PIA TRAINING CENTRE (PTC) Module 6 – MATERIALS & HARDWARE

Category – A/B1 Sub Module 6.10 – Control Cables

MODULE 6
Sub Module 6.10

CONTROL CABLES

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 PIA TRAINING CENTRE (PTC) Module 6 – MATERIALS & HARDWARE
Category – A/B1 Sub Module 6.10 – Control Cables

Contents

CONTROL CABLES ................................................................. 1

TYPES OF CABLES ................................................................. 2
END-FITTINGS ......................................................................... 4
TURNBUCKLES AND COMPENSATION DEVICES ................. 6
PULLEYS AND CABLE SYSTEM COMPONENTS ................. 12
AIRCRAFT FLEXIBLE CONTROL SYSTEMS ........................ 15
BOWDEN CONTROLS ........................................................... 15
TELEFLEX CONTROLS ......................................................... 17

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 PIA TRAINING CENTRE (PTC) Module 6 – MATERIALS & HARDWARE
Category – A/B1 Sub Module 6.10 – Control Cables

CONTROL CABLES system for control movement relates to thermal contraction. As

an aircraft climb to a high altitude; its temperature drops and its
A number of different systems are used to actuate flight and structure contracts. Furthermore, the aluminum structures
engine controls from the cockpit, flexible control cables are by contracts much more than the small mass of steel in a control
far the most commonly used method. cable, and as a result, cables lose their tension. Large aircraft
have a rather complex automatic tensioning system to keep
Cables are used in pairs and are stretched taut, very little play is control cable tension relatively constant as the aircraft contracts
present in system controls, and no lost motion exists between and expands. However, small aircraft must have their cable
the actuating device and the unit. Consequently, cable tension adjusted as a compromise so they are not too tight
controlled units respond quickly and accurately to cockpit when the airplane is neither hot nor too loose when it is cold.
control movement. In some simple cable systems, only one
cable is used, and a spring provides the return action. The basic element of a cable is strand, and number of strands
are braided together to form a wire and number of wires are
Cables have many advantages. They will not sever readily braided together to form a cable.
under sudden strains. Cables are stronger than steel rods or
tubing of the same size. They flex without setting (permanent The direction of the twist of strands and the twist of wire could
deformation) and can be led easily around obstacles by using be either in the same direction or to the opposite direction. The
pulleys. Cables can be installed over long distances (such as in later one has the tendency of resisting uncoiling of wires and
large aircraft) without a great degree of sagging or bending. strands together when the cable is twisted in one direction and
Vibration will not cause them to harden, crystallize, or break, as also the strands are less stressed, because when the wires are
may be the case with push-pull control rods. Because of the twisted on the opposite direction, the strands are reset.
great number of wires used in cables, cable failure is never
abrupt, but is progressive over periods of extended use. When This opposite direction twist, which is most commonly adopted,
used for the manipulation of a unit in a control system, they are called a regular or an ordinary lay. Cables may have a right
usually worked in pairs-one cable to move the unit in one regular lay or a left regular lay. If the strands are twisted in the
direction, the other to move it in the opposite direction. Weight is direction of twist around the centre strand or core, the lay is
saved inspite of a second cable because the push-pull rod called a lang lay. There is a right and left lang lay. The only other
needed to cause a similar movement in a unit would have to be twist arrangement twisting the strands alternately right and left,
quite thick and heavy. then twisting them all either to the right or to the left about the
core is called a reverse lay. Most aircraft cables have a right
Disadvantage of a cable system is only tension loads can be regular lay.
transmitted and thus two cables always needed in a system to
transmit signal in two directions. Other disadvantage of a cable
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 PIA TRAINING CENTRE (PTC) Module 6 – MATERIALS & HARDWARE
Category – A/B1 Sub Module 6.10 – Control Cables

