Cessna 172 Series Maintenance Manual

GENERAL DESCRIPTION . . . . . . . . . . 1-1 Aircraft Specifications . . . . . . . . . 1- 1 Model FR172-Series . . . . . . . . . . 1-1 Stations . . . . . . . . . . . . . . . . 1-1 Description . . . . . . . . . . . . 1-1 Torque Values . . . . . . . . . . . . . 1- 1 1-1. GENERAL DESCRIPTION. 1-2. MODEL 172-SERIES. 1-3. DESCRIPTION. Cessna Model 172 Series air- craft, described in this manual, a r e high-wing mono- planes of all-metal, semimonocoque construction. Thexe aircraft a r e equipped with a fixed tricycle land- ing gear with tubular spring-steel main gear struts. The steerable nose gear is equipped with an air/hy- draulic fluid shock strut. Four-place seating is stan- dard, and a double-width, fold-up auxiliary r e a r seat may be installed a s optional equipment. All a r e powered by four-cylinder, horizontally opposed, air- cooled Lycoming "Blue Streak" engines. Each of the engines drives a r e all-metal, fixed-pitch propeller. Model 172-Series aircraft feature r e a r side windows, a "wrap-around" r e a r window and a swept-back fin and rudder. 1-4. AIRCRAFT SPECIFICATIONS. Leading parti- culars of these aircraft, with dimensions based on gross weight, a r e given in figure 1-1. If these di- mensions a r e used for constructing a hangar o r com- puting clearances, remember that such factors a s nose gear strut inflation, tire pressures, tire sizes and load distribution may result in some dimensions that a r e considerably different from those listed. 1-5. STATIONS. Station diagrams a r e shown in fig- u r e s 1-2 to assist in locating equipment when a written description is inadequate o r impractical. 1-6. TORQUE VALUES. A chart of recommended nut torque values is shown in figure 1-3. These tor- que values a r e recommended for all installation pro- cedures contained in this manual, except where other values a r e stipulated. They a r e not to be used for checking tightness of installed parts during service. NOTE These specifications a r e applicable to both Model 172 and F172-Series aircraft, except a s indicated. GROSS WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . 2300 lb FUEL CAPACITY Standard Wing (Total) . . . . . . . . . . . . . . . . . . . . 43 gal. Standard Wing (Usable) . . . . . . . . . . . . . . . . . . . 40 gal. Long-Range Wing (Total) . . . . . . . . . . . . . . . . . . 54 gal. Long-Range Wing (Usable). . . . . . . . . . . . . . . . . . 50 gal. OIL CAPACITY (Without External Filter) . . . . . . . . . . . . . . . . . . 6 qt (With External Filter). . . . . . . . . . . . . . . . . . . . 7 qt ENGINE MODEL 172-Series (Refer to Section 11 for Engine Data) . . . . . . . . LYCOMING 0-320 Series F172-Series (Refer to Section 11 for Engine Data) . . . . . . . LYCOMING 0-320 Series PROPELLER (Fixed Pitch) . . . . . . . . . . . . . . . . . . . 75" McCA ULEY MAIN WHEEL TIRES . . . . . . . . . . . . . . . . . . . . . . 6.00 x 6, 4-Ply Rating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 29 psi NOSE WHEEL TIRE (Standard). . . . . . . . . . . . . . . . . . 5.00 x 5, 4-Ply Rating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 31 psi NOSE GEAR STRUT PRESSURE (Strut Extended). . . . . . . . . . 45 psi WHEEL ALIGNMENT (Tubular Spring Struts) Camber . . . . . . . . . . . . . . . . . . . . . . . . . . 2' to 4' Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . 0" t o . 18" * (Tubular Gear i s non-adjustable) AILERON TRAVEL Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20'  ± I Down . . . . . . . . . . . . . . . . . . . . . . . . . . . 15O lo WING FLAP TRAVEL. . . . . . . . . . . . . . . . . . . . . . 0' to 40'. +0° 2' RUDDER TRAVEL (Measured parallel to water line) Right . . . . . . . . . . . . . . . . . . . . . . . . . . . 16' 10'  ± l Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16' 10'  ± l RUDDER TRAVEL (Measured perpendicular to hinge line) Right . . . . . . . . . . . . . . . . . . . . . . . . . . . 17O 44'  ± l Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17' 44'  ± l ELEVATOR TRAVEL Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28O, +lo- O 0 Down . . . . . . . . . . . . . . . . . . . . . . . . . . . 23O, +lo- 0' ELEVATOR TRIM TAB TRAVEL Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28', +lo- O0 Down . . . . . . . . . . . . . . . . . . . . . . . . . . . 13', +lo- 0' PRINCIPA L DIMENSIONS Wing Span (Conical-Camber With Strobe Lights) . . . . . . . . 36' Tail Span . . . . . . . . . . . . . . . . . . . . . . . . . 11' 3" Length . . . . . . . . . . . . . . . . . . . . . . . . . . 26' 11" Fin Height (Maximum with Nose Gear Depressed and Flashing Beacon Installed on F i n . . . . . . . . . . . . . . 8' 9-1/2" Track Width . . . . . . . . . . . . . . . . . . . . . . . . 8' 3-1/2" BATTERY LOCATION . . . . . . . . . . . . . . . . . . . . . Firewall * No provisions a r e made for aligning wheels on tubular gear aircraft. The tolerances provided a r e to be used only for checking existing wheel alignment. Figure 1-1. Aircraft Specifications 1-2 Figure 1-2. Reference Stations RECOMMENDED NUT TORQUES THE TORQUE VALUES STATED ARE POUND-INCHES, RELATED ONLY T O STEEL NUTS ON OIL-FREE CADMIUM PLATED THREADS. FINE THREAD SERIES I TENSION 1 TORQUE 1 ST D (NOTE 1 ) ALT (NOTE 2) SHEAR 8-32 10-24 1/4 - 20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4 - 10 7/8-9 1-8 1 - 1 / 8 4 1-1/4-8 TORQUE (NOTE 4) 12-15 20-25 40-50 80-90 160-185 235-255 400-480 500-700 700-900 1150-1600 2200-3000 3700-5000 5500-6500 6500-8000 ST D (NOTE 3) COARSE THREAD SERIES (NOTE 5) NOTES ALT (NOTE 2) 1. Covers AN310, AN315, AN345, AN363, MS20365, MS21042, MS21044, MS21045 and MS21046. 2. When using AN310 o r AN320 castellated nuts where alignment between the bolt and cotter pin s l o t s is not reached using normal torque values, u s e alternate torque values o r replace the nut. 3. Covers AN316, AN320, MS20364 and MS21245. 4. Covers AN363, MS20365, MS21042, MS21043, MS21044, MS21045 and MS21046. 5. Covers AN340. I DO NOT REUSE SELF-LOCKING NUTS. The above values a r e recommended f o r a l l installation procedures contained in this manual, except where other values a r e stipulated. They a r e not t o be used f o r checking tightness of installed p a r t s during service. Figure 1-3. Torque Values SECTION 2 GROUND HANDLING, SERVICING, CLEANING, LUBRICATION AND INSPEC TION TABLE O F CONTENTS Page GROUND HANDLING . . . . . . . . . . . . 2 -1 Towing . . . . . . . . . . . . . . . . . 2-1 Hoisting . . . . . . . . . . . . . . . . 2 -4 Jacking . . . . . . . . . . . . . . . . 2 -4 Leveling . . . . . . . . . . . . . . . . 2 -4 Parking . . . . . . . . . . . . . . . . 2 -4 Tie -Down . . . . . . . . . . . . . . . 2 -4 Flyable Storage . . . . . . . . . . . . . 2 -4 Returning Aircraft To Service . . . . . . 2-4 Temporary Storage . . . . . . . . . . . 2 -4 Inspection During Storage . . . . . . . . 2-5 Returning Aircraft To Service . . . . . . 2-5 Indefinite Storage . . . . . . . . . . . . 2 -5 Inspection During Storage . . . . . . . . 2-6 Returning Aircraft To Service . . . . . . 2-6 SERVICING . . . . . . . . . . . . . . . . 2 -7 Fuel . . . . . . . . . . . . . . . . . . 2-7 Fuel Drains . . . . . . . . . . . . . . 2 -7 Carburetor Drain Plug Inspection . . . . 2-7 Engine Oil . . . . . . . . . . . . . . . 2 -7 Engine Induction Air Filter . . . . . . . . 2 -9 2-1. GROUND HANDLING. 2-2. TOWING. Moving the a i r c r a f t by hand i s ac- complished by using the wing s t r u t s and landing g e a r s t r u t s a s push points. A tow b a r attached to the nose g e a r should be used for steering and maneuvering the a i r c r a f t on the ground. When no tow b a r is available, p r e s s down a t the horizontal stabilizer front s p a r ad- jacent t o the fuselage to r a i s e the nose wheel off the ground. With the nose wheel c l e a r of the ground, the a i r c r a f t can be turned by pivoting it about the main wheels. Vacuum System Filter . . . . . . . . . . 2-9 B a t t e r y . . . . . . . . . . . . . . . . . 2-9 T i r e s . . . . . . . . . . . . . . . . . 2-9 Nose Gear Shock Strut . . . . . . . . . . 2-9 Nose Gear Shimmy Dampener . . . . . . . 2-10 Hydraulic Brake System . . . . . . . . . 2-10 CLEANING . . . . . . . . . . . . . . . . 2-10 Windshield and Windows . . . . . . . . . 2- 10 Plastic T r i m . . . . . . . . . . . . . . 2-10 Painted Surfaces . . . . . . . . . . . . 2- 10 Aluminum Surfaces . . . . . . . . . . . 2 - 10 Engine and Engine Compartment . . . . . 2-11 Upholstery and Interior . . . . . . . . . 2-11 Propeller . . . . . . . . . . . . . . . . 2-11 Wheels . . . . . . . . . . . . . . . . . 2-11 LUBRICATION . . . . . . . . . . . . . . 2- 11 Wheel Bearings . . . . . . . . . . . . . 2-11 Nose Gear Torque Links . . . . . . . . . 2-11 Wing Flap Actuator . . . . . . . . . . . 2-11 Fuel Selector Valve . . . . . . . . . . . 2-11 INSPECTION . . . . . . . . . . . . . . . 2-19 When towing the aircraft, never turn the nose wheel more than 30 degrees either side of center o r the nose g e a r will be damaged. Do not push on control surfaces o r outboard e m - pennage surfaces. When pushing on the tail- cone, always apply p r e s s u r e a t a bulkhead to avoid buckling the skin. TOW BAR: PART NUMBER 0501019-1 IS AVAILABLE FROM THE CESSNA SERVICE PARTS CENTER. Use tow b a r carefully to avoid s c a r r i n g finish on Figure 2-1. Tow B a r 2 -1 NOTE Corresponding points on both upper door s i l l s may be used to level the a i r c r a f t laterally. Reference points for longitudinal leveling of a i r c r a f t a r e two s c r e w s on left side of tailcone a t z e r o waterline. These a r e indicated i n illustration by A . (Also r e f e r to paragraph 2-5) Figure 2-2. Jacking and Leveling (Sheet 1 of 2) 2 -2 JACKING INFORMA TION - TEM NUMBER TYPE AND NUMBER REMARKS CD Block (Jack point not available) 1 x 4 ~ 4padded with 1/4" rubber Jack Any short jack of capable capacity Universal tail stand Any tail stand of capable capacity I Cessna #SE-576 (41-1/2" high) Universal jack stand (FOR USE WITH ITEM 2) @ IBuilt -in jack pad P a r t of step bracket (SEE CAUTION) #2-170 Basic jack (includes#2-71 Slide tube: Liftstroke 22 -1/2") #2 -70 Slide tube: Liftstroke 22-1/2" #2-64 Extension cap #2 -109 Leg extension Min. closed height: 34" Max. extension height: 56-1/2" Min. closed height: 57 -1/2" Max. extension height: 80" Adds 4" Adds 12" 1. Wing jacks a r e placed under front s p a r of wing just outboard of wing strut, and must extend f a r enough to r a i s e wheels off ground, and must b e of adequate strength. 