AIS-060

AUTOMOTIVE INDUSTRY STANDARDS

General Guidelines on
Control Cables for Automobiles

PRINTED BY
THE AUTOMOTIVE RESEARCH ASSOCIATION OF INDIA
P.B. NO. 832, PUNE 411 004

ON BEHALF OF
AUTOMOTIVE INDUSTRY STANDARDS COMMITTEE

UNDER
CENTRAL MOTOR VEHICLE RULES – TECHNICAL STANDING COMMITTEE

SET-UP BY
MINISTRY OF ROAD TRANSPORT & HIGHWAYS
(DEPARTMENT OF ROAD TRANSPORT & HIGHWAYS)
GOVERNMENT OF INDIA

July 2010

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 AIS-060

Status chart of the Standard to be used by the purchaser

for updating the record

Sr. Corr- Amend- Revision Date Remark Misc.

No. igenda ment

General remarks:

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 AIS-060

INTRODUCTION

The Government of India felt the need for a permanent agency to expedite the
publication of standards and development of test facilities in parallel when the
work on the preparation of the standards is going on, as the development of
improved safety critical parts can be undertaken only after the publication of the
standard and commissioning of test facilities. To this end, the erstwhile Ministry of
Surface Transport (MOST) has constituted a permanent Automotive Industry
Standard Committee (AISC) vide order No. RT-11028/11/97-MVL dated
September 15, 1997. The standards prepared by AISC will be approved by the
permanent CMVR Technical Standing Committee (CTSC). After approval, the
Automotive Research Association of India, (ARAI), Pune, being the Secretariat of
the AIS Committee, has published this standard. For better dissemination of this
information ARAI may publish this document on their Web site.

This guideline standard on control cables used in automobiles covers construction,

materials, shape, dimensions, testing procedure and requirements.

While preparing this standard considerable assistance is derived from following

standards:

i) JASO F 903 -75: Control Cables for Automobiles

ii) JASO T 001- 97: Control Cables for Motorcycles

The Automotive Industry Standards Committee (AISC) responsible for preparation

of this standard is given in Annexure: 31

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 AIS-060

General Guidelines on Control Cables for Automobiles

1. SCOPE
This standard covers the requirements of control cables (hereinafter
referred to as “cables”) mainly used for the purpose of tension control
(pulling) in automobiles in all types of four and two wheelers including
mopeds, motorbikes and motorcycles.
2. CONSTRUCTION DETAILS
2.1 Names of Main Components
The names of main components of the cable shall be as indicated in Table 1.
TABLE 1
Sr. Component Typical Sr. Component Typical
No. Name Assemblies No. Name Assemblies
(Reference) (Reference)
1 Inner Cable 6 Adjust Bolt
2 Outer Casing 7 Adjust Nut
3 Cable End Reference 8 Casing Protector Reference
(Terminal) Fig. 1 ~ 4` Fig. 1 ~ 4
4 Connector 9 Dust Cover
5 Casing Cap 10 Liner
Remark : Number indicates the parts in typical assemblies in Reference Fig. 1~4.

Reference Fig. 1

Reference Fig. 2

Reference Fig. 3

Reference Fig. 4

2.2 Types of Main Components

Types of cable main components shall be as indicated in Table 2.

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TABLE 2

Sr. Component Name Type Remarks Applicable Annexure

No.
1. Inner Cable Stranded Single Has the highest breaking strength / Annexure 1
Cable Strand shear load among cables of the
same outside diameter.
Multiple Has the highest flexibility / Annexure 2
Strands bending property. Among cables of
the same outside diameter.
Coated Wire Has high operating efficiency, Annexure 3
corrosion resistance.
Single Wire ----- Annexure 4
2. Outer Casing With liner Has a high operational efficiency Annexure 5
Without liner Used for the inner coat type Annexure 6
(Plastic Tube)
Twin wire conduit Conduit with twin wire
3. Cable End Type A Type A1 Drum Shape (Soldered) Annexure 7
Type A2 Drum Shape (Cast)
Type B Type B1 Umbrella Shape (Caulked) Annexure 8
Type B2 Umbrella Shape (Cast)
Type C1 Round Tube Shape (Soldered) Annexure 9

Type C Type C2 Round Tube Shape (Caulked or

Soldered)
Type C3 Square Tube Shape (Caulked)
Type C4 Ball Shape (Caulked, Soldered or
Cast)
Type D1 Screw Type (Caulked part same as Annexure 10
Type D rolling diameter)
Type D2 Screw Type (Caulked part larger
than rolling diameter)
Type E Threaded Type Annexure 11
4. Connector Type A Type A1 Clevis Type (Constant opening) Annexure 12
Type A2 Clevis Type (Opening becomes
smaller)
Type B ------ Annexure 13
5. Casing Cap Type A Type A1 Tubular type (Made by press) Annexure 14
Type A2 Tubular type (Made by machining)
Type B Type B1 Tubular type (with flange) Annexure 15
Type B2 Tubular type (with flange and dust
cover groove)
Type C Type C1 Screw type Annexure 16
Type C2 Screw type (with hexagon part)
Type D1 Clamp stoppage type Annexure 17

Type D Type D2 Clamp stoppage type (E ring Annexure 18

stoppage type)
Type D3 Clamp type Annexure 19
Type D4 Forced insertion type Annexure 20
6. Adjust Bolt Type A For stacking Annexure 21
7. Adjust Nut Type A For stacking box nut Annexure 22

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Sr. Component Name Type Remarks Applicable

No. Annexure

8. Round joint Type A Type A1 For rotary stacking Annexure 23

(without flange)
Type A2 For rotary stacking Annexure 24
(with flange)
Type B1 For direct stacking Annexure 25
Type B Type B2 For direct stacking Annexure 26
(threaded)
Type B3 For direct stacking Annexure 27
(non-threaded)
9. Casing Protector ----- ----- Annexure 28
10. Dust Cover Type A1 Boot type Annexure 29
Type A2 Boot type
Type B ----- Annexure 30

3. MAIN COMPONENT MATERIALS AND SURFACE TREATMENTS

Materials and surface treatment of the main components shall as a general rule, conform to
Table 3.

TABLE 3

Sr. Component Type Material Surface Treatment

No. Name
1. Inner Cable Stranded Cable Ropes and strands to confirm Correspond to
• IS: 5836-1977 Inner wire ropes JIS G 3535, 4.8
for automobile control cables
(First Revision)
• IS: 6594-1977 Technical supply
conditions for steel wire ropes
and strands (First Revision)
• IS: 1835-1976 Round steel wire
for ropes (Third Revision)
JIS G 3506, SWRH 57~82
JIS G 4308, SUS304-WR or SUS302- -----
WR
Coated Wire Synthetic resin (Coating material) -----
Single Wire JIS G 3521, SW Correspond to
JIS G 3535, 4.8
2. Outer Casing ----- Patented and cold-drawn spring steel Correspond to
wire of Grade 1 of IS:4454 (Part 1) – JIS G 3535, 4.8
1975 “Steel wires for cold formed
springs: Part 1 Patented and cold drawn
steel wires – unalloyed (First revision)”
JIS G 3506, SWRH 57 ~ 82
Outer casing insulation stable fibre yarn -----
with weatherproof lacquering or PVC as
per agreement between the purchaser
and the manufacturer.
Synthetic resin, black
Plastic Tube Synthetic resin -----

