The Complete Fastener Retention System

Typical Lock Wire Installation

1:42*
1 min. 42 sec.

System Benefits System Highlights Approvals & Recognitions Introducing Safe-T-Cable Cable Kits, Assemblies and Ferrules Special Applications Tool and Parts Kits Tools, Accessories & Verification Equipment

CONTENTS

2 3 3 4

5 6 8 10

Typical SAFE-T-CABLE Installation

SCT-TB4 Verification Tester Supplement insert .062 Safe-T-Cable Locking Cable 12 Installation Practice Guide 14

0:36*
36 sec.

Time Saving Technology . . .

SAFE-T-CABLE will

Improve the Efficiency and Quality of your Assembly Operations.

SAFE-T-CABLE may be

substituted, in most applications, for Hand Twisted Lockwire.

*Assembly time comparison shown is for reference only. Actual time saved will be dependent upon the application.
an

ISO9001 Registered Company

COPYRIGHT 2001, DANIELS MANUFACTURING CORP., ORLANDO, FLORIDA (USA)

Save Time and Money By Replacing Your Old Lockwire System With

System Benefits:
User Friendly Tooling Lighter Weight Than Lockwire Improved Security Of Fasteners Considerable Reduction Of Rework Minimal Operator Training Is Required Simplified Installation Procedures Reduces Installation And Inspection Time Cable Tension Consistent On Each Application Eliminates Injuries Due To Sharp Lockwire Ends Reduces Risk Of Carpel Tunnel Injuries Improved Access To Tight Areas

1.Thread
A Cable assembly is threaded thru the fasteners in a direction which will exert a positive pull on the fastener when tension is applied.

2.Insert
Simply insert the cable through the ferrule cartridge and the tool nose.

3.Crimp
Correct tension is applied, the ferrule is firmly crimped, and the cable is cut flush with the end of the ferrule.

4. Inspect
The job is complete. A secure installation in a fraction of the time it takes to install lockwire.

SYSTEM HIGHLIGHTS
The SAFE-T-CABLE system is comprised of various lengths of high tensile, pre-twisted, stainless steel cable with a fitting at one end, and a ferrule which may be terminated at any point along the length of the cable. The precision installation tool and its accessories allow the user to verify the calibration, and easily install the SAFE-T-CABLE in any location in which it is required. The SAFE-T-CABLE ADVANTAGE . . . Standards have been created to define the configuration and performance characteristics of this revolutionary system. Production and maintenance professionals who have evaluated this improved technology agree that it is far superior to any method they have previously used. The simplicity of the system is the reason why SAFE-T-CABLE is preferred by the user. The security which it provides is the reason for its preference by the system designer. SAFE-T-CABLE SAVES TIME . . . The operator follows a simple procedure, and the job is finished in half the time required to install lockwire. The SAFE-T-CABLE VERSATILITY ADVANTAGE . . . This innovative system can be made available in a hand or pneumatic tool that has interchangeable tips to accommodate various applications which may require a longer nose profile or a larger/small cable diameter. SAFE-T-CABLE MINIMIZES REWORK . . . It is common with lockwire to rework a single installation one or more times due to improper twist pattern, inadequate tension, or other defects. SAFE-T-CABLE seldom has to be cut and reworked because the installation tool applies consistent tension to the pre-twisted cable assembly. SAFE-T-CABLE REQUIRES LESS OPERATOR TRAINING . . . Extensive training is necessary to qualify an operator to install lockwire due to the stringent requirements. A few minutes is all that is necessary to enable an operator to produce high quality SAFE-T-CABLE installations. SAFE-T-CABLE MINIMIZES F.O.D. IN THE WORK AREA . . . Installed SAFE-T-CABLE can easily be removed in two pieces by simply cutting the cable in half. Discarded cable assemblies can be picked up with the use of magnet sweeps, allowing the work areas to remain clean and safe. SAFE-T-CABLE FITS WHERE LOCKWIRE HAS DIFFICULTIES . . . It can be installed in locations having limited access due to the design of the precision application tool. Often, these areas do not permit access of lockwire twisting pliers and visual inspection equipment. SAFE-T-CABLE WORLDWIDE SOURCE . . . The complete SAFE-T-CABLE system, cables, ferrules and tooling is available from DMC. We have developed a worldwide network of professionals to aid you in answering technical questions and to keep you up to date with the most current SAFE-TCABLE developments. DMC is your worldwide supplier of SAFE-T-CABLE products.

Approvals & Recognitions...

SAE*: AS4536 (Procurement & Installation), AS3509, & AS3510 (Detail/Design) AS3617, AS3618, AS3619, AS3620, & AS3621 (Recent Additions)

FAA: Code of Federal Regulations (F.A.R.) Subpart K, Section 21.303, Par. 4, Standard Part Classification for General Use. Consult DMC for Documentation. Many FAA Approved 70-XX-XX Series Standard Documents are also published and maintained by major engine and airframe manufacturers. US MILITARY: T.O. 1-1A-8 (USAF), Technical Manual, (General) Structural Hardware x TM 1-1500204-23-6 (US ARMY), Technical Manual, General Aircraft Maintenance x Drawing No. 13210868, US ARMY MICOM, Specification Control Drawing, Safety Cable u NAVAIR 02-1-20 Technical Manual, General Electric Engines x NAVAIR 01-1A-505, Technical Manual, Aircraft Electrical Systems, General, Lockwiring and Shearwiring NAVSEA MIL-STD-763, G revision and higher, DOD Standard Practice, Locking Devices x NASM33540 (Pending) National Aerospace Standard, Safety Wiring, Safety Cabling, Cotter Pinning, General Practices. NASA:
JA83-032A Design Standard, Reference Par. 3.3.3.10 and 3.3.3.14.

NATIONAL STOCK NUMBER LISTING (NSN): The majority of SAFE-TCABLE Tools and Components that are specified in Military Technical Manuals and Standards are covered by NSNs. Consult DMC for details.

SOCIETY OF BRITISH AEROSPACE COMPANIES (SBAC): JES 138 (Engineering

Design Standard) JDS843.02 (Wire Locking Design Standard), AS63236, AS63237, AS63238-9 (Detail Standard).

PRIVATE STANDARDS: Many prominent

companies in the Aerospace Industry have developed In-House Standards and Drawings for SAFE-TCABLE . Your DMC Customer Service Representative will have information about many of these documents, however, due to strict adherence to copyright regulations, copies of a private standard, in whole or in part, are not available from DMC.

526 THORPE ROAD, ORLANDO, FL 32824-8133 USA (407) 855-6161, FAX (407) 855-6884 EMAIL: DMC@DMCTOOLS.COM WWW.DMCTOOLS.COM SAE STANDARDS AVAILABLE FROM: WWW.SAE.ORG SAE INTERNATIONAL, 400 COMMONWEALTH DRIVE, WARRENDALE, PA 15044

526 THORPE ROAD, ORLANDO, FL 32824-8133 USA (407) 855-6161, FAX (407) 855-6884
EMAIL: DMC@DMCTOOLS.COM WWW.DMCTOOLS.COM 2001 DANIELS MANUFACTURING CORP., USA

INTRODUCING
BACKGROUND
Self locking fasteners are being used extensively in the Aircraft/Aerospace industry. However, there will always be a need to install constraining (safety) devices to many bolts and other threaded fasteners in applications where self lockers cannot be used. Their purpose is to restrict (to a minimum) the unintentional rotation of the fastener. The traditional method (devised in the early 1900s) is through the use of Hand Twisted Lockwire (often called Safety wire).

