En Ac Brands 03

We keep on moving
Business Unit Automotive Cables
The Quality Connection

2 Automotive Cables business unit www.leoni-marine-technologies.com
www.leoni-automotive-cables.com
About us
Page 4
Single-core cables
Unshielded, shielded, compliant

with international standards.
Our Automotive Cables business unit stands in first place Page 5

worldwide as a manufacturer of single-core automotive LEONI Mocar ®
cables. In the ABS/sensor cable segment we are number 1
High temperature resistant auto-
in Europe and North America, as we are Europe-wide in
motive cables for powertrain and
the automotive coaxial cable segment. engine compartment.
Being present locally to our customers is at the core of all

the Automotive Cables business unit’s activity. Through this
close contact with you we can identify requirements and Page 6
market demand at an early stage and develop innovative Compacted strands
solutions together with our direct and indirect customers. and conductors
The basis for our successful growth lies in our service as well
The alternative for reducing
as in the stability and ongoing optimisation of our production the weight of cables.
processes – the proverbial LEONI quality.
The international outlook of our Automotive Cables business

unit and its worldwide production network underpin the Page 7
proximity to customers. FLRMSY brass
Alternative conductor material

for vehicle signal cables.
Our claim:
Quality and environmental awareness
All the facilities of the Automotive Cables business unit are

ISO9001:2000 certified. All facilities that make automotive Page 8
cables are ISO/TS 16949:2002 certified. Aluminum (battery)
cables
Our organisation is DIN EN ISO 14001:2005 certified and ensures
pro-active and effective implementation of our environmental to copper.
policy. Scheduled audits monitor and ensure that the objectives
of our environmental policy are continually realised and devel-
oped, and that requirements under environmental legislation
are observed. Page 9
LEONI Hivocar ®
High voltage cables for electric
Dated: October 2008 vehicles and vehicles with hybrid
Technical changes excepted. and fuel cell power.
www.leoni-automotive-cables.com Automotive Cables business unit 3
Our areas of expertise

Overview of all brands and product groups.
Page 10
LEONI Adascar ®
Comfort / Control / Power
Multi-core automotive cables with
sheath; shielded and unshielded.
Page 12
LEONI Adascar ®
Safety
Multi-core automotive cables for
safety applications.
Page 13
LEONI Adascar ®
Truck
ADR-certified multi-core automotive
cables for commercial vehicles.
Page 14
LEONI Adascar ®
Wheel Sensor
Sensor cables for driver assistance
and active safety systems in the
axel wiring.
Page 15
SHC
Special heating cables for seat
heaters and other applications in
vehicles.
Page 17 Page 16
You will find the contacts
for the individual product LEONI Dacar ® LEONI Dacar ®
areas on our website at Coaxial cables Multi-core data cables
www.leoni-automotive- Coaxial cables (asymmetric) for Symmetric data transmission
cables.com antennas made for all special and cables for a wide variety of
under Products & Solutions. standard applications. telematic systems.
4 Automotive Cables business unit www.leoni-automotive-cables.com
Single-core cables
Your way to be connected.
Excerpt of LEONI’s product range.
Description Code Nominal cross section Insulation Temperature range

mm2
Single-core cables – unshielded

PVC automotive cable FLY 0.5 – 120 plasticised PVC –40 °C to +105 °C
PVC automotive cable, hot-pressure resistant FLYW 0.5 – 25 plasticised PVC –40 °C to +125 °C
PVC automotive cable, cold resistant, FLYK 0.5 – 2.5 plasticised PVC –50 °C to +105 °C
with increased flexibility
PVC automotive cable, cold and heat resistant FLYWK/FLRYWK 0.5 – 2.5 plasticised PVC –50 °C to +105 °C
PVC automotive cable with symmetric FLRY-A 0.22 – 2.5 plasticised PVC –40 °C to +105 °C
conductor (Type A) and thin wall insulation
PVC automotive cable with asymmetric FLRY-B 0.35 – 25 plasticised PVC –40 °C to +105 °C
conductor (Type B) and thin wall insulation
PVC automotive cable, hot-pressure resistant, FLRYW 0.35 – 25 plasticised PVC –40 °C to +125 °C
with thin wall insulation
PVC automotive cable according to PSA standard FLRY T2 IR 0.35 – 7 plasticised PVC –40 °C to +105 °C
PVC automotive cable according to PSA standard FLRY T2 ID 0.35 – 7 plasticised PVC –40 °C to +105 °C
PVC automotive cable, hot-pressure resistant (PSA) FLRY T3 IR 0.35 – 7 plasticised PVC –40 °C to +125 °C
PVC automotive cable, hot-pressure resistant (PSA) FLRY T3 ID 0.35 – 7 plasticised PVC –40 °C to +125 °C
PA automotive cable (Type A) FLR4Y-A 0.35 – 2.5 PA (polyamide) –40 °C to +105 °C
PA automotive cable (Type B) FLR4Y-B 0.35 – 4 PA (polyamide) –40 °C to +105 °C
SAE compliance
XLPE automotive cable, thin wall with TXL , SXL 0.35 – 5 XLPE (polyethylene, –40 °C to +125 °C
crosslinked insulation according to SAE J 1128 crosslinked), flame retardant
PVC automotive cable, thin wall TWP , GPT, HDT 0.35 – 5 PVC (polyvinylchloride) –40 °C to +85 °C/+105 °C
according to SAE J 1128
JASO compliance
PVC automotive cable AV 0.5 – 35 PVC (polyvinylchloride) –40 °C to +85 °C
according to JASO D 609-90
PVC automotive cable AVS 0.3 – 8 PVC (polyvinylchloride) –40 °C to +85 °C
PVC automotive cable, thin wall AVSS 0.3 – 1.25 PVC (polyvinylchloride) –40 °C to +85 °C
Automotive cable, thin wall AVX, AVSSX, AVSSH, 0.35 – 5 PVC crosslinked –40 °C to +100 °C
according to JASO D 609-90 HFS, HFSS 0.35 – 5 ZH TPE (halogen free) –40 °C to +85 °C
CAVS, CHFS, CHFUS 0.35 – 5 PVC/ZH TPE (halogen free) –40 °C to +85 °C
(compressed)
Automotive cable with core insulation and PVC sheath FLYY 0.5 – 2.5 plasticised PVC –40 °C to +105 °C
Automotive cable according to JASO D 609-90 AEX 0.75 – 8.0 XPE –40 °C to +125 °C
Single-core cables – shielded

