172 MM 1996 and On

Cessna
A Textron Company
TEMPORARY REVISION NUMBER 5-1

DATED 1 NOVEMBER 2001
MANUAL TITLE Model 172 Series 1996 And On Maintenance Manual

MANUAL NUMBER - PAPER COPY 172RMM06
MANUAL NUMBER - AEROFICHE 172RMM06AF
TEMPORARY REVISION NUMBER 172RMM06TR5-1
MANUAL DATE 2 December 1996 REVISION NUMBER 6 DATE 18 August 2001
This Temporary Revision consists of the following pages, which affect and replace existing pages in the paper
copy manual and supersede aerofiche information.
CHAPTER/
SECTION/ AEROFICHE
SUBJECT PAGE FICHE/FRAME
5-11-00 1 1/B14
5-11-00 2 1/B15
5-11-00 3 1/B16
REASON FOR TEMPORARY REVISION
1. Add Dry Vacuum Pump and Vacuum Pump Coupling to the Component Time Limits Table.
FILING INSTRUCTIONS FOR THIS TEMPORARY REVISION
1. For Paper Publications, file this cover sheet behind the publication's title page to identify inclusion of the
temporary revision in the manual. Insert the new pages in the publication at the appropriate locations
and remove and discard the superseded pages.
2. For Aerofiche Publications, draw a line, with permanent red ink marker, through any aerofiche frame
(page) affected by the temporary revision. This will be a visual identifier that the information on the
frame (page) is no longer valid and the temporary revision should be referenced. For "added" pages in
a temporary revision, draw a vertical line between the applicable frames. Line should be wide enough to
show on the edges of the pages. Temporary revisions should be collected and maintained in a notebook
or binder near the aerofiche library for quick reference.
COPYRIGHT © 2001
CESSNA AIRCRAFT COMPANY
WICHITA, KANSAS, USA
MODEL 172
MAINTENANCE MANUAL
COMPONENT TIME LIMITS
1. General
A. Most components listed throughout Chapter 5 should be inspected as detailed elsewhere in this
chapter and repaired, overhauled or replaced as required. Some components, however, have a time
or life limit associated with them, and must be overhauled or replaced on or before the specified time
limit.
NOTE: The terms overhaul and replacement as used within this section are defined as follows:
* Overhaul - Item may be overhauled as defined in FAR 43.2 or it can be replaced.
* Replacement - Item must be replaced with a new item or a serviceable item that is
within its service life and time limits or has been rebuilt as defined in FAR 43.2.
B. This section (5-11-00) provides a list of items which must be overhauled or replaced at specific time
limits. Table 1 lists those items which Cessna has mandated must be overhauled or replaced at specific
time limits. Table 2 lists component time limits which have been established by an outside supplier
on their product. In addition to these time limits, the components listed herein are also inspected at
regular time intervals set forth in Inspection Time Intervals, and may require overhaul/replacement
before their time limit is reached based on service usage and inspection results.
2. Cessna-Mandated Replacement Time Limits

A. The following component time limits have been established by The Cessna Aircraft Company.
Table 1. Cessna-Mandated Replacement Time Limits
CHAPTER COMPONENT PART NUMBER REPLACEMENT OVERHAUL

TIME
25 Restraint System, 504516-401-8013 10 years NO
Pilot Left
Hand/Right Hand
Auto Adjust.
Pilot Left
Hand/Right Hand
Manual Adjust.
Aft Bench Left
Hand/Right Hand
Auto Adjust.
Aft Bench Left
Hand/Right Hand
Manual Adjust.
25 Restraint Assy, 2000031-09-201 10 years NO
Pilot Seat
Copilot Seat
Right Rear Seat
Left Rear Seat
172RMM06 Temporary Revision Number 5-1 - Nov 1/2001 5-11-00 Page 1

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 1. Cessna-Mandated Replacement Time Limits (continued)

TIME
27 Trim Tab Actuator 1260074-1 1,000 hours or 3 YES
years, whichever
comes first.
37 Dry Vacuum Pump Various Note 9 NO
37 Vacuum Pump 350 Note 8 NO
Coupling
37 Gyro Filter C294502-0201 600 Hours NO
37 Regulator Valve B3-5-1 600 Hours NO
Filter
71 Engine Various 10 years or engine NO
Compartment overhaul, whichever
Flexible Fluid comes first (Note 1).
Carrying Teflon
Hoses (Cessna
Installed) Except
Drain Hoses
71 Engine Various On Condition NO
Compartment
Drain Hoses
71 Engine Flexible Various Note 2 NO
Hoses (Textron
Lycoming Installed)
71 Air Filter - 172R CA3559 100 hours NO
71 Air Filter-172R and P198281 500 hours NO
172S
71 Mixture and Throttle Refer to Illustrated At engine TBO NO
Cables Parts Catalog for
specific numbers.
71 Starter, Engine 31B22207 At engine TBO YES
3. Supplier Established Replacement Time Limits

A. The following component time limits have been established by specific suppliers and are reproduced
as follows:
Table 2. Supplier Established Replacement Time Limits

TIME
25 Pointer ELT Battery 2020 NOTE 3 NO
37 Vacuum Manifold 1H5-25 NOTE 4 NO
71 Slick Magnetos 4371 NOTE 5 YES

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 2. Supplier Established Replacement Time Limits (continued)

TIME
71 Engine IO-360-L2A NOTE 6 YES
71 Engine Oil Filter CH48110 NOTE 7 NO
NOTES:
Note 1: (This life limit is not intended to allow flexible fluid carrying teflon hoses in
a deteriorated or damaged condition to remain in service.) Replace engine
compartment flexible fluid carry teflon hoses (Cessna installed only) every ten
years or at engine overhaul, whichever occurs first. This does not include drain
hoses. Hoses which are beyond these limits and are in a serviceable condition,
must be placed on order immediately and then be replaced within 30 days after
receiving the new hose from Cessna.
Note 2: Refer to latest Textron Lycoming Engine Service Bulletins.
Note 3: Refer to FAR 91.207 for battery replacement time limits.
Note 4: Refer to Airborne Air & Fuel Product Reference Memo No. 39 or latest revision for
replacement time limits.
Note 5: Refer to Slick Service Bulletin SB2-80C or latest revision for time limits.
Note 6: Refer to Textron/Lycoming Service Instruction S.I. 1009AJ or latest revision for time
limits.
Note 7: Referto Textron/Lycoming Service Instructions S.I. 1492 B, S.I. 1267C, and Service
Bulletin SB 480C.
Note 8: Replace the engine driven dry vacuum pump coupling at 6 years or per the pump
manufacturer's recommended inspection and replacement interval, whichever
occurs first.
Note 9: Replace the engine driven dry vacuum pump not equipped with a wear indicator
every 500 hours of operating, or replace according to the vacuum pump
manufacturer's recommened inspection and replacement interval, whichever
occurs first. For vacuum pump equipped with a wear indicator, replace according
to the vacuum pump manufacturer's recommended inspection and replacement
interval.

Aug 18/2001
Cessna
A Textron Company
TEMPORARY REVISION NUMBER 61-1

DATED 15 NOVEMBER 2001
MANUAL TITLE Model 172 Series 1996 And On Maintenance Manual

MANUAL NUMBER - PAPER COPY 172RMM06
MANUAL NUMBER - AEROFICHE 172RMM06AF
TEMPORARY REVISION NUMBER 172RMM06TR61-1
MANUAL DATE 2 December 1996 REVISION NUMBER 6 DATE 18 August 2001

This Temporary Revision consists of the following pages, which affect and replace existing pages in the paper
copy manual and supersede aerofiche information.
CHAPTER/
SECTION/ AEROFICHE
SUBJECT PAGE FICHE/FRAME
61-10-00 201 4/C12
61-10-00 202 4/C13
REASON FOR TEMPORARY REVISION
1. Propeller bolt torque value.
FILING INSTRUCTIONS FOR THIS TEMPORARY REVISION
1. For Paper Publications, file this cover sheet behind the publication's title page to identify inclusion of the
temporary revision in the manual. Insert the new pages in the publication at the appropriate locations
and remove and discard the superseded pages.
2. For Aerofiche Publications, draw a line, with permanent red ink marker, through any aerofiche frame
(page) affected by the temporary revision. This will be a visual identifier that the information on the
frame (page) is no longer valid and the temporary revision should be referenced. For "added" pages in
a temporary revision, draw a vertical line between the applicable frames. Line should be wide enough to
show on the edges of the pages. Temporary revisions should be collected and maintained in a notebook
or binder near the aerofiche library for quick reference.
COPYRIGHT © 2001
WICHITA, KANSAS, USA
MODEL 172
MAINTENANCE MANUAL
PROPELLER - MAINTENANCE PRACTICES

