Chapter 1 - Aspöck Systems

Aspöck Systems – we bring light tot he roadAt Aspöck Systems we have made i tour business to design, develop and build the best possible totalsoluations for Europe’s vehicle manufactures. And here we mean the complete range of vehicles.Individual systems – Satisfied customers.Since their inception in 1977, Aspöck Systems GmbH has focused on a philosophy that has made itone of today’s leading producers of lighting systems fort he vehicle industry: developing customtailoredsolutions for each individual customer. Thos ist he flexibility that has become the successfultrademark of Aspöck Systems.Innovative products.We see it as our obligation to make our entire range of cable and light systems compaible with thesate-of-the-art, and play a pioneering role in setting new standards. We apply waterproof cables,connection systems and LED lighting to every field of application.Continous growth.Our headquarters in Peuerbach, Upper Austria has undergone continuous expansion in theproduction, storage and management sectors. Every year we invest in new production facilities, testingequipment and development systems to remain at the cutting edge of technology. At the same time wepromote the further education and training of our employees, so that they alwys have the right answerwhen confronted with difficult questions, such as specific legislation issues.Chapter 1 Februar 2009

2 pin bayonet with pin case1. The end of the cable max. 35mm cut away the cover and thread the pipe onto the cable (picture 1)2. aufcrimpen (Bild 1)3. About 6mm cut away from the single cores and fix the contacts onto the cable (picture 1)4. Put the contacts into the plug case, so that they engage in the plug case (picture 1)5. Screw the nut on the pipe over the case and fix the cable strip at the back of the pipe (picture 2)Picture 1Plug casecontactspipeCable stripScrew the nut until tot he block (picture)121 = white common return2 = current-carringStipulate working time to change a complete 2 pin connector: max. 15 minChapter 2

Chapter 2

8 pin bayonet with pin case1. The end of the cable max. 35mm cut away the cover and thread the pipe onto the cable (picture 1)2. About 6mm cut away from the single cores and fix the contacts onto the cable (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Screw the nut on the pipe over the case and fix the cable strip at the back of the pipe (picture 2)Picture 1plug case contacts cable strippipe756328411 = ye / flasher left4 = gn / flasher right2 = bl / rear fog lamp3 = wt / common return7 = bk / rear light left5 = Br / rear light right6 = rd / brake light8 = gr / reverse lightPicture 2Stipulate working time to change a complete 8 pin connector: max. 20 minChapter 2

15 pin bayonet with socket case1. Cut away max. 30mm the cover at the end of the cable and thread the pipe onto the cable(picture 1)2. Cut away ca. 4mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the bayonet nut onto the cable, and plug the single cores into the correct pin at the socket4. casing (picture 1) (shown in the drawing right). NOTE: they must engage in the socket casing5. Put the pipe over the case and fix the metal clamp at the front and the back of the pipe (picture 2)Picture 1socket casecontactsMetal clampView AHere must be a sealing,please checkBayonet nutpipe21Ansicht Aview Avue A10111213915814 671 = ye / flasher left2 = gn / flasher right3 = bl / rear fog lamp4 = wt / common return5 = bk / rear light left6 = Br / rear light right7 = rd / brake light8 = gr / reverse light9 = br-bl / feed current10= Br-rd/interior light11= Ye-bk / free12= rs / steering axle13 = Wt-bk / free14 = vi / drive up help15 = or / bogie lift345Picture 2Metal clampStipulate working time to change a complete 15 pin connector: max. 0,5 hChapter 2

15 pin bayonet with pin case1. The end of the cable max. 35mm cut away the cover and thread the pipe onto the cable (picture 1)2. About 4mm cut away from the single cores and fix the contacts onto the cable (picture 1)3. Put the pipe over the case and fix the metal clamp at the front and the back of the pipe (picture 2)Picture 1contactsMetal clampView Apipe76Ansicht Aview Avue A81514591341011123121 = ye / flasher left2 = gn / flasher right3 = bl / rear fog lamp4 = wt / common return5 = bk / rear light left6 = Br / rear light right7 = rd / brake light8 = gr / reverse light9 = br-bl / feed current10= Br-rd/interior light11= Ye-bk / free12= rs / steering axle13 = Wt-bk / free14 = vi / drive up help15 = or / bogie liftPicture 2Metal clampStipulate working time to change a complete 15 pin connector: max. 0,5 hChapter 2

Montageanleitung für Aspöck VerbinderMounting instruction for AspöckconnectorsSystem Bayonet15 pin female15 pin male2. 1. Look that this “anti twists” fit correct togetherAnti-twistChapter 2

2. Put the two connectors together so that they engage3. Put the plastic screw in the correct positioncorrect positionChapter 2

4. Turn the plastic screw, until it locks. If it´s correct, you will hear “click”Chapter 2

Spare parts SYSTEM BAYONETOrder-Nr. left (yellow) right (green) reversible describtion13-0230-031 X Bayonet 2-pin male yellow13-0232-031 X Bayonet 2-pin male green13-0236-031 X Bayonet 2-pin male black13-0220-031 X Bayonet 2-pin female yellow13-0222-031 X Bayonet 2-pin female green13-0226-041 X Bayonet 2-pin female black13-0831-031 X Bayonet 8-pin male yellow13-0833-031 X Bayonet 8-pin male green13-0834-021 X Bayonet 7-pin male white13-0836-021 X Bayonet 7-pin male grey13-0838-061 X Bayonet 8-pin male black13-0821-051 X Bayonet 8-pin female yellow13-0823-041 X Bayonet 8-pin female green13-0824-031 X Bayonet 7-pin female white13-0826-031 X Bayonet 7-pin female grey13-0828-061 X Bayonet 8-pin female black13-1530-101 Bayonet 15-pin male13-1520-051 Bayonet 15-pin femaleChapter 2

Chapter 3:ASS1 SystemChapter 3 Februar 2009

7 pin ASS1 connector white and black1. Cut away max. 35mm of the cover at the end of the cable, thread the gland, pipe and the ring ontothe cable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)picture 1ringcontactsglandplug caseASS1 7 pin blackASS1 7 pin. whiteGleitring76513241 = wh / common return2 = bk / rear light left3 = ye / flasher left4 = rd / brake light5 = Gr / flasher right6 = Br / rear light right7 = Ye/bl free1 = wh / common return2 = bk / rear light left3 = gr / reverse light4 = Br/bl feed current5 = or / free6 = Rs / bogie lift7 = bl / rear fog lampChapter 3 Februar 2009

picture 2Cable tieStipulate working time to change a complete 7 pin connector: max. 0,35 hChapter 3 Februar 2009

7 pin ASS1 connector with socket case green1. Cut away max. 35mm of the cover at the end of the cable, thread the gland, pipe and the ring onto thecable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)picture 1ringcontactsplug caseglandGleitringringbague81/432 6751/4 = gn / flasher ri2 = bl / rear fog lamp3 = wh / common return5 = br / rear light right6 = rd / brake light7 = Bk / rear light left8 = gr / reverse lightChapter 3 Februar 2009

picture 2Cable tieStipulate working time to change a complete 7 pin connector: max. 0,35 hChapter 3 Februar 2009

7 pin ASS1 connector yellow1. Cut away max. 35mm of the cover at the end of the cable, thread the gland, pipe and the ring onto thecable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)picture 1ringpipcontactsplug caseglandGleitring2781/43651/4 = ye / flasher ri2 = Bl / rear fog lamp3 = Wh / common return5 = Br / rear light right6 = Rd / brake light7 = Bk / rear light left8 = gr / reverse lightChapter 3 Februar 2009

picture 2Cable tieStipulate working time to change a complete 7 pin connector: max. 0,35 hChapter 3 Februar 2009

7 pin ASS1 connector green and yellow1. Cut away max. 35mm of the cover at the end of the cable, thread the gland and the pipe onto the cable(picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. sie den Kabelbinder am Tüllenende (Bild 2)picture 1plug casecontactsnutpiperinggland27 5381/461/4 = gr or ye / flasher2 = bl / rear fog lamp3 = wh / common return5 = br / rear light right6 = rd / brake light7 = bk / rear light left8 = gr / reverse lightChapter 3 Februar 2009

picture 2Cable tieStipulate working time to change a complete 7 pin connector: max. 0,35 hChapter 3 Februar 2009

2 pin ASS1 connector black1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe and the ring onto the cable(picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)picture 1contactspipe nutpipeplug casering121 = wh / common return2 = current carringpicture 2Cable tieStipulate working time to change a complete 2 pin connector: max. 0,25 hChapter 3 Februar 2009

2 pin ASS1 connector black1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe and the ring onto the cable(picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)picture 2contactspipe nutpipeplug casering1 = wh / common return2 = current carring1 2picture 2Cable tieStipulate working time to change a complete 2 pin connector: max. 0,25 hChapter 3 Februar 2009

System ASS1 – 2 pin connectorexplanation: the yellow connectors are for the left side, and the green ones are for the right side (indriving direction)1. the connector has an “anti twist” (flattening)“anti twist”Chapter 3 Februar 2009

2. put the connectors correct together, and mount the ASS1 nut3. the ASS1 nut has to be tighten only byhandASS1 nutChapter 3Februar 2009

System ASS1 – 7 pin connectorexplanation: the yellow connectors are for theleft side, and the green ones are forthe right side (indriving direction)1. check that both “anti twists” fit together, than put theconnectorstogether“anti twist”connector on the backside of the rear lamp“anti twist of the rearlightChapter 3Februar 2009

2. put the connectors together and mount the ASS1 nut screwonto the backlight. The ASS1 nut has to tighten only by hand!Chapter 3Februar 2009

mounting instructions ASS1 connector- Strip the Isolation 150 mm. Mount the screwing nut, slide-ring and rubber (look picture 1).Depending tot he diameter oft he cable use the right rubber (different colours). As a strain-bearingelement fit a plastic strip and tighten him.screwing nutslide ringrubber/ Picture 1Rubber black for cable diameter 5-6 mmRubber brown for cable diameter 2x5-6 mmRubber white for cable diameter 7-8 mmRubber bluefor cable diameter 9-10 mmRubber redfor cable diameter 11-13 mmRubber grey for the flat cable P&R 2x1,5 []Rubber green sealing rubber for 2 pin. Outside connector- Crimp the 6,3 fastons onto the conductors, pass the cable through the entrance on the junction boxand connect them corresponding DIN ISO. (look description – insde of the cover)- Close all screwing devices on the junction box as far as it will go- Close the cover with the housing from the junction-box with the 4 thermoplast screws 5x30 as faras it will go. Torque 3,0 Nm.- Mount the junction-box only in vertical position. Follow description „TOP“ (=at the top). Fix thecables from the junction-box down (waternoxe) together with several cable clips.Chapter 3 Februar 2009

- Whileconnection either the 2-pin or 7-pin connector follow the correct position (code).- Not used outside connectors must be closed with a screwing device + the green sealing rubberFittingand changing of bayonet-inserts in the junction-box ASS1Detail/ DetailPlastikstop pfen/ plastic part/VentilventedglandRubber /GummitülleGehäusebodenbox‐housing12 mm Loch an der tiefsten Stelle12 mm hole at the lowest pointThe vented gland must be positioned at thelowest point oft he junction-box and therubber whole must bepositioned against thedirection oft he traffic. Blean the rilled whole.After fitting the rubber, look detail, press theplastic part into the slot as far as it goes.Putthe O-ring-sealing (30x2,5 for the small insert ans34x2,5 for the big one) intothe deepening. Insert thebayonet-insertinto whole and make 1/ /8 turn, as faras it goes, turn tot he right. Fort he small insert useaspanner 23 andfort he big one use a spanner 30.Chapter 3Februar 2009

Spare parts:Junction-box ASS1 with rubbers, slide-rings and screwing nuts assembled 76-5100-007Bayonet housing black fort he rubber with whole and O-ring 13-5621-004Bayonet housing black fort he rubber without whole and O-ring 13-5621-014Bayonet housing yellow for 2 pins outside connector with O-ring and faston 6,3 13-5627-204Bayonet housing green for 2 pin outside connector with =-ring and faston 6,3 13-5627-224Bayonet housing black for 2 pin outside connector with O-ring and faston 6,3 13-5627-284Bayonet housing yellow for 7 pin outside connector with O-ring and faston 6,3 13-5627-704Bayonet housing green for 7 pin outside connector with O-ring and faston 6,3 13-5627-724Bayonet housing black for 7 pin outside connector with =-ring and faston 6,3 13-5627-784Bayonet housing 17 pin. ASS3 male, O-Ring with spring and contacts 13-1750-004Bayonet housing 17 pin. ASS3 female, with 2x O-Ring and contacts 13-1740-0045 pcs. Black rubbers 6mm open 15-5623-00V5 pcs. Black rubbers 6mm closed 15-5623-10V5 pcs. Brown rubbers 2x6mm open 15-5623-01V5 pcs. Brown rubbers 2x6 mm closed 15-5623-11V5 pcs. White rubbers 8mm open 15-5623-02V5 pcs. White rubbers 8mm closed 15-5623-12V5 pcs. Blue rubbers 10mm open 15-5623-03V5 pcs. Blue rubbers 10mm closed 15-5623-13V5 pcs. Red rubbers 12mm open 15-5623-04V5 pcs. Red rubbers 12mm closed 15-5623-14V5 pcs. Grey rubber fort he flat-cable P&R [] 15-5623-18V5 pcs. Sealing rubber for 2 pin outside connect 15-5623-30VChapter 3 Februar 2009

