Schaltbau UIC Series User manual

Connect - Contact - Control
1
Inhalt
Rundsteckverbinder für Spezialanwendungen, Baureihe SB 2
Besondere Merkmale 2
Applikationen 2
Baureihenübersicht 2
Kompetenz 2
Normen 2
Technische Daten 3
Bestellschlüssel 4
5-polig + PE Flanschstecker, Kabeldose 4
6-polig Flanschdose, Kabelstecker 5
14-polig Flanschstecker, Kabeldose 5
Montage 6
Werkzeuge Ausdrückwerkzeuge AWZ-A und AWZ-C/H, Crimpzange CWZ-600 6
Montagebohrungen 6
Kontakte Stecker: Crimpkontakte, Dosen: Lötkontakte 7
Deratingkurven 7
Sicherheitshinweise 7
ConnectorsConnectors
UIC Series
Inter-car jumpers
to UIC 558 VE
Manual F120.en

22016-08-25 / V1.0
Connectors UIC 558 – Installation and Maintenance Instructions
Inhalt
1. Important Basic Information......................................................................................... 3
1.1 Legal Notes.............................................................................................................................. 3
1.2 Conventions for this Installation and Maintenance Instructions......................... 3
2. General and Security Information................................................................................ 3
2.1 Observing the Instructions................................................................................................ 3
2.2 User Obligations.................................................................................................................... 3
2.3 Intended Use........................................................................................................................... 4
2.4 Ambient Conditions............................................................................................................. 4
3. Dangers and Security Measures ................................................................................... 5
3.1 Electrical Dangers ................................................................................................................. 5
3.2 Other Dangers........................................................................................................................ 5
3.3 Mechanical Dangers............................................................................................................. 6
3.4 Measures for Avoiding Damages..................................................................................... 6
3.5 Measures for Avoiding Malfunctions ............................................................................. 7
4. Description........................................................................................................................ 7
4.1 Details........................................................................................................................................ 7
4.2 Design ....................................................................................................................................... 8
4.3 Survey of the Components (Preferred Types) ............................................................. 9
5. Installation ......................................................................................................................12
5.1 Check Parts for Transport Damage ...............................................................................12
5.2 Dimensions/Interfaces to the Vehicle..........................................................................12
5.3 Installing Coupling Receptacles ....................................................................................12
5.4 Coupling Receptacles with Socket Insert
and Assembled Connector Cable..................................................................................13
5.5 Coupling Receptacles with Replacement Insert, Crimp Adapter
and Assembled Connector Cable..................................................................................14
5.6 Disassembly of Replacement Insert and Crimp Adapter......................................15
5.7 Installing the Dummy Receptacle.................................................................................16
5.8 Installing Wall-mount Cable Glands for Cable Plugs with
Connector Cable..................................................................................................................16
5.9 Storage of Connector Cables ..........................................................................................17
6. Plugging Procedure.......................................................................................................18
6.1 Plugging .................................................................................................................................20
6.2 Unplugging ...........................................................................................................................20
7. Maintenance...................................................................................................................21
7.1 Intervals for Checks and Maintenance ........................................................................21
7.2 Visual and Functional Inspection at each Plugging ...............................................21
7.3 Visual and Functional Inspection/Maintenance
of Coupling Receptacle and Dummy Receptacle....................................................21
7.4 Visual and Functional Inspection/Maintenance of the Cable Plug...................23
8. Special Tools ...................................................................................................................23
9. Spare Parts ......................................................................................................................24
10. Technical Data ................................................................................................................25

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2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Important Basic Information
1. Important Basic Information
1.1 Legal Notes
Without prior written consent of Schaltbau GmbH, the
instructions is not allowed to be electronically or me-
chanically reproduced – as a whole or in parts – be dis-
tributed, changed, transmitted, translated into another
language or used in any other way.
Schaltbau GmbH cannot be held liable for damage
caused by not observing (or only partly observing) the
Installation and installation instructions.
1.2 Conventions for this Installation and
Maintenance Instructions
This instructions describe the installation and mainte-
nance of the connectors.
Cross references are presented in bold italics.
To highlight particularly important safety instructions
and other information, the following symbols are used
in this instructions:
DANGER
Indicates a hazardous situation with a high level of
risk which, if not avoided, will result in death or seri-
ous injury.
WARNING
Indicates a hazardous situation with a medium level
of risk which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation with a low level of
risk which, if not avoided, may result in minor or
moderate injury.
NOTICE
Indicates a hazardous situation which, if not avoided,
may result in property damage, such as service inter-
ruption or damage to equipment or other materials.
Refers to technical features and methods
aimed at facilitating work or to particu-
larly important information.
2. General and Security Information
The connectors dealt with in this document are intend-
ed for use with low-voltage systems for special instal-
lations. They are designed and tested in compliance
with the generally recognised state of the art. However,
improper use, operation, handling, maintenance of or
tampering with electric equipment can cause serious
or fatal injury to the user or others, and the appliance or
other property can be damaged.
The operation, maintenance and installation instructions
for the connectors must therefore be strictly followed.
Any uncertainties must be claried and all queries must
include details of the type of device and the serial num-
ber.
Only authorized and trained personnel are allowed to
plan and carry out all mechanical and electrical instal-
lations, transport, commissioning, as well as mainte-
nance and repair work. This applies to the observation
of the general installation and safety regulations for
low-voltage systems as well as the proper use of tools
approved for this purpose.
Electrical devices are to be protected, as much as pos-
sible, from dust and moisture during installation or stor-
age.
2.1 Observing the Instructions
X All sta must read and understand the instruc-
tions and adhere to them when working with the
device.
X Always carefully observe all safety warnings!
2.2 User Obligations
X Observe the respective national instructions and
other applicable safety regulations for the use and
cable assembly of connectors and connector sys-
tems.
X Observe all applicable national provisions, all safety,
accident prevention and environmental regulations
as well as the recognized technical rules for safe and
proper working.
X Carry out regular inspections of all protection and
safety devices to see if they work properly.
X Work on electric equipment may only be performed
by a qualied electrician or trained personnel work-
ing under the direction and supervision of a quali-
ed electrician according to the applicable rules of
electrical engineering.

