MODEL 172RG SERIES (1980 THRU 1985) - AeroElectric

Revision .. 1 ....... 2 October 1995 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 566. * The asterisk indicates pages changed, added, or deleted by the current change. 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Aerofiche/Manual 1. GENERAL DESCRIPTION ........................ 1A9/1-1 2. GROUND HANDLING, SERVICING, CLEANING, LUBRICATION AND INSPECTION ................. 1A17/2-1 3. FUSELAGE ................................... 1C20/3-1 4. WINGS AND EMPENNAGE ........................ El/4-1 5. LANDING GEAR, BRAKES, AND HYDRAULIC SYSTEM 1F6/5-1 6. AILERON CONTROL SYSTEM .................... 1J1/6-1 7. WING FLAP CONTROL SYSTEM .................... 1J15/7-1 8. ELEVATOR CONTROL SYSTEM .................... 1K9/8-1 9. ELEVATOR TRIM TAB CONTROL SYSTEM ........... 1K21/9-1 10. RUDDER CONTROL SYSTEM ...................... 1L11/10-1 11. NORMALLY ASPIRATED ENGINE .................. 2A2/11-1 12. FUEL SYSTEM ................................. 2B21/12-1 13. PROPELLER .................................. 2D6/13-1 14. UTILITY SYSTEMS ............................. 2D16/14-1 15. INSTRUMENTS AND INSTRUMENT SYSTEMS ......... 2D24/15-1 16. ELECTRICAL SYSTEMS .......................... 2F16/16-1 17. STRUCTURAL REPAIR. .......................... 215/17-1 18. PAINTING .................................... 2K11/18-1 19. WIRING DIAGRAMS ............................ 3A2/19-1 WARNING When performing any inspection or maintenance that re- quires turning on the master switch, installing a battery, or pulling the propeller through by hand, treat the prop- eller as if.the ignition switch were ON. Do not stand, nor allow anyone else to stand, within the arc of the propel- ler, since a loose or broken wire, or a component mal- function, could cause the propeller to rotate. i MODEL 172RG SERVICE MANUAL CROSS REFERENCE LISTING OF POPULAR NAME VS. MODEL NUMBERS AND SERIALS All aircraft, regardless of manufacturer, are certified un- der model number designations. However, popular names are often used for marketing purposes. To provide a consis- tent method of referring to these aircraft, the model num- ber will be used in this publication unless the popular name is necessary to differentiate between versions of the same basic model. The following table provides a listing of popular name, model number and serial number. MODEL SERIAL POPULAR NAME YEAR MODEL BEGINNING ENDING CUTLASS RG 1980 172RG 172RG0001 172RG0570 CUTLASS RGII CUTLASS RG 1981 172RG 172RG0571 172RG0890 CUTLASS RGII CUTLASS RG 1982 172RG 172RG0891 172RG1099 CUTLASS RGII CUTLASS RG 1983 172RG 172RG1100 172RG1144 CUTLASS RGII CUTLASS RG 1984 172RG 172RG1145 172RG1177 CUTLASS RGII CUTLASS RG 1985 172RG 172RG1178 172RG1191 CUTLASS RGII ii Revision 1 MODEL 172RG SERVICE MANUAL INTRODUCTION This manual contains factory-recommended procedures and instructions for ground handling, servicing, and maintaining Cessna 172RG Series airplanes. Besides serving as a reference for the experienced mechanic, this manual also covers step-by-step procedures for the less experienced. If properly used, it will better enable the mechanic to maintain Cessna 172RG Series airplanes and thereby establish a reputation for reliable service. This service manual is designed for aerofiche presentation. To facilitate the use of the aerofiche, refer to the aerofiche header for basic information. KEEPING CESSNA PUBLICATIONS CURRENT The information in this publication is based on data available at the time of publication and is updated, supple- mented, and automatically amended by all information issued in Service News Letters, Service Bulletins, Sup- plier Service Notices, Publication Changes, Revisions, Reissues and Temporary Revisions. All such amendments become part of and are specifically incorporated within this publication. Users are urged to keep abreast of the latest amendments to this publication through information available at Cessna Authorized Service Stations or through the Cessna Product Support subscription services. Cessna Service Stations have also been supplied with a group of supplier publications which provide disassembly, overhaul, and parts breakdowns for some of the var- ious supplier equipment items. Suppliers publications are updated, supplemented, and specifically amended by supplier issued revisions and service information which may be reissued by Cessna; thereby automatically amending this publication and is communicated to the field through Cessna's Authorized Service Stations and/or through Cessna's subscription services. WARNING: ALL INSPECTION INTERVALS, REPLACEMENT TIME LIMITS, OVERHAUL TIME LIMITS, THE METHOD OF INSPECTION, LIFE LIMITS, CYCLE LIMITS, ETC., REC- OMMENDED BY CESSNA ARE SOLELY BASED ON THE USE OF NEW, REMANU- FACTURED, OR OVERHAULED CESSNA APPROVED PARTS. IF PARTS ARE DE- SIGNED, MANUFACTURED, REMANUFACTURED, OVERHAULED, PURCHASED, AND/OR APPROVED BY ENTITIES OTHER THAN CESSNA, THEN THE DATA IN CESSNA'S MAINTENANCE/SERVICE MANUALS AND PARTS CATALOGS ARE NO LONGER APPLICABLE AND THE PURCHASER IS WARNED NOT TO RELY ON SUCH DATA FOR NON-CESSNA PARTS. ALL INSPECTION INTERVALS, RE- PLACEMENT TIME LIMITS, OVERHAUL TIME LIMITS, THE METHOD OF INSPEC- TION, LIFE LIMITS, CYCLE LIMITS, ETC., FOR SUCH NON-CESSNA PARTS MUST BE OBTAINED FROM THE MANUFACTURER AND/OR SELLER OF SUCH NON- CESSNA PARTS. 1. REVISIONS/CHANGES. These are issued to the Service Stations by Cessna Aircraft Company for this publication as required, and include only pages that require updating. 2. REISSUE. Manual is reissued to Service Stations as required, and is a complete manual incorporating all the latest information and outstanding revisions/changes. It supersedes and replaces previous is- sue(s). REVISIONS/CHANGES and REISSUES can be purchased from your Cessna Service Station or directly from the Cessna Parts Distribution, (CPD 2) Dept. 701, Cessna Aircraft Company, 5800 East Pawnee. Wichita, Kansas 67218. All supplemental service information concerning this manual is supplied to all appropriate Cessna Service Sta- - tions so that they have the latest authoritative recommendations for servicing these Cessna aircraft. Therefore, it is recommended that Cessna owners utilize the knowledge and experience of the Cessna Service Station Or- ganization. Revision 1 iii MODEL 172RG SERVICE MANUAL CUSTOMER CARE SUPPLIES AND PUBLICATIONS CATALOG A Customer Care Supplies and Publications Catalog is available from your Cessna Service Station or directly from the Cessna Parts Distribution, (CPD 2) Dept. 701, Cessna Aircraft Company, 5800 East Pawnee, Wichita, Kansas 67218. The Supplies and Publications catalog lists all publications and Customer Care Supplies avail- able from Cessna for prior year models as well as new products. SUPPLEMENTAL TYPE CERTIFICATE INSTALLATIONS Inspection, maintenance and parts requirements for supplemental type certificate (STC) installations are not in- cluded in this manual. When an STC installation is incorporated on the airplane, those portions of the airplane affected by the installation must be inspected in accordance with the inspection program published by the owner of the STC. Since STC installations may change systems interface, operating characteristics and component loads or stresses on adjacent structures, Cessna provided inspection criteria may not be valid for airplanes with STC installations. CUSTOMER COMMENTS ON MANUAL Cessna Aircraft Company has endeavored to furnish you with an accurate, useful, up-to-date manual. This man- ual can be improved with your help. Please use the return card, provided with your manual, to report any errors, discrepancies, and omissions in this manual as well as any comments you wish to make. Iv Revision 1 MODEL 172RG SERVICE MANUAL SECTION 1 GENERAL DESCRIPTION Page No. TABLE OF CONTENTS Aerofiche Manual GENERAL DESCRIPTION ...... 1A9/1-1 Aircraft Specification ........ 1A9/1-1 Model 172RG ............. 1A9/1-1 Stations ................ 1A9/1-1 Description ............. 1A9/1-1 Bolt Torque ............ 1A12/1-4 1-1. GENERAL DESCRIPTION. 1-2. MODEL 172RG. 1-3. DESCRIPTION. Cessna Model 172RG aircraft are high-wing monoplanes of all-metal semimonocoque construction. These aircraft are equipped with fully retractable tricycle landing gear consisting of tubular spring-steel main gear struts and a steerable nose gear. The steerable nose gear is equipped with an air/hydraulic fluid shock strut. Four-place seating is standard. All are powered by a four-cylinder, horizontally-opposed air-cooled Lycoming engine which drives an all-metal. constant-speed propeller. Model 172RG aircraft feature rear side windows, a "wrap-around" rear window and a swept-back fin and rudder 1-4. AIRCRAFT SPECIFICATIONS. Leading particulars and measurements are based on static gross weight unless otherwise indicated, and are shown in figure 1-1. If these dimensions are used for constructing a hangar or computing clearances, remember that such factors as nose gear strut inflation, tire pressure, tire sizes and load distribution may result in some dimensions that are considerably different from those listed. 1-5. STATIONS. Station diagrams are shown in figure 1-2 to assist in locating equipment when a written description is inadequate or impractical. 1-1 MODEL 172RG SERVICE MANUAL GROSS WEIGHT Takeoff and Landing ............................... 250 Lbs. Ram p ............................................... 2658 Lbs. FUEL CAPACITY Total ................................................................ 66 G al. Usable ....................................................... 62 Gal OIL CAPACITY ....................................................... 8 Quarts With Oil Filter ...................................................... 9 Quarts ENGINE MODEL (Refer to Section 11 for Engine Data) ............................ 0-360-Series Lycoming PROPELLER ..................................................... 76.5 inch Diameter McCauley MAIN WHEELS ....................................................... 15-6.00 x 6.6 Ply Pressure .................................................... ... 6.0 to 68 Psig NOSE WHEELS ....................................................... 5.00 x 5.6 Ply Pressure ............................................................ 40 to 50 Psig Nose Gear Strut Pressure (Strut Extended) ......................... 55 Psig WHEEL ALIGNMENT *Camber .................................. ..................... 3° + 1° Toe-in ............. ................................................ 0° .06-.00 AILERON TRAVEL Up .................. ............................................... 20° ± 1° Down ............................ ............................. 15° ± 10 WING FLAP TRAVEL Up .................................. .................. .......... 0.... 0 Down .............. ....... .......... ....... 30 ° ± 2° RUDDER TRAVEL (Measured Parallel to Water Line) Right......... ............................. .......................... 