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1953 thru 1962 - Cessna Support

1. Textron Company TEMPORARY REVISION NUMBER 7 DATED 1 DECEMBER 2011 MANUAL TITLE Model 100 Series Service Manual 1953 Thru 1962 MANUAL NUMBER PAPER COPY 0138 1 13 TEMPORARY REVISION NUMBER D138 1TR7 MANUAL DATE February 1962 REVISION NUMBER 1 DATE 3 February 2003 This Temporary Revision consists of the following pages which add to existing pages in the paper copy manual SECTION PAGE SECTION PAGE 24 10 00 1 Thru 5 24 14 01 1 Thru 2 24 10 01 1 Thru 10 24 14 02 1 Thru 2 24 12 01 1 24 14 03 1 Thru 3 24 12 02 1 24 14 04 1 Thru 2 24 12 03 1 Thru 2 24 14 05 1 Thru 2 2A 12 04 1 Thru 2 24 14 06 1 Thru 3 24 12 05 1 24 14 07 1 Thru 3 24 12 06 1 Thru 2 24 14 08 1 Thru 3 24 12 07 1 24 14 09 1 Thru 2 24 12 08 1 24 14 10 1 Thru 2 24 12 09 1 24 14 11 1 Thru 3 2A 12 10 1 24 14 12 1 Thru 3 2A 12 11 1 Thru 2 24 14 13 1 Thru 3 2 12 12 1 2 14 14 1 Thru 3 24 12 13 1 Thru 2 24 14 15 1 24 12 14 1 24 14 16 1 Thru 2 24 12 15 1 24 14 17 1 Thru 3 24 12 16 1 24 14 18 1 Thru 2 2 12 17 1 2 14 19 1 Thru 4 24 12 18 1 2A 14 20 1 Thru 6 24 12 19 1 24 14 21 1 Thru 2 O Cessna Aircraft Company SECTION PAGE SECTION PAGE 2A 12 20 1 2 14 22 1 Thru 4 24 12 21 1 24 14 23 1 Thru 2 24 12 22 1 24 14 24 1 Thru 2 2 12 23 1 2 14 25 1 Thru 2 2 12 24 1 2 14 26 1 Thru 3 2 12 25 1 2 14 27 1 Thru 2 2 12 26 1 2A 14 28 1 Thru 3 24 12 27 1 24 14 29 1 Thru 2 2A 12 28 1 2A 14 30 1 Thru 2 24 12 29 1 2A 14 31 1 Thru 3 2A 12 30 1 Thru
2. Complete a check of the effect on the structural or operational condition b Complete a check of other high time airplanes to find if a service bulletin shall be issued c Find if a reinforcement is required d Change the SID if required D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 00 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 5 Inspection Methods A very important part of the SID program is selecting and evaluating state of the art nondestructive inspection methods applicable to each PSE Potential NDI methods were selected and evaluated on the basis of crack orientation part thickness and accessibility Inspection reliability depends on size of the inspection task human factors such as qualifications of the inspector equipment reliability and physical access Visual fluorescent liquid penetrant eddy current and magnetic particle methods are used A complete description of those methods are presented in Section 2A 13 01 Nondestructive Inspection Methods and Requirements 6 Related Documents A Existing Inspections Modifications and Repair Documents 1 Cessna has a number of documents that are useful to maintaining continued airworthiness of airplanes a Cessna Model 100 Series Service Manual P N D138 1 13 b Cessna Model 150 IPC P N P438 12 Model 172 and 175 IPC P N P257 12 Model 180 and 182 IPC P N
3. Total Time 1 Description A Operation 12 gives Supplemental Inspection Document items that are to be examined after the first 5 years The inspection is to be repeated every 5 years after the initial inspection has been accomplished for airplanes operating in a mild or moderate corrosion environment Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Doa preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual TASK ZONE MECH INSP REMARKS For Models 180 and 185 this inspection is for 721 722 mild moderate corrosion environment Insp
4. 5 Are the moisture drains blocked or is there inadequate drainage 6 What was the environment the time of exposure to the environment and the use of the airplane 7 Was there a variation in past maintenance history and or use of the airplanes in the operator s fleet 8 Were there variations in the production build standard in the operator s fleet 23 Reporting A The minimum requirements to prevent or control the corrosion in the Corrosion Prevention and Control Program CPCP were made on the best information knowledge and experience available at the time As this experience and knowledge increases the CPCP s intervals will be changed as necessary Refer to CPCP Damage Report Form Figure 2 in Section 2A 30 00 1 You must contact the Cessna Aircraft Company about all Level 2 or 3 corrosion of the structure that is on the list in the Baseline Program that is found during the second and subsequent corrosion program inspections Refer to Reporting System NOTE You do have to contact the Cessna Aircraft Company about corrosion that is found on structure that is not on the list in the Baseline Program for example the secondary structure 24 Program Implementation A When is started it is important to do the items that follow 1 Startinspections at the recommended interval following the completion of the first SID inspection 2 Once the corrosion program inspection CPI is started repeat the subsequent ap
5. GUAM J ER SEVERE PAPUA Sin gt NEW GUINEA INDONESIA dii Se Pa a DE AN D S FIJI M SEVERE 2 NEW CALEDONIA SEVERE 1 CORROSION SEVERITY LEGEND NEW ZEALAND LI MILD 4 es SEVERE South Pacific Corrosion Severity Map Figure 7 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 12 Cessna Aircraft Company Feb 3 2003
6. TITLE Elevator Trim Pulley Bracket and Actuator Bracket Structure Inspection Models 150 172 175 and 182 1962 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 182 Serial Numbers 18253599 thru 18254423 INSPECTION COMPLIANCE ALL USAGE INITIAL 1 000 Hours NOTE REPEAT 1 000 Hours NOTE NOTE Coordinate this inspection with the trim tab actuator overhaul PURPOSE To verify the integrity of the elevator trim pulley brackets and the actuator support brackets INSPECTION INSTRUCTIONS A Remove the trim tab door to get access to the actuator support hardware Refer to the Model 100 Series Service Manual B Remove seats floor covering and floor inspection panels as necessary to inspect elevator trim pulley brackets and actuator support brackets for cracks corrosion and bent flanges Straighten bent flanges and check for any cracking using at least a 4X power magnifying glass and a bright light Refer to Figure 1 1 Clean area before inspecting if grime or debris is present C Inspect all pulleys for wear flat spots and freedom of rotation D Inspect all fasteners and attaching structure for integrity ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATI
7. difference in the two values must not exceed 0 596 IACS The functional performance of the conductivity instrument must be verified at the intervals defined by the controlling specification or the manufacturer s recommendation whichever is less 3 Calibration Reference Standards a Each instrument must have a minimum of two aluminum alloy instrument conductivity standards Their values must be 1 Onein the range of 25 to 32 lACS 2 One in the range of 38 to 62 IACS b There must be a minimum difference of 1096 IACS between the standard for the low end of the range and that for the high end of the range The conductivity values of the low and the high reference standard must be beyond the expected range of conductivity of the material for inspection D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 9 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL c The instrument conductivity standards must be certified to be accurate within 0 85 IACS to 0 85 IACS by the comparison method to the laboratory conductivity standards Use the ASTM B193 procedure in a system per ISO 10012 1 ANSI NCSL Z540 1 or equivalent foreign documentation Inspection Considerations a Temperature Do not do tests until the temperature of the probe the standards and the part or material has been allowed to equalize The temperatures must stay equalized and constant th
8. 30 01 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 2 Care and replacement of solid film lubricants require special techniques peculiar to the particular solid film being used Good solid film lubricants are lubricants conforming to Specification MIL PRF 81322 a Solid film lubricants prevent galvanic coupling on close tolerance fittings and reduce fretting corrosion Surface preparation is extremely important to the service or wear life of solid film lubricants b Solid film lubricants are usually applied over surfaces coated with other films such as anodize and phosphate They have been successfully applied over organic coatings such as epoxy primers CAUTION Solid film lubricants containing graphite either alone or in mixture with any other lubricants should not be used since graphite is cathodic to most metals and will cause galvanic corrosion in the presence of electrolytes E Requirements peculiar to faying surfaces of airframes airframe parts and attaching surfaces of equipment accessories and components 1 When repairs are made on equipment or when accessories and components are installed the attaching surfaces of these items should be protected The following requirements are peculiar to faying surfaces on airframes airframe parts and attaching surfaces of equipment accessories and components 2 Surfaces of similar or dissimilar metal
9. AC current setting and the magnetic field strength to maximum NOTE current is preferred but DC current may be needed for increased penetration into the part 2 Space the legs of the electromagnetic yoke to allow the part to pass between them 3 Put the part between the legs of the electromagnetic yoke 4 Energize the yoke with a magnetic field higher than that used for the inspection Do not allow the part to touch the legs of the electromagnetic yoke 5 Pull the electromagnetic yoke away from the part D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 Page 18 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 6 De energize the electromagnetic yoke when about 2 feet from the part 7 Testthe remaining magnetic field in the part with the field indicator Hall effect meter or equivalent equipment 8 Ifthe remaining magnetic field in the part is no more than Gauss the part is considered demagnetized If more than 3 Gauss repeat the demagnetization procedure 7 After Inspection a Refer to the General Requirements section for information on how to report inspection results b Completely remove the magnetic particles from the part or assembly c Reapply any protective coatings to the part to prevent corrosion NOTE Materials and methods must be approved for use by the applicable Cessna Aircraft Service Manual Structural Repair Manual or Compone
10. D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 10 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Urgent Airworthiness An urgent airworthiness concern is damage that could jeopardize continued Concern safe operation of any airplane An urgent airworthiness concern typically requires correction before the next flight and expeditious action to inspect the other airplanes in the operator s fleet Widespread Corrosion Widespread corrosion is corrosion of two or more adjacent skin or web bays a web bay is defined by frame stringer or stiffener spacing Or widespread corrosion is corrosion of two or more adjacent frames chords stringers or stiffeners Or widespread corrosion is corrosion of a frame chord stringer or stiffener and an adjacent skin or web bay Refer to Inspection Area NOTE 1 lf Level corrosion is determined at an inspection it should be reported Any corrosion that is more than the maximum acceptable to the design approval holder or the FAA or applicable regulatory authority must be reported in accordance with current regulations This determination should be conducted jointly with the design approval holder 14 Corrosion Prevention Materials A Approved Corrosion Preventative Compounds Table 1 Corrosion Preventative Compounds U074098 Cessna Service Parts and To assist in protecting Programs airplanes from corrosion
11. D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 22 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL D If Level 3 corrosion is found during the first inspection 1 Immediately contact Cessna Aircraft Company and the FAA or applicable regulatory authority of the corrosion you found Refer to Reporting System Give sufficient information to make sure that the condition is a possible urgent airworthiness concern for your fleet Get assistance from Cessna Propeller Aircraft Product Support to develop a plan of action Apply the corrosion program inspection which includes the repair of the structure Contact Cessna Aircraft Company for an approved repair procedure Do a report that has the information of the findings Refer to Corrosion Prevention And Control Program Reporting System Description And Operation Continue with the Baseline Program and other steps of procedure required by the FAA or applicable regulatory authority Examine this area carefully during future inspections E If no corrosion is found during the second or subsequent inspection 1 2 Continue with the current Corrosion Prevention and Control Program No adjustment of the current program is required It is recommended that you record the results of the inspection for a possible increase of the corrosion inspection interval F If Level 1 corrosion is foun
12. NOTE A good quality program is one that will control all structural corrosion at Level 1 or better C Corrosion Program Levels NOTE In this manual the corrosion inspection tasks are referred to as the corrosion program inspection 1 Level 1 Corrosion a Corrosion damage occurring between successive inspection tasks that is local and can be reworked or blended out with the allowable limit b Local corrosion damage that exceeds the allowable limit but can be attributed to an event not typical of the operator s usage or other airplanes in the same fleet e g mercury spill c Operator experience has demonstrated only light corrosion between each successive corrosion task inspection the latest corrosion inspection task results in rework or blend out that exceeds the allowable limit 2 Level 2 Corrosion a Level 2 corrosion occurs between two successive corrosion inspection tasks that requires a single rework or blend out that exceeds the allowable limit A finding of Level 2 corrosion requires repair reinforcement or complete or partial replacement of the applicable structure 3 Level 3 Corrosion a Level 3 corrosion occurs during the first or subsequent accomplishments of a corrosion inspection task that the operator determines to be an urgent airworthiness concern 4 References A This is a list of references for the Corrosion Prevention and Control Program 1 FAA Advisory Circular AC120 CPCP Development and Implemen
13. 1953 1962 SERVICE MANUAL 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Vertical Stabilizer Rudder and Vertical Stabilizer Attachment Not Allowed 6 INSPECTION METHOD Visual Borescope and Eddy Current if required 7 REPAIR MODIFICATION Replace damaged bolts and nuts Replace damaged fittings and small parts Replace damaged or loose rivets Repairs may be made in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Any repair not available in Section 19 should be coordinated with Cessna Customer Service prior to beginning the repair 8 COMMENTS Coordinate this inspection with SID 55 10 01 Horizontal Stabilizer Elevators and Attachments Inspection D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 22 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18495 DETAIL VERTICAL STABILIZER CENTER RUDDER DETAIL NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL DETAIL B 051071007 VERTICAL STABILIZER RUDDER AND ATTACHMENTS INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 22 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18496 LOWER HINGE CENTER HINGE DETAIL G DETAIL E RUDDER UPPER HINGE DETAIL F N
14. CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 62 Each flight control cable will be physically inspected by passing a cloth along the entire cable Pay particular attention at all pulley fairlead bulkhead seal locations and other locations where the cable may be subject to chafing or wear NOTE may be necessary to a second person move the flight control System being inspected to ensure that the entire cable run in an affected area is checked ES Any flight control cable which snags the cloth due to broken wires is to be slackened if not previously slackened and a loop test performed to identify number and location of individual broken wires refer to Inspection of Control Cable Wire breakage criteria is as follows for all cable systems a Individual broken wires are acceptable in any cable provided that no more than three individual wires are broken in any given ten inch 0 254 m cable length If number of individual broken wires cannot be determined cable is to be rejected Any amount of cable or wire wear is acceptable provided the individual broken wire criteria is met b Reject any cable if corrosion is found which appears to have penetrated into interior of cable If extent of corrosion cannot be determined cable is to be rejected 5 Inspect all cable termination fittings clevises turnbuckles anchors swagged balls etc for security of installation proper hardware and evidence
15. Dec 1 2011 2A 20 01 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Inspection of Cable System NOTE Fortools and equipment used in checking and rigging refer to the appropriate sections of 1 Model 100 Series Service Manual Routing a Examine cable runs for incorrect routing fraying and twisting Look for interference with adjacent structure equipment wiring plumbing and other controls b Check cable movement for binding and full travel Observe cables for slack when moving the corresponding controls Cable Fittings a Check swaged fitting reference marks for an indication of cable slippage within the fitting Inspect the fitting for distortion cracks and broken wires at the fitting b Checkturnbuckles for proper thread exposure Also check turnbuckle locking clip or safety wire Inspection of Control Cable a The control cable assemblies are subjected to a variety of environmental conditions and forms of deterioration that ultimately may be easy to recognize as wire strand breakage or the not so readily visible types of corrosion and or distortion The following data will aid in detecting an unserviceable cable condition b Broken Wire 1 Examine cables for broken wires by passing a cloth along the length of the cable This will detect broken wires if the cloth snags on the cable Critical areas for wire breakage are those sections of
16. During preventative maintenance broken wire and wear of the control cable are also checked 2 If the surface of the cable is corroded carefully force the cable open by reverse twisting and visually inspect the interior Corrosion on the interior strands of the cable constitutes failure and the cable must be replaced If no internal corrosion is detected remove loose external rust and corrosion with a clean dry coarse weave rag or fiber brush CAUTION Do not use metallic wools or solvents to clean installed cables Metallic wools will embed dissimilar metal particles in the cables and create further corrosion Solvents will remove internal cable lubricant allowing cable strands to abrade and further corrode 3 After thorough cleaning of exterior cable surfaces if the cable appears dry the lubrication originally supplied on the cable has probably oxidized and needs to be replaced with a light oil bw motor oil 3 in 1 oil LPS 2 WD 40 or Diesel Fuel Apply the oil with a cloth and then rub the cable with the cloth to coat the cable with a thin layer of oil Excessive oil will collect dust and be as damaging to the cable as no lubrication D Piano Type Hinges 1 The construction of piano type hinges forms moisture traps as well as the dissimilar metal couple between the steel hinge pin and the aluminum hinge Solid film lubricants are often applied to reduce corrosion problems D138 1 13 Temporary Revision Number 7 Dec 1 2011 2
17. IR d Refer to the General Requirements section for information on how to report inspection results D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 8 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL D Conductivity Testing 1 a General Conductivity testing is effective to find the material properties of aluminum structures This is done through induction of eddy currents into the part The eddy currents will alter the magnetic field around the probe Data are taken and compared to approved ranges for the material tested Other materials or geometric changes in the area can influence the conductivity output of the instrument Therefore you must have the applicable material specification and engineering drawing A typical use is to define material properties following heat application Examples of such situations include structure heated by an engine or APU fire damage and lightning strike This is a general procedure to find the conductivity of aluminum structures This procedure is used along with the applicable material specification and structural engineering drawings to decide whether the conductivity values are in an approved range Instrument Parameters a NAME The following equipment was used to develop the inspection procedures referred to in this manual Alternative equipment may be used if it has the same sensitivity Ref
18. Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 5 Years NOTE REPEAT 5 Years NOTE SEVERE INITIAL 3 Years NOTE REPEAT 3 Years NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To ensure structural integrity of the root rib structure 4 INSPECTION INSTRUCTIONS A Remove the wing to fuselage fairing Refer to the Model 100 Series Service Manual B Visually inspect the inboard side of root ribs at WS 22 12 For Model 150 or WS 23 62 For all other models except 150 for corrosion 1 Clean area before inspecting if grime or debris is present C Remove the inspection cover if fitted outboard of WS 22 12 For Model 150 or WS 23 62 For all other models except 150 D Visually inspect outboard side of root ribs at WS 22 12 For Model 150 or WS 23 62 For all other models except 150 for corrosion 1 Clean area before inspecting if grime or debris is present E Repair any corroded areas in accordance with the Repair Modification section below Install the wing to fuselage fairing and inspection cover Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABL
19. are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS Elevator trim system for Models 150 172 175 330 340 and 182 1962 1 Inspect elevator trim brackets and actuator support brackets 2 Inspect pulleys attaching structure and fasteners Refer to Section 2A 14 02 Supplemental Inspection Document 27 30 01 for inspection procedures Elevator trim system for Models 180 182 prior to 330 340 1962 and 185 1 Inspect elevator trim brackets and actuator support brackets 2 Inspect pulleys attaching structure and fasteners Refer to Sec tion 2A 14 03 Supplemental Inspection Document 27 30 02 for inspection procedures For Models 180 182 prior to 1962 and 185 inspect 330 340 trim screw barrels and stabilizer screw jack actuator threads Refer to Section 2A 14 04 Supplemental Inspection Document 27 42 01 for inspection pro cedures End of Operation 15 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 15 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 16 Date Registration Number Serial Number Total Time 1 Description A Operation 16 gives Supplemental Inspection Document items that are to be examined after 3 000 hours or 10 years whichever occurs first The inspection is to be repeated every 500 hours o
20. control procedures in an inspection area and there is a report to show that corrosion is always controlled to Level 1 or better the current inspection program can be used a The Baseline Program is not always sufficient if the airplane is operated in high humidity severe environments has a corrosive cargo leakage or has had an unsatisfactory maintenance or repair When this occurs make adjustments to the Baseline Program until the corrosion is controlled to Level 1 or better Refer to Section 2A 30 01 Corrosion Severity Maps to determine the severity of potential corrosion 3 The CPCP consists of the corrosion inspection applied at a specified interval and at times a corrosion inspection interval can be listed in a Service Bulletin For the CPCP to be applied remove all systems equipment and interior furnishings that prevent sufficient inspection of the structure A nondestructive test NDI or a visual inspection can be necessary after some items are removed if there is an indication of hidden corrosion such as skin deformation corrosion under splices or corrosion under fittings Refer to the Baseline Program 4 The corrosion rate can change between different airplanes This can be a result of different environments the airplane operates in flight missions payloads maintenance practices for example more than one owner variation in rate of protective finish or coating wear a Some airplanes that operate under equivalent environm
21. electrolyte comes in contact with this type of structure the grains and boundary material will act as anode and cathode and undergo galvanic corrosion The corrosion proceeds rapidly along the grain boundaries and destroys the solidity of the metal Exfoliation gives the appearance of sheets of very thin metal separated by corrosion products lt is a form of intergranular corrosion Since the corroded products are thicker than the uncorroded aluminum exfoliation shows itself by lifting up the surface grains of a metal by the force of expanding corrosion This type of corrosion is most often seen on extruded sections where the grain thicknesses are usually less than in rolled alloy form Dissimilar Metal Corrosion Refer to Figure 1 1 Dissimilar metal corrosion occurs when dissimilar metals are in contact in the presence of an electrolyte A common example of dissimilar metal contact involves the attachment of aluminum parts by steel fasteners Concentration Cell Corrosion Refer to Figure 1 1 Concentration cell corrosion occurs when two or more areas of the same metal surface are in contact with different concentrations of the same solution such as moist air water and chemicals 2 The general types of concentration cell corrosion are identified as metal ion cells and oxygen cells Refer to Figure 1 Filiform Corrosion 1 Filiform corrosion is a concentration cell corrosion process When a break in the protective coating o
22. for example the insulation covers and upholstery as necessary to do the corrosion inspection 2 Clean the areas given in the corrosion inspection before you inspect them D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 2 Cessna Aircraft Company Feb 3 2003 10 11 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 3 Doavisual inspection of all of the Principal Structural Elements PSEs and other structure given in the corrosion inspection for corrosion cracking and deformation a Carefully examine the areas that show that corrosion has occurred before NOTE Areas that need a careful inspection are given in the corrosion inspection b Nondestructive testing inspections or visual inspections can be needed after some disassembly if the inspection shows a bulge in the skin corrosion under the splices or corrosion under fittings Hidden corrosion will almost always be worse when fully exposed 4 Remove all of the corrosion examine the damage and repair or replace the damaged structure a Apply a protective finish where it is required b Clean or replace the ferrous metal fasteners with oxidation b Remove blockages of foreign object debris so that the holes and clearances between parts can drain 6 For bare metal on any surface of the airplane apply corrosion prevention primer refer to the Application of Corrosion Preventative Compounds a Apply a polyurethane to
23. for inspection The condition of the surface of the inspection area is important to the inspection The surface must be cleaned of all paint and other surface contamination 2 The penetrant is a liquid that can get into surface openings A typical penetrant inspection uses four basic steps a The penetrant is put on the surface and allowed to stay for a period of time to let the penetrant get into the surface openings b The penetrant on the surface is removed c A developer is used The purpose of the developer is to pull the penetrant that is left in the surface openings back onto the surface It also improves the contrast between the indication and the background This makes indications of discontinuities or cracks more visible d Interpretation happens The area for inspection is examined for penetrant on the surface and the cause of the penetrant indication found B Materials and Equipment 1 The following equipment was used to develop the inspection procedures referred to in this manual Alternative equipment may be used if it has the same sensitivity Refer to the guidelines in this section for more information on equipment parameters NAME NUMBER MANUFACTURER Fluorescent Penetrant ZL 27A Magnaflux Corp 3624 W Lake Ave Glenview IL 60026 Phone 847 657 5300 Web http www magnaflux com Penetrant Cleaner Remover SKC S Magnaflux Corp Developer ZP 9F Magnaflux Corp Portable Ultraviolet Light ZB 23A Magnaflux Co
24. inspect these areas 1 Stabilizer attachment to the tailcone bulkhead 2 Front and rear spars NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information KKK End of Operation 6 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company ZONE 210 510 520 610 620 510 520 610 620 310 320 720 330 340 MECH INSP REMARKS 2 12 06 Page 2 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 7 Date Registration Number Serial Number Total Time 1 Description A Operation 7 gives Supplemental Inspection Document items that are to be examined after the first 4 000 hours of operation or 10 years whichever occurs first The inspection is to be repeated every 1 000 hours of operation or 3 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified insp
25. note the type of fastener and location to aid in reinstallation 4 Inspect the 0532001 28 skin for cracks a Check the skin centerline lightening hole for cracks If cracks are present and extend beyond the centerline lightening hole repair or replace the skin The skin may be repaired by trimming the damaged portion of the part and inserting a section of 0 020 in thick 2024 T42 AlClad aluminum with upper and lower flanges overlapping the existing skin b Skins that have minor cracking that does not extend beyond the flange of the centerline lightening hole may be repaired by bending out such cracking in the flange c Any buckled area should be straightened and inspected for cracking d If cracks extend beyond the flange replace the skin 5 Refer to Figure 1 Drill out the 6 rivets securing the leading edge skins to the spar on the left and right upper or lower not both surfaces to pull the skin back for tool access Use care to not buckle skins 6 Drill out rivets from the trailing edge of the horizontal stabilizer between the inboard and the second rib outboard at BL 17 25 Also remove the rivets attaching the pulley bracket doublers to the top and bottom skins in this area This will allow the skins to be flexed back to allow for tool access Use care to not buckle skins 7 From inside the right side of the stabilizer drill out the rivets securing the trim cable pulley bracket to the inboard rib Leave the cables routed
26. ribs and attach fittings for cracks corrosion loose fasteners elongated fastener attach holes and deterioration Visually inspect the forward and aft vertical stabilizer attach fittings for loose fittings and cracks 1 Clean area before inspecting if grime or debris is present Inspect rudder for deterioration resulting from fatigue wear overload wind damage and corrosion E Inspect skins spars and ribs for cracks corrosion and working fasteners Pay particular attention to the skins at the location where stringers pass through ribs Apply finger pressure at the intersection to check for free play indicating a broken rib 1 Visually inspect balance weight attach rib for cracks 2 Clean area before inspecting if grime or debris is present F corrosion or a frozen bearing is found 4 B above replace the rudder hinge or conduct a surface eddy current inspection for cracks of each rudder hinge attach fitting Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Surface Inspection for additional instructions The inspection is for the aluminum structure outside of the bearing so set the instrument for aluminum G Install rudder and install all previously removed access panels Refer to the Model 100 Series Service Manual D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 22 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES
27. the end of the crack until a point is reached where the crack signal amplitude has been reduced by 50 The center of the probe coil is considered to be the end of the crack d Refer to the General Requirements section for information on how to report inspection results C Bolthole Inspection 1 Description a This is a general procedure for the use of the eddy current method to find discontinuities within holes This should be used along with specific instructions for inspection in the procedure that referred to this section 2 Instrument Parameters a The following equipment was used to develop the inspection procedures referred to in this manual Alternative equipment may be used if it has the same sensitivity Refer to the guidelines in this section for more information on equipment parameters D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 5 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL NAME NUMBER MANUFACTURER Eddy Current Instrument Nortec 2000 Olympus NDT Phone 781 419 3900 Web http www olympusndt com Bolthole Eddy Current Probe VM101BS X XX VM Products Inc with 1 8 inch coil NOTE 1 Phone 253 841 2939 Web http www vmproducts net Combined Aluminum Surface VM 89A VM Products Inc and Bolthole Eddy Current Reference Standard NOTE 2 Combined Steel Surface VM89S VM Products Inc and Bolthole Eddy Current Ref
28. the latest corrosion inspection task results in rework or blend out that exceeds the allowable limit Level 2 Corrosion Level 2 corrosion occurs between two successive corrosion inspection tasks that requires a single rework or blend out that exceeds the allowable limit A finding of Level 2 corrosion requires repair reinforcement or complete or partial replacement of the applicable structure Level 3 Corrosion NOTE 1 Level 3 corrosion occurs during the first or subsequent accomplishments of a corrosion inspection task that the operator determines to be an urgent airworthiness concern Light Corrosion Light corrosion is corrosion damage so slight that removal and blendout over multiple repeat intervals RI may be accomplished before material loss exceeds the allowable limit Local Corrosion Generally local corrosion is corrosion of a skin or web wing fuselage empennage or strut that does not exceed one frame stringer or stiffener bay Local corrosion is typically limited to a single frame chord stringer or stiffener or the corrosion of more than one frame chord stringer or stiffener where no corrosion exists on two adjacent members on each side of the corroded member Principal Structural A PSE is an element that contributes significantly to carrying flight ground or Element PSE pressurization loads and whose integrity is essential in maintaining the overall structural integrity of the airplane Refer to Inspection Area
29. 1 2011 2 13 01 17 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL b Position the legs on opposite ends of the part along a line perpendicular to the expected direction of the discontinuity NOTE may take several inspections in several directions to find discontinuities that are oriented in different directions NOTE Experience with magnetic particle inspection is necessary to find the amount of aan o magnetic flux necessary to show discontinuities Spray the magnetic particles on the part Energize the electromagnetic yoke for a minimum of 1 second Test the magnetic field with the field indicator Hall effect meter or equivalent equipment Quality Indicators such as a Pie Gauge or shim can be used to show the strength of the magnetic field Most quality indicators will need the magnetic particles to be put on the part surface to show magnetic field strength 1 2 If the field strength is not sufficient small discontinuities might be missed Repeat these steps with more magnetization If the field strength is too large discontinuities might be hidden behind non relevant fluorescent indications Demagnetize the part and then repeat these steps with decreased magnetization NOTE If the strength of the magnetization cannot be adjusted on the electromagnetic yoke adjust the distance between the legs to adjust the strength of th
30. 100 SERIES 1953 1962 SERVICE MANUAL 2 Remove the wing front spar attach bolts Visually inspect the holes on the wing and fuselage sides of the fittings and surrounding area for corrosion a Pay particular attention to potential corrosion in the fitting inside the fuselage front carry thru spar b Conduct a bolt hole eddy current inspection of the front spar attach fittings Refer to Section 2A 13 01 Non destructive Inspection Methods and Requirements Eddy Current Inspection Bolt Hole Inspection for additional instructions NOTE With the front spar in position there are three segments through the hole There is a fabrication joint in the center segment wing side so expect a crack like indication at about 2 00 and 10 00 o clock positions Indications caused by the fabrication joint are not a cause for rejection c Install the front spar attach bolt 3 Remove the wing rear spar attach bolts Mark the location of the indexing slot in the heads of both eccentric bushings Remove the bushings Visually inspect the holes on the wing and fuselage sides of the fittings and surrounding area for corrosion a Pay particular attention to potential corrosion in the fitting inside the rear carry thru spar b Conduct a bolt hole eddy current inspection of the rear spar attach fittings Refer to Section 2A 13 01 Non destructive Inspection Methods and Requirements Eddy Current Inspection Bolt Hole Inspection for additional ins
31. 182 prior to 1962 and 185 2 14 04 27 42 01 Horizontal Stabilizer 1 000 Hours Screw Jack Actuator Inspection Models 180 182 prior to 1962 and 185 2 14 05 32 11 01 U Bolt Replacement 1 000 Hours or Models 172 175 3 Years and 182 2 14 06 32 13 01 Main Landing Gear MILD Flat Spring and MODERATE Attach Fittings 20 Years Corrosion Inspection All Models SEVERE 19 Years 2A 14 07 32 13 02 Main Landing Gear 3 000 Hours or Fittings Inspection 5 Years All Models 2A 14 08 32 13 03 Main Landing Gear 4 000 Hours or Axle Inspection 10 Years Models 2A 14 09 32 13 04 Main Landing Gear Every time skis Spring Axle Attach installed or Inspection with skis removed Models 180 and 185 2A 14 10 32 13 05 Main Landing Gear MILD Spring Axle Attach MODERATE Inspection without 5 Years skis pud 180 SEVERE 3 Years D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INSPECTION COMPLIANCE INSPEC TION OP REPEAT ERATION 3 000 Hours or 8 5 Years 1 000 Hours 15 1 000 Hours 15 1 000 Hours 15 1 000 Hours or 24 3 Years MILD 11 MODERATE 10 Years SEVERE 5 13 Years 1 000 Hours or 17 5 Years 1 000 Hours or 7 3 Years Every time skis 27 are installed or removed MILD 12 MODERATE 5 Years SEVERE 3 14 Years 2A 14 00 Page 2 Feb 3 2003 DETAILS FOUND IN SECTION 2A 14 XX 2 14 11 2 14 12 2 14 13 2 14 14 2 14 15 2 14 16 2 14 17 2 14 18 2 14
32. 2 2A 14 32 1 2A 13 00 1 Thru 8 2A 20 01 1 Thru 6 2A 13 01 1 Thru 23 2A 30 00 1 Thru 24 2A 14 00 1 Thru 5 2A 30 01 1 Thru 12 REASON FOR TEMPORARY REVISION 1 To add the Supplemental Inspection Documents 5105 Information 2 Toadd the Corrosion Prevention and Control Program Information 3 To add Control Cable Inspection Information RES INSTRUCTIONS FOR THIS TEMPORARY REVISION For Paper Publications file this cover sheet behind the publication s title page to identify inclusion of the temporary revision in the manual Insert the new pages in the publication at the appropriate locations 2 For CD Publications mark the temporary revision part number on the CD label with permanent red marker This will be a visual identifier that the temporary revision must be referenced when the content of the CD is being used Temporary revisions should be collected and maintained in a notebook or binder near the CD library for quick reference EXPORT COMPLIANCE 1 This publication contains technical data and is subject to U S export regulations This information has been exported from the United States in accordance with export administration regulations Diversion contrary to U S law is prohibited ECCN 9E991 Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION TIME LIMITS STRUCTURE 1 Scope A This provides the mandatory times and inspection time intervals for componen
33. 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Doa preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 04 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK Main landing gear axle assembly for All Models Make sure you inspect these areas 1 Main gear axle and attach bol
