Cessna 172 Skyhawk SERIES Maintenance Manual Download

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CESSNA AIRCRAFT COMPANY

SINGLE ENGINE

STRUCTURAL REPAIR MANUAL

CONTENTS

STANDARD PRACTICES AND STRUCTURES - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . .

51-00-00 Page 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-00-00 Page 1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-00-00 Page 1

DAMAGE INVESTIGATION AND CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-10-00 Page 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-10-00 Page 1

Damage Investigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-10-00 Page 1

Damage Classi

cation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-10-00 Page 2

nishing Damaged Areas Following Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-10-00 Page 2

CORROSION AND CORROSION CONTROL - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . .

51-11-00 Page 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-11-00 Page 1

Types of Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-11-00 Page 1

Typical Corrosion Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-11-00 Page 3

Corrosion Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-11-00 Page 4

Corrosion Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-11-00 Page 4

Corrosion Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-11-00 Page 5

Control of Corrosion on Landing Gear Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-11-00 Page 7

REPAIR MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-30-00 Page 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-30-00 Page 1

Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-30-00 Page 1

Extrusions and Formed Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-30-00 Page 1

FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 1

Rivets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 1

Replacement Of Hi-Shear Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 1

Substitution Of Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 1

Rivet Diameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 2

Rivet Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 2

Solid Shank Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 2

Blind Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 7

Spacing Of Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 10

Threaded Fasteners Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 10

Rivets for Plastic or Composite Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-40-00 Page 10

FLIGHT CONTROL SURFACE BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-60-00 Page 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-60-00 Page 1

Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-60-00 Page 1

Procedures for Balancing Control Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-60-00 Page 1

Balancing De

nitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-60-00 Page 1

Control Surface Balance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-60-00 Page 7

REPAIRS - GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-70-00 Page 801

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-70-00 Page 801

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-70-00 Page 801

Preparation for Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-70-00 Page 801

RIVETED ALUMINUM STRUCTURE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-71-00 Page 801

Preparing Riveted Aluminum Structure For Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-71-00 Page 801

GLASS FABRIC REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-73-00 Page 801

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-73-00 Page 801

Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-73-00 Page 801

Repair Of Glass Fabric Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-73-00 Page 801

REPAIR OF THERMO-FORMED THERMO PLASTIC COMPONENTS . . . . . . . . . . . . . . .

51-73-01 Page 801

Thermo-formed Thermo Plastic Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-73-01 Page 801

Temporary Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51-73-01 Page 801

CONTENTS

Page 1 of 2

Jun 1/2005

Summary of Contents for 172 Skyhawk SERIES

Page 1: ...Maintenance Manual SINGLE ENGINE MODELS 172 182 T182 206 AND T206 1996 And On Member of GAMA COPYRIGHT 1996 CESSNA AIRCRAFT COMPANY WICHITA KANSAS USA 2 DECEMBER 1996 SESR04 REVISION 4 1 JUNE 2005 ...

Page 2: ...BJECT PAGE DATE 00 Title 00 List of Effective Pages 00 Record of Revisions 00 Record of Temporary Revisions 00 Table of Contents INTRODUCTION Pages 1 3 Jun 1 2005 LIST OF REVISIONS Page 1 Jun 1 2005 LIST OF CHAPTER Page 1 Jun 1 2005 00 LIST OF EFFECTIVE PAGES Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 3: ...Page Number DOCTYPE chapter toc PUBLIC Cessna D171G031 DTD MM Generic V1 0 EN chapter toc chapnbr model chapter toc DOCTYPE chapter lot PUBLIC Cessna D171G031 DTD MM Generic V1 0 EN chapter lot table tgroup cols 3 colspec colnum 1 colwidth 3 colspec colnum 2 colwidth 12 colspec colnum 3 colwidth 4 tbody tbody tgroup table chapter lot Page 01 ...

Page 4: ...CESSNA AIRCRAFT COMPANY MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed By ...

Page 5: ... INTRODUCTION Page 1 Aerofiche microfiche INTRODUCTION Page 1 Using the Structural Repair Manual or Aerofiche INTRODUCTION Page 2 Revision Manual INTRODUCTION Page 2 Identifying Revised Material INTRODUCTION Page 3 LIST OF REVISIONS LIST OF REVISIONS Page 1 General LIST OF REVISIONS Page 1 LIST OF CHAPTERS LIST OF CHAPTERS Page 1 CONTENTS Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 6: ...tion life limits cycle limits etc for such non Cessna parts must be obtained from the manufacturer and or seller of such non Cessna parts 2 Coverage A The Cessna Single Engine Structural Repair Manual is prepared in accordance with the Air Transport Association Specification 2200 for Manufacturers Technical Data B This Structural Repair Manual contains material identification for structure subject...

Page 7: ...2 The page number complies with Air Transport Association Specification 100 for subdividing a Structural Repair Manual Blocks of sequential page numbers are used to identify Pages 1 Through 100 Structural Identification Pages 101 Through 199 Allowable Damage Pages 201 through 999 Repair Procedures 3 The date which appears below the page number signifies when the page was issued If no revisions to ...

Page 8: ... three element number shall also display the same Date of Page Issue The date column on the corresponding chapter Effectivity Page shall verify the active page These pages will display the current revision date in the Date of Page Issue location C When extensive technical changes are made to text in an existing section that requires extensive revision revision bars will appear the full length of t...

Page 9: ...re that information in this manual is current and the latest maintenance and inspections procedures are available revisions must be incorporated in the manual as they are issued Table 1 Original Issue 2 December 1996 Revision Number Date Writer Revision Number Date Writer 1 16 May 1997 2 16 July 1999 3 15 January 2001 4 1 June 2005 jmk LIST OF REVISIONS Page 1 Cessna Aircraft Company Jun 1 2005 ...

Page 10: ...5 1 A10 52 Doors Jun 1 2005 1 D2 53 Fuselage Jun 1 2005 1 D8 55 Stabilizers Jun 1 2005 1 E7 56 Windows Jun 1 2005 1 E16 57 Wings Jun 1 2005 1 F2 71 Powerplant Jun 1 2005 1 H2 NOTE 1 Represents date of page one of each chapter s List of Effective Pages which is applicable to Manual revision date LIST OF CHAPTERS Page 1 Cessna Aircraft Company Jun 1 2005 ...

