FIGURE 7-5. SAFETY-WIRING PROCEDURES EXAMPLE 1 EXAMPLE 2 EXAMPLE 3 EXAMPLE 4 Examples 1, 2, 3, and 4 apply to all types of bolts, fillister-head screws, square-head plugs, and other similar parts which are wired so that the loosening tendency of either part is counteracted by tightening of the other part. The direction of twist from the second to the third unit is counterclockwise in examples 1, 3, and 4 to keep the loop in position against the head of the bolt. The direction of twist from the second to the third unit in example 2 is clockwise to keep the wire in position around the second unit.
The wire entering the hole in the third unit will be the lower wire, except example 2, and by making a counterclockwise twist after it leaves the hole, the loop will be secured in place around the head of that EXAMPLE 5 EXAMPLE 6 EXAMPLE 7 EXAMPLE 8 Examples 5, 6, 7, & 8 show methods for wiring various standard items, NOTE: Wire may be wrapped over the unit rather than around it when wiring castellated nuts or on other items when there is a clearance problem.
EXAMPLE 9 EXAMPLE 10 EXAMPLE 11 Example 9 shows the Hollow-head plugs shall Correct application of single method for wiring bolts in be wired as shown with wire to closely spaced multidifferent planes. Note that the tab bent inside the ple group.
wire should always be ap- hole to avoid snags and plied so that tension is in _ possible injury to personthe tightening direction. nel working on the engine.
Par 7-126 Page 7-23
FIGURE 7-5A. SAFETY-WIRING PROCEDURES EXAMPLE 12 EXAMPLE 13 Examples 12 and 13 show methods for attaching lead seal to protect critical adjustments.
EXAMPLE 14 EXAMPLE 15 EXAMPLE 16 Example 14 shows bolt Example 15 shows correct Example 16 shows correct wired to a right-angle method for wiring adjustable method for wiring the coubracket with the wire connecting rod pling nut on flexible line to wrapped around the the straight connector bracket. brazed on rigid tube.
EXAMPLE 17 EXAMPLE 18 EXAMPLE 19 EXAMPLE 20 EXAMPLE 21 Fittings incorporating wire lugs shall be wired as shown in Exam- Small size coupling nuts ples 17 and 18. Where no lock-wire lug is provided, wire should shall be wired by wrapping be applied as shown in examples 19 and 20 with caution being the wire around the nut exerted to ensure that wire is wrapped tightly around the fitting. and inserting it through the holes as shown.
Par 7-126 Page 7-24
FIGURE 7-5B. SAFETY-WIRING PROCEDURES EXAMPLE 22 EXAMPLE 23 Coupling nuts attached to straight connectors shall be wired as, shown, when hex is an integral part of the connector.
EXAMPLE 24 Coupling nuts on a tee shall be wired, as shown above, so that tension is always in the tightening direction.
EXAMPLE 25 EXAMPLE 26 Straight Connector (Bulkhead Type) EXAMPLE 27 EXAMPLE 28 Examples 26, 27, and 28 show the proper method for wiring various standard fittings with checknut wired independently so that it need not be disturbed when removing the coupling nut.
7-127. SECURING WITH COTTER PINS.
a. Cotter pins are used to secure such items as bolts, screws, pins, and shafts. Their use is favored because they can be removed and installed quickly. The diameter of the cotter pins Par 7-126 Page 7-25
Par 7-127 Page 7-26 selected for any application should be the largest size that will fit consistent with the diameter of the cotter pin hole and/or the slots in the nut. Cotter pins should not be reused on aircraft.
b. To prevent injury during and after pin installation, the end of the cotter pin can be rolled and tucked.
NOTE: In using the method of cotter pin safetying, as shown in Figures 7-6 and 7-7, ensure the prong, bent over the bolt, is seated firmly against the bolt shank, and does not exceed bolt diameter. Also, when the prong is bent over the nut, ensure the bent prong is down and firmly flat against the nut and does not contact the surface of the washer.
FIGURE 7-6. SECURING WITH COTTER PINS F IGURE 7-7. ALTERNATE METHOD FOR SECURING WITH COTTER PINS 7-
128.–7-139. [RESERVED.]
Par 7-140 Page 7-27 SECTION 8. INSPECTION AND REPAIR OF CONTROL CABLES AND
TURNBUCKLES
7-140. GENERAL. Aircraft control cables are generally fabricated from carbon steel or corrosion-resistant steel wire of either flexible or nonflexible-type construction.
7-141. CABLE DEFINITIONS. The following cable components are defined in accordance with Military Specifications MIL-W-83420, MIL-C-18375, and MIL-W-87161.
a. Wire Center. The center of all strands shall be an individual wire and shall be designated as a wire center.
b. Strand Center or Core. A strand center is a single, straight strand made of preformed wires, similar to the other strands comprising the cable, in arrangement and number of wires.
c. Independent Wire Rope Center (IWRC) 7 by 7. A 7 by 7 independent wire rope center as specified herein shall consist of a cable or wire rope of six strands of seven wires each, twisted or laid around a strand center or core consisting of seven wires.