2. Attach a suitable stand to the tie-down ring. Be s u r e tail stand weighs enough to keep tail down and under all conditions that i t is strong enough to support any weight that might b e placed on i t (place shot bags o r sand bags on tail stand. In addition, the b a s e of adjustable tail stand is to b e filled with concrete for additional weight as a safety factor. 3. Operate jacks evenly until desired height is reached. When using built-in jack pad, flexibility of the g e a r s t r u t will cause the main wheel to slide inboard a s the wheel is raised, tilting the jack. The jack must be lowered for a second operation. Jacking both wheels simultaneously a t built-in jack pads is not r e - commended. Jack pad may be used to r a i s e only one main wheel. DO NOT USE brake casting a s a jack point. 4. Items (4) and (6) a r e available f r o m the Cessna Service P a r t s Center. Figure 2 -2. Jacking and Leveling (Sheet 2 of 2) 2 -3 2-3. HOISTING. The aircraft may be lifted with a NOTE hoist of two-ton capacity by using hoisting rings, which a r e optional equipment, or by means of suit- able 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 a r e used, a minimum cable length of 60 inches for each cable i s required to prevent bending of the eyebolt-type hoisting rings. If desired, a spreader jig may be fabricated to apply vertical force to the eyebolts. 2-4. JACKING. Refer to figure 2-2 for jacking procedures. 2 -5. LEVELING. Corresponding points on both upper door sills may be used to level the aircraft laterally. The reference points for longitudinally leveling the aircraft a r e the two screws located on the left side of the tailcone. Refer to figure 2 -2 for screw locations. 2 -6. PARKING. Parking precautions depend prin- cipally 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 con- ditions, tie down the aircraft a s outlined in paragraph 2-7 if a hangar is not available. 2-7. 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. Do not set parking brakes during cold weather when accumulated moisture may freeze the brakes or when the brakes a r e overheated. After completing the preceding, proceed to moor the aircraft a s follows: 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 rope (no chains or cables) to forward mooring ring and secure opposite end to ground an- chor, c. Secure the middle of a rope to the tail tie-down ring. Pull each end of rope away at a 45 degree angle and secure to ground anchors at each side of tail. d. Secure control lock on pilot control column. If control lock i s not available, tie pilot control wheel back with front seat belt. e. These aircraft a r e equipped with a spring-loaded steering system which affords protection against nor- mal wind gusts. However, if extremely high wind gusts a r e anticipated, additional external locks may be installed. 2- 8. FLYABLE STORAGE. Flyable storage is de- fined a s a maximum of 30 days non-operational stor- age and/or the f i r s t 25 hours of intermittent engine operation. The aircraft i s delivered from Cessna with a corrosion preventative aircraft engine oil (MIL-C-6529, Type II). This engine oil i s a blend of aviation grade straight mineral oil and a corrosion preventative compound. This engine oil should be used for the first 25 hours of engine operation. In the event i t i s necessary to add oil during the first 25 hours of operation, use only aviation grade straight mineral oil of the correct viscosity. During the 30 day non-operational storage or the first 25 hours of intermittent engine operation, every sev- enth day the propeller shall be rotated through five revolutions, without running the engine. If the air- craft is stored outside, tie-down in accordance with paragraph 2-7. 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 tem- perature. 1 - Excessive ground operation shall be avoided. 2-9. RETURNING AIRCRAFT TO SERVICE. After flyable storage, returning the aircraft to service i s accomplished by performing a thorough pre-flight in- spection. At the end of the first 25 hours of engine operation, drain engine oil and clean oil screens (or change external oil filter). Service engine with cor- rect grade and quantity of engine oil. Refer to figure 2-4 and paragraph 2-21 for correct grade of engine oil. 2- 10. TEMPORARY STORAGE. Temporary storage i s defined a s aircraft in a non-operational 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 a r e subject to oxidation. The f i r s t indication of corrosion on unpainted surfaces is in the form of white deposits or spots. On painted surfaces, the paint is discolored or blistered. Stor- age in a dry hangar i s essential to good preservation and should be procured if possible. Varying condi- tions 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 a r e suggested: a. Fill fuel tanks with correct grade of gasoline. b. Clean and wax aircraft thoroughly. c. Clean any oil o r grease from tires and coat tires with a tire preservative. Cover tires to pro- tect against grease and oil. d. Either block up fuselage to relieve pressure on tires or rotate wheels every 30 days to change sup- porting points and 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. NOTE The aircraft battery serial number is recorded in the aircraft equipment list. To assure ac- curate warranty records, the battery should be re-installed in the same aircraft from which it was removed. If the battery is returned to service in a different air craft, 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 the battery periodically and charge a s re- quired. 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 i s in storage. 2- 11. INSPECTION DURING STORAGE. a. Inspect airframe for corrosion a t least once a month and remove dust collections a s frequently a s possible. Clean and wax a s required. b. Inspect the interior of at least one cylinder through the spark plug hole for corrosion a t least once a month. NOTE NOTE An engine treated in accordance with the fol- lowing may be considered protected against normal atmospheric 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 The preservative oil must be Lubricating Oil-Contact and Volatile, Corrosion In- hibited, MIL-L-46002, Grade 1 o r equiva- lent. The following oils a r e approved for spraying operation by Lycoming, Socony Averex 901, o r Esso Rust-Ban 626, or equivalent. h. Using a portable pressure sprayer, atomize spray preservative oil through the upper spark plug hole of each cylinder with the piston in a down posi- tion. Rotate crankshaft a s each pair of cylinders is sprayed. i. After completing step "h, rotate crankshaft s o that no piston is a t a top position. If the aircraft is to be stored outside, stop two-bladed propeller s o that blades a r e a s near horizontal a s possible to pro- vide maximum clearance with 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 preserva- tive oil through the oil filler tube. m. Seal all engine openings exposed to the atmos- phere using suitable plugs or non- hygroscopic tape. Attach a red streamer a t each point that a plug or tape is installed. no If the aircraft is to be stored outside, perform the procedures outlined in paragraph 2-7. In addi- tion, the pitot tube, static source vents, a i r vents, openings in the engine cowling and other similar 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, again per- form the procedural steps "g thru o" of paragraph 2-10. 2- 12. RETURNING AIRCRAFT TO SERVICE. After temporary storage, use the following procedures to return the aircraft to service. a. Remove aircraft from blocks and check tires for proper inflation. Check for proper nose gear strut inflation. (Refer to figure 1-1.) b. Check battery and install. c. Check that oil sump has proper grade and quan- tity of engine oil. d. Service induction air filter and remove warning placard from propeller. e. Remove materials used to cover openings. f. Remove spark plugs from engine. go While spark plugs a r e removed, rotate propel- l e r several revolutions to clear excess rust preven- tive oil from cylinders. h. Clean, gap and install spark plugs. Torque plugs to the value specified in Section 11 and connect spark plug leads. i. Check fuel strainer. Remove and clean filter screen if necessary. Check fuel tanks and fuel lines for moisture and sediment, drain enough fuel to elimi nate moisture and sediment. j . Perform a thorough pre-flight inspection, then start and warm-up engine. 2- 13. INDEFINITE STORAGE. Indefinite storage is defined a s aircraft in a non-operational status for an indefinite period of time. Engines treated in accor- dance with the following may be considered protected against normal atmosphere corrosion, provided the procedure outlined in paragraph 2- 14 a r e performed at the intervals specified. a. Operate engine until oil temperature reaches normal operating range. Drain engine oil sump and reinstall drain plug. b. Fill oil sump to normal operating capacity with corrosion preventive mixture which has been thor- oughly mixed and pre-heated to a minimum of 221 OF a t the time i t is added to the engine. NOTE NOTE Corrosion preventive mixture consists of one part compound MIL-C-6529, type I, mixed with three parts new lubricating oil of the grade recommended for service. Lycoming recommends Esso Rust-Ban 628 or equivalent. During all spraying opera- tions corrosion mixture i s pre-heated to 221' to 250°F c. Immediately after filling the oil sump with cor- rosion preventative mixture, fly the aircraft for a period of time not to exceed a maximum of 30 min- utes. d. With engine operating at 1200 to 1500 rpm and induction a i r filter removed, spray corrosion pre- ventive mixture into induction airbox, at the rate of one-half gallon per minute, until heavy smoke comes from exhaust stack, then increase the spray until the engine is stopped. Injecting corrosion-preventive 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 pre- heated to 221' to 250°F into all spark plug holes to thorough- ly cover interior surfaces of cylinders. g. Install lower spark plugs or install solid plugs, and install dehydrator plugs in upper spark plug holes. Be sure that dehydrator plugs a r e 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 carburetor intake and seal open- ing with moisture resistant paper and tape. j. Place a bag of desiccant in the exhaust tail- p i p e ( ~ )and seal openings with moisture resistant tape. k. Seal cold air inlet to the heater muff with mois- ture resistant tape. 1. Seal engine breather by inserting a protex plug in the breather hose and clamping in place. m. Seal all other engine openings exposed to atmos- phere using suitable plugs or non-hygroscopic tape. NOTE Attach a red streamer to each place plugs or tape is installed. Either attach red streamers outside of 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 and reinstall drain plug. The corrosion-preventive mixture i s harmful to paint and should be wiped from painted sur- faces immediately. o. Attach a warning placard on the throttle control knob, to the effect that the engine contains no lubri- cating oil. Placard the propeller to the effect that i t should not be moved while the engine is in storage. p. Prepare airframe for storage a s outlined in paragraph 2-10 thru step "f." NOTE As an alternate method of indefinite storage, the aircraft may be serviced in accordance with paragraph 2-10 providing the aircraft i s run-up at maximum intervals of 90 days and then reserviced per paragraph 2-10. 