Fiber-Optic Cables, Repairing

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.

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 Fiber-Optic Repair Set - Pliers -VAS6223/1-.

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

Fiber Optic Cable, Cutting to Length

• Establish length of fiber optic cable required.
• Open the Fiber-Optic Repair Set - Pliers -VAS6223/1- and lay the fiber-optic cable -1- in the mount.
• Close the Fiber-Optic Repair Set - Pliers -VAS6223/1- to cut the fiber-optic cable lengths.

Stripping

• Open the Fiber-Optic Repair Set - Pliers -VAS6223/1-.
• Position the wire stripper in the lower position -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 Fiber-Optic Repair Set - Pliers -VAS6223/1- until the stop and keep closed.
• 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.

Insulation must make contact with cutting point stop.

• Close the Fiber-Optic Repair Set - Pliers -VAS6223/1- 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.

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-.
• Slide the safeguard on the Fiber-Optic Repair Set - Pliers -VAS6223/1- in direction of -arrow- so that the word "Stift" (pin) is legible.

• Insert a brass pin contact -1- in the mount.
• Close the securing lever on the Fiber-Optic Repair Set - Pliers -VAS6223/1- in direction of -arrow-.

• Insert the fiber-optic cable into the brass pin contact -arrow- all the way up to the threaded stop and then close the Fiber-Optic Repair Set - Pliers -VAS6223/1-.
• 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-.

• 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 Catalog.
• To install the new fiber optic cable in wiring harness connector.

Corrugated Tube, Install on Fiber Optic Cable

• Cut corrugated tube to appropriate length.

• Use the Hose Cutting Pliers -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 Fiber-Optic Repair Set - Tube Tool -VAS6223/10- as shown.
• 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.

Fiber-Optic Cable, Disconnecting from Wiring Harness Connector

Removing

• Unplug connector for fiber optic cable from appropriate control unit.
• Release the locking mechanism in the fiber-optic cable connector -1- by pushing on it.
• Release the secondary lock -2- with a small screwdriver.
• Remove the fiber-optic cable.

Caution

• Install the cap on the trunk, in order to protect the fiber-optic cable from dust and dirt.
• Use a new housing since it is likely that the secondary lock was damaged during the removal of the fiber-optic cable.
• Note the arrows for allocation on the base module "IN" and "OUT".

Installing

Install in reverse order of removal. Note the following

• Install the fiber-optic cable according to the markings.

Note

• Push the corrugated tube into the connector housing until it audibly engages.

• Cover the open connector -2- for the fiber-optic cable using the Fiber-Optic Repair Set - Connector Protective Caps -VAS6223/9--item 1-.
• The protective cap prevents contamination of or mechanical damage to end face of fiber optic cable which would impair signal transmission.