Professional Documents
Culture Documents
ATP Index
ATP Index
ATP Index
Section TopiC
General Information
Title Page
List of Parts
Manufacturer’s Introduction
Record of Revisions
Record of Temporary Revisions
List of Effective Pages
Part 1 General
Record of Temporary Revisions
List of Effective Pages
Personnel and Facilities
Part 2 X-Ray
Record of Temporary Revisions
List of Effective Pages
X-Ray Inspection General
Part 4 Ultrasonic
Record of Temporary Revisions
List of Effective Pages
Ultrasonic Inspection
CS 2614 ND
Section TopiC
Part 7 Penetrant
Record of Temporary Revisions
List of Effective Pages
Penetrant Inspection General
Part 9 Optical
Record of Temporary Revisions
List of Effective Pages
Optical Inspection General
Window Crack Prism Inspection
CS 2614 ND)
Section Topic
End of Index
CS 2614 ND
NI FG I
INTRO
Ilil
Cassna
A fextron Company
IVIODEL 208
NONDESTRUCTIVE
TESTING NIANUAL
~3 Member of GAMA
FAA APPROVAL HAS BEEN OBTAINED ON TECHNICAL DATA IN THIS PUBLICATION THAT AFFECTS AIRPLANE TYPE DESIGN.
COPYRIGHT 0 2003
CESSNA AIRCRAFT COMPANY
WICHITA, KANSAS, USA 3 NOVEMBER 2003
208ND00
RECORD OF REVISIONS
MFG REV
NO DESCRIPTION ISSUE DATE ATP REV DATEI INSERTED BY
3/15/2006
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
RECORD OF REVISIONS
LIST OF REVISIONS
1. Gieneral
A. This Model 208 Nondestructive Testing Manual includes the initial copy and the listed revisions that
follow. To make sure that information in this manual is the newest data and the latest maintenance
and inspection procedures are available, revisions must be put into the manual as they are supplied.
~´•F´•
TEMP ATP REV INSERT DATE REV REMOVE
REV NO DESCRIPTION ISSUE DATE DATE BY REMOVED INCOR BY
3/1512006
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
INTRODUCTION
i. Coverage
A. The Model 208 Nondestructive Testing Manual is prepared in accordance with the Air Transport
Association Specification 2200 for Manufacturers Technical Data.
B. This Nondestructive Testing Manual contains nondestructive inspection technical data to let approved
personnel, that do not know the airplane, do the nondestructive test procedures.
C. This manual has procedures by which all Model 208 and 203B personnel are told of nondestructive
test instructions. This manual will be revised to include more procedures as necessary, if service or
test programs show the need for these procedures.
2. Scope
A. Nondestructive tests have procedures to look for quality, integrity, properties, and dimensions of
materials and components, without damage to their serviceable condition. Inspection procedures
include visual, radiographic, ultrasonic, eddy current, penetrant, and magnetic particle.
B. Inspection personnel must know how to correctly do nondestructive tests. This will help to make sure
the correct procedures are used and that there are accurate reports of the results. Cessna has a
sequence for the certification of nondestructive test procedures and personnel. Refer to Part 1, 20-
00-00.
3. Airplane Identification
A. All airplanes have a serial number. These numbers are given one after the other to each airplane as
the assembly starts and stay with the airplane through its service life. The airplane serial number is
on the left side of the tailcone.
B. Inspections in this manual are to be applied to those airplanes identified by serial number for a given
inspection (refer to Inspections).
grouped together on the CD. These technical publications have the newest facts through regular
revisions.
Part 1- General
Part 2 X-Ray
Part 4 Ultrasonic
Part 7 Penetrant
INTRODUCTION Page 1
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
Part 9 Optical
(3) Effectivity Page. (There are paper and Aerofiche versions of this manual only)
(a) A list of effectivity pages is given with each part. All pages in the specified part are shown
in numerical sequence on the List of Effective Page(s) with the date of issue for each page.
C. Temporary Revision.
(1) Additional information which becomes available can be used as a temporary revision.
Temporary revisions are usually included into the Nondestructive Testing Manual at the next
regularly scheduled revision, and become a permanent part of the manual.
(2) Temporary revisions are printed on yellow paper for easy identification compared to regular
revised pages.
A. Changes or revisions to the text in a section will be identified by a revision bar in the left margin of the
page adjacent to the change.
B. When a large quantity of technical changes are made to the text in a section that needs a large revision,
the revision bars will be shown the full length of the text.
C. New or revised art added to a section will be identified by a change bar along the full length of the
page.
INTRODUCTION Page 2
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
A. Through all the text in this manual are warnings, cautions, and notes that are related to the procedures
that areused. These secondary parts of the text are used to identify important information.
(1) WARNING Tells information about use of materials, procedures, or limits which must be followed
accurately to prevent injury or death to personnel.
(2) CAUTION Tells information about procedures which must be followed to prevent damage to
equipment.
(3) NOTE Tells information about procedures which will make the task easier.
9. Terminology
A. Such items as left and right, top and bottom, front and rear, forward and aft, and clockwise and
counterclockwise refer to the airplane as viewed from the rear, on the centerline, or when you look
forward. All dimensions, material gages, and distances are given in inches if not diferently specified.
10. Inspections
A. The inspection procedures given in this manual will be done at intervals specified in applicable
inspection needs, found in the applicable 208 Maintenance Manual.
B. The necessary inspections are given in a procedure to show what airplane component is to
be inspected, the correct inspection procedure, and what conditions are to be looked for. The
instructions are written to point the technician to look at components and areas that possibly are
unserviceable.
C. This manual does not contain instructions for repair, adjustment, or other procedures to correct
unserviceable conditions. Refer to applicable parts of the Model 208 Maintenance Manual or Model
208 Structural Repair Manual for maintenance instructions.
INTRODUCTION Page 3
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
LIST OF PARTS
NOTE 1: *Represents date of page one of each chapter’s List of Effective Pages which is applicable to Manual
revision date.
GENERAL
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
CONTENTS
Temporary Revision
Number
Page Number Issue Date By Date Removed BY
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
Title
Part 1 List of Effective Pages 1 Nov 3/2003
Record of Temporary Revisions
Part 1 Contents 1 Nov 3/2003
Part 1 20-00-00 1 Nov 3/2003
1. Scope
A. This document is applicable to all facilities and personnel performing nondestructive inspections on
2. Purpose
A. The purpose of this document is to make sure the nondestructive inspections performed on Model
208 and 208B airplanes are accomplished by certified facilities and personnel.
(1) Facilities doing nondestructive inspection as defined in this Nondestructive Testing Manual must
hold a valid FAA Repair Station Certificate with a Specialized Service Rating in the applicable
method of nondestructive inspection. Facilities not under the jurisdiction of the FAA must meet
the requirements of their governing agencies’ Civil Aviation Authority or applicable regulatory
agency.
(2) Personnel that do nondestructive inspections defined in this Nondestructive Testing Manual must
be certified to a minimum of a Level II in the appropriate inspection method as defined in a written
practice that meets the minimum intent of an internationally recognized certification scheme,
such as but not limited to:
(a) The American Society for Nondestructive Testing Recommended Practice Number SNT-
TC-1A or
(b) National Aerospace Standard NAS 410, NAS Certification and Qualification of
Nondestructive Test Personnel or
(c) ISO 9712, Nondestructive Testing qualification and Certification of Personnel or
(d) BS EN 4179:2000, Qualification and approval of personnel for nondestructive testing or
(e) AINDT0.004, Guide to Qualification and Certification.
(3) Facilities that do nondestructive inspection as defined in this Nondestructive Testing Manual must
own or have access to the appropriate test equipment capable of performing the inspection and
X-RAY
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
CONTENTS
Temporary Revision
Page Number Issue Date By Date Removed By
Number
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
Title
Part 2 List of Effective Pages 1 Nov 3/2003
Record of Temporary Revisions
Part 2 Contents 1 Nov 3/2003
Part 2 20-00-00 1 Nov 3/2003
2 Nov 3/2003
PART 2 1
LIST OF EFFECTIVE PAGES Page 1
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
i. General
A. A radiographic inspection will show internal and external structural details. This inspection is
applicable for all types of parts and materials. It is a type of nondestructive test that lets you examine
the parts of the airframe structure that you cannot get access to or that you cannot examine with
other types of nondestructive tests.
B. In a radiographic inspection test, an X-ray beam passes through a part or an assembly to expose a
piece of radiographic film. Structural details of the part or assembly will show as differences in film
density after the film is processed. An operator must interpret the radiograph to find damage.
2. Safety
A. Obey all safety precautions. The X-rays used in this test are dangerous to the personnel who do
the test and to people around them. A good source of data about protection from radiation is the
National Bureau Of Standards Handbook 93, "Safety Standard For Non-Medical X-Ray And Sealed
Gamma-Ray Sources."
A. Symbols.
(1) The symbols in Figure 1 show the X-ray tube anode (source). The number corresponds to the
radiographic exposure.
A25912
a a
COORDINATE
GENERIC ANODE POSITION.
POSITION OF
ANODE (SOURCE) NUMERAL INDICATES
ANODE
POSITION RADIOGRAPH NUMBER.
REFER TO PROCEDURES
FOR RADIOGRAPH DATA
5583T1014
Symbols
Figure 1
B. Abbreviations.
(1) KV Kilovoltage.
(2) MAS Milliampere Seconds.
(3) MAM Milliampere Minutes.
(4) SFD Source to Film Distance.
4. Procedures
A. Make sure that the surface of the part that will be radiographed is clean. If you must clean the part, refer
to the Model 208 Structural Repair Manual or to the Model 208 Maintenance Manual for instructions.
B. Make sure that the central beam of radiation stays at a 90-degree angle to the surface of the film.
D. Keep the distance from the X-ray source to the film (the focal distance) sufficient to make a sharp
image on the film.
NOTE: The adjustments that are speci;;i in individual radiographic procedures in this manual are
guidelines to make good radiographs. It could be necessary to change the MA, time, and
KV settings to get the contrast, sensitivity, and density specified. This can be because of
differences in equipment, film, or method of processing. X-ray equipment is permitted if it
makes radiographs of the quality specified by this manual.
E. Use the lowest possible potential (kilovoltage) and the highest possible current (milliamperage) to get
correct sensitivity, contrast, and density.
NOTE: This manual gives the best densities for each inspection procedure. Densities lower than
1.5 and higher than 3.7 are not acceptable for proper film interpretation.
F. Be careful when you handle and store radiographic film that has not been developed. This will help
toprevent blemishes which can cause you to interpret radiographs incorrectly.
5. Test Equipment
A. The specified X-ray unit was used to make the X-ray inspection procedures in this manual. When you
use other equipment, it might be necessary to adjust the techniques in this manual.
Equipment Manufacturer
NOTE: Radioactive isotopes (Gamma Ray) are not permitted for the radiographic inspections in
this manual.
ULTRASONIC
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
CONTENTS
Title
Part 4 List of Effective Pages 1 Nov 3/2003
Record of Temporary Revisions
Part 4 Contents 1 Nov 3/2003
Part 4 20-00-00 1 Nov 3/2003
ULTRASONIC INSPECTION
1. General
A. Ultrasonic inspection uses high frequency sound waves as a probing medium to get information about
the condition of materials. This method is good for the inspection of most materials for surface and
subsurface defects. At least one surface of the part must be accessible in the vicinity of the area to
be examined.
B. The inspection of airframe structure is done when the ultrasound is put into the part by a contacting
probe (transducer) and the reflections of this sound are picked up from within the part. The detected
ultrasonic reflections are electronically shown on an oscilloscope and interpreted for possible defect
indications. Accessory devices must give sufficient probe coupling to curved surfaces, or to change
the angle of the sound beam in the material or part under inspection.
C. In most of the ultrasonic inspection techniques prepared for this manual, information has been given
for the fabrication of an ultrasonic Reference Standard. The selection and use of reference standards
is very important for successful ultrasonic inspection of airplane components.
D. Before most inspections, the type and general location of defects that may occur are known. Therefore,
when Reference Standards with calibrated reflectors that are similar to the defects are used, an
established inspection procedure can prove their validity. If the inspection procedure can clearly sense
the artificial defect, then theoretically it should also sense natural defects.
