Cessna 172 Maintenance Manual 61n5m

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Brake Master Cylinder Figure 202 (Sheet 1)

32-42-00 © Cessna Aircraft Company

Page 206 Apr 7/2003

0

CESSNA AIRCRAFT COMPANY

MODEL 172 MAINTENANCE MANUAL (3) (4)

Install bleeder screw at wheel brake assembly. Fill and bleed brake system. Refer to Brake System Bleeding below.

WARNING: ENSURE SEAT IS POSITIONED CORRECTLY ON SEAT RAILS AND THAT SEAT STOPS ARE PROPERLY INSTALLED. (5) 7.

Brake System Bleeding A.

8.

Install seat and rudder bar shield.

Bleeding Procedures. (1) Remove brake master cylinder filler plug. (2) Screw flexible hose with appropriate fitting into the filler hole. (3) Immerse opposite end of flexible hose in a container with enough hydraulic fluid to cover the end of the hose. (4) Connect a clean hydraulic pressure source to the bleeder valve in the wheel cylinder. (5) Pump clean hydraulic fluid into the system. Observe the immersed end of the hose at the master brake cylinder for evidence of air bubbles being forced from the brake system. When bubbling has ceased, all air has been removed from system. (6) Close bleeder valve at wheel cylinder and tighten. Remove pressure source from wheel cylinder bleeder valve. Remove flexible hose from master cylinder filler hose. (7) Reinstall filler plug on master cylinder. (8) Test system and ensure brakes are operating properly.

Parking Brake System A.

Figure 201, Detail A may be used as a guide in removal and installation of parking brake components.


Page 207 Apr 7/2003

CHAPTER

LIGHTS


MODEL 172 MAINTENANCE MANUAL

LIST OF EFFECTIVE PAGES CHAPTER-SECTION-SUBJECT

PAGE

DATE

33-00-00

Page 1

Apr 7/2003

33-10-00

Pages 201-204

Jan 2/2006

33-11-00

Pages 201-202

Apr 7/2003

33-12-00

Pages 201-202

Apr 7/2003

33-13-00

Pages 201-203

Jun 7/2004

33-14-00

Pages 201-202

Apr 7/2003

33-15-00

Pages 201-202

Apr 7/2003

33-40-00

Pages 201-203

Apr 7/2003

33-41-00

Pages 201-202

Jan 2/2006

33-43-00

Pages 101-102

Jul 1/2005

33-43-00

Pages 201-205

Jul 1/2005

33-44-00

Pages 201-202

Apr 7/2003

33-Title 33-List of Effective Pages 33-Record of Temporary Revisions 33-Table of Contents

33 - LIST OF EFFECTIVE PAGES © Cessna Aircraft Company

Page 1of 1 Jan 2/2006

RECORD OF TEMPORARY REVISIONS Temporary Revision Number

Page Number

Issue Date

By

Date Removed

By


MODEL 172

MAINTENANCE MANUAL

CONTENTS LIGHTING - GENERAL

.........

...............................................

S cope...................................................................... Definition...................................................................

33-00-00 Page 1 33-00-00 Page 1 33-00-00 Page 1

FLOOD LIGHTING - MAINTENANCE PRACTICES ................................. General ................................................................... Floodlight Bulb Removal/Installation .......................................... Light Assembly Removal/ Installation ......................................... Light Assembly Switch Removal/Installation ................................... Potentiometer Removal/Installation ...........................................

33-10-00 33-10-00 33-10-00 33-10-00 33-10-00 33-10-00

Page Page Page Page Page Page

GLARESHIELD LIGHTING - MAINTENANCE PRACTICES.......................... General .................................................................... Glareshield Light Removal/Installation ....................................... Glareshield Light Power Supply Removal/Installation ...........................

33-11-00 33-11-00 33-11-00 33-11-00

Page 201 Page 201 Page 201 Page 201

PEDESTAL LIGHTING - MAINTENANCE PRACTICES.............................. General .................................................................... Pedestal Light Bulb Replacement.............................................

33-12-00 Page 201 33-12-00 Page 201 33-12-00 Page 201

INSTRUMENT LIGHTING - MAINTENANCE PRACTICES........................... G eneral .................................................................... Flight Instrument Light Bar Assembly ......................................... Engine Instrument Light Bulb Assembly ....................................... Dimming Assembly Removal/Installation ......................................

33-13-00 33-13-00 33-13-00 33-13-00 33-13-00

Page Page Page Page Page

201 201 201 201 201

RADIO LIGHTING - MAINTENANCE PRACTICES.................................. General .................................................................... Dimming Module Removal/Installation ........................................ Dimmer Control Removal/Installation .........................................

33-14-00 33-14-00 33-14-00 33-14-00

Page Page Page Page

201 201 201 201

PILOT CONTROL WHEEL LIGHTING - MAINTENANCE PRACTICES................ General .................................................................... Map Light Removal/nstallation ............................................... Map Light Rheostat Removal/Installation ......................................

33-15-00 33-15-00 33-15-00 33-15-00

Page Page Page Page

201 201 201 201

NAVIGATION AND STROBE LIGHTS - MAINTENANCE PRACTICES ................ Description and Operation ................................................... Navigation Lights Removal/Installation ........................................ Strobe Lights Removal/nstallation ............................................

33-40-00 33-40-00 33-40-00 33-40-00

Page Page Page Page

201 201 201 201

VERTICAL FIN BEACON - MAINTENANCE PRACTICES ........................... Description and Operation ................................................... Beacon Removal/Installation................................................. LANDING/TAXI LIGHTS - TROUBLESHOOTING ................................... High-Intensity Discharge (HID) Landing and Taxi Lights Troubleshooting .........

33-41-00 Page 201 33-41-00 Page 201 33-41-00 Page 201

LANDING/TAXI LIGHTS - MAINTENANCE PRACTICES ............................ General .................................................................... Troubleshooting............................................................. Light Adjustment ........................................................... Light Removal and Installation ............................................... High-Intensity Discharge (HID) Ballast Removal and Installation.................

33-43-00 33-43-00 33-43-00 33-43-00 33-43-00 33-43-00

COURTESY WING LIGHTS - MAINTENANCE PRACTICES ......................... Description and Operation ................................................... Courtesy Wing Light Removal/Installation .....................................

33-44-00 Page 201 33-44-00 Page 201 33-44-00 Page 201

33-43-00 Page 101 33-43-00 Page 101

33 - CONTENTS © Cessna Aircraft Company

201 201 201 201 201 204

Page 201 Page 201 Page 201 Page 201 Page 201 Page 204



MODEL 172 MAINTENANCE MANUAL LIGHTING - GENERAL 1.

Scope A.

2.

This chapter provides information on internal and external lighting.

Definition A.

This chapter is divided into section and subsections to assist maintenance personnel in locating specific components and information. Consulting the Table of Contents will further assist in locating a particular subject.


Page 1

Apr 7/2003


MODEL 172 MAINTENANCE MANUAL FLOOD LIGHTING - MAINTENANCE PRACTICES 1.

General A.

2.

Cabin flood lighting is mounted in the aft and the forward parts of the overhead console. Each flood light has a switch. The forward and the aft lights are reading lights.

Floodlight Bulb Removal/Installation

CAUTION: The floodlight bulb can break if you apply too much pressure when you remove and install it.

3.

A.

Floodlight Bulb Removal (Refer to Figure 201). (1) Press the lens holder up and turn it counterclockwise. (2) Remove the lens holder. (3) Carefully push the bulb up and turn it counterclockwise. (4) Remove the bulb.

B.

Floodlight Bulb Installation (Refer to Figure 201). (1) Put the bulb in position. (2) Carefully push the bulb up and turn it clockwise. (3) Put the lens in position. (4) Push the lens holder up and turn it clockwise.

Light Assembly Removal/ Installation A.

Light Assembly Removal (Refer to Figure 201). NOTE:

Removal/Installation is typical for all three floodlights.

(1) Put the ALT/BAT MASTER switch in the off position.

CAUTION: the overhead console when you remove the screws to prevent damage to the electrical wiring in the overhead console. (2) Remove the screws that attach the overhead console to the attach brackets. (3) Identify, tag, and disconnect the electrical wires from the light assembly. (4) Remove the light assembly from the overhead console. B.

4.

Light Assembly Installation (Refer to Figure 201). (1) Put the light assembly in position. (2) Attach the light assembly to the overhead console. (3) Connect the electrical wires to the light assembly. (4) Attach the overhead console to the attach brackets with the screws. (5) Put the ALT/BAT MASTER switch in the ON position.

Light Assembly Switch Removal/Installation A.

Light Assembly Switch Removal (Refer to Figure 201). (1) Put the ALT/BAT MASTER switch in the off position.

CAUTION: the overhead console when you remove the screws to prevent damage to the electrical wiring in the overhead console. (2) (3) (4) B.

Remove the overhead console from the attach brackets. Identify, tag, and disconnect the wires from the switch. Remove the switch from the overhead console.

Light Assembly Switch Installation (Refer to Figure 201). (1) Install the switch in the overhead console. 33-10-00 © Cessna Aircraft Company

Page 201 Jan 2/2006



LENS HOLDER

DETAIL

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OVERHEAD

CONSOLE 051 T1007 A0519T1050

AIRPLANES WITHOUT GARMIN G1000 Flood Light Installation Figure 201 (Sheet 1)


Page 202 Jan 2/2006



BULB LENS HOLDER

POTENTIOMETER

DETAIL B

JAM NUT KNOB ASSEMBLY

DETAIL C

3

LIGHT

ASSEMBLY

7

DETAIL A AIRPLANES WITH GARMIN G1000

A0519T1104

C2618Tl153

Flood Light Installation Figure 201 (Sheet 2)

33-10-00 ©Cessna Aircraft Company

Page 203 Jan 2/2006


MODEL 172 MAINTENANCE MANUAL (2) (3) (4) 5.

Connect the electrical wires to the switch. Attach the overhead console to the attach brackets with the screws. Put the ALT/BAT MASTER switch in the ON position.

Potentiometer Removal/Installation A.

Potentiometer Removal (Refer to Figure 201). (1) Put the ALT/BAT MASTER switch in the off position.

CAUTION: the overhead console when you remove the screws to prevent damage to the electrical wiring in the overhead console. (2) (3) (4) (5) B.

Remove the overhead console from the attach brackets. Identify, tag, and disconnect the wires from the switch. Remove the knob assembly and the jam nut from the potentiometer. Remove the potentiometer from the overhead console.

Potentiometer Installation (Refer to Figure 201). (1) Install the jam nut and the knob assembly. (2) Connect the electrical wires to the potentiometer. (3) Attach the overhead console to the attach brackets with the screws. (4) Put the ALT/BAT MASTER switch in the ON position.


Page 204 Jan 2/2006


MODEL 172 MAINTENANCE MANUAL GLARESHIELD LIGHTING - MAINTENANCE PRACTICES 1.

General A.

2.

3.

A single white neon tube installed under the glareshield provides overall lighting for the instrument . A glareshield dimming control is mounted below and to the left of the throttle.

Glareshield Light Removal/Installation A.

Remove Glareshield Light (Refer to Figure 201). (1) Remove glareshield. (2) Disconnect glareshield electrical connector. (3) Remove glareshield light lens. (4) Remove light tube from individual retainers.

B.

Install Glareshield Light (Refer to Figure 201). (1) Secure light tube with individual retainers. (2) Install glareshield light lens. (3) Connect glareshield electrical connector. (4) Install glareshield.

Glareshield Light Power Supply Removal/Installation A.

Remove Glareshield Light Power Supply (Refer to Figure 201). (1) Remove electrical connector from power supply. (2) Remove screws securing power supply to back of instrument .

B.

Install Glareshield Light Power Supply (Refer to Figure 201). (1) Secure power supply to back of instrument with screws. (2) Connect electrical connector to power supply.


Page 201 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL

B

ELECTRICAL CONNECTOR POWER SUPPLY ELECTRICAL CONNECTOR

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0510T1007 A0519T1051 AA0519T1046 BB0585T1040

B-B

Glareshield Lighting Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL PEDESTAL LIGHTING - MAINTENANCE PRACTICES 1.

General A.

2.

A single bulb-type light is installed on the pedestal. This light provides illumination of the fuel selector.

Pedestal Light Bulb Replacement A.

Replace Pedestal Light (Refer to Figure 201). (1) Remove screws securing light hood to pedestal. (2) Replace pedestal light bulb. (3) Secure light hood to pedestal.


Page 201 Apr 7/2003



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Pedestal Lighting Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL INSTRUMENT LIGHTING - MAINTENANCE PRACTICES 1.

General A.

2.

3.

The flight instruments individually light by a replaceable light bar assembly. The light bar assembly is at the top of the instrument. Engine instruments are individually lighted by replaceable light bulb assemblies. Both flight and engine instruments are operated by a dimming control unit.

Flight Instrument Light Bar Assembly A.

Remove the Flight Instrument Light Bar Assembly (Refer to Figure 201). (1) Remove the applicable flight instrument. (2) Remove the screws that attach the light bar assembly to the flight instrument.

B.

Install the Flight Instrument Light Bar Assembly (Refer to Figure 201). (1) Replace the light bar assembly. (2) Install the flight instrument.

Engine Instrument Light Bulb Assembly A.

Remove the Engine Instrument Light Bulb Assembly (Refer to Figure 201). NOTE:

The engine instrument light bulb assembly is on the forward side of the engine instrument.

(1) Remove the applicable engine instrument. (2) Turn the light bulb assembly one-quarter turn. (3) Remove the light bulb assembly from the engine instrument. B.

Install the Engine Instrument Light Bulb Assembly (Refer to Figure 201). NOTE:

The engine instrument light bulb assembly is on the forward side of the engine instrument.

(1) Put the light bulb assembly in position. (2) Turn the light bulb assembly one quarter turn to attach to the engine instrument. (3) Install the engine instrument. 4.

Dimming Assembly Removal/Installation A.

Remove the Dimming Assembly (Refer to Figure 201). (1) Remove the screws that attach the dimming assembly (ZC001) to the structure. (2) Disconnect the dimming assembly electrical connector (P1). (3) Remove the dimming assembly.

B.

Install the Dimming Assembly (Refer to Figure 201). (1) Connect the dimming assembly electrical connector (P1). (2) Attach the dimming assembly (ZC001) to the structure with screws.


Page 201 Jun 7/2004


MODEL 172

MAINTENANCE MANUAL

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TYPICAL FLIGHT INSTRUMENT LIGHTING

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DETAIL C TYPICAL ENGINE INSTRUMENT LIGHTING

0585T1040 A0518T1036 B0518T1036 C0518T1037 AA0518T1037

Instrument Lighting Installation Figure 201 (Sheet 1)


Page 202 Jun 7/2004



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Instrument Lighting Installation Figure 201 (Sheet 2)

33-1 3-00 © Cessna Aircraft Company

Page 203 Jun 7/2004


MODEL 172

MAINTENANCE MANUAL RADIO LIGHTING - MAINTENANCE PRACTICES 1.

General A.

2.

Dimming Module Removal/Installation A.

3.

Radio lighting consists of internally lighted radios, a dimming module and a dimmer control. Maintenance practices include dimming module removal/installation and dimmer control removal/installation.

For Dimming Module Removal/Installation, refer to Instrument Lighting - Maintenance Practices, located in this chapter.

Dimmer Control Removal/Installation A.

Remove Dimmer Control (Refer to Figure 201). (1) Remove nut securing dimmer control to back of instrument . (2) Label and de-solder wires connected to dimmer control. (3) Remove dimmer control.

B.

Install Dimmer Control (Refer to Figure 201). (1) Solder proper pins to existing labeled wires as prepared in paragraph 3.A.(2). (2) Place dimmer control through hole in instrument and secure with nut.


Page 201 Apr 7/2003



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Radio Lighting Installation Figure 201 (Sheet 1)

33-14-00 ® Cessna Aircraft Company

Page 202 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL PILOT CONTROL WHEEL LIGHTING - MAINTENANCE PRACTICES 1.

General A.

2.

3.

A map light is installed on the lower surface of the pilot's control wheel.

Map Light Removal/Installation A.

Remove Map Light (Refer to Figure 201). (1) Remove nut and washer securing map light to control wheel. (2) Remove map light.

B.

Install Map Light (Refer to Figure 201). (1) Place map light over control wheel stud and secure with nut and washer.

Map Light Rheostat Removal/Installation A.

B.

Remove Map Light Rheostat (Refer to Figure 201). (1) Remove thumbwheel and jamnut from rheostat. (2) Pull rheostat out of control wheel and remove electrical wires. Install Map Light Rheostat (Refer to Figure 201). (1) Connect electrical wires to rheostat and place in control wheel. (2) Install jamnut and thumbwheel.


Page 201 Apr 7/2003



B1770

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Control Wheel Lighting Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL NAVIGATION AND STROBE LIGHTS - MAINTENANCE PRACTICES 1.

Description and Operation A.

2.

The airplane is equipped with both fixed intensity navigation lights and pulsing strobe lights. (1) Navigation lights are located on the left wing tip, right wing tip and tailcone. The navigation lights in the wing tip are co-located with the strobe assemblies, and the light in the tailcone is located in its own housing. (a) Bulbs for all three navigation lights are clear. The lens assembly on the right wingtip is colored green, the lens assembly on the left wing tip is colored red, and the lens assembly on the tailcone is clear. (b) The navigation lights are activated by placing the switch/circuit breaker in the NAV position. This position supplies power concurrently to all three lights. (2) Strobe lights are co-located with navigation lights in the wingtip housing. (a) The strobe and lens assembly are both clear. The strobes are activated by placing the switch/circuit breaker in the STROBES position. This position supplies power to the right and left power supply, providing pulsed energy to fire the strobes.

Navigation Lights Removal/nstallation A.

Remove Wingtip Navigation Lights (Refer to Figure 201). NOTE: (1) (2) (3) (4)

3.

Removal is typical for both the left and right bulbs.

Ensure electrical power to airplane is OFF. Remove screws securing lens retainer to wingtip. Remove lens from navigation portion of assembly. Grasp bulb, depress slightly and turn counterclockwise to release bulb from bayonet mount.

B.

Install Wingtip Navigation Lights (Refer to Figure 201). (1) Place bulb in bayonet socket, depress, and gently turn clockwise until bulb seats in socket. (2) Position lens and gasket in place. (3) Secure lens assembly using lens retainer and screws.

C.

Remove Tailcone- Mounted Navigation Light (Refer to Figure 201 ). (1) Ensure electrical power to airplane is OFF. (2) Remove screws and lens retainer. (3) Remove lens to gain access to bulb. (4) Grasp bulb, depress slightly and turn counterclockwise to release bulb from bayonet mount.

D.

Install Tailcone-Mounted Navigation Light (Refer to Figure 201). (1) Place bulb in bayonet socket, depress, and gently turn clockwise until bulb seats in socket. (2) Position lens and gasket over bulb. (3) Secure using lens retainer and screws.

Strobe Lights Removal/Installation A.

Remove Strobe Light Assembly (Refer to Figure 201). NOTE: (1) (2) (3) (4)

Removal/installation is typical for both the FR003 right strobe light and FL005 left strobe light.

Ensure electrical power to airplane is OFF. Remove screws securing lens retainer to wingtip. Remove lens from in front of flash tube assembly. Disconnect electrical connector P1 from power supply. NOTE:

It will be necessary to remove wingtip to gain access to electrical connector PI and power supply.


Page 201 Apr 7/2003



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0510T1007 A0518T1028 B0518T1027 C0518T1029

Navigation and Anti-Collision Strobe Light Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL

(5)

Remove flash tube assembly from wingtip.

B.

Install Strobe Light Assembly (Refer to Figure 201). (1) Install flash tube assembly to wingtip. Use protective gloves or cotton wrap to ensure fingertip oil does not come in with flash tube assembly. (2) Connect electrical connect PI to power supply. (3) Reinstall wingtip. (4) Place lens on flash tube assembly. (5) Secure lens using lens retainer and screws.

C.

Remove Power Supply (Refer to Figure 201). NOTE:

D.

Removal and installation is typical for both the UL001 left and UR001 right power supply.

(1) Ensure electrical power to airplane is OFF. (2) Remove wingtip. Disconnect electrical connectors from both ends of power supply. (3) (4) Remove ground wires as required. (5) Remove screws securing power supply to wing, and remove power supply from wing. Install Power Supply (Refer to Figure 201). (1) Secure power supply to wing using screws. (2) Secure ground wires from power supply to wing structure. (3) Reconnect electrical connectors. (4) Install wingtip. (5) Check strobe for proper operation.


Page 203 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL VERTICAL FIN BEACON - MAINTENANCE PRACTICES 1.

I 2.


The vertical fin beacon is located on top of the vertical fin cap assembly and provides a flashing red light to aid in airplane recognition.

B.

Put the LIGHTS BCN/OFF switch to the BCN position to start the flashing beacon. This position supplies power to the light. Internal circuitry makes the light flash on and off at approximately 50 cycles per minute.

Beacon Removal/Installation A.

B.

Remove Beacon (Refer to Figure 201). (1) Loosen screw on clamp ring assembly. (2) Remove lens assembly from base assembly. (3) Remove lamp assembly from base. Install Beacon (Refer to Figure 201). (1) Install lamp assembly to base. (2) Place lens assembly and gasket on base assembly. (3) Secure lens assembly to base assembly by tightening clamp ring assembly.


Page 201 Jan 2/2006



B1

A

LENS

CLAMP RING

GASKET

LAMP ASSEMBLY

SCREW CREW CAP AS

ELECTRICAL ELECTRICAL

0510T1007 A0518T1010

Flashing Beacon Light Installation Figure 201 (Sheet 1)


Page 202 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL LANDING/TAXI LIGHTS - TROUBLESHOOTING 1.

High-Intensity Discharge (HID) Landing and Taxi Lights Troubleshooting A. The troubleshooting flow chart that follows is for Airplanes 17281234 and On and 172S9771 and On, and Airplanes 17280001 thru 17281233 and Airplanes 172S8001 thru 172S9770 incorporating MK172-33-01 that have high-intensity discharge (HID) lighting installed. NOTE:

The troubleshooting procedure is typical for the landing light and taxi light.


Page 101 Jul 1/2005


MODEL 172

MAINTENANCE MANUAL

B4002

The landing light does not come on when the landing light switch is put into the LAND position with the MASTER/BAT switch in the ON position and electrical power applied to the airplane.

I Remove the landing light and connect it to the taxi light electrical connectors. Does the light come on? If-

I

Do a check for power and grounding at the ballast electrical connector (PL010). Is there power and grounding? If -

Replace thea landing light bulb. J

I

Do a check of the LAND LT, TAXI LT, and J-box circuit breakers to make sure that they are engaged. Are the circuit breakers engaged? If-

Replace the> landing light ballast.

I

/Do a check for broken, (disconnected, or loose wires \Repair any that are found/

Engage the circuit breakers.

Landing/Taxi Light Troubleshooting Figure 101 (Sheet 1)


Page 102 Jul 1/2005


MODEL 172

MAINTENANCE MANUAL LANDING/TAXI LIGHTS - MAINTENANCE PRACTICES 1.

2.

General A.

Airplanes 17280001 thru 17281233 and Airplanes 172S8001 thru 172S9770 not incorporating MK17233-01 have an incandescent landing and taxi light installed. The landing and taxi lights are installed on the left wing leading edge between WS 100.00 and WS 118.00. The landing and taxi lights are controlled by two switches on the circuit assembly. The landing light is operated by the landing light switch and the taxi light is operated by the taxi light switch.

B.

Airplanes 17281234 and On and Airplanes 172S9771 and On, and Airplanes 17280001 thru 17281233 and Airplanes 172S8001 thru 172S9770 incorporating MK172-33-01 have a high-intensity discharge (HID) landing and taxi light installed. The landing and taxi lights have an igniter installed on the back side of each light. A ballast is necessary for the operation of the HID bulbs. The ballast for the landing light HID bulb (inboard bulb) is installed on a bracket that is attached to a wing leading-edge rib inboard of the bulb. The ballast for the taxi light HID bulb (outboard bulb) is installed on a bracket that is attached to a wing leading-edge rib outboard of the bulb. The wiring is almost the same as the incandescent bulb installation, but there is one more cable necessary to connect the ballast to the HID bulbs. The landing and taxi light switches, and the landing and taxi light circuit breakers for the HID lighting system are the same as those for the incandescent lighting system.

Troubleshooting A.

For troubleshooting of the HID landing and taxi light installation, refer to Chapter 33, Landing/Taxi Lights - Troubleshooting.

3.

Light Adjustment A.

4.

The landing and taxi lights are set to specified positions, but you can adjust them as necessary. The procedures that follow give information on the correct landing and taxi light adjustment procedure. The procedures that follow are typical for incandescent and HID lights. (1) Park the airplane on a flat, level surface with the landing and taxi lights in front of a light-reflecting object. Make sure that the waterline of the airplane is level and that the wings are level. Refer to Chapter 8, Leveling - Maintenance Practices. (2) Park the airplane so that the distance from the light-reflecting object to the rivet line on the bottom of the front spar is approximately 3 feet. (3) Set the landing light switch to the LAND position. (4) Measure the distance from the floor to the center of the beam that shines on the light-reflecting object. The correct distance is 74.41 inches. (5) Set the landing light switch to the OFF position (6) Set the taxi light switch to the TAXI position. (7) Measure the distance from the floor to the center of the beam that shines on the light-reflecting object. The correct distance is 73.29 inches. (8) Set the taxi light switch to the OFF position. (9) To adjust the beam to the correct position, add or remove washers between the spacers and the plate.

Light Removal and Installation NOTE: A.

Removal and installation is typical for incandescent and HID landing and taxi lights.

Remove the Light (Refer to Figure 201). (1) Disconnect the main battery from the airplane. Refer to Chapter 24, Battery - Maintenance Practices. (2) Set the landing light and the taxi light switches to OFF. (3) Remove the screws that attach the lens assembly to the leading edge of the wing. (4) Remove the screws, brackets, and nuts that hold the light in position against the plate. NOTE:

Some airplanes that have the HID landing and taxi lights have an aluminum ring installed between the HID landing and taxi lights and the bracket. 33-43-00 © Cessna Aircraft Company

Page 201 Jul 1/2005



nanny

S

DETAIL A AIRPLANES 17280001 THRU 17281233 AND AIRPLANES 172S8001 THRU 172S9770 NOT INCORPORATING MK172-33-01 051 T1007 A052BR3001

Landing and Taxi Light Installation Figure 201 (Sheet 1)


Page 202 Jul 1/2005


MODEL 172

MAINTENANCE MANUAL

B4006

HID LANDING LIGHT BALLAST

SCREW

LIGHT

DETAIL A AIRPLANES 17281234 AND ON AND AIRPLANES 172S9771 AND ON AND AIRPLANES 17280001 THRU 17281233 AND AIRPLANES 172S8001 THRU 172S9770 INCORPORATING MK172-33-01

A0528T1002

Landing and Taxi Light Installation Figure 201 (Sheet 2)


Page 203 Jul 1/2005


MODEL 172

MAINTENANCE MANUAL (5) Disconnect the electrical wires from the back side of the light and remove the light from the airplane. B.

Install the Light (Refer to Figure 201). (1) Put the light at the correct wing location (between WS 100.00 and WS 118.00) and connect the electrical wires to the light. (2) With screws and nuts, attach the light to the bracket so the light is attached tightly against the plate. NOTE:

The top of the nuts is not flush with the lip of the plate. The remaining part of the nuts is behind the plate at the screw opening.

NOTE:

Some airplanes that have the HID landing and taxi lights will have an aluminum ring installed between the HID landing and taxi lights and the bracket.

(3) Install the lens assembly to the leading edge of the wing. (4) Connect the main battery to the airplane. Refer to Chapter 24, Battery - Maintenance Practices. (5) Set the landing light switch to LAND and the taxi light switch to TAXI. (6) Do a check of the operation of the landing and taxi lights. 5.

High-Intensity Discharge (HID) Ballast Removal and Installation NOTE: A.

The procedures that follow are for airplanes that have the HID landing and taxi light installation.

Remove the HID ballast (Refer to Figure 201). NOTE:

Removal and installation procedures are typical for the HID landing and taxi lights.

(1) Disconnect the main battery from the airplane. Refer to Chapter 24, Battery - Maintenance Practices. (2) Put the landing and taxi light switches in the OFF position. (3) Remove the HID landing and taxi lights. Refer to Light Removal and Installation. (4) Remove the screws and nylon washers that attach the HID ballast to the bracket on the wing leading-edge rib. (5) Disconnect the electrical connectors from the HID ballast. (a) Landing light connectors: PL010 and UL005. (b) Taxi light connectors: PL011 and UL006. (6) Remove the HID ballast from the airplane. B.

Install the HID ballast (Refer to Figure 201). (1) Disconnect the main battery from the airplane. Refer to Chapter 24, Battery - Maintenance Practices. (2) Put the landing and taxi light switches in the OFF position. (3) Put the ballast at the correct wing location. (a) Landing light: outboard side of the wing rib found at WS 100.00. (b) Taxi light: inboard side of the wing rib found at WS 118.00. (4) Connect the electrical connectors to the HID ballast. (a) Landing light connectors: PL010 and UL005. (b) Taxi light connectors: PL011 and UL006


Page 204 Jul 1/2005


MODEL 172

MAINTENANCE MANUAL

CAUTION: Do not install the HID ballast to the bracket without the nylon shoulder washers between the HID ballast and the bracket and the nylon washers between the HID ballast and the screw head. If the HID ballast is installed without the nylon washers, an electromagnetic field in the wing structure can cause incorrect operation of the magnetometer. (5) Install the screws and nylon washers that attach the HID ballast to the bracket on the wing leading-edge rib. (6) Install the HID landing and taxi lights. Refer to Light Removal and Installation. (7) Connect the battery to the airplane. Refer to Chapter 24, Battery - Maintenance Practices. (8) Set the landing light switch to LAND and the taxi light switch to TAXI. (9) Do a check of the operation of the landing and taxi lights.


Page 205 Jul 1/2005


MODEL 172 MAINTENANCE MANUAL COURTESY WING LIGHTS - MAINTENANCE PRACTICES 1.


2.

Each wing is equipped with a courtesy light located near the strut/wing intersection. The left wing light, the right right light and the rear dome light are connected in parallel on a single circuit. Pressing the overhead light switch supplies power to all three lights.Pressing the overhead light switch again removes power from all three lights.

Courtesy Wing Light Removal/Installation A.

B.

Remove Light (Refer to Figure 201). (1) Ensure electrical power to the airplane is OFF. (2) Remove screws securing cover to underside of wing. (3) Push in on lamp, rotate counterclockwise and remove lamp from bayonet socket. Install Light (Refer to Figure 201). (1) Insert lamp into bayonet socket. Turn clockwise until lamp seats in socket. (2) Reinstall cover to underside of wing.


Page 201 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL A . _s

B1

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DETAIL A 0510T1007 A0528T1001

Courtesy Wing Light Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003

CHAPTER

NAVIGATION


MODEL 172

MAINTENANCE MANUAL


PAGE

DATE

34-00-00

Page 1

Apr 7/2003

34-11-00

Pages 201 -213

Jul 3/2006

34-1 2-00

Pages 201-203

Apr 7/2003

34-13-00

Pages 201 -202

Jan 3/2005

34-20-00

Pages 201 -21 0

Jan 2/2006

34-21-00

Pages 201-202

Apr 7/2003

34-22-00

Pages 201-202

Jul 1/2007

34-23-00

Pages 201-203

Jan 3/2005

34 -30-00

Pages 201 -202

Jan 3/2005

34-50-00

Pages 201 -202

Jul 1/2005

34-50-10

Page 201

Janl1/2007

34-5 1-00

Pages 201-202

Apr 7/2003

34-52-00

Pages 201-204

Jul 3/2006

34-53-00

Pages 201-202

Jan 3/2005

34-53-01

Pages 201 -202

Jan 2/2006

34-53-10

Pages 201 -204

Jan 3/2005

34-54-00

Page 1

Jan 2/2006

34-54-00

Pages 201-202

Jan 2/2006

34-55-00

Pages 201-203

Jul 3/2006

34-60-01

Pages 201 -202

Jul 1/2005

34-60-10

Pages 201 -203

Jan 3/2005


©Cessna Aircraft Company

34 - LIST OF EFFECTIVE PAGES

Page 1 of 1 Jul 1/2007


Page Number

Issue Date

By

Date Removed

By



CONTENTS NAVIGATION - GENERAL............................. Scope.................................... Definition ..................................

34-00-00 Page 1 34-00-00 Page 1 34-00-00 Page 1

PITOT/STATIC SYSTEM - MAINTENANCE PRACTICES............... Description and Operation .......................... Pitot Tube Removal/Installation ........................ Sump Assembly Removal/installation ..................... Pitot Tube Heater Insulation Removal/installation ................ Vertical Speed Indicator Removal/Installation.................. Alternate Static Source Valve Removal/Installation ............... Blind Encoder Removal/Installation (For Airplanes without Garmin G1 000) .... Altimeter Removal/Installation......................... Airspeed Indicator Removal/Installation .................... Pitot System Leak Test............................ Static System Leak Test ........................... Blow Out the Lines..............................

34-11 -00 34-1 1-00 34-11 -00 34-1 1-00 34-1 1-00 34-1 1-00 34-1 1-00 34-11 -00 34-11 -00 34-11 -00 34-11 -00 34-11 -00 34-11 -00

Page 201 Page 201 Page 201 Page 201 Page 209 Page 209 Page 209 Page 211 Page 211 Page 211 Page 211 Page 212 Page 212

OUTSIDE AIR TEMPERATURE INDICATOR - MAINTENANCE PRACTICES ..... Description and Operation .......................... OAT Probe Removal/Installation........................ Clock/OAT Indicator Removal/installation ...................

34-12-00 34-12-00 34-12-00 34-12-00

Page Page Page Page

201 201 201 201

AIR DATA COMPUTER - MAINTENANCE PRACTICES ............... General................................... Troubleshooting ............................... GDC 74A Air Data Computer Removal/Installation ............... ATTITUDE AND DIRECTION - MAINTENANCE PRACTICES............. General................................... Operation Notes............................... Precautions................................. Prepare the Gyroscopic Instruments for Shipping................ Horizon Attitude Gyro Description and Operation ................ Horizon Gyro Removal and Installation..................... Horizon Attitude Gyro Operational Check.................... Directional Gyro Description and Operation................... Directional Gyro Removal and Installation (Airplanes without Garmin G-1000)... Directional Gyro Operational Check ...................... Turn Coordinator Removal and Installation (Airplanes without Garmin G1 000) .... Turn Coordinator Removal and Installation (Airplanes with Garmin G1OQO) ....

34-13-00 34-13-00 34-13-00 34-13-00

Page Page Page Page

201 201 201 201

34-20-00 34-20-00 34-20-00 34-20-00 34-20-00 34-20-00 34-20-00 34-20-00 34-20-00 34-20-00 34-20-00 34-20-00 34-20-00

Page 201 Page 201 Page 201 Page 201 Page 202 Page 202 Page 202 Page 205 Page 206 Page 206 Page 207 Page 208 Page 209

COM INSTALLATION - MAINTENANCE PRACTICES ............. General................................... Com Removal/Installation ........................

34-2 1-00 Page 201 34-21 -00 Page 201 34-21 -00 Page 201

MAGNETOMETER - MAINTENANCE PRACTICES ................. General................................... Troubleshooting ............................... GMU 44 Magnetometer Removal/Installation..................

34-22-00 34-22-00 34-22-00 34-22-00

Page Page Page Page

201 201 201 201

ATTITUDE HEADING REFERENCE SYSTEM (AHRS) - MAINTENANCE PRACTICES General................................... Troubleshooting ............................... GRS 77 AHRS Removal/installation...................... AHRS and Magnetometer Checkout Procedure.................

34-23-00 34-23-00 34-23-00 34-23-00 34-23-00


201 201 201 201 203

© Cessna Aircraft Company

34 - CONTENTS



MODEL 172 MAINTENANCE MANUAL MARKER BEACON - MAINTENANCE PRACTICES................. General................................... Audio Removal/installation ....................... Marker Beacon Antenna Removal/installation..................

34-30-00 34-30-00 34-30-00 34-30-00

Page Page Page Page

NAV/COM - MAINTENANCE PRACTICES ..................... General .................................. Nay Antenna Removal/installation....................... Nay Antenna Coupler Removal/Installation................... Nay Indicator Removal/Installation.......................

34-50-00 34-50-00 34-50-00 34-50-00 34-50-00

Page 201 Page 201 Page 201 Page 201 Page 201

GIA 63 INTEGRATED AVIONICS INSTALLATION - MAINTENANCE PRACTICES ... General................................... Troubleshooting ............................... GIA 63 Integrated Avionics Unit Removal/Installation ..............

34-50-10 34-50-10 34-50-1 0 34-50-1 0


GPS

34-51 -00 34-51 -00 34-51 -00 34-51 -00

Page Page Page Page

201 201 201 201

KR-87 ADF SYSTEM - MAINTENANCE PRACTICES ................ General................................... KR-87 ADF Receiver Removal/installation (Airplanes without Garmin G1 000) .. KR-87 ADF Receiver Removal/Installation (Airplanes with Garmin G1000) .... KA-44B ADF Antenna Removal/Installation (For Airplanes With or Without Garmin G100) .................................. KI-227 ADF Indicator Removal/Installation ...................

34-52-00 34-52-00 34-52-00 34-52-00

Page Page Page Page

201 201 201 201

KT76C TRANSPONDER - MAINTENANCE PRACTICES............... General................................... Transponder Removal/installation....................... Transponder Antenna Removal/Installation...................

34-53-00 34-53-00 34-53-00 34-53-00

KT-73 MODE S TRANSPONDER - MAINTENANCE PRACTICES........... General................................... KT-73 Mode S Transponder Removal and Installation..............

34-53-01 Page 201 34-53-01 Page 201 34-53-01 Page 201

GTX 33 TRANSPONDER - MAINTENANCE PRACTICES .............. General................................... Troubleshooting ............................... GTX 33 Transponder Removal/Installation................... Transponder Antenna Removal/Installation...................

34-53-1 0 34-53-10 34-53-1 0 34-53-1 0 34-53-1 0

MAINTENANCE PRACTICES........................ General................................... GPS Removal/installation........................... G PS Antenna Removal/Installation ...................... -

201 201 201 201

34-52-00 Page 201 34-52-00 Page 204 Page 201 Page 201 Page 201 Page 201


201 201 201 201 203

34-54-00 Page 1 34-54-00 Page 1

GDL-69A FIS - DESCRIPTION AND OPERATION.................. General................................... GDL-69A FIS - MAINTENANCE PRACTICES.................... General................................... GDL-69A XM Weather Data Link Removal/Installation..............

34-54-00 Page 201 34-54-00 Page 201 34-54-00 Page 201

DME

34-55-00 34-55-00 34-55-00 34-55-00

Page Page Page Page

201 201 201 201

34-60-01 34-60-01 34-60-01 34-60-01

Page Page Page Page

201 201 201 201

- MAINTENANCE PRACTICES........................ General................................... KN-63 DME Receiver Removal/Installation................... DME Antenna Removal/installation ......................

KMD-540 MULTI-FUNCTION DISPLAY - MAINTENANCE PRACTICES ........ General................................... KMD-540 Multi-Function Display (MFD) Removal and Installation ........ Operational Check of the MD-540 Multi-Function Display ............


Page 2of 3 Jul 1/2007


MODEL 172

MAINTENANCE MANUAL GARMIN DISPLAY UNIT (GDU) - MAINTENANCE PRACTICES ........... General................................... Troubleshooting ............................... Control Display Unit Removal/Installation ... .................

©D Cessna Aircraft Company

34-60-10 34-60-10 34-60-10 34-60-10

34 - CONTENTS

Page Page Page Page

201 201 201 201



MODEL 172

MAINTENANCE MANUAL NAVIGATION - GENERAL 1.

Scope A.

2.

This chapter describes the navigation systems, units, and components which provide airplane navigational information. Included are pitot/static temperature, gyros, com, VOR and indicators. For King KAP140 Autopilot information refer to Chapter 22.

Definition A.

This chapter is divided into sections to aid maintenance personnel in locating information. Consulting the table of Contents will further assist in locating a particular subject. A brief definition of the sections incorporated in this chapter is as follows: (1) The Flight Environmental Data Section describes systems that sense environment conditions, and use data to influence navigation of the airplane. This includes systems that depend on pitot and static information. (2) The Attitude and Direction Section describes systems that use magnetic gyroscopic and inertia forces. This includes items like gyros, com, magnetic heading, and turn and bank. (3) The Dependent Position Determining Section describes systems that provide information to determine position, and are mainly dependent on ground installation. This includes systems like VOR, ADF, GPS, and transponders.


Page 1

Apr 7/2003


MODEL 172 MAINTENANCE MANUAL PITOT/STATIC SYSTEM - MAINTENANCE PRACTICES 1.

2.


The pitot system supplies ram air pressure to the airspeed indicator. The static system connects the vertical speed indicator, altimeter, and airspeed indicator to atmospheric pressure through plastic tubing connected to a static port. A static line sump is installed at the source button to collect condensation in the static system. A heated pitot tube is standard, with the heating element controlled by a switch on the instrument and powered by the electrical system. An alternate static source valve is installed on the instrument to use when the external static source is not in operation. Refer to Figure 201 for the pitot/static system schematic.

B.

On airplanes with an autopilot, there is a tube that connects the autopilot to a static port on the left side of the airplane at FS 117.25. This part of the pitot/static system is not connected to the other parts of the pitot/static system.

C.

