Assembly - PWA 316 - Safety Cable Installation [PW11]

TASK 70-24-00-910-813-A
Assembly - PWA 316 - Safety Cable Installation

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

NOTE: Always obey the procedures and limits in the specific maintenance tasks of this manual. The specific maintenance tasks and limits always supersede those in this standard practices section.

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
PWA87398	1	MECHANICAL CRIMPER
OR	OR
PWA87399	1	MECHANICAL CRIMPER
OR	OR
PWA87400	1	MECHANICAL CRIMPER
OR	OR
PWA88229	1	CRIMPER, MECHANICAL

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.P05-291)	Safety Cable
(Material No.P05-292)	Safety Cable Ferrule

C. Referenced Information

REFERENCE	DESIGNATION
TASK 70-24-00-910-806-A	PWA 315 - Standard Torque Recommendations
Safety Cable Methods
Bergen Safety Cable Crimper
Bergen Safety Cable Crimper Method
Daniels Safety Cable Crimper
Daniels Safety Cable Crimper Method
Safety Cable Flex Limits

3. Job Set-up
Subtask 70-24-00-860-052-A ** ON A/C NOT FOR ALL

A. Not Applicable

4. Procedure
Subtask 70-24-00-910-052-A ** ON A/C NOT FOR ALL

A. Installation of the Safety Cable
(1) Use this safety cable process for Bergen tool installations or Daniels (DMC) tool installations.
(2) Safety cable is installed through two or more parts so that if the fastener loosens, the safety cable will tighten. When the safety cable tightens, it will prevent the fastener from loosening any further.
(3) The safety cable system has three components:
(a) Safety cable
1 The safety cable is available in several lengths and diameters. Use the correct diameter cable and ferrule as specified by the specific Engine Manual task. One end of the cable has an end fitting swaged to it. The strands of the cable on the opposite end of the cable are fused together to prevent the cable from fraying. The cable is typically installed through safety holes.
(b) Ferrules
1 The ferrule is available in several diameters. Use the correct diameter ferrule as specified by the specific Engine Manual task. Ferrules are purchased in a spring-loaded, disposable magazine. The ferrule is installed to the cable open end. The ferrule is crimped to the cable using the applicable crimping tool.
(c) Crimping equipment
1 The hand-operated crimping tool comes in different length and size heads (or noses). These different heads (or noses) are provided for the different diameter cables and ferrules and for the best access to a specific application. Use the crimping tool for the correct diameter ferrule. The crimping pressure of the tool is set by the manufacturer. This tool is used to crimp the ferrule on the end of the safety cable. The crimping tool will cut the safety cable even with the ferrule at the same time that the ferrule is crimped. Equipment, cables, and ferrules are available in kits. Crimping tools should be on a scheduled calibration program based on the frequency of use and the user's own experience. Anytime that a tool is dropped or damaged, the tool must be inspected and calibrated.
(4) This procedure gives general instructions to install safety cable, where specified by this Maintenance Manual, for the engine fasteners as follows:
(a) Bolts, screws and nuts
(b) Tube nuts, hose connectors and jam nuts
(c) Plugs and covers.
(5) Procedure
(a) Torque the parts before you install the Safety Cable (Material No.P05-291) as follows:
1 Torque all fasteners correctly before you install Safety Cable (Material No.P05-291) .
2 For two or more fasteners safetied together, put the safety holes in the correct position in relation to each other.

Safety Cable Methods ** ON A/C NOT FOR ALL

3 To get the correct wire hole alignment, do not torque the fasteners to more than (or less than) the specified limits (Ref. AMM TASK 70-24-00-910-806).
a Do not decrease the torque (loosen direction) to correctly align the wire holes.
b Do not increase the torque to more than the specified limit to correctly align the wire holes.
4 If necessary, use another fastener or part to correctly align the safety holes within the specified torque limits.
(b) Unless specified differently in the Maintenance Manual, plan the installation of the safety cable and obey the general requirements as follows:
1 Use the examples shown in the figures.
2 Where possible, install the Safety Cable (Material No.P05-291) so that it does not touch other parts.
3 Install the Safety Cable (Material No.P05-291) through existing holes only.
4 Do not install the safety cable down through the bolt lightening holes.
5 The maximum length of the safety cable between safety cabled parts is 6.0 in. (152.40 mm).
6 Do not safety more than three bolts with one safety cable.
7 Do not install the safety cable through the fasteners with sharp turns more than 90 degrees.
8 Choose the holes in the parts so that the cable will be as straight as possible but will have a minimum angle of pull (towards tight).
9 Use the examples in the safety cable method as a guide for the applicable cable installation.

