Republic of the Philippines

PHILIPPINE STATE COLLEGE OF AERONAUTICS

Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Institute of Engineering and Technology

Aircraft Maintenance Technology
AMT 1202 AIRCRAFT FLIGHT CONTROLS

Prepared by: MARK JOHN G. CORSINO

AMT Technical Instructor

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 1

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

MODULE I: MECHANICAL CABLE SYSTEM

Lecture

TABLE OF CONTENTS

REF. PAGE
TOPIC NO. NO.

Control Cables and Terminals 5

 Cable Construction 5
 Cable Fittings 1 6
 Turnbuckles 7
 Push-Pull Tube Linkage 8
Control Operating Systems 9
 Cable Systems 13
 Cable Inspection 14
2
 Cable System Installation 15
 Cable Tension 16
 Tension Regulators 17
 Cable Connectors 18
 Spring-Back 18
 Push Rods (Control Rods) 19
 Torque Tubes 20
 Cable Drums 21

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 2

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

TABLE OF REFERENCES

REFERENCES Ref no.

control-operating-systems-part-one available from 1

https://www.flight-mechanic.com
control-operating-systems-part-two available from 2
https://www.flight-mechanic.com

LEARNING OUTCOMES

Course Learning Outcomes

[CLO]

Module Learning Outcomes

CLO 3. Describe the principles [MLO]
and operation of aircraft flight
control system. Topic Learning Outcomes
MLO 1 Identify different types [TLO]
CLO 4. Distinguish and be able and sizes of cable construction.
to explain the different parts
and purposes of aircraft flight MLO 2 Discuss different types TLO 1 Describe the operation
control system. of cable assembles. of the Control cables and
Terminal and the Control
Operating System.
MLO 3 distinguish the operation
TLO 2 Explain the operation of
of Control cables and Terminal the Control cables and
and the Control Operating Terminal and the Control
System. Operating System.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 3

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

TIMEFRAME:

You should be able to complete this module including all the self-assessments,
research works, assignments, and other performance tasks within 7.86 hours.

Control Cables and Terminals

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. It is strong and light
weight, and its flexibility makes it easy to route through the aircraft. An aircraft cable
has a high mechanical efficiency and can be set up without backlash, which is very
important for precise control.

Cable linkage also has some disadvantages. Tension must be adjusted frequently due
to stretching and temperature changes.

Aircraft control cables are fabricated from carbon steel or stainless steel.

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.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 4

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

The 7 × 7 cable consists of seven strands of seven wires each. Six of these strands
are laid around the center strand. [Figure 5-67] 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. [Figure 5-67] 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. The diameter is
measured as shown in Figure 5-67.

Figure 5-67. Cable cross sections.

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, fork end, eye end, single shank ball end, and double shank ball end. The threaded
AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 5
 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

end, fork end, and eye end terminals are used to connect the cable to a turnbuckle,
bellcrank, or other linkage in the system. The ball end terminals are used for attaching
cables to quadrants and special connections where space is limited. Figure 5-68
illustrates the various types of terminal fittings.

Figure 5-68. Types of terminal fittings.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 6

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

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

Turnbuckles

A turnbuckle assembly is a mechanical screw device consisting of two threaded

terminals and a threaded barrel. [Figure 5-69]

Figure 5-69. Typical turnbuckle assembly.

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.

After a turnbuckle is properly adjusted, it must be safety. The methods of safety

turnbuckles are discussed later in this chapter.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 7

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

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. [Figure 5-70] The checknuts 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.

Figure 5-70. Push-pull tube assembly.

