Model 150 Series 1977 Service Manual

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A Change 1 LIST OF EFFECTIVE PAGES (Cont). Page Change No. No. * 15-1 thru 15-2 .......... 1 15-3 thru 15-8 .......... 0 * 15-9 thru 15-10 ......... 1 * 15-10A ................ 1 * 15-10B Blank .......... 1 15-11 thru 15-12 ........ 0 * 15-13 thru 15-16 ........ 1 * 15-16A ................ 1 * 15-16B Blank .......... 1 15-17 thru 15-19 ........ 0 15-20 Blank ............ 0 16-1 thru 16-5 .......... 0 * 16-6 ................... 1 16-7 thru 16-17 ......... 0 * 16-18 .................. * 16-18A ................ 1 * 16-18B Blank .......... 1 16-19 thru 16-31 ........ 0 * 16-32 ................. 1 16-33 thru 16-34 ........ 0 18-1 thru 18-7 .......... 0 * 18-8 thru 18-12 ......... 1 * 18-12A ................ 1 * 18-12B Blank .......... 1 18-13 thru 18-31 ........ 0 * 18-32 .................. 1 18-33 .................. 0 18-34 Blank ............ 0 * 19-1 ............ ...... 1 19-2 ................... 0 20-1 thru 20-3 .......... 0 20-4 Blank ............. 0 20-5 thru 20-16 ......... 0 20-16A ................ 0 20-16B Blank .......... 0 20-17 thru 20-26 ........ 0 Change 1 B/(C blank) TABLE OF CONTENTS SECTION Page 1 GENERAL DESCRIPTION ........................ 1-1 2 GROUND HANDLING, SERVICING, LUBRICATION AND INSPECTION .... 2-1 3 FUSELAGE . ........................ .. 3-1 4 WINGS AND EMPENNAGE ....................... 4-1 5 LANDING GEAR AND BRAKES ...................... 5-1 6 AILERON CONTROL SYSTEM ...................... 6-1 7 WING FLAP CONTROL SYSTEM ..................... 7-1 8 ELEVATOR CONTROL SYSTEM ..................... 8-1 9 ELEVATOR TRIM TAB CONTROL SYSTEM ................ 9-1 10 RUDDER CONTROL SYSTEM ...................... 10-1 11 ENGINE . ............................. . 11-1 12 FUEL SYSTEM. ............................ 12-1 13 PROPELLER. . ......................... . 13-1 14 UTILITY SYSTEMS . ................ ........ . 14-1 15 INSTRUMENTS AND INSTRUMENT SYSTEMS . ................. 15-1 16 ELECTRICAL SYSTEMS. . ....................... 16-1 17 ELECTRONIC SYSTEMS (DELETED) (See page iii) 18 STRUCTURAL REPAIR ....................... . 18-1 19 PAINTING ............................ . 19-1 20 WIRING DIAGRAMS ........................... 20-1 CROSS REFERENCE LISTING OF POPULAR NAME VS. MODEL NUMBERS AND SERIALS All aircraft, regardless of manufacturer, are certificated under model number designations. However, popular names are often used for marketing purposes. To provide a consistent method of referring to the various aircraft, model numbers will be used in this publication unless names are required to differentiate between versions of the same basic model. The following table provides a cross reference listing of popular name vs. model numbers. MODEL SERIALS POPULAR NAME YEAR MODEL BEGINNING ENDING 150 COMMUTER 1977 150M 15078506 15079405 150 COMMUTER II REIMS/CESSNA F150 1977 F150M F15001339 F15001428 REIMS/CESSNA F150 COM- MUTER 150 AEROBAT 1977 A150M A1500685 A1500734 REIMS/CESSNA F150 AEROBAT 1977 FA150M FA1500312 FA1500336 ii Change I FOREWORD This manual contains factory-recommended procedures and instructions for ground handling, servicing, and maintaining Cessna Model 150-Series aircraft. This includes the Models 150, Reims/ Cessna F150, 150 Aerobat, and Reims/Cessna F150 Aerobat. The Reims version of the model 150 is identical to the Model 150 except that it is powered by a 0-200-A Rolls Royce engine. Besides serving as a reference for the experienced mechanic, this book also covers step-by-step procedures for the less experienced If properly used, it will better enable the mechanic to maintain Cessna 150-Series aircraft and thereby establish a reputation for reliable service. 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 News Letters, 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 the Cessna Product Support subscription services. Cessna Service Stations have also been supplied with a group of supplier publications which provide disassembly, overhaul, and parts breakdowns for some of the 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 is communicated to the field through Cessna's Authorized Service Stations and/or through Cessna's subscription services. In addition to the information in this Service Manual, a group of vendor publications is available from Cessna Parts Distribution (CPD 2), which describe complete disassembly, overhaul, and parts breakdown of some of the various vendor equipment items. A listing of the available publications is issued periodically by the Cessna Propeller Product Support Department. Information for Nav-o-Matic Autopilots, Electronic Communi- cations, and Navigation Equipment are not included in this manual. These manuals are available from Cessna Parts Distribution. WARNING INSPECTION INTERVALS, REPLACEMENT TIME LIMIT'S 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 ALL APPROVED PARTS. IF PARTS ARE DESIGNED, MANUFACTURED, REMANUFACTURED, OVERHAULED, PURCHASED, AND/OR APPROVED BY ENTITIES OTHER THAN CESSNA, THEN THE DATA IN CESSNA'S MAINTENANCE/SERVICE MANUALS AND PARTS CATALOGS ARE NO LONGER APPLICABLE AND THE PURCHASER IS WARNED NOT TO RELY ON SUCH DATA FOR NON-CESSNA PARTS. ALL INSPECTION INTEVALS, 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. ChangE I iii/(iv Blank) SECTION 1 GENERAL DESCRIPTION TABLE OF CONTENTS GENERAL DESCRIPTION .... ...... 1-1 Description ............. 1-1 Model 150 and F150-Series ....... 1-1 Aircraft Specifications ........ 1-1 Description . ........... 1-1 Stations .............. 1-1 Model A150 and FA150-Series ...... 1-1 Torque Values ............ 1-1 1-1. GENERAL DESCRIPTION. ments of the Acrobatic Category, FAR Part 23. In addition to the "beef-up", quick-release cabin doors, 1-2. MODEL 150 AND F150-SERIES. two-strap shoulder harnesses, and aerobatic paint design are standard. Removable seat and back cush- 1-3. DESCRIPTION. Cessna Model 150 and F150- ions are provided to allow occupants to use either a Series aircraft, described in this manual, are high- seat-pack or back-pack type parachute during aero- wing monoplanes of all-metal, semimonocoque con- batic maneuvers. struction. Thes aircraft are equipped with fixed tu- bular spring-steel main gear struts and a steerable 1-6. AIRCRAFT SPECIFICATIONS. Leading partic- nose gear. The steerable nose gear is equipped with ulars of these aircraft, with dimensions based on an air/hydraulic fluid shock strut. Two-place seat- gross weight, are given in figure 1-1. If these di- ing is standard, and a double-width, fold-up auxiliary mensions are used for constructing a hangar or com- rear seat may be installed as optional equipment. puting clearances, remember that such factors as Each Model 150 and F150-Series aircraft is equipped nose gear strut inflation, tire pressures, tire sizes with a four-cylinder, horizontally opposed, air-cooled and load distribution may result in some dimensions Continental or Rolls Royce engine, driving an all- that are considerably different from those listed. metal, fixed-pitch propeller. These aircraft feature a "wrap around" rear window and a swept-back fin 1-7. STATIONS. Station diagrams are shown in fig- and rudder. ures 1-2 and 1-3 to assist in locating equipment when a written description is inadequate or impractical 1-4. MODEL A150 and FA150-SERIES. 1-8. TORQUE VALUES. A chart of recommended nut torque values is shown in figure 1-4. These tor- 1-5. DESCRIPTION. Aerobatic Model A150 and que values are recommended for all installation pro- FA150-Series aircraft are a modification of the cur- cedures contained in this manual, except where other rently produced Model 150. Structure has been values are stipulated. They are not to be used for "beefed-up" in some areas in order to meet require- checking tightness of installed parts during service. 1-1 GROSS WEIGHT * ..................... .. . 1600 lb FUEL CAPACITY Standard Wing (Total) ................ .. . 26 gal. Standard Wing (Usable) ................... 22.5 gal. Long-Range Wing (Total) .................. 38 gal. Long-Range Wing (Usable) .................. 35 gal. OIL CAPACITY Without External Filter ................ . 6 qt With External Filter ................ . ..7 qt ENGINE MODEL (Refer to Section 11 for Engine Data) ....... CONTINENTAL 0-200 Series PROPELLER (Fixed Pitch) ................... . 69" McCAULEY MAIN WHEEL TIRES ...................... 6.00x 6, 4-Ply Rating Pressure . . . . . . . . . . . . . . . . . . . . . . . . .21 psi NOSE WHEEL TIRE (Standard) .................. 5.00x 5, 4-Ply Rating Pressure . .. . .. . . . . ... . . . . . . . . . . . .30 psi NOSE WHEEL TIRE (Oversize) ................. 6.00x 6, 4-Ply Rating TIRE (Stan ard) ... .... .. . ... . . . . . NOSE GEAR STRUT PRESSURE (Strut Extended) ......... 20 psi WHEEL ALIGNMENT (Tubular Gear) Camber ... .................. ... 3* to 5- Toe-In . . . .................. 00" to +.16" AILERON TRAVEL Up ............................ 20, +2" -0 ° Down .......................... 140, +2° -0° WING FLAP TRAVEL ..................... 0 to 40 ° 2 RUDDER TRAVEL (Measured parallel to water line) Right ............... . ........ . 20' 30', +0 ° -2 ° Left . . . . . . . . . . . . . . . . . . . . . . . . . .. 20 ° 30', +0 ° -2 ° RUDDER TRAVEL (Measured perpendicular to hinge line) Right .. ...................... 23', +0 ° -2 ° Left .. ...................... 23', +00 -2 ° ELEVATOR TRAVEL Up ... .. . . ... ...... . . . ... ... . . 23, , +1" -0- Down ................ .......... 15" 1° ELEVATOR TRIM TAB TRAVEL Up ....................... .. 10 ° ±1 ° Down . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 +1 PRINCIPAL DIMENSIONS Wing Span. ................... ..... 33' 4" Length ... ..................... 23' 11-1/2" Fin Height (Maximum with Nose Gear Depressed and Flashing Beacon Installed on Fin) ............. 8' 6" Track Width ... .................... 7' 7-1/4" Tail Span . . . . . . . . . . . . . . . . . . . . . . . . .10' 0" BATTERY LOCATION ................... Firewall Figure 1-1. Aircraft Specifications 1-2 Change I 0.00 18.50 56.69 70.69 8.37 36.00 76.44 71.44 49.69 Figure 1-2. Fuselage Stations 22.12 31.75 44.12 56.87 69.87 84.00 102.00 120. 00 138.00 156. 00 174. 00 192.00 Figure 1-3. Wing Stations 1-3 RECOMMENDED NUT TORQUES THE TORQUE VALUES STATED ARE POUND-INCHES, RELATED ONLY TO STEEL NUTS ON OIL-FREE CADMIUM PLATED THREADS. FINE THREAD SERIES TENSION SHEAR TAP SIZE TORQUE TORQUE STD ALT STD ALT (NOTE 1) (NOTE 2) (NOTE 3) (NOTE 2) 8-36 12-15 7-9 10-32 20-25 20-28 12-15 12-19 1/4-28 50-70 50-75 30-40 30-48 5/16-24 100-140 100-150 60-85 60-106 3/8-24 160-190 160-260 95-110 95-170 7/16-20 450-500 450-560 270-300 270-390 1/2-20 480-690 480-730 290-410 290-500 9/16-18 800-1000 800-1070 480-600 480-750 5/8-18 1100-1300 1100-1600 660-780 660-1060 3/4-16 2300-2500 2300-3350 1300-1500 1300-2200 7/8-14 2500-3000 2500-4650 1500-1800 1500-2900 1-14 3700-5500 3700-6650 2200-3300 2200-4400 1-1/8-12 5000-7000 5000-10000 3000-4200 3000-6300 1-1/4-12 9000-11000 9000-16700 5400-6600 5400-10000 COARSE THREAD SERIES (NOTE 4) (NOTE 5) 8-32 12-15 7-9 10-24 20-25 12-15 1/4-20 40-50 25-30 5/16-18 80-90 48-55 3/8-16 160-185 95-100 7/16-14 235-255 140-155 1/2-13 400-480 240-290 9/16-12 500-700 300-420 5/8-11 700-900 420-540 3/4-10 1150-1600 700-950 7/8-9 2200-3000 1300-1800 1-8 3700-5000 2200-3000 1-1/8-8 5500-6500 3300-4000 1-1/4-8 6500-8000 4000-5000 NOTES 1. Covers AN310, AN315, AN345, AN363, MS20365, MS21042, MS21044, MS21045 and MS21046. 