Cessna 172 Series 1996 Maintenance Manual Download

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Summary of Contents for 172 Series 1996

Page 1: ...S FOR THIS TEMPORARY REVISION 1 For Paper Publications file this cover sheet behind the publication s title page to identify inclusion of the temporary revision in the manual Insert the new pages inthe publication at the appropriate locations and remove and discard the superseded pages 2 For Aerofiche Publications draw a line with permanent red ink marker through any aerofiche frame page affected ...

Page 2: ...ide supplier on their product In addition to these time limits the components listed herein are also inspected at regular time intervals set forth in Inspection Time Intervals and may require overhaul replacement before their time limit is reached based on service usage and inspection results 2 Cessna Mandated Replacement Time Limits A The following component time limits have been established by T...

Page 3: ...ondition NO Compartment Drain Hoses 71 Engine Flexible Various Note 2 NO Hoses Textron Lycoming Installed 71 Air Filter 172R CA3559 100 hours NO 71 Air Filter 172R and P198281 500 hours NO 172S 71 Mixture and Throttle Refer to Illustrated At engine TBO NO Cables Parts Catalog for specific numbers 71 Starter Engine 31B22207 At engine TBO YES 3 Supplier Established Replacement Time Limits A The foll...

Page 4: ...ttery replacement time limits Note 4 Refer to Airborne Air Fuel Product Reference Memo No 39 or latest revision for replacement time limits Note 5 Refer to Slick Service Bulletin SB2 80C or latest revision for time limits Note 6 Refer to Textron Lycoming Service Instruction S I 1009AJ or latest revisionfor time limits Note 7 Referto Textron Lycoming Service Instructions S I 1492 B S I 1267C and Se...

Page 5: ... 1 For Paper Publications file this cover sheet behind the publication s title page to identify inclusion of the temporary revision inthe manual Insert the new pages inthe publication at the appropriate locations and remove and discard the superseded pages 2 For Aerofiche Publications draw a line with permanent red ink marker through any aerofiche frame page affected by the temporary revision This...

Page 6: ...shaft flange overlap Starter ring gear must be located correctly on crankshaft to assure proper alignment of the timing marks on the ring gear 2 Clean mating surfaces and assemble the spacer propeller and bulkheads to crankshaft Assemble ensuring that the serial number stamped on the side of the spacer lines up with either of the propeller blades NOTE It is not necessary to align the spacer serial...

Page 7: ...E MANUAL B1786 A SPACER DOWEL byN AFT BULKHEAD ASSEMBLY PROPELLER FORWARD BULKHEAD ASSEMBLY DETAIL A 0510T1007 Propeller and Spinner Installation Figure 201 Sheet 1 172RMM06 Temporary Revision Number 61 1 Nov 15 2001 61 10 00 Page 202 Aug 18 2001 ...

Page 8: ...NAL INFORMATION NECESSARY TO MAINTAIN THE AIRPLANE AND INCORPORATES TEMPORARY REVISIONS 172RMM06 TR5 1 AND TR61 1 Member of GAMA FAA APPROVAL HAS BEEN OBTAINED ON TECHNICAL DATA IN THIS PUBLICATION THAT AFFECTS AIRPLANE TYPE DESIGN COPYRIGHT 1996 CESSNA AIRCRAFT CO WICHITA KANSAS 172RMM07 REVISION 7 15 FEBRUARY 2002 ...

Page 9: ...e Pages 1 Feb 15 2002 Record of Revisions Service Bulletin List 1 Feb 15 2002 2 Feb 15 2002 3 Feb 15 2002 4 Feb 15 2002 Introduction 1 Feb 15 2002 2 Feb 15 2002 3 Feb 15 2002 4 Feb 15 2002 5 Feb 15 2002 6 Feb 15 2002 List of Revisions Added 1 Feb 15 2002 List of Chapters 1 Feb 15 2002 INTRODUCTION LIST OF EFFECTIVE PAGES Page 1 Feb 15 2002 ...

Page 10: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF REVISIONS REVISION DATE DATE PAGE REVISION DATE DATE PAGE NUMBER INSERTED REMOVED NUMBER NUMBER INSERTED REMOVED NUMBER ...

Page 11: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF REVISIONS REVISION DATE DATE PAGE REVISION DATE DATE PAGE NUMBER INSERTED REMOVED NUMBER NUMBER INSERTED REMOVED NUMBER ...

Page 12: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF REVISIONS REVISION DATE DATE PAGE REVISION DATE DATE PAGE NUMBER INSERTED REMOVED NUMBER NUMBER INSERTED REMOVED NUMBER ...

Page 13: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF REVISIONS REVISION DATE DATE PAGE REVISION DATE DATE PAGE NUMBER INSERTED REMOVED NUMBER NUMBER INSERTED REMOVED NUMBER ...

Page 14: ...01 INSPECTION OF FUEL STRAINER DRAIN AND Jun 6 97 May 3 99 ENGINE MUFFLER TAILPIPE SB97 33 01 LIGHT DIMMING MODULE RESISTOR Dec 14 98 May 3 99 R1 INSTALLATION INSPECTION SB97 34 01 KLN 89B GPS NAVIGATION SYSTEM APPROACH Jul 2 97 May 3 99 RESTRICTIONS SB97 34 02 ALTERNATE STATIC SOURCE VALVE INSPECTION Dec 6 97 May 3 99 R1 SB97 53 01 INSPECTION OF FUSELAGE STATION 205 812 Jul 1 97 May 3 99 TAILCONE...

Page 15: ...ECTION SB98 27 07 CONTROL YOKE ATTACH BUSHING INSTALLATION Sep 21 98 May 3 99 SB98 28 01 ENGINE FUEL PRESSURE TRANSDUCER Mar 2 98 May 3 99 INSPECTION AND REPLACEMENT SB98 28 02 WING TO FUSELAGE FUEL HOSE CLAMP Feb 1 99 Aug 1 00 R1 INSPECTION SB98 28 03 FUEL SHUTOFF VALVE CABLE CLAMP May 4 98 May 3 99 INSPECTION SB98 34 01 KLN 89B GPS NAVIGATION SYSTEM IFR Aug 3 98 May 3 99 R1 NON PRECISION APPROAC...

Page 16: ...IGATION SYSTEM Apr 24 00 Jan 15 01 R1 MODIFICATION SB99 37 01 VACUUM HOSE MODIFICATION Dec 27 99 Aug 1 00 SB99 53 03 ELEVATOR CONTROL YOKE ROLLER Dec 6 99 Aug 1 00 ENGAGEMENT INSPECTION MODIFICATION SB99 55 01 VERTICAL FIN AFT SPAR INSPECTION Mar 29 99 May 3 99 SB99 71 01 ENGINE PISTON PIN PLUG WEAR INSPECTION Jul 12 99 Aug 1 00 R2 SB99 71 02 ENGINE OIL FILLER TUBE TO ENGINE MOUNT Aug 12 99 Aug 1 ...

Page 17: ...INSPECTION Apr 10 00 Jan 15 01 SB00 57 01 FLAP TRACK AND WING INBOARD TRAILING Jul 31 00 Jan 15 01 EDGE INSPECTION SB00 61 02 PROPELLER HUB INSPECTION Aug 14 00 Jan 15 01 SB00 73 01 ENGINE FUEL INJECTION LINES AND SUPPORT Jul 17 00 Jan 15 01 R1 CLAMPS INSPECTION SB00 79 01 ENGINE LOW OIL PRESSURE SWITCH Feb 21 00 Jan 15 01 R1 REPLACEMENT SB00 34 01 PITOT TUBE HEATER INSULATION INSTALLATION Apr 10 ...

Page 18: ...lication and are communicated to the field through Cessna s Authorized Service Stations and or through Cessna s subscription services B Inspection maintenance and parts requirements for STC installations are not included inthis manual When an STC installation isincorporated on the airplane those portions of the airplane affected by the installation must be inspected inaccordance with the inspectio...

Page 19: ...vide without delay new information which will assist in maintaining safe flight ground operations Temporary revisions are numbered consecutively within the ATA chapter assignment Page numbering utilizes the three element number which matches the maintenance manual Temporary revisions are normally incorporated into the maintenance manual at the next regularly scheduled revision 5 Serialization A Al...

Page 20: ...sections The major sections are in turn separated into chapters with each chapter having its own effectivity page and table of contents The manual divisions are as follows a Major Section 1 Airplane General Chapter Title 5 Time Limits Maintenance Checks 6 Dimensions and Areas 7 Lifting and Shoring 8 Leveling and Weighing 9 Towing and Taxiing 10 Parking Mooring Storage and Return to Service 11 Plac...

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Page 22: ...a 200 series document Maintenance Practices When specific topics require lengthy explanation they will utilize the page blocks mentioned above 6 A typical page number 22 10 00 Page 202 Second Page of Nov 3 97 Auto Pilot Auto Flight Auto Pilot Date of Page Issue Auto Pilot 7 Illustrations are also tied into the page block numbering system For example all illustrations within a Maintenance Practices...

Page 23: ... the full length of text E Revised and new illustrations will be indicated by either a revision bar along the side of the page or a hand indicator directing attention to the area 12 Warnings Cautions and Notes A Throughout the text in this manual warnings cautions and notes pertaining to the procedures being accomplished are utilized These adjuncts to the text are used to highlight or emphasize im...

Page 24: ...his manual is current and the latest maintenance and inspections procedures are available the revisions must be incorporated in the manual as they are issued Table 1 Basic Manual Original Issue 2 December 1996 Revision Date Revision Date Number Number 1 16 May 1997 5 15 January 2001 2 6 April 1998 6 18 August 2001 3 3 May 1999 7 15 February 2002 4 1 August 2000 LIST OF REVISIONS Page 1 Feb 15 2002...

Page 25: ... 2 G4 26 Fire Protection Aug 18 2001 2 H12 27 Flight Controls Aug 18 2001 2 11 28 Fuel Feb 15 2002 2 K5 31 Indicating Recording Systems Aug 18 2001 3 A1 32 Landing Gear Feb 15 2002 3 A14 33 Lights Aug 18 2001 3 C5 34 Navigation Feb 15 2002 3 D8 37 Vacuum Aug 18 2001 3 E12 51 Standard Practices Structures Aug 18 2001 3 F1 52 Doors Aug 18 2001 3 F11 55 Stabilizers Aug 18 2001 3 G1 56 Windows Aug 18 ...

Page 26: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER TIME LIMITS MAINTENANCE CHECKS ...

Page 27: ...Feb 15 2002 8 Feb 15 2002 9 Feb 15 2002 10 Feb 15 2002 11 Feb 15 2002 12 Feb 15 2002 13 Feb 15 2002 5 11 00 1 Feb 15 2002 2 Feb 15 2002 3 Feb 15 2002 5 12 00 1 Feb 15 2002 2 Feb 15 2002 5 12 01 1 Feb 15 2002 2 Feb 15 2002 3 Feb 15 2002 4 Feb 15 2002 5 Feb 15 2002 6 Feb 15 2002 7 Feb 15 2002 5 12 02 1 Feb 15 2002 2 Feb 15 2002 3 Feb 15 2002 4 Feb 15 2002 5 Feb 15 2002 Added 6 Feb 15 2002 5 12 03 1 ...

Page 28: ...03 O 9 6 ZL S 8 L 3L S L1 31 9 9L ZL 9 Zo00o3 q Z300Z L q 60 3Z 9 80 Z1 9 LO 3 S 90 3Z Vl ANVdVI ...

Page 29: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 30: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 31: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 32: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 33: ... 5 11 00 Page 2 PROGRESSIVE CARE PROGRAM 5 12 00 Page 1 General 5 12 00 Page 1 Procedure 5 12 00 Page 2 Inspection Terms and Guidelines 5 12 00 Page 2 PROGRESSIVE CARE 5 12 01 Page 1 Operation 1 5 12 01 Page 1 PROGRESSIVE CARE 5 12 02 Page 1 Operation 2 5 12 02 Page 1 PROGRESSIVE CARE 5 12 03 Page 1 Operation 3 5 12 03 Page 1 PROGRESSIVE CARE 5 12 04 Page 1 Operation 4 5 12 04 Page 1 PROGRESSIVE C...

Page 34: ...SIVE CARE 5 12 15 Page 1 Operation 15 5 12 15 Page 1 PROGRESSIVE CARE 5 12 16 Page 1 Operation 16 5 12 16 Page 1 PROGRESSIVE CARE 5 12 17 Page 1 Operation 17 5 12 17 Page 1 PROGRESSIVE CARE 5 12 18 Page 1 Operation 18 5 12 18 Page 1 PROGRESSIVE CARE 5 12 19 Page 1 Operation 19 5 12 19 Page 1 PROGRESSIVE CARE 5 12 20 Page 1 Operation 20 5 12 20 Page 1 5 CONTENTS Page 2 Feb 15 2002 ...

Page 35: ...high usage systems and components At 12 months or 600 flight hours whichever occurs first the airplane undergoes a complete Phase 3 inspection 3 Inspection Program Selection A The selection of an inspection program Annual Progressive Care or Phasecard is primarily based on owner operator preferences whether an airplane is flown for hire and numbers of hours flown during the year 4 Description List...

Page 36: ... insulation loose or broken terminals heat deterioration and corroded terminals 5 STRUCTURAL FASTENERS Inspect for correct torque in accordance with applicable torque values Refer to Chapter 20 Torque Data Maintenance Practices during installation or when visual inspection indicates the need for a torque check CAUTION TORQUE VALUES LISTED IN THIS MANUAL ARE NOT TO BE USED FOR CHECKING TIGHTNESS OF...

Page 37: ...tor s inspection intervals shall not deviate from the inspection time limits shown in this manual except as provided below Refer to FAR 91 409 a The aircraft can only exceed its inspection point up to ten hours ifthe aircraft is enroute to a facility to have the inspection completed b Inthe event of late compliance of any operation scheduled the next operation insequence retains a due point from t...

Page 38: ...hours or 1 year whichever occurs first E Not used NOTE First 100 hours and each 500 hours thereafter F Every 600 hours or 1 year whichever occurs first G Not used NOTE Every 1000 hours or 3 years whichever occurs first H Every 500 hours I Every 1000 hours J Every 2 years K Five years from the date of manufacturer and every twelve months thereafter L Not used NOTE Every 50 hours or four months whic...

Page 39: ...nlets and B 1 3 211 May 16 97 Outlets Inspect all lines ducts clamps seals and gaskets for condition restriction and security 214003 Cabin Heat and Ventilation Controls C 1 211 Check freedom of movement through full travel Check friction locks for proper operation 221001 Autopilot Rigging Refer to Autopilot F 7 610 Maintenance Practices Added 221002 Autopilot Servo Capstan Assemblies O 16 610 May ...

Page 40: ...ower C 2 120 Cables Inspect for condition and security 246001 Switch and Circuit Breaker Panel C 1 222 Terminal Blocks and Junction Boxes Inspect wiring and terminals for condition and security Revised 246002 Power Junction Box Check operation B 1 3 222 Aug 1 00 and condition Check availability and condition of spare fuse if applicable Revised 246101 Essential Bus Diodes Check for S 20 224 Feb 15 ...

Page 41: ...rform hydrostatic test The hydrostatic test shall be at twelve year intervals based on initial servicing or date of last hydrostatic test Added 262004 Cockpit Mounted Halon Type Fire Q 18 211 May 3 99 Extinguishers Empty inspect for damage and recharge Revised 271001 Aileron Controls Check freedom B 1 3 120 520 May 3 99 of movement and proper operation 620 through full travel 271002 Ailerons and C...

Page 42: ...k condition security and operation 272004 Rudder Pedals and Linkage Check C 1 230 for general condition proper rigging and operation Check for security of attachment Added 272005 Rudder Control Check freedom B 1 3 340 Aug 1 00 of movement and proper operation through full travel Check rudder stops for damage and security Revised 273001 Elevator Control Check freedom B 1 3 222 223 Aug 1 00 of movem...

Page 43: ...pect C 1 240 for damage and security Revised 275001 Flaps Check tracks rollers and B 1 3 510 610 Aug 1 00 control rods for security of attachment Check rod end bearings for corrosion Check operation 275002 Wing Flap Control Check operation C 1 221 through full travel and observe Flap Position indicator for proper indication 275003 Flap Structure Linkage Bellcranks C 3 510 610 Pulleys and Pulley Br...

Page 44: ... 1 3 510 610 Check freedom of movement security and proper operation Disassemble flush and clean screen and bowl 282008 Fuel Quantity Indicators Check for F 7 220 damage security of installation and perform accuracy test Revised 282009 Integral Fuel Bays Drain fuel Refer I 10 510 610 Feb 15 02 to Chapter 12 Fuel Servicing and purge tanks Refer to the Single Engine Structural Repair Manual 1996 and...

Page 45: ...heck strut barrel for corrosion pitting and cleanliness Check shimmy damper and or bungees for operation leakage and attach points for wear and security 322002 Nose Landing Gear Wheel Fairings B 2 4 720 Check for cracks dents and condition of paint 322003 Nose Gear Fork Inspect for cracks C 4 720 general condition and security of attachment 322004 Nose Gear Attachment Structure B 2 4 720 Inspect f...

Page 46: ...1101 Static System Inspect for security of C 3 210 installation cleanliness and evidence of damage 341102 Pitot and Static System Inspect in J 11 220 accordance with FAR Part 91 411 341103 Pitot Tube and Stall Warning Vane A 1 2 3 4 510 Check for condition and obstructions and verify operation of anti ice heat 342101 Magnetic Compass Inspect for C 1 225 security of installation cleanliness and evi...

Page 47: ...Regulator Valve and Filter Inspect B 2 4 120 May 16 97 valve assembly for security of installation Visually inspect filter for damage deterioration and contamination Clean or replace if required 371006 Vacuum Manifold Check Valve Check K 12 120 for proper operation Refer to Chapter 37 Vacuum System Maintenance Practices 521001 Doors Inspect general condition B 1 3 210 Check latches hinges and seal...

Page 48: ...ilcone B 1 3 340 Aug 1 00 Inspect externally for skin damage and condition of paint 561001 Windows and Windshield Inspect B 1 3 210 general condition Check latches hinges and seals for condition operation and security of attachment 571001 Wing Surfaces and Tips Inspect B 1 3 510 520 for skin damage loose rivets and 610 620 condition of paint 571002 Wing Struts and Strut Fairings Check B 1 3 510 61...

Page 49: ...e Mount C 2 120 Structure and Ground Straps Check condition security and alignment 716001 Alternate Induction Air System A 1 2 3 4 120 Check for obstructions operation and security 716002 Induction System Check security of A 1 2 3 4 120 clamps tubes and ducting Inspect for evidence of leakage Revised 716003 Induction Airbox Valves Doors and A 1 2 3 4 120 Aug 1 00 Controls Remove air filter and ins...

Page 50: ...A Troubleshooting for further procedures 730001 Engine Driven Fuel Pump Check B 2 4 120 for evidence of leakage security of attachment and general condition 730002 Fuel Injection System Check system B 2 4 120 for security and condition Clean fuel inlet screen check and clean injection nozzles and screens if evidence of contamination is found and lubricate air throttle shaft Added 730003 Idle and M...

Page 51: ...t for proper operation Check that throttle and fuel mixture arms operate through their full arc of travel Revised 781001 Exhaust System Inspect for cracks A 1 2 3 4 120 Aug 1 00 and security Special check in area of heat exchanger Refer to Chapter 78 Exhaust system Maintenance Practices Revised 791001 Engine Oil Drain oil sump and oil A 1 2 3 4 120 Aug 1 00 cooler Check for metal particles or fore...

Page 52: ...ir product In addition to these time limits the components listed herein are also inspected at regular time intervals set forth inInspection Time Intervals and may require overhaul replacement before their time limit is reached based on service usage and inspection results 2 Cessna Mandated Replacement Time Limits A The following component time limits have been established by The Cessna Aircraft C...

Page 53: ...Lycoming Installed 71 Air Filter 172R CA3559 100 hours No 71 Air Filter 172R and P198281 500 hours No 172S 71 Mixture and Throttle Refer to Illustrated At engine TBO No Cables Parts Catalog for specific numbers 71 Starter Engine 31B22207 At engine TBO Yes 3 Supplier Established Replacement Time Limits A The following component time limits have been established by specific suppliers and are reprodu...

Page 54: ...uel Product Reference Memo No 39 or latest revision for replacement time limits Note 5 Refer to Slick Service Bulletin SB2 80C or latest revision for time limits Note 6 Refer to Textron Lycoming Service Instruction S I 1009AJ or latest revision for time limits Note 7 RefertoTextron Lycoming Service Instructions S I 1492 B S I 1267C and Service Bulletin SB 480C Note 8 Replace the engine driven dry ...

Page 55: ...0 hour interval inspections items contained inthe engine compartment area Operation 3 Consists of all 50 hour interval inspections items and those 100 or 200 hour interval inspections items contained inthe wing Operation 4 Consists of all 50 hour interval inspections items and those 100 or 200 hour interval inspections items contained in the landing gear Operation 5 Every 400 hours or 1year whiche...

Page 56: ...s chart at more frequent intervals until the operator can set his own inspection periods based on field experience The operator s inspection intervals shall not deviate from the inspection time limits shown in this manual except as provided below 1 Each inspection interval can be exceeded by 10 hours if time controlled or by 30 days if date controlled or can be performed early at any time prior to...

Page 57: ...ion of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a checklist inperforming this inspection operation B General Inspection Criteria 1 During accomplishment of each of the specific inspections within this operation additional general inspections of the surrounding areas should be performed while access is available These general i...

Page 58: ...01 Alternate Induction Air System Check for 120 obstructions operation and security 716002 Induction System Check security of clamps tubes 120 and ducting Inspect for evidence of leakage 716003 Induction Airbox Valves Doors and Controls 120 Remove air filter and inspect hinges doors seals and attaching parts for wear and security Check operation 716004 Induction Air Filter Remove and clean Inspect...

Page 59: ...s general condition broken or inadequate clamps and sharp bends in wiring 521001 Doors Inspect general condition Check latches 210 hinges and seals for condition operation and security of attachment 531001 Fuselage Surface Inspect for skin damage loose 210 rivets condition of paint and check pitot static ports and drain holes for obstruction Inspect covers and fairings for security 561001 Windows ...

Page 60: ... Panel Ground Straps Inspect for 220 221 deterioration cracks and security of attachment 345003 Navigation Indicators Controls and Components 220 225 Inspect for condition and security 275002 Wing Flap Control Check operation through full 221 travel and observe Flap Position indicator for proper indication 246001 Switch and Circuit Breaker Panel Terminal Blocks 222 and Junction Boxes Inspect wirin...

Page 61: ...F GPS Transponder and Compass System Inspect for deterioration cracks and security of instrument panel mounts Inspect for security of electrical connections condition and security of wire routing 345002 Avionics Operating Controls Inspect for security 225 and proper operation of controls and switches and ensure that all digital segments will illuminate properly 262001 Portable Hand Fire Extinguish...

Page 62: ...0 proper operation through full travel Check rudder stops for damage and security 553001 Vertical Stabilizer Fin Inspect bulkheads spars 340 ribs and skins for cracks wrinkles loose rivets corrosion or other damage Inspect vertical stabilizer attach bolts for looseness Retorque as necessary Check security of inspection covers fairings and tip 553002 Vertical Stabilizer Fin and Tailcone Inspect 340...

Page 63: ...k 510 610 freedom of movement security and proper operation Disassemble flush and clean screen and bowl 571002 Wing Struts and Strut Fairings Check for dents 510 610 cracks loose screws and rivets and condition of paint 271003 Aileron Structure Control Rods Hinges Balance 520 620 Weights Bellcranks Linkage Bolts Pulleys and Pulley Brackets Check condition operation and security of attachment 27100...

Page 64: ...ortion of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a checklist inperforming this inspection operation B General Inspection Criteria 1 During accomplishment of each of the specific inspections within this operation additional general inspections of the surrounding areas should be performed while access is available These genera...

Page 65: ...al 120 Connections Check condition and security Check alternator belts for condition and proper adjustment Check belt tension 243001 Battery Check general condition and security 120 Check level of electrolyte Refer to Chapter 12 Battery Servicing 243002 Battery Box and Cables Clean and remove any 120 corrosion Check cables for routing support and security of connections 243004 External Power Recep...

Page 66: ... Induction Airbox Valves Doors and Controls 120 Remove air filter and inspect hinges doors seals and attaching parts for wear and security Check operation 716004 Induction Air Filter Remove and clean Inspect for 120 damage and service 722001 Engine Inspect for evidence of oil and fuel leaks 120 Wash engine and check for security of accessories 722002 Crankcase Oil Sump and Accessory Section 120 In...

Page 67: ...for condition Check timing to engine and internal timing if engine timing requires adjustment 742001 Ignition Harness and Insulators Check for proper 120 routing deterioration and condition of terminals 742002 Spark Plugs Remove clean analyze test gap 120 and rotate top plugs to bottom and bottom plugs to top 743001 Ignition Switch and Electrical Harness Inspect for 120 damage condition and securi...

Page 68: ...ng Vane Check for 510 condition and obstructions and verify operation of anti ice heat 322001 Nose Gear Inspect torque links steering rods 720 and boots for condition and security of attachment Check strut for evidence of leakage and proper extension Check strut barrel for corrosion pitting and cleanliness Check shimmy damper and or bungees for operation leakage and attach points for wear and secu...

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Page 70: ...f each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a checklist in performing this inspection operation B General Inspection Criteria 1 During accomplishment of each of the specific inspections within this operation additional general inspections of the surrounding areas should be performed while access is available These general inspe...

Page 71: ...01 Alternate Induction Air System Check for 120 obstructions operation and security 716002 Induction System Check security of clamps tubes 120 and ducting Inspect for evidence of leakage 716003 Induction Airbox Valves Doors and Controls 120 Remove air filter and inspect hinges doors seals and attaching parts for wear and security Check operation 716004 Induction Air Filter Remove and clean Inspect...

Page 72: ...nd security 120 520 of stops Check cables for tension routing fraying 620 corrosion and turnbuckle safety Check travel if cable tension requires adjustment or if stops are damaged Check fairleads and rub strips for condition 231001 Communication Antennas and Cables Inspect for 210 security of attachment connection and condition 341101 Static System Inspect for security of installation 210 cleanlin...

Page 73: ...plicable 273001 Elevator Control Check freedom of movement and 222 223 proper operation through full travel 273002 Elevator Control System Inspect pulleys cables 222 223 sprockets bearings chains and turnbuckles for condition security and operation Check cables for tension routing fraying corrosion and turnbuckle safety 273103 Elevator Trim Tab and Hinges Check condition 224 security and operation...

Page 74: ...ition cracks and security hinge bolts nuts hinge bearings hinge attach fittings and bonding jumper for evidence of damage and wear failed fasteners and security Inspect balance weight for looseness and the supporting structure for damage 272003 Rudder Tips Hinges Stops Clips and Cable 340 Attachment Check condition security and operation 272005 Rudder Control Check freedom of movement and 340 prop...

Page 75: ...ponents for 510 610 mounting and security 282002 Fuel Tank Vent Lines and Vent Valves Check 510 610 vents for obstruction and proper positioning Check valves for operation 282004 Integral Fuel Bays Check for evidence of leakage 510 610 and condition of fuel caps adapters and placards Using quick drains ensure no contamination exists Check quick drains for proper shut off 282005 Fuel Reservoir Usin...

Page 76: ... 172 MAINTENANCE MANUAL ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 275006 Flap Actuator Threads Clean and lubricate Refer 610 to Chapter 12 Flight Controls Servicing End of Operation 3 Inspection Items 5 12 03 Page 7 Feb 15 2002 ...

Page 77: ... of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a checklist in performing this inspection operation B General Inspection Criteria 1 During accomplishment of each of the specific inspections within this operation additional general inspections of the surrounding areas should be performed while access is available These general ins...

Page 78: ... Battery Box and Cables Clean and remove any 120 corrosion Check cables for routing support and security of connections 282010 Auxiliary Electric Fuel Pump Check pump and 120 fittings for condition operation security 371001 Vacuum System Inspect for condition and security 120 371002 Vacuum Pumps Check for condition and 120 security Check vacuum system breather line for obstructions condition and s...

Page 79: ...ttings Inspect for 120 signs of oil and fuel leaks Check for abrasions chafing security proper routing and support and for evidence of deterioration 723001 Engine Cylinders Rocker Box Covers and Pushrod 120 Housings Check for fin damage cracks oil leakage security of attachment and general condition 723003 Engine Baffles and Seals Check condition and 120 security of attachment 723004 Cylinder Comp...

Page 80: ...ation oil 792001 Oil Cooler Check for obstructions leaks and 120 security of attachment 801001 Starter and Electrical Connections Check security 120 and condition of starter electrical connection and cable 801002 Bendix Drive Starter Assembly Clean and lubricate 120 starter drive assembly 761001 Engine Controls and Linkage Check general 120 225 condition freedom of movement through full range Chec...

Page 81: ...tachment Structure Inspect for 720 cracks corrosion or other damage and security of attachment 325001 Nose Gear Steering Mechanism Check for wear 720 security and proper rigging 324004 Tires Check tread wear and general condition 720 721 Check for proper inflation 722 324006 Wheel Bearings Clean inspect and lube 720 721 722 321002 Main Gear Tubular Struts Inspect for cracks 721 722 dents corrosion...

Page 82: ...lation operational test and functional tests of components and or systems For items or components requiring lubrication as applicable refer to Chapter 12 Servicing General and Contents for lubricant lubricating points and method Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s i...

Page 83: ...Inspect clamps hoses and 211 valves for condition and security 252201 Upholstery Headliner Trim and Carpeting Check 211 condition and security 324003 Brake Lines Wheel Cylinders Hoses Clamps 721 722 and Fittings Check for leaks condition and security and hoses for bulges and deterioration Check brake lines and hoses for proper routing and support 5 12 05 Page 2 Aug 18 2001 ...

Page 84: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL PROGRESSIVE CARE 1 Operation 6 THERE ARE CURRENTLY NO PROGRESSIVE CARE OPERATIONS CONTAINED IN THIS SECTION 5 12 06 Page 1 Aug 18 2001 ...

Page 85: ...ation operational test and functional tests of components and or systems For items or components requiring lubrication as applicable refer to Chapter 12 Servicing General and Contents for lubricant lubricating points and method Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s in...

Page 86: ...mber Serial Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 282008 Fuel Quantity Indicators Check for damage 220 security of installation and perform accuracy test 221001 Autopilot Rigging Refer to Autopilot Maintenance 610 Practices 5 12 07 Page 2 Aug 18 2001 ...

Page 87: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL PROGRESSIVE CARE 1 Operation 8 THERE ARE CURRENTLY NO PROGRESSIVE CARE OPERATIONS CONTAINED INTHIS SECTION 5 12 08 Page 1 Aug 18 2001 ...

Page 88: ...l test and functional tests of components and or systems For items or components requiring lubrication as applicable refer to Chapter 12 Servicing General and Contents for lubricant lubricating points and method Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s initials and remar...

Page 89: ...L Date Registration Number Serial Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 741002 Magnetos Clean inspect and adjust as required 120 Refer to Slick 4300 4600 Series Magneto Maintenance and Overhaul Manual 5 12 09 Page 2 Aug 18 2001 ...

Page 90: ...pter in this Maintenance Manual for removal installation operational test and functional tests of components and or systems For items or components requiring lubrication as applicable refer to Chapter 12 Servicing General and Contents for lubricant lubricating points and method Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page ...

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Page 92: ...al test and functional tests of components and or systems For items or components requiring lubrication as applicable refer to Chapter 12 Servicing General and Contents for lubricant lubricating points and method Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s initials and rema...

Page 93: ...ODEL 172 MAINTENANCE MANUAL Date Registration Number Serial Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 341102 Pitot and Static System Inspect inaccordance with 220 FAR Part 91 411 5 12 11 Page 2 Aug 18 2001 ...

Page 94: ...omponent to service Refer to the appropriate chapter in this Maintenance Manual for removal installation operational test and functional tests of components and or systems Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a ch...

Page 95: ...ANUAL Date Registration Number Serial Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 371006 Vacuum Manifold Check Valve Check for proper 120 operation Refer to Chapter 37 Vacuum System Maintenance Practices 5 12 12 Page 2 Aug 18 2001 ...

Page 96: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL PROGRESSIVE CARE 1 Operation 13 THERE ARE CURRENTLY NO PROGRESSIVE CARE OPERATIONS CONTAINED INTHIS SECTION 5 12 13 Page 1 Aug 18 2001 ...

Page 97: ...ecific test must be reconfirmed after completion of any maintenance prior to returning the system or component to service Refer to the appropriate chapter in this Maintenance Manual for removal installation operational test and functional tests of components and or systems Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provi...

Page 98: ...A AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Date Registration Number Serial Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 342102 Magnetic Compass Calibrate 220 5 12 14 Page 2 Aug 18 2001 ...

Page 99: ... or component to service Refer to the appropriate chapter in this Maintenance Manual for removal installation operational test and functional tests of components and or systems Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as...

Page 100: ... MANUAL Date Registration Number Serial Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 743002 Inspect and lubricate ACS brand ignition switch 224 Refer to Chapter 74 Ignition System Maintenance Practices 5 12 15 Page 2 Aug 18 2001 ...

Page 101: ... Refer to the appropriate chapter in this Maintenance Manual for removal installation operational test and functional tests of components and or systems Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a checklist inperformin...

Page 102: ...221002 Autopilot Servo Capstan Assemblies Check 610 slip clutch torque settings Refer to Autopilot Maintenance Practices 221003 Autopilot Servo Actuators Inspect for evidence of 610 corrosion and or buildup of dirt or other particulate matter which may interfere with servo operation Refer to Autopilot Maintenance Practices 5 12 16 Page 2 Aug 18 2001 ...

Page 103: ...appropriate chapter in this Maintenance Manual for removal installation operational test and functional tests of components and or systems Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a checklist in performing this inspec...

Page 104: ...istration Number Serial Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 262002 Cockpit Mounted Halon Type Fire Extinguisher 211 Weigh bottle Bottle must be reserviced by qualified individual if more than 2 ounces is lost 5 12 17 Page 2 Aug 18 2001 ...

Page 105: ...priate chapter in this Maintenance Manual for removal installation operational test and functional tests of components and or systems Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a checklist in performing this inspection ...

Page 106: ... MAINTENANCE MANUAL Date Registration Number Serial Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 262004 Cockpit Mounted Halon Type Fire Extinguishers 211 Empty inspect for damage and recharge 5 12 18 Page2 Aug 18 2001 ...

Page 107: ...ropriate chapter in this Maintenance Manual for removal installation operational test and functional tests of components and or systems Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page provides room for the mechanic s and inspector s initials and remarks These pages may be reproduced as a checklist inperforming this inspection...

Page 108: ...Number Total Time ITEM CODE TASK ZONE MECH INSP REMARKS NUMBER 262003 Cockpit Mounted Halon Type Fire Extinguishers 211 Perform hydrostatic test The hydrostatic test shall be at twelve year intervals based on initial servicing or date of last hydrostatic test 5 12 19 Page 2 Aug 18 2001 ...