34. 30 minutes then you must use the SEVERE inspection time limits 2 If the airplane has been engaged in operations at low altitudes such as pipeline patrol fish or game spotting aerial applications police patrol sightseeing livestock management etc more than 30 of its life you must use the SEVERE inspection time limits b Typical Usage Environment 1 If neither 2 1 1 or 2 A 1 a 2 above applies the TYPICAL usage environment applies 2 Operating Environment a Severe Corrosion Environment 1 airplane is operating more than 30 of the time in a zone shown as severe on the corrosion severity maps in Section 24 30 01 then the SEVERE CORROSION environment time limits apply b Mild or Moderate Corrosion Environment 1 2 A 2 a 1 does not apply then the MILD MODERATE CORROSION environment time limits apply B After the operating usage and the operating environment are determined make a logbook entry that states which inspection schedules TYPICAL or SEVERE operating usage and MILD MODERATE or SEVERE operating environment are being used 3 Description NOTE Listed below is a detailed description and intended purpose of the following sections A Section 2 10 00 Time Limits Maintenance Checks General This section provides a description and purpose of the inspection time intervals D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 10 00 1 Cessna Aircraft Company Feb 3 2003 CESSNA A
35. Allowed 6 INSPECTION METHOD Visual Borescope Magnifying Glass D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 25 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 7 REPAIR MODIFICATION Replace cracked or excessively corroded parts If corrosion is present it must be removed before refinishing Contact Customer Service for assistance prior to beginning the repair if the disassembly exceeds the repair facilities experience or capability 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 25 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 11 04 1 TITLE Wing Splice Joint at Strut Attach Inspection Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MI
36. DOMINGO CORROSION SEVERITY LEGEND MILD MODERATE H SEVERE North America Corrosion Severity Map Figure 2 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 7 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A27651 E Salvador Rio De Janeiro Santiago Buenos Aires Montevideo CORROSION SEVERITY LEGEND MILD MODERATE SEVERE South America Corrosion Severity Map Figure 3 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 30 01 8 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 27659 m Algiers Cairo Khartoum e Accra Brazzaville o Kananga o Luanda Tolanaro MILD MODERATE Cape Town SEVERE Africa Corrosion Severity Map Figure 4 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 30 01 9 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100
37. Gear Torque Link Bolt and Fork Inspection Models 150 172 175 and 182 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 INSPECTION COMPLIANCE ALL USAGE INITIAL 3 000 Hours Or 5 Years NOTE REPEAT 3 000 Hours Or 5 Years NOTE NOTE Refer to Note 1 Section 2 14 00 3 PURPOSE To ensure structural integrity of the nose gear torque link and nose gear fork 4 INSPECTION INSTRUCTIONS A Deflate the strut Refer to the Model 100 Series Service Manual B Remove torque link bolts one at a time in accordance with the Model 100 Series Service Manual C Inspect for bent bolts or worn bolts Refer to Figure 1 Install serviceable bolts after inspection 1 Clean area before inspecting if grime or debris is present D Inspect the nose gear upper torque link for cracks in the area of the stop block and the flanges of the I section of the link using surface eddy current inspection Refer to Section 2A 13 01 Non destructive Inspection Methods and Requirements Eddy Current Inspection Surface Inspection for additional instructions E Inspect center torque link bushings fo
38. LH OUTBOARD FITTING LH DETAIL NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL 0510T1007 MAIN LANDING GEAR FITTINGS INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 07 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 13 03 1 TITLE Main Landing Gear Axle Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50000 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 4 000 hours Or 10 Years NOTE REPEAT 1 000 hours or 3 Years NOTE NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To ensure integrity of main landing gear axles 4 INSPECTION INSTRUCTIONS A Jackthe airplane in accordance with the Model 100 Series Service Manual B Remove the wheel Refer to the Model 100 Series Service Manual Inspect the axle for cracks and corrosion Refer to
39. MANUAL INSPECTION OPERATION 26 Date Registration Number Serial Number Total Time 1 Description A Operation 26 gives Supplemental Inspection Document items that are to be examined after the first 2 500 hours of operation or 5 years whichever occurs first The inspection is to be repeated every 2 500 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight
40. P259 12 c Cessna Single Engine Service Information Letters and Service Bulletin Summaries d Cessna Service Newsletters and Newsletter Summaries B For information regarding these documents contact Cessna Aircraft Company Customer Service P O Box 7706 Wichita KS 67277 USA Phone 816 517 5800 Fax 316 517 7271 7 Applicability Limitations A This SID is applicable to the Cessna Model 100 series Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 49544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 50912 thru 51183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 53008 thru 54423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 B 5 Modifications 1 The Cessna Model 100 Series airplanes can have modifications that were done by STCs by other organizations without Cessna Engineering approval The inspection intervals given in this SID are for unchanged airplanes 2 Airplanes that have been modified to alter the airplane design gross weight or airplane performance may need to be inspected more frequently Examples of common STC s not covered by this SID document include non Cessna wing extensions winglets speed brakes STOL conversions vortex generators tip tan
41. The reference standard must have a corner notch no larger than 0 050 inch x 0 050 inch 0 127 mm x 0 127 mm long d The dimensional accuracy of notches must have documentation and be traceable to the National Institute of Standards and Technology NIST or applicable foreign agency e some cases a specially fabricated reference standard will be necessary to simulate part geometry configuration and or the specific discontinuity location Artificial discontinuities may be used in the reference standard If a procedure specifies a reference standard made by Cessna Aircraft Company replacement with a different standard is not allowed A16318 Typical Bolthole Reference Standard Figure 3 4 Inspection Considerations a Surface Condition The surface finish of the area for inspection must be 150 RHR or RMS 165 or finer The areas for inspection must be free of dirt grease oil or other contamination You must have good contact between the probe and the part unless otherwise stated in the specific procedure Mildly corroded parts must be cleaned lightly with emery cloth Heavily corroded or painted parts must be lightly abraded and cleaned locally in the area on which the probe will be done b Bolthole eddy current inspection of holes with a bushing installed is not recommended The inspection will examine the condition of the bushing and not the structure underneath If a bushing cannot be removed it is recommended to do a surfac
42. and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Doa preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 03 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK Aileron attachments for All Models Make sure you inspect these areas 1 Aileron hinges 2 Hinge bolts 3 Hinge bearings 4 Hinge and pushrod support structure NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor on hinge bearing Elevator trim system for All Models Make sure you inspect these areas 1 Elevator trim brackets 2
43. be designated as a wire Strand Each group of wires helically twisted or laid together shall be designated as a strand Cable A group of strands helically twisted or laid about a central core shall be designated as a cable The strands and the core shall act as a unit Diameter The diameter of cable is the diameter of the circumscribing circle Wire Center The center of all strands shall be an individual wire and shall be designated as a wire center Strand Core A strand core shall consist of a single straight strand made of preformed wires similar to the other strands comprising the cable in arrangement and number of wires Preformed Type Cable consisting of wires and strands shaped prior to fabrication of the cable to conform to the form or curvature which they take in the finished cable shall be designated as preformed types Lay or Twist The helical form taken by the wires in the strand and by the strands in the cable is characterized as the lay or twist of the strand or cable respectively In a right lay the wires or strands are in the same direction as the thread on a right screw and for a left lay they are in the opposite direction Pitch or length of lay The distances parallel to the axis of the strand or cable in which a wire or strand makes one complete turn about the axis is designated as the pitch or length of lay of the strand or cable respectively D138 1 13 Temporary Revision Number 7
44. debris is present C Inspect the elevator trim system for wear 1 Clean area before inspecting if grime or debris is present 2 Pay particular attention to inspect the roll pin which secures the elevator trim shaft to the chain sprocket for signs of damage or deterioration Refer to Figure 1 Detail E NOTE Thelocation of the roll pin makes proper inspection difficult however rocking the trim control wheel back and forth should give an indication of roll pin looseness or shaft wear Inspect the actuator sprocket and groove pins for integrity Inspect all pulleys for wear flat spots and freedom of rotation Inspect all fasteners and attaching structure for integrity D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 03 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Stabilizer Not Allowed 6 INSPECTION METHOD Visual Magnifying Glass 7 REPAIR MODIFICATION Replace any cracked or excessively corroded 1096 or more of the material thickness is missing in the corroded section brackets Replace excessively worn flat spotted or stiff pulleys Replace any loose or sheared fasteners Make repairs in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Coordinate any repair not available in Section 19 with Cessna Customer Service prior to be
45. done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For Models 180 and 185 inspect main landing gear 721 722 spring axle attach bolt holes Refer to Section 2A 14 09 Supplemental Inspection Document 32 13 04 for inspection procedure End of Operation 27 Inspection Items kkk D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 27 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 28 Date Registration Number Serial Number Total Time 1 Description A Operation 28 gives Supplemental Inspection Document items that are to be examined after the first 1 000 hours of operation The inspection is to be repeated every 100 hours of operation after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Crite
46. for additional inspection requirements 3 Areview of test results applicable to the design was made to identify the critical areas of the PSE s 4 data collected was also used to find a component s susceptibility to corrosion or accidental damage as well as its inspectability D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 00 2 Cessna Aircraft Company Feb 3 2003 3 Usage A CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Aircraft Usage 1 2 3 Aircraft usage data for the SID program is based on the evaluation of the in service utilization of the aircraft This data was used to develop the representative fatigue loads spectra Operational data for development of the Supplemental Structural Inspection Program was obtained from surveys of aircraft operators Usage for spectra determination is defined in terms of a single flight representing typical average in service utilization of the aircraft This usage reflects the typical in service flight variation of flight length takeoff gross weight payload and fuel The flight is defined in detail in terms of a flight profile The profile identifies the gross weight payload fuel altitude speed distance etc required to define the pertinent flight and ground parameters needed to develop the fatigue loads The flight is then divided into operational segments where each segment represents the average values of the parameter
47. hole welded shut in the tube to be welded Open the hole prior to welding After welding while the welded area is still hot introduce 3cc of unboiled Linseed oil or 6cc of corrosion preventative compound conforming to D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 31 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL MIL PRF 81309 through the hole and reseal it using the same method as was used in the original fabrication The engine mount is not heat treated after fabrication so no processing after welding is required Repairs may be made in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Section 19 also describes tubes which MUST be replaced in their entirety rather than being repaired Any repair not available in Section 19 listed above should be coordinated with Cessna Customer Service prior to beginning the repair 8 COMMENTS This is a complex and involved inspection It is recommended that the inspection be coordinated with an engine overhaul even if the time does not exactly agree with inspection hours Recurring inspections will be satisfied by inspections at engine overhaul The initial inspection must be completed by June 30 2015 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 31 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MAN
48. inspection area at index steps that are no more than the width of the eddy current test coil You can do a scan of a part edge as long as the response from edge effect does not hide the calibration notch response Do not examine areas where edge effect is more than the calibration notch signal Another inspection method should be used if the edge effect can hide the calibration notch response d Whenever possible a fillet or radius should be examined both transverse and parallel to the axis of the radius Examine the edge of the fillet or radius transverse to the axis of the radius e For the best inspection sensitivity sealant must be removed from around fasteners This will allow you to put the surface eddy current probe closer to the edge of the fastener f If no guidance is given as to where to examine the part do an inspection of all part surfaces that you have access to Make sure to thoroughly examine radii corners edges and areas immediately next to fasteners 7 Interpretation a If an indication is found carefully repeat the inspection in the opposite direction of probe movement to make sure of the indication If the indication is still there carefully monitor the amount of probe movement or rotation needed to cause the response to move off maximum indication response b Unless otherwise specified you must reject a part with a crack c The end of a crack is found with the 50 percent method Move the probe slowly across
49. is a system to control the corrosion in the airplane s primary structure It is not the function of the CPCP to stop all of the corrosion conditions but to control the corrosion to a level that the airplane s continued airworthiness is not put in risk B Complete the initial CPCP inspection in conjunction with the first SID inspection 2 Corrosion Prevention and Control Program Objective A The objective of the CPCP is to help to prevent or control the corrosion so that it does not cause a risk to the continued airworthiness of the airplane 3 Corrosion Prevention and Control Program Function A function of this document is to give the minimum procedures necessary to control the corrosion so that the continued airworthiness is not put in risk The CPCP consists of a Corrosion Program Inspection number the area where the inspection will be done specified corrosion levels and the compliance time The CPCP also includes procedures to let Cessna Aircraft Company and the regulatory authorities know of the findings and the data associated with Level 2 and Level 3 corrosion This includes the actions that were done to decrease possible corrosion in the future to Level 1 B M Maintenance or inspection programs need to include a good quality The level of corrosion identified on the Principal Structural Elements PSEs and other structure listed in the Baseline Program will help make sure the CPCP provides good corrosion protection
50. is normally recommended 3 probe must have an operating frequency that has the necessary test sensitivity and depth of penetration For an aluminum part the frequency should be approximately 200 kHz For a steel part the frequency should be 500 to 800 kHz For a titanium part the frequency should be 1 0 to 2 0 MHz NOTE Instrument frequency may need adjustment for the instrument and probe combination used D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 6 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 4 Smaller coil diameters are better for crack detection A coil diameter of 0 125 inch 8 175 mm is normally used 5 For crack detection the coil will usually contain a ferrite core and external shield 6 The probe must not give responses from handling pressures scanning or normal operating pressure variations on the sensing coil which cause the signal to noise ratio to be less than 3 to 1 Teflon tape may be used to decrease the wear on the eddy current probe coil If Teflon tape is used make sure the instrument calibration is correct 3 Reference Standard a Nonferrous reference standards should be of an alloy having the same major base metal basic temper and the approximate electrical conductivity of the material for inspection Refer to Figure 3 b Reference standards must have a minimum surface finish of 150 RHR or RMS 165 c
51. little as 90 of the nominal thickness 3 This general allowance is not allowed if a The area of the part contains fasteners b The reduced thickness compromises the fit or function of a part F Finish the new or repaired parts 1 Apply Alodine or similar anticorrosion compounds to new or repaired parts or 2 Apply zinc chromate or 3 Apply epoxy fuel tank primer 4 Paint the exterior or visible interior parts according to Section 20 of the Model 100 Series Service Manual G Replace Removed Components 6 General A This section contains maps which define the severity of potential corrosion on airplane structure Corrosion severity zones are affected by atmospheric and other climatic factors The maps provided in this section are for guidance when determining types and frequency of required inspections and other maintenance Refer to Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 and Figure 7 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 30 01 6 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A27579 Fairbanks e Anchorage fg p Sk suche xm Seattle Montreal il e ILE WA Chicago c Denver t Y New York 53 Los Angeles HAWAII MODERATE qal M E r a E Ej Miami Havana PERR H am PUERTO RICO SEVERE JAMAICA ST
52. notletthe penetrant to dry on the surface If the penetrant has dried completely remove it and process the part again from the start 3 Penetrant Removal a Wipe the unwanted penetrant from the surface with a clean dry lint free cloth b Dampen a clean lint free cloth with penetrant cleaner CAUTION Do not use the penetrant cleaner directly on the surface of the part or assembly Do not saturate the cloth used to clean the area with the penetrant cleaner This may remove penetrant from discontinuities c Blot the area with the cloth to remove the unwanted penetrant NOTE Do not use the same dampened cloth more than one time This could cause penetrant removed the first time to be put back on the surface with the second use of the cloth This could cause non relevant indications d Examine the area with the ultraviolet light to make sure that the penetrant has been removed from the surface e If the penetrant is not sufficiently removed from the surface repeat these steps until the surface penetrant is removed 4 Apply Developer a Be sure the part or assembly is dry b Put the developer on the surface The best results happen when there is a very thin coat of developer on the surface You should be able to barely see the color of the part or assembly through the developer c If you use a dry powder developer 1 Thoroughly dust the part or assembly with the developer 2 Gently blow off the extra powder d If you
53. of operation after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For Models 180 and 185 inspect wing main spar and 510 520 rear spar Refer to Section 2A 14 25 Supplemental 610 620 Inspection Document 57 11 03 for inspection procedure End of Operation 29 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 29 1 Cessna Aircraft Company Feb 3 2003 C
54. pieces such as rivets and bolts are formed The amount of stress varies from point to point within the component Stress corrosion is most likely to occur at points of highest stress which are also subject to corrosion influence J Fatigue Corrosion 1 Fatigue corrosion is a special case of stress corrosion caused by the combined effects of cyclic stress and corrosion 4 Typical Corrosion Areas A Aluminum appears high in the electrochemical series of elements and its position indicates that it should corrode very easily However the formation of a tightly adhering oxide film offers increased resistance under mild corrosive conditions Most metals in contact with aluminum form couples which undergo galvanic corrosion attack The alloys of aluminum are subject to pitting intergranular corrosion and intergranular stress corrosion cracking B Battery Electrolyte 1 Battery electrolyte used in lead acid batteries is composed of 35 sulfuric acid and 65 water When electrolyte is spilled it should be cleaned up immediately A weak boric acid solution may be applied to the spillage area followed by a thorough flushing with clean cold running water If boric acid is not available flush the area with clean cold water 2 If corrosion appears use an approved repair method to repair the structure C Steel Control Cable 1 Checking for corrosion on a control cable is normally accomplished during the preventative maintenance check
55. plated steel fasteners used in aluminum 6 At normal atmospheric temperatures metals do not corrode appreciably without moisture However the moisture in the air is usually enough to start corrosive action 7 Theinitial rate of corrosion is usually much greater than the rate after a short period of time This slowing down occurs because of the oxide film that forms on the metal surfaces This film tends to protect the metal underneath 8 When components and systems constructed of many different types of metals must perform under various climatic conditions corrosion becomes a complex problem The presence of salts on metal surfaces sea or coastal operations greatly increases the electrical conductivity of any moisture present and accelerates corrosion 9 Other environmental conditions that contribute to corrosion are a Moisture collecting on dirt particles b Moisture collecting in crevices between lap joints around rivets bolts and screws 3 Types of Corrosion A The common types of corrosion that are encountered in airplane maintenance are described in this section In many instances more than one form of corrosion may exist at the same time While this makes it difficult to determine the exact type of corrosion it should still be possible to determine that a corrosive process is taking place If it is impractical to replace an assembly or component contact an authorized repair shop D138 1 13 Temporary Revision Number
56. pro cedure For All Models this interval is for mild moderate 210 corrosion environment Inspect the cabin interior skin panels frames and stringers Refer to Section 2A 14 16 Supplemental Inspection Document 53 30 01 for inspection procedure For All Models this interval is for mild moderate 510 520 corrosion environment Inspect wing for corrosion 610 620 and missing or loose fasteners Refer to Section 2A 14 24 Supplemental Inspection Document 57 11 02 for inspection procedure D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 11 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK ZONE MECH INSP REMARKS For All Models this interval is for mild moderate 510 610 corrosion environment Inspect wing splice joint at strut attach Refer to Section 2A 14 26 Supplemental Inspection Document 57 11 04 for inspection procedure For All Models this interval is for mild moderate cor 510 610 rosion environment Inspect flap tracks for corrosion Refer to Section 2A 14 30 Supplemental Inspection Document 57 53 01 for inspection procedure End of Operation 11 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 11 Page 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 12 Date Registration Number Serial Number
57. spray the corrosion inhibit 10630 Riggs Hill Road compound in aerosol form Suite S Jessup Maryland 20794 9425 Phone 1 800 937 4857 USA Respirator Half Face EE SERI Commercially Available For respiratory protection Commercially Available For masking the adjacent parts in the vicinity of corrosion inhibiting compound application area Commercially Available For masking the adjacent parts in the vicinity of corrosion inhibiting compound application area Cessna Service Parts and To be used for spray is Programs application Forni T8 Fan 7121 Southwest Blvd Wichita KS 67215 B roscope 7 Commercially Available To access the inspection area Magnifying Glass 721 Commercially Available ud the corrosion 16 Corrosion Inspections and Detection Methods HVLP Spray Gun Paint Masking Tape A Typical Inspection Methods 1 Remove all equipment or components that can interfere with your ability to clearly view the inspection area NOTE In some areas it may be necessary to use equipment such as a borescope to see the inspection area Fully clean the inspection area before starting the inspection Carefully examine the inspection area for any indication of corrosion Refer to Section 2A 30 01 Corrosion for additional information on the common indications that corrosion has occurred a Special attention should be given to inspection areas that have had corrosion repairs in the past b Nondestructi
58. system control 320 cables and pulleys in accordance with the flight ca ble inspection procedures in Section 2A 20 01 Ex panded Maintenance Control Cables kkk End of Operation 30 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 30 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION DOCUMENT 1 Supplemental Inspection Document A Introduction 1 The Supplemental Structural Inspection Program for the Cessna Model 100 Series airplane is based on the affected Model 100 Series airplane current usage testing and inspection methods practical state of the art inspection program is established for each Principle Structural Element PSE A PSE is that structure whose failure if it remained undetected could lead to the loss of the airplane Selection of a PSE is influenced by the susceptibility of a structural area part or element to fatigue corrosion stress corrosion or accidental damage The Supplemental Structural Inspection Program was developed through the combined efforts of Cessna Aircraft Company operators of affected Model 100 series airplanes and the FAA The inspection program consists of the current structural maintenance inspection plus supplemental inspections as required for continued airworthiness of the airplane as years of service are accumulated The current inspection program
59. to Cessna Aircraft Company on a reporting form Changes can then be made to SID program if necessary c The inspections presented in the SID apply to all Model 100 Series airplanes The inspection intervals presented are for unmodified airplanes Airplanes that have been modified to alter the airplane s design gross weight or performance may need to be inspected more frequently Examples of common STOs which will require modified inspection intervals include non Cessna wing extensions winglets speed brakes STOL conversions vortex generators tip tanks under wing tanks and nonstandard engines The owner and or maintenance organization should contact the STC holder s or modification originator for obtaining new FAA approved inspection criteria A Corrosion Prevention and Control Program CPCP should be established for each airplane Details of the CPCP are contained in Section 2A 30 00 of this manual 2 Principal Structural Elements A Principal Structural Elements Description An airplane component is classified as a Principal Structural Element PSE if The component contributes significantly to carrying flight and ground loads b Ifthe component fails it can result in a catastrophic failure of the airframe The monitoring of these PSE s is the main focus of this Supplemental Structural Inspection Program Typical examples of PSE s taken from FAA Advisory Circular 25 571 are shown in Table 1 D138 1 13 Temporary R
60. to Note 1 Section 2 14 00 3 PURPOSE To ensure structural integrity of the firewall 4 INSPECTION INSTRUCTIONS A For Model 172 units 630 17247747 thru 17249544 and Model 175 all units review the aircraft records to determine if SEBO7 2 has been incorporated If not incorporate SEBO7 2 with this inspection B Remove upper and lower cowling from the airplane C Disconnect all electrical power from the airplane D Visually inspect around each engine cowling shock mount bracket for cracking on forward and aft side of firewall 1 Clean area before inspecting if grime or debris is present E Visually inspect around each engine mount attach bracket for cracking on forward side of firewall 1 Clean area before inspecting if grime or debris is present F Visually inspect for missing or loose fasteners in the structure especially around the engine mount attach brackets G Inspect firewall for wrinkles cracks sheared rivets or other signs of damage or wear 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Under Cowl Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION If a crack is found in the firewall repair or replace as required prior to flight Repairs may be made in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Any repair not available in Section 19 of the Model 100 Series Service Manual should be coordinated with Cessna Customer Service prior to
61. 1 Year NOTE NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To verify integrity of the horizontal tail forward spar 4 INSPECTION INSTRUCTIONS A Review the aircraft records to determine if 0531037 1 reinforcement to the stabilizer front spar has been installed or an 0532001 98 stabilizer front spar has been installed If either of these installations have taken place this inspection is complete NOTE is any doubt about the installation of the reinforcement or replacement of the front spar begin the inspection Count the number of layers of material in the front spar at the center hole Two layers are the as built configuration If there is a third layer on the front side of the spar the reinforcement has been added or the spar has been replaced The replacement spar has the reinforcement added The reinforcement has a clearance hole for the lightening hole flange so the edge of the reinforcement is somewhat hidden If the reinforcement is present and is not reflected in the airplane records add this information to the records B Remove the fuselage to stabilizer fairings Refer to the Model 100 Series Service Manual C Using a flashlight and inspection mirror locate the center lightening hole of the forward spar in the horizontal stabilizer Refer to Figure 1 Detail A and View A A From the aft side of the horizontal forward spar examine the centerline lightening hole for cracks Cracks will generally radiate diag
62. 19 D138 1 13 Temporary Revision Number 7 Dec 1 2011 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION COMPLIANCE SUPPLEMENTAL Refer to Note 1 INSPECTION NUMBER TITLE INITIAL REPEAT 32 20 01 Nose Gear Torque 3 000 Hours 3 000 Hours or Link Bolt and Fork 5 Years 5 Years Inspection Models 150 172 175 and 182 53 11 01 Carry Thru Structure MILD MILD Corrosion Inspection MODERATE MODERATE All Models 20 Years 10 Years SEVERE 10 SEVERE 5 Years Years 53 12 01 Fuselage Forward TYPICAL TYPICAL 2 000 Doorpost Inspection 12 000 Hours Hours or 10 Models 150 172 or 20 Years Years 175 180 and 185 SEVERE 6 000 SEVERE 1 000 Hours or 10 Hours or 5 Years Years 53 12 02 Fuselage Forward 4 000 Hours or 1 000 Hours or Doorpost Inspection 10 Years 3 Years Model 182 53 12 03 Firewall Inspection 2 000 Hours 2 000 Hours or Models 172 and 175 5 Years 5 Years 53 30 01 Fuselage Interior MILD MILD Skin Panels MODERATE MODERATE Corrosion Inspection 20 Years 10 Years all Models SEVERE 10 SEVERE 5 Years Years 53 42 01 Vertical Stabilizer 1 000 Hours 100 Hours Attachment Inspection Model 182 53 47 01 Seat Rails and MILD MILD Seat Rail Structure MODERATE MODERATE Corrosion Inspection 10 Years 10 Years All MogelS SEVERE 5 SEVERE 5 Years Years 55 10 01 Horizontal Stabilizer 5 000 Hours or 2 000 Hours or Elevators and 20 Years 5 Years Attachments Inspection All Models Cessna
63. 1953 1962 SERVICE MANUAL B18125 110 WS 100 00 WS 100 00 120 Ip LJ 510 610 520 240 620 pareas EEE ens cud SEC SAU ee 310 330 340 PA FS 108 00 720 211 INTERIOR NOTE THE NUMBER IN THE INDICATES RIGHT SIDE OF AIRPLANE 0510T1007 Airplane Zones Figure 1 Sheet 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 5 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18337 110 WS 100 50 WS 100 50 FS 00 00 FS 90 00 211 730 INTERIOR NOTE THE NUMBER IN THE INDICATES RIGHT SIDE OF AIRPLANE 0710R1031 Airplane Zones Figure 1 Sheet 3 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 6 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B1081 110 120 w me 520 510 210 610 620 7 L LJ a 310 330 320 D 0710T1003 0710T1003 0710T1003 Airplane Zones Figure 1 Sheet 4 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 7 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MA
64. 2 12 16 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 17 Date Registration Number Serial Number Total Time 1 Description A Operation 17 gives Supplemental Inspection Document items that are to be examined after 3 000 hours or 5 years whichever occurs first The inspection is to be repeated every 1 000 hours or 5 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to ma
65. 2 13 01 20 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL distance at which objects can be distinctly seen by the unaided eye For example a lens with a focal length of 5 inches has a magnification of 2 or is said to be a two power lens A 10 power magnifier is needed for inspection Borescopes a These instruments are long tubular precision optical instruments with built in illumination designed to allow remote visual inspection of otherwise inaccessible areas The tube which can be rigid or flexible with a wide variety of lengths and diameters provides the necessary optical connection between the viewing end and an objective lens at the distant or distal tip of the borescope b Optical Designs Typical designs for the optical connection between the borescope viewing end and the distal tip are 1 A rigid tube with a series of relay lenses 2 A flexible or rigid tube with a bundle of optical fibers and 3 Aflexible or rigid tube with wiring that carries the image signal from a Charge Couple Device CCD imaging sensor at the distal tip NOTE Instruments used as an aid for visual inspection must be capable of resolving four line pairs per mm 4lp mm c These designs can have either fixed or adjustable focus of the objective lens at the distal tip The distal tip may also have prisms and mirrors that define the direction and field of view A fiber o
66. 2 Upper and lower wing attach spar fittings 3 Wing lower skins NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Wing structure external for All Models Make sure you inspect these areas 1 Skin with emphasis at skin overlaps and under access panels 2 Rear spar upper and lower caps 3 Rear spar web NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Vertical stabilizer structure for All Models Make sure you inspect these areas 1 Forward spar attachment to tailcone bulkhead 2 Aft spar attachment to lower vertical stabilizer spar 3 Front and rear spars 4 Rear spar rudder hinges NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Nose gear axle assembly for All Models Make sure you inspect these areas 1 Nose gear axle and attach bolt 2 Wheel halves NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE Disassemble the nose gear strut to get access NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor to the sliding surfaces of the oleo strut NOTE Coordinate with tire change Horizontal stabilizer structure for All Models Make sure you
67. 2 000 20 Wing Attachment 12 000 Hours Hours or 10 Inspection All or 20 Years Years Models SEVERE 6 000 SEVERE 1 000 21 Hours or 10 Hours or 5 Years Years D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 00 Page 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL DETAILS INSPECTION COMPLIANCE FOUND IN SUPPLEMENTAL Refer to Note 1 INSPEC SECTION INSPECTION TION OP 2 14 NUMBER TITLE INITIAL REPEAT ERATION 2A 14 29 57 51 01 Aileron Support 3 000 Hours or 500 Hours or 16 Structure Inspection 10 Years 5 Years All Models 2A 14 30 57 53 01 Flap Tracks MILD MILD 11 Corrosion Inspection MODERATE MODERATE All Models 20 Years 10 Years SEVERE 10 SEVERE 5 13 Years Years 2A 14 31 71 20 01 Engine Mount 10 000 Hours At Engine 10 Inspection All or 20 Years Overhaul Models 2A 14 32 71 20 02 Engine Mount 2 500 Hours or 2 500 Hours or 26 Bracket Inspection 5 Years 5 Years Models 172 and 175 NOTE 1 Time limits for the INITIAL inspections are set by either flight hours or calendar time whichever occurs first Except for Section 2A 14 31 Supplemental Inspection Document 71 20 01 corresponding calendar inspection times are per REPEAT flight hour or calendar time specified whichever occurs first Corrosion Prevention and Control Program CPCP remain calendar time based If the INITIAL inspe
68. 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 20 Years NOTE REPEAT 10 Years NOTE SEVERE INITIAL 10 Years NOTE REPEAT 5 Years NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To ensure corrosion protection of the carry thru spar structure 4 INSPECTION INSTRUCTIONS A Remove headliner and interior items necessary to gain access to the front and rear carry thru structure Refer to the Model 100 Series Service Manual B Visually inspect front spar carry thru area for loose or missing rivets or corrosion especially between the spar channel and reinforcement between the spar channel and upholstery retainer and between door post bulkhead attachment fittings and the spar channel Refer to Figure 1 1 Clean area before inspecting if grime or debris is present C Visually inspect rear spar carry thru area for loose or missing rivets or corrosion especially between the door post bulkhead attachment fittings and the spar channel 1 Clean area before inspecting if grime or debris is present D Inspect for corrosion at the wing attachment fittings lugs and spar blocks 1 Clean area before inspecting if grime or debris is present 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Cabin Interior Section Not Allowed 6 INSPE
69. 5 2 EFFECTIVITY Model 180 Serial Numbers 604 614 624 30000 thru 32999 50000 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18253598 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 1 000 Hours NOTE REPEAT 1 000 Hours NOTE NOTE Refer to Note 1 Section 2 14 00 3 PURPOSE To verify the integrity of the elevator trim pulley brackets and screwjack structure inspection 4 INSPECTION INSTRUCTIONS A Measure the free play between the stabilizer and the fuselage 1 Set the trim wheel to the takeoff position 2 Liftup on the leading edge of the stabilizer and measure and record the freeplay between the stabilizer and the fuselage NOTE Useadialindicator clamped to the fuselage with the probe contacting the stabilizer Repeat the test on the opposite side of the fuselage Deflection limits are 0 019 inches free play and 0 010 difference between sides Refer to Repair Modification section below if the limits are exceeded SL B Remove seats floor covering and floor inspection panels as necessary to inspect elevator trim pulley brackets and screw jack actuator support brackets for cracks corrosion and bent flanges Straighten bent flanges and check for any cracking using at least a 4X power magnifying glass and a bright light Refer to Figure 1 1 Clean area before inspecting if grime or