Page 11: ...CHAPTER STANDARD PRACTICES STRUCTURES ...

Page 12: ...1 Jun 1 2005 51 10 00 Pages 1 2 Jun 1 2005 51 11 00 Pages 1 8 Jun 1 2005 51 30 00 Pages 1 5 Jun 1 2005 51 40 00 Pages 1 12 Jun 1 2005 51 60 00 Pages 1 8 Jun 1 2005 51 70 00 Page 801 Jun 1 2005 51 71 00 Page 801 Jun 1 2005 51 73 00 Pages 801 802 Jun 1 2005 51 73 01 Page 801 Jun 1 2005 51 75 00 Pages 801 808 Jun 1 2005 51 76 00 Pages 801 803 Jun 1 2005 51 LIST OF EFFECTIVE PAGES Page 1 of 1 Cessna A...

Page 13: ...CESSNA AIRCRAFT COMPANY MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed By ...

Page 14: ...ge 1 Substitution Of Rivets 51 40 00 Page 1 Rivet Diameters 51 40 00 Page 2 Rivet Lengths 51 40 00 Page 2 Solid Shank Rivets 51 40 00 Page 2 Blind Rivets 51 40 00 Page 7 Spacing Of Rivets 51 40 00 Page 10 Threaded Fasteners Bolt Torques 51 40 00 Page 10 Rivets for Plastic or Composite Parts 51 40 00 Page 10 FLIGHT CONTROL SURFACE BALANCING 51 60 00 Page 1 General 51 60 00 Page 1 Tools and Equipmen...

Page 15: ...MANUAL TYPICAL SKIN REPAIRS 51 75 00 Page 801 General 51 75 00 Page 801 Guidelines for Corrugated Skin Crack Repairs 51 75 00 Page 801 CONTROL SURFACE REPAIR 51 76 00 Page 801 General 51 76 00 Page 801 CONTENTS Page 2 of 2 Cessna Aircraft Company Jun 1 2005 ...

Page 16: ...tal strut braced semimonocoque construction utilizing two spars Each wing consists of a wing panel with an integral fuel bay an aileron and a flap C The empennage group is of a fully cantilevered design and consists of a conventional rudder and elevator configuration The horizontal stabilizer is of one piece construction consisting of spars ribs and skins Elevators are constructed of spars ribs an...

Page 17: ...lts in a cross sectional area change due to scuffing rubbing scraping or other surface erosion It is usually rough and irregular 4 Gouge A gouge is a damaged area of any size which results in a cross sectional area change It is usually caused by contact with a relatively sharp object which produces a continuous sharp or smooth channel like groove in the material 5 Nick A nick is a local gouge with...

Page 18: ...o use in determining the extent and criticalness of any damage Obviously there will be some overlapping between categories and common sense should be used in determining the final action to be taken with regard to any damage 1 For damage criteria of specific structure wings fuselage and so forth refer to applicable chapters within this repair manual 4 Refinishing Damaged Areas Following Repairs A ...

Page 19: ...e plastic etc to the surface of the metal affected This will prevent the electrolyte from connecting the cathode to the anode and since current cannot flow it prevents corrosive reaction 4 At normal atmospheric temperatures metals do not corrode appreciably without moisture but the moisture in the air is usually enough to start corrosive action 5 When components and systems constructed of many dif...

Page 20: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Corrosion Identification Figure 1 Sheet 1 51 11 00 Page 2 Cessna Aircraft Company Jun 1 2005 ...

Page 21: ... gear shock struts with pipe thread type grease fittings clevis points and shrink fits F Corrosion Fatigue 1 This is a type of stress corrosion resulting from the cyclic stresses on a metal in corrosive surroundings Corrosion may start at the bottom of a shallow pit in the stressed area Once attack begins the continuous flexing prevents repair of protective surface coating or oxide films and addit...

Page 22: ...cases because the inspection area is obscured by structural members equipment installations or for other reasons it is awkward to check visually In such cases mirrors boroscopes or like devices must be used to inspect the obscured areas Any means which allows a thorough inspection can be used Magnifying glasses are valuable aids for determining whether or not all corrosion products have been remov...

Page 23: ... refer to Corrosion Damage Limits 3 Remove light corrosion by light hand sanding 4 Mechanically remove moderate or severe corrosion by hand scraping with a carbide tipped scraper or fine fluted rotary file 5 Remove residual corrosion by hand sanding Select appropriate abrasive from Figure 2 6 Blend into surrounding surface any depressions resulting from rework and surface finish with 400 grit abra...

Page 24: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Abrasives for Corrosion Removal Figure 2 Sheet 1 51 11 00 Page 6 Cessna Aircraft Company Jun 1 2005 ...

Page 25: ... to hydrogen embrittlement Acidic solutions such as rust removers and paint strippers have been found to cause hydrogen embrittlement Hydrogen embrittlement is an undetectable time delayed process Since the process is time delayed failure may occur after the part is returned to service The only reliable way to prevent hydrogen embrittlement is not to use chemical rust removers or paint strippers o...

Page 26: ...ration on skis causes more loads the criteria applies to all airplanes 2 There is no acceptable damage depth for pits that develop in the axle bolt holes If pits or corrosion is found it must be removed by reaming subject to the following limitations a Remove the minimum material required to clean up the damage b Make sure the diameter of the axle attachment holes is 0 383 inches maximum for 3 8 i...

Page 27: ... original part It is often practical to cut repair pieces from service parts listed in the parts catalog Steel sheet material for reinforcement is 4130 steel heat treated to a minimum of 90 000 pounds per square inch The firewall is annealed stainless steel sheet 3 Extrusions and Formed Sections A Refer to Figure 1 This section provides information on extrusions and formed sections It also provide...

Page 28: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Extrusions and Formed Sections Figure 1 Sheet 1 51 30 00 Page 2 Cessna Aircraft Company Jun 1 2005 ...

