LR
MINING WORK LAMPS
Page number
Product section
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
28
UltraBeamFF Halogen
Work Lamp – 12/24V
UltraBeam FF Halogen, available with Wide, Narrow
and Long Range Beams, are superior, compact
heavy-duty work lamps for use on mining machinery,
and suitable for both 24V and 12V electrical
systems.
Product dimensions
Alternative view
Alternative model
Spare parts or
options
112 94
101 84
127
24
87 50
Front View, Long Range
Narrow Beam
As part of our ongoing
development the Long Range
addition to the UltraBeam FF
range applies our most recent
advances in free-form (FF) reflector
technology. With a clear lens
and the popular H3 Halogen
globe it’s a compact long range
lamp for applications where the
performance of a Xenon light is not
required.
The very compact optics deliver
excellent lighting under continuous
use in the extreme environmental
conditions encountered in mining
applications. Electrical connection
is via integrated DT connector.
The UltraBeam FF clear lens
long range optical insert is a
modular assembly of a precision
die-cast specular reflector with
integral lamp holder, permanently
assembled to a corrosion resistant
hardened clear glass lens, for high
efficiency and perfect focus. The
new lens long range optical insert
is available as a spare part and
is 100% compatible with older
UltraBeam FF H3 work lamps to
enable simple on site maintenance
and perfect retrofitting.
In common with the all
Hella UltraBeam FF work
lamps, the basic version
of the patented MustADD ®
filter is included so the
optical system remains
virtually dust free over
the product life,
in the adverse
atmospheres
typically encountered
in mining.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant. The
UltraBeam FF features integral
DRACO ® dampers in the bracket
system to reduce the intensity of
shock and vibration.
The UltraBeam FF family is based
on very compact lamp housings
moulded from a highly corrosion
resistant, heavy-duty polymer
body.
A lens retaining ring enables easy
routine service access from the
front, while high temperature O-ring
seals ensure effective sealing.
Long Range Lens
Product features:
Powerful long range
and wide spread
illumination
AMP or DT electrical
connection
Robust polymer body
Stainless steel
mounting bracket
Draco ® suspension
MustADD ® multi
air-filter
Specifications:
Temperature Range
-40°C to +105°C
Mounting
Single bolt with tilt
adjustment for upright,
side or pendant
mounting on horizontal
or vertical surfaces.
Stainless steel bracket
and screws included
Free-form (FF) reflector
for powerful long range
illumination
Components tested
over a –40°C to
+105ºC temperature
range
IP6K7
O-ring seals
Clear protective covers
available
Protection
Sealed against dust
and moisture to IP6K7.
Shock resistant to 50G.
HM8158
HM8158AMBER
Spare parts or
options listing
Product feature
symbols (see above
for key)
MUSTADD
DRACO
H3, H9,
H11
IP6K7 50G 12/24V
DT &
AMP
70W
MAX
0.8Kg
Spare Parts:
HM8158
Clear Protective Cover
HM8158AMBER
Clear Protective Cover
- Amber
9.1533.03
Long Range Insert
9.HMUBHNB Insert –
Narrow Optic
9.HUMBHWB
Insert – Wide Optic
YC2470
H3 Globe, 24V 70W
YC1255
H3 Globe, 12V 55W

Contents
5
WORK LAMPS 6
8 Power Beam 1000 15 DuraLED Magnetic Base 28 UltraBeam FF Halogen
9 Power Beam 2000 16 AS500FF Xenon 30 HydroLUX
10 Megabeam 18 AS200FF Xenon 32 AS200 FF Halogen
11 Module 70 LED 20 UltraBeam FF X-PowerPack 34 Oval 100 FF Halogen
12 LED Task Lamps 22 UltraBeam FF Xenon 36 Module 70 Halogen
13 DuraLED 700 Lumen 24 Oval 100 FF Xenon
14 DuraLED 1000 Lumen 26 AS500FF Halogen
BEACONS 38
40 DuraRAY Phase II 48 OptiRAY 54 DuraLED M High Intensity
42 UltraRAY-R Twin 50 OptiRAY E 56 PulseRAY KLX
44 UltraRAY-R “Rotating” 52 MiniRAY 58 PulseRAY E67
46 UltraRAY 53 NaviLED M
SIGNAL LAMPS 60
62 DuraLED SAE 64 DuraLED M Combi 66 DuraLED Marker
63 DuraLED ECE 65 DuraLED MSIP 67 LED Daytime Running Lamp
ACCESSORIES 68
70 LED Buggy Whip 74 NumiLED 80 Weatherproof Relay
71 Remote Jump Start Terminals 75 NumiLED Pro 80 Self-Amalgamating Tape
71 Battery Master Lockout Switch 76 IR Dual Camera System 81 DT Connectors
72 Screened Extension Cables 77 Quad Screen IR Kit
73 HD Screened Ext. Cables 78 AccuPAX
84 EuroLED Touch M 86 SpotLED 89 MiniThinLED
85 CargoLED 88 FlexSPOT
INTERIOR LIGHTING 82
92 MotoVOX 94 RetroVOX Compression Driver
93 RetroVOX Self Adjusting 95 RetroVOX Broadband
HORNS & ALARMS 90
98 EziPAK DT Connector Kit 102 EziPAK Heat Shrink Kit 106 Super Seal Connector
100 EziPAK Double Crimp Kit 104 EziPAK Intelligent Fuse Kit 107 PowerPAK
SERVICE TOOLS 96
110 AC/DC Transformers 113 LED Pilot Lamps 116 MagCode
111 Power Connectors 114 Heavy Duty Circuit Breakers
112 LED Rocker Switches 115 Thermal Circuit Breakers
ELECTRICAL 108
120 H1, H2 122 H4 124 Xenon
121 H3 123 H7, H9, H11
GLOBES 118
126 Technical Information 145 Part Number Index
TECHNICAL 126

Work Lamps 7
WORK LAMPS
8 Power Beam 1000
9 Power Beam 2000
10 Megabeam
11 Module 70 LED
12 LED Task Lamps
13 DuraLED 700 Lumen
14 DuraLED 1000 Lumen
15 DuraLED Magnetic Base
16 AS500FF Xenon
18 AS200FF Xenon
20 UltraBeam FF X-PowerPack
22 UltraBeam FF Xenon
24 Oval 100 FF Xenon
26 AS500FF Halogen
28 UltraBeam FF Halogen
30 HydroLUX
32 AS200FF Halogen
34 Oval 100 FF Halogen
36 Module 70 Halogen

Power Beam 1000
LED Work Lamp
HMPB100
LED WORK LAMPS
WORK LAMPS
8
Power Beam 1000
LED Work Lamp – Multivolt 9-33V DC
As an addition to the Hella LED work lamp
range, the Power Beam 1000 has been
developed as a compact high-powered
illuminating source.
114.5
142
112
62
96
By combining 6 high-powered
LEDs into a compact fully sealed
die cast housing, the Power Beam
1000 provides a respectable
850 Lumen output to provide
close range illumination where
physical constraints on mining
machinery exist.
A rated operating temperature from
-40 to +50°C and an expected
lifespan of over 130 times that
of a halogen bulb, in addition to
excellent ingress protection, make
the Power Beam 1000 suitable
for the most unforgiving mining
environments.
With a low power consumption of
18 Watts, the lamp places minimal
strain on the vehicle’s electrical
system while the quality electronics
provide Multivolt operation over
a range of voltage levels from
9 to 33V DC. The Power Beam
1000 also
features
reverse
polarity
protection,
and
overheating
protection,
which turns the
light off when the
integrated thermal sensor
is triggered.
The integrated DT Plug allows
simple installation and waterproof
connectivity, and the heavy-duty
stainless steel bracket allows for a
wide variety of mounting options.
The low EMC signature ensures the
lamp does not interfere with any
critical safety equipment such as
radios or other electrical devices.
Product features
Operating voltage:
Multivolt 9-32 V DC
16 high power LEDs
Power consumption:
18 W
Light output 850 lm
Colour temperature
6500°K
Low EMC Signature
(CISPR25 class 5)
Ingress Protection
IP6K7 and IP6K9K
Lifespan up to 130
times of a halogen bulb
Connection: integrated
DT plug
Polarity protected
LED fail bridge
High-temperature
protection
Environment temp
-40 to +50°C
Power Beam 1000 LED 2.0m high at 10°
1 LUX 39m
MULTI
VOLT
LED
0.6 Kg
9 to 33
V DC
18W
IP6K7 IP6K9K 200G

Power Beam 2000
LED Work Lamp
HMPB200
LED WORK LAMPS
Power Beam 2000
LED Work Lamp – Multivolt 9-33V DC
As an addition to the Hella LED work lamp
range, the Power Beam 2000 has been
developed as a compact high-powered
illuminating source.
9
WORK LAMPS
By combining
16 highpowered
LEDs into a
compact fully
sealed die cast
housing, the Power Beam 2000
is able to achieve an outstanding
2200 Lumen output to provide
close range illumination where
physical constraints on mining
machinery exist.
With a low power consumption
of 43 Watts, the lamp places
minimal strain on the vehicle’s
electrical system, while the quality
electronics provide Multivolt
operation over a range of voltage
levels from 9 to 33V DC. The Power
Beam 2000 also features reverse
polarity protection, and overheating
protection, which turns the light off
when the integrated thermal sensor
is triggered.
144.5
114
103
107
Product features
Operating voltage:
Multivolt 9-33 V DC
16 high power LEDs
Power consumption:
43 W
Light output 2200 lm
Colour temperature
6000°K
Low EMC Signature
(CISPR25 class 5)
Environment temp
-40 to +50°C
Die cast aluminium
housing, bracket made
of stainless steel
Ingress Protection
IP6K7 and IP6K9K
Lifespan up to 130
times of a halogen bulb
Connection: integrated
cable
Polarity protected
LED fail bridge
High-temperature
protection
With a rated operating temperature
from -40 to +50°C and an expected
lifespan of over 130 times that
of a halogen bulb, in addition to
excellent ingress protection make
the Power Beam 2000 suitable
for the most unforgiving mining
environments.
The Power Beam 1000 comes
pre-wired with 1.8 metres of
electrical cable, allowing quick
and easy installation.
The low EMC signature (class 5)
ensures the lamp does not interfere
with any critical safety equipment
such as radios.
MULTI
VOLT
LED
1.4Kg
9 to 33
V DC
43W
IP6K7 IP6K9K 200G

MegaBeam
LED Work Lamp
LED Work Lamp DT
HM1539LED
HM1539LDD
MINING WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
10
MegaBeam
LED Work Lamp – Multivolt 12-24V
Hella MegaBeam LED is a compact close range
work lamp for use on special vehicles and mining
machines where high vibration or extreme cold
makes the use of conventional work lamps
impractical. High intensity white LEDs provide low
power illumination in an ultra reliable design.
Front View
Clear cover to be ordered separately
Solid-state LED light sources
enabled the design of a fitand-forget,
completely sealed
and waterproof work lamp that
needs no service. The very long
service life of the MegaBeam
LED, combined with no lighting
loss due to internal dirt build-up,
enables the work lamps to deliver
reliable lighting under extremely
tough operating conditions. Low
power consumption and Multivolt
operation features pioneered by
Hella LED products are integral to
the product design.
Brilliant Free-Form reflector optics,
combined with a clear lens,
optimize the light distribution of
the high intensity white LEDs in
the MegaBeam LED work lamp
to provide homogenous large
area illumination with maximum
efficiency. Maximum service
life and light output of the high
intensity LEDs is ensured through
using the die cast aluminium
body as a massive heat sink; its
ergonomic oval shape creates an
efficient and compact unit, easy to
fit into confined spaces.
Fully encapsulated
Multivolt drive circuitry
delivers consistent
illumination from 12-24V
DC – even under severe
voltage fluctuations and
low battery voltage.
Comprehensive
protection against
reverse polarity, highvoltage
spikes and
over-voltage, ensures
reliable operation.
Safe and reliable electrical
connection is facilitated via a 2m
length of highly flexible double
insulated cable, terminated with
either a DT connector or bare wire
ends.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant.
Product features
Yellow ring marks
product as mining
specification version
Electrical connection:
2m double insulated
cable with bare wire
ends or short length
with DT connector
Stainless steel
mounting bracket
IP5K9K
Multivolt 12V DC to
24V DC
Die cast aluminium
body
Multi stage anticorrosion
powder coat
High visibility yellow
identification ring
source array
Fully sealed “Fit and
Forget” design
Pre-wired with multi
strand double insulated
cable
Spike protected to
+500 volts
Over voltage protected
to +200 volts
Reverse polarity
protected to
-500 volts
Power consumption 7W
200G shock impulse
resistant
-40ºC to +50ºC
temperature range
CE compliant
Clear glass lens
High intensity LED light
Spare Parts & Options
HM8161
Clear Protective Cover
MULTI
VOLT
LED
DT &
AMP
0.8Kg
IP6K9
200G
12 to 24
V DC
7W

Module 70 LED
LED Work Lamp DT
HM70LEDD
MINING WORK LAMPS
Module 70 LED
Work Lamp – Multivolt 12-24V
11
WORK LAMPS
Module 70 LED is an ultra compact LED work lamp
for use on mining support function vehicles or
in applications where mounting space is limited.
The lamp provides uniform close-range illumination
with 12V or 24V electrical systems. High intensity
white LEDs provide energy efficient illumination in
an ultra reliable design.
Product features
4 high-performance
LEDs
Warm white light output
(colour temperature
6500°K)
200mm double
insulated cable harness
with DT connector
Low power
consumption
Multivolt 12-24V DC
Specifications
Voltage
Multivolt 12-24V DC
Power Consumption
15W
Mounting
Stainless steel pedestal
bracket for upright, side
or pendant mounting.
Cable
200mm double
insulated cable harness
with DT connector.
High-sheen free-form
(FF) reflector
Aluminium die cast
housing
Modern clear glass lens
Resistant to shock and
vibration
IP6K7 & IP6K9K
Reverse polarity and
over
voltage protected
Stainless steel
mounting bracket
Temperature Range
-40°C to +50°C
Protection
Reverse polarity and
Transient Voltage
Suppressor (TVS).
Fully sealed against
dust and moisture to
IP6K7 and IP6K9K.
Shock resistant to
200G.
Module 70 LED work
lamps utilise advanced
materials in a unitary
design that directly bonds a
cast aluminium free-form (FF)
reflector, clear glass lens and high
temperature polymer housing into
a low mass, efficient and very
compact work lamp. Solid-state
high-performance white LED light
sources enabled the design of a
‘fit & forget’, completely sealed
work lamp that requires no service.
The very long service life of
the Module 70 LED, combined
with no lighting loss due to
internal dirt build-up, enables
the work lamps to deliver reliable
lighting under extremely tough
operating conditions. Low power
consumption and Multivolt
operation features, which have
been pioneered by Hella LED
products, are integral to the
product design.
Brilliant free-form (FF) reflector
optics combined with a clear lens
optimise the light distribution of
the high intensity white LEDs in
the Module 70 LED work lamp
to provide and even illumination
with maximum efficiency, reduced
scatter losses and improved beam
control. Maximum service life and
light output of the high intensity
LEDs is ensured through using
the die cast aluminium body as a
massive heat sink; its ergonomic
Module 70 LED 2.0m high at 10°
shape creates an efficient and
compact unit, easy to fit into
confined spaces.
Module 70 LED work lamps
have been tested to withstand
extremely high levels of vibration
and mechanical shock, and
are highly suitable for use in
applications where extreme cold
and mechanical stress make
other work lamps unsuitable.
The low power consumption and
compact size also renders Module
70 LED work lamps suitable for
use inside confined spaces, with
portable power packs, on new
generation small equipment based
on recreational vehicles, battery
powered vehicles and to illuminate
the equipment bays on site service
vehicles and large machinery.
The Module 70 LED features a
rotating base as standard, which
allows vertical adjustment of +
48° to -115°, and 360° rotation
adjustment. The supplied stainless
steel hardware is non-resonant
and highly corrosion resistant. Safe
and reliable electrical connection
is facilitated via 200mm length of
highly flexible double insulated
cable, terminated with a DT
connector. Optional pipe mount
adaptors with and without rotating
adjustment is available. Additional
variants of the Module 70 LED are
available on special request.
83
111
M10
Front view
HM70PR
Ø15-28
52
105
83
HM70PI
75
Spare Parts & Options
HM70PR
Pipe mount tube
attachment (rotating)
HM70PI
Pipe mount tube
attachment
9.HM70BR
Stainless steel bracket
1 LUX 37m
MULTI
VOLT
IP6K7
LED
200G
DT
12 to 24
V DC
0.4Kg
15W

LED Task Lamp
Narrow Beam
Pencil Beam
Wide Beam
HM1535NB
HM1535PB
HM1535WB
LED TASK LAMPS
WORK LAMPS12
LED Task Lamp
On mine sites visibility is paramount to mine safety.
Hella has just launched a low power LED Task Lamp that
provides extra safety through enhanced visibility, at
a fraction of the power consumption of
halogen or HID light fittings.
136 49
53
42
Hella LED Task Lamps are
designed to provide an illuminating
light source in a compact, low
power draw package for various
applications where low profile
fitting and even illumination is
required. The lights are sealed to
withstand high-pressure washing
and require no maintenance (“fit
and forget”).
The lower power usage and
no-maintenance requirement, make
these lamps a sound investment
in enhanced mine safety. The lens
is manufactured from Swiss made
Grilamid ® Optical Nylon which
provides superior resistance to UV
and to a wide range of chemicals,
as well
as high
impact
strength
enabling
the lamp
to survive the
highly demanding environmental
conditions of today’s mining.
The new Hella Task Lamps are
suitable for upright or pendant
mounting and supplied with
universal stainless steel mounting
brackets. They have multiple
applications, which include area
illumination around and inside
the vehicle.
Product features
Multivolt (9-33V DC)
Equipped with
12 highly efficient LEDs
rated at 240 Lumens
Ultra long life ‘Fit and
Forget’
Low power
consumption

DuraLed ® 700 Lumen White LED Service Lamp
Wide Beam
HM15700WB
Narrow Beam
HM15700NB
Pencil Beam
HM15700PB
MINING LED SERVICE LAMPS
®
DuraLed
Hella has developed a new range of universal,
high intensity and ultra energy efficient
DuraLed ® LED Service Lamps offering the
industry benchmark highest efficacy for a variety
of heavy-duty mine lighting applications.
700 Lumen
White LED Service Lamp Multivolt 9-33V DC
13
WORK LAMPS
Product features
Industry benchmark
highest efficacy – 36
LEDs rated to a total of
700 lumen per lamp
Multivolt 9-33V DC
Power consumption

DuraLed ® 1000 Lumen White LED Service Lamp
Wide Beam
HM1550WB
MINING LED SERVICE LAMPS
WORK LAMPS
14
®
DuraLed
1000 Lumen
White LED Service Lamp Multivolt 9-33V DC
Hella has developed a new range of universal, high intensity
and ultra energy efficient DuraLed ® LED Service
Lamps offering the industry benchmark
highest efficacy for a variety of heavy-duty
mine lighting applications.
222
193
34
96
LED lighting offers a number
of decisive advantages over
conventional globe technology that
are beneficial for mining work area
lighting. The new Mining DuraLed ®
High Efficacy LED Service Lamps
consume as little as 9 watts of
power for minimal strain on both
alternator and battery.
In addition to significantly reduced
current draw, the highly efficient,
low temperature LED circuit design
ensures ultra long service life and
extremely low degradation
of performance.
Equipped with precision optics and
the most powerful LEDs available
to date, DuraLed ® High Efficacy
LED Service Lamps provide
exceptional white light output
and optimum light distribution for
significantly improved work safety
and reduced fatigue.
DuraLed ® High Efficacy LED
Service Lamps also offer superior
functional safety and operating
reliability. Unlike Halogen globes,
LEDs are
resistant to
shock and
vibration
and last a
minimum of
10,000 hours,
eliminating the risk of sudden light
failure during
lamp operation.
The lens is manufactured from
ultra-durable Grilamid ® nylon, a
revolutionary high-performance
clear polyamide developed and
manufactured in Switzerland for
extreme impact, UV, chemical and
stress resistance.
DuraLed ® High Efficacy LED
Service Lamps are fully sealed
against dust and moisture ingress
and available in a range of output
intensities and beam patterns:
narrow, pencil and spread beam, to
suit every individual mine lighting
requirement.
Product features
Industry benchmark
highest efficacy - 50
LEDs rated to a total of
1000 lumen per lamp
Multivolt 9-33V DC
Power consumption
< 12W
Ultra durable Grilamid ®
nylon lens for extreme
impact, UV, chemical
and stress resistance
Efficient, low
temperature LED circuit
design ensures ultra
long
life and low degradation
of performance
Wide beam precision
optic for optimum light
distribution
Intense white light
output provides
enhanced work safety
and reduced fatigue
Pre-wired with 2.5
metres connecting
cable
Reverse polarity, spike
and over voltage
protection
Fully sealed to IP6K6
and IP6K7
Resistant to vibration
and shock
EMC compliant
2-hole surface mount
(screw caps and
mounting bushes
included)
DuraLed 1000 Lumen Wide Beam 2.5m high at 0°
5
4
3
2
1
0
5 5
MULTI
VOLT
LED
DT &
BARE
WIRE
0.7Kg
IP6K7
200G
9 to 33
V DC
12W

DuraLed ® 1000 Lumen Magnetic Base
With DT connector
With 12V MagCode connector
With 24V MagCode connector
With CIG/DIN plug
HM1550DT
HM1550MAG-12
HM1550MAG-24
HM1550CIG
MINING LED WORK LAMPS
®
DuraLed
Magnetic Base
1000 Lumen Work Lamp – Multivolt 9-33V DC
Complementing the DuraLed ® range is
the new heavy duty magnetic base
service lamp which uses ultra powerful
neodymium magnets and a
flexible curly-cord cable.
15
WORK LAMPS
The compact 1 metre
extension cable extends
the range of the light
to 8 metres from the
power source.
222
34
96
Product features
1m coiled cord with
8-metre extension
potential.
1000 Lumen Wide
Beam Multivolt
DuraLed
Ideal for use in
confined spaces, such
as engine bays and
under machines
Low power
consumption

AS500 ® FF Xenon Trunnion Pedestal
Wide Beam Multivolt DT HM1512WB HM1513WB
Narrow Beam Multivolt DT HM1512NB HM1513NB
HID WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
16
®
AS500 FF Xenon
Heavy Duty Work Lamp
AS500 ® FF Xenon is a compact and highly versatile, ultra
heavy-duty work lamp for use on mining machinery,
suitable for 24V and 12V electrical systems.
Optional
Pedestal
Bracket
Shown with Pedestal Mount
MUSTADD
170
120
56
202
DRACO
IP6K7 50G 12/24V
Trunnion Bracket
D2S
135
141
Clear cover to be ordered separately
DT
41W
126
122
135
19
2.8Kg
26
M10
175
127
Good lighting is essential to create a
safe and productive work area where
machine operators can clearly see
their work environment and identify
hazards in time to take the required
action. The AS500 FF is engineered
to deliver excellent lighting
under continuous use in extreme
environmental conditions.
AS500 FF lamps’ Hella Free-Form
optics deliver a homogenous
spread of light, so operators can
see comfortably for long periods.
Its light distribution ensures there
are no sharp transitions from light
to dark in the operator’s visual field,
to significantly reduce adaptation
related eye fatigue and stress.
72
The optical modules comprise
a precision-moulded specular
reflector, permanently assembled
to a corrosion-resistant hardened
glass refractor lens and machined
lamp holder, ensuring perfect
focus. A choice of wide and narrow
asymmetric beam types is available.
The integrated, patented Hella
MustADD ® filter ensures optimum
optical performance is maintained
over product life in the adverse
atmospheres typically encountered
in mining. (See technical section for
more information.)
35W Xenon gas discharge lighting
systems pioneered by Hella have set
the standard across the world for
optimum visual acuity and comfort
for professional work lamp users.
The integral electronic ballast fitted
to the AS500 FF range is specifically
designed for continuous operation in
mining applications. (See technical
section for more information.)
Safe and reliable electrical
connection is via a short length of
highly flexible double insulated cable,
terminated with DT connectors.
An ergonomic heavyduty
cast aluminium
body with an integral
“non-snag” adjustment
handle is the basis of
all AS500 FF lights. A
robust lens retaining
ring with captive M4
Allen bolts enables rapid
routine service access from the
front, while high temperature O-ring
seals ensure effective sealing. A UV
resistant multi-stage powder coating
process ensures optimal corrosion
protection.
Accurate and stable aiming in
high vibration environments in all
assembly positions is vital. The
AS500 FF offers a range of secure
mounting options for almost any
requirement. The standard trunnion
bracket can be fitted to the body in
six different mounting positions; all
of which locate the axis of rotation
in the centre of gravity to minimize
mechanical stress. Four M6 Allen
bolts in arced slots and fixed pivot
points ensure that the aiming angle
can be locked securely. Secondary
mounting holes in the base of the
AS500 FF enable direct mounting
onto equipment, or the use of an
optional pedestal bracket. The heavy
gauge stainless steel hardware is
non-resonant and highly corrosion
resistant. Integral DRACO ® dampers
eliminate all metal-to-metal contact
between the lamp and bracket
to reduce shock and vibration
transmission. (See technical section
for more information.)
Sustainable use of resources is
ensured through the modular
system design, so users can reuse,
repair, or recycle lights into
new applications. Ballasts can be
replaced. Both beam types and
mounting bracket positions and
options can be changed. Halogen
models can also be upgraded to
Xenon and other future options.
Product features
Modular die cast
aluminium alloy body
Integral “non-snag”
handle
Multiple mounting
options with aiming
angles
Stainless steel trunnion
bracket with quad bolt
fastening
Draco ® suspension
Free-Form wide and
narrow beam optics
MustADD ® filter
Captive Allen bolts
Double insulated
silicone supply cable
with DT plug
Replaceable
encapsulated ballast
Spare Parts & Options
HM8164
Clear Protective Cover
AS500
9.HMAPEDL
Pedestal Mounting
Bracket Assembly
9.HM151TRN
Trunnion Mounting
Bracket Assembly
9.HMAWHKD
Cable harness kit AS500
Shown with
Trunnion Bracket
O-ring seals
Components tested
over a –40ºC to
+105ºC temperature
range
High efficiency & long
life D2S 35W Xenon
light
Multivolt 8-32V DC
IP6K7K
200G shock resistant
ballast
50G shock resistant
lamp
CE compliant
Protective clear covers
available
Consumable spares
interchangeable with
Hella AS200FF ® Xenon
range
9.HM15WB
Insert – Wide Optic –
AS200/500 GDL
9.HM15NB
Insert – Narrow Optic –
AS200/500 GDL
9.HM151BAL
Multivolt Ballast
XN4000
Globe – Xenarc D2S

17
WORK LAMPS
Optional
Pedestal
Bracket
Multi-adjustable trunnion bracket ensures accurate and stable aiming in a high vibration environment in all
assembly positions. Bracket locates the axis of rotation in the centre of gravity
AS500 FF Xenon Narrow Beam
AS500 FF Xenon Wide Beam
30
Peak 79 LUX
30
Peak 120 LUX
30
0
30
60
90 120 150
30
0
30
60
90 120 150

AS200 FF Xenon
Wide Beam Multivolt DT
Narrow Beam Multivolt DT
HM1504WB
HM1504NB
MINING WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
18
AS200FF Xenon
Heavy Duty Work Lamp
AS200 FF Xenon is a compact and highly
versatile, heavy-duty work lamp for use on
mining machinery; suitable for 24V and 12V
electrical systems.
160
163
50
191
62
54
6.5
69.5
27
Front View
Clear cover to be ordered separately
150
Good lighting is essential to create
a safe and productive work area
where machine operators can
clearly see their work environment
and identify any hazards in time
to take the required action.
The AS200 FF is engineered to
deliver excellent lighting in the
extreme environmental conditions
encountered in mining applications.
AS200 FF lamps employ Hella
Free-Form optics to deliver
an homogenous spread of
light enabling operators to see
comfortably for long periods of
time. The light distribution of the
beam ensures an absence of sharp
transitions from light to dark in
the operator’s visual field, thus
significantly reducing adaptationrelated
eye fatigue and stress.
The optical modules comprise
of a precision-moulded specular
reflector, permanently assembled
to a corrosion-resistant hardened
glass refractor lens and machined
lamp holder, ensuring perfect
focus of each unit. A choice of
wide and narrow asymmetric beam
types is available to suit different
applications. (See technical section
for more information on Hella’s
applications engineering service.)
Hella integrated a basic version
of the patented MustADD ® filter
into the AS200 FF to ensure the
optical system remains virtually
dust free over the product’s life
in the adverse atmospheres
typically encountered in mining.
(See technical section for more
information.)
35W Xenon gas discharge lighting
systems pioneered by Hella have
set the standard across the world
for delivering
optimum visual
acuity and comfort
to professional work
lamp users. The integral
electronic ballast fitted
to the AS200 FF
range is specifically
designed for continuous
operation in mining applications.
(See technical section for more
information.)
Safe and reliable electrical
connection is facilitated via a short
length of highly flexible double
insulated cable, terminated with DT
connectors.
AS200 FF lights use a highly
corrosion-resistant, heavy-duty
steel reinforced, UV resistant
polymer body, featuring an integral
non-snag handle for adjustment
and handling. A lens-retaining
ring enables easy routine service
access from the front, while high
temperature O-ring seals ensure
effective sealing.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant.
The AS200 FF features integral
DRACO ® dampers in the bracket
system to reduce the intensity of
shock and vibration communicated
to the light. (See technical section
for more information.)
Sustainable use of resources and
high ownership value is ensured
through the modular system
design, enabling AS200 FF users
to repair, or recycle their lights into
new applications. Ballasts can be
replaced, and beam-spread types
can be changed.
Product features
Steel-reinforced UVresistant
polymer body
Integral “non-snag”
handle
Stainless steel bracket
Draco ® suspension
Free-Form wide and
narrow beam optics
MustADD ® filter
Double insulated
silicone supply cable
with DT connector
Replaceable
encapsulated Xenon
ballast
O-ring seals
Spare Parts & Options
HM8154
Clear Protective Cover
HM8154AMBER
Clear protective Cover
– Amber
9.HM15WB
Insert – Wide Optic –
AS200/500 GDL
Components tested
over a –40ºC to
+105ºC temp. range
High efficiency & long
life D2S 35W Xenon
light
Multivolt 8-32V DC
IP6K7
200G shock resistant
ballast
50G shock resistant
lamp
CE compliant
Protective clear covers
available
Consumable spares
interchangeable with
Hella AS500FF Xenon
range
9.HM15NB
Insert – Narrow Optic –
AS200/500 GDL
9.HM151BAL
Multivolt Ballast
XN4000
Globe – Xenarc D2S
MUSTADD
DRACO
D2S
DT
1.8Kg
IP6K7 50G 12/24V
41W

19
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
30
AS200 FF Xenon Narrow Beam
Peak 79 LUX
30
AS200 FF Xenon Wide Beam
Peak 120 LUX
30
0
30
60
90 120 150
30
0
30
60
90 120 150

UltraBeam FF X-PowerPack Xenon 12V DC 24V DC
Wide Beam Pendant Mount HMUBXHWBD-12V HMUBXHWBD-24V
Narrow Beam Pendant Mount HMUBXSWBD-12V HMUBXSWBD-24V
MINING WORK LAMPS
MOBILE WORK LAMPS
EQUIPMENT
LIGHTING
20
UltraBeam FF X-PowerPack
Xenon Work Lamp
UltraBeam FF X-PowerPack is a very compact,
heavy-duty Xenon work lamp for use on small
mining machinery. It is suitable for 24V and 12V
electrical systems.
112 136
101 84
143
24
87 73
Pedestal Mount
Pendant Mount
HM8160
Good lighting is essential to create
a safe and productive work area
where machine operators can
clearly see their work environment
and identify any hazards in time to
take the required action. The 35W
Xenon discharge lighting systems
pioneered by Hella have set the
standard across the world for
delivering excellent visual acuity
and comfort to professional work
lamp users.
Hella Free-Form optics enables
the very compact UltraBeam
FF X-PowerPack to deliver a
homogenous spread of light,
enabling operators to see
comfortably for long periods of
time. The light distribution of the
beam ensures an absence of sharp
transitions from light to dark in
the operator’s visual field, thus
significantly reducing adaptationrelated
eye fatigue and stress.
The optical module comprises of
a precision Free Form reflector,
permanently assembled to a
corrosion resistant hardened glass
lens and machined lamp holder,
ensuring high efficiency and
perfect focus of each unit after
lamp changes.
The UltraBeam FF X-PowerPack is
constructed around a new ballast
module for applications where
space is at a premium. The integral
electronic ballast used by the
UltraBeam FF
X-PowerPack is a
“clean sheet” design
optimized for continuous
operation in mining applications,
with particular attention paid to
limit the impact of Electromagnetic
interference.
Hella integrated a basic version
of the patented MustADD ®
filter into the UltraBeamFF
X-PowerPack to ensure
the optical system remains
virtually dust free over product
life in the adverse atmospheres
typically encountered
in mining.
The optical assembly of the very
compact lamp housing is moulded
from a highly corrosion-resistant
heavy-duty UV resistant polymer;
the rear body and ballast housing
is die cast aluminium ensuring
optimal heat dissipation.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant.
Integral DRACO ® dampers in
the bracket system reduce the
intensity of shock and vibration
communicated to the light. The
UltraBeam FF X-PowerPack is
available in both pedestal mount
and pendant mount configurations.
Product features
In-built 5th generation
electronic ballast with
aluminium heatsink
Compact design
Fast, easy installation
High-sheen free-form
(FF) reflector
High efficiency D1S
35W Xenon Globe
Hardened glass lens
Wide Beam Optics
Specifications
Voltage
12 and 24V DC options
Power Consumption
35W Globe (42W total)
Mounting
Stainless steel pedestal
bracket for 4-point
mount and additional
stainless steel mounting
foot for single bolt mount
included.
Cable
Pre-wired with 0.2 metre
sheathed cable and
DT plug.
Supplied with stainless
steel pedestal bracket
and additional
mounting foot
Compatible with
existing UltraBeamFF
mounting brackets
12V DC and 24V DC
variants
IP6K7 and IP6K9K
200g shock resistant
(ballast/housing)
Clear protective cover
included
Temperature Range
-40°C to +80°C
Protection
Fully sealed against dust
and moisture to IP6K9K.
Shock resistant to 200G
(ballast/housing) and
30g (lamp).
EMC Approval
EMC Class 5 according
to CISPR25 for
absolutely
disturbance free
radio and wireless
transmission.
MUSTADD DRACO
DT
D1S
IP6K7 IP6K9K 200G 12/24V
1.26Kg
42W
Spare Parts & Options
HM8160
Clear Protective Cover
(included)
HMXN4001
D1S Xenon Globe

21
WORK LAMPS
Integral Xenon Ballast
(non-replaceable)
D1S Xenon Globe
HMXN4001
Stainless Steel Bracket
Wide Beam Optic
(not serviceable)