Correct maintenance of pitot and static system is essential for correct operation of altimeter, vertical speed and airspeed indicators, and, if installed, the autopilot. Leaks, moisture, and blockage can have an effect on the readings of the instruments. Under instrument flight conditions, you must use the instrument readings for the safe operation of the airplane. Keep the system clean and all instruments and all parts of the system correctly attached to the airplane. Keep the pitot tube and static ports clean with no blockage. (1) Test the pitot/static system in accordance with the time limits set forth in Chapter 5, Inspection Time Limits, or anytime components or lines within the system are opened. Refer to 14 CFR 91.411.

Pitot Tube Removal/Installation A.

B.

Pitot Tube Removal (Refer to Figure 202). (1) Remove the screws that attach the pitot tube to the wing and remove the pitot tube. (2) Disconnect the ram air tube from the pitot. (3) Disconnect the electrical connectors from the pitot heater and the pitot heat ground. Pitot Tube Installation (Refer to Figure 202).

CAUTION: Do not blow through the pitot lines toward the instrument, as damage will occur to the instruments. CAUTION: You must keep the pitot tube assembly clean and all system components free of blockage and leaks for correct operation. (1) Connect the ram air tube to the pitot. (2) Connect the electrical connectors to the pitot heater and the pitot heat ground. (3) Do a check of the system for leaks. Refer to Pitot System Leak Test. 3.

Sump Assembly Removal/Installation NOTE:

The removal/installation is typical for the two sump assemblies.

A.

Sump Assembly Removal (Refer to Figure 202). (1) Get access to the sump assembly. (2) Loosen the nut that connects the static tube to the sump assembly nipple. (3) Turn the sump assembly and remove the sump assembly from the elbow.

B.

Sump Assembly Installation (Refer to Figure 202). (1) Attach the sump assembly to the elbow. Apply Teflon® tape (U000912) as necessary where plastic and metal connections interface. (2) Connect static tube to the sump assembly nipple with nut. (3) Do a leak check. Refer to the Static Pressure System Inspection and Leakage Test.


Page 201 Jul 3/2006



B227

n

HEATED PITOT TUBE Al RSPEED

ALTIMETER

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BLIND ENCODER rx\ -N

ELECTRICAL CONNECTOR

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ALTERNATE STATIC AIR SOURCE KNOB (MOUNTED ON INSTRUMENT ) LEGEND V/////A PITOT )URCE -0 OUTSIDE)

STATIC

AIRPLANES WITHOUT GARMIN G1000

0595T1001

Pitot/Static System Schematic Figure 201 (Sheet 1)


Page 202 Jul 3/2006



B5979

AUTOPILOT

SOURCE

LEGEND PITOT / XO STATIC

059 I5T1001

AIRPLANES WITH AUTOPILOT



Page 203 Jul 3/2006



B5980

HEATED PITOT TUBE AIRSPEED INDICATOR

I///////////

AIR DATA COMPUTER

IETER STA R1 h1

ALTERNATE STATIC AIR SOURCE KNOB (MOUNTED ON INSTRUMENT )

OURCE

ro OUTSIDE) LEGEND PITOT STATIC AIRPLANES WITH GARMIN G1000

0595T1001



Page 204 Jul 3/2006


MODEL 172 MAINTENANCE MANUAL -

IBAA

PITOT LINE (TO AIRSPEED INDICATOR) .... - , / 'CONNECTOR

MAST BODY D

HEATER ELEMENT SCREW

DETAIL A

ALTERNATE AIR CONTROL VALVE NUT

ELBOW

BLIND ENCODER

3

PORT

DETAIL B

0510T1007 A0518R1046 B0518T1040

AIRPLANES WITHOUT GARMIN G1000 Pitot/Static System Installation Figure 202 (Sheet 1)


Page 205 Jul 3/2006



B3262

PITOT TUBE HEATER ASSEMBLY WIRE LEADS

RAM AIR

4 8.00-INCH PIECE OF H990000 NYLON SPIRAL WRAP

S

/

C--:: PITOT TUBE ASSEMBLY

DETAIL C

C0518R1070

Pitot/Static System Installation Figure 202 (Sheet 2)


Page 206 Jul 3/2006



B5985

/

/

/ I

NUT WASHER STATIC SUMP

INSERT

STATIC PORT

I

( DETAIL D AIRPLANES WITH KAP-140 AUTOPILOT

D0518T1153



Page 207 Jul 3/2006


MODEL 172

MAINTENANCE MANUAL

B59ss

I

AIR DAT COMPU

DETAIL E AIRPLANES WITH GARMIN G1000 E0518T1152



Page 208 Jul 3/2006



4.

Pitot Tube Heater Insulation Removal/lnstallation. A.

Pitot (1) (2) (3)

Tube Heater Insulation Removal (Refer to Figure 202). Set the ALT/BATT Master Switch to OFF. Make sure that the PITOT HEAT/OFF switch is put in the OFF position. Remove the 510BB access plate. Refer to Chapter 6, Access/Inspection Plates - Description And Operation.

CAUTION: Do not disconnect the pitot ram air tube from the pitot tube. (4) Remove the screws that attach the pitot tube to the wing. (5) Remove and discard all nylon spiral wrap insulation. B.

Pitot Tube Heater Insulation Installation (Refer to Figure 202). (1) Cut new nylon spiral wrap into two pieces. Make one piece that is 4.0 inches in length and make one piece that is 8.0 inches in length. (2) Start 0.10 inch from the pitot tube and install the 4.0-inch piece of spiral wrap around the pitot tube heater assembly. (a) Trim as necessary.

CAUTION: Do not let the pitot heater assembly wire leads touch the pitot ram air tubing, wire bundles, or heat-sensitive components. The pitot tube heater assembly wire leads operate at high temperatures. (3) Install the 8.0-inch piece of spiral wrap around the pitot ram air tube. (a) Trim as necessary. (4) Attach the pitot tube to the wing with the screws.

CAUTION: Do not blow through the pitot lines toward the instrument, as damage will occur to the instruments if you do. CAUTION: Keep the pitot tube assembly clean and make sure that all system components are free of blockage and leaks for correct operation. (5) Install the 510BB access plate. Refer to Chapter 6, Access/Inspection Plates - Description And Operation. (6) Connect electrical power to the airplane as necessary. 5.

6.

Vertical Speed Indicator Removal/Installation A.

Vertical Speed Indicator (VSI) Removal (Refer to Figure 203). (1) Remove the screws that attach the flight instrument to the instrument . (2) Disconnect the static tube and the electrical connector from the VSI. (3) Remove the screws that attach the VSI to the flight instrument . (4) Remove the VSI from the airplane.

B.

Vertical Speed Indicator (VSI) Installation (Refer to Figure 203). (1) Put the VSI on the flight instrument and attach it with screws. (2) Connect the static tube and the electrical connector to the VSI. (3) Attach the flight instrument to the instrument with the screws. (4) Do a check of the system for leaks. Refer to the Static System Leak Test.

Alternate Static Source Valve Removal/Installation A.

Alternate Static Source Valve Removal (Refer to Figure 202). (1) Behind the stationary control , loosen the nuts that attach the two static tubes to the alternate static source valve. Disconnect the static tubes from the alternate static source valve. (2) Remove the screws that attach the alternate static source valve to the stationary control . 34-11-00 © Cessna Aircraft Company

Page 209 Jul 3/2006



ISPEED DICATOR

COMPUTER

DETAIL A AIRPLANES WITH GARMIN G1000

0510T1007 A0718R1006 A0518T1151

Pitot and Static System Indicator Installation Figure 203 (Sheet 1)


Page 210 Jul 3/2006


MODEL 172 MAINTENANCE MANUAL (3) B.

7.

Remove the alternate static source valve from the airplane. Alternate Static Source Valve Installation (Refer to Figure 202). (1) Put the alternate static source valve behind the stationary control and attach the static tubes with the nuts. (2) Attach the alternate static source valve to the stationary control with the screws.

Blind Encoder Removal/Installation (For Airplanes without Garmin G1000) A. Blind Encoder Removal (Refer to Figure 202). NOTE:

The blind encoder is under the dash on the copilot side.

(1) Disconnect the static tube and the electrical connector and remove the encoder from the airplane. (2) Loosen the knurled knob and remove the encoder from the mount. B.

8.

9.

10.

Blind (1) (2) (3)

Encoder Installation (Refer to Figure 202). Put the encoder on the mount and attach with the knurled knob. Connect the static tube and the electrical connector to the encoder. Do a check of the system for leaks. Refer to the Static System Leak Test.

Altimeter Removal/nstallation A.

Altimeter Removal (Refer to Figure 203). (1) To get access to the back of the altimeter, remove the screws that attach the flight instrument to the instrument . (2) Disconnect the static tube and the electrical connector from the altimeter. (3) Remove the screws that attach the altimeter to the flight instrument . (4) Remove the altimeter from the airplane.

B.

Altimeter Installation (Refer to Figure 203). (1) Put the altimeter on the flight instrument and attach it with screws. (2) Connect the static tube and the electrical connector to the altimeter. (3) Attach the flight instrument to the instrument with the screws. (4) Do a check of the system for leaks. Refer to the Static System Leak Test.

Airspeed Indicator Removal/Installation A.

Airspeed Indicator Removal (Refer to Figure 203). (1) Remove the screws that attach the flight instrument to the instrument to get access to the back of the airspeed indicator. (2) Disconnect the static tube and the electrical connector from the airspeed indicator. (3) Remove the screws that attach the airspeed indicator to the flight instrument . (4) Remove the airspeed indicator from the airplane.

B.

Airspeed Indicator Installation (Refer to Figure 203). (1) Put the airspeed indicator on the flight instrument and attach with the screws. (2) Connect the static tube and the electrical connector to the airspeed indicator. (3) Attach the flight instrument to the instrument with the screws. (4) Do a check of the system for leaks. Refer to the Static System Leak Test.

Pitot System Leak Test A.

Test Procedures. (1) Put a piece of tape over the small hole in the lower aft end of the pitot tube. (2) Attach a piece of rubber or plastic tubing over the pitot tube and close the opposite end of the tube. (3) Slowly roll up the tube until the airspeed indicator shows in cruise range.


Page 211 Jul 3/2006


MODEL 172 MAINTENANCE MANUAL (4) Attach the tube to prevent air pressure change, and look at the airspeed after one minute. If there is a leak, the pressure in the system is reduced, and you will see a lower airspeed on the airspeed indicator. (5) If there is a leak in the system, you must examine and tighten all connections, hoses, and fittings before you do another check. (6) If there are no leaks, slowly unroll the tubing to let the pressure in the instrument slowly return to ambient pressure. 11.

Static System Leak Test A.

Test Procedures. (1) Make sure that the static system is free from moisture that is caught in the system, and that there are no restrictions in the system. (2) Make sure that there are no changes in or deformations to the airframe surface that can affect the relation between the air pressure in the static pressure system and true ambient static air pressure for any flight configuration. (3) Close the static pressure alternate source control. (4) Attach a vacuum source to the static pressure source opening. (5) Slowly apply the vacuum source until the altimeter indication is a 1,000-foot increase in altitude. (6) Cut off the vacuum source to make sure that there is a closed system for one minute. (7) If the altimeter loss is not more than 100 feet after one minute, the system is good and you can slowly release the vacuum until the system goes back to ambient. If the altimeter loss is more than 100 feet, tighten all connections and do the leak test again. If the rate continues to be more than the maximum allowable, do as follows. (a) Disconnect the static pressure lines from the airspeed indicator and the vertical speed indicator. Use suitable fittings to connect the lines together so that the altimeter is the only instrument connected into the static pressure system. (b) Do the leakage test again to see if the static pressure system or the instruments that you byed are the cause of the leakage. If the instruments are the cause of the leak, you must have the instruments repaired by an approved repair station, or replaced. If the static pressure system is the problem, do as follows.

CAUTION: Do not apply positive pressure with the airspeed indicator or the vertical speed indicator connected to the static pressure system. 1 2 3 4 5 12.

Attach a source of positive pressure to the static source opening. Slowly apply positive pressure until the altimeter indication decreases 500-feet, and stops on this value. Put a solution of mild soap and water on the line connections and the static source flange, and look for bubbles to find leaks. Tighten all leaking connections. Repair or replace all damaged parts. Connect the airspeed and the vertical speed indicators into the static pressure system and do the static system leak test again.

Blow Out the Lines

CAUTION: Do not blow through the pitot or static lines toward the instrument as damage will occur to the instrument. A. Pitot Lines. (1) Although the pitot system drains down to the pitot tube opening, condensation can collect at other areas in the system and cause some blockage of the line. To remove the blockage, disconnect the line at the airspeed indicator. With low-pressure air, blow from the indicator end of the line toward the pitot tube.


Page 212 Jul 3/2006



I

B.

Static Lines. (1) Keep static lines clear and keep connections tight. All models have a static source sump which collects moisture and keeps the system clear. If necessary, disconnect the static line at the first instrument to which it is connected, and then blow line clear with low-pressure air.


Page 213 Jul 3/2006


MODEL 172 MAINTENANCE MANUAL OUTSIDE AIR TEMPERATURE INDICATOR - MAINTENANCE PRACTICES 1.


Outside air temperature is measured using a remote-mounted probe connected to a cockpit-mounted indicator. (1) The OAT (outside air temperature) probe is mounted on the upper cabin roof line at FS 46.46. This probe transmits an electrical millivolt signal to the cockpit mounted gauge through a pair of wires which route above the cabin headliner, through the left side windshield pillar, and terminating behind the instrument . (2) The cockpit-mounted indicator is located in the upper left portion of the instrument . The indicator also incorporates a digital clock and voltage-reading functions. Inputs into the indicator include 28.0 VDC for power, internal lighting and keep-alive clock functions, and millivolt inputs from the temperature probe. NOTE:

B.

2.

The indicator has provisions for a single 1.5 VDC "AA" battery used to power the clock independent of airplane power. This battery, if installed, should be replaced every two years.

Maintenance practices consist of removal and installation of the probe and indicator. The probe and indicator are not matched, and may be replaced independent of each other. Probe replacement will require new shielded terminal pins to be attached at the indicator end of the probe.

OAT Probe Removal/Installation A.

Remove Probe (Refer to Figure 201). (1) Remove overhead console. Refer to Chapter 25, Interior Upholstery - Maintenance Practices, Figure 201. (2) From outside of cabin, loosen and remove nut securing probe to roof skin. (3) From inside of cabin, withdraw probe through roof skin. (4) Remove interior s as required to free probe wiring from airplane structure. (5) Disconnect electrical connector from backside of OAT/Clock indicator. (6) Remove probe pins from electrical connector.

B.

Install Probe (Refer to Figure 201). (1) Install new terminal pins to end of replacement probe. Ensure shielded wiring is properly grounded. Refer to Model 172R Wiring Diagram Manual, Chapter 20, Bonding and Grounding - Maintenance Practices.

(2) (3) (4) (5) (6) 3.

Install terminal pins into electrical connector. Reconnect electrical connector to backside of OAT/Clock indicator. Reroute probe wiring in cabin area, and insert probe and ground lug through roof skin. From outside of cabin, install metal washer (with o-ring insert) and hex nut to probe. Tighten until o-ring compresses and forms a water-tight seal. Reinstall interior s and overhead console. Refer to Chapter 25, Interior Upholstery Maintenance Practices, Figure 201.

Clock/OAT Indicator Removal/nstallation A.

Remove Indicator (Refer to Figure 201). (1) Remove fuse F4 from the power junction box. (2) Remove screws securing instrument sub to airplane structure. (3) Withdraw sub aft to gain access to electrical connector. (4) Remove electrical connector from OAT indicator. (5) Remove screws securing OAT indicator to sub .

B.

Install Indicator (Refer to Figure 201). (1) Secure OAT indicator to instrument sub using screws. (2) Connect electrical connector to backside of OAT Indicator. (3) Reinstall instrument sub to airplane structure. (4) Reinstall fuse F4 to power junction box.


Page 201 Apr 7/2003



,..

HEX NUT

\ >,

METAL WASHER WAITI-I Cn-DIM(

GROUND LUG

CABIN UPPER SKIN


OAT/CLOCK INDICATOR

INSTRUMENT

DETAIL

A

SCREW U-1

0510T1007 A0518R1067

Outside Air Temperature Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL (5) Test for proper operation. Refer to Pilot's Operating Handbook and FAA Approved Airplane Flight Manual, Supplements, for operation/test instructions.


Page 203 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL AIR DATA COMPUTER - MAINTENANCE PRACTICES 1.

General A.

B. 2.

Troubleshooting A.

3.

On airplanes with Garmin G1000, the GDC 74A air data computer compiles information from the pitot/static system and various sensors. The GDC 74A gives pressure, altitude, airspeed, vertical speed, and OAT information to the G1000 system. The GDC 74A communicates with the GIA 63 Integrated Avionics Units, GDU 1040 Control Display Units, and GRS 77 AHRS. Maintenance practices give procedures for the removal and installation of the GDC 74A air data computer. The unit is in the tailcone.

For troubleshooting procedures, refer to the Garmin G1000 Line Maintenance Manual.

GDC 74A Air Data Computer Removal/Installation A.

Remove the Air Data Computer (Refer to Figure 201). (1) Put the MASTER switch in the off position. (2) Put the AVIONICS switch in the off position. (3) Remove the aft seat. Refer to Chapter 25, enger Compartment - Maintenance Practices. (4) Remove the baggage compartment closeout. Refer to Chapter 25, Interior Upholstery Maintenance Practices. (5) Loosen the two thumb screws that attach the air data computer to the mounting rack. (6) Disconnect the electrical connector. (7) Disconnect the pitot/static lines. CAUTION:

Do not let foreign object debris get In the air data computer. Foreign

object debris can cause a blockage and make the computer give Incorrect Indications.

B.

(8) Put caps on the pitot/static lines and air data computer ports. Install the Air Data Computer (Refer to Figure 201). NOTE:

If a new air data computer is installed, the software must be loaded.

(1) Make sure the electrical connector and connector pins have no damage. (a) Replace the electrical connector or connector pins if applicable. Refer to the Model 172 Wiring Diagram Manual and the Garmin G1000 Line Maintenance Manual. (2) Remove the caps from the pitot/static lines and air date computer ports. (3) Make sure the pitot/static lines and air data computer ports have no damage. (a) Replace the pitot/static lines and/or air data computer ports if applicable. Refer to Chapter 34, Pitot/Static System - Maintenance Practices. (4) Connect the electrical connector. (5) Connect the pitot/static lines. (6) Tighten the two thumb screws that attach the air data computer to the mounting rack. (7) If a new unit is installed, load the software. Referto the Garmin G1000 Line Maintenance Manual. (8) Do a pitot system leak test and a static system leak test. Refer to Chapter 34, Pitot/Static System - Maintenance Practices. (9) Do a check to make sure the air data computer operates correctly. Refer to the Garmin G1000 Line Maintenance Manual. (10) Install the baggage compartment closeout. Refer to Chapter 25, Interior Upholstery Maintenance Practices. (11) Install the aft seat. Refer to Chapter 25, enger Compartment - Maintenance Practices.


Page 201 Jan 3/2005



DOO

AIR DATA

TRANSPONDER

DETAIL

A

AIRPLANES THAT HAVE THE GARMIN G1000

0510T1007 A0518T1103

Forward Avionics Equipment Installation Figure 201 (Sheet 1)


Page 202 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL ATTITUDE AND DIRECTION - MAINTENANCE PRACTICES 1.

2.

General A.

This section gives maintenance information, removal and installation procedures, and operational checks for the horizon attitude gyro, directional gyro, and turn coordinator.

B.

On airplanes without Garmin G1000, three gyroscopic instruments show attitude and direction. The instruments are in the pilot's instrument . Included are the horizon gyro (attitude indicator), directional gyro, and turn coordinator (roll rate gyro).

C.

On airplanes with Garmin G1000, two gyroscopic instruments give attitude and direction. The horizon gyro is in the center instrument . The horizon gyro gives attitude and direction and is the middle standby instrument. The turn coordinator gives roll rate data to the autopilot and is installed on the left side of the center instrument . The turn coordinator cannot be seen in the cockpit.

Operation Notes A. B.

C.

D. 3.

The vacuum system supplies air flow necessary to move the gyro rotor in the horizon gyro. Incorrect operation of the vacuum system will cause the horizon gyro to operate incorrectly. It is necessary for the horizon gyro to have 4.5 to 5.5 inches Hg of vacuum to operate correctly. The gyro will reach rated performance with correct vacuum applied in a minimum of 3 minutes of rotor spin time. The gyro rotor can continue to spin for approximately 15 minutes after vacuum in the system is removed. It can show a change in the roll and/or pitch indication while the rotor speed decreases. The gyro rotor will remain in a roll and/or pitch indication when stopped until the system starts again. If a gyro has been shut down and started again before the rotor has been permitted to stop, more time will be necessary to get the correct pitch and roll indication.

Precautions A.

Gyroscopic instruments are very sensitive. They have precision bearings on the gyroscope rotor, pivots, and yoke shaft. Be careful when you move or touch the instrument when it is out of the airplane. If you are not careful when you move or touch the instrument, you can cause damage to the bearings. Dirt and other contaminants can also cause damage to the bearings. Obey these special precautions when you move, install, remove, or ship any gyroscopic instruments. (1) To prevent damage to the gyro, do not move a gyro after the electrical power or vacuum pressure is removed and before the gyro rotor has stopped. The gyro rotor will not fully stop for approximately 15 minutes after the electrical power or vacuum pressure is removed. (2) During the removal of instruments, put soft material between the instruments and the control column. (3) Do not shake or cause vibration of the or the instruments. (4) Do not hit the gyroscope against any other object. Do not shake the gyroscope or put the gyroscope on a hard surface. If you are not careful, you can cause damage to the instrument. (5) Always be very careful when you move or hold gyroscopic instruments, because you can easily cause damage. (6) Do not remove any wires, labels, tie straps, or any other parts of the gyro that are installed by the manufacturer. (7) Visually examine the gyro for any external damage. There must be no scratches, dents, or dings on any part of the gyro. Do not install gyros that have scratches, dents, or dings. (8) If you must ship a gyroscopic instrument, make sure that all the female ports have plugs that you can remove, and that all the male receptacles have plastic caps that you can remove. (9) Put connector caps on all the electrical pin connectors to make sure that they are not bent or broken. (10) Put all gyros in Styrofoam or other soft material for storage and transportation. If possible, ship the gyroscope in the box from the manufacturer in which it was received. (11) Keep the plugs in the ports unless the instrument is installed in an airplane or maintenance personnel are doing a test.


Page 201 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL

4.

Prepare the Gyroscopic Instruments for Shipping A.

5.

Horizon Attitude Gyro Description and Operation A.

The vacuum system supplies the air flow necessary to move the gyro rotor in the horizon attitude gyro. Incorrect operation of the vacuum system will cause the horizon attitude gyro to operate incorrectly. Problems with the vacuum system can cause incorrect indication and decreased performance.

B.

The horizon attitude gyro must have between 4.5 and 5.5 inches Hg of vacuum to operate correctly. With the correct vacuum applied, the gyro will get rated performance in a minimum of 3 minutes of rotor turn time.

C.

The horizon attitude gyro rotor can continue to turn for approximately 15 minutes after the vacuum in the system is removed. It can show a change in the roll and/or pitch indication while the rotor speed decreases. When fully stopped, the gyro rotor will stay in a roll and/or pitch indication until the system starts again. If a gyro has been stopped and started again before the rotor fully stops, more time will be necessary for the gyro to correctly indicate the pitch and roll of the airplane.

D. 6.

All gyros that are shipped must obey the instructions that follow. (1) All ports and vents must have plugs installed in them. (2) All initial seals from the manufacturer must be installed and not damaged. (3) All gyros must be carefully put in the same type of container in which the replacement gyro was received. (4) Put connector caps or adhesive tape on all electrical pin connectors to make sure that they are not bent or broken.

Horizon Gyro Removal and Installation A.

Horizon Gyro Removal (Refer to Figure 201 or Figure 202).

CAUTION: Make sure that the gyro rotor has fully stopped before you move the instrument. The gyro rotor will not stop for approximately 15 minutes after the electrical power or vacuum source is removed. Damage to the instrument will occur if the instrument is moved before the gyro rotor has stopped. CAUTION: Be careful with the gyroscopic instruments. Do not hit, shake, or put the instruments on a hard surface. Put soft material between the gyroscopic instruments and any hard surface. Damage to the instruments will occur if the instruments are not carefully moved. The manufacturer's warranty can become void if the gyro is not kept in its initial condition as received from the manufacturer. (1) Put the MASTER switch and the AVIONICS switch in the off position.

(2) Remove the screws from the center pilot to get access to the back of the horizon gyro.

CAUTION: Make sure that you put soft material between the horizon attitude gyro and the control column before you remove the gyro. If you put the sub on the control column without any protection, you can damage the horizon attitude gyro and/or the other instruments in the sub . Be very careful when you remove the sub so that you do not hit the gyro. (3) Put a label on the three hoses that are attached to the horizon gyro. (4) Loosen the clamps and remove the hoses from the horizon gyro.


Page 202 Jan 2/2006



CENTER PILOT SCREW ATTITUDE

REGULATOR VALVE (WITH

FIREWALL

VACUUM GAGE CONNECTOR (J1008) FIREWALL

GYRO FILTER

DETAIL A 0510T1007 A0518T1052

AIRPLANES WITHOUT GARMIN G1000 Attitude and Direction Instrument Installation (Airplanes without Garmin G1000) Figure 201 (Sheet 1)


Page 203 Jan 2/2006



B

DETAIL A HORIZON GYRO ALTIMETER INDICATOR

AIRSPEED INDICATOR

BLIND TURN COORDINATOR

VACUUM TRANSDUCER

FILTER

DETAIL B AIRPLANES WITH GARMIN G1000 051OT1007 A393TD493

Attitude and Direction Instrument Installation (Airplanes with Garmin G1000) Figure 202 (Sheet 1)


Page 204 Jan 2/2006


MODEL 172 MAINTENANCE MANUAL (5) Disconnect the electrical connector from the horizon gyro. (6) Put female plugs over the ports and put a connector cap on the electrical connector. (7) Remove the screws that attach the horizon attitude gyro to the center pilot .

CAUTION: Put a cover on the applicable hose or port or on the applicable electrical connector when the gyroscopic instrument is out of the airplane or is to be shipped. Damage to the instrument will occur from foreign object debris if a cover is not used. (8) Remove the horizon gyro from the airplane. B.

Horizon Gyro Installation (Refer to Figure 201 or Figure 202).

CAUTION: Do not remove the horizon attitude gyro from the box in which it was shipped until it is ready to be installed into the airplane. This will minimize the possibility of accidentally causing damage to the gyro. CAUTION: Remove all plugs from the horizon attitude gyro before you install it in the airplane. CAUTION: Be careful with the gyroscopic instruments. Do not drop, shake, bump or put on a hard surface. Use soft material between the gyroscopic instruments and any hard surface. Damage to the instruments will occur if the instruments are not carefully moved. The manufacturer's warranty can become void if the gyro is not kept in it's initial condition as received from the manufacturer. (1) Attach the horizon gyro to the center pilot with the screws. (2) Make sure that the horizon altitude gyro is installed level in the . (3) Remove the female plugs from the ports and remove the connector cap from the electrical connector. (4) Make sure that the vacuum lines and the static lines have no kinks in them. (5) Attach the applicable hoses to the horizon gyro and tighten the clamps. (6) Attach the horizon gyro connector to the horizon gyro. (7) Attach the center pilot with the screws. (8) Tighten the screws in an opposite sequence. (9) Put the MASTER switch and the AVIONICS switch in the ON position. (10) Do an operational check of the horizon attitude gyro to make sure that it operates correctly. 7.

Horizon Attitude Gyro Operational Check A.

Horizon Attitude Gyro Operational Check. (1) Start the airplane engine. (2) Let the engine run for no less than 3 minutes. (3) Make sure that the vacuum gage shows between 4.5 and 5.5 inches Hg. (4) Make sure that the horizon bar becomes stable at the correct position for the attitude of the airplane, or becomes stable at the correct position, begins to vibrate, and then slowly stops vibration altogether. (5) Taxi in a straight line. Make sure that the horizon bar stays in the horizontal position while you taxi. (6) Do a 360-degree turn. Do not turn sharply as you make the turn. Make sure that the horizon bar does not tip more than 4 degrees from the horizontal during the turn. (7) If the horizontal gyro precession is more than 4 degrees from a heading in either direction during a 10-minute period, or does not operate within one or more of the limits given in steps 4 through 6 of this operational check, you must repair the system and/or replace the gyro.


Page 205 Jan 2/2006



8.

9.

Directional Gyro Description and Operation A.

The vacuum system supplies the air flow necessary to move the gyro rotor in the directional gyro. Incorrect operation of the vacuum system will cause the horizon attitude gyro to operate incorrectly. Problems with the vacuum system can cause incorrect indication and decreased performance.

B.

The directional gyro must have between 4.5 and 5.5 inches Hg of vacuum to operate correctly. With the correct vacuum applied, the gyro will get rated performance in a minimum of 3 minutes of rotor turn time.

C.

The directional gyro rotor can continue to turn for approximately 15 minutes after the vacuum in the system is removed. It can show a change in the directional indication while the rotor speed decreases, or the directional gyro dial can start to turn. When fully stopped, the gyro rotor will not correctly indicate changes in the airplane's direction until the system starts again.

D.

If a gyro has been stopped and started again before the rotor fully stops, more time will be necessary for the gyro to correctly indicate the directional changes of the airplane.

E.

The permitted limit for directional gyro drift on the ground or in flight is 4 degrees from a fixed heading, during a 10-minute period.

F.

Continuous turns around a point and/or banks of more than 55 degrees can cause the directional gyro to turn. This is a limit of the gyro and not a cause for removal.

Directional Gyro Removal and Installation (Airplanes without Garmin G1000) A.

Directional Gyro Removal (Refer to Figure 201).

CAUTION: Make sure that the gyro rotor has fully stopped before you move the instrument. The gyro rotor will not stop for approximately 15 minutes after the vacuum source is removed. Damage to the instrument will occur if the instrument is moved before the gyro rotor has stopped. CAUTION: Be careful with the gyroscopic instruments. Do not hit, shake, or put the instruments on a hard surface. Put soft material between the gyroscopic instruments and any hard surface. Damage to the instruments will occur if the instruments are not carefully moved. The manufacturer's warranty can become void if the gyro is not kept in its initial condition as received from the manufacturer.

(1) Put the MASTER switch and the AVIONICS switch in the off position.

(2) Remove the screws of the center pilot to get access to the back of the directional gyro.

CAUTION: Make sure that you put soft material between the directional gyro and the control column before you remove the gyro. If you put the sub on the control column without any protection, you can damage the directional gyro and/or the other instruments in the sub . Be very careful when you remove the sub so that you do not to hit the gyro. (3) (4) (5) (6) (7)

Put a label on the two hoses that are attached to the directional gyro. Loosen the clamps and remove the hoses from the directional gyro. Disconnect the gyro connector and electrical connector from the directional gyro. Put female plugs over the ports and put a connector cap on the electrical connector. Remove the directional gyro screws from the center pilot .


Page 206 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL CAUTION: Put a cover on the applicable hose or port or on the applicable electrical connector when the gyroscopic instrument is out of the airplane or is to be shipped. Damage to the instrument will occur from foreign object debris if a cover is not used. (8) Remove the directional gyro from the airplane. B.

Directional Gyro Installation (Refer to Figure 201).

CAUTION: Do not remove the directional gyro from the box in which it was shipped until it is ready to be installed into the airplane. This will minimize the possibility of accidentally causing damage to the gyro. CAUTION: Remove all plugs from the directional gyro before you install it in the airplane. CAUTION: Be careful with the gyroscopic instruments. Do not drop, shake, bump or put on a hard surface. Use soft material between the gyroscopic instruments and any hard surface. Damage to the instruments will occur if the instruments are not carefully moved. The manufacturer's warranty can become void if the gyro is not kept in it's initial condition as received from the manufacturer. (1) Attach the directional gyro to the center pilot with the screws. (2) Remove the female plugs from the ports and remove the connector cap from the electrical connector. (3) Attach the applicable hoses to the directional gyro and tighten the clamps. (4) Attach the electrical and gyro connectors to the directional gyro. (5) Attach the center pilot with the screws. (6) Put the MASTER switch and the AVIONICS switch in the ON position. (7) Do a test of the directional gyro to make sure it operates correctly. Refer to Directional Gyro Operational Check. 10.

Directional Gyro Operational Check A.

Directional Gyro Check (Refer to Figure 201). NOTE:

The permitted limit for gyro drift on the ground or in flight is 4 degrees from a fixed heading, during a 10-minute period.

(1) Start the airplane engine. (2) Make sure that the vacuum system operates correctly. (a) The vacuum gage must show between 4.5 and 5.5 inches Hg. (3) Let the directional gyro become stable for at least 3 minutes. (4) If the directional gyro dial starts to turn, let the gyro become stable and then push the gyro-caging knob. If the gyro dial continues to turn, repair the system and/or replace the gyro. NOTE: (5) (6) (7) (8)

It is usual for the directional gyro dial to turn when the gyro becomes stable. This is not a cause for removal.

Point the airplane's heading to the north. Set the directional gyro to the north. Make sure that the directional gyro dial drift is not more than 4 degrees in a 10-minute period. Do steps 5 through 7 again for each cardinal heading (North, West, South, and East).


Page 207 Jan 2/2006


MODEL 172 MAINTENANCE MANUAL (9) If the directional gyro dial drift is not satisfactory at any heading, repair the system and/or replace the gyro. NOTE: 11.

After you stop operation of the airplane, it is usual for the directional gyro dial to continue to turn. This is not a cause to remove the gyro.

Turn Coordinator Removal and Installation (Airplanes without Garmin G1000) A.

Turn Coordinator Removal (Refer to Figure 201).

CAUTION: Make sure that the gyro rotor has fully stopped before you move the instrument. The gyro rotor will not stop for approximately 15 minutes after the vacuum source is removed. Damage to the instrument will occur if the instrument is moved before the gyro rotor has stopped.

CAUTION: Be careful with the gyroscopic instruments. Do not hit, shake, or put the instruments on a hard surface. Put soft material between the gyroscopic instruments and any hard surface. Damage to the instruments will occur if the instruments are not carefully moved. The manufacturer's warranty can become void if the gyro is not kept in its initial condition as received from the manufacturer.

(1) Put the MASTER switch and the AVIONICS switch in the off position.

(2) Remove the screws from the center pilot to get access to the turn coordinator.

CAUTION: Make sure that you put soft material between the turn coordinator and the control column before you remove the turn coordinator. If you put the sub- on the control column without any protection, you can damage the turn coordinator and/or the other instruments in the sub-. Be very careful when you remove the sub- so that you do not to hit the turn coordinator. (3) Disconnect the turn coordinator connector and electrical connector from the turn coordinator.

CAUTION: Put a cover on the applicable electrical connector when the gyroscopic instrument is out of the airplane or is to be shipped. Damage to the instrument will occur from contamination if a cover is not used. (4) Put connector caps on the turn coordinator avionics connector and electrical connector. (5) Remove the screws that attach the turn coordinator to the center pilot . (6) Remove the turn coordinator from the airplane. B.

Turn Coordinator Installation (Refer to Figure 201).


Page 208 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL CAUTION: Do not remove the turn coordinator from the box in which it was shipped until it is ready to be installed into the airplane. This will minimize the possibility of accidentally causing damage to the gyro. CAUTION: Remove all plugs from the turn coordinator before you install it in the airplane. CAUTION: Be careful with the gyroscopic instruments. Do not drop, shake, bump or put on a hard surface. Use soft material between the gyroscopic instruments and any hard surface. Damage to the instruments will occur if the instruments are not carefully moved. The manufacturer's warranty can become void if the gyro is not kept in its initial condition as received from the manufacturer. (1) Attach the turn coordinator to the center pilot with the screws. (2) (3) (4) (5) (6) (7) 12.

Remove the connector caps from the turn coordinator avionics connector and the electrical connector. Attach the turn coordinator connector and electrical connector to the turn coordinator. Install the center pilot with the screws. Put the MASTER switch and the AVIONICS switch in the ON position. Set the autopilot roll null (if autopilot is installed). Refer to Autopilot - Maintenance Practices. Do an operational check of the turn coordinator to make sure that it operates correctly.

Turn Coordinator Removal and Installation (Airplanes with Garmin G1000) A.

Turn Coordinator Removal (Refer to Figure 202).

CAUTION: Make sure that the gyro rotor has fully stopped before you move the instrument. The gyro rotor will not stop for approximately 15 minutes after the vacuum source is removed. Damage to the instrument will occur if the instrument is moved before the gyro rotor has stopped. CAUTION: Be careful with the gyroscopic instruments. Do not hit, shake, or put the instruments on a hard surface. Use soft material between the gyroscopic instruments and any hard surface. Damage to the instruments will occur if the instruments are not carefully moved. The manufacturer's warranty can become void if the gyro is not kept in its initial condition as received from the manufacturer.

(1) (2) (3) (4)

Put the MASTER switch and the AVIONICS switch in the off position. Remove the center instrument . Remove the screws that attach the turn coordinator to the center instrument . Move the turn coordinator aft to get access to the turn coordinator avionics connector.

CAUTION: Put a cover on the applicable electrical connector when the gyroscopic instrument is out of the airplane or is to be shipped. Damage to the instrument will occur from foreign object debris if a cover is not used. (5) (6) B.

Disconnect the electrical connector and remove the turn coordinator from the airplane. Put connector caps on the electrical connector.

Turn Coordinator Installation (Refer to Figure 202).


Page 209 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL CAUTION: Do not remove the turn coordinator from the box in which it was shipped until it is ready to be installed into the airplane. This will minimize the possibility of accidentally causing damage to the gyro. CAUTION: Remove all plugs from the turn coordinator before you install it in the airplane. CAUTION: Be careful with the gyroscopic instruments. Do not drop, shake, bump or put on a hard surface. Use soft material between the gyroscopic instruments and any hard surface. Damage to the instruments will occur if the instruments are not carefully moved. The manufacturer's warranty can become void if the gyro is not kept in its initial condition as received from the manufacturer.

(1) (2) (3) (4) (5) (6) (7) (8)

Remove the connector caps from the electrical connector. Connect the electrical connector. Put the turn coordinator in position on the center instrument . Attach the turn coordinator with screws. Install the center instrument . Put the MASTER switch and the AVIONICS switch in the ON position. Set the autopilot roll null (if autopilot is installed). Refer to Autopilot - Maintenance Practices. Do an operational check of the turn coordinator to make sure that it operates correctly.


Page 210 Jan 2/2006


MODEL 172 MAINTENANCE MANUAL COM INSTALLATION - MAINTENANCE PRACTICES 1.

General A.

2.

A lighted, magnetic com is installed on top of the glareshield at the airplane centerline.

Com Removal/Installation A.

Remove Com (Refer to Figure 201). (1) Remove screws securing com to com base. (2) Disconnect electrical connector.

B.

Install Com (Refer to Figure 201). (1) Connect electrical connector. (2) Secure com to com base with screws. (3) Check com accuracy on com rose.


Page 201 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL B1

A COM BEZEL

ASE

DETAIL A

0510T1007 A0514T1007

Com Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL MAGNETOMETER

-

MAINTENANCE PRACTICES

1.General A. On airplanes with Garmin G1000, the GMU 44 magnetometer senses magnetic field information. The data is used by the GRS 77 AHRS to find aircraft magnetic heading. B. Maintenance practices give procedures for the removal and installation of the GMU 44 magnetometer. The unit is removed and installed through an access on the bottom side of the left wing. C. Maintenance practices also give procedures for the AHRS and magnetometer checkout. 2.

Troubleshooting A.

3.

For troubleshooting procedures, refer to the Garmin G1 000 Line Maintenance Manual.

G MU 44 Magnetometer Removal/installation A. Remove the Magnetometer (Refer to Figure 201). (1) Put the MASTER switch in the off position. (2) Put the AVIONICS switch in the off position.

CAUTION: Do not use magnetized tools or screws around the magnetometer. Use of magnetized tools or screws can cause an incorrect heading indication. (3)

B.

Remove access plate 520HB to get access to the magnetometer. Refer to Chapter 6, Access/ Inspection Plates - Description and Operation. (4) Remove the screws that attach the magnetometer to the flux detector bracket. (5) Disconnect the electrical connector. Install the Magnetometer (Refer to Figure 201).

NOTE:

If a new unit is installed, the software must be loaded.

