Skill Enhancement Training

Wire Locking

Safetying

•FAASTRam

Failure to properly secure aircraft components can compromise powerplant and control
system operation, leading to system and component failures.

Reason

Lockwire - installed to put tension on the wire

wire together 2 or more units, in such a manner that any tendency of 1 to loosen is
counteracted by the tightening of the wire.
most positive and satisfactory method of securing or safetying cap screws, studs,
nuts, boltheads and turn buckle

2 Methods:

1. Double Twist Method

-Most commonly used

-Recommended Method

-Studs, turnbuckles, flight controls, and engine accessory attaching bolts.

-Single fastener application -1 point of attachment

-Standard -3 fasteners

-Strength will be weakened it more than 3 bolts

2. Single wire Method

-Unlimited bolt

-Specified in related task

-Light vibration areas

-Used on closely spaced or closed geometrical pattern:

a) triangle

b) Square

c) Rectangle

d) Circle
1mm = 0.03937

1ft = 12in

when:

-A bolt could loosen during vibration

-wire remains taut prevents further movement

How to wire lock

•Observe warning and caution:

Warning – Injury or personal death

Caution – Damage to equipment

Twisting with special tool

a) Grip the wire in the jaws of the wire twister and slide the outer sleeve down with
your thumb to lock the handles or lock the spring-loaded pin
b) Pull the knob, and the spiral rod spins and twist the wire
c) Squeeze handles together to release the wire

Wire Locking rules

a) Use lockwire only one time

b) Lockwire is not damaged
c) Not permitted to use lockwire to lock control cables turnbuckles
d) Not be chafing or fatigue
e) Not have an effect on the quality
f) Do not used lockwire to prevent unwanted operation of controls
g) Not permitted to use lead seals
h) The length of the wire between the attachment points must be short as possible

Wire Locking Direction

-Tension against the direction of rotation to loosen the nut

-Righty-Tighty Test

Attachment point

-used for wirelocking when distance is more than 100mm(3.9in)

-provision

Maximum Distance of 2 fasteners – 3.9in (100mm)

Minimum wirelocking approach angle – 450 minimum approach angle to secure the
coupling
1. Lockwire in fuel tanks make sure that there is no protrusion of the wire ends:
-Single wire – protrusion back to the wire
-Double Wire bend the wire ends with protrusion back to the wire
2. Minimum distance between wire and parts that move:
-15mm (0.5906in)
3. Direction
-tangential to the parts that you will lock
-The lug must align with the wire. Start at the lug
-wire goes across the body of the item, the angle of approach of the wire must be
a minimum of 450

4. 2 units

Metric Standard (mm)

Us Standard (inch)

Additional Pipe Wirelocking Rules

-Lock will to the pipe swivel nut and not to the plugin which

-Do not use same will lock of more than 2

*Can apply safety will on the castellated not

Diameter of lockwire

Must note on procedure

-Twist the lockwire at 60° angle; do not put much tension

-Pigtail = half an inch - (10mm (0.39in) - 15mm (0.59in)

-Bead the pigtail around the fastener head

Must note on single wire locking

-Twist a minimum of four tiles,

-Bend the lockwire back by 180° below itself

Inspection

-Pass the Righty-tighty rest

Safety wiring/torque application

-RII

-Critical System

Wiring and Electrical wiring connection

WIRE IDENTIFICATION

-AMA ATA

-ESP DESC ATR

Definitions:

1.AWG - American wire Gauge

2. EN - European Normalisation

3. Conductor - conducting element of the cable formed from one or

more strands.

4. Core - Assembly of a conductor and insulation which then form part of a complete
single or multi conductor cable.

5. Cable or wire - Assembly consisting of a conductor, insulation and when applicable,

a sheath, screen, or jacket

P/N dentification

A. General cases

Standard P/N

code letter for # - Wire Gauge - Insulation color code of cores

B. Specific cases

A.

