Aircraft Control Cable Inspection and Swaged Terminal Maintenance Quiz

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Questions and Answers

What is the primary indicator that the cable has slipped during Nicopress sleeve testing?

The tension on the cable decreases

A gap appears between the cable and sleeve (correct)

The sleeve is not properly compressed

The cable breaks apart

What is the purpose of bending the cable during swaged terminal installation?

To ensure the terminal is properly compressed

To increase the cable's tension

To prevent the cable from sliding out of the terminal (correct)

To gauge the cable's length

What is required for aircraft cable termination using the swaging process?

No training or certification

Only proper equipment

Special training and certification (correct)

Basic training and certification

What is the purpose of the before-and-after gauge in the swaging process?

To determine the terminal's compression Signup and view all the answers

What should you do if a gap appears between the cable and sleeve during Nicopress sleeve testing?

Reject the splice and start over Signup and view all the answers

What is the primary function of a swaged terminal in aircraft control cables?

To provide a mechanical connection point Signup and view all the answers

What type of cable is commonly used in seaplanes and agricultural aircraft due to the corrosive environment?

Stainless steel cable Signup and view all the answers

What is the purpose of wiping cables with LPS-3, Boeshield T-9, or Dinitrol ML?

To protect and lubricate the cables Signup and view all the answers

What is the characteristic of external wear patterns on cables?

They occur on one side or the entire circumference of the cable Signup and view all the answers

What is the appearance of individual wires in a strand when it is time to replace the cable?

They appear to blend together Signup and view all the answers

What is the consequence of internal wear on a cable?

The cable's internal condition is not easily detected Signup and view all the answers

What causes the internal wear on a cable?

Relative motion between inner wire surfaces Signup and view all the answers

What is the purpose of applying a ring of brightly coloured paint around the end of the terminal and cable?

To indicate any subsequent slippage Signup and view all the answers

What is the purpose of the Proof-Load Test?

To load the cable to 60% of its breaking strength Signup and view all the answers

Where are cables most likely to wear or break?

Where they pass over pulleys or through fairleads Signup and view all the answers

What is the recommended method for inspecting cables for broken wires or strands?

Wiping the cable with a clean, dry rag Signup and view all the answers

What should be done to inspect cables for corrosion?

Disconnect the cable and bend it into a loop Signup and view all the answers

How long should the load be held during the Proof-Load Test?

At least 3 minutes Signup and view all the answers

What is the primary purpose of a guard pin?

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

What should be examined during pulley inspection?

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

Why is it important to maintain pulley alignment?

To ensure the cable rides squarely in the pulley groove Signup and view all the answers

What is the purpose of rotating the pulleys during inspection?

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

Why should a washer be fitted under the split pin?

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

What should be checked on pulley brackets and guards?

Damage, alignment, and security Signup and view all the answers

What is the primary function of rig pins in aircraft control systems?

To lock the control surfaces and major quadrants/bell cranks in place Signup and view all the answers

What is the purpose of a cable tensiometer?

To check the tension of control cables Signup and view all the answers

What is the function of a cable tension compensator assembly?

To regulate control cable tension and compensate for expansion and contraction of the airframe Signup and view all the answers

How is the correct cable tension determined using a cable tensiometer?

By referring to a chart that converts the reading for the riser being used Signup and view all the answers

What is the purpose of the risers on a cable tensiometer?

To correspond to the different diameters of control cables Signup and view all the answers

Why is a cable tensiometer used in a clear area of each section of cable?

To ensure accurate readings Signup and view all the answers

Study Notes

Cable Testing and Maintenance

When testing a cable, apply the recommended tension; if a gap appears between the cable and sleeve, the cable has slipped and the splice must be rejected.
Nicopress sleeve testing is used to determine if the cable has slipped.

Swaged Terminals

Most aircraft control cables are terminated with swaged terminals.
To install a swaged terminal, cut the cable to the proper length, bend it slightly, and slip it into the terminal so it bottoms at the end of the hole or is almost flush with the end of the hole if the terminal is drilled all the way through.
Swaging requires special training and certification for aircraft cable termination.
A before-and-after gauge is used to determine that the terminal is properly compressed; the sleeve should fit into the 'before' portion of the gauge before it is swaged, and then fit snugly into the 'after' slot of the gauge after it has been swaged.

Corrosion Prevention

Corrosion-resistant stainless steel cable is used in seaplanes and agricultural aircraft.
It is recommended to wipe cables with LPS-3, Boeshield T-9, or Dinitrol ML to protect and lubricate them.

Cable Wear and Inspection

External wear patterns will extend along the cable equal to the distance the cable moves at that location and may occur on one side or on the entire circumference.
Replace flexible and non-flexible cables when the individual wires in each strand appear to blend together (outer wires worn 40%–50%).
Internal wear can occur, particularly in sections of the cable that pass over pulleys and quadrants, and can be detected by separating the strands of the cable.
A brightly colored paint ring is applied around the end of the terminal and cable to indicate any subsequent slippage.

Swage Terminal Types

Fork end, clevis end, turnbuckle end, and balls with either a single or double shank are common swage terminal types.

Proof-Load Test

After the cable is completed with the terminals properly installed, checked, and marked with paint, it should be tested by loading it to 60% of its breaking strength.
The load should be applied gradually and held for at least 3 minutes.

Cable Inspection Practices

Cables should be carefully examined at each scheduled inspection.
Cables usually wear or break where they pass over pulleys or through fairleads.
Wear and corrosion are the two most common problems with control cables.
Inspect for broken wires or strands by wiping a clean, dry rag along the cable.
Move the controls through their full range and check the cable as near the pulleys as possible.

Pulley Inspection

Inspect pulleys for roughness, sharp edges, and foreign material embedded in the grooves.
Examine pulley bearings to ensure proper lubrication, smooth rotation, and freedom from flat spots, dirt, and paint spray.
Rotate the pulleys to provide a new bearing surface for the cable.
Maintain pulley alignment to prevent the cable from riding on the flanges and chafing against guards, covers, or adjacent structures.

Pulley Guards and Alignment

Pulleys must be equipped with guards to prevent the cable from jumping out of the groove when the cable is slack.
The guard pin is usually a clevis pin secured with a split pin.
Ensure a washer is fitted under the split pin to prevent damage to the pulley frame or structure.

Cable Tensioning

Rig pins are used to lock the control system in place when rigging the controls.
The control surfaces and major quadrants/bell cranks are locked in place with the rig pins, and the cables are tensioned in accordance with the maintenance manual.
Tension is checked with a cable tensiometer, which must be placed in a clear area of each section of cable, midway from any quadrants, bell cranks, or surfaces.
The tensiometer is equipped with a series of risers that correspond to the cable diameter.
The reading on the scale is not the cable tension, but an arbitrary reading for the particular riser; the tension in pounds is read from a chart that converts the reading for the riser being used.

Cable Tension Compensators

Most large transport aircraft are fitted with a cable tension compensator assembly, which compensates for expansion and contraction of the airframe and regulates control cable tension accordingly.

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Description

This quiz covers the maintenance practices of aircraft control cables and terminals, including the installation and testing of Nicopress sleeves and swaged terminals. It is based on the CASA Part 66 training materials. Test your knowledge of aircraft maintenance procedures.

Aircraft Control Cables and Terminals Maintenance

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