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Sr. Component Name Type Material Surface Treatment
No.
3. Cable End Type A1 The material shall conform to ---
(terminals) IS: 226-1975 “Structural steel (standard
quality) (Fifth Revision). If of brass, it
shall conform to IS: 4170-1967 “Brass
rods for general engineering purposes” or
IS: 4413-1967 “Brass wires for general
engineering purposes”.
JIS H 3422, BsBM
Type A2 JIS H 5301, ZDC ---
Type B1 JIS G 4051, S15C ~ S35C JIS D 0201, MFZn5-B
Type B2 JIS H 5301, ZDC or MFZn5-C
---
Type C1 JIS H 3422, BsBM ---
Type C2 JIS G 4051, S15C~S35C JIS D 0201, MFZn5-B
or MFZn5-C
JIS H 5301, ZDC ---
Type C3 JIS G 4051, S15C~S35C JIS D 0201, MFZn5-B
Type C4 JIS G 4051, S15C~S35C or MFZn5-C
JIS H 3422, BsBM ---
JIS H 5301, ZDC ---
Type D1 JIS G 4051, S15C~S35C JIS D 0201, MFZn5-B
Type D2 or MFZn5-C
4. Connector Type A1 JIS G 3131, SPHC JIS D 0201, MFZn5-B
Type A2 JIS G 3141, SPCC or MFZn5-C
Type B
5. Casing Cap Type A1 Steel conforming to IS: 226-1975. ---
(Bush) JIS H 3201, BsP JIS D 0201, MFZn5-B
JIS G 3141, SPCC or MFZn5-C
Type A2 ---
JIS H 3422, BsBM
JIS G 3101, SS or free cutting steel JIS D 0201, MFZn5-B
or MFZn5-C
Type B1 JIS H 3422, BsBM ---
JIS G 3101, SS or free cutting steel JIS D 0201, MFZn5-B
Type B2 JIS H 3422, BsBM or MFZn5-C
---
JIS G 3101, SS or free cutting steel JIS D 0201, MFZn5-B
or MFZn5-C
JIS H 5301, ZDC ---
Type C1 JIS H 3422, BsBM ---
Type C2 JIS G 3101, SS or free cutting steel JIS D 0201, MFZn5-B
or MFZn5-C
Type D1 JIS H 5301, ZDC ---
Type D2 JIS G 3101, SS or free cutting steel
Type D3 JIS D 0201, MFZn5-B
Type D4 JIS G 3101, SS or free cutting steel or MFZn5-C
6. Adjust Bolt ----- JIS G 3101, SS or free cutting steel JIS D 0201, MFZn5-B
or MFZn5-C
7. Adjust Nut ----- JIS G 3101, SS or free cutting steel JIS D 0201, MFZn5-B
or MFZn5-C
8. Casing Protector ----- Synthetic resin or rubber, black ---
9. Dust Cover Type A1, A2 Synthetic resin or rubber, black ---
Type B

Note: In case of material and construction not available as per Table 3, the material and construction shall be as per
the agreement between the cable supplier and the customer.

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4. SHAPES AND DIMENSIONS OF MAIN COMPONENTS

The shapes and dimensions of the cable main components shall be as

indicated in Annexures 1 ~ 30.

5. QUALITY

5.1 Appearance
(1) Components shall be free from bending, cracks, corrosion, turnback,
burrs, and other defects injurious to use.
(2) Surface treatment of components shall satisfy the requirements in 3.
(3) Cable shall have proper lubricant applied on the inner cable of filled in
the outer casing. The variety of lubricant used shall be as agreed
between the supplier and receiver.

5.2 Dimensions and Tolerances

(1) Dimensions and tolerances of components shall satisfy the requirements

in Annexures 1 ~ 30, except that in the caulked type cable ends, the
inner surface shall, as a rule, be chamfered before hand to prevent
decrease in strength.

(2) Unless otherwise specified, dimensional tolerances of the components

shall conform to Table 4.

TABLE 4
Dimensional Tolerances of Components

Manufacturing Division Applicable Standard

Commercial tolerance (Machining) JIS B 0405 medium grade or coarse
grade
Commercial tolerance (Forging) JIS B 0406 normal grade
Commercial tolerance (Pressing) JIS B 0408 normal grade
Commercial tolerance (Die casting) JIS B 0409 normal grade
Commercial tolerance (Shearing) JIS B 0410 normal grade
Dimensions of width across flats JIS B 1002 class 2

(3) Screw thread accuracy shall meet Class 2 or Class 3 in JIS B 0209
(Limits of Sizes and Tolerances for Metric Coarse Screw Threads) and
JIS B 0211 (Limits of Sizes and Tolerances for Metric Fine Screw
Threads). Plated screw thread accuracy shall meet JIS B 1180 (Hexagon
Head Bolts) and JIS B 1181 (Hexagon Nuts).

(4) Assembled product dimension tolerance shall conform to Table 5.

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TABLE 5-1
When Without Dust Cover

Unit: mm
l a + b (Travel length)
Nominal Tolerance Tolerance
100 and under Over 100
500 and under ±2 ± 1.5 ± 2.0
Over 500 to 1000 including ±3 ± 2.0 ± 2.5
Over 1000 to 2000 including ±4 ± 2.5 ± 3.0
Over 2000 to 3000 including ±5
TABLE 5-2
When with Dust Cover

Unit: mm
L and l
Nominal Tolerance
500 and under ±2
Over 500 to 1000 including ±3
Over 1000 to 2000 including ±4
Over 2000 to 3000 including ±5

5.3 Performance
(1) Cable shall operate smoothly in straight-line state.
(2) On the assembly parts, inner cable-shearing load, and cable end and
casing cap pull off loads shall meet the requirements in Annexures 1,
4, 7, 8, 9, 10, 13, 14, 15, 16, 17, 18, 19 and 20.
(3) Cable shall comply with the purpose of application and satisfy the
operating efficiency and other functions required in actual operation.

6. TESTING OF THE CABLES

The test procedure and acceptance norms for testing control cables listed
below.
a) Accelerator cable
b) Parking brake cable
c) Bonnet release cable
d) Ventilation cable
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e) Fuel lid opening cables.
f) Choke cable
g) Clutch cable
h) Idling adjuster cable.
i) Brake cable – Front & Rear

6.1 Tests
a) Bench performance tests
b) Durability / Endurance test.
c) Strength test
d) Environmental aging test.

6.1.1 Bench Performance Tests

Cable fitment shall be done on test bench with cable routing as described in
clause No. 6.1.2.1. No fouling of the cable with surrounding components
shall be observed. The following are the performance tests, which can
either be performed on a vehicle or on a test bench.

6.1.1.1 Operating Force Test

In order to check the smoothness of the cable operation, operating force
shall be measured. This is to be measured on the test bench which
simulates the test item cable e.g. force required to push the pedal for
accelerator cable.

6.1.1.2 Efficiency Test

Test procedure as per clause 6.1.3.

6.1.1.3 Load Efficiency Test: with cable installed as in actual vehicle

Sr. Cable type Temperature at which Load for the test

No. efficiency to be checked
1 All cables in the test a) 80 º C As agreed between the
standard except clutch b) -10 º C customer and supplier
cable & accelerator cable c) Ambient temp. or drawing
2 Clutch cable & accelerator d) 80 to 120 º C specification.
cable e) -35 to -40 º C
f) Ambient temp.

6.1.2 Durability / Endurance Test.

The test procedure shall be as follows:
(1) Performance measurement before durability test
(2) Operational durability test
(3) Performance measurement after durability test
(4) Performance measurement may also be conducted during the durability
test.

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6.1.2.1 Setting of Cable for Durability Test
The cable shall be sent in the same way as specified in figure 5 & 6.