(1)

I

Make sure the electrical connector and connector pins have no damage. (a) Replace the electrical connector or connector pins if applicable. Refer to the Model 172 Wiring Diagram Manual and the Garmin G1000 Line Maintenance Manual. (2) Connect the electrical connector. (3) Attach the magnetometer to the flux detector bracket with the screws. (a) Put the magnetometer in position on the flux detector bracket, temporarily aligned parallel to the longitudinal axis of the airplane. (4) If anew unit is installed, load the software. Refer to the Garmin Gl1000Line Maintenance Manual. (5) Do the calibration procedure. Refer to the Garmin GlOQO0 Line Maintenance Manual. (6) Install access plate 520HB. Refer to Chapter 6, Access/Inspection Plates - Description and (7)

~

~~~Operation.

Do a check to make sure the magnetometer operates correctly. Refer to the Garmin G1000 Line Maintenance Manual and Chapter 34, Attitude Heading Reference System (AHRS) Maintenance Practices, AHRS and Magnetometer Checkout Procedure.

34-22-00 C Cessna Aircraft Company

Page 201

Jul 1/2007



FLUX DETECTOR BRACKET

A

BOTTOM LEFT WING SKIN

RACK ELECTRICAL CABLE (NOTE)

MAGNETOMETER INSTALLATION-

COVER PLATE

NOTE:

ELECTRICAL CABLE THAT EXTENDS TO ELECTRICAL CONNECTOR.

DETAIL

A

(PL302)

0510T 1007 A0518T1 110

Magnetomneter Installation Figure 201 (Sheet 1)

34-22-00 C Cessna Aircraft Company

Page 202 Jul 1/2007


MODEL 172

MAINTENANCE MANUAL ATTITUDE HEADING REFERENCE SYSTEM (AHRS) - MAINTENANCE PRACTICES 1.

2.

General A.

On airplanes with Garmin G1000, the GRS 77 AHRS is an attitude, heading, and reference unit that gives airplane attitude and flight characteristics information to the Primary Flight Display (PFD) and Multi-Functin Display (MFD) and the GIA 63 Integrated Avionics Units. The unit has advanced tilt sensors, accelerometers, and rate sensors. In addition, the GRS 77 AHRS interfaces with both the GDC 74A Air Data computer and the GMU 44 Magnetometer. The GRS 77 AHRS also utilizes GPS signals sent from the GIA 63.

B.

Maintenance practices give procedures for the removal and installation of the GRS 77 AHRS. The unit is in the tailcone.

Troubleshooting A.

3.


GRS 77 AHRS Removal/Installation NOTE:

If the mounting bolts that attach the mounting rack to the airplane structure are loosened after post-calibration has been completed, the GRS 77 AHRS must be calibrated.

A.

Remove the AHRS unit (Refer to Figure 201). (1) Make sure the MASTER and AVIONICS switches are in the off position. (2) Remove the aft seat to get access to the AHRS unit. Refer to Chapter 25, enger Compartment - Maintenance Practices. (3) Remove the baggage compartment closeout to get access to the AHRS unit. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (4) Disconnect the electrical connector. (5) Remove the screws that attach the AHRS unit to the mounting tray.

B.

Install the AHRS unit (Refer to Figure 201). NOTE:

If a new AHRS unit is installed, the software must be loaded.

NOTE:

If the mounting bolts that attach the mounting rack to the airplane structure are loosened after post-calibration has been completed, the GRS 77 AHRS must be calibrated.

(1) Make sure the electrical connector and connector pins have no damage. (a) Replace the electrical connector or connector pins if applicable. Refer to the Model 172 Wiring Diagram Manual and the Garmin G1000 Line Maintenance Manual. (2) Put the AHRS unit in position in the mounting tray. (3) Attach the AHRS unit with the screws. (4) Connect the electrical connector. (5) Install the baggage compartment closeout. Refer to Chapter 25, Interior Upholstery Maintenance Practices. (6) Install the aft seat. Refer to Chapter 25, enger Compartment - Maintenance Practices. (7) Make sure the AHRS unit operates correctly. (a) If the mounting bolts that attach the mounting rack to the airplane structure have been loosened after post-calibration has been completed, calibrate the AHRS unit. Refer to the Garmin Line Maintenance Manual. (b) If a new unit is installed, load the software. Refer to the Garmin G1000 Line Maintenance Manual. (c) Do a check to make sure the AHRS operates correctly. Refer to the Garmin G1000 Line Maintenance Manual.


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AIR DATA

TRANSPONDER

DETAIL

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0510T1007 A0518T1103



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MODEL 172

MAINTENANCE MANUAL

4.

AHRS and Magnetometer Checkout Procedure A.

Checkout Instructions NOTE:

B.

The installation and verification of the system software must be completed before the AHRS and magnetometer checks can be done.

(1) Use the Garmin GRS 77/GMU 44 Installation Manual (P/N 190-00303-10) to do the check. Post Installation Calibration Procedures (1) Read Section 5.2 in the Garmin GRS 77/GMU 44 Installation Manual (P/N 190-00303-10). NOTE:

The Garmin Calibration Procedures A-1, B, and D must be fully completed.

(2) Do the Calibration Procedure A-1 in Section 5.3 of the Garmin GRS 77/GMU 44 Installation Manual. (a) Make the wings level to 0 degrees, +0.25 or -0.25 degrees. Refer to Chapter 8, Leveling Maintenance Practices. (b) Make the airplane nose up 2 degrees, +0.25 or -0.25 degrees. Refer to Chapter 8, Leveling - Maintenance Practices.

(c) Do the calibration procedure. (3) Do the Calibration Procedure B in Section 5.5 of the Garmin GRS 77/GMU 44 Installation Manual. (4) Do the Calibration Procedure D in Section 5.7 of the Garmin GRS 77/GMU 44 Installation Manual.


Page 203 Jan 3/2005

CESSNA AIRCRAFT COMPANY MODEL 172 MAINTENANCE MANUAL MARKER BEACON - MAINTENANCE PRACTICES 1.

General A.

2.

Audio Removal/Installation A.

3.

Maintenance practices have procedures for the removal and installation of the audio and marker beacon antenna.

For removal and installation of the audio , refer to Chapter 23, Audio - Maintenance Practices.

Marker Beacon Antenna Removal/Installation A.

Remove the Marker Beacon Antenna (Refer to Figure 201). (1) Make sure the AVIONICS and MASTER switches are in the off position. (2) Remove the baggage compartment lower access . Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (3) Remove the aft floorboard access/inspection plate to get access to the marker beacon antenna. (4) Disconnect the coaxial cable from the antenna.

CAUTION: Be careful when you remove the screws from the antenna. It can fall to the ground and as a result, be damaged. (5) Remove the screws that attach the antenna to the bottom of the fuselage. B.

Install the Marker Beacon Antenna (Refer to Figure 201). (1) Put the marker beacon antenna in position on the bottom of the fuselage. (2) Attach the antenna with the screws. (3) Attach the coaxial cable to the antenna. (4) Install the access/inspection plate to the floor of airplane. (5) Install the baggage compartment lower access . Refer to Chapter 25, Interior Upholstery - Maintenance Practices.


Page 201 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL - ---

COAX CABLE CONNECTOF (PF1001)

FUSELAGE SKIN

MARKER BE ANTENNA

DETAIL

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0510T1007 A0518T1035

Marker Beacon Antenna Figure 201 (Sheet 1)


Page 202 Jan 3/2005



NAV/COM - MAINTENANCE PRACTICES 1.

General A.

Nav/Com maintenance practices is primarily concerned with navigation hardware removal/installation. For removal/installation of the KX155A radio, refer to Chapter 23, Communications - Maintenance Practices.

CAUTION: Do not interchange the KX-155A and KX-165A NAV/COM Radios. You can cause damage to the NAV/COM Radio. 2.

3.

4.

Nav Antenna Removal/Installation A.

Remove Nav Antenna (Refer to Figure 201). (1) Remove boots over antenna rods. (2) Remove antenna rods by threading from base. (3) Remove fin cap assembly. (4) Remove screws securing antenna base to vertical fin. (5) Remove antenna base and disconnect coax connector.

B.

Install Nav Antenna (Refer to Figure 201). (1) Connect coax connector to antenna base. (2) Secure antenna base to vertical fin with screws. (3) Install fin cap assembly. (4) Thread antenna rods into base. (5) Install boots over antenna rods.

Nav Antenna Coupler Removal/Installation A.

Remove Nav Antenna Coupler (Refer to Figure 201). (1) Label and disconnect antenna coax connectors from nav antenna coupler. (2) Remove screws securing nav antenna coupler to fuselage. (3) Remove nav antenna coupler.

B.

Install Nav Antenna Coupler (Refer to Figure 201). (1) Place nav antenna coupler on fuselage and secure with screws. (2) Connect antenna coax connectors to nav antenna coupler.

Nav Indicator Removal/Installation A.

Remove Nav Indicator. (1) Remove screws securing right instrument sub- to instrument . (2) Disconnect electrical connector from nav indicator. (3) Remove screws securing nav indicator to right instrument sup-. (4) Remove nav indicator.

B.

Install Nav Indicator. (1) Place nav indicator on right instrument sub- and secure with screws. (2) Install electrical connector to nav indicator. (3) Secure right instrument sub- to instrument with screws.


Page 201 Jul 1/2005


MODEL 172

MAINTENANCE MANUAL

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Page 202 Jul 1/2005


MODEL 172 MAINTENANCE MANUAL GIA 63 INTEGRATED AVIONICS INSTALLATION

I

-


1.General A. Two GIA 63 Integrated Avionics Units (IAU's) are on the avionics shelf in the tailcone. B. The units have the communication and navigation receiver/transmitter components to operate the GPS, NAy, COM, and Glideslope functions. The GIA 63W has the Wide Area Augmentation System (WAAS) installed. The units are integrated components of the Garmin G1000 avionics system. 2.

Troubleshooting A. For troubleshooting procedures, refer to the Garmin Gi 000 Line Maintenance Manual.

3.

GIA 63 Integrated Avionics Unit Removal/installation A. Remove the Integrated Avionics Unit. (1) Refer to Chapter 23, Communications - Maintenance Practices

34-50-1 0 (DCessna Aircraft Company

Page 201 Janl1/2007


MODEL 172 MAINTENANCE MANUAL GPS - MAINTENANCE PRACTICES 1.

General A.

2.

3.

The KLN89B or the optional KLN94GPS is installed in the avionics radio rack. The GPS antenna is mounted above the cabin, in the general proximity of the comm antennas.

GPS Removal/Installation A.

Remove GPS (Refer to Figure 201). (1) Loosen single locking screw located in recessed hole on face of receiver. (2) Pull GPS from radio rack.

B.

Install GPS (Refer to Figure 201). (1) Place GPS in radio rack and slide forward, engaging fixed electrical plug. (2) Tighten single locking screw located in recessed hole on face of receiver.

GPS Antenna Removal/Installation A.

Remove GPS Antenna (Refer to Figure 201 ). (1) Remove screws securing GPS antenna to fuselage skin. (2) Disconnect coax connector from GPS antenna. (3) Remove antenna and gasket.

B.

Install GPS Antenna (Refer to Figure 201). (1) Place GPS antenna gasket in position on fuselage skin. (2) Connect coax connector to GPS antenna. (3) Secure GPS antenna to fuselage skin with screws.


Page 201 Apr 7/2003



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Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL KR-87 ADF SYSTEM - MAINTENANCE PRACTICES 1.

2.

3.

General A.

This section gives removal and installation procedures for the Kl-227 Automatic Direction Finder (ADF) indicator, KR-87 ADF receiver, and KA-44B ADF antenna.

B.

On airplanes without Garmin G1000, the KR-87 ADF receiver is installed in the avionics radio rack. The ADF antenna is installed on the bottom fuselage below the cabin. Use the KR-87 ADF receiver to tune the KR-87 system. Indications are shown on the Kl-227 ADF indicator, located to the left of the receiver.

C.

On airplanes with Garmin G1000, the KR-87 ADF receiver is installed on the instrument to the right of the Multi-Function Display (MFD). The ADF antenna is installed along the bottom fuselage centerline under the cabin. To tune the KR-87 ADF system, use the KR-87 ADF receiver. All indications are shown on the G1000 Primary-Flight Display (PFD).

KR-87 ADF Receiver Removal/Installation (Airplanes without Garmin G1000) A.

ADF Receiver Removal (Refer to Figure 201). (1) Remove electrical power from the airplane and turn the master switch to off. Disengage the ADF circuit breaker on the avionics circuit breaker . (2) Loosen the single locking screw that is in the recessed hole on the face of the receiver. (3) Pull the ADF receiver from the radio rack and remove from airplane.

B.

ADF (1) (2) (3)

KR-87 ADF Receiver Removal/Installation (Airplanes with Garmin G1000) A.

B.

4.

Receiver Installation (Refer to Figure 201). Put the ADF receiver in the radio rack and slide it forward to engage the fixed electrical plug. Tighten the single locking screw that is in the recessed hole on the face of the receiver. Connect electrical power to the airplane as needed and turn the master switch to ON. Engage the ADF circuit breaker on the avionics circuit breaker . (4) Do an operational test of the ADF receiver. (5) Remove electrical power from the airplane and turn the master switch to off. Disengage the ADF circuit breaker on the avionics circuit breaker .

ADF Receiver Removal (Refer to Figure 202). (1) Remove electrical power from the airplane and turn the master switch to off. Disengage the ADF circuit breaker on the avionics circuit breaker . (2) Loosen the single locking screw that is in the recessed hole on the face of the receiver. (3) Carefully pull the ADF receiver and the bezel from the instrument to disengage the electrical connector (P1602) from the ADF receiver. (4) Remove the ADF receiver, with the bezel, from the airplane. ADF Receiver Installation (Refer to Figure 202). (1) Carefully put the bezel on the rear of the ADF receiver and pull it forward until it is in position directly behind the face of the ADF receiver. (2) Put the ADF receiver in position in the instrument and pull it forward to engage the electrical connector (P1602) with the ADF receiver. (3) Tighten the single locking screw located in the recessed hole on the face of the receiver. (4) Connect electrical power to the airplane as needed and turn the master switch to ON. Engage the ADF circuit breaker on the avionics circuit breaker . (5) Do an operational test of the ADF receiver. (6) Remove electrical power from the airplane and turn the master switch to off. Disengage the ADF circuit breaker on the avionics circuit breaker .

KA-44B ADF Antenna Removal/Installation (For Airplanes With or Without Garmin G1000) A.

ADF Antenna Removal (Refer to Figure 201). (1) Remove electrical power from airplane and turn the master switch to off. (2) Remove the screws that attach the ADF antenna to the fuselage skin. 34-52-00 © Cessna Aircraft Company

Page 201 Jul 3/2006



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Page 202 Jul 3/2006



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Page 203 Jul 3/2006



B.

5.

(3) (4) ADF (1) (2)

Disconnect the antenna connector (PC600) from the ADF antenna. Remove the antenna and the gasket. Antenna Installation (Refer to Figure 201). Connect the electrical connector (PC600) to the ADF antenna. Attach the ADF antenna to the fuselage skin with the screws.

Kl-227 ADF Indicator Removal/Installation A.

ADF Indicator Removal (Refer to Figure 201). (1) Remove electrical power from airplane and set the MASTER switch to the off position. (2) Remove the inboard pilot assembly to gain access to the ADF indicator. Refer to Chapter 31, Instrument and Control s - Maintenance Practices. (3) Disconnect the electrical connector (P1603) from the ADF indicator. (4) Remove the screws that attach the ADF indicator to the inboard pilot assembly. (5) Remove the ADF indicator from the airplane.

B.

ADF (1) (2) (3)

Indicator Installation (Refer to Figure 201). Put the ADF indicator on the inboard pilot assembly and attach with the screws. Connect the electrical connector (P1603) to the ADF indicator. Attach the inboard pilot assembly to the structure with the screws. Refer to Chapter 31, Instrument and Control s - Maintenance Practices. (4) Connect power and set the MASTER switch to the ON position.


Page 204 Jul 3/2006


MODEL 172 MAINTENANCE MANUAL KT76C TRANSPONDER - MAINTENANCE PRACTICES 1.

General A.

2.

3.

The KT76C transponder is in the avionics radio rack. The transponder antenna is on the bottom of the cabin forward of the baggage area.

Transponder Removal/nstallation A.

Remove the Transponder (Refer to Figure 201). (1) Loosen the locking screw found in the recessed hole on the face of the receiver. (2) Pull the transponder from the radio rack.

B.

Install the Transponder (Refer to Figure 201). (1) Put the transponder in the radio rack and move it forward to engage the electrical plug. (2) Tighten the locking screw found in the recessed hole on the face of the receiver.

Transponder Antenna Removal/Installation A.

Remove the Transponder Antenna (Refer to Figure 201). (1) Remove the aft cabin to get access to the tailcone and transponder antenna. (2) Remove the nuts and washers that attach the transponder antenna to the tailcone. (3) From outside the airplane, disconnect the coax connector.

B.

Install the Transponder Antenna (Refer to Figure 201). (1) From outside the airplane, connect the coax connector to the transponder antenna. (2) From the tailcone, put the antenna studs through the mounting holes and attach with the nuts and washers.


Page 201 Jan 3/2005


MODEL 172

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Page 202 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL KT-73 MODE S TRANSPONDER - MAINTENANCE PRACTICES 1.

General A.

2.

The KT-73 (Mode S) transponder is installed in the avionics- radio mounting rack. The Cl-105 transponder antenna is installed on the bottom of the fuselage. For removal and installation procedures on the CI-105 transponder antenna, refer to Chapter 34, KT-76C Transponder Maintenance Practices.

KT-73 Mode S Transponder Removal and Installation A.

KT-73 Transponder Removal (Refer to Figure 201). (1) Disconnect the main battery. Refer to Chapter 24, Battery - Maintenance Practices. (2) Turn the single hex-screw counterclockwise. NOTE: (3) (4) (5) (6)

B.

The hex screw is in the recessed hole on the face of the transponder.

Remove the single hex screw from the transponder. Pull the transponder from the radio mounting rack. Disconnect the coaxial cable and electrical connector from the transponder. Remove the transponder from the airplane.

KT-73 Transponder Installation (Refer to Figure 201). (1) Put the transponder in the avionics radio mounting rack. (2) Connect the electrical connector and the coaxial cable. (3) Put the single hex screw in the recessed hole on the face of the transponder and turn it clockwise until it is tight. (4) Do a test of the KT-73 transponder.


Page 201 Jan 2/2006



DETAIL B

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Page 202 Jan 2/2006


MODEL 172 MAINTENANCE MANUAL GTX 33 TRANSPONDER - MAINTENANCE PRACTICES 1.

2.

General A.

On airplanes with Garmin G1000, the GTX 33 Transponder is a solid-state Mode-S transponder that gives Mode A, C, and S functions. Control and operation is through the Primary Flight Display (PFD). The transponder speaks with the GIA 63 Integrated Avionics Units.

B.

Maintenance practices give procedures for the removal and installation of the transponder. transponder is in the tailcone.

Troubleshooting A.

3.

The


GTX 33 Transponder Removal/Installation A.

Remove the GTX 33 Transponder (Refer to Figure 201). (1) Put the MASTER switch to the off position. (2) Put the AVIONICS switch to the off position. (3) Remove the aft seat. Refer to Chapter 25, enger Compartment - Maintenance Practices. (4) Remove the baggage compartment closeout. Refer to Chapter 25, Interior Upholstery Maintenance Practices. (5) Disconnect the duct from the aft side of the unit. Refer to Avionics Cooling - Maintenance Practices. (6) Release the unit handle. (a) For units with a Phillips screw, loosen the screw to unlock the unit handle. (b) For units with a D-Ring, push on the D-Ring and turn it 90 degrees counterclockwise to unlock the unit handle. (7) Move the lever up to disengage the locking stud with the dogleg slot in the mounting rack. (8) Remove the unit from the mounting rack.

B.

Install the GTX 33 Transponder (Refer to Figure 201). NOTE:

If a new unit is installed, it is necessary for the software and configuration to be loaded.

CAUTION: Make sure the unit goes Into position without resistance. Damage to the connectors, unit, or mounting rack will occur If the unit Is pushed Into position with force. NOTE:

The unit must be in position in the mounting rack to let the locking stud engage the channel.

(1) Make sure the connector and connector pins have no damage. (a) Replace the connector or connector pins if applicable. Refer to the Wiring Diagram Manual and the Garmin G1000 Line Maintenance Manual. (2) Carefully put the unit in position in the mounting rack.

CAUTION: Make sure the lever moves without resistance. Damage to the unit will occur If the lever Is pushed Into position with force. (3) Push the lever down toward the bottom of the unit to engage the locking stud with the dogleg slot in the mounting rack. (a) If the lever does not go down, adjust the backplate while the unit is engaged. (4) Lock the handle in position. (a) For units with a Phillips screw, tighten the screw to lock the unit handle. (b) For units with a D-Ring, push on the D-Ring and turn it 90 degrees clockwise to lock the unit handle. (5) Connect the duct to the aft side of the unit. Refer to Avionics Cooling - Maintenance Practices.


Page 201 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL -^^^-

AIR DATA

TRANSPONDER

DETAIL

A


0510T1007 A051BT1103



Page 202 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL (6) Install the baggage compartment closeout. Refer to Chapter 25, Interior Upholstery Maintenance Practices. (7) Install the aft seat. Refer to Chapter 25, enger Compartment - Maintenance Practices. (8) If a new unit is installed, load the software and configuration. Refer to the Garmin G1000 Line Maintenance Manual. (9) Do a check to make sure the transponder operates correctly. Refer to the Garmin G1000 Line Maintenance Manual. 4.

Transponder Antenna Removal/Installation A.

B.

Remove the Transponder Antenna (Refer to Figure 202). (1) Set the MASTER switch and AVIONICS switch to the off position. (2) Remove the screws that attach the antenna to the bottom of the fuselage. (3) Disconnect the coaxial cable from the antenna (PC1006). Install the Transponder Antenna (Refer to Figure 202). (1) Attach the coaxial cable to the antenna (PC1006). (2) Put the transponder antenna in position on the bottom of the fuselage. (3) Attach the antenna with screws.


Page 203 Jan 3/2005



A l=1 -AAv CONNECTOR COAX

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0510T1007 A0518T1042



Page 204 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL GDL-69A FIS - DESCRIPTION AND OPERATION 1.

General A.

The GDL-69A Flight Information System (FIS) is a remote-mounted component of the Garmin G 1000 avionics system. The GDL-69A gives weather and FIS information to the pilot. The information is controlled and seen through the Multi-Function Display (MFD). Information is sent from the data link receiver to the MFD through the high-speed data bus ethernet data path. With a current subscription, XM satellite radio service is available with the GDL-69A. The signals that the data link receives from satellites give better coverage than land-based transmissions. The XM radio is tuned through the MFD. Analog audio is sent to the audio and shares the AUX music input with the external audio entertainment input. GDL-69A capabilities include: · Graphical NEXRAD Data (NEXRAD) Graphical METAR Data (METAR) Textual METAR Data Textual Terminal Aerodrome Forecasts (TAF) · City Forecast Data Graphical Wind Data (WIND) · Graphical Echo Tops (ECHO TOP) Graphical Cloud Tops (CLD TOP) Graphical Lightning Strikes (XM LTNG) Graphical Storm Cell Movement (CELL MOV) · NEXRAD Radar Coverage (displayed with NEXRAD data) SIGMETs/AIRMETs (SIG/AIR) Surface Analysis with City Forecasts (SFC) County Warnings (COUNTY) Freezing Levels (FRX LVL) Hurricane Track (CYCLONE) Temporary Flight Restrictions (TFR).

B.

The GDL-69A XM Weather Data Link is the receiver for the FIS, and is installed aft of FS 108.00. It is a remote sensor.

C.

The Cl-2480 antenna for the GDL-69A FIS is installed on the upper surface of the fuselage at FS 64.57.


Page 1

Jan 2/2006


MODEL 172 MAINTENANCE MANUAL GDL-69A FIS - MAINTENANCE PRACTICES 1.

General A.

2.

The maintenance practices give the removal and the installation procedures for the GDL-69A XM Weather Data Link. For removal and installation of the Cl-2480 antenna for the GDL-69A Flight Information System (FIS), refer to Chapter 23, Communications - Maintenance Practices.

GDL-69A XM Weather Data Link Removal/Installation A.

Data (1) (2) (3) (4) (5) (6)

B.

Data (1)

Link Removal (Refer to Figure 201). Set the MASTER switch and the AVIONICS switch to the off position. Remove the aft seat. Refer to Chapter 25, enger Compartment - Maintenance Practices. Remove the baggage compartment closeout. Refer to Chapter 25, Interior Upholstery Maintenance Practices. Turn the quarter-turn fastener 90 degrees counterclockwise and lift the locking lever to disengage the data link. Move the data link out of the mounting rack. Remove the data link from the airplane. Link Installation (Refer to Figure 201). Inspect the connector for damaged pins.

CAUTION: Make sure the unit goes into position without resistance. Damage to the connectors, unit, or mounting rack will occur if the unit is pushed into position with force. (2) Carefully push the data link into the rack to engage the connector. (3) Put the data link in position with the locking lever stud in the mounting rack slot. (4) Push the locking lever down and turn the quarter-turn fastener 90 degrees clockwise to attach the data link to the mounting rack. (5) Install the baggage compartment closeout. Refer to Chapter 25, Interior Upholstery Maintenance Practices. (6) Install the aft seat. Refer to Chapter 25, enger Compartment - Maintenance Practices. (7) Set the MASTER switch and the AVIONICS switch to the ON position. (8) Do a check of the GDL-69A XM Weather Data Link FIS to make sure that it operates correctly. Refer to the Garmin G1000 Line Maintenance Manual, Revision D or later.


Page 201 Jan 2/2006



INTEGRATED AVIONICS UNIT AVIONICS UNIT TRANSPONDER RACK

GLUUL-69A XM WEATHER

DATA LINK

DETAIL A

0510T1007 A0518T1149

GDL-69A XM Weather Data Link Installation Figure 201 (Sheet 1)


Page 202 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL DME - MAINTENANCE PRACTICES

1.

General A.

2.

KN-63 DME Receiver Removal/Installation A.

|* ~ B.

|* ~

3.

On airplanes with Garmin G1000, the KN-63 Distance Measuring Equipment (DME) gives range, speed, and time-to-station information displayed through the G1000 display system. The KN-63 DME has a remote-mounted receiver in the rear fuselage aft of FS 142.00. The DME antenna is on the bottom fuselage below the cabin at FS 114.50.

KN-63 DME Receiver Removal (Refer to Figure 201). (1) Set the MASTER and the AVIONICS switches to the off position. (2) Disengage the DME/ADF circuit breaker on the avionics circuit breaker . (3) Remove the right, aft cabin for access to the DME receiver unit. (4) Disconnect the electrical connector (PT1031) from the receiver. (5) Disconnect the electrical connector (PT801) from the receiver. (6) Loosen the hold down screw. (7) Remove the screws that attach the mounting rack to the hold down bars. (8) Remove the hold down bars, rack, DME unit, and hardware from the airplane. KN-63 DME Receiver Installation (Refer to Figure 201). (1) Install the receiver with the connectors toward the rear of the airplane. (2) Install the receiver with the connectors on the same end of the mounting tray as the hold down clamp. (3) Attach the hold down clamp, hold down screw, compression spring, and lock washer to one of the hold down bars. (4) Put the two hold down bars under the mounting rack. (5) Attach the mounting rack to the hold down bars with the screws. (6) Tighten the hold down screw. (7) Make sure that there is a correct electrical bond between the unit and the airplane structure. (8) Attach the electrical connector (PT801) to the DME receiver. (9) Attach the electrical connector (PT1031) to the DME receiver. (10) Install the right, aft cabin . (11) Set the MASTER and the AVIONICS switches to the ON position. (12) Engage the DME/ADF circuit breaker on the avionics circuit breaker .

DME Antenna Removal/Installation A.

DME Antenna Removal (Refer to Figure 202). (1) Set the MASTER and the AVIONICS switches to the off position. (2) Disengage the DME/ADF circuit breaker on the avionics circuit breaker . CAUTION: Be careful when you remove the nuts from the antenna. antenna can fall to the ground.

The

(3) Remove the nuts and the washers that attach the DME antenna to the airplane at FS 114.50. (4) Disconnect the electrical connector (PF1011) from the antenna. (5) Remove the antenna from the airplane. B.

DME (1) (2) (3) (4) (5) (6) (7)

Antenna Installation (Refer to Figure 202). Solvent clean the surface of the airplane skin where you will install the antenna. Put the antenna in position on the airplane skin. Attach the antenna to the airplane skin with the nuts and the washers. Make sure that there is a correct electrical bond between the antenna connector and the skin. Connect the electrical connector (PF1011) to the antenna. Set the MASTER and the AVIONICS switches to the ON position. Engage the DME/ADF circuit breaker on the avionics circuit breaker .


Page 201 Jul 3/2006



KN-63 DME UNIT RECEIVER

COMPR HOLD DC LOCK

HOLD DOV\

DETAIL A

0510T1007 A0518T1139

KN-63 DME Receiver Installation Figure 201 (Sheet 1)


Page 202 Jul 3/2006


MODEL 172

MAINTENANCE MANUAL A .

E

In

COAX CONNECTOR

(PF1011)

R [

-16 JNA

DETAIL A 051OT1007 A0518T1138

DME Antenna Installation Figure 202 (Sheet 1)


Page 203 Jul 3/2006


MODEL 172 MAINTENANCE MANUAL KMD-540 MULTI-FUNCTION DISPLAY - MAINTENANCE PRACTICES 1.

General A.

The KMD-540 is a multi-function display (MFD) that can be installed to give the pilot more situational awareness during flight. Enhanced ground proximity warning system (EGPWS) and traffic advisory system (TAS) data is given on the color MFD display. Other data, such as global positioning system (GPS) data and weather data can be shown on the display. These displays can give the pilot more data that is easy to read in a short period of time.

2.

KMD-540 Multi-Function Display (MFD) Removal and Installation A. Remove the KMD-540 MFD. (Refer to Figure 201). (1) Disconnect the main battery. Refer to Chapter 24, Battery - Maintenance Practices. (2) Disengage the MFD circuit breaker on the circuit breaker . (3) Remove the screw in the face of the MFD. (4) Carefully pull the unit out of the avionics rack. (5) Disconnect the electrical connector from the MFD. (6) Remove the MFD from the airplane. B. Install the KMD-540 MFD. (Refer to Figure 201). (1) Put the MFD in the avionics rack. (2) Connect the electrical connector to the MFD. (3) Install the screw in the face of the MFD. (4) Engage the MFD circuit breaker on the circuit breaker . (5) Connect the main battery. Refer to Chapter 24, Battery - Maintenance Practices. (6) Do the operational check of the MFD.

3.

Operational Check of the MD-540 Multi-Function Display A. Do the MFD operational check. (1) Set the MASTER ALT/BAT switch to the ON position. (2) Set the AVIONICS master switch to the ON position. (3) Turn the ON/OFF knob on the KMD-540 MFD to the ON position. (4) Make sure that the KMD-540 title page comes on the screen. (5) Turn the ON/OFF knob on the KMD-540 MFD to the OFF position. (6) Set the AVIONICS master switch to the off position. (7) Set the MASTER ALT/BAT switch to the off position.


Page 201 Jul 1/2005



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KMD-540 Multi-Function Display Installation Figure 201 (Sheet 1)


Page 202 Jul 1/2005


MODEL 172

MAINTENANCE MANUAL GARMIN DISPLAY UNIT (GDU) - MAINTENANCE PRACTICES 1.

2.

General A.

The GDU 1040 has a 10.4 inch LCD display with 1024x768 resolution. The cockpit has two GDU 1040s. One is configured as a Primary Flight Display (PFD) and the other is configured as the MultiFunction Display (MFD). The MFD shows navigation, engine, and airframe information. The PFD shows primary flight information, in place of gyro systems. Both GDU 1040s connect and show all functions of the G1000 system during flight. The displays communicate with each other and the GIA 63 Integrated Avionics Units (IAU) through a High-Speed Data Bus (HSDB) Ethernet connection. The PFD and MFD have a reversionary switch in which one display can show all information usually shown by both displays in the event that one does not operate correctly.

B.

Two GDUs are in the instrument of airplanes with Garmin G1000. Maintenance practices give removal and installation procedures.

Troubleshooting A.

3.


Control Display Unit Removal/Installation

CAUTION: If possible, do not touch the lens. The GDU 1040 lens has a layer of antireflective material which Is very sensitive to skin oils, waxes and abrasive cleaners. CAUTION: Do not use cleaners that contain ammonia. Ammonia will cause damage to the anti-reflective material. It Is very Important to clean the lens with a clean, lint-free cloth and an eyeglass lens cleaner that Is specified as safe for anti-reflective material. A.

Remove the Garmin Display Unit (GDU) (Refer to Figure 201). (1) Disengage the applicable Primary Function Display (PFD) or Multi-Function Display (MFD) circuit breaker for the GDU. (2) Turn the quick release fasteners 1/4 turn counterclockwise with a 3/32" hex drive tool. (3) Carefully pull the GDU from the instrument . (4) Disconnect the electrical connector from the GDU.

B.

Install the Garmin Display Unit (GDU) (Refer to Figure 201).

CAUTION: If possible, do not touch the lens. The GDU 1040 lens has a layer of anti-reflective material which Is very sensitive to skin oils, waxes and abrasive cleaners. CAUTION: Do not use cleaners that contain ammonia. Ammonia will cause damage to the anti-reflective material. It Is very Important to clean the lens with a clean, lint-free cloth and an eyeglass lens cleaner that Is specified as safe for anti-reflective material. NOTE:

If a new unit is installed, it is necessary to load the software and configuration.

NOTE:

If the initial unit is installed in the initial location or in the opposite location, it is not necessary to load the software and configuration.

(1) Make sure the connector and connector pins have no damage. (a) Replace the connector or connector pins if applicable. Refer to The Wiring Diagram Manual and the Garmin G1000 Line Maintenance Manual. 34-60-10 © Cessna Aircraft Company

Page 201 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL new M

QUICK RELEASE FASTENER

PRIMARY FLIGHT DISPLAY (PFD)

MULTI-FUNCTION DISPLAY (MFD)

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AIRPLANES WITH GARMIN G1000 OPTION

0510T1 07 A0518T1109

Control Display Unit Installation Figure 201 (Sheet 1)


Page 202 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL (2) (3) (4)

Connect the electrical connector to the GDU. Put the GDU in position flush with the instrument . Make sure the locking-stud alignment marks are in the vertical position. NOTE:

(5) (6)

Light forward pressure can be required to engage the quick release fasteners.

Turn the quick release fasteners 1/4 turn clockwise with a 3/32" hex drive tool. Make sure the GDU operates correctly. (a) If a new unit is installed, load the software and configuration. Refer to the Garmin G1000 Line Maintenance Manual. (b) Do a check to make sure the GDU operates correctly. Refer to the Garmin G1000 Line Maintenance Manual.


Page 203 Jan 3/2005

CHAPTER

VACUUM



LIST OF EFFECTIVE PAGES PAGE

DATE

37-00-00

Page 1

Apr 7/2003

37-10-00

Page 101

Apr 7/2003

37-10-00

Pages 201-210

Jan 2/2006

CHAPTER-SECTION-SUBJECT 37-Title 37-List of Effective Pages 37-Record of Temporary Revisions 37-Table of Contents


Page 1 of 1 Jan 2/2006


Page Number

Issue Date

By

Date Removed

By


MODEL 172

MAINTENANCE MANUAL

CONTENTS VACUUM - GENERAL

...........

..............................................

S cope...................................................................... Definition ........... .. .................................................... VACUUM - TROUBLESHOOTING

..........................

...........

Troubleshooting ......... .. .................................................. VACUUM SYSTEM - MAINTENANCE PRACTICES................................. Description and Operation ................................................... Vacuum Pump Removal/Installation .......................................... Vacuum Manifold Removal/Installation ........................................

Regulator Valve Filter Removal/Installation .................................... Gyro Filter Removal/Installation .............................................. Vacuum Gage Removal/Installation........................................... Vacuum Transducer Removal/Installation .....................................

Vacuum Manifold Test (For airplanes with the Parker Airborne manifold) ......... Vacuum Pressure Adjustment/Test (For airplanes with the Parker Airborne regulator valve or the Aero Accessories regulator valve) ......... .....................

37-00-00 Page 1 37-00-00 Page 1 37-00-00 Page 1 37-10-00 37-10-00 37-10-00 37-10-00 37-10-00 37-10-00 37-10-00 37-10-00 37-10-00 37-10-00 37-10-00

37-10-00 Page 209


Page 101 Page 101 Page 201 Page 201 Page 201 Page 208 Page 208 Page 208 Page 208 Page 209 Page 209



MODEL 172 MAINTENANCE MANUAL VACUUM - GENERAL 1.

Scope A.

2.

This chapter describes those units and components used to provide vacuum necessary to operate the artificial horizon and directional gyros.

Definition A.

This chapter consists of a single section which describes those components used to distribute and indicate vacuum air.


Page 1

Apr 7/2003


MODEL 172

MAINTENANCE MANUAL VACUUM - TROUBLESHOOTING 1.

Troubleshooting

TROUBLE

PROBABLE CAUSE

REMEDY

OIL IN DISCHARGE.

Damaged engine driven seal.

Replace gasket.

HIGH SUCTION.

Vacuum regulator filter clogged.

Check filter for obstructions.

LOW SUCTION.

Vacuum regulator leaking.

Replace vacuum regulator.

Vacuum pump failure.

Substitute known good pump and check pump suction. Replace vacuum pump as required.

Vacuum regulator leaking.

Replace safety valve.

Vacuum pump failure.

Substitute known good pump and check pump pressure. Replace vacuum pump as required.

LOW PRESSURE.


Page 101 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL VACUUM SYSTEM - MAINTENANCE PRACTICES

* 1.


The vacuum system has a filter, vacuum gage, vacuum instruments, regulator valve, vacuum manifold, low vacuum annunciator switches, engine-driven vacuum pumps and related plumbing.

B.

On airplanes without Garmin G1000, the source of vacuum air is in the cabin and is pulled through the system by the engine-driven vacuum pumps. This air goes through the gyro filter at the cabin inlet source before it goes through the vacuum gage and gyro instruments. The vacuum is controlled by the regulator valve. The regulator valve is on the aft side of the firewall. The vacuum air is then pulled through the vacuum manifold and past the low vacuum annunciator switches and then into the vacuum pumps.

C.

On airplanes without Garmin G1000, vacuum pressure is measured by the low vacuum annunciator switches in the engine compartment. The vacuum gage in the instrument shows the vacuum pressure. (1) The vacuum gage gives a direct indication of the system vacuum in inches of mercury (in.hg.). (2) The low vacuum annunciator switches are part of the annunciator warning system. (a) If the left vacuum switch (SN012) senses a vacuum below 3.0 in.hg., the VAC annunciator will show L VAC. (b) If the right vacuum switch (SN011) senses a vacuum below 3.0 in.hg., the VAC annunciator will show VAC R. (c) If both switches sense a vacuum below 3.0 in.hg., the VAC annunciators will show L VAC R. (3) For more information on the maintenance practices for the -mounted annunciator (UI005), refer to Chapter 31, Annunciator - Maintenance Practices.

D.

On airplanes with Garmin G1000, the source of vacuum air is in the cabin and is pulled through system by the engine-driven vacuum pump. The vacuum pressure is measured by a vacuum transducer. The air goes through the gyro filter at the cabin inlet source before it is goes through the horizon gyro indicator. The vacuum is controlled by the regulator valve. The regulator valve and the vacuum transducer are on the aft side of the firewall.

_*O~ ~the

2.

Vacuum Pump Removal/nstallation NOTE:

Removal/Installation is typical for the vacuum pumps.

A.

Remove the Vacuum Pump (Refer to Figure 201). (1) Remove engine cowl. Refer to Chapter 71, Cowl - Maintenance Practices. (2) Remove the cooling shroud. (3) Disconnect the hoses from the inlet and outlet ports of the vacuum pump. (a) Put caps on the hoses and the vacuum pump ports to prevent entry of foreign object debris. (4) Remove the nuts, lockwashers, and flat washers that attach the vacuum pump to the engine. (5) Remove the vacuum pump from the engine. (6) Remove the elbow from the pump. (7) Replace any damaged fittings or nuts.

B.

Install the Vacuum Pump (Refer to Figure 201).


Page 201 Jan 2/2006



AANIFOLD

HOSE CLAMP VIEW A-A AIRPLANES 17280832 THRU 17280983 AND AIRPLANES 172S8349 THRU 172S8703

HOSE CLAMP RIGHT LOW VACUUM SWITCH

..

A

VIEW

A-A

A

IPLANES 17280001 THRU 17280831 AND IPLANES 172S8001 THRU 172S8348 =OLD

LEFT LOW VACUUM SWITCH

GASKET

SHROUD

DETAIL

0510T1007 A0514T1032 AA0514T1033 AA0514T1034

A

Vacuum System Installation Figure 201 (Sheet 1)


Page 202 Jan 2/2006



B1075

HORIZONTAL GYRO HOSE

TIONAL

RE

TION

W

TEE WASHERS NUT CLAMP FILTER WASHER

BOLT

DETAIL

B

GYRO INSTALLATION WITHOUT HSI

B0514T1031



Page 203 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL

B1559

HORIZONTAL GYRO

REGULATOR VALVE WITH FILTER

ON CLAMP

WASHER

REDUCER

NUT HOSE

FILTER

WASHER

BOLT

DETAIL

B

GYRO INSTALLATION WITH OPTIONAL HSI AIRPLANES 1728180 AND ON AND AIRPLANES 172S8922 AND ON

80514T1030



Page 204 Jan 2/2006



B3829

VACUUM TRANSDUCER HORIZONTAL GYRO INDICATOR

REPLACEMENT FILTER

TIP

VACUUM PUMP

GYRO FILTER

DETAIL

B

AIRPLANES WITH GARMIN G1000 0510T1007 B051BT1105



Page 205 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL CAUTION: Do not install a vacuum pump that has been dropped or shows that it was incorrectly held in a vise. CAUTION: Do not use any cork-type gaskets when the vacuum pump is installed. CAUTION: Make sure all unwanted material is removed from the system. Foreign object debris will cause damage to the vacuum system components. CAUTION: If a vise is used, hold the pump housing by the flange and protect the flange with soft material such as aluminum, copper or wood. The pump housing must never be set in a vise with pressure applied across the center of the housing. The pressure will cause damage to the carbon rotor. CAUTION: Do not use Teflon tape, pipe dope, or thread lubricants of any type. Foreign object debris will cause damage to the vacuum system components. (1) Put the vacuum pump in a jaw protected vise, with the drive coupling downward.

(2) Install the elbow in the pump hand tight. (3) Use only a box end wrench to tighten the fittings to the necessary position. Do not make more than 1.5 turns beyond the hand tight position (4) Make sure the pump and engine surfaces are clean and free of any old gasket material. (5) Set the new pad gasket on the studs of the engine. Put the vacuum pump on the studs. (6) (7) Attach the pump to the engine with the flat washers, new lockwashers, and nuts. (8) Torque and tighten the nuts in a cross pattern to 70 inch-pounds, +10 or -10 inch-pounds (7.9 N-m, +1.1 or- 1.1 N-m).

(a)

To torque the nuts, fabricate a torque wrench adapter (Refer to Figure 202). 1 Weld a 3/8 inch drive to a 7/16 inch wrench with a 12 point cut out in the box end of the wrench. 2 The wrench length must be 2.25 inches (57.15 mm) from the center of box end to the center of the drive.

CAUTION: For airplanes that are equipped with an HSI gyro system, make sure that the two hoses connected together between the horizon gyro and the regulator valve are connected with a metal reducer. If there is no metal reducer, you must install one. If a plastic reducer is installed, it can crack or break from maintenance. Refer to Service Bulletin SB02-37-03. (9) Connect the hose to the inlet and the outlet ports of the vacuum pump. (10) Put the hose in position so that the exhaust from the vacuum pump is not pointed at the magnetos or the electrical wiring. (11) Install the cooling shroud. (12) Operate the engine and examine the indication on the vacuum gage. Refer to the Pilot's Operating Handbook and FAA Approved Airplane Flight Manual. (13) Adjust the indication on the vacuum gage, if necessary. Refer to the vacuum pressure adjustment/test. (14) Install the upper engine cowl. Refer to Chapter 71, Cowl - Removal/Installation.


Page 206 Jan 2/2006



81876

A

FABRICATED TORQUE WRENCH ADAPTOR

2.25 INCHES

3/8 DRIVE

12 POINT

/

tA

CUTOUT

DETAIL

A

7/16 WRENCH

VIEW A-A

CUT END

Vacuum Pump Torque Wrench Adapter Figure 202 (Sheet 1)

37-10-00 Cessna Aircraft Company

Page 207 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL

3.

4.

5.

6.

Vacuum Manifold Removal/Installation NOTE:

The vacuum manifold has the check valve and vacuum switches.

NOTE:

Airplanes with Garmin G1000 do not have vacuum manifolds.

NOTE:

Removal/Installation is typical for the vacuum manifolds.

A.

Remove the Vacuum Manifold (Refer to Figure 201). (1) Remove the engine cowl. Refer to Chapter 71, Cowl - Removal/Installation. (2) Remove the hoses from the vacuum manifold. (3) Put a label on the applicable electrical connector (SN012 left, SN011 right). (4) Disconnect the applicable electrical connector from the vacuum manifold. (5) Loosen the B-nut that attaches the vacuum manifold to the nipple in the firewall. (6) Remove the vacuum manifold from the airplane.

B.

Install the Vacuum Manifold (Refer to Figure 201). (1) Attach the vacuum manifold to the nipple in the firewall and tighten the B-nut. (2) Connect the applicable electrical connector (SN012 left, SN011 right) to the vacuum manifold. (3) Connect the hoses to the vacuum manifold and attach with the clamps. (4) Install the upper engine cowl. Refer to Chapter 71, Cowl - Removal/Installation.

Regulator Valve Filter Removal/Installation A.

Remove the Regulator Valve Filter (Refer to Figure 201). (1) Get access to the regulator valve which is forward of the radio stack. (2) Carefully stretch the foam element filter over the top of the retaining bezel, and remove the filter from the regulator valve.

B.

Install the Regulator Valve Filter (Refer to Figure 201). (1) Stretch the regulator valve filter over the top of the retaining bezel.

Gyro Filter Removal/Installation A.

Remove the Gyro Filter (Refer to Figure 201). (1) Remove the bolt and retainer from the mount and remove the gyro filter.

B.

Install the Gyro Filter (Refer to Figure 201). (1) Put the gyro filter and the retainer on the mount and attach with the bolt.

Vacuum Gage Removal/Installation NOTE:

Airplanes with Garmin G1000 do not have a vacuum gage.

NOTE:

The vacuum gage and ammeter operate together as a single instrument.

A.

Remove the Vacuum Gage (Refer to Figure 201). (1) Disconnect the vacuum and air hoses from the vacuum gage. (2) Disconnect the electrical connector (JI019) from the vacuum gage. (3) Remove the screws that attach the vacuum gage to the instrument and remove the vacuum gage.

B.

Install the Vacuum Gage (Refer to Figure 201). (1) Install the vacuum gage in the instrument . (2) Attach with the screws. (3) Connect the electrical connector (JI019) to the vacuum gage. (4) Connect the vacuum and air hoses to the vacuum gage.


Page 208 Jan 2/2006



7.

Vacuum Transducer Removal/Installation NOTE: A.

B.

I

Only airplanes with the Garmin G1000 have a vacuum transducer. Remove the Vacuum Transducer (Refer to Figure 201). (1) Remove the center . Refer to Chapter 31, Instrument and Control s - Maintenance Practices. (2) Remove the screw and clamp that hold the vacuum transducer in position. (3) Remove the vacuum transducer. Install the Vacuum Transducer (Refer to Figure 201). (1) Install the vacuum transducer. (2) Install the screw and clamp that hold the vacuum transducer in position. (3) Install the center . Refer to Chapter 31, Instrument and Control s - Maintenance Practices.

8.

Vacuum Manifold Test (For airplanes with the Parker Airborne manifold) A. The vacuum manifold must be tested periodically to determine its condition and serviceability. Refer to Chapter 5, Inspection Time Limits for inspection intervals. Refer to Parker Hannifin Corporation/ Airborne Division's Product Reference Memo #39 (or latest revision) for the procedures.

9.

Vacuum Pressure Adjustment/Test (For airplanes with the Parker Airborne regulator valve or the Aero Accessories regulator valve) NOTE:

Before the adjustment procedure, the entire pneumatic system must be inspected and tested for leaks, restrictions, and unserviceable components. Failure to correct all system anomalies will lead to reduced dry air pump service life.

A.

Prepare the System for the Test (Refer to Figure 201). (1) Remove the gyro (central air) filter.

B.

Do a Check of the Regulator Valve.

CAUTION: Make sure that the temperature of the engine does not go above the maximum engine temperature during the adjustment/test of the regulator valve. NOTE:

At engine speeds between 1200 RPM and full throttle, suction must fall between 4.5 in.hg. and 5.5 in.hg. (green range on gage).

(1) Start the engine, warm up to the normal operating temperature, and run at static RPM. Refer to Pilot's Operating Handbook and FAA Approved Airplane Flight Manual. (2) Make sure the suction gage indication does not go above 5.5 in.hg. (3) Run the engine at 1200 RPM and make sure the gage indication does not go below 4.5 in.hg. (4) If the suction indication falls outside of the range, shut down the engine and adjust the regulator valve in the steps that follow. (a) Bend the locking tab upward on the lower surface of the regulator valve.

CAUTION: Be careful when you turn the adjustment screw. Do not turn it too much in either direction. When you turn it too much in either direction, damage can occur to the equipment. (b) Turn the adjustment screw on the lower surface of the regulator valve in the direction to increase or decrease the pressure as necessary. NOTE:

As you face the adjustment screw, when you turn it clockwise the pressure increases. When you turn it counterclockwise, the pressure decreases.


Page 209 Jan 2/2006



(5) (6) (7)

(8) (9)

(10) (11)

(12)

(c) Tap the regulator after you adjust it to help reset the components. (d) Bend the locking tab downward to keep the adjustment screw in place when the correct pressure has been set. Run the engine at static RPM and make sure the gage indication does not go above 5.5 in.hg. Run the engine at 1200 RPM and make sure the gage indication does not go below 4.5 in.hg. Shut down the engine. (a) For airplanes without the Garmin G1000, make sure that the L VAC R lights come on. (b) For airplanes with the Garmin G1000, make sure that the low vacuum annunciator visual and aural warnings come on. Attach the filter element to the gyro (central air) filter. Before you start the engine, make sure that the low vacuum annunciations are on. (a) For airplanes without the Garmin G1000, make sure that the L VAC R lights are on. (b) For airplanes with the Garmin G1000, make sure that the low vacuum annunciator visual warning is on. Run the engine for a final time at static RPM and observe the indication on the suction gage. (a) If the indication falls noticeably after the filter is installed, replace the filter. Reduce the engine speed to 1200 RPM and make sure that the suction stays in the green range (does not fall below 4.5 in.hg.). and that the low vacuum annunciations are off. (a) For airplanes without the Garmin G1000, make sure that the L VAC R lights go off. (b) For airplanes with the Garmin G1000, make sure that the low vacuum annunciator visual and aural warnings go off. Shut down the engine.


Page 210 Jan 2/2006

CHAPTER

STANDARD PRACTICES STRUCTURES




PAGE

DATE

51-00-00

Page 1

Apr 7/2003

51-10-00

Page 1

Apr 7/2003

51-11-00

Pages 1-4

Apr 7/2003

51-Title 51-List of Effective Pages 51-Record of Temporary Revisions 51-Contents




Page Number

Issue Date

By

Date Removed

By



CONTENTS S cope...................................................................... Definition ...................................................................

51-00-00 Page 1 51-00-00 Page 1 51-00-00 Page 1

STRUCTURES - DESCRIPTION AND OPERATION ................................ Description .................................................................

51-10-00 Page 1 51-10-00 Page 1

CORROSION - DESCRIPTION AND OPERATION ......... ...................... General................................................................... Characteristics of Corrosion.................................................. Types of Corrosion .......................................................... Typical Corrosion Areas ..................................................... Corrosion Detection ............................ ......................... Corrosion Damage Limits ......... ..........................................

51-11-00 51-11-00 51-11-00 51-11-00 51-11-00 51-11-00 51-11-00

STRUCTURES - GENERAL .........


.........

....................................

CONTENTS

Page 1 Page 1 Page 1 Page 1 Page 3 Page 4 Page 4



MODEL 172 MAINTENANCE MANUAL STRUCTURES - GENERAL 1.

Scope A.

2.

This chapter provides a description of general airplane structures and corrosion characteristics. For repair of structural and repair techniques used throughout the airplane, refer to the Single Engine Structural Repair Manual 1996 and On.

Definition A.

This chapter is divided into two sections briefly described below. (1) The section on structures provides an overall description of the airplane structure and methods of construction used on the airplane. (2) The section on corrosion provides a general description of corrosion characteristics, types of corrosion and typical corrosion areas.


Page 1

Apr 7/2003


MODEL 172 MAINTENANCE MANUAL STRUCTURES - DESCRIPTION AND OPERATION 1.

Description A.

The fuselage is of semimonocoque construction and consists of three major sections: forward section, center section, and tailcone section. Construction consists of formed bulkheads, longitudinal stringers, reinforcing channels and skin. Frame of the cabin section are constructed of formed bulkhead channels. Bulkheads are formed "U" channel sections. Principal material is 20240 alclad aluminum alloy which, after forming, is heat treated to a 2024-T42 condition and painted with epoxy primer. All bulkheads in the fuselage are constructed of formed sheet metal or reinforced sheet metal.

B.

The wings are of all-metal, strut-braced, semi monocoque construction, utilizing two spars. Each wing consists of an outer wing with an integral fuel bay, an aileron and a flap. Flanged upper and lower edges of all ribs serve as cap- strips, in addition to providing rigidity to the rib. The skin, riveted directly to each rib flange, provides the cellular strength for each successive rib bay. The nose, center, and trailing edge rib segments are riveted together through the front and rear spars to form the basic airfoil sections. Alclad stringers stiffen the skin between ribs. Spars are comprised of machine milled, tapered extrusions riveted to sheet metal webs. The full-cantilever, all- metal tail group consists of a vertical stabilizer and rudder, and a horizontal stabilizer and elevators. The horizontal stabilizer is of one-piece construction, consisting of spars, ribs and skins. Elevators are constructed of aluminum spars, ribs and skin s. The skin s are riveted to ribs and spars. A balance weight is located in the outboard end of each elevator, forward of the hinge line. An elevator trim tab, attached to each elevator, is constructed of a spar, ribs, and skin; all riveted together. The vertical stabilizer is constructed of a forward spar and aft spar, ribs and skin. The rudder is constructed of spars, ribs and skin s. The rudder trim tab is constructed of a spar, ribs, and skin; all riveted together. The main landing gear is constructed of 6150 alloy spring-steel tubing with attaching parts of high strength 7075-T73 aluminum alloy forgings. Nose gear components are 4130, 6150 alloy steel and 7075-T73 aluminum alloy forgings.

C.

D.

E. F.

The engine mount is constructed of welded 4130 steel tubing. The engine cowling consists of upper and lower formed aluminum sections. The upper section includes and oil inspection door, and the lower section includes an air induction scoop with an engine oil filter. Both sections are removable.


Page 1

Apr 7/2003


MODEL 172

MAINTENANCE MANUAL CORROSION - DESCRIPTION AND OPERATION 1.

General A.

2.

Characteristics of Corrosion A.

3.

This section describes corrosion so the maintenance technician can identify the various types of corrosion and apply preventative measures to minimize corrosion activity. For corrosion control and corrosion damage, refer to the Single Engine Structural Repair Manual 1996 and On.

Corrosion is a natural phenomenon which destroys metal by chemical or electrochemical action and converts it to a metallic compound, such as an oxide, hydroxide, or sulfate. All metals used in airplane construction are subject to corrosion. Attack may take place over an entire metal surface, if exposed, or it may be penetrating in nature, forming deep pits. It may follow grain boundaries or it may penetrate a surface at random. Corrosion may be accentuated by stresses from external loads or from lack of homogeneity in the metallic structure or from improper heat treatment. It is promoted by between dissimilar metals or with materials which absorb moisture, such as wood, rubber, felt, dirt, etc. (1) The following conditions must exist for electrochemical corrosion to occur. Refer to Figure 1 for an illustration of electrochemical corrosion. (a) There must be a metal that corrodes and acts as the anode. (b) There must be a less corrodible metal that acts as the cathode. (c) There must be a continuous liquid path between the two metals which acts as the electrolyte, usually condensation and salt or other contaminations. (d) There must be a conductor to carry the flow of electrons from the cathode to the anode. This conductor is usually in the form of a metal-to-metal (rivets, bolts, welds, etc.) (2) The elimination of any one of the four conditions described above will stop the corrosion reaction process. (3) One of the best ways to eliminate one of the four described conditions is to apply an organic film (such as paint, grease, plastic, etc.) to the surface of the metal affected. This will prevent the electrolyte from connecting the cathode to the anode, and current cannot flow, therefore, preventing corrosion reaction. Refer to Figure 1 for a typical organic film application. (4) At normal atmospheric temperatures, metals do not corrode appreciably without moisture, but the moisture in the air is usually enough to start corrosive action. (5) The initial rate of corrosion is usually much greater than the rate after a short period of time. This slowing down occurs because of the oxide film that forms on the metal's surface. This film tends to protect the metal underneath. (6) When components and systems constructed of many different types of metals must perform under various climatic conditions, corrosion becomes a complex problem. Salt on metal surfaces (from sea coast operation) greatly increases the electrical conductivity of any moisture present and accelerates corrosion. (7) Other environmental conditions which contribute to corrosion are: (a) Moisture collecting on dirt particles. (b) Moisture collecting in crevices between lap ts, around rivets, bolts and screws.

Types of Corrosion A.

Corrosion Types. (1) Direct Surface Attack - The most common type of general surface corrosion results from direct reaction of a metal surface with oxygen in the atmosphere. Unless properly protected, steel will rust and aluminum and magnesium will form oxides. The attack may be accelerated by salt spray or salt-bearing air, by industrial gases or by engine exhaust gases. (2) Pitting - While pitting can occur in any metal, it is particularly characteristic of ive materials, such as the alloys of aluminum, nickel and chromium. It is first noticeable as a white or gray powdery deposit similar to dust, which blotches the surface. When the deposits are cleaned away, tiny pits can be seen in the surface. (3) Dissimilar Metal Corrosion - When two dissimilar metals are in and are connected by an electrolyte (continuous liquid or gas path), accelerated corrosion of one of the metals occurs. The most easily oxidized surface becomes the anode and corrodes. The less active member 51-11-00 © Cessna Aircraft Company

Page 1

Apr 7/2003



B1781 ......... Ot

m6

CURRENT ............................................

..

~...........

FLOW

CURRENT FLOW

SIMPLIFIED CORROSION CELL

UNBROKEN PAINT FILM

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CORROSION ELIMINATION BY APPLICATION OF ORGANIC FILM

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Corrosion Identification Figure 1 (Sheet 1)


Page 2

Apr 7/2003


MODEL 172

MAINTENANCE MANUAL of the couple becomes the cathode of the galvanic cell. The degree of attack depends on the relative activity of the two surfaces; the greater the difference in activity the more severe the corrosion. Relative activity in descending order is as follows: (a) Magnesium and its alloys. (b) Aluminum alloys 1100, 3003, 5052, 6061, 220, 355, 356, cium and zinc. (c) Aluminum alloys 2014, 2017, 2024, 7075 and 195. (d) Iron, lead and their alloys (except stainless steel). (e) Stainless steels, titanium, chromium, nickel, copper, and their alloys. (f) Graphite (including dry film lubricants containing graphite). (4) Intergranular Corrosion - Selective attack along the grain boundaries in metal alloys is referred to as intergranular corrosion. It results from lack of uniformity in the alloy structure. It is particularly characteristic of precipitation hardened alloys of aluminum and some stainless steels. Aluminum extrusions and forgings in general may contain nonuniform areas, which in turn may result in galvanic attack along the grain boundaries. When attack is well advanced, the metal may blister or delaminate, which is referred to as 'exfoliation". (5) Stress Corrosion - This results from the combined effect of static tensile stresses applied to a surface over a period of time. In general, cracking susceptibility increases with stress, particularly at stresses approaching the yield point, and with increasing temperature, exposure time and concentration of corrosive ingredients in the surrounding environment. Examples of parts which are susceptible to stress corrosion cracking are aluminum alloy bellcranks employing pressed-in taper pins, landing gear shock struts with pipe thread-type grease fittings, clevis ts and shrink fits. (6) Corrosion Fatigue - This is a type of stress corrosion resulting from the cyclic stresses on a metal in corrosive surroundings. Corrosion may start at the bottom of a shallow pit in the stressed area. Once attack begins, the continuous flexing prevents repair of protective surface coating or oxide films and additional corrosion takes place in the area of stress. 4.

Typical Corrosion Areas A.

This section lists typical areas of the airplane which are susceptible to corrosion. These areas should be carefully inspected at periodic intervals to detect corrosion as early as possible. (1) Engine Exhaust Trail Areas. (a) Gaps, seams and fairings on the lower right side of the fuselage, aft of the engine exhaust stack, are typical areas where deposits may be trapped and not reached by normal cleaning methods. (b) Around rivet heads, skin laps and inspection covers on the airplane lower fuselage, aft of the engine secondary exhaust stack, should be carefully cleaned and inspected. (2) Battery Box and Battery Vent Opening. (a) The battery, battery cover, battery box and adjacent areas, especially areas below the battery box where battery electrolyte may have seeped, are particularly subject to corrosive action. If spilled battery electrolyte is neutralized and cleaned up at the same time of spillage, corrosion can be held to a minimum by using a weak boric acid solution to neutralize the battery electrolyte (ni-cad battery) or baking soda solution to neutralize the lead acid-type battery electrolyte. If boric acid or baking soda is not available, flood the area with water. (3) Steel Control Cables (including Stainless Steel). (a) Checking for corrosion on control cables is normally accomplished during the preventative maintenance check. During preventative maintenance, broken wires and wear of the control cables are also checked. (b) If the surface of the cable is corroded, carefully force the cable open by reverse twisting and visually inspect the interior. Corrosion on the interior strands of the cable constitutes failure and the cable must be replaced. If no internal corrosion is detected, remove loose external rust and corrosion with a clean, dry, coarse-weave rag or fiber brush. NOTE:

Do not use metallic wools or solvents to clean installed cables. Use of metallic wool will embed dissimilar metal particles in the cables and create further corrosion. Solvents will remove internal cable lubricant, allowing cable strands to abrade and further corrode. 51-11-00 © Cessna Aircraft Company

Page 3

Apr 7/2003


MODEL 172 MAINTENANCE MANUAL After thorough cleaning of the exterior cable surface, apply a light coat of lubricant (VV-L800) to the external cable surface. (4) Internal Fuel Tanks. (a) The presence of soil contamination (a brown slimy substance) and pitting-type corrosion may occur in the lower areas of the integral fuel tanks of certain airplanes. This condition can cause a general degradation of some top coating and some depolymerization and loosening of sealant materials in lower areas. (b) The contaminants resemble normal aluminum corrosion products, including a considerable quantity of iron. The brown, slimy deposits are microbial in nature. Examination of the corrosion pits by metallurgical techniques indicate the presence of intergranular attacks. (c)