United States (US)

-Us diameters

- AKA 24 19 strands, diameter 0.127mm (0.005inch)

B. Metric CM) types

- Installed for weight saving CF gauge 24 has 19 strands •CF gauge 24, 19 strands
diameter 0.12mm

Wire type Interchangeability table

1. Us to Metric. One way interchangeability Table

-One way

-Us to Metric only

-If US wiring is no longer available

2. Metric to Metric - one way interchangeability

3. Metric to Metric - two-way interchangeability

-ASNE to EN

-ABS to EN

4. Wire Type Codes

-written on the wire -PI/PTFE 4ADA

-single core and Multi-core Identification Coding

-special cable Identification coding

-Optic Fiber Cable Identification Coding

-IFE

-Loading & Uploading Data

-seen in cabin

5. Gauges
-AWG Decreases – real section increases

-EU Gauge – real section increases

-On electrical drawings, the large gauges have a special codification

6. Manufacturer. Identification

A. Identification by Printing of External sheath

-horizontally

-less than 1.27mm (0.05in)

-Vertical printing us wire Types

US wire types

-pitch-300mm (11.81m) I 50mm (1.97th)

-AKA FF 220

Group 1: For 3 letters wire type code

Group 2: Manufacturer and country

Group 3: Year of Manufacture

Group 4: Wire gauge

Metric Wire type

ASN/NSA Standard P/NS

-printing must be green

-Light green

-Dark green -depending on the insulations color

-red, blacks and dark green elements must be marked white

-black for purple optical cables

-300mm (11.81in) pitch

-Group 1: wire type - 2 letter

-Group 2: wire gauge

-Group 3: one letter indicates year of manufacture

-Group 4: 2 letters Country and manufacturer.

Group 5: no code, FEP coating; A: PTFE Coating

-CF 20X FA A

Fiber Glass Cable

-wire type code

-Manufacturer

-Year of Manufacturer

Coating codes

-wire insulation capacity to protect its environment from the electromagnetic or calorific
radiance of the wire.

-the coating type defines the marking type to be used.

-Letter marked after the wile type and before the wire gauge.

Identification by colored Thread

Single wire - between core and insulating sheath

Multi wire – threads are inserted between external sheath and conductors

Printed tapes

Single wire – between core and insulation sheath & external

Multi core – between the external sheath and the conductors

Multi Core Cables -Insulation color codes

Color Code A

-Light blue -002/006/012

-White other gauge code

Color Code B

-Light blue-002/006/012

-White other wire gauge

Band Group Configuration

Basis Color of Cones

Pink: 001/006/020
White: 002/010/030

L• Green: 004/012/050/051

Ringcolor: Green

Arrangement of Color Rings

-12m distance

Wiring Defects Inspection

1) General Visual Inspection (GUI)

-Visual examination

-not necessary to touch

-use a mirror

-usual lighting conditions

-Do not remove paint

2) Zonal Inspection

-GUI that you doing each zone

-not related to a specified component or assembly

Check

1. Cable Harnesses
2. Connectors
3. Switches
4. Splices and terminals
5. Ground points
6. Bonding braids
7. Identifications
8. Harness supports or clamps
9. Metal supports
10. Raceways
11. Terminal block
12. CB, Contactors, Relays
13. Backshells
14. Conduits
15. Lugs

Safetying processes
3 types of locking for the connectos
1. Lockwire
 2. Adhesive
3. self-locking device.

Safety w/ Lockwire

-coaxial connector
-battery phys

Safety Straight or elbow backshells

-adhesive
-with self-locking devices; Retainers
Main Rules and Instructions
- protect the lockwire pigtail
-secure electrical wiring to a field point, lug, riveted plate.
-0.8mm (0.03in) or 0.5mm (0.02 in) -lockwire
-not bend lockwire
-max distance -100mm (3.94in)
-max Length - 600mm (23-62 in)

Locking with adhesive

-Loctile 932
-High strength
-low strength
-med strength

1. Clean
2. Activator
3. Clean within 5 minutes
4. Adhesive
5. Install, Clean

Selection of Locking Type

-Locknut-Lockwire or lockwasher

Torque Application Definition:

-specified for (tightening down) that you need to apply to fasteners

Torque - specific range as prescribed in the AMM for the twisting, turning force
needed to create the proper tension.

-The tension you creates what makes fasteners perform the way the engineers
intended.

