Safe-T-Cable - Pan Pacific Electronics

Typical3-FastenerLockwireInstallation1:42 *1 min. 42 sec.0:36 *36 sec.Typical3-FastenerSafe-T-Cable ®InstallationSafe-T-Cable ® may be substituted, in many applications, for hand-twisted lockwire.Safe-T-Cable ® will improve the efficiency and quality of your assembly operations.DANIELS®MANUFACTURINGCORPORATIONan ISO9001 and AS9100 Registered Company© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL*Assembly time comparison shown is for reference only.Actual time saved will be dependent upon the application.

• 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 Carpal Tunnel Injuries• Improved Access To Tight AreasDANIELS ®MANUFACTURINGCORPORATION526 THORPE ROAD • ORLANDO, FL 32824-8133 USA(407) 855-6161 • FAX (407) 855-6884E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

The Steps are Simple…THREADA Cable assembly is threaded thru the fastenersin a direction which will exert a positive pull onthe fastener when tension is applied.INSERTSimply insert the cable through the ferrulecartridge and the tool nose.CRIMP & CUTCorrect tension is applied, the ferrule is firmlycrimped, and the cable is cut flush with the endof the ferrule.JOB IS FINISHEDThe job is complete. A secure installation in afraction of the time it takes to install lockwire.Introducing Safe-T-Cable ® . . . . . . . . . . . . . 2About DMC . . . . . . . . . . . . . . . . . . . . . . . . . 3Approvals and Recognitions . . . . . . . . . . . 4DMC Statement on Safe-T-Cable ® . . . . . . . 5Users of Safe-T-Cable ® . . . . . . . . . . . . . . . 5Safe-T-Cable ® Part Numbering System. . . 6Safe-T-Cable ® Kits . . . . . . . . . . . . . . . . . . . 7Safe-T-Cable ® Assemblies and Ferrules . . 8Table of ContentsElongated Ferrules . . . . . . . . . . . . . . . . . . . 9Fiberglass Sleeving . . . . . . . . . . . . . . . . . . 9Filler Washer. . . . . . . . . . . . . . . . . . . . . . . . 9Self-Looping Safe-T-Cable ® . . . . . . . . . . . 10Branded Safe-T-Cable ® . . . . . . . . . . . . . . 10Tool and Parts Kits . . . . . . . . . . . . . . . . . . 11Application Tools . . . . . . . . . . . . . . . . . . . 13Tool Accessories . . . . . . . . . . . . . . . . . . . 14Verification Equipment. . . . . . . . . . . . . . . 14.062 Diameter Safe-T-Cable ® . . . . . . . . . . 16Installation Practice Guide . . . . . . . . . . . 18FAA Classification Letter . . . . . . . . . . . . . 24F.A.R. Reference . . . . . . . . . . . . . . . . . . . . 25Limited Warranty . . . . . . . . . . . . . . . . . . . 25© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL

IntroducingConstructionSafe-T-Cable ® isconstructed of hightensile strength,stranded cable. It ismore flexible than itsLockwire counterpart,although the workingdiameters are equivalent.This provides astronger assemblywhich has greaterstrength and lighterweight. The cableends are electricallyfused to form an easythreading end.The cable is pre-cut tovarious lengths, and is suppliedwith a square-formedend cap attached to one end.Safe-T-Cable ® is available inthree nominal diameters. The.040 inch diameter cable is constructedof 77 stranded ropelaymaterial. Ropelay construction is alsoused for the 37, .032 diameter cablewhile the .022 diameter cable is madeof 17 unilay material.BackgroundThere will always be a need to installconstraining (safety) devices to threadedfasteners in applications where vibration,kinetic energy, or the need for high reliabilityis present. Their purpose is torestrict (to a minimum) the unintentionalrotation of the fastener. The traditionalmethod (devised in the early 1900’s)is through the use of Hand TwistedLockwire (often called Safety wire).Conventional LockwireThe only changes which have occurredsince the early uses of Lockwire are thetremendous costs in the installation ofthis material, and the levels of sophisticationin the systems on which Lockwireis being installed. It is used in Jet Enginesystems,Airframes,Electronics,Space Vehicles,and Land/Sea basedSystems.The process of installing lockwireremains awkward and costly, and theinspection process is demanding.The removal and rework of installedLockwire is a common occurrence.17 3777719Safe-T-Cable ® was invented to addressthese problems in modern Airframe andEngine Systems. The Safe-T-Cable ®Kits are consistent in their construction/application, and the user-friendly toolingguarantees a secure and reliable installationeach time it is used. Operatortraining is simple, Inspection is objective,and rework is virtually eliminated. Thisresults in fewer demands on the Operators,Inspectors, and Maintenance personnel.Sectional ViewThe ferrules are precisely manufacturedto a size and hardness whichassures their compatibility with thecable and application tooling. They aresupplied (50 pieces each) in an easyloading disposable cartridge, whichprovides orderly containment of individualferrules, and the easy release ofindividual ferrules as they are required.This feature minimizes the possibilityof Foreign Object Damage (FOD).PAGE 2© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

TestingThe application of Safe-T-Cable ®is consistent from one installation tothe next due to the repeatability anddependability of the application toolingand the quality of the materials used inthe manufacture of Safe-T-Cable ® Kits.All that is required to assure overallreliability in manufacturing and maintenanceuse is a periodic test of a fewcrimped cable assemblies. DMC offersfull instructions and the test equipmentto perform these simple tests in eitherremote or test lab locations.MaterialsThe same high performance alloysthat are used in aerospace fastenersand other components are also used inthe construction of Safe-T-Cable ® . Thestrength and corrosion resistance thatis required for durability and long life. Allcomponents (End Fitting, Cable, and userapplied Ferrule) are made of the samematerial. 321 Stainless Steel (AS3510)is the most common Safe-T-Cable ®material. It is used for most engineand airframe applications. Inconel 600(AS3509) is appropriate for high temperatureand/or non-magnetic applications,and the new Inconel 625 (AS3655) hassuperior corrosion resistant properties.Consult DMC for further materialselection information.Safe-T-Cable ®The pre-assembled cables havea square formed end cap securelyattached to one end. This provides apositive stop when threaded througha fastener. The other end is electricallyfused such that it will easily threadthrough the series of fasteners that areto be secured. The flexible cable materialis lightweight and easy to handle. Thestainless steel materials will not corrodeor deteriorate while in use. (See charton the following pages for material, size,and part number.) All Safe-T-Cable ® kitsand assemblies are supplied 50 piecesper package.Ferrules andCartridgeLoading SystemThe individual crimp ferrules arepreloaded into a disposable cartridgeunit (50 pieces per cartridge) which allowsconvenient transportation, storage, andavailability of these components. Theferrules are easily extracted individuallyby threading the cable end through theferrule, and snapping the ferrule loose.This system, when properly used, eliminatesthe possibility of Foreign ObjectDamage (FOD).About DMC…Daniels Manufacturing Corporationwas selected to participate in thedevelopment of Safe-T-Cable ® earlyin the program based upon our expertisein the design and implementationof crimping, swaging, and fasteningtools of many types.It was a reality to the inventor ofSafe-T-Cable ® that the quality andrepeatability of the application toolis the foundation to success in thedevelopment of Safe-T-Cable ® .electronics industries for over 50 years.Our products are the standards ofthese industries, and DMC Products/Services are sold throughout the world.DMC has been the leading manufacturerof crimping tools for theaircraft, aerospace, and high reliabilityOther DMC Products include:Manual Crimping Tools, Pneumatic,Electric, and Hydraulic CrimpingTools, Backshell/Accessory TorqueTools, Contact Insertion/RemovalTools, EMI/RFI Shielding Band Tools,Alphatron Wire Crimp Pull Testers,Fiber Optic Cleave Tools, and AircraftMaintenance Support Tool Kits.© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 3

