61 13... Crimping stop parts: Overview

Special tools required: 

• 12 1 080
• 12 1 081
• 12 1 083

1. Crimp the impact connectors and contact sleeves for comb connectors from 2.5 mm 2
2. Crimp the impact connectors and contact sleeves for comb connectors from 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)
   Fig 1: Hand Pliers (12 1 081) And Nest (12 1 083)
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   See repair instructions: 

   SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

   Release 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.

   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 Contact Sleeve 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: Locating Grip Contact And Crimping Tool

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   NOTE: Follow procedure for CUTTING OFF 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 5: Inserting Stripped End Of Wire In Contact

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   Compress crimping tool up to stop.

   Crimping tool unlocks automatically.

   Take contact out of crimping tool.

4. Checking crimping 

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

Fig 6: Locating Insulation Crimping And Wire Crimp

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Correct crimping: 

Visible conductor end (10).

Visible insulation end (11).

Fig 7: Conductor 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: Conductor End (Incorrect Crimping)

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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: Conductor End And Insulation End (Incorrect Crimping)

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