16 ° 10' ±1 ° Left ................................................................. 6° 10' ±1° RUDDER TRAVEL (Measured Perpendicular to Hinge Line) Right ............................................................. 17 44' 1 Left ................................................................. 170 44' ° ELEVATOR TRAVEL Up ................................................................... 28" 1 ° - 0 Down ............................................................... 23 ° 1° - 0 ELEVATOR TRIM TAB TRAVEL Up.......... .................................................... 22 1 - 0 Down ................................................................ 19° 1° - 0 ° PRINCIPAL DIMENSIONS Length .............................................................. 328.87 Inches Wing Span .......................................................... 429.84 Inches Horizontal Tail Span ............................................... 135.14 Inches Track Width ....................................................... 101.88 Inches Vertical Tail ........................................................ 105.30 Inches BATTERY LOCATION ............................................... Aft of Wheel Well RH Side *Measure At Rim With Aircraft Empty Figure 1-1. Specifications. 1-2 MODEL 172RG SERVICE MANUAL 22.875 85.875 100.50 Figure 1-2. Reference Stations MODEL 172RG SERVICE MANUAL 1-6. BOLT TORQUES. The importance of correct application cannot be overemphasized. Under- torque can result in unnecessary wear of nuts and bolts as well as parts they are holding to- gether. When insufficient pressures are applied, uneven loads will be transmitted through- out assembly, which may result in excessive wear or premature failure due to fatique. Over- torque can be equally damaging because of failure of a bolt or nut from overstressing threaded areas. There are a few simple, but very important, procedures that should be fol- lowed to assure that correct torque is applied: a. Calibrate torque wrench periodically to assure accuracy: and recheck frequently. b. Be sure that bolt and nut threads are clean and dry unless otherwise specified. a. Run nut down to near contact with washer or bearing surface and check "friction drag torque" required to turn nut. d. Add friction drag torque to desired torque recommended or obtain desired torque as shown in figure 1-3. This is referred to as final torque which should register on indicator or setting for a snapover-type wrench. e. Apply a smooth even pull when applying torque pressure. If chattering or a jerk- ing motion occurs during final torque, back off and re-torque. f. When installing a castle nut, start alignment with cotter pin hole at minimum re- commended torque, plus friction drag torque, and do not exceed maximum plus friction drag. If hole and nut castellation do not align, change washers or nut and try again Exceeding maximum recommended torque is not recommended unless specifically allowed or recommended for that particular installation. 1-4 MODEL 172RG SERVICE MANUAL BOLT TORQUE VALUES BOLTS Steel Tension Steel Tension BOLTS Steel Shear AN3 thru AN20 MS20004 thru MS20024 NAS464 AN42 thru AN49 NAS144 thru NAS148 AN73 thru AN81 NAS333 thru NAS340 AN173 thru AN186 NAS585 thru NAS590 MS20033 thru MS20046 NAS624 thru NAS844 MS20073 NAS1303 thru NAS1320 MS20074 NAS172 AN509NK9 NAS174 MS24694 NAS517 AN625NK525 MS27a39 NUTS NUTS Steel Tension Steel Sheer Steel Tension Steel Shear AN310 AN320 AN310 AN320 AN315 AN384 AN315 AN364 AN383 NAS1022 AN363 NAS1022 AN365 MS17826 AN365 MS17826 NAS1021 MS20384 MS17825 MS20364 MS17825 MS20365 MS21045 MS21045 MS20365 NAS1021 MS20500 NAS679 NAS679 . NAS1291 FINE THREAD SERIES FINE THREAD SERIES Nut-bolt Torque Limits Torque Limits Nut-bolt Torque Limits Torque Limits size in.-lbs. in.-lbs. size in.-lbs. in.-lbs. 8-36 12 15 7 9 10-32 25 30 15 20 10-32 20 25 12 15 1/4-28 80 100 50 60 1/4-28 50 70 30 40 5/16-24 120 145 70 90 5/16-24 100 140 60 85 3/8-24 200 250 120 150 3/8-24 160 190 95 110 7/16-20 520 630 300 400 7/16-20 450 500 270 300 1/2-20 770 950 450 550 1/2-20 480 690 290 410 9/16-18 1100 1300 650 800 9/16-18 800 1000 480 600 5/8-18 1250 1550 750 950 5/8-18 1100 1300 660 780 3/4-16 2650 3200 1600 1900 3/4-16 2300 2500 1300 1500 7/8-14 3550 4350 2100 2600 7/8-14 2500 3000 1500 1800 1-14 4500 5500 2700 3300 1-14 3700 4500 2200 3300 1-1/8-12 6000 7300 3600 4400 1-1/8-12 5000 7000 3000 4200 1-1/4-12 11000 13400 6600 8000 1-1/4-12 9000 11000 5400 6600 COARSE THREAD SERIES Nut-bolt Torque Limits Torque Limits COARSE THREAD SERIES NOT USED size in.-lbs.in.-lbs. fin. MMm 8-32 12 15 7 9 10-24 20 25 12 15 1/420 40 50 25 30 5/16-18 80 90 48 55 3/8-16 160 185 95 110 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 Figure 1-3. Torque Values 1-5/(1-6 blank) MODEL 172RG SERVICE MANUAL SECTION 2 GROUND HANDLING, SERVICING, CLEANING, LUBRICATION AND INSPECTION WARNING When performing any inspection or maintenance that re- quires turning on the master switch, installing a battery, or pulling the propeller through by hand, treat the prop- eller as if the ignition switch were ON. Do not stand, nor allow anyone else to stand, within the arc of the propel- ler, since a loose or broken wire, or a component mal- function, could cause the propeller to rotate. Page No. TABLE OF CONTENTS Aerofiche/ Manual GROUND HANDLING ......... 1A18/2-2 Tires .................... 1B8/2-16 Towing .................. 1A18/2-2 Nose Gear Shock Strut ....... 1B9/2-17 Hoisting ................. 1A21/2-5 ,Shimmy Dampener ......... 1B9/2-17 Jacking .................. 1A21/2-5 Hydraulic Fluid Sampling Leveling ................. 1A21/2-5 and Contamination Check ... 1B10/2-18 Weighing ................ 1A21/2-5 Landing Gear Hydraulic Parking ................. A21/2-5 Retraction System ....... 1.. lB10/2-18 Tie-Down ................ 1A21/2-5 Hydraulic Brake System ..... 1B11/2-19 Flyable Storage ............ 1A22/2-6 CLEANING ................ 1B11/2-19 Returning Aircraft to Service .. 1A22/2-6 General Description ......... 1B11/2-19 Temporary Storage ......... 1A22/2-6 Windshield/Windows ........ 1B11/2-19 nspection During Storage .. 1A24/2-8 Interior Trim .............. 1B11/2-19 Returning Aircraft to Painted Surfaces ........... 1B12/2-20 Service ................ 1A24/2-8 Aluminum Surfaces ........ 1B12/2-20 Indefinite Storage .......... 1A24/2-8 Engine/Engine Compartment .. 1B12/2-20 Inspection During Storage . . 1B1/2-9 Upholstery/Interior ......... 1B14/2-22 Returning Aircraft to Propeller ................. 1B15/2-23 Service ................ 1B2/2-10 Wheels .................. 1B15/2-23 SERVICING ................ 1B2/2-10 LUBRICATION .............. 1B15/2-23 General Description ......... 1B2/2-10 General Description ......... 1B15/2-23 Fuel ............... 1B2/2-10 Tachometer Drive Shaft ...... 1B15/2-23 Fuel Additives ............. 1B2/2-10 Wheel Bearings............ 1B15/2-23 Fuel Drains ............... 1B4/2-12 Nose Gear Torque Links ..... 1B15/2-23 Carburetor Drain Plug Wing Flap Acuator ......... 1B15/2-23 Inspection ................ 1B5/2-13 Rod End Bearings .......... 1B15/2-23 Engine Oil ............... 1B5/2-13 Nose Gear Steering Collar .... 1B16/2-24 Engine Oil Cooler .......... 1B7/2-15 Nose Gear Pivots ........... 1B16/2-24 Engine Induction Air Filter ... 1B7/2-15 Main Gear Pivot Points ...... 1B16/2-24 Vacuum System Filter ....... 1B8/2-16 INSPECTION ............... 1C3/2-35 Battery .................. 1B8/2-16 2-1 MODEL 172RG SERVICE MANUAL 2-1. GROUND HANDLING. 2-2. TOWING. Moving the aircraft by hand is accomplished by using the wing struts and landing gear struts as push points. A tow bar attached to the nose gear should be used for steering and maneuvering the aircraft on the ground. The tow bar is stowed under the rear seat with the handle secured behind the forward seat legs. CAUTION When towing the aircraft, never turn the nose wheel more than 29 degrees either side of center or the nose gear will be damaged. Do not push on control surfaces or outboard empennage surfaces. When pushing on the tailcone. always apply pressure at a bulkhead to avoid buckling the skin. Figure 2-1. Typical Tow Bar 2-2 MODEL 172RG SERVICE MANUAL NOTE Corresponding points on both upper door sills may be used to level the aircraft laterally. Reference points for longitudinal leveling of aircraft are two nutplates (5) on the left side of the tailcone at sta- tions 108.62 and 140.63. Figure 2-2. Jacking and Leveling (Sheet 1 of 2) 2-3 MODEL 172RG SERVICE MANUAL JACKING INFORMATION ITEM TYPE AND NUMBER REMARKS 1 Block (Jack points are available) 1 x4x4 padded with 1/4" rubber 2 Cessa No. 2-168 Tail Tie-Down Stand 3 Built-in jack pad Part of step bracket (SEE CAUTION) 4 No. 2-170 Basic jack (includes Min closed height: 34" No. 2-71 Slide tube Liftstroke 22-1/2") Ma. extension height: 56-1/2" No. 2-70 Slide tube Liftstroke 22-1/2" Min closed height: 57-1/2" Max. extension height: 80" No. 2-591 Extension cap Adds 4" No. 2-109 Leg extension Adds 12" 1. Wing jacks (4) are placed under front spar of wing at station 99.62, using the jack points or blocks and must be extended far enough to raise wheels off ground, and must be of adequate strength. 2. Be sure tail stand weighs enough to keep tail down under all conditions and that it is strong enough to support any weight that might be placed on it (place shot bags or sand bags on tail stand). In addition the base of adjustable tail stand is to be filled with concrete for additional weight as a safety factor. 3. Operate jacks evenly until desired height is reached. 4. Items 2 and 3 are available from the Cessna Supply Division. Figure 2-2. Jacking and Leveling (Sheet 2 of 2) 2-4 MODEL 172RG SERVICE MANUAL 2-3. HOISTING. The aircraft may be lifted with a hoist of two-ton capacity by using hoisting rings, which are optional equipment, or by means of suitable slings. The front sling should be hooked to each upper engine mount at the firewall, and the aft sling should be positioned around the fuselage at the first bulkhead forward of the leading edge of the stabilizer. If the optional hoisting rings are used, a minimum cable length of 60 inches for each cable is required to prevent bending of the eyebolt-type hoistingrings. If desired. a spreader jig may be fabricated to apply vertical force to the eyebolts. 2-4. JACKING. See figure 2-2 for jacking procedures. 2-5. LEVELING. Corresponding points on both upper door sills may be used to level the aircraft laterally. Leveling point nutplates are provided on the left side of the tailcone at Sta. 108.62 and 140.83. Use these points for leveling the aircraft by removing the screws and installing suitable studs to support a level. 2-6. WEIGHING. Refer to Plot's Operating Handbook. 2-7. PARKING. Parking precautions depend principally on local conditions. As a general precaution, set parking brake or chock the wheels and install the controls lock. In severe weather and high wind conditions, tie down the aircraft as outlined in paragraph 2-8 if a hangar is not available. 