7-142. FLEXIBLE CABLES.
a. Flexible, preformed, carbon steel, Type I, composition A cables, MIL-W-83420, are manufactured from steel made by the acid-open-hearth, basic-open hearth, or electric furnace process. The wire used is coated with pure tin or zinc.
b. Flexible, preformed, corrosion-resistant, Type I, composition B cables, MIL-W-87161, MIL-W-83420, and MIL-C-18375, are manufactured from steel made by the electric furnace process. (See Table 7-3 and Figure 7-8.)
TABLE 7-3. FLEXIBLE CABLE CONSTRUCTION AND PHYSICAL PROPERTIES MINIMUM BREAKING STRENGTH (Pounds)
NOMINAL
DIAMETER
OF WIRE ROPE CABLE
CONSTRUCTION
TOLERANCE ON
DIAMETER (PLUS ONLY)
ALLOWABLE
INCREASE OF
DIAMETER
AT CUT END MIL-W-83420 COMP A MIL-W-83420 COMP B (CRES) MIL-C-18375 (CRES)
INCHES INCHES INCHES LBS LBS LBS 1/32 3 x 7 0.006 0.006 110 110 3/64 7 x 7 0.008 0.008 270 270 1/16 7 x 7 0.010 0.009 480 480 360 1/16 7 x 19 0.010 0.009 480 480 3/32 7 x 7 0.012 0.010 920 920 700 3/32 7 x 19 0.012 0.010 1,000 920
Par 7-142 Page 7-28 MINIMUM BREAKING STRENGTH (Pounds)
NOMINAL
DIAMETER
OF WIRE ROPE CABLE
CONSTRUCTION
TOLERANCE ON
DIAMETER (PLUS ONLY)
ALLOWABLE
INCREASE OF
DIAMETER
AT CUT END MIL-W-83420 COMP A MIL-W-83420 COMP B (CRES) MIL-C-18375 (CRES)
INCHES INCHES INCHES LBS LBS LBS 1/8 7 x 19 0.014 0.011 2,000 1,760 1,300 5/32 7 x 19 0.016 0.017 2,800 2,400 2,000 3/16 7 x 19 0.018 0.019 4,200 3,700 2,900 7/32 7 x 19 0.018 0.020 5,600 5,000 3,800 1/4 7 x 19 0.018 0.021 7,000 6,400 4,900 9/32 7 x 19 0.020 0.023 8,000 7,800 6,100 5/16 7 x 19 0.022 0.024 9,800 9,000 7,600 11/32 7 x 19 0.024 0.025 12,500 3/8 7 x 19 0.026 0.027 14,400 12,000 11,000 7/16 6 x 19 IWRC 0.030 0.030 17,600 16,300 14,900 1/2 6 x 19 IWRC 0.033 0.033 22,800 22,800 19,300 9/16 6 x 19 IWRC 0.036 0.036 28,500 28,500 24,300 5/8 6 x 19 IWRC 0.039 0.039 35,000 35,000 30,100 3/4 6 x 19 IWRC 0.045 0.045 49,600 49,600 42,900 7/8 6 x 19 IWRC 0.048 0.048 66,500 66,500 58,000 1 6 x 19 IWRC 0.050 0.050 85,400 85,400 75,200 1-1/8 6 x 19 IWRC 0.054 0.054 106,400 106,400 1-1/4 6 x 19 IWRC 0.057 0.057 129,400 129,400 1-3/8 6 x 19 IWRC 0.060 0.060 153,600 153,600 1-1/2 6 x 19 IWRC 0.062 0.062 180,500 180,500
Par 7-142 Page 7-29 FIGURE 7-8. FLEXIBLE CABLE CROSS-SECTION
c. T hese cables are of the 3 by 7, 7 by 7, 7 by 19, or 6 by 19 IWRC construction, according to the diameter as specified in Table 7-3.
(1) The 3 by 7 cable consists of three strands of seven wires each. There is no core in this construction. The 3 by 7 cable has a length of lay of not more than eight times or less than five times the nominal cable diameter.
(2) The 7 by 7 cable consists of six strands of seven wires each, laid around a center strand of seven wires. The wires are laid so as to develop a cable which has the greatest bending and wearing properties. The 7 by 7 cable has a length of lay of not more than eight times or less than six times the cable diameter.
