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1966 thru 1984 - Cessna Support

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1. FS 143 00 FS 0 00 110 AN Es M IIND iS Be 211 o INTERIOR 730 740 NOTE The number in the indicates right side of airplane 1600002 Airplane Zones Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 4 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A17357 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 LI RIB LICHORD O BULKHEAD LIWEB LIFITTING LIOTHER LOCATION OF DAMAGE ZONES STA TO STA WL TO WL BL TO BL CAUSE OF DAMAGE LIENVIRONMENT INTERNAL LEAKAGE LICHEMICAL SPILL CILAVATORY SPILL LIBLOCKED DRAIN LIWET INSULATION BLANKET LIUNKNOWN ADDITIONAL DESCRIPTION OF DAMAGED AREA Corrosion Prevention and Control Program Damage Report Form Figure 2 Sheet 1 D2054 1 13 Temporary Revision Number 7 D
2. Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A2867 EXCESSIVE CABLE TENSION PULLEY MISALIGNMENT E 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 20 01 Page 4 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL on the outer surface of the cable Replace cable if internal corrosion is found For description of control cable corrosion refer to Section 24 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
3. CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A27651 E Salvador Rio De Janeiro Santiago Buenos Aires Montevideo CORROSION SEVERITY LEGEND MILD Il MODERATE SEVERE South America Corrosion Severity Map Figure 3 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 8 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A27659 Algiers Cairo llas Khartoum e ll Accra Brazzaville o Kananga o Luanda Antananarivo Tolanaro MILD IM MODERATE Cape Town SEVERE Africa Corrosion Severity Map Figure 4 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 9 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A27661 Cp vs 3 2 vg p P b L e cJ V i S Q o ll Q RUSSIA If e St Petersburg o Moscow em vi Baghdad i l gt seal A E Raz Al au E jal J i unl P diva pu
4. ZONE MECH INSP REMARKS Engine support structure Make sure you inspect 120 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 Make sure you examine 510 520 these areas 1 Main spar upper and lower 610 620 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 xxx D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 02 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 sp
5. tension 2 Check elevator cable system control 320 330 cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables D2054 1 13 Temporary Revision Number 7 Dec 1 2011 O Cessna Aircraft Company 2A 12 21 Page 1 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TASK Elevator Trim 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 Rudder 1 Check rudder travel and cable tension 2 Check rudder cable system control cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables End of Operation 21 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 ZONE MECH INSP REMARKS 210 310 320 330 210 310 340 Cessna Aircraft Company 2A 12 21 Page 2 Aug 1 1983 1 2 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION DOCUMENT Supplemental Inspection Document A Introduction 1 The Supplemental Structural Inspection Program for the Cessna Model 188 airplane is based on the affected Model 188 airplane current usage testing and inspection methods A practical state of the art inspectio
6. 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 C 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 D 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 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 p
7. 3 000 hours of operation or 5 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 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 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 l a 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 Inspect main landing gear fittings and attachment 210 of the fittings to the bulkheads Refer to Section 2A 14 05 Supplemental Inspection Document 32 13 02 for inspection procedure E
8. 5 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 Let the 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 15 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 13 Discard the used mask materials and remaining corrosion inhibiting compounds 19 Determination of the Corrosion Levels A Find the C
9. 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 condition is usually not evident D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 20 01 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 LD PEER AOS ST Pun LO ee LL 7 s UN LEE SK GE KI IH SINN IB NN DO NOT BEND THE CABLE INTO A LOOP SMALLER THAN 50 CABLE DIAMETERS CORE STRAND 556171119 Cable Broken Wires and Pulley Wear Patterns Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 20 01 Page 3
10. 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 Be 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 used for surface eddy current inspection 3 The instrument must have a repeatable sig
11. D Hoist the aircraft Remove fairings at upper end of gear strut Remove access covers inboard of fairings on aircraft belly Refer to the Model 188 Service Manual Remove outboard saddle and shim Remove bolt securing inboard end of strut and pull entire gear out of fuselage Inspect the landing gear attach points on the fuselage for corrosion or cracking Refer to Figure 1 1 Clean area before inspecting if grime or debris is present Inspect outboard saddle attach bolts and shims for corrosion or cracking 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 Support Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION A Replace any damaged fittings bolts or shims After the fittings are installed reverse preceding steps to install main landing gear Refer to Section 5 Landing Gear Wheels and Brakes of the Model 188 Service Manual for detailed instructions on removal and installation of the main landing gear For extensive damage or conditions not addressed contact Cessna Customer Service prior to beginning the repair 8 COMMENTS D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 05 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18393 MAIN LANDING GEAR SPRING OUTBOARD SADDLE MAIN LANDING GEAR SPRING DETAIL A 07
12. 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 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 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 used in the reference standard If a procedure specifies a reference standard made by Cessna Aircraft Company replacement with a different s
13. 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 Put the surface probe on the reference standard and move it across the notch D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 4 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 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 ef
14. 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 a 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 This interval is for severe corrosion environment 211 Inspect seat rails for corrosion Refer to Section 2A 14 07 Supplemental Inspection Document 53 47 01 for inspection procedure End of Operation 18 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 18 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 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 Inspection items
15. 00 Page 19 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL D If Level 3 corrosion is found during the first CPCP inspection 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 CPCP 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 found on the second or subsequent CPCP inspection 1 2 3 4 Do the corrosion
16. A1880034 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 attachments and attach structure 4 INSPECTION INSTRUCTIONS A Inspect the main landing gear spring for worn or chipped paint Refer to Figure 1 If rust has developed rework the gear in accordance with the REPAIR MODIFICATION section below NOTE The main landing gear flat springs are made from 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 1 Clean area before inspecting if grime or debris is present B If the finish is worn or chipped refinish the landing gear springs in accordance with the REPAIR MODIFICATION section below C Inspect the main landing gear axle attachment holes for evidence of corrosion 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 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION A If corrosion has developed on the flat spring landing gear it must be removed before refinishing The recommen
17. ADJACENT AREAS OF THE SKIN PANELS Corrosion Location Figure 3 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 9 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A59704 ADJACENT TO THE LONGITUDE e D lt o RR ADJACENT TO THE CIRCUMFERENCE CASE 1 WIDESPREAD CORROSION CORROSION FOUND IN ADJACENT AREAS OF THE SKIN PANELS 37 TI peed TAI Corrosion Location Figure 3 Sheet 2 Page 10 Aug 1 1983 2A 30 00 O Cessna Aircraft Company D2054 1 13 Temporary Revision Number 7 Dec 1 2011 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A59705 O EOS LOCAL CORROSION CORROSION FOUND IN NON ADJACENT FRAMES Corrosion Location Figure 3 Sheet 3 Page 11 Aug 1 1983 2A 30 00 O Cessna Aircraft Company D2054 1 13 Temporary Revision Number 7 Dec 1 2011 A59706 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL EL ae x 0 A VAM ERTL WIDESPREAD CORROSION CORROSION FOUND IN ADJACENT FRAMES Corrosion Location Figure 3 Sheet 4 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 O Cessna Aircraft Company 2A 30 00 Page 12 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL Table 2 Tools and Equipment Formit Extension Tube Chem Products mm spray the corrosion inhibit compound in ae
18. Aug 1 1983
19. Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 14AM 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 equivalent 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 L
20. 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 operators 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 the latest corrosion inspection task results in rework or blend out that exceeds the allowable limit 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 occurs during the first or subsequent accomplishments of a corrosion inspection task that the operator determines to be an urgent airworthiness concern 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 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 o
21. Do not apply LPS 3 Heavy Duty Rust Inhibitor to the bearing NOTE Coordinate with tire change Passenger Crew door retention system Make sure Every 48 months 5 210 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 Every 48 months 5 210 door 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 Fuselage lower internal structure beneath the floor Every 60 months 6 210 panels 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 Make Every 60 months 6 210 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 D2054 1 13 Temporary Revision N
22. 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 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 Supplemental Inspection Document items that are to be examined after the first 600 hours of operation or 1 year whichever occurs first The inspection is to be repeated every 600 hours of operation or 1 year whichever occurs first after the initial inspection has been accomplished O Cessna Aircraft Company 2A 10 00 Page 3 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL Operation Details 9 Supplemental Inspection Document item
23. 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 00 Page 7 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A25373 DISCREPANCY REPORT SID NO AIRPLANE LOCATION nm S N OF AIRPLANE INSPECTION CONDUCTED Date m 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 00 Page 8 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SER
24. Section 2A 14 00 NOTE 3 PURPOSE To ensure structural integrity of the engine mount 4 INSPECTION INSTRUCTIONS A Remove cowl engine and sufficient accessories to allow removal of the tubular engine mount Refer to the Model 188 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 magnifier of 7X or greater power to aid in inspection 1 Pay particular attention to the rear engine mount bearers rear cross tube and upper firewall attach fittings D If rust is found cracks are suspected or if airplane has exceeded the flight hour compliance time listed above remove the tubular engine mount Conducta 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 engine mount engine previously removed accessories and the cowling Refer to the Model 188 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 hole welded shut in the tube to be welded Open the hole prior to weld
25. 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 21 O Cessna Aircraft Company Aug 1 1983 A81712 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 5 TO 45 DEGREES LINE OF SIGHT INCANDESCENT EYES ABOVE LIGHT BEAM REFLECTED LIGHT BEAM REFLECTED LIGHT BEAM b 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 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
26. 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 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 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 kkk End of Operation 3 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 ZONE MECH INSP REMARKS 520 620 320 330 340 340 Cessna Aircraft Company 2A 12 03 Page 2 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 30 00 Corrosion Prevention and Control Program for additional info
27. 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 The 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 b FAA Service Difficulty Records and Foreign certification agency Service Difficulty Records were examined Existing analyses were reviewed to identify components in areas that may have exhibited the potential 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 The data collected was also used to find a component s susceptibility to corrosion or accidental damage as well as its inspectability D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 00 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 3 Usage A Aircraft Usage 1 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 survey
