Cessna Aircraft Company Model 172 Maintenance Manual

Manufacturers Part Number Publication Part Number Publication Title Manufacturer M881000D 006-00184-0005 006-10522-0001 006-00991-0000 006-0140-0003 006-10543-0000 Altitude Encoder/ Digitizer Owner/ Installation Manual Installation Manual Installation Manual Installation Manual Installation Manual Installation Manual G1000 Line Maintenance Manual G1000 Line Maintenance Manual G1000 Line Maintenance Manual G1000 Line Maintenance Manual G1000 Line Maintenance Manual G1000 Line Maintenance Manual Trans-Cal Industries, Inc. 16141 Cohasset St. Van Nuys, CA 91406 Allied Signal Allied Signal Allied Signal Allied Signal Allied Signal Garmin USA 1200 East 151st Street Olathe, KS 66062 Garmin USA Garmin USA Garmin USA Garmin USA Garmin USA LIST OF MANUFACTURERS' TECHNICAL PUBLICATIONS Page 4 C Cessna Aircraft Company Jul 3/2006 Blind Encoder SSD120-20 KR87 Automatic Direction Finder Global Po- sitioning System Autopilot KLN89/89B KAP 140 K1208/209 K1209A Nav Indicators Nav Indicators GDC 74 Air Data Unit GIA 63 Integrated Avionics Unit GMU 44 Magne- tometer GRS 77 AHRS GTX 33 Transpon- der GDU 1040 (PFD/ MFD) Item CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER 71 - POWERPLANT Cessna Part Manufacturers Number Part Number Publication Part Number Publication Title Manufacturer Engine 10360-L2A Engine 10360-L2A Engine 10360-L2A CHAPTER 73 - ENGINE FUEL AND CONTROL 60297-12 PC-306-12 60294-7 Operator's Manual Textron Lycoming Aircraft Engines Parts Catalog Direct Drive Engine Overhaul Manual Textron Lycoming 652 Oliver Street Williamsport, PA 17701 Textron Lycoming Textron Lycoming Cessna Part Manufacturers Number Part Number RSA-5 RSA-5 Publication Part Number 15-338D 15-810B Publication Title RSA-5 & RSA- 10 Fuel Injection Systems Operation & Service Manual Troubleshooting Techniques for the Precision Airmotive RSA Fuel Metering System Manufacturer Precision Airmotive 3220 100th St S.W.#E Everett, WA 98204 Precision Airmotive CHAPTER 74 - IGNITION Manufact- urers Part Number Publica- tion Part Number Publication Title 6351/6361 L-1363C 4300/6300 Series Magneto Maintenance and Overhaul Manual Manufacturer Slick Aircraft Products 530 Blackhawk Park Ave. Rockford, IL 61104 LIST OF MANUFACTURERS' TECHNICAL PUBLICATIONS Page 5 © Cessna Aircraft Company Jul 3/2006 Item Fuel Injection System Fuel Injection System Item Cessna Part Number Magneto Item CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CHAPTER 77 - ENGINE INDICATING Cessna Part Number Manufacturers Part Number Publication Part Number Publication Title G1000 Line Maintenance Manual Manufacturer Garmin USA 1200 East 151st Street Olathe, KS 66062 CHAPTER 79 - OIL Cessna Part Number Manufacturers Part Number Publication Part Number Publication Title G1000 Line Maintenance Manual Manufacturer Garmin USA 1200 East 151 st Street Olathe, KS 66062 LIST OF MANUFACTURERS' TECHNICAL PUBLICATIONS Page 6 © Cessna Aircraft Company Jul 3/2006 Item GEA 71 Engine/ Airframe Unit Item GDU 1040 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL SERVICE BULLETIN LIST 1. Service Bulletins Service Bulletin Date Manual Incorporation Pilot's Operating Handbook and Checklist Revision Aft Baggage Placard Inspection/Replacement Altimeter Certification Logbook Entry Verification Bendix/King Autopilot Flight Computer Modification Electrical Wire Bundle Inspection Aft Bench Seat Back Modification Fire Extinguisher Mounting Bracket Inspection Inspection of Elevator and Elevator Trim Control Cable Pulleys Inspection of Fuel Strainer Drain and Engine Muffler Tailpipe Light Dimming Module Resistor Installation Inspection KLN 89B GPS Navigation System Approach Restrictions Alternate Static Source Valve Inspection Inspection of Fuselage Station 205.812 Tailcone Bulkhead Lower Forward Doorpost Fastener Installation Alternate Air Door Hinge Assembly Replacement Engine Induction Drain Line Inspection Voltage Polarity Placard Installation Pilot's Operating Handbook and Checklist Revisions German Pilot's Operating Handbook and Checklist Revisions Brazilian Pilot's Operating Handbook Revision Firewall Sealant Replacement Alternator Replacement Pilot and Copilot Seat Back Pivot Fitting Inspection Pilot and Copilot Seat Roller Inspection Flap Follow Up System Cable Clamp Inspection ©Cessna Aircraft Company SERVICE BULLETIN LIST Pagel1 Jul 1/2007 Service Bulletin Number Title SB97-1 1-01 SB97-1 1-04 SB97-1 1-05 SB97-22-01 SB97-24-01 SB97-25-01 SB97-26-01 SB97-27-01 Rl SB97-28-01 SB97-33-01 Rl SB97-34-01 SB97-34-02 Rl SB97-53-01 SB97-53-02 Rl SB97 71 -01 Rl SB97-71 -02 SB98-1 1-01 SB98-1 1-02 SB98-1 1-05 SB98-1 1-06 SB98-20-01 Rl SB98-24-01 SB98-25-01 SB98-25-02 SB98-27-01 May 12/97 Nov 3/97 Dec 15/97 Oct 6/97 Dec 15/97 Aug 11/97 Dec 22/97 Dec 14/98 Jun 6/97 Dec 14/98 Jul 2/97 Dec 6/97 Jul 1/97 Sep 15/97 Jul 27/98 Dec 22/97 Mar 23/98 Mar 30/97 Sep 21/98 Oct 12/98 Dec 31/98 Mar 30/98 Jun 1/98 Sep 14/98 Mar 30/98 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 Jan 15/01 May 3/99 May 3/99 May 3/99 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Service Bulletin Date Manual Incorporation Aileron Control Cable Routing Inspection Aileron Primary Control Cable-to-Drum Lock Clamp Inspection Right Wing Aileron Control Cable Routing Inspection Flight Control Cables and Travel Inspection Control Yoke Attach Bushing Installation Engine Fuel Pressure Transducer Inspection and Replacement Wing to Fuselage Fuel Hose Clamp Inspection Fuel Shutoff Valve Cable Clamp Inspection KLN 89B GPS Navigation System IFR Non-Precision Approach Limitation Airborne Vacuum Pump Inspection Baggage Door Seal Replacement Firewall Rivet Inspection Firewall Inspection and Cowl Mount Alignment Elevator Stop Bolt Bracket Nutplate and Horizontal Stabilizer Installation Inspection Horizontal Stabilizer Inboard Skin Rivet Inspection Wing Strut Attach Bolts Nut Torque Inspection Forward Engine Baffle and Heat Shroud Modification Engine Air Filter Replacement Engine Exhaust Muffler Inspection and Replacement Pilot's Operating Handbook Revision Fresh Air Vent Replacement Electrical Power System Modification Circuit Panel Assembly Cover Installation Emergency Locator Transmitter (ELT) Operational Test Control Yoke Pivot Bolt Inspection/Replacement Wing Fuel Tank Vent Check Valve Inspection KLN 89B GPS Navigation System Modification SERVICE BULLETIN ©Cessna Aircraft Company LIST Page 2 Jul 1/2007 Service Bulletin Number Title SB98-27-02 R1 SB98-27-03 SB98-27-05 R2 SB98-27-06 SB98-27-07 SB98-28-01 SB98-28-02 R1 SB98-28-03 SB98-34-01 R1 SB98-37-01 R1 SB98-52-01 SB98-53-01 R1 SB98-53-02 R2 SB98-55-01 SB98-55-02 SB98-57-01 SB98-71 -01 SB98-71 -02 SB98-78-01 SB99-1 1-01 SB99-21 -01 SB99-24-01 SB99-24-02 SB99-25-01 R1 SB99-27-01 SB99-28-01 SB99-34-01 R1 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 Aug 1/00 May 3/99 May 3/99 Aug 1/00 May 3/99 May 3/99 Aug 18/01 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 May 3/99 Jan 15/01 Jan 15/01 Aug 1/00 Aug 1/00 Jan 15/01 Dec 31/98 Jun 1/98 Dec 31/98 Jun 15/98 Sep 21/98 Mar 2/98 Feb 1/99 May 4/98 Aug 3/98 Nov 2/98 Feb 23/98 Dec 14/98 Dec 26/00 Jul 6/98 Jul 27/98 Jun 1/98 Jul 27/98 Jul 27/98 Jan 10/98 Sep 27/99 Mar 15/99 Mar 15/99 Dec 27/99 Dec 27/99 Jul 12/99 Apr 26/99 Apr 24/00 Aug 1/00 Aug 1/00 Jan 15/01 0 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Service Bulletin Date Manual Incorporation Vacuum Hose Modification Elevator Control Yoke Roller Engagement Inspection/Modification Vertical Fin Aft Spar Inspection Engine Piston Pin Plug Wear Inspection Engine Oil Filler Tube to Engine Mount Clearance Engine Valve Seat Inspection Engine Fuel Manifold Spring Replacement Engine Fuel Injector Unit Inspection German Pilot's Operating Handbook Revision Pilot's Operating Handbook and Pilot's Checklist Revisions Pilot's Operating Handbook and Pilot's Checklist Revisions KAP-1 40 Autopilot Servo Inspection/Modification Main Power Junction Box Circuit Breaker Retrofit Kit Installation Electrical Panel Wiring Modifications Pitot Tube Heater Assembly Insulation Installation Vacuum System Air Filter Element Inspection! Replacement Rudder Attach Bolt Torque Inspection Flap Track and Wing Inboard Trailing Edge Inspection Propeller Hub Inspection Engine Fuel Injection Lines and Support Clamps Inspection Engine Low Oil Pressure Switch Replacement Pitot Tube Heater Insulation Installation Pilot's Operating Handbook Revisions Pilot's Operating Handbook and Pilot's Checklist Revisions Elevator Trim Tab Control Cable Stop Block Inspection Fuel Shutoff Valve Control Cable Inspection Engine Fuel Flow Divider Installation Modification ©Cessna Aircraft Company SERVICE BULLETIN LIST Page 3 Jul 1/2007 Service Bulletin Number Title SB99-37-01 SB99-53-03 SB99-55-01 SB99-71 -01 R2 SB99-71 -02 SB99-71 -05 SB99-73-01 SB99-73-02 SB00-1 1-01 5800-1 1-03 SB00-11-04 SBOO-22-01 SBOO-24-01 SBOO-24-02 SBOO-34-01 SBOO-37-01 SBOO-55-01 SBOO-57-01 R1 SBOO-61 -02 SBOO-73-01 R2 SBOO-79-01 Ril SBOO-34-01 5801 -11-01 SBO1 -11-02 SBO1 -27-01 R1 SBO1l-28-03 SBO1l-71-01 Dec 27/99 Dec 6/99 Mar 29/99 Jul 12/99 Aug 12/99 Oct 25/99 Jan 8/99 Feb 1/99 Mar 13/00 May 22/00 Aug 14/00 Feb 14/00 Mar 13/00 Jun 5/00 Apr 10/00 Aug 14/00 Apr 10/00 Apr 28/03 Aug 14/00 Dec 24/01 Feb 21/00 Apr 10/00 Feb 5/01 Mar 5/01 Feb 19/01 Jul 23/01 Jan 22/01 Aug 1/00 Aug 1/00 May 3/99 Aug 1/00 Aug 1/00 Aug 1/00 Aug 1/00 Aug 1/00 Aug 1/00 Jan 15/01 No Effect Aug 1/00 Aug 1/00 Jan 15/01 Jan 15/01 Jan 15/01 Jan 15/01 No Eff ect Jan 15/01 No Effect Jan 15/01 Feb 15/02 No Eff ect No Eff ect No Eff ect Feb 15/02 No Eff ect CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Service Bulletin N umber SB01l-74-0 1 S1BO1 -53-01 SB01l-55-0 1 SBOl-71-02 SBO01 -27-02 SBO1 -28-02 SBO1 -73-01 R2 SB02-22-01 SB02-52-01 SB02-37-02 SB02-37-03 SB02-25-01 SB02-37-04 SB02-53-02 SB02-61 -01 SB02-61 -02 SB03-1 1-02 SB03-1 1-04 SB03-23-01 SB03-24-01 S B03-24-02 SB03-25-01 SB03-27-02 SB03-28-01 SB03-32-01 SB03-34-01 SB03-34-02 R1 SB03-37-01 Title Service Bulletin Date Ignition Switch Center Ground Terminal Inspection Battery Box Support Inspection Modification Elevator Balance Weight Attach Screw Inspection/Installation Engine Crankshaft Inspection Control Yoke Assembly Inspection Fuel Selector Shaft Assembly Inspection/ Replacement Engine Driven Fuel Pump Inspection Honeywell KAP 140 Autopilot System Modification Cabin Door Handle Replacement Dry Vacuum Pump and Coupling Replacement Requirements Vacuum System Reducer Fitting Pilot and Copilot Shoulder Harness Removal Airborne Air and Fuel Products Check Valve Manifold Inspection Firewall Sealant Installation Propeller Spinner and Bulkhead