CONSTRUCTION
SAFE-T-CABLE is constructed of high tensile strength, stranded cable. It is more flexible than its Lockwire 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 ball. SECTIONAL VIEW .032 3x7

SAFE-T-CABLE
.020 1x7 .040 7x7 The cable is pre-cut to various lengths, and is supplied with a square-formed end cap attached to one end. SAFE-TCABLE is available in three nominal diameters. The .040 inch diameter cable is constructed of 7x7 stranded ropelay material. Ropelay construction is also used for the 3x7, .032 diameter cable while The .020 diameter cable is made of 1x7 unilay material. The ferrules are precisely manufactured to a size and hardness which assures their compatibility with the cable and application tooling. They are supplied (50 pieces each) in an easy loading disposable cartridge, which provides orderly containment of individual ferrules, and the easy release of individual ferrules as they are required. This feature minimizes the possibility of Foreign Object Damage (FOD). The pre-assembled cables have a square formed end cap securely attached to one end. This provides a positive stop when threaded through a fastener. The other end is electrically fused such that it will easily thread through the series of fasteners that are to be secured. The flexible cable material is lightweight and easy to handle. The stainless steel materials will not corrode or deteriorate while in use. (See chart on the following pages for material, size, and part number.) All SAFE-T-CABLE kits and assemblies are supplied 50 pieces per package.

CONVENTIONAL LOCKWIRE The only changes which have occurred since the early uses of Lockwire are the tremendous costs in the installation of this material, and the levels of sophistication in the systems on which Lockwire is being installed. It is used in Jet Engine systems, Airframes, Electronics, Space Vehicles, and Land/Sea based Systems. The process of installing remains awkward and costly, and the inspection process is demanding. The removal and rework of installed Lockwire is a common occurrence.

SAFE-T CABLE 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. This results in fewer demands on the Operators, Inspectors, and Maintenance personnel.
Page 4

TESTING
The application of SAFE-T-CABLE is consistent from one installation to the next due to the repeatability and dependability of the application tooling and the quality of the materials used in the manufacture of SAFE-T-CABLE Kits. All that is required to assure overall reliability in manufacturing and maintenance use is a periodic test of a few crimped cable assemblies.DMC offers full instructions and the test equipment to perform these simple tests in either remote or test lab locations. FERRULES AND CARTRIDGE LOADING SYSTEM The individual crimp ferrules are preloaded into disposable cartridge unit (50 pieces per cartridge) which allows convenient transportation, storage, and availability of these components. The ferrules are easily extracted individually by threading the cable end through the ferrule, and snapping the ferrule loose. This system, when properly used, eliminates the possibility of FOREIGN OBJECT DAMAGE (FOD).
2001 DANIELS MANUFACTURING CORP., USA

CABLE KITS, ASSEMBLIES AND FERRULES

PART NUMBER SYSTEM:
SAE PART NO. SYSTEM DMC PART NO. SYSTEM AS3510-02 18K C10-218 XX SPECIAL MATERIAL CONFIGURATION COMPONENTS CONFIGURATION* AS3509=INCONEL K=Kit(Cable & Ferrule) C=Kit(Cable & Ferrule) LENGTH LENGTH C=Cable Assembly AS3510=321CRES A=Assemblies(Cable Only) 9=9 9=9 (Cable Only) CABLE DIAMETER F=Ferrules Only 12=12 12=12 F=Ferrule (Ferrule Only) 01=.020 / .026 MATERIAL 15=15 15=15 02=.032 / .038 CABLE DIAMETER 09=INCONEL 18=18 18=18 03=.040 / .046 1=.020 / .026 21=21 10=321CRES 21=21 2=.032 / .038 24=24 24=24 3=.040 / .046 *SPECIAL CONFIGURATION: LOGO STAMP, SELF-LOOPING CABLE, ETC. (PAGE 6-7) AS3509=AMS5687 (INCONEL) AS3510=AMS5689 (321 CRES) CRES=Corrosion Resistant Stainless Steel NOTE: 321 CRES is considered to be Standard in the Aerospace Industry

Material Options: Cable Length Options:

SAFE-T-CABLE Kits*

9", 12", 15", 18", 21" & 24" (Dimensions are in inches) NOTE: 18 inch Length is the Most Common Lenght Specified. MATERIAL/PART NUMBER 321 CRES C10-312 C10-318 C10-321 C10-324 C10-212 C10-218 C10-221 C10-224 C10-112 C10-118 C10-121 C10-124 INCONEL C09-312 C09-318 C09-321 C09-324 C09-212 C09-218 C09-221 C09-224 C09-112 C09-118 C09-121 C09-124 DIAMETER LENGTH (INCHES) (SEE NOTE) .040 .040 .040 .040 .032 .032 .032 .032 .020 .020 .020 .020 12" 18" 21" 24" 12" 18" 21" 24" 12" 18" 21" 24"

*KIT PART NUMBER APPLIES TO ONE CABLE ASSEMBLY AND ONE FERRULE

SAFE-T-CABLE Assemblies

MATERIAL/PART NUMBER 321 CRES A10-312 A10-318 A10-321 A10-324 A10-212 A10-218 A10-221 A10-224 A10-112 A10-118 A10-121 A10-124 INCONEL A09-312 A09-318 A09-321 A09-324 A09-212 A09-218 A09-221 A09-224 A09-112 A09-118 A09-121 A09-124

DIAMETER LENGTH (INCHES) (SEE NOTE) .040 .040 .040 .040 .032 .032 .032 .032 .020 .020 .020 .020 12" 18" 21" 24" 12" 18" 21" 24" 12" 18" 21" 24"

Note: When Considering the cable length, be sure to add the extra cable required to engage the tension mechanism in the application tool: Add 6-8 inches for a tool with a 3 inch nose, and 10-12 inches for a tool with a 7 inch nose.

ASSEMBLY PART NUMBER APPLIES TO ONE CABLE WITH END CAP

SAFE-T-CABLE Ferrules

CABLE DIAMETER .020 .032 .040

321 CRES F10-1 F10-2 F10-3

STANDARD FERRULES INCONEL LENGTH DIAMETER F09-1 F09-2 F09-3 .095 max .164 max .164 max .090 .105 .105

ELONGATED FERRULES ARE DESCRIBED ON PAGE 6

ALL PRODUCTS ON THIS PAGE SUPPLIED 50 PIECES PER PACKAGE 321 SERIES CRES IS CONSIDERED TO BE STANDARD IN THE AEROSPACE INDUSTRY

FOR WARRANTY AND LIMITATION OF LIABILITY INFORMATION SEE PAGE 15

2001 DANIELS MANUFACTURING CORP., USA

Page 5

SPECIAL APPLICATIONS
ELONGATED FERRULES
For Low Profile Fastener Applications
SQUARE END DIA.

Fasteners that have limited clearance RADIUS END between the safety wire hole (less than .100 inch), and the surface of the component to which the fastener LENGTH is attached, can present a challenge to the installation of SAFE-TCABLE . This is due to the Most SAFE-T-CABLE A SPECIAL ELONGATED FERRULE clearance required by the application installations can be made with is available for those installations. tool nose, adjacent to the fastener. standard components and The longer reach of the ferrule application tools, however, there provides a stand off to the tool nose. are conditions that require Combine that with the radius on the modification or alterations to the end next to the fastener (radius not standard products. By addressing required on the F10-08 .020 these exceptions, and extending elongated ferrules due to the small the product lines to incorporate outside diameter). The angle allows simple solutions to the difficult the ferrule to be installed at an SAFE-T-CABLE applications, angle without loss of tension on the DMC has established itself as the cable when the ferrule returns to the industry leader straight position.