2. When using AN310 or AN320 castellated nuts where alignment between the bolt and cotter pin slots is not reached using normal torque values, use alternate torque values or replace the nut. 3. Covers AN316, AN320, MS20364 and MS21245. 4. Covers AN363, MS20365, MS21042, MS21043, MS21044, MS21045 and MS21046. 5. Covers AN340. ICAUTIONI DO NOT REUSE SELF-LOCKING NUTS. The above values are recommended for all installation procedures contained in this manual, except where other values are stipulated. They are not to be used for checking tightness of installed parts during service. Figure 1-4. Torque Values 1-4 SECTION 2 GROUND HANDLING, SERVICING, CLEANING LUBRICATION AND INSPECTION TABLE OF CONTENTS Page GROUND HANDLING . .............. 2-1 Vacuum System Filter ......... 2-12 Towing . ......... ......... 2-1 Battery ................ 2-12 Hoisting.... ................ 2-4 ' Tires ................. 2-12 Jacking . ......... ......... 2-4 Nose Gear Shock Strut ......... 2-12 Leveling. ............. . 2-4 Nose Gear Shimmy Dampener ...... 2-12 Parking . .......... ... . 2-4 Hydraulic Brake Systems ........ 2-13 Tie-Down ............... 2-4 CLEANING ............... . 2-13 Flyable Storage ........... 2-4 Windshield and Windows. ........ 2-13 Returning Aircraft to Service ..... 2-5 Plastic Trim. ............ 2-13 Temporary Storage ........... 2-5 Painted Surfaces ............ 2-13 Inspection During Storage . ....... 2-5 Aluminum Surfaces ......... 2-13 Returning Aircraft to Service ...... 2-5 Engine and Engine Compartment ..... 2-13 I Indefinite Storage .......... 2-6 Upholstery and Interior ......... 2-13 Inspection During Storage ...... .. 2-6 Propeller ............. . 2-14 Returning Aircraft to Service ...... 2-7 Wheels .............. . 2-14 SERVICING . ............... 2-7 LUBRICATION ............. . 2-14 Fuel . ........... . 2-7 Tachometer Drive Shaft ........ 2-14 Fuel Drains .............. 2-7 Wheel Bearings ............ 2-14 Carburetor Drain Plug Inspection . 2-7 Nose Gear Torque Links ........ 2-14 Engine Oil. . . 2-7 Wing Flap Actuator ......... .. 2-14 Engine Induction Air Filter ....... 2-8 INSPECTION. .. ...... .... 2-18 2-1. GROUND HANDLING. }CAUTION 2-2. TOWING. Moving the aircraft by hand is ac- When towing the aircraft, never turn the nose complished by using the wingstruts and landing gear wheel more than 30 degrees either side of struts as push points. A tow bar attached to the nose center or the nose gear will be damaged. Do gear should be used for steering and maneuvering the not push on control surfaces or outboard em- aircraft on the ground. When no tow bar is available, pennage surfaces. When pushing on the tail- press down at the horizontal stabilizer front spar ad- cone, always apply pressure at a bulkhead to jacent to the fuselage to raise the nose wheel off the avoid buckling the skin. ground. With the nose wheel clear of the ground, the aircraft can be turned by pivoting it about the main wheels. TOW BAR: PART NUMBER 0501019-1 IS AVAILABLE FROM CESSNA PARTS DISTRIBUTION (CPD 2). NOTE Use tow bar carefully to avoid scarring finish on speed fairing. Figure 2-1. Tow Bar Change 1 2-1 REFER TO SHEET 2 FOR ITEM NUMBERS NOTE Corresponding points on both upper door sills may be used to level the aircraft laterally. Reference points for longitudinal leveling of aircraft are two screws on left side of tailcone at zero waterline. These are indicated in illustration by A. (Also refer to paragraph 2-5) Figure 2-2. Jacking and Leveling (Sheet 1 of 2) 2-2 JACKING INFORMATION ITEM NUMBER TYPE AND NUMBER REMARKS 1 Block (Jack point not available) 1x4x4 padded with 1/4" rubber 1 Jack Any short jack of capable capacity 3 Universal tail stand Any tail stand of capable capacity 4) Cessna #SE-576 (41-1/2" high) Universal jack stand (FOR USE WITH ITEM 2) 5 Built-in jack pad Part of step bracket (SEE CAUTION) #2-170 Basic jack (includes #2-71 Min. closed height: 34" Slide tube: Liftstroke 22-1/2") Max. extension height: 56-1/2" #2-70 Slide tube: Liftstroke Min. closed height: 57-1/2" 22-1/2" Max. extension height: 80" #2-64 Extension cap Adds 4" #2-109 Leg extension Adds 12" 1. Wing jacks are placed under front spar of wing just outboard of wing strut, and must extend far enough to raise wheels off ground, and must be of adequate strength. 2. Attach a suitable stand to the tie-down ring. Be sure tail stand weighs enough to keep tail down and under all conditions that it is strong enough to support any weight that might be placed on it (place shot bags or sand bags on tail stand. In addition, the base of adjustable tail stand is to be filled with concrete for additional weight as a safety factor. 3. Operate jacks evenly until desired height is reached. ICAUTION When using built-in jack pad, flexibility of the gear strut will cause the main wheel to slide inboard as the wheel is raised, tilting the jack. The jack must be lowered for a second operation. Jacking both wheels simultaneously at built-in jack pads is not re- commended. Jack pad may be used to raise only one main wheel. DO NOT USE brake casting as a jack point. 4. Items (4) and (6) are available from the Cessna Parts Distribution CPD 21 Figure 2-2. Jacking and Leveling (Sheet 2 of 2) Change 1 2-3 2-3. HOISTING. The aircraft may be lifted with a NOTE hoist of two-ton capacity by using hoisting rings, which are optional equipment, or by means of suit- The aircraft is delivered from Cessna with a able slings. The front sling should be hooked to each corrosion-preventive aircraft engine oil upper engine mount at the'firewall. and the aft sling (MIL-C-6529, Type II). This engine oil is a blend should be positioned around the fuselage at the first of aviation grade straight mineral oil and a bulkhead forward of the leading edge of the stabilizer. corrosion preventive compound. This engine oil If the optional hoisting rings are used, a minimum should be used for the first 25 hours of engine cable length of 60 inches for each cable is required operation. In the event it is necessary to add oil to prevent bending of the eyebolt-type hoisting rings. during the first 25 hours of operation, use only If desired, a spreader jig may be fabricated to apply aviation grade straight mineral oil of the correct vertical force to the eyebolts. viscosity. 2-4. JACKING. Refer to figure 2-2 for jacking pro- a. Program I. During the 15 day non-operational cedures. storage or the first 50 hours of engine or cylinder operation, every fifth day the propeller shall be 2-5. LEVELING. Corresponding points on both up- rotated through six revolutions, without running the per door sills may be used to level the aircraft later- engine, stopping the propeller 45 ° to 90 ° from the ally. The reference points for longitudinal leveling original position. of the aircraft are the two screws on the left side of the tailcone at zero waterline. WARNING 2-6. PARKING. Parking precautions depend prin- cipally on local conditions. As a general precaution, For maximum safety, always take the following set parking brake or chock the wheels and install the precautions to ensure the engine cannot fire or controls lock. In severe weather and high wind con- cause injury when the propeller is moved: ditions, tie down the aircraft as outlined in paragraph 1. Verify magneto switches are OFF 2-7 if a hangar is not available. 2. Set throttle CLOSED. 3. Set mixture control "IDLE CUT-OFF. 2-7. TIE-DOWN. When mooring the aircraft in the 3 Set mixture Conttol IDLE CUT OFF open, head into the wind if possible. Secure control 5 Verify the cabin door latch is open. surfaces with the internal control lock and set brakes. 6. If the aircraft is stored outside, leave the aircraft tie-downs in place in accordance with CAUTION paragraph 2-7. 7. Do not stand within the arc of the propeller Do not set parking brakes during cold weather blades while rotating the propeller. when accumulated moisture may freeze the brakes or when the brakes are overheated. In addition, the pitot tube static air vents, air vents, openings in the engine cowling, and other similar After completing the preceding, proceed to moor the openings shall have protective covers installed to aircraft as follows: prevent entry of foreign material. After 15 days, the a. Tie ropes, cables, or chains to the wing tie- aircraft should be flown for 30 minutes reaching but down fittings located at the upper end of each wing not exceeding normal oil and cylinder operating strut. Secure the opposite ends of ropes, cables, or temperatures. If the aircraft cannot be flown, it chains to ground anchors. should be represerved in accordance with paragraph 2- b. Secure a tie-down rope (no chains or cables) to 10. Temporary Storage the exposed portion of the engine mount and secure opposite end of rope to a ground anchor. c. Secure the middle of a rope to the tail tie-down CAUTION ring. Pull each end of rope away at a 45 degree angle and secure to ground anchors at each side of tail. Excessive ground operations shall be avoided. d. Secure control lock on pilot control column. If control lock is not available, tie pilot control wheel b. Program II. After engine and cylinders have back with front seat belt. operated over 50 hours, the aircraft can be non- e. These aircraft are equipped with a spring-loaded operationally stored for up to 30 days. Every seventh steering system which affords protection against nor- day the propeller shall be rotated through six mal wind gusts. However, if extremely high wind revolutions, without running the engine, stopping at gusts are anticipated, additional external locks may 45 ° to 90 ° from the original position. The same be installed. warnings and cautions apply as with Program I flyable storage above. 2-8. FLYABLE STORAGE. Flyable storage is defined as a maximum of 30 days non-operational Protective covers shall be applied as with Program storage. Flyable storage has two programs: Program I flyable storage, but the aircraft need not be flown until (aircraft with engines or cylinders with less than 50 30 days non-operational storage have elapsed. If the operating hours) and Program II (aircraft with aircraft cannot be flown, it should be put into engines or cylinders with 50 or more operating hours). temporary storage in accordance with paragraph 2-10. 