CHAPTER 16

FIXED-WING FLIGHT CONTROL SYSTEMS

INTRODUCTION
A flight control system is either a primary or secondary system. Primary flight controls
provide longitudinal (pitch), directional (yaw), and lateral (roll) control of the aircraft.
Secondary flight controls provide additional lift during takeoff and landing, and decrease
aircraft speed during flight, as well as assisting primary flight controls in the movement
of the aircraft about its axis. Some manufacturers call secondary flight controls auxiliary
flight controls. All systems consist of the flight control surfaces, the respective cockpit
controls, connecting linkage, and necessary operating mechanisms.
The systems discussed in this course are representative systems. Values such as
tolerances, pressures, and temperatures provide better understanding of the text
material. It is important to remember to bear in mind that these values are for
representative units and are not accurate for all systems. When actually performing the
maintenance procedures discussed, the current maintenance instruction manual (MIM)
should be used.

LEARNING OBJECTIVES
When you have completed this chapter, you will be able to do the following:
1. Identify the types of flight control systems.
2. Recognize the functions of the three primary flight control systems (longitudinal,
directional and lateral).
3. Recognize the procedures for primary flight control system maintenance to
include trouble analysis, rigging/alignment, and operational checks.
4. Recognize the maintenance procedures for cable and push-pull rod (rigid control)
systems.
5. Identify the various functions of secondary flight control systems. Identify
maintenance procedures associated with each function.
6. Recognize the procedures for removal and installation of wings, stabilizers, and
flight control surfaces.
7. Identify the methods used to balance flight control surfaces and airframe/control
surface alignment checks.

FLIGHT CONTROL SYSTEMS

A flight control system includes all the components required to control the aircraft about
each of the three flight axes. A simple flight control system may be all mechanical; that
is, operated entirely through mechanical linkage and cable from the control stick to the
control surface. Other more sophisticated flight control systems may use electrical or
hydraulic power to provide some or all of the muscle in the system. Still others
combine all three methods.
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MECHANICAL (UNBOOSTED) FLIGHT CONTROL SYSTEM

A typical, simple, mechanical (unboosted) flight control system is the one used in flight
training aircraft. The flight control surfaces (ailerons, elevators, and rudder) are moved
manually through a series of push-pull rods, cables, bell cranks, sectors, and idlers.
Figure 16-1 schematically illustrates the elevator portion of a mechanical (unboosted)
flight control system. The control stick is mounted in such a way that it can pivot
backwards and forwards on its mounting pin. The control stick is connected to a pushpull rod attached to its lower end. As the stick is moved fore and aft, it causes the
elevators to be deflected proportionately.
The push-pull tube (rod) that connects to
the lowest point of the control stick extends
aft to the pulley. Figure 16-1 shows that the
function of the pulley changes the direction
of the push-pull action from fore and aft to
up and down. The second push-pull tube
(rod) connects the forward cable sector and
the pulley, and causes the sector to rotate
according to the stick movements.

Figure 16-1 Mechanical

(unboosted) flight control system.

From the forward sector, the cables extend

back through the aircraft to the aft cable
sector. In Figure 16-1, the graphic of the
cable length is shown smaller than the actual size only so the remaining essential
components of the elevator control system may all be shown in one drawing.

The aft sector is essentially the same as the forward sector, and it acts as a slave to the
forward sector. Cables from the forward sector attach to the aft edges of the aft sector.
A push-pull tube from the aft sector connects to the elevator fitting assembly.
The elevator fitting assembly, commonly called the elevator horn, is built onto the
elevators and extends outward (and usually downward) from the elevator surface at
right angles to the plane of rotation and the chord line of the elevator surfaces. As the
fitting assembly is moved fore or aft, the elevators are moved up or down.

HYDRAULIC (POWER BOOST) FLIGHT CONTROL SYSTEM

Power-boosted flight control systems are used on high-speed jet aircraft. Aircraft
traveling at or near supersonic speeds have such high airloads imposed upon the
primary control surfaces that it is impossible for a pilot to control the aircraft without
power-operated or power-boosted flight control systems. In the power-boosted system,
a hydraulic actuating cylinder is built into the control linkage to assist the pilot in moving
the control surface. The power-boost cylinder is still used in the rudder control system of
some high-performance aircraft; however, the other primary control surfaces use the full
power-operated system. In the full power-operated system, the force necessary to
operate the control surface is supplied by hydraulic pressure. Each movable surface is
operated by a hydraulic actuator (or power control cylinder) built into the control linkage.

PRIMARY FLIGHT CONTROL SYSTEMS

Different aircraft manufacturers call units of the primary flight control system by a variety
of names. The types and complexity of control mechanisms used depend on the size,
speed, and mission of the aircraft. A small or low-speed aircraft may have cockpit
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controls connected directly to the control surface by cables or pushrods. Some aircraft
have both cable and a pushrod system. See Figure 16-1. The force exerted by the pilot
is transferred through them to the control surfaces. On large or high-performance
aircraft, the control surfaces have high pressure exerted on them by the airflow. It is
difficult for the pilot to move the controls manually. As a result, hydraulic actuators are
used within the linkage to aid the pilot in moving the control surface. Figure 16-2 shows
a mechanically-controlled, hydraulically-assisted system. Because these systems
reduce pilot fatigue and improve system performance, they are now commonly used.
Such systems include automatic pilot, automatic landing systems, and stability
augmentation systems.
Navy specifications require two separate hydraulic systems for operating the primary
flight control surfaces. Current specifications call for an independent hydraulic power
source for emergency operation of the primary flight control surfaces. Some
manufacturers provide an emergency system powered by a motor-driven hydraulic
pump. Others use a ram-air-driven turbine for operating the emergency system pump.

Figure 16-2 Hydraulically-powered elevator control system.

LONGITUDINAL CONTROL SYSTEMS

Longitudinal control systems control pitch about the lateral axis of the aircraft. Many
aircraft use a conventional elevator system for this purpose. Aircraft that operate in the
higher speed ranges usually have a movable horizontal stabilizer.
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Elevator Control System

The elevator control system, shown in Figure 16-2, is typical of many conventional
elevator systems. It operates by the control stick in the cockpit and is hydraulically
powered.
The operation of the elevator control system starts when the control stick is moved fore
or aft. The movement of the stick transfers through the control cables to move the
elevator control bell crank. The bell crank transmits the movement to the hydraulic
actuating cylinder through the control linkage. The hydraulic actuating cylinder operates
a push-pull tube, which deflects the elevators up or down.
The elevator system uses forward and aft counterweights. The counterweights induce a
load on the control stick during pitching and vertical acceleration and prevent pilotinduced oscillations through the elevator controls. If the gravity force is increased on the
counterweights, the induced load tends to return the control stick to the neutral position.
Viscous dampers on the counterweight assemblies retard control stick movement to
prevent overcontrol. Overcontrol could cause airframe overstress.
The elevator forward counterweight serves to help recenter the control stick when a
heavy gravity load pulls against the airframe. The forward counterweight and damper
assembly is in the nose wheel well forward of the control stick from the cockpit. See
Figure 16-3. The assembly consists of a counterweight, eddy current damper, and a
crossover tube. The crossover
tube is interconnected between
the control columns and the
counterweight. The damper is
located at the pivot point of the
counterweight and restricts fast
movement of the counterweight.
The aft counterweight and
damper assembly work with the
forward assembly to overcome
the heavy pull of gravity and
retard the chance of overcontrol.
See Figure 16-4. This assembly
is installed in the fuselage,
forward and below the
horizontal stabilizer.
The aft assembly consists of a
counterweight, eddy current
damper, and a slide valve load
relief pushrod assembly. The
counterweight connects to the
elevator control bell crank and the
damper.

Figure 16-3 Elevator forward

counterweight and damper assembly.

The elevator power mechanism changes the mechanical movement of the control stick
to the hydraulic operation of the elevator. See Figure 16-5. The mechanism is in the aft
section of the aircraft directly below the horizontal stabilizer. As in the aileron power
system, the mechanism consists of a hydraulic power cylinder, control valves, linkage,
and hydraulic piping.
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Figure 16-4 Elevator aft counterweight and damper assembly.

When the elevator controls are operated, the control valves port hydraulic pressure to
the power cylinder. The hydraulic pressure extends or retracts the cylinder piston to
move the push-pull tubes. The push-pull tubes deflect the elevators. The control valves
are two separate valves connected in tandem by linkage. One valve is supplied
hydraulic pressure by the utility hydraulic system. The other valve is supplied hydraulic
pressure by the flight control hydraulic system. The power cylinder has dual hydraulic
chambers to work from each control valve. Each hydraulic system simultaneously
supplies 3000 pounds per square inch (psi) hydraulic pressure to the power
mechanism. If one hydraulic system fails, the other system supplies enough pressure to
operate the mechanism. If both hydraulic systems fail, the cylinder disconnects by
pulling the manual flight control (MAN FLT CONT) handle in the cockpit. The controls
work manually through the linkage of the mechanism to operate the elevators.
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The load-feel bungee, shown in Figure 16-5, provides an artificial feel to the control
stick. The bungee acts as a centering device for the elevator system. Control stick
movement compresses the spring in the bungee. Releasing the control stick causes the
compressed spring to return the stick to neutral. The bungee also adds a gearing effect
between the horizontal stabilizer and the elevators. When the stabilizer is trimmed to
give an aircraft nose up condition, the bungee action adds nose up attitude on the
elevator. With the stabilizer trimmed nose down, the bungee action adds nose down
attitude on the elevator.

Figure 16-5 Elevator power mechanism.

Horizontal Stabilizer Control System (Single Axis)

Various aircraft manufacturers identify the horizontal stabilizer control system by
different names. On one aircraft, it is called a unit horizontal tail (UHT) control system.
On another aircraft, it is called the stabilizer control system. Regardless of the variation
in nomenclature, these systems function to control the aircraft pitch about its lateral
axis.
The horizontal stabilizer control system shown in Figure 16-6 is representative of an EA6B aircraft. The slab-type stabilizer responds to fore-and-aft manual input at the control
stick. It responds to automatic flight control system (AFCS) electrical signals introduced
at the stabilizer actuator.
Pilot signals are conveyed through bell cranks and pushrods and a trim mechanism to
the input linkage of the stabilizer actuator. A trim switch on the control stick grip
provides a means of setting stabilizer trim. Stabilizer trim deflection is from -6 down to
+1 up. Stabilizer trim is displayed by the stabilizer trim indicator located on the pilots
lower instrument panel. See Figure 16-7.
The position of the stabilizer is shown on the integrated position indicator located on the
left side of the pilots instrument panel. When the stabilizer is in the clean
configuration, the STAB window of the indicator shows the word CLEAN. When the
stabilizer is in the dirty configuration, the window shows a picture of a stabilizer.
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Figure 16-6 Stabilizer control system.

The stabilizer actuator (Figure 16-7) is a tandem type actuator powered by both flight
and combined system pressures. It contains a power valve shuttle, two tandemmounted power pistons, a servo ram, an electrohydraulic servo valve, a lockout
actuator, and parallel and series mode solenoid valves. The actuator can operate in any
of three modesmanual, series, or parallel. Figure 16-7 contains information to help
understand the three modes of operation.
MANUAL MODE In this mode, the pilot input alone controls the power valve. Inputs
are transmitted through linkage to the mechanical input lever. The auxiliary lever is
locked in neutral by the servo ram centering springs, causing the mechanical input lever
to rotate about its pivot point, moving the power shuttle valve. As the valve shuttle is
displaced from neutral, a valve error is established, and pressure is ported to the
actuating pistons. The pressure moves the pistons and the attached stabilizer in
proportion to the input.
A mechanical feedback is transmitted through the differentiating lever, the load-relief
bungee, and the mechanical input lever back to the power valve shuttle, causing it to
return to the neutral position. For a constant velocity pilot input, a small constant valve
error is established, and the stabilizer moves at a constant speed. When the pilot input
stops, the power shuttle valve is returned to neutral, and the stabilizer stops until a new
input is introduced.

16-7

Figure 16-7 Stabilizer control system schematic.

