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Boeing 737-300/400/500

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BOEING 737-300/400/500
Control Cables Rigging

It is necessary to test the cycle of the control cables of a system after the replacement of the cable.

I. Adjust the Control Cables II. Tighten the control cable of the system to two times the usual tension. III. Adjust the cable system.
(Use the table below for the number of test cycles that are necessary for a system) Cable System | Number or Test Cycles At Twice Working Tension | Aileron | 20 | Elevator | 25 | Rudder | 25 |

Tools Related - General

Aileron | * Dial Indicator - Accurate to 0.001 inch * Spring Force Scale, Push Type - Capable of 5 +/- 0.2 pounds * Mounting Device (to hold the dial indicator) | Rudder | * Dial Indicator - 0.001 inch accuracy (Commercially available) * Push/Pull Scale - 0 to 25 lb capacity, 1/4 lb accuracy (commercially available) * Mounting Device (to hold the dial indicator) * Loading Block, 1/8 inch thick, 3 inches by 3 inches wood or fibreglass block with pad to prevent damage to the skin | Elevator | * Dial Indicator - Accurate to 0.001 inch * Spring Force Scale, Push Type - Capable of 15.0 +/-0.2 pounds * Mounting Device (to hold the dial indicator against the elevator tab) |

Special Tools and Equipment

Aileron Tab Alignment Protractor * to identify the aileron tab neutral position and movement

Elevator Index Plate Rigging Beam * to install or adjust the elevator index plates



Special Tools and Equipment

* Aileron Tab Alignment Protractor * Straightedge * Rigging Pin Kit



Rigging Procedure on Aileron Control System

1) Pressurize the hydraulic systems A and B 2) Make sure that the FLT CONTROL A and B switches are ON. 3) Make sure the aileron trim switches are at the zero trim position. 4) Make sure the trim roller is against the cam detent. 5) Move the control wheel in the backlash band to put the aileron control wheels in the center. 6) Make sure you can easily install or remove the rig pins A/S-1, A/S-1A, A/S-3, A/S-4 and A/S-15. 7) Make sure the ailerons align with the index marks on the wing structure. 8) Make sure the distances between the lug of the top bus drum and stop bolts on the bottom drum are as specified (Figure 505). 9) Make sure the index mark on the control wheel hub aligns with zero on the control column marker. 10) Operate the control wheel through a minimum of two cycles. 11) Make sure the aileron spring cartridge is not compressed. 12) Make sure the aileron spring cartridge can move freely.


Special Tools and Equipment * Rigging Pin Kit:

Consumable Materials * Grease - BMS 3-24


Adjusting the rudder control cables RA and RB

1) Make sure that the rudder trim indicator is at the zero units of trim. 2) Do a test of the rudder pedal adjustment and the rudder pedal limit travel 3) Adjust the bus rod. a) Make the bus rod shorter to compensate cable loads. b) Disconnect the bus rod at one end. c) Turn the rod end three turns to make the bus rod shorter d) Re-connect the bus rod.

Procedure in Strecthing New Cable Control

1) Operate the rudder trim indicator until you can install the rig pin R-5 in the rudder feel and centring unit easily. 2) Adjust the turnbuckles on the RA and RB cables to 260 ±20 pounds. a) Make sure you can install the rig pin R-3 freely in the captain’s forward quadrant. 3) Remove the rig pins R-3 and R-5. 4) Move the rudder pedals 25 times through the full travel and do the following checks a) Make sure that the cables do not touch the pulley or the quadrant flanges for the total cable travel. b) Make sure that the cables are in less than 2 degrees of the plane of the pulley or the quadrant. c) Make sure you install the cables through the grommets in the structure. d) Make sure that the cables do not move from the neutral rig position. e) Make sure that the pulleys turn freely with sufficient clearance with the guards.

