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August 29, 2003 · Cessna 650 · N651EJ

Rapid City, SD

Overview

Report Status
Final with probable cause
Event Type
Incident
Date
August 29, 2003
Injury Outcomes
No injuries (9 uninjured)
Location
Rapid City, SD
Aircraft
Cessna 650
Tail Number
N651EJ
Operator
Three Angels Broadcasting Network
Injuries
None
NTSB Number
CHI03IA300

A Cessna 650 experienced a right wing aileron cable failure while in cruise flight at FL390 approximately 200 miles southeast of Rapid City, South Dakota. The pilot in command reported that with the autopilot engaged, the airplane started a gentle roll to the right. The autopilot was disengaged and an approximate 40 degree control wheel deflection to the left was made to keep the wings level. The right aileron did not seem to move with control wheel deflection. The right roll control spoiler did respond to control wheel inputs. All left control surfaces appeared to function normally. The pilots consulted all control malfunction checklists, and there were no changes noted. The pilots decided to continue to the destination. An uneventful, full-flap landing was made at Rapid City Municipal Airport. Maintenance personnel discovered a completely broken right outboard aileron cable. The right aileron cable (Part Number 6260106-25) underwent a metallurgical examination. The wire strands displayed sheared and cut ends due to pinching as if the cable came off its large diameter pulley and was pulled over a small radius and pinched. Only a few tensile cup cone fractures were found, indicating nearly all the wire strands had been sheared or cut prior to final tensile separation of the few remaining strands.

NTSB Probable Cause

The in-flight failure of the right wing aileron cable during cruise.

Full Narrative

On August 29, 2003, at approximately 1635, a Cessna 650, N651EJ, experienced a right wing aileron cable failure while in cruise flight at FL390 approximately 200 miles southeast of Rapid City, South Dakota. The airline transport (ATP) rated pilot in command, the ATP rated co-pilot, and seven passengers on board were not injured. The 14 CFR Part 91 business flight was operating on an instrument flight rules flight plan in visual meteorological conditions. The flight originated from Marion, Illinois, about 1500 with the intended destination of the Rapid City Regional Airport (RAP). The pilot in command reported that with the autopilot engaged, the airplane started a gentle roll to the right. The autopilot was disengaged and an approximate 40 degree control wheel deflection to the left was made to keep the wings level. Positive roll control was available; however, the right aileron did not seem to move with control wheel deflection. The right roll control spoiler did respond to control wheel inputs. All left control surfaces appeared to function normally. The pilots consulted all control malfunction checklists, and there were no changes noted. The pilots decided to continue to destination with minimum maneuvering, for a straight in approach at RAP on runway 32 (8,600 feet long) with the wind closely aligned with the runway. The pilot in command noted that the airplane responded well to roll control inputs at lower airspeeds. An uneventful, full-flap landing was made at RAP. Maintenance personnel discovered a completely broken right outboard aileron cable. The right aileron cable (Part Number 6260106-25) underwent a metallurgical examination at Engineering Systems Inc. (ESI), Aurora, Illinois. ESI reported that the examination of the right aileron showed that the fracture ends were covered in grease and required cleaning using an ultrasonic cleaner with acetone. The cleaned wire stands displayed sheared and cut ends due to pinching. ESI further stated, these fractures are all typical of a wire rope cable coming off its large diameter pulley and being pulled over a small radius and being pinched. This creates the wear and loads necessary to start fracturing the outer strands and working in toward the center. Only a few tensile cup cone fractures were found, indicating nearly all the wire strands had been sheared or cut prior to final tensile separation of the few remaining strands. According to maintenance records, the airplane completed a phase 1-5 Citation continuous inspection program on June 25, 2003. The aileron cables and pulley assemblies were inspected at this time.

Flight

Event TypeIncident
Event Time15:35 MDT
Nearest AirportRapid City Regional (200nm SE)
Runway32
Runway Length8701 ft
Runway Width150 ft
Flight Plan FiledIFR
Flight Plan ActivatedNo
Aircraft FireNo
Aircraft ExplosionNo

Aircraft

AircraftCessna 650
Tail NumberN651EJ
Aircraft CategoryAir
OperatorThree Angels Broadcasting Network
Operating RulePart 91
Engines2
Engine TypeTurbofan
Engine DetailsGarrett · TFE-731-3C · Turbofan · 3481 | Garrett · TFE-731-3C · Turbofan · 3480
Seats10

People & Injuries

Injury SummaryNo injuries (9 uninjured)
Fatal0
Serious0
Minor0
Uninjured9
Total9
Crew 1Age 52 · First Class · None
Crew 2Age 35 · First Class · None

Conditions

ConditionsVMC
Wind30° @ 11 kt
Visibility10 sm
CeilingOvercast 7500 ft
Temperature / Dew Point61 F / 48
Altimeter30.32 inHg
Observation Time21:52
Weather SourceWFAC

Appendix: Source Data