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SERIES MODE In this mode, input signals from the AFCS may be used
independently or combined with manual input to control stabilizer movement. The series
mode solenoid valve is energized, porting flight system hydraulic pressure to the
electrohydraulic servo valve. Input signals from the AFCS amplifier are applied to the
coils of a torque motor in the servo valve, regulating flow from the valve to the servo
ram.
The servo ram is connected to the auxiliary lever. Movement of the lever moves the
mechanical input lever floating-pivot point. This movement causes mechanical input
lever rotation about the manual input point and moves the power shuttle valve, causing
a valve error.
A linear transducer, mounted on the servo ram centerline, provides electrical feedback
signals to the AFCS. Mechanical feedback is provided by the differentiating lever, as in
the manual mode. When operating in the series mode, control surface displacement is
not reflected at the control stick.
PARALLEL MODE In this mode, stabilizer movement is controlled by input signals
from the AFCS alone. Both series and parallel mode solenoid valves are energized.
Flight system pressure is ported to the electrohydraulic servo valve and the mechanical
input lockout piston. Fluid pressure stabilizes the lockout piston and holds the
mechanical input lever.
The transducer mounted on the servo ram provides an electrical signal feedback to the
AFCS. There is no mechanical feedback, since the mechanical input is locked.
Additional electrical signal feedback is provided by a transducer, which is mechanically
linked to the stabilizer actuating arm. In the parallel mode, the control stick follows the
motion of the stabilizer. Should the pilot desire to override the AFCS, he/she can
overpower the lockout actuator with a stick force of 24 pounds.
Stop bolts are attached to the control stick pedal to limit fore-and-aft stick movement.
The eddy current damper dampens out any rapid fore-and-aft stick movement.
All joints between the pushrods and bell cranks or idlers contain self-aligning bearings
to compensate for any misalignment during operation and airframe deflections in flight
that might cause binding.
Artificial feel is provided by the artificial-feel bungee. The bungee consists of two
springs, which have different spring constants. The stick force caused by the bungee is
proportional to stick displacement. At near neutral, the bungee provides a high stick
force that decreases a short distance from neutral and gradually increases with the
amount of stick displacement.
The electric trim actuator is mechanically linked to the artificial-feel bungee, and varies
the neutral position of the bungee to provide longitudinal trim of the aircraft. The
actuator consists of one high-speed and one low-speed motor, a gearbox, a brake, a
ball detent clutch, and a threaded power screw. The actuator is manually controlled
through inputs from the trim switch on the control stick grip. When the stabilizer is in
automatic trim, the actuator receives inputs from the AFCS. High speed is used during
manual trim and low speed during automatic trim.
The stabilizer shifting mechanism, shown in Figure 16-7, consists of a shift sector and
its linkage, plus cable that runs from the flap drive gearbox and the rudder cam shift
mechanism. A spin recovery cylinder is also attached to the shifting mechanism, and
provides an alternate method of shifting the stabilizer and rudder from the clean
configuration to the dirty, or increased throw configuration.
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In normal operation, when flaps are extended, a cable running from a drum on top of the
flap drive gearbox to the sector assembly of the shifting mechanism rotates the sector.
Linkage connecting the sector assembly and the control stick linkage is shifted. Linkage
shifting increases control stick travel. Stabilizer down travel is increased to a 24-degree
maximum. A cable is also connected from the sector assembly to the rudder cam stop
shifting mechanism, which increases rudder travel from 4 to 35 degrees each side of
neutral.
The pilot, at his/her option, may obtain increased stabilizer and rudder throw by
actuation of the spin recovery assist switch, eliminating the necessity of lowering the
flaps. This action ports hydraulic pressure through the spin recovery selector valve and
its flow regulators and check valve to the spin recovery cylinder, causing it to extend
and shift the mechanism in the same manner as provided by the cable action.
The two nonbypass-type filters in the system protect the intricate valving mechanisms of
the actuator from contamination, and are vitally important to proper stabilizer operation.
They are checked with the requirements listed in the maintenance requirements card
deck, and should not be overlooked when troubleshooting stabilizer system
malfunctions.
The stabilizer power package, used on various Navy aircraft, is linked to the approach
power compensator system (APC). This system aids the pilot in maintaining optimum
angle of attack for approach and landing. An APC potentiometer is mechanically linked
to the power package, and provides electrical inputs to the APC system to compensate
for changes in pitch attitude required during landing approaches. The APC system
regulates the throttle position to provide the engine thrust required to establish and
maintain the desired angle of attack. The potentiometer provides inputs relative to the
position of the horizontal stabilizer.

Horizontal Stabilizer (Stabilator) Control System (Double Axis)

Because of the complexity and interrelationships of the flight control systems of newer
model aircraft, only a brief description of a representative stabilizer/stabilator control
(pitch/roll axis) (F/A-18) follows. This system allows pitch about the aircrafts lateral axis
and roll about the aircrafts longitudinal axis.
The stabilator is a control surface located on either side of the tail section of the aircraft.
In flight, the stabilator deflects symmetrically to produce pitch motion and
asymmetrically to produce roll motion. The maximum surface deflection of each
stabilator is from 10.5 degrees trailing edge down to 24 degrees trailing edge up.

LATERAL CONTROL SYSTEMS

Lateral control systems control roll about the longitudinal axis of the aircraft. Several of
the different system arrangements used by aircraft manufacturers are discussed, as
well as general maintenance requirements for primary flight control systems.

Aileron Control System

The aileron control system, shown in Figure 16-8, is equipped with a power mechanism
that provides hydraulic power to operate the ailerons. If hydraulic power fails, the
mechanism can be disconnected, placing the system in complete manual operation.
Movement of the aileron control system begins when the control stick in the cockpit
moves left or right. When the stick is moved, cables connected to the bell crank in the
control stick housing are moved to operate the sector on the power mechanism. With
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the actuation of the sector, the power mechanism operates, transferring the movement
to the mechanical linkage that operates the ailerons.
The aileron power mechanism consists of two control valves, a dual-chambered
hydraulic power cylinder, cable sectors, and a system of latches and related cranks.
Linkage connects the control valves in tandem. The flight control hydraulic system
powers one valve, and the other is powered by the utility hydraulic system.

Figure 16-8 Hydraulically-powered aileron control system.

The power cylinder is a single tandem cylinder, composed of four chambers with pistons
connected to a common shaft. Each of the two control valves operates on that portion of
the power cylinder to which it is associated. Both hydraulic systems operate
simultaneously, and each delivers 3000 psi pressure to the mechanism. If one hydraulic
system should fail, the other system will supply enough power to operate the ailerons at
reduced hinge movement.
16-11

When the control stick moves, the control cables move the power mechanism sector.
Through linkage, the sector operates the control valves, which direct hydraulic fluid to
the power cylinder. The cylinder actuating shaft, which is connected to the power crank
through a latch mechanism, operates the power crank. The crank moves the push-pull
tubes, which actuate the ailerons. In the event of complete hydraulic power failure, a
handle in the cockpit may be pulled to disconnect the latch mechanisms from the
cylinder. When the handle is pulled, it places this particular aileron system in complete
manual operation. In manual operation, the power cylinder is disconnected from the
cable sector, causing the control stick to manually move the ailerons at a reduced rate.
The lateral control system incorporates a load-feel bungee, which serves a dual
purpose. See Figure 16-9. The bungee provides an artificial feel and centering device
for the aileron system. It is interconnected between the aileron system and the aileron
trim system. Energizing the aileron trim actuator moves the bungee operating the power
mechanism, which repositions the aileron control system to a new neutral position.
In normal operation of the control system, when the control stick is actuated left or right,
the power mechanism compresses the bungee. The compressed bungee returns the
stick to the neutral position upon release of the stick.

Figure 16-9 Aileron power mechanism.

Flaperon Control System

The flaperon control system, shown in Figure 16-10, is an example of lateral control
provided by an electrohydraulic-mechanical flaperon system. The system includes an
inboard and outboard flaperon for each wing and three actuators (a single flaperon
autopilot actuator and a flaperon power actuator in each wing).
Control stick movementleft or rightraises the respective two flaperons, while the
opposite two remain flush with the wing. Full throw of the control stick by the pilot
causes the inboard flaperon to rise 49 1/2 degrees and the outboard flaperon to rise 53
degrees. In flight, the flaperon can also be positioned by the AFCS. Control stick
movements are transferred through the pushrod and bell crank system to the flaperon
autopilot actuator. Mechanical outputs from this actuator are conveyed to a gearing
mechanism, at which point linkage to the left and right wing flaperon power actuators
16-12

separates. The gearing mechanism transmits movement to the left or right flaperon,
while the opposite flaperon is maintained flush with the wing. When the flaperon pop-up
cylinder is actuated, the gearing mechanism transmits pop-up motion to each wing
flaperon power actuator.
The semiautomatic flaperon pop-up device aids in reducing ground roll during landing.
The pop-up system is activated by the pilot placing the flaperon pop-up switch in the
ARM position. All flaperons (four) will then automatically pop up approximately 41
degrees when the aircraft weight is on the landing gear and the throttles are retarded.

Figure 16-10 Flaperon control system.

A mechanical interlock device prevents damage to the flaperons during folding of the
wings. When the wings are folding, the flaperons cannot be extended. In addition, the
folding operation cannot start unless the flaperons are flush with the wings.
16-13

A wing-fold interlock prevents flaperon pop-up after the wings are folded. A fail-safe
spring returns the flaperons to the flush position in case the combined hydraulic system
or electrical system should fail.
The eddy current damper links mechanically to a bell crank in the flaperon control
linkage. See Figure 16-11. It dampens any rapid left or right control stick movement by
producing an opposing force proportional to the speed at which the stick is moved. The
damper contains permanent magnets, a rotating copper disc, a gear train, and a clutch
assembly. Control stick motion rotates the clutch and gear train, which, in turn, rotates
the copper disc. The copper disc is sandwiched in the air gap between the six
permanent magnets and a flux plate. As the copper disc revolves, the magnetic field
between the magnets and the flux plate is disturbed, causing an opposing force (eddy
currents) that tries to stop the disc. The opposing force is proportional to the speed of
the rotating disc and to the speed of stick movement. The clutch will slip at a force of
275 to 325 inch-pounds to prevent control stick binding if the damper jams.
The flaperon autopilot actuator
is powered by the flight
hydraulic system and transmits
mechanical movement to the
flaperon power actuators. The
flaperon power actuators are
tandem type and powered by
the combined and flight
hydraulic systems. They are
capable of operating on only
one system if one system
should fail.
The artificial-feel bungee
provides an initial control stick
preload and increased force feel
over the full range of stick
displacement. The
electromechanical actuator
provides lateral trim, which
varies the neutral position of the
artificial-feel bungee. Trim is set
by the switch on the control stick
grip. The pilot may read the
mechanical flaperon trim indicator
on the control stick.

Figure 16-11 Eddy current damper.

AUTOPILOT ACTUATOR The flaperon autopilot actuator (Figure 16-12) contains an

electrohydraulic servo valve, actuator pistons, solenoid valve, transducer, series link,
and series-link rod. It indirectly controls flaperon movement in response to mechanical
movements from the pilot. It receives electrical inputs from the AFCS. The actuator can
operate in two modesmanual or series.
In manual mode, the solenoid valve is de-energized and no fluid is ported to any part of
the actuator. The actuator piston rod is free to idle. The series-link cylinder acts as a
rigid link that transfers input lever motion to the output lever.

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In series mode, the solenoid

valve energizes and ports
pressure to the servo valve.
Pressure from the servo valve
drives the actuator pistons
together. This pressure causes
the pistons and the rod to act as
one piece. When the servo
valve is at null, pressures in the
piston end chambers are equal.
Electrical signals from the AFCS
cause the electrohydraulic servo
valve to differ the pressures in
the end chambers. The signal
provides the working force for
the actuator. The actuator piston
rod drives the output lever.
Pressure at the series link
compresses a lock spring,
unlocking the series link. The
actuator can stroke the pilotcommanded piston. When the
Figure 16-12 Flaperon autopilot actuator.
pilot moves the input link, relative
motion between input and output
causes the transducer to send a signal to the AFCS amplifier. The signal combines with
other flight stability signals, and the resultant signal operates the servo valve. The AFCS
can be overridden by the pilot applying a stick force of 25 pounds.
SYSTEM ACTUATORS The flaperon system actuators directly control the flaperon
movement in response to mechanical movement from the autopilot actuator. The
actuator (Figure 16-13) consists of two tandem-mounted power pistons and a power
valve shuttle. Mechanical inputs are introduced through the load-relief (safety) bungee

Figure 16-13 Flaperon hydraulic actuator schematic.

16-15

and the valve input lever to the power valve shuttle portion of the actuator. The inputs
cause a valve error and the porting of hydraulic pressure to the power pistons. As the
flaperon moves, mechanical linkage attached to the actuator tends to null this valve
error. The power valve shuttle returns to neutral. The flaperons remain in the selected
position until new mechanical inputs are received from the pilot or the AFCS.

