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Product

Rolling-stock inter-vehicle jumper cableEN 45545-2 HL3UIC 558 / EN 50264−40 to +90 °C E-Beam

Inter-Vehicle Jumper CableEN 45545-2 HL3 electron-beam cross-linked railway inter-car jumper cable

Halogen-free rolling-stock jumper cable built with IEC 60228 Class 5/6 tinned copper conductors and electron-beam cross-linked EM 104 elastomer sheath for continuous 3D gangway pitching, yawing, ballast impact and −40 °C to +90 °C service per EN 45545-2 HL3.

Anti-torsion braid
Outdoor & humid
Flame-retardant
Oil-resistant
Order designation
RAIL-JMP-UIC558 13×1.5+5×1.5(C)
Outer Ø ≈
20.8 mm
Total copper
325 kg/km
Total weight ≈
640 kg/km
Min. bend R (dynamic)
125 mm
Check against my drumAll sizes (14)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Fire safety
EN 45545-2 HL3
R15 / R16 hazard level 1–3
Rated voltage
0.6/1 kV
300/500 V bus · 1.8/3 kV HEP
Temperature
−40…+90 °C
flexing · −50…+120 °C fixed
Bend radius
6 × OD
dynamic gangway · 4 × OD fixed
Conductor
Tinned Cu Cl.5/6
corrosion-free fine stranding
LSZH rating
IEC 60754/61034
zero halogen · low smoke density

Typical values for this cable type, based on EN 50264-3-2 / EN 45545-2 HL3 / UIC 558 — confirmed in the datasheet and quotation for your order.

Application fit

Is Inter-Vehicle Jumper Cable right for your machine?

Engineered for free-loop inter-coach gangway jumpers and chassis-to-bogie loops on high-speed trains, metro cars, EMUs, DMUs and locomotives.

Free-hanging vertical run

Suitable

Absorbs continuous 3D pitching, yawing, rolling and aerodynamic buffeting between coupled rail coaches.

Fixed installation

Suitable

EN 45545-2 HL3 (R15/R16) approval allows direct routing through underframe ducts and interior bulkheads.

Energy chain / drag chain

Suitable

Suitable for articulated tram/LRV roof energy chains and sliding door actuator carriers.

Motorised monospiral reel

Not suitable

Designed for railway inter-car loops and bogie leads rather than motorised crane drums.

Use NSHTÖU Reeling Cable
Typical machinesHigh-Speed Passenger Trains & EMUsMetro, Subway & Light Rail (LRV)Mainline Electric & Diesel LocomotivesChassis-to-Bogie Sensor & Brake LeadsUIC 558 / 541-5 / 552 Coupler Harnesses

Construction

Layer by layer

Shown: RAIL-JMP-UIC558 18-pole inter-vehicle jumper cable with tinned Class 6 copper conductors, EI 109 cross-linked insulation, screened WTB/PIS data quad,overall tinned copper braid and EM 104 cross-linked elastomer jacket.

123456
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Tinned copper conductorExtra-fine stranded tinned copper (IEC 60228 Class 5 / Class 6)Tinning prevents copper oxidation and aids crimp/solder reliability under railway vibration
2Cross-linked LSZH insulationElectron-beam cross-linked halogen-free compound (EI 109 per EN 50264-1)Will not melt or drip under short-circuit overload (+250 °C) or soldering
3Data quad / pair screen (UIC 558 / MVB)Tinned copper braid screen (≥ 85 %) over twisted WTB/MVB/Ethernet pairs where fittedProtects train control bus from 25 kV AC / 3 kV DC traction interference
4Torsion-absorbing fleece & aramid wrapNon-hygroscopic sliding fleece + reinforcing tape over short-pitch core bundleWithstands multi-axis gangway swinging and ice loading
5Overall EMC tinned copper screenTinned copper wire braid (≥ 85 % optical coverage on C/bus versions)Low transfer impedance for railway EMC (EN 50121-3-2)
6Heavy-duty railway outer sheathElectron-beam cross-linked halogen-free elastomer (EM 104 per EN 50264-1), black RAL 9005EN 45545-2 HL3 · resists diesel oil, acid/alkali wash, ozone, UV and track ballast impact

UIC 558 / Control & Bus Jumper

18-pole UIC 558 (13×1.5 mm² + screened data cores) or 9 to 37 core control/MVB/Ethernet inter-coach jumper

0.6/1 kV & 1.8/3 kV Power Jumper

Multi-core 4G4–4G25 auxiliary power or single-core 50–95 mm² UIC 552 Head-End Power (HEP) train-line jumper

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on EN 50264-3-2 / EN 45545-2 HL3 / UIC 558. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage U0/U
300/500 V (control) · 0.6/1 kV & 1.8/3 kV (power)
AC test voltage
2000 V / 3500 V / 6500 V AC (50 Hz, 5 min)
Screen / Field control
Tinned copper braid ≥ 85 % (EMC per EN 50121-3-2)
Insulation resistance
≥ 500 MΩ·km at 20 °C