Page 109: ...r in this Maintenance Manual for removal installation operational test and functional tests of components and or systems For items or components requiring lubrication as applicable refer to Chapter 12 Servicing General and Contents for lubricant lubricating points and method Refer to Chapter 6 Airplane Zoning Description and Operation for airplane zone definition The right portion of each page pro...

Page 110: ...swe s sepo sn ZZ8 uo lejedo jad liVnNVV 3ONVN31NIVIJ ...

Page 111: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER DIMENSIONS AND AREAS ...

Page 112: ...nts 1 Aug 18 2001 6 00 00 1 Aug 18 2001 6 10 00 1 Aug 18 2001 2 Aug 18 2001 3 Aug 18 2001 4 Aug 18 2001 6 15 00 1 Aug 18 2001 2 Aug 18 2001 3 Aug 18 2001 6 20 00 1 Aug 18 2001 2 Aug 18 2001 3 Aug 18 2001 4 Aug 18 2001 6 20 02 1 Aug 18 2001 2 Aug 18 2001 3 Aug 18 2001 4 Aug 18 2001 5 Aug 18 2001 6 Aug 18 2001 7 Aug 18 2001 6 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 113: ...EL 172 MAINTENANCE MANUAL CONTENTS ACCESS INSPECTION PLATES DESCRIPTION AND OPERATION 6 20 02 Page 1 General 6 20 02 Page 1 Access Inspection Plate Numbering 6 20 02 Page 1 Description 6 20 02 Page 1 6 CONTENTS Page 1 Aug 18 2001 ...

Page 114: ...und handling the airplane and locating components 2 Definition A Airplane Dimensions and Areas 1 The section on airplane dimensions and areas provides airplane dimensions and identifies areas of the airplane B Airplane Stations 1 The section on stations provides illustrations to identify reference points on the airplane along a three axis division C Airplane Zoning 1 The section on zoning provides...

Page 115: ...Wing Span Overall 36 0 Tail Span 11 4 Landing Gear Track Width 8 4 1 2 FUSELAGE DIMENSIONS Cabin Width Maximum Sidewall to Sidewall 3 3 1 2 Cabin Height Floorboard to Headliner 4 0 MAXIMUM WEIGHT Ramp 172R 2457 Pounds 172S 2558 Pounds And 172R Airplanes Incorporating MK172 72 01 Takeoff 172R 2450 Pounds 172S 2550 Pounds And 172R Airplanes Incorporating MK172 72 01 Landing 172R 2450 Pounds 172S 255...

Page 116: ...LIGNMENT DATA Main Tire Size 172R 6 00 X 6 4 Ply Rating 172S 6 00 X 6 6 Ply Rating And 172R Airplanes Incorporating MK172 72 01 Main Tire Pressure 172R 28 0 PSI 172S 38 0 PSI And 172R Airplanes Incorporating MK172 72 01 Nose Tire Size 172R 172S 5 00 X 5 6 Ply Rating Nose Tire Pressure 172R 34 0 PSI 172S 45 0 PSI And 172R Airplanes Incorporating MK172 72 01 Nose Gear Strut Pressure Strut Extended 4...

Page 117: ...t 17 Degrees 44 Min 1 Degree ELEVATOR Up Travel Relative to Stabilizer 28 Degrees 1or 0 Degree Down Travel Relative to Stabilizer 23 Degrees 1or 0 Degree Elevator Cable Tension 30 Pounds 10 Pounds ELEVATOR TRIM TAB Up Travel 22 Degrees 1or 0 Degree Down Travel 19 Degrees 1or 0 Degree Elevator Trim Cable Tension 20 Pounds 0 or 5 Pounds FLAPS Flap Setting 0 Degree UP 0 Degree 10 Degrees 10 Degrees 0...

Page 118: ... AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B1418 36 0 PROPELLER DIAMETER 172R 75 182S 76 AND 172R AIRPLANES INCORPORATING MK1 72 72 01 27 2 Airplane Dimensions Figure 1 Sheet 1 6 10 00 Page 4 Aug 18 2001 ...

Page 119: ... on or within the airplane Fuselage Stations begin at the firewall FS 0 00 and extend to the tailcone area FS 230 18 Wing Stations begin at the root WS 23 62 and extend to the tip WS 208 00 Both Fuselage Stations and Wing Stations are measured in inches For example FS 185 50 is 185 50 inches aft of the firewall FS 0 00 B For an illustration of Fuselage Stations refer to Figure 1 For an illustratio...

Page 120: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL FS 3 375 FS 65 33 FS 142 00 FS 16 66 FS 108 00 05101008 Fuselage Stations Figure 1 Sheet 1 6 15 00 Page 2 Aug 18 2001 Aug 18 2001 ...

Page 121: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 22 875 WS 208 00 WS 208 00 WS 05223001 Wing Stations Figure 2 Sheet 1 6 15 00 Page 3 Aug 18 2001 ...

Page 122: ...nd digit inthe sequence further divides the zone into submajor zone Zone 510 for inboard portion of the left wing and Zone 520 for outboard portion of the left wing etc The third digit further divides the submajor zones into subdivisions if no subdivision is needed this digit is typically assigned as 0 zero EXAMPLE 310 Major Zone Subdivision Zone Submajor Zone B Major Zones 1 100 Forward side of f...

Page 123: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 110 720 340 110 310 INTERIOR 05103001 120 05103001 05103001 Airplane Zones Figure 1 Sheet 1 6 20 00 Page 2 Aug 18 2001 ...

Page 124: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 224 INSTRUMENT PANEL 121 122 123 124 FIREWALL LOOKING FORWARD 0513C1003 0511T1 002 Airplane Zones Figure 1 Sheet 2 6 20 00 Page 3 Aug 18 2001 ...

Page 125: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INTERIOR FLOOR 05111015 Airplane Zones Figure 1 Sheet 3 6 20 00 Page 4 Aug 18 2001 ...

Page 126: ... of numbers and letters which specify zone exact panel identifier and location within the specific zone 1 The first three numbers of any plate identify the zone inwhich the plate can be found This three number sequence is assigned and designated inAirplane Zoning Description and Operation 2 Primary identifiers follow the three number sequence with the first plate identified as A the second plate i...

Page 127: ...lap and Aileron Cables 610DB Fuel Lines Fuel Transmitter 610NB Aileron Cables 610EB Flap Controls 620AB Auto Pilot Roll Servo 610FB Strut Bolt 620BB Aileron and Trim Cables 610GB Flap Actuator 620CB Aileron Cables 610HB Fuel Lines Fuel Transmitter 620DB Aileron Bellcrank 610JB Wing Access 0510T1011 Access Inspection Plates Figure 1 Sheet 1 6 20 02 Page 2 Aug 18 2001 ...

Page 128: ...Wing Access Courtesey light 510CB Strut Bolt 510KB Wing Access Flap Bellcrank 510DB Fuel Lines Fuel Transmitter 510LB Flap and Aileron Cables 510EB Flap Controls 510MB Flap and Aileron Cables 510FB Strut Bolt 510NB Aileron Cables 510GB Flap Actuator 520AB Aileron and Trim Cables 510HB Fuel Lines Fuel Transmitter 520BB Aileron Cables Aileron Bellcrank 0510T1 011 Access Inspection Plates Figure 1 Sh...

Page 129: ...IDE VIEW 120AT External Power 310AL Elevator and Elevator Trim Pulleys 510AT Fuel Bay 310AR Elevator and Elevator Trim Pulleys 510BT FuelBay 310BR Control Cables 520AT Fuel Bay 610AT Fuel Bay 61OBT Fuel Bay 620AT Fuel Bay Access Inspection Plates Figure 1 Sheet 3 6 20 02 Page 4 Aug 18 2001 ...

Page 130: ...INTENANCE MANUAL 510CT Flap Access 610CT Flap Access 510DT Flap Access 610DT Flap Access 510ET Flap Access 610ET Flap Access 510FT Flap Access 610FT Flap Access 05251002 Access Inspection Plates Figure 1 Sheet 4 6 20 02 Page 5 Aug 18 2001 ...

Page 131: ...ADF 230CT Fuel Pump and Reservoir Antenna 230DT Fuel Lines Wire Bundle 230LT Fuel Lines 230ET Elevator Bellcrank Fuel Lines 230MT Fuel Lines 230FT Fuel Selector Elevator Bellcrank 230NT Fuel Lines 230GT Fuel Line 230PT Wire Bundle Brake Line 230HT Fuel Line 230QT Control Cables 230RT Brake Line Access Inspection Plates Figure 1 Sheet 5 6 20 02 Page 6 Aug 18 2001 ...

Page 132: ...ing Gear Bulkhead 231GT Control Cables 231 BT Control Cables 231 HT Fuselage Access 231CT Main Landing Gear Bulkhead 231JT Control Cables 231DT Control Cables Flap Pulleys 231KT Fuselage Access 231 ET Control Cables Flap Pulleys 231 FT Transponder Antenna 0510T1011A Access Inspection Plates Figure 1 Sheet 6 6 20 02 Page 7 Aug 18 2001 ...

Page 133: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER LIFTING AND SHORING ...

Page 134: ...T OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 7 Title 7 List of Effective Pages 1 Aug 18 2001 7 Contents 1 Aug 18 2001 7 00 00 1 Aug 18 2001 7 10 00 201 Aug 18 2001 202 Aug 18 2001 7 11 00 201 Aug 18 2001 7 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 135: ... and Materials 7 00 00 Page 1 Definition 7 00 00 Page 1 JACKING MAINTENANCE PRACTICES 7 10 00 Page 201 General 7 10 00 Page 201 Tools Equipment and Materials 7 10 00 Page 201 Jacking Procedures 7 10 00 Page 201 EMERGENCY LIFTING HOISTING MAINTENANCE PRACTICES 7 11 00 Page 201 Lifting Procedures 7 11 00 Page 201 7 CONTENTS Page 1 Aug 18 2001 ...

Page 136: ...ompany To extend jack height Extension Universal Tail 2 168 Cessna Aircraft Company To secure tail Stand Padded Block Fabricate locally To provide cushion between wing jack and wing spar 3 Definition A This chapter is divided into sections to aid maintenance personnel inlocating information Consulting the Table of Contents will further assist inlocating a particular subject A brief definition of t...

Page 137: ...o be raised off the ground at all points the following procedure should be used A Raise Airplane Refer to Figure 201 CAUTION WHEN PLACED ON JACKS THE AIRPLANE IS NOSE HEAVY TAIL STANDS MUST WEIGH ENOUGH TO KEEP THE TAIL DOWN UNDER ALL CONDITIONS ADDITIONALLY THE TAIL STAND MUST BE STRONG ENOUGH TO SUPPORT ANY WEIGHT WHICH MIGHT BE TRANSFERRED TO THE TAILCONE AREA DURING MAINTENANCE CREATING A TAIL...

Page 138: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL TAILSTAND JACK 05801001 Airplane Jacking Figure 201 Sheet 1 7 10 00 Page 202 Aug 18 2001 ...

Page 139: ...uitable slings The front sling should be hooked to each upper engine mount and the aft sling should be positioned around the fuselage at the first bulkhead forward of the leading edge of the stabilizer If the optional hoisting rings are used a minimum cable length of 60 inches for each cable is required to prevent bending of the eyebolt type hoisting rings If desired a spreader jig may be fabricat...

Page 140: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER LEVELING AND WEIGHING ...

Page 141: ...NTENANCE MANUAL LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 8 Title 8 List of Effective Pages 1 Aug 18 2001 8 Contents 1 Aug 18 2001 8 00 00 201 Aug 18 2001 8 10 00 202 Aug 18 2001 8 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 142: ...NTENTS LEVELING AND WEIGHING GENERAL 8 00 00 Page 1 Scope 8 00 00 Page 1 Tools Equipment and Material 8 00 00 Page 1 Definition 8 00 00 Page 1 LEVELING MAINTENANCE PRACTICES 8 10 00 Page 201 Leveling Procedure 8 10 00 Page 201 8 CONTENTS Page 1 Aug 18 2001 ...

Page 143: ...e 3 Definition A This chapter isdivided into sections to aid maintenance personnel in locating information Consulting the Table of Contents will further assist inlocating a particular subject A brief definition of the sections incorporated inthis chapter is as follows 1 The section on leveling provides maintenance practices and instructions for longitudinal and lateral leveling of the airplane Thi...

Page 144: ...ES Leveling Procedure A Corresponding points on both upper door sills may be used to level the airplane laterally The reference points for longitudinal leveling the airplane are the two screws located on the left side of the tailcone Refer to Figure 201 8 10 00 Page 201 Aug 18 2001 ...

Page 145: ...OTE CORRESPONDING POINTS ON BOTH UPPER DOOR SILLS MAY BE USED TO LEVEL THE AIRPLANE LATERALLY REFERENCE POINTS FOR LONGITUDINAL LEVELING OF AIRPLANES ARE TWO SCREWS ON LEFT SIDE OF TAILCONE AT WATERLINE ZERO 05103001 Airplane Leveling Figure 201 Sheet 1 8 10 00 Page 202 Aug 18 2001 ...

Page 146: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER TOWING AND TAXIING ...

Page 147: ...E MANUAL LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 9 Title 9 List of Effective Pages 1 Aug 18 2001 9 Contents 1 Aug 18 2001 9 00 00 1 Aug 18 2001 9 10 00 201 Aug 18 2001 202 Aug 18 2001 9 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 148: ...MODEL 172 MAINTENANCE MANUAL CONTENTS TOWING AND TAXING GENERAL 9 00 00 Page 1 Scope 9 00 00 Page 1 Definition 9 00 00 Page 1 TOWING MAINTENANCE PRACTICES 9 10 00 Page 201 General 9 10 00 Page 201 9 CONTENTS Page 1 Aug 18 2001 ...

Page 149: ...es towing procedures for movement of the airplane on the ground For taxiing procedures refer to the applicable Pilots s Operating Handbook and FAA Approved Airplane Flight Manual 2 Definition A The section on towing describes towing procedures and cautions applicable to the Model 172 9 00 00 Page 1 Aug 18 2001 ...

Page 150: ...ALWAYS APPLY PRESSURE AT A BULKHEAD TO AVOID DAMAGING THE SKIN A Towing 1 Moving the airplane by hand isaccomplished by using the wing struts and landing gear struts as push points A tow bar attached to the nose gear should be used for steering and maneuvering the airplane on the ground When no tow bar is available press down on the tailcone at a bulkhead to raise the nose wheel off the ground Wit...

Page 151: ...ESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL WASHER RH SIDEWALL PANEL AFT BAGGAGE SPACER STRAP HOLDER TOW BAR ASSEMBLY DETAIL A Tow Bar Installation Figure 201 Sheet 1 9 10 00 Page 202 Aug 18 2001 ...

Page 152: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER PARKING MOORING STORAGE AND RETURN TO SERVICE ...

Page 153: ...R SECTION SUBJECT PAGE DATE 10 Title 10 List of Effective Pages 1 Aug 18 2001 10 Contents 1 Aug 18 2001 10 00 00 1 Aug 18 2001 10 10 00 201 Aug 18 2001 10 11 00 1 Aug 18 2001 2 Aug 18 2001 10 20 00 201 Aug 18 2001 10 30 00 201 Aug 18 2001 10 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 154: ... 10 10 00 Page 201 Parking Instructions 10 10 00 Page 201 STORAGE DESCRIPTION AND OPERATION 10 11 00 Page 1 Flyable Storage 10 11 00 Page 1 Temporary Storage 10 11 00 Page 1 Inspection During Storage 10 11 00 Page 2 MOORING MAINTENANCE PRACTICES 10 20 00 Page 201 Mooring 10 20 00 Page 201 RETURN TO SERVICE MAINTENANCE PRACTICES 10 30 00 Page 201 Flyable Storage Return to Service 10 30 00 Page 201 ...

Page 155: ...To static ground airplane Cable Rope 0 375 Available Commercially To tie down wing and tail inch diameter minimum or equivalent 3 Definition A This chapter is divided into sections to aid maintenance personnel inlocating information Consulting the Table of Contents will further assist inlocating a particular subject A brief definition of the sections incorporated in this chapter is as follows 1 Th...

Page 156: ...A Hard Surface and Sod CAUTION ANY TIME THE AIRPLANE IS LOADED HEAVILY THE FOOTPRINT PRESSURE PRESSURE OF THE AIRPLANE WHEELS UPON THE CONTACT SURFACE OF THE PARKING AREA OR RUNWAY WILL BE EXTREMELY HIGH AND SURFACES SUCH AS HOT ASPHALT OR DAMP SOD MAY NOT ADEQUATELY SUPPORT THE WEIGHT OF THE AIRPLANE PRECAUTIONS SHOULD BE TAKEN TO AVOID AIRPLANE PARKING OR MOVEMENT ON SUCH SURFACES 1 Position air...

Page 157: ... BE USED IN CASE OF ACCIDENTAL DISCONNECTION OF ONE GROUND WIRE ENSURE THAT FUELING NOZZLE IS GROUNDED TO THE AIRPLANE NOTE Tie down rings should be used as grounding points for all grounding wires during refueling procedures 2 Clean and wax airplane thoroughly 3 Clean any oil or grease from tires and coat tires with a tire preservative Cover tires to protect against grease and oil 4 Either block ...

Page 158: ...n at least once a month and remove dust collection as frequently as possible Clean and wax airplane as required 2 Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month NOTE Do not move crankshaft when inspecting interior of cylinder for corrosion 3 If at the end of the 90 day period the airplane is to be continued in nonoperational storage re...

Page 159: ... anchors 3 Secure rope no chains or cables to forward mooring ring and secure opposite end to ground anchor 4 Secure the middle of a rope to the tail tie down ring Pull each end of rope away at a 45 degree angle and secure to ground anchors at each side of tail 5 Secure control lock on pilot control column Ifcontrol lock is not available tie pilot control wheel back with front seat belt 6 These ai...

Page 160: ...e following procedures to return the airplane to service 1 Remove airplane from blocks and check tires for proper inflation Check for proper nose gear strut inflation 2 Check battery and install 3 Check that oil sump has proper grade and quantity of engine oil 4 Service induction air filter and remove warning placard from propeller 5 Remove materials used to cover openings 6 Remove spark plugs fro...

Page 161: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER PLACARDS AND MARKINGS ...

Page 162: ...203 Aug 18 2001 11 21 20 1 Aug 18 2001 11 21 24 1 Aug 18 2001 11 23 10 1 Aug 18 2001 11 25 10 1 Aug 18 2001 11 26 10 1 Aug 18 2001 11 27 20 1 Aug 18 2001 11 32 11 1 Aug 18 2001 11 32 12 1 Aug 18 2001 11 32 13 1 Aug 18 2001 11 32 14 1 Aug 18 2001 11 32 15 1 Aug 18 2001 11 32 20 1 Aug 18 2001 11 32 21 1 Aug 18 2001 11 32 22 1 Aug 18 2001 11 32 23 1 Aug 18 2001 11 32 24 1 Aug 18 2001 11 32 25 1 Aug 1...

Page 163: ...00 00 Page 1 Deciphering Page Number System for Internal External Placards 11 00 00 Page 1 INTERIOR EXTERIOR PAINT DESCRIPTION AND OPERATION 11 00 01 Page 1 General 11 00 01 Page 1 Tools and Equipment 11 00 01 Page 1 EXTERIOR GRAPHICS MAINTENANCE PRACTICES 11 20 00 Page 201 General 11 20 00 Page 201 Tools and Equipment 11 20 00 Page 201 Graphics Removal Installation 11 20 00 Page 201 Care and Clea...

Page 164: ...ter does not provide a complete illustration of all placards and marking used throughout the airplane 5 Placards and Markings as Silkscreens A Some of the placards and markings used on the airplane are actually silkscreens which have been printed on a component or panel These placards or markings may not be available without purchasing the component or panel on which itwas printed 1 If a placard o...

Page 165: ...ll Primer Sealer 483 928 Pratt Lambert Applied to airplane 16116 E 13th St before topcoat Wichita KS 67230 Hardener 120 828 Pratt Lambert Used with primer sealer Topcoat 830 Series High Solids Pratt Lambert Used as topcoat overall Acry Glo Color Code color WP 150 Matterhorn White Hardener 830 081 Pratt Lambert Used as a catalyst for Acry Glo Accelerator 830 H18 Pratt Lambert Shorten cure time of A...

Page 166: ...uncture air bubbles Artist s Paint None Commercially Available To apply primer to Brush airplane Squeegee None Commercially Available To aid in adhering graphics to flat surfaces 3 Graphics Removal Installation A Remove Graphics Refer to Figure 201 NOTE If a new graphic is being installed reference marks should be made on the airplane before removing old graphic These marks will aid inpositioning ...

Page 167: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL DECAL 051OC1009 Decal Application Figure 201 Sheet 1 11 20 00 Page 202 Aug 18 2001 ...

Page 168: ...et using a small diameter needle The air bubble should be perforated at 8 to 12 places around the rivet head b Warm the graphic and structure around each rivet to approximately 125 F using a heat gun When the graphic and metal have heated up work out all bubbles from around the rivet head using a dense closed cell foam block Temperfoam or equivalent 7 Remove entrapped air bubbles from flat areas o...

Page 169: ...EICHE SICH USE THE LIGHTER GRADE OIL USE ONLY UBERSCHNEIDEN DIE OLSORTE FUR DEN OIL THAT COMPLIES WITH APPLICABLE NIEDRIGEREN TEMPERATURBEREICH PILOT S HANDBOOK VERWENDEN 1A 05050484 DETAIL A ON OIL DOOR GERMANY ALL TEMP USE MULTIVISC OR 100A TEMPERATURA UTILICE YISCOSIDAO ABOVE 16 C 60F SAE 50 MULTIPLE 0 1C 30F TO 32 C 90 F 5AE40 A MAYOR DE 16C 60 F SAE 50 18C 0 F TO 21 C 70 F SAE 30 1C 30 F HAST...

Page 170: ...UND SYSTEM B ELECTRICAL COMPONENTS ATTENTION 24 VOLTS cc BATTERY VERKEHRTE POLAR DETAIL B 11 FRANCE DETAIL B BATTERY GERMANY BATTERY PRECAUC ION 24 VOLT OS D C 11A 1205024 4 ARGENTINA BATTERY BATTERY 0510T1007 Exterior Placards And Markings Figure 1 Sheet 1 11 21 24 Page 1 Aug 18 2001 ...

Page 171: ...BAGAGE 22kg EN ARRIERE DE LA PORTE DE SOUTE A BAGAGE CAPACITE MAXIMALE 54kg COMBINE 6A 0505043 4 POUR PLUS DE DETAILS SUR LES CONSIGNES DE CHARGEMENT SE REPORTER AUX DONNEES DETAIL DE MASSE ET DE CENTRAGE ON BAGGAGE DOOR DETAIL A ON BAGGAGE DOOR FRANCE CARGA MAXIMA DE 54kg NO COMPARTIMENTO A FRENTE DO FECHO DA PORTA DE CARGA E DE 22kg NO COMPARTIMENTO ATRAS DO 54 KG MAXIMO FECHO DA PORTA DE CARGA ...

Page 172: ...UX VALVE USE NON MAGNETIC 13 B CARBURANT FUEL 0 5C 5 DETAIL A DETAIL A FRANCE 0505094 7 0505094 8 5D 5A DETAIL A DETAIL A CANADA GERMANY 0505094 9 DETAIL A DETAIL A ARGENTINA BRAZIL Exterior Placards And Markings Figure 1 Sheet 1 11 25 10 Page 1 Aug 18 2001 ...

Page 173: ... MAINTENANCE MANUAL A B AVGAS ONLY 4 S2608 1 DETAIL A COMBUSTIBLE DE AVI ACION GRAOO GRADO 4C 0505048 9 ARGENTINA DETAIL A USE SOMENTE GASOLINA DETAIL A BRAZIL Exterior Placards And Markings Figure 1 Sheet 1 11 26 10 Page 1 Aug 18 2001 ...

Page 174: ... IN CONTACT WITH OUTER BARREL HUB 4 OILLEVEL a FLUID USED SHOULD COMPLY WITH SPECIFICATION MIL H 5606 b FILL STRUTTOBOTTOM OF VALVE INSTALLATION HOLE MAINTAIN OILLEVEL ATBOTTOM OF VALVE INSTALLATION HOLE 5 FULLY EXTEND STRUT 6 REPLACE VALVE HOUSING ASSEMBLY 7 WITH STRUT FULLY EXTENDED ANDNOSE WHEEL CLEAR OF GROUND INFLATE STRUT TO45 PSI 3 0543032 2 DETAIL A 0510T1007 Exterior Placards And Markings...

Page 175: ...IL A ON SEAT FRAME DETAIL A ON SEAT FRAME GERMANY SER INSTALADO VOLTADO PARA FRENTE 14A 0705097 4 DETAIL A BRAZIL MIRANDO HACIA ATRAS ESTE ASIENTO ESTA CERTIFICADO PARA MIRAR HACIA ADELANTE SOLAMENTE 1B 0705097 5 DETAIL A ARGENTINA 0510T1007 Interior Placards And Markings Figure 1 Sheet 1 11 32 11 Page 1 Aug 18 2001 ...

Page 176: ...l Normal Category No acrobatic maneuvers Including spins approved Utility Category No acrobatic maneuvers approved except those listed In the Pilots Operating Handbook Baggage compartment and rear seat must not be occupied Spin Recovery Opposite rudder forward elevator neutral ze controls Flight into known icing conditions prohibited This airplane iscertified for the following flight operation as ...

Page 177: ... __ _ __ _ _ 1 FliB In ba Flu TAG Fl DETAIL A 0505087 25 ON LEFT FORWARD TRIM PANEL All Fl T DETAIL A ON LEFT FORWARD TRIM PANEL Fl Dl Lu T DETAIL A ON LEFT FORWARD TRIM PANEL FOREIGN CERTIFICATION Interior Placards And Markings Figure 1 Sheet 1 11 32 13 Page Aug 18 2001 ...

Page 178: ...CRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 0705042 7 0705042 8 15 16 DETAIL A DETAIL B ON INTERIOR LH DOOR ON INTERIOR RH DOOR 0510T1007 Interior Placards And Markings Figure 1 Sheet 1 11 32 14 Page 1 Aug 18 2001 ...

Page 179: ...R GERMANY ON INTERIOR LH DOOR FECHADO ABERTO TRAVADO DETAIL A 19B ON INTERIOR LH DOOR DETAIL B BRAZIL ON INTERIOR RH DOOR BRAZIL ABR IR TRABADA TRABADA ABRIR 18C 0705042 17 19C 0705042 18 DETAIL A DETAIL A ON INTERIOR LH DOOR ON INTERIOR RH DOOR ARGENTINA ARGENTINA 0510T1007 Interior Placards And Markings Figure 1 Sheet 1 11 32 15 Page 1 Aug 18 2001 ...

Page 180: ...0408 1 17A 0505048 8 DETAIL C ON TOP OF PILOTS PANEL FRANCE DETAIL B MANOVERGESCHWINDIGKEIT MANOVERGESCHWINDIGKET 81 KG 90 KAS 862 726 KG 17 0505048 2 17050504814 GERMANY DETAIL B GERMANY DETAIL B MANEUVERING SPEED 105 KIAS 17C 0505048 36 DETAIL B AIRPLANES INCORPORATING MK172 72 01 0510T 1007 Interior Placards And Markings Figure 1 Sheet 1 11 32 20 Page 1 Aug 18 2001 ...

Page 181: ...S DER SITZ VOR DEM ROLLEN OEM START UND OER LAUXNG IN SEINER LAOE VERRIEELT IST EIN NICHTBEACHTEN DER SICH EREITSANWEISUNGEN UND DES SITZVERRIEELNS KANN ZU KtIRPL1ERLIC EFAHR ODER ZUM TOO FREN WARNUNG PITOTHEIZUNG MUSS AN SEIN WENN FLUGZEUG IN IMC UNTER 4 C BETRIEBEN WIRD AUSRUSTUNG FUR DEN WINTERBETRIEB ENTFERNEN WENN DIE AUBENTEMPERATUR 6 C UEERSTEIGT 15 0505048 1 GERMANY DETAIL A A REDE DE CARG...

Page 182: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL MAP LIGHT DIM 5 0415035 1 DETAIL A ON PILOT CONTROL WHEEL 0510T1007 Interior Placards And Markings Figure 1 Sheet 1 11 32 22 Page 1 Aug 18 2001 ...

Page 183: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A DETAIL A ON COPILOT CONTROL WHEEL Interior Placards And Markings Figure 1 Sheet 1 11 32 23 Page 1 Aug 18 2001 ...

Page 184: ...NA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A SEITENGLEITFLUG MIT AUSGEFAHRENEN KLAPPEN VERMEIDEN DETAIL A GERMANY 0510T1007 Interior Placards And Markings Figure 1 Sheet 1 11 32 24 Page 1 Aug 18 2001 ...

Page 185: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 1 4 0400213 5 DETAIL A RADIO 3 0400213 4 DETAIL A Interior Placards And Markings Figure 1 Sheet 1 11 32 25 Page 1 Aug 18 2001 ...

Page 186: ...NEL IN HINTER DIESEM ABSCHNITT ON ACCESS PANEL IN ER MUB ENTSPRECHEND DEN BAGGAGE COMPARTMENT GOLTIGEN VORSCHRI FTEN GEWARTET WERDEN 1 2 _i TRANSMISOR LOCALIZADOR DE 10A 1205085 5 EMERGENCIA INSTALADO DETRAS DE ESTA DIVISION GERMANY DEBE CUMPLIR CON EL DETAIL A DNAR PARTE 91 207 Ioo 2s e ON ACCESS PANEL IN BAGGAGE COMPARTMENT 10D ARGENTINA DE TAL3A TRANSMISSOR LOCAL IZADOR DE DETAIL A EMERGtNCIA E...

Page 187: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER SERVICING ...

Page 188: ...02 302 Feb 15 2002 303 Feb 15 2002 12 15 00 301 Feb 15 2002 12 16 00 301 Aug 18 2001 302 Aug 18 2001 12 17 00 301 Aug 18 2001 12 18 00 301 Aug 18 2001 302 Aug 18 2001 12 20 00 1 Aug 18 2001 12 21 00 1 Aug 18 2001 2 Aug 18 2001 3 Aug 18 2001 12 21 01 301 Aug 18 2001 302 Aug 18 2001 12 21 02 301 Aug 18 2001 302 Aug 18 2001 12 21 03 301 Aug 18 2001 302 Aug 18 2001 303 Aug 18 2001 304 Aug 18 2001 305 ...

Page 189: ...recautions 12 14 00 Page 1 FUEL SERVICING 12 14 01 Page 301 General 12 14 01 Page 301 Safety and Maintenance Precautions 12 14 01 Page 301 Fueling and Defueling 12 14 01 Page 301 Aviation Fuel Additive 12 14 01 Page 302 Fuel Loading 12 14 01 Page 302 ENGINE OIL SERVICING 12 14 02 Page 301 General 12 14 02 Page 301 Oil Change Intervals 12 14 02 Page 301 Checking Engine Oil 12 14 02 Page 301 Changin...

Page 190: ...Page 301 Flap System Lubrication 12 21 03 Page 301 Elevator System Lubrication 12 21 03 Page 301 Rudder System Lubrication 12 21 03 Page 301 ENGINE CONTROL CABLES SERVICING 12 21 04 Page 301 General 12 21 04 Page 301 Engine Control Cables Lubrication 12 21 04 Page 301 HEATING AND VENTILATION CONTROL CABLES SERVICING 12 21 05 Page 301 General 12 21 05 Page 301 Heating And Ventilation Control Cables...

Page 191: ...ng charts for the liquids most commonly used to service the airplane are grouped together to aid maintenance personnel inservicing b The subdivision of fuel and oil provides maintenance personnel with general servicing procedures Safety precautions and servicing procedures required by federal and local regulations may supersede the procedures described c The subject on hydraulic fluid servicing pr...

Page 192: ... various systems 1 Fuel Capacity Table 1 2 Approved Fuels Table 2 3 Engine Oil Capacity Table 3 3 Fuel Capacity Table A The following table lists airplane fuel capacity WARNING ONLY AVIATION GRADE FUELS ARE APPROVED FOR USE Table 1 Fuel Capacity U S Fuel Capacity 56 0 Gallons Usable Fuel 53 0 Gallons 4 Approved Fuel Table A The following table lists approved fuels for use inthe airplane Table 2 Ap...

Page 193: ... AND PROMPTLY REMOVE USED OIL FROM SKIN IN A LABORATORY STUDY MICE DEVELOPED SKIN CANCER AFTER SKIN WAS EXPOSED TO USED ENGINE OIL TWICE A WEEK WITHOUT BEING WASHED OFF SUBSTANCES FOUND TO CAUSE CANCER IN LABORATORY ANIMALS MAY ALSO CAUSE CANCER IN HUMANS Table 3 Engine Oil Capacity U S Quarts Oil Capacity total with filter oil cooler and cooler 8 0 quarts hoses 12 10 00 Page 2 Aug 18 2001 ...

Page 194: ...DERWING VACUUM RELIEF FUEL SUMP DRAINS OIL FILLER CAP AND DIPSTICK FUEL STRAINER INDUCTION AIR FILTER POWER JUNCTION BOX NOSE LANDING GEAR SHIMMY RECEPTACLE GEAR SHOCK BRAKE MASTER STRUT CYLINDERS BATTERY Airplane Service Points Figure 1 Sheet 1 12 10 00 Page 3 Aug 18 2001 ...

Page 195: ...2 Remove valve cap and release all air 3 Remove valve housing assembly 4 Compress strut completely stops incontact with outer barrel hub 5 Check and replenish oil level NOTE Fluid used should comply with specification MIL H 5606 a Fill strut to bottom of valve installation hole b Maintain oil level at bottom of valve installation hole 6 Fully extend strut 7 Reinstall valve housing assembly 8 With ...

Page 196: ...r shaft to its limit of travel 3 While holding dampener inthis position fill dampener through open end of cylinder with hydraulic fluid 4 Push the shaft upward slowly to seal off the filler hole 5 Clean dampener with solvent Be sure to keep the shaft protruding through the filler hole until dampener is installed on the aircraft 6 Install dampener on aircraft NOTE Keep the shimmy dampener especiall...

Page 197: ...s are located on the pilot s rudder pedals and are filled with MIL H 5606 hydraulic fluid 1 Brake master cylinders are filled by removing the filler plug located on topside of each master cylinder and filling to top of internal reservoir with MIL H 5606 hydraulic fluid 2 For bleeding procedures refer to Chapter 32 Brakes Maintenance Practices 12 13 00 Page 301 Aug 18 2001 ...