Inspection Propeller Blade Inspection Pilot's Operating Handbook and Pilot's Checklist Revisions Pilot's Operating Handbook and Pilot's Checklist Revision Honeywell KMA 26 Audio Panel Modification Alternator Replacement MC01-3A Main Electrical Power Junction Box Modification Armrest Shield Installation Flap Control Bracket Attach Bolts Replacement Fuel Cap Lanyard Removal Nose Landing Gear Wheel Fairing Modification Honeywell KS270C, KS271 C, and KS272C Servo Friction Inspection Altimeter Inspection Vacuum Manifold Inspection/Replacement Jun 25/01 Feb 05/01 Apr 2/01 Apr 2/01 May 28/01 May 28/01 Oct 17/05 Nov 25/02 Jan 21/002 Feb 18/02 Feb 18/02 Apr 28/02 Oct 28/02 Dec 16/02 Jan 21/02 Dec 16/02 Apr 14/03 Oct 27/03 Jul 28/03 Jul 28/03 Oct 13/03 Feb 3/03 Dec 22/03 Oct 27/03 Sep 29/03 Oct 27/03 Feb 16/04 Nov 10/03 Manual Incorporation No Eff ect Apr 7/03 No Eff ect No Eff ect No Eff ect Apr 7/03 No Eff ect No Effect No Eff ect No Eff ect Apr 7/03 Apr 7/03 Apr 7/03 No Effect Feb 15/02 No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect Jan 2/06 No Effect No Eff ect No Eff ect Apr 7/03 ©Cessna Aircraft Company SERVICE BULLETIN LIST Page 4 Jul 1/2007 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Title Service Bulletin Date Engine Fuel Supply System Modification Fuel Injection Servo Inspection Throttle Arm Retention Inspection Pilot's Operating Handbook Revision Alternator Control Unit Inspection/Replacement Crew Seat Recline Modification Crew Seat Back Cylinder Lock Inspection and Crank Arm Modification Passenger Bench Seat Bolt Installation Crew Seat Back Cylinder Lock Control Inspection/Adjustment Elevator Trim Tab Control Cable Inspection Fuel Hose Inspection Engine Fuel Return System Installation Landing Gear Shock Strut Metering Pin Replacement Nose Security Lock Installation Horizontal Stabilizer Attach Bolt Holes Inspection Engine Starter Inspection/Replacement Engine Fuel Injection Lines and Support Clamps Inspection Engine Fuel Manifold Spring Replacement Pilot's Operating Handbook Revisions Pilot's Operating Handbook Temporary Revision 2 Trim Servo Cable Chain Inspection MC01 -3A Main Electrical Power Junction Box Circuit Breakers Inspection Inflatable Seat Belt Restraint Installation Inspection Inflatable Seat Restraints Installation Fuel Strainer Gasket Inspection High Intensity Discharge (HID) Landing and Taxi Light Installation Garmin G1000 Obstacle and Terrain Avoidance System Database Update May 26/03 May 26/03 Nov .4/03 Aug 30/04 Mar 1/04 Dec 26/06 Oct 17/05 Jul 19/04 Oct 11/04 Oct 11/04 Mar 15/04 Aug 30/04 Feb 2/04 Jun 28/04 Jun 20/05 Nov 8/04 Aug 30/04 Oct 11/04 Jul 29/05 Aug 29/05 Dec 5/05 Jan 31/05 Mar 7/05 Apr 25/05 Jan 17/05 May 9/05 Sep 26/05 Manual Incorporation No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Effect No Effect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect Jan 2/06 No Eff ect No Eff ect No Eff ect No Eff ect No Effect No Eff ect No Effect No Effect Jul 1/05 No Eff ect ©Cessna Aircraft Company SERVICE BULLETIN LIST Page 5 Jul 1/2007 Service Bulletin Number SB03-71 -01 SB03-71 -02 SB03-73-01 SB04-1 1-02 SB04-24-01 SB04-25-01 R4 SB04-25-02 R1 SB04-25-03 SB04-25-04 SB04-27-02 R1 SB04-28-01 R1 SB04-28-03 SB04-32-01 SB04-52-01 SB04-55-01 R1 SB04-71 -02 SB04-73-01 SB04-73-02 SB05-1 1-02 SB05-1 1-03 SB05-22-01 SB05-24-01 SB05-25-01 SB05-25-02 SB05-28-01 SB05-33-01 SB05-34-07 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Service Bulletin Number SB05-34-08 SB05-34-09 SB05-34-1 1 SB05-34-1 2 SB05-37-01 SB05-53-03 SBOS-57-01 SB05-73-01 SB06-111-01 SB06-11-02 SB06-1 1-03 SB06-22-01 SB06-24-01 S B06-24 -02 R1 SB06-24-03 S B06-24 -04 SB06-24-05 SB06-27-01 SB06-32-01 SB06-34-01 SB06-34-02 R1 SB06-34-03 SB06-34-04 SB06-52-01 SB06-57-01 SB06-71 -02 Title Service Bulletin Date Garmin G1000 System Software Upgrade Garmin G1 000 GDL-69A Weather And Digital Audio Entertainment Interface Installation Garmin Gia 63 Integrated Avionics Unit Outside Cover Replacement Garmin G1 000 Display Unit (GDU) 1040 Cover Glass Delamination Vacuum Pump Inspection/Replacement Floorboard Bulkhead Rivet Inspection Wing Trailing Edge Rib Inspection Engine Driven Fuel Pump Inspection Pilot's Operating Handbook Revisions Pilot's Operating Handbook Revisions Pilot's Operating Handbook and Pilot's Checklist Revisions Honeywell KS270C Pitch Servo and KS271C Roll Servo Tach Generator Modification Electrical Ground Strap Inspection 60 Ampere Alternator Rotor Replacement 60 Ampere Alternator Brush Replacement Circuit Breaker Inspection Circuit Breaker Panel Assembly Inspection Flap Aft Roller Bearing Installation Modification Brake Master Cylinder Covers Inspection Honeywell KT 73 MODE S Transponder Installation Garmin G1000 System Software Upgrade Enablemnent of Garmin G 1000 Terrain Awareness Warning System CLASS-B3 (TAWS-B) Automatic Direction Finder (ADF) and Distance Measuring Equipment (DME) Installation Cabin Door Modification Upper Wing Skin Modification Engine Compartment Fuel Hoses Security Inspection Sep 26/2005 Sep 26/05 Nov 21/05 Dec 5/05 Nov 7/05 Dec 19/05 Oct 10/05 Mar 7/05 Mar 27/06 Nov 6/06 Dec 18/06 Apr 24/06 May 8/06 Dec 26/06 Dec 18/06 Dec 26/06 Dec 26/06 Apr 10/06 Sep 25/06 Feb 27/06 Nov 6/06 May 22/06 Oct 23/06 Mar 27/06 Nov 6/06 Jun 19/06 Manual Incorporation No Effect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Effect No Eff ect No Eff ect No Effect No Eff ect No Effect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Eff ect No Effect No Effect C Cessna Aircraft Company SERVICE BULLETIN LIST Page 6 Jul 1/2007 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INTRODUCTION 1. General WARNING: All Inspection Intervals, replacement time limits, overhaul time limits, the method of Inspection, life limits, cycle limits, etc., recommended by Cessna are solely based on the use of new, remanufactured, or overhauled Cessna approved parts. If parts are designed, manufactured, remanufactured, overhauled, and/or approved by entitles 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, replacement time limits, overhaul time limits, the method of Inspection, life limits, cycle limits, etc., for such non-Cessna parts must be obtained from the manufacturer and/or seller of such non-Cessna parts. A. The information in this publication is based on data available at the time of publication and is updated, supplemented, and automatically amended by all information issued in Service Newsletters, Service Bulletins, Supplier 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 Propeller Aircraft 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 various 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 are communicated to the field through Cessna's Authorized Service Stations and/or through Cessna's subscription services. B. Inspection, maintenance and parts requirements for STC installations are not included 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. C. REVISIONS, REISSUES and TEMPORARY REVISIONS can be purchased from a Cessna Service Station or directly from Cessna Parts Distribution, Department 701, CPD 2, Cessna Aircraft Company, 5800 East Pawnee Road, Wichita, Kansas 67218-5590. D. Information in this Maintenance Manual is applicable to all U.S. and Foreign-Certified Model 172 airplanes beginning at Serial 17280001 and On, and 172S8001 and On. Information unique to a particular country is identified in the chapter(s) affected. E. All supplemental service information concerning this manual is supplied to all appropriate Cessna Service Stations so that they have the latest authoritative recommendations for servicing these Cessna airplanes. Therefore, it is recommended that Cessna owners utilize the knowledge and experience of the Cessna Service Organization. 2. Cross-Reference Listing of Popular Name Versus Model Numbers and Serials A. All airplanes, regardless of manufacturer, are certified under model number designations. However, popular names are often used for marketing purposes. To provide a consistent method of referring to these airplanes, the model number 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 names, model numbers and serial numbers. INTRODUCTION Page 1 © Cessna Aircraft Company Jun 7/2004 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL NAME MODEL SERIALS BEGINNING Skyhawk 172R 17280001 Skyhawk SP 172S 172S8001 3. Coverage and Format A. The Cessna Model 172 1996 And On Maintenance Manual has been prepared to assist maintenance personnel in servicing and maintaining Model 172 airplanes (beginning at Serial 17280001 and 172S8001). This manual provides the necessary information required to enable the mechanic to service, inspect, troubleshoot, remove and replace components or repair systems. NOTE: This manual is not intended to cover Model 172 airplanes produced prior to 1996. For manuals related to these airplanes, please refer to applicable listings in the Cessna Propeller Aircraft Care Customer Supplies and Publications Catalog. B. This manual has been prepared in accordance with the Air Transport Association (ATA) Specification Number 100 for Manufacturer's Technical Data. C. Information beyond the scope of this manual may be found in the applicable Model 172 Wiring Diagram Manual, Model 172 Illustrated Parts Catalog and the Single Engine Models 172, 182, T182, 206 and T206, 1996 And On, Structural Repair Manual. D. Technical Publications are also available for the various components and systems which are not covered in this manual. These manuals must be utilized as required for maintenance of those components and systems, and may be purchased from the manufacturer. 4. Temporary Revisions A. Additional information which becomes available may be provided by temporary revision. This service is used to provide, without delay, new information which will assist in maintaining safe flight/ground operations. Temporary revisions are numbered consecutively within the ATA chapter assignment. Page numbering utilizes the three-element number which matches the maintenance manual. Temporary revisions are normally incorporated into the maintenance manual at the next regularly scheduled revision. 5. Serialization A. All Model 172 airplanes are issued a serial number. This number is assigned as construction begins and remains with the airplane throughout its service life. This serial number appears on the airplane ID plate, located below the horizontal stabilizer, and on a trim plate located on the pilot side doorpost. This serial number is used to identify changes within the text or within an illustration. The absence of a serial number in text or illustration indicates the material is applicable to all airplanes. 