FIBER-OPTIC CABLE, PREPARING WITH THE Fiber-Optic Conductor Repair Set :VAS6223A

Special tools and workshop equipment required

Fiber Optic Repair Set :VAS6223B
Hose Cutting Pliers :VAS6228

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.

Checking Remaining Cut Indicator

Fig 1: Identifying Fiber-Optic Repair Set - Pliers VAS 6223/1 Cutting Device Remaining Cut Indicator

Courtesy of AUDI OF AMERICA, LLC

-- Start by checking remaining cut indicator:

The :VAS6223/1 cutting device can perform approximately 1260 cuts. The blade is rotated for each further cut.
The remaining cut indicator -arrow - displays the last 150 cuts available.
Once no further cuts are available, the blade is blocked. It must be replaced. Refer to the Operating Instructions that come with :VAS6223/1 .

:VAS6223/1 Preparing

Fig 2: Locating Transport Safety Device On Cutter

Courtesy of AUDI OF AMERICA, LLC

-- Release the transport safety device on the cutter by loosening the bolt -arrow-.

Fiber Optic Cable, Cutting to Length

Fig 3: Cutting Fiber Optic Cable To Length

Courtesy of AUDI OF AMERICA, LLC

-- Establish length of fiber optic cable required.

-- Open :VAS6223/1 and insert fiber-optic cable -1- into trimming station.

-- Close cutting tool to cut fiber optic cable to length.

Stripping

Fig 4: Identifying Pliers For Fiber Optic Conductor VAS 6223/1 Stripping Lever

Courtesy of AUDI OF AMERICA, LLC

-- Open the :VAS6223/1 .

Stripping lever must be in lower position -arrow-.

-- Place the fiber optic cable -1- in the stripping point.

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

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

Fig 5: Closing Pliers For Fiber Optic Conductor VAS 6223/1 Until Stop And Keep Closed

Courtesy of AUDI OF AMERICA, LLC

-- Lift the stripping lever -arrow- upward.

-- Open the cutting tool and take out the fiber-optic cable -1-.

-- Detach the separated section of the insulation from the fiber-optic cable.

Precision Cutting (production of optical end face)

Fig 6: Sliding Fiber Optic Cable Into Cutting Point

Courtesy of AUDI OF AMERICA, LLC

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

The insulation must make contact with the cutting point stop -arrow-.

-- Close the :VAS6223/1 .

-- Press the cutting unit down -arrow-.

Fig 7: Pressing Cutting Unit Down

Courtesy of AUDI OF AMERICA, LLC

-- Open :VAS6223/1 and remove fiber-optic cable -1-.

NOTE:

The fiber-optic cable should only be placed on a completely clean surface.

Transport Protection, Activating

Fig 8: Locating Transport Safety Device On Cutter

Courtesy of AUDI OF AMERICA, LLC

-- Close the :VAS6223/1 .

-- Tighten the hex socket bolt -arrow- for the transport safety device on the cutter.

Attaching Brass Pin Contact to Fiber-Optic Cable

Fig 9: Opening Securing Lever On Crimping Pliers For Fiber-Optic Cable VAS 6223/2

Courtesy of AUDI OF AMERICA, LLC

-- Open securing lever on :VAS6223/2 in direction of -arrows 1 and 2-.

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

Fig 10: Closing Securing Lever On Crimping Pliers For Fiber-Optic Cable VAS 6223/2

Courtesy of AUDI OF AMERICA, LLC

-- Close the safety lever on the :VAS6223/2 -arrow-.

-- Slide the fiber optic cable -2- into the brass pin contact -1- as far as spring-loaded stop.

Fig 11: Sliding Fiber Optic Cable Into Brass Pin Contact As Far As Spring-Loaded Stop

Courtesy of AUDI OF AMERICA, LLC

-- Slide fiber-optic cable further in up to fixed stop and close :VAS6223/2 .

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

CAUTION:

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

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

Fig 12: Checking Proper Attachment Of Brass Pin Contact To Fiber Optic Cable

Courtesy of AUDI OF AMERICA, LLC

Four crimp points must be visible at the brass connection pin.
The brass pin contact must not be able to be removed by hand from the 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.

For installing the new fiber optic cable in the 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

Courtesy of AUDI OF AMERICA, LLC

-- Cut the corrugated tube to the 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.

-- Guide fiber-optic cable into :VAS6223/10 as shown in illustration.

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

Courtesy of AUDI OF AMERICA, LLC

-- Position the crimping pliers for fiber-optic cable at the slot on the corrugated tube.

-- Slide the crimping pliers for fiber-optic cable along the slot on the circumference of the corrugated tube. The fiber optic cable is then routed in the corrugated tube.

Special tools and workshop equipment required

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

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 Tool Head for the :VAS6223/1 .

Fig 1: Identifying Locking Pins

Courtesy of AUDI OF AMERICA, LLC

-- Remove the locking pin -arrows-.

Fig 2: Identifying Tool Set

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

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

Fig 5: Identifying Closed Position For VAS 6223/1

Courtesy of AUDI OF AMERICA, LLC

-- Bend the wire stripper upward -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

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- Change tool head -arrow-.

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

Courtesy of AUDI OF AMERICA, LLC

-- Slide the safeguard on the :VAS6223/1 -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

Courtesy of AUDI OF AMERICA, LLC

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

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

Fig 11: Identifying Inserted Fiber Optic Cable

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

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.

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

Courtesy of AUDI OF AMERICA, LLC

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- 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.