Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01

73.00 GENERAL ..................................................................... 1 74 IGNITION ...................................................................... 1 74.00 GENERAL ..................................................................... 1 75 LIQUID COOLING ........................................................ 1 75.00 GENERAL ..................................................................... 1 77 ENGINE INDICATION .................................................. 1 77.00 GENERAL ..................................................................... 1 78 EXHAUST ..................................................................... 1 78.00 GENERAL ..................................................................... 1 79 OIL ................................................................................ 1 79.00 GENERAL ..................................................................... 1 79.30 INDICATING ................................................................. 4 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-00-01 3 06.11.2013 4 4 Revision no.: Revision date: - - 80 STARTING.................................................................... 1 80.00 GENERAL ..................................................................... 1 91 CHARTS AND WIRING DIAGRAMS ........................... 1 91.10 WIRING DIAGRAMS..................................................... 1 91.20 SPECIAL TOOLS........................................................ 11 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-00-01 3 06.11.2013 1 2 - - 0.1 LIST OF REVISIONS Chapter Issue/ Revision Date Approved by Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-01-01 3 06.11.2013 1 8 - - 1 INTRODUCTION This operating and maintenance manual contains basic information related to the proper operation of the engine in various situations and under different conditions. It also contains instructions for maintenance. The information and descriptions of components and systems in this manual were correct at the time of publication. Any amendments released through the update information service must also be taken into account. Please contact Technify Motors GmbH if you have any questions. We would be glad to assist you further. 1.1 ACCOMPANYING APPLICABLE DOCUMENTS • Aircraft manufacturer's Service Manual • Aircraft manufacturer's Airplane Maintenance Manual • Installation Manual IM-02-01 for TAE 125-01 • Installation Manual IM-20-01 for TAE 125-01 in Cessna 172 • Repair Manual RM-02-01 for TAE 125-01 • Operation and Maintenance Manual OM-02-01 for TAE 125-01 • Operation and Installation Manual E-124 for Propeller MTV-6-A/187-129 • Installation Manual IM-TAE-CED-125 and Operation Manual OM-TAE-CED-125 • Installation Manual IM-TAE-AED-125 and Operation Manual OM-TAE-AED-125 • Constant Speed Unit Manual CSU TAE 125 • GILL Battery Service Manual • Panasonic Valve Regulated Lead Acid batteries Technical Handbook http://industrial.panasonic.com/eu/index.html • Component Repair Manual CRM-02-02 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-01-01 3 06.11.2013 2 8 Revision no.: Revision date: - - 1.2 IDENTIFICATION OF PARTS OF TAE 125-01 INSTALLATION Engine identification The serial number of the engine is provided on the type plate on the crankcase near the starter flange. Example: Fig. 1-1a Type Plate of TAE 125-01  Note: When making inquiries, always have the serial number of the engine ready. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-01-01 3 06.11.2013 3 8 - - Engine Mount identification The Engine Mount of the TAE 125-01 is indicated by a part number and a serial number as shown in the following picture. The first part constitutes the part number, the last four digits are the serial number. Fig. 1-2a Identification of Engine Mount AED/CED identification The AED and CED are indicated by a label as shown below. As an example the identification label of an AED is shown, the layout of the CED-label is similar. Fig. 1-3a Identification Label AED-125 20-7210-17001RX-XXXX P/N S/N Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-01-01 3 06.11.2013 4 8 Revision no.: Revision date: - - Propeller identification The serial number of the propeller MTV-6-A/187-129 consists of five digits and is provided at the back side of the propeller flange and on a label at the front side of one propeller blade. 1.3 COPYRIGHT © 1.4 CONVENTIONS IN THIS MANUAL The following symbols and warning signs are used in the manual. They must be heeded strictly to prevent injury and material damage, to avoid impairment of the operating safety of the aircraft and to rule out any damage to the aircraft as a consequence of improper handling. The indications "right", "left", "front" and "rear" are always relative to the flight direction. The following symbol is used: Example of flight direction right: > These technical data and the information contained therein are the property of Technify Motors GmbH and may not be reproduced either in full or in part or passed on to a third party without written consent from Technify Motors GmbH. This text must be included in any full or partial reproduction of this documentation. Copyright © Technify Motors GmbH  WARNING: Disregarding these safety rules can lead to injury or even death.  CAUTION: Disregarding these special instructions and safety measures can cause damage to the engine or to the other components.  Note: Additional note or instructions for better understanding of an instruction. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-01-01 3 06.11.2013 5 8 - - 1.5 VALIDITY OF THIS MANUAL This manual applies only to the engine having the following serial number:_________________________________ Installed in Cessna 172 type:___ serial number:_________________________________ Updates and modifications must be taken into account. 1.6 ABBREVIATIONS The following abbreviations are used in this manual: • FADEC, Full Authority Digital Engine Control • AED, Auxiliary Engine Display • CED, Compact Engine Display • CSU, Constant Speed Unit 1.7 PACKING AND TRANSPORT According to the Operation and Maintenance Manual OM-02-01. 1.8 STORAGE According to the Operation and Maintenance Manual OM-02-01. 1.9 QUALIFICATIONS OF THE OPERATING AND MAINTENANCE PERSONNEL Tasks described in this manual may be performed only by trained personnel having necessary certificates and licenses. All locally applicable national and international regulations must be observed. 1.10 UPDATE INFORMATION SERVICE This manual is updated regularly. The engine/ aircraft operator is responsible for keeping up-to-date with all amendment bulletins issued by Technify Motors GmbH and integrating them into this manual. Please inform Technify Motors GmbH if the owner of the engine / aircraft changes. This is the only way to ensure that information about any necessary / recommended changes to the engine / manual can be passed on. A form for this purpose is included in this manual. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-01-01 3 06.11.2013 6 8 Revision no.: Revision date: - - 1.11 SERVICE LIFE OF THE ENGINE For Service Life of the engine refer to Chapter 4. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-01-01 3 06.11.2013 7 8 - - 1.12 CONVERSION FACTORS Table 1-1a Conversion Factors - Length Table 1-2a Conversion Factors - Speed Table 1-3a Conversion Factors - Pressure  CAUTION: The US units in this manual are only benchmarks ! These conversion factors shall be used in case of doubt ! Unit [Abbreviation] Conversion Factor Conversion Factor SI to US / Imperial US / Imperial to SI Meter [m] [m] / 0.3048 = [ft] Millimeter [mm] [mm] / 25.4 = [in] Kilometer [km] [km] / 1.852 = [nm] [km] / 1.609 = [sm] Inch [in] [in] x 25.4 = [mm] Foot [ft] [ft] x 0.3048 = [m] Nautical mile [nm] [nm] x 1.852 = [km] Statute mile [sm] [sm] x 1.609 = [km] LENGTH Unit [Abbreviation] Conversion Factor Conversion Factor SI to US / Imperial US / Imperial to SI Kilometers per hour [km/h] [km/h] / 1.852 = [kts] [km/h] / 1.609 = [mph] Meters per second [m/s] [m/s] x 196.85 = [fpm] Miles per hour [mph] [mph] x 1.609 = [km/h] Knots [kts] [kts] x 1.852 = [km/h] Feet per minute [fpm] [fpm] / 196.85 = [m/s] SPEED Unit [Abbreviation] Conversion Factor Conversion Factor SI to US / Imperial US / Imperial to SI Bar [bar] [bar] x 14.5038 = [psi] Hectopascal [hpa]=Millibar[mbar] [hpa] / 33.864 = [inhg] [mbar] / 33.864 = [inhg] Pounds per square inch [psi] [psi] / 14.5038 = [bar] Inches of mercury column [inHg] [inHg] x 33.864 = [hPa] [inHg] x 33.864 = [mbar] PRESSURE Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-01-01 3 06.11.2013 8 8 Revision no.: Revision date: - - Table 1-4a Conversion Factors - Force Table 1-5a Conversion Factors - Mass Table 1-6a Conversion Factors - Volume Table 1-7a Conversion Factors - Torque Table 1-8a Conversion Factors - Temperature Unit [Abbreviation] Conversion Factor Conversion Factor SI to US / Imperial US / Imperial to SI Newton [N] [N] / 4.448 = [lb] Decanewton [daN] [daN] / 0.4448 = [lb] Pound [lb] [lb] x 4.448 = [N] [lb] x 0.4448 = [daN] FORCE Unit [Abbreviation] Conversion Factor Conversion Factor SI to US / Imperial US / Imperial to SI Kilogram [kg] [kg] / 0.45359 = [lb] Pound [lb] [lb] x 0.45359 = [kg] MASS Unit [Abbreviation] Conversion Factor Conversion Factor SI to US / Imperial US / Imperial to SI Liter [l] [l] / 3.7854 = [US gal] [l] / 0.9464 = [US qt] [l] / 4.5459 = [Imp gal] [l] / 61.024 = [in 3 ] US gallon [US gal] [US gal] x 3.7854 = [l] US quart [US qt] [US qt] x 0.9464 = [l] Imperial gallon [Imp gal] [Imp gal] x 4.5459 = [l] Cubic inch [in 3 ] [in 3 ] x 61.024 = [l] VOLUME Unit [Abbreviation] Conversion Factor Conversion Factor SI to US / Imperial US / Imperial to SI Newton meter [Nm] [Nm] / 1.3558 = [ft.lb] [Nm] x 8.851 = [in.lb] Foot pound [ft.lb] [ft.lb] x 1.3558 = [Nm] Inch pound [in.lb] [in.lb] / 8.851 = [Nm] TORQUE Unit [Abbreviation] Conversion Factor Conversion Factor SI to US / Imperial US / Imperial to SI Degree Celsius [°C] [°C] x 1.8 + 32 = [°F] Degree Fahrenheit [°F] ([°F] - 32) / 1.8 = [°C] TEMPERATURE Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-04-01 3 06.11.2013 1 2 - - 4 AIRWORTHINESS LIMITATIONS, Issue 3 4.1 ENGINE LIFE LIMIT The entire engine TAE 125-01 as defined by the Type Design Definition ref. TDD-02-01, issue 1 or later approved revisions has a specific life limit according to service bulletin TM TAE 125-0001. This limit calls for replacement of the entire engine. No overhauls are allowed to the core engine. No repairs outside the published ICA´s allowed to the engine. 