2. Test Equipment
A. In thedevelopment of the Ultrasonic Inspection Techniques contained in this manual, this ultrasonic
unit used (unless otherwise in a list in the specific inspection technique). When
was substitute
equipment is used, it may be necessary to make adjustments to the techniques.
Equipment Manufacturer
EDDY
CURRENT
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
CONTENTS
MAIN LANDING GEAR ATTACH FITTINGS AND AFT CARRY-THRU BULKHEAD. Part 6 53-20-05 Page 1
HORIZONTAL STABILIZER FORWARD AND AFT ATTACH POINTS Part 6 55-10-01 Page 1
Part 6 55-10-01 Page 1
Description
Personnel Requirements. Part 6 55-10-01 Page 1
Title
Part 6 List of Effective Pages 1 Nov 3/2003
2 Nov 3/2003
Record of Temporary Revisions
Part 6 Contents 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
Part 6 20-00-01 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
Part 6 20-00-02 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
Part 6 20-00-03 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
Part 6 53-10-01 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
5 Nov 3/2003
6 Nov 3/2003
Part 6 53-20-01 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
Part 6 53-20-02 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
Part 6 53-20-03 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
Part 6 53-20-04 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
5 Nov 3/2003
6 Nov 3/2003
Part 6 53-20-05 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
Part 6 53-20-06 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
5 Nov 3/2003
6 Nov 3/2003
i. Description
A. Eddy current inspection is good for the detection of surface or near-surface cracks in most metals. This
method is done when eddy currents are put into the part and then monitored for electrical changes of
the induced field. The field change is interpreted to find the type of defect. Eddy current inspection
can be used on airframe parts or assemblies where the inspection area is accessible to contact by the
eddy current probe. An important use of eddy current inspection is to find cracks caused by corrosion
and stress around fastener holes with the fasteners installed.
B. This section gives the general requirements for the use of the eddy current method to find defects
within holes. Use this section with specific instructions for the location of the inspection and the types
of discontinuities to be detected.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
A107fi6
SENS1TIVI~TY
i
~I(_ r~ 1-EWELr
_ ____ _I.~-
~-_ ~___´•
-c- i ´•´•i´•
´•´•r
Afs316
_
i- -1. --.´•-I. i., .f .i- -.-i....
´•´•´•r- -1´•- -i´•- -i´• .~1-´•:. MINIMUM
i´•´•
L __+._ ~._..´•.
-. .´•1
_
SENSITIV1TY
LEVEL IS 3
DIVISIONS FROM
-I
i
PEAK TO PEAK
zo´• i
LIFT-OFF
~I
..-i~ ~1.- li.~ I.i,..
7.
NULL POINT
i- -i~.i
i- ´•t ’j I-iii
i ´•´•i´• ´•1´• -_
´•t´• i´•´•´•- i
_,;.,
(3) Make sure the functional performance of the eddy current instrumentation is verified on an annual
basis.
8, Probe Sensitivity.
(1) The probe can have an absolute or differential coil arrangement.
(2) The probe can be shielded or unshielded. A shielded probe is usually recommended.
(3) The probe must have an operating frequency that gives the required test sensitivity and depth
of penetration,
(a) For a bolt hole inspection done on an aluminum part, the frequency must be 200 kHz.
(b) For a bolt hole inspection done on titanium, the frequency must be 1 MHz to 2 MHz.
(c) For a bolt hole inspection done on steel, the frequency must be 500 kHz to 800 kHz.
NOTE: The approximate frequencies must be used unless a different frequency is shown in
a specific procedure. The actual frequency used will depend on the ability of the test
systems (probe and instruments) to meet the required test sensitivity.
(4) Smaller coil diameters are better for the detection of cracks. A coil diameter of 1/8 inch is usually
used.
(5) For crack detection, the coil will usually contain a ferrite core.
(6) The probe must not give interference responses caused by pressure of use, probe movement,
or normal operating pressure variations on the sense coil which cause the signal-to-noise ratio
to be less than 3 to 1.
(7) Teflon tape can be used to decrease the wear on the eddy current probe coil. When Teflon tape
is used, a new instrument calibration must be done.
A. Nonferrous reference standards must be of an alloy that has the same major base metal, basic temper,
and the approximate electrical conductivity as the material to be inspected.
B, Reference standards must have a minimum surface finish of 150 RHR or RMS 165.
C. The dimensional accuracy of EDM notches must be documented and traceable to the National Institute
of Standards and Technology (NIST),
geometry, configuration, and/or the specific discontinuity location. Artificial discontinuities can be
used in the reference standard.
5. Inspection Considerations
A. Temperature: Inspections must not be done until the temperature of the probe, the standard, and the
material are equal.
B. Surface Condition:
(1) Finish: The surface finish of the area to be tested must be 150 RHR or RMS 165 or smoother.
(2) Cleanliness: The test area must be free of dirt, grease, oil, or other contaminants.
(3) Probe Contact: Eddy current inspection must be done with good contact made between the
probe and the part unless a specific procedure requires an offset. Lightly corroded parts must
be cleaned lightly with emery cloth. Severely corroded or painted parts must be lightly abraded
and cleaned locally in the area on which the probe will be put.
6. Instrument Calibration
A. The instrument must be calibrated and operated in accordance with this technique and the
manufacturer’s instructions.
B. Instrument calibration must be done before inspection. Calibration must be checked at intervals
as necessary to maintain calibration during continuous use and at the end of the inspection. The
instrument must be calibrated again if any part of the system is replaced or if any calibrated control
settings are changed.
C. A 0.050 inch x 0.050 inch corner notch must be used for calibration unless another dimension is given
in the procedure. A typical eddy current bolt hole reference standard with EDM notch depths of 0.050
inch x 0.050 inch is shown in Figure 3.
A16318
O
O
\9,
a
\a Oror
O,\~p,
~´•a: C3 ~9
s´•c~
D. Adjust the instrument to get a minimum separation of three major screen divisions between the
null/balance point and the applicable reference notch. The signal from a differential probe must be
considered peak-to-peak.
7. Inspection
A. When the inspection procedure does not give the depths at which the scans are to be made, this
general procedure must be used:
(1) Select the appropriate probe and instrument.
(2) Put the probe into the hole and get an indication for the near edge of the hole.
(a) This is the point when the signal is 50 percent between the signal for an air condition and
the probe fully in the hole.
(b) Record the distance between the center of the probe coil and the edge of the probe guide.
(3) Move the probe through the hole until the signal shows that it is past the far edge of the hole.
(a) This is the point when the signal is 50 percent between the signal for an air condition and
the probe fully in the hole.
(b) Record the distance between the center of the probe coil and the edge of the probe guide.
(4) More than one layer can be found by slow movement of the probe through the hole. A layer
interface will look like a crack indication. The difference is that the interface will be seen through
360 degrees 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 is at its maximum.
(5) Do the inspection at a hole depth of 0.070 inch from either edge of the hole. Do the inspection
every 0.070 inch through the hole. If the hole has more than one layer, the inspection
requirements must be done on each layer.
8. 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 found for left and right probe movement, carefully
monitor the amount of probe movement or turn needed to cause the instrument to move off from the
maximum indication.
B. When the eddy probe is centered over a crack, the signal will be at maximum and any
current
movement of the probe (exceeding 0.020 inch, or 2 degrees) will cause the signal to start to go
back to the original reading. Corrosion pits, foreign material, and out-of-round holes can cause an
instrument response for 20 to 30 degrees of bolt hole probe rotation before the indication starts to
go back to the original reading.
D. Find the end of a crack using the 50 percent method. Move the probe slowly across the end of the
crack until a point is found where the crack signal amplitude has been reduced by 50 percent. The
center of the probe coil at this point is the end of the crack.
9. Reporting Results
A. If theinspection procedure has not told you what to do damaged part, contact Cessna
with the
Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS 67277 USA.
Telephone 316-517-5800
Fax 316-942-9006. Include sufficient information in all written descriptions so that someone not
involved with the inspection can interpret the results. Give the following information:
(1) Location of the hole with the discontinuity.
(2) Depth of the discontinuity into the hole and, if applicable, the material layer.
(3) Discontinuity orientation relative to the hole.
i. Description
A. Eddy current inspection is good for the detection of surface or near-surface cracks in most metals. This
method is done when eddy currents are put into the part and then monitored for electrical changes of
the induced field. The field change is interpreted to find the type of defect. Eddy current inspection
can be used on airframe parts or assemblies where the inspection area is accessible to contact by the
eddy current probe. An important use of eddy current inspection is to find cracks caused by corrosion
and stress around fastener holes with the fasteners installed.
B. This section gives the general requirements for the use of the eddy current method to find surface
defects. Use this section with specific instructions for the location of the inspection and the types of
discontinuities to be detected.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
b107fi6
r´•l´•´•-´•
1;
´•´•t´•´• ´•i´•-´•´•´•´•´•~-
SENSI"I"IVITV
LEVEL
A16316
i-´•
i
i
i
,.,1,. .;;,._
-´•~r -´•i´•´•-´•´•
r- .;i.
i
i SENSITIVITY
LEVEL IS 3
DIVISIONS FROM
..i
PEAK TO PEAK
i zo´• I
LIFT-OFF
´•´•i I -I
NULL POINT j i
j20eC´•c~ )Y
i ´•´•I´• ´•-´•t´•; -´•1~´• I~
1 I I
´•.-_
.......,j _-.,___i ..............~.._
__.!
(3) Make sure the functional performance of the eddy current instrumentation is verified on an annual
basis.
B, Probe Sensitivity
(1) The probe can have an absolute or differential coil arrangement.
(2) The probe can be shielded or unshielded. A shielded probe is usually recommended.
(3) The probe must have an operating frequency that gives the required test sensitivity and depth
of penetration,
(a) Inspections done on aluminum must be done at an operating frequency of 200 kHz.
(b) Inspections done on titanium must be done at an operating frequency of 1 MHz to 2 MHz.
(c) Inspections done on titanium must be done at an operating frequency of 500 kHz to 800
kHz.
NOTE: The approximate frequencies must be used unless a different frequency is shown in
a specific procedure. The actual frequency used will depend on the ability of the test
systems (probe and instruments) to meet the required test sensitivity.
(4) Smaller coil diameters are better for detection of cracks. A coil diameter of 1/8 inch is usually
used.
(5) For crack detection, the coil will usually contain a ferrite core.
(6) The probe must not give interference responses caused by pressure of use, probe movement
or normal operating pressure variations on the sense coil which cause the signal-to-noise ratio
to be less than 3 to 1,
(7) Teflon tape can be used to decrease the wear on the eddy current probe coil. When Teflon tape
is used, a new instrument calibration must be done.
A, Nonferrous reference standards must be of an alloy that has the same major base metal, basic temper,
and the approximate electrical conductivity as the material to be inspected.
B. Reference standards must have a minimum surface finish of 150 RHR or RMS 165,
C. The dimensional accuracy of EDM notches must be documented and traceable to the National Institute
of Standards and Technology (NIST).
D. In some cases a specially fabricated reference standard will be necessary to simulate a part’s
geometry, configuration, and/or the specific discontinuity location. Artificial discontinuities can be
used in the reference standard.
5. Inspection Considerations
A. Temperature: Inspections must not be done until the temperature of the probe, the standard, and the
material are equal.
B. Surface Condition:
(1) Finish: The surface finish of the area to be tested must be 150 RHR or RMS 165 or smoother.
(2) Cleanliness: The test area must be free of dirt, grease, oil, or other contaminants.
(3) Probe Contact: Eddy current inspection must be done with good contact made between the
probe and the part unless a specific procedure requires an offset. Lightly corroded parts must
be cleaned lightly with emery cloth. Severely corroded or painted parts must be lightly abraded
and cleaned locally in the area on which the probe will be put.
6. Instrument Calibration
A. The instrument must be calibrated and operated in accordance with this technique and the
manufacturer’s instructions.
B. Instrument calibration must be done before inspection. Calibration must be checked at intervals
as necessary to maintain calibration during continuous use and at the end of the inspection. The
instrument must be calibrated again if any part of the system is replaced or if any calibrated control
settings are changed.