Page 198: ...ane Also a static ground device shall contact the fueling or defueling vehicle and ground b Fire fighting equipment shall be immediately available c Wear proper clothing 1 Do not wear clothing that has a tendency to generate static electricity such as nylon or synthetic fabrics 2 Do not wear metal taps on shoes when working in areas where fuel fumes may accumulate at ground level d The airplane sh...

Page 199: ...plane first b Ground vehicle or hose cart to the same ground as the airplane c Bond vehicle or hose cart to airplane d Bond refuel nozzle to airplane 2 Ensure fire fighting equipment is positioned and immediately available 3 Do not wear clothing that has a tendency to generate static electricity such as nylon or synthetic fabrics 4 Do not wear metal taps on shoes 5 The airplane should be ina desig...

Page 200: ...ergency and first aid procedures should be used 1 If ingested swallowed drink large quantities of water Then induce vomiting by placing a finger far back into the throat Contact a physician immediately If vomiting cannot be induced take victim immediately to the hospital or a physician Ifvictim is unconscious or inconvulsions take victim immediately to the hospital or a physician Do not induce vom...

Page 201: ... FUEL FLOW STARTS AND IS STOPPED BEFORE FUEL FLOW STOPS DO NOT ALLOW CONCENTRATED ADDITIVE TO CONTACT COATED INTERIOR OF FUEL TANK OR AIRPLANE PAINTED SURFACE b Start refueling then direct the fuel additive into the fuel stream so as to blend the additive simultaneously with the fuel as it fills the tank The additive concentration range shall be maintained in accordance with instructions in the Pi...

Page 202: ...after the engine has been stopped The aircraft should be inas near a level position as possible when checking the engine oil so that a true reading is obtained 2 Open engine oil door on upper cowling 3 Withdraw dipstick from engine and wipe down with clean cloth 4 Reinsert dipstick fully seat on filler neck and withdraw again 5 Read oil level on dipstick 6 If low service engine with correct quanti...

Page 203: ...ilter b Carefully remove and unfold the paper element Inspect the material trapped inthe filter NOTE If inspection indicates abnormal metal content additional investigation will be required to determine the source and possible need for corrective maintenance c Replace with new external oil filter and safety wire Refer to Chapter 20 Safetying Maintenance Practices 7 Refill engine oil sump through f...

Page 204: ...ANUAL B1669 SPECIFIED AVIATION GRADE OIL AVERAGE AMBIENT TEMPERATURE F OIL GRADE MAXIMUM OIL TEMPERATURE 0 100 200 30 40 50 60 70 80 90 F S R I SAE Iw I SAE 30 or 2450 Temperature Versus Oil Viscosity Figure 301 Sheet 1 12 14 02 Page 303 Feb 15 2002 ...

Page 205: ...that is loose or gapping away from the paper pleats is indicative of broken bonding and is cause to replace the filter element CAUTION DO NOT USE SOLVENT OR CLEANING FLUIDS TO WASH FILTER USE ONLY A WATER AND HOUSEHOLD DETERGENT SOLUTION WHEN WASHING THE FILTER d After cleaning as outlined in step 2 B 2 b the filter may be washed if necessary in a solution of warm water and a mild household deterg...

Page 206: ...ACUUM SYSTEM WITH AIR FILTER REMOVED OR WITH A VACUUM LINE DISCONNECTED PARTICLES OR DUST OR OTHER FOREIGN MATTER MAY ENTER THE SYSTEM AND DAMAGE THE VACUUM OPERATED INSTRUMENTS 1 Locate gyro filter behind instrument panel 2 Remove bolt and washer securing air filter to cover 3 Check for damage deterioration and contamination Clean or replace as required 4 Install air filter incover and secure usi...

Page 207: ...NA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INSTRUMENT PANEL SCREW ATTITUDE INDICATOR REGULATOR GYRO DETAIL A 0510T1007 A0518T1052 Vacuum System Filters Figure 301 Sheet 1 12 16 00 Page 302 Aug 18 2001 ...

Page 208: ...ffle plate at the bottom of the filler holes checking the battery cable connections and neutralizing and cleaning off any spilled electrolyte or corrosion Use bicarbonate of soda baking soda and water to neutralize electrolyte or corrosion Follow with a thorough flushing with a wire brush then coat with petroleum jelly before connecting The battery box should also be checked and cleaned if any cor...

Page 209: ...type tire that has been freshly mounted and installed should be closely monitored during the first week of operation ideally before every takeoff Air trapped between the tire and the tube at the time of mounting could seep out under the beard through sidewall vents or around the valve stem resulting in an under inflated assembly 2 The initial stretch or growth of a tire results ina pressure drop a...

Page 210: ...necessary pressure checks 2 If it is necessary to pressure check tires in cold climates always apply heat to air valves and surrounding areas before unseating valves 3 Continue application of heat during reinflation to ensure air valve seal flexibility when valve closes 4 Do not allow tires to stand insnow soaked with fuel or on fuel covered ramp areas 5 If tires become frozen to parking ramp use ...

Page 211: ...spection and or preventive maintenance programs This section does not include lubrication procedures required for the accomplishment of maintenance practices 2 Description A This section is subdivided to provide maintenance personnel with charts text and illustrations to prevent confusion Also included inthis section is a table containing a list of lubricants 1 The subdivisions are separated accor...

Page 212: ...bed on seat rails will ease sliding the seats fore and aft 10 Do not lubricate roller chains or cables except under sea coast conditions Wipe with a clean dry cloth 11 All piano hinges may be lubricated using PG powered graphite SS G 659 when assembly is installed 12 Lubricate door latching mechanism with MIL G 81322 general purpose grease applied sparingly to friction points if binding occurs No ...

Page 213: ...se Inc gear and 16215 Division Witco actuator screw 1400 S Harrison Olathe KS 66061 Aeroshell Shell Oil Co grease 7 Royco 27A Royal Lubricants Co Inc Supermil Amoco Oil Co grease No 200 East Randolph Dr A72832 Chicago IL 60601 Braycote Burmah Castrol Inc 6275 Bray Products Div 16815 Von Karman Ave Irving CA 92714 Cas Burmah Castrol Inc trolease A1 TG 11900 Southwest Petro low temp Chem Inc grease ...

Page 214: ...ter NJ 07020 PL VV P 236 Petrolatum Available Commercially technical PG SS G 659 Powdered Available Commercially Graphite GL MIL G 21164 High and Low Everlube E M Corporation Temperature 211 G Moly Box 2200 Grease Grease Highway 52 N W West Lafayette IN 47906 Royco 64 Royal Lubricants Co Inc GP NONE Number Available Commercially 10 weight non detergent oil OL VV L 800 Light Oil Available Commercia...

Page 215: ...ea free of contamination from sand dust or other environmental conditions that may contribute to improper lubrication practices 2 Battery Terminal Lubrication A Battery terminals should be lubricated when cables are installed to terminals B Refer to Figure 301 for lubrication requirements of the battery terminals 12 21 01 Page 301 Aug 18 2001 ...

Page 216: ... MAINTENANCE MANUAL B1671 ITEM ITEM LUBE NUMBER DESCRIPTION TYPE APPLICATION BATTERY 1 TERMINALS PL HAND TERMINALS PL GREASE PETROLATUM V V P 236 0518T1023 Battery Terminals Lubrication Figure 301 Sheet 1 12 21 01 Page 302 Aug 18 2001 ...

Page 217: ... 301 for lubrication requirements of the nose gear torque links 4 Shimmy Dampener Pivots Lubrication A Shimmy dampener pivots should be lubricated on an as needed basis and when assembled or installed B Refer to Figure 301 for lubrication requirements of the shimmy dampener pivots 5 Steering System Needle Bearing Lubrication A Steering system needle bearings should be lubricated on an as needed ba...

Page 218: ... TYPE 1 WHEEL BEARINGS GR HAND 2 TORQUE LINKS GR GUN 3 SHIMMY DAMPER PIVOTS OG OIL CAN 4 NEEDLE BEARINGS GR HAND 5 PARKING BRAKE HANDLE OG OIL CAN SHAFT GR GREASE GENERAL PURPOSE MIL G 81322 OG OIL GENERAL PURPOSE MIL L 7870 0542T2001 0514T3001 0541T3001 Landing Gear Lubrication Figure 301 Sheet 1 12 21 02 Page 302 Aug 18 2001 ...

Page 219: ...icated on an as needed basis and when assembled or installed C Refer to Figure 302 for lubrication requirements of the flap system 4 Elevator System Lubrication A Bearings inthe trim wheel controls should be lubricated on an as needed basis and when assembled or installed B Trim tab piano hinges should be lubricated on an as needed basis and when assembled or installed C The trim tab actuator shou...

Page 220: ...MANUAL 2 ITEM ITEM LUBE APPLICATION NUMBER DESCRIPTION TYPE 1 NEEDLE BEARINGS GR HAND BUSHINGS AND OILITE BEARINGS OG OIL CONTROL TUBE UNIVERSAL JOINTS OG OIL CAN 05603001 Aileron System Lubrication Figure 301 Sheet 1 12 21 03 Page 302 Aug 18 2001 ...

Page 221: ...MBER DESCRIPTION TYPE 4 ALL PIANO PG SYRINGE HINGES 5 BELLCRANK NEEDLE BEARINGS GR HAND GR GREASE GENERAL PURPOSE MIL G 81322 OG OIL GENERAL PURPOSE MIL L 7870 PG POWDERED GRAPHITE SS G 659 05611002 05611001 Aileron System Lubrication Figure 301 Sheet 2 12 21 03 Page 303 Aug 18 2001 ...

Page 222: ...MODEL 172 MAINTENANCE MANUAL ITEM ITEM LUBE APPLICATION NUMBER DESCRIPTION TYPE 1 SCREW JACK THREADS GP OIL CAN GP OIL NO 10 WEIGHT NONDETERGENT 05642003 Flap System Lubrication Figure 302 Sheet 1 12 21 03 Page 304 Aug 18 2001 ...

Page 223: ...2 MAINTENANCE MANUAL ITEM ITEM LUBE APPLICATION NUMBER DESCRIPTION TYPE ELEVATOR TRIM GL HAND TAB ACTUATOR GL MOLYBDENUM DISLULFIDE GREASE MIL G 21164 05631004 Elevator Trim Lubrication Figure 303 Sheet 1 12 21 03 Page 305 Aug 18 2001 ...

Page 224: ... MANUAL ITEM ITEM LUBE APPLICATION NUMBER DESCRIPTION TYPE OILITE BEARING RUDDER BAR ENDS OG OIL ALL LINKAGE PIVOT POINTS OG OIL OG OIL GENERAL PURPOSE MIL L 7870 05622002 Rudder Pedals Lubrication Figure 304 Sheet 1 12 21 03 Page 306 Aug 18 2001 ...

Page 225: ...n area free of contamination from sand dust or other environmental conditions that may contribute to improper lubrication practices 2 Engine Control Cables Lubrication A All housed pull type push pull or vernier controls should have each outer housing lightly lubricated internally with VV L 800 General Purpose Lube Oil 12 21 04 Page 301 Aug 18 2001 ...

Page 226: ...n area free of contamination from sand dust or other environmental conditions that may contribute to improper lubrication practices 2 Heating And Ventilation Control Cables Lubrication A All housed pull type push pull or vernier controls should have each outer housing lightly lubricated internally with VV L 800 General Purpose Lube Oil 12 21 05 Page 301 Aug 18 2001 ...

Page 227: ... household window cleaning sprays paint strippers or other types of solvents D Do not leave sun visors up against windshield when not in use The reflected heat from these items causes elevated temperatures on the windshield If solar screens are installed on the inside of the airplane ensure they are the silver appearing reflective type 3 Preventive Maintenance A Keep all surfaces of windshields an...

Page 228: ...5 Cleaning Windshield and Windows CAUTION WINDSHIELDS AND WINDOWS ARE EASILY DAMAGED BY IMPROPER HANDLING AND CLEANING TECHNIQUES CAUTION DO NOT USE ANY OF THE FOLLOWING FOR CLEANING WINDSHIELDS AND WINDOWS METHANOL DENATURED ALCOHOL GASOLINE BENZENE XYLENE MEK ACETONE CARBON TETRACHLORIDE LACQUER THINNERS COMMERCIAL OR HOUSEHOLD WINDOW CLEANING SPRAYS A Refer to Table 702 for cleaning materials B...

Page 229: ...For proper care and cleaning of the external graphics refer to Chapter 11 Exterior Graphics Maintenance Practices B To seal any minor surface chips or scratches and protect against corrosion the airplane should be waxed regularly with a good automotive wax applied in accordance with the manufacturer s instructions If the airplane is operated in a seacoast area or other salt water environment it mu...

Page 230: ...t based emulsion cleaner MIL C 4361 mixed 1part cleaner with 3 parts Stoddard Solvent 6 After applying solvent thoroughly rinse with clean warm water NOTE Cleaning agents should never be left on engine components for an extended period of time Failure to remove them may cause damage to components such as neoprene seals and silicone fire sleeves and could cause additional corrosion 7 Completely dry...

Page 231: ...le For cleaning nylon safety belts Ivory Liquid White or Commercially available For cleaning seat fabric colorless Cheer Commercially available For cleaning seat fabric Mr Clean Commercially available Recommended for cleaning Morbern vinyl 3 Cleaning Interior Panels A Interior panels headliners sidewalls door panels etc are constructed of a heavy vinyl and may be covered with softer Morbern vinyl ...

Page 232: ...d to the stain Table 701 Methods For Cleaning Trevira Fabric on Seats STAIN PROCESS AND STAIN PROCESS AND SEQUENCE SEQUENCE Antacid Maalox 1 Infant Formula 2 1 Betadine Iodine 2 3 4 6 Ink ball point 8 Blood 2 3 5 Motor Oil 1 2 3 4 Catsup 2 3 5 Mud 2 1 Chewing Gum 7 1 2 Petroleum Jelly 1 2 Chocolate Syrup 5 1 Pepto Bismol 6 1 Coffee Tea 2 4 5 1 Urine 2 3 4 Cola 2 3 4 Suntan Lotion 1 2 Cough Syrup 2...

Page 233: ...s removed 6 Rinse thoroughly with clean cool water 7 Sponge with soapy water containing a small amount of household ammonia 8 Wash with diluted bleach use a soft brush for stubborn stains 9 Fresh paint can be wiped off with a damp cloth Hot soapy water will normally remove dried latex 10 Remove immediately as prolonged contact will result in a permanent stain Use a cloth lightly dampened with mine...

Page 234: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER STANDARD PRACTICES AIRFRAME ...

Page 235: ...1 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 206 Aug 18 2001 20 12 00 201 Feb 15 2002 202 Feb 15 2002 203 Feb 15 2002 204 Feb 15 2002 205 Feb 15 2002 206 Feb 15 2002 207 Feb 15 2002 208 Feb 15 2002 209 Feb 15 2002 210 Feb 15 2002 20 30 00 1 Aug 18 2001 20 31 00 1 Feb 15 2002 2 Feb 15 2002 3 Feb 15 2002 20 31 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 20...

Page 236: ... OOZ 81 6nL 89 1OOZ 8 L 6n 8 00 90 OS ...

Page 237: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 238: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 239: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 240: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 241: ...e 202 Cotter Pin Installation 20 12 00 Page 206 Safetying Turnbuckles 20 12 00 Page 208 SEALING DESCRIPTION AND OPERATION 20 30 00 Page 1 General 20 30 00 Page 1 ACCEPTABLE REPLACEMENTS FOR CHEMICALS AND SOLVENTS DESCRIPTION AND OPERATION 20 31 00 Page 1 General 20 31 00 Page 1 Hand Wipe Cleaning Operations 20 31 00 Page 1 Priming Operations 20 31 00 Page 1 Topcoat Operations 20 31 00 Page 2 Paint...

Page 242: ...iVnNVVI 30NVN31NIV4 ...

Page 243: ...f Contents will further assist inlocating a particular subject A brief definition of the subjects and sections incorporated inthis chapter is as follows 1 The section on Material and Tool Cautions describes general cautions and warnings applicable to maintenance on or around the airplane 2 The section on Torque Data provides tables formulas requirements and torque limits for various type fasteners...

Page 244: ...ncluding goggles face shields breathing apparatus protective clothing and gloves Fuel engine oil solvents volatile chemicals adhesives paints and strong cleaning agents may cause injury when contacting the skin or eyes or when vapors are breathed When sanding composites or metals or otherwise working in an area where dust particles may be produced the area should be ventilated and the appropriate ...

Page 245: ...c chemicals in use inthe work area and to adhere to the labeling of containers Chemical manufacturers are required to label each container with a diamond shaped symbol red for flammable and yellow for oxidizers G Solvents can also damage the hands and skin Solvents dry out skin and dissolve the natural oils The condition can develop into an irritation or if left untreated with continuous exposure ...

Page 246: ...asured E General Torquing Notes 1 These requirements do not apply to threaded parts used for adjustment such as turnbuckles and rod ends 2 Torque values shown are for clean non lubricated parts Threads should be free of dust metal filings etc Lubricants other than that on the nut as purchased should not be used on any bolt installation unless specified 3 Assembly of threaded fasteners such as bolt...

Page 247: ...LE WITH E AS PLUS DIMENSION T 135 IN LB y 135x10 117 39 Y UNKNOWN 10 1 5 HOSE CLAMP E 1 5 IN Y 117 IN LB ADAPTER L 10 0 IN LEGEND T ACTUAL DESIRED TORQUE INDICATED TORQUE E EFFECTIVE LENGTH OF EXTENSION ADAPTER OPEN END WRENCH DRIVE HANDGRIP ADAPTER WRENCH CENTERLINE CENTERLINE DRIVE PREDETERMINED CENTERLINE FLARE NUT WRENCH ADAPTER TORQUE FORMULA TxL WRENCH L E EXAMPLE WITH E AS MINUS DIMENSION T...

Page 248: ...E NEXT TO BOLT HEAD RADIUS INTERNAL WRENCHING HEAD STANDARD COUNTERSUNK WASHER WASHER INCORRECT INSTALLATION CAUTION NEVER INSTALL STANDARD WASHER OR COUNTERSUNK WASHER IN REVERSE WHEN USING BOLTS WITH RADIUS UNDER THE HEAD 5598C1004 5598C1004A Washer Installation Close Tolerance Bolts Figure 202 Sheet 1 20 11 00 Page 203 Aug 18 2001 ...

Page 249: ...70 50 to 75 30 to 40 30 to 48 30 to 40 30 to 45 5 16 24 100 to 140 100 to 150 60 to 85 60 to 100 60 to 80 60 to 90 3 8 24 160 to 190 160 to 260 95 to 110 95 to 170 95 to 110 95 to 125 7 16 20 450 to 500 450 to 560 270 to 300 270 to 390 180 to 210 180 to 225 1 2 20 480 to 690 480 to 730 290 to 410 290 to 500 240 to 280 240 to 300 9 16 18 800 to 1000 800 to 1070 480 to 600 480 to 750 320 to 370 320 ...

Page 250: ... not be used on any bolt installations unless specified inthe applicable chapters of this manual 2 All threaded electrical current carrying fasteners for relay terminals shunt terminals fuse limiter mount block terminals and bus bar attaching hardware shall be torqued per Table 203 NOTE There is no satisfactory method of determining the torque previously applied to a threaded fastener When retorqu...

Page 251: ... 205 to determine torque requirements for tubes and hoses Table 205 Tubing Hose Torque Limits Inch Pounds Hose Size Tubing O D Aluminum Alloy Tubing Steel Tubing Min Max Min Max 2 1 8 20 30 75 85 3 3 16 25 35 95 105 4 1 4 50 65 135 150 5 5 16 70 90 170 200 6 3 8 110 130 270 300 8 1 2 230 260 450 500 10 5 8 330 360 650 700 12 3 4 460 500 900 1000 16 1 500 700 1200 1400 20 1 1 4 855 945 1520 1680 24...

Page 252: ...h of carbon steel or corrosion resistant wire 4 Wires are visually identifiable by their colors natural for inconel and monel yellow for copper and blue for aluminum B Cotter Pin 1 The selection of material shall be in accordance with temperature atmosphere and service limitations 2 Safety Wire A Wire Size 1 The size of the safety wire shall be inaccordance with the requirements of Table 201 a 0 0...

Page 253: ...nit and inserted through this set of safety wire holes The other end may go over the head when the clearances around the head are obstructed by adjacent parts b The strands while taut shall be twisted until the twisted part is just short of the nearest safety wire hole inthe next unit The twisted portion shall be within 1 8 inch of the holes ineach unit The actual number of twists will depend upon...

Page 254: ...OLT IFNECESSARY BEND WIRE ACROSS HEAD OF BOLT TWIST WIRES COUNTERCLOCKWISE 1 2 INCH OR SIX TWISTS CLIP ENDS BEND PIGTAIL BACK AGAINST PART NOTE RIGHT THREADED PARTS SHOWN REVERSE DIRECTIONS FOR LEFT PARTS BOLT B CLOCKWISE DOUBLE WIRE SAFETYING COUNTER CLOCKWISE CLOCKWISE COUNTER CLOCKWISE MULTIPLE FASTENER APPLICATION DOUBLE TWIST DOUBLE TWIST SAFETYING 0560R1025 Lockwire Safetying Figure 201 Shee...

Page 255: ...GEOMETRICAL PATTERN SINGLE WIRE METHOD SINGLE FASTENER APPLICATION DOUBLE TWIST METHOD SMALL SCREWS INCLOSELY SPACED CLOSED GEOMETRICAL PATTERN SINGLE WIRE METHOD NOTE RIGHT THREADED PARTS SHOWN REVERSE DIRECTION FOR LEFT THREADS 5598T1003 5598T1024 5598T1024 5598T1024 Lockwire Safetying Figure 201 Sheet 2 20 12 00 Page 204 Feb 15 2002 ...

Page 256: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 91680 SAFETY WIRE a_ 0560R1026 Lockwire Safetying Figure 201 Sheet 3 20 12 00 Page 205 Feb 15 2002 ...

Page 257: ...nd illustrated It is preferable to safety wire all electrical connectors individually Do not safety wire one connector to another unless it is necessary to do so 9 Drilled head bolts and screws need not be safety wired if installed into self locking nuts or installed with lockwashers Castellated nuts with cotter pins or safety wire are preferred on bolts or studs with drilled shanks but self locki...

Page 258: ...HOD PREFERRED METHOD MINIMUM MAXIMUM COTTER PIN 6 0 028 LENGTH 8 60 DEGREES 10 0 044 1 4 0 044 5 16 0 044 6 DEGREES 3 8 0 072 7 16 0 072 MINIMUM COTTER PIN COTTER PIN 9 16 0 086 LENGTH 5 8 0 086 3 4 0 086 7 8 0 086 1 0 086 1 1 8 0 116 1 1 4 0 116 13 8 0 116 1 1 2 0 116 PIN APPLICATION 0560R1028 Cotter Pin Safetying Figure 202 Sheet 1 20 12 00 Page 207 Feb 15 2002 ...

Page 259: ... Wire 1 Some turnbuckles are secured using safety wire These safetying procedures are detailed I and illustrated in Federal Publication AC 43 13 1B or latest revision Safety Methods For Turnbuckles B Use of Locking Clips Refer to Figure 203 1 Prior to safetying both threaded terminals shall be screwed an equal distance into the turnbuckle barrel They shall be screwed in at a minimum so that no mor...

Page 260: ...MODEL 172 MAINTENANCE MANUAL B1682 STRAIGHT END HOOK SHOULDER _zzzfl _ _ PULL FOR INSPECTION BARREL CABLE TERMINAL PULL FOR INSPECTION 0560R1023 Safetying Turnbuckle Assemblies Figure 203 Sheet 1 20 12 00 Page 209 Feb 15 2002 ...

Page 261: ...BARREL AND TERMINALS LOCKING CLIP TURNBUCKLE NOMINAL THREAD MS21256 BODY CABLE DIA UNF 3 NOTE MS21251 1 16 No 6 40 1 2S 3 32 No 10 32 3S 2 3L 1 4S 1 8 2 4L 5 32 1 4 28 1 5S 2 5L 6S 3 16 5 16 24 1 6L 7 32 7L 1 4 3 8 24 2 8L 9 32 7 16 20 9L 5 16 1 2 20 3 10L NOTE TWO LOCKING CLIPS REQUIRED FOR EACH TURNBUCKLE 0560R 1024 Safetying Turnbuckle Assemblies Figure 203 Sheet 2 20 12 00 Page 210 Feb 15 2002...

Page 262: ...2 MAINTENANCE MANUAL SEALING DESCRIPTION AND OPERATION 1 General A A list of the various sealants used throughout the airplane can be found inthe Tools Equipment and Materials table of the effected chapters 20 30 00 Page 1 Aug 18 2001 ...

Page 263: ...FACE APPROVED PRODUCT NUMBER SUPPLIER ADDRESS All Metals and Painted Surfaces Methyl n propyl ketone CAS No Eastman Chemical Products 107 87 9 Wilcox Dr And Lincoln St Kingsport TN Desoclean 110 020K19 Dynamold Solvents Incorporated 2905 Shamrock Ave Fort Worth TX 76107 All Plastics Isopropyl Alcohol TT I 735 Available Commercially All Rubber Natural or Synthetic Isopropyl Alcohol TT 1 735 Availab...

Page 264: ... equipment must be operated according to manufacturer s specifications company procedures or locally specified operating procedures 4 Topcoat Operations NOTE Topcoat operations may not exceed a maximum Hazardous Air Pollutant HAP limit of 3 5 lb Gallon 420 Grams Liter less water per application Topcoat operations may not exceed a volatile organic compounds VOC limit of 3 5 lb Gallon 420 Grams Lite...

Page 265: ...pping and decal removal is limited to 190 pounds per airplane per year Table 4 Replacement Products for Paint Stripping Operations APPLICATION APPROVED PRODUCT NUMBER SUPPLIER ADDRESS Chemical Stripping Turco T 6776 LO Turco Products Inc Westminster CA 92684 Mechanical Stripping See Note 5 180 Grit or finer Available Commercially NOTE 1 Mechanical and hand sanding operations are exempt from these ...

Page 266: ... toxic substances work only a clean well lighted and well ventilated area Rubber gloves and protective clothing should be worn Avoid breathing spray vapors as they are highly toxic C When working with toxic substances always be alert for symptoms of poisoning If symptoms are observed immediate removal of the victim from the contaminated area is most important 4 Description A Solvents exhibit asele...

Page 267: ...ION CATION Dry PD680 Type I 100 F General cleaning solvent FLAMMABLE Type II 140 F Dry cleaning of textile materials Grease removal 1 1 1 O T 620 Type I Spot removing from USE WITH ADEQUATE Inhibited Regular fabrics General cleaning VENTILATION Technical Type II with solvent Cleaning of AVOID PROLONGED Trichloroethane dauber assembled equipment BREATHING OF VAPOR Type III AVOID PROLONGED Aerosol C...

Page 268: ...al polish for use FLAMMABLE Aluminum P 6888C Type IIPaste on airplane aluminum surfaces Naphtha TT N 958 Type I For use with organic DO NOT USE WITH Aliphatic coatings only ACRYLIC PLASTICS FLAMMABLE Type II Cleanerfor acrylic plastics VAPOR HARMFUL and may be used in AVOID PROLONGED OR placeof Type I General REPEATED BREATHING cleaningagent OR CONTACT WITH SKIN Methyl Ethyl TT M Paint and adhesiv...

Page 269: ...LD BE USED WHEN Type II Clear Use full strength or diluted HANDLING THE Liquid with mineral spirits and COMPOUND water for maintenance WASH FROM SKIN of unfinished aluminum IMMEDIATELY WITH surfaces WATER OR A SOLUTION OF SODIUM BICARBO NATE AND APPLY GLYCERIN OR PETROLEUM JELLY WASH FROM EYES AS PER MANUFACTURER S INSTRUCTIONS AND REPORT TO NEAREST MEDICAL FACILITY Toluene TT T Use as a solvent o...

Page 270: ...tings Use of approved respirators while painting is a must for personal safety All solvent containers should be grounded to prevent static buildup Catalyst materials are toxic therefore breathing fumes or allowing contact with skin can cause serious irritation Material stock should be rotated to allow use of older materials first because its useful life is limited All supplies should be stored ina...

Page 271: ...maged area For best results itisrecommended to remove all paint covering sanding surfacer of that individual composite component 2 Remove sanding surfacer by sanding from individual component to expose fabric 3 Scuff sand area to be refinished with 320 grit paper Do not over expose fabric 4 Clean surface with Methyl n Propyl Ketone Follow manufacturer s instructions for final cleaning prior to san...

Page 272: ... tape so as to make a safety margin of at least one half inch 13 mm between protected surface and surface to be stripped NOTE Do not use masking tape a Mask all windows and transparencies CAUTION ACRYLIC WINDOWS MAY BE SOFTENED OR OTHERWISE DAMAGED BY PAINT STRIPPER SOLVENT OR PAINT USE WATER AND GREASE PROOF BARRIER MATERIAL AND POLYETHYLENE COATED TAPE TO PROTECT WINDOWS 1 Place barrier material...

Page 273: ...nside skin joints refer to Cleanout of Skin Joints 13 If corrosion is encountered refer to Structural Repair Manual Chapter 51 Corrosion Repair for corrosion treatment C Cleanout of Skin Joints 1 Install a surface conditioning disc on a pneumatic drill 2 Taper edge of disc to an edge which will allow edge to fit into skin joint seam a Run disc against a piece of coarse abrasive paper or a mill fil...

Page 274: ...377 or equivalent as directed by the primer manufacturer or supplier d On a properly prepared surface mix and apply polyurethane topcoat as directed by the paint manufacturer or supplier 2 Major defects which expose bare metal to an area larger than the size of a dime touch up as follows a Hand solvent clean and sand with 320 grit or finer sandpaper b Clean with compressed air hand solvent clean a...

Page 275: ... Angeles CA 90023 application Pro Seal 890 Courtaulds Aerospace 5426 San Fernando Rd Glendale CA 91209 PR 1440 Courtaulds Aerospace SEALANTS TYPE I CLASS B 1 4 QUICK REPAIR MIL S 83318 Sealant GC 435 Goal Chemical Sealant Corp Fuel pressure and weather sealant For limited repairs requiring rapid curing sealant SEALANTS TYPE I CLASS B 1 2 B 2 OR B 4 MIL S 8802 NAME NUMBER MANUFACTURER USE Sealants ...

Page 276: ...ght acrylic latex sealant for windows and metal lap joints SEALANT TYPE XI Sealant EP 7191T Fiber Resin Corp Permanently pliable 0877 extruded tape for fixed windows CLEANING SOLVENTS NAME NUMBER MANUFACTURER USE 1 1 1 Federal Commercially Available Presealing cleaning Trichloroethane Specification Technical O T 620 Inhibited Methyl Chloroform Methyl Propyl Commercially Available Cleaning organic ...

Page 277: ...tems Division of Courtaulds Aerospace Nozzles Semco Packaging and Application of sealant Applications Systems Division of Courtaulds Aerospace Round 1 16 orifice Semco No 420 Round 1 8 orifice Semco No 440 Duckbill Semco No 8615 Duckbill Semco No 8648 Comb Semco No 8646 Polyethylene Commercially available Application of sealant cartridges with plungers and caps for sealant gun Metal spatulas with ...

Page 278: ...ention must be taken to avoid metal chips or dirt at the faying surface 7 Fillet Seal Sealant material applied at the seam joint or fastener after the assembly has all permanent fasteners installed and shall conform to the dimension inapplicable figure 8 Hole An opening that has no appreciable depth such as a tool hole Holes that penetrate the seal plane must be metal filled with a fastener gusset...

Page 279: ...pressure and weather sealant a Class A Sealant which is suitable for brush application b Class B Sealant which is suitable for application by extrusion gun spatula etc c Class C Sealant which is suitable infaying surface applications d Quick Repair Sealant This material is for use only in making repairs when an extremely rapid curing sealant is required A possible application includes sealing a le...

Page 280: ...ealants which have thawed shall not be refrozen 6 Complete preassembly operations such as fitting filing drilling countersinking dimpling and deburring prior to cleaning and sealant application 7 Surfaces must be clean and dry free from dust lint grease chips oil condensation or other moisture and all other contaminating substances prior to the application of sealant a All exposed bonding primer o...

Page 281: ... Warm circulating air at a temperature not to exceed 140 F 60 C may be used to accelerate cure Heat lamps may be used if the surface temperature of the sealant does not exceed 140 F 60 C At temperatures above 120 F 49 C the relative humidity will normally be so low below 40 percent that sealant curing will be retarded If necessary the relative humidity may be increased by the use of water containi...

Page 282: ...IRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B2152 FOUR BLADE DASHER DASHER ROD RAMROD NOTE CARTRIDGE ISDISPOSABLE AFTER USE 0580T1005 Two Part Sealant Cartridge Figure 201 Sheet 1 20 32 00 Page 208 Aug 18 2001 ...

Page 283: ...stall cartridge in gun 6 Drill motor mixing NOTE A tapered rotary file or a 25 64 inch drill bit may be used with a drill motor to turn the dasher rod a Insert the rotary file drill bit into the dasher rod approximately 1 2 inch 13 mm WARNING THE CARTRIDGE SHOULD BE HELD FIRMLY BUT NOT SQUEEZED AS THE DASHER BLADES MAY PENETRATE THE CARTRIDGE AND INJURE THE HAND b Verify the drill motor will rotat...

Page 284: ...emoved from parts prior to sealing H Allow all cleaned surfaces to dry a minimum of 5 minutes before the application of sealant materials I Sealant shall be applied as soon as possible after cleaning and drying the surfaces to be sealed Do not handle the parts between the cleaning and sealing operations Sealant application personnel handling cleaned surfaces shall wear clean white gloves to preven...

Page 285: ...NTENANCE MANUAL B2153 INSPECTION COVER TYPICAL UPPER TRAILING UPPER SKIN FUEL BAY LEFT SHOWN RIGHT OPPOSITE TRAILING EDGE LOWER SKIN 0526T1010 0526T1009 0526T 1011 Integral Fuel Bay Sealing Figure 202 Sheet 1 20 32 00 Page 211 Aug 18 2001 ...

Page 286: ...AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL FAYING SURFACE SEAL TYPICAL RIB SECTION FAY SEAL SEALANT EXTRUDED CONTINUOUSLY 55982007 Integral Fuel Bay Sealing Figure 202 Sheet 2 20 32 00 Page 212 Aug 18 2001 ...

Page 287: ...NS OF SEALING METHODS AND TECHNIQUES USED INTHE FUEL BAY AREA INMOST CASES WING SKIN AND RIB THICKNESS COMBINED ISAPPROXIMATELY 0 070 INCH 1 8 mm MINIMUM SEALANT APPLICATION AT ANY POINT SHOULD NOT BE LESS THAN 0 060 INCH 1 5 MM Integral Fuel Bay Sealing Figure 202 Sheet 3 20 32 00 Page 213 Aug 18 2001 ...