DIRECTIONAL CONTROL SYSTEMS

Directional control systems provide a means of controlling and/or stabilizing the aircraft
about its vertical axis. Most Navy aircraft use conventional-type rudder control systems
for this purpose.
The rudder control system, shown in Figure 16-14, is operated by the rudder pedals in
the cockpit. The system is powered hydraulically through the rudder actuator. In the
event of hydraulic power failure, the hydraulic portion of the power system is bypassed.
The system is then powered mechanically through control cables and linkage. An
aerodynamic irreversible hydraulic system is employed in the rudder system. To
accomplish trim, the complete rudder surface is repositioned.
The actuation of the rudder pedals causes the control cables to move a cable sector
assembly. The cable sector, through a push-pull tube and linkage, actuates the power
mechanism. The rudder actuator deflects the rudder to the left or to the right.
A load-feel bungee is connected to the push-pull tube, and is compressed when the
push-pull tube is actuated. When the pedals are released, the compressed bungee
returns the system to the neutral position. In the event of hydraulic failure, a slip link
allows movement of the control valve linkage to port hydraulic fluid from the actuating
cylinder. Then the cylinder can be mechanically driven by pilot input during manual
operation. In manual operation, surface travels are reduced by the lost-motion effect of
the slip link.
The load-feel bungee is also the connecting link from the rudder trim actuator to the
power mechanism. When the trim actuator is operated, the bungee repositions the
power mechanism. The power mechanisms deflect the rudder for nose-left and noseright trim. Figure 16-14 is a functional schematic of the operation of the rudder control
system.
The rudder power mechanism is actuated when movement from the cable sector
assembly is transmitted through the push-pull tube to the primary control crank. The
crank is connected to the load-feel bungee, a slip link to the secondary crank, a link and
spring to the pedal position transmitter, and a link to the control valve of the actuator
assembly. The actuator assembly consists of an electromechanical dual input control
valve, a rudder surface position transmitter, and a power cylinder. When the mechanism
linkage is actuated, the control valve directs hydraulic pressure from both the utility
hydraulic system and the surface control hydraulic system to the power cylinder. The
valve directs the hydraulic pressure to two separate chambers in the cylinder. Each
chamber has a separate piston that is mounted on as common shaft. The shaft is
connected to a push-pull tube that moves the rudder. The actuator assembly normally
operates from both hydraulic systems. If one system should fail, the other supplies
sufficient pressure to operate the rudder with some lost hinge movement. In the event
both hydraulic systems fail, the slip link will allow movement of the control valve linkage
to port hydraulic fluid from the actuating cylinder.
When the AFCS is engaged, the actuator initiates the movement of the rudder system
through the electrical impulse received by the control valve from the surface control
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amplifier. The pedal position transmitter and the rudder surface transmitter function only
when the AFCS is engaged.

Figure 16-14 Rudder control system.

Rudder pedal movement mechanically transfers to the left and right rudder servo
cylinders through the rudder feel assembly, the yaw summing network, and the
reversing network. These servo cylinders, normally powered by the flight and combined
hydraulic power systems, move the rudders. If both hydraulic systems fail, the rudder
servo cylinders automatically receive hydraulic power from the backup hydraulic system
(flight control backup module). The rudder trim switch on the EXT ENVIRONMENT/
THROTTLE control panel enables trimming of the aircraft in yaw. Setting the switch to L
or R provides a trim-left or trim-right input, respectively, to the rudder trim actuator. The
actuator provides rudder movement through the rudder feel assembly, the yaw
summing network, the reversing network, and the rudder servo cylinders.
16-17

ELECTRONIC PRIMARY FLIGHT CONTROL SYSTEMS

All electronic flight control servo cylinders are controlled by electrical impulses from
computers. The computers compare all data received from the pilots control stick,
airspeed indicator, altimeter, angle of attack, and other sensors. They configure all flight
controls for best flight characteristics and performance of the aircraft. An example of the
electrical portion that replaces the mechanical linkages system is shown in Figure 1615. Each electric component is duplicated two to four times throughout the system.
Provisions are made to detect a failed component or sensor and remove its influence
from the system. These multiple redundant paths ensure that a single failure has no
effect, and multiple failures have minimum effect on controls.

Figure 16-15 Electronic flight controls.

16-18

PRIMARY FLIGHT CONTROL SYSTEM MAINTENANCE

Maintenance of primary flight control systems consist of periodic maintenance, trouble
analysis, removal and replacement of flight control components, rigging and adjustment
of the flight controls, and operational and alignment checks of the system. Most primary
flight control component maintenance is limited to removal and replacement of the
component. Check the applicable maintenance instruction manual (MIM) for proper
repair procedures.

MALFUNCTION OF PRIMARY FLIGHT CONTROLS

There have been many cases reported in which pilots have found flight controls jammed
while the aircraft was on the ground. Because the controls were freed by excessive
pressure before an inspection could be made, the causes for the jammed condition
could not be found. No positive corrective action was taken before the aircraft were
released for flight. In some cases, accidents occurred on such aircraft shortly after
takeoff.
When an aircraft experiences a control discrepancy during flight, a thorough
investigation should be conducted immediately. In cases where aircraft have safely
returned from a flight during which a control discrepancy was experienced, a thorough
investigation is necessary. This investigation must be made before further flight. All
parts of the affected control system should be inspected for proper rigging, clearances,
and potential causes for interferences. All sealed units that are suspect must be
replaced. Primary cause factors that should not be overlooked include maneuvers that
have exceeded the operational design of the control systems. Hydraulic system
contamination, corrosion and/or distorted or disconnected linkage may have caused the
problem. Inadequate lubrication and external contamination in the form of preservative
compounds, such as grease combined with dirt and dust, may have caused the
problem. An increasing number of flight control system malfunctions are related to
system contamination, and this ever-important aspect of hydraulic system maintenance
should be given the attention it deserves. Checking of system filters and contamination
inspection of suspected systems are within the capability of organizational activities. If a
system is found to be contaminated, the source of contamination must be eliminated
and the system cleaned by recycling or flushing in accordance with instructions
provided in the appropriate MIM. Contaminated components must be replaced as
necessary to restore proper system operation.
Disposition instructions for removed hydraulic components vary with the production
status of the aircraft model. Diligent care must be taken to retain the component in the
as-is condition, with no change in adjustment, disassembly, or cleaning. If the
component has slides or pistons that are jammed, no attempt to free them should be
made.
The aircraft must not be released for further flight until the cause has been determined
and corrected. If it is not readily apparent why the component malfunctioned, a
Hazardous Material Report/Engineering Investigation request should be submitted. If
the discrepancy cannot be duplicated or cause determined, an appropriate entry must
be made in the Miscellaneous History section of the aircraft logbook.

TROUBLE ANALYSIS
Trouble analysis of the flight control systems requires the same systematic approach as
any other hydraulic system. In many instances, malfunctions are written off with
incorrect corrective actions on the maintenance action form (MAF). Corrective action

16-19

labeled Could Not Duplicate or Replaced Suspected Component often results in a

repeat discrepancy or loss of the aircraft. The cause of the malfunction should be
thoroughly determined.
Trouble analysis of the flight controls requires complete cooperation with other work
centers that are involved in the operational checkouts. Most flight control systems have
electrical input, as well as mechanical input from autopilot, AFCSs, or stabilizing
augmentation systems. Inputs occasionally cause erratic and/or misleading aircraft flight
characteristics. Flight characteristics can be misinterpreted, and the resultant write-up in
the aircraft discrepancy portion of the aircraft flight record book may be vague or
misleading. To gain further insight regarding the vague discrepancy, the maintenance
crew should question the pilot who experienced the malfunction.
Isolating the mechanical and hydraulic portion of the flight control system from systems
that provide automatic input will serve to pinpoint the actual problem area. The MIM
provides troubleshooting/trouble analysis aids and appropriate schematics. The MIM
allows for the systematic checking out of the system and associated components. In
some MIMs these aids are general in nature and limited to the more common causes of
failure. Several MIMs combine the operational checkout procedures with trouble
analysis aids. Steps of the checkout procedures are performed in rigid sequence, and
any discrepancy must be corrected before proceeding to the next step.
A thorough knowledge of the system involved and consistent use of the mechanical and
hydraulic schematics will expedite the trouble analysis process. Excessive time required
for troubleshooting should be documented on a separate VIDS/MAF. This will separate
the actual repair time from troubleshooting time. Separate VIDS/MAFs provide more
accurate input information to the Maintenance Data Reporting System.
When the malfunction has been determined and corrected, the complete system should
be operationally tested. Testing should occur in all modes of operation to verify system
integrity. Quality assurance inspection during repair progression, testing, and of the end
product is a must. When prescribed in the applicable periodic maintenance information
cards, test flight requirements are mandatory. The test flight pilot should be briefed by a
qualified quality assurance representative regarding the nature of the discrepancy and
corrective action taken.

POWER ACTUATOR MAINTENANCE

Maintenance of primary flight control surface power actuators is generally beyond the
capability of organizational maintenance-level activities. Removal of hydraulic
components and associated linkages on the power actuators will destroy critical
adjustments. Readjustment requires special tooling, jigs, and other equipment available
only at intermediate- or depot-level maintenance facilities. When a power mechanism
has been isolated as the cause for flight system malfunction, it should be removed. It
should then be forwarded, along with the accompanying paperwork, to the supply
activity for disposition.

RIGGING AND OPERATIONAL CHECKS

Procedures for rigging flight control systems vary with each type of aircraft. Applicable
MIMs provide a list of tools, special equipment, preparatory considerations, and step-bystep instructions for rigging systems.

16-20

On some aircraft, the system rigging divides into a series of sections, such as the
control stick, control mechanism, power control actuator, and cables. If only that section
of the system has been affected, it may not be necessary to rig the complete system.
Pushrods, bell cranks, and idlers are installed so that end play is eliminated. They
should be free to rotate without binding. Cables should be inspected for corrosion,
broken strands, and proper tension. Correct cable tension is necessary to obtain proper
response of the control surface. Low cable tension may cause sluggishness, free play,
and flutter of the control surface. Excessively high cable tension causes increased
system friction and may result in damage to pulleys, bell cranks, or the cable itself.
A variety of fixtures, pins, and blocks are available for performing alignment and rigging
checks on flight control systems. Neutralizing (locking the controls and linkage in a
predetermined position), as described in the aircraft MIM, is required during the
alignment and adjustment of the flight controls.
NOTE
Installation and removal of the fixtures, pins, and blocks
should not require excessive force. Slight pressure is
permissible because of the system tolerance and
temperature effects on the aircraft. Always refer to the MIM
for tolerance information.
Figure 16-16 shows the throwboard used to check the travel of a horizontal stabilizer.
The throwboard is held in place by two wingnut attachment screws. Before tightening
these screws, the throwboard should be positioned so that the alignment hole at the
zero-degree mark is in line with the alignment screw in the aircraft fuselage.

Figure 16-16 Stabilizer throwboard installation.

16-21

Control surface throws may be measured in degrees and minutes or inches and
fractions. Figure 16-17 provides an example of an aileron throw indication in degrees ()
and minutes (). The protractor scale is calibrated in 30-minute increments. The indicator
reads 3 degrees 40 minutes obtained as follows:
1. Read 3 degrees 30 minutes, as shown on the protractor scale.
2. Since the indication mark does not fall directly on the calibrated mark of the
protractor scale, look for the closest
alignment of indicator and protractor
calibrated marks in the direction of
indicator travel. Read the value from
the 0-minute mark on the indicator to
the closest alignment, which, in this
example, is 10 minutes.
3. Add 3 degrees 30 minutes and 10
minutes to get the true indication of 3
degrees 40 minutes up travel.
Each mode of operation that was affected
by alignment or malfunction and
subsequent repair action must be
operationally checked, and the success of
the checkouts verified by a qualified quality
assurance representative. All maintenance,
including alignment, adjustment,
operational testing, and component
replacement, must be accomplished in
accordance with the instructions provided in
the applicable MIM.

Figure 16-17 Aileron throw

protractor indications.

CONTROL SYSTEMS MAINTENANCE

Cable and rigid control systems maintenance includes inspection to discover actual and
potential defects, servicing with lubricants, and correction of reported malfunctions and
defects. Malfunctions that occur in control systems include frayed and loosened
bearings, unnatural tightness (binding), and broken or damaged components.

CABLE CONTROL SYSTEM

Cables have many advantages. They will not sever readily under sudden strains.
Cables are stronger than steel rods or tubing of the same size. They flex without setting
(permanent deformation) and can be led easily around obstacles by using pulleys.
Cables can be installed over long distances (such as in large aircraft) without a great
degree of sagging or bending. Vibration will not cause them to harden, crystallize, or
break, as may be the case with push-pull control rods. Because of the great number of
wires used in cables, cable failure is never abrupt, but is progressive over periods of
extended use. When used for the manipulation of a unit in a control system, they are
usually worked in pairsone cable to move the unit in one direction, the other to move
it in the opposite direction. Weight is saved in spite of a second cable because the
push-pull rod needed to cause a similar movement in a unit would have to be quite thick
and heavy (comparatively speaking). Since cables are used in pairs and are stretched
taut, very little play is present in system controls, and no lost motion exists between the
16-22

actuating device and the unit. Consequently, cable-controlled units respond quickly and
accurately to cockpit control movement. In some simple cable systems, only one cable
is used, and a spring provides the return action.

Cable Maintenance
Cable control systems require more maintenance than rigid linkage systems; therefore,
they must be inspected more thoroughly. Cables must be kept clean and inspected
periodically for broken wires, corrosion, kinking, and excessive wear.
INSPECTION Broken wires are most apt to occur in lengths of cable that pass over
pulleys or through fairleads. On certain periodic inspections, cables are checked for
broken wires by passing a cloth along the length of the cable. Where the cloth snags the
cable is an indication of one or more broken wires.

WARNING
Your bare hands should NEVER be used to check for
broken wires. Using your bare hands to check for broken
wires could result in personal injury.