2-8. TIE-DOWN. When mooring the aircraft in the open, head into the wind if possible. Secure control surfaces with the internal control lock and set brakes. CAUTION Do not set parking brakes when they are overheated or during cold weather when accumulated moisture may freeze them a. Tie ropes, cables, or chains to the wing tie-down fittings located at the upper end of each wing strut. Secure the opposite ends of ropes, cables, or chains to ground anchors. b. Secure a tie-down rope (no chains or cables) to the nose gear strut, and secure opposite end of rope to ground anchor. c. Secure the middle of a rope to the tail tie-down ring. Pull each end of rope away at a degree angle and secure to ground anchors at each side of tail. d. Secure control lock on pilot control column. If control lock is not available, tie pilot control wheel back with front seat belt. e. These aircraft are equipped with a spring-loaded steering bungee which affords protection against normal wind gusts. However, if extremely high wind gusts are anticipated, additional external locks may be installed. 2-5 MODEL 172RG SERVICE MANUAL 2-9. FLYABLE STORAGE. Flyable storage is defined as a maximum of 30 days nonoperational storage and/or the first 25 hours of intermittent engine operation. NOTE The aircraft was delivered from Cessna with MIL-6082 aviation grade straight mineral oil. This engine oil should be used for the first 25 hours of engine operation. If if becomes necessary to add oil during this period, use oil of the recommended viscosity conforming to MIL-L- 6082. During the 30 day nonoperational storage or the first 25 hours of intermittent engine operation, the propeller shall be rotated through five revolutions every seventh day. without running the engine. If the aircraft is stored outside, tie it down in accordance with paragraph 2-8. In addition, the pitot tube, static air vents, air vents, openings in the engine cowling, and other similar openings shall have protective covers installed to prevent entry of foreign material. After 30 days, aircraft should be flown for 30 minutes or ground run-up until oil has reached operating temperature. CAUTION Excessive ground operation shall be avoided. 2-10. RETURNING AIRCRAFT TO SERVICE. After flyable storage, returning the aircraft to service is accomplished by performing a thorough preflight inspection. At the end of the first 25 hours of engine operation, drain engine oil, change external oil filter element, and service engine with correct grade and quantity of engine oil See figure 2-4 and paragraph 2- 22. for correct grade of engine oil. 2-1l. TEMPORARY STORAGE. Temporary storage is defined as aircraft in a nonoperational status for a maximum of 90 days. The aircraft is constructed of corrosion resistant alclad aluminum, which will last indefinitely under normal conditions if kept clean, however. these alloys are subject to oxidation. The first indication of corrosion on unpainted surfaces is in the form of white deposits or spots. On painted surfaces, the paint is discolored or blistered. Storage in a dry hangar is essential to good preservation and should be procured. if possible. Varying conditions will alter the measures of preservation, but under normal conditions in a dry hangar, and for storage periods not to exceed 90 days. the following methods of treatment are suggested. a. Fill fuel bays with the correct grade of aviation fuel. b. Clean and wax aircraft thoroughly. c. Clean any oil or grease from tires and coat tires with a tire preservative. Cover tires to protect against grease and oil. d. Either block up fuselage to relieve pressure on tires or rotate wheels every 30 days to prevent flat spotting the tires. e. Lubricate all airframe items and seal or cover all openings which could allow moisture and/or dust to enter. 2-6 MODEL 172RG SERVICE MANUAL NOTE The aircraft battery serial number is recorded in the aircraft equipment list. To assure accurate warranty records, the battery should be reinstalled in the same aircraft from which it was removed. If the battery is returned to service in a different aircraft, appropriate record changes must be made and notification sent to the Cessna Claims Department. f. Remove battery and store in a cool, dry place: service battery periodically and charge as required. NOTE An engine treated in accordance with the following may be considered being protected against normal atmos- pheric corrosion for a period not to exceed 90 days. g. Disconnect spark plug leads and remove upper and lower spark plugs from each cylinder. NOTE Corrosion-preventive mixture should conform to MIL-L- 6529C Type I heated to 220°F to 250°F spray nozzle temperature. h. Using a portable pressure sprayer, atomize spray preservative oil through the upper spark plug hole in each cylinder with the piston in a down position. Rotate crankshaft about five revolutions as each cylinder is sprayed. i. After completing step "h," rotate crankshaft so that no piston is at a top position. If the aircraft is to be stored outside, stop propeller so that blades are as near horizontal as possible to provide maximum clearance for passing aircraft. j. Again, spray each cylinder without moving the crankshaft, to thoroughly cover all interior surfaces of the cylinder above the piston. k. Install spark plugs and connect spark plug leads. 1. Apply preservative oil to the engine interior by spraying approximately two ounces of the preservative oil through the oil filler tube. m. Seal all engine openings exposed to the atmosphere, using suitable plugs or non- hygroscopic tape. Attach a red streamer at each point that a plug or tape is installed. n. If the aircraft is to be stored outside, perform the procedures in paragraph 2-8. In addition, the pitot tube, static source vents, air vents, openings in the engine cowling, and other sinilar openings should have protective covers installed to prevent entry of foreign material. o. Attach a warning placard to the propeller to the effect that the propeller shall not be moved while the engine is in storage. 2-7 MODEL 172RG SERVICE MANUAL 2-12. INSPECTION DURING STORAGE. a. Inspect airframe for corrosion at least once a month. Remove dust collections as frequently as possible. Clean and wax aircraft as required. b. Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once each month. NOTE Do not move crankshaft when inspecting interior of cylinder for corrosion. c. If at the end of the 90 day period, the aircraft is to be continued in non-operational storage, repeat the procedural steps "g" thru "o" of paragraph 2-11. 2-13. RETURNING AIRCRAFT TO SERVICE. After temporary storage, use the following procedures to return the aircraft to service. a. Remove aircraft from blocks. Check tires for proper inflation. b. Check and install battery. c. Check that oil sump has proper grade and quantity of engine oil. d. Service induction air filter and remove warning placard from propeller. e. Remove materials used to cover openings. f. Remove, clean and gap spark plugs. g. While spark plugs are removed, rotate propeller several revolutions to clear excess rust preventive oil from cylinders. h. Install spark plugs and torque to value specified in Section 11. Connect spark plug leads. i. Check fuel strainer. Remove and clean filter screen. if necessary. Check fuel bays and fuel lines for moisture and sediment. Drain enough fuel to eliminate moisture and sediment. j. Perform a thorough preflight inspection. then start and warmup engine. 2-14. INDEFINITE STORAGE. Indefinite Storage is defined as aircraft in a nonoperational status for an indefinite period of time. Engines treated in accordance with the following may be considered protected against normal atmosphere corrosion, provided the procedures outlined in paragraph 2-15 are performed at the intervals specified. a. Operate engine until oil temperature reaches normal operating range. Drain engine oil sump in accordance with procedures outlined in paragraph 2-22. b. Fill oil sump to normal operating capacity with corrosion preventive mixture which' has been thoroughly mixed. NOTE Corrosion-preventive mixture consists of one part by volume MIL-C-6529C. type I. added to three parts by volume of MIL-L-6082C mineral aircraft engine oil. c. Immediately after filling the oil sump with a corrosion preventive mixture, fly the aircraft for a period of time not to exceed a maximum of 30 minutes. d. After flight, with engine operating at 1200 to 1500 RPM. and induction air filter removed, spray corrosion preventive mixture into induction airbox. at the rate of one-half gallon per minute. Spray until heavy black smoke comes from exhaust stack. Then increase the spray until engine is stopped. 2-8 MODEL 172RG SERVICE MANUAL CAUTION Spraying the mixture too fast can cause a hydrostatic lock. e. Do not rotate propeller after completing step "d." f. Remove all spark plugs and spray corrosion preventive mixture, which has been preheated to 220°F to 250°F, into all spark plug holes to thoroughly cover interior surfaces of cylinders. g. Install spark plugs or solid plugs into the lower spark plug holes and install dehydrator plugs in the upper spark plug holes. Be sure that dehydrator plugs are blue in color when installed. h. Cover spark plug lead terminals with shipping plugs (AN4060-1), or other suitable covers. i. With throttle in full open position, place a bag of desiccant in the induction air intake and seal opening with moisture resistant paper and tape. j. Place a bag of desiccant in the exhaust tailpipe and seal openings with moisture resistant tape. k. Seal cold air inlet to the heater muff with moisture resistant tape. 1. Seal engine breather hose and clamping in place. m. Seal all other engine openings exposed to atmosphere, using suitable plugs or non- hygroscopic tape. NOTE Attach a red streamer to each location where plugs or tapes are installed. Either attach red streamers outside the sealed area with tape or to the inside of the sealed area with safety wire to prevent wicking of moisture into the sealed area. n. Drain corrosion-preventive mixture from engine sump in accordance with the procedures outlined in paragraph 2-22. The corrosion-preventive mixture is harmful to paint and should be wiped from painted surfaces immediately. o. Attach a warning placard on the throttle control knob, to the effect that the engine contains no lubricating oil. Placard the propeller to the effect that it should not be moved while the engine is in storage. p. Prepare airframe for storage as outlined in paragraph 2-11 thru step "f". NOTE As an alternate method of indefinite storage, the aircraft may be serviced in accordance with paragraph 2-11 providing the aircraft is runup at maximum intervals of 90 days and then reserviced per paragraph 2-11. 