Page 29: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Extrusions and Formed Sections Figure 1 Sheet 2 51 30 00 Page 3 Cessna Aircraft Company Jun 1 2005 ...

Page 30: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Extrusions and Formed Sections Figure 1 Sheet 3 51 30 00 Page 4 Cessna Aircraft Company Jun 1 2005 ...

Page 31: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Extrusions and Formed Sections Figure 1 Sheet 4 51 30 00 Page 5 Cessna Aircraft Company Jun 1 2005 ...

Page 32: ...ners of equivalent strength properties is permissible 1 The hardware used for the Hi Shear rivets is determined according to the size of the holes and the grip lengths required 2 Bolt grip length should be chosen so that no threads remain in the bearing area 3 Holes must not be elongated and the Hi Shear substituted must be a smooth push fit B Field replacement of main landing gear forgings on bul...

Page 33: ... care should be exercised before substituting other than the specified sizes of rivet diameter 6 Rivet Lengths A Proper length of rivets is an important part of a repair Should too long a rivet be used the formed head will be too large or the rivet may bend or be forced between the sheets being riveted Should too short a rivet be used the formed head will be too small or the riveted material will ...

Page 34: ...ribed except that no filing of the manufactured head is required before center punching Be very careful to avoid elongation of the dimpled or the countersunk holes The rivet head should be drilled to approximately one half the thickness of the top sheet Table 1 Approved Replacement Fasteners Chart REPLACE Inch thickness or thicker WITH MS20470AD3 0 025 NAS1398B4 NAS1398D4 0 020 NAS1738B4 NAS1738D4...

Page 35: ... HL18 HL70 HL82 Refer to Notes 1 4 NAS1054 NAS179 NAS528 Refer to Notes 1 4 NAS14XX NAS1080C NAS1080E NAS1080G NAS1080AG Refer to Notes 1 3 4 NAS529 NAS528 NAS179 Refer to Notes 1 2 5 NAS1146 NAS1080C NAS1080E NAS1080G NAS1080AG Refer to Notes 1 5 NAS7034 NAS1080K Refer to Notes 1 6 NAS464 MIL S 7742 Refer to Notes 1 6 NAS1103 NAS1116 MIL S 7742 Refer to Notes 1 6 NAS1303 NAS1316 MIL S 7742 Refer ...

Page 36: ...these steel nuts AN365 MS20365 MS17825 MS21044 MS21045 MS51943 or NAS1079 Approval of the use of these nuts in this application does not constitute a general approval to use these nut on high strength bolts NOTE 9 GENERAL NOTE These fastener substitutions address shear strength and hole tolerances only The specific application may not allow all of these substitutions because of space consideration...

Page 37: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Rivet Removal and Rivet Edge Distance Figure 1 Sheet 1 51 40 00 Page 6 Cessna Aircraft Company Jun 1 2005 ...

Page 38: ...nk for less than 30 percent of the circumference of the rivet head it shall not be classified as a loose rivet The feeler gauge shall be used to check the shear section between the riveted members such as skin to spar or different sections of skins in a similar manner to that used around the rivet head If the skin around the brazier head or countersunk rivet can be moved by depressing the skin wit...

Page 39: ...ert a stiff wire in adjacent hole to hold metal in position while pulling rivet 9 When placing pulling head on rivet stem hold riveter and pulling head in line with axis of rivet while holding tool in a light and flexible manner 10 When tool is actuated pulling head will pull down and seat against rivet head 11 Clamping action will pull sheets together and seat rivet when tool is actuated 12 When ...

Page 40: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Installation of Blind Rivets Figure 2 Sheet 1 51 40 00 Page 9 Cessna Aircraft Company Jun 1 2005 ...

Page 41: ...necessary wear of nuts and bolts as well as parts they are holding together When insufficient pressures are applied uneven loads will be transmitted throughout assembly which may result in excessive wear or premature failure due to fatigue Over torque can be equally damaging because of failure of a bolt or nut from overstressing threaded areas There are a few simple but very important procedures t...

Page 42: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Red Lining of Fasteners Figure 3 Sheet 1 51 40 00 Page 11 Cessna Aircraft Company Jun 1 2005 ...

Page 43: ...the specified installation hole for the fastener If the tail end of the rivet is installed through metal substructure the washer is not necessary Take care when driving rivets through non metal to not overdrive the rivet If the rivet is overdriven the shank will swell even with the washer in place The rivet butt should be driven to no more than necessary to retain the part never more than 1 4 time...

Page 44: ... required at end opposite the trailing edge support 6 When positioning balancing beam on control surface avoid rivets to provide a smooth surface for the beam and keep the beam 90 degrees to the hinge line of control surface 7 Paint is a considerable weight factor In order to keep balance weight to a minimum it is recommended that existing paint be removed before adding paint to a control surface ...

Page 45: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Flight Control Surface Balancing Fixture Kit Figure 1 Sheet 1 51 60 00 Page 2 Cessna Aircraft Company Jun 1 2005 ...

Page 46: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Balancing Control Surfaces Figure 2 Sheet 1 51 60 00 Page 3 Cessna Aircraft Company Jun 1 2005 ...

Page 47: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Balancing Control Surfaces Figure 2 Sheet 2 51 60 00 Page 4 Cessna Aircraft Company Jun 1 2005 ...

Page 48: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Balancing Control Surfaces Figure 2 Sheet 3 51 60 00 Page 5 Cessna Aircraft Company Jun 1 2005 ...

Page 49: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Balancing Control Surfaces Figure 2 Sheet 4 51 60 00 Page 6 Cessna Aircraft Company Jun 1 2005 ...

Page 50: ...ce Requirements NOTE Approved Flight must never be exceeded when the surface is in its final configuration for flight A Refer to Tables 1 2 and 3 for balance limits of the various airplane control surfaces These approved flight limits must take into account all items which may be attached and or applied to the various control surfaces static wicks trim tabs paint decorative trim stripes and so for...