Mounting instruction (detail) vented glandpicture 1Step 1:• Open the junction boxDrill a 12 mm dia hole at the thickest point in the bottom ofthe junction box• ATTENTION: care must be taken not to drill into existingcables or contacts, ensure tht the 12 mm dia hole is drilleasclose tot he rubber seal as possible• Ensure the mark „TOP“ is upright• Ensure all waste particles are removed from the boxpicture 2picture 3Step 2:• Insert the rubber part into the drilled hole, so that the hole ofthe vented gland is AGAINST the direction fot he traffic.Push the plastic gland firmly into the rubber part.ATTENTION: both items have a locating rail.Step 3:• Close the juntion box• Ensure that the vented gland is mounted correctly. If thejunction box mounted in the center oft eh rear bumber bar,the vented gland must point towards the rear oft he trailer(i.e. against the direction of travel), see pucture 3.• If the junction box is mounted tot he trailer main rail, thevented gland should point towards the mounting face.Chapter 3 Februar 2009

System ASS1Selection oft he correct sealing glands for additional outputs on the jucntion box cover:• All sealing glands for cable glands are marked with a different colour (please refer tot he fittinginstructions „junction box ASS1)• Different diamters for cables are mentioned on the junction box cover (please refer tot he drawingbelow)• Measure the diameter oft he required cable• Select the correct rubber (diameter oft he cable)• Thread the rubber, the slide ring fort he connector and the seal nut in the cable• Unwind the cable ca. 130 mm• Crimp the cables• Fit on the required terminal oft he junction box (refer to chapter 15 – electrical circuit plan)• Tightly fix the seal nut on the housing• Close the junction box (be careful not the jam any cables) and tightly fix the screwsChapter 3 Februar 2009

SYSTEM ASS1Order Nr. left (yellow) right (green) reversible describtion13-5625-211 X ASS1 2 pin male yellow13-5625-231 X ASS1 2 pin male green13-5625-361 X ASS1 2 pin male black13-5626-261 X ASS1 2 pin female yellow13-5626-271 X ASS1 2 pin female green13-5626-331 X ASS1 2 pin female blackSYSTEM ASS1Order Nr. left (yellow) right (green) reversible describtion13-5625-751 X ASS1 7 pin male yellow13-5625-811 X ASS1 7 pin male green13-5625-771 X ASS1 7 pin male white13-5625-821 X ASS1 7 pin male black13-5626-931 X ASS1 7 pin female yellow13-5626-921 X ASS1 7 pin female green13-5626-901 X ASS1 7 pin female white13-5626-911 X ASS1 7 pin female blackChapter 3 Februar 2009

Chapter 3aSystem ASS2Chapter 3a Februar 2009

7 pin ASS1 connector white and blackTypes: 2- and 7 pin Female terminal and connector / housing AMP (6,3 mm) male flat terminalsDifference to ASS1 System:As shown on the drawings below, bayonet ducts are implemented in the male parts with externalthread. The screwcap has only bayonet nobs without a thread.Measurements according to the drawing (diameter a little larger than ASS1 system).Advantages of the ASS2 to ASS1 system:On closing the connector the bayonet snaps in (click). The ASS1 system allows to adjust the tightnessof the seal depending on the strain applied.Protective evaluation ( www.aspoeck.at ):IP69K, ADR approved for Zone 2Colours:yellow, green, black, white (please refer to chapter 16 – colours)Diameter of the individual connectors:2 pol. ASS2 / 2 pin ASS237,40 28,8028,907 pol. ASS2 / 7 pin ASS240,90Chapter 3a Februar 2009

2pin ASS2 connector1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe and the ring onto thecable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)picture 1pipe nutplug casecontactspipering121 = wh / common return2 = Current carringpicture 2Stipulate working time to change a complete 2 pin connector: max. 0,25 hChapter 3a Februar 2009

2pin. ASS2 connector1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe onto the cable(picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe over the case, fix the metal clamp and the cable strip at the end of the pipe (picture 2)picture 1plug casecontactsmetal clamp12pipe1 = wh / common return2 = Current carringpicture 2cable stripmetal clampmetal clampStipulate working time to change a complete 2 pin connector: max. 0,25 hChapter 3a Februar 2009

7 pin. ASS2 connector with pin case black and white1. Cut away max. 35mm of the cover at the end of the cable, thread the gland and the pipe onto thecable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix both metal clamps. (picture 2)picture 1pipecontactsplug caseASS2 7 pin blackASS2 7 pin white76513241 = wh / common return2 = Bk / rear light left3 = Ye / flasher left4 = Rd / brake light5 = Gn / flasher right6 = Br / rear light right7 = Ye-sw / trailer brake control1 = wh / common return2 = Bk / free3 = gn / reverse light4 = Br-bl / feed current5 = or / free6 = rs / bogie lift7 = Bl / rear fog lamppicture 2metal clampmetal clampStipulate working time to change a complete 7 pin connector: max. 0,35 hChapter 3aFebruar 2009

7 pin. ASS2 connector with pin case green and yellow1. Cut away max. 35mm of the cover at the end of the cable, thread the gland and the pipe onto thecable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix both metal clamps (picture 2)picture 1pipecontactsplug case278351/461/4 = Gn or ye / flasher2 = Bl / rear fog lamp3 = Wh / common return5 = Br / rear light right6 = Rd / brake light7 = Bk / rear light left8 = Gr /reverse lightChapter 3aFebruar 2009

picture 2metal clampmetal clampStipulate working time to change a complete 7 pin connector: max. 0,35 hChapter 3aFebruar 2009

7 pin. ASS2 connector yellow/green1. Cut away max. 35mm of the cover at the end of the cable, thread the gland, pipe and the ringonto the cable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)picture 1contactsplug casepiperingpipe nutglandring2831/461/4 = ye / flasher2 = Bl / rear fog lamp3 = Wh / common return5 = Br / rear light right6 = Rd / brake light7 = Bk / rear light left8 = Gr /reverse light75Chapter 3aFebruar 2009

picture 2cable stripeStipulate working time to change a complete 7 pin connector: max. 0,35 hChapter 3aFebruar 2009

7pin. ASS2 connector white and black1. Cut away max. 35mm of the cover at the end of the cable, thread the gland, pipe and the ringonto the cable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe close to the plug case and fix the cable strip at the end of the pipe (picture 2)picture 1contactpipeplug caseringpipe nutringgland75 3141 = Wh / common return2 = Bk / rear light le3 = Ye / flasher left4 = Rd/ break light5 = Gn / flasher right6 = Br /rear light right7 = Ye/bl free6 2Chapter 3aFebruar 2009

picture 2cable strip7Stipulate working time to change a complete 7 pin connector: max. 0,35 hChapter 3aFebruar 2009

SYSTEM ASS2Order Nr. left (yellow) right (green) reversible describtion15-5624-041side marker lightconnector ASS213-5625-871 X ASS2 2 pin male yellow13-5625-881 X ASS2 2 pin male green15-0281-021 X ASS2 2 pin male black13-5626-341 X ASS2 2 pin female yellow13-5626-351 X ASS2 2 pin female green15-5624-031 X ASS2 2 pin female black13-5625-831 X ASS2 7 pin male yellow13-5625-841 X ASS2 7 pin male green13-5625-851 X ASS2 7 pin male white13-5625-861 X ASS2 7 pin male black13-5626-941 X ASS2 7 pin female yellow13-5626-951 X ASS2 7 pin female green13-5626-961 X ASS2 7 pin female white13-5626-971 X ASS2 7 pin female blackChapter 3a Februar 2009

2 pin. ASS2 connectorexplanation: the yellow connectors are for the left side, and the green ones are for the right side (indriving direction)2 pin male connector2 pin female connectorO-Ring1. check that both “anti twists” fit together (same “anti twists” like at ASS1) than put theconnectors togetherASS2 nutChapter 3a Februar 2009

2. put the connectors together and turn the nut until it snaps into the groove.groove3. lock the nut by hand, until you hear a click !CLICK !Chapter 3aFebruar 2009

7 pin. ASS2 connectorexplanation: the yellow connectors are for the left side, and the green ones are for the right side (indriving direction)7 pin male connector7 pin female connector1. check that both “anti twists” fit together (same “anti twists” like at ASS1) than put theconnectors togethernutChapter 3a Februar 2009

2. put the connectors together, turn the nut until it moves into the groovegroove3. lock the nut by hand, until you hear a click !CLICK !Chapter 3a Februar 2009

Chapter 3bASS3 SystemsChapter 3b Februar 2009

System ASS3Types: 15 pin Female and male housing Connector mounted inside the housing (divider ASS1) or loose on the cable with rubber sealing orhotmelt Tyco Mate N Lok pins and socketsProtective evaluation ( www.aspoeck.at ):IP69K, ADR approved for Zone 2Colour:blackDiameter of the individual connectors:in mm:Ansicht Amax. 33,5 mmAnsicht AAnsicht Amax. 37,3 mmAnsicht AATTENTION:Pin 4, 7, 8 and 17 are assembled with large Mate N Lok contactsFemale housingMale housingChapter 3b Februar 2009

Electrical circuit:1 ge / Blinker links234567891011121314151617gn / Blinker rechtsbl / NESws / Massesw / Standlicht linksbr / Standlicht rechtsrt / Bremsegr RFSbr-bl / Stromvers. 24Vbr-rt / Innenbeleuchtungge-sw / freirs / Lenkachsews-sw / freivi / Anfahrhilfeor / Achsliftfreifreiye / flasher leftgn / flasher rightbl / rear fog lampwt / common returnbk / rear light leftbr / rear light rightrd / brake lightgr / reverse lightbr-bl / feed currentbr-rd / interior lightyw-bk / freers / steering axlewt-bk / freevi / drive up helpor / bogie liftfreefreejaune / clignotant gauchevert / clignotant droitebleu / brouillard arriereblanc / massenoir / feux de position gauchebrun / feux de position droiterouge / stopgris / reculbrun-bleu / alimentatien en courantbrun-rouge / éclairage intérieurjaune-noir / librerose / essien de directionblanc-noir / libreviolet / aide de departorange / léve essieuouvertouvertChapter 3b Februar 2009

Installation instructions for repair purposes with rubber pipeBild / picture / photo 1Gehäusesocket caseconnecteurMetallschellemetal clampcollier de serrage métalliqueAnsicht Aview Avue AO - Ring DichtungO - ring sealingO - RingTüllepipedouilleBild / picture / photo 2Metallschellemetal clampcollier de serrage métalliqueChapter 3b Februar 2009

Bild / picture / photo 1Siftgehäuseplug caseconnecteurMetallschellemetal clampcollier de serrage métalliqueAnsicht Aview Avue AFeder muss eingerastet sein !the spring must be engagedle ressort doit être enclanchéTüllepipedouilleBild / picture / photo 2Metallschellemetal clampcollier de serrage métallique1. The end of the cable max. 35mm cut away the cover and thread the pipe onto the cable (picture 1)2. About 4mm cut away from the single cores and fix the contacts onto the cable (picture 1)3. Put the pipe over the case and fix the metal clamps at the front and the back of the pipe (picture 2)4. Put the contact-grease onto the contacts !ATTENTION:Before activating you vehicle check all electrical functions according to their properfunctionality. All warranties are void in case of non-compliance with this mounting instruction.Chapter 3b Februar 2009

3 pin. ASS3 female connector1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe and the ring onto thecable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe over the case, fix the cable strips at both ends of the pipe as well the o-ring on thecasing (picture 2)picture 1contactspipeconnector2 311 = wh / common return2 = Current carring3 = freepicture 2cable stripo‐ringStipulate working time to change a complete 3 pin connector: max. 0,25 hChapter 3b Februar 2009

3 pin. ASS3 male connector1. Cut away max. 30mm the cover at the end of the cable, and thread the pipe onto the cable(picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts into the plug case, so that they engage in the plug case (picture 1)4. Put the pipe over the case, fix the cable strips at both ends of the pipe (picture 2)picture 1contactspipeconnector3 411 = wh / common return2 = Current carring3 = freepicture 2cable stripStipulate working time to change a complete 3 pin connector: max. 0,25 hChapter 3b Februar 2009

17 pin. ASS3 connectorclose the connector1. check that the O-ring sealing and the spring is mountedfemale connectormale connector/O-Ring sealing/metal spring2. Put the connectors together, the locking mechanism must engage in the correctpositionLocking mechanism/positionChapter 3b Februar 2009

3. the connectoris correct closed, after you hear twoclicks !CLICK !!!open the connector1. you have to lift up the springwith a screwdriver, than you canopen the connectorlift up the spring only at this position !Chapter 3bFebruar 2009

2. lift the spring until it is in the catch “open” on the left and right side !closedopen3. now you can disconnect the connectors, put the spring down, until it engages in the catches “closed”.put the spring downChapter 3b Februar 2009

3 pin. ASS3 connectorclose the connector1. Check, that the O-ring is mounted.female connectormale connectorO-Ring sealing2. Put the connectors together, the locking device must engage in thecorrect position.Locking device, correctpositionKabelbinderTo fix the connector on the chassis, use a cable tie in this guide railChapter 3bFebruar 2009