-ensure the integrity of the aircraft and help prevent accidents uneven torque

-Result in unnecessary mean of nuts and bolts, as well as the parts they secure
Over toque

-Can case failure a bolt or not from overstressing the threaded areas.

Torque value given by the manufacturer, one also applicable to the first and second
oversize of the original standard

Terms on Torque

1. Torque- specified force that you need to apply to fasteners

2. Torque Tightening - application of preload to a fastener by turning of fastener’s nut

3. Preload - tension created in a fastener when it is tightened - "Clamp load"

4. Breakaway/Breakout Torque - initiate relative motion between mating threads when

the self-locking mechanism Is fully engaged and the fastener is unseated

5. Effective torque: Torque in excess of running torque

6. Running Torque: Toque related to overcome kinetic friction of the mating threads
plus the torque required to overcome the locking feature when 100% of the locking
feature is engaged and fastener is unseated.

7. Fastener-bolt or a screw that joins two or more parts and transfer load between
them

8. Drag Torque

-Free running Torque

-Run on torque

-See Running Torque

9. Final torque

-SUM of the friction torque plus the applicable torque values or friction torque plus
torque from the manufacturer’s instruction manual

10. Torque wrench

-tool used to apply precisely a specific torque to a fastener

11. Torque wrench Types

- Beam type

-Torque wrench type

-Clicker Type

-Dial Indicator Type

-Electronic type

Precautions

-Applied for the bolt shank not the wrench size

-Add the friction torque to the desired torque

-Calibrate once a year

-Apply torque to the nut

-Final torque

Torque sequence

-Inverted 4

1. Spanner tight ensuring that 2-3 threads extend above nut

2. Tighten each bolt to one-third final required

3. Increase the torque two-thirds

4. full torque

5. one final pass on each bolt.

"Castellated nut, start alignment with the cotterpin hole at the minimum recommended
torque plus friction drag torque

-If hole and not castellation do not align change washer or not and try again.

Formula: TAVL/L+A = TW

Plumbing Tubes

-Metal tubing and fittings or flexible hose used for fuel, oil, coolant, oxygen, instrument
and hydraulic lines

Aircraft tube plumbing

- installation and repair of rigid fluid lines

Why?

-inspected for cracks, holes, dents, bulges

-Replacement should be the same size of tubing

-Aircraft + fluid lines are usually made of metal tubing or flexible hoses •
Metal tubing - used in stationary applications and where long, relatively straight runs
are possible

- widely used in aircraft for fuel, oil, coolant, oxygen, instrument and hydraulic lines.

Flexible Hose - moving parts or where the hovers subject to considerable vibration

Safety and Cleanliness

-For air data tube - do not apply lubricant to the tuber and/or fittings

-Put safety devices and Warning notices:

-Flight Controls

-Flight Control Surfaces

-LDG and Doors

-Compartments that moves

Tube and fitting are not damaged:

-Examine the threads of the fitting

-Examine the sealing surfaces

-Examine The Tube for scratches, nicks, deformation

-Install Clamp blocks on the tube.

-use manufacturer specified lubricant

-Dust cape around the tube ends

-Do not twist

-Do a leaks Check

Rigid Tubing Inspection and Repair

-Scratches or nicks not deeper than 10% of the wall thickness in AA tubing, maybe
repaired

-Damage limits for CRES and Tit tubing are considerably less than AA

-Replace line with severe die marks, seams, or splits

-Dent of less than 20% of the tube diameter is not objectionable

Repair

-draw a bullet of proper size through the tube by means of a length of a cable or push
the bullet through by dowel rod.
-bullet ball bearing made of steel

-in the care of soft aluminum tubing, a hardwood

Severely damaged

-cutting tube around the tube

-Flare

-Flare both ends -make connections by standard unions

-Swaging Tools - Fix repair on the tube

-blanking caps - if open line is left unattended

-chaffing occur- reposition.

-Make a wire template -bonding the pattern

-Never select a path that does not require bonds in the tubing

Bending

-permit the tubing to expand or contract under temperature

-tube is small (under 1/4") can be hand formed.

