M7.13

Question 1

Which of the following methods can be used to swage a compression end fitting to a cable?

A) Kearney® swager
B) Hydraulic/pneumatic press swager
C) Nicopress® hand splicing tool
D) All of the above

Answer 1

D) All of the above

Question 2

What is the correct way to install the “UPPER” roll die in the Kearney® swaging tool, and what should be visible?

A) Install it on the bottom shaft so that the word “UPPER” is visible.
B) Install it on the top shaft so that the word “UPPER” is visible.
C) Install it on the top shaft with the word “LOWER” visible.

Answer 2

B) Install it on the top shaft so that the word “UPPER” is visible.

Question 3

How should the “LOWER” roll die be installed on the Kearney® swaging tool, and what should be visible?

A) Install it on the top shaft, ensuring the word “LOWER” is visible.
B) Install it on the bottom shaft, ensuring the word “LOWER” is visible, with the two protruding pins on the outside.
C) It doesn’t matter where the “LOWER” roll die is installed.

Answer 3

B) Install it on the bottom shaft, ensuring the word “LOWER” is visible, with the two protruding pins on the outside.

Question 4

What is the purpose of using the “No-Go” gauge when measuring the swaged terminal?

A) To ensure the terminal is too loose to fit
B) To confirm the terminal shank is within the required diameter
C) To check for any remaining flash or fin on the terminal

Answer 4

B) To confirm the terminal shank is within the required diameter

Question 5

Why should you not adjust the swaged terminal more than four times?

A) Over-swaging may cause work hardening or embrittlement, leading to cracking.
B) The terminal will become too loose to fit properly.
C) The terminal will become too soft and fail.

Answer 5

A) Over-swaging may cause work hardening or embrittlement, leading to cracking.

Question 6

What percentage of the cable’s breaking strength is used during the testing process?

A. 50%
B. 60%
C. 70%

Answer 6

B. 60%

Question 7

How long must the load be held during cable testing with a swaged terminal pull tester?

A. 2 minutes
B. 3 minutes
C. 5 minutes

Answer 7

B. 3 minutes

Question 8

What is applied to detect cable slippage in the Nicopress® swaged fitting process?

A. Rubber bands
B. Paint witness marks
C. Metal clamps

Answer 8

B. Paint witness marks

Question 9

What material is used in the Nicopress® swaged fitting process and mechanically compressed into a cable?

A. Copper sleeve
B. Steel rod
C. Aluminum ring

Answer 9

A. Copper sleeve

Question 10

What is one method used to detect broken wires during control cable inspection?

A. Passing a cloth over the cable
B. Using a laser scanner
C. Applying grease to the cable

Answer 10

A. Passing a cloth over the cable

Question 11

After how many hours should control cables be inspected for broken wire strands?

A. 50 hours
B. 100 hours
C. 150 hours

Answer 11

B. 100 hours

Question 12

What is considered a critical fatigue area when the cable runs over, under, or around a pulley, sleeve, or through a fair-lead?

A. The cable’s tension
B. The area where the cable rubs or flexes
C. The section where the cable is securely fastened

Answer 12

B. The area where the cable rubs or flexes

Question 13

When inspecting the cable, how close to a swaged end fitting should the critical fatigue areas be checked?

A. 24 inches
B. 6 inches
C. 12 inches

Answer 13

C. 12 inches

Question 14

During the inspection process, what method is recommended for checking broken wires in critical fatigue areas?

A. Use a cloth to snag on any broken wires
B. Use a magnifying glass to inspect each strand
C. Visually examine the cable without touching it

Answer 14

A. Use a cloth to snag on any broken wires

Question 15

What could cause premature failure of wires in critical fatigue areas near the swaged end fittings?

A. Pinching of small wires during the swaging process
B. Exposure to sunlight
C. Lubrication of the cable

Answer 15

A. Pinching of small wires during the swaging process

Question 16

When should flexible and non-flexible cables be replaced due to external wear patterns?

A. When the inner wires blend together
B. When the outer wires are worn out by 40-50%
C. When the cable is exposed to moisture

Answer 16

B. When the outer wires are worn out by 40-50%

Question 17

What materials are fair leads typically made from?