3.. The connector is correct closed, after you can see the two locking devices are fixedLocking device4.. MountingInstructions for the cable ties.Ca.100 mmca. 100 mmChapter 3bFebruar 2009

Chapter 4P&R SystemChapter 4 Februar 2009

Types: 2 pinP & R System(Press and ready)Connector on the cable with single conductor sealingProtective evaluation (www.aspoeck.at):IP69K, ADR approved for Zone 2Diameter of the individual connectors:In mm:Information: Quick, easy and flexible installation. Useable for all type of one-function-lights. All lights are already function-tested as well as pre-assembled. Absolutely water tight through silicon seal Useable for the transport of dangerous goods (ADR).ATTENTION:There is already a copy of our product on the market, which can optically not be distinguishedfrom our system. The only difference can be seen at the back of the connector. On ourconnectors (black part) you can see the Aspöck Logo ! ! Please be aware of this!Chapter 4 Februar 2009

Repairing instructionsChange of a 2-pin P&R connection on a flat cable1) Turn off the voltage supply oft he truck before teh repair.2) The defective P&R connection on the flat cable hast o remain fixed, this is necessary forpreventing water to pour in when the holes on the flat cable are open on the outer side.(please refer to picture 1).3) Cut the cable (dimensions: 2x1) ca. 10-20 cm after the P&R connection (please refer topicture 1)4) The cut end hast o be sealed water tight by the means of an appropriate rubber flat terminal(order no.: 15-5983-024) (pleae refer to picture 1).5) The new P&R connection now hast o be fixed on a different place oft he flat calbe (pleaserefer to picture 1)6) The further procedure is described in picture 2,3 and 4.BILD 2/picture 2BILD 3/picturevisual controlBILD 4/picture 4RICHTIG/rightFALSCH/wrongFALSCH/wrong• Please check all electrical functions for the functional ability before starting the vehicle.Chapter 4 Februar 2009

Repairing instructionsP&R flatcable / round cablesAll cables (round or flat) can be repaired and sealed watertight after a mechanical damage (drilled,scrubbed and so on…) Connecting Set 2pin:Order Nr.: 13-5625-284 / complete connecting component (male and female)For Flat cables 2x1,5 and round cables 2x1 qmm, in a PE bag.Repairing instructions:1) Cut the cable at the defective end.2) Cut the cable 25 mm at both ends.3) Thread the seal nuts and the slide rings on the rubber (please refer tot he drawing below) andthen put them on the cable ends.4) crimp the terminals on the flex (male flat terminals and terminals)5) Put all terminals in the housing and fix itATTENTION: Please nitice the electrical wiring on the inner side, otherwise the electronicsmight be damaged.CLAMP 1 – mass (White)CLAMP 2 – electrical circuit (e.g.: BROWN)6) Move the rubbers tightly tot he connecting component.7) Put the 2-pin main connecotr (female flat terminals) into the conterpartATTENTION: The housing is protected against pinning - do not use force.8) Tightly foix both seal nuts9) Fox both cable clips on the intended place – READYChapter 4 Februar 2009

Repairing set for the side marker cable1. Cut away max. 30mm the cover at the end of the cable, and thread the pipes and the rings onto thecable (picture 1, 2)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1, 2)3. Put the correct contacts into "case 1" and the other contacts into "case 2" they must engage in thecases !4. Put the pipes close to the cases, close the pipe nuts, and fix the cable strips at the end of eachpipe (picture 3)picture 1contactscontactsringPipe nutCase 2 Case 1 Rubber pipeChapter 4 Februar 2009

picture 2contactsATTENTION !!! this side is only for these contacts!!!picture 3cable stripsChapter 4 Februar 2009

P&R SystemFlatcableP&R connectorput the connector onto the flatcable (see photos)Chapter 4 Februar 2009

put the plastic cover onto the connector + flatcable, like in the photo belowClick the plastic cover and the P&Rconnector with the P&R tool together.Chapter 4 Februar 2009

Chapter 5Aspöck LightsChapter 5 Februar 2009

Aspöck LightsUnipoint SML Unipoint red Unipoint whiteSidepoint SML Sidepoint white Flatpoint IIFlatpoint II whiteFlatpoint II redSuperpoint URLSuperpoint IISuperpoint LEDSuperpoint III LEDChapter 5 Februar 2009

Monopoint white/redRückstrahler red/whiteEuropointEuropoint IIEcopoint mit URLEcopoint mit LEDEcopoint with triangle and/or outlinemarkerEarpointChapter 5 Februar 2009

Regpoint redRegpoint whiteRegpoint white LEDPosipoint redPosipoint whiteChapter 5 Februar 2009

Posipoint white II LEDPosipoint II red LEDMonopoint red II LEDMonopoint white II LED3- Chamberlight LED 3-Chamberlightfog lampfog lamp LEDChapter 5 Februar 2009

everseing lampreversing lamp LED• You will receive detailed information concerning order numbers, replacement parts, typesand possible wiring on our homepage www.aspoeck.at.Chapter 5 Februar 2009

Side marker lamp „Flatpoint II“ with ASS2 connector1. Cut away max. 25mm the cover, thread the nut, ring and the pipe onto the cable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts onto the light, it doesn´t matter which contact on the light you choose. Put theisolate hose onto on of the contacts (picture 2)4. Put the pipe close to the light and fix the cable strip (see picture 2) and mount the ASS 2 nut ontothe light. The nut must be screwed onto the light, as long as the pipe can´t be turned (picture 3)picture 1isolate hosecable tiecontactsringpipeASS2 nutChapter 5 Februar 2009

picture 2Cable tieIsolate hosepicture 3Stipulate working time to change a complete side marker light : max. 0,15 hoursChapter 5 Februar 2009

Side marker lamp „Unipoint“ with ASS2 connector1. Cut away max. 25mm the cover, thread the nut, ring and the pipe onto the cable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts onto the light, it doesn´t matter which contact on the light you choose. Put the isolate hoseonto on of the contacts (picture 2)4. Put the pipe close to the light and fix the cable strip (see picture 2) and mount the nut onto the light. The ASS2nut must be screwed onto the light, as long as the pipe can´t be turned (picture 3)picture 1isolate hosecable tiecontactsringpipeASS2 nutChapter 5 Februar 2009

picture 2Cable tieIsolate hosepicture 3Stipulate workingtime to change a complete side marker light : max. 0,15 hoursChapter 5Februar 2009

Side marker lamp „Unipoint“ with ASS2 connector1. Cut away max. 25mm the cover, thread the nut, ring and the pipe onto the cable (picture 1)2. Cut away ca. 6mm the cover of the single cores and fix the contacts onto these cores (picture 1)3. Put the contacts onto the light, it doesn´t matter which contact on the light you choose. Put theisolate hose onto on of the contacts (picture 1)4. Put the pipe close to the light and fix the cable strip (see picture 2) and mount the nut onto the light.5. The nut must be screwed onto the light, as long as the pipe can´t be turnedpicutre 1contactsringpipe nutIsolate hosepipepicture 2Stipulate working time to change a complete SML+holder: max. 0,15 hoursChapter 5 Februar 2009

Chapter 6:3-Socket Junction BoxChapter 6 Februar 2009

Installation instruction on the vehicle:Installation instructionsThe installation on the vehicle has to bedone at a gradient of 5 degree (towards theroad level).Cable ends down.It has to be fixed on the vehicle by nuts(8x90). Torque: 8-10 Nm.Dimension of the hole: 124 x 224 mmSubsequent installation of additional fittings:Step 1:Unscrew the plastic screws (5x30/15) at the back of the junction box.Cut the cable at roughly 150mm, thread the seal nuts, slide rings and the rubberaccording to drawing 1. Please use the appropriate sealing glands for the diameter ofthe cable. Please fix a cable clip and tighten it.Fix male flat terminals (6,3mm).Chapter 6 Februar 2009

Step 2:Thread the cable on the desired place and fix it according to DIN/ISO (please refer tothe explanation on the next page) on the free contacts of the terminal.Tightly fix the seal nut on the housing.Unused cable terminals have to be closed with a seal nut (green colour).Step 3:Please appropriately fix the loose wires inside the junction box or fix them on theother wires by means of cable clips.Close the back of the housing as well as the plastic screws (at torque 2,5 Nm).Chapter 6 Februar 2009

wiring schematic:PIN color Function1 yellow flasher left2 green flasher right3 blue fog light4 white 2,5 ground5 black tail light left6 brown tail light right7 red 2,5 brake8 grey reverse light9 brown/blue 2,5 feed current+10 brown/red wear control11 yellow/black trailer brake control12 pink axle lift13 white/black ground electronic14 violett data15 orange datastandard-wiring:Chapter 6 Februar 2009

special wiring:company PAGG (Italy)company SchwarzmüllerChapter 6 Februar 2009

spare parts:standard wiring N, S and 15pin for 3 socket junction box 58-3008-0073fach Steckdosen Verteiler (vorverkabelt - zur Selbstmontage) 76-7001-007Front – housing with sockets (empty) 15-5660-004Rear – housing with screws 15-5661-004socket ISO 12098 (15pin) incl. O – Ring 69-0001-004socket ISO 1185 incl. O – Ring 69-0002-004socket ISO 3731 incl. O – Ring 69-0003-0045 pieces sealing glands / black for cable diameter 5-6mm 15-5623-10V5 pieces sealing glands / brown for cable diameter 2 x 5-6mm 15-5623-11V5 pieces sealing glands / white for cable diameter 7-8mm 15-5623-12V5 pieces sealing glands / blue for cable diameter 9-10mm 15-5623-13V5 pieces sealing glands / red for cable diameter 11-13mm 15-5623-14V5 pieces sealing glands / grey for flat cables P&R System 15-5623-18V5 pieces sealing glands / green 15-5623-30V• Please check all electrical functions before you start your vehicle !• In case of non-compliance with these installation instructions all warrantiesare void!Chapter 6 Februar 2009

Chapter 7:Examples of lighting systemChapter 7 Februar 2009

All lighting systems of Aspöck Systems are designed to fulfil the specific customersrequirements.All lighting systems are planned in cooperation with our customers. Hereby we arestrongly following the requirements of our customers concerning design andpackaging.Our aim is to provide our customers cost saving solutions which are easy toassemble.On the following pages you will find a clear overview of our 24 V standard parts.Our customers may chose out of these components and put together a lightingsystems up to their requirements. All parts are in stock and are available on shortterm.Special requests will have to be produces separately and therefore have a longerlead time.Please find more details on our lighting equipment on our homepage www.aspoeck.at.Chapter 7 Februar 2009

festziehen !Dichtstopfen braun 2x5 - 6mmDichtstopfen blau 9 - 10mmDichtstopfen rot 11 - 13mmDICHTMUTTERN bis zum Anschlagfestziehen !15 Pol SteckerDIN ISO 11855x1+2x2,553-1667-0374800 mm12x1 + 3x2,558-6024-0174800 mmASS3 BuchsePos. LeuchteUNIPOINT - LED2x1Pos. LeuchteFLATPOINT II2x131-7707-107 0,5m31-7707-117 1,5m31-7707-127 3,5m o. Strahler2x1LED Unipoint31-6907-027 0,5m 31-2007-237 0,5m31-6907-037 1,5m 31-2007-247 1,5m31-6907-047 3,5m o. Strahler2x1LED Unipoint31-2067-097 0,5m31-2067-107 1,5m2x1LED Unipoint31-2067-687 0,5m31-2067-697 1,5m2x1LED Flat II31-2307-007 0,5m31-2307-017 1,5m2x1 2x1LED Flat II LED Flat II31-2367-027 0,5m 31-2367-047 0,5m31-2367-037 1,5m31-2367-057 1,5m31-3306-127 RT / WS31-3306-167 SW / WSLED1250 mm2x1 qmm4800 mm ASS3 Buchse7x1DIN ISO 373187-1285-007 87-1284-0073700 mm 3700 mm 3700 mm 3700 mm3700 mm 3500 mm3700 mm 3700 mm 3700 mm 31-3406-067 RT / WS3700 mm 5500 mm2x1 qmm2x1 qmm15 Pol Steckdose 53-6768-00765-6499-007 0,2m 87-1286-007 0,2m600 mm200 mm2x1DIN ISO 118524VNATO12x1 + 3x2,55x1+2x2,50,8m0,8mASS3 Buchse600 mm600 mmASS3 Buchse200 mm200 mm1250 mm2x1 qmm200 mm2x158-6647-007500 mm2x1 qmm1500 mm2x1 qmm200 mmASS3 Buchse76-6430-0071 500 mm 1300 mm 7x112x1 + 3x2,536-3007-397 0,5m15 pol. ISO 1209824VDAFDIN ISO 37312x1,5 qmm P&R7x11,65 m1300 mm 7x165-1003-007 9,0m65-1003-017 12,5m1250 mm2x1 qmm24VNATODIN ISO 118558-6649-00765-1003-027 15,0m5x1+2x2,56x1 + 2x2,5600 mmASS3 StiftASS3 Stift24V600 mm ASS3 BuchseDAF 7x165-1005-007 9,0mDIN ISO 373165-1005-017 12,5m31-3405-077 RT / WS65-1005-027 15,0m76-5123-00766-8893-00766-8892-0077x1 + 1x1,5 + 2x2,52x2,51000 mm76-7037-007600 mm12x1 + 3x2,5ASS3 Stift65-1007-007 9,0m65-1007-017 12,5m65-1007-027 15,0m12x1 + 3x2,5ASS3 Stift9x1200mm6x1+2x2,5200mmNESRFS31 / 541000 mm2x12x11000 mmASS3 BuchseASS3 StiftASS3 StiftASS3 StiftASS3 BuchseASS3 BuchseASS3 StiftNES / Masse RFS / MasseASS3 BuchseASS3 StiftTOPSYSTEMASPÖCKDichtstopfen schwarz 5 - 6mmKlemmbereiche f. Kabeldurchmesser:Dichtstopfen braun 2x5 - 6mmDichtstopfen weiß 7 - 8mmKlemmbereiche f. Kabeldurchmesser:Dichtstopfen schwarz 5 - 6mmDichtstopfen weiß 7 - 8mmDichtstopfen blau 9 - 10mmDichtstopfen rot 11 - 13mmDICHTMUTTERN bis zum Anschlag65-1499-007 0,5mTOPASPÖCKSYSTEM65-1499-017 1,5m68-4983-007ASS3 Buchse2x1,5 qmm P&R1,65 m7x12,5 m2,5 mKZ - Regpoint500 mm2x1Stop / Masse1250 mm2x1 qmmLED31-3305-127 RT / WSINDEX Datum Name Änderunggez. 080212 TMgepr.Prüfart.Bestell-Nr.OA-7000-045Standard TeileADR / PVC für Zone 2StandardKundenspez.KundenNr.:31-3305-167 SW / WSSYSTEMSChapter 7 Februar 2009