UltraBeam FF Xenon 8-32V DC
Wide Beam DT Plug
HM1522WB
MINING WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
22
UltraBeam FFXenon
Heavy Duty Work Lamp – 24V DC
UltraBeam FF Xenon is a superior, compact,
heavy-duty work lamp for use on mining
machinery. It is suitable for 12 to 24V
electrical systems.
101 84
127
24
112
350
93
24
101 84
140
Front View
Clear cover to be ordered separately
43
140
120
The UltraBeam FF utilizes an
350
93
43
externally 24 located ballast to enable
the use of Xenon lighting where
space is at a premium.
Good lighting is essential to 120 create
a safe and productive work area
where machine operators can
clearly see their work environment
and identify any hazards in time to
take the required action.
Hella Free-Form optics enables
the very compact UltraBeam
FF lamps employed to deliver
an homogenous spread of
light, enabling operators to see
comfortably for long periods of
time. The light distribution of the
beam ensures an absence of sharp
transitions from light to dark in
the operator’s visual field, thus
significantly reducing adaptationrelated
eye fatigue and stress.
The optical modules comprise
of a precision die cast specular
reflector, permanently assembled
to a corrosion-resistant hardened
glass refractor lens and machined
lamp holder, ensuring high
efficiency and perfect focus of
each unit.
Hella integrated a basic version
of the patented MustADD ® filter
into the UltraBeam FF to ensure
the optical system remains
virtually dust free over product
life in the adverse atmospheres
typically encountered in mining.
(See technical section for more
information.)
35W Xenon discharge
lighting systems
pioneered by Hella have
set the standard across
the world for delivering
excellent visual acuity and
comfort to professional
work lamp users. The
integral electronic
ballast used by
the UltraBeam FF is
designed specifically for
continuous operation in mining
applications. Safe and reliable
electrical connection between the
ballast and lamp housing is via
a short length of highly flexible
double insulated high voltage
cable, with a permanently fixed
safety lamp socket. (See technical
section for more information.)
The very compact lamp housing is
moulded from a highly corrosionresistant
heavy-duty, UV resistant
polymer body. A lens-retaining
ring enables easy routine service
access from the front, while high
temperature O-ring seals ensure
effective sealing.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant. The
UltraBeam FF features integral
DRACO ® dampers in the bracket
system to reduce the intensity of
shock and vibration communicated
to the light. (See technical section
for more information.)
Product features
UV resistant polymer
body
Stainless steel bracket
Draco ® suspension
Free-Form beam optics
MustADD ® filter
DT plug
Replaceable
encapsulated Xenon
ballast
O-ring seals
Components tested
over a –40ºC to
+105ºC temperature
range
Spare Parts & Options
HM8157
Clear Protective Cover
HM8157AMBER
Amber Protective Cover
High efficiency & long
life D2S 35W Xenon
light
8-32V DC
operationIP6K5K
200G shock resistant
ballast
50G shock resistant
lamp
CE compliant
Protective clear covers
available
9.HMUBXWB
Reflector & Optic Insert
9.HM151BAL
Multivolt Ballast
MUSTADD
DRACO
D2S
DT
2.0Kg
IP6K5 50G 12/24V
41W

23
WORK LAMPS
30
UltraBeam FF Xenon Wide Beam 2.5m high at 5°
30
0 20 40 60

OVAL 100 FF Xenon
Wide Beam DT
Narrow Beam DT
HMPVX35WBD
HMPVX35NBD
MINING WORK LAMPS
MOBILE WORK LAMPS
EQUIPMENT
LIGHTING
24
OVAL 100 FF Xenon
Heavy Duty Work Lamp – 24V DC
OVAL100 FF Xenon is a low profile,
heavy-duty work lamp for use on mining
machinery, suitable for 24V and 12V
electrical systems.
192mm
Front View
160mm
135mm
Good lighting is essential to create
a safe and productive work area
where machine operators can
clearly see their work environment
and identify any hazards in time
to take the required action. The
OVAL100 FF is engineered to
deliver excellent lighting in the
extreme environmental conditions
encountered in mining applications.
OVAL100 FF lamps employ Hella
Free-Form optics to deliver an
homogenous spread of light,
enabling operators to see
comfortably for long periods of
time. The light distribution of the
beam ensures an absence of sharp
transitions from light to dark in
the operator’s visual field, thus
significantly reducing adaptationrelated
eye fatigue and stress.
The optical modules comprise
of a precision-moulded specular
reflector, permanently assembled
to a corrosion-resistant hardened
glass refractor lens and machined
lamp holder, ensuring perfect
focus of each unit. A choice of
wide and narrow asymmetric beam
types is available to suit different
applications.
Hella integrated a basic version
of the patented MustADD ® filter
into the OVAL100 FF to ensure the
optical system remains virtually
dust free over the product’s life
in the adverse atmospheres
typically encountered in mining.
(See technical section for more
information.)
35W Xenon gas discharge lighting
systems pioneered by Hella, have
set the standard across the world
for delivering optimum visual
acuity and comfort to professional
work lamp users. The compact
electronic
ballast fitted
internally to the
OVAL100 FF range
operates a D1S
lamp with integral
ignitor.
Safe and reliable
electrical connection
is facilitated via a short
length of highly flexible double
insulated cable, terminated with
either DT or AMP connectors; other
connector options can be supplied
as special orders.
OVAL100 FF lights use a highly
corrosion-resistant, heavy-duty,
UV-resistant polymer body with a
lens-retaining ring to enable easy
routine service access from the
front, while high temperature O-ring
seals ensure effective sealing.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant.
OVAL100 FF features integral
DRACO ® dampers in the bracket
system to reduce the intensity of
shock and vibration communicated
to the light. (See technical section
for more information.)
Sustainable use of resources and
high ownership value is ensured
through the modular system
design, enabling OVAL100 FF
users to repair, or recycle their
lights into new applications.
Ballasts can be replaced or
exchanged to suit different supply
voltage values and beam-spread
types can be changed.
Product features
UV-resistant polymer
body
Low profile Oval shape
Stainless steel bracket
Draco ® suspension
Free-Form wide and
narrow beam optics
MustADD ® filter
Double insulated
silicone supply cable
with DT plug
Replaceable Xenon
ballast
Spare Parts & Options
9.HMPUXWB
Insert – Wide Optic
– GDL
9.HMPUXNB
Insert – Narrow Optic
– GDL
O-ring seals
Components tested
over a –40°C to
+105ºC temperature
range
High efficiency & long
life D1S 35W Xenon
light
12V DC & 24V DC
options
IP65
50G shock resistant
lamp
CE compliant
9.HMPUXB24
Ballast – OVAL100 FF
HMXN4001
Globe – Xenarc D1S
MUSTADD
DRACO
D1S
DT
1.5Kg
IP65 50G 12/24V
41W

25
WORK LAMPS
Peak
Peak ★
Oval 100FF 84 Lux Xenon Narrow Beam 2.5m high at 5°
Oval 100FF Xenon 82 Lux Wide Beam 2.5m high at 5°
30
30
30
0 20 40 60
30
0 20 40 60

AS500 ® FF Halogen H3 Trunnion Pedestal
Wide Beam DT HM1510WB HM1511WB
Narrow Beam DT HM1510NB HM1511NB
HALOGEN WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
26
AS500
®
FF Halogen
Heavy Duty Work Lamp
AS500 ® FF Xenon is a compact and highly versatile, ultra
heavy-duty work lamp for use on mining machinery,
suitable for 24V and 12V electrical systems.
Optional
Pedestal
Bracket
Shown with Pedestal Mount
Clear cover to be ordered separately
MUSTADD
170
120
56
202
DRACO
H3
IP6K7 50G 12/24V
Trunnion Bracket
135
141
DT
70W
126
122
135
19
2.2Kg
26
M10
175
127
Good lighting is essential to create a
safe and productive work area where
machine operators can clearly see
their work environment and identify
hazards in time to take the required
action. The AS500 FF is engineered
to deliver excellent lighting
under continuous use in extreme
environmental conditions.
AS500 FF lamps’ Hella Free-Form
optics deliver a homogenous
spread of light, so operators can
see comfortably for long periods.
Its light distribution ensures there
are no sharp transitions from light
to dark in the operator’s visual field,
to significantly reduce adaptation
related eye fatigue and stress.
72
The optical modules comprise
a precision-moulded specular
reflector, permanently assembled
to a corrosion-resistant hardened
glass refractor lens and machined
lamp holder, ensuring perfect
focus. A choice of wide and narrow
asymmetric beam types is available.
The integrated, patented Hella
MustADD ® filter ensures optimum
optical performance is maintained
over product life in the adverse
atmospheres typically encountered
in mining. (See technical section for
more information.)
Safe and reliable electrical
connection is via a short length of
highly flexible double insulated cable,
terminated with DT connectors.
An ergonomic heavy-duty cast
aluminium body with an integral
“non-snag” adjustment handle is
the basis of all AS500 FF lights. A
robust lens retaining ring with captive
M4 Allen bolts enables rapid routine
service access from the front, while
high temperature O-ring seals ensure
effective sealing. A UV
resistant multi-stage
powder coating process
ensures optimal
corrosion protection.
Accurate and stable
aiming in high vibration
environments in all
assembly positions is vital.
The AS500 FF offers a range of
secure mounting options for almost
any requirement. The standard
trunnion bracket can be fitted to
the body in six different mounting
positions; all of which locate the axis
of rotation in the centre of gravity to
minimize mechanical stress. Four
M6 Allen bolts in arced slots and
fixed pivot points ensure that the
aiming angle can be locked securely.
Secondary mounting holes in the
base of the AS500 FF enable direct
mounting onto equipment, or the use
of an optional pedestal bracket. The
heavy gauge stainless steel hardware
is non-resonant and highly corrosion
resistant. Integral DRACO ® dampers
eliminate all metal-to-metal contact
between the lamp and bracket
to reduce shock and vibration
transmission. (See technical section
for more information.)
Sustainable use of resources is
ensured through the modular
system design, so users can reuse,
repair, or recycle lights into
new applications. Ballasts can
be replaced or exchanged to suit
different voltages. Both beam types
and mounting bracket positions and
options can be changed. Halogen
models can also be upgraded to
Xenon and other future options.
Product features
Modular die cast
aluminium alloy body
Integral “non-snag”
handle
Multiple mounting
options
Stainless steel trunnion
bracket with quad bolt
fastening
Draco ® suspension
Free-Form wide and
narrow beam optics
MustADD ® filter
Captive Allen bolts
Double insulated
silicone supply cable
with DT plug
O-ring seals
Spare Parts & Options
HM8164
Clear Protective Cover
AS500
9.HMAPEDL
Pedestal Mounting
Bracket Assembly
9.HM151TRN
Trunnion Mounting
Bracket Assembly
Shown with
Trunnion Bracket
Components tested
over a –40ºC to
+105ºC temperature
range
H3 Halogen 70W 24V
supplied
H3 Halogen 55W 12V
can be fitted
High efficiency & long
life D2S 35W Xenon
light
12V DC & 24V DC
options
IP6K7K
200G shock resistant
lamp
Protective clear covers
available
Consumable spares
interchangeable with
Hella AS200FF ® Xenon
range
9.HMAWHKD
Cable harness kit
AS500
9.HM15WB
Insert – Wide Optic –
AS200/500 H3
9.HM15NB
Insert – Narrow Optic
– AS200/500 H3
YC2470
Globe – H3 24V
YC1255LL
Globe – H3 12V

27
WORK LAMPS
Optional
Pedestal
Bracket
Trunnion Bracket
Multi-adjustable trunnion bracket ensures accurate and stable aiming in a high vibration environment in all
assembly positions. Bracket locates the axis of rotation in the centre of gravity
20
AS500 FF Halogen Narrow Beam
2.5m high at 5°
20
AS500 FF Halogen Wide Beam
2.5m high at 5°
Peak
79 Lux
Peak ★
120 Lux
20
0 20 40 60 80
100
20
0 20 40 60 80
100

UltraBeam FF Halogen
Wide Beam
Narrow Beam
Long Range
24V H3
HM1526WB
HM1526NB
HM1526LR
MINING WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
28
UltraBeamFF Halogen
Work Lamp – 12/24V
UltraBeam FF Halogen, available with Wide, Narrow
and Long Range Beams, are superior, compact
heavy-duty work lamps for use on mining machinery,
and suitable for both 24V and 12V electrical
systems.
112 94
101 84
127
24
87 50
Front View, Long Range
Narrow Beam
As part of our ongoing
development the Long Range
addition to the UltraBeam FF
range applies our most recent
advances in free-form (FF) reflector
technology. With a clear lens
and the popular H3 Halogen
globe it’s a compact long range
lamp for applications where the
performance of a Xenon light is not
required.
The very compact optics deliver
excellent lighting under continuous
use in the extreme environmental
conditions encountered in mining
applications. Electrical connection
is via integrated DT connector.
The UltraBeam FF clear lens
long range optical insert is a
modular assembly of a precision
die-cast specular reflector with
integral lamp holder, permanently
assembled to a corrosion resistant
hardened clear glass lens, for high
efficiency and perfect focus. The
new lens long range optical insert
is available as a spare part and
is 100% compatible with older
UltraBeam FF H3 work lamps to
enable simple on site maintenance
and perfect retrofitting.
In common with the all
Hella UltraBeam FF work
lamps, the basic version
of the patented MustADD ®
filter is included so the
optical system remains
virtually dust free over
the product life,
in the adverse
atmospheres
typically encountered
in mining.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant. The
UltraBeam FF features integral
DRACO ® dampers in the bracket
system to reduce the intensity of
shock and vibration.
The UltraBeam FF family is based
on very compact lamp housings
moulded from a highly corrosion
resistant, heavy-duty polymer
body.
A lens retaining ring enables easy
routine service access from the
front, while high temperature O-ring
seals ensure effective sealing.
Long Range Lens
Product features:
Powerful long range
and wide spread
illumination
DT electrical
connection
Robust polymer body
Stainless steel
mounting bracket
Draco ® suspension
MustADD ® multi
air-filter
Specifications:
Temperature Range
-40°C to +105°C
Mounting
Single bolt with tilt
adjustment for upright,
side or pendant
mounting on horizontal
or vertical surfaces.
Stainless steel bracket
and screws included
Free-form (FF) reflector
for powerful long range
illumination
Components tested
over a –40°C to
+105ºC temperature
range
IP6K7
Clear protective covers
available
H3 Halogen 70W 24V
supplied
H3 Halogen 55W 12V
can be fitted
Protection
Sealed against dust
and moisture to IP6K7.
Shock resistant to 50G.
HM8158
HM8158AMBER
MUSTADD
DRACO
H3, H9,
H11
IP6K7 50G 12/24V
DT
70W
MAX
0.8Kg
Spare Parts:
HM8158
Clear Protective Cover
HM8158AMBER
Clear Protective Cover
- Amber
9.1533.03
Insert – Long Range
Optic
9.HMUBHNB
Insert – Narrow Optic
9.HMUBHWB
Insert – Wide Optic
YC2470
H3 Globe, 24V 70W
YC1255LL
H3 Globe, 12V 55W

29
WORK LAMPS
Narrow Beam Optic
Long Range Optic
UltraBeam FF Long Range 2.5m high at 5°
20
Peak ★
44 Lux
1 LUX 68m
20
0 20 40 60 80
100
UltraBeam FF Narrow 2.5m high at 5°
30
UltraBeam FF Wide 2.5m high at 5°
30
PEAK 44 LUX
PEAK 42 LUX
30
0 20 40 60
30
0 20 40 60

HydroLUX ® Submersible Driving Lamp 12/24V
Mining Yellow H3 Spread Beam HM1358
Mining Yellow H1 Pencil Beam HM1374D
Mining Yellow H1 Spread Beam HM1375D
Mining Yellow H4 RHD Driving Beam
Mining Yellow H4 LHD Driving Beam
HM1002
HM1002ECE
MINING WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
30
®
HydroLUX
Submersible Driving Lamp 12/24V
HydroLUX ® ultra-heavy duty submersible driving
lamps feature advanced engineering, focused
on the requirements of mining and emergency
vehicles that operate on and off public roads.
Suitable for 24V and 12V electrical systems.
185 145
Shown with H3 Insert
HM1002 (with H4 Insert)
Clear cover to be ordered separately
MUSTADD
H1, H3,
H4
BARE
WIRE
3.2Kg
198
Good lighting is essential to create
a safe and productive illumination
of the road, enabling drivers
to clearly see and identify any
hazards in time to take the required
action. The HydroLUX is not only
engineered to deliver excellent
lighting but also to withstand
regular submersion or continuous
under water operation, as well
as the extreme environmental
conditions encountered in mining
applications.
Hella’s patented isobaric system
prevents water ingress into the
optical module, whilst enabling
easy service access and reliable
long-term operation of the seals
under mining conditions. To ensure
correct operation of the isobaric
system and perfect focus, each
optical module unit comprises
a precision-moulded specular
reflector, with integral lamp
holder permanently assembled
to a corrosion resistant hardened
clear lens seated into a die cast
alloy frame. Each HydroLUX is
individually pressure tested and
certified. (See technical section for
more information.)
HydroLUX lamps are available with
Free-Form spread and pencil beam
auxiliary driving beam distribution
types, in addition to a wide range
of ECE and SAE approved high/
low beam versions for use as
headlamps in left and right hand
public road traffic.
All HydroLUX optical modules
feature a fully integrated, patented
Hella MustADD ® filter to ensure
that optimum optical performance
is maintained over the product’s
life in the adverse atmospheres
typically encountered in mining.
(See technical section for more
information.)
An ergonomic,
heavy-duty
cast aluminium
body with an
integral “non-snag”
adjustment handle
is the basis of all
HydroLUX lights. A
robust lens retaining
ring with captive M4 Allen
bolts enables rapid routine
service access from the front,
while high temperature O-ring
seals ensure effective sealing. A
UV resistant multi-stage powder
coating process ensures optimal
corrosion protection.
Accurate and stable aiming in
a high vibration environment is
a vital aspect of safe and legal
road lighting. The non-resonant
and corrosion resistant cast alloy
bracket fitted to the body shape
minimizes mechanical stress,
and a rubber damper between
the lamp and bracket eliminates
metal-to-metal contact to reduce
the intensity of shock and vibration
communicated to the light. Two M6
Allen bolts ensures that the critical
vertical aiming can be locked
securely, and a M8 bolt in the
base enables direct mounting onto
equipment.
Safe and reliable electrical
connection is facilitated via a 2m
length of highly flexible double
insulated cable, factory sealed
into the body, eliminating the
requirement for water-proof
connections at the lamp. Other
connector options can be supplied
as special orders.
Product features
Wide selection of optics
available
Die cast alloy body and
bracket
MustADD ® filter
Double insulated
silicone supply cable
O-ring seals
H1, H3 and H4 versions
available
Suitable for 12V or 24V
globes (24V supplied)
Spare Parts & Options
8151
Clear Protective Cover
HM9.1374.08
Mounting Bracket
Assembly
HM9.1374HD.01
Pencil Beam Insert
Assembly (H1 Version)
IP6K9K
50G shock resistant
lamp
ECE and SAE compliant
options
Right and left hand
traffic options
Protective clear covers
available
HM9.1375HD.01
Spread Beam Insert
Assembly (H1 Version)
9.HM1002ECE.01
Insert HM1002ECE (LHD,
H4 ECE Version)
9.HM1002.01
Insert HM1002 (RHD, H4
Version)
9.HM1385.05
Insert HM1358 (H3
Version)
IP6K9K 50G 12/24V 100W
MAX
ECE/
ADR
compliant

31
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
Note: Spread Beam Lamp is
ECE compliant with
12V/55W or 24V/70W globe.
Pencil Beam Recorded with single lamp. Distance in metres.
1 LUX .5 LUX
Spread Beam Recorded with single lamp. Distance in metres.
Front View

AS200 FF Halogen with AMP plug with DT Plug
Wide Beam HMASH70WBA HMASH70WBD
Narrow Beam HMASH70NBA HMASH70NBD
MINING WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
32
AS200FF Halogen
Heavy Duty Work Lamp – 12/24V
AS200 FF Halogen is a compact and highly
versatile heavy-duty work lamp for use on
mining machinery; suitable for 24V and
12V electrical systems.
137
Front View
160 160
Good lighting is essential to create
a safe and productive work area
where machine operators can
clearly see their work environment
and identify any hazards in time
to take the required action.
The AS200 FF is engineered to
deliver excellent lighting in the
extreme environmental conditions
encountered in mining applications.
AS200 FF lamps employ Hella
Free-Form optics to deliver an
homogenous spread of light,
enabling operators to see
comfortably for long periods of
time. The light distribution of the
beam ensures an absence of sharp
transitions from light to dark in
the operator’s visual field, thus
significantly reducing adaptationrelated
eye fatigue and stress.
The optical modules comprise
of a precision-moulded specular
reflector, permanently assembled
to a corrosion-resistant hardened
glass refractor lens and lamp
holder, ensuring perfect focus
of each unit. A choice of wide
and narrow asymmetric beam
types is available to suit different
applications. (See technical section
for more information on Hella’s
applications engineering service.)
Hella integrated a basic version
of the patented MustADD ® filter
into the AS200 FF to ensure the
optical system remains virtually
dust free over the product’s life
in the adverse atmospheres
typically encountered in mining.
(See technical section for more
information.)
Safe and
reliable electrical
connection is
facilitated via a
short length of
highly flexible double
insulated cable,
terminated with
either DT or AMP
connectors; other
connector options can
be supplied as
special orders.
AS200 FF lights use a highly
corrosion resistant heavy-duty,
steel reinforced, UV-resistant
polymer body, featuring an integral
non-snag handle for adjustment
and handling. A lens-retaining
ring enables easy routine service
access from the front while high
temperature O-ring seals ensure
effective sealing.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant.
The AS200 FF features integral
DRACO ® dampers in the bracket
system to reduce the intensity of
shock and vibration communicated
to the light. (See technical section
for more information.)
Sustainable use of resources and
high ownership value is ensured
through the modular system
design, enabling AS200 FF users
to repair, or recycle their lights into
new applications. Ballasts can
be replaced or exchanged to suit
different supply voltage values and
beam-spread types can
be changed.
Product features
AUV resistant polymer
body
Integral “non-snag”
handle
Stainless steel bracket
Draco ® suspension
Free-Form wide and
narrow beam optics
MustADD ® filter
Double insulated
silicone supply cable
with DT or AMP plug
O-ring seals
Spare Parts & Options
HM8156
Clear Protective Cover
AS200 H3
HM8156 AMBER
Amber Protective
Cover AS200 H3
Components tested
over a –40ºC to
+105ºC temperature
range
H3 Halogen 70W 24V
supplied
H3 Halogen 55W 12V
can be fitted
IP6K5K
50G shock resistant
lamp
Protective clear covers
available
Consumable spares
interchangeable
with Hella AS500 FF
Halogen range
9.HM15WB
Insert – Wide Optic
9.HM15NB
Insert – Narrow Optic
YC2470
Globe – H3 24V
YC1255LL
Globe – H3 12V
MUSTADD
DRACO
H3
DT &
AMP
0.8Kg
IP6K5 50G 12/24V
70W

33
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
20
AS200 FF Halogen Narrow Beam
2.5m high at 5°
20
AS200 FF Halogen Wide Beam
2.5m high at 5°
20
0 20 40 60 80
100
20
0 20 40 60 80
100

Oval 100 FF Halogen Double Beam with AMP plug with DT Plug
Wide Beam HMPV270WBA HMPV270WBD
Narrow Beam HMPV270NBA HMPV270NBD
MINING WORK LAMPS
MOBILE WORK LAMPS
EQUIPMENT
LIGHTING
34
OVAL 100 FF Halogen
Double Beam Work Lamp – 24V DC
OVAL100 FF Halogen is a low profile twin beam,
heavy-duty work lamp for use on mining machinery.
It is suitable for 24V and 12V electrical systems.
Narrow Beam model – front view
Clear cover to be ordered separately
The OVAL100 FF is engineered
to deliver excellent lighting in the
extreme environmental conditions
encountered in mining applications.
OVAL100 FF lights employ an
advanced version of the Hellapioneered
twin beam Free-Form
optics to deliver an homogenous
spread of light, enabling people to
see comfortably for long periods
of time. The light distribution of
the beam is engineered to ensure
minimum light spill and an absence
of sharp transitions from light
to dark in the operator’s visual
field, thus significantly reducing
adaptation-related eye fatigue
and stress.
The twin beam optical modules
comprise of a high precision
cast alloy specular reflector,
permanently assembled to a
corrosion-resistant hardened glass
refractor lens and lamp holder,
ensuring perfect focus of each
unit. A choice of wide and narrow
asymmetric beam types is available
to suit different applications.
(See technical section for more
information on Hella’s applications
engineering service.)
Hella integrated a basic version
of the patented MustADD ® filter
into the OVAL100 FF to ensure
the optical system remains
virtually dust free over product
life in the adverse atmospheres
typically encountered in mining.
(See technical section for more
information.)
Safe and
reliable
electrical
connection is
facilitated via a
short length of highly
flexible double insulated
cable, terminated with
either DT or AMP
connectors; other
connector options can
be supplied as
special orders.
OVAL100 FF lights use a highly
corrosion-resistant, heavy-duty,
UV-resistant polymer body, with a
lens-retaining ring to enable easy
routine service access from the
front, while high temperature O-ring
seals ensure effective sealing.
The supplied stainless steel
mounting hardware is non-resonant
and highly corrosion resistant.
The OVAL 100 FF features integral
DRACO ® dampers in the bracket
system to reduce the intensity of
shock and vibration communicated
to the light. (See technical section
for more information.)
Sustainable use of resources and
high ownership value is ensured
through the modular system
design, enabling OVAL100 FF
users to repair, or recycle their
lights into new applications.
Ballasts can be replaced or
exchanged to suit different supply
voltage values and beam-spread
types can be changed.
Product features
UV resistant polymer
body
Low profile Oval shape
Individual lamp
switching
Stainless steel bracket
Draco ® suspension
Free-Form wide and
narrow beam optics
MustADD ® filter
Spare Parts & Options
HM8159
Clear Protective Cover
HM8159AMBER
Amber Protective Cover
9.HMPU2NB
Insert – Narrow Optic –
OVAL100 DB
Wide Beam model
Double insulated
silicone supply cable
with DT or AMP plug
O-ring seals
H3 Halogen 70W 24V
supplied
H3 Halogen 55W 12V
can be fitted
IP6K5K
50G shock resistant
lamp
Protective clear covers
available
9.HMPU2WB
Insert – Wide Optic –
OVAL100 WB
YC2470
Globe H3 – 24V
YC1255LL
Globe H3 – 12V
MUSTADD
DRACO
H3
DT &
AMP
1.0Kg
IP6K5K 50G 12/24V
70W

35
WORK LAMPS
30
Peak ★
Oval 10050 FF Lux Halogen Narrow Beam
2.5m high at 5°
30
Peak
Oval 100 FF Halogen 45 Wide Lux Beam
2.5m high at 5°
30
0 20 40 60 80
100
30
0 20 40 60 80
100

Modul 70 Halogen 12V H9 24V H3
Wide Beam HM70H9WB-12V HM70H3WB-24V
Narrow Beam HM70H9NB-12V HM70H3NB-24V
MINING WORK LAMPS
MOBILE WORK LAMPS EQUIPMENT
LIGHTING
36
Modul 70 Halogen
Work Lamp
Hella Modul 70 is an ultra-compact Halogen
work lamp for use on mining support function
vehicles or in applications where space is very
limited. The lamp provides close-range illumination
or long-range illumination with 12V or
24V electrical systems.
Modul 70 utilizes advanced Hella
production and materials in a
unitary design that directly bonds a
cast aluminium Free-Form reflector,
lamp holder, clear glass lens and
high temperature polymer housing
into a low mass, efficient and very
compact work lamp.
Direct access to the globe
without the use of a tool
enables rapid routine service
access. High temperature O-ring
seals integral to the H9 globe,
and a protective rubber
cap for H3 variants, ensure
effective sealing.
Front view
H3
H9
The brilliant Free-Form optics and
clear lens of the Modul 70 reduce
scatter losses and improve beam
control. Designed specifically for
use with the new generation of high
performance Halogen globes, the
H9 (12V only) model is excellent
for applications where high levels
of light may be required for short
periods but the cost of Xenon
cannot be justified. H3 variants of
the Modul 70 are also available
for less demanding applications.
A choice of wide and narrow
asymmetric beam types is available
to suit different applications.
(See technical section for more
information on Hella’s applications
engineering service.)
A rotating base in addition to
the elevation allows vertical
adjustment of + 48° to -115°,
and 360° rotation adjustment. The
supplied stainless steel hardware is
non-resonant and highly corrosion
resistant.
Safe and reliable electrical
connection is facilitated via a
200mm length of highly flexible
double insulated cable, terminated
with a DT connector. Other
connector options can be supplied
as special orders.
Additional variants of the Modul 70
are available on special request.
Product features
Free-Form wide and
narrow beam optics
Clear lens “brilliant”
appearance
Die cast aluminium
reflector
Tool less globe access
Impact resistant
housing
50G shock resistant
lamp
ROHS compliant
Electrical connection:
200mm double
insulated cable
harness, terminated
with DT connector;
other terminations
available on special
request
Stainless steel
mounting bracket
IP5K9K
H9 12V 65W Halogen
globe included
H3 24V 70W Halogen
globe included
HM70PR
HM70PI
Yellow mounting
bracket denotes
product as mining
specification version
9.HM70WH
Spare Parts & Options
HM70PR
Pipe mount tube
attachment for rotating
HM70PI
Pipe mount tube
attachment
9.HM70BR
Bracket Stainless steel
Modul 70
9.HM70DC
Dust Cap H3 Modul 70
CF1265
Globe H9 – 12V
9.HM70WH
Wiring harness H9, 2m
YC2470
Globe H3 – 24V
MULTI
VOLT
H3, H9
DT
0.5Kg
IP5K9
50G
12/24V 70W
max

12V H9
Halogen Globe
37
WORK LAMPS
24V H3
Halogen Globe
Peak ★
84 Lux
Peak ★
82 Lux
Modul 70 Halogen Narrow Beam H9 12V
20
2.5m high at 5°
20
Modul 70 Halogen Wide Beam H9 12V
2.5m high at 5°
20
0 20 40 60 80
100
20
0 20 40 60 80
100
Modul 70 Halogen Narrow Beam H3 24V
20
2.5m high at 5°
20
Modul 70 Halogen Wide Beam H3 24V
2.5m high at 5°
20
0 20 40 60 80
100
20
0 20 40 60 80
100

39
BEACONSBeacons
40 DuraRAY Phase II
42 UltraRAY-R Twin
44 UltraRAY-R “Rotating”
46 UltraRAY
48 OptiRAY
50 OptiRAY E
52 MiniRAY
53 NaviLED M
54 DuraLED M High Intensity
56 PulseRAY KLX
58 PulseRAY E67

DuraRAY ® Phase II
LED Warning Beacons
l Amber LED
l Yellow Base
l Red LED
l Yellow Base
l Green LED
l Yellow Base
l Amber LED
l Amber Base
l Red LED
l Amber Base
l Green LED
l Amber Base
2 LED Disks HM9400YEL2A HM9400YEL2R HM9400YEL2G HM9400AMB2A HM9400AMB2R HM9400AMB2G
3 LED Disks HM9400YEL3A HM9400YEL3R HM9400YEL3G HM9400AMB3A HM9400AMB3R HM9400AMB3G
4 LED Disks HM9400YEL4A HM9400YEL4R HM9400YEL4G HM9400AMB4A HM9400AMB4R HM9400AMB4G
LED BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
40
®
DuraRAY
LED Warning Beacons
Phase II
Hella DuraRAY ® II ultra durable LED warning
beacons improve on the award winning design
of its predecessor. DuraRAY ® II beacons are
designed for mining and construction applications
where the cost of equipment down time is large
and safety is paramount.
130.6
130.6
153.5
132.5
159
3 x Ø6
equispaced
on PCD Ø150
3 x M4
equispaced
on PCD Ø107
3 x M4
equispaced
on PCD Ø130
25mm Pipe Thread
169
130.6
111.5
2 LED Disks
3 LED Disks
4 LED Disks
The cast alloy construction and
modular lens design enables
DuraRAY ® II beacons to survive
much larger crush or impact
loads than conventional optical
beacons. DuraRAY ® II beacons
offer excellent beam control to
ensure very good penetration of
fog and dust without blinding the
operator through back scatter,
whilst delivering high observability
from a distance with minimal closeup
glare.
Solid state LED beacons are
gaining popularity due to their
zero maintenance and long
service life over conventional
rotating beacons, particularly
in harsh mining conditions. The
new range of DuraRAY ® II LED
warning beacons build on an
award winning design with the
addition of a new electronic control
system, combined with higher
output LEDs, and further user
customisation within the range.
Higher EMC standard ISO13766-
2006 certification improves safety
and reliability with other electrical
devices. Coloured secondary
reflectors were added to ensure
easy identification of LED function
colour when the beacon is in ‘off’
mode.
Using an advanced control system
gives users the option to select
from a flashing
or rotating LED
beam pattern by
simply changing
the polarity of
the two wires.
The Multivolt
system allows
for installation on
electrical machines that
may have varying outputs due
to the load on the engine.
The light output from the high
emitting LEDs is not affected by
this varying supply, with a range
of 9-33 Volts DC.
The increased light output from
the LEDs combined with multiple
layers of LEDs delivers a high
degree of redundancy in the
optical system to ensure safety
is not compromised under partial
failure or obscuring conditions.
Utilising ceramic coated aluminium
reflectors and durable XYLEX ®
lenses provides excellent longterm
resistance against cleaning
chemicals, UV and impact damage
for increased durability and long
service life.
DuraRAY ® II beacons are fully
sealed ‘fit and forget’ products
that can be submerged and
high-pressure washed from any
direction.
Product features
Multivolt 9-33V DC
New electronics offer
both ‘rotating’ and
flashing functionality
Modular system of
circular LED discs for
intense, 360˚ visible
light output
Brilliant clear, high
impact resistant
XYLEX ® lens system
Heavy-duty cast alloy
base and cap for
increased mechanical
strength and vibration
resistance
Multi-stage paint
coating for optimal
corrosion and UV
protection
ISO 13766-2006
Flame retardant to
UL94HB
Fully sealed and
pre-wired to prevent
ingress of dirt and
moisture
200G shock resistant
Low EMC signature
Low current draw
Self-diagnostic
electronics for
protection against
transient voltage spikes
and reverse polarity
LED Function colour
variants available
(Amber, Green, Red)
Spare Parts
9.HM9386.02
Installation Kit
MULTI
VOLT
LED
DT &
BARE
WIRE
IP6K7
200G
9 to 33
V DC
33W
MAX

41
BEACONS
Top View
Bottom View
Yellow Housing
Amber Housing
Amber Function
Colour
Red Function
Colour
Green Function
Colour

