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Cessna 182 Skylane Manual Set Engine To 1959 – 1968 – PDF DOWNLOAD
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Cessna 182 Skylane Manual Set Engine To 1959 – 1968
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CESSNA 182 SKYLANE MANUAL SET ENGINE TO 1959 – 1968 – PDF DOWNLOAD:
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Cessna 182 Skylane Manual Set Engine To 1959 – 1968
PREFACE:
This advisory circular is printed for persons preparing for a mechanics certificate with a power plant rating. It is intended to provide basic information on principles, fundamentals, and technical procedures in the areas relating to the power- plant rating. This is designed to serve as a guide for students enrolled in a formal course of instruction, as well as the individual who is studying on his own.
- This volume is devoted to an explanation of the units which- make up each of ‘ the systems that bring fuel, air, and ignition together in an aircraft engine for com- bustiOn. It also contains information on engine construction features, lubrication systems, exhaust systems, cooling systems, cylinder removal and replacement, compression checks, and valve adjustments.
- Because there are so many different types of aircraft engines in use today, it is reasonable to expect minor differences to exist in like system components. To avoid undue repetition, the practice of using representative systems and units is carried out throughout the advisory circular.
- Subject-matter treatment throughout the text is from a generalized point of view and its use can be supplemented by reference to manufacturer’s manuals and other textbooks if more detail is desired. This advisory circular is not intended to replace, substitute for, or supersede official reg» ulations or manufacturer’s instructions which should be consulted for final authority. Grateful acknowledgement is extended to the manufacturers of engine, propellers, and powerplant accessories for their cooperation in making material available for inclusion in this handbook.
- This handbook contains material for which a copyright has been issued. Copy- right material is used by special permission of United Aircraft Corporation, Pratt and Whitney Aircraft Division, and may not be extracted or reproduced, without permission of the copyright owner.
- The advancements in aeronautical technology dictate that this advisory circular biz-brought up-to-date periodically. ‘ It has been updated, errors have been corroded, new material has been added, and some material has been rearranged to improve the usefulness of the handbook.
- We would appreciate, however, having errors brought to our attention, as well as suggestions for improving its usefulness. Your comments and suggestions will be retained in our files until such time as’the next revision is completed.
TABLE OF CONTENTS:
Cessna 182 Skylane Manual Set Engine To 1959 – 1968
D138-1-13 - MODEL 100 SERIES (1962 AND PRIOR).............................................. 2 TEMPORARY REVISION NUMBER 4............................................................ 3 LIST OF EFFECTIVE PAGES................................................................ 4 FOREWORD............................................................................... 5 TABLE OF CONTENTS...................................................................... 7 SECTION 1 - GENERAL DESCRIPTION........................................................ 9 GENERAL DESCRIPTION................................................................ 9 REFERENCE STATIONS................................................................. 13 SECTION 2 - GROUND HANDLING, SERVICING, LUBRICATION AND INSPECTION..................... 17 TABLE OF CONTENTS.................................................................. 17 GROUND HANDLING.................................................................... 17 HOISTING....................................................................... 18 JACKING........................................................................ 18 TIE-DOWN....................................................................... 18 HANGAR STORAGE................................................................. 18 OUTSIDE STORAGE................................................................ 19 EXTENDED STORAGE............................................................... 19 LEVELING....................................................................... 20 SERVICING.......................................................................... 20 FUEL TANKS..................................................................... 20 FUEL DRAINS.................................................................... 20 ENGINE OIL..................................................................... 20 INDUCTION AIR FILTERS.......................................................... 20 BATTERY........................................................................ 20 TIRES.......................................................................... 21 NOSE GEAR STRUTS............................................................... 21 NOSE GEAR SHIMMY DAMPENERS..................................................... 21 HYDRAULIC BRAKE SYSTEMS........................................................ 21 OXYGEN CYLINDER................................................................ 21 OXYGEN FACE MASKS.............................................................. 22 CLEANING........................................................................... 22 WINDSHIELD AND WINDOWS......................................................... 22 PLASTIC CONTROL WHEELS......................................................... 22 ALUMINUM SURFACES.............................................................. 22 PAINTED SURFACES............................................................... 22 ENGINE COMPARTMENT............................................................. 22 UPHOLSTERY AND INTERIOR........................................................ 22 PROPELLERS..................................................................... 22 WHEELS......................................................................... 22 SERVICING AND LUBRICATION.......................................................... 22 INSPECTION......................................................................... 29 25-HOUR INSPECTION............................................................. 29 100-HOUR INSPECTION............................................................ 29 SECTION 3 - FUSELAGE................................................................... 39 TABLE OF CONTENTS.................................................................. 39 WINDOWS AND WINDSHIELDS............................................................ 39 CLEANING....................................................................... 39 WAXING......................................................................... 