When aircraft cables are manufactured, each strand is first NONFLEXIBLE CABLE
formed to the spiral or helical shape to fit the position it is to
occupy in the finished cable. The process of such forming is In areas where a linkage does not pass over any pulleys,
called pre-forming, and cables made by such a process are said nonflexible cable can be used. It is available in either a 1 x 7 or
to be pre-formed. The process of pre-forming is adopted to 1x 19 configuration (refer fig. 01). The 1 x 7 cable is made up of
ensure flexibility in the finished cable and to relieve bending and one strand comprised of seven individual wires, whereas the 1 x
twisting stresses in the strands as they are woven into the 19 consists of one strand made up of 19 individual wires.
cable. It also keeps the strands from spreading when the cable Nonflexible cable is available in both galvanized carbon steel
is cut. All aircraft cables are internally lubricated during and stainless steel.
construction. Aircraft control cables are fabricated either from
flexible, preformed carbon steel wire or from flexible, preformed, FLEXIBLE CABLE
corrosion-resistant steel wire. The small corrosion-resistant
steel cables are made of steel containing not less than 17 Flexible steel cable made up of seven strands of seven wires
percent chromium and 8 percent nickel, while the larger ones each is called 7 x 7 or flexible cable (refer fig. 01), and is
(those of the 5/16-, 3/8-, and 7/16-inch diameters) are made of available in 1/16 and3/32 inch sizes in both galvanized carbon
steel that, in addition to the amounts of chromium and nickel steel and stainless steel. Both types are preformed
just mentioned, also contains not less than 1.75 percent
molybdenum. EXTRA-FLEXIBLE CABLE

TYPES OF CABLES The most widely used cable, 7 x 19, (refer fig, 01) is available in
sizes from 1/8inch up. It is extra flexible and is made of 133
Cables are designated according to the number of wires in a individual wires wound in seven strands, each strand having 19
cable and number of strands in a wire. Cables may be wires. These cables are preformed and are available in both
designated 7 x 7, 7 x 19, or 6 x 19 according to their galvanized and stainless steel. Galvanized cable is more
construction. A 7 x 7 cable consists of six strands of seven resistant to fatigue than stainless steel, but in applications
wires each, laid around a centre strand of seven wires. A 7 x 19 where corrosion is a factor, stainless steel is used.
cable consists of six strands of 19 wires, laid around a 19-wire
central strand, A 6 x 19 cable consists of six strands of 19 wires
each, laid around an independent wire rope centre. Flexibility
depends on the number of strands for cable with a given
diameter.

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Category – A/B1 Sub Module 6.10 – Control Cables

LOCKCLAD CABLE

Lock clad cable is used on some large aircraft for all long,
straight runs. It consists of the conventional flexible cable with
aluminium tubing swaged to it to lock the cable inside tubing.
This construction has certain advantages. Changes in tension
due to temperatures are less than with conventional cables,
also the amount of stretch at a given load is less. The cable
diameter is that of the smallest circle that would enclose the
entire cross section of the cable. Aircraft control cables vary in
diameters, ranging from 1/16 of an inch to 3/8 of an inch.

CABLE SYSTEM COMPONENTS

There are many components associated with cable systems

and a selection is presented here merely for information. They
include:

 End-Fittings
 Turnbuckles
Fig. 01 Cables Designation  Tensioning Devices
 Fairleads
 Pulleys

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Category – A/B1 Sub Module 6.10 – Control Cables

END-FITTINGS

Cable ends may be equipped with several different types of

fittings such as terminals, thimbles, bushings, and shackles.
Terminal fittings are generally of the swaged type. Terminal
fittings are available with threaded ends, fork ends, eye ends,
and single-shank and double-shank ball ends.

Threaded-end, fork-end, and eye-end terminals are used to

connect the cable to turnbuckles, bell cranks, and other linkage
in the system. The ball terminals are used for attaching cable to
quadrants and special connections where space is limited. The
single-shank ball end is usually used on the ends of cables, and
the double-shank ball end may be used at either the ends or in
the centre of a cable run. Thimble and bushing fittings may be
used in place of some types of terminal fittings when facilities
and supplies are limited and immediate replacement of the Fig. 02 (a)
cable is necessary. Figures 2 (a & b) below show these fitting.

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Category – A/B1 Sub Module 6.10 – Control Cables

Fig. 02 (b)

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Category – A/B1 Sub Module 6.10 – Control Cables

TURNBUCKLES AND COMPENSATION DEVICES Turnbuckles are fitted in the cable assembly for the purpose of
making minor adjustments in cable length and for adjusting
A turnbuckle is a mechanical screw device consisting of two cable tension. This is done by rotating the barrel so that the two
threaded terminals and a threaded barrel. Figure below shows terminals either move towards each other or move apart,
atypical turnbuckle assembly. increasing or decreasing the cable tension.