Tests have proven that control cables may have broken wires and still be capable of
carrying their designated load. However, any 7 x 19 cable that shows more than six
broken wires in any 1-inch length, or any 7 x 7 cable that shows more than three broken
wires in any 1-inch length, must be replaced. A maximum of three broken wires per inch
is allowable in the length of cables passing over pulleys, drums, or through fairleads.
Figure 16-18 shows how to determine if a cable is serviceable.
Corrosion, kinking, and excessive wear should be given particular attention during cable
inspection. If a cable is found to be kinked or badly worn, it should be replaced, even
though the number of broken wires is less than that specified for replacement. If the
surface of the cable is corroded, the tension on the cable should be relieved and the
cable carefully untwisted to visually inspect the interior. Any corrosion on the interior
strands of the cable constitutes failure, and the cable must be replaced. If no internal
corrosion is detected, loose external corrosion should be removed with a clean dry rag
or fiber brush and the specified preservative compound applied.
NOTE
Do not use metal wool or solvents to clean installed cable.
Metal wool will embed tiny dissimilar metal particles and
create further corrosion problems. The use of solvents will
remove the internal cable lubricant and allow the cable
strands to abrade and further corrode.
When a cable is found to be unserviceable and a spare cable is not available, an exact
duplicate of the damaged cable may be prepared. This will involve cutting a length of
16-23

cable to the proper length,

attaching the necessary end
fittings, and testing the assembly.
To determine the proper length to
which the new cable will be cut, the
overall length of the finished cable
assembly should first be
determined. This may be
accomplished by measuring the
old cable assembly or by reading
the measurements provided in the
MIM for the aircraft concerned.
REPLACEMENT Replacing
cables in the aircraftespecially
those routed through inaccessible
spacescan be difficult. One
method is to secure a snaking line
to the cable to be replaced,
remove the pulleys from the
Figure 16-18 Determining serviceable
brackets, and pull out the old cable
cable.
while pulling the snaking line into the
cable system run at the same time.
The new cable assembly can be attached to the snaking line, and the snaking line
pulled out to pull the new assembly into place. The pulleys should be replaced and the
new cable attached in the system.

Quick Disconnects
Quick disconnects are used in cable systems that may require frequent disconnecting.
One type of quick disconnect is made with steel balls swaged to the ends of the cable,
slipped into a slotted bar, and secured with spring-loaded sleeves on each end of the
bar. Figure 16-19 shows the procedures for disconnecting and connecting this type of
quick-disconnect fitting.

RIGID CONTROL SYSTEMS

Rigid control systems transfer useful movement through a system of push-pull rods, bell
cranks, walking beams, idler arms, and bungees. The simplest rigid control system may
consist of push-pull rods and bell cranks only.

Push-pull Rods
Push-pull rods are rigid tubes equipped with eye fittings at each end or with a clevis
fitting at one end and an eye fitting at the other. The eyes contain a pressed-in bearing.
The rods are generally hollow and neck down to a smaller diameter at each end where
the fittings are attached. One or both of the fittings are screwed into the necked portion
of the rod, and are held in place by locknuts. When only one stem is adjustable, the
stem of the other eye fitting is riveted into the neck at its end of the rod. A hole is drilled
into the threaded neck of a push-pull rod for inspection to ensure that the stem has
engaged a safe number of threads. The stem must be visible through the hole. Pushpull rods are generally made in short lengths to prevent bending under compression
loads and vibration.
16-24

Figure 16-19 Quick-disconnect procedures.

Push-pull rod linkage must be inspected closely for dents, cracks, and bent tubing.
Damaged tubes may have to be replaced. End fittings are checked for damage, wear,
and security of attachment. Worn or loose fittings must be replaced.
When replacing a damaged push-pull tube, the correct length of the new tube may be
obtained by loosening the check nut and turning the end fitting in or out, as necessary.
When the push-pull tube has been adjusted to its correct length, the check nut must be
tightened against the shoulder of the end fitting. Normally, only one end of a push-pull
rod is adjustable. The adjustable end has a hole (witness hole) drilled in the rod. The
hole is located at the maximum distance the base of the end fitting is allowed to be
extended. If the threads of the end fitting can be seen through this hole, the end fitting is
within safe limits.
16-25

When attaching push-pull rods with ball bearing end fittings, the attaching bolt and nut
must tightly clamp the inner race of the bearing to the bell crank, idler arm, or other
supporting structure. Nuts should be tightened to the torque values listed in the aircraft
MIM.
After installing a new push-pull rod in a flight control system, the control surface must be
checked for correct travel. Procedures for accomplishing this are described later in this
chapter. If the travel is incorrect, the length of the push-pull rod must be readjusted.

Bell Cranks and Walking Beams

Bell cranks and walking beams are levers used in rigid control systems to gain
mechanical advantage. They are also used to change the direction of motion in the
system when parts of the airframe structure do not permit a straight run. They are often
used in push-pull tube systems
to decrease the length of the
individual tubes, and thus add
rigidity to the system.
A bell crank has two arms that
form an angle of less than 180
degrees, with a pivot point
where the two arms meet. The
walking beam is a straight beam
with a pivot point in the center.
Bell cranks and walking beams
are mounted in the structure in
much the same way as pulley
assemblies. Brackets, or the
structure itself, may be used as
the point of attachment for the
shaft or bolt on which the unit is
mounted. Examples of a bell
crank and a walking beam are
shown in Figure 16-20. The two
are similar in construction and
use. The names bell crank and
walking beam are often used
interchangeably.

Figure 16-20 Bell crank and walking

beam.

Idler Arms
Idler arms are levers with one end attached to the aircraft structure so it will pivot and
the other end attached to push-pull tubes. Idler arms are used to support push-pull
tubes and guide them through holes in structural members.

Bungee
Bungees are tension devices used in some rigid systems that are subject to a degree of
shock or overloading. They are similar to push-pull rods, and perform essentially the
same function except that one of the fittings is spring-loaded in one or both directions.
That is, a load may press so hard (compression) against the fittings that the bungee
spring will yield and take up the load. This protects the rest of the rigid system against
damage. The internal spring may also be mounted to resist tension rather than
16-26

compression. An internal double-spring arrangement will result in a bungee that protects

against both overtension and overcompression.

TROUBLESHOOTING
When the cause and remedy for a reported malfunction in a control system are not
immediately obvious, it may be necessary to troubleshoot the system. Most aircraft
MIMs provide troubleshooting charts that list some of the more common malfunctions in
a system. Each discrepancy is accompanied by one or more probable causes, and a
remedy is prescribed for each cause. The troubleshooting charts are organized in a
definite sequence under each possible trouble, according to the probability of failure and
ease of investigation. To obtain maximum value from these charts, they should be used
systematically according to the aircraft manufacturers recommendations.
Since most aircraft use some form of electrical control or hydraulic boost in their flight
control systems, maintenance of these systems must include the related electrical
circuits and hydraulic systems. Although an AE or AM is generally called upon to locate
the correct electrical or hydraulic troubles respectively, the circuits can be inspected for
loose connections, continuity checks performed, and minor troubleshooting of the
hydraulic system accomplished.

RIGGING AND ADJUSTING

The purpose of rigging and adjusting a primary flight control system is to ensure neutral
alignment of all connecting components and to regulate and limit the surface deflection
in both directions.

Special Tools
Each aircraft has a set of special tools for flight control maintenance that may include
rigging fixtures, pins, blocks, throwboards, and protractors. Other common equipment,
such as micrometers, pressure gauges, push-pull gauges, feeler gauges, tensiometers,
and calipers may also be required. These are usually maintained in the tool room and
checked out when needed.
TENSIOMETER The tensiometer is an instrument used in checking cable tension.
Tension is the amount of pulling force applied to the cable. The amount of tension
applied in a cable linkage system is controlled by turnbuckles in the system.
A tensiometer is a precision cable tension measuring device, but it has limitations and
can be awkward to use. It is inaccurate for cable tension less than 30 pounds. When
tension measurements are taken, the instrument must not be pressed against any part
of the aircraft; it cant be pushed or pulled against the cable; and the cable must not be
pressed against fairleads or any part of the aircraft. Any one of these actions may lead
to inaccurate measurements. A major advantage of cable linkage is its minimal space
requirement and the ease in which it can be routed around, through, and behind aircraft
structures and components. This can make access difficult and the tensiometer
awkward or difficult to use. Adequate clearance for the tensiometer is necessary. All
tensiometers must be certified by a calibration laboratory for accuracy at least once a
month.
One type of tensiometer is shown in Figure 16-21. This instrument works on the
principle of measuring the amount of force required to deflect a cable a certain distance
at right angles to its axis. The cable to be tested is placed under the two blocks on the
instrument, and the lever assembly on the side of the instrument is pulled down.

16-27

Movement of this lever pushes up on the center block, called a riser. The riser pushes
the cable at right angles to the two clamping points. The force required to do this is
indicated by a pointer on the dial. Different risers are used with different size cables.
Each riser carries an identifying number, and is easily inserted in the instrument.
Each tensiometer is supplied with a calibration table to convert the dial readings into
pounds. One of these calibration tables is shown in Figure 16-21. For example, if the
pointer on the dial indicates 48 with a No. 2 riser and a 3/16-inch diameter cable, the
actual tension on the cable is 100 pounds. With this particular instrument, the No. 1 riser
is used with 1/16-, 3/32-, and 1/8-inch diameter cables.

Figure 16-21 Cable tensiometer and chart.

CAUTION
The calibration table applies to the particular instrument
only, and cannot be used with any other. For this reason,
the calibration table is secured inside the cover of the box
in which the instrument is kept. The chart is serialized with
the same serial number as the instrument. Using the
calibration table from another instrument will result in
inaccurate reading.

During the adjustment of turnbuckles, the calibration table must be used to obtain the
desired tension in a cable. For example, to obtain a tension of 110 pounds in a 3/16inch diameter cable, the No. 2 riser is inserted in the instrument and the number
opposite 110 pounds is read from the calibration table. In this case, the number 52 is
shown in the example in Figure 16-21. The turnbuckle is then adjusted until the pointer
indicates 52 on the dial.
16-28

NOTE
Tensiometer readings should not be taken within 6 inches
of any turnbuckle, end fitting, or quick disconnect.
In some cases, the position of the tensiometer on the cable may be such that the face of
the dial cannot be seen by the operator. In such cases, after the lever has been set and
the pointer moved on the dial, the brake-lever rod on the top of the instrument should be
moved to the closed position. This locks the pointer in place. Then, the lever assembly
should be released and the instrument removed from the cable with the pointer locked
in position. After the reading has been noted, the brake-lever rod should be moved to
the open position, and the pointer will return to zero.
The tensiometerlike any other measuring instrumentis a delicate piece of
equipment and should be handled carefully. Tensiometers should never be stored in a
toolbox.
Temperature changes must be considered in cable-type systems since this will affect
cable tensions. When a temperature is encountered that is lower than that at which the
aircraft was rigged, the cables become slack because the aircraft structure contracts
more than the cables. When temperatures higher than that at which the aircraft was
rigged are encountered, the aircraft structure expands more than the cables and tension
is increased.
The cables in any cable linkage system are rigged according to a temperature chart that
is contained in the applicable MIM. This chart will give the proper tensions for the
various temperature changes above and below the temperature at which the system
was rigged.
RIG PINS Rig pins are used in rigging control systems. Figure 16-22 shows a rigging
pin kit used on one of the Navys aircraft.
As shown in this figure, rig pins may come
in various sizes and shapes and may be
designed for one or many installations. The
specific MIM should be used for use and
selection of rig pins.
THROWBOARDS Throwboards are
special equipment used on specific aircraft
for accurate measurement of control
surface travel. See Figure 16-23. Each
throwboard has a protractor scale that
indicates a range of travel in degrees. Zero
degrees normally indicates the neutral
position of the control surface. When the
throwboard is mounted and the control
column or stick is in neutral, the trailing
edge of the control surface should be
aligned to zero. As the control column or
stick is moved to its extreme limits, the
corresponding degree indication can be read
on the throwboard. If the travel of the control

Figure 16-22 Rigging pin set.

16-29

surface is out of limits, the

cables, push-pull rods, and
control limit stops should be
adjusted to obtain the correct
control surface travel. When
inspecting and rigging control
surfaces, the specific MIM
should be consulted.

Cable and Rigid Control

System Rigging
In the elevator system shown in
Figure 16-24, rigging begins at
the aft sector. The aircraft
manufacturer has determined
the position of the aft sector
when it is in the neutral position.
A rig pin hole has been
furnished in the sector and a
mating hole in the adjoining
structure. The three rig pins are
shown in Figure 16-24. With the

Figure 16-23 Typical throwboard used for

rigging rudder and rudder tab controls.

Figure 16-24 Typical elevator flight control system.

16-30

rig pin inserted in the aft sector and in the aircraft structure, the sector is held firmly in
the neutral position. With the sector in this position, the push-pull tube connecting the
sector with the elevator fitting assembly is adjusted to position the elevators to the
neutral position.

CABLE FABRICATION
Control cables are fabricated mostly of extra flexible, preformed, corrosion-resistant
steel. Control cables vary from 1/16 to 3/8 of an inch in diameter. Cables 1/8 of an inch
and larger are composed of 7 strands of 19 wires each. Cables 1/16 and 3/32 of an inch
in diameter are composed of 7 strands of 7 wires each.