ELONGATED FERRULES
Cable Dia. Part No. Diameter Length Radius .020 in. F10-08" .090 .180 NO .032 in. F10-04 .105 .320 YES .040 IN. F10-07 .105 .320 YES

INCORRECT
STANDARD FERRULE (short)

CORRECT
ELONGATED FERRULE (radius end toward fastener)

Elongated Ferrules are available in 321 CRES (AMS5689) Consult DMC for availability of other materials. Supplied in 50 pieces per Package

SQUARE (both ends) TOOL NOSE TOOL NOSE ELONGATED FERRULE

FIBERGLASS SLEEVING
PROTECTIVE JACKETING PROTECTIVE JACKETING

FILLER WASHER
FLAT WASHER

OBSTRUCTION

SAFE-T-CABLE Jacketing for Protection. It is recommended that a tubular jacket be placed over SAFE-T-CABLE when it is installed in an area where it will be in contact with obstructions or surfaces that may damage the SAFE-T-CABLE . The tubular jacket material shall be capable of meeting the temperature range of the application. It shall also be resistant to oil, and chemical environments. 50-FOOT SPOOL: PART NUMBER SCTD010

FIGURE 1: FLAT WASHER SAFE-T-CABLE INSTALLATION

Applications where SAFE-T-CABLE is to be installed through a hole having a diameter greater than .095 inch, (2.4mm), but less than .200 inch (5.08mm) can be accommodated by a filler washer. NOTE: Compatible materials are required, and care must be taken to restrain the washer during removal/service operations. FILLER WASHER MATERIAL 321 CRES PART NUM. FW10-1

Page 6

2001 DANIELS MANUFACTURING CORP., USA

SELF-LOOPING
It is DMCs mission to be responsive to the needs of SAFE-T-CABLE users. One more example of that DMC responsiveness is the Self-Looping SAFET-CABLE . There are many applications for lockwire where holes do not exist in a fastener or other part of the assembly. The common practice is to wrap the wire around a casting web, pin, or similar feature, and then anchor the other end to the fastener. The SelfLooping SAFE-T-CABLE provides the user with a means of anchoring a threaded fastener to almost any structure.
The operator simply wraps the cable through (or around) the structure, and back through the hole in the captive link at the head of the cable. The operator then pulls the slack out of the cable, and threads it through the head of the fastener, and terminates it with a standard application tool. Another type of application where the Self-Looping SAFE-T-CABLE offers a clear advantage over lockwire is when it replaces lockwire on turnbuckles, castellated fittings, and other applications where holes are not provided at either end of the cable. In those cases, the cable is threaded around the fittings and terminated back at the hole in the captive link on the head of the SAFE-TCABLE .
DIAMETER LENGTH** (INCHES) (SEE NOTE) .040 .040 .040 .032 .032 .032 .020 .020 .020 12 18 24 12 18 24 12 18 24

MATERIAL/PART NUMBER

SELF-LOOPING KIT with Standard Ferrule

321 CRES C10-312JA C10-318JA C10-324JA C10-212JA C10-218JA C10-224JA C10-112JA C10-118JA C10-124JA

INCONEL CF CF CF CF CF CF CF CF CF

Supplied 50 pieces per Package

*KIT PART NUMBER APPLIES TO ONE CABLE ASSEMBLY AND ONE FERRULE **OTHER LENGTH COMBINATIONS ARE AVAILABLE CF: CONSULT FACTORY FOR AVAILABILITY/DETAILS

Note: Individual cable assemblies and special ferrule combinations are available. Consult factory for availability/details.

BRANDED
Logo/Distinctive Mark Identification by the Factory
One more value-added service available from DMC to the users of SAFE-T-CABLE is the application of a permanent mark (unique to one customer only) on the head of the SAFE-T-CABLE . The distinctive brand on the cable end fitting, when installed on an engine, accessory, or other assembly, becomes a reliable identification flag that can be used to trace the final assembly to a date, location, or another significant purpose. The most common reasons that the DMC SAFE-T-CABLE branding service has become very popular are the following: WARRANTY TRACEABILITY SAFE-T-CABLE with a corporate logo or other distinctive mark can be applied by the factory or authorized repair stations to limit warranty claims. Products returned for warranty repair can be easily inspected to verify that the factory applied logo or symbol is on the head of each SAFE-T-CABLE . SERVICE LOCATION VERIFICATION The exact location of the last service/repair of a product or component can be easily identified if your organization utilizes a well thought-out SAFE-T-CABLE branding program. The application of a distinctive mark, logo or initials allows for easy verification and/or routing of product for repair, rework, or other function.

2001 DANIELS MANUFACTURING CORP., USA

Page 7

TOOL AND PARTS KITS

DMC Offers Complete Tool & Parts Kits to Support your Applications.

DMC1000-4R
DMC is well known throughout the aerospace industry for the quality and capability of the Tool Kits that we manufacture. The packaging materials (case, inserts, and instructions) are manufactured to specifically meet the most demanding handling conditions. FOD (Foreign Object Damage) is always a concern when workers are required to use tools and small components in or around an aircraft. The DMC SAFE-T-CABLE kits are designed to minimize that
Page 8

supply or Cable/Ferrules, and the Instructions all in one package. concern. The shadowing principal is a proven concept for Tool/parts control. SAFE-T-CABLE Tool and Parts Kits are available in a Variety of configurations to support your specific requirements. Our most requested Tool & Parts Kit is the DMC1000-4R (pictured above) due to the popularity of .032 diameter SAFE-TCABLE , and the demand for a travel-ready system whereby the user has Tools, Verification Equipment, Accessories, a Other Kits are available to support your particular needs. The most popular selections are listed on the following page. If you have specific needs that cannot be covered by the Tool Kits that are described here, please call a DMC customer service representative for information on a Kit that will more appropriately meet your requirements.

2001 DANIELS MANUFACTURING CORP., USA

DMC1000-4R
PART NUMBER
SCTR323 SCTN32-7 C10-218 SCT-TB1 4-1501 SDD4 45-6N SCT32084

.032 SAFE-T-CABLE Tool and Parts Kit DESCRIPTION

SAFE-T-CABLE Tool with 3 Nose Attached (.032) 7 Nose Assembly (.032) SAFE-T-CABLE (.032 x 18) SAFE-T-CABLE Torque Verification Block 9/64 Hex Wrench Screwdriver Diagonal Cutter/Gripper Spanner Tool

QUANTITY
1 1 100 1 1 1 1 1

DMC1001-7R
PART NUMBER
SCTR203 SCTN20-7 C10-118 SCT-TB1 4-1501 SDD440 45-6N SCT32084

.020 SAFE-T-CABLE Tool and Parts Kit DESCRIPTION

SAFE-T-CABLE Tool with 3 Nose Attached (.020) 7 Nose Assembly (.020) SAFE-T-CABLE (.020 x 18) SAFE-T-CABLE Torque Verification Block 9/64 Hex Wrench Screwdriver Diagonal Cutter/Gripper Spanner Tool