C. A 0.020 inch surface notch must be used for surface inspections unless another dimension is given
in the procedure. A typical eddy current surface reference standard with EDM notch depths of 0.010
inch, 0,020 inch, and 0.040 inch is shown in Figure 3.
A1G917
OQ~
D. Adjust the instrument to get a minimum separation of three major screen divisions between the
null/balance point and the applicable reference notch. The signal from a differential probe must be
considered peak-to-peak.
7. Inspection
A. When possible, the area of inspection must be inspected from two different directions which are at
paths 90 degrees to each other.
PART 6 1
20-00102 Page 3
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
B. Do the inspection in sections that are not wider than the eddy current test coil. The part edge must be
scanned if response from edge effect does not prevent the display of the calibration notch response.
Areas where edge effect is greater than the calibration notch signal must not be inspected using eddy
current.
C. When possible, fillets and radii must be scanned both transverse and parallel to the axis of the radius.
The edge of the fillet or radius must be scanned transverse to the axis of the radius.
8. 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 found for left and right probe movement, carefully
monitor the amount of probe movement or turn needed to cause the instrument to move off from the
maximum indication.
C. Find the end of a crack using the 50 percent method. Move the probe slowly across the end of the
crack until a point is found where the crack signal amplitude has been reduced by 50 percent. The
center of the probe coil at this point is the end of the crack.
9. Reporting Results
A. If the inspection procedure has not told you what to do with the damaged part, contact Cessna
Propeller Aircraft Product Support, PO. Box 7706, Wichita, KS 67277 USA. Telephone 316-517-5800
Fax 316-942-9006. Include sufficient information in all written descriptions so that someone not
involved with the inspection can interpret the results. Give the following information:
(1) Location of the discontinuity.
(2) The discontinuity size.
(3) The discontinuity orientation.
1. Description
A. This is a general inspection procedure that is used to find the conductivity of aluminum structures by
use of the eddy current method. This procedure is to be used with the applicable material specification
and structural engineering drawings to find if the conductivity values are acceptable or unacceptabie.
B. Conductivity testing is an effective method for determining the material properties of aluminum
structures. Eddy currents are put into the part and the variations in the electrical field caused by
conductivity changes are observed. Indications are recorded and compared to acceptable ranges
for the materialtested. However, other materials or geometric changes in the area can influence the
conductivity indication of the instrument. Therefore, accurate determination of material properties
cannot be made based on conductivity without access to the appropriate material specification and
engineering drawings.
C. A field application is to determine material properties after heat has been applied.
typical Such
situations include: structure heated by an engine or APU, fire damage, and lightning strike.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
B. Instrument Accuracy: The instrument used must be an eddy current instrument capable of determining
the conductivity of aluminum alloys as a percentage of the International Annealed Copper Standard
IACS) with an accuracy of within 1.0% IACS or better through electrically nonconductive films and
coatings up to at least 0.003 inch (0.08 mm) thick.
C. Instrument Sensitivity: The instrument must have a sensitivity such that changes of at least 0.5%
IACS are clearly distinguishable over the conductivity range of the aluminum alloys under test.
D. Probe: The probe to measure conductivity must have a flat contact surface. The contact surface
diameter must not be greater than 0.500 inch (13 mm).
E. Test lift-off compensation as follows: put the probe on a bare standard, then put a 0.003 inch (0.08
mm) thick nonconductive flat shim between the probe and the standard. The difference in the two
readings must not exceed 0.5% IACS. If it does, return the instrument to the calibration laboratory for
repair and recertification.
F The functional performance of the conductivity instrument must be verified at the intervals required by
the controlling specification or the manufacturer’s recommendation, whichever is less.
A. Each instrument must have a minimum of two aluminum alloy instrument conductivity standards that
are always kept with the instrument.
(1) One must have a value in the range of 25% to 32% IACS.
(2) One must have a value in the range of 38% to 62% IACS.
B. There must be a minimum spread of 10% IACS between the standard with the low range and the one
C. The instrument conductivity standards must be certified to be accurate within plus or minus 0.85%
IACS by the comparison method to the laboratory conductivity standards in accordance with ASTM
B193 procedure in a system per ISO 10012-1 ANSI/NCSL 2540-1.
D. Calibration must be made initially and at intervals such that they coincide with the conductivity
instrument recalibration cycle.
5. Inspection Considerations
A. Temperature: Inspections must not be done until the temperature of the probe, the standard, and the
material are equal. The temperatures must stay equalized and constant throughout the test within
3"C (5.4"F) of each other.
B. Surface Condition
(1) Finish: The surface finish of the area to be tested must be 150 RHR or RMS 165 or finer.
(2) Cleanliness: The areas to be tested must be free of dirt, grease, oil, or other contaminants.
(3) Nonconductive Coatings: Conductivity measurements may be made through anodize, chemical
film, primer, paint, or other nonconductive coatings, if these coatings do not exceed 0.003 inch
(0.08 mm) thickness. Coatings with a thickness greater than this must be removed prior to
conductivity testing.
(4) Surface Curvature: On concave surfaces, a curvature radius of 10 inches (250 mm) or more is
required. On convex surfaces, a curvature radius of 3 inches (8 mm) or larger is required.
(a) A correction factor must be applied for smaller radii.
(5) Probe Contact Area: The surface of the part to which the conductivity measuring probe is applied
must be at least as large as the outside diameter of the probe. If the part dimension is very nearly
equal to the probe diameter, the probe must be centered on the part.
6. Instrument Calibration
B. The instrument must be calibrated and operated as specified in this technique and the manufacturer’s
instructions.
C. Each time the conductivity instrument is used, it must be calibrated (standardized) using the
instrument conductivity standards before checks are made and rechecked at 15 minute intervals
during continuous operation. If the instrument is found to be out of calibration, all measurements
done since the last calibration must be rechecked.
A. Nonferrous reference standards must be of an alloy that has the same major base metal, basic temper
and the approximate electrical conductivity of the material to be inspected.
B. Reference standards must have a minimum surface finish of 150 RHR or RMS 165.
8. Inspection
A. The purpose of the inspection is to collect information to let the responsible engineering group
determine the material properties in the affected area.
NOTE: Because variations in materialproperties, material stacking, and geometry cause changes
of conductivity readings, conductivity readings alone must not be used to determine
if the affected area is accepted. Reference must be made to the applicable material
specifications and engineering drawings.
B. Visual
(1) Clean the area to be examined with methods specified in the appropriate maintenance manual.
Remove all dirt, grit, soot, and other debris that will not let the probe maintain good contact with
the structure.
(2) Examine the area visually for indications of possible heat damage. Some signs include paint/
metal discoloration and bubbled or peeled paint.
(3) Record the location and description of the heat damaged area. This description will be used
along with the conductivity readings to determine the type of repair. if photographs are used to
describe the area, take the picture before the conductivity test is done.
NOTE: A detailed map will need to be made of the inspection area. It must include
dimensions to locate the reference point and enough information to let the
engineering personnel that do the review of the information locate the places the
conductivity readings were taken.
(3) The total area to be examined, and the distance between readings will depend on the specific
situation. It is recommended that the distance between conductivity readings not exceed 1 .0 inch
(25 mm). If the visual evidence or the conductivity readings suggest rapid changes in severity,
decrease the distance between test points. It is recommended that the total area to be examined
exceed the area of visual evidence by at least 2.0 inches (50 mm). If the conductivity readings
continue to change, the of examination should be expanded until readings remain fairly
area
constant to make sure a complete map ofthe area is prepared.
(4) Locate the reference point at the corner of a square, refer to Figure 1 Take conductivity readings
as you work away from the reference point in the increments and distance determined in the
previous step. Enough information must be recorded along with the conductivity reading to allow
a person not familiar with the inspection to locate the data point.
NOTE: Structural considerations may make it necessary that the test points do not follow the
pattern of Figure 1. It is up to the inspector to set a pattern that best covers the area
to be inspected.
PART 6 1
20100103 Page 3
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
A16319
REFERENCE POINTS
INTERVAL BETWEEN
INSPECTION POINTS
9. Reporting Results
A. If theinspection procedure has not told you what to do with the damaged part, contact Cessna
Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS 67277 USA. Telephone 316-517-5800
Fax 316-942-9006. Include sufficient information in all written descriptions so that someone not
involved with the inspection can interpret the results. Give the following information:
(1) Location of the affected area.
(2) A visual description of the affected area.
(3) Location of the reference point and the relative location and interval between conductivity
readings.
(4) A map of the area with the conductivity readings recorded on it.
1. Description
A. This procedure will show you how to find cracks in the engine mount fittings on the fuselage.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-01, Supplemental
Inspection Number 53-10-01.
2. Personnel Requirements
3. Preparation
A. Remove the engine and truss. Refer to the Maintenance Manual Chapter 71, Engine Mount
Maintenance Practices.
4. Equipment
NOTE: This equipment was used to do this procedure. You can use replacements for the items below if
theyhave the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
NOTE 1: If plate is made from a different thickness material, all probe depths must be adjusted.
PART 6 1
53110101 Page 1
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
5. Calibration
6. Inspection
A. Top and Bottom Outboard Mounts Surface Inspection (Refer to Figure 1 and Figure 2).
(1) Calibrate the 200 kHz surface probe and instrument. Refer to Calibrate the 200 kHz Surface
Probe.
(2) Use the 200 kHz surface probe to examine ail of the countersunk area of each of the top and
bottom outboard mounts.
(a) Put the probe in the hole until the collar is against the inspection plate.
(b) Turn the probe a minimum of 360 degrees while you monitor the display for cracks.
(4) Adjust the collar of the probe so that it is at 0.74 inch (18.80 mm) away from the center of the
coil.
(a) Put the probe in the hole until the collar is against the inspection plate.
(b) Turn the probe a minimum of 360 degrees while you monitor the display for cracks.
nns1oo
UPPER CENTER
ENGINE MOUNT
UPPER RIGHT
ENGINE MOUNT UPPER LEFT
ENGINE MOUNT
R´• .6..;1. O
´•f
i C1
O o
R:
REINFORCEMENT
FITTING
NOTE 1: REINFORCEMENT
(NOTE 1) FITTING IS INSTALLED
ON SOME MODEL
208 Al RPLAN ES
BOLT HOLE
INSPECTION
COUNTERSINK
AREA
INSPECTION
AREA
DETAIL A
2613T3007A
A2613T1016
A29103
A2683T1001
Inspection Plate
Figure 2 (Sheet 1)
PART 6 1
53-10101 Page 4
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
(5) Adjust the collar of the probe so that it is at 0.85 inch (21.59 mm) away from the center of the
coil.
(a) Put theprobe in the hole until the collar is against the inspection plate.
(b) Turn the probe a minimum of 360 degrees while you monitor the display for cracks.
(6) Do the inspection on the other bottom hole.
C. Airplanes 20800001 thru 20800329 and 208B Bottom Mount Bolt Hole Inspection
NOTE: Airplanes 20800001 thru 20800329 with a lower reinforcement assembly installed, use the
inspection depths for Airplanes 20800330 and On.
(1) Calibrate the bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole Probe.
(2) Set the probe at a depth of 0.55 inch (13.97 mm), measurement is from the edge of the collar
to the center of the coil.
(3) Put the inspection plate over one of the bottom mount holes.
(a) Put the probe in the hole until the collar is against the inspection plate.
(b) Turn the probe a minimum of 360 degrees while you monitor the display for cracks.
(4) Adjust the collar of the probe so that it is at 0.67 inch (17.02 mm) away from the center of the
coil.
(a) Put the probe in the hole until the collar is against the inspection plate.
(b) Turn the probe a minimum of 360 degrees while you monitor the display for cracks.
(5) Adjust the collar of the probe so that it is at 0.78 inch (19.81 mm) away from the center of the
coil.
(a) Put the probe in the hole until the collar is against the inspection plate.
(b) Turn the probe a minimum of 360 degrees while you monitor the display for cracks.
(6) Do the inspection on the bottom hole.
2 0.72 18.29
3 0.86 21.84
4 1.00 25.40
5 1.14 28.96
6 1.28 32.51
7 1.42 36.07
8 1.56 39.62
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5600. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
1. Description
A. This procedure will show you how to find cracks in the door doublers on the cargo and passenger door
corners.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-03, Supplemental
Inspection Number 53-20-01.