Permaswage Repair

1. Pinhole leak or circumferential crack

a. Make lor 2 cuts necessary to remove damage sections-shall not exceed 0.30"
b. Swage 1 tube to tube union

2. Longitudinal cracking tubing (in excess of 30")

a. Make 2 cuts to enable removal at damaged section.

b. Remove damage section and duplicate

c. Swage replacement

3. Leakingtee or elbow

a. Cutout defective tee

b. duplicate for each branch

c. Swage splice sections

d. Connect each splice

4. Leaking flared, flareless, or lipseal end fittings

a. cut tubing to remove defective fitting

b. swage appropriate end fitting

c. connect new end fitting to mating connection

Plumbing Hoses

-multiple layered flexible conduit through which fluid is conveyed from one point to
another

2 Groups

Group A:

-Fuel, Oil, Pneumatic & Hydraulic pressure Hoses

Group B:

-All other hoses like hydraulic return line and instruments hoses, etc.

Flexible hose - to connect moving parts with station any parts in locations subject to
vibration

Hose Materials

-Pure Rubber is never used

-Synthetics are used

-Buna 10

-Neoprene

-Butyl

-Ethylene propylaea diene rubber (EPDM)

-Teflon

Construction Material

-Outer cover - Synthetic Rubber; impregnated cotton braid

-Reinforcement Inner cotton braid and wire braid

-Inner Tube – synthetic rubber compound, seamless construction

Buna-N

-excellent resistance to petroleum products

-Do not use for phosphate ester base hydraulic fluid (Skydrol)

Neoprene

-Acetylene base
-better abrasive resistance

-Skydrol

Butyl

-synthetic rubber compound

-petroleum raw materials

-excellent material for Skydrol

-Do not use with petroleum products

Flexible Rubber

-layers of cotton braid and wire braid and an outer layer of rubber impregnated cotton
braid.

-fuel, oil, coolant, hydraulic systems.

Classified by amount of pressure

Low Pressure Areas Hose

-Below 200 psi

-Fabric Braid Reinforcement

-Instruments mounted on panels equipped with vibration isolators and the rudder

Medium Parque Areas Hose

-Up to 3000 psi

-one wire braid reinforcement

-Larger sizes carry up to 11500 psi

High Pressure Hose

-all sizes up to 3000 psi

-inner tube on lining covered by one or two closely woven wire braids, either
molded on sandwiched bet. synthetic rubber

-enclosed by outer cover

-protect the other parts of the nose to resist abrasion and the effects of weather, to
provide a degree of fire resistance

Extra High Pressure Hose

-pressive higher than 3000psi

Teflon Hoses
 -DuPont trade name for tetra fluoroethylene resin. (-65°F to + 450°F)

-Compatible with nearly every substance

-little resistance to flow

-Les volumetric expansion

-covered with SS wire, which is braided over the tube

-Medium Pressure Teflon hoses - using the shortest possible length

-use a support wire

-performed to clean obstructions

Hose Identification

-type, quarter and year of manufacture. 5-digit code at manufacturer

-contrasting colored letters, repeated at intervals of not more than 9 inch along the
length of the hose

Sizing

-identified by dash

-Inside Diameter - 16th of an inch

Cure Date

-used to ensure that they do not deteriorate beyond material and performance
specifications

-quarter and year of manufacture.

Synthetic Rubber Hose

Process to note during Installation

1. Slack

-Slack or send

-5 to 8% of its total length

-Provide for changes in length that occurs when pressure is applied

2. Flex

-sufficient slack must be left between rigid fittings

-remain straight at least 2 hose diameters from the end fittings

-avoid clamp locations that restrict or prevent have flexure

3. Twisting

-avoid possible rupture of the hose or loosening of attaching nuts

-Stripe running along its length

4. Bending

-Hose of elbow fittings

5.Clearance

-Clear all other likes, equipment, and adjacent structure under every operating
condition

-supported at least every 24 inches,

-minimum gap "G" shall be 1/2" or tube OD/4

-1/16" max offset - 3 max angular deviation

Retightening lose hose clamps

Non self-sealing hose

-clamp screw cannot be tightened with the fingers, do not disturb

-do no If leatase is present. tighten One-fourth turn

Self-sealing hose

-loosen than finger tight, tighten to finger tight and add one fourth turn.