Fig.03 (a) Turn Buckle

Fig.03 (b) Turn Buckle

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Category – A/B1 Sub Module 6.10 – Control Cables

One of the terminals has right-hand threads and the other has
left-hand threads, the barrel has matching right- and left-hand
threads internally. The end of the barrel, with left-hand threads
inside, can usually be identified by either a groove or knurl
around the end of the barrel. Barrels and terminals are available
in both long and short lengths. When you install a turnbuckle in
a control system, it is necessary to screw both of the terminals
an equal number of turns into the turnbuckle barrel. It is also
essential that all turnbuckle terminals be screwed into the barrel
at least until not more than three threads are exposed. On initial
installation, the turnbuckle terminals should not be screwed
inside the turnbuckle barrel more than four threads.

After a turnbuckle is properly adjusted, it must be safetied. Prior

to locking, it should be ensured that the end fittings are in safety
(i.e. the internal fitting extends past the inspection hole in the
external fitting) by attempting to pass a hardened pin probe
through the inspection hole.

Fig.03 (C) Turn Buckle

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Category – A/B1 Sub Module 6.10 – Control Cables

SAFETY METHODS TURNBUCKLE ASSEMBLY LOCK WIRING

LOCK-CLIP TURNBARREL ASSEMBLY Double Wrap Method

Lock clip is a bent metal pin. The straight end is installed into a Of the methods using safety wire for safetying turnbuckles, the
slot between the barrel and terminal and the hook loop inserted double wrap method is preferred. Run one end of the wire
into a hole in the barrel. The spring action of the hook loop through the hole in the barrel of the turnbuckle and bend the
prevents the dislodging of the clip. The contact between the ends of the wire towards opposite ends of the turnbuckle. Then
barrel, terminal and the straight end locks the terminal. A typical pass the second length of the wire into the hole in the barrel and
installation procedure is as below: bend the ends along the barrel on the side opposite the first.
Then pass the wires at the end of the turnbuckle in opposite
 Check turnbuckle and terminal grooves, before directions through the holes in the turnbuckle eyes or between
assembly, for possible obstructions, which may prevent the jaws of the turnbuckle fork, as applicable. Bend the laid
proper installation of locking clip. wires in place before cutting off the wrapped wire. Wrap the
remaining length of safety wire at least four turns around the
 Align slot in barrel with slot in cable terminal. shank and cut it off. Repeat the procedure at the opposite end
of the turn buckle. When a swaged terminal is being safetied,
 Insert straight end of lock clip into aligned slots and slide passes the ends of both wires, if possible, through the hole
into place until hook loop is over hole in centre of provided in the terminal for this purpose and wrap both ends
turnbuckle. around the shank as described above.

 Both lock-clip may be inserted in the same barrel hole or If the hole is not large enough to allow passage of both wires,
may be inserted in opposite hole. pass the wire through the hole and loop it over the free end of
the other wire, and then wrap both ends around the shank as
 Verify proper engagement of hook lip in barrel by described.
application slight pressure in disengaging direction.
Single-Wrap Method
Note: do not reuse lock clips after removal
The single-wrap safetying methods described in the following
 Lock-clips are removed by pulling the hook loop out of paragraphs are acceptable but are not the equal of the double
the turn barrel hole with a pair of pliers and sliding the wrap methods.
straight end out of the slot.

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Category – A/B1 Sub Module 6.10 – Control Cables

Pass a single length of wire through the cable eye or fork, or

through the hole in the swaged terminal at either end of the
turnbuckle assembly. Spiral each of the wire ends in opposite
directions around the first half of the turnbuckle barrel so that
the wires cross each other twice. Thread both wire ends -
through the hole in the middle of the barrel so that the third
crossing of the wire ends is in the hole. Again, spiral the two
wire ends in opposite directions around the remaining half of the
turnbuckle, crossing them twice. Then, pass one wire end
through the cable eye or fork, or through the hole in the swaged
terminal. In the manner described above, wrap both wire ends
around the shank for at least four turns each, cutting off the
excess wire. An alternate to the above method is to pass one
length of wire through the centre hole of the turnbuckle and
bend the wire ends toward opposite ends of the turnbuckle.
Then pass each wire end through the cable eye or fork, or
through the hole in the swaged terminal and wrap each wire end
around the shank for at least four turns, cutting off the excess
wire. After safetying, no more than three threads of the
turnbuckle-threaded terminal should be exposed.