UltraRAY ® -R TWIN LED Warning Beacon l Amber l Red l Blue l Green l White
Direct Mount HM500ADIR HM500RDIR HM500BDIR HM500GDIR HM500WDIR
Magnetic Mount HM500AMAG HM500RMAG HM500BMAG HM500GMAG HM500WMAG
MINING WARNING BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
42
®
UltraRAY -R TWIN
LED Warning Beacon
As an addition to the Hella LED beacon range, a new
Twin LED beacon has been developed for increased
visibility in bright sunlight with more than double the
luminous intensity of the original UltraRAY ® .
132
120°
3 x Ø4
equispaced
on PCD 130
136
187
130
120°
Amber
4 x Ø4
equispaced
on PCD 178
Red
Blue
Green
The UltraRAY ® -R Twin LED features
either a rotating or flashing pattern
easily selectable by grounding the
function wire, allowing users to
change the flashing pattern with an
in-cabin switch, removing the need
to open the unit.
It is extremely robust, tolerant to
severe vibration levels and very
compact in design. Equipped with
a high impact and shock resistant
polycarbonate lens bolted to a
heavy-duty cast alloy base, it
is sealed by a neoprene O-ring
against dust and water ingress.
The UltraRAY ® -R Twin LED warning
beacon is maintenance free with
no moving parts or fragile globes.
LED beacons are highly efficient,
delivering up to a 70% energy
saving over conventional beacons.
This greatly reduces both operating
temperature and demand on the
vehicle’s electrical system.
Maximum service life and light
output of the high intensity LEDs
is ensured by integrating the heat
sinks into the cast alloy base.
The Multivolt control module
encapsulated directly into the base
also protects the UltraRAY ® -R Twin
against damage from overheating,
reverse polarity and short circuits.
(See technical
section for more
Multivolt
information.)
The
UltraRAY ® -R
Twin LED
warning beacon
is optimized for
continuous use applications
on mining equipment, to ensure
highly effective warning efficiency
in daylight on surface operations
in the extreme environmental
conditions encountered in mining
applications.
The UltraRAY ® -R Twin LED also
features a patented Helio ® shield,
which protects the beacon’s
internal components from UV
damage. The UltraRAY ® -R Twin
LED beacon is available in five LED
signal colours (amber, red, blue,
green and white) to suit all signal
applications. Installation is possible
with either the standard direct
mount, or an optional magnetic
mount or pipe mounting kit.
Product features
Certified SAE J845
Class 1 red & amber
Available in amber, red,
blue, green and white
User selectable output
(rotate or quad flash
patterns)
Automatic daylight
detection
Impact resistant
smooth polycarbonate
lens
Precision Fresnel optics
Powdercoated cast
alloy base
Specifications
Voltage
Multivolt 12 –30V DC
Power consumption
50W average
Frequency
Rotating: 80 cycles/min
Flash: 72 fpm (quad)
Direct, pipe mount or
magnetic installation
options
Low current draw
EMC Tested
Fully encapsulated
electronics
Overheat, reverse
polarity and short
circuit protection
High efficiency, long life
LED light
Requires 10 Amp fuse
Lead Length
2 metres (doubleinsulated
cable)
Protection
Overheat, reverse
polarity and short
circuit protected.
Sealed against dust
and moisture to IP6K5
White
Temperature Range
–20°C to +50°C
Shock resistant to
200G
MULTI
VOLT
IP6K5
LED
200G
BARE
WIRE
0.9Kg
12 to 24
V DC
SAE
COMPLIANT
50W
AVERAGE
HM500AFLX UltraRAY-R TWIN including
vibration proof pole-mount adapter
Spare Parts
9.HM450ALENS
Amber PC Lens
9.HM450RLENS
Red PC Lens
9.HM450BLENS
Blue PC Lens
9.HM450GLENS
Green PC Lens
9.HM450WLENS
White PC Lens
HM400PIPE
Pipe Mount Kit
9.HM450FLX
FlexiMount Adapter

43
BEACONS
Polycarbonate lens
with Helioshield
Cast alloy base
Rubber vibration insulator

UltraRAY ® -R LED Warning Beacon l Amber l Red l Blue l Green l White
Direct Mount HM450ADIR HM450RDIR HM450BDIR HM450GDIR HM450WDIR
Magnetic Mount HM450AMAG HM450RMAG HM450BMAG HM450GMAG HM450WMAG
MINING WARNING BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
44
UltraRAY
®-R “ Rotating ”
LED Warning Beacon
UltraRAY ® -R LED warning beacons are optimized
to deliver high visibility warning signals in the
dusty conditions encountered on surface mining
operations – day and night. The new UltraRAY ® -R
beacons feature user-selectable ‘rotating’ or quad
flash patterns.
132
120°
3 x Ø4
equispaced
on PCD 130
136
187
130
120°
Amber
4 x Ø4
equispaced
on PCD 178
Red
Blue
Green
White
UltraRAY ® beacons are extremely
robust, tolerant to severe vibration
levels and very compact in design.
Each beacon is equipped with a
high impact and shock resistant,
polycarbonate lens bolted to a
heavy-duty cast alloy base, sealed
by a neoprene O-ring against dust
and water ingress. The UV resistant
multi-stage powder coating
process ensures optimal corrosion
protection. UltraRAY ® LED warning
beacons are maintenance free with
no moving parts or fragile globes.
UltraRAY ® -R ‘rotating’ beacons
incorporate the unique Hella
Helioshield technology developed
specifically for warning beacons
used on mine sites to significantly
increase the signal
contrast against bright-sky or
snow backgrounds and reduce the
occurrence of phantom signals in
direct sunlight.
All UltraRAY ® -R LED beacons are
highly energy efficient delivering
up to 70% energy saving over
conventional beacons, which
greatly reduces both operating
temperature and demand on
the vehicle’s electrical system.
Maximum service life and light
output of the high intensity LEDs is
ensured through
integrating the
heat sinks into
the cast alloy
base. The
Multivolt
control module
encapsulated
directly into the base
ensures full light intensity
independent of supply voltage
and protects the beacon against
damage from overheating, reverse
polarity and short circuits.
Safe and reliable electrical
connection
is facilitated via a highly flexible
double- insulated cable sealed into
the base, terminated with bare wire
ends. Other connector options can
be supplied as special orders.
UltraRAY ® beacons are available
in five LED signal colours (amber,
red, blue, green and white) to suit
all signal applications. Installation
is possible with either the standard
direct mount or an optional pipe
mounting kit. Temporary use
applications are best served with
the magnetic mount version,
complete with a pre-wired cable
and power plug.
Product features
User selectable
‘rotating’ or quad
flash patterns*
SAEJ845 Class I (red
and amber)
Impact resistant
polycarbonate lens
Precision Fresnel optics
Powdercoated cast
alloy base
Direct, pipe mount or
magnetic installation
options
Low current draw
Specifications
Voltage
Multivolt 12 –30V DC
Power consumption
20W max.
Frequency
Rotating: 80 cycles/min
Flash: 72 fpm (quad)
Temperature Range
–20°C to +50°C
Fully encapsulated
electronics
Overheat, reverse
polarity and short
circuit protection
Double insulated supply
cable
O-ring seals
High efficiency, long life
LED light
Unique Helioshield
ambient light
suppression improves
daylight visibility
* Preset to ‘rotating’
pattern
Lead Length
2 metres (doubleinsulated
cable)
Protection
Overheat, reverse
polarity and short
circuit protected.
Sealed against dust
and moisture to IP6K5
Shock resistant to
200G
MULTI
VOLT
IP6K5
LED
200G
BARE
WIRE
0.9Kg
12 to 24
V DC
SAE
COMPLIANT
20W
MAX.
HM450AFLX UltraRAY-R including
vibration proof pole-mount adapter
Spare Parts
9.HM450ALENS
Amber PC Lens
9.HM450RLENS
Red PC Lens
9.HM450BLENS
Blue PC Lens
9.HM450GLENS
Green PC Lens
9.HM450WLENS
White PC Lens
HM400PIPE
Pipe Mount Kit
9.HM450FLX
FlexiMount Adapter

45
BEACONS
Polycarbonate lens
with Helioshield
Cast alloy base
Rubber vibration insulator

UltraRAY ® LED Warning Beacon l Amber l Red l Blue l Green l White
Direct Mount HM400ADIR HM400RDIR HM400BDIR HM400GDIR HM400WDIR
Magnetic Mount HM400AMAG HM400RMAG HM400BMAG HM400GMAG HM400WMAG
MINING WARNNG BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
46
®
UltraRAY
LED Warning Beacon
UltraRAY ® LED warning beacons are optimized for
continuous use applications on mining equipment,
to ensure highly effective warning efficiency in
daylight on surface operations in the extreme
environmental conditions encountered in
mining applications.
132
120°
3 x Ø4
equispaced
on PCD 130
136
187
130
120°
Amber
4 x Ø4
equispaced
on PCD 178
Red
Blue
Green
UltraRAY LED beacons offer
multiple, user-selectable flash
patterns to suit a large variety
of applications. Additional user
selectable features include a
battery saver mode to alert users if
the equipment power supply drops
below normal operating voltage
levels to conserve power, as well
as a daylight sensing that can
automatically adjust the intensity of
the beacon to ambient light levels.
A reverse gear circuit allows the
flash pattern to be changed to alert
staff of the travel direction of the
equipment. The desired operational
mode can be selected by simply
changing the DIP switch settings
on the circuit board.
UltraRAY beacons are extremely
robust, tolerant to severe vibration
levels and very compact in design.
Each beacon is equipped with a
high impact and shock- resistant,
clear polycarbonate lens bolted
to a heavy-duty cast alloy base,
sealed by a neoprene O-ring
against dust and water ingress. A
UV resistant multi-stage powder
coating process ensures optimal
corrosion protection.
Unlike Xenon flash strobes,
UltraRAY LED beacons are
maintenance free and extremely
power efficient, which greatly
reduces both operating
temperature and demand on
the vehicle’s
electrical
system.
Maximum
service life
and light
output of the
high intensity
LEDs is ensured
through integrating the
heat sinks into the cast alloy
base. The Multivolt control module
encapsulated directly into the base
also protects the UltraRAY against
damage from overheating, reverse
polarity and short circuits. (See
technical section for more Multivolt
information.)
Safe and reliable electrical
connection is facilitated via a highly
flexible double insulated cable
sealed into the base, terminated as
a short length with a DT connector
or 2m cable with bare wire ends.
Other connector options can be
supplied as special orders.
UltraRAY beacons are available
in five LED signal colours (amber,
red, blue, green and white) to suit
all signal applications. Installation
is possible with either the standard
direct mount or an optional pipe
mounting kit. Temporary use
applications are best served with
the magnetic mount version,
complete with a pre wired cable
and power plug.
Product features
SAE J845 Class 1 red
& amber
Available in amber, red,
blue, green and white
User selectable flash
patterns (4)
Automatic daylight
detection
Impact resistant
smooth polycarbonate
lens
Clear precision Fresnel
optics
Cast alloy base
Direct, pipe mount or
magnetic installation
options
Multivolt 12 –30V DC
Low current draw
Fully encapsulated
electronics
1.5kg mass
200G shock impulse
resistant
Overheat, reverse
polarity and short
circuit protection
Double insulated supply
cable with DT or AMP
plug
O-ring seals
Tested over a –20ºC
to +50ºC temperature
range
High efficiency, long life
LED light
IP6K5
200G shock resistant
Spare Parts
White
9.HM400LENS
Clear Lens
HM400PIPE
Pipe Mount Kit
9.HM450FLX
FlexiMount Adapter
MULTI
VOLT
LED
BARE
WIRE
0.9Kg
SAE
COMPLIANT
HM400AFLX UltraRAY including
vibration proof pole-mount adapter
IP6K5
200G
12 to 24
V DC
20W
MAX.

47
BEACONS
Polycarbonate lens
Cast alloy base
Rubber vibration insulator

OptiRAY ® LED Warning Beacon l Amber l Red l Blue l Green l White
Direct Mount HM360ADIR HM360RDIR HM360BDIR HM360GDIR HM360WDIR
Magnetic Mount HM360AMAG HM360RMAG HM360BMAG HM360GMAG HM360WMAG
Battery Pack HM360ABP HM360RBP
Magnetic Battery Pack HM360ABPMAG HM360BBPMAG
MINING WARNING BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
48
®
OptiRAY
LED Warning Beacon
OptiRAY ® LED warning beacons are versatile lights
designed for heavy duty use on mining equipment and
service vehicles that need light output matched to the
ambient lighting, for optimum warning efficiency day or
night, surface or underground.
113
optiray
106
140
Amber on
Red on
Blue on
Green on
White on
OptiRAY LED beacons offer
multiple, user-selectable flash
patterns, including a rotating
beam, to suit a large variety of
applications. Additional userselectable
features include a
battery saver mode to alert users if
the equipment power supply drops
below normal operating voltage
levels to conserve power, as well
as daylight sensing that can switch
the beacon off during daylight
hours or automatically adjusts the
intensity of the beacon to ambient
light levels. The desired operational
mode can be selected by simply
changing the DIP switch settings
on the circuit board.
OptiRAY beacons are extremely
robust, tolerant to severe vibration
levels and very compact in design.
Each beacon is equipped with a
high impact and shock resistant,
clear polycarbonate lens, and
a rugged, UV damage resistant
fibreglass nylon composite base for
increased mechanical strength and
maximum durability. A neoprene
O-ring seals the assembly against
dust and water. The OptiRAY is well
suited to corrosive environments
where metal products should not
be used.
Unlike Xenon flash strobes,
OptiRAY LED beacons are
maintenance free and extremely
power efficient. Each beacon
draws a maximum of only 1 Amp
at 12V, which greatly reduces
both operating temperature
and demand on the
vehicle’s electrical
system. Maximum
service life and light
output of the high
intensity LEDs is ensured
through using internal
aluminium heat sinks. The
Multivolt control module also
protects the OptiRAY against
damage from overheating, reverse
polarity and short circuits. (See
technical section for more Multivolt
information.)
Safe and reliable electrical
connection is facilitated via a
highly flexible double insulated
cable sealed into the base. Other
connector options can be supplied
as special orders.
OptiRAY beacons are available
in five LED signal colours (amber,
red, blue, green and white) to suit
all signal applications. The beacon
can be installed with either the
standard direct mount or optional
pipe mounting kit; temporary
use applications are best served
with the magnetic mount version,
complete with pre wired cable
and plug. A self-contained version
with battery power supply is also
available for independent use.
Product features
SAE J845 (Class 1 red,
Class 2 amber)
Available in amber, red,
blue, green and white
User selectable flash
patterns (16)
Automatic daylight
detection
Impact resistant
smooth polycarbonate
lens
Clear precision Fresnel
optics
Direct, pipe mount or
magnetic installation
options
Battery pack option
Multivolt 12 – 30V DC
Low current draw
(1Amp)
Spare Parts
9.HM360LENS
Clear Lens
200G shock impulse
resistant
Overheat, reverse
polarity and short
circuit protection
Double insulated supply
cable
O-ring seals
Tested over a –20ºC
to +50ºC temperature
range
High efficiency, long life
LED light
IP6K5
200G shock resistant
Spares interchangeable
with Hella OptiRAY E
range
9.HM300FLX
FlexiMount Adapter
HM360PIPE
Pipe Mount Kit
MULTI
VOLT
LED
BARE
WIRE
0.5Kg
SAE
COMPLIANT
IP6K5
200G
12 to 30
V DC
12W
MAX
HM360AFLX OptiRAY including
vibration proof pole-mount adapter
Battery pack

49
BEACONS

OptiRAY ® E LED Warning Beacon l Amber l Red l Blue l Green l White
Direct Mount HM300ADIR HM300RDIR HM300BDIR HM300GDIR HM300WDIR
Magnetic Mount HM300AMAG HM300RMAG HM300BMAG HM300GMAG HM300WMAG
MINING WARNING BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
50
®
OptiRAY E
LED Warning Beacon
Hella OptiRAY ® E LED warning beacons are designed
for heavy duty use on mining equipment and service
vehicles where complex functionality is not required.
113
optiray
106
140
Amber on
Red on
Blue on
Green on
OptiRAY E beacons are engineered
to the same high standard as the
full-featured OptiRAY products,
but including only the essential
features enables the benefits of
LED products to be extended
into a significantly wider range of
applications.
OptiRAY E beacons are extremely
robust, tolerant to severe vibration
levels and very compact in design.
Each beacon is equipped with a
high impact and shock resistant,
clear polycarbonate lens and a
rugged, UV damage resistant
fibreglass nylon composite
base for increased mechanical
strength and maximum durability.
A neoprene O-ring seals the
assembly against dust and water.
The OptiRAY E is well suited to
corrosive environments where
metal products should not be used.
Unlike Xenon flash strobes,
OptiRAY E LED beacons are
maintenance-free and extremely
power efficient. Each beacon
draws a maximum of only 1 AMP
at 12V, which greatly reduces
both operating temperature and
demand on the vehicle’s electrical
system. Maximum service life
and light output of
the high intensity
LEDs is ensured
through using internal
aluminium heat sinks.
The Multivolt control
module also protects the
OptiRAY E against damage
from overheating, reverse
polarity and short circuits. (See
technical section for more Multivolt
information.)
Safe and reliable electrical
connection is facilitated via a highly
flexible double insulated cable
sealed into the base, terminated as
a short length with a DT connector
or 2m cable with bare wire ends.
Other connector options can be
supplied as special orders.
OptiRAY E beacons are available
in five LED signal colours (amber,
red, blue, green and white) to suit
all signal applications. Installation
is possible with either the standard
direct mount or optional pipe
mounting kit; temporary use
applications are best served with
the magnetic mount version,
complete with a pre wired cable
and power plug.
Product features
SAE J845 (Class 1 red,
Class 2 amber)
Available in amber, red,
blue, green and white
Impact resistant
smooth polycarbonate
lens
Clear precision Fresnel
optics
Direct, pipe mount or
magnetic installation
options
Multivolt 12 – 30V DC
Low current draw
1AMP
Fully encapsulated
electronics
Overheat, reverse
polarity and short
circuit protection
Double insulated supply
cable with DT or AMP
plug
O-ring seals
Tested over a –20ºC
to +50ºC temperature
range
High efficiency, long life
LED light
IP6K5
200G shock resistant
Spares interchangeable
with Hella OptiRAY
range
Double Flash, 80FPM
0.5kg mass
200G shock impulse
resistant
White on
HM300AFLX OptiRAY-E including
vibration proof pole-mount adapter
Spare Parts
9.HM360LENS
Clear Lens
HM360PIPE
Pipe Mount Kit
9.HM300FLX
FlexiMount Adapter
MULTI
VOLT
LED
DT BARE
WIRE
0.5Kg
SAE
COMPLIANT
IP6K5 IP6K7
200G
12 9 to 31 30
V DC
12W 6W
MAX

51
BEACONS

MiniRAY ® LED Warning Beacon l Amber l Red l Blue l Green l White
Direct Mount HM180ADIR HM180RDIR HM180BDIR HM180GDIR HM180WDIR
Magnetic Mount HM180AMAG HM180RMAG HM180BMAG HM180GMAG HM180WMAG
Battery Pack HM180ABP HM180RBP HM180GBP
MINING WARNING BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
52
®
MiniRAY
LED Warning Beacon
From the unique, virtually indestructible triangular design and
sealed polycarbonate lens, to its superior, long lasting LED
illumination and ultra low current draw, Hella MiniRAY ® LED
Warning Beacons offer outstanding lighting performance and
maximum durability for a vast range of applications where
highly directional optical warning signals are required.
161 140.5
113
miniray
Amber on
Red on
Blue on
Green on
White on
Battery pack
30
130
Utilising a high-intensity LED
lighting system incorporated into a
triangular, solid-state circuit board,
MiniRAY beacons produce high
intensity, axially symmetrical cones
of light to both front and rear of
the machine ensuring high visibility
along the axis of travel, whilst a
low intensity beam to either side
effectively reduces dangerous
glare to machine operators caused
by light reflecting from adjacent
structures or the warning
beacon itself.
MiniRAY beacons have been
specifically designed to protect
machinery operating underground
or in other areas where both
machine type (identified by LED
colour) and direction of travel are
essential indicators to identify
potential dangers.
MiniRAY beacons produce
different light source patterns to
the front and rear of the vehicle
identifying the direction of travel
and effectively reducing the risk
of collisions in poor visibility
conditions. In addition, MiniRAY
beacons provide 3 user-selectable
power levels to suit specific mine
requirements along with a selection
of flash patterns, which can be
linked to the operating mode of
the machinery, making changes in
equipment travel direction
highly visible.
Each MiniRAY beacon is resistant
to prolonged vehicle vibration and
sealed against damaging ingress of
moisture and dust for increased
durability and long service
life. The unique triangular
design deflects direct
impact and reliably
protects against damage
caused by falling rocks,
vehicles, hand tools or
construction debris,
whilst rounded corners
minimize the risk of personal
injury
when working in
confined spaces.
MiniRAY LED beacons require only
very little power, which allows them
to operate day and night, even
when the machinery is turned off.
And when they do run off truck
batteries or other field equipment,
they will operate for days without
draining the battery cells, making
them a cost-effective and reliable
lighting solution for any type
machinery from large earth moving
vehicles to smaller equipment
such as welders, generators
and compressors. And, unlike
Xenon flash tubes, LEDs produce
very little radio interference and
light pulses that do not disturb
lasertesting equipment.
MiniRAY LED beacons are available
in 5 different function colours
(amber, red, green, blue and white)
and offer a variety of mounting
options to suit every installation
requirement including direct
mount, magnetic base, battery box
(selfpowered).
Product features
Multivolt 12-30V DC
Multiple flash patterns
with over-ride function
to link flash patterns
to vehicle’s direction
of travel
Front and rear
identifiable beam
patterns
Unique asymmetrical
light output directing
high power beams
along the travel axis
and low power beams
across the travel axis
Three different power
settings allowing the
user to select between
maximum intensity and
minimum power draw
Solid-state, vibration
resistant circuit
board sealed in
clear, weatherproof
polycarbonate case
for optimum impact
resistance and long
service life
Triangular design
deflects direct impact
and protects against
damage from falling
rocks, vehicles, hand
tools and construction
debris
Versatile power
supply specifications
(permanent installation
or self-powered battery
pack operation or from
a coiled flexible supply
cable)
Modular base system
enables direct mount,
magnetic mount and a
battery pack mount
Low EMC signature.
Side view
Designed to
identify machine
type (colour) and
direction of travel
(beam pattern).
Front view
Rear view
Spare Parts
9.HM180LENS
Clear Lens
MULTI
VOLT
LED
BARE
WIRE
0.9Kg
IP6K5
200G
12 to 30
V DC
12W
MAX

NaviLED ® M Surface Mount l Amber l Red l Blue l Green l White
Signal Lamp Yellow Housing HM980910621 HM980910421 HM980910721 HM980910221 HM980910021
MINING SIGNAL LAMPS
FLASHING
®
NaviLED
M
Warning Beacon
53
BEACONS MOBILE EQUIPMENT
LIGHTING
Hella NaviLED ® M is a range of surface mount LED signal
lamps, specifically designed to provide all-round visibility.
NaviLED M is targeted for use on mining production
equipment where coloured signal lamps are required to
provide operational status and identification information.
Product features
‘Flashing’ or ‘Steady
On’ signal light
Flash rate 100 fpm
(approx)
High visibility yellow,
impact-resistant acrylic
base
Clear UV and chemical
resistant modified
acrylic lens
Function colours coded
into lens caps
Amber, red, blue, green
and white functions
available
Minimum visible
distance of 3 km
Single high intensity
LED light source
Sealed unit pre-wired
with multi strand
double insulated cable
Multivolt 9-33V DC
Spike protected to
+500 volts
Over voltage protected
to +200 volts
Reverse polarity
protected to -500 volts
Low power
consumption (2W)
Sealed to IP6K6 and
IP6K7 to withstand
temporary immersion
and high pressure
washing
200G shock tested
Tested over a –40ºC
to +70ºC temperature
range
External elements
manufactured
from flame retardant
polymers rated UL94
HB
As a new feature all
NaviLED ® M LED signal
lamps now offer a
single flashing signal
light in addition to the
standard ‘steady on’
signal light function.
The additional flashing
function provides optimum
warning efficiency and renders
the lamp suitable for use as a fault
indication device. The preferred
signal function is selected by
simply reversing the wiring polarity.
The highly ergonomic and userfriendly
design ensures that the
NaviLED M has no sharp edges
or protruding fasteners when
installed. Hella engineers NaviLED
M lamps to ensure a very long
service life with no lighting loss
due to internal dirt build-up;
they are very well suited to wet
and corrosive environments and
tolerate short-term immersion.
Excellent durability of the housing
and active LED electronics, as well
as long term impact, chemical and
UV damage resistance in the highly
corrosive and abrasive mining
environment, is ensured through
meticulous testing and selection of
materials and assembly processes.
NaviLED M signal lamps have
undergone extensive ‘test to
destruction’ programs to ensure
product reliability meets Hella
Mining requirements.
Advanced Multivolt circuitry
pioneered by Hella which provides
reverse polarity, spike and overvoltage
protection for long life and
reliable operation of the LED, is
sealed into the base. The lamps
deliver consistent illumination from
9-33V (See technical section for
additional information.) NaviLED
M lamps are available in five LED
signal colours (amber, red, blue,
green and white).
Maximum service life and light
output of the high intensity LED
light source is ensured through
an integral aluminium heat sink. A
multi component refractor system
delivers controlled rotationally
symmetrical light distribution
with minimal losses. The smooth
self-cleaning exterior lens can be
re-polished if required, with no
detrimental effect on light-output or
chemical resistance.
Safe and reliable electrical
connection is facilitated via a short
length double insulated multi core
cable. Other connector options can
be supplied as special orders.
83
Amber
Illuminated
Red
Illuminated
Blue
Illuminated
Green
Illuminated
White
Illuminated
90
Optic appears clear until illuminated in all lamps
MULTI
VOLT
LED
DT
0.5Kg
IP6K7
200G
9 to 33
V DC
2W

DuraLed ® M High Intensity Warning Beacon l Amber l Red l Blue l Green l White
Narrow Beam Bare Wire HM95903710 HM95903700 HM95903760 HM95903780 HM95903790
Narrow Beam DT Plug HM95903710D HM95903700D HM95903760D HM95903780D HM95903790D
MINING WARNING BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
54
®
DuraLed
Warning Beacon
M High Intensity
DuraLed ® M MultiFlash are versatile high
intensity LED optical warning beacon lights
designed for heavy duty installation on
mining equipment and service vehicles in
applications where roof-mounted warning
beacons may not be desirable or sufficient.
100
177
148
Amber
Illuminated
Red
Illuminated
Blue
Illuminated
Green
Illuminated
White
Illuminated
31
22
Hella MultiFlash LED beacons
offer multiple, user-selectable flash
patterns to suit a large variety
of applications. The desired
operational mode can be selected
by simply changing the settings
via the power cable. No external
control systems are required.
DuraLed M beacons are extremely
robust, fully sealed truly “fit and
forget” products, tolerant to severe
vibration levels and very compact
in design. A high impact and
shock resistant clear Xylex lens is
permanently bonded to a rugged,
UV damage-resistant composite
base for increased mechanical
strength and maximum durability.
Hella engineered DuraLed M lamps
to ensure a very long service life
and no lighting loss due to internal
dirt build-up; they are also very
well suited to wet and corrosive
environments and tolerate shortterm
immersion. (See technical
section for more Xylex information.)
Unlike Xenon flash strobes,
DuraLed M LED beacons
are maintenance free and
extremely power efficient which
greatly reduces both operating
temperature and demand on
the vehicle’s electrical system.
Maximum service life and light
output of the high intensity LEDs
is ensured through using internal
heat sinks. The integral Multivolt
and MultiFlash control module also
protects the DuraLed M against
damage from overheat, reverse
polarity and short circuits. (See
technical section for more Multivolt
information.)
Safe and reliable electrical
connection is facilitated via a highly
flexible double insulated cable
sealed into
the base,
terminated
as a short
length with a
DT connector
or 2m cable with
tinned wire ends. Other connector
options can be supplied as special
orders.
DuraLed M MultiFlash beacons
are equipped with advanced clear
micro optic lenses to prevent the
hazardous occurrence of “ghost”
signals by internally reflected light
from other sources. Five LED signal
colours are available (amber, red,
blue, green and white) to suit all
signal applications.
The smooth ergonomic design
and very low profile (under 35mm)
allows DuraLed M units to be
installed on almost any surface.
Specially designed nylon bushes
prevent stress fractures developing
in the base, by distributing the
fasting bolt load over a large
surface of the base without
transferring any torque. Tamper
proof screw covers securely
lock the product into place and
simplify cleaning by eliminating dirt
collecting cavities.
Flash Patterns
0
1
2
3
4
5
6
7
8
9
10
MultiFLASH ®
Product features
Available in amber, red,
blue, green and white
User selectable flash
patterns
Impact resistant
smooth Xylex lens
Clear precision micro
optics
Multivolt 9-33V DC
Low power < 10W
Fully sealed “fit and
forget” design
0.5kg mass
200G shock impulse
resistant
Spare Parts
9.HMDLM001
Cover Kit Yellow
1 second
Overheat, reverse
polarity and short
circuit protection
Double insulated supply
cable with DT plug or
bare wire
Tested over a –40ºC
to +70ºC temperature
range
High efficiency, long life
LED light
IP6K7K
UL94 flame retardant
rated external parts
Spares interchangeable
with Hella DuraLed
range
MULTI
VOLT
MULTI
FLASH
LED
DT &
BARE
WIRE
0.5Kg
250 ms 500 ms 750 ms
IP6K7
200G
9 to 33
V DC
9W

55
BEACONS
Optic appears clear
until illuminated in
all lamps
DuraLED Blue 95906070 DuraLED Red 95906080
DuraLED Green 95906090 DuraLED Amber 95907080
10.0lx 10.0lx 12.0lx 10.0lx
Average Beam
Illuminance
7.5lx 7.5lx 9.0lx 7.5lx
10m
5m
Beam Width
and Height
4.0m
80%
60%
5.0lx
5.0lx
6.0lx
5.0lx
0.8m
0m
0.8m
40%
20%
2.5lx
2.5lx
3.0lx
2.5lx
5m
4.0m
-90.0° -72.0° -54.0° -36.0° -18.0° 0.0°
18.0° 36.0° 54.0° 72.0° 90.0°
0.3lx
0.0lx
0.8lx
0.0lx
1.3lx
0.0lx
1.0lx
0.0lx
5m
10m
15m
20m
25m
10m
30m
Maximum Intensity
DuraLED Red 95906080 500 cd
DuraLED Amber 95907080 400 cd
DuraLED Green 95906090 300 cd
DuraLED Blue 95906070 100 cd

PulseRAY ® KLX
Heavy Duty Xenon Warning Beacon Amber
HMX7500A
MINING WARNING BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
56
®
PulseRAY
KLX
Heavy Duty Xenon Warning Beacon
PulseRAY ® KLX Xenon strobe warning beacons
are specifically developed to fulfill the demands of
markets with SAE standards. The beacon is designed
for heavy duty use on mining machinery; suitable for
24V and 12V electrical systems.
Front View
174.8
165
Reliable, unambiguous and highly
visible optical warning signals
are essential to create a safe
and productive work area where
machine operators can clearly see
and identify any hazards in their
work environment at the correct
time to take the required action.
The PulseRAY KLX is engineered
to deliver intense high visibility
signals under continuous use in the
extreme environmental conditions
encountered in mining applications.
PulseRAY KLX beacons combine a
smooth outer polycarbonate amber
lens in the classic Hella shape, with
a high clear precision Fresnel optic
internal lens, reducing dirt build-up
compared to textured lenses and
delivering significant improvements
in long term light output and beam
control under actual operating
conditions. (Other lens colours
available as special order.)
Extended service life, and
maximum light output of the
PulseRAY is ensured by using the
die cast aluminium base as heat
sink for the Multivolt drive circuitry.
The electronics are encapsulated
as protection against shock
damage and ingress of moisture or
other atmospheric contaminants.
Rapid service access to
the PulseRAY is enabled
by its thread-on lens
and captive O-ring
seal, while the
field replaceable
Xenon flash tube
with clip-in base
ensures correct
polarity. User
selection between
double or quad flash
as well as high or low flash
intensity is done by setting DIP
switches when fitting the PulseRAY.
Comprehensive protection
is provided against reverse
voltage, high voltage spikes and
over-voltage.
The heavy-duty cast alloy base,
finished in high visibility yellow
UV resistant multi-stage powder
coating process, ensures optimal
corrosion protection. The PulseRAY
KLX base suits the standard 6”
(150mm) diameter mounting
pattern used in North America, as
well as a threaded pole.
Product features
Heavy cast alloy base
Impact resistant
smooth polycarbonate
lens
Clear precision Fresnel
optics
Voltage nominal: 12V –
24V DC
Voltage operating: 9V –
32V DC
Field selectable double
or quad flash
Field selectable high/
low flash intensity
10 Joules @ 80 FPM
16 Joules @ 65 FPM
Mounting: 150mm PCD
from above and 30mm
SPT from below.
SAE J1318 Class 2
compliant
SAE J575 compliant
Components tested
over a –40ºC to +50ºC
temperature range
IP6K6
50G shock resistant
lamp
Suitable for use with
GuardRAY protective
cage
Consumable spares
interchangeable with
PulseRAY E67 beacons
Reverse polarity,
voltage spike & surge
protection
XENON
BARE
WIRE
1.1Kg
SAE
COMPLIANT
ECE
COMPLIANT
HMWGA220 (optional)
Spare Parts
9.HMX7500.01
Lens KLX inner -
Fresnel
9.HMX7500.02
Lens KLX outer –
Amber
HMWGA220
GuardRAY ® Protective
Cage
XN6750
Globe – Xenon E67
Flash Tube
IP6K6
50G
12/24V 60W