Thermal

Temperature, flexing
−40 °C to +90 °C (arctic −50 °C option)
Temperature, fixed installation
−50 °C to +120 °C
Max. conductor temperature
+90 °C (+120 °C fixed)
Short-circuit temperature
+250 °C (max. 5 s, non-melting)

Mechanical

Min. bending radius, moving
6 × OD (free gangway & bogie loop)
Min. bending radius, fixed
4 × OD
Dynamic endurance
≥ 3,000,000 3D multi-axis gangway swing cycles
Ballast & stone impact
High notch and tear resistance per EN 50305

Resistance

Fire performance
EN 45545-2 Hazard Level HL1, HL2, HL3 (R15/R16)
Flame retardance
IEC 60332-1-2 & IEC 60332-3-24 / EN 50305
Halogen-free / Smoke density
IEC 60754-1/2 · IEC 61034-2 · EN 50305 ITC ≤ 6
Oil, fuel & chemical resistance
Resists IRM 902/903 mineral oil, diesel, acid & alkali
UV & ozone
Ozone resistant per EN 50305 Method B

Reference standards

Cable type (construction standard)
EN 50264-3-2 · UIC 558 · UIC 541-5 · UIC 552
Conductor
IEC 60228 Class 5 / Class 6 tinned copper
Product approvals
EN 45545-2 HL3 · DIN 5510-2 · NF F 16-101
RoHS & REACH
2011/65/EU (RoHS 2) & EC 1907/2006 compliant

Identification

Sheath colour
Black (RAL 9005)
Core identification
White numbered cores or UIC 558 colour/number code
Marking
TEBAOFLEX RAIL-JMP <size> EN 50264 EN 45545-2 HL3 CE
Customs tariff (HS)
8544.49

Sizes

14 standard UIC & EN 50264 rolling-stock jumper configurations

Covers UIC 558/541-5 control & brake jumpers, WTB/MVB/Ethernet train-backbone jumpers, and 0.6/1 kV – 1.8/3 kV power jumpers.

Dimensions & weights
Order designationConfigurationRolling-stock systemOuter Ø ≈
mm		Total Cu
kg/km		Weight ≈
kg/km		Min. bend R
dynamic mm		Enquiry
UIC 558 / UIC 541-5 & Multi-Core Inter-Car Control Jumpers
RAIL-JMP-UIC558 13×1.5+5×1.5(C)13×1.5 + 5×1.5 (2×2×1.0)CUIC 558 18-Pole Remote Control & PIS20.8325640125
RAIL-JMP-UIC541 9G1.59G1.5UIC 541-5 Electropneumatic (EP) Brake14.213029585
RAIL-JMP-HL3 12G1.5 C12G1.5 (Screened)12-Core Coupled Coach Control Jumper16.423543598
RAIL-JMP-HL3 19G1.5 C19G1.5 (Screened)19-Core Bogie & Gangway Control Jumper19.2345610115
RAIL-JMP-HL3 27G1.5 C27G1.5 (Screened)27-Core Multi-Unit Train Control Jumper22.8478825137
RAIL-JMP-HL3 37G1.5 C37G1.5 (Screened)37-Core High-Density Gangway Jumper25.96381,080155
IEC 61375 Train Communication Network (WTB / MVB / ETB) Hybrid Jumpers
RAIL-JMP-MVB 4×2×0.5+12×1.5 C4×(2×0.5)C + 12×1.5IEC 61375 WTB/MVB Train Bus + Control20.4310595122
RAIL-JMP-ETB 2×(4×2×AWG22)+8×1.52×Cat.5e Quad + 8×1.5IEC 61375-2-5 Ethernet Train Backbone21.6295625130
0.6/1 kV Auxiliary Power & 1.8/3 kV UIC 552 Head-End Power (HEP) Jumpers
RAIL-JMP-PWR 4G4.0 (0.6/1 kV)4G4.0Auxiliary 400 V AC HVAC / Compressor14.815434089
RAIL-JMP-PWR 4G10 (0.6/1 kV)4G10Inter-Car Auxiliary Power Bus19.8384685119
RAIL-JMP-PWR 4G16 (0.6/1 kV)4G16Heavy Auxiliary Converter Jumper23.46141,020140
RAIL-JMP-PWR 4G25 (0.6/1 kV)4G253-Phase Train Auxiliary Supply28.29601,540169
RAIL-JMP-HEP 1×50 (1.8/3 kV)1×50 mm²UIC 552 Head-End Power (HEP) Single16.548066599
RAIL-JMP-HEP 1×95 (1.8/3 kV)1×95 mm²UIC 552 1000/1500 V Train Heating Bus21.49121,185128
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Available both as bulk cable on drums and as overmoulded plug-and-play UIC 558 / 541-5 / 552 jumper assemblies.

