SERVICE MANUAL 100 - SERIES

5-30A thru 5-30B .................... 0 5-31 thru 5-39...... 0 5-40 Blank 0 6-1 thru 6-12............................0 7-1 thru 7-7..............................0 7-8 Blank ... 0 7A-1 thru 7A-5 ........................ 0 7A-6 Blank 0 8-1 thru 8-7..... 0 8-8 blank ....... 0 9-1 thru 9-6 0 10-1 thru 10-12 0 11-1 thru 11-8 0 12-1 ......................................... 0 *12-2 ....................................... 1 12-2A thru 12-2B .................... 0 12-3 thru 12-8..........................0 Page Revision No. No. 12-8A thru 12-8B .................... 0 12-9 thru 12-12 ........................ 0 12-12A thru 12-12B ................ 0 12-13 thru 12-31 ...................... 0 12-31A thru 12-31B ................ 0 12-32 thru 12-36 ...................... 0 12A-1 thru 12A-6 .................... 0 12A-7 thru 12A-12..................0 13-1 thru 13-2 0 13-2A thru 13-B ...................... 0 13-3 thru 13-9 .......................... 0 13-9A thru 13-9B .................... 0 13-10 thru 13-17 ...................... 0 13-17A thru 13-17B ................ 0 13-18 thru 13-19 ...................... 0 13-20 Blank ............................. 0 14-1 thru 14-14 ........................ 0 14A-1 thru 14A-4 .................... 0 15-1 thru 15-10 ........................ 0 16-1 thru 16-18 .0 *16-19 ..................................... 1 16-20 ....................................... 0 *16-21 thru 16-22.................... 1 16-23 thru 16-24 ...................... 0 *16-25 ..................................... 1 16-26 ....................................... 0 *16-26A thru 16-26C .............. 1 *16-26D Blank ........................ 1 17-1 thru 17-143 ...................... 0 17-144 Blank............................0 18-1 ......................................... 0 18-2 Blank ............................... 0 19-1 thru 19-8 0 *19-8A .................................... 1 19-9 thru 19-24 .... 0 *19-25 thru 19-26.................... 1 *19-26A ... 1 19-27 thru 19-36 ...................... 0 20-1 thru 20-3 .......................... 0 20-4 Blank ............................... 0 © Cessna Aircraft Company Revision 1 Feb 3/2003 A SERVICE MANUAL Foreword FOREWORD This manual contains recommended procedures and instructions for ground han- dling, servicing and maintaining Cessna single-engine commercial aircraft prior to 1963 models. These include the Model 150, 172, 175, 180, 182, and 185. Al- though not specifically written for earlier models which have been discontinued, much of the information can be used as a guide for maintenance of the Model 120, 140 and 170. Besides serving as a reference for the experienced mechanic, this book also covers step-by-step procedure for the less experienced man. This manual should be kept in a handy place for ready reference. If properly used, it will better enable the mechanic to maintain Cessna single-engine aircraft and thereby establish a reputation for reliable service. The material presented in this manual is divided into twenty sections. All sec- tions and their major paragraph titles are listed in the table of contents at the front of the book. A section table of contents, listing each paragraph and the page on which it appears, is located at the front of each individual section. All information, illustrations, and specifications contained in this manual are based on the latest information available at the time of publication. This information is supplemented and kept current by service letters and service news letters published by Cessna Aircraft Company. This information goes to all Cessna Dealers so that they have the latest authoritative information for servic- ing Cessna Airplanes. Therefore, Cessna recommends that all Cessna owners utilize the Cessna-trained Dealer Service Organization to the fullest, to receive the benefit of their knowledge and experience. SERVICE MANUAL This page intentionally left blank. ii SERVICE MANUAL Table of Contents TABLE OF CONTENTS SECTION 1 - GENERAL DESCRIPTION Page SECTION 7 - FLAP CONTROL SYSTEMS General Description ........... 1-1 Flap Control Systems. .......... 7-1 Reference Stations ............ 1-5 SECTION 7A - FLAP CONTROL SYSTEM SECTION 2 - GROUND HANDLING, SERVICING, (ELECTRIC) LUBRICATION AND INSPECTION Flap Control System (Electric) ...... 7A-1 Ground Handling ............. 2-1 Servicing ................ 2-4 SECTION 8 - ELEVATOR CONTROL SYSTEMS Cleaning .... .... .. ...... 2-6 Lubrication ............... 2-6 Elevator Control Systems. ........ 8-1 Inspection. ............ ... 2-13 SECTION 9 - ELEVATOR TRIM TAB CONTROL SECTION 3 - FUSELAGE SYSTEMS Windows and Windshields ......... 3-1 Elevator Trim Tab Control Systems . . . . 9-1 Cabin Doors .............. 3-4 Cabin Door Latches ........... 3-5 SECTION 10 - RUDDER CONTROL SYSTEMS Baggage Doors ............. 3-9 Seats ................. 3-9 Rudder Control Systems ......... 10-1 Cabin Upholstery ............ 3-9 Headliner and Cabin Top SECTION 11 - STABILIZER CONTROL SYSTEM Soundproofing ........... 3-16 Carpeting. .............. . 3-16 Stabilizer Trim Control System ...... 11-1 Baggage Compartment Upholstery ..... 3-16 Safety Belts ............... 3-16 SECTION 12 - POWERPLANT Cargo Tie-Downs ............ 3-20 Description .............. 12-1 SECTION 4 - AIRFRAME Trouble Shooting. ............ 12-3 Engine Removal ............. 12-6 Wings ................. 4-1 Engine Installation ........... . 12-7 Wing Struts .............. 4-5 Extreme Weather Maintenance. ...... 12-7 Fin .................. 4-7 Starting Systems ............ 12-9 Horizontal Stabilizer ........... 4-12 Engine Controls ............. .12-12 Ignition . . . . . . . . . . . . . . .. 12-15 SECTION 5 - LANDING GEAR Engine Cowling ............. 12-32 Baffles . . . . . . . . . . . . . . . .12-32 Landing Gear .............. 5-1 Engine Mounts. ............ .12-32 Main Gear. ............... 5-3 Oil System . .......... . .12-34 Main Wheel and Axle . .......... 5-4 Exhaust System .... .... ..12-36 Main Wheels (Goodyear) ......... 5-5 Main Wheels (Cleveland) ......... 5-10 SECTION 12A - MODEL 185 POWERPLANT Main Wheel Alignment .......... 5-16 Crosswind Wheels ............ 5-16 Description ............ .12A-1 Nose Gear. ............... 5-16 Trouble Shooting ......... .12A-3 Nose Wheel ............... 5-26 Engine Removal ......... .12A-5 Nosewheel Steering System ........ 5-29 Engine Installation ........... 12A-6 Tailgear ............... 5-30B Extreme Weather Maintenance . .... 12A-6 Anti-Swivel Mechanism (Model 185) . . .5-30B Starting System ............ 12A-7 Tailwheel .............. . 5-30B Fuel Injection System ......... .12A-7 Speed Fairings. ............. 5-31 Engine Controls ......... . 12A-10 Brake System ............... 5-33 Ignition ............... 12A-11 Parking Brake Systems. ......... 5-39 Engine Cowling ............ 12A-11 Baffles . .. .. .... .. . ... 12A-11 SECTION 6 - AILERON CONTROL SYSTEM Engine Mount ............. 12A-12 Oil System. .............. 12A- Aileron Control System .......... 6-1 Exhaust System ............ 12A-12 iii Table of Contents SERVICE MANUAL TABLE OF CONTENTS (Cont) SECTION 13 - FUEL SYSTEMS SECTION 18 - ELECTRONIC SYSTEMS Fuel Systems ............... 13-1 Deleted. See the "Cessna Electronics Manual and Parts Catalog. SECTION 14 - PROPELLERS SECTION 19 - STRUCTURAL REPAIR Propellers ............. .. 14-1 Fixed Pitch Propellers .......... 14-2 Repair Criteria ......... . 19-1 Hartzell Propeller ........... 14-5 Equipment and Tools .......... 19-1 McCauley Propeller ......... . 14-9 Control Surface Balancing ........ 19-3 Propeller Governor .......... .14-12 Skin Repair Materials .......... 19-7 Wing . . ... . .. . . .. . . .... 19-8 SECTION 14A - PROPELLERS (MODEL BHC- Wing Skin ................ 19-8 C2YF-1) Wing Ribs. ............... 19-8 Wing Spars ............... 19-8 Propellers (Model BHC-C2YF-1) . . .. 14A-1 Ailerons ................ 19-8 Flaps. ................ .19-24 SECTION 15 - HEATING, VENTILATING Tail Group .............. .19-26 Vertical Fin and Dorsal Area ....... 19-26 Heating ........... . .. ... 15-1 Stabilizer ........... ... .19-26 Cabin Air Ventilation .......... 15-1 Elevators and Rudder ......... .19-26 Fuselage .............. 19-27 SECTION 16 - INSTRUMENTS AND INSTRUMENT Bulkheads. ................ 19-27 SYSTEMS Landing Gear Bulkheads ....... . .19-30 Replacement of Hi-Shear Rivets . .... .19-30 General.. ............... 16-1 Firewall Damage ........... .19-30 Instrument Panels ............ 16-1 Replacement of Portions of Skin Panels . .19-30 Pitot and Static Systems ......... 16-4 Engine Mount .............. 19-36 Vacuum Systems .......... .16-11 Baffles ................ .19-36 Engine Indicators ............ 16-18 Engine Cowling ............ 19-36 Magnetic Compass ......... ... 16-25 Royalite Repairs ............. 19-36 Stall Warning System .......... 16-26 Fiberglas Repairs ......... ... 19-36 Turn-and-Bank Indicator ........ 16-26 SECTION 20 - PAINTING SECTION 17 - ELECTRICAL SYSTEMS Painting ... ........ ..... 20-1 Electrical Power Supply System ..... . 17-2 Enmar 27H Series Lacquer ....... . 20-1 Battery and External Power System .... 17-2 Enmar 82A Series Vinyl ......... 20-1 Generator Power System ........ .17-10 Hi-Visibility Paint .......... 20-3 Aircraft Lighting System ........ .17-14 Fiberglas Speed Fairings ........ 20-3 Stall Warning Circuit. ......... .17-24 Pitot and Stall Warning Heat Circuits. . . .17-24 Index of Electrical Wiring Diagrams .... 17-25 Symbols Chart. .............. 17-27 iv SERVICE MANUAL General Description SECTION 1 GENERAL DESCRIPTION 1-1. GENERAL DESCRIPTION. The Cessna marked degree of fin and rudder sweep-back. Other single-engine aircraft described in this manual are refinements, such as a lower ground attitude, wider similar in that all models are of a high-wing mono- main landing gear, engine and propeller model plane configuration, employing patented spring- changes, and internal and external styling, have steel main landing gear struts, opposed air-cooled been made from time to time. Continental engines, and all-metal semi-monocoque airframe construction. Except for the Model 150 Leading particulars of each model, with dimensions series aircraft, which have four-cylinder engines, based on gross weight, are given in the following these aircraft use six-cylinder engines. The Model charts. If these dimensions are used for con- 150 is two-place and all others except the Model 185 structing a hangar or computing clearances, re- are four-place. The Model 185 is a multi-purpose member that such factors as nose strut inflation, aircraft, designed as a one-, two-, four-, or six- tire inflation, and load distribution may result in place aircraft. An auxiliary seat may be installed some dimensions that are considerably different in most models. The Models 180 and 185 are equip- from those listed. Control surface travels are ped with tailwheels and the others have a tricycle- listed in nominal degrees; refer to the applicable type landing gear. Beginning in 1960, Models 172, section of this manual for specific travels and 175, and 182 series aircraft were designed with a tolerances. MODEL 150 DESIGN GROSS WEIGHT ......... 1500 lb ELEVATOR TRIM TAB TRAVEL TOTAL FUEL CAPACITY ......... 26 gal Up .................. 10 ° OIL CAPACITY .... ... .... ... 6 qt Down .. . .. .... . . .. . ... 