Page 51: ...N INCH LBS AILERON 0 0 TO 9 64 RUDDER 0 0 TO 6 0 LEFT ELEVATOR 0 0 TO 20 47 RIGHT ELEVATOR 0 0 TO 20 47 Table 3 Model 206 Static Balance Limits CONTROL SURFACE STATIC BALANCE LIMITS APPROVED FOR FLIGHT CONFIGURATION INCH LBS AILERON 0 0 TO 3 0 RUDDER Landplane 4 0 TO 3 0 LEFT ELEVATOR 0 0 TO 12 1 RIGHT ELEVATOR 0 0 TO 12 1 51 60 00 Page 8 Cessna Aircraft Company Jun 1 2005 ...

Page 52: ... and will include only those parts or members necessary to show the typical situation 2 Usage A Typical repairs may be accomplished individually or combined with other repairs for a major repair Technique and material variation is permissible only so far as to facilitate fabrication and ensure the original strength and usefulness of the affected component 3 Preparation for Repair A The airplane sh...

Page 53: ...ed area parallel to any square or rectangular edges of the unit 4 Round all corners 5 Smooth out abrasions and dents 6 Deburr all edges of repair and ensure that no nicks or scratches remain 7 Brush all aluminum parts having rough edges with a solution of Iridite or alodine mixed in a ratio of one ounce of Iridite or alodine to one gallon of water and rinse thoroughly 8 To restore original paint a...

Page 54: ...t least 1 1 2 inches larger in diameter than the cut out section 2 Prepare necessary size and number of patches of glass fabric style No 181 WARNING Always follow manufacturer s mixing instructions carefully to ensure proper cure and prevent a spontaneous fire 3 Mix sufficient amount of resin in accordance with manufacturers instructions 4 Ensure that hands are free from oil grease and dirt and ap...

Page 55: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Glass Fiber Panel Repair Figure 801 Sheet 1 51 73 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 56: ... may be reinforced with a doubler on the back side for additional strength After the repair has been made the area may be sanded smooth and painted Parts that are extensively damaged should be replaced instead of repaired 2 Temporary Repairs A Crack Repair 1 It is permissible to stop drill crack s that originate at the edge of a fairing if the crack is less than 2 inches 50 mm in length a Stop dri...

Page 57: ... without additional repair 7 Refer to Figure 802 as applicable for repair information B Corrugated Flap Skin Repair 1 It is permissible to stop drill crack s that originate at the trailing edge of the control surface provided the crack s is are not more than 2 inches in length 2 Stop dill crack s using a Number 30 0 128 inch diameter drill 3 A crack may only be stop dilled once NOTE A crack that p...

Page 58: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Skin Repair Figure 801 Sheet 1 51 75 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 59: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Skin Repair Figure 801 Sheet 2 51 75 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 60: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Skin Repair Figure 801 Sheet 3 51 75 00 Page 804 Cessna Aircraft Company Jun 1 2005 ...

Page 61: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Skin Repair Figure 801 Sheet 4 51 75 00 Page 805 Cessna Aircraft Company Jun 1 2005 ...

Page 62: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Skin Repair Figure 801 Sheet 5 51 75 00 Page 806 Cessna Aircraft Company Jun 1 2005 ...

Page 63: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Corrugated Skin Repair Figure 802 Sheet 1 51 75 00 Page 807 Cessna Aircraft Company Jun 1 2005 ...

Page 64: ...al a A crack that is longer than 2 inches b A crack that does not originate from the trailing edge or a trailing edge rivet c Cracks in more than six trailing edge rivet locations per skin 6 Affected control surfaces with corrugated skins and having a stop drilled crack that does not extend past the stop drilled hole may remain in service without additional repair 7 Refer to Figure 802 as applicab...

Page 65: ...age which would involve a control surface repair After the repair is completed the control surface balance must be checked as described in Flight Control Surface Balancing Refer to Figures 801 and 802 which illustrate typical control surface repairs 51 76 00 Page 801 Cessna Aircraft Company Jun 1 2005 ...

Page 66: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Control Surface Rib Repair Figure 801 Sheet 1 51 76 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 67: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Control Surface Trailing Edge Repair Figure 802 Sheet 1 51 76 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 68: ...CHAPTER 52 DOORS ...

Page 69: ...F EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 52 Title 52 List of Effective Pages 52 Record of Temporary Revisions 52 Table of Contents 52 00 00 Page 1 Jun 1 2005 52 10 00 Page 101 Jun 1 2005 52 LIST OF EFFECTIVE PAGES Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 70: ...CESSNA AIRCRAFT COMPANY MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed By ...

Page 71: ... ENGINE STRUCTURAL REPAIR MANUAL CONTENTS DOORS GENERAL 52 00 00 Page 1 General 52 00 00 Page 1 DOOR DAMAGE CLASSIFICATION 52 10 00 Page 101 Repairable Damage 52 10 00 Page 101 CONTENTS Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 72: ...escribes general repair practices materials and procedures which are applicable to the doors and door structure B If questions arise concerning approved repairs or for repairs not shown in this section contact Cessna Propeller Aircraft Product Support 52 00 00 Page 1 Cessna Aircraft Company Jun 1 2005 ...

Page 73: ...used for riveted structure Rivets are a satisfactory substitute for bonded seams on these assemblies The strength of the bonded seams in doors may be replaced by a single 3 32 2117 AD rivet per running inch of bond seam The standard repair procedures outlined in AC43 13 1b are also applicable to bonded doors 52 10 00 Page 101 Cessna Aircraft Company Jun 1 2005 ...

Page 74: ...CHAPTER 53 FUSELAGE ...

Page 75: ...3 Title 53 List of Effective Pages 53 Record of Temporary Revisions 53 Table of Contents 53 00 00 Pages 1 3 Jun 1 2005 53 10 00 Pages 1 2 Jun 1 2005 53 20 00 Pages 801 805 Jun 1 2005 53 30 00 Pages 801 806 Jun 1 2005 53 40 00 Pages 801 803 Jun 1 2005 53 LIST OF EFFECTIVE PAGES Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 76: ...CESSNA AIRCRAFT COMPANY MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed By ...