(3) The 7 by 19 cable consists of six strands laid around a center strand in a clockwise direction. The wires composing the seven individual strands are laid around a center wire in two layers. The center core strand consists of a lay of six wires laid around the central wire in a clockwise direction and a layer of 12 wires laid around this in a clockwise direction. The six outer strands of the cable consist of a layer of six wires laid around the center wire in a counterclockwise direction and a layer of 12 wires laid around this in a counterclockwise direction.
(4) The 6 by 19 cable consists of six strands of 19 wires each, laid around a 7 by 7 MIL-C-18375 cable, although not as strong as MIL-W-83420, is equal in corrosion resistance and superior in non-magnetic and coefficient of thermal expansion properties.
7-143. NYLON-COATED CABLES.
a. Nylon-coated cable is made by extruding a flexible nylon coating over corrosion resistant steel (CRES) cable. The bare CRES cable must conform and be qualified to MIL-W-83420. After coating, the jacketed cable must still conform to MIL-W-83420.
b. The service life of nylon-coated cable is much greater than the service life of the same cable when used bare. Most cable wear occurs at pulleys where the cable bends. Wear is caused by friction between strands and between wires. In bare cable, this is aggravated by dirt and grit
Par 7-144 Page 7-30 working its way into the cable and the lubricant working its way out leaving dry, dirty wires rubbing against each other. In long, straight runs of cable, vibration work hardens the wires causing the brittle wires to fracture with eventual failure of the cable.
c. The nylon jacket protects the cable in a threefold manner. It keeps the lubricant from oozing out and evaporating, it keeps dirt and grit out, and it dampens the vibrations, thereby, greatly reducing their effect on the cable.
7-144. NONFLEXIBLE CABLES. (See Table 7-4 and Figure 7-9.) Nonflexible, preformed, carbon steel cables, MIL-W-87161, composition A, are manufactured by the same processes as MIL-W-83420, composition B, flexible corrosion-resistant steel cables. The nonflexible steel cables are of the 1 by 7 (Type I) or 1 by 19 (Type II) construction according to the diameter as specified in Table 7-4. The 1 by 7 cable consists of six wires laid around a center wire in a counterclockwise direction. The 1 by 19 cable consists of a layer of six wires laid around a center wire in a clockwise direction plus twelve wires laid around the inner strand in a counterclockwise direction.
TABLE 7-4. NONFLEXIBLE CABLE CONSTRUCTION AND PHYSICAL
PROPERTIES STRAND TYPE
NOMINAL
DIAMETER
OF WIRE STRAND Inches
TOLERANCE ON
DIAMETER (Plus Only) Inches
ALLOWABLE
INCREASE IN
DIAMETER
AT THE END Inches
CONSTRUCTION MIL-W-87161
MINIMUM BREAK
STRENGTH
COMP A & B Pounds I 1/32 0.003 0.006 1 x 7 185 I 3/64 0.005 0.008 1 x 7 375 II 3/64 0.005 0.008 1 x 19 375 I 1/16 0.006 0.009 1 x 7 500 II 1/16 0.006 0.009 1 x 19 500 II 5/64 0.008 0.009 1 x 19 800 II 3/32 0.009 0.010 1 x 19 1,200 II 7/64 0.009 0.010 1 x 19 1,600 II 1/8 0.013 0.011 1 x 19 2,100 II 5/32 0.013 0.016 1 x 19 3,300 II 3/16 0.013 0.019 1 x 19 4,700 II 7/32 0.015 0.020 1 x 19 6,300 II 1/4 0.018 0.021 1 x 19 8,200 II 5/16 0.022 0.024 1 x 19 12,500 II 3/8 0.026 0.027 1 x 19 17,500
Par 7-144 Page 7-31 FIGURE 7-9. NONFLEXIBLE CABLE CROSS-SECTION 7-
145. CABLE SPECIFICATIONS. Cable diameter and strength data are given in Table 7-3 and Table 7-4. These values are acceptable for repair and modification of civil aircraft.
7-146. CABLE PROOF LOADS. Cable terminals and splices should be tested for proper strength before installation. Gradually apply a test load equal to 60 percent of the cable breaking strengths given in Table 7-3 and Table 7-4, for a period of 3 minutes. Place a suitable guard over the cable during the test to prevent injury to personnel in the event of cable failure.
7-147. REPLACEMENT OF CABLES. Replace control cables when they become worn, distorted, corroded, or otherwise damaged. If spare cables are not available, prepare exact duplicates of the damaged cable. Use materials of the same size and quality as the original.
Standard swaged cable terminals develop the full cable strength and may be substituted for the original terminals wherever practical. However, if facilities and supplies are limited and immediate corrective action is necessary, repairs may be made by using cable bushings, eye splices, and the proper combination of turnbuckles in place of the original installation. (See Figure 7-12, image (c).)
a. Location of Splices. Locate splices so that no portion of the splice comes closer than 2 inches to any fair-lead or pulley. Locate connections at points where jamming cannot occur during any portion of the travel of either the loaded cable or the slack cable in the deflected position.
b. Cutting and Heating. Cut cables to length by mechanical means. The use of a torch, in any manner, is not permitted. Do not subject wires and cables to excessive temperature.