20 ° ENGINE MODEL (Continental) . . ... 0-200-A PRINCIPAL DIMENSIONS HP RATING ......... ...... 100 Wing Span (prior to 1962) . ..... 33'4" RATED RPM ............ . 2750 Wing Span (1962 & on) .. ..... 33'6" MAIN WHEELS ............ 5:00 x 5 Tail Span ............... 10' Pressure .............. 30 psi Length ............ .. *21'6" NOSE WHEEL ............. 5:00 x 5 Height ............. **6'11" Pressure .............. 30 psi Track Width .............. 6'5" AILERON TRAVEL BATTERY LOCATION Up .................. 20 ° Aft of baggage compartment Down . ................ 15 ° SERIAL NUMBERS FLAP TRAVEL .............. 39 ° 1959 ........... 17001 thru 17683 RUDDER TRAVEL 1960 ........... 17684 thru 17999 Right ................. 16 ° & 59001 thru 59018 Left . .... ... ... .. .... 16 ° 1961 (150A) .. ... 15059019 thru 15059350 ELEVATOR TRAVEL 1962 (150B) ......... 15059351 & on Up .................. 25° Down . . . . . . . . . . . . . . . . . 15 ° *If bullet-shaped spinner is installed, add approximately 6" to length. **If rotating beacon is installed on vertical fin, add approximately 3" to height. 1-1 General Description SERVICE MANUAL MODEL 172 DESIGN GROSS WEIGHT ELEVATOR TRIM TAB TRAVEL Prior to 1962 ... ....... . 2200 lb Up .................. 28 ° 1962 & on .............. 2250 lb Down .............. .. . 13 ° TOTAL FUEL CAPACITY ......... 42 gal PRINCIPAL DIMENSIONS OIL CAPACITY ............. 8 qt Wing Span (prior to 1962) ........ 36' ENGINE MODEL (Continental) Wing Span (1962 & on) ........ 36'2" Prior to 1960 ........... O-300-A Tail Span .............. 10'8" 1960 & on ............. O-300-C Length (prior to 1960) ......... 25' 1961 & on (Skyhawk) ........ O-300-D Length (1960 & on) .......... 26'6" HP RATING ................ 145 Height (prior to 1960) ........ **8'6" RATED RPM ................... 2700 Height (1960) ............ **8'4" MAIN WHEELS ............ 6:00 x 6 Height (1961 & on) ........... **8' Pressure ......... ..... 23 psi Track Width ........ ...... 7'2" NOSE WHEEL . . ..... 5:00 x 5 BATTERY LOCATION Pressure (tube type tire) ...... 26 psi Forward left side of firewall Pressure (tubeless tire) ....... 35 psi SERIAL NUMBERS AILERON TRAVEL 1956 ........... 28000 thru 29174 Up .................. 20 ° 1957 ........... 29175 thru 29999 Down ................. 15 ° & 36000 thru 36215 FLAP TRAVEL .............. 39 ° 1958 ........... 36216 thru 36965 RUDDER TRAVEL 1959 ........... 36966 thru 36999 Right ................. *16 ° & 46001 thru 46754 Left ................. *16 ° 1960 (172A) ... . .... 46755 thru 47746 ELEVATOR TRAVEL 1961 (172B) ..... 17247747 thru 17248734 Up .. . . .. ...... .... .. 28 ° 1962 (172C) ... . .. . .. 17248735 & on Down ............ ......... . 26 ° *Rudder travel on swept tails measured parallel to water line. When measuring perpendicular to hinge line, equivalent is 17°44 ' . **If rotating beacon is installed on vertical fin, add approximately 3" to height. MODEL 175 DESIGN GROSS WEIGHT RATED RPM (Crankshaft) ......... 3200 Prior to 1962 . ........... 2350 lb MAIN WHEELS ............ 6:00 x 6 1962 & on .............. 2450 lb Pressure .... .. 23 psi TOTAL FUEL CAPACITY ......... 52 gal NOSE WHEEL ............. 5:00 x 5 OIL CAPACITY . ............. 10 qt Pressure (tube type tire) .. . 26 psi ENGINE MODEL (Continental) Pressure (tubeless tire) ...... . 35 psi Prior to 1960 . ......... GO-300-A AILERON TRAVEL 1960 & on . ....... ...... GO-300-C Up .................. 20 ° 1961 (Skylark) .......... GO-300-D Down ............. ......... 15 ° 1962 & on (Skylark) ........ GO-300-E FLAP TRAVEL .............. 39 ° HP RATING . .......... 175 1-2 SERVICE MANUAL General Description MODEL 175 (Cont) RUDDER TRAVEL Length (prior to 1960) ......... 25' Right ................. *16 ° Length (1960 & on) ........ 26'6" Left ................. *16 ° Height (prior to 1960) ........ **8'6" ELEVATOR TRAVEL Height (1960 & on) ........... **8' Up .................. 28 ° Track Width ........ ..... 7'2" Down .............. .. . 26 BATTERY LOCATION ELEVATOR TRIM TAB TRAVEL Aft of baggage compartment Up .................. 28 ° SERIAL NUMBERS Down ................ 13° 1958 .............. 55001 thru 55703 PRINCIPAL DIMENSIONS 1959 ........... 55704 thru 56238 Wing Span (prior to 1962) ........ 36' 1960 (175A) ........ 56239 thru 56777 Wing Span (1962 & on) ........ 36'2" 1961 (175B) ..... 17556778 thru 17557002 Tail Span .............. 10'8" 1962 (175C) ......... 17557003 & on *Rudder travel on swept tails measured paralled to water line. When measuring perpendicular to hinge line, equivalent is 17 44 ' . **If rotating beacon is installed on vertical fin, add approximately 3" to height. MODEL 180 DESIGN GROSS WEIGHT ELEVATOR TRAVEL Prior to 1957 ... ........ . 2550 lb Up ................. . *25 ° 1957 & on ..... . 2650 lb Down . .............. *23 ° TOTAL FUEL CAPACITY (prior to 1957) . . 60 gal STABILIZER TRAVEL (prior to 1960) TOTAL FUEL CAPACITY (1957 & on) . . 65 gal Up .......... 1°50' OIL CAPACITY ........ 12 qt Down ...... ......... . 8°20' ENGINE MODEL (Continental) STABILIZER TRAVEL (1960 & on) Prior to 1955 ........ .. . O-470-A Up . ................ 0°45' 1955 .......- 470-J Down .......... ..... 8°45 ' 1956 thru 1959 .......... O-470-K PRINCIPAL DIMENSIONS 1960 & 1961 ........ O-470-L Wing Span (prior to 1962) ........ 36' 1962 & on. ........ O-470-R Wing Span (1962 & on) ....... 36'2" HP RATING Tail Span ............. 10'10" O-470-A and -J ........... 225 Length ......... 25'6" O-470-K, -L, and -R ....... .. 230 Fin Height ....... **7'6" RATED RPM Track Width ....... . . ..... 7'8" O-470-A, -K, -L, and R ....... 2600 BATTERY LOCATION O-470-J ............. 2550 Aft of baggage compartment MAIN WHEELS ............ 6:00 x 6 SERIAL NUMBERS Pressure .............. 28 psi 1953 ......... . 30000 thru 30639 TAILWHEEL ........... 8:00 S.C. 1954 .......... 30640 thru 31260 Pressure ....... ...... 35 psi 1955 ........... 31261 thru 32150 AILERON TRAVEL 1956 ........... 32151 thru 32661 Up ....... ... ........ 20 ° 1957 (180A) .. ...... 32662 thru 32999 Down ..................... 15 ° & 50001 thru 50105 FLAP TRAVEL .............. 39 ° 1958 (180A) ........ 50106 thru 50355 RUDDER TRAVEL 1959 (180B) ........ 50356 thru 50661 Right ...... ........ ... 24 ° 1960 (180C) .. ...... 50662 thru 50911 Left ................. 24 ° 1961 (180D) ..... 18050912 thru 18051063 1962 (180E) ......... 18051064 & on *With stabilizer full down. **If rotating beacon is installed on vertical fin, add approximately 3" to height. 1-3 General Information SERVICE MANUAL MODEL 182 DESIGN GROSS WEIGHT STABILIZER TRAVEL (1960 & 1961) Prior to 1957 ... ........... 2550 lb Up ................. . 045' 1957 thru 1961 .......... . 2650 lb Down ............ 8°45' 1962 & on ............ 2800 lb ELEVATOR TRIM TAB TRAVEL (1962 & on) TOTAL FUEL CAPACITY (prior to 1957) . . 60 gal Up .................. 25 ° TOTAL FUEL CAPACITY (1957 & on) . . 65 gal Down ... ............ 15 ° OIL CAPACITY ............. 12 qt PRINCIPAL DIMENSIONS ENGINE MODEL (Continental) Wing Span (prior to 1962) ........ 36' Prior to 1962 ........... O-470-L Wing Span (1962 & on) ........ 36'2" 1962 & on ............. O-470-R Tail Span .............. 10'10" HP RATING ................ 230 Length (prior to 1960) ........ 25'4" RATED RPM . . . . . . . . . . . . 2600 Length 1960 & 1961) ......... 27'4" MAIN WHEELS ............ 6:00 x 6 Length (1962 & on) .......... 27'9" Pressure (prior to 1962) ....... 28 psi Height (1956) ............ ***9'3" Pressure (1962 & on) ......... 32 psi Height (1957 thru 1960) ..... . ***8'6" NOSE WHEEL ............. 5:00 x 5 Height (1961) ...... ***7'5" Pressure (tube type tire) ....... 29 psi Height (1962 & on) ......... ***7'10" Pressure (tubeless tire) ....... 45 psi Track Width (1956) ..... ..... 7'8" AILERON TRAVEL Track Width (1957 thru 1961) ...... 8'2" Up .................. 20 ° Track Width (1962 & on) .... .. 7'11" Down ................. 15 ° BATTERY LOCATION FLAP TRAVEL .............. 39 ° Aft of baggage compartment RUDDER TRAVEL SERIAL NUMBERS Right ................. *24 ° 1956 ........... 33000 thru 33842 Left ................. *24 ° 1957 (182A) ........ 33843 thru 34753 ELEVATOR TRAVEL (prior to 1962) 1958 (182A) ........ 34754 thru 34999 Up . ................. **25 ° & 51001 thru 51556 Down ................ **23 ° 1959 (182B) ........ 51557 thru 52358 ELEVATOR TRAVEL (1962 & on) 1960 (182C) ........ 52359 thru 53007 Up .................. 26 ° 1961 (182D) ..... 18253008 thru 18253598 Down . .. . ............. 17 ° 1962 (182E) ......... 18253599 & on STABILIZER TRAVEL (prior to 1960) Up . . . . . . . . . . . . . . . . . . 1°50' Down ...................... 820' *Rudder travel on swept tails measured parallel to water line. When measuring perpendicular to hinge line, equivalent is 27°13'. **With stabilizer full down. ***If rotating beacon is installed on vertical fin, add approximately 3" to height. MODEL 185 DESIGN GROSS WEIGHT ......... 3200 lb ELEVATOR TRAVEL TOTAL FUEL CAPACITY ........ 65 gal Up .................. **25 ° OIL CAPACITY .............. 12 qt Down ................ .**23 ENGINE MODEL (Continental) ...... IO-470-F STABILIZER TRAVEL HP RATING ................ 260 Up ................. 0°45 ' RATED RPM ............... 2625 Down ................ 830' MAIN WHEELS ............ *6:00 x 6 PRINCIPAL DIMENSIONS Pressure ............ . *35 psi Wing Span (prior to 1962) ........ 36' TAILWHEEL .......... 10:00 x 3. 50-4 Wing Span (1962 & on) ........ 36'2" Pressure .............. 45 psi Tail Span .............. 10'10" AILERON TRAVEL Length . .............. 25'6" Up .................. 20 ° Fin Height (including rotating beacon) . . 7'9" Down ................. 15 ° Track Width .............. 7'7" FLAP TRAVEL .............. 39 ° BATTERY LOCATION RUDDER TRAVEL Aft of baggage compartment Right ................. 24 ° SERIAL NUMBERS Left ................. 24 ° 1961 ........ 185-0001 thru 185-0237 1962 (185A) ......... 185-0238 & on *8:00 x 6 tires are also available. Inflate to 25 psi. **With stabilizer full down. 1-4 SERVICE MANUAL General Description 22.12 31.75 44.12 11.0 / 70.69 76.44 36.0 49.69 Figure 1-1. Reference Stations - Model 150 1-5 General Description SERVICE MANUAL 23.62 39.0 57.125 71.37 Figure 1-2. Reference Stations - Models 172 & 175 MODEL 175 44.0 Figure 1-2. Reference Stations - Models 172 & 175 1-6 SERVICE MANUAL General Description 23.62 56.53 71.97 85. 87 100.5 118.0 172.0 190.0 23.62 39.0 PRIOR TO 1957 56.53 208.0 89.0 MODEL 182 (1962 & on) - .- , 92.0 110.0 0 17.0 65.33 90.0 108.0 140.0 172.0 209.0 230.18 *124. 