Fig. 5
Test set up for Durability test

Fig. 6
Test set up for Durability Test at the End of Cable
(when round joint is used)

6.1.2.2 Performance Measurement before Durability Test

Pull input side of the inner cable of assembly at the operating speed
shown in Table 6. Apply the specified load to the output side, and then
measure the load efficiency and stroke loss.
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TABLE 6
Specifications for Performance Measurement

Sr. Type of cable Type Load Operating speed

No. application mm/sec
1 Front brake cable Force 540 N
2 Rear brake lever type application 540 N
3 Rear brake foot type and release. 780 N 10
4 Clutch 290 N
5 Throttle 100 N
6 Hood release cable, 50 N
Tailgate cable, Fuel
lid cable, Door latch
cable.

The measurement of any items other than the load efficiency and stroke loss
shall be in accordance with an agreement between the suppliers and users.

6.1.2.3 Operational Durability Test

Give the load and stroke repeatedly to the input side of cable so that the
maximum load and stroke shown in Table 7 can be kept at the output side.
The repetition times per minute and endurance times are also shown in
Table 7.

TABLE 7
Specifications for Operational Durability Test

Sr. Type of cable Specified load Stroke of Cycling Total no. Acceptance norm
No. of output side output rate of cycles
(N) side
(mm)
1 Front cable 540 15 10 to 60 1,00,000 No failure of the
cycles/ cable throughout
minute the test
2 Rear brake lever type 540 15 10 to 60 50,000 No failure of the
cycles/ cable throughout
minute the test
3 Rear brake foot type 780 10 10 to 60 50,000 No failure of the
cycles/ cable throughout
minute the test
4 Clutch 290 20 10 to 60 1,00,000 No failure of the
cycles/ to cable throughout
minute 5,00,000 the test
5 Throttle 100 25 10 to 60 1,00,000 No failure of the
cycles/ to cable throughout
minute 10,00,000 the test
6 Hood release cable, 50 20 10 to 60 5,000 No failure of the
Tail gate cable, Fuel cycles/ to cable throughout
lid cable, Door latch minute 20,000 the test
cable.

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6.1.2.4 Performance Measurement after Durability Test

This test shall be conducted by the same method as specified in
clause 6.1.2.2. Performance Measurement before Durability Test.
6.1.2.5 Endurance Test at Cold and Hot Temperature
Sr. Cable type Operating load and Temp and cycle of thermal
No. stroke and cycling rate. stress
1 Accelerator Cycling rate a) -40 to 120 º C
cable and choke = 30 Cycles / minute b) -40 º C for 4h, ambient temp
cable for 16 h, 120 ºC for 4 h
c) Temp rise rate = 4 ºC / min
2 Clutch cable Cycling rate d) -40 to 120 º C
= 30 Cycles / minute e) -40 º C for 4h, ambient temp
for 16 h, 120 ºC for 4 h
f) Temp rise rate = 4 ºC / min

3 Parking brake Cycling rate g) -40 to 80 º C

cable = 30 Cycles / minute h) -40 º C for 4h, ambient temp
for 16 h, 120 ºC for 4 h
i) Temp rise rate 4 ºC / min

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6.1.3 Performance Evaluation (Operational Efficiency Test)

Operating efficiency shall be expressed by load efficiency ηs. As indicated in

Reference Fig. 7, outer casing 1000 mm long shall be installed at 400 mm
fixed distance and 180o bending angle, with inner cable 1500 mm long
inserted before hand. One end of the cable shall be secured and the other end
gradually pulled, and fixed side load W, deflection δ1, tension side load F,
deflection δ2, and apparent permanent elongation δ0 after removal of tension
side load F shall be measured. In case of load efficiency test, fixed side load
W may be constant load.

δ1 (mm)

Reference Fig. 7

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(1) Load Efficiency

Load efficiency shall be expressed by following equation. (Refer to Reference Fig. 8).

Reference Fig.8

a) In case inner cable is fixed through spring, the load efficiency shall be
expressed as follows,
Area OCD
ηw (%) = ----------------- x 100
Area OABD

When initial tension is already impressed, then this becomes,

Area GFCD
ηw0 - w (%) = ----------------- x 100
Area GEBD

W and W0 values shall be as agreed between parties concerned.

(b) When making fixed side load W to constant load.

W
ηw (%) = ------ x 100
F
Value of constant load W shall be as agreed between parties concerned.

(2) Stroke Efficiency

Stroke efficiency shall be expressed by the following equation.

(Refer to Reference Fig. 9).

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Reference Fig. 9
δ1
ηs (%) = ---------- x 100
δ2 - δ0
Apparent permanent elongation δ0 value shall also be indicated. Values
of W and K shall be as agreed between parties concerned.
6.1.4 Strength Test
The test shall be performed for the following test items:
(1) Inner cable breaking load test
(2) Inner cable elongation test
(3) Outer casing compression load test
(4) Cable end, casing cap and round joint pull-off test
(5) Performance evaluation (Operational Efficiency Test) for assemblies :-
operational durability test
6.1.4.1 Inner Cable Breaking Test
Both ends of the test piece shall be clamped in the testing machine by
proper method at a distance of at least 250 mm apart, pulled at speed not
exceeding 50 mm/min, broken, and the breaking load shall be
measured. In this test, out of the test pieces that failed to met the breaking
load specified in Annexure 1 and 4, with regard to those that broken at the
clamped portion, retest shall be carried out with a new test piece.
6.1.4.2 Inner Cable Elongation Test
Clamp both ends of the test piece in the testing machine by proper method,
apply a load of 2% of the breaking load specified in attached Annexure 1 to
test piece, give gauge marking on it less than 250 mm apart and measure
the distance between gauge marking (L1). Then pull the test piece at a
speed of less than 50 mm/min, apply a load of 60% of the specified
breaking load and measure the distance between gauge markings (L2).
Return the applied load to 2% of the breaking load and measure the
distance between gauge markings (L3).

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Then total elongation percentage, permanent elongation percentage and
elastic elongation percentage shall be expressed in the following formulae”

L2-L1
C1 = -------- X 100
L1

L3-L1
Co = --------- X 100
L1

C2 = (C1-Co)

Where Co: Permanent Elongation percentage of inner cable (%)

C1: Total Elongation percentage of inner cable (%)
C2: Elastic Elongation percentage of inner cable (%)

6.1.4.3 Outer Casing Compression Load Test

Set 300 mm long test piece of outer casing on the test apparatus as shown
in Fig. 10. Apply the compression load to the test piece at a speed of less
than 20 mm/min until it is crushed, and then measure the compression load.

Fig. 10
Size of Guide Wire
Unit: mm
Outside diameter of outer casing Φ5 Φ6 Φ7 Φ8 Φ9
Diameter of guide wire Φ1.8 Φ2.1 Φ2.6 Φ3.5 Φ4.0

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6.1.4.4 Cable End, Casing Cap and Round Joint Pull-Off Test
Both the ends of a test piece shall be clamped on the testing machine in such
a manner as to allow the pull load to be measured and in an appropriate way,
respectively as shown in Fig. 11. Pull the test piece at a speed of less than
50 mm/min until the cable end, casing cap and round joint are separated and
then measure the pull-off load. For the test piece which does not meet the
pull-off load values specified in attached Annexure 7, 8, 9, 10, 13, 14, 15, 16,
17, 18, 19 and 20 and broke at any portions other than the cable end, casing
cap or round joint, take a new test piece from the same cable and test it again.