Page 77: ... 53 10 00 Page 2 CABIN BULKHEAD REPAIR 53 20 00 Page 801 General 53 20 00 Page 801 Repair of Webs or Flanges 53 20 00 Page 801 Repair of Channels 53 20 00 Page 801 Landing Gear Bulkheads 53 20 00 Page 801 Repair After Hard Landing 53 20 00 Page 801 STRINGER AND CHANNEL REPAIR 53 30 00 Page 801 General 53 30 00 Page 801 FIREWALL REPAIR 53 40 00 Page 801 General 53 40 00 Page 801 Material 53 40 00 P...

Page 78: ...ions of fuselage stations B For repairs beyond the scope of this chapter refer to Chapter 51 Typical Skin Repairs 2 Fuselage A The fuselage is of semimonocoque construction and consists of formed bulkheads longitudinal stringers reinforcing channels and skin panels B If questions arise concerning approved repairs or for repairs not shown in this section contact Cessna Propeller Aircraft Product Su...

Page 79: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Fuselage Stations Figure 1 Sheet 1 53 00 00 Page 2 Cessna Aircraft Company Jun 1 2005 ...

Page 80: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Fuselage Stations Figure 1 Sheet 2 53 00 00 Page 3 Cessna Aircraft Company Jun 1 2005 ...

Page 81: ... the stringer will usually restore the original strength characteristics of the area NOTE Wrinkles occurring in the skin of the main landing gear bulkhead areas must not be considered negligible The skin panel must be opened sufficiently to permit a thorough examination of the lower portion of the landing gear bulkhead and its tie in structure D Wrinkles occurring in open areas which disappear whe...

Page 82: ...of any material and structural parts made of steel must be replaced if damaged Structural members of a complicated nature that have been distorted or wrenched should be replaced Seat rails serve as structural parts of the fuselage and must be replaced if damaged 53 10 00 Page 2 Cessna Aircraft Company Jun 1 2005 ...

Page 83: ...ng procedures are for the repair of severely bent kinked or torn channels 1 If practical severely bent kinked or torn portions of bulkheads should be removed and replacement sections installed and joined at the original splice joint 2 If the procedure outlined in the preceding step is not justified cutting away the damaged portion and inserting a trimmed portion of the original section adequately ...

Page 84: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Cabin Bulkhead Repair Figure 801 Sheet 1 53 20 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 85: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Cabin Bulkhead Repair Figure 801 Sheet 2 53 20 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 86: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Cabin Bulkhead Repair Figure 801 Sheet 3 53 20 00 Page 804 Cessna Aircraft Company Jun 1 2005 ...

Page 87: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Rib Repair Figure 802 Sheet 1 53 20 00 Page 805 Cessna Aircraft Company Jun 1 2005 ...

Page 88: ...URAL REPAIR MANUAL STRINGER AND CHANNEL REPAIR 1 General A Damage to the stringers or channels can be repairable Refer to Figure 801 for an illustration of typical stringer and channel repairs 53 30 00 Page 801 Cessna Aircraft Company Jun 1 2005 ...

Page 89: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Stringer and Channel Repair Figure 801 Sheet 1 53 30 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 90: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Stringer and Channel Repair Figure 801 Sheet 2 53 30 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 91: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Stringer and Channel Repair Figure 801 Sheet 3 53 30 00 Page 804 Cessna Aircraft Company Jun 1 2005 ...

Page 92: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Stringer and Channel Repair Figure 801 Sheet 4 53 30 00 Page 805 Cessna Aircraft Company Jun 1 2005 ...

Page 93: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Stringer and Channel Repair Figure 801 Sheet 5 53 30 00 Page 806 Cessna Aircraft Company Jun 1 2005 ...

Page 94: ...ired using MS20450 steel rivets B Following any repair to the firewall assembly seal the damaged areas as follows 1 Clean area on surface to be sealed with methyl propyl ketone 2 Mix one part of catalyst thoroughly with 100 parts of Pro Seal No 700 base NOTE Sealant should be mixed by weight It is important that accelerator be completely and uniformly dispersed throughout the base compound 3 Using...

Page 95: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Firewall Repair Figure 801 Sheet 1 53 40 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 96: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Firewall Angle Repair Figure 802 Sheet 1 53 40 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 97: ...CHAPTER 55 STABILIZERS ...

Page 98: ...GE DATE 55 Title 55 List of Effective Pages 55 Record of Temporary Revisions 55 Table of Contents 55 00 00 Page 1 Jun 1 2005 55 10 00 Page 801 Jun 1 2005 55 20 00 Page 801 Jun 1 2005 55 30 00 Page 801 Jun 1 2005 55 40 00 Page 801 Jun 1 2005 55 LIST OF EFFECTIVE PAGES Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 99: ...CESSNA AIRCRAFT COMPANY MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed By ...

Page 100: ...eral 55 20 00 Page 801 Negligible Damage 55 20 00 Page 801 Repairable Damage 55 20 00 Page 801 Replacement Damage 55 20 00 Page 801 VERTICAL STABILIZER 55 30 00 Page 801 General 55 30 00 Page 801 Vertical Stabilizer and Dorsal 55 30 00 Page 801 Negligible Damage 55 30 00 Page 801 Repairable Damage 55 30 00 Page 801 Replacement Damage 55 30 00 Page 801 RUDDER 55 40 00 Page 801 Rudder 55 40 00 Page ...

Page 101: ...rtical Stabilizers B The horizontal and vertical stabilizers are of all metal fully cantilever semimonocoque design consisting of spars stringers ribs and skins Skins are riveted to supporting structure with conventional MS20470AD rivets C If questions arise concerning approved repairs or for repairs not shown in this section contact Cessna Propeller Aircraft Product Support 55 00 00 Page 1 Cessna...

Page 102: ... are illustrated in Chapter 51 Typical Skin Repairs Figure 801 For skin damage which includes corrugations Refer to Chapter 51 Typical Skin Repairs Figure 802 B Access to the internal stabilizer structure may be gained by removing a portion of the rivets along the rear spar and ribs and springing back the skin By using the proper bucking bars through holes in spar web skins may by closed with a mi...

