Date: 201404
Local time of day: 0601-1200
Location: ZZZ.Airport, US
Light: Daylight
Aircraft: Citation Excel (C560XL)
Operator: Fractional
Flight plan: IFR
Mission: Passenger
Flight phase: Parked
Aircraft component: Elevator ControlSystem
Component problem: Design; Malfunctioning
Reporter organization: Fractional
Reporter function: Captain; Pilot Flying
Reporter qualification: Flight Crew Air Transport Pilot (ATP)
Human factors: Communication Breakdown; Situational Awareness
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Flight Crew
When detected: Pre-flight
Result: Aircraft Aircraft Damaged; General Flight Cancelled / Delayed; General Work Refused; General Maintenance Action
Contributing factors: Aircraft; Company Policy; Procedure
Primary problem: Ambiguous

Narrative: During the preflight inspection of this C560XLS I discovered a problem with the aircraft elevator cables. The cables routed through the aft maintenance access bay; along the floor of the bay; through a kevlar pulley assembly and on through two holes in the aft bulkhead of the bay. The cables pass through holes in the bracket that mounts the pulley assembly to the aft bulkhead; and also through a phenolic block that is supposed to prevent direct contact between the elevator cables and the holes in the bracket assembly and the aft bulkhead. This phenolic block appears to be mounted too low against the bracket; such that its holes' lower edge is flush with the lower edge of the holes in the pulley bracket and the aft bulkhead. In this position it cannot insulate direct contact between the elevator cables and the metal edges of the holes in the bracket assembly and aft bulkhead. Preflight inspection revealed that the elevator cables had been rubbing against the lower metal edge of the holes in the pulley bracket assembly. There was an abraded area and fine metal shavings present in the area. The aicraft was AOG.Upon next duty assignment on this aircraft; I saw that the discrepancy was signed off as 'Inspected; no defect noted.' There was still clear evidence that the elevator cable was contacting and abrading the metal edges as described above. I spoke with maintenance controllers; and forwarded more photos via email to Maintenance Control. The aircraft was AOG for a second time without flying. Later in that day; I spoke with the Mechanic contracted to correct this discrepancy. He showed me the area from my write-up; and it appeared that the pulley bracket had been adjusted and there was now greater clearance between the elevator cable and the metal brackets. There did not appear to be any further contact between the two; and touchup paint had been applied to the abraded area of the metal bracket holes. The phenolic block was still positioned too low to insulate metal to metal contact between cable and bracket; so it did not appear the mounting had been adjusted. This morning I again reported to the same aircraft. On preflight inspection I discovered the elevator cables once again in direct contact with the metal edges of the bracket holes. I asked my partner to manipulate the elevator while I stood in the aft maintenance access bay and observed. I observed that the elevator cable was once again in direct contact with the metal bracket edge and its movement was abrading the metal around the holes through which the elevator cable runs. I also noticed that the pulley bracket assembly appeared to be slightly loose; allowing its position to shift up and down with very light pressure applied. This shifting made the difference between the elevator cables having enough clearance to not contact the metal edges and the cables directly rubbing along the metal edges. This looseness possibly accounts for the difference in cable clearance between the Mechanic's observation yesterday and my own again this morning. For the third time; the aircraft was AOG; and a maintenance item submitted. I believe maintenance action is required to repair the above situation prior to assigning flights in this aircraft. I am submitting this report because I am concerned that the situation had to be written up three times. There is clear evidence of direct contact and abrasion between the elevator cables and the metal edges of their travel holes. This situation is not allowed; nor deferrable; and needs to be rectified before assigning the aircraft for passenger flights.




Synopsis: During preflight; a C560XLS Captain discovered elevator cables rubbing against the holes in a bracket assembly and aft bulkhead apparently because the pulley bracket was mounted too low. This is the third event with this aircraft.