Cable-Cutting Equipment
Cutting cables may be accomplished by any convenient method except an oxyacetylene
cutting torch. The method of cutting usually depends upon the tools and machines
available. If a cable tends to unravel, the ends may be sweat soldered or wrapped with
a strip of tape prior to cutting.
Small diameter cable may be cut satisfactorily with a pair of heavy-duty diagonal
cutters, side cutters, or a pair of wire nippers. Best results are obtained if the cutting
jaws are held perpendicular to the cable during the cutting operation. Cables up to 3/32
of an inch in diameter may be cut in one operation by this method. Larger cables may
require two or more cuts. When cutting
large diameter cables, the end of the
cutting blade should be used, and only a
few strands should be cut at a time.
The most satisfactory method of cutting
cables is with a cable-cutting machine that
has special jaws to accommodate various
sizes of cable. See Figure 16-25. To use
this machine, the cable should be
positioned in the proper diameter groove
and the cable held firmly within 2 inches of
the cutting blades. The cable should be
held at right angles to the cutting blades
and the operating handle pulled down
sharply.
A cold chisel and a soft metal block may
also be used for cutting cables. This method
should be used only as a last resort because
this method will cause the cable ends to fray.

Figure 16-25 Cable-cutting

machine.

Swaging Equipment
After the cable is cut, the next step in making up an aircraft cable is attachment of the
terminals. Most terminal fittings are swaged onto the ends of control system cables.
Swaging is essentially a squeezing process in which the cable is inserted into the barrel
of the terminal. Then pressure is applied by dies in a swaging machine to compress the
barrel of the terminal tightly around the cable. The metal of the inside walls of the barrel
is molded and cold flowed by force into the crevices of the cable. Figure 16-26 shows
16-31

two types of hand-swaging tools. The one

in the upper part of the illustration is
mechanically operated, while the lower one
is pneumatically operated.
When preparing to swage a terminal, the
cable should be cut to the required length
allowing for the elongation (increase in
length due to stretching) of the fitting that
will occur during the swaging process. The
amount of elongation will vary with the type
and size of fitting used. Therefore, the
elongation must be taken into account
making up any cable. The Structural
Hardware Manual, NAVAIR 01-1A-8,
provides elongation data for all types and
sizes of fittings.
The cable end should be cut square and
Figure 16-26 Hand-swaging
clean and all strands should remain in a
toolsmechanical and
compact group, as shown in Figure 16-27. A
pneumatic.
drop or two of light lubricating oil should be
placed on the cable end. Then, the end should be inserted into the terminal to a depth
of about 1 inch. The cable should be bent toward the terminal, straightened back to the
normal position, and then the cable should be pushed all the way into the terminal
barrel. This bending process puts a kink in the cable end to hold the terminal in place
until the swaging operation is completed. It also tends to separate and spread the
strands inside the terminal barrel and reduces the strain caused by swaging.
Both of the hand-swaging tools shown in Figure 16-26 are widely used by naval aircraft
maintenance activities. When operating the mechanical swaging tool, the proper size
pair of dies should be placed on the swaging tool. The terminal will then be located in
the jaws of the tool, as shown in Figure 16-28, and the swaging operation performed. As
the dies rotate, they pull the terminal from
right to left. The dies compress the terminal
barrel onto the cable, and swaging occurs.
Rotation of the dies is accomplished by
opening and closing the handles.
After completion of swaging and removal of
the fitting from the swaging tool, the outside
diameter of the shank should be measured
with a micrometer or with the gauge
furnished with the swaging outfit to
Figure 16-27 Inserting cable in
determine whether or not the terminal has
swage terminal.
been swaged sufficiently. This may be
determined by checking the measurement
with the applicable cable terminal table in NAVAIR 01-1A-8.
The pneumatic swaging tool shown in Figure 16-26 is a lightweight portable unit
designed to precision swage the metal of a terminal into the interstices (crevices) of the
cable strands. The swager may be mounted on a baseplate and used on a bench, or it
can be taken to the job. When the swaging tool is taken to the location of the job, it may
be held by hand or cradled in the operators arm.
16-32

The pneumatic swaging kit has several

different sizes and types of dies used for
swaging ball-and-sleeve terminals and for
cutting and trimming cable. Like the
mechanical swaging tool, the dies come in
matched sets and must be used together.
The dies are installed by inserting either die
through the yoke opening into the die
cavity. The keyway should be down and the
shank facing the rear of the swager. The
first die should be slid back in order to clear
the opening for the insertion of the mating
die. The second die should be inserted with
the shank facing forward.
The following step-by-step procedures are
recommended for setting up the pneumatic
swaging tool:

Figure 16-28 Locating the

1. Connect the air supply to the foot
terminal in the swaging tool.
valve. For efficient operation, use an
inlet air line with at least a 3/8-inch
inside diameter and a minimum of 90 pounds of line pressure.

2. Connect the swager air line to the foot valve.

3. Clean the dies; remove any steel particles that may have adhered to the die
cavity; and apply a light film of oil to the entire die.
4. Insert the dies in the swaging tool as previously described.

WARNING
Do not insert or remove dies until the air supply that is
connected to the swager is shut off. Failure to secure the
air supply connected to the swager could result in personal
injury to the operator.
With the pneumatic tool set up for use, the following steps should be performed while
swaging terminals to cables:
1. Position the terminal on the cable, using the old cable as a pattern, or follow the
instructions given in the applicable technical directives. When you are using a
ball terminal, a minimum of 1 1/2 inches of cable must extend beyond the ball to
allow room for holding and turning the terminal during swaging. The excess is
trimmed, if necessary, after the swaging operation. When you use MS 20667
terminals, 1/4 inch of cable must extend through the terminal. On all other
terminals, the cable is bottomed (inserted all of the way into the terminal).
2. Each terminal is cleaned with a suitable solvent, and then coated with a light oil.
3. With the terminals positioned in the cavity of the forward die, slide the rear die to
its forward position using the slot provided in the yoke for the index finger.
16-33

NOTE
To prevent damage to terminal or cable during the swaging
cycle, maintain light pressure on the cable toward the front
of the swager. This holds the terminal and cable firmly in
the forward die cavity.

4. Depress the foot valve firmly and rotate the cable back and forth in 180-degree
arcs or complete revolutions. The length of time the foot valve is held depends
upon the type and size of fitting being swaged. The proper time can be found by
referring to the chart supplied with the pneumatic swaging tool. If the terminal will
not rotate, stop swaging immediately; rotate the terminal 90 degrees, and start
swaging again.
5. Release the foot pedal to stop swaging, and remove the terminal from the
swaging tool for inspection. If the diameter is oversize or the terminal surface is
too rough, repeat the operation.
If swaged terminals are to be used on both ends of the cable, recheck the overall length
of the cable. Trim it, if necessary, prior to installing the second terminal. Make certain
that all additional fittings and accessories, such as cable stops and fairleads, are slipped
onto the cable in the proper sequence. The other terminal may then be swaged, using
the same procedures as used for the first one.

Proof (Load) Testing Cables

All newly fabricated cables should be tested for proper strength before they are installed
in aircraft. The test consists of applying a specified tension load on the cable for a
specified number of minutes. The proof loads for testing various size cables are given in
tables contained in NAVAIR 01-1A-8. Proof loading will result in a certain amount of
permanent stretch being imparted to the cable. This stretch must be taken into account
when fabricating cable assemblies. Cables that are made up slightly long may be
entirely too long after proof loading.

SECONDARY FLIGHT CONTROL SYSTEMS

Secondary flight controls, such as wing flaps and speed brakes, are usually
hydraulically operated and either mechanically or electrically controlled. The design of
these flight controls slows the aircraft in flight and provides additional lift and stability.
These design features greatly increase the versatility and performance of the aircraft.

CONVENTIONAL WING FLAP SYSTEM

A flap is a hinged or pivoted section that forms the rear portion of an airfoil used to vary
the effective chamber. Wing flaps in their most commonly used form are hinged
sections of the trailing edges of a wing. Flaps extend from the fuselage to the inboard
side of the aileron. Wing flaps are connected to the main wing by various kinds of
hinges and slides.
The flap system discussed in this section is a representative system. The number of
flaps will vary according to the size of the aircraft. The components may have different
16-34

names, depending on the manufacturer, but the operational theory remains the same.
This system consists of a series of six flapsthree on the trailing edge of each wing.
They raise and lower in the conventional manner by a hydraulically-actuated linkage of
bell cranks, pushrods, and idlers. The flap control lever in the cockpit mechanically
controls the system. The lever connects by conventional and teleflex cables to the
hydraulic actuating mechanism. An emergency system is provided for lowering the flaps
by operating a hand pump if the primary system malfunctions. The flap system has a
position indicator and several safety devices to prevent lowering of the flaps while the
wings are folded, or folding of the wings while the flaps are lowered.
The movement of the flap selector lever in the cockpit sets the flaps in motion.
Movement of the selector lever operates a cable quadrant to which a set of conventional
control cables attach. These cables connect to another sector just forward of the main
wing beam. A teleflex cable, also attached to this aft sector, and a spring-loaded
pushrod on the main flap actuating bell crank connect to the two ends of a short floating
arm installed on the hydraulic selector valve lever. Figure 16-29 is a drawing of the
cylinder, linkage, and selector valve installation. Reference to the index numbers on this
drawing is made in the following description of the operation of the flap control system.
When the flap handle in the cockpit moves down, the upper end of the floating arm (9)
pulls to the left, pivoting at its lower end and moving the selector valve lever to the left.
This action directs pressure from the hydraulic system to the flap actuating cylinder (1).

Figure 16-29 Flap cylinder, linkage, and selector valve installation.

The cylinder piston rod extends and lowers the flaps by rotating the flap drive bell crank
(3) in a clockwise direction. As the bell crank moves, the lower end of the floating arm
moves to the right by the spring-loaded pushrod (7). This action pivots the arm at its
upper connection to the sector pushrod and returns the selector valve to neutral,
stopping the action of the system.
Moving the flap handle upward reverses the foregoing procedure by pushing the
selector valve lever to the right, directing hydraulic pressure to the retract side of the
cylinder piston and raising the flaps. The follow-up rod then moves the lower end of the
floating arm to the left and returns the selector valve to neutral. The valve will not return
16-35

completely to neutral, maintaining pressure in the flap cylinder and ensuring positive
locking of the flaps in the up position.
The spring mechanism in the follow-up rod normally does not function. The spring
mechanism is provided only as a safety feature, permitting actuation of the flap drive
crank by emergency hydraulic power if the selector valve becomes jammed.
The flap hydraulic system consists primarily of the selector valve and the actuating
cylinder. See Figure 16-30. The selector valve is a four-way, poppet-type valve. The
poppets operate in pairs to direct pressure to one side of the cylinder while opening the
other side to reservoir return.
The cylinder is double acting and internally locked in the retracted (flaps up) position.
The cylinder also has an integral shuttle valve (built into the mounting end cap). This
provides for the separation between the normal and emergency hydraulic pressure
lines. An adjustable terminal on the piston rod provides for length variation.

Figure 16-30 Wing flap system.

When the cylinder extends, the internal lock is hydraulically released, allowing the
piston to move. When the flaps raise, the hydraulic pressure on the lock is relieved, and
a compression spring engages the lock mechanism with the piston when the cylinder
becomes fully retracted.
A relief valve installed in the normal flap down line provides a blowup feature that
prevents overloading of the flaps and flap linkage. This valve is adjustable to a narrow
range between full flow and reseat, providing a controlled blowup feature. As the flaps
16-36

blow up, the flap air load decreases, gradually reseating the relief valve and preventing
further flap retraction.
In the landing configuration, the flaps are partially or fully down. Safety microswitches
prevent folding of the wings until the flaps are in the full up position. To reduce the
recovery interval aboard ship, the aircraft wings must be folded and the aircraft taxied
forward as quickly as possible. A wing flap retraction shutoff valve installed in the flap
down line expedites flap retraction. This normally closed, solenoid-operated, hydraulic
shutoff valve energizes only when the weight of the aircraft is on the wheels. When
energized, the valve permits return fluid to bypass the restrictor in the down pressure
line, permitting fast retraction of the flaps and quicker wing-fold operation.
A relief valve is located in the pressure line ahead of the flap normal system selector
valve. The valve relieves pressure from thermal expansion, which may build up on the
inlet side of the selector valve.
An emergency system for flap down operation includes a selector valve and an
emergency dump valve. The emergency flap down selector valve is usually in the
NORMAL position. In this position, the cylinder emergency line to return is vented.
When moving the emergency selector valve handle to the FLAPS DOWN position, the
flaps can be lowered by operating the hand pump. This action directs hand pump
pressure through the integral shuttle valve to the actuating cylinder. At the same time,
the emergency dump valve is actuated. The emergency dump valve opens the up side
of the cylinder directly to return and closes off its normal return line through the selector
valve.
Once actuated, the dump valve must be reset manually to restore the system to normal
operation. The emergency selector valve handle must first be returned to the NORMAL
position, relieving the pressure in the emergency line. The dump valve should then reset
by pushing the button on the dump valve. The button is marked PUSH TO RESET. With
pressure in the normal system, the normal selector handle must be placed in the down
position to reset the integral shuttle valve. The flaps will then rise using normal control,
provided the flap up portion of the system is operative. There are no provisions for
emergency retraction of the flaps.

