cables and tubes:
| Identification colours | |
Conductor cross-section mm² | Identification colour |
0,1 – 0,5 | yellow |
0,5 – 1 | red |
1,5 – 2,5 | blue |
4 – 6 | yellow |
10 | red |
16 | blue |
25 | yellow |
35 | red |
50 | blue |
70 | yellow |
95 | red |
120 | blue |
150 | yellow |
| Comparison of conductor cross-sections | ||
| comparable ISO cross-section | AWG / MCM | |
mm² | size | QS mm² |
0,14 | 26 | 0,128 |
0,2 | 24 | 0,205 |
0,34 | 22 | 0,325 |
0,5 | 20 | 0,519 |
0,75 | 18 | 0,823 |
1 | - | - |
1,5 | 16 | 1,31 |
2,5 | 14 | 2,08 |
4 | 12 | 3,31 |
6 | 10 | 5,27 |
10 | 8 | 8,35 |
16 | 6 | 13,3 |
25 | 4 | 21,2 |
35 | 2 | 33,6 |
How many cables fit into an insulating tube?
It is important to note that the longer the length of hose into which the cables are to be inserted, the greater the safety factor that needs to be taken into account.
It is better to choose a longer hose than to find out later that the cables get stuck halfway through. Silicone spray, for example, is helpful here.
The following table will help you choose the right size:
Please note: These values are purely recommendations and are based on the cable diameters of the older and thicker insulated vehicle cables.
However, you will receive slightly thinner, more modern FLRY cables from us. This means that the next smaller hose size can often be used.
It is important to note that the longer the length of hose into which the cables are to be inserted, the greater the safety factor that needs to be taken into account.
It is better to choose a longer hose than to find out later that the cables get stuck halfway through. Silicone spray, for example, is helpful here.
The following table will help you choose the right size:
| Inner diameter of the hose | Number of cables with 1.0 mm² | Number of cables with 1,5 mm² | Number of cables with 2,5 mm² | |
| 3mm | 1 | 1 | 0 | |
| 4mm | 2 | 1 | 1 | |
| 5mm | 3 | 2 | 1 | |
| 6mm | 4 | 3 | 2 | |
| 7mm | 5-6 | 4 | 3 | |
| 8mm | 7 | 5 | 3 | |
| 9mm | 8 | 6 | 4 | |
| 10mm | 12 | 8 | 6 | |
| 12mm | 16 | 12 | 8 | |
| 14mm | 25 | 16 | 12 | |
| 16mm | 30 | 20 | 16 | |
| 18mm | info will follow | info will follow | info will follow | |
| 20mm | info will follow | info will follow | info will follow | |
| 22mm | info will follow | info will follow | info will follow | |
| 24mm | info will follow | info will follow | info will follow | |
| 26mm | info will follow | info will follow | info will follow |
Please note: These values are purely recommendations and are based on the cable diameters of the older and thicker insulated vehicle cables.
However, you will receive slightly thinner, more modern FLRY cables from us. This means that the next smaller hose size can often be used.
Cable lugs and connectors:
General assembly instructions for cable lugs and connectors
1. the cable end must be cut at right angles to the conductor and stripped according to the sleeve length of the cable lug + approx. 10 %.
(The sleeve elongates slightly during crimping.)
2. The conductor ends must be thoroughly cleaned of dirt and oxide residues before crimping.
3. the conductor is pushed into the cable lug sleeve up to the stop or up to the centre of the connector.
4. before crimping, check whether the conductor and the cable lug or connector have the same cross-section designation.
5. check that the crimping tool with the correct crimping inserts/jaws is ready for assembly.
6. the crimping process is carried out on the cable lug and connector from the cable end in the direction of the sleeve end.
(The sleeve elongates slightly during crimping.)
2. The conductor ends must be thoroughly cleaned of dirt and oxide residues before crimping.
3. the conductor is pushed into the cable lug sleeve up to the stop or up to the centre of the connector.
4. before crimping, check whether the conductor and the cable lug or connector have the same cross-section designation.
5. check that the crimping tool with the correct crimping inserts/jaws is ready for assembly.
6. the crimping process is carried out on the cable lug and connector from the cable end in the direction of the sleeve end.
Temperature resistance
Cable lugs and connectors with PC insulation: -40°C to +120°C
Butt connectors with shrink insulation : -55°C to +105°C
Flat receptacles and flat plugs with PVC insulation: -10°C to + 70°C
Flat receptacles and flat plugs with PC insulation: -40°C to + 100°C
Flat receptacles and flat plugs, tin-plated brass, without insulation: -55°C to + 100°C
Wire-end ferrules with insulation up to max. 105°C
Butt connectors with shrink insulation : -55°C to +105°C
Flat receptacles and flat plugs with PVC insulation: -10°C to + 70°C
Flat receptacles and flat plugs with PC insulation: -40°C to + 100°C
Flat receptacles and flat plugs, tin-plated brass, without insulation: -55°C to + 100°C
Wire-end ferrules with insulation up to max. 105°C
Information to Helicoil®:
Helicoil® thread inserts do not have an ‘external thread’ because they are flexible and suitable for space-saving thread repairs.
They are manufactured in such a way that they have the specified dimensions when installed. The length and diameter of a threaded insert when not installed is not comparable with the dimensions when installed. This is because the threaded insert is compressed like a spring before installation and is therefore shorter and has a larger diameter. Only after installation is the thread insert pulled apart to the specified size and the diameter is then also reduced to the nominal dimension accordingly.
