TRAINING NOTES

6.10 CONTROL CABLES (LP – 50 to 54)

a. Types of cables;
b. End fittings, turnbuckles and compensation devices;
c. Pulleys and cable system components;
d. Bowden cables;
e. Aircraft flexible control systems.

CONTROL CABLES

 Cables are the most widely used linkage in primary flight control systems.
 Cable-type linkage is also used in engine controls, emergency extension systems for the
landing gear, and various other systems throughout the aircraft.
 Cable-type linkage has several advantages over the other types.
 Aircraft control cables are fabricated from carbon steel or stainless steel.

 DIFFERENT TYPES OF CONTROL CABLES AND CABLE CONSTRUCTION

 The basic component of a cable is a wire.
 The diameter of the wire determines the total diameter of the cable.
 A number of wires are preformed into a helical or spiral shape and then formed into a strand.
 These preformed strands are laid around a straight center strand to form a cable.
 Cable designations are based on the number of strands and the number of wires in each
strand.
 The most common aircraft cables are the 7 × 7, and 7 × 19.
 The 7 × 7 cable consists of seven strands of seven wires each.
 Six of these strands are laid around the center strand.
 This is a cable of medium flexibility and is used for trim tab controls, engine controls, and
indicator controls.
 The 7 × 19 cable is made up of seven strands of 19 wires each. Six of these strands are laid
around the center strand.
 This cable is extra flexible and is used in primary control systems and in other places where
operation over pulleys is frequent.
 Aircraft control cables vary in diameter, ranging from 1/16 to 3/8 inch.

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 Cable fittings
 Cables may be equipped with several different types of fittings such as terminals, thimbles,
bushings, and shackles.
 Terminal fittings are generally of the swaged type.
 They are available in the threaded end, form end, eye end, single shank ball end, and double-
shank ball end.
 The threaded end, fork end, and eye end terminals are used to connect the cable to a
turnbuckle, bell crank or other linkage in the system.
 The ball-end terminals are used for attaching cables to quadrants and special connections
where space is limited.

 Turnbuckles and Compensation Device

 A turnbuckle assembly is a mechanical screw device consisting of two threaded terminals and
a threaded barrel.
 Turnbuckles are fitted in the cable assembly for the purpose of making minor adjustments in
cable length and for adjusting cable tension.
 One of the terminals has right-hand threads and the other has left-hand threads.
 The barrel has matching right - and left - hand internal threads.
 The end of the barrel with the left-hand threads can usually be identified by a groove or knurl
around that end of the barrel.
 When installing a turnbuckle in a control system, it is necessary to screw both of the terminals
an equal number of turns into the barrel.
 It is also essential that all turnbuckle terminals be screwed into the barrel until not more than
three threads are exposed on either side of the turnbuckle barrel.

 PUSH-PULL TUBE LINKAGE

 Push-pull tubes are used as linkage in various types of mechanically operated systems.
 This type linkage eliminates the problem of varying tension and permits the transfer of either
compression or tension stress through a single tube.
 A push-pull tube assembly consists of a hollow aluminum alloy or steel tube with an adjustable
end fitting and a checknut at either end.

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 The check nuts secure the end fittings after the tube assembly has been adjusted to its correct
length.
 Push-pull tubes are generally made in short lengths to prevent vibration and bending under
compression loads.

 Cable System Components

 Turnbuckles
 The turnbuckle is a device used in cable control systems to adjust cable tension.
 The turnbuckle barrel is threaded with left-hand threads inside one end and right-hand threads
inside the other.
 When adjusting cable tension, the cable terminals are screwed into either end of the barrel and
equal distance by turn turning the barrel. After a turnbuckle is adjusted, it must be safe tied.

 Cable Connectors
 In addition to turnbuckles, cable connectors are used in some systems.
 These connectors enable a cable length to be quickly connected or disconnected from a
system.
 This type is connected or disconnected by compressing the spring.

