61 13... Crimping stop parts

Special tools required:

12 1 080
12 1 081
12 1 083

1. Crimping butt connectors and contact sleeves for comb connectors up to 2.5 mm

2. Crimping butt connectors and contact sleeves for comb connectors larger than 2.5 mm 2

3. Crimping contact sleeves for 4 mm² comb connectors and ignition cable contacts

Use special tool kit 12 1 080 to attach ignition cable contacts and crimp 4 mm² contact sleeves for comb connectors.

12 1 081 (hand pliers)
12 1 083 (nest)

See Repair Instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 1: Identifying Hand Pliers (12 1 081) And Nest (12 1 083)

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Release special tool 12 1 081:

Squeeze grips (1) lightly and push release lever (2) in direction of arrow.

Or:

Compress handles until limit position, hand pliers unlock automatically.

Fig 2: Pushing Release Lever

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Place 4 mm² contact sleeve in nest with anti-twist safeguard (1) as far as possible.

Fig 3: Locating Nest With Anti-Twist Safeguard

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Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.

Fig 4: Identifying Crimping Tool Grip Contact

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NOTE: Follow procedure for CUTTING AND STRIPPING INSULATION from cables.

Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in contact.

Compress crimping tool to limit position.

Crimping tool unlocks automatically.

Take contact out of crimping tool.

Fig 5: Inserting Wire Stripped End In Contact

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4. Checking crimping

Check insulation crimping (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.

NOTE: Illustration shows butt connectors and contact sleeves for comb connectors knocked on one side. The crimping procedure is identical here.

Fig 6: Identifying Insulation Crimping And Wire Crimp

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Correct crimping:

Visible conductor end (10).

Visible insulation end (11).

Fig 7: Identifying Correct Crimping Of Conductor End And Insulation End

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Incorrect crimping:

Conductor end (10) inserted too far.

Insulation end (11) in wire crimp.

If necessary, repeat crimping with a new contact.

Fig 8: Identifying Incorrect Crimping Of Visible Conductor End And Insulation End

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Incorrect crimping:

Conductor end (10) not visible.

Insulation end (11) not visible.

If necessary, repeat crimping with a new contact.

Fig 9: Identifying Incorrect Crimping Of Conductor End And Insulation End

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