Crimping Butt Connectors And Contact Sleeves For Fan Connectors Up To 2.5 MM2

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The special tool 61 9 041 (crimping tool) in conjunction with 61 9 042 (matrix) are used for crimping stop parts (contacts), refer to 61 13 CRIMPING ON STOP PARTS .

Fig 1: Identifying Special Tool 61 9 041 (Crimping Tool)

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Refer to repair instructions:

Special tools for wiring harness repairs, refer to 61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Unlock special tool 61 9 041:

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: Unlocking Special Tool 61 9 041

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NOTE: Designation on nests (3) of special tool 61 9 042 indicate which contacts can be used in which crimping nests.

The following wire cross-section sizes and their corresponding stops can be used:

Wire cross-section size

0.35 ... 0.5 mm²
0.75 ... 1.0 mm²
1.5 mm³
2.5 mm²

Fig 3: Identifying Cross-Section Sizes And Their Corresponding Stops

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Example for choosing a nest:

Fig 4: Choosing A Nest

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For further operating instructions, refer to operating instructions for repair range IV for vehicle electrical system 61 9 020.

CAUTION: The contacts must be inserted in the matrix nest with utmost care. In so doing, ensure wire crimp and insulation crimp are exactly positioned.

Insert contact section of contact sleeves (4) for comb connector or crimp connector (5) in predetermined nest.

Fig 5: Identifying Contact Sleeves (4) And Connector (5)

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Preload contact by squeezing matrix in crimping tool. Grip contact (6) firmly only, do not crimp.

Fig 6: Preloading Contact By Squeezing Matrix In Crimping Tool

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NOTE: Follow procedure for cutting and stripping insulation from cable, refer to 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.

Fig 7: Inserting Stripped End Of Wire (7) In The Contact

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Compress crimping tool as far as it will go.

Crimping tool unlocks automatically.

Take contact out of crimping tool.