PVC cable, shielded, FLRYDY 0.75 – 1.5 plasticised PVC –40 °C to +105 °C
with reduced insulation and sheath wall thickness
LEONI Mocar ®
Beat the heat.
High temperature resistant automotive cables

for powertrain and engine compartment.
BENEFITS / PROPERTIES Cables in engine compartments must be particularly heat

■■ temperature resistant to +260 °C resistant because of the high temperatures prevailing in these
■■ flame retardant areas. We have developed special insulation materials to meet
■■ space and weight saving due to reduced this requirement.
insulation wall thicknesses LEONI Mocar® cables are also available in halogen-free versions.
■■ ultra thin-wall versions optional (in some cases)
■■ good media resistance STANDARDS
Compliant with ISO 6722, LV 112 and customer specifications.
APPLICATIONS
■■ engine compartment
■■ exhaust system
■■ temperature sensors

mm2
Single-core cables – unshielded

PP automotive cable, LEONI Mocar 125 P 0.22 – 35 PP-FR –40 °C to +125 °C
heat resistant, with thin wall insulation (polypropylene, flame retardant)
PE-X automotive cable, LEONI Mocar 125 XE Type A ➔ 0.22 – 2.5 PE-X halogen free –40 °C to +125 °C
heat resistant, with thin wall insulation HFFR Type B ➔ 0.35 – 6 (polyethylene, crosslinked)
PE-LH automotive cable, LEONI Mocar 125 XS Type A ➔ 0.22 – 2.5 PE-LH low halogen –40 °C to +125 °C
heat resistant, with thin wall insulation Type B ➔ 0.35 – 6 (polyethylene, crosslinked)
TPE-S insulation, flexible application LEONI Mocar 125 S 0.35 – 6 TPE-S –50 °C to +125 °C
Vehicle battery cable, LEONI Mocar 125 R 16 – 70 TPE-O –40 °C to +125 °C
heat resistant (thermoplastic polyester
elastomer based on polyolefin)
Automotive cable, LEONI Mocar 150 A Type A ➔ 0.35 – 2.5 TPE-E (thermoplastic –40 °C to +150 °C
heat resistant, with TPE-E insulation Type B ➔ 0.35 – 6 polyester elastomer)
Automotive cable, LEONI Mocar 180 E Type A ➔ 0.35 – 2.5 ETFE –65 °C to +180 °C
heat resistant, with ETFE insulation Type B ➔ 0.35 – 4 (ethylene tetrafluoroethylene)
Automotive cable, LEONI Mocar 210 F Type A ➔ 0.35 – 2.5 FEP (tetrafluoroethylene –65 °C to +210 °C
heat resistant, with FEP insulation Type B ➔ 0.35 – 4 hexafluoropropylene)
Automotive cable, LEONI Mocar 260 T 0.35 – 4 PFA –80 °C to +260 °C
high temperature resistant, with PFA insulation (perfluoralkoxy copolymer)
Compacted strands and conductors

Also for ISO cross sections.
The alternative for reducing the weight

of cables.
BENEFITS / PROPERTIES The “compacting” process involves the strand being pressed
■■ reduced diameter / thinner wall thickness using an additional drawing die and thus being tapered.
■■ saving of insulation material As a result, the profile of the copper conductor becomes rounder
■■ substantial weight reduction and its diameter is reduced, thereby achieving thinner cable wall
■■ for fixed installation thicknesses.
STANDARDS
APPLICATIONS Compliant with ISO 6722, JASO and customer specifications.
■■ areas with tight installation space
WEIGHT REDUCTION
Example: max. Ø max. Ø Weight reduction
ISO cross sections Cross section FLRY (PVC) CFLUNY (halogen free) CFLUNY
mm2 mm mm %
0.22 1.2 1.05 17.6