2-4 Change 1 2-9. RETURNING AIRCRAFT TO SERVICE. After MIL-L-46002, Grade 1 or equivalent. The flyable storage, returning the aircraft to service is following oils are approved for spraying accomplished by performing a thorough pre-flight operations by Teledyne Continental Motors: inspection. At the end of the first 25 hours of engine NOX RUST VCI-105 - Daubert Chemical Co., operation, drain engine oil and clean oil pressure 4700 So. Central Ave., Chicago, Illinois, screen (or change external oil filter element). Service Petratect VA - Pennsylvania Refining Co., engine with correct grade and quantity of engine oil. Butler, Pennsylvania. Refer to figure 2-4 and paragraph 2-21 for correct grade of engine oil. h . Using a portable pressure sprayer, atomize spray preservative oil through the upper spark plug hole of 2-10. TEMPORARY STORAGE. Temporary storage each cylinder with the piston in approximately the is defined as aircraft in a non-operational status for a bottom dead center position. A pressure pot or pump- maximum of 90 days. The aircraft is constructed of up type garden pressure sprayer may be used. The corrosion resistant alclad aluminum, which will last spray head should have ports around the indefinitely under normal conditions if kept clean, circumference to allow complete coverage of cylinder however, these always are subject to oxidation. The walls. Rotate crankshaft as each pair of cylinders is first indication of corrosion on unpainted surfaces is in sprayed. the form of white deposits or spots. On painted i. After completing step "h," rotate crankshaft so surfaces, the paint is discolored or blistered. Storage that no piston is at top dead center. If the aircraft is to in a dry hangar is essential to good preservation and be stored outside, stop two-bladed propeller so that should be procured if possible. Varying conditions will blades are as near horizontal as possible to provide alter the measures of preservation, but under normal maximum clearance with passing aircraft. conditions a dry hangar, and for storage periods not to j. Again spray each cylinder without moving the exceed 90 days, the following methods of treatment crankshaft to thoroughly cover all interior surfaces of are suggested: the cylinder above the piston. a. Fill fuel tanks with correct grade of gasoline. k. Install spark plugs and connect spark plug leads. b. Clean and wax aircraft thoroughly. 1. Apply preservative oil to the engine interior by c. Clean any oil or grease from tires and coat tires spraying approximately two ounces of the with a tire preservative. Cover tires to protect against preservative oil through the oil filler tube. grease and oil. m. Seal all engine openings exposed to the d. Either block up fuselage to relieve pressure on atmosphere using suitable plugs or non-hygroscopic tires or rotate wheels every 30 days to change tape. Attach a red streamer at each point that a plug supporting points and prevent flat spotting the tires, or tape is installed. e. Lubricate all airframe items and seal or cover all n. If the aircraft is to be stored outside, perform the openings which could allow moisture and/or dust to procedures outlined in paragraph 2-7. In addition, the enter. pitot tube, static source vents, air vents, openings in the engine cowling and other similar openings should NOTE have protective covers installed to prevent entry of foreign material. The aircraft battery serial number is recorded in o. Attach a warning placard to the propeller with the the aircraft equipment list. To assure accurate following notation, "DO NOT TURN PROPELLER -- warranty records, the battery should be re- ENGINE PRESERVED - preservation date." installed in the same aircraft from which it was removed. If the battery is returned to service in a 2-11. INSPECTION DURING STORAGE. different aircraft, appropriate record changes a. Inspect airframe for corrosion at least once a must be made and notification sent to the Cessna month and remove dust collections as frequently as Claims Department. possible. Clean and wax as required. b. Inspect the interior of at least one cylinder f. Remove battery and store in a cool dry place; through the spark plug hole for corrosion at least once service the battery periodically and charge as a month. required. NOTE NOTE Do not move crankshaft when inspecting An engine treated in accordance with the interior of cylinder for corrosion. following may be considered protected against normal atmospheric corrosion for a period not to c. If the engine is not returned to flyable status at exceed 90 days. end of the 90 day temporary storage period and the aircraft is to be continued in non-operational storage, g. Disconnect spark plug leads and remove upper it must be preserved in accordance with Indefinite and lower spark plugs from each cylinder. Storage, paragraph 2-13. NOTE 2-12. RETURNINGAIRCRAFTTOSERVICE. After temporary storage, use the following procedures to The preservative oil must be Lubricating Oil- return the aircraft to service. Contact and Volatile, Corrosion Inhibited, a. Remove aircraft from blocks and check tires for Change 1 2-5 proper inflation. Check for proper nose gear strut Accomplish temporary storage steps 2-10.g. thru inflation. 2-10.j.. b. Check battery and install. e. Apply preservative oil to the engine interior by c. Check that oil sump has proper grade and spraying approximately two ounces of MIL-L-46002, quantity of engine oil. Grade I oil or equivalent through the oil filler tube. d. Service induction air filter and remove warning f. Do not rotate propeller after completing step "e." placard from propeller. g. Install lower spark plug or install solid plugs, and e. Remove materials used to cover openings. install dehydrator plugs in upper spark plug holes. Be f. Remove, clean, and gap spark plugs. sure that dehydrator plugs are blue in color when g. While spark plugs are removed, rotate propeller installed. several revolutions to clear excess rust preventative h. Cover spark plug lead terminals with shipping oil from cylinders. plugs (AN4060-1) or other suitable covers. h. Install spark plugs. Torque spark plugs to value i. With throttle in full open position, place a bag of specified in Section 11 and connect spark plug leads. desiccant in the carburetor intake and seal opening i. Check fuel strainer. Remove and clean filter with moisture resistant paper and tape. screen if necessary. Check fuel tanks and fuel lines for j. Place a bag of desiccant in the exhaust tailpipe(s) moisture and sediment, and drain enough fuel to and seal openings with moisture resistant tape. eliminate moisture and sediment. k. Seal cold air inlet to the heater muff with moisture j. Perform a thorough pre-flight inspection, then resistant tape. start and warm up engine. i. Seal engine breather by inserting a dehydrator k. Give the airplane a thorough cleaning and visual MS27215-2 plug in the breather hose and clamping in inspection. A test flight is recommended. place. m. Seal all other engine openings exposed to 2-13. INDEFINITE STORAGE Indefinite storage is atmosphere using suitable plugs or non-hygroscopic defined as aircraft in a non-operatonal status for an tape. indefinite period of time. Engines treated in accordance with the following may be considered NOTE protected against normal atmosphere corrosion, provided the procedures outlined in paragraph 2-14 Attach a red streamer to each place on engine are performed at the intervals specified. where plugs or bags desiccant are placed or a. Operate engine until oil temperature reaches moisture resistant paper or tape is installed. normal operating range. Drain engine oil sump and Either attach red streamers outside of the sealed reinstall drain plug. area with tape or to the inside of the sealed area b. Fill oil sump to normal operating capacity with with safety wire to prevent wicking of moisture I MIL-C-6529 Type II corrosion-preventive mixture into the sealed area. which has been thoroughly mixed and pre-heated to a minimum of 221 ° F (105 ° C) at the time it is added to n. If the aircraft is to be stored outside, perform the the engine. procedures outlined in paragraph 2-7. In addition, the pitot tube, static source vents, air vents, openings in NOTE the engine cowling and other similar openings should have protective covers installed to prevent entry of MIL-C-6529, Type 11 corrosion-preventive foreign material. mixture consists of one part compound MIL-C- o. Attach a warning placard on the throttle control 6529, Type I (Cosmoline No. 1223, supplied by E. knob, to the effect that the engine contains no F. Houghton & Co., 305 W. LeHigh Avenue, lubricating oil. Attach a warning placard to the Philadelphia, PA, or Esso Rus-ban 628, or propeller with the following notation, "DO NOT equivalent) mixed with three parts new TURN PROPELLER - ENGINE PRESERVED - lubricating oil of the grade recommended for preservation date." service. Single grade oil is recommended. . p. Prepare airframe for storage a outlined in During all spraying operations corrosion mixture paragraph 2-10 thru step "f." is pre-heated to 221 ° to 250 ° F (105 ° to 121 ° C). NOTE NOTE As an alternate method of indefinite storage, the The corrosion-preventive mixture is harmful to aircraft may be serviced in accordance with paint and should be wiped from painted surfaces paragraph 2-10 providing the aircraft is run-up immediately. at maximum intervals of 90 days and then reserviced per paragraph 2-10. c. Immediately after filling the oil sump with MIL- C-6529, Type II corrosion-preventive mixture, fly the 2-14. INSPECTION DURING STORAGE. Aircraft aircraft for a period of time not to exceed a maximum in indefinite storage shall be inspected as follows: of 30 minutes, reaching but not exceeding normal oil a. Inspect cylinder dehydrator plugs each seven and cylinder temperatures.. days. s d. Allow engine to cool to ambient temperature. b. Change dehydrator plugs if their color indicates an unsafe condition. 