festziehen !Dichtstopfen braun 2x5 - 6mmDICHTMUTTERN bis zum Anschlagfestziehen !Dichtstopfen blau 9 - 10mmDichtstopfen rot 11 - 13mm15 Pol SteckerDIN ISO 1185DIN ISO 37315x1+2x2,57x153-1666-0474800 mm12x1 + 3x2,558-6020-0574800 mm4800 mmASS3 BuchseASS3 BuchsePos. LeuchteUNIPOINT - LED2x1Pos. LeuchteFLATPOINT II2x131-7707-107 0,5m31-7707-117 1,5m31-7707-127 3,5m o. Strahler2x1LED Unipoint31-6907-027 0,5m 31-2007-237 0,5m31-6907-037 1,5m 31-2007-247 1,5m31-6907-047 3,5m o. Strahler3700 mm 3700 mm3700 mm3700 mm2x1 qmm2x1LED Unipoint31-2067-097 0,5m31-2067-107 1,5m3700 mm3500 mm2x1LED Unipoint31-2067-687 0,5m31-2067-697 1,5m3700 mm2x1LED Flat II31-2307-007 0,5m31-2307-017 1,5m3700 mm2x1 qmm3700 mm2x1 2x1LED Flat II LED Flat II31-2367-027 0,5m31-2367-037 1,5m3700 mm31-2367-047 0,5m31-2367-057 1,5m87-1288-007 87-1287-0075500 mm31-3306-127 RT / WS31-3306-167 SW / WSLED1250 mm2x1 qmm31-3406-067 RT / WS15 Pol Steckdose 53-6769-00765-6499-007 0,2m 87-1286-007 0,2m600 mm200 mm2x1DIN ISO 118524VNATO12x1 + 3x2,55x1+2x2,50,8m0,8mASS3 Buchse600 mm600 mmASS3 Buchse200 mm200 mm1250 mm2x1 qmm200 mm2x158-6648-007500 mm2x1 qmm1500 mm2x1 qmm200 mmASS3 Buchse76-6431-0071 500 mm 1300 mm 7x112x1 + 3x2,5KZ - Regpoint36-3007-397 0,5m500 mm2x115 pol. ISO 1209824VDAF7x1DIN ISO 37315x1+2x2,524VNATO600 mmDIN ISO 1185ASS3 StiftASS3 Stift600 mm24VASS3 BuchseDAF 7x1DIN ISO 373176-7037-007600 mm12x1 + 3x2,5ASS3 Stift7x1 + 1x1,5 + 2x2,52x2,51000 mm12x1 + 3x2,5ASS3 Stift9x1200mm66-8892-0076x1+2x2,5200mmNESRFS31 / 541000 mm2x12x11000 mmASS3 BuchseASS3 StiftASS3 Stift76-5123-007ASS3 StiftASS3 BuchseASS3 Buchse66-8893-007ASS3 StiftNES / Masse RFS / MasseASS3 BuchseASS3 StiftTOPSYSTEMASPÖCKDichtstopfen schwarz 5 - 6mmKlemmbereiche f. Kabeldurchmesser:Dichtstopfen braun 2x5 - 6mmDichtstopfen weiß 7 - 8mmTOPKlemmbereiche f. Kabeldurchmesser:Dichtstopfen schwarz 5 - 6mmDichtstopfen weiß 7 - 8mmDichtstopfen blau 9 - 10mmDichtstopfen rot 11 - 13mmDICHTMUTTERN bis zum Anschlag65-1499-007 0,5mASPÖCKSYSTEM65-1499-017 1,5m68-4984-007ASS3 Buchse2x1,5 qmm P&R1,65 m7x12,5 m2,5 m58-6650-0072x1,5 qmm P&R1,65 m1300 mm 7x165-1004-007 9,0m1250 mm2x1 qmm65-1004-017 12,5m65-1004-027 15,0m6x1 + 2x2,565-1006-007 9,0m65-1006-017 12,5m65-1006-027 15,0m65-1008-007 9,0m65-1008-017 12,5m65-1008-027 15,0mStop / Masse31-3405-077 RT / WS1250 mm2x1 qmmLED31-3305-127 RT / WSINDEX Datum Name Änderunggez. 080212 TMgepr.Prüfart.Bestell-Nr.OA-7000-046Standard TeilePVCStandardKundenspez.KundenNr.:31-3305-167 SW / WSSYSTEMSChapter 7 Februar 2009

festziehen !Dichtstopfen braun 2x5 - 6mmDichtstopfen blau 9 - 10mmDichtstopfen rot 11 - 13mmDICHTMUTTERN bis zum Anschlagfestziehen !Dichtstopfen schwarz 5 - 6mmKlemmbereiche f. Kabeldurchmesser:DIN ISO 118524VNATO5x1+2x2,50,8m0,8m600 mm600 mm15 pol. ISO 120982x2,51000 mm24VDAFDIN ISO 373165-1003-007 9,0m7x165-1003-017 12,5m5x1+2x2,524VNATO600 mm65-1003-027 15,0m6x1 + 2x2,558-6649-007DIN ISO 118524V600 mm ASS3 BuchseDAF 7x1DIN ISO 373165-1005-007 9,0m65-1005-017 12,5m65-1005-027 15,0m 7x1 + 1x1,5 + 2x2,5600 mm12x1 + 3x2,565-1007-007 9,0mASS3 Buchse65-1007-017 12,5m65-1007-027 15,0m12x1 + 3x2,5INDEX Datum Name Änderunggez. 070613 TMOS-7000-118 neu66-8892-0079x1200mm6x1+2x2,5200mmNESRFS31 / 541000 mm2x12x11000 mmASS3 BuchseASS3 StiftASS3 StiftASS3 StiftASS3 StiftASS3 StiftASS3 Stift76-5123-00766-8893-007ASS3 StiftASS3 BuchseASS3 StiftASS3 BuchseASS3 StiftTOPSYSTEMASPÖCKDichtstopfen braun 2x5 - 6mmDichtstopfen weiß 7 - 8mm15 Pol Stecker4800 mm12x1 + 3x2,5ASS3 Buchsegepr.Prüfart.Bestell-Nr.1 500 mm 1300 mm 7x1ASS3 Buchse12x1 + 3x2,576-6430-0071,65 m1300 mm 7x1ASS3 BuchseStop / MasseNES / Masse RFS / MasseStandard TeileADR / PVC für Zone 2StandardKundenspez.KundenNr.:SYSTEMSTOPASPÖCKSYSTEMKlemmbereiche f. Kabeldurchmesser:Dichtstopfen schwarz 5 - 6mmDichtstopfen weiß 7 - 8mmDichtstopfen blau 9 - 10mmDichtstopfen rot 11 - 13mmDICHTMUTTERN bis zum Anschlag53-1667-037Pos. LeuchtenGlühlampenversion31-5004-027 1,0m31-2004-017 0,5m31-2004-027 1,0m31-2004-037 1,5m31-2064-007 0,25m31-2064-017 0,5m31-2064-027 1,0m31-2064-037 1,5mDIN ISO 118558-6024-0175x1+2x2,52x14800 mmLED Unipoint2x14800 mm ASS3 Buchse2x17x1DIN ISO 373115 Pol Steckdose53-6768-007600 mm12x1 + 3x2,5ASS3 Buchse58-6647-007Pos. LeuchtenLED-Version31-6614-037 1,5m2x12x1Pos. LeuchteUNIPOINT - LED31-7704-017 0,5m31-7704-037 1,5m76-7037-00731-2064-707 0,25m 31-2104-017 0,5m 31-2064-227 1,0m 31-2064-407 0,25m31-2064-717 0,5m 31-2104-037 1,5m 31-2064-237 1,5m31-2064-727 1,0m31-2064-737 1,5m2x12x12x1LED UnipointKabeldirektabgang2x168-7503-007 13,0m2x 1,5 qmm2x 1,5 qmm68-7503-017 15,0m68-7503-177 16,0m68-7503-027 17,0m2x1,5 qmm P&R1,65 m68-4983-007ASS3 Buchse7x12,5 m2,5 m2x1,5 qmm P&R31-3404-007 RT / WS31-3404-027 SW / WS1250 mm2x1 qmmKZ - Regpoint36-3004-017 0,5m2x12x1KZ - Regpoint36-3004-017 0,5m1250 mm2x1 qmm31-3404-017 RT / WS31-3404-037 SW / WSChapter 7 Februar 2009

festziehen !Dichtstopfen braun 2x5 - 6mmDichtstopfen blau 9 - 10mmDichtstopfen rot 11 - 13mmDICHTMUTTERN bis zum Anschlagfestziehen !Dichtstopfen schwarz 5 - 6mmKlemmbereiche f. Kabeldurchmesser:4800 mm12x1 + 3x2,5DIN ISO 118558-6020-0575x1+2x2,52x14800 mmLED Unipoint2x1DIN ISO 118524VNATO5x1+2x2,50,8m0,8m600 mm600 mm15 pol. ISO 120982x2,51000 mm24VDAFDIN ISO 373165-1004-007 9,0m7x165-1004-017 12,5m5x1+2x2,524VNATO600 mm65-1004-027 15,0m6x1 + 2x2,558-6650-007DIN ISO 118524V600 mm ASS3 BuchseDAF 7x1DIN ISO 373165-1006-007 9,0m65-1006-017 12,5m65-1006-027 15,0m 7x1 + 1x1,5 + 2x2,5600 mm12x1 + 3x2,565-1008-007 9,0mASS3 Buchse65-1008-017 12,5m65-1008-027 15,0m12x1 + 3x2,5INDEX Datum Name Änderunggez. 070613 TMOS-7000-119 neu66-8892-0079x1200mm6x1+2x2,5200mmNESRFS31 / 541000 mm2x12x11000 mmASS3 BuchseASS3 StiftASS3 StiftASS3 StiftASS3 StiftASS3 StiftASS3 Stift76-5123-00766-8893-007ASS3 StiftASS3 BuchseASS3 StiftASS3 BuchseASS3 StiftTOPSYSTEMASPÖCKDichtstopfen braun 2x5 - 6mmDichtstopfen weiß 7 - 8mm15 Pol SteckerASS3 Buchsegepr.Prüfart.Bestell-Nr.1 500 mm 1300 mm 7x1ASS3 Buchse12x1 + 3x2,576-6431-0071,65 m1300 mm 7x1ASS3 BuchseStop / MasseNES / Masse RFS / MasseStandard TeileVersion PVCStandardKundenspez.KundenNr.:SYSTEMSTOPASPÖCKSYSTEMKlemmbereiche f. Kabeldurchmesser:Dichtstopfen schwarz 5 - 6mmDichtstopfen weiß 7 - 8mmDichtstopfen blau 9 - 10mmDichtstopfen rot 11 - 13mmDICHTMUTTERN bis zum Anschlag53-1666-047Pos. LeuchtenGlühlampenversion31-5004-027 1,0m31-2004-017 0,5m31-2004-027 1,0m31-2004-037 1,5m31-2064-007 0,25m31-2064-017 0,5m31-2064-027 1,0m31-2064-037 1,5m4800 mm ASS3 Buchse2x17x1DIN ISO 373115 Pol Steckdose53-6769-007600 mm12x1 + 3x2,5ASS3 Buchse58-6648-007Pos. LeuchtenLED-Version31-6614-037 1,5m2x12x1Pos. LeuchteUNIPOINT - LED31-7704-017 0,5m31-7704-037 1,5m76-7037-00731-2064-707 0,25m 31-2104-017 0,5m 31-2064-227 1,0m 31-2064-407 0,25m31-2064-717 0,5m 31-2104-037 1,5m 31-2064-237 1,5m31-2064-727 1,0m31-2064-737 1,5m2x12x12x1LED UnipointKabeldirektabgang2x168-7502-007 13,0m2x 1,5 qmm2x 1,5 qmm68-7502-017 15,0m68-7502-167 16,0m68-7502-027 17,0m2x1,5 qmm P&R1,65 m68-4984-007ASS3 Buchse7x12,5 m2,5 m2x1,5 qmm P&R31-3404-007 RT / WS31-3404-027 SW / WS1250 mm2x1 qmmKZ - Regpoint36-3004-017 0,5m2x12x1KZ - Regpoint36-3004-017 0,5m1250 mm2x1 qmm31-3404-017 RT / WS31-3404-037 SW / WSChapter 7 Februar 2009

