Lock Wiring Midterms

LOCK WIRING
What is lock wring?

 Lock wiring is the securing of two or more
parts with a wire installed so that any
tendency of any part to disengage will
counteracted by additional tightening of the
wire.
 The application of wire prevent relative
movement of structural or other critical

component subjected to vibration, tension,
torque, etc.
What is lock wiring?
 The process uses to correct and approved
type of wire pieces to secure bolts or nuts to
anchor points in a specified direction to
achieve positive locking.
 It also found in securing plumbing and
electrical connectors to prevent the

connections from working loose.
What is lock wiring?
 It is a positive and proven method of securing
critical fasteners with wire that must not be
allowed to back-out during operation.
 Any tendency of the fasteners to loosen is
counteracted by tightening of the safety wire.

Why lock wiring?
 SAFETYING
 FUSE WIRELOCKING
 ANTI-TAMPERING
Why wire locking?
 SAFETYING
 During operations, the aircraft is subjected to
loads and vibrations.

 Over long periods of time, the fasteners
securing the various installation tend to get

loose.
 Lock wiring will prevent relative movement of
structural or other critical components

subjected to vibration, torsion, torque etc.
Why wire locking?
 Anti-tampering
 Certain device and equipment in the aircraft
required a lock wire to prevent tampering and

inadvertent operation.
 The wire installed is such that it will be easily
broken to permit operation or actuation of

the emergency equipment during certain
conditions.
Why wire locking?
 Anti-tampering
 Some equipment and fasteners are sealed
with wire with a “lead seal” to prevent

tampering or use of the device.
Why wire locking?
 FUSE WIRE LOCKING
 Lock wiring should not be confused with “
fuse wire-locking” for certain installation.

Why wire locking?
 FUSE WIRE LOCKING
 An example of fuse wire-locking is used
secure Constant Speed Drive (CSD) or

Integrated Drive Generator (IDG) Disconnect
switch in the cockpit.
Why wire locking?
 FUSE WIRE LOCKING?
 The fuse wire breaks instantaneously when
the switch is flipped open to disconnect the

drive in an emergency condition.
◦ If lock wire is used instead, disconnecting the drive
in an emergency will be delayed.
When to lock wire?
 Wire locking should be carried out when the
procedure specifies the need.
 This is evident on parts that have hole
provision in them, to facilitate the installation

of lock wires.
 Safety lock wire should not be reused, as
safety wires weaken after first twisting.

When to lock wire?
 DOUBLE TWIST
 Double twisted
safety wire method

is required for all
safety wire-locking
except when single
wire is specified
When to lock wire?
 DOUBLE TWIST  image
 A double twist is
defined as that
produced by
twisting the wirers
through an arc of
180 degrees and is
equal to one half a
complete turn.
When to lock wire?
 SINGLE WIRE
 Single wire method is used for small screws
in closely spaced, closed pattern, such as

square or triangle.
 Single wire method is also used for parts in
electrical systems where accessibility or

frequent removal makes the double twist
method impractical.
 image
How to lock wire?
 MATERIALS
 The selection of the wire shall be in
accordance with the service limitations

outlines in the Aircraft Maintenance Manual
 (AMM).
How to lock wire?
 MATERIALS FOR LOCK WIRING
 The material of the lock wiring can be:
◦ CRES (C)
◦ MONEL (NC)
◦ INCONEL (N)
How to lock wire?
 MATERIAL PART NO:
◦ MS 20995 C 20
 MS :military standard
 20995 :specification number
 C :material specification letter
 20 :wire gauge size
How to lock wire?
 MATERIAL SPECIFICATION LETTER
◦ C :corrosion resistant steel
◦ NC :nickel copper alloy (MONEL)
◦ N :nickel chromium iron alloy (INCONEL)
◦ CY :copper annealed, cadmium plated golden
yellow.
◦ AB :aluminium alloy wire 5056 anodised, dyed blue.
How to lock wire
 INTERCHANGEABILITY
 CRES, MONEL and INCONEL lock wire are
interchangeable when the same length and

diameter are used, except for airplane
areas/systems where temperatures exceed
700 ˚F (371 ˚C) or the magnet properties of
CRES do not meet the necessary
requirements.
How to lock Wire
 INTERCHANGEABILITY
 INCONEL must be used for all areas which
exceed 700 ˚F (371 ˚C).