Page 288: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INJECTION IS COMPLETE WHEN SEALANT EMERGES FROM THIS SIDE 0598T 1002 Integral Fuel Bay Sealing Figure 202 Sheet 4 20 32 00 Page 214 Aug 18 2001 ...

Page 289: ...led remove uncured sealant which extrudes onto the exterior of the airplane using clean rags moistened with TT T 548 Toluene or Methyl Propyl Ketone C Injection Sealing 1 Sealant shall be injected into the channel joggle void or cavity from one point only using a sealant gun in such a manner that no air is entrapped and the channel joggle void or cavity is completely filled and sealant isobserved ...

Page 290: ...shank sealed soft rivet and then brush coated with Type I Class A sealant 10 Sealant Repair A Materials Repairs in general shall be accomplished with the same type of material as that being repaired NOTE Type I Class B 1 2 is recommended for use during cold weather to obtain an accelerated cure NOTE Type I Quick Repair sealant may be used as a repair for sealant in fuel tanks ifdesired for fast cu...

Page 291: ...ughly clean with solvent and abrade old areas which are to be over coated Clean one small area at a time then dry with a clean cloth before the solvent evaporates NOTE Always pour solvent on the cloth to maintain a clean solvent supply NOTE In fuel tanks which have been inoperation the sealant will be soaked and should be dried inarea of the repair with a vapor proof heat lamp or hot air blower be...

Page 292: ...e and move to the right horizontally to locate decimal equivalent figure in the decimal equivalent column and millimeter numeral inthe millimeter column C Temperature 1 Formula F 9 5 C 32 C 5 9 F 32 2 Figure 5 is a table containing conversion data for converting temperature from either Celsius to Fahrenheit or Fahrenheit to Celsius a Select the desired number in the middle column of the three colu...

Page 293: ...C FEET 61 023 CUBIC INCHES 264 2 GALLON 999 97 LITERS FEET 0 3048 METERS 12 000 MILS 304 8 MILLIMETERS 0 3333 YARDS FOOT POUNDS 0 1383 METER KILOGRAMS 0 001285 BRITISH THERMO UNIT 0 000000376 KILOWATTS PER HOUR FLUID OUNCE 8 DRAM 29 6 CUBIC CENTIMETERS GALLON 277 4 CUBIC INCHES IMPERIAL 1 201 U S GALLON 4 546 LITERS GALLON 268 8 CUBIC INCHES U S DRY 0 1556 CUBIC FEET 1 164 U S GALLON LIQUID 4 405 ...

Page 294: ...9 807 JOULES OUNCES 0 0625 POUND AVOIRDUPOIS AVOIRDUPOIS 28 35 GRAMS 437 5 GRAINS OUNCES FLUID 29 57 CUBIC CENTIMETERS 1 805 CUBIC INCHES POUND 453 6 GRAMS AVOIRDUPOIS 7000 GRAINS 16 0 OUNCES SQUARE INCH 6 4516 SQUARE CENTIMETERS POUND PER 0 0703 KILOGRAM CENTIMETER SQUARE INCH SQUARED PSI STATUTE MILE 1 609 KILOMETER 0 0684 NAUTICAL MILE NAUTICAL MILE 1 151 STATUTE MILE QUART 0 9463 LITER MILLIME...

Page 295: ...S KILOGRAMS 2 5 346 67 5 9 332 165 22 813 5 0 691 70 0 9 678 170 23 504 7 5 1 037 72 5 10 024 175 24 195 10 0 1 383 75 0 10 369 180 24 887 12 5 1 728 77 5 10 715 185 25 578 15 0 2 074 80 0 11 060 190 26 269 17 5 2 419 82 5 11 406 195 26 960 20 0 2 765 85 0 11 752 200 27 652 22 5 3 111 87 5 12 097 205 28 343 25 0 3 456 90 0 12 443 210 29 034 27 5 3 802 92 5 12 789 215 29 726 30 0 4 148 95 0 13 134 ...

Page 296: ... KILOGRAMS POUNDS KILOGRAMS POUNDS KILOGRAMS POUNDS 1 7 23 8 57 86 15 108 49 2 14 46 9 65 89 16 115 72 3 21 69 10 72 32 17 122 95 4 28 93 11 79 56 18 130 19 5 36 16 12 86 79 19 137 42 6 43 39 13 94 02 20 144 65 7 50 63 14 101 26 21 151 89 22 159 12 Torque Conversion Chart Figure 2 Sheet 2 20 50 00 Page 5 Aug 18 2001 ...

Page 297: ...2032 0 2057 0 2082 0 2108 0 2133 0 2159 0 2184 0 2209 0 2235 0 2260 0 009 0 2286 0 2311 0 2336 0 2362 0 2387 0 2413 0 2438 0 2463 0 2489 0 2514 INCHES 0 000 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 008 0 009 MILLIMETER 0 00 0 025 0 050 0 076 0 101 0 127 0 152 0 177 0 203 0 228 0 01 0 254 0 279 0 304 0 330 0 355 0 381 0 406 0 431 0 457 0 482 0 02 0 508 0 533 0 558 0 584 0 609 0 635 0 660 0 685 0...

Page 298: ... 844 22 098 22 352 22 606 0 9 22 860 23 114 23 368 23 622 23 876 24 130 24 384 24 638 24 892 25 146 INCHES 0 00 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 MILLIMETER 0 2 54 5 08 7 62 10 16 12 70 15 24 17 78 20 32 22 86 1 25 40 27 94 30 48 33 02 35 56 38 10 40 64 43 18 45 72 48 26 2 50 80 53 34 55 88 58 42 60 96 63 50 66 04 68 58 71 12 73 66 3 76 20 78 74 81 28 83 82 86 36 88 90 91 44 93 98 96 52 99 06 4 ...

Page 299: ... 859 7 32 0 218 5 556 23 32 0 718 18 256 15 64 0 234 5 953 47 64 0 734 18 653 1 4 0 250 6 350 3 4 0 750 19 050 17 64 0 265 6 746 49 64 0 765 19 446 9 32 0 281 7 143 25 32 0 781 19 843 19 64 0 296 7 540 51 64 0 796 20 240 5 16 0 312 7 937 13 16 0 812 20 637 21 64 0 328 8 334 53 64 0 828 21 034 11 32 0 343 8 731 27 32 0 843 21 431 23 64 0 359 9 128 55 64 0 859 21 828 3 8 0 375 9 525 7 8 0 875 22 225...

Page 300: ...3 117 4 41 7 43 45 4 19 4 3 26 6 2 8 37 98 6 63 3 82 115 6 41 1 42 43 6 18 9 2 28 4 3 3 38 100 4 62 8 81 113 8 40 6 41 41 8 18 3 1 30 2 3 9 39 102 2 62 2 80 112 0 40 0 40 40 0 17 8 0 32 0 4 4 40 104 0 61 7 79 110 2 39 4 39 38 2 17 2 1 33 8 5 0 41 105 8 61 1 78 108 4 38 9 38 36 4 16 7 2 35 6 5 6 42 107 6 60 6 77 106 6 38 3 37 34 6 16 1 3 37 4 6 1 43 109 4 60 0 76 104 8 37 8 36 32 8 15 6 4 39 2 6 7 ...

Page 301: ...316 4 92 2 198 388 4 26 1 79 174 2 48 3 119 246 2 70 6 159 318 2 92 8 199 390 2 26 7 80 176 0 48 9 120 248 0 71 1 160 320 0 93 3 200 392 0 27 2 81 177 8 49 4 121 249 8 71 7 161 321 8 93 9 201 393 8 27 8 82 179 6 50 0 122 251 6 72 2 162 323 6 94 4 202 395 6 28 3 83 181 4 50 6 123 253 4 72 8 163 325 3 95 0 203 397 4 28 9 84 183 2 51 1 124 255 2 73 3 164 327 2 95 6 204 399 2 29 4 85 185 0 51 7 125 25...

Page 302: ... 1 790 1454 0 115 0 239 462 2 201 7 395 743 0 312 8 595 1103 0 423 9 795 1463 0 115 6 240 464 0 204 4 400 752 0 315 6 600 1112 0 426 7 800 1472 0 116 1 241 465 8 207 2 405 761 0 318 3 605 1121 0 429 4 805 1481 0 116 7 242 467 6 210 0 410 770 0 321 1 610 1130 0 432 2 810 1490 0 117 2 243 469 4 212 8 415 779 0 323 9 615 1139 0 435 0 815 1499 0 117 8 244 471 2 215 6 420 788 0 326 7 620 1148 0 437 8 8...

Page 303: ... 0 535 0 995 1823 0 646 1 1195 2183 0 757 2 1395 2543 0 868 3 1595 2903 0 537 8 1000 1832 0 648 9 1200 2192 0 760 0 1400 2552 0 871 1 1600 2912 0 540 6 1005 1841 0 651 7 1205 2201 0 762 8 1405 2561 0 873 9 1605 2921 0 543 3 1010 1850 0 654 4 1210 2210 0 765 6 1410 2570 0 876 7 1610 2930 0 546 1 1015 1859 0 657 2 1215 2219 0 768 3 1415 2579 0 879 4 1615 2939 0 548 9 1020 1868 0 660 0 1220 2228 0 77...

Page 304: ... 0 979 4 1795 3263 0 1090 6 1995 3623 0 1201 7 2195 3983 0 1312 8 2395 4343 0 982 2 1800 3272 0 1093 6 2000 3632 0 1204 4 2200 3992 0 1315 6 2400 4352 0 985 0 1805 3281 0 1096 1 2005 3641 0 1207 2 2205 4001 0 1318 3 2405 4361 0 987 8 1810 3290 0 1098 9 2010 3650 0 1210 0 2210 4010 0 1321 1 2410 4370 0 990 6 1815 3299 0 1101 7 2015 3659 0 1212 8 2215 4019 0 1323 9 2415 4379 0 993 3 1820 3308 0 1104...

Page 305: ... 0 1435 0 2615 4739 0 1382 2 2520 4568 0 1410 0 2470 4658 0 1437 8 2620 4748 0 1385 0 2525 4577 0 1412 8 2575 4667 0 1440 6 2625 4757 0 1387 8 2530 4586 0 1415 6 2580 4676 0 1443 3 2630 4766 0 1390 6 2535 4595 0 1418 3 2585 4685 0 1446 1 2635 4775 0 1393 3 2540 4604 0 1421 1 2590 4694 0 1448 9 2640 4784 0 1396 1 2545 4613 0 1423 9 2595 4703 0 1451 7 2645 4793 0 Fahrenheit and Celsius Centigrade Te...

Page 306: ...4687 66 0 0330 31 0 1200 B 0 2380 31 64 0 4843 65 0 0350 1 8 0 1250 C 0 2420 1 2 0 5000 64 0 0360 30 0 1285 D 0 2460 33 64 0 5156 63 0 0370 29 0 1360 E 0 2500 17 32 0 5312 62 0 0380 28 0 1405 1 4 0 2500 35 64 0 5469 61 0 0390 9 64 0 1406 F 0 2750 9 16 0 5625 60 0 0400 27 0 1440 G 0 2610 37 64 0 5781 59 0 0410 26 0 1470 17 64 0 2656 19 32 0 5937 58 0 0420 25 0 1495 H 0 2660 39 64 0 6094 57 0 0430 2...

Page 307: ...3425 19 50 0 7677 1 10 0 0433 2 90 0 1142 5 80 0 2283 8 75 0 3445 20 00 0 7874 1 15 0 0453 3 00 0 1181 5 90 0 2323 8 80 0 3465 20 50 0 8071 1 20 0 0472 3 10 0 1220 6 00 0 2362 8 90 0 3504 21 00 0 8268 1 25 0 0492 3 20 0 1260 6 10 0 2401 9 00 0 3543 21 50 0 8465 1 30 0 0512 3 25 0 1280 6 20 0 2441 9 10 0 3583 22 00 0 8661 1 35 0 0531 3 30 0 1299 6 25 0 2461 9 20 0 3622 22 50 0 8858 1 40 0 0551 3 40...

Page 308: ...1669 10 24 0 1941 0 1944 10 32 0 1931 0 1934 12 24 0 2201 0 2204 12 28 0 2196 0 2199 1 4 20 0 2551 0 2555 1 4 28 0 2536 0 2540 5 16 18 0 3181 0 3185 5 16 24 0 3166 0 3170 3 8 16 0 3811 0 3815 3 8 24 0 3791 0 3795 7 16 14 0 4446 0 4450 7 16 20 0 4426 0 4430 1 2 13 0 5076 0 5080 1 2 20 0 5051 0 5055 9 16 12 0 5701 0 5705 9 16 18 0 5681 0 5685 5 8 11 0 6331 0 6335 5 8 18 0 6306 0 6310 3 4 10 0 7592 0...

Page 309: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER AIR CONDITIONING ...

Page 310: ...21 Title 21 List of Effective Pages 1 Aug 18 2001 21 Contents 1 Aug 18 2001 21 00 00 1 Aug 18 2001 21 20 00 1 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 21 21 00 201 Aug 18 2001 202 Aug 18 2001 21 40 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 21 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 311: ...eral 21 20 00 Page 201 Air Outlet Valve Removal Installation 21 20 00 Page 201 AVIONICS COOLING FAN MAINTENANCE PRACTICES 21 21 00 Page 201 Cooling Fan Removal Installation 21 40 00 Page 201 HEATING AND DEFROSTING MAINTENANCE PRACTICES 21 40 00 Page 201 General 21 40 00 Page 201 System Operation 21 40 00 Page 201 System Troubleshooting 21 40 00 Page 201 Heat Exchanger Removal Installation 21 40 00...

Page 312: ...all Type IVSealant GC 1900 Courtaulds Aerospace To seal shutoff valve to firewall 3 Definition A This chapter isdivided into sections to aid maintenance technicians inlocating information Consulting the Table of Contents will further assist in locating a particular subject A brief description of the sections follows 1 The section on fresh air distribution describes that portion of the system used ...

Page 313: ... air plenum and is distributed through the heated air distribution system 3 System Operation A The amount of fresh air entering the cabin can be controlled by any of the six air valves Rotating the air valve will vary the airflow from fully closed to fully open B Air flow into the cabin can also be controlled by the CABIN AIR control cable Pulling the control aft allows the maximum amount of fresh...

Page 314: ...nstallation A Remove Air Outlet Valve Refer to Figure 201 1 Remove retaining ring from air outlet valve 2 Remove upholstery panel Refer to Chapter 25 Interior Upholstery Maintenance Practices 3 Remove clamp securing ducting hose to air outlet valve adapter 4 Remove air outlet valve and adapter B Install Air Outlet Valve Refer to Figure 201 1 Install air outlet valve and valve adapter to ducting Se...

Page 315: ...SSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B1691 PLENUM CAP DUCT DUCT AIR OUTLET AIR INLET ASSEMBLY AIR DETAIL A PLENUM CAP Fresh Air Distribution Figure 201 Sheet 1 21 20 00 Page 202 Aug 18 2001 ...

Page 316: ...OMPANY MODEL 172 MAINTENANCE MANUAL B1692 FITTING SCOOP AIR VALVE OUTLET DUCT DETAIL B RIGHT SIDE SHOWN LEFT SIDE OPPOSITE DOOR ASSEMBLEY DETAIL C Fresh Air Distribution Figure 201 Sheet 2 21 20 00 Page 203 Aug 18 2001 ...

Page 317: ...lts securing cooling fan to firewall 4 Disconnect electrical connector from avionics cooling fan 5 Disconnect flexible ducts from cooling fan 6 Remove cooling fan from airplane B Install Cooling Fan Refer to Figure 201 1 Connect flexible ducts to cooling fan Secure using tie wraps 2 Connect electrical connector to cooling fan 3 Install cooling fan to firewall using existing hardware 4 Reconnect ne...

Page 318: ...IRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL ELECTRICAL CONNECTOR FLEXIBLE DUCT TO AVIONICS STACK FIREWALL AVIONICS COOLING FAN Avionics Cooling Fan Installation Figure 201 Sheet 1 21 21 00 Page 202 Aug 18 2001 ...

Page 319: ... must be repaired or replaced When checking controls ensure that valves respond freely to control movement that they move inthe correct direction and that they move through theirfull range of travel and seal properly Check that hoses are properly secured and replace hoses that are burned frayed or crushed B If fumes are detected in the cabin a thorough inspection of the exhaust system should be ac...

Page 320: ... MAINTENANCE MANUAL B B VALVE SEAT DETAIL A VALVE SPRING VALVE PLATE CONTROL ARM SCREW VALVE BODY DETAIL C VALVE GUIDE NOZZLE DEFROSTER HOSE C05141020 Heating and Defrosting installation Figure 201 Sheet 1 21 40 00 Page 202 Aug 18 2001 ...

Page 321: ...ewall 2 Secure CABIN HT control cable to backside of instrument panel using existing jam nut 3 Thread end of control cable through the clamp bolt 4 Tighten clamp bolt and test control cable to ensure full range of travel 5 When full range of travel has been established bend end of control cable around clamp bolt area 6 Install engine cowling Refer to Chapter 71 Cowling Maintenance Practices 7 Dist...

Page 322: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER AUTO FLIGHT ...

Page 323: ...ION SUBJECT PAGE DATE 22 Title 22 List of Effective Pages 1 22 Contents 1 Aug 18 2001 22 00 00 1 Aug 18 2001 22 10 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 206 Aug 18 2001 207 Aug 18 2001 208 Aug 18 2001 22 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 324: ...ENANCE PRACTICES 22 10 00 Page 201 General 22 10 00 Page 201 Roll Servo Removal Installation 22 10 00 Page 201 Pitch Servo Removal Installation 22 10 00 Page 201 Pitch Trim Servo Removal Installation 22 10 00 Page 205 Servo Inspection 22 10 00 Page 206 KAP 140 Autopilot Controller Removal Installation 22 10 00 Page 207 22 CONTENTS Page 1 Aug 18 2001 ...

Page 325: ...MPANY MODEL 172 MAINTENANCE MANUAL AUTO FLIGHT GENERAL 1 Scope and Definition A This chapter contains a single section which deals with removal and installation of the autopilot and roll servo 22 00 00 Page 1 Aug 18 2001 ...

Page 326: ...g is required upon reinstallation of the servo mount 3 Install roll servo cable on roll servo NOTE System rigging should be accomplished with aileron and bellcrank inneutral position NOTE Wrap cable around servo drum approximately 1 25 turns each direction from swaged ball drum ball detent facing inboard NOTE When installing cable guard ensure that the legs of the cable guard do not touch the cabl...

Page 327: ...SSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL NOTE CABLE GUARD LEG CABLES MUST NOT AILERON LOCATION OF DETAIL A A0000214 Autopilot Servo Installation Figure 201 Sheet 1 22 10 00 Page 202 Aug 18 2001 ...

Page 328: ...CH TRIM SERVO NOTE CABLES MUST NOT CONTACT CABLE GUARD LEGS CABLES LOCATION OF SWAGED BALL VIEW B B CABLE ELEVATOR CLAMP BLOCK BELLCRANK CABLE CABLE ASSY CLAMP BLOCK B DETAIL B A0000240 B0560T1018 B B0560T1019 Autopilot Servo Installation Figure 201 Sheet 2 22 10 00 Page 203 Aug 18 2001 ...

Page 329: ...DEL 172 MAINTENANCE MANUAL CABLE GUARD LEG CABLE GUARD NOTE VIEW C C NOTE CABLES MUST NOT CONTACT CABLE GUARD LEGS TURNBUCKLE CABLES DETAIL C A0000241 Autopilot Servo Installation Figure 201 Sheet 3 22 10 00 Page 204 Aug 18 2001 ...

Page 330: ...urnbuckle 4 Remove cable guard and cable 5 Remove bolts securing pitch trim servo to bracket assembly 6 Remove pitch trim servo from airplane B Install Pitch Trim Servo Refer to Figure 201 1 Position pitch trim servo to bracket assembly inthe install position and secure with bolts 2 Connect electrical connector to pitch trim servo NOTE Removal of servo mount requires disconnecting the servo cable ...

Page 331: ...e should be no dirt contamination or corrosion around the solenoid plunger This could impede the actuation of the solenoid b The release spring should pull the plunger out of the solenoid and against its stop freely and without hesitation With hands clear of the solenoid plunger and spring the pinion gear should spin with no interference from the clutch gears 3 Perform general inspection a Inspect...

Page 332: ... on face of autopilot controller 3 Pull autopilot controller aft and remove from mounting tray B Install Autopilot Controller Refer to Figure 202 1 Slide autopilot controller forward into mounting tray 2 Tighten mounting screw on face of autopilot controller 3 Test static system for leaks 4 Turn power ON to autopilot controller 5 Functionally test autopilot operation per manufacturer s instruction...

Page 333: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL AUTOPILOT LOCATION DETAIL A A0000215 KAP140 Autopilot Installation Figure 202 Sheet 1 22 10 00 Page 208 Aug 18 2001 ...

Page 334: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER COMMUNICATIONS ...

Page 335: ...3 Title 23 List of Effective Pages 1 Aug 18 2001 23 Contents 1 Aug 18 2001 23 00 00 1 Aug 18 2001 23 10 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 23 50 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 23 60 00 201 Aug 18 2001 202 Aug 18 2001 23 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 336: ...on 23 10 00 Page 201 AUDIO PANEL MAINTENANCE PRACTICES 23 50 00 Page 201 General 23 50 00 Page 201 General 23 50 00 Page 201 Audio Panel Removal Installation 23 50 00 Page 201 Intercom Jacks Removal Installation 23 50 00 Page 201 Marker Beacon Antenna Removal Installation 23 50 00 Page 204 STATIC WICKS MAINTENANCE PRACTICES 23 60 00 Page 201 General 23 60 00 Page 201 Tools and Equipment 23 60 00 P...

Page 337: ...hley Instruments Inc To check electrical bonding Instrument Division connections 28775 Aurora Rd Cleveland OH 44139 Megohmmeter Model 2850 Associated Research To check resistance of static Inc wicks 3773 W Belmont Ave Chicago IL 60618 3 Definition A Information contained in this chapter provides the basic procedures which can be accomplished at the flight line level such as removal and installatio...

Page 338: ...t back of mounting tray 2 Turn recessed mounting screw on face of Nav Com clockwise until Nav Com is secured to mounting tray 3 Place MASTER switch inthe BATT position and avionics master switch in the ON position 4 Turn Nav Com power ON and verify electronic display illuminates 5 Place Master Avionics and Nav Com switches in the OFF position 3 Antenna Removal Installation NOTE Antenna removal ins...

Page 339: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL DETAIL A 0585C1040 Figure 201 Sheet 1 23 1 0 00 Page 202 Aug 18 2001 ...

Page 340: ...SSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL SCREW WASHER COM ANTENNA GASKET FUSELAGE SKIN NUTPLATE DOUBLER ELECTRICAL CONNECTOR NAV COM Installation Figure 201 Sheet 2 23 10 00 Page 203 Aug 18 2001 ...

Page 341: ...cated between instrument panel and forward doorpost Refer to Chapter 25 Interior Upholstery Maintenance Practices 3 Loosen and remove jamnuts securing jacks to interior panel 4 Carefully label all wires to microphone jack small plug and headphone jack large plug 5 Cut wires near solder point at each jack B Install Pilot Front Passenger Intercom Jacks Refer to Figure 201 1 Remove all traces of old ...

Page 342: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B AUDIO PANEL LOCKING SCREW ...

Page 343: ...PANY MODEL 172 MAINTENANCE MANUAL B1697 CONSOLE TYPICAL JACK HEADPHONE JACK DETAIL C COAX CABLE CONNECTOR MARKER BEACON ANTENNA DETAIL D D0518T1035 Audio Panel Installation Figure 201 Sheet 2 23 50 00 Page 203 Aug 18 2001 ...

Page 344: ...nnect coax cable from antenna 5 Remove screws securing antenna to belly of fuselage NOTE Antenna may free fall to ground when last retaining screw is removed Use additional personnel to prevent antenna from striking ground B Install Marker Beacon Antenna Refer to Figure 201 1 Position marker beacon antenna to belly of fuselage 2 Secure to belly from inside of fuselage using existing hardware 3 Att...

Page 345: ...lane skin B Install Static Wick Refer to Figure 201 1 Clean surface of airplane skin where static wick will attach to skin Remove all traces of contaminants including paint primer using scotchbrite and P D 680 solvent 2 Secure static wick to airplane skin using rivets 3 Repaint at base of new wick if required 4 Rebalance control surfaces Refer to 1996 and On Single Engine Structural Repair Manual ...

Page 346: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL STATIC WICK SCREW SPACER SCREW NUT Static Discharger Installation Figure 201 Sheet 1 23 60 00 Page 202 Aug 18 2001 ...

Page 347: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER ELECTRICAL POWER ...

Page 348: ...20 00 101 Aug 18 2001 102 Aug 18 2001 103 Aug 18 2001 104 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 24 30 00 101 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 24 60 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 24 61 00 201 Aug 18 2001 202 Aug 18 2001 24 61 01 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 24 70 00 1 Aug 18 2001 2 Aug 18 2001 24 LIST OF EFFECT...

Page 349: ...y 24 30 00 Page 203 Testing the Battery 24 30 00 Page 203 POWER JUNCTION BOX MAINTENANCE PRACTICES 24 60 00 Page 201 General 24 60 00 Page 201 Power Junction Box Removal Installation 24 60 00 Page 201 Component Removal Installation 24 60 00 Page 201 CIRCUIT BREAKER MAINTENANCE PRACTICES 24 61 00 Page 201 General 24 61 00 Page 201 Circuit Breaker Removal Installation 24 61 00 Page 201 ESSENTIAL BUS...

Page 350: ...r This arrangement allows the battery to be on line without the alternator however operation of the alternator without the battery is not possible The battery switch when operated connects the battery contactor coil to ground so that the contacts close and powers the system with the battery only The alternator portion of the switch when activated applies positive voltage to the ACU and to the alte...

Page 351: ...cal Company vent drain tubes to battery 1509 Sublette case elbows St Louis MO 63110 Rubber Gloves Rubber Available Commercially Clean battery Apron and Protective Goggles Cleaning Cloth Available Commercially Clean battery Test Set TE03 Precision Airmotive Test J box Corporation 3220 100th Street Southwest E Everett WA 98204 NOTE Only test sets with a serial number of 1 through 800 and 1001 and up...

Page 352: ...t to ground Repair or replace B lead as necessary If no problem with B lead is found proceed to step 3 Short in alternator field winding STEP 3 Disconnect field wire from FLD terminal on alternator If circuit breaker no longer trips replace alternator Otherwise reinstall the field wire and proceed to step 4 Short in field wire STEP 4 Inspect field wire for short to ground between alternator and AC...

Page 353: ...reaker Engine running ALTERNATOR FIELD CIRCUIT Defective ACU STEP 1 Disconnect ACU BREAKER TRIPS WHEN connector in J box If circuit BATTERY AND ALTERNATOR breaker no longer trips replace SWITCHES ARE TURNED ON ACU Otherwise proceed to step DOES NOT TRIP WHEN ENGINE 2 ISNOT RUNNING Short between field wire and STEP 2 Look for short between alternator B lead field wire and alternator B lead Repair o...

Page 354: ... circuit and the other a numerical value in very high resistance usually greater than 1 Megaohm If using the resistance function and a setting on very high resistance greater than 1 Megaohm then the meter may show leakage although the diodes are fine Since the alternator has an internal capacitor readings taken with meters selected on resistance may be unstable If readings are not ok then replace ...

Page 355: ...running and alternator switch on check field voltage at FLD terminal of alternator Field voltage should be approximately 2 volts less than battery voltage If field voltage is ok replace alternator Otherwise proceed to step 6 Open in field wire STEP 6 If there is no voltage at FLD terminal check for open in field wire between alternator and ACU Repair or replace as necessary If nothing is found pro...

Page 356: ... airplane B Install Alternator Refer to Figure 201 1 Position alternator on mounting bracket and install mounting bolt and nut Do not tighten at this time 2 Place drive Micro V Belt on alternator pulley 3 Install adjusting bolt CAUTION ANY AIRPLANE WITH A NEW ALTERNATOR BELT INSTALLED INCLUDING NEW AIRPLANES BELT TENSION SHOULD BE RE CHECKED WITHIN THE FIRST 10 TO 25 HOURS OF OPERATION 4 Apply a t...

Page 357: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL ADJUSTING BOLT WASHER ALTERNATOR ASSEMBLY C BRACKET ASSEMBLY MOUNTING BOLT Alternator Installation Figure 201 Sheet 1 24 20 00 Page 202 Aug 18 2001 ...

Page 358: ...connection STEP 3 With master switch between battery terminal and master closed measure voltage at switch master switch terminal on bus bar contactor Normal indication is zero volts If voltage reads zero proceed to Step 4 If a voltage reading is otained check wiring between battery terminal and master switch Also check master switch Open coil on contactor STEP 4 Check continuity between battery te...

Page 359: ...stall the battery according to the preceding paragraph 7 Coat the battery terminals with petroleum jelly or an ignition spray product to reduce corrosion 4 Adding electrolyte or water to the battery CAUTION Do not add any type of battery rejuvenator to the electrolyte When acid has been spilled from a battery the acid balance may be adjusted by following instructions published by the Association o...

Page 360: ...RCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A BATTERY CABLE BATTERY GROUND CABLE BATTERY BATTERY TRAY FIREWALL DETAIL A 0510T1007 A0518T1023 Battery Installation Figure 201 Sheet 1 24 30 00 Page 202 Aug 18 2001 ...

Page 361: ...under this system must be 48 to 72 hours This long slow charge will tend to equalize all cells and bring the battery back to a useful state Failure to utilize this charge can leave the battery with one or more weak cells which will drastically reduce service life C When activating new dry charged batteries ensure that the proper strength of electrolyte is used The specific gravity of this electrol...

Page 362: ...uilt in temperature compensation chart and a thermometer If this type tester is used disregard this chart B If the specific gravity indicates the battery is not fully charged the battery should be charged at approximately 28 volts for 30 minutes or until the battery voltage rises to 28 volts Refer to charging the battery for battery charging instructions for acompletely discharged battery After ch...

Page 363: ...box B Install Power Junction Box Refer to Figure 201 1 Position power junction box on firewall and secure with screws 2 Connect power junction box electrical connectors 3 Connect battery 3 Component Removal Installation A General Precautions and Notes CAUTION ENSURE ALL ELECTRICAL POWER IS REMOVED FROM AIRPLANE AND BATTERY IS DISCONNECTED BEFORE WORKING ON JUNCTION BOX COMPONENTS 1 Individual comp...

Page 364: ...FT COMPANY MODEL 172 MAINTENANCE MANUAL A FIREWALL WASHER POWER JUNCTION BOX EXTERNAL POWER RECEPTACLE A DETAIL A 0510T1007 A0558T1001 Power Junction Box Installation Figure 201 Sheet 1 24 60 00 Page 202 Aug 18 2001 ...

Page 365: ...172 MAINTENANCE MANUAL B1700 ALTERNATOR CONTROL UNIT ALTERNATOR SPARE FUSE CURRENT BATTERY RELAY K3 ELECTRICAL CONNECTORS J1 AND J2 VIEW A A 0558T1002 Power Junction Box Installation Figure 201 Sheet 2 24 60 00 Page 203 Aug 18 2001 ...

Page 366: ...it Breaker Refer to Figure 201 1 Disconnect battery cables 2 In the cockpit cabin area remove screws securing circuit breaker panel to lower instrument panel 3 Disconnect and label wires from circuit breaker 4 Remove nut and washer securing circuit breaker to circuit breaker panel 5 Remove circuit breaker B Install Circuit Breaker Refer to Figure 201 1 Place circuit breaker incircuit breaker panel...

Page 367: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL BREAKER CIRCUIT BREAKER 24 61 00 Page 202 Aug 18 2001 Aug 18 2001 ...

Page 368: ...low A Inspect Essential Bus Diodes Refer to Figure 201 CAUTION DO NOT REMOVE ANY FUSES WITH BATTERY MASTER SWITCH ON 1 Position Battery Master Taxi Light and Landing Light switches to the ON position 2 Verify operation of Landing and Taxi Lights 3 Position Battery Master Taxi Light and Landing Light switches to the OFF position 4 Remove screws securing power junction box cover and remove cover 5 R...

Page 369: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL DETAIL A DIODE DIODE VIEW A A VIEW LOOKING AFT Essential Bus Diode Inspection Figure 201 Sheet 1 24 61 01 Page 202 Aug 18 2001 ...

Page 370: ...g Light switches to the ON position 7 If BOTH Landing Lights and Taxi Lights illuminate then replace both Essential Bus Diodes 8 Position Battery Master Taxi Light and Landing Light switches to the OFF position 9 Reinstall the bus wire back to the circuit breaker 1 terminal using the same hex nut and washer that was removed and torque nut to 20 to 25 inch pounds 10 Remove hex nut and lock washer t...

Page 371: ... w o GS Transmit mode 2 4 2 4 ADF Receiver 0 5 0 5 Annunciator engine off 0 1 0 1 Beacon 50 duty cycle 1 2 1 3 Courtesy Lights left right aft cabin 1 7 1 8 Flap Motor 1 1 1 2 Fuel Pump 2 0 2 0 Glareshield Light 0 9 0 9 GPS KLN 89 89B 1 0 1 0 GPS KLN 94 1 1 1 2 Landing Light 8 0 8 8 Nav Map Light 2 3 2 4 Panel Lights 0 8 0 9 Pedestal Light 0 1 0 1 Pitot Heat 5 3 6 2 Radio Lights 0 5 0 6 Left Right ...

Page 372: ...IRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Component Draw at 24 0 VDC Draw at 28 0 VDC In Amps In Amps Power Port Current input at 10 Amp 5 4 5 5 output Storm Scope WX 500 0 9 0 9 24 70 00 Page 2 Aug 18 2001 ...

Page 373: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER EQUIPMENT FURNISHINGS ...

Page 374: ...2001 204 Aug 18 2001 25 10 04 201 Aug 18 2001 202 Aug 18 2001 25 11 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 25 21 00 201 Aug 18 2001 202 Aug 18 2001 25 22 00 201 Feb 15 2002 202 Feb 15 2002 203 Feb 15 2002 204 Feb 15 2002 205 Feb 15 2002 206 Feb 15 2002 25 50 00 201 Aug 18 2001 202 Aug 18 2001 25 60 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 25 80...

Page 375: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 376: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 377: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 378: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 379: ...REAR SEAT MAINTENANCE PRACTICES 25 21 00 Page 201 General 25 21 00 Page 201 Rear Seat Removal Installation 25 21 00 Page 201 INTERIOR UPHOLSTERY MAINTENANCE PRACTICES 25 22 00 Page 201 General 25 22 00 Page 201 Cabin Panels Removal Installation 25 22 00 Page 201 Door Panels Carpet and Rubber Mat Removal Installation 25 22 00 Page 201 CARGO TIE DOWNS MAINTENANCE PRACTICES 25 50 00 Page 201 General ...