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

A. Remove Propeller and Spinner (Refer to Figure 201).
WARNING: EXERCISE CARE WHEN WORKING WITH THE PROPELLER. ENSURE

MAGNETO SWITCH IS IN THE OFF POSITION BEFORE TURNING
PROPELLER.
(1) Remove screws securing spinner to bulkheads. Remove spinner and cut safety wire from
propeller mounting bolts.
(2) Remove mounting bolts and remove forward bulkhead, propeller, aft bulkhead and spacer from
crankshaft.
(3) If starter ring gear is to be removed, loosen alternator adjusting arm and slip alternator belt off
of starter ring gear before removing gear.
NOTE: Remove cowling and nosecap for access. Refer to Chapter 71, Cowling -
Maintenance Practices.
B. Install Propeller and Spinner (Refer to Figure 201).
(1) If starter ring gear was removed, clean the mating surfaces of the ring gear and crankshaft before
reassembly.
NOTE: Ensure that "O" identification mark on starter ring gear and "0" identification mark on
crankshaft flange overlap. Starter ring gear must be located correctly on crankshaft
to assure proper alignment of the timing marks on the ring gear.
(2) Clean mating surfaces and assemble the spacer, propeller and bulkheads to crankshaft.
Assemble ensuring that the serial number stamped on the side of the spacer lines up with
either of the propeller blades.
NOTE: It is not necessary to align the spacer serial number with a specific blade. However,
the spacer and propeller have been balanced as a pair and must be reinstalled
together.
(3) Secure propeller assembly using propeller bolts and washers. Tighten bolts in a crossing pattern
to 660-780 inch-pounds (55-65 foot-pounds), safety wire and install spinner.
(4) After securing spinner to the bulkheads, check spinner to aft bulkhead clearance.
(a) If not removed, remove upper cowling and upper nosecap. Refer to Chapter 71, Cowling -
(b) Using a 0.03 inch feeler gauge insert gauge between spinner and aft bulkhead to ensure
the gap is 0.03 inches or less.
NOTE: 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.
(c) Replacement of the Aft Bulkhead will be required if gap is more than 0.03 inches.
(d) Adjust alternator belt tension. Refer to Chapter 24, Alternator - Maintenance Practices.
(e) Reinstall nosecap and cowling. Refer to Chapter 71, Cowling - Maintenance Practices.
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1786
~~~~~~~~~~A ~~~SPACER
DOWEL
byN !^ \ ( \\ |AFT
/> BULKHEAD
ASSEMBLY
PROPELLER
FORWARD
BULKHEAD
-\ ' ASSEMBLY
DETAIL A
0510T1007
Propeller and Spinner Installation

Figure 201 (Sheet 1)
Aug 18/2001
Cessna
A Textron Company
Maintenance Manual
1996 & ON
MODEL 172
SERIES
REVISION 7 TO THE BASIC MANUAL PROVIDES ADDITIONAL INFORMATION NECESSARY TO MAINTAIN THE AIRPLANE AND
INCORPORATES TEMPORARY REVISIONS 172RMM06 TR5-1 AND TR61-1.
) Member of GAMA
FAA APPROVAL HAS BEEN OBTAINED ON TECHNICAL DATA IN THIS PUBLICATION THAT AFFECTS AIRPLANE TYPE DESIGN.
COPYRIGHT © 1996
CESSNA AIRCRAFT CO
WICHITA, KANSAS,
172RMM07 REVISION 7 15 FEBRUARY 2002

MODEL 172
MAINTENANCE MANUAL
LIST OF EFFECTIVE PAGES

CHAPTER-SECTION-SUBJECT PAGE DATE
Introduction - List of Effective Pages 1 Feb 15/2002
Record of Revisions
Service Bulletin List 1 Feb 15/2002
2 Feb 15/2002
3 Feb 15/2002
4 Feb 15/2002
Introduction 1 Feb 15/2002
2 Feb 15/2002
3 Feb 15/2002
4 Feb 15/2002
5 Feb 15/2002
6 Feb 15/2002
List of Revisions Added 1 Feb 15/2002
List of Chapters 1 Feb 15/2002
INTRODUCTION - LIST OF EFFECTIVE PAGES Page 1

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
RECORD OF REVISIONS
REVISION DATE DATE PAGE REVISION DATE DATE PAGE

NUMBER INSERTED REMOVED NUMBER NUMBER INSERTED REMOVED NUMBER
MODEL 172
MAINTENANCE MANUAL
RECORD OF REVISIONS

MODEL 172
MAINTENANCE MANUAL
RECORD OF REVISIONS

MODEL 172
MAINTENANCE MANUAL
RECORD OF REVISIONS

MODEL 172
MAINTENANCE MANUAL
SERVICE BULLETIN LIST

1. Service Bulletins
Service Title Service Manual

Bulletin Bulletin Date Incorporation
Number
SB97-11-01 PILOT'S OPERATING HANDBOOK AND May 12/97 May 3/99
CHECKLIST REVISION
SB97-11-04 AFT BAGGAGE PLACARD INSPECTION/ Nov 3/97 May 3/99
REPLACEMENT
SB97-11-05 ALTIMETER CERTIFICATION LOGBOOK ENTRY Dec 15/97 May 3/99
VERIFICATION
SB97-22-01 BENDIX/KING AUTOPILOT FLIGHT COMPUTER Oct 6/97 May 3/99
MODIFICATION
SB97-24-01 ELECTRICAL WIRE BUNDLE INSPECTION Dec 15/97 May 3/99
SB97-25-01 AFT BENCH SEAT BACK MODIFICATION Aug 11/97 May 3/99
SB97-26-01 FIRE EXTINGUISHER MOUNTING BRACKET Dec 22/97 May 3/99
INSPECTION
SB97-27-01 INSPECTION OF ELEVATOR AND ELEVATOR TRIM Dec 14/98 May 3/99
R1 CONTROL CABLE PULLEYS
SB97-28-01 INSPECTION OF FUEL STRAINER DRAIN AND Jun 6/97 May 3/99
ENGINE MUFFLER TAILPIPE
SB97-33-01 LIGHT DIMMING MODULE RESISTOR Dec 14/98 May 3/99
R1 INSTALLATION INSPECTION
SB97-34-01 KLN 89B GPS NAVIGATION SYSTEM APPROACH Jul 2/97 May 3/99
RESTRICTIONS
SB97-34-02 ALTERNATE STATIC SOURCE VALVE INSPECTION Dec 6/97 May 3/99
R1
SB97-53-01 INSPECTION OF FUSELAGE STATION 205.812 Jul 1/97 May 3/99
TAILCONE BULKHEAD
SB97-53-02 LOWER FORWARD DOORPOST FASTENER Sep 15/97 May 3/99
R1 INSTALLATION
SB97-71-01 ALTERNATE AIR DOOR HINGE ASSEMBLY Jul 27/98 May 3/99
R1 REPLACEMENT
SB97-71-02 ENGINE INDUCTION DRAIN LINE INSPECTION Dec 22/97 May 3/99
SB98-11-01 VOLTAGE POLARITY PLACARD INSTALLATION Mar 23/98 May 3/99
SB98-11-02 PILOT'S OPERATING HANDBOOK AND Mar 30/97 May 3/99
CHECKLIST REVISIONS
SB98-11-05 GERMAN PILOT'S OPERATING HANDBOOK AND Sep 21/98 May 3/99
CHECKLIST REVISIONS
SB98-11-06 BRAZILIAN PILOT'S OPERATING HANDBOOK Oct 12/98 May 3/99
REVISION
SERVICE BULLETIN LIST Page 1

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

Number
SB98-20-01 FIREWALL SEALANT REPLACEMENT Dec 31/98 May 3/99
R1
SB98-24-01 ALTERNATOR REPLACEMENT Mar 30/98 Jan 15/01
SB98-25-01 PILOT AND COPILOT SEAT BACK PIVOT FITTING Jun 1/98 May 3/99
INSPECTION
SB98-25-02 PILOT AND COPILOT SEAT ROLLER INSPECTION Sep 14/98 May 3/99
SB98-27-01 FLAP FOLLOW UP SYSTEM CABLE CLAMP Mar 30/98 May 3/99
INSPECTION
SB98-27-02 AILERON CONTROL CABLE ROUTING Dec 31/98 May 3/99
R1 INSPECTION
SB98-27-03 AILERON PRIMARY CONTROL CABLE-TO-DRUM Jun 1/98 May 3/99
LOCK CLAMP INSPECTION
SB98-27-05 RIGHT WING AILERON CONTROL CABLE Dec 31/98 May 3/99
R2 ROUTING INSPECTION
SB98-27-06 FLIGHT CONTROL CABLES AND TRAVEL Jun 15/98 May 3/99
INSPECTION
SB98-27-07 CONTROL YOKE ATTACH BUSHING INSTALLATION Sep 21/98 May 3/99
SB98-28-01 ENGINE FUEL PRESSURE TRANSDUCER Mar 2/98 May 3/99
INSPECTION AND REPLACEMENT
SB98-28-02 WING TO FUSELAGE FUEL HOSE CLAMP Feb 1/99 Aug 1/00
R1 INSPECTION
SB98-28-03 FUEL SHUTOFF VALVE CABLE CLAMP May 4/98 May 3/99
INSPECTION
SB98-34-01 KLN 89B GPS NAVIGATION SYSTEM IFR Aug 3/98 May 3/99
R1 NON-PRECISION APPROACH LIMITATION
SB98-37-01 AIRBORNE VACUUM PUMP INSPECTION Nov 2/98 Aug 1/00
R1
SB98-52-01 BAGGAGE DOOR SEAL REPLACEMENT Feb 23/98 May 3/99
SB98-53-01 FIREWALL RIVET INSPECTION Dec 14/98 May 3/99
R1
SB98-53-02 FIREWALL INSPECTION AND COWL MOUNT Dec 26/00 Aug 18/01
R2 ALIGNMENT
SB98-55-01 ELEVATOR STOP BOLT BRACKET NUTPLATE Jul 6/98 May 3/99
AND HORIZONTAL STABILIZER INSTALLATION
INSPECTION
SB98-55-02 HORIZONTAL STABILIZER INBOARD SKIN RIVET Jul 27/98 May 3/99
INSPECTION
SB98-57-01 WING STRUT ATTACH BOLTS NUT TORQUE Jun 1/98 May 3/99
INSPECTION

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

Number
SB98-71-01 FORWARD ENGINE BAFFLE AND HEAT SHROUD Jul 27/98 May 3/99
MODIFICATION
SB98-71-02 ENGINE AIR FILTER REPLACEMENT Jul 27/98 May 3/99
SB98-78-01 ENGINE EXHAUST MUFFLER INSPECTION AND Jan 10/98 May 3/99
REPLACEMENT
SB99-11-01 PILOT'S OPERATING HANDBOOK REVISION Sep 27/99 Jan 15/01
SB99-21-01 FRESH AIR VENT REPLACEMENT Mar 15/99 Jan 15/01
SB99-24-01 ELECTRICAL POWER SYSTEM MODIFICATION Mar 15/99 Aug 1/00
SB99-24-02 CIRCUIT PANEL ASSEMBLY COVER INSTALLATION Dec 27/99 Aug 1/00
SB99-25-01 EMERGENCY LOCATOR TRANSMITTER (ELT) Dec 27/99 Jan 15/01
R1 OPERATIONAL TEST
SB99-27-01 CONTROL YOKE PIVOT BOLT INSPECTION/ Jul 12/99 Aug 1/00
REPLACEMENT
SB99-28-01 WING FUEL TANK VENT CHECK VALVE Apr 26/99 Aug 1/00
INSPECTION
SB99-34-01 KLN 89B GPS NAVIGATION SYSTEM Apr 24/00 Jan 15/01
R1 MODIFICATION
SB99-37-01 VACUUM HOSE MODIFICATION Dec 27/99 Aug 1/00
SB99-53-03 ELEVATOR CONTROL YOKE ROLLER Dec 6/99 Aug 1/00
ENGAGEMENT INSPECTION/MODIFICATION
SB99-55-01 VERTICAL FIN AFT SPAR INSPECTION Mar 29/99 May 3/99
SB99-71-01 ENGINE PISTON PIN PLUG WEAR INSPECTION Jul 12/99 Aug 1/00
R2
SB99-71-02 ENGINE OIL FILLER TUBE TO ENGINE MOUNT Aug 12/99 Aug 1/00
CLEARANCE
SB99-71-05 ENGINE VALVE SEAT INSPECTION Oct 25/99 Aug 1/00
SB99-73-01 ENGINE FUEL MANIFOLD SPRING Jan 8/99 Aug 1/00
REPLACEMENT
SB99-73-02 ENGINE FUEL INJECTOR UNIT INSPECTION Feb 1/99 Aug 1/00
SB00-11-01 GERMAN PILOT'S OPERATING HANDBOOK Mar 13/00 Aug 1/00
REVISION
SB00-11-03 PILOT'S OPERATING HANDBOOK AND PILOT'S May 22/00 Jan 15/01
CHECKLIST REVISIONS
SB00-11-04 PILOT'S OPERATING HANDBOOK AND PILOT'S Aug 14/00 Jan 15/01
CHECKLIST REVISIONS
SB00-22-01 KAP-140 AUTOPILOT SERVO INSPECTION/ Feb 14/00 Aug 1/00
MODIFICATION
SB00-24-01 MAIN POWER JUNCTION BOX CIRCUIT BREAKER Mar 13/00 Aug 1/00
RETROFIT KIT INSTALLATION

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

Number
SB00-24-02 ELECTRICAL PANEL WIRING MODIFICATIONS Jun 5/00 Jan 15/01
SB00-34-01 PITOT TUBE HEATER ASSEMBLY INSULATION Apr 10/00 Jan 15/01
INSTALLATION
SB00-37-01 VACUUM SYSTEM AIR FILTER ELEMENT Aug 14/00 Jan 15/01
INSPECTION/REPLACEMENT
SB00-55-01 RUDDER ATTACH BOLT TORQUE INSPECTION Apr 10/00 Jan 15/01
SB00-57-01 FLAP TRACK AND WING INBOARD TRAILING Jul 31/00 Jan 15/01
EDGE INSPECTION
SB00-61-02 PROPELLER HUB INSPECTION Aug 14/00 Jan 15/01
SB00-73-01 ENGINE FUEL INJECTION LINES AND SUPPORT Jul 17/00 Jan 15/01
R1 CLAMPS INSPECTION
SB00-79-01 ENGINE LOW OIL PRESSURE SWITCH Feb 21/00 Jan 15/01
R1 REPLACEMENT
SB00-34-01 PITOT TUBE HEATER INSULATION INSTALLATION Apr 10/00 Feb 15/02
SB01-28-03 FUEL SHUTOFF VALVE CONTROL CABLE Jul 23/01 Feb 15/02
INSPECTION
SB02-61-01 PROPELLER SPINNER AND BULKHEAD Jan 21/02 Feb 15/02
INSPECTION

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
INTRODUCTION
1. General
WARNING: ALL INSPECTION INTERVALS, REPLACEMENT TIME LIMITS, OVERHAUL TIME
LIMITS, THE METHOD OF INSPECTION, LIFE LIMITS, CYCLE LIMITS, ETC.,
RECOMMENDED BY CESSNA ARE SOLELY BASED ON THE USE OF NEW,
REMANUFACTURED, OR OVERHAULED CESSNA APPROVED PARTS. IF PARTS
ARE DESIGNED, MANUFACTURED, REMANUFACTURED, OVERHAULED, AND/OR
APPROVED BY ENTITIES OTHER THAN CESSNA, THEN THE DATA IN CESSNA'S
MAINTENANCE/SERVICE MANUALS AND PARTS CATALOGS ARE NO LONGER
APPLICABLE AND THE PURCHASER IS WARNED NOT TO RELY ON SUCH DATA
FOR NON-CESSNA PARTS. ALL INSPECTION INTERVALS, REPLACEMENT TIME
LIMITS, OVERHAUL TIME LIMITS, THE METHOD OF INSPECTION, LIFE LIMITS,
CYCLE LIMITS, ETC., FOR SUCH NON-CESSNA PARTS MUST BE OBTAINED FROM
THE MANUFACTURER AND/OR SELLER OF SUCH NON-CESSNA PARTS.
A. The information in this publication is based on data available at the time of publication and is updated,
supplemented, and automatically amended by all information issued in Service Newsletters, Service
Bulletins, Supplier Service Notices, Publication Changes, Revisions, Reissues and Temporary
Revisions. All such amendments become part of and are specifically incorporated within this
publication. Users are urged to keep abreast of the latest amendments to this publication through
information available at Cessna Authorized Service Stations or through the Cessna Propeller Aircraft
Product Support subscription services. Cessna Service Stations have also been supplied with a
group of supplier publications which provide disassembly, overhaul, and parts breakdowns for some
of the various supplier equipment items. Suppliers publications are updated, supplemented, and
specifically amended by supplier issued revisions and service information which may be reissued by
Cessna thereby automatically amending this publication and are communicated to the field through
Cessna's Authorized Service Stations and/or through Cessna's subscription services.
B. Inspection, maintenance and parts requirements for STC installations are not included in this manual.
When an STC installation is incorporated on the airplane, those portions of the airplane affected by the
installation must be inspected in accordance with the inspection program published by the owner of the
STC. Since STC installations may change systems interface, operating characteristics and component
loads or stresses on adjacent structures. Cessna provided inspection criteria may not be valid for
airplanes with STC installations.
C. REVISIONS, REISSUES and TEMPORARY REVISIONS can be purchased from a Cessna Service
Station or directly from Cessna Parts Distribution, Department 701, CPD 2, Cessna Aircraft Company,
5800 East Pawnee Road, Wichita, Kansas 67218-5590.
D. Information in this Maintenance Manual is applicable to all U.S. and Foreign Certified Model 172
airplanes beginning at Serial 17280001 and On, and 172S8001 and On. Information unique to a
particular country is identified in the chapter(s) affected.
E. All supplemental service information concerning this manual is supplied to all appropriate Cessna
Service Stations so that they have the latest authoritative recommendations for servicing these Cessna
airplanes. Therefore, it is recommended that Cessna owners utilize the knowledge and experience of
the Cessna Service Organization.
2. Cross Reference Listing of Popular Name Verses Model Numbers and Serials
A. All airplanes, regardless of manufacturer, are certified under model number designations. However,
popular names are often used for marketing purposes. To provide a consistent method of referring
to these airplanes, the model number will be used in this publication unless the popular name is
necessary to differentiate between versions of the same basic model. The following table provides a
listing of popular names, model numbers and serial numbers.
INTRODUCTION Page 1
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
NAME MODEL SERIALS

BEGINNING
Skyhawk 172R 17280001
Skyhawk SP 172S 172S8001
| 3. Coverage and Format

A. The Cessna Model 172 1996 And On Maintenance Manual has been prepared to assist maintenance
personnel in servicing and maintaining Model 172 airplanes (beginning at Serial 17280001 and
172S8001). This manual provides the necessary information required to enable the mechanic to
service, inspect, troubleshoot, remove and replace components or repair systems.
NOTE: This manual is not intended to cover Model 172 airplanes produced prior to 1996. For
manuals related to these airplanes, please refer to applicable listings in the Cessna
Propeller Aircraft Care Customer Supplies and Publications Catalog.