Procedure adjusting control cable to their correct cable rigging tension

1) Install the rig pin R-5 in the output crank of the feel and centering unit. 2) Adjust the turnbuckles to get the cable tension in table 1. 3) Make sure you can install the rig pins R-3 and R-4 freely in the forward quadrants. 4) If you can not install the rig pins freely, do these steps: a) Turn the turnbuckles to release the cable tension. b) Remove the pin, nut, washer, spacer and bolt to disconnect one end of the bus rod from the rudder forward quadrant. c) Adjust the bus rod until you can install the bolt easily. d) Install the bolt, spacers, washers, nut, and cotter pin to connect the bus rod to the rudder forward quadrant. e) Adjust the turnbuckles to get the cable tension in table 1 5) Make sure you can install the rig pins R-1 and R-2 freely in the pedal arms. 6) If you can not install the rig pins R-1 or R-2 freely in the pedal arms, then do these steps to adjust the tension rod: a) Loosen the two checknuts on the tension rod which connected to the pedal arm. b) Remove the nut, washer and bolt from the forward end of the tension rod. c) Adjust the tension rod end until you can install the rig pin R-1 or R-2 freely. d) Install the tension rod with the bolt, washer, nut, and cotter pin. e) Tighten the checknuts. 7) Remove the rig pins R-1, R-2, R-3, R-4, and R-5. 8) Operate the rudder pedals through one full travel cycle. 9) Loosen the seal retainer bolt. 10) Align the pressure seals at the aft pressure bulkhead with the RA and RB cables 11) Install the turnbuckle locking clips. 12) Apply a thin layer of grease to the threads. 13) Make sure the threads engage correctly on the tension rods and bus rod. 14) Make sure the rod ends covers at least 50 percent of the inspection holes at two end of the rods (10 locations).


Special Tools and Equipment * Rig Pins (E-1, E-4, and E-5) - 0.309 +0.002/-0.000-inch diameter, 6.7 ±.25 inches long * Rig Pins (E-2 and E-3) - 0.4941 ±0.0004-inch diameter, 4.5 ±0.25 inches long * Trammel Bar * Elevator Rigging and Restraining Tool * Rigging Fixture, Elevator Tab * Stabilizer / Elevator (Ski Jump)

Standard Tools and Equipment * Scale - 0-2 feet, in inches and hundredths of an inch increments * Tensiometer - 0-320 pounds capacity * Spring Scale - 0-50 pound capacity, graduated in 1-pound increments

Consumable Materials * Grease - BMS 3-33 (Preferred) * Grease - BMS 3-24 (Alternate)

Installing New Cable Procedure

1) Adjust the turnbuckles on the EA and EB cables to 300 ±20 pounds. 2) Adjust the seals in the pressure bulkhead, if it is necessary, to keep the cables straight. 3) Remove the rig pins E-1 and E-5. 4) Move the control column 25 times through full travel in the two longitudinal directions. 5) Install the rig pin E-5 in the right aft quadrant. a) Make sure you can move the rig pin freely. b) If it is necessary, move the elevator surface by hand until the rig pin holes align. 6) Install the rig pin E-1 in the left forward quadrant. 7) Remove the shoulder bolt from the two control column quadrants. 8) Make sure the rig pins E-2 and E-3 move freely through the installation holes of the shoulder bolts. 9) Make sure the tension in cables EAR, EBR, EAL, and EBL is in +/- 10 pounds of the table value at the ambient temperature.

Adjusting Control Cable to Correct Cable Rigging Tension Procedure

1) Remove the bolts from the adjustable ends of the pitch force tranducer. 2) Use the turnbuckles to adjust the cable tension to the value for ambient temperature 3) Check the neutral position. 4) Adjust the pitch force transducers (PAGEBLOCK 22-11-92/501). 5) Connect the pitch force transducers. 6) Remove the rig pins E-2 and E-3. 7) Install the shoulder bolts. 8) Install the locking clips on all the turnbuckles. 9) Remove the rig pins E-1 and E-5.

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