2. Personnel Requirements
A. Personnel certification procedures are found in Part 1 of this manual.
3. Preparation
A. Clean the area to be examined of any unwanted material and/or burrs.
4. Equipment
NOTE: This equipment was used to do this procedure. You can use replacements for the items below if
they have the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
5. Calibration
6. Inspection
A. Door Doubler (Refer to Figure 1).
(1) Calibrate the surface probe and instrument. Refer to Calibrate the 200 kHz Surface Probe.
(2) Insert the surface probe through a door frame lightning hole and do an inspection of the doubler
for cracks.
A29104
DOUBLER
DOUBLER
2611R4004
A29978
II OUTED
ORIGINAL
As Received By
ATP
221281288
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, PO. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5309 FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
1. Description
A. This procedure will show you how to find cracks in the fuselage to wing attach fitting lugs.
8. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-08, Supplemental
Inspection Number 53-20-02.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the wing. Refer to the Maintenance Manual Chapter 57, Wing Removal/lnstallation.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
they have the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
6. Inspection
NOTE: Inspections must be done on both the left and right: side of the airplane.
A. Forward Attach Fitting Bolt Hole Inspection (Refer to Figure 1).
(1) Calibrate the 7/8 inch bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(2) Set the probe at a depth of 0.050 inch (1.27 mm). Measure from the collar to the center of the
coil.
(3) Put the probe in the hole from the forward side of the lugs.
(4) Turn the probe a minimum of 360 degrees while you monitor the display.
(5) Do the inspection at each of the probe depths in Table 1.
2 0.150 3.81
3 0.250 6.35
4 0.862 21.89
5 0.962 24.43
6 1.062 26.97
2 0.140 3.56
3 0.230 5.84
4 0.778 19.76
5 0.868 22.05
6 0.958 24.33
nns1os
AFT
CARRY-THRU
BULKHEAD
FORWARD VVING
ATTACH LUG
AFT WING
ATTACH LUG
FORWARD
CARRY-THRU
BULKHEAD
2611R4001
Wing Attach
Fitting Lug
Figure 1(Sheetl)
7. Part Disposition
A. If crack is found, contact Cessna Propeller Aircraft Product Support, PO. Box 7706, Wichita, KS
a
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
1. Description
A. This procedure will show you how to find cracks in the wing strut attach fittings in the bottom forward
carry-thru bulkhead.
8. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-05, Supplemental
Inspection Number 53-20-03.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove any of the interior necessary to get access to the fittings from the inside of the fuselage.
Refer to the Maintenance Manual.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
they have the necessary parameters. You can use metered instruments as repiacements. The
metered equipment must have the parameters specified in the general sections of this manual.
5. Calibration
6. Inspection
NOTE: Inspections must be done on both the left and right side of the airplane.
A. Stiffener and Top Bulkhead Surface Inspection (Refer to Figure 1).
(1) Calibrate the 200 kHz surface probe and instrument. Refer to Calibrate the 200 kHz Surface
Probe.
(2) Remove one bolt.
(a) Remove nut from aft side.
(b) Remove the bolt far enough to cut off the head.
(c) Remove the shank of the bolt from the aft side.
(3) Examine around the circumference of the hole.
(4) Do a bolt hole inspection on the hole from the aft side. Refer to the appropriate Attach Fitting
Bolt Hole Inspection.
(5) Install a new bolt from the aft side of the hole.
(6) Use the previous steps to examine each hole shown in Figure 1.
2 0.321 8.15
3 0.441 11.20
4 0.561 14.25
6 0.921 23.39
7 1.041 26.44
8 1.061 26.95
9 1.226 31.14
10 1.329 33.76
11 1.449 36.80
12 1.569 39.85
13 1.689 42.90
14 1.809 45.95
15 1.929 49.00
16 2.049 52.04
17 2.169 55.09
18 2.289 58.14
19 2.354 59.79
C. Attach Fitting Bolt Hole Inspection for Holes 1, 2, and 3. (Refer to Figure 1).
(1) Calibrate the 3/16 inch bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(2) Set the probe at a depth of 0.211 inch (5.36 mm). Measure from the collar to the center of the
coil.
(3) Put the probe in the hole.
(4) Turn the probe a minimum of 360 degrees while you monitor the display.
(5) Do the inspection for holes 1, 2, and 3.
NOTE: Inspection for holes 1, 2, and 3 must be done from the forward and aft sides of the
bulkhead.
NOTE: Inspection for holes 7, 8, and 9 must be done on the forward and aft sides of
the bulkhead.
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, PO. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
A29111
i ~poa d;i~
2
3
1111 1 V
o
A
7 8
9’ 1 a
VIEW A-A
MODEL 208B
RIGHT SIDE SHOWN i?,
LEFT SIDE OPPOSITE ~S,
B
C- A
3 1
2
0
5
4
0 6
5_ IlcC i
6 o B
0 8
0 8
9 ATTACH LUG
VIEW B-B
VIEW A-A 26133003
MODEL 208 AA26131001
BB2613T1017
MODEL 208
Wing Strut Attach Fittings
Figure 1(Sheetl)
i. Description
A. This procedure will show you how to find cracks in the main landing gear fittings on the fuselage.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-06, Supplemental
Inspection Number 53-20-04.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the main landing gear. Refer to the Maintenance Manual Chapter 32, Main Landing Gear
Maintenance Practices.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
theyhave the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
5. Calibration
6. Inspection
A. Main Gear Forgings (Refer to Figure 1, Figure 2, Figure 3, and Figure 4).
(1) Calibrate the 200 kHz surface probe and instrument. Refer to Calibrate the 200 kHz Surface
Probe.
(2) Examine around the circumference of the four cap attach holes in the forward and aft fitting.
(a) Keep the probe as near to the edge of the hole as possible but try to avoid any edge effect.
(3) Examine around the circumference of the main landing gear forging slot. (Refer to Figure 3).
(a) Keep the probe as near to the edge of the hole as possible, but try to avoid any edge effect.
(4) Examine the inner radii around the circumference of the main landing gear forging slot. (Refer
to Figure 4).
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5300. FAX 316-942-9006. Give the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
A29115
´•´•.:´•4:
ORIGINAL
As Received By
ATP
2683P1006
A29116
ORIGINAL
As Received By
ATP
2682P1007
A29117
ORIGINAL
As Received By
ATP
2683p1006
A29t18
ORIGINAL
As Received By
ATP
26831>1009
PART 6 1
53~20-04 Page 6
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208 i
NONDESTRUCTIVE TESTING MANUAL
1. Description
A. This procedure will show you how to find cracks in the main landing gear attach fittings and bottom
aft carry thru bulkhead at FS 194.40 and 208.00.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-07, Supplemental
Inspection Number 53-20-05.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove any of the interior necessary to get access to the fittings from the inside of the fuselage.
Refer to the Maintenance Manual.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
theyhave the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
5. Calibration
(6) Move the probe over the notch. Monitor the display to make sure the signal moves up and toward
the left the probe moves across the notch.
as
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
B. Calibrate the 200 kHz Bolt Hole Probe.
(1) Connect the probe to the instrument.
(2) Set the eddy current instrument frequency to 200 kHz.
(3) Put the probe in the appropriate hole in the standard with the probe coil away from the notch.
(4) Push the null (balance) button.
(a) Adjust the instrument so that the lift-off signal goes horizontal and to the left.
(5) Move the probe coil across the notch. Monitor the display to make sure the signal moves up and
toward the left as the probe moves across the notch.
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
6. Inspection
NOTE: Inspections on the bottom fittings must be done on both the left and right and forward and aft
sides of the bulkhead.
(1) Calibrate the 3/16 inch bolt holeprobe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(2) Set the probe at a depth of 0.180 inch (4.57 mm).
(3) Measure from the collar to the center of the coil.
(4) Put the probe in the hole.
(5) Turn the probe a minimum of 360 degrees while you monitor the display.
(6) Install the bolt before removing the next bolt.
2 0.313 7.95
3 0.433 11.00
4 0.553 14.05
5 0.673 17.09
6 0.793 20.14
7 0.913 23.19
8 1.033 26.24
9 1.123 28.52
A29121
~jf
i:
a/ ss‘
a~";
u~iCio\
2
3/ 4
5 6
BRACE
DETAIL A 26133013
A26133015
(7) Do the inspection at each of the depths for holes 4, 5, and 6, forward and aft, left and right..
C. Attach Fitting Bolt Hole lnspectioli for Holes 1,2, and 3 (Refer to Figure 1).
(1) Calibrate the 3/16 inch bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(2) Set the probe at a depth of 0.203 inch (5.16 mm). Measure from the collar to the center of the
coil.
(3) Put the probe in the hole.
(4) Turn the probe a minimum of 360 degrees while you monitor the display.
(5) Do the inspection for holes 1, 2, and 3.
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5300 FAX 316-942-9006. Provide the followinginformation:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
1. Description
A. This procedure will show you how to find cracks in the wing attach fittings in the forward and aft carry
through bulkheads.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-21, Supplemental
Inspection Number 53-20-06.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove any of the interior necessary to get access to the fittings from the inside of the fuselage.
Refer to the Maintenance Manual.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
they have the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
5. Calibration
(6) Move the probe over the notch. Monitor the display to make sure the signal moves up and toward
the left asthe probe moves across the notch.
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
B. Calibrate the 200 kHz Bolt Hole Probe.
(1) Connect the probe to the instrument.
(2) Set the eddy current instrument frequency to 200 kHz.
(3) Put the probe in the appropriate hole in the standard with the probe coil away from the notch.
(4) Push the null (balance) button.
(a) Adjust the instrument so that the lift-off signal goes horizontal and to the left.
(5) Move the probe coil across the notch. Monitor the display to make sure the signal moves up and
toward the left as the probe moves across the notch.
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
6. Inspection
NOTE: Inspections must be done on both the left and right side of the airplane.
A. Top Bulkhead Surface Inspection (Refer to Figure 1).
(1) Calibrate the 200 kHz surface probe and instrument. Refer to Calibrate the 200 kHz Surface
Probe.
(2) Remove one bolt.
(3) Examine around the circumference of the hole.
(4) Do a bolt hole inspection on the hole. Refer to the appropriate Attach Fitting Bolt Hole Inspection.
(5) Use the previous steps to examine each hole shown in Figure 1.
2 0.210 5.33
3 0.290 7.37
4 0.370 9.40
5 0.450 11.43
6 0.530 13.46
7 0.610 15.49
9 0.770 19.56
10 0.850 21.59
11 0.930 23.62
12 1.010 25.65
13 1.090 27.69
14 1.155 29.34
15 1.255 31.88
16 1.335 33.91
17 1.415 35.94
18 1.495 37.91
19 1.575 40.01
20 1.655 42.04
21 1.735 44.07
22 1.815 46.10
23 1.895 48.13
24 1.975 50.17
25 2.055 52.20
26 2.135 54.23
27 2.215 56.26
28 2.280 57.91
C. Attach Fitting Bolt Hole Inspection for Holes 5A, 5B, 6A, 6B, 7A, 7B (Refer to Figure 1).
(1) Calibrate the adjustable bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(2) Set the probe at a depth of 0.230 inch (5.84 mm). Measure from the collar to the center of the
coil.
(3) Remove only one bolt.
(4) Put the probe in the hole.
(5) Turn the probe a minimum of 360 degrees while you monitor the display.
(6) Do the inspection for holes 5A, 5B, 6A, 6B, 7A, 7B.
A29126
81
´•dP
ca~
2611F14001
A29119
7B
6B
4; /j
.s
7A~ 6A
5A
2’
DETAIL A
FORWARD
CARRY-TH RU
BULKHEAD
AFT
CARRY-TH R U
BULKHEAD 8;1%-9~
43
2~d/ DETAIL B
A2613R3012
82613R3014
(9) Do the complete inspection of each of the bolt holes shown on the aft top carry-thru bulkhead.