LEADING/TRAILING EDGE WING FLAP SYSTEMS

Several types of naval aircraft are equipped with flap systems that feature both leading
edge and trailing edge flap panels. On some aircraft these leading edge panels are
referred to as slats.
Figure 16-31 shows a leading edge and trailing edge flap arrangement. The figure
shows flap operation with aileron drooping and boundary layer control. These features
create even greater lift and stability than with flaps alone.
This flap system consists of three leading edge and one trailing edge flap panels for
each wing, with each panel having its own actuator. A three-position flap control switch
in the cockpit is labeled UP, 1/2, and DN.
The leading edge flaps operate by a manifold-mounted selector valve and dual
actuating cylinders. Trailing edge flaps use this same selector valve plus a wingmounted selector valve and dual tandem actuating cylinders.
When the flap control switch is placed in the 1/2 position, the manifold-mounted selector
valve directs utility system pressure through the shuttle valves. Pressure is sent into the
down lines of the leading edge flap actuators. The leading edge flaps are lowered to the
16-37

Figure 16-31 Flap control circuit.

full down position. The inboard leading edge flap deflection is 30 +0, -2 degrees. The
center flap deflection is 60 +0, -2 degrees. The outboard flap deflection is 55 1/2
degrees 1/2 a degree.
At the same time, hydraulic fluid flows through the fuselage-mounted flow divider and
into the extend side of the dual tandem trailing edge flap actuating cylinder. This action
moves the trailing edge flaps to the 1/2 position with a deflection of 30, 2 degrees. The
cockpit flap position indicator indicates barber poles while the flaps are in transit and
flap position at the completion of selected movement. The limit switches are connected
into the control circuit in series to provide an indication of flap position and to
continuously energize the electrical circuits to maintain hydraulic pressure when the
flaps are down.
Moving the flap control switch to the full down position actuates the wing-mounted
selector valve, porting pressure through a second flow divider. Pressure is sent into the
down side of the retracted half of the trailing edge flap cylinder, moving the flaps from
the 1/2 to the full down position. Full down position is 60 +1, -2 degrees. Both flap
position indicators will indicate DN when the cycle is completed.
Placing the flap control switch to the UP position allows hydraulic pressure to be
directed to the retract side of all flap actuators. Position indicators indicate UP. The
electrical control circuits and solenoids of both selector valves are de-energized.

16-38

The leading edge flaps are locked in the UP position by the overcenter locking
mechanism. The trailing edge flaps are locked up by internal locks within the trailing
edge actuating cylinders.

HYDRAULIC DROOP AILERON SYSTEM

When the flap switch is placed in 1/2 or DN position, with PC 1, PC 2, and utility
hydraulic power applied, the ailerons will extend 16 1/2 degrees down. The control stick
will remain centered. The droop aileron actuating cylinder (Figure 16-32)one in each
wingextends by flap down utility hydraulic pressure. The droop aileron is retracted by
springs in the cylinder when extend pressure is removed. The droop cylinder connects
between the aircraft structure and an idler bell crank in the aileron power package
linkage. With flaps up, the droop cylinder acts as a solid link. When the flap control
switch is placed in the 1/2 or DN position, the droop aileron extend relay energizes. This
relay completes the extend electrical circuit to the droop aileron actuators. As the
actuators extend, the aileron power cylinder input levers reposition, and both ailerons
droop as before. The actuators are de-energized by the integral extend limit switch. The
ailerons are free to operate normally. When the flap control switch is placed to UP, the
droop aileron extend relay is de-energized. The droop actuator repositions the aileron
power cylinder input levers. Both ailerons move back to their normal position. The droop
actuators are de-energized at the completion of the retract cycle by the integral limit
switch.

EMERGENCY FLAP SYSTEM

If electrical and hydraulic power fails, the flaps can be lowered by the emergency
system. An emergency flap extension bottle with a 300-cubic-inch capacity and charged
to 3000 psi provides a power source. Emergency extension is controlled by the
emergency flap control handle, which is mechanically linked to the emergency flap air
selector valve. Pulling the handle aft, the piston inside the air selector valve shifts,
allowing high-pressure air to flow through a separate set of lines to shuttle valves in the
flap system. The shuttle valves reposition, and air pressure extends the flap actuators.
Air pressure also repositions the flap system dump valve, dumping return side hydraulic
fluid overboard. The leading edge flaps extend to the full down position and trailing edge
flaps to the 1/2 down position. The aileron drooping feature does not operate when the
flaps are lowered by the emergency flap system.

SEMI-INDEPENDENT FLAP AND SLAT SYSTEM

This system consists of semi-independent flap and slat systems, which raise and lower
using hydraulic motors, drive units, torque tubes, and screw jack-type actuators.

Flap System
The flaps divide into two panels per wing at the wing-fold joint. Each panel is supported
by two sets of tracks and rollers that are driven by two ball screw actuators. Pressure
from the combined hydraulic system powers the flap drive motor and gearbox assembly,
shown in Figure 16-32.
If the combined hydraulic system fails, a hydraulic brake locks the hydraulic motor, and
an emergency electric motor provides continued operation. Emergency flap extension
and retraction is controlled by placing the EMERG FLAP switch on the throttle quadrant
16-39

at either UP or DN. Camoperated switches within the

flap drive gearbox provide input
signals to show the flap position
on the cockpit-integrated
position indicator.
Operation of the flap control
handle energizes the solenoidoperated flap selector valve,
directing hydraulic pressure to
the extend or retract lines of the
flap drive motor. The wings
must be spread and locked to
provide a complete electrical
circuit through the wing unlock
relay to the selector valve.
Placing the flap control handle
to the TAKEOFF position
completes the electrical circuit
through the 30-degree switch
and cam-operated flap drive
Figure 16-32 Flap drive gearbox.
gearbox limit switch to the
selector valve. Pressure ports to
the down side of the high-speed hydraulic motor, which drives the gearbox. The flap
drive gearbox, through a series of torque tubes and offset gearboxes, drives all eight
flap actuators.
The flap actuators, shown in Figure 16-31, drive the carriage and attaching flaps out
and down to the 30-degree position. The limit switch in the flap drive gearbox opens,
de-energizing the selector valve circuit, allowing the valve shuttle to return to neutral,
blocking flow to the motor, and preventing further flap extension.
Placing the flap control handle to LAND mechanically closes the 40-degree down flap
handle switch. The electrical circuit to the selector valve completesthis time through
the now closed 40-degree down limit switch in the flap drive gearbox. The flaps will
extend to 40 degrees, and the electrical circuit will be broken by the action of the limit
switch.
Moving the flap control handle to the TAKEOFF or UP position will energize the
opposite solenoid of the flap selector valve and port pressure to the retract side of the
flap hydraulic motor. If the TAKEOFF position is selected, a limit switch will again halt
flap movement at the 30-degree position. If UP is selected, retraction will be halted
when the flaps reach the full up position. Stopping the flaps is a function of the flaps up
limit switch. At the same time, linkage from the up limit switch actuates a second switch
to complete the electrical circuit to the flap hydraulic motor brake valve. The energized
valve blocks combined hydraulic system pressure that is holding the hydraulic brake in
the unlocked position. The brake locks the hydraulic motor, which, in turn, locks the
flaps in the up position.
If combined hydraulic system pressure fails and the emergency flap switch is used, the
flap action is powered by the electric motor. See Figure 16-32. The flap hydraulic brake
valve is energized, and the pressure holding the spring-loaded hydraulic motor brake
unlocked will port to return. The brake is then free to lock the motor and input shaft.
16-40

The electric motor now drives the flap gearbox and associated linkage, bypassing the
locked hydraulic motor. This action occurs until the flaps reach a 40-degree trailing edge
down position. Limit switches shut the electric motor off when the flaps reach the 40degree down and full up positions.
FLAP ACTUATOR The flap actuator shifts rotary motion of the input shaft to linear
flap motion, using bevel gears and the ball screw jack mechanism. See Figure 16-33. A
load-sensing device in each flap actuator operates a clutch assembly to stall out the flap
system if it is overloaded. An impact plate at the end of the ball screw (screw jack shaft)
and mechanical stops on the actuator body protect the actuator against possible
overtravel during flap extension and retraction.

Figure 16-33 Flap actuator.

OFFSET GEARBOXES The eight offset gearboxes in the flap system transmit power
produced by the flap drive gearbox around wing structure obstacles and compensate for
wing angularity. They also reduce the flap drive gearbox speed of 1,080 rpm to about
550 rpm at the outboard actuators.
FLAP WING-FOLD SHAFT A wing-fold shaft consists of two interlocking splined
sections and two universal joints connected to quill shafts. It provides a telescoping fold
joint in the flap drive system linkage between the inboard and outboard wing panels.

Slat System
The slat system, shown in Figure 16-34, provides additional lift and stability to the
aircraft at lower speeds in the same manner as the leading edge flap system previously
discussed. The flap control handle controls the movement of the slats. Moving the flap
control handle to the TAKEOFF or LAND position causes the slats to extend to a 27.5degree leading edge down position.
The slat panelsone inboard and one outboard interlock by a pin when the wings are
spread. When fully retracted, the slats align with the top and bottom wing contours to
form the wing leading edge. Shim spacers between the slats and the slat tracks provide
adjustment for proper aerodynamic fairing.
16-41

Components of the slat system are similar to those in the flap system. The slats extend
and retract by using six series-linked ball screw actuators. The actuators are powered
by the hydraulic motor through gearboxes and torque tubes.
If combined hydraulic system pressure fails, the hydraulic motor is locked in the same
manner as the flap hydraulic motor, permitting the emergency electric motor to move
the slats. Emergency slat operation is accomplished simultaneously with emergency
flap operation, using the emergency flap switch. Slat position is also displayed on the
cockpit integrated position indicator.
Placing of the flap control handle to either the TAKEOFF or LAND position mechanically
closes switches to provide electrical current to the slat selector valve. The selector valve
ports hydraulic pressure to the extend side of the high-speed hydraulic motor. This
action drives the center gearbox and extends the slats.
Two ball screw actuators drive each outboard slat, and one drives each inboard slat of
each wing. Each actuator connects to its downstream actuator by torque tubes and
gearboxes. The slats move as one unit. Limit switches in the center drive gearbox deenergize the slat selector valve, blocking flow to the drive motor when the slats fully
extend (27.5 degrees) or retract. Placing the flap control handle to the UP position
energizes the opposite solenoid of the selector valve and reverses slat motor direction,
retracting the slats.

Figure 16-34 Slat drive system.

SLAT WING FOLD GEARBOX A wing fold gearbox disconnects slat drive linkage at
the wing fold joint when the wings fold. The gearbox consists of two identical halves
16-42

interconnected by a spring-loaded disconnect coupling when the wings are spread. As

the disconnect coupling halves move away from each other during the wing folding
operation, a spring-operated brake engages, preventing relative motion between the
inboard and outboard sections.
SLAT ANGLE GEARBOXES Four slat angle gearboxes are provided in the slat
system for changing direction of the slat torque tube linkage from the center gearbox to
the wing actuators.

SPEED BRAKE SYSTEM

The speed brake system provides a means of extending a flat surface into the airstream
to slow the aircraft. This is done by various electrical and hydraulic components of the
speed brake system, see Figure 16-35.

Fuselage Type
On the F/A18 aircraft the speed brake is a hinged surface mounted on top of the aft
fuselage and attached to a hydraulic cylinder that extends the speed brake into the
airstream. The speed brake cylinder provides the power to extend the speed brake. The
cylinder is mounted in the speed brake well on top of the aft fuselage. The speed brake
cylinder moves the speed brake as directed by the speed brake manifold and solenoid
valve. Hydraulic power is routed to the speed brake cylinder through swivel joints. The
swivel joints are mounted in line with the cylinder attach bolt. Half of the swivel joint is
attached to aircraft structure. The other half is attached to, and rotates with the cylinder
during speed brake extension.
The speed brake manifold and solenoid valve is a solenoid-controlled, hydraulic valve.
Solenoid valves in the manifold control movement of a selector valve, which routes
hydraulic pressure to the speed brake cylinder. The selector valve also provides a path
for return fluid from the speed brake cylinder to the hydraulic system return. A relief
valve in the manifold relieves system pressure at approximately 3300 psig. The relief
valve is connected between the pressure and return ports in the manifold and relieves
to system return.
SPEED BRAKE CONTROL With the speed brake control relay deenergized the
speed brake switch directly controls the speed brake manifold and control valve.
Moving the speed brake switch to the extend position energizes solenoid B and
deenergizes solenoid A in the speed brake manifold and control valve. This condition
causes the selector valve spool to move to allow hydraulic pressure to be applied to the
extend side and removed from the retract side of the speed brake cylinder. Speed brake
extension results. Releasing the speed brake switch causes it to return to the hold
position. The hold position causes both solenoids A and B to energize. This condition
causes the selector valve spool to be positioned to trap hydraulic pressure on both
sides of the speed brake cylinder. The speed brake is held in its existing position.
Moving the speed brake switch to the retract position energizes solenoid A and
deenergizes solenoid B. This condition also occurs when the speed brake control relay
energizes. It causes the selector valve spool to move to allow hydraulic pressure to be
applied to the retract side and removed from the extend side of the speed brake
cylinder. Speed brake retraction occurs.