4.2 MANDATORY MAINTENANCE ACTIONS Mandatory maintenance actions of the engine are listed in Chapter 02-OM-05-01 of the current Operation and Maintenance Manual OM-02-01. AIRWORTHINESS LIMITATIONS AIRWORTHINESS LIMITATIONS APPROVAL SHEET This Airworthiness Limitations Section is EASA approved and mandatory by EASA AD 2006-0044. It specifies required maintenance unless an alternative program has been EASA approved. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-04-01 3 06.11.2013 2 2 Revision no.: Revision date: - - 4.3 LOG OF REVISIONS TO AIRWORTHINESS LIMITATIONS AIRWORTHINESS LIMITATIONS Rev. No Description of Revision Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-05-01 3 06.11.2013 1 6 - - 5 TIME LIMITS / MAINTENANCE CHECKS The maintenance work on Centurion aircraft engines must be carried out after specific time intervals or on reaching a specific operating hours interval. The Preflight check must be conducted before each start. Parts that are not included within the scope of delivery of the engine must be maintained and checked according to the airplane manufacturer's specifications (refer to airplane manual).  WARNING: The entire engine has a service life ("time between replacement“); refer to Chapter 4.  WARNING: It is strongly recommended that the maintenance intervals specified by the manufacturer be adhered to. Non-compliance with the maintenance schedule can amongst other things lead to lapse of any claims to warranty.  Note: For this engine, an extension program for the service life (time between replacement) is in progress. The up-to-date information is published in service bulletins.  Note: Further information concerning service partners and servicing or parts to be replaced can be obtained from Technify Motors GmbH.  Note: Technify Motors GmbH must be informed immediately in case of engine malfunction. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-05-01 3 06.11.2013 2 6 Revision no.: Revision date: - - 5.10 TIME LIMITS INSPECTION REQUIREMENTS The required periodic inspection procedures are listed in 5.20 Sheduled Maintenance. PREFLIGHT CHECKS Perform a thorough preflight and walk-around check in addition to inspection intervals in periodic inspections. Pilot or mechanic must include pre-flight check as normal procedure necessary for safe aircraft operation. Refer to TAE 125-Supplement of the Pilot´s Operating Handbook for items that must be checked. 5.20 SCHEDULED MAINTENANCE CHECKS A. PROPELLER GROUP Refer to Operation and Installation Manual of MT-Propeller E124 (ATA 61-01-24) for Inspections and Maintenance of the propeller MTV-6-A-/187-129. B. ENGINE GROUP  WARNING: Under extreme conditions such as low usage combined with operation in a salt water environment or in an environment laden with sand and dust, shorter maintenance and inspection intervals are recommended for your own safety.  Note: Due to the Diesel principle of the engine TAE 125-01, all information of the Airplane Maintenance Manual relating to - Carburetor and carburetor pre-heating - Ignition magnetos and spark plugs and - Mixture control and priming system are no longer valid. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-05-01 3 06.11.2013 3 6 - - 5.20.01 Checks dependent on engine operating time: After initial 3rd - 6th operating hour • Further maintenance action according to Operation and Maintenance Manual OM-02-01 Every 100 operating hours / Annual Inspection • Check engine mount for signs of corrosion (refer to Chapter 71, Section 71.20, Maintenance Practices) • Check coolant "WATER LEVEL" signal (refer to Chapter 31, Section 31.60, Maintenance Practices) and perform „coolant tank cap pressure relief test“ (refer to Chapter 75, Section , Maintenance Practices) • Check if the turbocharger clamp can be moved easily and inspect for cracks. • Visually inspect of the joints (e.g. hose connections) • Replace fuel filter (refer to Chapter 28, Section 28.20, Maintenance Practices) • Check airplane fuel pump (refer to airplane manufacturer´s specifications) • Further maintenance action according to Operation and Maintenance Manual OM-02-01 • Inspect FADEC backup battery (refer to Chapter 24, Section 24.30, Maintenance Practices) Every 200 operating hours • Work as described for every 100 operating hours • Further maintenance action according to Operation and Maintenance Manual OM-02-01 Every 300 operating hours • Work as described for every 100 operating hours • Further maintenance action according to Operation and Maintenance Manual OM-02-01 • Inspect turbocharger clamp (refer to Chapter 71, Section 71.60, Maintenance Practices) Every 500 operating hours • Work as described for every 100 operating hours • Inspect main battery and excitation battery, servicing the batteries (refer to Chapter 24, Section 24.30, Maintenance Practices) Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-05-01 3 06.11.2013 4 6 Revision no.: Revision date: - - Every 800 operating hours • Work as described for every 200 operating hours • Further maintenance action according to Operation and Maintenance Manual OM-02-01 Every 1000 operating hours • Work as described for every 200 operating hours • Work as described for every 500 operating hours • Replace the turbocharger clamp (refer to Chapter 71, Section 71.60, Maintenance Practices) • Further maintenance action according to Operation and Maintenance Manual OM-02-01 Every 3000 operating hours • Replace silicate cartridge of the expansion tank (refer to Chapter 75, Section 75.00, Maintenance Practices). Carry out maintenance action in reference to the 6 years limit; whichever occurs first. 5.20.02 Checks dependent on calendar time: Every month • Further maintenance action according to Operation and Maintenance Manual OM-02-01 Every 12 months • Further maintenance action according to Operation and Maintenance Manual OM-02-01 • Replace FADEC Backup- Battery (refer to Chapter 24) Every 24 months • Visual inspection and function test of all relays (refer to Chapter 24, Section 24.50, Maintenance Practices) • Function test of all switches and circuit breakers (refer to Chapter 24, Section 24.50, Maintenance Practices) • Visual inspection and function test of all 14V/28V converters, if installed (refer to Chapter 24, Section 24.50, Maintenance Practices) • Further maintenance action according to Operation and Maintenance Manual OM-02-01 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-05-01 3 06.11.2013 5 6 - - Every 60 months • Check engine mount for signs of corrosion (refer to Chapter 71, Section 71.20, Maintenance Practices) • Inspect the radiator mounts (refer to Chapter 71, Section 71.40, Maintenance Practices) • Further maintenance action according to Operation and Maintenance Manual OM-02-01 Every 6 years • Replace silicate cartridge of the expansion tank (refer to Chapter 75, Section 75.00, Maintenance Practices). Carry out maintenance action in reference to the 3000 hours limit; whichever occurs first. Every 10 years • Inspect the entire engine electrical system on corrosion and abrasion. Renew all corrode and worn out components (refer to RM-02-01) Every 25 years • Renew following electrical components (refer to Chapter 24, Section 24.30, Maintenance Practices and airplane manufacturer´s specifications): - Main battery according to Gill Battery Service - Battery relay - ALT / Battery switch - Alternator relay - Battery fuse - Alternator fuse, if installed - 50A FADEC fuse - 100A Main Bus fuse - FADEC IGN switch Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-05-01 3 06.11.2013 6 6 Revision no.: Revision date: - - 5.50 UNSCHEDULED MAINTENANCE Engine Events: Overspeed, sudden stoppage, loss of oil, over temperature, lightning strike, propeller strike. Refer to • Operation and Maintenance Manual OM-02-01 of the TAE 125-01 • Repair Manual RM-02-01 of the TAE 125-01 • Engine Manufacturer Technify Motors GmbH for necessary corrective actions and repair. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-06-01 3 06.11.2013 1 4 - - 6 DIMENSIONS AND AREAS 6.1 MODEL C-172 F,G,H,I,K,L,M,N,P,R,S with TAE 125-01 installation 6.2 ENGINE Manufacturer......................................Technify Motors GmbH Model .................................................TAE 125-01 FAA Type Certificate..........................E00069EN EASA Type Certificate .......................E.055 Takeoff power ....................................132.8 hp / 99 kw Rated Speed ......................................2300 rpm Fuels approved ..................................JET A-1 JET A JP-8 JP-8+100 Jet Fuel No. 3 (GB 6537-2006) Diesel (DIN EN 590) Engine Oil ..........................................AeroShell Oil Diesel Ultra AeroShell Oil Diesel 10W-40 Shell Helix Ultra 5W-30 Shell Helix Ultra 5W-40 Engine Oil Sump Capacity .................4.5 to 6.0 liters (1.19 to 1.59 US gal) Gearbox Oil........................................Shell Getriebeöl EP 75W-90 API GL-4 Shell Spirax EP 75W-90 Shell Spirax S4 G 75W-90 Shell Spirax GSX 75-80 GL-4 Shell Spirax S6 GXME 75W-80 Oil Capacity Gearbox.........................1 liter (0.26 US gal) Coolant...............................................Water / Radiator Protection at a ratio of 50:50 Radiator Protection ............................BASF Glysantin Protect Plus/G48 Mobil Antifreeze Extra/G48 ESSO Antifreeze Extra/G48 Comma Xstream Green - Concen- trate/G48 Valvoline/ Zerex Glysantin G 48 Gear Reduction..................................1,689:1  CAUTION: Further information in the IM-02-01 must be taken into account ! Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-06-01 3 06.11.2013 2 4 Revision no.: Revision date: - - 6.3 PROPELLER Manufacturer......................................MT Propeller Entwicklung GmbH Flugplatzstrasse 1 D-94348 Atting Model .................................................MTV-6-A187/129 Number of blades...............................3 Diameter ............................................1.87 m (6.14 ft) Type ...................................................Constant Speed 6.4 FUEL SYSTEM C-172 F,G,H 2 Standard tanks:..................each 16.6 US gal (62,85 l) total capacity: ........................33.2 US gal (125,7 l) total usable fuel:....................30.2 US gal (114,3 l) total unusable fuel:................3.0 US gal (11,4 l) 2 Long-range tanks: ..............each 22.1 US gal (83,65 l) total capacity: ........................44.2 US gal (167,3 l) total usable fuel:....................40.2 US gal (152,2 l) total unusable fuel:................4.0 US gal (15,1 l) C-172 I,K,L,M 2 Standard tanks:..................each 17.85 US gal (68,55 l) total capacity: ........................35.7 US gal (135,1 l) total usable fuel:....................31.7 US gal (120,0 l) total unusable fuel:................4.0 US gal (15,1 l) 2 Long-range tanks: ..............each 22.1 US gal (83,65 l) total capacity: ........................44.2 US gal (167,3 l) total usable fuel:....................40.2 US gal (152,2 l) total unusable fuel:................4.0 US gal (15,1 l)  Note: Due to the higher specific density of Kerosene in comparison to Aviation Gasoline (AVGAS) with the TAE 125-01 installation the permissible tank capacity has been reduced. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-06-01 3 06.11.2013 3 4 - - C-172 N,P 2 Standard tanks:..................each 18.3 US gal (69,4 l) total capacity: ........................36.6 US gal (138,8 l) total usable fuel:....................33.6 US gal (127,4 l) total unusable fuel:................3.0 US gal (11,4 l) 2 Long-range tanks: ..............each 22.95 US gal (86,8 l) total capacity: ........................45.9 US gal (173,6 l) total usable fuel:....................41.9 US gal (158,6 l) total unusable fuel:................4.0 US gal (15,1 l) C-172 N,P normal category 2 Integral Tanks: ...................each 29 US gal (119.8 l) total capacity: ........................58 US gal (219.6 l) total usable fuel:....................52 US gal (196.8 l) total unusable fuel:................6 US gal (22.8 l) C-172 N,P utility category 2 Integral Tanks: ...................each 23.95 US gal (90.7 l) total capacity: ........................47.9 US gal (181.4 l) total usable fuel:....................41.9 US gal (158.6 l) total unusable fuel:................6 US gal (22.8 l) C-172 R,S normal category: 2 tanks: .................................each 23.8 US gal (90,1 l) total capacity: ........................47.6 US gal (180,2 l) total usable fuel.....................44.6 US gal (168,8 l) total unusable fuel:................3.0 US gal (11,4 l) C-172 R,S utility category: 2 tanks: .................................each 15.5 US gal (58,7 l) total capacity: ........................31.0 US gal (117,4 l) total usable fuel.....................28.0 US gal (106,0 l) total unusable fuel:................3.0 US gal (11,4 l) Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-06-01 3 06.11.2013 4 4 Revision no.: Revision date: - - This page intentionally blank Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-12-01 3 06.11.2013 1 6 - - 12 SERVICING 12.00 GENERAL The following figures show the service points of the TAE 125-01 installation. Fig. 12-1a Service Points TAE 125-01 1 Coolant Filler 2 Engine Oil Filler with Dip Stick 3 Engine Oil Filter 4 Gearbox Oil Filler 5 Gearbox Oil Micro Filter 6 Gearbox Oil Viewer Fig. 12-2a Service Points TAE 125-01 7 Air Filter 8 Fuel Filter 9 Fuel Filter Drain Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-12-01 3 06.11.2013 2 6 Revision no.: Revision date: - - Cleaning of the engine compartment Care must be taken when cleaning the engine compartment. If leaks are noticed, determine their location before cleaning. The engine has to be cold before cleaning. The use of cold cleansers is recommended (for instance Berner Kaltreiniger, Art.no.: 13618.0). Do not clean the engine electrical system, since it could be damaged. Do not use high pressure cleaning equipment. Dry the engine after cleaning with pressurized air (pressure less than 8 bar). 12.10 REPLENISHING FUEL SYSTEM Filling Fuel Tanks For capacity of each wing tank refer to Chapter 6 of this Supplement to airplane maintenance manual.  CAUTION: The use of flammable and acidly cleansers is not allowed !  WARNING: Observe all required safety precautions for handling kerosene.  CAUTION: Fill tanks with approved fuels only! For approved fuel refer to Chapter 6, Section 6.2. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-12-01 3 06.11.2013 3 6 - - Draining Fuel Filter Bowl Fig. 12-3a Fuel Filter Bowl and Screen Drain at least a cupful of fuel (using sampler cup) from valve to check for water, sediment and proper fuel grade before each flight and after each refueling. If water is observed, take further samples until clear and then gently rock wings and lower tail to the ground to move any additional contaminants to the sampling points. Take repeated samples from all fuel drain points until all contamination has been removed. If contaminants are still present, refer to following WARNING and do not fly the airplane. Engine Oil System Check engine oil level before each flight according to appropriate POH Supplement for TAE 125-01 installation. Change engine oil and engine oil filter according to Operation and Maintenance Manual OM-02-01 of the TAE 125-01. Gearbox Oil System Check gearbox oil level before each flight according to appropriate POH Supplement for TAE 125-01 installation. Change gearbox oil and gearbox oil filter according to Operation and Maintenance Manual OM-02-01 of the TAE 125-01.  WARNING: If, after repeated sampling, evidence of contamination still exists, the airplane should not be flown. Tanks should be drained and system purged by qualified maintenance personnel. All evidence of contamination must be removed before further flight. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-12-01 3 06.11.2013 4 6 Revision no.: Revision date: - - Liquid Cooling system 1. General 2. Drain/Refill the coolant A. Drain the coolant (1) Open the clamp on the lower hose of the water radiator, disconnect the hose and allow the coolant to drain into a prepared collecting container. (2) Open the clamp on the lower hose of the heat exchanger, disconnect the hose and allow the coolant to drain into a prepared collecting container. (3) Loosen the drain plug of the engine, but do not open it yet. (4) Attach a suitable length of hose with a diameter of 14-15 mm (0.55 in to 0.59 in) onto the collar of the plug, and insert the other end of the hose into a collecting container. (5) Open the drain plug. The coolant can drain off through the plug. (6) Open the cover of the coolant filler (this allows the cool- ant to drain faster). (7) After draining install a new seal and tighten the drain plug Tightening torque: 10 Nm (7.4 lbf .ft) (8) Reconnect the lower hoses of the water radiator and the heat exchanger and tighten the clamps.  WARNING: Risk of scalding ! The cooling system may be pressurized. Carefully release the pressure before opening the drain plug.  CAUTION: Do not drain the coolant if its temperature is above 40°C ! Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-12-01 3 06.11.2013 5 6 - - B. Fill up new coolant (1) Fill up the cooling system with coolant according to Chapter 3 of Operation and Maintenance Manual OM-02-01 by opening the coolant filler. (2) Close the cover of the coolant filler. (3) Perform a test run according to point 4.4.2 of Operation and Maintenance Manual OM-02-01. (4) Check the cooling system for leaks according to Annex 3 of Operation and Maintenance Manual OM-02-01. (5) Allow the engine to cool down. (6) Check coolant level. 12.20 SCHEDULED SERVICING Electrical System Refer to Chapter 5 of this Supplement for checks of the electrical system. Fuel System Refer to Chapter 5, Section 5.20 of this Supplement for checks of the fuel system. Propeller Refer to Operation and Installation Manual of MT-Propeller E124 (ATA 61-01-24) for Inspections and Maintenance of the propeller MTV-6-A/187-129. Power Plant Regularly check the engine compartment for oil and fuel leaks, chafing of lines, loose wires and tightness of all parts. Be careful when cleaning the engine compartment. Refer to Chapter 12 of this Chapter. Induction Air Filter Regularly check and change the Induction Air Filter. Refer to Chapter 5.  Note: See also Scheduled Maintenance Checks in Chapter 5, Section 5.20. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-12-01 3 06.11.2013 6 6 Revision no.: Revision date: - - Coolant System Refer to Chapter 5, Section 5.20 of this Supplement for checks of the coolant system. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-20-01 3 06.11.2013 1 4 - - 20 STANDARD PRACTICES - AIRFRAME 20.00 GENERAL DESCRIPTION This Chapter contains data about Standard and Special Torque Values as well as the approved Firewall Sealants. 20.10 Standard Torque Values This Chapter only has data about standard threaded fasteners. Always tighten the nut or bolt to the torque shown in the tables below. Always use the correct locking device with the nut or bolt. These tables show the correct torque values for bolts and nuts to AN and DIN specifications. Use the following torque values for all bolts, nuts and screws which meet the specifications unless they are in the list of special torque values below. Table 1: Tightening torques for set screws in accordance with VDI standard 2230  CAUTION: Discard self-locking nuts after removal. The friction torque reduces with use. Screw Size Property Class Nm ( Loctite or similar) Nm (dry screw joints) M4 8.8 3.0 4.1 10.9 4.6 6.0 M5 8.8 5.9 8.1 10.9 8.6 11.9 M6 8.8 10.1 14.1 10.9 14.9 20.7 M8 8.8 24.6 34.3 10.9 36.1 50.3 M10 8.8 48 68 10.9 71 100 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-20-01 3 06.11.2013 2 4 Revision no.: Revision date: - - Table 2: Tightening torques for Dash connectors Special Torque Values Table 3: Special torque values Dash Size Material Nm Dash 03 Aluminium 10 Stahl 14 Dash 04 Aluminium 15 Stahl 20 Dash 06 Aluminium 20 Stahl 30 Dash 08 Aluminium 35 Stahl 55 Dash 10 Aluminium 45 Stahl 75 Dash 12 Aluminium 55 Stahl 105 Part Nm Propeller to engine bolts Refer to MT Propeller OPERATION AND INSTALLATION MANUAL, ATA 61-01-24 (E-124) Bolts attaching the engine mount to the firewall 20 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-20-01 3 06.11.2013 3 4 - - 20.20 Firewall Sealants Manufacturer Description Address PRC-DeSoto International / Hutchinson PR-812 Hutchinson Le Joint