Reel check

Will it fit your machine?

A first screen using datasheet values. Engineering confirms drum geometry, acceleration and tension with your quotation.

Check results

Drum core 150 mm is below 250 mmUse a larger drum core or a smaller cable size
60 m/min ≤ 120 m/minWithin the rated travel speed
Minimum bending radius
125 mm
Min. drum core diameter
≈ 250 mm
Cable weight on drum
3.2 kg
Copper content
1.6 kg
Indicative only: based on the datasheet outer diameter and 6 × OD bending radius. Current derating for wound layers per DIN VDE 0298-4 is assessed separately.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
AC high-voltage dielectric test2000 V / 3500 V / 6500 V AC for 5 min per voltage gradeEvery manufactured drum length
Sample tests
3D multi-axis inter-car gangway swing test≥ 3 million combined bending, pitching and torsion cycles at −25 °C to +40 °CQualification & periodic audit
EN 45545-2 HL3 fire, smoke & toxicity suitePass IEC 60332-3-24, IEC 61034-2, IEC 60754-1/2 and EN 50305 toxicity (ITC ≤ 6)Type approval
Diesel oil, acid/alkali & −40 °C cold impact testPass EN 50264-1 EM 104 fluid immersion and −40 °C cold impactType approval

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

EN 45545-2 Hazard Level HL1 / HL2 / HL3 (R15/R16)EN 50264-3-2 / UIC 558 / UIC 541-5 / UIC 552CE, RoHS 2 (2011/65/EU) & REACH Compliant

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX RAIL-JMP <size> EN 50264-3-2 EN 45545-2 HL3 CE
Delivery form
Non-returnable fumigated wooden drums or coils
Standard lengths
100 m · 500 m · 1000 m (cut lengths on request)
MOQ
100 m (stock sizes) · 300 m (custom)
Lead time
2–3 weeks ex-works
Incoterms
EXW, FCA, FOB, CIF, DAP

Technical documents

Downloads

PDFInter-Vehicle Jumper Cable – technical datasheet14 sizes · construction, technical data, approvalsXLSXInter-Vehicle Jumper Cable spec data (Excel)All 14 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

Why must an Inter-Vehicle Jumper Cable meet EN 45545-2 Hazard Level HL3 (R15/R16)?
Inter-vehicle jumper cables and bogie leads run across the coupled gangways and underframes of passenger trains, including underground metro and sleeping coaches (Operation Category OC3/OC4, Design Category N/A/S). Under EN 45545-2 requirements R15 (interior) and R16 (exterior), HL3 is the highest fire safety classification, guaranteeing self-extinguishing vertical bundle flame spread (IEC 60332-3-24), ultra-low smoke density (IEC 61034-2), zero halogens (IEC 60754-1/2), and low gas toxicity (EN 50305 ITC ≤ 6).
What are the differences between UIC 558, UIC 541-5, and UIC 552 railway jumper cables?
UIC 558 specifies the 18-pole remote control, door-interlock, passenger information system (PIS), and WTB/MVB data bus jumper between coupled passenger coaches. UIC 541-5 specifies the 9-core electropneumatic (EP) brake control jumper. UIC 552 specifies the 1.8/3 kV single-core (50 mm² to 185 mm²) Head-End Power (HEP) train-heating and auxiliary power bus.
Why is electron-beam cross-linked elastomer (EM 104 / EI 109) used instead of thermoplastic LSZH?
Thermoplastic LSZH compounds soften above +90 °C and crack under −40 °C winter stone ballast impact or continuous gangway flexing. Electron-beam cross-linking creates a permanent 3D molecular network that will not melt even during +250 °C short-circuit overloads, resists diesel fuel and bogie washing chemicals, and survives millions of multi-axis flex cycles at −40 °C.
Does TEBAOFLEX supply complete pre-terminated UIC 558, UIC 541-5, and UIC 552 jumper assemblies?
Yes. Alongside bulk drum lengths, we supply fully tested inter-car jumper assemblies complete with overmoulded or metallic UIC plugs, strain-relief trumpets, and protective polyamide/elastomer anti-chafing sleeves.

Request a quote

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01Selected sizes

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03Message for our engineers

Inter-Vehicle Jumper Cable

Selected sizes:


Reel & motion:
- Reel type: 
- Drum core diameter (mm): 
- Cable length on drum (m): 
- Travel speed (m/min): 
- Max. acceleration: 
- Cycles per hour: 
- Length and quantity: 
- Ambient temperature: 
- Exposure (outdoor, water, oil, abrasion): 
- Destination country: 
- Equipment and operating conditions:
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