HELLA 2-Pole Cable Connector (8KW 744 806-801) Instruction Manual

1. Product Overview

This manual provides essential information for the proper installation, operation, and maintenance of your HELLA 2-Pole Cable Connector, model 8KW 744 806-801. This connector is designed for reliable electrical connections in demanding environments, offering maximum protection against water and dust ingress with an IP 67 rating.

HELLA 2-Pole Cable Connector, showing male and female parts

Figure 1: HELLA 2-Pole Cable Connector (Male and Female components)

Key Features:

Original Equipment Quality
Reliable electrical connection
Maximum protection against external influences (IP 67 rated)
High resistance to vibrations and corrosion
Based on traditional crimp contact concept (SUPERSEAL system)

2. Setup and Installation

Proper installation is crucial for the performance and longevity of the HELLA SUPERSEAL connector. Ensure all components are clean and free from damage before assembly.

Required Tools:

Crimping tool suitable for SUPERSEAL terminals
Wire strippers
Unlocking tool (if disassembly is required)

Installation Steps:

Prepare Wires: Strip approximately 3-4 mm of insulation from the wire ends. Ensure the wire cross-section is suitable for the connector (up to 2.5 mm²).
Crimp Terminals: Insert the stripped wire into the appropriate SUPERSEAL terminal (male or female). Use a specialized crimping tool to securely crimp the terminal onto the wire. Ensure both the conductor and insulation are properly crimped.
Insert Seals: Slide the rubber seals onto the crimped wires. These seals are critical for achieving the IP 67 rating.
Insert Terminals into Housing: Carefully push the crimped terminals (with seals) into the correct cavities of the connector housing until they click into place. Ensure the terminals are fully seated and locked.
Connect Halves: Align the male and female connector halves and push them together firmly until they lock. A distinct click indicates a secure connection.

Note: Refer to the specific crimping tool instructions for detailed crimping procedures. Incorrect crimping can lead to poor electrical contact and compromise the waterproof seal.

3. Operating Instructions

Once installed, the HELLA 2-Pole Cable Connector operates as a reliable electrical junction. No specific operational steps are required beyond ensuring a secure connection.

Ensure the connector is fully engaged and locked to maintain its IP 67 protection against water and dust.
Avoid applying excessive force or strain to the connected cables.
Do not attempt to disconnect the connector by pulling on the wires; always grasp the connector housing.

4. Maintenance

The HELLA SUPERSEAL connector is designed for minimal maintenance due to its robust construction and sealing properties.

Periodic Inspection: Periodically inspect the connector for any signs of physical damage, cracks, or degradation of the rubber seals.
Cleaning: If necessary, clean the exterior of the connector with a damp cloth. Avoid using harsh chemicals or solvents that could damage the plastic or rubber components.
Seal Integrity: Ensure the seals are properly seated and not displaced, especially after any handling or exposure to extreme conditions.

5. Troubleshooting

This section addresses common issues that may arise with the HELLA 2-Pole Cable Connector.

Problem	Possible Cause	Solution
No electrical connection	Improperly crimped terminals Terminals not fully seated in housing Damaged wire or terminal Connector not fully engaged	Re-crimp terminals ensuring proper technique. Verify terminals are clicked into place. Inspect wires and terminals for damage; replace if necessary. Ensure male and female halves are securely locked.
Water or dust ingress	Seals improperly installed or damaged Connector not fully engaged Damaged housing	Inspect and re-seat or replace seals. Ensure connector halves are securely locked. Inspect housing for cracks; replace connector if damaged.
Difficulty connecting/disconnecting	Misalignment Debris in connector Damaged locking mechanism	Ensure proper alignment before pushing. Clean connector cavities. Inspect locking tabs; replace connector if damaged.

6. Specifications

Brand	HELLA
Model Number	8KW 744 806-801 (Manufacturer Model: 744806801)
Type	2-Pole Cable Connector (Male/Female)
Max. Wire Cross-section	2.5 mm²
Ingress Protection (IP) Rating	IP 67 (Dust tight and protected against immersion in water up to 1 meter for 30 minutes)
Compliance	IEC 529, DIN ISO 40050
Item Weight	15 g
Product Dimensions (L x W x H)	5.5 x 3.3 x 9 cm
Country of Origin	Germany

7. Warranty Information

Specific warranty details for this product are not provided in the available information. Please refer to the official HELLA website or contact HELLA customer support for warranty terms and conditions.

8. Support and Contact

For technical assistance, product inquiries, or further support, please visit the official HELLA website or contact their customer service department.

Official Website: www.hella.com
Customer Service: Refer to the contact section on the HELLA website for regional support options.

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HELLA 8KW 744 806-801