QUANTITY
1 1 100 1 1 1 1 1

DMC1000-20R
PART NUMBER
SCTR323 SCTR203 SCTN32-7 SCTN20-7 C10-218 C10-118 C10-218JA SCT-TB1 4-1501 F10-04 SCT32084

.020 & .032 SAFE-T-CABLE Tool & Parts Kit

QUANTITY
1 1 1 1 100 100 50 1 1 50 1

DESCRIPTION
SAFE-T-CABLE Tool with 3 Nose Attached (.032) SAFE-T-CABLE Tool with 3 Nose Attached (.020) 7 Nose Assembly (.032) 7 Nose Assembly (.020) SAFE-T-CABLE (.032 x 18) SAFE-T-CABLE (.020 x 18) Self Looping SAFE-T-CABLE (.032 x 18) SAFE-T-CABLE Torque Verification Block 9/64 Hex Wrench Elongated Ferrules (.032) Spanner Tool

DMC1000-11R
PART NUMBER
SCTR407 C10-318 SCT-TB1 4-1501 SDD440 45-6N SCT32084
2001 DANIELS MANUFACTURING CORP., USA

.040 SAFE-T-CABLE Tool and Parts Kit DESCRIPTION

SAFE-T-CABLE Tool with 7 Nose Attached (.040) Safety Cable (.040 x 18) SAFE-T-CABLE Torque Verification Block 9/64 Hex Wrench Screwdriver Diagonal Cutter/Gripper Spanner Tool
Page 9

QUANTITY
1 100 1 1 1 1 1

TOOLS, ACCESSORIES & VERIFICATION EQUIPMENT

Over 50 Years of success in the design, production, and support of Tooling for high-reliability applications in the aircraft and aerospace industry is the reason DMC was included in the development team for SAFE-T-CABLE . The Tooling, which was initially designed to meet the challenges of SAFE-T-CABLE installation, has evolved into a product line that is flexible enough to meet the users exact needs. Its your choice as to which model and accessories to specify, but always with the understanding that interchangeability, adjustability, and overall reliability was the basis of each application tool series.

Its a matter of Choice . . .

2 1 q ADJUSTABLE TENSION q PRE-SET TENSION

HAND TOOL SERIES: The most popular hand operated application tool for SAFE-TCABLE is the SCTR Series Adjustable Tension Tool. The tool features replaceable noses of various lengths (see chart on page 10), and a rotary tension mechanism which can be adjusted to precise cable tension requirements. The tension will repeat at the setting which has been set for reliable SAFE-T-CABLE installations. HAND TOOL SERIES: In some factories where control of tool adjustments are not possible, where the skill level is minimal, or applications where a single-handed operation of the tool is desirable, the Pre-Set Series Application Tool may be the best choice. All tools in this series feature a patented tension mechanism, which allows single-handed use of the tool (after the cable is threaded through and into the tool). Multiple actuations of the tool handle will draw the cable into the tool until all slack is removed from the cable. When the tool senses the correct tension (pre-set at the factory), it will shift into the crimp-cut mode, and complete the installation of the SAFE-T CABLE on the next closure of the handle. Its as simple as that.

3 q PNEUMATIC
APPLICATION TOOL SERIES: When Ergonomics and production demands are critical issues, the DMC SCTP Series Pneumatic Application Tool is a must. SAFE-TCABLE is threaded through the fasteners, into the ferrule, and into the tool in the same fashion as the manual tools, but the push of a button is all that is necessary to complete the termination. The tool automatically applies tension (adjustable), crimps and cuts flush in one actuation of the trigger. These tools operate on standard shop air pressure, and may be suspended from a load balancer for an even greater improvement in ergonomics.

3 q

1 q

2 q
Page 10
2001 DANIELS MANUFACTURING CORP., USA

DMC PART NUMBER

CABLE DIAMETER
.020 .020 .032 .032 .040 .040 .020 .020 .032 .032 .040 .040 .020 .020 .032 .032 .040 .040 .020 .020 .020 .032 .032 .032 .040 .040 .040

NOSE LENGTH
3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 5 7 3 5 7 3 5 7 INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES INCHES

1 q ADJUSTABLE TENSION HAND

TOOL SERIES

SCTR203 SCTR207 SCTR323 SCTR327 SCTR403 SCTR407 SCT203 SCT207 SCT323 SCT327 SCT403 SCT407 SCTP203 SCTP207 SCTP323 SCTP327 SCTP403 SCTP407 SCTN20-3 SCTN20-5 SCTN20-7 SCTN32-3 SCTN32-5 SCTN32-7 SCTN40-3 SCTN40-5 SCTN40-7

Special Accessories and Tools

DMC extends the capabilities of the SAFE-T-CABLE Product Line by making available the following accessories and tools: SCT32084 Spanner Tool is for adjusting all SAFE-T-CABLE Application Tools (one spanner is supplied with each new tool). SCT32059-SA Nose Extender adds two inches in length. Can be used with any tool/nose combination. Tension Assembly Required for conversion of any SCTR Tool from one cable size to another. SCTR20TWSA .020 Dia. SCTR32TWSA .032 Dia. SCTR40TWSA .040 Dia. 45-6N Cutter/Gripper For SAFE-TCABLE and Lockwire

2 q PRE-SET

TENSION HAND TOOL SERIES

3 q PNEUMATIC
APPLICATION TOOL SERIES

REPLACEMENT NOSES

4 q SCT-TB1 TOOL 5 q SCT-TB1R PERFORMANCE

VERIFICATION EQUIPMENT

TORQUE VERIFICATION BLOCK FOR .020, .032, AND .040 SAFE-T-CABLE TORQUE VERIFICATION BLOCK CONFIGURED FOR RIGHT-HAND READING TORQUE WRENCHES TORQUE WRENCH FOR .020, .032, AND .040 SAFE-T-CABLE (20-150 IN-LB) 2 LB PUSH FORCE TESTER FOR USE WITH SCT-TB1, AND OTHER TORQUE BLOCKS MOTORIZED PULL TESTER FOR TESTING .020, .032, AND .040 SAFE-T-CABLE

5 q SCTD0001 6 q SCTD013 7 q MPT-200A-SC

4 q

5 q 6 q

TOOL PERFORMANCE 7 VERIFICATION EQUIPMENT Repeatability and traceability in the management of SAFE-T-CABLE tools at all stages of their life cycle requires periodic testing and verification. DMC supplies all the equipment necessary to perform a quick reliable verification of the application tools either on-sight, or in the metrology lab. Our objective has always been to provide a self-supporting system that does not require that tools be returned to the factory for simple testing and verification.

2001 DANIELS MANUFACTURING CORP., USA

Page 11

SCT-TB4 PORTABLE ELECTRONIC SAFE-T-CABLE VERIFICATION TESTER

Advanced Technology for Safe-T-Cable Application Tool Testing
The SCT-TB4 SAFE-T-CABLE ELECTRONIC VERIFICATION TESTER is a complete diagnostic center for Safe-TCable application tools. The SCT-TB4 is the first system approach tester for optimum Safe-T-Cable installation performance. It combines the simple principals of the DMC Safe-T-Cable Torque Verification Block (SCT-TB1) and the reliable circuitry of the Alphatron HPT series digital electronic pull tester. This one tester will provide all the information that previously required two separate testers, and increased consumption of Safe-T-Cable for verification of application tools. A single installed cable assembly can first be tested for minimum load hold (flex limit test), and then be tested to destruct load (optimum tool performance). The SCT-TB4 Tester will also provide applied tension and residual tension data for engineering study and employee training purposes. The SCT-TB4 tester is designed and packaged to survive in a shop environment, and the self contained, battery powered, design allows the user to perform tests in all areas of the shop and field support activities. The SCT-TB4 Tester is a costeffective quality assurance tool in most factory and maintenance applications where Safe-T-Cable is used.