Control Operating Systems

Cable Systems

There are various types of cable:

 Material—aircraft control cables are fabricated from carbon steel or stainless

(corrosion resistant) steel. Additionally, some manufacturers use a nylon coated

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 8

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

cable that is produced by extruding a flexible nylon coating over corrosion-

resistant steel (CRES) cable. By adding the nylon coating to the corrosion
resistant steel cable, it increases the service life by protecting the cable strands
from friction wear, keeping dirt and grit out, and dampening vibration which can
work-harden the wires in long runs of cable.
 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—based on the number of strands and wires in each strand.
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 very flexible and is used
in primary control systems and in other locations where operation over pulleys is
frequent. The 7 × 7 cable consists of seven strands of seven wires each. Six of
these strands are laid around the center strand. This cable is of medium flexibility
and is used for trim tab controls, engine controls, and indicator controls. [Figure
2-65] Types of control cable termination include:
 Woven splice—a hand-woven 5-tuck splice used on aircraft cable. The process
is very time consuming and produces only about 75 percent of the original cable
strength. The splice is rarely used except on some antique aircraft where the
effort is made to keep all parts in their original configuration.
 Nicopress process—a patented process using copper sleeves and may be used
up to the full rated strength of the cable when the cable is looped around a
thimble. [Figure 2-66] This process may also be used in place of the 5-tuck splice
on cables up to and including 3⁄8- inch diameter. Whenever this process is used
for cable splicing, it is imperative that the tools, instructions, and data supplied
by Nicopres be followed exactly to ensure the desired cable function and
strength is attained. The use of sleeves that are fabricated of material other than
copper requires engineering approval for the specific application by the FAA.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 9

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

 Swage-type terminals—manufactured in accordance with Army-Navy (AN) and

Military Standards (MS), are suitable for use in civil aircraft up to, and including,
maximum cable loads. [Figure 2-67]

Figure 2-65. Cable construction and cross-section.

Figure 2-66. Typical Nicopress Thimble-eye splice

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 10

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Figure 2-67. Swage-type terminal fittings.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 11

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

When swaging tools are used, it is imperative that all the manufacturer’s instructions,
including ‘go’ and ‘no-go’ dimensions, be followed exactly to avoid defective and
inferior swaging. Compliance with all of the instructions should result in the terminal
developing the full-rated strength of the cable.

Cable Inspection

Aircraft cable systems are subject to a variety of environmental conditions and

deterioration. Wire or strand breakage is easy to recognize visually. Other kinds of
deterioration, such as wear, corrosion, and distortion, are not easily seen. Special
attention should be given to areas where cables pass through battery compartments,
lavatories, and wheel wells. These are prime areas for corrosion. Special attention
should be given to critical fatigue areas. Those areas are defined as anywhere the
cable runs over, under, or around a pulley, sleeve, or through a fairlead; or any section
where the cable is flexed, rubbed, or within 1 foot of a swaged-on fitting. Close
inspection in these critical fatigue areas can be performed by rubbing a rag along the
cable. If there are any broken strands, the rag snags on the cable. A more detailed
inspection can be performed in areas that may be corroded or indicate a fatigue failure
by loosing or removing the cable and bending it. This technique reveals internal broken
strands not readily apparent from the outside. [Figure 2-72]

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 12

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Figure 2-72. Cable inspection technique.

Cable System Installation

Cable Guides

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. Pulleys should be examined to ensure proper lubrication;
smooth rotation and freedom from abnormal cable wear patterns which can provide
an indication of other problems in the cable system. [Figure 2-73]

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 13

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Figure 2-73. Pulley wear patterns.

Fairleads may be made from a nonmetallic material, such as phenolic, or a metallic

material, such as soft aluminum. 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 3° 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 but not enough to
hinder movement of the cable. Pressure seals should be inspected at regular intervals
to determine that the retaining rings are in place. If a retaining ring comes off, it may
slide along the cable and cause jamming of a pulley. [Figure 2-74]

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 14

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Figure 2-74. Cable guides.

Travel Adjustment

Control surfaces should move a certain distance in either direction from the neutral
position. These movements must be synchronized with the movement of the flight
deck controls. The flight control system must be adjusted (rigged) to obtain these
requirements. The tools for measuring surface travel primarily include protractors,
rigging fixtures, contour templates, and rulers. These tools are used when rigging flight
control systems to assure that the desired travel has been obtained.

Cable Tension

For the aircraft to operate as it was designed, the cable tension for the flight controls
must be correct. To determine the amount of tension on a cable, a tensiometer is used.
When properly maintained, a tensiometer is 98 percent accurate. Cable tension is
determined by measuring the amount of force needed to make an offset in the cable
between two hardened steel blocks called anvils. A riser or plunger is pressed against

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 15

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

the cable to form the offset. Several manufacturers make a variety of tensiometers,
each type designed for different kinds of cable, cable sizes, and cable tensions. [Figure
2-75]

Figure 2-75. Tensiometer.

