TASK 70-11-04-400-008
1 . General.
Subtask 70-11-04-400-076
A.Method No. 2 is an equivalent alternative to:
TASK 70-11-03-400-007, Safety Cable Method No. 1 (Bergen Tool), and
TASK 70-11-05-400-009, Safety Cable Method No. 3 (Daniels (DMC) Tool).
B.Safety cable is an alternative to safety wire unless specifically prohibited by the assembly procedure. Safety cable is installed through a maximum of three parts in such a way that as the fastener or part loosens, the safety cable will tighten. When the safety cable tightens it will not permit the fastener or part to turn.
C.The safety cable system has three components: The safety cable, ferrules and crimping tool. See Figure 1.
(1)The safety cable C10-145   is available in one size, 0.032 inch (0.81 mm), and is made of AMS 5689 (321 stainless steel) material. One end of the cable will have a cable end fitting swaged to it. The cable end fitting is made of AMS 5674 (347 stainless steel) or AMS 5689(321 stainless steel) material. The strands of the cable on the opposite end of the cable are fused together to prevent the cable from fraying.
(2)The ferrules C10-144   are made of AMS 5674 (347 Stainless Steel) or AMS 5689 (321 stainless steel) material and are purchased in a spring-loaded, disposable magazine. When the safety cable is installed the ferrule will be crimped on the open end of the cable.
(3)The hand-operated crimping tool C10-148   operates in one direction only and has a cycle end dead stop to tell the operator when the ferrule is fully crimped. The crimping pressure of the tool is set by the manufacturer. If necessary, the crimping pressure can be adjusted with standard hand tools. The Snap-On tool has a spring-loaded crimp rod to hold the ferrule in place during the crimping procedure. Cable tension is done automatically by the internal retraction mechanism.
Figure 1   Safety Cable System Components (Method No. 2)
2 . Tools and Equipment (Method No. 2).
Subtask 70-11-04-400-071
 
Code No.
Description
 
C10-146  
Test Block, Safety Cable
 
C10-147  
Tester, Safety Cable
 
C10-148  
Crimping Tool, Safety Cable (0.032 inch dia)
 
C10-149  
Side Cushioned Diagonal Cutter
3 . Consumables (Method No. 2).
Subtask 70-11-04-400-072
 
Code No.
Description
 
C10-143  
Safety Cable Assembly (0.032 inch Dia)
 
C10-144  
Ferrule, Safety Cable (0.032 inch dia cables)
 
