Preliminary Requirements

Safety Requirements

WARNING

IT IS THE RESPONSIBILITY OF THE OPERATOR TO OBTAIN AND OBSERVE THE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS INFORMATION SUCH AS, HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL MEASURES AND ALSO TO TAKE LOCAL REGULATIONS IN TO CONSIDERATION.

Procedure

1. SUBTASK 70-42-08-400-003 Applicability of Safety Cable as an Alternative to Lockwire/Safety Wire

   1. Safety cable is permitted at limited locations as an alternative to lockwire/safety wire. It is permitted to use SPM TASK 70-42-08-400-501 Safety Cable as an alternative to lockwire/safety wire as specified below.

      1. At all external and fan stream locations where the safety wire hole is sufficiently large for the cable, it is permitted to use only Safety Cable Part No AS3510-0218C (0.032 inch (0.813 mm) diameter) and safety cable ferrule Part No AS3510-02F.

   2. Safety cable is not permitted at the subsequent locations:

      1. Locations where the safety wire hole is more than 0.100 inch (2.540 mm) diameter (the safety cable ferrule will pull through a hole larger than this)

      2. Internal areas of the engine

      3. Internal areas of gearboxes

      4. Internal areas of accessories

      5. Heat shields (as lacing)

      6. Vendor-controlled (Category 1) components.

2. SUBTASK 70-42-08-400-002 Equipment and Materials

   1. Standard equipment.

      1. Crimping tool such as.

         - Daniels SCT 203, SCT 207, SCT 323, SCT 327		Vendor code 11851 or U0419
         - Bergen M203, M303, M305, M307		Vendor code 70958

      2. Manual load test block such as.

         - Daniels SCT-TB1	(Facility Equipment Manual AD 039)
         - Bergen TB-101	(Facility Equipment Manual AD 039)

      3. Torque wrench 3/4 inch drive such as.

         - Daniels SCTD0001.

   2. Consumable materials.

      Cable diameter 0.032 inch (0.8 mm)
      CoMat 02-272 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-273 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-274 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-275 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-276 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-277 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-278 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-279 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-280 SAFETY CABLE FERRULE	Safety cable ferrules
      CoMat 02-281 SAFETY CABLE FERRULE	Safety cable ferrules

      Cable diameter 0.020 inch (0.5 mm )
      CoMat 02-282 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-283 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-284 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-285 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-286 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-287 SAFETY CABLE KIT	Safety cable kits
      CoMat 02-288 SAFETY CABLE KITS	Safety cable kits
      CoMat 02-289 SAFETY CABLE FERRULES	Safety cable ferrules
      CoMat 02-290 SAFETY CABLE FERRULES	Safety cable ferrules

3. SUBTASK 70-42-08-400-001 Safety Cable Installation

   1. Basic rules.

      Where safety cable is specified on the assembly illustrations, use the procedure that follows to install the cable.

      1. Maximum span.

         1. The maximum span of safety cable between two end points is 6.0 inch (152.4 mm), unless specified differently by the assembly illustration.

      2. Installation defects.

         1. Nicks, kinks, fraying or any damage to the safety cable found before, during, or subsequent to installation at or between end points is not permitted.

      3. Installation holes.

         1. 

            CAUTION

            DO NOT USE SAFETY CABLE IF THE HOLES ARE MORE THAN 0.100 INCH (2.54 MM) DIAMETER. THE FERRULES ON THE ENDS OF THE CABLE ARE 0.106 TO 0.108 INCH (2.693 TO 2.743 MM) DIAMETER AND WILL FALL THROUGH HOLES LARGER THAN THIS.

            Always install safety cable through the safety cable or safety wire holes given on the part.

         2. The threading of safety cable down through bolt lightening holes is not permitted. An Unacceptable Installation is illustrated in Figure.

      4. Permitted number of times to use the safety cable and ferrule:

         1. The safety cable and its ferrule must be new for each application. It is not permitted to use the safety cable and ferrule again.

      5. Installation.

         1. Refer to Figureand Figure for examples of safety cable methods. Other methods are possible.

         2. No more than three fasteners shall be secured with one cable.

         3. Install safety cable in two or three bolt patterns, unless specified differently in the assembly procedure. The two bolt pattern is preferred when you apply safety cable to an even number of fasteners.

         4. All possible combinations are not shown in Figure and Figure but every combination must follow the basic rules for safety cable.

      6. Pull-off load.

         1. The pull-off load is the force necessary to pull the cable out of either the ferrule or the cable end fitting.

         2. Each safety cable installation tool shall be checked for pull-off load on a daily basis. This check can be extended up to a maximum of one month, when the user has obtained sufficient reliable experience on each tool.

      7. Crimp requirements (pull-off load).

         1. Crimp the ferrule to the cable using one of the crimping tools in Equipment and Materials (refer to Step ).

         2. The safety cable must meet the minimum crimp requirements as shown in Table.

            Table 6. Safety Cable Minimum Crimp Requirements (Pull-off Load)

            Nominal Cable Diameter Inch (mm)		Minimum Pull-off Load Pound-Inches (Nm)
            0.020 (0.5)		30 (3.39)
            0.032 (0.8)		70 (7.91)
            0.040 (1.0)		130 (14.69)

      8. Cable size.

         1. The 0.032 inch (0.8 mm) diameter safety cable is the preferred size and must be used for all fittings, unless the cable will not fit, because the holes are smaller than the cable size, then the 0.02 inch (0.5 mm) safety cable shall be used.