Approvals And RecognitionsU.S. MilitaryNASM 33540(Formerly MIL-STD-33540)Safety Wiring, Safety Cabling,Cotter Pinning, General PracticesThisdocumentis calledout in manycontracts,drawings,and processmanuals.Safe-T-Cable ® wasincludedin NASM33540 inrevision 1,6 Jan, 2003.It is publishedand controlled by AIA(Aerospace Industries Association)http://www.aia-aerospace.org1250 Eye Street, Washington DC20005, and can be purchasedon-line at the following web address:http://global.ihs.com/?RID=AIATechnical Manuals,Technical Orders,And MS SpecsTO-1-1A-8TO-1-1A-14TO-1-1A-15TM 1-1500-204-23-6TM 1-1500-323-24-1NAVAIR 01-1A-505NAVSEA MIL-STD-763ARMY MICOM, Drawing 13210868Several Platform Specific TOs andTMs feature instructions and guidelinesfor Safe-T-Cable ® . Consult the publicationsorganization that supports yourparticular platform, or contact DMCfor further information.National StockNumber Listing (NSN)The majority of Safe-T-Cable ® Toolsand Components that are specifiedin Military Technical Manuals andStandards are covered by NSNs.Consult DMC for Details.SAEAS3509AS3510AS3511AS4536AS3618AS3619AS3620AS3621AS3655Cable, Safety, Kit, Nickel Alloy,UNS N06600Cable, Safety, Kit, Corrosion andHeat Resistant Steel, UNS S32100Cable, Safety, Kit, CorrosionResistant Steel, UNS S30400Cable, Safety, Kit, ProcurementSpecification For Requirementsand UseCable, Safety, Ferrule, Elongated,Corrosion and Heat ResistantSteel, UNS S32100Cable, Safety, Ferrule, Elongated,Nickel Alloy, UNS N06600Cable, Safety, Self Looping,Corrosion Resistant and HeatResistant Steel, UNS S32100Cable, Safety, Self-Looping,Nickel Alloy, UNS N06600Cable, Safety, Kit, CorrosionResistant Nickel Alloy, UNS N06625Please contact DMC for furtherinformation on SAE Specifications,Publication Status, or ApplicationReferences.NASAMany Tech Manuals and Tech Ordersthat are used by the U.S. Military andFMS Organizations to support Aircraft,Aerospace, and Defense Systems havebeen revised to include Safe-T-Cable ® .The technical information that is requiredto select, install, and maintain the Safe-T-Cable ® and Application/VerificationTooling is included. The General TechManuals/ Tech Orders are the following:SAE International (Society ofAutomotive Engineers) maintainsand distributes the procurement anddetail specifications that control thedesign, packaging, and performancerequirements of Safe-T-Cable ® . SAESpecifications are available on-lineat www.sae.org, or at the followingaddress:SAE INTERNATIONAL400 Commonwealth DriveWarrendale, OH 15044(724) 776-4841The List of Safe-T-Cable ® Specificationsare the following:The National Aeronautical and SpaceAdministration, in cooperation withmajor contractors have developedseveral reports and standards involvingthe testing, selection, use, procurement,and application of Safe-T-Cable ® . Twosignificant NASA funded documentsare CR4473 – CONTRACTOR REPORT(Intersel 1992), and JA83-032ATeledyne Brown.NASA Tech Briefs magazine has alsorecognized Safe-T-Cable ® as a modernSpace Program Technology on one ormore occasions. Safe-T-Cable ® is usedon the Space Shuttle main orbiter engines,structure, and payload applications.PAGE 4© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

Companies AndOrganizations CurrentlyUsing Safe-T-Cable ®(partial list)FAAMany FAA Approved 70-XX-XX Standard Documents are publishedand maintained by major engine, airframe, and component/subsystemmanufacturers.The FAA Approved Manual (supplied by the OEM) on the specificaircraft (or subsystem) will advise the operator/maintainer if Safe-T-Cable ®is approved by the OEM on that aircraft/application. If it can not bedetermined from this, or other documentation, the operator/maintainershould contact the OEM assigned representative, and request informationconcerning the use of Safe-T-Cable ® on that aircraft or subsystem.DMC StatementOn Safety Cable(Safe-T-Cable ® )Daniels Manufacturing Corporation, “DMC” manufactures and sellssafety cable under license by General Electric Aircraft Engines inconformity with Society of Automotive Engineers Standard (SAE)Standard AS4536, AS3509, AS3510 and customer specifications.The Federal Aviation Administration (FAA) classified safety cableto be a standard part by issuance of a letter on November 23, 1993.This letter, in its entirety, along with the Federal Aviation Regulations(FAR) of that date referred to therein appears on the DMC Web Site,and on pages 24 and 25 of this catalog. The third paragraph of thatletter states:Installation of AS3509, AS3510 and AS3511 safety cable on aircraftis governed by FAR § 43.13, Performance Rules (general). FAR § 43.13(a) states in part: “Each person performing maintenance, alteration, orpreventative maintenance on an aircraft, engine, propeller, or applianceshall use the methods, techniques and practices prescribed in thecurrent manufacturer’s maintenance manual or Instructions for ContinuedAirworthiness prepared by its manufacturer, or other methods, techniques,and practices acceptable to the Administrator…”It is the responsibility of the installer of safety cable to determinewhere safety cable can or cannot be installed in accordance with FAAregulations, OEM Practice Standards, or Department of Defense(DOD) directives. Where authorization is required, the installer shouldcontact the Equipment OEM for the necessary authorization.DMC IS NOT LIABLE FOR CONSEQUENTIAL OR SPECIAL DAMAGESOF ANY NATURE OR KIND RESULTING FROM INSTALLATIONOF SAFETY CABLE IN VIOLATION OF FAA, OEM, AND/OR DODDIRECTIVES AND REGULATIONS.Safety Cable is a time saving technology. Please feel free to contactDMC for recommendations concerning the appropriate type of safetycable to be used for installation on authorized applications.The referenced FAA Letter, and copy of the referenced F.A.R. as ofthe date of the referenced letter, are shown on pages 24 and 25 of thiscatalog, and on the www.dmctools.com website.MANUFACTURERSAND GOVERNMENTORGANIZATIONSAllison (Rolls Royce)American EurocopterArgo TechBAE SystemsBath Iron WorksBell HelicopterBF Goodrich AerospaceBoeing-CommercialDivisionBoeing-Military DivisionBoeing-RocketdyneBoeing-Sea LaunchBoeing-SpaceBombardier RegionalsBombardier ShortsBombardier LearjetCaterpillarCessna AircraftDallas AirmotiveDassault FalconDyncorpExelonFederal AviationAdministration (FAA)FPL EnergyGE Aircraft EnginesGE TransportationSystemsGE Power SystemsGeneral AtomicGeneral DynamicsElectric BoatGeneral DynamicsLand SystemsGeneral ServicesAdmin. (U.S. Gov.)Goodrich AerospaceGulfstream AerospaceHispano-SuizaHamilton SundstrandHarris (U.S. ArmyMissile Com.)Helicopter Support, Inc.Honeywell(Allied Signal)Honeywell (Garrett)Int'l Aero Engines (IAE)Kaman AerospaceKelly AerospaceKollsmanL3 Aerospace Corp.L3 VertexLearjet (Bombardier)LockheedAeronautical Co.Lockheed Missile& SpaceLockheed Martin Corp.Lucas AerospaceMarine MechanicalMilitary(Air National Guard)Military (U.S. Army)Military (U.S. Air Force)Military (USMC)Military (NAVAIR)Military (NAVSEA)MitsubishiMoogNASANewport NewsShipbuildingNorthrop GrummanNOAAPall AeropowerParker AerospacePetroleum HelicoptersPratt & Whitney (USA)Pratt & Whitney(Canada)Raytheon AircraftRaytheon SystemsRohr IndustriesRolls RoyceSBAC (Scty BritishAero Companies)Shorts Bros(Bombardier)Sikorsky AircraftSNECMAStandard AeroTeledyne BrownEngineeringTurbomecaU.S. Coast GuardWilliams InternationalWoodward GovernorAIRLINESAir CanadaAir ChinaAir FranceAir New ZealandAlaska AirlinesAmerican AirlinesASAAtlantic SoutheastAirlinesCom AirContinental AirlinesDelta AirlinesFedEXFrontier AirlinesIcelandairJetBlueLufthansaNorthwest AirlinesPinnacle AirlinesSouthwest AirlinesUPS InternationalUS Airways© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL

Part Numbering SystemDMC Part No. SystemCOMPONENTSC = Kit (Cable & Ferrule)A = Assemblies(Cable Only)F = Ferrules OnlyMATERIAL08 = INCONEL 62509 = INCONEL 60010 = 321 CRESC10-218 XXCONFIGURATIONBLANK = StandardXX = Special* (Consult DMC)PKG. = One Part No. For Each50-Piece PackageCABLE DIAMETER1 = .022 / .0262 = .032 / .0383 = .040 / .0464 = .062 / .072LENGTH9 = 912 = 1215 = 1518 = 1821 = 2124 = 24SAE Part No. SystemAS3510-02 18KMATERIALAS3509 = INCONEL 600AS3510 = 321 CRESAS3511 = 304 CRES (Consult DMC)AS3655 = INCONEL 625CABLE DIAMETER01 = .022 / .02602 = .032 / .03803 = .040 / .04604 = .062 / .072LENGTH9 = 912 = 1215 = 1518 = 1821 = 2124 = 24CONFIGURATIONK = Kit (Cable& Ferrule)C = CableAssembly(Cable Only)F = Ferrule(Ferrule Only)OTHER SAE PART NUMBERS – AS3618, AS3619 (Elongated Ferrules), AS3620, AS3621 (Self-Looping Cable Assemblies)*SPECIAL CONFIGURATION – Logo Stamp, Self-Looping Cable, etc. may require more than two characters. Consult DMC for details.COLOR CODEStandard packaging defines size by a standard DMC color code to avoid mixing ferrules and cable:.022 RED/PINK .032 BLUE .040 YELLOW .062 GREENPAGE 6© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

Time-SavingOptionsElongated FerrulesFor Low Profile Fastener ApplicationsMost Safe-T-Cable ® installations canbe made with standard componentsand application tools, however, thereare conditions that require modificationor alterations to the standard products.By addressing these exceptions, andextending the product lines to incorporatesimple solutions to the difficultSafe-T-Cable ® applications, DMC hasestablished itself as the industry leader.Fasteners that have limited clearancebetween the safety wire hole (less than.100 inch), and the surface of the componentto which the fastener is attached,can present a challenge to the installationof Safe-T-Cable ® . This is due to theclearance required by the applicationtool nose, adjacent to the fastener.Radius End*Square EndDia.LengthA Special Elongated Ferruleis available for those installations. Thelonger reach of the ferrule provides astand off to the tool nose. Combinethat with the radius on the end next tothe fastener (radius not required on theF10-08 .022 elongated ferrules due tothe small outside diameter). The angleallows the ferrule to be installed at anangle without loss of tension on thecable when the ferrule returns to thestraight position.*Radius featured on .032 and .040 ferrulediameters only.IncorrectCorrectSee previous pagefor elongatedferrule material,dimension andpart numberinformation.Square(both ends)ToolNoseStandardFerrule(short)Elongated Ferrule(RadiusEndTowardFastener)Tool NoseElongatedFerruleFiberglass SleevingProtectiveJacketingProtectiveJacketingFiller WasherFlat WasherObstructionSafe-T-Cable ® Jacketing for Protection. It isrecommended that a tubular jacket be placedover Safe-T-Cable ® when it is installed in an areawhere it will be in contact with obstructions orsurfaces that may damage the Safe-T-Cable ® .The tubular jacket material shall be capable ofmeeting the temperature range of the application.It shall also be resistant to oil, and chemicalenvironments.50-Foot Spool: Part No. SCTD010Figure 1: Flat Washer Safe-T-Cable ® InstallationApplications where Safe-T-Cable ® is to be installedthrough 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, andcare must be taken to restrain the washer duringremoval/service operations.Filler Washer • Material 321 CRES • Part No. FW10-1© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 9

Tool And Parts KitsDMC Offers CompleteTool And Parts KitsTo Support YourApplications.DMC1000-4RDMC is well known throughout the aerospace industry for thequality and capability of the Tool Kits that we manufacture.The packaging materials (case, inserts, and instructions)are manufactured to specifically meet the mostdemanding handling conditions.FOD (Foreign Object Damage) is always aconcern when workers are required to usetools and small components in or aroundan aircraft. The DMC Safe-T-Cable ® kitsare designed to minimize that concern.The “shadowing” principal is a provenconcept for Tool/parts control.Safe-T-Cable ® Tool and Parts Kits areavailable in a variety of configurations tosupport your specific requirements. Our mostrequested Tool & Parts Kit is the DMC1000-4R due to thepopularity of .032 diameter Safe-T-Cable ® , and the demand for atravel-ready system whereby the user has Tools, Verification Equipment,Accessories, a supply of Cable/Ferrules, and the Instructions all in one package.Other Kits are available to support your particular needs. The most popularselections are listed on the following page.If you have specific needs that cannot be covered by the Tool Kits that aredescribed here, please call a DMC customer service representative forinformation on a Kit that will more appropriately meet your requirements.DMC1000-4R.032 Safe-T-Cable ® Tool and Parts KitPART NUMBER QUANTITY DESCRIPTIONSCTR323 1 Safe-T-Cable ® Tool with 3 Nose Attached (.032)SCTN32-7 1 7 Nose Assembly (.032)C10-218 100 Safe-T-Cable ® (.032 x 18)SCT-TB1 1 Safe-T-Cable ® Torque Verification Block4-1501 1 9/64 Hex WrenchSDD440 1 Screwdriver45-6N 1 Diagonal Cutter/GripperSCT32084 1 Spanner Tool© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 11