B. This manual has been prepared in accordance with the Air Transport Association (ATA) Specification
Number 100 for Manufacturer's Technical Data.
C. Information beyond the scope of this manual may be found in the applicable Model 172 Wiring Diagram
Manual, Model 172 Illustrated Parts Catalog and the Single Engine Models 172, 182, T182, 206 and
T206, 1996 And On, Structural Repair Manual.
D. Technical Publications are also available for the various components and systems which are not
covered in this manual. These manuals must be utilized as required for maintenance of those
components and systems, and may be purchased from the manufacturer.
| 4. Temporary Revisions
A. Additional information which becomes available may be provided by temporary revision. This service
is used to provide, without delay, new information which will assist in maintaining safe flight/ground
operations. Temporary revisions are numbered consecutively within the ATA chapter assignment.
Page numbering utilizes the three-element number which matches the maintenance manual.
Temporary revisions are normally incorporated into the maintenance manual at the next regularly
scheduled revision.
5. Serialization
A. All Model 172 airplanes are issued a serial number. This number is assigned as construction begins
and remains with the airplane throughout its service life. This serial number appears on the airplane
ID plate, located below the horizontal stabilizer, and on a trim plate located on the pilot side doorpost.
This serial number is used to identify changes within the text or within an illustration. The absence of
a serial number in text or illustration indicates the material is applicable to all airplanes.
6. Material Presentation
A. This Maintenance Manual is available on paper, aerofiche or Compact Disc (CD/ROM). The CD/ROM
contains the Maintenance Manual, Illustrated Parts Catalog Manual, Wiring Diagram Manual and
Structural Repair Manual on a single disc.
7. Service Bulletins
A. Service Bulletins may require special inspections and authorize modifications to the airplane and/or
system. As service bulletins are issued, they will be incorporated in the next scheduled revision and
noted in the Service Bulletin List, located previous to the Introduction. The list of service bulletins
utilizes four columns to summarize information.
(1) Service Bulletin Number - This service bulletin number column identifies the bulletin by number.
Service Bulletins are numbered consecutively within ATA chapter assignment.
INTRODUCTION Page 2
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
(2) Service Bulletin Date - The service bulletin date column indicates the initial date the bulletin
became active.
(3) Title - The title column identifies the service bulletin by nomenclature. It isthe same title displayed
on page one of the service bulletin.
(4) Manual Incorporation - The manual incorporation column indicates the date the service bulletin
has been incorporated in the maintenance manual.
8. Using the Maintenance Manual

A. Division of Subject Matter.
(1) The Maintenance Manual is divided into four major sections. The major sections are in turn
separated into chapters, with each chapter having its own effectivity page and table of contents.
The manual divisions are as follows:
(a) Major Section 1 - Airplane General
Chapter Title
5 Time Limits/Maintenance Checks

6 Dimensions and Areas
7 Lifting and Shoring
8 Leveling and Weighing
9 Towing and Taxiing
10 Parking, Mooring, Storage and Return to Service
11 Placards and Markings
12 Servicing
(b) Major Section 2 - Airframe Systems
Chapter Title
20 Standard Practices - Airframe
21 Air Conditioning
22 Auto Flight
23 Communications
24 Electrical Power
25 Equipment/Furnishings
26 Fire Protection
27 Flight Controls
28 Fuel
31 Indicating/Recording Systems
32 Landing Gear
33 Lights
34 Navigation
INTRODUCTION Page 3
Feb 15/2002
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MODEL 172
MAINTENANCE MANUAL
(3) When the section/subsystem element number is followed with zeros in the subject/unit element
number (22-10-00), the information is applicable to the subsystem within the system.
(4) The subject/unit element number is used to identify information applicable to units within the
subsystems. The subject/unit element number progresses sequentially from the number -01 in
accordance with the number of subsystem units requiring maintenance information.
(5) All system/subsystem/unit (chapter/section/subject) maintenance data is separated into specific
types of information: description and operation, troubleshooting, maintenance practices. Blocks
of sequential page numbers are used to identify the type of information:
Page 1 through 99 - Description and Operation
Page 101 through 199 - Troubleshooting
Page 201 through 299 - Maintenance Practices
Page 301 through 399 - Servicing
Page 401 through 499 - Removal/Installation
Page 501 through 599 - Adjustment/Test
Page 601 through 699 - Inspection/Check
Page 701 through 799 - Cleaning/Painting
Page 801 through 899 - Approved Repairs
NOTE: In most cases, the individual topics have been combined into a 200-series document
(Maintenance Practices). When specific topics require lengthy explanation, they will
utilize the page blocks mentioned above.
(6) A typical page number:
22-10-00 Page 202 Second Page of

Nov 3/97 Auto Pilot
Auto Flight Auto Pilot

Date of Page Issue
Auto Pilot
(7) Illustrations are also tied into the page block numbering system. For example, all illustrations
within a Maintenance Practices section will begin with the number 2 (i.e. Figure 201, Figure 202,
etc.). Conversely, all illustrations within an Approved Repair section will begin with the number
8 (i.e. Figure 801, Figure 802, etc.).
9. Effectivity Pages
A. A list of effective pages is provided at the beginning of each maintenance manual chapter. All pages in
the specific chapter are listed in numerical sequence on the Effectivity Page(s) with the date of issue
for each page.
10. Revision Filing Instructions
A. Regular Revision.
(1) Pages to be removed or inserted in the maintenance manual are determined by the effectivity
page. Pages are listed in sequence by the three-element number (chapter/section/subject) and
then by page number. When two pages display the same three-element number and page
number, the page with the most recent Date of Page Issue shall be inserted in the maintenance
manual. The date column on the corresponding chapter effectivity page shall verify the active
* page.
INTRODUCTION Page 5
Feb 15/2002
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B. Temporary Revision.
1(1i) File tempora.y revisions in th e applicable chapter in accordance with filing instructions appearing
on the first page of the temporary revision.
(2) The rescission of a temporary revision is accomplished by incorporation into the maintenance
manual or by a superseding temporary revision. A Record of Temporary Revisions is furnished
in the Temporary Revision List located previous to the Introduction. A Manual Incorporation Date
column on the Temporary Revision List page will indicate the date the temporary revision was
incorporated, thus authorizing the rescission of the temporary revision.
11. Identifying Revised Material
A. Additions or revisions to text in an existing section will be identified by a revision bar in the left margin
of the page and adjacent to the change.
B. When technical changes cause unchanged text to appear on a different page(s), a revision bar will be
placed in the left margin opposite the chapter/section/subject, page number and date of all affected
pages, providing no other revision bar appears on the page. These pages will display the current
revision date in the Date of Page Issue location.
C. Chapter 5 may contain revision bars to indicate revised text. Inspection items in section 5-10-01 are
also noted as revised, added or deleted by the date of changed item code. A revision date is indicated
below the page number.
D. When extensive technical changes are made to text in an existing section that requires extensive
revision, revision bars will appear the full length of text.
E. Revised and new illustrations will be indicated by either a revision bar along the side of the page or a
hand indicator directing attention to the area.
| 12. Warnings, Cautions and Notes
A. Throughout the text in this manual, warnings, cautions and notes pertaining to the procedures being
accomplished are utilized. These adjuncts to the text are used to highlight or emphasize important
points. Warnings and Cautions precede the text they pertain to, and Notes follow the text they pertain
to.
(1) WARNING - Calls attention to use of materials, processes, methods, procedures or limits which
must be followed precisely to avoid injury or death to persons.
(2) CAUTION - Calls attention to methods and procedures which must be followed to avoid damage
to equipment.
(3) NOTE - Calls attention to methods which will make the job easier.
| 13. Propeller Aircraft Customer Care Supplies and Publications Catalog
A. A Cessna Propeller Aircraft Customer Care Supplies and Publications Catalog is available from
a Cessna Service Station or directly from Cessna Propeller Product Support Dept. 751,Cessna
Aircraft Company, P.O. Box 7706, Wichita, Kansas 67277-7706. This catalog lists all publications and
Customer Care Supplies available from Cessna for prior year models as well as new products. To
maintain this catalog in a current status, it is revised yearly and issued in paper and aerofiche form.
14. Customer Comments on Manual
A. Cessna Aircraft Company has endeavored to furnish you with an accurate, useful and up-to-date
manual. This manual can be improved with your help. Please use the return card, provided with
your manual, to report any errors, discrepancies, and omissions in this manual as well as any general
comments you wish to make.
INTRODUCTION Page 6
Feb 15/2002
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MAINTENANCE MANUAL
LIST OF REVISIONS
1. Revisions
A. This Maintenance Manual includes the original issue and the revisions listed in Table 1. To ensure
information in this manual is current and the latest maintenance and inspections procedures are
available, the revisions must be incorporated in the manual as they are issued.
Table 1. Basic Manual - Original Issue - 2 December 1996
Revision Date Revision Date

Number Number
1 16 May 1997 5 15 January 2001
2 6 April 1998 6 18 August 2001
3 3 May 1999 7 15 February 2002
4 1 August 2000
LIST OF REVISIONS Page 1

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MAINTENANCE MANUAL
* LIST OF CHAPTERS
CHAPTER EFFECTIVE DATE* FICHE/FRAME
Introduction Feb 15/2002 1 A7
5 Time Limits/Maintenance Checks Feb 15/2002 1 A15
6 Dimensions and Areas Aug 18/2001 1 E1
7 Lifting and Shoring Aug 18/2001 1 F1
8 Leveling and Weighing Aug 18/2001 1 F9
9 Towing and Taxiing Aug 18/2001 1 F16
10 Parking and Mooring Aug 18/2001 1 G1
11 Placards and Markings Aug 18/2001 1 G11
12 Servicing Feb 15/2002 1 H14
20 Standard Practices - Airframe Feb 15/2002 2 A1
21 Air Conditioning Aug 18/2001 2 D1
22 Auto Flight Aug 18/2001 2 D15
23 Communications Aug 18/2001 2 E4
24 Electrical Power Aug 18/2001 2 F1
25 Equipment/Furnishings Feb 15/2002 2 G4
26 Fire Protection Aug 18/2001 2 H12
27 Flight Controls Aug 18/2001 2 11
28 Fuel Feb 15/2002 2 K5
31 Indicating/Recording Systems Aug 18/2001 3 A1
32 Landing Gear Feb 15/2002 3 A14
33 Lights Aug 18/2001 3 C5
34 Navigation Feb 15/2002 3 D8
37 Vacuum Aug 18/2001 3 E12
51 Standard Practices -Structures Aug 18/2001 3 F1
52 Doors Aug 18/2001 3 F11
55 Stabilizers Aug 18/2001 3 G1
56 Windows Aug 18/2001 3 G10
57 Wings Feb 15/2002 3 H1
61 Propellers Feb 15/2002 3 H12
71 Powerplant Aug 18/2001 3 11
73 Engine Fuel and Control Aug 18/2001 3 J7
74 Ignition Aug 18/2001 3 K1
76 Engine Controls Aug 18/2001 3 K12
77 Engine Indicating Aug 18/2001 3 L1
78 Exhaust Aug 18/2001 3 L10
79 Oil Aug 18/2001 4 A1
80 Starting Feb 15/2002 4 A13
NOTE 1: *Represents date of page one of each chapter's List of Effective Pages which is applicable to Manual
revision date.
LIST OF CHAPTERS Page 1

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CHAPTER
TIME LIMITS/
MAINTENANCE
CHECKS
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5-Title
5-List of Effective Pages 1 Feb 15/2002
2 Feb 15/2002
5-Record of Temporary Revisions
5-Contents 1 Feb 15/2002
2 Feb 15/2002
5-00-00 1 Feb 15/2002
2 Feb 15/2002
5-10-00 Added 1 Feb 15/2002
Added 2 Feb 15/2002
5-10-01 1 Feb 15/2002
2 Feb 15/2002
3 Feb 15/2002
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5 Feb 15/2002
6 Feb 15/2002
7 Feb 15/2002
8 Feb 15/2002
9 Feb 15/2002
10 Feb 15/2002
11 Feb 15/2002
12 Feb 15/2002
13 Feb 15/2002
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2 Feb 15/2002
3 Feb 15/2002
5-12-00 1 Feb 15/2002
2 Feb 15/2002
5-12-01 1 Feb 15/2002
2 Feb 15/2002
3 Feb 15/2002
4 Feb 15/2002
5 Feb 15/2002
6 Feb 15/2002
7 Feb 15/2002
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2 Feb 15/2002
3 Feb 15/2002
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5 Feb 15/2002
Added 6 Feb 15/2002
5-12-03 1 Feb 15/2002
2 Feb 15/2002
3 Feb 15/2002
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6 Feb 15/2002
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5-12-04 1 Feb 15/2002
2 Feb 15/2002
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5 - LIST OF EFFECTIVE PAGES Page 1

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MODEL 172
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RECORD OF TEMPORARY REVISIONS
TEMPORARY PAGE ISSUE DATE

REVISION NUMBER NUMBER DATE BY REMOVED BY
|~~~~~~~~~~~ I
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MODEL 172
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CONTENTS
TIME LIMITS/MAINTENANCE CHECKS ................... ........................ 5-00-00 Page 1
Scope ...................................................................... 5-00-00 Page 1
Inspection Requirements .................................................... 5-00-00 Page 1
Inspection Program Selection ................................................ 5-00-00 Page 1
D escription ................................................................. 5-00-00 Page 1
General Inspection Terms and Guidelines ..................................... 5-00-00 Page 2
INSPECTION TIME INTERVALS .................................................. 5-10-00 Page 1
General .................................................................... 5-10-00 Page 1
Procedure .................................................................. 5-10-00 Page 1
Inspection Terms and Guidelines ............................................. 5-10-00 Page 1