57
BEACONS

PulseRAY ® E67 l Amber l Red l Blue l Green l Clear
Heavy Duty Xenon Strobe 12/24V DC HMX6750A HMX6750R HMX6750B HMX6750G HMX6750C
MINING WARNING BEACONS
MOBILE BEACONS EQUIPMENT
LIGHTING
58
®
PulseRAY
E67
Heavy Duty Xenon Warning Beacon 12/24V DC
PulseRAY ® E67 Xenon strobe warning beacons are
designed for heavy duty use on mining machinery;
suitable for 24V and 12V electrical systems.
121
4.8
165
6.5
Amber Lens
Red Lens
Blue Lens
Green Lens
Reliable, unambiguous and highly
visible optical warning signals
are essential to create a safe
and productive work area where
machine operators can clearly see
and identify any hazards in their
work environment at the correct
time to take the required action.
The PulseRAY E67 is engineered
to deliver intense high visibility
signals under continuous use in the
extreme environmental conditions
encountered in mining applications.
PulseRAY E67 beacons feature
an impact resistant polycarbonate
lens with Fresnel optics.
Extended service life, and
maximum light output of the
PulseRAY is ensured by using the
die cast aluminium base as a heat
sink for the Multivolt drive circuitry.
The electronics is encapsulated as
protection against shock damage
and ingress of moisture or other
atmospheric contaminants.
Rapid service access to the
PulseRAY is enabled by its threadon
lens and captive O-ring seal,
while the field replaceable Xenon
flash tube with clip-in
base ensures correct
polarity. Reliable fault
diagnosis of the
lamp is facilitated
through the i.beam
LED status indicator
visible through
the outer lens. (See
technical section for more
information.)
Selection between double or quad
flash operation of the PulseRAY is
done by simply reversing operating
polarity. Comprehensive protection
provided against high voltage
spikes and over-voltage ensures
reliable operation.
The heavy duty cast alloy base
finished in high visibility yellow
UV resistant multi-stage powder
coating process, ensures optimal
corrosion protection. The PulseRAY
E67 base suits the standard 6”
(150mm) diameter mounting
pattern used in North America as
well as a threaded pole.
Product features
Heavy cast alloy base
Impact resistant
polycarbonate lens
Voltage nominal: 12V –
24V DC
Voltage operating: 9V –
32V DC
Field selectable double
or quad flash
i.beam Monitor
10 Joules @ 80 FPM
16 Joules @ 65 FPM
Reverse polarity,
voltage spike & surge
protection
Mounting: 150mm PCD
from above and 30mm
SPT from below
Components tested
over a –40°C to +50ºC
temperature range
IP6K6
50G shock resistant
lamp
SAE J1318 Class 2
compliant
SAE J575 compliant
Suitable for use with
GuardRAY protective
cage
Consumable spares
interchangeable with
PulseRAY KLX beacons
Clear Lens
HMWGA160 (optional)
Spare Parts
9.1602.01
E67 Lens - Amber
9.1601.01
E67 Lens - Red
9.1600.01
E67 Lens - Blue
9.1603.01
E67 Lens - Green
HMWGA160
GuardRAY ® Protective
Cage
XN6750
Globe - Xenon E67
Flash Tube
9.1600.06
Lens Clear Dust Cover
XENON
BARE
WIRE
1.2Kg
SAE
COMPLIANT
9.1604.01
E67 Lens - Clear
IP6K6
50G
12/24V 60W

59
BEACONS

Signal Lamps
61
SIGNAL LAMPS
62 DuraLED SAE
63 DuraLED ECE
64 DuraLED M Combi
65 DuraLED MSIP
66 DuraLED Marker
67 LED Daytime Running Lamp

DuraLed ® SAE Signal Lamp
Stop/Tail Rear Turn Signal (Red)
Rear Turn Signal/Indicator
HM060321
HM070321
MINING SIGNAL LAMPS
SIGNAL LAMPS
62
®
DuraLed
Signal Lamps
SAE
Hella’s DuraLed ® lamps include models which are
ECE approved, and SAE compliant. They suit
a variety of vehicle applications and are easy
to fit and durable. The lamps incorporate the
latest in LED technology for low maintenance
requirements, low current draw and ultra long
service life.
100
HM060321
177
148
31
22
DuraLed lamps feature unique
designs with shallow shapes
and concealed mounting screws
for enhanced protection against
damage. All lamps are pre-wired
with multi-core sheathed cable,
fully sealed against dust and
moisture to International Protection
Standards IP6K6 and IP6K7, and
are compliant with current SAE
regulations.
The material used for these part
numbers is a new generation of
acrylics which has a high tolerance
to chemicals and washing fluids
as well as an enhanced impact
resistance. This suits vehicles
frequently washed with standard
automotive chemicals.
DuraLed SAE Signal Lamps feature
low power consumption and
Multivolt circuitry, ensuring full
light output from 9 to 33 volts (8
to 28 volts for the Marker Lamp).
The lamps are fully
sealed against
dust and moisture
and may be
mounted vertically
or horizontally
(2-hole surface mount
and mounting bushes supplied).
Multivolt for optimum brightness
at input voltage from 9 to 33 volts
with 9W power consumption.
Reverse polarity protection
and 5.0kW Transient Voltage
Suppressor (TVS). Made to IP6K6
(Protection against dust and high
pressure water jets) and IP6K7
(Protection against temporary
water immersion) standards.
Standard lamp comes with 2.5m
of cable.
Product features
Easy installation
Variety of surface
mount options
Ultra wide optics for
enhanced visibility
Low power
consumption and
Multivolt circuitry for
maximum light output
Multivolt9 - 33V DC
SAE compliant
IP6K6 (Protection
against dust and high
pressure water jets)
IP6K7 (Protection
against temporary
water immersion).
HM070321
MULTI
VOLT
LED
DT&
BARE
WIRE
0.4Kg
SAE
COMPLIANT
IP6K7
200G
9 to 33
V DC
5W

DuraLed ® ECE Signal Lamp
Stop/Tail Signal (Red Illuminated)
Rear Turn Signal (Amber Illuminated)
HM060621
HM070621
MINING SIGNAL LAMPS
®
DuraLed
Hella DuraLed ® ECE lamps are high quality, long lasting
mining signal lamps that are ECE approved. They suit
a variety of vehicle applications and are easy to fit and
durable. They incorporate the latest in LED technology
for low maintenance requirements, low current draw
and ultra long service life.
ECE
Signal Lamps
63
SIGNAL LAMPS
Product features
Easy Installation
Variety of surface
mount options
Ultra wide angle optics
for enhanced side
visibility
Ultra low power
consumption
Multivolt 9-33V DC
ECE Approval
Fully sealed against
dust and moisture
DuraLed ® lamps are
extremely robust,
fully sealed truly “fit
and forget” products,
tolerant to severe vibration levels
and very compact in design with
concealed mounting screws for
enhanced protection against
damage.
All lamps are pre-wired with
multi-core sheathed cable, fully
sealed against dust and moisture
to International Protection
Standards IP6K6 and IP6K7, and
are compliant with current SAE
regulations.
(maximum 9 Watts) for minimal
strain on a vehicle’s electrical
system.
The high quality circuitry features
reverse polarity protection
and 5.0kW Transient Voltage
Suppressor (TVS).
Lamps are sealed to IP6K6
(protection against dust and high
pressure water jets) and IP6K7
(protection against temporary
water immersion) standards.
They come pre-wired with
integrated DT plug for easy
installation.
100
177
148
31
22
Specifications
Voltage
Multivolt 9-33V DC
Power Consumption:
Rear Direction
Indicator 9W
Rear Position
Lamp 2W
Park Lamp 2W
Stop Lamp 9W
Protection:
Reverse Polarity
Protection
5.0kW Transient
Voltage Suppressor
(TVS)
Protection Codes:
IP6K6 (protection
against dust and high
pressure water jets)
IP6K7 (protection
against temporary
water immersion)
Approvals:
HM060621 (Red)
E13 020533
e4 020889
HM070621 (Amber)
E13 010363
e4 020904
The material used for these lights
includes a new generation of
acrylics which has a high tolerance
to chemicals and washing fluids
as well as an enhanced impact
resistance. This suits vehicles
frequently washed with highly
corrosive mining chemicals.
DuraLed ® SAE Signal Lamps
feature low power consumption
and Multivolt circuitry, ensuring
full light output from 9 to 33 volts.
The lamps are fully sealed against
dust and moisture and may be
mounted vertically or horizontally
(2-hole surface mount and
mounting bushes supplied).
LED technology ensures the lamps
have ultra-low power consumption
DuraLed ® lamps are equipped
with advanced clear micro optic
lenses to prevent the hazardous
occurrence of “ghost” signals by
internally reflected light from other
sources.
The smooth ergonomic design
and very low profile (under 35mm)
allows DuraLed ® units to be
installed on almost any surface.
Specially designed nylon bushes
prevent stress fractures developing
in the base, by distributing the
fastening bolt load over a large
surface area of the base without
transferring any torque. Tamper
proof screw covers securely lock
the product into place and simplify
cleaning by eliminating dirtcollecting
cavities.
HM060621 (Red Illuminated)
HM070621 (Amber Illuminated)
MULTI
VOLT
LED
DT&
BARE
WIRE
0.4Kg
ECE
APPROVED
IP6K7
200G
9 to 31
V DC
2W
to 9W

DuraLed ® M Combination
Signal Lamp Bare Wire
Signal Lamp DT
HM2379
HM2379D
MINING SIGNAL LAMPS
SIGNAL LAMPS
64
®
DuraLed
M
Combination Signal Lamp
DuraLed ® M Combi are “Fit and Forget”
stop/tail/indicator combination signal
lamps, utilising the latest LED technology,
and engineered specifically for ultra
heavy-duty applications on mining
equipment and service vehicles.
222
193
34
96
Optic appears
clear until
illuminated (off)
Tail lamp
function
displayed
Stop lamp
function
displayed
DuraLed M Combi lamps are
extremely robust, fully sealed truly
“fit and forget” products, tolerant
to severe vibration levels and very
compact in design. A high impact
and shock resistant clear Xylex
lens is permanently bonded to
a rugged, UV damage-resistant
composite base for increased
mechanical strength and maximum
durability. Hella engineered
DuraLed M Combi lamps to
ensure a very long service life and
no lighting loss due to internal
dirt build-up; they are also very
well suited to wet and corrosive
environments and tolerate shortterm
immersion. (See technical
section for more Xylex information.)
Unlike normal signal lamps,
DuraLed products are maintenance
free and extremely power efficient,
which greatly reduces both
operating temperature and demand
on the vehicle’s electrical system.
Maximum service life and light
output of the high intensity LEDs
is ensured by using internal heat
sinks. The integral Multivolt control
module
also
protects
the DuraLed M against damage
from overheating, reversed
polarity and short circuits. (See
technical section for more Multivolt
information.)
Safe and reliable electrical
connection is facilitated via a highly
flexible double insulated cable
sealed into the base, terminated as
a short length with a DT connector
or 2m cable with tinned wire ends.
Other connector options can be
supplied as special orders.
DuraLed M Combi lamps are
equipped with advanced, clear
micro optic lenses to prevent the
hazardous occurrence of “ghost”
signals by internally reflected light
from other sources.
The smooth ergonomic design
and very low profile (under 35mm)
allows DuraLed units to be installed
on almost any surface.
Product features
Impact resistant
smooth Xylex lens
Clear precision micro
optics
Multivolt 8-28V DC
Low power < 10W
Fully sealed “fit and
forget” design
0.5kg mass
200G shock impulse
resistant
Overheat, reverse
polarity and short
circuit protection
Double insulated supply
cable with DT plug or
tinned wire
Spare Parts
9.HMDLM001
Cover Kit Yellow
(Pack of 4)
Tested over a –40ºC
to +70ºC temperature
range
High efficiency, long life
LED light
IP6K7K
UL94 flame retardant
rated external parts
ADR, ECE and SABS
compliant
Spares interchangeable
with Hella DuraLed
range
CE compliant
Indicator
function
displayed
All functions
displayed (on)
MULTI
VOLT
LED
DT&
BARE
WIRE
0.7Kg
ADR/
ECE/
SABS
COMPLIANT
IP6K7
200G
8 to 28
V DC
9W

DuraLed ® MSIP Signal Lamp
Red/Green
HM95905030
MINING SIGNAL LAMPS
®
DuraLed
DuraLed ® MSIPs (Mine Safety Indicator Panel)
are LED signal lamps offering both red and green
signals in one compact housing, engineered
specifically for ultra heavy-duty applications where
safety is important, such as on underground
transport equipment sharing space with foot traffic.
MSIP
Signal Lamp
65
SIGNAL LAMPS
Product features
Impact resistant
smooth Xylex lens
Clear precision micro
optics
Multivolt 8-28V DC
Low power < 10W
Fully sealed “fit and
forget” design
0.5kg mass
200G shock impulse
resistant
Overheat, reverse
polarity and short
circuit protection
Spare Parts
9.HMDLM001
Cover Kit Yellow
(Pack of 4)
Double insulated supply
cable with DT plug or
tinned wire
Tested over a –40ºC
to +70ºC temperature
range
High efficiency, long life
LED light
IP6K7K
UL94 flame retardant
rated external parts
ROHS compliant
Spares interchangeable
with Hella DuraLed
range
DuraLed
MSIP
lamps are
extremely
robust, fully sealed truly “fit and
forget” products, tolerant to severe
vibration levels and very compact
in design. A high impact and
shock resistant, clear Xylex lens is
permanently bonded to a rugged,
UV damage resistant composite
base for increased mechanical
strength and maximum durability.
Hella engineered DuraLed MSIP
lamps to ensure a very long
service life and no lighting loss
due to internal dirt build-up; they
are also very well suited to wet
and corrosive environments and
tolerate short-term immersion. (See
technical section for more Xylex
information.)
Unlike normal signal lamps,
DuraLed products are maintenance
free and extremely power
efficient, which greatly reduces
both operating temperature and
demand on the vehicle’s electrical
system. Maximum service life and
light output of the high intensity
LEDs is ensured through using
internal heat sinks. The integral
Multivolt control module also
protects the DuraLed MSIP against
damage from overheating, reverse
polarity and short circuits. (See
technical section for more Multivolt
information.)
Safe and reliable electrical
connection is facilitated via a
highly flexible double insulated
cable, sealed into the base and
terminated with tinned wire ends.
Other connector options can be
supplied as special orders.
DuraLed MSIP lamps are equipped
with advanced clear micro optic
lenses to prevent the hazardous
occurrence of “ghost” signals by
internally reflected light from other
sources.
The smooth ergonomic design
and very low profile (under 35mm)
allows DuraLed units to be installed
on almost any surface.
222
193
34
96
Optic appears
clear until
illuminated (off)
Red
illuminated
shown
Green
illuminated
shown
Red & green
illuminated
shown
MULTI
VOLT
LED
DT&
BARE
WIRE
0.7Kg
ADR/
ECE/
SABS
COMPLIANT
IP6K7
200G
8 to 28
V DC
9W

DuraLed ® M
l White
Inspection Point
l l Red/Amber
Side Marker
l Red
Marker
l Amber
Cabin Marker
l Amber
Marker
Marker Lamp Bare Wire HM2054 HM2053PC HM2307 HM2026 HM2051
Marker Lamp DT HM2054D HM2053PCD HM2307D HM2026D HM2051D
MINING SIGNAL LAMPS
SIGNAL LAMPS
66
®
DuraLed
Marker Lamps
M
DuraLed ® M “Fit and Forget” robust waterproof clearance
marker and inspection lamps utilise the latest LED
technology specifically for heavy duty applications.
32
38
60
28.5
White Inspection
Point Lamp
Red/Amber
Side
Marker Lamp
(not ECE
compliant)
Red Marker
Lamp
(SAE/ECE
compliant)
The DuraLed M clearance and
marker lamps are heavy duty
injection moulded units in UV
resistant polymers that offer a
high resistance to corrosion and
attack from a range of aggressive
elements commonly found in
mining, industrial and chemical
plants (Please refer to the technical
section for detailed information).
The polymers used also offer high
levels of protection against impact
damage whilst exhibiting a large
degree of self-damping vibration
protection.
DuraLed M signal lamps feature
the Hella pioneered Multivolt
system that ensures the same
ultra bright light output at supply
voltages between 8V DC and
28V DC, eliminating the problems
associated with voltage drop and
allowing the fitment of the same
products on plant and machinery
with 12V DC or 24V DC electrical
systems.
All DuraLed M products are
fully sealed and pre-wired to
cope with temporary immersion
and high pressure cleaning. To
enable easy integration into most
mining machine wiring harnesses,
DuraLed M products are supplied
optional with DT Plug.
Product features
-40°C to +70°C.
200G shock resistant
Sealed to IP6K6 &
IP6K7 to withstand
temporary immersion
and high pressure
washing
Multivolt 8 - 28V DC
Up to 60% less current
draw than comparable
globe lamps
Ultrafast response time
Transient spike
protection
Reverse polarity
protection
Sealed unit pre-wired
with multi-core double
insulated wire
Available with DT Plugs
or bare wire ends
ADR & ECE compliant
approved for road use
High visibility yellow
mounting base
Polycarbonate lens
material rated UL94
5VB
PMMA lens material
rated UL94 HB
Mounting base material
rated UL94 UB
Amber Cabin
Marker Lamp
Amber
Marker Lamp
(SAE/ECE
compliant)
Marker Lamps displayed in OFF and ON modes.
Optics on marker ;amps appear clear until illuminated.
Spare Parts
9.HMDLM002
Marker Housing Yellow
(Pack of 4)
HM2051
HM2307
MULTI
VOLT
LED
DT&
BARE
WIRE
0.4Kg
ADR/
ECE
COMPLIANT
IP6K7
200G
8 to 28
V DC
1W

LED Daytime Running Lamp
2 Lamp Kit HM1535DRL
DAYTIME RUNNING LAMPS
LED Daytime Running Lamp
67
SIGNAL LAMPS
On mine site safety is paramount. On most
sites the use of headlights on vehicles is
mandatory at all times, however dipped
beam headlights are less visible during
daylight hours than dedicated Daytime
Running Lamps (DRLs).
Product features
Multivolt (9-33V DC)
Equipped with 12
highly
efficient LEDs
Ultra long life ‘Fit and
Forget’
Low power
consumption
< 2 Watts
Fully sealed against
dust and high-pressure
water jets
Inbuilt overtemperature
protection
Stainless steel
universal
mounting bracket
Polarity protected
Spike and overvoltage
protection
Long term UV resistant
Pre-wired with 2.5
metres of 3 x 0.75mm²
automotive cable
Homogenous close
range illumination
ADR/ECE: ADR 76/00
Hella has just launched a low
power LED Daytime Running Lamp
that provides extra safety through
enhanced visibility, at a fraction
of the power consumption of
conventional headlights.
Hella LED Daytime Running Lamps
(DRLs) are designed to significantly
improve vehicle visibility on site.
These lights are sealed and require
no maintenance (“fit and forget”)
and are ADR approved for road
use, giving the lights the versatility
to suit multiple applications.
With lower power usage and a
zero maintenance requirement,
make these lamps a sound
investment into enhanced mine
safety. The lens is manufactured
from Swiss made Grilamid ® Optical
Nylon which provides superior
resistance to UV and to a
wide range of chemicals, as well
as high impact strength, enabling
the lamp to survive the highly
demanding environmental
conditions of today’s mining.
The new Hella LED Daytime
Running Lamp (DRL) is suitable for
upright or pendant mounting and
supplied with universal stainless
steel mounting brackets. LED DRLs
have multiple applications, which
include area illumination around
the vehicle.
53
136 49
42
Kit contains two lamps
MULTI
VOLT
LED
BARE
WIRE
0.72Kg
IP6K7 IP6K9K
9 to 33
V DC
2W
ADR
COMPLIANT

Accessories
69
ACCESSORIES
70 LED Buggy Whip
71 Remote Jump Start Terminals
Battery Master Lockout Switch
72 Screened Extension Cables
73 Heavy Duty Screened
Extension Cables
74 NumiLED
75 NumiLED Pro
76 IR Dual Camera System
77 Quad Screen IR Kit
78 AccuPAX
80 Weatherproof Relay
Self-Amalgamating Tape
81 DT Connectors

LED BUGGY WHIPS
ACCESSORIES
70
LED Buggy Whip
LED Buggy Whip
1.2 metre HM4612
2.0 metre HM4620
3.0 metre HM4630
MULTI
VOLT
IP6K7
LED
200G
DT
0.5Kg
12V
1W
To meet safety regulations, mine
sites often require light vehicles
to display high visibility safety
flags to
improve visibility for drivers of
heavy machinery. Mounting onto
the bumper bars of light vehicles,
these give vehicles an extra layer
of protection.
During night and poor visibility
levels the operation of light
vehicles generally requires the
use of rotating safety beacons to
improve visibility. However in mine
sites where the topological surface
contains large dips and hills, these
may not be adequate.
By combining a bright LED with a
long reflective safety flag, drivers
of light vehicles can ensure they
are always in the line of sight of
heavy machinery.
The LED module puts negligible
load on the vehicles electrical
system (less than 1W), the
shaft is constructed from a high
quality fiberglass rod, sealing
the electrical components from
weather damage. The flag mounts
to the vehicle via a quality quick
release latch allowing the flag to
be taken down when the vehicle
is off site. The cable is terminated
with a DT plug, allowing quick
removal whilst sealing the electrics
from environmental damage.
The flag contains reflective UV
resistant material and the nylon
material repels the high levels of
dirt and dust often encountered in
mine sites.
9.HM46FX
Technical Specifications:
Light source
Quality LEDs in BA9 bulb
holder
Voltage 12V
Power Consumption
< 1W
Length
1.2 metres, 2.0 metres or
3.0 metres
Mounting
Integrated mounting
bolt on base with snap
on/off quick-release
shaft for quick and
easy installation
Spare Parts:
9.HM46MP
Male Pin Connector for Quick
Release
9.HM46MS
Medium Spring
9.HM46GL
LED Globe
9.HM46MP
9.HM46MS
9.HM46FX
Replacement Reflective Cross
Flag
Snap On/Off Quick Release

TERMINALS & SWITCHES
Remote Jump Start Terminals
71
ACCESSORIES
Heavy duty, high capacity
jump-start connectors for
vehicles and equipment.
Ideal for use where access
to terminals is restricted
or dangerous. Eliminates
the chance of cross polarity
connections through the
specially shaped plug. Reduces
chance of sparking and possible
ignition of flammable materials.
Features high impact ABS
plastic housing/insulator.
Zinc coated terminals.
Easy to mount and connect,
supplied with washers and M12
Nyloc Nuts.
Remote Jump Start Terminals
HM7546J
78
63 45
63
Technical information:
Removes risk of terminal
crossing
High Impact ABS Plastic
Zinc Coated Terminals
Battery Master Lockout Switch
As a further extension to
the accessories range Hella
has developed a heavy-duty
2-pole lockable battery lock
out switch. The Battery lockout
switch provides a reliable power
disconnection and safety cut-off
that protects the vehicle against
tampering, theft and battery drain.
It also protects service personnel
from electrical hazards during
service operations.
Battery Master Lockout Switch
HM7592B
69.1
10
Technical information:
Waterproof and Dustproof
to IP67
Tested to 200G shock for 10
000 cycles.
Sealed design allows switch
to be mounted in the best
location regardless of
environment.
Large red handle makes it
easy to operate with gloved
hands.
Composite-engineered
polymer housing that will not
corrode.
300A continuous current
rating at 12V and 250A at
24V
Temperature operating range
-40°C to + 85°C.
Divider on base prevents
accidental shorting of battery
cables.
Easy to read designations
on bezel and 90° switch
travel make it easy to identify
switch position.
11.4
60.3
135.6

SCREENED CABLES
ACCESSORIES
72
Screened Extension Cables
Screened Extension Cables
with 10A Plug/Socket
10m
HMEC1010AU
15m
HMEC1510AU
20m
HMEC2010AU
25m
HMEC2510AU
Screened Extension Cables
with 15A Plug/Socket
20m
HMEC2015AU
30m
HMEC3015AU
40m
HMEC4015AU
Braid is earthed when cord is in use
10A Socket
15A Socket
Electrical safety is an important
aspect in the overall Occupation
Health and Safety environment,
and there is increasing awareness
that passive elements like cables
and extension cords form a key
link in the safety system.
Permanently installed power
cables are protected from
mechanical damage by conduit,
cable trays and steel wire armour.
Extension cords are not so
protected. This lower degree of
protection is even more obviously
an anomaly when it is considered
that the extension cords used in
construction and maintenance
are not only more likely to be
damaged mechanically than the
permanent cables but also in
much closer proximity to people.
Hella Screened Extension Cables
are specifically designed to
improve safety in a mining and
general industry environment by
offering a more durable and safer
product for tradespeople to use.
Hella Screened Extension Cables
are approved to Australian and
New Zealand standards AS/NZS
3191/3120/3112 and 3199.
Hella Screened Extension Cables
offer superior protection with a
durable protective UV resistant
outer sheath made from PVC
that is designed to withstand the
general wear and tear
of electrical cables in workshop
and field applications.
Hella screened cables also
incorporate clear moulded plug
and socket ends for greater
protection of the user and
the internal conductors
by ensuring there is no
separation of the plug and
cables. These moulded plugs
and sockets also prevent
moisture ingress to minimise
corrosion and ensure a much
longer service life.
Hella Screened Extension
Cables utilise a tinned braided
copper screen for maximum
flexibility and electromagnetic
suppression of the extension
cable. This makes for easy use for
the operator in daily applications
and avoids time-consuming cable
tangles. This protective copper
braid offers greater protection
against damage to the cable and
is also connected to the earth pin
on each end of the extension cable
ensuring that a residual current
device is activated immediately if a
catastrophic failure occurs.
The copper conductor cores used
in all Hella Screened Extension
Cables have a cross sectional
area of 2.5mm². This is to ensure
minimum voltage drop over the
length of the cable and longer life
due to the reduction of heat buildup
within the product.
Utilising a flexible and safer
screened extension cable is
a must for every mine, quarry
and general industry and is
recommended by mining
department safety officials as a
matter of course.
Hella Screened Extension Cables
are available in various length
and current options to suit every
application.
Product Features:
Triple insulated cable
Tinned copper braided shield
is earthed for additional
protection
Extra soft flex to avoid tangles
Heavy-duty strain reliefs
Fully encapsulated plugs and
sockets
Approved to Australian and
New Zealand standards AS/
NZS 3191/3120/3112 and
9199
Reduced electromagnetic
interference
No corrosion of conductors
from moisture in cables,
plugs or sockets
Plug and socket impact
tested to 100 Joule
Cable impact tested to IK10
(20 Joule)
2.5mm² conductors on all
screened extension cables

SCREENED CABLES
Heavy Duty Screened Extension Cables
73
ACCESSORIES
Electrical safety is an
important aspect in the overall
Occupational Health and
Safety environment, and
there is increasing awareness
that passive elements like
cables and extension cords
form a key link in the safety
system.
Permanently installed power
cables are protected from
mechanical damage by conduit, cable
trays and steel wire armour. Extension
cords are not so protected. This lower
degree of protection is an obvious
anomaly – extension cords used in
construction and maintenance are
not only more likely to be damaged
mechanically than permanent cables
but also in much closer proximity to
people.
Hella Heavy Duty Screened Extension
Cables are designed specifically for
ease of use and to improve electrical
safety in the mining and construction
industries by offering a more durable,
safer product for tradespeople to
use in wet and dusty environments.
The electrical plug and socket are
protected against water and dust
ingress to IP66 by a proprietary cover
system that mates with the majority
industry standard screw covers
industrial electrical outlets used in
Australia and New Zealand.
Hella Heavy Duty Screened Extension
Cable insulation and connectors are
moulded using clear protective UV
resistant PVC outer sheath enabling
users and inspectors to rapidly and
reliably visually identity the condition
of all the safety features of cables
brought onto the site or used in the
workshop. A neon lamp indicating
if power is present in the cable is
incorporated in the socket of all Hella
Heavy Duty Screened Extension cables
enabling users to immediately identify
live circuits, and aid testing.
Extended service life and greater user
safety is ensured by reducing moisture
ingress into the extension cable itself
through the use of clear moulded plug
and socket ends ensuring a perfect
seal and stress transfer between the
electrical connectors and the cable
itself. The electrical conductors and
screen are welded to the connector
pins to minimize contact resistance
and the risk of separation between the
plug and cables.
Hella Screened Extension Cables
utilise a braided tinned copper screen
for maximum flexibility across a wide
range temperature range, and avoids
time-consuming cable tangles.
The earthed screen provides
significantly improved suppression
of electro magnetic fields radiated
by the cable, and provides additional
protection fro equipment connected to
the cables against induced currents. As
the first contact caused by mechanical
damage to the cable is to the earthed
screen it ensures that a residual current
device is activated immediately.
The copper conductor cores used in
all Hella Screened Extension Cables
have a cross sectional area of 2.5mm².
This is to ensure minimum voltage drop
over the length of the cable and longer
life due to the reduction of heat buildup
within the product.
Hella Heavy Duty Screened Extension
Cables are approved to Australian
and New Zealand standards AS/NZS
3191/3120/3112 and 3199.
Utilising a flexible and safer screened
extension cable with IP66 rating or
better ingress protection is a must
for every mine, quarry and general
industry and is recommended by
mining department safety officials as a
matter of course.
Hella Heavy Duty Screened Extension
Cables are available in various length
and current options to suit every
application.
Screened Extension Cables
with 10A Plug/Socket
20m
HMIC2010AU
Screened Extension Cables
with 15A Plug/Socket
20m
HMIC2015AU
Screened Extension Cables
with 20A Plug/Socket
30m
HMIC3020AU
IP66
Braid is earthed when cord is in use
10A Socket
15A Socket
20A Socket
Product Features:
Triple insulated cable
Tinned copper braided shield
earthed for additional protection
Extra soft flex to avoid tangles
Heavy-duty strain reliefs
Fully encapsulated plugs and
sockets
Approved to Australian and
New Zealand standards AS/
NZS 3191/3120/3112 and
9199
Reduced electromagnetic
interference
No corrosion of conductors
from moisture in cables,
plugs or sockets
Neon safety light fitted in
socket
IP66 rated protection on
plug/socket connection when
assembled correctly
IP66 cover designed to
suit other major brands of
manufacturers
2.5mm² conductors on all
screened extension cables

NumiLED ® Kits – Small (396mm)
Set of 10 small LED modules, 24V DC
Single number housing, stainless steel
Single number housing, black
Triple number housing, stainless steel
Triple number housing, black
HMTNM6605
HMTNM6606
HMTNM6607
HMTNM6608
HMTNM6609
NumiLED ® Kits – Large (720mm)
Set of 10 large LED modules, 24V DC
Housing, stainless steel
Housing, black
HMTND2156
HMTND2157
HMTND2158
MINING SIGNAL LAMPS
ACCESSORIES
74
®
NumiLED
Number Boards
NumiLED ® is a modular system of robust illuminated
identification panels developed for use in work environments
where situational awareness forms the basis of safe operation,
and where visibility is often very poor. Typical applications are:
identification numbers for mining haul trucks and shovels,
process tanks and conveyor transfer stations.
247
396
Small Board Single
720
Small Board Triple
400
720
Large Board Single
396
The very high levels of dirt in
mining and many industrial
applications render retro-reflective
and normal high contrast signage
ineffective within a short period.
The NumiLED ® system overcomes
these challenges through the
combination of advanced optical
engineering and the best high
intensity LED technology available.
NumiLED ® panels provide
clear, legible identification for
instances up to one kilometre.
Each NumiLED ® unit consists of
a robust housing equipped with
an array of high intensity LED
modules arranged to display
an alphanumeric character of
choice. Hella engineered every
aspect of the NumiLED ® system to
withstand the corrosion, vibration
and generally hostile operational
environment for extended periods.
Designed to indefinitely retain its
full integrity after maintenance,
repairs can be made quickly
without any requirement for
specialised tools or skills.
The active LED modules are
custom versions of proven ‘fit &
forget’ Hella products adapted
to suit this application. The LED
modules are fully sealed and
pre-wired with double insulated
cabling and keyed DT connectors
to eliminate malfunctions due to
water ingress, corrosion or user
errors. Cognisant of the operating
environment, the NumiLED ®
system is designed to allow any
one LED module to be damaged
without impairing the function
of the whole unit. Individual LED
modules can be added, removed
and replaced at any time, allowing
users to re-use or repair, or
recycle NumiLED ® units into new
applications.
To ensure long term reliability
and maintainability, the power
distribution and control of the
LED modules is implemented
as a weatherproof distribution
module with keyed DT sockets
affixed to the rear of the NumiLED ®
housing. The power module is
based on an ultra heavy-duty
military grade dual layer gold
plated PCB incorporating fault
finding diagnostics as well as the
programming control system in the
NumiLED ® PRO versions.
NumiLED ® housings are precision
fabricated from heavy gauge grade
304 stainless plates. A corrosion
and UV resistant black semi gloss
powder coat or natural finishes are
standard options. The NumiLED ®
housing is supplied complete with
power module, prepared fixing
and mounting holes, with the
larger cabling holes fitted with high
quality rubber grommets to prevent
cable chafing. In addition, each
NumiLED ® housing is equipped
with four high quality vibration
dampers to isolate the NumiLED ®
number board from the vibration
generated by the machine it
is mounted to.
Product features
Improves safety &
visibility
Low maintenance
Low energy
consumption
Long service life
Expandable fleet
numbers
Easy to assemble
Spare Parts
9.HMTN001
NumiLED ® 8-Way
Distribution Board
9.HMTN002
NumiLED ® Connection
Cable - Single, 2m
Excellent performance
in hot, cold and wet
environments
Fully sealed against
dust and moisture to
IP6K7
Durable PMMA lens
Robust ABS and PC
housing
9.HMTN003
NumiLED ® Connection
Cable - Triple, 2m
9.HMTN004
NumiLED ® Vibration
Mounting Kit
HM4960SA
DT Connector Kit -
Male (pack of 10)
MULTI
VOLT
LED
DT
5.0Kg
IP6K7
200G
24V DC
60W
MAX

NumiLED ® Pro Boards – Small (396mm)
Single number board, stainless steel
Single number board, black
Triple number board, stainless steel
Triple number board, black
HMTNM6612
HMTNM6613
HMTNM6610
HMTNM6611
NumiLED ® Pro Boards – Large (720mm)
Board, stainless steel
Board, black
HMTND2159
HMTND2160
MINING SIGNAL LAMPS
®
NumiLED
NumiLED ® PRO number boards are even more versatile
featuring the advanced programmable power board with
internal memory function.
Pro
Number Boards
75
ACCESSORIES
Programming
dongle
Product features
Improves safety &
visibility
Pre-assembled and
fitted with all required
LED modules
Programmable power
distribution board
with internal memory
function
Integrated front
mounted MagCode ®
programming port
Supplied with
special MagCode ®
programming dongle to
change characters
Reverse polarity and
voltage spike protected
Low maintenance
Long service life
Expandable fleet
numbers
Sate of the art design
Low energy
consumption
(max. 20W per digit)
Excellent performance
in hot, cold and wet
environments
Fully sealed against
dust and moisture to
IP6K7
Durable PMMA lens
Robust ABS and PC
housing
While the standard NumiLED ® Kit
consists of empty housings and
packs of LED modules that the
end user assembles to create the
desired digits, the programmable
NumiLED ® PRO boards are
supplied fully assembled with all
seven LED modules. The required
digit is selected by simply using
the supplied dongle on the
special integrated MagCode ®
programming port. The NumiLED ®
PRO board will cycle through all
possible digits and stop when the
socket is removed.
The internal memory function
ensures that the selected digit
is displayed every time power is
supplied and will continue to do
so even if a damaged LED module
is replaced. The NumiLED ® PRO
board can be re-programmed at
any time using the same process.
To prevent unauthorized tampering
with the displayed digits, the
front mounted programming port
mechanically disconnects the
electrical connection when the
dongle is removed, which itself
incorporates encrypted data
that the power module must
validate prior to responding to any
programming inputs.
To suit different equipment types,
mounting preferences and visibility
distance requirements found on
mines, Hella offers NumiLED ®
boards in two sizes. While the large
(720mm tall) housing is supplied
as single digits only for ease of
handling, the smaller (396mm tall)
housing is available in both single
and triple digit versions.
The standard NumiLED ® LED
colour is red, but users can obtain
different coloured LED modules
for applications where different
equipment types are identified
through their colour as special
orders.
247
396
Small Board Single
720
Small Board Triple
400
720
Large Board Single
396
Spare Parts
9.HMTN002
NumiLED ® Connection
Cable - Single, 2m
9.HMTN003
NumiLED ® Connection
Cable - Triple, 2m
9.HMTN004
NumiLED ® Vibration
Mounting Kit
9.HMTN005
NumiLED ® PRO
Programming Dongle
9.HMTN006
NumiLED ® PRO
Programmable PCB
HM4960SA
DT Connector Kit -
Male (pack of 10)
HMTNM6605
Small LED Modules,
24V DC (pack of 10)
HMTNM2156
Large LED Modules,
24V DC (pack of 10)
Vibration Damping (Detail)
Distribution Board (Rear View)
MULTI
VOLT
IP6K7
LED
200G
DT
5.0Kg
24V DC
60W
MAX