39 REPAIRS........................................................................ 39 SCRATCHES...................................................................... 39 CRACKS......................................................................... 40 WINDSHIELDS........................................................................ 40 REMOVAL........................................................................ 40 REPLACEMENT.................................................................... 42 MOVABLE WINDOWS.................................................................... 42 SIDE AND REAR WINDOWS.............................................................. 42 CABIN DOORS........................................................................ 42 REMOVAL AND REPLACEMENT........................................................ 42 CABIN DOOR WEATHERSTRIP........................................................ 43 ADJUSTMENT..................................................................... 43 CABIN DOOR LATCHES................................................................. 43 REMOVAL AND REPLACEMENT........................................................ 44 BAGGAGE DOORS...................................................................... 47 REMOVAL AND REPLACEMENT........................................................ 47 SEATS.............................................................................. 47 REMOVAL AND REPLACEMENT OF FORWARD SEATS....................................... 47 REMOVAL AND REPLACEMENT OF REAR SEATS.......................................... 47 REPAIR OF SEATS................................................................ 47 CABIN UPHOLSTERY................................................................... 47 UPHOLSTERY MATERIALS AND TOOLS................................................. 47 SOUNDPROOFING.................................................................. 47 HEADLINER AND CABIN TOP SOUNDPROOFING.............................................. 58 REMOVAL........................................................................ 58 INSTALLATION................................................................... 58 UPHOLSTERY SIDE PANELS............................................................. 58 REMOVAL AND REPLACEMENT........................................................ 58 WINDLACE (DOOR SEALS).............................................................. 58 CARPETING.......................................................................... 58 BAGGAGE COMPARTMENT UPHOLSTERY..................................................... 58 SAFETY BELTS....................................................................... 58 REMOVAL AND REPLACEMENT........................................................ 58 CARGO TIE-DOWN PROVISIONS.......................................................... 62 SECTION 4 - AIRFRAME................................................................... 65 TABLE OF CONTENTS.................................................................. 65 WINGS.............................................................................. 65 REMOVAL........................................................................ 65 REPAIR......................................................................... 65 REPLACEMENT.................................................................... 67 ADJUSTMENT..................................................................... 67 WING STRUTS........................................................................ 69 REMOVAL AND REPLACEMENT........................................................ 69 REPAIR......................................................................... 69 FIN................................................................................ 71 REMOVAL........................................................................ 71 REPAIR......................................................................... 71 REPLACEMENT.................................................................... 71 HORIZONTAL STABILIZER.............................................................. 76 REMOVAL........................................................................ 76 REPLACEMENT.................................................................... 76 SECTION 5 - LANDING GEAR............................................................... 80 TABLE OF CONTENTS.................................................................. 80 LANDING GEAR....................................................................... 80 TROUBLE SHOOTING............................................................... 81 MAIN GEAR.......................................................................... 82 REMOVAL........................................................................ 82 INSTALLATION................................................................... 83 STEP BRACKET REPLACEMENT....................................................... 83 MAIN WHEEL AND AXLE................................................................ 83 REMOVAL........................................................................ 83 INSTALLATION................................................................... 83 MAIN WHEELS (GOODYEAR)............................................................. 84 REMOVAL........................................................................ 84 DISASSEMBLY.................................................................... 84 INSPECTION AND REPAIR.......................................................... 84 ASSEMBLY....................................................................... 84 INSTALLATION................................................................... 84 MAIN WHEELS (CLEVELAND)............................................................ 89 REMOVAL........................................................................ 89 DISASSEMBLY.................................................................... 89 INSPECTION AND REPAIR.......................................................... 89 ASSEMBLY....................................................................... 89 INSTALLATION................................................................... 95 MAIN WHEEL ALIGNMENT............................................................... 89 CROSSWIND WHEELS................................................................... 95 NOSE GEAR.......................................................................... 95 SHIMMY DAMPENER................................................................ 95 TORQUE LINKS................................................................... 95 REPLACEMENT.................................................................... 