28. before inspecting if grime or debris is present 2 Confirm any suspected cracks with surface eddy current Refer to Section 2A 13 01 Nondestructive inspection methods and requirements Eddy Current Inspection Surface Inspection for additional instructions D Visually inspect the strut firewall wing and tailcone attachment fittings and surrounding area for evidence of cracks or corrosion 1 Clean area before inspecting if grime or debris is present 2 If evidence of corrosion is found cracks are suspected or compliance time limit exceeded then conduct a surface eddy current inspection around the strut attach fitting Refer to Section 2A 13 01 Nondestructive inspection methods and requirements Eddy Current Inspection Surface Inspection for additional instructions E Replace all fairings and skin panels Refer to the Model 188 Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION ZONE DETECTABLE CRACK SIZE Main Gear Section Not Allowed D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 06 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 6 INSPECTION METHOD Visual and Surface Eddy Current to confirm any suspected cracks 7 REPAIR MODIFICATION A If rust has developed on the tubular fuselage structure it must be removed The recommended procedure to remove rust is by hand sanding using a fine grained sandpaper B Use 180 or finer grit ab
29. does not have bulging resulting from corrosion and does not have missing or loose fasteners Refer to Figure 1 E lfanyofthese 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 F If corrosion is not found install the removed access panels fairings and the wing strut attach fitting Refer to the Model 188 Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wing Forward Spar Not Applicable 6 INSPECTION METHOD Visual Ultrasonic Thickness Eddy Current D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 13 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 7 PURPOSE Replace any cracked parts If corroded sand area lightly to remove corrosion If more than 10 of the thickness has been removed in any one area replace the part 8 COMMENTS D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 13 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18450 WING STRUT WING STRUT ATTACH FITTING WING
30. 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 This interval is for severe corrosion environment 210 Inspect tubular fuselage structure frames and members for cracks and corrosion Refer to Section 2A 14 06 Supplemental Inspection Document 53 10 01 for inspection procedure End of Operation 14 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 O Cessna Aircraft Company 2A 12 14 Page 1 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 3 000 hours of operation or 10 years whichever occurs first The inspection is to be repeated every 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 mechan
31. have had corrosion repairs in the past b Nondestructive testing can be necessary after some disassembly if the inspection shows a bulge in the skin or corrosion below structural splices or fittings D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 13 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 A magnifying glass can be a valuable tool to use to make sure all the corrosion has been removed 17 Corrosion Evaluation and Classification A B Complete an Initial Corrosion Damage Assessment 1 For classification of corrosion damage refer to Determination of the Corrosion Levels 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 Ref
32. 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 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 curva
33. m Ms t M m PAPUA MILD m s i IM MODERATE SEVERE Asia Corrosion Severity Map Figure 5 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 10 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A27662 Reykjavik Torshavn Bi Petersburg 1 TT eKiev su ale E IE Lisbon Nu gore NP Wa Hi Algiers Tunis Ef ES M I i Athens m P ce CORROSION SEVERITY LEGEND a MILD I MODERATE SEVERE Europe and Asia Minor Corrosion Severity Map Figure 6 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 11 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A27660 WAKE E SEVERE Elgg PHILIPPINES _ GUAM An SEVERE A PAPUA NEW GUINEA ne INDONESIA s Na Passe Oro vez x RNA A FIJI M SEVERE s ea NEW CALEDONIA SEVERE 1 CORROSION SEVERITY LEGEND NEW ZEALAND MILD B 1 MODERATE SEVERE South Pacific Corrosion Severity Map Figure 7 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 12 Cessna Aircraft Company
34. 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 of the 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 5 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 If the instrument is found to be out of calibration all measurements taken since the last calibration must be done again 6 Inspection a The purpose of the inspection is to collect information to permit the responsible engineering activity to find the material properties in the affected area IG NO ES NOTE Since conductivity values are affected by variations in material properties materi
35. oriented in different directions NOTE Experience with magnetic particle inspection is necessary to find the amount of 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 Ifthe field strength is not sufficient small discontinuities might be missed Repeat these steps with more magnetization 2 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 aan a0 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 the 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
36. 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 18 of the Model 188 Service Manual G Replace Removed Components 6 General A This section contains maps which define the severity of potential corrosion on airplane structure B 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 6 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A27579 P C m Fairbanks Anchorage g P 4 3 a n j q le eMe V Seattle p Montreal ls ji pa Chic g 0 M ll il Deger 1137 New York Los Angeles Mute He HAWAII MODERATE EN jm E u EN AA b I B ig Miami E Havana E HAITI D CORROSION SEVERITY LEGEND LI MILD EN JAMAICA ST DOMINGO M MODERATE SEVERE North America Corrosion Severity Map Figure 2 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 7 Cessna Aircraft Company Aug 1 1983
37. 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 6 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 4 Smaller coil diameters are better for crack detection A coil diameter of 0 125 inch 3 175 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 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 documenta
38. 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 CPCP 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 Ifthe 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 that are well beyond the allowable limits and there is an airworthiness concern in which prompt a
39. 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 Make 210 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 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 End of Operation 5 Inspection Items xxx D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 05 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION OPERATION 6 Date Registration Number Serial Number Total Time 1 Description A Operation 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 Corros
40. 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 5 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 topcoat 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 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 Ce
41. 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 7 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 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 adjustm
42. years whichever occurs first after the initial inspection has been accomplished for airplanes operating in a typical usage environment 20 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 21 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 10 00 Page 5 Cessna Aircraft Company Aug 1 1983 1 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION TIME LIMITS Inspection Items TASK 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 th
43. 001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE ALL USAGE INITIAL 1 000 Hours or 3 Years NOTE REPEAT 1 000 Hours or 3 Years NOTE NOTE Refer to Note 1 Section 2A 14 00 NOTE Coordinate this inspection with the trim tab actuator overhaul 3 PURPOSE To ensure integrity of the elevator trim system 4 INSPECTION INSTRUCTIONS A B F Remove the access plate from the lower side of the right stabilizer to get access to the actuator support hardware Refer to the Model 188 Service Manual Remove the access panels from below the left door and from the left side of the tailcone to get access to the elevator trim pulley brackets Inspect the 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 Check for looseness of elevator trim tab horn Inspect for cracks that appear in the skin where the trim tab horn attaches to the trim tab 1 Clean area before inspecting if grime or debris is present Install all access covers that were removed Refer to the Model 188 Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Elevator Trim Tab N A 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION If the trim tab horn is loos
44. 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 188 Service Manual Refer to the appropriate section for complete detailed information Section 24 30 00 Corrosion Prevention and Control Program CPCP 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 prevent 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 188 Service Manual B The intervals shown are recommended intervals at which items are to be inspected 1 Th
45. 1071032 MAIN LANDING GEAR FITTINGS INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 05 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 10 01 1 TITLE Tubular Fuselage Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 CORROSION SEVERITY INSPECTION COMPLIANCE MILD MODERATE INITIAL 2 Years NOTE REPEAT 2 Year NOTE SEVERE INITIAL 1 Year NOTE REPEAT 1 Year NOTE NOTE Refer to Section 2A 30 01 and associated maps to determine corrosion severity 3 PURPOSE To ensure structural integrity of the tubular fuselage structure 4 INSPECTION INSTRUCTIONS NOTE The tubular fuselage structure is fabricated from normalized SAE 4130 steel tubes The structure is NOT heat treated after welding The structure is coated with epoxy primer A Remove all fairings and skin panels that are not riveted in place Refer to the Model 188 Service Manual B Conduct a detailed inspection of all tubes and joints for corrosion Refer to Figure 1 1 Clean area before inspecting if grime or debris is present 2 Pay particular attention to any area where the primer has been abraded or otherwise damaged and to areas in the lower fuselage 3 Pay particular attention to cross tubing in the lower fuselage C Inspect the tubular frame members and joints for cracks 1 Clean area
46. 14 13 Supplemental Inspection Document 57 11 03 for inspection procedure D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL Initial 10 000 hours or 20 years whichever occurs first Repeat 3 000 hours or 5 years whichever occurs first Initial 10 000 hours or 20 years whichever occurs first Repeat 3 000 hours or 5 years whichever occurs first Initial 1 000 hours or 3 years whichever occurs first Repeat 1 000 hours or 3 years whichever occurs first 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 20 years Repeat 10 years Initial 10 years Repeat 5 years Initial 20 years Repeat 10 years 2A 10 01 OPERATION ZONE 7 320 330 7 310 340 11 510 610 19 510 610 20 510 610 10 510 520 610 620 12 510 520 610 620 10 510 610 Page 5 Aug 1 1983 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TASK This interval is for severe corrosion environment Inspect wing splice joint at strut attach Refer to Section 2A 14 13 Supplemental Inspection Document 57 11 03 for inspection procedure This interval is for typical usage environment Inspect wing strut and strut t
47. 40 01 for inspection procedure End of Operation 19 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 19 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION OPERATION 20 Date Registration Number Serial Number Total Time 1 Description A Operation 20 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 has been accomplished for airplanes operating in a severe usage environment 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 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 l a component or system is changed after a required task has been comple
48. 78 36 have been accomplished If not complete SE81 32 and SE78 36 with this inspection Remove the ailerons Refer to the Model 188 Service Manual Visually inspect the aileron hinges for condition cracks and security hinge bolts hinge bearings for condition and security bearings for freedom of rotation hinge and pushrod attach fittings for evidence of damage wear failed fasteners and security Refer to Figure 1 1 Clean area before inspecting if grime or debris are present Visually inspect aileron hinge fittings for cracks If cracks are suspected if corrosion is found or if flight hours exceed 3 000 hours conduct Surface Eddy Current Inspection Refer to Section 2A 13 01 Nondestructive Inspection Methods and Requirements Eddy Current Inspection Surface Inspection for additional instructions NOTE The inspection is for the aluminum structure outside of the bearing and the steel sleeve so set the instrument for aluminum Install the ailerons Refer to the Model 188 Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wings Not Allowed 6 INSPECTION METHOD Visual and Eddy Current 7 REPAIR MODIFICATION Replace any damaged or cracked fittings Replace damaged hinge bolts Replace loose corroded or tight bearings Repairs may be made in accordance with Section 17 of the Model 188 Service Manual Any repair not available in Section 17 should be coordinated with Cessna Custom
49. AUTION 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 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 Take care not to use too much developer If the developer puddles or begins to drip across t
50. Company for an approved repair procedure 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 Send a plan of corrective action to the FAA or applicable regulator authority for approval and Cessna Aircraft Company as needed Use the approved plan of action It is 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 3 corrosion when you think about how to change your CPCP 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 b Are the moisture drains blocked or is there inadequate drainage 6 What was the environment the time o
51. D J4 Cincinnati Ohio 45215 Web http www geinspectiontechnologies com b Inspection Frequency The instrument must have an operating frequency of 60 kHz NOTE Cessna conductivity 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 c 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 lACS It must have an accuracy of at least 1 0 lACS or 1 0 lACS through electrically nonconducting films and coatings up to a minimum of 0 003 inch 0 076 mm thick d Instrument Sensitivity The instrument must be sensitive enough to show changes of a minimum of 0 5 lACS over the conductivity range of the aluminum alloys for inspection e Probe The probe must have a flat contact surface The contact surface diameter must not be larger than 0 500 inch 12 700 mm f 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 The difference in the two values must not exceed 0 596 IACS g The functional performance of the conductivity instrument must be verified at the intervals defined by the controlling specification or the manufacture
