SERVICE BULLETIN SERIAL NUMBERS. 525A (CJ2) thru -0125

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1 TITLE SB FLIGHT CONTROLS - AILERON CABLE AND FAIRLEAD TUBE REPLACEMENT EFFECTIVITY MODEL SERIAL NUMBERS 525A (CJ2) thru REASON The equivalent of this service bulletin has been incorporated on production airplanes and On. To reduce the possibility of the aileron cables becoming frayed by chafing on the fairleads in the wings. DESCRIPTION This service bulletin provides the parts and instructions necessary to replace the fairleads with redesigned fairleads that will not cause chafing damage or fraying of the aileron cables. COMPLIANCE RECOMMENDED. This service bulletin should be accomplished during a scheduled maintenance period or inspection. A service bulletin published by Cessna Aircraft Company may be recorded as completed in an aircraft log only when the following requirements are satisfied: 1) The mechanic must complete all of the instructions in the service bulletin, including the intent therein. 2) The mechanic must correctly use and install all applicable parts supplied with the service bulletin kit. Only with written authorization from Cessna Aircraft Company can substitute parts or rebuilt parts be used to replace new parts. 3) The mechanic or airplane owner must use the technical data in the service bulletin only as approved and published. 4) The mechanic or airplane owner must apply the information in the service bulletin only to aircraft serial numbers identified in the Effectivity section of the bulletin. 5) The mechanic or airplane owner must use maintenance practices that are identified as acceptable standard practices in the aviation industry and governmental regulations. No individual or corporate organization other than Cessna Aircraft Company is authorized to make or apply any changes to a Cessna-issued service bulletin, service letter, or flight manual supplement without prior written consent from Cessna Aircraft Company. Cessna Aircraft Company is not responsible for the quality of maintenance performed to comply with this document, unless the maintenance is accomplished at a Cessna-owned Citation Service Center. FLIGHT CREW OPERATIONS No Change Page 1 of 23 Cessna Aircraft Company, Citation Marketing Division, P.O. Box 7706, Wichita, KS 67277, U.S.A , Fax COPYRIGHT 2009

2 APPROVAL SB FAA approval has been obtained on technical data in this publication that affects airplane type design. This information shall be considered an amendment to the Cessna Manufacturer's Maintenance Manual. MANPOWER WORK PHASE MAN-HOURS Modification * MATERIAL - Cost and Availability PART NUMBER AVAILABILITY COST SB * * It may be necessary to order one or more of the following parts. NEW P/N QUAN- TITY KEY WORD OLD P/N INSTRUCTIONS/ DISPOSITION MS Nut Same Discard MS Cotter Pin Same Discard Outboard Intermediate Aileron Cable Assembly Left Cabin Aileron Cable Assembly Right Cabin Aileron Cable Assembly Same Same Same Discard Discard Discard * Refer to the attached Service Bulletin Supplemental Data sheet for man-hours, material cost and availability, and warranty information. CONSUMABLE MATERIAL The following materials, or equivalent, are required for the accomplishment of this service bulletin. NAME NUMBER MANUFACTURER USE Sealant CMNP021 Class B1/2 Cessna Citation Parts Distribution 7121 Southwest Boulevard Wichita, KS To wet install rivets. TOOLING None Page 2

3 SB CHANGE IN WEIGHT AND BALANCE MODEL 525A WEIGHT INCREASE pounds RESULTANT MOMENT inch-pounds MOMENT/ REFERENCES Cessna Model 525A Maintenance Manual Cessna Model 525A Structural Repair Manual PUBLICATIONS AFFECTED Cessna Model 525A Illustrated Parts Catalog ACCOMPLISHMENT INSTRUCTIONS 1. Set the flaps to the GROUND FLAP position. 2. Set the speedbrakes to the EXTEND position. 3. Prepare the airplane for maintenance as follows: A. Make sure that all switches are in the OFF/NORM position. B. Disconnect electrical power from the airplane. (1) Disconnect the airplane battery. (2) Disconnect external electrical power. C. Attach maintenance warning tags to the battery and external power receptacle that have "DO NOT CONNECT ELECTRICAL POWER - MAINTENANCE IN PROGRESS" writtenonthem. 4. Remove access panels 192B, 191BL, 192BR, 321A, 512DB, 522AB, 542JB, 542HB, 612DB, 622AB, 642JB and 642HB. (Refer to the Model 525A Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description and Operation.) 5. (Refer to Figure 2, Detail A and Detail B.) Inspect the Inboard Intermediate Aileron Cable Assembly, Left Cabin Aileron Cable Assembly and Right Aileron Cable Assembly. A. Install new cables if there are any worn spots or signs of chafing. (Refer to the Model 525A Maintenance Manual, Chapter 27, Aileron and Tab System Control Cables - Maintenance Practices.) 6. Put the aileron trim tab and aileron trim control indicator to the neutral position. 7. Remove and discard the Left Aileron Servo Cable Assembly and Right Aileron Servo Cable Assembly. (Refer to the Model 525A Maintenance Manual, Chapter 27, Aileron and Tab System Control Cables - Maintenance Practices.) A. Keep the attaching hardware. 8. (Refer to Figure 1, View A-A.) Install two Fairleads at WS A. Disconnect the Left Cabin Aileron Cable and Right Cabin Aileron Cable at the outboard wing and pull them inboard. (Refer to the Model 525A Maintenance Manual, Chapter 27, Aileron and Tab System Control Cables - Maintenance Practices.) B. Disconnect the Lower Wing Cables at the wing root and pull them outboard. (Refer to the Model 525A Maintenance Manual, Chapter 27, Aileron and Tab System Control Cables - Maintenance Practices.) Page 3