Chapter 8:Spare PartsFor detailed information on our spare parts and accessories as well as drawings please refertot he respective product on our website www.aspoeck.at.Chapter 8 Februar 2009

Chapter 9:ADR EquipmentChapter 9 Februar 2009

ADR regulations concerning Aspöck lighting systemsAbbreviation “ADR”:Accord europeènne relatif en transport des marchandises dangerauses per route.European arrangement for transportation of hazardous goods on the roadMeaning of the expression “GGVSE”:This abbreviation only expresses that the ADR regulations are superior to any otherexcept national regulationsExcerpt of VdTÜV instructions 5205 edition 12.03ATTENTION:The following guidelines refer to the current “ADR frame guidelines 94/55/EC”and may be re-enacted any time in the ADR handbook.Range of validityThe following regulations do not repeat all appropriated regulations of ADR, but onlyserve for explanation of the partly indefinite terms for the “electrical” equipment oftransport units mentioned in passage 9.2.1.Note: The electrical equipment of tanks (for ex.: electrical installations in theinstrument panel, appliances for reference dimension measuring, pumps, heatinstallations) will be tested by tank experts.2 Zone division (9.7.8.2) EX/II, EX/III AT, FL, OXGeneral explanation of the zones: The following zones may also come into effect incase of temporary stops (e.g. loading and unloading) in dangerous areas as e.g. inwarehouses containing explosives etc.2.1.1 Zone 0:Zone 0 covers areas where explosive atmospheres exist often, on a long-term basisor constantly.For tank vehicles, vehicles with tanks and battery vehicles these are i.e.:• interior of the tanks, fittings and pipes for dispensing or filling and gasrecirculationATTENTION: Aspöck Systems GmbH does not deliver parts for lightingsystems for Zone 0.Chapter 9 Februar 2009

2.1.2 Zone 1Zone 1 covers areas, in which you have to expect that dangerous explosiveatmospheres can occasionally arise.For tank vehicles, vehicles with tanks and battery vehicles these are i.e.:• interior of locked instrument panels• within a radius of 0,5 m around stop fittings• within a radius of 0,5 m around ventilation systems that cannot be locked butare open under normal operating conditions (i.e. tipping valve)• within a radius of 0,5 m around security valvesRequirements concerning installed equipment:- lamps: CE – label, added by the lamps manufacturer- plug and socket connector: CE – label, added by the manufacturer- housing (for ex. junction box ...): CE – label, added by the manufacturer- cable: the wire and cover isolation meet the requirements 3.1.3,verification of norm (for ex. ISO 6722),verification of a component label TÜ.EGG- mounting place has to be defined EXACTLY by the vehiclemanufacturerExplanation to CE – label:In order to obtain a CE label the manufacturer of the equipment has to provide anapproved IP inspection and a shock test in order to verify compliance with therequirements. Afterwards ONLY official test institutes are authorized to grant therelease for a vehicle.2.1.3 Zone 2Zone 2 covers areas, in which one does not expect a dangerous explosiveatmosphere, but in case they arise are rare and of short duration.• Zone 2 is not covered by ADR.• Zone 2 is not to be expected for tank vehicles, vehicles with tanks and batteryvehicles:- in front of the operator’s cab back wall- within the vehicle frame- with a bigger distance of 1,5m around Zone 1 and around leak- anddrainage drains (e.g. drains of instrument panel, blank hose box,chapter pan)- within a bigger distance of 0,2m in the distance around the whole tankcontour by tanks, which have the open installation in the parting (e.g.chapter top, air-bleed valve)Chapter 9 Februar 2009

Requirements for the installed equipment:- lamps: CE – label, added by the lamp manufacturer- connector: CE – label, added by the manufacturer- housing(e.g. junction box ...): CE – label, added by the manufacturer- cables: the wire and cover isolation meet the requirements 3.1.3,verification of norm (e.g. ISO 6722),verification of component label TÜ.EGG- mounting place requires no exact definition.Explanation to CE label:In order to obtain a CE label the manufacturer of the equipment has to provide anapproved IP inspection and a shock test in order to verify compliance with therequirements. Afterwards the manufacturer is entitled to place the CE label on therespective part which is then valid ARD-checked for Zone 2.3.1 Electrical pipes and cables (9.2.2.2) EX/II, EX/III AT, FL, OX3.1.1 Electrical pipe (conductor)If we speak of „conductor“ we mean of course both, the positive as well as thenegative poled conductor. A so-called mass return over structural parts like thevehicle frame, contradicts all rules of technology of the explosion protection.3.1.2 „sufficiently measured“Is given when the pipe is corresponding to the conductor cross-section (e.g. ISO6722-2002³ or ISO 4141:1998)For mechanical reasons we recommend that the pipe cross-section of fine-wiryconductors which are not coated, should be no smaller than:- 1,0 mm² for one-wire pipes- 0,75 mm² for multi-wire pipes up to 5 wires- 0,5 mm² for multi-wire pipes with more than 5 wires or pipes in cablechannels3.1.3 „suitably isolated“Is given if the pipe corresponds with the wire isolation (e.g. ISO 6722-2002² or ISO4141:1998)Examples for usual isolation materials for wire and coating:- PVC (special mixture of raw material)- PU- rubberChapter 9 Februar 2009

3.1.4 „well fixed“Is given if the pipe (regarding to the pipe coating) is fixed for example by clamps,bands or other fixture so that it cannot sag, scrub or loosen itself. Because of thepossibility of mechanical damage you should not lay the pipes in touch with theplastic brake air pipes.3.1.5 „protected against mechanical and thermal stress“Is fulfilled if the pipe (corresponding to the pipe coat) is layed as for example inEN 60079-14:1997 No. 9.1.1 protected- through laying in conduits, plastic tube, metal tube or- through covers (e.g. vehicle frame).The connecting cables between tractor and trailer vehicle meet the requirements ifthey are corresponding to e.g. ISO 4141:1998.3.2 Battery switch (9.2.2.3) EX/II, EX/III AT, FL, OX3.2.1 “as close as possible to the battery”Fulfilled if the switch is fitted as close to the battery as constructively possible.The connecting cables must have a wire and coat isolation.3.2.2 „operating device in the operators’s cab, easily accessible and clearly marked”Must be easily accessible without the aid of auxiliaries and clearly marked. Followingthe norms of other regulations the marking shall be red.Note: Further activity facilities are allowed only if they are marked and protectedagainst unintentional operating.3.2.3 „IEC-norm“is corresponding to DIN EN 40 050 (IP – kinds of protection).3.3 Batteries (9.2.2.4) EX/II, EX/III AT, FL, OXThe battery connection clamp must be- isolated electrically- covered by an isolated cap of the battery boxIf the batteries are not situated under the bonnet (a tiltable operator’s cab is regardedas a bonnet), they must be fixed in an aerated battery box.3.4 Continuous Circuit (9.2.2.5.1, 9.7.8.3) EX/II, EX/III AT, FL, OX3.4.1 „is suited for using within a danger zone (except inside the operator’s cab)”The parts (appliances, accessory pipes and connections) of the electrical installation,which stay under current while the battery switch is open must be suited for use inzone 1 (certificate 94/9/EG, see“requirements on the installed appliances” item2.1.2).Chapter 9 Februar 2009

The parameters of the correct danger zone are defined by:- temperature class T6- explosion group IICThis means a max. surface temperature of 85°C!At use in an external environment where the temperature caused by the electricalequipment installed in this area is higher than 85° C (T6) the electrical equipment hasto correspond to temperature class T4 (135° C)Examples for continuous circuits:- securing for EG-control appliance- circuits for appliances to measure the reference dimension- circuits for QSS- parts of a GPS-installation- alarm system3.4.2 „is suited for use within a danger zone (in the operator’s cab)The parts (appliances, accessory pipes and connections) of the electrical installation,which stay under current while the battery switch is open must be suited for use inzone 2 (certificate 94/9/EG, see“requirements on the installed appliances” item2.1.3).Examples for continuous circuits:- EG-control appliances- toll measuring appliances- alarm systems- parts of a GPS-installation3.5 Regulations for the parts of electrical installation fixed behind theoperator’s cab (9.2.2.6) EX/II, EX/III AT, FL, OXInformation: Not valid for installations in zone 0, 1 and 2!!!3.5.1 „in such a state, installed and protected, that....“Fulfilled, if e.g. a CE-label according to explosion protection regulation exists and theoperating instructions allow the use, or the following regulations concerning therequirements for the construction are adhered to:- suited for Zone 0, 1, 2 or- manufacturing equipment does not cause sparks, arcs or inadmissible temperatures(≤ 200°C) during the undisturbed running. (to be conf irmed by the producer or EX-n),orChapter 9 Februar 2009

- housing of manufacturing equipment, which causes sparks and/or arcs are “waftsafe”or simply overpressure-capsuled (tight). (to be confirmed by the producer orEX-n), and- junction boxes have to comply with safety class IP54 (to be confirmed by theproducer), as well as- electrical connections protected by soldering, welding, screws or against selflooseningand- lamps which comply at minimum with safety class IP 54 (to be confirmed by theproducer),- lamps (light bulb) must be protected by a housing against mechanical damage (EN50014 table 4, low mechanical stress); (to be confirmed by the producer).- the surface temperature of the pre-finished lamp must at no place be higher than195°C (to be confirmed by the producer, pls. note i tem 3.4.1!)- bulb lamps must not exceed the maximum surface temperature of 250° C on thelamp (light bulb) (usually fulfilled by vehicle lamps up to 21 W; in case of higheroutput a verification by the producer is necessary)- metal steam, glow discharge and halogen lamps must noch exceed the maximumsurface temperature of 200° C on the lamp (light bu lb); (to be confirmed by theproducer).3.5.2 „normal operating“This is the accident-free operating of a vehicle.3.5.3 „the danger is minimized by shock or deformation“lights (light bulbs) in lamps, except on the vehicle, must be protected by- a breakproof housing (to be confirmed by the producer) or- a housing protecting against mechanical damage (EN 50 014 table 4, highmechanical stress) or- installed in a protected area (e.g. the vehicle outline).examples for protected installation:- rear lights are integrated in the rear bumper- SML do not limit the contour of the vehicle.Chapter 9 Februar 2009

examples for non-protected installation:- end outline marker lights on the rubber arms- end outline marker lights on the front of the semi-trailer in the frontexposed to cantilever arm.3.5.4 „connections protected against shock, wear, scrub“Fulfilled if the laying of the connections corresponds to e.g. EN 60 079-17:1997 no9.1.1:- by laying in conduits, plastic tubes or- protected by a cover (e.g. vehicle frame)- by laying in protected areas.For connection cables between the towing vehicle and the trailer this requirement isfulfilled if they comply with e.g. ISO 4141:1998.Nevertheless, it is recommended not to lay cables and pipes in gas-tight pipesystems. In order to avoid liquid aggregation or dangerous atmospheres in protectiontube systems,the protection tube connection on appliances do not need to be insulated particularly.A drainage hole should be included at the lowest point of the protection tube system.The wear resistance of wire insulation of single layed wires and the abrasionresistance of coat insulation of coat pipes respectively has to be determinedindependently from the nominal wire size in compliance with the test methoddocumented in ISO 6722:2002 item 9.2providing that the number of cycles must be 1000 and the remaining wall thickness ofthe wire /coat insulation has to be at least 60 % of the nominal wall thickness.3.5.5 „ABV (ABS) – sensor pipes are not additionally insulated“Only one wire may carry wire insulation (i.e. without coat insulation or protectiontube). Due to the mechanical stress an insulation of the quality PUR or equivalent isrecommended.3.5.6 “Electrical plug connection” (e.g. between motor tractor and trailer)IEC norm 529 complies with EN 40 050.Both ISO 12098 (15 pin socket) and ISO 7638:1985 (ABS connection) demand testto ensure these requirements and are therefore suitable for these demands.Chapter 9 Februar 2009

