Zlin Aviation
Section 2
Maintenance Manual Line Maintenance, Repairs and Alterations
Issued: 01/02/2006
QAP-AMM-Rev02
Date of latest Revision: 23/01/2013
Page Number: 2-5
2.3.2 REMOVAL AND REPLACEMENT OF COMPONENTS
For aircraft assembly instructions (wings, tail surfaces, etc…), please follow instructions detailed in
QAP-RTF-API (Assembly procedure Instructions) manual.
2.3.2.1 STEEL WIRE CABLES AND PULLEYS
The following is a partial extract from FAA AC 43.13-1B.
REPLACEMENT OF CABLES.
Replace control cables when they become worn, distorted, corroded, or otherwise damaged.
If spare cables are not available, prepare exact duplicates of the damaged cable. Use only
manufacturer’s approved cables and materials of the same size and quality as the original.
Location of Splices.
Locate splices so that no portion of the splice comes closer than 2 inches to any fair-lead or pulley.
Locate connections at points where jamming cannot occur during any portion of the travel of either
the loaded cable or the slack cable in the deflected position.
Cutting and Heating.
Cut cables to length by mechanical means. The use of a
torch, in any manner, is not permitted. Do not subject wires and cables to excessive temperature.
Soldering the bonding braid to the control cable is not permitted.
Ball-and-Socket Type Terminals.
Do not use ball-and-socket type terminals or other types for
general replacement that do not positively prevent cable untwisting, except where they were utilized
on the original installation by the aircraft manufacturer.
Substitution of Cable.
Substitution of cable for hard or streamlined wires will not be acceptable
unless specifically approved by a representative of the FAA.
Thimble-Eye Splice.
Before undertaking a thimble-eye splice, initially position the cable so the end
will extend slightly beyond the sleeve, as the sleeve will elongate somewhat when it is compressed.
If the cable end is inside the sleeve, the splice may not
hold the full strength of the cable. It is desirable that the
oval sleeve be placed in close proximity to the thimble
points, so that when compressed, the sleeve will contact
the thimble as shown in the figure. The sharp ends of
the thimble may be cut off before being used; however,
make certain the thimble is firmly secured in the cable
loop after the splice has been completed. When using a
sleeve requiring three compressions, make the center
compression first, the compression next to the
thimble second, and the one farthest from the thimble
last.