70. 557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE TYPICAL INITIAL 12 000 Hours or 20 Years NOTE REPEAT 2 000 Hours 07 10 Years NOTE SEVERE INITIAL 6 000 Hours Of 10 Years NOTE REPEAT 1 000 Hours OF 5 Years NOTE NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To verify the integrity of the strut and strut attachment fitting to the wing 4 INSPECTION INSTRUCTIONS A Remove the wing strut upper and lower fairings Refer to the Model 100 Series Service Manual B Ifthe flight hours meet or exceed the inspection compliance hours above proceed to Detailed Attach Fitting Inspection 1 Visually inspect the strut attachment fittings for cracks or corrosion Refer to Figure 1 a Clean area before inspecting if grime or debris is present b If crack s or corrosion is found proceed to Detailed Attach Fitting Inspection 2 Visually inspect the strut tube for cracks or corrosion a Clean area before inspecting if grime or debris is present b If crack s or corrosion is found proceed to Detailed Attach Fitting Inspection 3 If no crack s or corrosion is found install fairings The inspection is complete C Detailed Attach Fitting Inspection 1 Support the wing to minimize the load on the
71. 6 gives Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 60 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals B Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection C Theright portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual TASK ZONE MECH INSP REMARKS Fuselage lower internal structure beneath the floor panels for 211 All Models Make sure you inspect these areas 1 Cabin structur
72. 7 Dec 1 2011 2A 30 01 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Direct Chemical Attack 1 Direct chemical attack may take place when corrosive chemicals such as battery electrolyte caustic cleaning solutions or residual flux deposits are allowed to remain on the surface or become entrapped in cracks or joints Welding or soldering flux residues are hydroscopic and will tend to cause severe pitting Any potentially corrosive substance should be carefully and completely removed whenever such spillage occurs Pitting Corrosion 1 The most common effect of corrosion on polished aluminum parts is called pitting It is first noticeable as a white or gray powdery deposit similar to dust which blotches the surface Refer to Figure 1 2 When the deposit is cleaned away tiny pits can be seen in the surface Pitting may also occur in other types of metal alloys Intergranular Corrosion 1 Intergranular corrosion Refer to Figure 1 takes place because of the nature of the structure of metal alloys As metals cool from the molten state a granular structure is formed The size and composition of the grains and the material in the grain boundaries depend on several factors including the type of alloy and rate of cooling from the molten state or cooling after heat treating The grains differ chemically and may differ electrochemically from the boundary material If an
73. 78 68 U Bolt Replacement for Model 172 SE80 30 Landing Gear Support Replacement for Model 172 SK172 53A SK172 54A SE84 22 Aileron Hinge Assembly Inspection SEBO7 2 Engine Mount Bracket Inspection for Model 172 units 630 17247747 thru 17249544 and all Model 175 units SEBO7 5 Pilot and Copilot Secondary Seat Stop Installation for SK210 174A Models 172 175 180 182 and 185 SK210 175A SEB94 8 Horizontal Stabilizer Forward Spar Inspection Modification for Models 172 and 175 SEB95 3 Flap Support Inspection and Roller Washer Installation SK180 44 SEB96 7 AN3 5A Bolt Inspection Replacement SEB95 19 Lower Forward Doorpost and Strut Fitting Inspection and SK182 115 Modification for Model 182 SEB99 12 Vertical Stabilizer Aft Spar Attach Bulkhead Replacement 5 210 161 for Model 182 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 00 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 2 Supplemental Inspections DETAILS FOUND IN SUPPLEMENTAL Refer to Note 1 SECTION INSPECTION 2A 14 XX NUMBER TITLE INITIAL 2A 14 01 27 20 01 Rudder Pedal Torque 10 000 Hours Tube Inspection or 20 Years Models 2 14 02 27 30 01 Elevator Trim Pulley 1 000 Hours Bracket and Actuator Bracket Structure Inspection Models 150 172 175 and 182 1962 2A 14 03 27 30 02 Elevator Trim 1 000 Hours Pulley Bracket and Screw Jack Structure Inspection Models 180
74. 8 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 18 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 55 10 01 1 TITLE Horizontal Stabilizer Elevators and Attachments Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 5 000 Hours 07 20 Years NOTE REPEAT 2 000 Hours Or 5 Years NOTE NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To inspect horizontal stabilizer elevator and attachments for signs of damage fatigue or deterioration 4 INSPECTION INSTRUCTIONS A Openallstabilizer and elevator access panels including the stinger and vertical stabilizer to horizontal tail fairings Refer to the Model 100 Series Service Manual B Visually inspect stabilizer and elevator for condition cracks and security elevator hinges hinge bolts hing
75. 80 30 and install Service Kits SK172 53A and SK172 54A B Main landing gear fittings are contained between two wrap around bulkheads which physically contain the bulkheads even after the attach fasteners are removed A recommended method to replace main landing gear fittings is to support the airplane to maintain alignment during rework remove D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 07 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL the floorboard just forward of the forward main gear bulkhead remove the longerons forward of the forward main landing gear bulkhead and then slide the forward main landing gear bulkhead forward to disengage it from the fittings Since the attach holes will be reused to reinstall the parts remove rivets carefully to avoid excessively enlarging rivet holes After the fittings are installed reinstall the removed parts in reverse order Make repairs in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Coordinate any repair not available in Section 19 with Cessna Customer Service prior to beginning the repair 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 07 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18487 OUTBOARD FITTING RH INBOARD FITTING RH INBOARD FITTING
76. 953 1962 SERVICE MANUAL A81680 Start Evaluation STC Non STC Alteration or Modification Repair Does installation affect an existing Does repair affect an existing inspection inspection area listed in the SID If area listed in the SID If Has installation altered Analytical the affected structure y or increased redistributed Assessment the loads acting on it If and supplemental inspections are required Analytical Assessment and supplemental inspections are required Analytical Assessment and supplemental inspections are not required Analytical Assessment Flowchart Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 00 7 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A25373 DISCREPANCY REPORT SID NO AIRPLANE LOCATION nm S N OF AIRPLANE INSPECTION CONDUCTED Date mmummumm Airplane Total Hours Cycles Component Total Hours Cycles OWNER NAME OWNER PHONE NUMBER OWNER ADDRESS SERVICE HISTORY INSPECTION METHOD LIMITS ACCESS REQUIRED REPAIR DESCRIPTION COMMENTS Enclose all available data including photos sketches etc to Cessna Aircraft Company Attn SID Program Customer Service P O Box 7706 Wichita Kansas USA 67277 FAX 316 517 7271 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 00 8 Cessna Aircraft Company Feb 3 2003 CE
77. A AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18493 AFT SPAR DETAIL HORIZONTAL STABILIZER FORWARD SPAR HINGE HINGE ASSEMBLY ASSEMBLY BEARING BEARING DETAIL C pETAIL B NOTE MODEL 182 SHOWN OTHER MODELS TYPICAL 0710T1001 HORIZONTAL STABILIZER ELEVATORS AND ATTACHMENTS INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 19 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18494 TRIM TAB DETAIL D ELEVATORS TORQUE TUBE TRIM TAB TORQUE TUBE HORN DETAIL E BELL CRANK DETAIL F NOTE MODEL 182 SHOWN OTHER MODELS TYPICAL 0710T1001 HORIZONTAL STABILIZER ELEVATORS AND ATTACHMENTS INSPECTION ALL MODELS Figure 1 Sheet 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 19 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 55 11 01 1 TITLE Horizontal Stabilizer Forward Spar Inspection Modification Models 172 and 175 2 EFFECTIVITY Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 INSPECTION COMPLIANCE ALL USAGE INITIAL 100 Hours 07 1 Year NOTE REPEAT 100 Hours 07
78. ACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Cabin Interior N A 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION A If corrosion is found repair in accordance with the following 1 Clean and lightly sand corroded area to remove surface damage and pits 2 Buff out scratch marks 3 Reinspect area and assess amount of material removed a If thickness of flange has been reduced by 10 or more rail must be replaced b Alocal flange reduction of 20 of thickness is acceptable where confined to one side of extrusion provided that the reduced area does not coincide with both seat pin hole and fastener hole If thickness of web is reduced by 10 or more rail must be replaced d If local web reduction of 20 exceeds 1 in length rail must be replaced D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 18 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL e If bulb is reduced in thickness at seat pin hole by 5 or more rail must be replaced f If bulb is reduced by more than 10 at areas between holes rail must be replaced 4 Brush coat sanded areas with alodine B Reinstall seat and check for proper operation If removed material on bulb interferes with proper operation of seat replace rail C For extensive damage or conditions not addressed contact Cessna Customer Service prior to beginning the repair 8 COMMENTS D13
79. ANUAL B18210 MATCH DRILL 0 128 INCH TO EXISTING SPAR DIAMETER HOLE HOLES 0 098 INCH 20 REQUIRED DIAMETER HOLE Sn gear 4 REQUIRED HORIZONTAL REINFORCEMENT STABILIZER REFERENCE CENTER LINE 1 25 INCHES 1 00 INCHES gt 1 78 INCHES gt MATCH DRILL TO EXISTING SPAR HOLES NUMBER 30 3 22 INCHES 7 gt 0 128 INCH DIAMETER HOLE 4 44 INCHES gt 6 REQUIRED lt 4 66 INCHES gt lt 5 25 INCHES DETAIL VIEW LOOKING FORWARD NOTE DIMENSIONS REFERENCE 051071007 HORIZONTAL STABILIZER FORWARD SPAR INSPECTION MODIFICATION MODELS 172 AND 175 Figure 1 Sheet 3 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 20 6 Feb 3 2003 Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 55 11 02 1 TITLE Horizontal Stabilizer Forward Attachment Inspection Model 150 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 INSPECTION COMPLIANCE ALL USAGE INITIAL 100 hours 07 1 Year NOTE REPEAT 100 hours 07 1 Year NOTE NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To inspect the horizontal stabilizer attachment for cracks or damage 4 INSPECTION INSTRUCTIONS A Remove the horizontal stabilizer to vertical stabilizer fairings to obtain access to the forwa
80. Actuator support brackets and bearings 3 Pulleys and attaching structure NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor on hinge bearing Rudder attachments for All Models Make sure you inspect these areas 1 Hinge brackets 2 Hinge bolts 3 Hinge bearings NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor on hinge bearing Rudder structure for All Models Make sure you inspect these areas 1 Skin 2 Forward and aft spars at hinge locations NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information End of Operation 3 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 ZONE 520 620 330 340 320 320 Cessna Aircraft Company MECH INSP REMARKS 2A 12 03 Page 2 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 4 Date Registration Number Serial Number Total Time 1 Description A Operation 4 gives Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 36 months Refer to Section 2A
81. Aircraft Company INSPEC TION OP ERATION 9 20 21 23 28 22 2A 14 00 Page 3 Feb 3 2003 DETAILS INSPECTION COMPLIANCE FOUND IN SUPPLEMENTAL Refer to Note 1 INSPEC SECTION INSPECTION TION OP 2A 14 XX NUMBER TITLE INITIAL REPEAT ERATION 24 14 20 55 11 01 Horizontal Stabilizer 100 Hours or 100 Hours or 25 Forward Spar 1 Year 1 Year Inspection Modification Models 172 and 175 2A 14 21 55 11 02 Horizontal Stabilizer 100 Hours or 100 Hours or 25 Forward Attachment 1 Year 1 Year Inspection Model 150 24 14 22 55 30 01 Vertical Stabilizer 5 000 Hours 2 000 Hours or 22 Rudder and 20 Years 5 Years Attachments Inspection All Models 24 14 23 57 11 01 Wing Structure TYPICAL TYPICAL 2 000 20 Inspection All 12 000 Hours Hours or 10 Models or 20 Years Years SEVERE 6 000 SEVERE 1 000 21 Hours or 10 Hours or 5 Years Years 2 14 24 57 11 02 Wing Structure MILD MILD 11 Corrosion Inspection MODERATE MODERATE All Models 20 Years 10 Years SEVERE 10 SEVERE 5 13 Years Years 2A 14 25 57 11 03 Wing Spar Inspection 4000 Hours 100 Hours 29 Models 180 and 185 2A 14 26 57 11 04 Wing Splice Joint MILD MILD 11 at Strut Attach MODERATE MODERATE Inspection All 20 Years 10 Years Models SEVERE 10 SEVERE 5 13 Years Years 2A 14 27 57 12 01 Wing Root Rib MILD MILD 12 Corrosion Inspection MODERATE MODERATE All Models 5 Years 5 Years SEVERE 3 SEVERE 3 14 Years Years 2A 14 28 57 40 01 Strut and Strut TYPICAL TYPICAL
82. Airplane Flight Manual TASK ZONE MECH INSP REMARKS Flaps All Models 1 Check flap travel cable ten 210 510 sion and travel time 2 Check flap cable system 610 control cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables Aileron All Models 1 Check aileron travel and 210 510 ble tension 2 Check aileron cable system control 520 610 cables and pulleys in accordance with the flight ca 620 ble inspection procedures in Section 2 20 01 Ex panded Maintenance Control Cables Elevator All Models 1 Check elevator travel and 210 310 cable tension 2 Check elevator cable system con 330 340 trol cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company 2 12 30 Page 1 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK ZONE MECH INSP REMARKS Elevator Trim All Models 1 Check elevator trim 210 310 travel and cable tension 2 Check elevator trim 330 340 cable system control cables and pulleys in accor dance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables Rudder All Models 1 Check rudder travel and ca 210 310 ble tension 2 Check rudder cable
83. CTION METHOD Visual 7 REPAIR MODIFICATION A Clean any corrosion products The recommended procedure to remove corrosion is by hand sanding using a fine grained sandpaper D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 12 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B Use 180 or finer grit abrasive cloth to produce a diameter to depth ratio of about 10 1 Use ultrasonic methods to determine thickness after removing corrosion Repairs are required if thickness is less than 9096 of uncorroded material C Apply corrosion protection 8 COMMENTS 2A 14 12 Page 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 Feb 3 2003 Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18491 FRONT CARRY THRU SPAR D 2 gt SPAR BLOCK FORWARD DOORPOST SPAR BLOCK DETAIL AFT DOORPOST DETAIL B NOTE MODEL 150 SHOWN OTHER MODELS TYPICAL 041071003 CARRY THRU STRUCTURE CORROSION INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 12 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 12 01 1 TITLE Fuselage Forward Doorpost Inspection Models 150 172 175 180 and 185 2 EFFECTIVITY NOTE M
84. Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 7 REPAIR MODIFICATION A If cracks are present 1 Repair in accordance with SEB95 19 For conditions beyond SEB95 19 contact Cessna Customer Service 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 14 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18295 FORWARD DOORPOST VISUALLY INSPECT FOR POSSIBLE CRACKS AT THESE LOCATIONS CRITICAL INSPECTION AREA LOOK FOR CRACKS FOLLOWING B THE CONTOUR OF THE WING STRUT SUPPORT FITTING WING STRUT gu SUPPORT FITTING REFERENCE p DETAIL B LEFT SHOWN RIGHT TYPICAL 071071001 FUSELAGE FORWARD DOORPOST INSPECTION MODEL 182 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 14 Page 3 Cessna Aircraft Company Feb 3 2003 1 2 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 12 03 TITLE Firewall Inspection Models 172 and 175 EFFECTIVITY Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 INSPECTION COMPLIANCE ALL USAGE INITIAL 2 000 Hours OF 5 Years NOTE REPEAT 2 000 Hours OF 5 Years NOTE NOTE Refer
85. Current Probe VM202RAF 6 VM Products Inc with 1 8 inch coil NOTE 1 Phone 253 841 2939 Web http www vmproducts net Combined Aluminum Surface VM89A VM Products Inc and Bolthole Eddy Current Reference Standard NOTE 2 Combined Steel Surface VM89S VM Products Inc and Bolthole Eddy Current Reference Standard NOTE 2 Combined Stainless Steel VM89SS VM Products Inc Surface and Bolthole Eddy Current Reference Standard NOTE 2 NOTE 1 The style and length of the surface probe will vary with the inspection situation NOTE 2 sure that the reference standard has the necessary hole size for bolthole inspections If used only for surface eddy current inspection it is not necessary that the reference standard have holes This part number was included to allow the use of a single reference standard for both surface and bolthole eddy current inspection The reference standard material aluminum steel stainless steel will vary with the material for inspection b Instrument Sensitivity 1 Some inspection procedures need instruments that give both phase and amplitude information on a storage cathode ray tube for impedance plane analysis Impedance plane instruments can be used as an alternative for metered instruments Metered instruments must not be used as an alternative for impedance plane instruments where the ability to show phase information is necessary 2 Eddy current instruments with a meter display can be us
86. E ACCESS LOCATION ZONE DETECTABLE CRACK SIZE Main Gear Spring Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION A Referto the Model 100 Series Service Manual Section 5 5A C for detailed instructions of corrosion removal on the landing gear axle attachment holes NOTE The springs are very hard approximately 250 000 psi UTS A carbide tipped or similar reamer is recommended 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 09 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18321 MAIN LANDING GEAR AXLE DETAIL 0710T1030 MAIN LANDING GEAR SPRING AXLE ATTACH INSPECTION MODELS 180 AND 185 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 09 Page 2 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 13 05 1 TITLE Main Landing Gear Spring Axle Attach Inspection Models 180 and 185 2 EFFECTIVITY Model 180 Serial Numbers 604 614 624 30000 thru 32999 50000 thru 50911 18050912 thru 18051183 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 5 Years NOTE REPEAT 5 Years NOTE SEVERE INITIAL 3 Years NOTE REPEAT 3 Years NOTE NOTE Refer to Note 1 Section 2A 14 00 This inspection applies only
87. E CRACK SIZE Root Rib Not Allowed 6 INSPECTION METHOD Visual D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 27 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 7 REPAIR MODIFICATION A If corroded sand corroded area lightly to remove corrosion If corrosion is found on the outboard side of the rib it may be necessary to provide additional access in the leading edge skin Contact Cessna Customer Service for instructions to cut and repair B Clean area thoroughly to assess remaining thickness C If more than 20 of the thickness has been removed in any area replace the rib Up to 20 is acceptable if confined to an area of 2 inches or less in length and less than one square inch in area D Brush coat sanded areas with alodine 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 27 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 40 01 1 TITLE Strut and Strut Wing Attachment Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17
88. E MANUAL B18485 DETAIL NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL U BOLT REPLACEMENT MODELS 172 175 AND 182 Figure 1 Sheet 1 0510T1007 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 05 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 13 01 1 TITLE Main Landing Gear Flat Spring and Attach Fittings Corrosion Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50000 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 20 Years NOTE REPEAT 10 Years NOTE SEVERE INITIAL 10 Years NOTE REPEAT 5 Years NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To ensure corrosion protection of main landing gear flat springs 4 INSPECTION INSTRUCTIONS NOTE Themain landing gear flat springs are made from
89. ENTRATION CONCENTRATION CONCENTRATION CELL CORROSION CORROSION ELECTROLYTE PRODUCTS ELECTROLYTE TEEL RARE QRH PASSIVE FILM FASTENER ALUMINUM ALLOY PINHOLE CORROSION DISSIMILAR METAL CORROSION FILIFORM CORROSION WORM LIKE TRACKS INTERGRANULAR METALLIC GRAIN CORROSION STRUCTURE INTERGRANULAR CORROSION HIGHLY MAGNIFIED FILIFORM CORROSION PAINTED HIGHLY MAGNIFIED 65911001 SURFACE 80911002 62911013 62916004 Corrosion Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 3 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL c Keep the airplane hangared to protect it from the atmosphere d Fly the airplane to promote aeration of enclosed parts e Ensure all vent drain holes are open to ventilate the interior of airplane 3 To remove filiform corrosion once it has been discovered Remove paint from corroded area b Remove corrosion by sanding area to metal surface using either a ScotchBrite pad or 320 grit sandpaper aluminum oxide or silicone carbide grit c Clean and refinish surface l Stress Corrosion Cracking 1 This corrosion is caused by the simultaneous effects of tensile stress and corrosion The stress may be internal or applied Internal stresses are produced by nonuniform shaping during cold working of the metal press and shrink fitting general hardware and those induced when
90. ESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 30 Date Registration Number Serial Number Total Time 1 Description A Operation 30 gives Expanded Maintenance Inspection items that are to be examined after the first 100 hours of operation The inspection is to be repeated every 600 hours of operation or 12 months whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Doa preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved
91. Figure 1 Pay particular attention to the flange radius for cracks 1 Clean area before inspecting if grime or debris is present 2 Confirm suspected cracks with eddy current inspection D Install the wheel and remove the airplane from jacks Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION ZONE DETECTABLE CRACK SIZE Main Gear Section Not Allowed 6 INSPECTION METHOD Visual with Eddy Current if required for confirmation 7 REPAIR MODIFICATION A If corrosion has developed on the landing gear axle it must be removed before refinishing B Use 180 or finer grit abrasive cloth to produce a diameter to depth ratio of about 10 1 Use ultrasonic methods to determine thickness after removing corrosion Repairs are required if thickness is less than 9096 of uncorroded material NOTE If the corrosion pit is deeper than 0 005 in contact Cessna Customer Service for repair replacement instructions C Clean and apply corrosion protection D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 08 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL D Replace cracked axles 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 08 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18488 MAIN LANDING GEAR S
92. INSPECTION OPERATION 23 Date Registration Number Serial Number Total Time 1 Description A Operation 23 gives Supplemental Inspection Document items that are to be examined after the first 2 000 hours of operation or 5 years whichever occurs first The inspection is to be repeated every 2 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual
93. IRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Section 2A 10 01 Inspection Time Limits 1 This section lists in chart format all inspection requirements which must be performed Each page contains the following five columns a Revision Status provides the date that a given item was added deleted or revised A blank entry in this column indicates no change since the reissue of this manual Inspection Requirements provide a short description of the maintenance item Inspection Interval indicates the frequency of the item Applicable Operation s indicates the applicable inspection operation currently containing the inspection item The frequencies corresponding to each operation are listed in Inspection Interval Requirements in this section e Applicable Zone refers to the physical location s in the airplane affected by the item 2 Primary purpose of the Inspection Time Limits Section is to provide a complete listing of all inspection items in an order that allows easy access for the information listed previously This section is not intended to be utilized as a guideline for inspection of the airplane 3 The Inspection Time Limits Table shows the recommended intervals at which items are to be inspected based on usage and environmental conditions The operator s inspection intervals shall not deviate from the inspection time limits shown in this table except as provided below a Each inspection interval can
94. If you use Cor Ban 23 or ARDROX AV 8 for the corrosion treatment make sure that the wet layer thickness is between 1 to 2 mils 6 If you use Cor Ban 35 or ARDROX AV 15 for the corrosion treatment make sure that the wet layer thickness is between 2 to 3 mils 7 f you use Corrosion X for the corrosion treatment make sure that the wet layer thickness is between 2 to 3 mils 8 Letthe wet layer dry for two to three hours to become tack free NOTE The airplane must stay in the paint facility until tack free NOTE The minimum cure temperature must not be below 50 F 10 C 9 Remove the masks from around the corrosion inhibiting compound application area 10 Visually examine the oleos actuators control cables pulleys and electrical or mechanical Switches for signs of overspray a If you find signs of over spray or a penetration of the corrosion inhibiting compound clean the area with MPK 11 Let the applied corrosion inhibiting compound layer cure indoors or outdoors after it become tack free 12 Discard the aerosol extension tube used during the application NOTE Use the extension tube one time only D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 18 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 13 Discard the used mask materials and remaining corrosion inhibiting compounds 19 Determination of the Corrosion Levels A Fin
95. K ACTUATOR NOTE MODEL 180 SHOWN OTHER MODELS TYPICAL 071071030 HORIZONTAL STABILIZER SCREW JACK ACTUATOR INSPECTION Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 04 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 11 01 1 TITLE U Bolt Replacement Models 172 175 and 182 2 EFFECTIVITY Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 INSPECTION COMPLIANCE ALL USAGE INITIAL 1 000 Hours Or 3 Years NOTE REPEAT 1 000 Hours Of 3 Years NOTE NOTE Refer to Note 1 Section 2 14 00 3 PURPOSE To secure the flat leaf main landing gear assembly 4 INSPECTION INSTRUCTIONS A Replace the U bolts every 1 000 hours Refer to Figure 1 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Fuselage Main Landing Gear Not Allowed 6 INSPECTION PROCEDURE Visual 7 REPAIR MODIFICATION Replace the U bolts every 1 000 hours 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 05 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVIC
96. KS For Models 150 172 175 180 and 185 this 210 interval is for typical usage environment Inspect fuselage forward doorpost bulkhead at the lower end wing strut attach area and door hinge area Refer to Section 2A 14 13 Supplemental Inspection Document 53 12 01 for inspection procedure For All Models this interval is for typical usage environment 1 Inspect inboard wing structure and wing attachment to fuselage including working rivets 2 Inspect flap actuator support structure Refer to Section 2A 14 23 Supplemental Inspection Document 57 11 01 for inspection procedure For All Models this interval is for typical usage environment Inspect wing strut and strut tube Refer to Section 2A 14 28 Supplemental Inspection Document 57 40 01 for inspection procedure kkk End of Operation 20 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 510 610 510 610 Cessna Aircraft Company 2A 12 20 Page 1 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 21 Date Registration Number Serial Number Total Time 1 Description A Operation 21 gives Supplemental Inspection Document items that are to be examined after the first 6 000 hours of operation or 10 years whichever occurs first The inspection is to be repeated every 1 000 hours of operation or 5 years whichever occurs first after the initial inspection
97. LD MODERATE INITIAL 20 Years NOTE REPEAT 10 Years NOTE SEVERE INITIAL 10 Years NOTE REPEAT 5 Years NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To verify the integrity of the forward spar wing splice 4 INSPECTION INSTRUCTIONS A Remove the four access panels inboard and outboard of the wing strut attach fitting to gain access to the forward and aft side of the wing strut attachment Refer to the Model 100 Series Service Manual B Visually inspect for corrosion at the edge of the upper and lower spar caps and the edge of the splice doublers Refer to Figure 1 In addition confirm the spar splice does not have bulging resulting from corrosion and does not have missing or loose fasteners C Ifany ofthese conditions are confirmed conduct an Ultrasonic Thickness Test on the area to determine if the doubler and or spar thickness has been reduced in thickness from corrosion Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Ultrasonic Thickness Testing If testing indicates the thickness varies by more than 0 004 inch in any area contact Cessna Customer Support for additional instructions D If corrosion is not found install the removed access panels Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wing Forward Spar Not Allowed 6 INSPECTION METHOD Visual Ultrasoni
98. METHOD Visual 7 REPAIR MODIFICATION A If rust has developed on the flat spring landing gears it must be removed before refinishing recommended procedure to remove rust is by hand sanding using a fine grained sandpaper B Referto Section 5 5A CORROSION CONTROL ON LANDING GEAR SPRINGS of the Model 100 Series Service Manual C Refinish sanded areas 1 Solvent Wipe a Wipe off excess oil grease or dirt from the surface to be cleaned b Apply solvent to a clean cloth preferably by pouring solvent onto cloth from a safety can or other approved labeled container The cloth must be well saturated but not dripping c Wipe surface with the moistened cloth as necessary to dissolve or loosen soil Work a small enough area so the surface being cleaned remains wet d Immediately wipe the surface with a clean dry cloth while the solvent is still wet Do not allow the surface to evaporate dry e Do steps b through d again until there is no discoloration on the drying cloth Apply corrosion primer in accordance with Corrosion Resistant Primer MIL PRF 23377G or later a Mix and apply in accordance with manufacturer s instructions b Apply mixture with a wet cross coat to yield a dry film thickness of 0 6 to 0 8 mils c Allow to air dry for two to four hours d Apply topcoat within 24 hours 3 Apply Polyurethane Enamel Topcoat a Mix and apply in accordance with manufacturer s instructions b Apply mixture w
99. Manual ZONE MECH INSP REMARKS For Models 172 and 175 inspect engine mount 120 210 brackets Refer to Section 2A 14 32 Supplemental Inspection Document 71 20 02 for inspection procedure End of Operation 26 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 26 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 27 Date Registration Number Serial Number Total Time 1 Description A B C Operation 27 gives Supplemental Inspection Document items that are to be examined every time when skis are installed or removed Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be
100. Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 5 000 Hours Or 20 Years NOTE REPEAT 2 000 Hours 07 5 Years NOTE NOTE Refer to Note 1 Section 24 14 00 3 PURPOSE To inspect vertical stabilizer rudder and attachments for signs of damage cracks or deterioration 4 INSPECTION INSTRUCTIONS A Remove rudder from airplane and open all vertical stabilizer access panels Refer to the Model 100 Series Service Manual B Visually inspect vertical stabilizer and rudder for condition cracks and security rudder hinges for condition cracks and security hinge bolts hinge bearings for condition and security bearings for freedom of rotation attach fittings for evidence of damage wear failed fasteners and security Refer to Figure 1 1 Clean area before inspecting if grime or debris is present C Using a borescope inspect forward and aft vertical stabilizer and rudder spars
101. NS A Open all access panels and remove wing strut upper fairings Refer to the Model 100 Series Service Manual B Visually inspect the wing main spar for damaged corroded or cracked parts Use a borescope or magnifying glass where required 1 Clean area before inspecting if grime or debris is present 2 Visually inspect the corners of skin cutouts through which the lift strut fork passes 3 Visually inspect the main spar lower flange front and rear faces in the region of the lift strut attachment Pay particular attention to the areas around the spar to skin rivets C Using at least a 4X magnifying glass and a bright light inspect the rear spar web for fatigue cracks in the root area especially along the radius which is located under the attachment fittings 1 Clean area before inspecting if grime or debris is present D Access the flap bay inner inspection panel to inspect the upper flange of the rear spar channel at the outer end of the attachment fitting E Visually inspect the rear spar for cracks at the trailing edge where the root end fits closely to the spar If doubt exists the trailing edge root end rib can be removed for more detailed inspection 1 Clean area before inspecting if grime or debris is present F Install previously removed access panels and wing strut upper fairings Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wings Not
102. NUAL 17357 CORROSION PREVENTION AND CONTROL PROGRAM DAMAGE REPORT FORM To Cessna Aircraft Company Customer Service P O Box 7706 Wichita Kansas 67277 7706 Phone Number 316 517 5800 Fax Number 316 517 7271 From Facility Airplane Serial No Address Utilization Year Hrs Total Time In Service Hrs Registration No Total Landings Cycles Phone No Fax No Corrosion Inspection Number Interval Years Since Last Inspection Level Of Corrosion LILEVEL 2 LILOCAL LILEVEL 3 LIWIDESPREAD DAMAGED PART NAME LILONGERON STRINGER O SKIN LIFRAME O DOUBLER LIBRACKET SHEAR TIE O RIB LICHORD O BULKHEAD LIWEB LIFITTING LIOTHER LOCATION OF DAMAGE ZONES STA TO STA WL TO WL BL TO BL CAUSE OF DAMAGE LIENVIRONMENT OINTERNAL LEAKAGE LICHEMICAL SPILL OLAVATORY SPILL LIBLOCKED DRAIN INSULATION BLANKET LIUNKNOWN ADDITIONAL DESCRIPTION OF DAMAGED AREA Corrosion Prevention and Control Program Damage Report Form Figure 2 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 8 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 3 The corrosion reports that are sent to Cessna Aircraft Company and data from the FAA Service Difficulty Records were used to identify the inspection areas of the Baseline Program When more than one incident of corrosion was identifie
103. ON DETECTABLE CRACK SIZE Stabilizer Not Allowed INSPECTION METHOD Visual REPAIR MODIFICATION Replace any cracked or excessively corroded 1096 or more of the material thickness is missing in the corroded section brackets Replace excessively worn flat spotted or stiff pulleys Straighten bent pulley brackets and actuator brackets with finger pressure and recheck for cracking Replace any loose or sheared fasteners Make repairs in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Coordinate any repair not available in Section 19 with Cessna Customer Service prior to beginning the repair COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 02 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18482 TRIM TAB B PULLEYS DETAIL E ACTUATOR PULLEYS PULLEYS m pETAIL D DETAIL C NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL ELEVATOR TRIM PULLEY BRACKET AND ACTUATOR BRACKET STRUCTURE INSPECTION MODELS 150 172 175 AND 182 1962 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 02 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 27 30 02 1 TITLE Elevator Trim Pulley Bracket and Screw Jack Structure Inspection Models 180 182 prior to 1962 and 18
104. OTE MODEL 172 SHOWN OTHER MODELS TYPICAL 0510T1007 VERTICAL STABILIZER RUDDER AND ATTACHMENTS INSPECTION ALL MODELS Figure 1 Sheet 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 22 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 11 01 1 TITLE Wing Structure Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE TYPICAL INITIAL 12 000 Hours 07 20 Years NOTE REPEAT 2 000 Hours 07 10 Years NOTE SEVERE INITIAL 6 000 Hours Of 10 Years NOTE REPEAT 1 000 Hours OF 5 Years NOTE NOTE Refer to Note 1 Section 2 14 00 3 PURPOSE To ensure structural integrity of the wing structure 4 INSPECTION INSTRUCTIONS A Remove all access panels fairings and the wing tips from the wings Refer to the Model 100 Series Service Manual B Visual Insp
105. PANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL tanks and examine them with lighted borescopes or other aids Flight and control surfaces are difficult to inspect since access is difficult Extensive use of aids is recommended for such locations NOTE Theuse ofa center punch or awl to indent a surface should be used with care since awl or center punch pricks can cause fatigue cracks 3 Sites Careful detailed inspection of corrosion sites is then done to measure the amount of corrosion You may need to remove skin panels or other measures to further measure the damage e Disbonds Many airplanes have adhesive bond panels These may have disbonds and adhesive failures Remember that in adhesively bonded structures evidence of corrosion can signal the loss of bond integrity A good example of this condition is the pillowing which appears behind rivets If the structure is bonded as well as riveted the bond may be damaged where pillowing exists f X Painted Surfaces Examine painted surfaces for chipped missing loose or blistered paint and for signs of corrosion g Other surface discontinuities Look for other surface discontinuities such as discoloration from overheating buckled bulged or dented skin cracked chafed split or dented tubing chafed electrical wiring delamination of composites and damaged protective finishes D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 23 Cessna Aircraft Comp
106. PRING DETAIL NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL 051071007 MAIN LANDING GEAR AXLE INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 08 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 13 04 1 TITLE Main Landing Gear Spring Axle Attach Inspection Models 180 and 185 2 EFFECTIVITY Model 180 Serial Numbers 604 614 624 30000 thru 32999 50000 thru 50911 18050912 thru 18051183 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION INSPECTION COMPLIANCE SEVERITY Any INITIAL Every time skis are installed or removed NOTE REPEAT Every time skis are installed or removed NOTE NOTE Refer to Note 1 Section 2A 14 00 This inspection applies only to airplanes operated on skis 3 PURPOSE To ensure corrosion does not develop in main landing gear axle attachment holes 4 INSPECTION INSTRUCTIONS A Inspect the four axle attach bolt holes for any indication of rusting or rust pits Refer to Figure 1 NOTE Mainlanding gear springs of airplanes operated on skis can fail from fatigue cracks initiated by corrosion pits as small as 0 003 inches to 0 010 inches Corrosion pits must not be allowed to develop inside the axle attach holes To minimize the potential for corrosion always install dry bolts in dry holes 5 ACCESS AND DETECTABLE CRACK SIZ