PULLEYS AND STOP SEFTEYING Fig.04 Pulleys and stop safetying

Insert wire through hole, make approximately six twists, and cut CABLE GUARDS
excess of wire, bend twisted end flat along side of pulley.
Guard pins are installed in the flanges of pulley brackets to
Note: Twisted end of the safety wire must clear pulley bracket, prevent the cable from jumping out of the pulley. the guard must
adjacent mechanism and guard pins throughout normal travel of be located so it does not interface with the rotation of the pulley.
pulley. A guard pin can be either a bolt or a clevis pin.

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 PIA TRAINING CENTRE (PTC) Module 6 – MATERIALS & HARDWARE
Category – A/B1 Sub Module 6.10 – Control Cables

GUIDES PRESSURE SEALS

Fairleads (rub strips), grommets, pressure seals, and pulleys Control cable Pressure Seals are installed where cables route
are all types of cable guides. They are used to protect control from a pressurized to a non-pressurized area. They fit tightly
cables by preventing the cables from rubbing against nearby enough to prevent air pressure loss, but not so tightly as to
metal parts. They are also used as supports to reduce cable hinder movement of the unit. The seals are mould of synthetic
vibration in long stretches (runs) of cable. or silicon rubber, which are ozone resistance. The silicone
rubber seals are less susceptible to damage caused by bushing
FAIRLEADS pop out, cleaning abuse and aging. When replacement is
necessary, the damaged seal should be replaced according to
Fairleads are used to guide cables in a straight line or change the applicable maintenance directives. Pressure Seal normally
indirection slightly. In no case should the fairlead be permitted do not need lubrication. Removal and Installation are subject to
to deflect a cable more than 30 and it is good practice to install maintenance manual directives.
fairleads so cable deflection is as small as possible, however
consult the applicable specification for proper alignment. Typical Installation procedure

They may be made of a solid piece of material made from non Fill the seal with approved grease as stated in AMM.
metallic material, such as phenolic, micarta, fibre, tuflon, nylon
or a metallic material such as soft aluminium to completely  Lubricate the cable with graphite grease for the length of
encircle cables when they pass through holes in bulkheads or travel within the seal.
other metal parts. Fairleads may be used to maintain cable
alignment, seal openings in bulk heads, whipping and vibration  Bend the seal open and place it on the cable an
in long runs of cable. Split fairleads are made for easy unpressurized side of the bulkhead, with the small end
installation around single cables to protect them from rubbing on of the seal toward the bulkhead
the edges of holes. .
 Insert the seal in the bulkhead so that the bulkhead web
GROMMETS is entirely within the retainer groove of the seal and the
small end of the seal is in the pressurized section.
Grommets are made of rubber, and they are used on small
openings where single cables pass through the walls of
 Install two restraining rings on the seal on the
unpressurized compartments.
pressurized side and one restraining ring on the
unpressurized side of the bulkhead.

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 PIA TRAINING CENTRE (PTC) Module 6 – MATERIALS & HARDWARE
Category – A/B1 Sub Module 6.10 – Control Cables

Fig.05 (a) Split Fairlead

Fig.06 Grommet

Fig.05 (b) Solid Fairlead

Fig.07 Grommet

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 PIA TRAINING CENTRE (PTC) Module 6 – MATERIALS & HARDWARE
Category – A/B1 Sub Module 6.10 – Control Cables

