- Caterpillar Products: All
Introduction
Important Safety Information
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| Illustration 1 | g02139237 |
Think Safety | |
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.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.
Service Parts Section
The Service Parts Section is a reference for parts identification and available part numbers.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No smoking |
Hazard Avoidance
| Crushing hazard (foot) |
| Crushing hazard (hand) |
| Pinch point |
| Fire hazard |
| Electrical Shock - Hazard |
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| Fire hazard |
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Plastic Ties
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| Illustration 3 | g03869562 |
Part No. 326-8203 | |
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| Illustration 4 | g03869641 |
Part No. 4C-5877 | |
Scope
This specification applies to the tensioning of plastic cable straps (also called cable ties).
Applications
- Tying/securing bundles of electrical wire or cables together as would be done in manufacturing wire harnesses/assemblies, and in some cases, securing the bundle to a fixed mounting surface with a ladder clip, T-slot, chain link, saddle/swivel clip, etc.
- Securing saddle/swivel clips to hose routings. This type of application is intended for hose separation to prevent hose rub situations only. Plastic cable ties are not to restrain hose routings.
- General use of cable straps for applications other than stated above may not apply to Figure 1 tensioning settings. Validation of a proper setting will need to be done beforehand or contact Design Control A526 for assistance.
General Requirements
- Cable straps are intended to restrain the product onto a mounting component or intended support surface.
- Cable straps must not be loosely tensioned. A loose cable strap may allow wear of the restrained product, wear between the product and the adjacent mounting surface, or allow movement of the product through the strap.
- Cable straps must not be overly tight to the product. An overly tight cable strap may damage the harness/hose covering or wiring insulation. An overly tight cable strap may damage electrical conductors and splices within the harness bundle.
- Cable straps used for electrical applications shall be used to press the electrical wiring harness or cable to adjoining surface perpendicular to the axis of the harness bundle or cable. Before cable strap tensioning, the electrical wiring harness or cable shall be positioned in a manner that minimizes axial loading.
- Tensioning tools shall be serviced regularly to assure proper tensioning and avoid a sharp edge at the cutoff location, which could cause laceration to the skin. If a sharp edge is found when the cable tie is cut, the tension tool requires maintenance to have the blade changed.
Specific Requirements
- Cable straps with less than 150 N minimum tensile strength, shall not be used in supporting or mounting electrical wiring harness.
- Use Figure 1 to determine the correct tool tension setting. Other tensioning tools may be used as long as the specific cutoff force is attained. For cable strap cross sections that are not listed, strap tension will need to be determined so the aforementioned criteria are met. Figure 2 lists Average Cut off Force for Hellermann Tyton and Panduit tension tools. Use this chart to determine correct setting for other tensioning tools.
Show/hide table
Table 1 Tool Tension Settings Cable Strap Width (mm) Hellermann-Tyton Setting 326-8203 Panduit Setting 4C-5877 Braid, Conduit, Hose, Sleeve, or Tape Bare Wire Braid, Conduit, Hose, Sleeve, or Tape Bare Wire 2.5 - 3.5 2 2 2 2 4.6 - 6 4 4 4 4 7.6 - 8.8 8 6 8 6 12.7 8 N/A N/A N/A Show/hide tableTable 2 Average cutoff Force Hellermann-Tyton Panduit Tool Setting Average Cutoff Force "N" Tool Setting Average Cutoff Force "N" MIN MAX MIN MAX 1 96 116 1 29 65 2 128 148 2 62 98 3 162 182 3 93 129 4 189 219 4 133 169 5 213 243 5 173 209 6 252 282 6 229 265 7 281 311 7 258 294 8 318 348 8 271 307
- Cable straps are to be hand tightened first as the part is routed/placed in correct position.
- When tensioning cable straps, the tension tools will require up to (2) pulls of the lever. The first pull will bring the cable strap tight to the wiring harness or electrical cable; the second pull will tension the cable strap and cut the tail flush to the head of the cable strap.
Stainless Steel Ties
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| Illustration 5 | g03869568 |
Part No. 305-2395 | |
Scope
This specification applies to the tensioning of Hellermann Tyton stainless steel cable straps (also called Stainless Steel cable ties) with 305-2395 (MK9SST) hand tension tool.