16-43

Figure 16-35 Speed brake control system.

Wingtip Type
The wing tip speed brake control system is a hydraulically-operated, electricallycontrolled system that provides braking capability during flight. The speed brake (SPD
BRK) control switch on the inner surface of the power lever, permits symmetrical
extension and retraction of the wing tip speed brakes.
Wing tip speed brakes (Figure 16-36) consist of painted aluminum- tip surfaces, hinged
in a clamshell arrangement. When retracted, they lie flush with the wing surfaces;
extended, they protrude into the airstream. Serving as brakes, they can be held at any
angle between 0 and 120, depending upon the amount of braking desired. Wing tip
speed brakes are extended by hydraulic cylinders, powered by the combined hydraulic
system. The SPD BRK control switch controls a solenoid-operated hydraulic selector
valve, which ports hydraulic pressure to the wing tip actuating cylinders, through flow
16-44

regulators. A hydraulic synchronizing system is provided to prevent uneven wing tip

speed brake extension. When wing tip brakes are asymmetrical by more than 8, an
electrical circuit senses this undesired condition, causing the brakes to automatically
retract. Wing tip speed brakes may be extended with aircraft on the ground.

Figure 16-36 Wingtip speed brakes.

The integrated position indicator displays wing tip speed brake configuration. Each wing
tip speed brake consists of a set of trailing edge surfaces at each wing tip. The lower
half of each brake is attached to the wing with two external, fixed hinges; the upper half
is attached to the wing with two adjustable tension links at the same wing station as the
lower hinges. An interconnecting hinge, between the upper and lower halves, provides a
common connection point for the actuating cylinder. This configuration provides
symmetrical deflection of upper and lower wing tip brakes. The individual brake panels
measure approximately 2 feet by 4 feet. When fully extended, each panel opens 60 for
an included angle of 120 for each wing tip speed brake.
The wing tip speed brake control system receives electrical power from the 28 V dc
essential bus and 3000 psi hydraulic power from the combined hydraulic power system.
Speed brake extension and retraction is controlled by the three-position SPD BRK
control switch S46. Normal position for this switch is center (hold); it is spring-loaded to
return from aft (extend) position and from forward retract position to the center (hold)
position. When pins A and B of the speed brake wing tip solenoid selector valve are
energized, hydraulic pressure is applied to the extend sides of the speed brake
cylinders, causing speed brakes to extend. When only pin B is energized, hydraulic fluid
return is blocked from both extend and retract sides of the speed brake cylinders,
hydraulically locking the speed brakes. In the event of a 28 V dc power failure, pins A
and B are deenergized and the speed brakes fail-safe to retract condition. The wing tip
speed brake control system normally depends upon hydraulic flow regulators to
maintain symmetrical extension of left and right speed brakes. If a malfunction causes
asymmetrical extension, an electrical disparity signal is sensed by the speed brake null
detector. When the disparity between the extension of the right and left wing tip speed
brakes reaches 8, the speed brake null detector removes the ground from the speed
16-45

brake null sensor relay, which removes power from pins A and B of the speed brake
wing tip solenoid selector valve, causing the speed brakes to retract.

TRIM SYSTEM
A trim system is provided in the flight controls to lessen the need for constant effort on
the part of the pilot to maintain the desired heading and altitude. The trim system
stabilizes the aircraft during flight.

Lateral Trim
The aileron trim control system is shown in Figure 16-37. Lateral trim is accomplished
by varying the neutral position of the aileron control system. This is done by means of
an electrically operated aileron trim actuator. Trim position is controlled by the manual
trim switch on the inboard side of each control wheel. An aileron trim position transmitter
is linked to the output of the trim actuator to relay actuator position to the trim position
indicator on the copilots instrument panel.

Figure 16-37 Aileron trim control.

In the manual mode of operation, lateral trim is accomplished through the trim system.
When the aileron manual trim switch is closed to the left with the control wheels in
neutral and the aileron in the stream lined position, 115 vac power flows from BUS NO 1
through AC ESS BUS NO 1circuit breaker and AILERON TRIM circuit breaker. Power
then continues to flow through the manual trim cutout relay and the aileron manual trim
switches. The trim actuator extends, moving the trim system, the control wheels, and
the linkage to a new neutral position and deflecting the left aileron up and the right
aileron down. The trim range in the clean configuration is 5 of aileron deflection. Trim
ranges, however, vary with various droop configurations. When the switch is returned to
neutral, the circuit that supplies power from the bus to the actuator is broken, and the
actuator stops.
When the aileron manual trim switch is closed to the right with the control wheels in
neutral and the ailerons in the streamlined position, 115 vac power flows through the
same circuit as described in the preceding paragraph, causing the actuator to retract.
16-46

When the switch is returned to neutral, the circuit that supplies power from the bus to
the actuator is broken, and the actuator stops.
In the series mode of operation, power flows from the AFCS to the coil of the manual
trim cutout relay. When the relay is energized, it breaks the circuit that supplies 115 vac
power to the trim actuator. There by preventing manual trim of the aileron control
system.

Longitudinal Trim
Longitudinal or pitch trim can be accomplished in several ways. On aircraft with a
nonmovable horizontal stabilizer, trim could be provided by a trim tab arrangement or
deflection of the elevators in much the same manner as described for the lateral trim
systems.
Aircraft with a movable horizontal stabilizer and elevators are longitudinally trimmed by
changing the angle of incidence of the stabilizer. Moving the four-way trim control switch
on the stick grip fore or aft will raise or lower the leading edge of the stabilizer to provide
the angle of incidence necessary for balanced flight. An electric trim motor and actuator
arrangement provides movement of the stabilizer.
Aircraft that use a movable horizontal stabilizer for longitudinal control trim do so by
varying the neutral position of the control linkage, which, in turn, moves the surface. For
example, longitudinal trim is provided by varying the position of the artificial-feel bungee,
repositioning the linkage, and setting up a new neutral position for the stabilizer linkage.
Anytime a new neutral is introduced by the trim actuator, the power valve shuttle is
displaced. The stabilizer assumes a new neutral location, changing the attitude of the
aircraft. The trim inputs may be provided by the pilot or the AFCS. The actuator has two
operating speeds-high speed for manual trim and low speed for AFCS trim.

Directional Trim
Directional trim is necessary to compensate for yaw of the aircraft. Rudder trim is
basically similar to the aileron trim. When the momentary throw rudder trim switch
moves left or right, the trim actuator energizes to move the load-feel bungee,
repositioning the rudder power mechanism input crank. The rudder linkage and the
rudder are repositioned accordingly to a new neutral position.
Most aircraft with power-controlled actuators work in a similar manner, using an electric
trim actuator to change the neutral position of linkage, deflecting the rudder to maintain
the desired directional stability. Like the lateral and longitudinal trim systems, rudder
trim action can be accomplished manually or automatically. Trim position indicators
provide a cockpit indication of the amount of trim or surface deflection required by each
trim system.

SECONDARY CONTROL SYSTEM MAINTENANCE

Organizational maintenance of the secondary flight control system includes checking
system operation, rigging, periodic inspection, lubrication, isolation of malfunctions, and
replacement of faulty components.
Proper operation of the gearboxes, interconnecting splined shafts, and screw jack
actuators are dependent on proper lubrication. Lack of proper lubrication will generally
result in binding and excessive loading of torque tube assemblies. Lack of proper
lubrication promotes corrosion. Space and time limitations during shipboard operations
16-47

often detract from the timely access to some of the slat and flap actuators. In many
cases a wing spread and extension of the surfaces are necessary. Attention to these
corrosion-prone areas will materially contribute to trouble-free operation of the screw
jack mechanisms.
Repair of most of the gearboxes and screw jack actuators at the intermediate level of
maintenance is limited to replacement of nuts, bolts, washers, gaskets, bearings, and
shims. At the intermediate level of maintenance, components of a secondary flight
control system may be disassembled for routine maintenance, such as cure date seal
and miscellaneous parts replacement.
NOTE
Before disassembly of any component, reference should be
made to the Intermediate Maintenance section of the
applicable MIM or accessories manual to determine repair
procedures and test equipment requirements. If the
component is beyond the repair capability of a given
activity, it should be forwarded through channels to an
authorized higher level repair activity.

The repair process for many of the flap hydraulic components will generally include the
following considerations:
1. Clean the disassembled part, using a suitable solvent followed by air drying with
low-pressure air.
2. Inspect all parts, using a strong light and some means of magnification, or one of
the nondestructive methods of metal inspection. Threaded parts are inspected for
crossed, stripped, worn, or otherwise damaged threads. Springs are checked for
distortion, permanent set, and alignment. Spring alignment may be verified by
rolling them on a smooth, flat surface. The free length, compressed length, and
reflected load of the springs should be verified in accordance with the values
provided in the applicable MIM.
3. Inspect mated surfaces for excessive wear, separation of plating, and evidence
of nicks or scratches. All parts that show signs of excessive scoring, pitting, or
other surface irregularities should be replaced. Minor imperfections can
sometimes be removed with fine crocus cloth or lapping compound, depending
on the design and tolerance specifications of the part.
4. Be sure that all passages and chambers of the part under repair are clean and
free from obstructions.
Following reassembly, the component must be bench tested to verify its proper
performance. Usually, testing will include proof testing, leakage testing to verify proper
internal seal operation, and operational testing.

16-48

NOTE
During the complete repair process, cleanliness of the work
area, as well as the external and internal parts, is a prime
consideration. The close tolerance mated surfaces within
most hydraulic components are extremely susceptible to
damage by contamination regardless of the manner of
introduction.

Quality assurance verification is required throughout the repair process and at the
completion of repair. All repairs must be accomplished as specified in the Intermediate
Maintenance section of the applicable MIM or 03 accessories manuals. Steps that
require quality assurance verification are so indicated by appearing in italics, being
underlined, or some other obvious manner. Following repair, the component should be
partially filled with preservative hydraulic fluid and capped and/or plugged to prevent
contamination.

MAJOR ASSEMBLY REMOVAL/INSTALLATION

The primary flight control surfaces and some of the secondary control surfaces are
attached to the wings and stabilizers of the aircraft. In many instances, the wings and
stabilizers are damaged beyond repair. When this occurs, the wings and stabilizers
must be removed and sent to a depot-level maintenance facility for repair, and a
replacement installed.

WINGS
Removal and installation of a wing are major operations that require experienced
personnel and close supervision by a senior petty officer.
The airframes section of the applicable MIM should be read carefully before attempting
to remove a wing. This manual will give step-by-step instructions for wing removal and
installation. It is necessary to follow these instructions to prevent possible damage
caused by failure to disconnect or connect units in the proper sequence.
Listed below are some general precautions that should be observed when removing
and installing a wing or wing section.
1. The aircraft should be placed in a hangar or other area protected from the wind.
2. Make certain all the necessary equipment is available and at hand. A list of the
necessary special tools and equipment can be found in the applicable MIM.
3. Ensure that you have sufficient manpower for proper handling.
4. Ensure that all screws, bolts, and other removed fasteners are placed in
containers and properly marked to prevent loss.
5. Ensure that all removed fairings are marked and stowed in a safe place.
6. In disconnecting tubing, electrical connectors, control cables, and bonding wires,
see that the instructions given in the aircraft MIM are carried out.
16-49

7. Make certain that all disconnected tubing is capped.

8. If hoisting equipment is to be used, be sure it is in good condition and a qualified
operator is available. Also, ensure the hoist fittings are properly installed. Some
wings will not balance at their hoist fittings, which make it necessary to attach
guide ropes to keep the wing steady after it is disconnected from the aircraft.
9. Before attempting to remove any structural bolts, make certain that the wing is
properly supported with all loads removed from the fittings. A mallet and brass
drift pin may be used in removing these bolts.
10. After the wing is removed from the aircraft, all fittings, connections, and
unremoved structural members should be inspected for secondary damage
before installing the new wing or wing section. (Secondary damage is damage to
adjacent structures, which may have resulted from the transmission of the shock
or load that caused the primary damage.)
11. Before installing the new wing, you should take advantage of improved
accessibility to inspect and repair corrosion damage, and renew preservative
coatings in previously inaccessible areas.
The petty officer in charge should ensure that the following general precautions are
taken in installing a wing or wing section.
1. Check the identification tag of the new assembly to make sure it is the correct
replacement unit.
2. See that extreme care is taken in removing the wing from the container,
preventing any possible damage.
3. Inspect the new wing or wing section for possible damage incurred during
shipment or removal from the container. The container should be used for
shipping the damaged wing to the depot maintenance facility.
4. With the wing in position for installation and properly supported, ensure that all
structural bolts are installed and the nuts properly torqued.