 Gust lock
 A cam on the control quadrant shaft engages a spring-loaded roller for the purpose of
centering and neutralizing the controls with hydraulic system off (aircraft parked).
 Pressure is trapped in the actuators and since the controls are neutralized by the cam and
roller, no movement of the control surfaces is permitted.

 Cable guides
 Cable guides consist primarily of fairleads, pressure seals, and pulleys.

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 A fairlead may be made from the nonmetallic material, such as Phenolic or a metallic material
such soft aluminium.
 The fairlead completely encircles the cable where it passes through holes in bulkheads or other
metal parts.
 Fairleads are used to guide cables in a straight line through or between structural members of
the aircraft.
 Fairleads should never deflect the alignment of a cable more than 3mm from a straight line.
 Pressure seals are installed where cables (or rods) move through pressure bulkheads.
 The seal grips tightly enough to prevent excess air pressure loss not enough to hinder
movement of the cable. Pressure seals should be inspected cable and cause jamming of a
pulley.
 Pulleys are used to guide cables and also to change the direction of cable movement.
 Pulley bearings are sealed, and need no lubrication other than the lubrication done at the
factory.
 Brackets fastened to the structure of the aircraft support the pulleys.
 Cables passing over pulleys are kept in place by guards.
 The guards are close-fitting to prevent jamming or to prevent the cables from slipping off when
they slacken due to temperature variations.

Mechanical linkages
 The linkage consists primarily of control (push pull) rods, torque tubes, quadrants, sectors, bell
cranks and cable drums.
 Control rods are used as links in flight control system to give a push-pull motion.

 Torque tubes
 Where an angular or twisting motion is needed in control system, a torque tube is installed.
 Quadrants, bell cranks, sectors, and drums change direction of motion and transmit motion to
parts such as control rods, cables and torque tubes.
 The quadrant is typical of flight control system linkages used by various manufacturers.
 Cable drums are used primarily in trim tab system.
 As the trim tab control wheel is moved clockwise or counter clockwise, the cable drum winds or
unwinds to actuate the trim tab cables.

 BOWDEN CABLES
 A Bowden cable is a type of flexible cable used to transmit mechanical force or energy by the
movement of an inner cable (most commonly of steel or stainless steel) relative to hollow outer
cable housing.
 The housing is generally of composite construction, consisting of helical steel wire, often lined
with plastic, and with a plastic outer sheath.
 The linear movement of the inner cable is generally used to transmit a pulling force, although
for very light applications over shorter distances (such as the remote shutter release cables on
mechanical film cameras) a push may also be used.
 Usually provision is made for adjusting the cable tension using an inline hollow bolt (often
called a “barrel adjuster”), which lengthens or shortens the cable housing relative to a fixed
anchor point. Lengthening the housing (turning the barrel adjuster out) tightens the cable;
shortening the housing (turning the barrel adjuster in) loosens the cable.

 Cable Assembly Inspection

 At each regular inspection period, cables should be inspected for broken wires by passing a
cloth along their length and observing points where the cloth snags.

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 To thoroughly inspect the cable, move the surface control to its extreme travel limits.
 This will reveal the cable in pulley, fair lead, and drum areas.
 If the surface of the cable is corroded, relieve cable tension.
 Then carefully force the cable open by reverse twisting, and visually inspect the interior for
corrosion.
 Corrosion on the interior strands of the cable indicates failure of the cable and requires
replacement of the cable.
 If there is no internal corrosion, remove external corrosion with a coarse weave rag or fibber
brush.
 Never use metallic wools or solvents to clean flexible cable.
 Metallic wools embed dissimilar metal particles, which cause further corrosion.
 Solvents remove the internal cable lubricant, which also results in further corrosion.
 After thoroughly cleaning the flexible cable, apply corrosion-preventive compound.
 This compound preserves and lubricates the cable.
 Breakage of wires occur most of frequently where cables pass over pulleys and through
fairleads.
 Control cables and wires should be replaced if worn, distorted, corroded, or otherwise
damaged.
 Special attention should be given to areas where cables pass through battery compartments,
lavatories, and wheel wells.

Signature of the Instructor Signature of Training Manager

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