Page 103: ...cracks appearing in web of hinge fitting or in tip rib which supports overhanging balance weight Cracks in overhanging tip rib in the area at the front spar intersection with web of the rib also cannot be considered negligible 3 Repairable Damage A Skin patches may be used to repair skin damage These patches are illustrated in Chapter 51 Typical Skin Repairs Figure 801 For skin damage which includ...

Page 104: ...re is best gained by removing skin attaching rivets on one side of the rear spar and ribs and springing back the skin Access to the stabilizer may be gained by removing skin attaching rivets on one side and springing back the skin If the damaged area would require a repair which could not be made between adjacent ribs or a repair would be located in an area with compound curves replacement of part...

Page 105: ...ng that considered negligible damage can be repaired by patching Typical repairs are illustrated in Chapter 51 Typical Skin Repair and Control Surface Repair B A flight control surface which has been repaired or replaced must be balanced in accordance with the procedures outlined in Chapter 51 Flight Control Surface Balancing 4 Replacement Damage A Assemblies that have been twisted or warped beyon...

Page 106: ...CHAPTER 56 WINDOWS ...

Page 107: ...FFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 56 Title 56 List of Effective Pages 56 Record of Temporary Revisions 56 Table of Contents 56 00 00 Page 1 Jun 1 2005 56 10 00 Pages 801 804 Jun 1 2005 56 LIST OF EFFECTIVE PAGES Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 108: ...CESSNA AIRCRAFT COMPANY MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed By ...

Page 109: ...URFACE REPAIR 56 10 00 Page 801 Repair of Plastic Window Surfaces 56 10 00 Page 801 Tools and Materials 56 10 00 Page 801 Stop Drilling 56 10 00 Page 801 Surface Patch 56 10 00 Page 801 Insert Plug Patch 56 10 00 Page 801 Minor Scratches 56 10 00 Page 804 Cleaning Plastic 56 10 00 Page 804 CONTENTS Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 110: ...ion applicable to windshields and windows used on the 1996 and On single engine airplanes These repairs may be utilized without removing components from the airplane B For windshield window removal or replacement refer to the various model Maintenance Manuals Chapter 56 Windows 56 00 00 Page 1 Cessna Aircraft Company Jun 1 2005 ...

Page 111: ...cedure should be used when stop drilling 1 When a crack appears in a panel drill a hole at the end of the crack to prevent further spreading The hole should be approximately 1 8 inch in diameter depending on the length of the crack and the thickness of the material This is a temporary repair NOTE If temporary repairs are made operations should be kept to a minimum until replacement of window or wi...

Page 112: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Windshield and Windows Repair Figure 801 Sheet 1 56 10 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 113: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Windshield and Windows Repair Figure 801 Sheet 2 56 10 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 114: ...hes A The following procedure should be used when repairing minor scratches 1 Remove minor scratches by vigorously rubbing the affected area by hand using a soft clean cloth dampened with Novus 2 plastic polish and finish by polishing with Novus 1 Remove polish with a soft dry cloth NOTE Plastics should not be rubbed with a dry cloth since this is likely to cause scratches and also builds up an el...

Page 115: ...CHAPTER 57 WINGS ...

Page 116: ...05 57 11 00 Pages 801 802 Jun 1 2005 57 12 00 Pages 801 803 Jun 1 2005 57 20 00 Pages 801 803 Jun 1 2005 57 21 00 Pages 801 805 Jun 1 2005 57 22 00 Pages 601 606 Jun 1 2005 57 23 00 Page 801 Jun 1 2005 57 24 00 Pages 801 802 Jun 1 2005 57 25 00 Pages 801 802 Jun 1 2005 57 26 00 Pages 801 802 Jun 1 2005 57 27 00 Pages 801 802 Jun 1 2005 57 40 00 Page 801 Jun 1 2005 57 50 00 Page 801 Jun 1 2005 57 L...

Page 117: ...CESSNA AIRCRAFT COMPANY MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed By ...

Page 118: ...for Repair 57 11 00 Page 801 FUEL BAY SEALING DURING STRUCTURAL REPAIR 57 12 00 Page 801 General 57 12 00 Page 801 Integral Fuel Bay Sealant 57 12 00 Page 801 Mixing Sealant 57 12 00 Page 801 Applying Sealant 57 12 00 Page 801 Sealing Fuel Leaks 57 12 00 Page 802 Curing Time 57 12 00 Page 802 Testing Integral Fuel Bay 57 12 00 Page 802 WING RIB 57 20 00 Page 801 General 57 20 00 Page 801 Wing Rib ...

Page 119: ...ge Damage Classification 57 26 00 Page 801 Bonded Leading Edge Repair 57 26 00 Page 801 FLAP LEADING EDGE REPAIR 57 27 00 Page 801 Flap Leading Edge Damage Classification 57 27 00 Page 801 Flap Repairs 57 27 00 Page 801 FLAPS AND AILERONS 57 40 00 Page 801 General 57 40 00 Page 801 Damage Criteria 57 40 00 Page 801 Flap and Aileron Repair 57 40 00 Page 801 WING LIFT STRUTS 57 50 00 Page 801 Genera...

Page 120: ...eller Aircraft Product Support Box 7706 Wichita KS 67277 316 517 5800 Facsimile 316 942 9006 2 Tools Equipment and Materials A Refer to Figure 1 for an illustration of wing and fuselage support stands which may by fabricated locally and used during structural repair 3 Installation of Access Holes NOTE In some instances it may be advantageous to create access holes in the wing skin to facilitate wi...

Page 121: ...NE STRUCTURAL REPAIR MANUAL 3 Cut out access hole using dimension shown 4 Flex doubler and insert through access hole and rivet in place 5 Position cover and secure using screws as shown 57 00 00 Page 2 Cessna Aircraft Company Jun 1 2005 ...