2-6 Change 1 c. If the dehydrators plugs have changed color in capacities are listed in Section 1. The recommended one-half of the cylinders, all desiccant material in the fuel grade to be used is given in. figure 2-4. engine shall be replaced with new material. d. Every six months, respray the cylinder interiors IWARNING with corrosion-preventive mixture. NOTE Do not fly with contaminated or unapproved fuel. Before spraying, inspect the interior of one 2-19. FUEL DRAINS. Fuel quick-drains are located cylinder for corrosion through the spark plug in the fuel tanks, fuel line, fuel strainer, carburetor, hole and remove at least one rocker box cover and fuel line forward of the ON-OFF valve and carburetor. inspect the valve mechanism. A drain plug is installed in the carburetor. The fuel tanks and fuel strainer have drain valves. To activate 2-15. RETURNING AIRCRAFT TO SERVICE. After quick-drain valves for fuel samplings, place cup up to indefinite storage, use the following procedure to the valve and depress valve with rod protruding from return the aircraft to service: cup. See Section 12 for illustration of fuel tank drain a. Remove aircraft from blocks and check tires for valve. The strainer drain valve is an integral part of correct inflation. Check for correct nose gear strut the fuel strainer assembly. The strainer drain is inflation. equipped with a control which is located adjacent to b. Check battery and install. the oil dipstick. Access to the control is through the oil c. Remove all paper, tape, desiccant bags, and dipstick access door. Open drains and remove drain streamers used to seal and preserve the engine. plugs at intervals specified in figure 2-4. Also, during d. Remove warning placards posted at throttle and daily inspection of the fuel strainer and tanks, if water propeller. is found in the system, all fuel drains should be e. Remove and clean engine oil screen, then reinstall temporarily opened and all water drained from the and safety. On aircraft that are equipped with an system. If the aircraft has been serviced with external oil filter, install new filter element. improper fuel grade, defuel completely and refuel with f. Remove oil sump drain plug and drain sump. the correct grade. Provided weight and balance Install and safety drain plug. considerations will permit, fuel tanks should be kept full between flights. NOTE NOTE The corrosion-preventive mixture will mix with the engine lubricating oil, so flushing the oil If fuel tank quick-drains are not installed, at system is not necessary. Draining the oil sump least one quart of fuel should be drained from the will remove enough of the corrosion-preventive fuel strainer with the selector valve in a position mixture. to assure each tank is draining fuel. NOTE 2-20. CARBURETOR DRAIN PLUG INSPECTION. In order to prevent the possibility of thread sealant The corrosion-preventive mixture is harmful to contamination in the carburetor float chamber, paint and should be wiped from painted surfaces cleaning and inspection of the carburetor should be immediately. accomplished at each 100-hour inspection and anytime water in the fuel is suspected. g. Service and install the induction air filter. a. With the fuel valve OFF, remove carburetor drain h. Remove dehydrator plugs and spark plugs or plug and clean off any sealant present on the end of plugs installed in spark plug holes and rotate the plug or in the threads on the plug. propeller by hand several revolutions to clear b. Inspect drain plug hole in the carburetor and corrosion-preventive mixture from cylinders. remove any sealant remaining in the hole. i. Clean, gap, and install spark plugs. Torque plugs c. Turn fuel valve to ON to flush float chamber and to the value listed in Section 11. ascertain that all residue of sealant material is j. Check fuel strainer. Remove and clean filter dislodged and washed out of the chamber. Flushing screen. Check fuel tanks and fuel lines for moisture operation should last 15 to 30 seconds. and sediment, and drain enough fuel to eliminate. d. A second flushing should then be accomplished k. Perform a thorough pre-flight inspection, then and the drained fuel retained for inspection to insure start and warm-up engine. that no sealant particles are present. 1. Thoroughly clean and visually inspect aircraft and e. Install drain plug as follows: flight test aircraft. 1. Install drain plug in carburetor 1-1/2 to 2 turns. 2-16. SERVICING. 2. Apply sealant to drain plug threads (use NS- 40 [RAS-41 or equivalent). 2-17. Servicing requirements are shown in figure 2-4. 3. Tighten and safety drain plug. The following paragraphs supplement this figure by f. Turn fuel valve ON and inspect for evidence of fuel adding details not included in the figure. leakage. 2-18. FUEL. Fuel tanks should be filled immediately 2-21. ENGINE OIL. Checkengine lubricatingoil after flight to lessen moisture condensation. Tank with the oil dipstick five to ten minutes after the Change 1 2-7 engine has been stopped. Engine oil should be drained while the engine is still hot so that more positive draining is obtained. Refer to the inspection charts for required intervals for oil and filter changes. Change Valve shown open. To close, twist oil every six months even though less than the screwdriver until valve unlocks and specified hours have accumulated. Reduce these snaps down to closed position. periods for prolonged operation in dusty areas, in cold climate where sludging conditions exist, or where short flights and long idle periods are encountered, which cause sludging conditions. Always change oil and install a new filter element or clean screen whenever oil on dipstick appears dirty. Oil capacity is six quarts total with a normal operating capacity of five quarts for flights of less than three hours. For. extended flight, fill to the six quart level on the dipstick. DO NOT operate with less than the mini- mum for flight quantity of four quarts. If the engine is equipped with an external oil filter, an additional quart of oil is required when the filer element is changed. When adding or changing engine oil, use aviation grade oil in accordance with figure 2-4. Figure 2-3. Quick-Drain Valve NOTE c. (Without Quick-Drain Valve.) Remove oil drain plug from oil sump and allow oil to drain into a The aircraft is delivered from Cessna with a container. corrosion-preventive aircraft engine oil (MIL-C- 6259, Type II). If oil must be added during the NOTE first 25 hours of operation, use only aviation grade straight mineral oil conforming to To ensure complete draining of engine oil sumps, Specification MIL-L-6082 of the correct grade. the nose of the aircraft should be raised slightly After the first 25 hours of operation, drain engine and the oil drained while hot. oil sump and clean the oil pressure screen. If an optional oil filter is installed, change filter d. After engine oil has drained, close quick-drain element at this time. Refill sump with correct valve as shown in figure 2-3 and remove hose, or quantity and grade of aviation grade straight install and safety drain plug. mineral oil and use until a total of 50 hours has accumulated or oil consumption has stabilized, e. Remove and clean oil screen, or change external then change to ashless dispersant oil conforming oil filter element. to MILL-22851, Continental Motors f. On aircraft equipped with oil cooler, remove drain Specification MHS-24, or current Continental plug in adapter (using Allen wrench) and drain oil Aircraft Engine Service Bulletins. Newly cooler at each oil change. After oil cooler has drained, overhauled engines should also be operated on reinstall plug in adapter. aviation grade straight mineral oil conforming to Specification MIL-L-6082 until a total of 50 NOTE hours has accumulated or oil consumption has stabilized. Multi-viscosity oils meeting When servicing aircraft equipped with an oil Continental Motors Specification MHS-24 are cooler, refer to Continental Aircraft Engine approved. Service Bulletin M76-5 and any revisions or supplements thereto. When changing engine oil, remove and clean oil screen, or install a new filter element on aircraft g. Service engine with correct quantity of aviation equipped with an external oil filter. An oil quick- grade engine oil as specified herein. drain valve may be installed. This valve provides a quicker and cleaner method of draining engine oil. NOTE The valve is installed in the oil drain port of the oil sump and allows oil to be drained by inserting a hose Check oil with dipstick after the first engine run- over the fitting end and pushing up to lock the valve up when oil cooler is drained or external filter open, allowing the oil to drain through the hose into a element is changed. Add oil as required to bring container. To drain the engine oil, proceed as follows: oil in sump to correct level. a. Operate engine until oil temperature is at normal operating temperature. 2-22. ENGINE INDUCTION AIR FILTER. The b. (With Quick-Drain Valve.) Attach a hose to the induction air filter keeps dust and dirt from entering quick-drain valve in the oil sump. Push up on quick- the induction system. The value of maintaining the drain valve until it locks open, and allow oil to drain air filter in a good clean condition can never be through hose into container. overstressed. More engine wear is caused through the 2-8 Change 1 use of dirty or damage air filter than is generally the filtering panels, which will allow unfiltered believed. The frequency with which the filter should air to enter the induction system. Any filter that be removed, inspected, and cleaned will be determined appears doubtful, shall have a new filter primarily by aircraft operating conditions. A good installed in its place. general rule however, is to remove, inspect and clean e. Install filter at entrance to air box with gasket on the filter at least every 50 hours of engine operating aft face of filter frame and with air flow arrow on filter time and more frequently if warranted by by operating pointed in the correct direction. conditions. Some operators prefer to hold a spare induction air filter at their home base of operation so To service the dry type filter, proceed as follows; that a clean filter is always readily available for use. Under extremely dusty conditions, daily servicing of NOTE the filter is recommended. Two types of filters are used. One is a flock-coated, oiled filter and the other is Paper induction air filters must be replaced at a dry, paper -media filter. intervals not exceeding 500 hours time-in-service on the filter. NOTE a. Remove filter from aircraft. The aircraft is equipped with the flock-coaled, oiled filter when it leaves the factory. However, NOTE new filters ordered from Cessna Parts Distribution (CPD 2) will be the dry, paper Use care to prevent damage to filter element media filter with an improved element. when cleaning filter with compressed air. To service the flock-coated, oiled filter, proceed as b. Clean filter by blowing with compressed air (not follows: over 100 psi) from the direction opposite of normal air flow. Arrows on filter case indicate direction of a. Remove filter from aircraft. normal air flow. b. Wash filter thoroughly in solvent (Federal Specification P-S-661 or equivalent). Wash with CAUTION soiled face down in solvent. c. Drain and dry filter, then dip flock-coated screen filter in the same grade of oil used in the engine and Do not use solvent or cleaning fluids to wash allow excess oil to drain from the filter. filter. Use only a water and household detergent d. Be sure airbox is cleaned, inspect filter. If filter is solution when washing the filter. damaged, install a new filter. c. After cleaning as outlined in step "b," the filter - NOTE may be washed, if necessary, in a solution of warm water and a mild household detergent. A cold water A damaged filter may have broken filtering solution may be used. panels or the flock coating may be missing from Change I 2-8A/(2-8B blank) SPEC. NO. MIL-H-5606 11 ONLY AVIATION GRADE FUELS ARE APPROVED FOR USE. ENGINE MODEL APPROVED FUEL GRADES NOTE CONTINENTAL 0-200-A 80 (red) (formerly 80/87) 1 100LL (blue) 1 100 (green) (formerly 100/130) 1 NOTE 1. Compliance with Continental Aircraft Engine Service Bulletins M74-6 and M75-2, and all supplements or revisions thereto, must be accomplished. SPECIFIED AVIATION GRADE OIL: ABOVE 40*F SAE 40 BELOW 40*F SAE 20 NOTE 1. When operating temperatures overlap, use lighter grade of oil. Multi-viscosity oils meeting Continental Motors Specification MHS-24 are approved. Aviation grade ashless dispersant oil, conforming to Continental Motors Specification MHS-24, and all revisions and supplements thereto, must be used except as noted in paragraph 2-21, herein. Refer to Continental Aircraft Engine Service Bulletin M75-2, and any superseding bulletins, revisions or supplements thereto, for further recommendations. Figure 2-4. Servicing (Sheet I of 3) Change 1 2-9 DAILY 3 FUEL TANK FILLER Service after each flight. Keep full to retard condensation. Refer to paragraph 2-18 for details. 