107. R 57 53 01 1 TITLE Flap Tracks Corrosion Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 20 Years NOTE REPEAT 10 Years NOTE SEVERE INITIAL 10 Years NOTE REPEAT 5 Years NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To ensure the integrity of the flap tracks 4 INSPECTION INSTRUCTIONS A Check airplane records to verify that Service Bulletin SEB95 03 has been incorporated If not complete SEB95 03 with this inspection B Visually inspect the inboard and outboard flap tracks for exfoliation corrosion particularly along exterior edges and edges of roller tracks Refer to Figure 1 1 Clean area before inspection if grime or debris is present C Visually inspect the flap track rib assembly attachment bracket and angles for condition cracks loose rivets and secu
108. REFERENCE REMOVE AND RETAIN FOR REINSTALLATION IF NO CRACKS ARE PRESENT DETAIL DISCARD EXISTING SKIN IF CRACKS ARE DETECTED AND INSTALL NOTE LEADING EDGE NOT SHOWN NEW SKIN FOR CLARITY ONLY 051071007 HORIZONTAL STABILIZER FORWARD SPAR INSPECTION MODIFICATION MODELS 172 AND 175 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 20 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18209 REPLACE THE FORWARD SPAR IF CRACKS ARE PRESENT THAT EXTEND TO THE SPAR FLANGE RADIUS HORIZONTAL STRAIGHTEN ANY HORIZONTAL STABILIZER STABILIZER BUCKLING IN THE FORWARD SPAR AFT CENTER LINE SPAR WEB SURFACE REFERENCE DRILL OUT RIVETS BLEND OUT SECURING EXISTING CRACKING INSPECT FOR CRACKS TWO 0532001 LIMITED TO RADIATING FROM CENTER REINFORCEMENTS LIGHTENING REMOVE AND DISCARD HOLE FLANGE STOP DRILL CRACKS REINFORCEMENTS USING A NUMBER 30 0 128 INCH DIAMETER OR LARGER DRILL BIT VIEW VIEW LOOKING FORWARD AT AFT RIGHT SURFACE OF HORIZONTAL STABILIZER FORWARD SPAR LEFT SIDE TYPICAL 0510T1007 HORIZONTAL STABILIZER FORWARD SPAR INSPECTION MODIFICATION MODELS 172 AND 175 Figure 1 Sheet 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 20 5 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE M
109. ROSION CORROSION FOUND IN ADJACENT AREAS OF THE SKIN PANELS Corrosion Location Figure 3 Sheet 2 Page 13 Feb 3 2003 2A 30 00 D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A59705 Ai hy EN j RATE AT BOCK A One Ro iu ss BOO EL ERES UP RA C S AS ECON PSA A ELO xE x LT EE DELE ci EE OR e rame aca AUS Page 14 3 2003 2 30 00 Corrosion Location Figure 3 Sheet 3 LOCAL CORROSION CORROSION FOUND IN NON ADJACENT FRAMES Cessna Aircraft Company D138 1 13 Temporary Revision Number 7 Dec 1 2011 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A59706 De ETT ava De z IIA ESR gt di e n aererana chrome 4 a N h a SSI A pese PARRA BAS DEA Ma aw WIDESPREAD CORROSION CORROSION FOUND IN ADJACENT FRAMES Corrosion Location Figure 3 Sheet 4 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 15 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Table 2 Tools and Equipment Zip Chem Products To spray the corrosion inhibit UU T pU qe Inm e aerosol foun 3100 Microflex AirVerter To
110. Repair the structure Contact Cessna Aircraft Company for an approved repair procedure 2 Report the details of the corrosion you see to Cessna Aircraft Company and the FAA or applicable regulatory authority 3 Continue to use the Baseline Program but check the corroded area carefully when you do a subsequent CPCP inspection 4 lt is recommended that you record the results of the inspection to show compliance with the program D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 30 00 Page 19 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A59709 The Corrosion Prevention and Control Program CPCP inspection is complete Was corrosion found If Was the corrosion in a Continue with the same structure that is reported Corrosion Prevention and in the CPCP If Control Program Was the corrosion the Use an approved method result of a unique event If to repair the structure Continue with the same Corrosion Prevention and Control Program Level 1 Use an approved Is it necessary at this time to replace or reinforce the corrosion damaged area If repair method to repair the structure Corrosion Level Determination Chart Figure 4 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 20 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A17383 is the r
111. Requirements section c Prepare the part or assembly surface for the inspection The area must be clean dry and free of dirt grease oil or other contamination Magnetic particle inspection can be done through thin layers of paint If the paint is thick enough to cause interference with the inspection the paint must be removed It is recommended to remove paint if more than 0 003 inch thick NOTE Cleaning materials and methods must be approved for use by the applicable Cessna Aircraft Service Manual Structural Repair Manual or Component Maintenance Manual NOTE Mechanical methods to clean and remove paint should be avoided when practical Take care to avoid filing in or sealing the entrance to a surface discontinuity when using mechanical methods to clean or remove paint Mechanical methods can result a rough surface condition which can cause non relevant indications 4 Create the magnetic field a Electric current passes through the yoke to create a magnetic field between the legs of the yoke 1 A discontinuity that is perpendicular to a line directly between the legs of the yoke has the highest probability for detection 2 There are two types of electrical current Direct current DC is better able to find discontinuities deeper in the part Alternating current AC is more sensitive to discontinuities on the surface of the part Alternating current is preferred for this inspection D138 1 13 Temporary Revision Number 7 Dec
112. Revision Number 7 Dec 1 2011 2 12 14 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 15 Date Registration Number Serial Number Total Time 1 Description A Operation 15 gives Supplemental Inspection Document items that are to be examined after the first 1 000 hours The inspection is to be repeated every 1 000 hours after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items
113. Rudder structure for All Models Make sure you inspect Every 24 months 3 320 these areas 1 Skin 2 Forward and aft spars at hinge locations NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information Engine support structure for All Models Make sure you Every 12 months 2 120 inspect these areas 1 Engine truss Pay particular attention to vicinity of welds NOTE Corrosion Prevention and Control Program Inspection item refer to Section 2A 30 00 for additional inspection information D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 10 01 Page 10 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 1 Date Registration Number Serial Number Total Time 1 Description A B C Operation 1 gives Records Inspections items that are to be examined every 100 hours of operation or 12 months whichever occurs first Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specif
114. S 3 Heavy Duty Rust Inhibitor to the sliding surfaces of the oleo strut NOTE Coordinate with tire change Horizontal stabilizer structure for All Models Make Every 60 months 6 330 sure you inspect these areas 1 Stabilizer attachment 340 to the tailcone bulkhead 2 Front and rear spars NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2 30 00 for additional inspection information Elevator trim system for All Models Make sure you Every 24 months 3 330 inspect these areas 1 Elevator trim brackets 2 340 Actuator support brackets and bearings 3 Pulleys and attaching structure NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor on hinge bearing D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 10 01 Page 9 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL REVI TASK INTERVAL OPERATION ZONE SION STATUS Rudder attachments for All Models sure Every 24 months 3 320 you inspect these areas 1 Hinge brackets 2 Hinge bolts 3 Hinge bearings NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor on hinge bearing
115. SERIES 1953 1962 SERVICE MANUAL A27661 vs 5 2 4 9 5 5 DI 22 cJ 5 d i S Q E Q RUSSIA y mj St Petersburg Moscow em is Baghdad m A E 7 T E i A MILD oi s IM MODERATE SEVERE Asia Corrosion Severity Map Figure 5 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 10 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 A27662 Reykjavik i Torshavn 7 Lisbon CORROSION SEVERITY LEGEND a MILD MODERATE SEVERE SERVICE MANUAL alm D Q6 Seul y Tp 1 Rome Algiers Tunis Europe and Asia Minor Corrosion Severity Map Figure 6 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company H tH Im M Athens Ji Er 5 Petersburg 2 30 01 11 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A27660 WAKE E SEVERE Elgg PHILIPPINES
116. SNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL REVI TASK SION STATUS For Model 182 inspect vertical stabilizer attachment bolts forward and aft vertical stabilizer structures and vertical stabilizer attach bulkheads Refer to Section 2A 14 17 Supplemental Inspection Document 53 42 01 for inspection procedures For All Models this interval is for mild moderate corrosion environment Inspect seat rails for corrosion Refer to Section 2A 14 18 Supplemental Inspection Document 53 47 01 for inspection procedure For All Models this interval is for severe corrosion environment Inspect seat rails for corrosion Refer to Section 2A 14 18 Supplemental Inspection Document 53 47 01 for inspection procedure For All Models inspect horizontal stabilizer and elevator including spars ribs hinge bolts hinge bearings attach fittings and torque tube Section 2A 14 19 Supplemental Inspection Document 55 10 01 for inspection procedures For Models 172 175 inspect stabilizer forward spar Refer to Section 2A 14 20 Supplemental Inspection Document 55 11 01 inspection procedure For Model 150 inspect horizontal forward attachments Refer to Section 2A 14 21 Supplemental Inspection Document 55 11 02 inspection procedure For All Models inspect vertical stabilizer and rudder including spars ribs hinge bolts hinge bearings Refer to Section 2A 14 22 Supplemental Inspection Docume
117. SSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL NONDESTRUCTIVE INSPECTION METHODS AND REQUIREMENTS 1 GENERAL REQUIREMENTS A General 1 Facilities performing nondestructive inspections described in this section must hold a valid FAA Repair Station Certificate with the appropriate rating in the applicable method of nondestructive testing 2 Personnel performing NDT must be qualified and certified to a recognized standard in AC65 31A and comply with all recommendations The minimum certification is Level 1 Special as described in 8 c 1 3 Organizations and personnel that operate under the jurisdiction of a foreign government must use the applicable documentation issued by their regulatory agency to comply with the above requirements Reporting Results 1 Use the Discrepancy Report Form found in 2A 13 00 Section 4 Reporting Communications to report crack s that are found in an inspection If a part is rejected refer to the Model 100 Series Service Manual for information to replace the part or repair the part If a repair for crack s is required for a repair not available in the Model 100 Series Service Manual contact Cessna Propeller Aircraft Product Support for possible repair instructions or replace the part a Type of discontinuity b Location of the discontinuity c Discontinuity size d Discontinuity orientation or direction 2 EDDY CURRENT INSPECTION A General 1 Eddy
118. Temporary Revision Number 7 Dec 1 2011 2 13 00 Page 3 Cessna Aircraft Company Feb 3 2003 4 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL For all other operating environments inspections should be conducted using the TYPICAL Inspection Time Limits Corrosion Severity 1 2 Prior to conducting the initial corrosion inspection determine where the airplane has resided throughout its life If the airplane has resided in a severe corrosion environment for 3096 or more of the years to the initial inspection refer to maps in Section 2A 30 01 use the severe inspection time otherwise use the mild moderate inspection time Prior to conducting a repetitive corrosion inspection determine where the airplane has resided since the last inspection If the airplane has resided in a severe environment for 3096 or more of the years since the last inspection use the severe inspection time otherwise use the mild moderate inspection time 4 Reporting Communications A Discrepancies 1 2 3 For the SID to continue to stay applicable it is necessary to have free flow of information between the operator the FAA and Cessna Aircraft Company The important information about the inspection results repairs and modifications done must be supplied to Cessna Aircraft Company in order to assess the effectiveness of the recommended inspection procedures and inspection intervals Also the oper
119. The inspection is to be repeated every 3 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For Models inspect rudder pedal torque tube 211 and cable attachment arms Refer to 24 14 01 Supplemental Inspection Document 27 20 01 for inspection procedure End of Operation 8 Inspection Items D138 1 13 Temporary Revision Number 7 D
120. UAL B18503 A NC MOUNT L X DETAIL NOTE MODEL 182 SHOWN OTHER MODELS TYPICAL 071071001 ENGINE MOUNT INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 31 Page 3 Cessna Aircraft Company Feb 3 2003 1 2 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 71 20 02 TITLE Engine Mount Bracket Inspection Models 172 and 175 EFFECTIVITY Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 INSPECTION COMPLIANCE ALL USAGE INITIAL 2 500 Hours OF 5 Years NOTE REPEAT 2 500 Hours OF 5 Years NOTE NOTE Refer to Note 1 Section 2 14 00 3 PURPOSE To ensure structural integrity of the engine mount 4 INSPECTION INSTRUCTIONS A For Model 172 units 630 47747 thru 49544 and Model 175 units 619 626 55001 thru 56777 56778 thru 57119 check airplane records to verify that SEBO7 2 Engine Mount Bracket Inspection has been incorporated If SEBO7 2 has not been incorporated complete SEBO7 2 with this inspection B Remove upper and lower engine cowling Refer to the Model 100 Series Service Manual C Remove the pilot and copilot seats D Visually inspect the upper left and upper right engine mount brackets for cracks Use a borescope to aid in insp
121. Y MODEL 100 SERIES 1953 1962 SERVICE MANUAL 5 Inspection Time Limits Legend A Each page of the inspection listed in Inspection Time Limits Section 2A 10 01 contains the following five columns REVISION STATUS This column provides the date that a given item was added deleted or revised A blank entry in this column indicates no change since the reissue of this manual TASK This column provides a short description of the inspection and or servicing procedures Where a more detailed description of the procedure is required a reference will be made to either another section located within the Model 100 Series Service Manual or a specific reference to a 1 2 supplier publication INTERVAL This column lists the frequency of the inspection OPERATION All of the inspections included in one operation are grouped together in the 2A 12 XX documents XX equals the operation number ZONE This column locates the components within a specific zone For a breakdown of how the airplane is zoned refer to 2A 30 00 Figure 1 Airplane Zones 6 Inspection Interval Requirements Operation 1 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 Details Every 100 hours of operation or 12 months whichever occurs first Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 12 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additi
122. ZONE MECH INSP REMARKS For Models 172 and 175 inspect firewall structure 210 Refer to Section 2A 14 15 Supplemental Inspection Document 53 12 03 for inspection procedure End of Operation 23 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 23 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 24 Date Registration Number Serial Number Total Time 1 Description A Operation 24 gives Supplemental Inspection Document items that are to be examined after the first 1 000 hours of operation or 3 years whichever occurs first The inspection is to be repeated every 1 000 hours of operation or 3 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditi
123. a ANOTE A 7121 Southwest Blvd Wichita KS 67215 0074100 Cessna Service Parts and To assist in protecting Commercially Available To assist in protecting Commercially Available To assist in protecting Commercially Available To assist in protecting Extreme Simple green or Commercially Available To be used for cleaning equivalent NOTE 2 MPK Methyl Propyl Commercially Available To be used for cleaning Ketone NOTE 1 Use Cor Ban 23 or ARDOX AV 8 in areas where a high penetration of corrosion inhibiting compound is necessary NOTE 2 Do not use any Simple Green products other than Extreme Simple Green as some have been found to be corrosive to some parts of the airplane structure 15 Tools and Equipment NOTE You can use equivalent alternatives for the items that follow D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 30 00 11 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A59703 5 EU n AAA CE PLZ LOCAL CORROSION CORROSION FOUND IN NON ADJACENT AREAS OF THE SKIN PANELS Corrosion Location Figure 3 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 12 Cessna Aircraft Company Feb 3 2003 55 AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A59704 ADJACENT TO THE LONGITUDE CASE 2 ADJACENT TO THE CIRCUMFERENCE WIDESPREAD COR
124. access Visual inspection aids such as a powerful flashlight a mirror with a ball joint and a 10 power magnifying glass are needed for the inspection 2 Flashlights used for visual inspection should be suitable for industrial use and where applicable safety approved for use in hazardous atmospheres such as airplane fuel tanks These characteristics should be considered when selecting a flashlight foot candle rating explosive atmosphere rating beam spread adjustable spot or flood efficiency battery usage rate brightness after extended use and rechargeable or standard batteries Inspection flashlights are available in several different bulb brightness levels a Standard incandescent for long battery life b Krypton for 7096 more light than standard bulbs c Halogen for up to 10096 more light than standard bulbs d Xenon for over 100 more light than standard bulbs 3 An inspection mirror is used to view an area that is not in the normal line of sight The mirror should be of the applicable size to easily see the component and a swivel joint tight enough to keep its position 4 A single converging lens is often referred to as a simple magnifier Magnification of a single lens can be found by the equation M 10 f In this equation M is the magnification f is the focal length of the lens in inches and 10 is a constant that represents the average minimum D138 1 13 Temporary Revision Number 7 Dec 1 2011
125. al Inspection Document 57 11 02 for inspection procedure D138 1 13 Temporary Revision Number 7 Dec 1 2011 210 210 510 520 610 620 Cessna Aircraft Company 2 12 13 Page 1 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK ZONE MECH INSP REMARKS For All Models this interval is for severe corrosion 510 610 environment Inspect wing splice joint at strut attach Refer to Section 2A 14 26 Supplemental Inspection Document 57 11 04 for inspection procedure For All Models this interval is for severe corrosion 510 610 environment Inspect flap tracks for corrosion Refer to Section 2A 14 30 Supplemental Inspection Document 57 53 01 for inspection procedure End of Operation 13 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 13 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 14 Date Registration Number Serial Number Total Time 1 Description A Operation 14 gives Supplemental Inspection Document items that are to be examined after the first 3 years The inspection is to be repeated every 3 years after the initial inspection has been accomplished for airplanes operating in a severe corrosion environment Inspection items are given in the order of the zone in which the inspection is to be completed Fre
126. any Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL LISTING OF SUPPLEMENTAL INSPECTIONS 1 Supplemental Inspection Procedures A Each of the supplemental inspections listed in this section has the instructions to do each Nondestructive Testing procedure needed B Procedure 1 Each 2A 14 XX section has the details of the inspection and if needed a reference to the Nondestructive Testing procedure for that inspection 2 The supplemental inspections that reference a Nondestructive Testing procedure will refer to 2 13 01 document for the details of the procedure 3 The supplemental inspection numbers in the list below agree with the number for the Nondestructive Testing procedure if applicable Refer to Inspection Requirements Hours to Years Equivalence C Ifan airplane has exceeded the inspection limits given the inspection must be done before June 30 2014 Inspections in subsequent revisions to the SID shall be accomplished in accordance with the requirements of the revised inspection D Service Information Letters Service Bulletins 1 In addition to this service manual the following service information will be required to complete the SID inspections 2A 14 XX document sections Bulletin Title Associated Service Kit SE71 23 Horizontal Stabilizer Attachment for Model 150 SK150 33 SE72 29 Aft Tailcone Assembly Inspection for Model 182 units SK182 46 18253599 thru 18254423 SE
127. apply LPS 3 Heavy Duty Rust Inhibitor to the sliding surfaces of the oleo strut End of Operation 4 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 ZONE 721 722 720 720 720 Cessna Aircraft Company MECH INSP REMARKS 2A 12 04 Page 2 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 5 Date Registration Number Serial Number Total Time 1 Description A Operation 5 gives Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 48 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or
128. ars whichever occurs first The inspection is to be repeated every 2 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after the first 2 000 hours of operation or 5 years whichever occurs first The inspection is to be repeated every 2 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after the first 1 000 hours of operation or 3 years whichever occurs first The inspection is to be repeated every 1 000 hours of operation or 3 years whichever occurs first after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after the first 100 hours of operation or 1 year whichever occurs first The inspection is to be repeated every 100 hours of operation or 1 year whichever occurs first after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after the first 2 500 hours of operation or 5 years whichever occurs first The inspection is to be repeated every 2 500 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined every time when skis are installed or removed Supplemental I
129. as used to develop the inspection procedures referred to in this manual Alternative equipment may be used if it has the same sensitivity Refer to the guidelines in this section for more information on equipment parameters D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 15 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL NAME NUMBER MANUFACTURER Electromagnetic Yoke DA 200 Parker Research Corp 2642 Enterprise Rd W Clearwater FL 33528 Phone 800 525 3935 Web http www parkreshcorp com Fluorescent Magnetic Particle 14 Aerosol Can Magnaflux Corp Bath 3624 W Lake Ave Glenview IL 60026 Phone 847 657 5300 Web http www magnaflux com Magnetic Field Strength Magnaglo 2480 Magnaflux Corp Indicator Portable Ultraviolet Light ZB 23A Magnaflux Corp Light Meter DSE 2000A Spectronics Corp 956 Brush Hollow Road Westbury New York 11590 Phone 800 274 8888 Web http www spectroline com Fluorescent magnetic particles have a high sensitivity and the ability to Show small fatigue cracks Visible or dry magnetic particles do not have the needed sensitivity CAUTION Do not use visible or dry magnetic particles for inspection of airplanes or components Refer to industry specifications ASTM E1444 Standard Practice for Magnetic Particle Examination and ASTM E 709 Standard Guide for Magnetic Particle Examination or an e
130. ator s inspections and reports can find items not included in the SID before These items will be examined by Cessna Aircraft Company and will be added to the SID for all of the operators if applicable Cessna Customer Service has a system to collect the reports The applicable forms are included in this document Copies of these forms are also available from a Cessna Service Station or Cessna Field Service Engineer B Discrepancy Reporting 1 2 Discrepancy reporting is essential to provide for adjusting the inspection thresholds and the repeat times as well as adding or deleting PSE s It may be possible to improve the inspection methods repairs and modifications involving the PSE s based on the data reported All cracks multiple cut off fasteners and corrosion found during the inspection must be reported to Cessna Aircraft Company within ten days The PSE inspection results are to be reported on a form as shown on the pages that follow C Send the Discrepancy Form 1 Send all available data which includes forms repairs photographs sketches etc to Cessna Aircraft Company Attn Customer Service P O Box 7706 Wichita KS 67277 USA Phone 316 517 5800 Fax 316 517 7271 NOTE This system does not replace the normal channels to send information for items not included in the SID D Cessna Aircraft Company Follow Up Action 1 SID reports will be examined to find if any of the steps are necessary
131. be condensation or in some cases only the humidity in the air 2 Elimination of any one of the three conditions will stop the corrosion reaction process 3 Asimple method of minimizing corrosion is adding a layer of pure Aluminum to the surface The pure Aluminum is less susceptible to corrosion and also has a very low electropotential voltage relative to the remainder of the alloyed sheet This process is conducted at the fabricating mill and the product is called Alclad Model 100 Series airplanes had sheet metal parts constructed of Alclad sheet 4 One of the best ways to eliminate one of the conditions is to apply an organic film such as paint grease or plastic to the surface of the metal affected This will prevent electrolyte from connecting the cathode to the anode so current cannot flow and therefore prevent corrosive reaction and was not available for production Model 100 Series airplanes b Other means employed to prevent electrochemical corrosion include anodizing and electroplating Anodizing and other passivating treatments produce a tightly adhering chemical film which is much less electrochemically reactive than the base metal Because the electrolyte cannot reach the base metal corrosion is prevented Electroplating deposits a metal layer on the surface of the base material which is either less electrochemically reactive Example chrome on steel or is more compatible with the metal to which it is coupled Example cadmium
132. be exceeded by 10 hours if time controlled or by 30 days if date controlled or can be performed early at any time prior to the regular interval as provided below b c d 1 In the event of late compliance of any operation scheduled the next operation in sequence retains a due point from the time the late operation was originally scheduled 2 In the event of early compliance of any operation scheduled that occurs 10 hours or less ahead of schedule the next operation due point may remain where originally set In the event of early compliance of any operation scheduled that occurs more than 10 hours ahead of schedule the next operation due point must be rescheduled to establish a new due point from the time of early accomplishment 109 Section 24 20 01 Expanded Maintenance This section provides additional information on some maintenance inspection procedures lt describes where the component item is located what to inspect for how to inspect it etc Detailed requirements such as functional checks operational checks etc are listed in the appropriate section of the Model 100 Series Service Manual Refer to the appropriate section for complete detailed information Section 2A 30 00 Corrosion Prevention and Control Program This section gives the guidelines and applications of the CPCP This is a program used to control the corrosion in the airplane s primary structure The objective of the CPCP is to help to preven
133. beginning the repair 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 15 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 30 01 1 TITLE Fuselage Interior Skin Panels Corrosion Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50000 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 20 Years NOTE REPEAT 10 Years NOTE SEVERE INITIAL 10 Years NOTE REPEAT 5 Years NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To verify the integrity of the cabin skins stringers and frames under and around sound deadening material 4 INSPECTION INSTRUCTIONS A Remove interior of airplane to gain access to inside skins stringers and frames Remove sound dampening material B Visually inspect skin panels for c
134. ble limits may be established by the design approval holder The FAA or applicable regulatory authority may also establish allowable limits The design approval holder normally publishes allowable limits in the Structural Repair Manual or in Service Bulletins Baseline Program A Baseline Program is a CPCP developed for a specific model airplane The design approval holder typically develops the Baseline Program However it may be developed by a group of operators who intend to use it in developing their individual CPCP It contains the corrosion program inspection an implementation threshold and a repeat interval for the procedure accomplishment in each area or zone Refer to Corrosion Program Inspection Corrosion Program The Corrosion Program Inspection CPI is a specific and fundamental set Inspection CPI of work elements that should be performed repetitively in all task areas or zones to successfully control corrosion The contents of the CPI may vary depending upon the specific requirements in an airplane area or zone The CPI is developed to protect the primary structure of the airplane Corrosion Metal The physical deterioration of metals caused by a reaction to an adverse environment D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 9 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Corrosion Prevention and A Corrosion Prevention and Contro
135. bs buck the fasteners that attach the pulley bracket doublers to the stabilizer skin 16 Install the 0532001 23 stabilizer center skin using MS20470AD3 3 rivets in the same locations recorded in the removal process Reinstall the stabilizer vertical stabilizer rudder and elevators Check the control rigging per the appropriate section of the Model 100 Series Service Manual N 3 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 20 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 8 COMMENTS This inspection supersedes and replaces SEB94 08 Installation of 0531037 1 horizontal spar reinforcement or 0532001 98 horizontal stabilizer forward spar is a terminating action for this inspection NOTE Improper ground handling can cause cracking and deformation in the horizontal stabilizer Itis recommended that a tow steering bar be used when the airplane is manually positioned on the ground Do not steer the airplane by pushing down on the horizontal tail D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 20 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18208 STABILIZER LEADING EDGE REFERENCE STABILIZER FORWARD SPAR CENTER LIGHTENING HOLE REFERENCE RBL DETAIL NOTE REMOVE 6 RIVETS THIS LOCATION BOTH LEFT AND RIGHT SIDE 0532001 SKIN
136. c Thickness 7 REPAIR MODIFICATION Replace any cracked parts If corroded sand area lightly to remove corrosion If more than 1096 of the thickness has been removed in any one area replace the part D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 26 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 8 5 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 26 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18499 STRUT ATTACH FITTING HOLES WING SPLICE DOUBLER DETAIL INSPECT FOR CORROSION HIDDEN UNDER DOUBLER DETAIL B NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL BEER WING SPLICE JOINT AT STRUT ATTACH INSPECTION Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 26 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 12 01 1 TITLE Wing Root Rib Corrosion Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119
137. ction has been completed and a CPCP is in effect then REPEAT inspections are based entirely on flight hours D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 00 Page 5 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 27 20 01 1 TITLE Rudder Pedal Torque Tube Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 49544 Model 175 Serial Numbers 619 626 55001 thru 56777 56778 thru 57119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 50912 thru 51183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 53008 thru 54423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 10 000 Hours OF 20 Years NOTE REPEAT 3 000 Hours 07 5 Years NOTE NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To verify integrity of the rudder pedal torque tube assembly 4 INSPECTION INSTRUCTIONS A Inspect rudder pedal torque tubes for corrosion or cracking and cable and pedal attachment arms for wear cracks or weld failures Refer to Figure 1 1 Clean area before inspecting if grime or debris is present B Inspect the rudder bar support brackets for cracks at the bend radii in the mounting flan
138. current inspection is effective for the detection of surface and subsurface cracks in most metals You do this through induction of eddy currents into the part These eddy currents will alter the magnetic field around the probe Changes to the magnetic field are monitored and then interpreted 2 You can do eddy current inspection on airplane parts or assemblies where the inspection area is accessible for contact by the eddy current probe An important use of eddy current inspection is to find cracks caused by corrosion and stress A second important use is measurement of electrical conductivity Surface Inspection 1 General a Thisis a general procedure for the eddy current method used to find surface discontinuities This should be used along with specific instructions for inspection in the procedure that referred to this section 2 Instrument Parameters a The following equipment was used to develop the inspection procedures referred to in this manual Alternative equipment may be used if it has the same sensitivity Refer to the guidelines in this section for more information on equipment parameters D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL NAME NUMBER MANUFACTURER Eddy Current Instrument Nortec 2000 Olympus NDT Phone 781 419 3900 Web http www olympusndt comVM Products Surface Eddy
139. curs first Repeat 3 000 hours or 5 years whichever occurs first 2A 10 01 Page 2 Feb 3 2003 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK For All Models this interval is for mild moderate corrosion environment Inspect the carry thru spar area door post bulkhead attach fittings and spar channel Refer to Section 2A 14 12 Supplemental Inspection Document 53 11 01 for inspection procedure For All Models this interval is for severe corrosion environment Inspect the carry thru spar area door post bulkhead attach fittings and spar channel Refer to Section 2A 14 12 Supplemental Inspection Document 53 11 01 for inspection procedure For Models 150 172 175 180 and 185 this interval is for typical usage environment Inspect fuselage forward doorpost bulkhead at the lower end wing strut attach area and door hinge area Refer to Section 2A 14 13 Supplemental Inspection Document 53 12 01 for inspection procedure For Models 150 172 175 180 and 185 this interval is for severe usage environment Inspect fuselage forward doorpost bulkhead at the lower end wing strut attach area and door hinge area Refer to Section 2A 14 13 Supplemental Inspection Document 53 12 01 for inspection procedure For Model 182 inspect forward doorpost and surrounding structure Refer to Section 2A 14 14 Supplemental Inspection Document 53 12 02 for inspection procedure Fo
140. d at a specified location an inspection was included for that location in the Baseline Program 4 When corrosion was found once the data was examined to find if the corrosion was caused by one specified occurrence or if other airplanes could have corrosion in the same location If the corrosion is not linked to one specific occurrence the inspection should be added to the Baseline Program b The inspection interval was specified by the duration and corrosion severity 12 Appendix B Procedures For Recording Inspection Results A Record the Inspection Results 1 Itis not an FAA mandatory procedure to record the results but Cessna Aircraft Company recommends that records be kept to assist in program adjustments when necessary The inspection of records will make sure the identification repeat inspections and level of corrosion are monitored The data can identify whether there is more or less corrosion at repeat intervals The data can also be used to approve increased or decreased inspection intervals 13 Appendix C Guidelines A Glossary 1 The following additional information clarifies the previous sections of this document Refer to Figure 3 B Glossary of General Descriptions Allowable Limit The allowable limit is the maximum amount of material usually expressed in material thickness that may be removed or blended out without affecting the ultimate design strength capability of the structural member Allowa
141. d each layer Examine the hole at a depth of 0 070 inch 1 778 mm from either edge of the hole if thickness allows Also examine the hole at index steps of 0 070 inch 1 778 mm through the hole If multiple layers are present in the hole the inspection parameters must be applied to each layer If the hole depth or layer depth is less than 0 150 inch 8 810 mm thick examine the hole at the center of the depth b Carefully examine each hole at the applicable depths Examine the entire circumference of the hole at each depth c It may be necessary to null the instrument on the airplane in the hole for inspection to adjust the display for differences between the reference standard and the airplane 7 Interpretation a If an indication is found carefully repeat the inspection in the opposite direction to make sure of the indication If the indication is still there carefully monitor the amount of probe movement or rotation needed to cause the instrument to move off maximum indication response b When the eddy current probe is over the center over a crack the signal will be at maximum and any movement of the probe will cause the signal to begin returning to the normal signal Corrosion pits foreign material and out of round holes can cause an instrument response for 20 to 30 of bolthole probe rotation before the indication begins to return to the normal signal c Unless otherwise specified you must reject a part with a crack d IN
142. d on the second or subsequent inspection 1 2 3 4 Do the corrosion program inspection which includes the repair of the structure Contact Cessna Aircraft Company for an approved repair procedure Continue with the Baseline Program No adjustment of the existing program is required It is recommended that you record the corrosion inspection number and the results of the inspection to show that the program was complied with G If Level 2 corrosion is found on the second or subsequent inspection 1 2 3 Repair the structure Contact Cessna Aircraft Company for an approved repair procedure Do a report that shows the information about the corrosion and send it to Cessna Aircraft Company and the FAA or applicable regulatory authority If corrosion damage required the removal of material just beyond the allowable limits within 10 percent complete a check of the other airplanes in the fleet before you change your aircraft s maintenance program a corrosion is typical of Level 2 use the fleet data to find what changes are required to control corrosion to Level 1 or better b If fleet damage is typically Level 1 examine the corroded area during subsequent inspections on all affected airplanes c Make changes to your aircraft s maintenance program if the typical corrosion becomes Level 2 Further evaluation by Cessna Aircraft Company is recommended for Level 2 corrosion findings