95 DISASSEMBLY....................................................................105 ASSEMBLY.......................................................................105 NOSE WHEEL.........................................................................111 REPLACEMENT....................................................................111 DISASSEMBLY....................................................................111 INSPECTION AND REPAIR..........................................................112 ASSEMBLY.......................................................................112 INFLATING AND BALANCING........................................................113 NOSE WHEEL STEERING SYSTEM.........................................................114 STEERING TUBE ASSEMBLIES.......................................................114 ADJUSTMENT.....................................................................114 TAIL GEAR..........................................................................117 REPLACEMENT....................................................................117 MODEL 185 ANTI-SWIVEL MECHANISM....................................................117 REPLACEMENT AND RIGGING........................................................117 TAILWHEEL..........................................................................117 REPLACEMENT....................................................................117 TIRE REPLACEMENT...............................................................117 CLEANING AND LUBRICATION.......................................................117 SPEED FAIRINGS.....................................................................118 REPLACEMENT....................................................................118 REPAIR.........................................................................120 PRECAUTIONS....................................................................120 BRAKE SYSTEMS......................................................................120 BRAKE MASTER CYLINDERS.........................................................120 HYDRAULIC BRAKE LINES..........................................................120 WHEEL BRAKE ASSEMBLIES.........................................................120 TROUBLE SHOOTING...............................................................121 REPLACEMENT OF BRAKE LINES.....................................................121 REPLACEMENT OF MASTER CYLINDERS................................................121 REPAIR OF MASTER CYLINDERS.....................................................123 REMOVAL OF WHEEL BRAKES........................................................123 DISASSEMBLY OF WHEEL BRAKES....................................................123 INSPECTION AND REPAIR OF WHEEL BRAKES..........................................123 ASSEMBLY OF WHEEL BRAKES.......................................................123 INSTALLATION OF WHEEL BRAKES...................................................123 CHECKING BRAKE LININGS.........................................................123 BRAKE LINING REPLACEMENT.......................................................123 BRAKE BLEEDING.................................................................126 PARKING BRAKE SYSTEMS..............................................................126 REPLACEMENT....................................................................126 SECTION 6 - AILERON CONTROL SYSTEM.....................................................127 TABLE OF CONTENTS..................................................................127 AILERON CONTROL SYSTEM.............................................................127 CONTROL TEE OR "Y".............................................................127 CONTROL COLUMN.................................................................127 AILERON CABLES.................................................................127 AILERON BELLCRANKS.............................................................127 AILERONS.......................................................................128 CHECKOUT OF THE AILERON SYSTEM.................................................128 TROUBLE SHOOTING...............................................................128 REMOVAL OF CONTROL TEE.........................................................133 REMOVAL OF CONTROL "Y".........................................................133 REMOVAL OF CONTROL COLUMN......................................................133 REPAIR OF CONTROL COLUMN, TEE, OR "Y"..........................................133 REPLACEMENT OF CONTROL COLUMN, TEE, OR "Y".....................................133 REMOVAL OF AILERON BELLCRANK...................................................133 REPAIR OF AILERON BELLCRANK....................................................133 REPLACEMENT OF AILERON BELLCRANK...............................................133 REPLACEMENT OF AILERON CABLES AND PULLEYS......................................133 REMOVAL OF AILERON.............................................................133 REPAIR OF AILERON..............................................................137 REPLACEMENT OF AILERON.........................................................137 RIGGING AILERON CONTROL SYSTEM.................................................137 SECTION 7 - FLAP CONTROL SYSTEMS.......................................................139 TABLE OF CONTENTS..................................................................139 FLAP CONTROL SYSTEMS...............................................................139 WING FLAPS.....................................................................139 FLAP BELLCRANKS................................................................139 FLAP HANDLE....................................................................139 OPERATIONAL CHECKOUT OF FLAP SYSTEM............................................141 TROUBLE SHOOTING THE FLAP SYSTEM...............................................141 REMOVAL OF THE FLAP LEVER......................................................142 REPAIR OF THE FLAP LEVER.......................................................142 INSTALLATION OF THE FLAP LEVER.................................................142 REMOVAL OF FLAP BELLCRANKS.....................................................142 REPAIR OF FLAP BELLCRANKS......................................................142 INSTALLATION OF FLAP BELLCRANKS................................................142 REMOVAL AND REPLACEMENT OF CABLES AND PULLEYS..................................142 REMOVAL OF FLAP................................................................142 REPAIR OF FLAP.................................................................145 INSTALLATION OF FLAP...........................................................145 RIGGING FLAP CONTROL SYSTEM....................................................145 INSTALLATION OF PLUG BUTTONS...................................................145 SECTION 7A - FLAP CONTROL SYSTEM.......................................................146 TABLE OF CONTENTS..................................................................146 FLAP CONTROL SYSTEM................................................................146 WING FLAPS.....................................................................146 FLAP DRIVE PULLEY