0.35 1.4 1.20 12.7
0.50 1.6 1.40 15.5
0.75 1.9 1.60 16.1
FLY 0.5 mm 2
FLRY 0.5 mm 2
CFLUNY 0.5 mm 2
1.00 2.1 1.75 14.8
min. wall thickness min. wall thickness min. wall thickness 1.50 2.4 2.10 7.7
0.48 mm 0.22 mm 0.16 mm 2.50 3.0 2.70 13.7
Comparison of conductor types for thin-wall dimensions
Standard: ISO 6722 JASO D611-94 Compacted, halogen free cables

Code min. wall thickness Code min. wall thickness Code min. wall thickness
FLY 0.5 0.48 mm AVS 0.32 mm CHFS 0.32 mm
FLRY 0.5 0.22 mm AVSS 0.24 mm CHFSS 0.24 mm
FLUY 0.5 0.16 mm
CFLUNY 0.16 mm CHFUS 0.16 mm
FLRMSY brass
A traditional material for innovative applications.

for vehicle signal cables.
BENEFITS / PROPERTIES LEONI offers standard automotive cables with brass conductors
■■ increased tensile strength for use as signal cables.
■■ reduction in conductor cross section from 0.35 to 0.22 mm2
with minimum tensile strength of 70 N and a weight saving Brass is a modern material with a long tradition. The material
of approx. 1.5 kg per km is used in both everyday and also highly technical applications.
■■ greater flexibility compared with copper
■■ maintaining the mechanical properties with respect to Brass is an alloy of copper and zinc. The common compounds
processing contain zinc proportions of between 5 and 45 %.
STANDARDS
Compliant with ISO 6722, LV 112 and customer specifications.
APPLICATIONS
■■ signal cables

mm2
Single-core automotive cable FLRMSY 0.17-A 0.17 plasticised PVC, –40 °C to +105 °C
with reduced wall thickness and brass conductor lead free
Single-core automotive cable FLRMSY 0.22-A 0.22 plasticised PVC, –40 °C to +105 °C
with reduced wall thickness and brass conductor lead free
Aluminum (battery) cables

Maximum performance – minimum weight.
Alternative conductor material to copper.
BENEFITS / PROPERTIES Saving weight and therefore also fuel is a determining issue
■■ up to 40 % lighter than copper in the automotive industry. Replacing the conventional
■■ temperature resistant to +125 °C copper alloys with aluminum makes it possible to achieve
■■ conductor material: aluminum 99.7 % / aluminum alloy major weight savings. This applies to both smaller cross
sections and battery cables with large cross sections.
STANDARDS
Compliant with ISO 6722, LV 112-2 and customer specifications.

mm2
Automotive cable with aluminum conductor FLRALY 0.35 – 6.0 plasticised PVC, lead free –40 °C to +105 °C
Vehicle battery cable FLAL91Y T125 10 – 160 TPE-O –40 °C to +125 °C
with aluminum conductor (thermoplastic polyolefin elastomer)
Vehicle battery cable FLALY T105 10 – 160 plasticised PVC, lead free –40 °C to +125 °C
with aluminum conductor
LEONI Hivocar ®
Powered by progress.
High voltage cables for electric vehicles

and vehicles with hybrid and fuel cell power.
BENEFITS / PROPERTIES The carmakers are developing vehicles with alternative drive
■■ specially selected materials for high voltage applications technology to protect the environment and reduce CO2 emissions.
■■ very good thermal properties up to 200 °C (240 hrs)
■■ very good mechanical properties These require special high-voltage cables in the wiring system.
■■ highly flexible for bending radii up to 3 x d, shielded, And these are available in both copper and aluminum versions.
to avoid EMC problems
■■ high current carrying capacity up to 450 A STANDARDS
■■ aluminum version for weight optimisation Compliant with ISO 6722 for 600 V and customer specifications.
APPLICATIONS
■■ air conditioning compressors
■■ DC/DC converters
■■ electric heating
■■ HV battery connections
■■ connection for the electric drive motor
Excerpt from our present product portfolio
Description Code No. of cores Shield type Nominal cross section Insulation/Sheath Temperature range
mm2
High voltage cable LEONI Hivocar 105-F High flex braids made 0.5 PVC/PVC –40 °C to +105 °C (3000 hrs)
Single- and of tinned copper wires
High voltage cable LEONI Hivocar 125-F multi-core Nom. surface coverage: 95 %. 0.5 – 240 TPE-O/TPE-U –40 °C to +125 °C (3000 hrs)
cables Optional: Combination with
High voltage cable LEONI Hivocar 150-F foil shield. 0.5 – 240 XPE/TPE-U –40 °C to +150 °C (4000 hrs)
LEONI Adascar® Comfort / Control / Power

Advanced Automotive Special Cables.
Multi-core automotive cables with sheath;

shielded and unshielded.
BENEFITS / PROPERTIES The LEONI Adascar® Comfort, Control and Power family products
■■ customer-specific cables available are geared precisely to their respective applications. The materials are
■■ shielded versions selected according to the mechanical, thermal and electrical require-
■■ certified according to international standards ments, and the cables are designed to the customer’s specifications.
■■ extensive OEM approvals
The assembly, contacts and laying are also important criteria in
passenger cars, and which play a considerable role in the design
APPLICATIONS of multi-core automotive cables. Special media resistance deviating
from the international standards (e.g. AdBlue®), as well as environ-
LEONI Adascar® Comfort mental influences or customer-specific properties such as being
■■ seat systems, power windows, mirror wiring halogen free or flame retardant are requirements that are, in an
■■ heating, ventilation and climate control systems application-specific way, already taken into account in the design
■■ consumer electronics phase.
■■ car phone
■■ convertible roof, tailgate and sun roof systems
■■ park assist
■■ driver authentication system
LEONI Adascar® Control