2-15. INSPECTION DURING STORAGE. Aircraft in indefinite storage shall be inspected as follows: a. Inspect cylinder protex plugs each seven days. b. Change protex plugs if their color indicates an unsafe condition. c. If the protex plugs have changed color in one half of the cylinders, all desiccant material in the engine should be replaced with new material. d. Respray the cylinder interiors with corrosion preventive mixture every six months. 2-9 MODEL 172RG SERVICE MANUAL NOTE Before spraying, inspect the interior of one cylinder for corrosion through the spark plug hole and remove at lease one rocker box cover and inspect the valve mecha- nism. 2-16. RETURNING AIRCRAFT TO SERVICE. After indefinite storage. use the following proce- dure to return the aircraft to service. a. Remove aircraft from blocks. Check tires for correct inflation. b. Check and install battery . c. Remove all materials used to seal and cover openings. d. Remove warning placards posted at throttle and propeller. e. Drain engine oil sump in accordance with the procedures outlined in paragraph 2-22. f. Change engine oil filter. Service engine with oil in accordance with figure 2-5 of this manual. g. Install the induction air filter. NOTE The corrosion preventive mixture will mix with the engine lubricating oil. so flushing the oil system is not necessary. Draining the oil sump will remove enough of the corrosion preventive mixture. h. Remove protex plugs and spark plugs or plugs installed in spark plugs holes. Rotate propeller several revolutions by hand to clear corrosion preventive mixture from cylinders. i. Clean, gap and install spark plugs. Torque spark plugs to value specified in Section 11. Connect leads. j. Check fuel strainer. Remove and clean filter screen. Check fuel bays and fuel lines for moisture and sediment, and drain enough fuel to eliminate. k. Perform a thorough preflight inspection. then start and warm-up engine. 1. Thoroughly clean and flight test aircraft. 2-17. SERVICING. 2-18. GENERAL DESCRIPTION. Servicing requirements are shown in figure 2-5. The following paragraphs supplement this figure by adding details not included in the figure. 2-19. FUEL. Fuel bays should be filled immediately after flight to lessen moisture condensation. Bay capacities are listed in Section 1. The recommended fuel grade to be used is given in figure 2-5. 2-20. USE OF FUEL ADDITIVES FOR COLD WEATHER OPERATION. Strict adherence to recommended preflight draining instructions will eliminate any free water accumulations from the tank sumps. While small amounts of water may still remain in solution in the gasoline, it will normally be consumed and go unnoticed in the operation of the engine. One exception to this can be encountered when operating under the combined effect of: (1) use of certain fuels, with (2) high humidity conditions on the ground (3) followed by flight at high altitude and low temperature. Under these unusual conditions, small amounts of water 2-10 MODEL 172RG SERVICE MANUAL in solution can precipitate from the fuel stream and freeze in sufficient quantities to induce partial icing of the engine fuel system. While these conditions are quite rare and will not normally pose a problem to owners and operators, they do exist in certain areas of the world and consequently must be dealt with. when encountered. Therefore, to alleviate the possibility of fuel icing occuring under these unusual conditions it is permissible to add isopropyl alcohol or ethylene glycol monomethyl ether (EGME) compound to the fuel supply. See Figure 2-3 for fuel additive mixing ratio. The introduction of alcohol or EGME compound into the fuel provides two distinct effects: (1) it absorbs the dissolved water from the gasoline and (2) alcohol has a freezing temperature depressant effect. Alcohol, if used, is to be blended with the fuel in a concentration of 1% by volume. Concentrations greater than 1% are not recommended since they can be detrimental to fuel tank materials. The manner in which the alcohol is added to the fuel is significant because alcohol is most effective when it is completely dissolved in the fuel. To insure proper mixing the following is recommended 1. For best results the alcohol should be added during the fueling operation by pouring the alcohol directly on the fuel stream issuing from the fueling nozzle. 2. An alternate method that may be used is to premix the complete alcohol dosage with some fuel in a separate clean container (approximately 2-3 gallon capacity) and then transfer this mixture to the tank prior to the fuel operation. Any high quality isopropyl alcohol may be used, such as: Anti-icing fluid (MIL-F-5566) or Isopropyl alcohol (Federal Specification TT-I-735a). Ethylene glycol monomethyl ether (EGME) compound in compliance with MIL-I-27686 or Phillips PFA-55MB, if used, must be carefully mixed with the fuel in concentrations not to exceed 0.15% by volume. CAUTION Mixing of the EGME compound with the fuel is extremely important because concentration in excess of that recom- mended (0.15 percent by volume maximum) will result in detrimental affects to the fuel tanks, such as deterioration of protective primer and sealants and damage to 0-rings and seals in the fuel system and engine components. Use only blending equipment that is recommended by the manufacturer to obtain proper proportioning. Do not allow the concentrated EGME compound to come in contact with the airplane finish or fuel cell as damage can result. 2-11 MODEL 172RG SERVICE MANUAL Prolonged storage of the airplane will result in a water build-up in the fuel which "leeches out" the additive. An indication of this is when an excessive amount of water accumulates in the fuel tank sumps. The concentration can be checked using a differential refractometer. It is imperative that the technical manual for the differential refractometer be followed explicitly when checking the additive concentration. Figure 2-3. Fuel Additive Mixing Ratio Chart 2-21. FUEL DRAINS. On aircraft serials 172RG0001 thru 172RG0890, the fuel drains are located in the fuel bays, fuel strainer, fuel selector valve, and carburetor. Drain plugs are installed in the fuel selector valve and carburetor; drain valves are located in the fuel bays and fuel strainer. Beginning with 172RG0891, a drain valve is located in the bottom of the fuel selec- tor valve for sampling and draining of fuel. To activate the drain valves for fuel sampling, place cup up to valve and depress valve with rod protruding from cup. Refer to Section 12 for illustration of fuel bay drain valve. The strainer valve is an integral part of the fuel strainer assembly. The strainer drain is equipped with a control which is located adjacent to the oil dipstick. Access to the control is through the oil dipstick access door. Open drains and remove drain plugs at intervals specified in figure 2-5. Also, during daily inspection of the fuel strainer, fuel selector, and bays, if water is found in the system, all fuel drain plugs should be removed and all water drained from the system. 2-12 MODEL 172RG SERVICE MANUAL * 2-22. CARBURETOR DRAIN PLUG INSPECTION. In order to prevent the possibility of thread sealant contamination in the carburetor float chamber, cleaning and inspection of the carburetor should be accomplished at each 100-hour inspection and any time water in the fuel is suspected. a. With the fuel selector valve OFF, remove carburetor drain plug and clean off any sealant present on the end of the plug or in the threads on the plug. b. Inspect drain plug hole in the carburetor and remove any sealant remaining in the hole. c. Turn fuel selector valve to ON to flush float chamber and drain plug chamber while probing drain plug hole to ascertain that all residue of sealant material is dislodged and washed out of the chamber. Flushing operation should last 15 to 30 seconds. d. A second flushing should then be accomplished and the. drained fuel retained for inspection to insure that no sealant particles are present. e. Install drain plug as follows: 1. Install drain plug in carburetor 1-1/2 to 2 turns. 2. Apply sealant to drain plug threads (use NS-40 (RAS-4) or equivalent). 3. Tighten and safety drain plug. f. Turn fuel selector valve ON and inspect for evidence of fuel leakage. 2-23. ENGINE OIL. Check engine lubricating oil with the dipstick five to ten minutes after the engine has been stopped. The aircraft should be in as near a level position as possible when checking the engine oil, so that a true reading is obtained. Engine oil should be drained while the engine is still hot, and the nose of the aircraft should be raised slightly for more positive draining of any sludge which may have collected in the engine oil sump. Engine oil should be changed every six months, even though less than the specified hours have accumulated. Reduce these intervals for prolonged operations in dusty areas, in cold climates where sludging conditions exist, or where short flights and long idle periods are encountered. 0_ - which cause sludging conditions. Always change oil and oil filter whenever oil on the dipstick appears dirty. Aviation grade oil conforming to AVCO Lycoming Service Instruc- tion No. 1014, and any revisions or supplements thereto, shall be used in the Lycoming engine. NOTE New or newly-overhauled engines should be operated on aviation grade straight mineral oil until the first oil change. If an ashless dispersant oil is used in a new or newly-overhauled engine, high oil consumption may be experienced. The anti-friction additives in detergent and dispersant oils will retard "break-in" of the pistons, rings and cylinder walls. This condition can be avoided by the use of straight mineral oil. The aircraft is delivered from Cessna with MIL-L-6082 mineral oil. If oil must be added during the first 25 hours, use only aviation grade straight mineral oil (non-detergent) conforming to MIL- L-6082. After the first 25 hours of operation, drain en- gine oil sump and change the oil filter. Refill sump with aviation grade straight mineral oil (non-detergent) con- forming to MIL-L-6082 and use until a total of 50 hours have accumulated or oil consumption has stabilized, then change to ashless dispersant oil. 2-13 MODEL 172RG SERVICE MANUAL When changing engine oil. install a new oil filter. An oil quick-drain valve may be installed. This valve provides a quick and cleaner method of draining the engine oil. This valve is installed in the oil drain port of the oil sump. To drain the oil. proceed as follows: a. Operate engine until oil temperature is at normal operating temperature and then shut down. b. (With Quick-Drain Valve) Attach a hose to the quick-drain valve in the oil sump. Push on quick drain valve until it locks open. and allow oil to drain through the hose into the container. c. (Without Quick-Drain Valve) Remove oil drain plug from engine sump and allow oil to drain into a container. d. After engine oil has drained. close quick-drain valve or install and safety drain plug. e. Change external oil filter. f. Service engine with correct quantity and viscosity of aviation grade engine oil NOTE See figure 2-5 for oil and filter change interval. Valve shown open. To close, twist screwdriver until valve unlocks and snaps down to closed position. Figure 2-4. Quick-Drain Valve 2-14 MODEL 172RG SERVICE MANUAL 2-24. ENGINE OIL COOLER. Oil coolers can be a cause of internal engine damage if not properly serviced. Trapped air in the lines and cooler, as a result of draining oil from the oil cooler. can cause oil aeration, which gives insufficient valve train lubrication resulting in premature engine wear. Therefore, anytime oil is drained, for changing or flushing, the following procedures should be used to eliminate trapped air. a. Prior to starting, remove lower spark plugs. If available, the use of an Auxiliary Power Cart is recommended. b. With mixture in idle cut off, and magneto switch on "START", rotate engine with the starter. Rotate engine to stabilize oil pressure, but DO NOT CRANK LONGER THAN THIRTY (30) SECONDS EACH TIME. ALLOW AT LEAST ONE (1) FULL MINUTE BETWEEN CYCLES FOR STARTER MOTOR COOLING. After oil pressure gage stabilizes, crank an additional ten (10) seconds, IF WITHIN THE THIRTY SECONDS LIMIT. c. Repeat this procedure at least four (4) times, but DO NOT EXCEED THIRTY (30) SECONDS "ON" nor ONE (1) MINUTE "OFF" Limitation. d. Reinstall the lower spark plugs. e. Start engine and run at 900 - 1,000 RPM for approximately five (5) minutes. Shut engine down. and check oil level. Add oil as necessary to fill crankcase to full mark on dipstick. Ensure that oil filter is safety wired. 