Fig. 11
6.1.5 Environmental Test
Salt Spray Test
Salt spray test shall be conducted for a duration given in Table 8 on
complete cable assembly as per IS: 9000 (Part 11) for following duration.
There shall not be visible red rust which will harm the performance.
TABLE 8
Test for Observation of red rust.
Inner cable 48 hrs
Outer cable 24 hrs

7. INSPECTION
7.1 Inspection Items
Cable inspection items shall be as follows :
(1) Material inspection
(2) Appearance inspection
(3) Dimension inspection
(4) Performance inspection
7.1.1 Material Inspection
Material shall conform to the requirements in 3.
7.1.2 Appearance Inspection
Appearance shall conform to requirements in 5.1.
7.1.3 Dimension Inspection
Dimensions of components and assemblies shall conform to the
requirements in 5.2.

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ANNEXURE 1
(See Table 2 (1))
INNER CABLE (STRANDED CABLE)
Unit : mm
Inner cable diameter Single Wire Twist Informative Reference Multiple Wire Twist Informative Reference

Nominal Tolerance Breaking Twist Form Elongation (%) Breaking Twist Form Elongation (%)
Load Load
(kgf Symbol Standard Elasticity Perm- (kgf Symbol Standard Elasticity Permanent
Min.) strand anent Min.) strand
1.2 + 0.12 150 1 x 12 0.30 120 7x7 0.14
0
1.5 + 0.15 240 1x7 0.50 180 7x7 0.17
0 (1x12) (0.38)
1 x 19 0.30
2.0 + 0.20 420 1 x 19 0.40 0.8 310 7x7 0.22
0
2.5 + 0.20 630 1 x 19 0.50 0.2 480 7x7 0.28 0.9 0.2
0
3.0 + 0.24 850 1 x 19 0.60 700 7x7 0.35
0 7x19 0.20
(12+7x7) (0.30)
3.5 + 0.28 1100 1 x 19 0.70 920 7x7 0.40
0 0.9 (19+7x7) (0.30)
(0.34) 1.1
4.0 + 0.32 1500 1 x 37 0.57 1200 7x7 0.45
0

Remarks

1. Stranded method may be common S or common Z twist as prescribed in JIS G 3525 (Wire Rope) with
the exception that inner cable shall be of non-repelling twist prescribed in JIS G 3535 (Wire Ropes for
Aeronautical Use).

2. Diameter of inner cable is defined as the diameter of the inner cable circumscribed circle.

3. Elongation shall be the value measured by 8.2 test method.

4. Dimension and formation of the inner cable in case rolled wire is to be wound in the cable shall be
agreed between the parties concerned.

5. Dimensions enclosed by parentheses should not be used whenever possible.

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ANNEXURE 2
(See Table 2 (1))
INNER CABLE SECTION AND FORMATION

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ANNEXURE 3
(See Table 2 (1))
INNER CABLE (COATED)

Unit: mm
Inner cable diameter (d) Coat Finish diameter (D) Min. wall thickness (t)
Size Tolerance
1.2 1.8
1.5 2.1
2.0 2.6 0.15
2.5 3.1 + 0.2
3.0 3.8 - 0.1
3.5 4.3 0.2
4.0 4.8

Remark : Inner cable (strand) used in inner cable (coated) shall conform to main Text
Annexure 1 and 2.

ANNEXURE 4
(See Table 2 (1))
INNER CABLE (SINGLE WIRE)
Unit: mm
Inner cable diameter Breaking Load (kgf)
Nominal Tolerance
1.2
1.4 ± 0.05 As prescribed in JIS G 3521
1.6

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ANNEXURE 5
(See Table 2 (2))
OUTER CASING

Unit: mm
Applicable Inner Cable D D0 d1 Reference

Uncoated Coated finish Size Tolerance Standard Min. cover

Diameter diameter strand thickness
Diameter
1.2 ---
1.4 --- 5 2.4 3.6 1.0 0.4
1.5 1.8 1.2
1.6 ---
1.5 1.8 6 2.9 4.7 1.6 0.4
2.0 2.1 1.7
2.5 2.6 7 3.8 5.6 1.6 0.4
1.7
7 3.8 5.6 1.6 0.4
1.7
3.0 3.1 8 4.3 6.1 1.6
± 0.2 1.7 0.6
9 4.8 7.2 1.8
2.0
10 4.8 7.2 1.8 0.6
2.0
9 4.8 7.2 1.8 0.6
3.5 3.8 2.0
10 4.8 7.2 1.8 0.6
2.0
10 5.2 8.1 2.2 0.8
4.3 12 5.4 8.5 2.6 1.1
4.8 12 5.9 9.0 2.6 1.1
13 6.2 9.8 3.0 1.1
Remarks
1. Outer casing winding direction may be either S twist or Z twist.
2. Outer casing end surfaces shall be provided with inner chamfer.
3. Standard strand diameter is defined as round wire diameter prior to forming into flat
wire.

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ANNEXURE 6
(See Table 2 (2))
OUTER CASING (WITH LINER)

Unit: mm
Finished D d Compression
diameter of load (N)
applicable
inner cable Dimension Tolerance Dimension Tolerance
(without
coating)
1.8 5 2.5 1,000 or more
1.8
2.1 6 3.0 2,500 or more
2.6
2.6 7 +0.1 3.8 ±0.2 5,900 or more
3.1 -0.2
3.1 8 4.2 7,800 or more
3.1 9 4.8 9,800 or more

Remark

1. The material of spring portion and coating shall be IS 4454 and synthetic resin
respectively. The working temperature shall be between 800C to 1000C.

2. The method of surface treatment for spring portion shall be in accordance with
clause 5.

3. For the winding direction of outer casing, both S winding and Z winding may be
available.

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ANNEXURE 7
(See Table 2 (3))
CABLE END TYPE A

Unit: mm
Applicable inner Pull off load (kgf Min.) D L
cable diameter Size Tolerance Size Tolerance
1.2 70 5 8
6 8 10
5 8 10
1.5 100 6 8 10 12
8 10 12
2.0 180 6 ± 0.15 8 10 12 ± 0.2
8 10
2.5 280 8 10
10 10
3.0 420 8 10 12 (14)
10 10 12 (14)

Remarks

1. Pull off loads in Table above are applicable to both soldered and cast types.

2. Dimensions enclosed by parentheses shall not be used as far possible.

3. In case of establishing pull off load exceeding the value in the Table, the value shall be as
agreed between the persons concerned.

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ANNEXURE 8
(See Table 2 (3))
CABLE END TYPE B

Unit : mm
Type Inner cable D L H d1 L D2
φ x pull off (Reference (Reference)
load Size Tolerance Size Tolerance Size Tolerance Min.)
(kgf Min.)
25 6
7
6.1 30 5 7
Type 3.0 x 420 6 7 14
B1 3.5 x 550 30 5 8
8.1 + 0.2 ± 1.5 8 ± 0.2
0 (35) (5) (8) (20) (16)
4.0 x 720 8.1 30 8 8 8 16
Type 3.0x 420 6.1 25 6 6 --- 14
B2 3.5 x 550 7 7
4.0 x 720 8.1 30 8 8 --- 16

Remarks

1. Type B1 caulking method shall, as a rule, be square caulking.

2. In case of heavy load, pull off load exceeding the value specified in the above Table may
be established upon agreement between the parties concerned and limited to Type B1.

