ICON A5 MM : Fuselage and Vertical Tail : Water Rudder : Maintenance Instructions : Installation of Water Rudder Cable
Installation of Water Rudder Cable
100328-00
The water rudder is actuated by cables. This task explains how to install the water rudder cables.
Applicable Aircraft Serial Numbers
All
Type of Maintenance
Line
Level of Certification
LSA-RM
Task Specific Training Required
No
Special Tools Required
Cable Swaging Tool
Parts Required
ICA012033 Cable
97855A510 Retaining Pin
MS24694C53 Screws
97851A104 Binding Post
91950A029 Washer
AN100C-3 Cable Thimble
Aircraft System and Number
08—Fuselage and Vertical Tail
Safety Equipment
As Needed
Consumables
Tef-Gel®
LOCTITE® 609™
LOCTITE® 243™
Task Instructions
1. Route a new cable (ICA012033, FN 017) around the groove in the ICA008933 Water Rudder Puck, engaging the swaged ball on the cable in the mating recess in the puck.
2. Install a new retaining pin 97855A510 into puck.
3. Coat the sides of the puck, hardware, and cable that will be hidden, with a light coat of Tef-Gel® to help minimize water intrusion.
4. Slide the puck into the water rudder. The puck is properly oriented when the two mating screw holes align and the swaged ball faces aircraft aft when rudder is in the retracted position.
5. Coat two MS24694C53 screws with Tef-Gel® and install them through the water rudder, attaching it to the puck inside. Note that one screw installs from the left and one from the right. Torque these screws to 20 in-lbf.
6. Reinstall the two M81934/2-05C012 bearings M81934/2-05C012 in water rudder using LOCTITE® 609™.
7. Slide a ICA008934 Pivot Bushing into the pivot bore in the water rudder.
8. Verify that nylon tubes are still bonded to pivot flange and secure. Run cable through each one to make sure the cables slides through freely. If either of these are not OK, the nylon tubing will need to be replaced and rebonded.
9. Insert the cable ends into the Nylon tubes in the aft face of the pivot flange. The cable coming off the top of the puck inserts into the top tube, bottom into the bottom.
10. Pull the cable ends out through the top of the pivot flange while guiding the rudder into position with pivot bores aligned. Pay special attention as to not kink the cable.
11. Connect the water rudder to the pivot flange with a 97851A104 Binding Post, with a 91950A029 Washer under each head. Use LOCTITE® 243™ on the threads and torque to 20 in-lbf.
12. Measure each cable from the top face of the pivot flange torque tube and mark with a paint marker. The cable on aircraft right-hand side gets a mark at 71-9/16” form the top face. The cable on aircraft left-hand side gets a mark at 70-1/4” from the top face.
13. Insert the two cable ends up through the water rudder bellcrank assembly in the hull. There is a fore/aft bushing in the bore of the water rudder bellcrank, visible from the bottom. The rudder right-side cable must pass to the right of the bushing and the left cable to the left of it.
14. Pull cable ends out through the water rudder access panel and keep pulling while guiding the water rudder assembly into position, pushing its steering shaft up into the water rudder bellcrank assembly. Use caution to not damage the shaft seal.
15. Prepare the surface of the pivot tang (ICA009078) that mates with the fuselage skin, as well as the corresponding fuselage skin surface, for potting by doing the following:
a. Apply carnauba wax (ICA013211) onto mating surfaces on pivot tang and fuselage and on threads of screws retained from removal steps.
b. Wipe carnauba wax off using a lint free cloth.
c. Allow 5 minutes for the wax to flash off.
d. Repeat the previous steps 3x.
16. Using ICA012218 sealant, apply a thin void-free layer to the mating surfaces of the pivot tang, the fuselage, and both screws.
Note: 
Ensure no sealant is applied to the portion of the pivot tang that interfaces with the water rudder.
17. Fasten the prepped pivot tang to the fuselage with wet-installed screws. Torque the screws to 25-28 in-lbs.
18. Remove any sealant that may have been squeezed out from around the pivot tang and/or around the fasteners to create a clean fillet around the entire perimeter.
Note: 
Ensure no squeeze out is present that will interfere with the operatino of the water rudder.
19. Tape the cable that comes off the top of the water rudder puck to the previously installed “A” string and the cable end that comes off the bottom of the puck to the “S” string. Use the strings to pull the cable ends under the pulley cable guard bolt, over the water rudder retraction pulleys, and once around the pulleys, pull the cable ends out through the water rudder access panel. Remove the string from the cable ends temporarily (keep them marked).
Note: 
It helps to pull one cable at a time through the pulley, swage it, then go to the actuator bay and connect it before doing the other. This prevents any accidental crossing of cables.
20. Terminate the two cable ends as follows:
a. Spread open an AN100C-3 cable thimble just enough to slide it through the aft cable eye of the retraction turnbuckle assembly. Repeat this with the aft cable eye of the extension turnbuckle assembly.
b. Feed the end of the retraction cable first through one side of an MS51844-22 sleeve then through the retraction turnbuckle eye from the previous step, then back around through the other end of the sleeve. Repeat this for the extension end of the cable and its turnbuckle.
c. Find the swage location mark on the retraction cable end. Position the cable so that the center mark is located at the center point of the thimble of the retraction turnbuckle assembly and tighten the cable by drawing the free end through the sleeve and running the sleeve up against the thimble.
d. Verify that the cable is tight around the thimble, the sleeve is hard against the thimble and the mark on the cable is located on the center apex of the thimble, then use a swaging tool to swage the sleeve. Use a go-no-go gauge to very a correct swage.
e. The length of the free end of the cable beyond the edge of the swage fitting should be .125-.250” when finished.
f. Repeat steps c-e with the extension end of the cable.
21. Use adhesive tape to attach cable end to the appropriate string used earlier and use these strings to pull the cable ends up to the retraction actuator and spring.
22. Ensure that the cables are not twisted and that the “retraction” end will connect to the water rudder actuator and the “extension” end to the extension spring.
23. Attach the retraction turnbuckle assembly by inserting the clevis pin through its forward eye, connecting it to the cheek plates attached to the actuator. Install an NAS1149CN616R washer under the cotter pin. Insert and bend a new MS24665-151 cotter pin in the clevis pin per standard practice.
24. Attach the extension turnbuckle assembly by slipping its forward eye onto the aft hook end of the extension spring.
25. Adjust the turnbuckles per rigging procedure. (Inspect Yaw Rigging)
Verification Method
Perform the Water Rudder Actuator and Cables inspection and the Water Rudder Rigging Check procedure. (Installation of Water Rudder Cable)(Water Rudder Actuator and Cables)