4 SB C. Remove and discard the parts that follow: (1) The Left Fairlead or Right Fairlead. (2) Two Retainers. D. Install the Fairleads. (1) Install one Left Bracket Assembly or Right Bracket Assembly on the structure and attach with a clamp. (a) Put the Left Bracket or the Right Bracket on the structure and attach with a clamp. (b) Drill two Number 30 (0.128-inch diameter) holes in the Left Bracket or the Right Bracket to match the existing holes in the structure. (c) Remove the Left Bracket or the Right Bracket and deburr all holes. (d) Attach the Left Bracket or the Right Bracket to the structure with two MS20470AD4-4 Rivets wet installed with CMNP021 Class B1/2 Sealant or equivalent. (Refer to the Model 525A Maintenance Manual, Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.) (2) Install the Fairleads and the two Retainers. (a) Attach each Fairlead and Retainer to the Left Bracket or Right Bracket with two each MS Screws and NAS1149FN832P Washers. (3) Do Step 8D for the opposite side. 9. (Refer to Figure 1, Detail A and View B-B.) Install two Fairleads. A. Remove the Left Speed Brake Tube Retract Assembly and Right Speed Brake Retract Tube Assembly and the speed brake hydraulic tubes. (1) Depressurize the hydraulic system. (Refer to the Model 525A Maintenance Manual, Chapter 29, Main Hydraulic System - Maintenance Practices.) (2) Discard the Left Speed Brake Retract Tube Assembly or Right Speed Brake Retract Tube Assembly. (3) Keep the hardware for speed brake hydraulic tubes. B. Remove and discard the following parts: (1) The Left Fairlead or Right Fairlead. (2) The Left Retainer and Right Retainer. (3) Four MS Screws. (4) Four MS21044N08 Nuts. C. Install the Fairleads. (1) Install one Left Bracket or Right Bracket. (a) Put the Left Bracket or the Right Bracket on the structure and attach with a clamp. (b) Drill four Number 30 (0.128-inch diameter) holes in the Left Bracket or the Right Bracket to match the existing holes in the structure. (c) Remove the Left Bracket or the Right Bracket and deburr all holes. Page 4