3. Dimensions enclosed by parentheses shall not be used so far as possible.

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ANNEXURE 9
(See Table 2 (3))
CABLE END TYPE C

Unit: mm
Inner Pull Type C1 Type C2 Type C3 Type C4
cable off
Dia- load D L D L Mater Dia- D L D
meter (kgf, ial meter (Reference)
d
Min.) (max)
Dia- (max.)
Size Toleran Size Tolerance Size Tolerance meter Size Toler- Refe- Toler-
ce ance rence ance
1.5 60 3 4 4 4 5 5.5 4.0 6 8 5
2.0 180 6 6 6 8 5 5.5 4.0 8 8 5
2.5 280 --- --- 7 10 6 6.5 5.0 10 8 5
7 7.5 5.5
3.0 420 --- --- 7 10 7 7.5 5.5 12 8 5
8 10
10 12 8 8.5 6.5 10
± 0.2 ± 0.5 ±1 ± 0.5 ±1
3.5 550 --- --- 7 10 8 8.5 6.5 14 10 6
(7) (12)
8 12 9 9.5 7.5 12
10 12
(10) (14)
4.0 720 --- --- 8 14 8 8.5 6.5 14 10 6
10 (9) (9.5) (7.5) (14)

Remarks
1. In case of heavy load, pull off load exceeding the value specified in above Table may be specified
upon agreement between parties concerned. In such case, L may be lengthened if found necessary.
2. Dimensions enclosed by parentheses shall not be used as far as possible.

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ANNEXURE 10
(See Table 2 (3))
CABLE ENDS TYPE D

Unit : mm
Applicable Pull off load D L ± 2.0 x l Type D1 Type D2
inner cable (kgf Max.) d1 x a Max. d1 x a Max.
diameter Nominal Pitch
1.5 100 50 x 30
2.0 180 6 1.0 65 x 45 5.2 x 6.2 6 x 7.2
2.5 280 80 x 60
90 x 70
3.0 420 55 x 30
3.5 550 65 x 40 6 x 7.2
6 1.0 75 x 50 --- 7 x 8.5
85 x 60 8 x 9.5
95 x 70
3.0 420 65 x 40
3.5 550 75 x 50
4.0 720 8 1.25 85 x 60 7.1 x 8.5 8 x 9.5
95 x 70 9 x 10.5
105 x 80

Remarks

1. Screw threads shall conform to JIS B 0205 (Metric Coarse Screw Threads).

2. Caulking method shall, as a rule, be square caulking.

3. Values with *mark in the Table shall not be used in 3.5 diameter inner
cable.

4. In case of heavy load, pull off load exceeding the value specified in above
Table may be specified upon agreement between the parties concerned. In
such case L may be lengthened if found necessary.

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ANNEXURE 11
(See Table 2 (3))
CABLE END TYPE E

Unit: mm
Diameter of d L h k Pull-off load (N)
applicable
inner cable
36 20
2.0 2.2 56 40 13 2,500 or more
76 60 (1,700 or more)
38 20
2.5 2.7 58 40 15 3,500 or more
78 60 (2,000 or more)

Remarks

1. The material shall be S35C given under JIS G 4051

2. The surface treatment shall be done with Ep-Fe/Zn8 as specified in JIS D 0201

3. The used staking method shall be optional and satisfy the specified pull-off load

4. The screw thread shall conform to JIS B 0205. The screw thread accuracy shall be in
accordance with 6g or 8g of JIS B 0209

5. All dimensions shall be the ones of cable end with surface treatment

6. The values of Pull-off load in the parentheses shall apply where the material of inner cable is
SUS304WR or SUS302ER

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ANNEXURE 12
(See Table 2 (4))
CONNECTOR TYPE A

Unit : mm
Type Inner D do A B C t L l
cable
diameter Size Tolerance Size Tolerance Size Tolerance
4.1 2.5 7 10 1.2
Type 3.5 max. 6.1 3.0 6 12 1.6 20
A1 3.5 8 14 2.3
4.0 --- ---
8.1 10 16 2.3 30
± 0.2 ± 0.5 16 ± 0.5 40
6.1 0 3.0 0 20 8
3.5 3 14 10 1.6 30 18
Type 4.0 5 2.3 40 28
A2 4.0 max. 4.5 7
8.1 0 25 11
3.5 5 16 10 2.3 30 15
4.0 7 12 2.6 40 25
4.5 9

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ANNEXURE 13
(See Table 2 (4))
CONNECTOR TYPE B

Unit : mm

Inner A B L t d0 d1 d2 C D
cable
diameter
3 12 16 60 2.3 Inside M6 x 1.0 --- --- ---
70 2.6 diameter
+ 0.5 ~ 1.0
3.5 6.5 Inside M6 x 1.0 7 10
diameter
+ 0.5 ~ 10

Remark : Screw threads shall conform to JIS B 0205.

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ANNEXURE 14
(See Table 2 (5))
CASING CAP TYPE A

Unit : mm
Applicable Do Type A1 Type A2 Pull off load
outer (kgf Min.)
casing D1 L D1 L
diameter
Size Tolerance Size Tolerance Size Tolerance

5 2.5 5.8 12 5.8 15 5

6 3.0 7 13 7 15 6
7 3.5 8 15 8 15 7
8 4.0 ± 0.3 --- 0 --- 9 0 17 8
10 4.5 - 0.2 --- - 0.3 --- 12 - 0.3 23 10
5.0
12 5.0 --- --- 14 25 12
5.5
ANNEXURE 15
(See Table 2 (5))
CASING CAP TYPE B

Applicable do Type B1 Type B2 Pull off

outer casing Size Tolerance D1 D2 L D1 D2 L d1 d2 load
diameter Size Tolera- Size Tolera- (kgf
nce nce Min.)
5 2.5 5.8 6.8 13 --- --- --- --- --- 8
6 3.0 + 0.3 8 ± 0.1 10 23 --- ± 0.1 --- --- --- --- 10
8 4.0 - 0.2 --- 13.5 17 28 9.5 7.5 14
Remark: Caulking shall, as general rule, be hexagon caulking.

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ANNEXURE 16
(See Table 2 (5))
CASING CAP TYPE C

Unit : mm

Applicable do D D1 *d1 C1 Type C2 type Pull

outer casing off
outer Size Tolerance Nominal Pitch Size Tolerance L l L l1 l2 B load
diameter (kgf
Min.)
5 2.5 6 1.0 7 4 33 17 28 12 4 10 8
43 27 38 22
6 3.0 6 1.0 8 6 36 17 31 12 5 12 10
8 1.25 46 27 41 22
7 3.5 8 1.25 9 6 48 27 33 12 5 12 12
58 37 43 22
8 4.0 10 1.25 10 7.5 48 27 38 17 5 14 14
58 37 48 27
+ 0.3 + 0.3
9 4.5 - 0.2 10 1.25 11 7.5 -0 61 37 41 17 5 14 16
71 47 51 27
10 4.5 10 1.25 12 7.5 63 37 43 17 5 14 18
5.0 73 47 53 27
12 5.0 12 1.25 14 9.5 76 47 46 17 6 17 22
5.5 86 57 56 27
13 5.8 12 1.25 15 9.5 78 47 48 17 6 17 24
88 57 58 27

Remarks

1. Dimensions d1 (dust cover setting groove) with * mark in table may be abbreviated.

2. ** marked chamfer part may be abbreviated.

