PART-66 SYLLABUS LEVELS

CERTIFICATION CATEGORY ¦ B1 B2

Sub-Module 10
CONTROL CABLES
Knowledge Requirements

6.10 - Control Cables

Types of cables; 2 1
End fittings, turnbuckles and compensation devices;
Pulleys and cable system components;
Bowden cables;
Aircraft flexible control systems.

Level 1 Level 2
A familiarization with the principal elements of the subject. A general knowledge of the theoretical and practical aspects of the subject
and an ability to apply that knowledge.
Objectives:
(a) The applicant should be familiar with the basic elements of the Objectives:
subject. (a) The applicant should be able to understand the theoretical
(b) The applicant should be able to give a simple description of the fundamentals of the subject.
whole subject, using common words and examples. (b) The applicant should be able to give a general description of the
(c) The applicant should be able to use typical terms. subject using, as appropriate, typical examples.
(c) The applicant should be able to use mathematical formula in
conjunction with physical laws describing the subject.
(d) The applicant should be able to read and understand sketches,
drawings and schematics describing the subject.
(e) The applicant should be able to apply his knowledge in a practical
manner using detailed procedures.

[Link]
> Visit our website to download all latest EASA / DGCA CAR 66 Module examination Question papers and study material
CONTROL CABLES

Module 06 - Materials and Hardware 10.1

CONTROL CABLES AND TERMINALS

Cables are the most widely used linkage in primary The 7 × 7 cable consists of seven strands of seven wires
flight control systems. Cable-type linkage is also used each. Six of these strands are laid around the center
in engine controls, emergency extension systems for strand. (Figure 10-1) This is a cable of medium flexibility
the landing gear, and various other systems throughout and is used for trim tab controls, engine controls, and
the aircraft. indicator controls. The 7 × 19 cable is made up of seven
strands of 19 wires each. Six of these strands are laid
Cable-type linkage has several advantages over the around the center strand. (Figure 10-1)
other types. It is strong and light weight, and its
flexibility makes it easy to route through the aircraft. This cable is extra flexible and is used in primary control
An aircraft cable has a high mechanical efficiency and systems and in other places where operation over pulleys
can be set up without backlash, which is very important is frequent. Aircraft control cables vary in diameter,
for precise control. ranging from 1⁄16 to 3⁄8-inch. The diameter is measured as
shown in Figure 10-1.
Aircraft control cables are fabricated out of carbon steel
or stainless steel. A disadvantage of cable linkage is CABLE FITTINGS
that tension must be adjusted frequently. This is due to Cables may be equipped with several different types
stretching as well as expansion and contraction due to of fittings, such as terminals, thimbles, bushings, and
temperature changes. shackles.

CABLE CONSTRUCTION Terminal fittings are generally of the swaged type. They
The basic component of a cable is a wire. The diameter are available in the threaded end, fork end, eye end,
of the wire determines the total diameter of the cable. single shank ball end, and double shank ball end. The
A number of wires are preformed into a helical or spiral threaded end, fork end, and eye end terminals are used
shape and then formed into a strand. These preformed to connect the cable to a turnbuckle, bellcrank, or other
strands are laid around a straight center strand to form linkage in the system. The ball end terminals are used
a cable. Cable designations are based on the number of for attaching cables to quadrants and special connections
strands and the number of wires in each strand. The where space is limited. Figure 10-2 illustrates the various
most common aircraft cables are the 7 × 7 and 7 × 19. types of terminal fittings.

1/8 - 3/8 Diameter 7 × 19 Diameter 7 Strands, 19 Wires

to Each Strand

1/16 - 3/32 Diameter 7 × 7 Diameter 7 Strands, 7 Wires

to Each Strand

Figure 10-1. Cable cross sections.

10.2 Module 06 - Materials and Hardware

The thimble, bushing, and shackle fittings may be used and supplies are limited and immediate replacement of
in place of some types of terminal fittings when facilities the cable is necessary.

AN663 Double Shank Ball End Terminal

AN664 Single Shank Ball End Terminal

AN665 Rod End Terminal

AN666 Threaded Cable Terminal

AN667 Fork End Cable Terminal

AN668 Eye End Cable Terminal

Figure 10-2. Types of terminal fittings.

