AUTOMOTIVE
AFTERMARKET
CIRCUIT
PROTECTION
CATALOG
AFTERMARKET
Genuine OEM Circuit Protection Products
LITTELFUSE
®
WORLDWIDE LEADER IN CIRCUIT PROTECTION
Circuit Protection Today
An overview of today’s fuse market . . .
• New vehicles contain 90 to 150 fuses throughout the vehicle in 3
to 4 different fuse blocks. For example, the BMW 750i uses over
150 fuses.
• High amperage products — MAXI, MEGA, MIDI, and ZCASE fuses
— make up 1 out of every 5 fuses in new vehicles.
• The past decade has produced more automotive circuit
protection devices than the entire history of the industry.
• Fuse and circuit breaker applications have grown by 400% in the
past 10 years.
• Glass fuses have not been used as a primary original equipment
circuit protection device since 1981. Unit movement has been
steadily declining, although glass fuses are used in many
accessory applications.
Littelfuse partners with every major automotive and heavy-duty
OEM. That is why more than 95% of domestic and 70% of foreign
new vehicles contain Littelfuse fuses. (Your customers and
installers will have a Littelfuse fuse in their hand when they need
a source to replace a fuse.) Littelfuse has introduced every new
fuse in the industry for the past three decades, starting with the
ATO blade fuse. Littelfuse holds more than 130 patents on circuit
protection devices, more than all the other fuse manufacturers in
the world combined. Other fuse manufacturers are licensed by
Littelfuse to utilize its product designs and trademarks.
What is Driving the
Circuit Protection Market?
The Circuit Protection market is experiencing accelerated growth
caused by a combination of powerful forces driving the market.
There has never been a better time to invest in the distribution of
the Circuit Protection category.
•
One Wire — One Fuse Protection Trend:
Auto manufacturers are
moving towards protecting every wire in the vehicle.
•
More Power Consumption:
Vehicles are consuming power at
higher amperages than ever before, and manufacturers are now
protecting high amp applications, such as the alternator, with
MEGA, MIDI, MAXI and ZCASE fuses.
•
Space & Weight Efficiency:
As vehicle designs get more complex,
fuses must get smaller so more fuses can fit in the same amount
of space.
•
Greater Diversity of Fuses:
Vehicles contain more fuses than ever
before, so Aftermarket Customers and Installers are requiring
a greater variety of circuit protection devices in their displays,
assortments and merchandisers.
•
More On-Board Electronics:
Auto manufacturers and Aftermarket
suppliers are offering a broader range of on-board components
like cellular phones, DVD players, WI-FI, Bluetooth, navigation,
alarm systems and remote starters which require circuit
protection for installation and replacement.
•
New Market Niches:
The increased demand in circuit protection
is offering current channels of distribution new marketing
opportunities in the Fast Lube, Warehouse Club and Electrical
Accessories Installer channels or any outlet stocking electrical
replacement parts.
•
Longer Vehicle Life:
The life expectancy of cars is increasing to
20+ years. This results in more miles driven and wiring that is
aging, leading to more blown fuses that need to be replaced.
•
Easier Access to Fuse Blocks:
Auto manufacturers have moved
fuse blocks into the passenger compartments, e.g. glove box,
dashboard and trunk, making it easier for DIY replacement.
Fuseblocks are also better marked for easier identification of the
proper circuit.
• Infotainment:
The increasing use of video and other new
electronics in vehicles have challenged designers to protect even
more sensitive automotive electronics. New technologies in
circuit protection and fuse box design eliminate transient surges
that can damage vehicle equipment.
The Future of Circuit Protection
Littelfuse’s new product development process is based on practical
innovations designed around the needs of the customer. The
circuit protection products of the future will offer greater features
to protect increasingly complex electrical systems, meet the
booming demand for on-board electronics and make the Circuit
Protection category a continuously stronger part of the Automotive
Aftermarket.
Here is a glimpse of Littelfuse’s vision of circuit protection
for tomorrow . . .
• Fuse count per vehicle to grow each year.
• Increased need for higher amp protection with MCASE and bolt-
on devices like MEGA and MIDI fuses.
• Greater need for a broader range of fuse blocks and fuseholders,
testers and pullers, fuse kits and assortments and creative
merchandising systems.
©2016 Littelfuse Automotive Aftermarket Circuit Protection
• Greater need for more technical training materials, point of sale
education support and more reliable application data.
• More compact fuses such as MINI, Micro and electronic surface
mount fuses.
• Smart circuit protection — the vehicle will tell you what fuse
needs to be replaced and its location.
• Special circuit protection products designed for electric and
alternative fuel vehicles.
• Modular electrical systems that require modular fuseblocks in
locations throughout the vehicle like the quarter panels, fender
wells, door panels, etc.
From small beginnings, through decades of innovation in circuit protection,
to advancing beyond circuit protection.