6. Material Presentation A. This Maintenance Manual is available on paper, aerofiche or Compact Disc (CD/ROM). The CD/ROM contains the Maintenance Manual, Illustrated Parts Catalog Manual, Wiring Diagram Manual and Structural Repair Manual on a single disc. 7. Service Bulletins A. Service Bulletins have special inspections and approved modifications to the airplane and/or systems. As service bulletins are issued, they will be included in subsequent scheduled manual revisions and recorded in the Service Bulletin List, which is before the Introduction of the manual. The list includes: (1) Service Bulletin Number - This Service Bulletin number column identifies the bulletin by number. Service Bulletins are numbered to agree with ATA chapter assignment. (2) Service Bulletin Date - The service bulletin date column gives the date the bulletin became active. (3) Title - The title column gives the service bulletin by name. It is the same title shown on page one of the service bulletin. INTRODUCTION Page 2 © Cessna Aircraft Company Jun 7/2004 CESSNA AIRCRAFT COMPANY MODEL 1 72 MAINTENANCE MANUAL (4) Manual Incorporation - The manual incorporation column shows the date of incorporation of the service bulletin in the maintenance manual, if applicable. If incorporation of the service bulletin is not necessary, this column shows "No Effect" or dashed lines if the service bulletin has not been worked. 8. Using the Maintenance Manual A. Division of Subject Matter. (1) The Maintenance Manual is divided into four major sections. The major sections are in turn separated into chapters, with each chapter having its own effectivity page and table of contents. The manual divisions are as follows: (a) Major Section 1 - Airplane General Chapter Title 5 6 7 8 9 10 11 12 (b) Major Section Chapter 20 21 22 23 24 25 26 27 28 31 32 33 34 37 Time Limits/Maintenance Checks Dimensions and Areas Lifting and Shoring Leveling and Weighing Towing and Taxiing Parking, Mooring, Storage and Return to Service Placards and Markings Servicing 2 - Airframe Systems Title Standard Practices - Airframe Air Conditioning Auto Flight Communications Electrical Power Equipment/Furnishings Fire Protection Flight Controls Fuel Indicating/Recording Systems Landing Gear Lights Navigation Vacuum (c) Major Section 3 - Structures © Cessna Aircraft Company INTRODUCTION Page 3 Jun 7/2004 I CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Title Standard Practices and Structures - General Doors Stabilizers Windows Wings (d) Major Section 4 - Power Plant Chapter Title 61 Propeller 71 Power Plant Engine Fuel and Control Ignition Engine Controls Engine Indicating Exhaust Oil Starting B. Page Numbering System. (1) The page numbering system used in the Maintenance Manual consists of three-element numbers separated by dashes. Refer to the example below for an illustration of typical numbering layout as used in the ATA format. Chapter/System (Auto Flight) 22-10-00 Subject/Unit (Auto Pilot) Section/Subsystem (Auto Pilot) (2) When the chapter/system element number is followed with zeros in the section/subsystem and subject/unit element number (22-00-00), the information is applicable to the entire system. (3) When the section/subsystem element number is followed with zeros in the subject/unit element number (22-10-00), the information is applicable to the subsystem within the system. (4) The subject/unit element number is used to identify information applicable to units within the subsystems. The subject/unit element number progresses sequentially from the number -01 in accordance with the number of subsystem units requiring maintenance information. (5) All system/subsystem/unit (chapter/section/subject) maintenance data is separated into specific types of information: description and operation, troubleshooting, maintenance practices. Blocks of sequential page numbers are used to identify the type of information: Page 1 through 99 - Description and Operation © Cessna Aircraft Company INTRODUCTION Page 4 Jun 7/2004 Chapter 51 52 55 56 57 73 74 76 77 78 79 80 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL Page 101 through 199 - Troubleshooting Page 201 through 299 - Maintenance Practices Page 301 through 399 - Servicing Page 401 through 499 - Removal/Installation Page 501 through 599 - Adjustment/Test Page 601 through 699 - Inspection/Check Page 701 through 799 - Cleaning/Painting Page 801 through 899 - Approved Repairs NOTE: In most cases, the individual topics have been combined into a 200-series document (Maintenance Practices). When specific topics require lengthy explanation, they will utilize the page blocks mentioned above. (6) A typical page number: 22-1 0-00 Page 202 Second Page of Nov 3/97 Auto Pilot Auto Flight Auto Pilot Date of Page Issue Auto Pilot (7) Illustrations are also tied into the page block numbering system. For example, all illustrations within a Maintenance Practices section will begin with the number 2 (i.e. Figure 201, Figure 202, etc.). Conversely, all illustrations within an Approved Repair section will begin with the number 8 (i.e. Figure 801, Figure 802, etc.). 9. Effectivity Pages A. A list of effective pages is provided at the beginning of each maintenance manual chapter. All pages in the specific chapter are listed in numerical sequence on the Effectivity Page(s) with the date of issue for each page. 10. Revision Filing Instructions A. Regular Revision. (1) Pages to be removed or inserted in the maintenance manual are determined by the effectivity page. Pages are listed in sequence by the three-element number (chapter/section/subject) and then by page number. When two pages display the same three-element number and page number, the page with the most recent Date of Page Issue shall be inserted in the maintenance manual. The date column on the corresponding chapter effectivity page shall verify the active page. B. Temporary Revision. (1) File temporary revisions in the applicable chapter in accordance with filing instructions appearing on the first page of the temporary revision. (2) The rescission of a temporary revision is accomplished by incorporation into the maintenance manual or by a superseding temporary revision. A Record of Temporary Revisions is furnished in the Temporary Revision List located previous to the Introduction. A Manual Incorporation Date column on the Temporary Revision List page will indicate the date the temporary revision was incorporated, thus authorizing the rescission of the temporary revision. INTRODUCTION Page 5 © Cessna Aircraft Company Jun 7/2004 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 11. Identifying Revised Material A. Additions or revisions to text in an existing section will be identified by a revision bar in the left margin of the page and adjacent to the change. B. When technical changes cause unchanged text to appear on a different page(s), a revision bar will be placed in the left margin opposite the chapter/section/subject, page number and date of all affected pages, providing no other revision bar appears on the page. These pages will display the current revision date in the Date of Page Issue location. C. Chapter 5 may contain revision bars to indicate revised text. Inspection items in section 5-10-01 are also noted as revised, added or deleted by the date of changed item code. A revision date is indicated below the page number. D. When extensive technical changes are made to text in an existing section that requires extensive revision, revision bars will appear the full length of text. E. Revised and new illustrations will be indicated by either a revision bar along the side of the page or a hand indicator directing attention to the area. 12. Warnings, Cautions and Notes A. Throughout the text in this manual, warnings, cautions and notes pertaining to the procedures being accomplished are utilized. These adjuncts to the text are used to highlight or emphasize important points. Warnings and Cautions precede the text they pertain to, and Notes follow the text they pertain to. (1) WARNING - Calls attention to use of materials, processes, methods, procedures or limits which must be followed precisely to avoid injury or death to persons. (2) CAUTION - Calls attention to methods and procedures which must be followed to avoid damage to equipment. (3) NOTE - Calls attention to methods which will make the job easier. 13. Propeller Aircraft Customer Care Supplies and Publications Catalog A. A Cessna Propeller Aircraft Customer Care Supplies and Publications Catalog is available from a Cessna Service Station or directly from Cessna Propeller Product Support Dept.751, Cessna Aircraft Company, P.O. Box 7706, Wichita, Kansas 67277-7706. This catalog lists all publications and Customer Care Supplies available from Cessna for prior year models as well as new products. To maintain this catalog in a current status, it is revised yearly and issued in paper and aerofiche form. 14. Customer Comments on Manual A. Cessna Aircraft Company has endeavored to furnish you with an accurate, useful and up-to-date manual. This manual 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 general comments you wish to make. INTRODUCTION Page 6 © Cessna Aircraft Company Jun 7/2004 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL LIST OF REVISIONS 1. Revisions A. This Maintenance Manual includes the original issue and the revisions listed in Table 1. To make sure information in this manual is current and the latest maintenance and inspections procedures are available, the revisions must be incorporated in the manual as they are issued. Table 1. Basic Manual - Original Issue - 2 December 1996 Date Writer 1 16 May 1997 3 3 May 1999 5 15 January 2001 7 lS February 2002 9 7 June 2004 11 1 July 2005 13 3 July 2006 15 1 July 2007 jgb rdg dll bjo jcn Revision Number 2 4 6 8 10 12 14 ©Cessna Aircraft Company Date 6 April 1998 1 August 2000 18 August 2001 7 April 2003 3 January 2005 2 January 2006 1 January 2007 Rei Nu wisiofl mber Writer I jgb jgb rdg/dll bjo jcn LIST OF REVISIONS Page 1 Jul 1/2007 CESSNA AIRCRAIFT COMPANY MODEL 172 MAINTENANCE MANUAL LIST OF CHAPTERS CHAPTER Time Limits/Maintenance Checks Dimensions and Areas Lifting and Shoring Leveling and Weighing Towing and Taxiing Parking and Mooring Placards and Markings Servicing Standard Practices - Airframe Air Conditioning Auto Flight Communications Electrical Power Equipment/Furnishings Fire Protection Flight Controls Fuel Indicating/Recording Systems Landing Gear Lights Navigation Vacuum Standard Practices -Structures Doors Stabilizers Windows Wings Propellers Powerplant Engine Fuel and Control Ignition Engine Controls Engine