2-14. INSPECTION DURING STORAGE. Aircraft in indefinite storage shall be inspected a s follows: a. Inspect cylinder protex plugs each 7 days. b. Change protex plugs if their color indicates an unsafe condition. c. If the dehydrator plugs have changed color in one half of the cylinders, all desiccant material in the engine shall be replaced with new material. d. Every 6 months respray the cylinder interiors with corrosion-preventive mixture. NOTE Before spraying, inspect the interior of one cylinder for corrosion through the spark plug hole and remove a t least one rocker box cover and inspect the valve mechanism. 2- 1 5 . RETURNING AIRCRAFT TO SERVICE. After indefinite storage, use the following procedure to return the aircraft to service. a. Remove aircraft from blocks and check tires for correct inflation. Check for correct nose gear strut inflation. b. Check battery and install. c. Remove all materials used to seal and cover openings. d. Remove warning placards posted at throttle and propeller. e. Remove and clean engine oil screen, then re- install and safety. On aircraft that a r e equipped with an external oil filter, install new filter element. f . Remove oil sump drain plug and drain sump. Install and safety drain plug. NOTE The corrosion-preventive mixture will mix with the engine lubricating oil, s o flushing the oil system is not necessary. Draining the oil sump will remove enough of the cor- r osion-preventive mixture. g. Service and install the induction air filter. h. Remove dehydrator plugs and spark plugs or plugs installed in s p a r k plug holes and rotate pro- peller by hand s e v e r a l revolutions to c l e a r corrosion- preventive mixture f r o m cylinders. i. Clean, gap, and install spark plugs. Torque plugs to the value listed in Section 11. j. Check fuel strainer. Remove and clean filter screen. Check fuel tanks and fuel lines f o r moisture and sediment, and drain enough fuel to eliminate. k. Perform a thorough pre-flight inspection, then s t a r t and warm up engine. 1. Thoroughly clean aircraft and flight test a i r - craft. 2-16. SERVICING. 2-17. Servicing requirements a r e shown in figure 2-4. The following paragraphs supplement this figure by adding details not included in the figure. 2-18. FUEL. Fuel tanks should be filled immedi- ately after flight to reduce condensation. Tank capa- cities a r e listed in figure 1-1. The recommended fuel grade to be used in given in figure 2-4. 2-19. FUEL DRAINS. Fuel drains a r e located a t various places throughout the fuel system. Refer to Section 12 for location of the various drains in the system. The fuel tanks and fuel strainer have drain valves. To activate the tank drain valve for fuel sampling, place cup up to valve and depress valve with rod protruding f r o m cup. See Section 12 f o r illustration of fuel tank drain valve. The s t r a i n e r drain valve is an integral p a r t of the fuel s t r a i n e r assembly. The s t r a i n e r drain i s equipped with a control which i s located adjacent to the oil dipstick. Access to the control i s through the oil dipstick a c c e s s door. Open drains and remove drain plugs a t the intervals specified in figure 2 -4. Also, during daily inspection of the fuel s t r a i n e r o r fuel tanks, if water is found in the fuel s t r a i n e r all fuel drain plugs should be removed and a l l water drained from the system. 2-20. CARBURETOR DRAIN PLUG INSPECTION. In o r d e r to prevent the possibility of thread sealant contamination in the carburetor float chamber, clean- ing and inspection of the carburetor should be accom- plished a t each 100-hour inspection and anytime water in the fuel i s suspected. a. With the fuel valve OFF, remove carburetor drain plug and clean off any sealant present on the end of the plug o r in the threads on the plug. b. Inspect drain plug hole in the carburetor and r e - move any sealant remaining in the hole. c. Turn fuel valve t o ON t o flush float chamber and drain plug chamber while probing drain plug hole t o ascertain that all residue of sealant material is dis- lodged and washed out of the chamber. Flushing operation should last 15 t o 30 seconds. d. A second flushing should then be accomplished and the drained fuel retained f o r inspection to insure that no sealant particles a r e present. e. Install drain plug a s follows: 1. Install drain plug in carburetor 1-1/2 to 2 turns. 2. Apply NS-40 (RAS-4) MIL-T-5544 (Antiseize, Graphite Petrolatum) o r equivalent to plug threads. 3. Tighten and safety drain plug. f. Turn fuel valve ON and inspect for evidence of fuel leakage. 2-21. ENGINE OIL. Check engine lubricating oil with the dipstick five t o ten minutes after the engine has been stopped. The a i r c r a f t should be in as near a level position a s possible when checking the engine oil, s o that a t r u e reading is obtained. Engine oil should be drained while the engine is still hot, and the nose of the a i r c r a f t 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 l e s s than the specified hours have accumulated. Reduce these intervals f o r prolonged operations in dusty areas, in cold climates where sludging conditions exist, o r where short flights and long idle periods a r e encoun- tered, which cause sludging conditions. Always change oil and oil filter whenever oil on the dipstick appears dirty. Aviation grade oil conforming to AVCO Lycoming Specification No. 301 and Service Instruction No. 1014, and to any revisions o r supple- ments thereto, shall be used in the "Blue Streak" (Lycoming) engine. NOTE New o r newly-overhauled engines should be operated on aviation grade straight mineral oil until the f i r s t oil change. If an ashless dispersant oil i s used in a new o r newly- overhauled engine, high oil consumption may be experienced. The anti-friction additives in detergent and dispersant oils will r e t a r d "break-in" of the pistons, rings and cylinder walls. This condition can be avoided by the u s e of straight mineral oil. The aircraft is delivered from Cessna with a Corrosion Valve shown open. To close, twist screwdriver until valve unlocks and snaps down to closed position. Figure 2 -3. Quick-Drain Valve Preventative Aircraft Engine Oil (MIL -C - 6529, Type II, RUST BAN). If oil must be added during the f i r s t 25 hours, use only aviation grade straight mineral oil (non- detergent) conforming to Specification No. MIL-L-6082. After the f i r s t 25 hours of operation, drain engine oil sump and clean the oil suction s t r a i n e r and p r e s s u r e screen. If an external oil filter i s installed change the oil filter. Refill sump with straight mineral oil (non-detergent) and use until a total of 50 hours have accumulated o r oil consumption has stabilized, then change to a s h l e s s dispersant oil. When changing engine oil, if equipped with an e x t e r - nal oil filter, install a new oil filter. An oil quick- drain valve may be installed. This valve provides a quicker and cleaner method of draining the engine oil. This valve is installed i n the oil d r a i n port of the oil sump and allows oil to be drained by attaching a hose over the fitting end and pushing up, causing SHOP NOTES: the oil to drain through the hose into a container. T o d r a i n the engine oil, proceed a s follows: a . Ooerate engine until oil temperature i s a t normal operating temperature. b . (With Quick-Drain Valve.) Attach a hose to the quick-drain valve in oil sump. Push up on quick- drain valve until it locks open, and allow oil to d r a i n through hose into container. c . (Without Quick-Drain Valve.) Remove oil drain plug f r o m engine sump and allow oil to drain into a container. d. After engine oil h a s drained, close quick-drain valve a s shown in figure 2-3 and remove hose. In- stall and safety drain plug. e . Change external oil filter if installed. f . Service engine with c o r r e c t quantity and grade of engine oil in accordance with figure 2-4. NOTE R e f e r to figure 2-4 for intervals f o r changing oil and filters. 2 -22. ENGINE INDUCTION AIR FILTER. The indue - tion air filter keeps dust and dirt from entering the in- duction system. The value of maintaining the a i r filter in a good clean conditioncan never be overstressed. More engine wear i s caused through the use of a dirty or damaged a i r filter than i s generally believed. The frequency with which the filter should be removed, in- spected and cleaned will be determined primarily by aircraft operating conditions. A good general rule how- ever, i s toremove, inspect and clean the filter at least every 50 hours of engine operating time and more f r e - quently if warranted by operating conditions. Some operators prefer to hold spare induction air filters at their home base of operation s o that a clean filter i s always readily available for use. Under extremely dusty conditions, daily servicing of the filter i s recom- mended. To service the filter, proceed a s 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 a i r flow. Arrows on filter case indicate direction of. normal air flow. Do not use solvent or cleaning fluids to wash filter. Use only a water and household deter- gent solution when washing the filter. c. After cleaning a s 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. NOTE The filter assembly may be cleaned with compressed a i r a maximum of 30 times o r it may be washed a maximum of 20 times. A new filter should be installed after using 500 hours of engine operating time o r one year, whichever should occur first. How- ever, a new filter should be installed at anytime the existing filter is damaged. A damaged filter may have sharp o r broken edges in the filtering panels which would allow unfiltered a i r 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 un- t i l 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. Be sure a i r box is clean, inspect filter. If filter i s damaged, install a new filter. f . Install filter at entrance to air box with gasket on aft face of filter frame and with a i r flow arrows on filter frame pointed in the correct direction. 