The stripped thread must first be drilled out with a twist drill of the appropriate size. Next, the external thread of the Helicoil® insert must be cut with the special Helicoil® insert tap.
With an insert tap, the pitch remains the same as the original thread, only the diameter is slightly larger, as the external thread dimension of the Helicoil® must be cut so that the original screw fits again at the end. This dimension is calculated precisely for the insert tap.
The length refers to the nominal length of the defective thread.
In the next step, the Helicoil® is inserted using the Helicoil® insertion tool. This gives the Helicoil® the necessary pre-tension to fit into the cut thread after installation. If installed correctly, no adhesives or similar are required.
The last step is to remove the tang at the predetermined breaking point using the tang breaker.
Please note that the Helicoil® tools mentioned are absolutely essential for installing a Helicoil®.
Below you will find an overview of the number of turns and twist drill sizes for the respective thread sizes:
| nominal size | number of windings | recomm. Twist- drill-Ø | |||
| 1 x d | 1,5 x d | 2 x d | |||
| M | 2 | 2,9 | 4,9 | 6,9 | 2,1 |
| M | 2,5 | 3,5 | 5,9 | 8,1 | 2,6 |
| M | 3 | 3,9 | 6,3 | 8,7 | 3,2 |
| M | 3,5 | 3,7 | 6,3 | 8,7 | 3,7 |
| M | 4 | 3,7 | 6,1 | 8,4 | 4,2 |
| M | 5 | 4,3 | 6,9 | 9,7 | 5,2 |
| M | 6 | 4,2 | 6,9 | 9,6 | 6,3 |
| M | 7 | 5,3 | 8,2 | 11,1 | 7,3 |
| M | 8 | 4,7 | 7,4 | 10,6 | 8,4 |
| M | 8x1 | 6,1 | 9,5 | 12,9 | 8,3 |
| M | 9 | 5,3 | 8,6 | 11,9 | 9,4 |
| M | 10 | 5,0 | 8,1 | 11,2 | 10,5 |
| M | 10x1 | 7,6 | 12,1 | 16,3 | 10,25 |
| M | 10x1,25 | 6,0 | 9,7 | 13,1 | 10,4 |
| M | 11 | 5,6 | 9,0 | 12,3 | 11,5 |
| M | 12 | 5,2 | 8,4 | 11,7 | 12,5 |
| M | 12x1 | 9,3 | 14,5 | 19,5 | 12,25 |
| M | 12x1,25 | 7,4 | 11,6 | 15,9 | 12,25 |
| M | 12x1,5 | 6,2 | 9,8 | 13,5 | 12,5 |
| M | 14 | 5,6 | 8,8 | 12,0 | 14,5 |
| M | 14x1 | 11,2 | 17,2 | 23,2 | 14,25 |
| M | 14x1,25 (spark plugs) | 4,6 | 7,4 | 9,1 | 14,25 |
| M | 14x1,5 | 7,4 | 11,6 | 15,7 | 14,5, |
| M | 16 | 6,5 | 10,1 | 13,8 | 16,5 |
| M | 16x1,5 | 8,7 | 13,4 | 18,1 | 16,5 |
| M | 18 | 2,3 | 3,8 | 5,6 | 18,75 |
| M | 18x1,5 | 4,2 | 7,0 | 9,5 | 18,5 |
Processing information for cable ties:
During processing, the force with which the cable tie is tightened is of great importance. Together with the weight to be held, it adds up to the so-called working load:
Working load = tightening force + constant load
The tightening force should be approx. 10 % of the working load. The working load of a cable tie is calculated as follows:
Working load = tightening force + constant load
The tightening force should be approx. 10 % of the working load. The working load of a cable tie is calculated as follows:
working load = strength according to catalogue
safety factor
safety factor
Under normal conditions, a safety factor of 2 should be taken into account. If the connection is exposed to vibrations, shocks, strong elongation or tension, the safety factor should be higher. For continuous temperatures below 0°C or above 40°C, a safety factor of 10 should be used.
If the constant load (+ 10% tightening force) is higher than the determined working load of the cable tie, several ties should be placed next to each other or a wider tie should be used.
If cable ties are tightened by hand, tightening forces can occur that exceed the tensile strength of the cable tie, especially with narrow ties. In this case, the tie will tear or come undone immediately or after a short time. To ensure a constant, correctly measured tightening force, cable tie pliers should be used.
If the constant load (+ 10% tightening force) is higher than the determined working load of the cable tie, several ties should be placed next to each other or a wider tie should be used.
If cable ties are tightened by hand, tightening forces can occur that exceed the tensile strength of the cable tie, especially with narrow ties. In this case, the tie will tear or come undone immediately or after a short time. To ensure a constant, correctly measured tightening force, cable tie pliers should be used.
Other information:
Tightening torques for fastening screws:
If no tightening torques for the fixing screws are specified by the appliance manufacturer, the values based on EN60947-1, DIN 43673-1 or DIN 46200 can be used:
| Connection thread | brass | steel 8.8 | stainless steel |
M5 | 2 | 2,5 | 3 |
M6 | 3 | 4,5 | 5,5 |
M8 | 6 | 10 | 15 |
M10 | 10 | 20 | 30 |
M12 | 14 | 40 | 60 |
M14 | 19 | 80 | 120 |
M16 | 25 | ||
M20 | 36 | ||
M24 | 50 |
de