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Module 7: Maintenance Practices (B1) > 7.13 - Control Cables > Flashcards

7.13 - Control Cables Flashcards

1
Q

When using the Pacific T5 tensiometer, what 2 things should be noted?

A

Pacific T5 tensiometer. Correct chart and correct riser

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2
Q

What proof loading should the cable be subject to after swaging?

A

Proof loading after swaging. 50 to 60% of the cable max load

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3
Q

How would you check that a cable has been swaged correctly?

A

Swaging of a cable end fitting is checked by a Go/No-go gauge on the barrel

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4
Q

What is the smallest component of a control cable?

A

In a control cable, a wire is the smallest component of a control cable

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5
Q

How is linear to rotary motion in a control cable achieved?

A

Linear to rotary motion in a control cable run is achieved using Quadrants

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6
Q

What’s not acceptable over pulleys?

A

Broken wires over a pulley aren’t acceptable

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7
Q

What does 7x19 mean?

A

7x19
7 strands, 19 wires

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8
Q

When should a cable be replaced (% of wear)?

A

Cable should be replaced when individual wires are worn greater than 40%

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9
Q

Should you measure tension near pulleys or end fittings?

A

No, tension should be measured 6 inchs or more away from pulleys or fittings

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10
Q
A

Use correct chart and correct riser

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11
Q
A

Run a rag the full length of the cable

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12
Q
A

to have control surface locks into support weight and adjust turnbuckles equally

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13
Q
A

50% minimum breaking strain

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14
Q
A

use a go/no-go gauge on the barrel

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15
Q
A

the basic smallest component of a control cable

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16
Q
A

Remain in service

7x7 -Replace if 2 broken wires in a one-foot length of a 7x7 cable. Max of 3 broken within its full length between end fittings. Note: Cable must be replaced if a single wire is broken due to corrosion or rust or where it passes over a fairlead

7x19 - Replace the cable if 4 wires broken within a 12 inch section OR more than 6 broken wires between end fittings OR if a single wire is broken due to corrosion

Note: Broken wires are NOT PERMITTED at bends/over pulleys/pressure seals or fairleads

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17
Q
A

Quadrants

Quadrants and Bell Cranks are used to convert Linear to Rotary motion & vice versa

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18
Q
A

50%-60% of the cable max load

When swaging is complete confirm correct plastic deformation of the end fitting by means of a micrometre or Go/No Go gauge & PROOF LOADING TEST. 50% OF MAX CABLE STRENGTH PER BRITISH SPEC & 60% PER US SPEC.
Note: Proof loading the entire cable run Pre Stretches the cable

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19
Q
A

3 for any cable diameter

'’Check turnbuckles, max 3 threads visible & locking clips or lock wire installed - Secondary cable stops are at the controls on the flight deck rigged with a small clearance’’

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20
Q
A

Is not acceptable

Cable must be replaced if a single wire is broken due to corrosion or rust or WHERE IT PASSES OVER A FAIRLEAD
Broken wires are NOT PERMITTED at bends/over pulleys/pressure seals or fairleads

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21
Q
A

7 strands of 19 wires

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22
Q
A

40%

Cable wear: replace cables if wires are worn beyond 40% of original cross section

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23
Q
A

the end fittings on the cable are secure

'’When the swaging is complete confirm correct plastic deformation of the end fitting by means of a micrometre or Go/No Go gauge & PROOF LOADING TEST. 50% OF MAX CABLE STRENGTH PER BRITISH SPEC & 60% PER US SPEC
Proof loading the entire cable run Pre stretches the cable

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24
Q
A

Option B: not required

Proof testing after cable installation is not required, however it is required after swaging an end of the cable to ensure end fitting is secure. i.e 50 - 60% of maximum cable strength

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25
Q
A

Option B: rejected

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26
Q
A

Option C: enable the cable to be tensioned

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27
Q
A

Option A: Use correct chart and correct riser

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28
Q
A

Option B: Equalizes control cable tension

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29
Q
A

Option C: Run a rag the full length of the cable

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30
Q
A

Option C: using a chisel on a flat metal surface

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31
Q
A

Option B: looking for a shiny surface on the cable near the fitting

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32
Q
A

Option C: at least 40 times that of the cable diameter

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33
Q
A

Option C: A tube is fitted over the turnbuckle assembly and drilled to take up to 3 bolts, to prevent rotation of any part