Page 122: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Wing and Fuselage Support Stands Figure 1 Sheet 1 57 00 00 Page 3 Cessna Aircraft Company Jun 1 2005 ...

Page 123: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Access Hole Installation Figure 2 Sheet 1 57 00 00 Page 4 Cessna Aircraft Company Jun 1 2005 ...

Page 124: ...must be made to lie along structural members and each seam must be made exactly the same in regard to rivet size spacing and pattern as the manufactured seams at the edges of the original sheet If the manufactured seams are different the stronger must be copied If the repair ends at a structural member where no seam is used enough repair panel must be used to allow an extra row of staggered rivets...

Page 125: ...the structure Since aluminum work hardens it is much more likely to crack when reformed and should be carefully inspected for such cracks after rework Removal and replacement of a damaged section is preferred to reformation C Damage Necessitating Replacement Of Parts Due to the amount of fuel bay sealant which must be removed from fuel bay components to facilitate repair individual parts are not a...

Page 126: ...f the original material thickness 11 Aileron Damage Criteria Corrugated Skin Aileron A Negligible damage Any smooth dents in the aileron skin that are not more than 0 050 inch 1 27 mm below contour and circumscribable with not more than a 1 5 inch 38 1 mm diameter circle that have no evidence of skin tears cracks or skin penetrations and which do not include a corrugation constitute negligible dam...

Page 127: ...f parts should be made based on the feasibility of repair verses complete replacement of the skin 14 Wing Flap Damage Criteria Model 206 Flap A Negligible damage Any smooth dents in the flap skin that are not more than 0 030 inch 0 76 mm below contour and circumscribable with not more than a 1 5 inch 38 1 mm diameter circle that have no evidence of skin tears cracks or skin penetrations and which ...

Page 128: ...as much fuel as possible through filler opening 6 Remove drain valves from bottom side of fuel bay and drain remaining fuel into a clean open container Use defueling nozzle to remove fuel from container 7 If necessary repeat procedures for opposite wing WARNING Purge fuel bays with an inert gas argon or carbon dioxide prior to repairing fuel leaks to preclude possibility of explosions 8 Insert ine...

Page 129: ... remove all chips filings dirt etc from bay area 17 All surfaces to be sealed after repair should be thoroughly cleaned by wiping with a clean cloth dampened with methyl propyl ketone MPK acetone or similar solvent and dried with a clean cloth before allowing solvent to evaporate Always pour the solvent on the cloth to prevent contaminating solvent Do not allow cloth to drip Never use contaminated...

Page 130: ...ss B 2 and Type VIII Class B 2 access sealants with Cessna Parts Distribution contains Type I Class B 1 2 and Type VIII Class B 12 access sealants with the proper quantity of accelerator for each sealant WARNING The accelerators contain heavy metal peroxides Keep them away from heat and flame Use only in well ventilated areas Avoid skin and eye contact Wear eye shields In case of eye contact flush...

Page 131: ...F 25 C and 50 percent relative humidity B Class B 1 2 sealant has a maximum tack free time of 10 hours and a maximum cure time of 30 hours These values are based on a standard condition of 77 F 25 C and 50 percent relative humidity C The cure of sealants can be accelerated by an increase in temperature and or relative humidity Warm circulating air at a temperature not to exceed 140 F 60 C may be u...

Page 132: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL 10 Reseal and retest if any leaks are found 57 12 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 133: ...each successive rib bay The nose center and trailing rib segments are riveted together through the front and rear spars to form the basic airfoil section Spanwise Alclad stringers stiffen the skin between ribs 2 Wing Rib Damage Classification A Damage to the wing rib can be divided into three major categories and is detailed in Wing Damage Classification 3 Wing Rib Repair A Repairs to the wing rib...

Page 134: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Rib Repair Figure 801 Sheet 1 57 20 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 135: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Rib Repair Figure 801 Sheet 2 57 20 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 136: ...ar spars are of riveted construction 2 Damage Classification A Damage to the wing spar can be divided into three major categories and is detailed in Wing Damage Classification 3 Spar Repair A Repairs to the wing spar are illustrated in Figure 801 57 21 00 Page 801 Cessna Aircraft Company Jun 1 2005 ...

Page 137: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Wing Spar Repair Figure 801 Sheet 1 57 21 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 138: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Wing Spar Repair Figure 801 Sheet 2 57 21 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 139: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Wing Spar Repair Figure 801 Sheet 3 57 21 00 Page 804 Cessna Aircraft Company Jun 1 2005 ...

Page 140: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Wing Spar Repair Figure 801 Sheet 4 57 21 00 Page 805 Cessna Aircraft Company Jun 1 2005 ...

Page 141: ...ith a felt tip pen approximately 0 50 inch aft of lateral row of rivets in wing leading edge spar flange B Measure Wing Twist at Each Wing Station Refer to Figure 601 NOTE While performing the following procedure stay as far away as possible from the canned areas of the wing 1 At WS 39 00 a Grind bolt A to a dimension of 2 00 inches Grind bolt B to a dimension of 1 00 inch Place these bolts 29 50 ...

Page 142: ...om straightedge Grind another bolt A to a dimension of 0 45 inch Place this bolt 24 00 inches from bolt B and secure to straightedge b Hold straightedge parallel to wing station and place bolt A on mark c Check to assure that protractor bubble is still centered If proper twist is present the protractor readings will be the same parallel NOTE Forward or aft bolt may be lowered from wing 0 10 inch m...

Page 143: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Measuring Model 172 Series Wing Twist Figure 601 Sheet 1 57 22 00 Page 603 Cessna Aircraft Company Jun 1 2005 ...

Page 144: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Measuring Model 182 Series Wing Twist Figure 602 Sheet 1 57 22 00 Page 604 Cessna Aircraft Company Jun 1 2005 ...

Page 145: ...rom straightedge Grind another bolt A to a dimension of 0 66 inch Place this bolt 20 00 inches from bolt B and secure to straightedge b Hold straightedge parallel to wing station and place bolt A on mark c Check to assure that protractor bubble is still centered If proper twist is present the protractor readings will be the same parallel NOTE Forward or aft bolt may be lowered from wing 0 10 inch ...