2-23. VACUUM SYSTEM FILTER. The vacuum sys- tem central air filter keeps dirt and dust from enter- ing the vacuum operated instruments. Change central a i r filter element every 500 hours of operating time and whenever suction gage reading drops below 4.6 inches of mercury. Also, do not operate the vacuum system with the filter removed, or a vacuum line disconnected a s particles of dust o r other foreign matter may enter the system and damage the gyros. 2-24. BATTERY. Battery servicing involves add- ing 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 off and spilled electro- lyte or corrosion. Use bicarbonate of soda (baking soda) and water to neutralize electrolyte or corro- sion. Follow with a thorough flushing with water. Brighten cables and terminals with a wire brush, then coat with petroleum jelly before connecting. The battery box also should be checked and cleaned if any corrosion i s noted. Distilled water, not acid or "rejuvenators, l 1 should be used to maintain elec - trolyte level. Check the battery every 50 hours (or at least every 30 days) oftener in hot weather. See Section 16 for detailed battery removal, installation and testing. 2-25. TIRES. Maintain tire pressure at the a i r pressures 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. NOTE Recommended tire pressures should be main- tained. Especially in cold weather, remember that any drop in temperature of the a i r inside a tire causes a corresponding drop in a i r pres- sure. 2-26. NOSE GEAR SHOCK STRUT. The nose gear shock strut requires periodic checking to ensure that the strut i s filled with hydraulic fluid and i s inflated to the correct a i r pressure. To service the nose gear shock strut, proceed a s follows: a. Remove valve cap and release air pressure. b. Remove valve housing. c. Compress nose gear to its shortest length and fill strut with hydraulic fluid to the bottom of the filler hole. d. Raise nose of aircraft, extend and compress strut several times to expel any entrapped air, then lower nose of aircraft and repeat step "c. l1 e. With strut compressed, install valve housing assembly. f. With nose wheel off ground, inflate strut. Shock strut pressure is listed in Section 1. NOTE The nose landing gear shock s t r u t will nor- mally require only a minimum amount of service. Maintain the s t r u t extension pres- s u r e , a s shown i n figure 1-1. Lubricate landing gear as shown i n figure 2-5. Check the landing gear daily for general cleanliness, security of mounting, and f o r hydraulic fluid leakage. Keep machined surfaces wiped f r e e of d i r t and dust, using a clean lint-free cloth saturated with MIL-H- 5606 hydraulic fluid o r kerosene. All surfaces should be wiped f r e e of excessive hydraulic fluid. 2-27. NOSE GEAR SHIMMY DAMPENER. The shimmy dampener should be serviced at least every 50 hours. The shimmy dampener must be filled completely witn fluid, f r e e of entrapped a i r , t o s e r v e its purpose. To service the shimmy damp- ener, proceed a s follows: a. Remove shimmy dampener f r o m aircraft. b. While holding the dampener in a vertical posi- tion with fitting end pointed downward, pull fitting end of the dampener shaft to i t s limit of travel. c. While holding dampener in this position, fill dampener through open end of cylinder with hydraulic fluid. d. Push the shaft upward slowly to s e a l off the filler hole. e. Clean dampener with solvent. Be s u r e t o keep the shaft protruding through the filler hole until dampener is installed on the aircraft. f. Install dampener on aircraft. NOTE Keep the shimmy dampener, especially the exposed portions of the dampener piston shaft, clean to prevent collection of dust and g r i t which could cut the s e a l s i n the dampener barrel. Keep machined surfaces wiped f r e e of d i r t and dust, using a clean lint-free cloth saturated with MIL-H-5606 hydraulic fluid o r kerosene. All surfaces should be wiped f r e e of excessive hydraulic fluid. 2-28. HYDRAULIC BRAKE SYSTEMS. Check brake master cylinders and refill with hydraulic fluid a s specified i n the inspection charts. Bleed the brake system of entrapped a i r whenever there is a spongy response to the brake pedals. Refer to Section 5 f o r filling and bleeding of the brakes. 2- 29. CLEANING. 2-30. Keeping the a i r c r a f t clean is important. Be- sides maintaining the t r i m appearance of the aircraft, cleaning lessens the possibility of corrosion and makes inspection and maintenance easier. 2 -31. WINDSHIELD AND WINDOWS. Windshield and windows should b e cleaned carefully with plenty of f r e s h water and a mild detergent, using the palm of the hand t o feel and dislodge any caked d i r t or mud. A sponge, soft cloth, o r chamois may b e used, but only a s a means of carrying water t o the plastic. Rinse thoroughly, then d r y with a clean moist cham- ois. Do not r u b the plastic with a d r y cloth as this builds up a n electrostatic charge which a t t r a c t s dust. Oil and g r e a s e may be removed by rubbing lightly with a soft cloth moistened with Stoddard solvent. Do not use gasoline, alcohol, benzene, acetone, carbon tetrachloride, f i r e extinguisher fluid, de-icer fluid, lacquer thinner, o r g l a s s window cleaning spray. These solvents will soften and c r a z e the plastic. After washing, the plastic windshield and windows should be cleaned with an a i r c r a f t windshield cleaner. Apply the cleaner with soft cloths and r u b with mod- e r a t e 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 s c r a t c h e s and help prevent further scratching. Do not use a canvas cover on the wind- shield o r windows unless freezing r a i n o r s l e e t is anticipated since the cover may s c r a t c h the plastic surface. 2-32. PLASTIC TRIM. The instrument panel, plas- t i c t r i m , and control knobs need only be wiped with a damp cloth. Oil and g r e a s e on the control wheel and control knobs can be removed with a cloth moist- ened with Stoddard solvent. Volatile solvents, such as mentioned in paragraph 2-31, must never be used since they soften and c r a z e the plastic. 2-33. PAINTED SURFACES. The painted exterior surfaces of the aircraft, under normal conditions, require a minimum of polishing and buffing. Approxi- mately 15 days a r e required f o r acrylic o r lacquer paint to c u r e completely; in most cases, the curing period will have been completed p r i o r t o delivery of the aircraft. In the event that polishing o r buffing is required within the curing period, it is recommended that the work be done by an experienced painter. Generally, the painted surfaces can be kept bright by washing with water and mild soap, followed by a r i n s e with water and drying with cloths o r chamois. Harsh o r abrasive soaps o r detergents which could cause corrosion o r make s c r a t c h e s should never be used. Remove stubborn oil and g r e a s e with a cloth moistened with Stoddard solvent. After the curing period, the a i r c r a f t may be waxed with a good auto- motive wax. A heavier coating of wax on the leading edges of the wing and tail and on the engine nose cap will help reduce the abrasion encountered in these a r e a s . 2 -34. ALUMINUM SURFACES. The aluminum s u r - faces require a minimum of c a r e , but should never be neglected. The a i r c r a f t may be washed with clean water t o remove d i r t and may be washed with non- alkaline g r e a s e solvents t o remove oil and/or grease. Household type detergent soap powders a r e effective cleaners, but should be used cautiously since some of them a r e strongly alkaline. Many good aluminum cleaners, polishes, and waxes a r e available from commercial suppliers of a i r c r a f t products. 2-35. ENGINE AND ENGINE COMPARTMENT. The engine should be kept clean since dirty cooling fins and baffle plates can cause overheating of the engine. Also, cleaning is essential t o minimize any danger of f i r e and provide for e a s i e r inspection of components. The entire engine cowling may be removed to facili- tate engine and interior cowl cleaning. Wash down the engine and components with a suitable solvent, such a s Stoddard solvent o r equivalent, then d r y thor- oughly with compressed a i r . Particular c a r e should be given t o electri- cal equipment before cleaning. Solvent should not be allowed t o enter magnetos, s t a r t e r s , alternators, voltage regulators, and the like. Hence, these components should be protected before saturating the engine with solvent. Any fuel, oil, and a i r openings should be covered before washing the engine with solvent. Caustic cleaning solutions should not be used. After clean- ing engine, re-lubricate a l l control a r m s and moving parts. 2-36. UPHOLSTERY AND INTERIOR. Keeping the upholstery and interior t r i m clean prolongs uphol- s t e r y fabric and interior t r i m life. T o clean the in- t e r i o r proceed a s follows: a. Empty all a s h t r a y s and refuse containers. b. Brush o r vacuum clean the upholstery and carpet t o remove dust and dirt. c. Wipe leather and plastic t r i m with a damp cloth. d. Soiled upholstery fabrics and carpet may be cleaned with a foam-type detergent used according to the manufacturer's instructions. e. Oil spots and stains may be cleaned with house- hold 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 sol- vent; it may damage the padding and backing m a t e r i a l f. Scrape sticky material from fabric with a dull knife, then spot clean the a r e a . 2-37. PROPELLER. Wash hub and blade with a soft cloth and Stoddard cleaning solvent o r equivalent, then dry thoroughly with compressed air. The pro- peller should be wiped occasionally with a n oily cloth, then wiped with a dry cloth. In s a l t water a r e a s this will a s s i s t in corrosion proofing the propeller. 2-38. WHEELS. The wheels should be washed per- iodically and examined f o r corrosion, chipped paint, and cracks or dents in the wheel halves o r in the flanges o r hubs. If defects a r e found remove and r e - pair in accordance with Section 5. Discard cracked wheel halves, flanges o r hubs and install new parts. 2-39. LUBRICATION. 2-40. Lubrication requirements a r e shown in figure 2-5. Before adding grease to grease fittings, wipe d i r t from fitting. Lubricate until g r e a s e appears around parts being lubricated, and wipe excess g r e a s e from parts. The following paragraphs sup- plement figure 2-5 by adding details. 