ALL DMC TESTERS HAVE A BUILT-IN CALIBRATION TEST SPC COMPATIBLE TRACEABLE TO NIST FACTORY CALIBRATION AND SUPPORT RUGGED DESIGN, AND CUSTOM CARRY CASE INCLUDED ONE SAMPLE TESTING TO THE REQUIREMENTS OF AS4536 AND OTHER STANDARDS IMPROVES TOOL CONTROL AND CALIBRATION OPERATIONS RS232 DATA OUTPUT AVAILABLE

DANIELS MANUFACTURING CORPORATION

526 Thorpe Rd. Orlando, FL 32824 USA Phone: 407-855-6161 Fax: 407-855-6884 E-Mail: dmc@dmctools.com www.dmctools.com

OPERATING THE SCT-TB4 ELECTRONIC SAFE-T-CABLE VERIFICATION TESTER

Typical application of the SCT-TB4 Tester would include the following steps:

Step 1: Switch the meter on, and zero by adjusting the knob and pressing the reset button.

Step 2: Install a Safe-T-Cable sample between the test points using the application tool that is to be verified.

Step 3: Reset the display and notice the value shown. This is the residual tension that is on the Safe-T-Cable sample.

Step 4: Apply light pressure to the cable in the TEST AREA until the number on the display increases by approximately two pounds. The cable should not touch the walls of the test fixture.

Step 5: Slowly apply pressure to the test fixture handle until minimum pull-off values are displayed.

Step 6: The peak load pressure will remain on the display. Typically, this is 30 lbs. for .020, 70 lbs. for .032, and 110 lbs. for .040 diameter Safe-T-Cable.

Step 7: Reset the meter, and repeat step four, making sure the cable does not touch the walls of the test fixture. For basic verification of tools, you can stop with this step, and remove the Safe-T-Cable sample from the fixture by cutting.

Step 8: If tool adjustments and servicing is the purpose of this test, apply pressure to the handle of the test fixture sufficient to break the cable assembly.

Step 9: The peak load force will display on the meter. This represents the force at the time of separation of the cable assembly. The difference between the minimum test value, and the displayed value is the Safe-T-Cable safety margin for that particular tool.

Complete instructions for use of this precision tester is supplied with the unit. A copy of these instructions are also available from DMC by contacting the customer service department. An optional canvas shoulder bag is available for the tester. Contact DMC for complete details on all the time saving Safe-T-Cable equipment and components that are available to help you get the job done faster, more efficiently, and with better quality performance.

Other Torque Verification Testers from DMC

DANIELS MANUFACTURING CORPORATION

526 THORPE ROAD ORLANDO, FL 32824 USA PHONE: 407-855-6161 FAX: 407-855-6884 E-MAIL: DMC@DMCTOOLS.COM WWW.DMCTOOLS.COM

SCT-TB1 Manual Torque Verification Block for .020, .032, and .040 diameter Safe-T-Cable SCTD0001 Micrometer (Click) Torque Wrench for .020, .032, and .040 diameter Safe-T-Cable. The torque range is 20 to 150 inch/pounds. Other models available. Consult factory for details.

.062

(LOCKING CABLE)
for use onboard nuclear submarines, and carriers. The .062 diameter SAFE-T-CABLE (Locking Cable) was later tested and certified for use by the commercial power producing industry, and other applications are under consideration.The practice of twisting lockwire onto fasteners and threaded assemblies is a tedious task, which requires skill and time. Lockwire measuring .062 diameter is anything but user friendly. SAFE-T-CABLE (Locking Cable) allows maintenance and other operations to be performed in the minimum time, in tight access areas, with limited inspection, and with no rework due to faulty lockwiring. Also, handling the tool and materials for SAFE-T-CABLE (Locking Cable) will not damage special gloves or protective clothing .032 and .062 diameter SAFE-T-CABLE (Locking Cable) is recognized and defined in MIL-STD-763 (G Revision). Construction: The standard .062 diameter SAFE-T-CABLE (Locking Cable) is 24 inches in length, and measures .062 min./.072 inch max. diameter. The cable is comprised of 7 strands of 19 wires each for maximum strength and flexibility. The factoryapplied end fitting (square) measures approximately .155 inch across the flats, and the outside diameter of the user applied ferrule (round) measures .150 inch. The minimum pull-off load of the ferrule after crimping is 280 pounds (per Mil-Std 763). Product samples, application information, and technical data may be obtained by contacting DMC.

CONVENTIONAL LOCKWIRE

SAFE-T CABLE

An urgent need for a fast reliable fastener security system for the Nuclear Power Industry resulted in the further expansion of SAFE-T-CABLE (Locking Cable) by DMC. Working with a major contractor to NAVSEA and commercial power organizations, DMC developed and certified a .062 diameter SAFE-T-CABLE

Page 12

2001 DANIELS MANUFACTURING CORP., USA

Two application tools are available from DMC, (one manual, and one self contained hydraulic), and two installation kits are also available. The Manual Application Tool (part number SCT625) (pictured this page) is set-up with a ratchet-controlled handle that performs the crimp termination on the cable, and another handle on top of the tool that cuts the cable flush with the ferrule. The Hydraulic Application Tool (part number SCTH625) (not pictured) utilizes a lightweight hand actuated hydraulic pump to develop the force required to crimp and cut the .062 diameter SAFE-TCABLE (Locking Cable).

The tool crimps and cuts the assembly flush to the ferrule by multiple actuation of a single handle. Both application tool models feature an easy to use adjustable tension clutch mechanism with a rotary tension wheel, replaceable crimp nose assemblies, and user adjustable crimp depth settings for maximum tool life/performance. Other accessories offered by DMC include a Torque Verification Block for periodic monitoring of application tool performance, a 100-750 inch-pound torque wrench, and other tool accessories.

Description SAFE-T-CABLE 1 (Locking Cable) Kit q (.062 X 24 inches) Manual Application Tool with 5 Nose Manual Application Tool with 9 Nose Replacement Nose Assembly for Manual Tool Series Replacement Cut-Off Blade Hydraulic Application Tool with 5 Nose Hydraulic Application Tool with 9 Nose

Part Number

C10-924

SCT-625

SCT-629

2 q

SCTN62-X

SCT62024

SCTH625

SCTH629

.062
PART NUMBER SCT625 C10-924 SCT-TB2 SCT62024 91-S 45-6N SCT32084 SCTD011 SCTD012

TOOL & PARTS KITS

PARTS LIST
QUANTITY 1 500 1 4 1 1 1 1 1 DESCRIPTION .062 SAFE-T-CABLE Tool with 5 Nose Attached SAFE-T-CABLE .062 X 24 SAFE-T-CABLE Torque Verification Block SAFE-T-CABLE Cut Off Blades Hex Key Set Diagonal Cutter Spanner Tool Torque Wrench 100-750 Inch Pound Retaining Ring Pliers

DMC1000-62 Depot Level Support Kit

Replacement Nose Assembly for Hydraulic q 2 Tool Series SCTHN62-X Torque Verification Block Torque Wrench 100-750 Inch-LB Cable Cutter/ Gripper

