Wire Locking

Not Amended – For Training Use Only

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INTRODUCTION

The use of wire locking various components of an aircraft to ensure a positive means
of locking has long been a feature of aircraft engineering. This objective deals
broadly with the principle and practice of wire locking threaded items used in the
construction and maintenance of aircraft, aero engines and associated equipment.
The locking procedures for these items must be considered of paramount importance
and carried out in accordance with the basic principles given in Marshall
Manufacturing Process No.31A, and any special instructions given in a specific
drawing.

METHODS OF WIRE LOCKING

The following techniques (figure 1), are equally effective and may be used as
specified in the Marshall Manufacturing Process No.31A:
• Double twist method.
• Single strand with 2.5 twists at originating end and closing end.

Figure 1 - Methods of Wire Locking

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Double Twist Method

(1) In the double twist method figure 2, one piece of wire is threaded through
the lock hole to approximately mid-length of the wire, then bent through 180º,
the two strands so formed being twisted together. One twist is defined as
being produced by twisting the wire through an arc of 180º, and is equivalent
to half of one complete turn. The wire must be pulled taut while being twisted.

(2) Twist the wire taut until the twisted part is just short of the next lock hole.
Ideally the twisted portions should be within approximately 3 mm C/g in.) of
each lock wire hole.

(3) After inserting the wire in the second hole, pull up tight and continue
twisting the wire to form a 'pigtail' of three to five twists, cut off surplus wire.
After the surplus wire has been removed, position the pigtail end in such a
way that as to prevent it from becoming a snag.

Figure 2 - Double Twist Method

Notes:
(1) The maximum number of pm1s in a series to be locked together by the
double twist method is three.
(2) The maximum distance pe1711ittedbetween two components locked
together using the double twist method figure 3, is 75 1I1m(3.0 in.).
(3) All illustrations in this Training 01~iective depict components having right
hand threads unless otherwise stated.

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 Figure 3 - Maximum Distance Between Components (Double Twist Method)

Single Wire Method. The single wire method figure 4, may be used when
appropriate such as a closely spaced, closed geometrical patterns (triangular,
square, rectangular or circular) or on parts in electrical systems, and in such places
that would make the single wire method more advisable. In such cases the single
wire is limited to one pattern or similar group of parts. The maximum number of parts
to be locked together in a series by the single strand method is determined by the
number of parts that can be locked together by a 600 mm (24 in.) length of wire.

Figure 4 - Single Wire Method

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 PRINCIPLES OF WIRE LOCKING

Although a high standard of wire locking can only be achieved by individuals through
practice, the following basic principles must be adopted from the outset:

o Locking wire must never be re-used and must be renewed whenever it is

disturbed.

o Caution should be exercised during the twisting operation to keep the wire
tight without over-stressing or allowing it to become kinked, nicked or
otherwise mutilated.

o Abrasions normally caused by pliers are acceptable.

o Locking wire should be installed in such a manner as to prevent the wire from
becoming subjected to, or cause, chafing and/or fatigue through vibration or
additional tension imposed on the wire to prevent loosening.

o Wire locking of flexibly mounted components is to be so arranged that neither

the characteristics of the mounting nor the efficiency of the locking is impaired.

o Lengths of wire between components is to be kept to a minimum and should

not exceed 75 mm (3.0 in.).

o The lay of the wire must be such as to resist any tendency for the locked parts
to work loose, always taking care to differentiate between parts having left-
hand and right- hand threads.

o Where locking wire is inserted through a locking hole and taken around the
head of the part figure 5, the direction of wrap and twist of strands must be
such that the loop around the part comes under the strand protruding from the
hole so that the loop is held down and will not be able to ride up and slacken
off.

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 Figure 5 - Direction of Wire Wrap and Twist
o All wire locking debris must be carefully disposed of, during and after any wire
locking task. Remember, a small portion of wire is a loose article and could
cause a control system to become jammed or an electrical component to short
circuit.

Figure 6 - Angle of Approach - Pipe Coupling

o The angle of approach of the wire figure 6, is not to be less than 45° to the
rotational axis of the component to be locked, whilst the line of approach
should be as near as possible tangential to the arc of maximum radius.

o Where a locking tab is used figure 7, it must be aligned with the wire in such a
way as not to impart any radial movement to the tab. Whenever possible, the
closed end of the wire must be in the tab, with the open end at the component
to be locked.

Figure 7- Locking Tabs

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 o Where a pipe adapter is used figure 8, the pipe union is to be locked to the
component, not to the adapter. Adjacent union nuts may be locked together.

Figure 8 - Pipe to Component Coupling

o A wide range of caps and covers are in use on aircraft equipment and in each
specific case the locking instructions in the relevant Manufactures Procedures
must be followed. Figure 9 shows an example of locking a cap.

(1) Figure 9 - The cap is locked to the component starting at the locking
lug provided and ending at the cap to conform to the principles stated
above.
(2) Adjacent caps may be locked together as shown in figure 4.

Figure 9 - Cap Locking Method

o Where clips or fasteners are used in retaining items of aircraft equipment, that
are not required for quick release, eg, fire extinguishers, they are to be wire
locked by an approved method.

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 o When pipe adapters or union parts are to be locked using the single strand
method the following may be adopted. One end is passed through the lock
wire hole, sufficient to form five twists by the double twist method. The closing
end is finished by pulling the wire through the closing end hole until taut, then
bent back underneath the locking strand. A further two and a half turns around
the strand is then applied and the excess cut off.

o When a considerable amount of double twist wire locking or extensive lengths

of double twist wire locking is required, the locking wire pliers figure 10, are
particularly useful. They are classified by type and length.

Figure 10 • Locking Wire Pliers

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