4 FUEL TANK SUMP DRAINS Drain off any water and sediment before first flight of the day. 6 PITOT AND STATIC PORTS Check for obstructions before first flight of the day. 10 FUEL STRAINER Drain off any water and sediment before the first flight of the day. Refer to paragraph 2-19 for 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 as necessary. Refer to paragraph 2-21 for details. 18 OIL FILLER CAP: Whenever oil is added, check that filler cap is tight and oil filler door is secure. FIRST 25 HOURS 15, 17 ENGINE OIL SYSTEM Refill with straight mineral oil, non-detergent, and use until a total of 50 hours have accumulated or oil consumption has stabilized, then change to ashless dispersant oil. )50 HOURS 13 INDUCTION AIR FILTER Clean filter per paragraph 2-22. Replace as required. 14 BATTERY Check electrolyte level and clean battery compartment each 50 hours or each 30 days. 15 ENGINE OIL SYSTEM Change oil each 50 hours if engine is NOT equipped with external oil filter; if equipped with external oil filter. change filter element each 50 hours and oil at each 100 hours, or every 6 months. 12 SHIMMY DAMPENER Check fluid level and refill as required with hydraulic fluid. Refer to paragraph 2-27 for details. 7 TIRES Maintain correct tire inflation as listed in figure 1-1. Also refer to paragraph 2-25 for details. Figure 2-4. Servicing (Sheet 2 of 3) 2-10 50 HOURS (Cont) 11 NOSE GEAR SHOCK STRUT Keep strut filled and inflate to correct pressure. Refer to paragraph 2-26 for details. -100 HOURS 5 SHUT-OFF VALVE DRAIN Remove plug and drain off any water or sediment. Also refer to paragraph 2-19. 10 FUEL STRAINER Disassemble and clean strainer bowl and screen. 17 ENGINE OIL SYSTEM On aircraft equipped with an external full flow oil filter change engine oil, providing the filter element is changed at 50 hour intervals. Change engine oil at least every six months even though less than the recommended hours have accumulated. Reduce these intervals under severe operating conditions. 200 HOURS 1 VACUUM RELIEF FILTER Change each 1000 hours, or to coincide with engine overhauls. 9 BRAKE MASTER CYLINDERS Check fluid level and refill as required with hydraulic fluid. Refer to paragraph 2-28 for details. Landing gear brake master cylinders used prior to 1979 still require overhaul every five years to replace rubber components. Refer to paragraphs 5-57 thru 5-61 for details. 500 HOURS 2 VACUUM SYSTEM CENTRAL AIR FILTER Replace every 500 hours. AS REQUIRED 8 GROUND SERVICE RECEPTACLE Connect to 12-volt DC, negative-ground power unit. Refer to Section 11 for details. Figure 2-4. Servicing (Sheet 3 of 3) Change 1 2-11 NOTE NOTE The filter assembly may be cleaned with com- Recommended tire pressures should be main- pressed air a maximum of 30 times, or it may tained. Especially in cold weather, remember be washed a maximum of 20 times. A new that any drop in temperature of the air inside filter should be installed after using 500 hours a tire causes a corresponding drop in air pres- of engine operating time or one year, which- sure. ever should occur first. Paper induction air filters must be replaced at intervals not 2-26. NOSE GEAR SHOCK STRUT. The nose gear exceeding 500 hours time-in-service on the shock strut requires periodic checking to ascertain filter. However, a new filter should be that the strut is filled with hydraulic fluid and is in- installed anytime it is damaged. A damaged flated to the correct air pressure. To fill the nose filter may have sharp or broken edges in the gear strut with hydraulic fluid and inflate with air, filtering panels which would allow unfiltered proceed as follows: air to enter the induction system. Any filter a. Remove filler valve cap and depress valve core that appears doubtful shall have a new filter to completely deflate nose strut. installed in its place. b. Remove filler valve from strut. d. After washing, rinse filter with clear water until c. With nose gear strut compressed to its shortest rinse water draining from filter is clear. Allow water length, fill strut with hydraulic fluid to the bottom of to drain from filter and dry with compressed air (not the filler hole. over 100 psi). d. Raise nose of aircraft, extend and compress strut several times to expel any entrapped air, then NOTE lower nose of aircraft and repeat step "c". e. With strut compressed to its shortest length, The filtering panels of the filter may become install filler valve assembly. distorted when wet, but they will return to f. With nose wheel off ground, inflate strut. Shock their original shape when dry. strut pressure is listed in figure 1-1. e. Be sure air box is clean; inspect filter. If filter is NOTE damaged, install a new filter. f. Install filter at entrance to air box with gasket on The nose landing gear shock strut will nor- aft face of filter frame and with air flow arrow on filter mally require only a minimum amount of frame pointed in the correct direction. service. Maintain the strut extension pres- 2-23. VACUUM SYSTEM FILTER. The vacuum sure, as shown in figure 1-1. Lubricate2-23. VACUUM SYSTEM FILTER. The vacuum system central air filter keeps dust and dirt from landing gear as shown in figure 2-5.Check entering the vacuum operated instruments. Change the landing gear daily for general cleanli- central air filter element every 500 hours of operating ness, security of mounting, and for hydrau- time and whenever suction gage reading drops below lic fluid leakage. Keep machined surfaces 4.8 inches of mercury. Also, do not operate the wiped free of dirt and dust, using a clean vacuum system with the filter removed, or a vacuum lint-free cloth saturated with MIL-H-5606 line disconnected as particles of dust or other foreign hydraulic fluid or kerosene. All surfaces matter may enter the system and damage the gyros. should be wiped free of excessive hydraulic fluid. 2-24. BATTERY. Battery servicing involves adding distilled water to maintain the electrolyte level even 2-27. NOSE GEAR SHIMMY DAMPENER. The with the horizontal baffle plate or split ring at the bot- shimmy dampener should be serviced at least every tom of the filler holes, checking cable connections, and 50 hours. The shimmy dampener must be filled neutralizing and cleaning off any spilled electrolyte or completely with fluid, free of entrapped air, to corrosion. Use bicarbonate of soda (baking soda) and serve its purpose. To service the shimmy damp- clean water to neutralize electrolyte or corrosion. ener, proceed as follows: Follow with a thorough flushing with clean water. Do a. Remove shimmy dampener from aircraft. not allow bicarbonate of soda to enter battery. b. While holding the dampener in a vertical posi- Brighten cable and terminal connections with a wire tion with fitting end pointed downward, pull fitting brush, then coat with petroleum jelly before end of the dampener shaft to its limit of travel. connecting cables. Check the battery every 50 hours c. While holding dampener in this position, fill (or at least every 30 days), more often in hot weather. dampener through open end of cylinder. Add only distilled water, not acid or "rejuvenators," to d. Push the shaft upward slowly to seal off the fil- maintain electrolyte level in the battery. Inspect the ler hole. battery box and surrounding area and clean and e. Clean dampener with solvent. Be sure to keep remove any evidence of corrosion. Refer to Section 16 the shaft protruding through the filler hole until for detailed battery removal, installation, and testing. dampener is installed on the aircraft. f. Install dampener on aircraft. 2-25. TIRES. Maintain tire pressure at the air pressure specified in figure 1-1. When checking tire NOTE pressure, examine tires for wear, cuts, bruises, and slippage. Remove oil, grease and mud from tires with Keep shimmy dampener, especially the ex- soap and water. posed portions of the dampener piston shaft, 2-12 Change 1 clean to prevent collection of dust and grit which since the cover may scratch the plastic surface. could cut the seals in the dampener barrel. Keep machined surfaces wiped free of dirt and dust, using a clean lint-free cloth saturated with MIL- CAUTION H-5606 hydraulic fluid or kerosene. All surfaces should be wiped free of excessive hydraulic fluid. Do not use rain repellent on acrylic surfaces such as windshield. 2-28. HYDRAULIC BRAKE SYSTEMS. Check brake master cylinders and refill with hydraulic fluid 2-32. PLASTIC TRIM. The instrument panel, plas- as specified in the inspection charts. Bleed the brake tic trim, and control knobs need only be wiped with a system of entrapped air whenever there is a spongy damp cloth. Oil and grease on the control wheel and response to the brake pedals. Refer to paragraph 5-58 control knobs can be removed with a cloth moistened for filling and bleeding the brake system. with Stoddard solvent. Volatile solvents, such as mentioned in paragraph 2-31, must never be used 2-29. CLEANING. since they soften and craze the plastic. 