LUG-CAPSURE 3896796 - Caterpillar

On batteries that are constructed per Illustration 10, ensure that the nut (9) that is used for connecting the cable to the post points away from the battery. This orientation allows adequate clearance for the socket of a torque wrench.Note: The length of screws and bolts shall provide a minimum of 1 1/2 threads and a maximum that is limited by the nearest practical standard length of the screw beyond the nut or joining surfaces, except when such projections would invalidate good workmanship or when the projections would invalidate the requirements of the design.Connecting a Conductor to a Mechanical Connection
Use the following procedure in order to connect a conductor to a mechanical connector.
Remove the insulation that is around the conductor of the wire.Ensure that you do not nick the strands of the conductor or do not damage the strands.
Carefully remove the oxide film on the outer strands of the conductor. Lightly brush the strands with a wire brush or use fine sandpaper in order to remove the film.
Apply a joint compound to the conductor in order to prevent oxidation.
Illustration 11 g02073641
Typical mechanical connector (10) Set screw (11) Connector (12) Conductor
Insert the cable into the barrel of the connector (11) .
Tighten the set screw (10) against the conductor (12) .Table 1 contains the typical torque that is required in order to tighten the set screw.Note: Refer to the specifications that are provided by the manufacturer of the connector in order to determine the torque that is required.
Table 1
Tightening Torque for Set Screws    
Size of Threads in Inches
   Torque    
lb-in n-m    
1/4     72     8.2    
5/16     132     15.0    
3/8     228     25.8    
7/16     360     40.8    
1/2     540     61.2    
5/8     1116     126.5    Connecting a Conductor to a Compression Connection
Use the following procedure in order to connect a conductor to an aluminum compression lug.
Select the proper connector.Use a connector that is marked for the wire size that will be used.Note: Never use a copper connector on aluminum wire.
Remove the insulation that is around the conductor of the wire.Ensure that you do not nick the strands of the conductor or damage the strands.
Carefully remove the oxide film on the outer strands of the cable. Lightly brush the strands with a wire brush or use fine sandpaper in order to remove the film.
Apply a joint compound to the conductor in order to prevent oxidation.Note: Some lugs are manufactured with joint compound in the barrel of the lug.
Illustration 12 g02073974
Typical compression connection (11) Connector (12) Conductor
Insert the conductor (12) into the connector 11.
Insert the connector into the die.Ensure that you select the correct installation tool and select the correct die for the wire that will be crimped.
Crimp the connector onto the wire.Note: The connector may contain knurl marks in order to indicate the correct location for crimping.
Inspect the connection for the following: sharp edges, flash, burns and excess joint compound.Using a Splice Connector
The following procedure provides instruction for