52. IES 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 188 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 188 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 current inspection is effective for the detection of surface and s
53. ION DETECTABLE CRACK SIZE Horizontal Tail Not Allowed 6 INSPECTION METHOD Visual with Eddy Current if required D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 08 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 7 REPAIR MODIFICATION Replace damaged bolts and nuts Replace damaged fittings and small parts Replace damaged or loose rivets Hinge bearings are prepacked 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 operator option to replace stiff bearings Repairs may be made in accordance with Section 17 Structural Repair of the Model 188 Service Manual Coordinate any repair not available in Section 17 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 08 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18395 DETAIL A HORIZONTAL STABILIZER BEARING HINGE ASSEMBLY HINGE ASSEMBLY DETAIL B DETAIL D TYPICAL BEARING HINGE ASSEMBLY DETAIL C TYPICAL HORIZONTAL STABILIZER ELEVATORS AND ATTACHMENTS INSPECTION Figure 1 Sheet 1 071071032 D2054 1 13 Temporary Revision Number 7 D
54. ION ZONE Every 100 hours 1 or 12 months whichever occurs first Every 100 hours 1 or 12 months whichever occurs first Every 100 hours 1 5 or 12 months whichever occurs first Every 100 hours 1 or 12 months whichever occurs first Every 12 months 2 510 520 610 620 Every 12 months 2 120 Every 24 months 3 520 620 Every 24 months 3 320 330 2A 10 01 Page 1 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL REVI TASK INTERVAL OPERATION ZONE SION STATUS Rudder attachments Make sure you inspect these Every 24 months 3 340 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 Make sure you inspect these areas Every 24 months 3 340 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 Inspect main landing gear axle assembly Make sure Every 36 months 4 721 you inspect these areas 1 Main gear axle and attach 722 bolts 2 Wheel halves NOTE Corrosion Prevention and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information NOTE
55. 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 Aleakage field will be shown by a fluorescent pattern of the magnetic particles This is called an indication 2 An indication caused by a discontinuity on the part surface will be a sharp distinct pattern 3 An indication caused by a subsurface discontinuity will usually be broader and fuzzier compared to an indication of a surface discontinuity 4 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 on AC current setting and the magnetic field strength to maximum NOTE AC 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
56. MENT HOLE FRONT SPAR ASSEMBLY DETAIL D TRAILING EDGE RIB i i ATTACHMENT o OS REARSPAR il A HOLE SG lj AREATO ASSEMBLY Paco Ye T rl ovp v INSPECT N A S en gt SPAR WEB Ye ALES R CENTER RIB 7 NDS RADIUS de ATTACHMENT i MOSES RIVET FITTING d AREA TO INSPECT CENTER gt gt SPAR WEB RADIUS DETAIL B RIB VIEW LOOKING UP AND OUTBOARD DETAIL C LEFT HAND SPAR SHOWN RIGHT HAND SPAR OPPOSITE VIEW LOOKING UP AND OUTBOARD LEFT HAND SPAR SHOWN RIGHT HAND SPAR OPPOSITE 071071032 WING STRUCTURE INSPECTION Figure 1 Sheet 1 2A 14 11 Page 3 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Aug 1 1983 O Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 11 02 1 TITLE Wing Structure Corrosion Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 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 24 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 wing tips from the wings Refer to the Model 188 Service Manual 1 Clean area before inspecting if grime or debris is present B Visually inspect
57. N 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 O Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION TIME LIMITS STRUCTURE 1 Scope A This provides the mandatory times and inspection time intervals for components 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 a
58. N DISSIMILAR METAL CORROSION FILIFORM CORROSION WORM LIKE TRACKS INTERGRANULAR METALLIC GRAIN CORROSION STRUCTURE INTERGRANULAR CORROSION HIGHLY MAGNIFIED FILIFORM CORROSION MR PAINTED HIGHLY MAGNIFIED 65911001 SURFACE 65911002 62911013 62916004 Corrosion Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 3 Cessna Aircraft Company Aug 1 1983 J 3 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 To remove filiform corrosion once it has been discovered a 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 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 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 stres
59. PERATION 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 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 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 This inspection is for mild m
60. 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 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 188 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 STCs 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 inspectio
61. R 57 11 03 1 TITLE Wing Splice Joint at Strut Attach Inspection 2 EFFECTIVITY 188 0001 thru T 18803974 T A A1880001 thru A A1880034 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 forward wing spar splice 4 INSPECTION INSTRUCTIONS A Remove the strut fairings at the wing strut attach fitting and any access panels installed on the wing to gain access to the forward and aft side of the wing spar Refer to the Model 188 Service Manual B Remove the 8 bolts attaching the wing strut attach fitting to the wing Refer to Figure 1 Visually inspect for corrosion between the wing skin and the wing strut attach fitting Visually inspect the bolt holes for indications of damage If necessary confirm any cracking with bolt hole eddy current Refer to Section 2A 13 01 Non destructive Inspection Methods and Requirements Eddy Current Inspection Bolt Hole Inspection for additional instructions The hole size is 0 312 inches in diameter C Visually inspect the lower side of the upper spar cap for damage at the strut attach fitting attach holes D Visually inspect for corrosion at the edge of the upper and lower spar caps and the edge of the splice doublers In addition confirm the spar splice
62. Refer to the Model 188 Service Manual C 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 D Using a borescope inspect forward and aft vertical stabilizer and rudder spars 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 E Inspect rudder for deterioration resulting from fatigue wear overload wind damage and corrosion 1 Clean area before inspecting if grime or debris is present F 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 G If corrosion or a frozen bearing is found in 4 C 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 Requirement
63. SERIES SERVICE MANUAL INSPECTION OPERATION 2 Date Registration 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 a 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
64. SPAR STRUT ATTACH INSPECT FOR CORROSION FITTING HOLES HIDDEN UNDER DOUBLER WING SPLICE DOUBLER DETAIL C 071071032 WING SPLICE JOINT AT STRUT ATTACH INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 13 Page 3 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 40 01 1 TITLE Strut and Strut Wing Attachment Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE TYPICAL INITIAL 12 000 Hours or 20 Years NOTE REPEAT 2 000 Hours or 10 Years NOTE SEVERE INITIAL 6 000 Hours Or 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 188 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 and jury strut for cracks or corrosion a Clean area before inspecting
65. TITLE Aileron Cable and Control System Inspection 2 EFFECTIVITY 188 0001 thru 188 0707 INSPECTION COMPLIANCE ALL USAGE INITIAL 600 Hours OF 1 Year NOTE REPEAT 600 Hours OF 1 Year NOTE NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To ensure integrity of the Aileron Cables and control system 4 INSPECTION INSTRUCTIONS A Inspect aileron cables for possible fraying and wear Pay particular attention to the areas where cables have direct contact with pulleys and fairleads Refer to Figure 1 B Deflect the control stick full travel sideways in order to inspect the entire cable surface in contact with pulleys and fairleads C Pay particular attention to cable areas in contact with pulleys located near WS 75 just inboard of ailerons D Acloth may be passed over the cables which will cause snagging of the cloth where broken strands exist Also the cable may be twisted against the direction of spiral to detect internal broken strands E abnormal wear is noted in the area of the grommet located at the outboard section of the fuselage incorporate SK188 25 with this inspection F The aileron cable tension must be maintained as defined in the Model 188 Service Manual Section 6 Figure 6 1 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wings Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION Replace all cables showing wear or fraying 8 COMMENTS D2054 1 13 Tempor
66. TITLE Wing Structure Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE TYPICAL INITIAL 12 000 Hours or 20 Years NOTE REPEAT 2 000 Hours or 10 Years NOTE SEVERE INITIAL 6 000 Hours Or 10 Years NOTE REPEAT 1 000 Hours OF 5 Years NOTE NOTE Refer to Note 1 Section 24 14 00 3 PURPOSE To ensure structural integrity of the wing structure 4 INSPECTION INSTRUCTIONS A Forunits 1880001 thru 18800832 check airplane records to verify that Service Bulletin SE74 4 has been accomplished If not complete SE74 4 with this inspection B Remove all access panels all fairings and the wing tips from the wings Refer to the Model 188 Service Manual C Visual Inspection 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 stub wing 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 th
67. 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 threads 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 asse
68. 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 This interval is for mild moderate corrosion 211 environment Inspect seat rails for corrosion Refer to Section 2A 14 07 Supplemental Inspection Document 53 47 01 for inspection procedure End of Operation 17 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 17 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 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 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
69. ace 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 l a 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 03 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TASK Aileron attachments 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 Make sure you inspect these areas 1 Elevator trim brackets 2 Actuator support brackets
70. adient 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 a trapped salt deposit which is capable of accumulating moisture and developing into filiform corrosion D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 0 HIGH OXYGEN HIGH METAL ION CONCENTRATION CONCENTRATION WK A WON SS METAL ION OXYGEN CONCENTRATION CONCENTRATION CELL CELL LOW METAL ION LOW OXYGEN CONCENTRATION CONCENTRATION CONCENTRATION CELL CORROSION CORROSION ELECTROLYTE PRODUCTS ELECTROLYTE TEEL BINT CRE PASSIVE FILM FASTENER ALUMINUM ALLOY PINHOLE CORROSIO
71. aft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL D Conductivity Testing 1 General a 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 b 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 c 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 d 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 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 NAME NUMBER MANUFACTURER Portable Conductivity Tester Autosigma 3000 GE Sensing amp Inspection Technologies 1 Neumann Way M
72. age structure frames and members for cracks and corrosion Refer to Section 2A 14 06 Supplemental Inspection Document 53 10 01 for inspection procedure End of Operation 13 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 13 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 year The inspection is to be repeated every 1 year after the initial inspection has been accomplished for airplanes operating in a severe corrosion environment 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 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
73. 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 22 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 The use of a 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 corrosi
74. al 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 188 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 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 A detailed map is needed of the inspection area to include dimensions to
75. al to the alloy and temper of the material for test NOTE When gage material is used mechanically measure the thickness of the material D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 19 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 2 3 Set up the instrument with the manufacturer s instructions Choose steps on the reference standard for the calibration It is recommended that there is a 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 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 grease 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 Refer to the General Requirements section for information on how to report inspection resu
76. applies the TYPICAL usage environment applies 2 Operating Environment a Severe Corrosion Environment 1 Ifthe 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 If 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 2A 10 00 Time Limits Maintenance Checks General This section provides a description and purpose of the inspection time intervals D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 10 00 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL Section 24 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 Inspect
77. 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 a 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 This interval is for typical usage environment 1 510 610 Inspect inboard wing structure for damage and working rivets 2 Inspect flap actuator support structure Refer to Section 2A 14 11 Supplemental Inspection Document 57 11 01 for inspection procedure This interval is for typical usage environment 510 610 Inspect wing strut and strut tube Refer to Section 2A 14 14 Supplemental Inspection Document 57