5 SB (d) Attach the Left Bracket or the Right Bracket to the structure with four S Rivets wet installed with CMNP021 Class B1/2 Sealant or equivalent. (Refer to the Model 525A Maintenance Manual, Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.) (2) Install the Fairleads and the Left Retainer and the Right Retainer. (a) Attach one Fairlead and the Left Retainer to the Left Bracket with two each NAS1149FN832P Washers, MS Screws, MS21919WDG4 Clamps, MS21043L3 Nuts and one each AN3-4A and AN3-5A Bolt. (b) Attach one Fairlead and Right Retainer to the Right Bracket with two each NAS1149FN832P Washers, MS Screws, MS21919WDG4 Clamps, MS21043L3 Nuts and one each AN3-4A and AN3-5A Bolt. D. Do Steps 9A through 9C for the opposite side. 10. (Refer to Figure 1, View C-C.) Install one Left Bracket Assembly or the Right Bracket Assembly. A. Remove and discard the following parts: (1) The Left Fairlead and the Left Retainer or the Right Fairlead and the Right Retainer. (2) Four MS Screws. (3) Four MS21044N08 Nuts. B. Mark and drill two Number 30 (0.128-inch diameter) holes in the Left Bracket Assembly or the Right Bracket Assembly. C. Remove three rivets from the stiffener. (Refer to the Model 525A Structural Repair Manual, Chapter 51, Fastener Removal and Installation.) D. Put the Left Bracket Assembly or the Right Bracket Assembly on the flap hinge as shown. E. Attach the bracket assembly to the flap hinge with clamps. F. Drill two Number 30 (0.128-inch diameter) holes in the flap hinge to match the holes that were drilled in the Left Bracket Assembly or the Right Bracket Assembly. G. Drill three Number 30 (0.128-inch diameter) holes in the Left Bracket Assembly or the Right Bracket Assembly to match the holes that were drilled in the stiffener. H. Remove the Left Bracket Assembly or the Right Bracket Assembly from the flap hinge. (Refer to the Model 525A Structural Repair Manual, Chapter 51, Fastener Installation and Removal.) I. Deburr all holes. J. Attach the Left Bracket Assembly or the Right Bracket Assembly to the flap hinge and stiffener with five MS20470AD4-4 Rivets wet installed with CMNP021 Class B1/2 Sealant or equivalent. (Refer to the Model 525A Maintenance Manual, Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.) K. (Refer to View C-C and D-D.) Attach one Fairlead and the Retainer to the Left Bracket Assembly or the Right Bracket Assembly with two each MS Screws and NAS1149FN832P Washers. L. Do Steps 10A through 10K for the opposite side. Page 5

6 SB 11. (Refer to Figure 1, View E-E and View F-F.) Install one Left Bracket Assembly or the Right Bracket Assembly. A. Remove and discard two Rub Strips and one each Left Bracket and Right Bracket and all fasteners. B. Install the Left Bracket Assembly or the Right Bracket Assembly. (1) Remove and discard the rivets from the three locations shown. (Refer to the Model 525A Structural Repair Manual, Chapter 51, Fastener Removal and Installation.) (2) Put the Left Bracket Assembly or the Right Bracket Assembly on the closeout as shown and attach with clamps. (3) Drill three Number 30 (0.128-inch diameter) holes in the Left Bracket Assembly or the Right Bracket Assembly to match the fastener locations that were drilled out in the closeout. (4) Remove the Left Bracket Assembly or the Right Bracket Assembly. (5) Deburr the holes in the bracket assembly. (6) Attach the Left Bracket Assembly or the Right Bracket Assembly to the closeout with three S Rivets wet installed with CMNP021 Class B1/2 Sealant or equivalent. (Refer to the Model 525A Maintenance Manual, Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.) (7) Install one each Retainer and Fairlead on the Left Bracket Assembly or Right Bracket Assembly with two each MS Screws and NAS1149FN832P Washers. C. Do Steps 11A and 11B for the opposite side. 12. Install one each Left Aileron Servo Cable Assembly, Right Aileron Servo Cable Assembly and Left Aileron Servo Cable Assembly. A. Remove and discard the following parts: (1) Two NAS D Bolts. (2) Two NAS427K24 Pins. (3) One Mid Left Bracket Assembly or Mid Right Bracket Assembly. (a) Keep the rub strips that are on the Mid Left Bracket Assembly or Mid Right Bracket Assembly. (4) One MS21251B3S Turnbuckle Body Clip. (5) Two MS Clips. (6) One MS RL Eye End Turnbuckle. (7) One AN23-15 Bolt. (8) One NAS1149F0363P Washer. B. (Refer to Figure 1, View K-K and L-L.) Install the new pulley brackets. (1) Remove the Mid Left Bracket Assembly or the Mid Right Bracket Assembly. (a) Remove the hiloks that attach the Mid Left Bracket Assembly or Mid Right Bracket Assembly to the structure. (Refer to the Model 525A Structural Repair Manual, Chapter 51, Fastener Removal and Installation.) (b) Discard the Mid Left Bracket Assembly or the Mid Right Bracket Assembly. Page 6

