Aero Twin, Inc. Rudder Gust Lock Kit No. AT-RL-1001

ENSURE CONTROL SYSTEM OPERATES NORMALLY WITHOUT BINDING OR TORQUE -2 NUT 65 TO 80 IN/LBS. INTERFERENCE PER APPLICABLE MAINTENANCE MANUAL Figure 1: Elevator Interconnect Hardware Page 5 of 10 Revision I, January 30, 2012 Aero Twin, Inc. 2403 Merrill Field Drive Anchorage, Alaska 99501 Rudder Gust Lock Kit No. AT-RL-1001 Instructions for Continued Airworthiness Doc No. AT-RL-1001-ICA (v): Reinstall the tail stinger/fairing assembly in accordance with the FAA approved Cessna 208 Series Maintenance Manual. Install the rudder lock handle cover plate. Install the control handle on the shaft. 1.5 Detailed Functional Checks and Adjustments: (i): Remove the tail stinger/fairing assembly in accordance with paragraph 1.1 of this document. (ii): Check control linkage travel and ensure it does not rub or bind. Ensure that a minimum 3/16 inch clearance exists between the rudder torque tube and the control linkage throughout the range of motion of the mechanism. (iii): Engage the elevator control lock in the cabin on the control yoke. Engage the rudder lock, using the control handle to raise the pin to the 'locked' position. (iv): Ensure release rod stop is 0.050 to 0.100 inch aft of the rudder lock cam follower (see Figure 2). This clearance determines the elevator angle at which the rudder lock releases. A clearance of 0.050 to 0.080 will cause the rudder lock to release at approximately 1 degree up elevator. Any required adjustment should be made as follows: a) Disconnect the rod end located at the aft end of the connection tube from the lower end of the bell crank by removing the nut and bolt (AN3-7). Loosen the AN315- 3R check nut that secures the rod end and turn the rod end in or out as required to provide proper clearance. At least four threads of the rod end must be engaged in the connection tube. When clearance is set, torque the check nut to 20 to 25 inch pounds, and reconnect the rod end to the bell crank; use a new cotter pin to secure the nut. b) If the available adjustment at the rod end is insufficient, adjustment can be made at the pin eye at the forward end of the release rod. The two nuts which secure the pin eye to the bar can be run up or down the pin eye threads to produce the required clearance at the release rod stop. After adjustment torque the nuts to 10 to 15 inch pounds. Note that adjustments made here can affect the motion of the release rod so as to change the vertical clearance between the release rod stop and the lock body (see next step). (v): Check that there is at least a ¼ inch of clearance between the top of the release rod stop and the bottom of the rudder lock body. If not, carefully bend the release rod (1"x1/8" aluminum bar) as required to provide adequate clearance (vi): Remove the elevator control lock and pull back on the yoke; the rudder lock should release when the elevator is between neutral and 4 degrees up. Make additional adjustments if required. (vii): Reinstall the tail stinger/fairing assembly in accordance with the FAA approved Cessna 208 Series Maintenance Manual. Install the rudder lock handle cover plate. Install the control handle on the shaft. Page 6 of 10 Revision H, June 23, 2011 Aero Twin, Inc. 2403 Merrill Field Drive Anchorage, Alaska 99501 Rudder Gust Lock Kit No. AT-RL-1001 Instructions for Continued Airworthiness Doc No. AT-RL-1001-ICA ° о 0 0.25 MIN 0.05-0.10 FIRST POINT OF ADJUSTMENT SECOND POINT OF ADJUSTMENT- 1.6 Condition Inspection: Figure 2: Measurements and Adjustments (i): Remove the tail stinger/fairing assembly