2-25. ENGINE INDUCTION AIR FILTER. The induction air filter keeps dust and dirt from enter- ing the induction system. The value of maintaining the air filter in a good clean condition: can never be overstressed. More engine wear is caused through the use of a dirty or dam- aged air filter than is generally believed. The frequency with which the filter should be re- moved, inspected, and cleaned will be determined primarily by aircraft operating conditions. A good general rule, however, is to remove, inspect and clean the filter at least every 100 hours of engine operating time and more frequently if warranted by operating conditions. Under extremely dusty conditions, daily servicing of the filter is recommended. To service the induction air filter, proceed as follows: a. Remove filter from aircraft. NOTE Use care to prevent damage to filter element when cleaning filter with compressed air. b. Clean filter by blowing with compressed air (not over 100 psi) from direction opposite of normal air flow. Arrows on filter case indicate direction of normal air flow. CAUTION Do not use solvent or cleaning fluids to wash filter. Use only a water and household detergent solution when washing the filter. c. After cleaning as outlined in step "b", the filter may be washed, if necessary, in a solution of warm water and a mild household detergent. A cold water solution may be used. 2-15 MODEL 172RG SERVICE MANUAL NOTE The filter assembly may be cleaned with compressed air a maximum of 30 times or it may be washed a maximum of 20 times. A new filter should be installed after 500 hours of engine operating time or one year. whichever should occur first. However, a new filter should be installed at anytime the existing filter is damaged. A damaged filter may have sharp or broken edges in the filtering panels which would allow unfiltered air to enter the induction system. Any filter that appears doubtful shall have a new filter installed in its place. d. After washing, rinse filter with clear water until rinse water draining from filter is clear. Allow water to drain from filter and dry with compressed air (not over 100 psi). NOTE The filtering panels of the filter may become distorted when wet, but they will return to their original shape when dry. e. Ensure that the air box is clean and the filter and filter gasket are undamaged and serviceable. f. Install filter in air box with gasket on aft face of filter frame pointed in the correct direction. 2-26. VACUUM SYSTEM FILTER. The vacuum system central air filter keeps dust and dirt from entering the vacuum operated instruments. Inspect the filter every 200 hours of operating time for damage. Change central air filter element every 500 hours of operating time and whenever it becomes sufficiently clogged to cause suction gage readings to drop below 4.6 inches of mercury. Also, do not operate the vacuum system with the filter removed, or a vac- uum line disconnected as particles of dust or other foreign matter may enter the system and damage the vacuum-operated instruments. CAUTION Excessive smoking will cause premature filter clogging. 2-27. BATTERY. Battery servicing involves adding distilled water to maintain the electrolyte even with the horizontal baffle plate at the bottom of the filler holes, checking the battery cable connections, and neutralizing and cleaning spilled electrolyte or corrosion. Use bicarbonate of soda (baking soda) and water to neutralize electrolyte or corrosion. Follow with a thorough flushing with water. Brighten cables and terminals with a wire brush, then coat with petroleum jelly before connecting. Distilled water, not acid or "rejuvenators". should be used to maintain electrolyte level. Check the battery every 50 hours (or at least every 30 days), more often in hot weather. See Section 16 for detailed battery removal. installation and testing. Refer to Service Letter SE80-4 for information concerning proper charging and servicing of 24 volt lead acid batteries, currently used in 1978 and 1979 models of Cessna Single Engine Aircraft; 2-28. TIRES. Maintain tire pressure at the pressure specified in figure 1-1. When checking tire pressure, examine tires for wear. cuts, bruises, and slippage. Remove oil, grease. and mud from tires with soap and water. 2-16 MODEL 172RG SERVICE MANUAL NOTE Recommended tire pressures should be maintained. Especially in cold weather, remember that any drop in temperature of the air inside a tire causes a correspond- ing drop in air pressure. 2-29. NOSE GEAR SHOCK STRUT. The nose gear shock strut requires periodic checking to ensure that the strut is filled with hydraulic fluid and is inflated to the correct air pressure. To service the nose gear shock strut, proceed as follows: a Remove valve core and fully compress strut. (Fork and outer barrel in contact.) b. Remove upper filler plug. c. Extend strut one inch, fill to overflow with MIL-H-5606 Hydraulic fluid and replace filler plug. d. Compress strut. If strut compresses fully, repeat operation "c" and "d" until strut will no longer compress fully. e. Remove filler plug, compress strut fully and allow fluid to overflow. f. Replace filler plug and valve core. g. With no load on strut inflate to 55 PSI. NOTE The nose landing gear shock strut will normally require only -a minimum amount of service. Maintain the strut extension air pressure shown in figure 1-1. Lubricate landing gear as shown in figure 2-6. Check landing gear daily for general cleanliness, security of mounting. and for hydraulic fluid leakage. Keep machined surface of strut barrel wiped free of dirt and dust, using a clean, lint- free cloth moistened with hydraulic fluid (MIL-H-5606) or kerosene. All surfaces should be wiped free of excess hydraulic fluid or kerosene. Leave a light film of fluid on the machine surface of the strut barrel. 2-30. SHIMMY DAMPENER. The shimmy dampener contains a compensating mechanism within the hollow piston rod for thermal expansion and contraction of the hydraulic fluid. The shimmy dampener must be filled completely with fluid, free of entrapped air. to serve its purpose. In addition, the piston rod must also be partially full of fluid before the temperature compensating mechanism will function properly. It should be noted that the fluid is under pressure exerted against the floating piston by a spring, and that loosening or removing the filler plug will cause loss of fluid and necessitate removal and refilling of the shimmy dampener and piston rod. NOTE The shimmy dampener should be checked at each 50-hour inspection to see if it should be serviced. 2-17 MODEL 172RG SERVICE MANUAL Use the following procedure to fill the shimmy dampener. a. Using the tow bar, turn the nose wheel strut to the extreme right position against the stop. This will place the shimmy dampener piston to the rear of the cylinder and eliminate the possibility of trapping air in the cylinder. b. Remove the filler plug and fill with hydraulic fluid. c. Replace filler plug and turn nose wheel strut through its entire travel several times. d. Return strut to the extreme right position against the stop. e. Remove filler plug and add whatever fluid is needed to fill the cylinder. f. Replace and safety the filler plug. NOTE Keep shimmy dampener, especially the exposed portions of the dampener piston shaft, clean to prevent collection of dust and grit which could cut the seals in the dampener barrel Keep machined surfaces wiped free of dirt and dust, using a clean lint-free cloth saturated with hydrau- lic fluid (MIL-H-5606) or kerosene. All surfaces should be wiped free of excessive hydraulic fluid. 2-31. HYDRAULIC FLUID SAMPLING AND CONTAMINATION CHECK. At the first 50 and first 100-hour inspection and thereafter at each 500-hour inspection or one year. whichever should occur first, a sample of fluid should be taken and examined for sediment and discoloration. This may be done as follows: a. Place aircraft master switch in OFF position and place aircraft on jacks as shown in figure 2-2. Bleed pressure from system by moving landing gear selector handle to a neutral position, after 15 seconds. return gear selector handle to the DOWN position. CAUTION Do not turn master switch ON while hydraulic system is open to atmosphere. The pump will automatically start, causing hydraulic fluid to spray from any open line. b. Remove cap plug from tee fitting on right hand side of power pack and place a non- metal container below opening. c. Operate emergency hand pump to pump fluid into container. d. If the drain fluid is clear and is not appreciably darker in color than new fluid. continue to use the present fluid. e. If the fluid color is doubtful, place fluid sample in a non-metallic container and insert a strip of polished copper in the fluid. f. Keep copper in the fluid for six hours at a temperature of 70°F or more. A slight darkening of the copper is permissible, but there should be no pitting or etching visible up to 20X magnification. If pitting or etching is evident, drain fluid from power pack reservoir. Fill power pack with MIL-H-5606 hydraulic fluid and bleed air from system. 2-32. LANDING GEAR HYDRAULIC RETRACTION SYSTEM. Draining, filling and bleeding of the landing gear hydraulic retraction system can be accomplished by the following method. a. Place aircraft master switch in OFF position and place aircraft on jacks as shown in figure 2-2. Bleed pressure from system by moving landing gear selector handle to a neutral position, after 15 seconds, return gear selector handle to the DOWN position. 