3.6 Grounding (9.7.4, 6.8.2.1.27) and grounding connection (6.8.2.1.27) of thevehicles FL and AT which are allowed to carry UN1202 diesel, gasoline orheating oil light each complying with the norms EN 590:1993 as well as UN1361 coal or soot of the packing group II3.6.1 “Grounding”Due to mechanical reasons the ground cable between tank and chassis should havemin. 6 mm². The matching bolted connection should have min. 1 x M10 or 2 x M 8and be protected against self-loosening. The resistor between the touching partsmust not exceed 10 Ohm.3.6.2 “Grounding Connection”The tag for the marking may be depicted either negatively or positively.3.7. Information on electrical equipment of thermal superstructures forparceled goods of class 4.1. and 5.2 (7.2., special regulation V8, par. 3, R3 andR5)3.7.1 “Explosion-proof electrical equipment Eex IIB T3”Concerning the required verifications please refer to item 2.23.7.2 “Explosion-proof electrical connections Eex IIB T3”Concerning the required verifications please refer to item 2.23.8 Electrical equipment EX/II and EX/III (9.2.2.5.2, 9.3.7)3.8.1 “Nominal voltage”The nominal voltage of the electrical installation must not exceed 24 V.3.8.2 “Electrical installation in a fold”IP54 or IP65 (for compatibility group J) or equivalent have to be verified (to beconfirmed by the manufacturer). All safety classes with a higher digit than demandedcount as equivalent, whereas each digit counts for itself. Letters following this digithave no restrictive effect in this case.3.8.3 “Continuous circuits protected against overheating”The continuous circuits have to be protected by suitable means as e.g. fuses, circuitinterrupters or circuit limiters.ATTENTION:If you need further information on ADR please refer to ADR manual chapter 9.We kindly ask for your understanding that we cannot state all details in thisdocument.Chapter 9 Februar 2009

If you have any further questions please contact the sales department ofAspöck Systems.Chapter 9 Februar 2009

Chapter 10:BBVA II – Brake Pad Wear IndicatorChapter 10 Februar 2009

DescriptionThe brake pad wear indicator is a newinnovative additional possibility to detect thewear ofthe brakepads. However, thesystem cannot reduce or replace thenecessary test and maintenance requirements for such anassessment.These usual test and maintenance requirementsare furthermore necessaryregardless of the use of thebrake padwear indicator and must not be limited!We willl not guarantee if youdisregardd this assembly instruction!1. Check the completenesss and theproper condition of the system.Thesystem consists of theSPIDER, the indicator OPTI-andControl, the wear indicatorsthe cable harness (connectsSPIDER, OPTI-Control and thejunction box).SpiderOpti-ControlChapter 10Februar 2009

wiring schematic:cable harness7pin connectorconnection junction boxOPTI-Control2pin connectorSPIDERSensor cables with 2-pinplugs for the wear contacts2. Mount the SPIDER at a place where it is protected against direct impact ofwater and stones above the first or last axle by means of the two mountingstraps. The place has to be as vibration poor as possible. High vibrations andshocks may damage the SPIDER.3. Mount the sensor cables with the 2-pole plugs to the brakes. Avoid any tensionat the SPIDER as this may lead to damages due to the changes of temperature.Furthermore, it is important that the cables do not stretch, even if the axle iscompletely released.4. Connect the 2-pole plugs to the wear contacts, fix them on the trailer and fastenthem in such a way to the vehicle that no tension at the patch cord can occur.Assemble the brake lining wear sensors in accordance with the enclosed fittinginstructions. The provided wear contacts are suitable for the axles of thefollowing manufacturers:a) BPWb) Gigantc) Mercedesd) Sauere) Lecinenaf) Rabag) SMB5. Mount the OPTI-Control to a place where it can be seen easily and where it isprotected against damage. The mounting place has to be as free from vibrationChapter 10 Februar 2009

and shocks as possible. To ensure this, the OPTI-Control has to be mounted onthe main carrier of the towed vehicle. High vibration and shocks may damagethe OPTI-Control.6. The cable harness has 3 connections. One 7-pin for the connection to OPTI-Control, one 2-pin for the connection to the SPIDER and one 3-pin (connector or“open end”) for the connection in the junction box.cablewhitebrownbluefunction= ground (white)= tail light left (brown) or tail light right (black)= brake (red)Masse wsBremse bl+ 24 V brjunction boxOpti-Control7 pol. ASS2 (schwarz)3 pol. SteckerSPIDERSpiderIf the cable is too long, do not mount it in round loops.7. After finishing the assembly of the system, it has to be tested according to thefollowing steps:a) tail light on OPTI-control has to signal blackb) tail light off OPTI-control has to stay blackc) plug off one wear contact and switch tail light on OPTI-Control has tosignal redd) plug on the wear contact again OPTI-Control has to signal black afterswitching on tail light8. Due to extraordinary circumstances the brake pad wear indicator may fail orreact inappropriately. The test and maintenance requirements that arenecessary if there is no brake pad wear indicator must not be reduced in anyway if such a brake pad wear indicator is used. Any and all liabilities fordamages that will arise – the liability according to PHG included – due to theuse, especially due to a failure of the brake pad wear indicator is excluded, tothe extent as permitted by law.Chapter 10 Februar 2009

Chapter 11:Ramp-Distance-ControlChapter 11 Februar 2009

Description of the system:The Ramp Distance Control is an innovative new technology to support the driverwhen reversing a trailer up to a loading bay.Before using the system please read the description and the operation instructionscarefully.The system can not replace the driver’s responsibility to ensure a clear passage whenmanoeuvring.Components:Pos 1:Pos 2a, 2b:Pos 3:Pos 4:Pos 5:RDC junction box incl. ElectronicsOptional power supplyAdjustable sensor in the metal bumperReversing alarm (Audible warning system)‘’Superpoint’’ LED outline marker (Visual warning system)Chapter 11 Februar 2009

Mounting instructionsPreparation:• Ensure you have all the parts necessary to complete the installation.• Remove existing outline markers.• Determine a suitable mounting point for : RDC junction box (Pos 1) Reversing buzzer (Pos 4)• We recommend a minimum spatial requirement of approx. 500 x 500 mm.Installation:• General information: All cables must be installed suitably protected bythe trailer chassis.Fix all cables every 10-15 cm with a cable strip/tie.Do not fit the cables onto surfaces that can become hot. Hydraulic Fluidpipe lines are not allowed!! Unnecessary cables should be fixed coiledup. Ensure that the junction box bayonets are closed correctly.o Installation of RDC junction box (Pos 1)The position of the junction box should be in a suitably protectedposition in the rear part of the trailer. The box should be fixed on to theChassis. Position in a rigid location unsuseptable to large vibration andensure cables are safely installed.o Installation of new Led-outline marker (Pos 5)The new LED-outline marker should be assembled in the same locationas the old lamp, (Ensure that from within the tractor unit mirrors youcan see the LED-lamps clearly). Refer to drawing (page 1) theconnectors should be plugged into the RDC junction box. Please sealthe existing connectors for old outline marker (2 pin. central plug orjunction box exit) seal with a connector sealing gland.It is essential that you only use LED Outline markers not bulbed, theyare clearer in daylight and require less power.o Installation of reversing buzzer (Pos 4)Fit the reversing alarm in a protected position unsuseptable tovibration. Normally on the front panel or near the rear axle. Whenassembling pay attention to the location of the alarm, the cable entrymust be at the top. (observe “TOP” on the alarm). Plug the cable intothe RDC junction box referring to drawing (page 1)o Installation of sensor onto rear bumper (Pos 3)Drill a hole with ∅ 45 mm, pass the sensor lead through with the 7pinASS2 connector from the sensor, Fix the sensor with four fixing screwChapter 11 Februar 2009

onto the rear bumper. Plug the cable into the connector from the RDCjunction box referring to drawing (page 1)o Installation of power supply with an adapter cable (Pos 2 a)Disconnect the connector between main cable and the rear junctionbox cable.Plug the adapter for the power supply (Pos 2a) between these twoconnectors (main cable and rear junction cable).o Installation of power supply into an existing junction box (Pos 2b)Open the junction box. Insert and connect the power supply cablethrough a spare entry in the existing junction box, connect the terminalsand ensure a waterproof installation.Contact allocation:black – tail light left grey– reverse lightbrown – tail light rights white –earth connectionClose the junction box. IMPORTANT: Ensure the junction box gasket isfixed correctly!Functional test:After the installation is completed you should test the system thoroughly.For this test you require a test sample (preferred material is a cardboard boxapprox. 500 x 500 mm, if there is no box available, you can use a similar objectmaterial with a smooth surface). Please ensure that there are no obstaclessituated within the range of 4m x 4m behind the vehicle. The test proceduremust carried out in the following steps:step 1:step 2:step 3:step 4:step 5:step 6:activityignition on / tail light onEngage reverse gearPlace the test sample inperpendicular to a sensor within arange of 3 m behind the vehicle (seepicture 1).Remove the test sample from thevehicle until the beeping and ledoutline are extinguished.Slowly Move the test sample inwardstowards the trailer sensor (see picture1)Repeat step 4 with the second sensorresultLED-outline markerLED-outline marker is deactivated after 2secondsLED-outline marker: slow flashingfrequencyReverse alarm: slow beepCompleted phase I (see picture 2)(area greater than 3m)run through the complete range of phases asshown within diagram (picture 2).see step 4marker has to shineChapter 11Februar 2009

step 7:Repeat step 5 with the second sensorsee step 5testing of the silent mode (night silent switch off)step 8:step 9:step 10:step 11:place the test sample in the distanceas in step 3.Engage the reverse gear twice(within 2 seconds)let the system work for min. 10seconds. After this, disengage thereverse gear.Engage reverse gear once only,LED-outline marker: slow flashingfrequencyReverse alarm: no signalLED-outline marker: slow flashingfrequencyReverse alarm: returns to slow beepfrequencypicture 1 picture 2Please note during the function test that the test sample will be moved alwaysperpendicular to the respective sensor axis (see picture 1)Chapter 11 Februar 2009

Adjusting the sensors:If you cannot assemble the steel ram buffer on the outermostarea of the rear panel, you can adjust the detection of the sensors with a special tool.The available adjustable area of the sensor is 10° horizontal and verticalAdjust the sensor by rotating 3 fixing nuts (DIN 546)To adjust these slotted nuts you require a special key tool (see above).By rotating the nut clockwise, the housing will be inclined in the direction of therotated nut. Due to the order of the screws (3 x 120°) you have the possibility toincline the sensor in any direction (maximum adjusting area is 10°)Chapter 11 Februar 2009

The adjustment should only be made with an obstacle in placeobstacle.Technical data:ATTENTION: The RDC is protected against an AC voltage supply, but willnot function. It will function again correctly whenreconnected with DC supply.nominal voltage 24 Voperating voltage 19 to 32 Voperating temperature -30 to +65 °Ccurrent consumption (total system) < 300 mAUltrasonic SensorsMax Range 2500 mmMin Range 350 mmDetection Angle 15 °operating voltage 12-30 VMax current consumption < 35 mAFrequency 180 kHzReversing alarmOperating voltage 12-30 VChapter 11 Februar 2009

Max current consumption < 35 mASuperpoint LEDoperating voltage 24 VMax current consumption < 35 mAThe sensor has an area (

If you get nearer than 3m to the obstacle, the system switches to the 5 test phases(please see below).System check 2 (activation of the system during the day with tail lights switched on):After engaging the reverse gear the outline marker is turned on.Distance to the obstacle > 3m: Outline marker is on, buzzer is silent !Distance to the obstacle < 3m: System switches to the five test phases.If the reverse gear is engaged twice (within 2 seconds) the acoustic warninginstallation (buzzer) will be ‘’night silent’’. The outline marker is however active.The ‘’night silent’’ option is to prevent audible nuisance at night in residential areas.Chapter 11 Februar 2009

The maximum detectable distance is 3m from the sensor.And is Graduated into five phases, Please study the sketch below.ERROR &Chapter 11 Februar 2009

Error repair / Sensor diagnosis:Error possible reason repairDisplay an obstacle,when no presentRDC doesn’t workURL doesn’t shineReverse alarmdoesn’t workA sensor is Obscuredreversing light, tail light L/R and Earthconnection is defectiveone of the fuses (tail light L/R or reversinglight) defectivesupply voltage is too small (< 19V)LED defectiveWhen activating the system and erroroccursDefective alarmSilent mode is activeAdjust SensorEstablish or check all theconnectionschange one of the fusescheck the light control unitis the truckchange the URLactivate the system onceagainchange the alarmengage the reverse gearThe sensor diagnosis is shown by the 6 leds inside the RDC junction box.Circuit boardin the RDCjunctionbox1) One green LED: indicates, that the voltage supply is in order.2) Two red LEDs: indicate in which of the sensors a fault has occurred.3) Three yellow LEDs: indicate an error code, which describes the type of default.Chapter 11 Februar 2009

ERROR CODE2 1 0possible reasonscable break of a sensor cabledefect on the head of the sensorrepairchange the sensorchange the sensorcable break of a sensor cablechange the sensorIn the case of an “error” the Led outline markerwill permanently illuminate and theReverse alarm will permanently sound for about 5-7 sec.!!!permanent tone 5-7 sec.Afterwards the alarm switches off automatically, The Led outline marker continues tooperate.Except a complete failure of the system the following situations can lead to anerroneous signal on the display. The reason for this is that in these cases, thephysical limits of the ultrasonic sound are exceeded.If you drive at an angle to the ramp it can occur that thereflected sound will be to small for the sensor to detect.Ramps with floors that jut out from the main body.Caution !ramps with curtains require special attention:a) The material of the curtains can absorb the ultrasonic,this means that the reflected sound is too weak for thesensor to detect.b) If the curtain is deformed, so that the ultrasonic signalcould be absorbed.abSome materials like textiles weaken the ultrasonic signals, significantly reducing thesensing distance !ATTENTION: It is the driver’s responsibility to manoeuvre safely.Chapter 11 Februar 2009

Abbreviations:RDC Ramp Distance ControlURL LED outline markerRFLReverse lampStdL Tail lightGND EarthLED Light Emitting DiodeTRIG TriggerVDD + supplyChapter 11 Februar 2009