C hart Legend ............................................................... 5-10-00 Page 1
INSPECTION TIME LIMITS ....................................................... 5-10-01 Page 1
Inspection Items ............................................................ 5-10-01 Page 1
COMPONENT TIME LIMITS ...................................................... 5-11-00 Page 1
General ............................ .... 55-11-00 Page 1
-....................
Cessna-Mandated Replacement Time Limits .................................. 5-11-00 Page 1
Supplier Established Replacement Time Limits ................................ 5-11-00 Page 2
PROGRESSIVE CARE PROGRAM ................................................ 5-12-00 Page 1
General .................................................................... 5-12-00 Page 1
Procedure .................................................................. 5-12-00 Page 2
Inspection Terms and Guidelines ............................................. 5-12-00 Page 2
PROGRESSIVE CARE ....................................................... .. 5-12-01 Page 1
Operation 1................................................................. 5-12-01 Page 1
PROGRESSIVE CARE ........................................................... 5-12-02 Page 1
Operation 2................................................................. 5-12-02 Page 1
Operation 3 ................................................................. 5-12-03 Page 1
Operation 4 ................................................................. 5-12-04 Page 1
Operation 5................................................................. 5-12-05 Page 1
Operation 6................................................................. 5-12-06 Page 1
Operation 7................... ............................................. 5-12-07 Page 1
Operation 8................................................................. 5-12-08 Page 1
Operation 9................................................................. 5-12-09 Page 1
Operation 10 ............................................................... 5-12-10 Page 1
Operation 11 ............................................................... 5-12-11 Page 1
Operation 12 ............................................................... 5-12-12 Page 1
5- CONTENTS Page 1
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Operation 13 ..................................................... .......... 5-12-13 Page 1
Operation 14 ...................................... .................. ...... 5-12-14 Page 1
Operation 15 ............................................................... 5-12-15 Page 1
O peration 16 ............................................................... 5-12-16 Page 1
O peration 17 ............................................................... 5-12-17 Page 1
O peration 18 ............................................................... 5-12-18 Page 1
Operation 19 ............................................................... 5-12-19 Page 1
Operation 20 ............................................................... 5-12-20 Page 1
5 - CONTENTS Page 2
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TIME LIMITS/MAINTENANCE CHECKS

1. Scope
A. This chapter provides the time limits and maintenance checks for the Model 172 airplanes. It is divided
into several sections, each with a specific purpose toward providing information necessary to establish
inspection criteria.
2. Inspection Requirements
A. As required by U.S. Federal Aviation Regulations, all civil aircraft of U.S. registry must undergo
a complete inspection (annual) each twelve calendar months. In addition to the required annual
inspection, aircraft operated commercially (for hire) must have a complete inspection every 100
hours of operation.
B. Compliance with the regulations is accomplished using one of three methods:
(1) Traditional (Annual/100 Hour) inspection program which utilizes FAR 43, Appendix D (scope
and detail) to inspect the airplane. In addition, Cessna recommends certain components or
items be inspected at 50 hour intervals. These inspection items are listed in Inspection Time
Intervals, Section 5-10-01.
(2) Progressive Care inspection program which allows the work load to be divided into smaller
operations that can be accomplished in a shorter time period. This method is detailed in
Progressive Care Program, Section 5-12-00. Progressive Care Inspection programs can be
ordered through Propeller Product Support, P.O. Box 7706, Wichita, KS 67277-7706. Phone
(316) 517-5800, Fax (316) 517-7271.
(3) PhaseCard inspection program which is geared toward high-utilization flight operations
(approximately 600 flight hours per year). This system utilizes 50 hour intervals (Phase 1 and
Phase 2) to inspect high-usage systems and components. At 12 months or 600 flight hours,
whichever occurs first, the airplane undergoes a complete (Phase 3) inspection.
3. Inspection Program Selection
A. The selection of an inspection program (Annual, Progressive Care or Phasecard) is primarily based
on owner/operator preferences, whether an airplane is flown for hire, and numbers of hours flown
during the year.
4. Description
Listed below is a brief description and intended purpose of each section of this chapter. For detailed information
related to each particular inspection program, refer to the specific section within this chapter.
A. Section 5-00-00, Time Limits/Maintenance Checks - General. This section provides a general
overview of inspection requirements.
B. Section 5-10-01, Inspection Time Intervals. The primary purpose of this section is to provide a central
location for inspection time intervals. This section may also be utilized in conjunction with FAR Part
43 to provide greater detail on inspection criteria when performing Annual/100 Hour inspections.
C. Section 5-11-00, Component Time Limits. This section provides a list of components which are life-
or time-limited. Although these components are not listed in any of Cessna's inspection programs,
they must be considered and included in whatever inspection program is used.
D. Section 5-12-00, Progressive Care Program. This section outlines the progressive inspection
program. The program is divided into four primary operations which cover all inspection requirements
up through the 200-hour interval inspection items. The remaining operations cover inspections which
are at intervals other than what the four primary operations cover. Refer to the Progressive Care
Program section for a more detailed description of the Progressive Care Program.
5-00-00 Page 1
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5. General inspection Terms and Guidelines

NOTE: When inspections criteria is required, this criteria is spelled out in the text. If more detailed
instructions are required for an inspection, these instructions will be referenced out to appropriate
locations (supplier publications and/or the maintenance manual).
A. Definitions of terms used through the inspection programs are as follows:
(1) ON CONDITION is defined as the necessary inspections and/or checks to determine that a
malfunction or failure of the component will not occur prior to the next scheduled inspection.
(2) CONDITION is defined as inspection for (but not limited to) cleanliness, cracks, deformation,
corrosion, wear, and loose or missing fasteners.
(3) SECURITY: Inspect for looseness of fasteners and fastener securing devices such as safety
wire, cotterpins and self-locking nuts.
B. During Inspections, use the following general guidelines:
(1) MOVABLE PARTS: Inspect for lubrication, servicing, security of attachment, binding, excessive
wear, safetying, proper operation, proper adjustment, correct travel, cracked fittings, security of
hinges, defective bearings, cleanliness, corrosion, deformation, sealing, and tension.
(2) FLUID LINES AND HOSES: Inspect for leaks, cracks, bulging, collapsed, twisted, dents, kinks,
chafing, proper radius, security, discoloration, bleaching, deterioration, and proper routing;
rubber hoses for hardness or flexibility and metal lines for corrosion.
(3) METAL PARTS: Inspect for security of attachment, cracks, metal distortion, loose or broken
terminals, heat deterioration, and corroded terminals.
(4) WIRING: Inspect for security, chafing, burning, arcing, defective insulation, loose or broken
terminals, heat deterioration, and corroded terminals.
(5) STRUCTURAL FASTENERS: Inspect for correct torque in accordance with applicable torque
values. Refer to Chapter 20, Torque Data - Maintenance Practices, during installation or when
visual inspection indicates the need for a torque check.
CAUTION: TORQUE VALUES LISTED IN THIS MANUAL ARE NOT TO BE USED FOR
CHECKING TIGHTNESS OF INSTALLED PARTS DURING SERVICE.
(6) FILTERS, SCREENS, AND FLUIDS: Inspect for cleanliness and the need for replacement at
specified intervals.
(7) System check (operation or function) requiring electrical power must be performed using 28.5
Volts, +0.25 or -0.25 Volts, bus voltage. This will ensure all components are operating at their
operational voltage.
C. Airplane file.
(1) Miscellaneous data, information, and licenses are a part of the airplane file. Check that the
following documents are up-to-date and in accordance with current Federal Aviation Regulations.
Most of the items listed are required by the Federal Aviation Regulations. Since the regulations
of other nations may require other documents and data, owners of airplanes operated outside
the United States should check with their own aviation officials to determine their individual
requirements.
(a) To be displayed in the airplane at all times:
1 Standard Airworthiness Certificate (FAA Form 8100-2).
2 Aircraft Registration Certificate (FAA Form 8050-3).
3 Aircraft Radio Station License (Federal Communication Commission Form 556 if
transmitter is installed).
(b) To be carried in the airplane at all times:
1 Weight and Balance Data Sheets and associated papers (all copies of the Repair and
Alteration Form, FAA Form 337, are applicable).
2 Equipment List.
3 Pilot's Operating Handbook and FAA Approved Airplane Flight Manual.
(c) To be made available upon request:
1 Airplane, Engine and Propeller Logbooks.
5-00-00 Page 2
Feb 15/2002
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INSPECTION TIME INTERVALS

1. General
A. The primary purpose of this section is to provide for inspection time intervals. The section 5-10-01
may be utilized in conjunction with FAR Part 43 inspection scope and detail, but is not intended to be
utilized as the primary checklist for inspection of the airplane.
NOTE: The inspection guidelines contained in this section are not intended to be all inclusive, for no
such charts can replace the good judgment of certified airframe and powerplant mechanics
in performance of their duties. As the one primarily responsible for the airworthiness of
the airplane, the owner or operator should select only qualified personnel to maintain the
airplane.
2. Procedure
A. A complete airplane inspection includes all inspection items as required by FAR 43, Appendix D,
Scope and Detail of annual/100 hour inspections. The chart provided in this section should be used
to augment the inspection.
B. The Component Time Limits section (5-11-00) should be checked in conjunction with this inspection
to ensure proper overhaul and replacement requirements are accomplished at the specified times.
C. The intervals shown are recommended intervals at which items are to be inspected based on
normal usage under average environmental conditions. Airplanes operated in extremely humid
areas (tropics), or in exceptionally cold, damp climates, etc., may need more frequent inspections
for wear, corrosion, and lubrication. Under these adverse conditions, perform periodic inspections
in compliance with this chart at more frequent intervals until the operator can set his own inspection
periods based on field experience.
(1) The FAR Part 91 operator's inspection intervals shall not deviate from the inspection time limits
shown in this manual except as provided below: (Refer to FAR 91.409)
(a) The aircraft can only exceed its inspection point up to ten hours if the aircraft is enroute to
a facility to have the inspection completed.
(b) In the event of late compliance of any operation scheduled, the next operation in sequence
retains a due point from the time the late operation was originally scheduled (reschedule if
late).
(c) In the event of early compliance of any operation scheduled, that occurs 10 hours or less
ahead of schedule, the next phase due point may remain where originally set.
(d) In the event of early compliance on any operation scheduled, that occurs more than 10
hours ahead of schedule, the next phase due point must be rescheduled to establish a
new due point from the time of early accomplishment.
3. Inspection Terms and Guidelines
A. For inspection terms and guidelines, refer to Chapter 5, Time Limits/Maintenance Checks - General.
4. Chart Legend
A. Each page of the inspection listed in Inspection Time Limits, section 5-10-01 contains the following
five columns:
(1) REVISION STATUS - This column provides the date that a given item was added, deleted or
revised. A blank entry in this column indicates no change since the original issue of this manual.
(2) INSPECTION ITEM CODE NUMBER - This column lists a six-digit number permanently
assigned to a scheduled maintenance item. A given inspection item code number will never
change and will not be reused in the event the scheduled maintenance item is deleted.
(3) REQUIREMENTS - This column provides a short description of the inspection and/or servicing
procedures. Where a more detailed description of the procedure is required, a reference will be
made to either another selection located within the maintenance manual or a specific reference
to a supplier publication.
5-10-00 Page 1
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(4) INTERVAL - This column lists the frequency of inspection in alphabetic coded form. The legend
or the alpha code is listed be-low...
(5) OPERATION - The Progressive Care inspection program allows the work load to be divided into
smaller operations that can be accomplished in a shorter time period. This program is detailed
in section 5-12-00, which is the Progressive Care Program.
(6) ZONE - This column locates the components within a specific zone. For a breakdown of how
the airplane is zoned, refer to Chapter 6, Airplane Zoning - Description and Operation.
INTERVAL INTERVAL
LETTER
A. Every 50 hours.
B. Every 100 hours.
C. Every 200 hours.
D. Every 400 hours or 1 year, whichever occurs first.
