Conquest TITLE AILERON HINGE BRACKET REPLACEMENT EFFECTIVITY Model Serial Numbers 441 441-0001 thru 441-0349, 698 DESCRIPTION To install stainless-steel aileron hinge brackets as a replacement for aluminum hinge brackets. APPROVAL FAA approval has been obtained on technical data in this publication that affects airplane type design. REFERENCE CQB04-1 CHANGE IN WEIGHT AND BALANCE MODEL... 441 WEIGHT INCREASE... 1.5 pounds ARM... 202.00 Inches RESULTANT MOMENT... 303.00 Inch-Pounds MOMENT/1000... 0.303 Inch-Pounds June 3, 2004 Original Issue: April 19, 2004 Page 1 of 11 To obtain satisfactory results, procedures specified in this publication must be accomplished in accordance with accepted methods and prevailing government regulations. Cessna Aircraft Company cannot be responsible for the quality of work performed in accomplishing the requirements of this publication. Cessna Aircraft Company, Product Support, P.O. Box 7706, Wichita, Kansas 67277, U.S.A. (316) 517-5800, Facsimile (316) 942-9006 COPYRIGHT 2004
MATERIAL INFORMATION The parts listed below cover installation for one airplane. NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION SK441-112 1 Kit, consisting of the following parts: MS17826-3 1 Nut MS17826-4 4 Nut MS17826-4 Discard MS20426A4-3N 8 Rivet MS24665-134 1 Cotter Pin MS24665-134 Discard MS24665-136 4 Cotter Pin MS24665-136 Discard CR3553-4-3 60 Rivet CR3555-4-3 16 Rivet MS20427M4-5 16 Rivet MS20615-4M5 16 Rivet NAS464P4-12 4 Bolt Same Discard 5799010-3 4 Bracket 5799010-4 4 Bracket 5799010-5 2 Clip 5799010-6 2 Clip 5799010-7 2 Clip 5799010-8 2 Clip 5799010-9 2 Clip 5799010-10 2 Clip 5799010-11 2 Clip 5799010-12 2 Clip 5799010-13 2 Doubler 5799010-14 2 Doubler 1 Instructions Page 2 June 3, 2004
The following material, or equivalent, is necessary. NUMBER NAME MANUFACTURER USE EA9309.3NA Adhesive (24 gram Pack, 4 required) Cessna Aircraft Company Cessna Parts Distribution 5800 East Pawnee PO Box 1521 Wichita, KS 67218 To bond the doubler to the spar. ACCOMPLISHMENT INSTRUCTIONS 1. Prepare the airplane for maintenance. A. Make sure that all switches are in the OFF/NORM position. B. Disconnect electrical power from the airplane. (1) Disconnect the airplane battery. (2) Disconnect external electrical power. C. Attach maintenance warning tags to the battery and external power receptacle that have "DO NOT CONNECT ELECTRICAL POWER - MAINTENANCE IN PROGRESS" written on them. 2. Remove the left aileron and keep all the hardware. (Refer to the Maintenance Manual, Chapter 27, Flight Controls - Maintenance Practices.) 3. (Refer to Figure 1.) Replace the outboard hinge bracket on the left aileron. NOTE: Replacement is similar for the outboard hinge bracket on the right aileron. NOTE: For removal and installation of the fasteners, refer to the Model 441 Maintenance Manual, Chapter 51, Fastener Installation and Removal - Maintenance Practices. A. Remove the rivets that attach the outboard hinge bracket to the aileron and remove the bracket. B. Make hole location marks for the new bracket and doubler, and drill the holes. (1) Put the new 5799010-13 Doubler (outboard) centered in position on the back side of the removed bracket and use the removed bracket as a template to mark the holes. (2) Drill the marked holes in the doubler with a Number 28 (0.140 inch-diameter) drill bit. (3) (Refer to Figure 1, Sheet 5.) Measure and mark the location of the vertical centerline on the doubler as shown. (4) Mark the location of the holes in the doubler onto the new brackets. (a) Measure the width of the outboard bearing race on the wing and use that measurement to make aspacer from stacked washers, which will be installed between the brackets. Use masking tape to hold the stacked washers together. (b) Temporarily attach the new brackets and stacked washers together with the NAS464P4-13 Bolt and MS17826-4 Nut removed in Step 2. (c) Find and make amark of the centerline between the brackets on the washer stack and put the brackets in position on the doubler with the marked center lines in alignment. (d) Attach the brackets in position on the doubler with a clamp. (e) (Refer to Figure 1. Sheets 2 and 3.) Mark the Number 28 (0.140 inch-diameter) holes on the bracket attachment flange as shown. NOTE: The holes may not be in a straight line as shown in the illustration. (f) Drill the marked Number 28 (0.140 inch-diameter) holes in the brackets. June 3, 2004 Page 3