ASSEMBLIES...................................................146 TRANSMISSION...................................................................146 ELECTRIC MOTOR.................................................................146 FLAP SWITCH....................................................................146 FLAP POSITION TRANSMITTER......................................................146 OPERATIONAL CHECKOUT OF FLAP SYSTEM............................................146 TROUBLE SHOOTING THE FLAP SYSTEM...............................................147 REMOVAL OF FLAP POSITION TRANSMITTER...........................................148 ADJUSTMENT OF FLAP POSITION TRANSMITTER........................................148 INSTALLATION OF FLAP POSITION TRANSMITTER......................................148 REMOVAL OF TRANSMISSION AND MOTOR ASSEMBLY.....................................148 REPAIR OF TRANSMISSION AND MOTOR ASSEMBLY......................................148 INSTALLATION OF TRANSMISSION AND MOTOR ASSEMBLY................................148 REMOVAL OF DRIVE PULLEY ASSEMBLIES.............................................148 REPAIR OF DRIVE PULLEY ASSEMBLIES..............................................148 INSTALLATION OF DRIVE PULLEY ASSEMBLIES........................................148 REMOVAL, REPAIR & INSTALLATION OF THE FLAP.....................................148 REPLACEMENT OF FLAP CABLES AND PULLEYS.........................................148 RIGGING THE FLAP SYSTEM........................................................148 SECTION 8 - ELEVATOR CONTROL SYSTEMS...................................................151 TABLE OF CONTENTS..................................................................151 ELEVATOR CONTROL SYSTEM............................................................151 TROUBLE SHOOTING...............................................................151 REPLACEMENT OF COMPONENTS..........................................................155 ELEVATORS......................................................................155 CONTROL COLUMN.................................................................155 AFT BELLCRANK - 180, 182 AND 185...............................................155 AFT BELLCRANK - 150, 172 AND 175...............................................155 FORWARD BELLCRANK..............................................................156 CABLES.........................................................................156 RIGGING............................................................................156 SECTION 9 - ELEVATOR TRIM TAB CONTROL SYSTEMS..........................................158 TABLE OF CONTENTS..................................................................158 ELEVATOR TRIM TAB CONTROL SYSTEM...................................................158 TROUBLE SHOOTING...............................................................159 REMOVAL........................................................................159 INSTALLATION...................................................................161 RIGGING........................................................................161 SECTION 10 - RUDDER CONTROL SYSTEMS....................................................164 TABLE OF CONTENTS..................................................................164 RUDDER CONTROL SYSTEMS.............................................................164 TROUBLE SHOOTING...............................................................165 REMOVAL OF RUDDER PEDAL ASSEMBLY...............................................165 INSTALLATION OF RUDDER PEDAL ASSEMBLY..........................................165 REMOVAL OF RUDDER CABLES.......................................................165 INSTALLATION OF RUDDER CABLES..................................................165 REMOVAL OF THE RUDDER..........................................................171 INSTALLATION OF THE RUDDER.....................................................171 RIGGING (150, 172, 175, 180, AND 182 (PRIOR TO SERIAL NO. 34754)...............171 RIGGING (182 SERIAL NO. 34754 THRU 18253598)...................................171 RIGGING (182 SERIAL NO. 18253599 & ON).........................................173 RIGGING (185)..................................................................173 SECTION 11 - STABILIZER CONTROL SYSTEM.................................................176 TABLE OF CONTENTS..................................................................176 STABILIZER TRIM CONTROL SYSTEM.....................................................176 TROUBLE SHOOTING...............................................................177 REPLACEMENT OF THE STABILIZER..................................................180 REPLACEMENT OF STABILIZER ACTUATORS AND CONTROL CABLE..........................180 REPLACEMENT OF THE STABILIZER TRIM WHEEL.......................................180 STABILIZER ACTUATOR OVERHAUL...................................................180 DISASSEMBLY OF STABILIZER ACTUATOR.............................................180 REPAIR OF STABILIZER ACTUATOR..................................................180 RIGGING THE STABILIZER CONTROL SYSTEM..........................................182 SECTION 12 - POWERPLANT................................................................184 TABLE OF CONTENTS..................................................................184 DESCRIPTION........................................................................184 ENGINE DATA........................................................................185 TROUBLE SHOOTING...................................................................188 ENGINE REMOVAL.....................................................................191 CLEANING.......................................................................191 REMOVAL OF ACCESSORIES.........................................................191 DISASSEMBLY AND OVERHAUL.......................................................191 POWER PLANT BUILD-UP...........................................................192 ENGINE INSTALLATION................................................................192 EXTREME WEATHER MAINTENANCE........................................................192 COLD WEATHER...................................................................192 LOW BATTERY STARTING...........................................................193 HAND-CRANKING..................................................................193 USING 12-VOLT AUTOMOBILE AS EXTERNAL POWER.....................................193 EMERGENCY BATTERY CHARGING (DELETED)...........................................195 HOT WEATHER....................................................................195 DUSTY CONDITIONS...............................................................195 SEACOAST AREAS, HUMID AREAS....................................................195 STARTING SYSTEMS...................................................................196 MANUALLY