CABLE SYSTEM INSTALLATION

CABLE GUIDES
Pulleys are used to guide cables and also to change the
direction of cable movement. Pulley bearings are sealed Excessive Cable Tension Pully Wear From Misalignment
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
CONTROL CABLES

Pully Too Large For Cable Cable Misalignment

prevent jamming or to prevent the cables from slipping
off when they slacken due to temperature variations.
Pulleys should be examined to ensure proper lubrication;
smooth rotation and freedom from abnormal cable
wear patterns which can provide an indication of other Frozen Bearing Normal Condition
problems in the cable system. (Figure 10-3) Figure 10-3. Pulley wear patterns.

Module 06 - Materials and Hardware 10.3

Fairleads may be made from a nonmetallic material, rigging fixtures, contour templates, and rulers. These
such as phenolic, or a metallic material, such as soft tools are used when rigging f light control systems to
aluminum. The fairlead completely encircles the cable assure that the desired travel has been obtained.
where it passes through holes in bulkheads or other
metal parts. Fairleads are used to guide cables in a Generally speaking, the rigging consists of the following:
straight line through or between structural members of 1. Positioning the flight control system in neutral and
the aircraft. Fairleads should never deflect the alignment temporarily locking it there with rig pins or blocks;
of a cable more than 3° from a straight line. 2. Adjusting system cable tension and maintaining
rudder, elevator, and ailerons in the neutral
Pressure seals are installed where cables (or rods) move position; and
through pressure bulkheads. The seal grips tightly 3. Adjusting the control stops to the aircraft
enough to prevent excess air pressure loss but not enough manufacturer's specifications.
to hinder movement of the cable. Pressure seals should
be inspected at regular intervals to determine that the CABLE TENSION
retaining rings are in place. If a retaining ring comes For the aircraft to operate as it was designed, the cable
off, it may slide along the cable and cause jamming of a tension for the f light controls must be correct. To
pulley. (Figure 10-4) determine the amount of tension on a cable, a tensiometer
is used. When properly maintained, a tensiometer is
TRAVEL ADJUSTMENT 98 percent accurate. Cable tension is determined by
Control surfaces should move a certain distance in either measuring the amount of force needed to make an offset
direction from the neutral position. These movements in the cable between two hardened steel blocks called
must be synchronized with the movement of the flight anvils. A riser or plunger is pressed against the cable to
deck controls. The flight control system must be adjusted form the offset. Several manufacturer's make a variety of
(rigged) to obtain these requirements. The tools for tensiometers, each type designed for different kinds of
measuring surface travel primarily include protractors, cable, cable sizes, and cable tensions, Figure 10-5.

Fairlead
Rubstrip

Split Fairlead
Solid Fairlead

Retaining Rings

Control Cable

Guard Pin

Bulkhead Groove

rized
essu
Unpr
Bracket
d
urize
Press
Air Seal Bulkhead
Pulley

Figure 10-4. Cable guides.

10.4 Module 06 - Materials and Hardware

 Pointer Lock Riser Anvil and left hand internal threads. The end of the barrel
with the left hand threads can usually be identified by a
Anvil
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. After a turnbuckle is properly
adjusted, it must be safetied. There are a number of
Trigger
methods to safety a turnbuckle and/or other types of
Figure 10-5. Tensiometer. swaged cable ends that are satisfactory. A double wrap
safety wire method is preferred.
RIGGING FIXTURES
Rigging fixtures and templates are special tools (gauges) Some turnbuckles are manufactured and designed to
designed by the manufacturer to measure control surface accommodate special locking devices. A typical unit is
travel. Markings on the fixture or template indicate shown in Figure 10-7.
desired control surface travel.
CABLE CONNECTORS
TENSION REGULATORS In addition to turnbuckles, cable connectors are used in
Cable tension regulators are used in some flight control some systems. These connectors enable a cable length
systems because there is considerable difference in to be quickly connected or disconnected from a system.
temperature expansion of the aluminum aircraft Figure 10-8 illustrates one type of cable connector in use.
structure and the steel control cables. Some large aircraft
incorporate tension regulators in the control cable SPRING-BACK
systems to maintain a given cable tension automatically. With a control cable properly rigged, the flight control
The unit consists of a compression spring and a locking should hit its stops at both extremes prior to the flight
mechanism that allows the spring to make correction in deck control. The spring-back is the small extra push
the system only when the cable system is in neutral. that is needed for the f light deck control to hit its
mechanical stop.
TURNBUCKLES
A turnbuckle assembly is a mechanical screw device
consisting of two threaded terminals and a threaded
barrel. (Figure 10-6) 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