2-18 MODEL 172RG SERVICE MANUAL CAUTION Do not turn master switch ON while hydraulic system is open to atmosphere. The pump will automatically start, causing hydraulic fluid to spray from any open line. b. Drain system by removing cap plug from tee fitting on right hand side of power pack and attaching a drain hose to opening. Place end of hose in a container of at least one gallon capaity and using emergency hand pump, pump fluid into container. When power pack reservoir is empty, replace cap plug on tee fitting. c. Fill power pack reservoir with MIL-H-5606 hydraulic fluid by inserting funnel or filler hose in dipstick opening on top of power pack body. d. Bleed system by cycling landing gear through several cycles. Refill power pack reservoir with MIL-H-5606 hydraulic fluid and remove aircraft from jacks. 2-33. HYDRAULIC BRAKE SYSTEMS. Check brake master cylinders and refill with MIL-H-5606 hydraulic fluid as required every 200 hours. Bleed the brake system of entrapped air whenever there is a spongy response to the brake pedals. Refer to Section 5 for filling and bleeding of the brake systems. 2-34. CLEANING. 2-35. GENERAL DESCRIPTION. Keeping the aircraft clean is important. Besides maintaining the trim appearance of the aircraft, cleaning lessens the possiblity of corrosion and makes inspection and maintenance easier. . 2-36. WINDSHIELD AND WINDOWS. Windshield and windows should be cleaned carefully with plenty of fresh water and a mild detergent, using the palm of the hand to feel and dislodge any caked dirt or mud. A sponge, soft cloth or chamois may be used, but only as a means of carrying water to the plastic. Rinse thoroughly, then dry with a clean moist chamois. Do not rub the plastic with a dry cloth as this builds up an electrostatic charge which attracts dust. Oil and grease may be removed by rubbing lightly with a soft cloth moistened with Stoddard solvent. CAUTION Do not use gasoline, alcohol, benzene, acetone, carbon tetrachloride, fire extinguisher fluid. de-icer fluid, lac- quer thinner, or glass window cleaning spray. These solvents will soften and craze the plastic. After washing, the plastic windshield and windows should be cleaned with an aircraft windshield cleaner. Apply the cleaner with soft cloths and rub with moderate pressure. Allow the cleaner to dry, then wipe it off with soft flannel cloths. A thin, even coat of wax, polished out by hand with soft flannel cloths, will fill in minor scratches and help prevent further scratching. Do not use a canvas cover on the windshield or windows unless freezing rain or sleet is anticipated since the cover may scratch the plastic surface. 2-37. INTERIOR TRIM. The instrument panel, interior plastic trim, and control knobs need only be wiped with a damp cloth. Oil and grease on the control wheels and control knobs can be removed with a cloth moistened with Stoddard solvent. Volatile solvents, mentioned in the caution note of paragraph 2-36, must never be used since they soften and craze the plastic trim. 2-19 MODEL 172RG SERVICE MANUAL 2-38. PAINTED SURFACES.The painted exterior surfaces of your new Cessna have a durable, long lasting finish. Approximately 10 days are required for the paint to cure completely; in most cases, the curing period will have been completed prior to delivery of the airplane. In the event that polishing or buffing is required within the curing period, it is recommended that the work be done by someone experienced in handling uncured paint. Any Cessna Dealer can accomplish this work. Generally, the painted surfaces can be kept bright by washing with water and mild soap, fol- lowed by a rinse with water and drying with cloths or a chamois. Harsh or abrasive soaps or detergents which cause corrosion or scratches should never be used. Remove stubborn oil and grease with a cloth moistened with Stoddard solvent. To seal any minor surface chips or scratches and protect against corrosion, the airplane should be waxed regularly with a good automotive wax applied in accordance with the man- ufacturer's instructions. If the airplane is operated in a seacoast or other salt water environ- ment, it must be washed and waxed more frequently to assure adequate protection. Special care should be taken to seal around rivet heads and skin laps, which are the areas most sus- ceptible to corrosion. A heavier coating of wax on the leading edges of the wings and tail and on the cowl nose cap and propeller spinner will help reduce the abrasion encountered in these areas. Reapplication of wax will generally be necessary after cleaning with soap solu- tions or after chemical de-icing operations. 2-39. ALUMINUM SURFACES. The aluminum surfaces require a minimum of. care, but should never be neglected. The aircraft may be washed with clean water to remove dirt and may be washed with nonalkaline grease solvents to remove oil and/or grease. Household type deter- gent soap powders are effective cleaners, but should be used cautiously since some of them are strongly alkaline. Many good aluminum cleaners, polishes and waxes are available from commercial suppliers of aircraft products. 2-40. ENGINE AND ENGINE COMPARTMENT. An engine and accessories wash-down should be accomplished during each 100-hour inspection to remove oil, grease, salt corrosion or other residue that might conceal component defects during inspection. Also, periodic cleaning can be very effective in preventive maintenance. Precautions should be taken when working with cleaning agents such as wearing of rubber gloves, an apron or coveralls and a face shield or goggles. Use the least toxic of available cleaning agents that will satisfactorily accomplish the work. These cleaning agents include: (1) Stoddard Solvent (Specification P-D-680 type II), (2) A water alkaline detergent cleaner (MIL-C-25769J) mixed, 1 part cleaner, 2 to 3 parts water and 8 to 12 parts Stoddard solvent or (3) A solvent base emulsion cleaner (MIL-C-4361B) mixed 1 part cleaner and 3 parts Stod- dard solvent. 2-20 MODEL 172RG SERVICE MANUAL CAUTION Do not use gasoline or other highly flammable sub- stances for wash down. Perform all cleaning operations in well ventilated work areas and ensure that adequate fire- fighting and safety equipment is available. Do not smoke or expose a flame, within 100 feet of the cleaning area. Compressed air, used for cleaning agent, application or drying , should be regulated to the lowest practical pressure. Use of a stiff bristle brush rather than a steel brush is recommended if cleaning agents do not remove excess grease and grime during spraying. A recommended procedure for cleaning an engine and accessories is as follows: CAUTION Do not attempt to wash an engine which is still hot or running. Allow the engine to cool before cleaning. a. Remove engine cowling. b. Carefully cover the coupling area between the vacuum pump and the engine drive shaft so that no cleaning solvent can reach the coupling or seal. c. Cover the open end of the vacuum discharge tube. d. Cover the vacuum relief valve filter, if installed in the engine compartment. e. Use fresh water for wash-down when the engine is contaminated with salt or corro- sive chemicals. A cleaning agent such as described previously may then be used. to remove oil and grime. CAUTION Care should be exercised to not direct cleaning agents or water streams at openings on the starter, magnetos, al- ternator or vacuum pump. f. Thoroughly rinse with clean warm water to remove all traces of cleaning agents. CAUTION Cleaning agents should never be left on engine compo- nents for an extended period of time. Failure to remove them may cause damage to components such as neoprene seals and silicone fire sleeves, and could cause additional corrosion. 2-21 MODEL 172RG SERVICE MANUAL g. Completely dry engine and accessories using clean, dry compressed air. h. Remove the cover over the coupling area i. Remove the cover from the vacuum discharge tube. j. Remove the cover from the vacuum relief valve filter, if installed. k. If desired, engine cowling may be washed with the same cleaning agents, then rinsed thoroughly and wiped dry. After cleaning engine, relubricate all control arms and moving parts as required. L Reinstall engine cowling. WARNING For maximum safety, check that the magneto switches are OFF, the throttle is closed, the mixture control is in the idle cut-off position, and the airplane is secured be- fore rotating the propeller by hnd. Do not stand within the arc of the propeller blades while turning the propel- ler. m. Before starting engine, rotate the propeller by hand no less than four complete revo- lutions. 2-41. UPHOLSTERY AND INTERIOR cleaning prolongs the life of upholstery fabrics and interior trim. To clean the interior, proceed as follows:. a. Empty all ash trays and refuse containers. b. Brush or vacuum clean the upholstery and carpet to remove dust and dirt. c. Wipe leather and plastic trim with a damp cloth. d. Soiled upholstery fabrics and carpet may be cleaned with a foam-type detergent used according to manufacturer's instructions. e. Oil spots and stains may be cleaned with household spot removers, used sparingly. Before using any solvent. read the instructions on the container and test it on an obscure place in the fabric to be cleaned. Never saturate the fabric with volatile solvent; it may damage the padding and backing material f. Scrape sticky material from fabric with a dull knife, then spot clean the area. NOTE Repair kits are available for the repair of cracks in ABS, PBC, PVCP, graphite and fiberglass material (Cessna Supply Division, P.O. Box 949, Wichita, KS 67201, 316/ 685-9111, Telex 417-489.) 2-22 MODEL 172RG SERVICE MANUAL 2-42. PROPELLER. The propeller should be wiped occasionally with an oily cloth to remove grass and bug stains. In salt water areas this will assist in corrosion proofing the propeller. 2-43. WHEELS. The wheels should be washed periodically and examined for corrosion. chipped paint, and cracks or dents in the wheel halves or in the flanges or hubs. If defects are found. remove and repair in accordance with Section 5. Discard cracked wheel halves, flanges or hubs and install new parts. 2-44. LUBRICATION. WARNING Thoroughly wash used oil off skin as soon as possible with soap and water. A waterless hand cleaner can be used when soap and water are not available. Apply skin cream after using waterless hand cleaner. 2-45. GENERAL DESCRIPTION. Lubrication requirements are shown in figure 2-6. Before adding lubricant to a fitting, wipe fitting free of dirt. Lubricate until grease appears around part being lubricated, and wipe excess grease from parts. The following paragraphs supplement figure 2-6 by adding details not shown in the figure. 2-46. TACHOMETER DRIVE SHAFT. Refer to Section 15. 2-47. WHEEL BEARINGS. Clean and repack the wheel bearings at the first 100-hour inspection and at each 500-hour inspection thereafter. If more than the usual number of takeoffs and landings are made. extensive taxiing is required, or the aircraft is operated in dusty areas or under seacoast conditions, cleaning and lubrication of the wheel bearings shall be accomp- lished at each 100-hour inspection. 