85
YEARS
OF EXPERTISE
A History of Littelfuse Automotive Firsts
For more than 75 years, Littelfuse has been the Circuit Protection manufacturer to achieve the automotive industry’s most
significant accomplishments, beginning in 1927 by inventing electronic circuit protection technology with the first small
fast-acting protective fuse.
1930
–
Automotive fuse introduced by Littelfuse.
1950
–
Littelfuse develops design of industry’s first centralized
under dash fuseblock.
1976
– ATO
®
blade fuse revolutionizes automotive circuit
protection.
1978
– Introduced Value Pak Emergency Fuse Kits offering 8–10
fuses with fuse puller.
1983
– Littelfuse begins battle with fuse counterfeiters
and helps establish a Federal exclusion order prohibiting
the importation of look-alike fuses into the United States.
1986
– U.S. Auto Industry selects the MAXI fuse to replace the
commonly used high amp fusible wire and fusible links in
under-the-hood electrical harnesses.
1987
– Littelfuse expands high amp coverage with reliable new
line of PAL Auto Links for complete Japanese coverage.
1988
– Littelfuse develops the ATO
®
style diode assembly
to control surge voltages caused by electromagnetic
components.
1991
– High amp protection MEGA
®
fuse introduced as the first
OEM and Aftermarket fuse rated up to 250 amps.
1993
– The MINI
®
diode is introduced to perform omni-directional
blocking of current flow in automotive applications.
1993
– The ATO
®
resistor assembly is released to adjust
and suppress excess voltage in sensitive automotive
circuits.
1993
– Littelfuse becomes the first circuit protection manufacturer
to receive ISO 9000 certification.
1994
– Littelfuse partners with Chrysler and BMW to design and
patent the MIDI
®
fuse for specific applications.
1994
– MIDI
®
compact bolt-down automotive fuse introduced for
European high amp applications.
1995
– The MINI
®
resistor joins the Littelfuse line of Automotive
products.
1995
– Littelfuse introduced Circuit Alert – a blown fuse indicating
device for ATO
®
fuses.
1995
– Add-A-Circuit fuseholder introduced as new way to add an
additional circuit without cutting or splicing.
1996
– Littelfuse became first circuit protection manufacturer to
receive QS 9000 certification.
1997
– JCASE introduced as compact version of MAXI
Fuse for domestic autos beginning in 1998.
©2016 Littelfuse Automotive Aftermarket Circuit Protection
1997
– Littelfuse celebrates 70 years of quality circuit protection
innovation.
1999
– Littelfuse acquires Harris Suppression and its
overvoltage technology to compliment it’s overcurrent
product lines.
2001
– The patented CablePro
®
is introduced to replace fuse links
in high-current, battery direct applications such as starters
or alternators.
2002
– Littelfuse acquires Semitron Industries, LTD and becomes
the only company in the world that can supply all the major
circuit protection technologies.
2004
– Purchases majority ownership of Heinrich Industries
AG, including WICKMANN, Pudenz and Efen, to expand
European market for automotive and electronic circuit
protection
2006
– Acquires SMARTGLOW
®
fuse, the first indicated automotive
blade type fuse.
2010
– Opens the High Power Lab, located in Champaign, Illinois,
providing customers with product design and specialized
testing services.
2010
– Acquires the Cole Hersee Company, a supplier of switches
and control devices to the commercial vehicle market.
2012
– Acquires ACCEL AB, located in Vänersborg, Sweden,
a leading supplier and manufacturer of advanced
electromechanical products and components, primarily for
the automotive industry.
2012
– Acquires Terra Power Systems, LLC, a Bellingham, WA –
based manufacturer of electrical distribution products for
heavy-duty vehicle applications.
2013
– Acquires Hamlin, Inc., of Lake Mills, WI. - a leader in
sensor technology providing product for teh automotive,
electronics, and industrial markets.
2015
– Acquires Sigmar, an Ozegna, Italy based manufacturer of
water-in-fuel and AdBlue®/urea sensors and PTC heaters,
solenoid valves and rotating oil filters for automotive and
commercial vehicle applications.
2016
– Acquires TE Connectivity’s Circuit Protection Division
(CPD) business, headquartered in Menlo Park, CA with
manufacturing facilities in Shanghai and Kunshan, China
and Tsukuba, Japan. It is a leader in polymer-based
resettable circuit protection devices in the automotive,
battery, industrial, communications and mobile computing
markets.
2016
– Acquires Menber’s Corporation of Legnano, Italy, expanding
our commercial vehicle presence and offering in Europe.
1
www.littelfuse.com
TABLE OF CONTENTS
FUSEOLOGY...............................................4-5
1
ATO
®
FUSES ................................................. 6
Developed by Littelfuse for the automotive industry, the ATO
®
fuse has become the original equipment circuit protection
standard for foreign and domestic automobiles and trucks.
2
MINI
®
FUSES ............................................... 8
Its miniature design meets the need for more circuits to be
protected while utilizing less space, and its ability to cope with
high temperatures in adverse environments makes the MINI
®
Fuse the recommended choice for protection.