6. Hose Clamps

-Grommet

-Follow finger tight plus turns method

"Coldflow" describes the deep, permanent impressions in the hose Produced by the
pressure of hose Clamps or supports

*Read Core of hoses on NB

Shelf Life:

-10 years from cure date

-periodic inspection. Once a year, pressure tested 1-1/2 times the working pressure
every 2 years

-Pressure test before installation

Servile Life:

Group A - 4 years - up to 6years

Group B- 6 years - up to 8 years

Temp = 50°F to 70°F

-3ft from source of heat

Humidity

-65%

Light

-not exposed to strong lights

-airtight containers

Ozone
-avoided - 120°F (48.88°C)

Deformation

- relaxed portion

Contamination

-no contact with Liquids or vapor concentrations

Sealing

-application of a material that prevents a fluid from passing a contain point, and to keep
air and dirt out of the system in which today he used.

Can be in the form of:

•Seals

•Sealants

Seals

-used throughout aircraft hydraulic systems to minimize internal and external leakage
of hydraulic fluid.

Sealant

-compounds used to keep moisture out and prevent pressurization and fuel leak.

Why Sealing

a) maintain an expective seal

b) lower than the specified leakage rate during the required working hours

-Created a need for (seals) packings and gaskets

-Aviation seals - parts that require an effective seal in challenging environments

3 main classes of seals

1. Packings

-hydraulic seals used internally on a sliding or moving assembly

-Synthetic rubber

-running seals-cylinders, pumps, selector cakes.

a) O-ring

-prevent both internal and external leakage

-pressure above 1,500psi - Back up rings are used with Orings to Prevent extrusion
-effective in both directions

-Backup Ring - Made Of Teflon - tolerate temperature extremes

-dash number-size relate to Oring

-not color coded

b) V-ring

-One-way seals

-Open end of the 'V' facing the pressure

-male and female adapter to hold them

-torque the seal retainer

c) U-ring

-brake asseys and brake master cylinder

-U-ring and U cup seals pressure in only one direction.

-low pressure packings

-less than 1000 psi

2. Gaskets

-Hydraulic seals used between nonmoving fittings and hoses

-Static (stationary) seals.

-asbestos, copper, cork and rubber

-End caps of actuating cylinders, valves and other units.

a) Asbestos gasket

-Asbestos thee tiny is used wherever a heat resistant gasket is needed

-exhaust system gaskets

-thin sheet of copper edging

b) Copper Gasket

-spark plug

-noncompressible, yet semisoft gasket

c) Cork Gasket

-oil seal between the engine crankcase and accessories

-occupying an uneven or varying space caused by a rough surface or expansion and
contraction

d) Rubber Gasket

-need for a compressible gasket

-not be used in any place where it may contact gasoline or fuel

3. Wipers

-clean and lubricate the exposed portions of piston shafts

-prevent dirt from entering the system

-either metallic or felt

Sealants

-Seals are made from synthetic materials that are compatible with the hydraulic fluid
used

-seals - MIL-H-5606 are made of neoprene or buna-N

-Seals for Skydrol are made from butyl rubber on ethylene propylene Elastomers

-sealed to withstand pressurization by air, to prevent leakage to fuel, to prevent

passage of fumes, onto prevent corrosion by sealing against the weather.

1. One part sealants

-prepared by the manufacturer

-Ready for application

-Consistency may be altered

2. Two Part Sealants

-Separate packaging to prevent cure prior to application

a) base sealing compound

b) accelerator

-Combining equal portions, by weight, of a and b mixes the sealants

part sealants.