2 0.260 6.60
3 0.340 8.64
4 0.420 10.67
5 0.500 12.70
6 0.580 14.73
7 0.660 16.76
8 0.740 18.80
9 0.820 20.82
10 0.900 22.86
11 0.980 24.89
12 1.060 26.92
13 1.180 29.97
14 1.260 32.00
15 1.340 34.04
16 1.420 36.07
17 1.500 38.10
18 1.580 40.13
19 1.660 42.16
20 1.740 44.20
21 1.820 46.23
22 1.900 48.26
23 1.980 50.29
24 2.060 52.32
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
1. Description
A. This procedure will show you how to find cracks in the wing strut attach fitting lugs on the bottom
forward carry through bulkhead.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-04, Supplemental
Inspection Number 53-20-07.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the strut. Refer to the Maintenance Manual.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
theyhave the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
5. Calibration
6. Inspection
NOTE: Inspections must be done on both the left and right side of the airplane.
A. Attach Lug Bolt Hole Inspection. (Refer to Figure 1).
(1) Calibrate the 3/4 inch bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(2) Set the probe at a depth of 0.05 inch. Measure from the collar to the center of the coil.
(3) Put the probe in the hole from the forward side of the lugs.
(4) Turn the probe a minimum of 360 degrees while you monitor the display.
(5) Do the inspection at each of the probe depths of Table 2 for each lug.
2 0.13 3.30
3 0.21 5.33
4 0.267 6.78
5 0.871 22.12
6 0.951 24.16
7 1.031 26.19
8 1.075 27.31
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, PO. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
A3W61
i ~poa da
ATTACH LUG
26133003
1. Description
A. This procedure will show you how to find cracks in the fuselage to horizontal stabilizer attach fittings
on the fuselage.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-17, Supplemental
Inspection Number 53-50-01.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the horizontal stabilizer. Refer to the Maintenance Manual, Chapter 55, Horizontal Stabilizer
Removal/lnstallation.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
they have the necessary parameters, You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
NOTE 1: If plate is made from a different thickness material, all probe depths must be adjusted.
5. Calibration
PART 6 1
53-50101 Page 1
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
(3) Put the probe on the face of the standard away from the notch.
(4) Push the null (balance) button.
(5) Lift the probe away from the standard. Monitor the display.
(a) Adjust the instrument so that the lift-off signal goes horizontal and to the left.
(6) Move the probe over the notch. Monitor the display to make sure the signal moves up and toward
the left as the probe moves across the notch.
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
B. Calibrate the 200 kHz Bolt Hole Probe.
(1) Connect the probe to the instrument.
(2) Set the eddy current instrument frequency to 200 kHz.
(3) Put the probe in the 112 inch hole in the standard with the probe coil away from the notch.
(4) Push the null (balance) button.
(a) Adjust the instrument so that the lift-off signal goes horizontal and to the left.
(5) Move the probe coil across the notch. Monitor the display to make sure the signal moves up and
toward the left as the probe moves across the notch.
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
6. Inspection
2 0.52 13.21
3 0.62 15.75
4 0.72 18.29
C. Do an Inspection of the Bolt Hole for the Aft Attach Fitting (Refer to Figure 1)
(1) Calibrate the bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole Probe.
(2) Set the probe to a depth of 0.165 inch (4.19 mm).
(3) Measure from the collar to the center of the coil.
(4) Put the probe in the hole.
(5) Turn the probe a minimum of 360 degrees while you monitor the display.
A29129
A~
~tv,;,
o HORIZONTAL
A SPAR AFT
ATTACH POINTS
bp p
C~cp
oC~P,
DETAIL A 2612R3001
A2612R3D02
PART 6 1
53-50-01 Page 3
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
A29124
BOLT HOLE
INSPECTION AREA
SURFACE PROBE
INSPECT
VIEW A-A
CROSS SECTION OF FORWARD
FITTING AT THE ATTACH POINT
2683T1005
A29103
n2se3Tlool
Inspection Plate
Figure 2 (Sheet 1)
PART 6 1
53150101 Page 5
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5300? FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
1. Description
A. This procedure will show the techniques used to find cracks in the forward vertical stabilizer attach
points on the fuselage.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-18, Supplemental
Inspection Number 53-50-02.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the vertical stabilizer. Refer to the Maintenance Manual, Chapter 55, Vertical Stabilizer
Removal/lnstallation.
B. Clean the attach holes of any unwanted materials and/or burrs that can cause interference with the
inspection.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
theyhave the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
Eddy Current Unit Nortec 2000 Staveley NDT Technologies To find cracks
421 N. Quay St.
Kennewick, WA 99336
Web: www.staveleyndt.com
Bolt Hole Surface HRS-15A NDT Engineering Corp. To calibrate the system
Reference Standard
5. Calibration
(a) Adjust the instrument to get a minimum of three major screen areas between the null point
and the notch point.
6. Inspection
A. Forward Attach Holes Inspection (Refer to Figure 1).
(1) Bolt hole inspection for the top attach holes.
(a) Calibrate the bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(b) Set the depth of the probe to 0.065 inch (1.65 mm).
(c) Adjust the diameter of the probe to the diameter of the hole.
(d) Inspect the bore of each hole from the aft side of the bulkhead.
(e) Set the probe at a depth of 0.130 inch (3.30 mm).
(f) Do an inspection of the bore of each hole from the aft side of the bulkhead.
(g) Set the probe at a depth of 0.170 inch (4.32 mm).
(h) Do an inspection of the bore of each hole from the aft side of the bulkhead.
(2) Bolt hole inspection for the bottom attach holes.
(a) Calibrate the bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(b) Set the probe at a depth of 0.080 inch (2.03 mm).
(c) Adjust the diameter of the probe to the diameter of the hole.
(d) Do an inspection of the bore of each hole from the aft side of the bulkhead.
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Give the information that follows:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
A29131
RIGHT TOP
LEFT TOP
ATTACH HOLE
ATTACH HOLE
RIGHT BOTTOM
LEFT BOTTOM
ATTACH HOLE
ATTACH HOLE
ol lo
01 \O
Of ~o
lo o
o\ io
O\ io
o o
o
p_~
VERTICAL STABILIZER
FORWARD BULKHEAD
2612T1008
A29125
Q------------------g
I
LEFT TOP
TOP
ATTACH HDLE
ATTACH THGIRELOH
8-’
L____L-------------I___-1
~1
r-----------------------~
AFT CANTED
BULKHEAD
2612T1007
1. Description
A. This procedure will show the techniques used to find cracks in the horizontal stabilizer forward and aft
attach points.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-19, Supplemental
Inspection Number 55-10-01.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the horizontal stabilizer. Refer to the Maintenance Manual, Chapter 55, Horizontal Stabilizer
Removal/lnstallation.
B. Clean the attach holes of any unwanted material and/or burrs that can have an affect on the inspection.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
theyhave the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
Eddy Current Unit Nortec 2000 Staveley NDT Technologies To find cracks
421 N. Quay St.
Kennewick, WA 99336
Web: www.staveleyndt.com
Bolt Hole Reference HRS-1BA NDT Engineering Corp. To calibrate the system
Standard
5. Calibration
(6) Move the probe over the notch. Monitor the display to make sure the signal moves up and toward
the left the probe moves across the notch.
as
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
B. Calibrate the 200 kHz Bolt Hole Probe.
(1) Connect the probe to the instrument.
(2) Set the eddy current instrument frequency to 200 kHz.
(3) Put the probe in the appropriate hole in the standard with the probe coil away from the notch.
(4) Push the null (balance) button.
(a) Adjust the instrument so that the lift-off signal goes horizontal and to the left.
(5) Move the probe coil across the notch. Monitor the display to make sure the signal moves up and
toward the left as the probe moves across the notch.
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
2 0.250 6.35
3 0.310 7.87
2 0.17 4.32
3 0.29 7.37
4 0.41 10.41
5 0.53 13.46
6 0.65 16.51
7 0.77 19.56
8 0.89 22.61
9 1.01 25.65
10 1.07 27.18
8. Part Disposition
A. If a crack is found, contact CessnaPropeller Aircraft Product Support, PO. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
A29130
BOLT
HOLE
FORWARD
ATTAC
FITTING
VIEW B-B
sy r,
o o
~-´•L
B
g
SUPPORT
~C"i A FITTING
DETAIL A
Horizontal Stabilizer Attach Points
Figure 1(Sheetl)
i. Description
A. This procedure gives the techniques used to find cracks in the forward and aft spars of the horizontal
stabilizer.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-20, Supplemental
Inspection Number 55-10-02.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the horizontal stabilizer. Refer to the Maintenance Manual, Chapter 55, Horizontal Stabilizer
Removal/lnstallation.
B. Clean the inspection area of any unwanted materials and/or burrs that can have an effect on the
inspection.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
theyhave the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
Eddy Current Unit Nortec 2000 Staveley NDT Technologies To find cracks
421 N. Quay St.
Kennewick, WA 99336
Web: www.staveleyndt.com
5. Calibration
6. Inspection
A. Inspect the Forward Spar (Refer to Figure 1).
(1) Calibrate the ring probe and instrument. Refer to Calibrate the Ring Probe.
A29128
HORIZONTAL
STABILIZER
A
INSPECTION AREA
:C:
2632T1003
2632TlaM
Spars
Horizontal Stabilizer
Figure 1(Sheet i)
(2) Inspect each fastener on the top and bottom spar between RSS 9.90 and LSS 9.90.
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
PART 6 1
55-10-02 Page 3
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRU%TIVE TESTING MANUAL
1. Description
A. This procedure will show you how to find cracks in the spars of the vertical stabilizer.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-22, Supplemental
Inspection Number 55-30-01.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the vertical stabilizer. Refer to the Maintenance Manual, Chapter 55, Vertical Stabilizer
Removal/i nstallation.
4. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
they have the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
Bolt Hole Probe 3/8 BPMF-24 NDT Engineering Corp. To find cracks
inch diameter
5. Calibration
6. Inspection
A. Inspect the Forward Spar Between WL 134.38 and WL 138.00 (Refer to Figure 1).
(1) Calibrate the 200 kHz surface probe and instrument. Refer to Calibrate the 200 kHz Surface
Probe.
(2) Examine around each of the fasteners in the circled area on the forward and aft side of the spar.
NOTE: Access to the aft side will be through a lightening hole in the bottom rib.
7. Part Disposition
A. If crack is found, contact Cessna Propeller Aircraft Product Support, PO. Box 7706, Wichita, KS
a
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
A29138
s/L~533.
JLp
~L=i
~tu,
;e~l
FORWARD SPAR
HOLES TO BE
EXAMINED
Q/i ~"u’,
Vertical Stabilizer
Soars
Figure 1(Sheet 1)
A29139
ORIGINAL
As Received By
ATP
ii i i’
ii
I
(NOTE)
I/
FORWARD SPAR
’i
jI 1 i
NOTE: DO A SURFACE
SCAN AROUND EACH
OF THE FASTENERS
SHOWN IN THE AREAS
CIRCLED.
A29140
i i j i
I i
I;ji
ORIGINAL i
As Received
ATP
By I /;I’ ii
i I
ii’
’I- (NOTE)
;I:1
’1 I
ii
i jI
I i tt
~I
;II j
_1 i
I~
i II
11’1
I! i t ---i-
1;’
i’ ii
I~
I
ii-´•- REAR SPAR
,,I ij
1’11
iii’ I
i
i
_.._..~
j -i-i/
I i iI i
1 I
1111- 1
I
jI
i;ll I
NOTE: DOASURFACE
SCAN AROUND EACH
OF THE FASTENERS VIEW B-B
SHOWN IN THE AREAS
CIRCLED.
PART 6 1
55130101 Page 5
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
1. Description
A. Examine for fatigue cracks in specific holes of the spar attach fittings.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-24, Supplemental
Inspection Number 57-20-01.
2. Personnel Requirements
A. Personnel certification requirements are in Part 1 of this manual.
3. Preparation
A. Remove the wing. Refer to the Maintenance Manual Chapter 57, Wings Removal/lnstallation.
C. Clean the area to remove substances that may interfere with the inspection.
4. Equipment
NOTE: This equipment was used to do this procedure. You can use replacements for the items below if
they have the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
Eddy Current Unit Nortec 1000s Staveley Instruments, Inc. To find cracks
with X-Y storage 421 N. Quay
oscilloscope Kennewick, WA 99336
Web: www.staveleyndt.com
5. Calibration
(5) Move the probe coil across the notch. Monitor the display to make sure the signal moves up and
toward the left as the probe moves across the notch.