Français 84-116, rue Salvador Allende B.P. 16F- 95870 Bezons, France or PRC-DeSoto International, Inc. 5454 San Fernando Road, PO Box 1800 Glendale, California 91209 PRC-DeSoto International PS 700 PRC-DeSoto International, Inc. 5454 San Fernando Road, PO Box 1800 Glendale, California 91209 Flamemaster CS 1900 Flamemaster Corporation Supercedes 11120 Sherman Way Sun Valley, California 91352 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-20-01 3 06.11.2013 4 4 Revision no.: Revision date: - - This page intentionally blank Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-21-01 3 06.11.2013 1 4 - - 21 ENVIRONMENTAL SYSTEMS 21.00 GENERAL DESCRIPTION The TAE 125-01 installation includes a heat exchanger, which is part of the liquid coolant system and is located at the lower front section of the engine compartment. The heat exchanger for cabin heat is installed inline with the unregulated exit of the cooling system thermostat. Engine coolant passes through the heater core and heats incoming air . The coolant flow through the heater core is always open. The warm air supply is regulated by the pilot over the heating valve. In normal operation the control knob “Shut-off Cabin Heat“ must be open, with the control knob “Cabin Heat“ the supply of warm air into the cabin can be controlled. In case of certain emergencies (refer to the appropriate Pilot´s Operating Handbook), the control knob “Shut-off Cabin Heat“ has to be closed according to the appropriate procedures. Fig. 21-1a Coolant System of TAE 125-01 Engine Coolant Circuit of TAE 125 functional schematic Flow Flow Flow IN IN OUT IN OUT OUT IN Short Circuit Version 30.10.2002 External Circuit Heating Circuit OUT Coolant level caution Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-21-01 3 06.11.2013 2 4 Revision no.: Revision date: - - Fig. 21-2a Heat Exchanger C-172 with TAE 125-01 installation 1 Heat Exchanger 2 Coolant OUT 3 Coolant IN Fig. 21-3a Coolant Hose System (Heat Exchanger) C-172 with TAE 125-01 installation 1 Coolant Hose, Heat Exchanger IN 2 Coolant Hose, Heat Exchanger OUT 1 2 3 1 2 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-21-01 3 06.11.2013 3 4 - - Fig. 21-4a Air Hose System C-172 F,G,H,I,K,L,M,N,P with TAE 125-01 installation 1 Air Hose, Heat Exchanger to Firewall Fig. 21-5a Air Hose System C-172 R,S with TAE 125-01 installation 1 Air Hose, Heat Exchanger to Firewall 1 1 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-21-01 3 06.11.2013 4 4 Revision no.: Revision date: - - This page intentionally blank Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 1 16 - - 24 ELECTRICAL POWER 24.00 GENERAL DESCRIPTION AND OPERATION For Cessna 172 with TAE 125-01 installation there are two electrical system variants possible: • 14 Volt or • 28 Volt The 14 V system is equipped with a 90 amp alternator, a 14 V starter, a 12 V battery and an excitation battery for the alternator. The 28 V system is equipped with a 60 amp alternator, a 28 V starter, a 24 V battery and an excitation battery for the alternator. The alternator and the battery are operated by a separate rocker switch (BAT and ALT) located on the instrument panel. The excitation battery of the alternator is operated with the BAT switch simultaneously. A warning light (ALT WRNG LT) on the lightpanel will illuminate if the alternator fails to produce current, accompanied by a zero indication on the AED-125. The battery switch (BAT) must be ON before any electrical equipment will operate. In addition to the main battery and alternator, a backup battery which only supplies power to FADEC A is part of the electrical system when installed. The FADEC backup battery is integrated into the electrical system without manual control. The pilot can not manually switch the FADEC backup battery on or off. Under normal operating conditions when the alternator voltage is greater than the battery voltage, the alternator charges the battery. In the event of an alternator failure and a depleted or failed main battery, the FADEC backup battery is the only power source and will automatical- ly supply power to FADEC A. This prevents the engine from stopping in the unlikely event of interrupted power supply from both alternator and main battery. . For wiring diagrams of the electrical systems of TAE 125-01 installations refer to Chapter 91, Section 91.10 of this Supplement.  WARNING When operating on FADEC backup battery only, the "Force B" switch must not be activated. This will shut down the engine. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 2 16 Revision no.: Revision date: - - 24.30 DC GENERATION PRECAUTIONS The following precautions must be observed when testing the electrical system.  WARNING: Failure to observe these precautions will result in serious damage to the electrical equipment!  CAUTION: Refer to wiring diagram in Chapter 91, Section 91.10 when installing or testing alternator.  CAUTION: Disconnect battery, excitation battery and backup battery before connecting or disconnecting test instruments (except voltmeter), or before removing or replacing any unit or wiring. Accidental grounding or shorting at alternator with internal regulator (14V version only), alternator without internal regulator (28V version only), regulator (28V version only), excitation battery, ammeter or accessories, will cause severe damage to units and/or wiring.  CAUTION: Disconnect main battery before connecting or disconnecting the excitation or backup battery! The excitation battery wire from the alternator (14V version) or from the regulator (28V version) may carry electrical power even without connected excitation battery in case the main battery is still connected to the system.  CAUTION: Grounding the alternator output terminal will damage alternator and/or circuit and components! Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 3 16 - - TROUBLESHOOTING Table 24-1a Troubleshooting TAE 125-01 DC Generation  CAUTION: Reversed battery connections will damage rectifiers, wiring, regulator and other charging system components ! Battery polarity must be checked with a voltmeter before connecting battery. The aircraft is negative ground.  CAUTION: If booster battery or fast charger is used, its polarity must be connected correctly to prevent damage to electrical system components! Trouble Che ck Corre ctive Action Check alternator wiring Replace alternator wiring Check alternator fuse Replace alternator fuse Check alternator relay Replace alternator relay Check alternator switch Replace alternator switch Check alternator funcion Replace alternator Check excitation battery Replace excitation battery Check excitation battery wiring Repair wiring FADEC backup battery capacity low Replace Battery FADEC backup battery defect Replace Battery FADEC backup battery system wiring defective Do a test of the FADEC backup battery system wiring Refer to chapter 91 for the wiring diagram s Lack of alternator current A lternator does not work correctly without m ain battery connected and switched on FADEC backup battery functioning test negative Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 4 16 Revision no.: Revision date: - - MAINTENANCE PRACTICES 1. General These maintenance practices provide instructions to • Inspecting the main battery • Replacing the main battery • Charging the main battery • Replacing the excitation battery • Functioning check of the FADEC backup battery • Replacing the FADEC backup battery (if installed per TM TAE 601-0007) 2. Inspecting the Main Battery or FADEC backup battery • Visually inspect the battery for signs of damage, leaks and corrosion. Refer to the battery manufacturer’s specifications (refer to 01.1). • Check for incorrect mounting. • Check the terminal connections. 3. Disconnecting/Connecting the Main Battery for Maintenance A. Disconnect the Main Battery for Maintenance (1) Remove the bottom of the extended baggage area. Refer to the airplane manufactuerer´s specifications. (2) Remove the cover from the battery box. (3) Disconnect the negative cable from the main battery. See Fig. 24-1a. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 5 16 - - Fig. 24-1a Main Battery 1 Main battery 2 Negative cable 3 Battery box (4) Disconnect the positive cable from the main battery. B. Connect the Main Battery after Maintenance (1) Connect the positive cable to the main battery (2) Connect the negative cable to the main battery. (3) Install the cover to the battery box (4) Install the bottom of the extended baggage area. Refer to the airplane manufacturer´s specifications. 1 2 3  CAUTION: Make sure that you connect the cables to the correct terminals. Incorrect connection can damage the electrical and avionic systems. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 6 16 Revision no.: Revision date: - - 4. Replacing the Main Battery A. Remove the Main Battery (1) Remove the bottom of the extended baggage area. Refer to the airplane manufactuerer´s specifications. (2) Remove the cover from the battery box. (3) Disconnect the negative cable from the main battery. See Fig. 24-1a. (4) Disconnect the positive cable from the main battery. (5) Remove the main battery from the airplane. B. Install the new Main Battery in the Airplane (1) Make sure that the main battery is dry and clean. (2) Place the main battery into position in the battery box. (3) Connect the positive cable to the main battery. (4) Connect the negative cable to the main battery. (5) Install the cover to the battery box. (6) Install the bottom of the extended baggage area. Refer to the airplane manufacturer´s specifications. 5. Charging the Main Battery (1) Engine Master off (2) Main Bus off (3) Connect External Power to the appropriate connector. (4) Turn the BAT Master switch on.  CAUTION: Make sure that you connect the cables to the correct terminals. Incorrect connection can damage the electrical and avionic systems.  CAUTION: Do not start the engine while charging.  Note: The external power connector is only to be used to charge the battery. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 7 16 - - 6. Replacing the Excitation Battery A. Remove the Excitation Battery (1) Disconnect the main battery. Refer to 3, Disconnect / Connect the Main Battery for Maintenance. (2) Disconnect the negative cable from the excitation battery. (3) Disconnect the positive cable from the excitation battery. (4) Remove the battery carrier (top) (5) Remove the excitation battery from the airplane. B. Install the new Excitation Battery (1) Place the excitation battery into position in the battery carrier (bottom). (2) Install the battery carrier (top) (3) Connect the positive cable to the excitation battery (4) Connect the negative cable to the excitation battery (5) Connect the main battery. Refer to 3, Disconnect / Connect the Main Battery for Maintenance. (6) Do an engine ground run. Refer to OM-02-01. The Alternator Warning Lamp (AWL) must go OFF. 7. Functioning check of the FADEC backup battery (1) Start engine in accordance with Technify Motors GmbH POH supplement (2) Turn off all avionics (3) FADEC Backup Battery Test a) Alternator - OFF, engine must operate normally b) Battery - OFF, engine must operate normally, FADEC Battery test successfull c) Battery - ON d) Alternator - ON (4) Shut down engine Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 8 16 Revision no.: Revision date: - - 8. Replacing the FADEC Backup Battery A. Remove the Backup Battery (1) Disconnect the main battery. Refer to 3, Disconnect / Connect the Main Battery for Maintenance. (2) Disconnect the negative cable from the backup battery. (3) For 28V system only: disconnect the cable which interconnects the two batteries. (4) Disconnect the positive cable from the backup battery. (5) Remove the battery carrier (top) (6) Remove the backup battery from the airplane. B. Install the new Backup Battery (1) Place the backup battery into position in the battery carrier (bottom). (2) Install the battery carrier (top) (3) Connect the positive cable to the backup battery (4) Connect the negative cable to the backup battery (5) For 28V system only: interconnect the two batteries (6) Connect the main battery. Refer to 3, Disconnect / Connect the Main Battery for Maintenance. (7) Perform functioning check of the FADEC backup battery.  Note: Charge the battery i.a.w. the manufacturers instruction before installation into the aircraft. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 9 16 - - 24.50 ELECTRICAL LOAD DISTRIBUTION TROUBLESHOOTING For Troubleshooting in case of malfunction refer to Chapter 71. MAINTENANCE PRACTICES 1. General These maintenance practices provide instructions to inspect • all relays • all 14V/28V converters, if installed They also provide instructions to accomplish a function test of the following parts: • all relays • all switches • all circuit breakers • all 14V/28V converters, if installed 2. Inspecting the relays This is a visual inspection. Inspect whether the connections of the relays are firmly attached. In addition, the relays have to be checked for signs of corrosion. The following relays have to be checked: • Battery Relay (located in the Junction-Box on the firewall) • Alternator Relay (located in the Junction-Box on the firewall) • Glow Relay (located in the Junction-Box on the firewall) • Main Bus Relay, only C172 K,L,M,N,P (located on the LH of the airframe, underneath the Panel LH) 3. Inspecting the 14V/28V Converters, if installed This is ab visual inspection. Inspect whether the connections of the 14V/28V are firmly attached. In addition, the 14V/28V convertershas to be checked for signs of corrosion. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 10 16 Revision no.: Revision date: - - 4. Accomplishing a function test of all relays The following relays must be tested: • Battery Relay (located in the Junction-Box on the firewall) • Alternator Relay (located in the Junction-Box on the firewall) • Glow Relay (located in the Junction-Box on the firewall) • Main Bus Relay, only C172 K,L,M,N,P (located on the LH of the airframe, underneath the Panel LH) A. Accomplish the function test of the Battery Relay (1) Battery Switch “ON“ (2) AED, CED illuminate (without data) (3) Fuel Pump functional (switch Fuel Pump) (4) => Battery Relay OK (5) Battery Switch “OFF“ B. Accomplish the function test of the Alternator Relay (1) Battery Switch “ON“ (2) Alternator “ON“ (3) A voltmeter must indicate the same voltage at the Alternator (Terminal Wire 3) as at the battery (4) Alternator “OFF“: No voltage at the Alternator (Terminal Wire 3) (5) => Alternator Relay OK (6) Battery Switch “OFF“ C. Accomplish the function test of the Glow Relay (1) Battery Switch “ON“ (2) Engine Master “ON“ (3) Voltage at the Glow Plugs, Glow Lamp “ON“ (approx. 5sec.) (4) => Glow Relay OK (5) Engine Master “OFF“ (6) Battery Switch “OFF“ Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 11 16 - - D. Accomplish the function test of the Main Bus Relay (1) Battery Switch “ON“ (2) Main Bus Switch “ON“ (3) Avionics, Lights etc. functional (4) => Main Bus Relay OK (5) Main Bus Switch “OFF“ (6) Battery Switch “OFF“ 5. Accomplishing a function test of all switches/knobs The following switches must be tested: • Main Bus Switch • Engine Master Switch • Force B Switch • FADEC Test Knob • AED/CED Test Knob • Alternator Switch A. Inspect all switches/knobs (1) Visual inspect all switches/knobs on signs of corrosion (2) Visual inspect whether all connections of the switches/ knobs are firmly attached B. Accomplish the function test of the Main Bus Switch (1) Battery Switch “ON“ (2) Main Bus Switch “ON“ (3) Main Bus Relay on, Avionics, Lights etc. functional (4) => Main Bus Switch OK (5) Main Bus Switch “OFF“ (6) Battery Switch “OFF“  WARNING: Only run the engine on the ground with the propeller running, even for testing purposes, in a safe and clear area and ensure that prop area is clear ! Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 12 16 Revision no.: Revision date: - - C. Accomplish the function test of the Engine Master Switch (1) Battery Switch “ON“ (2) Engine Master “ON“ => AED/CED indicate data (3) Start engine (4) Load Selector “IDLE“ (5) Accomplish FADEC Test procedure => OK (6) Battery Switch “OFF“ => Engine must run without Battery (7) Switch FADEC A to FADEC B using the Force B switch => Engine running OK (8) => Engine Master Switch OK (9) Engine Master “OFF“ (10) Battery Switch “OFF“ D. Accomplish the function test of the Force B Switch (1) Battery Switch “ON“ (2) Engine Master “ON“ (3) Start engine (4) Load Selector “IDLE“ (5) FADEC toggles from FADEC A to FADEC B using the Force B switch (6) => Force B switch OK (7) Engine Master “OFF“ (8) Battery Switch “OFF“  WARNING: Only run the engine on the ground with the propeller running, even for testing purposes, in a safe and clear area and ensure that prop area is clear !  WARNING: Only run the engine on the ground with the propeller running, even for testing purposes, in a safe and clear area and ensure that prop area is clear ! Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 13 16 - - E. Accomplish the function test of the FADEC Test Knob (1) Battery Switch “ON“ (2) Engine Master “ON“ (3) Start engine (4) Load Selector “IDLE“ (5) Push FADEC test knob => Test procedure OK (6) => FADEC Test knob OK (7) Engine Master “OFF“ (8) Battery Switch “OFF“ F. Accomplish the function test of the AED/CED Test Knob (1) Battery Switch “ON“ (2) Push AED/CED test knob => Selftest AED/CED OK (3) => AED/CED Test Knob OK (4) Battery Switch “OFF“ G. Accomplish the function test of the Alternator Switch (1) Battery Switch “ON“ (2) Engine Master “ON“ (3) Start engine (4) Load Selector “IDLE“ (5) Alternator on: Load current (AED), Voltage > 14V (AED), Alternator Warning Lamp (AWL) off (6) Alternator off: No load current, voltage <14V, Alternator Warning Lamp on (7) => Alternator OK (8) Engine Master “OFF“ (9) Battery Switch “OFF“  WARNING: Only run the engine on the ground with the propeller running, even for testing purposes, in a safe and clear area and ensure that prop area is clear !  WARNING: Only run the engine on the ground with the propeller running, even for testing purposes, in a safe and clear area and ensure that prop area is clear ! Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 14 16 Revision no.: Revision date: - - 6. Accomplishing a function test of all Circuit Breakers The following circuit breakers must be tested: • FADEC A/B • AED/CED • Starter A. Accomplish the function test of the Circuit Breaker FADEC A/B (1) Battery Switch “ON“ (2) Engine Master “ON“ (3) Establish CAN communication by connecting the computer to the airplane (4) Switch FADEC A/B via Circuit Breaker (5) => Circuit Breaker FADEC A/B OK (6) Remove CAN communiction (7) Engine Master “OFF“ (8) Battery Switch “OFF“ B. Accomplish the function test of the Circuit Breaker AED/ CED (1) Battery Switch “ON“ (2) Engine Master “ON“ (3) Switch AED/CED via Circuit Breaker AED/CED (4) => Circuit Beaker AED/CED OK (5) Engine Master “OFF“ (6) Battery Switch “OFF“ C. Accomplish the function test of the Circuit Breaker Starter (1) Battery Switch “ON“ (2) Engine Master “ON“ (3) Switch Starter via Circuit Breaker Starter (4) => Circuit Breaker Starter OK (5) Engine Master “OFF“ (6) Battery Switch “OFF“ 7. Accomplishing a function test of all 14V/28V converters, if installed A. Accomplish the function test of all 14V/28V converters (1) Battery Switch “ON“ (2) Main Bus Switch “ON“ Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 15 16 - - (3) Consumer of electricity “ON“ (check under Load) (4) Check Voltage, a voltmeter must indicate the transformed voltage (refer to the 14/28V Converter manufacturer) (5) => 14V/28V Converters OK (6) Main Bus Switch “OFF“ (7) Battery Switch “OFF“ Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-24-01 3 06.11.2013 16 16 Revision no.: Revision date: - - This page intentionally blank Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 1 16 - - 28 FUEL 28.00 GENERAL DESCRIPTION The fuel system of the TAE 125 installation includes the original standard or long-range tanks of the Cessna 172. Additional sensors for Fuel Temperature and "Low Level" Warning (if not installed already) are installed in the fuel tanks. The fuel flows out of the tanks to the Fuel Selector Valve. The electrically driven Fuel Pump supports the fuel flow to the Filter Module if required. Upstream to the Fuel Filter Module a thermostat- controlled Fuel Pre-heater is installed. Then, the engine-driven feed pump and the high-pressure pump supply the rail, from where the fuel is injected into the cylinders depending upon the position of the thrust lever and regulation by the FADEC. Surplus fuel flows to the Filter Module and then through the Fuel Selector Valve back into the pre-selected tank. A thermostat switch in the Filter Module controls the heat exchange between the fuel feed and return.  