143. d the Corrosion Levels refer to Figure 4 1 Corrosion found on a structure when you use the Corrosion Program and Corrosion Prevention CPCP Baseline Program will help find the extent of the corrosion 2 The second and subsequent inspections will find how well the program has been prepared or if there is a need to make adjustments to the Baseline Program A good quality CPCP is one that controls corrosion to Level 1 or better If Level 2 corrosion is found during the second or subsequent inspection you must do something to decrease the future corrosion to Level 1 or better b If Level 3 corrosion is found you must also do something to decrease the future corrosion to Level 1 Also a plan to find or prevent Level 3 corrosion in the same area on other airplanes must be added to the CPCP 6 All the corrosion that you can repair in the allowable damage limits less than 10 percent of the part thickness is Level 1 corrosion 7 If all corrosion is Level 1 the is correctly prepared 8 If you must reinforce or replace the part because of corrosion the corrosion is Level 2 9 Ifthe part is not airworthy because of the corrosion you must do an analysis to find out if the corrosion is Level 3 10 The chart found in this section will help find the level of the corrosion 1 The probability that the same problem will occur on another airplane is dependent on several factors such as past maintenance history ope
144. dditional information B Surface Area Preparation 1 Cleaning WARNING Always use the proper level of Personal Protective Equipment when using cleaning compounds Personnel Injury or death may occur CAUTION Use Extreme Simple Green or approved equivalent to clean the corrosion inhibiting compound application area CAUTION Prevent the direct contact of cleaner or rinse water spray on wheel bearings or lubrication bearings a Clean the surfaces where the corrosion inhibiting compound will be applied as follows 1 Use a handheld sprayer to apply the cleaner 2 Make sure that the cleaner pressure is less than 100 psi 12065 83 kPa 3 X Apply a full layer of the cleaner to the area where the corrosion inhibiting compound will be applied 4 Let the cleaner stay on the area for 5 10 minutes 5 Scrub the area with a soft bristeled brush non metalic 6 If necessary apply the cleaner again to keep the surface wet NOTE Ifthe surface dries before the rinse apply the cleaner again 7 Rinse the surface with reverse osmosis or de ionized water 8 Make sure that the water pressure is less than 100 psi 12065 83 kPa 9 Letthe corrosion area fully dry NOTE not apply corrosion inhibiting compound to a wet surface D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 17 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 2 Masking NOTE It is n
145. denly joining into a long crack e g as in a line of rivet holes c redistribution of load from adjacent failing or failed parts causing accelerated damage of nearby parts i e the domino effect and d concurrent failure of multiple load path structure e g crack arrest structure Initial inspections of a particular area of structure are based on fatigue analytical results For locations with long fatigue the maximum initial inspection was limited to 12 000 flight hours Classifications for Types of Operation 1 The severity of the operation environment needs to be identified to determine the correct inspection program a You mustfirst find the category of your airplane s operation based on average flight length b You must also find the number of hours and number of landings on the airplane then find the average flight length based on the formula found below Average Flight Length Number of Flight Hours Number of Flights If the average flight length is less than 30 minutes then you must use the SEVERE inspection time limits For airplanes with an average flight length greater than thirty minutes you must find the severity of the operating environment Airplanes which have engaged in operations at low altitudes such as pipeline patrol fish or game spotting aerial applications police patrol sightseeing livestock management etc more than 30 of its life must use the SEVERE inspection time limits D138 1 13
146. e bearings for condition and security bearings for freedom of rotation attach fittings for evidence of damage wear failed fasteners and security Refer to Figure 1 1 Clean area before inspecting if grime or debris is present C Visually inspect the torque tube for corrosion and rivet security Pay particular attention to the flange riveted onto the torque tube near the airplane centerline for corrosion 1 Clean area before inspecting if grime or debris is present D Visually inspect forward and aft stabilizer and elevator spars ribs and attach fittings for cracks corrosion loose fasteners elongated fastener attach holes and deterioration Pay particular attention to the skins at the location where stringers pass through ribs and at the leading edge skin close to the fuselage Apply finger pressure at the stringer intersection or the rib to spar juncture to check for free play indicating a broken rib Visually inspect the forward stabilizer attachment bulkhead for cracks 1 Clean area before inspecting if grime or debris is present E f corrosion or a frozen bearing is found conduct a surface eddy current inspection for cracks of each elevator hinge attach fitting Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Surface Inspection for additional instructions The inspection is for the aluminum structure outside of the bearing so set the instrument for aluminum F Visual
147. e eddy current inspection at either end of the hole around the edge of the bushing b Instrument Standardization a The instrument must be set up and operated in accordance with this procedure and the manufacturer s instructions b Before you begin the inspection standardize instrument using the appropriate reference standard Accuracy must be checked at intervals necessary to maintain consistency during continuous use and at the end of the inspection Verify the accuracy if any part of the system is replaced or if any calibrated control settings are changed JOO DO D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 7 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL c A corner notch no larger than 0 050 inch x 0 050 inch 0 127 mm x 0 127 mm must be used for calibration unless otherwise specified A typical eddy current bolthole reference standard is shown in Figure 3 d Put the bolthole probe into the applicable hole with the coil turned away from the notch in the hole e Set the null point f Remove the bolthole probe from the hole and monitor the display for the lift off response g Adjust the display until the lift off response goes horizontal and to the left of the null point h Put the bolthole probe into the applicable hole and rotate it so the coil moves across the notch in the hole i Adjust the instrument to get a minimum sepa
148. e link attach pin and attach bolt 4 Nose gear fork 5 Nose gear axle NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 24 30 00 for additional inspection information Nose gear trunnion torque link assembly and nose Every 36 months 4 720 gear fork for All Models Make sure you inspect these areas 1 Nose gear trunnion upper and lower inner bore surface and bearing 2 Torque link bolt and attach pin inner bore surface 3 Nose gear fork lug inner bore surface NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information Nose landing gear outer barrel assembly for All Every 36 months 4 720 Models Make sure you inspect these areas 1 Outer barrel assembly 2 Upper strut end and lower collar assembly NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2 30 00 for additional inspection information NOTE do not apply LPS 3 Heavy Duty Rust Inhibitor to the sliding surfaces of the oleo strut Nose gear axle assembly for All Models Make sure Every 60 months 6 720 you inspect these areas 1 Nose gear axle and attach bolt 2 Wheel halves NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 24 30 00 for additional inspection information NOTE Disassemble the nose gear strut to get access NOTE Do not apply LP
149. e magnetic field Put the legs closer together to increase the magnetic field Put the legs farther apart to decrease the magnetic field f Allow 30 seconds for the magnetic particles to collect at discontinuities With wet magnetic particles if practical tilt the part to allow the magnetic particles to flow across the expected direction of the discontinuity 5 Interpretation a Interpretation must happen in the lighting conditions described in the Lighting Parameters section b Theinspector must not wear darkened or light sensitive eye wear These lenses can reduce the amount of fluorescence you see c The inspector must enter the darkened area and remain there for a minimum of 1 minute before interpretation to allow the eyes to adapt to the darkened conditions d Examine the part or assembly with the ultraviolet light 1 9 IN ES A leakage field will be shown by a fluorescent pattern of the magnetic particles This is called an indication An indication caused by a discontinuity on the part surface will be a sharp distinct pattern An indication caused by a subsurface discontinuity will usually be broader and fuzzier compared to an indication of a surface discontinuity Be aware that indications which are not relevant to the inspection may be caused by surface conditions or geometry 6 Demagnetize Part a Unless otherwise specified demagnetize the part after the inspection 1 Put the electromagnetic yoke
150. e under floorboards NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Fuselage internal structure in upper fuselage for All Models 211 Make sure you inspect these areas 1 Cabin bulkhead corners 2 Fuselage skin NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Areas of the cabin structure for All Models Make sure 210 you inspect these areas 1 Firewall 2 Firewall attachments NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 06 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK Areas of the cabin structure for All Models Make sure you inspect these areas 1 Cabin door forward and aft frames 2 Window frames with emphasis at stringers and channel assemblies from aft of door frame to aft bulkhead 3 Seat attachment structure 4 Aft Cabin Bulkhead NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Wing structure internal for All Models Make sure you inspect these areas 1 Wing front spar and lower spar caps
151. eads such as tie rod ends turnbuckles etc should be protected with solid film lubrication conforming to Specification MIL PRF 46010 and or MIL L 46147 7 Slip fits should be assembled using wet primer conforming to Specification MIL PRF 23377G or later non drying zinc chromate paste or solid film lubricant conforming to Specification MIL PRF 46010 and or MIL L 46147 8 Press fits should be accomplished with oil containing material conforming to Specification MIL C 11796 Class 3 and or MIL C 16173 Class 1 or with other suitable material that will not induce corrosion F Electrical 1 Bonding and ground connections should be as described by the installation procedure 2 Potting compounds are used to safeguard against moisture Corrosion in electrical systems and resultant failure can often be attributed to moisture and climatic condition D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 5 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 83 Corrosion of metal can be accelerated because of the moisture absorbed by fungi Fungi can create serious problems since it can act as an electrolyte destroying the resistance of electrical insulating surfaces Specification ASTM D3955 or ASTM D295 58 outlines moisture and fungus resistant varnish to be used 5 General Corrosion Repair A This section provides general guidance on the repair of corroded area T
152. ec 1 2011 2A 12 08 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 9 Date Registration Number Serial Number Total Time 1 Description A Operation 9 gives Supplemental Inspection Document items that are to be examined after the first 3 000 hours of operation or 5 years whichever occurs first The inspection is to be repeated every 3 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection aft
153. ect main landing gear spring axle attach bolt holes Refer to Section 2A 14 10 Supplemental Inspection Document 32 13 05 for inspection procedure For All Models this interval is for mild moderate 510 610 corrosion environment Inspect wing root rib Refer to Section 2A 14 27 Supplemental Inspection Document 57 12 01 for inspection procedure End of Operation 12 Inspection Items KKK D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 12 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 13 Date Registration Number Serial Number Total Time 1 Description A Operation 13 gives Supplemental Inspection Document items that are to be examined after the first 10 years The inspection is to be repeated every 5 years after the initial inspection has been accomplished for airplanes operating in a severe corrosion environment Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections
154. ection 1 Clean area before inspecting if grime or debris is present E Remove floorboard access panels and rudder pedal access panels Refer to the Model 100 Series Service Manual F Visually inspect the lower left and lower right engine mount brackets for cracks 1 Clean area before inspecting if grime or debris is present G Install previously removed accessories and the engine cowling Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Under Cowl Not Allowed 6 INSPECTION METHOD Visual and Borescope 7 REPAIR MODIFICATION Replace cracked brackets 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 32 Page 1 Cessna Aircraft Company Feb 3 2003 1 Control Cables CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL EXPANDED MAINTENANCE A Thechromium nickel steel wire is helically twisted into strands and the strands laid about other strands forming the flexible steel cable The diameter of the cable is determined by the number of wires and the number of strands in the cable 1 Construction of Cables a b Cable diameter 1 32 inch 3 by 7 construction Cable of this construction shall consist of three strands of seven wires each There shall be no core in this construction The cable shall have a length of lay of not more than eight times nor less than five times the nominal cable diameter Cable diamete
155. ection C Theright portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Doa preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual TASK ZONE MECH INSP REMARKS For Models 172 and 175 inspect horizontal 330 340 stabilizer forward spar Refer to Section 2A 14 20 Supplemental Inspection Document 55 11 01 for inspection procedure For Model 150 inspect horizontal stabilizer forward 330 340 attachments Refer to Section 2A 14 21 Supple mental Inspection Document 55 11 02 for inspec tion procedure End of Operation 25 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 25 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE
156. ection 1 Clean area before inspecting if grime or debris is present 2 Visually inspect the wing structure for damage corroded or cracked parts Use a borescope or magnifying glass where required a Pay particular attention to the wing attach area Visually inspect both the fuselage and wing where the wing attaches to the carry thru spar in the fuselage b Visually inspect for working rivets at the inboard portion of the main wing spar NOTE Working rivets will have a trail of black dust downwind from the fastener The dust is oxidized aluminum produced by the fastener moving in the hole c Visually inspect for working Hi Shear rivets at the inboard spar fittings on the main wing spar d Pay particular attention to the trailing edge ribs and the span wise segments supporting the flap actuator or flap bell cranks 3 Ifthe flight hours meet or exceed the inspection compliance hours above proceed to Detailed Inspection below 4 If crack s or corrosion is found at the wing attach fittings proceed to the Detailed Inspection below b If no crack s or corrosion is found and the aircraft flight hours are below the inspection compliance hours above install access panels fairings and wing tips Inspection is complete C Detailed Inspection 1 Support the wing outboard of the strut D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 23 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL
157. ection has been accomplished for airplanes operating in a mild or moderate corrosion environment Supplemental Inspection Document items that are to be examined after the first 5 years The inspection is to be repeated every 5 years after the initial inspection has been accomplished for airplanes operating in a severe corrosion environment Supplemental Inspection Document items that are to be examined after 12 000 hours or 20 years whichever occurs first The inspection is to be repeated every 2 000 hours or 10 years whichever occurs first after the initial inspection has been accomplished for airplanes operating in a typical usage environment D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 10 00 4 Cessna Aircraft Company Feb 3 2003 21 22 23 24 25 26 27 28 29 30 D138 1 13 Temporary Revision Number 7 Dec 1 2011 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Details Supplemental Inspection Document items that are to be examined after the first 6 000 hours of operation or 10 years whichever occurs first The inspection is to be repeated every 1 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished for airplanes operating in a severe usage environment Supplemental Inspection Document items that are to be examined after the first 5 000 hours of operation or 20 ye
158. ection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For All Models inspect main landing gear axle 721 722 Refer to Section 2A 14 08 Supplemental Inspection Document 32 13 03 for inspection procedure For Model 182 inspect forward doorpost and 210 surrounding structure Refer to Section 2A 14 14 Supplemental Inspection Document 53 12 02 for inspection procedure End of Operation 7 Inspection Items kkk D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 07 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 8 Date Registration Number Serial Number Total Time 1 Description A Operation 8 gives Supplemental Inspection Document items that are to be examined after the first 10 000 hours of operation or 20 years whichever occurs first
159. ed for surface eddy current inspection 3 instrument must have a repeatable signal response which has a signal to noise ratio of more than 3 to 1 Impedance plane instruments must have the resolution to show a signal within the guidelines shown in Figure 1 and Figure 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A10766 MINIMUM SENSITIVITY LEVEL LIFT OFF A NULL POINT Absolute Probe Calibration Range Figure 1 A16316 MINIMUM SENSITIVITY LEVEL IS 3 DIVISIONS FROM 20 LIFT OFF NULL POINT 20 Differential Probe Calibration Range Figure 2 4 functional performance of the eddy current instrument must be verified at interval of not more than a year c Probe Sensitivity 1 The probe may have an absolute or differential coil arrangement 2 probe be shielded or unshielded shielded probe is normally recommended D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 62 The probe must have an operating frequency that has the necessary test sensitivity and depth of penetration For an aluminum part the frequency should be approximately 200 kHz For a steel part the frequency should be 500 to 800 kHz For a titanium part
160. ed in the reference standard If a procedure specifies a reference standard made by Cessna Aircraft Company replacement with a different standard is not allowed 4 Surface Condition 0 The surface finish of the area for inspection must be 150 RHR or RMS 165 or finer If the surface finish interferes with the ability to do the inspection it should be smoothed or removed Refer to the Model 100 Series Service Manual for approved methods The area for inspection must be free of dirt grease oil or other contamination You must have good contact between the probe and the part unless otherwise stated in the specific procedure Mildly corroded parts must be cleaned lightly with emery cloth Heavily corroded or painted parts must be lightly abraded and cleaned locally in the area where the inspection will be done 5 Instrument Standardization 0 The instrument must be set up and operated in accordance with this procedure and the manufacturer s instructions Before you begin the inspection standardize instrument using the appropriate reference standard Accuracy must be checked at intervals necessary to maintain consistency during continuous use and at the end of the inspection Verify the accuracy if any part of the System is replaced or if any calibrated control settings are changed A 0 020 inch 0 508 mm deep surface notch or smaller must be used for calibration unless otherwise specified A typical eddy curren
161. ents and maintenance practices can be able to extend the inspection intervals if a sufficient number of inspections do not show indications of corrosion in that area Refer to the Glossary 5 Later design and or production changes done as a result of corrosion conditions can delay the start of corrosion Operators that have done corrosion related Service Bulletins or the improved procedures listed in the Corrosion Program Inspection can use that specified inspection interval Unless the instructions tell you differently the requirements given in this document apply to all airplanes 6 Another system has been added to report all Level 2 and Level 3 corrosion conditions identified during the second and each subsequent CPCP inspection This information will be reviewed by Cessna Aircraft Company to make sure the Baseline Program is sufficient and to change it as necessary 6 Baseline Program A The Baseline Program is part of the Corrosion Prevention and Control Program CPCP It is divided into Basic Task and Inspection Interval In this manual the Basic Tasks are referred to as the Corrosion Program Inspection This program is to be used on all airplanes without an approved CPCP Those who currently have a CPCP that does not control corrosion to Level 1 or better must make adjustments to the areas given in the Baseline Program Typical Airplane Zone Corrosion Program Inspection Procedures 1 Remove all the equipment and airplane interior
162. er these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For Models 150 172 175 and 182 inspect nose 720 landing gear torque links bolts bushings and fork Refer to Section 2A 14 11 Supplemental Inspection Document 32 20 01 for inspection procedure End of Operation 9 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 09 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 10 Date Registration Number Serial Number Total Time 1 Description A Operation 10 gives Supplemental Inspection Document items that are to be examined after the first 10 000 hours of operation or 20 years whichever occurs first The inspection is to be repeated at engine overhaul after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done m
163. er to Section 2A 30 00 for additional inspection information NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor on hinge bearing Vertical stabilizer structure for All Models Make sure Every 60 months 6 310 you inspect these areas 1 Forward spar attachment 320 to tailcone bulkhead 2 Aft spar attachment to lower vertical stabilizer spar 3 Front and rear spars 4 Rear spar rudder hinges NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Main landing gear axle assembly for All Models Every 36 months 4 721 Make sure you inspect these areas 1 Main gear 722 axle and attach bolts 2 Wheel halves NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 24 30 00 for additional inspection information NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor to the bearing NOTE Coordinate with tire change D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 10 01 Page 8 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL REVI TASK INTERVAL OPERATION ZONE SION STATUS Nose gear trunnion steering assembly torque link Every 36 months 4 720 assembly nose gear fork and axle for All Models Make sure you inspect these areas 1 Nose gear trunnion surface 2 Steering collar and steering collar attach bolt 3 Torque link torqu
164. er to the guidelines in this section for more information on equipment parameters NUMBER MANUFACTURER Portable Conductivity Tester Autosigma 3000 GE Sensing amp Inspection Technologies b 9 1 Neumann Way MD J4 Cincinnati Ohio 45215 Web http www geinspectiontechnologies com Inspection Frequency The instrument must have an operating frequency of 60 kHz NOTE Cessnaconductivity information is based on an instrument frequency of 60 kHz Use of a frequency other than 60 kHz will cause differences in the conductivity reading when compared to the 60 kHz value on thinner material Instrument Accuracy The instrument must be an eddy current instrument that can show the conductivity of aluminum alloys as a percentage of the International Annealed Copper Standard 96 IACS It must have an accuracy of at least 41 096 IACS or 1 0 IACS through electrically nonconducting films and coatings up to a minimum of 0 003 inch 0 076 mm thick Instrument Sensitivity The instrument must be sensitive enough to show changes of a minimum of 0 5 IACS over the conductivity range of the aluminum alloys for inspection Probe The probe must have a flat contact surface The contact surface diameter must not be larger than 0 500 inch 12 700 mm To test the lift off compensation of the probe 1 Put the probe on a bare standard 2 Put a nonconducting flat shim of 0 003 inch 0 076 mm thick between the probe and the standard 3
165. erence Standard NOTE 2 Combined Stainless Steel VM89SS VM Products Inc Surface and Bolthole Eddy Current Reference Standard NOTE 2 NOTE 1 Bolthole probe diameter and lengths will vary with the inspection situation NOTE 2 Be sure that the reference standard has the necessary hole size for the bolthole inspection The reference standard material aluminum steel stainless steel will vary with the material of the hole for inspection b Instrument Sensitivity 1 Some inspection procedures need instruments that give both phase and amplitude information on a storage cathode ray tube for impedance plane analysis Impedance plane instruments can be used as an alternative for metered instruments Metered instruments must not be used as an alternative for impedance plane instruments where the ability to show phase information is necessary 2 Eddy current instruments with a meter display are allowed for bolthole eddy current inspection 3 instrument must have a repeatable signal response which has a signal to noise ratio of more than 3 to 1 Impedance plane instruments must have the resolution to show a signal within the guidelines shown in Figure 1 and Figure 2 The functional performance of the eddy current instrument must be verified at an interval of not more than a year c Probe Sensitivity 1 The probe may have an absolute or differential coil arrangement 2 probe may be shielded or unshielded shielded probe
166. ers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 3 000 Hours Or 5 Years NOTE REPEAT 1 000 Hours OF 5 Years NOTE NOTE Refer to Note 1 Section 24 14 00 PURPOSE To ensure structural integrity of the main landing gear fittings INSPECTION INSTRUCTIONS A For Model 172 units 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 review the aircraft records to determine if Service Bulletin SE80 30 has been complied with and associated Service Kits SK172 53A and SK172 54A have been installed B Inspect the outboard main landing gear fittings for cracking Refer to Figure 1 Pay particular attention to the area directly above the forward and aft edges of the landing gear spring and the attachment of the fittings to the bulkheads 1 Clean area before inspecting if grime or debris is present C Inspect the inboard main landing gear fittings for cracking Pay particular attention to the area directly below the landing gear spring attachment and the attachment of the fittings to the bulkheads 1 Clean area before inspecting if grime or debris is present ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION ZONE DETECTABLE CRACK SIZE Main Gear Support Not Allowed INSPECTION METHOD Visual REPAIR MODIFICATION A For Model 172 units 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 if replacement of support forgings is necessary refer to Service Bulletin SE
167. erval refer to Section 2A 30 00 for additional inspection information D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL OPERATION ZONE Initial 6 000 hoursor 21 510 10 years whichever 610 occurs first Repeat 1 000 hours or 5 years whichever occurs first Initial 3 000 hoursor 16 520 10 years whichever 620 occurs first Repeat 500 hours or 5 years whichever occurs first Initial 20 years 11 510 Repeat 10 years 610 Initial 10 years 13 510 Repeat 5 years 610 Initial 10 000 10 120 hours or 20 years whichever occurs first Repeat At Engine Overhaul Initial 2 500 hoursor 26 120 5 years whichever 210 occurs first Repeat 2 500 hours or 5 years whichever occurs first Every 60 months 6 211 Every 60 months 6 211 2A 10 01 Page 6 Feb 3 2003 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK Areas of the cabin structure for All Models Make sure you inspect these areas 1 Firewall 2 Firewall attachments NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 24 30 00 for additional inspection information Passenger Crew door retention system for All Models Make sure you inspect these areas 1 Bell cranks 2 Pushrods 3 Handle 4 Pin retention 5 Pins 6 Lockplates and guides 7 Hinges 8 Internal door framing NOTE Corro
168. esult of the corrosion blending procedure Is the corrosion widespread more than the permitted limits If H ls the result of the corrosion blending procedure more than the permitted limits but less than 10 percent more than the permitted limits If Is the result of the corrosion blending procedure near the permitted limits If Was the corrosion Is the corrosion damage a damage found during possible airworthiness the first CPCP concern If inspection If The corrosion damage is a possible airworthiness concern if it is possible that it has an effect on the safety of flight of any airplane before its next scheduled inspection The determination if the corrosion damage is a airworthiness concern is the responsibility of the operator Cessna Aircraft can help make the determination Level 1 Did the corrosion damage occur during many inspections H Corrosion Level Determination Chart Figure 4 Sheet 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 21 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A18517 Level 2 Inspect the same location on other airplanes Adjust the CPCP as necessary to control the corrosion to a Level 1 or better Does Cessna Aircraft agree that the corrosion damage is a possible airworthiness concern Corrosion Level Determination Chart Figure 4 Sheet 3
169. evision Number 7 Dec 1 2011 2 13 00 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Table 1 Typical Examples of Principal Structural Elements Wing and Empennage Control surfaces flaps and their mechanical systems and attachments hinges tracks and fittings Primary fittings Principal splices Skin or reinforcement around cutouts or discontinuities Skin stringer combinations Spar caps Spar webs Fuselage Circumferential frames and adjacent skin Door frames Pilot window posts Bulkheads Skin and single frame or stiffener element around a cutout Skin and or skin splices under circumferential loads Skin or skin splices under fore and aft loads Skin around a cutout Skin and stiffener combinations under fore and aft loads Door skins frames and latches Window frames Landing Gear and Attachments Engine Support Structure and Mounts B Selection Criteria 1 factors used to find the PSE s in this document include a Service Experience 1 Multiple sources of information were used to find the service discrepancies a Cessna Service Bulletins and Service Information Letters issued to repair common service discrepancies were examined Difficulty Records were examined b FAA Service Difficulty Records and Foreign certification agency Service Existing analyses were reviewed to identify components in areas that may have exhibited the potential
170. for acoustic attenuation and may be replaced or omitted at owner s option 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 16 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 42 01 1 TITLE Vertical Stabilizer Attachment Inspection Model 182 2 EFFECTIVITY Model 182 Serial Numbers 18253599 thru 18254423 INSPECTION COMPLIANCE ALL USAGE INITIAL 1 000 Hours REPEAT 100 Hours 3 PURPOSE To inspect the aft fuselage bulkhead for cracks 4 INSPECTION INSTRUCTIONS A Check aircraft records to determine if SEB99 12 has been complied with or SK210 161 has been installed If SEB99 12 has been complied with this inspection is complete NOTE is any doubt about the installation of SK210 161 look at the vertical spar rear spar attachment to the bulkhead If there are three fasteners through the bulkhead SK210 161 has not been installed If there are four fasteners SK210 161 has been installed B Vertical stabilizer attachment inspection 1 Remove the stinger and fairings between the vertical and the horizontal stabilizers Refer to the Model 100 Series Service Manual 2 Visually inspect the attachment bolts for indications of looseness i e cracked inspection putty or signs of working If signs of looseness are found remove the attach bolts one at a time and a Check the hole dia
171. for looseness integrity proper size and fit and corrosion Dished cracked or missing rivet heads and loose rivets should be identified and recorded Control Systems Examine cables control rods rod ends fairleads pulleys and all other items for integrity structural soundness and corrosion Visual Inspection for Corrosion Inspection of an airplane for corrosion follows a systematic pattern 1 IN Clues The airplane is initially observed for clues about the care with which it has been maintained Locations Examine likely corrosion sites These include galleys and food service areas lavatories bilges tank drains and fastenings When debris is found it should be examined for iron oxide and the characteristically white powdery aluminum hydride Biological contamination mold algae which may feel greasy or slippery frequently causes corrosion since it changes the acidity of any moisture it contains Caulking and sealing compounds should be examined for good bond since corrosion can get under such materials Nutplates should be examined for corrosion under them Tap tests should be done often and the cause of any dull sounding areas found The omission of fuel additives by some fuel vendors can increase the deterioration of fuel tanks on a small airplane In such cases it is necessary to drain D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 22 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COM
172. ft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 47 01 1 TITLE Seat Rails and Seat Rail Structure Corrosion Inspection Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50000 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 10 Years NOTE REPEAT 10 Years NOTE SEVERE INITIAL 5 Years NOTE REPEAT 5 Years NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To verify the integrity of the seat rails 4 INSPECTION INSTRUCTIONS A Verify accomplishment of AD 2011 10 09 for inspection of seat rails for cracks B Remove seats and carpet or mat as necessary to gain access to inspect seat rails and seat rail base C Visually inspect seat rails for corrosion 1 If adhesive grime or debris is present clean area to inspect around base 5 ACCESS AND DETECTABLE CR
173. g with the conductivity values so a person unfamiliar with the inspection can find the data point IO a NOTE Structural considerations may not allow the test points to follow the pattern of Figure 4 It is up to the inspector to decide on a pattern that best works with the area for inspection INTERVAL BETWEEN REFERENCE POINTS INSPECTION POINTS O O INSPECTION LOCATIONS AT THE CORNERS OF THE SQUARES Sample of Conductivity Inspection Grid Pattern Figure 4 7 Reporting Results Use the Discrepancy Report Form in Section 2A 13 00 to report inspection results All written descriptions should include enough information so someone not involved in the inspection may interpret the results Give this information a IWIN ES Location of the affected area A visual description of the affected area Location of the reference point and the relative location and interval between conductivity data points A map of the area with the conductivity values on it D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 11 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 3 INSPECTION A General 1 Penetrant inspection is used to find small cracks or discontinuities open to the surface of the part Penetrant inspection can be used on most parts or assemblies where the surface is accessible
174. ge C Confirm the integrity of the cable and pedal attachments to the rudder bars 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Fuselage Near Forward Firewall Not Allowed 6 INSPECTION PROCEDURE Visual 7 REPAIR MODIFICATION Typical failures occur at or close to welds in the rudder bar Since the rudder bar is not heat treated after welding it can be rewelded and used without subsequent heat treatment Examine the rewelded area after welding for any new or additional cracking Make other repairs by replacing damaged or missing parts with spare parts Make repairs in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Coordinate any repair not available in Section 19 with Cessna Customer Service prior to beginning the repair 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 01 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18481 RUDDER PEDAL as V 2 TORQUE TUBE EX 14 RUDDER PEDAL TORQUE TUBE 4X DETAIL A NOTE MODEL 182 SHOWN OTHER MODELS TYPICAL 071071001 RUDDER PEDAL TORQUE TUBE INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 01 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 27 30 01
175. ginning the repair If the freeplay limits measured in 4 A are exceeded then Remove the horizontal stabilizer and the actuators Examine the freeplay of the actuators If the freeplay exceeds limits repair the actuators If the freeplay of the actuators is within limits examine the attach brackets and hardware and replace or repair the brackets and hardware Reinstall the horizontal stabilizer and confirm the rigging according to Section 11 of the Model 100 Series Service Manual 8 COMMENTS Coordinate this inspection with SID 27 42 01 Horizontal Stabilizer Screw Jack Actuator Inspection D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 03 2 Cessna Aircraft Company Feb 3 2003 55 AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18483 DETAIL SCREW JACK ACTUATOR DETAIL B PULLEYS PULLEYS gt DETAIL D DETAIL NOTE MODEL 180 SHOWN OTHER MODELS TYPICAL ELEVATOR TRIM PULLEY BRACKET AND SCREW JACK STRUCTURE INSPECTION Figure 1 Sheet 1 0710T1030 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 03 Page 3 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 27 42 01 1 TITLE Horizontal Stabilizer Screw Jack Actuator Inspection Models 180 182 Prior to 1962 and 185 2 EFFECTIVITY Model 180 Serial Numbers 604 614 624 30000 thr
176. has been accomplished for airplanes operating in a severe usage environment Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For Models 150 172 175 180 and 185 this 510 610 interval is for severe usage environment Inspect fuselage forward doorpost bulkhead at the lower end wing strut attach area and door hinge area Refer to Section 2A 14 13 Supplemental Inspection Document 53 12 01 for inspection procedure For All Models this interval i
177. he adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For All Models this interval is for mild moderate 211 corrosion environment Inspect seat rails for corrosion Refer to Section 2A 14 18 Supplemental Inspection Document 53 47 01 for inspection procedure End of Operation 18 Inspection Items kkk D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 18 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 19 Date Registration Number Serial Number Total Time 1 Description A Operation 19 gives Supplemental Inspection Document items that are to be examined after the first 5 years The inspection is to be repeated every 5 years after the initial inspection has been accomplished for airplanes operating in a severe corrosion environment Inspection items are given in the order of the zone in which the inspecti