78. ary Revision Number 7 Dec 1 2011 2A 14 01 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18389 BELLCRANK RIGHT oec s CABLE ex i 8 2 PULLEY s A 5 DETAIL E PULLEYS PULLEY CARRY THRU PULLEY CABLE DETAIL B gus A yo py o Nd Rn PULLEYS DETAIL D DETAIL C 0710T1032 AILERON CABLE AND CONTROL SYSTEM INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 01 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 27 20 01 1 TITLE Rudder Pedal Torque Tube Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE ALL USAGE INITIAL 10 000 Hours or 20 Years NOTE REPEAT 3 000 Hours Or 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 For applicable units check airplane records to verify that Service Bulletin SL67 47 has been accomplished If not complete SL67 47 with this inspection B 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 C Inspect the rudder bar support brackets for crac
79. at all SID Inspections have been complied with as scheduled Wing structure internal Make sure you inspect these areas 1 Main spar upper and 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 Engine support structure Make 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 Aileron attachments 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 Make sure you inspect these areas 1 Elevator trim brackets 2 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL OPERAT
80. attach holes in the wing spar flange Refer to Figure 1 Determine if they are elongated to a diameter greater than 0 210 inch and cone shaped more than half way thru the spar flange buildup If the holes are out of tolerance repair in accordance with the REPAIR MODIFICATION section below 1 Clean area before inspecting if grime or debris is present C Install spray boom and mounting bracket at WS 103 38 Refer to the Model 188 Service Manual ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Lower Wing Not Allowed INSPECTION METHOD Visual REPAIR MODIFICATION If holes are elongated greater than 0 210 inch and cone shaped more than half way modify in accordance with SK188 65 For extensive damage or conditions not addressed contact Cessna Customer Service prior to beginning the repair COMMENTS D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 10 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18448 BRACKET SPRAY BOOM WS 103 38 SUPPORT ASSEMBLY SPRAY BOOM SUPPORT ASSEMBLY DETAIL VIEW LOOKING UP AT BOTTOM OF LH WING RH OPPOSITE 071071032 WING SPAR SPRAY BOOM HOLE INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 10 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 11 01 1
81. b NOTE Corrosion Prevention 620 and Control Program Inspection item baseline interval refer to Section 2A 30 00 for additional inspection information Vertical stabilizer structure Make sure you inspect Every 60 months 6 310 these areas 1 Forward spar attachment to tailcone 340 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 Horizontal stabilizer structure Make sure you inspect Every 60 months 6 320 these areas 1 Stabilizer attachment to the tailcone 330 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 Inspect aileron cables areas in contact with Initial 600 hoursor1 8 510 pulleys and fairleads Refer to Section 2A 14 01 year whichever oc 520 Supplemental Inspection Document 27 10 01 for curs first Repeat 610 inspection procedure 600 hours or 1 year 620 whichever occurs first D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 10 01 Page 3 O Cessna Aircraft Company Aug 1 1983 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TASK Inspect rudder pedal torque tube and cable attachment arms Refer to 2A 14 02 Suppl
82. 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 2 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 3 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 corrosion in place or do a treatment of the corrosion before inspection it may hide other discontinuities 4 Clean After the preliminary inspection clean the areas or surface of the parts for inspection Do not remove the protective finish from the part b Inspection Carefully examine the area for discontinuities with optical aids as needed An inspector normally should have available applicable measuring devices
83. ch bracket Refer to Section 2A 14 10 Supplemental Inspection Document 57 10 01 for inspection procedures End of Operation 11 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 11 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION OPERATION 12 Date Registration Number Serial Number Total Time 1 Description A Operation 12 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 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 a component or system is changed after a required task has been completed then that spec
84. ction 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 20 Cessna Aircraft Company Aug 1 1983 K L CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL If Level 3 corrosion is found on the second or subsequent CPCP inspection 1 Contact Cessna Aircraft Company and the FAA or applicable regulatory authority about the corrosion that was found 2 Send a plan to examine the same area on other affected airplanes in the operator s fleet 3 Apply the corrosion program inspection which includes the repair of the structure Contact Cessna Aircraft
85. d for airplanes operating in a severe corrosion environment 15 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 16 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 17 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 18 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 10 00 Page 4 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL Operation Details 19 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
86. d At tachments Inspection Engine Mount In spection Inspec Support INSPECTION COMPLIANCE Refer to Note 1 INITIAL MILD MODERATE 20 Years SEVERE 10 Years MILD MODERATE 20 Years SEVERE 10 Years TYPICAL 12 000 Hours or 20 Years SEVERE 6 000 Hours or 10 Years 3 000 Hours or 10 Years MILD MODERATE 20 Years SEVERE 10 Years 10 000 Hours or 20 Years REPEAT MILD MODERATE 10 Years SEVERE 5 Years MILD MODERATE 10 Years SEVERE 5 Years TYPICAL 2 000 Hours or 10 Years SEVERE 1 000 Hours or 5 Years 500 Hours or 5 Years MILD MODERATE 10 Years SEVERE 5 Years At Engine Overhaul INSPEC TION OP ERATION 10 12 12 19 20 12 Time limits for the INITIAL inspections are set by either flight hours or calendar time whichever occurs Except for Section 2A 14 17 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 inspection has been completed and a CPCP is in effect then REPEAT inspections are based entirely on flight hours D2054 1 13 Temporary Revision Number 7 Dec 1 2011 O Cessna Aircraft Company 2A 14 00 Page 3 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 27 10 01 1
87. d in Paragraph 3 D below C Fatigue Assessment 1 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 anumber of small less than detectable size adjacent cracks suddenly 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 2 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 D 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 th
88. d 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 The 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 Itis 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 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 practic
89. damaged components 5 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 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
90. ded procedure to remove corrosion is by hand sanding using a fine grained sandpaper D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 04 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL CAUTION Do not use chemical paint strippers Some chemical strippers are acidic and can produce hydrogen The springs are high heat treated steel which is subject to hydrogen embrittlement if exposed to hydrogen Hydrogen embrittlement can cause delayed failure B Refer to the Model 188 Maintenance Manual Section 5 5A for detailed instructions on corrosion removal on the gear springs and axle C Refinish sanded areas 1 Solvent Wipe a b Wipe off excess oil grease or dirt from the surface to be cleaned 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 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 Immediately wipe the surface with a clean dry cloth while the solvent is still wet Do not allow the surface to evaporate dry Do steps b through d again until there is no discoloration on the drying cloth ply corrosion primer in accordance with Corrosion Resistant Primer MIL PRF 23377G or later Mix and apply in accordance with manufacturer
91. dividual 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 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 c 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 Any flight control cable system which has been torn down requires a flight control rigging check prior to release of airplane for flight D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 20 01 Page 6 O Cessna Aircraft C
92. ds 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 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 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 12 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBE
93. e bearing NOTE Coordinate with tire change End of Operation 4 Inspection Items xxx D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 04 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 a component or system is changed after a required task has been completed then that specified task must be done again to make
94. e 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 It is recommended that you record the results of the inspection to show compliance with the program D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 16 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 unigue 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 17 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A17383 is the result of the corrosion blending procedure Is t
95. e 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 10 00 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 o
96. e 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 12 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 penetrantis 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 Materials 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
97. e environment for 30 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 For the SID to continue to stay applicable it is necessary to have a 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 2 Also the operator 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 3 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 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 2 All cracks multiple cut off fasteners and corrosion found during the inspection must be reported to Cessna Aircraft Company wit
98. e 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 3 810 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 IR d Refer to the General Requirements section for information on how to report inspection results D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 8 O Cessna Aircr
99. e 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 l a 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 Elevator trim system 1 Inspect elevator trim 320 330 brackets and actuator support brackets 2 Inspect pulleys attaching structure and fasteners 3 Inspect trim tab horn Refer to Section 2A 14 03 Supplemental Inspection Document 27 30 01 for inspection procedures Inspect the attach holes in the wing spar flange 510 610 under the wing spar spray boom atta
100. e 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 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 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 4 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 2 Care and replacement of solid film lubrican
101. e or skin around horn attachment is cracked replace trim tab Replace any cracked or excessively corroded 10 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 For extensive damage or conditions not addressed contact Cessna Customer Service prior to beginning the repair D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 03 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 8 COMMENTS D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 03 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL a TRIM TAB DETAIL A ELEVATOR TRIM WHEEL ELEVATOR TRIM TAB HORN Ey 0 PUSH PULL ji Oy BRACKET TUBE a DETAIL B 4 N ACTUATOR 3 P j CLEVIS AF TURNBUCKLE DETAIL C DETAIL D 071071032 ELEVATOR TRIM SYSTEM INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 03 Page 3 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 13 01 1 TITLE Main Landing Gear Flat Spring Corrosion Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A
102. e trailing edge ribs and the span wise segments supporting the flap actuator or flap bell cranks 3 Inspect angle in the bays inboard and outboard of STA 100 giving close attention to surface and aft edges of angle in the area marked Refer to Figure 1 Detail A a Visually inspect the lower flange edges of spar channel and splice channel 4 Inspect the front spar web radius for cracks Refer to Figure 1 Detail B a Pay particular attention to web radius immediately below and outboard of attachment hole Inspect from forward and aft side of spar 5 Inspect the rear spar web radius area for cracks Refer to Figure 1 Detail C a Pay particular attention to web radius immediately below and outboard of attachment hole Inspect from forward and aft side of spar 6 Ifthe flight hours meet or exceed the inspection compliance hours above proceed to Detailed Inspection below 7 If crack s or corrosion is found at the wing attach fittings proceed to the Detailed Inspection below D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 11 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 8 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 Refer to the Model 188 Service Manual Inspection is complete D Detailed Inspection 1 Support the wing outboard of the stru
103. 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 l a 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 Flaps 1 Check flap travel cable tension and 210 510 travel time 2 Check flap cable system control 610 cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables Aileron 1 Check aileron travel and cable 210 510 tension 2 Check aileron cable system control 520 610 cables and pulleys in accordance with the flight 620 cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables Elevator 1 Check elevator travel and cable 210 310