2-30. Keeping the aircraft clean is important. Be- 2-33. PAINTED SURFACES. The painted exterior sides maintaining the trim appearance of the aircraft, surfaces of the aircraft, under normal conditions, cleaning lessens the possibility of corrosion and makes require a minimum of polishing and buffing. Approxi- inspection and maintenance easier. mately 15 days are required for acrylic or lacquer paint to cure completely; in most cases, the curing 2-31. WINDSHIELDS AND WINDOWS. Wind- period will have been completed prior to delivery of shield and windows should be cleaned carefully with the aircraft. In the event that polishing or buffing is plenty of fresh water and a mild detergent, using the required within the curing period, it is recommended palm of the hand to feel and dislodge any caked dirt or that the work be done by an experienced painter. mud. Be sure to frequently refold the cloth to avoid Generally, the painted surfaces can be kept bright by redepositing soil and/or scratching windshield. A washing with water and mild soap, followed by a rinse sponge, soft cloth, or chamois may be used, but only as with water and dying with cloths or chamois. Harsh a means of carrying water to the plastic. Aliphatic or abrasive soaps or detergents which could cause naphtha Type II (conforming to Federal Specification corrosion or make scratches should never be used. TT-N-95) can be used to remove deposits which cannot Remove stubborn oil and grease with a cloth be removed using mild soap solution. Rinse moistened with Stoddard solvent. After the curing thoroughly, then dry with a clean moist chamois. Do period, the aircraft may be waxed with a good not rub the plastic with a dry cloth as this builds up an automotive wax. A heavier coating of wax on the electrostatic charge which attracts dust. leading edges of the wing and tail and on the engine. nose cap will help reduce the abrasion encountered in CAUTION these areas. 2-34. ALUMINUM SURFACES. The aluminum sur- Do not use methanol, gasoline, denatured faces require a minimum of care, but should never be alcohol, benzene, xylene, MEK, acetone, carbon neglected. The aircraft may be washed with non- tetrachloride, fire extinguisher fluid, de-icer alkaline grease solvents to remove oil and/or grease. fluid, lacquer thinner, or glass window cleaning Household type detergent soap powders are effective spray. These solvents will soften and craze the cleaners, but should be used cautions since some of plastic. When in doubt, do not use it. them are strongly alkaline. Many good aluminum cleaners, polishes, and waxes are available from After washing, the plastic windshield and windows commercial suppliers of aircraft products. should be cleaned with an aircraft windshield cleaner. Apply the cleaner with soft cloths and rub with mod- 2-35. ENGINE AND ENGINE COMPARTMENT. erate pressure. Allow the cleaner to dry, then wipe it The engine should be kept clean since dirty cooling off with soft flannel cloths. A thin, even coat of wax, fins and baffle plates can cause overheating of the polished out by hand with soft cotton flannel or cotton engine. Also, cleaning is essential to minimize any terry cloths, will fill in minor scratches and help danger of fire and provide for easier inspection of prevent further scratching. components. The entire engine cowling may be removed to facilitate engine and interior cowl NOTE cleaning. Wash down the engine and components with a suitable solvent, such as Stoddard solvent or Approved and effective acrylic waxes include: equivalent, then dry thoroughly with compressed air. Turtle Wax (paste), Great Reflections Paste Wax by Du Pont de Nemours, Slip-stream Wax (paste) CAUTION by Classic Chemical, and acrylic polish CAUTION conforming to Federal Specification P-P-560 (such as Permatex plastic cleaner or Mirror Particular care should be given to electrical Glaze MGH -7 by Mirror Bright Polish Co.). equipment before cleaning. Solvent should not be allowed to enter magnetos, starters, Do not use a canvas cover on the windshield or alternators, voltage regulators, and the like. windows unless freezing rain or sleet is anticipated. Hence, these components should be protected Change 1 2-13 before saturating the engine with solvent. Any NOTE fuel, soil, and air openings should be covered before washing the engine with solvent. Caustic During tire or tube change or when wheel is cleaning solutions should not be used. After otherwise disassembled, use dye penetrant to cleaning engine, relubricate all control arms and inspect wheel hub. moving parts. If defects are found remove and repair in accordance 2-36. UPHOLSTERY AND INTERIOR. Keeping the with Section 5. Discard cracked wheel halves, flanges upholstery and interior clean prolongs upholstery or hubs and install new parts. fabric and interior trim life. To clean the interior, proceed as follows: 2-39. LUBRICATION. a. Empty all ash trays and refuse containers. b. Brush or vacuum clean the upholstery and carpet 2-40. Lubrication requirements are shown if figure to remove dust and dirt. 2-5. Before adding grease to grease fittings, wipe dirt c. Wipe leather and plastic trim with a damp cloth. from fitting. Lubricate until grease appears around d. Soiled upholstery fabrics and carpet may be parts being lubricated, and wipe excess grease from cleaned with a foam-type detergent used according to parts. The following paragraphs supplement figure the manufacturer's instructions. 2-5 by adding details. e. Oil spots and stains may be cleaned with house- hold spot removers, used sparingly. Before using any 2-41. TACHOMETER DRIVE SHAFT. Refer to solvent, read the instructions on the container and test Section 15 for details on lubrication of shaft. it on an obscure place in the fabric to be cleaned. Never saturate the fabric with volatile solvent; it may 2-42. WHEEL BEARINGS. Clean and repack the damage the padding and backing material, wheel bearings at the first 100-hour inspection and at f. Scrape sticky material from fabric with a dull each 500-hour inspection thereafter. If more than the knife, then spot clean the area. usual number of take-offs and landings are made, extensive taxiing is required, or the aircraft is 2-37. PROPELLER. Wash hub and blades with a soft operated in dusty areas or under seacoast conditions, cloth and Stoddard cleaning solvent or equivalent, cleaning and lubrication of the wheel bearings shall be then dry thoroughly with compressed air. The pro- acomplished at each 100-hour inspection. peller should be wiped occasionally with an oily cloth, then wiped with a dry cloth. In salt water areas this 2-43. NOSE GEAR TORQUE LINKS. Lubricate will assist in corrosion proofing the propeller. nose gear torque links every 50 hours. When operating in dusty conditions, more frequent 2-38. WHEELS. The wheels should be washed lubrication is required. periodically and examined for corrosion, chipped paint, and cracks or dents in the wheel halves, in the 2-44. WING FLAP ACTUATOR. Clean and lubri- flanges or hubs, and especially around flange cate wing flap actuator jack screw each 100 hours as mounting screw holes. follows: a. Expose jack screw by operating flaps to full-down NOTE position. b. Clean jack screw threads with solvent rag and dry During 100 hour or annual inspections, check with compressed air. socket head cap screws for proper torque (190 - 200 pound-inches). Loss of torque on socket head NOTE is sign of cracks. It is not necessary to remove actuator from NOTE aircraft to clean or lubricate threads. When repacking wheel bearings, clean wheel c. With oil can, apply light coat of No. 10 eight non- assembly, and using magnifying glass, sight detergent oil to threads of jack screw. through opening to inspect webs around flange mounting screw holes for cracks. SHOP NOTES: 2-14 Change 1 FREQUENCY (HOURS) METHOD OF APPLICATION HAND GREASE OIL SYRINGE GUN CAN (FOR POWDERED GRAPHITE) WHERE NO INTERVAL IS SPECIFIED, LUBRICATE AS REQUIRED AND WHEN ASSEMBLED OR INSTALLED. NOTE The military specifications listed are not mandatory, but are intended as guides in choosing satisfactory materials. Products of most reputable manufacturers meet or exceed these specifications. LUBRICANTS PG - SS-G-659 ........ ............ POWDERED GRAPHITE GR - MIL-G-81322 ........................ GENERAL PURPOSE GREASE GH - MIL-G-23827 .......................... AIRCRAFT AND INSTRUMENT GREASE GL - MIL-G-21164 ........................ MOLYBDENUM DISULFIDE GREASE OG - MIL-L-7870 .......................... GENERAL PURPOSE OIL PL - VV-P-236 ............................. PETROLATUM GS - MIL-S-8660 ......................... DC4 (DOW CORNING) GP .................... ............ NO. 10-WEIGHT, NON-DETERGENT OIL GR STEERING SYSTEM NEEDLE SHIMMY ALSO REFER TO SHIMMY PARAGRAPH 2-43 DAMPENER TORQUE LINKS STEERING ARM ALSO REFER TO BEARING PARAGRAPH 2-42 WHEEL BEARINGS GR MAIN GEAR NOSE GEAR WHEEL BEARINGS Figure 2-5. Lubrication (Sheet 1 of 3) 2-15 CONTROL WHEEL SHAFT BUSHINGS AND OG UNIVERSALS OILITE BEARINGS BUSHINGS AND OILITE BEARINGS BATTERY BUSHINGS AND OILITE BEARINGS GL NEEDLE BEARINGS 4 GR CONTROL "Y" ALL PIANO HINGES ELEVATOR TRIM TAB GR ACTUATOR / AILERON BELLCRANK NEEDLE BEARINGS ALSO REFER TO INSPECTION CHART IN THIS SECTION AND TO SECTION 9 OF THIS MANUAL ROTATED 180 X WING FLAP INDICATOR GH CABIN DOOR WINDOW INSERT GROOVES Figure 2-5. Lubrication (Sheet 2 of 3) 2-16 OILITE BEARINGS NEEDLE (RUDDER BAR ENDS) BEARINGS ALL LINKAGE GR POINT PIVOTS RUDDER BARS AND PEDALS NEEDLE BEARINGS REFER TO PARAGRAPH 2-44 ELECTRIC FLAP DRIVE MECHANISM NOTES Sealed bearings require no lubrication. Do not lubricate roller chains or cables except under seacoast conditions. Wipe with a clean, dry cloth. Lubricate unsealed pulley bearings, rod ends, Oilite bearings, pivot and hinge points, and any other friction point obviously needing lubrication, with general purpose oil every 1000 hours or oftener if required. Paraffin wax rubbed on seat rails will ease sliding the seats fore and aft. Lubricate door latching mechanism with MIL-G-81322A general purpose grease, applied sparingly to friction points, every 1000 hours or oftener, if binding occurs. No lubrication is recommended on the rotary clutch. Figure 2-5. Lubrication (Sheet 3 of 3) 2-17 I INSPECTION REQUIREMENTS. As required by Federal Aviation Regulations, all civil aircraft of U.S. registry must undergo a COMPLETE INSPECTION (ANNUAL) each twelve calendar months. In addition to the required ANNUAL inspection, aircraft operated commercially (for hire) must also have a COMPLETE AIRCRAFT INSPECTION every 100 hours of operation. In lieu of the above requirements, an aircraft may be inspected in accordance with a progressive inspection schedule, which allows the work load to be divided into smaller operations that can be accomplished in shorter time periods. Therefore, the Cessna Aircraft Company recommends PROGRESSIVE CARE for aircraft that are being flown 200 hours or more per year, and the 100 HOUR inspection for all other aircraft. II INSPECTION CHARTS. The following charts show the recommended intervals at which items are to be inspected. As shown in the charts, there are items to be checked each 50 hours, each 100 hours, each 200 hours, and also Special Inspection items which require servicing or inspection at intervals other than 50, 100 or 200 hours. a. When conducting an inspection at 50 hours, all items marked under EACH 50 HOURS would be inspected, serviced or otherwise accomplished as necessary to insure continuous airworthiness. b. At each 100 hours, the 50 hour items would be accomplished in addition to the items marked under EACH 100 HOURS as necessary to insure continuous airworthiness. c. An inspection conducted at 200 hour intervals would likewise include the 50 hour items and 100 hour items in addition to those at EACH 200 HOURS. d. The numbers appearing in the SPECIAL INSPECTION ITEMS column refer to data listed at the end of the inspection charts. These items should be checked at each inspection interval to insure that applicable servicing and inspection requirements are accomplished at the specified intervals. e. A COMPLETE AIRCRAFT INSPECTION includes all 50, 100 and 200 hour items plus those Special Inspection Items which are due at the time of the inspection. 