Aircraft Cable Construction and Maintenance

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What type of cable is used where cables must change direction over relatively small-diameter pulleys?

Extra-flexible cable (correct)

Woven splice cable

Pre-formed cable

Flexible cable

What is the primary purpose of pre-forming the wires in an aircraft cable?

To prevent the wires from springing out when the cable is cut (correct)

To reduce the cable's weight

To make the cable more flexible

To increase the cable's breaking strength

What is the recommended method for cutting aircraft control cables?

Using a wire cutter with a round nose

Using a bolt cutter

Using a parrot-beak wire cutter or a sharp, cold chisel on a hardwood block (correct)

Using a hacksaw

What was the primary limitation of the original hand-woven splice termination method?

It was time-consuming and required great skill Signup and view all the answers

What is the certified strength of the original hand-woven splice termination method?

75% of the cable strength Signup and view all the answers

What type of cable is used for straight runs or where pulleys are large?

Flexible cable Signup and view all the answers

What is the purpose of applying a band of paint to the cable and sleeve in a Nicopress termination?

To provide a visual inspection aid for sleeve slippage Signup and view all the answers

What percentage of the cable's strength is achieved with a proper Nicopress termination?

100% Signup and view all the answers

What is the correct sequence of compression for a Nicopress sleeve?

Centre, then thimble, then end Signup and view all the answers

What tool is used to compress a Nicopress sleeve?

Special crimping tool Signup and view all the answers

What is the purpose of a Nicopress gauge?

To check the compression of the sleeve Signup and view all the answers

What is the result of a properly made running splice with two Nicopress sleeves?

A splice with 100% of the cable strength Signup and view all the answers

What is the primary concern with internal wear of control cables?

It can be greater than surface wear under certain conditions. Signup and view all the answers

What should be done if a control cable is found to be worn, distorted, or corroded?

Replace the cable with a spare or duplicate of the same size and quality. Signup and view all the answers

What is the advantage of using standard swaged cable terminals?

They develop the full cable strength and can be substituted for original terminals. Signup and view all the answers

What was the contributing factor to the failure of the rudder cables in a recent fatal aircraft accident?

The incorrect swaging of the copper sleeve at the thimble ends. Signup and view all the answers

What was the result of incorrectly swaging the copper sleeves onto the cables?

The cables would pull out of the sleeve at low load. Signup and view all the answers

What is the purpose of using cable bushings, eye splices, and turnbuckles as a substitute for original terminals?

To provide a temporary fix until spare parts are available. Signup and view all the answers

What is the primary function of a spring in a Bowden cable?

To return the cable to its original position Signup and view all the answers

What is the key difference between Bowden cables and Teleflex cables?

The ability to pull and push Signup and view all the answers

What is the recommended course of action for Bowden cables that are damaged or faulty?

Replace them with a new one Signup and view all the answers

What is a common example of a Bowden cable in everyday life?

A bicycle brake cable Signup and view all the answers

What is the purpose of inspections and checks on Bowden cables?

To check for freedom of movement and smooth operation Signup and view all the answers

What is the advantage of Teleflex cables over Bowden cables?

They are stronger in construction Signup and view all the answers

What is the primary reason for ensuring pulley alignment with the cable?

To prevent the cable from riding on the flanges Signup and view all the answers

What should be examined during pulley inspection to ensure proper operation?

Pulley bearings for lubrication and smooth rotation Signup and view all the answers

Why is it necessary to rotate the pulleys during inspection?

To provide a new bearing surface for the cable Signup and view all the answers

What is the purpose of the guard pin in a pulley system?

To prevent the cable from jumping out of the groove when slack Signup and view all the answers

Why is a washer necessary under the split pin?

To prevent damage to the pulley frame or structure Signup and view all the answers

What should be inspected during maintenance to prevent cable chafing?

Pulley brackets and guards for damage and alignment Signup and view all the answers