07/03/13Victorian Soaring Association Inc. AIRWORTHINESS COURSE VICTORIAN SOARING ASSOCIATION INC. CABLE SYSTEM - INSPECTIONS

07/03/13Victorian Soaring Association Inc. CONTROL CABLES - INSPECTION CHECK.

07/03/13Victorian Soaring Association Inc. General This procedure contains five tasks: Inspection for control cable corrosion Inspection for control cable wear limits Inspection of the control cable pulley Inspecting the bracket/s of the pulley Inspection of control cable travel. 1

07/03/13Victorian Soaring Association Inc. Identifying Cables The type and construction of cables is identified by two numbers: The first number is the number of strands; The second number is the number of wires in a strand 2

07/03/13Victorian Soaring Association Inc. Identifying Cables A 7 x 7 flexible cable has seven strands, each of which has 7 wires; The more strands a cable has, the more flexible it is. Thus use a 7 x 7 or a 7 x 19 cable when cables go through pulleys or when you must bend the wires. Thicker strands wear better. Hemp Cored – Banned. 3

07/03/13Victorian Soaring Association Inc. Identifying Cables Tests show that flexible cables can have broken wires without an important decrease in strength. A 7x 7 cable, for example can have two broken wires in a 30cm length and continue to hold its specified load. 4

07/03/13Victorian Soaring Association Inc. Control Cables Wires break most frequently where cables go through fairleads or around pulleys. Examine these areas carefully; Replace worn cables and cables with bad corrosion. 5

07/03/13Victorian Soaring Association Inc. Inspecting Cables To do an inspection for broken wires, rub a cloth along the length of the cable in both directions; Corrosion can make a cable unserviceable; Make sure clearances of the control cables are within specification. 6

07/03/13Victorian Soaring Association Inc. Inspecting Cables Do not use solvents such as; Vapor Degreasing Solvent, Steam cleaning solvent, Methyl Ethyl Ketone, to clean cables. Solvents will remove the cable internal lubricant, which will cause corrosion and rapid wear. 7

07/03/13Victorian Soaring Association Inc. Cable Inspection Technique 8

07/03/13Victorian Soaring Association Inc. Replacing Cables Replace a 7x7 cable when two wires are broken in a 30cm continuous length More than 3 wires are broken in the total cable length between two terminals; One wire is broken caused by rust or corrosion 9

07/03/13Victorian Soaring Association Inc. Replacing Cables Check cables for wear and replace them when: One strand has worn wires where one wire cross section is decreased by 40% or more; Replace cable assemblies which have damage caused by rust 10

07/03/13Victorian Soaring Association Inc. Inspection Of Cable Pulleys Visually examine the pulleys for roughness, sharp edges, and unwanted material in the grooves. Visually examine the pulley wear pattern Examine the pulley bearings to make sure they are lubricated correctly, can turn smoothly, and have no flat spots. 11

07/03/13Victorian Soaring Association Inc. Inspection Of Cable Pulleys Examine the pulley for wobble: Examine the pulley bolts for worn locations. Remove a pulley from the aeroplane when: There is an unusual pulley wear pattern. There is to much pulley wobble. The pulley does not turn freely and smoothly. 14

07/03/13Victorian Soaring Association Inc. Inspection Of Cable Pulleys EXCESSIVE CABLE TENSION PULLEY MISALIGNMENT PULLEY TOO LARGE FOR CABLE CABLE MISALIGNMENT FROZEN BEARING NORMAL CONDITION 15

07/03/13Victorian Soaring Association Inc. Inspection of the Brackets on the Pulley Examine brackets for cracks or other damage to the structure. Repair or replace damaged brackets 16

07/03/13Victorian Soaring Association Inc. Inspection of Control Cable Travel Examine the cable guides and fairleads for worn locations, broken parts, correct alignment, clean parts, and correctly attached parts. Make sure the cable deflection angle at the fairleads is not more than three degrees. 17

07/03/13Victorian Soaring Association Inc. Inspection of Control Cable Travel Examine the cables to make sure they go along the correct routing, and do not have twists or rub on anything. Make sure the cable is free to move through its full travel. 18

07/03/13Victorian Soaring Association Inc. Turnbuckle lock wiring schemes 19

07/03/13Victorian Soaring Association Inc. Typical Cable End Sleeve/Swage Thimble 21

07/03/13Victorian Soaring Association Inc. SWAGING sequence for 1/8" cable