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
(3) Set the probe at a depth of 0.05 inch. Measure from the collar to the center of the coil.
(4) Put the probe in the hole.
(5) Turn the probe a minimum of 360 degrees while you monitor the display.
(6) Do the inspection at each of the probe depths of the applicable table for each hole.
Table 1. Hole 1
Table 2. Hole 2
Table 3. Hole 3
Table 4. Hole 4
(3) Set the probe at a depth of 0.05 inch. Measure from the collar to the center of the coil.
(4) Put the probe in the hole.
(5) Turn the probe a minimum of 360 degrees while you monitor the display.
(6) Do the inspection at each of the probe depths of the applicable table for each hole.
Table 5. Hole 5
Table 6. Hole 6
Table 7. Hole 7
Table 8. Hole 8
(3) Set the probe at a depth of 0.05 inch. Measure from the collar to the center of the coil.
(4) Put the probe in the hole.
(5) Turn the probe a minimum of 360 degrees while you monitor the display.
(6) Do the inspection at each of the probe depths of Table 9 for each hole.
2 0.15 3.81
3 0.25 6.35
4 0.35 8.89
5 0.45 11.43
(3) Set the probe at a depth of 0.05 inch. Measure from the collar to the center of the coil.
(4) Put the probe in the hole.
(5) Turn the probe a minimum of 360 degrees while you monitor the display.
(6) Do the inspection at each of the probe depths of Table 10 for each hole.
2 0.15 3.81
3 0.22 5.59
5 0.39 9.91
9. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
A29142
t
II HOLE 2
f~
c
FORWARD
SPAR
HOLE1
3´•
-e 9
i
t
t ~d
k 9
9 9 ´•o 9
X
C+
HOLE 6
c+t --t t 3´• i ik
7 f f´•
HOLE 5
REAR
SPAR
A29132
WEB
(0.040 INCH THICK) WEB
SPACER SPACER (0.040 INCH THICK)
(0.080 INCH THICK) (0.080 INCH THICK)
LE
ANGLE
ANGLE 1 (0.063 INCH THICK)
(0.063 INCH THICK)
(0.063 INCH THICK) ~CJ ANGLE
(0.063 INCH THICK)
FITTING FITTING
(0.140 INCH THICK (0.440INCH THICK
WEB
(0.040 INCH THICK) WEB
CAP CAP !0.040 INCH THICK)
(0.100 INCH THICK) (0.100 INCH THICK)
SPACER
SPACER
SPACER (0.040 INCH THICK)
(0.040 INCH THICK)
(0.040 INCH THICK) \nJ SPACER
(0.040 INCH THICK)
FITTING FITTING
(0.140INCH THICK (0.440 INCH THICK
2683T1003
A29133
WEB WEB
INCH
SPACER !0.032 THICK) SPACER !0.032 INCH THICK)
(0.063 INCH THICK) (0.063 INCH THICK)
LE GLE
ANGLE ANGLE
(0.050 INCH THICK) INCH
(0.050 THICK)
(0.050 INCH THICK) (0.050 INCH THICK)
FITTING FITTING
(0.200 INCH THICK) (0.360 INCH THICK)
HOLE 5 MATERIAL CROSS SECTION HOLE 6 MATERIAL CROSS SECTION
WEB WEB
INCH
CAP !0.032 THICK) CAP (0.032 INCH THICK)
(0.080 INCH THICK) (0.080 INCH THICK)
SPACER ACER
SPACER SPACER
(0.040 INCH THICK) (0.040 INCH THICK)
(0.040 INCH THIC (0.040 INCH THICK)
FITTING FITTING
(0.200 INCH THICK) (0.360 INCH THICK)
HOLE 7 MATERIAL CROSS SECTION HOLE 8 MATERIAL CROSS SECTION
2683T1 004
1. Description
A. Examine for fatigue cracks in the lower forward spar cap inboard of WS 141.20.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-25, Supplemental
Inspection Number 57-20-02.
2. Personnel Requirements
A. Personnel certification requirements are in Part 1 of this manual.
3. Preparation
A. Remove panels 501AB (601AB) to access the inboard end of the bottom forward spar. (Refer to Figure
1).
B. Remove the inboard side bracket of the strut fairing to get access to the skin at the forward spar.
C. Clean the skin and spar cap to remove substances that can interfere with the inspection.
4. Equipment
NOTE: This equipment was used to make this procedure. You can use replacements for the items
below if they have the necessary parameters. Metered instruments are not allowed. There is no
alternate for the Cessna reference standard.
Eddy Current Unit Nortec 1000s Staveley Instruments, Inc. To find cracks
with X-Y storage 421 N. Quay
oscilloscope Kennewick, WA 99336
Web: www.staveleyndt.com
5. Calibration
(3) Put the probe on the standard away from the notch.
NOTE: The spar cap has two angles bonded to a center web. Be sure you use an area on
the standard that best matches the area of the airplane you are to inspect.
NOTE: There may be greater edge effect, compared to the reference standard, when you inspect
the area parallel to the edge of a spar cap. This can be caused if the distance between the
fasteners and the edge of the spar cap is smaller than on the reference standard. If edge
effect interference is noticed, use the alternate calibration.
NOTE: The spar cap consists of two angles bonded to a center web. Be sure you use an
area on the standard that best matches the area of the airplane you are to inspect.
up and toward the left as the probe moves across the notch.
NOTE: You are looking for cracks between the fastener and the edge of the spar cap. Make
sure that the EDM cut on the standard is in the same relative position as the airplane
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
6. Inspection
A. Bottom Forward Spar Cap (Refer to Figure 1).
(1) Make sure the instrument and probe are calibrated. Refer to Calibrate the 200 kHz Surface
Probe.
(2) Use the eddy current surface probe to inspect along the edges of the bottom spar cap at the
strut attach point between the ribs at WS 126.50 and WS 141.20.
(3) Do an inspection around the nut plate fasteners and holes located at the inboard end of the spar.
PART 6 1
57-20-02 Page 2
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
A29143
00000
0 0 0 0 0000
~4 (I-L´•~
ht,J
O O
O O
O O
O O
O O
O O
2610R2008
2683T1002
B. Use the eddy current spot probe to inspect around each fastener common to the bottom spar and skin
from the inboard end of the wing to the rib at WS 126.50.
(1) Make sure the instrument and probe are calibrated. Refer to Calibrate the Spot Probe.
(2) The spar cap has two angles bonded to a center web.
(3) Do a calibration and inspection parallel to the forward and aft edges of each cap with a
nonconductive straight edge as a guide for the probe.
NOTE: If greater edge effect is sensed, use the Alternate Calibration for the Spot Probe to
recalibrate the equipment.
(4) Do a calibration and inspection with the spot probe around the remaining area of each of the
fasteners from the inboard end of the wing spar to WS 126.50.
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, PO. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
1. Description
A. Examine for fatigue cracks in the bottom aft spar cap inboard of WS 141.20.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-26, Supplemental
Inspection Number 57-20-03.
2. Personnel Requirements
A. Personnel certification requirements are in Part 1 of this manual.
3. Preparation
A. Clean skin and spar cap to remove substances that may interfere with the inspection.
4. Equipment
NOTE: This equipment was used to make this procedure. You can use replacements can be used for
the items below if they have the necessary parameters. Metered instruments are not allowed.
There is no alternate for the Cessna reference standard.
Eddy Current Unit Nortec 1000s Staveley Instruments, Inc. To find cracks
with X-Y storage 421 N. Quay
oscilloscope Kennewick, WA 99336
Web: www.staveleyndt.com
5. Calibration
NOTE: The spar cap consists of two angles bonded to a center web. Be sure you use an
area on the standard that best matches the area of the airplane you are to inspect.
NOTE: There may be greater edge effect, compared to the reference standard, when you inspect
the area parallel to the edge of a spar cap. This can be caused if the distance between the
fasteners and the edge of the spar cap is smaller than on the reference standard. If edge
effect interference is noticed, use the alternate calibration.
NOTE: The spar cap consists of two angles bonded to a center web. Be sure you use an
area on the standard that best matches the area of the airplane you are to inspect.
up and toward the left as the probe moves across the notch.
NOTE: You are looking for cracks between the fastener and the edge of the spar cap. Make
sure that the EDM cut on the standard is in the same relative position as the airplane
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
6. Inspection
A. Bottom Aft Spar Cap (Refer to Figure 1).
(1) Use the eddy current spot probe to inspect around each fastener common to the bottom spar
and skin from the inboard end of the wing to the rib at WS 141.20.
(a) Make sure the instrument and probe are calibrated. Refer to Calibrate the Spot Probe.
(b) Do a calibration and inspection parallel to the forward and aft edges of each cap using a
nonconductive straight edge as a guide for the probe.
NOTE: If greater edge effect is sensed, recalibrate the equipment using the Alternate
Calibration for the Spot Probe.
(c) Do a calibration and inspection with the spotprobe around the remaining area of each of
the fasteners from the inboard end of the wing spar to WS 141.20.
7. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, PO. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
A29207
WS 141.20
STRUT
ATTACH
POINT
O o B Oi--~
00000
o o o o ooo o_
AFT SPAR
O O
O O
O O
O O
O O
O O
2610R2008
2683T1002
FLAP TRACKS
1. General
A. Included in this section are instructions to do an eddy current inspection for fatigue cracks in the flap
tracks.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-27, Supplemental
Inspection Number 57-50-01.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
NOTE: You can use equivalent alternatives for the following items:
Eddy Current Nortec 2000 Staveley NDT Technologies To inspect flap tracks
instrument 421 N. Quay St.
Kennewick, WA 99336
Web: www.stavelevndt.com
4. Calibration
A22506
‘B
D
FLAP TRACK
DETAIL A
CENTER FLAP TRACK SHOWN,
INBOARD FLAP AND OUTBOARD
FLAP TRACK TYICAL
26107004
A2622X1030
A22178
RIGHT ANGLE
SURFACE PROBE
WING
DETAIL B
TYPICAL INTERNAL SURFACE
FLAP TRACK INSPECTION
RIGHT ANGLE
SURFACE PROBE
DETAIL C
TYPICAL UPPER AND LOWER EXTERNAL
SURFACE FLAP TRACK INSPECTION
B2622T1027
C2622T1029
A22180
RIGHT ANGLE
SURFACE PROBE
DETAIL D
TYPICAL INBOARD AND OUTBOARD
SURFACE FLAP TRACK INSPECTION
D2622T1028
(3) Remove the left and right flap assemblies from the airplane. Refer to Maintenance Manual
Chapter 57, Flap Removal/lnstallation.
(4) Do an eddy current inspection of the flap tracks.
NOTE: Eddy current inspection of the center, inboard, and outboard flap tracks is typical.
(a) Calibrate the 200 kHz surface probe and instrument. Referto Calibrate the 200 kHz Surface
Probe.
(b) With the probe, scan the top and bottom internal and external surfaces, and inboard and
outboard surfaces of the flap tracks. Scan first in one direction, then the opposite direction.
1 If cracks are not found, no further action is necessary.
(5) Replace the flap track(s) if any cracks are found. Refer to the Model 208 Series Illustrated Parts
Catalog for flap track part number.
(6) Install the left and right flap assemblies. Refer to Maintenance Manual Chapter 57, Flap
Removal/lnstallation.
(7) Do an operational check of the flap system. Refer to the Maintenance Manual, Chapter 27, Flap
Rigging Guide AdjustmentTTest.
(8) Remove the maintenance warning tag and connect the airplane battery.
1. General
A. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-28, Supplemental
Inspection Number 57-60-01.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
NOTE: You can use equivalent alternatives for the following items:
Eddy Current Nortec 2000 Stave\ey NDT Technologies To inspect strut fittings
Instrument 421 N. Quay St.
Kennewick, WA 99336
Web: www.stavelevndt.com
4. Preparation
A. Remove the Strut.
(1) Defuel the airplane Refer to the Maintenance Manual Chapter 12, Fuel Servicing.
(2) Disconnect all electrical power from the airplane. Attach maintenance warning tags to the battery
connector(s) and external power receptacle that have the following written on them: WARNING:
DO NOT CONNECT ELECTRICAL POWER MAINTENANCE IN PROGRESS.