Soldering the bonding braid to the control cable is not permitted.
c. Ball-and-Socket Type Terminals. Do not use ball-and-socket type terminals or other types for general replacement that do not positively prevent cable untwisting, except where they were utilized on the original installation by the aircraft manufacturer.
d. Substitution of Cable. Substitution of cable for hard or streamlined wires will not be acceptable unless specifically approved by a representative of the FAA.
Par 7-148 Page 7-32
7-148. MECHANICALLY-FABRICATED CABLE ASSEMBLIES.
a. Swage-Type Terminals. Swage-type terminals, manufactured in accordance with AN, are suitable for use in civil aircraft up to, and including, maximum cable loads. When swaging tools are used, it is important that all the manufacturers’ instructions, including “go and no-go” dimensions, be followed in detail to avoid defective and inferior swaging. Observance of all instructions should result in a terminal developing the full-rated strength of the cable. Critical dimensions, both before and after swaging, are shown in Table 7-5.
TABLE 7-5. STRAIGHT-SHANK TERMINAL DIMENSIONS (CROSS REFERENCE AN TO MS: AN-666 TO MS 21259, AN-667 TO MS 20667, AN-668 TO MS 20668, AN-669 TO MS 21260) Before swaging After swaging Cable size (inches) Wire strands Outside diameter Bore diameter Bore length Swaging length Minimum breaking strength (pounds) Shank diameter* 1/16 7 x 7 0.160 0.078 1.042 0.969 480 0.138 3/32 7 x 7 .218 .109 1.261 1.188 920 .190 1/8 7 x 19 .250 .141 1.511 1.438 2,000 .219 5/32 7 x 19 .297 .172 1.761 1.688 2,800 .250 3/16 7 x 19 .359 .203 2.011 1.938 4,200 .313 7/32 7 x 19 .427 .234 2.261 2.188 5,600 .375 1/4 7 x 19 .494 .265 2.511 2.438 7,000 .438 9/32 7 x 19 .563 .297 2.761 2.688 8,000 .500 5/16 7 x 19 .635 .328 3.011 2.938 9,800 .563 3/8 7 x 19 .703 .390 3.510 3.438 14,400 .625 *Use gauges in kit for checking diameters.
(1) Terminals. When swaging terminals onto cable ends, observe the following procedures.
(a) Cut the cable to the proper length allowing for growth during swaging. Apply a preservative compound to the cable ends before insertion into the terminal barrel.
NOTE: Never solder cable ends to prevent fraying since the presence of the solder will greatly increase the tendency of the cable to pull out of the terminal.
(b) Insert the cable into the terminal approximately 1 inch, and bend toward the terminal, then push the cable end entirely into the terminal barrel. The bending action puts a kink or bend in the cable end and provides enough friction to hold the terminal in place until the
Par 7-148 Page 7-33 swaging operation can be performed. Bending also tends to separate the strands inside the barrel, thereby reducing the strain on them.
NOTE: If the terminal is drilled completely through, push the cable into the terminal until it reaches the approximate position shown in Figure 7-10. If the hole is not drilled through, insert the cable until the end rests against the bottom of the hole.
FIGURE 7-10. INSERTION OF CABLE INTO TERMINAL (
c) Accomplish the swaging operation in accordance with the instructions furnished by the manufacturer of the swaging equipment.
(d) Inspect the terminal after swaging to determine that it is free from the die marks and splits, and is not out-of-round. Check for cable slippage in the terminal and for cut or broken wire strands.
(e) Using a “go no-go” gauge or a micrometer, check the terminal shank diameter as shown in Figure 7-11 and Table 7-5.
(f) Test the cable by proof-loading it to 60 percent of its rated breaking strength.
Par 7-148 Page 7-34 FIGURE 7-11. GAUGING TERMINAL SHANK AFTER SWAGING (
2) Splicing. Completely severed cables, or those badly damaged in a localized area, may be repaired by the use of an eye terminal bolted to a clevis terminal. (See Figure 7-12, image (a).) However, this type of splice can only be used in free lengths of cable which do not pass over pulleys or through fair-leads.
FIGURE 7-12. TYPICAL CABLE SPLICES (
3) Swaged Ball Terminals. On some aircraft cables, swaged ball terminals are used for attaching cables to quadrants and special connections where space is limited. Single shank terminals are generally used at the cable ends, and double shank fittings may be used at either the end or in the center of the cable. Dies are supplied with the swaging machines for attaching these terminals to cables by the following method.
(a) The steel balls and shanks have a hole through the center, and are slipped over the cable and positioned in the desired location.