MINING REVERSING CAMERA KIT
ACCESSORIES
76
Infra-red Dual Camera System
Colour 5.6 inch Monitor, Infra-red
Camera, 20m Cable, 12-24V
HM5700KIT
Colour 7.0 inch Monitor, Infra-red
Camera, 20m Cable, 12-24V
HM5701KIT
Spare Parts:
9.HM5700
Colour 5.6”
Monitor
9.HM5701
Colour 7.0”
Monitor
9.HM5702
Infra-red Reverse
Camera
9.HM5703
Connection cable,
20m
Visibility around vehicles on mine
sites can be an issue, particularly
on large machinery. Hella has
introduced a highly durable LED
Infra-red system with the ability for
customized setup based on the
application.
The Infra-red camera enables
greater visibility by penetrating
harsh dusty environments with
minimal backscatter. The option of
a compact 5.6” monitor or larger
7.0” screen enables site operators
to greatly improve safety.
The unit has a low power burden
on the system of less than 5W
for monitor and less than 2W
for camera and is powered by a
Multivolt system, allowing safe
operation during fluctuation in the
vehicle voltage level between 9
and 32V. The camera also includes
audio pickup with built in speaker
in the monitor for additional safety.
Other features include highly
durable splash proof screen with
automatic day/night dimming
function and manual brightness,
contrast, colour and
volume control as well
as true and mirror image
display modes for camera
mounting flexibility.
The highly durable LED
Infra-red Camera is
constructed from aluminum
alloy and has been designed
to withstand heavy vibration
as well as damage from
harsh environments,
dust and moisture often
encountered on mine sites.
Equipped with 18 high-quality
Infra-red LEDs for excellent night
vision up to 12 metres. The system
features a small physical footprint
for versatile mounting and
overall weight of only 380 grams
(including mounting bracket).
Designed and tested to withstand
a temperature range of -10°C to
+65°C.
9.HM5700 5.6" Monitor
Technical Specifications –
5.6 inch and 7.0 inch
Monitor:
LCD Display
Multivolt system 12V or 24V
DC supply
Low power consumption
< 5W
Built-in speaker
Adjustable brightness,
contrast, colour and volume
control
Auto day/night dimming
function
True/Mirror image selection
on monitor
Camera switching on monitor
Auto trigger function for
optional second camera
Operating temperature range
-15°C to +65°C
Signal system PAL/NTSC Auto
9.HM5701 7.0" Monitor
Technical Specifications –
Infra-red Camera:
Robust aluminium alloy
18pcs IR LEDs for improved
night vision (10-12 metres)
1/4” image size
Focal length of lens 2.6mm,
F2.0
110° diagonal lens angle
Ingress protected to IP68
Low power consumption
< 2W
Compact size (82 x 73 x
58mm)
Light weight of only 380g
(including mounting bracket)
Camera activation by means
of reverse gear selection
Operating temperature range
-30°C to +65°C
9.HM5703 Connection Cable

MINING REVERSING CAMERA KIT
Quad Screen Input Infra-red Camera System
77
ACCESSORIES
To complement
Hella’s visual display
systems a quad screen
system capable of up
to 4 camera inputs has
been developed.
The system is
designed for large
mining machinery
such as loaders
and excavators
where drivers require
viewpoints from multiple angles.
Offering the flexibility of displaying
one, two, three, or even four
camera views, the system caters
for the largest of mining machinery
in many applications.
The monitor is rugged enough for
mining use, with an aluminium
alloy housing providing ingress
protection to IP65. With a weight
of only 800 grams, the monitor has
a small physical footprint in the
driver’s cabin.
The monitor has the ability to
automatically adjust the display
mode according to the number of
camera inputs detected.
Other features include an
automatic day/night dimming
function, along with manual
brightness, contrast, colour
and volume control as well as
independent true and mirror image
display modes for each camera,
offering further mounting flexibility.
The seven inbuilt languages allow
the system to be used in many
different countries by a wide range
of operators.
Also now available is a custommade
heavy-duty steel camera
guard, designed to protect the
infra-red camera from damage and
vandalism.
The kit is designed to withstand
heavy vibration as well as
damage from dust, moisture and
the harsh environments often
encountered on mine sites. The
quality electronics provide reverse
polarity and high and low voltage
protection.
Kit contains monitor bracket, roll
of silicon tape, 1.5m loom cable,
sun visor, 20m extension cable
and IR camera.
Quad Screen IR Camera Kit Monitor,
Infra-red Camera, 20m Cable, 12-24V
HM5800KIT
Spare Parts:
9.HM5702
Infra-red Reverse
Camera
9.HM5703
Connection cable,
20m
9.HM5801 7" Monitor
9.HM5801
Colour Multiscreen
Monitor 17.8cm
(7.0”)
9.HM5802
Steel Camera
Guard
Technical Specifications –
Quad Monitor:
LCD Display 16:9 7”
Multivolt system 12V DC or
24V DC supply
Low power consumption
< 5W
Built-in speaker
Adjustable brightness,
contrast, colour and volume
control
Auto day/night dimming
function
Brightness 350 cd/m²
Resolution 336,960 pixels
True/Mirror image selection
on monitor
Camera switching on monitor
Auto trigger function for
optional second camera
Operating temperature range
–20°C to +70°C
Signal system PAL/NTSC Auto
Dimensions
200(L)*76(W)*138.5(D)
9.HM5802 Steel Camera Guard
9.HM5703 Connection Cable

MASTER SWITCH
ACCESSORIES
78
AccuPAX ®
Battery Master Switch
Battery Master Switch 12V
HM4660A
Battery Master Switch 24V
HM4660B
Spare Parts:
HM4660ROD
iROS Roll-over
Protection Device
HM4660SWA
Latching Push On /
Twist Off Switch -
Double Pole, IP65
HM4660SWB
Latching Push On /
Twist Off Switch -
Double Pole with
Guard, IP65
HM4660SWC
Momentary Push
Button Switch -
Single Pole, IP65
HM4660SWD
Momentary Push
Button Switch -
Single Pole with
Guard, IP65
HM4660SWE
Rotary On / Off
Switch, 4 pin, with
Lid (use connector
1-0967325-kit)
HM4660SWF
Push Button Switch,
2 pin (use connector
1-0967325-kit)
HM4660LOC
Lockable Cover,
Stainless Steel
HM4660KTB 7
Pin DIN Connector
with 5M Harness
HM4660KTC 7
Pin DIN Connector
with 700mm
Harness
AccuPAX ® is an intelligent 2-pole,
bi-stable, electro-mechanical
battery master switch with
mechanical locking. It is approved
for hazardous goods transport. It
incorporates a micro controller to
monitor and operate several safety
functions, that is unavailable on
older style battery isolator switches,
and is suitable for 12V and 24V
systems.
Its prime function is to disconnect
and isolate the main battery positive
and negative circuits of the vehicle
or engine plant to render it safe
and/or inoperable. It may be wired
and operated directly at the control
panel on the switch face to replace
existing products. Significantly
more sophisticated control systems
can be implented, with multiple
safety isolators located in the cabin
or elsewhere at desired locations
around the vehicle. AccuPAX can
also be activated by an external
trigger like a roll-over sensor.
In normal situations, AccuPAX will
step through a pre-programmed
shut-down sequence, ensuring
the safe disconnection of onboard
engine management systems
to avoid data corruption.
Incorporated in this sequence
is an alternator field isolation
procedure to prevent damage
to the alternator, battery and
electrical system due to
voltage surges.
In emergency shut down
situations, such as a rollover,
AccuPAX disconnects all
power immediately via the
emergency shut down
switch, or the optional
rollover detection device.
AccuPAX constantly monitors
system voltage and disconnects the
battery if system voltage falls below
the user selected safety level, to
prevent damage to the electrical
system.
The AccuPAX complies with
Australian Standards AS 2809.2
and European ADR 2005.
In addition to the rollover sensor,
optional equipment includes
lock-out guards, switches and
cable harnesses to facilitate easy
installation of the AccuPAX unit.
168
104
130
Technical information:
Ex & CE Certified
Compliant with ADR 2005
Compliant with AS 2809
(Draft)
Field isolation for North
American vehicles
D+ shutdown for European
vehicles
Delayed ECM shutdown to
prevent re-programming
Direct plug in iROS roll
over device – works with
all other roll over devices
(optional equipment - not
supplied)
Roll over simulation test with
status light
Luminous On/ Off/ Roll Over
push button switches
Robust IP65 rated enclosure
Stainless Steel mounting
bracket (Lucas SSB
interchangeable)
Low battery voltages
disconnect
Lockable cover (optional
equipment – not supplied)
104
Switch Rating: HM4660A HM4660B
Operating Voltage 9 to 15 Volts 18 to 30 Volts
118
Current Rating 300A continuous 300A continuous
127
Max Current 5 Sec 2500A 2500A
130
HM4660A
Max Current 30 Sec 600A 600A
Field Isolation Circuit 10A max 10A max
Optional Low Voltage Monitoring

MASTER SWITCH
79
ACCESSORIES
HM4660LOC Lockable Stainless Steel Cover
HM4660SWA
Latching Push On / Twist Off Switch -
Double Pole, IP65
HM4660SWD
Momentary Push Button Switch -
Single Pole with Guard, IP65
HM4660ROD iROS Roll-over Protection Device

WEATHERPROOF KIT, LOOM TAPE
ACCESSORIES
80
12V Weatherproof Changeover Relay
and Connector Assembly Kit
12V Kit
12V ISO mini relay and connector assembly kit:
HMWPR001
87
87a
86 85
1 x ISO-style 12 volt c/cover relay
1 x Connector body with seals for pull to seat terminals
3 x Large barrel pull to seat terminal 6.3mm width suits
cable size 3.00mm 2
2 x Small barrel pull to seat terminal 6.3mm width suits
cable size 1.00 - 2.00mm 2
30
Voltage
10 -16V DC
30 86 85 87 87a
Operating Range Temp
-40°C to +125°C
35mm
Contact current rating
NO 35A / NC 20A
Coil Resistance @ 23°C
Transient Suppressor Resistor
70-90 Ohms
680 Ohms
56.5mm
Self-Amalgamating Tape
Self-Amalgamating Tape
HMAT85
Polyethylene self-amalgamating loom tape ideal for waterproof sealing of
electrical connections, temporary repair and sealing of plumbing joints.
Also suitable for emergency repair of radiators, engine hoses and auto
electrics. Easy to unwind and resistant to water, ozone, UV and a wide
range of chemicals including alkalis, hydraulic fluids and vegetable oils.
Tape Thickness
Breakdown Voltage
0.5mm, tensile strength at break 12 N/cm
34 kV/mm
Elongation 600%
Service Temperature
-35˚C to +130˚C

CONNECTORS
DT Connectors
81
ACCESSORIES
DT Connectors
Environmentally sealed connectors rated -55°C to
+125°C. Supplied complete with removable, solid
copper crimp contacts (1.0 – 2.0mm 2 ) and secondary
locks. All contacts rated 13A.
HM4960
HM4961
Qty. in
pack
2 Pole DT Connector Set 1 HM4960
2 Pole DT Connector Half-Set* 10 HM4960FM
3 Pole DT Connector Set 1 HM4961
3 Pole DT Connector Half-Set* 10 HM4961FM
4 Pole DT Connector Set 1 HM4962
6 Pole DT Connector Set 1 HM4963
6 Pole DT Connector Half-Set* 10 HM4963FM
8 Pole DT Connector Set 1 HM4964
12 Pole DT Connector Set 1 HM4965
HM4962
HM4963
Spare Parts
Small I.D. plug contact to suit cable 0.5 – 1.0mm 2
Small I.D. socket contact to suit cable 0.5 – 1.0mm 2
Large I.D. plug contact to suit cable 1.0 – 2.0mm 2
Large I.D. socket contact to suit cable 1.0 – 2.0mm 2
Sealing plug
9.HM4960.01
9.HM4960.02
9.HM4960.03
9.HM4960.04
9.HM4960.05
* Half-Set = female socket with male contacts.
HM4964
DT Connector Crimping Tool
Specially dsigned crimping tool with multiple
jaws for even crimp of DT Terminals
HM8275
HM4965
HM8275 DT Connector Crimping Tool

Interior Lighting
83
INTERIOR LIGHTING
84 EuroLED Touch M
85 CargoLED
86 SpotLED
88 FlexSPOT
89 MiniThinLED

EuroLED ® Touch M Interior Lamp
with 2.5m cable
with 0.5m cable and DT plug
HM959950211
HM959950221
MINING INtERIOR LAMPS
INTERIOR LIGHTING
84
®
EuroLED
Touch M
Interior Lamp – Multivolt 9-33V DC
Harnessing the durability and power saving benefits of
advanced single LED technology, EuroLED ® Touch
interior lamps offer long lasting, dual colour LED light
output of white light for general interior illumination
and the additional function of red light to help
maintain night vision (see below).
110
White On
Red On
30
13
Cable Exit
130
30
130
EuroLED Touch interior lamps are
equipped with high-performance
LEDs – a single white LED in the
centre of the lamp plus multiple
red LEDs arranged in a circular
pattern – and highly advanced
lens optics providing a uniform
light distribution without glare for
optimum efficiency and increased
safety. The use of MultivoltTM
electronics ensures a consistent
level of brightness at any input
voltage between 9 and 33V DC,
even when subjected to severe
voltage fluctuations.
Lighting control is made easy
thanks to integral, touch sensitive
switch pads (white pad for white
light, red pad for red light) and a
4-stage dimming function with
memory. All it needs is the touch of
a finger to switch the light colour
and regulate the light intensity
to suit individual cabin lighting
requirements. When the finger is
held on either switch pad for longer
than two seconds, the lamp will
automatically cycle through four
dimming stages until the
finger is released on the
light level required. The
integrated memory function
ensures the lamp turns on at
the light level last selected.
In addition to touch sensitive
switching, EuroLED Touch lamps
are also suitable for synchronised
remote operation from multiple
points using standard On/Off/On
momentary switches.
EuroLED Touch lamps are shock
and vibration resistant and
completely sealed against dust and
moisture to international protection
standards for maximum durability
and increased service life. The
unique rounded and low profile
design allows fitment into narrow
panels, whilst offering distinct
operational and safety benefits.
Compared to common fluorescent
lamps, EuroLED Touch interior
lamps will not interfere with other
electronic equipment and run
completely silent.
Product features
Dual colour LED
lighting
Integral, touch sensitive
switching
Dimming function with
memory
Multivolt 9-33V DC
Ultra low power
consumption
Spare Parts
8HG959952022
EuroLED ® Mounting
Spacer
Shock and vibration
resistance
Over voltage, reverse
polarity and transient
spike circuit protection
Low EMC signature
IP 6K6 6K7 completely
sealed against dust and
moisture
Red Light and Night Vision
The human eye contains two types of receptors,
rods and cones. Both have an increased
sensitivity to frequency bands at different ends of
the visual spectrum. Rods are largely responsible
for our daytime and colour vision and have an increased sensitivity
towards the red band of the visual spectrum. In contrast cones are
responsible for our night vision capability and have an increased
sensitivity towards the blue, shorter wavelength band of the visual
spectrum. For this reason red light helps to preserve our night vision
as it will not affect the sensitivity of the cones.
Mounting Spacer – designed to suit all
EuroLED ® interior lamps. Enables easy
surface mount with side cable exit
MULTI
VOLT
LED
DT &
BARE
WIRE
0.3Kg
IP6K7
200G
9 to 33
V DC
5W

CargoLED ®
Heavy Duty Interior Lamp
HM227HD
MINING INTERIOR LAMPS
®
CargoLED
Heavy Duty Interior Lamp Multivolt 9-31V DC
Hella CargoLED ® is an advanced interior light
designed with particular attention to visual comfort
for applications where operators need high quality
light to perform visually intensive tasks for extended
periods, in operating environments unsuitable for
conventional light sources.
85
INTERIOR LIGHTING
Product features
Aluminium core body
for optimal thermal
performance of LEDs
Clear UV and chemical
resistant modified
acrylic lens
Large optical system
for high light output
Low luminance indirect
design ensures low
glare
High intensity LED light
source array
Sealed unit pre-wired
with multi strand
double insulated cable
Available with DT plugs
Multivolt 9-31V DC
Spike protected to
+500volts
Over voltage protected
to +200volts
Reverse polarity
protected to -500volts
Power consumption:
6W
Sealed to IP6K9 to
withstand temporary
immersion and high
pressure washing when
installed
Surface mount
accessories available
200G shock impulse
resistant
-40ºC – +60ºC
External elements
manufactured from
flame retardant
polymers rated
UL94 HB
ADR 2006 (hazardous
goods transport)
compliant
Traditional vehicle interior
lighting systems do not
deliver the quality of light
required by operators of drill
rigs and other complex plants
who often spend large amounts
work time reading detail maps or
drawings. Concurrently, flat display
panels containing more information
are replacing analogue instruments
in cabins adding to the intensity
and complexity of the visual tasks.
To overcome the limitations of high
susceptibility to physical damage
and poor efficiency inherent in
conventional solutions, Hella
produced the CargoLED. This
unique product combines the best
LED experience with advanced,
glare free, low luminance “indirect”
lighting technology originally
developed for CAD studios. This
highly innovative solution delivers
the visual comfort normally found
in offices into almost any mining
machine cabin.
The low power consumption and
minimal heat output of CargoLED
enables continuous operation in
confined spaces and reduces burn
injury risk.
CargoLED employs a large
“brilliant” Free-Form optical system
and clear lens to provide a large
homogenous area illumination
with maximum efficiency. Hella
engineered CargoLED lamps to
ensure a very long service life and
no lighting loss due to internal dirt
build-up. Maximum service life and
light output of the high intensity
LEDs is ensured through using the
aluminium body as a massive heat
sink. The clear exterior lens can
be re-polished if required, with no
detrimental effect on light-output or
chemical resistance. CargoLED is
unaffected by shock and vibration,
ensuring high reliability. The lamp is
fully sealed and designed for a true
“fit and forget” installation.
Advanced Multivolt control of
the LEDs ensures consistent
illumination from 9-31V DC – even
under severe voltage fluctuations
and low battery voltages. This
delivers significantly better
performance than low-power
fluorescent or incandescent interior
lights. The circuitry also provides
reverse polarity, spike and overvoltage
protection for long life and
reliable operation.
Safe and reliable electrical
connection is facilitated via a
short length double insulated
cable terminated as standard in
DT connectors. A thick gasket is
supplied to ensure reliable sealing
for recessed installation, and an
optional surface mount adaptor
is available.
Shown lit
MULTI
VOLT
LED
DT
0.5Kg
IP6K9
200G
9 to 31
V DC
6W

SpotLED ®
Screw Mount, DT
l White Cover
l White Cover
l Red Ambient Ring
l Yellow Cover
l Yellow Cover
l Red Ambient Ring
l Black Cover
l Black Cover
l Red Ambient Ring
Fixed HM680FNW HM680FRW HM680FNY HM680FRY HM680FNB HM680FRB
Adjustable HM680ANW HM680ARW HM680ANY HM680ARY HM680ANB HM680ARB
MINING INTERIOR LAMPS
MOBILE INTERIOR EQUIPMENT LIGHTING
LIGHTING
86
®
SpotLED
Fixed & Adjustable Interior Lamps Multivolt 9-31V DC
SpotLED ® lamps are sophisticated LED interior lights
designed for applications where there is a requirement
for low glare, spill free lighting, with the option to
switch from white primary to red ambient light to
maintain night vision.
Fixed Model
Adjustable Model
Adjustable Model (20°), shown with
white LED illuminated, and white cover
SpotLED interior lights are available
in a number of versions: These
include fixed or adjustable optical
modules either with or without the
low level ambient illumination to
monitor critical instruments.
General illumination is provided by
a single high intensity white LED
located deep inside a Free-Form
reflector with a black sleeve to
eliminate direct view of the light
source and discomfort glare. A
separately switched, low intensity
red LED illuminates a circular
light CELIS light guide, to provide
low intensity ambient illumination
for safety and night vision
compatability.
The low power consumption,
combined with minimal heat output
in continuous use, and ergonomic,
smooth design of SpotLED reduces
personal injury risk in confined
spaces, while the fit-and-forget
completely sealed and waterproof
optical units will not suffer lighting
loss due to internal dirt build up.
Advanced Multivolt drive circuitry,
providing reverse polarity, spike
and over-voltage
protection for long life
and reliable operation,
is sealed into the
optical module. SpotLED
lamps deliver consistent
illumination from 9-31V
DC – even under severe voltage
fluctuations and low battery
voltages. Maximum service life and
light output of the high intensity
LED light source is ensured
through an integral aluminium
heat sink.
SpotLED lights require external
switching systems, and can
operate on standard interior
light circuits.
Safe and reliable electrical
connection is facilitated via a short
length double insulated multi core
cable terminated as standard in
DT connectors.
The screw cover end caps are
available in a range of colours.
Ambient light functions in amber,
blue, green or white can also be
delivered on special order.
Product features
Available in fixed or
adjustable versions
20 degree angle
adjustment to each side
Low intensity red CELIS
ambient light
Aluminium heat sink
mounted LED
Clear polycarbonate
lens and CELIS light
guide for excellent
optical performance
and impact resistance
Impact resistant, easy
to clean ABS housing
components
Low glare homogenous
light distribution
High intensity LED light
sources
Changeable colour side
caps
Pre-wired with multi
strand double insulated
cable with DT
Multivolt 9-31V DC
Reverse polarity
protected to -500 volts
Power consumption:
3W
Fully sealed to IP6K9K
(optical unit) to
withstand temporary
immersion and high
pressure washing
200G shock impulse
resistant
-40ºC – +60ºC
External elements
manufactured from
flame retardant
polymers rated UL94
HB
ADR 2006 (hazardous
goods transport)
compliant
Fixed Model, shown with Red Ambient
Ring illuminated, and white cover
Spare Parts
9.HMDLM002
Marker Housing Yellow
(Pack of 4)
MULTI
VOLT
LED
DT
0.3Kg
IP6K7
200G
9 to 31
V DC
3W

87
INTERIOR LIGHTING
Adjustable model shown
Optional
Yellow
Cover
Optional
Black
Cover
Optional
White
Cover

FlexSPOT ® LED Interior Lamp l White Shroud l Yellow Shroud
150mm flexible arm HM720150W HM720150Y
400mm flexible arm HM720400W HM720400Y
MINING INTERIOR LAMPS
INTERIOR LIGHTING
88
FlexSPOT
®
LED Interior Lamp Multivolt 9-31V DC
FlexSPOT LED ® is a flexible arm LED interior lamp with
integral switch, for use in applications where the operating
environment is unsuitable for conventional light sources.
A new generation of high efficiency
white LED light sources enabled
the design of a fit-and-forget low
power reading light with a very long
service life and little heat build-up,
enabling continuous use of the
FlexSPOT with no danger of over
heating or burn injury.
FlexSPOT LED is unaffected by
shock and vibration and has a
high-reliability switch integrated
into the lamp head, for ease of
use and integration into work
environments. Advanced Multivolt
circuitry, providing reverse polarity,
spike and over-voltage protection
for long life and reliable operation
of the LED, is sealed into the
light. FlexSPOT lamps will deliver
consistent illumination from 9-31V
DC – even under severe voltage
fluctuations and low battery
voltages. Maximum service life and
light output of the high intensity
LED light source is ensured by an
aluminium heat sink internal to the
lamp head.
We have tested the SpotLED
lamp head to the same exacting
standards demanded of Hella
Mining LED signal lights. Hella
bonded the best quality flexible
arm available into the head and
mounting bracket to ensure a
long, trouble-free life for the
FlexSPOT.
Safe and reliable electrical
connection is facilitated via a short
length double insulated cable
terminated as standard with bare
wire ends.
Product features
Aluminium heat sink
for optimal thermal
performance of LEDs
UV and chemical
resistant modified
acrylic lens
Impact resistant
polycarbonate and ABS
housing
Integral switch
Low glare homogenous
light distribution
High intensity LED light
source
Pre-wired with multi
strand double insulated
cable
Available with DT plugs
or bare wire ends
Reverse polarity
protected to
-500 volts
Power consumption:
2.5W
Sealed to IP53 protects
active electronics and
optics against splashed
liquid
200G shock impulse
resistant
-40ºC to +60ºC
External elements
manufactured from
flame retardant
polymers rated
UL94 HB
EC, ROHS and ADR
2006 (hazardous goods
transport) compliant
Multivolt 9-31V DC
MULTI
VOLT
LED
BARE
WIRE
0.4Kg
IP53
200G
9 to 31
V DC
2W

MiniThinLED ® Interior Lamp l Red l White l Blue l Green
24V DC HM6605RD-24V HM6605WD-24V HM6603BD-24V HM6603GD-24V
12V DC HM6605RD-12V HM6605WD-12V HM6603BD-12V HM6603GD-12V
MINING INTERIOR LAMPS
®
MiniThinLED
Interior Lamp
89
MOBILE EQUIPMENT
INTERIOR LIGHTING
LIGHTING
MiniThinLED ® lamps are robust low profile
multi-use LED lamps ideal for general
applications such as insteps, ambient and
storage lights.
MiniThinLED lamps feature an
ergonomic and user-friendly
design only 11mm high, with no
sharp edges when installed. Hella
engineered MiniThinLED lamps
to ensure a very long service life
and no lighting loss due to internal
dirt build-up; they are also very
well suited to wet and corrosive
environments and tolerate short
term immersion.
Designed for flush mounting,
the clear exterior lens can be
re-polished if required with no
detrimental effect on light-output or
chemical resistance. MiniThinLED
is fully sealed and unaffected by
shock and vibration, ensuring high
reliability for a true “fit and forget”
installation. The lamps are available
in a range of LED colours (red,
blue, green and white) to suit a
wide range of applications.
Safe and reliable electrical
connection is facilitated via a
short length double insulated
multi core cable terminated with
bare wire ends.
Product features
Approximately 136 x
30 x 11mm
12V or 24V versions
Various colour
possibilities
State of the art design
Easy flush mounting
screw version
Excellent durability “Fit
and Forget”
Low energy
consumption 1.2W –
2.8W
Excellent performance
in heavy, cold and wet
environments
Water resistant IP69
Performance
temperature range -40
to +60C
Quality materials:
PMMA (Lens) and
ABS+PC (Housing)
5 LED Red
5 LED White
3 LED Blue
3 LED Green
LED
BARE
WIRE
0.1Kg
IP69
200G
12/24
V DC
3W

Alarms & Horns
91
ALARMS & HORNS
92 MotoVOX
93 RetroVOX Self Adjusting
94 RetroVOX Compression Driver
95 RetroVOX Broadband

REVERSING ALARMS
ALARMS & HORNS
92 MotoVOX
®
Compact 117dB Horn
MotoVOX ® 117dB Compact Horn
HMFH312P
128
95
+
- 77
Solid state electronic horn designed for extremely long life and to
replace high maintenance electromechanical horns. This model is
designed to meet or exceed all applicable SAE specifications. Used
by major OEMs.
Voltage 12-24V DC
Decibel 117 @ 1.2m
Approval SAE J1105 Sept 89, Type K.
U.L. recognised for electric vehicles and fork lifts.
MotoVOX ®
Forward 117dB Horn
MotoVOX ® FH117 92mm 117dB Horn
HMFH117P
118mm
183.1mm
81mm
Electronic forward horn is designed to be used where a high-decibel
rugged horn is necessary.
Voltage 12-24V DC
Decibel 117 @ 1.2m
Approval SAE J1105 Sept 89, Type J @ 24V systems
SAE J1105 Sept 89, Type K @ 12V systems
81mm
127mm
MotoVOX ®
Compact 107dB Horn
78mm
MotoVOX ® FH107 107dB Horn
HMFH107P
Solid state electronic horn designed for extremely long life and to
replace high maintenance electromechanical horns. This model is
designed to meet or exceed all applicable SAE specifications. Used
by major OEMs.
Voltage 12-48V DC
Decibel 107 @ 1.2m
Approval SAE J1105 Sept 89, Type L
92mm
118mm
81mm
183.1mm
81mm

REVERSING ALARMS
RetroVOX ®
Self Adjusting Reversing Alarm
93
ALARMS & HORNS
Steel housing and construction for rugged applications.
Integral bracket includes same mounting pattern with OEMs, self
adjusting. Suitable for high pressure washing, epoxy encapsulated
circuit board protects alarm against moisture and vibration damage.
RA917 Self Adjusting 112dB Alarm
HMRA917E
Voltage
12- 24V DC
Decibel 87 - 112 @ 1.2m
Approval
SAE J994 Type D
180
4.4
78
3.08
102
4.0
RetroVOX ®
Ultra Heavy Duty Reversing Alarm
One of the most rugged adjustable, heavy-duty alarms
on the market. These alarms are designed to withstand the most
punishing environments. They have #8-32 UNC terminal studs on the
back of the unit. Used by major OEMs.
Voltage
12- 36V DC
Decibel 97, 107, 112 @ 1.2m
RA112 Ultra Heavy Duty 112dB Alarm
HMRA112P
163
102
Approval
SAE J994 Types A, B & C

REVERSING ALARMS
ALARMS & HORNS
94 RetroVOX
®
Compression Driver Reversing Alarm
(Manual)
RetroVOX ® Compression Driver
112dB Alarm (Manual)
HMRA603P
178
152
101
New high-efficiency reversing alarms with reduced power draw
and significantly better acoustic performance over life. Heavy-duty
polymer construction fits popular OEM dimensions. Fully encapsulated
spark-free electronics (IP68) allows high pressure water cleaning.
200G shock resistant.
HMRA603P
81
Voltage
Decibel
Approval
12-24V DC (reverse polarity protected)
117dB @ 1.2m, 97/107/112dB @1.2m, manual
adjustment
SAE J994 class A/B/C
RetroVOX ®
Compression Driver Reversing Alarm
(Automatic)
RetroVOX ® Compression Driver
112dB Alarm (Automatic)
HMRA611P
178
152
101
New high efficiency reversing alarm with reduced power draw and
significantly better acoustic performance over life. Heavy-duty
polymer construction fits popular OEM dimensions. Fully encapsulated
spark-free electronics (IP68) allows high pressure water cleaning.
200G shock resistant.
HMRA603P
81
Voltage
Decibel
Approval
12-24V DC (reverse polarity protected)
87-112dB @1.2m, automatic adjustment to SAE J994
requirement
SAE J994 classes A-D

ALARMS
RetroVOX ® Compact Broadband 87dB Alarm
95
ALARMS & HORNS
Noise Pollution can be an issue for mine sites close to residential areas.
Hella have introduced a range of broadband or ‘white noise’ reversing
alarms to prevent miners from having to compromise on safety. By
emitting sound over a large range of frequencies, the sound dissipates
faster and is localized so that sound doesn’t carry. The RetroVOX features
a rugged design, which is highly reliable and unaffected by continuous
vibration, moisture, heat, cold, sun glare and dirt.
RetroVOX Broadband 87dB Alarm
HMRA087B
91
45
76
55
Voltage
Current
Decibel
12-24V DC
Max. 0.5 Amps
87 @ 1m
Approval SAE J994 Class E 11
CE & EMC Approved
Product Features:
Ingress Protected to IP68
(waterproof)
Solid-state, spark-free
electronics
Epoxy-sealed against mud,
water and vibration
Can be steam-cleaned and
pressure-hosed
RetroVOX ®
Broadband 87-112dB Reversing Alarm
Broad band or “white noise” reversing alarm for applications where normal
reversing alarm sounds cause problems. Heavy-duty construction fits
popular OEM dimensions. Solid-state fully sealed spark-free electronics
(IP68) allows high pressure water cleaning. 200G shock resistant.
RetroVOX Broadband 112dB Alarm
(Manual)
HMRA107B
Voltage
Decibel
Approval
12-24V DC (reverse polarity protected)
87-112dB @1.2m
SAE J994 class A-D EC, E11
95
152
173
80
155

Service Tools
97
SERVICE TOOLS
98 EziPAK DT Connector Kit
100 EziPAK Double Crimp Kit
102 EziPAK Heat Shrink Kit
104 EziPAK Intelligent Fuse Kit
106 Super Seal Connector
107 PowerPAK

CONNECTOR KITS
SERVICE TOOLS
98
EziPAK ®
DT Connector Kit
EziPAK ® DT Connector Kit
(389 Pieces)
(See list of included components next page)
EziPAK ® DT Connector Kit
(incl. Crimping Tool HM8276)
Accessories
Universal DT Contact
Crimping Tool
HM8283
HM8275
DT Contact Crimping Tool
0.5 - 1.0mm HM8277
EziPAK ® Double Drawer
Storage Module (empty)
EziPAK ® Single Divisional
Carry Case (empty)
HM8285
HM8286
Hella has developed a new range
of EziPAK ® service kits to meet
the need of mobile field service
technicians maintaining mining
machines on site.
EziPAK ® kits are based on many
years of practical experience.
Each kit is contained in an
impact resistant and washable,
heavy-duty injection moulded
carry case that slides into a self
locking modular double storage
tray for easy installation into field
service vehicles or use as a central
storage point in the workshop
environment.
The DT connector kit to service the
popular DEUTSCH connectors is
the first module of the range to be
released.
The EziPAK ® kit is supplied with
the most popular DEUTSCH
connectors including the
essential tools to make and
repair these connections and
a highly detailed step-bystep
instruction document
ensuring that users obtain truly
professional results.
Each EziPAK ® kit is supplied
with a hard wearing large format
visual reference of it’s contents,
this also contains the re-order
information for refill packs of
DT consumables, thus enabling
customers to maintain the
EziPAK ® service kit indefinitely.
Additional tools, empty carry
cases and rack modules are
also available to allow service
teams to create their own
customised kits if needed.
HM8283
HM8285
HM8275
HM8277