Indicating Exhaust Oil Starting EFFECTIVE DATE* Jul 1/2007 Jul 1/2007 Jan 3/2005 Jan 3/2005 Jan 3/2005 Jan 3/2005 Jan 3/2005 Jan 1/2007 Jan 1/2007 Jan 2/2006 Jan 3/2005 Jan 1/2007 Jul 3/2006 Jan 1/2007 Jan 3/2005 Jul 1/2007 Jul 1/2007 Jan 2/2006 Jan 1/2007 Jan 2/2006 Jul 1/2007 Jan 2/2006 Jan 3/2005 Jul 3/2006 Jan 3/2005 Jan 2/2006 Jan 3/2005 Jul 1/2007 Jan 1/2007 Jan 1/2007 Jan 3/2005 Jan 2/2006 Jul 1/2007 Jan 3/2005 Jan 2/2006 Jul 1/2007 FICHE/FRAME 1 B2 1 E6 1 F5 1 F13 1 G2 1 G9 1 H2 H8 A2 C12 D6 E2 E2 1 G21 Ji13 Ji19 A2 C9 D2 F2 G12 Ji13 KS K15 L10 A2 A16 B2 B10 Cl16 D10 E2 El13 F5 F13 G5 NOTE 1: *Represents date of page one of each chapter's List of Effective Pages which is applicable to Manual revision date. Q Cessna Aircrafl Company LIST OF CHAPTERS Page 1 Jul 1/2007 5 6 7 8 9 10 11 12 20 21 22 23 24 25 26 27 28 31 32 33 34 37 51 52 55 56 57 61 71 73 74 76 77 78 79 80 CHAPTER TIME LIMITS/ MAINTENANCE CHECKS CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE STATUS NUMBER TASK INTERVAL OPERATION Revised 246101 Essential and Crossfeed Bus Diodes - 5 20 224 Jul 1/05 Complete a check for proper operation. Complete the Essential and Crossfeed Bus Diode Inspection. Refer to Chapter 24, Essential and Crossfeed Bus Diodes - Maintenance Practices. Revised 251001 Seats - Examine the seats to make B 1, 3 211 Jul 3/06 sure they are serviceable and installed correctly. Make sure the seat stops and adjustment mechanism operate correctly. Examine the seat recline control and attaching hardware to make sure the hardware and lock are not damaged and are correctly installed. Lubricate the threads of the Seat Crank Handle Assembly with MlIL-PRF-81 322 general purpose grease. 251002 Seat Tracks and Stops - Inspect seat B 2, 4 230 tracks for condition and security of installation. Check seat track stops for damage and correct location. Inspect seat rails for cracks. 251101 Restraint System, front and rear - B 1,3 211 Check belts for thinning, fraying, cutting, broken stitches, or ultra-violet deterioration. Check system hardware for security of installation. Revised 251102 AMSAFE Aviation Inflatable Restraint 5 20 211 Jul 1/05 (AAIR) - Examine the restraint for dirt, frayed edges, unserviceable stitching, loose connections, and other wear. 252201 Upholstery, Headliner, Trim, and D 5 211 Carpeting - Check condition and security. Revised 256001 Emergency Locator Transmitter - B 1, 3 310 Jan 2/06 Inspect for security of attachment and check operation by verifying transmitter output. Check cumulative time and useful life of batteries in accordance with 14 CFR Part 91 .207. 262001 Portable Hand Fire Extinguisher - B 1, 3 230 Inspect for proper operating pressure, condition, security of installation, and servicing date. Added 262002 Cockpit Mounted Halon Type Fire P 17 211 May 3/99 Extinguisher - Weigh bottle. Bottle must be reserviced by qualified individual if more than 2 ounces is lost. 5-10-01 Page 3 Jul 3/2006 0 Cessna Aircraft Company ZONE CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL LIST OF EFFECTIVE PAGES CHAPTER-SECTION-SUBJECT 05-Title 05-List of Effective Pages 05-Record of Temporary Revisions 05-Table of Contents 5-00-00 5-00-10 5-1 0-00 5-1 0-01 5-11 -00 5-1 2-00 5-1 2-01 5-1 2-02 5-1 2-03 5-12-04 5-1 2-05 5-1 2-07 5-1 2-09 5-12-10 5-12-11 5-12-12 5-12-13 5-12-14 5-12-15 5-12-16 5-12-17 5-12-18 5-12-19 5-1 2-20 5-12-2 1 5-1 2-22 5-1 2-23 5-1 2-24 5-1 2-25 5-50-00 ©Cessna Aircraft Company 05 - LIST OF EFFECTIVE PAGES Page 1 of 1 Jul 1/2007 PAGE Pages 1-2 Page 1 Pages 1-2 Pages 1-14 Pages 1-2 Pages 1-2 Pages 1-6 Pages 1-5 Pages 1-6 Pages 1-5 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Page 1 Pages 1-5 DATE Jul 1/2007 Jan 3/2005 Jul 3/2006 Jan 3/2005 Jul 1/2007 Jul 1/2007 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jul 3/2006 Jan 2/2006 Temporary Revision Number RECORD OF TEMPORARY REVISIONS Page Number Issue Date By Date Removed By CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL CONTENTS TIME LIMITS/MAINTENANCE CHECKS ...................... Scope.................................... Inspection Requirements........................... Inspection Program Selection......................... Description ................................. General Inspection Terms and Guidelines.................... AIRWORTHINESS LIMITATIONS - FAA APPROVED DATA.............. Scope.................................... Airworthiness Limitations........................... INSPECTION TIME INTERVALS.......................... General................................... Procedure.................................. Inspection Terms and Guidelines ....................... Chart Legend ................................ INSPECTION TIME LIMITS ............................ Inspection Items............................... COMPONENT TIME LIMITS............................ General................................... Cessna-Supplied Replacement Time Limits .................. Supplier-Supplied Replacement Time Limits .................. PROGRESSIVE CARE PROGRAM ........................ General................................... Procedure.................................. Inspection Terms and Guidelines ....................... INSPECTION OPERATION 1........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 2 ........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 3 ........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 4 ........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 5 ........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 7........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 9 ........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 10........................... Description ................................. General Inspection Criteria .......................... 5-00-00 Page 1 5-00-00 Page 1 5-00-00 Page 1 5-00-00 Page 1 5-00-00 Page 1 5-00-00 Page 2 5-00-10 Page 1 5-00-10 Page 1 5-00-10 Page 1 5-1 0-00 Page 1 5-10-00 Page 1 5-10-00 Page 1 5-10-00 Page 1 5-10-00 Page 1 5-10-01 Page 1 5-10-01 Page 1 5-11 -00 Page 1 5-1 1-00 Page 1 5-1 1-00 Page 1 5-1 1-00 Page 2 5-12-00 Page 1 5-12-00 Page 1 5-12-00 Page 2 5-12-00 Page 2 5-12-01 Page 1 5-12-01 Page 1 5-12-01 Page 1 5-12-02 Page 1 5-12-02 Page 1 5-12-02 Page 1 5-12-03 Page 1 5-12-03 Page 1 5-12-03 Page 1 5-12-04 Page 1 5-12-04 Page 1 5-12-04 Page 1 5-12-05 Page 1 5-12-05 Page 1 5-12-05 Page 1 5-12-07 Page 1 5 12 07 Page 1 5-12-07 Page 1 5-12-09 Page 1 5-12-09 Page 1 5-12-09 Page 1 S-1 2-1 0 Page 1 5-12-1 0 Page 1 5-12-1 0 Page 1 05 - CONTENTS Page 1 of 2 Jul 1/2007 © Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INSPECTION OPERATION 11........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 12........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 13........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 14........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 15........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 16........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 17........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 18........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 19........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 20........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 21........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 22........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 23........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 24........................... Description ................................. General Inspection Criteria .......................... INSPECTION OPERATION 25........................... Description ................................. General Inspection Criteria .......................... UNSCHEDULED MAINTENANCE CHECKS .................... General................................... Unscheduled Maintenance Checks Defined and Areas of Inspection ....... 5-12-11 Page 1 5-12-11 Page 1 5-12-11 Page 1 5-12-12 Page 1 5-12-12 Page 1 5-12-12 Page 1 5-12-13 Page 1 5-12-13 Page 1 5-12-13 Page 1 5-12-14 Page 1 5-12-14 Page 1 5-12-14 Page 1 5-12-15 Page 1 5-12-15 Page 1 5-12-15 Page 1 5-12-16 Page 1 5-12-16 Page 1 5-12-16 Page 1 5-12-17 Page 1 5-12-17 Page 1 5-12-17 Page 1 5-12-18 Page 1 5-12-18 Page 1 5-12-18 Page 1 5-12-19 Page 1 5-12-19 Page 1 5-12-19 Page 1 5-12-20 Page 1 5-12-20 Page 1 5-12-20 Page 1 5-12-21 Page 1 5-12-21 Page 1 5-12-21 Page 1 5-12-22 Page 1 5-12-22 Page 1 5-12-22 Page 1 5-12-23 Page 1 5-12-23 Page 1 5-12-23 Page 1 5-12-24 Page 1 5-12-24 Page 1 5-12-24 Page 1 5-12-25 Page 1 5-12-25 Page 1 5-12-25 Page 1 5-50-00 Page 1 5-50-00 Page 1 5-50-00 Page 1 05 - CONTENTS Page 2 of 2 Jul 1/2007 ©0 Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL TIME LIMITS/MAINTENANCE CHECKS 1.Scope A. This chapter provides the time limits and maintenance checks for the Model 172 airplanes. It is divided into several sections, each with a specific purpose toward providing information necessary to establish inspection criteria. 2. Inspection Requirements A. As required by U.S. 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 have a complete inspection every 100 hours of operation. B. Compliance with the regulations is accomplished using one of three methods: (1) Traditional (Annual/1OU Hour) inspection program which utilizes 14 CFR 43, Appendix D (scope and detail) to inspect the airplane. In addition, Cessna recommends certain components or items be inspected at 50 hour intervals. These inspection items are listed in Inspection Time Intervals, Section 5-10-01. (2) Progressive Care inspection program which allows the work load to be divided into smaller operations that can be accomplished in a shorter time period. This method is detailed in Progressive Care Program, Section 5-12-00. (3) PhaseCard inspection program which is geared toward high-utilization flight operations (approximately 600 or more flight hours per year). This system utilizes 50-hour intervals (Phase 1 and Phase 2) to inspect high-usage systems and components. At 12 months or 600 flight hours, whichever occurs first, the airplane undergoes a complete (Phase 3) inspection. PhaseCard Inspection programs can be ordered through Propeller Aircraft Product Support, P.O. Box 7706, Wichita, KS 67277-7706, Phone (316) 517-5800, Fax (316) 517-7271. 