Page 380: ...6207 structure Carson CA 3 Definition A The chapter isdivided into sections to aid maintenance personnel inlocating information Consulting the Table of Contents will further assist inlocating a particular subject A brief definition of the subjects and sections incorporated in this chapter is as follows 1 The section on Flight Compartment covers those items installed in the cabin area including sea...

Page 381: ...er clears seat track 3 Move seat backward on seat track until rear rollers clear seat track 4 Remove seat from airplane B Install Seats Refer to Figure 201 1 Position rear roller of seat on seat track 2 Move seat forward on seat track until front roller can be installed on seat track 3 Install seat stops to front and rear of seat track WARNING IMPROPERLY INSTALLED SEAT STOPS COULD ALLOW SEAT MOVEM...

Page 382: ...T COMPANY MODEL 172 MAINTENANCE MANUAL HEAD REST HARNESS GUIDE SEAT BACK PAN BACK HEIGHT ADJUSTMENT CRANK SEAT LOCK BASE ASSEMBLY DETAIL A A0519T1036 Seat Installation Figure 201 Sheet 1 25 10 00 Page 202 Aug 18 2001 ...

Page 383: ... MODEL 172 MAINTENANCE MANUAL B SPACERS DETAIL E WASHERS WASHERS FORWARD AFT FOOT HALVES BUSHING A0519T1036 DETAIL C B0519T1037 DETAIL D C0519T1038 D0519T1039 Seat Installation Figure 201 Sheet 2 25 10 00 Page 203 Aug 18 2001 ...

Page 384: ...ELY IMPORTANT THAT PILOT S SEAT STOPS ARE INSTALLED SINCE ACCELERATION AND DECELERATION COULD POSSIBLY PERMIT SEAT TO BECOME DISENGAGED FROM SEAT RAILS AND CREATE A HAZARDOUS SITUATION ESPECIALLY DURING TAKEOFF AND LANDING Seat Stop Installation Figure 202 Sheet 1 25 10 00 Page 204 Aug 18 2001 ...

Page 385: ...nstallation of the map compartment 2 Map Compartment Removal Installation A Remove Map Compartment Refer to Figure 201 1 Remove interior screws securing map compartment to instrument panel structure B Install Map Compartment Refer to Figure 201 1 Place map compartment in position and secure to instrument panel structure using screws 25 10 04 Page 201 Aug 18 2001 ...

Page 386: ...NA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL MAP COMPARTMENT SCREWS PIANO HINGE HINGE MAP WIRE COMPARTMENT CLOSURE 05193003 Map Compartment Installation Figure 201 Sheet 1 25 10 04 Page 202 Aug 18 2001 ...

Page 387: ...l locations A Remove Restraints Refer to Figure 201 1 Remove access covers if installed to gain access to the restraint assembly attaching hardware 2 Remove nuts bolts washers and spacers securing restraint assemblies to fuselage or to seats 3 Remove assemblies from airplane B Install Restraints Refer to Figure 201 1 Install restraint assemblies to fuselage or to seat Ensure spacers if installed a...

Page 388: ...ODEL 172 MAINTENANCE MANUAL PLATE BRACKET WASHER BOLT A PLUG BUTTON BOLT WASHERS B NUT DETAIL D D BOLT DETAIL C DETAIL A C A109 C0519T1047 Seat Belts and Restraints Installation Figure 201 Sheet 1 25 11 00 Page 202 Aug 18 2001 ...

Page 389: ...A AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL BOLT NUT DETAIL H ASSEMBLY H DETAIL E WASHER A108 G0519T1049 H1219T1003 Seat Belts and Restraints Installation Figure 201 Sheet 2 25 11 00 Page 203 Aug 18 2001 ...

Page 390: ...r removal and installation of the rear seat 2 Rear Seat Removal Installation A Remove Rear Seat Refer to Figure 201 1 Remove bolts and washers securing seat frame to fuselage 2 Remove seat from airplane B Install Rear Seat Refer to Figure 201 1 Install seat to fuselage and secure using bolts and washers 25 21 00 Page 201 Aug 18 2001 ...

Page 391: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL HARNESS SEAT BACK BASE B WASHER DETAIL A ROD SEAT BACK ADJUSTMENT HANDLE Aft Bench Seat Installation Figure 201 Sheet 1 25 21 00 Page 202 Aug 18 2001 ...

Page 392: ...s are typically attached to fuselage structure using screws Refer to Figure 201 for an exploded view of the interior panels headliner and overhead console 3 Door Panels Carpet and Rubber Mat Removal Installation A Cabin door panels are typically attached to the fuselage and door structure using small screws Carpet and rubber mats are attached to the floorboard using Velcro Refer to Figure 202 for ...

Page 393: ... L eeLa4S LO aJn6 30 13NVd HOO VOVJL l3a 13NVd 3G ln0O3SO ...

Page 394: ...MPANY MODEL 172 MAINTENANCE MANUAL B1705 ELECTRICAL CONNECTOR LIGHT LIGHT SWITCH OVERHEAD CONSOLE DETAIL C C0519T1050 Cabin Interior Trim And Overhead Console Installation Figure 201 Sheet 2 25 22 00 Page 203 Feb 15 2002 ...

Page 395: ... DOORPOST MOLDING GRILL COVER DOORPOST MOLDING DETAIL D LEFT SIDE SHOWN RIGHT SIDE OPPOSITE 172080984 THRU 172081074 AND 172S087704 THRU 172S08908 D0719T1012 Cabin Interior Trim And Overhead Console Installation Figure 201 Sheet 3 25 22 00 Page 204 Feb 15 2002 ...

Page 396: ... PANEL DOOR PANEL FORWARD SIDE PANEL VIEW A A ACCENT TRIM FORWARD SIDE PANEL DOOR PANEL REAR PANEL oVIEW B B 0510T1007 AA0519T1042 ACCENT TRIM BB0519T1042 Cabin Side Panel And Floorboard Upholstery Installation Figure 202 Sheet 1 25 22 00 Page 205 Feb 15 2002 ...

Page 397: ...3i1V d di nos IVnNVA 30NVN31NIVIAI ...

Page 398: ...Cargo tie downs are provided for the airplane to accommodate a variety of loading positions These tie downs are secured directly to the floorboard through nutplates or indirectly to the floorboard through seat rails Refer to Figure 201 for an illustration of these tie downs 25 50 00 Page 201 Aug 18 2001 ...

Page 399: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CARGO TIE DOWN RING CARGO TIE DOWN LUG SLIDE ASSEMBLY SEAT RAIL Cargo Tie Downs Installation Figure 201 Sheet 1 25 50 00 Page 202 Aug 18 2001 ...

Page 400: ...ONNECTOR FROM THE ELT TRANSMITTER BEFORE PERFORMING AIRCRAFT MAINTENANCE IN AREA OF THE PANEL REMOTE MOUNTED SWITCH FAILURE TO REMOVE THE CONNECTOR COULD CAUSE INADVERTENT BLOWING OF THE ELT S INTERNAL FUSE A Remove Switch Refer to Figure 201 1 Ensure all electrical power to the airplane is off 2 Gain access to backside of remote mounted switch Compress locking tabs on either side of switch and at...

Page 401: ...NG SKIN DOUBLER ANTENNA ANCHOR MASTER SWITCH REMOTE CONNECTOR TO REMOTE MOUNTED SWITCH TRANSMITTER BATTERY PACK BASE PLATE NEOPRENE WASHER ATTACH STRAP MOUNTING BRACKET DETAIL A Emergency Locator Transmitter Installation Figure 201 Sheet 1 25 60 00 Page 202 Aug 18 2001 ...

Page 402: ...RCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL DETAIL B REMOTE MOUNTED SWITCH T 0 T RESET TOTAL HOURS DETAIL C B0585C1040 Emergency Locator Transmitter Installation Figure 201 Sheet 2 25 60 00 Page 203 Aug 18 2001 ...

Page 403: ...e date should be noted on switch nameplate on side of unit and in instruction nameplate on top of unit 4 Install transmitter to airplane 6 Emergency Locator Transmitter Test A Operational Test Using Control Tower Monitoring 1 Request permission from control tower and or flight service station to test emergency locator transmitter system 2 Activate emergency locator transmitter system by placing re...

Page 404: ...ed suspect blown internal PICO fuse 5 If signal is not detected suspect defective transmitter WARNING REMOVE REMOTE CONNECTOR FROM ELT BEFORE PERFORMING AIRCRAFT MAINTENANCE INAREA OFTHE PANEL REMOTE MOUNTED SWITCH FAILURE TO REMOVE THE CONNECTOR COULD CAUSE INADVERTENT BLOWING OF THE ELT S INTERNAL FUSE D G Switch Operation Check 1 Remove transmitter from airplane 2 Hold transmitter firmly inone ...

Page 405: ...e area This material is glued into place using spray adhesive Anytime old material is being replaced care should be taken to ensure all traces are removed from fuselage skin before reapplication For a list of spray adhesives refer to Equipment Furnishing General B For an illustration of soundproofing and insulation locations refer to Figure 201 and Figure 202 25 80 00 Page 201 Aug 18 2001 ...

Page 406: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 05191029 Soundproofing Installation Figure 201 Sheet 1 25 80 00 Page 202 Aug 18 2001 ...

Page 407: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 05191030 25 80 00 Page 203 ...

Page 408: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER FIRE PROTECTION ...

Page 409: ... MANUAL LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 26 Title 26 List of Effective Pages 1 Aug 18 2001 26 Contents 1 Aug 18 2001 26 00 00 1 Aug 18 2001 26 20 00 1 Aug 18 2001 2 Aug 18 2001 26 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 410: ...NTENANCE MANUAL CONTENTS FIRE PROTECTION GENERAL 26 00 00 Page 1 Scope and Definition 26 00 00 Page 1 HAND FIRE EXTINGUISHER DESCRIPTION AND OPERATION 26 20 00 Page 1 Description and Operation 26 20 00 Page 1 26 CONTENTS Page 1 Aug 18 2001 ...

Page 411: ... COMPANY MODEL 172 MAINTENANCE MANUAL FIRE PROTECTION GENERAL 1 Scope and Definition A This chapter contains a single section which describes the portable fire extinguisher used inthe cabin 26 00 00 Page 1 Aug 18 2001 ...

Page 412: ...the event of a fire The extinguishing agent is Halon 1211 and may be used on solid combustible electrical or liquid fires Servicing of the extinguisher can be handled by most fire equipment dealers The fire extinguisher is mounted within a quick release clamp type bracket assembly Refer to Figure 1 2 Operation A For operation of the fire extinguisher refer to Section 7 of the Pilot s Operating Han...

Page 413: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A COPILOTSEAT FIRE EXTINGUISHER DETAIL A MOUNTING BRACKET Fire Extinguisher Installation Figure 1 Sheet 1 26 20 00 Page 2 Aug 18 2001 ...

Page 414: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER FLIGHT CONTROLS ...

Page 415: ...01 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 27 30 00 101 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 27 31 00 101 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 206 Aug 18 2001 207 Aug 18 2001 208 Aug 18 2001 209 Aug 18 2001 210 Aug 18 2001 211 Aug 18 2001 27 50 00 101 Aug 18 2001 10...

Page 416: ...eshooting 27 30 00 Page 101 ELEVATOR CONTROL SYSTEM MAINTENANCE PRACTICES 27 30 00 Page 201 General 27 30 00 Page 201 Forward Elevator Bellcrank Removal Installation 27 30 00 Page 201 Aft Elevator Bellcrank Removal Installation 27 30 00 Page 201 Elevator Removal Installation 27 30 00 Page 201 Elevator Control Adjustment Test 27 30 00 Page 204 ELEVATOR TRIM CONTROL TROUBLESHOOTING 27 30 00 Page 101...

Page 417: ...FLAP FOLLOW UP AND INDICATING SYSTEM MAINTENANCE PRACTICES 27 51 00 Page 201 Description and Operation 27 51 00 Page 201 Follow Up and Indicating System Removal Installation 27 51 00 Page 201 System Rigging 27 51 00 Page 201 27 CONTENTS Page 2 Aug 18 2001 ...

Page 418: ...0 Polyurethane Tape Y8761 3M To prevent flap chafing 3M Center Minneapolis MN 55144 3 Definition A This chapter is divided into sections and subsections to assist maintenance personnel in locating specific systems and information The following is a brief description of each section For locating information within the chapter refer to the Table of Contents at the beginning of the chapter 1 The aile...

Page 419: ...y which requires that the cable be bent ina loop to confirm broken wires Loosen or remove cable to allow it to be bent in a loop as shown While rotating cable inspect bent area for broken wires 2 Wire breakage criteria for cables inflap aileron rudder and elevator systems are as follows a Individual broken wires at random locations are acceptable in primary and secondary control cables when there ...

Page 420: ...CLOTH ALONG CABLE BROKEN WIRE DETECTED VISUALLY WHEN CABLE WAS REMOVED AND BENT DO NOT BEND INTO LOOP SMALLER THAN 50 CABLE DIAMETERS NORMAL TECHNIQUE FOR BENDING CABLE AND CHECKING FOR BROKEN WIRES 5561C1119 Cable Broken Wire Examination Figure 201 Sheet 1 27 00 01 Page 202 Aug 18 2001 ...

Page 421: ...en properly and safety Rusty chain or chain binding with Replace chain or defective parts sprocket CONTROL WHEELS Improper adjustment of chains or Adjust in accordance with Aileron NOT LEVEL WITH cables With control wheel centered Control System Maintenance AILERONS NEUTRAL aileron bellcrank stop bushing should Practices Adjustment Test be centered inslot both left and right bellcranks Improper ad...

Page 422: ...move bolts attaching control wheel tubes to universal joints 12 Remove bolt attaching push pull tube to control yoke 13 Remove pivot bolt from base of control yoke and carefully work control yoke out from under right hand side of instrument panel B Install Control Yoke Refer to Figure 202 1 Place control yoke inposition under instrument panel 2 Secure control yoke to structure with pivot bolt 3 Co...

Page 423: ...NY MODEL 172 MAINTENANCE MANUAL REFER TO FIGURE 204 REFER TO FIGURE 203 DETAIL C DETAIL K DETAIL J DETAIL G 051 0T1007 A0561 4001 F0561C1006 G0561C1010 Aileron Control System Figure 201 Sheet 1 27 10 00 Page 202 Aug 18 2001 ...

Page 424: ...SNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A CONTROL LATEST REVSION BUSHING BEARING SHAFT CONTROL SECONDARY YOKE SECONDARY CABLE TURNBUCKLE PRIMARY CABLE SPACER TURNBUCKLE Control Yoke Installation ...

Page 425: ... TURNBUCKLE PIVOT BOLT BOLT PIVOT BOLT STOP BUSHING SPACER CARRY THROUGH CABLE SPACER DIRECT CABLE BRASS WASHER BELLCRANK LOWER WING CHANNEL SKIN DETAIL A LEFT SIDE SHOWN A05613001 RIGHT SIDE TYPICAL A05613002 Aileron Bellcrank Installation Figure 203 Sheet 1 27 10 00 Page 204 Aug 18 2001 ...

Page 426: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL I B223 HINGE PIN DETAIL A AILERON HINGE Aileron Installation Figure 204 Sheet 1 27 10 00 Page 205 Aug 18 2001 ...

Page 427: ...ety turnbuckle Refer to Chapter 20 Safetying Maintenance Practices 5 Adjustment Test A Rig Aileron Cables 1 Verify primary cable is inaft groove of cable drum and wrapped once around drum The primary cable lock is installed at bottom of drum and direct cable lock is installed at top 2 With control wheels neutral ensure that chain ends are approximately equally spaced from center of sprockets 3 Kee...

Page 428: ...moval Installation A Cables And Pulleys Removal 1 Remove access plates wing root fairings and upholstery as required 2 Disconnect cables from aileron bellcranks and remove cable guards and pulleys as necessary to work cables free of aircraft NOTE To ease routing of cables a length of wire may be attached to end of cable before being withdrawn from aircraft Leave wire in place routed through struct...

Page 429: ...rrectly over pulleys Binding broken or defective pulleys or Replace defective pulleys and cable guards install guards properly Pedal bars need lubrication Lubricate as required Defective rudder bar bearings If lubrication fails to eliminate binding replace bearing blocks Defective rudder hinge bushings Replace defective bushings Clevis bolts too tight Readjust to eliminate binding Steering rods no...

Page 430: ...occurs A few drops of 1 Position rudder bars inarea below instrument panel and secure bearing blocks with bolts 2 Reconnect cables return springs trim bungee and steering tubes to rudder bars 3 Set distance from pivot shaft to firewall at 6 50 inches 4 Install rudder pedals and brake links 5 Connect parking brake cables at master cylinders 6 Connect master cylinders at pilot rudder pedals 7 Instal...

Page 431: ...172 MAINTENANCE MANUAL RIGHT REAR CABLE CABLE PIVOT SHAFT CABLE FIREWALL 6 50 INCHE AFT RUDDER BA BEARING BLOCK SINGLE RETURN SPRIN MASTER DETAIL B BRACKET Rudder Control Installation Figure 201 Sheet 1 27 20 00 Page 202 Aug 18 2001 ...

Page 432: ...UAL ANTI RATTLE SPACER CABLE SPACER GUARD BRAKE LINK DETAIL D TURNBUCKLE DETAIL J PULLEY BRAKE TORQUE TUBE DETAIL E DETAIL H BELLCRANK RUDDER BAR SHACKLE E05623003 K0561C1013 Rudder Control Installation Figure 201 Sheet 2 27 20 00 Page 203 Aug 18 2001 ...

Page 433: ...o align rudder and pedals inneutral position to 6 50 inches from firewall to pedal pivot shafts Cable tension is automatically set by return springs on the rudder bar NOTE Due to thickness of insulation of firewall it is recommended that a piece of 0 0625 inch welding rod be ground to asharp point and notched at the 6 50 inch dimension Pierce insulation on firewall and use notch to measure proper ...

Page 434: ...1 ESTABLISHING NEUTRAL STEP 2 MEASURING POSITION OF RUDDER RUDDER TRAVEL RUDDER 5 29 INCH TO 5 91 INCH BLOCK RUDDER HALF WIRE POINTER THE DISTANCE BETWEEN STRAIGHTEDGES 05621009 05621009 Rudder Travel Adjustment Figure 202 Sheet 1 27 20 00 Page 205 Aug 18 2001 ...

Page 435: ...ve pulleys Route cables correctly over pulleys Nylon bearing on instrument panel Disconnect universal joint and binding check for binding Replace bearing if binding is felt Defective control yoke pivot bearing Disconnect elevator push pull tube at lower end of control yoke and check that control yoke moves freely Replace bearing iffound defective Defective elevator hinges Move elevators by hand ch...

Page 436: ...and re rig system Refer to Elevator Control Adjustment Test 4 Install floorboard access panels Refer to Chapter 6 Access Inspection Plates Description and Operation 5 Install seats and carpet Refer to Chapter 25 Front Seats Maintenance Practices and Interior Upholstery Maintenance Practices 3 Aft Elevator Bellcrank Removal Installation A Remove Aft Elevator Bellcrank Refer to Figure 201 1 Remove r...

Page 437: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL BELLCRANK PUSH PULL TUBE TURNBUCKLE A05633002 D05631015 E05631003 Elevator Control System Figure 201 Sheet 1 27 30 00 Page 202 Aug 18 2001 ...

Page 438: ... A BOLT JAMNU G ELEVATOR TIP ELEVATOR TRIM TAB NOTE 2 A NOTE 2 ELEVATOR NOTE 1 INSTALL UPPER BOLT WITH HEAD TO THE RIGHT AND LOWER BOLT WITH HEAD TO THE LEFT THE CABLE END CLEVISES MUST BE FREE TO SWIVEL NOTE 2 DO NOT PAINT CABLE TERMINALS D BOLTS OR ENDS OF ELEVATOR BELL CRANK BOLT SCREW C05631007 Elevator Installation Figure 202 Sheet 1 27 30 00 Page 203 Aug 18 2001 ...

Page 439: ...tom of the stabilizer 3 Holding elevators inneutral position adjust turnbuckles equally to obtain 30 pounds 10 or 10 pounds of cables tension 4 Mount an inclinometer on elevator and keeping elevator streamlined with stabilizer set inclinometer to 0 degrees 5 Remove control column neutral rigging tool and adjust travel stop bolts to range of travel specified inChapter 6 Airplane Dimensions and Spec...

Page 440: ...ROL COLUMN A SUPPORT 0 46 INCH 0 62 INCH 0 19 INCH RADIUS TYPICAL 0 35 INCH RADIUS DETAIL A NOTE FABRICATE FROM 0 125 INCH STEEL PLATE AND 0 209 INCH DIAMETER DRILL ROD ACCORDING TO DIMENSIONS SHOWN 05601005 A0560C1004 Control Column Neutral Rigging Tool Figure 203 Sheet 1 27 30 00 Page 205 Aug 18 2001 ...

Page 441: ...ective trim tab actuator Remove chain from actuator sprocket and operate actuator manually Replace actuator if defective Rusty chain Replace rusty chain Damaged sprocket Replace damaged sprocket Bent sprocket shaft Observe motion of sprockets Replace bent sprocket shaft LOST MOTION Cable tension too low Adjust tension from 15 to 20 BETWEEN CONTROL foot Lbs at average temperature WHEEL AND TRIM for...

Page 442: ...hrough access opening B Install Trim Tab Actuator Refer to Figure 201 and Figure 202 1 Place actuator in position and attach actuator clamps to bracket using screws 2 Install chain to actuator sprocket 3 Install chain guard 4 Install access plate 320AB Refer to Chapter 6 Access Inspection Plates Description and Operation 5 At the elevator hinge gap connect push pull channel to actuator 6 Rig trim ...

Page 443: ...AL F D B DETAIL L AFT DETAIL M LEFT CABLE RIGHT FORWARD RIGHT CABLE AFT DETAILB DETAIL K CABLE DETAIL J E DETAIL P F05633001 NOTE SAFETY WIRE ROLL PIN FORWARD R05631 001 Elevator Trim Tab Control System Figure 201 Sheet 1 27 31 00 Page 202 Aug 18 2001 ...

Page 444: ...Y MODEL 172 MAINTENANCE MANUAL TAB UP TAB UP TAB DOWN TAB UP TAB UP DETAIL N TAB DOWN TAB UP DETAIL H C05631017 E05631017 H05631017 N05631017 Elevator Trim Tab Control System Figure 201 Sheet 2 27 31 00 Page 203 Aug 18 2001 ...

Page 445: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL ACTUATOR CHAIN GUARD DETAIL A A05633001 Elevator Trim Tab Actuator Installation Figure 202 Sheet 1 27 31 00 Page 204 Aug 18 2001 ...

Page 446: ...72 MAINTENANCE MANUAL C ACTUATOR ASSEMBLY THREADED ROD END DETAIL A HOUSING RETAINING RING BEARING COLLAR GROOVE PIN DETAIL B Elevator Trim Tab Actuator Cleaning Inspection and Repair Figure 203 Sheet 1 27 31 00 Page 205 Aug 18 2001 ...

Page 447: ...NTENANCE MANUAL TRIM TAB DETAIL C HINGE POINT TRAILING EDGE FREE PLAY UP NEUTRAL POSITION FREE PLAY DOWN TOTAL FREE PLAY C0563C1012 Elevator Trim Tab Actuator Cleaning Inspection and Repair Figure 203 Sheet 2 27 31 00 Page 206 Aug 18 2001 ...

Page 448: ...and out smoothly with no indication of binding 4 Trim Tab Actuator Cleaning Overhaul Inspection and Repair A Clean Inspect and Repair Trim Tab Actuator Refer to Figure 203 1 Do not remove bearing from threaded rod end unless replacement of bearing is necessary 2 Clean all component parts except bearing by washing in Stoddard solvent or equivalent Do not clean sealed bearing 3 Inspect all component...

Page 449: ... threaded rod end is out of tolerance and must be replaced 6 Trim Tab Control Wheel Removal Installation A Remove Trim Tab Control Wheel Refer to Figure 204 1 Relieve cable tension at turnbuckle 2 Remove pedestal cover 3 Remove screws attaching control wheel retainer 4 Remove retainer and pointer using care not to drop trim control wheel B Install Trim Tab Control Wheel Refer to Figure 204 1 Insta...

Page 450: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL PEDESTAL RETAINER TRIM FORWARD REAR CHAIN CHAIN DETAIL A Elevator Trim Tab Wheel Installation Figure 204 Sheet 1 27 31 00 Page 209 Aug 18 2001 ...

Page 451: ...STOP BLOCK 1 TURNBUCKLE STOP BLOCK 4 CABLE B STOP BLOCK 2 STOP BLOCK 3 TURNBUCKLE CABLE A STOP BLOCK 2 CABLE B STOP BLOCK 1 STOP BLOCK 3 CONFIGURATION WITH OPTIONAL DUAL AXIS AUTOPILOT Elevator Trim Tab Travel Adjustment Figure 205 Sheet 1 27 31 00 Page 210 Aug 18 2001 ...

Page 452: ...mits of travel 2 Position observer at bottom aft access opening intailcone Apply power to the aircraft and run electric trim to full nose up position until the observer notices clutch slippage With servo clutch still slipping apply an additional 1 4 turn of the manual trim wheel nose up test load condition 3 Inthis condition observer needs to verify that the stop blocks do not slip on the trim tab...

Page 453: ... and replace transmission if defective Defective limit switch Check continuity of switches Replace switches found defective BINDING IN SYSTEM Cables not riding on pulleys Check visually Route cables AS FLAPS ARE correctly over pulleys RAISED AND LOWERED Bind in drive pulleys Check drive pulleys in motion Replace drive pulleys found defective Broken or binding pulleys Check pulleys for free rotatio...

Page 454: ...of switches Replace switches found defective FLAPS FAIL TO Defective or disconnected flaps UP Check continuity of switch RETRACT operating switch Connect or replace switch FLAPS FAIL TO Defective or disconnected flaps DOWN Check continuity of switch EXTEND operating switch Connect or replace switch 27 50 00 Page 102 Aug 18 2001 ...

Page 455: ...o Chapter 6 Access Inspection Plates Description and Operation 4 Remove bolt securing actuating tube to drive pulley 5 Screw actuating tube intoward transmission as far as possible by hand 6 Remove bolt securing flap motor hinge to wing Retain brass washer between hinge and wing structure for use on reinstallation 7 Disconnect electrical connectors from motor and limit switches 8 Carefully work as...

Page 456: ...MANUAL FWD FLAP MOTOR AND TRANSMISSION DRIVE PULLEY DRIVE PULLEY SETSCREW FLAP MOTOR TURNBUCKLES ACTUATING LEFT TO LEFT TO RIGHT WING FLAP WING FLAP VIEW LOOKING DOWN 0525C1007 Flap System Schematic Figure 201 Sheet 1 27 50 00 Page 202 Aug 18 2001 ...

Page 457: ...RCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B D FLAP DRIVE PULLEY RETRACT CABLE DIRECT CABLE FLAP FLAP CONTROL CONTROL SPACER PULLEY BOLT Flap System Installation Figure 202 Sheet 1 27 50 00 Page 203 Aug 18 2001 ...

Page 458: ... 05 INCH WITH FLAPS IN FULL UP POSITION BOLT WING STRUCTURE BOLT ASSEMBLY SWITCH ACTUATING COLLAR SETSCREW DOWN LIMIT SWITCH DRIVE PULLEY ACTUATING TUBE RETRACT CABLE DIRECT CABLE DETAIL D AA05641007 Flap System Installation Figure 202 Sheet 2 27 50 00 Page 204 Aug 18 2001 ...

Page 459: ...2 MAINTENANCE MANUAL FLAP BRACKET DETAIL G NYLON PLUG BUTTON DETAIL E ACCESS PLATE SPACER BUSHING ROLLER ASSEMBLY SPACER FLAP INBOARD BUSHING E05251002 SUPPORT Flap System Installation Figure 202 Sheet 3 27 50 00 Page 205 Aug 18 2001 ...

Page 460: ...ove bolt attaching drive pulley to wing structure 8 Remove drive pulley through access opening without dropping bushing Retain brass washer from between drive pulley and wing structure for use during reinstallation B Install Flap Drive Pulley Refer to Figure 202 1 Install drive pulley and bushing through access opening install brass washer and secure to wing structure with bolt 2 Remove identifica...

Page 461: ...alled 14 With flaps up adjust turnbuckles to obtain 30 pounds 10 or 10 pounds tension on cables Adjust retract cable first 15 Disconnect push pull rod at left drive pulley 16 Run motor to extend flaps approximately 20 degrees and check tension on each flap cable 17 If necessary readjust turnbuckles to maintain 30 pounds 10 or 10 pounds tension on each cable and safety turnbuckles 18 Fully retract ...

Page 462: ...ing A Rigging Procedures Refer to Figure 201 NOTE The flaps must be properly rigged before rigging the follow up system 1 Disconnect spring from switch mounting arm Detail C 2 With flaps and flap lever in full UP position and holding flap position indication to a clearance of 0 03 inch maximum with top of instrument panel opening pull center cable of flap follow up cable Detail B to remove slack T...

Page 463: ...A AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B DETAIL A BELLCRANK GUIDE WASHER WASHER SPACER CLAMP DETAIL B A05641001 B05641003 Flap Indicator Installation Figure 201 Sheet 1 27 51 00 Page 202 Aug 18 2001 ...

Page 464: ...AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL SUPPORT SPACER WASHER SPACER OPERATING CLAMP BOLT INSULATOR SWITCH DETAIL C C05641002 Flap Indicator Installation Figure 201 Sheet 2 27 51 00 Page 203 Aug 18 2001 ...

Page 465: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER FUEL ...

Page 466: ... 15 2002 205 Feb 15 2002 206 Feb 15 2002 207 Feb 15 2002 208 Feb 15 2002 209 Feb 15 2002 210 Feb 15 2002 211 Feb 15 2002 212 Feb 15 2002 213 Feb 15 2002 214 Feb 15 2002 215 Feb 15 2002 216 Feb 15 2002 28 21 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 206 Aug 18 2001 207 Aug 18 2001 208 Aug 18 2001 209 Aug 18 2001 210 Aug 18 2001 211 Aug 18 2001 212 Aug 18 200...

Page 467: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 468: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 469: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 470: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 471: ...ment 28 20 00 Page 209 Electric Auxiliary Fuel Pump Removal Installation 28 20 00 Page 209 Fuel Bay Vents Adjustment Test 28 20 00 Page 209 Vented Fuel Filler Cap Adjustment Test 28 20 00 Page 210 Fuel Quantity Calibration 28 20 00 Page 210 Fuel Strainer Disassembly Cleaning Assembly 28 20 00 Page 211 FUEL BAY SEALING MAINTENANCE PRACTICES 28 21 00 Page 201 General 28 21 00 Page 201 Tools and Equi...

Page 472: ...ealant Type 1 Pro Seal 890 Courtaulds Aerospace To seal fuel tank area Class B 1 2 Class B 2 Sealant Type 1 PR 1440 Courtaulds Aerospace To seal fuel tank area Class B 1 2 Class B 2 Sealant Type 1 PR 1826 Courtaulds Aerospace To seal fuel tank area Class B Sealant Type 1 CS 3204 Flame Master Chem Seal Div To seal fuel tank area Class B 1 2 Class B 2 Sealant Type PR 1428 Courtaulds Aerospace To sea...

Page 473: ...uel Quantity 0580001 1 Cessna Aircraft Company To calibrate fuel quantity Test Box system 680 Loctite To improve the installation of the fuel strainer fittings 3 Definition A This chapter is divided into sections and subsections to assist maintenance personnel in locating specific systems and information For locating information within the chapter refer to the Table of Contents at the beginning of...

Page 474: ...eservoir tank an electrically driven auxiliary fuel pump a fuel shutoff valve and a fuel strainer B Components beyond the fuel strainer include the engine driven fuel pump the fuel injection servo and the fuel distribution valve These components are considered part of the powerplant and are covered inChapter 73 Fuel Injection System Description and Operation C A schematic of the entire fuel system...

Page 475: ...TOTAL 5 TOTAL DRAIN VALVE FUEL RESERVOIR TANK FUEL RESERVOIR TANK DRAIN AUXILIARY FUEL PUMP AUXILIARY FUEL SHUTOFF FUEL PUMP VALVE KNOB FUEL SHUTOFF SWITCH VALVE KNOB VALVE ENGINE DRIVEN FUEL STRAINER FUEL PUMP STRAINER FUEL INJECTION DRAIN SERVO VALVE _________ FUEL DISTRIBUTION LEGEND VALVE FUEL SUPPLY FUEL FLOW INDICATOR VENT MECHANICAL LINKAGE ELECTRICAL CONNECTION 0591R1001 Fuel System Schema...

Page 476: ...efer to Figure 203 1 Defuel airplane Refer to Chapter 12 Fuel Servicing 2 Remove access panels 510DB and 51 OHB left wing or 610DB and 61 OHB right wing to gain access to the sender Refer to Chapter 6 Access Inspection Plates Description and Operation 3 Disconnect wire ring terminals from fuel level sender 4 Disconnect fuel level sender ground wire from rib CAUTION DO NOT BEND FUEL LEVEL SENDER FL...

Page 477: ...v 11V13a v iVnNVIV 3ONVN31NIVV ...

Page 478: ...2 2362 REAR SPAR 7162 FRONT SPAR B DETAIL A LOOKING UP AT BOTTOM OF WING RIGHT SIDE SHOWN LEFT SIDE TYPICAL LOWER WING SKIN DRAIN VALVE BOSS FUEL DRAIN VALVE DETAIL B 0510T1007 A0516R1016 B1516R1017 Fuel Drain Valve Installation Figure 202 Sheet 1 28 20 00 Page 203 Feb 15 2002 ...

Page 479: ... IeeqiS CO eaJn6 j JapuaS l aA l anj VOIldA1l 3GIS lHOID NMOHS 3lIS 1i33 3C3aN3S 13A31 133 n i ...

Page 480: ...ure fuel reservoir drain is closed 6 Place fuel shutoff valve inthe ON position 7 Check fuel reservoir connections for any fuel leaks 8 Turn on auxiliary fuel pump and note positive fuel pressure on fuel pressure gage 9 Install access panel to floorboard 10 Install carpet and copilot seat Refer to Chapter 25 Front Seats and Rails Maintenance Practices and Chapter 25 Interior Upholstery Maintenance...

Page 481: ...NY MODEL 172 MAINTENANCE MANUAL B1480 A TO VENT MOUNT TYPICAL FROM SELECTOR VALVE DRAIN TO AUXILIARY VALVE FUEL PUMP DETAIL A 051T1007 A0516T1004 Fuel Reservoir Installation Figure 204 Sheet 1 28 20 00 Page 206 Feb 15 2002 ...

Page 482: ...INTENANCE MANUAL 81737 A FUEL SUPPLY LINE FUEL VENT FUEL LINE SHUTOFF KNOB FUEL RESERVOIR ELECTRIC FUEL PUMP FUEL i ir ti iHA FUEL DETAIL A STRAINER 0510T1007 A0516T1007 Fuel System Details Figure 205 Sheet 1 28 20 00 Page 207 Feb 15 2002 ...