■■ sensor applications
■■ knock sensor
■■ weight sensor
■■ rain sensor
■■ engine management sensor
■■ fill level sensor
■■ occupant recognition
LEONI Adascar® Power

■■ lighting and cabling systems
■■ wiring of electrical equipment (in board and out board, bodywork)
■■ engine compartment, catalytic converter
■■ power distributors
TYPES OF SHIELD FOR FILTERING EMC INTERFERENCE STANDARDS

■■ B shield: Foil shield, usually spirally wrapped, overlapping Compliant with ISO 6722, LV 112, ISO 14572, LV 212, JASO
aluminum-coated foil. Drain wire or conductive core for and customer specifications.
easy electric contact by means of insulation displacement
connection (IDC) or crimping.
■■ D shield: spiral shield made of copper wires
■■ C shield: wire braid made of copper wires
Description Type according No. of Nominal Insulation Shield type Insulation Standard Temperature
to DIN/JASO cores6 cross section range
mm2
Cables up to 105 °C
Round cable AVSS 1–4 0.3 to 2.0 PVC – PVC JASO –40 °C to +85 °C
Round cable with ASW 1–4 0.3 to 2.0 PVC B shield with PVC JASO –40 °C to +85 °C
complete shielding drain wire
Round cable with AVSS-SW 1–4 0.3 to 2.0 PVC D shield PVC JASO –40 °C to +85 °C
complete shielding
Round cable with AVSS-BS 1–4 0.3 to 2.0 PVC C shield PVC JASO –40 °C to +85 °C
complete shielding
Round cable FLYY 2 – 19 0.5 to 4.0 PVC – PVC ISO 14572 –40 °C to +105 °C
Round cable with FLRYY 2 – 19 0.5 to 4.0 PVC – PVC ISO 14572 –40 °C to +105 °C
reduced core wall thickness
Round cable with FLRY(B/D/C)Y 1–7 0.22 to 2.5 PVC B shield PVC ISO 14572 –40 °C to +105 °C
complete shielding D shield
C shield
Flat cable FLRYYF 2–4 0.22 to 2.5 PVC – PVC ISO 14572 –40 °C to +105 °C
Twin cable FLRYZ 2 0.22 to 2.5 PVC – – ISO 6722 –40 °C to +105 °C
Round cable FLRY(B/D/C)11Y 2 – 19 0.5 to 4.0 PVC B shield TPE-U ISO 14572 –40 °C to +105 °C
D shield
C shield
Flat cable FLRY(Y)11YF 2 0.5 to 1.5 PVC – (PVC)/TPE-U ISO 14572 –40 °C to +105 °C
Round cable FLRY91Y 2 0.22 bis 0.37 PVC – TPE-O ISO 14572 –40 °C to +105 °C
Coilable round cable FLR12Y11Y 2–7 0.22 bis 1.5 TPE-E – TPE-U ISO 14572 –40 °C to +105 °C
Round cable FLRYWYW 2 – 19 0.5 to 4.0 PVC – PVC ISO 14572 –40 °C to +125 °C
Twin cable FLRYWZ 2 0.22 to 2.5 PVC – – ISO 14572 –40 °C to +125 °C
Flat cable FLRYWYWF 2–4 0.22 to 2.5 PVC – PVC ISO 14572 –40 °C to +125 °C
Round cable with and FLRYW(B/D/C)YW 1–7 0.22 to 2.5 PVC B shield PVC ISO 14572 –40 °C to +125 °C
without complete shielding D shield
C shield
Round cable with and FLR91Y(B/D/C)11Y 1–7 0.22 to 2.5 TPE-O B shield TPE-U ISO 14572 –40 °C to +125 °C
C shield
Round cable with and FLR12Y(B/D/C)11Y 1–7 0.22 to 2.5 TPE-E B shield TPE-U ISO 14572 –40 °C to +125 °C
C shield
Round cable with and FLR2X(B/D/C)11Y 1–7 0.22 to 2.5 PE-X B shield TPE-U ISO 14572 –40 °C to +125 °C
C shield
Round cable with and FLU7Y(D/C)11Y 1–7 0.14 to 1.0 ETFE D shield TPE-U ISO 14572 –40 °C to +150 °C
without complete shielding C shield
Round cable with and FLU6Y(D/C)11Y 1–7 0.14 to 1.0 FEP D shield TPE-U ISO 14572 –40 °C to +150 °C
Cables above 150 °C
Round cable with and FLU7Y(D/C)7Y 1–7 0.14 to 1.0 ETFE D shield ETFE ISO 14572 –65 °C to +180 °C
Round cable with and FLU7Y(D/C)7Y 1–7 0.14 to 1.0 FEP D shield FEP ISO 14572 –65 °C to +210 °C
6 Further types upon request.
LEONI Adascar ® Safety