DMC1001-7RTool And Parts Kits.022 Safe-T-Cable ® Tool and Parts KitPART NUMBER QUANTITY DESCRIPTIONSCTR203 1 Safe-T-Cable ® Tool with 3 Nose Attached (.022)SCTN20-7 1 7 Nose Assembly (.022)C10-118 100 Safe-T-Cable ® (.022 x 18)SCT-TB1 1 Safe-T-Cable ® Torque Verification Block4-1501 1 9/64 Hex WrenchSDD440 1 Screwdriver45-6N 1 Diagonal Cutter/GripperSCT32084 1 Spanner ToolDMC1000-20R.022 & .032 Safe-T-Cable ® Tool and Parts KitPART NUMBER QUANTITY DESCRIPTIONSCTR323 1 Safe-T-Cable ® Tool with 3 Nose Attached (.032)SCTR203 1 Safe-T-Cable ® Tool with 3 Nose Attached (.022)SCTN32-7 1 7 Nose Assembly (.032)SCTN20-7 1 7 Nose Assembly (.022)C10-218 100 Safe-T-Cable ® (.032 x 18)C10-118 100 Safe-T-Cable ® (.022 x 18)C10-218JA 50 Self-Looping Safe-T-Cable ® (.032 x 18)SCT-TB1 1 Safe-T-Cable ® Torque Verification Block4-1501 1 9/64 Hex WrenchF10-04 50 Elongated Ferrules (.032)SCT32084 1 Spanner ToolSDD440 1 Screwdriver45-6N 1 Diagonal Cutter GripperDMC1000-11R.040 Safe-T-Cable ® Tool and Parts KitPART NUMBER QUANTITY DESCRIPTIONSCTR407 1 Safe-T-Cable ® Tool with 7 Nose Attached (.040)C10-318 100 Safe-T-Cable ® (.040 x 18)SCT-TB1 1 Safe-T-Cable ® Torque Verification Block4-1501 1 9/64 Hex WrenchSDD440 1 Screwdriver45-6N 1 Diagonal Cutter/GripperSCT32084 1 Spanner ToolDMC1007-28R Master Kit (.022, .032, and .040 Safe-T-Cable ® )PART NUMBER QUANTITY DESCRIPTIONSCTR203 1 Safe-T-Cable ® Tool with 3 Nose Attached (.022)SCTR323 1 Safe-T-Cable ® Tool with 3 Nose Attached (.032)SCTR403 1 Safe-T-Cable ® Tool with 3 Nose Attached (.040)SCTN20-7 1 7 Nose Assembly (.022)SCTN32-7 1 7 Nose Assembly (.032)SCTN32-7 1 7 Nose Assembly (.040)SCT-TB1 1 Torque Verification BlockSCT32084 1 Spanner ToolSDD440 1 Screwdriver4-1501 1 9/64 Hex Wrench45-6N 1 Diagonal Cutter/GripperC10-118 100 Safe-T-Cable ® (.022 x 18)C10-118JA 50 Self-Looping Safe-T-Cable ® (.022)C10-218 100 Safe-T-Cable ® (.032)C10-218JA 50 Self-Looping Safe-T-Cable ® (.032)C10-318 100 Safe-T-Cable ® (.040)C10-318JA 50 Self-Looping Safe-T-Cable ® (.040)F10-04 50 Elongated Ferrules (.022)F10-07 50 Elongated Ferrules (.032)F10-08 50 Elongated Ferrules (.040)PAGE 12© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

It’s a Matter of Choice…Over 50 years of success in the design, production, and support of tooling for high-reliability applications in the aircraft andaerospace industry is the reason DMC was included in the development team for Safe-T-Cable ® . The Tooling, which was initiallydesigned to meet the challenges of Safe-T-Cable ® installation, has evolved into a product line that is flexible enough to meetthe users’ exact needs. It’s your choice as to which model and accessories to specify, but always with the understanding thatinterchangeability, adjustability, and overall reliability was the basis of each application tool series.Adjustable TensionHand Tool SeriesThe most popular hand operated application tool forSafe-T-Cable ® is the SCTR Series Adjustable TensionTool. The tool features replaceable noses of variouslengths (see chart on page 14), and a rotary tensionmechanism which can be adjusted to precise cabletension requirements. The tension will repeat atthe setting which has been selected for reliableSafe-T-Cable ® installations.Pre-Set TensionHand Tool SeriesIn some factories where control of tool adjustmentsare not possible, where the skill level is minimal, orapplications where a single-handed operation of the toolis desirable, the SCT Series Application Tool may bethe best choice. All tools in this series feature a tensionlockmechanism, which allows single-handed use of thetool (after the cable is threaded through and into the tool).Multiple actuations of the tool handle will draw the cableinto the tool until all slack is removed from the cable.When the tool senses the correct tension (pre-set atthe factory), it will shift into the crimp-cut mode, andcomplete the installation of the Safe-T-Cable ® on thenext closure of the handle. It’s as simple as that.Pneumatic ApplicationTool SeriesWhen ergonomics and production demands are criticalissues, the DMC SCTPR (No. 3) and SCTP (No. 4) SeriesPneumatic Application Tool are a must. Safe-T-Cable ® isthreaded through the fasteners, into the ferrule, and intothe tool in the same fashion as the manual tools, butthe push of a button is all that is necessary to completethe termination. The tool automatically applies tension(adjustable), crimps and cuts flush in one actuation ofthe trigger. These tools operate on standard shop airpressure, and may be suspended from a load balancerfor an even greater improvement in ergonomics.Application ToolsBattery PoweredTool SeriesThe DMC SCTE Series Battery PoweredSafe-T-Cable ® tool is an ergonomic alternative tothe other Safe-T-Cable ® Application Tools wherea portable tool, without a hose or cord is required.The self contained hydraulic crimp system is reliableand the tool accommodates the same changeablenoses and other accessories that are interchangeablewith other DMC Safe-T-Cable ® Application Tools.© Copyright 2006 Daniels Manufacturing Corp., Orlando, FL • Phone 407-855-6161 • Fax 407-855-6884 • E-Mail: dmc@dmctools.com • www.dmctools.comPAGE 13

Tools, Accessories AndVerification EquipmentAdjustableTensionHand ToolSeriesPre-SetTensionHand ToolSeriesPneumaticApplicationTool SeriesReplacementNosesMPT-250B-SCMotorized pulltester for testing.022, 032 and .040Safe-T-Cable ® .DMCPART NUMBERCABLEDIAMETER(INCHES)NOSELENGTH(INCHES)SCTR203 .022 3SCTR207 .022 7SCTR323 .032 3SCTR327 .032 7SCTR403 .040 3SCTR407 .040 7SCT203 .022 3SCT207 .022 7SCT323 .032 3SCT327 .032 7SCT403 .040 3SCT407 .040 7ADJUSTABLE PRE-SETSCTPR203 SCTP203 .022 3SCTPR207 SCTP207 .022 7SCTPR323 SCTP323 .032 3SCTPR327 SCTP327 .032 7SCTPR403 SCTP403 .040 3SCTPR407 SCTP407 .040 7Note: SCTPR Series Tools are preferred where precise tension adjustments are needed.BatterySCTE203 .022 3PoweredSCTE207 .022 7ApplicationSCTE323 .032 3Tool SeriesSCTE327 .032 7SCTE403 .040 3SCTE407 .040 7SCTN20-3 .022 3SCTN20-5 .022 5SCTN20-7 .022 7SCTN32-3 .032 3SCTN32-5 .032 5SCTN32-7 .032 7SCTN40-3 .040 3SCTN40-5 .040 5SCTN40-7 .040 7Tool PerformanceVerificationEquipmentRepeatability and traceability in themanagement of Safe-T-Cable ® toolsat all stages of their life cycle requiresperiodic testing and verification. DMCsupplies all the equipment necessaryto perform a quick reliable verificationof the application tools either on-sight,or in the metrology lab. Our objectivehas always been to provide a selfsupportingsystem that does not requirethat tools be returned to the factory forsimple testing and verification.SCT-TB1Torque verification block for .022,.032, and .040 Safe-T-Cable ® .SCT-TB1RTorque verification block configured forright-hand reading torque wrenches.SCTD0001Torque wrench for .022, .032,and .040 Safe-T-Cable ® .SCTD0132 lb. push force tester for use withSafe-T-Cable ® torque verification block.Refer to Safe-T-Cable ®application tool instructionsfor information onTool Performance Verification.PAGE 14© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