42016-08-25 / V1.0
General and Security Information
Connectors UIC 558 – Installation and Maintenance Instructions
X A qualied electrician is a person who can judge
and recognise the possible dangers of the jobs
commended to him based on his training, knowl-
edge and experience and by knowledge of the ap-
propriate regulations.
X Sta must be informed clearly about who is re-
sponsible for the maintenance of the connectors.
2.3 Intended Use
X The connectors are intended for plug-in and de-
tachable connections of components, devices and
systems only. They are used for the transmission of
power and signals.
X In order to comply with DIN EN IEC 61984 make
sure that always the live side of the connector is
tted with socket contacts.
X Crimp connections have to be manufactured
according to DIN EN IEC 60352-2 – Solderless Con-
nections.
X Make sure that there are no undue tensile, pres-
sure, exing and torsion loads on the connection
cable.
X None of the operating conditions dened in our
catalogue F120.en in section “Specications“,
such as voltages, currents, ambient conditions,
etc. may be changed.
X Work on the connectors must only be carried out
by sta who meets the requirements set out in
these instructions.
X According to DIN EN IEC 61984 connectors used
as intended must not be engaged or disengaged
when live or under load.
X The connectors must not be contaminated with
aggressive media.
X A connector that does not engage easily requires
special attention:
Check for the correct orientation, pollution or if
contacts got bent. Remedy the cause without de-
lay. Never use force! The connector should always
engage easily.
X In order to meet the requirements of the protec-
tion class and to protect the connectors against
the entry of dirt or moisture, make sure that when
not mated,
-the plug is always inserted into a dummy recep-
tacle
-the hinged lid of receptacles is closed, accord-
ing to its intended use.
X The connector cables have to be stored / kept
properly in the vehicle.
X When disengaging a connector, pull the plug and
never the cable.
X Open the hinged lid of the receptacle by an angle
of at least 110° but not more than 130°. An over-
stretching of the hinged lid may shorten the op-
erational life span of the torsion spring and may
damage the hinge mechanism.
X Always close the hinged lid by hand, don’t let it
slam.
X Use the connector only according to its intended
use. Replace or repair damaged parts exclusively
with original parts. Any other usage of or tamper-
ing with the connector is considered contrary to its
intended use. No liability is assumed for damages
and accidents caused due to non-compliance with
the instructions or improper use of the connector.
2.4 Ambient Conditions
NOTICE
The connectors are constructed for specic ambient
conditions.
X Operate the connectors only under the ambi-
ent conditions, like temperature ranges and IP
protection classes as dened in our catalogue
F120.en in section “Specications“.
schaltbau.info/download1en
Note:
In case of a very low or very high ambient temperature
which approximates the limits of the allowable operat-
ing temperature range specied in our catalogue F120.
en in section “Specications“,
-a higher eort may be needed for the plugging and
unplugging and
-the operational life span of plug and coupling recep-
tacle may thus be reduced due to increased wear and
tear.

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2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Dangers and Security Measures
3. Dangers and Security Measures
3.1 Electrical Dangers
DANGER
The connectors contain components that carry voltage. Risk of electric shock!
Always observe the following safety regulations before beginning any work on electrical
constructions:
X Disconnect
X Ensure that it is not possible to reconnect unintentionally
X Clearly mark your work area
X Make sure that there is no voltage present
X Earth and short circuit the installation
X Insulate or cover adjacent energized parts
X Only an electrically skilled person may determine if there is no voltage present
WARNING
Dirt, moisture, snow and ice in the interior of coupling receptacles or dummy receptacles contami-
nate the plug. The coupling of a contaminated plug to the coupling receptacle may lead to electric
shock, short circuit and damage to the connectors!
X Always check if the interior of the receptacles is free from dirt, moisture, snow and ice before
inserting a plug into a coupling receptacle or a dummy receptacle.
X Do not insert a plug into a receptacle when the latter is contaminated, moist or contaminated
with snow and ice.
X Remove dirt, moisture, snow and ice without residues from the interior of receptacles and from
the plug.
X Never couple a contaminated plug to the coupling receptacle.
3.2 Other Dangers
WARNING
Exclusively use the connectors for purposes as indicated in the specications and data sheets.
A wrong application can cause accidents and severe damages to persons.
X The manufacturer doesn‘t take the responsibility for accidents which were caused by improper
use of the product.
X We recommend the use of fault current safety systems in constructions with voltages higher
than safety extra-low voltage.
WARNING
The plugging and disconnecting of the connectors on-load can cause electric arcs. When explosive
substances or ignition sources of any kind are nearby, there is a risk of re and explosion!
X Never plug and disconnect the connectors on-load.