5.

Corrosion Detection A.

6.

Corrosion Defoliation. The primary means of corrosion detection is visual, but in situations where visual inspection is not feasible, other techniques must be used. The use of liquid dye penetrant, magnetic particle, X-ray and ultra-sonic devices can be used, but most of these sophisticated techniques are intended for the detection of physical flaws within metal objects, rather than the detection of corrosion. (1) Visual Inspection. A visual check of the metal surface can reveal the signs of corrosive attack, the most obvious of which is a corrosive deposit. Corrosion deposits of aluminum or magnesium are generally a white or grayish-white powder, while the color of ferrous compounds varies from red to dark reddish-brown. (a) The indications of corrosive attack are small, localized discolorations of the metal surface. Surfaces protected by paint or plating may only exhibit indications of more advanced corrosive attack by the presence of blisters or bulges in the protective film. Bulges in lap ts are indications of corrosive build-up which is well advanced. (b) In many cases the inspection area is obscured by structural , equipment installations or, for other reasons, are awkward to check visually. In such cases, mirrors, borescope or similar devices can be used to inspect the obscured areas. Any means which allows a thorough inspection can be used. Magnifying glasses are valuable aids for determining whether or not all corrosive products have been removed during clean up operations. (2) Liquid Dye Penetrant Inspection. Inspection for large stress-corrosion or corrosion fatigue cracks on nonporous or nonferrous metals may be accomplished using dye penetrant processes. The dye applied to a clean metallic surface will enter small openings or cracks by capillary action. After the dye has an opportunity to be absorbed by any surface discontinuity, the excess dye is removed and a developer is applied to the surface. The developer acts like a blotter and draws the dye from cracks or fissures back to the surface, giving visible indication of any fault that is present on the surface. The magnitude of the fault is indicated by the quantity of dye brought back to the surface by the developer.

Corrosion Damage Limits A.

Following cleaning and inspection of the corroded area, the actual extent of the damage may be evaluated using the following general guidelines and good, sound maintenance judgement. Determine the degree of corrosion damage (light, moderate, or severe) with a dial-type depth gage, if accessibility permits. If the area is inaccessible, clay impressions, or any other means which will give accurate results, should be used. In the event the corrosion damage is severe, Cessna Propeller Aircraft Product for assistance. (1) Light Corrosion - Characterized by discoloration or pitting to a depth of approximately 0.001 inch maximum. This type of damage is normally removed by light hand-sanding or a minimum of chemical treatment. (2) Moderate Corrosion - Appears similar to light corrosion except there may be blistering or some evidence of scaling or faking. Pitting depths may be as deep as 0.010 inch. This type of damage is normally removed by extensive hand-sanding or mechanical sanding. (3) Severe Corrosion - General appearance may be similar to moderate corrosion with severe blistering exfoliation and scaling or flaking. Pitting depths may be as deep as 0.10 inch. This type of damage is normally removed by extensive mechanical sanding or grinding (if not complete part replacement). 51-11-00 © Cessna Aircraft Company

Page 4

Apr 7/2003

CHAPTER

DOORS


MODEL 172

MAINTENANCE MANUAL


PAGE

DATE

52-00-00

Page 1

Apr 7/2003

52-10-00

Page 1

Jun 7/2004

52-10-00

Pages 201-209

Jul 3/2006

52-30-00

Pages 201-204

Jul 3/2006





Page Number

Issue Date

By

Date Removed

By



CONTENTS DOORS - GENERAL .........

............................

........................

S cope...................................................................... Definition ................................................................... CABIN DOORS - DESCRIPTION AND OPERATION ................................

Description ................................................................. Operation ............................ ........... ........................... CABIN DOORS - MAINTENANCE PRACTICES .................................... G en eral .................................................................... Cabin Door Removal/Installation .................... ......................... Cabin Door Weatherstrip Removal/Installation ......... ........................ Cabin Door Latch Lock Removal/Installation .............................. Cabin Door Latch Assembly Removal/Installation .............................. Cabin Door Latch Cable Assembly Installation ................................. Cabin Door Lock Assembly Removal/Installation (on airplanes with standard locks) Cabin Door Lock Assembly Removal/Installation (on airplanes with Medeco locks) Cabin Door Lock Cam Assembly Removal/Installation (on airplanes with standard locks)................ ... ................................................. Cabin Door Lock Cam Assembly Removal/Installation (on airplanes with Medeco locks)............... ......... ......... ................................... Cabin Door Adjustment/Test ......... ......... ............................... Cabin Door Latch Cable Assembly Rigging .................................... Latch Assembly Adjustment/Test ............................................. BAGGAGE DOOR - MAINTENANCE PRACTICES................................. G eneral .................................................................... Baggage Door Removal/Installation. .......................................... Baggage Door Weatherstrip Removal/Installation .......... .................... Baggage Door Weatherstrip Inspection ....................................... Baggage Door Lock Assembly Removal/Installation (On airplanes with Medeco lock).................................... ................................. Baggage Door Lock Cam Assembly Removal/Installation (On airplanes with Medeco lock).............................................................

52-00-00 Page 1 52-00-00 Page 1 52-00-00 Page 1 52-10-00 Page 1 52-10-00 Page 1 52-10-00 Page 1 52-10-00 Page 201 52-10-00 Page 201 52-10-00 Page 201 52-10-00 Page 201 52-10-00 Page 201 52-10-00 Page 206 52-10-00 Page 206 52-10-00 Page 207 52-10-00 Page 207 52-10-00 Page 207 52-10-00 52-10-00 52-10-00 52-10-00


52-30-00 52-30-00 52-30-00 52-30-00 52-30-00


52-30-00 Page 204 52-30-00 Page 204

CONTENTS © Cessna Aircraft Company



MODEL 172 MAINTENANCE MANUAL DOORS - GENERAL

1.

Scope A.

2.

This chapter provides maintenance information on doors. instructions and rigging procedures.

Provided are removal/installation

Definition A.

This chapter is divided into sections and subsections to assist maintenance personnel in locating specific systems and information. The following is a brief description of each section. For locating information within the chapter, refer to the Table of Contents at the beginning of the chapter. (1) The cabin door section provides information on removal/installation and rigging of the doors. (2) The baggage door section provides information on removal/installation of baggage door, seal replacement and inspection.


Page 1

Apr 7/2003


MODEL 172 MAINTENANCE MANUAL CABIN DOORS - DESCRIPTION AND OPERATION 1.

Description A.

2.

A cabin door is installed on each side of the airplane. Each door has an outer sheet skin that is chemically bonded to an inner pan assembly. Each door has a latch assembly, an inside handle, a pair of external hinges, and a doorstop assembly.

Operation A.

The cabin doors open by the inside or outside handle, that is connected to internal components. (1) The cabin door latch is a two-part assembly latch base, external handle, spring-loaded latch bolt and pull-bar assembly, and a spring-loaded catch pin assembly. The interior handle base plate assembly is directly connected to the cabin door latch by an adjustable push rod assembly. This push rod assembly has two clamps attached 180 degrees apart on the main rod. These clamps operate a cable assembly that moves a cable pin from the top aft end of the cabin door into the aft top door sill. (2) The door latch exterior handle is extended when the cabin door is open. The handle is held in position by the spring-loaded latch catch engaged with the latch bolt through the hole in the bolt. The push rod assembly will move forward. The attached cable assembly will be retracted from the top door sill with the cable pin in a recess in the pin guide. The interior handle will move approximately 15 degrees aft of the vertical position.

B.

The cabin doors close and latch by the internal or external handle connected with internal components. (1) The cabin door moves the catch pin over the actuator attached to the cover plate. The cover plate is on the rear door post. The catch pin disengages the latch catch from the latch bolt as the catch pin is moved forward. The latch handle extends and the pull-bar assembly compresses. The latch handle is pulled in and the latch bolt is moved on the latch striker. The latch striker is on the rear door post. (2) The push rod assembly moves aft and moves the cable pin from the pin guide in the door into the top aft door sill receptacle when the exterior handle is pushed flush with the fuselage skin. The interior door handle has moved from approximately 15 degrees aft of the vertical position to approximately 45 degrees forward of the vertical position. The interior handle pushed to the horizontal position, flush with the armrest, will overcenter the door latch.

C.

The cabin doors have a key lock. (1) The key lock turns and moves the pin into the exterior latch handle when the cabin door is closed and the exterior latch handle is flush. NOTE:

It is possible to lock the cabin door when the exterior handle is used and the push rod assembly is not adjusted correctly. The rigging and adjustment procedures must be used to correctly adjust the push rod.

,


52-1 0-00

Page 1

Jun 7/2004



CABIN DOORS - MAINTENANCE PRACTICES 1.

I 2.

General A.

The cabin door maintenance practices give procedures for the removal and installation of the cabin doors, weatherstrip, locks, latches, handles, and cable assemblies.

B.

The cabin door maintenance practices also give procedures for the adjustment and test of the cabin door, latch cable, and inside handle.

C.

An optional Medeco lock is installed on the cabin doors on some airplanes.

Cabin Door Removal/Installation NOTE:

3.

4.

The removal and installation procedures given are for the pilot's door. The procedures for the copilot's door are typical.

A.

Cabin Door Removal (Refer to Figure 201). (1) Open the cabin door. (2) Remove the nut, screw, and spacers from the stop fitting. (3) Remove the nuts and screws that attach the hinges to the fuselage structure. (4) Remove the cabin door from the airplane.

B.

Cabin Door Installation (Refer to Figure 201). (1) Put the cabin door in position and attach the door with the screws and nuts. (2) Install the screw, spacers, and nut on the stop fitting. (3) Close and latch the cabin door. (4) Make sure the cabin door is correctly adjusted. Refer to Cabin Door Adjustment/Test.

Cabin Door Weatherstrip Removal/Installation A.

Cabin Door Weatherstrip Removal (Refer to Figure 201). (1) Use a nonmetallic scraper to remove the weatherstrip and adhesive from the door assembly. (2) Use solvent to remove all remaining adhesive from the door surface.

B.

Cabin Door Weatherstrip Installation (Refer to Figure 201). (1) Cut the new weatherstrip to the correct length with the used weatherstrip as a template. (2) Cut a small notch in the butt ends of the new weatherstrip to let water drain. (3) Put the weatherstrip in position with the notches at the door low point. (4) Apply a thin, smooth layer of EC-1300L, or equivalent adhesive to the two surfaces. (5) Let the adhesive dry until it is tacky. (6) Push the weatherstrip in position. (7) Do not stretch the weatherstrip around the door corners.

Cabin Door Latch Lock Removal/Installation A.

Cabin Door Latch (1) Remove the (2) Remove the (3) Remove the

B.

Cabin Door Latch Lock Installation (Refer to Figure 201). (1) Assemble the locking arm with the locking arm pin. (a) Put one washer on each side of the locking arm. (b) Swage the locking arm pin so there is minimum movement between the parts. (c) Cut the unwanted material from the pin. (2) Put the locking arm pin into the 0.125 inch (3.2 mm) diameter hole at the catch base assembly. (3) Align the hole in the locking arm with the hole in the latch base assembly and install the pin. (4) Put three washers between the cam and the locking arm. (5) Attach the cam to the latch side of the locking arm.

Lock Removal (Refer to Figure 201). cam from the latching side of the locking arm. washers between the cam and the locking arm. locking arm pin from the locking arm and the catch base assembly.


Page 201 Jul 3/2006



A

3

I TOP HING

CLEVIS PIN

DETAIL A RIGHT SIDE SHOWN, LEFT SIDE OPPOSITE NUT WASHER

DETAIL B AIRPLANES WITH STANDARD LOCKS

DETAIL C

0510T1007 A0511R1004 B0511R1005 C0511R1005

Cabin Door Installation Figure 201 (Sheet 1)


Page 202 Jul 3/2006



B230

PIN-

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CABLE ASSEMBLY

PIN PUSHROD

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Page 203 Jul 3/2006



8231

AS NECESSARY FOR GOOD SEAL (TYPICAL ENTIRE PERIMETER)

4.

WEATHERSTRIP

DOOR STRUCTURE

VIEW A-A

WEATHERSTRIP

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0.25 INCH NOTCH

VIEW B-B

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Page 204 Jul 3/2006


MODEL 172

MAINTENANCE MANUAL

B6020

BEND THESE TABS TO MAKE SURE THAT THEY DO NOT TOUCH THE LATCH HOUSING

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COTTER PIN WASHEF LOCKING ARM

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LOCK SHOWN IN UNLOCKED POSITION Cabin Door Installation Figure 201 (Sheet 4)


Page 205 Jul 3/2006



5.

Cabin Door Latch Assembly Removal/Installation A.

Cabin Door Latch Assembly Removal (Refer to Figure 201). (1) Remove the cabin door lock assembly. Refer to Cabin Door Lock Assembly Removal/ Installation. (2) Remove the rivets that attach the latch base to the door skin. (3) Remove the screws that attach the latch to the door pan. (4) Remove the pushrod and bolt. (5) Pull the latch handle through the cutout in the door skin. (6) Remove the latch assembly from the airplane.

B.

Cabin Door Latch Assembly Installation (Refer to Figure 201). (1) Put the latch assembly in the closed position between the door pan and the door skin. (2) Make sure the cable assembly is forward of the latch base attach plate, and inboard of latch base cup. (3) Extend the latch handle through the cutout in the door skin. (4) Push the latch assembly aft so the bolt and pushrod extend through their related holes. (5) Release the pushrod so the bolt is fully extended and the handle is flush. (6) Attach the latch to the door pan with the screws through the base assembly and through the aft flange of the door pan. (7) Make sure the door skin dimension around the latch assembly is correct.

CAUTION: Do not make the holes oversize in the latch base. Drill eleven 0.128 inch (3.25 mm) diameter holes that align with the latch base. Make sure the cabin door latch cable assembly rigging and the cabin door inside handle rigging is done before the latch base is attached to the skin. Refer to Cabin Door Latch Cable Assembly Adjustment/Test and Cabin Door Inside Handle Rigging. (10) Attach the latch base to the door skin with rivets. (11) Install the cabin door lock assembly. Refer to Cabin Door Lock Assembly Removal/Installation. (8) (9)

6.

Cabin Door Latch Cable Assembly Installation A.

Cabin Door Latch Cable Assembly Removal (Refer to Figure 201). (1) Remove the screw and clamp that attach the cable assembly to the door. (2) Remove the plug button. (3) Remove the pin from the pin guide. (4) Pull the pin end of the cable from the top of the door. (5) Remove the nut and clamp from the opposite end of the cable casing. (6) Remove the cable assembly from the door.

B.

Cabin Door Latch Cable Assembly Installation (Refer to Figure 201). (1) Attach the clamp and nut one inch (25 mm) from the end of the cable casing on the pin end of the cable assembly. (2) Put the pin end of the cable between the door pan and the door skin at the aft end of the door. (3) Push the pin end of the cable to the top of the door. (4) Remove the plug button and align the pin of the cable with the pin guide. (5) Put the pin through the pin guide. (6) Align the clamp on the cable casing through the hole that is below the 0.875 inch (22.22 mm) access hole. (7) Install the screw. (8) Make sure the cable operates freely. (a) Add washers as required if the cable does not operate freely. (9) Do the cabin door latch cable assembly rigging. Refer to Cabin Door Latch Cable Assembly Rigging.


Page 206 Jul 3/2006



7.

|

Cabin Door Lock Assembly Removal/Installation (on airplanes with standard locks) A. Cabin Door Lock Assembly Removal (Refer to Figure 201). (1) Remove the lower door accent and main door to get access to the cabin door lock assembly. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (2) Remove the armrest door plugs, door insert, armrest, door handle, and cover plate from the door to get access to the cabin door lock assembly. (3) Remove the nut and washer. (4) Remove the cabin door lock assembly. B.

Cabin Door Lock Assembly Installation (Refer to Figure 201). (1) Put the cabin door lock assembly in position. (2) Install the washer and nut. (3) Install the armrest door plugs, door insert, armrest, door handle and cover plate. (4) Install the lower door accent and main door . Refer to Chapter 25, Interior Upholstery - Maintenance Practices.

8.

9.

Cabin Door Lock Assembly Removal/Installation (on airplanes with Medeco locks) A.

Cabin Door Lock Assembly Removal (Refer to Figure 201). (1) Remove the lower door accent and main door to get access to the cabin door lock assembly. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (2) Remove the armrest door plugs, door insert, armrest, door handle, and cover plate from the door to get access to the cabin door lock assembly. (3) Remove the cotter pin, washer, locking arm, and spacer from the lock assembly. (4) Remove the hex nut and the anti-rotational washer that attach the lock tumbler assembly to the door structure and the cam assembly. (5) Remove the lock assembly from the door.

B.

Cabin Door Lock Assembly Installation (Refer to Figure 201). (1) Put the cabin door lock assembly in position on the cabin door. (2) Install the hex nut and the anti-rotational washer that attach the lock tumbler assembly to the door structure and the cam assembly. Make sure that the anti-rotational washer is installed under the hex nut. (3) Torque the nut. (4) Bend the applicable tab on the anti-rotational washer against the flat part of the nut. (5) Install the spacer, locking arm, washer, and cotter pin that connect the lock assembly to the door handle. (6) Bend the applicable tabs on the cam-pin assembly to make sure that they do not touch the latch housing. (7) Install the armrest door plugs, door insert, armrest, door handle, and cover plate. (8) Install the lower door accent and the main door . Refer to Chapter 25, Interior Upholstery - Maintenance Practices.

Cabin Door Lock Cam Assembly Removal/Installation (on airplanes with standard locks) A.

Cabin Door Lock Cam Assembly Removal (Refer to Figure 201). (1) Remove the lower door accent and the main door to get access to the cabin door lock cam assembly. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (2) Remove the armrest door plugs, door insert, armrest, door handle, and cover plate from the door to get access to the cabin door lock cam assembly. (3) Remove the cam stop screw from the cabin door lock cam assembly. (4) Remove the cam assembly.

B.

Cabin Door Lock Cam Assembly Installation (Refer to Figure 201). (1) Put the cam assembly in position. Install the cam stop screw with Loctite 242. (2) (3) Install the armrest door plugs, door insert, armrest, door handle and cover plate. (4) Install the lower door accent and main door . Refer to Chapter 25, Interior Upholstery - Maintenance Practices.


Page 207 Jul 3/2006



10.

11.

Cabin Door Lock Cam Assembly Removal/Installation (on airplanes with Medeco locks) A.

Cabin Door Lock Cam Assembly Removal (Refer to Figure 201). (1) Remove the lower door accent and main door to get access to the cabin door lock cam assembly. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (2) Remove the armrest door plugs, door insert, armrest, door handle, and cover plate from the door to get access to the cabin door lock cam assembly. (3) Remove the machine screws, serrated washers, and retaining washer from the cabin door lock cam assembly. (4) Remove the cam assembly.

B.

Cabin Door Lock Cam Assembly Installation (Refer to Figure 201). (1) Put the cam assembly in position. (2) Install the machine screws, serrated washers, and retaining washer that attach the cam assembly to the cabin door lock. Install the machine screws with Loctite 242. (3) Install the armrest door plugs, door insert, armrest, door handle, and cover plate. (4) Install the lower door accent and main door . Refer to Chapter 25, Interior Upholstery - Maintenance Practices.

Cabin Door Adjustment/Test A.

Adjust the new cabin doors.

CAUTION: Do not adjust the bonded door flange or the airplane structure with force. Damage to the bonded areas and the structural components can occur. (1) Trim the door flange as required to get a gap between the door skin and fuselage skin of 0.09 inch (2.3 mm) or less. B.

Adjust the cabin doors. NOTE:

The cabin doors must be smooth with the fuselage skin.

(1) Use the slots at the door latch plate to adjust the latch assembly and the bolt engagement with the rotary clutch on the door post. 12.

Cabin Door Latch Cable Assembly Rigging A.

Do the Cabin Door Latch Cable Assembly Rigging (Refer to Figure 201). (1) Pull the cable tight. (2) Attach the clamp and the nut to the cable so it aligns with the 0.193 inch (4.9 mm) diameter hole in the door pan. (3) Make sure the door latch is open. (4) Cut the casing of the cable assembly approximately two inches (50 mm) from the clamp bolt on the push rod assembly. (5) Put the core of the cable through the clamp. (6) Pull the core of the cable through the clamp bolt so the pin extends approximately 0.125 inch (3.2 mm) from the door pan contour. (7) Cut the core of the cable approximately one inch (25 mm) forward of the push rod clamp. (8) Attach the two nuts to the push rod clamp bolt. (9) Make sure the latch operates freely. (a) Remove the cable core from the clamp and operate the latch if the latch binds and will not operate freely. (b) Do a check of the cable for possible adjustments that will make the operation easier. (10) Install the cover assembly and do another check of the cable operation.


Page 208 Jul 3/2006



13.

Latch Assembly Adjustment/Test A.

Do the adjustment of the latch assembly. (Refer to Figure 201). (1) Make sure the cabin door is installed and fitted to the fuselage before the adjustment/test can be done. (2) Make sure the cabin door latch is in the OPEN position before the adjustment/test can be done. (3) Make sure the door latch operates smoothly and freely. (4) Make sure the bolt or pull bar are not filed, ground or sanded in any way. NOTE: (5)

Install shims to adjust the striker plate forward to give a minimal clearance between the bolt and the striker plate. NOTE:

(6)

A noise can be heard when the inside handle is pushed down. It is recommended that the outside door handle be flush with the door skin, although the noise is heard.

This adjustment will make sure the pushrod will engage the latch catch. It will also make sure the exterior handle will stay open until the door is closed again when the door is opened from the outside.

Install shims as required, beneath the actuator on the cover assembly. NOTE:

If the cabin door is too far forward for correct operation of the door latch, the latch assembly pushrod will not let the bolt move.

Close the cabin door. Make sure the exterior handle is flush with the door skin when the door is closed. (a) Adjust the push-pull rod out, if the exterior handle is not flush with the door skin when the door is closed. 1 Remove the screws and nuts that attach the base plate to the door. 2 Remove the smaller end of the push-pull rod and turn it 180 degrees. 3 Install the screws and nuts that attach the base plate. (9) Do a check for slippage between the cable casing and clamps that attach the cable. (10) Install the cotter pin in the clevis pin. (7) (8)


Page 209 Jul 3/2006


MODEL 172 MAINTENANCE MANUAL BAGGAGE DOOR - MAINTENANCE PRACTICES 1.

2.

3.

4.

General A.

A baggage door is installed on the left side of the airplane, aft of the cabin door. The baggage door allows access into the baggage area and into the tailcone.

B.

A rubber weatherstrip is cemented around the edge of the baggage door. It seals the door to the fuselage structure when the door is closed.

C.

An optional Medeco lock is installed on the baggage door on some airplanes.

Baggage Door Removal/Installation A.

Baggage Door Removal (Refer to Figure 201). (1) Open the baggage door. (2) Disconnect the doorstop chain. (3) Remove the upholstery from the door. (4) Remove the bolts that attach the door to the hinges.

B.

Baggage Door Installation (Refer to Figure 201). (1) Put the baggage door in position on the hinges and attach it with the bolts. (2) Install the upholstery to the door. (3) Connect the door stop chain. (4) Close the baggage door and do a check for smooth operation.

Baggage Door Weatherstrip Removal/Installation A.

Baggage Door Weatherstrip Removal (Refer to Figure 201).. (1) Remove the baggage door. (2) With a nonmetallic scraper, remove the seal and adhesive from the baggage door. (3) Remove the adhesive residue and clean the door seal area with DeSoclean 110 Solvent. (4) Install the baggage door.

B.

Baggage Door Weatherstrip Installation (Refer to Figure 201).. (1) With the old seal or the door seal area of the baggage door as a pattern, measure and cut the new seal to length. (2) Apply a thin, even coat of RTV157 Adhesive around the circumference of the door seal area of the baggage door. (3) Make sure that you do not stretch the seal around the corners of the door. (4) Push the new seal into the adhesive. Let the adhesive cure in accordance with the manufacturer's instructions, and make sure that the seal is completely adhered to the door with no gaps between the seal and the door.

Baggage Door Weatherstrip Inspection A.

Do an Inspection of the Baggage Door Weatherstrip. (1) Put a 4-inch by 11-inch piece of paper between the baggage doorframe and the baggage door. Close the baggage door. Slowly pull on the paper to make sure that there is seal tension. Move the paper around the perimeter of the door to do a test of the door seal tension. (2) Remove the paper from the doorframe. Make sure that the baggage door is closed. Pour a gallon of water over the door and tailcone doorframe. After the water no longer drips, open the door and do an inspection for leaks. (3) If any leaks are found, towel dry the upholstery with a clean, dry towel. Install the weatherstrip again as necessary to make sure that there are no leaks around the seal area of the baggage door. (4) If necessary, apply U064158 Aerodynamic Filler Compound before you install the seal. Sand and do a touch-up of the paint as necessary.


Page 201 Jul 3/2006



8113

A

STRIKER PLATE

DETAIL C

A iGAGE )R

b BOLT LATCH AQCCQfMPI V

DOOR HINGE

LUJ'-r\

ASSEMBLY

A

DETAIL

B

DETAIL AIRPLANES WITH STANDARD LOCK

0512T1004 A0512T1006 B0512T1005 C0512T1007

Baggage Door Installation Figure 201 (Sheet 1)


Page 202 Jul 3/2006


MODEL 172

MAINTENANCE MANUAL

B6019

B DCKE

K

VIEW A-A AIRPLANES WITH MEDECO LOCK

HEX NUT

LATCH ASSEMBLY

-1

LOCK TUMBLER ASSEMBLY

VIEW B-B LOCK SHOWN IN LOCKED POSITION

AA0711T1048 BB071 1T1048

Baggage Door Installation Figure 201 (Sheet 2)

52-30-00 O Cessna Aircraft Company

Page 203 Jul 3/2006



5.

6.

Baggage Door Lock Assembly Removal/Installation (On airplanes with Medeco lock) A.

Baggage Door Lock Assembly Removal (Refer to Figure 201). (1) Remove the baggage door to get access to the baggage door lock assembly. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (2) Remove the 0.75-inch hex nut and the anti-rotational washer that attach the lock tumbler assembly to the door structure and the cam assembly. (3) Remove the lock assembly from the door.

B.

Baggage Door Lock Assembly Installation (Refer to Figure 201). (1) Put the baggage door lock assembly in position on the baggage door. (2) Install the 0.75-inch hex nut and the anti-rotational washer that attach the lock tumbler assembly to the door structure and the cam assembly. Make sure that the anti-rotational washer is installed under the 0.75-inch hex nut. (3) Torque the nut. (4) Bend the applicable tab on the anti-rotational washer against the flat part of the nut. (5) Install the baggage door to the baggage door. Refer to Chapter 25, Interior Upholstery Maintenance Practices.

Baggage Door Lock Cam Assembly Removal/Installation (On airplanes with Medeco lock) A.

Baggage Door Lock Cam Assembly Removal (Refer to Figure 201). (1) Remove the baggage door to get access to the baggage door lock assembly. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (2) Remove the hex nut and the serrated washer that attach the cam assembly to the baggage door lock. (3) Remove the cam assembly.

B.

Baggage Door Lock Cam Assembly Installation (Refer to Figure 201). (1) Put the cam assembly in position. (2) Install the hex nut and the serrated washer that attach the cam assembly to the baggage door lock. Install the hex nut with Loctite 242. (3) Install the baggage door to the baggage door. Refer to Chapter 25, Interior Upholstery Maintenance Practices.


Page 204 Jul 3/2006

CHAPTER

STABILIZERS




PAGE

DATE

55-00-00

Page 1

Apr 7/2003

55-10-00

Pages 201-202

Apr 7/2003

55-30-00

Pages 201-202

Apr 7/2003



Page 1of 1 Apr 7/2003


Page Number

Issue Date

By

Date Removed

By


MODEL 172

MAINTENANCE MANUAL

CONTENTS STABILIZERS - GENERAL .......................................................

Scope ..................................................................... Definition .................................................................. HORIZONTAL STABILIZER- MAINTENANCE PRACTICES.......................... General ....................................................................

Horizontal Stabilizer Removal/Installation ..................................... VERTICAL STABILIZER FIN - MAINTENANCE PRACTICES ........................

G eneral .................................................................... Vertical Stabilizer Fin Removal/Installation..................................

55-00-00 Page 1 55-00-00 Page 1 55-00-00 Page 1 55-10-00 Page 201 55-10-00 Page 201 55-10-00 Page 201 55-30-00 Page 201 55-30-00 Page 201 55-30-00 Page 201


Page 1 of 1 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL STABILIZERS - GENERAL 1.

Scope A.

2.

This chapter provides maintenance information on the horizontal and vertical stabilizer.

Definition A. B.

The section on horizontal stabilizer provides instructions for removal and installation of the horizontal stabilizer. The section on vertical stabilizer fin provides instructions for removal and installation on the vertical stabilizer fin.


Page 1 55-00-00 Apr 7/2003



HORIZONTAL STABILIZER - MAINTENANCE PRACTICES 1.

2.

General A.

The horizontal stabilizer is primarily of all-metal construction, consisting of ribs and spars covered with skin. A formed metal leading edge is riveted to the assembly to complete the structure. The elevator trim tab actuator is contained within the horizontal stabilizer. The underside of the stabilizer contains a covered opening which provides access to the actuator. Hinges are located on the rear spar assembly to the elevators.

B.

This section provides removal and installation instructions for the horizontal stabilizer.

Horizontal Stabilizer Removal/Installation A.

Remove Horizontal Stabilizer (Refer to Figure 201). (1) Remove elevators. Refer to Chapter 27, Elevator Control System- Maintenance Practices. (2) Remove rudder. Refer to Chapter 27, Rudder Control System - Maintenance Practices. (3) Remove vertical stabilizer. Refer to Vertical Stabilizer - Maintenance Practices. (4) Disconnect elevator trim control cables at clevis and turnbuckle inside tailcone. (5) Remove pulleys which route the aft cables into horizontal stabilizer, and pull cables out of tailcone. (6) Remove bolts securing horizontal stabilizer to fuselage. NOTE: (7)

B.

Note the order in which any spacers or shims are removed for reinstallation.

Remove horizontal stabilizer.

Install Horizontal Stabilizer (Refer to Figure 201). (1) Install horizontal stabilizer to fuselage using bolts. NOTE: (2) (3) (4) (5) (6)

Reinstall any spacers and shims in the exact order in which they were removed.

Reroute cables into tailcone and install pulleys. Reconnect elevator trim control cables at clevis and turnbuckle inside tailcone. Install vertical stabilizer. Refer to Vertical Stabilizer - Maintenance Practices. Install rudder. Refer to Chapter 27, Rudder Control System - Maintenance Practices. Install elevators. Refer to Chapter 27, Elevator Control System - Maintenance Practices.


Page 201 Apr 7/2003



B232

A

UPPER RIGHT FAIRING

B

UPPER LEFT FAIRING

HORIZONTAL LIZER

FORWARD RIGHT FAIRING

, FORWARD LEFT FAIRING

STABILIZER TIP

OUTBOARD ELEVATOR HINGE

BRACKET

DETAIL

A

BUSHING

DETAIL C INBOARD ELEVATOR HINGE

DETAIL B

BUSHING 0532T1004 A0532T1003 B0532T1003 C0532T1002

Horizontal Stabilizer Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL VERTICAL STABILIZER FIN - MAINTENANCE PRACTICES 1.

2.

General A.

The vertical stabilizer fin is of metal construction, consisting of ribs and spars covered with aluminum skin. The trailing edge of the fin contains three hinges used to attach the rudder.

B.

Maintenance practices consist of removal and installation of the vertical stabilizer fin.

Vertical Stabilizer Fin Removal/Installation A.

Remove Vertical Stabilizer Fin (Refer to Figure 201). (1) Remove rudder. Refer to Chapter 27, Rudder Control System - Maintenance Practices. (2) Remove upper left and upper right fairings. (3) Disconnect all electrical, navigation light, and antenna leads from base of fin area. (4) Remove screws attaching dorsal to fin. (5) Disconnect elevator cable from elevator bellcrank. (6) Remove bolts and shims (if installed) attaching fin rear spar to fuselage fitting. (7) Remove upper elevator stop bolt. (8) Remove bolts attaching fin front spar to fuselage bulkhead and remove fin from fuselage.

B.

Install Vertical Stabilizer Fin (Refer to Figure 201). (1) Place fin on fuselage and secure front spar of fin to fuselage. (2) Install upper elevator stop bolt. (3) Attach fin rear spar to fuselage fitting using shims (if required) and bolts NOTE:

If new fin is being installed, gap between the fin rear spar and the fuselage fitting should not exceed 0.030 inch. If gap exceeds this dimension, it is permissible to use one shim per bolt to obtain desired clearance. Use the following chart for shim part numbers:

Gap between fitting and spar

Shim Thickness

Shim Part Number

0.030 to 0.050 inch

0.020 inch

0531115-1

0.050 to 0.070 inch

0.040 inch

0531115-2

(4) (5) (6) (7)

(8)

Connect elevator cable to elevator bellcrank. Secure dorsal to fin using screws. Reconnect all electrical, navigation, and antenna leads. Install upper left and upper right fairings. Install rudder. Refer to Chapter 27, Rudder Control System - Maintenance Practices.


Page 201 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL . .B112

NOTE:

UPPER RUDDER IINGE

FAIRING AND DORSAL FIN ARE RIVETED TO FUSELAGE.

FIN TIP

DORSAL

DETAIL A

CENTER

FAIRING

FIN ASSEMBLY

NUTPLATES UPPER RIGHT FAIRING

AILB LOWER RUDDER HINGE SHIM

WASHER FUSELAGE

FAIRING

DETAIL C 0560T1012 A0560T1006 B0560T1007 C0560T1008

Vertical Stabilizer Fin Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003

CHAPTER

WINDOWS




PAGE

DATE

56-00-00

Pages 1-2

Jan 2/2006

56-00-01

Pages 1-2

Apr 7/2003

56-10-00

Pages 201-202

Apr 7/2003

56-20-00

Pages 201-202

Apr 7/2003

56-30-00

Pages 201-202

Apr 7/2003





Page Number

Issue Date

By

Date Removed

By



CONTENTS WINDOWS - GENERAL ..........................................................

Scope...................................................................... Tools, Equipment and Materials .............................................. Definition ................................................................... WINDSHIELDS AND WINDOWS - DESCRIPTION AND OPERATION ................ General .................................................................... Tools, Equipment and Materials .............................................. Cleaning Instructions........................................................ Windshield and Window Preventive Maintenance .............................. Windshield and Window Installation Techniques ............................... Windshield Rain Repellent................................................... WINDSHIELD - MAINTENANCE PRACTICES...................................... General .................................................................... Windshield Removal/Installation.............................................. Temporary Repairs .......................................................... CABIN WINDOWS - MAINTENANCE PRACTICES ................................. G en era l .................................................................... Rear Window Removal/Installation............................................ Side Window Removal/Installation ............................................ CABIN DOOR WINDOWS - MAINTENANCE PRACTICES .......................... General .................................................................... Cabin Door Window Removal/Installation .....................................

56-00-00 56-00-00 56-00-00 56-00-00

1 1 1 2

56-00-01 Page 1 56-00-01 Page 1 56-00-01 Page 1 56-00-01 Page 1 56-00-01 Page 1 56-00-01 Page 2 56-00-01 Page 2 56-10-00 Page 201 56-10-00 Page 201 56-10-00 Page 201 56-10-00 Page 201 56-20-00 56-20-00 56-20-00 56-20-00


56-30-00 Page 201 56-30-00 Page 201 56-30-00 Page 201


Page Page Page Page



MODEL 172 MAINTENANCE MANUAL WINDOWS - GENERAL 1.

Scope A.

2.

This chapter provides information on windows used throughout the airplane.

Tools, Equipment and Materials NOTE:

Equivalent substitutes may be used for the following listed items:

NAME

NUMBER

Mild Soap or Detergent (hand dishwashing type without abrasives)

MANUFACTURER

USE

Commercially Available

To clean windshields and windows.

Aliphatic Naphtha

Type II Federal Specification TT-N-95


To remove deposits from windshields and windows.

Novus

Number 1


To clean acrylic windshields and windows.

Novus

Number 2


To remove minor surface scratches in acrylic windshields and windows.

Novus

Number 3


To remove heavy scratches and abrasions in acrylic windshields and windows.

Mirror Glaze

MGH-7

Meguiars Mirror Bright Polish 210 N First Ave. Arcadia, CA 91006

To clean and polish acrylic windshields and windows.


To apply and remove wax and polish.

Soft cloth, such as: Cotton flannel or cotton terry cloth Windshield sealant tape

U000927S

Available from Cessna Parts Distribution Cessna Aircraft Company Department 701 5800 E. Pawnee Rd. Wichita, KS 67218-5590

To seal windshield.

Repcon rain repellent

6850-00-1395297

Unelko Corporation 7428 East Karen Drive Scottsdale, Arizona 85260

To repell rain from windshield.


Page 1

Jan 2/2006



3.

Definition A.

This chapter is divided into sections and subsections to assist maintenance personnel in locating specific systems and information. The following is a brief description of each section. For locating information within the chapter, refer to the Table of Contents at the beginning of the chapter. (1) The section on windshields and windows provides installation notes and precautions applicable to the entire chapter. (2) The section on flight compartment windows provides maintenance instructions for repair and replacement of the windshield. (3) The section on cabin windows provides maintenance instructions for the cabin side and cabin rear windows. (4) The section on door windows provides maintenance instructions for openable windows located in the cabin doors.


Page 2

Jan 2/2006


MODEL 172

MAINTENANCE MANUAL WINDSHIELDS AND WINDOWS - DESCRIPTION AND OPERATION 1.

General A.

2.

Tools, Equipment and Materials A.

3.

This section provides instructions and tips for cleaning and installing windshields and windows used in the airplane.

For a list of required tools, equipment and materials, refer to Windows - General.

Cleaning Instructions

CAUTION: WINDSHIELDS AND WINDOWS (ACRYLIC-FACED) ARE EASILY DAMAGED BY IMPROPER HANDLING AND CLEANING TECHNIQUES. CAUTION: DO NOT USE METHANOL, DENATURED ALCOHOL, GASOLINE, BENZENE, XYLENE, METHYL N-PROPYL KETONE, ACETONE, CARBON TETRACHLORIDE, LACQUER THINNERS, COMMERCIAL OR HOUSEHOLD WINDOW CLEANING SPRAYS ON WINDSHIELDS OR WINDOWS. A.

Instructions For Cleaning. (1) Place airplane inside hangar or in shaded area and allow to cool from heat of suns direct rays. (2) Using clean (preferably running) water, flood the surface. Use bare hands with no jewelry to feel and dislodge any dirt or abrasive materials. (3) Using a mild soap or detergent (such as a dishwashing liquid) in water, wash the surface. Again use only the bare hand to provide rubbing force. (A clean cloth may be used to transfer the soap solution to the surface, but extreme care must be exercised to prevent scratching the surface.) (4) When contaminants on acrylic windshields and windows cannot be removed by a mild detergent, Type II aliphatic naphtha, applied with a soft clean cloth, may be used as a cleaning solvent. Be sure to frequently refold cloth to avoid redepositing contaminants and/or scratching windshield with any abrasive particles. (5) Rinse surface thoroughly with clean fresh water and dry with a clean cloth. (6) Hard polishing wax should be applied to acrylic surfaces. (The wax has an index of refraction nearly the same as transparent acrylic and will tend to mask any shallow scratches on the windshield surface). (7) Acrylic surfaces may be polished using a polish meeting Federal Specification P-P-560 applied per the manufacturers instructions. NOTE:

4.

When applying and removing wax and polish, use a clean, soft cloth, such as cotton or cotton flannel.

Windshield and Window Preventive Maintenance NOTE: A.

Utilization of the following techniques will help minimize windshield and window crazing.

General Notes and Techniques For Acrylic Windshields. (1) Keep all surfaces of windshields and windows clean. (2) If desired, wax acrylic surfaces. (3) Carefully cover all surfaces during any painting, powerplant cleaning or other procedure that calls for use of any type of solvents or chemicals. (4) Do not park or store airplane where it might be subjected to direct with or vapors from: methanol, denatured alcohol, gasoline, benzene, xylene, methyl n-propyl ketone, acetone, carbon tetrachloride, lacquer thinners, commercial or household window cleaning sprays, paint strippers, or other types of solvents.


Page 1 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL (5) Do not leave sun visors up against windshield when not in use. The reflected heat from these items causes elevated temperatures on the windshield. If solar screens are installed on the inside of the airplane, make sure they are the silver appearing, reflective type. (6) Do not use a power drill motor or other powered device to clean, polish, or wax surfaces. 5.

Windshield and Window Installation Techniques A.

Installation Techniques. (1) Special drills must be used when drilling holes in acrylic. Standard drills will cause the hole to be oversized, distorted, or excessively chipped. (2) Whenever possible, a coolant such as a plastic drilling wax should be used to lubricate the drill bit. (3) Drilled holes should be smooth with a finish of 125 rms (root mean square). (4) The feed and speed of the drill is critical. Refer to Table 1 for thickness verses drill speed information.

Table 1. Material Thickness vs. Drill Speed

Thickness (in inches)

Drill Speed (RPM)

0.062 to 0.1875

1500 to 4500

0.250 to 0.375

1500 to 2000

0.4375

1000 to 1500

0.500

500 to 1000

0.750

500 to 800

1.00

500

(5) In addition to feed and speed of the drill bit, the tip configuration is of special importance when drilling through acrylic windows and windshields. Tip configuration varies with hole depth, and the following information applies when drilling through acrylic: (a) Shallow Holes - When hole depth to hole diameter ratio is less than 1.5 to 1, the drill shall have an included tip angle of 55 degrees to 60 degrees and a lip clearance angle of 15 degrees to 20 degrees. (b) Medium Deep Holes - When hole depth to hole diameter ratio is from 1.5 to 1 up to 3 to 1, the drill shall have an included tip angle of 60 degrees to 140 degrees and a lip clearance angle of 15 degrees to 20 degrees. (c) Deep Holes - when hole depth of hole diameter ratio is greater than 3.0 to 1,the drill shall have an included tip angle of 140 degrees and a lip clearance of 12 degrees to 15 degrees. (6) Parts which must have holes drilled shall be backed up with a drill fixture. Holes may be drilled through the part from one side. However, less chipping around holes will occur if holes are drilled by drilling the holes from both sides. This is accomplished by using a drill with an acrylic backup piece on the opposite side. Remove the drill from the hole and switch the backup plate and finish drilling from the opposite side. 6.

Windshield Rain Repellent A.

Repcon is a rain repellent and surface conditioner that may be used to increase the natural cleaning of the windshield during rain. Apply in accordance with manufacturers instructions.


Page 2 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL WINDSHIELD - MAINTENANCE PRACTICES

1.

General A.

2.

This section provides instructions for removal and installation of the window as well as repair techniques applicable to acrylic windshields and windows.

Windshield Removal/Installation A.

Remove Windshield (Refer to Figure 201). (1) Remove wing fairings. (2) Remove air vent tubes. (3) Drill out rivets securing front retainer strip. CAUTION:

B.

3.

IF WINDSHIELD IS TO BE REINSTALLED, PROTECT WINDSHIELD DURING REMOVAL.

BE

SURE TO

(4) Pull windshield straight forward, out of side and top retainers. Remove top retainer if necessary. (5) Clean sealer from inner sidewalls and bottom of retainers. Install Windshield (Refer to Figure 201). (1) If windshield is to be reinstalled, clean off old sealer and felt, then install new felt around edges of windshield. (2) If new windshield is to be installed, remove protective cover and clean. (3) Apply new felt to edges of windshield. (4) Apply windshield sealant tape along the sides and bottom of felt. Refer to Windows - General for a list of sealant tape. (5) Position the bottom edge of windshield against deck skin. (6) Using a piece of bent sheet metal (8 inches wide x length of top edge of windshield) placed under top edge of upper retainer, bow windshield and guide top edge of windshield into upper retainer using bent sheet metal in a shoe horn effect. (7) Secure front retainer strip using rivets. (8) Install air vent tube. (9) Install wing fairings.

Temporary Repairs A.

Temporary repairs to windshields and windows can be accomplished using techniques illustrated and described in the Single Engine Structural Repair Manual, Chapter 56, Plastic Window Surface Repair.


Page 201 Apr 7/2003



B1

OUTER

FELT

INNER RETAINER

DETAIL A

jOUTER RETAINER

FELT SEAL

RETAINER

DETAILD

DETAIL

D

0510T1007 A0511T3002 B0511T3002 C0511T3002 D0511T3002

RETAINER

DETAIL C Windshield Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL CABIN WINDOWS - MAINTENANCE PRACTICES 1.

General A.

2.

3.

The airplane is equipped with two side windows and a rear window, all located in the rear cabin area. Maintenance practices are limited to removal and installation of the windows. For instructions on temporary repair, refer to Windshield - Maintenance Practices.

Rear Window Removal/Installation A.

Remove Rear Window (Refer to Figure 201). (1) Remove external center strip retainer. (2) Remove upholstery as necessary to expose retainer strips inside cabin. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (3) Drill out rivets as necessary to remove outer retainer strip along aft edge of window. (4) Remove window by lifting aft edge and pulling window aft. If difficulty is encountered, rivets securing retainer strips inside cabin may also be drilled out and retainer strips loosened or removed.

B.

Install Rear Window (Refer to Figure 201). (1) If old window is being reinstalled, remove all traces of old sealant from window. (2) Clean out channels and retainers to remove all traces of old sealant. (3) Check fit and carefully file or grind away excess plastic. (4) Apply felt strip and sealant to all edges of window to prevent leaks. (5) Reinstall rear window to airplane and secure using retainer strips and rivets. (6) Install upholstery. Refer to Chapter 25, Interior Upholstery - Maintenance Practices.

Side Window Removal/nstallation A. Remove Side Window (Refer to Figure 201 ). (1) Remove upholstery as required to gain access to retainer strips inside cabin. Refer to Chapter 25, Interior Upholstery - Maintenance Practices. (2) Drill out rivets securing retainer strips to airplane. B. Install Side Window (Refer to Figure 201). (1) If old window is being reinstalled, remove all traces of old sealant from window. (2) Clean out channels and retainers to remove all traces of old sealant. (3) Apply felt strip and sealant to all edges of window to prevent leaks. (4) Reinstall retainer strips using rivets. (5) Reinstall upholstery. Refer to Chapter 25, Interior Upholstery - Maintenance Practices.


Page 201 Apr 7/2003



B1784

IAREAR 1 KI r%/r'%AI

SIDE WINDOW

0512T4001

Cabin Windows Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL CABIN DOOR WINDOWS - MAINTENANCE PRACTICES 1.

General A.

2.

This maintenance practices section consists of removal and installation of the hinged windows located in each door. For instructions on temporary repair to the cabin door windows, refer to Windshield Maintenance Practices.

Cabin Door Window Removal/Installation A.

Remove Cabin Door Window (Refer to Figure 201). (1) Disconnect arm from window assembly. (2) Remove hinge pins from hinge.

B.

Install Cabin Door Window (Refer to Figure 201). (1) Position window assembly to door. (2) Secure window assembly to hinge using hinge pin.


Page 201 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL

B1

LATCH BRACKET

WINDOW ASSEMBLY

DETAIL B

HINGE ASSEMBLY

ARM

DETAIL

A 0510T1007 A0511T3001 B0511T1002

Cabin Door Window Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003

CHAPTER

WINGS




PAGE

DATE

57-00-00

Page 1

Apr 7/2003

57-10-00

Pages 201-206

Apr 7/2003





Page Number

Issue Date

By

Date Removed

By


MODEL 172

MAINTENANCE MANUAL

CONTENTS W INGS - GENERAL..........

..................................................

S cope...................................................................... Tools, Equipment and Materials .............................................. Definition ................................................................... WINGS AND WING STRUTS - MAINTENANCE PRACTICES........................ Description and Operation ................................................... Wing and Strut Removal/Installation .......................................... Adjustment (Correcting Wing Heavy Conditions) ............................... Strut Damage and Repair Criteria ............................................ Wing Tip Removal/Installation ................................................

57-00-00 57-00-00 57-00-00 57-00-00 57-10-00 57-10-00 57-10-00 57-10-00 57-10-00 57-10-00


Page Page Page Page


1 1 1 1

201 201 201 204 205 205



MODEL 172 MAINTENANCE MANUAL WINGS - GENERAL 1.

Scope A.

2.

This chapter provides instructions on wing removal and installation. Information and repair procedures beyond the scope of this chapter can be found in the Single Engine 1996 and On Structural Repair Manual.


Equivalent substitutes may be used for the following listed items:

NAME

NUMBER

MANUFACTURER

USE

Grease

MIL-G-21164

E/M Corporation Box 2200 Highway 52 N.W. West Lafayette, IN 47906

To lubricate wing attach fittings and bolts upon reinstallation.

3.

Definition A.

This chapter contains a single section on wing removal, installation and adjustment.


57-00-00 Page 1 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL WINGS AND WING STRUTS - MAINTENANCE PRACTICES 1.

2.


Each metal wing is a strut braced type, with two main spars and suitable ribs for the attachment of the skin. Skin s are riveted to ribs, spars and stringers to complete the structure. An all metal, piano hinged aileron, flap and detachable wing tip are mounted on each wing assembly. Each wing also incorporates an integral fuel bay located between the two spars at the inboard portion of the wing. Each wing is ed in position by a single lift strut which consists of a streamlined tube riveted to two end fittings for attachment at the wing and at the fuselage.

B.

For a skeletal view of the wing assembly, refer to Chapter 6, Airplane Stations - Description and Operation, Figure 2.

Wing and Strut Removal/Installation A.

Remove Wing and Strut (Refer to Figure 201). NOTE:

Wings are most easily removed if four people are available to handle the wing. Otherwise, the wing should be ed with a sling or maintenance stand when the fasteners are loosened.

(1) Remove fasteners from fairings at wing/fuselage intersections. (2) Remove inspection plates as required to allow for disconnection of all electrical, mechanical and fuel connections. (3) Drain fuel from wing. (4) Disconnect electrical wires at wing root disconnects. (5) Disconnect fuel lines at wing root. (6) On left wing, disconnect pitot line. (7) Disconnect fresh air distribution duct at wing root. (8) Loosen and disconnect aileron cables at aileron bellcrank. (9) Disconnect flap cables at turnbuckle above cabin headliner, and pull cables into wing root area. NOTE:

To ease rerouting of cables, a guide wire may be attached to each cable before it is pulled free from the wing. Cable may then be disconnected from the guide wire. Leave the guide wire routed through the wing; it will be reattached to the cable during installation and used to pull the cable into place.

(10) Remove screws from strut fairings and slide fairings toward center of strut. (11) wing at outboard end. Remove strut-to-wing attach bolt and strut-to-fuselage attach bolt. (12) Remove strut from between wing and fuselage. NOTE:

Tape flaps in the streamlined position during wing removal. This will prevent flap movement during handling.

(13) Mark position of wing attachment eccentric bushings in relationship to fittings. These bushings are used to rig out wing heaviness, and if bushings are not marked, wings may require readjustment at installation. (14) Remove nuts, washers, bushings and bolts attaching wing spars to fuselage. NOTE:

It may be necessary to rock the wings slightly and/or to use a long drift punch to remove attaching bolts.

(15) Remove wing and lay on padded stand.


Page 201 Apr 7/2003


MODE

172

MAINTENANCE MANUAL

B234

WASHERS

NUT

LOWER REAR FAIRING

ECCENTRIC BUSHINGS

A

FAIRING

DETAIL A WING FLAP

AILERC

FUEL FILLER CAP COURTESY LIGHT

G TIP

WASHERS

NAVIGATION AND STROBE LIGHTS

BOLT NUT

DETAIL

B

0520T2001 A0520T1003 B0520T1002

Wing Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003



B233

NOTE:

LUBRICATE BOLT AND HOLE PRIOR TO INSTALLATION

A TIE-DOWN RING

SCREW

LOWER FAIRING FAIRING

SPACER

WING STRUT

WING WING STRUT STRUT

ATTACHMENT

RING FUSEL ATTAC FITTING

DETAIL DETAIL B

A 0520T1006 0520T 1006 0520T1006 A0520T1006 B0520T1006

BOLT (NOTE) Wing Installation Figure 201 (Sheet 2)


Page 203 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL B.

Install Wing and Strut (Refer to Figure 201). (1) Hold wing in position and install bolts, bushings, washers and nuts attaching wing spars to fuselage fittings. Ensure eccentric bushings are positioned as marked. NOTE:

Lightly lubricate wing attach bolts and holes with MIL-G-21164 grease before installing bolts.

CAUTION: DO NOT LUBRICATE THE THREADS OF THE BOLTS. (2) Torque front wing spar bolts from 300 to 690 inch pounds. Torque rear wing spar bolts from 300 to 500 inch pounds. (3) Position upper and lower strut fairings on strut. NOTE:

Wrap wing strut using 3MY8671 polyurethane tape (1 inch wide) centered at point where cuff terminates.

(4) Install bolts, spacers and nuts to secure upper and lower ends of wing strut to wing and fuselage fittings. Torque nuts to 480 to 690 inch-pounds. NOTE:

Lightly lubricate bolts and holes with MIL-G-21164 grease before installing bolts.

CAUTION: DO NOT LUBRICATE THE THREADS OF THE BOLTS. (5) (6) (7) (8) (9) (10) (11) (12) 3.

Route flap and aileron cables, using guide wires. Reconnect all fuel, electrical and mechanical connections removed above. Rig flap system. Refer to Chapter 27, Flap Control System - Maintenance Practices. Rig aileron systems. Refer to Chapter 27, Aileron Control System - Maintenance Practices. Refuel wing tank. Check operation of all mechanical, electrical and fuel systems. Install wing root fairings. Install all removed access/inspection plates and upholstery.

Adjustment (Correcting Wing Heavy Conditions) NOTE: A.

If considerable control wheel pressure is required to keep the wings level in normal flight, a "wing heavy" condition exists and can be corrected by the following procedure.

Adjustment Procedures (Refer to Figure 201, Detail A). (1) Remove wing fairing strip on the wing heavy side of the airplane.

CAUTION: ENSURE THE ECCENTRIC BUSHINGS ARE ROTATED SIMULTANEOUSLY. ROTATING THEM SEPARATELY WILL DESTROY THE ALIGNMENT BETWEEN THE OFF-CENTER BOLT HOLES IN THE BUSHINGS, THUS EXERTING A SHEARING FORCE ON THE BOLT, WITH POSSIBLE DAMAGE TO THE HOLE INTHE WING SPAR. NOTE:

The eccentric cams should only be adjusted after other flight control systems have been adjusted and rigged.

(2) Loosen nut and rotate eccentric bushings simultaneously until the bushings are positioned with the thick side of the eccentrics up. This will lower the trailing edge of the wing, and decrease wing heaviness by increasing angle of incidence of the wing. (3) Torque the nut from 300 to 500 inch pounds and reinstall fairing strip.


Page 204 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL (4)

(5) 4.

Strut Damage and Repair Criteria A.

5.

Test fly the airplane. If the wing heavy condition still exists, remove fairing strip on the lighter wing, loosen nut and rotate bushing simultaneously until the bushings are positioned with the thick side of the eccentrics down. This will raise the trailing edge of the wing, thus increasing wing heaviness to balance heaviness in the opposite wing. Torque nut from 300 to 500 inch pounds, install fairing strip and repeat flight test.

For wing strut damage and repair criteria, refer to the Single Engine Structural Repair Manual Chapter 57, Wing Damage Classification.

Wing Tip Removal/Installation A.

Remove Wing Tip (Refer to Figure 202). (1) Remove screws securing wing tip to wing. (2) Remove screw securing strobe light and navigation light ground straps to power supply. (3) Disconnect navigation light electrical connector. (4) Disconnect strobe light electrical connector. (5) Remove wing tip from wing.

B.

Install Wing Tip (Refer to Figure 202). (1) Connect strobe light electrical connector, and connect navigation light electrical connector. (2) Slide the wing tip into position over the wing tip rib ensuring the existing holes in the wing tip align with the attach holes in the wing skin/rib nutplates. (3) Fabricate a curved spacer from phenolic or aluminum which is 0.01 to 0.03 inch thick X 1.0 inch X 2.0 inches which matches the contour of the leading edge. (4) Insert the spacer at the leading edge of the wing between the skin and the inside contour of the wing tip. (5) Secure wing tip to wing using screws starting at the aft of the tip and working forward. (6) When all screws are secure, remove the spacer to leave a gap of 0.01 inch to 0.03 inch between the skin and the inside contour of the wing tip.


Page 205 Apr 7/2003



B110

P

A

INCH

r

WING ROOT WING

TIP

-w A-A

SCREW

GAP BETWEEN WING TIP AND FRONT OF WING LEADING EGDE 0.01 INCH MINIMUM 0.03 INCH MAXIMUM

WING LEADING EDGE

DETAIL

A 0510T1007 A0510T1001 A-A0523T1001

Wing Tip Installation Figure 202 (Sheet 1)


Page 206 Apr 7/2003

CHAPTER

PROPELLERS




PAGE

DATE

61-00-00

Page 1

Apr 7/2003

61 -10-00

Pages 201-203

Jul 1/2007

61 -Title 61 -List of Effective Pages 61 -Record of Temporary Revisions 61 -Table of Contents

61 ©Cessna Aircraft Company

-

LIST OF EFFECTIVE PAGES



Page Number

Issue Date

By

Date Removed

By



CONTENTS PROPELLERS - GENERAL ............................ Scope.................................... Definition .................................. PROPELLER - MAINTENANCE PRACTICES.................... Description and Operation .......................... Propeller and Spinner Removal/installation...................

61 -00-00 Page 1 61 -00-00 Page 1 61 -00-00 Page 1 61 -10-00 Page 201 61 -10-00 Page 201 61 -10-00 Page 201

61 -CONTENTS © Cessna Aircraft Company

Pagel1ofi1 Jul 1/2007


MODEL 172

MAINTENANCE MANUAL PROPELLERS - GENERAL 1.

Scope A.

2.

This chapter provides instructions on propeller and spinner.

Definition A.

This chapter contains a single section on removal and installation of the propeller and spinner.


Page 1

Apr 7/2003


MODEL 172

MAINTENANCE MANUAL PROPELLER

-


1.Description and Operation propeller. Maintenance practices consist A. The airplane is equipped with a two bladed, fixed pitch metal beyond the scope of this section, refer of propeller/spinner removal and installation. For information to the applicable McCauley Service Manual. 2.

Propeller and Spinner Remnoval/Installation A. Remove the Propeller and Spinner (Refer to Figure 201).

Ensure the propeller. WARNING: Exercise care when working with before turning propeller. magneto switch is in the off position - Maintenance Practices. Remove the cowling and nosecap. Refer to Chapter 71, Cowling Remove the spinner. bulkheads. aft Remove screws securing the spinner to the forward and bolts. mounting propeller Cut and discard safety wire from the aft bulkhead and spacer from Remove the mounting bolts, forward bulkhead, propeller, crankshaft. when removed. A dowel pin holds the propeller, aft bulkhead and spacer together NOTE: inspected, refer to ASTM E-1414 or (5) The propeller mounting bolts must be magnetic particle at every overhaul. The propeller replaced or liquid penetrant inspected, refer to ASTM E-1 417, in a blade strike. involved is propeller the mounting bolts must be replaced when propeller. the from bulkhead aft the and (6) Remove the spacer bags placed as close to the hub (a) the propeller by setting it between two sand filled for the spacer and aft clearance of inches (2) two as possible with the spacer down. Allow to separate from the hub. ~ ~~~~~~bulkhead long. Insert rod into propeller hub (b) Select a rod of proper diameter and is six (6) inches in a alternating pattern to free the dowels dowel pin holes. Using a hammer, lightly tap remain in the spacer. will dowels The hub. spacer and bulkhead from propeller remove dowels from spacer hub, propeller the in installed were (c) If the tapered end of dowels lightly tap dowels in hammer, a by inserting the rod into dowel pin holes in spacer. Using spacer. a alternating pattern to remove dowels from

(1) (2) (3) (4)

S B.

Aft bulkhead and spacer assembly.

as a pair and must be CAUTION: The spacer and propeller are balanced or propellers from spacers installed together. Do not exchange other airplanes. surface facing up. (1) Position spacer on a arbor press table with hub mating tapered end into spacer. with dowels (2) If dowels were removed from spacer, install spacer. into press and dowel (a) Lightly oil each Extension of both dowels above (b) Engage dowel into spacer enough to hold dowel firmly. pressing. face of spacer must be the same after propeller hub. Final dowel location will be made when spacer is installed in mating surface facing up. (c) Position propeller hub on arbor press table with spacer holes. dowel with aligned (d) Place bulkhead over hub hub. (e) Align serial number on spacer with serial number on propeller against the dowels for rotate to bulkhead (f) Press spacer down against hub and allow the adjustment. Install the Propeller and Spinner (Refer to Figure 201). NOTE:

C.

61 -1 000 © Cessna Aircraft Company

Page 201 Jul 1/2007


MODEL 172

MAINTENANCE MANUAL B1 786

A

SPACER

DOWEL

FORWARD BULKHEAD ASSEMBLY WASHER

FAD

PROPELLER

PROPELLER MOUNTING BOLT SCREWS

DETAIL

A

051OT 1007 A0555R3001

Propeller and Spinner Installation Figure 201 (Sheet 1) ©Cessna Aircraft Company

61 -10-00

Page 202 Jul 1/2007

0



CAUTION: The spacer and propeller are balanced as a pair and must be installed together. other airplanes.

I

Do not exchange spacers or propellers from

(1) Clean the mating surfaces and install the spacer, propeller and bulkheads to crankshaft. Make sure the serial number stamped on the side of the spacer lines up with either of the propeller blades. (2) Clock the propeller as follows: (a) Find the top center (TC) mark on the aft face of the starter ring gear.

~