104. ec 1 2011 2A 14 08 Page 3 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18396 TRIM TAB H NAS SS 4 LPS G De DETAIL E LZ ELEVATOR F T TRIM TAB HORN BEARING DETAIL J HINGE BRACKETS DETAIL F TORQUE TUBE RH TYPICAL ARM ASSEMBLY BEARING HINGE BRACKETS BEARING G pETAIL H DETAIL TYPICAL 0710T1032 HORIZONTAL STABILIZER ELEVATORS AND ATTACHMENTS INSPECTION Figure 1 Sheet 2 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 08 Page 4 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 55 30 01 1 TITLE Vertical Stabilizer Rudder and Attachments Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE ALL USAGE INITIAL 10 000 Hours Or 20 Years NOTE REPEAT 3 000 Hours or 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 For applicable units check airplane records to verify that Service Bulletin SB80 85 and SB95 02 has been accomplished and that SK180 43 and SK188 74A has been installed If not complete SB80 85 and SB95 02 and install SK180 43 and SK188 74A with this inspection B Remove rudder from airplane and open all vertical stabilizer access panels
105. ec 1 2011 2A 30 00 Page 5 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 identified 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 5 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 notan FAA mandatory procedure to record the CPCP 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 additiona
106. ection Bolt Hole Inspection for additional instructions The hole size is 0 687 inches in diameter 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 188 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 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 Attach Inspection D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 11 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 818449 CENTER FRONT SPAR RIB STA 100 00 ASSEMBLY PEN s uu LIGHTENING HOLE IN RIB FITTING BA D RIVET 2 AREATO ACCESS HOLE INSPECT LINE OF IN LOWER AANI WING SKIN RIVET 1 DETAIL VIEW LOOKING FORWARD LEFT HAND SPAR SHOWN RIGHT HAND SPAR OPPOSITE REAR STUB WING FITTING ATTACH
107. emental Inspection Document 27 20 01 for inspection procedure Elevator trim system 1 Inspect elevator trim brackets and actuator support brackets 2 Inspect pulleys attaching structure and fasteners 3 Inspect trim tab horn Refer to Section 2A 14 03 Supplemental Inspection Document 27 30 01 for inspection procedures This inspection is for mild moderate corrosion environment Inspect main landing gear flat spring for rust or damage to finish Refer to Section 2A 14 04 Supplemental Inspection Document 32 13 01 for inspection procedure This interval is for severe corrosion environment Inspect main landing gear flat spring for rust or damage to finish Refer to Section 2A 14 04 Supplemental Inspection Document 32 13 01 for inspection procedure Inspect main landing gear fittings and attachment of the fittings to the bulkheads Refer to Section 2A 14 05 Supplemental Inspection Document 32 13 02 for inspection procedure This interval is for mild moderate corrosion environment Inspect tubular fuselage structure frames and members for cracks and corrosion Refer to Section 2A 14 06 Supplemental Inspection Document 53 10 01 for inspection procedure This interval is for severe corrosion environment Inspect tubular fuselage structure frames and members for cracks and corrosion Refer to Section 24 14 06 Supplemental Inspection Document 53 10 01 for inspection procedure This interval is for mild moderate corro
108. en find the average flight length based on the formula found below Average Flight Length Number of Flight Hours Number of Flights 2 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 3 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 00 Page 3 Cessna Aircraft Company Aug 1 1983 4 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 30 or more of the years to the initial inspection refer to maps in Section 24 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 sever
109. ent years in service inspectability of the corroded area and the cause of the problem 3 22 E ZZ 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 CPCP 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 CPCP inspection 1 Repair the structur
110. ent 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 50 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 and 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 th
111. er Service prior to beginning the repair D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 15 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 8 COMMENTS Aileron hinges may be replaced in lieu of eddy current inspection D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 15 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18457 PUSH PULL TUBE B DETAIL A Er AILERON HINGE BEARING DETAIL B TYPICAL 071071032 AILERON SUPPORT STRUCTURE INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 15 Page 3 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 53 01 1 TITLE Flap Tracks and Attachments Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 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 accomplished If not complete SEB95 03 with this inspection B Visually inspect the
112. er to Section 2A 30 01 Corrosion for additional 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 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 metallic 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 Do not apply corrosion inhibiting compound to a wet surface D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 14 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 2 Masking NOTE It i
113. eter D 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 E 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 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 recomme
114. f 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 Youdonothave 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 a CPOP 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 applications of the CPI at the recommended interval for each CPI 3 You can start a CPCP on the basis of individua
115. f more than one frame chord stringer or stiffener where no corrosion exists on two adjacent members on each side of the corroded member A PSE is an element that contributes significantly to carrying flight ground or pressurization loads and whose integrity is essential in maintaining the overall structural integrity of the airplane Refer to Inspection Area D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 7 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 3 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
116. f 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 5 O Cessna Aircraft Company Aug 1 1983 NAME Eddy Current Instrument CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL NUMBER MANUFACTURER 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 Reference Standard NOTE 2 Combined Stainless Steel VM89SS VM Products Inc Surface and Bolthole Eddy Current Reference Standard NOTE 2 NOTE 1 Bolthole pr
117. fect 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 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 o
118. 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 inspection 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
119. 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 Corp Light Meter DSE 2000A Spectronics Corp 2 956 Brush Hollow Road Westbury New York 11590 Phone 800 274 8888 Web http www spectroline com Penetrant materials are defined by specific classification per SAE AMS 2644 Materials must meet at minimum th
120. fter 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 Airplane Flight Manual TASK ZONE MECH INSP REMARKS Inspect tubular engine mount Refer to Section 120 2A 14 17 Supplemental Inspection Document 71 20 01 for inspection procedure End of Operation 9 Inspection Items xxx D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 09 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION O
121. 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 13 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL b Leave the penetrant on the surface for a minimum of 15 minutes if the temperature is at least 50 F 10 C Leave the penetrant on the surface for a minimum of 25 minutes if the temperature is less than 50 F 10 C c The maximum dwell time should not be more than one hour except for special circumstances d Donotlet the 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 C
122. he corrosion reaction process A simple 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 188 airplanes had sheet metal parts constructed of Alclad sheet 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 188 airplanes 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 plated steel fasteners used in aluminum At normal atmospheric temperatures metals do not corrode appreciably without moisture However the moisture
123. he 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 18 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 l Corrosion Level Determination Chart Figure 4 Sheet 3 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30
124. he 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 The inspector 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 14 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 3 Acrack will 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 disconti
125. heckturnbuckles for proper thread exposure Also check turnbuckle locking clip or safety wire 3 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 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
126. hin 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 All SID reports will be examined to find if any of the steps are necessary a 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 00 Page 4 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 5 Inspection Methods A very important part of the SID program is selecting and evaluating state of the art nondestructive inspection NDI 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 f
127. ic 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 a 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 Inspect aileron hinges hinge bolts hinge bearings 520 620 and hinge and pushrod attach fittings Refer to Section 2A 14 15 Supplemental Inspection Document 57 51 01 for inspection procedure End of Operation 15 Inspection Items kkk D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 15 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 the first
128. ication 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 environments 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 i
129. 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 CAUTION The strut tube contains a spacer that must remain in place if the eyebolt is removed for the inspection Remove bolts and nuts securing jury strut Remove screws securing strut fairings and remove fairings Support wing securely Remove nut and bolt securing strut to wing Remove nut and bolt securing strut to fuselage and remove strut Visually examine the strut tube and jury strut 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 8 Install the wing strut and the jury strut Refer to the Model 188 Service Manual PER Res ROC sie ae ee D Install the wing strut upper and lower fairings Refer to the Model 188 Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Wing Strut Not Applicable D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 14 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 6 INSPECTION METHOD Visual and Eddy Current 7 REPAIR MODIFICATION A If corrosion is found remove corrosion by lightly sanding cor
130. ified 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 This interval is for severe corrosion environment Inspect main landing gear flat spring for rust or damage to finish Refer to Section 2A 14 04 Supplemental Inspection Document 32 13 01 for inspection procedure This interval is for severe corrosion environment Inspect wing for corrosion and missing or loose fasteners Refer to Section 2A 14 12 Supplemental Inspection Document 57 11 02 for inspection procedure This interval is for severe corrosion environment Inspect wing splice joint at strut attach Refer to Section 2A 14 13 Supplemental Inspection Document 57 11 03 for inspection procedure This interval is for severe corrosion environment Inspect flap tracks for corrosion Refer to Section 2A 14 16 Supplemental Inspection Document 57 53 01 for inspection procedure kkk End of Operation 12 Inspection Items 721 722 510 520 610 620 510 610 510 610 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company 2A 12 12 Page 1 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION OPERATION 13 Date Registration Number Serial Nu
131. in the air is usually enough to start corrosive action The initial 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 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 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B Direct Chemical Attack
132. 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 inspecting if grime or debris is present C Visually inspect the flap track rib assembly attachment brackets and angles for condition cracks loose rivets and security 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Flap Tracks Not Allowed 6 INSPECTION METHOD Visual 7 REPAIR MODIFICATION Replace damaged or loose rivets Replace damaged flap tracks or attachments 8 COMMENTS D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 16 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18452 INBOARD FLAP TRACK RIB ASSEMBLY OUTBOARD FLAP TRACK RIB ASSEMBLY DETAIL E PUSH PULL TUBE PUSH PULL TUBE d ATTACH BRACKET ARM ASSEMBLY SEO DETAIL B E 071071032 FLAP TRACKS AND ATTACHMENTS INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 16 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 71 20 01 1 TITLE Engine Mount Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE ALL USAGE INITIAL 10 000 Hours or 20 Years NOTE REPEAT At Engine Overhaul NOTE Refer to Note 1
133. ing After welding while the welded area is still hot introduce 3cc of unboiled Linseed oil or 6cc of corrosion preventative compound conforming to 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 17 Structural Repair of the Model 188 Service manual Any repair not available in Section 17 should be coordinated with Cessna Customer Service prior to beginning the repair D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 17 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 17 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18458 Engine Mount DETAIL A 071071032 ENGINE MOUNT INSPEGTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 17 Page 3 Cessna Aircraft Company Aug 1 1983 1 Control Cable