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 as 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 as defined in paragraph II above. In addition, it is recommended that between annual inspections, all items be inspected at the intervals specified in the inspection charts. 2-18 2. IF THE AIRCRAFT IS FLOWN MORE THAN 200 HOURS ANNUALLY. Whether flown for hire or not, it is recommended that aircraft operating in this category be placed on the CESSNA PROGRESSIVE CARE PROGRAM. However, if not placed on Progressive Care, the inspection requirements for aircraft in this category are the same as those defined under paragraph II 1. (a) and (b). Cessna Progressive Care may be utilized as a total concept program which insures that the inspection intervals in the inspection charts are not exceeded. Manuals and forms which are required for conducting Progressive Care in- spections are available from Cessna Parts Distribution (CPD 2). IV INSPECTION GUIDE LINES. (a) MOVABLE PARTS for: lubrication, servicing, security of attachment, binding, excessive wear, safetying, proper operation, proper adjustment, correct travel, cracked fittings, security of hinges, defective bearings, cleanliness, corrosion, deformation, sealing and tension. CAUTION Braided steel covered fluid lines will cause rapid wear of any object they are allowed to chafe against. Check that minimum one-half (/2) inch clearance be maintained between steel covered lines and any component. If this is not feasible, ensure lines are securely clamped or tied to the component. (b) FLUID LINES AND HOSES for: leaks, cracks, dents, kinks, chafing, proper radius, security, corrosion, deterioration, obstruction and foreign matter. (c) METAL PARTS for: security of attachment, cracks, metal distortion, broken spotwelds, corrosion, condition of paint and any other apparent damage. (d) WIRING for: security, chafing, burning, defective insulation, loose or broken terminals, heat deterioration and corroded terminals. (e) BOLTS IN CRITICAL AREAS for: correct torque in accordance with torque values given in the chart in Section 1, when installed or when visual inspection indicates the need for a torque check. NOTE Torque values listed in Section 1 are derived from oil-free cadmium-plated threads, and are recommended for all installation procedures contained in this book except where other values are stipulated. They are not used for checking tightness of installed parts during service. (f) FILTERS, SCREENS & FLUIDS for: cleanliness, contamination and/or replacement at specified intervals. (g) AIRCRAFT FILE. Miscellaneous data, information and licenses are a part of the aircraft file. Check that the following documents are up-to-date and in accordance with current Federal Aviation Regulations. Most of the items listed are required by the United States Federal Aviation Regulations. Since the regulations of other nations may require other documents and data, owners of exported aircraft should check with their own aviation officials to determine their individual requirements. To be displayed in the aircraft at all times: 1. Aircraft Airworthiness Certificate (FAA Form 8100-2). 2. Aircraft Registration Certificate (FAA Form 8050-3). 3. Aircraft Radio Station License, if transmitter is installed (FCC Form 556). To be carried in the aircraft at all times: 1. Weight and Balance, and associated papers (Latest copy of the Repair and Alteration Form, FAA Form 337, if applicable). 2. Aircraft Equipment List. To be made available upon request: 1. Aircraft Log Book and Engine Log Book. Change 1 2-19 (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 or abnormalities: 1. Engine temperatures and pressures. 2. Static RPM. (Also refer to Section 11 of this Manual.) 3. Magneto drop. (Also refer to Section 11 of this Manual.) 4. Engine response to changes in power. 5. Any unusual engine noises. 6. Fuel selector and/or shut-off valve; operate engine(s) on each tank (or cell) position and OFF position long enough to ensure shut-off and/or selector valve functions properly. 7. Idling speed and mixture; proper idle cut-off. 8. Alternator and ammeter. 9. Suction gage. 10. Fuel flow indicator. After the inspection has been completed, an engine run-up should again be performed to determine that any discrepancies or abnormalities have been corrected. SHOP NOTES: 2-20 SPECIAL INSPECTION ITEM IMPORTANT EACH 200 HOURS READ ALL INSPECTION REQUIRE- EACH 200 HOURS MENTS PARAGRAPHS PRIOR TO EACH 100 HOURS USING THESE CHARTS. EACH 50 HOURS PROPELLER 1. Spinner . . . . . . . . . . . . . . . . . . 2. Spinner bulkhead ................ 3. Blades . . . . . . . . . . . . . . . . . . 4. Bolts and/or nuts . . . . . . . . . . . . . . ...... . .. ... ... 5. Hub . . . . . . . . . . . . . . . . . . . ENGINE COMPARTMENT Check for evidence of oil and fuel leaks, then clean entire engine and compartment, if needed, prior to inspection. 1. Engine oil, screen, filler cap, dipstick, drain plug and external filter element .· · · 1 2. Oil cooler . . . . . . . . . . . . . . . .. 3. Induction air filter ...................... ..... . 2 4. Induction airbox, air valves, doors and controls ............... . 5. Cold and hot air hoses . ......... ... 6. Engine baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. Cylinders, rocker box covers and push rod housings ............... 8. Crankcase, oil sump, accessory section and front crankshaft seal ......... 9. Hoses, metal lines and fittings . *................ .. 3 10. Intake and exhaust systems .......................... 4 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) ............... .... 5 18. Engine controls and linkage .................. ....... .. 19. Engine shock mounts, mount structure and ground straps ... .......... 20. Cabin heat valves, doors and controls . .................... 21. Starter, solenoid and electrical connections ................... 2-21 SPECIAL INSPECTION ITEM EACH 200 HOURS EACH 100 HOURS EACH 50 HOURS 22. Starter brushes, brush leads and commutator ..................................... 23. Alternator and electrical connections ............................................. 24. Alternator brushes, brush leads, commutator or slip rings ......... ............... 7 25. Voltage regulator mounting and electrical leads .................................... 26. Magnetos (externally) and electrical connections ................................... 27. Magnetos (internally) ........................................................... 15 28. Magnetos timing ............................................................... 29. Carburetor and drain plug ....................................................... 30. Firewall ....................................................................... 31. 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 ..................... 5 6. Fuel vent valves .......................... ........ ......... 7. Vent line drain ................................................................. 8. Fuel shut-off valve and placards ................................................. 9. Fuel valve drain plug .......................................................... 10. Engine primer ................................................................. 11. Perform a fuel quantity indicating system operational test. Refer to Section 15 for detailed accomplishment instructions. ......................................... 18 LANDING GEAR 1. Main gear wheels and fairings ................................................... 17 2. Nose gear wheel, torque links, steering tubes, boots and fairing ...................... 17 3. Wheel bearings .................... .......................... 9 4. Nose gear strut and shimmy dampener (service as required) ........................ 5. Tires ......................................................................... 6. Brake fluid, lines and hoses, linings, discs, brake assemblies and master cylinders ..... 7. Parking brake system........................................................... 8. Main gear springs .............................................................. Temporary Revision Number 3 2-22 © 2002 Cessna Aircraft Company 7 October 2002 SPECIAL INSPECTION ITEM EACH 200 HOURS EACH 100 HOURS EACH 50 HOURS 9. Nose steering arm lubrication .................................................... 10. Torque link lubrication ......................................................... 11. parking brake and toe brakes - operational check.............. .................... AIRFRAME 1. Aircraft exterior ................................................................ 2. Aircraft structure ............................................................... 16 3. Windows, windshield, doors and seals ............................................ 4. Seat belt and shoulder harness .................................................. 19 5. Seat stops, seat rails, upholstery, structure and mounting............................ 6. Control "Y" bearings, sprockets, pulleys, cables, chains and turnbuckles.............. 7. Control lock, control wheel and control "Y" mechanism .............................. 8. Instruments and markings ....................................................... 9. Gyros central air filter ......... .. ......... ....................................... 10 10. Magnetic compass compensation ................................................ 20 11. Instrument wiring and plumbing ................................................. 12. Instrument panel, shock mounts, ground straps, cover, decals and labeling ............ 13. Defrosting, heating and ventilating systems and controls ............................ 14. Cabin upholstery, trim, sun visors and ashtrays .................................... 15. Area beneath floor, lines, hose, wires and control cables ............................ 16. Lights, switches, circuit breakers, fuses, and spare fuses ............................ 17. Exterior lights................................................................. 18. Pitot and static systems ......................................................... 