General method for sealing x

a) Interfaying
-very thin layer of sealant between the surfaces

-cured sealant

≤0.1mm (0.004in) between fasteners

≤0.04mm (0.0016in) at fasteners, practically 200 for bolted assys

-Uncured – Same above

b) Bead

-applying a sealant with high viscosity on the edge & structural assembly

-assembly is made on uncured sealant

-Bend Thickness will vary according to the thicknesses of the sheets

c) Over coating of fasteners

1. On metallic structure

-end of fasteners must be coated with sealant

-applied by either brush on with an extrusion gun

2.On Laminate Structure

-install a plastic cap to protect the fastener

d) filling of cavities

-filled with high viscosity sealant

e) Injection

-injecting high viscosity sealant under HP into an injection groove through holes

f) wet installation of fasteners

-in the countersinks, 3 to 8 drops of class A

g) Bonding

-use or silicone products, allowing especially in hot areas, the bonding Of elastomer
seals by applying on thin layer of sealant between the support and the seal to be
bonded.

h) Bonding of metal bushes, ball bearings and spherical bearings

-only to the bonding joint

-flush with a spatula, sealant penetrates into the chamfer

Sealant to be used according to type of environment:

-general sealing areas except for tanks

-fuel tank areas

- high temp. areas - Special cases

Skydrol - hydraulic fluid and most advanced hydraulic fluid

Curing

-a process during which a chemical reaction or physical action takes place, resulting in
a harder, toughen. or more stable linkage

Retaining Devices

-available to apply or affix to ac system components to prevent accidental movement

when main is being performed

Locking Devices

-Prevents mated shafts and other machine elements from moving at of position when
subjected to external forces.

-Critical components

-Coupling multiple components

Aircraft locking devices

-mechanical fasteners used in variety of aerospace applications

-positive lock to prevent rotation

-removes the chance of and loosening

Aircraft Nuts 2 general groups

1. Self-locking Nuts

-locking feature as an integral part

-no auxiliary areas of safetying they will not be removed often

-applications:

+ Attachment & antifriction bearings and control pulleys

+ Attachment of Accessories

+ Attachment of rocker box covers & exhaust stacks

-acceptable for use on certificated aircraft

-provide tight connections that do not shake loose under severe vibration

-Do not use self-locking nuts at JOINTS

3 typical kinds

a) Books self-locking nut

-One piece

-hold tight despite severe vibration

- 2 sections

-locking nut and a load-carrying nut

-Connected with a spring

b) Stainless Steel self-locking nut,

-locking action takes place only when the nut is seated against a solid surface and
tightened

- 2 parts:

-Case with a beveled locking shoulder and key and a thread insert with a locking
shoulder and slotted keyway

c) Elastic Stop nut

-height increases to accommodate a fiber locking collar.

-fiber collar is very tough and durable

2. Non self locking Nuts

-Safetied by external locking devices

-plan but

-Castle nut

-Castellated shear not

-plain hex nut

-light hex nut

-plain check nut

External Locking Device

-used in safetying non self-locking nuts

Pins:

Taper Pins

Flathead Pins
 Cotter Pins

Roll Pins

Split pins

Safety wire

Locknuts

Pins

-used in shear applications,

-roll pins are finding increasing yes in A/C construction

a) Taper Pins

-Joints which carry shear loads and where absence of play is essential

-Plain taper pins drilled and usually safe tied with wire.

-Threaded taper pin is used with a taper pin washer and shear nut

b) Flathead Pins

-Clevis pins

-used with tie rod terminals and in secondary controls

-not subject to continuous operation

-head up

c) Cotter pins

-safetying bolts, screws, nuts other pins

-nonmagnetic material is required

+Hair Pin Cotter Pins

-used in clevis pins to secure its ends

+ wire snap/wire lock cotter pins

-shafts to keep components aligned

+ Hammer set/Hammer lock cotter pins tapped with a hammer for temporary hold

+ Wedge Lock Cotter Pin

Roller Pins
 - chaffed ends

-tubular shape

-slotted the length at tube

-compressed as it is driven into place.

Greases Application

-AMM

Equipment and Materials

-A grease gun

-oil can

-brush

-A clean lint-free clot

-aerosol spray

Lubricant Grease Specifications

-you must not mix greases when you apply them on A/C

-always use the same specifications

-continue to put the new grease into the grease fitting while the old grease comes at

Potential Adverse Effects

-intermixing can negatively impact grease performance

-react together and cause a separation of the base oils

-mixing of base oil types, problem of seal compatibility

-Resultant mix is poorer

-performance is compromised

-Fully purge all old greases from any application