62016-08-25 / V1.0
Dangers and Security Measures
Connectors UIC 558 – Installation and Maintenance Instructions
CAUTION
The connectors may grow warm during operation and they may become hot depending on the
ambient temperature and the conditions of use. Risk of burn to the hands!
X Wear safety gloves when plugging and disconnecting the connectors in the case of a high
ambient temperature.
3.3 Mechanical Dangers
CAUTION
The connectors contain components that are subject to mechanical stress. There is a risk of crushing!
X Use only appropriate tools for work on the connectors.
X Ensure that components, which are subject to mechanical stress, are secured before installing
or dismantling these components.
CAUTION
The connectors contain sharp-edged parts. Risk of injury!
X Use only appropriate tools afor maintenance work on the connectors.
X Wear protective gloves when working with sharp-edged components.
3.4 Measures for Avoiding Damages
NOTICE
Aggressive uids may damage the connectors.
X Make sure that the connectors are not exposed to aggressive uids.
NOTICE
Improper handling of the connectors, e.g. when hitting the oor with some impact, can result in breakage, bent
pin contacts, cracks and deformation.
X Make sure that the connectors are always used properly.
X Regularly sight-check the connectors for potential damages.
X Regularly check the connectors for bent or pushed back contacts.
X Immediately replace damaged components.

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2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Description
3.5 Measures for Avoiding Malfunctions
NOTICE
In the case of damage, wear and tear and/or soiling of the connector components - in the form of a partial break,
sharp edges and discoloured surfaces - the functional safety of the connectors is no longer guaranteed.
X Carry out regular visual checks to detect wear and tear and dirt.
X Immediately replace damaged parts.
X Immediately remove dirt without leaving any residues.
X Immediately replace parts with stubborn dirt.
NOTICE
Inappropriate handling when plugging or disconnecting may damage the connectors. The functional safety of
the connectors is no longer guaranteed when parts are damaged.
X Make sure that the guideways and slots of plug and receptacle always interlock when plugging!
X Take care that plug and receptacle do not tilt and that they are plugged without force.
X Make sure before the plugging procedure that plug and receptacle as well as the hinged lid of the recepta-
cle are not contaminated. Remove any existing dirt.
X Make sure that when not mated,
-the plug is always inserted into a dummy receptacle,
-the hinged lid of receptacles is closed according to its intended use.
4. Description
4.1 Details
Break-away connector
X If installed as intended, the break-away connector
guarantees the non-destructive separation of the
plug from the receptacle when two vehicles that
are not electrically decoupled move away from
each other.
Replacement Insert for receptacles
X With the 18-pole version in compliance with
UIC558, a coupling receptacle is now available
which leads to a considerable reduction of the
times of maintenance and idleness. In the case of
maintenance, you don’t have to rewire but only
the replacement insert has to be changed. The
contact insert can be replaced directly on-site –
the lengthy electrical test of contacts and cables is
no longer necessary.
Shell
X quick and easy to install
X individual components are easy to replace
X seals can be replaced without disassembling the
contacts
X Same basic design for empty, coupling and dum-
my receptacle: empty receptacles are converted to
coupling or dummy receptacles by tting the ap-
propriate contact inserts.
Cable Assembly
Connector cables (single and double ended) can be
made to customer specications upon request.
Technical Information and Material
Specications
X For technical information and material specica-
tions, see our catalogue catalogue F120.en.
Download at: schaltbau.info/download1en