Applications
- Tying/securing bundles of electrical wire or cables together in high temperature applications as would be done in manufacturing wire harnesses/assemblies, and in some cases, securing the harness bundle to a fixed mounting surface with a ladder clip, T-slot, chain link, or weld clip.
- Securing cover jackets, sheathing and covers on hoses, exhaust, and electrical harnesses.
- General use of cable straps for applications other than stated above may not apply to Figure 1 tensioning settings. Validation of a proper setting will need to be done beforehand or contact Design Control A526 for assistance.
General Requirements
- Cable straps are intended to restrain the product onto a mounting component or intended support surface.
- Cable straps shall not be loosely tensioned. A loose stainless steel cable strap may allow wear of the restrained product, wear between the product and the adjacent mounting surface, or allow movement of the product through the strap.
- Cable straps must not be overly tight to the product. An overly tight cable strap may damage the harness/hose covering or wiring insulation. An overly tight cable strap may damage electrical conductors and splices within the harness bundle.
- Cable straps used for electrical applications shall be used to press the electrical wiring harness or cable to adjoining surface perpendicular to the axis of the harness bundle or cable. Before cable strap tensioning, the electrical wiring harness or cable shall be positioned in a manner that minimizes axial loading.
Specific Requirements
- Table 3 is a manufacturer's guide to determine the correct tool tension setting. Validation of the product to be secured shall be done.
- Cable straps are to be hand tightened first as the part is routed/placed in correct position.
- When tensioning cable straps, the tension tools will require up to (2) pulls of the lever. The first pull will bring the cable strap tight to the wiring harness or electrical cable; the second pull will tension the cable strap and cut the tail flush to the head of the cable strap.
| CAT Part Number SS Tie | Width (mm) | Length (mm) | Tensioning Tool Setting | Estimated Tensioning Force (N) |
| 369-9841 | 4.6 | 127 | 1 - 2 | 273-341 |
| 3 - 4 | 421-491 | |||
| 290-1993 | 4.6 | 200 | 1 - 2 | 273-341 |
| 3 - 4 | 421-491 | |||
| 143-9607 | 4.6 | 363 | 1 - 2 | 273-421 |
| 3 - 4 | 421-491 | |||
| 108-9656 | 7.9 | 200 | 5 - 6 | 570-660 |
| 7 - 8 | 715-776 | |||
| 131-1578 | 7.9 | 363 | 5 - 6 | 570-660 |
| 7 - 8 | 715-776 |
Blade Replacement
- Tensioning tools shall be serviced regularly to assure proper tensioning and avoid a sharp edge at the cutoff location, which could cause laceration to the skin. If a sharp edge is found when the cable tie is cut, the tension tool requires maintenance to have the blade changed.
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| Illustration 6 | g03869552 |
- Remove the screws from the nose piece. Carefully lift off the nose piece and remove and discard the old blade. Install the new blade with the bevel side facing towards the tool and the cutting edge facing up. Make sure that the blade is set securely on the blade link. Carefully place the nose piece over the blade and reinsert the screws. Nose piece screws should not be over tightened.
Note: For 326-8203 Gun, use replacement blade 490-6593 (Available 4th Quarter 2015). For other guns, purchase from manufacturer.
Large Mining Truck Special Procedures
This section outlines the specifications on individual part numbered tie straps. These tie straps are used on large mining products and mimic that of factory installation procedures.
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| Illustration 7 | g03870186 |
Flow Chart Diagram | |
Cable Tie Part Number and Tool Usage.
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| Illustration 8 | g03869562 |
Part No. 326-8203 | |
The cable ties above are the only ones that require this special procedure, which mimics that of the factory installation procedure.
Procedure
- Set the 326-8203 Tool to the "HVY" setting and adjust the dial indicator to position "8".
- Lock out adjustments per manufacturer instructions outlined below. A copy of the manufacturer instructions are also provided with the tool.
- Incorporate a service cycle for replacing cutting blades. The service replacement blade for the 326-8203 Tool has a part number of 490-6593.
Lockout Procedure
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| Illustration 9 | g03870204 |