2-41. WHEEL BEARINGS, Clean and repack the wheel bearings a t f i r s t 100-hour inspection and a t each 500-hour inspection thereafter. If more than the usual number of take-offs and landings a r e made, extensive taxiing i s required, o r the aircraft is operated in dusty a r e a s o r under seacoast condi- tions, cleaning and lubrication of the wheel bearings shall be accomplished at each 100-hour inspection. 2-42. NOSE GEAR TORQUE LINKS. Lubricate nose gear torque links every 50 hours. When operating i n dusty conditions, more frequent lubrication is re- quired. 2-43. WING FLAP ACTUATOR. Clean and lubricate wing flap actuator jack screw each 100 hours a s follows: a. Expose jack screw by operating flaps to full- down position. b. Clean jack screw threads with solvent r a g and dry with compressed a i r . NOTE It is not necessary to remove actuator from a i r c r a f t t o clean o r lubricate threads. c. With oil can, apply light coat of No. 10 weight, non-detergent oil to threads of jack screw. 2-44. FUEL SELECTOR VALVE. At each 100 hour inspection, check the fuel selector valve and drive shaft f o r the following: a. Valve control detent plate f o r cleanliness and excessive wear. Dirt accumulation on this plate can cause binding, poor detent feel and rapid wear of the plate. b. All drive shaft attach points f o r security, bind- ing, excessive wear and lubrication, if required. c. Operate valve handle through a l l positions and check f o r proper operation, detent feel and freedom of movement. HYDRAULIC FLUID: SPEC. NO. MIL-H-5606 Refer to Sheet 2 f o r Fuel and Oil Specifications. Figure 2-4. Servicing (Sheet 1 of 4) SPECIFIED AVIATION GRADE FUELS: I ONLY AVIATION GRADE FUELS ARE APPROVED FOR USE. 100 (green) (formerly 100/130) 1 I ENGINE MODEL LYCOMING 0-320-H NOTE I1. Compliance with Avco Lycoming Service Instruction No. 1070J, and all revisions thereto, must be accomplished. APPROVEDFUELGRADES 100LL (blue) SPECIFIED AVIATION GRADE OIL: NOTE 1 AVERAGE AMBIENT TEMPERATURE (OF)/OIL GRADE O0 l o 0 20' 30 40 50' 60 70' 80' 90' MAXIMUM OIL INLET TEMPERATURE O F NOTE The overlap of oil grades i s based on a mid-range of ambient ground temperatures vs. maximum oil inlet temperature. Aviation Grade ashless dispersant oil conforming to Avco Lycoming Specification No. 301, and all revisions and supplements thereto, MUST BE USED except a s noted in paragraph 2-21 herein. Refer to the latest Revision of Avco Lycoming Service Instruction No. 1014, and any applicable Service Bulletins o r service Letters, for further recommendations. Oil capacities for the aircraft a r e given in the following chart. To minimize loss of oil through the breather, fill to specified oil level on dipstick for normal operation (flight of l e s s than three hours duration). For extended flight, fill to FULL mark on dipstick. Do not operate with l e s s than MINIMUM FOR FLIGHT quantities listed. If an external oil filter i s installed, one additional quart of oil i s required when filter is changed. Figure 2-4. Servicing (Sheet 2 of 4) 2 -13 CAPACITY (TOTAL) 6 CAPACITY (TOTAL WITH FILTER) 7 NORMAL OPERATION 5 7 MINIMUM FOR FLIGHT 4 b 3 FUEL TANK FILLER Service after each flight. Keep full to r e t a r d condensation. Refer to paragraph 2-18 f o r details. 4 FUEL TANK SUMP DRAINS Drain off any water and sediment before f i r s t flight of the day 6 PITOT AND STATIC PORTS Check for obstructions before f i r s t flight of the day. 10 FUEL STRAINER Drain off any water and sediment before the f i r s t flight of the day. Refer to paragraph 2-19 f o r details. 13 INDUCTION AIR FILTER Inspect and service under dusty conditions. Refer to paragraph 2-22 for details. 16 OIL DIPSTICK Check oil on preflight. Add oil a s necessary. Refer to paragraph 2-21 for details. 18 OIL FILLER CAP: Whenever oil i s added, check that filler cap i s tight and oil filler door is secure. 0FIRST 25 HOURS 15,17 ENGINE OIL SYSTEM Refill with straight mineral oil (non-detergent) and use until a total of 50 hours h a s accumulated o r oil consumption h a s stabilized, then change to a s h l e s s dispersant oil. Refer to paragraph 2-21 f o r details. 050 HOURS 13 INDUCTION AIR FILTER Clean filter p e r paragraph 2-22. Replace as required. 14 BATTERY Check electrolyte level and clean battery compartment each 50 hours o r each 30 days. 15 17 ENGINE OIL SYSTEM Change oil each 50 hours if engine is NOT equipped with external oil filter. If engine i s equipped with external oil filter, change filter each 50 hours and oil a t each 100 hours, o r every s i x months. 17 SHIMMY DAMPENER Check fluid level and refill a s required with hydraulic fluid. Refer to paragraph 2-27. 7 TIRES Maintain correct t i r e p r e s s u r e a s listed in figure 1-1. Also r e f e r t o paragraph 2-25 for details. - - Figure 2-4 Servicing (Sheet 3 of 4) 050 HOURS (Cont) 11 NOSE GEAR SHOCK STRUT Keep s t r u t filled and inflate to c o r r e c t p r e s s u r e . Refer to paragraph 2-26 for details. n 100 HOURS 10 FUEL STRAINER Disassemble and clean s t r a i n e r bowl and screen. 1 5,17 ENGINE OIL SYSTEM If engine i s equipped with external oil filter, change oil (and filter) every 100 hours, or every s i x months, whichever comes first. 1 VACUUM RELIEF FILTER Change each 1000 hours, o r to coincide with engine overhauls. 5 SELECTOR VALVE DRAIN Remove plug and drain off any water o r sediment. Also r e f e r to paragraph 2-19. 9 BRAKE MASTER CYLINDERS Check fluid level and refill a s required with hydraulic fluid. Refer to paragraph 2-28. 2 VACUUM SYSTEM CENTRAL A m FILTER Replace every 500 hours. // ASREQUIRED 8 GROUND SERVICE RECEPTACLE Connect to 12-volt DC, negative-ground power unit. Refer to paragraph 11-67 for details. Figure 2-4. Servicing (Sheet 4 of 4) 1 FREQUENCY (HOURS) METHOD OF APPLICATION LUBRICATE AS REQUIRED AND WHEN ASSEMBLED OR INSTALLED. NOTE HAND GREASE OIL SYRINGE GUN CAN (FOR POWDERED The military specifications listed a r e not mandatory, but a r e intended as guides i n choosing satisfactory materials. Products of most reputable manufacturers meet o r exceed these specifications. I LUBRICANTS PG - SS-G-659 . . . . . . . . . . . . POWDERED GRAPHITE GR - MIL-G-81322A . . . . . . . . . . . GENERAL PURPOSE GREASE Gti - MIL-G-23827A . . . . . . . . . . . AIRCRAFT AND INSTRUMENT GREASE G L - MIL- G- 2 1164C . . . . . . . . . . . MOLYBDENUM DISLULFIDE GREASE O G - MIL-L-7870A . . . . . . . . . . . GENERAL PURPOSE OIL P L - VV-P-236 . . . . . . . . . . . . . PETROLATUM GS - MIL-S-8660 . . . . . . . . . . . . DC4 DOW CORNING GP - . . . . . . . . . . . . . . . . . . NO. 10-WEIGHT, NON-DETERGENT OIL t-\ GR STEEIRING \ SYSTEM NEEDLE ALSO RE"-- - - l - n A n & n n BEARINGS FER TO \i ' - ~ r i ~ i - r n A P H 2 -42 TORQUE LINKS PARAGRAPH STEERING ARM BEARING V WHEEL BEARINGS NOSE GEAR ALSO REFER TO PARAGRAPH 2 -41 WHEEL BEARINGS I Figure 2-5. Lubrication (Sheet 1 of 3) di CONTROL WHEEL SHAFT BUSHINGS AND UNIVERSALS OILITE BEARINGS BUSHINGS AND ELEVATOR TRIM TAB ACTUATOR ALSO REFER TO INSPECTION CHART IN THIS SECTION AND TO SECTION 9 O F THIS MANUAL /NEEDLE BEARINGS $ G'R CONTROL "U" AILERON BELLCRANK NEEDLE BEARINGS ALL PIANO \? DOORSTOP CABIN DOOR WINDOW INSERT GROOVES G H Figure 2 -5. Lubrication (Sheet 2 of 3) NEEDLE RUDDER BARS AND PEDALS WING SPAR AND STRUT-ATTACH SCREW JACK THREADS NOTES Sealed bearings require no lubrication. Do not lubricate roller chains o r 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 o r oftener i f required. Paraffin wax rubbed on seat rails will ease sliding the seats f o r e and aft. Lubricate door latching mechanism with MIL- G-8 1322A general purpose grease, applied sparingly to friction points, every 1000 hours o r oftener, if binding occurs. No lubrication is recommended on the rotary clutch. 1 Figure 2- 5. Lubrication (Sheet 3 of 3) I INSPECTION REQUIREMENTS. As required b 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 INSPEC TION 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 a r e being flown 200 hours o r more per year, and the 100 HOUR inspection for all other aircraft. I1 INSPECTION CHARTS. The following charts show the recommended intervals a t which items a r e to be inspected. As shown in the charts, there a r e items to be checked each 50 hours, each 100 hours, each 200 hours, and also Special Inspection items which require servicing o r inspection a t intervals other than 50, 100 o r 200 hours. When conducting an inspection at 50 hours, all items marked under EACH 50 HOURS would be inspected, serviced o r otherwise accomplished a s necessary to insure continuous airworthiness. At each 100 hours, the 50 hour items would be accomplished in addition to the items marked under EACH 100 HOURS a s necessary to insure continuous airworthiness. An inspection conducted a t 200 hour intervals would likewise include the 50 hour items and 100 hour items in addition to those a t EACH 200 HOURS. The numbers appearing in the SPECIAL INSPECTION ITEMS column refer to data listed a t the end of the inspection charts. These items should be checked a t each inspection interval to insure that applicable servicing and inspection requirements a r e accomplished a t the specified intervals. A COMPLETE AIRCRAFT INSPECTION includes all 50, 100 and 200 hour items plus those Special Inspection Items which a r e due a t the time of the inspection. I11 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 COMPLETE AIRCRAFT INSPECTION consists of all 50, 100, 200 and Special Inspection Items shown in the in- spection charts a s defined in paragraph II above. b. IF NOT FLOWN FOR HIRE An aircraft operating in this category must have a COMPLETE AIRCRAFT INSPECTION each 12 calendar months (ANNUAL). A COMPLETE AIRCRAFT INSPECTION consists of all 50, 100, 200 and Special Inspection Items shown in the inspection charts a s defined in paragraph I1 above. In addition, it is recommended that between annual inspections, all items be inspected a t the intervals specified in the inspection charts. 2 . IF THE AIRCRAFT IS FLOWN MORE THAN 200 HOURS ANNUALLY. Whether flown for hire o r 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 a r e the same a s those defined under paragraph 111 1. (a) and (b). Cessna Progressive Care may be utilized a s a total concept program which insures that the inspection intervals in the inspection charts a r e not exceeded. Manuals and forms which a r e required for conducting Progressive Care in- spections a r e available from the Cessna Service P a r t s Center. IV INSPECTION GUIDE LINES. 