0 *ADDITIONAL ON MODEL 182 (1962 & on) 44.0 MODELS 180 & 185; MODEL 182 (Prior to 1962) 45.0 MODEL 182 (1962 & on) Figure 1-3. Reference Stations - Models 180, 182 & 185 1-7 General Description SERVICE MANUAL TORQUE VALUES IN POUND-INCHES FINE THREAD SERIES STANDARD TYPE NUTS SHEAR TYPE NUTS BOLT SIZE Alternate Alternate (See Note 1) (See Note 2) Values MS20364, AN320 Values AN310 AN316, AN7502 AN320 (See Note 4) (See Note 4) 10-32 20-25 20-28 12-15 12-19 1/4-28 50-70 50-75 30-40 30-48 5/16-24 100-140 100-150 60-85 60-106 3/8-24 160-190 160-260 95-110 95-170 7/16-20 450-500 450-560 270-300 270-390 1/2-20 480-690 480-730 290-410 290-500 9/16-18 800-1000 800-1070 480-600 480-750 5/8-18 1100-1300 1100-1600 660-780 660-1060 3/4-16 2300-2500 2300-3350 1300-1500 1300-2200 7/8-14 2500-3000 2500-4650 1500-1800 1500-2900 1-14 3700-5500 3700-6650 2200-3300 2200-4400 1-1/8-12 5000-7000 5000-10000 3000-4200 3000-6300 1-1/4-12 9000-11000 9000-16700 5400-6600 5400-10000 CAUTION These torque values are derived from oil-free cadmium-plated threads. COARSE THREAD SERIES BOLT SIZE STANDARD TYPE NUTS SHEAR TYPE NUTS (See Note 1) (See Note 3) MS20364, AN320, AN316 8-32 12-15 7-9 10-24 20-25 12-15 1/4-20 40-50 25-30 5/16-18 80-90 48-55 3/8-16 160-185 95-100 7/16-14 235-255 140-155 1/2-13 400-480 240-290 9/16-12 500-700 300-420 5/8-11 700-900 420-540 3/4-10 1150-1600 700-950 7/8-9 2200-3000 1300-1800 1-8 3700-5000 2200-3000 1-1/8-8 5500-6500 3300-4000 1-1/4-8 6500-8000 4000-5000 NOTES: (1) AN3, AN23, AN42, AN173, MS20004, NAS334, NAS464 Series bolts; AN502, AN503, NAS220 and NAS517 Series Screws. (2) AN310, AN315, AN345, AN362, AN363, MS20365, AN366, "EB","1452", "Z1200," "UWN" and other self-locking nuts. (3) AN310, AN340, MS20365, AN366 and other self-locking anchor nuts. (4) When using AN310 and AN320 castellated nuts where alignment between bolt and cotter pin holes is not reached using normal torque values, use alternate torque values or replace nut. These torque values are recommended for all procedures contained in this book except where other values are stipulated. 1-8 SERVICE MANUAL Ground Handling/Servicing Ground Handling SECTION 2 GROUND HANDLING, SERVICING, LUBRICATION AND INSPECTION TABLE OF CONTENTS Page GROUND HANDLING ............ 2-1 Nose Gear Shimmy Dampeners ...... 2-5 Hoisting ................ 2-2 Hydraulic Brake Systems ......... 2-5 Jacking ....... ....... .. . 2-2 Oxygen Cylinder ............. 2-5 Parking ............... . 2-2 Oxygen Face Masks ......... . 2-6 Tie-Down ............... 2-2 CLEANING ............... 2-6 Hangar Storage ............. 2-2 Windshield and Windows ......... 2-6 Outside Storage ............. 2-3 Plastic Control Wheels .......... 2-6 Extended Storage ............ 2-3 Aluminum Surfaces. ........... 2-6 Leveling ................ 2-4 Painted Surfaces............. 2-6 SERVICING ............... 2-4 Engine Compartment ........... 2-6 Fuel Tanks ............... 2-4 Upholstery and Interior. ......... 2-6 Fuel Drains .......... ..... 2-4 Propellers ............ . 2-6 Engine Oil . ........... . 2-4 Wheels . ... ........... 2-6 Induction Air Filters .......... 2-4 SERVICING AND LUBRICATION ....... 2-7 Battery ................. 2-4 INSPECTION. ............... 2-13 Tires ................. 2-5 25-Hour Inspection. ........... 2-13 Nose Gear Struts ............ 2-5 100-Hour Inspection ........... 2-13 2-1. GROUND HANDLING. nose wheel clear of the ground, the airplane can be turned by pivoting it about the main gear. 2-2. Moving the aircraft by hand is accomplished by using the wing struts and landing gear as push points. On tricycle gear airplanes, a tow bar attached to the . nose gear should be used for steering and maneuver- CAUTION ing the airplane. Never turn the nose gear more than 30 degrees in either direction or damage will result. Do not push on control surfaces or outboard em- When no tow bar is available, press down at the hor- pennage surfaces. When pushing on the tail- izontal stabilizer front spar, adjacent to the fuselage, cone, always apply pressure at a bulkhead to to raise the nose wheel off the ground. With the avoid buckling the skin. STANDARD TOW BAR TOW BAR USED WITH SPEED-FAIRING- EQUIPPED AIRCRAFT Figure 2-1. Typical Tow Bars 2-1 Ground Handling/Servicing SERVICE MANUAL Ground Handling MAKE JACKING BLOCK OF 4"x 4" WOOD. TRIM ENDS TO BEAR AGAINST UPPER UNIVERSAL LANDING GEAR SPRINGS. JACK POINT CONTOUR TO CLEAR FUSELAGE JACK NOTE DIMENSION "A" WILL VARY WITH DIFFERENT MODELS AND YEAR OF MANUFACTURE. THE JACKING BLOCK MUST BE LONG ENOUGH TO BEAR AGAINST THE LANDING GEAR SPRINGS, CLEAR OF THE FUSELAGE. Figure 2-2. Jacking Details 2-3. HOISTING. The airplane may be hoisted with available. In severe weather, follow tie-down and hoists of two-ton capacity, either by using hoisting storage procedures described below if inside storage rings (optional equipment) or by using suitable slings. is not available. The front sling should be attached to each upper engine mount at the firewall and the aft sling should be posi- 2-6. TIE-DOWN should be accomplished in anticipa- tioned around the fuselage at the first bulkhead for- tion of high winds. Tie down aircraft as follows: ward of the leading edge of the stabilizer. a. Tie ropes or chains to the wing tie-down fittings located at the upper end of each wing strut. Secure 2-4. JACKING. A special main gear jack point the opposite ends of the ropes or chains to ground which slips over the main gear strut may be used to anchors. jack one wheel at a time. DO NOT use the brake b. Secure a tie-down line through the nose gear tie- casting as a jacking point. down ring. On tricycle gear aircraft without a nose gear tie-down ring, use a rope (no chains or cables) CAUTION to secure the outer strut to ground anchors. c. On tricycle gear aircraft, secure the middle of Flexibility of the gear strut will cause the main a length of rope to ring at tail. Pull each end of rope wheel to slide inboard as the wheel is raised, away at a 45 ° angle and secure to ground anchors at tilting the jack. The jack must then be lowered each side of tail. On aircraft with conventional tail- for a second jacking operation. Jacking both gear, tie down the tailwheel. wheels simultaneously with universal jack d. Install surface control locks between flap and points is not recommended. To jack both aileron and over fin and rudder. Be sure electric wheels use the jacking block illustrated in flaps are not operated inadvertently. figure 2-2. Keep the airplane from tipping e. Install control lock on pilot's control column if while using this block. available; if control lock is not available, tie pilot's control wheel back with front seat belt. On tricycle gear aircraft, the nose wheel may be f. If rain, sleet, snow, or blown dust are antici- lifted by weighting the tail down. pated, cover the pitot tube. 2-5. PARKING precautions depend principally on 2-7. HANGAR STORAGE. The aircraft stored in a local conditions. As a general precaution, it is wise hangar will require little attention. The following to set the parking brake and install a control lock if operations will maintain it in serviceable condition. 2-2 SERVICE MANUAL Ground Handling/Servicing Ground Handling NOTE 4. Remove air cleaner and inject corrosion-pre- ventive oil into induction airbox at the rate of 1/2 gal- If the airplane is to be stored foralongperiod, lon per minute until smoke comes from the exhaust see EXTENDED STORAGE instructions. stack, then increase spray until the engine stops. Do not turn crankshaft after engine stops. a. Turn the propeller over by hand every few days - to maintain an oil film on the internal parts of the CAUTION engine. b. Keep the fuel tanks full to prevent moisture con- Injecting oil too fast can cause a hydrostatic densation in the tanks. lock. c. Keep the battery fully charged to prevent it from freezing in an unheated hangar. 5. Remove spark plugs and spray corrosion-pre- ventive oil into upper spark plug holes, then into low- 2-8. OUTSIDE STORAGE. Short-term outside storage er spark plug holes. of the aircraft requires secure tie-down combined with 6. Replace lower plugs or install solid plugs. the precautions listed in paragraph 2-6. In addition, 7. Install dehydrator plugs in upper spark plug suitable protective covers, if available, should be holes. installed. 8. Install shipping plugs or other suitable covers over detached spark plug cable terminals. 2-9. EXTENDED STORAGE. Lengthy storage re- 9. Cover all engine and accessory openings. quires the following precautions besides good tie-down 10. Drain corrosion-preventive oil from sump and or hangaring. replace plug. a. Engine: 11. Post a conspicuous warning against propeller 1. Warm up engine and drain engine oil. movement on the aircraft. 2. Fill sump with pre-heated corrosion preventive b. Airframe: oil (Continental recommends Cosmoline No. 1223, sup- 1. Lubricate all airframe items. plied by E. F. Houghton & Co, 310 W. Lehigh Ave, 2. Seal and cover all openings. Philadelphia, Pa.). c. Battery: 3. Operate engine five minutes at 1200-1500 rpm 1. Remove from aircraft and service periodically. with 215-225°F oil temperature. d. Block up fuselage to take weight off tires. TAIL WHEEL SECURE CONTROL WHEEL SET PARKING BRAKE OR WITH CONTROL LOCK USE WHEEL CHOCKS OR SAFETY BELT Figure 2-3. Tie-Down Details 2 -3 Ground Handling/Servicing SERVICE MANUAL Leveling NOTE minimum-for-flight quantities listed. Oil should be added to the full mark on the dipstick if extended Tires will take a set, causing wheels to flight is planned. become out-of-round, if an airplane is left parked for more than a few days. For this MODEL 150 172 175 180, 182 reason a stored airplane should not have its & 185 weight on the tires. Total Capacity (quarts) 6 8 10 12 2-10. LEVELING. An upper cabin door sill may be Add oil used to level the aircraft longitudinally, and corres- if below 4 6 6 9 ponding points on both sills may be used to level the aircraft laterally. Oil should be changed every 25 hours. At the time of oil change, remove the engine oil screen and 2-11. SERVICING. (See figure 2-4.) wash with solvent (Fed. Spec. P-S-661). On air- craft equipped with a Fram oil filter, the oil should 2-12. FUEL TANKS should be filled immediately still be changed at 25-hour intervals and the filter after flight to lessen moisture condensation. Tank element should be replaced every 100 hours. On capacities are given below in U.S. gallons. Some aircraft equipped with a Winslow or AC full-flow oil aircraft have optional larger tanks. filter, change engine oil and filter element at 50- hour intervals. Change oil every four months even MODEL 150 172 175 180, 182 though less than 50 hours have accumulated. Re- & 185 duce these periods for prolonged operation in dusty areas, in cold climates where sludging conditions TOTAL exist, or where short flights and long idle periods CAPACITY 26 42 52 65 are encountered which cause sludging conditions. Always change oil and replace filter element when- CAPACITY ever oil on dipstick appears dirty. EACH TANK 13 21 26 32.5 It is recommended that detergent oil not be used RECOMMENDED during the first 25 hours of engine operation, in FUEL GRADE: 80/87 octane minimum, aviation order to permit piston rings to seat properly. This grade, for all except the Model 185, which requires applies to an overhauled engine as well as a new one. 100/130 octane, aviation grade. After the first 25 hours, either straight mineral oil or detergent oil may be used. If a detergent oil is NOTE used, it must conform to Continental Motors Corpo- ration Specification MHS-24. Fuel capacity for Models 180 and 182 prior to 1957 is 60 gallons total, 30 gallons each 2-15. INDUCTION AIR FILTERS keep dust and dirt tank. from entering the induction system. They should be serviced every 25 hours, oftener under dusty condi- 2-13. FUEL DRAINS are located at various points in tions. Under extremely dusty conditions, daily main- the fuel systems to provide for drainage of water and tenance of the filter is recommended. sediment. Each airplane is equipped with a fuel a. Remove the filter and wash in solvent (Fed. Spec. strainer drain valve, fuel line or selector valve P-S-661). The newer "dry" filters used on some drain plugs or valves, and fuel tank sump drain models may be cleaned by blowing with compressed plugs or valves. In many aircraft the fuel strainer air (not over 100 psi) from the back side, or they drain valve may be operated by a control located at may be washed with mild household detergent and the instrument panel. warm water. b. Drain and dry, then dip flock-coated screen 2-14. ENGINE OIL should be checked with the oil filters in same grade of oil used in engine, and drain dipstick 5 to 10 minutes after shutdown to allow the off the excess oil. The newer type should be allowed oil to flow back to the sump. When adding or chang- to dry if washed. ing oil, use the following aviation grades: c. Be sure airbox is clean, inspect filter and re- place if necessary, then install. Maximum recom- mended life of the dry (paper element) filters is 300 hours. Below 40°F (150, 172, 175) SAE 20 Below 40°F (180, 182, 185) SAE 30 NOTE Above 40°F (150, 172, 175) SAE 40 Above 40°F (180, 182, 185) SAE 50 Keeping a supply of clean, serviced filters on hand will speed up air filter servicing. Refer to figure 2-5. Oil capacities for the various models are given be- low. If the aircraft is equipped with an external 2-16. BATTERY servicing involves adding distilled filter, one additional quart is required when the fil- water to maintain the electrolyte even with the hori- ter element is changed. When servicing the oil sys- zontal baffle plate or split ring at the bottom of the tem, oil should be added if the oil level is below the filler holes, checking the battery cable connections, 2-4 SERVICE MANUAL Ground Handling/Servicing Servicing and neutralizing and cleaning off any spilled elec- off with a clean dry cloth to remove dust and trolyte or corrosion. Use bicarbonate of soda (bak- grit which may cut the seals in the strut barrel. ing soda) and water to neutralize electrolyte or cor- Do not wipe the strut with hydraulic fluid, since rosion. Follow with a thorough flushing with water. this tends to collect even more dust and grit. Brighten cables and terminals with a wire brush, then coat with petroleum jelly before connecting. The 2-19. NOSE GEAR SHIMMY DAMPENERS should be battery box also should be checked and cleaned if any serviced at least every 100 hours. The dampener corrosion is noticed. Distilled water, not acid or must be filled completely with fluid, free of en- "rejuvenators" should be used to maintain electro- trapped air, to serve its purpose. Two types of lyte level. Check the battery every 25 hours (or at dampeners were used, one of which must be removed least every 30 days), oftener in hot weather, to check fluid level and refill. If the dampener has a filler plug, refill as follows: 2-17. TIRES should be maintained at the air pres- a. Remove the filler plug. sures specified below in psi. When checking tire b. Using the tow bar, turn the nose gear in the pressure, examine tires for wear, cuts and bruises. direction that places the dampener piston at the end opposite the filler plug. MODEL 150 172 175 180 182 185 c. Fill with MIL-H-5606 hydraulic fluid. d. Install and safety the filler plug. MAIN If the dampener does not have a filler plug, refill as TIRES 30 23 23 28 *28 **35 follows: a. Remove the dampener from the airplane. NOSE b. Pull the fitting end of the dampener shaft to its (OR TAIL) travel limit. TIRES 30 ***26 ***26 35 ***29 45 c. Fill through the opposite end with MIL-H-5606 hydraulic fluid, while holding the dampener vertical. *32, 1962 and on. d. Push the shaft upward slowly to seal off the **35, for 6:00 x 6 tires; 25, for 8:00 x 6 tires, filler hole, and reinstall the dampener on the air- ***These pressures are used for tube-type tires and plane. Be sure to keep the shaft protruding through magnesium nose wheels only. The pressures for the filler hole until the dampener is installed. tubeless tires and aluminum nose wheels are: 172 An alternate method of filling either type shimmy and 175, 35 psi; 182, 45 psi. The older, magnesium dampener is to submerge it in clean hydraulic fluid wheels used on these models can be easily identified and work the dampener shaft back and forth (filler by the presence of six webs which are evenly spaced plug removed) to expel air and fill completely between the rim and center hub. The newer, alumi- with fluid. num wheels do not have these webs. The higher pressures help prevent damage to wheel flanges. NOTE NOTE Keep the shimmy dampener, especially the ex- posed portions of the dampener shaft wiped off Since low tire pressure may result in leakage with a clean dry cloth to remove dust and grit around tubeless tire beads, the recommended which may cut the seals in the dampener barrel. tire pressures should be maintained. Es- Do not wipe the shaft with hydraulic fluid, since pecially in cold weather, remember that any this tends to collect even more dust and grit. drop in temperature of the air inside a tire causes a corresponding drop in pressure. 2-20. HYDRAULIC BRAKE SYSTEMS should be checked for fluid at least every 100 hours. Add MIL- 2-18. NOSE GEAR STRUTS require periodic check- H-5606 hydraulic fluid at the brake master cylinders ing to ensure that the strut is filled with hydraulic as required. Brakes should be bled of entrapped air fluid and is inflated to the correct air pressure. The whenever there is a spongy response to the brake servicing procedure is stated on the strut placard, pedals. or the following procedure may be used. a. Remove valve cap and release all air. 2-21. OXYGEN CYLINDER. Some aircraft are b. Remove valve housing assembly. equipped with an optional oxygen system. The oxygen c. Compress strut completely (that is, with the cylinder should be refilled when oxygen system pres- stops in contact with the outer barrel hub). sure is below 300 psi. When fully charged, the d. Fill strut level to valve hole with MIL-H-5606 cylinder contains 48 cubic feet of oxygen at 1800 hydraulic fluid. psi at 70°F. To refill the oxygen cylinder: e. Lift nose of aircraft and extend strut, a. Unfasten baggage compartment rear wall or f. Replace valve housing assembly and inflate the access plate to gain access to the oxygen cylinder. strut with nose wheel off the ground. Inflate to 35 b. Turn off oxygen cylinder valve by turning it psi (20 psi on the Model 150 and 50 psi on the full clockwise. Model 182, 1962 and on). c. Disconnect oxygen line from cylinder. d. Loosen clamps securing cylinder and remove NOTE cylinder. e. Refill cylinder with aviators' breathing oxygen Keep the nose gear shock strut, especially (Fed. Spec. BB-O-925, or equivalent). the exposed portion of the strut piston, wiped f. Reverse the above steps to install the cylinder. 2-5 Ground Handling/Servicing SERVICE MANUAL Cleaning WARNING 2-26. ALUMINUM SURFACES require a minimum of care, but should never be neglected. The airplane Oil, grease, or other lubricants in contact may be washed with clean water to remove dirt, and with oxygen create a serious fire hazard, and with carbon tetrachloride or other non-alkaline such contact must be avoided. Only a thread grease solvents to remove oil and/or grease. House- compound approved under MIL-T-5542 can be hole type detergent soap powders are effective used safely on oxygen systems. Apply only to cleaners, but should be used cautiously since some the first three threads of male fittings to pre- of them are strongly alkaline. Many good aluminum vent thread seizure. cleaners, polishes, and waxes are available from commercial suppliers of aircraft products. NOTE 2-27. PAINTED SURFACES are best cared for by Some oxygen systems are equipped with a washing with clean water and a mild soap, then wax- filler valve so the system may be refilled ing with any good automotive wax. Use only clean, without removing the oxygen cylinder. cold water and a mild soap during the initial curing period of the paint, which may be as long as 90 days. 2-22. OXYGEN FACE MASKS. Disposable oxygen face masks are normally stowed in a plastic bag on 2-28. ENGINE COMPARTMENT cleaning is essen- the baggage shelf. Oxygen servicing should include tial to minimize any danger of fire, and for proper checking the condition of the face masks and a re- inspection of components. The engine and engine plenishment of the supply as required. compartment may be washed down with a suitable solvent, then dried thoroughly. 2-23. CLEANING. 2-29. UPHOLSTERY AND INTERIOR cleaning pro- 2-24. Keeping the aircraft clean is important. Be- longs the life of upholstery fabrics and interior trim. sides maintaining the trim appearance of the airplane To clean the interior: cleaning lessens the possibility of corrosion and a. Empty the ash trays. makes inspection and maintenance easier. b. Brush out or vacuum clean the carpeting and upholstery to remove dirt. 2-25. WINDSHIELDS AND WINDOWS should be c. Wipe off leather, Royalite, and plastic sur- cleaned carefully with plenty of fresh water and soap, faces with a damp cloth. using the palm of the hand to feel and dislodge any d. Soiled upholstery fabrics and carpeting may be caked dirt or mud. A sponge, soft cloth or chamois cleaned with a foam-type detergent, used accord- may be used, but only as a means of carrying water ing to the manufacturer's instructions. to the plastic. Dry with a clean, damp chamois. e. Oily spots and stains may be cleaned with Rubbing with a dry cloth will build up an electro- household spot removers, used sparingly. Before static charge which will attract dust particles. Oil using any solvent, read the instructions on the con- and grease may be removed by rubbing lightly with tainer and test it on an obscure place in the fabric a kerosene-moistened cloth. to be cleaned. Never saturate the fabric with a volatile solvent; it may damage the padding and CAUTION backing materials. f. Scrape off sticky materials with a dull knife, then spot clean the area. Do not use gasoline, alcohol, benzene, acetone, carbon tetrachloride, fire extinguisher fluid, 2-30. PROPELLERS should be wiped off occasion- de-icer fluid, lacquer thinner or glass window ally with an oily cloth to clean off grass and bug cleaning spray. These solvents will soften stains. In salt water areas this will assist in and craze the plastic. corrosion-proofing the propeller. 2-25A. PLASTIC CONTROL WHEELS and other 2-31. WHEELS should be washed off periodically plastic parts, such as some fuel valve handles, and examined for corrosion, chipped paint, and should be cleaned with soap and water. Observe cracks or dents in the wheel castings. Sand smooth, the precautions listed in the preceding paragraph. prime, and repaint minor defects. 2-32. LUBRICATION. (See figure 2-4.) 2-6 SERVICE MANUAL Ground Handling/Servicing Servicing 1 2 3 4 5 6 DAILY 3 FUEL TANK FILLERS Fill after each flight. Keep full to retard condensation. Refer to paragraph 2-12 for tank capacities and fuel grades. 5 FUEL TANK SUMP DRAINS If optional quick-drain valves are installed, drain off any water and sediment before the first flight of the day. 6 OXYGEN CYLINDER Check for anticipated requirements before each oxygen flight. Refer to paragraph 2-21 for de- tailed servicing instructions. 