Fiber-Optic Cable, Assemble

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Fiber Optic Pliers Repair Set -VAS 6223A-

Fig 1: Identifying Fiber Optic Pliers Repair Set VAS 6223A
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Air Hose Pliers -VAS 6228-

Fig 2: Identifying Air Hose Pliers VAS 6228
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Vehicle Diagnostic Tester

CAUTION:

Fiber optic cables must not be sharply bent, bending radius must be no less than 25 mm (1 inch).

Fiber optic cables must not be routed over sharp edges.

The fiber-optic cable must not be dirty or touched with bare fingers.

Fiber optic cables may not be heated.

It is not permitted to twist together 2 fiber optic cables or one fiber optic cable with a copper wire.

Protect the connector and the connection box from dust. Place the cap on the trunk.

Install the tool set for the Pliers -VAS 6223/1-.

-- Remove the locking pin -arrows-.

Fig 3: Identifying Locking Pins

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-- Insert the tool set -arrow- and pull the locking pin back.

Fig 4: Identifying Tool Set

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Fiber Optic Cable, Cutting To Length

Fig 5: Identifying Method To Cut Fiber Optic Cable To Length

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-- Establish length of fiber optic cable required.

-- Open the -VAS 6223/1- and lay the fiber-optic cables -1- in the mount.

-- Close the -VAS 6223/1- to cut the fiber-optic cable lengths.

Stripping

-- Open the -VAS 6223/1-.

Fig 6: Identifying Open Position For VAS 6223/1

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-- Position the wire stripper in the lower position -arrow-.

-- Insert fiber-optic cable into the stripping station.

Fiber-optic cable must terminate flush to rear side of cutting pliers.

-- Close -VAS 6223/1- until stop and keep closed.

Fig 7: Identifying Closed Position For VAS 6223/1

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-- Bend the wire stripper upward -arrow- and remove the fiber-optic cable.

Precision Cutting (Production Of Optical End Face)

-- Push the fiber-optic cable -1- into the cutting station.

Fig 8: Identifying Position Of Fiber-Optic Cable In Cutting Position

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Insulation must make contact with cutting point stop.

-- Close the -VAS 6223/1- and remove the wire.

-- Visually inspect the wire -1- to make sure that it was cut correctly and that there are no burrs on the front surface.

Fig 9: Identifying Visual Inspection Of Cut Wire

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NOTE:

Fiber-optic cable is only to be placed on an absolutely clean surface or held in hand.

Use the cap if there is a risk of the fiber-optic cable surface becoming dirty.

Attaching Brass Pin Contact To Fiber-Optic Cable

-- Change tool head -arrow-.

Fig 10: Identifying Change Of Tool Head

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-- Move the fuse on the -VAS 6223/1- -arrow- so that the word "Stift" (pin) is legible.

Fig 11: Identifying Movement Of Fuse On VAS 6223/1 To Show "Stift"

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-- Insert a brass pin contact -1- in the mount.

-- Close the securing lever on the -VAS 6223/1- -arrow-.

Fig 12: Identifying Inserted Brass Pin And Securing Lever

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-- Insert the fiber-optic cable into the brass pin contact -arrow- all the way up to the threaded stop and then close the -VAS 6223/1-.

Fig 13: Identifying Inserted Fiber Optic Cable

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-- Open the fiber-optic cable pliers and remove the fiber-optic cable along with the brass contact pin.

CAUTION:

Do not excessively bend or kink fiber optic cables. (min. bending radius 25 mm).

-- Make sure that the brass contact pin -2- is secured on the fiber-optic cable -1-.

Fig 14: Identifying Brass Contact Pin and Fiber Optic Cable

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4 crimped points must be visible on the brass connecting pin.
The brass pin contact must not be able to be removed by hand from fiber-optic cable.
The end face of the fiber-optic cable is located 0.01 to 0.1 mm behind the brass pin contact (visual inspection).

NOTE:

Connector couplings are available for connecting fiber-optic cables.

For installing new fiber optic cable in wiring harness connector, refer to FIBER-OPTIC CABLE, DISCONNECTING FROM WIRING HARNESS CONNECTOR .

Corrugated Tube, Install On Fiber Optic Cable

Fig 15: Identifying VAS 6228 And Length Of Corrugated Tube To Cut

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-- Cut corrugated tube to appropriate length.

Use -VAS 6228- or a sharp knife for cutting.
The corrugated tube must not be cut through using a side cutter under any circumstances
The corrugated tube must be cut on the wave peak -arrow-, not in the wave trough.
The corrugated tube must audibly engage in the fiber-optic cable housing when installing.

-- Guide the fiber-optic cable into the Pliers for corrugated tube installation -VAS 6223/10- as shown in the illustration.

Fig 16: Guiding Fiber-Optic Cable Into Corrugated Tube With VAS 6223/10

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Position corrugated tube assembly pliers on slot on the tube.

-- Position crimping pliers for fiber-optic cable at slot of corrugated tube. By doing this, fiber-optic cable is fed in corrugated tube.