Chapter 11 Februar 2009

Chapter 12:LED Control Gear GearLCGATTENTION:Due to technical attributes this device is not suitable formotor tractors and must not be used unless released forvarious types by Aspöck SystemsChapter 12 Februar 2009

Description of the system:This control device enables the connection of modern LED rear lamps of trailers toconventional motor tractors equipped with electronical light control devices and onboardcomputers.Advantages:• Adapts the electrical features of LED lamps to the requirements of a modernmotor tractor.• Checks the function of a LED direction indicator and increases the powerconsumption if the direction indicator function exists according to statuoryregulations.• Easy retrofitting by using lamp mounting screws to fix the LCG.• If the LCG adapter is mounted with a respective 7-pin plug retrofitting ispossible without having to interfere in the lamp or the cabling of Aspöcksystems.• By installing additional components the power consumption for parking andstop light is increased so that modern motor tractors with electronic lightcontrol devices do not put out error messages anymore.• Compact construction styleMounting instructions LED Control Gear (LCG) from AspöckThe LED Control Gear is needed for the adjustment of the electrical characteristics of theLED lights to the requirements of the tractors. Due to the necessary power consumptionthe LCG can become very hot! Therefore the housing of the LCG must be alwaysmounted on a larger metallic part for the purpose of cooling!IT IS FORBIDDEN (disclaimer):oto assemble the LCG within the range of temperature sensitive componentsoconnect and disconnect under powero current and voltage measurements with conventional measurementinstrumentsATTENTION: As truck manufacturers constantly adjust the electronic systems on theirtrucks we cannot grant any warranty on the LCG concerning functionality. Therefore,Aspöck Systems GmbH will not accept any claims for this LCG.Chapter 12Februar 2009

Description:75-0300-00, 75-0301-0075-0302-00, 75-0303-0075-0304-0000IN / OUT is interchanged„a“ LCG – Electronic housing„b“ Connector to the rear lamp„c“ Power supply (cable rear lightsupply)„a“ LCG – Electronic housing„b“ Connector to the rear lamp„c“ Power supply (cable rear light supply)1. Remove protection cap if mounted and disconnect the cable from the lampChapter 12Februar 2009

2. LCG connection:75-0300-00, 75-0301-0075-0302-00, 75-0303-0075-0304-00„b“„a“„c“1. Fix LCG to the mounting bolt of the lamp2. Connector angular to the lamp3. Connector straight cable rear light supply1. Mount the LCG on an appropriate*place2. Connector angular to the connectorbox3. Connector straight to the lamp3. Mounting without protection cover:1. fix the lamp + LCG + protection cover withthe nuts2. fix the cable with cable ties4. Mounting of the protection cap:1. Put the connection above the lamp connector (seepictures)2. The 3 cables must go downwards3. Fix the protection cap4. Put cable ties into the holes of the protection cap and fixthe cables5. Mount the lamp + LCG + protection cap with the nuts fromthe lamp* WARNING: The LCG must have full contact to the bumpersurface! If it’s not possible to mount on the bumper with the lampfixation nuts, it must be mounted on a place with low vibration.This place must have a metal ground to aid cooling of the LCG !Don’t mount the LCG next to temperature sensitive components!(fuel tanks, etc…)Chapter 12Februar 2009

Chapter 12 Februar 2009

Chapter 13:Detection of errorsChapter 13 Februar 2009

Detection of errorsIn most cases errors occur due to incoming (salt) water into not properly closedconnectors or lamps. However, it is also possible that defects in the lighting systemoccur due to mechanically damaged cables (chafing on sharp edges and so on.).In both cases a short circuit will occur and as a result a fuse in the tractionengine will be damaged.As such errors are sometimes not easy to detect for the mechanic, we suggest thefollowing procedure for such repairs:For example:1. Remove the conductor cable of the trailer from the traction engine.2. Insert a new fuse.3. Measure the required function of the sockets of the truck with a proper inspectiondevice. (please refer to chapter 15 – electrical circuit plan).4. Separate all main connectors from the lamps. The error usually lies with functionssuch as side marker lamps and so on.5. Reconnect the conductor cable of the trailer with the truck.6. Press the desired function in the truck.7. Reconnect the main connectors beginning from the front. A mechanic is supposedto control the fuses in the truck.8. Once the fuses is again failing when connecting the connector, the error is found.9. Repair according to our repair instructions.Usually the error detection is supposed to be done from FRONT to BACK inelectrical circuit direction.Chapter 13 Februar 2009

Chapter 14:Legal Installation Instructions for LampsChapter 14 Februar 2009

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Chapter 14 Februar 2009

Chapter 14 Februar 2009

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Chapter 14 Februar 2009

Chapter 15:Installation of single componentsChapter 15 Februar 2009

Installation of single componentsPrecautions• Installation work on the lighting equipment All installation work on the lighting equipment has to be done with voltageturned off . Please follow all mentioned torques of the screws. The electrical circuits have to be free of dust, grease, lye or acids. All sealing material has to be fitted on the intended place. The cables on all electrical fittings have to be fixed in such a way, that watercan drip by building a water drip nose. Only lamps or electrical fitting with separated mass return travel can beused. The installation of the triple socket junction box has to be done according tothe regulations. Please notice the colour coding of the pre assembledconnection components please refer to section „colour coding“.• Colour coding:All plug connectors of Aspöck Systems lighting equipment are marked bycolours. We distinguish 5 colours and their functions:YELLOW: LEFT side of the vehicle seen from facing the front (indicator,sidelights)GREEN: RIGHT side of the vehicle seen from facing the front (indicator,sidelights)BLACK: Can be used for BOTH sides or for functions, which can not beapplied to aspezial side (axle lift, NES, RFS and so o.)BLACK – forfunctions of socket ISO 1185WHITE: for functions of socket ISO 3731• Dimensions of the pass holes on the frame of our plug connectors:•P&R System in a non-pressed condition(without P&R cover) - min. 20 mmASS 1 connector 2-pin (mit Dichtmutter) - mind. 30 mmASS 1 connector 7-pin (mit Dichtmutter) - mind. 40 mmASS 2 connector 2-pin (mit Dichtmutter) - mind. 30 mmASS 2 connector 7-pin (mit Dichtmutter) - mind. 42 mmASS 3 connector 17-pin - mind. 40 mmBayonet connector 15-pin - mind. 40 mmChapter 15 Februar 2009

• Diameter of the various connectors:2pol. Bajonett / 2pin bajonett2 pol. ASS1 / 2 pin ASS17 odern 8pol. Bajonett / 7 or 8pin bajonett28,0030,7017,0020,007 pol. ASS1 / 7 pin ASS133,8039,1021,6028,2028,2015pol. Bajonett / 15pin bajonett2 pol. ASS2 / 2 pin ASS216,635,541,534,0038,10P&R System1637,40 28,8028,907 pol. ASS2 / 7 pin ASS240,08Buchsengehäuse Syst. ASS3Stiftgehäuse Syst. ASS333,5mm37,3mm17 polig17 polig17,5 mmASS3 3pol.Stift SWASS3 3pol.Buchse SW• Correct assembly of the flat cable or other cables: Both P&R flat cables may either be assembled on the outer frame or betweenthe longitudinal supports backwards up to the last connector. The cables must be protected against mechanical influences (for example:stone throws, sharp edges, heat etc.). The cables must not be drilled or assembled in loops. It is not permitted to varnish the cables before contacting the individualconnectors. The fixing material of the cables may be chosen freely. However, the cablehas to be fixed every 10 – 15 cm on the frame. No “free cables” are allowed. All pass holes (on the frame) must covered by rubber so that the cablescannot be chafed. Furthermore, please ensure that no ice clumps may be formed during winterdue to the cabling. This may lead to mechanical damage of the cables or theconnectors.Chapter 15 Februar 2009

Chapter 15 Februar 2009

Chapter 16:Labelling of spare partsChapter 16 Februar 2009

Recognizing spare parts numbers of Aspöck Systems in case ofrepairThe labelling of spare parts of Aspöck Systems is being done by adhesive labels onthe cablesor on the housing.On these labels you will find the number of the spare part without the packagingcode.Furthermore, the year and month of production, the controlling code as well as theproductionnumber is written on the labels.Please indicate all the below mentioned data in case of warranty.Please only indicate the 8-digit order number in case of reordering spare parts.The labels are waterproof and can be read even after years!Chapter 16 Februar 2009

Chapter 17:Electrical circuit planChapter 17 Februar 2009

Chapter 17 Februar 2009

Chapter 18:General terms and conditions of warrantyChapter 18 Februar 2009

General Terms and Conditions of Aspöck SystemsGesmbH1. In general, we accept - in accordance with the following terms and conditions - justifiedwarranty claims of our contracting party regarding all parts of our range of products ofproducts notified to us in writing within two years of delivery of our products to ourcontracting party, not later than within one year of first registration of the vehicle. Anyclaims raised after the said period shall be excluded, also claim of a recourse according §933 ABGB. Prerequisite for any claim shall be that assembly war carried out properly oraccording to the assembly instructions of Aspöck Systems GesmbH through a specialbusiness, respectively.2. Any kind of mechanical destruction (e.g. breakage of luminescent glass) shall exclude aclaim against us. Claims related to defects of wearing parts, such as defective bulbs, andthe cost of repair of the same or claims which are attributable to such defects as well asclaims in connection with defects due to material defects or material fatigue or put downto our product or separates of its parts are unusual or in material data sheet or productinformation called, unreliably physically, chemically, mechanically or were otherinfluences exposure ( e.g. acid or alcoholics, temperatures beyond the range of minus30° - plus 65°, leaking cargo, chemical cleaning agent or their results, UV - radiation,outside the UV - regulation ISO 4892T2) shall be executed.3. Claims related to defective parts which we have purchased ourselves, such as plugs,sockets ISO 1185/3731,… may only be raised against us to extent to which we have ajustified claims against our suppliers, than raise a claim to our suppliers. In such an eventwe shall be entitled to finally defend ourselves against being held liable by assigning theclaims we have against our suppliers.4. In addition, no claims may be raised if our components are combined with third - partyparts, if the assembling is done self of their completion, particularly sealing, or if oursystem is tested by third parties. If our system is also interfered by third parties, all claimsare deleted as well.5. Aspöck Systems GesmbH shall decide on whether the replacement or an improvementwill be carried out. Any repair work must be done in garages authorized by us; otherwiseany warranty claims and other claims shall expire in general. The cost of labour incurredif a decision is made in favour or repair, shall be reimbursed to the extent it is absolutelynecessary but in no case in an amount exceeding that which is usually paid.6. Claims exceeding those stated in these General Terms and conditions of Warranty, inparticular claims for damages (e.g. loss of use, lost, profit, consequential damage toproperty of any kind, shall in no event be reimbursed.Chapter 18 Februar 2009

7. Rights of recourse pursuant to sections § 933 ABGB (Austrian General Civil Code) shallbe excluded.8. In any event claims of any kind may only be raised, if the defective old parts are present,a warranty protocol is filled out completely and signed. Only upon receipt andexamination of those parts a relevant decision will be taken by us.I. General1. These General Terms and Conditions of Sale and Delivery (GTCS&D) shall constitute anintegral part of all of our offers, sales and deliveries. Deviations from these Terms andConditions shall only be valid on a case-by-case basis if we have confirmed them inwriting. Customer's terms and conditions of purchase shall only be binding on us if wehave recognised applicability of the same in writing.2. If a separate agreement was entered into with the Customer, the terms and conditionsstated therein shall apply primarily. Subsidiary, the GTCS&D shall be applicable to theextent reference is made to them or if the relevant facts and circumstances are onlyregulated in the GTCS&D.II. Acceptance of order/Seller's right of rescission1. Customer shall be bound by his order for a period of four weeks as of receipt of the sameby Aspöck. If Aspöck issues an acceptance of order (AO) on such order, the order shallbe effective upon receipt of the AO and deemed concluded in a way, which is binding onboth parties. Customer shall immediately examine acceptances of orders with respect tocorrectness of their contents. Any deviations from the order shall be notified in writingwithin 2 (two) days; otherwise the delivery and the services described in the AO shall beconsidered approved by the party conclusively.2. If upon acceptance of the order it turns out that Customer's financial situation is so badthat our claims are at risk or if facts become known which reduce Customer'screditworthiness sustainable, we shall be entitled to withhold our services until theconsideration has been obtained or secured. In addition, we shall be entitled to rescindthe contract and claim damages.III. Prices1. Our services shall be charged according to the current price list subject to deductionsaccording to the agreed terms. Provided that the order is accepted, the price list shall beused which is valid at the time of receipt of the proper order. The order is proper if it ismade in a form commercially and technically clears to Aspöck.2. Unless otherwise agreed our prices are exclusive of value-added tax, assembly,insurance and other ancillary charges ex our distributing warehouse.Chapter 18 Februar 2009

