Safe-T-Cable 

Save Time and Money by Replacing Your Old Lockwire System with Safe-T-Cable 

 

There will always be a need to install constraining (safety) devices to threaded fasteners in applications where vibration, kinetic energy, or the need for high reliability is present. Their purpose is to restrict (to a minimum) the unintentional rotation of the fastener.

 

The process of installing Safety Wire remains awkward and costly, and the inspection process is demanding. The removal and rework of installed Safety Wire is a common occurrence. Safe-T-Cable® was invented to address these problems in modern Airframe and Engine Systems. The Safe-T-Cable® Kits are consistent in their construction/ application, and the user-friendly tooling guarantees a secure and reliable installation each time it is used. Operator training is simple, Inspection is objective, and rework is virtually eliminated.

 

Safe-T-Cable® is constructed of high tensile strength, stranded cable. It is more flexible than its Safety Wire counterpart, although the working diameters are equivalent. This provides a stronger assembly which has greater strength and lighter weight. The cable ends are electrically fused to form an easy threading end. The cable is pre-cut to various lengths, and is supplied with a square formed end cap attached to one end.

 

 

 

System Benefits 

  • Improved Security of Fasteners 
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  • Reduced Installation and Inspection Time 
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  • Improved Access to Tight Areas  
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  • Consistent Cable Tension on Each Application 
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  • Reduction of Rework 
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  • Minimal Operator Training Required 
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  • Lighter Weight Than Safety Wire 
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  • Eliminates Injuries Due to Sharp Safety Wire Ends 

 

 

 

Operation Overview

1. Thread 

A cable assembly is threaded through the fasteners in a direction which will exert a positive or neutral pull when tension is applied

2. Insert 

The ferrule is threaded on the cable and the cable is inserted through the nose of the tool

3. Tension 

Correct tension is applied with the tool

4. Crimp and Cut 

The ferrule is crimped and the cable is cut flush with the end of the ferrule. Discard excess cable and the job is complete! 

Safe-T-Cable Approvals & Recognitions

SAE:

SAE International (Society of Automotive Engineers) maintains and distributes the procurement and detail specifications that control the design, packaging, and performance requirements of Safe-T-Cable™. SAE Specifications are available on-line at www.sae.org, or at the following address:

 

The List of Safe-T-Cable™ Specifications are the following:

 

  • AS567 - Safety Cable, Safety Wire, Key Washers, and Cotter Pins for Production Systems,
    General Practices for Use of
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  • AS3509 - Cable, Safety, Kit, Nickel Alloy, UNS N06600
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  • AS3510 - Cable, Safety, Kit, Corrosion and Heat Resistant Steel, UNS S32100
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  • AS3511 - Cable, Safety, Kit, Corrosion Resistant Steel, UNS S30400AS4536 Cable, Safety, Kit, Procurement Specification For Requirements and Use
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  • AS3618 - Cable, Safety, Ferrule, Elongated, Corrosion and Heat Resistant Steel, UNS S32100
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  • AS3619 - Cable, Safety, Ferrule, Elongated, Nickel Alloy, UNS N06600
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  • AS3655 - Cable, Safety, Kit, Corrosion Resistant Nickel Alloy, UNS N06625
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  • AS4536 - Cable, Safety, Kit, Procurement Specification For Requirements and Use

 

Please contact DMC for further information on SAE Specifications, Publication Status, or Application References.

US Military: 

NASM 33540 (Formerly MIL-STD-33540) Safety Wiring, Safety Cabling, Cotter Pinning, General Practices.

This document is called out in many contracts, drawings, and process manuals. Safe-T-Cable™ was included in NASM 33540 in revision 1, 6 Jan, 2003. It is published and controlled by AIA (Aerospace Industries Association) and can be purchased on-line at the following web address: http://global.ihs.com/?RID=AIA

 

Technical Manuals, Technical Orders, and MS Specs:

Many Tech Manuals and Tech Orders that are used by the U.S. Military and FMS Organizations to support Aircraft, Aerospace, and Defense Systems have been revised to include Safe-T-Cable™. The technical information that is required to select, install, and maintain the Safe-T-Cable™ and Application/Verification Tooling is included.

 

The General Tech Manuals/Tech Orders are the following:

  • TO-1-1A-8
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  • TO-1-1A-14
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  • TO-1-1A-15
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  • TM 1-1500-204-23-6
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  • TM 1-1500-323-24-1
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  • NAVAIR 01-1A-505
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  • NAVSEA MIL-STD-763
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  • ARMY MICOM, Drawing 13210868
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  • NA 01-1A-505-1
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  • NA 01-1A-8
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  • TO 00-25-255-1
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  • TM 1-1500-323-24-2

FAA: 

Many FAA Approved 70-XX-XX Standard Documents are published and maintained by major engine, airframe, and component/subsystem manufacturers.

 

The FAA Approved Manual (supplied by the OEM) on the specific aircraft (or subsystem) will advise the operator/maintainer if Safe-T-Cable™ is approved by the OEM on that aircraft/application. If it cannot be determined from this, or other documentation, the operator/maintainer should contact the OEM assigned representative, and request information concerning the use of Safe-T-Cable™ on that aircraft or subsystem.

 

  • FAA Classification Letter dated November 23, 1993
  • F.A.R. 43.13  Performance Rules General

 

NASA:

The National Aeronautical and Space Administration, in cooperation with major contractors have developed several reports and standards involving the testing, selection, use, procurement, and application of Safe-T-Cable™. Two significant NASA funded documents are CR4473 – CONTRACTOR REPORT (Intersel 1992), and JA83-032A Teledyne Brown.

 

NASA Tech Briefs magazine has also recognized Safe-T-Cable™ as a modern Space Program Technology on one or more occasions. Safe-T-Cable™ has been used on the Space Shuttle main orbiter engines, structure, and payload applications.