Safety Cable Methods ** ON A/C NOT FOR ALL

NOTE: The safety cable method does not show every possible combination of parts that can be safety cabled. Use these figures as a guide for other applications and obey the basic rules for safety cable.

CAUTION: DO NOT USE A SAFETY CABLE IF THE HOLES ARE LARGER THAN THE SPECIFIED LIMITS. IF YOU DO, THE FERRULES ON THE END OF THE CABLE WILL PULL THROUGH THE LARGER HOLES.

1 For 0.032 in. (0.81 mm) diameter cable installations, make sure that the safety hole on the parts are less than 0.100 in. (2.54 mm) diameter.
a The ferrule on the end of the 0.032 in. (0.81 mm) diameter cables are 0.105 in. (2.67 mm) diameter and will pull through any hole larger than this.
2 For 0.020 in. (0.51 mm) diameter cable installations, make sure that the safety holes on the parts are less than 0.085 in. (2.16 mm) diameter.
a The ferrule on the end of the 0.020 in. (0.51 mm) diameter cables are 0.090 in. (2.29 mm) diameter and will pull through any holes larger than this.
3 Examine the holes for damage.
a Remove the burrs or sharp edges from the safety wire holes.
b Replace any part with damaged holes or, if possible, use another hole to install the safety cable.
(d) Select the correct diameter and length cable and ferrule as follows:
1 Use the correct diameter cable and ferrule as specified in the specific Engine Manual task.
2 Use the correct length cable for the fastener application and the length of the tool used.
(e) Examine the safety cable before installation as follows:
1 Get a new Safety Cable (Material No.P05-291) and Safety Cable Ferrule (Material No.P05-292) for each application.
a It is not permitted to use the Safety Cable (Material No.P05-291) and Safety Cable Ferrule (Material No.P05-292) again.
2 Examine the safety cable for nicks, bends, frayed strands, kinks or any damage.
a Replace, as necessary.
(f) Operate the Bergen safety cable crimper as follows:

Bergen Safety Cable Crimper ** ON A/C NOT FOR ALL

Bergen Safety Cable Crimper Method ** ON A/C NOT FOR ALL

1 Make sure that the PWA87398 MECHANICAL CRIMPERPWA87399 MECHANICAL CRIMPERPWA87400 MECHANICAL CRIMPERPWA88229 CRIMPER, MECHANICAL is on a scheduled calibration program based on the frequency of use and the user's own experience.
a Inspect the tool for a valid calibration expiration label.
2 Make sure that the installation conforms to the examples shown.
3 Choose the holes in the parts so that the cable will be as straight as possible but will have a minimum angle of pull (towards tight).
4 Put the end of the Safety Cable (Material No.P05-291) through the hole in the first part and pull the cable through.
5 Put the end of the cable through the hole in the second part and pull the cable through.
6 If you must safety three parts, do the same procedure for the third part.
7 Put the end of the safety cable through a ferrule in the ferrule magazine.
8 Use the Safety Cable (Material No.P05-291) to pull the ferrule out of the ferrule magazine.
9 Operate the crimping tool handles to make sure that the handles open fully.
10 Put the end of the safety cable through the larger hole of the crimping tool head.
11 Move the crimping tool along the safety cable until the crimping head is against the part and the ferrule goes inside the hole in the crimping head.
12 Put the safety cable in the two slots of the tensioning wheel that are in line with the crimping head.
13 For the remaining steps, make sure that:
a The nose is held perpendicular to the cable.
b The ferrule remains in the nose tightly against the fastener.
c You let the tool put the correct tension on the cable.
14 Turn the tensioning wheel on the side of the crimping tool until a click is heard.
15 Close the crimping tool handles.

CAUTION: BEFORE YOU CRIMP THE FERRULE, MAKE SURE THAT THE TENSIONING WHEEL APPLIED THE CORRECT TENSION TO THE CABLE. IF YOU DO NOT OBEY THIS INSTRUCTION, THE CABLE WILL BE TOO TIGHT OR TOO LOOSE.

CAUTION: DO NOT TRY TO REMOVE THE CRIMPING TOOL FROM THE FERRULE WITH THE HANDLES IN THE CRIMPED OR CLOSED POSITION. IF YOU DO, YOU CAN CAUSE STRESS OR DAMAGE TO THE CABLE.

a Apply constant pressure to close the crimping tool handles until the handles release and the cable is cut.

NOTE: If the handles on the crimping tool are not completely closed when the operator releases them, the handles will remain in the same position and will not open. If this should happen, apply pressure to close the handles again until the handles will release.