7 SB (2) (Refer to Figure 1, View K-K and L-L.) Install one Left Bracket or Right Bracket. (a) Remove the four lower rivets in the spar cap. (Refer to the Model 525A Structural Repair Manual, Chapter 51, Fastener Installation and Removal.) (b) Put the Left Bracket or the Right Bracket on the rear spar cap. Attach with clamps. (c) Drill eight Number 21 (0.159 inch diameter) holes in the Left Bracket or the Right Bracket to match the holes that were drilled in the rear spar where the Mid Left Bracket Assembly and the Mid Right Bracket Assembly was removed. (d) Ream the holes to inch diameter, ± inch diameter. (e) Remove the Left Bracket or the Right Bracket from the rear spar. (f) Deburr all of the holes that were drilled. (g) Put the kept rub strips on the Left Bracket and the Right Bracket. (h) Put the Left Bracket or the Right Bracket on the rear spar cap and attach with four HL18PB5-6 Pins, HL19PB5-10 Pins and eight HL70-5 Collars wet installed with CMNP021 Class B1/2 Sealant or equivalent. (Refer to the Model 525A Maintenance Manual, Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing - Maintenance Practices.) (3) (Refer to Figure 1, View H-H and J-J.) Install the kept S Pulley in the Left Bracket or the Right Bracket with one NAS D Bolt, two each NAS43DD4-13FC Spacers, NAS43DD4-43FC Spacers and NAS427K32 Pins, one kept NAS1149F0416P Washer and one each MS Nut and MS Cotter Pin. (4) Do Step 12B for the opposite side. C. Install the Left Aileron Servo Cable Assembly, Right Aileron Servo Cable Assembly and Left Aileron Servo Cable Assembly. (Refer to the Model 525A Maintenance Manual, Chapter 27, Aileron and Tab System Control Cables - Maintenance Practices.) (1) (Refer to Figure 1, View M-M and View P-P.) Install the Right Aileron Servo Cable Assembly with one AN23-13 Bolt and one kept NAS1149F0332P Washer, one each MS Nut and MS Cotter Pin. (a) Position the AN23-13 Bolt head facing forward. (b) Tighten the MS Nut, then back it off until the NAS1149F0332P Washer spins and install the MS Cotter Pin. (2) (Refer to Figure 1, View M-M and View O-O.) Install the Left Aileron Servo Cable Assembly and Right Aileron Servo Cable Assembly with one MS21251B3S Turnbuckle Body Clip and two MS Clips. D. (Refer to Figure 2, Detail A.) Connect the Left Cabin Aileron Cable and Right Cabin Aileron Cable. (Refer to the Model 525A Maintenance Manual, Chapter 27, Aileron and Tab System Control Cables - Maintenance Practices.) E. (Refer to Figure 2, Detail A.) Connect the Lower Wing Cables with one each AN23-13 Bolt, MS Nut and MS Cotter Pin. (Refer to the Model 525A Maintenance Manual, Chapter 27, Aileron and Tab System Control Cables - Maintenance Practices.) 13. (Refer to Figure 1, Detail A.) Install one Left Speed Brake Retract Tube Assembly and Right Speed Brake Retract Tube Assembly. 14. Bleed the hydraulic system to remove air from the speed brake system. (Refer to the Model 525A Maintenance Manual, Chapter 29, Main Hydraulic System - Adjustment/Test.) Page 7

8 SB 15. Do an operational check of the speed brake system. (Refer to the Model 525A Maintenance Manual, Chapter 27, Speed Brake System - Adjustment/Test.) 16. Do an operational check of the aileron and tab system control cable. (Refer to the Model 525A Maintenance Manual, Chapter 27, Aileron and Tab System - Adjustment/Test.) 17. Install the removed access panels 192B, 191BL, 192BR, 321A, 512DB, 522AB, 542JB, 542HB, 612DB, 622AB, 642JB and 642HB. (Refer to the Model 525A Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description and Operation.) 18. Record that this service bulletin has been completed. A. Complete a Maintenance Transaction Report. B. Put a copy of the completed Maintenance Transaction Report in the airplane logbook. C. Send a copy of the completed Maintenance Transaction Report to: CESCOM, P.O. Box 7706, Wichita, KS MATERIAL INFORMATION NOTE: The parts included in this service bulletin cover installation for one airplane. NEW P/N QUAN- TITY KEY WORD OLD P/N INSTRUCTIONS/ DISPOSITION SB 1 Kit, consisting of the following parts: AN3-4A 2 Bolt None AN3-5A 2 Bolt None AN Bolt AN23-15 Discard HL18PB5-6 8 Pin None HL19PB Pin None HL Collar None MS Nut Same Discard MS Nut Same MS20470AD Rivet None MS21042L3 4 Nut None MS21251B3S 1 Turnbuckle Body Clip MS21251B3S, MS21254RL and NAS1149F0363P Discard MS Clip Same Discard MS21919WDG4 4 Clamp Same Discard MS Cotter Pin Same Discard MS Screw MS and MS21044N08 Discard MS Screw None Page 8