 If a specific lock wire material is listed in a
maintenance procedure, it is recommended

to use the listed material if available.
Otherwise, follow the interchange ability
information above.
How to lock wire
 WIRE SEALING
 Wire sealing is a practice for security of
selected switches, levers, switch guards, etc.

 Such will:
◦ Allow for physical breakout in an emergency

How to lock wire
 WIRE SEALING
 Identify to the flight crew and engineers that,
when present intact, the relevant switches,

levers, switch guards, etc. are in their correct
configuration position, and
 Show that no person has used the emergency
equipment.
◦ Emergency equipment includes portable fire
extinguishers, first aid kits, emergency valves, and
oxygen regulators.
How to lock wire
 MATERIAL FOR WIRE SEALING
 The material for wire sealing is:
◦ Copper (CY)
Copper wire, 0.020 in (0.508 mm) in diameter is the
only option for wire sealing.
Copper wire is not interchangeable with CRES,
MONEL, and INCONEL lock wire.
How to lock wire
 CLAD ALUMINUM
 Clad 5056 aluminium alloy wire should be
used for lock wire which touches magnesium

to prevent galvanic corrosion.
Lock wiring guidelines
 Do not use lock wire more than once.
 Do not install lock wire in such a way as to
cause the wire to be subjected to chafing,

fatigue through vibration, or additional
tension other than the tension imposed on
the wire to prevent disengagement.
Lock wiring guidelines
 Exercise caution during the twisting operation
to keep wire tight without overstressing it or
permitting it to become nicked, kinked, or
otherwise mutilated.
 Make three to six double twists at the end of
the wire (i.e. pigtail) Bend the twists back or

under to give the ends protection so they will
not catch something.
Lock wiring procedures
 Check lock wire holes of the parts to be lock
wires for proper alignment.
◦ NOTED: proper alignment means that the lock wire
holes are alignment so that the installed lock wire
will prevent disengagement of the part.
 Do not exceed torque value limits of any part in an
attempt to align the holes.
Lock wiring procedures
 CAUTION: LOCKWIRE IS NOT REUSABLE.
ALWAYS USE NEW LOCKWIRE FOR EACH
ASSEMBLY OPERATION.
 CAUTION: DO NOT EXCEED 15 TWISTS PER

INCH. DAMAGE TO LOCKWIRE MAY RESULT.
LOCK WIRING PROCEDURES
 video
LOCK WIRING PROCEDURES
DIAGONAL CUTTING
PLIER
LOCK WIRE
TWISTER PLIER
Final inspection
 Review the completed wire-locking regarding
the wire specification and gauge.
 No nicks, kinks or damage on the wire.
Final inspection
 Check that the direction of locking is correct.
◦ If the fasteners were to turn, the wire must be
pulling direction.
Final inspection
 The twisting and tightening of the wire is of
the correct tension, ensure that it is tight but
not overstressed.
◦ Vibration can also cause damage to the wire.
◦ If it is necessary for the wire to be loose between
the tension points, it will be specified the
instruction
◦ The number of twist should be as per the wire
gauge.
 CRES 0.0032gauge- for training and general purposes
Final inspection
 The excess wire shall be cut-off at the end of
the pigtail.
◦ The pigtail shall be bent-in towards the part to
prevent it from becoming a snag.
All unused and cut wires are properly disposed-off

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LOCK WIRING

What is lock wring?

movement of structural or other critical

electrical connectors to prevent the

counteracted by tightening of the safety wire.

loads and vibrations.

securing the various installation tend to get

structural or other critical components

required a lock wire to prevent tampering and

broken to permit operation or actuation of

with wire with a “lead seal” to prevent

fuse wire-locking” for certain installation.

secure Constant Speed Drive (CSD) or

the switch is flipped open to disconnect the

provision in them, to facilitate the installation

safety wires weaken after first twisting.

safety wire method

in closely spaced, closed pattern, such as

electrical systems where accessibility or

accordance with the service limitations

interchangeable when the same length and

exceed 700 ˚F (371 ˚C).

maintenance procedure, it is recommended

selected switches, levers, switch guards, etc.

◦ Allow for physical breakout in an emergency

when present intact, the relevant switches,

used for lock wire which touches magnesium

cause the wire to be subjected to chafing,

the wire (i.e. pigtail) Bend the twists back or

 CAUTION: DO NOT EXCEED 15 TWISTS PER

All unused and cut wires are properly disposed-off

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