Multi-core automotive cables

for safety applications.
BENEFITS / PROPERTIES The LEONI Adascar® Safety product range is used in all safety-related
■■ excellent processability applications in vehicles. These jacketed cables are the perfect solution
■■ extensive OEM approvals for a very wide variety of restraint and safety systems because of
■■ customised solutions their good mechanical properties.
■■ worldwide production facilities
Its easy stripping and suitability for injection-mold qualifies the
LEONI Adascar® Safety cable for various refining processing.
APPLICATIONS The product family is made of high-quality materials – in compli-
■■ impact protection (airbag) ance with the international standards – and is subject to strictest
■■ restraint systems (belt) re-qualification tests.
■■ active headrest, seats, engine cover (pre/in crash)
■■ locking systems, clamping protection STANDARDS

■■ chassis safety Compliant with ISO 6722, LV 112, ISO 14572, LV 212
■■ pre-impact warning sensors, distance controller and customer specifications.
(collision avoidance)

Description Code No. of cores Nominal cross section Insulation Sheath Temperature range
mm2
Round cable LEONI Adascar Safety 2020 2x0,5-A 2 0.5 PVC PVC –40 °C to +105 °C
Round cable LEONI Adascar Safety 2025 2x0,5sn-A 2 0.5 PVC PVC –40 °C to +105 °C
Flat cable LEONI Adascar Safety 2520-F 2x0,5-A 2 0.5 PVC PVC –40 °C to +105 °C
Flat cable LEONI Adascar Safety 2511-F 2x0,35-A 2 0.35 PVC PVC –40 °C to +105 °C
Round cable LEONI Adascar Safety 2710 2x0,22-A 2 0.22 PVC TPE-O –40 °C to +90 °C
LEONI Adascar® Truck

ADR-certified multi-core automotive cables

for commercial vehicles.
BENEFITS / PROPERTIES Automotive LEONI Adascar® Truck cables are extremely robust and made with
■■ with ADR/GGVS certificates the adequate sheathing material to suit the respective requirement.
■■ with integrated data pair LEONI also offers coilable versions with materials that have excellent
■■ coilable versions reset force.
■■ with double jacket
With the specified capacitance according to ISO 4141, data of the
electronic brake system can be transmitted with the integrated
APPLICATIONS data pair cable.
■■ cable to connect the tractor and trailer or semi trailer
■■ wiring of the electrical equipment STANDARDS

■■ front, rear and side illumination as well as cabling systems Compliant with ISO 6722, LV 112, ISO 14572, LV 212, JASO 4141
and customer specifications.

Description Code No. of cores Nominal Insulation Sheath Temperature range
cross section
mm2
Power supply cable LEONI Adascar Truck 10xxx 1 – 15 0.5 – 6.0 PVC PVC –40 °C to +105 °C
Power supply cable flat version LEONI Adascar Truck 11xxx 2 0.5 – 1.5 PVC PVC –40 °C to +105 °C
Power supply cable LEONI Adascar Truck 14xxx 1 – 15 0.5 – 6.0 PVC TPE-U –40 °C to +105 °C
Power supply cable flat version LEONI Adascar Truck 14xxx 2 0.5 – 1.5 PVC TPE-U –40 °C to +105 °C
Double jacket cable LEONI Adascar Truck 12xxx 1 – 15 0.5 – 6.0 PVC PVC/TPE-U –40 °C to +105 °C
Double jacket cable flat version LEONI Adascar Truck 13xxx 2 0.5 – 1.5 PVC PVC/TPE-U –40 °C to +105 °C
Power supply cable
LEONI Adascar Truck 15xxx 1 – 15 0.5 – 6.0 PVC/PP PVC –40 °C to +90 °C
with integrated data pair
Coilable cable
LEONI Adascar Truck 16xxx 1 – 15 0.5 – 6.0 TPE–O/PP TPE–E –40 °C to +90 °C
with integrated data pair
LEONI Adascar® Wheel Sensor

Sensor cables for driver assistance and active

safety systems in the axel wiring.
BENEFITS / PROPERTIES Anti-lock braking systems have been in use for more than 25 years
■■ highly flexible already. Their development is nevertheless still nowhere near com-
■■ available in halogen-free version pleted. Consumers respond exceptionally sensitively in particular to
■■ extremely high abrasion resistance the subject of safety in vehicles, and welcome any improvement.
■■ very good media resistance Originally the objective was only to prevent the wheels from locking
■■ long-term temperature resistance to +150 °C under braking and to improve the vehicle’s tractability and stability.
■■ resistant to charring
■■ resistant to hydrolysis Over time these systems were developed further. Nowadays accelera-
■■ bending strength tion skid control, brake wear indicators and the electronic stability
■■ recyclability programme (ESP) are among the standard features offered by vehicle
manufacturers.
APPLICATIONS STANDARDS
■■ ABS/ESP sensor cables Compliant with customer specifications.
■■ ABC (active body control)
■■ brake wear indicator
■■ sensor cables for automatic regulation of head lamp leveling
■■ extension cables for ABS systems on trucks and trailers
Description Code No. of cores Nominal cross section Insulation Temperature range
mm2
Cable with EVA insulation LEONI Adascar 125 G… ≥2 ≥ 0.35 EVA –40 °C to +125 °C
(ethyl vinyl acetate)
Cable with PE-X insulation LEONI Adascar 125 X… ≥2 ≥ 0.35 PE-X –40 °C to +125 °C
(polyethylene, crosslinked)
Cable with TPE-S insulation LEONI Adascar 125 S… ≥2 ≥ 0.35 TPE-S –40 °C to +125 °C
(thermoplastic styrene
block copolymer)
Cable with PVC insulation LEONI Adascar 105 V… ≥2 ≥ 0.35 PVC (polyvinylchloride) –40 °C to +105 °C
Sensor cables for high LEONI Adascar 150 E… ≥2 ≥ 0.35 ETFE –40 °C to +150 °C
temperature applications
SHC
Special Heating Cables.
Special heating cables for seat heaters

