61 13... Cutting to length and strip off insulation from cables: Notes

Special tools required: 

• 12 1 080
• 12 1 081
• 12 1 083
• 2 221 122
• 0 494 159
• 0 496 849
• 0 496 833
• 2 407 379
• 61 4 320
• 61 4 340
• 61 0 210
• 61 0 220
• 61 0 230

For cutting cables to length and strip off insulation, use the insulation strippers 2 221 122.

Stripped length:

1. Crimping of NanoMQS stops (only G11; G12) 

   Crimping of NanoMQS contacts (MQS).

   • Special tool handle 0 494 159 or 0 496 849
   • Special tool die-plate 0 496 833
   • Stripping tool 2 407 379
2. Crimping of stops up to 2.5 mm  2

   Crimping Micro Quadlock System contacts (MQS).

   • Special tool 61 4 320

   Crimping Micro Power Quadlock contacts (MPQ).

   • Special tool 61 4 320

   Crimping miscellaneous stop parts up to 2.5 mm²

   • Special tool 61 4 340
3. Crimping of stops above 2.5 mm ² 

   Crimping load current contacts (LSK 8).

   • Special tool 61 0 210

   Crimping load current contact 2.8.

   • Special tool 61 0 220

   Crimping double spring contact (DFK 40)

   Crimping MAK8

   • Special tool 61 0 230
4. Crimp the impact connectors and contact sleeves for comb connectors from 2.5 mm  2
5. Crimp the impact connectors and contact sleeves for comb connectors from 2.5 mm ² 
6. Crimp contact sleeves for 4 mm ²  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)

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   Unlock special tool 12 1 081:

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

   Or:

   Compress handles up to stop, and hand pliers unlock automatically.

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

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

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   NOTE: Follow procedure for cutting and stripping off insulation from cables.

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

   Compress crimping tool up to stop.

   Crimping tool unlocks automatically.

   Take contact out of crimping tool.

7. Check 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.

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   Example of correct crimping: 

   Visible conductor end (10).

   Visible insulation end (11).

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   Example 1 of incorrect crimping: 

   Conductor end (10) inserted too far.

   Insulation end (11) in wire crimp.

   If necessary, repeat crimping with a new contact.

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   Example 2 of incorrect crimping: 

   Conductor end (10) not visible.

   Insulation end (11) not visible.

   If necessary, repeat crimping with a new contact.

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8. Insulate the crimping point with the heat-shrink tubing: 

   Push the heat-shrink tubing (8) onto the free wire end before crimping.

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   Crimp unused wire end using butt connector.

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   Position the heat-shrink tubing centrally over the butt connector.

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   Attention! 

   Do not combustion shrink-on sleeve.

   Mount the solder shrink reflector on the hot air blower.

   Shrink the heat-shrink tubing at 400°C using a hot-air blow blower until adhesive is visibly emerging evenly on both sides (9) of the heat-shrink tubing.

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