2-48. NOSE GEAR TORQUE LINKS. Lubricate nose gear torque links every 50 hours. When operating from a dirt strip or in extremely dusty areas. more frequent lubrication of the torque links is required. 2-49. WING FLAP ACTUATOR. Clean and lubricate wing flap actuator jack screw each 100 hours as follows: a. Expose jack screw by operating flaps to full down position. b. Clean jack screw threads with solvent rag and dry with compressed air. NOTE It is not necessary to remove actuator from aircraft to clean or lubricate threads. c. With oil can, apply light coat of No. 10 weight non-detergent oil to threads of jack screw. 2-50. ROD END BEARINGS. Periodic inspection and lubrication is required to prevent corrosion of the bearing in the rod end. At each 100-hour inspection. disconnect the control rods at the aileron, flap and nose gear steering bungee. and inspect each rod end for corrosion. If no corrosion is found, wipe the surface of the rod end balls with general purpose oil and rotate ball freely to distribute the oil over its entire surface and connect the control rods to their respective units. If corrosion is detected during the inspection, install new rod ends. 2-23 MODEL 172RG SERVICE MANUAL 2-51. NOSE GEAR STEERING COLLAR. Lubricate nose gear steering collar spindle links at each 100-hour inspection. 2-52. NOSE GEAR PIVOTS. Lubricate all nose gear pivot points at each 100-hour inspection. including the drag link pivot points. More frequent lubrication may be required when operating in dusty areas. 2-53. MAIN GEAR PIVOT POINTS. Lubricate main landing gearpivot assembly at each 500-hour inspection. If more than the usual number of takeoffs and landings are made, lubrication of the pivot assembly should be accomplished at each 100-hour inspection. 2-24 MODEL 172RG SERVICE MANUAL MODEL 172RG SERVICE MANUAL HYDRAULIC FLUID: SPEC. NO. MIL-H-5606 SPECIFIED AVIATION GRADE FUELS: WARNING ONLY AVIATION GRADE FUELS ARE APPROVED FOR USE. ENGINE MODEL LYCOMING 0-360-F1A6 APPROVED FUEL GRADES 100LL (blue) 100 (formerly 100/130. green) NOTE 1. Compliance with Avco Lycoming Service Instruction No. 1070K, and all revisions thereto, must be accomplished. SPECIFIED AVIATION GRADE OIL: AVERAGE AMBIENT TEMPERATURE (°F)/OIL GRADE MAXIMUM OIL INLET TEMPERATURE 0° 10 ° 20 ° 30 40 ° 50 60 70 80 90 TEMPERATURE OF "-SAE 40 OR SAE 50 - 245 NOTE The overlap of oil grades is based on a mid-range of ambient ground temperatures vs. maximum oil inlet temperature. Aviation Grade ashless dispersant oil conforming to Avco Lycoming Service Instruction No. 1014 and all revisions and supplements thereto. MUST BE USED except as noted in paragraph 2-23. CAPACITY EXTENDED NORMAL MINIMUM (TOTAL) FLIGHT OPERATION FOR FLIGHT 9 8 7 5 Figure 2-5. Servicing (Sheet 2 of 4) 2-26 MODEL 172RG SERVICE MANUAL * DAILY 3 FUEL BAYS: Service after each flight. Keep full to retard condensation. Refer to paragraph 2-21. 10 FUEL SELECTOR VALVE DRAIN: Drain off any water or sediment. Refer to paragraph 2-21. 6 FUEL BAY SUMP DRAINS: Drain off any water and sediment before first flight of the day. 18 FUEL STRAINER Drain off any water and sediment before first flight of the day. 17 OIL DIPSTICK: Check on preflight. Add oil as necessary. Refer to paragraph 2-23 for details. Check that filler cap is tight and secure. 8 PITOT AND STATIC PORTS: Check for obstructions before first flight of the day. 14 NOSE GEAR SHOCK STRUT: Check on preflight Check inner barrel showing below outer barrel to be approximately two inches. Deviation from these dimensions is cause to check and service strut per paragraph 2-29. 25HOURS 17 ENGINE OIL SYSTEM: FIRST 25 HOURS Refill with straight mineral oil. non-detergent, and use until a total of 50 hours have accumulated or oil consumption has stabilized, then change to ashless dispersant oil. Refer to paragraph 2-23. 5 HYDRAULIC POWER PACK: Check fluid level. and after a gear extension-which uses the hydraulic hand pump. -50 HOURS 16 INDUCTION AIR FILTER: Clean filter per paragraph 2-25. Replace as required. 1 BATTERY: Check electrolyte level and clean battery each 50 hours or each 30 days. 15 SHIMMY DAMPENER: Check fluid level and refill as required in accordance with paragraph 2-30. 9 TIRES: Maintain correct tire inflation as listed in figure 1-1. Refer to paragraph 2-28. 14 NOSE GEAR SHOCK STRUT: Keep strut filled and inflated to correct pressure. Refer to paragraph 2-29. Figure 2-5. Servicing (Sheet 3 of 4) 2-27 MODEL 172RG SERVICE MANUAL 50 HOURS (Cont.) 10 FUEL SELECTOR VALVE DRAIN: Drain off any water or sediment. Refer to paragraph 2-21. 5 HYDRAULIC FLUID RESERVOIR: At first 50 and first 100 hours, thereafter at each 500 hours or one year. whichever comes first, a sample of hydraulic fluid should be examined for sediment and discoloration as outlined in paragraph 2-31. 100 HOURS 12 CARBURETOR DRAIN PLUG: Check for thread sealant residue in float chamber. Refer to paragraph 2-22. 2 ENGINE OIL FILTER: Change filter every 100 hours. 4 VACUUM RELIEF VALVE FILTER: Replace every 100 hours. 18 FUEL STRAINER: Disassemble and clean strainer bowl and screen. 17 ENGINE OIL: Change oil at least every 100 hours or every six months. D 200 HOURS 7 VACUUM SYSTEM CENTRAL AIR FILTER: Inspect for damage. 11 BRAKE MASTER CYLINDERS: Check fluid level and fill as required with hydraulic fluid. 2 0500 HOURS 7 VACUUM SYSTEM CENTRAL AIR FILTER: Replace every 500 hours. ~S AS REQUIRED 13 GROUND SERVICE RECEPTACLE: Connect to 24-volt DC. negative-ground power unit. Refer to Section 16. Figure 2-5. Servicing (Sheet 4 of 4) 2-28 MODEL 172RG SERVICE MANUAL FREQUENCY (HOURS) GRAPHITE) WHERE NO INTERVAL IS SPECIFIED. LUBRICATE AS REQUIRED AND WHEN ASSEMBLED OR INSTALLED. NOTE The military specifications listed are not mandatory, but are intended as guides in choosing satisfactory materials. Products of most reputable manufacturers meet or exceed these specifications. LUBRICANTS PG SS-G-659 ..................... POWDERED GRAPHITE GR MIL-G-81322A ................. GENERAL PURPOSE GREASE GH MIL-G-23827A ................. AIRCRAFT AND INSTRUMENT GREASE GL MIL-G-21164C ................ HIGH AND LOW TEMPERATURE GREASE OG MIL-L-7870A ................... GENERAL PURPOSE OIL PL W-P-236 .............. .... PETROLATUM GP .................. .......... NO. 10-WEIGHT. NON-DETERGENT OIL OL VV-L-800A ................ LIGHT OIL Figure 2-6. Lubrication (Sheet 1 of 6) 2-29 MODEL 172RG SERVICE MANUAL NOSE GEAR WHEEL BEARINGS / PARAGRAPH 2-53 ': ELEVATOR DOWN SPRING LINK RUB STRIP MAIN GEAR PIVOT ASSEMBLY Figure 2-6. Lubrication (Sheet 2 of 6) 2-30 MODEL 172RG SERVICE MANUAL ALSO REFER TO INSPECTION CHART IN THIS SECTION AND TO SECTION 9 OF THIS MANUAL. ELEVATOR TRIM TAB ACTUATOR OILITE BEARINGS . (RUDDER BAR ENDS) TYPICAL GH CABIN DOOR WINDOW ALL LINKAGE INSERT GROOVES ALL LINKAGE - POINT PIVOTS OG RUDDER BARS AND PEDALS BATTERY TERMINALS * DO NOT LUBRICATE IF OPERATING IN EXTREMELY DUSTY CONDITIONS. OG PARKING BRAKE ENGINE CONTROLS PARKING BRAKE HANDLE SHAFT Figure 2-6. Lubrication (Sheet 3 of 6) 2-31 MODEL 172RG SERVICE MANUAL WING STRUT-ATTACH (UPPER) BOLT & HOLE* L (LOWER) BOLT & HOLE* UPON INSTALLATION TRIM WHEEL OILITE AND NEEDLE BEARINGS Figure 2-6. Lubrication (Sheet 4 of 6) 2-32 MODEL 172RG SERVICE MANUAL BUSHINGS AND OILITE BEARINGS CONTROL WHEEL SHAFT UNIVERSALS CONTROL "U" NEEDLE BEARINGS NEEDLE .BEARINGS - GR ELECTRIC FLAP DRIVE MECHANISM ALSO REFER TO PARAGRAPH 2-49 Figure 2-6. Lubrication (Sheet 5 of 6) 2-33 MODEL 172RG SERVICE MANUAL BEARINGS PARAGRAPH 2-50 NEEDLEBEARINGS SPRAY BOTH SIDES OF SHADED AREAS WITH ELECTROFILM LUBRI-BOND "A" WHICH IS AVAILABLE IN AEROSOL SPRAY CANS, OR AN EQUIVALENT LUBRICANT. TORQUE ATTACHING BOLT TO 10-20 LB-IN. NOTES Sealed bearings require no lubrication. Do not lubricate roller chains or cables except under seacoast conditions. Wipe with a clean. dry cloth. Lubricate unsealed pulley bearings, rod ends. Oilite bearings. pivot and hinge points, and any other friction point obviously needing lubrication. with general purpose oil every 1000 hours or oftener if required. Paraffin wax rubbed on seat rails will ease sliding the seats for and aft. Lubricate door latching mechanism with MIL-G-81322A general purpose grease. applied sparirigly to friction points. every 1000 hours or oftener. if binding occurs. No lubrication is recommended on the rotary clutch. Figure 2-6. Lubrication (Sheet 6 of 6) 2-34 MODEL 172RG SERVICE MANUAL I INSPECTION REQUIREMENTS. As required by Federal Aviation Regulations, all civil aircraft of U.S. registry must undergo a COMPLETE INSPECTION (ANNUAL) each twelve calendar months. In addition to the required ANNUAL inspection, aircraft operated commercially (for hire) must also have a COMPLETE AIRCRAFT INSPECTION every 100 hours of operation. In lieu of the above requirements, an aircraft may be inspected in accordance with a progressive inspection schedule, which allows the work load to be divided into smaller operations that can be accomplished in shorter time periods. Therefore, the Cessna Aircraft Company recommends PROGRESSIVE CARE for aircraft that are being flown 200 hours or more per year, and the 100 HOUR inspection for all other aircraft. II INSPECTION CHARTS. The following charts show the recommended intervals at which items are to be inspected. As shown in the charts, there are items to be checked each 50 hours. each 100 hours. each 200 hours, and also Special Inspection items which require servicing or inspection at intervals other than 50, 100 or 200 hours. a. 50 HOUR INSPECTIONS: (Refer to the Inspection Charts, Column 1.) This inspection requires each item marked with a symbol * to be inspected at each 50 hours of flight time. b. 100 HOUR AND/OR ANNUAL INSPECTIONS: (Refer to the Inspection Charts. Column 2.) This inspection requires each item marked with a symbol * to be inspected at each 100 hours of flight time and/or each 12th month following the last inspection recorded for the aircraft. c. 200 HOUR INSPECTIONS: (Refer to the Inspection Charts. Column 3.) This inspec- tion requires each item marked with a symbol * to be inspected at each 200 hours of flight time. d. SPECIAL INSPECTIONS: (Refer to the Inspection Charts. Column 4.) This inspec- tion requires each item that has a numeral inserted in the column be inspected in accordance with the corresponding numeral listed in the back of the Inspection Charts. e. PROGRESSIVE INSPECTION: In lieu of the conventional 100 hour/ annual inspec- tion as covered in Part 91.169 of the Federal Aviation Regulations. an aircraft may be Inspected in accordance with a progressive inspection. Progressive Inspection allows the inspection work load to be divided into smaller operations that can be accomplished in a shorter time period and offers increased safety reliability, and utility while decreasing downtime. Aircraft on this program do not require the 100 hour/annual inspection. "Cessna Progressive Care" has been designed for this purpose. It is highly recommended for aircraft being flown 200 hours or more per year. 2-35 MODEL 172RG SERVICE MANUAL NOTE The inspection intervals shown in Column 5 are pres- ented for comparitive purposes only and SHALL NOT BE USED AS THE PROGRESSIVE CARE INSPECTION SCHEDULE. A complete program and operations man- ual are available for this purpose. Cessna Progressive Care has been designed for use Worldwide. While the develop- ment of the Cessna Progressive Care Program has been coordinated primarily with the Federal Aviation Administration in the United States. program information has been in the United States, program information has been forwarded to and discussed with the Governmental Aviation Agencies in many countries throughout the World. These Governments are in basic agreement with Progressive Care. Therefore. Export Agencies and Dealers are directed to contact the Governmental Aviation Agency in their areas prior to placing the first aircraft on Progressive Care. to make certain they are in basic accord with the program. f. INSPECTION GUIDE-LINES. The guide-lines shown. preceeding the Inspection Charts, are suggested for your use when making the detailed inspections listed in the Inspection Charts. In III INSPECTION PROGRAM SELECTION. AS A GUIDE FOR SELECTING THE INSPECTION PROGRAM THAT BEST SUITS THE OPERATION OF THE AIRCRAFT, THE FOLLOWING IS PROVIDED. 