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Locating the terminal in the swaging tool
SECONDARY FLIGHT CONTROL SYSTEMS

Aviation Structural Mechanic (H&S) 3&2 - How airplanes are built and how to maintain them
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the terminal from right to left. The dies compress the terminal barrel onto the cable, and swaging occurs. Rotation of the dies is accomplished by opening and closing the handles. After completion of swaging and removal of the fitting from the swaging tool, measure the outside diameter of the shank with a micrometer or with the gauge furnished with the swaging outfit to determine whether or not the terminal has been swaged sufficiently. This may be determined by checking the measurement with the applicable cable terminal table in NAVAIR 01-1A-8. The pneumatic swaging tool shown in figure 9-29 is a lightweight portable unit designed to precision swage the metal of a terminal into the interstices (crevices) of the cable strands. The swager may be mounted on a baseplate and used on a bench, or it can be taken to the job. When the swaging tool is taken to the location of the job, it may be held in your hand or cradled in your arm. The pneumatic swaging kit has several different sizes and types of dies used for swaging ball-and- sleeve terminals and for cutting and trimming cable. Like the mechanical swaging tool, the dies come in matched sets and must be used together. The dies are installed by inserting either die through the yoke opening into the die cavity. The keyway should be down and the shank facing the rear of the swager. Slide the first die back in order to clear the opening for the insertion of the mating die. The second die is inserted with the shank facing forward. The following step-by-step procedures are recommended for setting up the pneumatic swaging tool : 1. Connect the air supply to the foot valve. For efficient operation, use an inlet air line with at least 3/8-inch inside diameter and a minimum of 90 pounds of line pressure. 2. Connect the swager air line to the foot valve. 3. Clean the dies, remove any steel particles that may have adhered to the die cavity, and apply a light film of oil to the entire die. 4. Insert the dies in the swaging tool as previously described. WARNING Do not insert or remove dies until the air supply that is connected to the swager is shut off. Failure to secure the air supply connected to the swager could result in personal injury to the operator. With the pneumatic tool set up for use, perform the following steps while swaging terminals to cables: 1. Position the terminal on the cable, using the old cable as a pattern, or follow the instructions given in the applicable technical directives. When you are using a ball terminal, a minimum of 1 1/2 inches of cable must extend beyond the ball to allow room for holding and turning the terminal during swaging. The excess is trimmed, if necessary, after the swaging operation. When you use MS 20667 terminals, 1/4 inch of cable must extend through the terminal. On all other terminals, the cable is bottomed (inserted all of the way into the terminal). 2. Each terminal is cleaned with a suitable solvent, and then coated with a light oil. 3. With the terminals positioned in the cavity of the forward die, slide the rear die to its forward position using the slot provided in the yoke for the index finger. NOTE: To prevent damage to terminal or cable during the swaging cycle, maintain light pressure on the cable towards the front of the swager. This holds the terminal and cable firmly in the forward die cavity. 4. Depress the foot valve firmly and rotate the cable back and forth in 180-degree arcs or complete revolutions. The length of time the foot valve is held depends upon the type and size of fitting being swaged. The proper time can be found by referring to the chart supplied with the pneumatic swaging tool. If the terminal will not rotate, stop swaging immediately; rotate the terminal 90 degrees, and start swaging again. 5. Release the foot pedal to stop swaging, and remove the terminal from the swaging tool for inspection.   If the diameter is oversize or the terminal surface is too rough, repeat the operation. If swaged terminals are to be used on both ends of the cable, recheck the overall length of the cable and trim it, if necessary, prior to installing the second terminal. Make certain that all additional fittings and accessories, such as cable stops and fairleads, are slipped onto the cable in the proper sequence. The other terminal may then be swaged, using the same procedures as used for the first one. Proof-Testing Cables All newly fabricated cables should be tested for proper strength before they are installed in aircraft The test consists of applying a specified tension load on the cable for a specified number of minutes. The 9-36







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