WARNING: Any modification to the fuel system (e.g. installation of ferry tank installation), must be approved by Technify Motors GmbH. Any un- approved modification may lead to an unsafe situation. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 2 16 Revision no.: Revision date: - - 28.20 DISTRIBUTION Fig. 28-1aFuel System Diagram C-172 K/L/M (left, right) with TAE 125-01 installation Fuel tank right Engine Fuelfiltermodule Fuel tank left Fuel selector 60°C Fuel tank venting line Fuel tank temperature indication Fuel tank level indication Low fuel warning Electrical Pump Shut-off valve Reservoir tank Reservoir tank venting line Check valve fuel pump sensor filter / screen vent line non return valve selector valve Thermostat valve Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 3 16 - - Fig. 28-2a Fuel System Diagram C-172 K/L/M (left, right, both) with TAE 125-01 installation Fuel tank right Engine Fuel filter module Fuel tank left Fuel selector 60°C Fuel tank venting line Fuel tank temperature indication Fuel tank level indication Low fuel warning Electrical Pump Shut-off valve Reservoir tank Reservoir tank venting line non return valve fuel pump sensor filter / screen vent line non return valve selector valve Thermostat valve Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 4 16 Revision no.: Revision date: - - Fig. 28-3a Fuel System Diagram C-172 N/P (Left, Right) with TAE 125-01 installation Fuel tank right Engine Fuel filter module Fuel tank left Fuel selector & shut-off valve 60°C Fuel tank ventilation line Fuel tank temperature indication Fuel tank level indication Low fuel warning Electrical Pump non-return valve fuel pump sensor filter / screen vent line non return valve selector valve Thermostat valve Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 5 16 - - Fig. 28-4a Fuel System Diagram C-172 N/P (Left, Right, Both ) with TAE 125-01 installation Fuel tank right Engine Fuel filter module Fuel tank left Fuel selector 60°C Fuel tank venting line Fuel tank temperature indication Fuel tank level indication Low fuel warning Electrical Pump Shut-off valve Reservoir tank Reservoir tank venting line non return valve fuel pump sensor filter / screen vent line non return valve selector valve Thermostat valve Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 6 16 Revision no.: Revision date: - - Fig. 28-5a Fuel System Diagram C-172 R/S with TAE 125-01 installation Fuel tank right Engine Fuelfiltermodule Fuel tank left Fuel selector 60°C Fuel tank venting line Fuel tank temperature indication Fuel tank level indication Low fuel warning Electrical Pump Shut-off valve Reservoir tank Reservoir tank venting line Check valve Spill valve fuel pump sensor filter / screen vent line non return valve selector valve Thermostat valve Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 7 16 - - Fuel Filter Bowl Fig. 28-6a Fuel Filter Bowl of TAE 125-01 installation Fig. 28-7a Fuel Filter Bowl Disassembled 1 Top Lid 2 Fuel Filter Housing 3 Fuel Filter Cartridge 4 Spring 5 Bottom Lid 1 2 3 4 5 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 8 16 Revision no.: Revision date: - - Fig. 28-8a Bottom Lid with O-ring 6 Bottom Lid 7 O-Ring Fig. 28-9a Bleed screw in top lid 8 Bleed Screw Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 9 16 - - MAINTENANCE PRACTICES 1. General These maintenance practices provide instructions to remove/install the Fuel Filter and replace the Fuel Filter Cartridge. 2. Removing/Installing the Fuel Filter and replace the Fuel Filter Cartridge A. Remove the Fuel Filter (1) Remove the Fuel Filter from the aircraft by disconnecting all fuel lines and loosening the hose clamps that hold the filter in place. Use a wrench to hold the fittings in the fuel filter bowl while loosening the fuel lines to avoid inadvertently loosening the lines. Be careful to protect all lines and openings of the housing from contamination. B. Replace the Fuel Filter Cartridge (1) Unscrew the bottom lid (5) of the filter using a 27mm oil filter socket wrench (short socket). Remove the fuel filter cartridge (3) from the fuel filter housing. See Fig. 28-7a. (2) Replace the O-Ring (6) in the bottom lid (5), carefully seating it in the groove. Stretching the ring a little helps to retain it in the groove. See Fig. 28-8a. (3) Insert the new fuel filter cartridge into the fuel filter. Ensure that the open end of the lid faces up into the housing. (4) Carefully screw the bottom lid (5) onto the fuel filter housing (2), ensuring the spring seats correctly both in the lid and the fuel filter cartridge. Tighten the lid using a 27 mm oil filter socket wrench (short socket).  Note: If the top lid (1) of the fuel filter bowl should loosen, refit the top lid using Loctite 243.  CAUTION: When using Loctite 243 (blue, medium- strength), only apply a thin film to about 3 or 4 threads, depending on thread size and the threaded length. If any drops collect on the thread or if Loctite fluid escapes from the threaded connection, this is an indication that it has been used too generously and should be avoided. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 10 16 Revision no.: Revision date: - - C. Install the Fuel Filter (1) Install the fuel filter assembly in the aircraft. Tighten the hose clamps, and connect the fuel lines to the assembly. Ensure correct connection of the lines to the filter housing, as the fittings are the same size. All connections are clearly labelled on the top lid of the fuel filter assembly. (2) Bleed the fuel filter bowl by opening the allen head screw, opening the fuel selector valve and activating the auxiliary fuel feed pump until fuel drains from the opening. Replace and tighten the allen head screw, ensuring the crush washer is in place. See Fig. 28-9a. (3) Conduct a ground run after completing any other maintenance on the aircraft. 28.40 INDICATING DESCRIPTION Low Fuel Sensors Electric cables connect the two low fuel sensors (each in one tank) to two low fuel warning lamps in the lightpanel. Chapter 31, Section 31.50 for more data on the lightpanel. Fuel Temperature Sensors Electric cables connect the two fuel temperature sensors (each in one tank) to the AED, where the LH and RH fuel temperatures are indicated. Refer to Chapter 31, Section 31.60 for more data on the AED. TROUBLESHOOTING Table 28-1a Troubleshooting TAE 125-01 / Low Fuel Sensor Trouble Ca use Corre ctive Action Fuel low level warning lam p illum inate on the lightpanel when the tank has m ore than 2.6 US gal (C-172 F,G,H,I,K ,L,M ,N,P ) or 5 US gal (C-172 R,S ) Low Fuel S ens or defec tive Replac e Low Fuel S ens or Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 11 16 - - MAINTENANCE PRACTICES 1. General These maintenance practices provide instructions to replace the low fuel sensor (C-172 F,G,H,I,K,L,M,N,P) and the fuel temperature sensor. 2. Replacing the Low Fuel Sensor (C-172 F,G,H,I,K,L,M,N,P) A. Remove the Low Fuel Sensor (1) Remove the tank. Refer to the aircraft manufacturer´s specifications. (2) Disconnect the electrical cables for the low fuel sensor. (3) Remove the rivets of the fitting for the low fuel sensor. (4) Remove the fitting of the low fuel sensor. (5) Remove the low fuel sensor out of the fitting. See Fig. 28-10a.  WARNING: Do not get fuel on you. Fuel can cause skin desease !  WARNING: Do not allow fire near fuel. Fuel burns and causes injury to persons and damage to equipment !  WARNING: Do not breath fuel vapor ! Fuel vapor can make you ill ! Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 12 16 Revision no.: Revision date: - - Fig. 28-10a Low Fuel Sensor C-172 F,G,H,I,K,L,M,N,P with TAE 125-01 installation 1 Low Fuel Sensor 2 Crush Washer 3 Fitting (6) Clean the tank and the fitting. B. Install the new Low Fuel Sensor (1) Refer to IM-20-01. 3. Replacing the Fuel Temperature Sensor (C-172 F,G,H,I,K, L,M,N,P) A. Remove the Fuel Temperature Sensor (1) Remove the tank. Refer to the aircraft manufacturer´s specifications. (2) Remove the rivets of the fitting for the fuel temperature sensor. (3) Remove the fitting of the fuel temperature sensor. (4) Remove the cover of the fitting. (5) Disconnect the connector of the fuel temperature sensor. (6) Remove the fuel temperature sensor. See Fig. 28-11a. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 13 16 - - Fig. 28-11a Fuel Temperature Sensor C-172 F,G,H,I,K,L,M,N,P with TAE 125-01 installation 1 Cover 2 Fuel Temperature Sensor 3 Seal Ring 4 Connector 5 Fitting (7) Clean the tank and the fitting. B. Install the new Fuel Temperature Sensor (1) Refer to IM-20-01. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 14 16 Revision no.: Revision date: - - 4. Replacing the Fuel Temperature Sensor (C-172 R,S) A. Remove the Fuel Temperature Sensor (1) Remove the access panel. See Fig. 28-12a. Fig. 28-12a Access Panel C-172 R,S 1 Access Panel 2 Access Panel (2) Disconnect the connector of the fuel temperature sensor. (3) Remove the fuel temperature sensor. See Fig. 28-13a. Fig. 28-13a Fuel Temperature Sensor C-172 R,S with TAE 125-01 installation 1 Connector 2 Fuel Temperature Sensor 2 1 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 15 16 - - (4) Make sure that the tank and the adaptor of the fuel temperature sensor are clean. B. Install the new Fuel Temperature Sensor (1) Refer to IM-20-01. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-28-01 3 06.11.2013 16 16 Revision no.: Revision date: - - This page intentionally blank Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-31-01 3 06.11.2013 1 6 - - 31 INDICATING / RECORDING SYSTEMS 31.50 CENTRAL WARNING SYSTEMS Lightpanel The TAE 125 installation includes a lightpanel, which is installed on the instrument panel with the following functions: C-172 F,G,H,I,K,L,M,N,P Table 31-1a Description of the Lightpanel C-172 F,G,H,I,K,L,M,N,P with TAE 125-01 installation Fig. 31-1a Lightpanel C-172 F,G,H,I,K,L,M,N,P with TAE 125-01 installation C-172 R,S Table 31-2a Description of the Lightpanel C-172 R,S with TAE 125-01 installation Lightpanel Function FADEC Test Knob A FADEC B Warning lamps for FADEC A and B Alt Alternator Warning Lamp (red) AED Lamp (amber) for AED 125 CED Lamp (amber) for CED 125 CED/AED Test/Confirm knob for CED 125, AED 125 an Caution Lamps Fuel L; Fuel R Lamps for Low Fuel Level (amber) Glow Glow Control Lamp (amber) Lightpanel Function FADEC Test Knob A FADEC B Warning Lamps for FADEC A and B Force B Switch for FADEC Alt Alternator Warning Lamp (red) AED Lamp (amber) for AED 125 CED Lamp (amber) for CED 125 CED/AED Test/Confirm knob for CED 125, AED 125 an Caution Lamps Glow Glow Control Lamp (amber) Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-31-01 3 06.11.2013 2 6 Revision no.: Revision date: - - Lightpanel Description and Function Table 31-3a Description of Lightpanel functions 31.60 INDICATING INSTRUMENTS CED 125 Fig. 31-2a CED 125 The engine data of the TAE 125 installation to be monitored are integrated in the combined engine instrument CED-125. The ranges of the individual engine monitoring parameters are shown in the following table. Nomenclature Colour Function FADEC N/a Test Knob A FADEC B red Warning Lamps for FADEC A and FADEC B Force B N/a Switch for manual switching to FADEC B Alt red Alternator Warning Lamp AED amber Caution Lamp for AED 125 CED amber Caution Lamp for CED 125 CED/AED N/a Test/Confirm Knob for CED 125, AED 125 and Caution Lamps Fuel L; Fuel R amber Lamps for Low Fuel Level Glow amber Glow Control Lamp Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-31-01 3 06.11.2013 3 6 - - Table 31-4a Markings of the CED 125 Instrum e nt Re d Ra nge Am be r Ra nge Gre e n Ra nge Am be r Ra nge Re d Ra nge Tachometer [rpm] - - 0-2300 - > 2300 Oil Pressure [mbar] 0-1200 1200-2300 2300-5200 5200-6000 > 6000 Oil Pressure [psi] 0-17.4 17.4-33.4 33.4-75.4 75.4-87 > 87 Coolant Temperature [°C] < -32 -32...+60 60-101 101-105 > 105 Oil Temperature [°C] < -32 -32...+50 50-125 125-140 > 140 Gearbox Temperature [°C] - - < 115 115-120 > 120 Load [% ] - - 0-100 - -  Note: If an engine reading is in the amber or red range, the "Caution" lamp is activated. It only extinguishes when the "CED/AED -Test/ Confirm" button is pressed. If this test button is pressed longer than a second, a selftest of the instrument is initiated. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-31-01 3 06.11.2013 4 6 Revision no.: Revision date: - - AED 125 Fig. 31-3a AED 125 Additional airplane data of the TAE 125-01 installation to be monitored are integrated in the auxiliary engine instrument AED-125: • Warning Lamp "Water Level" for low level of coolant • Indication of fuel temperature in the fuel tanks • Voltage • Fuelflow  Note: If an airplane reading is in the amber or red range, the "Caution" lamp is activated. It only extinguishes when the "CED/AED-Test/ Confirm" button is pressed. If this button is pressed longer than a second, a selftest of the instrument is initiated. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-31-01 3 06.11.2013 5 6 - - MAINTENANCE PRACTICES 1. General This maintenance practice provides instructions to check the “WATER LEVEL“ signal. 2. Checking the “WATER LEVEL“ signal A. Drain the Coolant from the Expansion Tank (1) Remove the cap of the expansion tank. (2) Disconnect the coolant hose and allow the coolant to drain in a suitable container. See Fig. 31-4a. Fig. 31-4a Expansion Tank of TAE 125-01 1 Cap 2 Expansion Tank 3 Coolant Connection (3) Seal the coolant connection of the expansion tank. See Fig. 31-4a.  WARNING: Risk of scalding ! The cooling system may be pressurized. Carefully release the pressure before opening the coolant system.  CAUTION: Do not drain the coolant if its temperature is above 40°C ! Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-31-01 3 06.11.2013 6 6 Revision no.: Revision date: - - B. Check the “WATER LEVEL“ signal (1) C 172 F,G,H,I,K,L,M,N,P: BATT and Main Bus Switch - “ON“ (1) C 172, R,S: BATT - “ON“ (2) The “WATER LEVEL“ - Signal (AED-Instrument) must be illuminate (3) Fill the expansion tank half with coolant (4) The “WATER LEVEL“ - Signal (AED-Instrument) must be extinguished, otherwise the “WATER LEVEL“ - Sensor must be replaced C. Replenish the Coolant (1) Connect the coolant hose to the expansion tank. See Fig. 31-4a. (2) Replenish the coolant (refer to Chapter 12, Liquid Cooling System) Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-37-01 3 06.11.2013 1 2 - - 37 VACUUM 37.00 GENERAL DESCRIPTION The TAE 125-01 engine includes a vacuum pump, which is supplying the following flight instruments with suction air: • the artificial horizon • the directional gyro and • the turn and bank indicator. The vacuum pump is mounted to the camshaft and works as an excenter with oildust seal. An inline spring loaded valve limits the suction pressure and the stream of the volume. The original suction indicator of the concerned aircraft is used to indicate the suction pressure. For adjusting the vacuum system refer to Aircraft manufacturer´s Service Manual. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-37-01 3 06.11.2013 2 2 Revision no.: Revision date: - - This page intentionally blank Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-61-01 3 06.11.2013 1 6 - - 61 PROPELLER 61.10 CONSTANT SPEED PROPELLER The TAE 125-01 installation is equipped with the propeller MTV-6-A/187-129. For Inspections and Maintenance of the propeller refer to Operation and Installation Manual of MT-Propeller E124 (ATA 61-01-24). The propeller control system uses gearbox oil to function. The oil pump delivers oil to the constant speed unit. Inside the constant speed unit the oil passes through a micro filter and a pressure relief valve where the pressure is reduced to a constant 20 bar (290 psi) before reaching the actual control valve. The propeller control valve regulates the oil pressure to the propeller to regulate pitch. Returned oil from the control valve is used to lubricate the gearbox. The propeller control valve is regulated by an electric signal from the FADEC while the pilot has no direct input to the propeller. The propeller itself is a conventional variable pitch propeller, pitch is increased by increasing oil pressure and is decreased by the blade pitching moment and a servo spring. The next Figure shows a schematic of the propeller control system. See Fig. 61-1a. Fig. 61-1a Propeller Control System of TAE 125-01 Gearbox Pump Micro Filter Relief Valve FADEC Propeller Control Valve Propeller Constant Speed Unit Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-61-01 3 06.11.2013 2 6 Revision no.: Revision date: - - 61.20 CONSTANT SPEED UNIT The Constant Speed Unit (CSU) of the TAE 125 installation is a FADEC- controlled single-acting propeller governor produced by Technify Motors GmbH for hydraulically variable pitch propellers with and without feathering. The CSU TAE 125 is installed on the front side of the gearbox. No overhaul permitted. The micro filter have to be exchanged according to Chapter 5, Section 5.20. No cleaning allowed. Enter each filter exchange in CSU installation record. The governor uses gear box oil with a pressure of 20 bar (290 psi) Limitations Maximum acceptable operation temperature:.....+120°C Range of altitude:................................................up to 18 000ft Dimensions of CSU TAE 125-01 (figures not to scale) Fig. 61-2a CSU front view Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-61-01 3 06.11.2013 3 6 - - Fig. 61-3a CSU side view Fig. 61-4a CSU bottom view 1 Pressure Control Valve with Electrical Connection 2 Micro Filter 3 Pressure Relief Valve 1 2 3 Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-61-01 3 06.11.2013 4 6 Revision no.: Revision date: - - Fig. 61-5a CSU top view TROUBLESHOOTING Table 61-1a Troubleshooting TAE 125-01 / Propeller Trouble Cause Corrective Action check oil level at oil viewer glass at front side of the gear box fill up gear box oil (see OM- 02-01) check, when micro filter has been changed last time (every 50 operating hours) authorised maintenance will change the microfilter change gear box oil broken connection between FADEC and pressure control valve check electrical connection to pressure control valve incorrect function of the pid- regulator contact authorised maintenance or engine manufacturer dirty gear box oil Contaminants in dirty gear box oil can cause blockage of close tolerance passages in the CSU, leading to erratic operation. Timely gear box oil changes should eliminate this problem low level of gear box oil high contamination of micro filter Propeller surging or "wandering" Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-61-01 3 06.11.2013 5 6 - - MAINTENANCE PRACTICES 1. General These maintenance practices provide instructions to remove/install the Micro Filter. They also provide instructions to calibrate the CSU. 2. Exchanging the Micro Filter A. Remove the Micro Filter (1) Open safety wire at bottom of the module block. (2) Turn the cover of the filter with a wrench, remove the cover and the aluminum o-ring. (3) Pull the filter downwards. B. Install the new Micro Filter (1) Take a new filter (P/N 02-6120-16107R1) lubricate the rubber o-ring with gear box oil. (2) Install the new filter. (3) Take a new aluminum gasket (P/N NM-0000-0029601) and install it with the cover. Torque: 40 Nm (29.5 lbf. ft) (4) Attach safety wire so that filter cover cannot move. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-61-01 3 06.11.2013 6 6 Revision no.: Revision date: - - 3. Calibrating the CSU A. Calibrate the CSU (1) Install a manometer between gear pump and micro filter (2) Loose the nut at pressure relief valve with a 25 mm wrench (3) Check the pressure indicated at the manometer (4) If pressure not 20 bar ± 2 bar (290 psi ± 29 psi), turn screw at pressure relief valve with a 10 mm wrench until this value is reached (5) Tighten the nut with a 25 mm wrench. Torque: 25 Nm (18.4 lbf. ft).  Note: The calibration of the CSU will be done by the engine manufacturer. If calibration is necessary by authorized maintenance, proceed at a gear box temperature of 50°C as follows:  Note: The propeller pitch limits will be set by the propeller manufacturer. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-71-01 3 06.11.2013 1 32 - - 71 POWER PLANT 71.00 GENERAL DESCRIPTION The TAE 125-01 is a liquid-cooled in-line four-stroke 4-cylinder motor with DOHC (double overhead camshaft). The engine is a direct Diesel injection engine with common-rail technology and turbocharging. The engine is controlled by a FADEC system. The propeller is driven by a built-in gearbox (i = 1.69) with mechanical vibration damping and overload release. The engine has an electrical self starter and an alternator. Due to the specific characteristic, all of the information from the airplane maintenance manual are no longer valid with reference to: • carburetor and carburetor pre-heating • ignition magnetos and spark plugs, and • mixture control and priming system Whole Assembly The capacity is 1689 cm 3 , each cylinder has a swept volume of 422 cm 3 . The engine produces 99 kW (132.8 hp) at 2300 rpm (Propeller rotational speed) with a static compression ratio of 19:1 or 18:1 respectively. (19:1 up to serial number -0100; 18:1 from serial number -0101 and on) Crankcase The aluminium crankcase is made using pressure die casting with ductile iron liners, bore is 80 mm (3.15 in). The gauge for boreholes is 90 mm (3.54 in). The crankcase is fine ribbed and the main bearing caps are cross-bolted to get maximum stiffness to weight. In normal running the cylinder pressure is always less than 155 bar (2248 psi). Crankshaft The stroke is 84 mm (3.31 in), main journal diameter is 55 mm (2.17 in), rod journal diameter is 46 mm (1.81 in). The original 2-mass flywheel is changed to a 1-mass type.  CAUTION: The engine requires an electrical power source for operation ! If the battery and alternator fail simultaneously, this leads to engine stop. Therefore, it is important to pay attention to indications of alternator failure. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-71-01 3 06.11.2013 2 32 Revision no.: Revision date: - - Connecting Rods The connecting rods are made of forged steel each including big end bearing. The big end diameter is 50 mm (1.97 in), the bushing in the small end has a diameter of 28 mm (1.1 in). In the case of overload the rod has the tendency to become shorter, it shows no bending tendency. The rods are forged in one piece, then the big end is cracked, so that the mating surfaces are perfectly aligned at assembly. They are equipped with M7 bolts and are axially guided at the piston. The rod length is 140 mm (5.51 in). Pistons The original aluminum pistons have special steel inlays in the piston ring groove and are a cooling duct design. Special chrome ceramic rings guarantee good wear resistance. Cylinder Head The 4 valve cast aluminum cylinder head has diametrically opposed valves. There are 2 water jackets which reduce the temperatures in the critical areas around the exhaust valve seats and the injector to less than 200 °C. The hydraulically adjusted roller lifters acting on the nimonic valves guaranty low friction values benefiting the efficiency and reliability of the engine. An original three layer steel head gasket is used. A glow plug is installed for the reason of starting in very cold conditions. Camshafts The forged steel camshafts are gun drilled. A simplex timing chain is fitted. The cam profiles provide an intake valve lift of 8.5 mm (0.33 in) and an exhaust valve lift of 8 mm (0.31 in). Valve Train The intake valves have a shaft diameter of 6 mm (0.24 in) and a valve head diameter of 29.6 mm (1.17 in), the exhaust valves have a shaft diameter of 7 mm (0.28 in) and a valve head diameter of 24.6 mm (0.97 in). The valve springs have an inside diameter of 15.5 mm (0.61 in), an outside diameter of 21 mm (0.83 in) and 2.75 mm (0.108 in) wire diameter. The unstressed height of the spring is 45.5 mm (1.79 in), assembled height is 32.5 mm (1.28 in), it has 8 threads. The valve keys are of type MK6 to guarantee a good valve rotation. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-71-01 3 06.11.2013 3 32 - - Induction and Fuel System A common rail system with electrically actuated injectors is used. The high-pressure fuel pump is driven by the intake cam and is a three piston radial pump. The injection pump is set to a more advanced timing for a cooler exhaust temperature, the aim is a exhaust temperature below 900°C (during maximum continuous power), the preinjection is retained. The airflow passes through the air filter, the turbo charger and then the air-to-air intercooler into the intake manifold. The improved intake manifold is short but provides an undisturbed intake spin. Oil System The wet oil sump system has a 1 sectioned oil pump and is driven by a gear from the crank. The oil thermostat maintains the oil temperature always to a constant level. Cooling system The water flow through the engine guaranties a perfect heat transfer from the hottest section in the engine to the radiator and maintains the optimum engine operating temperature. An oil thermostat maintains the oil temperature at a constant level. Propeller Drive System The drive for the propeller is via a gear set. The propeller shaft speed is 2300 rpm during start conditions and continues fly conditions. The gears are steel forged to reduce mass and to guaranty good reliability. The die cast housing is mounted directly to the crankcase and incorporates internal oil paths to lubricate the gears and constant speed propeller drive. Governor System The prop-pitch-control system is integrated in the FADEC. The gear oil is sucked off at the lower side of the gear and is brought to the pressure control and control unit with a gear pump. The system pressure regulator provides a constant system pressure of 20 bar (290 psi). The control unit controls the oil flow to the cylinder over a pulse valve, the cylinder controls the propeller pitch adjustment. Auxiliary System The vacuum pump is direct driven by camshaft and provides the necessary vacuum for the navigation instruments. Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-71-01 3 06.11.2013 4 32 Revision no.: Revision date: - - Electronic and Electronical System The engine is controlled via a 32-bit Microprocessor Engine Management system (FADEC) incorporating redundancy. The FADEC consists of two complete and identical redundant halves and the most important sensors (Cam and Crank signals) are redundant as well. An intelligent control strategy manages switching between the two redundant FADEC channels in case of a failure. All sensor signals are continuously monitored, sensor failures are detected automatically and the control strategies account for sensor failures. The FADEC is equipped with two warning lights (one for each redundant half) that constitute the means to alert the crew of failures and when crew action is needed. An event log store logging all failures and extreme sensor input values as well as an integral hours run meter ensure maximum safety against potentially damaging events. An independent safety system monitors the stored events before every take off and independently makes a check of all functions including a switch to the other redundant half to make sure both FADEC channel are in working order. The control system includes a data stream interface implemented as a CAN line that carries several sensor and FADEC internal values and can be used to drive an engine instrument like the CED-125. Fig. 71-1a TAE 125-01 FADEC overview CAN BUS Crank Sensor CAM Sensor Injector 1 Injector 2 Injector 3 Injector 4 Railvalve Boostvalve Glow Control 2 x Check Engine Lamp CAN BUS Load-Poti Airtemperature Sensor Railpressure Sensor Oil pressure BARO-Sensor MAP-Sensor ECU Test Switch ECU A/B Switch Gear Temperature (Prop Pressure) Watertemperature Sensor Oil Temperature I n p ut Si g n al s Act u at or s (Fuel Pressure) Re d u n d a nt S e ns or s A d diti o n al Se ns ors F A D E C I n p ut Si g n als Integrated Sensors (redundant) CED Laptop with CAN Interface TAE 125 FADEC Overview Issue 11/02 (Fuel Temperature) Propvalve Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Revision no.: Revision date: Chapter: Issue: Issue date: Page: Content: 20-AMM-71-01 3 06.11.2013 5 32 - - Technical Data Type of engine: ..................................4-cylinder inline, DOHC, 4 valves per cylinder Engine code: ......................................TAE 125 Displacement: ....................................1689 cm3 Piston-swept volume:.........................422 cm3 Engine principle: ................................4 cycle Diesel Direct Injection with turbocharger Power:................................................99 kW (132.8 hp) at 2300 rpm (Prop. rotational speed) Torque:...............................................410 Nm (302.4 lbf . ft) at 2300 rpm (Prop. rotational speed) Bore: ..................................................80.0 mm (3.15 in) Stroke:................................................84.0 mm (3.31 in) Gauge of boreholes: ..........................90.0 mm (3.54 in) Compression ratio:.............................19:1 up to serial number -0100 18:1 from serial number -0101 and on Main journal diameter: .......................55.0 mm (2.17 in) Rod journal diameter:.........................46.0 mm (1.81 in) Connecting rod length:.......................140.0 mm (5.51 in) Rod big end diameter:........................50.0 mm (1.97 in) Rod small end diameter: ....................28.0 mm (1.1 in) Wrist pin diameter: .............................28.0 mm (1.1 in) Valves per cylinder:............................2 intakes, 2 exhausts Valve lift intake:..................................8.5 mm (0.33 in) Valve lift exhaust:...............................8.0 mm (0.31 in) Intake valve head diameter:...............29.6 mm (1.17 in) Exhaust valve head diameter:............24.6 mm (0.97 in) Intake valve shaft diameter: ...............6.0 mm (0.24 in) Exhaust valve shaft diameter:............7.0 mm (0.28 in) Valve spring outside diameter:...........21.0 mm (0.83 in) Valve spring inside diameter:.............15.5 mm (0.61 in) Valve spring wire diameter:................2.75 mm (0.108 in) Valve spring threads: .........................8 Valve spring height: ...........................45.5 mm (1.79 in) Valve spring installed height: .............32.5 mm (1.28 in) Max. fuel pressure: ............................1350 bar (19580 psi) Supplement Airplane Maintenance Manual Cessna 172 / TAE 125-01 AMM-20-01 Chapter: Issue: Issue date: Page: Content: 20-AMM-71-01 3 06.11.2013 6 32 Revision no.: Revision date: - - Oil system: Oil pump:............................................1 stage Tappet clearance compensation:.......Hydraulic Type of cam timing drive:...................Chain TROUBLESHOOTING To isolate a fault, proceed as follows: "Sensor Properties" and "Act