NOTE: Removal and installation procedures for both left and right wing lift struts are typical.
(3) Remove the wing lift strut fairings. Refer to the Maintenance Manual Chapter 57, Wings
Removal/lnstallation.
(4) Put a support on the outboard section of the wings. Refer to the Maintenance Manual Chapter
57, Wings- Removal/lnstallation.
(5) With the outboard section of wings supported, remove the left wing lift strut. Keep the hardware
for reinstallation. Refer to the Maintenance Manual Chapter 57, Wings Removal/lnstallation.
5. Calibration
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
6. Inspection Procedure
A22184
’I"
C, C1
Jp,
A I I
TIEDOWN
(REFERENCE)
3,
VIEW A-A
MS21 042L5
NUT
(REFERENCE)
B _3-
C C
OUTED
~f DETP~IL A
FWD
LOOKING UP AT LEFT
WING STRUT ASSEMBLY
26107004
A262251022
AA2622T1024
882622T1023
PART 6 1
57-60-01 Page 3
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
A22185
INSPECTION
TYPICAL FOR INSPECT TH ESE
THIS FITTING AREAS
J/
RIGHT ANGLE
SURFACE PROBE
(REFERENCE)
DETAIL B
LOWER ATTACH
FITTING INSPECTION
82622T1020
A22186
INSPECT THESE
AREAS
DETAIL C
UPPER ATTACH
FITTING INSPECTION
C2622T1021
1. Description
A. Look for fatigue cracks in the fitting of the strut attachment to the front spar.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-29, Supplemental
Inspection Number 57-60-02.
2. Preparation
A. Remove the wing. Refer to Maintenance Manual Chapter 57, Wing Removalll nstallation.
3. Equipment
NOTE: This was used to do this procedure. You can use replacements for the items below if
equipment
theyhave the necessary parameters. You can use metered instruments as replacements. The
metered equipment must have the parameters specified in the general sections of this manual.
4. Calibration
(a) Adjust the instrument to get a minimum of three major screen divisions between the null
point and the notch point.
5. Inspection
A. Support Fitting Surface Inspection (Refer to Figure 1).
NOTE: This inspection is not necessary for Airplanes 20800001 thru 20800010 and Airplane
20800012.
(1) Calibrate the surface probe. Refer to Calibrate the 200 kHz Surface Probe
(2) Holes 1 thru 4.
(a) Remove the nut from each bolt one at a time.
(b) Pull the bolt out of the hole far enough to allow you to do a surface inspection around the
bolt shank.
(c) Do a surface scan inspection around the bolt on the fitting.
(d) Do a surface scan inspection around the bolt hole on the opposite fitting.
(e) Install the nut and torque to standard torque.
(f) Do the inspection at each of the holes.
(3) Holes 5 thru 7.
(a) Do a surface scan inspection around each of the fastener heads and collars. Do not remove
collars.
(1) Calibrate the 7/8 inch bolt hole probe and instrument. Refer to Calibrate the 200 kHz Bolt Hole
Probe.
(2) Set the probe at a depth of 0.05 inch (1.27 mm). Measure from the collar to the center of the coil.
(3) Put the probe in the hole.
(4) Turn the probe a minimum of 360 degrees while you monitor the display.
(5) Do the inspection at each of the depths in Table 1 for each of the lug holes.
2 0.17 4.32
3 0.29 7.37
4 0.41 10.14
5 0.53 13.46
6 0.65 16.51
nls098
WING STRUT
ATTACH FITTING
FRONT SPAR
o´•~)
o
3
1
2
i
ATTACH
LUG HOLE VIEW A-A
2652R1009
2622R1035
6. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006. Give the information that follows:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
PENETRANT
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
CONTENTS
Temporary Revision
Number
Page Number lesue Date By Date Remaved By
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
Title
Part 7 List of Effective Pages 1 Nov 3/2003
Record of Temporary Revisions
Part 7 Contents 1 Nov 3/2003
Part 7 20-00-00 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
i. General
A. Visible
dye penetrants (Type 2) must not be used for inspections done to this airplane or its
components. The reason for this is that visible dye penetrants will penetrate very fine cracks, but
their sensitivity is so poor, they are easily missed and will not show an indication. The dye trapped in
these tight defects cannot be removed completely under even the best conditions. Removal under
field conditions is not possible. In-service inspections are usually reinspections of specific critical
areas. The possibility of dye build-up in defects that prevent the entrance of subsequently applied
NOTE: If Type 2 penetrant (visible dye) was used for an inspection, penetrant is no longer an
approved inspection method for that part or area. Eddy current or another inspection
procedure must be used.
B. Penetrant inspection is used to find small cracks or discontinuities open to the surface that may not
be evident by a visual inspection. Penetrant inspection can be used on most airframe parts and
assemblies accessible for its application. A liquid that penetrates into surface defects is applied to
do the inspection. Excess penetrant liquid is removed and a suitable developer applied to draw the
penetrant from the surface defects. A visual indication is obtained by color contrast and fluorescence
of the penetrant under the display of a "black light." The penetrant method of inspection requires that
the surface in the inspection area be fully cleaned and free of paint.
C. Penetrant materials are defined by specific classifications per SAE AMS-2644 and must meet or
exceed the classification listed.
Type 1 (Fluorescent)
Level 3 (Sensitivity)
Method C (Solvent removable)
Form d (Nonaqueous Type 1 Fluorescent, Solvent Based)
Class 2 (Non-halogenated Solvent Removers)
they must be exposed to ultraviolet light with a wavelength of 320 to 380 nanometers.
PART 7 1
20-00100 Page 1
0 Cessna Aircraft Company Nov 3/2003
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
(1) The black light must have a minimum light intensity of 1200 CIW/cm2 at the part surface or 1000
C1W/cm2 at a distance of 15 inches. Let the black light warm up for a minimum of 10 minutes
before use.
(2) Both the ultraviolet light and ambient light intensities must be measured with a calibrated light
meter before each inspection.
NOTE: It is recommended that the inspector allow 3 minutes for the eyes to adapt to the dark
before the interpretation/evaluation of parts.
4. Procedure
A. Surface Cleaning.
(1) The area to be inspected must be free from any dirt, grease, oil, paint, or any contaminants
which can mask or close a defect that is open to the surface. The surface must be dry before
the penetrant is applied.
(2) Thepenetrant materials and the area to be tested must have a temperature of 40"F minimum to
120"F maximum (4"C to 49"C).
B. Application of Penetrant.
(1) Apply the penetrant with a brush fully over the area to be examined. Let the penetrant stay
(dwell) on the area for a minimum of 15 minutes at temperatures of 51"F (11"C) and above, or
25 minutes for temperatures of 40"F to 50"F. (4"C to 10"C).
(2) The maximum dwell times must not exceed one hour unless it is specified to do so. If the
penetrant has dried on the surface, it must be fully removed and penetrant be applied again.
C. Removal of Excess Penetrant.
(1) Wipe with a clean, dry lint free cloth to remove the excess penetrant from the surface. Remove
the penetrant that remains with a clean lint free cloth, dampened with the penetrant cleaner.
Examine the inspection area under the black light to make sure all surface penetrant has been
removed.
D. Application of Developer.
(1) Use a very thin coating of developer to get the best results. The essential step of application
of developeris to get the minimum thickness possible. The film of developer must be slightly
translucent, that is, the color of the part or area must be barely seen through the film of developer.
Shake nonaqueous developers frequently to prevent settling of the solid particles in the liquid
vehicle.
(a) When you apply the dry powder developer, thoroughly dust the part or area.
E. Interpretation of Indications.
(1) An 8X magnifying glass must be used to examine the area unless the indications are seen by
the naked eye.
(a) Any surface break will be shown by the fluorescent indication on a bluish background.
(b) A crack will show as a fluorescent line. It will be sharply indicated at first.
(c) Watch indications grow, because the first sharp indications tell much of the nature of the
defect, and the amount of bleeding gives information as to its extent.
(d) The amount of bleeding gives a clue to the depth of the crack.
(e) A deep discontinuity indication will reappear a number of times when the area is wiped
clean and developer applied again.
NIAG N ETIC
PA RTI C L E
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
CONTENTS
Temporary Revision
Page Number Issue Date By Date Removed By
Number
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
Title
Part 8 List of Effective Pages 1 Nov 3/2003
Record of Temporary Revisions
Part 8 Contents 1 Nov 3/2003
Part 8 20-00-00 1 Nov 3/2003
2 Nov 3/2003
Part 8 32-10-01 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
Part 8 32-10-02 1 Nov 3/2003
2 Nov 3/2003
Part 8 32-20-01 1 Nov 3/2003
2 Nov 3/2003
Part 8 71-20-01 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
1. General
A. Magnetic particle inspection is a nondestructive procedure to find surface and near subsurface
discontinuities in parts made of magnetic materials. It has three basic operations.
(1) Put in an applicable magnetic field.
(2) Application of magnetic particles.
(3) Examination and evaluation of the way the particles are arranged.
B. Discontinuities can be in materials, be made during the process of fabrication of parts, or exist
raw
as fatigue cracks or cracks due to excessive service stresses. Discontinuities are defects if they are
dangerous to the function or service life of the parts. Magnetic particle inspection will easily find
discontinuities in ferromagnetic material to reveal manufacturing and/or service defects.
C. Alloys which contain a high percentage of iron and can be magnetized, make up a class of
metals called ferromagnetic. Magnetic particle inspection can find discontinuities in parts made of
ferromagnetic materials. If the part is made of material which is nonmagnetic, it cannot be inspected
by this method. The magnetic particle inspection method will find surface discontinuities that are
too fine to be seen without magnification and those that lie slightly below the surface. When special
equipment is used, the more deeply seated discontinuities can be found.
D. Electric current is used to cause magnetic fields in magnetic materials.
(1) The direction of the magnetic field can be altered, and is controlled by the direction of the current.
(a) The direction and location of the current paths are used to induce the magnetic lines of force
so that
they intercept and are as near as possible to a transverse direction to a discontinuity.
(b) Either longitudinal or circular fields can easily be set up.
(c) The strength of the field can be changed, and by use of different types of current, variations
in field strength and distribution can be made.
(2) There are two types of electric current used. These are direct current (DC) and alternating
current (AC).
(a) The type of current used for magnetization affects the strength, direction, and distribution
of the fields.
(b) It is very important for persons performing the inspection to understand the magnetizing
characteristics of these types of current and the various modifications in their use, for the
correct application of magnetic particle testing.
E. When a magnetic field within a part is interrupted by a discontinuity, some of the field is forced out into
the air above the discontinuity. This forms a leakage field.
(1) The closer the discontinuity is to the surface, the stronger and more concentrated the leakage
field will be.
(2) The presence of a discontinuity is located by the application of finely divided ferromagnetic
particles to the surface of the part.
(3) Some of the particles will be collected and held by the leakage field.
(4) The magnetically held collection of particles makes an outline of the discontinuity and shows its
location, size, and shape.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Test Equipment
A. The specific magnetic particle equipment necessary to accomplish an inspection will be specified for
each procedure contained in this manual.
B. When parts are magnetized by the use of spring-loaded contact clamps to cause circular
magnetization, the contact clamps must not conduct more than 800 amperes.
B. Black Light
(1) The black light used for inspection must produce a minimum intensity of 1000 micro watts per
square centimeter at the part surface.
(a) You must make sure of the black light intensity before you do the inspection.
(b) Use a light meter that meets the requirements of this section.
(2) You must check black light reflectors and filters prior to use to make sure they are clean and are
not damaged. Damaged or dirty reflectors and filters must be replaced or corrected immediately.
1. Description
A. This procedure will show you how to find cracks in the radius of the main landing gear axle.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-01, Supplemental
Inspection Number 32-10-01.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Refer to the Maintenance Manual. Remove the main landing gear axle.
4. Equipment
NOTE: This equipment was used to make this procedure. You can use replacements for the items below
if they have the necessary parameters.
Fluorescent 14AM (Aerosol Illinois Tool Works Inc, ITW Finding cracks
Magnetic Particle Can) Magnaflux
Bath Wet Method 3624 W Lake Ave.