Page 483: ...A AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B3263 LOCK NUT WASHER NAS1149F0363P j j CLAMP FUEL SHUTOFF VALVE CABLE DETAIL B B0516T1014 Fuel System Details Figure 205 Sheet 2 28 20 00 Page 208 Feb 15 2002 ...

Page 484: ...e copilot s rudder pedal shields secure with screws D Install footwell carpet E Install the copilot s seat Refer to Chapter 25 Front Seats and Rails Maintenance Practices 7 Electric Auxiliary Fuel Pump Removal Installation A Remove Electric Auxiliary Fuel Pump Refer to Figure 205 1 Set MASTER ALT BAT switch to the OFF position 2 Turn the fuel selector handle to the OFF position 3 Disconnect the ba...

Page 485: ...ge occurs with the engine not running fuel expansion can pressurize the fuel bays causing fuel spillage A Test Fuel Bay Vents Refer to Figure 206 1 Attach a rubber tube to the end of vent line beneath the wing 2 Blow into tube to slightly pressurize fuel bay If air can be blown into the fuel bay vent line is open 3 After tank is slightly pressurized insert end of rubber tube into a container of wa...

Page 486: ...sembly 10 Fuel Quantity Calibration NOTE Anytime a fuel level sender transmitter or indicator is replaced the fuel quantity system must be calibrated to establish both empty and full reading levels A Prepare Airplane 1 Drain fuel from wing tanks only Do not drain fuel from drains located on underside of fuselage Refer to Chapter 12 Fuel Servicing 2 Place the airplane at 2 degree nose up and wings ...

Page 487: ...100 OHM switch to the NORM position The indicators must read full and the message L LOW FUEL R must be extinguished 12 Reset time and return clock to clock mode 13 Turn Master Switch OFF 14 Remove test box from airplane 15 Reconnect fuel quantity indicator to electrical connector 16 Reinstall fuel quantity indicator in instrument panel D Turn Master Switch ON Observe that fuel quantity indicators ...

Page 488: ...off valve to get a pressure value as shown in Table 201 for the applicable part number to test b Monitor the current draw of the auxiliary fuel pump electric motor c Measure the fuel pump current draw and output The output will be 1gallon in2 5 minutes NOTE To help determine an acceptable pump output the output will be 1 gallon in2 5 minutes 24 GPH NOTE The Dukes Model 5100 00 1 auxiliary fuel pum...

Page 489: ...1N3A inuis auvMUod NdVO I M3 _ X S3HONI 13UOtl9 F N3 A 9NIM lIvnNVWI 3ONVN31NIV81 ...

Page 490: ...NT CHECK VALVE DETAIL C C LINE ASSEMBLY VENT NOTE IFTHE PRESSURE TEST INDICATES THE BYPASS PORT ISBLOCKED THE CHECK VALVE MUST BE REPLACED INSTALL NEW VALVE WITH THE HINGE BYPASS PORT FACING THE TOP OF THE FUEL BAY REQUIRED DETAIL 1007 B1226R1004 C0516T1015 Wing Fuel Tank Vent Check Valve Figure 207 Sheet 1 28 20 00 Page 215 Feb 15 2002 ...

Page 491: ... L geaaqS 80 aeJn6 j deo jejll lenj paluaA NMOHS 3lIS ll31 V113H8V 3AIVA 103H H3HSVM SS3qNO aoa8 dvol 3nj lVnNVAI 30NVN31NIV1 ...

Page 492: ...RAFT COMPANY MODEL 172 MAINTENANCE MANUAL TOP GASKET O RING FILTER STANDPIPE BOWL O RING NUT O RING DRAIN VALVE DETAIL A 0510T1007 A0516T1010 Fuel Strainer Assembly Figure 209 Sheet 1 28 20 00 Page 217 Feb 15 2002 ...

Page 493: ...pressure and 3137 East 26th Street weather sealant brush Los Angeles CA 90023 application Pro Seal 890 Courtaulds Aerospace 5426 San Fernando Rd Glendale CA 91209 PR 1422 Courtaulds Aerospace PR 1440 Courtaulds Aerospace MC 236 Morton Aerospace Polymer Systems 9341 Anaconda Ave Garden Grove CA 92641 SEALANTS TYPE I CLASS B 1 4 QUICK REPAIR MIL S 83318 Sealant GC 435 Goal Chemical Sealant Corp Fuel...

Page 494: ... for access B2 PR 1081 Class Courtaulds Aerospace B2 CLEANING SOLVENTS NAME NUMBER MANUFACTURER USE 1 1 1 Federal Commercially Available Presealing cleaning Trichloroethane Specification Technical O T 620 Inhibited Methyl Chloroform Methyl Ethyl Federal Commercially Available Cleaning organic coating Ketone Specification TT M 261 Naphtha Type II Federal Commercially Available Presealing cleaning S...

Page 495: ...tems Division of Courtaulds Aerospace Nozzles Semco Packaging and Application of sealant Applications Systems Division of Courtaulds Aerospace Round 1 16 orifice Semco No 420 Round 1 8 orifice Semco No 440 Duckbill Semco No 8615 Duckbill Semco No 8648 Comb Semco No 8646 Polyethylene Commercially available Application of sealant cartridges with plungers and caps for sealant gun Metal spatulas with ...

Page 496: ...urface 7 Fillet Seal Sealant material applied at the seam joint or fastener after the assembly has all permanent fasteners installed and shall conform to the dimension in applicable figure 8 Hole An opening that has no appreciable depth such as a tool hole Holes that penetrate the seal plane must be metal filled with a fastener gusset or patch 9 Injection Seal Filling of channels by forcing sealan...

Page 497: ...suitable for brush application b Class B Sealant which is suitable for application by extrusion gun spatula etc c Class C Sealant which is suitable infaying surface applications d Quick Repair Sealant This material is for use only in making repairs when an extremely rapid curing sealant is required A possible application includes sealing a leaking fuel tank on an airplane which must be dispatched ...

Page 498: ...have thawed shall not be refrozen 6 Complete preassembly operations such as fitting filing drilling countersinking dimpling and deburring prior to cleaning and sealant application 7 Surfaces must be clean and dry free from dust lint grease chips oil condensation or other moisture and all other contaminating substances prior to the application of sealant a All exposed bonding primer or bonded assem...

Page 499: ...o accelerate cure Heat lamps may be used if the surface temperature of the sealant does not exceed 140 F At temperatures above 120 F the relative humidity will normally be so low below 40 percent that sealant curing will be retarded If necessary the relative humidity may be increased by the use of water containing less than 100 parts per million total solids and less than 10 parts per million chlo...

Page 500: ...tinue clockwise rotation and slowly move the dasher rod to the FULL IN position 1 A minimum of five full clockwise revolutions must be made for each full out stroke and for each full in stroke of the dasher rod Approximately sixty strokes are necessary for a complete mix NOTE If streaks are present in the sealant viewing through the side of the cartridge the sealant is not completely mixed c End m...

Page 501: ...s grease wax etc will not be redeposited F It is essential that only clean cheesecloth and clean solvent be used in the cleaning operations Solvents shall be kept insafety containers and shall be poured onto the cheesecloth The cheesecloth shall not be dipped into the solvent containers and contaminated solvents shall not be returned to the clean solvent containers G Final cleaning shall be accomp...

Page 502: ...ompletely filled with sealant and a small excess is squeezed out in a continuous bead around the periphery of the joint when the joint is secured refer to Figure 201 Sheet 2 2 Place parts inassembly position and install the fasteners within the application time of the faying surface sealant When assembly with permanent type fasteners is not feasible temporary fasteners clecos or bolts may be used ...

Page 503: ...NTENANCE MANUAL INSPECTION COVER UPPER TRAILING UPPER SKIN FUEL BAY LEFT SHOWN RIGHT OPPOSITE TRAILING EDGE SKIN STIFFENER LOWER SKIN 0526T1010 0526T1009 0526T1011 Integral Fuel Bay Sealing Figure 201 Sheet 1 28 21 00 Page 211 Aug 18 2001 ...

Page 504: ...HE FOLLOWING EXAMPLES SHOW TYPICAL CROSS SECTIONS OF SEALING METHODS AND TECHNIQUES USED INTHE FUEL BAY AREA IN MOST CASES WING SKIN AND RIB THICKNESS COMBINED IS APPROXIMATELY 0 070 INCH MINIMUM SEALANT APPLICATION AT ANY POINT SHOULD NOT BE LESS THAN 0 060 INCH 55982007 Integral Fuel Bay Sealing Figure 201 Sheet 2 28 21 00 Page 212 Aug 18 2001 ...

Page 505: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 5598C1010 6280C 1003 Integral Fuel Bay Sealing Figure 201 Sheet 3 28 21 00 Page 213 Aug 18 2001 ...

Page 506: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INJECTION IS COMPLETE WHEN SEALANT EMERGES FROM THIS SIDE 5598C1009 Integral Fuel Bay Sealing Figure 201 Sheet 4 28 21 00 Page 214 Aug 18 2001 ...

Page 507: ...pplication of sealant is made If the fillet has only cured to a tack free state it shall be wiped lightly with a gauze pad or cheesecloth pad dampened with cleaning solvent 6 Allow the sealant to cure to a tack free condition prior to the airplane being moved handled and or worked on 7 In cases where a fillet seal connects to an injection seal the full bodied fillet shall extend past the end of th...

Page 508: ...er is removed during the cleaning operation it is permissible to apply the new fillet seal directly over the clean bare metal and then touch up with the proper primer all exposed areas of bare metal after the sealant has been applied D Faying Surface Sealing Repair After determining the area which contains the faulty and or leaking faying surface seal the repair shall be accomplished by applying a...

Page 509: ...n of wing inboard or outboard of the fuel bays C The following leaks require correction when the airplane is grounded for other maintenance 1 Stains seeps or heavy seeps not in an enclosed area 12 Sealing Fuel Leaks A Determine Source of Leak 1 Fuel can flow along a seam or structure of the wing for several inches making the leak source difficult to find A stained area is an indication of the leak...

Page 510: ... INCHES STAIN 0 75 INCH MAXIMUM RUNNING LEAK SIZE WILL VARY WITH LOCATION AND INTENSITY OF LEAK FUEL WILL USUALLY FLOW INTHIS AREA ALONG SKIN CONTOUR AFTER IT IS WIPED DRY FUEL USUALLY DRIPS AT THIS POINT 05161006 Classification of Fuel Leaks Figure 202 Sheet 1 28 21 00 Page 218 Aug 18 2001 ...

Page 511: ...e bay might be exposed to temperature changes while testing 5 Make sure filler cap is installed and sealed 6 Apply pressure slowly until 0 5 PSI isobtained 7 Apply a soap solution as required 8 Allow 15 to 30 minutes for pressure to stabilize 9 If bay holds for 15 minutes without pressure loss seal is isacceptable 10 Reseal and retest if any leaks are found 28 21 00 Page 219 Aug 18 2001 ...

Page 512: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER INDICATING RECORDING SYSTEMS ...

Page 513: ...E 31 Title 31 List of Effective Pages 1 Aug 18 2001 31 Contents 1 Aug 18 2001 31 00 00 1 Aug 18 2001 31 10 00 201 Aug 18 2001 202 Aug 18 2001 31 20 00 201 Aug 18 2001 31 30 00 201 Aug 18 2001 202 Aug 18 2001 31 50 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 31 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 514: ...ge 201 DIGITAL CLOCK MAINTENANCE PRACTICES 31 20 00 Page 201 Description and Operation 31 20 00 Page 201 Clock Removal Installation 31 20 00 Page 201 HOUR METER MAINTENANCE PRACTICES 31 30 00 Page 201 Descriptio and Operation 31 30 00 Page 201 Hour Meter Removal Installation 31 30 00 Page 201 ANNUNCIATOR PANEL MAINTENANCE PRACTICES 31 50 00 Page 201 Description and Operation 31 50 00 Page 201 Trou...

Page 515: ... into sections to aid maintenance personnel inlocating information Consulting the Table of Contents will assist in locating a particular subject A brief definition of the sections incorporated inthis chapter is as follows 1 The section on instrument and control panels provides general removal and installation instructions for the various panels used in the cockpit 2 The section on indicating provi...

Page 516: ...trument panel and houses the majority of switches and circuit breakers in a single location 3 The copilot side of the instrument panel houses the Hobbs meter and remote ELT activation switch and is designed to allow for panel expansion NOTE For an overview of the various sub panels which make up the instrument panel refer to Figure 201 2 Panel Removal and Installation A The individual panels may b...

Page 517: ...AFT COMPANY MODEL 172 MAINTENANCE MANUAL 1743 PILOT S PILOT S PILOT S COPILOT S OUTBOARD CENTER INBOARD RADIO PANEL CIRCUIT BREAKER CONTROLS VENTILATING PANEL Instrument Panels Figure 201 Sheet 1 31 10 00 Page 202 ...

Page 518: ... and Operation A The digital clock is located in upper left side of the instrument panel and incorporates clock temperature and voltage readings ina single unit For removal installation of the OAT Clock refer to Chapter 34 Outside Air Temperature Gauge Maintenance Practices 31 20 00 Page 201 Aug 18 2001 ...

Page 519: ...r isgrounded through the Oil Pressure Switch and anytime oil pressure exceeds 20 PSI a ground is sent from the switch to the hour meter completing a circuit and activating the hour meter 2 Hour Meter Removal Installation A Remove Hour Meter Refer to Figure 201 1 Gain access to backside of instrument panel and hold nuts while loosening screws 2 Disconnect electrical connectors leading into hour met...

Page 520: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B1745 HOUR METER NUT INSTRUMENT PANEL SCREW DETAIL A Hour Meter Installation Figure 201 Sheet 1 31 30 00 Page 202 Aug 18 2001 ...

Page 521: ...OW FUEL R Amber Low fuel condition detected Left and right fuel quantity in both the left and right fuel systems tanks L LOW FUEL and Amber Short open or increasing Left fuel transmitter or left fuel gauge resistance over time electrical line between needle parked transmitter and fuel below 0 gauge LOW FUEL Rand Amber Short open or increasing Right fuel transmitter or right fuel gauge resistance o...

Page 522: ...l Installation A Remove Annunciator Panel Refer to Figure 201 1 Ensure electrical power to airplane is OFF 2 Gain access to backside of annunciator panel and disconnect electrical connector 3 Remove screws securing annunciator panel to instrument panel and remove from airplane B Install Annunciator Panel Refer to Figure 201 1 Connect electrical connector to annunciator panel 2 Position annunciator...

Page 523: ...RAFT COMPANY MODEL 172 MAINTENANCE MANUAL ELECTRICAL CONNECTOR ANNUNCIATOR PANEL INSTRUMENT PANEL SCREW DETAIL A 0585T1040 A0518T1022 Annunciator Panel Installation Figure 201 Sheet 1 31 50 00 Page 203 Aug 18 2001 ...

Page 524: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER LANDING GEAR ...

Page 525: ...2001 206 Aug 18 2001 32 20 00 101 Aug 18 2001 32 20 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 206 Aug 18 2001 207 Aug 18 2001 208 Aug 18 2001 209 Aug 18 2001 210 Aug 18 2001 211 Aug 18 2001 e 32 40 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 32 41 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 32 42 00 101 Feb 15 2002 32 42 00 201...

Page 526: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 527: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 528: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 529: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 530: ...32 20 00 Page 210 Steering Rod Assembly 32 20 00 Page 211 MAIN LANDING GEAR WHEEL AND AXLE MAINTENANCE PRACTICES 32 40 00 Page 201 General 32 40 00 Page 201 Main Wheel Removal Installation 32 40 00 Page 201 Main Wheel Axle Removal Installation 32 40 00 Page 201 Main Wheel Disassembly Assembly 32 40 00 Page 201 Main Wheel Inspection Check 32 40 00 Page 204 Wheel Balancing 32 40 00 Page 204 NOSE LAN...

Page 531: ...nition of the sections incorporated in this chapter is as follows 1 The section on main landing gear provides troubleshooting maintenance practices and adjustment instructions for the main landing gear 2 The section on nose landing gear provides troubleshooting maintenance practices and inspection checks for the nose landing gear 3 The section on wheels and brakes provides description operation tr...

Page 532: ...LY Incorrect tire pressure Ensure tire is inflated to 28 PSI air pressure Main wheels out of alignment Check main wheel alignment Refer to Main Landing Gear Wheel and Axle Maintenance Practices Landing gear tubular strut Replace tubular strut Refer to excessively sprung Main Landing Gear Maintenance Practices Bent axle Replace axle Refer to Main Landing Gear Wheel and Axle Maintenance Practices Dr...

Page 533: ...ove cap fairing and clamp D Remove Tubular Strut Fairing Refer to Figure 201 1 Remove screws securing step to step bracket 2 Remove screws from lower side of tubular strut fairing 3 Carefully separate tubular strut fairing along aft edge and work over step bracket 4 Pull tubular strut fairing out of fuselage fairing and remove from tubular strut E Remove Fuselage Fairing Refer to Figure 201 1 Remo...

Page 534: ...E FAIRING BUSHING STRUT LANDING GEAR BULKHEAD TUBULAR BRAKE STRUT FAIRING STEP BRAKE CLAMP LINE MAIN LANDING STIFFENER MOUNTING PLATE BRAKE MAIN WHEEL DETAIL A SPEED FAIRING DETAIL B Main Landing Gear Installation Figure 201 Sheet 1 32 10 00 Page 202 Aug 18 2001 ...

Page 535: ...ine NOTE The tubular strut is a compression fit in the bushing in the outboard landing gear forging B Install Main Landing Gear Refer to Figure 201 1 Install all parts removed from strut 2 Apply Dow Corning Compound DC 7 to approximately 11 inches on upper end of tubular strut NOTE Avoid use of Dow Corning DC 7 on surfaces to be painted DC 7 contains silicone which is harmful to painted areas 3 Sl...

Page 536: ...tween bracket and tubular strut 6 Mix adhesive inaccordance with manufacturer s directions 7 Spread acoat of adhesive on bonding surfaces and place step bracket inposition on the tubular strut Clamp bracket to strut to ensure a good tight fit 8 Form asmall fillet of the adhesive at all edges of the bonded surfaces Remove excess adhesive with lacquer thinner 9 Allow adhesive to cure thoroughly acco...

Page 537: ... TAIL TIE DOWN RING AFT AND FROM FORWARD INSPECTION COVER PLATE COVER PLATE IS LOCATED JUST AFT OF NOSE GEAR ON BOTTOM OF FUSELAGE PLUMB BOB SHOULD BE ATTACHED TO THE FORWARD MOST SCREW OF THE INSPECTION PLATE STRAIGHTEDGE PERPENDICULAR 05411003 05411003 Main Wheel Alignment Check Figure 202 Sheet 1 32 10 00 Page 205 Aug 18 2001 ...

Page 538: ... CAMBER CHECK POSITIVE NEGATIVE CAMBER INBD MEASURE CAMBER BY READING PROTRACTOR LEVEL HELD VERTICALLY AGAINST OUTBOARD FLANGES OF WHEEL NOTE THESE PROCEDURES ARE SPECIFICALLY FOR CHECKING MAIN WHEEL ALIGNMENT NO PROVISIONS ARE MADE FOR ALIGNING THE NOSE WHEEL FOR CAMBER AND TOE IN SPECS REFER TO CHAPTER 6 AIRPLANE DIMENSIONS AND SPECIFICATIONS 05411004 05411004 Main Wheel Alignment Check Figure 2...

Page 539: ... Properly install wheel bearings Defective shimmy damper Repair or install new damper Shimmy damper fluid low Service shimmy damper Refer to Chapter 12 Nose Gear Shimmy Damper Servicing Loose torque links Add shims or install new parts as required NOSE STRUT DOES Defective strut seals Install new seals Refer to Nose NOT HOLD AIR Landing Gear Maintenance PRESSURE Practices Defective or loose air fi...

Page 540: ...olt securing speed fairing and tow bar spacers to strut 5 Slide speed fairing up and remove nose wheel Loosen scraper as necessary 6 Rotate speed fairing 90 degrees to centerline of airplane and work fairing down over the fork to remove B Install Nose Wheel Speed Fairing Refer to Figure 201 1 With speed fairing 90 degrees to center line of airplane work fairing up over nose gear fork 2 Slide fairi...

Page 541: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL DETAIL B COVER WASHER WASHER NOSE WASHER BOLT Nose Wheel Speed Fairing Installation Figure 201 Sheet 1 32 20 00 Page 202 Aug 18 2001 ...

Page 542: ...E MANUAL BOLT UPPER NOSE STRUT ASSEMBLY TUBE LOWER STRUT BOLT SHIMMY DAMPENER SHIMMY DAMPENER D ARM BOLT STRUT CLAMP CAP STEERING ARM ASSEMBLY WHEEL ASSEMBLY 05421006 Nose Landing Gear Installation Figure 202 Sheet 1 32 20 00 Page 203 Aug 18 2001 ...

Page 543: ...EL 172 MAINTENANCE MANUAL UPPER NOSE UPPER NOSE LOWER STRUT DETAIL A FITTING BALL SHIM CHECK CLEVIS CLAMP CAP DETAIL C DETAIL B 0511 T1006 A05421008 Nose Landing Gear Installation Figure 202 Sheet 2 32 20 00 Page 204 Aug 18 2001 ...

Page 544: ...MODEL 172 MAINTENANCE MANUAL UPPER TORQUE SHIM GREASE FITTING NUT BUSHING GREASE SPACER BUSHING GREASE FITTING LINK SHIM SPACER DETAIL D D05421011 Nose Landing Gear Installation Figure 202 Sheet 3 32 20 00 Page 205 Aug 18 2001 ...

Page 545: ...R 1 00 ROD VIEW A A ORIFICE PISTON SUPPORT UPPER STRUT NO 40 HOLE UPPER STRUT VIEW B B RETAINING B RING STEERING ASSEMBLY END ROD END SHIM TO AS SHEET 5 REQUIRED DETAIL E E05421010 Nose Landing Gear Installation Figure 202 Sheet 4 32 20 00 Page 206 Aug 18 2001 ...

Page 546: ...ARING STRUT PACKING SUPPORT RING RING RING PACKING RETAINING RING LOCK RING RING C SCRAPER TOW BAR LOCK RING SPACER RING VIEW C C RETAINING SPACER TOW BAR SPACER FORK METERING PIN 05421010 C C05421010 Nose Landing Gear Installation Figure 202 Sheet 5 32 20 00 Page 207 Aug 18 2001 ...

Page 547: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL BARREL SNAP PISTON PISTON ROLL PIN BEARING DETAIL F F0542T1003 Nose Landing Gear Installation Figure 202 Sheet 6 32 20 00 Page 208 Aug 18 2001 ...

Page 548: ...lug were removed from the upper torque linkduring disassembly they must be reinstalled and the retaining bolts tightened from 20 to 25 In lbs After torqueing bolts safety them into position by bending the tips of the safety lug 1 With shock strut completely deflated install upper and lower torque link assemblies 2 Install bolt attaching upper and lower assemblies 3 Tighten nuts at both ends of tor...

Page 549: ...retaining ring and lock ring from lower strut noting relative position and top side of each ring Wire or tape together if desired 7 Remove O ring and back up rings from packing support ring 8 Remove bolt securing tow bar spacers NOTE Bolt attaching tow bar spacers also holds bushing and base plug inplace 9 Remove bolt attaching fork to strut barrel and remove base plug and metering pin from lower ...

Page 550: ...raper ring on lower strut making sure they are installed in same positions as they were removed 10 Install O rings and back up rings inpacking support ring slide packing support ring over lower strut 11 Install bearing and lock ring at upper end of lower strut assembly Note top side of bearing 12 Install upper strut assembly over lower strut assembly 13 Install lock ring in groove in lower end of ...

Page 551: ...Figure 201 1 Remove main wheel speed fairing Refer to Main Landing Gear Maintenance Practices 2 Remove main landing gear wheel 3 Disconnect drain and cap or plug hydraulic brake line at the wheel brake cylinder 4 Remove bolts attaching brake torque plate and speed fairing mounting plate to axle 5 Remove cotter pin nut washer and bolt attaching axle to tubular strut 6 Remove axle from spring strut ...

Page 552: ...NY MODEL 172 MAINTENANCE MANUAL A TUBULAR STRUT MAIN LANDING GEAR AXLE BRAKE BACKPLATE TIRE AXLE NUT COTTER PIN HUB CAP DETAIL A 0510T1 007 A05413001 Main Wheel Installation Figure 201 Sheet 1 32 40 00 Page 202 Aug 18 2001 ...

Page 553: ...L 172 MAINTENANCE MANUAL BEARING CONE TIRE TUBE WASHER BEARING CUP WHEEL HALF GREASE SEAL BEARING CUP FELT GREASE SEAL RETAINER DETAIL A RETAINING RING A05411001 Main Wheel Assembly Figure 202 Sheet 1 32 40 00 Page 203 Aug 18 2001 ...

Page 554: ...2 inch pounds 6 Inflate tire to seat tire beads then adjust pressure to proper inflation 5 Main Wheel Inspection Check A Inspect Main Wheel Refer to Figure 202 1 Clean all metal parts and grease seal felts insolvent and dry thoroughly NOTE A soft bristle brush may be used to remove hardened grease dust or dirt 2 Inspect wheel halves for cracks or damage 3 Inspect bearing cones cups retaining rings...

Page 555: ...eel halves WARNING SERIOUS INJURY CAN RESULT FROM ATTEMPTING TO SEPARATE WHEEL HALVES WITH TIRE AND TUBE INFLATED 2 Remove thru bolts and washers 3 Separate and remove wheel halves from tire and tube 4 Remove retaining rings grease seal retainer felt grease seal grease retainer and bearing cone from each wheel half NOTE Bearing cups are a press fit inwheel half and should not be removed unless a n...

Page 556: ...ELT GREASE SEAL NUT WHEEL HALF GREASE SEAL RETAINER BEARING CONE WHEEL HALF BEARING CUP CUP WASHER BOLT BEARING CONE DETAIL A GREASE SEAL RETAINER FELT GREASE SEAL GREASE SEAL RETAINER RETAINING RING A05421001 Nose Landing Gear Wheel Assembly Figure 201 Sheet 1 32 41 00 Page 202 Aug 18 2001 ...

Page 557: ...nspect bearing cones cups retaining rings and seals for wear or damage 4 Inspect thru bolts and nuts for cracks inthreads or radius of bolt heads 5 Replace cracked or damaged wheel half 6 Replace damaged retaining rings and seals 7 Replace any worn or cracked thru bolts or nuts 8 Replace worn or damaged bearing cups or cones 9 Remove any corrosion or small nicks 10 Repair reworked areas of wheel b...

Page 558: ...aning lines fails to give satisfactory results the master cylinder may be faulty and should be repaired Worn scored or warped brake disc Install new disc and brake linings Refer to Brakes Maintenance Practices Damaged or accumulated dirt Clean and repair or install new restricting free movement of wheel parts as necessary Refer to brake parts Brakes Maintenance Practices BRAKES FAIL TO Leak in sys...

Page 559: ... and damage and are also available inreplacement assemblies through Cessna 3 Brake Assembly and Line Removal Installation A Remove Brake Assembly Refer to Figure 201 1 Ensure parking brake is OFF 2 Disconnect brake line at brake assembly 3 Remove bolts securing back plate and remove brake assembly NOTE If torque plate needs to be removed wheel must be removed from axle Ifbrake disc isto be removed...

Page 560: ...INSTRUMENT PANEL ASSEMBLY LOWER INSTRUMENT CABLE POSITIONING PIN POSITIONING RACK RUDDER TUBE PEDALS ASSEMBLY BELLCRANK BRACKET DETAIL B SPRING BRACKET PULLEY A A05141011 B05141011 Brake System Installation Figure 201 Sheet 1 32 42 00 Page 202 Aug 18 2001 ...

Page 561: ...TENANCE MANUAL BRAKE LINE LINE DETAIL C BRAKE LINE BRAKE LINE BRAKE LINE DETAIL D BRAKE MASTER CYLINDER BRAKE LINES BRAKE HOSE DETAIL E C05141009 D05141009 E05143002 Brake System Installation Figure 201 Sheet 2 32 42 00 Page 203 Aug 18 2001 ...

Page 562: ...EL BEARINGS GR HAND 2 TORQUE LINKS GR GUN 3 SHIMMY DAMPER PIVOTS OG OIL CAN 4 NEEDLE BEARINGS GR HAND 5 PARKING BRAKE HANDLE OG OIL CAN SHAFT GR GREASE GENERAL PURPOSE MIL G 81322 OG OIL GENERAL PURPOSE MIL L 7870 0542T2001 0514T3001 0541T3001 Brake System Installation Figure 201 Sheet 3 32 42 00 Page 204 Aug 18 2001 ...

Page 563: ...e instructions set forth in this conditioning procedure 6 Master Cylinder Removal Disassembly Installation A Remove Master Cylinder Refer to Figure 201 1 Remove front seats and rudder bar shield to access the brake master cylinders 2 Remove bleeder screw at wheel brake assembly and drain hydraulic fluid from brake cylinders 3 Disconnect parking brake and disconnect brake master cylinders from rudd...

Page 564: ... MODEL 172 MAINTENANCE MANUAL BACK UP RING A SPRING FILLER PLUG COVER BODY CYLINDER BODY BACK UP RING PACKING SPRING PISTON VIEW A A 05141012 A A05141012 Brake Master Cylinder Figure 202 Sheet 1 32 42 00 Page 206 Aug 18 2001 ...

Page 565: ...he end of the hose 4 Connect a clean hydraulic pressure source to the bleeder valve in the wheel cylinder 5 Pump clean hydraulic fluid into the system Observe the immersed end of the hose at the master brake cylinder for evidence of air bubbles being forced from the brake system When bubbling has ceased all air has been removed from system 6 Close bleeder valve at wheel cylinder and tighten Remove...

Page 566: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER LIGHTS ...

Page 567: ...01 33 11 00 201 Aug 18 2001 202 Aug 18 2001 33 12 00 201 Aug 18 2001 202 Aug 18 2001 33 13 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 33 14 00 201 Aug 18 2001 202 Aug 18 2001 33 15 00 201 Aug 18 2001 202 Aug 18 2001 33 40 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 33 41 00 201 Aug 18 2001 202 Aug 18 2001 33 43 00 201 Aug 18 2001 202 Aug 18 2001 33 44 00 201 Aug 18 2001 202 Aug 18 2...

Page 568: ...tallation 33 13 00 Page 201 RADIO LIGHTING MAINTENANCE PRACTICES 33 14 00 Page 201 General 33 14 00 Page 201 Dimming Module Removal Installation 33 14 00 Page 201 Dimming Control Removal Installation 33 14 00 Page 201 PILOT CONTROL WHEEL LIGHTING MAINTENANCE PRACTICES 33 15 00 Page 201 General 33 15 00 Page 201 Map Light Removal Installation 33 15 00 Page 201 Map Light Rheostat Remove Installation...

Page 569: ...formation on internal and external lighting 2 Definition A This chapter is divided into section and subsections to assist maintenance personnel in locating specific components and information Consulting the Table of Contents will further assist in locating a particular subject 33 00 00 Page 1 Aug 18 2001 ...

Page 570: ...to right 3 Floodlight Removal Installation A Remove Floodlight Refer to Figure 201 NOTE Removal Installation is typical for all three floodlights 1 Remove screws securing overhead console to structure 2 Disconnect electrical connectors from light assembly 3 Remove light assembly from overhead console B Install Floodlight Refer to Figure 201 1 Install light assembly inoverhead console 2 Connect ele...

Page 571: ...IRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL LENS LIGHT HOLDER BULB DETAIL B B LIGHT SWITCH LIGHT ASSEMBLY OVERHEAD CONSOLE DETAIL A Flood Lighting Installation Figure 201 Sheet 1 33 10 00 Page 202 Aug 18 2001 ...

Page 572: ...ght lens 4 Remove light tube from individual retainers B Install Glareshield Light Refer to Figure 201 1 Secure light tube with individual retainers 2 Install glareshield light lens 3 Connect glareshield electrical connector 4 Install glareshield 3 Glareshield Light Power Supply Removal Installation A Remove Glareshield Light Power Supply Refer to Figure 201 1 Remove electrical connector from powe...

Page 573: ...RCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL ELECTRICAL CONNECTOR DETAIL A GLARESHIELD LIGHT VIEW A A GLARESHIELD DIMMING CONTROL Glareshield Lighting Installation Figure 201 Sheet 1 33 11 00 Page 202 Aug 18 2001 ...

Page 574: ...ulb type light is installed on the pedestal This light provides illumination of the fuel selector 2 Pedestal Light Bulb Replacement A Replace Pedestal Light Refer to Figure 201 1 Remove screws securing light hood to pedestal 2 Replace pedestal light bulb 3 Secure light hood to pedestal 33 12 00 Page 201 Aug 18 2001 ...

Page 575: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A DETAIL A 0585C1040 A05181012 Pedestal Lighting Installation Figure 201 Sheet 1 33 12 00 Page 202 Aug 18 2001 ...

Page 576: ...rument 3 Replace light bar and secure with screws 4 Install flight instrument 3 Engine Instrument Light Bulb Replacement A Replace Engine Instrument Light Bulbs Refer to Figure 201 1 Remove engine instrument 2 Remove screws securing light cover plate to bottom of instrument 3 Replace light bulbs 4 Secure light coverplate to bottom of instrument with screws 5 Install engine instrument 4 Dimming Mod...

Page 577: ...NTENANCE MANUAL DETAIL A TYPICAL FLIGHT INSTRUMENT LIGHTING REPLACEABLE LIGHT BULB LEMENTS VIEW A A DETAIL C TYPICAL ENGINE INSTRUMENT LIGHTING AA051 8C1037 Instrument Lighting Installation Figure 201 Sheet 1 33 13 00 Page 202 Aug 18 2001 ...

Page 578: ...OMPANY MODEL 172 MAINTENANCE MANUAL INSTRUMENT LIGHTS DIMMER ALT DETAIL D VOLTAGE REGULATOR DIMMING MODULE ELECTRICAL CONNECTOR DETAIL E Instrument Lighting Installation Figure 201 Sheet 2 33 13 00 Page 203 Aug 18 2001 ...

Page 579: ...dule Removal Installation refer to Instrument Lighting Maintenance Practices located in this chapter 3 Dimmer Control Removal Installation A Remove Dimmer Control Refer to Figure 201 1 Remove nut securing dimmer control to back of instrument panel 2 Label and de solder wires connected to dimmer control 3 Remove dimmer control B Install Dimmer Control Refer to Figure 201 1 Solder proper pins to exi...

Page 580: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL DETAIL A B R PUSH PULL B ALT RADIO LIGHT DIMMER DETAIL Radio Lighting Installation Figure 201 Sheet 1 33 14 00 Page 202 Aug 18 2001 ...

