What is the preferred action if a control cable pulley shows signs of excessive wear?

The preferred action when a control cable pulley shows signs of excessive wear is to replace it. This approach is crucial because excessive wear indicates that the pulley may not function optimally and could fail during operation, potentially leading to safety hazards or equipment malfunction. A worn pulley can cause increased friction and strain on the cable, leading to further damage to the system.

Proper maintenance practices dictate that any component showing signs of wear that compromise its integrity should be replaced to ensure the system operates safely and efficiently. Simply lubricating a worn pulley does not address the underlying issue of degradation and can mask symptoms without providing a long-term solution. Rotating it does not resolve wear issues either, as the areas of wear would still remain compromised. Ignoring the wear is not an option, as that can lead to catastrophic failure and is contrary to safety protocols in assembly and rigging practices. Therefore, replacing the pulley is the most responsible and effective action to ensure continued safe operation.