SCT-TB4 PortableVerification TesterAdvanced Technology forSafe-T-Cable ® Application Tool TestingThe SCT-TB4 Safe-T-Cable ® Electronic Verification Tester is a complete diagnosticcenter for Safe-T-Cable ® application tools. The SCT-TB4 is the first system approachtester for optimum Safe-T-Cable ® installation performance. It combines the simpleprincipals of the DMC Safe-T-Cable ®Torque Verification Block (SCT-TB1)and the reliable circuitry of theAlphatron “HPT” series digitalelectronic pull tester.This one tester will provideall the information thatpreviously required twoseparate testers, andincreased consumptionof Safe-T-Cable ® forverification of applicationtools. A single installedcable assembly can firstbe tested for minimumload – hold (flex limittest), and then be testedto destruct load (optimum toolperformance). The SCT-TB4 Testerwill also provide applied tension andresidual tension data for engineeringstudy 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 testsin all areas of the shop and field support activities.The SCT-TB4 Tester is a cost-effective quality assurance tool in most factory andmaintenance applications where Safe-T-Cable ® is used.• All DMC testers havea built-in calibrationtest• SPC compatible• Traceable to NIST• Factory calibrationand support• Rugged design, andcustom carry caseincluded• One sample testingto the requirementsof AS4536 and otherstandards• Improves tool controland calibrationoperationsSpecial Tools and AccessoriesDMC extends the capabilities of the Safe-T-Cable ® Product Line by making available the following accessories and tools:SCT32084Spanner Tool is foradjusting all Safe-T-Cable ®Application Tools(one spanner is suppliedwith each new tool).SCT32059SANose Extenderadds two inches inlength. Can be usedwith any tool/nosecombination.Tension AssemblyRequired for conversion of any SCTRTool from one cable size to another.SCTR20TW-SA .022 Dia.SCTR32TW-SA .032 Dia.SCTR40TW-SA .040 Dia.45-6NCutter/Gripper for.022, .032 and .040Safe-T-Cable ®and Lockwire© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 15

.062 (Locking Cable)Conventional LockwireSafe-T-Cable ®An urgent need for a fast reliablefastener security system for the NuclearPower Industry resulted in the furtherexpansion of Safe-T-Cable ® (LockingCable) by DMC. Working with a majorcontractor to NAVSEA and commercialpower organizations, DMC developedand certified a .062 diameter Safe-T-Cable ®for use onboard nuclear submarines, andcarriers. The .062 diameter Safe-T-Cable ®(Locking Cable) was later tested andcertified for use by the commercialpower industry, aircraft applications,and industrial use. The practice of twistinglockwire onto fasteners and threadedassemblies is a tedious task, whichrequires skill and time. Lockwire measuring.062 diameter is anything but “userfriendly”. Safe-T-Cable ® (Locking Cable)allows maintenance and other operationsto be performed in the minimum time, intight access areas, with limited inspection,and with no rework due to faultylockwiring. Also, handling the tool andmaterials for Safe-T-Cable ® (LockingCable) will not damage special glovesor protective clothing..032 and .062 diameter Safe-T-Cable ®(Locking Cable) is recognized anddefined in MIL-STD-763 (G Revision).Construction: The standard .062diameter Safe-T-Cable ® (Locking Cable)is 24 inches in length, and measures.062 min./.072 inch max. diameter. Thecable is comprised of 7 strands of 19wires each for maximum strength andflexibility. The factory-applied end fitting(square) measures approximately .155inch across the flats, and the outsidediameter of the user applied ferrulemeasures .150 inch. The minimumpull-off load of the ferrule after crimpingis 280 pounds (per Mil-Std 763). Productsamples, application information, andtechnical data may be obtained bycontacting DMC.Two application tools are availablefrom DMC, and two installation kitsare also available.The Hydraulic Application Tool(part number SCTH625) utilizes alightweight hand actuated hydraulicpump to develop the force requiredto crimp and cut the .062 diameterSafe-T-Cable ® (Locking Cable).The tool crimps and cuts theassembly flush to the ferrule bymultiple actuation of a single handle.The Battery Powered HydraulicApplication Tool (part numberSCTE625) provides the same reliableSafe-T-Cable ® termination by pressinga trigger. This tool is lightweight andself-contained. The Nicad batteryis rechargeable (charger supplied).SCTE 625SCTH 625Other NoseLength ToolsAre Available(See ChartNext Page)SCT-TB2SCT-D011PAGE 16© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

.062 (Locking Cable)DMC1000-62 NAV Soft Canvas CaseOPTIONAL CONFIGURATION FLANGEFITTINGS FOR FASTENERS WITHHOLES UP TO 8 MM DIAMETERCrimp FerruleCable End FittingConsult DMC for Part Numbersand Availability.062 CABLE KITS* (ONE CABLE AND ONE FERRULE)LENGTH 321 CRES INCONEL 625 INCONEL 60018 C10-918 Consult DMC C09-91824 C10-924 Consult DMC C09-92430 C10-930 Consult DMC C09-930.062 CABLE ASSEMBLY* (CABLE ONLY – NO FERRULE)18 A10-918 Consult DMC A09-91824 A10-924 Consult DMC A09-92430 A10-930 Consult DMC A09-930.062 FERRULES* (STANDARD AND ELONGATED)Standard F10-9 Consult DMC F09-9Elongated F10-10 Consult DMC Consult DMC.062 TOOLS AND ACCESSORIESSCTH 625 Manual Hydraulic Application Tool with 5 NoseSCTH 629 Manual Hydraulic Application Tool with 9 NoseSCTE 625 Battery Powered Application Tool with 5 NoseSCTE 629 Battery Powered Application Tool with 9 NoseSCTN 62-5 Replacement Nose – 5 LengthSCTN 62-9 Replacement Nose – 9 LengthSCT-TB2 Torque Verification Block for .062 Safe-T-Cable ®SCTD011 Torque Wrench – 100 to 750 Pound RangeSCTD015 Cable Cutter/GripperSCTD012 Retaining Ring Plier*Supplied in packages of 50 pieces.**Add “PKG” to part number when ordering a 50 piece bag of cable and/or ferrules..062 Tool & Parts KitsDMC1000-62NAVSoft Case Support KitDMC1000-625Hard Case Support KitPARTS LISTPART NUMBER QUANTITY DESCRIPTIONSCTH625 1 .062 Safe-T-Cable ® Hydraulic Tool with 5 NoseSCTHN62-9 1 .062 Nose Assembly 9 LongA10-924 250 Safe-T-Cable ® .062 x 24F10-9 250 Safe-T-Cable ® Ferrule, .062SCTD015 1 .062 Diagonal Cutter4-1136 1 3/32 Hex WrenchSCTD012 1 Retaining Ring Pliers565B 1 Drive PunchSCTD011 1 Torque Wrench 100–750 PoundsSCT-TB2 1 Torque Verification Block1 Handbook (Instructions)PARTS LISTPART NUMBER QUANTITY DESCRIPTIONSCTH625 1 .062 Safe-T-Cable ® Hydraulic Tool with 5 NoseC10-924 100 Safe-T-Cable ® 321 CRES .062 24SCT-TB2 1 Safe-T-Cable ® Torque Verification BlockSCTD015 1 Diagonal CutterSCT32084 1 Spanner ToolSCTD011 1 Torque Wrench 100–750 Inch PoundSCTD012 1 Retaining Ring Pliers4-1501 1 9/64 Hex Wrench565B 1 Drive Punch© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 17

