Fiber-Optic Cable, Assembling

Special Tools And Workshop Equipment Required

Fiber-Optic Conductor Repair Set:VAS6223A
Hose Cutting Pliers:VAS6228
Vehicle Diagnostic Tester

It is very difficult to find the exact location of the problem. Replace the damaged fiber-optic cable and lay a new wire parallel to the defective fiber-optic cable.

NOTE:

Select the damaged fiber-optic cable components with the "Guided Fault Finding" or "Guided Functions" from the Vehicle Diagnostic Tester menu options.

A fiber-optic cable that needs repair is represented by a "yellow" color.

Procedure

-- Choose "Guided Fault Finding" or "Guided Functions" in the Vehicle Diagnostic Tester. Refer to Vehicle Diagnostic Tester.

-- Assemble the fiber-optic cable. Refer to FIBER-OPTIC CABLE, ASSEMBLING .

CAUTION:

Do not bend the fiber-optic cable too much. The bending radius must be no less than 25 mm.

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.

CAUTION:

Do not bend the fiber-optic cable too much. The bending radius must be no less than 25 mm.

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.

Mount the Tool Head for the :VAS6223/1 .

Fig 1: Identifying Locking Pins

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-- Remove the locking pin in direction of -arrows-.

Fig 2: Identifying Tool Set

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

Fiber Optic Cable, Cutting to Length

Fig 3: Identifying Method To Cut Fiber Optic Cable To Length

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-- Establish length of fiber optic cable required.

-- Open the :VAS6223/1 and lay the fiber-optic cable -1- in the mount.

-- Close the :VAS6223/1 to cut the fiber-optic cable lengths.

Stripping

Fig 4: Identifying Open Position For VAS 6223/1

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-- Open the :VAS6223/1 .

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

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

The end of the fiber-optic cable must be flush with the rear side of the cutting pliers.

-- Close the :VAS6223/1 until the stop and keep closed.

Fig 5: Identifying Closed Position For VAS 6223/1

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

Precision Cutting (Production of Optical End Face)

Fig 6: Identifying Position Of Fiber-Optic Cable In Cutting Position

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

Insulation must make contact with cutting point stop.

-- Close the :VAS6223/1 and remove the wire.

Fig 7: Identifying Visual Inspection Of Cut Wire

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

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

Fig 8: Identifying Change Of Tool Head

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-- Change tool head in direction of -arrow-.

Fig 9: Identifying Movement Of Fuse On VAS 6223/1 To Show "Stift"

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-- Slide the safeguard on the :VAS6223/1 in direction of -arrow- so that the word "Stift" (pin) is legible.

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

Fig 10: Identifying Inserted Brass Pin And Securing Lever

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-- Close the securing lever on the :VAS6223/1 in direction of -arrow-.

-- Insert the fiber-optic cable into the brass pin contact in direction of -arrow- all the way up to the threaded stop and then close the :VAS6223/1 .

Fig 11: 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 the fiber-optic cables (minimum bending radius 25 mm).

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

Fig 12: Checking Proper Attachment Of Brass Pin Contact To 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 front surface of the fiber-optic cable is 0.01 to 0.1 mm behind the brass pin contact (visual check).

NOTE:

Connector couplings are available for connecting the fiber-optic cables. Refer to Parts Information.

To install the 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 13: Cutting Corrugated Tube To Appropriate Length Using Air Hose Pliers VAS 6228 Or A Sharp Knife

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-- Cut corrugated tube to appropriate length.

Use the :VAS6228 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 :VAS6223/10 as shown.

Fig 14: Guiding Fiber-Optic Cable Into Corrugated Tube With VAS 6223/10

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

-- Position crimping pliers for fiber-optic cable at slot of corrugated tube. The fiber optic cable is then routed in the corrugated tube.