3. Inspection Program Selection A. The selection of an inspection program (Annual, Progressive Care or PhaseCard) is primarily based on owner/operator preferences, whether an airplane is flown for hire, and numbers of hours flown during the year. 4. Description A. Listed below is a brief description and intended purpose of each section of this chapter. For detailed information related to each particular inspection program, refer to the specific section within this chapter. B. Section 5-00-00, Time Limits/Maintenance Checks - General. This section provides a general overview of inspection requirements. C. Section 5-1 0-01, Inspection Time Intervals. The primary purpose of this section is to provide a central location for inspection time intervals. This section may also be utilized in conjunction with 14 CFR Part 43 to provide greater detail on inspection criteria when performing Annual/i 00-Hour inspections. D. Section 5-11-00, Component Time Limits. This section provides a list of components which are life- or time-limited. Although these components are not listed in any of Cessna's inspection programs, they must be considered and included in whatever inspection program is used. E. Section 5-12-00, Progressive Care Program. This section outlines the progressive inspection program. The program is divided into four primary operations which cover all inspection requirements up through the 200-hour interval inspection items. The remaining operations cover inspections which are at intervals other than what the four primary operations cover. Refer to the Progressive Care Program section for a more detailed description of the Progressive Care Program. 5-00-00 Page 1 © Cessna Aircraft Company Jul 1/2007 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL 5. General Inspection Terms and Guidelines NOTE: When inspections criteria is required, this criteria is spelled out in the text. If more detailed instructions are required for an inspection, these instructions will be referenced out to appropriate locations (supplier publications and/or the maintenance manual). A. Definitions of terms used through the inspection programs are as follows: (1) ON CONDITION is defined as the necessary inspections and/or checks to determine that a malfunction or failure of the component will not occur prior to the next scheduled inspection. (2) CONDITION is defined as inspection for (but not limited to) cleanliness, cracks, deformation, corrosion, wear, and loose or missing fasteners. (3) SECURITY: Inspect for looseness of fasteners and fastener securing devices such as safety wire, coffer pins and self-locking nuts. B. During Inspections, use the following general guidelines: (1) MOVABLE PARTS: Inspect 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. (2) FLUID LINES AND HOSES: Inspect for leaks, cracks, bulging, collapsed, twisted, dents, kinks, chafing, proper radius, security, discoloration, bleaching, deterioration, and proper routing; rubber hoses for hardness or flexibility and metal lines for corrosion. (3) METAL PARTS: Inspect for security of attachment, cracks, metal distortion, loose or broken terminals, heat deterioration, and corroded terminals. (4) WIRING: Inspect for security, chafing, burning, arcing, defective insulation, loose or broken terminals, heat deterioration, and corroded terminals. (5) STRUCTURAL FASTENERS: Inspect for correct torque in accordance with applicable torque values. Refer to Chapter 20, Torque Data - Maintenance Practices, during installation or when visual inspection indicates the need for a torque check. CAUTION: Torque values listed in this manual are not to be used for checking tightness of installed parts during service. (6) FILTERS, SCREENS, AND FLUIDS: Inspect for cleanliness and the need for replacement at specified intervals. (7) A system check (operation or function) that requires electrical power, must be performed using 28.5 Volts, +0.25 or -1 .00 Volts, bus voltage. This will make sure that all components are I ~ ~~~operating at their operational voltage. C. Airplane file. (1) Miscellaneous data, information, and licenses are a part of the airplane 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 Federal Aviation Regulations. Since the regulations of other nations may require other documents and data, owners of airplanes operated outside the United States should check with their own aviation officials to determine their individual requirements. (a) To be displayed in the airplane at all times: 1 Standard Airworthiness Certificate (FAA Form 81 00-2). 2 Aircraft Registration Certificate (FAA Form 8050-3). 3 Aircraft Radio Station License (Federal Communication Commission Form 556 if transmitter is installed). (b) To be carried in the airplane at all times: .1 Weight and Balance Data Sheets and associated papers (all copies of the Repair and Alteration Form, FAA Form 337, are applicable). 2 Equipment List. 3 Pilot's Operating Handbook and FAA Approved Airplane Flight Manual. (c) To be made available upon request: 1 Airplane, Engine and Propeller Logbooks. 5-00-00 Page 2 © Cessna Aircraft Company Jul 1/2007 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL AIRWORTHINESS LIMITATIONS - FAA APPROVED DATA 1. Scope A. The Airworthiness Limitations section is FAA-approved and specifies maintenance required under Parts 43.16 and 91.403 of Title 14 of the Code of Federal Regulations unless an alternative program has been FAA-approved. 2. Airworthiness Limitations A. There are no airworthiness limitations associated with this airplane. 5-00-10 Page 1 Jan 3/2005 © Cessna Aircraft Company CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INSPECTION TIME INTERVALS 1. General A. The primary function of this section is to give inspection time intervals. Section 5-10-01 is an index of the inspections that you can use with 14 CFR, Part 43 inspection scope and detail. It is not recommended, however, that you use Section 5-10-01 as the primary checklist for inspection of the airplane. NOTE: The inspection information in this section is not made to be all-inclusive. No chart can replace the good judgment of certified Airframe and Powerplant mechanics. The owner or operator must make sure of the airplane's airworthiness and must use only qualified personnel to do maintenance on the airplane. 2. Procedure A. A complete airplane inspection includes all inspection items as required by 14 CFR 43, Appendix D, Scope and Detail of annual/100 hour inspections. Use the chart in this section as an augmentation for the inspection. B. Examine the Component Time Limits section (5-11-00) with this inspection to make sure the correct overhaul and replacement requirements are completed at the specified times. C. The intervals shown are recommended intervals at which items are to be examined for normal use under average environmental conditions. Airplanes operated in extremely humid areas (tropics), or in unusually cold, damp climates, etc., can need more frequent inspections for wear, corrosion, and lubrication. Under these adverse conditions, complete periodic inspections related to this chart at more frequent intervals until operator field experience is used to set individual inspection intervals. (1) The 14 CFR Part 91 operator's inspection intervals must obey the inspection time limits shown in this manual except as given below: (Refer to 14 CFR 91.409.) (a) The airplane can operate only ten hours more than its inspection point, if the airplane is enroute to a facility to have the inspection completed. (b) If any operation is scheduled after its inspection point, the next operation in sequence keeps the required date from the time that the late operation was originally scheduled (schedule again if late). (c) If any scheduled operation is completed early, and is 10 hours or less ahead of schedule, the next scheduled phase can keep its original date. (d) If any scheduled operation is obeyed early, and it is more than 10 hours ahead of schedule, the next phase must be rescheduled from the time the operation was completed. 3. Inspection Terms and Guidelines A. For inspection terms and guidelines, refer to Time Limits/Maintenance Checks - General. 4. Chart Legend A. Each page of the inspection given in Inspection Time Limits, Section 5-10-01, contains the five columns that follow: (1) REVISION STATUS - This column supplies the date that a given item was added, deleted or revised. A blank entry in this column is an indication there have been no changes since the original issue of this manual. (2) INSPECTION ITEM CODE NUMBER - This column gives a six-digit number permanently assigned to a scheduled maintenance item. A given inspection item code number will never change and will not be used again if the scheduled maintenance item is deleted. (3) REQUIREMENTS - This column supplies a short description of the inspection and/or servicing procedures. Where more detailed procedure information is required, a reference will be made to either another section in the maintenance manual or a specific reference to a supplier publication. (4) INTERVAL - This column gives the frequency of the inspection in an alphabetic coded form. The legend for the alpha code is shown below. 5-10-00 Page 1 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL (5) OPERATION - The Progressive Care inspection program lets the work load to be divided into smaller operations, that can be completed in a shorter time period. This program is supplied in section 5-12-00, which is the Progressive Care Program. (6) ZONE - This column gives the locations for the components within a specific zone. For a breakdown of how the airplane is zoned, refer to Chapter 6, Airplane Zoning - Description and Operation. INTERVAL OPERATION INTERVAL LETTER A. 1, 2, 3, 4 Every 50 hours. B. 1, 2, 3, 4 Every 100 hours. C. 1, 2, 3, 4 Every 200 hours. D. 5 Every 400 hours or 1 year, whichever occurs first. E. (Not used. NOTE) First 100 hours and each 500 hours thereafter. F. 7 Every 600 hours or 1 year, whichever occurs first. G. (Not used. NOTE) Every 1000 hours or 3 years, whichever occurs first. H. 9 Every 500 hours. I. 10 Every 1000 hours. J. 11 Every 2 years. K. 12 Beginning five years from the date of the manufacture, you must make sure of the serviceability of the components every twelve months. Refer to Airborne Air and Fuel Products Service Letter Number 39A or latest revision. L. 13 Every 50 hours or four months, whichever occurs first. M. 14 Every 2 years, or anytime components are added or removed which have the potential to affect the magnetic accuracy and/or variation of the compass calibration, or anytime the accuracy of the compass is in question. N. 15 Every 2000 hours. O. 16 Every 1000 hours or 1 year, whichever occurs first. P. 17 Every 12 calendar months. Q. 18 Every 6 years. R. 19 Every 12 years. S. 20 Every 1 year. T. 21 Every 6 years, or every 1000 hours, whichever occurs first. U. 22 Every 100 hours or every one year, whichever occurs first. V. 23 Every 100 hours, every annual inspection, every overhaul, and any time fuel lines or clamps are serviced, removed or replaced. W. 24 First 600 hours and as defined by the manufacturer thereafter. X. 25 Every 1000 hours or 3 years, whichever occurs first. NOTE: This interval is not currently used but is given to supply information only. 5-10-00 Page 2 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL INSPECTION TIME LIMITS 1. Inspection Items REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER Revised 110000 Interior Placards, Exterior Placards, S 20 All Jul 3/06 Decals, Markings and Identification Plates - Examine for correct installation and legibility. Refer to Chapter 11 Placards and Markings - Inspection/ Check. Deleted 112101 Jul 1/05 Deleted 113101 Jul 1/05 212001 Ventilation System - Inspect clamps, D 5 211 hoses, and valves for condition and security. Added 212002 Primary Flight Display (PFD) Fan and U 22 220, 225 Jul 1/05 Multi-Function Display (MFD) Fan, Deck Skin Fan, and Remote Avionics Cooling Fan - Operational Check. Refer to Chapter 21, Avionics Cooling - Maintenance Practices. 