~~~(b) Align one of the propeller blades with the TC mark.

(c) Rotate the propeller clockwise, looking from in front of the airplane until the bolt holes align. (3) Install the spacer, aft bulkhead, propeller and forward bulkhead to crankshaft with mounting bolts finger tight. (4) Install spinner over bulkheads and install screws in forward bulkhead finger tight.

NOTE:

The aft bulkhead may need to be pushed forward slightly to engage spinner screws. It may be necessary to rotate the spinner 180 degrees for the best spinner and screw attach alignment.

(5) Rotate the aft bulkhead until the spinner screws can be installed with little effort. (6) Identify on the propeller, spinner, forward and aft bulkheads index marks for screw alignment. (7) Carefully remove spinner so the forward and aft bulkhead remains in the same aligned position.

NOTE:

The mounting bolt holes in the forward bulkhead may be undersized due to the original torquing of the mounting bolts. This may cause the spinner to bulkhead screws holes not to align. The required hole diameter for the forward bulkhead is 0.516 inch diameter to 0.527 inch diameter. If necessary, remove the forward bulkhead and enlarge bolt hole using a 33/64th (0.516 inch diameter) drill.

NOTE:

If necessary, the spinner screw holes in the aft bulkhead flanges may be increased to 0.205 inch diameter for adjustment.