8 PITOT AND STATIC PORTS Check for obstructions before first flight of the day. SERVICING Figure 2-4. Servicing and Lubrication - Sheet 1 of 5 2-7 Ground Handling/Servicing SERVICE MANUAL Servicing 12 OIL DIPSTICK Check on preflight. Add oil as necessary. 17 FUEL STRAINER Drain off any water and sediment before the first flight of the day. 25 HOURS 7 BATTERY Check level of electrolyte every 25 hours (or at least every 30 days), oftener in hot weather. Maintain level of electrolyte even with the horizontal baffle plate or split ring at the bottom of the filler holes by adding distilled water only. 13 OIL FILLER AND DRAIN Change engine oil and clean oil screen every 25 hours, oftener under severe operating con- ditions. Refer to paragraph 2-14 for detailed servicing instructions. 16 INDUCTION AIR FILTER Service every 25 hours, oftener under dusty conditions. Refer to paragraph 2-15 for detailed servicing instructions. 50 HOURS 18 WINSLOW OR AC OIL FILTER Change engine oil and replace filter element every 50 hours. Refer to paragraph 2-14 for oil filter servicing. 100 HOURS FUEL/AIR CONTROL UNIT SCREEN Every 100 hours, remove and clean the screen in the bottom of the fuel/air control unit on fuel injection engines, then reinstall and resafety the screen. 2 GYRO INSTRUMENT AIR FILTERS Replace every 100 hours and when erratic or sluggish responses are noted with normal suction gage readings. 4 FUEL LINE DRAIN PLUGS OR VALVES Every 100 hours, remove plugs, drain off any water and sediment, reinstall plugs, and resafety. Some aircraft use drain valves instead of drain plugs. 5 FUEL TANK SUMP DRAINS If quick-drain valves are not installed, remove plugs and drain off any water and sediment every 100 hours. Reinstall and resafety plugs. SERVICING 2-8 Figure 2-4. Servicing and Lubrication - Sheet 2 of 5 SERVICE MANUAL Ground Handling/Servicing Servicing 10 BRAKE MASTER CYLINDERS Every 100 hours, check fluid level and refill if required with MIL-H-5606 hydraulic fluid. 14 SHIMMY DAMPENER Every 100 hours, check fluid level in shimmy dampener, refill if required. Refer to paragraph 2-19 for detailed instructions. 17 FUEL STRAINER AND ELECTRIC FUEL PUMP SCREENS Disassemble and clean strainer bowl and screen every 100 hours. On fuel injection aircraft, remove and clean screens in electric fuel pumps every 100 hours. 18 FRAM OIL FILTER Replace filter element whenever oil on dipstick appears dirty; maximum interval, 100 hours. Refer to paragraph 2-14 for detailed instructions. 19 VACUUM SYSTEM OIL SEPARATOR Remove, flush with solvent, dry with compressed air every 100 hours. 20 SUCTION RELIEF VALVE SCREEN Every 100 hours, check inlet screen for cleanliness. Remove, flush with solvent, and dry with compressed air if required. AS REQUIRED 9 TIRES Maintain proper tire inflation as given in paragraph 2-17. Remove oil and grease with soap and water; periodically check tires for wear, cuts, and bruises. GROUND SERVICE RECEPTACLE Connect to 12-volt, DC, negative-ground power unit for cold weather starting and lengthy ground maintenance of the electrical system. Master switch should be turned on before con- necting a generator type external power source; it should be turned off before connecting a battery type external power source. 15 NOSE GEAR SHOCK STRUT Keep strut filled and inflated to correct pressure. Refer to paragraph 2-18 for servicing instructions. The military specifications listed throughout this book are not mandatory, but are intended as guides in choosing satisfactory materials. Products of most reputable manufacturers meet or exceed these specifications. SERVICING Figure 2-4. Servicing and Lubrication - Sheet 3 of 5 2-9 Ground Handling/Servicing SERVICE MANUAL Lubrication HARTZEI L- PROPE LLER STEERING SYSTEM TAIL , GB NEEDLE BEARINGS GEAR SHIMMY DAMPENER PIVOTS TORQUE BATTERY NOSE GEAR * When lubricating Hartzell propellers. use any good quality general purpose lithium base waterproof grease. Re- move grease fitting adjacent to the **WHEEL **Clean and repack at first 100-hours; fitting being greased and fill until the BEARINGS thereafter, at each 500-hour inspec- grease oozes from adjacent hole. The tion, or more often in dusty or humid newly-designed Hartzell propellers areas, or if more than usual number should be lubricated in the same way. of take-offs are made. Use MIL-G- 25760 (or equivalent) grease. CONTROL COLUMN MODEL 182 (1962 & ON) NOTE The military specifications listed below are not mandatory, but are intended as guides in choosing MAIN satisfactory materials. Products GEAR of most reputable manufacturers THRUST BEARING meet or exceed these specifications. FREQUENCY (HOURS) NEEDLE BEARINGS NEEDLE BEARING ........ METHOD OF APPLICATION NOTE HAND GREASE OIL SYRINGE GUN CAN (FOR POWDERED Sealed bearings require no lubrication. GRAPHITE) McCauley propellers are lubricated at overhaul LUBRICANTS and require no other lubrication. GG- POWDERED GRAPHITE GB -MIL-G-7711 GREASE Do not lubricate roller chains or cables except OGP-MIL-L-7870 GENERAL PURPOSE OIL under seacoast conditions. Wipe with a clean VV-PETROLATUM dry cloth. Lubricate unsealed pulley bearings, rod ends, Oilite bearings, pivot and hinge points, and any other friction point obviously needing WHERE NO INTERVAL IS SPECIFIED, lubrication, with general purpose oil every LUBRICATE AS REQUIRED AND 1000 hours or oftener if required. WHEN ASSEMBLED OR INSTALLED. LUBRICATION Figure 2-4. Servicing and Lubrication - Sheet 4 of 5 2-10 SERVICE MANUAL Ground Handling/Servicing Lubrication CONTROL. AILERON BELLCRANK WHEEL SHAFT NEEDLE BEARINGS UNIVERSALS GB OGP FLAP BELLCRANK NEEDLE BEARINGS CONTROL "T" AND RELEASE BUTTON & CONTROL "Y" RATCHET LATCH OGP OILITE BRGS. NEEDLE BRGS. FLAP LEVER NEEDLE BRGS. ALLPIANO ELECTRIC FLAP HINGES DRIVE MECHANISM BEARINGS SCREW JACK GB THREADS SPRING-LOADED OGP FRICTION STOPS GB STABILIZER ACTUATORS GB OGP ALL TRIM WHEEL ELEVATOR TRIM RUDDER PEDAL NEEDLE BEARINGS TAB ACTUATOR OILITE BEARINGS NOTE Paraffin wax rubbed on seat rails will ease sliding the seats fore and aft. Lubricate door latches with an automotive type door latch lubricant, and the latching mechanism with general purpose oil, every 1000 hours or oftener if binding occurs. LUBRICATION Figure 2-4. Servicing and Lubrication - Sheet 5 of 5 2-11 Ground Handling/Servicing SERVICE MANUAL Air Filter Servicing Box HOLDER BRACKET 2 REQD MATERIAL: (. 040) HANDLE 2024-T4 CLAD .50 FLANGE BEND RADII .09 .75 1.62 BEND EDGES OF BOTTOM .25 AND LID .50 FLANGE 1.25 LID 1 REQD .88 BOTTOM 1 REQD WELD BOTTOM BOX AND ENDS AS REQD 1.62 48.00 ANGLE 1.25 1. 00 x 1.00 x 1/8(OR EQUIV) DRILL 1/4 (.250) DRAIN HOLES 4 INCH CENTER BOX ASSEMBLY MATERIAL FOR BOTTOM AND ENDS 6061-0 (.062), MATERIAL FOR TOP 2024-T3 (. 051) RIVET HINGES, BRACKET, AND ANGLE WITH AN470AD4 RIVETS AS REQD. AN470AD4 RIVET - AS REQD ON HINGE AN470AD3 RIVET - AS REQD Figure 2-5. Construction of Induction Air Filter Servicing Box 2-12 SERVICE MANUAL Ground Handling/Servicing Inspection INSPECTION 25-HOUR INSPECTION Before beginning the inspection, determinethat engine and propeller performance is normal and that all systems function properly. 1. Engine and engine compartment for fuel and oil leaks, security of parts, correct engine and propeller control travel, proper safetying, and visible defects. 2. Propeller and spinner for apparent damage or defects. 3. Remainder of airplane for security of attaching bolts, screws, and rivets, broken spot- welds, fuel leaks, and apparent exterior damage or defects. 4. Items for servicing and lubrication in accordance with Figure 2-4 as required at 25- hour intervals. NOTE 50-hour and 75-hour inspections are 25-hour inspections repeated at these intervals. Also check any items of servicing and lubrication required at these intervals. 100-HOUR INSPECTION The 100-hour (periodic) inspection is a thorough, searching inspection of the entire airplane. Unless the progressive inspection method is used, it is required every twelve months as a periodic inspection or every 100 hours, if the airplane is operated for hire, in accordance with Civil Air Regulations. ENGINE RUN-UP. Before beginning the inspection proper, start, run up, and shut down the engine in accordance with instructions in the Owner's Manual. During the run-up observe the following, making note of any discrepancies or abnormalities: 1. Engine temperatures and pressures. 2. Static rpm. 3. Magneto drop; note particularly any difference between the drop on the two magnetos. 4. Engine response to changes in power. 5. Any unusual engine noises. 6. Propeller response through pitch range. 7. Fuel tank selector or shut-off valve; operate engine on each tank and off positions long enough to make sure the valve functions properly. 8. Idling speed and mixture; proper idle cut-off. 9. Generator warning light or ammeter. 10. Suction gage. 11. Fuel flow indicator. After the inspection has been completed, an engine run-up should again be performed to ascertain that any discrepancies or abnormalities have been corrected. PREPARATION. Remove engine cowling, and loosen or remove all fuselage, wing, empennage, and upholstery inspection doors, plates, and fairings as necessary to accomplish the inspection. Replace after the inspection has been completed. 2-13 Ground Handling/Servicing SERVICE MANUAL Inspection ENGINE COMPARTMENT. 1. Engine oil for changing, screen for cleaning; filler cap, dipstick, drain plug, and screen for security and safetying as required. Refer to Figure 2-4 for aircraft equipped with external oil filters. NOTE Examine oil screens, filters, and sump oil for metal particles or contamination that could indicate internal damage to the engine. 2. Oil cooler for security, leaks, and obstructed air passages. 3. Induction air filter for servicing, proper fit, security, cracks in frame, and tears or bare spots in filter element. Paper element "dry" filters for replacement every 300 hours. 4. Entire engine assembly for cleanliness. 5. Induction airbox for internal cleanliness, cracks, and security; air valve and doors for operation and sealing; controls for security and operation. 6. Cold air and hot air flexible hoses for security, kinks, holes, chafing, and burnt spots. 7. Engine baffles for security, sealing, cracks, metal deformation, and attachment of sealing strips. 8. Cylinders for security, cracks, broken cooling fins; rocker box covers and push rod housings for security, oil leaks, cracks, and dents. 9. Crankcase, oil pan, reduction gear housing, and accessory section for security, oil leaks, safetying; front crankshaft seal for oil leakage. 10. All lines and hoses for security, leaks, cracks, dents, kinks, corrosion, hose deterioration, and chafing. 11. Intake system for security, leaks, deteriorated hoses, and loose or corroded clamps; manifold drains for proper operation, drain lines and hoses for security, leaks, and chafing. 12. Exhaust system for security, leaks, cracks, and burned-out spots. Refer to paragraph 12-74. 13. Ignition harness for security, chafing, burning, defective insulation, and loose or broken terminals. 14. Spark plugs for proper gap, cleanliness, and evidence of reliable operation. (Also see paragraph 12-40.) 15. Crankcase and vacuum system breather lines for security, obstructions, corrosion, cracks, and chafing. 16. All electrical wiring in the engine compartment for security, chafing, defective insulation, and loose or broken terminals. 