214001 Cold and Hot Air Hoses - Check B 2, 4 120 condition, routing, and security. Revised 214002 Heater Components, Inlets, and B 1, 3 211 May 16/97 Outlets - Inspect all lines, ducts, clamps, seals, and gaskets for condition, restriction, and security. 214003 Cabin Heat and Ventilation Controls - C 1 211 Check freedom of movement through full travel. Check friction locks for proper operation. 221001 Autopilot Rigging - Refer to Autopilot - F 7 610 Maintenance Practices. Added 221002 Autopilot Servo Capstan Assemblies. O 16 610 May 3/99 Check slip-clutch torque settings. Refer to Autopilot - Maintenance Practices. Added 221003 Autopilot Servo Actuators. Inspect for O 16 610 May 3/99 evidence of corrosion and or buildup of dirt or other particulate matter which may interfere with servo operation. Refer to Autopilot - Maintenance Practices. 231001 Communication Antennas and Cables C 3 210 - Inspect for security of attachment, connection, and condition. 5-10-01 Page 1 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER 235001 Microphones, Headsets, and Jacks - C 1 211 Inspect for cleanliness, security, and evidence of damage. Added 235002 Microphone Push-To-Talk Switch B 1, 3 222, 223 Jun 7/04 - Clean the pilot's and copilot's microphone switches. Refer to Chapter 23, NAV/COM - Maintenance Practices. 242001 Alternator, Mounting Bracket, and A 1, 2, 3, 4 120 Electrical Connections - Check condition and security. Check alternator belts for condition and proper adjustment. Check belt tension. Revised 243001 Main Battery - Examine the general B 2, 4 120 Jul 1/05 condition and security. Complete a check of the level of electrolyte. Refer to Chapter 12, Battery - Servicing. Revised 243002 . - Main Battery Box and Cables - Clean B 2, 4 120 Jul 1/05 and remove any corrosion. Examine the cables for routing, support, and security of the connections. 243003 General Airplane and System Wiring C 1 210 - Inspect for proper routing, chafing, broken or loose terminals, general condition, broken or inadequate clamps, and sharp bends in wiring. 243004 External Power Receptacle and Power C 2 120 Cables - Inspect for condition and security. Revised 243005 Standby Battery - Complete the S 20 220 Jul 1/05 Standby Battery Capacity Test. Refer to Chapter 24, Standby Battery - Maintenance Practices. 246001 Switch and Circuit Breaker Panel, C 1 222 Terminal Blocks, and Junction Boxes - Inspect wiring and terminals for condition and security. Revised 246002 Power Junction Box - Check operation B 1, 3 222 Aug 1/00 and condition. Check availability and condition of spare fuse (if applicable). Added 246003 Alternator Control Unit - Complete the J 11 222 Jul 3/06 Over-voltage Protection Circuit Test. Refer to Chapter 24, Alternator Control Unit. 5-10-01 Page 2 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER Revised 246101 Essential and Crossfeed Bus Diodes - S 20 224 Jul 1/05 Complete a check for proper operation. Complete the Essential and Crossfeed Bus Diode Inspection. Refer to Chapter 24, Essential and Crossfeed Bus Diodes - Maintenance Practices. Revised 251001 Seats - Examine the seats to make B 1,3 211 Jul 3/06 sure they are serviceable and installed correctly. Make sure the seat stops and adjustment mechanism operate correctly. Examine the seat recline control and attaching hardware to make sure the hardware and lock are not damaged and are correctly installed. Lubricate the threads of the Seat Crank Handle Assembly with MIL-PRF-81322 general purpose grease. 251002 Seat Tracks and Stops - Inspect seat B 2, 4 230 tracks for condition and security of installation. Check seat track stops for damage and correct location. Inspect seat rails for cracks. 251101 Restraint System, front and rear - B 1, 3 211 Check belts for thinning, fraying, cutting, broken stitches, or ultra-violet deterioration. Check system hardware for security of installation. Revised 251102 AMSAFE Aviation Inflatable Restraint S 20 211 Jul 1/05 (AAIR) - Examine the restraint for dirt, frayed edges, unserviceable stitching, loose connections, and other wear. 252201 Upholstery, Headliner, Trim, and D 5 211 Carpeting - Check condition and security. Revised 256001 Emergency Locator Transmitter - B 1, 3 310 Jan 2/06 Inspect for security of attachment and check operation by verifying transmitter output. Check cumulative time and useful life of batteries in accordance with 14 CFR Part 91.207. 262001 Portable Hand Fire Extinguisher - B 1, 3 230 Inspect for proper operating pressure, condition, security of installation, and servicing date. Added 262002 Cockpit Mounted Halon Type Fire P 17 211 May 3/99 Extinguisher - Weigh bottle. Bottle must be reserviced by qualified individual if more than 2 ounces is lost. 5-10-01 Page 3 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER Added 262003 Cockpit Mounted Halon Type Fire R 19 211 May 3/99 Extinguishers - Perform hydrostatic test. The hydrostatic test shall be at twelve-year intervals based on initial servicing or date of last hydrostatic test. Added 262004 Cockpit Mounted Halon Type Fire Q 18 211 May 3/99 Extinguishers - Empty, inspect for damage, and recharge. Revised 271001 Aileron Controls - Check freedom B 1, 3 120, 520, May 3/99 of movement and proper operation 620 through full travel. 271002 Ailerons and Cables - Check operation C 3 120, 520, and security of stops. Check cables for 620 tension, routing, fraying, corrosion, and turnbuckle safety. Check travel if cable tension requires adjustment or if stops are damaged. Check fairleads and rub strips for condition. 271003 Aileron Structure, Control Rods, B 1, 3 520, 620 Hinges, Balance Weights, Bellcranks, Linkage, Bolts, Pulleys, and Pulley Brackets - Check condition, operation, and security of attachment. 271004 Ailerons and Hinges - Check condition, B 1, 3 520, 620 security, and operation. 271005 Control Wheel Lock - Check general C 1 222 condition and operation. Revised 271006 Control Yoke - Inspect pulleys, cables, C 1 222, 223 May 16/97 bearings, and turnbuckles for condition and security. 272001 Rudder - Check internal surfaces for C 3 340 corrosion, condition of fasteners, and balance weight attachment. Revised 272002 Rudder - Inspect the rudder skins for B 1, 3 340 Aug 1/00 cracks and loose rivets, rudder hinges for condition, cracks and security; hinge bolts, nuts, hinge bearings, hinge attach fittings, and bonding jumper for evidence of damage and wear, failed fasteners, and security. Inspect balance weight for looseness and the supporting structure for damage. Revised 272003 Rudder, Tips, Hinges, Stops, Clips and B 1, 3 340 Aug 1/00 Cable Attachment - Check condition, security, and operation. 5-10-01 Page 4 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER 272004 Rudder Pedals and Linkage - Check C 1 230 for general condition, proper rigging, and operation. Check for security of attachment. Added 272005 Rudder Control - Check freedom B 1, 3 340 Aug 1/00 of movement and proper operation through full travel. Check rudder stops for damage and security. Revised 273001 Elevator Control - Check freedom B 1, 3 222, 223 Aug 1/00 of movement and proper operation through full travel. Revised 273002 Elevator Control System - Inspect B 1, 3 222,223 May 3/99 pulleys, cables, sprockets, bearings, chains, and turnbuckles for condition, security, and operation. Check cables for tension, routing, fraying, corrosion, and turnbuckle safety. Revised 273003 Elevator, Hinges, Stops, and Cable B 1, 3 320, 330 Aug 1/00 Attachment - Check condition, security, and operation. 273101 Elevator Trim System - Check cables, B 1, 3 224, 240, push-pull rods, bellcranks, pulleys, 310 turnbuckles, fairleads, rub strips, etc. for proper routing, condition, and security. Revised 273102 Elevator Trim Control and Indicator C 1 224, 240, May 3/99 - Check freedom of movement and 310 proper operation through full travel. Check pulleys, cables, sprockets, bearings, chains, and turnbuckles for condition and security. Check cables for tension, routing, fraying, corrosion, and turnbuckle safety. 273103 Elevator Trim Tab and Hinges - Check B 1, 3 224 condition, security, and operation. Revised 273104 Elevator Trim Tab Actuator - Examine B 1, 3 320 Jul 3/06 the free play limits. Refer to Chapter 27, Elevator Trim Control - Maintenance Practices, Trim Tab Free Play Inspection. If the free play is more than the permitted limits, lubricate the actuator and examine the free play limits again. If the free play is still more than the permitted limits, replace the actuator. Deleted 273105 Dec 1/98 273106 Elevator Trim Tab Stop Blocks - Inspect C 1 240 for damage and security. 5-10-01 Page 5 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER Added 273107 Elevator Trim Tab Actuator - Remove, X 25 320 Jul 3/06 clean, examine, and lubricate the actuator. Refer to Chapter 27, Elevator Trim Control - Maintenance Practices. Revised 275001 Flaps - Check tracks, rollers, and B 1, 3 510,610 Aug 1/00 control rods for security of attachment. Check rod end bearings for corrosion. Check operation. 275002 Wing Flap Control - Check operation C 1 221 through full travel and observe Flap Position indicator for proper indication. 275003 Flap Structure, Linkage, Bellcranks, C 3 510, 610 Pulleys, and Pulley Brackets - Check for condition, operation and security. 275004 Flaps and Cables - Check cables C 3 510, 610 for proper tension, routing, fraying, corrosion, and tumbuckle safety. - - - --- Check travel if cable tension requires adjustment. Revised 275005 Flap Motor, Actuator, and Limit C 3 610 May 16/97 Switches - Check wiring and terminals for condition and security. Check actuator for condition and security. Revised 275006 Flap Actuator Threads - Clean and B 1, 3 610 Feb 15/02 lubricate. Refer to Chapter 12, Flight Controls - Servicing. 