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34
Q
A

Option C: to have control surface locks in to support weight and adjust turnbuckles equally

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35
Q
A

Option C: if a chemical spillage is suspected

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36
Q
A

Option C: 50% of minimum breaking strain

37
Q
A

Option A: run a rag along the cable in both directions

38
Q
A

Option C: the aircraft will be heavy on controls

39
Q
A

Option A: the end fittings on the cable are secure

40
Q
A

Option B: attempting to pass a hardened pin probe through the inspection hole

41
Q
A

Option B: replace the cable

42
Q
A

Option A: Galvanising

43
Q
A

Option A: To ensure the cable end passes the inspection hole on drilled through type fittings but leaves the locking wire hole clear

44
Q
A

Option C: to ensure that the turnbuckle is in safety

45
Q
A

Option B: using a go/no-go gauge on the barrel

46
Q
A

Option A: single wires are blended together

47
Q
A

Option B: it will prevent the control surface and the control column movement

48
Q
A

Option B: full and free movement

49
Q
A

Option A: 40%

50
Q

What is the criteria for allowable broken wires in a 7x7 and a 7x19?

A

7x7
Replace if 2 broken wires in a one-foot length
Max of 3 broken wires in its full length

**7x19 **
Replace if 4 broken wires in a one-foot length
Max of 6 broken wires in its full length

Broken wires are NOT PERMITTED at bends/over pulleys/pressure seals or fairleads and any single wire broken due to corrosion, whole cable must be rejected.

51
Q
A

Middle of a control run

52
Q
A

is strong and light

53
Q
A

broken

Note: Trick question, says worn TO 40%, cable must be replaced if individual wire is worn GREATER than 40%

54
Q
A

Dipping the cable end in lanolin to fit

55
Q
A

both ends simultaneously

56
Q
A

Teleflex control

57
Q
A

1/ The inspection hole is covered or only the required number of threads is shown (max 3)

58
Q
A

3/ Locking clip or wire

'’Check turnbuckles, max 3 threads visible & LOCKING CLIPS or Lock Wire installed’’

59
Q
A

3/ A single steel extrusion

60
Q
A

1/ Swaged

61
Q
A

3/ It will transmit both tensile and compressive loads

'’Teleflex Helix Cables; Similar to Bowden cable but has a CORE TENSION CABLE SURROUNDED BY MAN LH or RH SPIRALLY WOUND CABLES / it is better able to transmit push / pull movement due to its greater strength NOTE; Follow AMM procedure for removing, inspecting & lubricating inner cable. TRANSMITS BOTH TENSILE & COMPRESSIVE LOADS
Bowden & Teleflex are ‘‘Flexible Cables’’

62
Q
A

3/ Convert linear to rotary and vice versa

'’Quadrants & Bell Cranks are used to convert LINEAR TO ROTARY MOTION & VICE VERSA’’

63
Q
A

3/ A weight that pulls the cable in the return direction

'’Bowden Cables = A flexible inner cable operating within a hollow outer cover (similar to a bicycle break cable) / used as a pull cable (most common) or as a push/pull cable / eg CESSNA throttle cable. Advantage is its ability to bend, dis-advantage is BACKLASH, making it unsuitable for a large force over a long distance. NOTE: IT USES A WEIGHT TO RETURN CABLE’’

64
Q
A

2/ Another cable in the control set (balance cable)

(answer needs to be verified)

65
Q
A

a) a cable tension regulator

'’A Tension Regulator is used to maintain correct tension despite fuselage flex and temperature changes’’

66
Q
A

B. have ontrol surface locks in to support weight and adjust turnbuckles equally

'’Cable Tension Check = First confirm cable diameter / Use Tensiometer / adjust turnbuckles / check Rigging Pins. Check that tensiometer & its chart are valid / check temperature of the day V cable load / check correct RISER is fitted. Take several readings along Straight Cable Runs
Note: it is easier to take readings if the flight control surfaces are supported’’