19. Stall warning unit and pitot heater ................................................ 20. Radios, radio controls, avionics and flight instruments ............................... 21. Antennas and cables ......... ... .................. ........................ 22. Battery, battery box and battery cables............................................ 23. Battery electrolyte ......... .. ................... ........................... 11 24. Emergency locator transmitter ......... ......................................... 12 25. Inspect all fluid carrying lines and hoses in the cabin and wing areas for leaks, damage, abrasion, and corrosion. ....................................... Temporary Revision Number 3 7 October 2002 © 2002 Cessna Aircraft Company 2-23 SPECIAL INSPECTION ITEM EACH 200 HOURS EACH 100 HOURS EACH 50 HOURS 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 stops . . . . . . . . . . . . . . . . . 5. Decals and labeling ............... 6. Flap control switch, flap rollers and tracks, flap indicator ......... 7. Flap motor, transmission, limit switches, structure, linkage, bellcranks, etc . ............... 8. Elevator and trim tab hinges, tips and control rods .............. 9. Elevator trim tab system free-play inspection .. ................ 10. Elevator trim tab actuator lubrication and tab free-play inspection ........... 13 11. Rudder pedal assemblies and linkage ...................... 12. Skins (external) of control surfaces and tabs ............... 13. Internal structure of control surfaces ........... 14. Balance weight attachment .............. 15. Flap actuator jack screw threads 14 2-24 Change I SPECIAL INSPECTION ITEMS 1. First 25 hours: Use mineral oil confirming with MIL-C-6529 Type II for the first 25 hours of operation or until oil consumption has stabilized, or six months, whichever occurs first. If oil consumption has not stabilized in this time, drain and replenish the oil and replace the oil filter. After oil consumption has stabilized, change to an ashless dispersant oil, refer to Teledyne Continental Service Information Letter SIL99-2, or latest revision for a current listing of lubricants authorized by TCM. Change oil each 25 hours if engine is NOT equipped with external oil filter; if equipped with an external oil filter, change oil filter element and oil at each 50 hours of operation or every six months, whichever occurs first. Refer to the latest edition of the TCM engine operator/maintenance manual for the latest oil change intervals and inspection procedures. 2. Clean filter per paragraph 2-22. Replace as required. 3. Replace engine compartment hoses per the following schedule: A. Cessna-Installed Flexible Fluid Carrying Rubber Hoses; replace every 5 years or at engine overhaul, whichever occurs first. B. Cessna Installed Flexible Fluid Carrying Teflon Hoses, replace every 10 years or at engine overhaul, whichever occurs first. C. TCM Installed Engine Compartment Flexible Fluid Carrying Hoses, refer to Teledyne Continental Service Bulletin SB97-6 or latest revision for hose replacement intervals. 4. General inspection every 50 hours. Refer to Section 11 for 100 hour inspection. 5. Each 1000 hours, or at engine overhaul, whichever occurs first. 6. Each 50 hours for general condition and freedom of movement. These controls are not repairable, replace throttle and mixture controls at each engine overhaul. 7. Each 500 hours. 8. Internal Timing: For airplanes equipped with Slick 4100 series magnetos: These magnetos cannot be overhauled in the field. The coil, capacitor, and breaker assembly are non- replaceable. These magnetos shall be removed from service upon reaching 800 hours total time in service. For airplanes equipped with Slick 4300 Series magnetos or TCM/Bendix magnetos: Refer to the applicable service manual and service bulletins for internal timing procedures and service intervals. Magneto-To-Engine Timing: First 50 hours, first 100 hours and each 200 hours thereafter. 9. First 100 hours and each 500 hours thereafter. More often if operated under prevailing wet of dusty conditions. 10. Replace each 500 hours. 11. Check electrolyte level and clean battery compartment each 50 hours or 30 days, whichever occurs first. 12. Refer to Section 16 of this manual. Temporary Revision Number 3 7 October 2002 © 2002 Cessna Aircraft Company 2-25 13. Replacement or overhaul of the actuator is required each 1000 hours and/or 3 years, whichever comes first. Refer to figure 2-5 for grease specifications. NOTE:Refer to Section 9 of this service manual and Cessna Single Engine Service Letter SE73-25, or latest revision, for free-play limits, inspection, replacement and/or repair information. 14. Refer to paragraph 2-44 for detailed instructions for various serial ranges. 15. Each 500 hours. Inspect contact points. Inspect carbon brush, high tension lead, and distributor block. Inspect impulse coupling and pawls. Replace as required. Inspect and lubricate bearings and contact point cam. 16. Vertical stabilizer attachment each 100 hours or annual inspection. However it is recommended that nutplates used to attach the vertical stabilizer be inspected after each 100 hours of operation. Refer to paragraph 4-14A for detailed instructions. 17. Each 100 hours or annual inspection, check socket head cap screws for proper torque. When replacing wheel bearings, check webs around flange mounting screw holes. During tire or tube change, or when the wheel is otherwise disassembled, use dye penetrant to inspect the hubs. Refer to paragraph 2-38. 18. Fuel quantity indicating system operational test is required every 12 months. Refer to Section 15 for detailed accomplishment instructions. 19. Inspect each 50 hours for general condition and security. Replacement is required every 10 years. 20. When the accuracy of the compass is in question, when components are added or removed which have the potential to affect the magnetic accuracy and/or variation of the compass calibration, or after a lightning strike. Refer to Advisory Circular AC43.13-1B, Chapter 12, Section 3 Ground Operational Checks for Avionics Equipment for a detailed listing of conditions requiring the performance of a compass swing and compass swing procedures. 2-45. COMPONENT TIME LIMITS 1. General A. Most components listed throughout Section 2 should be inspected as detailed elsewhere in this section and repaired, overhauled or replaced as required. Some components, however, have a time or life limit, and must be overhauled or replaced on or before the specified time limit. NOTE: The terms overhaul and replacement as used within this section are defined as follows: Overhaul - Item may be overhauled as defined in FAR 43.2 or it can be replaced. Replacement - Item must be replaced with a new item or a serviceable item that is within its service life and time limits or has been rebuilt as defined in FAR 43.2. B. This section provides a list of items which must be overhauled or replaced at specific time limits. Table 1 lists those items which Cessna has mandated must be overhauled or replaced at specific time limits. Table 2 lists component time limits which have been established by a supplier to Cessna for the supplier's product. C. In addition to these time limits, the components listed herein are also inspected at regular time intervals set forth in the Inspection Charts, and may require overhaul/replacement before the time limit is reached based on service usage and inspection results. Temporary Revision Number 3 2-26 © 2002 Cessna Aircraft Company 7 October 2002 2. Cessna-Established Replacement Time Limits A. The following component time limits have been established by Cessna Aircraft Company. Table 1: Cessna-Established Replacement Time Limits COMPONENT REPLACEMENT OVERHAUL TIME Restraint Assembly Pilot, Copilot, 10 years NO and Passenger Seats Trim Tab Actuator 1,000 hours or 3 years, YES whichever occurs first Vacuum System Filter 500 hours NO Vacuum System Hoses 10 years NO Pitot and Static System Hoses 10 years NO Vacuum Relief/Regulator Valve Filter 500 hours NO (If Installed) Engine Compartment Flexible Fluid 10 years or engine overhaul, NO Carrying Teflon Hoses (Cessna- whichever occurs first Installed) Except Drain Hoses (Note 1) (Drain hoses are replaced on condition) Engine Compartment Flexible Fluid 5 years or engine overhaul, NO Carrying Rubber Hoses (Cessna- whichever occurs first Installed) Except Drain Hoses (Note 1) (Drain hoses are replaced on condition) Engine Air Filter 500 hours or 36 months, NO whichever occurs first (Note 9) Engine Mixture, and Throttle, At engine TBO NO Controls Engine Driven Dry Vacuum Pump 6 years or at vacuum NO Drive Coupling pump replacement, (Not lubricated with engine oil) whichever occurs first Engine Driven Dry Vacuum Pump 500 hours NO (Not lubricated with engine oil) (Note 10) Standby Dry Vacuum Pump 500 hours or 10 years, NO whichever occurs first (Note 10) Temporary Revision Number 3 7 October 2002 © 2002 Cessna Aircraft Company 2-27 3. Supplier-Established Replacement Time Limits A. The following component time limits have been established by specific suppliers and are reproduced as follows: Table 2: Supplier-Established Replacement Time Limits COMPONENT REPLACEMENT OVERHAUL TIME ELT Battery Note 3 NO Vacuum Manifold Note 4 NO Magnetos Note 5 YES Engine Note 6 YES Engine Flexible Hoses Note 2 NO (TCM Installed) Auxiliary Electric Fuel Pump Note 7 YES Propeller Note 8 YES NOTES: Note 1: This life limit is not intended to allow flexible fluid-carrying Teflon or rubber hoses in a deteriorated or damaged condition to remain in service. Replace engine compartment flexible Teflon (AE3663819BXXXX series hose) fluid-carrying hoses (Cessna installed only) every ten years or at engine overhaul, whichever occurs first. Replace engine compartment flexible rubber fluid-carrying hoses (Cessna installed only) every five years or at engine overhaul, whichever occurs first (this does not include drain hoses). Hoses which are beyond these limits and are in a serviceable condition, must be placed on order immediately and then be replaced within 120 days after receiving the new hose from Cessna. Note 2: Refer to Teledyne Continental Service Bulletin SB97-6, or latest revision. Note 3: Refer to FAR 91.207 for battery replacement time limits. Note 4: Refer to Airborne Air & Fuel Product Reference Memo No. 39, or latest revision, for replacement time limits. Note 5: For airplanes equipped with Slick magnetos, refer to Slick Service Bulletin SB2-80C, or latest revision, for time limits. For airplanes equipped with TCM/Bendix magnetos, refer to Teledyne Continental Motors Service Bulletin No. 643, or latest revision, for time limits. Note 6: Refer to Teledyne Continental Service Information Letter SIL98-9, or latest revision, for time limits. Note 7: Refer to Cessna Service Bulletin SEB94-7 Revision 1/Dukes Inc. Service Bulletin NO. 0003, or