9 SB NEW P/N QUAN- TITY KEY WORD OLD P/N INSTRUCTIONS/ DISPOSITION NAS427K32 4 Pin NAS427K24 Discard NAS43DD4-13FC 4 Spacer None NAS43DD4-43FC 4 Spacer None NAS1149FN832P 16 Washer None NAS D 2 Bolt NAS D Discard S Rivet Same Discard Tube Assembly - Speed Discard Brake Retract Tube Assembly - Speed Discard Brake Retract Left Aileron Servo Cable Discard Assembly Right Aileron Servo Cable Discard Assembly Left Aileron Servo Cable None Assembly Left Bracket Assembly None Right Bracket Assembly None Left Retainer Discard Right Retainer Discard Left Bracket Assembly Right Bracket Assembly Fairlead Discard Left Bracket Assembly Discard Right Bracket Assembly Discard Retainer None Fairlead None Left Bracket Assembly and Discard Right Bracket Assembly and Discard Retainer None Fairlead Retainer Left Bracket Discard Right Bracket Discard Page 9

10 SB NEW P/N QUAN- TITY KEY WORD OLD P/N INSTRUCTIONS/ DISPOSITION Fairlead and SB 1 Instructions Discard Page 10

11 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 1) Page 11

12 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 2) Page 12

13 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 3) Page 13

14 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 4) Page 14

15 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 5) Page 15

16 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 6) Page 16

17 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 7) Page 17

18 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 8) Page 18

19 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 9) Page 19

20 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 10) Page 20

21 SB Figure 1. Aileron and Cable Fairlead Tube Replacement (Sheet 11) Page 21

22 SB Figure 2. Aileron Cable Inspection/Replacement (Sheet 1) Page 22

23 SB Figure 2. Aileron Cable Inspection/Replacement (Sheet 2) Page 23

25 TITLE SUPPLEMENTAL DATA SB FLIGHT CONTROLS - AILERON CABLE AND FAIRLEAD TUBE REPLACMENT EFFECTIVITY MODEL SERIAL NUMBERS 525A (CJ2) thru The equivalent of this service bulletin has been incorporated on production airplanes and On. MANPOWER MATERIAL - Cost and Availability WORK PHASE MAN-HOURS Modification PART NUMBER AVAILABILITY COST SB * * It may be necessary to order one or more of the following parts. NEW P/N QUAN- TITY KEY WORD OLD P/N INSTRUCTIONS/ DISPOSITION MS Nut Same Discard MS Cotter Pin Same Discard Outboard Intermediate Same Discard Aileron Cable Assembly Left Cabin Aileron Cable Same Discard Assembly Right Cabin Aileron Cable Assembly Same Discard * Please contact Citation Parts Distribution for current cost and availability of parts listed in this service bulletin. Phone at (Domestic) or (International). Send to: citationparts@cessna.textron.com or telefax at Based on availability and lead times, parts may require advanced scheduling. In cases where the required part(s) are available as exchange, order the exchange part and, upon completion, expedite the return of the removed core to avoid return penalties. Contact the Citation Parts Distribution Sales Desk for availability of exchange parts. Page 1 of 2 Cessna Aircraft Company, Citation Marketing Division, P.O. Box 7706, Wichita, KS 67277, U.S.A , Fax COPYRIGHT 2009

26 SUPPLEMENTAL DATA SB WARRANTY CREDIT PROGRAM This bulletin is recommended. Eligible airplanes may qualify for parts and labor coverage, as described below. Eligibility: Parts Coverage: Labor Coverage: Credit Application: All affected airplanes. Authorized Citation Service Facilities, operators, or other maintenance facilities may submit a Citation Credit Claim Form for the parts required to accomplish this bulletin. Authorized Citation Service Facilities may submit a Citation Credit Claim Form for the labor necessary to accomplish this service bulletin. Please note Manpower Requirements for coverage guidelines. If actual labor differs from coverage guidelines, claim actual labor and detail all discrepancies. All work must be completed and the Citation Credit Claim Form submitted before the date shown below. Send the Citation Credit Claim, along with any required parts (see Material Information), to the point of purchase. Parts to be returned to Citation Parts Distribution should be forwarded to: Citation Warranty Administration 7121 Southwest Boulevard Wichita, KS USA Expiration: May 30/2011 Page 2

ALERT SERVICE BULLETIN Alert Service Bulletin No. 072

ALERT SERVICE BULLETIN Alert Service Bulletin No. 072 2900 Selma Highway Montgomery, AL 36108 USA Tel: 334-386-5400 Fax: 334-386-5450 ALERT SERVICE BULLETIN 1. Planning Information A. Effectivity (1) Sky-Tec Master Contactor P/N STS-M12 manufactured by Hartzell