(8) Secure propeller assembly using the propeller bolts and washers. Tighten the mounting bolts in a crossing pattern to 660-780 inch-pounds dry (55-65 foot-pounds dry). Safety wire the mounting bolts. Refer to Chapter 20, Safetying - Maintenance Practices. D.

Install spinner in same position with index marks

E.

Check the spinner to aft bulkhead clearance. (1) If not removed, remove upper cowling and upper nosecap. Refer to Chapter 71, Cowling Maintenance Practices. (2) Using a 0.03 inch feeler gauge insert gauge between spinner and aft bulkhead to ensure the gap is 0.03 inches or less. If a gauge is not available, fabricate a gauge from phenolic, aluminum or steel that is 0.5 inches wide by 0.03 inches thick and 2.0 inches long. (3) Replacement of the Aft Bulkhead will be required if gap is more than 0.03 inches. (4) Adjust alternator belt tension. Refer to Chapter 24, Alternator - Maintenance Practices. (5) Install nosecap and cowling. Refer to Chapter 71, Cowling - Maintenance Practices. Check the spinner to propeller clearance. (1) Clearance between the spinner and propeller must be a minimum of 0.10 inch. (2) If clearance is not a minimum of 0. 10 inch, remove and adjust the spinner.

F.

NOTE:

It is acceptable to trim the spinner a maximum of 0.08 inch. Trim spinner only if maximum adjustment does not allow adequate clearance. Trim as little as possible to obtain clearance. Apply corrosion protection. Refer to Chapter 20, Interior and Exterior Finish - Cleaning/Painting.

61 -1 0-00 c Cessna Aircraft Company

Page 203 Jul 1/2007

CHAPTER

POWER PLANT


MODEL 172

MAINTENANCE MANUAL


PAGE

DATE

71 -Title 71 -List of Effective Pages 71 -Record of Temporary Revisions 71 -Table of Contents 71-00-00 71 -00-01

Page 1 Pages 1-5

Jan 3/2005

71-00-01

Pages 101 -105

Jan 3/2005

71 -00-01

Pages 201 -203

Jan 3/2005

71 -10-00

Pages 201-203

Apr 7/2003

71-20-00

Pages 201 -204 Pages 201-203

Janl1/2007

71-60-00 71-70-00

Pages 201-202

Apr 7/2003


71

-

Apr 7/2003

Jan 3/2005


Page 1 of 1 Janl1/2007


Page Number

Issue Date

By

Date Removed

By


MODEL 172

MAINTENANCE MANUAL

CONTENTS POWERPLANT - GENERAL............................ Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition .................................. ENGINE - DESCRIPTION AND OPERATION .................... Description and Operation .......................... 10-360-1-2A - TROUBLESHOOTING ........................ Troubieshooting Chart ............................ 10-360-1-2A - MAINTENANCE PRACTICES..................... General................................... Engine Removal/Installation.......................... Engine Cleaning............................... Engine Storage ............................... COWL - MAINTENANCE PRACTICES ....................... Description and Operation .......................... Cowl Removal/installation .......................... Cowl Shock Mounts ............................. Cowl Repair................................. ENGINE MOUNT - MAINTENANCE PRACTICES .................. Description and Operation .......................... Engine Mount Procedures .......................... Engine Mount Repairs ............................ AIR INDUCTION SYSTEM - MAINTENANCE PRACTICES.............. Description and Operation .......................... Air Induction System Removal/Installation ................... 172S Engine Induction Air Filter Maintenance Practices............. DRAIN LINES - MAINTENANCE PRACTICES.................... Description and Operation .......................... Maintenance Practices............................


71

-

71 -00-00 Page 1 71 -00-00 Page 1 71 -00-00 Page 1 71 -00-01 Page 1 71 -00-01 Pagel1 71-00-01 Page 101 71 -00-01 Page 101 71-00-01 71-00-01 71-00-01 71-00-01 71-00-01 71 -10-00 71 -10-00 71 -10-00 71 -10-00 71 -10-00

Page Page Page Page Page Page Page Page Page Page

71-20-00 71-20-00 71-20-00 71-20-00


71 -60-00 71-60-00 71-60-00 71-60-00

201 201 201 201

Page Page Page Page 71-70-00 Page 71-70-00 Page 71 -70-00 Page

CONTENTS

201 201 201 203 203 201 201 201 201 201

201 201 201



MODEL 172

MAINTENANCE MANUAL POWERPLANT - GENERAL

1.

Scope A.

2.

This chapter contains maintenance information on the powerplant and associated components. For engine related information not found in this chapter, refer to applicable Textron Lycoming maintenance manuals, listed in Introduction - List of Supplier Publications.

Definition A.

This chapter is divided into sections to aid maintenance personnel in locating information. Consulting the Table of Contents will further assist in locating a particular subject. A brief definition of the sections incorporated in this chapter is as follows: (1) The section on powerplant provides description, operation, troubleshooting and removal/ installation information for the engine. (2) The section on engine cowlings provides removal and installation instructions for the engine cowlings. (3) The section on mounts provides removal and installation procedures for the engine mount. (4) The section on air induction provides removal and installation procedures for the air induction part of the fuel system. (5) The section on drain lines provides removal and installation instructions on the various drain lines used in the engine compartment.


Page 1

Apr 7/2003


MODEL 172

MAINTENANCE MANUAL ENGINE - DESCRIPTION AND OPERATION 1.


The Textron Lycoming IO-360-L2A engine is direct drive, four cylinder, fuel injected, horizontally opposed, and air cooled. The cylinders, numbered from front to rear, are staggered to have individual throws on the crankshaft for each connecting rod. The right front cylinder is number 1 and cylinders on the right side of the engine are identified by odd numbers 1 and 3. The left front cylinder is number 2 and the cylinders on the left side are identified as 2 and 4.

B.

For a technical description of the engine, refer to Table 1. For an illustration of the engine, refer to Figure 1.

C.

If more information is necessary than is given in this chapter, refer to the applicable engine manuals given in the Introduction - List of Supplier Publications.

Table 1. IO-360-L2A Technical Description 172R Rated Horsepower at 2400 RPM

160

172S* Rated Horsepower at 2700 RPM

180

Number of Cylinders

4 Horizontally Opposed

Displacement

361.0 Cubic Inches

Bore

5.125

Stroke

4.375

Compression Ratio

8.5:1

Firing Order

1-3-2-4

Magnetos: Right Magneto

Slick Model No. 4371 (fires at 25° BTDC)

Left Magneto

Slick Model No. 4371 (fires at 25° BTDC)

Spark Plugs

18MM

Torque:

420 In lbs

Valve Rocker Clearance (hydraulic tappets collapsed)

0.028 to 0.080 inch

Fuel Injector

RSA-5AD1

Tachometer

Mechanical Drive

Oil Capacity

8.0 Quarts

Oil Pressure Minimum Idling

20 PSI

Normal

50 to 90 PSI

Maximum

115 PSI

Oil Temperature Normal

100°Fto 245°F


Page 1

Jan 3/2005


MODEL 172 MAINTENANCE MANUAL Table 1. IO-360-L2A Technical Description (continued) Maximum 245°F Dry Weight - without alternator or vacuum pumps

278 Lbs

*And 172R Airplanes that incorporate MK172-72-01


Page 2

Jan 3/2005



B1419

ER/

;K ESSURE ;DUCER

OIL FILTER

:CASE HER

FUEL PRESSURE/ FLOW TRANSDUCER

0550T1005

Engine Installation Figure 1 (Sheet 1)


Page 3

Jan 3/2005



81420

STARTFR

FUEL FLOW TRANSDUCER

ENGINE MOUNT

CABIN HEAT DUCT

DRAIN LINES

AIRPLANES 17280001 THRU 17281187 AND AIRPLANES 172S8001 THRU 172S9490 0550T1006


71 -00-01 © Cessna Aircraft Company

Page 4

Jan 3/2005



B1421

VACUUM PUMP

REAR REAR

ETOS ENGINE DRIVEN FUEL PUMP

M (NOT RATED)

FUEL STRAINER DRAIN

0550T1007



Page 5

Jan 3/2005


MODEL 172

MAINTENANCE MANUAL IO-360-L2A - TROUBLESHOOTING 1.

Troubleshooting Chart A.

The following chart has been provided to help maintenance technicians in system troubleshooting. This chart should be used in conjunction with Chapter 73, Fuel Injection System - Troubleshooting and Chapter 74, Ignition System - Troubleshooting to get a comprehensive look at solutions to engine problems. For information beyond the scope of this chapter, refer to applicable engine manuals and publications listed in Introduction - List of Supplier Catalogs. NOTE:

B.

If low power is suspected, the following static run-up procedures may by used inconjunction with the troubleshooting chart to develop a diagnosis:

Static Run-Up Procedures. (1) Align airplane 90 degrees to the right of wind direction. (2) Run up engine at full throttle in accordance with procedures outlined in the Pilot's Operating Handbook and FAA Approved Airplane Flight Manual. (3) Record RPM. (4) Realign airplane 90 degrees to the left of wind direction and perform second run-up. (5) Record RPM from second run-up. (6) Average the results of the RPM from the two run-ups. (a) For the 172R, RPM must be from 2065 to 2165 RPM. (b) For the 172S, RPM must be from 2300 to 2400 RPM. NOTE:

Variances in atmospheric pressure, temperature and humidity can have a significant impact on run-up RPM. Low static run-up RPM information should be used only in conjunction with other troubleshooting procedures to determine if a problem actually exists.

(7) If run-up indicates low power, check the following items: (a) Do a check of the operation of the alternate air door and make sure the door remains closed in normal operation. (b) Do a check of the magneto timing, spark plugs and ignition harness for settings and condition. (c) Do a check of the fuel injection nozzles for restriction and check for correct unmetered fuel flow. (d) Do a check of the condition of the induction air filter. Clean or replace as required. (e) Do an engine compression check. TROUBLE

PROBABLE CAUSE

REMEDY

ENGINE WILL NOT START (NO FLOW INDICATED ON FUEL GAUGE).

No fuel to engine.

Check fuel level in tanks, check mixture control for proper position, fuel boost pump on and operating, fuel valves open, fuel filters clean and unblocked.

ENGINE WILL NOT START (SUFFICIENT FUEL FLOW INDICATED ON FUEL GAUGE).

Engine flooded.

Reset throttle, clear engine of excess fuel and attempt re-start.

ENGINE WILL NOT START (SUFFICIENT FUEL FLOW INDICATED ON FUEL GAUGE) (Cont.).

No fuel to engine.

Loosen line at fuel injector nozzle. If there is no fuel flow with fuel flow showing on gauge, replace the flow divider valve.


Page 101 Jan 3/2005



TROUBLE

ENGINE WILL NOT RUN AT IDLING SPEED.

ROUGH IDLING.

PROBABLE CAUSE

REMEDY

Grounded ignition switch wires.

Check for grounded switch wires.

Magneto improperly timed to engine.

Retime magnetos. Refer to Chapter 74, Ignition System Maintenance Practices.

Magneto internal timing incorrect, weak capacitor, or improperly adjusted breaker points.

Refer to applicable Bendix supplier Publications.

Fouled spark plugs.

Remove and clean, check gaps and insulators. Reinstall with new gaskets. Check ignition harness.

Weak spark, magneto coils burned out, moisture in distributor.

Remove and bench test magnetos, ignition harness and spark plugs.

Leak in intake manifold.

Check hose connections, gaskets and tighten hose clamps and flange attaching bolts.

Idle stop screw or idle mixture lever incorrectly adjusted.

Refer to Chapter 73, Fuel Injection System - Maintenance Practices.

Air leak in intake manifold.

Tighten loose connections or replace damaged parts.

Weak magneto capacitor.

Install new capacitor.

Spark plugs fould by oil escaping past piston rings.

Top overhaul engine.

Improper idle mixture adjustment.


Manual mixture control set for lean mixture.

Use full rich mixture for all ground operation.

Fouled spark plugs.

Remove and clean, adjust gaps, test ignition harness, inspect magneto breaker points. If persistent, top overhaul engine.

Loose or deteriorated engine mounts.

Check mounts, tighten or install new parts.

Burned or warped exhaust valves and/or seats. Scored valve stems.



Page 102 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL

TROUBLE

ENGINE DOES NOT ACCELERATE PROPERLY.

ENGINE RUNS ROUGH AT HIGH SPEED.

CONSTANT MISFIRING AT HIGH RPM.

SLUGGISH OPERATION AND LOW POWER.

LOW FLOW ON FUEL FLOW GAUGE.

LOW FLOW ON FUEL FLOW GAUGE (Cont.).

PROBABLE CAUSE

REMEDY

Hydraulic tappet sticking or worn.

Listen for tappet noise. Refer to applicable engine overhaul manual in Introduction - List of Supplier's Publications.

Idle mixture too lean.


Worn throttle or mixture linkage.

Install new parts as required.

Loose or deteriorated engine mount pads.

Check, tighten or install new parts.

Propeller out of balance or track.

Remove and repair.

Spark plug gasket leaking, improper gap, or damaged insulator.

Install new parts.

Ignition cable insulator deteriorated.

Test cables for leakage and install new parts as necessary.

Improper mixture.

Check mixture control setting.

Valve spring broken.

Install new spring.

Valve warped or burned.


Hydraulic tappet worn or dirty.

Remove, clean or install new parts.

Injectors clogged.

Test and clean injectors.

Worn valve seats.


Worn or stuck piston rings.


Line to flow transducer clogged or restricted.

Check line for bends, kinks or obstructions.

Restricted flow to flow divider valve.

Check mixture control for full travel. Check for clogged fuel filters.

Inadequate flow from pump.

Worn pump or pump plunger shaft. Install new parts.

Interference with mixture control.

Check mixture control for freedom of movement.


Page 103 Jan 3/2005



I

TROUBLE

PROBABLE CAUSE

REMEDY

HIGH FLOW ON FUEL FLOW GAUGE.

Restricted flow beyond flow divider valve.

Check for restricted nozzles or flow divider valve. Clean nozzles or install new valve.

FLUCTUATING PRESSURE ON FUEL FLOW INDICATOR.

Vapor in system. Excessive fuel temperature.

If not cleared with boost pump, drain fuel pressure line.

Fuel leak in line from flow divider to flow transducer.

Check line, replace as required.

ENGINE DOES NOT STOP WITH MIXTURE CONTROL IN IDLE CUTOFF.

Mixture control valve leaking in idle cutoff position.

Check mixture control, should be in full idle cutoff. Check fuel boost pump off.

HIGH OIL TEMPERATURE.

Oil cooler fins clogged.

Clean thoroughly.

Oil cooler oil ages restricted.

Remove and flush cooler.

Oil cooler by valve damaged or held open.

Remove cooler, and clean valve and seat.

Low oil supply.

Replenish.

Oil viscosity too high.

Use correct grade of oil.

Prolonged high speed operation on ground.

Avoid prolonged ground operation above 1500 RPM.

Dirty/clogged oil filter.

Replace filter.

Low fuel grade.

Use correct grade of fuel.

Excessive carbon deposits in cylinder head and on piston.


Clogged cylinder fins.

Clean thoroughly.

Leaking exhaust valves.


Low oil supply.

Add oil.

Viscosity too low.

Use correct grade oil.

Sludge or foreign material in relief valve.

Remove and clean valve.

Defective oil pressure gauge.

Install new gauge.

HIGH CYLINDER HEAD TEMPERATURE.

LOW OIL PRESSURE.


Page 104 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL TROUBLE

PROBABLE CAUSE

REMEDY

Restricted oil transducer line.

Check line from front of crankcase to pressure transducer for kinks or restrictions.

Internal leak, damaged gasket or bearing.

Major overhaul engine.

OIL LEAK AT FRONT OF ENGINE.

Crankshaft oil seal leaking.

Install new seal.

OIL LEAK AT PUSHROD HOUSING.

Damaged housing seal.

Install new seals.

LOW COMPRESSION.

Worn cylinder and/or rings.

Top overhaul engine or replace defective cylinder.

Valve not properly seating.

Top overhaul engine or replace defective cylinder.

Low grade of oil.

Use specified grade of oil.

Failed or failing bearings.

Check oil filter for metal particles, and if found, overhaul engine.

Worn piston rings.

Install new rings.

Incorrect ring installation.

Install new rings.

EXCESSIVE OIL CONSUMPTION.


Page 105 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL IO-360-L2A - MAINTENANCE PRACTICES 1.

General A.

2.

This section gives instructions to remove and install the engine and mount from the firewall. If more information is necessary than is given in this chapter, refer to the applicable engine publications which are given in the Introduction - List of Supplier Publications.

Engine Removal/Installation A.

Remove the Engine and Mount. NOTE:

The procedures that follow remove the engine and mount from the firewall. If the engine is removed from the mount and the mount will stay attached to the firewall, some of the steps will not be necessary. To remove the engine from the mount, the four bolts that connect the four shock mounts to the engine mounting flange and the engine mount tube must be removed.

(1) Put all cabin switches and the fuel shutoff valve in the OFF position. (2) Remove the engine cowl. NOTE:

The steps that follow can be done from the right side of the airplane.

(3) Disconnect the positive and negative battery leads from the battery. (4) Loosen the clamp that attaches the flexible duct to the firewall-mounted heater valve. (5) Remove the flexible duct from the heater valve.

WARNING: When the P lead wire Is disconnected from the magnetos to remove the electrical ground from the magneto circuit, the magnetos become electrically active. A ground wire must be connected to the magnetos or the high tension wires removed from the spark plugs to prevent accidental engine start when the propeller Is turned. An accidental engine start can cause Injury to persons In the area of the propeller. (6)

Disconnect the P lead wires on the magnetos. NOTE:

Airplanes with Garmin G1000 have EGT probes at each cylinder.

NOTE:

Airplanes without Garmin G1000 have one EGT probe in the exhaust pipe.

(7) (8) (9) (10) (11) (12) (13)

Remove the propeller. Refer to Chapter 61, Propeller - Maintenance Practices. Disconnect the electrical connector from the EGT probe. Disconnect the fuel outlet line at the fuel strainer. Disconnect the throttle and mixture cables at the fuel/air control unit. Record the position of the washers and spacers for assembly. Disconnect the vacuum hoses at the firewall-mounted manifold/check valve. Put a label on the electrical wires on the low vacuum annunciator switches, low oil pressure transducer, and alternator. (14) Disconnect the low vacuum annunciator switches, low oil pressure transducer, and alternator. NOTE:

The steps that follow can be done from the left side of the airplane.

(15) Remove the tachometer drive cable or electrical connector. (a) On airplanes without Garmin G1000, loosen and remove the tachometer drive cable. (b) On airplanes with Garmin G1000, disconnect the electrical connector from the tachometer sending unit. 71-00-01 © Cessna Aircraft Company

Page 201 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL (16) Cut the tie wraps (sta straps) that attach the wire bundles to the engine mount. (17) On the bottom side of the engine, loosen and remove the clamps that attach the starter wires to the sump area. (18) Remove the starter wires from the starter. (19) Disconnect the ground strap from the engine mount. (20) Disconnect the electrical connector (JN001) from the fuel flow transducer (UN003). (21) Disconnect the electrical connector (JN005) from the low oil pressure switch (SN001). (22) Disconnect the electrical connector (JN004) from the oil pressure transducer (UI006). NOTE:

(23) (24) (25) (26) (27) (28) (29)

To remove the electrical connector JN004 from the baffle area, it will be necessary to remove the two screws on the rear of the upper right baffles and remove the baffles from each other.

Loosen the clamps that attach the battery vent tube to the drain line cluster. Remove the vent tube through the clamps. Remove the bolt and spacer that attach the drain lines to the firewall. Loosen and remove the ram air tubes on the rear of the upper left baffle. Put a stand under the tail tie-down. Attach a hoist to the lifting strap on the top of the engine. Lift the engine only as high as necessary with the hoist. NOTE:

It can be necessary to get access to the bolt heads from the inside of the cockpit.

(30) Remove the bolts that attach the engine and the engine mount to the firewall. (31) Record the sequence of the nuts, washers and flat washers. (32) Slowly lift the engine with the hoist until the engine and the mount move from the bolts. B.

Install the Engine and Mount. (1) Lift the engine into position and attach the mount to the firewall with the hardware removed. Refer to Engine Mount - Maintenance Practices for the sequence of the washer, nut and flat washer. (2) Torque the firewall bolts from 160 in-lbs to 190 in-lbs (18.1 N-m to 21.5 N-m). (3) Remove the stand from the tail tie-down. (4) Attach the ram air tubes to the rear of the upper left baffle. (5) Attach the drain lines to the firewall with the bolt and spacer. (6) Put the battery vent tube through the drain line clamps and tighten the clamps. (7) Put the wires from electrical connector JN004 through the baffle cutout area. (8) Attach the baffle pieces to each other with the screws. (9) Connect the electrical connector (JN004) to the oil pressure transducer (UI006). (10) Connect the electrical connector (JN005) to the low oil pressure switch (SN001). (11) Connect the electrical connector (JN001) to the fuel flow transducer (UN003). (12) Connect the ground strap to the engine mount. (13) Install the starter wires to the starter. (14) Attach the starter wires to the sump area with the clamps. (15) Attach the wire bundles to the engine mount with tie wraps. (16) Attach the tachometer drive cable or electrical connector. (a) On airplanes without Garmin G1000, attach the tachometer drive cable. (b) On airplanes with Garmin G1000, connect the electrical connector to the tachometer sending unit. (17) Connect the wires to the low vacuum annunciator switches, low oil pressure transducer, and alternator. (18) Remove the labels from the low vacuum annunciator switches, low oil pressure transducer, and alternator. (19) Connect the vacuum lines to the firewall-mounted manifold/check valve. (20) Connect the throttle and mixture control cables to the fuel air control unit.


Page 202 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL (21) Connect the fuel outlet line at the fuel strainer.

(22) (23) (24) (25) (26) (27) (28) (29) (30) (31) 3.

Airplanes with Garmin G1000 have EGT probes at each cylinder.

NOTE:

Airplanes without Garmin G1000 have one EGT probe in the exhaust pipe.

Connect the electrical connector to the EGT probe. Install the propeller. Refer to Chapter 61, Propeller - Maintenance Practices. Connect the P leads to the magnetos. Connect the high tension wires to the spark plugs, if applicable. Connect the flexible duct to the firewall-mounted heater valve. Make sure all controls and lines are correctly installed and move freely. Make sure all fuel fittings are tight and do not have leaks. Connect the positive and negative leads to the battery. Install the engine cowl. Make sure the engine operates correctly.

Engine Cleaning A.

4.

NOTE:

The engine can be cleaned with a stoddard solvent or equivalent chemicals. Be careful that all openings have caps or plugs to prevent solvent entry into the engine. All electrical accessories (starter, alternator, etc.) must have covers before the solvent is applied.

Engine Storage A.

If the engine is removed and is to be stored, it must be preserved. Refer to Chapter 10, Storage Description and Operation for preservation procedures.


Page 203 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL COWL - MAINTENANCE PRACTICES

1.


2.

3.

Cowl Removal/Installation A.

Remove Cowl (Refer to Figure 201). (1) Release quick release fasteners around perimeter of upper cowl. (2) Remove upper cowl. (3) Remove induction air filter bracket from lower cowl. (4) Unscrew upper nose piece from lower nose piece. (5) Release quick release fasteners around perimeter of lower cowl. (6) Remove lower cowl.

B.

Install Cowl (Refer to Figure 201). (1) Install lower cowl to engine area and secure using quick release fasteners. (2) Install induction air filter bracket to lower cowl using quick release fasteners. (3) Attach upper nose piece to lower nose piece using screws. (4) Install upper cowl to engine area and secure using quick release fasteners.

Cowl Shock Mounts A.

4.

The engine cowl consists of upper and lower sheet metal halves and upper and lower composite nose pieces. The cowl is attached to the shock mounts using quick release, quarter turn fasteners to allow for easy removal and installation. The nose pieces are attached to each other using screws and nutplates.

Shock Mount Adjustment/Replacement (Refer to Figure 202). (1) The shock mounts are riveted to brackets, which in turn are secured to the fuselage. Mounts may be replaced as needed or adjusted with shims as shown in Figure 202. (2) If new shock mounts or brackets are installed, careful measurements should be taken to ensure new parts are positioned correctly on the firewall. New parts are not predrilled and care should be taken to align new shock mounts with existing cowl openings. If required, sheet aluminum may be used as shim stock to provide proper cowl contour.

Cowl Repair A.

For repair procedures to the cowl, refer to the Structural Repair Manual.


Page 201 Apr 7/2003



A0552T3001 B0550T1002 C0552T1003

DETAIL B Engine Cowl Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL B1788

DETAIL A ENGINE

COWL SNUBBER BRACKET ASBESTOS SEAL SHOCK MOUNT ACKET -SNUBBER SHIM

FIREWALL

SNUBBER

NOSE(

DETAIL B

DETAIL C NOTE:

SHIM CAN BE INSTALLED AS REQUIRED (MAXIMUM 4) BETWEEN SNUBBER AND SNUBBER TO OBTAIN A MAXIMUM GAP OF 0.125 INCH BETWEEN SNUBBER AND COWL SNUBBER BRACKET. 0510T1007 A0511T1006 B0552T1002 C0552T1002

Engine Cowl Shock Mount Installation Figure 202 (Sheet 1)


Page 203 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL ENGINE MOUNT

-


1.Description and Operation A. The dynafocal engine mount is made of 4130 steel and uses four rubber mounts to isolate engine noise and vibration from the engine mount. The mount is attached to the fuselage at four points on the firewall using bolts, washers and nuts. 2.

Engine Mount Procedures A. Shock Mount Procedures (Refer to Figure 201). (1) The shock mounts which connect the engine to the engine mount are of rubber and metal construction and are assembled in a sandwich to isolate noise and vibration from the cabin area. Shock mounts should be assembled as illustrated in Figure 201. Nuts should be torqued from 450 to 500 In-lbs upon installation. (a) If necessary, adjust the oil filler tube clearance. Make sure the oil filler tube does not touch the engine mount or hoses. NOTE:

B.

C.

3.

One or two washers are permitted between the mounting and engine flange to adjust the oil filler-tube clearance. Both of the bottom mounts must have the same number of washers between the mounting and engine flange. Both top mounts must have the same number of washers between the mounting and engine flange.

(2) The shock mounts should never be cleaned with any type of solvent. If shock mounts need cleaning, use a clean, dry cloth. (3) Shock mounts should be inspected when removed. Metal components should be inspected for cracks and excessive wear due to aging and deterioration. Rubber components should be inspected for separation, swelling, cracking or a pronounced set of the pad. Shock mounts showing any of these signs should be replaced. Firewall Mounting Procedures (Refer to Figure 202). (1) The engine mount should be secured to the firewall using bolts, washers, flatwashers and nuts as illustrated in Figure 202. Nuts should be torqued from 160 to 190 In-lbs. Removal Notes. (1) Specific instructions for removing the engine mount have been included earlier in this chapter under 10-360-L2A - Maintenance Practices.

Engine Mount Repairs A. The engine mount may be repaired using procedures described in the Single Engine 1996 and On Structural Repair Manual.


71-20-00

Page 201 Janl1/2007



B1789

NOTE:

BOL

ONE OR TWO WASHERS PERMITTED. BOTH TOP MOUNTS MUST HAVE THE SAME NUMBER OF WASHERS. O1UUN1 I 0 MUZ- I I1MVLz 3ER OF WASHERS.

ENGINE FLANGE

SPACER WASH ER

ENGINE MOUNT

(NOTE) UPPER RIGHT HAND SHOCK MOUNT

BC ENGINE MOUNT WASHER (NOTE)

MOUNTING DAMPER

4UT MOUNTING

FLANGE

WASHER

LOWER RIGHT HAND SHOCK MOUNT

05511002 05511002

Engine Shock Mount Installation Figure 201 (Sheet 1)

71-20-00 ©Cessna Aircrati Company

Page 202 Janl1/2007


MODEL 172

MAINTENANCE MANUAL Bi1790

NOTE:

ONE OR TWO WASHERS PERMITTED. BOTH TOP MOUNTS MUST HAVEF THE

WASH ER

Li MOUNT v

MOUNTING

UPPER LEFT HAND SHOCK MOUNT WASHER

ENGINE MOUNT

FL MOUNTING

MOUNTING

LOWER LEFT HAND SHOCK MOUNT

BOLT 05511002 05511002

Engine Shock Mount Installation Figure 201 (Sheet 2)


71-20-00

Page 203 Jan-1/2007


MODEL 172

MAINTENANCE MANUAL

B

A

0 NUT

DETAIL

A

051 OT1007 A0551TIO01

Firewall Engine Mount Installation Figure 202 (Sheet 1)


Page 204 Jan 1/2007


MODEL 172

MAINTENANCE MANUAL AIR INDUCTION SYSTEM - MAINTENANCE PRACTICES 1.


B. 2.

3.

Ram air to the engine goes into the induction air box through the induction filter in the forward part of the lower engine cowl. From the induction air box, the air is pointed to the inlet of the fuel/air control unit and through the intake runners of the related cylinders. For more information of how the air induction system relates to fuel injection, refer to Chapter 73, Fuel Injection System - Description and Operation.

Air Induction System Removal/Installation A.

Remove the System Components (Refer to Figure 201). (1) Loosen the fasteners that attach the air filter bracket to the lower cowl. (2) Remove the air filter bracket and the air filter. (3) Remove the lower cowl. Refer to Cowling - Maintenance Practices. (4) Loosen the clamps on the duct to disconnect the filter box from the induction air elbow. (5) To remove the induction air elbow, loosen the clamps at the inlet adapter and at the drain line. (6) Move the induction air elbow down and away from the inlet adaptor.

B.

Install the System Components (Refer to Figure 201). (1) Put the induction air elbow in position to the inlet adaptor and attach with the clamp. (2) Attach the drain line to the induction air elbow with the clamp. (3) Install the lower cowl. Refer to Cowling - Maintenance Practices. (4) Attach the air filter and the air filter bracket to the lower cowl with the quick release fasteners.

172S Engine Induction Air Filter Maintenance Practices A.

The induction air filter keeps dust and dirt from the induction system. The air filter must be kept in a good clean condition. More engine wear is caused through the use of a dirty or damaged air filter than is usually thought. The frequency with which the filter must be removed, examined and cleaned will be given by aircraft conditions of operation. A good general rule, however, is to remove, examine and clean the filter at least every 100 hours of engine operation time, and more frequently if given by the conditions of operation. Under very dusty conditions, daily servicing of the filter is recommended. To service the induction filter, do the steps that follows. (1) Remove the filter from the airplane. NOTE:

Be careful when the filter element is cleaned with compressed air.

NOTE:

Arrows on the filter case show the direction of normal airflow.

(2) Clean the filter with compressed air (not over 100 psi) from the direction opposite of normal airflow. NOTE:

(3)

The bond holds the paper pleats to the face screen and, if the bond is broken, the pleats are free to move and decrease filter operation. A face screen that is loose or has gaps shows that the bond is broken and the filter element must be replaced.

Do a check to make sure the paper pleats are correctly bonded to the face screen.


Page 201 Jan 3/2005



B1

A SPRING

DETAIL

B

ALTERNATE AIR DOOR

INLET ADAPTOR

DRAIN LINE CLAMPS

DETAIL A

0510T1007 A0550T1002 B0550T1003

Induction Air Installation Figure 201 (Sheet 1)


Page 202 Jan 3/2005



CAUTION: Do not use solvent or cleaning fluids to wash the filter. Use only a water and household detergent solution when washing the filter. (4) After compressed air has been blown through the filter, the filter can be washed, if necessary, in a solution of warm water and a mild household detergent. A cold water solution can be used. NOTE:

The filter assembly can be cleaned with compressed air a maximum of 30 times or it can be washed a maximum of 20 times.

NOTE:

A new filter must be installed at 500 hours of engine operation or one year, whichever occurs first. A new filter must be installed if the filter is damaged.

(5) Flush the filter with clear water until the water from the filter is clear. Let the water drain from the filter and dry with compressed air (not over 100 psi). NOTE:

The s of the filter can have distortion when wet, but they will go back to their normal shape when dry.

(6) Make sure the airbox is clean. (7) Examine the filter and replace if applicable. (8) Install the filter in the airbox with the gasket on the aft face of the filter frame and with the flow arrows on the filter frame pointed in the correct direction.


Page 203 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL DRAIN LINES - MAINTENANCE PRACTICES 1.


2.

Various components within the engine compartment are equipped with drain lines to allow fluid and/or vapor to escape and vent to the atmosphere. These lines are typically secured using hose clamps, and are routed together in a cluster on the left side of the forward firewall.

Maintenance Practices A.

Maintenance practices for all drain lines are typical. Line removal and installation consists of removing clamps and other devices used to secure the lines to various structure. Lines should be checked for condition and security when removed, and installed in reverse order.

B.

For an illustration of various drain lines, refer to Figure 201.


Page 201 Apr 7/2003



FUEL DISTRIBUTION VALVE DRAIN HOSE

CLAMP INLET DRAIN HOSE INLET DRAIN LINE DETAIL FUEL DISTRIBUTION VALVE DETAIL A DRAIN LINE Engine Drain Lines Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003

CHAPTER

ENGI INE FUEL AN D CONT RO L




PAGE

DATE

73-00-00

Page 1

Apr 7/2003

73-00-0 1

Pages 1-3 Pages 101 -102

Apr 7/2003


73-00-01 73-00-01

Pages 201-205 Pages 201 -202

73-30-00


73

-

Janl1/2007 Janl1/2007 Jan 3/2005




Page Number

Issue Date

By

Date Removed

By


MODEL 172

MAINTENANCE MANUAL

CONTENTS ENGINE FUEL AND CONTROL - GENERAL .................... Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition .................................. FUEL INJECTION SYSTEM - DESCRIPTION AND OPERATION........... General................................... Description ................................. Operation.................................. Fuel Injection System - TROUBLESHOOTING.................... General................................... Fuel Injection System Troubleshooting..................... FUEL INJECTION SYSTEM - MAINTENANCE PRACTICES ............. General................................... Precautions................................. Fuel/Air Control Unit Removal/installation ................... Fuel Distribution Valve Removal/installation .................. Injection Nozzles Removal/Installation..................... Injection Nozzle Flow Test .......................... Idle and Mixture Adjustment.......................... Injector Nozzle Cleaning ........................... Fuel Strainer Cleaning ............................ Air Throttle Shaft Lubrication ......................... FUEL FLOW INDICATOR - MAINTENANCE PRACTICES .............. General................................... EGT/Fuel Flow Gage Removal/Installation................... Transducer and Line Removal/installation ...................


73-00-00 Page 1 73-00-00 Page 1 73-00-00 Page 1 73-00-0 1 Page 1 73-00-0 1 Page 1 73-00-0 1 Page 1 73-00-0 1 Page 1 73-00-01 Page 101 73-00-01 Page 101 73-00-01 Page 101 73-00-01 Page 201 73-00-01 Page 201 73-00-0 1 Page 201 73-00-01 Page 201 73-00-01 Page 202 73-00-01 Page 202 73-00-0 1 Page 202 73-00-0 1 Page 203 73-00-01 Page 205 73-00-01 Page 205 73-00-01 Page 205 73-30-00 Page 201 73-30-00 Page 201 73-30-00 Page 201 73-30-00 Page 201

73- CONTENTS



MODEL 172 MAINTENANCE MANUAL ENGINE FUEL AND CONTROL - GENERAL 1.

Scope A.

2.

This chapter provides information on the fuel injection system used for the 10-360- L2A engine. Information beyond the scope of this chapter can be found in Chapter 28, Fuel - General and in various publications which are listed in Introduction - General.

Definition A.

This chapter is divided into sections and subsections to assist maintenance personnel in locating specific systems and information. The following is a brief description of each section. For locating information within the chapter, refer to the Table of Contents at the beginning of the chapter. (1) The section on fuel injection covers procedures used to troubleshoot and maintain the fuel injection system. (2) The section on fuel flow indicator covers procedures used to maintain the indicating portion of the system.


Page 1

Apr 7/2003


MODEL 172 MAINTENANCE MANUAL FUEL INJECTION SYSTEM - DESCRIPTION AND OPERATION 1.

General A.

2.

3.

This section covers the RSA Fuel Injection system used on the IO-360-L2A engine. For a schematic of the fuel injection system, refer to Figure 1.

Description A.

The fuel injection system is a low pressure, multi nozzle, continuous flow system which injects raw fuel into the engine cylinder heads. The injection system is based on the principle of measuring engine air consumption to control fuel flow. More air flow through the venturi will result in more fuel being delivered to the engine, and less air flow through the venturi results in a decreased flow of fuel to engine.

B.

System components consist of the fuel/air control unit, the fuel distribution valve (flow divider), injection nozzles (4 total) and lines used to connect the components. A description of the components is as follows: (1) Fuel/Air Control Unit - The fuel/air control unit, also known as the 'servo regulator,' is located on the underside of the engine and integrates the functions of measuring airflow and controlling fuel flow. The control unit consists of an airflow sensing system, a regulator section and a fuel metering section. (2) Fuel Distribution Valve - The fuel distribution valve, also known as a 'spider' or a flow divider, is located on top of the engine and serves to distribute fuel evenly to the four cylinders once it has been regulated by the fuel/air control unit. Also attached to the fuel distribution valve is a rigid line which feeds into a pressure transducer. This transducer measures fuel pressure and translates that reading into fuel flow at the cockpit indicator. (3) Injection Nozzles - Each cylinder contains an injection nozzle, also known as an air bleed nozzle or a fuel injector. This nozzle incorporates a calibrated jet that determines, in conjunction with fuel pressure, the fuel flow entering each cylinder. Fuel entering the nozzle is discharged through the jet into an ambient air pressure chamber within the nozzle assembly. This nozzle assembly also contains a calibrated opening which is vented to the atmosphere, and allows fuel to be dispersed into the intake portion of the cylinder in an atomized, cone-shaped pattern.

Operation A.

Fuel is stored in the wing tanks and is delivered to the fuel injection system via a series of lines, valves and pumps. From the engine-driven fuel pump, fuel enters the fuel/air control unit, es through the fuel distribution valve, and is routed to individual injection nozzles at each cylinder. NOTE:

B.

For a schematic of the entire fuel system, refer to Chapter 28, Fuel Storage and Distribution - Description and Operation, Figure 1.

The heart of the injection system is the fuel/air control unit, which occupies the position ordinarily used by the carburetor at the engine intake manifold inlet. The fuel/air control unit is comprised of an integrated airflow sensing system, a regulator section and a fuel metering section. Operation of the fuel injection system is based on the principle of measuring airflow and using the airflow signal to operate a servo valve. The accurately regulated fuel pressure established by the servo valve, when applied across the fuel control system, makes fuel flow proportional to airflow. (1) THE AIRFLOW SENSING SYSTEM consists of a throttle body which houses the air throttle valve, the venturi, servo valve and fuel control unit. The differential pressure between impact air and the venturi throat pressure is a measurement of the velocity of the air entering the engine. These pressures are vented through drilled channels in the throttle body to both sides of an air diaphragm and create a force across the diaphragm. A change in air throttle position or a change in engine speed will change the air velocity, which in turn changes the force across the air diaphragm.


Page 1 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL

B235

I

IDLE VA CON T...L.IVR THROTTLE LEVER JTTLE LEVER LINK AGE

MANUAL MIXTURE U

CONTROL AND IDLE

VIEW A-A

CUT-OFF LEVER

!I 1 "

I

,;-- …------................

jI

I IE

THROTTLE VALVE I

IDLE SPEED ADJUSTMEN1 BALL VAI VF

CONSTANT HEAD IDLE SPRING

N

CONSTANT EFFORTSPRING AIR DIAPHRAGM FUEL DIAPHRAGM' ees * 1///////\ l///// r'/"///

/,l

INLET AIR I (SCOOP PRESSURE) /vclTII

V LI

IDI I 1I IrTInTl I II, U_ ...

.

v*

.

,1/8 INCH STAINLESS STEEL LINE

PRESSURE BELOW

THROTTLE iii.....i .. B:r::

FUEL INLET PRESSURE TO FUEL NOZZLE (ONE PER CYLINDER)

METERED FUEL PRESSURE (P1) METERED FUEL PRESSURE (P2)

Tfr CIl ICI FLOW GAUGE

__ NOZZLE DISCHARGE __B PRESSURE

FLOW GAUGE

05e16T2001

Fuel Injection System Schematic Figure 1 (Sheet 1)


Page 2 Apr 7/2003


MODEL -172 MAINTENANCE MANUAL (2) THE REGULATOR SECTION contains the air diaphragm mentioned in the preceding paragraph and a fuel diaphragm. Fuel inlet pressure is applied to one side of the fuel diaphragm. The other side of the fuel diaphragm is exposed to fuel that has ed through the metering jet (metered fuel pressure). The differential pressure across the fuel diaphragm is referred to as the fuel metering force. (a) The air metering force applied to the air diaphragm is transmitted through the regulator stem and tends to move the ball valve in the opening direction. The fuel metering force across the fuel diaphragm acts to oppose the air metering force and tends to close the ball valve. Because the air forces are very low in the idle range, a constant head idle spring is provided to maintain an adequate fuel metering force at low rpm. (b) As the air metering force increases, the spring compresses until the spring retainer touches the air diaphragm and acts as a solid member. The constant effort spring produces a force which provides a smooth transfer from idle to low power cruise operation. Whenever the air metering, fuel metering and spring forces are balanced, the ball valve maintains a fixed position. (3) THE FUEL METERING SECTION is contained within the throttle body casting and consists of an inlet fuel screen, a rotary idle valve and a rotary mixture valve. Both idle speed (closed throttle position) and idle mixture (relationship between throttle position and idle valve position) may be adjusted externally to meet individual engine requirements. (a) The idle valve is connected to the throttle valve by means of an external adjustable link. The idle valve controls fuel flow through the low speed range of operation and is adjustable to obtain good idling characteristics without affecting fuel metering in the high power range. (b) The mixture control valve gives full rich mixture on one stop and a progressively leaner mixture as it is moved toward idle cutoff. The full rich stop defines sea level requirements and the mixture control provides for altitude leaning.