E. (Not used. NOTE) First 100 hours and each 500 hours thereafter.
F. Every 600 hours or 1 year, whichever occurs first.
G. (Not used. NOTE) Every 1000 hours or 3 years, whichever occurs first.
H. Every 500 hours.
I. Every 1000 hours.
J. Every 2 years.
K. Five years from the date of manufacturer and every twelve months thereafter.
L. (Not used. NOTE) Every 50 hours or four months, whichever comes first.
M. Every 2 years, or anytime components are added or removed which have the potential to
affect the magnetic accuracy and/or variation of the compass calibration, or anytime the
accuracy of the compass is in question.
N. Every 2000 hours.
0. Every 1000 hours or 1 year, whichever occurs first.
P Every 12 calendar months.
Q. Every 6 years.
R. Every 12 years.
S. Every 1 year.
NOTE: This interval is not currently used but is listed to provide information only.
5-10-00 Page 2
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INSPECTION TIME LIMITS

1. Inspection Items
REVISION ITEM CODE TASK INTER- OPERA- ZONE

STATUS NUMBER VAL TION
112101 Exterior Placards and Decals - Inspect B 1, 3 220, 221
presence, legibility, and security.
Consult Pilot's Operating Handbook
and FAA Approved Airplane Flight
Manual for required placards.
113101 Interior Placards and Decals - Inspect B 1, 3 220, 221
presence, legibility, and security.
Consult Pilot's Operating Handbook
and FAA Approved Airplane Flight
212001 Ventilation System - Inspect clamps, D 5 211
hoses, and valves for condition and
security.
214001 Cold and Hot Air Hoses - Check B 2, 4 120
condition, routing, and security.
Revised 214002 Heater Components, Inlets, and B 1, 3 211
May 16/97 Outlets - Inspect all lines, ducts,
clamps, seals, and gaskets for
condition, restriction, and security.
214003 Cabin Heat and Ventilation Controls - C 1 211
Check freedom of movement through
full travel. Check friction locks for
proper operation.
221001 Autopilot Rigging - Refer to Autopilot - F 7 610
Added 221002 Autopilot Servo Capstan Assemblies. O 16 610
May 3/99 Check slip-clutch torque settings.
Refer to Autopilot - Maintenance
Practices.
Added 221003 Autopilot Servo Actuators. Inspect for O 16 610
May 3/99 evidence of corrosion and or buildup
of dirt or other particulate matter which
may interfere with servo operation.
Refer to Autopilot - Maintenance
Practices.
231001 Communication Antennas and Cables C 3 210
- Inspect for security of attachment,
connection, and condition.
235001 Microphones, Headsets, and Jacks - C 1 211
Inspect for cleanliness, security, and
evidence of damage.
5-10-01 Page 1
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242001 Alternator, Mounting Bracket, and A 1,2,3,4 120
Electrical Connections - Check
condition and security. Check
alternator belts for condition and proper
adjustment. Check belt tension.
Revised 243001 Battery - Check general condition and B 2, 4 120
Feb 15/02 security. Check level of electrolyte.
Refer to Chapter 12, Battery
Servicing.
243002 Battery Box and Cables - Clean and B 2, 4 120
remove any corrosion. Check cables
for routing, support, and security of
connections.
243003 General Airplane and System Wiring C 1 210
- Inspect for proper routing, chafing,
broken or loose terminals, general
condition, broken or inadequate
clamps, and sharp bends in wiring.
243004 External Power Receptacle and Power C 2 120
Cables - Inspect for condition and
security.
246001 Switch and Circuit Breaker Panel, C 1 222
Terminal Blocks, and Junction Boxes
- Inspect wiring and terminals for
condition and security.
Revised 246002 Power Junction Box - Check operation B 1, 3 222
Aug 1/00 and condition. Check availability and
condition of spare fuse (if applicable).
Revised 246101 Essential Bus Diodes - Check for S 20 224
Feb 15/02 proper operation. Refer to Chapter 24,
Essential Bus Diodes - Maintenance
Practices.
251001 Seats - Check general condition and B 1, 3 211
security. Check operation of seat stops
and adjustment mechanism.
251002 Seat Tracks and Stops - Inspect seat B 2, 4 230
tracks for condition and security of
installation. Check seat track stops for
damage and correct location. Inspect
seat rails for cracks.
251101 Restraint System, front and rear - B 1, 3 211
Check belts for thinning, fraying,
cutting, broken stitches, or ultra-violet
deterioration. Check system hardware
for security of installation.
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MAINTENANCE MANUAL

252201 Upholstery, Headliner, Trim, and D 5 211
Carpeting - Check condition and
security.
256001 Emergency Locator Transmitter - B 1, 3 310
Inspect for security of attachment and
check operation by verifying transmitter
output. Check cumulative time and
useful life of batteries in accordance
with FAR Part 91.207.
262001 Portable Hand Fire Extinguisher - B 1, 3 230
Inspect for proper operating pressure,
condition, security of installation, and
servicing date.
Added 262002 Cockpit Mounted Halon Type Fire P 17 211
May 3/99 Extinguisher - Weigh bottle. Bottle
must be reserviced by qualified
individual if more than 2 ounces is
lost.
Added 262003 Cockpit Mounted Halon Type Fire R 19 211
May 3/99 Extinguishers - Perform hydrostatic
test. The hydrostatic test shall be at
twelve-year intervals based on initial
servicing or date of last hydrostatic
test.
Added 262004 Cockpit Mounted Halon Type Fire Q 18 211
May 3/99 Extinguishers - Empty, inspect for
damage, and recharge.
Revised 271001 Aileron Controls - Check freedom B 1, 3 120, 520,
May 3/99 of movement and proper operation 620
through full travel.
271002 Ailerons and Cables - Check operation C 3 120, 520,
and security of stops. Check cables for 620
tension, routing, fraying, corrosion, and
turnbuckle safety. Check travel if cable
tension requires adjustment or if stops
are damaged. Check fairleads and rub
strips for condition.
271003 Aileron Structure, Control Rods, B 1, 3 520, 620
Hinges, Balance Weights, Bellcranks,
Linkage, Bolts, Pulleys, and Pulley
Brackets - Check condition, operation,
and security of attachment.
271004 Ailerons and Hinges - Check condition, B 1, 3 520, 620
security, and operation.
271005 Control Wheel Lock - Check general C 1 222
condition and operation.
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Revised 271006 Control Yoke - Inspect pulleys, cables, C 1 222, 223
May 16/97 bearings, and turnbuckles for condition
and security.
272001 Rudder - Check internal surfaces for C 3 340
corrosion, condition of fasteners, and
balance weight attachment.
Revised 272002 Rudder - Inspect the rudder skins for B 1, 3 340
Aug 1/00 cracks and loose rivets, rudder hinges
for condition, cracks and security;
hinge bolts, nuts, hinge bearings, hinge
attach fittings, and bonding jumper
for evidence of damage and wear,
failed fasteners, and security. Inspect
balance weight for looseness and the
supporting structure for damage.
Revised 272003 Rudder, Tips, Hinges, Stops, Clips and B 1, 3 340
Aug 1/00 Cable Attachment - Check condition,
272004 Rudder Pedals and Linkage - Check C 1 230
for general condition, proper rigging,
and operation. Check for security of
attachment.
Added 272005 Rudder Control - Check freedom B 1, 3 340
Aug 1/00 of movement and proper operation
through full travel. Check rudder stops
for damage and security.
Revised 273001 Elevator Control - Check freedom B 1, 3 222, 223
Aug 1/00 of movement and proper operation
through full travel.
Revised 273002 Elevator Control System - Inspect B 1, 3 222, 223
May 3/99 pulleys, cables, sprockets, bearings,
chains, and turnbuckles for condition,
security, and operation. Check cables
for tension, routing, fraying, corrosion,
and turnbuckle safety.
Revised 273003 Elevator, Hinges, Stops, and Cable B 1, 3 320, 330
Aug 1/00 Attachment - Check condition, security,
and operation.
273101 Elevator Trim System - Check cables, B 1, 3 224, 240,
push-pull rods, bellcranks, pulleys, 310
turnbuckles, fairleads, rub strips, etc.
for proper routing, condition, and
security.
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Revised 273102 Elevator Trim Control and Indicator C 1 224, 240,
May 3/99 - Check freedom of movement and 310
proper operation through full travel.
Check pulleys, cables, sprockets,
bearings, chains, and turnbuckles for
condition and security. Check cables
for tension, routing, fraying, corrosion,
273103 Elevator Trim Tab and Hinges - Check B 1, 3 224
condition, security, and operation.
Revised 273104 Elevator Trim Tab Actuator - Check C 3 320
Feb 15/02 free play limits. Refer to Chapter 27,
Elevator Trim Control - Maintenance
Practices. Trim Tab Free Play
Inspection. If free play still exceeds
limits, actuator must be overhauled or
replaced.
Deleted 273105
Dec 1/98
273106 Elevator Trim Tab Stop Blocks - Inspect C 1 240
for damage and security.
Revised 275001 Flaps - Check tracks, rollers, and B 1, 3 510, 610
Aug 1/00 control rods for security of attachment.
Check rod end bearings for corrosion.
Check operation.
275002 Wing Flap Control - Check operation C 1 221
through full travel and observe Flap
Position indicator for proper indication.
275003 Flap Structure, Linkage, Bellcranks, C 3 510, 610
Pulleys, and Pulley Brackets - Check
for condition, operation and security.
275004 Flaps and Cables - Check cables C 3 510, 610
for proper tension, routing, fraying,
corrosion, and turnbuckle safety.
Check travel if cable tension requires
adjustment.
Revised 275005 Flap Motor, Actuator, and Limit C 3 610
May 16/97 Switches - Check wiring and terminals
for condition and security. Check
actuator for condition and security.
Revised 275006 Flap Actuator Threads - Clean and B 1, 3 610
Feb 15/02 lubricate. Refer to Chapter 12, Flight
Controls - Servicing.
282001 Fuel System - Inspect plumbing and B 1, 3 510, 610
components for mounting and security.
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

Revised 282002 Fuel Tank Vent Lines and Vent Valves B 1, 3 510, 610
Aug 1/00 - Check vents for obstruction and
proper positioning. Check valves for
operation.
282003 Fuel Selector Valve - Check controls B 1, 3 224
for detent in each position, security of
attachment, and for proper placarding.
Revised 282004 Integral Fuel Bays - Check for evidence B 1, 3 510, 610
Aug 1/00 of leakage and condition of fuel caps,
adapters, and placards. Using quick
drains, ensure no contamination exists.
Check quick drains for proper shut off.
282005 Fuel Reservoir - Using quick drain, B 1, 3 510, 610
ensure no contamination exists.
282006 Fuel Selector - Using quick drain, B 1, 3 224
ensure no contamination exists.
282007 Fuel Strainer, Drain Valve, and Controls B 1, 3 510, 610
- Check freedom of movement,
security, and proper operation.
Disassemble, flush, and clean screen
and bowl.
282008 Fuel Quantity Indicators - Check for F 7 220
damage, security of installation, and
perform accuracy test.
Revised 282009 Integral Fuel Bays - Drain fuel (Refer I 10 510, 610
Feb 15/02 to Chapter 12, Fuel - Servicing) and
purge tanks (Refer to the Single Engine
Structural Repair Manual, 1996 and
On). Inspect tank interior and remove
any foreign particles. Inspect interior
surfaces for sealant deterioration and
corrosion (especially in the sump
areas). Check tank vents and outlet
screens thoroughly for condition,
obstruction, correct installation, and
proper operation of check valves.
Added 282010 Auxiliary (Electric) Fuel Pump - B 2, 4 120
Aug 1/00 Check pump and fittings for condition,
operation, security.
311001 Instruments - Check general condition B 1, 3 220
and markings for legibility.
Revised 311002 Instrument Panel Ground Straps - C 1 220, 221
May 16/97 Inspect for deterioration, cracks, and
security of attachment.
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311003 Instrument Lines, Fittings, Ducting, and C 1 220
Instrument Panel Wiring - Check for
proper routing, support, and security of
attachment.
321001 Main Landing Gear Wheel Fairings, B 2, 4 721,722
Strut Fairings, and Cuffs - Check for
cracks, dents, and condition of paint.
321002 Main Gear Tubular Struts - Inspect for B 2, 4 721,722
cracks, dents, corrosion, condition of
paint or other damage. Check axles for
321003 Main Landing Gear Attachment B 2, 4 721,722
Structure - Check for damage, cracks,
loose rivets, bolts and nuts and security
of attachment.
322001 Nose Gear - Inspect torque links, B 2, 4 720
steering rods, and boots for condition
and security of attachment. Check
strut for evidence of leakage and
proper extension. Check strut barrel
for corrosion, pitting, and cleanliness.
Check shimmy damper and/or bungees
for operation, leakage, and attach
points for wear and security.
322002 Nose Landing Gear Wheel Fairings - B 2, 4 720
Check for cracks, dents, and condition
of paint.
322003 Nose Gear Fork - Inspect for cracks, C 4 720
general condition, and security of
attachment.
322004 Nose Gear Attachment Structure - B 2, 4 720
Inspect for cracks, corrosion, or other
damage and security of attachment.
324001 Brakes - Test toe brakes and parking B 2, 4 230
brake for proper operation.
Revised 324002 Brakes, Master Cylinders, and Parking B 2, 4 224, 230
Feb 15/02 Brake - Check master cylinders and
parking brake mechanism for condition
and security. Check fluid level and
test operation of toe and parking brake.
Refer to Chapter 12, Hydraulic Brakes
- Servicing.
324003 Brake Lines, Wheel Cylinders, Hoses, D 5 721,722
Clamps, and Fittings - Check for leaks,
condition, and security and hoses for
bulges and deterioration. Check brake
lines and hoses for proper routing and
support.
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MODEL 172
MAINTENANCE MANUAL

324004 Tires - Check tread wear and general B 2, 4 720, 721,
condition. Check for proper inflation. 722
324005 Wheels, Brake Discs, and Linings B 2, 4 721,722
- Inspect for wear, cracks, warps,
dents, or other damage. Check wheel
through-bolts and nuts for looseness.
Revised 324006 Wheel Bearings - Clean, inspect and B 4 720, 721,
May 16/97 lube. 722
325001 Nose Gear Steering Mechanism - C 4 720
Check for wear, security, and proper
rigging.
331001 Instrument and Cabin Lights - Check B 1, 3 220, 211,
operation, condition of lens, and 221
334001 Navigation, Beacon, Strobe, and B 1, 3 340, 520,
Landing Lights - Check operation, 620
condition of lens, and security of
attachment.
341101 Static System - Inspect for security of C 3 210
installation, cleanliness, and evidence
of damage.
341102 Pitot and Static System - Inspect in J 11 220
accordance with FAR Part 91.411.
341103 Pitot Tube and Stall Warning Vane - A 1,2, 3, 4 510
Check for condition and obstructions
and verify operation of anti-ice heat.
342101 Magnetic Compass - Inspect for C 1 225
security of installation, cleanliness,
and evidence of damage.