Glenview, IL 60025
Web: www.maElnaflux.com
Portable Blacklight ZB-23A Illinois Tool Works Inc, ITW Finding cracks
Magnaflux
Magnetic Field 500203 Uresco Inc. System calibration
Indicator 10603 Midway Ave.
Cerrito, CA 90701
5. Inspection
A. Main Landing Gear Axles (Refer to Figure 1).
(1) Put the legs of the yoke on the axle as shown. Keep as much contact between the legs and axle
as possible.
(2) Apply the flourescent magnetic particles to the axle. Immediately energize the yoke with
alternating current for approximately one second.
(3) Examine the radius of the axle for cracks parallel to the circumference in an area.
(4) Turn the part to the subsequent position as shown. Do the inspection again (steps 2 and 3) until
all of the circumference is examined.
(5) Demagnatize the axle with maximum alternating current. The maximum remaining magnetic
field must not be more than two Gauss, as measured with the magnetic field indicator.
A4734
AXLE
ELECTROMAGNETIC
YOKE LEG
A
u/ CRITICAL
CRACK
ELECTROMAGNETIC
YOKE LEG
LOCATION
L~J
1
3(0 O O)E
161
NOTE: NUMBERED ELECTROMAGNETIC
YOKE LEG POSITIONS INDICATE
SUCCESSIVE TEST POSITIONS
VIEW A-A
2641T1014
AA2641T1015
Axle Inspection
Figure 1(Sheetl)
6. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5300. FAX 316-942-9006. Give the information that follows:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
1. Description
A. This procedure will show you how to find cracks in the main landing gear spring.
B. You can use this procedure to make sure there are no cracks in the main gear spring after you do
blending repairs.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Clean the area to be examined of any unwanted material and/or burrs.
4. Equipment
NOTE: This equipment was used to make this procedure. You can use replacements for the items below
if they have the necessary parameters.
Fluorescent 14AM (Aerosol Illinois Tool Works Inc, ITW To find cracks
Magnetic Particle Can) Magnaflux
Bath Wet Method 3624 W Lake Ave.
Glenview, IL 60025
Web: www.ma~naflux.com
Portable Black Light ZB-23A Illinois Tool Works Inc, ITW To find cracks
Magnaflux
Magnetic Field 500203 Uresco Inc. To calibrate system
Indicator 10603 Midway Ave.
Cerrito, CA 90701
NOTE: If access to the inspection area is sufficient, it is permitted to let the main landing gear
spring stay installed on the airplane while you do the magnetic particle inspection.
(1) Use magnetic particle inspection and examine the repaired area of the main landing gear
spring(s) and/or center spring for cracks.
(2) To remove the dirt and grease, clean the inspection area with methyl n-propyl ketone solvent or
acetone.
(3) Remove sufficient paint from the landing gear so that the yoke legs can be put on bare metal.
Do not remove all the paint, only a sufficient amount to bare the metal. Refer to the Model 208
Maintenance Manual, Chapter 20 Interior and Exterior Finish Cleaning/Painting, Paint Stripping.
(4) Use the electromagnetic yoke to magnetize the main gear spring(s) and/or center spring in two
directions.
(a) Put the legs of the yoke around the circumference of the spring so that it is centered over
the repaired area.
1 Put each of the yoke legs approximately 1.00 to 1.50 inches from the repaired area.
2 Apply the fluorescent magnetic particle bath.
3 Stop the application of the bath and immediately energize the yoke for approximately
two seconds.
(5) Adjust the
legs of the electromagnetic yoke for a leg spacing of 4.00 to 6.00 inches.
(a) Center the yoke over the repaired area along the length of the spring.
(6) Use a black light and examine the main gear spring(s) and/or center spring repaired area for
cracks.
NOTE: The ambient light in the inspection area must not be more than two foot candles.
(a) After theinspection is completed, demagnetize the main gear spring(s) and/or center
spring.
1 Make sure that the maximum residual field strength is 2G (two gauss).
1. Description
A. This procedure will show you how to find cracks in the nose landing gear spring.
B. You can use this procedure to make sure there are no cracks in the nose gear spring after you do
blending repairs.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Clean the area to be examined of any unwanted material and/or burrs.
4. Equipment
NOTE: This equipment was used to make this procedure. you can use replacements for the items below
if they have the necessary parameters.
Fluorescent 14AM (Aerosol Illinois Tool Works Inc, ITW To find cracks
Magnetic Particle Can) Magnaflux
Bath Wet Method 3624 W Lake Ave.
Glenview, IL 60025
Web: www.maRnaflux.com
Portable Black Light ZB-23A Illinois Tool Works Inc, ITW To find cracks
Magnaflux
Magnetic Field 500203 Uresco Inc. To calibrate system
Indicator 10603 Midway Ave.
Cerrito, CA 90701
5. Inspection
A. Do a Magnetic Particle Inspection of the Nose Landing Gear Spring.
(1) Inspect the repaired area of the nose landing gear spring for cracks. Use the magnetic particle
inspection
(2) Clean the area to be inspected with Methyl N-Propyl Ketone solvent or Acetone to remove the
dirt and grease.
(3) Magnetize the landing gear spring in two directions using the electromagnetic yoke.
(a) Put the legs of the yoke around the circumference of the spring so that it is centered over
the blended area.
1 Put each of theyoke legs approximately 1.00 to 1.50 inches from the blended area.
2 Apply fluorescent magnetic particle bath.
3 Stop the application of the bath and immediately energize the yoke for approximately
two seconds.
(4) Adjust the legs of the electromagnetic yoke for a leg spacing of 4.00 to 6.00 inches.
(a) Put the center of the yoke over the blended area along the length of the spring.
(5) Use a black light to inspect the nose landing gear spring blended area for cracks.
NOTE: The ambient light in the inspection area must not exceed two foot candles.
(a) After the inspection is done, demagnetize the landing gear spring.
(b) Make sure the maximum residual field strength is 2G (two gauss).
1 If cracks are found, replace the nose landing gear drag link spring. Refer to the
Maintenance Manual Chapter 32, Drag Link Spring Removal/lnstallation.
2 If no cracks are found on the nose landing gear drag link spring, install the nose
landing gear drag link spring. Refer to the Maintenance Manual Chapter 32, Drag
Li n k Spring Removal/In stal lation.
(6) Install the nose landing gear drag link spring fairing. Refer to the Maintenance Manual Chapter
32, Drag Link Spring Fairing Removal/lnstallation.
(7) Lower the airplane from the jacks. Refer to the Maintenance Manual Chapter 7, Jacking
Maintenance Practices.
1. Description
A. This procedure will show you how to find cracks in welds of the engine truss and ring assembly.
B. This procedure agrees with the Model 208 Maintenance Manual, Chapter 5, 5-14-30, Supplemental
Inspection Number 71-20-01.
2. Personnel Requirements
A. Personnel certification requirements are found in Part 1 of this manual.
3. Preparation
A. Remove the engine. Remove the truss and ring assembly from the engine. Refer to the Maintenance
Manual Chapter 71, Powerplant Maintenance Practices.
4. Equipment
NOTE: This equipment was used to make this procedure. You may use replacements for the items
below if they have the necessary parameters.
Fluorescent 14AM (Aerosol Illinois Tool Works Inc, ITW To find cracks
Magnetic Particle Can) Magnaflux
Bath Wet Method 3624 W Lake Ave.
Glenview, IL 60025
Web: www.magnaflux.com
Portable Black Light ZB-23A Illinois Tool Works Inc, ITW To find cracks
Magnaflux
Magnetic Field 500203 Uresco Inc. To calibrate system
Indicator 10603 Midway Ave.
Cerrito, GA 90701
5. Inspection
A. Engine Truss and Ring Assembly (Refer to Figure 1).
(1) Put the legs of the yoke on each side of the weld. Keep as much contact between the legs and
the part as possible.
(2) Apply the fluorescent magnetic particles to the weld. Immediately energize the yoke with
alternating current for approximately one second.
(3) Examine each weld for cracks parallel and perpendicular to the weld direction.
(4) Do the inspection for each weld on the truss and ring assembly.
A29214
ENGINE
TRUSS
ENGINE
TRUSS RING
26521009
Engine Truss
Figure 1 (Sheet 1)
(a) Make sure the maximum remaining magnetic field is not more than two Gauss, as
measured with the magnetic field indicator.
(6) Clean the truss and ring assembly.
6. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. FAX 316-942-9006, Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
OPTICAL
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
CONTENTS
Temporary Revision
Number
Page Number Issue Date By Date Removed By
CESSNA AIRCRAFT COMPANY
MODEL 208
NONDESTRUCTIVE TESTING MANUAL
Title
Part 9 List of Effective Pages 1 Nov 3/2003
Record of Temporary Revisions
Part 9 Contents 1 Nov 3/2003
Part 9 20-00-00 1 Nov 3/2003
Part 9 56-30-01 1 Nov 3/2003
2 Nov 3/2003
3 Nov 3/2003
4 Nov 3/2003
5 Nov 3/2003
6 Nov 3/2003
i. General
A. A borescope lets the technician examine structural details of parts that can not be seen easily because
of distance or location from the viewer.
B. The method is used to help look at airframe structure, engine components, and
optical inspection
parts that are see with the unaided eye or those areas where access is not easy. You can
not easy to
use this method when other nondestructive testing methods are not applicable.
1. Description
A. This procedure will define the techniques used to locate fatigue cracks in the windshield that start at
fastener hole(s) and propagate to adjacent fastener holes, into the viewing area, or to the edge of a
window using the optical prism inspection technique.
NOTE: Optical prism may be purchased or locally fabricated (Refer to Figure 1).
2. Preparation
A. Prepare airplane for inspection, refer to the applicable section in the Maintenance Manual for cleaning
instructions.
B. Clean six to eight inches (150 to 200 mm) around the outside of the windshield.
3. Equipment
NOTE: Equivalent couplants may be used, however, the operator/inspector will make sure that the
material will not be evasive or damaging to the window surface, painted surfaces, or airplane
structure.
Inspection Prism AWR P-17 Aircraft Window Repairs Company To detect cracks
2207 Border Ave.
Torrance, CA 90501
Web:
www. ai rcraftwindowrepai rs. com
Couplant Propylene Glycol Del Amo Chemical Co. To couple prism to window
535 W. 152 St.
Gardena, CA 90248
4. Inspection
A. Procedure using 70-degree prism
(1) Apply couplant to 70-degree face of prism and area of window to be inspected (refer to Figure
2).
(2) Couple the prism to the window per Figure 2, and with the light source at an angle of 30 to 60
degrees from the vertical face of the prism, illuminate and inspect the fastener holes.
NOTE: In order to get a clear view of both the top and bottom surfaces of the fastener hole,
it may be necessary to slide the prism toward and away from the fastener being
inspected.
(a) The image of an undamaged fastener hole will appear as a frosty cylinder.
(b) The image of a fastener hole with a crack that extends from one surface of the material
under inspection into the hole, will appear as a frosty or reflective ear or projection that
extends from the fastener hole as in View A-A of Figure 2.
(c) The image of a crack which has progressed from one fastener hole to another will appear
as a frosty irregular surface. View B-B of Figure 2 illustrates a crack from hole to hole.
5. Part Disposition
A. If a crack is found, contact Cessna Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS
67277 USA. Telephone 316-517-5800. Provide the following information:
(1) Crack location.
(2) Crack length.
(3) Crack orientation.
nnwn
0.75 INCH
OR GREATER
1.30
o
INCHES/ 75
PRISM
70"
5583T1011
nnoos
WINDSHIELD
COUPLANT
EYE
SIGHTLIGHT SOURCE
-/O"ANGLE
PRISMREFRACTION
75"ANGLE ~´•´•8
ssssmol
A16122
WINDSHIELD
COUPLANT
PRISM
i7$
,I
A5583T1012
A16123
GROUND GLASS OR
OPTICAL PRISM
CLOUDY APPEARANCE
INDICATES CRACK IN
OUTER MAIN PLY
FASTENERS
oc,a
o
COUPLANT
INNER MAIN PLY
WITHOUT CRACK LIGHT SOURCE
ACRYLICPANEi DAMAGE
EXTERNAL SURFACE
A5583T1013