178. he procedure presented is 1 Gain access to the entire corroded area 2 Mechanically remove the corrosion products 3 Determine the extent of the corrosion damage 4 Repair or replace the damaged components b Finish the new or repaired parts 6 Replace removed components B Gain access to the entire corroded area 1 Corrosion products typically retain moisture If those products are not removed corrosion will continue Corrosion can take place within layered construction or under behind equipment fastened in place C Mechanically remove the corrosion 1 Chemicals will not remove corrosion The best chemicals can do is interrupt the corrosion cell by either displacing water or shielding corrosion products from oxygen In either case the effect is temporary and will need to be renewed 2 Sand mild corrosion 3 Use rotary files or sanding disks for heavier corrosion Finish up with fine sand paper NOTE Donotuse metallic wool Metal particles will be embedded in the surface which will initiate additional corrosion D Determine the extent of corrosion damage 1 Direct measurement is simplest 2 Indirect measurement may be necessary a Eddy Current or ultrasound tools can be used for thickness measurement away from part edges E Repair or replace corrosion damaged components 1 Replace damaged or corroded steel or aluminum fasteners 2 If the material is sheet or plate the thickness is allowed to be as
179. high strength steel that is shot peened on the lower surface to increase the fatigue life of the part If the protective layer of paint is chipped or worn away corrosion rust is likely to occur A Inspect the main landing gear springs for worn or chipped paint Refer to Figure 1 If rust has developed rework the gears in accordance with the Repair Modification section below 1 Clean area before inspecting if grime or debris is present B Inspect the area under and around the entry step attachment for corrosion C Ifthe finish is worn or chipped refinish the landing gear springs D Inspect the outboard main landing gear fittings for corrosion Pay particular attention to the area directly above the forward and aft edges of the landing gear spring and the attachment of the fittings to the bulkheads 1 Clean area before inspecting if grime or debris is present E Inspect the inboard main landing gear fittings for corrosion Pay particular attention to the area directly below the landing gear spring attachment and the attachment of the fittings to the bulkheads 1 Clean area before inspecting if grime or debris is present 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION ZONE DETECTABLE CRACK SIZE Main Gear Section Not Allowed D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 06 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 6 INSPECTION
180. hours Initial 1 000 hours 15 330 340 Repeat 1 000 hours 2A 10 01 Page 1 Feb 3 2003 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK For Models 172 175 and 182 replace U bolts securing the flat leaf main landing gear assembly Refer to Section 2A 14 05 Supplemental Inspection Document 32 11 01 for inspection procedures For All Models this inspection is for mild moderate corrosion environment Inspect main landing gear spring and attach fittings for rust or damage to finish Refer to Section 2A 14 06 Supplemental Inspection Document 32 13 01 for inspection procedure For Models this inspection is for severe corrosion environment Inspect main landing gear spring and attach fittings for rust or damage to finish Refer to Section 2A 14 06 Supplemental Inspection Document 32 13 01 for inspection procedure For All Models inspect main landing gear fittings and attachment of the fittings to the bulkheads Refer to Section 2A 14 07 Supplemental Inspection Document 32 13 02 for inspection procedure For All Models inspect main landing gear axle Refer to Section 2A 14 08 Supplemental Inspection Document 32 13 03 for inspection procedure For Models 180 and 185 inspect main landing gear spring axle attach bolt holes Refer to Section 2A 14 09 Supplemental Inspection Document 32 13 04 for inspection procedure For Models 180 and 185 this inspection is fo
181. hru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 10 000 Hours or 20 Years NOTE REPEAT At Engine Overhaul NOTE NOTE Refer to Note 1 Section 24 14 00 3 PURPOSE To ensure structural integrity of the engine mount 4 INSPECTION INSTRUCTIONS A Remove engine cowling engine and sufficient accessories to allow removal of the tubular engine mount Refer to the Model 100 Series Service Manual B Clean area before inspecting if grime or debris is present C Conduct a visual inspection for cracks in the welds of the tubular engine mount and within three inches on either side of the welds Refer to Figure 1 Use a bright light and magnification lens of 7X or greater power to aid in inspection D Ifrustis found cracks are suspected or if airplane has exceeded the compliance flight hour time listed above remove the tubular engine mount Conduct a magnetic particle inspection of these areas Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Magnetic Particle Inspection for additional instructions E Replace the tubular engine mount engine previously removed accessories and the engine cowling Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Under Cowl Not Allowed 6 INSPECTION METHOD Visual and Magnetic Particle 7 REPAIR MODIFICATION Repair any cracks by rewelding Prior to welding locate either a drive pin or a
182. ial inspection has been accomplished for airplanes operating in a mild or moderate corrosion environment Supplemental Inspection Document items that are to be examined after the first 10 years The inspection is to be repeated every 5 years after the initial inspection has been accomplished for airplanes operating in a severe corrosion environment Supplemental Inspection Document items that are to be examined after the first 3 years The inspection is to be repeated every 3 years after the initial inspection has been accomplished for airplanes operating in a severe corrosion environment Supplemental Inspection Document items that are to be examined after the first 1 000 hours The inspection is to be repeated every 1 000 hours after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after 3 000 hours or 10 years whichever occurs first The inspection is to be repeated every 500 hours or 5 years whichever occurs first after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after 3 000 hours or 5 years whichever occurs first The inspection is to be repeated every 1 000 hours or 5 years whichever occurs first after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after the first 10 years The inspection is to be repeated every 10 years after the initial insp
183. ied inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS ALL Inspect aircraft records to verify that all applicable Cessna Service Information Letters Cessna Service Bulletins and Supplier Service Bulletins are complied with ALL Inspect aircraft records to verify that all applicable Airworthiness Directives and Federal Aviation Regulations are complied with ALL Inspect aircraft records to verify that all logbook entries required by the Federal Aviation Regulations are complied with ALL Inspect aircraft records to verify that all SID Inspections have been complied with as scheduled End of Operation 1 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company 2A 12 01 Page 1 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 2 Date Regi
184. ing repair F Replace strut attach fittings that have crack indications 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 13 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18492 FORWARD 1 DOORPOST 1 CABIN DOOR Y LOWER HINGE ATTACH AREA STRUT FITTING NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL 051071007 FUSELAGE FORWARD DOORPOST INSPECTION MODELS 150 172 175 180 AND 185 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 13 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 12 02 TITLE Fuselage Forward Doorpost Inspection Model 182 EFFECTIVITY Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 INSPECTION COMPLIANCE ALL USAGE INITIAL 4 000 Hours Of 10 Years NOTE REPEAT 1 000 Hours Of Years NOTE NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To verify integrity of the fuselage lower forward doorpost 4 INSPECTION INSTRUCTIONS A For Model 182 units 18253599 thru 18254423 Check airplane records to verify that SEB95 19 or SK182 115 has been incorporated If SEB95 19 has not been installed complete SEB95 19 with this inspection NOTE as built configuration consists of the wing strut support fitting riveted t
185. ion 24 20 01 Expanded whichever occurs Maintenance Control Cables first Wing structure internal for All Models Make sure Every 12 months 2 510 inspect these areas 1 Main spar upper and lower 520 carry thru fittings 2 Main spar upper and lower caps 610 3 Main spar web NOTE Corrosion Prevention and 620 Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Wing structure internal for All Models Make sure you Every 60 months 6 510 inspect these areas 1 Wing front spar and lower spar 520 caps 2 Upper and lower wing attach spar fittings 3 610 Wing lower skins NOTE Corrosion Prevention and 620 Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Wing structure external for All Models Make sure Every 60 months 6 510 you inspect these areas 1 Skin with emphasis at 520 skin overlaps and under access panels 2 Rear spar 610 upper and lower caps 3 Rear spar web NOTE 620 Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 24 30 00 for additional inspection information Aileron attachments for All Models Make sure you Every 24 months 3 520 inspect these areas 1 Aileron hinges 2 Hinge bolts 620 3 Hinge bearings 4 Hinge and pushrod support structure NOTE Corrosion Prevention and Control Inspection Item baseline interval ref
186. ion is usually not evident D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 20 01 2 Cessna Aircraft Company Feb 3 2003 55 AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A2861 BROKEN WIRE NOT FOUND WHEN RUBBED WITH A CLOTH ALONG THE LENGTH OF THE CABLE BROKEN WIRE FOUND VISUALLY WHEN THE CABLE A CORRECT TECHNIQUE IS TO WAS REMOVED AND BENT BEND THE CABLE TO INSPECT FOR BROKEN WIRES gt T LAOS TXA I ALALLAAN 7 gt UN LEE SK IB NN DO NOT BEND THE CABLE INTO A LOOP SMALLER THAN 50 CABLE DIAMETERS CORE STRAND 556111119 Cable Broken Wires and Pulley Wear Patterns Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 20 01 Page 3 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL A2867 EXCESSIVE CABLE TENSION PULLEY MISALIGNMENT SSS AAA A PULLEY TOO LARGE FOR CABLE CABLE MISALIGNMENT FROZEN BEARING NORMAL CONDITION 556171115 Cable Broken Wires and Pulley Wear Patterns Figure 1 Sheet 2 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 20 01 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL on the outer surface of the cable Replace cable if internal corro
187. is considered to be adequate in detecting corrosion and accidental damage The emphasis of the Supplemental Structural Inspection Program is to detect fatigue damage whose probability increases with time Since fatigue damage increases at an increasing rate with increasing crack length earlier detection and repair minimizes the damage and the magnitude of the repair The Supplemental Structural Inspection Program is valid for Model 100 series airplanes with less than 30 000 flight hours Beyond this continued airworthiness of the airplane can no longer be assured Retirement of this airframe is recommended when 30 000 flight hours has been accumulated Function 1 2 The function of the Supplemental Structural Inspection Program is to find damage from fatigue overload or corrosion through the use of the Nondestructive Inspections NDI and visual inspections This Supplemental Inspection Document SID is only for primary and secondary airframe components Engine electrical items and primary and secondary systems are not included in this document A list is included to show the requirements for the SID program for primary and secondary airframe components a The airplane has been maintained in accordance with Cessna s recommendations or the equivalent b If the SID is for a specific part or component you must examine and evaluate the surrounding area of the parts and equipment If problems are found outside these areas report them
188. ith a wet cross coat to produce a dry film thickness of 1 5 2 0 mils c Allow to air dry per the manufacturer s instruction 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 06 2 Cessna Aircraft Company Feb 3 2003 55 AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18486 INBOARD FITTING RH INBOARD FITTING LH OUTBOARD FITTING LH DETAIL MAIN LANDING GEAR SPRING ENTRY STEP NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL 051071007 MAIN LANDING GEAR FLAT SPRING AND ATTACH FITTINGS CORROSION INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 06 Cessna Aircraft Company Page 3 Feb 3 2003 1 2 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 13 02 TITLE Main Landing Gear Fittings Inspection All Models EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50000 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numb
189. ke sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For All Models inspect main landing gear fittings 210 and attachment of the fittings to the bulkheads Refer to Section 2A 14 07 Supplemental Inspection Document 32 13 02 for inspection procedure End of Operation 17 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 17 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 18 Date Registration Number Serial Number Total Time 1 Description A Operation 18 gives Supplemental Inspection Document items that are to be examined after the first 10 years The inspection is to be repeated every 10 years after the initial inspection has been accomplished for airplanes operating in a mild or moderate corrosion environment Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of t
190. klist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For All Models inspect horizontal stabilizer and 330 340 elevator including spars ribs hinge bolts hinge bearings attach fittings and torque tube Refer to Section 2A 14 19 Supplemental Inspection Document 55 10 01 for inspection procedures For All Models inspect vertical stabilizer and rudder 310 320 including spars ribs hinge bolts hinge bearings and attach fittings Refer to Section 2A 14 22 Supplemental Inspection Document 55 30 01 for inspection procedure End of Operation 22 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 22 Page 1 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL
191. ks under wing tanks and nonstandard engines The owner and or maintenance organization should contact the STC holder s or modification originator for obtaining new FAA approved inspection criteria C SID inspection times are based on total airframe hours OR calendar times in service If a specific airframe component has been replaced the component is to be inspected based on total component hours or calendar time requirements However any attachment structure that was not replaced when the component was replaced must be inspected based on the total airframe hours or calendar time requirements Inspections are due at the lessor of specified flight hours or calendar time The inspections must be completed by Jun 30 2014 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 00 5 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 8 PSE DETAILS A Details 1 This section contains the important instructions selected by the rationale process described in Section 2 Principal Structural Elements Those items are considered important for continued airworthiness of the Model 100 Series B PSE Data Sheets A data sheet for each PSE is provided in Section 2A 14 XX Supplemental Inspection Documents Each data sheet contains the following 1 Supplemental Inspection Number 2 Title 3 Effectivity 4 Inspection Compliance 5 Initial Inspection Interva
192. l Program is a comprehensive and Control Program CPCP systematic approach to controlling corrosion such that the load carrying capability of an airplane structure is not degraded below a level necessary to maintain airworthiness It contains the corrosion program inspections a definition of corrosion levels implementation thresholds a repeat interval for task accomplishment in each area or zone and specific procedures that apply if corrosion damage exceeds Level 1 in any area or zone Design Approval Holder The design approval holder is either the type certificate holder for the aircraft or the supplemental type certificate holder Inspection Area The inspection area is a region of airplane structure to which one or more CPIs are assigned The inspection area may also be referred to as a Zone Inspection Interval The inspection interval is the calendar time between the accomplishment of successive corrosion inspection tasks for a Task Area or Zone Level 1 Corrosion Level 1 Corrosion is one or more of the items that follow Corrosion damage occurring between successive inspections that is local and can be reworked or blended out within the allowable limit Local corrosion damage that exceeds the allowable limit but can be attributed to an event not typical of the operator s usage or other airplanes in the same fleet e g mercury spill Operator experience has demonstrated only light corrosion between each successive corrosion task inspection
193. l s 6 Repeat Inspection Interval s 7 Purpose 8 Inspection Instructions 9 Access Location Zone 10 Detectable Crack Size 11 Inspection Procedure 12 Repair Modification 13 Comments NOTE Accomplishment of SID inspections does not in any way replace preflight inspections good maintenance practices or maintenance and inspections specified in the Model 100 Series Service Manual NOTE Inspection intervals are given in both hour and calendar time After the completion of each initial SID inspection repeat inspections may be completed based on hour time if the Corrosion Prevention and Control Program CPCP in Section 2A 30 00 is included in the airplane maintenance program C Repairs Alterations and Modifications RAM 1 Repairs alterations and modifications RAM made to PSE s may affect the inspection times and methods presented in the SID The flowchart in Figure 1 can be used to determine if a new assessment and FAA approved supplemental inspections are required 2 Repairs may be made in accordance with Section 19 of the Model 100 Series Service Manual or the REPAIR MODIFICATION Section of the SID 3 Repairs not covered by the recommendations in these documents may be coordinated with Cessna Customer Service at telephone 316 517 5800 FAX 316 517 7271 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 00 6 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1
194. ll Models this interval is for severe corrosion environment Inspect wing root rib Refer to Section 2A 14 27 Supplemental Inspection Document 57 12 01 for inspection procedure For All Models this interval is for typical usage environment Inspect wing strut and strut tube Refer to Section 2A 14 28 Supplemental Inspection Document 57 40 01 for inspection procedure D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL Initial 6 000 hours or 10 years whichever occurs first Repeat 1 000 hours or 5 years whichever occurs first Initial 20 years Repeat 10 years Initial 10 years Repeat 5 years Initial 4 000 hours Repeat 100 hours Initial 20 years Repeat 10 years Initial 10 years Repeat 5 years Initial 5 years Repeat 5 years Initial 3 years Repeat 3 years Initial 12 000 hours or 20 years whichever occurs first Repeat 2 000 hours or 10 years whichever occurs first OPERATION ZONE 21 510 610 11 510 520 610 620 13 510 520 610 620 29 510 520 610 620 11 510 610 13 510 610 12 510 610 14 510 610 20 510 610 2A 10 01 Pages Feb 3 2003 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL TASK For All Models this interval is for severe usage environment Inspect wing strut and strut tube Refer to Section 2A 14 28 Supplemental Inspectio
195. ll show as a fluorescent line It will be sharp when it first becomes visible 4 Monitor indications that become visible during the developer dwell time This will show the nature of the discontinuity The amount of penetrant from the discontinuity will give some information as to the size 5 An indication from a deep discontinuity will become visible again if the area is blotted clean and developer put on again After Inspection a Clean the part and inspection area to remove the developer and penetrant b Refer to the General Requirements section for information on how to report inspection results 4 MAGNETIC PARTICLE INSPECTION A General 1 Magnetic particle inspection is a nondestructive inspection method to show surface and near surface discontinuities in parts made of magnetic materials Alloys that contain a high percentage of iron and can be magnetized make up the ferromagnetic class of metals Some types of steel may not have sufficient magnet properties to do a successful inspection NOTE Magnetic particle inspection cannot be used to examine nonmagnetic parts or parts with weak magnet properties 2 The magnetic particle inspection uses three basic steps a Create a suitable magnetic field in the part b Put the magnetic particles on the part c Examine the area for inspection for magnetic particle patterns on the surface and decide on the cause of the patterns B M Materials and Equipment 1 The following equipment w
196. ly inspect the trailing edge portion of the elevator for indications of cracks corrosion or deterioration Visually inspect the attachment of the trim tab horn to the trim tab G Install all previously removed access panels Refer to the Model 100 Series Service Manual D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 19 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Horizontal Tail Not Allowed 6 INSPECTION METHOD Visual with Eddy Current if required 7 REPAIR MODIFICATION Replace damaged bolts and nuts Replace damaged fittings and small parts Replace damaged or loose rivets Hinge bearings are pre packed with grease which will eventually oxidize and harden after years of service Several applications of penetrating oil will help free up a stiff bearing It is the owner s operator s option to replace stiff bearings Repairs may be made in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Any repair not available in Section 19 should be coordinated with Cessna Customer Service prior to beginning the repair 8 COMMENTS Coordinate this inspection with SID 55 30 01 Vertical Stabilizer Rudder and Attachments Inspection D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 19 2 Cessna Aircraft Company Feb 3 2003 CESSN
197. meter The lower two holes are V 0 377 inch diameter and the upper hole is 5 16 0 312 inch diameter b Conduct a bolt hole eddy current inspection of the hole Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Bolt Hole Inspection for additional instructions 3 Visually inspect the forward and aft vertical stabilizer structures The most important areas are shaded in Figure 1 4 Conduct a surface eddy current inspection of the front vertical stabilizer attachment bulkhead around the edges of the holes for the rudder cable Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Surface Inspection for additional information 5 If cracks are found in the front vertical stabilizer attachment bulkhead a Remove the attach bolts that pass through the front vertical stabilizer attachment bulkhead one at a time b Conduct a bolt hole eddy current inspection of each vertical stabilizer attachment hole Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Bolt Hole Inspection for additional instructions 6 Conduct a surface eddy current inspection of the aft vertical stabilizer attachment bulkhead a around the edges of the holes for the rudder cable Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Surface Ins
198. n Document 57 40 01 for inspection procedure For All Models inspect aileron hinges hinge bolts hinge bearings and hinge and pushrod attach fittings Refer to Section 2A 14 29 Supplemental Inspection Document 57 51 01 for inspection procedure For All Models this interval is for mild moderate corrosion environment Inspect flap tracks for corrosion Refer to Section 2A 14 30 Supplemental Inspection Document 57 53 01 for inspection procedure For All Models this interval is for severe corrosion environment Inspect flap tracks for corrosion Refer to Section 2A 14 30 Supplemental Inspection Document 57 53 01 for inspection procedure For All Models inspect engine mount Refer to Section 2A 14 31 Supplemental Inspection Document 71 20 01 for inspection procedure For Models 172 and 175 inspect engine mount brackets Refer to Section 2A 14 32 Supplemental Inspection Document 71 20 02 for inspection procedure Fuselage lower internal structure beneath the floor panels for All Models Make sure you inspect these areas 1 Cabin structure under floorboards NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Fuselage internal structure in upper fuselage for All Models Make sure you inspect these areas 1 Cabin bulkhead corners 2 Fuselage skin NOTE Corrosion Prevention and Control Program Inspection item baseline int
199. n Number Serial Number Total Time 1 Description Operation 20 gives Supplemental Inspection Document items that are to be examined after 12 000 hours or 20 years whichever occurs first The inspection is to be repeated every 2 000 hours or 10 years whichever occurs first after the initial inspection has been accomplished for airplanes Inspection items are given in the order of the zone in which the inspection is to be completed A operating in a typical usage environment B Frequently tasks give more information about each required inspection C The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Doa preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual TASK ZONE MECH INSP REMAR
200. n Number 7 Dec 1 2011 2A 14 28 Page 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18500 STRUT TUBE STRUT ATTACHMENT FITTING DETAIL STRUT TUBE STRUT ATTACHMENT yp FITTING DETAIL B NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL STRUT AND STRUT WING ATTACHMENT INSPECTION ALL MODELS Figure 1 Sheet 1 051071007 0138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 28 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 51 01 1 TITLE Aileron Support Structure Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 3 000 Hours 07 10 Years NOTE REPEAT 500 Hours Or 5 Years NOTE NOTE Refer to Note 1 Section 24 14 00 3 PURPOSE To ensure struc
201. no more than 0 375 inch 9 525 mm and a delay line b The recommended frequency is 5 to 10 MHz for material 0 5 inch 12 700 mm thick or more an 10 to 20 MHz for material less than 0 5 inch 12 700 mm thick 4 Reference Standard a The reference standard must be of the same base alloy as the metal for measurement b Gage material can be used for a reference standard It should be as close as practical to the alloy and temper of the material for test NOTE When gage material is used mechanically measure the thickness of the material D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 19 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL c The reference standard must have enough thickness range that one step will be thinner and one step thicker than the expected thickness range of the material C Calibration 1 Setup the instrument with the manufacturer s instructions 2 Choose steps on the reference standard for the calibration It is recommended that there is step between the chosen steps NOTE Itis important that the expected material thickness be between the range of the steps chosen on the reference standard 3 Calibrate the instrument on the chosen steps of the reference standard If there are any steps between the calibration steps use them to make sure of the calibration D Inspection 1 The area must be clean and free of g
202. nspection Document items that are to be examined after the first 1 000 hours of operation The inspection is to be repeated every 100 hours of operation after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after the first 4 000 hours of operation The inspection is to be repeated every 100 hours of operation after the initial inspection has been accomplished Expanded Maintenance Inspection items that are to be examined after the first 100 hours of operation The inspection is to be repeated every 600 hours of operation or 12 months whichever occurs first after the initial inspection has been accomplished Cessna Aircraft Company 2A 10 00 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION TIME LIMITS 1 Inspection Items REVI TASK SION STATUS Inspect aircraft records to verify that all applicable Cessna Service Information Letters Cessna Service Bulletins and Supplier Service Bulletins are complied with Inspect aircraft records to verify that all applicable Airworthiness Directives and Federal Aviation regulations are complied with Inspect aircraft records to verify that all logbook entries required by the Federal Aviation Regulations are complied with Inspect aircraft records to verify that all SID Inspections have been complied with as scheduled For All Models inspect rudder pedal torque tube and cable attachmen
203. nt 55 30 01 and attach fittings inspection procedure For All Models this interval is for typical usage environment 1 Inspect inboard wing structure and wing attachment to fuselage including working rivets 2 Inspect flap actuator support structure Refer to Section 2A 14 23 Supplemental Inspection Document 57 11 01 for inspection procedure D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL Initial 1 000 hours Repeat 100 hours Initial 10 years Repeat 10 years Initial 5 years Repeat 5 years Initial 5 000 hours or 20 years whichever occurs first Repeat 2 000 hours or 5 years whichever occurs first Initial 100 hours or 1 year whichever occurs first Repeat 100 hours or 1 year whichever occurs first Initial 100 hours or 1 year whichever occurs first Repeat 100 hours or 1 year whichever occurs first Initial 5 000 hours or 20 years whichever occurs first Repeat 2 000 hours or 5 years whichever occurs first Initial 12 000 hours or 20 years whichever occurs first Repeat 2 000 hours or 10 years whichever occurs first OPERATION ZONE 28 310 320 18 211 19 211 22 330 340 25 330 340 25 330 340 22 310 320 20 510 610 2A 10 01 Page 4 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL REVI TASK SION STATUS For All Models this interval is for severe usage e
204. nt Maintenance Manual 5 ULTRASONIC THICKNESS TESTING A General 1 A common application for ultrasonic inspection is to find material thickness The instrument will measure the time of flight of the ultrasonic wave through the part This procedure will show you how to find the thickness of metal after removal of corrosion or a blending procedure B Equipment 1 The following equipment was used to develop the inspection procedures referred to in this manual Alternative equipment may be used if it has the same sensitivity Refer to the guidelines in this section for more information on equipment parameters NAME NUMBER MANUFACTURER Ultrasonic Thickness Gage with 25 Multiplus Olympus NDT A scan ability Phone 781 419 3900 Web http www olympusndt com 20 MHz Ultrasonic Transducer M208 Olympus NDT 0 125 inch diameter Sonopen 15 MHz 0 125 inch V260 SM Olympus NDT diameter Couplant Water Based Ultragel Il Sonotech Inc 774 Marine Drive Bellingham WA 98225 Phone 360 671 9121 Web http www sonotech inc com 2 Instrument a expected material thickness must be within the measurement range of the instrument b The instrument resolution must be a minimum of 0 001 inch 0 0254 mm c t is recommended that the instrument have an A scan display This will let the operator monitor the interaction between the signal and the gating of the instrument 3 Transducer a The transducer must have a diameter of
205. ntaining rivets F Install previously removed access panels fairings and wing tips Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION ZONE DETECTABLE CRACK SIZE Wing Not Allowed D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 24 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 6 INSPECTION METHOD Visual Borescope 7 REPAIR MODIFICATION lf corrosion is present it must be removed before refinishing The recommended procedure to remove corrosion is by hand sanding using a fine grained sandpaper NOTE Particularly if corrosion is detected using a borescope significant disassembly may be required to remove corrosion and to refinish and repair surfaces Contact Cessna Customer Service for assistance prior to beginning the repair if the disassembly exceeds the repair facilities experience or capability B Use 180 or finer grit abrasive cloth to produce a diameter to depth ratio of about 10 1 Use ultrasonic methods to determine thickness after removing corrosion Repairs are required if thickness is less than 90 of uncorroded material C Refinish sanded areas 1 Solvent Wipe a Wipe off excess oil grease or dirt from the surface to be cleaned b Apply solvent to a clean cloth preferably by pouring solvent onto cloth from a safety can or other approved labeled container The cloth mu
206. ntal Inspection Document items that are to be examined after the first 10 000 hours of operation or 20 years whichever occurs first The inspection is to be repeated every 3 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Cessna Aircraft Company 2A 10 00 Page 3 Feb 3 2003 9 10 13 14 15 16 17 18 19 20 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL Details Supplemental Inspection Document items that are to be examined after the first 3 000 hours of operation or 5 years whichever occurs first The inspection is to be repeated every 3 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after the first 10 000 hours of operation or 20 years whichever occurs first The inspection is to be repeated at engine overhaul after the initial inspection has been accomplished Supplemental Inspection Document items that are to be examined after the first 20 years The inspection is to be repeated every 10 years after the initial inspection has been accomplished for airplanes operating in a mild or moderate corrosion environment Supplemental Inspection Document items that are to be examined after the first 5 years The inspection is to be repeated every 5 years after the init
207. nvironment 1 Inspect inboard wing structure and wing attachment to fuselage including working rivets 2 Inspect flap actuator support structure Refer to Section 2A 1 4 23 Supplemental Inspection Document 57 11 01 for inspection procedure For All Models this interval is for mild moderate corrosion environment Inspect wing for corrosion and missing or loose fasteners Refer to Section 2A 14 24 Supplemental Inspection Document 57 11 02 inspection procedure For All Models this interval is for severe corrosion environment Inspect wing for corrosion and missing or loose fasteners Refer to Section 2A 14 24 Supplemental Inspection Document 57 11 02 inspection procedure For Models 180 and 185 inspect wing main spar and rear spar Refer to Section 2A 14 25 Supplemental Inspection Document 57 11 03 for procedure For All Models this interval is for mild moderate corrosion environment Inspect wing splice joint at strut attach Refer to Section 2A 14 26 Supplemental Inspection Document 57 11 04 for procedure For All Models this interval is for severe corrosion environment Inspect wing splice joint at strut attach Refer to Section 2A 14 26 Supplemental Inspection Document 57 11 04 for inspection procedure For All Models this interval is for mild moderate corrosion environment Inspect wing root rib Refer to Section 2A 1 4 27 Supplemental Inspection Document 57 12 01 for inspection procedure For A
208. o the forward side of the bulkhead If there is a channel assembly riveted to the strut support fitting and bulkhead on both the LH and RH side of the airplane the Service Kit has been installed If the channel assemblies are present in both sides and not reflected in the airplane records add this information to the records B Pull back the upholstery that covers the front and right floorboards at the intersection of the forward doorpost and floor C Remove and retain the upholstery and heater ducts on both sides at the bottom of the forward left and right doorposts The critical inspection area must be fully exposed Remove floorboard inspection covers in areas fore and aft of doorpost E Refer to Figure 1 Using a flashlight and inspection mirror visually inspect areas shown for cracks If there are cracks present they should be visible at the intersection of the doorpost and the forward doorpost bulkhead Look for cracks that follow the contour of the wing strut support fitting 1 Clean area before inspecting if grime or debris is present an entry into the airplane records stating that this SID has been accomplished the method of compliance and the time when the next inspection is due 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Fuselage Front Doorpost Not Allowed 6 INSPECTION PROCEDURE Visual D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 14 1 Cessna Aircraft
209. odel 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47747 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE TYPICAL INITIAL 12 000 Hours 07 20 Years NOTE REPEAT 2 000 Hours 07 10 years NOTE SEVERE INITIAL 6 000 Hours OF 10 Years NOTE REPEAT 1 000 Hours Of 5 years NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To verify the integrity of the fuselage lower forward doorpost 4 INSPECTION INSTRUCTIONS A Remove a portion of the interior of the airplane to gain access to the lower end of the forward left and right doorpost bulkheads B Remove floorboard inspection covers in areas fore and aft of doorposts The critical inspection area must be fully exposed C Using a flashlight and inspection mirror visually inspect the area at the intersection of the doorpost and the forward doorpost bulkhead Look for cracks that follow the bottom contour Refer to Figure 1 1 Clean area before inspecting if grime or debris is present D Visually inspect the door post area for cracks where the cabin door lower hinges attach to the door posts 1 Clean area bef
210. of damage a All turnbuckles are required to be secured Safety wire or prefabricated clips are acceptable 6 Inspect cable pulleys a Inspect all pulleys for security of installation evidence of damage and freedom of rotation b Pulleys which do not rotate with normal cable movement due to internal bearing failure are to be rejected Pulleys with grooving etc due to normal in service use are deemed serviceable as long as overall function is not impaired 7 Restore cable system as required following cable teardown if performed a Tension tasks and other tasks specific to individual systems are described under applicable individual tasks b Anyflight control cable system which has been torn down requires a flight control rigging check prior to release of airplane for flight D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 20 01 6 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL CORROSION PREVENTION AND CONTROL PROGRAM CPCP 1 Introduction A Asthe airplane ages corrosion occurs more often while at the same time other types of damage such as fatigue cracks occur Corrosion can cause damage to the airplane s structural integrity and if itis not controlled the airframe will carry less load than what is necessary for continued airworthiness 1 To help prevent this we started a Corrosion Prevention and Control Program
211. of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Doa preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual TASK ZONE MECH INSP REMARKS For All Models this inspection is for severe corrosion 721 722 environment Inspect main landing gear spring and attach fittings for rust or damage to finish Refer to Section 2A 14 06 Supplemental Inspection Document 32 13 01 for inspection procedure For All Models this interval is for severe corrosion environment Inspect the carry thru spar area door post bulkhead attach fittings and spar channel Refer to Section 2A 14 12 Supplemental Inspection Document 53 11 01 for inspection procedure For All Models this interval is for severe corrosion environment Inspect the cabin interior skin panels frames and stringers Refer to Section 2 14 16 Supplemental Inspection Document 53 30 01 for inspection procedure For All Models this interval is for severe corrosion environment Inspect wing for corrosion and missing or loose fasteners Refer to Section 24 14 24 Supplement
212. ollect information to permit the responsible engineering activity to find the material properties in the affected area IG n 1 ES NOTE Since conductivity values are affected by variations in material properties material stacking and geometry conductivity values alone must not be used to decide to accept the affected area without reference to the applicable material specifications and engineering drawings b Visual Inspection 1 Visually examine the area for indications of possible heat damage Some signs include paint or metal discoloration and bubbled or peeled paint 2 Note the location and describe the affected area This description will be used along with the conductivity values to decide the part disposition If photographs are used to describe the area take the picture before you do the conductivity test c dd Current Conductivity Inspection Clean the area for inspection with methods specified in the Model 100 Series Service Manual Remove all dirt grit soot and other debris that will not allow the probe to have good contact with the structure Set up the instrument within the general conductivity range of aluminum structures with the reference standards After the visual inspection make a reference point If there is visual evidence of possible heat damage make the reference point at the center of the area that appears to have been the most affected If there is no visual evidence of possible heat damage make