CAUTION
The attaching bolts should never be forced; if they bind,
check alignment of the wing. Forcing the attaching bolts will
result in damage to the wing structure.
5. Make certain that all tubing, electrical connectors, control cables, and any other
disconnected mechanisms are properly connected.
6. Check the operation of all mechanisms that were disconnected during removal.
Make the necessary rigging adjustments in accordance with the applicable MIM
before installing access doors and fairings.
7. Make a final inspection of the completed job.

STABILIZERS
The removal and installation of stabilizers are similar, in most cases, to that of wings
and wing panels. On many aircraft the horizontal stabilizer is a movable airfoil,
16-50

controllable from the cockpit. On some of these aircraft, it is used in conjunction with the
elevators to maintain longitudinal control at sonic speeds where the elevators have a
tendency to lose their effectiveness. On other aircraft the movable horizontal stabilizer
serves the dual purpose of elevators and stabilizers and, in many instances, is referred
to as a stabilator.
Some aircraft have an empennage or tail group that consists of all-movable horizontal
stabilizers and a single all-movable vertical stabilizer. These aircraft do not have
elevators or a rudder.
The removal and installation of stabilizers, like that of the wing, are major jobs and must
be accomplished with care and close supervision. Step-by-step instructions of the
removal and installation of stabilizers are also included in the Airframes section of the
applicable MIM. Many of the general precautions listed under Removal and Installation
of Wings also apply to stabilizer removal and installation.

FLIGHT CONTROL SURFACES

It is sometimes necessary to remove control surfaces from aircraft to repair or replace
them. The instructions presented in the following paragraphs are general instructions,
applicable to several types of aircraft. For specific instructions and precautions,
operators should always consult the MIM before removing a control surface from any
aircraft.
Removal of a control surface should not be attempted until the aircraft is placed in a
hangar or an area protected from the wind. Before any control surface is removed from
the aircraft, it should be tagged with the bureau number of the aircraft and the location
of the control surface on the aircraft.
The first step is to remove the access covers and fairings. To prevent the loss of these
parts, they should be left attached to the aircraft by one screw or by a piece of safety
wire. The other screws should be put in a container to prevent them from being lost.
Bonding wires, electrical connectors, and control linkage should be disconnected.
Before disconnecting cable linkage, the tension at the most convenient turnbuckle
should be removed. Next, the entire control surface should be supported, either
manually or with mechanical supports, in such a manner as to remove the entire load
from the hinges. The hinge bolts should be removed by using a mallet and brass pin.
The control surface should be supported and all the hinges kept in alignment until the
last hinge bolt has been removed. On long control surfaces, it may be necessary to
replace the hinge bolts with drift pins to keep the hinges aligned while removing the
remaining hinge bolts.
Control surfaces are sometimes attached with piano wire hinges. Removal of the piano
wire can be accomplished by removing the ends, securing one end of the wire in the
chuck of a hand drill, and rotating the wire with the drill while withdrawing it. Excessive
spinning will have a wearing effect on the hinge material and should be avoided. The
reuse of piano hinge wire is not safe; therefore, any wire removed should be discarded.
After all the hinges are disconnected, the control surface should be removed from the
aircraft and supported carefully to prevent damage to the hinge brackets and adjoining
surfaces. The hinge bolts should be replaced in the hinges to prevent them from being
lost or damaged.
Before installing a control surface, the identification tag should be checked to determine
its proper location on the aircraft. The surface should be placed in position carefully
16-51

ensuring all hinge holes are properly aligned. Drift pins may be used to align the holes.
With the control surface correctly supported, the hinge bolts should be installed. For a
surface attached by piano hinge wire, a new wire should be used. After a control
surface is installed, the control linkage should be connected and the rigging of the
system checked.

AIRFRAME AND CONTROL SURFACE ALIGNMENT

Alignment of the airframe structure means checking the position relationship of each
major componentthe wing group, tail group, and fuselage groupto the other. The
alignment of the airframe is important since it is directly related to the aerodynamic
performance of the aircraft. Misalignment may affect the flight characteristics of the
aircraft, and consequently, the efficiency of the pilot-aircraft combination.
For this reason and for purposes of determining if any hidden structural failures exist, an
alignment check should be performed when an aircraft has encountered excessive g
force in flight, when a hard landing has been experienced, or when the aircraft has been
subjected to extensive damage.
The need for an alignment check after extensive damage is rather apparent; however,
this is not necessarily so in situations where the aircraft exceeds the g design limit or
where a hard landing has been experienced. The alignment check under these
conditions may expose damage that might otherwise go unnoticed.

BALANCING CONTROL SURFACES

Some flight control surfaces are balanced at the time of manufacture by adding
counterweights to the inside of the leading edge of the control surface. This balance
must be maintained (within certain tolerances) throughout the service life of the control
surface because flutter or dynamic oscillation of these surfaces in flight is not desirable.
Balance tolerances are always specified in the aircraft structural repair manual.

ALIGNMENT LEVELING METHODS

Prior to making an alignment check, it is necessary to level the aircraft both laterally and
longitudinally. This may be accomplished by using the transit, spirit level, or plumb bob
and datum plate method. The method of leveling used should always be the method
specified by the manufacturer.
When leveling an aircraft for an alignment check, the aircraft should be inside a hangar
where air currents will not interfere with the accuracy of the alignment readings. Jacks
should be used to control the attitude of the aircraft during the check.

Transit
The transit method is the most accurate. Transit leveling is accomplished by sighting
specified points on the aircraft. Two longitudinal and two lateral points are used for this
method. The reference points are sighted through a surveyors transit.

Spirit Level
Aircraft that use the spirit level method have leveling lugs either built into the structure
or provisions for mounting them on the structure. The leveling lugs are usually in the
nosewheel well. Spirit leveling lugs are shown in Figure 16-38.
16-52

Figure 16-38 Spirit leveling lugs.

Plumb Bob and Datum Plate

This method uses a datum plate or scale mounted on the deck of a compartment.
Provisions for hanging the plumb bob are located directly above the datum plate. The
aircraft is level when the plumb bob pointer is at 0 degrees on the datum plate. Figure
16-39 shows the plumb bob and datum plate method of aircraft leveling.

16-53

Figure 16-39 Plumb bob and datum plate leveling.

ALIGNMENT CHECK
The alignment or symmetry check is made after the aircraft has been leveled. This
check is made by measuring the distance between certain points on the aircraft. These
points are selected because they are relatively static and because their location will best
reflect any misalignment. Most manufacturers recommend that the measurements be
taken directly from one specified point to another. Figure 16-40 shows typical alignment
dimensions for an F/A-18 aircraft.
On other types of aircraft, drop points are provided at various locations for use in
checking the alignment. Plumb bobs are dropped from each of these points to the
reference plane (floor) so that the pattern for measurement may be described. When
using this method, the elevation check dimensions are measured from the drop points

16-54

to the reference plane; in this case, the floor. The horizontal check dimensions are
measured from one point (described by the plumb bob), along the reference plane
(floor), to another point.
If the alignment check measurements exceed the tolerances listed in the aircraft
structural repair manual, the aircraft must be considered non-airworthy until a special
disposition can be made by higher authority.

Figure 16-40 Structure alignment dimensions.

WING TWIST CHECK

With the aircraft leveled and the wings folded, it is possible to check the wings for twist.
One checkpoint is provided on each wing. Clinometer readings taken at these points,
when compared to the fuselage longitudinal clinometer readings, will enable an operator
to determine the condition of each wing.
16-55

This is possible because there is a definite relationship between the fuselage

longitudinal and wing reference lines. The steps below should be followed to perform a
wing twist check:
1. Fold the wings and level the aircraft laterally.
2. Install the leveling bar in the forward lockpin holes of the outboard panel fold rib.
3. Turn the rod until the milled flat at the forward end is straight up.
4. Set the clinometer on the flat and record the reading when the dial has stopped
rotating.
The right- and left-hand wing readings must be within 0 degrees, 12 minutes of each
other for acceptable aerodynamic tolerances with respect to twist. They must also fall
within the following upper and lower limits. The lower limit is established by subtracting
0 degrees, 20 minutes from the longitudinal reading, and the upper limit is established
by adding 0 degrees, 40 minutes to the longitudinal reading taken in the auxiliary wheel
well. For example, if the longitudinal reading was 1 degree, 35 minutes, the lower limit
would be 1 degree, 15 minutes, and the upper limit would be 2 degrees, 15 minutes.
The wing clinometer readings must fall within this range as well as within 0 degree, 12
minutes of each other (right- to left-hand wing readings). This check, together with the
steel tape measurements taken when the wings are spread, is a satisfactory check of
wing bending and twisting. If the clinometer readings and tape measurements are not
within the tolerances specified, the aircraft must be taken to a depot-level maintenance
facility for a complete inspection and final disposition.

16-56

End of Chapter 16
FIXED-WING FLIGHT CONTROL SYSTEMS
Review Questions
16-1. What type of flight control provides additional lift during takeoff and landing?
A.
B.
C.
D.

Elevator flight control

Primary flight control
Secondary flight control
Wings

16-2. What type of flight control system is used on high-speed jet aircraft?
A.
B.
C.
D.

Cable and pulley type flight control system

Mechanical unboosted flight control system
Power-boost flight control system
Pushrods and cable type control system

16-3. What type of pressure supplies the force necessary to operate the control
surface in a full power-operated system?
A.
B.
C.
D.

28 V dc applied pressure
Hydraulic pressure
Mechanical pressure
Pneumatic Pressure

16-4. On small or low-speed aircraft, cockpit flight controls are connected directly to
control surfaces by what means?
A.
B.
C.
D.

Cables or pushrods
Electric wires
Hydraulic lines
Pulleys

16-5. On high-speed aircraft, what components aid the pilot in moving the flight control
surface?
A.
B.
C.
D.

Counter weights
Hydraulic actuators
Pneumatic pressure valves
Push pull rods

16-6. In an elevator system, what component ports hydraulic pressure to the power
cylinder?
A.
B.
C.
D.

Control stick
Pushrod
Selector valves
Control valves
16-57

16-7. What must be done to a flight control hydraulic component when it is found to be
contaminated?
A.
B.
C.
D.

All internal filters changed

Flushed and cycled 10 times
Must be removed and replaced
Entry logged in the aircraft discrepancy book

16-8. When an aircraft has a discrepancy with the flight controls system, when is the
aircraft released for further flights?
A.
B.
C.
D.

After a functional test flight

Once the discrepancy has been logged
When cleared by quality assurance
When the discrepancy has been determined and corrected

16-9. Maintenance of the primary flight control power actuator is generally beyond the
capability of what maintenance level?
A.
B.
C.
D.

Depot-level maintenance
Flight line maintenance
Intermediate-level maintenance
Organizational-level maintenance

16-10. How many control cables are there in a simple cable system?
A.
B.
C.
D.

One
Two
Three
Four

16-11. Other than periodic inspections, what else must be done to a control cable?
A.
B.
C.
D.

Cold stretched
Kept clean
Lubricated
Painted

16-12. What is the maximum number of broken wires allowed in a 1-inch length of a 7 x
19 cable?
A.
B.
C.
D.

Two
Four
Six
Eight

16-13. What component of the wing flap system shifts rotary motion to linear motion?
A.
B.
C.
D.

Combine hydraulic pump

Flap actuator
Flap gear box
Torque tubes
16-58

16-14. What is the purpose of the relief valve located in the pressure line ahead of the
flap normal system selector valve?
A.
B.
C.
D.

Relieves system volume

Relieves excessive air
Relieves pressure from thermal expansion
Relieves pump pressure

16-15. In a leading/trailing edge flap system, what is the full-down deflection of the
trailing edge flap?
A.
B.
C.
D.

30 5 degrees
45 +1, -2 degrees
60 +1, -2 degrees
60 10 degrees

16-16. What tool is used for removing the piano hinge wire of a flight control surface?
A.
B.
C.
D.

A hand drill
Pneumatic drill
Punch and hammer
Safety wire pliers and a hammer

16-17. What is the first step the person in charge must perform before installing a new
wing assembly?
A.
B.
C.
D.

Bolt the wing to the aircraft

Check out proper support equipment
Check the identification tag to make sure it is the correct replacement unit
Place the aircraft in a hangar

16-18. Many of the general precautions listed under the removal and installation of what
component apply to the removal and replacement of a stabilizer?
A.
B.
C.
D.

Empennage
Flight control actuator
Rudders
Wing assembly

16-19. What is used to control the attitude of an aircraft during an alignment check?
A.
B.
C.
D.

Clinometer
Jacks
Leveling lugs
Transit level

16-20. How are flight control surfaces balanced at the time of manufacture?
A.
B.
C.
D.

By adding an equal of weight to the leading and trailing edges

By adding weight to the center of the control surface
By adding weights to the inside of the leading edge of the control surface
By using a manufacturing jig
16-59

16-21. What must be accomplished prior to performing an alignment check on an

aircraft?
A.
B.
C.
D.

Cycle the landing gear ten times

Fold the wings
Level the aircraft both laterally and longitudinally
Weigh the aircraft

16-60