17. Vacuum pump for security, oil leaks, and safetying. 18. Vacuum relief valve for security and the inlet screen for cleanliness, holes, corrosion, and safetying. 19. Vacuum system oil separator for security, cracks, oil leaks, and servicing. 20. Engine and propeller controls and linkage for security, proper rigging, binding, excessive wear, cracks, misalignment, corrosion, safetying, and chafing. 21. Engine shock mounts for security, safetying, deterioration; engine mount for cracks, corrosion, dents, bends, and evidence of overheating; ground straps for security, corrosion, fraying of braided straps, and cracking of metal straps. 22. Cabin heater valve and door for proper operation, sealing, cracks, and defor- mation; controls for security, binding, proper rigging, and alignment. 23. Starter for security, oil leaks, tight electrical connections; engagement lever for proper rigging and return spring tension. Every 200 hours, check starter brushes for sufficient length, binding; brush leads for fraying, chafing; commutator for glaze, pits, grooves, high mica, and cleanliness. 24. Generator for security and oil leaks if generator is fastened to accessory case; drive belt for cuts, fraying, and excessive wear; electrical connections for security. Every 200 hours, check generator brushes for sufficient length, binding; brush leads for fraying, chafing; commutator for glaze, pits, grooves, high mica, and cleanliness. 25. Voltage regulator for security and tight electrical connections. Every 200 hours, check contact points for discoloration, pits, and corrosion. 26. Starting vibrator for security and tight electrical connections. Every 500 hours, check vibrator contact points for discoloration, pits, and corrosion. 2-14 SERVICE MANUAL Ground Handling/Servicing Inspection 27. Bendix-Scintilla Magnetos. a. Breaker compartment for dirt and grease. b. Breaker points for security, pits, burns and carbon deposits. c. Cam followers for correct lubrication. d. Ventilator screens for cleanliness and security. e. Magnetos for correct internal timing, timing to engine, and security of attachment. 28. Slick (formerly Case) Magnetos. a. Magnetos for correct timing to engine and security of attachment. NOTE As long as Slick magneto timing is correct, the magnetos need be checked internally only at 500-hour intervals. Check the following items whenever a magneto is disassembled. b. Breaker points for security, pits, burns, and carbon deposits. c. Cam oilier pad for correct lubrication. d. Ventilator screens for cleanliness and security. e. Carbon brush for excessive wear. The brush should protrude a minimum of 1/32" from the shaft. f. Each end of the distributor gear shaft for correct lubrication. g. The magnetos for correct internal timing during reassembly, timing to the engine, and security of attachment. 29. Carburetor for security, cracks, corrosion, fuel leaks, cleanliness of inlet screen and proper safetying. 30. Fuel/air control unit for security, cracks, corrosion, fuel leaks, cleanliness of inlet screen, proper safetying, and security of cooling shrouds. 31. Engine-driven fuel pump for security, cracks, leaks, proper safetying, and security of cooling shrouds. 32. Fuel manifold valve (fuel injection distributor) for security, proper safetying, and leaks. 33. Fuel injection lines for security, kinks, cracks, dents, leaks, and chafing. 34. Fuel injection nozzles for cleanliness and security. 35. Engine cowling for cleanliness, proper fit, security, cracks, dents, cuts, tears, loose or broken hinges, defective latches or fasteners, and deteriorated paint. 36. Cowl flaps for cleanliness, proper fit, security, cracks, dents, cuts, tears, loose or broken hinges, and deteriorated paint; control for security, proper rigging, and binding. PROPELLER 1. Fixed-pitch propeller for track, nicks, cracks, corrosion, bends, dents, security and proper safetying. 2. Constant-speed propellers for nicks, cracks, corrosion, bends, dents, loose nuts and bolts, oil leaks, freedom of blade movement, excessive looseness of blades, security, and proper safetying. 3. Hartzell constant-speed propeller for correct lubrication. 4. Propeller governor for security, safetying, cracks, oil leaks; control for correct rigging, security, binding and proper safetying. 5. Spinner and spinner bulkhead for cracks, dents, alignment, security, and condition of paint. FUEL SYSTEM 1. Fuel strainer for internal cleanliness, security, leaks, and safetying; drain valve and control for proper rigging, operation, leaks and security. 2. Electric fuel pumps for cleanliness of filter screens, security, leaks, proper operation, and tight electrical connections. 3. Fuel tank sump drains for water and sediment, leaks, security, and safetying; quick drain valves for proper operation. 4. Under side of wings for evidence of fuel leaks; rubber fuel cells for loose fasteners attaching upper surface of wing; fuel tank filler cap placards for legibility; caps for leaks and security. NOTE At engine overhaul periods (or approximately 1000 hours), drain all fuel and inspect interior of rubber fuel cells for checks and cracks, and the area around the filler opening for visible defects. On metal fuel tanks, remove the wing skin above the tanks and check for deformed metal, chaffing, condition of straps and rubber pads, and security. On rubber or metal tanks, check outlet screens for contamination. These are coarse screens, designed to filter out larger foreign particles. Revision 1 Feb 3/2003 © Cessna Aircraft Company 2-15 SERVICE MANUAL Ground Handling/Servicing Inspection 5. Fuel vents for obstructions, operation of check valve, leaks, security, and proper position of vent behind wing strut. 6. Fuel selector valve, or shut-off valve, for proper operation, security, leaks, positive detent positions, and legibility and correct indexing of placard. 7. All fuel lines for security, chafing, leaks, cracks, dents, kinks, and corrosion. 8. Fuel line and selector valve drains for servicing, security, leaks, and safetying. 9. Fuel accumulator tank for cracks, dents, leaks, and security. 10. Fuel quantity gauges (direct reading), electrical fuel quantity gages, and fuel quantity electrical transmitters for security, correct indication, defective electrical wiring, cracked glass, legibility, and leaks. 11. Engine primer for proper operation, leaks and security. 12. Vapor return line solenoid and fuel system check valves for proper operation, leaks and security. 13. Fuel quantity indicating system operational test is required every 12 months. Refer to Section 16 for detailed accomplishment instructions. 14. Carburetor fuel bowl drain, drain fuel from carburetor and check for fuel contaminants. Refer to Cessna Service Bulletin SEB99-19, Engine Carburetor Fuel Inspection (or latest revision) for detailed accomplishment instructions. 15. For airplanes equipped with a TCM fuel injected engine: Inspect/Clean the fuel injection nozzles. At the first 100-hour inspection on new, rebuilt, or overhauled engines, remove and clean the fuel injection nozzles. Thereafter, the fuel injection nozzles must be cleaned at 300-hour intervals or more frequently if fuel stains are found. LANDING GEAR 1. Brakes for proper operation, sponginess, failure to hold pressure, and fluid level. 2. Master cylinders, brake lines, and hoses for security, leaks, cracks, dents, and chafing. 3. Brake linings for wear, cleanliness, chips, cracks, and security. 4. Brake discs for scoring, warping, excessive wear, and loose or broken brake clips. 5. Wheel and brake assembly for cracks, dents, corrosion, leaks, loose bolts, defective paint, freedom of moving parts, and excessive wear. 6. Axles for security, cleanliness, cracks, bends, defective threads, axle nuts for proper adjustment and safetying. 7. At the first 100-hour inspection and at 500-hour intervals thereafter, remove wheel bearings and inspect for cleanliness, rust, cracks, pits, scoring, brinelling, discoloration, excessive wear, and lubrication. 8. Main landing gear spring struts for security, cracks, bends, deep scratches, dents, chipped paint, and security of steps. 9. Tires for proper inflation, sufficient tread, cleanliness, cuts, blisters, breaks, and uneven wear. 10. Tail wheel for lubrication, security, cracks; tire for proper inflation, cuts, sufficient tread, breaks, and blisters; tailwheel spring, steering and anti-swivel mechanism for security, proper operation, cracks, frayed cables, and worn links. 11. Nose gear shock strut for proper servicing, leaks, cleanliness, proper operation, excessive wear, looseness, visible damage, and security. 12. Nose gear steering linkage for correct alignment, proper steering travel, lubrication, excessive wear, and visible damage or defects. 13. Torque links for lubrication, cracks, binding, security, safetying, and excessive wear. 14. Shimmy dampener for servicing, security, proper operation, leaks and excessive wear. 15. Speed fairings for security, cleanliness, proper adjustment of scrapers, cracks, tears, separation of laminate, and condition of paint. 16. Parking brake for proper operation, correct adjustment, security, excessive wear, and full release. AIRFRAME 1. Pitot and static ports for obstructions; pitot and static lines for security, cracks, kinks, chafing, and moisture; pitot and static systems for leaks; pitot tube for alignment. 2. Aircraft exterior for cracks, metal distortion, broken spot welds, loose or missing rivets, screws, and bolts, corrosion, condition of paint, and any other apparent damage or defects. Especially check wing and empennage tips for damage. 2-16 D138-1-13 Temporary Revision Number 4 - Apr 5/2004 © Cessna Aircraft Company SERVICE MANUAL Ground Handling/Servicing Inspection 3. Aircraft structure for corrosion, cracks, metal distortion, loose or missing rivets, screws, and bolts, and evidence of excessive loads. 4. Windows and windshield for cleanliness, proper attachment, sealing, crazing, cracks, deep scratches, and discoloration. 5. Door and window hinges and latches for lubrication, alignment, proper operation, cracks, distortion, binding, and security. 6. Seats for ease of movement, positive locking, security, and seat stops; seat up- holstery for rips, tears, holes, and cleanliness; seat structure for cracks, bends, and corrosion; seat rails for security, cracks, and damage. 7. Safety belts for security, proper latching, cuts, tears, fraying, and broken stitching; attaching parts for cracks, deformed metal, and excessive wear. 8. Control column for security, binding, cracks, looseness, and restricted travel; bearings, sprockets, and pulleys for cleanliness, lubrication, binding, security, and excessive wear; cables and chains for security, cleanliness, corrosion, fray- ing, binding, broken links, and misalignment; turnbuckles for safetying; bell- cranks for cracks, distortion, and binding. 9. Control wheels for alignment, binding, security, bent tube, and excessive wear; control lock for proper operation and availability. 10. Instruments for cracked glass, security, proper operation, cleanliness, and legibility of markings; gyro instrument air filters for replacement. 