CESSNA AIRCRAFT COMPANY P. O. BOX 7704 WICHITA, KANSAS 67277-7704

STRUCTURES

MODEL NO: 150 (and others)

REPORT NO: S-150-ATA25/01RD

REPAIR DEFINITION

STEEL SEAT FOOT / ROLLER HOUSING REPAIR

REPORT DATE: July 28, 2011

PREPARED BY: John Baldessari John Baldessari

PREPARED BY: Gale Meek Gale Meek

APPROVED BY: Tony Massucci Tony MassucciCessna Aircraft Company Page 1.1

P. O. Box 7704 Report S-150-ATA25/01RD Wichita, KS 67277 Aircraft: multiple serial nos.

1.0 AIRCRAFT DATA
This repair is valid for the following aircraft mod els and serials numbers:
Model Serial Range
150 15059019 15079405
F150 F150-0001 F15001428
A150 A1500001 A1500734
FA150 FA1500001 FA1500120
FRA150 FRA1500121 FRA1500336
152 15279406 15286033
F152 F15201429 F15201980
A152 A1520735 A1521049
FA152 FA1520337 FA1520425
FA152 FA1520348 FA1520425

SPECIAL NOTES

• This Repair Definition covers only the damage defi ned in this document and it is the responsibility of the repair facility to assure that the defined damage agrees with the actual damage, i.e. no crack s, no twisting, or other damage.

• All nondestructive inspections (NDI) specified in the Repair Definition must be performed by a qualified facility.
The repair described in the report satisfies applic able strength and fatigue, fail
safe, and/or damage tolerance requirements. Approv ed data for structural substantiation and back-up data for this repair are contained in Engineering’s Repair Definition Archive.
The structural repairs designed herein for these ai rcraft do not affect the original structural inspection criteria (procedures or timin g) as published in the appropriate Cessna Maintenance Manuals.
The repair definition contained within this documen t has been found to comply with the following regulations:
Part 3 of the Civil Air Regulations dated May 25, 1 956, as amended by 3-4, Paragraphs 3.171, 3.172, 3.173, 3.174, 3.292, 3.293 , 3.294, 3.295, 3.296,
and 3.386. A

ACessna Aircraft Company Page 2.1

P. O. Box 7704 Report S-150-ATA25/01RD Wichita, KS 67277 Aircraft: multiple serial nos.

2.0 DAMAGE DESCRIPTION
FAA Airworthiness Directive (AD) 2011-10-09 became effective June 17, 2011, and requires Cessna Aircraft owners to inspect seat rails and seat foot (“roller housing”) structure for cracks, wear, or other defo rmations.
Among other requirements, the AD specifies that the geometry for the tangs of the seat roller housings must fall within certain l imits -- reference. AD 2011-10- 09 paragraphs (g)(6), (g)(6)(i), and Figure 4 (rep roduced in Fig. 2.0-1 below).

FIGURE 2.0-1 ROLLER HOUSING TANG GEOMETRY REQUIREM ENTS PER AD 2011-10-09

(6) Due to wear or deformation of the tangs, inspec t the tang length from the inner edge of the tang to the outer edge (the bend area) of the r oller housing (see figure 4).

(i) The minimum measurement allowed for the remaini ng tang length is 0.230 inches remaining on either of the tangs, from the inner ed ge of the tang to the outer edge (the bend area) of the roller housing. If the measurement is less than 0.230 inches on either of the tangs, before further flight, replace the roller housing. ACessna Aircraft Company Page 2.2

P. O. Box 7704 Report S-150-ATA25/01RD Wichita, KS 67277 Aircraft: multiple serial nos.

In the case of seats which use steel roller housing s (e.g. as defined by Cessna drawings 0311310 “Roller, Pilot Seat”, and 0514016 “Housing Assy – Seat Roller”), the tangs may not meet the dimensional re quirements set forth in the AD due to primarily to deformation or bending of the s eat feet, rather than being caused by actual wear / loss of material. Ref. Fig ures 2.0-2 and 2.0-3 for examples of this type of deformation / bending of r oller housing geometry.

