Service difficulty report · Control Cable · Diamon DA20A1

Difficulty date
September 21, 2009
Submitted
October 23, 2009
Operation
General aviation
Make and model
Diamon DA20A1
Aircraft time
5,277 hours
Part
Control Cable
Part number
SF12579
Condition
Worn
Location
Rudder
Part time
5,310 hours
Stage of operation
IN
How discovered
V
Nature of condition
O
Precautionary procedure
K

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

(CAN) FWD 4 RUDDER CABLES ARE ROUTED FROM RUDDER PEDAL ASSYS TO RUDDER BELLCRANK (AFT OF THE MAIN SPAR) THROUGH NYLON GUIDE TUBES THAT PASS UNDER THE SPAR THROUGH A TUNNEL ENCLOSURE. IT WAS NOTED THAT THE CABLES WERE SOMEWHAT WORN AT EACH EXIT END OF THE GUIDE TUBES. AFTER REMOVAL OF THE CABLE (THE CABLES ARE BUILT IN PLACE AND MUST HAVE THE END CUT OFF TO REMOVE), IT WAS NOTED THAT THE WEAR WAS CONSIDERABLY WORSE IN THE GUIDE TUBES THAN INITALLY THOUGHT. 3 OUT OF 4 CABLES HAD BROKEN STRANDS AS WELL AS NUMEROUS SPOTS WHERE CABLE WEAR CAUSED "BLENDING" OF THE CABLE STRANDS. AFT RUDDER CABLES (2) ARE ROUTED FROM THE RUDDER BELCRANK TO THE RUDDER HORN IN A STRAIGHT LINE DOWN THE TAIL CONE. 2 LARGE (APROX 1 1/4" ID) FAIRLEADS AND ONE RUB STRIP (LH CABLE) KEEP THE CABLES FROM SLAPPING THE TAIL CONE STRUCTURE. THESE FAIRLEADS AND RUB STRIP ARE NOT ACCESSABLE UNLESS THE FUEL TANK IS REMOVED. EVEN THEN BECAUSE OF RESTRICTED ACCESS AND BEING UPSIDE DOWN (THE INSPECTOR), IT IS EXTREMELY DIFFICULT TO ASERTAIN THE CONDITION OF THE CABLE PASSING THROUGH/BY THE FAIRLEADS. SOME WEAR WAS NOTED AND UPON REMOVAL AND SIGNIFICANT BLENDING HAD OCCURRED. AIRCRAFT TOTAL TIME WAS 5454 HRS. IT IS UNKNOWN IF THE CABLES HAD BEEN PREVIOUSLY REPLACED. (TC# 20090928014)

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