InstallationPractice GuideSafe-T-Cable ® Application/Installation information which appearson these pages was adapted from a U.S. Military Handbook.It is intended for reference only. It is the responsibilityof the user to verify and confirm that the installation ofSafe-T-Cable ® is safe and appropriate for the application.1. Safe-T-Cable ®1.1. General Instructions for the selection ofSafe-T-Cable ® . The selection of materials shall be inaccordance with AS4536 (SAE), available from SAEInternational, 400 Commonwealth Avenue, Warrendale,PA 15096-0001, and shall be in accordance with theservice limitations outlined herein.NOTEMinimize mixing of safety wire and Safe-T-Cable ® .1.1.1. AS3510 series (UNS S32100 CRES) Safe-T-Cable ®shall be selected for general purpose use on all applicationsup to 800° F.1.1.2. AS3509 series (UNS N6600 Nickel Alloy)Safe-T-Cable ® shall be selected for applications wheretemperature range is between 800° F and 1500° F.1.1.3. Only Safe-T-Cable ® and ferrules supplied by amanufacturer that meets all the requirements of AS4536shall be allowed.1.1.4. Safe-T-Cable ® shall not be used for any shear,or break away applications.1.1.5. Safe-T-Cable ® shall be installed with a calibratedtool which is supplied by the Safe-T-Cable ® manufacturerfor the purpose of applying a predetermined cable tension,crimping the ferrule, and cutting the excess cable withoutallowing tension to be lost.1.2 The size of Safe-T-Cable ® shall be in accordancewith the following requirements:1.2.1. 0.022 inch diameter Safe-T-Cable ® is intendedfor use on parts having a nominal hole diameter of 0.045inch (1.14 mm) or smaller.1.2.2 0.032 inch diameter Safe-T-Cable ® is intendedfor use on parts having a nominal hole diameter of 0.075inch (1.91 mm) or smaller.1.2.3. 0.040 inch diameter Safe-T-Cable ® is intendedfor use on parts having a nominal hole diameter of 0.095inch (2.41 mm) or smaller.1.2.4. The specified length of the cable shall be selectedto accommodate the span between fasteners addedto the length of cable required to correctly engage theapplication tool.FIGURE 1: Flat Washer Safe-T-Cable ® Installation1.2.5. Applications where Safe-T-Cable ® is to beinstalled through a hole having a nominal diameter ofgreater than .095 inch (2.41 mm), but less than .200inch (5.08 mm) shall require a flat washer (same materialcomposition as the Safe-T-Cable ® ) which is supplied bythe Safe-T-Cable ® manufacturer for this purpose, andshall be used as shown in Figure 1.1.2.6. Safe-T-Cable ® shall be installed with an applicationtool which has been calibrated to meet the performancerequirements of AS4536 (SAE) and this manual.1.3. Safe-T-Cable ® Installation. Safe-T-Cable ® may beused as a substitute for lockwire to prevent looseningduring service. Threaded parts, such as drilled-headbolts, fillister head screws, turnbuckles, thumbscrews,hose fittings and electrical connectors, plugs, caps, andsimilar items are within the scope of the Safe-T-Cable ®application. The following rules shall apply when usingSafe-T-Cable ® .NOTERouting of Safe-T-Cable ® may vary from that of lockwirein order to achieve a proper installation.1.3.1. When Safe-T-Cable ® is being substituted forlockwire in an existing installation (maintenance, rework,etc.), equivalent diameter Safe-T-Cable ® to that of thelockwire shall be selected for use, providing that selectioncriteria for Safe-T-Cable ® as defined in the section1.1 (General Instructions) are met.1.3.2. Adjacent Units: Safe-T-Cable ® shall be installedin such a manner that any tendency for a fastener toloosen will be counteracted by an additional tensionon the cable. Safe-T-Cable ® shall be threaded throughthe fasteners in such a way as to produce installedSafe-T-Cable ® with either positive or neutral pull.1.3.3. Maximum Span: The maximum span ofSafe-T-Cable ® between two termination points shallbe 6 inches (152.4mm) unless otherwise specified.PAGE 18© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

InstallationPractice Guide1.3.4. Installing Defects: Any cable defect (nick,fray, kink, or any other mutilation of the Safe-T-Cable ® )found prior to, during, or subsequent to installation,is not acceptable.1.3.9. Excess Cable: After installing Safe-T-Cable ® ,excess cable from the crimped ferrule shall be cut bythe installation tool. The maximum allowable length ofcable extending beyond the ferrule shall be .031 inch(0.79 mm).1.3.10. Crimping Requirements (Pull-Off Load, referto Table 1): Safe-T-Cable ® shall be installed with theSafe-T-Cable ® manufacturers recommended tool,which has been tested and calibrated in accordancewith procedures specified in this manual.FIGURE 2: Self Looping Safe-T-Cable ®NOTEAvoid kinks or sharp bends while handling andthreading Safe-T-Cable ® .1.3.5. Installing Holes: Safe-T-Cable ® must be installedthrough the holes intended for this purpose in the partbeing secured, or through the holes provided in a selflooping device (Figure 2) secured to the Safe-T-Cable ®by the Safe-T-Cable ® manufacturer. In applicationswhere holes are not provided for Safe-T-Cable ® in thecomponent to which it is attached the self loopingSafe-T-Cable ® may be used in a manner like, or similarto Figure 3.FIGURE 3: Self Looping Safe-T-Cable ®Anchored to a PIN Assembly1.3.6. Safe-T-Cable ® /Ferrule Reuse: Safe-T-Cable ®and ferrule shall be new upon each application. Reuseis not allowed.1.3.7. Installation: Various examples of Safe-T-Cable ®installation are shown in this section. All possiblecombinations and applications are not shown. Unlessotherwise specified in the application engineeringdrawing, Safe-T-Cable ® shall be installed in two or threebolt patterns with two bolt patterns being the preferredmethod where an even number of fasteners are to besecured. The installer must adhere to the basic rulesoutlined in this manual.1.3.8. Hose Fittings and Electrical ConnectorRequirements: Hose Fittings and electrical couplingnuts shall have Safe-T-Cable ® installed in the samemanner as tube coupling nuts.1.3.11. Hole Alignment: Undertorquing or overtorquingto obtain proper alignment of the holes is not permitted.Apply recommended torque values to parts to be secured,and alignment of holes shall be evaluated before attemptingto proceed with Safe-T-Cable ® installation.CAUTIONThe maximum bend exit limit of Safe-T-Cable ® , whenapplied to a threaded fastener head, shall be 135°.This does not apply to hose fittings, electrical connectorcoupling mechanisms, turnbuckles, and similarapplications where the Safe-T-Cable ® is constrainedby the shape of the component being secured.1.3.12. In applications where Safe-T-Cable ® shall berequired to exceed the 135° maximum bend exit limit inorder to achieve neutral to positive pull on a threadedfastener head, a self looping device which is secured tothe Safe-T-Cable ® by the Safe-T-Cable ® manufacturermay be used to obtain a secured installation as shown(Figure 4).CAUTIONThis method should only be used in applicationswhere the Safe-T-Cable ® can not “flip” over the corneror over the head of the fastener being secured.© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 19

InstallationPractice GuideSafe-T-Cable ® Application/Installation information which appearson these pages was adapted from a U.S. Military Handbook.It is intended for reference only. It is the responsibilityof the user to verify and confirm that the installation ofSafe-T-Cable ® is safe and appropriate for the application.It is important to hold the tool as steady and perpendicularto the fastener as possible during the crimp/cutcycle in order to maintain consistent tensioning of thecable after the tool is removed.FIGURE 4: Self Looping Safe-T-Cable ® inHigh Bend Exit Application1.3.13. Cable Flex Limits: After installing Safe-T-Cable ® ,the maximum flex between termination points shall beno greater than that specified in the Cable Flex LimitTable (Table 2).NOTELight finger pressure of approximately 2 poundsshall be applied at mid-span when inspectingtotal flex limit of installed Safe-T-Cable ® .FIGURE 6: Correct Application ofSafe-T-Cable ®1.4. Elongated Ferrules: Ferrules of extra length,having a radius at one end and a straight surface atthe other end, may be used in applications which restrictthe clearance for the installation tool nose to be placedin correct alignment with the fastener (such as low profilefastener heads, recess locations, or obstructions bystructures or installed components).NOTEAlways install elongated ferrules with the radius endtoward the fastener, and the straight end in thetool crimp cavity. Double check cable tensionbetween fasteners after removal of application tool.FIGURE 5: Safe-T-Cable ® Flex LimitsFIGURE 7: Low Profile Application For.022, .032 and .040 Inch Safe-T-Cable ®PAGE 20© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