134. inspection Do not allow the part to touch the legs of the electromagnetic yoke 5 Pull the electromagnetic yoke away from the part D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 18 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 6 De energize the electromagnetic yoke when about 2 feet from the part 7 Test the 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 3 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 Component 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 use
135. inspection procedure Inspect horizontal stabilizer and elevator including 320 330 spars ribs hinge bolts hinge bearings attach fittings and torque tube Refer to Section 2A 14 08 Supplemental Inspection Document 55 10 01 for inspection procedures Inspect vertical stabilizer and rudder including 310 340 spars ribs hinge bolts hinge bearings and attach fittings Refer to Section 2A 14 09 Supplemental Inspection Document 55 30 01 for inspection procedure xxx End of Operation 7 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company 2A 12 07 Page 1 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 600 hours of operation or 1 year whichever occurs first The inspection is to be repeated every 600 hours of operation or 1 year 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 inspec
136. ion 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 TASK ZONE MECH INSP REMARKS Fuselage lower internal structure beneath the 210 floor panels 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 Fu
137. ion 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 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
138. ks at the bend radii in the mounting flange 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 Repairs may be made in accordance with Section 17 Structural Repair of the Model 188 Service Manual Coordinate any repair not available in Section 17 with Cessna Customer Service prior to beginning the repair 8 COMMENTS D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 02 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18390 RIGHT RUDDER PEDAL TORQUE TUBE CABLE ATTACHMENT ARMS DETAIL A PARKING BRAKE e AMA CABLE BRACKET DETAIL C BEGINNING WITH AIRCRAFT SERIAL 188 0318 SHAFT ASSEMBLY DETAIL B BEGINNING WITH AIRCRAFT SERIAL 18800573 ironii RUDDER PEDAL TORQUE TUBE INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 02 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 27 30 01 1 TITLE Elevator Trim System Inspection 2 EFFECTIVITY 188 0
139. l CPIs or groups of CPIs 4 Cessna Aircraft Company highly recommends to start all of the CPIs as soon as possible This is the most cost effective way to prevent or control corrosion D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 21 O Cessna Aircraft Company Aug 1 1983 1 General CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL CORROSION 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 9 Electrochemical corrosion can best be compared to a battery cell Three conditions must exist before electrochemical corrosion can occur a 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 be condensation or in some cases only the humidity in the air Elimination of any one of the three conditions will stop t
140. l 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 Allowable 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 itin 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 airp
141. lane Corrosion Metal The physical deterioration of metals caused by a reaction to an adverse environment D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 6 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL Corrosion Prevention and Control Program CPCP A Corrosion Prevention and Control Program is a comprehensive and 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 CPls 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 2 Corrosion Level 3 Corrosion NOTE 1 Light Corrosion Local Corrosion Principal Structural Element PSE Level 1
142. le 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 20 01 Page 5 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 100 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 lt may be necessary to have 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 in
143. leted 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 a 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company 2A 12 01 Page 1 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188
144. liance Initial Inspection Interval s Repeat Inspection Interval s Purpose Inspection Instructions Access Location Zone 0 Detectable Crack Size 1 Inspection Procedure 2 Repair Modification 3 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 188 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 17 of the Model 188 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 00 Page 6 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES
145. light 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 70 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 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 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 is the focal length of the lens in inches and 10 is a constant that represents the average minimum D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 20 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 5 Borescopes a These instruments are long tubula
146. locate the reference point and enough information to allow the responsible engineering activity to find the sites of the conductivity data D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 10 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL ES 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 in 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 along with the conductivity values so a person unfamiliar with the inspection can find the data point IO a 101 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
147. lts E After Inspection 1 2 Refer to the General Requirements section for information on how to report inspection results Clean any couplant off the area 6 VISUAL INSPECTION A General 1 2 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 Personnel that do visual inspection tasks do not need to have certification in nondestructive inspection B Visual Aids 1 2 Structure and components that must be routinely examined are sometimes difficult to 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 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 flash
148. luorescent liquid penetrant eddy current and magnetic particle methods are used A complete description of those methods are presented in Section 24 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 188 Service Manual P N D2054 1 13 b Cessna 188 Illustrated Parts Catalog P N P545 12 and P694 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 316 517 5800 Fax 316 517 7271 7 Applicability Limitations A This SID is applicable to the Cessna Model 188 Serial Numbers 188 0001 thru T18803974 T and A A1880001 thru A A1880034 B STC Modifications 1 The Cessna 188 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 extension
149. mber Total Time 1 Description A Operation 13 gives Supplemental Inspection Document items that are to be examined after the first 2 years The inspection is to be repeated every 2 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 This 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 a 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 interval is for mild moderate corrosion 210 environment Inspect tubular fusel
150. mbled 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 01 Page 5 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 3 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 The 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
151. me 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 Maintenance or inspection programs need to include a good quality CPCP 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 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
152. n 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 Principal Structural Elements A Principal Structural Elements Description An airplane component is classified as a Principal Structural Element PSE if a 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 00 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 Doorframes 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
153. n program is established for each Principle Structural Element PSE APSE 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 188 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 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 188 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
154. nal 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 PEAK TO PEAK LIFT OFF NULL POINT 20 Differential Probe Calibration Range Figure 2 4 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 The probe may be shielded or unshielded A shielded probe is normally recommended D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 3 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 100 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 the frequency should be 1 0 to 2 0 MHz NOTE Instrument frequency may need adjustment for the instrument and probe combination used
155. nd of Operation 16 Inspection Items D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 16 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 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 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
156. nded 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 17 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL b Position the legs on opposite ends of the part along a line perpendicular to the expected direction of the discontinuity NOTE It may take several inspections in several directions to find discontinuities that are
157. nuity will become visible again if the area is blotted clean and developer put on again 6 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 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 15 Cessna Aircraft Company
158. ny 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 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 ind
159. obe 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 IN 109 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 Eddy current instruments with a meter display are allowed for bolthole eddy current inspection The 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 Probe Sensitivity 1 The probe may have an absolute or differential coil arrangement 2 The probe may be shielded or unshielded A shielded probe is normally recommended 3 The probe must have an operating frequency that has the necessary test sensitivity and depth of penetration For an aluminum
160. ocalized 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 16 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 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 m
161. oderate corrosion 721 722 environment Inspect main landing gear flat spring for rust or damage to finish Refer to Section 24 14 04 Supplemental Inspection Document 32 13 01 for inspection procedure This interval is for mild moderate corrosion 510 520 environment Inspect wing for corrosion and 610 620 missing or loose fasteners Refer to Section 2A 14 12 Supplemental Inspection Document 57 11 02 for inspection procedure This interval is for mild moderate corrosion 510 610 environment Inspect wing splice joint at strut attach Refer to Section 2A 14 13 Supplemental Inspection Document 57 11 03 for inspection procedure This interval is for mild moderate corrosion 510 610 environment Inspect flap tracks for corrosion Refer to Section 2A 14 16 Supplemental Inspection Document 57 53 01 for inspection procedure End of Operation 10 Inspection Items KKK D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 10 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 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 th
162. ompany Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL CORROSION PREVENTION AND CONTROL PROGRAM CPCP 1 Introduction A As the 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 CPCP A CPCP 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 The 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 ti
163. on 2 The supplemental inspections that reference a Nondestructive Testing procedure will refer to 2A 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 SE74 4 SE74 6 SE80 57 SE80 85 SEB95 02 SEB95 03 SEB96 07 SL67 47 SE72 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Title Wing Spar Inspections for units 188 0001 thru 18800832 Main Landing Gear Attachment Improvement for units 1880001 thru 18801374 Elevator Trim Tab Inspection for units 188 0001 thru 18803658 Vertical Fin Rear Spar Inspection for units 18801375 thru 18803725 and T18803307T thru T18803725T Vertical Stabilizer Rear Spar Inspection and Reinforcement for units 18801375 thru 18803973 18801375T thru 18803973T T18803307T thru T18803974T and A A1880019 thru A A1880034 Flap Support Inspec
164. on 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 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 23 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 inspecti
165. orrosion 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 CPCP 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 5 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 CPCP 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 operating environm
166. pany INSPECTION COMPLIANCE Refer to Note 1 INITIAL 600 Hours or 1 Year 10 000 Hours or 20 Years 1 000 Hours or 3 Years MILD MODERATE 20 Years SEVERE 10 Years 3 000 Hours or 5 Years MILD MODERATE 2 Years SEVERE 1 Year MILD MODERATE 10 Years SEVERE 5 Years 10 000 Hours or 20 Years 10 000 Hours or 20 Years 1 000 Hours or 3 Years TYPICAL 12 000 Hours or 20 Years SEVERE 6 000 Hours or 10 Years REPEAT 600 Hours or 1 Year 3 000 Hours or 5 Years 1 000 Hours or 3 Years MILD MODERATE 10 Years SEVERE 5 Years 1 000 Hours or 5 Years MILD MODERATE 2 Years SEVERE 1 Year MILD MODERATE 10 Years SEVERE 5 Years 3 000 Hours or 5 Years 3 000 Hours or 5 Years 1 000 Hours or 3 Years TYPICAL 2 000 Hours or 10 Years SEVERE 1 000 Hours or 5 Years 2A 14 00 INSPEC TION OP ERATION 8 10 12 16 13 14 17 18 19 20 Page 2 Aug 1 1983 DETAILS FOUND IN SECTION 2A 14 XX 24 14 12 24 14 13 24 14 14 24 14 15 2A 14 16 2A 14 17 NOTE 1 first SUPPLEMENTAL INSPECTION NUMBER 57 11 02 57 11 03 57 40 01 57 51 01 57 53 01 71 20 01 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TITLE Wing Structure Cor rosion Inspection Wing Splice Joint at Strut Attach Inspec tion Strut and Strut Wing Attachment tion Aileron Structure Inspection Flap Tracks an
167. r 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 optic 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
168. r 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 If 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 Visually 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 188 Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCAT
169. r 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 COMMENTS D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 07 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 55 10 01 1 TITLE Horizontal Stabilizer Elevators and Attachments Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE ALL USAGE INITIAL 10 000 Hours Or 20 Years NOTE REPEAT 3 000 Hours or 5 Years NOTE NOTE Refer to Note 1 Section 24 14 00 3 PURPOSE To inspect horizontal stabilizer elevator and attachments for signs of damage fatigue or deterioration 4 INSPECTION INSTRUCTIONS A Open all stabilizer and elevator access panels including the stinger and vertical stabilizer to horizontal tail fairings Refer to the Model 188 Service Manual B Visually inspect stabilizer and elevator 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 Visually inspect the torque tube for corrosion and rivet security Pay particula
170. r 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 9 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 2540 1 or equivalent foreign documentation 4 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 throughout 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
171. r 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 188 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 24 30 00 Figure 1 Airplane Zones 6 Inspection Interval Requirements Operation 1 2 D2054 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 additional 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
172. rasive cloth to produce a diameter to depth ratio of about 10 1 Use ultrasonic methods to determine thickness after removing corrosion Refer to Section 17 Structural Repair of the Model 188 Service Manual for original tube wall thickness If more than 2096 of the tube thickness has been removed by the polishing process the tube must be repaired 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 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 d Apply topcoat within 24 hours 3 Apply Polyurethane Enamel Topcoat a Mix and apply in accordance with manufacturer s instructions b Apply mix
173. re 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 As 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 a Severe Usage Environment 1 If the average flight length is less than 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 A 1 a 1 or 2 A 1 a 2 above
174. 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 7121 Southwest Blvd Wichita KS 67215 U074100 Cessna Service Parts and To assist in protecting Commercially Available To assist in protecting Cor Ban 23 NOTE 1 5 Commercially Available To assist in protecting Commercially Available To assist in protecting ELEME AAA c o 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 8 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL A59703 W V 2 P Sa moon re dna a M z LE P LOCAL CORROSION CORROSION FOUND IN NON
175. res Inspect vertical stabilizer and rudder including spars ribs hinge bolts hinge bearings and attach fittings Refer to Section 2A 14 09 Supplemental Inspection Document 55 30 01 for inspection procedure Inspect the attach holes in the wing spar flange under the wing spar spray boom attach bracket Refer to Section 2A 14 10 Supplemental Inspection Document 57 10 01 for inspection procedures This interval is for typical usage environment 1 Inspect inboard wing structure for damage and working rivets 2 Inspect flap actuator support structure Refer to Section 2A 14 11 Supplemental Inspection Document 57 11 01 for inspection procedure This interval is for severe usage environment 1 Inspect inboard wing structure for damage and working rivets 2 Inspect flap actuator support structure Refer to Section 2A 14 11 Supplemental Inspection Document 57 11 01 for inspection procedure This interval is for mild moderate corrosion environment Inspect wing for corrosion and missing or loose fasteners Refer to Section 24 14 12 Supplemental Inspection Document 57 11 02 for inspection procedure This interval is for severe corrosion environment Inspect wing for corrosion and missing or loose fasteners Refer to Section 2A 14 12 Supplemental Inspection Document 57 11 02 for inspection procedure This interval is for mild moderate corrosion environment Inspect wing splice joint at strut attach Refer to Section 2A
176. rmation 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 a 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 Inspect main landing gear axle assembly Make 721 722 sure you inspect these areas 1 Main gear axle and attach bolts 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 th
177. roceeds rapidly along the grain boundaries and destroys the solidity of the metal E Exfoliation gives the appearance of sheets of very thin metal separated by corrosion products It 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 F 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 G 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 H Filiform Corrosion 1 Filiform corrosion is a concentration cell corrosion process When a break in the protective coating over 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 gr
178. roded 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 B 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 14 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18451 UPPER END STRUT FITTING JURY STRUT P u cS LOWER END STRUT FITTING DETAIL A 0710T1032 STRUT AND STRUT WING ATTACHMENT INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company 2A 14 14 Page 3 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 51 01 1 TITLE Aileron Support Structure Inspection 2 EFFECTIVITY NOTE 188 0001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE ALL USAGE INITIAL 3 000 Hours Or 10 Years NOTE REPEAT 500 Hours OF 5 Years NOTE Refer to Note 1 Section 24 14 00 3 PURPOSE To ensure structural integrity of the Aileron Support Structure 4 INSPECTION INSTRUCTIONS A B C E Check airplane records to verify that SE81 32 and SE
179. rosol form HVLP Spray Gun Paint Masking Tape MF 3100 Microflex AirVerter To 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 be J Commercially Available For respiratory protection Commercially Available For masking the adjacent Aluminum Foil 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 Programs application Form Te Fan 7121 Southwest Blvd Wichita KS 67215 n Commercially Available To access the inspection area Magnifying Glass ooo Commercially Available eae the corrosion 16 Corrosion Inspections and Detection Methods A Typical Inspection Methods 1 nn mH WH 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
180. s CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 diameter 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
181. s 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 H Install rudder and all previously removed access panels Refer to the Model 188 Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION DETECTABLE CRACK SIZE Vertical Stabilizer Rudder and Vertical Stabilizer Attachment Not Allowed D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 09 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 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 prepacked 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 operators option to replace stiff bearings Repairs may be made in accordance with Section 17 Structural Repair of the Model 188 Service manual Coordinate any repair not available in Section 17 with Cessna Customer Service prior to beginning the repair 8 COMMENTS Coordinate this inspection with SID 55 10 01 Horizontal Stabilizer Elevators amp Attachments Inspection D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 09 Page 2 O Cessna Aircraft Compan
182. s which are also subject to corrosion influence 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 D 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 Battery Electrolyte 1 2 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 If corrosion appears use an approved repair method to repair the structure Steel Control Cable 1 2 Checking for corrosion on a control cable is normally accomplished during the preventative maintenance check During preventative maintenance broken wire and wear of the control cable are also checked If the surface of the cable is corroded carefully force the cabl
183. s 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 C The 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 June 30 2014 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 188 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 00 Page 5 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 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 Title Effectivity Inspection Comp
184. s 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 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 2 Cessna Aircraft Company Aug 1 1983 10 11 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 3 Doa visual 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
185. s instructions Apply mixture with a wet cross coat to yield a dry film thickness of 0 6 to 0 8 mils Allow to air dry for two to four hours Apply topcoat within 24 hours 3 Apply Polyurethane Enamel Topcoat to landing gear flat spring a b c 8 COMMENTS Mix and apply in accordance with manufacturer s instructions Apply mixture with a wet cross coat to produce a dry film thickness of 1 5 2 0 mils Allow to air dry per the manufacturer s instruction D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 04 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18392 MAIN LANDING GEAR SPRING MAIN LANDING GEAR SPRING MAIN LANDING GEAR AXLE DETAIL A 071071032 MAIN LANDING GEAR FLAT SPRING CORROSION INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 04 Page 3 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 32 13 02 1 TITLE Main Landing Gear Fittings Inspection 2 EFFECTIVITY NOTE 188 0001 thru T18803974 T A A1880001 thru A A1880034 INSPECTION COMPLIANCE ALL USAGE INITIAL 3 000 Hours Or 5 Years NOTE REPEAT 1 000 Hours OF 5 Years NOTE Refer to Note 1 Section 2A 14 00 3 PURPOSE To ensure structural integrity of the main landing gear fittings 4 INSPECTION INSTRUCTIONS A B C
186. s not 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 Put paint 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 CO 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 Theapplied 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 MPK Methyl Propyl Ketone to clean the sag or drip from the airplane After you clean the area apply the corrosion inhibiting compound
187. s of aircraft operators 2 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 3 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 parameters speed payload fuel etc that are used to calculate the loads spectrum B Stress Spectrum 1 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 2 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 describe
188. s 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 10 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 11 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 12 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 13 Supplemental Inspection Document items that are to be examined after the first 2 years The inspection is to be repeated every 2 years after the initial inspection has been accomplished for airplanes operating in a mild or moderate corrosion environment 14 Supplemental Inspection Document items that are to be examined after the first year The inspection is to be repeated every 1 year after the initial inspection has been accomplishe
189. selage internal structure in upper fuselage 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 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 210 210 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 O Cessna Aircraft Company 2A 12 06 Page 1 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TASK Areas of the cabin structure 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 Make sure you inspect these areas 1 Wing front spar and lower spar caps 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 struct
190. 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 Implementation of Corrosion Prevention and Control Program D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 2 FAA Advisory Circular AC43 4A Corrosion Control for Aircraft 3 Cessna Illustrated Parts Catalog part number P545 12 and P694 12 4 Cessna Service Manual part number D2054 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 Compa
191. sion environment Inspect seat rails for corrosion Refer to Section 2A 14 07 Supplemental Inspection Document 53 47 01 for inspection procedure This interval is for severe corrosion environment Inspect seat rails for corrosion Refer to Section 2A 14 07 Supplemental Inspection Document 53 47 01 for inspection procedure D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL Initial 10 000 hours or 20 years whichever occurs first Repeat 3 000 hours or 5 years whichever occurs first Initial 1 000 hours or 3 years whichever occurs first Repeat 1 000 hours or 3 years whichever occurs first Initial 20 years Repeat 10 years Initial 10 years Repeat 5 years Initial 3 000 hours or 5 years whichever occurs first Repeat 1 000 hour or 5 years whichever occurs first Initial 2 years repeat 2 years Initial 1 year Repeat 1 year Initial 10 years Repeat 10 years Initial 5 years Repeat 5 years 2A 10 01 OPERATION ZONE 7 211 11 320 330 10 721 722 12 721 722 16 210 13 210 14 210 17 211 18 211 Page 4 Aug 1 1983 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TASK Inspect horizontal stabilizer and elevator including spars ribs hinge bolts hinge bearings attach fittings and torque tube Refer to Section 2A 14 08 Supplemental Inspection Document 55 10 01 for inspection procedu
192. spection 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 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 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 l a 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 Inspect rudder pedal torque tube and cable 211 attachment arms Refer to 2A 14 02 Supplemental Inspection Document 27 20 01 for
193. ssna 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 Airworthiness 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 The CPCP Baseline Program consists of a Corrosion Program Inspection CPI and an inspection time Each inspection is to be done in an airplane zone D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 30 00 Page 3 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18379 1 1 0 WS 100 00 WS 100 00 340
194. 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 5 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 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 cab