67
Q
A

B. Overall diameter

68
Q
A

A. 9 strands of 16 wires

'’7 X 19 = 7 strands made up of 19 wires’’
Note; There are TWO cables in every control loop, one carrying the motion and the second called a BALANCE CABLE’’

69
Q
A

C. adjust minor tensions on the cable on set-up

70
Q
A

C. the cable is misaligned

'’Pulley inspection - made from Tufnol or Micarta for roughness, unusual wear, wobble, flat spots, interference with structure. Eg Wear to one side of pulley indicates MIS-ALIGNED CABLE’’

71
Q
A

C. At the controls in the cockpit

'’Secondary Cable stops are at the controls on the flight deck rigged with a small clearance’’

72
Q
A

A/ a small gap

'’Secondary Cable stops are at the controls on the flight deck rigged with a small clearance’’

73
Q
A

B. a high tensile steel wire with a right or left hand helix wire wound on to it in a conduit tube. The system can operate in two directions.

'’Teleflex Helix Cables; Similar to Bowden cable but has a CORE TENSION CABLE surrounded by MANY LH or RH SPIRALLY WOUND CABLES / it is better able to transmit push / pull movement due to its greater strength NOTE; Follow AMM procedure for removing, inspecting & lubricating inner cable. TRANSMITS BOTH TENSILE & COMPRESSIVE LOADS
Bowden & Teleflex are ‘‘Flexible Cables’’

74
Q
A

B. maintain the necessary tension

'’A Tension Regulator is used to maintain correct tension despite fuselage flex and temperature changes’’

75
Q
A

C. Pulleys

'’Pulleys are used to change cable direction’’

76
Q
A

A. Single wires are blended together

77
Q
A

c/ to check the end fitting swage and to pre-stretch the cable

'’When the swaging is complete confirm correct plastic deformation of the end fitting by means of a micrometre or Go/No Go gauge & PROOF LOADING TEST. 50% of max cable strength per british spec and 60% per US spec. Note; Proof loading the entire cable run Pre Stretches the cable’’

78
Q
A

a/ four wires are broken in a 12 inch length

Replace cables if:
7x7 2 broken wires in one-foot length - Max 3 full length between end fittings
7x19 4 broken wires in one-foot length - max 6 full length between end fittings

Cable must be replaced if a single wire is broken due to corrosion or rust or where it passes over a fairlead

79
Q
A

b/ it is replaced

'’Cable must be replaced if a single wire is broken due to corrosion or rust or where it passes over a fairlead’’

80
Q
A

b/ it is replaced

'’Cable must be replaced if a single wire is broken due to corrosion or rust or where it passes over a fairlead’’

81
Q
A

a/ 50/ 60% of the breaking load

'’When the swaging is complete confirm correct plastic deformation of the end fitting by means of a micrometre or Go/No Go gauge & PROOF LOADING TEST. 50% of max cable strength per British spec & 60% per US spec. Note; Proof loading the entire cable run Pre stretches the cable’’

82
Q
A

a/ bigger than the final diameter

83
Q
A

c/ operate and check full free and correct

'’Ensure cables havve Full Free & Correct Movement’’

84
Q
A

b/ bowden and teleflex

'’Bowden & Teleflex are ‘Flexible Cables’’’

85
Q
A

b/ use a dry clean cloth to pick out broken wires

'’DO NOT use solvents to clean cables, it removes lubricant, use a clean dry cloth. Apply correct grease to Carbon Steel with a cloth after inspection. Note; Do not lubricate CRS cables’’

86
Q
A

b/ it is checked in usual way but at an area without the cladding

'’LOCKCLAD CABLES have a swaged AL ALLOY tube swaged onto it to help reduce temperature effects, check tension standard way (cable diameter/use tensiometer -correct riser/adjust turnbuckles etc) but not on the cladded portion.’’

87
Q
A

b/ too many passes of the swager dies were made during manufacture

'’Cracks on end fitting indicate too many blows resulting in work hardening cracking’’

88
Q
A

b/ more than the breaking strength of the cable

'’The grip of a correctly fitted terminal will be greater than the breaking strength of the cable’’

89
Q
A

b/ 3

'’Check turnbuckles, max 3 threads visible & LOCKING CLIPS or LOCKWIRE installed ‘’

Module 7: Maintenance Practices (B1) (20 decks)

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