Airplane Flight Manual

tion. Connecting the transfer line into the fuel line going to the right wing tank is extremely easy to accomplish. A union in the fuel line over the right door post is removed and a T-fitting is then installed in its place. A photograph of this installation is enclosed. A check valve in- corporated into the transfer line and two more check valves in the transfer pump prevent fuel from flowing back into the auxiliary tank from the wing tank. AUXILIARY FUEL GAUGE: An accurately calibrated electric fuel quantity transmitter is built into the top of the tank. A gauge with luminescent markings indentified as "Auxiliary Fuel" mounts on the instrument panel. NEW BAGGAGE COMPARTMENT FLOOR: While this new floor is seven inches higher than the original floor it is over eight inches wider than the original floor. This is due to the fuselage contour. Four average suitcases can be set side by side where previously only three could go side by side. This new floor is covered with plastic impregnated fabric material comparable to the material in the baggage compartment area. This material also completely encloses the auxiliary fuel tank; the enclosed compartment is then ventilated by a fuselage vent furnished with the auxiliary fuel system kit. A support column which goes through the tank transmits loads from the new floor to structure in the bottom of the airplane without allowing any loads to be im- posed upon the tank. FAA does not allow any type of load to be carried on a fuel tank due to the possibility of damage to the tank causing a leak. A photograph on the opposite page shows the new baggage floor. A photograph with the hat shelf removed (for photographic purposes) shows the same view with baggage. WEIGHT OF INSTALLATION: The complete auxiliary fuel system weighs only twenty-four pounds. Fifteen pounds of this weight is located in the baggage compartment, resulting in the maximum baggage placard being reduced from 120 pounds to 105 pounds. INSTALLATION: The installation kit for this auxiliary fuel system incorporates all necessary parts and instructions and can be installed by your local mechanic in approximately eight hours time. This installation kit fits all models of Cessna 170 and 180 series aircraft including float and/or tri-cycle geared aircraft of the series. However, due to variations in ground attitude, the model number of the airplane and type of landing gear must be specified when the kit is ordered. If the airplane is on tri-cycle landing gear or floats, additional sump drain fittings must be welded to the front of the tank. For conventional landing gear, the sump drain at the rear of the tank is utilized. FAA APPROVAL: This auxiliary fuel system has been fully FAA approved in kit form for field installation; which included FAA approval of all components, installation blueprints, and installa- tion instructions. FAA approval of the installation is indicated by its being listed in the Airplane Specifications. The installation also has engineering approval of Cessna Aircraft Company. INCREASED UTILITY AND VALUE: The solo pilot with perhaps one passenger constitutes the majority of cross-country flying in business and personal airplanes. On many flights these people are vitally concerned about reserve fuel. There is no need to accept this condition since several hundred pounds of the airplane's useful load is not being utilized. Surveys of the used airplane market show that an airplane equipped with an auxiliary fuel system will sell for as much as $500.00 more than an airplane not so equipped. The cost of this auxiliary fuel system is entirely offset by the airplane's increase in value. صارت تار Jaukun 18 M Sup m #113 September 15, 1955 Revised & reprinted March 1, 1961 Reprinted March 1976 JAVELIN AIRCRAFT COMPANY, INC. 9175 E. Douglas Wichita 6, Kansas 316-733-1011 INSTRUCTIONS FOR INSTALLING JAVELIN AUXILIARY FUEL SYSTEM INTO CESSNA 170, 172, 175, 180 and 182 SERIES AIRCRAFT IN ACCORDANCE TO JAVELIN DRAWING NO. 782. FOR CESSNA FACTORY INSTALLATION, CESSNA DRAWING 0716128 DEFINES THIS INSTALLATION. This auxiliary fuel system consists of an 18 gallon tank located in the bottom of the baggage compartment and protected by a new baggage compartment floor. An electric pump transfers the fuel to the right wing tank. A check valve in the line and two more in the pump prevent the fuel from flowing back to the auxiliary tank. A fill cap for this system locates on the right side of the airplane and a sump drain valve mounts on the bottom of the airplane. An electric fuel quantity indicat- ing system is incorporated, which is accurately calibrated and which allows the pilot to plan his loading, utilizing less than the full 18 gallons of auxiliary fuel if he so desires. A Form ACA-337 must be executed showing the airplane's new empty weight and C.G. This auxiliary fuel system weighs 24 pounds, and is located 99" aft of datum (forward face of firewall). The unusable fuel in level flight attitude is ½ gallon. (F.A.A. required sump capacity for 18 gallons is .45 gallon). With unusable fuel added the system's weight is 27 pounds, for a total moment of 2673. This installation is F. A. A. approved and is listed in the airplane specifications. 