Page 146: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Measuring Model 206 T206 Series Wing Twist Figure 603 Sheet 1 57 22 00 Page 606 Cessna Aircraft Company Jun 1 2005 ...

Page 147: ...he wing stringers can be divided into three major categories and is detailed in Wing Damage Classification 2 Stringer Repair A Repairs to wing stringer are similar to repairs to fuselage stringers Refer to Chapter 52 Stringer and Channel Repair Figure 801 for repair illustrations 57 23 00 Page 801 Cessna Aircraft Company Jun 1 2005 ...

Page 148: ...mately WS 100 50 to 208 00 The auxiliary spar is attached to upper skins lower skins and other wing structure using rivets 2 Auxiliary Spar Damage A Damage to the auxiliary spar can be divided into three major categories and is detailed in Wing Damage Classification 3 Auxiliary Spar Repair A Repairs to the auxiliary spar are illustrated in Figure 801 57 24 00 Page 801 Cessna Aircraft Company Jun 1...

Page 149: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Auxiliary Spar Repair Figure 801 Sheet 1 57 24 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 150: ...e to lading edge repairs 1 Dimple leading edge skin and filler material counter sink the doubler 2 Use MS20426AD4 rivets to install filler except where bucking is impossible Use blind rivets where regular rivets cannot be bucked 3 Contour must be maintained After repair has been completed use epoxy filler as necessary and sand smooth before painting 4 Vertical size of patch is limited by ability t...

Page 151: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Leading Edge Repair Figure 801 Sheet 1 57 25 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 152: ...airplanes The following repairs apply to these airplanes only 2 Bonded Leading Edge Damage Classification A Damage to the bonded leading edge can be divided into three major categories and is detailed in Wing Damage Classification 3 Bonded Leading Edge Repair A Repairs to the bonded leading edge are illustrated in Figure 801 57 26 00 Page 801 Cessna Aircraft Company Jun 1 2005 ...

Page 153: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Bonded Leading Edge Repair Figure 801 Sheet 1 57 26 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 154: ...mage to the wing flap can be divided into three major categories and is detailed in Wing Damage Classification 2 Flap Repairs A Repairs to the flap leading edge are illustrated in Figure 801 Repairs to the corrugated skin are illustrated in Chapter 51 Typical Skin Repairs Figure 802 57 27 00 Page 801 Cessna Aircraft Company Jun 1 2005 ...

Page 155: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Flap Leading Edge Repair Figure 801 Sheet 1 57 27 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 156: ...amage to the flaps and ailerons can be divided into three major categories and is detailed in Wing Damage Classification 3 Flap and Aileron Repair A Skin damage exceeding that considered negligible that can be repaired with minor patches can be considered repairable Flush skin patches are illustrated in Chapter 51 Typical Skin Repairs Figure 801 A typical rib repair is illustrated in Chapter 51 Co...

Page 157: ...be stock formed into an aerodynamic shape Attach fittings are machined from 7075 T73 bar stock and attached to the strut tubes 2 Wing Strut Damage Classification A Damage to the wing lift strut can be divided into three major categories and is detailed in Wing Damage Classification 57 50 00 Page 801 Cessna Aircraft Company Jun 1 2005 ...

Page 158: ...CHAPTER 71 POWER PLANT ...

Page 159: ... CHAPTER SECTION SUBJECT PAGE DATE 71 Title 71 List of Effective Pages 71 Record of Temporary Revisions 71 Table of Contents 71 00 00 Page 1 Jun 1 2005 71 10 00 Page 801 Jun 1 2005 71 20 00 Pages 801 804 Jun 1 2005 71 LIST OF EFFECTIVE PAGES Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 160: ...CESSNA AIRCRAFT COMPANY MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed By ...

Page 161: ...ENGINE COWLING REPAIRS 71 10 00 Page 801 General 71 10 00 Page 801 Repair of Cowling Skins 71 10 00 Page 801 Repair of Reinforcement Angles 71 10 00 Page 801 DYNAFOCAL TYPE ENGINE MOUNT REPAIRS 71 20 00 Page 801 General 71 20 00 Page 801 Engine Mount Repairs 71 20 00 Page 801 CONTENTS Page 1 of 1 Cessna Aircraft Company Jun 1 2005 ...

Page 162: ...82T and T182T or by sheet metal bed mounts 206H and T206H B This chapter covers structural repair to the cowlings 172R 172S 182S 182T and T182T and structural repair to the welded engine mounts 172R 172S 182S 182T and T182T For repair information not covered in this manual contact Cessna Propeller Aircraft Product Support P O Box 7706 Wichita KS 67277 Telephone 316 517 5800 or Facsimile 316 942 90...

Page 163: ...maged complete sections of cowling must be replaced Standard insert type skin patches however may be used if repair parts are formed to fit Small cracks may be stop drilled and dents straightened if they are reinforced on the inner side with a doubler of the same material 3 Repair of Reinforcement Angles A Due to their small size cowl reinforcement angles should be replaced rather than repaired if...

Page 164: ...present and cause fatigue cracks Engine mount members are preferably repaired by using larger diameter replacement tube welds However reinforced 30 degree scarf welds in place of the fishmouth welds are considered satisfactory for engine mount repair work 2 Minor damage such as a crack adjacent to an engine attaching lug may be repaired by rewelding the tube and extending a gusset past the damaged...

Page 165: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Engine Mount Repairs Figure 801 Sheet 1 71 20 00 Page 802 Cessna Aircraft Company Jun 1 2005 ...

Page 166: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Engine Mount Repairs Figure 801 Sheet 2 71 20 00 Page 803 Cessna Aircraft Company Jun 1 2005 ...

Page 167: ...CESSNA AIRCRAFT COMPANY SINGLE ENGINE STRUCTURAL REPAIR MANUAL Typical Engine Mount Repairs Figure 801 Sheet 3 71 20 00 Page 804 Cessna Aircraft Company Jun 1 2005 ...

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