(5) Install the doubler and brackets to the spar with temporary sheet metal fasteners. (6) With the brackets attached to the spar, make marks and drill the four new Number 28 (0.140 inch-diameter) holes through the brackets, doubler and spar to the dimensions as shown. NOTE: Before drilling these holes make sure they are located with sufficient clearance from the bracket to use a pull fastener tool while keeping minimum edge distance. Adjust hole placement as necessary. C. (Refer to Figure 1.) Install the new clips. (1) Use clamps to hold the clips in position on the spar flange and on the new brackets. Make sure the clips are installed in the correct part number sequence as shown. (a) Remove material from the clips as necessary to give clearance between the clips and wing ribs. (Refer to the Model 441 Maintenance Manual, Chapter 51 - Hole Size and Edge Distance.) CAUTION: MAKE SURE PROPER EDGE DISTANCE IS KEPT WHEN MARKING AND DRILLING NEW HOLE LOCATIONS OR REMOVING MATERIAL (Refer to the Model 441 Maintenance Manual, Chapter 51 - Hole Size and Edge Distance.) (2) Make marks and drill the new Number 28 (0.140 inch diameter) holes through the clips as shown. (3) Match drill the Number 28 (0.140 inch diameter) holes through the spar flanges and clips with the holes that exist in the spar flange. (4) Remove the nut, washers, bolt and remove the brackets from the aileron with the clips still clamped on the brackets. (5) Make amark and drill the Number 30 (0.128 inch-diameter) holes through the sides of the clips and brackets. Use a drill press if possible. (6) Install the MS20426A4-3N Rivets as plugs in the top and bottom center holes as shown. (7) Make sure the hole alignment and installation is correct. (a) Assemble the brackets with the bolt, stacked washers (as a spacer) and nut with the clips clamped in position. (b) Position the bracket assembly and the doubler to the aileron spar with temporary fasteners. Examine this installation to make sure there is correct hole alignment. (8) After you complete a check of the installation, remove the brackets with the clips and doubler from the spar. (9) Remove the clips and brackets, and countersink 100 degrees, the holes in the clips as shown. (10) Install the clips to the brackets with MS20427M4-5 and MS20615M-4M5 Rivets as shown. D. Install the doubler to the spar. CAUTION: The doubler and the clip/bracket assemblies must be installed before the adhesive reaches pot life of approximately thirty minutes. (1) Clean the area on the spar that will be bonded to the doubler with Scotchbrite and MPK or equivalent. (2) Wipe dry with a clean cloth. (3) Use the instructions in the adhesive kit to bond the doubler to the spar with EA9309.3NA adhesive. E. Install the brackets with clips to the doubler and spar with CR3553-4-3 Rivets before the adhesive is cured as shown. Page 4 June 3, 2004
F. Install the CR3555-4-3 and CR3553-4-3 Rivets through the top and bottom spar flange and clips as shown. 4. (Refer to Figure 1.) Replace the inboard hinge bracket on the left aileron. NOTE: Replacement is similar for the inboard right hinge bracket on the right aileron. NOTE: For removal and installation of the fasteners, refer to the Model 441 Maintenance Manual, Chapter 51, Fastener Installation and Removal - Maintenance Practices. A. Remove the rivets that attach the inboard hinge bracket to the aileron and remove the bracket. B. Make hole location marks for the new bracket and doubler, and drill the holes. (1) Put the new 5799010-14 Doubler (inboard) centered in position on the back side of the removed bracket and use the removed bracket as a template to mark the holes. (2) Drill the marked holes in the doubler with a Number 28 (0.140 inch-diameter). (3) (Refer to Figure 1, Sheet 5.) Measure and mark the location of the vertical centerline on the doubler as shown. (4) Mark the location of the holes in the doubler onto the new brackets. (a) Measure the width of the inboard bearing race on the wing and use that measurement to make aspacer from stacked washers, which will be installed between the brackets. Use masking tape to hold the stacked washers together. (b) Temporarily attach the new brackets and stacked washers together with the NAS464P4-13 Bolt and MS17826-4 Nut removed in Step 2. (c) Find and make amark of the centerline between the brackets on the washer stack and put the brackets in position on the doubler with the marked center lines in alignment. (d) Attach the brackets in position on the doubler with a clamp. (e) Mark the Number 28 (0.140 inch-diameter) holes on the bracket attachment flange as shown. NOTE: The holes