Instructions for Continued Airworthiness

MC1211661-5 Aft Cargo Door, Lower, Aft 1211661-5 MC1211661-5S MC1211661-6 Aft Cargo Door, Upper, Aft 1211661-6 MC1211661-6S MC1211661-7 Aft Cargo Door, Lower, Forward 1211661-7 MC1211661-7S MC1211661-8 Aft Cargo Door, Upper, Forward 1211661-8 MC1211661-8S MC1211661-9 Forward Cargo Door, Upper, Forward 1211661-3, 1211661-9 MC1211661-9S Instructions for Continued Airworthiness McFarlane Aviation, LLC. PMA Door Hinges, Cessna 100 and 200 Series FAA PMA Number: PQ3732CE Notice: Verify that this document is the latest approved revision before use! Current version can be found at: www.McFarlaneAviation.com/ICA Page 4 of 7 McFarlane Drawing: 1170 Rev A HINGE HALVES – SPECIAL OPERATING INFORMATION The control and operation of the cabin door does not change with the installation of the McFarlane cabin door hinge halves; see applicable Cessna model 150 Series, 180 Series or 200 series Service Manual for the operational control of this system. HINGE HALVES – PART REMOVAL, REPLACEMENT, AND SERVICE INFORMATION Note: For best results, McFarlane recommends replacing the forward and aft hinge halves and replacing both the upper and the lower hinges simultaneously. Hinge half removal and replacement: 1. There may be a film of paint connecting the hinge half to the door and/or fuselage. If it is present, score the paint with a sharp razor blade or utility knife. 2. Disconnect door stops and other non-hinge connections to the fuselage. Remove interior trim as needed to access to the hinge half fasteners. 3. Remove the old hinge pin(s) per the applicable Cessna model 150 Series, 180 Series or 200 Series Service Manual. If replacing an aft hinge half, remove the door from the aircraft. 4. Door Mounted Hinge Half Removal: Remove the rivets fastening the hinge half to the door, taking care not to damage the door or rivet holes. Remove the hinge half from the door. Note: Some rivet removal techniques can be found in FAA Advisory Circular 65-15A, page 177. This document can be downloaded from: https://www.faa.gov/regulations_policies/advisory_circulars/index.cfm/go/document.information/documentID/23018 5. Fuselage Mounted Hinge Half Removal: Remove the hinge half from the fuselage by removing the threaded fasteners. 6. As needed, perform surface cleaning, corrosion repair, and paint preparation of the door & fuselage skins prior to installing the replacement hinge half. 7. Door Mounted Hinge Half Installation: Prior to riveting, temporarily install the hinge half with Cleco type fasteners to facilitate door and hinge alignment and checking for proper function. Once alignment and function are appropriate, install the McFarlane hinge half onto the door with appropriate rivets. a. Note: The MC0413426-33 & MC0413426-34 door hinges must be match drilled for the rivet holes through the door’s flange. Mark their locations on the back/inner face but drill them perpendicular to the front/outer face so that the rivet heads lie flat against the front/outer face. These two part numbers are provided with plain fastener holes; they must be countersunk if the installer desires to use countersunk rivets. 8. Fuselage Mounted Hinge Half Installation: Install the McFarlane hinge half onto the fuselage with appropriate threaded fasteners, tightening fully after the door and hinge alignment and function are appropriate. Note: McFarlane Aviation recommends replacing the threaded fasteners with new parts at this time. 9. Lubricate the pin joint with a solid film lubricant (as specified for piano-style hinges in the applicable Cessna 150 Series, 180 Series or 200 Series Service Manuals) or with a light coating of oil. 10. Reinstall the door by installing the McFarlane hinge pins per the instructions in Section 2 of this document or by installing NEW Cessna pins. Note: Not every Cessna pin is reusable, if hinge contains a peened/swaged pin it must be replaced every time a Cessna pin is removed. 11. McFarlane provides the hinge halves with a corrosion preventing coating. For complete corrosion protection, the hinges MUST be painted with an appropriate aircraft grade exterior paint per applicable aircraft maintenance manual. The McFarlane hinge pins do not require painting. 12. Reconnect door stops and other non-hinge connections to the fuselage. Reinstall interior trim. When replacing a hinge half with an undrilled part, the installer must locate, mark, and drill the fastener holes. The above instructions apply for the following: 1. The hole pattern must be marked on the undrilled part. Some suggestions for performing this are: • After removing the old hinge half, use it to create a drill template. OR • Only remove the hinge half to be replaced, maintaining the door’s location and alignment within the door opening. Attach the undrilled half with a McFarlane reusable pin. Using a strap duplicator or accessing the holes from the back side, mark the hole drill centers on the undrilled part. 2. Drill the fastener holes through the part, maintaining perpendicularity between the bit and the part while drilling. 