Length (threads flush with ends of barrel)

CONTROL CABLES

Swaged Terminal Barrel Pin Eye

Figure 10-6. Typical turnbuckle assembly.

Module 06 - Materials and Hardware 10.5

 Turnbuckle Body Locking-clip

Figure 10-7. Typical turnbuckle assembly.

Spring Connector

Figure 10-8. Spring type connector.

PUSH RODS (CONTROL RODS)

Push rods are used as links in the flight control system end or clevis from loosening. They may have adjustments
to give push-pull motion. They may be adjusted at one at one or both ends. The rods should be perfectly straight,
or both ends. Figure 10-9 shows the parts of a push rod. unless designed to be otherwise. When installed as part
of a control system, the assembly should be checked for
Notice that it consists of a tube with threaded rod ends. correct alignment and free movement.
An adjustable antifriction rod end, or rod end clevis,
attaches at each end of the tube. The rod end, or clevis, It is possible for control rods fitted with bearings to
permits attachment of the tube to flight control system become disconnected because of failure of the peening
parts. The checknut, when tightened, prevents the rod that retains the ball races in the rod end. This can be

Checknut Threaded Rod End Tube

Adjustable Antifriction Rod End Rivets Adjustable Rod End Clevis

Figure 10-9. Push rod.

10.6 Module 06 - Materials and Hardware

avoided by installing the control rods so that the flange Anchored End

of the rod end is interposed between the ball race and

Flange
the anchored end of the attaching pin or bolt as shown
in Figure 10-10.

Another alternative is to place a washer, having a larger Flange Ends

Peening

diameter than the hole in the flange, under the retaining

nut on the end of the attaching pin or bolt. This retains Figure 10-10. Attached rod end.
the rod on the bolt in the event of a bearing failure.

TORQUE TUBES
Where an angular or twisting motion is needed in a Quadrant

control system, a torque tube is installed. Figure 10-11

shows how a torque tube is used to transmit motion in
opposite directions.

CABLE DRUMS
Cable drums are used primarily in trim tab systems.
Torque Tube
As the trim tab control wheel is moved clockwise or
counterclockwise, the cable drum winds or unwinds to
actuate the trim tab cables. (Figure 10-12)

BOWDEN CABLE Horn

A Bowden cable is a type of f lexible cable used to
transmit mechanical force or energy. An inner steel or Push-pull Rod

stainless steel cable is free to slide inside an outer cable

housing. The housing may be constructed of various
materials but is traditionally a heavy gauge helical steel Figure 10-11. Torque tube.
wire. The inner cable moves linearly to transmit force
while the outer housing is typically fixed at both ends.
(Figure 10-13) Light single engine aircraft often use a
Bowden cable to open and close the throttle. Carburetor
mixture controls can also be operated this way.

CONTROL CABLES

Module 06 - Materials and Hardware 10.7

 Bearing Shaft Drum

Control Wheel

Figure 10-12. Trim tab cable drum.

Figure 10-13. A Bowden cable.

10.8 Module 06 - Materials and Hardware

 QUESTIONS

Question: 10-1 Question: 10-3

Control cable tension must be adjusted frequently A __________________ cable is a type of flexible cable
because of stretching as well as __________________ used to transmit mechanical force or energy.
due to temperature change.

Question: 10-2
To determine the amount of tension on a cable, a
__________________ is used.

Module 06 - Materials and Hardware 10.9

 ANSWERS

Answer: 10-1 Answer: 10-3

expansion and contraction. Bowden.

Answer: 10-2
tensiometer.

10.10 Module 06 - Materials and Hardware