61 13 Crimping stop parts

Special tools required: 

• 12 1 080
• 12 1 081
• 12 1 083

Spare parts for in-car electronics (housing and contacts): 

1. Crimping butt connectors and contact sleeves for fan connectors up to 2.5 mm  ² 
2. Crimping butt connectors and contact sleeves for fan connectors from 2.5 mm  ² 
3. Crimping contact sleeves for fan connectors 4 mm  ²  and ignition cable contacts 

   Special tool kit 12 1 080  is used to fit ignition cable contacts to crimp 4 mm² contact sleeves for fan connectors.

   • 12 1 081  (hand crimping tool)
   • 12 1 083 (matrix)

   Special tools for wiring harness repairs, see 61 13 Special tools for wiring harness repairs 

   Fig 1: Identifying Special Tool (12 1 083) And (12 1 081)

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   Unlock special tool 12 1 081  :

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

   Or:

   Compress handles as far as they will go, tool unlocks automatically.

   Fig 2: Identifying Grips And Lever

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   Insert contact sleeve 4 mm2 in nest with lock (1) as far as it will go.

   Fig 3: Locating Lock

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

   Fig 4: Locating Grip Contact

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   NOTE: Follow procedure for cutting and stripping insulation from cables, see 61 13 Cutting to length 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 as far as it will go.

   Crimping tool unlocks automatically.

   Take contact out of crimping tool.

   Fig 5: Identifying Wire And Crimping Tool

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4. Checking crimping 

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

Fig 6: Identifying Insulation Crimp And Wire Crimp

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Correct crimping: 

Visible conductor end (10).

Visible insulation end (11).

Fig 7: Identifying Conductor End And Insulation End (Correct Crimping)

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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 Conductor End And Insulation End (Incorrect Crimping) (1 Of 2)

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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 Conductor End And Insulation End (Incorrect Crimping) (2 Of 2)

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