ENGAGED STARTING SYSTEMS..............................................196 REMOVAL OF STARTER AND DRIVE...................................................196 INSTALLATION OF STARTER AND DRIVE..............................................196 AUTOMATICALLY ENGAGED STARTING SYSTEMS.........................................196 REPLACEMENT OF STARTER.........................................................196 REPLACEMENT OF STARTER ADAPTER.................................................196 STANDARD MAINTENANCE...........................................................196 OVERRUNNING CLUTCH CHECK.......................................................197 TROUBLE-SHOOTING THE STARTER...................................................197 ENGINE CONTROLS....................................................................199 ENGINE CONTROL ADJUSTMENTS.....................................................199 IDLE SPEED AND MIXTURE ADJUSTMENT..............................................199 THROTTLE ADJUSTMENTS...........................................................199 IGNITION...........................................................................204 BENDIX-SCINTILLA AND SLICK (FORMERLY CASE) MAGNETOS............................204 SLICK MAGNETOS.....................................................................204 REMOVAL........................................................................204 INTERNAL TIMING................................................................204 INSTALLATION AND TIMING TO THE ENGINE..........................................205 MAINTENANCE....................................................................205 BENDIX-SCINTILLA MAGNETOS..........................................................208 REMOVAL........................................................................208 INTERNAL TIMING OF S-20 SERIES MAGNETOS........................................208 INTERNAL TIMING OF S-200 SERIES MAGNETOS.......................................211 INSTALLATION AND TIMING TO THE ENGINE..........................................212 MAINTENANCE....................................................................212 ENGINE COWLING.....................................................................223 REMOVAL AND REPLACEMENT........................................................223 CLEANING.......................................................................223 REPAIR.........................................................................223 BAFFLES............................................................................223 REMOVAL AND REPLACEMENT........................................................223 REPAIR.........................................................................223 ENGINE MOUNT (TUBULAR).............................................................223 REPAIR.........................................................................223 OIL SYSTEM.........................................................................225 TROUBLE SHOOTING...............................................................225 EXHAUST SYSTEM.....................................................................227 REMOVAL AND REPLACEMENT........................................................227 INSPECTION.....................................................................227 SECTION 12A - MODEL 185 POWERPLANT.....................................................228 TABLE OF CONTENTS..................................................................228 DESCRIPTION........................................................................228 ENGINE DATA....................................................................229 TROUBLE SHOOTING...................................................................230 ENGINE REMOVAL.....................................................................232 PIVOTING ENGINE FROM FIREWALL..................................................232 CLEANING.......................................................................233 REMOVAL OF ACCESSORIES.........................................................233 DISASSEMBLY AND OVERHAUL.......................................................233 POWERPLANT BUILD-UP............................................................233 ENGINE INSTALLATION................................................................233 EXTREME WEATHER MAINTENANCE........................................................233 COLD WEATHER...................................................................233 HOT WEATHER....................................................................233 DUSTY CONDITIONS...............................................................234 SEACOAST AREAS, HUMID AREAS....................................................236 STARTING SYSTEM....................................................................236 AIR INDUCTION SYSTEM...............................................................236 AIRBOX REPLACEMENT.............................................................236 FUEL INJECTION SYSTEM..............................................................236 FUEL-AIR CONTROL UNIT..............................................................236 REPLACEMENT....................................................................236 ADJUSTMENTS....................................................................236 FUEL MANIFOLD VALVE................................................................237 REMOVAL........................................................................237 CLEANING.......................................................................238 INSTALLATION...................................................................238 FUEL DISCHARGE NOZZLES.............................................................238 REMOVAL........................................................................238 CLEANING.......................................................................238 INSTALLATION...................................................................238 FUEL INJECTION PUMP................................................................238 REPLACEMENT....................................................................239 ADJUSTMENTS....................................................................239 ENGINE CONTROLS....................................................................239 RIGGING ENGINE CONTROLS............................................................240 INDUCTION HOT AIR..............................................................240 PROPELLER GOVERNOR.............................................................240 THROTTLE.......................................................................240 MIXTURE........................................................................240 IGNITION...........................................................................240 ENGINE COWLING.....................................................................240 BAFFLES............................................................................240 