PULLEYS AND CABLE SYSTEM COMPONENTS Besides holding the pulley in the correct position and at the
correct angle, the brackets prevent the cable from slipping out
Pulleys (or sheaves) are grooved wheels used to change cable of the groove on the pulley wheel.
direction and to allow the cable to move with a minimum of
friction. Metallic and non-metallic pulleys are in use. Depending BELL CRANKS
on areas with high temperature and other environmental
conditions, metallic pulleys be installed. For high-tension cable A bell crank is used to transmit force and permit a change in the
system most frequently metal pulleys are installed. Most pulleys direction of the force and also use as the interface between
used on aircraft are made from layers of cloth impregnated with cable system and rigid control systems.
phenolic resin and fused together under high temperatures and
pressures. Aircraft pulleys are extremely strong and durable, SECTORS AND QUADRANTS
and cause minimum wear on the cable passing over them.
Pulleys are provided with grease-sealed bearings, and usually These units are generally constructed in the form of an arc or in
do not require further lubrication. However, pulley bearings may a complete circular form. They are grooved around the outer
be pressed out, cleaned, and re-lubricated with special circumference to receive the cable. The names sector and
equipment. This is usually done only by depot-level quadrant are used interchangeable.
maintenance activities. Pulley brackets made of sheet or cast
aluminium are required with each pulley installed in the aircraft.

Fig.08 Simple Pulley

Fig.09 (a) Sector

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Category – A/B1 Sub Module 6.10 – Control Cables

A quadrant serves the same purpose as a wheel; however, the

quadrant moves through a relatively small arc, perhaps as low
as 1000. Sectors and quadrants are also used as the interface
of cable to rigid control systems.

Fig.09 (b) Quadrant

A quadrant, shown above is often employed at the base of a

control column or control stick to impart force and motion to
cable system.

CABLE TENSION REGULATORS

The cable tension regulator is used in control systems to Fig. 10 (a) Tension Regulator
mechanically compensate for effect of relative length change
resulting from temperature variations, pressurization, and The cable tension regulator consists of a spring loaded
structural deflections. The regulator maintains the cable tension (preloaded) pulley. The slackness caused by relative length
within preselected limits throughout all operating limits. This change is absorbed by the movement of the pulley. As the
results in a lower and more nearly constant control system tension of any spring tends to deteriorate with time cable
function with subsequent increase in cable fatigue life and tension should be check and adjust as required from time to
decrease in cable wear. time. For this reason a scale and a index is provided.
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Category – A/B1 Sub Module 6.10 – Control Cables

Fig.10 (b) Tension Regulator

MEASURING CABLE TENSION

Fig.11 Tensiometer
To determine the amount / load of tension on a cable, a
tensiometer is used. Cable tension is determined by measuring Example:
the amount of force needed to make an offset in the cable
between two steel blocks, called "anvils". A "riser" is pressed Cable size is 1/8-'inch. in diameter, that is a 7 x 19 cable, the
against the cable to form the offset. Several manufacturers ambient temperature is 850 Fahrenheit. Follow the 850 F line
make a variety of tensiometer, each type designed for different upwards to where it intersects the curve for 1/8-inch cable.
kinds of cable, cable sizes and cable tension. To check the
tension of aircraft control cables a tensiometer is used. To use a Extend a horizontal line from the point of intersection to the right
tensiometer a cable is placed between the two blocks on the edge of the chart. The value at this point indicates the rig load in
frame and the riser. The trigger is then pulled to apply pressure pound to establish on the cable. Cable tensiometer shall bear
to the cable and indicate the cable tension. In addition each current calibration dates. Prior to use tensiometer verify the
tensiometer has a calibration chart, which is used to convert dial serviceability.
reading to pound. To use the chart, determine the size of the
cable that is to be adjusted and the ambient temperature. Tensiometer used on nylon-coated cables shall be calibrated
using a “riser” which corresponds to the outside diameter of the
nylon coating.

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Category – A/B1 Sub Module 6.10 – Control Cables