82016-08-25 / V1.0
Description
Connectors UIC 558 – Installation and Maintenance Instructions
4.2 Design
Connectors in the UIC 558 series are 13 or 18-pole
connectors to loop through dierent control signals
between railway vehicles. The connectors are in com-
pliance with UIC 558. They connect lines used for:
X remote control of lights
X remote control of doors
X public address system in passenger coaches and
traction vehicle
X transmission of binary data
Connectors in the UIC 558 series consist of the follow-
ing components:
X Connector cable, single ended, in the desired
length with cable plugs, single-sided assembly,
or connector cable, double ended, with two cable
plugs, double-sided assembly.
X Receptacle (consisting of empty receptacle + con-
tact insert with assembled connector cable, single
ended, in the desired length)
X Receptacle (consisting of empty receptacle + re-
placement insert and crimp adapter with assem-
bled connector cable, single ended, in the desired
length)
X Dummy receptacle (consisting of empty recepta-
cle + contact insert unpopulated; for the insertion
of a non-coupled cable plug)
X Full customer-specic cable sets
Contact inserts for 13 and 18 contacts in compliance
with UIC 558 as well as 22 contacts + PE for other ap-
plications and customer-specic contact arrangements
are available.
Fig. 1: Receptacle with socket contacts
A A-A
A
Fig. 2: Receptacle with replacement insert and crimp adapter
Fig. 3: Plug with pin contacts
UIC 558 contact insert arrangements
No. of
contacts
Pin insert
for plugs
Socket insert
for receptacles
13 15
18
17
14
16
7
6 5
4 2
3
10
1 12
11
13
8 9
UIC E-13P
Pole 1 -13:
Pin type
SHC-1,00-X1)-30
18
17
14
16
7
6
5
4
2
3
10
1
12
11
13 8
9
15
UIC E-13S
Pole 1 -13: Socket type
BHC-1,00-X1)-30
18 15
18
17
14
16
7
65
42
3
10
1
12
11
13
8
9
UIC E-18P
Pole 1 -18: Pin type
SHC-1,00-X1)-30
18
17
14
16
7
6
5
4
2
3
10
1
12
11
13 8
9
15
UIC E-18S
Pole 1 -18: Socket type
BHC-1,00-X1)-30
Non-UIC 558 compliant contact insert arrangements
No. of
contacts
Pin insert
for plugs
Socket insert
for receptacles
22 + PE
7
6
54
3
21
9
18
17 16 15 14
13
12
11
19 810 22
21
20
UIC E-22P + PE
Pole 1 - 22: Pin type
SHC-1,00-X1)-30
Pole PE: Pin type
SHC-1,00-X1)-30
21 20
22 10 819
11
12
13
14 15 16
17
18
9
1
2
3
45
6
7
UIC E-22S + PE
Pole 1 - 22: Socket type
BHC-1,00-X1)-30
Pole PE: Socket type
BHC-1,00-X1)-30
1) Contact surfaces optionally:
-Ni (nickel), complying with the standard
-Au (gold)*
-Ag (silver)*
* Special design on request

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2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Description
4.3 Survey of the Components (Preferred Types)
Connector cable with plug (single ended)
No. of contacts Figure/description (dimensions in mm) Ordering code
13
54 Lxxxx 180 53
100 ±5
115 40 11
121 (11 x 11)
red
white
yellow
black
red
white
yellow
black
red
white
yellow
black
Schirm
1 2 3 4 5 6 7 8 9
10 11 12 13
Connector cable with cable harness and plug,
completely assembled cable set in required length, 13-pole, pin contacts
(13-pole plug with less equipped 18 pole cable)
UIC SK 13P E0 Lxxxx 1)
18
54 Lxxxx
115 40
Connector cable with plug, completely assembled cable set in required length
18-pole, pin contacts
UIC SL 18P ER Lxxxx 1)
Connector cable with plug (double ended)
No. of contacts Figure/description (dimensions in mm) Ordering code
13
18
54
Lxxxx
115 40
13-pole
18-pole
Connector cable with 2 plugs, completely assembled cable set in required length,
available in 13-pole and 18-pole version, pin contacts
(13-pole plug with less equipped 18-pole cable)
13-pole version:
UIC VK 13P E0 Lxxxx 1)
18-pole version:
UIC VK 18P ER Lxxxx 1)
13-pole coupling receptacle with socket insert, connector cable and cable harness
No. of contacts Figure/description (dimensions in mm) Ordering code
13
Lxxxx
125
43
65
52
28
18053
100
±5
11
121 (11 x 11)
schwarz12
11 10
9 8 7 6 5 4 3 2 1
13
gelb
weiß
rot
schwarz
gelb
weiß
rot
schwarz
gelb
weiß
rot
Schirm
6,6
Socket insert with connector cable and cable harness, completely assembled
cable set in required length, 13-pole, socket contacts + empty receptacle
(13-pole socket insert with less equipped 18-pole cable)
Socket insert with
connector cable and
cable harness:
UIC DK 13S 00 Lxxxx 1)
+
Empty receptacle:
UIC LD 130 C0
(RAL 7035, light grey)
1) Cable length Lxxxx in mm: we assemble the required cable length by arrangement

10 2016-08-25 / V1.0
Description
Connectors UIC 558 – Installation and Maintenance Instructions
18-pole coupling receptacle with socket insert and connector cable
No. of contacts Figure/description (dimensions in mm) Ordering code
18
Lxxxx
125
43
65
52
28
6,6
Connector cable with socket insert, completely assembled
cable set in required length, 18-pole, socket contacts + empty receptacle
18-pole socket insert
with connector cable:
UIC DL 18S 00 Lxxxx 1)
+
Empty receptacle:
UIC LD 180 CR
(RAL 7035, light grey,
red colour markings)
18-pole coupling receptacle with replacement insert, crimp adapter and connector cable
No. of contacts Figure/description (dimensions in mm) Ordering code
18
Lxxxx 35.5 41.9
125
Ø
60
43
65
52
28
6.6
Crimp adapterReplacement
insert
Empty
receptacle
Crimp adapter with connector cable, completely assembled cable set in required
length, 18-pole, pin contacts + 18-pole replacement insert with socket contacts im-
plemented on both sides + empty receptacle
18-pole crimp adapter
with connector cable:
UIC CA 18P 00 Lxxxx 1)
+
18-pole replacement
insert:
UIC BT 18S/P
+
Empty receptacle:
UIC LD 180 CR ZW
(RAL 7035, light grey,
red colour markings)
1) Cable length Lxxxx in mm: we assemble the required cable length by arrangement