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. FLUID LINES AND HOSES for: leaks, cracks, dents, kinks, chafing, proper radius, security, corrosion, deterioration, obstruction and foreign matter. METAL PARTS for: security of attachment, cracks, metal distortion, broken spotwelds, corrosion, condition of paint and any other apparent damage. WIRING for: security, chafing, burning, defective insulation, loose o r broken terminals, heat deterioration and corroded terminals. BOLTS IN CRITICAL AREAS for: correct torque in accordance with torque values given in the chart in Section 1, when installed o r when visual inspection indicates the need for a torque check. NOTE Torque values listed in Section 1 a r e derived from oil-free cadmium-plated threads, and a r e recommended for all installation procedures contained in this book except where other values a r e stipulated. They a r e not to be used for checking tightness of installed parts during service. FILTERS, SCREENS & FLUIDS for: cleanliness, contamination and/or replacement at specified intervals. AIRCRAFT FILE. Miscellaneous data, information and licenses a r e a part of the aircraft file. Check that the following documents a r e up-to-date and in accordance with current Federal Aviation Regulations. Most of the items listed a r e 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 a t 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. To be made available upon request: 1. Aircraft Log Book and Engine Log Book. (h) ENGINE RUN-UP. Before beginning the step-by-step inspection, 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 o r abnormalities: Engine temperatures and p r e s s u r e s . Static RPM. (Also r e f e r to Section 11 of this Manual.) Magneto drop. (Also r e f e r to Section 11 of this Manual.) Engine response to changes in power. Any unusual engine noises. Fuel selector and/or shut-off valve; operate engine(s) on each tank (or cell) position and O F F position long enough to ensure shut-off and/or selector valve functions properly. Idling speed and mixture; proper idle cut-off. Alternator and ammeter. Suction gage. Fuel flow indicator. After the inspection h a s been completed, an engine run-up should again be performed to determine that any discrepancies o r abnormalities have been corrected. SHOP N O T E S : I IMPORTANT IREAD ALL INSPECTION REQUIRE - MENTS PARAGRAPHS PRIOR TO PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Spinner 2. Spinner bulkhead . . . . . . . . . . . . . . . . . . . . . . 3. Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . Bolts and/or nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. H u b . ENGINE COMPARTMENT Check for evidence of oil and fuel leaks, then clean entire engine and compar if needed, prior to inspection. 1. Engine oil, screen, filler cap, dipstick, drain plug and external oil . . . . . . . . . . . . . . . . . . . . . . . . . 2. Oil cooler 3. Induction a i r filter . . . . . . . . . . . . . . . . . . . . . . 4. Induction airbox, a i r valves, doors and controls . . . . . . . . 5. Cold and hot a i r hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Engine baffles . . . . . . . 7. Cylinders, rocker box covers and push rod housing 8. Crankcase, oil sump, accessory section and front crankshaft seal . . . . . . . . . . . . . . . . . 9. Hoses, metal lines and fittings 10. Intake and exhaust systems . . . . . . . . . . . . . . . . . . 11. Ignition harness . . . . . . . . . . . . . . . . . . . . . . . 12. Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. Compression check 14. Crankcase and vacuum system breather lines . . . . . . . . . . 15. Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . 16. Vacuum pump and oil separator . . . . . . . . . . . . . . . . 17. Vacuum relief valve filter (cabin area) . . . . . . . . . . . . . 18. Engine controls and linkage . . . . . . . . . . . . . . . . . . 19. Engine shockmounts, mount structure and ground straps . . . . . 20. Cabin heat valves, doors and controls . . . . . . . . . . . . . 2 1. Starter, solenoid and electrical connections . . . . . . . . . . . . . . . . . . . . 22. Starter brushes, brush leads and commutator 23. Alternator and electrical connections . . . . . . . . . . . . . 24. Alternator brushes, brush leads, commutator o r slip rings . . . . 25. Voltage regulator mounting and electrical leads . . . . . . . . . 26. Magnetos (externally) and electrical connections . . . . . . . . . 27. Magneto timing. . . . . . . . . . . . . . . . . . . . . . . . 28. Carburetor and drain plug . . . . . . . . . . . . . . . . . . . 29. Firewall . . . . . . . . . . . . . . . . . . . . . . . . . . 30. Engine cowling . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 1. Fuel strainer, drain valve and control . . . . . . . . . . . . . 2. Fuel strainer screen and bowl . . . . . . . . . . . . . . . . . 3 . Fuel tank vents, caps and placards . . . . . . . . . . . . . . . . . . . . . . . . . 4. Fuel tanks, sump drains and fuel line drains 5. Drain fuel and check tank interior, attachment and outlet screens . 6. Fuel vent valves . . . . . . . . . . . . . . . . . . . . . . . 7. Fuel vent line drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Fuel selector valve and placards . . . . . . . . . . . . . . . . . . . . . 9. Fuel valve drain plug 10. Engine primer . . . . . . . . . . . . . . . . . . . . . . . . LANDING GEAR 1. Main gear wheels and fairings . . . . . . . . . . . . . . . . . 2. Nose gear wheel, torque links, steering rods, boots and fairing . . 3. Wheel bearings. . . . . . . . . . . . . . . . . . . . . . . . 4. Nose gear strut and shimmy dampener (service a s required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. T i r e s . 6. Brake fluid, lines and hoses, linings, discs, brake assemblies and master cylinders . . . . . . . . . . . . . . . . . . . . . . . 7. Parking brake system . . . . . . . . . . . . . . . . . . . . . SPECIAL INSPEC TION ITEM EACH 200 HOURS 1 10 5 11 12 ITEM   0     SPECIAL INSPECTION EACH 200 HOURS EACH 100 HOURS EACH 50 HOURS 8. Main gear springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. Steering a r m lubrication 10. Torque link lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. Park brake and toe brakes - operational check. RFRAME 1. Aircraft exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Aircraft structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Windows, windshield, doors and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Seat belts and shoulder harnesses . . . . . . . . . . . . . 5. Seat stops, seat rails, upholstery, structure and mounting . . . . . . 6. Control "U" bearings, sprockets, pulleys, cables, chains and turnbuckles . . . . . . . . . . . . . . 7. Control lock, control wheel and control "U" mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Instruments and markings 9. Gyros central a i r filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. Magnetic compass compensation 11. Instrument wiring and plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. Instrument panel, shockmounts, ground straps, cover, decals and labeling . . . . . . . . . . . . . . 13. Defrosting, heating and ventilating systems and controls . . . . . . . . . . . . . . . . . 14. Cabin upholstery, trim, sunvisors and ash trays . . . . . . . . . . . . . 15. Area beneath floor, lines, hoses, wires and control cables . . . . . . . . . . . . . 16. Lights, switches, circuit breakers, fuses and spare fuses 17. Exterior lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18. Pitot and static systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19. Stall warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20. Radios, radio controls, avionics and flight instruments. 2 1. Antennas and cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. Battery, battery box and battery cables 23. Battery electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24. Emergency locator transmitter. A     SPECIAL INSPEC TION ITEM SPECIAL INSPEC TION ITEMS EACH 200 HOURS EACH 100 HOURS 1 F i r s t 25 hours: Refill with straight mineral oil (non-detergent) and use until a total of 50 hours have accumulated o r oil consumption has stabilized, then change to ashless dispersant oil. Change filter each 50 hours and oil at each 100 hours; or every six months, whichever comes first. EACH 50 HOURS3 CONTROL SYSTEMS In addition to the items listed below, always check for correct direction of movement, correct travel and correct cable tension. 1. Cables, terminals, pulleys, pulley brackets, cable guards, turnbuckles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and fairleads . . . . . . . . . . . . . . . . . . 2. Chains, terminals, sprockets and chain guards . . . . . . . . . . . . . . . 3 . Trim control wheels, indicators, actuator and bungee 4. Travel s t o p s , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Decalsandlabeling. . . . . . . . . . . . 6. Flap control switch, flap rollers and tracks and flap indicator 7. Flap motor, transmission, limit switches, structure, linkage, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bellcranks, etc. . . . . . . . . . . . . . . . . 8. Elevator and t r i m tab hinges, tips and control rods . . . . . . . . . 9. Elevator t r i m tab actuator lubrication and tab free-play inspection. . . . . . . . . . . . . . . . . . . . . . . . 10. Rudder pedal assemblies and linkage 11. Skins (external) of control surfaces and tabs . . . . . . . . . . . . . . . . . . . 1 2 Internal structure of control surfaces . . . . . . . . . . . . . . . . . . . . . . 13. Balance weight attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 14. Flap actuator jack screw threads . . . . . . . . . . . . . . . . . . . . . . . . 2 Clean filters per paragraph 2-22. Replace a s required.  3 Replace hoses a t engine overhaul o r after 5 years, whichever comes first. 4 General inspection every 50 hours. Refer to Section 11 for 100 hour inspection. SPECIAL INSPECTION ITEMS 5 Each 1000 hours, o r to coincide with engine overhauls. 6 Each 50 hours f o r general condition and freedom of movement. These controls a r e not repairable. Replace as required a t each engine overhaul. 7 Each 500 hours 8 INTERNAL TIMING AND MAGNETO-TO-ENGINE TIMING: F i r s t 25 hours, f i r s t 50 hours, f i r s t 100 hours and thereafter a t each 100 hours, the contact breaker point compartment and magneto-to-engine timing should be inspected and checked. If magneto-to-engine timing is c o r r e c t within plus z e r o degrees and minus two degrees, internal timing need not be checked. If timing i s out of tolerance, remove magneto and s e t internal timing, then install and time t o the engine. 9 F i r s t 100 hours and each 500 hours thereafter. More often if operated under prevailing wet o r dusty conditions. 10 Replace each 500 hours. 11 Check electrolyte level and clean battery compartment each 50 hours o r each 30 days. 12 R e f e r to Section 16 of this Manual. 