aviation cable factory

How to Document Aviation Cable Maintenance

Properly documenting aviation cable maintenance is critical for safety, compliance, and future troubleshooting. Here’s a clear, step-by-step approach:

What You Need

• Torque wrenches (calibrated)
• Cable tension gauges
• Inspection mirrors/boroscopes
• Calipers
• Wire rope inspection guides (e.g., broken strand gauges)
• Camera
• Aircraft Maintenance Manual (AMM) / Component Maintenance Manual (CMM)
• Pen or digital device
• Approved maintenance forms or digital tracking system

Step-by-Step Documentation Process

1. ​Identify the Cable:
   • Record the exact cable ​Part Number (P/N) and ​Serial Number (S/N) if applicable.
   • Note the ​Specific Location (e.g., “Aft Rudder Control Cable, Station 245, Left Side”).
   • Record the ​System (e.g., “Flight Controls – Elevator”).
   • Note the ​Wire Specification/Grade (e.g., MIL-W-5088K, Type I or AMS 5688).
   • Record the ​Length (if measured or replaced).
   • Record ​Termination Types (e.g., Nicopress sleeve, swaged fitting P/N XXX).
2. ​Record the Maintenance Action:
   • Clearly state what was done:
     • Routine Inspection
     • Cable Tension Adjustment (Specify final tension value and units – e.g., “230 lb”)
     • Cable Turnbuckle Adjustment (Record new PIN position)
     • Cable Lubrication (Specify lubricant P/N and method)
     • Cable Removal/Replacement (Explain reason clearly)
     • Termination Inspection (e.g., swage sleeves)
     • Cable Repair (Specify approved splice kit P/N or repair method per AMM)
3. ​Detail Inspection Findings (Be Specific & Quantifiable):
   • ​Condition: Report exactly what you saw.
     • Bad: “Cable worn.”
     • Good: “Cable shows 3 visible broken strands within 1-inch span. Surface corrosion noted on strands over 6-inch section near fairlead block PN XXX.” OR “No broken strands, corrosion, kinks, or fraying observed.” OR “Evidence of chafing against hydraulic line PN XXX at Station 180; protective sleeve damaged.”
   • ​Broken Strands: Count and locate them precisely relative to an end fitting or known landmark.
   • ​Corrosion: Describe type (surface, pitting), location, and extent (e.g., “surface corrosion on approx. 40% of strands over 12-inch section”).
   • ​Wear/Abrasion: Measure depth/width if possible. Note location relative to pulleys or fairleads.
   • ​Kinks/Damage: Describe and measure location/size.
   • ​Tension: Record measured value.
   • ​Loose Strands/End Conditions: Report at terminations.
   • ​Attach Photos: Clearly focused, well-lit pictures highlighting any damage or the area worked are invaluable evidence.
4. ​Reference Authoritative Sources:
   • State the exact maintenance document used (e.g., “Performed per AMM 27-21-00, Para. 5.C.” or “Inspected per MSB XXX-XX”). This is crucial for justification.
5. ​Record Parts & Materials Used:
   • If replaced: Document the ​Removed Cable P/N, S/N, Reason for Removal and ​Installed Cable P/N, S/N.
   • If lubricated: Record the exact ​Lubricant P/N and quantity/method if specified.
   • If repaired: Record ​Splice Kit P/N, ​Swaging Tool P/N/Calibration Due, etc.
6. ​Document Personnel & Certification:
   • Record the name and ​Certificate Number (e.g., FAA A&P License Number, EASA Part-66 License Number) of the technician performing the work.
   • Record the name and ​Certificate Number of the inspector if required for the task (e.g., for critical flight controls).
7. ​Record Date & Aircraft Details:
   • Date the maintenance was completed.
   • Aircraft Registration (Tail Number).
   • Aircraft Model and Serial Number.
   • Total Aircraft Flight Hours/Cycles at time of maintenance.
8. ​Signatures/Certification Statement:
   • The technician must sign and add certificate number.
   • If inspection is required, the inspector signs and adds certificate number with a clear certification statement (e.g., “Work performed meets requirements and aircraft is approved for return to service”).

Essential Documentation Requirements Table

By consistently capturing these details accurately and clearly, you create a vital record that ensures safety, supports compliance with regulations (like FAR 43.9 or EASA Part-M), aids future maintenance decisions, and provides crucial evidence of airworthiness. ​Clear, specific, and complete records are non-negotiable in aviation maintenance. Always refer to your specific aircraft manuals and regulatory requirements.