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PULLEYS
Inspect pulleys for roughness, sharp edges, and presence of foreign material embedded in the grooves. Examine pulley bearings to assure proper lubrication, smooth rotation, freedom from flat spots, dirt, and paint spray.  Periodically rotate pulleys, which turn through a small arc, to provide a new bearing surface for the cable. Maintain pulley alignment to prevent the cable from riding on flanges and chafing against guards, cov-ers, or adjacent structure. Check all pulley brackets and guards for damage, alignment, and security.
PULLEY WEAR PATTERNS
Various cable system malfunctions may be detected by analyzing pulley conditions.  These include such discrepancies as too much tension, misalignment, pulley bearing problems, and size mismatches between cables and pulleys. Examples of these conditions are shown in Figure 27-5.
27-00-00 Page 27-11 Issued: April 1, 1997

TROUBLESHOOTING.
Chart 2702 list troubles peculiar to the flight controls along with their probable causes and suggested remedies. When troubleshooting the flight controls, additional reference may be obtained from Chapters 55 and 57 on control surface balancing if required. After the trouble has been corrected, check the entire system for security and operation.
CHART 2702.  TROUBLESHOOTING CONTROL SURFACES
AILERON CONTROL SYSTEM 
Trouble  Cause  Remedy 
Lost motion between control wheel and aileron. Resistance to control wheel rotation.  Cable tension too low. Linkage loose or worn. Broken pulley. Cables not in place on pulleys. System not lubricated properly. Cable tension too high.  Adjust cable tension. Check linkage and tighten or replace. Replace pulley. Install cables correctly. Check cable guards. Lubricate system. Adjust cable tension. 

27-00-00 Page 27-12 Issued: April 1, 1997
CHART 2702.  TROUBLESHOOTING CONTROL SURFACES (cont.)
AILERON CONTROL SYSTEM 
Trouble  Cause  Remedy 
Resistance to control wheel rotation.  (cont.)  Control column horizontal chain improperly adjusted. Pulleys binding or rubbing. Cables not in place on pulleys. Bent aileron and/or hinge. Cables crossed or routed incorrectly.  Adjust chain tension. Replace binding pulleys and/or provide clearance between pul-leys and brackets. Install cables correctly.  Check cable guards. Repair or replace aileron and / or hinge. Check routing of control cables. 
Control wheels not synchronized.  Incorrect control column rigging.  Rig control column. 
Control wheels not horizontal when ailerons are neutral.  Incorrect rigging of aileron system.  Rig ailerons. 
Incorrect aileron travel.  Aileron control rods not adjusted properly. Aileron bellcrank stops not adjusted properly.  Adjust control rods. Adjust bellcrank stops. 
Correct aileron travel cannot be obtained by adjusting bellcrank stops.  Incorrect rigging of aileron cables, control wheel and control rod.  Rig system. 
Control wheel stops before control surfaces reach full travel.  Incorrect rigging between control wheel and control cables.  Rig system. 
RUDDER CONTROL SYSTEM 
Trouble  Cause  Remedy 
Lost motion between rudder pedals and rudder.  Cable tension too low. Linkage loose or worn.  Adjust cable tension. Check linkage and tighten or replace. 

27-00-00 Page 27-13 Issued: April 1, 1997
CHART 2702.  TROUBLESHOOTING CONTROL SURFACES (cont.)
Trouble Lost motion between rudder pedals and rudder.  (cont.) Excessive resistance to rudder pedal movement. Rudder pedals not neutral when rudder is streamlined. Incorrect rudder travel.  RUDDER CONTROL SYSTEM Cause Broken pulley. Bolts attaching rudder to bell-crank are loose. System not lubricated properly. Rudder pedal torque tube bearing in need of lubrication. Cable tension too high. Pulleys binding or rubbing. Cables not in place on pulleys. Cables crossed or routed incorrectly. Rudder cables incorrectly rigged. Rudder sector stop incorrectly adjusted. Nose wheel contacts stops before rudder.  Remedy Replace pulley. Tighten bellcrank bolts. Lubricate system. Lubricate torque tube bearings. Adjust cable tension. Replace binding pulleys and/or provide clearance between pul-leys and brackets. Install cables correctly.  Check cable guards. Check routing of control cables. Rig rudder cables. Check sector stops rigging. Adjust nose wheel stops. 
RUDDER TRIM CONTROL SYSTEM 
Trouble  Cause  Remedy 
Trim control knob moves with excessive resistance.  System not lubricated properly.  Lubricate system. 
STABILATOR CONTROL SYSTEM 
Lost motion between control wheel and stabilator.  Cable tension too low.  Adjust cable tension. 

27-00-00 Page 27-14 Issued: April 1, 1997
　
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