(g) Operate the Daniels (DMC) safety cable crimper as follows:

Daniels Safety Cable Crimper ** ON A/C NOT FOR ALL

Daniels Safety Cable Crimper Method ** ON A/C NOT FOR ALL

1 Make sure that the PWA87398 MECHANICAL CRIMPERPWA87399 MECHANICAL CRIMPERPWA87400 MECHANICAL CRIMPERPWA88229 CRIMPER, MECHANICAL is on a scheduled calibration program based on the frequency of use and the user's own experience.
a These Daniels tools are pre-set for the correct cable tension.
b Inspect the tool for a valid calibration expiration label.
2 Make sure that the installation conforms to the examples shown.
3 Choose the holes in the parts so that the cable will be as straight as possible but will have a minimum angle of pull (towards tight).
4 Put the end of the safety cable through the hole in the first part and pull the cable through.
5 Put the end of the cable through the hole in the second part and pull the cable through.
6 If you must safety three parts, do the same procedure for the third part.
7 Put the end of the safety cable through a ferrule in the ferrule magazine.
8 Use the Safety Cable (Material No.P05-291) to pull the ferrule out of the ferrule magazine.
9 Put the end of the safety cable through the larger hole of the crimping tool nose.
10 Move the crimping tool along the safety cable until the crimping nose is against the part and the ferrule goes inside the hole in the crimping head.
11 Put the safety cable in the cable entrance hole and push the cable into the cavity.
12 Pull the free end of the cable.

CAUTION: DO NOT PULL THE CABLE TOO TIGHT. DO NOT PUT TENSION ON THE CABLE WHEN YOU OPERATE THE HANDLES. IF YOU PUT TOO MUCH TENSION ON THE CABLE, YOU CAN CAUSE A MALFUNCTION OF THE CABLE AND FERRULE.

a Lightly pull the free end of the cable only enough to remove any slack.
13 For the remaining steps, make sure that:
a The nose is held perpendicular to the cable.
b The ferrule remains in the nose tightly against the fastener.
c You let the tool put the correct tension on the cable.
14 Use several short strokes of the handles to make the nose of the tool snug to the fastener.
15 Crimp the ferrule and cut the access cable.

CAUTION: MAKE SURE THAT YOU KEEP THE NOSE PERPENDICULAR TO THE CABLE AND THAT YOU USE A FULL STEADY STROKE OF THE HANDLES. IF YOU DO NOT, THE CABLE TENSION CAN BE TOO LOOSE.

a Open and close the handles fully (with constant pressure) to crimp the ferrule and cut the access cable.
16 Release the crimper and remove the tool from the ferrule.
(h) Examine the safety cable after installation as follows:
1 Make sure that the length of unwanted cable past the crimped ferrule is not more than 0.031 in. (0.79 mm).
a Cut the excess or replace, if necessary.
2 Examine the crimped ferrule to make sure that it has a good crimp.
a Replace, if necessary.
3 Examine the safety cable for nicks, frayed strands, kinks, or any damage.
a Remove and replace, if necessary.
4 Examine the safety cable for flex limits as follows:
a Push on the safety cable at mid-span with light finger pressure, approximately 2 lb (0.91 kg).
b The total flex for the safety cable must not be more than the following limits:

Safety Cable Flex Limits ** ON A/C NOT FOR ALL

Index A - Safety Cable Length (Span) Inch (mm)	Index B - Full Flex Limit Inch (mm)	Index C - Half Flex Limit Inch (mm)
0.5 in. (12.70 mm)	0.125 in. (3.17 mm)	0.063 in. (1.60 mm)
1.0 in. (25.40 mm)	0.250 in. (6.35 mm)	0.125 in. (3.17 mm)
2.0 in. (50.80 mm)	0.375 in. (9.52 mm)	0.188 in. (4.78 mm)
3.0 in. (76.20 mm)	0.375 in. (9.52 mm)	0.188 in. (4.78 mm)
4.0 in. (101.60 mm)	0.500 in. (12.70 mm)	0.250 in. (6.35 mm)
5.0 in. (127.00 mm)	0.500 in. (12.70 mm)	0.250 in. (6.35 mm)
6.0 in. (152.40 mm)	0.625 in. (15.87 mm)	0.313 in. (7.95 mm)

c The cable must not be too tight.

NOTE: Use your experience to feel that the cable and ferrule is not tensioned more than what the tool applies.

d Replace, if necessary.

[Rev.10 from 2021] 2026.04.01 02:20:19 UTC