282001 Fuel System - Inspect plumbing and B 1, 3 510, 610 components for mounting and security. Revised 282002 Fuel Tank Vent Lines and Vent Valves B 1, 3 510, 610 Aug 1/00 - Check vents for obstruction and proper positioning. Check valves for operation. 282003 Fuel Selector Valve - Check controls B 1, 3 224 for detent in each position, security of attachment, and for proper placarding. Revised 282004 Integral Fuel Bays - Check for evidence B 1, 3 510, 610 Aug 1/00 of leakage and condition of fuel caps, adapters, and placards. Using quick drains, ensure no contamination exists. Check quick drains for proper shut off. 282005 Fuel Reservoir - Using quick drain, B 1, 3 510, 610 ensure no contamination exists. 282006 Fuel Selector - Using quick drain, B 1, 3 224 ensure no contamination exists. 5-10-01 Page 6 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER 282007 Fuel Strainer, Drain Valve, and B 1,3 510, 610 Controls - Check freedom of movement, security, and proper operation. Disassemble, flush, and clean screen and bowl. Revised 282008 Fuel Quantity Indicators - Examine for F 7 220 Jul 1/05 damage and security of installation. Complete a fuel quantity calibration check. Refer to Chapter 28, Fuel Storage and Distribution - Maintenance Practices. Revised 282009 Integral Fuel Bays - Drain the fuel I 10 510, 610 Jul 1/05 (Refer to Chapter 12, Fuel - Servicing) and purge tanks (Refer to the Single Engine Structural Repair Manual, 1996 and On). Complete an inspection of the tank interior and outlet screens and remove any foreign object debris. Complete an inspection of the tank interior surfaces for sealant deterioration and corrosion (especially in the sump areas). Added 282010 Auxiliary (Electric) Fuel Pump - B 2, 4 120 Aug 1/00 Check pump and fittings for condition, operation, security. 311001 Instruments - Check general condition B 1, 3 220 and markings for legibility. Deleted 311002 Jul 1/05 311003 Instrument Lines, Fittings, Ducting, and C 1 220 Instrument Panel Wiring - Check for proper routing, support, and security of attachment. 321001 Main Landing Gear Wheel Fairings, B 2, 4 721,722 Strut Fairings, and Cuffs - Check for cracks, dents, and condition of paint. Revised 321002 Main Gear Spring Assemblies - B 2, 4 721, 722 Jul 1/05 Examine for cracks, dents, corrosion, condition of paint or other damage. Examine for chips, scratches, or other damage that lets corrosion get to the steel spring. Examine the axles for condition and security. 321003 Main Landing Gear Attachment B 2, 4 721,722 Structure - Check for damage, cracks, loose rivets, bolts and nuts and security of attachment. 5-10-01 Page 7 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER 322001 Nose Gear - Inspect torque links, B 2, 4 720 steering rods, and boots for condition and security of attachment. Check strut for evidence of leakage and proper extension. Check strut barrel for corrosion, pitting, and cleanliness. Check shimmy damper and/or bungees for operation, leakage, and attach points for wear and security. 322002 Nose Landing Gear Wheel Fairings - B 2, 4 720 Check for cracks, dents, and condition of paint. 322003 Nose Gear Fork - Inspect for cracks, C 4 720 general condition, and security of attachment. 322004 Nose Gear Attachment Structure - B 2, 4 720 Inspect for cracks, corrosion, or other damage and security of attachment. 324001 Brakes - Test toe brakes and parking B 2, 4 230 brake for proper operation. Revised 324002 Brakes, Master Cylinders, and Parking B 2, 4 224, 230 Feb 15/02 Brake - Check master cylinders and parking brake mechanism for condition and security. Check fluid level and test operation of toe and parking brake. Refer to Chapter 12, Hydraulic Brakes - Servicing. 324003 Brake Lines, Wheel Cylinders, Hoses, D 5 721,722 Clamps, and Fittings - Check for leaks, condition, and security and hoses for bulges and deterioration. Check brake lines and hoses for proper routing and support. 324004 Tires - Check tread wear and general B 2, 4 720, 721, condition. Check for proper inflation. 722 324005 Wheels, Brake Discs, and Linings B 2, 4 721,722 - Inspect for wear, cracks, warps, dents, or other damage. Check wheel through-bolts and nuts for looseness. Revised 324006 Wheel Bearings - Clean, inspect and B 4 720, 721, May 16/97 lube. 722 325001 Nose Gear Steering Mechanism - C 4 720 Check for wear, security, and proper rigging. 331001 Instrument and Cabin Lights - Check B 1, 3 220, 211, operation, condition of lens, and 221 security of attachment. 5-10-01 Page 8 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER 334001 Navigation, Beacon, Strobe, and B 1, 3 340, 520, Landing Lights - Check operation, 620 condition of lens, and security of attachment. 341101 Static System - Inspect for security of C 3 210 installation, cleanliness, and evidence of damage. Revised 341102 Pitot and Static System - Inspect in J 11 220 Jan 2/06 accordance with 14 CFR Part 91.411. 341103 Pitot Tube and Stall Warning Vane - A 1, 2, 3, 4 510 Check for condition and obstructions and verify operation of anti-ice heat. 342101 Magnetic Compass - Inspect for C 1 225 security of installation, cleanliness, and evidence of damage. Revised 342102 Magnetic Compass - Calibrate. M 14 220 May 16/97 Revised 345001 Instrument Panel Mounted Avionics C 1 225 Aug 1/00 Units (Including Audio Panel, VHF Nav/Com(s), ADF, GPS, Transponder, and Compass System) - Inspect for deterioration, cracks, and security of instrument panel mounts. Inspect for security of electrical connections, condition, and security of wire routing. 345002 Avionics Operating Controls - Inspect C 1 225 for security and proper operation of controls and switches and ensure that all digital segments will illuminate properly. 345003 Navigation Indicators, Controls, and C 1 220, 225 Components - Inspect for condition and security. 345004 Navigation Antennas and Cables - C 1 310 Inspect for security of attachment, connection, and condition. 371001 Vacuum System - Inspect for condition B 2, 4 120 and security. 371002 Vacuum Pumps - Check for condition B 2, 4 120 and security. Check vacuum system breather line for obstructions, condition, and security. 371003 Vacuum System Hoses - Inspect for B 2, 4 120 hardness, deterioration, looseness, or collapsed hoses. 5-10-01 Page 9 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER Revised 371004 Gyro Filter - Inspect for damage, B 2, 4 120 May 16/97 deterioration and contamination. Clean or replace if required. Deleted 371005 Apr 7/03 Revised 371006 Vacuum Manifold Check Valve - T 12 120 Jul 1/05 Complete a check for proper operation. (Only airplanes with dual vacuum pumps and Airborne manifolds. Refer to the Airborne Air & Fuel Products Service Letter Number 39A or latest revision, and in accordance with SB02-37-04.) Refer to Chapter 37, Vacuum System - Maintenance Practices for the removal and installation of the check valve. Added 371007 Do an inspection of the wear indicator W 24 120 Jan 2/06 . -- -- ports on the vacuum pump described in - the Tempest Service Letter 004. 521001 Doors - Inspect general condition. B 1, 3 210 Check latches, hinges, and seals for condition, operation, and security of attachment. 531001 Fuselage Surface - Inspect for skin B 1, 3 210 damage, loose rivets, condition of paint, and check pitot-static ports and drain holes for obstruction. Inspect covers and fairings for security. 531002 Firewall Structure- Inspect for wrinkles, C 2 120 damage, cracks, sheared rivets, etc. Check cowl shock mounts for condition and security. 531003 Internal Fuselage Structure - Inspect C 1 211 bulkheads, doorposts, stringers, doublers, and skins for corrosion, cracks, buckles, and loose rivets, bolts and nuts. 551001 Horizontal Stabilizer and Tailcone B 1, 3 320, 330 structure - Inspect bulkheads, spars, ribs, and skins, for cracks, wrinkles, loose rivets, corrosion, or other damage. Inspect horizontal stabilizer attach bolts for looseness. Retorque as necessary. Check security of inspection covers, fairings, and tips. 551002 Horizontal Stabilizer and Tips - Inspect B 1, 3 320, 330 externally for skin damage and condition of paint. 5-10-01 Page 10 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER Revised 553001 Vertical Stabilizer Fin - Inspect B 1, 3 340 Aug 1/00 bulkheads, spars, ribs, and skins for cracks, wrinkles, loose rivets, corrosion, or other damage. Inspect vertical stabilizer attach bolts for looseness. Retorque as necessary. Check security of inspection covers, fairings, and tip. Revised 553002 Vertical Stabilizer Fin and Tailcone - B 1, 3 340 Aug 1/00 Inspect externally for skin damage and condition of paint. 561001 Windows and Windshield - Inspect B 1, 3 210 general condition. Check latches, hinges, and seals for condition, operation, and security of attachment. 571001 Wing Surfaces and Tips - Inspect B 1,3 510, 520, for skin damage, loose rivets, and 610,620 condition of paint. 571002 Wing Struts and Strut Fairings - Check B 1,3 510,610 for dents, cracks, loose screws and rivets, and condition of paint. 571003 Wing Access Plates - Check for C 3 510, 520, damage and security of installation. 610, 620 571004 Wing Spar and Wing Strut Fittings - C 3 510, 520, Check for evidence of wear. Check 610,620 attach bolts for indications of looseness and retorque as required. 571005 Wing Structure - Inspect spars, C 3 510, 520, ribs, skins, and stringers for cracks, 610,620 wrinkles, loose rivets, corrosion, or other damage. 611001 Spinner - Check general condition and A 1,2, 3, 4 110 attachment. 611002 Spinner and Spinner Bulkhead - B 2, 4 110 Remove spinner, wash, and inspect for cracks and fractures. 611003 Propeller Blades - Inspect for cracks, A 1, 2, 3, 4 110 dents, nicks, scratches, erosion, corrosion, or other damage. 611004 Propeller Hub - Check general C 2 110 condition. 611005 Propeller Mounting - Check for security A 1, 2, 3, 4 110 of installation. 611006 Propeller Mounting Bolts - Inspect C 2 110 mounting bolts and safety wire for signs of looseness. Retorque mounting bolts as required. 