Instructions for Installing Connector Lock Wires on Off-Highway Trucks {1401, 1402, 1408} Caterpillar

Off-Highway Truck/Tractor

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Introduction

This Special Instruction provides information about how to install 5P-6025 Lockwire. The use of lock wire is an effective means to ensure that certain interface and high-voltage accessory cables do not come loose during machine operation .

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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 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 all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine. Secure clevis pin with locking pin. Before operating the machine, fasten the steering frame lock link into the stored position and secure the clevis pin with locking pin. Failure to lock into the stored position before operating can result in loss of steering.

Machine Preparation

1. Drive the machine onto a smooth level surface that can support the weight of the machine.

2. Turn off the engine and remove the key from the starting switch.
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   Illustration 1	g00104545

3. Perform Lockout Tag Out procedure by attaching a warning tag to the machine controls.

Required Tools

Required Part

Military Spec (MS) Connectors

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Illustration 2	g06136402
(A) 314-8478 Pliers (LOCK WIRE)

1. Coupling nuts on MS connectors (designed for lock wire) shall be locked with lock wire (1). Lock wire shall be attached using tooling (A).
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   Illustration 3	g06136403
   (1) 5P-0562 Lockwire

2. Coupling nuts shall be lock wired and assembled to prevent loosening. Coupling nuts and backshell nuts (if used) may be connected together (in tension) and wired to a stationary attachment point.
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   Illustration 4	g06136758
   Damage Caused By the Wrong Connector

3. Inspect connector and terminals for any damage or misalignment prior to assembly. If connector or terminal is damaged or misaligned, the component shall be rejected. If a connector is dirty or contaminated, clean with non-residue cleaner, only use isopropyl alcohol.

4. Do not use any lubricants on connector terminals. Lubricants can break down (electrically) and cause arcing or shorts. Lubricants can also collect and trap dirt causing early connector failure.
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   Illustration 5	g06136761
   Connector Seated Properly

5. MS connectors shall be hand tightened first. MS connectors are normal to have to wiggle the harness connector, then hand tighten the threaded collar several turns, and repeat until the connector is seated as shown in Illustration 5. After the connector is fully seated by hand, connector shall then be torqued to the assembly print requirement using the proper torque tool. Illustration 4 shows the results of a mis-mated connector.

6. For MS connectors, the torque is based on the shell size for both coupling nuts and mounting hex nuts.

Lock Wiring Procedure

Securing MS Connector

Illustration 6	g06136762

Before you begin, inspect tools, material, and working area. Plan lock wire installation by locating mounting holes such that the lock wire will not allow the connector to become loose. Lock wire hole locations for both the connector and nut can be anchored into position.

Note: Inspect working area for any physical damage and cleanliness. Hand tighten connector until locking ring is difficult to turn.

Working Area, Proper Tooling - Torque

Illustration 7	g06136801
(B) 459-0233 Wrench (C) 165.1 mm (6.50 inch) approximately (D) 9.5 mm (0.37 inch) Square Drive for Torque Wrench (E) 76.2 mm (3.00 inch)

Proper tightening of the lock ring can be accomplished by several tools. To achieve torque, strap wrench can be used with a torque tool to deliver the appropriate torque within the tolerance ranges.

Note: Do not loosen or tighten connectors to align lock wire holes. Torque of MS connector shall be performed, prior to installing lock wire.

Note: Do not use pliers or lock jaw pliers to tighten connectors.

Illustration 8	g06136830
(F) Connector plug (coupling nut)

Illustration 9	g06136843
(G) Anchor point

Locate the lock wire mounting hole at the connector receptacle jam nut (hereafter referred to as anchor point (G) ). Locate the lock wire mounting hole at the connector plug coupling nut (F).

Illustration 10	g06136414

Illustration 11	g06136419

The direction of the wire shall be from the coupling plug to the anchor point (G), in a tightening direction (typically clockwise). Wire length will be more than what you need, there will be excess wire waste. Review the application and estimate distance between the 2 holes. Double the estimated distance, and add about another 100 mm (4 inch). Install wire in the connector plug (G), and fold with 2 equal lengths. Squeeze both wires together with your fingers at the connector plug.

Illustration 12	g06136423

Illustration 13	g06136425

Align lock wire in the intended path and make a bend in the wire where the hole is in the anchor point. This bend is to locate the tooling (A). Length shall be from connector plug to slightly past the anchored hole. There are 2 options to twist the lock wire.

• Twist with tooling (A). Refer to "Procedure to Use Lock Wire Pliers".

• Manually twist wire by hand. Refer to "Procedure To Manually Twisting Lock Wire".

Note: Grip the wire in the jaws of the wire twister and slide the locking cap down with your thumb to lock the handles or lock the spring-loaded pin.

Illustration 14	g06136436

Illustration 15	g06136437

Pull the knob, and the spiral rod spins and twists the wire clockwise. There should be 6 to 8 twists per 25 mm (1 inch). When using wire twisters, the wire should extend approximately 77 mm (3 inch) beyond the jaws of the twisters. Loosely wrap the wire around tooling (A) to prevent whipping and possible personal injury. Excessive twisting of the wire will weaken the wire. Pull and turn tooling (A) clockwise in a circular motion to twist wire closer at the locking ring hole. Pull and twist wire. Squeeze handles together to release wire. Tighten wire loop at the anchor point. Be sure to select wire securement orientation that will prevent the component from loosening.

Illustration 16	g06136440

Illustration 17	g06136446

Tighten wire loop at anchor point. Route the bottom wire (H) perpendicularly over the top wire (J) into the hole of the anchor point. Pull wire tight with the tip of pliers. This wire must be positioned on top of second wire (J) to maintain a downward pressure while wrapping wire around the edge. Insert wire into the anchor point as shown below. Pull wire tight.

Illustration 18	g06136440

Illustration 19	g06136768

Pull second wire (J) around on the anchor point edge (nut) in a triangle pattern. Make sure that wire is routed under top wire (H). Route wire around nut as shown. Grip wire about 25 mm away from anchored point, and twist wire clockwise while maintaining 6 to 8 twists per 25 mm (1 inch).

Illustration 20	g06136770

Illustration 21	g06136771

Illustration 22	g06136773

Anchor twisted wire, leaving 12.0 - 15.0 mm (0.4 - 0.6 inch) long after anchor point, and trim the excess. Loop wire ends by using the wire twisting pliers, closing the wire ends tightly with tooling (A). Position wire ends to avoid sharp or projecting ends.

Proper Lock Wire Installation

Illustration 23	g06136774

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 should 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 12.0 to 15.0 mm (0.4 to 0.6 inch)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

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Illustration 24	g06132440

1. Use tooling (A) as the reference part number.

2. When using wire twisters, and the wire extends 77 mm (3 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.

Procedure To Manually Twisting Lock Wire

Illustration 25	g06132439

Terminals

Never bend a terminal. A bent terminal will not guarantee proper connection and may fail from stress. Note, certain designs may have a terminal at an angle. These terminals are received as such from the supplier.

Terminals shall be flush to the surface before torque is applied to the bolt.

Apply torque to terminals without allowing cables to rotate. Position of cables shall maintain routing orientation per the engineering drawing.

Lock Wire for Transmission

Illustration 26	g06132426

Illustration 27	g06132427

Lock Wire for Automatic External Field Regulator (AEFR)

Illustration 28	g06132430

Illustration 29	g06132433