SCT-TB2

SCTD011

45-6N

DMC1000-625 Intermediate Level Support Kit

PARTS LIST
PART NUMBER SCT629 C10-924 SCT-TB2 SCT62024 45-6N SCT32084 SCTD011 SCTD012 4-1190 3-1008 4-1326 QUANTITY 1 100 1 2 1 1 1 1 1 1 1 DESCRIPTION .062 SAFE-T-CABLE Tool with 9 Nose Attached SAFE-T-CABLE .062 X 24 SAFE-T-CABLE Torque Verification Block SAFE-T-CABLE Cut Off Blades Diagonal Cutter Spanner Tool Torque Wrench 100-750 Inch Pound Retaining Ring Pliers 5/64 Hex Wrench 1/16 Hex Wrench 3/16 Hex Wrench

1 q C10-924 part number applies to one cable assembly, and one ferrule. If required separately, the following part numbers apply: A10-924 (Cable Assembly only), F10-09 (Ferrule only). All Cable Kits, Individual Cables, and/or ferrules are supplied 50 per package. All Ferrules supplied in disposable metal cartridges. 2 Insert Nose Length in place of X. q
Page 13

2001 DANIELS MANUFACTURING CORP., USA

INSTALLATION PRACTICE GUIDE

A. SAFE-T-CABLE 1.

SAFE-T-CABLE Application/Installation information which appears on these pages was adapted from a U.S. Military Handbook. It is intended for reference only. It is the responsibility of the user to verify and confirm that the installation of SAFE-T-CABLE is safe and appropriate for the application.

General instructions for the selection of Safe-T-Cable: The selection of materials shall be in accordance with AS4536 (SAE), available from SAE International, 400 Commonwealth Avenue, Warrendale, PA 15096-0001 U.S.A., and shall be in accordance with the service limitations outlined herein. NOTE: Minimize mixing of safety lockwire and Safe-T-Cable. AS3510 series (UNS S321000 CRES) Safe-T-Cable shall be selected for general purpose use on all application up to 649C (1200F). (b) AS3509 series (UNS N6600 Nickel Alloy) Safe-T-Cable shall be selected for up to 982C (1800F). (c) Only Safe-T-Cable and ferrules supplied by a manufacturer that meets all the requirements of AS4536 shall be allowed. (d) Safe-T-Cable shall not used for any shear or breakaway applications. (e) Safe-T-Cable shall be installed with a calibrated tool which is supplied by the manufacturer for the purpose of applying a predetermined cable tension, crimping the ferrule, and cutting the excess cable without allowing tension to be lost. (a)

2.

The size of Safe-T-Cable shall be in accordance with the following requirements: (a) 0.020 inch diameter Safe-T-Cable is intended for use on parts having a nominal hole diameter of 0.045 inch (1.14 mm) or smaller. (b) 0.032 inch diameter Safe-T-Cable is intended for use on parts having a nominal hole diameter of 0.075 inch (1.91 mm). (c) 0.040 inch diameter Safe-T-Cable is intended for use on parts having a nominal hole diameter of 0.095 inch (2.41 mm). (d) The specified length of the cable shall be selected to accommodate the span between fasteners added to the length of cable required to correctly engage the application tool. (e) Applications where Safe-T-Cable is to be installed through a hole having a nominal diameter greater than 0.095 inch (2.41 mm), but less than 0.200 inch (5.08 mm) shall require a flat washer (same material composition as the cable) which is supplied by the cable manufacturer for this purpose, and shall be used as shown in Figure 10.

Figure 10: Flat Washer Safe-T-Cable Installation (f) Safe-T-Cable shall be installed with an application tool which has been been calibrated to meet the performance requirements of AS4536 (SAE) and this specification.

526 THORPE ROAD, ORLANDO, FL 32824-8133 USA (407) 855-6161, FAX (407) 855-6884
Page 14 EMAIL: DMC@DMCTOOLS.COM WWW.DMCTOOLS.COM
2001 DANIELS MANUFACTURING CORP., USA

3.

Safe-T-Cable Installation: NOTE: All Safe-T-Cable installation will be accomplished in accordance with AS4536. Safe-T-Cable may be used as a substitute for safety lockwire to prevent loosening during service. Threaded parts, such as drilled-head bolts, fillister head screws, turnbuckles, thumbscrews, hose fittings and electrical connectors, plugs, caps, and similar items are within the scope of Safe-T-Cable applications. The following rules shall apply when using Safe-T-Cable. NOTE: Routing of Safe-T-Cable may vary from that of safety lockwire in order to achieve a proper installation. When Safe-T-Cable is being substituted for safety lockwire in an existing installation (maintenance, rework, etc.), equivalent diameters of cable to that of safety lockwire shall be selected for use, provided that selection criteria for Safe-T-Cable as defined in General Instructions are met. (b) Adjacent Units: Safe-T-Cable shall be installed in such a manner that any tendency for a fastener to loosen will be counteracted by an additional tension on the cable. Safe-T-Cable shall be threaded through the fasteners in such a way as to produce installed cable with either positive or neutral pull. (c) Maximum Span: The maximum span of Safe-T-Cable between two termination points shall be 6 inches (152.4 mm) unless otherwise specified. (a) CAUTION: Installing defects: Any defect (nick, fray, kink or any other mutilation of the Safe-T-Cable) found prior to, during or subsequent to installation, is not acceptable!

Figure 11: Self Looping Safe-T-Cable NOTE: Avoid kinks or sharp bends while handling or installing Safe-T-Cable. (d) Installing Holes in Fasteners: Safe-T-Cable must be installed through the holes intended for this purpose in the part being secured, or through the holes provided in a self-looping device secured to the cable by the cable manufacturer (see Figure 11). In applications where holes are not provided for Safe-T-Cable in the component to which it is attached, the self-looping Safe-T-Cable may be used in a manner like, or similar to Figure 12.

2001 DANIELS MANUFACTURING CORP., USA

Page 15

INSTALLATION PRACTICE GUIDE

SAFE-T-CABLE Application/Installation information which appears on these pages was adapted from a U.S. Military Handbook. It is intended for reference only. It is the responsibility of the user to verify and confirm that the installation of SAFE-T-CABLE is safe and appropriate for the application.

Figure 12: Self Looping Safe-T-Cable Anchored to a Pin Assembly (e) (f) Safe-T-Cable and Ferrule Reuse: Safe-T-Cable and ferrule shall be new upon each application. Reuse is not allowed. Installation: Various examples of Safe-T-Cable installations are shown in this section. All possible combination and applications are not shown. Unless otherwise specified in the application engineering drawing, Safe-T-Cable shall be installed in two or three bolt patterns with two bolt patterns being the preferred method where an even number of fasteners is to be secured. The installer must adhere to the basic rules outlined in the specification. Hose Fittings and Electrical Connector Requirements: Hose fittings and electrical coupling nuts shall have Safe-T-Cable installed in the same manner as tube coupling nuts. Excess Cable: After installing Safe-T-Cable, excess cable from the crimped ferrule shall be cut by the installation tool. The maximum allowable length of cable extending beyond the ferrule shall be 0.031 inch (0.79 mm). Crimping Requirements (Pull-Off Load see Table I): Safe-T-Cable shall be installed with the cable manufacturers recommended tool, which has been tested and calibrated in accordance with procedures specified in this specification.

