Instructions to Install Connector Lock Wire on D7E Track-Type Tractors{1408, 7553} Caterpillar

Track-Type Tractor:

D7E (S/N: HKA1-UP; TJA1-UP; MDB1-UP; SCG1-UP; SSH1-UP; TAN1-UP)

Introduction

This Special Instruction provides information about how to install lock wire and cable locks. The use of either the lock wire or the cable locks is an effective means to ensure the high voltage accessory cables do not come loose during machine operation .

Important Safety Information

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Parts Information

Steps in Applying the Cable Locks

Note: Before applying the cable lock, make sure that the connector has received the proper torque.

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Illustration 1	g03884081
Interface rubber lock 's molded hex with connector (1) Cable Lock (2) High Voltage Cable

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Illustration 2	g03884101
Install zip ties in molded in grooves (1) Cable Locks (3) Power Inverter Output

1. Install the two halves of the cable lock over the accessory high voltage cable end connector as shown in Illustration 1. The cable lock has a hex molded into it. It is meant to interface with the nut on the high voltage accessory cable connector.

2. Fasten two strap-cables to the cable locks in the molded in grooves. As shown in Illustration 2 .

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Illustration 3	g03884104
Accessory Power Converter (APC) and the external connections

3. Repeat Steps 1 and 2 for the following locations: Inverter output, Accessory Power Converter input, Accessory Power Converter A/C output, Accessory Power Converter electric water pump output (if equipped).

Steps in Applying the Connector Lock Wire

Note: Before applying the lock wire, make sure that the connector has received the proper torque.

1. Install the two halves of the sable lock over the accessory high voltage cable end connector as shown in image 1. The cable lock has a hex molded into it. (Image 2) It is meant to interface with the nut on the high voltage accessory cable connector.

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Illustration 4	g02420176

1. Thread lock wire (1) through the hole in the top connector, pulling ends towards the bottom connector. Make sure that the wire is pulling both the connectors in the tightening direction. Extend ends of the wire about 102 mm (4.0 inch) past the bottom connector (wire can be trimmed later in the process).

   Note: Be careful not to damage, nick, or kink wires during lock wire installation. Do not reuse lock wire. Replace lock wire if damaged during installation. Do not under torque or over torque to obtain proper alignment of the holes.

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Illustration 5	g02420256

2. Align lock wire (1) in the intended path and make a bend in the wire where the hole is in the bottom connector. This is to locate the pliers.

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Illustration 6	g02420257

3. Straighten the lock wire (1), lock the pliers (2), and begin twisting. Ensure that the number of twists is in accordance with the guidelines in Illustration 14.

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Illustration 7	g02420259

4. Align the lock wire (1) in the intended path to ensure the wire twists stops short of the second connector hole. Thread wire through bottom connector hole. Ensure that lock wire (1) is pulled taught with pliers but use caution to not damage, nick, or kink the wire.

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Illustration 8	g02420260

5. Secure the lock wires (1) together and the lock wire pliers (2) to the end of the wires and begin twisting. Ensure that the number of twists is in accordance with guidelines in Illustration 14.

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Illustration 9	g02420276

6. Once complete, cut the twisted lock wire (1) so that there is between 26 mm and 51 mm (1.0 inch and 2.0 inch) of wire extended past second hole.

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Illustration 10	g02420278

7. Clamp the twisted lock wire (1) with pliers (2) and rotate so that wire bends inward to ensure that the lock wire will not pierce the skin when complete. Refer to Illustration 11.

Different Methods of Lock Wiring for Applying the Lock Wire on MS Connectors

Double-twist method

Illustration 11	g02420316

Use single wire and twist wires between holes. Double twist method is the preferred method and most commonly used wire. Refer to the illustration 11.

Single-wire method

Illustration 12	g02420356

Use single wire and do not twist between holes. May be used in the areas where the place is too difficult to reach. When using the single-wire method, the largest size wire that the hole will accommodate should be used. Refer to the Illustration 12.

Points to Be Noted During Lock Wire Application

• Before applying lock wire, make sure that connector has received proper torque.

• To prevent failure due to rubbing or vibration, lock wire must be tight after installation.

• When using the lock wire, the lock wire must be installed in such a manner that any tendency for the part to loosen will be counteracted by additional tightening of the wire.

• Wire must be pulled tight while being twisted, but not overstressed.

• New lock wire must be used for each application.

• Lock wire ends should be bent under and inward toward the part to avoid sharp or projecting ends.

• To prevent damage of the twisted section of the wire, when using pliers, grasp the wires at the ends.

• Lock wire must not be nicked, kinked, or damaged. Never twist the wire ends off with pliers when cutting off the ends, leave at least four to six complete turns (1/2 to 5/8 inch long) after the loop.

• When removing the lock wire, never twist off the wire with pliers. Cut the lock wire close to the hole, exercising caution.

Procedure to Use Lock Wire Pliers

1. Use 314-8478 Diagonal Cutter as the reference part number.

2. When using wire twisters, and the wire extends 77 mm (3.0 inch) beyond the jaws of the twisters, loosely wrap the wire around the pliers to prevent whipping and possible personal injury. Excessive twisting of the wire will weaken the wire.

3. Thread the wire through connector hole. Grip the wire in the jaws of the pliers and slide the outer sleeve down to lock the handles or lock the spring-loaded pin.

4. Pull the knob, and the spiral rod spins and twists the wire.

5. Squeeze handles together to release wire once the twisting is complete.

Illustration 13	g02420418

Illustration 14	g02420419

Illustration 15	g02420420
Different types of lock wire application (1) Example 1 (2) Example 2 (3) Example 3 (4) Example 4

Lock Wire for APC Application

Illustration 16	g02422776

Illustration 17	g02422777

Illustration 18	g02422778

Lock Wire for Water Pump

Illustration 19	g02449416

Lock Wire for Electric Water Pump Controller

Illustration 20	g02422796

Illustration 21	g02422797

Illustration 22	g02422798

Lock Wire for Inverter

Illustration 23	g02449417