1. Remove the back of the rear seat. Remove the screws from the right rear corner of the floor mat and roll the mat forward until access is gained to the inspection covers in the metal floor of the airplane. Remove access panel to tail cone. Remove the in- spection covers from the belly of the airplane. 2. Route the wire bundle provided in the kit behind the instrument panel, down the firewall, underneath the floor and aft through the enlightening holes of the bulkheads. Do not route the wire bundle through any enlightening hole which also contains control cables or fuel lines. The wire bundle should go underneath the fuel lines between the bulkheads and lie on the external skin of the aircraft. Following installation of the wire bundle, replace all inspection covers with the exception of those in the baggage compartment. On 172, 175 and 182 series aircraft, enlightening holes are not present in the landing gear bulkhead, therefore, the wire bundle must go through the hole with a control cable; however, these holes are some 5" in diameter allowing adequate clearance. Install a clamp to secure the wire bundle where it goes through this hole. Wiring may be routed through the top of the cabin instead of. through the belly, if desired. Page #2 3. Remove the false panel from the instrument panel and the empty instrument hole cover from the location that the aircraft owner desires to utilize. Mount the gauge on the back side of the panel. The holes in the Cessna panel are smaller than standard; however, it is not necessary to enlarge the hole. The gauge will readily mount on the back side of the panel. If an empty hole is not available, fabricate a bracket to support the gauge. Regardless of the type of mounting, determine that the gauge will be grounded. Connect the green wire in the wire bundle to the fuel gauge. Connect the yellow power lead attached to the gauge to the navigation and dome light fuse holder in the 170, 172, and 175 series and to the instrument light circuit braker in the 180 and 182. Install -13 decal adjacent to the fuse holder or circuit braker. Replace the false panel. 4. Install transfer pump switch and decal. A ivory colored knob is provided which conforms to the later model airplanes; if an early model airplane is involved utilizing brown or grey knobs, a brown or grey knob can be obtained from Cessna spare parts. Connect the red wire in the wire bundle to one terminal of the switch and connect the other terminal to the same source of power as the gauge. The current drain of the transfer pump is negligible, being only ½ amp. 5. Place the transfer pump into position on the aft side of the rear baggage compartment bulkhead with the holes in the pump- mounting bracket 12" above the baggage compartment floor. Drill two #10 holes in the bulkhead to match the holes in the pump- bracket and mount the pump with one AN 3-3A bolt with large washer and one AN365-1032 nut. Connect the red lead in the wire bundle to the lead on the pump and slide spaghetti into place The bottom of the pump contains over the disconnect terminal. a screen which protects the check valves from foreign matter. Observe that the bottom cap is securely tightened. This is a very high quality pump; an accumulator in the top absorbs pressure surges to provide a smooth flow of fuel. This pump is now used on several single and multi-engine aircraft as a transfer pump and as an emergency electric pump to pump fuel direct to the carburetor. The pump rate is 2½ minutes per gallon. One hour should be allowed to transfer the 18 gallons. 6. The fill-cap adapter is to be installed in the right side of the fuselage in the area of the baggage compartment. The lo- cation of the hole in the skin is up 3" from the bottom row of rivets in the side splice plate and forward 2½" from the line of rivets in the rear baggage compartment bulkhead. Cut a 24" diameter hole at this location, being careful not to get it over- size. Cut the upholstery away in the side of the baggage com- partment to match the hole in the skin 7. Install the -7 fill-cap placard with the 6-32, screws, washers and nuts provided in the kit. Reach through the hole cut in the upholstering in step No. 6. to install washers and nuts. Page #3 8. To prevent fuel from flowing into the airplane around the bottom of the cap adapter, the following method accomplishes a seal. Remove the fiberglass insulation from the area to allow the adapter to seat onto the skin utilizing the plastic uphostery as a