A. Hard metals
B. Soft plastic or fibre, such as Nylon® or Tufnell®
C. Wood or rubber

Answer 17

B. Soft plastic or fibre, such as Nylon® or Tufnell®

Question 18

What is the purpose of a fair lead in cable systems?

A. To guide the cable without changing its direction
B. To change the direction of the cable
C. To support the weight of the cable

Answer 18

A. To guide the cable without changing its direction

Question 19

What is commonly used to secure the guard pin on a fair lead?

A. A spring clip
B. A clevis pin secured with a split pin
C. A rivet

Answer 19

B. A clevis pin secured with a split pin

Question 20

Which tool is used to determine the amount of tension on a cable?

A. Caliper
B. Tensiometer
C. Torque wrench

Answer 20

B. Tensiometer

Question 21

What is the purpose of a turnbuckle in cable tensioning?

A. To adjust the length of the cable
B. To change the tension of the cable
C. To lubricate the cable

Answer 21

B. To change the tension of the cable

Question 22

What marks the left-hand side of a turnbuckle?

A. A groove
B. A label
C. A notch

Answer 22

A. A groove

Question 23

What is the accuracy of a properly maintained tensiometer?

A. 98%
B. 100%
C. 90%

Answer 23

A. 98%

Question 24

The reading from a tensiometer is:

A. The actual cable tension
B. An arbitrary reading that needs to be converted
C. The final adjusted tension

Answer 24

B. An arbitrary reading that needs to be converted

Question 25

What does a Bowden cable typically consist of? A. A single cable only B. An inner cable running inside a conduit C. A series of pulleys and levers

Answer 25

B. An inner cable running inside a conduit

Question 26

What is placed around the cable in Bowden cables to help protect it from moisture and contaminants? A. A layer of rubber B. A coiled wire C. A plastic cover

Answer 26

B. A coiled wire

Question 27

What is used to further protect the Bowden cable after the coiled wire? A. Steel casing B. Cotton braiding C. Plastic tubing

Answer 27

B. Cotton braiding

Question 28

In a Bowden cable control system, how does the cable operate? A. In both push and pull directions B. Only in the push direction C. Only in the pull direction

Answer 28

C. Only in the pull direction

Question 29

What is a common method used to return a Bowden cable after it has been pulled? A. Using a hydraulic system B. Using a cable with a return spring C. Using gravity

Answer 29

B. Using a cable with a return spring

Question 30

What issue can moisture cause in a Bowden cable system? A. It can cause the cable to expand and lose tension B. It can lead to corrosion and reduced cable performance C. It enhances the smooth movement of the inner cable

Answer 30

B. It can lead to corrosion and reduced cable performance

Question 31

What is a common issue to check for during a Bowden cable inspection? A. Cable twisting B. Deformation, bends, and kinks C. Excessive lubrication

Answer 31

B. Deformation, bends, and kinks

Question 32

What should be done if a Bowden cable shows signs of deformation, bends, or kinks during inspection? A. Lubricate the cable B. Replace the cable C. Tighten the cable tension

Answer 32

B. Replace the cable

Question 33

What is the purpose of a Bowden cable? A. To transmit energy through electrical signals B. To transmit mechanical force by the movement of an inner cable inside a conduit C. To store mechanical energy

Answer 33

B. To transmit mechanical force by the movement of an inner cable inside a conduit

Question 34

What is the main difference between a Teleflex cable system and a Bowden cable system? A. Teleflex cables only transmit push forces B. Teleflex cables can transmit both push and pull forces C. Teleflex cables are weaker in construction

Answer 34

B. Teleflex cables can transmit both push and pull forces

Question 35

In the attachment of a Teleflex end fitting, what should be ensured for a single-entry system? a) The cable should wrap at least 180 degrees b) The cable should wrap at least 40 degrees c) The cable should wrap 90 degrees

Answer 35

b) The cable should wrap at least 40 degrees

Question 36

For a double-entry Teleflex system, how much should the cable wrap around the pinion? a) 90 degrees b) 180 degrees c) 360 degrees

Answer 36

b) 180 degrees

Question 37

What is the primary function of a pulley in a cable system? a) To transmit power b) To change the direction of the cable c) To reduce tension

Answer 37

b) To change the direction of the cable