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2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Description
Coupling receptacle, dummy receptacle, empty receptacle
No. of contacts Figure/description (dimensions in mm) Ordering code
13
18
22
45
65
125
R115
43
65
52
28
6.6
83
45
65
83
30
Earthing bolt M6,
only special design F4
Coupling receptacle,
dummy receptacle Empty receptacle
- Coupling receptacle with socket insert and crimp contacts
(all socket contacts are included in delivery)
- Dummy receptacle with socket insert without crimp contacts
- Empty receptacle without socket insert without crimp contacts
Coupling receptacle
-13-pole:
UIC KD 13S C0
(RAL 7035, light grey)
-18-pole:
UIC KD 18S CR
(RAL 7035, light grey,
red colour markings):
-22-pole:
UIC KD 22S CB
(RAL 7035, light grey,
blue colour markings):
Dummy receptacle
-13-pole:
UIC BD 130 C0
(RAL 7035, light grey)
-18-pole:
UIC BD 180 CR
(RAL 7035, light grey,
red colour markings):
-22-pole:
UIC BD 220 CB
(RAL 7035, light grey, blue
colour markings)
Empty receptacle
-13-pole:
UIC LD 130 C0 (RAL
7035, light grey)
-18-pole:
UIC LD 180 CR
(RAL 7035, light grey,
red colour markings):
-22-pole:
UIC LD 220 CB
(RAL 7035, light grey,
blue colour markings)
Wall-mount cable gland
Figure/description (dimensions in mm) Ordering code
0 ... 8
39.5+124
Ø
30
Pg 21
36
D2
Mounting wall
Mounting
hole
Strain relief
bushing
PA 6 GF30, black
Nut
PA 6 GF30
black
Supporting
ring
Spring
disc
Tensioning screw
PA 6 GF30
black
Cable gland PG21 with antikink tting
Cable glands PG21
with antikink tting
UIC KK D2
cable diameter 16.5 ...18.5 mm

12 2016-08-25 / V1.0
Installation
Connectors UIC 558 – Installation and Maintenance Instructions
5. Installation
DANGER
The connectors contain components
that carry voltage. Risk of electric shock!
Always observe the following safety
regulations before beginning any work
on electrical constructions:
X Disconnect
X Ensure that it is not possible to re-
connect unintentionally
X Clearly mark your work area
X Make sure that there is no voltage
present
X Earth and short circuit the instal-
lation
X Insulate or cover adjacent ener-
gized parts
X Only an electrically skilled person
may determine if there is no volt-
age present
NOTICE
During installation, ensure that dirt caused by sur-
rounding construction activities does not get into
the connectors.
5.1 Check Parts for Transport Damage
NOTICE
If parts are damaged, the functional reliability of the
connectors is no longer given.
X Before installing, check all parts for any possible
transport damage.
X Do not install any damaged parts.
5.2 Dimensions/Interfaces to the
Vehicle
The dimensions to the interfaces of the vehicle are given
inthe respectivedatasheetsorinourcatalogueF120.en.
(Download: schaltbau.info/download1en)
5.3 Installing Coupling Receptacles
Preliminaries
The assembly has to be carried out by qualied trained
personnel.
Correct mounting position
The break-away connector function guarantees a non-
destructive separation of plug and receptacle when
two electrically not uncoupled vehicles move away
from each other. For this purpose, the mounting posi-
tion of the coupling receptacle must be performed in
compliance with UIC 558 VE in order to guarantee the
prescribed tensile forces / directions on the exible ca-
ble. Fig. 4/D shows an example: Vertical mounting posi-
tion, lid opening to the top.
Moreover, a mounting position up to an angle of max.
90° clockwise is possible for coupling receptacles. In
this instance, the lid must show downward (for exam-
ples refer to Fig. 4/E and F).
NOTICE
An installation of the coupling receptacle with lid
showing upward (refer to Fig. 4/G) is not permissible!
When the lid is open in this mounting position, con-
tamination and moisture might penetrate the con-
tacts and accumulate there during the plugging
procedure or in the plugged condition. Moreover,
this mounting position causes a not denable limi-
tation of the prescribed tensile forces / directions on
the exible cable and thus on the contact retainer
and locking mechanism. In this mounting position,
the plug connection is strained in transverse direc-
tion and the cable causes a unilateral strain on shell,
contacts and locking mechanism!
D
G
F
E
max.
90°
Fig. 4: Permissible and not permissible mounting positions
for receptacles
Requirements to the vehicle wall / mounting surface
The surface of the vehicle wall / mounting surface must
show an average surface roughness Rz of 6.3 ... 12.5 µm.
The tightening torque for the fastening screws is
10.5Nm, for screws of steel with strength class 8.8.