3. Screw threads shall conform to JIS B 0205 or JIS B 0207.

4. Caulking shall, as general rule, be hexagon caulking.

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ANNEXURE 17
(See Table 2 (5))
CASING CAP TYPE D1

Unit : mm
pplicable do D D1 D2 d1 d2 L l1 l2 L3 Pull
outer casing (Ref- (Ref- off
outer Size Tole- Size Tole- erence Size Tole- erence Size Tole- load
diameter rance rance rance rance (kgf
Min.)
7 3.5 10 30 2.5 --- 12
(*) 9 2.5
3.5 1.0
8 4.0 + 11 + 0.3 33 2.8 --- 14
0.3 1.3 ±0.2 (*) 10 16 9.5 0 12 ±0.2
- 0.2
3.5 1.0
10 4.5 13 36 3.5 1.0 18
5.0 (*) 12 3.0 4.5 2.0
12 5.0 15 40 3.5 1.0 22
5.5 (*) 14 4.5 2.0

Remarks

1. Dimension D1 in the Table indicates the case of die cast part or machined part (with * mark).

2. Caulking shall, as general rule, be hexagon caulking.

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ANNEXURE 18
(See Table 2 (5))
CASING CAP TYPE D2

Unit : mm
Applicable do D D1 D2 d1 d2 d3 L l2 l3 Pull off
Outer (Ref- (Ref- load
casing outer Size Tolerance Size Tolerance erence Size Tolerance erence Size Tolerance (kgf
diameter Min.)
8 2.8
5 2.5 (*) 7 25 3.2 8
3.6
9 2.8
6 3.0 (*) 8 28 3.2 1.0 10
10 14 6 8 8 3.6
10 3.2
7 3.5 (*) 9 3.6 12
3.9 2.0
4.2
31 3.2 1.0
+ 0.3 0 + 0.3 + 0.2
8 4.0 - 0.2 - 0.2 11 0 3.6 - 0.1 14
(*) 10 3.9 2.0
4.2
12 3.6 1.0
9 4.5 (*) 11 3.9
15 20 7.5 10 12 34 2.0 16
4.2
4.8
13 3.6 1.0
10 4.5 (*) 12 3.9 18
5.0 36 4.2 2.0
4.8

Remark

1. Dimension D1 in the Table indicates the case of die cast part or machined part (with * mark).

2. Caulking shall, as general rule, be hexagon caulking.

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 AIS-060
ANNEXURE 19
(See Table 2 (5))
CASING CAP TYPE D3

Unit : mm
Applicable do D D1 D2 d1 d2 D3 L L1 Pull
outer casing (Refer- (Refer- off
outer Size Tolerance Size Tolerance ence) Size Tolerance ence) Size Tolerance load
diameter (kgf,
Min.)
7 3.5 13 10 (*) 13 7 42 12
+ 0.3 ± 0.2 9 15
9 4.5 - 0.2 15 12 (*) 15 7.5 + 0.3 10 9 45.5 ± 0.2 16
11 0
4.5 13 47.5
10 5.0 16 (*) 16 10 52.5 20 18
12 62.5 30

Remarks

1. Dimension D1 in the Table indicates the case of the die cast part or machined part (with * mark).
2 Caulking shall, as general rule, be hexagaon caulking.

ANNEXURE 20
(See Table 2 (5))
CASING CAP TYPE D4

Unit : mm
Applicable do D D1 D2 d1 D2 L l1 L2 Pull
outer casing (Ref- (Refer- off
outer Size Tolerance Size Tolerance erence Size Tolerance ence) Size Tolerance load
diameter (kgf,
Min.)
8 4.0 + 0.3 16.5 ± 0.1 10 20 7.5 + 0.3 10 35 5 3 ± 0.2 25
- 0.2 0

Remark : Caulking shall, as general rule, be hexagon caulking.

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ANNEXURE 21
(See Table 2 (6))
ADJUST BOLT

Unit : mm
Applicable do D1 D B L l1 L2
Casing Cap
Type A1
and A2 Size Tolerance Size Tolerance Nominal Pitch
Outside
diameter
5.8 3.0 5.9 8 1.25 10 38 20
7 2.8 6 1.0 58 40
3.0 + 0.5 + 0.3 8 1.25 10 38 20 12
- 0.2 7.1 0 53 35
8 4.0 8 1.25 12 58 40
8.1 10 1.25 43 14
Remark : Screw threads shall conform to JIS B 0205 or JIS B 0207.

ANNEXURE 22
(See Table 2 (7))
ADJUST NUT

Unit: mm
Applicable D B d1 d2 L a b H
casing cap
Type C and Nominal Pitch Size Tolerance
Adjust Bolt
diameter
6 6 1.0 10 7.5 10 11 2 4 5
8 8 1.25 12 9.5 + 0.3 12 15 3 6 6
10 10 1.25 14 11.5 0 14 11 2 4 5

Remark : Screw threads shall conform to JIS B 0205 or JIS B 0207.

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ANNEXURE 23
(See Table 2 (8))
ROUND JOINT TYPE A 1

Unit : mm
0
End shape θ( ) R l1 l2
90
Type I & II 110 30 45 40
130

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ANNEXURE 24
(See Table 2 (8))
ROUND JOINT TYPE A 2

Unit : mm

End shape θ (0) l1 l2

90
Type I & II 110 40 40
130

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ANNEXURE 25
(See Table 2 (8))
ROUND JOINT TYPE B 1

Unit : mm
Diameter of End shape θ(0) R l1 l2 Pull-off
applicable load (N)
outer casing
90 25
6 Type I & II 40 40
100 100 or
120 30 more

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ANNEXURE 26
(See Table 2 (8))
ROUND JOINT TYPE B 2

Unit : mm
Diameter End Pull
of shape off
applicable d1 d2 d3 d4 l1 l2 l3 l4 a load
outer (N)
casing
5 Type I 5.1 7.1 3.0 6.0 45 55 25 M8x1.25 80 or
80 40 more
6 Type II 6.2 9.1 4.2 7.5 63 70 25 M10x1.25 100
85 45 or
more
Type I --- 70 25
--- 85 40 120
7 Type II 7.2 9.1 4.2 7.5 63 70 25 M10x1.25 or
85 40 more

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ANNEXURE 27
(See Table 2 (8))
ROUND JOINT TYPE B 3

Unit :
mm
Diameter of θ(0) R l1 l2 Pull-off
applicable load (N)
outer casing
90 30
7 50 45 120 or
110 more
130 40

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ANNEXURE 28
(See Table 2 (9))
CASING PROTECTOR

Unit : mm

Applicable outer D t L
casing diameter Size Tolerance Size Tolerance Size Tolerance
5 5.5
6 6.5 1.0
7 7.5 1.5 40 60 80 ± 5% For
8 8.5 ± 0.3 ± 0.3 100 125 150 minimum
9 9.5 1.0 175 200 225 value of L
10 10.5 1.5 250 275 300 shall
12 12.5 2.0 325 350 375 conform
13 13.5 400 425 450 to ± 5.
475 500
Remarks

1. Casing protector shall, as general rule, be secured with adhesive or other proper method so as to prevent
shifting
easily from the designated position on outer casing.

2. Casing protector with dimension L exceeding 500 shall be by agreement between the persons concerned.

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ANNEXURE 29
(See Table 2 (10))
DUST COVER TYPE A

Unit : mm
Inner cable diameter do d1
Uncoated Coated Size Tolerance Size Tolerance
1.2 ---
1.4 1.2 3.5
1.5 --- 1.5 5.5
1.6
--- 1.8 2.0 5.5
2.0 2.1 0
2.5 2.6 2.5 0 5.5 - 0.5
3.0 3.1 3.0 - 0.5 7.0
3.5 --- 3.5 9.0
--- 3.8 4.0
4.0 --- 7.0
--- 4.3 4.3 9.0
--- 4.8 4.8

Remark : Standard wall thickness at tube center portion shall be 1.0

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ANNEXURE 30
(See Table 2 (10))
DUST COVER TYPE B

Unit : mm
Inner cable diameter do d1
Uncoated Coated Size Tolerance Size Tolerance
1.2 --- 1.2 3.5
1.5 --- 1.5 5.5
--- 1.8 2.0 5.5
2.0 2.1
2.5 2.6 2.5 5.5 0
3.0 3.1 3.0 7.0 - 0.5
3.5 --- 3.5 0 9.0
--- 3.8 3.5 - 0.5
4.0 --- 4.0 7.0
--- 4.3 4.0 9.0
4.8 4.5

Remark : Standard wall thickness at tube center portion shall be 1.0.

