One of the biggest challenges that DOM’s face is setting maintenance inspection budgets and informing the owners of costs associated with upcoming maintenance events. Better forecasting and communication on high-failure items can help prepare for significant discrepancy correction costs.   

West Star Aviation has had multiple G550’s in for the following 24-month control cable inspection tasks:

• CMP 271011 – Aileron control and trim cables in the main wheel well/wing tailing edge – detailed inspection
• CMP 272108 – Rudder control and trim cables in main wheel wells/tail compartment – detailed inspection
• CMP 273100 – Elevator control and trim cables in main wheel well and tail compartment – detailed inspection
• CMP 276105 – Speed brake cable assemblies in main wheel well/wing trailing edge – detailed inspection

West Star technicians have noted flat spotting of the cross sections of the control cables exceeding maintenance manual limits. The damage is stemming from contact with aircraft structure and grommet feedthroughs.

While these inspection tasks are not significant in terms of labor costs, replacing the cable can become costly and add to aircraft downtime due to interior removal for access. 

A notable example is replacement of both Aileron control and trim cables. This task alone can exceed 300 hours and add a week to downtime to gain access below the floor to facilitate the replacement.