5-10-01 Page 11 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER Revised 611007 1A170E/JHA7660 propellers installed T 21 110 Jul 3/06 on Model 172R airplanes incorporating SB02-61-02 and all Model 172S airplanes (for airplanes operated by pilot schools under Title 14 of the Code of Federal Regulations, Part 141, and airplanes with more than 2000 takeoff cycles for each 1000 flight hours) - Complete a liquid penetrant inspection. (Refer to the latest revision of McCauley Service Bulletin 240.) Revised 711001 Cowling and Cowl Flaps - Inspect A 1, 2, 3, 4 120 Aug 1/00 for cracks, dents, other damage and security of cowl fasteners. Check cowl flaps for condition, security, and operation. Check cowl flap controls for freedom of movement through full travel. --712001 - - Engine Shock Mounts, Engine Mount C 2 120 Structure, and Ground Straps - Check condition, security, and alignment. Added 712002 Do a check of the engine mount and A 1, 2, 3, 4 120 Jun 7/04 the oil filter tube for evidence of contact. Refer to SB99-71-02. 716001 Alternate Induction Air System - A 1, 2, 3, 4 120 Check for obstructions, operation, and security. 716002 Induction System - Check security of A 1, 2, 3, 4 120 clamps, tubes, and ducting. Inspect for evidence of leakage. Revised 716003 Induction Airbox, Valves, Doors, and A 1, 2, 3, 4 120 Aug 1/00 Controls - Remove air filter and inspect hinges, doors, seals, and attaching parts for wear and security. Check operation. Revised 716004 Induction Air Filter-Remove and clean. A 1,2,3,4 120 May 3/99 Inspect for damage and service. Added 720000 Fuel line (Stainless steel tube V 23 120 Jan 2/06 assembly) and support clamp inspection and installation. Refer to Lycoming Service Bulletin Number 342E or later version. 722001 Engine - Inspect for evidence of oil and A 1, 2, 3, 4 120 fuel leaks. Wash engine and check for security of accessories. 5-10-01 Page 12 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER 722002 Crankcase, Oil Sump, and Accessory B 2, 4 120 Section - Inspect for cracks and evidence of oil leakage. Check bolts and nuts for looseness and retorque as necessary. Check crankcase breather lines for obstructions, security, and general condition. 722003 Hoses, Metal Lines, and Fittings - A 1, 2, 3, 4 120 Inspect for signs of oil and fuel leaks. Check for abrasions, chafing, security, proper routing and support and for evidence of deterioration. 723001 Engine Cylinders, Rocker Box Covers, B 2, 4 120 and Pushrod Housings - Check for fin damage, cracks, oil leakage, security of attachment, and general condition. 723002 Engine Metal Lines, Hoses, Clamps, C 2 120 and Fittings - Check for leaks, condition, and security. Check for proper routing and support. 723003 Engine Baffles and Seals - Check A 1, 2, 3, 4 120 condition and security of attachment. Revised 723004 Cylinder Compression - Complete a B 2, 4 120 Jul 1/05 differential compression test. If there is weak cylinder compression, refer to Chapter 71, Engine - Troubleshooting, for further procedures. 730001 Engine-Driven Fuel Pump - Check B 2, 4 120 for evidence of leakage, security of attachment, and general condition. 730002 Fuel Injection System - Check system B 2, 4 120 for security and condition. Clean fuel inlet screen, check and clean injection nozzles and screens (if evidence of contamination is found), and lubricate air throttle shaft. Added 730003 Idle and Mixture - Run the airplane B 2, 4 120 Jun 1/01 engine to determine satisfactory performance. If required, adjust the idle rpm and fuel mixture. Refer to Chapter 73, Fuel Injection Systems - Maintenance Practices. 5-10-01 Page 13 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK INTERVAL OPERATION ZONE STATUS NUMBER Revised 741001 Magnetos - Examine the external B 2, 4 120 Jul 1/05 condition and for correct installation and condition of the electrical leads. Complete a check of the engine timing (external timing). You must set the internal timing if the total of all external adjustments are more than 0.125 inch (3.17 mm) from the original factory position, or between each of the internal timing adjustments. Refer to Chapter 74, Ignition System - Maintenance Practices. Revised 741002 Magnetos - Clean, examine, and H 9 120 Jul 3/06 adjust as necessary. Do the 500-hour inspection in accordance with the Slick 4300/6300 Series Magneto Maintenance and Overhaul Manual. 742001 Ignition Harness and Insulators-Check B 2, 4 120 for- proper routing, deterioration, and condition of terminals. 742002 Spark Plugs - Remove, clean, analyze, B 2, 4 120 test, gap, and rotate top plugs to bottom and bottom plugs to top. 743001 Ignition Switch and Electrical Harness B 2, 4 120 - Inspect for damage, condition, and security. Revised 743002 Inspect and lubricate ACS brand N 15 224 Aug 1/00 ignition switch. Refer to Chapter 74, Ignition System - Maintenance Practices. Revised 761001 Engine Controls and Linkage - A 1, 2, 3, 4 120, 225 Jul 1/05 Examine the general condition and freedom of movement through the full range. Complete a check for the proper travel, security of attachment, and for evidence of wear. Complete a check of the friction lock and vernier adjustment for proper operation. Complete a check to make sure the throttle, fuel mixture, and propeller governor arms operate through their full arc of travel. The maximum linear freeplay is 0.050 inch. Revised 781001 Exhaust System - Inspect for cracks A 1, 2, 3, 4 120 Aug 1/00 and security. Special check in area of heat exchanger. Refer to Chapter 78, Exhaust system - Maintenance Practices. 5-10-01 Page 14 © Cessna Aircraft Company Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL REVISION ITEM CODE TASK STATUS NUMBER Revised Apr 7/03 791001 792001 Revised May 3/99 Added Feb 15/02 801001 801002 Engine Oil - Drain oil sump and oil L cooler. Check for metal particles or foreign material in filter, on sump drain plug, and on engine suction screen. Replace filter, and refill with recommended grade aviation oil. Oil Cooler - Check for obstructions, A leaks, and security of attachment. Starter and Electrical Connections - Check security and condition of starter, electrical connection, and cable. B Bendix Drive Starter Assembly - Clean A and lubricate starter drive assembly. © Cessna Aircraft Company INTERVAL OPERATION 13 1, 2,3, 4 2, 4 1,2,3,4 ZONE 120 120 120 120 5-10-01 Page 15 Jul 3/2006 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL COMPONENT TIME LIMITS General A. Most components given in Chapter 5 are examined as shown elsewhere in this chapter and repaired, overhauled, or replaced as necessary. Some components have a time or life limit and must be overhauled or replaced on or before the specified limit. B. The terms overhaul and replacement as used in this section are defined as follows: (1) Overhaul - Overhaul the item as given in 14 CFR 43.2 or replace it. (2) Replacement - Replace the item with a new item or a serviceable item that is in its service life and time limits or has been rebuilt as given in 14 CER 43.2. C. This section (5-11 -00) gives a list of items which must be overhauled or replaced at specific time limits. The Cessna-Supplied Replacement Time Limits section shows those items which Cessna has found necessary to overhaul or replace at specific time limits. The Supplier-Supplied Replacement Time Limits section shows component time limits which have been given by an outside supplier for their products. In addition to these time limits, the components shown in this section are also examined at regular time intervals given in the Inspection Time Intervals section. If necessary, based on service use and inspection results, these components can be overhauled or replaced before their time limit is reached. 2. Cessna-Supplied Replacement Time Limits A. Equipment/Furnishings (Chapter 25). (1) 504516-401 -XXXX Restraint System, Pilot's Left Hand or Right Hand Auto Adjust - Replace every 10 years. (2) 504851-401 -XXXX Restraint System, Pilot's Left Hand or Right Hand Manual Adjust - Replace every 10 years. (3) 50451 6-403-XXXX Restraint System, Aft Bench Left Hand or Right Hand Auto Adjust - Replace every 10 years. (4) 504851 -403-XXXX Restraint System, Aft Bench Left Hand or Right Hand Manual Adjust - Replace every 10 years. (5) 2000031 -09-201 Restraint Assembly, Pilot's Seat - Replace every 10 years. (6) 2000031-10-201 Restraint Assembly, Copilot's Seat - Replace every 10 years. (7) 2000031-11-201 Restraint Assembly, Right Rear Seat - Replace every 10 years. (8) 2000031-12-201 Restraint Assembly, Left Rear Seat - Replace every 10 years. B. Flight Controls (Chapter 27). (1) 1260074-1 Trim Tab Actuator - Replace the trim tab actuators when the free play cannot be kept in limits by the adjustment or replacement of the rod ends, rod end bolts, screw assembly, and the lubrication of the trim tab actuator. C. Vacuum (Chapter 37). (1) 0294502-0201 Gyro Filter - Replace at 600 hours. D. Powerplant (Chapter 71). (1) Engine Compartment Flexible Fluid-Carrying Teflon Hoses (Cessna-Installed), Except Drain Hoses - Replace every 10 years or at the engine overhaul, whichever occurs first. NOTE: This life limit is intended not to let flexible, fluid-carrying Teflon hoses in a deteriorated or damaged condition stay in service. Replace the flexible, fluid-carrying Teflon hoses in the engine compartment (Cessna-installed only) every 10 years or at the engine overhaul, whichever occurs first. This does not include drain hoses. Serviceable hoses which are beyond these limits must be put on order immediately and replaced within 30 days after the new hose is received from Cessna. (2) Engine Compartment Drain Hoses - Replace on condition. (3) Engine Flexible Hoses (Textron Lycoming Installed) - Refer to latest Textron Lycoming Engine Service Bulletins. 5-1 1-00 Page 1 © Cessna Aircraft Company Jul 1/2007 CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL (4) P1 98281 Air Filter - Replace every 500 hours or if the condition of the part shows the need for replacement. (5) CA3559 Air Filter - Replace every 100 hours or if the condition of the part shows the need for ()replacement. 6)Mixture and.Throttle Cables - Replace at every engine TBO or any time freeplay is more than 0.05 inch. (7) 31 B22207 Engine Starter - Replace at every engine TBO. E. Chapter 79 (Oil). (1) 83278 Oil Pressure Switch - Replace every 3000 hours. NOTE: If the 83278 Oil Pressure Switch has more than 3000 hours and is in serviceable condition, you must submit an order for a new switch immediately and replace the switch within 60 days after you receive it from Cessna. 3. Supplier-Supplied Replacement Time Limits A. Chapter 25 (Equipment/Furnishings). (1) 2020-0 Pointer ELT Battery - Refer to 14 CFR 91 .207 for battery replacement time limits. (2) 508358-409 and 508358-421 AMSAFE Aviation Inflatable Restraint (AAIR) Forward and Aft Electronics Module Assemblies (EMA) - Remove and return the forward and aft EMA's to AMSAFE Aviation after seven years from the manufacture date.-The expiration of the service life, that is t