in accordance with paragraph 1.1 of this document. (ii): Closely inspect the entire system for cracks, loose rivets, corrosion, and general condition. a) If any cracks are found the rudder lock system should be removed and returned to Aero Twin, Inc. for repair/replacement. b) Loose rivets can be replaced following standard practices. c) Light surface corrosion can be can be cleaned up and the affected area re-coated. Corroded hardware should be replaced. (iii): Check the release rod stop, P/N AT-RL-1007, for wear. If any part of the stop is worn to 0.030 inch or less thickness (from the original thickness of 0.040), remove the release rod stop and install a new one: a) Positioning the elevator in the full down position moves the release rod fully aft for best access. b) Drill out the two rivets that secure the stop. c) RELEASE ROD STOP d) Install a new rod stop using two MS20470AD4-6 rivets. Perform functional checks in accordance with paragraph 1.5 of this document. RELEASE ROD Figure 3: Release Rod Stop Page 7 of 10 Revision H, June 23, 2011 Aero Twin, Inc. 2403 Merrill Field Drive Anchorage, Alaska 99501 Rudder Gust Lock Kit No. AT-RL-1001 Instructions for Continued Airworthiness Doc No. AT-RL-1001-ICA Note: Wear of the release rod stop indicates that the rudder lock has not been routinely disengaged using the handle - that the pilots have been disengaging the rudder lock using the elevator safety connection. If such is the case, the pilots should review the normal procedures described in the flight manual supplement provided with the kit. (iv): Check the complete release linkage for signs of wear or rubbing. If the linkage exhibits excessive wear or sloppiness, the condition should be rectified by replacement of worn components, or by removing the entire rudder lock assembly and returning it to Aero Twin for service. (v): Check the condition of the rudder strike plate located at the bottom of the rudder. Replace if excessively warn or damaged. Follow standard sheet metal repair practices. P/N AT-RL-1027: Strike Plate Assembly, Standard P/N AT-RL-1030: Strike Plate Assembly, Sea Plane Rudder (vi): Thoroughly Rinse the rudder gust lock assembly and surrounding area with clear water. Apply a non-congealing corrosion block / lubrication product, such as Corrosion-X™ (or equivalent), to the linkage and the entire lock body. (vii): Reinstall the tail stinger/fairing assembly in accordance with the FAA approved Cessna 208 Series Maintenance Manual. Install the rudder lock handle cover plate. Install the control handle on the shaft. (viii): Check that the rudder lock placard on the handle cover plate is legible and secure. Install a new placard if needed: P/N 5100181-20: English Placard, Black Letters / Transparent Field P/N 5100181-21: English Placard, White Letters / Transparent Field P/N AT-RL-SP01: Spanish Placard, Black Letters / Transparent Field P/N AT-RL-SP02: Spanish Placard, White Letters / Transparent Field P/N AT3001-P-BL1: English and Portuguese, Black Letters / Transparent Field P/N AT3001-P-BL2: English and Portuguese, White Letters / Transparent Field 1.7 General Operational Check (i): Check operation by first securing the elevator with the control yoke lock, then engaging the rudder lock. (ii): With the rudder lock engaged, the rudder should only move about ½ inch at its trailing edge. (iii): Remove the elevator control yoke lock and pull back on the yoke. The rudder lock should disengage. (iv): With the lock free, the rudder should move freely with at least 1/8 inch minimum clearance between the top of the rudder lock body and the bottom of the strike plate on the rudder. 