AIRCRAFT FLEXIBLE CONTROL SYSTEMS BOWDEN CONTROL FITTINGS

Normal aircraft cables are only capable of performing a pulling These are the items, which transform a simple length of cable
action, due to their lack of rigidity, so, where a two-directional and conduit into a practical control run. Although they may vary
movement (push/pull) is required it would be necessary either to in design to suit the particular installation, the following are
basic components of a Bowden control system.
employ the use of rods, with the attendant weight penalty, or to
use flexible control systems. The two most common are: HAND LEVER
 Bowden cables Normally, the transmitting end of a control is fitted with a hand
 Teleflex Control Systems lever, which engages with a nipple on one end of the cable. If it
becomes necessary to dismantle a control or to fit a new length
BOWDEN CABLES of cable, the existing cable can be detached from the hand lever
by removing the central screw, taking off the cover plate and
The Bowden-type control consists of a stainless steel wire after slackening, sliding the cable from its groove in the base of
housed in a flexible sleeve, or conduit. The control is intended the lever.
for `pull' operation only, the cable being returned, on release of
the control lever, by a spring. At the transmitting end of a ADJUSTABLE STOP
Bowden control run, the fitting takes the form of a hand lever,
whilst at the receiving end, the cable is connected by an end At the remote, receiving end of the control run, the cable passes
fitting to the component to be operated. The flexible cable is through an adjustable stop and is connected to the component
made up of several strands of stainless steel wire. When a operating lever by the cable nipple. The purpose of the stop is
control run is constructed, the ends of the cable are threaded to provide a means of adjusting the length of the conduit, thus
through brass nipples, which are then soldered or swaged on to altering the tension of the control cable. The stop is simply a
the cable. The surrounding conduit consists of a close-coiled screw engaging with a nut, which is anchored to part of the
wire covered with cotton braiding, and finished with a black component or aircraft structure. The screw is drilled to allow the
waterproof coating. When conduit is cut to length metal caps cable to pass through and its hexagon-shaped head is counter
are fitted on each end to prevent the braiding from un-raveling bored to provide seating for the protective metal cap fitted over
and to reinforce the end of the conduit. On the lengthier control the end of the conduit. Where it is inconvenient, due to the
runs rigid metal tubing is used over the long straight sections, inaccessibility of the component, to fit the adjustable stop at the
while the flexible conduit is used where the bends occur. end of the conduit a double-ended stop may be fitted at an
accessible point in the control run.

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Category – A/B1 Sub Module 6.10 – Control Cables

A safety feature of this type of adjustable stop is the witness

hole drilled in the stop body; the position of the hole indicates
the minimum index thread engagement between the movable
and fixed parts of the stop and is to be checked whenever an
adjustment is made. The screw thread of the adjusting screw
should always be visible or detectable in the hole.

Fig.12 (a) Bowden cable

Fig.12 (b) Bowden type control

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Category – A/B1 Sub Module 6.10 – Control Cables

TELEFLEX CONTROLS THE TELEFLEX CABLE

This is a system, which is installed in many modern aircraft and The cable consists of a high tensile steel core around which is
is used to operate from the cockpit, such components as engine wound either a left-hand or right hand helix wire. The pitch of
and propeller controls, trimming controls, and fuel valves. The the helix wire is designed to engage with gear teeth of the
advantage of this is it is capable of transmitting both push and control units and with the internal attachment points of the
pull motion through a single cable. Like the Bowden system various cable end fittings. There are two types of Teleflex cable
already described, the Teleflex system of remote control in current use the DS23/2 (or No 2) and the DS 380, one being
consists, basically of a flexible transmitting cable operating much stronger than the other.
inside a rigid or flexible metal conduit. Its main advantages over
the Bowden system are that it provides a more accurate and
positive control throughout the range of movement and
furthermore, that the controlled component can be temporarily
locked in any desired position. The basic components of the
Teleflex system are its unique cable, which is wound with a left
hand, or right hand helix wire, a protective conduit and a wide
range of connectors and end fittings. Depending upon the
particular control system and the distance separating the
cockpit controls from the components to be operated, the
control run may or may not be completely Teleflex. In most
instances a single length of Teleflex cable is used, operating on
the pull-push mode. In some installations, where the component
and its cockpit control are a considerable distance apart,
orthodox cable, chains and rigid linkages may be used to bridge
the gap between Teleflex units situated at the extreme ends of
the control run. The figure A shows several examples of
Teleflex control runs and the various fittings used to operate Fig.13 (a) Teleflex control cable
them.

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Category – A/B1 Sub Module 6.10 – Control Cables

SCREWJACK

A cable-operated trimming tab control system usually operates

a screw jack at the receiving end of the system. The screw jack
(see figure 14) is attached by means of a adjustable rod to the
trimming tab. The cable movement rotates the sprocket of the
screw jack to reposition the trimming tab. This unit acts as a
lock, retaining the trimming tab in the desired position until the
cockpit control is next moved.

Fig.13 (b) Teleflex control cable run

Fig.14 Screw Jack

ISO 9001 - 2008 Approved For Training Purpose Only

PTC/CM/B1.1 Basic/M06/01 Rev. 00
6.10 - 18 Mar 2014