13
2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Installation
Mounting points
The coupling receptacle is fastened with 3 cylinder
screws M6 or alternatively with 4 cylinder screws M6.
The tightening torque (10.5 Nm for screws of steel
with strength class 8.8) and the length of the fastening
screws must be determined by the manufacturer of the
vehicles depending on the structural conditions.
AA
A
BB
B/C BC
M6
Fig. 5: Mounting points of receptacle
A Mounting points for installation with 3 holes
B Mounting points for installation with 4 holes
C Earthing bolt M6 (only special design F4)
The dimensions and arrangement of the mounting
holes are shown in Figures 6 and 7.
Ø 6.5 or M6
Ø 6.5
25
25
45
65
69.3
34.65
Ø
40
G
Fig. 6: 3-hole mounting, G = hole for M6 earthing bolt M6
(only for receptacle with special design F4)
Ø 6.2 or M6
25
50
50
25
*
*
*
*
Ø
40
Fig. 7: 4-hole mounting
* Diameter for all xing and securing elements, such
as screw heads: 12.5 mm max.
Two possibilities of installation are available for cou-
pling receptacles:
-Installation with socket insert and completely assem-
bled connector cable (13-, 18-pole)
-Installation with a replacement insert and complete-
ly assembled crimp adapter (18-pole)
5.4 Coupling Receptacles with Socket
Insert and Assembled Connector
Cable
X Thread the O-ring (3) onto the open end of the
connector cable (1).
X Pull the open end of the connector cable (1)
through the prepared mounting hole (max. 40mm
diameter) in the vehicle wall (2).
2
13 4 5
Fig. 8: Coupling receptacle with assembled socket insert and
connector cable
1 Connector cable, completely assembled
2 Vehicle wall with prepared mounting holes
3 O-ring for socket insert
4 Socket insert, completely assembled
5 Empty receptacle with inserted rubber seal (lamella ring)
X Slide the assembled socket insert (4) in the speci-
ed coding position with the slots (A) onto the lat-
eral guideways (B) of the coupling receptacle (5).
4 3 1
5
B
AA
Fig. 9: Coding position with slots (A) on the socket insert and
guideways (B) in the coupling receptacle

14 2016-08-25 / V1.0
Installation
Connectors UIC 558 – Installation and Maintenance Instructions
NOTICE
To ensure the proper operation, the socket insert and
the contacts may not be under tension.
X Make sure that the specied bending ra-
dius is observed when laying the cables:
8 x cable diameter = 145 mm
X Slightly fasten the receptacle (5) with the three M6
cylinder screws (or alternatively with four M6 cyl-
inder screws) to the vehicle wall (2).
X Check if the O-ring (3) of the socket insert and
rubber seal (lamella ring) (6) are properly in place.
Align seals where applicable.
X Adjust all of the parts and fasten the M6 cylinder
screws.
Tightening torque: 10.5 Nm for screws of steel
with strength class 8.8.
23
6
5
M6
*
*
Fig. 10: Screw coupling receptacle with socket insert to the
vehicle wall
* Diameter for all xing and securing elements, such
as screw heads: 12.5 mm max.
Test
X Check that all of the installed parts are in the cor-
rect position and function properly.
X Make sure that there are no undue tensile, pres-
sure, exing and torsion loads on the connection
cables.
X Check the functionality of the receptacle lid.
Commissioning
DANGER
In the case of a contact of the traction
current line with the vehicle, the cou-
pling receptacle may be highly ener-
gised. Deadly hazard!
X Before commissioning the recep-
tacle, a high voltage test must be
carried out.
X Before commissioning the receptacle, it must be
tested in accordance with EN 50215.
5.5 Coupling Receptacles with
Replacement Insert, Crimp Adapter
and Assembled Connector Cable
X Thread the O-ring (7) onto the open end of the
connector cable (1) and slide it onto the crimp
adapter (8).
X Pull the open end of the connector cable (1)
through the prepared mounting hole (max. 40mm
diameter) in the vehicle wall (2).
X Attach the O-ring (3) to the replacement insert (9).
78
1 2 39 5
Fig. 11: Coupling receptacle with replacement insert and
crimp adapter (18-pole) with assembled connector
cable
1 Connector cable, completely assembled
2 Vehicle wall with prepared mounting holes
3 O-ring for replacement insert
5 Empty receptacle with inserted rubber seal (lamella ring)
7 O-ring for crimp adapter
8 Crimp adapter, completely assembled
9 Replacement insert
X Fit the replacement insert (9) in the specied cod-
ing position onto the assembled crimp adapter (8).
X Slide the replacement insert (9) plugged together
with the crimp adapter (8) with the slot (K) into the
guideway (L) on the top of the coupling receptacle
(5).
8
9
5
LK
Fig. 12: Coding position with slots (K) on the replacement in-
sert and guideways (L) in the coupling receptacle