(g)

(h)

(i)

NOMINAL CABLE DIAMETER INCH .020 .032 .040

CABLE MINIMUM CONSTRUCTION PULL-OFF LOAD LB. F. (N) 1X7 3X7 7X7 Table I 30 (133.4) 70 (311.4) 110 (489.3)

(j)

Hole Alignment: Undertorquing or overtorquing to obtain proper alignment of the holes in not permitted. Apply recommended torque values to part to be secured, and alignment of holes shall be evaluated before attempting to proceed with the Safe-T-Cable installation. CAUTION: The maximum bend exit limit of Safe-T-Cable, when applied to a threaded fastener head, shall be 135. This does not apply to hose fittings, electrical connector coupling mechanisms, turnbuckles, and similar applications where the cable is constrained by the shape of the component being secured.

Page 16

2001 DANIELS MANUFACTURING CORP., USA

(k) In applications where Safe-T-Cable shall be required to exceed the 135 maximum bend exit limit in order to achieve neutral to positive pull on a threaded fastener head, a self-looping device which is secured to the Safe-TCable by the cable manufacturer may be used to obtain a secured installation as shown in Figure 13.

CAUTION: This method should only be used in applications where the SafeT-Cable can not flip over the corner or over the head of the fastener being secured!

Figure 13: Self Looping Safe-T-Cable In High Bend Exit Application (l) Cable Flex Limits: After installing Safe-T-Cable, the maximum flex between termination points shall be no greater than that specified in Cable Flex Limit Table (Table II). NOTE: When calculating the flex limit (B & C) of Safe-T-Cable which is installed through three fasteners, the A = D + E formula shall apply (see Figure 14). The total length of cable (from the point where it exits the first fastener, to the point where it enters the last fastener) shall be measured. The corresponding length from Table II, column A shall be used to determine the flex limit.

Figure 14: Safe-T-Cable Flex Limits NOTE: Light finger pressure of approximately 2 lb. shall be applied at midspan when inspecting total flex limit of installed Safe-T-Cable.

2001 DANIELS MANUFACTURING CORP., USA

Page 17

INSTALLATION PRACTICE GUIDE

SAFE-T-CABLE Application/Installation information which appears on these pages was adapted from a U.S. Military Handbook. It is intended for reference only. It is the responsibility of the user to verify and confirm that the installation of SAFE-T-CABLE is safe and appropriate for the application.

CAUTION: It is important to hold the tool as stead and perpendicular to the fastener as possible during the crimp/cut cycle in order to maintain consistent tensioning of the cable after the tool is removed! 4. Elongated Ferrules: Ferrules of extra length, having a radius at one end and a flat surface at the other end, may be used in applications which restrict the clearance for the installation tool nose to be placed in correct alignment with the fastener (such as low profile fastener heads, recess locations, or obstructions by structures or installed components).

Figure 15: Correct Application of Safe-T-Cable NOTE: Always install elongated ferrules with the radius end toward the fastener and the flat end in the tool crimp cavity. Double check cable tension between fasteners after removal of application tool. NOTE: Radius required on .032 inch diameter and larger elongated ferrules. Radius is optional on .020 inch diameter elongated ferrules.

Figure 16: Low Profile Application for .032 & .040 Inch Safe-T-Cable

Page 18

2001 DANIELS MANUFACTURING CORP., USA

Figure 17: Examples of Installed Safe-T-Cable 5. Safe-T-Cable Indentification Stamp: In applications where the user requires a logo or identification code to be a permanent part of the cable installation (for warranty or traceability), it shall be applied by the Safe-T-Cable manufacturer to one or more surfaces of the square end fitting of the cable. Only impression stamping is permitted, no paint, ink, or labels are acceptable (see Figure 18).

Figure 18: Safe-T-Cable Identification Stamp 6. Safe-T-Cable on Turnbuckles: The standard procedure for securing turnbuckles with Safe-T-Cable is shown in Figure 19. (a) A self looping cable is threaded through the turnbuckle. One end shall be wrapped in one direction around the turnbuckle. The Safe-T-Cable is then threaded through the hole in the self-looping jumper, and terminated with the appropriate application tool.

2001 DANIELS MANUFACTURING CORP., USA

Page 19

INSTALLATION PRACTICE GUIDE

SAFE-T-CABLE Application/Installation information which appears on these pages was adapted from a U.S. Military Handbook. It is intended for reference only. It is the responsibility of the user to verify and confirm that the installation of SAFE-T-CABLE is safe and appropriate for the application.

Figure 19: Routing of Safe-T-Cable on Turnbuckles

Figure 20: Example of Final Safe-T-Cable Turnbuckle Installation (b) Safe-T-Cable diameter selection for turnbuckle applications: .032 inch diameter cable shall be used on assemblies where cable diameter in 1/16 inch (1.6 mm) or smaller, and .040 inch diameter cable or greater shall be used on turnbuckle cable diameters greater than 1/16 inch. Safe-T-Cable Jacketing for Protection: It is recommended to use a tubular jacket over Safe-T-Cable when it is installed in a location where it is in contact with (or may contact) surfaces which may damage the cable. The tubular jacket material shall be capable of meeting the temperature range of the application and shall be resistant to oil and chemical environments.

7.

Figure 20: Safe-T-Cable Jacketing for Protection

Page 20

2001 DANIELS MANUFACTURING CORP., USA

B. SAFE-T-CABLE APPLICATION TOOLS: 1. Procedures: When Safe-T-Cable is used, the following basics apply for the application tools and calibration equipment. (a) Minimize mixing of safety lockwire and Safe-T-Cable. (b) For convenience, install the ferrule cartridge into the tool body under the handle grip. NOTE: When loading and using the Safe-T-Cable application tool, be certain that the correct size Safe-T-Cable kit is being used with the tool. (c) Install the Safe-T-Cable through the fastener to be secured. (d) The nose of the tool can rotate 360. To rotate the nose, turn the nose with your fingers (see Figure 1). (e) Insert the free end of the cable through the ferrule in the cartridge, and remove the ferrule by pulling the cable away from the end of the cartridge (see Figure 2). NOTE: Do not release the free end of the cable until it has been inserted through the tool nose. (f) Insert the free end of the cable through the tool nose (see Figure 2) and slide the tool along the cable to the fastener being secured (see Figure 3).

Figure 1: Pre-Set Tension Safe-T-Cable Tool

Figure 2: Pre-Set Tension Safe-T-Cable Tool

2001 DANIELS MANUFACTURING CORP., USA

Page 21

INSTALLATION PRACTICE GUIDE

C.

SAFE-T-CABLE Application/Installation information which appears on these pages was adapted from a U.S. Military Handbook. It is intended for reference only. It is the responsibility of the user to verify and confirm that the installation of SAFE-T-CABLE is safe and appropriate for the application.

TYPES OF SAFE-T-CABLE APPLICATION TOOLS: 1. Pre-Set Tension Tool: (see Figures 1 and 2) Insert the free end of the Safe-T-Cable into the cable entrance and continue to push the cable into the cavity. When the free end of the cable appears at the bottom of the tool, grasp the cable and pull the slack from the cable until resistance is felt. Begin removing slack from the cable by repeatedly closing the tool handle, allowing the handle to open fully before closing again. When all slack is removed from the cable, snug the tool against the fastener being secured by using several short strokes of the handle. Release the handle to the full open position and fully close the handle to crimp securely and cut flush. CAUTION: It is important on the final stroke to hold the tool as steady and perpendicular to the cable as possible while completing a full stroke. This assures consistent tensioning of the cable (see Figure 3).