   2. Installation.

      1. Hole alignment.

         1. Do not decrease or increase the torque on the parts to correctly align the holes for the cable.

      2. Adjacent units.

         1. Install safety cable so that any tendency for a fastener to loosen is counteracted by more tension on the cable.

         2. Safety cable is not a means to get or keep a torque. It is a safety device used to prevent disengagement of the parts only.

         3. It is recommended that there are no turns, more than 90 deg, if possible, when the cable goes through the fasteners. The result is the installation of safety cable with either a positive or neutral pull. The better condition is to have the cable positive. Where this is not possible because of interference across an edge of a gusset, bracket, or other part, the use of a neutral condition is permitted.

      3. Cable flex limits.

         1. Cable installation tools will give the specified flex limits. (Refer to Step.) The maximum cable flex limits between end points must be no greater than given in the table following and illustrated in Figure when light finger pressure (approximately 2 pounds) is applied at mid-span.

            Table 7. Safety Cable Flex Limits

            Dimension A			Dimension B			Dimension C
            Inch	mm		Inch	mm		Inch	mm
            0.5	12.7		0.125	3.175		0.062	1.575
            1.0	25.4		0.250	6.350		0.125	3.175
            2.0	50.8		0.375	9.525		0.188	4.775
            3.0	76.2		0.375	9.525		0.188	4.775
            4.0	101.6		0.500	12.700		0.250	6.350
            5.0	127.0		0.500	12.700		0.250	6.350
            6.0	152.4		0.625	15.875		0.312	7.925

      4. Excess cable.

         1. After installation of safety cable, cut off the excess cable from the crimped ferrule.

         2. The maximum length of unwanted cable permitted to extend past the crimped ferrule is 0.031 inch (0.79 mm).

      5. Security Seals.

         1. Where specified in the assembly instructions, apply and crimp a security seal to the safety cable.

      6. Procedure.

         1. Check the units to make sure that they have been correctly torqued. Under torque or overtorque to obtain correct alignment of the holes is not permitted. If it is not possible to obtain correct alignment with the specified torque limit, back off the unit and try again or select another unit.

         2. In adjacent units, it is desirable that the holes be in approximately the same relationship to each other.

         3. Insert the end of the cable without the end fitting (ferrule) through the hole in the first part and pull the cable through until the end fitting is against the part. Keep the safety cable as straight as possible during its installation through parts.

         4. Insert the end of the cable through the second part and pull it through (Refer to Figure Step 1). If there is a third part to be safety cabled, pass the cable through this in the same manner.

         5. Insert the free end of the cable through a ferrule in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull out the ferrule from the magazine (Refer to Figure Step 2).

         6. Insert the free end of the cable through the crimping tool. Make sure the large hole of the crimping head is on the same side as the ferrule (Refer to Figure Step 3).

         7. Move the crimping tool along the cable until the crimping head is against the part. Make sure the ferrule is inside the hole in the crimping head (Refer to Figure Step 4).

         8. If the ferrule will not go into the crimping head, remove the tool from the cable and then push the handles completely together. When the handles are released, they will open automatically. Insert the cable back through the crimping head and move the tool along the cable until the crimping head is against the part. Make sure that the ferrule is inside the crimping head.

         9. Place the cable into the tensioning device on the crimping tool and tension the cable (Refer to Figure Step 5).

         10. 

             CAUTION

             DO NOT CRIMP THE FERRULE UNLESS THE CORRECT TENSION HAS BEEN APPLIED BY THE TENSIONING DEVICE.

             Crimp the ferrule and cut the cable. Obey the manufacturer's instructions (Refer to Figure Step 6).

         11. Remove and discard the unused cable from the tensioning device.

         12. Push against the safety cable with a light finger pressure half way between the components that have been wire locked. If the cable feels loose, do a dimensional check as follows to make sure that the cable is serviceable:

             1. Measure the distance between the safety cabled parts; write this down as Dimension A. If three parts are safety cabled together, measure the distance between each of the parts (Dimensions D and E) and add the measurements together, that is, D + E = A. (Refer to Safety Cable Flex Limits, Figure.).

             2. Push against the safety cable with light finger pressure half way between two safety cabled parts. Measure the distance the safety cable moves laterally. Write this dimension down as Dimension C.

             3. Compare the dimensions written down to the acceptable limits given in Table 2.

             4. If the safety cable is not within the acceptable limits given, cut and remove the installed cable and then install a new safety cable.

Figure: Examples of safety cable methods

Examples of safety cable methods



Figure: Examples of safety cable methods

Examples of safety cable methods



Figure: Safety cabling procedure

Safety cabling procedure



Figure: Unacceptable Installation

Unacceptable Installation



Figure: Safety Cable Flex Limits

Safety Cable Flex Limits