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 AIS-060

EXPLANATORY NOTE ON CONTROL CABLES FOR AUTOMOBILES

Supplementary explanations shall be given in regard to the contents of this

standard. (The following item numbers are identical to those in the text).

3 MAIN COMPONENT MATERIALS AND SURFACE

TREATMENTS

3.1 Inner Cable

(1) In case the corrosion resistance of inner cable is required to be specially

strong, SUS304WR or SUS302WR of JIS G 4308 (Stainless Steel Wire
Rods) is recommended.
(2) For inner cable (coated wire) coating material, selection is made from
polyethylene, polyacetal, polyamide plastics and the like, depending on
the application and type of cable.

3.2 Outer Casing

(1) Polyvinyl chloride is most widely used as coating material for outer
casing but there is increasing demand for heat resistance, cold
resistance, and other special matters and as materials for these purposes,
development is being advanced on various plastics such as
polyethylene, polypropylene and polyamide resins. As a result, only
synthetic resin was designated in this standard so that actual type of
resin and properties shall be as treated as direction to the parties
concerned.
(2) For the outer casing (synthetic resin tube), material mainly used are
polyethylene, polypropylene, and polyacetal resins, but for the same
reason given above, only synthetic resin was designated so as to leave
the details agreed on between the parties concerned.

3.3 Cable End

The material differs depending on the part shape, dimensions, and whether
the connecting method with inner cable is by caulking or casting in, and
selection made from materials such as BsBM of JIS H 3422 (Free Cutting
Brass Rods), S15C ~ 35C of JIS G 4051 (Carbon Steel for Machine
Structural Use) and ZDC of JIS H 5301 (Zinc Alloy Die Castings).

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4. SHAPES AND DIMENSIONS OF MAIN COMPONENTS

4.1 Inner Cable (Annexure 1, 2, 3 and 4)

(1) Tolerance

In the tolerances, there are those on the minus side but only those on
plus side were taken, using JIS G 3535 as reference. For nominal
diameter 2.0 and under, plus side 0.1 nominal diameter, and for nominal
diameter 2.5 and above, plus side 0.08 nominal diameter were
established as basis.

(2) Elongation

Since the yield point does not appear clearly in steel stranded cable,
tensile load corresponding to 60 percent of designated breaking load
was added, and indicated with the elongation investigated at that time
as reference.

(3) Inner cable (coated cable)

The minimum wall thickness designated indicates the value that shall
be required for minimum assurance in case of eccentric wall thickness
in resin coating.

4.2 Outer Casing (Annexure 5 and 6)

(1) Standard strand diameter has been indicated here as reference to

express the workability from round wire.

(2) Outer casing (resin tube) is normally formed using single resin but
different resins may be used to form two-layer casing.

4.3 Cable End

(1) It is necessary that the cable end pull off load be a value that satisfies
the operating conditions and safety factor but as this is largely
influenced by the cable end shape and size and inner cable diameter, the
value for cable ends used on same inner cable diameter, as principle, is
set to the same value.

(2) Solder penetration length is defined as the length of the part, in which
during the soldering of the cable end, the solder had been drawn up into
the cable by capillary action and hardened.

(3) When joining the inner cable (coated cable) to cable end, the standard
method is to peel off the coating as indicated below before joining.

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 AIS-060

(a) Type A cable end (Annexure 7)

Joining method with inner cable is mainly by soldering but those made by die
casting (inner cable cast in) are increasing. On the pull off load, die cast
formed type is generally higher and although this type has little dispersion in
manufacturing, the use of metal mold makes it unsuited for small volume
production.

(b) Type B cable end (Annexure 8)

The method of making up a connector combination with type A or type B

cable end is generally cheaper than type B1, but there is an advantage in
using die cast formed cable end line type B2.

(c) Type C cable end (Annexure 9)

When installing, the type conforming to the shape of companion hardware is

selected.

(d) Type D cable end (Annexure 10)

Type D cable end is utilized when inner cable installed length is to be

adjusted. Caulking method most largely used is square caulking, but other
caulking method may be used if pull off load is satisfied.

4.4 Connector (Annexures 12 and 13)

Connectors will be utilized in combination with cable ends Type A, C or D.
Commonly called clevis. Those that have been standardized are assembled in
with the cables. Some are provided with side hole and slit to enable installing
to cable during vehicle assembly as shown below.

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4.5 Casing Cap

(1) Type A casing cap (Annexure 14)

Type A casing cap will be used by fitting into companion hole like
adjust bolt or clamped by suitable companion hardware.

(2) Type B casing cap (Annexure 15)

Type B casing cap will be used by fitting into companion hole and
securing the brim.

(3) Type C casing cap (Annexure 16)

Type C1 is installed on outer casing with double nut to permit adjusting

the length. Type C2 is a general fixed system.

(4) Type D casing cap (Annexure 17 ~ 20)

Type D casing cap will be fitted into companion hole and fixed by use
of wave clip, E ring, needle clip and the like. Classified into Type D1,
D2, and D3 by the method used for fixing. Type D4 is secured by force
fit method.

4.6 Adjust Bolt (Annexure 21)

Adjust Bolt will utilized in combination with Type A casing cap for adjusting
outer casing installed length.

4.7 Adjust Nut (Annexure 22)

As special nut for installing dust cover, Adjust Nut will be used in
combination with Type C casing cap or adjust bolt.

4.8 Casing Protector (Annexure 28)

In regard to length, those exceeding 500 mm were considered to be free.

4.9 Dust Cover (Annexure 29 and 30)

On the tightening of the assembling portion, the inner diameter do that

directly cover the inner cable was prescribed to be equal to or slightly smaller
than the inner cable diameter and the inner diameter d1 that covers the casing
cap or adjust nut at the outer casing side was prescribed to 0.5 mm smaller
than the outer diameter of fitting part.

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 AIS-060
5. QUALITY

5.1 Dimensions and Tolerance

(1) On proper use of "medium class" and "rough class" in JIS B 0105,
general practice is to use medium class. On lengthwise dimension,
rough class is sometimes used.
(2) On proper use of "Class 2" and "Class 3" in screw thread accuracy,
Class 2 is generally used and on nuts, Class 3 is partially used.
(3) On cable length dimensions, it is desired that these be determined by
outer casing overall length (with cap and inner cable exposed lengths a
+ b. (Main Text Table 5-1). On cable where construction necessitates
use of dust covers at inner cable exposed part, there is difficulty in
bringing the exposed parts to one place for measurement. In regard to
this, it was decided to determine the dimension as inner cable overall
length (with cable end) L1 indicated in Main Text Table 5-2. On
designating the inner cable nominal length, this may be done to comply
with the individual demand items.

6. TEST METHODS

(1) Load speed in strength test

In the strength tests such as inner cable breaking test and cable end and
casing cap pull-off load test, it is known that high value will be
indicated when the load speed is too fast so that speed not exceeding 50
mm/min. was adopted, taking into consideration working efficiency.

(2) Operating efficiency

It was decided to indicate the operating efficiency in terms of load

efficiency and stroke efficiency.