Page 3 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL Fuel Injection System

-

TROUBLESHOOTING

1.

General A. This section gives troubleshooting information for the installation of the fuel injection system.

2.

Fuel Injection System Troubleshooting A. Do the troubleshooting procedures if the problem is found on the chart. Refer to Table 101.

Table 101. Fuel Injection System Troubleshooting PROBLEM HIGH FUEL FLOW READING.

UNSATISFACTORY FUEL CUTOFF. ENGINE WILL NOT INCREASE TO THE NECESSARY RPM.

PROBABLE CAUSE SOLUTION Plugged nozzle if the high fuel flow Remove and clean the nozzles. reading is combined with a loss of Soak the nozzles in Hoppes power and roughness. #9 Gun cleaning solvent for 20 minutes. Rinse the nozzles in a Stoddard solvent. Blow dry the nozzles. Do a check of the system for contamination. Faulty gage or pressure Replace the gage or pressure transdiir-pr tranndijr Incorrect installation of the aircraft Adjust the linkage. Refer to servo linkage to the mixture control. mixture value RS-16. Contamination in the air chamber. Refer to Precision Airmotive Corporation service information _____

ROUGH IDLE.

_____ _____

___________________________Contamination

____

letter RS-40.

Small air leaks in the induction system through loose intake pipes or a damaged 0-ring,

Do a check of the clamps and connectors. Repair leaks as necessary.

Large air leaks in the induction system.

Repair leaks as necessary.

Fuel vaporizes in the fuel lines or distributor. Found only in high ambient temperature conditions or after a long operation at a low RPM setting.

Keep temperatures low: Avoid long ground runs. During a hot engine restart: Operate the engine at 1,200 - 1,500 for several minutes to reduce residual heat in the engine

____ ____ ___ ___

LOW TAKEOFF FUEL FLOW.

_____

Faulty gage transducer.

____

or

___

___

pressure

in the flow divider.


compartment.

Replace the gage or pressure transducer. Clean the flow divider.

73-00-01

Page 101 Jan-1/2007


MODEL 172

MAINTENANCE MANUAL Table 101. Fuel Injection System Troubleshooting (continued) ENGINE IS DIFFICULT TO START. Incorrect starting procedure.

ENGINE OPERATES ROUGH.

Refer to the Pilot's Operating Handbook.

Flooded engine.

Crank the engine to clear it with the throttle open and the mixture in the IDLE/CUTOFF position.

Throttle valve is opened too far.

Open the throttle to approximately 800 RPM.

A prime that is not sufficient (usually combined with a backfire).

Increase the quantity of priming.

Adjust the mixture control. If the mixture is too rich, the engine will run smoothly when leaned. If the mixture is too lean, the engine will run smoothly when the mixture is enriched. Adjust idle mixture to give a 10 - 50 PRMV rise at idle. (usually Remove and cla tIIe nozzles nozzle(s) Plugged combined with high takeoff fuel Soak the nozzles in a Hoppes #9 Gun cleaning solvent for 20 flow). minutes. Rinse the nozzles with a Stoddard solvent. Blow dry the nozzles. Do a check of the system for contamination.

Too rich or too lean mixture.

Air leak in the induction system.

Do a check for leaks.

Air leak in the fuel line from the fuel Do a check for the leak. Connect clear tubing between the servo tank to the servo. and the flow divider and look for Find and correct air bubbles. the source of the leak. This can include the boost pump or the engine-driven pump. Flow divider sticks.

Do an inspection of the flow divider. Clean the flow divider.


Page 102 Janl1/2007


MODEL 172

MAINTENANCE MANUAL FUEL INJECTION SYSTEM

-


1.

General A. This section provides instructions for removal/installation, adjustment and cleaning of various components used in the fuel injection system. For maintenance information beyond the scope of this section, refer to applicable fuel injection component maintenance manuals which are listed in Introduction - List of Supplier Publications.

2.

Precautions A. Observe the following general precautions and rules during fueling, defueling, fuel bay purging, repairing, assembly or disassembly of system components, and electrical system checks and repairs on the airplane fuel system. (1) Plugs or caps should be placed on all disconnected hoses, lines and fittings to prevent residual fuel drainage, thread damage, or entry of dirt or foreign material into fuel system. (2) Any time fuel system is opened, flush system with 1/2 gallon of fuel at the inlet of servo and flow divider using the fuel boost pump. (3) When working on fuel injection system, keep all parts clean and free of contaminants.

3.

Fuel/Air Control Unit RemovaVlnstallation A. Remove Fuel/Air Control Unit. (1) Place cockpit-mounted FUEL SHUTOFF valve in the OFF position. (2) Remove lower cowling. Refer to Chapter 71, Cowling - Maintenance Practices. (3) Remove clamp securing induction air elbow to inlet adaptor. (4) Disconnect fuel inlet and outlet lines from control unit. (5) Remove mixture and throttle control linkages from control unit. Note number and position of washers for reinstallation. (6) Cut safety wire at base of control unit. Remove bolts securing inlet adaptor and throttle cable bracket to base of control unit and mixture cable bracket. (7) Remove nuts, lock washers and flat washers securing control unit to oil sump/intake manifold. Cover engine intake opening and place control unit in a sealed, dust-free environment to prevent accumulation of foreign particles into unit. B. Install Fuel/Air Control Unit. (1) Remove engine intake cover from sump area. (2) Install control unit, spacer and gaskets to sump using washers, new lock washers and nuts. Finger tighten nuts to control unit. (3) First torque nuts in a crisscross (opposite) pattern to 90 inch-pounds and then retorque nuts in the same manner to a final torque value of 180-200 inch pounds. (4) Install inlet adaptor and throttle cable bracket to base of control unit using hardware removed above. Safety wire bolts. (5) Install mixture cable bracket. (6) Install mixture and throttle control linkages to control unit. Ensure all washers are in proper position. Refer to Chapter 76, Throttle Control - Maintenance Practices, Figure 201 and Chapter 76, Fuel Mixture Control - Maintenance Practices, Figure 201 for an illustration of washer and linkage sequence.

CAUTION: Do not back the nuts off to line the cotter pin hole up with the castellations in the nut.

(7) Torque each nut to 30 inch-pounds and then proceed tightening the nut until the cotter pin hole lines up with the castellation in each nut. Do not exceed 50 inch-pounds. (a) If the cotter pin hole and the nut castellations will not line up, install a different thickness NAS1 149F0363P washer or use a thin, NAS1 149F0332P washer at the location between the throttle cable rod end and S1450-3-14-032 washer to obtain the specified torque on the nut. It may also be necessary to use a different AN310-3 nut. (8) Install cotter pins.


73-00-01

Page 201 Janl1/2007


MODEL 172 MAINTENANCE MANUAL (9) Move the mixture and throttle control through each controls entire range of movement and ensure that there is no binding. (10) Connect fuel inlet and outlet lines to control unit. (11) Secure induction air elbow to inlet adaptor using clamp. (12) Install lower cowling. Refer to Chapter 71, Cowling - Maintenance Practices. (13) Place cockpit-mounted FUEL SHUTOFF valve in the ON position. (14) Check for leaks during engine run. 4.

5.

Fuel Distribution Valve RemovaVinstallation A.

Remove Fuel Distribution Valve. (1) Remove upper cowling. Refer to Chapter 71, Cowling - Maintenance Practices. (2) Disconnect all lines leading in to and out of fuel distribution valve. (3) Remove nuts, bolts, washers and spacers securing fuel distribution valve to engine case.

B.

Install Fuel Distribution Valve. (1) Secure fuel distribution valve to engine case using nuts, bolts, washers and spacers. Torque to 75 In-lbs. (2) Reinstall all lines leading in to and out of fuel distribution valve. (3) Check for leaks during engine run. (4) Install upper cowling. Refer to Chapter 71, Cowling - Maintenance Practices.

Injection Nozzles Removal/installation A.

Remove Injection Nozzles. (1) Remove upper cowling. Refer to (Thapter 71, Cowling - Maintenance Practices. (2) Remove- rigid fuel lines leading into individual nozzles. (3) Remove nozzles from cylinders.

B.

Install Injection Nozzles.

CAUTION: Use only fuel-soluble lubricants (such as engine oil) on the nozzle threads during installation. (1) Install nozzles to intake cylinders. Torque from 55 to 60 In-lbs. (2) Install rigid fuel lines to nozzles. Torque 25 to 50 In-lbs. (3) Install upper cowling. Refer to Chapter 71, Cowling - Maintenance Practices. 6.

Injection Nozzle Flow Test A.

Check Injection Nozzles For Plugging. (1) If nozzle plugging is suspected, disconnect injector lines at the nozzles. (2) Cap nozzles with clean valve stem caps to protect nozzles from contamination during removal. (3) Remove nozzles. Refer to Injection Nozzles Removal/Installation. (4) Pull up injector lines taking care that lines are not kinked. (5) Install nozzles back into lines and torque from 25 to 50 in-lbs. (6) Using clear containers (bottles with graduations are preferred) flow fuel into containers using aircraft boost pump and observe nozzle discharge pattern. (7) When the mixture control is placed in the full rich position the nozzles should display a pencil stream pattern. The nozzles should also flow the same amount of fuel from cylinder to cylinder. If an unusual flow pattern or an unequal amount of fuel is noted in any of the containers the nozzles should be thoroughly cleaned. Refer to Injector Nozzle Cleaning. (8) After cleaning install clean protective valve stem caps. It is recommended that after cleaning the nozzles, they be reinstalled in the injector lines and a nozzle flow check is conducted to that the nozzles are clean. (9) Following a successful flow check reinstall the protective flow caps and reinstall the nozzles in the cylinders and torque from 55 to 60 in-lbs.. (10) Remove protective caps and reinstall injector lines to the nozzles and torque from 25 to 50 in-lbs. (11) Perform leak check.


Page 202 Janl1/2007



7.

Idle and Mixture Adjustment A. For airplanes with the RSA Fuel Injection System, refer to the Precision Airmotive Service Letter SIL RS-67. B. Adjustment Procedures (Refer to Figure 201).

WARNING: During adjustment procedure stay clear of propeller and/or propeller blast to avoid possible injury or death. NOTE:

-

Ensure that the alternate air door is in the closed position during this adjustment.

(1) Run engine to warm the oil to 150 degrees F. NOTE:

*

If the cowling is off, it may not be possible to attain 150 degrees oil temperature at cooler ambient temperatures. In that case it will be necessary to set idle speed and mixture at a lower temperature.

~~(2)

With the mixture control in the full rich position, set the idle speed to 675 +25 or -25 RPM. (3) Advance the throttle to approximately 1800 RPM and immediately return it to idle. Idle speed should be approximately the same as set above.

CAUTION: Adjust the fuel mixture control by rotating the knob briskly for approximately the first inch, then very slowly until the peak rpm is obtained and the engine speed starts to drop off. When the engine speed first starts to increase, a slight rise in rpm will be obtained. Then a speed hesitation will occur as the mixture control is continually moved toward the lean position. Do not mistake this as the total rpm rise. Continue the slow rotation movement of the mixture control until observing or sensing a drop in the engine rpm. This is the total rpm rise which indicates the mixture strength at the engine idle speed. (4)

Rotate the mixture control to lean the mixture. Note the rise in engine RPM. This rise should be set to 10 to 50 RPM. NOTE:

To aid in the adjustment of the fuel mixture, a stamp on one half of the clevis on the fuel servo indicates the direction that the thumb wheel should be moved to enrichen the mixture and increase the RPM rise. Likewise, rotating the thumb wheel in the opposite direction will lean the mixture and decrease the RPM rise.

(5) After each adjustment is made, the engine speed should be increased to approximately 1800 RPM and held for about 10-1 5 seconds to clean the spark plugs and clear the cylinders of excess fuel. (6) Return the throttle to the idle position. Repeat procedure until desired RPM rise at idle is obtained. NOTE:

(7)

If the mixture was excessively rich or lean when this procedure was started, the engine speed will require readjustment as the fuel mixture is adjusted to the desired value. Set the idle speed to the specified RPM after the mixture has been set to obtain the 10 to 50 RPM rise on lean out.

Run engine to full throttle and back to idle to that the setting has not changed.

(DCessna Aircraft Company

73-00-0 1

Page 203 Janl1/2007



B235

UEL JLET MtE I EMIl

JET

I.