1.8 Weight and Balance The weight, arm, and moment of the installed rudder gust lock assembly is as follows: Wt. (lb.) F.S. (in) Mom/1000 Model 208 &208A: Model 208B: 4.0 437.6 1.75 4.0 485.6 1.94 Page 8 of 10 Revision H, June 23, 2011 Aero Twin, Inc. 2403 Merrill Field Drive Anchorage, Alaska 99501 Rudder Gust Lock Kit No. AT-RL-1001 Instructions for Continued Airworthiness Doc No. AT-RL-1001-ICA 2.0 Airworthiness Limitations Aero Twin, Inc. Rudder Gust Lock Kit No. AT-RL-1001 The Airworthiness Limitations section is FAA approved and specifies maintenance required under paragraphs 43.16 and 91.403(c) of the Federal Aviation Regulations unless an alternative program has been FAA approved. This section describes required inspections and maintenance. There are no scheduled replacement items. When repairs are deemed necessary, follow accepted standard practices and/or specific maintenance instructions in Section 1 of this manual. This section constitutes Component Airworthiness Limitations which apply to the rudder gust lock installation only. 2.1 Scheduled Inspections and Maintenance: The rudder gust lock assembly must be inspected every 200 flight hours. When operated in a salt- water environment, the rudder gust lock assembly must be inspected every 100 flight hours or 3 months, which ever occurs first. To inspect the mechanism: 1. Perform a Condition Inspection in accordance with paragraph 1.6 of this document. 2. Perform a General Operational Check in accordance with paragraph 1.7 of this document. FAA Approval: Amal Al --End of Section 2.0 Airworthiness Limitations- Page 9 of 10 Revision H, June 23, 2011 Aero Twin, Inc. 2403 Merrill Field Drive Anchorage, Alaska 99501 3.0 0 -39 1B PL Rudder Gust Lock Kit No. AT-RL-1001 Instructions for Continued Airworthiness Doc No. AT-RL-1001-ICA Illustrated Parts List -16 -15 -11 -20 -3 )OR -4 -6 -1 OR -2 b -3 )OR( -4 -1 OR -2 -8 ELEVATOR PUSH POD ARM RESEMBLY. (CESSNA P/N 2534010-11ALSO CALLED ELEVATOR CONTROL HOR ELEVATOR PUSH ROD (CESSNA P/N 2834002-1) -19 -14 -34 -4 -33 -3 OR -4 -14 -13 -12 -10 -2 -28 8 PL -35 -2 8 PL 8 PL -21 -3 JOR -4 -18 -3 OR -4 -13 -1 OR -2 -3 OR -4 -20 -25 0 -26 -24 2 PL -2 -31 -10 (-2) -17 -36 4 PL ° ° -27 -2 2 PL 2 PL -14 -38 & PL -37 -2 -29 2 PL о -30 ° -4 -32 0 NAS1149F0363P WASHER QUANTITY MAY VARY. -20 2 -2 -3 NAS1149F0332P WASHER QUANTITY MAY VARY. -21 1 NAS1149F0463P WASHER QUANTITY MAY VARY. -23 20 AT-RL-1006 AN4-35 MS20470AD4-4 OUTER BUSHING BOLT RIVETS -4 NAS1149F0432P WASHER QUANTITY MAY VARY. -24 2 MS2C470AD4-6 RIVETS -5 1 AN3-7 BOLT -25 1 AN3-34 BOLT -6 1 AN4-10 BOLT -26 1 AN525-10R7 SCREW ALT: ANS25-10R6 -7 1 AN310-3 CASTLE NUT -27 2 MS21045-3 LOCK NUT -8 1 MS24665-132 COTTER PIN -28 10 AN3-5A -9 2 AT-RL-1003 -10 2 MS21042-L3 -11 1 $1105-3 12 1 AT-RL-1009 -13 2 AN310-4 BELL CRANK LOCK NUT TIE ROD END PIN EYE CASTLE NUT -29 2 AN970-3 -30 1 ATI-4111-1 -31 1 AT-RL-1007 -32 1 AN4-14 -33 NAS77-4-006 -14 3 MS24665-134 COTTER PIN -34 1 MS17825-4 -15 1 AN315-3R LOCK NUT -35 8 MS21044N3 BOLT WASHER RUDDER LOCK ASSEMBLY RELEASE ROD STOP BOLT BUSHING, FLANGED CASTLE NUT NUT ALT: NAS1149FD363P ALT: 4111-1 16 1 AT-RL-1020 CONNECTION TUBE ASSEMBLY -36 4 AT-RL-1018 SHIM -17 1 AT-RL-1002 -18 1 AT-RL-1010 RELEASE ROD ASSEMBLY W/ HINGE P/N AT-RL-1005 MOUNTING BRACKET -37 1 AT-RL-1027 RUDDER STRIKE PLATE -1030 FOR FLOATPLANE -38 B CR3243-4-3 -19 1 AT-RL-1008 INNER BUSHING -39 1 ITEM QTY PART NO. DESCRIPTION ITEM QTY AT-RL-1024 PART NO. RIVET DOUBLER DESCRIPTION Page 10 of 10 Revision K, November 11, 2013