Figure 3: Position of Safe-T-Cable Tool 2. Adjustable Tension Tool: (see Figure 4) Thread the Safe-T-Cable through the fastener, ferrule, and tool nose in the same way as with other models of tools. Wrap the cable one full revolution (clockwise) around the tension wheel, and with slight pressure applied by pulling the cable, secure the cable into the slot. Rotate the tension wheel until several clicks are heard and felt. If additional tension is required, adjustment can be made with the tension adjuster on the opposite side of the tool. CAUTION: Do not overtighten Safe-T-Cable. It is a good practice to find a tension setting which removes the slack from the cable, (in order to meet the flex limit requirement) without over stressing the cable components. (a) Completely close the handle to crimp and cut the cable. Hold the tool steady and perpendicular to the cable to maintain consistent cable tension. Release the handle and remove the tool from the crimped ferrule. Remove the excess cable segment from the tool prior to the next application. (b) If it is more convenient to use the adjustable tension tool with the tension wheel located on the opposite side, you may remove the retaining ring located below the tension adjuster, slide the wheel assembly out of the tool body, a re-insert it on the opposite side. Re-install the retaining ring (see Figure 4).

Page 22

2001 DANIELS MANUFACTURING CORP., USA

NOTE: When using a Safe-T-Cable hand tool, the tool handle is to remain fully open during the cable entry process (in both tool models). The handle is to be actuated in the pre-set tension model after the tension pawl is engaged with the cable, and in the adjustable tension model only after the desired tension is achieved.

Figure 4: Adjustable Tension Safe-T-Cable Tool 3. Pneumatic Adjustable Tension Tool: (see Figure 5) Connect the Pneumatic Safe-T-Cable tool to a clean, dry air supply of 80-100 psi (5.56.9 BAR). (a) Install the cable through the fastener being secured. (b) The nose of the tool can rotate 360. To rotate the nose, turn the nose with your fingers. (c) Insert the free end of the cable through the ferrule in the cartridge, and remove the ferrule by pulling the cable away from the end of the cartridge. NOTE: Do not release the free end of the cable until it has been inserted through the tool nose. (d) Insert the free end of the cable through the tool nose and slide the tool along the cable to the fastener being secured. (e) Rotate the tension wheel on the tool clockwise if necessary to move the cable entry slot to an accessible position. Align the nose such that the ferrule is pressed squarely against the fastener. Make certain that the ferrule is fully seated into the nose cavity. Insert the free end of the cable into the cable entry slot of the cable tension wheel. When the end of the cable exits the wheel, grasp the cable and pull the slack from the cable. Do not leave more than 1-1/2 of total slack in the cable. (f) Press the trigger and hold. The tool will apply tension to the cable, crimp the ferrule and cut the cable in one continuous operation. When the trigger is released, the crimp mechanism will retract (after the cycle is complete), and the tool nose can be moved away from the ferrule. The excess cable should be discarded.

2001 DANIELS MANUFACTURING CORP., USA

Page 23

INSTALLATION PRACTICE GUIDE

SAFE-T-CABLE Application/Installation information which appears on these pages was adapted from a U.S. Military Handbook. It is intended for reference only. It is the responsibility of the user to verify and confirm that the installation of SAFE-T-CABLE is safe and appropriate for the application.

(g) The tension is adjustable by inserting the manufacturer supplied adjustment key into the adjustment port located on the tool handle. Clockwise rotation increases tension; counterclockwise rotation decreased tension.

Figure 5: Pneumatic Safe-T-Cable Tool D. SAFE-T-CABLE APPLICATION TOOL MAINTENANCE AND CALIBRATION: The tool should be stored in a clean, dry place when not in use. Clean any debris (especially in the crimp cavity in the tool nose) from the tool with a small brush and solvent if necessary. Lubricate the tool nose with a drop of oil (into the crimp cavity) on a regular basis. 1. Tool calibration verification with the Safe-T-Cable test fixture or electronic pull tester. NOTE: Indenter calibration should be verified periodically and must always be checked if the nose assembly has been removed or changed. (a) Use the calibration text fixture and torque wrench to verify the tool indenter adjustment (see Figure 6). Thread the cable into the left swivel and through the right swivel, holding the lever against the built-in stop. If the lever is not kept against the stop, the results may be adversely affected. Terminate the cable with the tool being tested. (b) Apply approximately 2 lb. force to the cable with your finger at the line marked TEST AREA". If the cable touched either the side or the bottom surface of the text fixture, remove the cable from the text block, and re-install another cable being careful to set the tool tension properly, and to hold the lever against the stop. (c) Place a calibrated 3/8 inch drive torque wrench (capable of indicating 30 in. lb. for .020 inch cable, 70 in. lb. for .032 inch cable, and 110 in. lb. for .040 inch cable) into the square drive hole, orienting the test block and torque wrench on a flat surface. Do not over-torque the cable.

Page 24

2001 DANIELS MANUFACTURING CORP., USA

SAFE-T-CABLE DIAMETER ( INCH) .020 .032 .040

TORQUE WRENCH MINIMUM PULL-OFF LOAD ( IN. LB.) 30 70 110

(d) The Safe-T-Cable should remain in place during application of the measured force. Apply approximately 2 lb. force to the cable with your finger at the line marked TEST AREA. If the cable touches either the side or the bottom surface of the test fixture, the crimp is unacceptable and the tool indenter should be adjusted.

Figure 6: Calibration Test Fixture and Torque Wrench (e) Electronic Pull Tester: It may be required in some applications to pull test Safe-TCable to destruction. If this is required, an electronic pull tester may be used in place of the calibration test fixture/torque wrench method. The type of machine shown in Figure 7 will satisfy this requirement.

Figure 7: Electronic Safe-T-Cable Pull Tester

2001 DANIELS MANUFACTURING CORP., USA

Page 25

INSTALLATION PRACTICE GUIDE

2.

SAFE-T-CABLE Application/Installation information which appears on these pages was adapted from a U.S. Military Handbook. It is intended for reference only. It is the responsibility of the user to verify and confirm that the installation of SAFE-T-CABLE is safe and appropriate for the application.

Indenter adjustments for all Safe-T-Cable application tool models. NOTE: Calibration should be checked frequently by the use of the calibration test fixture/torque wrench or the electronic pull tester. (a) Remove the nose assembly by removing the two 8-32 socket head cap screws with a 9/64 inch hex wrench (see Figure 8). (b) Adjust the pushrod adjustment screw with a flat blade screwdriver, or the manufacturer supplied adjustment key. Turn the pushrod adjustment screw clockwise to loosen the crimp (enlarge the gaging dimension), or counterclockwise to tighten the crimp (reduce the gaging dimension). Replace the nose assembly and the two 8-32 socket head cap screws, being certain that they are tightened firmly. Check calibration as previously described. NOTE: Some tool models utilize a pushrod lock nut. This must be loosened prior to adjustment, and tightened after any adjustment has been made with the adjustment key provided by the manufacturer. CAUTION: Do not adjust the pushrod more than a quarter of a turn at a time! Severe adjustment may damage the tool!

Figure 8: Removal of Safe-T-Cable Tool Nose Assembly

Figure 9: Adjustment of Safe-T-Cable Indenter (Same for hand or pneumatic tool models)

Page 26

2001 DANIELS MANUFACTURING CORP., USA