FIGURE 2.0-2 DETAIL OF BENDING / DEFORMATION OF SE AT ROLLER HOUSING SIDE WALL

steel seat foot / roller housing m/f 0.080” thick 4130 sheet, 90 ksi (typ.)

roller housing side wall bent out from vertical / parallel to opposite side wallCessna Aircraft Company Page 2.3

P. O. Box 7704 Report S-150-ATA25/01RD Wichita, KS 67277 Aircraft: multiple serial nos.

FIGURE 2.0-3 DETAIL OF DEFORMED / BENT SEAT ROLLER HOUSING TANGS

steel seat foot / roller housing

m/f 0.080” thick 4130 sheet, 90 ksi (typ.) roller housing tang bent out from nominal position of approx. 10.33° from horizontalCessna Aircraft Company Page 3.1

P. O. Box 7704 Report S-150-ATA25/01RD Wichita, KS 67277 Aircraft: multiple serial nos

3.0 REPAIR DEFINITION
Read the entire service document prior to beginning the repair; contact Cessna Customer Service if the repair cannot be performed as described below. Steel seat roller housings may be gently formed (or “bent”) back to a configuration conforming to specifications as shown in Figure3.2-1 below and AD 2011-10-09, followed by an NDI inspection (as identified in paragraph 3.2.4) for any cracking. Note that this is a cold forming operation. No heating is to be done for this operation.
This repair procedure is only applicable to seats which are listed in Section 1.0 which have not been modified with non-production roller housings. Production seat roller housings are made of 4130 steel and in normalized (90 ksi) condition.

3.1 MATERIALS REQUIRED FOR REPAIR
No special materials are required to perform this repair. A

A ACessna Aircraft Company Page 3.2

P. O. Box 7704 Report S-150-ATA25/01RD Wichita, KS 67277 Aircraft: multiple serial nos

3.2 REPAIR PROCEDURE
1. Using suitable tools, form (or “bend”) the rolle r housing side walls and tangs to match the geometry specifications shown in Figure 3.2-1 below (or as close as possible, while still preventing in terference with the seat rail and allowing free movement). Suitable tools in clude a hardwood block that will fit inside the roller housing, a non-marr ing hammer, pliers or vice grips with smooth jaws, or similar tools suitable f or forming or bending without damage to the roller housing.

FIGURE 3.2-1 ROLLER HOUSING GEOMETRY SPECIFICATION S

0311312 -4, -5 Roller Housing 0514016 -2, -4 Housing 0.080” thick 4130 sheet normalized (90 ksi)

0.41” (ref.) 90° ± 5° 2 pl.

10.33° ± 5° 2 pl. 0.11” R min., 2 pl. 0.77” (ref.) A

A ACessna Aircraft Company Page 3.3

P. O. Box 7704 Report S-150-ATA25/01RD Wichita, KS 67277 Aircraft: multiple serial nos

2. Polish to a surface finish of 125 RMS (surface s moothness, ref. ASME B46.1-2009) or better following all forming operati ons. Take care not to nick, gouge, or wrinkle any of the roller housing s urfaces during forming operations.
3. Following forming operations, check roller housi ng geometry against the requirements set forth in AD 2011-10-09. If the ge ometry still does not meet the requirements of AD 2011-10-09, the roller housing must be replaced.
4. Following forming operations, check all surfaces of the roller housing for cracks using dye penetrant and/or eddy current insp ection methods. If any cracks are found, the roller housing must be re placed.
5. Repair surface finish / paint where required in accordance with the appropriate Cessna Maintenance Manual for the model of aircraft being repaired.
6. Make a logbook entry stating compliance with thi s repair definition. ACessna Aircraft Company Page 3.4

P. O. Box 7704 Report S-150-ATA25/01RD Wichita, KS 67277 Aircraft: multiple serial nos

3.3 GENERAL

• This repair is authorized for the stated Serial Nu mbered airplanes only.

• This repair is for an unmodified airplane. Any no n-Cessna modification that affects the aircraft gross weight, original design, or performance may invalidate published Continued Airworthiness requir ements (i.e., inspection techniques and/or interval). Contact the STC Holde r or originator of the modification for revised inspection criteria.