InstallationPractice Guide1.6 Safe-T-Cable ® on Turnbuckles: The standardprocedure for securing turnbuckles with Safe-T-Cable ®is shown in Figure 11 and 12.1.6.1 A self looping cable is threaded through theturnbuckle. One end shall be wrapped in one directionaround the turnbuckle. The Safe-T-Cable ® is thenthreaded through the hole in the self-looping jumper,and terminated with the appropriate application tool.FIGURE 8: Standard HardwareFIGURE 11: Routing of Safe-T-Cable ® on TurnbucklesFIGURE 12: Example of Final Safe-T-Cable ®Turnbuckle InstallationFIGURE 9: Examples of Installed Safe-T-Cable ®1.5. Safe-T-Cable ® identification stamp. In applicationswhere the user requires a logo or ID code to be a permanentpart of the Safe-T-Cable ® installation (for warrantyor traceability), it shall be applied by the Safe-T-Cable ®manufacturer to one or more surfaces of the square endfitting of the Safe-T-Cable ® . Only impression stampingis permitted, no paint, ink, or labels are acceptable(Figure 10).NOTESafe-T-Cable ® diameter selection for turnbuckleapplications: .032 inch (diameter) cable shall be usedon assemblies where cable diameter in 1/16 inch(1.6 mm) or smaller, and .040 inch diameter cableor greater shall be used on turnbuckle cable diametersgreater than 1/16 inch.1.7 Safe-T-Cable ® Jacketing for Protection: It isrecommended to use a tubular jacket over Safe-T-Cable ®when it is installed in a location where it is in contactwith (or may contact) surfaces which may damage thecable (shown in Figure 13). The tubular jacket materialshall be capable of meeting the temperature range ofthe application and shall be resistant to oil and chemicalenvironments.FIGURE 10: Safe-T-Cable ® Identification StampFIGURE 13: Safe-T-Cable ® Jacketing for Protection© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 21

InstallationPractice Guide2. Safe-T-Cable ® Application Tools2.1 Procedures. When Safe-T-Cable ® is used, thefollowing basics apply for the application tools andcalibration equipment.Safe-T-Cable ® Application/Installation information which appearson these pages was adapted from a U.S. Military Handbook.It is intended for reference only. It is the responsibilityof the user to verify and confirm that the installation ofSafe-T-Cable ® is safe and appropriate for the application.2.1.6. Insert the free end of the cable through the toolnose (Figure 15) and slide the tool along the cable to thefastener being secured (Figure 16).2.1.1. Minimize mixing of safety wire and Safe-T-Cable ® .2.1.2. Install the ferrule cartridge into the tool bodyunder the handle grip.NOTEWhen loading and using the Safe-T-Cable ® hand tool,be certain that the correct size Safe-T-Cable ® kitis being used with the tool.2.1.3. Install the Safe-T-Cable ® through the fastenersto be secured.2.1.4. The nose can index to any position. To selectthe position grasp the nose, and rotate to the desireposition (Figure 14).FIGURE 14: Safe-T-Cable ® Tools2.1.5. Insert the free end of the cable through theferrule in the cartridge, and remove the ferrule bypulling the cable away from the end of the cartridge(Ref. Figure 14).NOTEDo not release the free end of the cable untilit has been inserted through the tool nose.FIGURE 16: Position of Safe-T-Cable ® Tool3. Types of Safe-T-Cable ® Tools3.1. The pre-set tension tool (Figures 14 and 15).Insert the free end of the cable into the cable entranceand continue to push the cable into the cavity. When thefree end of the cable appears at the bottom of the tool,Grip the cable and pull the slack from the cable untilresistance is felt. Begin removing slack from the cableby repeatedly closing the tool handle allowing thehandle to open fully before closing again. When allslack is removed from the cable, snug the tool againstthe fastener by using several short strokes of the handle.Release the handle to the full open position and fullyclose the handle to crimp securely and cut flush.CAUTIONIt is important on this final stroke to hold the toolas steady and perpendicular to the cable as possiblewhile completing a full stroke. This assures consistenttensioning of the cable (Figure 16).3.2 Adjustable tension tool (Figure 17). Thread theSafe-T-Cable ® through the fastener, ferrule, and toolnose in the same way as with other models. Wrap thecable one full revolution (clockwise) around the tensionwheel, and with slight pressure applied by pulling thecable, secure the cable into the slot. Rotate the tensionknob until several clicks are heard and felt. If additionaltension is required, adjustment can be made with thetension adjuster on the opposite side of the tool.CAUTIONDo not overtighten Safe-T-Cable ® . It is a good practiceto find a tension setting which removes the slack fromthe cable (in order to meet the flex limit requirement),without over stressing the Safe-T-Cable ® components.FIGURE 15: Pre-Set Tension Safe-T-Cable ® ToolPAGE 22© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

InstallationPractice Guide3.2.1 Completely close the handle to crimp and cutthe cable. Hold the tool steady and perpendicular to thecable to maintain consistent cable tension. Release thehandle and remove the tool from the crimped ferrule.Remove the excess cable segment from the tool priorto the next application.3.2.2 If it is more convenient to use the adjustabletension tool with the screw located on the opposite side,you may remove the retaining ring located below thetension adjuster, slide the knob assembly out of the toolbody, and re-insert it on the opposite side. Re-install theretaining ring (Figure 17).NOTEWhen using a hand tool, the tool handle is to remainfully open during the cable entry process (in both toolmodels). The handle is to be actuated in the pre-settension model after the tension pawl is engaged withthe cable, and in the adjustable tension model onlyafter the desired tension is achieved.4.4. Rotate the cable tensioning wheel clockwise ifnecessary to move the cable entry slot to an accessibleposition. Align the nose such that the ferrule is pressedsquarely against the fastener. Make certain that theferrule is fully seated into the nose. Insert the free endof the cable into the cable entry slot of the cable tensioningwheel. When the end of the cable exits thewheel, grip the cable and pull the slack from the cable.Do not leave more than 1-1/2 of total slack in the cable.4.5. Press the trigger and hold. The tool will applytension to the cable, crimp and cut. When the triggeris released, the crimp mechanism will retract (after thecycle is complete), and the tool nose can be movedfrom the ferrule. The excess cable shall be discarded.4.7. The tension is adjustable by inserting the manufacturersupplied adjustment key into the adjustmentport located on the tool handle. Clockwise rotationincreases tension, and counter clockwise rotationdecreases tension.FIGURE 17: Adjustable Tension Safe-T-Cable ® Tool4. The Pneumatic Safe-T-Cable ® application tool(Figure 18). Connect the Pneumatic Safe-T-Cable ®Tool to a clean, dry air supply of 80 to 100 psi.4.1. Install the Safe-T-Cable ® through the fastenerswhich are to be secured.4.2. The nose can be indexed any position. To selectthe position grasp the nose and rotate to the desiredposition.4.3. Insert the free end of the cable through the ferrulein the cartridge and remove the ferrule by pulling thecable away from the end of the cartridge. Insert the freeend of the cable through the nose of the tool and slidethe tool along the cable to the desired position.FIGURE 18: Pneumatic Safe-T-Cable ®Application Tool5. Safe-T-Cable ® Application Tool Maintenance andCalibration. The Safe-T-Cable ® tools should bestored in a clean, dry place when not in use.Clean any debris (especially in the crimp cavityin the tool nose) from the tool with a smallbrush and solvent if necessary. Lubricate thetool nose (in the crimp cavity) with a drop of oilon a regular basis.5.1. Calibration instructions are supplied with each tool.© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 23