CONNECTOR KITS
99
SERVICE TOOLS
DT Connectors (included in EziPAK ® DT
Connector Kit)
Qty in
pack
2-Way Male DT Connector (incl. wedge) 15
9.HM4940
2-Way Female DT Connector (incl. wedge) 15 9.HM4941
3-Way Male DT Connector (incl. wedge) 15
9.HM4942
3-Way Female DT Connector (incl. wedge) 15
9.HM4943
4-Way Male DT Connector (incl. wedge) 10
9.HM4944
4-Way Female DT Connector (incl. wedge) 10
9.HM4945
6-Way Male DT Connector (incl. wedge) 10
9.HM4946
6-Way Female DT Connector (incl. wedge) 10
9.HM4947
8-Way Male DT Connector (incl. wedge) 5
9.HM4948
8-Way Female DT Connector (incl. wedge) 5
9.HM4949
12-Way Male DT Connector (incl. wedge) 5
9.HM4950
12-Way Female DT Connector (incl. wedge) 5
9.HM4951
3-Way Round Male HDT Connector 5
9.HM4952
3-Way Round Female HDT Connector 5
9.HM4953
Male DT Connector Pin 100
9.HM4954
Female DT Connector Socket 100
9.HM4955
Connector Sealing Plug 50
9.HM4956
9.HM4940
9.HM4942
9.HM4944
9.HM4946
9.HM4941
9.HM4943
9.HM4945
9.HM4947
Service Tools (included in EziPAK ® DT
Connector Kit)
DT Contact Crimping Tool 1.0 - 2.0mm 1
HM8276
9.HM4948
9.HM4949
DT Contact Removal Tool 1.0 - 2.0mm 3
9.HM4957
DT Contact Removal Tool 0.5 - 1.0mm 3
9.HM4958
DT Connector Wedge Removal Tool 1
9.HM4959
9.HM4950
9.HM4951
9.HM4954 9.HM4955 9.HM4956
9.HM4952
9.HM4953
9.HM4957 9.HM4958 9.HM4959
HM8276

CONNECTOR KITS
SERVICE TOOLS100
EziPAK ®
Double Crimp Connector Kit
EziPAK ® Double Crimp
Connector Kit (3,652 Pieces)
(See list of included components next page)
EziPAK ® Double Crimp
Connector Kit
Accessories
EziPAK ® Double Drawer
Storage Module (empty)
EziPAK ® Single Divisional
Carry Case (empty)
HM8284
HM8285
HM8286
Hella has developed a new range
of EziPAK ® service kits to meet
the need of mobile field service
technicians maintaining mining
machines on site.
EziPAK ® kits are based on many
years of practical experience.
Each kit is contained in an
impact resistant and washable,
heavy-duty injection moulded
carry case that slides into a self
locking modular double storage
tray for easy installation into field
service vehicles or use as a central
storage point in the workshop
environment.
The professional double crimp
connector kit is supplied with
the most popular terminals and
connectors as well as a ratchet
crimping tool ensuring that users
obtain truly professional results.
Each EziPAK ® kit is supplied
with a hard wearing large
format visual reference of it’s
contents, this also contains
the re-order information for
refill packs of consumables,
thus enabling customers to
maintain the EziPAK ® service kit
indefinitely.
Additional empty carry cases
and rack modules are also
available to allow service teams
to create their own customised
kits if needed.
HM8284
HM8285

CONNECTOR KITS
101
SERVICE TOOLS
Double Crimp Connectors (included in EziPAK ®
Double Crimp Connector Kit)
Qty in
pack
Push-On Female Terminal - Red, 6.3mm 200
9.HM8500
Push-On Female Terminal - Blue, 6.3mm 200
Push-On Female Terminal - Yellow, 6.3mm 150
9.HM8501
9.HM8502
9.HM8500
9.HM8501
Push-On Female Terminal - Yellow, 9.5mm 100
9.HM8503
Fully Insulated Female Blade Terminal - Red, 6.3mm 200
9.HM8504
Fully Insulated Female Blade Terminal - Blue, 6.3mm 200
9.HM8505
9.HM8502
9.HM8503
Push-On 2-Way Male/Female Terminal - Blue, 6.3mm 200
9.HM8511
Male Blade Terminal - Red, 6.3mm 200
9.HM8513
Male Blade Terminal - Blue, 6.3mm 200
Single Male Bullet Connector - Red 200
9.HM8514
9.HM8520
9.HM8504
9.HM8505
Single Male Bullet Connector - Blue 200
9.HM8521
Single Female Bullet Connector - Red 200
9.HM8522
Single Female Bullet Connector - Blue 200
Cable Connector - Red 200
9.HM8523
9.HM8530
9.HM8511
9.HM8513
Cable Connector - Blue 200
9.HM8531
Cable Connector - Yellow 100
Eye Terminal - Red, 5.0mm 200
9.HM8532
9.HM8541
9.HM8514
9.HM8520
Eye Terminal - Blue, 5.0mm 200
9.HM8543
Eye Terminal - Yellow, 9.5mm 200
Eye Terminal - Yellow, 5.0mm 100
9.HM8548
9.HM8549
9.HM8521
9.HM8522
Crimping Tool (included in
EziPAK ® Double Crimp Connector Kit)
Ratchet Crimping Tool 1
8273
9.HM8523
9.HM8530
9.HM8531
9.HM8532
9.HM8541
9.HM8543
8273
9.HM8548
9.HM8549

REPAIR KITS
SERVICE TOOLS102
EziPAK ®
Heat Shrink Harness Repair Kit
EziPAK ® Heat Shrink Harness
Repair Kit (270Pieces)
(See list of included components next page)
EziPAK ® Heat Shrink Harness
Repair Kit
Accessories
EziPAK ® Double Drawer
Storage Module (empty)
EziPAK ® Single Divisional
Carry Case (empty)
HM8287
HM8285
HM8286
Hella has developed a new range
of EziPAK ® service kits to meet
the need of mobile field service
technicians maintaining mining
machines on site.
EziPAK ® kits are based on many
years of practical experience.
Each kit is contained in an impact
resistant and washable, heavyduty
injection moulded carry
case that slides into a self locking
modular double storage tray for
easy installation into field service
vehicles, or use as a central
storage point in the workshop
environment.
The EziPAK ® kit comprises six of
the most popular size heat shrink
sleeves as well as five different
sized solder sleeves. A battery
operated soldering iron and a
flameless heat gun are also part
of the kit.
Hella adhesive-lined, medium-wall
heat-shrink sleeving is a versatile,
environmentally friendly choice for
many commercial and heavy-duty
mining applications that require
mechanical protection and sealing
against moisture and chemical
ingress, whilst maintaining
flexibility when installed. Typical
applications include environmental
sealing and protection or irregular
shapes, such as wire splices,
breakouts and connector-tocable
transitions, in demanding
industries. Hella heat-shrink
sleeving features an outer
jacket of radiation-cross
linked, flexible, flame-retardant
polyolefin. Unlike other typical
flame-retardant sleeving,
Hella Mining sleeving is free
of polybrominated biphenyl
oxides (PBBOs). In Europe,
these chemicals are classified
as environmentally hazardous
substances.
As the sleeving shrinks, the
inner adhesive liner melts and
flows to seal and encapsulate
components or splices
contained within. The adhesive
bonds to a wide range of
plastics, rubber and metals,
including polyethylene,
neoprene and steel. With a
high shrink ratio of 3:1, only a
few sizes of Hella heat-shrink
sleeving are needed to cover
a wide range of substrate
diameters and irregular
shapes, enhancing inventory
efficiency. Hella heat-shrink
sleeving is UL recognized (E35586)
and CSA-certified (LR31929) at
125ºC, 600V.
Additional empty carry cases and
rack modules are also available to
allow service teams to create their
own customised kits if needed.
HM8287
HM8285

REPAIR KITS
103
SERVICE TOOLS
Heat Shrink Sleeving (included in
EziPAK ® Heat Shrink Harness Repair Kit)
Qty in
pack
Adhesive Lined Heat Shrink Sleeving 3.2mm 35 9.HM4960
Adhesive Lined Heat Shrink Sleeving 6.4mm 35 9.HM4961
Adhesive Lined Heat Shrink Sleeving 9.5mm 35 9.HM4962
Adhesive Lined Heat Shrink Sleeving 12.7mm 20 9.HM4963
Adhesive Lined Heat Shrink Sleeving 19.1mm 10 9.HM4964
9.HM4965
Adhesive Lined Heat Shrink Sleeving 25.4mm 6 9.HM4965
Solder Sleeve – Clear, 1.7mm 25 9.HM4966
Solder Sleeve – Red, 2.7mm 25 9.HM4967
Solder Sleeve – Blue, 4.5mm 25 9.HM4968
9.HM4964
Solder Sleeve – Yellow, 6.0mm 25 9.HM4969
Solder Sleeve – Grey, 7.0mm 25 9.HM4970
Service Tools (included in
EziPAK ® Double Crimp Connector Kit)
9.HM4963
Battery powered soldering iron 1 HM8288
Flameless gas heat gun 1 HM8289
Lead Free Solder in Cartridge 1 9.HM4971
9.HM4962
Insulation Tape – Black, 19mm x 20m Lead Free 10 9.HM4972
9.HM4961
9.HM4960
HM8288
9.HM4970
HM8289
9.HM4969
9.HM4968
9.HM4967
9.HM4971
9.HM4972
9.HM4966

FUSE KITS
SERVICE TOOLS104
EziPAK ®
Intelligent Fuse Kit
EziPAK ® Intelligent Fuse Kit
(556 Pieces)
(See list of included components next page)
EziPAK ® Intelligent Fuse Kit
Accessories
EziPAK ® Double Drawer
Storage Module (empty)
EziPAK ® Single Divisional
Carry Case (empty)
HM8290
HM8285
HM8286
Hella has developed a new range
of EziPAK ® service kits to meet
the need of mobile field service
technicians maintaining mining
machines on site.
EziPAK ® kits are based on many
years of practical experience.
Each kit is contained in an impact
resistant and washable, heavyduty
injection moulded carry
case that slides into a self locking
modular double storage tray for
easy installation into field service
vehicles, or use as a central
storage point in the workshop
environment.
The professional Intelligent
Fuse Kit features all the popular
amperage and blade fuse
sizes. The range of blade fuses
contained in the EziPAK ® kit
comprises of mini fuses, standard
fuses and maxi fuses all equipped
with an LED to indicate when a
fuse is blown.
This aid in visual fault finding and
a blown fuse can be recognised
in an instant due to the LED
indicating the condition of the
fuse. When the LED on the
fuse is illuminated, this would
indicate a blown fuse. The fuses
are a direct replacement for
standard blade fuses and no
modifications are necessary to
convert to this system.
The Intelligent Fuse Kit also
comes complete with a fuse
puller and a universal voltage
tester.
The fuse puller is also a terminal
tester with test LED. The
terminal tester is adjustable to
all sizes of fuse terminal as per
the kit offering.
Additional empty carry cases
and rack modules are also
available to allow service
teams to create their own
customised kits if needed.
HM8290
HM8285
LED glows if fuse blows, for instant identification

FUSE KITS
105
SERVICE TOOLS
LED Fuses
(included in EziPAK ® Intelligent Fuse Kit)
Qty in
pack
Mini Blade Fuse - 3A, Violet 30 9.HM4973
Mini Blade Fuse - 5A, Tan 30 9.HM4974
Mini Blade Fuse - 7.5A, Brown 30 9.HM4975
Mini Blade Fuse - 10A, Red 30 9.HM4976
Mini Blade Fuse - 15A, Blue 30 9.HM4977
Mini Blade Fuse - 20A, Yellow 30 9.HM4978
Mini Blade Fuse - 25A, Natural 30 9.HM4979
Mini Blade Fuse - 30A, Green 30 9.HM4980
Blade Fuse - 3A, Violet 30 9.HM4981
Blade Fuse - 5A, Tan 30 9.HM4982
Blade Fuse - 7.5A, Brown 30 9.HM4983
Blade Fuse - 10A, Red 30 9.HM4984
Blade Fuse - 15A, Blue 30 9.HM4985
Blade Fuse - 20A, Yellow 30 9.HM4986
Blade Fuse - 25A, Natural 30 9.HM4987
Blade Fuse - 30A, Green 30 9.HM4988
Blade Fuse - 40A, Amber 30 9.HM4989
Maxi Blade Fuse - 20A, Yellow 15 9.HM4990
Maxi Blade Fuse - 30A, Green 15 9.HM4991
Maxi Blade Fuse - 40A, Orange 15 9.HM4992
Service Tools
(included in EziPAK ® Intelligent Fuse Kit)
LED Fuse Puller/Tester - Yellow 1 9.HM4993
9.HM4973
9.HM4975
9.HM4977
9.HM4979
9.HM4981
9.HM4983
9.HM4974
9.HM4976
9.HM4978
9.HM4980
9.HM4982
9.HM4984
9.HM4985
9.HM4986
9.HM4987
9.HM4988
9.HM4989
9.HM4990
9.HM4993
9.HM4991
9.HM4992

CONNECTORS
SERVICE TOOLS106 Super Seal Connectors
Super Seal Connector Kit
5 of each Super Seal connector plug and socket
100 x Plug terminals, Part No. 9.HM4980.02
100 x Socket terminals, Part No. 9.HM4980.04
100 x Yellow con ductor seals, Part No. 9.HM4980.06
100 x Red cavity plugs, Part No. 9.HM4980.09
HM4980
Super Seal Connectors
Waterproof (IP 67) connectors with secondary locks.
Supplied without metal terminals, seals and cavity plugs; these are to be
ordered separately under part numbers HM4980.01/02/04/05/06/07/09.
Qty. in
pack
1 Pole Super Seal Plug 4 HM4981-P
1 Pole Super Seal Socket 4 HM4981-S
2 Pole Super Seal Plug 4 HM4982-P
2 Pole Super Seal Socket 4 HM4982-S
3 Pole Super Seal Plug 3 HM4983-P
3 Pole Super Seal Socket 3 HM4983-S
4 Pole Super Seal Plug 3 HM4984-P
4 Pole Super Seal Socket 3 HM4984-S
5 Pole Super Seal Plug 2 HM4985-P
5 Pole Super Seal Socket 2 HM4985-S
6 Pole Super Seal Plug 2 HM4986-P
6 Pole Super Seal Socket 2 HM4986-S
HM4980 Super Seal Connector Kit
HM4981-P HM4982-P HM4983-P
HM4981-S HM4982-S HM4983-S
HM4984-P HM4985-P HM4986-P
Spare Parts
Qty. in
pack
Plug terminals to suit cable 0.35 – 0.50mm 2 50 9.HM4980.01
Plug terminals to suit cable 0.75 – 1.50mm 2 50 9.HM4980.02
Socket terminals to suit cable 0.35 – 0.50mm 2 50 9.HM4980.03
Socket terminals to suit cable 0.75 – 1.50mm 2 50 9.HM4980.04
Green seal to suit cable insulation 1.4 – 1.7mm dia. 50 9.HM4980.05
Yellow seal to suit cable insulation 1.8 – 2.4mm dia. 50 9.HM4980.06
Red seal to suit cable insulation 2.5 – 3.3mm dia. 50 9.HM4980.07
Red cavity plug 50 9.HM4980.09
HM4984-S HM4985-S HM4986-S
Plug Terminal
Socket Terminal
9.HM4980.05 9.HM4980.06 9.HM4980.07
Super Seal Connector Crimping Tool
Crimping tool designed for use with
Super Seal connector terminals.
HM8298
HM8298 Super Seal Connector Crimping Tool

POWER PACK
PowerPAK
Portable Power Pack
107
SERVICE TOOLS
The
PowerPAK
is designed
for portable
emergency
power to run
remote area work
lamps, signal
beacons or other
12 volt accessories.
PowerPAK is a fully integrated
battery pack with three different
styles of power outlets.
PowerPAK is a plug and play
user friendly system that is fully
integrated into a water resistant
lockable carry case and has
an internal battery charger that
charges off mains power.
Alternatively, the PowerPAK can
also be recharged from a vehicle
12 volt system.
The PowerPAK is a highly mobile
and easy to carry power supply,
particularly useful for service
technicians and mining
maintenance personnel operating
in remote and isolated locations.
The three different style power
outlets make the unit suitable for
a diverse range of applications in
mining, automotive, camping or
marine environments.
Each power outlet is independently
fused to 15 Amps using a quality
LED fuse that illuminates when
blown, enabling users to visually
see which circuit has had a fault.
Combining a quality deep cycle
marine-grade battery with a water
resistant heavy-duty carry case
and a truly rugged power supply
enables trades people to carry out
repairs in the field when 240 volt
mains supply is not suitable.
The three different power outputs
allow for simultaneous operation of
12 volt equipment and lighting.
The quality electronics allow the
unit to be charged on 12 volt
supply through the bi-directional
power outputs for charging on the
go or via 240 volt mains supply.
The Deep cycle 18Ah marine gel
battery can be replaced if required,
extending the lifetime of the
PowerPAK system.
PowerPAK Portable
Emergency Unit
HM8600
12V
DC
15A
Max
Spare Parts:
Mag
Code
9.HM8600B
Replacement battery
9.HM8600C
Charging cable to
suit vehicle
CIG
DIN
9.HM4985
15A LED Blade
Fuses
(30 Pack)
Product Features:
1 MagCode connection
1 Cigarette lighter connection
1 Din plug connection
240 Volt and 12 Volt charge
Deep Cycle Marine GEL 12
Volt
18Ah battery
Compatible with DuraLed ® Work Lamp, Magnetic Base,
Part No. HM1550MAG12
Part No. HM1550CIG

Electrical
109
ELECTRICAL
110 AC/DC Transformers
111 Power Connectors
112 LED Rocker Switches
113 LED Pilot Lamps
114 Heavy Duty Circuit Breakers
115 Thermal Circuit Breakers
116 MagCode

ELECTRONIC TRANSFORMERS
ELECTRICAL
110 AC/DC Electronic Transformers
240V AC – 12V DC
20VA HM1220AC
60VA HM1260AC
240V AC – 24V DC
20VA HM2420AC
60VA HM2460AC
IP67 200G
On mine sites, quality is critical
to the survival of electronic
equipment.
Hella has introduced a range of
electronic converters to increase
the potential of low voltage
applications, such as LED lighting,
where only mains power is
available.
The converters are fully sealed
to IP67 and have endured
200G-shock testing, making
them suitable for the vigorous
demands of mining.
Highly efficient components
enable the converters to operate
with low heat generation.
Units operate from an input
voltage of 90 to 264V AC and
provide output
voltage levels of 12
or 24 Volts, in either
a 20 or 60 watt
power supply.
The units feature
an intelligent over
current protection system,
which recovers automatically once
the fault is removed.
Pre-wiring removes the need to
open the casing, requiring a simple
crimp or solder for installation.
With a small physical footprint
and high environmental
specifications, the converters
can be installed in the most
demanding mining locations.
Product Features:
Full range AC input
Short circuit protection
Over current protection
Over voltage protection
Fully isolated plastic case
Pre-wired, no assembly
required
Compact size
Suitable for LED lighting
200G shock tested
Technical Specifications
HM1220 HM1260 HM2420 HM2460
DC Voltage 12V 12V 24V 24V
Rated Current 1.67A 5A 0.84A 2.5A
Rated Power 20W 60W 20.2W 60W
Ripple 120mVp-p 120mVp-p 150mVp-p 150mVp-p
Voltage Tolerance 5% 5% 5% 5%
Setup, Rise Time
(230V AC)
500ms, 20ms 500ms, 30ms 500ms, 20ms 500ms, 30ms
Hold Up Time
(230V AC)
50ms 50ms 50ms 50ms
Voltage Tolerance 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC 90 ~ 264V AC
Frequency Range 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz 47 ~ 63Hz
Efficiency 81% 83% 83% 86%
AC Current
(230V AC)
0.35A 1A 0.35A 1A
Max Inrush Current
(230V AC)
70A 60A 70A 60A
Leakage Current
(230V AC)
0.25mA 0.25mA 0.25mA 0.25mA
Over Current 110 to 150% 110 to 150% 110 to 150% 110 to 150%
Over Voltage 13.8 to 16V 13.8 to 16.2V 28 to 32V 27.6 to 32.4V
Operating
Temperature (°C)
-30 to +70º C -30 to +70º C -30 to +70º C -30 to +70º C
Vibration 200G 200G 200G 200G
Ingress Protection IP67 IP67 IP67 IP67

POWER CONNECTORS
Power Connectors
111
ELECTRICAL
Power Connectors are
high current, industry
standard connectors.
Power Connectors
are suitable for mining and
industrial applications where
durability, ease of connection and
release, and reliable connection
are of paramount importance.
They are available in various
sizes relating to their current
carrying capacity.
Power Connectors are made
from polycarbonate resin that
meets UL94 V0 requirements.
The housings are genderless
to help reduce inventory,
while still ensuring correct
polarity connection.
The housings have an integral
stainless steel locking spring for
improved contact retention and
mating force. The colour-coded
connector housing designates
the suggested application voltage
maximum. Hella has selected the
grey range, which can manage
voltage levels up to 600 Volts
(AC or DC). The housings also
incorporate mechanical keys
to prevent mating with different
housings.
The contacts are cold-headed
and can be crimped or soldered
to the cable. They are flat wiping
and therefore self-cleaning as
they are fitted and removed from
other compatible connectors. The
contacts can carry high current for
a broad range of applications.
Power Connectors are suitable for
use in most mining and industrial
applications, due to their robust
construction and ease of fitment.
Power Connectors
Connector Kit AND,
50A 6AWG
Connector Kit AND,
175A 6AWG
Connector Kit AND,
50A 6AWG
Connector Kit,
75A 6AWG, black
Connector Kit,
75A 6AWG, green
Connector Kit,
75A 6AWG, red
Connector Kit,
75A 6AWG, blue
HM50AND
HM175AND
HM350AND
HMPS75S
HMPS75G
HMPS75R
HMPS75B
Product Features:
Easy to install, reducing
installation costs
Ultra durable, reducing
replacement costs
High current capacity suits
a broad range of product
applications
Quick to connect and remove,
saving time spent on
servicing
Products accept varied cable
sizes, reducing inventory
Genderless connector
reduces possibility of fitment
errors
One-way fitment ensures
correct polarity connection
every time
2 pole housing
Silver-plated copper contacts
Rated to 600 V AC or DC
HM50AND: 50A, 6-12 AWG
wire (B&S cable)
HM175AN: 175A, 4-1/0 AWG
wire (B&S cable)
HM350AND: 275A, 1/0-300
MCM wire (B&S cable).

LED ROCKER SWITCHES
ELECTRICAL
112 Compact LED Rocker Switches
LED Rocker Switches 24V DC
Amber Illuminated HM4400A
Red Illuminated HM4400R
Blue Illuminated HM4400B
Green Illuminated HM4400G
LED Rocker Switches 12V DC
Amber Illuminated HM4400A-12V
Red Illuminated HM4400R-12V
Blue Illuminated HM4400B-12V
Green Illuminated HM4400G-12V
Compact, heavy-duty LED illuminated Rocker Switches featuring
durable nylon frame and waterproof rubber sealing boot for additional
protection in industrial and mining environments. Fitted with push-on
terminals and ultra durable LEDs for illumination, removing the need for
regular globe replacement. Weatherproof from front if installed correctly.
Mounting
Panels
Protection
Voltage
Mounting opening 20mm dia.
Suitable for panels up to 2.5mm thick.
Weatherproof (from front)
12 or 24V DC LED included (non-replaceable).
12/24V
DC
Maximum Load
10A at 12V DC
5A at 24V DC
25 11.5
14
8.3
20
Amber
25 11.5
14
8.3
Red
20
Blue
Green

LED PILOT LAMPS
LED Pilot Lamps
113
ELECTRICAL
Heavy-duty multi-chip LED Pilot
Lamps featuring shock-resistant
one-piece construction for long
service life, polycarbonate
lens and screws with screw
retainer and in-built finger
protection.
LED Pilot Lamp, 12V AC/DC
Red, Super Bright 2716
Green 2717
Amber, Super Bright 2718
White 2719
Mounting
For Panels
Protection
Voltage
Mounting opening 22mm dia.
Up to 38mm thick
IP65
12V / 24V AC/DC
Other voltages available upon request
Blue, Super Bright 2720
LED Pilot Lamp, 24V AC/DC
Red, Super Bright 2716-24V
Green 2717-24V
Amber, Super Bright 2718-24V
White 2719-24V
Blue, Super Bright 2720-24V
LED Pilot Lamp, 24V
Green, Super Bright
White, Super Bright
HM2717-24V
HM2719-24V
Red
51.5 30
Green
13 42.6
2716
Amber
White
Blue

CIRCUIT BREAKERS
ELECTRICAL
114
Heavy Duty Circuit Breakers
Heavy Duty Circuit Breakers
3A - Max. 28V DC 8736
6A - Max. 28V DC 8737
10A - Max. 28V DC 8738
15A - Max. 28V DC 8739
20A - Max. 28V DC 8740
25A - Max. 28V DC 8741
18.9
6.4
160
Automotive circuit breaker, plug in mounting, manual release with locking
tangs for vibration resistance.
Voltage Rating
Current Ratings
Typical Life /
Contact Rating
Interrupting
Capacity Icn
Note
12 - 28V DC
3–25A. (30A upon request)
6,000 operations at 1 x IN
3,000 operations at 2 x IN ≤ 20A
1,000 operations at 2 x IN ≤ 25A
3...15A
20...25A
200A
400A
Replaces standard blade fuses
Panel Mount Circuit Breakers
Panel Mount Circuit Breakers
10A - Max. 28V DC 8742
20A - Max. 28V DC 8743
25A - Max. 28V DC 8744
30A - Max. 28V DC 8745
35A - Max. 28V DC 8746
29
10.4
46.5
22.5
Threadneck panel mounting, with optional push/push switch actuation.
Voltage Rating
250V AC / 12-28V DC
Current Ratings
0.05...25A
Typical Life/Contact Rating 5,000 operations at 2 x IN
Interrupting Capacity Icn 0.05...2.5A 8 x IN
3...5A 20 x IN
6...12A 200 x A
13...25A 400 x A
Approvals
VDE, CSA, UL, Semko, SEV, LRoS, BV
Thermal Overcurrent Circuit Breakers
Thermal Overcurrent Circuit Breakers
6A - Max. 28V DC 8730
8A - Max. 28V DC 8731
10A - Max. 28V DC 8732
15A - Max. 28V DC 8733
20A - Max. 28V DC 8734
25A - Max. 28V DC 8735
160 6
Operated simply by the heating effect
of current, thermal circuit breakers
are some of the most reliable, cost
effective protection devices available.
They are ideally suited to the protection
of a broad range of components and
systems – motors and transformer
windings, printed circuit boards, low
voltage power distribution circuits
of road vehicles, boats, and battery
powered machines. These all require
the ability to discriminate between safe
switch-on surges or transients, and
harmful sustained overloads. They can,
for example, withstand large surges
arising from lamp loads or motor
starting. They also protect against
effects of genuine failure such as motor
locked rotors. Their characteristics can
be matched closely to the ratings of
protected components, so wiring and
connectors don’t need to be oversized.
They offer dependable protection, even
under low level overcurrent conditions
that can’t be adequately covered by
other methods.
24
.945
Automotive circuit breaker, standard fuseblock mounting with
manual release option (-H2)
Voltage Rating
Current Ratings
Typical Life / Contact Rating
Interrupting Capacity I cn
Note
12 - 28V DC
6–25A. (30A upon request)
300 operations at ≤ 50A
≥ 3 operations @ ≤ 150A
≥ 1 operation @ ≤ 2000A
Replaces standard blade fuses

CIRCUIT BREAKERS
Thermal Circuit Breakers
115
ELECTRICAL
Single pole, miniaturised, aircraftstyle
thermal circuit breaker with
tease-free, trip-free, snap action
mechanism
and push/pull on/off manual
actuation (M-type TO CBE to EN
60934). An indicator band on
the push button clearly shows
the tripped/off position. The
circuit is threadneck panel
Voltage Rating
mounted in metric configurations.
Advanced two-chamber design
contributes to fail-safe operation.
Temperature compensation from
-55°C to +125°C, with auxiliary
contacts, and fully approved for
use on a wide range of aircraft
and equipment. Full specification
ensures suitability for the most
demanding applications.
115V AC / 12-28 V DC
Thermal Circuit Breakers
3A - Max. 28V DC HMET483.03
5A - Max. 28V DC HMET483.05
7.5A - Max. 28V DC HMET483.07
10A - Max. 28V DC HMET483.10
15A - Max. 28V DC HMET483.15
20A - Max. 28V DC HMET483.20
25A - Max. 28V DC HMET483.25
30A - Max. 28V DC HMET483.30
35A - Max. 28V DC HMET483.35
16.2
.638
min 4.6
min.181
10
.394
12.8
.504
31
1.22
M12x1
Typical Life
8.4
.331
Ambient Temperature
Insulation co-ordination
(IEC 60664 & 60664A)
Dielectric Strength (IEC
8.5
60664 & 60664A)
.335
20,000 operations mechanical or,
10,000 operations at IN (≤ 25A)
5,000 operations at IN (30 + 35A)
-55°C to +125°C (-67°C to +257°F)
Rated impulse withstand voltage
Pollution degree 3
Test Voltage
Operating area AC 1,500V
Main to aux. circuit AC 1,500V
1.5kV
Spare Parts:
HMET307.01
ID collar Black
HMET307.02
ID collar White
HMET307.03
ID collar Red
HMET307.04
ID collar Green
HMET307.05
ID collar Blue
HMET307.51
Safety lock-out
collar Red
HMET200.08
IP66 safety cover
Clear
10
94
M12x1
8.4
.331
3.2 +3 +5
.123 +.006
Interrupting
Capacity I cn
9.5 +0.2
.374 +.008
AC 115V (400 Hz)
≤4A 1,000A
5A 2,000A
7.5 to 35A 2,500A
HMET307.01
HMET307.01
12.8
.504
31
1.22
8.5
.335
12.5 +0.2
.492 +.008
DC 28V
1 to 25A 6,000A
30 + 35A 4,000A
Vibration 15g (70 - 2000Hz) -
Sinus 16.4 grams - Random
Acceleration
17g
10
.394
HMET307.01
M12x1
8.4
.331
HMET307.01
Shock
75g
HMET307.01
HMET307.01
3.2 +3 +5
.123 +.006
9.5 +0.2
Explosion to VG 95210, sheet 10/MIL -
STD-202, meth. 109
31
1.22
+.008
.374
16.2
.638
min 4.6
min.181
12.5 +0.2
+.008
.492
7.7
.303
14.8
.429
6.4
.252
13.97
.550
12.8
.504
3.2 +3 +5
.123 +.006
8.5
HMET307.01 .335
9.5 +0.2
.374 +.008
HMET307.01
8.6
.339
10.9
.429
8.7
.343
12.35
.486
18.9
12.5 +0.2
+.008
.492
0.8
.041
0.65
.026

POWER OUTLET SYSTEMS
ELECTRICAL
116
MagCode
Power Outlet Systems
MagCode Power System
Power System 12V HMPS12VKIT
Power Port 12V HMPS12VPT
Power Clip 12V HMPS12VCP
Power System 24V HMPS24VKIT
Power Port 24V HMPS24VPT
Power Clip 24V HMPS24VCP
MagCode Power System Plus
Power System 12V HMPS12VPROKIT
Power Port 12V HMPS12PROVPT
Power Clip 12V HMPS12PROVCP
Power System 24V HMPS24PROVKIT
Power Port 24V HMPS24PROVPT
Power Clip 24V HMPS24PROVCP
MagCode
Power Port Cap
HMPSPCAP
MagCode Power Systems are
revolutionary power outlet systems
for 12 and 24V DC circuits. Unlike
conventional connectors, MagCode
Power Systems utilise magnetically
coded flat contacts, delivering safe
power across modular components
far superior to the ubiquitous
cigarette lighter sockets.
Both port (outlet) and clip
(connector) feature powerful
magnets with integral switching
function ensuring a stable
connection and safe power supply.
Other metal objects or permanent
magnets cannot energise the
contacts at any time, making the
outlet completely safe and 100%
short-circuit-proof.
MagCode Power System Plus
for higher power circuits features
an additional mechanical twist
lock offering greater security
(higher separation forces) and
reliable prevention of arcing. The
mechanical twist lock ensures that
the automatic switching does not
occur before the outside contact is
securely fastened, thus effectively
eliminating problems associated
with arcing.
MagCode Power Systems are dust
and water resistant, easy to clean
and suitable for straightforward
retrofitting a vast range of
applications. Their advanced
technology and superior design
makes MagCode Power Systems
the ideal exterior connector on
vehicles under conditions of
sustained charging and high
current load. They are available
in 12V DC and 24V DC variants;
the magnets of the two voltage
variants are coded differently to
avoid mix-ups.
Power Clip
Power Port
HMPSPCAP. Stylish protective cover to suit
all MagCode Power Ports. Snap shut cap
provides reliable protection from the elements.
Key Features:
Latest high tech design
Stable connection
100% short-circuit-proof
Easy to install
Minimal mounting depth
(port)
Up to 25A current load
Dust and water resistant
Easy to clean
Novel coded system to avoid
12V and 24V products
Additional Features –
Power System Plus:
Suitable for high current
loads
Greater security (higher
separation forces)
No arcing
Specifications: MagCode Power System MagCode Power System Plus
Locking Mechanism Magnetic connection Magnetic connection plus
mechanical twist lock
Terminal
Power Port 6.3mm flat connectors Cable tails
Power Clip Screw terminals Screw terminals
Max. Wire Cross Section 2.5mm 2 2.5mm 2
Mounting Opening 28mm dia. (M28) 28mm dia. (M28)
Rated Voltage 12V / 24V DC 12V / 24V DC
Max. Current Load 25A at +20°C 26A at +20°C
14A at +70°C
25A at +70°C
12A at +85°C
20A at +85°C
Vibration Resistance 3 axes, 8h, 3 axes, 8h,
5Hz - 200Hz, 8.5m/s 2 5Hz - 200Hz, 8.5m/s 2
Shock Resistance 3 axes, 3,000 shocks, 3 axes, 3,000 shocks,
11ms, 30g
11ms, 30g
Protection
Port (front side installed) IP 6K9K IP 6K9K
Port (connection side) IP 5K0 IP 5K0
Clip (not connected) IP 40 IP 40
Clip (on port) IP 42 IP 42
Duty Cycles
Without load > 10,000 cycles > 10,000 cycles
At 25A 4,000 cycles 4,000 cycles

POWER OUTLET SYSTEMS
117
ELECTRICAL
MagCode
Power System
Incoming
current
Incoming
current
Pole without
Current
Pole under
Current
Open System
(1)
Closed System
(2)
Colour code: l Permanent magnets l Plate with permanent magnets l Voltageless l Under current
Incoming
current
MagCode
Power System Plus
Open System
(1)
Pole without
Current
Incoming
Incoming
current
current
Pole under
Closed System
(2)
Pole without
Current
Locked System
(3)
Current