11. Magnetic compass for security, fluid discoloration, leaks, lighting, and proper operation. Accuracy of the compass on all cardinal headings should be checked whenever equipment replacement, modification, or relocation might cause compass deviation, and at engine overhaul periods (or approximately 1000 hours). Compensate the compass and record deviation on the compass correction card. 12. Instrument wiring and plumbing for security, chafing, leaks, cracks, kinks, defective insulation, loose terminals, and interference with control column travel. 13. Instrument panel for security, deteriorated shockmounts, cracks, damaged decorative cover, and legibility of all decals and labeling. 14. Defrosting, heating, and ventilating systems for proper operation, security, chafing, and deterioration; controls for proper rigging, binding, and security; ram air inlets for obstructions. 15. Cabin upholstery and trim for cleanliness, rips, tears, holes, and security; sunvisors for security and proper operation; ash trays for cleanliness and security. 16. Area beneath floor for cleanliness, chafing and security of lines, hoses, and electrical wires; control cables for fouling. 17. Stall warning horn and light for proper operation and security. 18. Electrical switches, circuit breakers, and fuses for security, proper functioning, correct rating, and legibility of placarding; wiring for security, proper insulation, and chafing; spare fuses for availability. 19. Instrument and cabin lights for proper operation, security, and cleanliness; instrument light rheostat for proper functioning. 20. Radios and radio controls for proper operation and security. 21. Radio components in the aft fuselage for security, proper shock mounting, cracked or deformed mounting brackets, and cleanliness. 22. Oxygen system for proper operation, leaks, security of oxygen bottle, lines, regulator, and gage; mounting brackets for cracks, security, and damaged metal; oxygen masks and hoses for availability; oxygen supply for servicing for anticipated requirements. 23. Battery for servicing, security, and corroded terminals; battery cables for condition of terminals, security, and defective insulation; battery box for cracks, corrosion, damaged mounting brackets, and security; vent line for corrosion, security, and obstructions. 24. Firewall for proper sealing, security of grommets and shields, cracks, dents, wrinkles, loose or missing rivets, screws, or bolts, and evidence of excessive loads. 25. Radio antennas for cleanliness, security, proper connections, corrosion, and cracked insulators; external loop housing for security, cleanliness, cracks, loose or missing screws, sealing, and obstructed drain hole. 26. Navigation lights, landing lights, and rotating beacon for proper operation, security, cleanliness, and cracked glass. 27. Stall warning sensing unit for freedom of vane, security, cleanliness, and proper operation. 28. Pitot and stall warning heaters for proper operation. 2-17 Ground Handling/Servicing SERVICE MANUAL Inspection 29. Aileron control system: a. Ailerons for correct direction of movement when operated from the cabin. b. Pulleys for security, cleanliness, binding, misalignment, cracks, cracked or deformed pulley brackets, and chipped or broken flanges. c. Cables for cleanliness, security of terminals, corrosion, fraying, correct tension, and safetying of turnbuckles. d. Bellcranks and push-pull rods for cleanliness, lubrication, security, bind- ing, cracks, and distortion. e. Fairleads and cable guards for security and excessive wear. f. Aileron system for correct rigging and proper travel. 30. Ailerons for security of attachment, smooth operation, security of balance weights, cracks, corrosion, and skin or structural damage. 31. Flap control system: a. Pulleys for security, cleanliness, binding, misalignment, cracks, cracked or deformed pulley brackets, and chipped or broken flanges. b. Cables for cleanliness, security of terminals, corrosion, fraying, correct tension, and safetying of turnbuckles. c. Bellcranks and push-pull rods for cleanliness, lubrication, security, bind- ing, cracks, and distortion. d. Fairleads and cable guards for security and excessive wear. e. Flap system for correct rigging and proper travel. f. Flap control lever for security, proper operation of latch, lubrication, and binding; flap decal for legibility. g. Electric flap motor and transmission assembly for security, proper opera- tion, security of electrical wires, and cleanliness; flap motor hinge for cracks, distortion, binding and cleanliness; screwjack threads for clean- ing and relubrication as required. h. Electric flap position transmitter for security, proper adjustment, proper operation of actuating linkage, cracked or deformed mounting bracket, and tight electrical connections. i. Flap position indicator for cracked glass, security, proper indication, clean- liness and legibility of markings. 32. Flaps for security of attachment, smooth operation, binding rollers, cracked, bent, or loose tracks, corrosion, and skin or structural damage. 33. Elevator control system: a. Elevators for correct direction of movement when operated from the cabin. b. Pulleys for security, cleanliness, binding, misalignment, cracks, cracked or deformed pulley brackets, and chipped or broken flanges. c. Cables for cleanliness, security of terminals, corrosion, fraying, correct tension, and safetying of turnbuckles. d. Bellcranks and push-pull rods for cleanliness, lubrication, security, binding, cracks, and distortion. e. Fairleads and cable guards for security and excessive wear. f. Elevator downspring system for security and proper operation. Where the attachment to the push-pull tube is adjustable, check that the downspring system applies load to the elevator as it reaches the streamlined position (with stabilizer leading edge full down). g. Elevator system for correct rigging andproper travel. 34. Elevators for security of attachment, smooth operation, security of balance weights, cracks, corrosion, and skin or structural damage. 35. Elevator or stabilizer trim control system: a. Elevator trim tab or stabilizer for correct direction of movement when operated from the cabin. b. Pulleys and sprockets for security, cleanliness, binding, misalignment, cracks, cracked or deformed brackets and chipped or broken flanges or teeth. c. Cables and chains for cleanliness, security of terminals, corrosion, fraying, correct tension, broken or damaged links, and safetying of turnbuckles. d. Push-pull rod for security, cracks, and distortion. e. Fairleads, cable guards, and chain guards for security and excessive wear. f. Trim control wheel for lubrication, cleanliness, security, binding, and opera- tion of friction stop and position indicator; indicator for correct indexing and legible markings. g. Trim tab or stabilizer actuators for security, cleanliness, lubrication, proper operation, corrosion, cracks, and excessive wear. h. Trim control system for correct rigging and proper travel. 2-18 SERVICE MANUAL Ground Handling/Servicing Inspection i. For model 180, 185, and 182 serials 33000 thru 53007, 18253008 thru 18253598 airplanes: Each 1000 hours, measure the amount of free play between the horizontal stabilizer and the fuselage. To measure the free play: 1 Set the trim wheel to the takeoff position. 2 Lift up on the horizontal stabilizer forward spar adjacent to the fuselage and measure the free play between the front spar of the stabilizer and the fuselage. Do this procedure again on the opposite side of the fuselage. 3 The maximum permitted free play is 0.01 9 inch with a maximum difference between the two sides of the stabilizer is 0.010 inch. a If the free play is 0.01 9 inch or less and within 0.01 0 inch of each side, this inspection is complete, no more action is necessary. b If the free play is more than the permitted tolerance, remove the horizontal stabilizer and examine the free play between the top and bottom of each actuator. c The maximum actuator free play is 0.01 9 inch. If an actuator free play is greater than 0.01 9 inch or 0.01 0 inch of each side, remove and repair the actuator. d If an actuator has 0.01 9 inch or less of tree play and is within 0.01 0 inch ot each side, examine the attach brackets and attach hardware for wear. e Replace worn attach brackets and hardware. 4 Install the brackets, hardware, actuators, and horizontal stabilizer as applicable. 5 Do steps 35. i. 1 thru 3 again, as applicable. 36. Movable stabilizer or elevator trim tab for security of attachment, smooth operation, cracks, corrosion, and skin or structural damage. 37. Rudder control system: a. Rudder for correct direction of movement when operated from the cabin. b. Rudder pedal assembly for binding, cleanliness, lubrication, security, cracks, bent linkage, and excessive wear. c. Pulleys for security, cleanliness, binding, misalignment, cracks, cracked or deformed pulley brackets, and chipped or broken flanges. d. Cables for cleanliness, security of terminals, corrosion, fraying, correct tension on "closed" systems, and safetying of turnbuckles. e. Fairleads and cable guards for security and excessive wear. f. Rudder system for correct rigging and proper travel. 38. Rudder for security of attachment, smooth operation, security of balance weight, cracks, corrosion, and skin or structural damage. 39. Rudder trim control system: a. Trim control wheel for lubrication, cleanliness, security, binding, and proper operation. b. Position indicator for proper operation, correct indexing, legible markings, and security. c. Bungee for cleanliness, security, proper operation, excessive wear, and correct safetying. d. Chain for cleanliness, proper tension, broken or damaged links, corrosion, and binding. e. Sprockets and connecting shaft for security, binding, misalignment, cracks, excessive wear, cleanliness, and chipped or broken teeth. f. Trim control system for correct rigging. 40. Wings, wing struts, and empennage for security of attachment, cracked fittings, loose or missing rivets and bolts, security of hinges, defective bearings, and evidence of elongated bolt holes and excessive wear of attaching parts. PAPER REQUIREMENTS 1. Check that all aircraft and engine documents are in accordance with current 14 C.F.R. Part 43. 2. Check FAA Airworthiness Directives, Cessna Service Letters and Service Bulletins for compliance at the time specified by them. Revision 1 D138-1-13 Temporary Revision 5 -July 1/2007 Feb 3/2003 © Cessna Aircraft Company 2-19 SERVICE MANUAL Ground Handling/Servicing Component Time Limits 2-33. COMPONENT TIME LIMITS a. General 1. Most components listed throughout Section 2 should be inspected as detailed elsewhere in this section and repaired, overhauled or replaced as required. Some components, however, have a time or life limit, and must be overhauled or replaced on or before the specified time limit. NOTE: The terms overhaul and replacement as used within this section are defined as follows: Overhaul - Item may be overhauled as defined in FAR 43.2 or it can be replaced. Replacement - Item must be replaced with a new item or a serviceable item that is within its service life and time limits or has been rebuilt as defined in FAR 43.2. 2. This section provides a list of items which must be overhauled or replaced at specific time limits. Table 1 lists those items which Cessna has mandated must be overhauled or replaced at specific time limits. Table 2 lists component time limits which have been established by a supplier to Cessna for the supplier's product. 