Page 581: ...ol wheel 2 Remove map light B Install Map Light Refer to Figure 201 1 Place map light over control wheel stud and secure with nut and washer 3 Map Light Rheostat Removal Installation A Remove Map Light Rheostat Refer to Figure 201 1 Remove thumbwheel and jamnut from rheostat 2 Pull rheostat out of control wheel and remove electrical wires B Install Map Light Rheostat Refer to Figure 201 1 Connect ...

Page 582: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RHEOSTAT JAMNUT SETSCREW THUMBWHEEL 2618X1 153 Control Wheel Lighting Installation Figure 201 Sheet 1 33 15 00 Page 202 Aug 18 2001 ...

Page 583: ...ure electrical power to airplane is OFF 2 Remove screws securing lens retainer to wingtip 3 Remove lens from navigation portion of assembly 4 Grasp bulb depress slightly and turn counterclockwise to release bulb from bayonet mount B Install Wingtip Navigation Lights Refer to Figure 201 1 Place bulb inbayonet socket depress and gently turn clockwise until bulb seats insocket 2 Position lens and gas...

Page 584: ...CTRICAL LEADS WASHER INSULATED SCREW SPRING LENS DETAIL A RETAINER LENS GASKET WING TIP RECEPTACLE POWER MOUNT SCREW ELECTRICAL DETAIL C LEADS DETAIL B A05181028 C05181029 Navigation and Anti Collision Strobe Light Installation Figure 201 Sheet 1 33 40 00 Page 202 Aug 18 2001 ...

Page 585: ...rews C Remove Power Supply Refer to Figure 201 NOTE Removal and installation is typical for both the UL001 left and UR001 right power supply 1 Ensure electrical power to airplane is OFF 2 Remove wingtip 3 Disconnect electrical connectors from both ends of power supply 4 Remove ground wires as required 5 Remove screws securing power supply to wing and remove power supply from wing D Install Power S...

Page 586: ... BCN position This position supplies power to the light which uses internal circuitry to flash on and off at approximately 20 cycles per minute 2 Beacon Removal Installation A Remove Beacon Refer to Figure 201 1 Loosen screw on clamp ring assembly 2 Remove lens assembly from base assembly 3 Remove lamp assembly from base B Install Beacon Refer to Figure 201 1 Install lamp assembly to base 2 Place ...

Page 587: ...E MANUAL A LENS ASSEMBLY CLAMP RING ASSEMBLY SCREW LAMP ASSEMBLY SCREW BASE ASSEMBLY PLATE ASSEMBLY SCREW CAP ASSEMBLY ELECTRICAL CONNECTOR 4 ELECTRICAL CONNECTOR Flashing Beacon Light Installation Figure 201 Sheet 1 33 41 00 Page 202 Aug 18 2001 ...

Page 588: ...ts to assembly using brackets and screws 3 Reinstall lens assembly to leading edge of wing 3 Light Adjustment A If lights are aimed too high or too low to provide effective coverage during operation washers may be added between spacers and plate aft of the actual light to reorient the beam Proper aim points are as follows 1 Park airplane on a flat level surface in front of a light reflecting objec...

Page 589: ...NTENANCE MANUAL A SPACER SPACER LANDING LIGHT SPACER BRACKET SCREW BRACKET BRACKET NUTPLATE LIGHT BRACKET LENS SCREW ASSEMBLY DETAIL A 051 T1007 A05283001 Landing and Taxi Light Installation Figure 201 Sheet 1 33 43 00 Page 202 Aug 18 2001 ...

Page 590: ...witch supplies power to all three lights Pressing the overhead light switch again removes power from all three lights 2 Courtesy Wing Light Removal Installation A Remove Light Refer to Figure 201 1 Ensure electrical power to the airplane is OFF 2 Remove screws securing cover to underside of wing 3 Push inon lamp rotate counterclockwise and remove lamp from bayonet socket B Install Light Refer to F...

Page 591: ...CE MANUAL TINNERMAN GROMMET SCREW TINNERMAN NUT LAMP TINNERMAN NUT LENS COVER NOTE RIGHT WING SHOWN TINNERMAN LEFT WING TYPICAL SCREW DETAIL A 051 T1 007 A05281001 Courtesy Wing Light Installation Figure 201 Sheet 1 33 44 00 Page 202 Aug 18 2001 ...

Page 592: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER NAV IGATION ...

Page 593: ... 2002 202 Feb 15 2002 203 Feb 15 2002 204 Feb 15 2002 205 Feb 15 2002 206 Feb 15 2002 207 Feb 15 2002 34 12 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 34 20 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 34 21 00 201 Aug 18 2001 202 Aug 18 2001 34 50 00 201 Aug 18 2001 202 Aug 18 2001 34 51 00 201 Aug 18 2001 202 Aug 18 2001 34 52 00 201 Aug 18 2001 202 Aug 18 2001 34 53 00 201 Aug 18 ...

Page 594: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 595: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 596: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 597: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 598: ...age 201 General 34 20 00 Page 201 Precautions 34 20 00 Page 201 Horizon Gyro General Operation Notes 34 20 00 Page 201 Attitude Indicator Removal Installation 34 20 00 Page 201 Directional Gyro Removal Installation 34 20 00 Page 203 Directional Gyro Operational Test 34 20 00 Page 203 Turn Coordinator Removal Installation 34 20 00 Page 203 COMPASS INSTALLATION MAINTENANCE PRACTICES 34 21 00 Page 20...

Page 599: ...bject A brief definition of the sections incorporated inthis chapter is as follows 1 The Flight Environmental Data Section describes systems that sense environment conditions and use data to influence navigation of the airplane This includes systems that depend on pitot and static information 2 The Attitude and Direction Section describes systems that use magnetic gyroscopic and inertia forces Thi...

Page 600: ...limits set forth in Chapter 5 Inspection Time Limits or anytime components or lines within the system are opened Refer to FAR 91 411 2 Pitot Tube Removal Installation A Remove Pitot Tube Refer to Figure 202 1 Remove screws securing pitot tube to wing and remove pitot tube 2 Disconnect ram air tube from pitot 3 Disconnect electrical connectors from pitot heater and from pitot heat ground B Install ...

Page 601: ...o VERTICAL SPEED_ INDICATOR s ALTERNATE STATIC AIR SOURCE s VENTED TO COCKPIT STATIC SUMP ELECTRICAL CONNECTOR 0 ALTERNATE STATIC AIR SOURCE KNOB 0OA MOUNTED ON INSTRUMENT PANEL LEGEND PITOT STATIC SOURCE STATIC VENTED TO OUTSIDE 0595T1001 Pitot Static System Schematic Figure 201 Sheet 1 34 11 00 Page 202 Feb 15 2002 ...

Page 602: ...ALTERNATE AIR CONTROL VALVE CONTROL KNOB NUT INSTRUMENT PANEL INSERT TEE i TYPICAL STATIC LINES TO STATIC INSTRUMENTS MOUNTING TRAY KNURLED KNOB INSERT STATIC SUMP ELECTRICAL CONNECTOR STATIC PORT ELBOW BLIND ENCODER 0510T1007 DETAIL A0518R1046 B0518T1040 Pitot Static System Installation Figure 202 Sheet 1 34 11 00 Page 203 Feb 15 2002 ...

Page 603: ...BE HEATER ASSEMBLY WIRE LEADS 4 INCH PIECE OF H990000 NYLON RAM AIR SPIRAL WRAP TUBE 8 INCH PIECE IF H990000 NYLON SPIRAL WRAP 0 10 INCH CLEARANCE PITOT TUBE DETAIL C ASSEMBLY C0518R 1070 Pitot Static System Installation Figure 202 Sheet 2 34 11 00 Page 204 Feb 15 2002 ...

Page 604: ...VSI 1 Position VSI on flight instrument subpanel and secure with screws 2 Connect static tube and electrical connector to VSI 3 Secure flight instrument subpanel to instrument panel with screws 4 Check system for leaks Refer to step 10 Static System Leak Test 5 Alternate Static Source Valve Removal and Installation A Remove Alternate Static Source Valve Refer to Figure 202 1 Reach behind stationar...

Page 605: ...l to instrument panel with screws 4 Check system for leaks Refer to step 10 Static System Leak Test 9 Pitot System Leak Test A Testing Procedures 1 Place a piece of tape over small hole in lower aft end of pitot tube 2 Fasten a piece of rubber or plastic tubing over pitot tube and close opposite end of tube 3 Slowly roll up tube until airspeed indicator registers in cruise range 4 Secure tube to p...

Page 606: ... to static source opening 2 Slowly apply positive pressure until altimeter indicates a 500 foot decrease inaltitude and maintain this altimeter indication 3 Coat line connections and static source flange with solution of mild soap and water watching for bubble to locate leaks 4 Tighten leaking connections Repair or replace parts found defective 5 Reconnect airspeed and vertical speed indicators in...

Page 607: ...tices Figure 201 2 From outside of cabin loosen and remove nut securing probe to roof skin 3 From inside of cabin withdraw probe through roof skin 4 Remove interior panels as required to free probe wiring from airplane structure 5 Disconnect electrical connector from backside of OAT Clock indicator 6 Remove probe pins from electrical connector B Install Probe Refer to Figure 201 1 Install new term...

Page 608: ...CE MANUAL HEX NUT WITH O RING INSERT GROUND CABIN LUG UPPER SKIN DETAIL B ELECTRICAL OAT CLOCK CONNECTOR INDICATOR INSTRUMENT PANEL SCREW 0510T1007 A0518R1067 Outside Air Temperature Installation Figure 201 Sheet 1 34 12 00 Page 202 Aug 18 2001 ...

Page 609: ...T COMPANY MODEL 172 MAINTENANCE MANUAL 5 Test for proper operation Refer to Pilot s Operating Handbook and FAA Approved Airplane Flight Manual Supplements for operation test instructions 34 12 00 Page 203 Aug 18 2001 ...

Page 610: ... an aircraft or being tested 3 Horizon Gyro General Operation Notes A The horizon gyro attitude is an instrument that requires air flow to move the gyro rotor for normal operation The airflow is provided by the vacuum system Any abnormalities vacuum system or other that effect the function and movement of the gyro rotor can effect indicating accuracy and performance B The horizon gyro requires app...

Page 611: ... MODEL 172 MAINTENANCE MANUAL INSTRUMENT PANEL SCREW REGULATOR VALVE WITH VACUUM GYRO ELECTRIC DIRECTIONAL FIREWALL GYRO DETAIL A A0518T1052 Attitude and Direction Instruments Figure 201 Sheet 1 34 20 00 Page 202 Aug 18 2001 ...

Page 612: ...anel with screws 6 Directional Gyro Operational Test A Test Directional Gyro NOTE Acceptable limits for gyro drift in flight is 4 in either direction from a heading during a ten minute period 1 Start airplane and verify proper operation of the vacuum system Suction gauge should read 4 5 to 5 5 in Hg 2 Align airplane into the wind 3 Allow directional gyro to stabilize for at least one minute 4 Set ...

Page 613: ... airplane centerline 2 Compass Removal Installation A Remove Compass Refer to Figure 201 1 Remove screws securing compass to compass base 2 Disconnect electrical connector B Install Compass Refer to Figure 201 1 Connect electrical connector 2 Secure compass to compass base with screws 3 Check compass accuracy on compass rose 34 21 00 Page 201 Aug 18 2001 ...

Page 614: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A COMPASS BEZEL COMPASS BASE DETAIL A 0510T1007 A0514T1007 Compass Installation Figure 201 Sheet 1 34 21 00 Page 202 Aug 18 2001 ...

Page 615: ...5 Install boots over antenna rods 3 Nav Antenna Coupler Removal Installation A Remove Nav Antenna Coupler Refer to Figure 201 1 Label and disconnect antenna coax connectors from nav antenna coupler 2 Remove screws securing nav antenna coupler to fuselage 3 Remove nav antenna coupler B Install Nav Antenna Coupler Refer to Figurre 201 1 Place nav antenna coupler on fuselage and secure with screws 2 ...

Page 616: ...RCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL NAV B ANTENNA FIN CAP ASSEMBLY ANTENNA BASE COAX CONNECTOR DETAIL A NAV ANTENNA COUPLER SCREW Nav Antenna Installation Figure 201 Sheet 1 34 50 00 Page 202 Aug 18 2001 ...

Page 617: ...adio rack B Install GPS Refer to Figure 201 1 Place GPS in radio rack and slide forward engaging fixed electrical plug 2 Tighten single locking screw located in recessed hole on face of receiver 3 GPS Antenna Removal Installation A Remove GPS Antenna Refer to Figure 201 1 Remove screws securing GPS antenna to fuselage skin 2 Disconnect coax connector from GPS antenna 3 Remove antenna and gasket B ...

Page 618: ...ESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B DETAIL A GPS ANTENNA GPS SCREW GASKET DETAIL B COAX CONNECTOR 0510T1007 A0518T1003 GPS Installation Figure 201 Sheet 1 34 51 00 Page 202 Aug 18 2001 ...

Page 619: ... 2 Pull ADF from radio rack B Install ADF Refer to Figure 201 1 Place ADF in radio rack and slide forward engaging fixed electrical plug 2 Tighten single locking screw located in recessed hole on face of receiver 3 ADF Antenna Removal Installation A Remove ADF Antenna Refer to Figure 201 1 Remove screws securing ADF antenna to fuselage skin 2 Disconnect antenna connector from ADF antenna 3 Remove ...

Page 620: ...A AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL U INDICATOR SKIN DOUBLER LOCKING SCREW DETAIL A ADF ANTENNA ANTENNA SCREW CONNECTOR DETAIL B ADF Installation Figure 201 Sheet 1 34 52 00 Page 202 Aug 18 2001 ...

Page 621: ... slide forward engaging fixed electrical plug 2 Tighten single locking screw located in recessed hole on face of receiver 3 Transponder Antenna Removal Installation A Remove Transponder Antenna Refer to Figure 201 1 Remove the aft cabin panel gaining access to the tailcone and transponder antenna 2 Remove nuts and washers securing transponder antenna to tailcone 3 From outside the airplane remove ...

Page 622: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B COAX DOUBLER SCREW DETAIL Transponder Installation Figure 201 Sheet 1 34 53 00 Page 202 Aug 18 2001 ...

Page 623: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER VACUUM ...

Page 624: ...APTER SECTION SUBJECT PAGE DATE 37 Title 37 List of Effective Pages 1 Aug 18 2001 37 Contents 1 Aug 18 2001 37 00 00 1 Aug 18 2001 37 10 00 101 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 37 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 625: ...nd Operation 37 10 00 Page 201 Vacuum Pump Removal Installation 37 10 00 Page 201 Regulator Valve Filter Removal Installation 37 10 00 Page 203 Gyro Filter Removal Installation 37 10 00 Page 203 Vacuum Gauge Removal Installation 37 10 00 Page 203 Regulator Valve Filter Removal Installation 37 10 00 Page 203 Gyro Filter Removal Installation 37 10 00 Page 203 Vacuum Gauge Removal Installation 37 10 ...

Page 626: ...er describes those units and components used to provide vacuum necessary to operate the artificial horizon and directional gyros 2 Definition A This chapter consists of a single section which describes those components used to distribute and indicate vacuum air 37 00 00 Page 1 Aug 18 2001 ...

Page 627: ...ulator filter clogged Check filter for obstructions LOW SUCTION Vacuum regulator leaking Replace vacuum regulator Vacuum pump failure Substitute known good pump and check pump suction Replace vacuum pump as required LOW PRESSURE Vacuum regulator leaking Replace safety valve Vacuum pump failure Substitute known good pump and check pump pressure Replace vacuum pump as required 37 10 00 Page 101 Aug ...

Page 628: ...d VAC R If both switches activate the message will read L VAC R NOTE Maintenance practices for the panel mounted annunciator can be found in Chapter 31 Annunciator Panel Maintenance Practices 2 Vacuum Pump Removal Installation NOTE Removal Installation is typical for both vacuum pumps A Remove Vacuum Pump Refer to Figure 201 1 Remove engine cowling Refer to Chapter 71 Cowling Maintenance Practices...

Page 629: ...DEL 172 MAINTENANCE MANUAL A ATTITUDE INDICATOR REGULATOR VALVE WITH VACUUM MANIFOLD ELBOW LEFT LOW VACUUM VACUUM GAGE ELBOW VACUUM PUMP FILTER DETAIL A Vacuum System Installation Figure 201 Sheet 1 37 10 00 Page 202 Aug 18 2001 ...

Page 630: ...vacuum switch 4 Loosen B nut securing vacuum manifold to nipple in firewall 5 Remove vacuum manifold from airplane B Install Vacuum Manifold and Annunciator Switches Refer to Figure 201 1 Position vacuum manifold on nipple in firewall and secure with B nut 2 Connect electrical wires to left low vacuum switch or right low vacuum switch 3 Connect hoses to vacuum manifold 4 Install upper engine cowli...

Page 631: ...CRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A FABRICATED TORQUE WRENCH ADAPTOR 2 25 INCHES 3 8 DRIVE DETAIL A 7 16 WRENCH VIEW A A Vacuum Pump Torque Wrench Adapter Figure 202 Sheet 1 37 10 00 Page 204 Aug 18 2001 ...

Page 632: ...s Operating Handbook and FAA Approved Airplane Flight Manual 2 Ensure suction gauge reads between 5 3 In Hg and 5 5 In Hg 3 If suction reading falls outside of range adjust regulator valve in the following steps a Bend locking tab upward on lower surface of regulator valve b Turn adjustment screw located on lower surface of regulator valve in desired direction to increase or decrease pressure as r...

Page 633: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER STANDARD PRACTICES AND STRUCTURES GENERAL ...

Page 634: ...PAGES CHAPTER SECTION SUBJECT PAGE DATE 51 Title 51 List of Effective Pages 1 Aug 18 2001 51 Contents 1 Aug 18 2001 51 00 00 1 Aug 18 2001 51 10 00 1 Aug 18 2001 51 11 00 1 Aug 18 2001 2 Aug 18 2001 3 Aug 18 2001 4 Aug 18 2001 51 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 635: ...PTION AND OPERTION 51 10 00 Page 1 Description 51 10 00 Page 1 CORROSION DESCRIPTION AND OPERATION 51 11 00 Page 1 General 51 11 00 Page 1 Characteristics of Corrosion 51 11 00 Page 1 Types of Corrosion 51 11 00 Page 1 Typical Corrosion Areas 51 11 00 Page 3 Corrosion Detection 51 11 00 Page 4 Corrosion Damage Limits 51 11 00 Page 4 51 CONTENTS Page 1 Aug 18 2001 ...

Page 636: ...he airplane refer to the Single Engine Structural Repair Manual 1996 and On 2 Definition A This chapter is divided into two sections briefly described below 1 The section on structures provides an overall description of the airplane structure and methods of construction used on the airplane 2 The section on corrosion provides a general description of corrosion characteristics types of corrosion an...

Page 637: ...stringers stiffen the skin between ribs Spars are comprised of machine milled tapered extrusions riveted to sheet metal webs C The full cantilever all metal tail group consists of a vertical stabilizer and rudder and a horizontal stabilizer and elevators The horizontal stabilizer is of one piece construction consisting of spars ribs and skins Elevators are constructed of aluminum spars ribs and sk...

Page 638: ...etc to the surface of the metal affected This will prevent the electrolyte from connecting the cathode to the anode and current cannot flow therefore preventing corrosion reaction Refer to Figure 1 for a typical organic film application 4 At normal atmospheric temperatures metals do not corrode appreciably without moisture but the moisture in the air is usually enough to start corrosive action 5 T...

Page 639: ...SIMPLIFIED CORROSION CELL UNBROKEN PAINT FILM NO CONTACT BETWEEN ELECTROLYTE AND ANODE AND CATHODE ELECTRON CONDUCTOR METAL CORROSION ELIMINATION BY APPLICATION OF ORGANIC FILM 26821017 Corrosion Identification Figure 1 Sheet 1 51 11 00 Page 2 Aug 18 2001 ...

Page 640: ...f protective surface coating or oxide films and additional corrosion takes place in the area of stress 4 Typical Corrosion Areas A This section lists typical areas of the airplane which are susceptible to corrosion These areas should be carefully inspected at periodic intervals to detect corrosion as early as possible 1 Engine Exhaust Trail Areas a Gaps seams and fairings on the lower right side o...

Page 641: ...d to inspect the obscured areas Any means which allows a thorough inspection can be used Magnifying glasses are valuable aids for determining whether or not all corrosive products have been removed during clean up operations 2 Liquid Dye Penetrant Inspection Inspection for large stress corrosion or corrosion fatigue cracks on nonporous or nonferrous metals may be accomplished using dye penetrant p...

Page 642: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER DOORS ...

Page 643: ...TE 52 Title 52 List of Effective Pages 1 Aug 18 2001 52 Contents 1 Aug 18 2001 52 00 00 1 Aug 18 2001 52 10 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 206 Aug 18 2001 207 Aug 18 2001 52 30 00 201 Aug 18 2001 202 Aug 18 2001 52 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 644: ... Weatherstrip Remove Installation 52 10 00 Page 202 Installation of Lock to Latch Assembly 52 10 00 Page 202 Install Latch Assembly to Door 52 10 00 Page 206 Upper Cabin Door Cable Installation 52 10 00 Page 206 Upper Cabin Door Cable Rigging 52 10 00 Page 206 Inside Door Handle Rigging 52 10 00 Page 207 BAGGAGE DOOR MAINTENANCE PRACTICES 52 30 00 Page 201 General 52 30 00 Page 201 Baggage Door Re...

Page 645: ...assist maintenance personnel in locating specific systems and information The following is a brief description of each section For locating information within the chapter refer to the Table of Contents at the beginning of the chapter 1 The cabin door section provides information on removal installation and rigging of the doors 2 The baggage door section provides information on removal installation...

Page 646: ...y moves aft which also drives the cable pin from the pin guide inthe door into the upper aft door sill receptacle The interior door handle has now moved from approximately 15 aft of vertical to approximately 45 forward of vertical Pushing the interior handle to the horizontal position flush with the arm rest will overcenter the door latch securing the doorfor flight The cabin door latch assembly a...

Page 647: ...its cable As the handle is moved further aft to the OPEN position the latch bolt disengages from the striker plate allowing the door to open 3 Cabin Door Removal Installation A Remove Cabin Door Refer to Figure 201 1 Open cabin door 2 Remove clevis pin from door stop spring 3 Remove screws securing hinges to fuselage 4 Remove cabin door from airplane B Install Cabin Door Refer to Figure 201 1 Posi...

Page 648: ...ENANCE MANUAL AS REQUIRED FOR GOOD SEAL WEATHERSTRIP SEAL TYPICAL ENTIRE PERIMETER DOOR STRUCTURE WEATHERSTRIP SEAL DOOR STRUCTURE NOTCH DETAIL E A A05111003 E05111003 Cabin Door Installation Figure 201 Sheet 1 52 10 00 Page 203 Aug 18 2001 ...

Page 649: ...ANY MODEL 172 MAINTENANCE MANUAL CABLE CLAMP PIN PUSH PULL ROD SPACER D ASSEMBLY NUT CAM ASSEMBLY S Cabin Door Installation ARM CAM ASSEMBLY OUTSIDE Cabin Door Installation Figure 201 Sheet 2 52 10 00 Page 204 Aug 18 2001 ...

Page 650: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL LOCK ASSEMBLY A SPRING HINGE E DETAIL B 05111004 A05111005 B05111005 Cabin Door Installation Figure 201 Sheet 3 52 10 00 Page 205 Aug 18 2001 ...

Page 651: ...n and door skin at aft end of door Push pin end of cable to top of door 3 Remove plug button and align pin of cable with pin guide and insert pin through guide Access is gained through a 0 875 inch diameter hole after removal of plug button 4 Align clamp on cable casing through hole located one inch below 0 875 inch access hole and install screw 5 Check operation of cable Ifsluggish operation of c...

Page 652: ...r cam does not appear to engage when inside handle is placed in the LOCK position and the door can be opened from the outside proceed as follows a Check sheathing on cable for interference against clamp bolt With handle in LOCK position the cable sheathing should be within approximately 0 125 inch of the clamp bolt but should not be touching it If sheathing is touching clamp bolt loosen clamps and...

Page 653: ... the door seal area of the baggage door measure and cut the new seal to length 5 Apply a thin even coat of RTV157 Adhesive around the circumference of the door seal area of the baggage door 6 Press the new seal into the adhesive Allow the adhesive to cure per the manufacturer s instructions ensuring that the seal is completely adhered to the door with no gaps between the seal and the door NOTE Do ...

Page 654: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL SPACER STRIKER PLATE DETAIL C DOOR BOLT BAGGAGE DOOR HINGE DETAIL B Baggage Door Installation Figure 201 Sheet 1 52 30 00 Page 202 Aug 18 2001 ...

Page 655: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER STABILIZERS ...

Page 656: ...VE PAGES CHAPTER SECTION SUBJECT PAGE DATE 55 Title 55 List of Effective Pages 1 Aug 18 2001 55 Contents 1 Aug 18 2001 55 00 00 1 Aug 18 2001 55 10 00 201 Aug 18 2001 202 Aug 18 2001 55 30 00 201 Aug 18 2001 202 Aug 18 2001 55 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 657: ... Page 1 HORIZONTAL STABILIZER MAINTENANCE PRACTICES 55 10 00 Page 201 General 55 10 00 Page 201 Horizontal Stabilizer Removal Installation 55 10 00 Page 201 VERTICAL STABILIZER FIN MAINTENANCE PRACTICES 55 30 00 Page 201 General 55 30 00 Page 201 Vertical Stabilizer Fin Removal Installation 55 30 00 Page 201 55 CONTENTS Page 1 Aug 18 2001 ...

Page 658: ...on on the horizontal and vertical stabilizer 2 Definition A The section on horizontal stabilizer provides instructions for removal and installation of the horizontal stabilizer B The section on vertical stabilizer fin provides instructions for removal and installation on the vertical stabilizer fin 55 00 00 Page 1 Aug 18 2001 ...

Page 659: ...rol System Maintenance Practices 3 Remove vertical stabilizer Refer to Vertical Stabilizer Maintenance Practices 4 Disconnect elevator trim control cables at clevis and turnbuckle inside tailcone 5 Remove pulleys which route the aft cables into horizontal stabilizer and pull cables out of tailcone 6 Remove bolts securing horizontal stabilizer to fuselage NOTE Note the order inwhich any spacers or ...

Page 660: ...RIZONTAL STABILIZER FORWARD RIGHT FAIRING FORWARD LEFT FAIRING STABILIZER TIP OUTBOARD ELEVATOR HINGE DETAIL A BUSHING DETAIL C INBOARD ELEVATOR 05321004 A05321003 B05321003 C05321002 Horizontal Stabilizer Installation Figure 201 Sheet 1 55 10 00 Page 202 Aug 18 2001 ...

Page 661: ...fitting 7 Remove upper elevator stop bolt 8 Remove bolts attaching fin front spar to fuselage bulkhead and remove fin from fuselage B Install Vertical Stabilizer Fin Refer to Figure 201 1 Place fin on fuselage and secure front spar of fin to fuselage 2 Install upper elevator stop bolt 3 Attach fin rear spar to fuselage fitting using shims if required and bolts NOTE If new fin is being installed ga...

Page 662: ...RUDDER NOTE FAIRING AND DORSAL HINGE FIN ARE RIVETED TO FUSELAGE FIN TIP DORSAL FAIRING RUDDER ASSEMBLY NUTPLATES UPPER RIGHT FAIRING RUDDER HINGE SHIM FUSELAGE FAIRING Vertical Stabilizer Fin Installation Figure 201 Sheet 1 55 30 00 Page 202 Aug 18 2001 ...

Page 663: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER WINDOWS ...

Page 664: ...Title 56 List of Effective Pages 1 Aug 18 2001 56 Contents 1 Aug 18 2001 56 00 00 1 Aug 18 2001 2 Aug 18 2001 56 00 01 1 Aug 18 2001 2 Aug 18 2001 56 10 00 201 Aug 18 2001 202 Aug 18 2001 56 20 00 201 Aug 18 2001 202 Aug 18 2001 56 30 00 201 Aug 18 2001 202 Aug 18 2001 56 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 665: ...ions 56 00 01 Page 1 Windowshield and Window Preventive Maintenance 56 00 01 Page 1 Windshield and Window Installation Techniques 56 00 01 Page 2 Windshield Rain Repellent 56 00 01 Page 2 WINDSHIELD MAINTENANCE PRACTICES 56 10 00 Page 201 General 56 10 00 Page 201 Rear Windshield Removal Installation 56 20 00 Page 201 Side Window Removal Installation 56 20 00 Page 201 CABIN DOOR WINDOWS MAINTENANC...

Page 666: ...ons inacrylic windshields and windows Mirror Glaze MGH 7 Meguiars Mirror Bright Polish To clean and polish 210 N First Ave acrylic windshields and Arcadia CA 91006 windows Soft cloth such Commercially Available To apply and remove wax as Cotton flannel and polish or cotton terry cloth Windshield U000926 Fiber Resin Corp To seal windshield sealant Tape 170 W Providencia Ave P O Box 4187 Burbank CA ...

Page 667: ...tenance instructions for repair and replacement of the windshield 3 The section on cabin windows provides maintenance instructions for the cabin side and cabin rear windows 4 The section on door windows provides maintenance instructions for openable windows located in the cabin doors 56 00 00 Page 2 Aug 18 2001 ...

Page 668: ...ntaminants and or scratching windshield with any abrasive particles 5 Rinse surface thoroughly with clean fresh water and dry with a clean cloth 6 Hard polishing wax should be applied to acrylic surfaces The wax has an index of refraction nearly the same as transparent acrylic and will tend to mask any shallow scratches on the windshield surface 7 Acrylic surfaces may be polished using a polish me...

Page 669: ...hole depth to hole diameter ratio is less than 1 5 to 1 the drill shall have an included tip angle of 55 degrees to 60 degrees and a lip clearance angle of 15 degrees to 20 degrees b Medium Deep Holes When hole depth to hole diameter ratio is from 1 5 to 1 up to 3 to 1 the drill shall have an included tip angle of 60 degrees to 140 degrees and a lip clearance angle of 15 degrees to 20 degrees c De...

Page 670: ... clean off old sealer and felt then install new felt around edges of windshield 2 If new windshield is to be installed remove protective cover and clean 3 Apply new felt to edges of windshield 4 Apply windshield sealant tape along the sides and bottom of felt Refer to Windows General for a list of sealant tape 5 Position the bottom edge of windshield against deck skin 6 Using a piece of bent sheet...

Page 671: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL OUTER RETAINER FELT SEAL INNER RETAINER D DETAIL A D0511T3002 Windshield Installation Figure 201 Sheet 1 56 10 00 Page 202 Aug 18 2001 ...

Page 672: ...f old window is being reinstalled remove all traces of old sealant from window 2 Clean out channels and retainers to remove all traces of old sealant 3 Check fit and carefully file or grind away excess plastic 4 Apply felt strip and sealant to all edges of window to prevent leaks 5 Reinstall rear window to airplane and secure using retainer strips and rivets 6 Install upholstery Refer to Chapter 2...

Page 673: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REAR SIDE 05124001 Cabin Windows Installation Figure 201 Sheet 1 56 20 00 Page 202 Aug 18 2001 ...

Page 674: ...or instructions on temporary repair to the cabin door windows refer to Windshield Maintenance Practices 2 Cabin Door Window Removal Installation A Remove Cabin Door Window Refer to Figure 201 1 Disconnect arm from window assembly 2 Remove hinge pins from hinge B Install Cabin Door Window Refer to Figure 201 1 Position window assembly to door 2 Secure window assembly to hinge using hinge pin 56 30 ...

Page 675: ... AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL LATCH BRACKET LATCH ASSEMBLY ASSEMBLY ARM DETAIL A 0510T1007 A05113001 B05111002 Cabin Door Window Installation Figure 201 Sheet 1 56 30 00 Page 202 Aug 18 2001 ...

Page 676: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER WINGS ...

Page 677: ...JECT PAGE DATE 57 Title 57 List of Effective Pages 1 Feb 15 2002 57 Record of Temporary Revisions 57 Contents 1 Aug 18 2001 57 00 00 1 Aug 18 2001 57 10 00 201 Feb 15 2002 202 Feb 15 2002 203 Feb 15 2002 204 Feb 15 2002 205 Feb 15 2002 206 Feb 15 2002 57 LIST OF EFFECTIVE PAGES Page 1 Feb 15 2002 ...

Page 678: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 679: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 680: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 681: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 682: ...on 57 00 00 Page 1 WINGS AND WING STRUTS MAINTENANCE PRACTICES 57 10 00 Page 201 Description and Operation 57 10 00 Page 201 Wing and Strut Removal Installation 57 10 00 Page 201 Adjustment Correcting Wing Heavy Conditions 57 10 00 Page 204 Strut Damage and Repair Criteria 57 10 00 Page 205 Wing Tip Removal Installation 57 10 00 Page 205 57 CONTENTS Page 1 Aug 18 2001 ...

Page 683: ...ine 1996 and On Structural Repair Manual 2 Tools Equipment and Materials NOTE Equivalent substitutes may be used for the following listed items NAME NUMBER MANUFACTURER USE Grease MIL G 21164 E M Corporation To lubricate wing attach Box 2200 fittings and bolts upon Highway 52 N W reinstallation West Lafayette IN47906 3 Definition A This chapter contains a single section on wing removal installatio...

Page 684: ...in fuel from wing 4 Disconnect electrical wires at wing root disconnects 5 Disconnect fuel lines at wing root 6 On left wing disconnect pitot line 7 Disconnect fresh air distribution duct at wing root 8 Loosen and disconnect aileron cables at aileron bellcrank 9 Disconnect flap cables at turnbuckle above cabin headliner and pull cables into wing root area NOTE To ease rerouting of cables a guide w...

Page 685: ...NANCE MANUAL B234 WASHERS LOWER NUT REAR ECCENTRIC FAIRING A BUSHINGS FAIRING DETAIL A WING FLAP NAVIGATION AND BOLT STROBE LIGHTS NUT DETAIL B 052T2001 A0520T1003 80520T1002 Wing Installation Figure 201 Sheet 1 57 10 00 Page 202 Feb 15 2002 ...

Page 686: ...TION A ccv UPPER FAIRING TIE DOWN SCREW 0 cRING LOWER FAIRING SPAC ER BOLT NOTE B WING STRUT WING STRUT S O_ WING ATTACHMENT FITTING TIE DOWN RING FUSELAGE ATTACHMENT DETAIL A FITTING BOLT 0520T1006 DETAIL B NOTE 0520T1006 A0520T1006 B0520T1006 Wing Installation Figure 201 Sheet 2 57 10 00 Page 203 Feb 15 2002 ...

