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An EMB135 on a scheduled flight control test flight the crew discovers roughness in the aileron controls. Found aileron cable guard installation incorrect causing aileron cable fraying.
| Attributes | |
| ACN | 723386 |
| Time | |
| Date | 200701 |
| Place | |
| Locale Reference | airport : zzz.airport |
| State Reference | US |
| Altitude | agl single value : 0 |
| Environment | |
| Light | Night |
| Aircraft 1 | |
| Operator | common carrier : air carrier |
| Make Model Name | EMB ERJ 135 ER&LR |
| Operating Under FAR Part | Part 121 |
| Flight Phase | ground : parked |
| Person 1 | |
| Affiliation | company : air carrier |
| Function | maintenance : technician |
| Qualification | technician : powerplant technician : airframe |
| ASRS Report | 723386 |
| Person 2 | |
| Affiliation | company : air carrier |
| Function | maintenance : lead technician |
| Qualification | technician : airframe technician : powerplant |
| ASRS Report | 723385 |
| Events | |
| Anomaly | aircraft equipment problem : critical maintenance problem : improper maintenance maintenance problem : improper documentation non adherence : far non adherence : published procedure |
| Independent Detector | other flight crewa |
| Resolutory Action | other |
| Consequence | other other |
| Factors | |
| Maintenance | contributing factor : schedule pressure performance deficiency : testing performance deficiency : scheduled maintenance performance deficiency : non compliance with legal requirements performance deficiency : logbook entry performance deficiency : inspection performance deficiency : installation |
| Supplementary | |
| Problem Areas | Aircraft Chart Or Publication Maintenance Human Performance |
| Primary Problem | Maintenance Human Performance |
Narrative:
During installation of right aileron upper control cable in the wing a cable guard was installed on the wrong side of the cable; resulting in the cable being frayed and changed again. No personnel injury or other aircraft damage noted. I originally installed the cable and my lead technician did the rii on it. This is a difficult area to inspect and we both did not notice that one of the cable guards was installed incorrectly. When the aircraft was released for a functional control flight; the pilots felt the ailerons were difficult to operate. Upon further investigation the cable was found frayed.
Original NASA ASRS Text
Title: AN EMB135 ON A SCHEDULED FLT CTL TEST FLT THE CREW DISCOVERS ROUGHNESS IN THE AILERON CTLS. FOUND AILERON CABLE GUARD INSTALLATION INCORRECT CAUSING AILERON CABLE FRAYING.
Narrative: DURING INSTALLATION OF R AILERON UPPER CTL CABLE IN THE WING A CABLE GUARD WAS INSTALLED ON THE WRONG SIDE OF THE CABLE; RESULTING IN THE CABLE BEING FRAYED AND CHANGED AGAIN. NO PERSONNEL INJURY OR OTHER ACFT DAMAGE NOTED. I ORIGINALLY INSTALLED THE CABLE AND MY LEAD TECHNICIAN DID THE RII ON IT. THIS IS A DIFFICULT AREA TO INSPECT AND WE BOTH DID NOT NOTICE THAT ONE OF THE CABLE GUARDS WAS INSTALLED INCORRECTLY. WHEN THE ACFT WAS RELEASED FOR A FUNCTIONAL CTL FLT; THE PLTS FELT THE AILERONS WERE DIFFICULT TO OPERATE. UPON FURTHER INVESTIGATION THE CABLE WAS FOUND FRAYED.
Data retrieved from NASA's ASRS site as of January 2009 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.