3. Before installing the hinge half, treat the edges of the drilled holes with primer to help prevent corrosion. No exceptions to Cessna instructions, specific to the McFarlane hinge halves, apply. The McFarlane hinge halves install using the same methods and hardware. Instructions for Continued Airworthiness McFarlane Aviation, LLC. PMA Door Hinges, Cessna 100 and 200 Series FAA PMA Number: PQ3732CE Notice: Verify that this document is the latest approved revision before use! Current version can be found at: www.McFarlaneAviation.com/ICA Page 5 of 7 McFarlane Drawing: 1170 Rev A HINGE HALVES – SUPPLEMENTAL ELIGIBILITY INFORMATION The following information is provided to help identify the correct hinge half on certain models, serial ranges, and installation locations. Cessna 180B-E, 182B-C: Lower Left Forward Cabin Door Hinge Half 1. These models’ Illustrated Parts Catalogs may call out Cessna P/N 0711037-10, which has two screw holes. 2. For these models, use McFarlane PMA P/N MC0711037-7 if the installation requires three screws. See Figure 1 for illustrations of P/Ns MC0711037-10 and MC0711037-7. Figure 1: McFarlane PMA P/Ns MC0711037-10 (left images) and MC0711037-7 (right images) Cessna 205 & 205A, P206-P206E, TP206A-E: Lower Forward Baggage Door Hinge Half 1. These models’ Illustrated Parts Catalogs may call out Cessna P/N 0711037-1, which has three knuckles and nine rivet holes. 2. For these models, use McFarlane PMA P/N MC0711037-7 if: a. the existing half is small (about 1-3/4” tall by about 1-7/16” wide), b. has two knuckles, c. has three screw holes, and d. is thicker on its lower edge and thinner on its upper edge. See Figure 1 for illustrations of P/N MC0711037-7 and Figure 2 for an illustration of P/N MC0711037-1. Figure 2: McFarlane PMA P/N MC0711037-1 Cessna 207A & T207A S/N 20700563 & on, 210N & T210N S/N 21063641 & on: Lower Left Aft Cabin Door Hinge Half 1. These models’ Illustrated Parts Catalogs may call out Cessna P/N 0711037-2, which has three knuckles and nine rivet holes. 2. For these models, use McFarlane PMA P/N MC0711037-3 if: a. the existing half is about 4-3/4” wide, b. has seven rivet holes, and c. is thicker on its lower edge and thinner on its upper edge. See Figure 3 for an illustration of P/N MC0711037-3. P/N MC0711037-2 is a mirror image of P/N MC0711037-1, which is shown in Figure 2. Figure 3: McFarlane PMA P/N MC0711037-3 ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- Instructions for Continued Airworthiness McFarlane Aviation, LLC. PMA Door Hinges, Cessna 100 and 200 Series FAA PMA Number: PQ3732CE Notice: Verify that this document is the latest approved revision before use! Current version can be found at: www.McFarlaneAviation.com/ICA Page 6 of 7 McFarlane Drawing: 1170 Rev A SECTION 2: HINGE PINS Current part eligibility information can be found at: http://www.mcfarlaneaviation.com/reference/documents/Eligibility Charts McFarlane P/N Installation Location Replaces Cessna P/N MC0711038-1 Hinge Pin 0711038-1 HINGE PINS – SPECIAL OPERATING INFORMATION The control and operation of the cabin door hinge does not change with the installation of the reusable cabin door hinge pin; see applicable Cessna model 150 Series, 180 Series or 200 Series Service Manual for the operational control of this system. HINGE PINS – PART REMOVAL, REPLACEMENT, AND SERVICE INFORMATION Remove the old hinge pin per the applicable Cessna Model 150 Series, 180 Series or 200 Series Service Manual. No exceptions to the Cessna instructions, specific to the McFarlane parts, apply. The following instructions, specific to the McFarlane parts, apply: Install the McFarlane reusable hinge pin as follows: 1. Lubricate with a solid film lubricant (as specified for piano-style hinges in Cessna 150 Series, 180 Series and 200 Series Service Manuals) or with a light coating of oil. 2. Insert the pin into the topmost hinge knuckle hole. While maintaining alignment between the forward and aft hinge halves, slide the pin through all hinge knuckle holes until the cotter pin hole is visible underneath the bottom most knuckle and the top of the pin is seated against the top knuckle. 3. Rotate the pin so the cotter pin hole is parallel to the surface of the aircraft and install the cotter pin. Cotter pins must NOT be reused and must be replaced every time they are removed from the hinge pin. Note: McFarlane reusable hinge pins are NOT to be installed on aircraft equipped with an emergency door-release system! ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- SECTION 3: HINGE ASSEMBLIES Current part eligibility information can be found at: http://www.mcfarlaneaviation.com/reference/documents/Eligibility Charts McFarlane P/N (Hinge Assembly) Installation Location Replaces Cessna P/N McFarlane P/N (Undrilled Assembly) MC0413426-17 Cabin Door, Lower Left & Upper Right Hand 0413426-17, 0413426-4 MC0413426-17S MC0413426-18 Cabin Door, Upper Left & Lower Right Hand 0413426-18, 0413426-3 MC0413426-18S MC0413426-23 Cabin Door, Lower Left & Upper Right Hand 0413426-22, 0413426-23 MC0413426-23S MC0413426-24 Cabin Door, Upper Left & Lower Right Hand 0413426-21, 0413426-24 MC0413426-24S HINGE ASSEMBLIES – SPECIAL OPERATING INFORMATION The control and operation of the cabin door does not change with the installation of the McFarlane cabin door hinge assemblies; see applicable Cessna model 150 Series Service Manual for the operational control of this system. Cessna 180 Series and 200 Series hinges do not have assembly part numbers, just part numbers for the individual three pieces. Cessna 150 Series models with an emergency door release system are not eligible for installation of the hinge assemblies, as they come with the MC0711038-1 hinge pin. These ineligible models include but may not be limited to the A150 and A152 Aerobatic models. HINGE ASSEMBLIES – PART REMOVAL, REPLACEMENT, AND SERVICE INFORMATION Note: For best results, McFarlane recommends replacing both the upper and the lower hinge assemblies simultaneously. Hinge assembly removal and replacement follows the same process as the hinge halves in Section 1 of this ICA document. Hinge pin installation follows the process as written in Section 3 of this ICA document. No exceptions to Cessna instructions, specific to the McFarlane hinge halves, apply. The McFarlane hinge assemblies install using the same methods and hardware. Instructions for Continued Airworthiness McFarlane Aviation, LLC. PMA Door Hinges, Cessna 100 and 200 Series FAA PMA Number: PQ3732CE Notice: Verify that this document is the latest approved revision before use! Current version can be found at: www.McFarlaneAviation.com/ICA Page 7 of 7 McFarlane Drawing: 1170 Rev A TROUBLESHOOTING The following troubleshooting instructions, specific to the McFarlane hinges and pins, apply: 1. Door binds during operation. a. Upper and lower hinges are misaligned relative to each other. Upper and lower hinge pins must be on the same hinge line (coaxial). b. One or both hinge halves of a hinge assembly are misaligned. Hinge knuckle pin holes must be on the same hinge line (coaxial). 2. Door sags and doesn’t align. a. Hinge pin is worn and/or undersized. Use a new McFarlane hinge pin or a new Cessna hinge pin. b. Knuckles and/or knuckle pin holes are excessively worn. Replace affected hinge halves. c. Hinge halves are misaligned and/or upper and lower hinges are misaligned. 3. Hinge pin cannot be inserted or inserts with great difficulty. a. Ensure the knuckle holes of adjacent halves are aligned. b. Ensure the knuckle holes are clear, clean and not obstructed with metal burrs, paint, debris, corrosion, pieces of previous pins, etc. c. Lubricate pin and knuckle holes with a solid film lubricant or a light coating of oil. 4. Cotter pin cannot be inserted after hinge pin insertion, regardless of orientation. a. Ensure the hinge pin is inserted from the top. b. Ensure the hinge pin’s head is fully seated on the topmost hinge knuckle. c. Ensure the cross hole in the hinge pin is free of obstructions. PLACARDS None applicable. DATA All information to support the continued airworthiness of these replacement parts is as defined herein and contained in: • Relevant Cessna model 150 Series, 180 Series or 200 Series Service Manuals. • Relevant Cessna model 150 Series, 180 Series or 200 Series Illustrated Parts Catalogs. INSPECTION McFarlane cabin door hinge halves and reusable cabin door hinge pins must be inspected as part of pre-flight checks. Ensure the cotter pins are installed, intact, and are free of damage, corrosion, and breakage. Inspect the hinge half knuckles for cracks and bending. Outside of these checks, McFarlane reusable cabin door hinge pins should be inspected at the same intervals as the original pins and adjacent components of the cabin door and its retention systems, as contained in relevant Cessna model 150 Series, 180 Series or 200 Series Service Manuals. RECOMMENDED OVERHAUL PERIODS No additional overhaul time limitations exist with the use of these parts. AIRWORTHINESS LIMITATIONS The Airworthiness Limitations section is FAA approved and specifies maintenance required under Sec. 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. No additional airworthiness limitations exist. ASSISTANCE & REVISIONS ICA revisions shall be made available on the McFarlane website, www.mcfarlaneaviation.com/ICA. For questions or assistance regarding these Instructions for Continued Airworthiness (ICA), contact McFarlane Aviation, LLC. via email or phone. Email: engineering@mcfarlaneaviation.com Phone: 1-800-544-8594 (within the US) or 1-785-594-2741.