IV. Information of the Customer/plans1. In any case the Customer shall be solely responsible for correctness and usefulness ofhis order details (e.g. details on units, measurements and quantities; order numbersstated; details on colour, form and other specifications, etc.); likewise he shall be solelyresponsible for a technically faultless solution for the plans and drawings provided bycustomer.2. If in the course of placing of an offer Customer requires us to provide plans, extensivesketches, etc., we shall retain the right to charge the cost incurred in connection therewithseparately.3. In connection with offers, sales or deliveries, copyrights or other industrial property rightsshall be transferred or made available by us.V. Terms of payment1. Unless any other payment date or arrangement on cash discounts was agreed, ourdeliveries and services shall be due for payment within 10 days in the event of a cashdiscount of 2 %, otherwise within 30 days without deduction, in each case as of the dateof the invoice. In case of a delay in payment we shall be entitled to demand bank defaultinterest of 10 % p.a. in each case. In case of a default, in addition, all dunning charges,collection charges and legal costs shall be reimbursed, including those incurred inconnection with collection measures out of court. In case of default Customer already atthis point acknowledges his duty to pay both as to the merits and the amount in theamount that is calculated on the basis of the Autonomous Fee Guidelines for Lawyers(AHR 1976) as amended.2. If customer is in delay of payment for deliveries and services properly provided by us andif these arrears exceed an amount of EUR 10,000 exclusive of VAT (in words: tenthousand euros) on a case by case basis or from several orders together, Aspöck shall,in addition, be entitled to demand immediate payment of all other outstanding accountsreceivable. Furthermore, Aspöck may refuse performance of any purchase agreements,contracts for work and service contracts not fully discharged until total payment of thearrears. Apart from that Aspöck shall also be entitled to rescind any and all contracts notperformed at that time with immediate effect.3. Customer shall not be entitled to set off its own accounts receivable from Aspöck againstclaims of Aspöck for payment of outstanding accounts receivable under individualpurchase agreements, contracts for work and supply contracts or to withhold or reduceservices owed for whatsoever reason. This waiver of setoff shall not apply to thosecounterclaims, which Aspöck recognised in writing, or which were ascertained towardsAspöck by court.4. Bills of exchange shall only be accepted if expressly agreed. Discount charges and billcharges shall always be borne by the Customer. Bills shall only be accepted on accountof payment and, in addition, only if our banks will discount the bills. Such payments shallonly be considered made upon payment of the bill.Chapter 18 Februar 2009

VI. Retention of title1. All goods shall be delivered subject to retention of title. They shall remain our propertyuntil full payment of all our accounts receivable including those that will arise under ourbusiness relation with the Customer in future. In case of an open account the goods towhich title is retained shall be deemed a security for our account receivable. Customershall not receive title to the item delivered through installation of the same either, and allremovable parts (lamps, etc.) shall remain the property of the seller as an independentpart unless items are inseparably connected. An act of returning and securing shall notbe deemed a rescission of the contract and shall not lift Customer's duties, in particularthat of payment of the purchase price.2. Customer shall be entitled to process and sell the goods. In that case the reselling pricereceived shall not become the property of the reselling Customer up to the amount of thepurchase price still outstanding in case of a cash transaction. The reselling Customershall rather keep the reselling price separately and transfer the same to us without delayin the amount of the purchase price still outstanding. In the event of a sale on credit,Customer already at this point assigns the account receivable to which he is entitledunder the resale vis-à-vis his customer to us as security. Customer shall be authorised tocollect the assigned account receivable as long as he fulfils his payment obligationtowards us in accordance with the contract. Upon request Customer shall immediatelyadvise the name and address of the buyer as well as the amount of his accountreceivable and surrender all documents for enforcement of our claims. Customer shallfurthermore be obliged to immediately inform us about attachments or seizures of thegoods by third parties. Customer shall be obliged to bear the cost of measures for thepurpose of removing seizure of goods being subject to retention of title by third parties, inparticular the cost of intervention procedures to the extent it cannot be obtained from theopposing party.3. In the event that we assert our title retained, Customer already at this point authorises usto seize our goods without judicial assistance. Likewise we shall be entitled to either sellthe object of the purchase at the best possible price and credit the revenue achieved toliabilities of the Customer still outstanding or to take the object of the purchase back forthe invoice price and charge Customer an amount of rent at the customary rate for theterm during which he possessed the products delivered; assertion of further claims fordamages reserved.VII. Delivery/cancellation1. The delivery dates announced by us shall be non-binding. Mere announcing or agreeingon delivery dates concludes no fixed transaction. The delivery period, which shall alwaysbe considered an approximate period, shall commence not earlier than upon acceptanceof the order and in no case before clarification of the technical details.2. If the delivery dates stated by us are exceeded by 14 days, the Customer shall, upon anadditional grace period of 14 days having been granted by him, be entitled to rescind thecontract through written declaration. All other claims, in particular claims for damages ofany kind, shall be excluded. If in case of an overall order delivery dates announced areonly exceeded with respect to a part of the delivery, the foregoing provision shall applyprovided that rescission shall only be admissible with respect to the partial delivery thathas not been made within the grace period. Plant interruptions and events of forceChapter 18 Februar 2009

majeure shall entitle us to extend delivery periods or lift the delivery obligation and anyclaims for damages shall be excluded.3. In principle we shall be entitled to make partial or advance delivery and to issue partialinvoices thereon.4. If we receive a written cancellation of an order from Customer before delivery of thegoods, we shall be entitled to demand a cancellation fee of 30 % of the list price or thehigher loss actually incurred plus lost profit without being obliged to prove the concreteloss. The cancelled transaction shall not be performed.5. After delivery of the goods an order may only be cancelled with Aspöck's approval. Alsoin that case Customer shall pay at least 30 % of the list price as cancellation fee (seehandling of returns).6. Unless otherwise explicitly agreed transport shall be at the cost and risk of Customer,also in case of partial deliveries. The goods shall only be insured on the account andupon express instruction of Customer.VIII. General Terms and Conditions of Warranty of AspöckSystems GesmbH1. In general, we accept - in accordance with the following terms and conditions - justifiedwarranty claims of our contracting party regarding all parts of our range of productsnotified to us in writing within two years of delivery of our product to our contracting party,however, not later than within one year of first registration of the vehicle. Any claimsraised after the said period shall be excluded. Prerequisite for any claim shall be thatassembly was carried out properly or according to the assembly instructions of Messrs.Aspöck through a specialised business, respectively.2. Any kind of mechanical destruction (e.g. breakage of luminescent glass) shall exclude aclaim vis-à-vis us. Claims related to defects of wearing parts, such as defective bulbs,and the cost of repair of the same or claims which are attributable to such defects as wellas claims in connection with defects due to material defects or material fatigue, e.g. dueto impact of hazardous substances (acids or alkalis, etc.), temperatures beyond therange of minus 30° Celsius and plus 65° Celsius, leaking cargo and the consequencesresulting there from, etc. shall be excluded.3. Claims related to defective parts, which we have purchased ourselves, such asplugs/sockets ISO 1185/3731, .... may only be raised vis-à-vis us to the extent to whichwe have a justified claim vis-à-vis our suppliers. In such an event we shall be entitled tofinally defend ourselves against being held liable by assigning the claims we havetowards our suppliers.4. In addition, no claims may be raised if our components are combined with third-partyparts or if third parties interfere with our system.5. Aspöck Systems GesmbH shall decide on whether a replacement or an improvement(repair) will be carried out. Any repair work must be done in garages authorised by us;otherwise any warranty claims and other claims shall expire in general. The cost of labourincurred if a decision is made in favour of repair shall be reimbursed to the extent it isabsolutely necessary but in no case in an amount exceeding that which is usually paid.Chapter 18 Februar 2009

6. Claims exceeding those stated in these General Terms and Conditions of Warranty, inparticular claims for damages, e.g. loss of use, lost profit, consequential damage ordamage to property of any kind, shall in no event be reimbursed. Rights of recoursepursuant to Section 933b ABGB [Austrian General Civil Code] shall be excluded.7. In any event claims of any kind may only be raised if the defective old parts arepresented. Only upon receipt and examination of those parts will we make a relevantdecision.IX. Product Liability Statute1. Customer undertakes to observe all our warnings, instructions for use and other productdeclarations, etc. and notify the same to the end user in a complete and up-to-dateversion. Notification shall, if possible, be made in writing and, to the extent possible, byusing relevant information material (product description, etc.).2. If Customer is held liable within the scope of the Product Liability Statute, he already atthis point explicitly waives recourse to us as laid down in Section 12 Product LiabilityStatute. In the event that such a transfer should not be made, Customer undertakes toindemnify and hold us harmless and to reimburse all costs arising in connection with strictliability. If Customer is held liable within the scope of the Product Liability Statute, healready at this point waives recourse to us.Chapter 18 Februar 2009

X. Severability clauseIf any of the provisions of these General Terms and Conditions of Sale and Delivery shouldbe or become ineffective, the validity of the remaining provisions shall not be affectedthereby.XI. Place of performance and place of jurisdiction1. The place of performance for all deliveries and payments shall be Peuerbach alsoif delivery is made at a different place agreed.2. The court in A-4600 Wels having jurisdiction over the subject matter shall havejurisdiction over all legal disputes arising between us and Customer. The supplier mayalso call upon a different court that has jurisdiction over the buyer.3. In all cases between Customer Austrian and us law shall be applicable. Applicability ofthe Vienna Sales Law Convention of 1980 shall be explicitly excluded.XII. These General Terms and Conditions of Sale and Delivery shallalso apply to consumer transactions unless mandatory statutoryprovisions provide otherwise.Place/DateSignatureChapter 18 Februar 2009

Chapter 19:ClaimsChapter 19 Februar 2009

Procedure of Service Partners (factory):1 Determine the damage.2 Check whether the claim is justified by reviewing the licensing papers ( pleaserefer to chapter 16 – warranty terms).3 Repair.4. Fill out the „Warranty protocol of Aspöck Systems“ (only the first section in capitalletters). All questions have to be answered Should there not be enough space, please use the warranty attachment.Please do not forget to fill in the serial number. The forwarding agent is supposed to receive the original Our service partner is supposed to receive a copy5. Please send the rest of the protocol and the damaged parts to your Service Totalpartner (regional representatives of Aspöck Systems).• Item 5 may be ignored by direct customers of Aspöck Systems. Please senddamaged parts and the protocol directly to Aspöck Systems, Enzing 4, A-4722Peuerbach; Austria.Procedure of the regional representatives of Aspöck Systems:1. Check of the damaged parts and statements.2. Once the claims is clearly not justified by reviewing the parts or statements, theclaims can immediately be declined. However, this can only be done by a written(please always fill in the serial number).3. Once the claim is justified, the protocol has to be filled out (only section 2). Ifnecessary, you can also use the attachment (please fill in the serial number).4. Our regional representative is supposed to receive a copy.5. Please send both, the parts and the protocol to Aspöck Systems.Procedure of Aspöck Systems:1. Check of the parts and statements by our quality assurance department.2. Decision by our quality assurance department.3. The whole correspondence is forwarded to our sales department.4. Invoice is paid or a credit note is issued.5. The whole correspondence will be filed.General issues: Please always fill in the serial number and the address of our service shop, nomatter whether the claim is made in written form or by phone. Warranty protocols of Aspöck Systems can be ordered directly and free of chargeat Aspöck Systems.Order Numbers:Protocol (1 piece DIN A4 with 50 application forms) 10-V702-007Attachment (1 piece DIN A4 with pages) 10-V702-107Chapter 19 Februar 2009

Chapter 20:Price list of changed or repaired parts• Aspöck Systems generally pays an hourly rate of Euro 60 €uro netto for theservice work.• Cancellation costs will not be paid by Aspöck Systems (please refer to chapter 15– Warranty Terms).• Preparatory works are also included in the following listChapter 20 Februar 2009

overview time – repair list:change / rework product:max repair time per part (in hours):side marker light (SML)•incl. P&R•incl. ASS2 and ASS3•only SML lenseposition lights•incl. P&R•incl. ASS2 and ASS3•only Lense white / redoutline marker•change rear outline marker (per unit) incl. P&R•incl. ASS2 and ASS3number plate lights and number plate holder LED•number plate light incl. P&R•only number plate light•number plate with ASS2•number plate holder LED P&R•number plate holder LED ASS2rear lights•with 7 pin connector•with 7 pin and 2 pin connector•with PG - connector•3-chamber light with PG•3-chamber light with Bayonet•Miniledplugs and sockets0,25 h0,25 h0,25 h0,25 h0,25 h0,25 h0,25 h0,25 h0,25 h0,25 h0,25 h0,25 h0,25 h0,50 h0,50 h0,50 h0,50 h0,25 h0,50 h•7 pin ISO 3731 or 1185 0,25 h•15 pin ISO 12098 0,50 hP&R flatcable and ASS3 3pin loom•P&R flatcable total 2 pcs (left and right)•repair of P&R flatcable with repair set•change of one ASS3 3pin loomchange connectors on cables•Bayonet- or system ASS1 + ASS2 + ASS3 (2 pin)•Bayonet- or system ASS1 (7 pin)•Bayonet (15 pin) - or ASS3 (17 pin)junction boxes•3socket front junction box•rear junction boxchange of complete lightning set•semi trailer•trailerspecial / options•LED interiour light with P&R•reverse light with ASS2•LCG•change main cable•RDC - sensor•RDC - junction box•rear supply cable•led insert2,00 h0,25 h1,50 h0,25 h0,50 h0,75 h0,50 h0,50 h5-6 h4-5 h0,25 h0,25 h0,75 h1,50 h0,50 h0,75 h0,75 h0,15 hChapter 20 Februar 2009