13 Lubrication is required of the actuator each 1000 hours and/or 3 years, whichever comes f i r s t . Refer t o figure 2-5 for g r e a s e specification. Refer to Section 9 of this Manual for free-play limits, inspection, r e - placement and/or repair. 14 Refer to paragraph 2-43 for detailed instructions. SECTION 3 FUSELAGE TABLE O F CONTENTS Page FUSELAGE a . . . . . . . . . . . . . . . 3-1 Windshield and Windows. . . . . . . . . 3-1 Description . . . . . . . . . . . . 3-1 Cleaning . . . . . . . . . . . . . 3-1 Waxing . . . . . . . . . . . . . . 3-1 Repairs . . . . . . . . . . . . . . 3-1 Scratches . . . . . . . . . . . . . 3-1 Cracks . . . . . . . . . . . . . . 3-2 Windshield . . . . . . . . . . . . . 3-4 Removal. . . . . . . . . . . . 3-4 Installation . . . . . . . . . . 3-4 Windows . . . . . . . . . . . . . . 3-4 Movable . . . . . . . . . . . . 3-4 Removal and Installation . . 3-4 Wrap-Around R e a r . . . . . . . 3-4 Removal and Installation . . 3-4 Overhead . . . . . . . . . . . 3-5 Removal and Installation . . 3-5 Fixed . . . . . . . . . . . . . 3-5 Cabin Doors . . . . . . . . . . . . . . 3-5 Removal and Installation . . . . . . 3-5 Adjustment . . . . . . . . . . . . 3-5 Weatherstrip . . . . . . . . . . . 3-5 Latches . . . . . . . . . . . . . . 3-5 . . . . . . . . . . Description 3-5 Adjustment . . . . . . . . . . 3-9 Lock . . . . . . . . . . . . . . . 3-9 Indexing Inside Handle . . . . . . . 3-9 Baggage Door . . . . . . . . . . . . . 3-9 . . . . . . Removal and Installation 3-9 Weather s t r i p . . . . . . . . . . . . 3-9 S e a t s . . . . . . . . . . . . . . . . . 3-9 3 - 1. FUSELAGE 3-2. WINDSHIELD AND WINDOWS. 3-3. DESCRIPTION. The windshield and windows a r e single-piece acrylic plastic panels set in sealing s t r i p s and held by formed retaining s t r i p s secured to the fuselage with screws and rivets. Presstite No. 579.6 sealing compound used in conjunction with a felt seal i s applied to a l l edges of the windshield and windows with exception of wing root a r e a . The wing root fairing has a heavy felt s t r i p that completes the windshield sealing. 3-4. CLEANING. (Refer to Section 2.) 3-5. WAXING. Waxing will fill i n minor scratches in clear plastic and help protect the surface from further abrasion. Use a good grade of commercial wax applied in a thin, even coat. Bring wax to a high polish by rubbing lightly with a clean, dry flan- nel cloth. 3-6. RE PAIRS. Damaged window panels and wind- Pilot and Copilot . . . . . . . . . . 3-9 Reclining Back/Fore-And-Aft Adjust. . . . . . . . . . . . 3-9 Articulating ~ e c l i n e / ~ e r t i c a l Adjust. . . . . . . . . . . . 3-9 Description . . . . . . . . 3-9 Removal and Installation . . 3-9 Center . . . . . . . . . . . . . . 3-9 Double-Width Bottom and Back/ Single Reclining Back. . . . . 3-9 Double-Width ~ o t t o m / ~ n d i v i d u a l RecliningBacks . . . . . . . 3-9 Description . . . . . . . . 3-9 Removal and Installation . . 3-9 Auxiliary . . . . . . . . . . . . . 3-9 Fold-Up . . . . . . . . . . . . 3-9 Description . . . . . . . . 3-9 Removal and Installation . . 3-14 Repair . . . . . . . . . . . . . . 3-14 Cabin Upholstery . . . . . . . . . . 3-14 Materials and Tools . . . . . . . . 3-14 Soundproofing . . . . . . . . . . . 3- 14 Cabin Headliner . . . . . . . . . . 3-14 Removal and Installation . . . . 3-14 Upholstery Side Panels . . . . . . . 3-16 Carpeting . . . . . . . . . . . . . 3-16 Safety Provisions . . . . . . . . . 3-16 Cargo Tie-Downs. . . . . . . . 3-16 Safety Belts . . . . . . . . . . 3-16 Shoulder Harness. . . . . . . . 3-16 Glider Tow Hook . . . . . . . . . . 3-16 Rear View M i r r o r . . . . . . . . . 3-16 shield may be removed and replaced i f damage i s extensive. However, certain r e p a i r s a s prescribed in the following paragraphs can be made successfully without removing damaged part from aircraft. Three types of temporary r e p a i r s for cracked plastic a r e possible. No r e p a i r s of any kind a r e recommended on highly -stressed o r compound curves where repair would be likely to affect pilot's field of vision. Curved a r e a s a r e more difficult to repair than flat a r e a s and any repaired a r e a is both structurally and optically inferior to the original surface. 3-7. SCRATCHES. Scratches on clear plastic s u r - faces can be removed by hand-sanding operations followed by buffing and polishing, if steps below a r e followed carefully. a. Wrap a piece' of No. 320 (or finer) sandpaper o r abrasive cloth around a rubber pad or wood block. Rub surface around scratch with a circular motion, keeping abrasive constantly wet with clean water to prevent scratching surface further. Use minimum p r e s s u r e and cover a n a r e a large enough to prevent formation of "bull's-eyes" o r other optical distor- tions. WOOD REINFORCEMENT CUSHION OF ALWAYS DRILL END OF CRACK TO RELIEVE STRAIN ORFABRIC - - SOFT WIRE CEMENTED LACING FABRIC PATCH TEMPORARY RE PAIR O F CRACKS SANDING REPAIR Figure 3-1. Repair of Windshield and Windows NOTE Do not use a coarse grade of abrasive. No. 320 i s of maximum coarseness. b. Continue sanding operation, using progressively finer grade abrasives until scratches disappear. c. When scratches have been removed, wash a r e a thoroughly with clean water to remove a l l gritty par- ticles. The entire sanded a r e a will be clouded with minute scratches which must be removed to r e s t o r e transparency. d. Apply fresh tallow or buffing compound to a motor-driven buffing wheel. Hold wheel against plas- tic surface, moving it constantly over damaged a r e a until cloudy appearance disappears. A 2000 -foot -per - minute surface speed i s recommended to prevent overheating and distortion. (Example: 750 rpm polishing machine with a 10 inch buffing bonnet.) NOTE Polishing can be accomplished by hand but will require a considerably longer period of time to attain the same result as pro- duced by a buffing wheel. e. When buffing i s finished, wash a r e a thoroughly and dry with a soft flannel cloth. Allow surface to cool and inspect a r e a to determine if full transpar- ency has been restored. Apply a thin coat of hard wax and polish surface lightly with a clean flannel cloth. Rubbing plastic surface with a dry cloth will build up a n electrostatic charge which a t t r a c t s dirt particles and may eventually cause scratching of surface. After wax has hardened, dissipate this charge by rub- bing surface with a slightly damp chamois. This will a l s o remove dust particles which have collected while wax i s hardening. f. Minute hairline scratches can often be removed by rubbing with commercial automobile body clean- e r o r fine-grade rubbing compound. Apply with a soft, clean, dry cloth o r imitation chamois. 3-8. CRACKS. (Refer to figure 3-1.) a . When a crack appears, drill a hole a t end of crack to prevent further spreading. Hole should be approximately 1/8 inch in diameter, depending on length of crack and thickness of material. b. Temporary r e p a i r s to flat surfaces can be a c - complished by placing a thin s t r i p of wood over each side of surface and inserting small bolts through wood and plastic. A cushion of sheet rubber o r a i r - craft fabric should be placed between wood and plas- tic on both sides. c. A temporary repair can be made on a curved surface by placing fabric patches over affected a r e a s . Secure patches with aircraft dope, Specification No. MIL-D-5549, or lacquer, Specification No. MIL-L- 7178. Lacquer thinner, Specification No. MIL-T- 6094 can a l s o be used to secure patch. Detail B NOTE à ˆ P r e s t i t No. 579.6 s e a l e r and EC-1202 reinforced tape sealant should be applied t o over-head cabin windows. B Detail A c 3 / 2 / 4 Detail F Presstite No. 579.6 s e a l e r should be anolied to a l l edges of windshield and windows when felt sealing s t r i p (3) is used. 1. Inner Retainer 2. Windshield 3. Felt Seal 4. Outer Retainer Y 5. Cabin Top Skin 6. Overhead Cabin Window 7. External Centerstrip 8. Rear Window Sealer TYPICAL METHODS OF RE- 9. Fuselage Structure TAINING FIXED WINDOWS 10. Window 11. Cover Figure 3 -2. Windshield and Fixed Window Installation d. A temporary repair can be made by drilling small holes along both sides of crack 1/4 to 1/8 inch apart and lacing edges together with soft wire. Small-stranded antenna wire makes a good temporary lacing material. This type of repair i s used a s a temporary measure ONLY, and a s soon a s facilities a r e available, panel should be replaced. 3-9. WINDSHIELD. (Refer to figure 3-2.) 3-10. REMOVAL. a. Drill out rivets securing front retainer strip. b. Remove wing fairings over windshield edges. c. Pull windshield straight forward, out of side and top retainers. Remove top retainer if necessary. 3-11. INSTALLATION. a. Apply felt strip and sealing compound o r sealing tape to a l l edges of windshield to prevent leaks. b. Reverse steps in preceding paragraph for instal- lation. c. When installing a new windshield, check fit and carefully file o r grind away excess plastic. d. Use c a r e not to crack windshield when installing. If not previously removed, top retainer may be r e - moved if necessary. Starting a t upper corner and gradually working windshield into position is recom- mended. NOTE 3-12. WINDOWS. 3-13. MOVABLE. (Refer to figure 3-3. ) A movable window, hinged a t the top, is installed in the left cab- in door. 3-14. REMOVAL AND INSTALLATION. a. Disconnect window stop (5). b. Remove pins from window hinges (6). c. Reverse preceding steps for installation. To remove f r a m e from plastic panel, drill out blind rivets a t frame splice. When replacing plastic panel in frame, ensure sealing s t r i p and an adequate coating of Presstite No. 579.6 sealing compound i s used around a l l edges of panel. 3-15. WRAP-AROUND REAR. (Refer to figure 3 - 2 . ) The r e a r window is a one-piece acrylic plastic panel set in sealing s t r i p s and held in place by retaining strips. 3-16. REMOVAL AND INSTALLATION. a. Remove external centerstrip (7). b. Remove upholstery as necessary to expose r e - tainer s t r i p s inside cabin. c. Drill out rivets a s necessary to remove outer retainer s t r i p along aft edge of window. d. Remove window by lifting aft edge and pulling window aft. If difficulty i s encountered, rivets s e - curing retainer s t r i p s inside cabin may a l s o be Screws and self-locking nuts may be used instead of rivets which fasten front retaining strip to cowl deck. If a t least No. 6 s c r e w s a r e used, no l o s s of strength will result. drilled out and retainer s t r i p s loosened o r removed. e. Reverse preceding steps for installation. Apply felt s t r i p and sealing compound to all edges of win- dow to prevent leaks. Check fit and carefully file o r grind away excess plastic. Use care not to crack plastic when installing. 