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MAINTENANCE INSTRUCTIONS
4.12
7 Perform the following inspections of the control cable:
a. Use the Model 550 NO GO gauge to inspect the control cable connector for wear. Closely inspect
the connector for bends or cracks in the neck (shank) area and dented areas on the ball of the
connector. Remove the control cable from service if any cracks or bends in the shank or dents in
the ball of the male connector are found during this inspection. The male connector should not be
bent at an angle greater than 15 degrees from the axis of the control cable in the area where it is
crimped. Using your hands, attempt to twist or rotate the male connector off the control cable. If
any movement is possible during this test, the control cable must be removed from service and
the male connector must be replaced.
b. Carefully inspect the control cable directly behind the remote control cable connector and
approximately 12 in (305 mm) beyond the male connector looking for the following anomalies:
• Cuts, breaks, nicks or fraying in the spiral windings of the cable.
• Kinks or permanent bends.
• Rust (red oxide) on the inner and outer core of the cable.
• Uniformity of the spacing between the outer helical windings of the cable. Check for flattened
areas and excessive wear that reduces the cable's outer diameter less than 0.183 in (4.7
mm).
• Perform a flexibility (spring) test of the cable by bending the connector end of the cable into a
‘U’ shape and then releasing it. A cable that is bent/released and does not spring back into an
essentially straight shape is indicative of internal corrosion of the cable. The cable must be
removed from service.
• Carefully examine the cable in the area of the control crank assembly looking for cuts,
breaks, fraying, rust, unusual stiffness and uniformity of the spacing between the outer spiral
windings.
• Examine the entire length of cable looking for defects described above.
If a control cable is deemed as defective during this inspection, remove it from service and tag it
with a label to prevent inadvertent use.
The control cable (Model 550 male) connector must be replaced at intervals not to exceed five (5)
years. Maintenance program administrators must maintain traceability records for replacement of all
‘Safety Class A’ designated components.
8 Lightly lubricate the control cable using MIL-G-23827B (or C), MIL-PRF-23827C, or equivalent
grease. Apply additional grease to the first 3 ft (approximately 1m) of control cable (male connector
end).
9 Clean the exterior of the remote control conduits using clean rags and a detergent. Remove all dirt
and grease from the polyvinyl conduits and swaged fittings. Carefully inspect the entire length of
remote control conduits for cuts and melted areas. Repairs to cut or melted areas can be
accomplished by taping the area with 3M™ yellow polyvinyl tape (or black polyvinyl electrical tape).
The tape will prevent the ingress of water and other liquid that would cause corrosion of the remote
control conduit's inner braids and the remote control cable. Look and feel for dents and depressions
in the remote control conduits. Minor dents can be rounded out by gently tapping the area with a
small hammer.
Examine the control conduits where they protrude from the swage fittings, looking for bulges or
cracks in the polyvinyl. Remote control conduits with large dented areas or cracks/ bulges near the
swage fittings should be sent to the manufacturer for repairs.