119
GLOBESGlobes
120 H1
120 H2
121 H3
122 H4
123 H7
123 H9
123 H11
124 Xenon

HALOGEN GLOBES
120 H1 Globes
GLOBES
10
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
39
H1 PREMIUM XENON HALOGEN - PLUS 50
CX1255BL 12 55 P14.5s H1 •
H1 PREMIUM XENON HALOGEN - COOL BLUE
24
CB1255BL 12 55 P14.5s H1 •
Xenon
Plus 50
Xenon
Cool Blue
CB1255BLdia
Part No. Voltage Wattage Base ADR 51/00
Category
UV
Cut
Rated Life
Long Life / Standard
H1 HALOGEN LONG LIFE
C1255LL 12 55 P14.5s H1 • 1250 400
H1 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE
C2470LTS 24 70 P14.5s H1 • 1200 650
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
H1 HALOGEN HIGH PERFORMANCE
C12100 12 100 P14.5s - •
C24100 24 100 P14.5s - •
HALOGEN
C2470 24 70 P14.5s H1 •
Halogen
Premium Long
Life Halogen
H2 Globes
9
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
29
H2 HALOGEN HIGH PERFORMANCE
CD12100 12 100 X511 - •
CD24100 24 100 X511 - •
HALOGEN
CD1255 12 55 X511 H2 •
CD2470 24 70 X511 H2 •
CD12100BLdia

HALOGEN GLOBES
H3 Globes
121
GLOBES
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
11
H3 PREMIUM XENON HALOGEN - PLUS 50
30.5
Xenon Plus 30
YCX1255BL 12 55 PK22s H3 •
H3 PREMIUM XENON HALOGEN - PLUS 30
YCP1255BL 12 55 PK22s H3 •
H3 PREMIUM XENON HALOGEN - COOL BLUE
YCB1255BL 12 55 PK22s H3 •
YC12100BLdia
Part No. Voltage Wattage Base ADR 51/00
Category
UV
Cut
Rated Life
Long Life / Standard
Long Life Halogen
H3 HALOGEN LONG LIFE
YC1255LL 12 55 PK22s H3 • 1500 450
H3 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE
YC2470LTS 24 70 PK22s H3 • 1200 650
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
H3 HALOGEN HIGH PERFORMANCE
Halogen
YC12100 12 100 PK22s - •
YC24100 24 100 PK22s - •
HALOGEN
YC2470 24 70 PK22s H3 •
Premium Long Life Halogen

HALOGEN GLOBES
122
H4 Premium Xenon Globes
GLOBES
14
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
78.5
H4 PREMIUM XENON HALOGEN - PLUS 50
XDX1260/55BL 12 60/55 P43t H4 •
H4 PREMIUM XENON HALOGEN - COOL BLUE
44
XDB1260/55BL 12 60/55 P43t H4 •
Xenon
Cool Blue
XD1260/55dia
Xenon
Plus 50
H4 Halogen Globes
14
Part No. Voltage Wattage Base ADR 51/00
Category
UV
Cut
Rated Life T c
Long Life / Standard
78.5
44
H4 HALOGEN LONG LIFE
XD1260/55LL 12 60/55 P43t H4 • 1500 700
XD2475/70LL 24 75/70 P43t H4 • 1500 700
H4 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE
XD2475/70LTS 24 75/70 P43t H4 • 1400 700
XD1260/55dia
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
H4 HALOGEN HIGH PERFORMANCE
XD12100/55 12 100/55 P43t - •
XD12100/90 12 100/90 P43t - •
XD24100/90 24 100/90 P43t - •
H4 HALOGEN
XD1260/55 12 60/55 P43t H4 •
XD2475/70 24 75/70 P43t H4 •

HALOGEN GLOBES
H7 Globes
123
GLOBES
Part No. Voltage Wattage Base ADR 51/00
Category
UV
Cut
Rated Life Tc
Long Life / Standard
11
H7 HALOGEN LONG LIFE
CA1255LL 12 55 PX26d H7 • 930 550
H7 HALOGEN PREMIUM HIGH PERFORMANCE LONG LIFE
CA2470LTS 24 70 Px26d H7 • 1000 500
42
15
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
CA1255dia
H7 HALOGEN
CA1255X 12 55 PX26d H7 •
CA2470 24 70 PX26d H7 •
H9 Globes
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
11
H9 HALOGEN
CF1265 12 65 PGJ 19-5 H9 •
46
40
CF1265
H11 Globes
Part No. Voltage Wattage Base ADR 51/00
Category
UV Cut
11
H11 HALOGEN
CG1255 12 55 PGJ 19-2 H11 •
CG2470 24 70 PGJ 19-2 H11 •
46
40
CG1255

XENON GAS DISCHARGE
124 Xenon Gas Discharge Lamps
GLOBES
9
Description
Comparison
Xenon Gas Discharge globes for driving and work lamps.
D1S/D2S
82
Rated Wattage
Luminous Flux
Luminous Efficacy
35W
3200lm
91Im/W
HMXN4001
D1S
Colour Temperature 4250°K
Average Luminance 6500*cd/cm 2
43
Lamp Life B3 1500h
Tc 3000h
9
Filament/arc length
Note
4.2mm
Replace Lamps only with same type.
D1S lamps must be used in Oval 100FF Xenon work lamps.
D2S lamps must be used in all other Xenon work lamps in
this catalogue.
75
Part No. Type Voltage Wattage Base ADR 51/00
Category
UV Cut
HMXN4001 D1S 85 35 PK32d-2 D1S •
25
XN4000 D2S 85 35 P32d-2 D2S •
HMXN4YEL
D2S 85 35 P32d-2 D2S •
XN4000dia
XN4000
D2S/R/C
HMXN4YEL
D2S
Xenon Gas Discharge Flash Tube
Part No. Voltage Wattage Base ADR 51/00
Category
UV
Cut
49mm
Xenon gas discharge globes suitable for
emergency flasher, revolving and/or strobe lamps
XN6750 12-24 - Circuit Board Plug-In - -
15mm
43mm
Note: Use this lamp for PulseRAY Xenon strobe warning beacons.

Engineering Based Solutions:
Australian Antarctic Division
125
Due to the high reflectance properties of ice and snow in Antarctica,
backscatter was becoming an issue from the white xenon light of the AS500.
To overcome this issue an amber version of the AS500 was developed in
conjunction with the Australian Antarctic Division, as the colour temperature
of the globe eliminated this issue.
Hella AS500 – Proven lighting for the most unforgiving environments.
HMXN4YEL
Yellow D2S Xenon Globe

Technical
127
TECHNICAL
128 General Information
130 High Intensity Discharge Lamp Operation
131 What is Xenon lighting technology
132 Spectral power distribution of fluorescent
and discharge lamps
133 Ignitors and ballasts
135 Capacitors
136 Transformers
138 LED technology
139 Hella work lamp systems
140 DRACO ® vibration damping systems
140 Xenon Gas Discharge work lamps
141 What is Xenon light
141 MustADD ® filter technology
142 Chemical resistance tables
144 Ingress Protection
145 Applications Engineering

128 General Information
TECHNICAL
Luminous Efficacy
Unit of measurement: lumen per watt
[lm/W]: Luminous efficacy indicates
the efficiency with which the electrical
power consumed is converted into
light.
The maximum that can be achieved
in theory, with all the energy being
converted into visible light, is 683
lm/W. In reality, the figures are much
lower, between 10 and 150 lm/W.
Luminous efficacies of
various light sources
1000
100
10
683 lm/W = Theoretical limit for
monochrome green light (555nm)
199lm/W = Theoretical limit for
"white" light (380–780nm)
Low Pressure Sodium Lamps
High Pressure Sodium Lamps
Fluorescent, Metal Halide, Yellow Compact,
Xenarc Lamps
High Pressure Mercury Vapour Lamps
High Intensity white LED
Special Light Bulbs Xenon Lamps,
Mercury Tungsten Blended Lamps
Tungsten-Halogen Lamps
General Lighting Service Lamps
Colour Rendering
Depending on the location and the
purpose, artificial light should enable
colours to be perceived correctly, as
though being seen by natural daylight.
Such assessments are based on the
colour rendering properties of a light
source, which are expressed in terms
of categories of the general colour
rendering index, R a. The colour
rendering index is a measure of the
correspondence between the colour
of an object under the light source
being measured and its colour under a
reference light source.
Carbon Thread Incandescent Lamps
1
Glow Lamps, Electroluminiscent Plate
Paraffin Lamp
lm/W
0.1
Candle
Incandescent and Halogen
Lamp Operation
Incandescent lamps are classic thermal
radiators in which electricity flows through
a Tungsten wire in an enclosed glass bulb
filled with a vacuum or inert gas, heating
it to approximately 2600˚C to 3000˚C and
making it glow. Most of the radiation emitted
is at the infra-red end of the spectrum.
L e λ ref
Luminous efficacies of various light sources
4
3
2
1
UV - radiation
IR radiation
Tw 2800˚C
Tw 2600˚C
Tungsten filament winding
temperatures T w
for incandescent lamps
2400˚C corresponds to a
15W lamp (vacuum bulb)
2600˚C corresponds to a
40W lamp (bulb filled with gas)
2800˚C corresponds to a
500W lamp (bulb filled with gas)
Tw 2400˚C
0
1000
2000 3000 4000
5000
visible light
wave length unit of measure nm
Relative Spectral Power Distribution Of Incandescent Lamps
The main properties of an incandescent lamp, namely its luminous efficacy and
life, are influenced largely by the filament temperature.

129
TECHNICAL
Operating principle of an
Incandescent Lamp
The higher the filament temperature, the
higher the luminous efficacy, but the shorter
the lamp life.
A reduction in lamp life is a consequence of
the rapid increase in the rate of vaporization
of the Tungsten atoms as the temperature
rises; this process not only produces a black
coating on the bulb but also ultimately causes
the filament to break.
Blackening of the bulb can be effectively
countered by using as heavy an inert gas
as possible (Argon, Krypton or Xenon) and
ensuring that this gas is at high pressure
to reduce the rate at which the Tungsten
vaporises.
The principal types of incandescent lamp
are: general-purpose lamps, special-purpose
lamps, decorative lamps and incandescent
reflector lamps. The luminous efficacy of
incandescent lamps in the 25 to 1000W range
is between about 9 and 19 lm/W for lamps
with an average life of 1000 hours.
%
250
200
65% = 40 000% life
75% = 10 000% life
75% = 3600% life
80% = 1700% life
85% = 1000% life
90% = 600% life
Tungsten-Halogen Lamps
Tungsten-Halogen lamps operate in the
same way as incandescent lamps and have
a similar design. The small quantities of
Halogens (Bromine, Chlorine, Fluorine and
Iodine) and their compounds added to the
filler gas, almost entirely prevent the bulb
from blackening due to vaporizing Tungsten
atoms within a particular temperature range,
so there is no associated drop in luminous
flux. The bulbs in Tungsten-Halogen lamps
can therefore be made much smaller, which
means the pressure of the filler gas can be
increased and more economical use can
therefore be made of expensive inert gases
like Krypton and Xenon. The life of Tungsten
lamps varies from 50 hours for photographic
studio types, to over 2000 hours for
commercial display lighting types. Automotive
Halogen lamps are generally rated in the 300
hour range.
95% = 190% life
Halogen Cycle
As already mentioned, the main
characteristics of an incandescent lamp,
namely its luminous efficacy and service
life, are determined to a large extent by the
filament temperature. The higher the filament
temperature, the higher the luminous efficacy
but the shorter the life of the lamp.
This reduction in the life of the lamp is a
consequence of the rate at which Tungsten
vaporises from the filament. This rate
increases rapidly with temperature. Not only
does it blacken the inside of the bulb, it
causes the filament ultimately to burn right
through.
This blackening of the bulb can be effectively
countered by adding halogens to the filler
gas to keep the vaporized Tungsten away
from the bulb wall in a cycle process . The
Tungsten that vaporises from the filament
during normal operation drifts towards
the bulb wall by diffusion or convection
in thermal regions (•1 1400°C) where
they disintegrate. Some of the Tungsten is
transported back to the filament, but not
to its original location. The normal Halogen
cycle therefore merely prevents the bulb from
blackening, it does not extend the life of the
lamp. The lamp comes to the end of its life
when the filament breaks at one of its
hot spots.
150
Lamp life
Light output
Tungsten
Halogenide
Lamp power
Halogen cycle
100
Tungsten
Halogenide
Lamp power
Halogen cycle
50
Light output
Tungsten
Lamp life
Halogenide
0
70 80 90 100 110 120 130 %
Halogen cycle
Halogen Cycle
A regenerative cycle would be feasible with Fluorine
but because this Halogen is so corrosive towards
the quartz and hard glass used for the bulb, and
resistant to the Halogen currently used, a satisfactory
solution has not yet been found.

130 High Intensity Discharge (HID) Lamp Operation
TECHNICAL
Metal Halide (MH)Lamps
Metal Halide lamps are high-pressure mercury
lamps with added metal iodides or iodides of
the rare earths – Dysprosium (Dy), Holmium (Ho)
and Thulium (Tm) – and complex compounds of
Caesium (Cs) and Tin Halide (Sn). The Halides
decompose in the core of the discharge arc
and the metals can be excited to emit light
with an intensity and spectral distribution that
depends on the vapour pressure of the metal
halides. The luminous efficacy and the colour
rendering properties of the Mercury discharge
are significantly improved and the gaps in the
mercury spectrum are closed. Metal Halide
(MH) lamps are similar in their construction
to mercury vapour lamps. They are popular
for their excellent colour rendering which is
achieved by the inclusion of rare earth elements
in the discharge tube.
Metal Halide lamps are temperature sensitive,
with optimal operation occurring at 100°C to
180°C ambient temperature. Luminaires should
be designed to provide suitable conditions.
Ballasts must operate lamps from the correct
supply voltage and their impedance should
not vary more than ±3% from the specified
value. The supply voltage should not deviate
for extended periods for more than 3% of the
nominal rated voltage of the ballast, and the
supply frequency should not deviate by more
than ±3%.
Metal Halide lamps require higher voltages for
starting than the usual supply voltages. Various
circuits are used to achieve the required starting
conditions.
Metal Halide lamps require leakage reactance
ballasts, constant wattage auto-transformer
control equipment or series reactor type
ballasts with ignitor. The latter is the most
economical solution, with the constant wattage
circuit being the best for electrical performance.
Electronic control gear for lower wattage MH
lamps is also available
Separate information and data is available for
the Hella range of constant wattage control
equipment.
Most Metal Halide lamps will require an ignitor
to start the discharge in the arc. The ignition
voltage is generally 4.0–5.0kV peak for a cold
start with the lamps requiring a cooling period
of between 10–15 minutes before they will
re-ignite. Certain lamps are capable of hot reignition,
in which case voltages of up to 35kV
peak are required. Some of the higher wattage
2000W and 3500W lamps can require hot,
instant re-strike voltages of up to 60kV peak.
NOTE: Not all makes and/or types of Metal
Halide lamps can be operated on ignitor circuits
– consult the lamp manufacturer or Hella for
information or lamp control gear compatibility.
High Pressure Sodium (HPS)
Lamps
High Pressure Sodium (HPS) lamps can operate
satisfactorily from –30°C to +100°C on series
reactor ballast circuits, but precautions against
increase arc tube voltage, due to thermal back
radiation when mounted in luminaires, should
be considered. Only a typical 10 volt increase
in lamp voltage is tolerable. The lamp power
and discharge tube temperature are highly
dependent upon the lamp voltage. It is therefore
important that the mains voltage does not
exceed 105% of the nominal rated voltage of
the choke for extended periods.
The ballast should exhibit a closely controlled
current/voltage characteristic, to prevent the
lamp from exceeding the maximum power limit
as it ages and the lamp voltage rises.
Standard lamps with standard ignitors
re-ignite after 60 to 90 seconds, requiring 2kV
to 5kV to ignite from a cold start, depending on
the lamp specifications. High pressure sodium
lamps can only be re-ignited hot if they are of
linear double-ended construction because hot
re-strike requires 18kV to 25kV peak starting
pulses.

What is Xenon lighting technology 131
TECHNICAL
Xenon globes use an
electric current passed
through Xenon gas to
produce light, rather
than a filament. Not
only does this method
require minimal electric
current draw compared
to filament lighting, it is
much more robust and
lasts much longer than
the Halogen lamps it is
designed to replace.
Xenon (XGD) lamps are
specialized high pressure
discharge lamps developed
for use in the automotive
industry. Unlike industrial HID
lamp types (MH and HPS) that
require several minutes to warm up
and reach full light output, XGD lamps are
designed to strike immediately and the
associated ballast systems are capable of
restarting them when hot.
The light colour spectrum of XGD lamps is
specifically optimised to provide the best
performance when used in applications
where the user is in a scotopic vision (dark)
adapted condition, whereas most other
lamps are balanced for photopic (daylight)
vision. This is one of the key reasons
why Xenon lighting causes less eye strain
than other globe types, making it a more
convenient and safer night lighting option.
It also reflects off road signs and markings
more brightly.
The XGD technology consists of a very
compact quartz glass arc tube discharge
vessel, filled with Xenon gas and metal
halide salts. In this hybrid system, Xenon
gas provides the instant start aspect while
the metal halide salts contribute the very
high luminous efficacy of a XGD lamp.
The arc tube assembly also contains two
electrodes that protrude into the gas via
special seals, to ensure the system remains
hermetically sealed after many switching
cycles and despite all the vibration the lamp
will be exposed to under normal operating
conditions. The arc tube itself is encased in
a soda lime glass outer jacket to filter out the
ultra-violet generated by the gas discharge.
This is of particular importance, considering
the widespread use of polycarbonate lenses
in automotive lighting. This active part of the
XGD lamp is mounted in one of two basic
lamp holder types: D1/D3 range contains an
integrated ignitor module and suits designs
where space efficiency is very important and
lamp replacement cost is less important,
the D2 range requires an external ignitor
(typically integrated into the ballast) and
suits high duty cycle systems where lamp
replacement occurs on a regular basis.

TECHNICAL
132 Spectral Power Distribution of
Fluorescent and Discharge Lamps
Visible range from 380 to 780 nm
Vertical scale: 400 nW
1000 Im -10 nm
Fluorescent Lamps
Metal Halide (MH) Lamps
Colour 840 LUMILUX ®
Cool White
HQI ® .../N Daylight
HQI ® -TS.../WDL Warm White
High Pressure Sodium (HPS) Lamps
Xenon Gas Discharge (XGD) Lamps
VIALOX ®
Relative emission and sensitivity
300,0 400,0 500,0 600,0 700,0 800,0
wave length unit of measure nm
Xenon spectral power distribution
V(λ) Human vision photopic sensitivity (day light adapted)
V’(λ) Human vision scotopic sensitivity (night adapted)
The spectrum of light produced by Xenon lamps is optimised to
maximize visual performance of people with dark adapted vision

Ignitors and Ballasts
133
TECHNICAL
Maintenance-Free Long
Service Life Ballasts
The choice of insulating materials and
their operating temperatures determine
the ballast life. Hella ballasts use class H
insulation materials which are designed for
temperatures up to 180°C, thus ensuring
maximum service life.
The permitted maximum working temperature
of the winding is designated ‘tw’. The
adherence to this temperature guarantees an
average life of 10 years continuous usage. If
the temperature in application is lower, then
the life is correspondingly higher.
Hella HID ballast windings are designed
and constructed using Class H insulation
materials, the tw130 or in OG models tw150
rated winding ensuring maximum service life.
In normal operation in a 40°C ambient
temperature, probable service life of more
than 50 years could be expected.
The graph below shows the theoretical
service life of an Hella HID ballast. Even
when arduously operated at the maximum
recommended temperature, more than 10
years service life can be expected. Every 10°C
over maximum winding temperature of 130°C
or 150°C halves ballast life. The winding
temperature is the ambient temperature plus
∆t, the temperature rise, which is a function of
ballast power consumption.
The high quality and reliability of insulated
conductors is dependent not only on the
production process, but also on the choice of
raw materials.
Many years of experience, both as a user
and manufacturer of enamelled winding
wire has given Hella the knowledge and
expertise to select the best raw materials from
internationally approved suppliers.
Critical attention is paid to the enamel as the
material utilised to insulate the conductor.
Choice of enamel is a key factor and is
linked both to the enamelling system as well
as the electrical, mechanical and technical
characteristics of the finished product.
Special features of Hella HID ballasts:
100% final testing
• very short magnetic paths
• continuity
• transverse laminations with no stray field • winding short circuit
junctions
• core to coil high voltage
• short heat paths
test
• winding insulation Class H materials
• operating values
• vacuum impregnated core and coil
• long service life
• low power consumption
• tw150 winding temperature rating
• fully automatic production technology with
assured manufacturing procedures and quality

134 Ignitors and Ballasts
TECHNICAL
HID Ignitors and Ballasts
The starting voltage for most High-Intensity
Discharge (HID) lamps, especially metal halide
and high-pressure sodium types, is higher
than the mains voltage.
Ignitors provide the necessary high voltage to
start such lamps.
The high-voltage pulse varies from 1 to 5kV
depending upon the type of the lamp and is
inhibited when the lamp starts.
Hella ignitors are manufactured in
accordance with IEC 60926 and IEC 60927,
the International Standards specifying
performance, general and safety requirements
for starting devices.
Old high-pressure sodium and metal
halide lamps with conventional ignitor
technology often cause visual discomfort and
electromagnetic interference at the end of the
lamp life when the ignitor would repeatedly
strike the lamp, and it would not stabilize
electrically.
This cycling can be a significant irritant and
become a safety risk.
The solution: ‘PulseControl’ from Hella, the
first digital ignitor in the world.
Greater reliability, greater ignition power,
reduced re-strike time and minimum
interference through digital, precise
management of all lamp types without
annoying flashing.
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Ballast
HV
BLa N
IGN
Precise lamp management
through digital technology
The patented switching circuit digitally
controls the ignition and automatic tripping
logic functions. PulseControl does not
consider the time of the re-strike period but
the number of attempts made. Because of
this, all lamps are switched off after 3 cycles
regardless of luminaire or lamp type.
Re-strike time reduced by
up to 50%
Depending on the lamp wattage, 4–10 ignition
pulses per half wave will be generated.
As a result of the increased ignition power
and the pulse/break cycle, the re-strike time is
reduced by up to 50%.
Interference reduced by
up to 90%
This 90% reduction in interference time (only
about 30 sec instead of 300 sec), is due to the
reduced re-strike period and the pulse/break
cycle which strikes for 5 seconds then pauses
for 25 seconds.
Ignitor Temperature Rise
Because ignitors have heat-sensitive
elements, their suitability for particular
applications is determined by the rise in the
element’s temperature. When mounting an
ignitor in the luminaire on a control equipment
enclosure, the ambient temperature range of
the application must be considered.
Quality components in Hella ignitors ensure
that they can withstand temperatures from
–30°C to +100°C with a minimum power loss.
Long life
Lighting control electronic equipment is
designed to run continuously for a minimum of
80,000 hours when operating at its maximum
temperature. This high level of reliability
can be achieved only by using high-quality
insulation and heat-resistant components.
Very low temperature rise in Hella ignitors
makes them highly reliable components for
use in all lighting control equipment.

Capacitors 135
TECHNICAL
Power factor in Fluorescent and
HID Circuits
For a pure resistive load in an electrical circuit,
the voltage (V) and current (I) are in phase with
each other and the overall power factor (cosΦ)
has a value of unity. It can also be said that
the average power (P) of the resistive circuit is
equal to the apparent power (S), ie. P = V x I.
However, in a pure reactive electrical circuit,
there is no resistive component; the voltage
and current are 90° out of phase, ie. cosΦ = 0.
Electrical circuits containing a combination of
both resistive and reactive elements display
both average power and apparent power
components.
Power factor is therefore the ratio by which
the apparent power is multiplied, in order
to obtain the average power actually being
consumed in the circuit, ie. P = V x I x cosΦ.
For example, a power factor of 0.5 indicates
that the circuit has a reactive component
having a phase angle of +60° or -60°.
In common practice most loads are inductive
and therefore the current lags the voltage
(lagging power factor), whereas a typical
capacitive load has a leading power factor.
Fluorescent and HID lamp circuits have an
inherent low power factor (around 0.4 to
0.5), due to the control gear inductance.
The inductance is in the circuit to limit the
current through the lamp, however, in lighting
installations where many lamps are used,
high input current increases the cost of mains
reticulation.
Raising the power factor by means of the
inclusion of a capacitor (opposite effect to an
inductor) substantially reduces the current
drawn from the mains, giving improvement
in the reticulation efficiency, which in turn
enables a reduction in copper wire size and
transformer sizes (the generating equipment).
Most power distribution authorities have a
requirement of high power factor (HPF) for
lighting installations of generally 0.85 to 0.95
minimum.
Figure 1 Figure 2
A typical discharge lighting circuit without
power factor correction, eg. 400W high
pressure sodium, has a power factor of
approximately 0.4. Figure 1 shows the
relationship of current and voltage in this
application.
This power factor characteristic can be
corrected to approximately 0.9 by adding
a capacitor (leading) to the lagging line
current, to cancel the phase shift. Figure 2
illustrates this.
In common application therefore, by
connecting a capacitor into the lighting circuit,
the power factor can be improved to the
values normally prescribed by the regulatory
authorities so that practically inductance free
operation results.
L
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Ballast
S
Lamp
Capacitor Quality
Assured quality of capacitors is first and
foremost and cannot be compromised. Hella
uses accepted IEC and BSI Standards as the
minimum measure of quality.
Production is integrated with an audited
Quality System that is accredited to AS/NZS
ISO9002 and supported by a technical team
and fully equipped laboratory facilities.
Hella power factor correction lighting
capacitors have been certified by British
Standards Institute to BSEN 61048, and
BSEN 61049 and has ENEC approval (License
no. KM 30180).
These standards provide, thorough quality
checks of materials and capacitance
characteristics, a capacitor that retains its
integrity under the required conditions of
operation.
Quality Test Program
• materials / component inspection
• end spray thickness test
• voltage test
• capacitance tolerance check
• dissipation factor
• physical inspection
• end product batch test
• endurance test
• Assured Quality Systems (ISO9002 series)
• BSI certification
• ENEC approval
• testing of the dielectric materials
• in-line 100% capacitance testing
• new automatic ‘AC’ tester
• stud mounting or alternative clip spring
accessories.

136 Transformers
TECHNICAL
Principles of operation of the
Safety Isolating Transformer
A transformer transfers electrical energy from
one circuit to another through the medium of
a magnetic field. The transformer may step up
the voltage, step it down or deliver energy at
the same voltage.
The safety isolating transformer is one of the
most widely used of all transformers. It is
designed to achieve an accurate voltage ratio
within a specific load range.
There is no direct connection between the
windings. They are only connected by the
intangible lines of magnetic flux in the core. In
some types of circuits the transformers may
have 1:1 ratio.
Long life
Because of the long hours of use, low voltage
transformers have to be designed and built
to a high specification, which involves the
use of quality heat-resistant materials. Class
H insulation materials ensure long service
life, which, according to EN60742, allows a
maximum winding temperature rise of 140°C
at 6% over voltage.
At an actual winding temperature of 130°C,
10 years life can be expected. The graph
above shows the theoretical service life of
a transformer against winding temperature.
Every 10°C over the winding temperature of
130°C, halves the transformer life.
The manufacturing technique used by Hella
is to vacuum impregnate the transformer
with an unsaturated polyester resin. Typical
characteristics are thermal class ‘H’ (180°C
IEC600). Vacuum impregnation improves
quality and longevity because the resin is
drawn into the heart of the core and coil. This
maximises heat transfer and also ensures
silent operation.
Safety Extra Low Voltage (SELV) Lighting Recommendations
Voltage Regulation
The secondary voltage of a transformer
changes with the load, therefore, for multilamp
applications, a transformer with good
voltage regulation must be used. This is
because unloading of the transformer occurs
as lamps burn out, eg: there may be 4 x
50W lamps wired to a 200VA transformer
and if one or two lamps fail, the transformer
regulation may not be able to compensate
for the decrease in load. This will subject
the remaining lamps to an over supply
of secondary voltage. Therefore, it is
recommended that failed lamps always be
replaced.
On a one lamp/one transformer installation,
the regulation of the transformer is not
important as long as the lamp wattage
matches the full load of the transformer. These
small transformers generally have higher
impedance and regulation characteristics.
It follows that the higher impedance limits the
in-rush current on a cold lamp.
The lower in-rush current (or “soft start”) helps
lamp life. Filament evaporation eventually
creates a weak spot on the filament. This
weak spot is effected by in-rush current. As a
result, the one lamp/one transformer system is
beneficial for ferro-magnetic transformers, but
does not apply for correctly rated electronic
transformers.
High current on the
secondary side
Another important consideration in Extra
Low Voltage systems is the impact of high
currents. Circuits must be designed and
cables sized to carry the higher currents. A
12V lamp can draw 20 times more current
than a 240V lamp of the same wattage.
For maximum safety, optimum voltage at the
lamp and consequently lamp performance,
it is preferable to use one (1) ferro-magnetic
transformer per lamp.
On multi-lamp systems, each lamp should be
cabled back to the transformer independently,
particularly as the relatively smaller cables
used would be more practical and easier
to terminate at both the light fitting and
the transformer. In these installations it is
necessary to estimate voltage drop to each
lamp and use the appropriate sized cable
according to each cable run. If each light
fitting in a multi-lamp system individually
wired back to the transformer, then the
possibility of using cable lugs to a common
stud connection should be considered.

137
TECHNICAL
Safety Extra Low Voltage (SELV) Lighting Recommendations (continued)
Protection and Approval
It is mandatory under the wiring rules that
transformers for remote mounting are housed
in a suitable enclosure and, as a prescribed
item, must be approved by the Statutory
Authority to EN 60742.
The approval number must be clearly marked
on the enclosure. Also, under the wiring rules,
the transformer must be installed in a position
where it is easily accessible for inspection and
maintenance.
The transformer enclosure
and wiring to the light
fitting must have adequate
ventilation. If the wiring and
the transformer enclosure
are covered with insulation
material then substantial
derating and overheating
may occur.
Electronic Safety Isolating Transformers for Low Voltage Lamps
Immunity
A transient mains voltage surge may
occur when inductive loads (e.g. motors
or conventional chokes) are switched off.
TE electronic transformers are protected
against voltage surges and spurious pulses
of any polarity by random phase position
superimposed on the supply voltage, in
accordance with EN 61547.
Emission
The limits for emission as per EN 61000-3-2
are maintained by high-quality filter circuits.
Electromagnetic Compatibility
Harmonics from non-linear loads cause
distortions in the mains supply. The special
circuit design fulfils the requirements of
EN 61000-3-2.
RFI Protection
The sophisticated filtering system of
electronic transformers TE ensures
compliance with EN 55015 and
VDE 0875-151
Harmonics
The requirements of the EMS Directive
89/336/EEC are fulfilled by observance of the
standards for emission and immunity.
Disposal of old lamps and control gear
Hella products comply with the RoHS regulations passed by the EC on electronic waste
Disposal of incandescent lamps
Incandescent lamps consist of glass and
metal. They do not contain any materials
that will harm the environment so they can
be simply thrown away with the household
refuse. They should not be placed in
containers for recycled glass, however,
because the glass used for these lamps is not
the same as the glass used for bottles.
Tungsten-Halogen lamps contain very small
quantities of halogens and Halogen-hydrogen
compounds, but the amounts are insignificant
(only a few millionths of a gram). Even several
lamps together do not present any risk to
people or the environment. The lamps can
therefore be thrown away with household
waste.
Disposal of discharge lamps
Small quantities of mercury can be found
in most HID fluorescent and compact
fluorescent lamps. These lamps also contain
small quantities of recyclable phosphors
so they should not be placed in household
refuse or recycled glass containers but sent
for proper recycling at community recycling
centres. Low-pressure sodium lamps and
sodium Xenon lamps can be disposed of
without the need for any special action.
Disposal of control gear
Hella ECGs, ballasts, ignitors, capacitors
and other electronic units do not contain
any material that will harm the environment
but they do contain recyclable electronic
components so they should be disposed of
as electronic waste.