ENGINE MOUNT.......................................................................241 REPLACEMENT....................................................................241 REPAIR.........................................................................241 OIL SYSTEM.........................................................................241 EXHAUST SYSTEM.....................................................................241 SECTION 13 - FUEL SYSTEMS..............................................................242 TABLE OF CONTENTS..................................................................242 FUEL SYSTEMS.......................................................................242 TROUBLE SHOOTING...............................................................242 TROUBLE SHOOTING - MODEL 185...................................................246 FUEL CELL REPLACEMENT..........................................................255 PRESERVATION OF FUEL CELLS.....................................................255 FUEL CELL REPAIRS..............................................................255 FUEL TANK REPLACEMENT..........................................................258 REPLACEMENT OF DIRECT-READING FUEL QUANTITY GAGE...............................258 REPLACEMENT OF FUEL GAGE TRANSMITTERS..........................................258 CHECKING FUEL VENT.............................................................258 FUEL SELECTOR VALVE REPLACEMENT................................................265 FUEL SELECTOR VALVE REPAIR.....................................................265 FUEL STRAINER REPLACEMENT AND CLEANING.........................................265 FUEL STRAINER DRAINS...........................................................265 PRIMER SYSTEMS.................................................................266 ELECTRIC FUEL PUMPS - MODEL 185................................................266 ELECTRIC FUEL PUMP FILTER SCREENS..............................................266 SECTION 14 - PROPELLERS................................................................267 TABLE OF CONTENTS..................................................................267 PROPELLERS.........................................................................267 REPAIR.........................................................................267 FIXED-PITCH PROPELLERS.............................................................268 REMOVAL........................................................................268 INSTALLATION...................................................................268 REPAIR.........................................................................268 MCCAULEY PROPELLER.................................................................275 TROUBLE SHOOTING...............................................................275 REMOVAL........................................................................278 CLEANING OF PROPELLER HUB......................................................278 INSTALLATION OF PROPELLER......................................................278 PROPELLER GOVERNOR.................................................................278 TROUBLE SHOOTING...............................................................278 REMOVAL........................................................................278 INSTALLATION...................................................................280 CHECKING GOVERNOR PLUG LOCATIONS...............................................280 HIGH RPM STOP ADJUSTMENT.......................................................280 RIGGING PROPELLER GOVERNOR CONTROL.............................................280 SECTION 14A - PROPELLERS (HARTZELL MODEL BHC-C2YF-1)...................................281 TABLE OF CONTENTS..................................................................281 DESCRIPTION........................................................................281 REPAIR.............................................................................281 TROUBLE SHOOTING...................................................................283 REMOVAL............................................................................284 INSTALLATION.......................................................................284 GOVERNOR AND CONTROL...............................................................284 SECTION 15 - HEATING, VENTILATING......................................................285 TABLE OF CONTENTS..................................................................285 HEATING............................................................................285 TROUBLE SHOOTING...............................................................285 HEATER HOSE REPLACEMENT........................................................285 HEATER INSPECTION..............................................................285 HEATER VALVE...................................................................285 CABIN AIR VENTILATION..............................................................285 SECTION 16 - INSTRUMENTS AND INSTRUMENT SYSTEMS........................................295 TABLE OF CONTENTS..................................................................295 GENERAL............................................................................295 INSTRUMENT PANELS..................................................................295 REMOVAL........................................................................298 ADDING EXTRA SHOCK MOUNTS......................................................298 INSTALLATION...................................................................298 INSTRUMENT REMOVAL.............................................................298 INSTRUMENT INSTALLATION........................................................298 PITOT AND STATIC SYSTEMS...........................................................298 TROUBLE SHOOTING - PITOT-STATIC SYSTEM.........................................299 TROUBLE SHOOTING - AIRSPEED INDICATOR..........................................300 TROUBLE SHOOTING - ALTIMETER...................................................300 TROUBLE SHOOTING - VERTICAL SPEED INDICATOR....................................301 TROUBLE SHOOTING - PITOT-STATIC HEAD...........................................301 PITOT AND STATIC SYSTEM MAINTENANCE............................................302 ALIGNING PITOT TUBE............................................................302 CHECKING FOR LEAKS.............................................................302 BLOWING OUT PITOT LINES........................................................302 REMOVAL OF PITOT AND STATIC PRESSURE SYSTEM....................................302 REPLACEMENT OF PITOT AND STATIC PRESSURE SYSTEM................................302 VACUUM SYSTEMS.....................................................................305 TROUBLE SHOOTING - VACUUM SYSTEM...............................................305 TROUBLE SHOOTING - GYRO