Page 687: ...s 12 Install all removed access inspection plates and upholstery 3 Adjustment Correcting Wing Heavy Conditions NOTE If considerable control wheel pressure is required to keep the wings level in normal flight a wing heavy condition exists and can be corrected by the following procedure A Adjustment Procedures Refer to Figure 201 Detail A 1 Remove wing fairing strip on the wing heavy side of the air...

Page 688: ...202 1 Connect strobe light electrical connector and connect navigation light electrical connector 2 Slide the wing tip into position over the wing tip rib ensuring the existing holes in the wing tip align with the attach holes in the wing skin rib nutplates 3 Fabricate a curved spacer from phenolic or aluminum which is0 01 to 0 03 inch thick X 1 0 inch X 2 0 inches which matches the contour of the...

Page 689: ...l o3llino 3 30VdS iVnNVW 3ONVN31NIVIA ...

Page 690: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER PROPELLERS ...

Page 691: ...S CHAPTER SECTION SUBJECT PAGE DATE 61 Title 61 List of Effective Pages 1 Feb 15 2002 61 Record of Temporary Revisions 61 Contents 1 Feb 15 2002 61 00 00 1 Aug 18 2001 61 10 00 201 Feb 15 2002 202 Feb 15 2002 Added 203 Feb 15 2002 61 LIST OF EFFECTIVE PAGES Page 1 Feb 15 2002 ...

Page 692: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 693: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 694: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 695: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 696: ...PELLERS GENERAL 61 00 00 Page 1 Scope 61 00 00 Page 1 Definition 61 00 00 Page 1 PROPELLER MAINTENANCE PRACTICES 61 10 00 Page 201 Description and Operation 61 10 00 Page 201 Propeller and Spinner Removal Installation 61 10 00 Page 201 61 CONTENTS Page 1 Feb 15 2002 ...

Page 697: ...ENANCE MANUAL PROPELLERS GENERAL 1 Scope A This chapter provides instructions on propeller and spinner 2 Definition A This chapter contains a single section on removal and installation of the propeller and spinner 61 00 00 Page 1 Aug 18 2001 ...

Page 698: ...se to the hub as possible with the spacer down Allow two 2 inches of clearance for the spacer and aft bulkhead to separate from the hub b Select a rod of proper diameter and is six 6 inches long Insert rod into propeller hub dowel pin holes Using a hammer lightly tap dowels in a alternating pattern to free the spacer and bulkhead from propeller hub The dowels will remain inthe spacer c Ifthe taper...

Page 699: ...MANUAL B1786 A SPACER DOWEL FORWARD BULKHEAD ASSEMBLY WASHER o SPINNER AFT BULKHEAD ASSEMBLY PROPELLER PROPELLER MOUNTING BOLT SCREWS DETAIL A 0510T1007 A0555R3001 Propeller and Spinner Installation Figure 201 Sheet 1 61 10 00 Page 202 Feb 15 2002 ...

Page 700: ...h 0 516 inch diameter drill NOTE If necessary the spinner screw holes in the aft bulkhead flanges may be increased to 0 205 inch diameter for adjustment 7 Secure propeller assembly using the propeller bolts and washers Tighten the mounting bolts in a crossing pattern to 660 780 inch pounds dry 55 65 foot pounds dry Safety wire the mounting bolts Refer to Chapter 20 Safetying Maintenance Practices ...

Page 701: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER POWER PLANT ...

Page 702: ...g 18 2001 3 Aug 18 2001 4 Aug 18 2001 5 Aug 18 2001 101 Aug 18 2001 102 Aug 18 2001 103 Aug 18 2001 104 Aug 18 2001 105 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 71 10 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 71 20 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 71 60 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 71 70 00 201 Aug 18 2001 202 Aug 18 2001 71 LIST ...

Page 703: ...age 201 Description and Operation 71 10 00 Page 201 Cowling Removal Installation 71 10 00 Page 201 Cowling Shock Mounts 71 10 00 Page 201 Cowling Repair 71 10 00 Page 201 ENGINE MOUNT MAINTENANCE PRACTICES 71 20 00 Page 201 Description and Operation 71 20 00 Page 201 Engine Mount Procedures 71 20 00 Page 201 Engine Mount Repairs 71 20 00 Page 201 AIR INDUCTION SYSTEM MAINTENANCE PRACTICES 71 60 00...

Page 704: ...ng a particular subject A brief definition of the sections incorporated in this chapter is as follows 1 The section on powerplant provides description operation troubleshooting and removal installation information for the engine 2 The section on engine cowlings provides removal and installation instructions for the engine cowlings 3 The section on mounts provides removal and installation procedure...

Page 705: ...lustration of the engine refer to Figure 1 C For information beyond the scope of this chapter refer to applicable engine manuals listed in Introduction List of Supplier Publications Table 1 IO 360 L2A Technical Description 172R Rated Horsepower at 2400 160 RPM 172S Rated Horsepower at 2700 180 RPM Number of Cylinders 4 Horizontally Opposed Displacement 361 0 Cubic Inches Bore 5 125 Stroke 4 375 Co...

Page 706: ...2 MAINTENANCE MANUAL Table 1 IO 360 L2A Technical Description continued Normal 100 F to 245 F Maximum 245 F Dry Weight without alternator or 278 Lbs vacuum pumps And 172R Airplanes Incorporating MK172 72 01 71 00 01 Page 2 Aug 18 2001 ...

Page 707: ...INTENANCE MANUAL OIL PRESSURE RELIEF VALVE LOW OIL PRESSURE OIL SWITCH COOLER ALTERNATOR DIPSTICK OIL FILTER CRANKCASE FUEL BREATHER DISTRIBUTION LINE VALVE FLOW TRANSDUCER Engine Installation Figure 1 Sheet 1 71 00 01 Page 3 Aug 18 2001 ...

Page 708: ...MPANY MODEL 172 MAINTENANCE MANUAL FUEL FLOW ENGINE STARTER TRANSDUCER RING GEAR HEAT MUFFLER WITH HEAT SHROUD AIR FILTER INLET DUCT DRAIN LINES 0550C1006 Engine Installation Figure 1 Sheet 2 71 00 01 Page 4 Aug 18 2001 ...

Page 709: ...SNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL BAFFLE MAGNETOS ENGINE DRIVEN ILLUSTRATED PIPE CONTROL UNIT FUEL STRAINER DRAIN 0550C1007 Engine Installation Figure 1 Sheet 3 71 00 01 Page 5 Aug 18 2001 ...

Page 710: ... temperature and humidity can have a significant impact on run up RPM Low static run up RPM information should be used only in conjunction with other troubleshooting procedures to determine ifa problem actually exists 7 If run up indicates low power check the following items a Check operation of alternate air door and ensure door remains closed in normal operation b Check magneto timing spark plug...

Page 711: ...T RUN AT Idle stop screw or idle Refer to Chapter 73 Fuel IDLING SPEED mixture lever incorrectly Injection System Maintenance adjusted Practices Air leak in intake manifold Tighten loose connections or replace damaged parts Weak magneto capacitor Install new capacitor Spark plugs fould by oil Top overhaul engine escaping past piston rings ROUGH IDLING Improper idle mixture Refer to Chapter 73 Fuel...

Page 712: ...es for leakage and deteriorated install new parts as necessary Improper mixture Check mixture control setting CONSTANT MISFIRING AT Valve spring broken Install new spring HIGH RPM Valve warped or burned Top overhaul engine Hydraulic tappet worn or Remove clean or install new dirty parts SLUGGISH OPERATION Injectors clogged Test and clean injectors AND LOW POWER Worn valve seats Top overhaul engine...

Page 713: ...HIGH OIL TEMPERATURE Oil cooler fins clogged Clean thoroughly Oil cooler oil passages Remove and flush cooler restricted Oil cooler bypass valve Remove cooler and clean valve damaged or held open and seat Low oil supply Replenish Oil viscosity too high Use correct grade of oil Prolonged high speed Avoid prolonged ground operation on ground operation above 1500 RPM Dirty clogged oil filter Replace ...

Page 714: ...seal ENGINE OIL LEAK AT PUSHROD Damaged housing seal Install new seals HOUSING LOW COMPRESSION Worn cylinder and or rings Top overhaul engine or replace defective cylinder Valve not properly seating Top overhaul engine or replace defective cylinder EXCESSIVE OIL Low grade of oil Use specified grade of oil CONSUMPTION Failed or failing bearings Check oil filter for metal particles and iffound overh...

Page 715: ...magnetos 6 Disconnect electrical connector JN004 from EGT Probe UN005 7 Disconnect fuel outlet line at the fuel strainer 8 Disconnect throttle and mixture cables at fuel air control unit Note position of washers and spacers for later reassembly 9 Disconnect vacuum hoses 2 at firewall mounted manifold check valve 10 Disconnect and label electrical wires on low vacuum annunciator switches low oil pr...

Page 716: ...to oil pressure transducer U1006 9 Connect electrical connector JN005 to low oil pressure switch SN001 10 Connect electrical connector JN00 to fuel flow transducer UN003 11 Connect ground strap to engine mount 12 Install starter wires to starter and secure wires to sump area using clamps 13 Secure various wire bundles to engine mount using tie wraps 14 Connect tachometer drive cable to back of acc...

Page 717: ...nstall lower cowl to engine area and secure using quick release fasteners 2 Install induction air filter bracket to lower cowl using quick release fasteners 3 Attach upper nose piece to lower nose piece using screws 4 Install upper cowl to engine area and secure using quick release fasteners 3 Cowling Shock Mounts A Shock Mount Adjustment Replacement Refer to Figure 202 1 The shock mounts are rive...

Page 718: ...SSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL PIN HINGE UPPER COWL UPPER NOSE CAP INDUCTION AIR ASSEMBLY A0552T3001 DETAIL Engine Cowling Installation Figure 201 Sheet 1 71 10 00 Page 202 Aug 18 2001 ...

Page 719: ...ENGINE BRACKET SNUBBER SHIM FIREWALL SNUBBER NOSE CAP SUPPORT DETAIL B DETAIL C NOTE SHIM CAN BE INSTALLED AS REQUIRED MAXIMUM 4 BETWEEN SNUBBER SUPPORT AND SNUBBER TO OBTAIN A MAXIMUM GAP OF 0 125 INCH BETWEEN SNUBBER AND COWL SNUBBER BRACKET 0510T1007 A0511T1006 B05521002 C05521002 Engine Cowling Shock Mount Installation Figure 202 Sheet 1 71 10 00 Page 203 Aug 18 2001 ...

Page 720: ... should never be cleaned with any type of solvent If shock mounts need cleaning use a clean dry cloth 3 Shock mounts should be inspected when removed Metal components should be inspected for cracks and excessive wear due to aging and deterioration Rubber components should be inspected for separation swelling cracking or a pronounced set of the pad Shock mounts showing any of these signs should be ...

Page 721: ...INTENANCE MANUAL 1789 WASHER ENGINE ENGINE MOUNT M MOUNTING NUT UPPER RIGHT HAND SHOCK MOUNT BOLT WASHER MOUNTING DAMPER WASHER LOWER RIGHT HAND SHOCK MOUNT Engine Shock Mount Installation Figure 201 Sheet 1 71 20 00 Page 202 Aug 18 2001 ...

Page 722: ... MANUAL BOLT DAMPER WASHER ENGINE WASHER ENGINE UPPER LEFT HAND SHOCK MOUNT WASHER WASHER NUT ENGINE SPACER MOUNTING MOUNTING WASHER BOLT LOWER LEFT HAND SHOCK MOUNT Engine Shock Mount Installation Figure 201 Sheet 2 71 20 00 Page 203 Aug 18 2001 ...

Page 723: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL MOUNT WASHER DETAIL A 051 OT1007 A05511001 Firewall Engine Mount Installation Figure 202 Sheet 1 71 20 00 Page 204 Aug 18 2001 ...

Page 724: ...ir filter bracket to lower cowl using quick release fasteners 3 172S Engine Induction Air Filter Maintenance Practices A The induction air filter keeps dust and dirt from entering the induction system The value of maintaining the air filter inagood clean condition can never be overstressed More engine wear is caused through the use of a dirty or damaged air filter than is generally believed The fr...

Page 725: ...MPANY MODEL 172 MAINTENANCE MANUAL HINGE SPRING DOOR DETAIL B ALTERNATE AIR DOOR FILTER INDUCTION BOX AIR ELBOW INLET DUCT DRAIN CLAMPS DETAIL A Induction Air Installation Figure 201 Sheet 1 71 60 00 Page 202 Aug 18 2001 ...

Page 726: ... installed anytime the existing filter is damaged A damaged filter may have sharp or broken edges in the filtering panels which would allow unfiltered air to enter the induction system Any filter that appears doubtful shall have a new filter installed inits place 5 After washing rinse filter with clearwater until rinse water draining from filter is clear Allow water to drain from filter and dry wi...

Page 727: ...ured using hose clamps and are routed together in a cluster on the left side of the forward firewall 2 Maintenance Practices A Maintenance practices for all drain lines are typical Line removal and installation consists of removing clamps and other devices used to secure the lines to various structure Lines should be checked for condition and security when removed and installed inreverse order B F...

Page 728: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL DETAIL C DETAIL B INLET DRAIN HOSE INLET DRAIN LINE BREATHER Engine Drain Lines Installation Figure 201 Sheet 1 71 70 00 Page 202 Aug 18 2001 ...

Page 729: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER ENGINE FUEL AND CONTROL ...

Page 730: ... Title 73 List of Effective Pages 1 Aug 18 2001 73 Contents 1 Aug 18 2001 73 00 00 1 Aug 18 2001 73 00 01 1 Aug 18 2001 2 Aug 18 2001 3 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 204 Aug 18 2001 205 Aug 18 2001 73 30 00 201 Aug 18 2001 202 Aug 18 2001 73 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 731: ...Air Control Unit Removal Installation 73 00 01 Page 201 Fuel Distribution Valve Removal Installation 73 00 01 Page 202 Injection Nozzle Removal Installation 73 00 01 Page 202 Injection Nozzle Flow Test 73 00 01 Page 202 Idle and Mixture Adjustment 73 00 01 Page 203 Injector Nozzle Cleaner 73 00 01 Page 205 Fuel Strainer Cleaner 73 00 01 Page 205 Air Throttle Shaft Lubrication 73 00 01 Page 205 FUE...

Page 732: ...finition A This chapter is divided into sections and subsections to assist maintenance personnel in locating specific systems and information The following is a brief description of each section For locating information within the chapter refer to the Table of Contents at the beginning of the chapter 1 The section on fuel injection covers procedures used to troubleshoot and maintain the fuel injec...

Page 733: ...mines in conjunction with fuel pressure the fuel flow entering each cylinder Fuel entering the nozzle is discharged through the jet into an ambient air pressure chamber within the nozzle assembly This nozzle assembly also contains a calibrated opening which is vented to the atmosphere and allows fuel to be dispersed into the intake portion of the cylinder inan atomized cone shaped pattern 3 Operat...

Page 734: ...IDLE VALVE LEVER MANUAL MIXTURE THROTTLE LEVER LINKAGE CONSTANT EFFORT SPRING PRESSURE BELOW FLOW DIVIDER 1 8 INCH STAINLESS THROTTLE STEEL LINE METERED FUEL PRESSURE P2 TO FUEL FLOW GAUGE PRESSURE 05162001 Fuel Injection System Schematic Figure 1 Sheet 1 73 00 01 Page 2 Aug 18 2001 ...

Page 735: ...the air diaphragm and acts as a solid member The constant effort spring produces a force which provides a smooth transfer from idle to low power cruise operation Whenever the air metering fuel metering and spring forces are balanced the ball valve maintains a fixed position 3 THE FUEL METERING SECTION is contained within the throttle body casting and consists of an inlet fuel screen a rotary idle ...

Page 736: ...ing inlet adaptor and throttle cable bracket to base of control unit and mixture cable bracket 7 Remove nuts lock washers and flat washers securing control unit to oil sump intake manifold Cover engine intake opening and place control unit inasealed dust free environment to prevent accumulation of foreign particles into unit B Install Fuel Air Control Unit 1 Remove engine intake cover from sump ar...

Page 737: ...nstall nozzles to intake cylinders Torque from 55 to 60 In lbs 2 Install rigid fuel lines to nozzles Torque 25 to 50 In lbs 3 Install upper cowling Refer to Chapter 71 Cowling Maintenance Practices 6 Injection Nozzle Flow Test A Check Injection Nozzles For Plugging 1 If nozzle plugging is suspected disconnect injector lines at the nozzles 2 Cap nozzles with clean valve stem caps to protect nozzles...

Page 738: ...NTROL UNTIL OBSERVING OR SENSING A DROP IN THE ENGINE RPM THIS IS THE TOTAL RPM RISE WHICH INDICATES THE MIXTURE STRENGTH AT THE ENGINE IDLE SPEED 4 Rotate the mixture control to lean the mixture Note the rise inengine RPM This rise should be set to 10 to 20 RPM NOTE To aid in the adjustment of the fuel mixture a stamp on one half of the clevis on the fuel servo indicates the direction the thumb w...

Page 739: ...UAL A IDLE SPEED ADJUSTMENT INLET FUEL PRESSURE TAP AND STRAINER IDLE MIXTURE ADJUSTMENT IDLE VALVE ART USED BY PERMISSION DETAIL A 0510T1007 OF PRECISION AIRMOTIVE A05561002 Idle and Mixture Adjustment Figure 201 Sheet 1 73 00 01 Page 204 Aug 18 2001 ...

Page 740: ...l nozzles to intake cylinders Torque from 55 to 60 In lbs 6 Install rigid fuel lines to nozzles Torque 25 to 50 In lbs 7 Perform leak check 9 Fuel Strainer Cleaning A The fuel strainer should be cleaned at time intervals set forth in Chapter 5 Inspection Time Limits B Cleaning Procedures Refer to Figure 201 1 Remove fuel inlet hose to access fuel strainer 2 Remove and clean fuel strainer inStoddar...

Page 741: ...ical connector from gauge B Install Fuel Flow Gauge 1 Connect electrical connector to gauge 2 Install gauge ininstrument panel using screws 3 Restore electrical power to airplane and ensure gauge isconnected and functioning properly 3 Transducer and Line Removal Installation A Remove Transducer Refer to Figure 201 1 Ensure all electrical power to airplane is off 2 Remove upper cowling Refer to Cha...

Page 742: ...ODEL 172 MAINTENANCE MANUAL A ELECTRICAL CONNECTOR FUEL DISTRIBUTION FUEL FLOW TRANSDUCER VALVE ENGINE BAFFLE NUT RIGID FUEL LINE CLAMP DETAIL A Fuel Flow Indicating Installation Figure 201 Sheet 1 73 30 00 Page 202 Aug 18 2001 ...

Page 743: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER IGNITION ...

Page 744: ...APTER SECTION SUBJECT PAGE DATE 74 Title 74 List of Effective Pages 1 Aug 18 2001 74 Contents 1 Aug 18 2001 74 00 00 1 Aug 18 2001 74 10 00 101 Aug 18 2001 102 Aug 18 2001 201 Aug 18 2001 202 Aug 18 2001 601 Aug 18 2001 602 Aug 18 2001 74 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 745: ...e 101 General 74 10 00 Page 101 IGNITION SYSTEM MAINTENANCE PRACTICES 74 10 00 Page 201 Description and Operation 74 10 00 Page 201 Magneto Removal Installation 74 10 00 Page 201 Check Magneto Timing 74 10 00 Page 202 IGNITION SWITCH INSPECTION CHECK 74 30 00 Page 601 Description 74 30 00 Page 601 Tools Equipment and Materials 74 30 00 Page 601 ACS Ignition Switch Inspection and Lubrication 74 30 ...

Page 746: ... 1206 Cessna Aircraft Company To lubricate ignition Cessna Parts Distribution switch components Department 701 CPD 25800 East Pawnee Wichita KS 67218 5590 Ignition Switch A3770 Cessna Aircraft To rebuild ignition switch Parts Kit 3 Definition A This chapter contains two sections on the ignition system The first section provides a troubleshooting chart to aid in identifying common problems which ma...

Page 747: ...isture or deposits Defective ignition harness If no defects are found by a visual inspection check with a harness tester Replace defective parts Magneto P lead grounded Check continuity P lead should not be grounded in the ON position but should be grounded on OFF position Repair or replace P lead Failure of impulse coupling Impulse coupling pawls should engage at cranking speeds Listen for loud c...

Page 748: ...pection check with a harness tester Replace defective parts Defective magneto Refer to Ignition System Maintenance Practices Impulse coupling pawls Listen for loud clicks as impulse remain engaged coupling operates Remove magneto and determine cause Replace defective magneto Spark plugs loose Check and install properly 74 1 0 00 Page 102 Aug 18 2001 ...

Page 749: ...r TDC 3 Disconnect P lead and ground wire from magneto Remove screws securing high tension outlet cover to the magneto 4 Remove nuts washers and clamps securing magneto to engine accessory housing Note approximate position of the magneto for reinstallation B Install Magneto 1 If magneto was rotated or a new magneto is being installed perform the following steps a Insert timing pin into back of mag...

Page 750: ...istinctive click is heard from the impulse couplings on the magnetos 3 Turn propeller backward to approximately 30 BTDC and then slowly forward to 25 BTDC 4 Loosen mounting clamps securing magneto to accessory case 5 Connect a standard timing light between a suitable engine ground and the P lead terminal of the magneto 6 Turn ignition switch to the ON position 7 Rotate entire magneto opposite norm...

Page 751: ...or corrosion and for loose contacts or terminals If the silver plating on the contact cups is worn through to the brass material or they are burned or pitted from arcing or are corroded they should be replaced Ifthe contacts on the contact block exhibit any of the above conditions or the terminals are loose the terminal board assembly should be replaced E Switch Reassembly 1 Apply a thin coating o...

Page 752: ...AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A SWITCH CONTACTS CONTACT CUPS SPRING TERMINAL BOARD SWITCH BODY SCREW ACS Ignition Switch Inspection Lubrication Figure 601 Sheet 1 74 30 00 Page 602 Aug 18 2001 ...

Page 753: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER ENGINE CONTROLS ...

Page 754: ... SECTION SUBJECT PAGE DATE 76 Title 76 List of Effective Pages 1 Aug 18 2001 76 Contents 1 Aug 18 2001 76 00 00 1 Aug 18 2001 76 10 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 76 11 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 76 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 755: ...le Control Removal Installation 76 10 00 Page 201 Throttle Control Adjustment Test 76 10 00 Page 203 Throttle Control Inspection Check 76 10 00 Page 203 FUEL MIXTURE CONTROL MAINTENANCE PRACTICES 76 11 00 Page 201 General 76 11 00 Page 201 Fuel Mixture Control Removal Installation 76 11 00 Page 201 Fuel Mixture Control Adjustment Test 76 11 00 Page 203 Fuel Mixture Control Inspection Check 76 11 0...

Page 756: ...cians in locating information Consulting the Table of Contents will further assist in locating a particular subject A brief description of the sections follows 1 The section on throttle control describes the throttle handle cable and linkage 2 The section on fuel mixture control describes the mixture handle cable and linkage 3 Both sections include removal installation rigging and inspection requi...

Page 757: ...e cable retaining nut and washer from forward side of instrument panel 6 Carefully pull throttle control through firewall and instrument panel and remove from airplane B Install Throttle Control Refer to Figure 201 NOTE When installing throttle control ensure that control is routed exactly as previously installed Ensure that no binding or preloading occurs from a too small bend radius 1 Inside the...

Page 758: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INSTRUMENT PANEL LOCKWASHER FIREWALL LOCKWASHER ROD END BOLT DETAIL A Throttle Control Installation Figure 201 Sheet 1 76 10 00 Page 202 Aug 18 2001 ...

Page 759: ... 4 Throttle Control Inspection Check A Inspect Throttle Control 1 The throttle control attachment to throttle body should be inspected in accordance with time limits established in Chapter 5 Inspection Time Limits Check bolt castellated nut cotter pin and rod end for security and condition Check that throttle control slides smoothly throughout its full range of travel that it locks securely with t...

Page 760: ...wall 5 Inthe cockpit cabin area remove mixture control retaining nut and washer from forward side of instrument panel 6 Carefully pull throttle control through firewall and instrument panel and remove from airplane B Install Fuel Mixture Control Refer to Figure 201 NOTE When installing mixture control ensure that control is routed exactly as previously installed Ensure that no binding or preloadin...

Page 761: ...AFT COMPANY MODEL 172 MAINTENANCE MANUAL INSTRUMENT PANEL JAMNUTS WASHER WITH WASHERS COTTER PIN CABLE LARGE WASHER WASHER MIXTURE DETAIL A BOLT Fuel Mixture Control Figure 201 Sheet 1 76 11 00 Page 202 Aug 18 2001 ...

Page 762: ...ion Check A Inspect Fuel Mixture Control 1 The mixture control attachment to the throttle body should be inspected inaccordance with time limits established inChapter 5 Inspection Time Limits Check bolt castellated nut cotter pin and rod end for security and condition Check that fuel mixture control slides smoothly throughout its full range of travel that it adjusts through its full vernier range ...

Page 763: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER ENGINE INDICATING ...

Page 764: ...VE PAGES CHAPTER SECTION SUBJECT PAGE DATE 77 Title 77 List of Effective Pages 1 Aug 18 2001 77 Contents 1 Aug 18 2001 77 00 00 1 Aug 18 2001 77 10 00 201 Aug 18 2001 202 Aug 18 2001 77 20 00 201 Aug 18 2001 202 Aug 18 2001 77 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 765: ...TENANCE PRACTICES 77 10 00 Page 201 Description and Operation 77 10 00 Page 201 Tachometer and Drive Cable Removal Installation 77 10 00 Page 201 EGT SYSTEM MAINTENANCE PRACTICES 77 20 00 Page 201 Description and Operation 77 10 00 Page 201 EGT Indicator Removal Installation 77 20 00 Page 201 Probe Removal Installation 77 20 00 Page 201 77 CONTENTS Page 1 Aug 18 2001 ...

Page 766: ...nto sections to aid maintenance technicians inlocating information Consulting the Table of Contents will further assist in locating a particular subject A brief description of the sections follows 1 The section on tachometer describes the instrument used to measure engine RPM 2 The section on exhaust gas temperature describes the system used to monitor and measure engine temperature 77 00 00 Page ...

Page 767: ...securing tachometer to instrument panel and remove tachometer 4 Remove upper engine cowling Refer to Chapter 71 Engine Cowling Maintenance Practices 5 Disconnect drive cable at rear of accessory case 6 Remove two screws securing firewall shield to firewall 7 Withdraw drive cable through firewall B Install Tachometer and Drive Cable Refer to Figure 201 1 Install drive cable through firewall 2 Conne...

Page 768: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL TACHOMETER DRIVE CABLE ASSEMBLY ENGINE TACHOMETER DETAIL A Tachometer Installation Figure 201 Sheet 1 77 10 00 Page 202 Aug 18 2001 ...

Page 769: ...crews securing indicator to instrument panel and withdraw indicator from airplane B Install EGT Indicator Refer to Figure 201 1 Place indicator in instrument panel and secure using screws 2 Connect electrical connector to indicator 3 Probe Removal Installation A Remove Probe Refer to Figure 201 1 Remove engine cowling Refer to Chapter 71 Engine Cowling Maintenance Practices CAUTION EXHAUST SYSTEM ...

Page 770: ...NA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL PROBE DETAIL A EGT INDICATOR NUT INSTRUMENT PANEL LOCKWASHER 0510T1007 AA051T 1049 DETAIL B EGT Installation Figure 201 Sheet 1 77 20 00 Page 202 Aug 18 2001 ...

Page 771: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER EXHAUST ...

Page 772: ...ST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 78 Title 78 List of Effective Pages 1 Aug 18 2001 78 Contents 1 Aug 18 2001 78 00 00 1 Aug 18 2001 78 10 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 78 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 773: ... ERAL 78 00 00 Page 1 Scope and Definition 78 00 00 Page 1 EXHAUST SYSTEM MAINTENANCE PRACTICES 78 10 00 Page 201 Description 78 10 00 Page 201 Exhaust System Removal Installation 78 10 00 Page 201 Muffler Inspection 78 10 00 Page 201 78 CONTENTS Page 1 Aug 18 2001 ...

Page 774: ...NTENANCE MANUAL EXHAUST GENERAL 1 Scope and Definition A This chapter is comprised of a single section on the exhaust system The section details removal installation and testing procedures for the exhaust system 78 00 00 Page 1 Aug 18 2001 ...

Page 775: ...tself using screws 2 Loosely install risers 4 total to muffler using clamps 3 Install riser muffler assembly to engine using new gaskets 4 Tighten risers 200 210 inch pounds at engine then tighten clamps connecting risers to muffler 5 Reconnect EGT probe 6 Reinstall engine cowling Refer to Chapter 71 Engine Cowling Maintenance Practices 3 Muffler Inspection NOTE The exhaust system must be thorough...

Page 776: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RISER 05552001 Exhaust System Installation Figure 201 Sheet 1 78 10 00 Page 202 Aug 18 2001 ...

Page 777: ...ler using rubber expansion plugs NOTE One expansion plug should be adapted to allow for introduction of low pressure air into muffler b Using a pressure gauge or manometer apply approximately 3 0 PSI 0 5 or 0 5 PSI 6 inches mercury to interior of muffler and submerge muffler into water Any leaks will appear as bubbles and can be readily detected c If any leaks are detected the muffler must be remo...

Page 778: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER OIL ...

Page 779: ...JECT PAGE DATE 79 Title 79 List of Effective Pages 1 Aug 18 2001 79 Contents 1 Aug 18 2001 79 00 00 1 Aug 18 2001 79 20 00 201 Aug 18 2001 202 Aug 18 2001 79 30 00 201 Aug 18 2001 202 Aug 18 2001 203 Aug 18 2001 79 31 00 201 Aug 18 2001 202 Aug 18 2001 79 LIST OF EFFECTIVE PAGES Page 1 Aug 18 2001 ...

Page 780: ...CE PRACTICES 79 30 00 Page 201 Description and Operation 79 30 00 Page 201 Oil Pressure Indicator and Transducer Removal Installation 79 30 00 Page 201 Low Oil Pressure Switch Removal Installation 79 30 00 Page 201 OIL TEMPERATURE INDICATOR MAINTENANCE PRACTICES 79 31 00 Page 201 Description and Operation 79 31 00 Page 201 Oil Temperature Sending Unit Removal Installation 79 31 00 Page 201 Oil Tem...

Page 781: ...bleshooting 2 Definition A This chapter isdivided into sections to assist maintenance personnel in locating specific information The following is a brief description of each section For locating information within the chapter refer to the Table of Contents at the beginning of the chapter 1 The section on distribution provides information on removal and installation of the external oil cooler 2 The...

Page 782: ...fer to Chapter 71 Cowling Maintenance Practices 2 Label and disconnect inlet and outlet hoses leading into oil cooler 3 Remove bolts washers and spacers securing oil cooler to back of engine baffles B Install Oil Cooler Refer to Figure 201 1 Secure oil cooler to rear of engine baffles using bolts spacers and washers 2 Attach inlet and outlet hoses to oil cooler 3 Run engine and check oil cooler fo...

Page 783: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL A OIL COOLER ELBOW WASHER HOSE BOLT CAP DETAIL A Oil Cooler Installation Figure 201 Sheet 1 79 20 00 Page 202 Aug 18 2001 ...

Page 784: ...electrical power to airplane is off 2 Remove screws securing indicator to instrument panel 3 Unscrew electrical connector from backside of indicator 4 Carefully withdraw indicator from backside of instrument panel B Install Oil Pressure Indicator Refer to Figure 201 1 Connect electrical connector to backside of indicator 2 Position indicator to instrument panel 3 Secure to panel using screws 4 Run...

Page 785: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL ELECTRICAL CONNECTOR ELECTRICAL SWITCH Oil Pressure Indication Installation Figure 201 Sheet 1 79 30 00 Page 202 Aug 18 2001 ...

Page 786: ...inch wrench to tighten switch approximately 1to 1 1 2 turns not to exceed 60 inch pounds beyond hand tight CAUTION DO NOT USE EXCESSIVE TORQUE ON PLASTIC SWITCH CONNECTION HOUSING WHEN HAND TIGHTENING CAUTION USE ONLY THE HEX FITTING TO FINAL TIGHTEN EXCESSIVE TORQUE WILL DAMAGE THE SWITCH DO NOT ROUND THE CORNERS OF THE HEX FITTING 3 Connect electrical connector to switch 4 Reinstall upper cowlin...

Page 787: ...Refer to Chapter 71 Cowling Maintenance Practices 2 Disconnect ring terminal wiring at sending unit 3 Loosen and remove sending unit from accessory case B Install Oil Temperature Sending Unit Refer to Figure 201 1 Reinstall sending unit to accessory case 2 Attach ring terminal wire to sending unit Torque jamnut to 20 Inch Pounds maximum 3 Run engine and check for leaks and proper indicator operati...

Page 788: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL VIEW A A JAMNUTS SENDING UNIT DETAIL AS2335C Oil Temperature Installation Figure 201 Sheet 1 79 31 00 Page 202 Aug 18 2001 ...

Page 789: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER STARTING ...

Page 790: ...ECTIVE PAGES CHAPTER SECTION SUBJECT PAGE DATE 80 Title 80 List of Effective Pages 1 Feb 15 2002 80 Record of Temporary Revisions 80 Contents 1 Feb 15 2002 80 00 00 1 Aug 18 2001 80 10 00 201 Feb 15 2002 202 Feb 15 2002 80 LIST OF EFFECTIVE PAGES Page 1 Feb 15 2002 ...

Page 791: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 792: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS l TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY I ...

Page 793: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 794: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE REVISION NUMBER NUMBER DATE BY REMOVED BY ...

Page 795: ...0 Page 1 Scope and Definition 80 00 00 Page 1 STARTER MAINTENANCE PRACTICES 80 10 00 Page 201 Description and Operation 80 10 00 Page 201 Starter Removal Installation 80 10 00 Page 201 Bendix Drive Starter Assembly Cleaning and Lubrication 80 10 00 Page 201 80 CONTENTS Page 1 Feb 15 2002 ...

Page 796: ...AINTENANCE MANUAL STARTING GENERAL 1 Scope and Definition A This chapter is comprised of a single section on the starting system The section details removal and installation instructions for the engine starter 80 00 00 Page 1 Aug 18 2001 ...

Page 797: ...ng the starter to the crankcase and remove the starter from the engine B Install The Starter Refer to Figure 201 1 Using the four 4 bolts attach the starter to the engine crankcase 2 Attach the alternator attach bracket to the starter with the bolt 3 Safety wire the bolt to the attach bracket Refer to Chapter 20 Safetying Maintenance Practices 4 Reconnect the positive lead to the starter Make sure...

Page 798: ...CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL B1804 A A ALTERNATOR STARTER ENGINE SUMP VIEW A A Starter Installation Figure 201 Sheet 1 80 10 00 Page 202 Feb 15 2002 ...

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