Rigging Fixtures

Rigging fixtures and templates are special tools (gauges) designed by the
manufacturer to measure control surface travel. Markings on the fixture or template
indicate desired control surface travel.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 16

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Tension Regulators

Cable tension regulators are used in some flight control systems because there is
considerable difference in temperature expansion of the aluminum aircraft structure
and the steel control cables. Some large aircraft incorporate tension regulators in the
control cable systems to maintain a given cable tension automatically. The unit
consists of a compression spring and a locking mechanism that allows the spring to
make correction in the system only when the cable system is in neutral.

Figure 2-76. Spring-type connector.

Spring-Back

With a control cable properly rigged, the flight control should hit its stops at both
extremes prior to the flight deck control. The spring-back is the small extra push that
is needed for the flight deck control to hit its mechanical stop.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 17

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Push Rods (Control Rods)

Push rods are used as links in the flight control system to give push-pull motion. They
may be adjusted at one or both ends. Figure 2-77 shows the parts of a push rod. Notice
that it consists of a tube with threaded rod ends. An adjustable antifriction rod end, or
rod end clevis, attaches at each end of the tube. The rod end, or clevis, permits
attachment of the tube to flight control system parts. The checknut, when tightened,
prevents the rod end or clevis from loosening. They may have adjustments at one or
both ends.

Figure 2-77. Push rod.

The rods should be perfectly straight, unless designed to be otherwise. When installed
as part of a control system, the assembly should be checked for correct alignment and
free movement.

It is possible for control rods fitted with bearings to become disconnected because of
failure of the peening that retains the ball races in the rod end. This can be avoided by
installing the control rods so that the flange of the rod end is interposed between the
ball race and the anchored end of the attaching pin or bolt as shown in Figure 2-78.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 18

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Figure 2-78. Attached rod end.

Another alternative is to place a washer, having a larger diameter than the hole in the
flange, under the retaining nut on the end of the attaching pin or bolt. This retains the
rod on the bolt in the event of a bearing failure.

Torque Tubes

Where an angular or twisting motion is needed in a control system, a torque tube is

installed. Figure 2-79 shows how a torque tube is used to transmit motion in opposite
directions. [Figure 2-79]

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 19

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Figure 2-79. Torque tube.

Cable Drums

Cable drums are used primarily in trim tab systems. As the trim tab control wheel is
moved clockwise or counterclockwise, the cable drum winds or unwinds to actuate the
trim tab cables. [Figure 2-80]

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 20

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Figure 2-80. Trim tab cable drum.

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 21

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Formative Assessments (You have 10 Minutes to answer)

Identify the Following
1. This is a moved clockwise or counterclockwise, the cable drum winds or
unwinds to actuate the trim tab cables.
2. It permits attachment of the tube to flight control system parts.
3. What do you the special tools that designed by the manufacturer to measure
control surface travel.
4. It sealed and need no lubrication other than the lubrication done at the factory.
5. A patented process using copper sleeves and may be used up to the full rated
strength of the cable when the cable is looped around a thimble.
6. A hand-woven 5-tuck splice used on aircraft cable. The process is very time
consuming and produces only about 75 percent of the original cable strength
7. the basic component of a cable is a wire
8. based on the number of strands and wires in each strand
9. fitted in the cable assembly for the purpose of making minor adjustments in cable
length and for adjusting cable tension
10. AN stands for What

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 22

 Republic of the Philippines
PHILIPPINE STATE COLLEGE OF AERONAUTICS
Villamor, Piccio Garden, Pasay City
Acc. No.: M2700903PM
Certificate Number: AJA16.0920
AIRCRAFT MAINTENACE TECHNOLOGY

Honesty Clause

My signature below constitutes my pledge that all of the writing is my own work, with
the exception of those portions which are properly documented.

________________________ _____________________

Students Name and Signature Parent/Guardian Signature

AMT 1202 AIRCRAFT FLIGHT CONTROLS Page 23