gasket, Utilizing a small brush, coat the inside of the skin around the hole with the tite seal provided in the kit. Press the upholstery into position and apply a light coat of the tite seal to the upholstery. Do not exceed diameter of adapter. Press the fill-cap adapter into position from the in- side out. While holding the adapter in place, drill six #230 holes to match the ones in the adapter; insert the screws from the outside and install the nuts and washers on the inside. The screws are AN526-632R7, the washers are AN960D6 and the nuts are AN365-632. NOTE It has been observed on some installations that the mechanic has not removed the fiberglass insulation between the skin and the upholstering in the area of the fill-cap adapter, as per the installation instructions. This results in the skin bulging out- ward between the mounting screws. Also, a satisfactory seal can- not be obtained if this fiberglass is not removed. 9. In aircraft on conventional gear, drill three 3/16" drain holes at the first bulkhead aft of the baggage compartment; one hole on the center line and the other two holes approximately 4" each side of the center line. Crawl aft in the fuselage and drill drain holes before each of the other bulkheads. 10. Locate a point 5" inboard from the right side of the flange on the bottom of the opening to the tail cone. Measure from the bottom end of the part on the side of the opening. Cut a notch 1" wide in the flange at this location for the sump drain on the bottom of the tank. If the airplane has a floor mat in the baggage compartment area, cut out a 4" diameter hole to match the inspection hole at the forward right side of the baggage compartment. 11. Check all fittings in the tank for security. Part 3, airplane air worthiness regulations, which this system is designed and built to, requires that the finger strainer in the tank be re- movable for inspection. By removing the plug, in the front of the tank, the finger strainer can be pulled out. However, it should not be unnecessarily disturbed. The finger strainer is located in the end of a probe reaching to the front of the tank to provide maximum usable fuel in flight and allowing the outlet to be at the rear of the tank, adjacent the transfer pump. 12. Set the tank into place being careful not to tear off any of the felt padding glued to the tank. Connect the green fuel quantity transmitter wire and slide spaghetti into place. Install the other AN3-3A bolt, large washer and AN365-1032 nut onto the pump mounting bracket, utilizing this bolt to secure the black ground lead soldered to the fuel quantity transmitter. Page #4 13. 14. Drop the dowel pin into the hole through the tank. The pur- pose of the dowel pin is to carry loads from the new floor to the structure in the bottom of the airplane; thereby preventing any load from being imposed on the tank (which F.A.A. does not allow). Place the rear floor support into position with the cut- out providing clearance for the fittings. Place the new floor into position. Pull up the covering on the floor, insert the access panel retainer (aluminum angle) between the rear edge of the floor and the rear floor support, so that the holes align with the screw holes. Then install the four wood screws pro- vided in the kit through the rear edge of the floor and into the rear floor support, replace covering. Place the floor support brackets into place, two on each side. Place a large AN970-3 washer on the bottom of the floor at each fitting and one on the backside of the bulkhead at each fitting. Attach the fittings to the floor with AN3-6A bolts and to the bulkheads with AN3-3A bolts. Install rear floor bolts with heads down. Place the -10 angle into position at the front of the tank to hold down the tank enclosure and install the eight metal screws; observe that the enclosure is slack so that it will not be damaged by the seat back when it is moved forward at the top. Push the tank enclosure down around the tank on both sides. Pull the tank enclosure aside and drill a 4" hole in the metal floor of the airplane on the aft side of -10 enclosure clamp at each end. (F.A.A. required drain holes). On aircraft with baggage compartment door, remove the stainless steel strip at the bottom of the baggage door. After the tank enclosure has been pulled down, replace this stainless steel strip utilizing it to secure the enclosure. 15. Place the two large clamps in the kit onto the fill neck elbow and place the fill neck into position with the longest end of the elbow down. This elbow is molded of very strong neoprene material and is fuel proof. Tighten the two clamps securely. 16. Remove all fuel lines from the kit, inspect the fittings for security. Look through the hose to determine that it is open and clean. Blow dry compressed air through them or run gasoline through them. These hoses are carefully inspected before they are put in the kit, but it is the mechanics responsibility to inspect them also. Fuel hoses have been installed into airplanes that were completely plugged. 