Revised 342102 Magnetic Compass - Calibrate. M 14 220
May 16/97
Revised 345001 Instrument Panel Mounted Avionics C 1 225
Aug 1/00 Units (Including Audio Panel, VHF
Nav/Com(s), ADF, GPS, Transponder,
and Compass System) - Inspect for
deterioration, cracks, and security of
instrument panel mounts. Inspect
for security of electrical connections,
condition, and security of wire routing.
345002 Avionics Operating Controls - Inspect C 1 225
for security and proper operation of
controls and switches and ensure
that all digital segments will illuminate
properly.
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

345003 Navigation Indicators, Controls, and C 1 220, 225
Components - Inspect for condition
and security.
345004 Navigation Antennas and Cables - C 1 310
Inspect for security of attachment,
connection, and condition.
371001 Vacuum System - Inspect for condition B 2, 4 120
and security.
371002 Vacuum Pumps - Check for condition B 2, 4 120
and security. Check vacuum
system breather line for obstructions,
condition, and security.
371003 Vacuum System Hoses - Inspect for B 2, 4 120
hardness, deterioration, looseness, or
collapsed hoses.
Revised 371004 Gyro Filter - Inspect for damage, B 2, 4 120
May 16/97 deterioration and contamination. Clean
or replace if required.
Revised 371005 Regulator Valve and Filter - Inspect B 2, 4 120
May 16/97 valve assembly for security of
installation. Visually inspect filter
for damage, deterioration and
contamination. Clean or replace if
required.
371006 Vacuum Manifold Check Valve - Check K 12 120
for proper operation. Refer to Chapter
37, Vacuum System - Maintenance
Practices.
521001 Doors - Inspect general condition. B 1, 3 210
Check latches, hinges, and seals for
condition, operation, and security of
attachment.
531001 Fuselage Surface - Inspect for skin B 1, 3 210
damage, loose rivets, condition of
paint, and check pitot-static ports and
drain holes for obstruction. Inspect
covers and fairings for security.
531002 Firewall Structure- Inspect forwrinkles, C 2 120
damage, cracks, sheared rivets, etc.
Check cowl shock mounts for condition
and security.
531003 Internal Fuselage Structure - Inspect C 1 211
bulkheads, doorposts, stringers,
doublers, and skins for corrosion,
cracks, buckles, and loose rivets, bolts
and nuts.
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

551001 Horizontal Stabilizer and Tailcone B 1, 3 320, 330
structure - Inspect bulkheads, spars,
ribs, and skins, for cracks, wrinkles,
loose rivets, corrosion, or other
damage. Inspect horizontal stabilizer
attach bolts for looseness. Retorque
as necessary. Check security of
inspection covers, fairings, and tips.
551002 Horizontal Stabilizer and Tips - B 1, 3 320, 330
Inspect externally for skin damage
and condition of paint.
Revised 553001 Vertical Stabilizer Fin - Inspect B 1, 3 340
Aug 1/00 bulkheads, spars, ribs, and skins
for cracks, wrinkles, loose rivets,
corrosion, or other damage. Inspect
vertical stabilizer attach bolts for
looseness. Retorque as necessary.
Check security of inspection covers,
fairings, and tip.
Revised 553002 Vertical Stabilizer Fin and Tailcone - B 1, 3 340
Aug 1/00 Inspect externally for skin damage and
condition of paint.
561001 Windows and Windshield - Inspect B 1, 3 210
general condition. Check latches,
hinges, and seals for condition,
operation, and security of attachment.
571001 Wing Surfaces and Tips - Inspect B 1, 3 510, 520,
for skin damage, loose rivets, and 610, 620
condition of paint.
571002 Wing Struts and Strut Fairings - Check B 1, 3 510, 610
for dents, cracks, loose screws and
rivets, and condition of paint.
571003 Wing Access Plates - Check for C 3 510, 520,
damage and security of installation. 610, 620
571004 Wing Spar and Wing Strut Fittings - C 3 510, 520,
Check for evidence of wear. Check 610, 620
attach bolts for indications of looseness
and retorque as required.
571005 Wing Structure - Inspect spars, C 3 510, 520,
ribs, skins, and stringers for cracks, 610, 620
wrinkles, loose rivets, corrosion, or
other damage.
611001 Spinner - Check general condition and A 1, 2, 3, 4 110
attachment.
611002 Spinner and Spinner Bulkhead - B 2, 4 110
Remove spinner, wash, and inspect for
cracks and fractures.
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

611003 Propeller Blades - Inspect for cracks, A 1,2, 3, 4 110
dents, nicks, scratches, erosion,
corrosion, or other damage.
611004 Propeller Hub - Check general C 2 110
condition.
611005 Propeller Mounting - Check for security A 1,2, 3, 4 110
of installation.
611006 Propeller Mounting Bolts - Inspect C 2 110
mounting bolts and safety wire for signs
of looseness. Retorque mounting bolts
as required.
Revised 711001 Cowling and Cowl Flaps - Inspect A 1,2, 3, 4 120
Aug 1/00 for cracks, dents, other damage and
security of cowl fasteners. Check
cowl flaps for condition, security, and
operation. Check cowl flap controls
for freedom of movement through full
travel.
712001 Engine Shock Mounts, Engine Mount C 2 120
Structure, and Ground Straps - Check
condition, security, and alignment.
716001 Alternate Induction Air System - A 1,2, 3, 4 120
Check for obstructions, operation,
and security.
716002 Induction System - Check security of A 1,2, 3, 4 120
clamps, tubes, and ducting. Inspect for
evidence of leakage.
Revised 716003 Induction Airbox, Valves, Doors, and A 1,2, 3, 4 120
Aug 1/00 Controls - Remove air filter and inspect
hinges, doors, seals, and attaching
parts for wear and security. Check
operation.
Revised 716004 Induction Air Filter- Remove and clean. A 1,2, 3, 4 120
May 3/99 Inspect for damage and service.
722001 Engine - Inspect for evidence of oil and A 1, 2, 3, 4 120
fuel leaks. Wash engine and check for
security of accessories.
722002 Crankcase, Oil Sump, and Accessory B 2, 4 120
Section - Inspect for cracks and
evidence of oil leakage. Check bolts
and nuts for looseness and retorque as
necessary. Check crankcase breather
lines for obstructions, security, and
general condition.
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

722003 Hoses, Metal Lines, and Fittings - A 1,2, 3, 4 120
Inspect for signs of oil and fuel leaks.
Check for abrasions, chafing, security,
proper routing and support and for
evidence of deterioration.
723001 Engine Cylinders, Rocker Box Covers, B 2, 4 120
and Pushrod Housings - Check for fin
damage, cracks, oil leakage, security of
attachment, and general condition.
723002 Engine Metal Lines, Hoses, Clamps, C 2 120
and Fittings - Check for leaks,
condition, and security. Check for
proper routing and support.
723003 Engine Baffles and Seals - Check A 1,2, 3, 4 120
condition and security of attachment.
Revised 723004 Cylinder Compression - Perform B 2, 4 120
May 16/97 differential compression test. If
there is weak cylinder compression,
refer to Chapter 71, 10-360-
L2A Troubleshooting, for further
procedures.
730001 Engine-Driven Fuel Pump - Check B 2, 4 120
for evidence of leakage, security of
attachment, and general condition.
730002 Fuel Injection System - Check system B 2, 4 120
for security and condition. Clean fuel
inlet screen, check and clean injection
nozzles and screens (if evidence of
contamination is found), and lubricate
air throttle shaft.
Added 730003 Idle and Mixture - Run the airplane B 2, 4 120
Jun 1/01 engine to determine satisfactory
performance. If required, adjust the
idle rpm and fuel mixture. Refer to
Chapter 73, Fuel Injection Systems -
741001 Magnetos - Check external condition, B 2, 4 120
security, and electrical leads for
condition. Check timing to engine
and internal timing if engine timing
requires adjustment.
741002 Magnetos - Clean, inspect and adjust H 9 120
as required. Refer to Slick 4300/4600
Series Magneto Maintenance and
Overhaul Manual.
742001 Ignition Harness and Insulators - Check B 2, 4 120
for proper routing, deterioration, and
condition of terminals.
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

742002 Spark Plugs - Remove, clean, analyze, B 2, 4 120
test, gap, and rotate top plugs to bottom
and bottom plugs to top.
743001 Ignition Switch and Electrical Harness B 2, 4 120
- Inspect for damage, condition, and
security.
Revised 743002 Inspect and lubricate ACS brand N 15 224
Aug 1/00 ignition switch. Refer to Chapter
74, Ignition System - Maintenance
Practices.
761001 Engine Controls and Linkage - B 1,2, 3, 4 120, 225
Check general condition, freedom
of movement through full range.
Check for proper travel, security
of attachment, and for evidence of
wear. Check friction lock and vernier
adjustment for proper operation. Check
that throttle and fuel mixture arms
operate through their full arc of travel.
Revised 781001 Exhaust System - Inspect for cracks A 1,2, 3, 4 120
Aug 1/00 and security. Special check in area
of heat exchanger. Refer to Chapter
78, Exhaust system - Maintenance
Practices.
Revised 791001 Engine Oil - Drain oil sump and oil A 1,2, 3, 4 120
Aug 1/00 cooler. Check for metal particles or
foreign material in filter, on sump
drain plug, and on engine suction
screen. Replace filter, and refill with
recommended grade aviation oil.
792001 Oil Cooler - Check for obstructions, A 1,2, 3, 4 120
leaks, and security of attachment.
Revised 801001 Starter and Electrical Connections - B 2, 4 120
May 3/99 Check security and condition of starter,
electrical connection, and cable.
Added 801002 Bendix Drive Starter Assembly - Clean A 1,2, 3, 4 120
Feb 15/02 and lubricate starter drive assembly.
5-10-01 Page 13
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
COMPONENT TIME LIMITS

1. General
A. Most components listed throughout Chapter 5 should be inspected as detailed elsewhere in this
chapter and repaired, overhauled or replaced as required. Some components, however, have a time
or life limit associated with them, and must be overhauled or replaced on or before the specified time
limit.
NOTE: The terms overhaul and replacement as used within this section are defined as follows:
* Overhaul - Item may be overhauled as defined in FAR 43.2 or it can be replaced.
* Replacement - Item must be replaced with a new item or a serviceable item that is
within its service life and time limits or has been rebuilt as defined in FAR 43.2.
B. This section provides a list of items which must be overhauled or replaced at specific time limits.
Table 1 lists those items which Cessna has mandated must be overhauled or replaced at specific time
limits. Table's 2 lists component time limits which have been established by outside suppliers on their
product. In addition to these time limits, the components listed herein are also inspected at regular
time intervals set forth in Inspection Time Intervals, and may require overhaul/replacement before their
time limit is reached based on service usage and inspection results.
2. Cessna-Mandated Replacement Time Limits
A. The following component time limits have been established by The Cessna Aircraft Company.
Table 1. Cessna-Mandated Replacement Time Limits

TIME
25 Restraint System, Pilot 504516-401-8013 10 years No
Left Hand/Right Hand
Auto Adjust.
25 Restraint System, Pilot 504851-401-8013 10 years No
Left Hand/Right Hand
Manual Adjust.
25 Restraint System, Aft 504516-403-8013 10 years No
Bench Left Hand/Right
Hand Auto Adjust.
25 Restraint System, Aft 504851-403-8013 10 years No
Bench Left Hand/Right
Hand Manual Adjust.
25 Restraint Assy, 2000031-09-201 10 years No
Pilot Seat
Copilot Seat
Right Rear Seat
Left Rear Seat
27 Trim Tab Actuator 1260074-1 1,000 hours or 3 Yes
years, whichever
comes first.
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
Table 1. Cessna-Mandated Replacement Time Limits (continued)

TIME
37 Dry Vacuum Pump Various (Note 9) No
37 Vacuum Pump 350 (Note 8) No
Coupling
37 Gyro Filter C294502-0201 600 Hours No
37 Regulator Valve B3-5-1 600 Hours No
Filter
71 Engine Various 10 years or No
Compartment engine overhaul,
Flexible Fluid whichever comes
Carrying Teflon first (Note 1).
Hoses (Cessna
Installed) Except
Drain Hoses
71 Engine Compartment Various On Condition No
Drain Hoses
71 Engine Flexible Various (Note 2) No
Hoses (Textron
Lycoming Installed)
71 Air Filter - 172R CA3559 100 hours No
71 Air Filter-172R and P198281 500 hours No
172S
71 Mixture and Throttle Refer to Illustrated At engine TBO No
Cables Parts Catalog for
specific numbers.
71 Starter, Engine 31B22207 At engine TBO Yes
3. Supplier Established Replacement Time Limits

A. The following component time limits have been established by specific suppliers and are reproduced
as follows:
Table 2. Supplier Established Replacement Time Limits

TIME
25 Pointer ELT Battery 2020 (Note 3) No
28 Electric Fuel Pump Various 10 Years (if not 10 Years
overhauled)
37 Vacuum Manifold 1H5-25 (Note 4) No
61 Propeller (Model 172S Refer to McCauley 7000 Hours No
Only) publication (SB240)
71 Slick Magnetos 4371 (Note 5) Yes
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
Table 2. Supplier Established Replacement Time Limits (continued)

TIME
71 Engine IO-360-L2A (Note 6) Yes
71 Engine Oil Filter CH48110 (Note 7) No
NOTES:
Note 1: This life limit is not intended to allow flexible fluid carrying Teflon hoses in
a deteriorated or damaged condition to remain in service. Replace engine
compartment flexible fluid carry Teflon hoses (Cessna installed only) every ten
years or at engine overhaul, whichever occurs first. This does not include drain
hoses. Hoses which are beyond these limits and are in a serviceable condition,
must be placed on order immediately and then be replaced within 30 days after
receiving the new hose from Cessna.
Note 2: Refer to latest Textron Lycoming Engine Service Bulletins.
Note 3: Refer to FAR 91.207 for battery replacement time limits.
Note 4: Refer to Airborne Air & Fuel Product Reference Memo No. 39 or latest revision for
replacement time limits.
Note 5: Refer to Slick Service Bulletin SB2-80C or latest revision for time limits.
Note 6: Refer to Textron/Lycoming Service Instruction S.I. 1009AJ or latest revision for time
limits.
Note 7: RefertoTextron/Lycoming Service Instructions S.I. 1492 B,S.I. 1267C, and Service
Bulletin SB 480C.
Note 8: Replace the engine driven dry vacuum pump coupling at 6 years or per the pump
occurs first. Refer to the manufacturers publication for the particular type pump.
Refer to the List of Manufacturers Technical Publications in the Introduction
section of this manual.
Note 9: Replace the engine driven dry vacuum pump not equipped with a wear indicator
every 500 hours of operating, or replace according to the vacuum pump
occurs first. For vacuum pump equipped with a wear indicator, replace according
to the vacuum pump manufacturer's recommended inspection and replacement
interval.