C10-145  
Cable, Safety (for 0.032 inch dia cables)
4 . Safety Cable Practices (Method No. 2).
Subtask 70-11-04-400-073
A.Where possible, install the safety cable so it does not touch other parts.
B.Make sure the cable is not damaged or bent when you install the safety cable through the holes in the fastener or part. Frayed cable assemblies are not permitted.
C.Install the safety cable through existing holes only.
D.Unless specified differently in the engine manual:
(1)The maximum length of the safety cable between safety cabled parts is 6.0 inches (152.4 mm).
(2)Do not safety more than three bolts with one safety cable.
(3)Do not use safety cable on titanium fasteners.
5 . Crimping Tool Verification (Method No. 2).
Subtask 70-11-04-400-074
A.Do a pulloff load test as often as necessary to make sure the crimp done by the crimping tool meets the necessary requirements. GE Aircraft Engines recommends the pulloff load test be done at the beginning, middle and end of each shift. Do the pulloff load test as follows: See Figure 3.
(1)If the test block C10-146   is not already set up, set it up at this time. Refer to manufacturers instructions for set up information.
(2)Make sure the pivot joint is in the forward direction.
(3)Move the cable stop at the end of the test block. Install the safety cable C10-145   through the hole that was covered by the cable stop. Pull the safety cable through the hole in the test block and then put it through the hole in the pivot joint. Pull the cable through the hole in the pivot joint.
(4)Put the end of the safety cable coming out of the pivot joint through a ferrule C10-144   in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine. See Figure 2, step 2.
(5)Put the end of the safety cable through the crimping head of the crimping tool C10-148  . Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the ferrule. Pull back on the retraction knob. Put the ferrule in the crimping head and release the retraction knob. Make sure the ferrule is fully in the crimping head. See Figure 2, steps 3, 4, and 5.
CAUTION:
DO NOT PUT TOO MUCH TENSION ON THE SAFETY CABLE. THE CRIMPING TOOL WILL AUTOMATICALLY SET THE TENSION. TOO MUCH TENSION WILL CAUSE UNNECESSARY STRESS ON THE SAFETY CABLE.
(6)Pull the safety cable to the tension post on the crimping tool. Wrap the cable completely around the post. Make sure the cable is in the groove at the top of the post. Pull the cable toward the drive handle until the cable goes behind the locking ball. See Figure 2, step 5.
(7)Hold the crimping tool perpendicular to the cable in the bolt head. Make sure the ferrule is tightly against the bolt head. Lightly pull on the end of the safety cable to remove slack. See Figure 2, step 5.
(8)Push the start cycle button and turn the drive handle clockwise. At the start of the cycle, the tension block will move backwards. This movement backwards provides the cable tension. When the drive handle is turned, release the start cycle button. Turn the drive handle until it stops (approximately two full turns).
(9)Pull up on the end of the safety cable end to remove it from the tension block.
(10)Pull back on the retraction knob and remove the crimping tool from the crimped ferrule and the remaining safety cable.
(11)Cut the unused safety cable even with the crimped ferrule. Use the side cushioned diagonal cutters C10-149  . Discard the safety cable end.
(12)Find the center of the safety cable in the test block. Use light finger pressure and push the center of the safety cable toward the wall on the test block. The safety cable must not touch the wall.
(13)If the safety cable touches the wall, the safety cable is not serviceable. Cut the safety cable with wire cutters C10-149   and remove the safety cable from the test block. Install a new safety cable and do the pulloff load test again. Make sure the tension on the safety cable is correct. Make sure when you crimp the ferrule the crimping tool is perpendicular to the safety cable and the ferrule is tightly against the bolt head. If the cable touches the wall again, remove the crimping tool from service.
(14)Set a calibrated breakaway torque wrench to 80 lb in. (9.0 N·m). Install the torque wrench in the pivot joint on the test block.
(15)Move the torque wrench handle counter-clockwise until the torque wrench clicks or the ferrule moves. If the ferrule moves before you hear the torque wrench click, remove the crimping tool from service.
(16)Find the center of the safety cable in the test block. Use light finger pressure and push the center of the safety cable toward the wall on the test block. If the safety cable does not touch the wall the crimping tool can be released for service. See Figure 3.
(17)If the safety cable touches the wall, the safety cable is not serviceable. Cut and remove the safety cable from the test block. Do the pulloff load test again with a new cable. Make sure when you crimp the ferrule the crimping tool is perpendicular to the safety cable and the ferrule is tightly against the bolt head. If the new safety cable is unserviceable, remove the crimping tool from service.
B.Do a test to determine the exact amount of pressure necessary to cause the crimped ferrule or safety cable to fail. It is recommended that this test be done a minimum of once a month. Use a safety cable tester C10-147   to do this test. See Figure 3. Do the test according to the manufacturers instructions. This test can also be used as an alternative to the test block test.
Figure 2   Safety Cable Procedure (Method No. 2)
Figure 3   Crimping Tool Verification Equipment (Method No. 2)
6 . Specific Techniques for Safety Cable (Method No. 2).
Subtask 70-11-04-400-075
A.Do a visual inspection of the holes to be safety cabled to find all damage. If the hole is damaged, replace the part or, if possible, use another hole to safety cable.
NOTE:
Keep the safety cable as straight as possible when you safety cable the fasteners or parts together. See Figure 5.
B.Put the end of the cable without the cable end fitting into the hole in the part. Pull the cable through the hole until the cable end fitting is against the part. See Figure 2, step 1.
NOTE:
Although every possible combination of safety cabling is not shown in Figure 5, all safety cabling must conform generally to the examples shown.
C.Insert the end of the cable through the second part. Choose the hole in the part that permits the cable to be as straight as possible. Pull the cable through the second part. If three parts must be safety cabled, do the same procedure for the third part.
NOTE:
On a two bolt pattern, do not cable in a negative pull direction. Make sure the cable has a positive or neutral pull.
D.Put the end of the safety cable coming out of the last part to be safety cabled through a ferrule in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine. See Figure 2, step 2.
E.Put the end of the safety cable through the crimping head of the crimping tool. Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the ferrule. Pull back on the retraction knob. Put the ferrule in the crimping head and release the retraction knob. Make sure the ferrule is fully in the crimping head. See Figure 2, steps 3,4, and 5.
CAUTION:
DO NOT PUT TOO MUCH TENSION ON THE SAFETY CABLE. THE CRIMPING TOOL WILL AUTOMATICALLY SET THE TENSION. TOO MUCH TENSION WILL BREAK THE SAFETY CABLE.
F.Pull the safety cable to the tension post on the crimping tool. Wrap the cable completely around the post. Make sure the cable is in the groove at the top of the post. Pull the cable toward the drive handle until the cable goes behind the locking ball. See Figure 2, step 5.
G.Hold the crimping tool perpendicular to the cable in the bolt head. Make sure the ferrule is tightly against the bolt head. Lightly pull on the end of the safety cable to remove slack. See Figure 2, step 5.
H.Push the start cycle button and turn the drive handle clockwise. At the start of the cycle, the tension block will move backwards. This movement backwards provides the cable tension. When the drive handle is turned, release the start cycle button. Turn the drive handle until it stops (approximately two full turns).
I.Pull up on the safety cable end to remove it from the tension block.
J.Pull back on the retraction knob and remove the crimping tool from the crimped ferrule and the remaining safety cable.
K.Cut the unused safety cable even with the crimped ferrule. Use the side cushioned cutters C10-149  . Discard the unused safety cable.
L.Visually inspect safety cable for kinks, frayed wires, or improper crimps. Remove and replace safety cable if a problem exists.
M.Push against the safety cable with light finger pressure halfway between the safety cabled parts. If the cable feels loose, do a dimensional check to make sure the safety cable is serviceable(see Figure 4) as follows:
(1)Measure the distance between the safety cabled parts. Write this measurement down as Dimension A. If three parts are safety cabled together, measure the distance between each of the parts and add the two measurements together to get Dimension A.
(2)Push against the safety cable with light finger pressure halfway between two safety cabled parts. Measure the distance the safety cable moves laterally. Write this measurement down as Dimension C.
(3)Compare the dimensions that were written down to the limits given in Figure 4.
CAUTION:
DO NOT TRY TO BREAK THE SAFETY CABLE. IF THE SAFETY CABLE MUST BE REMOVED, CUT THE SAFETY CABLE TO AVOID DAMAGE TO THE HOLES IN THE PARTS.
N.If the safety cable is not in the limits given in Figure 4, cut the safety cable with wire cutters C10-149   and remove the installed safety cable. Install new safety cable.
Figure 4   Safety Cable Flex Limits (Method No. 2)
Figure 5   (Sheet 1 ) Safety Cable Patterns (Method No. 2)
Figure 5   (Sheet 2 ) Safety Cable Patterns (Method No. 2)