3
4
LOW PROFILE MINI
®
FUSES ................... 10
The Low Profile MINI
®
fuse has similar performance
characteristics as the standard MINI
®
fuse.
MICRO2™ / MICRO3™ FUSES ...........11-12
Its sub-miniature design meets the need for more circuits to
be protected while utilizing less space and its ability to cope
with high temperatures in adverse environments makes the
MICRO2
TM
and MICRO3
TM
Fuse the recommended choice for
protection.
5
6
MAXI FUSES .............................................. 13
The MAXI fuse uses “Diffusion Pill Technology” to provide
predictable time delay characteristic and low heat dissipation.
JCASE
®
FUSES .......................................... 15
The JCASE
®
is a cartridge style fuse with female terminal
design. JCASE
®
provides both increased time delay and low
voltage drop to protect high current circuits. JCASE
®
has the
ability to handle inrush currents. The JCASE
®
was designed
and patented by Littelfuse.
7
LOW PROFILE JCASE
®
FUSES ................ 16
The Low Profile JCASE
®
fuse has similar performance
characteristics as the standard JCASE
®
fuse. The lower overall
height reduction allows for more space and weight savings
and also allows for a shorter male blade terminal, saving
additional weight and material savings in fuse box designs.
©2016 Littelfuse Automotive Aftermarket Circuit Protection
8
MCASE+™ FUSES ............................................... 17
It has a miniaturized footprint for optimal usage of space. It is a time
delayed fuse and can handle inrush currents. MCASE™ is designed and
patented by Littelfuse.
14
15
16
17
18
19
20
21
ZCASE FUSE ......................................................... 25
FUSE BLOCKS ...................................................... 26
POWER FEED ....................................................... 27
FUSE HOLDERS.................................................... 28
SWITCHES............................................................ 30
PULLERS / TESTERS ........................................... 30
CNL/CNN FUSES ................................................. 31
FUSIBLE LINKS .................................................... 31
RETAIL
COMMERCIAL ASSORTMENT PACKS ............................. 32
CADDYS ................................................................................. 33
RED BOX ................................................................................ 34
MODULAR RACK SYSTEMS ............................................... 35
SUPER VALUE PACKS ......................................................... 36
FUSE ASSORTMENTS ......................................................... 36
EMERGENCY KITS................................................................ 37
PLANOGRAM ........................................................................ 38
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
9
PAL AUTOLINK FUSES ....................................... 18
Commonly found on many Japanese and Domestic built vehicles in
current ratings up to 140 amperes. Available with female connector,
male connector, bent connector and locking female connector. Color
coded to indicate amp rating.
10
GLASS FUSES ...................................................... 19
AG and SFE fuses were designed into North American vehicles prior to
1981. Glass fuses are also used for auto accessory applications.
11
CIRCUIT BREAKERS ........................................... 21
Type I – Automatic Reset
Cycles or continuously resets until the fault is corrected. Type I circuit
breakers are typically used to protect circuits which occasionally
experience momentary overloads such as wiper motor and headlamp
circuits where a self resetting device is preferred.
Type II – Modified Reset
Non-cycling, remains in open position while there is power to the
circuit. Resets when ignition is turned off. Type II circuit breakers are
typically used in applications where fuse replacement is objectionable,
such as power window, seat and sunroof circuits.
Type III – Manual Reset
Manually resettable circuit breakers remain in the open position until a
button, lever or other external reset device is manually depressed. Type
III circuit breakers are typically used in applications where a manual
reset is desired for safe diagnosis of a circuit fault.
12
MEGA
®
BOLT ON FUSES.................................... 24
The MEGA
®
Fuse is designed for high current circuit protection up to
500A with “Diffusion Pill Technology.” The MEGA
®
Fuse also provides
time delay characteristics. Designed and patented by Littelfuse, the
MEGA
®
Fuse is ideal for battery and alternator protection application
and other heavy gauge cables requiring ultra-high current protection.
REFERENCE
PACKAGING / PART NUMBERING .................................... 39
SYSTEM AND MARKETING NUMBERS ........................... 40
FUSE SELECTION CHART ................................................... 41
CROSS REFERNCE GUIDE ................................................... 43
13
MIDI
®
BOLT ON FUSES ...................................... 25
This MIDI
®
style fuse offers a bolt-on space saving fuse for high
current wiring protection and provides time delay characteristics with
“Diffusion Pill Technology”. The MIDI
®
was designed and patented by
Littelfuse.
LIttelfuse products are designed for specific applications and should not be used for any purpose (including, without limitation, automotive
applications) not expressly set forth in applicable Littelfuse documentation. Warranties granted by Littelfuse shall be deemed void for
products used for any purpose not expressly set forth in applicable Littelfuse product documentation. Littelfuse shall not be liable for any
claims or damages arising out of products used in applications not expressly intended by Littelfuse as set forth in applicable Littelfuse
product documentation.
©2016 Littelfuse Automotive Aftermarket Circuit Protection
3
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