3-17. OVERHEAD. (Refer to figure 3-2. ) Overhead cabin windows, located in the cabin top, may be in- stalled. These windows a r e one-piece acrylic plastic panels set in sealing s t r i p s and held in place by r e - taining strips. 3- 18. REMOVAL AND INSTALLATION. a. Remove headliner and t r i m panels. b. Drill out rivets a s necessary to remove retainer strips. c. Reverse preceding steps for installation. Apply felt s t r i p and sealing compound to all edges of window to prevent leaks. Check fit and carefully file o r grind away excess plastic. Use care not to crack plastic when installing. 3-19. FIXED. (Refer to figure 3-2. ) Fixed win- dows, mounted in sealing s t r i p s and sealing com- pound, a r e held in place by various retainer strips. To replace side windows, remove upholstery and t r i m panels a s necessary and drill out rivets secur- ing retainers. Apply felt s t r i p and sealing compound to all edges of window to prevent leaks. Check fit and file o r grind away excess plastic. Use care not to crack plastic when installing. 3-20. CABIN DOORS. (Refer to figure 3-3. ) 3-21. DESCRIPTION. A cabin door is installed on each side of the a i r c r a f t consisting of a sheet outer skin chemically bonded t o a formed inner pan assem- bly. T o this rigid structure a r e attached the door latch assembly, a remote inside handle, a pair of external hinges and a n integral doorstop assembly. A openable window is installed on the LH door and may a l s o be optionally installed on the RH door. N O T E S : 3-22. REMOVAL AND INSTALLATION. Removal of cabin doors is accomplished either by removing screws attaching the door hinges o r by removing hinge pins. NOTE Ensure clevis pin (index 21, figure 3-3) is removed before removing door. During reinstallation permanent-type hinge pins may be replaced with clevis pins secured with cotter pins. 3-23. ADJUSTMENT. Cabin doors should be adjust- ed s o that door skin f a i r s smoothly with fuselage skin. Slots a t door latch plate permit re-positioning of latch assembly and hence bolt engagement with rotary clutch on door post. If fitting a new door assembly, some trimming of door flange may be necessary but gap be- tween door skin and fuselage skin should be .09 inch o r less. Reforming of bonded door flange by striking with soft mallet etc. is NOT permissible due to possible damage t o bonded a r e a s . 3-24. CABIN DOOR WEATHERSTRIP. A hollow fluted-type, rubber weatherstrip is cemented around all edges of the cabin door. When replacing weather- strip, ensure that contact surfaces a r e clean and dry. Cut new weatherstrip t o length using old weatherstrip a s a guide. Cut small notch in butt ends of new weath- e r s t r i p t o allow f o r drainage. Position splice with notch at door low point and apply a thin, even coat of EC-880 adhesive (3-M Company) o r equivalent t o both surfaces. Allow t o dry until tacky before pressing into place on door. Do not stretch weatherstrip around door corners. 3-25. LATCHES. (Refer to figure 3-4.) 3-26. DESCRIPTION. The cabin door latch i s a push-pull bolt type, utilizing a rotary clutch for posi- NOTE 3. upholstery Panel 4. spring " Detail D 5. Window Stop 13. Washer 6. Window Hinge 14. Latch Handle 7. Latch s t r i k e r Plate 15. Hinge Pin 8. Door Structure 16. Inside Handle 9. Window F r a m e 17. A r m r e s t 10. Window 18. Washer 11. Cam 12. Lock Assembly A s required for good s e a l Al. View E-E 19. Doorstop Bracket 20. Doorstop Spring 21. Clevis Pin 22. Clevis Pin 23. Weatherstrip Figure 3 -3. Cabin Door Installation 1. Bearing Assembly 2. Nut A 3. Spacer 4. Push-Pull Rod 5. Base Plate 6. Roll Pin 7. Bolt 8. Housing 9. Outside Handle 10. Spring 11. Support 12. Shaff Assembly 13. Screw 14. Upholstery Panel 15. Armrest 16. Screw 17. Inside Handle 18. Placard Detail A Rotated 180" Figure 3 -4. Door Latch Installation Detail A 1. Inside Handle 8. Hinge 2. Cam 9. Hinge Bracket 3. Latch Assembly 10. Clevis Pin 4. Lock Assembly 11. Bolt 5. Shim 12. Cotter Pin 6. Outside Handle 13. Nut 7. Chain Reforming of the bonded door by striking with a soft mallet etc. i s NOT permissible due t o possible damage to the bonded areas. Figure 3 -5. Baggage Door Installation tive bolt engagement. As door is closed, teeth on underside of bolt engage gear teeth on clutch. The clutch gear rotates in one direction only and holds door until handle is moved to LOCK position, driving bolt into slot. 3-27. ADJUSTMENT. Adjustment of latch o r clutch cover is afforded by oversize and/or slotted holes. This adjustment ensures sufficient gear-to-bolt en- gagement and proper alignement. NOTE Lubricate door latch per Section 2. No lu- brication is recommended for rotary clutch. 3-28. LOCK. In addition to interior locks, a cylin- der and key type lock is installed on left door. If lock is to be replaced, the new one may be modified to accept the original key. This is desirable, a s the same key is used for ignition switch and cabin door lock. After removing old lock from door, proceed a s follows: a. Remove lock cylinder from new housing. b. Insert original key into new cylinder and file off any protruding tumblers flush with cylinder. Without removing key, check that cylinder rotates freely in housing. c. Install lock assembly in door and check lock operation with door open. d. Destroy new key and disregard code number on cylinder. 3-29. INDEXING INSIDE HANDLE. (Refer to figure 3-4. ) When inside door handle is removed, reinstall in relation to position of bolt (7) which is spring- loaded to CLOSE position. The following procedure may be used. a. Temporarily install handle (17) on shaft assem- bly (12) approximately vertical. b. Move handle (17) back and forth until handle centers in spring-loaded position. c. Without rotating shaft assembly (12), remove handle (17) and install placard (18) with CLOSE index at top. d. Install handle (17) to align with CLOSE index on placard (18), using screw (16). e. Install a r m r e s t (15) on upholstery panel (14). 3-30. BAGGAGE DOOR. (Refer to figure 3-5. ) 3-31. REMOVAL AND INSTALLATION. a. Remove door-pull handle (1). b. Disconnect door-stop chain (7). c. Remove buttons securing upholstery panel and remove panel. d. Remove bolts (11) securing door to hinges. e. Reverse preceding steps for installation. 3-32. BAGGAGE DOOR WEATHERSTRIP. A rubber weatherstrip is cemented around the edge of the bag- gage door and seals the door to the fuselage structure when the door is closed. A new seal can be installed after carefully cleaning door and weatherstrip contact surfaces. Apply a thin even coat of EC-880 adhesive, (3M Co.) o r equivalent and allow to dry until tacky before pressing into place. 3-33. SEATS. (Refer to figure 3-6. ) 3-34. PILOT AND COPILOT. a. RECLINING BA CK/FORE-A ND-A F T ADJUST. b. ARTICULATING RECLINE/VERTICAL ADJUST. 3-35. DESCRIPTION. These seats a r e manually operated throughout their full range of operation. Seat stops a r e provided to limit fore-and-aft travel. 3-36. REMOVAL AND INSTALLATION. a. Remove seat stops from rails. b. Slide seat fore-and-aft to disengage seat rollers from rails. c. Lift seat out. d. Reverse preceding steps for installation. En- sure all seat stops a r e reinstalled. It is extremely important that pilot's seat stops a r e installed, since acceleration and deceleration could possibly permit seat to become disengaged from seat rails and create a hazardous situation, especially during takeoff and landing. 3-37. CENTER. a. DOUBLE-WIDTH BOTTOM AND BACK/SINGLE RECLINING BA CK. b. DOUBLE-WIDTH BOTTOM/INDIVIDUAL RECLINING BACKS. 3-38. DESCRIPTION. These seats a r e permanently bolted to the cabin structure and incorporate no ad- justment provisions other than manually-adjustable three position backs. 3-39. REMOVAL AND INSTALLATION. a. Remove bolts securing seat to cabin structure. b. Lift seat out. c. Reverse preceding steps for installation. 3-40. AUXILIARY. a. FOLD-UP. 3-41. DESCRIPTION. These seats a r e permanently bolted to the cabin structure and have no adjustment provisions. The seat structure is mounted on hinge brackets with pivot bolts, thus allowing seat to be pivoted upward to acquire more baggage area. Reforming of bonded door flange by striking with soft mallet etc. is NOT permissible due to possible damage to bonded areas. 1. Link Seat Back Adjust 2. Torque Tube 3. Seat Back Adjustment Cam 4. Bushing 5. Spacer 6. Spring 7. Seat Adjustment Pawl 8. Roller 9. Bracket 1 15' NOTE Refer to figure 3-7 for seat back cam replacement. 10. Washer 11. Pin 12. Adjustment Pin 13. Seat Stop 14. Seat Rail 15. Fore/Aft Adjustment Handle 16. Recline Handle 17. Roll Pin 18. Seat Belt Retainer NOTE Install s e a t stop in eleventh hole f r o m the front of the outboard s e a t rail. Figure 3-6. Seat Installation (Sheet 1 of 5) f PILOT AND COPILOT SEATS (OPTIONAL) 1. Articulating Adjustment Handle 2. Bellcrank 3. Torque Tube 4. Seat Back 5. Magazine Pocket 6. Seat Bottom 7. Bearing Block 8. Channel 9. Seat Structure ARTICULATING RECLINE/ VERTICAL ADJUST 10. Roller 11. Vertical Adjustment Handle 12. Spring 13. Adjustment P i n 14. F'ore/Aft Adjustment Handle 15. Seat Stop 16. Screw 17. Seat Belt Retainer Install s e a t stop i n f i r s t and thirteenth hole f r o m the front of the outboard s e a t rail. F i g u r e 3-6. Seat Installation (Sheet 2 of 5) 3-11 CENTER SEAT (STANDARD) 10. Knob -- - Figure 3-6. Seat Installation (Sheet 3 of 5) 1. Seat Bottom 2. Spring 3 . Spacer 4. Seat Back 5. Bushing 6. Recline Handle 7. Pawl 8. Control Shaft 9. Headrest Detail A 1. Attach Bracket 2. Seat Bottom Structure 3. Seat Bottom 4. Seat Back 5. Floorboard 6. Mounting Bracket AUXILIARY SEAT (OPTIONAL) 6 Figure 3-6. Seat Installation (Sheet 5 of 5) 3-42. REMOVAL AND INSTALLATION. a. Remove bolts securing seat structure to hinge brackets. b. Lift seat out. c. Reverse preceding steps for installation. 3-43. REPAIR. Replacement of defective parts i s recommended in repair of seats. However, a cracked framework may be welded, provided the crack is not in an a r e a of s t r e s s concentration (close to a hinge o r bearing point). The square-tube framework i s 6061 aluminum, heat-treated to a T-6 condition. Use a heliarc weld on these seats, as torch welds will de- stroy heat-treatment of frame structure. Figure 3-7 outlines instructions for replacing defective cams on reclining bench-type seat backs. 3-44. CABIN UPHOLSTERY. Due to the wide selec- tion of fabrics, styles and colors, it is impossible to depict each particular type of upholstery. The follow- ing paragraphs describe general procedures which will serve a s a quide in removal and repl