(a) Load efficiency test

In general, load efficiency indicates better value when the load W
at the operated side is high than when low. This could be
considered as being due to the effects of dust cover tightening
allowance, lubricating oil and grease viscosity, and other being
more readily received. On the operating side load F, considerable
amplitude will be recorded by oscillograph in case of sticking or
slipping. In such cases, the central value should be indicated.
The faster the operating speed at measurement, the greater will
become the amplitude but there will be no transition in the central
value. It could be considered that some relation may exist between
the amplitude size and the operating smoothness or feeling but
this could not be clarified quantitatively.

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The load efficiency differs depending on the curved state of the
outer casing. It is known that the following experimental equation
obtained based on the contacting angle of the outer casing and
inner cable at the curvature part shows highly accurate estimation
when the outer casing is bent with in the range of R100 to 300,
this could be utilized as necessary.
n
-µΣθ
Load efficiency η = c

where µ : Coefficient of friction

n
Σθ : Contact angle between outer casing and inner cable
n
In regard to Σθ, examples of single and multiple curves will be
indicated in Explanatory Note Fig. 1.

Explanatory Note Fig. 1

In general the equation will be as follows in case on n number of
multiple curves.
n n
Σθ = nπ - Σθ1
When the outer casing curved part is properly supported along a
round plate, it has been found that the load efficiency will be
somewhat improved. This could be considered as being due to the
buckling trend of outer casing being prevented.
It is now becoming a general practice to coat the inner cable with
synthetic resin or utilize synthetic resin tube as means of raising
load efficiency.
(b) Stroke efficiency test
The equation indicated in Main Text 6.1.3 (2) expresses the case
of stroke loss resulting from apparent elastic elongation (inner
cable elastic elongation and outer casing elastic contraction).
Operating play resulting from apparent permanent elongation
(inner cable permanent elongation and outer casing permanent
contraction) is not included.
On the inner cable elongation, measurements can be made with
relative ease, and moreover, the inner cable can be utilized alone.

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Taking these into consideration, the reference values and test

method have been indicated in Main Text Annexures 1 and 8.

On the outer casing contraction, casing is difficult to measure by

itself and in addition, it is used in combination with the inner
cable. These have been taken into consideration, resulting in
deciding to represent this by stroke efficiency test prescribed in
Main Text 6.1.3 (2). In the stroke efficiency test, load elongation
curve is derived, and by deriving that for the inner cable
separately, it will be possible to estimate that for the outer casing
alone from the curve.

As a means of raising the stroke efficiency, presetting the strands

in the inner cable is sometimes practiced. By presetting, the
apparent elasticity of the inner cable will be raised but this
amounts to only a few percent and has little effect on improving
the stroke efficiency. It should also be noted that this will not
constitute a positive countermeasure in removing the operating
play.
In case of stranded cable in general, as shown in Explanatory Note
Fig. 2, for the same nominal diameter inner cable, the single has
less elongation than the multi type. For the same load and with
same composition, the larger the nominal diameter, the less will
be elongation. These facts should be taken into consideration.

Explanatory Note Fig. 2

(3) Outer Casing Buckling

When tensile operating load is impressed, the outer casing is subjected to

compressive load and may indicate buckling trend.

Functional impedance caused by buckling would first of all be loss in stroke

efficiency. Aside from this, if the buckling becomes large enough to make it
difficult to return to original shape, it could result in improper operation.

According to the results of various observations, it was found that buckling

had adverse effect on load efficiency and control feeling.

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The general tendency for buckling to develop has been found to start by
buckling in installed surface outer direction, followed by inside surface, and
when both occur, the operating efficiency drops.

When at surface outer buckling, elastic recovery is generally possible but

surface inner buckling is sometimes accompanied by permanent deformation.

On synthetic resin tubes, studies have shown that smaller the outer casing
sectional secondary moment and larger the curve R, the smaller will be the
buckling development load. This has been proved both theoretically and
experimentally.

As related above, development of buckling is not functionally desirable. It is

necessary to know the pattern of its development but on the general handling
of the test method, it would be difficult to define at what point of the
buckling deformation the limiting load should be taken. Also, when
maximum diameter inner cables were inserted into outer casings of the sizes
recommended in this standard, and with tension up to cable breaking load
applied under the condition of 90o bend, 180 o bend and 90o successive bends
over R 100 ~ 300 curves, no symptoms such as inability to recover elasticity
could be observed. Such being the case, test method was not specially
prescribed in this standard. However, if it is considered that buckling is
mainly developed as an effect of operating efficiency, investigation could be
made by detailed performance of operating efficiency test.

Thus, if the operating function should become a special problem or in case of

special application, individual investigation should be made. In the case of
utilizing synthetic resin tube for outer casing, precaution should be taken
since the bending strength is generally low.

(4) Control Feeling

In the control cable functions, aside from operating efficiency, control feeling
or operating smoothness becomes a problem.

As a cause for decling in feeling, sticking slipping symptoms can be listed

first. The most effective countermeasure for this would be to plan on
lowering the friction. For this, studies in lubrication grease selection and
effects of temperature and operating speed would be required. There are also
cases where the problem of resonance in the elastic properties of inner cable,
outer casing and installation parts have been considered.

In regard to feeling, it would be difficult to indicate this by numerical value

at the present stage. Aside from special examples, this is still in the research
stage and is a problem that should be investigated further.

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In relation to the buckling and feeling mentioned above, bending rigidity of

the outer casing becomes a factor. As a simple test method for this, the free
bending of a given length outer casing is supported as a cantilever beam is
compared.

(5) Control Cable Seal

On the preservation of control cable durability, main factors are outer casing
cover maintenance and effectiveness of seals such as dust covers. As a means
of raising the sealing property of dust cover, a method widely used is to
clamp both ends of the dust cover with steel or aluminum rings. Aside from
this, use of packing material such as felt is also utilized.

(6) Functional Deterioration and Longevity by Repeated Operation

Repeated operation and also accumulation of running operational conditions

including environmental changes will generally cause deterioration in
operating functions. Especially with the lowering of operating efficiency and
feeling, operation could become impossible even though inner cable and
outer casing remain unbroken.
The subjects that become the object of investigation include the longevity of
inner cable and cable ends under corrosion or frictional conditions, apparent
accumulative elongation of the inner cable, accumulative elongation of outer
casing, changes in frictional resistance and lubricating function, and
performance and longevity of the various seals.

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ANNEXURE 31
(See Introduction)

COMMITTEE COMPOSITION
Automotive Industry Standards Committee

Chairman
Shri Shrikant R. Marathe Director
The Automotive Research Association of India, Pune
Members Representing
Representative from Ministry of Road Transport & Highways
(Dept. of Road Transport & Highways), New Delhi

Representative from Ministry of Heavy Industries & Public Enterprises

(Department of Heavy Industry), New Delhi

Shri S. M. Ahuja Office of the Development Commissioner, MSME,

Ministry of Micro, Small & Medium Enterprises,
New Delhi

Shri T. V. Singh Bureau of Indian Standards, New Delhi

Director Central Institute of Road Transport, Pune

Shri D. P. Saste
(Alternate)
Dr. M. O. Garg Indian Institute of Petroleum, Dehra Dun
Shri C. P. Ramnarayanan Vehicles Research & Development Establishment,
Ahmednagar
Representatives from Society of Indian Automobile Manufacturers
Shri T.C. Gopalan Tractor Manufacturers Association, New Delhi
Shri K.N.D. Automotive Components Manufacturers Association of
Nambudiripad India, New Delhi
Shri Arvind Gupta Automotive Components Manufacturers Association of
India, New Delhi

Member Secretary
Mrs. Rashmi Urdhwareshe
Deputy Director
The Automotive Research Association of India, Pune

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