195. t 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 CRACK 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 A local 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 If local web reduction of 20 exceeds 1 in length rail must be replaced 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 c d e D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 07 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B Reinstall seat and check for prope
196. t while removing attach bolts 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 front stub wing fitting Refer to Figure 1 Detail E 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 The hole size is 0 50 inches in diameter 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 the 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 rear stub wing fitting Refer to Figure 1 Detail F 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 Insp
197. tandard is not allowed 4 Surface Condition a b c 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 188 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 a b 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 current 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
198. ted 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 This interval is for severe usage environment 1 510 610 Inspect inboard wing structure for damage and working rivets 2 Inspect flap actuator support structure Refer to Section 2A 14 11 Supplemental Inspection Document 57 11 01 for inspection procedure This interval is for severe usage environment Inspect wing strut and strut tube Refer to Section 2A 14 14 Supplemental Inspection Document 57 40 01 for inspection procedure End of Operation 20 Inspection Items 510 610 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 O Cessna Aircraft Company 2A 12 20 Page 1 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION OPERATION 21 Date Registration Number Serial Number Total Time 1 Description A B C Operation 21 gives Expanded Maintenance Inspection items that are to be examined at the first 100 hours then every 600 hours or 12 months whichever occurs first thereafter Inspection items are given in the order of the zone in which the inspection is to be completed Frequently tasks give more information about
199. throughout the wing sections for corrosion or traces of corrosion products through the access panels and wing tips C 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 D 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 During the borescope inspection pay particular attention to rivet butts and flanges containing rivets E Install previously removed access panels fairings and wing tips Refer to the Model 188 Service Manual 5 ACCESS AND DETECTABLE CRACK SIZE ACCESS LOCATION ZONE DETECTABLE CRACK SIZE Wing Not Allowed 6 INSPECTION METHOD Visual Borescope D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 12 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 7 REPAIR MODIFICATION A If 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 Services for assistance prior to beginning the repair if the disassembly excee
200. tion and Roller Washer Installation AN3 5A Bolt Inspection Replacement Reinforced Rudder Pedal Attachment for units 188 0052 thru 188 0318 Aileron Control System Modification for units 188 0001 thru 188 0707 O Cessna Aircraft Company Associated Service Kit SK188 32 SK188 23A SK188 30 SK188 31 SK188 33 SK188 34 SK188 35 SK188 21D SK188 74 SK180 43 SK188 74A SK180 44 2A 14 00 Page 1 Aug 1 1983 2 Supplemental Inspections DETAILS FOUND IN SECTION 2A 14 XX 2A 14 01 2A 14 02 2A 14 03 2A 14 04 2A 14 05 2A 14 06 2A 14 07 2A 14 08 2A 14 09 2A 14 10 2A 14 11 SUPPLEMENTAL INSPECTION NUMBER 27 10 01 27 20 01 27 30 01 32 13 01 32 13 02 53 10 01 53 47 01 55 10 01 55 30 01 57 10 01 57 11 01 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TITLE Aileron Cable and Control System In spection Rudder Pedal Torque Tube Inspection Elevator Trim System Inspection Main Landing Gear Flat Spring Corrosion Inspection Main Landing Gear Fittings Inspection Tubular Fuselage In spection Seat Rails and Seat Rail Structure Corro sion Inspection Horizontal Stabilizer Elevators and Attach ments Inspection Vertical Stabilizer Rudder and Attach ments Inspection Wing Spar Spray Boom Hole Inspec tion Wing Structure In spection D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Com
201. tion and be traceable to the National Institute of Standards and Technology NIST or applicable foreign agency e In 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 surface 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
202. tions 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 a 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 Inspect aileron cables areas in contact with 510 520 pulleys and fairleads Refer to Section 2A 14 01 610 620 Supplemental Inspection Document 27 10 01 for inspection procedure End of Operation 8 Inspection Items xxx D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 12 08 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 10 000 hours of operation or 20 years whichever occurs first The inspection is to be repeated at Engine Overhaul a
203. ts 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 metals a 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
204. ture 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 20 01 Page 1 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B Inspection of Cable System NOTE For tools and equipment used in checking and rigging refer to the appropriate sections of the Model 188 Service Manual 1 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 2 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 C
205. ture with 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 D Cracks can be repaired in accordance with Section 17 Structural Repair of the Model 188 Service Manual Coordinate any repair not available in Section 17 with Cessna Customer Service prior to beginning the repair 8 COMMENTS D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 06 Page 2 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL DETAIL A TUBULAR FUSELAGE STRUCTURE 071071032 TUBULAR FUSELAGE INSPECTION Figure 1 Sheet 1 Page 3 Aug 1 1983 2A 14 06 O Cessna Aircraft Company B18394 N D2054 1 13 Temporary Revision Number 7 Dec 1 2011 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 53 47 01 1 TITLE Seat Rails and Seat Rail Structure Corrosion Inspection 2 EFFECTIVITY 188 0001 thru T18803974 T A A1880001 thru A A1880034 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 24 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 ma
206. ube Refer to Section 2A 14 14 Supplemental Inspection Document 57 40 01 for inspection procedure This interval is for severe usage environment Inspect wing strut and strut tube Refer to Section 2A 14 14 Supplemental Inspection Document 57 40 01 for inspection procedure Inspect aileron hinges hinge bolts hinge bearings and hinge and pushrod attach fittings Refer to Section 2A 14 15 Supplemental Inspection Document 57 51 01 for inspection procedure This interval is for mild moderate corrosion environment Inspect flap tracks for corrosion Refer to Section 2A 14 16 Supplemental Inspection Document 57 58 01 for inspection procedure This interval is for severe corrosion environment Inspect flap tracks for corrosion Refer to Section 2A 14 16 Supplemental Inspection Document 57 53 01 for inspection procedure Inspect tubular engine mount Refer to Section 2A 14 17 Supplemental Inspection Document 71 20 01 for inspection procedure Flaps 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 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 D2054 1 13 Temporary Re
207. ubsurface 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 This is 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 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 1 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL NAME NUMBER MANUFACTURER Eddy Current Instrument Nortec 2000 Olympus NDT Phone 781 419 3900 Web http www olympusndt comVM Products Surface Eddy Current Probe VM202RAF 6 VM Products Inc with 1 8 inch coil NOTE 1 Phone 253
208. umber 7 Dec 1 2011 2A 10 01 Page 2 Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL REVI TASK INTERVAL OPERATION ZONE SION STATUS Areas of the cabin structure Make sure you inspect Every 60 months 6 210 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 Areas of the cabin structure Make sure you inspect Every 60 months 6 210 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 Make sure you inspect these Every 60 months 6 510 areas 1 Wing front spar and lower spar caps 520 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 Make sure you inspect these Every 60 months 6 510 areas 1 Skin with emphasis at skin overlaps and 520 under access panels 2 Rear spar upper and lower 610 caps 3 Rear spar we
209. ure external 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 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 Horizontal stabilizer structure Make sure you 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 xxx End of Operation 6 Inspection Items ZONE 210 510 520 610 620 510 520 610 620 310 340 320 330 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company MECH INSP REMARKS 2A 12 06 Page 2 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL INSPECTION OPERATION 7 Date Registration Number Serial Number Total Time 1 Description A Operation 7 gives Supplemental In
210. v Cessna A Textron Company TEMPORARY REVISION NUMBER 7 DATED 1 DECEMBER 2011 MANUAL TITLE Model 188 amp T188 Series 1966 Thru 1984 Service Manual MANUAL NUMBER PAPER COPY D2054 1 13 TEMPORARY REVISION NUMBER D2054 1TR7 MANUAL DATE 25 March 1983 REVISION NUMBER 1 DATE 1 August 1983 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 13 00 1 Thru 8 24 10 01 1 Thru 7 24 13 01 1 Thru 23 24 12 01 1 24 14 00 1 Thru 3 24 12 02 1 24 14 01 1 Thru 2 24 12 03 1 Thru 2 24 14 02 1 Thru 2 2A 12 04 1 2A 14 03 1 Thru 3 2A 12 05 1 2A 14 04 1 Thru 3 2A 12 06 1 Thru 2 2A 14 05 1 Thru 2 2A 12 07 1 2A 14 06 1 Thru 3 2A 12 08 1 2A 14 07 1 Thru 2 2A 12 09 1 2A 14 08 1 Thru 4 2A 12 10 1 2A 14 09 1 Thru 4 2A 12 11 1 2A 14 10 1 Thru 2 2A 12 12 1 2A 14 11 1 Thru 3 24 12 13 1 24 14 12 1 Thru 2 24 12 14 1 24 14 13 1 Thru 3 24 12 15 1 24 14 14 1 Thru 3 24 12 16 1 24 14 15 1 Thru 3 2A 12 17 1 2A 14 16 1 Thru 2 2A 12 18 1 2A 14 17 1 Thru 3 2A 12 19 1 2A 20 01 1 Thru 6 Cessna Aircraft Company SECTION PAGE SECTION PAGE 2A 12 20 1 2A 30 00 1 Thru 21 24 12 21 1 Thru 2 2A 30 01 1 Thru 12 REASON FOR TEMPORARY REVISION 1 To add the Supplemental Inspection Documents SIDs Information 2 To add the Corrosion Prevention and Control Program CPCP Information 3 To add Control Cable Inspection Information dd INSTRUCTIONS FOR THIS TEMPORARY REVISIO
211. vision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL OPERATION ZONE Initial 10 years 12 510 Repeat 5 years 610 Initial 12 000 19 510 hours or 20 years 610 whichever occurs first Repeat 2 000 hours or 10 years whichever occurs first Initial 6 000 20 510 hours or 10 years 610 whichever occurs first Repeat 1 000 hours or 5 years whichever occurs first Initial 3 000 15 520 hours or 10 years 620 whichever occurs first Repeat 500 hours or 5 years whichever occurs first Initial 20 years 10 510 Repeat 10 years 610 Initial 10 years 12 510 Repeat 5 years 610 Initial 10 000 9 120 hours or 20 years whichever occurs first Repeat At Engine Overhaul Initial 100 hours 21 210 Repeat every 600 510 hours or 12 months 610 whichever occurs first Initial 100 hours 21 210 Repeat every 600 510 hours or 12 months 520 whichever occurs 610 first 620 2A 10 01 Page 6 Aug 1 1983 REVI SION STATUS CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL TASK Elevator 1 Check elevator travel and cable tension 2 Check elevator 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 1 Check elevator trim travel and cable tension 2 Check elevator trim cable system control cables and pulleys in accordance
212. with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables Rudder 1 Check rudder travel and cable tension 2 Check rudder cable system control cables and pulleys in accordance with the flight cable inspection procedures in Section 2A 20 01 Expanded Maintenance Control Cables D2054 1 13 Temporary Revision Number 7 Dec 1 2011 Cessna Aircraft Company INTERVAL OPERATION ZONE Initial 100 hours 21 210 Repeat every 600 310 hours or 12 months 320 whichever occurs 330 first Initial 100 hours 21 210 Repeat every 600 310 hours or 12 months 320 whichever occurs 330 first Initial 100 hours 21 210 Repeat every 600 310 hours or 12 months 340 whichever occurs first 2A 10 01 Page7 Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES 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 comp
213. works with the area for inspection A16319 INTERVAL BETWEEN REFERENCE POINTS INSPECTION POINTS O O x O INSPECTION LOCATIONS AT THE CORNERS OF THE SQUARES Sample of Conductivity Inspection Grid Pattern Figure 4 7 Reporting Results a 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 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 IG IN I ES D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 13 01 Page 11 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL 3 PENETRANT INSPECTION A General 1 2 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 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 The penetrant is a liquid that can get into surface openings A typical penetrant inspection uses
214. y Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18397 F LY B DETAIL A mea VERTICAL STABILIZER DETAIL E HINGE ASSEMBLY UPPER HINGE ASSEMBLY CENTER DETAIL B HINGE BRACKET LOWER DETAIL C DETAIL D 071071032 VERTICAL STABILIZER RUDDER AND ATTACHMENTS INSPECTION Figure 1 Sheet 1 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 09 Page 3 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL B18398 HINGE BRACKETS H s H 4 A Es gt i AS SA ZA gt pd DAS HINGE BRACKETS nd MA DETAIL F RUDDER J e BUSHING i TORQUE TUBE BELLCRANK ASSEMBLY DETAIL H BUSHING DETAIL J bus VERTICAL STABILIZER RUDDER AND ATTACHMENTS INSPECTION Figure 1 Sheet 2 D2054 1 13 Temporary Revision Number 7 Dec 1 2011 2A 14 09 Page 4 O Cessna Aircraft Company Aug 1 1983 CESSNA AIRCRAFT COMPANY MODEL 188 SERIES SERVICE MANUAL SUPPLEMENTAL INSPECTION NUMBER 57 10 01 TITLE Wing Spar Spray Boom Hole Inspection EFFECTIVITY 18801178 thru 18802057 INSPECTION COMPLIANCE ALL USAGE INITIAL 1 000 Hours Of 3 Years NOTE REPEAT 1 000 Hours or 3 Years NOTE NOTE Refer to Note 1 Section 2A 14 00 PURPOSE To inspect the boom attach holes for elongation INSPECTION INSTRUCTIONS A Remove spray boom and mounting bracket at WS 103 38 Refer to the Model 188 Service Manual B Inspect the two mounting bracket

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