may not be in a straight line as shown in the illustration. (f) Drill the marked Number 28 (0.140 inch-diameter) holes in the brackets. (5) Install the doubler and brackets to the spar with temporary fasteners. (6) With the brackets attached to the spar, make marks and drill the four new Number 28 (0.140 inch-diameter) holes through the brackets, doubler and spar to the dimensions as shown. NOTE: Before drilling these holes make sure they are located with sufficient clearance from the bracket to use a pull fastener tool while keeping minimum edge distance. Adjust hole placement as necessary. C. Install the new clips. (1) Use clamps to hold the clips in position on the spar flange and on the new brackets. Make sure the clips are installed in the correct part number sequence as shown. (a) Remove material from the clips as necessary to give clearance between the clips and wing ribs. Make sure to keep the specified edge distance. (Refer to the Model 441 Maintenance Manual, Chapter 51 - Hole Size and Edge Distance.) (2) Make marks and drill the new Number 28 (0.140 inch diameter) holes through the clips as shown. (3) Match drill the Number 28 (0.140 inch diameter) holes through the clips with the holes that exist in the spar flange. (4) Remove the nut, washers, bolt and remove the brackets from the aileron with the clips still clamped on the brackets. June 3, 2004 Page 5
(5) Make a mark and drill the Number 30 (0.128 inch-diameter) holes through the sides of the clips and brackets. Use a drill press if possible. (6) Install the MS20426A4-3N Rivets as plugs in the top and bottom center holes as shown. (7) Make sure the hole alignment and installation is correct. (a) (b) (c) Assemble the brackets with the bolt, stacked washers (as a spacer) and nut with the clips clamped in position. Position the bracket assembly and the doubler to the aileron spar with temporary sheet metal fasteners. Examine this installation to make sure there is correct hole alignment. If holes and brackets are not aligned and cannot be adjusted, replace the affected parts. (8) Remove the clips and brackets and countersink the holes in the clips 100 degrees as shown. (9) Install the clips to the brackets with MS20427M4-5 and MS20615M-4M5 Rivets as shown. D. Install the doubler to the spar. CAUTION: The doubler and the clip/bracket assemblies must be installed before the adhesive reaches pot life of approximately thirty minutes. (1) Clean the area on the spar that will be bonded to the doubler with Scotchbrite and MPK or equivalent. (2) Wipe dry with a clean cloth. (3) Use the instructions in the adhesive kit to bond the doubler to the spar with EA9309.3NA adhesive. E. Install the brackets with clips to the doubler and spar with CR3553-4-3 Rivets before the adhesive is cured as shown. F. Install the CR3555-4-3 and CR3553-4-3 Rivets through the top and bottom spar flange and clips as shown. G. Complete Steps 2 through 4F for the right aileron hinge brackets. 5. Paint the assemblies. (Refer to the Model 441 Maintenance Manual, Chapter 20, Cleaning/Painting.) A. The adhesive must cure for at least four hours at room temperature, or two hours with 150 to 180 F before you apply paint. B. Use corrosion resistant primer first and allow to cure. C. Paint the hinge brackets, rivets and applicable areas to match the finish paint on the airplane. 6. Balance the left and right aileron assemblies. (Refer to the Maintenance Manual, Chapter 27, Flight Controls - Maintenance Practices.) 7. Install the aileron with the retained washers and the new bolts, new nuts and new cotter pins that came with the kit. (Refer to the Maintenance Manual, Chapter 27, Flight Controls - Maintenance Practices.) NOTE: A maximum of four NAS1149C0416R Washers can be used for shims between the new hinge brackets and bearing. Use no more than three washers stacked together on any side. 8. Make an entry in the airplane logbook stating this Service Kit has been installed. NOTE: This information shall be considered an amendment to the Cessna Manufacturer s Service/Maintenance Manual and should be accomplished within the specified time requirement. Page 6 June 3, 2004
Figure 1. Aileron Hinge Bracket Replacement (Sheet 1) June 3, 2004 Page 7
Figure 1. Aileron Hinge Bracket Replacement (Sheet 2) Page 8 June 3, 2004
Figure 1. Aileron Hinge Bracket Replacement (Sheet 3) June 3, 2004 Page 9
Figure 1. Aileron Hinge Bracket Replacement (Sheet 4) Page 10 June 3, 2004
Figure 1. Aileron Hinge Bracket Replacement (Sheet 5) June 3, 2004 Page 11