15
2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Installation
NOTICE
To ensure the proper operation, the socket insert and
the contacts may not be under tension.
X Make sure that the specied bending ra-
dius is observed when laying the cables:
8 x cable diameter = 145 mm
X Slightly fasten the receptacle (5) with the three M6
cylinder screws (or alternatively with four M6 cyl-
inder screws) to the vehicle wall (2).
X Check if the two O-rings (3/7) of the replacement
insert and crimp adapter as well as the rubber seal
(lamella ring) are properly in place. Align seals
where applicable.
X Adjust all of the parts and fasten the M6 cylinder
screws.
Tightening torque: 10.5 Nm for screws of steel
with strength class 8.8.
23/7
6
5
M6
*
*
Fig. 13: Screw coupling receptacle with crimp adapter and
replacement insert to vehicle wall
* Diameter for all xing and securing elements, such
as screw heads: 12.5 mm max.
Test
X Check that all of the installed parts are in the cor-
rect position and function properly.
X Make sure that there are no undue tensile, pres-
sure, exing and torsion loads on the connection
cables.
X Check the functionality of the receptacle lid.
Commissioning
DANGER
In the case of a contact of the traction
current line with the vehicle, the cou-
pling receptacle may be highly ener-
gised. Deadly hazard!
X Before commissioning the recep-
tacle, a high voltage test must be
carried out.
X Before commissioning the receptacle, it must be
tested in accordance with EN 50215.
5.6 Disassembly of Replacement Insert
and Crimp Adapter
Special Tools Required
Pull o tool for pulling o the crimp adapter from the
replacement insert, ordering code: UIC DWZ, also refer
to chapter „8. Special Tools“.
Disassembly
X Dismount the coupling receptacle from the vehi-
cle wall / mounting surface and take it o from the
replacement insert.
X Pull the replacement insert (A) with crimp adapter
(B) and connector cable (C) out of the interior of
the vehicle through the mounting hole in the vehi-
cle wall so that the replacement insert (A) and the
crimp adapter (B) are exposed (Fig. 14).
AB
C
Fig. 14: Replacement insert (A) with crimp adapter (B)
and connector cable (C)
X Take the pull o tool and prepare as follows:
1) Release the 2 screws (D) of the pull o tool until
the springs (E) are stress-free (Fig. 15).
2) Totally unscrew screw (F) so that the clamp of
the pull o tool can be opened.
X Then lay the pull o tool around the crimp adapter
in such a way that the retaining clips (G) touch the
edge of the replacement insert.
X Screw down screw (F) until the pull o tool rmly
clasps the crimp adapter.
D
F
GE
Fig. 15: Put on pull o tool

16 2016-08-25 / V1.0
Installation
Connectors UIC 558 – Installation and Maintenance Instructions
X Tighten the 2 screws (D) until the crimp adapter
loosens from the replacement insert and can be
taken o (Fig. 16).
DD
Fig. 16: Pull o crimp adapter from the replacement insert
X To remove the pull o tool, release screw (F) and
open the clamp (Fig. 17).
F
Fig. 17: Remove pull o tool
5.7 Installing the Dummy Receptacle
Installation
The dummy receptacle is installed in the same way as
the coupling receptacles. The dummy receptacle uses
an unpopulated insert without cable and contacts in-
stead of the assembled socket insert with connector
cable or replacement insert with crimp adapter.
X Install the dummy receptacle as described under
„5.3 Installing Coupling Receptacles“.
X Insert an unpopulated insert instead of the assem-
bled socket insert/replacement insert.
Test
X Check that all of the installed parts are in the cor-
rect position and function properly.
X Check the functionality of the receptacle lid.
Commissioning
DANGER
In the case of a contact of the traction
current line with the vehicle, the dum-
my receptacle may be highly energised.
Deadly hazard!
X Before commissioning the dummy
receptacle, a high voltage test must
be carried out.
X Before commissioning the dummy receptacle, it
must be tested in accordance with EN 50215.
5.8 Installing Wall-mount Cable Glands
for Cable Plugs with Connector
Cable
The connector cables have to be installed in such a way
that they are free from undue tensile, pressure, exing
and torsion loads.
We recommend using the UIC KK D2 wall-mount cable
gland for installation on the vehicle body.
Preparing measures
For the installation of wall-mount cable glands, a
mounting hole with 30 mm diameter has to be provid-
ed in the vehicle wall.

17
2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Installation
Installation
FCEDG
36
B
A
OutsideInside
Fig. 18: Wall-mount cable gland UIC KK D2
A Mounting hole Ø 30 mm
B Vehicle wall
C Nut
D Spring washer
E Supporting ring
F Strain relief tting
G Tension screw
NOTICE
To ensure the proper operation, the socket insert and
the contacts may not be under tension.
X Make sure that the specied bending ra-
dius is observed when laying the cables:
8 x cable diameter = 145 mm
X Thread tension screw (G) and strain relief (F) on the
open end of the assembled connector cable.
X Lead the connector cable from the outside
through the mounting hole (A) (Ø30mm) in the
vehicle wall (B) to the inside.
X Thread supporting ring (E), spring washer (D) and
nut (C) from the inside on the connector cable and
attach to the thread of the strain relief (F).
X Screw nut (C) only slightly on the thread of the
strain relief (F).
X Adjust all of the parts and fasten nut (C).
(Tightening torque: 3 Nm)
X Establish strain relief and screw clamping screw
(G) into the strain relief (F).
(Tightening torque: 3 Nm)
Test
X Check that all of the installed parts are in the cor-
rect position.
X Make sure that there are no undue tensile, pres-
sure, exing and torsion loads on the connection
cables.
X All contacts must be aligned, i.e. they must not be
crooked.
X Make sure the strain relief ts properly.
Commissioning
DANGER
In the case of a contact of the traction
current line with the vehicle, the cable
plug with connector cable may be high-
ly energised. Deadly hazard!
X Before commissioning the ca-
ble plug with connector cable,
a high voltage test must be carried
out.
X Before commissioning the plug connection, it
must be inspected in accordance with EN 50215.
5.9 Storage of Connector Cables
When storing double ended connector cables in the
carriages or driver’s cabins, make sure the bending ra-
dius (based on the cable type) is observed and that the
cable is protected against shocks and dirt.