5-11-00 Page 3
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE PROGRAM

1. General
NOTE: The inspection charts contained within the Progressive Care Program are not intended to be all
inclusive, for no such charts can replace the good judgment of a certified airframe and powerplant
mechanic in performance of his duties. As the one primarily responsible for the airworthiness
of the airplane, the owner or operator should select only qualified personnel to maintain the
airplane.
A. The program is divided into four primary operations (operations 1 through 4) which cover all 50 hour,
100 hour and 200 hour inspection requirements. The remaining operations include all of the inspection
requirements due at other intervals.
B. The inspection program is divided into operations to enable the progressive inspection to be
accomplished.
OPERATION INTERVAL
NUMBER
Operation 1 Consists of all 50 hour interval inspections items and those 100 or 200 hour
interval inspections items contained in the fuselage area.
interval inspections items contained in the engine compartment area.
interval inspections items contained in the wing.
interval inspections items contained in the landing gear.
Operation 5 Every 400 hours or 1 year, whichever occurs first.
|* ~ Operation 6 (Not used. NOTE) First 100 hours and each 500 hours thereafter.
|* ~ Operation 8 (Not used. NOTE) Every 1000 hours or 3 years, whichever occurs first.
Operation 9 Every 500 hours.
Operation 11 Every 2 years.
Operation 12 Five years from the date of manufacture, and every twelve months thereafter.
~ ~|Operation 13 (Not used. NOTE) Every 50 hours or 4 months, whichever comes first.
Operation 14 Every 2 years, or anytime components are added or removed which have
the potential to effect the magnetic accuracy and/or variation of the compass
calibration, or anytime the accuracy of the compass is in question.
Operation 17 Every 12 calendar months.
5-12-00 Page 1
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
OPERATION INTERVAL
NUMBER
Operation 20 Every 1 year.
NOTE: This operation and interval is not currently used but is listed to provide information only.
2. Procedure
A. A COMPLETE AIRPLANE INSPECTION includes all 50, 100 and 200 hour items plus those inspection
items contained in other operations which are due at the specified time.
B. The Component Time Limits Section (5-1 1-00) should be checked at each inspection interval to ensure
proper overhaul and replacement requirements are accomplished at the specified times.
C. The Progressive Care Charts have been developed based on normal usage under average
environmental conditions. Airplanes operated in extremely humid areas (tropics), or in exceptionally
cold, damp climates, etc., may need more frequent inspections for wear, corrosion, and lubrication.
Under these adverse conditions, perform periodic inspections in compliance with this chart at more
frequent intervals until the operator can set his own inspection periods based on field experience.
The operator's inspection intervals shall not deviate from the inspection time limits shown in this
manual except as provided below:
(1) Each inspection interval can be exceeded by 10 hours (if time controlled), or by 30 days (if date
controlled) or can be performed early at any time prior to the regular interval as provided below:
(a) In the event of late compliance of any operation scheduled, the next operation in sequence
retains a due point from the time the late operation was originally scheduled.
(b) In the event of early compliance of any operation scheduled, that occurs 10 hours or less
ahead of schedule, the next phase due point may remain where originally set.
(c) In the event of early compliance of any operation scheduled, that occurs more than 10
hours ahead of schedule, the next operation due point must be rescheduled to establish a
0
d
new due point from the time of early accomplishment.

3. Inspection Terms and Guidelines
A. For inspection terms and guidelines, refer to Time Limits/Maintenance Checks - General.
5-12-00 Page 2
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
*flP()~~~ ~PROGRESSIVE CARE

1. Operation 1
A. Description
Operation 1 consists of all 50-hour interval inspection items and those 100- or 200-hour interval
inspection items contained in the fuselage area. Items from other areas are included to meet their
required time interval.
Inspection items are listed in order of the zone in which the inspection is to be performed. A descriptive
statement of the inspection requirement and the Inspection Item Code, for cross-reference to section
5-10-01 is provided.
If a component or system is disturbed (due to maintenance being performed) after completion of
an initially required operational or functional test, then that specific test must be reconfirmed after
completion of any maintenance prior to returning the system or component to service. Refer to
the appropriate chapter in this Maintenance Manual for removal, installation, operational test and
functional tests of components and/or systems.
For items or components requiring lubrication as applicable, refer to Chapter 12, Servicing - General,
and Contents for lubricant, lubricating points and method.
Refer to Chapter 6, Airplane Zoning - Description and Operation, for airplane zone definition.
The right portion of each page provides room for the mechanic's and inspector's initials and remarks.
These pages may be reproduced as a checklist in performing this inspection operation.
B. General Inspection Criteria
(1) During accomplishment of each of the specific inspections within this operation, additional
general inspections of the surrounding areas should be performed while access is available.
These general inspections are intended to detect obvious conditions which may warrant further
action.
C. Post Inspection Checks
(1) Replace all fairings, doors, floorboard and access covers previously removed.
(2) Inspect Pilot's Operating Handbook and FAA Approved Flight Manual for condition and latest
revision(s). Ensure all required airplane documents are in good condition and properly displayed.
(3) Conduct a preflight inspection upon completion of this Operation to ensure all required items are
properly serviced; refer to the Pilot's Operating Handbook and FAA Approved Flight Manual.
(4) Start and operate the engine per the Pilot's Operating Handbook. Perform a complete
operational check of any system on which maintenance has been performed.
(5) Perform engine shutdown per the Pilot's Operating Handbook and FAA Approved Flight Manual.
Inspect the engine compartment for oil and fuel leaks. Pay close attention to components that
have been removed or replaced. All leaks shall be corrected prior to returning the airplane to
service.
5-12-01 Page 1
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
Date:
Registration Number:
Serial Number:
Total Time:
ITEM CODE TASK ZONE MECH INSP REMARKS

NUMBER
611001 Spinner - Check general condition and attachment. 110
611003 Propeller Blades - Inspect for cracks, dents, nicks, 110
scratches, erosion, corrosion, or other damage.
611005 Propeller Mounting - Check for security of 110
installation.
242001 Alternator, Mounting Bracket, and Electrical 120
Connections - Check condition and security. Check
alternator belts for condition and proper adjustment.
Check belt tension.
711001 Cowling and Cowl Flaps - Inspect for cracks, dents, 120
other damage and security of cowl fasteners.
Check cowl flaps for condition, security, and
operation. Check cowl flap controls for freedom of
movement through full travel.
716001 Alternate Induction Air System - Check for 120
obstructions, operation, and security.
716002 Induction System - Check security of clamps, tubes, 120
and ducting. Inspect for evidence of leakage.
716003 Induction Airbox, Valves, Doors, and Controls - 120
Remove air filter and inspect hinges, doors, seals,
and attaching parts for wear and security. Check
operation.
716004 Induction Air Filter - Remove and clean. Inspect for 120
damage and service.
722001 Engine - Inspect for evidence of oil and fuel leaks. 120
Wash engine and check for security of accessories.
722003 Hoses, Metal Lines, and Fittings - Inspect for 120
signs of oil and fuel leaks. Check for abrasions,
chafing, security, proper routing and support and
for evidence of deterioration.
723003 Engine Baffles and Seals - Check condition and 120
781001 Exhaust System - Inspect for cracks and security. 120
Special check in area of heat exchanger. Refer
to Chapter 78, Exhaust system - Maintenance
Practices.
5-12-01 Page 2
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
791001 Engine Oil - Drain oil sump and oil cooler. Check for 120
metal particles or foreign material in filter, on sump
drain plug, and on engine suction screen. Replace
filter, and refill with recommended grade aviation oil.
792001 Oil Cooler - Check for obstructions, leaks, and 120
801002 Bendix Drive Starter Assembly - Clean and lubricate 120
starter drive assembly.
761001 Engine Controls and Linkage - Check general 120, 225
condition, freedom of movement through full range.
Check for proper travel, security of attachment,
and for evidence of wear. Check friction lock and
vernier adjustment for proper operation. Check that
throttle and fuel mixture arms operate through their
full arc of travel.
271001 Aileron Controls - Check freedom of movement and 120, 520,
proper operation through full travel. 620
243003 General Airplane and System Wiring - Inspect for 210
proper routing, chafing, broken or loose terminals,
general condition, broken or inadequate clamps,
and sharp bends in wiring.
521001 Doors - Inspect general condition. Check latches, 210
hinges, and seals for condition, operation, and
531001 Fuselage Surface - Inspect for skin damage, loose 210
rivets, condition of paint, and check pitot-static ports
and drain holes for obstruction. Inspect covers and
fairings for security.
561001 Windows and Windshield - Inspect general 210
condition. Check latches, hinges, and seals
for condition, operation, and security of attachment.
214002 Heater Components, Inlets, and Outlets - Inspect 211
all lines, ducts, clamps, seals, and gaskets for
214003 Cabin Heat and Ventilation Controls - Check 211
freedom of movement through full travel. Check
friction locks for proper operation.
235001 Microphones, Headsets, and Jacks - Inspect for 211
cleanliness, security, and evidence of damage.
251001 Seats - Check general condition and security. 211
Check operation of seat stops and adjustment
mechanism.
251101 Restraint System, front and rear - Check belts 211
for thinning, fraying, cutting, broken stitches, or
ultra-violet deterioration. Check system hardware
5-12-01 Page 3
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
531003 Internal Fuselage Structure - Inspect bulkheads, 211
doorposts, stringers, doublers, and skins for
corrosion, cracks, buckles, and loose rivets, bolts
and nuts.
311001 Instruments - Check general condition and 220
markings for legibility.
311003 Instrument Lines, Fittings, Ducting, and Instrument 220
Panel Wiring - Check for proper routing, support,
and security of attachment.
331001 Instrument and Cabin Lights - Check operation, 220, 211,
condition of lens, and security of attachment. 221
112101 Exterior Placards and Decals - Inspect presence, 220, 221
legibility, and security. Consult Pilot's Operating
Handbook and FAA Approved Airplane Flight
113101 Interior Placards and Decals - Inspect presence, 220, 221
311002 Instrument Panel Ground Straps - Inspect for 220,221
deterioration, cracks, and security of attachment.
345003 Navigation Indicators, Controls, and Components - 220, 225
Inspect for condition and security.
275002 Wing Flap Control - Check operation through full 221
travel and observe Flap Position indicator for proper
indication.
246001 Switch and Circuit Breaker Panel, Terminal Blocks, 222
and Junction Boxes - Inspect wiring and terminals
for condition and security.
246002 Power Junction Box - Check operation and 222
condition. Check availability and condition of
spare fuse (if applicable).
271005 Control Wheel Lock - Check general condition and 222
operation.
271006 Control Yoke - Inspect pulleys, cables, bearings, 222, 223
and turnbuckles for condition and security.
273001 Elevator Control - Check freedom of movement and 222, 223
273002 Elevator Control System - Inspect pulleys, cables, 222, 223
sprockets, bearings, chains, and turnbuckles for
condition, security, and operation. Check cables for
tension, routing, fraying, corrosion, and turnbuckle
safety.
273103 Elevator Trim Tab and Hinges - Check condition, 224
5-12-01 Page 4
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
282003 Fuel Selector Valve - Check controls for detent in 224
each position, security of attachment, and for proper
placarding.
282006 Fuel Selector - Using quick drain, ensure no 224
contamination exists.
273101 Elevator Trim System - Check cables, push-pull 224, 240,
rods, bellcranks, pulleys, turnbuckles, fairleads, 310
rub strips, etc. for proper routing, condition, and
security.
273102 Elevator Trim Control and Indicator- Check freedom 224, 240,
of movement and proper operation through full 310
travel. Check pulleys, cables, sprockets, bearings,
chains, and turnbuckles for condition and security.
Check cables for tension, routing, fraying, corrosion,
342101 Magnetic Compass - Inspect for security of 225
installation, cleanliness, and evidence of damage.
345001 Instrument Panel Mounted Avionics Units (Including 225
Audio Panel, VHF Nav/Com(s), ADF, GPS,
Transponder, and Compass System) - Inspect
for deterioration, cracks, and security of instrument
panel mounts. Inspect for security of electrical
connections, condition, and security of wire routing.
345002 Avionics Operating Controls - Inspect for security 225
and proper operation of controls and switches
and ensure that all digital segments will illuminate
properly.
262001 Portable Hand Fire Extinguisher - Inspect for 230
proper operating pressure, condition, security of
installation, and servicing date.
272004 Rudder Pedals and Linkage - Check for general 230
condition, proper rigging, and operation. Check for
273106 Elevator Trim Tab Stop Blocks - Inspect for damage 240
and security.
256001 Emergency Locator Transmitter - Inspect for 310
security of attachment and check operation by
verifying transmitter output. Check cumulative time
and useful life of batteries in accordance with FAR
Part 91.207.
345004 Navigation Antennas and Cables - Inspect for 310
security of attachment, connection, and condition.
273003 Elevator, Hinges, Stops, and Cable Attachment - 320, 330