IDLE VALVE LE\ CON NFC.TFn T( * TH R(DTTLE LEVER LINK AGE

*

I,

I

#5I

.I

~~~~~~~~~~IVIMI-WJL-L IVII/\ I LJFL VIEW

A-A

CONTROL AND IDLEL CUT-OFF LEVER

…~~~TRTL

I.

AV

IDLE SPEED ADJUSTMENI WALL V/ALVr-

CONSTANT HEAD IDLE SPRING CONSTANT EFFORT--_ SPRING AIR DIAPHRAGM

-

FUEL DIAPHRAGMv< INLET AIR (SCOOP PRESSURE) VENTURI SUCTION LM ...

PRESSURE BELOW TH ROTTLE FUEL INLET

PRESSURE ___METERED

FUEL

PRESSURE (Pl) METERED FUEL PRESSURE (P2)

I %.I

%J"L.

FLOW GAUGE

NOZZLE DISCHARGE 'M PRESSURE

0516T2001

Idle and Mixture Adjustment Figure 201 (Sheet 1)

73-00-01 0 Cessna Aircraft Company

Page 204 Jan 1/2007


MODEL 172 MAINTENANCE MANUAL (8) Re-cowl engine and run until oil temperature is 150 degrees F (minimum) to settings have not changed. NOTE:

Small changes in the idle speed and RPM are acceptable. Any large variations should be investigated.

8.

Injector Nozzle Cleaning A. The injector nozzles should be cleaned at time intervals set forth in Chapter 5, Inspection Time Limits. B. Cleaning Procedures. (1) Remove nozzles from engine. Individual two-piece nozzles should be kept as matched assemblies. (2) Inspect carefully for evidence of varnish build up and/or contaminated screens. (3) Soak nozzles in Methyl Ethyl Ketone, Acetone or other suitable solvent to remove all contamination and varnish from nozzle. Stubborn deposits may benefit from ultrasonic cleaning methods. (4) Dry nozzles using compressed shop air not to exceed 30 PSI. Blow through nozzle in direction opposite of fuel flow. (5) Install nozzles to intake cylinders. Torque from 55 to 60 In-lbs. (6) Install rigid fuel lines to nozzles. Torque 25 to 50 In-lbs. (7) Perform leak check.

9.

Fuel Strainer Cleaning A. The fuel strainer should be cleaned at time intervals set forth in Chapter 5, Inspection Time Limits. B. Cleaning Procedures (Refer to Figure 201). (1) Remove fuel inlet hose to access fuel strainer. (2) Remove and clean fuel strainer in Stoddard solvent. (3) Using new 0-rings, install fuel strainer to control unit. Torque 65 to 70 In-lbs. (4) Install the fuel inlet hose. Use a wrench to hold the fuel strainer adapter and torque to 270 to 300 in-lbs. (5) Perform leak check.

10.

Air Throttle Shaft Lubrication A. The air throttle shaft should be lubricated at time intervals set forth in Chapter 5, Inspection Time Limits. B. To lubricate air throttle shaft, apply a drop of engine oil to ends of air throttle shaft in such a manner that the oil can work into throttle shaft bushings.

73-00-01 (D Cessna Aircraft Company

Pagie 205 Janl/2007


MODEL 172

MAINTENANCE MANUAL FUEL FLOW INDICATOR - MAINTENANCE PRACTICES 1.

2.

General A.

Airplanes without Garmin G1000, engine fuel flow is measured by an engine-compartment attached transducer and an indicator in the cockpit. Components of the system are the fuel flow transducer, the EGT/Fuel Flow gage in the cockpit, wiring to connect the two electrical components and fuel line from the fuel distribution valve to the transducer.

B.

Maintenance practices are given for the removal and installation of the components.

C.

Airplanes with Garmin G1000 use the fuel flow transducer installed on the engine and the fuel flow indicator on the Garmin Display Units to show fuel flow. For information applicable to the Garmin Display Units, refer to Garmin Display Unit - Maintenance Practices.

EGT/Fuel Flow Gage Removal/Installation NOTE:

3.

The fuel flow gage is on the right half of the dual-function EGT/Fuel Flow gage on the left side of the instrument .

A.

Remove the Fuel Flow Gage. (1) Make sure all electrical power to the airplane is off. (2) Remove the screws that attach the gage to instrument . (3) Carefully remove the gage from the bottom side of the instrument and disconnect electrical connector from the gage.

B.

Install the Fuel Flow Gage. (1) Connect the electrical connector to the gage. (2) Install the gage in the instrument with the screws. (3) Make sure the gage operates correctly.

Transducer and Line Removal/Installation NOTE:

Transducer and line removal and installation are typical for all avionics packages.

A.

Remove the Transducer (Refer to Figure 201). (1) Make sure the electrical power to airplane is off. (2) Remove the upper cowl. Refer to Chapter 71, Cowling - Maintenance Practices. (3) Disconnect the electrical connector from the fuel flow transducer. (4) Disconnect the fuel line from the fuel distribution valve to the transducer. (5) Remove the transducer from the baffle. (6) Remove the fitting from the transducer.

B.

Install the Transducer (Refer to Figure 201). (1) Install the fitting and the O-ring in the transducer. (2) Install the fuel flow transducer to the baffle. (3) Connect the fuel line from the fuel distribution valve to the transducer. (a) Torque the fuel line to 25 in-lbs to 50 in-lbs (2.8 N-m to 5.6 N-m). (4) Connect the electrical connector to the fuel flow transducer. (5) Install the upper cowl. Refer to Chapter 71, Cowling - Maintenance Practices. (6) Make sure the gage operates correctly.


Page 201 Jan 3/2005



B1795

A ELECTRICAL CONNE( FUEL DISTRIBUTION VALVE

FUEL FLOW TRA FITTING O-RING ( ENGINE BAFFLE

NUT

RIGID FUEL LINE CLAMP

DETAIL A 0510T1007 A0516T1009

Fuel Flow Indicating Installation Figure 201 (Sheet 1)


Page 202 Jan 3/2005

CHAPTER

IGNITION




PAGE

DATE

74-00-00

Page 1

Apr 7/2003

74-10-00

Pages 101-102

Apr 7/2003

74-10-00

Pages 201-205

Apr 7/2003

74-30-00

Pages 601-602

Apr 7/2003





Page Number

Issue Date

By

Date Removed

By



CONTENTS IGNITION SYSTEM - GENERAL ............................

......................

Scope...................................................................... Tools, Equipment and Materials .............................................. Definition ................................................................... IGNITION SYSTEM - TROUBLESHOOTING .......................................

74-00-00 74-00-00 74-00-00 74-00-00

Page Page Page Page

1 1 1 1

74-10-00 Page 101 74-10-00 Page 101

General .................................................................... IGNITION SYSTEM - MAINTENANCE PRACTICES ................................ Description and Operation ................................................... Magneto Removal/Installation................................................ Magneto-to-Engine External Timing Adjustment................................ Magneto-to-EngineTiming Check.............................................

74-10-00 74-10-00 74-10-00 74-10-00 74-10-00


201 201 201 204 204

IGNITION SWITCH - INSPECTION/CHECK........................................ Description ................................................................. Tools, Equipment and Materials .............................................. ACS Ignition Switch Inspection and Lubrication ................................

74-30-00 74-30-00 74-30-00 74-30-00

Page Page Page Page

601 601 601 601




MODEL 172 MAINTENANCE MANUAL IGNITION SYSTEM - GENERAL 1.

Scope A.

2.

This chapter covers the ignition system used on the 10-360 L2A engine.


Refer to the following table for tools, equipment and material used throughout the chapter.

NAME

NUMBER

MANUFACTURER

USE

Luberex Grease

10-1206

Cessna Aircraft Company Cessna Parts Distribution Department 701, D 25800 East Pawnee Wichita, KS 67218-5590

To lubricate ignition switch components.

Ignition Switch Parts Kit

A3770

Cessna Aircraft

To rebuild ignition switch.

3.

Definition A.

This chapter contains two sections on the ignition system. The first section provides a troubleshooting chart to aid in identifying common problems which may occur in the ignition system. The second section contains maintenance practices for the ignition system.


74-00-00 Page 1 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL IGNITION SYSTEM - TROUBLESHOOTING

1.

General A.

The following chart has been provided to aid maintenance technicians in system troubleshooting. This chart should be used in conjunction with Chapter 71, IO-360-L2A - Troubleshooting to provide a comprehensive look at solutions to engine problems. For information beyond the scope of this chapter, refer to applicable engine and ignition system manuals and publications listed in Introduction - List of Supplier Catalogs.

TROUBLE

PROBABLE CAUSE

REMEDY

ENGINE WILL NOT START

Defective ignition switch.

Check switch continuity. Replace if defective.

Spark plugs defective, improperly gapped or fouled by moisture or deposits.

Clean, regap and test plugs. Replace if defective.

Defective ignition harness.

If no defects are found by a visual inspection, check with a harness tester. Replace defective parts.

Magneto "P" lead grounded.

Check continuity. "P" lead should not be grounded in the ON position, but should be grounded on OFF position. Repair or replace "P" lead.

Failure of impulse coupling.

Impulse coupling pawls should engage at cranking speeds. Listen for loud clicks as impulse couplings operate. Remove magnetos and determine cause. Replace defective magnetos.

Defective magneto.

Refer to Ignition System Maintenance Practices.

Broken drive gear.

Remove magneto and check magneto and engine gears. Replace defective parts. Make sure no pieces of damaged parts remain in engine, or engine disassembly will be required.

Spark plugs defective, improperly gapped or fouled by moisture or deposits.

Clean, regap and test plugs. Replace if defective.

Defective ignition harness.

If no defects are found by a visual inspection, check with a harness tester. Replace defective parts.

ENGINE WILL NOT IDLE OR RUN PROPERLY.


Page 101 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL TROUBLE

PROBABLE CAUSE

REMEDY

Defective magneto.

Refer to Ignition System Maintenance Practices.

Impulse coupling pawls remain engaged.

Listen for loud clicks as impulse coupling operates. Remove magneto and determine cause. Replace defective magneto.

Spark plugs loose.

Check and install properly.


Page 102 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL IGNITION SYSTEM - MAINTENANCE PRACTICES 1.

Description and Operation A. B.

C.

2.

The engine uses two Unison/Slick 4371 series, impulse-coupled magnetos to fire two spark plugs in each cylinder. For complete description, operation, troubleshooting, maintenance, overhaul and lubrication requirements of the magnetos, refer to the Lycoming Direct Drive Engine Overhaul Manual, Lycoming Operators Manual, Lycoming Service Instruction 1437 and the Unison 4300/6300 Series Magneto Maintenance and Overhaul Manual. For the inspection time requirements of the magnetos, refer to Chapter 5, Inspection Time Limits. For the inspection procedures, refer to the Unison 4300/6300 Series Magneto Maintenance and Overhaul Manual.

Magneto Removal/Installation NOTE: A.

The removal and installation for each magneto is typical.

Remove the Magneto (Refer to Figure 201). (1) Remove the engine cowl. Refer to Chapter 71, Engine Cowl - Maintenance Practices. WARNING: MAKE SURE THAT EACH MAGNETO P LEAD IS GROUNDED. WARNING: BEFORE YOU ROTATE THE PROPELLER REMOVE A MINIMUM OF ONE SPARK PLUG FROM EACH CYLINDER TO PREVENT THE START OF THE ENGINE. (2) Remove the screws that attach the high tension outlet cover to the magneto. (3) Disengage the high tension cover from the magneto. (4) For a reference point when you install the magneto, turn the propeller in the normal direction until each impulse coupling releases near Top Dead Center (TDC) on the number one cylinder compression stroke. NOTE:

You will hear a click sound from the impulse couplings when they release.

(5) The crankshaft position can be found by the marks on the front or aft face of the starter ring gear . Refer to the Lycoming Service Instruction 1437 or latest revision for more instructions. (a) When you use the marks on the front face of the ring gear, they must be aligned with the small hole that is found at the two o'clock position on the front face of the starter housing. (b) When you use the marks on the aft face of the ring gear, they must be aligned with the engine case parting line. (6) Turn the propeller in the opposite direction of the normal propeller operation to approximately 30 degrees BTDC (Before Top Dead Center) on the number one cylinder compression stroke. (7) Turn the propeller in the normal direction to 25 degrees BTDC on the number one cylinder compression stroke. (8) Disconnect the P lead and ground wire from the magneto. (9) Examine the magneto angle to help make sure you put it in the same position for installation. (10) Remove the nuts, washers and clamps that attach the magneto to the engine housing. (11) Remove the magneto from the housing. B.

Install the Magneto (Refer to Figure 201). (1) Apply a small quantity of silicone grease such as DC4 to each side of the new magneto base gasket, which will help future timing adjustments. (2) Make sure the magneto drive gear is installed correctly, the nut torqued correctly and the cotter pin is installed. Refer to the Lycoming Service Instructions 1437 or latest revision and the Unison 4300/6300 Magneto Maintenance and Overhaul Manual Instructions.


Page 201 Apr 7/2003



B1421

VACUUM PUMP

REAR RAFFLE

MAGNETOS ENGINE DRIVEN FUEL PU

VACUUM PUMP (NOT -USTRATED)

TAIL PIPE

FUEL STRAINER DRAIN

0550T1007

Magneto Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL CAUTION: MAKE SURE YOU REMOVE THE T-118 TIMING PIN IMMEDIATELY AFTER YOU ATTACH THE MAGNETO TO THE ACCESSORY CASE AND BEFORE THE MAGNETO OR PROPELLER IS TURNED. (3) Insert the T-118 timing pin into the L timing hole in the magneto distributor block. (4) Turn the magneto rotor in the opposite of normal direction until the timing pin is engaged fully into the distributor gear. (a) If the magneto rotor does not move freely and the pin will not go into the hole in the gear, the pin has hit the pointer on the gear. (b) Pull the pin out far enough to continue to turn the magneto freely in the opposite direction of normal movement until the pointer has ed the pin, then insert the pin. 1 Turn the magneto rotor until the pin engages the gear. (5) Do a check of the crankshaft to make sure the propeller has not moved and is still set in position with the number one cylinder at 25 degrees BTDC (Before Top Dead Center) on the compression stroke. (6) If the propeller as been turned and only one magneto was removed, it will be necessary to engage the impulse coupling on the magneto that is installed, and establish the crankshaft position. Refer to step 2.A.(4) thru 2.A.(7) before you continue. (7) With the number one cylinder at 25 degrees BTDC on the compression stroke, do the steps that follow.

CAUTION:

MAKE SURE YOU REMOVE THE T-118 TIIVIING PIN IMMEDIATELY AFTER YOU ATTACH THE MAGNETO TO THE ACCESSORY CASE AND BEFORE THE MAGNETO OR PROPELLER IS TURNED.

(a) (b)

(8) (9) (10) (11) (12) (13) (14)

Install the magneto with the new base gasket and the T-118 timing pin in position. Engage the magneto drive gear with the engine gear, in a position that will give a range of magneto timing adjustments in each direction. (c) Hold the magneto in position against the accessory case and install the nuts, flat washers, clamps and new lock washers. (d) Finger tighten each nut by hand. (e) Remove the timing pin. Before you continue, you must adjust the magneto timing. Refer to Magneto-to Engine External Timing Adjustment. With the magneto set in position, first tighten each nut to 8 foot-pounds (10 N.m). Tighten each nut from one side to another, to a torque of 17 foot-pounds (23 N.m). Connect the P lead to the magneto. Attach a ground wire to the magneto. Attach the high tension outlet cover to the magneto. Tighten the P lead nut to a torque of 13 to 15 inch-pounds (17 to 20 N.m).

CAUTION: MAKE SURE YOU REMOVE THE T-118 TIMING PIN BEFORE THE MAGNETO OR PROPELLER IS TURNED. (15) Install the spark plugs. (16) Install the cowl. Refer to Chapter 71, Engine Cowl - Maintenance Practices. (17) Complete a engine preflight operational check of the ignition system. Refer to the Pilot's Operating Handbook.


Page 203 Apr 7/2003



3.

Magneto-to-Engine External Timing Adjustment A.

Adjust the Magneto-to-Engine Timing (Refer to Figure 201). NOTE:

(1)

(2) (3) (4) (5) (6)

The Magneto-to-Engine timing can be adjusted a maximum total of 0.125 inch (3.17 mm) movement from the original factory position, or between each internal timing adjustment. The external timing movement of 0.125 inch (3.17 mm) approximately equals 5 degrees of internal timing change.

Before the first field adjustment of external timing, the magneto and accessory case must be indexed as necessary to monitor external timing adjustments. (a) The magneto must be removed and internal timing adjusted in accordance with Unison 4300/6300 Series Aircraft Magnetos Maintenance and Overhaul Instructions Form L-1363B or latest revision, when the external timing adjustments collect up to 0.125 inch (3.17 mm) movement change. Make sure the ignition is in the OFF position. Remove the engine cowl. Refer to Chapter 71, Engine Cowl - Maintenance Practices. Remove a minimum of one spark plug from each cylinder. Make sure that cylinder number one is at 25 degrees BTDC (Before Top Dead Center) on the compression stroke. Connect a standard aircraft magneto timing light between a acceptable engine ground and the P lead terminal of the magneto. NOTE:

(7) (8)

Most standard aircraft magneto timing lights show open points with a Light On condition and/or a signal that you can hear.

Loosen the mount clamps that attach the magneto to the accessory case so that the magneto will turn on the accessory case. Turn the ignition switch to the BOTH position. (a) Look at the magneto from the aft side of the engine. 1 If the timing light is luminated, turn the magneto frame clockwise until the timing light shuts off. 2 Turn the magneto frame counter-clockwise until the timing light comes on, which shows that the breaker points are open.

CAUTION : DO NOT TORQUE THE NUTS MORE THAN 17 FOOT-POUNDS (23 N.m.) OR THE MOUNTING FLANGE CAN CRACK. (9) With the magneto set in position, first tighten each nut to 8 foot-pounds (10 N.m). (10) Tighten each nut from one side to another, to a torque of 17 foot-pounds (23 N.m). (11) Complete a check of the magneto timing to make sure it has not changed. Refer to Magnetoto-Engine Timing Check. 4.

Magneto-to-EngineTiming Check A.

Complete a Check of the Magneto-to-Engine Timing (Refer to Figure 201). (1) Make sure the ignition is in the OFF position. (2) Remove the engine cowl. Refer to Chapter 71, Engine Cowl - Maintenance Practices. (3) Remove a minimum of one spark plug from each cylinder. (4) Connect a standard aircraft magneto timing light between an acceptable engine ground and the P lead terminal of the magneto. NOTE: (5)

Most standard aircraft magneto timing light indicate open points with a Light On condition and/or an signal that you can hear.

Turn the ignition switch to the BOTH position.


Page 204 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL (6) Turn the propeller in the normal direction of movement until each impulse coupling releases as the number one cylinder moves near TDC (Top Dead Center) on the compression stroke. NOTE:

You will hear a click sound from the impulse couplings when they release.

(7) Turn the propeller in the opposite direction of normal movement to approximately 30 degrees BTDC (Before Top Dead Center) on the number one cylinder compression stroke. (8) Slowly turn the propeller in the normal direction of movement until the timing light comes on. (9) Examine the crankshaft to make sure it is in the correct position. NOTE:

The timing light must come on at 25 degrees BTDC with the number one cylinder on the compression stroke.

(10) If the crankshaft is not in the correct position you will have to make an adjustment. Refer to Magneto-to-Engine External Timing Adjustment. (11) Turn the ignition switch to the OFF position. (12) Install the spark plugs. (13) Install the ignition leads on the spark plugs. (14) Install the cowl. Refer to Chapter 71, Engine cowl - Maintenance Practices. (15) Complete a engine preflight operational check of the ignition system. Refer to the pilot's operating handbook.


Page 205 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL IGNITION SWITCH - INSPECTION/CHECK 1.

Description A.

2.

Tools, Equipment and Materials A.

3.

The following inspection and lubrication procedures are designed for the ACS brand ignition switch and should be accomplished every 2000 hours.

Refer to Ignition System - General for a list of required tools, equipment and materials.

ACS Ignition Switch Inspection and Lubrication NOTE: A.

Refer to Figure 601 for the following steps.

Switch Removal. (1) Disconnect battery. (2) Remove switch assembly from instrument by loosening locknut on the forward side of and removing decorative nut on aft side of . NOTE:

Wiring need not be removed from posts of switch if wiring is of sufficient length to allow switch assembly to be moved to a position where disassembly can be accomplished. If wiring is to be disconnected, tag or mark wires for reinstallation.

B.

Switch Disassembly. (1) Hold switch body in position shown in Figure 601. (2) Remove screws and washers. (3) Lift terminal board assembly from body, being careful not to lose springs and cups.

C.

Switch Cleaning. (1) Clean switch s and the three movable cups using alcohol on a cotton tip swab.

D.

Switch Inspection. (1) Inspect movable cups and switch s on the terminal board assembly for excessive wear or corrosion and for loose s or terminals. If the silver plating on the cups is worn through to the brass material, or they are burned or pitted from arcing or are corroded, they should be replaced. If the s on the block exhibit any of the above conditions or the terminals are loose, the terminal board assembly should be replaced.

E.

Switch Reassembly. (1) Apply a thin coating of Luberex 10-1206 lubricant to switch s and the three movable cups. Ensure all areas are covered with lubricant. (2) Reassemble switch using new parts, if required. Ensure that cups and springs are positioned in switch body so that no binding occurs. Secure terminal board assembly to switch body with retained washers and screws. (3) Mark switch with a dab of red paint on the terminal board retaining screws. (4) If removed, reconnect wiring to backside of switch. (5) Install switch in and secure using existing hardware. (6) Reconnect battery and perform an operational check of the switch.

F.

Operational Check. (1) Start engine. Refer to Model 172R Pilot's Operating Handbook and FAA Approved Airplane Flight Manual. (2) Check magnetos for normal engine RPM drop. (3) that both magnetos are grounded when switch is in the OFF position. (a) Reduce engine RPM to idle, and turn switch to the OFF position. Engine should quit immediately, signifying that both magnetos have been grounded through the ignition switch. (4) After engine stops, move mixture control to idle cutoff position.


Page 601 Apr 7/2003



B1796

SWITCH S

TERMINAL BOARD ASSEMBLY SWITCH LOCKWASHE

SCREW

DETAIL

A

0510T1007 A0558T1004

ACS Ignition Switch Inspection/Lubrication Figure 601 (Sheet 1)


Page 602 Apr 7/2003

CHAPTER

ENGINE CONTROLS




PAGE

DATE

76-00-00

Page 1

Apr 7/2003

76-10-00

Pages 201-203

Jan 2/2006

76-11-00

Pages 201-203

Jan 2/2006





Page Number

Issue Date

By

Date Removed

By



CONTENTS ENGINE CONTROLS - GENERAL ................................................

Scope. ..................................................................... Definition ................................................................... THROTTLE CONTROL - MAINTENANCE PRACTICES ............................. General ................................................................... Throttle Control Removal/Installation......................................... Throttle Control Adjustment/Test.............................................. Throttle Control Inspection/Check ............................................ FUEL MIXTURE CONTROL - MAINTENANCE PRACTICES......................... General ....................................................................

Fuel Mixture Control Removal/Installation ..................................... Fuel Mixture Control Adjustment/Test ......................................... Fuel Mixture Control Inspection/Check ........................................

76-00-00 Page 1 76-00-00 Page 1 76-00-00 Page 1 76-10-00 76-10-00 76-10-00 76-10-00 76-10-00


76-11-00 76-11-00 76-11-00 76-11-00 76-11-00



201 201 201 201 203



MODEL 172 MAINTENANCE MANUAL ENGINE CONTROLS - GENERAL

1.

Scope A.

2.

This chapter describes those controls used to regulate engine power.

Definition A.

This Chapter is divided into sections to aid maintenance technicians in locating information. Consulting the Table of Contents will further assist in locating a particular subject. A brief description of the sections follows: (1) The section on throttle control describes the throttle handle, cable and linkage. (2) The section on fuel mixture control describes the mixture handle, cable and linkage. (3) Both sections include removal/installation, rigging and inspection requirements.


Page 1 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL THROTTLE CONTROL - MAINTENANCE PRACTICES 1.

General A.

The throttle control is the push-pull type that incorporates a knurled friction knob, which prevents vibration induced "creeping" of the control. The ball bearing-type rod end on the throttle is secured to the engine with a predrilled AN bolt, a castellated nut and a cotter pin. NOTE:

2.

Steel AN bolts with an undrilled shank are identified with an "A" suffix (AN3-6A). A steel bolt of the same size, with the shank drilled for castellated nut and cotter pin is identified as AN3-6. Aluminum AN bolts shall not be used in this application.

B.

When adjusting the throttle control, it is important to check that throttle control slides smoothly throughout its full range of travel, that it locks securely with the friction lock and the throttle arm operates through its full arc of travel. Do not lubricate throttle control. If excessive binding is noticed, replace throttle control.

C.

Whenever engine controls are being disconnected, pay particular attention to the exact position, size and number of attaching parts for re-connecting controls.

Throttle Control Removal/Installation A.

B.

Remove Throttle Control (Refer to Figure 201). (1) Remove engine cowling. Refer to Chapter 71, Cowling - Maintenance Practices. (2) Remove cotter pin, castellated nut, bolt and washers securing throttle control rod end to throttle body arm. (3) Remove clamp securing throttle control to engine mount. (4) Remove throttle cable retaining nut and washer from forward side of firewall. (5) Inside the cockpit/cabin area, remove throttle cable retaining nut and washer from forward side of instrument . (6) Carefully pull throttle control through firewall and instrument , and remove from airplane. Install Throttle Control (Refer to Figure 201). NOTE:

When installing throttle control, ensure that control is routed exactly as previously installed. Ensure that no binding or preloading occurs from a too small bend radius.

(1)

Inside the cockpit/cabin area, carefully route throttle control rod end through instrument and then place washer and retaining nut over rod end. (2) Route throttle control rod end through firewall and position throttle control in instrument . (3) Secure throttle control in instrument by tightening retaining nut against washer and instrument . NOTE:

To prevent damage to the instrument finish and markings, ensure the control housing does not rotate against the instrument during installation.

(4) In the engine compartment, place washer and retaining nut over throttle control rod end and secure against firewall. (5) Attach throttle control rod end to throttle body with bolt, washers, castellated nut and cotter pin. (6) Secure throttle control to engine mount with clamp. (7) Adjust throttle control as required. Refer to Throttle Control Adjustment/Test. (8) Install engine cowling. Refer to Chapter 71, Cowling - Maintenance Practices. 3.

Throttle Control Adjustment/Test A.

Check Throttle Control (Refer to Figure 201). (1) Pull throttle control knob full out and check that idle stop on throttle body is ed. (2) Push throttle control knob full in and check that full power stop on throttle body is ed. (3) Do a check to make sure that the throttle has no less than 0.12-inch (3.18 mm) and no more than 0.25-inch (6.35 mm) cushion at each stop.


Page 201 Jan 2/2006



INSTRUMENT LOCKWASHEI JAMNUT

FIREWAL

LOCKWASHER /

THROTTLE ASSEMBLY

CASTELLATED WA

DETAIL

A

0510T1007 0515T1005

Throttle Control Installation Figure 201 (Sheet 1)


Page 202 Jan 2/2006



B.

4.

(4) Work throttle control in and out several times to check for binding. Adjust Throttle Control (Refer to Figure 201). (1) Disconnect throttle control rod end from the throttle body. (2) Loosen jam nut and adjust throttle control rod end to obtain desired setting. (3) Tighten jam nut. (4) Connect throttle control rod end to throttle body.

Throttle Control Inspection/Check A.

Inspection of Throttle Control. (1) The throttle control attachment to throttle body should be inspected in accordance with time limits established in Chapter 5, Inspection Time Limits. Do a check of the bolt, castellated nut, cotter pin, rod end, and rod end jam nut for security and condition. (2) Do a check of the rod end witness hole for proper rod end engagement with the throttle control. (3) Do a check to make sure that the throttle control slides smoothly throughout its full range of travel, that it locks securely with the friction lock, and that the throttle arm operates through its full arc of travel.


Page 203 Jan 2/2006


MODEL 172 MAINTENANCE MANUAL FUEL MIXTURE CONTROL - MAINTENANCE PRACTICES 1.

General A.

The mixture control is the push-pull type that incorporates a threaded vernier mechanism for fine adjustment. The ball bearing rod end on the mixture control is secured to the engine with a predrilled AN bolt, a castellated nut and a cotter pin. NOTE:

2.

Steel AN bolts with an undrilled shank are identified with an 'A' suffix (AN3-6A). A steel bolt of the same size, with the shank drilled for castellated nut and cotter pin is identified as AN3-6. Aluminum bolts and undrilled bolts must not be used in this application.

B.

When adjusting the fuel mixture control, it is important to check that fuel mixture control slides smoothly throughout its full range of travel, that it adjusts through its full vernier range and the mixture arm operates through its full arc of travel. Do not lubricate fuel mixture control. If excessive binding is noticed, replace fuel mixture control.

C.

Whenever engine controls are being disconnected, pay particular attention to the exact position, size and number of attaching parts as noted when connecting controls.

Fuel Mixture Control Removal/Installation A.

B.

Remove Fuel Mixture Control (Refer to Figure 201). (1) Remove engine cowling. Refer to Chapter 71, Cowling - Removal/Installation. (2) Remove cotter pin, nut, bolt and washers securing mixture control rod end to throttle body mixture arm. (3) Remove clamp securing fuel mixture control to mixture control bracket. (4) Remove fuel mixture control retaining nut and washer from forward side of firewall. (5) In the cockpit/cabin area, remove mixture control retaining nut and washer from forward side of instrument . (6) Carefully pull mixture control through firewall and instrument , and remove from airplane. Install Fuel Mixture Control (Refer to Figure 201). NOTE:

When installing mixture control ensure that control is routed exactly as previously installed. Ensure that no binding or preloading occurs from a too small bend radius.

(1) In the cabin/cockpit area, carefully route fuel mixture control through instrument , and then place washer and retaining nut over fuel mixture control rod end. (2) Route fuel mixture control through firewall. (3) Secure fuel mixture control in instrument by tightening retaining nut against washer and instrument . NOTE:

To prevent damage to the instrument finish and markings, ensure the control housing does not rotate against the instrument during installation.

(4) In the engine compartment, place washer and retaining nut over fuel mixture control rod end and secure against firewall. (5) Attach mixture control rod end to throttle body mixture arm with bolt, washers, nut and cotter pin. (6) Secure fuel mixture control to mixture control bracket with clamp. (7) Install Engine Cowling. Refer to Chapter 71, Cowling - Removal/Installation. 3.

Fuel Mixture Control Adjustment/Test A.

Check Fuel Mixture Control. (1) Push fuel mixture control full in and that mixture arm on throttle body is fully open (rich). (2) Pull fuel mixture control full out and that mixture arm on throttle body is fully closed (lean). (3) Do a check to make sure that the fuel mixture control has no less than 0.12-inch (3.18 mm) and no more than 0.25-inch (6.35 mm) cushion at each stop. (4) Work fuel mixture control in and out several times to check for binding. 76-11-00 © Cessna Aircraft Company

Page 201 Jan 2/2006



INSTRUMENT

ITH

JAMNUTS WITH WASHERS

ER

FIREW

ARM /

MIXTURE CABLE

BOLT

NUT

LARGE WA WA

PIN

DETAIL A 0510T1007 A0515T1008

Fuel Mixture Control Figure 201 (Sheet 1)


Page 202 Jan 2/2006



I I 4.

Adjust Fuel Mixture Control. (1) Disconnect fuel mixture control rod end from throttle body. (2) Loosen jam nut and adjust rod end to obtain desired setting. The witness hole in the rod end must be covered with the mixture cable threads. (3) Tighten jam nut. (4) Connect rod end to throttle body. If necessary, you can reposition the mixture control housing in the mixture control bracket clamp.

Fuel Mixture Control Inspection/Check A.

Inspect Fuel Mixture Control. (1) The mixture control attachment to the throttle body should be inspected in accordance with time limits established in Chapter 5, Inspection Time Limits. Check bolt, castellated nut, cotter pin and rod end for security and condition. The witness hole in the rod end must be covered with the mixture cable threads. Check that fuel mixture control slides smoothly throughout its full range of travel, that it adjusts through its full vernier range and the mixture arm operates through its full arc of travel.


Page 203 Jan 2/2006

CHAPTER

ENGINE INDICATING



LIST OF EFFECTIVE PAGES PAGE

DATE

77-00-00

Page 1

Apr 7/2003

77-1 0-00

Pages 201-203

Jul 1/2007

77-20-00

Page 1

Jan 3/2005

77-20-00

Pages 201 -205

77-40-00

Pages 201 -202

Jan 3/2005 Jul 3/2006

CHAPTER-SECTION-SUBJ ECT 77-Title 77-List of Effective Pages 77-Record of Temporary Revisions 77-Table of Contents


-




Page Number

Issue Date

By

Date Removed

By



CONTENTS ENGINE INDICATING - GENERAL......................... Scope.................................... Definition .................................. TACHOMETER - MAINTENANCE PRACTICES................... Description and Operation .......................... Tachometer and Drive Cable Removal/Installation................ Tachometer Sending Unit Removal/Installation ................. ENGINE TEMPERATURE - DESCRIPTION AND OPERATION............ Description ................................. Operation.................................. ENGINE TEMPERATURE INDICATING SYSTEM - MAINTENANCE PRACTICES. Description and Operation .......................... EGT Indicator Removal/Installation ...................... EGT Probe Removal/Installation........................ EGT Probe Removal/installation (Airplanes with Garmin G1000)......... CHT Probe Removal/Installation........................ ENGINE/AIRFRAME UNIT - MAINTENANCE PRACTICES.............. General................................... Troubleshooting ............................... GEA 71 Engine/Airframe Unit Removal/installation ...............

77-00-00 Page 1 77-00-00 Page 1 77-00-00 Page 1 77-1 0-00 77-1 0-00 77-1 0-00 77-1 0-00

201 201 201 201

77-20-00 Page 1 77-20-00 Page 1 77-20-00 Page 1 77-20-00 77-20-00 77-20-00 77-20-00 77-20-00 77-20-00


201 201 201 201 201 205

77-40-00 77-40-00 77-40-00 77-40-00

Page Page Page Page

201 201 201 201


Page Page Page Page



MODEL 172 MAINTENANCE MANUAL ENGINE INDICATING - GENERAL 1.

Scope A.

2.

This chapter describes those components used to measure and indicate engine output.

Definition A.

This chapter is divided into sections to aid maintenance technicians in locating information. Consulting the Table of Contents will further assist in locating a particular subject. A brief description of the sections follows: (1) The section on tachometer describes the instrument used to measure engine RPM. (2) The section on exhaust gas temperature describes the system used to monitor and measure engine temperature.


Page 1

Apr 7/2003


MODEL 172 MAINTENANCE MANUAL TACHOMETER

-


1.Description and Operation A.

B.

2.

On airplanes with standard avionics, the engine speed (RPM) is measured by an indicator in the cockpit. The tachometer maintenance practices give removal and installation procedures for the tachometer and drive cable. On airplanes with Garmin G1000, the engine speed (RPM) is measured by the tachometer sending unit and changed to an electrical signal. The Garmin Control Display Units (CDU) display the engine speed. The tachometer maintenance practices give removal and installation procedures for the tachometer sending unit.

Tachometer and Drive Cable Removal/installation NOTE: A.

B.

3.

Airplanes without Garmin G1000 have a tachometer and drive cable.

Remove the Tachometer and Drive Cable (Refer to Figure 201). (1) Disconnect the drive cable from the tachometer. (2) Disconnect the electrical connector (J1014) from the tachometer. (3) Remove the screws that attach the tachometer to the instrument and remove the tachometer. (4) Remove the upper engine cowl. Refer to Chapter 71, Engine Cowling - Maintenance Practices. (5) Disconnect the drive cable at the rear of the accessory case. (6) Remove the two screws that attach the firewall shield to the firewall. (7) Remove the drive cable through the firewall. Install the Tachometer and Drive Cable (Refer to Figure 201). (1) Install the drive cable through the firewall. (2) Connect the drive cable to the accessory case housing. (3) Install the firewall shield to the firewall with the screws. (4) Install the tachometer to the instrument with the screws. (5) Connect the electrical connector (JI014) to the tachometer. (6) Connect the drive cable to rear of the tachometer. (7) Install the upper engine cowl. Refer to Chapter 71, Engine Cowling - Maintenance Practices.

Tachometer Sending Unit Remova~l/nstallation NOTE:

Airplanes with Garmin G1000 have a tachometer sending unit.

A.

Remove the Tachometer Sending Unit (Refer to Figure 202). (1) Make sure the MASTER switch is in the off position. (2) Remove the side cowl. Refer to Chapter 71, Cowl - Maintenance Practices. (3) Disconnect the electrical connector. (4) Loosen the knurled nut. (5) Remove the tachometer sending unit from the airplane.

B.

Install the Tachometer Sending Unit (Refer to Figure 202). (1) Put the tachometer sending unit in position on the airplane. (2) Tighten the knurled nut. (3) Connect the electrical connector. NOTE:

If irregular tachometer indications have occurred, the use of Stabilant 22 enhancer on the electrical connector (PN025) can possibly decrease the occurrence

of these indications. (4) Install the side cowl. Refer to Chapter 71, Cowl

-

Maintenance Practices.


Page 201

Jul 1/2007


MODEL 172

MAINTENANCE MANUAL

91799

A

TACHOM ETER DRIVE CABLE

INSTRUMENT

El

DETAIL A

(WITHOUT GARMIN G1000)

as51rOT1D0 A0514T1 018

Tachometer Installation Figure 201 (Sheet 1)

77-1 0-00 ©Cessna Aircraft Company

Page 202 Jul 1/2007

0


MODEL 172

MAINTENANCE MANUAL

W3M30

A

. -

VIEw

A-A

TACHOMETER 0CK1F`%hI~rf1 1 WMI

ELECTRICAL CON NECTOR (PN025)

DETAIL A

(WITH GARMIN G1 000)

051 OTI 007 AAO55OTl 008 A0l758T1 003

Tachometer Sending Unit Installation Figure 202 (Sheet 1)


Page 203 Jul 1/2007


MODEL 172

MAINTENANCE MANUAL ENGINE TEMPERATURE - DESCRIPTION AND OPERATION 1.

Description A.

2.

The section that follows has removal and installation procedures for the system which will show different temperatures in the engine. The system that shows the temperature for the engine includes the indicators and probes for the Cylinder Head Temperature (CHT) and Exhaust Gas Temperature (EGT).

Operation A.

The EGT system is used to measure the temperature of the exhaust gas. The measurement gives an indication of the fuel/air mixture for the pilot. The system has one indicator installed in the instrument , which gives the two functions that show the EGT and CHT information. A probe installed in the exhaust and a probe installed in a cylinder, send the temperature information to the EGT/CHT indicator. On airplanes with Garmin G1000, each cylinder has EGT and CHT probes.


Page 1

Jan 3/2005


MODEL 172 MAINTENANCE MANUAL ENGINE TEMPERATURE INDICATING SYSTEM - MAINTENANCE PRACTICES 1.


2.

Maintenance of the engine temperature system includes the removal and installation of the different components.

EGT Indicator Removal/Installation NOTE:

3.

The procedures that follow are for airplanes without Garmin G1000.

A.

Remove the EGT Indicator (Refer to Figure 201). (1) Get access to the forward side of the indicator. (2) Disconnect the electrical connector from the indicator. (3) Remove the screws that attach the indicator to the instrument and remove the indicator from the airplane.

B.

Install the EGT Indicator (Refer to Figure 201). (1) Put the indicator in the instrument and attach with the screws. (2) Connect the electrical connector to the indicator.

EGT Probe Removal/Installation NOTE: A.

The procedures that follow are for airplanes without Garmin G1000.

Remove the EGT Probe (Refer to Figure 201). (1) Remove the engine cowl. Refer to Chapter 71, Engine Cowling - Maintenance Practices.

CAUTION: Make sure that the exhaust system and engine are cool before you remove the probes. (2) (3) (4) B.

4.

Cut the tie strap that attaches the electrical connectors (JN006) and wire. Disconnect the probe at the electrical connector. Remove the probe from the muffler tailpipe.

Install the EGT Probe (Refer to Figure 201). (1) Install the probe to the muffler tailpipe. (2) Tighten the screw for the clamp. (3) Attach safety wire to the EGT probe clamp and screw. Refer to Chapter 20, Safetying Maintenance Practices. (4) Connect the probe at the electrical connector (JN006). (5) Attach the electrical connector and wire with the tie straps. (6) Install the engine cowl. Refer to Chapter 71, Engine Cowling - Maintenance Practices.

EGT Probe Removal/Installation (Airplanes with Garmin G1000) A.

Remove the EGT Probe (Refer to Figure 202 ). NOTE:

The EGT probe is welded to the clamp.

NOTE:

Airplanes with Garmin G1000 have an EGT probe at each cylinder. installation of the EGT probes are typical.

(1)

Removal and

Remove the engine cowl. Refer to Chapter 71, Engine Cowling - Maintenance Practices.

CAUTION: Make sure the exhaust system and engine are cool before the probes are removed. (2) (3)

Disconnect the electrical connectors. Cut and remove the safety wire from the EGT probe clamp and screw.

77-20-00 © Cessna Aircraft Company .

.

Page 201 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL

A, A A

A

VIEW A-A

PROBE

DETAIL

A EGT INDICATOR INSTRUMENT

NUT LOCK WASHI SCREW

DETAIL

B

0510T1007 AA0518T1049 A07181037 B0518T1048

EGT Installation Figure 201 (Sheet 1)


Page 202 Jan 3/2005



B3768

BOLT

SAFETY WIRE I I

DETAIL

C C0755T1001

EGT Installation Figure 201 (Sheet 2)


Page 203 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL B3831

VIEW A-A AIRPLANES WITH GARMIN G1000

0510T1007 A0555T1009

EGT/CHT Probe Location Figure 202 (Sheet 1)


Page 204 Jan 3/2005



(4)

(5)

B.

5.

Loosen the clamp screw. Remove the clamp with the attached probe from the exhaust pipe.

Install the EGT Probe (Refer to Figure 202). (1) Attach the clamp with the EGT probe to the exhaust pipe. (2) Tighten the screw on the clamp (3) Attach safety wire to the EGT probe clamp and screw. (4) Connect the electrical connectors. (5) Attach the connectors together with a tie strap. (6) Install the engine cowl. Refer to Chapter 71, Engine Cowling - Maintenance Practices. (7) Make sure the EGT probe operates correctly. Refer to the Pilot's Operating Handbook.

CHT Probe Removal/Installation A.

Remove the CHT Probe (Refer to Figure 202). NOTE:

The CHT probes use a bayonet-style connector.

NOTE:

Airplanes with Garmin G1000 have a CHT probe for each cylinder. installation of the CHT probes is typical.

Removal and

(1) Remove the engine cowl. Refer to Chapter 71, Engine Cowling - Maintenance Practices.

CAUTION: Make sure the exhaust system and engine are cool before the probes are removed. (2) Remove the terminal nut. (3) Disconnect the terminal from the CHT probe. (4) Turn the CHT probe to remove from the cylinder head. B.

Install the CHT Probe (Refer toFigure 202). (1) Install the CHT probe into the cylinder head. (2) Connect the terminal on the CHT probe. (3) Install the terminal nut. (4) Install the engine cowl. Refer to Chapter 71, Engine Cowling - Maintenance Practices. (5) Make sure the CHT operates correctly. Refer to the Pilot's Operating Handbook.


Page 205 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL ENGINE/AIRFRAME UNIT - MAINTENANCE PRACTICES 1.

2.

General A.

On airplanes with Garmin G1000, the GEA 71 Engine/Airframe Unit is a microprocessor-based Line Replaceable Unit (LRU) that receives and processes signals from the engine and airframe sensors. The GEA 71 Engine/Airframe Unit speaks directly with the GIA 63 Integrate Avionics Units.

B.

Maintenance practices give procedures for the removal and installation of the GEA 71 Engine/Airframe Unit. The unit is in the cockpit forward of the instrument .

Troubleshooting A.

3.

GEA 71 Engine/Airframe Unit Removal/Installation A.

|

I


B.

Remove the Engine/Airframe Unit (Refer to Figure 201). (1) Put the MASTER switch in the off position. (2) Put the AVIONICS switch in the off position. (3) Remove the Multi-Function Display (MFD). Refer to Chapter 34, Control Display Unit Maintenance Practices. (4) Release the engine/airframe unit handle. (a) For units with a Phillips screw, loosen the screw to unlock the unit handle. (b) For units with a D-Ring, push on the D-Ring and turn it 90 degrees counterclockwise to unlock the unit handle. (5) Move the lever up to disengage the locking stud with the dogleg slot in the mounting rack. (6) Remove the unit from the mounting rack. Engine/Airframe Unit Installation (Refer to Figure 201). NOTE:

If a new unit is installed, it is necessary to load the software and configuration.

CAUTION: Make sure the unit goes into position without resistance. Damage to the connectors, unit, or mounting rack will occur if the unit is pushed into position with force. NOTE: (1) (2)

The unit must be in position in the mounting rack to let the locking stud engage the channel.

Make sure the electrical connector and connector pins have no damage. (a) Replace the electrical connector or connector pins if applicable. Refer to the Wiring Diagram Manual and the Garmin G1000 Line Maintenance Manual. Carefully put the unit in position in the mounting rack.

CAUTION: Make sure the lever moves without resistance. Damage to the unit will occur if the lever is pushed into position with force. (3) (4)

(5) (6) (7)

Push the lever down toward the bottom of the unit to engage the locking stud with the dogleg slot in the mounting rack. (a) If the lever does not go down, adjust the backplate while the unit is engaged. Lock the handle in position. (a) For units with a Phillips screw, tighten the screw to lock the unit handle. (b) For units with a D-Ring, push on the D-Ring and turn it 90 degrees clockwise to lock the unit handle. Install the MFD. Refer to Chapter 34, Control Display Unit - Maintenance Practices. If a new unit is installed, load the software and configuration. Refer to the Garmin G1000 Line Maintenance Manual. Do a check to make sure that the engine/airframe unit operates correctly. Refer to the Garmin G1000 Line Maintenance Manual.


Page 201 Jul 3/2006

''



NOTE:

MULTI-FUNCTION DISPLAY NOT SHOWN.

i

( ENGINE/ AIRFRAME

0510T1007 A0518T1106

DETAIL A Engine/Airframe Unit Removal/Installation Figure 201 (Sheet 1)


Page 202 Jul 3/2006


MODEL 172 MAINTENANCE MANUAL (7) Do a check to make sure the engine interface unit operates correctly. Refer to the Garmin G 1000 Line Maintenance Manual.


Page 203 Jan 2/2006

CHAPTER

EXHAUST




PAGE

DATE

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MAINTENANCE MANUAL

CONTENTS EXHAUST - GENERAL

.........

.........

...........

...........................

Scope and Definition ........................................................ EXHAUST SYSTEM - MAINTENANCE PRACTICES ......... ..................... Description ................................................................. Exhaust System Removal/Installation ......................................... Muffler Inspection ...........................................................

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201 201 201 201



MODEL 172 MAINTENANCE MANUAL EXHAUST - GENERAL 1.

Scope and Definition A.

This chapter is comprised of a single section on the exhaust system. The section details removal, installation and testing procedures for the exhaust system.


78-00-00 Page 1 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL EXHAUST SYSTEM - MAINTENANCE PRACTICES 1.

Description A.

B. 2.

3.

The exhaust system consists of an exhaust pipe (riser) from each cylinder to the muffler with a single tailpipe which routes exhaust gases out through the lower cowling area. The muffler is located beneath the engine, and is enclosed by a shroud which captures radiated exhaust heat. This heated air is then ducted to the airplane cabin through flexible hoses. Maintenance practices for the exhaust system consist of removal, installation and testing of the exhaust system for leaks.

Exhaust System Removal/Installation A.

Remove Exhaust System (Refer to Figure 201). (1) Remove engine cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices. (2) Loosen left front baffle to allow heat shroud inlet to clear baffle. (3) Remove EGT probe. (4) Disconnect flexible heat duct from heat shroud. (5) Remove clamps securing risers to muffler. (6) Remove nuts and washers securing risers to engine and remove risers/muffler as an assembly from engine. (7) Remove screws securing heat shroud to itself, and unwrap heat shroud from around muffler. (8) Inspect muffler for leaks. Refer to Muffler Inspection below.

B.

Install Exhaust System (Refer to Figure 201). (1) Wrap heat shroud around muffler and secure to itself using screws. (2) Loosely install risers (4 total) to muffler using clamps. (3) Install riser/muffler assembly to engine using new gaskets. (4) Tighten risers 200-210 inch-pounds at engine, then tighten clamps connecting risers to muffler. (5) Reconnect EGT probe. (6) Reinstall engine cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices.

Muffler Inspection NOTE:

The exhaust system must be thoroughly inspected at time intervals set forth in Chapter 5, Inspection Time Limits, or anytime exhaust fumes are detected in the cabin.

WARNING: FAILURE TO INSPECT MUFFLER FOR LEAKS COULD RESULT IN CARBON MONOXIDE ENTERING THE CABIN, LEADING TO SERIOUS INJURY OR DEATH. A.

Inspection Procedures. NOTE:

If muffler shows signs of leaks or damage as indicated in steps 3.A.(1) thru 3.A.(3), it must be replaced.

(1) Using a flashlight and mirror, examine the interior of the muffler, looking for cracks or general deterioration. (2) Using visual inspection, examine the exterior of muffler, looking for holes, cracks and burned spots. Pay special attention to areas adjacent to welds and to exhaust gas deposits (which indicate an exhaust leak). (3) After visual inspection an air leak check should be made on the system as follows: (a) Attach the pressure side of an industrial vacuum cleaner to the tail pipe opening, using a rubber plug to effect a seal as required. NOTE:

The inside of vacuum cleaner hose should be free of any contamination that might be blown into the engine exhaust system.


Page 201 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL

B236

RISER PICAL)

MUFFLER

CLAMP

HEAT SHROUD

0555T2001

Exhaust System Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172

MAINTENANCE MANUAL (b) With vacuum cleaner operating, all ts in the exhaust system may be checked by using a soap and water solution and watching for bubbles. Forming of bubbles is considered acceptable; if bubbles are blown away, system is not considered acceptable. (4) Use a water test to determine muffler integrity: (a) Seal openings in muffler using rubber expansion plugs. NOTE:

One expansion plug should be adapted to allow for introduction of low-pressure air into muffler.

(b) Using a pressure gauge or manometer, apply approximately 3.0 PSI, +0.5 or -0.5 PSI (6 inches mercury), to interior of muffler and submerge muffler into water. Any leaks will appear as bubbles and can be readily detected. (c) If any leaks are detected, the muffler must be removed from service and repaired or replaced. (d) If no defects are found, remove muffler from water, remove plugs and dry muffler with compressed air.


Page 203 Apr 7/2003

CHAPTER

OIL


MODEL 172

MAINTENANCE MANUAL


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DATE

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Apr 7/2003

79-20-00

Pages 201-202

Apr 7/2003

79-30-00

Pages 101-102

Jan 2/2006

79-30-00

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Jan 3/2005

79-31-00

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Jan 2/2006

79-31-00

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Jan 3/2005



79 - LIST OF EFFECTIVE PAGES



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CONTENTS OIL - GENERAL ...................... ........................................... S cope...................................................................... Definition ...................................................................

79-00-00 Page 1 79-00-00 Page 1 79-00-00 Page 1

OIL COOLER - MAINTENANCE PRACTICES .................................... General .................................................................... Oil Cooler Removal/Installation...............................................

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OIL PRESSURE INDICATOR - TROUBLESHOOTING .............................. General ....................................................................

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OIL PRESSURE INDICATOR - MAINTENANCE PRACTICES ....................... Description and Operation ................................................. Oil Pressure Indicator and Transducer Removal/Installation ..................... Low Oil Pressure Switch Removal/Installation .................................

79-30-00 79-30-00 79-30-00 79-30-00

OIL TEMPERATURE INDICATOR - TROUBLESHOOTING .......................... General ....................................................................

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OIL TEMPERATURE INDICATOR - MAINTENANCE PRACTICES ................... Description and Operation ................................................... Oil Temperature Sending Unit Removal/Installation............................. Oil Temperature/Oil Pressure Indicator Removal/Installation ....................

79-31-00 79-31-00 79-31-00 79-31-00


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Page Page Page Page

201 201 201 201

201 201 201 201



MODEL 1 72

MAINTENANCE MANUAL OIL - GENERAL 1.

Scope A.

2.

This chapter provides maintenance instructions for those components which distribute oil and which indicate oil condition. For information beyond the scope of this material, refer to appropriate Textron Lycoming Operator's and Overhaul Manuals, and to Chapter 71, IO-360-L2A - Troubleshooting.

Definition A.

This chapter is divided into sections to assist maintenance personnel in locating specific information. The following is a brief description of each section. For locating information within the chapter, refer to the Table of Contents at the beginning of the chapter. (1) The section on distribution provides information on removal and installation of the external oil cooler. (2) The section on indicating provides information on gauges, transducers and switches used to indicate oil temperature and pressure.


Page 1

Apr 7/2003


MODEL 172 MAINTENANCE MANUAL OIL COOLER - MAINTENANCE PRACTICES 1.

General A.

2.

This section provides maintenance instructions for removal and installation of the externally mounted oil cooler.

Oil Cooler Removal/Installation A.

Remove Oil Cooler (Refer to Figure 201). (1) Remove upper cowling. Refer to Chapter 71, Cowling - Maintenance Practices. (2) Label and disconnect inlet and outlet hoses leading into oil cooler. (3) Remove bolts, washers and spacers securing oil cooler to back of engine baffles.

B.

Install Oil Cooler (Refer to Figure 201). (1) Secure oil cooler to rear of engine baffles using bolts, spacers and washers. (2) Attach inlet and outlet hoses to oil cooler. (3) Run engine and check oil cooler for leaks. (4) Install upper cowling. Refer to Chapter 71, Cowling - Maintenance Practices.


Page 201 Apr 7/2003



B1801

OIL COOLER

HOSE

BOLT

CAP

DETAIL

A 0510T1007 A0550T1004

Oil Cooler Installation Figure 201 (Sheet 1)


Page 202 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL OIL PRESSURE INDICATOR - TROUBLESHOOTING 1.

I

General A. B.

On airplanes with Garmin G1000, the oil pressure is shown on the Multi-Function Display (MFD). Refer to the Garmin G1000 Line Maintenance Manual for GDU 1040 troubleshooting. This section gives a troubleshooting chart and table to help find the problem that will not let the oil pressure indicator system function correctly. To help with troubleshooting the oil pressure indicator, refer to the Model 172 1996 and On Wiring Diagram Manual. (1) The table that follows is to be used with the troubleshooting chart (refer to Figure 101).

CAUTION: Do not apply voltages that are more than the voltages shown in Table 101. Too much voltage can cause damage to the indicator. CAUTION: Do not calibrate the oil pressure indicator without a calibrated pressure source. NOTE:

A test of the calibration for the oil pressure transducer (JN004) can be completed at a facility that has a calibrated pressure source. Table 101 can be used to do a check of the correct output of the transducer.

Table 101. Oil Pressure Values Volts Output at 77°F (25°C)

Oil Pressure

1.03 volts +0.080 or -0.080 volts

20 psi

2.63 volts +0.080 or -0.080 volts

80 psi

3.57 volts +0.080 or -0.080 volts

115 psi


Page 101 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL

B1489

OIL PRESSURE INDICATOR (JI015) DOES NOT OPERATE OR SHOWS THE INCORRECT PRESSURE.

MAKE SURE THERE IS AIRPLANE BUS POWER AT PIN 1 (PC001) AND PIN 9 (GI001) ON THE WIRE BUNDLE SIDE OF THE INDICATOR (JI015). IF-

I OK, MAKE SURE THERE IS ELECTRICAL CONTINUITY FOR THE TWO WIRES BETWEEN THE TRANSDUCER CONNECTOR (JN004) AND THE INDICATOR CONNECTOR (JI015). MAKE SURE THE WIRES DO NOT HAVE A SHORT TO GROUND. IF-

NOT OK, REPAIR OR REPLACE THE APPLICABLE WIRING.

OK, MAKE SURE THERE IS GROUND AT PIN A ON THE TRANSDUCER CONNECTOR. IF-


OK, MAKE SURE THERE IS 5.00 VOLTS +0.10 OR -0.10 VOLTS BETWEEN PIN C ON THE TRANSDUCER CONNECTOR AND GROUND. IF-


OK, APPLY A CALIBRATED DC VOLTAGE SOURCE OF 5.00 VOLTS +0.10 OR -0.10 VOLTS BETWEEN PIN C ON THE TRANSDUCER CONNECTOR AND GROUND. THE INDICATOR MUST SHOW THE PRESSURE GIVEN IN TABLE 101. REFER TO TABLE 101. IF-

NOT OK, REPLACE THE INDICATOR (JI015). REFER TO OIL PRESSURE INDICATOR REMOVAL/INSTALLATION.

NOT OK, REPLACE THE INDICATOR (JI015). REFER TO OIL PRESSURE INDICATOR REMOVALINSTALLATION.

Oil Pressure Indicator Figure 101 (Sheet 1)


Page 102 Jan 2/2006


MODEL 172

MAINTENANCE MANUAL OIL PRESSURE INDICATOR - MAINTENANCE PRACTICES 1.


2.

3.

Oil pressure is measured at two points on the engine and gives both indicator readings and low oil pressure annunciation. (1) On airplanes with Garmin G1000, the oil pressure is shown on the Multi-Function Display (MFD). The oil pressure transducer is the same for all avionics packages. (2) The oil pressure indicator system has an oil pressure line, a transducer and a pressure/ temperature indicator in the cockpit. Oil for the system is tapped at the upper right side of the case. This oil goes through a rigid line to a transducer on the rear baffle area. This transducer gives an electrical signal which goes to the oil pressure/oil temperature indicator in the cockpit. (3) The low oil pressure annunciation system has a pressure switch and related wiring. The switch is on the upper right rear of the engine case. It is configured so that when oil pressure is below 20 PSI, a ground is supplied to the annunciator in the instrument . This causes the OIL PRESS light on the annunciator to come on. When oil pressure is greater than 20 PSI, the ground switches to the Hobbs meter and extinguishes the OIL PRESS light.

Oil Pressure Indicator and Transducer Removal/Installation NOTE:

On airplanes with Garmin G1000, the oil pressure is shown on the Multi-Function Display (MFD). Refer to Control Display Unit - Maintenance Practices for removal and installation procedures of the MFD.

NOTE:

Oil pressure transducer removal and installation is typical for all avionics packages.

A.

Remove the Oil Pressure Indicator (Refer to Figure 201). (1) Make sure the electrical power to airplane is off. (2) Remove screws that attach the indicator to instrument . (3) Disconnect the electrical connector from forward side of the indicator. (4) Carefully remove the indicator from the instrument .

B.

Install the Oil Pressure Indicator (Refer to Figure 201). (1) Connect the electrical connector to the indicator. (2) Put the indicator in position in the instrument . (3) Attach the indicator with the screws. (4) Operate the engine to make sure the indicator operates correctly.

C.

Remove the Transducer (Refer to Figure 201). (1) Remove the upper cowl. Refer to Chapter 71, Cowling - Maintenance Practices. (2) Disconnect the oil pressure line at the transducer. (3) Disconnect the electrical connector from the transducer. (4) Remove the nut that attaches the transducer to the rear of the baffle and remove the transducer. (5) Remove the O-ring and fitting, if applicable.

D.

Install the Transducer (Refer to Figure 201). (1) Install the O-ring and fitting to the transducer. (2) Install the transducer to the rear baffle and attach with the nut. (3) Connect the electrical connector to the transducer. (4) Connect the oil line at the transducer. (5) Install the upper cowl. Refer to Chapter 71, Cowling - Maintenance Practices. (6) Operate the engine to make sure the transducer operates correctly and does not have leaks.

Low Oil Pressure Switch Removal/Installation A.

Remove the Low Oil Pressure Switch (Refer to Figure 201). (1) Make sure the electrical power to the airplane is off. (2) Remove the upper cowl. Refer to Chapter 71, Cowling - Maintenance Practices. (3) Disconnect the electrical connector from the switch. (4) Remove the switch from the engine case. 79-30-00 © Cessna Aircraft Company

Page 201 Jan 3/2005



B

ELECTRICAL CONNECTOR OIL PRESSURE/ TEMPERATURE INDICATOR

-I/


mi

DETAIL A

OIL PRESSURE SWITCH

C DETAIL C OIL PRESSURE s

'' -'

ESSURE

DUCER

rf onrn run

DETAIL B

0510T1007 A0518T1034 B0556T1008 C0556T1006

L

Oil Pressure Indication Installation Figure 201 (Sheet 1)


Page 202 Jan 3/2005



Install the Low Oil Pressure Switch (Refer to Figure 201).

CAUTION: Do not use teflon tape. CAUTION: Clean any sealer or other foreign object debris from the switch fitting before Installation. Make sure foreign object debris Is removed and clear of the pressure hole In the end of the switch fitting. (1)

Put U544006 sealant (or equivalent) on threads.

CAUTION: Do not use too much torque on the plastic switch connection housing when the switch Is tightened by hand. (2)

Install switch and tighten by hand.

CAUTION: Use only the hex fitting to final tighten. Too much torque will damage the switch. Do not damage the corners of the hex fitting. (3) Use a 7/16 inch wrench to tighten switch approximately 1 to 1 1/2 turns beyond hand tight. Do not tighten the switch to more than 60 in-lbs (6.8 N-m). (4) Connect the electrical connector to the switch. (5) Install the upper cowl. Refer to Chapter 71, Cowling - Maintenance Practices.


Page 203 Jan 3/2005


MODEL 172 MAINTENANCE MANUAL OIL TEMPERATURE INDICATOR - TROUBLESHOOTING 1.

I

General A.

On airplanes with Garmin G1000 the oil temperature is shown on the Multi-Function Display (MFD). Refer to the Garmin G1000 Line Maintenance Manual for GDU 1040 troubleshooting.

B.

This section gives a troubleshooting chart and table to help find the problem that will not let the oil temperature indicator system function correctly. To help with troubleshooting the oil temperature indicator, refer to the Model 172 1996 and On Wiring Diagram Manual. (1) The table that follows is to be used with the troubleshooting chart (refer to Figure 101).

Table 101. Oil Temperature Values OHMS

Temperature

497 +65 or -65

100°F (38°C)

36 +2 or -2

245°F (118°C)

79-31-00 O Cessna Aircraft Company

Page 101 Jan 2/2006



B1491

THE OIL TEMPERATURE INDICATOR (JI015) DOES NOT OPERATE OR SHOWS THE INCORRECT TEMPERATURE.

MAKE SURE THERE IS AIRPLANE BUS POWER AT PIN 1 (PC001) AND PIN 9 (GI001) ON THE WIRE BUNDLE SIDE OF THE INDICATOR (JI015). IF-

I OK, MAKE SURE THERE IS A RESISTANCE OF 34 TO 2000 OHMS BETWEEN PIN 2 (JI015) OF THE INDICATOR CONNECTOR AND GROUND (SEAT RAIL). IF-


OK, DISCONNECT THE WIRE FROM THE SENSOR (UN004). APPLY A VARIABLE RESISTANCE BETWEEN THE SENSOR WIRE TERMINAL AND GROUND AS SHOWN IN TABLE 101. THE INDICATOR (JI015) MUST SHOW THE TEMPERATURE GIVEN IN TABLE 101. IF-

NOT OK, DISCONNECT THE WIRE FROM THE SENSOR (UN004). MAKE SURE THE RESISTANCE SHOWS 34 TO 2000 OHMS BETWEEN THE TEMPERATURE SENSOR TERMINAL AND GROUND. IFI

NOT OK, REPLACE THE OIL TEMPERATURE INDICATOR (JI015). REFER TO OIL TEMPERATURE INDICATOR REMOVAL/INSTALLATION.

OK, REPAIR OR REPLACE THE APPLICABLE WIRING BETWEEN THE SENSOR (UN004) AND THE INDICATOR (JI015).

I NOT OK, REPLACE THE SENSOR (UN004).

Oil Temperature Indicator Figure 101 (Sheet 1)


Page 102 Jan 2/2006


MODEL 172 MAINTENANCE MANUAL OIL TEMPERATURE INDICATOR - MAINTENANCE PRACTICES 1.

Description and Operation A. B.

2.

On airplanes with Garmin G1000, the oil temperature is shown on the Multi-Function Display (MFD). The oil temperature sending unit is the same for all avionics packages. The oil temperature system has a sending unit, an oil temperature/oil pressure indicator and wire between the two components. Oil temperature is measured in the accessory case area and gives cockpit readings in °F.

Oil Temperature Sending Unit RemovaL/Installation NOTE:

3.

Oil temperature sending unit removal and installation is typical for all avionics packages.

A.

Remove the Oil Temperature Sending Unit (Refer to Figure 201). (1) Remove the upper engine cowl. Refer to Chapter 71, Cowling - Maintenance Practices. (2) Disconnect the ring terminal wiring at the sending unit. (3) Loosen and remove the sending unit from the accessory case.

B.

Install the Oil Temperature Sending Unit (Refer to Figure 201). (1) Install the sending unit to the accessory case. (2) Attach the ring terminal wire to the sending unit. (3) Torque the jamnut to a maximum of 20 in-lbs (2.3 N-m). (4) Operate the engine to make sure the indicator operates correctly and there are no leaks. (5) Install the upper engine cowl. Refer to Chapter 71, Cowling - Maintenance Practices.

Oil Temperature/Oil Pressure Indicator Removal/Installation A. On airplanes with Garmin G1000, the oil temperature is shown on the Mult-Function Display (MFD). Refer to Control Display Unit - Maintenance Practices for removal and installation procedures of the MFD. B.

For removal and installation of the Oil Temperature/Oil Pressure Indicator, refer to Oil Pressure Indicators - Maintenance Practices.


Page 201 Jan 3/2005


MODEL 172

MAINTENANCE MANUAL

B

AA

VIEW A-A

JAMNUTS SENDING

DETAIL A

0510T1007 AA0550T1007 AS2335C

Oil Temperature Installation Figure 201 (Sheet 1)


Page 202 Jan 3/2005

CHAPTER

STARTING




PAGE

DATE

80-00-00

Page 1

Apr 7/2003

80-1 0-00

Pages 201 -204

Jul 1/2007



-




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Issue Date

By

Date Removed

By


MODEL 172

MAINTENANCE MANUAL

CONTENTS STARTING - GENERAL.............................. Scope and Definition............................. STARTER - MAINTENANCE PRACTICES ..................... Description and Operation .......................... Starter Removal/installation.......................... Bendix Drive Starter Assembly Cleaning And Lubrication ............

©0 Cessna Aircraft Company

80-00-00 Page 1 80-00-00 Page 1 80-1 0-00 80-1 0-00 80-1 0-00 80-1 0-00

80 - CONTENTS

Page Page Page Page

201 201 201 201



MODEL 172 MAINTENANCE MANUAL STARTING - GENERAL 1.

Scope and Definition A.

This chapter is comprised of a single section on the starting system. The section details removal and installation instructions for the engine starter.


80-00-00 Page 1 Apr 7/2003


MODEL 172 MAINTENANCE MANUAL STARTER

-


1.Description and Operation A.

2.

The airplane is equipped with a direct drive 24 VDC starter mounted at the front (propeller end) lower left side of the engine. The ignition key in the instrument operates the starter solenoid. When the solenoid is operated, its s close and a electrical current energizes the starter. A pinion gear in the starter engages the crankshaft ring gear. When the engine reaches a given speed, centrifugal action decouples the starter pinion from the crankshaft ring gear.

Starter RemovaVlnstallation A.

Remove the Starter (Refer to Figure 201). (1) Remove the upper and lower engine cowling. Refer to Chapter 71, Engine Cowling Maintenance Practices. (2) Disconnect the negative terminal from the battery. (3) Remove the screws securing the left front baffle to the engine assembly. (4) Remove the baffle from the engine. (5) Disconnect the large electrical wire which is the positive lead, at the starter. (6) Cut and discard the safety wire to the bolt securing the alternator attach bracket to the starter. (7) Remove the bolt that attaches the alternator attach bracket to the starter. If necessary, loosen the alternator belt. (8) Remove the one bolt and three nuts that attach the starter to the crankcase and remove the starter from the engine.

B.

Install the Starter (Refer to Figure 201) (1) With the one bolt and three nuts, attach the starter to the engine crankcase. Step torque the fasteners diagonally.

(a) On Sky-Tec starters, torque the bolt and nuts to 204 inch-pounds.

(2) Attach the alternator attach bracket to the starter with the bolt and torque. ~~~~(a) On Sky-Tec starters, torque the bolt to 204 inch-pounds. (3) If necessary, reset the alternator belt tension. (4) Safety wire the bolt to the attach bracket. Refer to Chapter 20, Safetying - Maintenance Practices. (5) Connect the positive lead to the starter. Make sure the protective boot fully covers the power terminal stud on the starter. (a) On Sky-Tec starters, torque the nut on the power terminal stud to 50 inch-pounds, +5 or -5 inch-pounds.

*

NOTE:

Sky-Tec starters have a metric nut on the power terminal stud.

(6) On Sky-Tec starters, use high-temperature tie straps and connector to attach the positive lead to the starter. Refer to Figure 202. (7) Attach the left front baffle to the engine assembly. (8) Attach the negative terminal to the battery. (9) Install the upper and lower engine cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices. 3.

Bendix Drive Starter Assembly Cleaning And Lubrication A.

Clean the Bendix starter drive assembly (Refer to Figure 201).

CAUTION: Use only a clean petroleum spirit. Do not use any other type of solvent. (1) Clean the starter drive with a clean petroleum spirit. B.

Lubricate the starter drive assembly (Refer to Figure 201).


Page 201 Jul 1/2007


MODEL 172

MAINTENANCE MANUAL

Bi

LI A

ALTERNATO FER

SUMP VIEw

A-A

0510T 1007 A055OT 1008

Starter Installation Figure 201 (Sheet 1)

80-10-00 ©D Cessna Aircraft Company

Page 202 Jul 1/2007


MODEL 172

MAINTENANCE MANUAL

DETAIL

A

TARTER HIGH TEMPERATURE TIE STRAP

)NNECTOR TAN DOFF)

MPERATURE :STRAP )SITIVE LEAD)

bULlI

DETAIL

051OTi007 A0550T365 6055OT1 010 C055OT1010

B

Sky-Tec Starter Installation Figure 202 (Sheet 1)


Page 203 Jul 1/2007


MODEL 172 MAINTENANCE MANUAL CAUTION: Do not use grease, oil or graphite lubricants. Use only silicone spray lubricants which are recommended for correct operation. (1) Lubricate the Bendix starter drive assembly with a silicone spray such as Crown Industrial Products silicone spray 8034.


Page 204 Jul 1/2007

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