18 2016-08-25 / V1.0
Plugging Procedure
Connectors UIC 558 – Installation and Maintenance Instructions
6. Plugging Procedure
For the plugging procedure observe the requirements
in chapter „2.3 Intended Use“.
WARNING
Dirt, moisture, snow and ice in the interior of coupling receptacles or dummy receptacles contami-
nate the plug. The coupling of a contaminated plug to the coupling receptacle may lead to electric
shock, short circuit and damage to the connectors!
X Always check if the interior of the receptacles is free from dirt, moisture, snow and ice before
inserting a plug into a coupling receptacle or a dummy receptacle.
X Do not insert a plug into a receptacle when the latter is contaminated, moist or contaminated
with snow and ice.
X Remove dirt, moisture, snow and ice without residues from the interior of receptacles and from
the plug.
X Never couple a contaminated plug to the coupling receptacle.
WARNING
The plugging and disconnecting of the connectors on-load can cause electric arcs. When explosive
substances or ignition sources of any kind are nearby, there is a risk of re and explosion!
X Never plug and disconnect the connectors on-load.
CAUTION
The connectors contain sharp-edged components as well as components which are subject to me-
chanical tension. Crushing hazard / risk of injury!
X Wear safety gloves when plugging and disconnecting the connectors.
CAUTION
The connectors may grow warm during operation and they may become hot depending on the
ambient temperature and the conditions of use. Risk of burn to the hands!
X Wear safety gloves when plugging and disconnecting the connectors in the case of a high
ambient temperature.

19
2016-08-25 / V1.0 Connectors UIC 558 – Installation and Maintenance Instructions
Plugging Procedure
NOTICE
Inappropriate handling when plugging or disconnecting may damage the connectors. The functional safety of
the connectors is no longer guaranteed when parts are damaged.
X Make sure that the slots (1) and guideways (2) of receptacle and plug always interlock when plugging
(Fig. 19)!
X Take care that plug and receptacle do not tilt and that they are plugged without force.
X Make sure before the plugging procedure that plug and receptacle as well as the hinged lid of the recepta-
cle are not contaminated. Remove any existing dirt.
X Make sure that when not mated,
-the plug is always inserted into a dummy receptacle,
-the hinged lid of receptacles is closed according to its intended use.
X Open the hinged lid of the receptacle by an angle of at least 110° but not more than 130° (refer to Fig. 20).
Overstretching of the hinged lid may shorten the operational life span of the torsion spring and may dam-
age the hinge mechanism.
X Always close the hinged lid by hand, don’t let it slam!
Receptacle Plug
1
2
Fig. 19: Slots (1) on receptacle and guideways (2) on plug
Note:
In case of a very low or very high ambi-
ent temperature which approximates the
limits of the allowable operating tem-
perature range specied in our catalogue
F120.en in section “Specications”,
-a higher eort may be needed for the
plugging and unplugging and
-the operational life span of plug and
coupling receptacle may thus be re-
duced due to increased wear and tear.

20 2016-08-25 / V1.0
Plugging Procedure
Connectors UIC 558 – Installation and Maintenance Instructions
6.1 Plugging
X Open the hinged lid (3) of the coupling receptacle
(4).
In doing so, observe the opening angle:
-at least 110 °
-but not more than 130 °
max. 130 °
min. 110 °
3
4
Fig. 20: Open the hinged lid (3) of the coupling receptacle (4):
Opening angle at least 110 °, at most 130 °
X Position the plug (5) in such a way that the arrow
(6) on the plug is congruent with the arrow (7) on
the hinged lid of the coupling receptacle (4).
6
7
4
5
Fig. 21: Align arrow (6) on plug congruent with arrow (7) on
the receptacle lid
Then insert the plug in such a way that the guide-
ways (2) in the plug slide without much eort into
the slots (1) of the receptacle (refer to Fig. 19).
In doing so, take care
-that plug and receptacle are aligned axially (a
plug set diagonally by more than 8 ° cannot be
plugged by hand anymore!),
-that the plug is completely (ush) inserted in
the receptacle.
X After that close the hinged lid (3) by hand until the
locking mechanism (8) on lid and plug latches.
3
8
Fig. 22: Close the hinged lid (3) by hand until the locking
mechanism (8) on lid and plug latches
6.2 Unplugging
X Open the hinged lid (3) of the coupling receptacle
(4). In doing so, observe the opening angle:
-at least 110°
-but not more than 130°
X Hold the hinged lid (3) and take o the plug (5)
from receptacle (4). Only pull on the plug, not on
the cable.
X Close the hinged lid (3) by hand until the locking
mechanism (9) on lid and receptacle shell latches.
3
9
9
4
Fig. 23: Close the hinged lid (3) of the coupling receptacle (4)
by hand until the locking mechanism (9) latches