1. IF THE AIRCRAFT IS FLOWN LESS THAN 200 HOURS ANNUALLY. a. IF FLOWN FOR HIRE An aircraft operating in this category must have a COMPLETE AIRCRAFT INSPECTION each 100 hours and each 12 calendar months of operation. A COM- PLETE AIRCRAFT INSPECTION consists of all 50. 100.200 and Special Inspection Items shown'in the inspection charts as defined in paragraph II above. b. IF NOT FLOWN FOR HIRE An aircraft operating in this category must have a COMPLETE AIRCRAFT INSPEC- TION each 12 calendar months (ANNUAL). A COMPLETE AIRCRAFT INSPEC- TION consists of all 50. 100, 200 and Special Inspection Items shown in the inspection charts as defined in paragraph II above. In addition. it is recommended that between annual inspections, all items be inspected at the intervals specified in the inspection charts. 2. IF THE AIRCRAFT IS FLOWN MORE THAN 200 HOURS ANNUALLY. Whether flown for hire or not. it is recommended that aircraft operating in this category be placed on the CESSNA PROGRESSIVE CARE PROGRAM. However. if not placed on Progressive Care. the inspection requirements for aircraft in this category are the same as those defined under paragraph III 1. (a) and (b). Cessna Progressive Care may be utilized as a total concept program which insures that the inspection intervals in the inspection charts are not exceeded. Manuals and forms which are required for conducting Progressive Care inspections are available from the Cessna Supply Division. P.O. Box 949, Wichita, KS 87201, 316/685-9111, Telex 417- 489.) 2-36 MODEL 172RG SERVICE MANUAL IV INSPECTION GUIDE LINES. (a) MOVABLE PARTS for. lubrication, servicing, security of attachment. binding. excessive wear, safetying, proper operation. proper adjustment. correct travel. cracked fittings, security of hinges. defective bearings. cleanliness, corrosion. deformation, sealing and tension. (b) FLUID LINES AND HOSES for: leaks, cracks, dents, kinks, chafing, proper radius. security, corrosion, deterioration, obstruction and foreign matter. (c) METAL PARTS for: security of attachment, cracks, metal distortion. broken spot- welds, corrosion, condition of paint and any other apparent damage. (d) WIRING for: security, chafing, burning, defective insulation. loose or broken terminals, heat deterioration and corroded terminals. (e) BOLTS IN CRITICAL AREAS for: correct torque in accordance with torque values given in the chart in Section 1. when installed or when inspection indicates the need for a torque check. NOTE Torque values listed in Section 1 are derived from oil-free cadmium-plated threads, and are recommended for all installation procedures contained in this book except where other values are stipulated. They are not to be used for checking tightness of installed parts during service. (f) FILTERS, SCREENS & FLUIDS for: cleanliness. contamination and/or replace- ment at specified intervals. (g) AIRCRAFT FILE. Miscellaneous data, information and licenses are a part of the aircraft file. Check that the following documents are up-to-date and in accordance with current Federal Aviation Regulations. Most of the items listed are required by the United States Federal Aviation Regulations. Since the regulations of other nations may require other documents and data, owners of exported aircraft should check with their own aviation officials to determine their individual requirements. To be displayed in the aircraft at all times: 1. Aircraft Airworthiness Certificate (FAA Form 8100-2). 2. Aircraft Registration Certificate (FAA Form 8050-3). 3. Aircraft Radio Station License, if transmitter is installed (FCC Form 556). To be carried in the aircraft at all times: 1. Weight and Balance, and associated papers (Latest copy of the Repair and Alteration Form, FAA Form 337, if applicable). 2. Aircraft Equipment List. 3. Pilot's Operating Handbook. To be made available upon request: 1. Aircraft Log Book and Engine Log Book. 2-37 MODEL 172RG SERVICE MANUAL (h) ENGINE RUNUP. Before beginning the step-by-step inspection. start, run up and shut down the engine in accordance with instructions in the Pilot's Operating Handbook. During the run- up observe the following, making note of any discrepancies or abnormalities: 1. Engine temperatures and pressures. 2. Static RPM. (Also refer to Section 11 of this manual.) 3. Magneto drop. (Also refer to Section 11 of this manual.) 4. Engine response to changes in power. 5. Any unusual engine noises. 6. Fuel selector valve; operate engine on each bay position and OFF position long enough to ensure that selector valve functions properly. 7. Idling speed and mixture; proper idle cut-off. 8. Alternator and ammeter. 9. Suction gage. After the inspection has been completed. an engine runup should again be performed to determine that any discrepancies or abnormalities have been corrected. 2-38 MODEL 172RG SERVICE MANUAL INSPECTION CHARTS IMPORTANT READ ALL PRECEDING PARAGRAPHS FOR IN- SPECTION REQUIREMENTS PRIOR TO USING THESE CHARTS. TYPE OF INSPECTION 4. SPECIAL 3. 200 HOURS 2. 100 HOURS 1. 50 HOURS PROPELLER 1. Spinner ....... ...... .................. ................. . 2. Spinner bulkhead ...................................... - 3. B lades.................................................. 4. Bolts and nuts ......................................... 5. Hub . 5. Hub ................................................... 6. Governor and control .................................. 15 ENGINE COMPARTMENT Check for evidence of oil and fuel leaks, then clean entire engine compartment. if needed, prior to inspection. 1. Engine oil filler cap, dipstick, drain plug and external filter element ................................. 1 2. O il cooler .............................................. 3. Induction air filter ................... ................. 4. Induction airbox, air valves, doors and controls ....... 5. Cold and hot air hoses ................................. · 6. Engine baffles ............. ........... ............. 7. Cylinders, rocker box covers and push rod housings .... 8. Crankcase, oil sump, accessory section and front crankshaft seal ........................................ 9. Hoses, metal lines and fittings ......................... 3 10. Intake and exhaust systems ........................... 0 4 11. Ignition harness ....................................... 2-39 MODEL 172RG SERVICE MANUAL TYPE OF INSPECTION 4. SPECIAL 3. 200 HOURS 2. 100 HOURS 1. 50 HOURS 12. Spark plugs ............................................ - 13. Compression check ....................................... ... 14. Crankcase and vacuum system breather lines ......... 15. Electrical wiring ...................................... 16. Vacuum pump, oil separator and relief valve ......... 17. Vacuum relief valve filter ............................. 5 18. Engine controls ........................................ 6 19. Engine shock mounts, mount structure and ground straps ..................................... 20. Cabin heat valves, doors and controls ................. 21. Starter, solenoid and electrical connections ........... 22. Starter brushes, brush leads and commutator ......... 2 23. Alternator, belt and electrical connections ............ 19 24. Alternator brushes, brush leads, commutator or slip ring ............................................ 7 25. Alternator support bracket for security ............... - 26. Voltage regulator mounting and electrical leads ...... 27. Magnetos (externally/ internally) and electrical connections ......................... * 8 28. Magneto tim ing ........................................ 8 29. Carburetor and drain plug ............................. 30. Firewall ............................................... · 31. Engine cowl flaps and controls ........................ - 32. Engine cowling ........................................ · 33. Cowl flap hinges and hinge pins ...................... - 34. Carburetor throttle arm attachment ................... · FUEL SYSTEM 1. Fuel strainer, drain valve and control, fuel bay vents, caps and placards ...................................... · 2-40 Revision I MODEL 172RG SERVICE MANUAL TYPE OF INSPECTION 4. SPECIAL 3. 200 HOURS 2. 100 HOURS 1. 50 HOURS 2. Fuel strainer screen and bowl .................................................. 3. Drain fuel and check bay interior and outlet screens .............................. 21 4. Fuel bays and sump drains ................................................... 5. Fuel selector valve and placards ............................................... 6. Engine primer ............................................................... 7. Fuel quantity indicators and transmitters ........................................ 8. Auxiliary fuel pump ........................................................... 22 9. Engine-driven fuel pump ...................................................... 10. Perform a fuel quantity indicating system operational test. Refer to Section 15 for detailed accomplishment instructions ............................... 24 LANDING GEAR, BRAKE SYSTEM AND RETRACTION SYSTEM MAIN GEAR 1. Wheels ........................................................... 2. Bearings .................................................................... 9 3. Tires ....................................................................... 4. Tubular struts ............................................................... 5. Pivot ....................................................................... 1