AMT628

Lesson 2:

A/C Assembly and Rigging

Prepared by: Mr. Niño Jay R. Francisco

 Control Operating Systems
Cable Systems
• Material
• Cable construction
• Cable designations
 Material

Aircraft control cables are fabricated from

carbon steel or stainless (corrosion resistant)
steel. Additionally, some manufacturers use a
nylon coated 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 workharden 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.
7 x 19 & 7 x 7 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.
 Cable Inspection
Prime areas for critical fatigue areas:
corrosion: • anywhere the cable
• battery runs over, under, or
compartments around a pulley, sleeve,
through a fairlead
• lavatories
• any section where the
• wheel wells cable is flexed, rubbed
• within 1 foot of a
swaged-on fitting
 Cable Inspection
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.
Cable Inspection
 Activity 2.1
• Illustrate and define the following:
– Cable System Installation
• Cable Guides • Turnbuckles
• Pulley Wear Patterns • Cable Connectors
• Cable Tension • Spring-back
• Rigging Fixtures • Push Rods (Control Rods)
• Tension Regulators • Torque Tubes
• Cable Drums
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.
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.
Pulley wear patterns
Cable Guides
• 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.
 Cable Guides
• 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.
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.
– Rigging Tools
• protractors
• rigging fixtures
• contour templates
• Rulers
Aircraft Cable Rigging
1. Positioning the flight control system in neutral
and temporarily locking it there with rig pins
or blocks;
2. Adjusting system cable tension and
maintaining rudder, elevator, and ailerons in
the neutral position;
3. Adjusting the control stops to the aircraft
manufacturer’s specifications.
Cable Tension
• 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 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.
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
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.
Torque Tubes
• Torque tubes are used
in control systems
where an angular or
twisting motion is
needed
 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.