3. In addition to these time limits, the components listed herein are also inspected at regular time intervals set forth in the Inspection Charts, and may require overhaul/replacement before the time limit is reached based on service usage and inspection results. b. Cessna-Established Replacement Time Limits 1. The following component time limits have been established by Cessna Aircraft Company. Table 1: Cessna-Established Replacement Time Limits COMPONENT REPLACEMENT TIME OVERHAUL Restraint Assembly Pilot, Copilot, and Passenger Seats Trim Tab Actuator Vacuum System Filter Vacuum System Hoses Pitot and Static System Hoses Vacuum Relief/Regulator Valve Filter (If Installed) Engine Compartment Flexible Fluid Carrying Teflon Hoses (Cessna- Installed) Except Drain Hoses (Drain hoses are replaced on condition) 1,000 hours or 3 years, whichever occurs first 500 hours 10 years 10 years 500 hours 10 years or engine overhaul, whichever occurs first (Note 1) © Cessna Aircraft Company 10 years NO YES NO NO NO NO NO Revision 1 Feb 3/2003 2-20 SERVICE MANUAL Ground Handling/Servicing Component Time Limits COMPONENT REPLACEMENT TIME OVERHAUL Engine Compartment Flexible Fluid Carrying Rubber Hoses (Cessna- Installed) Except Drain Hoses (Drain hoses are replaced on condition) Engine Air Filter Engine Mixture, Throttle, and Propeller Controls Engine Driven Dry Vacuum Pump Drive Coupling (Not lubricated with engine oil) Engine Driven Dry Vacuum Pump (Not lubricated with engine oil) Standby Dry Vacuum Pump c. Supplier-Established Replacement Time Limits 1. The following component time limits have reproduced as follows: 5 years or engine overhaul, whichever occurs first (Note 1) 500 hours or 36 months, whichever occurs first (Note 9) At engine TBO 6 years or at vacuum pump replacement, whichever occurs first 500 hours (Note 10) 500 hours or 10 years, whichever occurs first (Note 10) been established by specific suppliers and are Table 2: Supplier-Established Replacement Time Limits COMPONENT REPLACEMENT TIME OVERHAUL ELT Battery Vacuum Manifold Magnetos Engine Engine Flexible Hoses (TCM-Installed) Auxiliary Electric Fuel Pump Propeller © Cessna Aircraft Company NO NO NO NO NO NO (Note 3) (Note 4) (Note 5) (Note 6) (Note 2) (Note 7) (Note 8) NO NO YES YES NO YES YES Revision 1 Feb 3/2003 2-21 SERVICE MANUAL Ground Handling/Servicing Component Time Limits NOTES: Note 1: This life limit is not intended to allow flexible fluid-carrying Teflon or rubber hoses in a deteriorated or damaged condition to remain in service. Replace engine compartment flexible Teflon (AE3663819BXXXX series hose) fluid-carrying hoses (Cessna-installed only) every ten years or at engine overhaul, whichever occurs first. Replace engine compartment flexible rubber fluid-carrying hoses (Cessna-installed only) every five years or at engine overhaul, whichever occurs first (this does not include drain hoses). Hoses which are beyond these limits and are in a serviceable condition, must be placed on order immediately and then be replaced within 120 days after receiving the new hose from Cessna. Note 2: For TCM engines, refer to Teledyne Continental Service Bulletin SB97-6, or latest revision. Note 3: Refer to FAR 91.207 for battery replacement time limits. Note 4: Refer to Airborne Air & Fuel Product Reference Memo No. 39, or latest revision, for replacement time limits. Note 5: For airplanes equipped with Slick magnetos, refer to Slick Service Bulletin SB2-80C, or latest revision, for time limits. For airplanes equipped with TCM/Bendix magnetos, refer to Teledyne Continental Motors Service Bulletin No. 643, or latest revision, for time limits. Note 6: Refer to Teledyne Continental Service Information Letter S1L98-9, or latest revision, for time limits. Note 7: Refer to Cessna Service Bulletin SEB94-7 Revision 1/Dukes Inc. Service Bulletin NO. 0003, or latest revision. Note 8: Refer to the applicable McCauley or Hartzell Service Bulletins and Overhaul Manual for replacement and overhaul information. Note 9: The air filter may be cleaned, refer to Section 2 of this service manual for servicing instructions. For airplanes equipped with an air filter manufactured by Donaldson, refer to Donaldson Aircraft Filters Service Instructions P46-9075 for detailed servicing instructions. The address for Donaldson Aircraft Filters is: Customer Service 115 E. Steels Corners RD Stow OH. 44224 Do not overservice the air filter, overservicing increases the risk of damage to the air filter from excessive handling. A damaged/worn air filter may expose the engine to unfiltered air and result in damage/excessive wear to the engine. Note 10: Replace engine driven dry vacuum pump not equipped with a wear indicator every 500 hours of operation, or replace according to the vacuum pump manufacturer's recommended inspection and replacement interval, whichever occurs first. Replace standby vacuum pump not equipped with a wear indicator every 500 hours of operation or 10 years, whichever occurs first, or replace according to the vacuum pump manufacturer's recommended inspection and replacement interval, whichever occurs first. For a vacuum pump equipped with a wear indicator, replace pump according to the vacuum pump manufacturer's recommended inspection and replacement intervals. Revision 1 2-22 © Cessna Aircraft Company Feb 3/2003 SERVICE MANUAL Fuselage Windows and Windshield SECTION 3 FUSELAGE TABLE OF CONTENTS Page WINDOWS AND WINDSHIELDS ........ 3-1 SEATS .................. 3-9 Cleaning ............... 3-1 Removal and Replacement of Forward Seats. 3-9 Waxing ................. 3-1 Removal and Replacement of Rear Seats . . 3-9 Repairs. ............. ... 3-1 Repair of Seats ............ 3-9 Scratches ... ............ . 3-1 CABIN UPHOLSTERY. ........... 3-9 Cracks ................. 3-2 Upholstery Materials and Tools ...... 3-9 WINDSHIELDS ............... 3-2 Soundproofing ............. 3-9 Removal ................ 3-2 HEADLINER AND CABIN TOP Replacement .............. 3-4 SOUNDPROOFING ........... 3-16 MOVABLE WINDOWS ............ 3-4 Removal ................ 3-16 SIDE AND REAR WINDOWS ......... 3-4 Installation ............... 3-16 CABIN DOORS ............... 3-4 UPHOLSTERY SIDE PANELS ....... . 3-16 Removal and Replacement ........ 3-4 Removal and Replacement ........ 3-16 Cabin Door Weatherstrip ......... 3-5 WINDLACE (DOOR SEALS) ......... 3-16 Adjustment ............... 3-5 CARPETING ............... 3-16 CABIN DOOR LATCHES. .......... 3-5 BAGGAGE COMPARTMENT UPHOLSTERY . . 3-16 Removal and Replacement. ........ 3-6 SAFETY BELTS .............. 3-16 BAGGAGE DOORS ............. 3-9 Removal and Replacement ........ 3-16 Removal and Replacement ....... . 3-9 CARGO TIE-DOWN PROVISIONS ...... 3-20 3-1. WINDOWS AND WINDSHIELDS. CAUTION 3-2. CLEANING. (See paragraph 2-25.) Do not use a coarse grade of abrasive. No. 320 is of maximum coarseness. 3-3. WAXING will fill in minor scratches in clear plastic and help protect the surface from further b. Continue the sanding operation,usingprogressively abrasion. Use a good grade of commercial wax ap- finer grade abrasives until the scratches disappear. plied in a thin, even coat. Bring the wax to a high c. When the scratches have been removed, wash the polish by rubbing lightly with a clean, dry flannel cloth, area thoroughly with clean water to remove all gritty particles. The entire sanded area will be clouded with 3-4. REPAIRS. Damaged window panels and windshield minute scratches which must be removed to restore may be removed and replaced if the damage is exten- transparency. sive. However, certain repairs as prescribed in the d. Apply fresh tallow or buffing compound to a motor- following paragraphs can be made successfully with- driven buffing wheel. Hold the wheel against the plastic out removing the damaged part from the airplane, surface, moving it constantly over the damaged area Three types of temporary repairs for cracked plastic until the cloudy appearance disappears. A 2000-foot- are possible. No repairs of any kind are recommend- per-minute surface speed is recommended to prevent ed on highly-stressed or compound curves where the heating, distortion, or burns. repair would be likely to affect the pilot's field of vision. Curved areas are more difficult to repair than NOTE flat areas and any repaired area is both structurally and optically inferior to the original surface. Polishing can be accomplished by hand but it will require a considerably longer period of 3-5. SCRATCHES on clear plastic surfaces can be time to attain the same result as produced by removed by hand-sanding operations followed by a buffing wheel. buffing and polishing, if steps below are followed care- fully. e. When buffing is finished, wash the area thoroughly a. Wrap a piece of No. 320 (or finer) sandpaper or and dry it with a soft flannel cloth. Allow the surface abrasive cloth around a rubber pad or wood block. to cool and inspect the area to determine if full trans- Rub the surface around the scratch with a circular parency has been restored. Then apply a thin coat of motion,keeping the abrasive constantly wet with clean hard wax and polish the surface lightly with a clean water to prevent scratching the surface further. Use flannel cloth. minimum pressure and cover an area large enough to prevent the formation of "bull's-eyes" or other optical distortions. 3-1 Fuselage SERVICE MANUAL Windows and Windshield WOOD REINFORCEMENT WOOD CUSHION OF ALWAYS DRILL END OF CRACK RUBBER - TO RELIEVE STRAIN OR FABRIC WRONG SOFT WIRE CEMENTED LACING FABRIC PATCH TEMPORARY REPAIR SANDING REPAIR OF CRACKS Figure 3-1. Repair of Windows and Windshield NOTE No. MIL-T-6094 can also be used to secure the patch. d. A temporary repair can be made by drilling Rubbing the plastic surface with a dry cloth will small holes along both sides of the crack 1/4 to 1/8 build up an electrostatic charge which attracts inch apart and lacing the edges together with soft wire. dirt particles and may eventually cause scratch- Small-stranded antenna wire makes a good temporary ing of the surface. After the wax has hardened, lacing material. This type of repair is used as a dissipate this charge by rubbing the surface with temporary measure only, and as soon as facilities are a slightly damp chamois. This will also remove available the panel should be replaced. the dust particles which have collected while the wax is hardening. 3-7. WINDSHIELDS. (See figure 3-2.) Windshields are single-piece, "free-blown" acrylic plastic panels f. Minute hairline scratches can often be removed set in sealing strips and held by formed retainer by rubbing with commercial automobile body cleaner strips riveted to the fuselage. In all aircraft except or fine-grade rubbing compound. Apply with a soft, the 150 series, a windshield centerstrip supports the clean, dry cloth or imitation chamois. center of the windshield. Various sealants have been used to prevent leakage around the windshield. How- 3-6. CRACKS. (See figure 3-1.) ever, Presstite No. 579.6 sealing compound used in a. When a crack appears in a panel, drill a hole at conjunction with a felt strip at the top and sides, and the end of the crack to prevent further spreading. The EC-1202 tape (manufactured by the Minnesota Mining hole should be approximately 1/