Engine Maintenance Manual
Jabiru Aircraft
Pty Ltd
JEM0002-5
Jabiru 2200 & 3300 Aircraft Engines
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ISSUE
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Dated : 2nd June 2015
Issued By: AS
Page: 75 of 103
L:\files\Manuals_For_Products\Engine_Manuals\Engine Maintenance Manual 22 & 33\JEM0002-5.docx
When using double-twist method of safety wiring, 0.032 inch minimum diameter wire should be
used on parts that have a hole diameter larger than 0.045 inch (1.1mm). When using the
single-wire method, the largest size wire that the hole will accommodate should be used.
CAUTION
Care must be taken not to confuse steel with Aluminium wire.
There are many combinations of safety wiring with certain basic rules common to all
applications. These rules are as follows.
a. When bolts, screws, or other parts are closely grouped, it is more convenient to safety wire
them in series. The number of bolts, nuts, screws, etc., that may be wired together depends
on the application.
b. Drilled boltheads and screws need not be safety wired if installed with self-locking nuts.
c. To prevent failure due to rubbing or vibration, safety wire must be tight after installation.
d. Safety wire must be installed in a manner that will prevent the tendency of the part to
loosen.
e. Safety wire must never be over-stressed. Safety wire will break under vibrations if twisted
too tightly. Safety wire must be pulled taut when being twisted, and maintain a light tension
when secured (Figure 46).
f. Safety-wire ends must be bent under and inward toward the part to avoid sharp or
projecting ends, which might present a safety hazard.
g. Safety wire inside a duct or tube must not cross over or obstruct a flow passage when an
alternate routing can be used.
h. Check the units to be safety wired to make sure that they have been correctly torqued, and
that the wiring holes are properly aligned to each other. When there are two or more units,
it is desirable that the holes in the units be aligned to each other. Never over-torque or
loosen to obtain proper alignment of the holes. It should be possible to align the wiring
holes when the bolts are torqued within the specified limits. However, if it is impossible to
obtain a proper alignment of the holes without under-torquing or over-torquing, try another
bolt which will permit proper alignment within the specified torque limits.
i. To prevent mutilation of the twisted section of wire, when using pliers, grasp the wires at
the ends. Safety wire must not be nicked, kinked, or mutilated. Never twist the wire ends off
with pliers; and, when cutting off ends, leave at least four to six complete turns (1/2 to 5/8
inch long) after the loop. When removing safety wire, never twist the wire off with pliers. Cut
the safety wire close to the hole, exercising caution.
j. Install safety wire where practicable with the wire positioned around the head of the bolt,
screw, or nut, and twisted in such a manner that the loop of the wire fits closely to the
contour of the unit being safety wired.
When using a wire twister (safety wire pliers), grip the wire in the jaws of the wire twister and
slide the outer sleeve down with your thumb to lock the handles or lock the spring-loaded pin.
Pull the knob, and the spiral rod spins and twists the wire.
Squeeze handles together to release wire.
CAUTION
When using wire twisters, and the wire extends 3 inches beyond the jaws of the twisters,
loosely wrap the wire around the pliers to prevent whipping and possible personal injury.
Excessive twisting of the wire will weaken the wire.