138 LED Technology
TECHNICAL
An LED (Light Emitting Diode) is a solid state
electronic device that consists of several
layers of semiconductor material, in contrast
to a lamp that consists of a glass envelope
and electrodes assembled into a base. The
mechanically robust nature and low voltage
operation inherent in LED technology makes it
attractive to use in many lighting applications.
LED benefits
LED Technology has enormous benefits for
the mining industry, the most obvious being
the reduction in maintenance requirements
of our “fit and forget” design principle that
reduces vehicle servicing down times, as
there are no globes to burn out or holders to
corrode.
Hella LED lamps are pre-wired for easy
installation and manufactured to offer
maximum impact resistance and high
tolerance to chemicals, salt spray and
cleaning fluids. Most of the LED products
offered can survive shock impulses of 200G,
and operate over a much wider range of
ambient temperatures than normal products.
LED technology
Unlike conventional lamps that produce a
broad spectrum of colours (white light), an
LED emits light only in a particular single
colour. The specific colour is dependent on
the semiconductor material system used
(AllnGaP and InGaN) and ranges from red
through amber, green and blue. Creating a
coloured light signal from a conventional
globe requires the use of a filter (generally a
coloured lens) that absorbs most of the light
and passes through only the desired colour
spectrum. The filter losses normally range
from 30% to 80% depending on the colour
and intensity requirements. LED technology
eliminates this inefficient process. Hella LED
signal and warning lamps operate with up to
60% less current draw than comparable globe
lamps.
White light from an LED is produced by one of
two methods. The most common is a process
of luminescence conversion where a blue LED
light excites a phosphor to emit yellow light,
the mixture resulting in white light. The other
process of RGB colour mixing uses individual
red, green and blue LEDs and by altering the
relative mix of the three primary colours, any
other colour including white can be created.
The efficiency of white LEDs has risen
considerably over the past few years; values
of 50 lm/W and more are now being achieved.
It is now possible to produce white LED
lights that are more efficient than Halogen
and incandescent lamps, but still significantly
less efficient than gas discharge lamps. The
relatively high cost of high-efficiency white
LEDs still limits their use to applications where
a small amount of light with minimal heat is
required, areas where mechanical damage
due to shock and vibration destroys other
lights, or where the safety of low voltage
operation is paramount.
LED temperature behaviour
The amount of light emitted by an LED
reduces as the temperature rises:
yellow LEDs are more affected by high
temperatures than green and blue
LEDs. Loss of output as a result of high
temperature reverses when the LED
cools down and should not be confused
with degradation which happens over a
long time or in lamps in which LEDs are
operated beyond
their design current.
LED product
design
The high efficiency,
low power demand
that Hella LED lamps
are known for is not
an automatic result of
using LED technology.
Many competitor
products are no more
efficient or durable than conventional
lights. Hella invests considerable time and
diligence into the four most significant
aspects of LED product design, thereby
producing award winning, class-leading,
innovative products that set new standards
and receive worldwide recognition.
The most important issue relates to the
selection and optimum application of LED
devices suited to each task. Like all electronic
components, LEDs are mass-produced, with
each production batch yielding LEDs that vary
enormously in efficiency and colour. As one
of the largest global users of high intensity
LEDs, Hella has developed sophisticated
techniques that enable us to select only the
most efficient LEDs that fall within very tight
colour specification parameters.
The second aspect depends on maximising
optical system efficiency. Individual LED
devices typically produce a hundred times
less light than a conventional light globe.
To use the light effectively requires highly
meticulous optical system design.
The third aspect relates to effective power
supply and control circuit designs. LEDs
are much more sensitive to heat and
electrical issues than conventional lamps.
The development of robust, efficient circuits
that manage the operation of LEDs is just as
important as the optical aspects. Years of
experience gained through the production
and worldwide use of millions of LED
lights, enables Hella to keep
delivering
innovative and
effective solutions
to the challenges
faced by LED
systems.
The final aspect is
the physical product
design. All the
mechanical, thermal
management and operational environment
and production requirements are integrated
into a robust product that is expected to
remain fully operational under severe cold,
heat and humidity, while also being subjected
to high levels of vibration. Hella backs up
our innovative physical design and assembly
processes with a large investment in extensive
in-house test and development facilities to
prove all of our products meet the demands
placed on them in the field.
®

Hella Work Lamp systems 139
TECHNICAL
For mining vehicles and production plant,
good lighting is essential for activities other
than just driving. Haul trucks, shovels, drills,
cranes and other special purpose vehicles
often need separate, pivotable ‘work lamps’
for loading, unloading, and other operations.
Using the right work lamp can make the work
easier and, in most cases, a lot safer. That’s
why Hella, long a pioneer in innovative lighting
technology, offers a wide range of work lamps
designed for specific applications.
Hella Lighting Technology
Hella’s range of work lamps includes long,
short and mid-range lamps, offering close or
wide illumination. You can select Hella work
lamps that suit the specific task best using
Halogen, Xenon or LED technology. Lamps
are available with integral handles, dual beam
optics and a wide range of mounting options.
For complex projects we would suggest you
contact our applications engineering service.
Multivolt
One of the leading advantages of Hella LED
technology is the unique Multivolt circuitry
fitted to most LED products. The system
ensures a uniform level of light intensity and
full light output at any voltage in the range
stated (typically from less than 10V to more
than 28V). Multivolt lamps can be connected
to 12V or 24V automotive electrical systems,
without modification. The light output will not
be adversely affected by the voltage drop
commonly encountered in such systems
on large machines and trailers. In all but
the most compact lights, the Hella Multivolt
system also incorporates sophisticated
over voltage, transient impulse and reverse
voltage protection and thermal management
circuitry to ensure that the LED lamp functions
problem free.
The Paraboloid Lamp
The paraboloid lamp is classic amongst the
lamp systems in use today. It uses a parabolic
reflector and the light source is located at it’s
focal point. The reflector captures the light,
bundles it and radiates it.
The lens ensures that the light is distributed as
required, directing it to pre-specified areas in
front of the lamp. Effective paraboloid lamps
have a large reflector in order to capture a
great deal of light.
The lens must be as vertical as possible
in order to ensure good light refraction.
Reflectors with a long focal length provide
good long-range illumination; those with short
focal lengths collect more light and provide
good short-range illumination.
The Free-Form (FF) Lamp
The FF lamp represents a quantum leap in
lamp technology. Its reflector surface no
longer corresponds to an even paraboloid.
Rather, each point of the reflector surface has
an exactly defined function: to collect light,
concentrate and direct and distribute it.
The reflector alone generates the desired light
distribution. The entire light output of an FF
lamp is comprised of more than 50,000 spots
of light. The entire reflector is effective in Hella
Free-Form work lamps. The FF lamp takes the
light exactly to where it is supposed to be.
The result: brighter, more even illumination of
the work area, greater range, and hardly any
scatter loss or dazzling.
In order to calculate the reflector surface of
an FF lamp, extremely powerful electronic
computers and high-precision tools and
production machines are required. Fractions
of a thousandth of a millimetre alter the
effectiveness of the entire system.
Paraboloid lamp
Free-Form (FF) lamp

140 DRACO
®
vibration damping systems
TECHNICAL
Operational duty cycles in mining are some
of the most demanding, and field research by
Hella has measured shock and vibration levels
of remarkable magnitudes.
Equipment designed for less demanding
environments will fail rapidly when used in
mining, and often when most needed. Our
design aim is to produce equipment that will
function reliably in a continuously shock and
vibration laden environment.
Most types of mine lighting equipment
requires single point mounting to allow
for azimuth and elevation adjustments.
This arrangement concentrates stress and
maximizes overturning moment of inertia
in the light that is mounted. To analyse the
mechanical design effectively and deliver
reliable and predictable results, it is essential
that these aspects are thoroughly integrated
at the design stage; just adding impressive
looking brackets often leads to poorer
performance and progressively
cascading failures.
Hella developed our unique DRACO ® vibration
damping technology to enable us to limit the
vibration passing from the mounting surface
of the mining machine to
the relatively fragile globe
in the light fitting. DRACO
dampening effectively
eliminates resonant
behaviour and is specifically
designed for systems
subject to stochastic
(random) vibration with
a large dynamic range,
like that typically found
on mining machines. We
can adjust the system
parameters to suit each light
and its application
DRACO vibration damping systems consist of
at least two rigid mounting plates separated
by two (or more) flexible compounds of
differing hardness and damping properties,
arranged in parallel in one damper assembly.
This provides a non-ridgid mounting
arrangement between the vibration source
(the mining machine) and load (the light
fitting). Vibration signals are delayed in time,
reduced in amplitude, as well as altered in
spectral composition when some vibration
Vibration
Time
— Input
— DRACO ® output
— Std output
— Difference
(DRACO ® -Std)
energy is converted into heat as it passes
through each of the flexible compounds.
Detail differences between the damping
behaviour compound types creates a relative
phase shift in the vibration signals exiting
each compound. When the two (or more)
vibration signals are re-combined in the light
fitting, a new vibration signal is created with a
compressed dynamic range and lower peak
vibration level, reducing the stress in the load
(light fitting) significantly.
Xenon Gas Discharge (XGD) work lamps
What is Xenon lighting technology
Xenon globes use an electric current passed
through Xenon gas to produce light, rather
than a filament. Not only does this method
require minimal electric current draw
compared to filament lighting, it is also very
close to daylight.
As the human eye is designed to see in
daylight, Xenon lighting causes less eye strain
than other globe types, making it a more
convenient and safer night lighting option.
It also reflects road signs and markings
more brightly.
Advantages of Xenon lighting
• Wider (up to three times as large) and more
uniform illumination
• Twice the light of standard Halogen globes,
with less than half the power usage – safer
and more environmentally friendly
• Light colour very similar to daylight –
reduces strain on the eye
• Steady brightness levels even if power
supply varies
• Impact and vibration-resistant light arc
ensures a globe service life five times
longer than standard globes
Xenon Gas Discharge Work Lamps
The Hella XGD models are high-performance,
robust work lamps designed for most extreme
and heavy-duty assignments.
Hella Mining Work Lamp features:
• Improved lens protection through extended
housing
• Custom built Xenon ballast and electronic
circuitry integrated into housing for greater
reliability
• Inbuilt handle for easy aiming
• Integrated AMP plug with connection cable
or DT Plug
• DRACO ® vibration-damping pivot base and
mounting bracket
• Available in 12V DC and 24V DC application
• Special seals
• MUSTADD ® filter.

What is Xenon light
141
TECHNICAL
Instead of a coiled filament, a light arc is the
light source in Xenon lamps. The bulb, which
is only the size of a cherry stone, is filled with
Xenon gas and metal salts. In order to ignite
the Xenon bulb, an extremely high voltage of
approximately 20,000 volts is required.
This is provided by an electronic ballast: 12V
or 24V and direct current is transformed into
20,000V alternating current.
At temperatures of around 5000˚C, a light arc
is created. With a power consumption of a
mere 35 watts, this generates 2.5 times the
light flux of an Halogen globe of the same
power or equivalent to a 100W Halogen globe.
The current generation of control units is only
half the size of and approximately one third
lighter than the first and second generation.
The ignition electronics can now be
completely integrated into the control unit.
As a result of these control units, the lamp’s
light is almost independent of voltage
fluctuations in the vehicle electrical system, as
the electronics operate the Xenon globes at
constant output.
MustADD ® Filter Technology
Environment
Mechanical
Filtration
(3 micron)
Dehydration
Chemical
Scrub
Light
Source
Operational duty cycles in mining are some
of the most demanding and are normally
combined with intensive switching cycles,
dust-loaded air, corrosive atmospheres and
often high levels of humidity.
Equipment designed for less demanding
environments will not maintain their claimed
lighting performance for a long period when
used in mining. Hella designs fully sealed LED
“fit and forget” lights whenever possible for
mining applications. Where “fit and forget” is
not practical, the reality of mining operational
demands is taken into account. Due to their
heavy usage loads, mining lights must be
designed to allow for far more globe changes
than are required elsewhere, and they must
Reflector
be fitted with seals that will
function under less than perfect
conditions.
To overcome the problems
encountered in practice with
Seal
semi-perfect seals, Hella
mining work lamps incorporate
sophisticated breathing paths
and air filters. This ensures that
a low-resistance route is always
Lens
available for air to enter and
leave the luminaire; eliminating
pressure gradients across
seals and the consequence
of unpredictable leakage
behaviour. It is essential that
these aspects are thoroughly
integrated at the design stage.
Hella’s patented MustADD ®
breathing system chemically
cleans and dehydrates the air drawn into the
lamp every time it is switched off, resulting
in significantly extended product life. The
combined particulate, chemical and dehydrating
barrier effectively reduces corrosive
damage and allows AS500 FF ® work lamps to
operate repeatedly in harsh environments for
extended periods.
MustADD ® air filters remove dust particles to
sub-micron level from the air and minimise
airborne moisture, ensuring optimum light
performance is maintained in corrosive
environments.
Heavily contaminated air typical in mining
environments rapidly deteriorates the
operational performance of most air filter
systems. The MustADD ® system is designed
to substantially regenerate itself through two
actions:
Action 1
When switched on, the active components
in the system rapidly heat up and impart
some heat to the air inside the assembly.
This heating action increases the internal air
pressure and lowers the relative humidity
simultaneously; thereby forcing the vented air
to re-absorb moisture from the desiccant as it
is expelled from the light.
Action 2
The vigorous vibration of the equipment
to which the work lamp is mounted,
mechanically cleans accumulated particulate
matter from the membrane. The physical
structure of the micro-porous membrane is
specified so that the particulates are stopped
on the surface and not trapped within the filter
medium.
MustADD systems of various levels of
sophistication are implemented across
the Hella mining product range, to deliver
optimum value according to the product’s
intended application. Even the least
sophisticated implementation, using only the
particulate barrier, delivers remarkable results
due to the fact that the same design methods
and specialised materials are used, regardless
of product.

142 Tables for Chemical Resistance
Aluminium
Fibreglass
Acrylic
Polycarbonate
Chemical Material
Investigated
Accumulator Acid N R R L L
Acetic Acid up to 5% L R R R R
Acetic Acid up to 15% N R R R R
Acetone R N N N R
Alcohol up to 30% L R R R R
Alcohol concentrate R N N R R
Ammonia 25% R L R L R
Aniline R N N N R
Aromatic Hydrocarbons R L R S R
Benzine R N N L R
Carbon Dioxide R R R R R
Carbon Monoxide R R R R R
Carbon Tetrachloride L L L R R
Caustic Soda 2% N L R N R
Caustic Soda 10% N N R N R
Chloroform R N N N L
Common Salt L R R L R
Crude Oil R R R S R
Diesel Oil R R R L R
Dioxane R N N R
Ether R L N N R
Ethyl Acetate R N N R R
Glycerine R R R L R
Glycol R R R R R
Hydrobromic Acid N N L N
Hydrocarbons R L L S R
Hydrochloric Acid 5% N R R R N
Hydrochloric Acid 30% N R R R N
Stainless Steel
Aluminium
TECHNICAL
Fibreglass
Acrylic
Polycarbonate
Chemical Material
Investigated
Hydrochloric Acid 96% N R R R N
Hydrogen Peroxide over 40% R N L N R
Hydrogen Sulphide R R R R R
Ketones R N N R R
Lyso R N N N R
Metal Salts and their
aqueous solutions
Stainless Steel
N R R R L
Methanol R L N L R
Methylene Chloride L N N N R
Milk of Lime N R R L R
Nitric Acid 5% N R R R R
Nitric Acid 30% N L L L L
Nitric Acid concentrate N N N N R
Petrol R R R R R
Petroleum Ether R R R R R
Phenol L N N N R
Pyridine R N N R R
Sea Water L R R R R
Soap Suds L R R S R
Soda N R R R L
Sulphuric Acid 5% N R R R N
Sulphuric Acid 30% N R R R N
Sulphuric Acid concentrate N N N L N
Sulphurous Acid 5% L L R N L
Synthetic detergent N R R R R
Turpentine R R R R R
Water up to 70° C R R R R R
Xylene R N N N R
Ambient temperature 20° C
R Resistant
L Resistant within limits
N
S
Not resistant
Resistant when saturated, resistant within
limits when saturated.

Chemical Resistance Table (Standard Polycarbonate) 143
TECHNICAL
Polycarbonate
Polycarbonate is soluble in a number of
technical solvents. Good solvents include:
methylene chloride, ethylene chloride,
trichloroethane, tetrachloroethane,
chloroform, m-cresol and pyridine.
Comparatively poor solvents for
polycarbonate include: deoxane,
tetrahydrofuran, cyclohexanone and
dimethylformamide.
Examples of swelling agents are:
benzene, chlorobenzene, tetralin, acetone,
ethyl acetate, acetonitrile and carbon
tetrachloride.
Polycarbonate is resistant to mineral acids,
even in high concentrations, many organic
acids, oxidising and reducing agents, neutral
and acid salt solutions, many greases,
waxes and oils, saturated, aliphatic and
cycloaliphatic hydrocarbons and alcohols,
with the exception of methyl alcohol.
Polycarbonate is chemically degraded by
aqueous or alcoholic alkaline solutions,
ammonia gas and its solutions and also
by amines.
Chemicals
acetaldehyde
acetic acid up to 10%
acetone
acrylonitrile
ammonia
ammonium
hydroxide solution
ammoniym sulphate,
saturated solution in
water
benzene
benzoic acid
borax, saturated
solution in water
bromine
butylene glycol
calcium hypochlorite
carbon dioxide, moist
caustic potash
caustic soda
chlorinated lime
solution 2% in water
chlorine gas, dry
chlorine gas, moist
chromic acid, 20%
in water
coal gas
cresol
dibutyl phthalate
(plasticiser)
diethylene glycol
dioxane
ethanol
N
R
N
N
N
N
R
N
N
R
N
R
R
R
N
N
R
L
N
R
R
N
N
R
N
R
ether
ethyl alcohol 96%
pure
ethylene chloride
ethylene glycol
formalin 10%
formic acid 30%
glycol
heptane
hydrochloric acid,
conc.
hydrochloric acid
20%
hydrogen sulphide
ligroin (hydrocarbon
mixture)
methane
methanol
methylmethacrylate
nitric acid 10%
nitric acid 20%
nitrous fumes, dry
ozone
petroleum ether
(hydrocarbon mixture)
petroleum spirit (for
dry cleaning, free of
aromatics)
phenol
potassium cyanide
potassium
permanganate, 10%
in water
potassium sulphate,
saturated solution in
water
N
R
N
R
R
L
R
R
N
R
R
R
R
N
N
R
N
N
R
L
R
N
N
R
R
propionic acid 20% R
sodium bicarbonate,
saturated solution in R
water
sodium chloride,
saturated solution in R
water
sulphur dioxide L
sulphuric acid, conc. N
sulphuric acid 50% R
toluene
N
trichloroethylene N
Disinfectants
carbolic acid N
hydrogen peroxide R
iodine, tincture L
perhydrol
R
Pharmaceuticals,
Cosmetics
lanolin
R
nail varnish remover N
Foodstuffs, drinks
and tobacco
allspice
N
coffee
R
edible oil
R
fruit juices
R
glucose
R
linseed oil
R
nutmeg
N
sugar solution,
saturated
R
vegetable juices R
vegetable oil R
Detergents, rinsing
and cleaning
agents
Ajax ®
R
Persil ®
L
Pril ®
R
silicone oil emulsion R
soft soap
R
tuba carpet
shampoo conc.
L
Technical oils and
greases
Baysilone ® fluids
(silicone fluids)
R
brake fluid (ATE) N
camphor oil
N
diesel oil
L
fish liver oil
R
hydraulic fluid (Vac
HLP 16)
R
paraffin oil
R
silicone oil
R
turpentine substitute R
varnish
L
Adhesives and
sealants
Cellux ® adhesive
films
R
glazier’s putty R
insulating tape R
rubber (free of
plasticiser)
R
Polishes and antistatic
agents
Delu ® anti-static
solution
R
Perspex polish 3 ®
R
Plexiklar ®
R
Polifac ® grinding
paste
R
Inks
multimarker (Faber
Castell)
L
pelican royal blue
4001
R
Miscellaneous
battery acid
R
chrome oxide green
(grinding paste)
R
cleaning petrol R
coal gas
R
exhaust fumes, acidic R
kerosene, (aviation
fuel)
N
motor fuel, high
octane
N
motor fuel, ordinary L
grade
polyethylene R
polymeric plasticisers L
tannic acid
N
thinners
N
white spirit
N
R Resistant L Resistant within limits N Not resistant
This information and technical data advice, whether verbal, in writing or through trials, is given in good faith without warranty.
This also applies where proprietary rights of third parties are involved.
This advice does not release you from the obligation to check its validity.

144 Construction and meaning of the IP (Ingress Protection) Code
TECHNICAL
The specification of a degree of
protection for protection against
access and foreign object
includes all lower degrees of
protection.
The degrees of protection 1 to
6K for protection against water
include all the lower degrees
of protection. Due to different
physical affects, this does not
automatically have to apply to
water protection grades 7, 8
and 9K.
Code letters
(Ingress Protection)
First characteristic numeral
(numerals 0 to 6 or letter X)
Second characteristic numeral
(numerals 0 to 8 or letter X)
Additional letter (optional)
(letters A, B, C, D)
Supplementary letter (optional)
(letters M, S)
(letter K)
IP 2 K 3 K C M
Ingress Protection: Overview of the Elements of the IP Code
Element
Numeral/
Letter
Meaning for the
protection of electrical equipment
Meaning for the
protection of persons
First characteristic
numeral/ supplementary
letter
0
12345K
6K
Against the ingress of solid
foreign objects (including dust):
not protected
with Ø ≥ 50mm
with Ø ≥ 50mm
with Ø ≥ 50mm
with Ø ≥ 50mm
dust-protected
dust-tight
Against access to hazardous parts
(unless described by extra letters):
not protected
with back of hand
with finger
with tool
with wire
with wire
with wire
Second characteristic
numeral/ supplementary
letter
0
1
2
3
4
4K
5
6
6K
7
8
9K
Against the ingress of water:
Not protected
Vertical dripping
Dripping (inclined 15°)
Spraying
Splashing
Same with increased pressure
Jetting
Powerful jetting
Same at increased pressure
Temporary immersion
Continuous immersion
High-pressure/steam jet cleaning
Additional letter
(optional)
A
B
C
D
Meaning for the protection of electrical
equipment
Against access to hazardous parts
(unless described by first characteristic
numeral):
with back of hand
with finger
with tool
with wire
Supplementary letter
(optional)
M
S
K
Movement of moving parts
during water test
Standstill of moving parts
during water test
Specifically for the electrical equipment
in road vehicles

Applications Engineering 145
TECHNICAL
The Hella Centre of Excellence – Mining
provides an Applications Engineering lighting
design service for Hella Mining customers.
The aim of this unique service is to reduce
risk to end users and OEMs of implementing
an inappropriate lighting design, enabling
all stakeholders to evaluate, comment and
change the design prior to implementation.
The Hella team combines decades of
lighting expertise across many countries
and industries with the most sophisticated
software. However, our most valuable asset
is ongoing consultation combined with
extensive practical on-site mining experience,
enabling us to understand the unique visual
and environmental requirements of the mining
industry.
We are fully aware of the wide and sometimes
conflicting range of operational requirements,
covering the need for greater equipment,
operator and maintenance personnel safety,
lowered cost of ownership and maintenance,
increased productivity requirements and the
need for a predictable
service life.
We use appropriate, proven
technologies and methods to
provide the mining operation
with an engineering-based,
application-focussed,
customised solution. The
system design not only
complies with the relevant
occupational health and
safety regulations, but also
with real life maintenance and
operational needs.
Hella lighting designs
typically include; aiming
and orientation angles, number and type
of luminaires, part numbers, spare parts,
illumination level achieved and appropriate
standards referenced. Our service extends
to both fixed and mobile plant lighting
designs. The final design is contained in a
clear and concise document that can be
presented to all relevant stakeholders, ready
to be integrated into on site maintenance
documentation systems.
Our experience in Applications Engineering
allows us to create lighting designs in a short
time frame and with limited information.

146 Part Number Index
2 PAGE
2716 113
2717 113
2718 113
2719 113
2720 113
2716-24V 113
2717-24V 113
2718-24V 113
2719-24V 113
2720-24V 113
8 PAGE
8151 30
8273 101
8730 114
8731 114
8732 114
8733 114
8734 114
8735 114
8736 114
8737 114
8738 114
8739 114
8740 114
8741 114
8742 114
8743 114
8744 114
8745 114
8746 114
8HG959952022 84
9 PAGE
9.1533.03 28
9.1600.01 58
9.1600.06 58
9.1601.01 58
9.1602.01 58
9.1603.01 58
9.1604.01 58
9.HM
PAGE
9.HM1002.01 30
9.HM1002ECE.01 30
9.HM1385.05 30
9.HM151BAL 16
9.HM151TRN 16
9.HM15NB 16
9.HM15WB 16
9.HM180LENS 52
9.HM300FLX 48
9.HM360LENS 48
9.HM400LENS 46
9.HM450ALENS 46
9.HM450BLENS 46
9.HM450FLX 42
9.HM450GLENS 46
9.HM450RLENS 46
9.HM450WLENS 46
9.HM46FX 70
9.HM46GL 70
9.HM46MP 70
9.HM46MS 70
9.HM4940 99
9.HM4941 99
9.HM4942 99
9.HM4943 99
9.HM4944 99
9.HM4945 99
9.HM4946 99
9.HM4947 99
9.HM4948 99
9.HM4949 99
9.HM4950 99
9.HM4951 99
9.HM4952 99
9.HM4953 99
9.HM4954 99
9.HM4955 99
9.HM4956 99
9.HM4957 99
9.HM4958 99
9.HM4959 99
9.HM4960 103
9.HM4960.01 81
9.HM4960.02 81
9.HM4960.03 81
9.HM4960.04 81
9.HM4960.05 81
9.HM4961 103
9.HM4962 103
9.HM4963 103
9.HM4964 103
9.HM4965 103
9.HM4966 103
9.HM4967 103
9.HM4968 103
9.HM4969 103
9.HM4970 103
9.HM4971 103
9.HM4972 103
9.HM4973 105
9.HM4974 105
9.HM4975 105
9.HM4976 105
9.HM4977 105
9.HM4978 105
9.HM4979 105
9.HM4980 105
9.HM4980.01 106
9.HM4980.02 106
9.HM4980.03 106
9.HM4980.04 106
9.HM4980.05 106
9.HM4980.06 106
9.HM4980.07 106
9.HM4980.09 106
9.HM4981 105
9.HM4982 105
9.HM4983 105
9.HM4984 105
9.HM4985 105
9.HM4986 105
9.HM4987 105
9.HM4988 105
9.HM4989 105
9.HM4990 105
9.HM4991 105
9.HM4992 105
9.HM4993 105
9.HM5700 76
9.HM5701 76
9.HM5702 76
9.HM5703 76
9.HM5801 77
9.HM5802 77
9.HM70BR 11
9.HM70BR 36
9.HM70DC 36
9.HM70WH 36
9.HM8500 101
9.HM8501 101
9.HM8502 101
9.HM8503 101
9.HM8504 101
9.HM8505 101
9.HM8511 101
9.HM8513 101
9.HM8514 101
9.HM8520 101
9.HM8521 101
9.HM8522 101
9.HM8523 101
9.HM8530 101
9.HM8531 101
9.HM8532 101
9.HM8541 101
9.HM8543 101
9.HM8548 101
9.HM8549 101
9.HM8600B 107
9.HM8600C 107
9.HM9386.02 40
9.HMAPEDL 16
9.HMAWHKD 16
9.HMDLM001 54
9.HMDLM001 64
9.HMDLM002 66
9.HMDLM002 86
9.HMPU2NB 34
9.HMPU2WB 34
9.HMPUXB24 24
9.HMPUXNB 24
9.HMPUXWB 24
9.HMTN001 74
9.HMTN002 74
9.HMTN003 74
9.HMTN004 74
9.HMTN005 75
9.HMTN006 75
9.HMUBHWB 28
9.HMUBHNB 28
9.HMX7500.01 56
9.HMX7500.02 56
C
PAGE
C12100 120
C1255LL 120
C24100 120
C2470 120
C2470LTS 120
CA1255LL 123
CA1255X 123
CA2470 123
CA2470LTS 123
CB1255BL 120
CD12100 120
CD1255 120
CD24100 120
CD2470 120
CF1265 123
CG1255 123
CG2470 123
CX1255BL 120
HM0
PAGE
HM060321 62
HM060621 63
HM070321 62
HM070621 63
HM1
PAGE
HM1002 30
HM1002ECE 30
HM1220AC 110
HM1260AC 110
HM1358 30
HM1374D 30
HM1375D 30
HM1504NB 18
HM1504WB 18
HM1510NB 26
HM1510WB 26
HM1511NB 26
HM1511WB 26
HM1512NB 16
HM1512WB 16
HM1513NB 16
HM1513WB 16
HM1522WB 22
HM1526LR 28
HM1526NB 28
HM1526WB 28
HM1535DRL 67
HM1535NB 12
HM1535PB 12
HM1535WB 12
HM1539LDD 10
HM1539LED 10
HM1550CIG 15
HM1550DT 15
HM1550MAG-12 15
HM1550MAG-24 15
HM1550WB 14
HM15700NB 13
HM15700PB 13
HM15700WB 13
HM175AND 111
HM180ABP 52
HM180ADIR 52
HM180AMAG 52
HM180BDIR 52
HM180BMAG 52
HM180GBP 52
HM180GDIR 52
HM180GMAG 52
HM180RBP 52
HM180RDIR 52
HM180RMAG 52
HM180WDIR 52
HM180WMAG 52
HM2
PAGE
HM2026 66
HM2026D 66
HM2051 66
HM2051D 66
HM2053PC 66
HM2053PCD 66
HM2054 66
HM2054D 66
HM227HD 85
HM2307 66
HM2307D 66
HM2379 64
HM2379D 64
HM2420AC 110
HM2460AC 110
HM2717-24V 113
HM2719-24V 113
HM3
PAGE
HM300ADIR 50
HM300AFLX 50
HM300AMAG 50
HM300BDIR 50
HM300BMAG 50
HM300GDIR 50
HM300GMAG 50
HM300RDIR 50
HM300RMAG 50
HM300WDIR 50
HM300WMAG 50
HM350AND 111
HM360ABP 48
HM360ABPMAG 48
HM360ADIR 48
HM360AMAG 48
HM360BBPMAG 48
HM360BDIR 48
HM360BMAG 48
HM360FLX 48
HM360GDIR 48
HM360GMAG 48
HM360PIPE 48
HM360RBP 48
HM360RDIR 48
HM360RMAG 48
HM360WDIR 48
HM360WMAG 48
HM4
PAGE
HM400ADIR 46
HM400AFLX 46
HM400AMAG 46
HM400BDIR 46
HM400BMAG 46
HM400GDIR 46
HM400GMAG 46
HM400PIPE 46
HM400RDIR 46
HM400RMAG 46
HM400WDIR 46
HM400WMAG 46
HM4400A 112
HM4400A-12V 112
HM4400B 112

147
HM4400B-12V 112
HM4400G 112
HM4400G-12V 112
HM4400R 112
HM4400R-12V 112
HM450ADIR 44
HM450AFLX 44
HM450AMAG 44
HM450BDIR 44
HM450BMAG 44
HM450GDIR 44
HM450GMAG 44
HM450RDIR 44
HM450RMAG 44
HM450WDIR 44
HM450WMAG 44
HM4612 70
HM4620 70
HM4630 70
HM4660A 78
HM4660B 78
HM4660KTB7 78
HM4660KTC7 78
HM4660LOC 78
HM4660ROD 78
HM4660SWA 78
HM4660SWB 78
HM4660SWC 78
HM4660SWD 78
HM4660SWE 78
HM4660SWF 78
HM4960 81
HM4960FM 81
HM4960SA 74
HM4961 81
HM4961FM 81
HM4962 81
HM4963 81
HM4963FM 81
HM4964 81
HM4965 81
HM4980 106
HM4981-P 106
HM4981-S 106
HM4982-P 106
HM4982-S 106
HM4983-P 106
HM4983-S 106
HM4984-P 106
HM4984-S 106
HM4985-P 106
HM4985-S 106
HM4986-P 106
HM4986-S 106
HM5
PAGE
HM500ADIR 42
HM500AFLX 42
HM500AMAG 42
HM500BDIR 42
HM500BMAG 42
HM500GDIR 42
HM500GMAG 42
HM500RDIR 42
HM500RMAG 42
HM500WDIR 42
HM500WMAG 42
HM50AND 111
HM5700KIT 76
HM5701KIT 76
HM5800KIT 77
HM6
PAGE
HM6603BD-12V 89
HM6603BD-24V 89
HM6603GD-12V 89
HM6603GD-24V 89
HM6605RD-12V 89
HM6605RD-24V 89
HM6605WD-12V 89
HM6605WD-24V 89
HM680ANB 86
HM680ANW 86
HM680ANY 86
HM680ARB 86
HM680ARW 86
HM680ARY 86
HM680FNB 86
HM680FNW 86
HM680FNY 86
HM680FRB 86
HM680FRW 86
HM680FRY 86
HM7
PAGE
HM70H3NB-24V 36
HM70H3WB-24V 36
HM70H9NB-12V 36
HM70H9WB-12V 36
HM70LEDD 11
HM70PI 11
HM70PI 36
HM70PR 11
HM70PR 36
HM720150W 88
HM720150Y 88
HM720400W 88
HM720400Y 88
HM7546J 71
HM7592B 71
HM8
PAGE
HM8154 18
HM8154AMBER 18
HM8156 32
HM8156AMBER 32
HM8158 28
HM8158AMBER 28
HM8159 34
HM8159AMBER 34
HM8160 20
HM8161 10
HM8164 16
HM8275 81
HM8275 98
HM8276 98
HM8277 98
HM8283 98
HM8284 100
HM8285 98
HM8286 98
HM8287 102
HM8288 103
HM8289 103
HM8290 104
HM8298 106
HM8600 107
HM9
PAGE
HM9.1374.08 30
HM9.1374HD.01 30
HM9.1375HD.01 30
HM9400AMB2A 40
HM9400AMB2G 40
HM9400AMB2R 40
HM9400AMB3A 40
HM9400AMB3G 40
HM9400AMB3R 40
HM9400AMB4A 40
HM9400AMB4G 40
HM9400AMB4R 40
HM9400YEL2A 40
HM9400YEL2G 40
HM9400YEL2R 40
HM9400YEL3A 40
HM9400YEL3G 40
HM9400YEL3R 40
HM9400YEL4A 40
HM9400YEL4G 40
HM9400YEL4R 40
HM95903700 54
HM95903700D 54
HM95903710 54
HM95903710D 54
HM95903760 54
HM95903760D 54
HM95903780 54
HM95903780D 54
HM95903790 54
HM95903790D 54
HM95905030 65
HM959950211 84
HM959950221 84
HM980910021 53
HM980910221 53
HM980910421 53
HM980910621 53
HM980910721 53
HMA
PAGE
HMASH70NBA 32
HMASH70NBD 32
HMASH70WBA 32
HMASH70WBD 32
HMAT85 80
HME
PAGE
HMEC1010AU 72
HMEC1510AU 72
HMEC2010AU 72
HMEC2015AU 72
HMEC2510AU 72
HMEC3015AU 72
HMEC4015AU 72
HMET200.08 115
HMET307.01 115
HMET307.02 115
HMET307.03 115
HMET307.04 115
HMET307.05 115
HMET307.51 115
HMET483.03 115
HMET483.05 115
HMET483.07 115
HMET483.10 115
HMET483.15 115
HMET483.20 115
HMET483.25 115
HMET483.30 115
HMET483.35 115
HMF
PAGE
HMFH107P 92
HMFH117P 92
HMFH312P 92
HMI
PAGE
HMIC2010AU 73
HMIC2015AU 73
HMIC3020AU 73
HMP
PAGE
HMPB100 8
HMPB200 9
HMPS12PROVCP 116
HMPS12PROVPT 116
HMPS12VCP 116
HMPS12VKIT 116
HMPS12VPROKIT 116
HMPS12VPT 116
HMPS24PROVCP 116
HMPS24PROVKIT 116
HMPS24PROVPT 116
HMPS24VCP 116
HMPS24VKIT 116
HMPS24VPT 116
HMPS75B 111
HMPS75G 111
HMPS75R 111
HMPS75S 111
HMPSPCAP 116
HMPV270NBA 34
HMPV270NBD 34
HMPV270WBA 34
HMPV270WBD 34
HMPVX35NBD 24
HMPVX35WBD 24
HMR
PAGE
HMRA087B 95
HMRA107B 95
HMRA112P 93
HMRA603P 94
HMRA611P 94
HMRA917E 93
HMT
PAGE
HMTND2156 74
HMTND2157 74
HMTND2158 74
HMTND2159 75
HMTND2160 75
HMTNM6605 74
HMTNM6606 74
HMTNM6607 74
HMTNM6608 74
HMTNM6609 74
HMTNM6610 75
HMTNM6611 75
HMTNM6612 75
HMTNM6613 75
HMU
PAGE
HMUBXHWBD-12V 20
HMUBXHWBD-24V 20
HMUBXSWBD-12V 20
HMUBXSWBD-24V 20
HMW
PAGE
HMWGA160 58
HMWGA220 56
HMWPR001 80
HMX
PAGE
HMX6750A 58
HMX6750B 58
HMX6750C 58
HMX6750G 58
HMX6750R 58
HMX7500A 56
HMXN4001 20
HMXN4001 24
HMXN4001 124
HMXN4YEL 124
X
PAGE
XD12100/55 122
XD12100/90 122
XD1260/55 122
XD1260/55LL 122
XD24100/90 122
XD2475/70 122
XD2475/70LL 122
XD2475/70LTS 122
XDB1260/55BL 122
XDX1260/55BL 122
XN4000 124
XN6750 124
Y
PAGE
YC12100 121
YC1255LL 121
YC24100 121
YC2470 121
YC2470LTS 121
YCB1255BL 121
YCP1255BL 121
YCX1255BL 121

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