and other applications in vehicles.
BENEFITS / PROPERTIES
DESIGNS
■■ narrow tolerances in terms of electrical resistance Conductor
■■ highly flexible Soft-annealed, DIN EN 13602 (C) compliant electrolyte copper Cu-ETP1
■■ very good mechanical performance Tinsel: Core thread braided with laminated copper wires (T)
■■ small diameter Conductor made of enamelled wires: single wires with lacquer coat (E)
■■ insulation materials with good thermal conductivity Hybrid conductor: strand with single wires made of various metals (H)
■■ media resistance Special conductor with strain reinforcement elements (R)
Insulation
PVC (Y)
APPLICATIONS ETFE (7Y)
■■ seat heater cables FEP (6Y)
■■ heating cables for automotive applications
STANDARDS
In accordance with ISO 6722, LV 112 and customer specifications.

Code Electrical resistance at 20 °C Conductor Insulation Temperature range
Ω/km
LEONI SHC-Y-C 60 – 260 Cu PVC –40 °C to +105 °C
LEONI SHC-Y-A 550 – 4,500 CuNi alloy PVC –40 °C to +105 °C
LEONI SHC-Y-T 300 – 920 Cu tinsel PVC –40 °C to +105 °C
LEONI SHC-Y-H 350 – 600 Cu/CuNi alloy PVC –40 °C to +105 °C
LEONI SHC-7Y-C 60 – 260 Cu ETFE –65 °C to +180 °C
LEONI SHC-7Y-A 550 – 4,500 CuNi alloy ETFE –65 °C to +180 °C
LEONI SHC-6Y-C 60 – 260 Cu FEP –65 °C to +210 °C
LEONI SHC-6Y-A 550 – 4,500 CuNi alloy FEP –65 °C to +210 °C
LEONI Dacar® Multi-core data cables

Your link to mobile communication.
Symmetric data transmission cables

for a wide variety of telematic systems.
BENEFITS APPLICATIONS
■■ flexible CD changer, multimedia / MP3 player, TFT, reversing camera
■■ heat resistant system, Bus systems (Flexray/FireWire/CAN/USB), LVDS,
■■ very good transmission properties mobile phone interface and iPod.
■■ best coupling resistance and shield attenuation properties
■■ stable impedance
■■ lowest Alien Next PROPERTIES
■■ environmental properties/recyclability ■■ solid / foam dielectrics
■■ flame retardant ■■ standard temperature range –40 °C to +105 °C
■■ high mechanical resistance
Description Code No. of Shield type Nominal cross Dielectric Temperature

cores section (mm2) range
Image transmission
LVDS LEONI Dacar 502 4x2 aluminum-coated foil 0.22 PP –40 °C to +105 °C
Braid of tinned copper wires and drain wire (polypropylene)
LVDS LEONI Dacar 511 5x2 aluminum-coated foil 0.22 PP foamed –40 °C to +105 °C
Braid of tinned copper wires and drain wire (polypropylene)
Bus systems
CAN LEONI Dacar 562 2 unshielded 0.5 XPE –40 °C to +125 °C
Flexray LEONI Dacar 538 4 aluminum-coated foil 0.14 PP –40 °C to +105 °C
Braid of tinned copper wires
FireWire LEONI Dacar 536 4 aluminum-coated foil 0.14 PP –40 °C to +105 °C
USB LEONI Dacar 516 2+2 aluminum-coated foil 0.089/0.24 PP/PVC –40 °C to +105 °C
Special cables
LEONI Dacar 550 2 aluminum-coated foil, earth core with conductive PVC 0.35 PVC –40 °C to +105 °C
Hybrid designs
Car phone LEONI Dacar 590 10+Z50 aluminum-coated foil 0.22 ETFE/PE –40 °C to +85 °C
iPod interface LEONI Dacar 591 10 aluminum-coated foil 0.057/0.14 PP –40 °C to +105 °C
Braid of tinned copper wires (polypropylene)
TV tuner LEONI Dacar 805 5+ aluminum-coated foil 0.055/0.14 PE foamed –25 °C to +90 °C
4 x Z50 Shield of bare copper wires (polypropylene)
LEONI Dacar® Coaxial cables

Focused on communication.
Coaxial cables for antennas made for all

special and standard applications.
BENEFITS / PROPERTIES APPLICATIONS

■■ fits all standard components GSM, GPS/Galileo, DVB, radio, WCDMA, HSPDA, WLAN, WiMAX,
■■ excellent properties for processing mobile broadcast
■■ approvals for all major OEMs
■■ high degree of uptime CUSTOMISED OPTIMISATIONS OF
■■ best coupling resistance and shield attenuation properties ■■ High frequency properties such as
■■ stable impedance ➔ EMC properties