17. Connect the longest of the two small fuel lines to the elbow in the back of the tank and the elbow at the bottom of the transfer pump. Tighten fittings securely. Page #5 18. Drill a 7/16" diameter hole in the botton skin 8" aft of the rear bulkhead below the tank and 2" outboard of the radio rack. Place one of the fiber washers onto the male end of the drain valve, insert male end through hole in the skin from outside of the airplane; place another of the fiber washers onto the male end of the valve inside the airplane. Coat the threads of the drain valve with tite seal and turn the drain valve into the adapter until the tapered pipe threads are securely tightened. 19. Attach one end of the remaining small fuel line to the union in the bottom of the tank, route the other end of the fuel line to the elbow in the drain valve adapter, tighten fittings securely. If the kit is for a tri-cycle gear or float equipped aircraft install a plug in the rear sump drain fitting and utilize the sump drain fittings at the front of the tank. Due to the seat leg cut-out, two sump drain fittings are necessary at the front. They are interconnected with a manifold line. 20. Open zipper in the top of the cabin, remove screws in clips hold- ing headliner up aft of the zipper and pull out bow to drop head- liner down. Insert one end of transfer line (MIL-H-5593A-6 fuel hose) through the large enlightening hole in the top right side of the rear baggage compartment bulkhead and forward over the upholst- ery. Connect transfer line to check valve at pump and tighten fittings. Place support clamp provided in the kit onto hose above transfer pump. Slide clamp up to the edge of the enlightening hole at the top of the bulkhead. Place clamp into optimum position and drill #2310 hole in bulkhead. Mount support clamp with AN3-3A bolt and AN365-1032 nut. Install AN3-3A bolt into clamp and tighten securely. This clamp supports the transfer line and prevents it from sliding down and drawing on headliner. Replace head-liner bow and screws. NOTE On 1961 Models and on with the raised head-liner the transfer line must be routed through holes in the cabin bulkheads. 172 and 175 Models Drill 7/8" diameter hole 5/8" down and 1/4" outboard from 3/16" tooling hole in top right corner of station 90 (seat back). Drill 7/8 hole in the bulkhead at station 108 (rear of baggage compartment) 5/8" down and 1/4" outboard of rivet securing upholstery clip on right side of bulkhead. For Cessna Factory installations or for field installations with head-liner removed wherein it is desired to route the wiring through the top of the cabin instead of through the belly, drill a ½" hole 1" up and inboard from tooling hole in bulkhead at station 90 and 1½" up from transfer line hole at station 108. See illustration Page #7 Page #6 21. 180 and 182 Models Utilize the existing hole at top right corner of station 108 (rear of baggage compartment) ream it out from 13/16 to 7/8. After transfer line is routed in place assemble support clamp onto transfer line to determine position for a No. 10 hole to mount the support clamp. The existing hole is provided for routing of an oxygen line. If the aircraft involved has an oxygen system and this existing hole has already been utilized, drill a 7/8" diameter hole 1" down and 7/8" outboard from center of exisiting hole. At station 90 (seat back) drill a 7/8 diameter hole in the top right corner of the bulkhead in its widest portion. The raised head-liner of the 1961 and on 180 and 182 aircraft have caused this bulkhead to be very narrow drilling a 7/8 hole through the bulkhead requires that a doubler be installed. The doubler is made of .032 24"x5", 2024-T4 material with a flange being formed on one side only to fit the inside flange of the bulkhead and is secured by 470AD4 rivets. After routing the transfer line through the hole assemble support clamp onto the transfer line and drill a No. 10 hole for the AN3 bolt to secure the support clamp. See illustration Page #8 NOTE As of March 15, 1961 all auxiliary fuel system kits will incorporate three -12 support clamps for the 1961 airplanes. Utilize one at station 65 (rear door post) one at station 90 on forward side and one at station 108 on aft side. Place the fuel selector valve to "off"; utilizing a funnel and hose, drain all fuel from the right wing tank to the auxiliary tank. Replace and lock wire drain plug. 22. Utilizing a table knife, putty knife, or other satisfactory tool, pry open the metal strip holding the headliner of the upholstery above the right rear door post and forward 12", being careful not to tear the upholstery or to pry the metal strip open so far that it will not retain the upholstery when it is replaced. 