213. on in place or do a treatment of the corrosion before inspection it may hide other discontinuities Clean After the preliminary inspection clean the areas or surface of the parts for inspection Do not remove the protective finish from the part Inspection Carefully examine the area for discontinuities with optical aids as needed An inspector normally should have available applicable measuring devices a flashlight and a mirror a Surface cracks Refer to Figure 5 To look for surface cracks with a flashlight Point the light beam toward the face with between a 5 and 45 angle to the surface Refer to Figure 5 2 Do not point the light beam at an angle such that the reflected light beam shines directly into the eyes 3 Keep the eyes above the reflected light beam Measure the size of any cracks found with the light beam at right angles to the crack and trace the length D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 21 Cessna Aircraft Company Feb 3 2003 A81712 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 5 TO 45 DEGREES LINE OF SIGHT INCANDESCENT EYES ABOVE LIGHT BEAM REFLECTED LIGHT BEAM REFLECTED LIGHT BEAM b N 4 FAYING CRACK OPEN SURFACE TO SURFACE 141371010 Visual Inspection for Cracks Figure 5 Use a 10 power magnifier to make sure of a suspected crack Hardware and Fasteners Examine rivets bolts and other hardware
214. on is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For All Models this interval is for severe corrosion 211 environment Inspect seat rails for corrosion Refer to Section 2A 14 18 Supplemental Inspection Document 53 47 01 for inspection procedure End of Operation 19 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 19 Page 1 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 20 Date Registratio
215. onal information concerning repeat Corrosion Program Inspection intervals Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 24 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 36 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 48 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 60 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals Supplemental Inspection Document items that are to be examined after the first 4 000 hours of operation or 10 years whichever occurs first The inspection is to be repeated every 1 000 hours of operation or 3 years whichever occurs first after the initial inspection has been accomplished Suppleme
216. onally from the lightening hole 1 Clean area before inspecting if grime or debris is present 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Horizontal tail Not Allowed 6 INSPECTION PROCEDURE Visual 7 REPAIR MODIFICATION A If cracks are present 1 Cracks that have not progressed past the centerline lightening hole flange may be blended out 2 Cracks that have progressed past the centerline hole flange but do not extend to the spar flange radius may be repaired Stop drill the crack tip using a number 30 0 128 inch diameter hole and installing the spar reinforcement as detailed below D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 20 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 3 If cracks have progressed past the centerline hole flange to the spar flange radius replace the spar with a 0532001 98 spar assembly as detailed below B Installation of repair parts 1 Block the elevator trim tab actuator and cables to retain rigging Do not remove the actuator pulleys or cables from the stabilizer Label the cables for convenience of reinstallation 2 Remove the horizontal stabilizer from the airplane This will require removing the vertical tail and rudder 3 Remove the fasteners securing the 0532001 23 stabilizer center skin and remove the skin by sliding it forward When drilling out fasteners
217. ons which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For Models 172 175 and 182 replace U bolts 721 722 securing the flat leaf main landing gear assembly Refer to Section 2A 14 05 Supplemental Inspection Document 32 11 01 for inspection procedures End of Operation 24 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 24 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 25 Date Registration Number Serial Number Total Time 1 Description A Operation 25 gives Supplemental Inspection Document items that are to be examined after the first 100 hours of operation or 1 year whichever occurs first The inspection is to be repeated every 100 hours of operation or 1 year whichever occurs first after the initial inspection has been accomplished B Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required insp
218. ore general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For All Models inspect engine mount Refer 120 to Section 2A 14 31 Supplemental Inspection Document 71 20 01 for inspection procedure End of Operation 10 Inspection Items kkk D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 10 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 11 Date Registration Number Serial Number Total Time 1 Description A Operation 11 gives Supplemental Inspection Document items that are to be examined after the first 20 years The inspection is to be repeated every 10 years after the initial inspection has been accomplished for airplanes operating in a mild or moderate corrosion environment B Inspection items are given in the order of the zone in which the inspection is to be completed Frequentl
219. ore inspecting if grime or debris is present E Visually inspect the strut fitting area for evidence of corrosion 1 Clean area before inspecting if grime or debris is present F If evidence of corrosion is found cracks are suspected or compliance flight hours exceeded then conduct a surface eddy current inspection through the fuselage wing strut attach fitting components and around the hinge area Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Surface Inspection for additional instructions D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 13 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Cabin Not Applicable 6 INSPECTION METHOD Visual with Eddy Current if needed 7 REPAIR MODIFICATION lf corrosion is found remove corrosion by lightly sanding corroded area taking care to remove as little material as necessary to completely remove corrosion and remaining pits in fitting or bulkhead B Buff out sanding marks C Assessremaining bulkhead thickness If more than 1096 of bulkhead material has been removed from the local area the area must be repaired or replaced Clean and prime sanded areas E Damaged bulkheads be repaired Coordinate any repair needed with Cessna Customer Service prior to beginn
220. orrosion Particular attention should be given to inspection of panels below windows belly and other areas where moisture could enter or accumulate 1 Clean area before inspecting if grime or debris is present C Inspect interior of door skins and structure for corrosion D Inspect frames and stringers for corrosion E Inspect cabin windows for integrity of seal to preclude entry of water into cabin 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Fuselage Interior Not Applicable 6 INSPECTION METHOD Visual Ultrasonic Thickness Test 7 REPAIR MODIFICATION A If corrosion is found remove corrosion by lightly sanding corroded area taking care to remove as little material as necessary to completely remove corrosion and remaining pits in skin D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 16 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL w Buff out sanding marks C Assess remaining skin stringer or frame thickness to determine maximum material removed An ultrasonic thickness test can be used for this 1 If more than 0 004 inch of skin material has been removed from the local area the area must be repaired or replaced 2 If more than 10 of stringer or frame material has been removed from the local area the area must be repaired or replaced Clean and prime sanded areas E Sound deadening material is
221. ot necessary to apply masking tape to aluminium or stainless steel tubes plastics sealants adhesives placards and rubber before the corrosion inhibiting compound is applied a Putpaint mask paper or plastic on windows light ramps brakes tires and adjacent areas of possible over spray b Putan aluminum foil or paint masking tape on the following parts or assemblies if they are in the area where the corrosion inhibiting compound will be applied Landing Gear Components Actuator Components Movable Mechanical Components Electrical Components wires switches and sensors etc Seals Bleed Air Lines C Methods of Application 1O gt O1 109 Po WARNING Always use the proper level of Personal Protective Equipment when you use cleaning compounds Personnel Injury or death can occur NOTE Refer to the manufacturer s specifications for the proper application temperature 1 Use a spray gun if the corrosion inhibiting compound is in a bulk resin form 2 If necessary you can use an extension tube with a spray gun to keep the over spray to a minimum 3 Apply the corrosion inhibiting compound in one full wet layer NOTE The applied area of corrosion inhibiting compound will show as a light yellow or amber color 4 If you find a sag or drip mark in the compound use the Methyl Propyl Ketone to clean the sag or drip from the airplane After you clean the area apply the corrosion inhibiting compound 5
222. pcoat paint to the exterior painted surface Refer to the manufacturer s procedures 7 Install the dry insulation blankets 8 Install the equipment and airplane interior that was removed to do the corrosion inspection Baseline Program Implementation A The Baseline Program is divided into specific inspection areas and zone locations The inspection areas and zone locations apply to all airplanes Refer to the applicable model in Figure 1 Airplane Zones Reporting System A Corrosion Prevention and Control Program Reporting System Refer to Figure 2 1 The Corrosion Prevention and Control Program CPCP includes a system to report to Cessna Aircraft Company data that will show that the Baseline Program is sufficient and if necessary make changes 2 At the start of the second Corrosion Program Inspection of each area report all Level 2 and Level 3 Corrosion results that are listed in the Baseline Program to Cessna Aircraft Company Send the Control Prevention and Control Program Damage Reporting Form to Cessna Aircraft Company Customer Service P O Box 7706 Wichita KS 67277 USA Phone 316 517 5800 FAX 816 517 7271 Periodic Review A Use the Service Difficulty Reporting System to report all Level 2 and Level 3 Corrosion results to the FAA and to Cessna Aircraft Company All corrosion reports received by Cessna Aircraft Company will be reviewed to determine if the Baseline Program is adequate Corrosion Related Air
223. pection for additional information b along the forward edge and the bend radii Inspect the area between the edge of the tailcone horizontal bulkhead assembly and three inches above Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Surface Inspection for additional information 7 If cracks are found in the aft vertical stabilizer attachment bulkhead Remove the vertical stabilizer D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 17 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL b Conducta surface eddy current inspection of the front spar fitting of the vertical stabilizer Pay particular attention to areas around the attach holes and along the edges of the part Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Surface Inspection for additional information 8 Install the removed parts including the stinger and fairings Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Stabilizer Not Allowed 6 INSPECTION METHOD Visual Eddy Current 7 REPAIR MODIFICATION A B If any cracks are found in the aft vertical stabilizer attach bulkhead replace the aft vertical stabilizer attach bulkhead If any cracks are found in the front vertical s
224. plications of the CPI at the recommended interval for each CPI 3 You can start a on the basis of individual CPIs or groups of CPIs 4 Cessna Aircraft Company highly recommends to start all of the 5 as soon as possible This is the most cost effective way to prevent or control corrosion D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 24 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL CORROSION 1 General A This section describes corrosion to assist maintenance personnel in identification of various types of corrosion and application of preventative measures to minimize corrosion activity B Corrosion is the deterioration of a metal by reaction to its environment Corrosion occurs because most metals have a tendency to return to their natural state 2 Corrosion Characteristics A Metals corrode by direct chemical or electrochemical galvanic reaction to their environment The following describes electrochemical reaction 1 Electrochemical corrosion can best be compared to a battery cell Three conditions must exist before electrochemical corrosion can occur There must be a metal that corrodes and acts as the anode positive b There must be a less corrodible metal that acts as the cathode negative c There must be a continuous liquid path between the two metals which acts as the electrolyte This liquid path may
225. pply the corrosion program inspection which includes the repair of the structure Contact Cessna Aircraft Company for an approved repair procedure l Find the action needed to control the corrosion finding to Level 1 or better between future successive inspections These can include any or all of the following 1 A structural modification such as additional drainage 2 Improvements to the corrosion prevention and control inspections such as more care and attention to corrosion removal reapplication of protective finish drainage path clearance 3 A decrease in the inspection interval for additional airplanes entering the program J Send a plan of corrective action to the FAA or applicable regulator authority for approval and Cessna Aircraft Company as needed K Use the approved plan of action L Itis recommended that you give the details of the findings to Cessna Aircraft Company 22 Factors Influencing Corrosion Occurrences A If you find Level 2 or Level corrosion when you think about how to change your think about the list that follows 1 Is there a presence of LPS 3 Heavy Duty Rust Inhibitor 2 Is there a presence or condition of protective finish 3 What was the length of time since the last inspection and or application of corrosion inhibiting compound 4 Was there inadequate clean up removal of corrosion prior to application of corrosion inhibiting compound during previous maintenance of the area
226. ptic light guide with white light is generally used in the illumination system Some long borescopes use light emitting diodes at the distal tip for illumination C Visual Inspection Procedures 1 Factors That Can Affect Inspection a Lighting Get sufficient lighting for the part or area Do not look into glare to do the inspection b Comfort The comfort temperature wind rain etc of the inspector can be a factor in visual inspection reliability c Noise Noise levels are important Too much noise reduces concentration creates tension and prevents effective communication All these factors will increase the chance of errors d Inspection Area Access Ease of access to the inspection area has been found to be of major importance in reliable visual inspection Access includes that into an inspection position primary access and to do the visual inspection secondary access Poor access can affect the interpretation of discontinuities decisions motivation and attitude Preliminary Inspection Do a preliminary inspection of the general area for foreign objects deformed or missing fasteners security of parts corrosion and damage If the location is not easy to access use visual aids such as a mirror or borescope Corrosion Remove but do not do a treatment of any corrosion found during preliminary inspection Do a treatment of corrosion found after the entire visual inspection is complete NOTE If you leave corrosi
227. quently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For Models 180 and 185 this inspection is for severe 510 610 corrosion environment Inspect main landing gear spring axle attach bolt holes Refer to Section 2A 14 10 Supplemental Inspection Document 32 13 05 for inspection procedure For All Models this interval is for severe corrosion 510 610 environment Inspect wing root rib Refer to Section 2A 14 27 Supplemental Inspection Document 57 12 01 for inspection procedure End of Operation 14 Inspection Items D138 1 13 Temporary
228. quivalent specification for requirements for magnetic particle inspection materials and equipment Permanent magnets must not be used The intensity of the magnetic field cannot be adjusted for inspection conditions CAUTION Do not use permanent magnets for inspection of airplanes or components Contact prods must not be used Localized heating or arcing at the prod can damage parts CAUTION Do not use contact prods for inspection of airplanes or components Referto ASTM E 1444 ASTM E 709 or equivalent documentation for instructions to do magnetic particle inspections This section assumes the use of a portable magnetic particle system The use of stationary magnetic particle inspection equipment is allowed Stationary equipment must show that it can meet the inspection sensitivity requirements and is maintained correctly Refer to the specifications in the Equipment Quality Control section C Lighting Requirements 1 Do the magnetic particle inspection in a darkened area where the background intensity of the white light is no more than 2 foot candles If inspection is done on the airplane the area must be darkened as much as practical for inspection D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 16 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 2 Ultraviolet lights must operate in the range of 320 to 380 nanometers to maximize penetran
229. r 1 16 inch and 3 32 inch 7 by 7 construction Cable of this construction shall consist of six strands of seven wires each laid around a core strand of seven wires The cable shall have a length of lay of not more than eight times nor less than six times the nominal cable diameter Cable diameter 1 8 inch through 3 8 inch 7 by 19 construction Cable of this construction shall consist of six strands laid around a core strand The wire composing the seven individual strands shall be laid around a central wire in two layers The single core strand shall consist of a layer of 6 wires laid around the central wire in a right direction and a layer of 12 wires laid around the 7 wire strand in a right direction The 6 outer strands of the cable shall consist of a layer of 6 wires laid around the central wire in a left direction and a layer of 12 wires laid around the 7 wire strand in a left direction Lubrication A pressure type friction preventative compound having noncorrosive properties is applied during construction as follows Friction preventative compound is continuously applied to each wire as it is formed into a strand so that each wire is completely coated Friction preventative compound is continuously applied to each strand as it is formed into a cable so that each strand is completely coated Definitions The following definitions pertain to flexible steel cable Wire Each individual cylindrical steel rod or thread shall
230. r 5 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For All Models inspect aileron hinges hinge bolts 520 620 hinge bearings and hinge and pushrod attach fittings Refer to Section 2A 14 29 Supplemental Inspection Document 57 51 01 for inspection procedure End of Operation 16 Inspection Items kkk D138 1 13 Temporary Revision Number 7 Dec 1 2011
231. r Models 172 and 175 inspect firewall structure Refer to Section 2A 14 15 Supplemental Inspection Document 53 12 03 for inspection procedure For All Models this interval is for mild moderate corrosion environment Inspect the cabin interior skin panels frames and stringers Refer to Section 2A 14 16 Supplemental Inspection Document 53 30 01 for inspection procedure For All Models this interval is for severe corrosion environment Inspect the cabin interior skin panels frames and stringers Refer to Section 2A 14 16 Supplemental Inspection Document 53 30 01 for inspection procedure D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL Initial 20 years Repeat 10 years Initial 10 years Repeat 5 years Initial 12 000 hours or 20 years whichever occurs first Repeat 2 000 hours or 10 years whichever occurs first Initial 6 000 hours or 10 years whichever occurs first Repeat 1 000 hours or 5 years whichever occurs first Initial 4 000 hours or 10 years whichever occurs first Repeat 1 000 hours or 3 years whichever occurs first Initial 2 000 hours or 5 years whichever occurs first Repeat 2 000 hours or 5 years whichever occurs first Initial 20 years Repeat 10 years Initial 10 years Repeat 5 years 2A 10 01 OPERATION 20 21 23 ZONE 210 210 210 210 210 210 210 210 Page 3 Feb 3 2003 CES
232. r excessive wear or deformation Maximum new clearance between the NAS bushings in the mid joint upper torque link lug ID 0 1900 to 0 1915 in and the bolt OD 0 1885 to 0 1894 in is 0 0030 in A clearance of 0 006 in is the maximum wear limit 1 Clean area before inspecting if grime or debris is present F Inspect upper and lower joint torque link bushings for excessive wear or deformation As the bolt clamps up on the spacer the wear is to be measured between the NAS bushing and the spacer Maximum new clearance between the NAS bushings in the torque link ID 2 0 3750 to 0 3765 in and the spacer OD 0 3744 to 0 3750 in is 0 0021 in A clearance of 0 006 in is the maximum wear limit 1 Clean area before inspecting if grime or debris is present G Inspect the fork for cracking along the forging parting line 1 Clean area before inspecting if grime or debris is present Install the removed bolts l Charge the nose strut Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Nose Gear Section Not Allowed D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 11 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 6 INSPECTION METHOD Visual and Eddy Current 7 REPAIR MODIFICATION Replace worn or bent bolts or worn bushings with new parts if wear limits are exceeded C
233. r mild moderate corrosion environment Inspect main landing gear spring axle attach bolt holes Refer to Section 2A 14 10 Supplemental Inspection Document 32 13 05 for inspection procedure For Models 180 and 185 this inspection is for severe corrosion environment Inspect main landing gear spring axle attach bolt holes Refer to Section 2A 14 10 Supplemental Inspection Document 32 13 05 for inspection procedure For Models 150 172 175 and 182 inspect nose landing gear torque links bolts bushings and fork Refer to Section 2A 14 11 Supplemental Inspection Document 32 20 01 for inspection procedure D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL OPERATION ZONE Initial 1 000 hoursor 24 721 3 years whichever 722 occurs first Repeat 1 000 hours or 3 years whichever occurs first Initial 20 years 11 721 Repeat 10 years 722 Initial 10 years 13 721 Repeat 5 years 722 Initial 3 000 hours or 17 210 5 years whichever occurs first Repeat 1 000 hours or 5 years whichever occurs first Initial 4 000 hours or 7 721 10 years whichever 722 occurs first Repeat 1 000 hours or 3 Years whichever occurs first Initial Every time 27 721 skis are installed or 722 removed Repeat Every time skis are installed or removed Initial 5 years 12 721 Repeat 5 years 722 Initial 3 years 14 721 Repeat 3 years 722 Initial 3 000 hoursor 9 720 5 years whichever oc
234. racked torque link or fork is not repairable and must be replaced Make other repairs in accordance with Section 19 Structural Repair of the Model 100 Series Service Manual Coordinate any repair not available in Section 19 with Cessna Customer Service prior to beginning the repair 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 11 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18490 UPPER TORQUE LINK DETAIL BOLT BUSHING DETAIL B NOTE MODEL 150 SHOWN OTHER MODELS TYPICAL NE NOSE GEAR TORQUE LINK BOLT AND FORK INSPECTION MODELS 150 172 175 AND 182 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 11 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 11 01 1 TITLE Carry Thru Structure Corrosion Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru
235. rating environment years in service inspectability of the corroded area and the cause of the problem 3 LE 20 Level 2 Corrosion Findings A All Level 2 corrosion that is more than the rework limits of the approved repair procedures must be reported to Cessna Aircraft Company Cessna Aircraft Company engineering will do an analysis to make sure the corrosion is not an urgent airworthiness concern When doing the analysis Cessna Aircraft Company will consider 1 Can the cause of the corrosion be identified such as a chemical spill or protective finish breakdown 2 Has the same level of corrosion been found on other airplanes 3 Are the corrosion protection procedures applied during manufacture the same for earlier and later models 4 Age of the corroded airplane compared to others checked 5 Is the maintenance history different from the other airplanes in the fleet 21 Typical Actions That Follow the Determination of the Corrosion Level A If corrosion is found find the corrosion level then do the necessary steps for a specific inspection B If Level 1 corrosion is found during the first inspection 1 Repair the structure Contact Cessna Aircraft Company for an approved repair procedure 2 Continue with the Baseline Program a Optional Document the results of the inspection for use in validating program compliance C If Level 2 corrosion is found during the first inspection 1
236. ration of three major screen divisions between the null point and the applicable reference notch The signal from a differential probe should be considered peak to peak NOTE This adjustment is used to set the sensitivity of the inspection It is not intended as accept or reject criteria NOTE Filters may be used to improve the signal to noise ratio 6 Inspection a When the inspection procedure does not show the depths where the scans are made for a manual probe the following general procedure is used 1 Put the probe into the hole for inspection and find the near edge of the hole This is the point when the signal is 5096 between that for an in air condition and that fully into the hole Record the distance between the center of the probe coil and the edge of the probe guide Move the probe through the hole until the signal indicates that the probe is beyond the far edge of the hole Locate this edge of the hole as in step 1 Record the distance between the center of the probe coil and the edge of the probe guide 3 To find the edge of a layer slowly push the probe through the hole The response to a layer interface will look similar to that of a crack indication The difference is that the interface will be seen through 360 of the hole Measure the distance between the center of the probe coil and the edge of the probe guide when the signal from the interface has been maximized Use the measurements to find the thickness of the hole an
237. rd stabilizer attachments Refer to the Model 100 Series Service Manual B Visually inspect the horizontal tail attachment for cracks or corrosion in the attachment doubler Look through the two holes in the aft web of the fuselage bulkhead If damage is found refer to the Repair Modification section below 1 Clean area before inspecting if grime or debris is present C Install the horizontal stabilizer to vertical stabilizer fairings Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Aft Fuselage Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION If damage is found repair in accordance with Cessna Service Kit SK150 33A 8 COMMENTS This inspection supersedes Cessna Service Bulletins SE68 32 and SE71 23 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 21 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18021 0432169 1 DOUBLER TAILCONE DETAIL 0410T1003 HORIZONTAL STABILIZER FORWARD ATTACHMENT INSPECTION MODEL 150 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 21 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 55 30 01 1 TITLE Vertical Stabilizer Rudder and Attachments Inspection All
238. rease dirt corrosion or other material that may affect the inspection Examine the area for inspection Record material thickness to the nearest 0 001 inch Take enough measurements that the minimum thickness is found in the blended area If possible take a measurement in an adjacent area to get a nominal thickness Referto the General Requirements section for information on how to report inspection results E After Inspection 1 Refer to the General Requirements section for information on how to report inspection results 2 Clean any couplant off the area 6 VISUAL INSPECTION A General 1 Visual inspection is the most common form of airplane inspection Visual inspection can find a wide variety of component and material surface discontinuities such as cracks corrosion contamination surface finish weld joints solder connections and adhesive disbonds The results of a visual inspection may be improved with the use of applicable combinations of magnifying instruments borescopes light sources video scanners and other devices The use of optical aids for visual inspection is recommended Optical aids magnify discontinuities that cannot be seen by the unaided eye and also allow inspection in inaccessible areas 2 Personnel that do visual inspection tasks do not need to have certification in nondestructive inspection B Visual Aids 1 Structure and components that must be routinely examined are sometimes difficult to
239. requirements shall apply until the cable is installed in its normal position in the airplane If only a part of the cable is installed in an assembly cable storage requirements apply to the uninstalled portion of the cable 6 Flight Control Cable Inspection a General Information WARNING If the flight control cable system s are removed disconnected or cable section s are replaced make sure that all rigging travel checks cable tensions and control surface checks are done in accordance with the procedures in the appropriate section for the affected flight control system NOTE Flight control cable inspections are normally performed without removing or disconnecting any part of the flight control system However it may be necessary to derig or remove the cable to get access to the entire cable b Cable Inspection Procedure 1 Each flight control cable must be visually inspected along its entire length for evidence of broken wires corrosion fraying or other damage Visual inspection may be via direct sight mirror and flashlight or borescope 2 _ Visually check for proper routing along entire length of cable Make sure that cables pulleys attaching sectors and bell cranks are free and clear of structure and other components NOTE Some systems use rub blocks it is permissible for control cables to rub against these blocks D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 20 01 Page 5 Cessna Aircraft Company Feb 3 2003
240. ria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS For Model 182 inspect vertical stabilizer attachment 510 610 bolts forward and aft vertical stabilizer structures and vertical stabilizer attach bulkheads Refer to Section 2A 14 17 Supplemental Inspection Document 53 42 01 for inspection procedures End of Operation 28 Inspection Items kkk D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 28 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 29 Date Registration Number Serial Number Total Time 1 Description A Operation 29 gives Supplemental Inspection Document items that are to be examined after the first 4 000 hours of operation The inspection is to be repeated every 100 hours
241. rials Penetrant or an equivalent specification may be used for penetrant inspection All materials must be from the same family group Do not interchange or mix penetrant cleaners penetrant materials or developers from different manufacturers CAUTION Components intended for use in liquid oxygen systems must be examined with special penetrants designated as LOX usage penetrants These are compatible with a liquid oxygen environment Reaction between a liquid oxygen environment and penetrant not designed for use in that environment can cause explosion and fire C Lighting Requirements 1 Dothe penetrant inspection in a darkened area where the background intensity of the white light is no more than 2 foot candles If inspection is done on the airplane the area must be darkened as much as practical for inspection 2 Ultraviolet lights must operate in the range of 320 to 380 nanometers to maximize penetrant fluorescence The ultraviolet light intensity must be a minimum of 1000 microWatts per square centimeter with the light held 15 inches 381 mm from the light meter Let the ultraviolet light warm up for a minimum of 10 minutes before use 3 Measure the ultraviolet and ambient white light intensities before each inspection with a calibrated light meter D Inspection 1 Before Inspection a The penetrant materials and the area for inspection must stay at a temperature between 40 F and 125 F 4 to 52 C throughout the in
242. rity 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Flap Tracks Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION Replace damaged flap tracks or attachments Replace damaged or loose rivets 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 30 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18502 INBOARD A FLAP TRACK OUTBOARD FLAP TRACK NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL 051071007 FLAP TRACKS CORROSION INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 30 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 71 20 01 1 TITLE Engine Mount Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17257119 Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 t
243. roughout the test within 5 4 F 3 C of each other b Material Surface Condition The surface finish of the area for inspection must be 150 RHR or RMS 165 or finer The areas for inspection must be free of dirt grease oil or other contamination Conductivity measurements may be made through anodize chemical film primer paint or other nonconducting coatings if the thickness of these coatings are no more than 0 003 inch 0 076 mm Coatings with thickness more than this must be removed before conductivity testing On concave surfaces a curvature radius of no less than 10 inches is needed On convex surfaces a curvature radius of no less than 3 inches can be tested without use of correction factors 5 The surface ofthe part must be no smaller than the outside diameter of the probe The coil must be put in the center on all parts whose dimensions approach this limitation Instrument Calibration a The instrument must be set up and operated in accordance with this procedure and the manufacturer s instructions b Each time the conductivity instrument is used it must be set up with the instrument conductivity standards before data are taken and checked again at 15 minute intervals during continuous operation Check calibration at the end of the test c Ifthe instrument is found to be out of calibration all measurements taken since the last calibration must be done again Inspection a The purpose of the inspection is to c
244. rp Light Meter DSE 2000A Spectronics Corp 956 Brush Hollow Road Westbury New York 11590 Phone 800 274 8888 Web http www spectroline com 2 Penetrant materials are defined by specific classification per SAE AMS 2644 Materials must meet at minimum the classification listed This list assumes the use of a portable penetrant inspection kit If other penetrant inspection equipment is used refer to industry standard ASTM E 1417 Standard Practice for Liquid Penetrant Testing or an equivalent specification for other information on materials and inspection quality instructions a Type 1 Fluorescent Penetrant b Level 3 Penetrant sensitivity D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 Page 12 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL c Method C Solvent Removable Penetrant d Form d Nonaqueous Type 1 Fluorescent Solvent Based Developer e Class 2 Non halogenated Solvent Removers NOTE Do not use Type 2 Visible Dye Penetrant on this airplane or components If Type 2 penetrant was previously used for this inspection penetrant is no longer an approved method of inspection Another NDT method such as eddy current must be used to do the inspection 3 Only materials approved in the most recent revision of QPL AMS2644 Qualified Products List of Products Qualified under SAE Aerospace Material Specification AMS 2644 Inspection Mate
245. s 120 sure you inspect these areas 1 Engine truss Pay particular attention to vicinity of welds NOTE Corrosion Prevention and Control Program Inspection item refer to Section 2A 30 00 for additional inspection information Wing structure internal for All Models Make sure 510 520 you inspect these areas 1 Main spar upper and 610 620 lower carry thru fittings 2 Main spar upper and lower caps 3 Main spar web NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information End of Operation 2 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 02 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 3 Date Registration Number Serial Number Total Time 1 Description A Operation 3 gives Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 24 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s
246. s All faying surfaces seams and lap joints protected by sealant must have the entire faying surface coated with sealant Excess material squeezed out should be removed so that a fillet seal remains Joint areas which could hold water should be filled or coated with sealant 3 Attaching Parts a Attaching parts such as nuts bushings spacers washers screws self tapping screws self locking nuts and clamps do not need to be painted in detail except when dissimilar metals or wood contact are involved in the materials being joined Such parts should receive a wet or dry coat of primer NOTE Corrosion inhibiting solid film lubricants Specification MIL PRF 46010 and or MIL L 46147 may be used to protect attaching parts from corrosion b All holes drilled or reworked in aluminum alloys to receive bolts bushings screws rivets and studs should be treated before installation of fasteners or bushings c All rivets used to assemble dissimilar metals should be installed wet with sealant conforming to Specification MIL PRF 81733 Corrosion inhibiting sealer Type X 4 Close tolerance bolts passing through dissimilar metals should be coated before installation with a corrosion inhibiting solid film lubricant conforming to Specification MIL PRF 46010 and or MIL L 46147 5 Washers made of aluminum alloy of suitable design should be used under machine screws countersunk fasteners bolt heads and nuts 6 Adjustable parts thr
247. s speed payload fuel etc that are used to calculate the loads spectrum Stress Spectrum 1 2 A fatigue loads spectrum in terms of gross area stress was developed for each PSE to be analyzed based on the usage flight profiles The spectrum represents the following loading environments flight loads gust and maneuver landing impact taxi loads and ground air ground cycles The resulting spectrum is a representative flight by flight cycle by cycle loading sequence that reflects the appropriate and significant airplane response characteristics After reviewing the aircraft usage data and the way in which the surveyed aircraft were flown two sets of stress spectra were developed The first flight profile represents typical usage while the second profile represents severe usage as described in Paragraph 3 D below Fatigue Assessment 1 2 The fatigue assessment provides the basis for establishing inspection frequency requirements for each PSE The evaluation includes a determination of the probable location and modes of damage and is based on analytical results available test data and service experience In the analysis particular attention is given to potential structural condition areas associated with aging aircraft Examples include a large areas of structure working at the same stress level which could develop widespread fatigue damage b a number of small less than detectable size adjacent cracks sud