■■ low signal attenuation ➔ impedance
■■ best environmental properties/recyclability ➔ reflection and transmission parameters
■■ solid / foam dielectrics ■■ mechanical properties
■■ standard temperature range –40 to +85 °C/–65 to +205 °C ■■ chemical and thermal parameters based on own
■■ high mechanical resistance materials and high frequency laboratories

■■ standard diameter ranging from 1.6 to 6.7 mm
■■ standard impedances of 50/75/120/125/130 Ohm available
Description Code Impe- Shield type Nominal Dielectric Temperature

dance cross section range
mm2
HF coax cable LEONI Dacar 300 50 Braid of tinned copper wires of Electrolyte copper, 0.14 PP –40 °C to +105 °C
with solid Ø 1.92 mm, DIN EN 13602-compliant CU-ETP1, (polypropylene)
dielectric 90 % nom. visual covering
HF coax cable LEONI Dacar 302 50 aluminum-coated foil, Braid of tinned 0.4 Cell PP, –40 °C to +105 °C
with foamed copper wires, Ø 2.6 mm, DIN EN 13602-compliant CU-ETP1, foamed
dielectric 90% nom. visual covering (polypropylene)
HF coax cable LEONI Dacar 380 50 aluminum-coated foil, Braid of tinned copper wires, 0.22 Cell PP, –40 °C to +105 °C
with foamed Ø 2.03 mm, DIN EN 13602-compliant CU-ETP1, foamed
dielectric 80 % nom. visual covering (polypropylene)
HF coax cable LEONI Dacar 037 50 aluminum-coated foil, Braid of tinned copper wires, 0.75 Cell PP, –40 °C to +105 °C
with foamed Ø 3.58 mm, DIN EN 13602-compliant CU-ETP1, foamed
dielectric 95 % nom. visual covering (polypropylene)
HF coax cable LEONI Dacar 200 75 Braid of tinned copper wires, 0.182 PE –40 °C to +85 °C
with solid Ø 3.7 mm, DIN EN 13602-compliant CU-ETP1, (polypropylene)
dielectric 95 % nom. visual covering
International standards
Automotive Cables
ISO 6722
FLRY Automotive standard cable with reduced insulation
FLRYW Automotive standard cable heat resistant with reduced insulation
FLY Automotive standard cable with PVC insulation, e.g. battery cables
LEONI Mocar® 125P Automotive standard cable with PP insulation
LEONI Mocar® 125XE Automotive standard cable with crosslinked PE insulation
LEONI Mocar® 180E Automotive standard cable with ETFE insulation
LEONI Mocar® 210F Automotive standard cable with FEP insulation
LEONI Mocar® 260T Automotive standard cable with PFA insulation
ISO 4141
FLRY(9Y)Y11Y Designs with double sheath (PVC + PU) and data pairs
FLRY(9Y)Y LEONI Adascar® Truck
ISO 14572
FLRY Y Multi-core automotive cable with reduced insulation
FLRYWYW Multi-core automotive cable heat resistant with reduced insulation
FLR9Y11Y Multi-core automotive cable with reduced PP insulation and TPE-U sheath
FLRYCY Multi-core automotive cable with reduced insulation and braiding of copper wires
FLRYDY Multi-core automotive cable with reduced insulation and spiral shield of copper wires
FLRYBY Multi-core automotive cable with reduced insulation and foil shield
FLRY Y11Y/FLRYYF LEONI Adascar® Comfort, LEONI Adascar® Control, LEONI Adascar® Power,
LEONI Adascar® Safety, LEONI Adascar® Truck
JASO D 609-90 Japanese Automobile Standard

AV Vinyl insulated low tension electric cable for automobiles
AVS Low tension cable with reduced outside diameter for automobiles, general wall thickness
AVSS Low tension cable with reduced outside diameter for automobiles, thin wall thickness
AVSSf Low tension cable with reduced outside diameter for automobiles, thin wall thickness, high flexibility
AVX Crosslinked vinyl heat-resistant low tension cable for automobiles
AEX Crosslinked polyethylene heat resistant low tension cable for automobiles
SAE J 1128/SAE J 1678 Society of Automotive Engineers

TWP Thin wall, thermoplastic insulated low tension main cable
GPT General purpose, thermoplastic insulated low tension main cable
HDT Heavy duty, thermoplastic insulated low tension main cable
TXL Thin wall, Cross (X) Linked polyolefin insulated low tension main cable
GXL General purpose, Cross (X) Linked polyolefin insulated low tension main cable
SXL Special purpose, Cross (X) Linked polyolefin insulated low tension main cable
WTA Ultra thin wall, PVC insulated low tension main cable
WXC Ultra thin wall, XLPE insulated low tension main cable
SAE/USCAR-23
SAE/USCAR-23 Single-core (ISO/METRIC) cable
Customer standards
FIAT 91107/17, 91107/18
VW 603 06
BMW GS 95007-1, GS 95007-2, GS 95007-3
Chrysler Chrysler LLC MS-7889, MS-8288
Daimler DBL 6312/MB 22014
Ford WSK 1A348-A2 + A3, ES-AU5T-1A348-AA, WSB-M1L134-A, WSS-M1L135-A,
ESB-M1L120-A, ESB-M1L123-A, WSB-M1L58-A, WSK-M1L124-A, ESA-M1L77-A
PSA 96 418 794 99, 96 638 214 99, B25 1110
MAN 3135
Bosch 5 970 66…, 5 998 340
Renault 36-05-009/--L, 36-05-045/---
GM GME 14022, GMW 15626
Volvo 7611, 131
Joint Company Standards (LV) BMW, DaimlerChrysler, VW, Porsche