FAA Classification LetterMr. David KellyDirector of Corporate PlanningDaniels Manufacturing Corporation526 Thorpe RoadOrlando, FL 32824Federal Aviation AdministrationDear Mr. Kelly:This letter is a follow up to our conversation of October 20 concerning an acceptable means of approving safetycable for installation on aircraft.The Federal Aviation Administration (FAA) has determined that safety cable manufactured in accordance withSociety of Automotive Engineers (SAE) Aerospace Standard 3509 (AS3509), AS3510, and AS3511 would be astandard parts under Federal Aviation Regulation (FAR) § 21.303 (b) (4). As such, safety cable manufactured inaccordance with AS3509, AS3510, and AS3511 do not require a Parts Manufacturer Approval.Installation of AS3509, AS3510, and AS3511 safety cable on aircraft is governed by FAR § 43.13, PerformanceRules (general). FAR § 43.13 (a) states in part: “Each person performing maintenance, alteration, or preventativemaintenance on an aircraft, engine, propeller, or appliance shall use the methods, techniques, and practicesprescribed in the current manufacturer’s maintenance manual or Instructions for Continued Airworthinessprepared by its manufacturer, or other methods, techniques, and practices acceptable to the Administrator…”In the absence of explicit instructions by the aircraft manufacturer (type certificate holder) for the use of safetycable, the installer could meet the provisions of FAR § 43.13 (b). FAR § 43.13 (b) states: “Each person maintainingor altering, or performing preventive maintenance, shall do that work in such a manner and use materials of sucha quality, that the condition of the aircraft, airframe, aircraft engine, propeller, or appliance worked on will be atleast equal to its original or properly altered condition (with regard to aerodynamic function, structural strength,resistance to vibration and function, structural strength, resistance to vibration and deterioration, and otherqualities affecting airworthiness).” The installer would need to provide data to the FAA that substantiates thatthe safety cable installed was equal to or better than the safety wire called out by the type certificate holder.This data could consist of certified comparative performance testing conducted by a specification issuing body(in this case SAE) or could be a comparison of the safety wire specifications vs. safety cable specificationsshowing where all aspects of the performance of safety cable is equal to or better than that of safety wire. Ineither case, the data must also specify, by part numbers, which safety cable could replace which safety wire.If I can be of further assistance, please contact me at (202) 267-9596.Sincerely,Bruce A. KaplanPolicy and Procedures BranchAircraft Engineering DivisionAircraft Certification ServicePAGE 24© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM

F.A.R. Reference And Limited WarrantySubpart K — Approval of Materials,Parts, Processes, and AppliancesSOURCE: Docket No. 5085, 29 FR 14574. Oct. 24, 1964, unlessotherwise noted.§ 21.301 Applicability.This subpart prescribes procedural requirements for the approval ofcertain materials, parts, processes, and appliances.§ 21.303 Replacement and modification parts.(a) Except as provided in paragraph (b) of this section, no personmay produce a modification or replacement part for sale for installationon a type certificated product unless it is produced pursuant to a PartsManufacturer Approval issued under this subpart.(b) This section does not apply to the following:(1) Parts produced under a type or production certificate.(2) Parts produced by an owner or operator for maintaining oraltering his own product.(3) Parts produced under an FAA Technical Standard Order.(4) Standard parts (such as bolts and nuts) conforming to establishedindustry or U.S. specifications.(c) An application for a Parts Manufacturer Approval is made to theManager of the Aircraft Certification Office for the geographic area inwhich the manufacturing facility is located and must include thefollowing:(1) The identity of the product on which the part is to be installed.(2) The name and address of the manufacturing facilities at whichthese parts are to be manufactured.(3) The design of the part, which consists of—(i) Drawings and specifications necessary to show the configurationor the part; and(ii) Information on dimensions, materials, and processes necessaryto define the structural strength of the part.(4) Test reports and computations necessary to show that thedesign of the part meets the airworthiness requirements of the FederalAviation(3) Any alteration, for fraudulent purpose, of any record or reportunder this part(b) The commission by any person of an act prohibited underparagraph (a) of this section is a basis for suspending or revokingthe applicable airman, operator, or production certificate, TechnicalStandard Order Authorization. FAA-Parts Manufacturer Approval, orProduct and Process Specification issued by the Administrator andheld by the person.[Amdt. 43-19 FR 22639, May 25, 1978, as amended by Amdt. 43-23,47 FR 41085. Sept. 16, 1982]§ 43.13 Performance rules (general).(a) Each person performing maintenance, alteration, or preventativemaintenance on an aircraft, engine, propeller, or appliance shall usethe methods, techniques, and practices prescribed in the currentmanufacturer’s maintenance manual or Instructions for ContinuedAirworthiness prepared by the manufacturer, or other methods, techniques,and practices acceptable to the Administrator, except as notedin § 43.16. He shall use the tools, equipment, and test apparatus isrecommended by the manufacturer involved, he must use that equipmentor apparatus or its equivalent acceptable to the Administrator.(b) Each person maintaining or altering, or performing preventivemaintenance, shall do that work in such a manner and use materialsof such a quality, that the condition of the aircraft, airframe, aircraftengine, propeller, or appliance worked on will be at least equal toits original or properly altered condition (with regard to aerodynamicfunction, structural strength, resistance to vibration and deterioration,and other qualities affecting airworthiness).(c) Special provisions for holders of air carrier operating certificatesand operating certificates issued under the provisions of Part 121,127, or 135 and Part 129 operators holding operations specifications.Unless otherwise notified.NOTICE: This printing of the Federal AcquisitionRegulation is current with the date of the FAA letter(previous page).Limitation of Liability/Limited Warranty*DANIELS MANUFACTURING CORPORATION IS NOT LIABLE FOR CONSEQUENTIAL OR SPECIALDAMAGES OF ANY NATURE OR KIND RESULTING FROM THE USE OF ANY OF ITS PRODUCTS.OWNERS AND USERS OF DMC PRODUCTS ASSUME FULL RESPONSIBILITY FOR INSTRUCTINGTHEIR EMPLOYEES IN THE PROPER AND SAFE USE OF SUCH PRODUCTS.Daniels Manufacturing Corporation warrants each new unit sold by it to be free from defects in materialand workmanship under normal use and service. Its obligation under this warranty is limited to the freecorrection or, at its option, the refund of the purchase price of any such unit which proves defective withinninety (90) days after delivery to the first user, provided that the unit is returned to it with all transportationcharges prepaid, and which shall appear to its satisfaction, upon inspection by it, to have been defectivein material or workmanship. This warranty shall not cover any damage to such products, which in theopinion of Daniels Manufacturing Corporation, was caused by normal wear, misuse, improper operation oraccident. This warranty is in lieu of all other warranties express or implied. No warranty, express or implied,is made or authorized to be made or assumed with respect to products of Daniels ManufacturingCorporation, other than that herein set forth.*as defined by PL93-637DANIELS ®MANUFACTURINGCORPORATION526 THORPE ROAD • ORLANDO, FLORIDA 32824-8133 USA(407) 855-6161 • FAX (407) 855-6884E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COM© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL • PHONE 407-855-6161 • FAX 407-855-6884 • E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMPAGE 25

DANIELS®MANUFACTURINGCORPORATION526 Thorpe Road • Orlando, Florida 32824 USAPhone: 407-855-6161 • Fax: 407-855-6884E-Mail: dmc@dmctools.comWWW.DMCTOOLS.COM© COPYRIGHT 2006 DANIELS MANUFACTURING CORP., ORLANDO, FL