23. Disconnect the fuel line at the union over the door frame.. Re- move the union and discard. Install the tee-fitting provided in the kit into the aft fuel line fitting, so that the side connec- tion of the tee-fitting is up and slightly inboard. Tighten nut. Push aft on the fuel line until the tee-fitting is moved 5/8". The fuel line is soft, and it will bend easily. This small change in its 90°bend at the top of the door frame will not injure it or cause any interference. Connect the forward section of the fuel line to the tee-fitting and tighten the nut. Connect the forward end of the transfer line to the tee-fitting and tighten fitting. Close zipper. Observing the photograph in the brochure for this Auxiliary Fuel System will aid in orientation. 091 الله aircraft with raised head-liner. 1961 and on Models 172 and 175 -12 support clamp AN824-6D Tee added in place of AN815-6D Union Page #7 784-6 transfer line Transfer pump and gauge wiring Drill 7/16 hole for AN931-4-7 grommet Rivet securing upholstering AN3-3A Bolt in tooling hole -12 Support Clamp PLEXI MLP5425 B F THICKNESS 060 Drill 7/8 hole for transfer line clip AN3-3A Bolt in No 10 hole for support clamp on aft side FOR ALL MODELS PRIOR TO 1961 ROUTE FUEL LINE THROUGH THIS ENLIGHTING HOLE AND FORWARD OVER HEAD LINER aircraft with raised head-liner 1961 and on Models 180 and 182 Page #8 -12 Support Clamp For Cessna Factory installation or field, installation where upholstering is removed route wiring overhead as shown. Drill 7/8 hole for transfer line -12 Support Clamp Rear Door post Sta. 65.33 Seat back Sta. 90 Existing hole 784-6 Transfer Line 製 Rear of baggage compartment Sta. 108. FOR ALL MODELS PRIOR TO 1961 ROUTE FUEL LINE THROUGH THIS ENLIGHTING HOLE AND FORWARD OVER HEAD-LINER. Hole for fill neck Page #9 24. Submerge the baggage compartment decal in 70° F. water for 30 seconds and slide it off of the paper backing onto the forward edge of the hat shelf so as to cover the original placard. In the event that the hat shelf is removed to improve the utility and access of the baggage compartment area, slide the decal off inside the bulkhead at station 90 (even with seat back). If the hat shelf is removed, the baggage compartment floor brackets provide a means to tie the baggage down. Install the -3 fuel transfer placard with metal screws at the left hand side of flap handle immediately forward of the fuel selector valve. The plate must be located longitudinally to the airplane with the bottom of the plate toward the pilot's seat. 25. Support the tail as necessary to obtain level flight attitude, place airplane master switch "on" and pull the transfer switch out to "on". Check to see that the transfer pump operates. Allow pump to operate until all fuel is pumped back to wing tank. Care- fully check all fittings for leakage. When auxiliary tank becomes empty, air will be heard bubbling in the wing tank. Check gauge to determine that it reads empty. With airplane master switch "off", pump nine gallons of gasoline into auxiliary tank. Very carefully check all fittings for any sign of leakage. Place master switch to "on" and see that gauge reads 2. Place master switch "off", pump gasoline into the tank until it is full; again very carefully check for leakage. Place master switch "on" and check that gauge reads "full". CAUTION Due to the existence of electrical equipment in the aft fuselage section of many of the involved airplanes, any fuel leakage from the main fuel system or from this auxiliary fuel system causes a very hazardous condition. It is mandatory that the mechanic employ good workmanship and carefully check all fuel fittings in the airplane. 26. Utilizing a putty knife, push the headliner back into the metal strip. Remove the snap buttons from the bottom half of the tail cone access panel. Install the access panel in the airplane after the new floor is bolted into place and draw a pencil mark across its forward side, then remove the access panel. Transfer the mark to the back side and cut the metal off at this point. Leave the upholstering some 2" longer so that it can be lapped over and glued on the back side. 27. Install the fuselage vent kit Javelin Part #2787 as per instruc- tions contained on the drawing. The function of this vent is to draw any fuel vapor from the sub floor or tail cone area which may accumulate around fittings on the fuel selector valve. The valve prevents entry of exhaust fumes during ground operation. This kit is available as a separate accessory and is beneficial in reducing cabin pressure, thereby improving the operation of the cabin heating and ventilation system. Also on some airplanes, the reduction in cabin pressure will stop the doors from whistling. This complete kit as a separate accessory lists for $19.50 and is available from this Company.