LV112 FLY +85 °C – LEONI Mocar® +260 °C
LV115 LEONI exFC®
LV122 Twisted pair cable
LV212 LEONI Adascar® Comfort, LEONI Adascar® Control, LEONI Adascar®
Power, LEONI Adascar® Safety, LEONI Adascar® Truck
LV213 LEONI Dacar®
LEONI worldwide The latest from LEONI

Cable facilities of the LEONI Group
Germany ➔ LEONI Kabel GmbH Our regularly updated information services such as the
China ➔ LEONI Cable (Changzhou) Co. Ltd. customer publication “LEONI inTeam” keep you abreast of
Hungary ➔ LEONI Kábelgyár Hungaria Kft. recent developments at LEONI and on the market, either by
Poland ➔ LEONI Kabel Polska S.p.z.o.o. mail or by e-mail. So that we can tailor our choice of topics
Mexico ➔ LEONI Cable Mexico S.A. de C.V. even more closely to your requirements and interests, we would
Turkey ➔ LEONI Kablo ve Teknolojileri San. ve Tic. Ltd. Sti. be delighted to receive your suggestions and comments.
Slovakia ➔ LEONI Slowakia spol. s.r.o.
Production facilities of the Automotive Cables business unit
Poland
Germany Slovakia
Turkey
Mexico China
Proximity to our customers is a core element of our corporate policy. Visit our website
LEONI is a dependable partner to its customers – all over the world. www.leoni-automotive-cables.com
We also regard maintaining, as well as raising, quality and service at
the same high level everywhere in the world as a sign of proximity.
We support efficient operating as well as our customers’ power of

innovation and market position on the basis of our own international
positioning, standardised methods and clearly defined processes.
No matter where we apply and realise our know-how, commitment
and ideas: we want confident customers around the world.
LEONI Kabel GmbH Stieberstrasse 5
Automotive Cables D-91154 Roth
business unit Phone +49 (0)9171-804-2218
Fax +49 (0)9171-804-2232
Email cable-info@leoni.com
www.leoni-automotive-cables.com

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We keep on moving

Business Unit Automotive Cables

The Quality Connection

Unshielded, shielded, compliant

Our Automotive Cables business unit stands in first place Page 5

Being present locally to our customers is at the core of all

The international outlook of our Automotive Cables business

Alternative conductor material

All the facilities of the Automotive Cables business unit are

Our areas of expertise

Excerpt of LEONI’s product range.

Description Code Nominal cross section Insulation Temperature range

Single-core cables – unshielded

Single-core cables – shielded

High temperature resistant automotive cables

BENEFITS / PROPERTIES Cables in engine compartments must be particularly heat

Description Code Nominal cross section Insulation Temperature range

Single-core cables – unshielded

Compacted strands and conductors

The alternative for reducing the weight

0.22 1.2 1.05 17.6

Comparison of conductor types for thin-wall dimensions

Standard: ISO 6722 JASO D611-94 Compacted, halogen free cables

Alternative conductor material

Description Code Nominal cross section Insulation Temperature range

Aluminum (battery) cables

Alternative conductor material to copper.

Description Code Nominal cross section Insulation Temperature range

High voltage cables for electric vehicles

■■ connection for the electric drive motor

Excerpt from our present product portfolio

LEONI Adascar® Comfort / Control / Power

Multi-core automotive cables with sheath;

LEONI Adascar® Control

LEONI Adascar® Power

TYPES OF SHIELD FOR FILTERING EMC INTERFERENCE STANDARDS

■■ C shield: wire braid made of copper wires

Excerpt from our present product portfolio

LEONI Adascar ® Safety

Multi-core automotive cables

■■ locking systems, clamping protection STANDARDS

Excerpt from our present product portfolio

LEONI Adascar® Truck

ADR-certified multi-core automotive cables

■■ wiring of the electrical equipment STANDARDS

Excerpt from our present product portfolio

LEONI Adascar® Wheel Sensor

Sensor cables for driver assistance and active

■■ brake wear indicator

■■ sensor cables for automatic regulation of head lamp leveling

■■ extension cables for ABS systems on trucks and trailers

Special heating cables for seat heaters

Excerpt from our present product portfolio

LEONI Dacar® Multi-core data cables

Symmetric data transmission cables

■■ flame retardant ■■ standard temperature range –40 °C to +105 °C

■■ high mechanical resistance

Excerpt from our present product portfolio

Description Code No. of Shield type Nominal cross Dielectric Temperature

LEONI Dacar® Coaxial cables

Coaxial cables for antennas made for all

BENEFITS / PROPERTIES APPLICATIONS

■■ stable impedance ➔ EMC properties