HORIZON................................................306 TROUBLE SHOOTING - VACUUM PUMP.................................................307 TROUBLE SHOOTING - VACUUM SWITCH...............................................308 VACUUM SYSTEM REMOVAL..........................................................308 VACUUM SYSTEM REPLACEMENT......................................................308 VACUUM SYSTEM CLEANING.........................................................308 SUCTION GAGE READINGS..........................................................308 ENGINE INDICATORS..................................................................312 TACHOMETER.....................................................................312 MANIFOLD PRESSURE GAGE.........................................................312 TROUBLE SHOOTING - MANIFOLD PRESSURE GAGE......................................312 CYLINDER HEAD TEMPERATURE GAGES................................................313 TROUBLE SHOOTING - CYLINDER HEAD TEMPERATURE GAGES.............................314 CYLINDER HEAD TEMPERATURE GAGE MAINTENANCE.....................................315 OIL PRESSURE GAGE..............................................................315 TROUBLE SHOOTING - OIL PRESSURE GAGE (DIRECT READING)..........................315 ELECTRIC OIL PRESSURE GAGE.....................................................315 TROUBLE SHOOTING - OIL PRESSURE GAGE (ELECTRIC)................................316 OIL TEMPERATURE GAGE...........................................................316 CARBURETOR AIR TEMPERATURE GAGES...............................................316 TROUBLE SHOOTING - CARBURETOR AIR TEMPERATURE GAGE (ELECTRIC)..................317 FUEL QUANTITY INDICATORS (ELECTRIC)............................................318 TROUBLE SHOOTING -- FUEL QUANTITY INDICATORS (ELECTRIC)........................318 TRANSMITTER CALIBRATION........................................................319 FUEL FLOW INDICATOR............................................................319 TROUBLE SHOOTING - FUEL FLOW INDICATOR.........................................319 MAGNETIC COMPASS...................................................................319 STALL WARNING HORN AND TRANSMITTER.................................................320 TURN-AND-BANK INDICATOR............................................................320 TROUBLE SHOOTING - TURN-AND-BANK INDICATOR.....................................320 SECTION 17 - ELECTRICAL SYSTEMS........................................................324 TABLE OF CONTENTS..................................................................324 ELECTRICAL POWER SUPPLY SYSTEM.....................................................325 BATTERY AND EXTERNAL POWER SYSTEM..................................................325 BATTERY........................................................................325 TROUBLE SHOOTING...........................................................325 REMOVAL AND REPLACEMENT....................................................330 CLEANING THE BATTERY.......................................................330 ADDING ELECTROLYTE OR WATER TO THE BATTERY.................................330 CHARGING THE BATTERY.......................................................333 BATTERY BOX....................................................................325 REMOVAL AND REPLACEMENT....................................................333 MAINTENANCE OF BATTERY BOX.................................................333 BATTERY SOLENOID...............................................................325 REMOVAL AND REPLACEMENT....................................................333 MASTER SWITCH..................................................................325 GROUND SERVICE RECEPTACLE......................................................325 REMOVAL AND REPLACEMENT....................................................333 GENERATOR POWER SYSTEM.............................................................333 GENERATOR......................................................................334 TROUBLE SHOOTING...........................................................334 REMOVAL AND REPLACEMENT - MODELS 180, 182 AND 185..........................335 REMOVAL AND REPLACEMENT OF STANDARD GENERATOR - MODELS 150, 172 AND 175....335 REMOVAL AND REPLACEMENT OF HEAVY DUTY GENERATOR - MODEL 175................336 POLARIZING THE GENERATOR...................................................337 VOLTAGE REGULATOR..............................................................334 REMOVAL AND REPLACEMENT....................................................337 GENERATOR WARNING LIGHT........................................................334 REMOVAL AND REPLACEMENT....................................................337 AMMETER........................................................................334 AIRCRAFT LIGHTING SYSTEM...........................................................337 LANDING AND TAXI LIGHTS........................................................337 TROUBLE SHOOTING...........................................................338 REMOVAL AND REPLACEMENT....................................................339 NAVIGATION LIGHTS..............................................................337 TROUBLE SHOOTING...........................................................338 REMOVAL AND REPLACEMENT....................................................339 NAVIGATION LIGHTS FLASHER......................................................337 ROTATING BEACON................................................................337 TROUBLE SHOOTING...........................................................339 REMOVAL AND REPLACEMENT....................................................339 INTERIOR LIGHTS CONSOLE, MAP LIGHT AND DOME LIGHT..............................338 TROUBLE SHOOTING...........................................................339 REMOVAL AND REPLACEMENT OF DOME AND INSTRUMENT LIGHTS......................340 ADJUSTMENT OF OVERHEAD LIGHT CONSOLE FOR LATE 182 MODELS.......................340 COURTESY LIGHTS................................................................338 TROUBLE SHOOTING...........................................................339 REMOVAL AND REPLACEMENT....................................................340 COMPASS AND RADIO DIAL LIGHTS..................................................338 STALL WARNING CIRCUIT..............................................................347 PITOT AND STALL WARNING HEATER CIRCUITS............................................347 REMOVAL AND REPLACEMENT OF STALL WARNING HORN AND SWITCH.......................347 REMOVAL AND REPLACEMENT OF PITOT HEATER........................................347 INDEX OF ELECTRICAL WIRING DIAGRAMS................................................348 SYMBOLS CHART......................................................................350 SECTION 18 - ELECTRONIC SYSTEMS........................................................467 SECTION 