248. s 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18254423 Model 185 Serial Numbers 632 185 0001 thru 185 0512 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 20 Years NOTE REPEAT 10 Years NOTE SEVERE INITIAL 10 Years NOTE REPEAT 5 Years NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To ensure corrosion protection of the wing structure 4 INSPECTION INSTRUCTIONS A Remove all access panels fairings and the wing tips from the wings Refer to the Model 100 Series Service Manual 1 Clean area before inspecting if grime or debris is present B Visually inspect throughout the wing sections for corrosion or traces of corrosion products through the access panels and wing tips C Remove forward tank covers and inspect spars for corrosion 1 Clean area before inspecting if grime or debris is present D Visually inspect for open fastener holes or loose rivets in the structure Open fastener holes are an indication that a rivet has corroded and departed the airplane E Use a borescope to inspect inaccessible areas 1 Some additional areas can be reached by threading the borescope probe through lightening holes in the trailing edge ahead of the flap and aileron 2 Use the borescope to pay particular attention to rivet butts and flanges co
249. s for severe usage 3510 610 environment 1 Inspect inboard wing structure and wing attachment to fuselage including working rivets 2 Inspect flap actuator support structure Refer to Section 2A 14 23 Supplemental Inspection Document 57 11 01 for inspection procedure For All Models this interval is for severe usage 3510 610 environment Inspect wing strut and strut tube Refer to Section 2A 14 28 Supplemental Inspection Document 57 40 01 for inspection procedure End of Operation 21 Inspection Items D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 21 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 22 Date Registration Number Serial Number Total Time 1 Description A Operation 22 gives Supplemental Inspection Document items that are to be examined after the first 5 000 hours of operation or 20 years whichever occurs first The inspection is to be repeated every 2 000 hours of operation or 5 years whichever occurs first after the initial inspection has been accomplished Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a chec
250. sion Prevention and Control Program Inspection item baseline interval refer to Section 24 30 00 for additional inspection information Note Remove interior panels for access Areas of the cabin structure for the passenger crew door for All Models Make sure you inspect these areas 1 Door frames 2 Door hinges NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Areas of the cabin structure for All Models Make sure you inspect these areas 1 Cabin door forward and aft frames 2 Window frames with emphasis at stringers and channel assemblies from aft of door frame to aft bulkhead 3 Seat attachment structure 4 Aft Cabin Bulkhead NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 24 30 00 for additional inspection information Flaps All Models 1 Check flap travel cable tension and travel time 2 Check flap cable system control cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables Aileron All Models 1 Check aileron travel and cable tension 2 Check aileron cable system control cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables Elevator All Models 1 Check elevator travel and cable tension 2 Check ele
251. sion is found For description of control cable corrosion refer to Section 2A 30 01 paragraph 4 C Steel Control Cables b Areas conducive to cable corrosion are below the refreshment center in the wheel well and in the tailcone Also if a cable has been wiped clean of its corrosion preventative lubricant and metal brightened the cable must be examined closely for corrosion 4 Pulleys a Inspection of Pulleys 1 Inspect pulleys for roughness sharp edges and presence of foreign material embedded in the grooves Examine pulley bushings or bearings to ensure smooth rotation freedom from flat spots and foreign material 2 Periodically rotate pulleys which turn through a small arc to provide a new bearing surface for the cable 3 Check pulley alignment Check pulley brackets and guards for damage alignment and security Various failures of the cable system may be detected by analyzing pulley conditions Refer to Figure 1 for pulley wear patterns these include such discrepancies as too much tension misalignment pulley bearing problems and size mismatch between cable and pulley b Cable Storage a Cable assemblies shall be stored straight or in a coil When stored in coil form the coil inside diameter shall not be less than 150 times the cable diameter or bent in a radius of not less than 75 times the cable diameter Refer to Table 1 for coil diameter criteria Coils shall not be flattened twisted or folded during storage Storage
252. spection process b Do the tests needed in the Lighting Requirements section c Prepare the part or assembly surface for the inspection Paint must be removed from the surface to let the penetrant get into surface openings The area must also be clean dry and free of dirt grease oil or other contamination NOTE Cleaning materials and methods must be approved for use by the applicable Cessna Aircraft Service Manual Structural Repair Manual or Component Maintenance Manual NOTE Mechanical methods to clean and remove paint should be avoided when practical Take care to avoid filing in or sealing the entrance to a surface discontinuity when using mechanical methods to clean or remove paint Mechanical methods can result a rough surface condition which can cause non relevant indications 2 Apply the Penetrant a Put the penetrant on the part or assembly surface with a brush or swab Be sure to completely cover the area D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 13 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL b Leave the penetrant on the surface for a minimum of 15 minutes if the temperature is at least 50 10 Leave the penetrant on the surface for a minimum of 25 minutes if the temperature is less than 50 10 c The maximum dwell time should not be more than one hour except for special circumstances d Do
253. st be well saturated but not dripping c Wipe surface with the moistened cloth as necessary to dissolve or loosen soil Work a small enough area so the surface being cleaned remains wet d Immediately wipe the surface with a clean dry cloth while the solvent is still wet Do not allow the surface to evaporate dry e Do steps b through d again until there is no discoloration on the drying cloth 2 Apply corrosion primer in accordance with Corrosion Resistant Primer MIL PRF 23377G or later a Mix and apply in accordance with manufacturer s instructions b Apply mixture with a wet cross coat to yield a dry film thickness of 0 6 to 0 8 mils c Allow to air dry for two to four hours 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 24 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 11 03 1 TITLE Wing Spar Inspection Models 180 and 185 2 EFFECTIVITY Model 180 Serial Numbers 604 614 624 30000 thru 32999 50001 thru 50911 18050912 thru 18051183 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 4 000 Hours NOTE REPEAT 100 Hours NOTE NOTE Refer to Note 1 Section 2A 14 00 This inspection only applies to agricultural dispersal system aircraft 3 PURPOSE To ensure structural integrity of the wing structure 4 INSPECTION INSTRUCTIO
254. stration Number Serial Number Total Time 1 Description A Operation 2 gives Corrosion Prevention and Control Program Inspections Baseline Program items that are to be examined every 12 months Refer to Section 2A 30 00 Corrosion Prevention and Control Program for additional information concerning repeat Corrosion Program Inspection intervals Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about each required inspection The right portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A TASK While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance If component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS Engine support structure for All Model
255. strut to wing attach bolt Remove the upper attach bolt and lower the strut to a support Remove the lower attach bolt and remove the strut Visually examine the strut tube for cracks or corrosion Visually inspect the strut attachment fittings for corrosion Inspect using Eddy Current for cracks radiating from the wing and fuselage attach holes in the wing strut end fitting 7 Replace the strut by installing the lower attachment then the upper attachment Refer to the Model 100 Series Service Manual D 3 4 5 6 2 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wing Strut Not Applicable D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 28 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 6 INSPECTION METHOD Visual and Eddy Current 7 REPAIR MODIFICATION A If corrosion is found remove corrosion by lightly sanding corroded area taking care to remove as little material as necessary to completely remove corrosion If the material thickness is less than 90 of the uncorroded section then replace the affected part Buff out sanding marks C Corrosion or damage to attachment holes will require specialized rework Contact Cessna Field Service for rework of corroded or damaged attachment holes D Clean and prime sanded areas 8 COMMENTS D138 1 13 Temporary Revisio
256. system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to Service Do a preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual ZONE MECH INSP REMARKS Passenger Crew door retention system for All 210 Models Make sure you inspect these areas 1 Bell cranks 2 Pushrods 3 Handle 4 Pin retention 5 Pins 6 Lockplates and guides 7 Hinges 8 Internal door framing NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Note Remove interior panels for access Areas of the cabin structure for the passenger crew 210 door for All Models Make sure you inspect these areas 1 Door frames 2 Door hinges NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 24 30 00 for additional inspection information End of Operation 5 Inspection Items kkk D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 12 05 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL INSPECTION OPERATION 6 Date Registration Number Serial Number Total Time 1 Description A Operation
257. t fluorescence The ultraviolet light intensity must be a minimum of 1000 microWatts per square centimeter with the light held 15 inches 381 mm from the light meter Let the ultraviolet light warm up for a minimum of 10 minutes before use 3 Measure the ultraviolet and ambient white light intensities before each inspection with a calibrated light meter Equipment Quality Control 1 Refer to ASTM E 1444 ASTM E 709 or equivalent documentation for instructions for the quality control of magnetic particle materials and equipment This section assumes use of an electromagnetic yoke 2 Dead Weight Check a The electromagnetic yoke must be able to lift 10 pounds while on AC current and with the legs spaced 2 to 6 inches apart b While on DC current the electromagnetic yoke must be able to lift either 30 pounds with the legs spaced 2 to 4 inches apart or 50 pounds with the legs spaced 4 to 6 inches apart Inspection 1 This section assumes the use of a portable magnetic particle system 2 Unless otherwise specified inspection coverage should be 100 of the part surfaces NOTE Be aware of objects near the area of the inspection Other parts may become magnetized during the inspection process Be aware of the location of airplane systems that may be sensitive to magnetic fields in the area of the inspection 3 Before Inspection a Do the tests needed in the Equipment Quality Control section b Do the tests needed in the Lighting
258. t arms Refer to 2A 14 01 Supplemental Inspection Document 27 20 01 for inspection procedure Elevator trim system for Models 150 172 175 and 182 1962 1 Inspect elevator trim brackets and actuator support brackets 2 Inspect pulleys attaching structure and fasteners Refer to Section 2A 14 02 Supplemental Inspection Document 27 30 01 for inspection procedures Elevator trim system for Models 180 182 prior to 1962 and 185 1 Inspect elevator trim brackets and actuator support brackets 2 Inspect pulleys attaching structure and fasteners Refer to Section 2A 14 03 Supplemental Inspection Document 27 30 02 for inspection procedures For Models 180 182 prior to 1962 and 185 inspect trim screw barrels and stabilizer screw jack actuator threads Refer to Section 2A 14 04 Supplemental Inspection Document 27 42 01 for inspection procedures D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL OPERATION ZONE Every 100 hours 1 ALL or 12 months whichever occurs first Every 100 hours 1 ALL or 12 months whichever occurs first Every 100 hours 1 ALL or 12 months whichever occurs first Every 100 hours 1 ALL or 12 months whichever occurs first Initial 10 000 8 211 hours or 20 years whichever occurs first Repeat 3 000 hours or 5 years whichever occurs first Initial 1 000 hours 15 330 Repeat 1 000 hours 340 Initial 1 000 hours 15 330 340 Repeat 1 000
259. t or to control the corrosion so that it does not cause a risk to the continued airworthiness of the airplane 4 Inspection Time Limits A A complete airplane inspection includes all inspection items as required by 14 CFR Part 43 Appendix D Scope and Detail of annual 100 hour inspections Refer to Section 2 of the Model 100 Series Service Manual The intervals shown are recommended intervals at which items are to be inspected 1 The 14 CFR Part 91 operator s inspection intervals shall not deviate from the inspection time limits shown in this manual except as provided below Refer to 14 CFR 91 409 a The airplane can only exceed its inspection point up to 10 hours if the airplane is en route to a facility to have the inspection completed b Inthe event of late compliance of any operation scheduled the next operation in sequence retains a due point from the time the late operation was originally scheduled c In the event of early compliance of any operation scheduled that occurs 10 hours or less ahead of schedule the next phase due point may remain where originally set d In the event of early compliance of any operation scheduled that occurs more than 10 hours ahead of schedule the next operation due point must be rescheduled to establish a new due point from the time of early accomplishment D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 10 00 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPAN
260. t surface reference standard with EDM notch depths of 0 010 inch 0 020 inch and 0 040 inch 0 254 mm 0 508 mm 1 016 mm is shown in Figure 3 Put the surface probe on the reference standard away from the notch e Set the null point f Lift the surface probe from the reference standard and monitor the display for the lift off response g Adjust the display until the lift off response goes horizontal and to the left of the null point h Putthe surface probe on the reference standard and move it across the notch D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL i Adjust the instrument to get a minimum separation of three major screen divisions between the null point and the applicable reference notch The signal from a differential probe should be considered peak to peak NOTE This adjustment is used to set the sensitivity of the inspection It is not intended as accept or reject criteria NOTE Filters may be used to improve the signal to noise ratio 6 Inspection a It may be necessary to randomly null the instrument on the airplane in the area for inspection to adjust the display for differences between the reference standard and the airplane b Whenever possible the area of inspection must be examined in two different directions that are 90 degrees to each other c Examine the
261. tabilizer spar fitting replace the front vertical stabilizer spar attach fitting If the lower holes are larger than 0 383 inch or the upper hole is larger than 0 321 inch ream the lower holes oversize 0 437 to 0 442 inches and install AN 7 bolts torqued to 500 840 or the upper hole 0 375 to 0 379 inches and install an AN 6 bolt torqued to 190 390 in lb Alternatively the rear spar bulkhead and fittings can be replaced as described in SEB99 12 Revision 1 or as listed below Installation of this service kit is a terminating action for AD 72 07 09 and this inspection 1 Obtain Cessna Service Kit 5 210 161 1 2 Install the service kit in accordance with the included instructions 3 a copy of the FAA letter included as an attachment to SEB99 12 Revision 1 and attach it to the airplane records 8 COMMENTS Refer to SE72 03 and SEB99 12 Revision 1 and associated FAA letter D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 17 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18297 VISUAL CHECK AREAS 1 0 INCH VISUAL CHECK AREAS VIEW VIEW OF BULKHEAD AND FRONT FIN SPAR LOOKING FORWARD 071071001 VERTICAL STABILIZER ATTACHMENT INSPECTION MODEL 182 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 17 Page 3 Cessna Aircra
262. tation of Corrosion Prevention and Control Program D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 2 FAA Advisory Circular AC43 4A Corrosion Control for Aircraft 3 Cessna Illustrated Parts Catalog Model 150 IPC P N P438 12 Model 172 175 IPC P N P257 12 Model 180 and 182 IPC P N P259 12 4 Cessna Service Manual P N D138 1 13 5 Control Prevention and Control Program Application A The Corrosion Prevention and Control Program gives the information required for each corrosion inspection Maintenance personnel must fully know about corrosion control The regulatory agency will give approval and monitor the CPCP for each airplane 1 The CPCP procedures apply to all airplanes that have exceeded the inspection interval for each location on the airplane Refer to the Glossary and the Baseline Program a Cessna Aircraft Company recommends that the CPCP be done first on older airplanes and areas that need greater changes to the maintenance procedures to meet the necessary corrosion prevention and control requirements 2 Maintenance programs must include corrosion prevention and control procedures that limit corrosion to Level 1 or better on all Principal Structural Elements PSEs and other structure specified in the Baseline Program If the current maintenance program includes corrosion
263. that are well beyond the allowable limits and there is an airworthiness concern in which prompt action is required NOTE The airworthiness concern is because of the possibility to have similar but more severe corrosion on any other airplane in the operator s fleet prior to the next scheduled inspection of that area Find the action required to control the corrosion to a Level 1 or better between future successive inspections These can include the items that follow a A structural modification such as additional drainage b Improvements to the corrosion prevention and control inspections such as more care and attention to corrosion removal reapplication of protective finish drainage path clearance c Decrease the inspection interval for additional airplanes that go into the program Send a plan of corrective action to the FAA or applicable regulatory authority for approval and to Cessna Aircraft Company as needed Use the approved plan of action D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 23 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL H If Level corrosion is found on the second or subsequent inspection 1 Contact Cessna Aircraft Company and the FAA or applicable regulatory authority about the corrosion that was found 2 Send plan to examine the same area on other affected airplanes in the operator s fleet 3 A
264. the cable which pass through fairleads across rub blocks and around pulleys If no snags are found then no further inspection is required If snags are found or broken wires are suspected then a more detailed inspection is necessary which requires that the cable be bent in a loop to confirm the broken wires Refer to Figure 1 for an example Loosen or remove the cable to allow it to be bent in a loop as shown Refer to Table 1 for bend diameter criteria While rotating cable inspect the bent area for broken wires Table 1 Loop and Coil Diameter Criteria Cable Diameter Smallest Allowable Smallest Allowable Loop Diameter Loop Inside Diameter of Coil Test Cable Storage 1 32 Inch 1 6 Inch 4 7 Inch 1 16 Inch 3 2 Inch 9 4 inch 3 32 Inch 4 7 Inch 14 1 Inch 1 8 Inch 6 3 Inch 18 8 Inch 5 32 Inch 7 9 Inch 23 5 Inch 3 16 Inch 9 4 Inch 28 2 Inch 2 Wire breakage criteria for the cables in the flap aileron rudder and elevator systems are as follows a Individual broken wires are acceptable in primary and secondary control cables at random locations when there are no more than three broken wires in any given 10 inch 0 254 m cable length 3 Corrosion a Carefully examine any cable for corrosion that has a broken wire in a section not in contact with wear producing airframe components such as pulleys fairleads rub blocks etc It may be necessary to remove and bend the cable to properly inspect it for internal strand corrosion as this condit
265. the frequency should be 1 0 to 2 0 MHz NOTE Instrument frequency may need adjustment for the instrument and probe combination used ES Smaller coil diameters are better for crack detection A coil diameter of 0 125 inch 3 175 mm is normally used For crack detection the coil will usually contain a ferrite core and external shield The probe must not give responses from handling pressures scanning or normal operating pressure variations on the sensing coil which cause the signal to noise ratio to be less than 3 to 1 7 Teflon tape may be used to decrease the wear on the eddy current probe coil If Teflon tape is used make sure the instrument calibration is correct ID 101 3 Reference Standards Nonferrous reference standards should be of an alloy having the same major base metal basic temper and the approximate electrical conductivity of the material for inspection Refer to Figure 3 Reference standards must have a minimum surface finish of 150 RHR or RMS 165 The reference standard must have an EDM notch on the surface of no more than 0 020 inch 0 508 mm deep The dimensional accuracy of notches must have documentation and be traceable to the National Institute of Standards and Technology NIST or applicable foreign agency In some cases a specially fabricated reference standard will be necessary to simulate part geometry configuration and the specific discontinuity location Artificial discontinuities may be us
266. the reference point at the center of the area for inspection The reference point should be approximately in the center of the area of interest IN 109 NOTE detailed map is needed of the inspection area to include dimensions to locate the reference point and enough information to allow the responsible engineering activity to find the sites of the conductivity data D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 10 O Cessna Aircraft Company Feb 3 2003 16319 ES CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL The total area for inspection and the distance between data points will vary with the situation a It is recommended that the distance between data points be no larger than 1 0 inch 25 400 mm b If the visual evidence or the conductivity values suggest rapid changes severity the distance between data points should be decreased It is recommended that the total area for inspection should be larger than the area of visual evidence by a minimum of 2 0 inches 50 800 mm If the conductivity values continue to change the area of inspection should be expanded until values remain fairly constant to ensure complete coverage of the area Locate the reference point at the corner of a square refer to Figure 4 Take conductivity values working away from the reference point in the increments and distance found in Step 4 Enough information should be included alon
267. through the lightening holes and pulleys Pull the ribs and cables out of the way and secure them while working to ensure proper routing and rigging upon reassembly 8 Remove the fasteners securing the existing 0532001 11 reinforcements to the aft face of the forward spar Remove and discard these reinforcements 9 Ifthe forward spar cracks are present that extend to the spar flange replace the forward spar 10 Locate the 0531037 1 one piece reinforcement which replaces the two pieces previously removed Install the spar web rivets in the left side only in existing rivet locations Deburr all holes If edge distance is sufficient to maintain 1 5 rivet diameters oversized rivets may be used to obtain good holes and fit 11 Using a number 30 0 128 inch diameter drill add equally spaced holes for new fasteners between the rivets securing the reinforcements to the spar flanges and skins All rivets in the spar web can be driven from inside the stabilizer and bucked on the front side Leave the rivet holes in the flange open where the center skin will attach Reattach the leading edge skin using MS20470AD3 3 rivets 13 Locate and position the inboard ribs Working through the loose stabilizer skin along the aft spar reattach the trim cable pulley bracket ensuring the cables are properly routed Reattach the stabilizer skin along the trailing edge using MS20470AD3 3 rivets 15 Working through the lightening holes in the inboard ri
268. to airplanes operated without Skis 3 PURPOSE To ensure corrosion does not develop in main landing gear axle attachment holes 4 INSPECTION INSTRUCTIONS A Inspect the four axle attach bolt holes for any indication of rusting or rust pits Refer to Figure 1 NOTE Corrosion pits must not be allowed to develop inside the axle attach holes To minimize the potential for corrosion always install dry bolts in dry holes 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION ZONE DETECTABLE CRACK SIZE Main Gear Spring Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION A Refer to the Model 100 Series Service Manual Section 5 5A C for detailed instructions of corrosion removal on the landing gear axle attachment holes NOTE The springs are very hard approximately 250 000 psi UTS A carbide tipped or similar reamer is recommended 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 10 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18321 MAIN LANDING GEAR AXLE DETAIL 0710T1030 MAIN LANDING GEAR SPRING AXLE ATTACH INSPECTION MODELS 180 AND 185 Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 10 Page 2 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 20 01 1 TITLE Nose
269. tructions c Install the bushings in the spar in the same orientation as they were when removed d Install the rear spar attach bolt 4 Install previously removed access panels fairings and wing tips Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wing Attach Points Not Allowed 6 INSPECTION METHOD Visual Eddy Current Borescope Magnifying Glass 7 REPAIR MODIFICATION Replace cracked or excessively corroded parts If corrosion is present it must be removed before refinishing Contact Cessna Customer Service for assistance prior to beginning the repair if the disassembly exceeds the repair facilities experience or capability 8 COMMENTS Coordinate this inspection with SID 57 40 01 Strut and Strut Wing Attachment Inspection D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 23 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 11 02 1 TITLE Wing Structure Corrosion Inspection All Models 2 EFFECTIVITY Model 150 Serial Numbers 617 628 17001 thru 17999 59001 thru 59018 15059019 thru 15059700 Model 172 Serial Numbers 610 612 615 622 625 630 28000 thru 29999 36000 thru 36999 46001 thru 47746 17247747 thru 17249544 Model 175 Serial Numbers 619 626 55001 thru 56777 17556778 thru 17557119 Model 180 Serial Number
270. ts 2 Wheel halves NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE Do not apply LPS 3 Heavy Duty Rust Inhibitor to the bearing NOTE Coordinate with tire change Nose gear trunnion steering assembly torque link assembly nose gear fork and axle for All Models Make sure you inspect these areas 1 Nose gear trunnion surface 2 Steering collar and steering collar attach bolt 3 Torque link torque link attach pin and attach bolt 4 Nose gear fork 5 Nose gear axle NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information Nose gear trunnion torque link assembly and nose gear fork for Models Make sure you inspect these areas 1 Nose gear trunnion upper and lower inner bore surface and bearing 2 Torque link bolt and attach pin inner bore surface 3 Nose gear fork lug inner bore surface NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information Nose landing gear outer barrel assembly for All Models Make sure you inspect these areas 1 Outer barrel assembly 2 Upper strut end and lower collar assembly NOTE Corrosion Prevention and Control Inspection Item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE do not
271. ts and airplane structures This section also gives the required details to monitor them using scheduled inspections This section applies to items such as fatigue components and structures which are part of the certification procedures Refer to the description paragraph below for detailed information concerning each of these sections NOTE The time limits and maintenance checks listed in this section are the minimum requirements for airplanes operated under normal conditions For airplanes operated in areas where adverse operating conditions may be encountered such as high salt coastal environments areas of high heat and humidity areas where industrial or other airborne pollutants are present extreme cold unimproved surfaces etc the time limits should be modified accordingly NOTE The inspection guidelines contained in this section are not intended to be all inclusive for no such charts can replace the good judgment of certified airframe and power plant mechanics in performance of their duties the one primarily responsible for the airworthiness of the airplane the owner or operator should select only qualified personnel to maintain the airplane 2 Inspection Requirements A Twotypes of inspection requirements are available based on operating usage and two additional types of inspections are available based on operating environment 1 Operating Usage Severe Usage Environment 1 If the average flight length is less than
272. tural integrity of the Aileron Support Structure 4 INSPECTION INSTRUCTIONS A Remove the ailerons Refer to the Model 100 Series Service Manual 1 Clean area before inspecting if grime or debris is present B Visually inspect the aileron hinges for condition cracks and security Pay particular attention to the hinge pin segment knuckle area as shown in Figure 1 C Visually inspect the pushrod attach fittings for evidence of damage wear failed fasteners and security D Install the ailerons Refer to the Model 100 Series Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wings Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION Replace any damaged or cracked hinges Replace damaged or worn hinge pins 8 COMMENTS D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 29 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18501 INSPECT FOR CRACKS AILERON HINGE view PUSHROD ATTACH BRACKET AILERON HINGE DETAIL B DETAIL C NOTE MODEL 172 SHOWN OTHER MODELS TYPICAL 051071007 AILERON SUPPORT STRUCTURE INSPECTION ALL MODELS Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 29 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBE
273. u 32999 50000 thru 50911 18050912 thru 18051183 Model 182 Serial Numbers 613 631 33000 thru 34999 51001 thru 53007 18253008 thru 18253958 Model 185 Serial Numbers 632 185 0001 thru 185 0512 INSPECTION COMPLIANCE ALL USAGE INITIAL 1 000 Hours NOTE REPEAT 1 000 Hours NOTE NOTE Refer to Note 1 Section 2 14 00 3 PURPOSE To inspect the horizontal stabilizer trim screw jack actuator for wear or corrosion 4 INSPECTION INSTRUCTIONS A Inspect the horizontal stabilizer screw jack actuators for signs of damage or deterioration 1 Clean area before inspecting if grime or debris is present 2 Inspect the trim screw barrels in the tail for wear or corrosion Pay particular attention to inspect the stabilizer screw jack actuator threads for wear Refer to Figure 1 B Inspect fasteners and attaching structure for integrity 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Stabilizer Not Allowed 6 INSPECTION METHOD Visual 7T REPAIR MODIFICATION Refer to the Model 100 Series Service Manual Section 11 9 for detailed instructions of repair modification 8 COMMENTS Coordinate this inspection with SID 27 30 02 Elevator Trim Pulley Bracket and Screw Jack Inspection D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 14 04 1 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18484 DETAIL SCREW JAC
274. use a nonaqueous wet developer 1 Thoroughly shake the can to be sure that the solid particles in the developer do not settle to the bottom of the liquid 2 Spray a thin coat of developer on the surface NOTE care not to use too much developer If the developer puddles or begins to drip across the surface the part or assembly must be processed again from the start e The developer must be allowed to stay on the surface for a minimum of 10 minutes before interpretation of the results If the developer dwell time exceeds two hours the part or assembly must be processed again from the beginning 5 Interpretation a Interpretation must happen in the lighting conditions described in the Lighting Parameters section b Theinspector must not wear darkened or light sensitive eye wear These lenses can reduce the amount of fluorescence you see c The inspector must enter the darkened area and remain there for a minimum of 1 minute before interpretation to allow the eyes to adapt to the darkened conditions d Examine the part or assembly with the ultraviolet light 1 Examine the surface with an 8x magnifier or more to show indications not visible with normal vision 2 A surface opening will be shown by a fluorescent indication D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 13 01 Page 14 Cessna Aircraft Company Feb 3 2003 6 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL 3 A crack wi
275. vator cable system control cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables Elevator Trim All Models 1 Check elevator trim travel and cable tension 2 Check elevator trim cable system control cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables D138 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL OPERATION ZONE Every 60 months 6 210 Every 48 months 5 210 Every 48 months 5 210 Every 60 months 6 210 Initial 100 hours 30 210 Repeat every 600 510 hours or 12 months 610 whichever occurs first Initial 100 hours 30 210 Repeat every 600 510 hours or 12 months 520 whichever occurs 610 first 620 Initial 100 hours 30 210 Repeat every 600 310 hours or 12 months 330 whichever occurs 340 first Initial 100 hours 30 210 Repeat every 600 310 hours or 12 months 330 whichever occurs 340 first 2A 10 01 Page 7 Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL REVI TASK INTERVAL OPERATION ZONE SION STATUS Rudder All Models 1 Check rudder travel and Initial 100 hours 30 210 cable tension 2 Check rudder cable system control Repeat every 600 310 cables and pulleys in accordance with the flight cable hours or 12 months 320 inspection procedures in Sect
276. ve testing can be necessary after some disassembly if the inspection shows a bulge in the skin or corrosion below structural splices or fittings nn D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 16 O Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL CAUTION Remove only the minimum amount of material to completely remove the corrosion Removal of too much material can result in additional repairs and rework 4 Remove all of the corrosion from the structure or component NOTE magnifying glass can be a valuable tool to use to make sure all the corrosion has been removed 17 Corrosion Evaluation and Classification A Complete an Initial Corrosion Damage Assessment 1 For classification of corrosion damage refer to Determination of the Corrosion Levels B Measure the Depth of Corrosion Damage 1 You can remove a small area of corrosion with a MPK wipe 2 Use a dial depth gage or similar tool to measure the depth of the corrosion damage 3 If you find that the corrosion exceeds allowable limits during corrosion evaluation contact Cessna Customer Support for further instructions 18 Application of Corrosion Preventative Compounds A Detection of previously applied compounds 1 Visually determine if the corrosion is in an area that has corrosion preventative compounds previously applied Refer to Section 2A 30 01 Corrosion for a
277. ver aluminum occurs the oxygen concentration at the back or bottom of the corrosion cell is lower than that at its open surface The oxygen concentration gradient thus established causes an electric current flow and corrosion results Filiform corrosion results when this happens along the interface between the metal and the protective coating and appears as small worm like tracks Filiform corrosion generally starts around fasteners holes and countersinks and at the edge of sheet metal on the outer surface of the airplane Filiform corrosion is more prevalent in areas with a warm damp and salty environment 2 To help prevent filiform corrosion development the airplane should be a Spray washed atleast every two to three weeks especially in a warm damp environment b Waxed with a good grade of water repellent wax to help keep water from accumulating in skin joints and around countersinks NOTE Wax only clean surfaces Wax applied over salt deposits will almost guarantee trapped salt deposit which is capable of accumulating moisture and developing into filiform corrosion D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 2 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL HIGH OXYGEN HIGH METAL ION CONCENTRATION CONCENTRATION WK lt WON SS METAL ION OXYGEN CONCENTRATION CONCENTRATION CELL CELL LOW METAL ION LOW OXYGEN CONC
278. worthiness Directives A Safety related corrosion conditions transmitted by a Service Bulletin can be mandated by an Airworthiness Directive AD Airworthiness Directives can be found on the FAA website www faa gov Appendix A Development Of The Baseline Program A The Corrosion Prevention and Control Program Baseline Program 1 The function of the Corrosion Prevention and Control Program CPCP is to give the minimum procedures necessary to prevent and control corrosion so that continued airworthiness is not at risk The Principal Structural Elements PSE s are areas where the CPCP applies 2 CPCP Baseline Program consists of a Corrosion Program Inspection CPI and an inspection time Each inspection is to be done in an airplane zone D138 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 3 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES 1953 1962 SERVICE MANUAL B18031 110 wo WS 84 00 nee WS 84 00 510 210 610 310 330 340 FS 0 00 FS 95 00 110 740 211 en INTERIOR NOTE THE NUMBER IN THE INDICATES RIGHT SIDE OF AIRPLANE orioa Airplane Zones Figure 1 Sheet 1 D138 1 13 Temporary Revision Number 7 Dec 1 2011 2 30 00 4 Cessna Aircraft Company Feb 3 2003 CESSNA AIRCRAFT COMPANY MODEL 100 SERIES
279. y tasks give more information about each required inspection C Theright portion of each page gives space for the mechanic s and inspector s initials and remarks A copy of these pages can be used as a checklist when these inspections are completed 2 General Inspection Criteria A While each of the specified inspection tasks in this section are done more general inspections of the adjacent areas must be done while access is available These general inspections are used to find apparent conditions which can need more maintenance B Ifa component or system is changed after a required task has been completed then that specified task must be done again to make sure it is correct before the system or component is returned to service C Doa preflight inspection after these inspections are completed to make sure all the required items are correctly serviced Refer to the Approved Airplane Flight Manual TASK ZONE MECH INSP REMARKS For All Models this inspection is for mild moderate 721 722 corrosion environment Inspect main landing gear spring and attach fittings for rust or damage to finish Refer to Section 2A 14 06 Supplemental Inspection Document 32 13 01 for inspection procedure For All Models this interval is for mild moderate 210 corrosion environment Inspect the carry thru spar area door post bulkhead attach fittings and spar channel Refer to Section 2A 14 12 Supplemental Inspection Document 53 11 01 for inspection

1953 thru 1962 - Cessna Support

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