19 - STRUCTURAL REPAIR.........................................................468 TABLE OF CONTENTS..................................................................468 REPAIR CRITERIA....................................................................468 EQUIPMENT AND TOOLS................................................................468 CONTROL BALANCING FIXTURES.....................................................468 SUPPORT STANDS.................................................................468 FUSELAGE REPAIR JIG............................................................468 WING JIG.......................................................................469 SKIN REPAIR MATERIALS..............................................................474 WING...............................................................................475 ACCESS OPENINGS................................................................475 WING SKIN..........................................................................475 NEGLIGIBLE DAMAGE..............................................................475 DAMAGE REPAIRABLE BY PATCHING..................................................475 DAMAGE REPAIRABLE BY INSERTION.................................................475 DAMAGE NECESSITATING REPLACEMENT OF PARTS......................................475 WING RIBS..........................................................................475 NEGLIGIBLE DAMAGE..............................................................475 REPAIRABLE DAMAGE..............................................................475 DAMAGE NECESSITATING REPLACEMENT OF PARTS......................................475 WING SPARS.........................................................................475 REPAIR OF WING SPARS...........................................................475 AILERONS...........................................................................475 REPAIR.........................................................................475 FLAPS..............................................................................492 REPAIR.........................................................................492 TAIL GROUP.........................................................................494 VERTICAL FIN AND DORSAL AREA.......................................................494 NEGLIGIBLE DAMAGE..............................................................494 REPAIRABLE DAMAGE..............................................................494 DAMAGE NECESSITATING REPLACEMENT OF PARTS......................................494 STABILIZER.........................................................................494 NEGLIGIBLE DAMAGE..............................................................494 REPAIRABLE DAMAGE..............................................................494 ELEVATORS AND RUDDER...............................................................494 NEGLIGIBLE DAMAGE..............................................................494 DAMAGE NECESSITATING REPLACEMENT OF PARTS......................................495 REPAIR CONSIDERATIONS..........................................................495 FUSELAGE...........................................................................496 NEGLIGIBLE DAMAGE..............................................................496 REPAIRABLE DAMAGE..............................................................496 DAMAGE REPAIRABLE BY INSERTION.................................................496 DAMAGE NECESSITATING REPLACEMENT OF PARTS......................................496 BULKHEADS..........................................................................496 DESCRIPTION....................................................................496 CRACKED BULKHEAD WEBS OR FLANGES...............................................496 SEVERELY DAMAGED CHANNELS......................................................496 DAMAGED FITTINGS...............................................................496 LANDING GEAR BULKHEADS.............................................................499 REPLACEMENT OF HI-SHEAR RIVETS.....................................................499 FIREWALL DAMAGE....................................................................499 REPLACEMENT OF PORTIONS OF SKIN PANELS.............................................499 ENGINE MOUNT.......................................................................505 DESCRIPTION....................................................................505 GENERAL CONSIDERATIONS.........................................................505 SUPPORT CRADLE DAMAGE..........................................................505 MOUNTING LUGS AND FITTINGS.....................................................505 BAFFLES............................................................................505 REPAIR CONSIDERATIONS..........................................................505 ENGINE COWLING.....................................................................505 REPAIR OF COWLING SKINS........................................................505 REPAIR OF REINFORCEMENT ANGLES.................................................505 ROYALITE REPAIRS...................................................................505 FIBERGLAS REPAIRS..................................................................505 SECTION 20 - PAINTING..................................................................506 TABLE OF CONTENTS..................................................................506 PAINTING...........................................................................506 ENMAR 27H SERIES LACQUER...........................................................506 PREPARATION....................................................................506 MIXTURE AND APPLICATION OF PRIMER..............................................506 PREPARATION OF LACQUER COLORS..................................................506 APPLICATION OF LACQUER COLORS..................................................506 ENMAR 82A SERIES VINYL.............................................................506 INITIAL PREPARATION............................................................506 MIXTURE AND APPLICATION OF PRIMER..............................................507 PREPARATION OF VINYL COLORS....................................................507 APPLICATION OF VINYL COLORS....................................................507 HI-VISIBILITY PAINT................................................................508 MATERIALS......................................................................508 MIXING.........................................................................508 SURFACE PREPARATION............................................................508 APPLICATION....................................................................508 FIBERGLAS SPEED FAIRINGS...........................................................508
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