Check condition, security, and operation.
5-12-01 Page 5
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
551001 Horizontal Stabilizer and Tailcone structure - 320, 330
Inspect bulkheads, spars, ribs, and skins, for
cracks, wrinkles, loose rivets, corrosion, or other
damage. Inspect horizontal stabilizer attach bolts
for looseness. Retorque as necessary. Check
security of inspection covers, fairings, and tips.
551002 Horizontal Stabilizer and Tips - Inspect externally for 320, 330
skin damage and condition of paint.
272002 Rudder - Inspect the rudder skins for cracks and 340
loose rivets, rudder hinges for condition, cracks and
security; hinge bolts, nuts, hinge bearings, hinge
attach fittings, and bonding jumper for evidence of
damage and wear, failed fasteners, and security.
Inspect balance weight for looseness and the
272003 Rudder, Tips, Hinges, Stops, Clips and Cable 340
Attachment - Check condition, security, and
operation.
272005 Rudder Control - Check freedom of movement and 340
proper operation through full travel. Check rudder
stops for damage and security.
553001 Vertical Stabilizer Fin - Inspect bulkheads, spars, 340
ribs, and skins for cracks, wrinkles, loose rivets,
corrosion, or other damage. Inspect vertical
stabilizer attach bolts for looseness. Retorque as
necessary. Check security of inspection covers,
fairings, and tip.
553002 Vertical Stabilizer Fin and Tailcone - Inspect 340
externally for skin damage and condition of paint.
334001 Navigation, Beacon, Strobe, and Landing Lights - 340, 520,
Check operation, condition of lens, and security of 620
attachment.
341103 Pitot Tube and Stall Warning Vane - Check for 510
condition and obstructions and verify operation of
anti-ice heat.
571001 Wing Surfaces and Tips - Inspect for skin damage, 510, 520,
loose rivets, and condition of paint. 610, 620
275001 Flaps - Check tracks, rollers, and control rods for 510, 610
security of attachment. Check rod end bearings for
corrosion. Check operation.
282001 Fuel System - Inspect plumbing and components for 510, 610
mounting and security.
282002 Fuel Tank Vent Lines and Vent Valves - Check 510, 610
vents for obstruction and proper positioning. Check
valves for operation.
5-12-01 Page 6
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
282004 Integral Fuel Bays - Check for evidence of leakage 510, 610
and condition of fuel caps, adapters, and placards.
Using quick drains, ensure no contamination exists.
282005 Fuel Reservoir - Using quick drain, ensure no 510, 610
282007 Fuel Strainer, Drain Valve, and Controls - Check 510, 610
freedom of movement, security, and proper
operation. Disassemble, flush, and clean screen
and bowl.
571002 Wing Struts and Strut Fairings - Check for dents, 510, 610
cracks, loose screws and rivets, and condition of
paint.
271003 Aileron Structure, Control Rods, Hinges, Balance 520, 620
Weights, Bellcranks, Linkage, Bolts, Pulleys, and
Pulley Brackets - Check condition, operation, and
271004 Ailerons and Hinges - Check condition, security, and 520, 620
operation.
275006 Flap Actuator Threads - Clean and lubricate. Refer 610
to Chapter 12, Flight Controls - Servicing.
*** End of Operation 1 Inspection Items ***
5-12-01 Page 7
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
*()JR~~~~ ~PROGRESSIVE CARE

1. Operation 2
A. Description
Operation 2 consists of all 50-hour interval inspection items and those 100- or 200-hour interval
inspection items contained in the engine compartment. Items from other areas are included to meet
their required time interval.
action.
service.
5-12-02 Page 1
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
611002 Spinner and Spinner Bulkhead - Remove spinner, 110
wash, and inspect for cracks and fractures.
611004 Propeller Hub - Check general condition. 110
installation.
611006 Propeller Mounting Bolts - Inspect mounting bolts 110
and safety wire for signs of looseness. Retorque
mounting bolts as required.
214001 Cold and Hot Air Hoses - Check condition, routing, 120
and security.
Check belt tension.
243001 Battery - Check general condition and security. 120
Check level of electrolyte. Refer to Chapter 12,
Battery - Servicing.
243002 Battery Box and Cables - Clean and remove any 120
corrosion. Check cables for routing, support, and
security of connections.
243004 External Power Receptacle and Power Cables - 120
Inspect for condition and security.
282010 Auxiliary (Electric) Fuel Pump - Check pump and 120
fittings for condition, operation, security.
371001 Vacuum System - Inspect for condition and security. 120
371002 Vacuum Pumps - Check for condition and 120
security. Check vacuum system breather line
for obstructions, condition, and security.
371003 Vacuum System Hoses - Inspect for hardness, 120
deterioration, looseness, or collapsed hoses.
371004 Gyro Filter - Inspect for damage, deterioration and 120
contamination. Clean or replace if required.
5-12-02 Page 2
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
371005 Regulator Valve and Filter - Inspect valve assembly 120
for security of installation. Visually inspect filter for
damage, deterioration and contamination. Clean or
replace if required.
531002 Firewall Structure - Inspect for wrinkles, damage, 120
cracks, sheared rivets, etc. Check cowl shock
mounts for condition and security.
712001 Engine Shock Mounts, Engine Mount Structure, 120
and Ground Straps - Check condition, security, and
alignment.
operation.
damage and service.
722002 Crankcase, Oil Sump, and Accessory Section - 120
Inspect for cracks and evidence of oil leakage.
Check bolts and nuts for looseness and retorque
as necessary. Check crankcase breather lines for
obstructions, security, and general condition.
723001 Engine Cylinders, Rocker Box Covers, and Pushrod 120
Housings - Check for fin damage, cracks, oil
leakage, security of attachment, and general
condition.
723002 Engine Metal Lines, Hoses, Clamps, and Fittings - 120
Check for leaks, condition, and security. Check for
proper routing and support.
5-12-02 Page 3
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
723004 Cylinder Compression Perform differential 120
compression test. If there is weak cylinder
compression, refer to Chapter 71, 1O-360-L2A
Troubleshooting, for further procedures.
730001 Engine-Driven Fuel Pump - Check for evidence 120
of leakage, security of attachment, and general
condition.
730002 Fuel Injection System - Check system for security 120
and condition. Clean fuel inlet screen, check and
clean injection nozzles and screens (if evidence of
contamination is found), and lubricate air throttle
shaft.
730003 Idle and Mixture - Run the airplane engine to 120
determine satisfactory performance. If required,
adjust the idle rpm and fuel mixture. Refer to
Chapter 73, Fuel Injection Systems - Maintenance
Practices.
741001 Magnetos - Check external condition, security, 120
and electrical leads for condition. Check timing to
engine and internal timing if engine timing requires
adjustment.
742001 Ignition Harness and Insulators - Check for proper 120
routing, deterioration, and condition of terminals.
742002 Spark Plugs - Remove, clean, analyze, test, gap, 120
and rotate top plugs to bottom and bottom plugs to
top.
743001 Ignition Switch and Electrical Harness - Inspect for 120
damage, condition, and security.
Practices.
801001 Starter and Electrical Connections - Check security 120
and condition of starter, electrical connection, and
cable.
5-12-02 Page 4
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
full arc of travel.
324002 Brakes, Master Cylinders, and Parking Brake 224, 230
- Check master cylinders and parking brake
mechanism for condition and security. Check fluid
level and test operation of toe and parking brake.
Refer to Chapter 12, Hydraulic Brakes - Servicing.
251002 Seat Tracks and Stops - Inspect seat tracks for 230
condition and security of installation. Check seat
track stops for damage and correct location.
Inspect seat rails for cracks.
324001 Brakes - Test toe brakes and parking brake for 230
proper operation.
anti-ice heat.
322001 Nose Gear - Inspect torque links, steering rods, 720
and boots for condition and security of attachment.
Check strut for evidence of leakage and proper
extension. Check strut barrel for corrosion, pitting,
and cleanliness. Check shimmy damper and/or
bungees for operation, leakage, and attach points
for wear and security.
322002 Nose Landing Gear Wheel Fairings - Check for 720
322004 Nose Gear Attachment Structure - Inspect for 720
cracks, corrosion, or other damage and security of
attachment.
324004 Tires - Check tread wear and general condition. 720, 721,
Check for proper inflation. 722
321002 Main Gear Tubular Struts - Inspect for cracks, 721,722
dents, corrosion, condition of paint or other
damage. Check axles for condition and security.
321003 Main Landing Gear Attachment Structure - Check 721, 722
for damage, cracks, loose rivets, bolts and nuts and
324005 Wheels, Brake Discs, and Linings - Inspect for 721,722
wear, cracks, warps, dents, or other damage.
Check wheel through-bolts and nuts for looseness.
5-12-02 Page 5
Feb 15/2002
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MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 3
A. Description
Operation 3 consists of all 50 hour interval inspection items and those 100 or 200 hour interval
inspection items contained in the wing. Items from other areas are included to meet their required
time interval.
action.
service.
5-12-03 Page 1
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
installation.
Check belt tension.
operation.
damage and service.
Practices.
5-12-03 Page 2
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
full arc of travel.
271001 Aileron Controls - Check freedom of movement and 120, 520,
proper operation through full travel. 620
271002 Ailerons and Cables - Check operation and security 120, 520,
of stops. Check cables for tension, routing, fraying, 620
corrosion, and turnbuckle safety. Check travel
if cable tension requires adjustment or if stops
are damaged. Check fairleads and rub strips for
condition.
231001 Communication Antennas and Cables - Inspect for 210
security of attachment, connection, and condition.
341101 Static System - Inspect for security of installation, 210
cleanliness, and evidence of damage.
521001 Doors - Inspect general condition. Check latches, 210
hinges, and seals for condition, operation, and
531001 Fuselage Surface - Inspect for skin damage, loose 210
rivets, condition of paint, and check pitot-static ports
and drain holes for obstruction. Inspect covers and
fairings for security.
561001 Windows and Windshield - Inspect general 210
condition. Check latches, hinges, and seals
for condition, operation, and security of attachment.
214002 Heater Components, Inlets, and Outlets - Inspect 211
all lines, ducts, clamps, seals, and gaskets for
251001 Seats - Check general condition and security. 211
Check operation of seat stops and adjustment
mechanism.
5-12-03 Page 3
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
251101 Restraint System, front and rear - Check belts 211
for thinning, fraying, cutting, broken stitches, or
ultra-violet deterioration. Check system hardware
311001 Instruments - Check general condition and 220
markings for legibility.
331001 Instrument and Cabin Lights - Check operation, 220, 211,
condition of lens, and security of attachment. 221
112101 Exterior Placards and Decals - Inspect presence, 220, 221
113101 Interior Placards and Decals - Inspect presence, 220, 221
246002 Power Junction Box - Check operation and 222
condition. Check availability and condition of
spare fuse (if applicable).
273001 Elevator Control - Check freedom of movement and 222, 223
273002 Elevator Control System - Inspect pulleys, cables, 222, 223
sprockets, bearings, chains, and turnbuckles for
condition, security, and operation. Check cables for
tension, routing, fraying, corrosion, and turnbuckle
safety.
273103 Elevator Trim Tab and Hinges - Check condition, 224
282003 Fuel Selector Valve - Check controls for detent in 224
each position, security of attachment, and for proper
placarding.
282006 Fuel Selector - Using quick drain, ensure no 224
273101 Elevator Trim System - Check cables, push-pull 224, 240,
rods, bellcranks, pulleys, turnbuckles, fairleads, 310
rub strips, etc. for proper routing, condition, and
security.
262001 Portable Hand Fire Extinguisher - Inspect for 230
proper operating pressure, condition, security of
installation, and servicing date.
256001 Emergency Locator Transmitter - Inspect for 310
security of attachment and check operation by
verifying transmitter output. Check cumulative time
and useful life of batteries in accordance with FAR
Part 91.207.
5-12-03 Page 4
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
273104 Elevator Trim Tab Actuator - Check free play 320
limits. Refer to Chapter 27, Elevator Trim Control
- Maintenance Practices. Trim Tab Free Play
Inspection. If free play still exceeds limits, actuator
must be overhauled or replaced.
273003 Elevator, Hinges, Stops, and Cable Attachment - 320, 330
Check condition, security, and operation.
551001 Horizontal Stabilizer and Tailcone structure - 320, 330
Inspect bulkheads, spars, ribs, and skins, for
cracks, wrinkles, loose rivets, corrosion, or other
damage. Inspect horizontal stabilizer attach bolts
for looseness. Retorque as necessary. Check
security of inspection covers, fairings, and tips.
551002 Horizontal Stabilizer and Tips - Inspect externally for 320, 330
skin damage and condition of paint.
272001 Rudder - Check internal surfaces for corrosion, 340
condition of fasteners, and balance weight
attachment.
272002 Rudder - Inspect the rudder skins for cracks and 340
loose rivets, rudder hinges for condition, cracks and
security; hinge bolts, nuts, hinge bearings, hinge
attach fittings, and bonding jumper for evidence of
damage and wear, failed fasteners, and security.
Inspect balance weight for looseness and the
272003 Rudder, Tips, Hinges, Stops, Clips and Cable 340
Attachment - Check condition, security, and
operation.
272005 Rudder Control - Check freedom of movement and 340
proper operation through full travel. Check rudder
stops for damage and security.
553001 Vertical Stabilizer Fin - Inspect bulkheads, spars, 340
ribs, and skins for cracks, wrinkles, loose rivets,
corrosion, or other damage. Inspect vertical
stabilizer attach bolts for looseness. Retorque as
necessary. Check security of inspection covers,
fairings, and tip.
553002 Vertical Stabilizer Fin and Tailcone - Inspect 340
externally for skin damage and condition of paint.
334001 Navigation, Beacon, Strobe, and Landing Lights - 340, 520,
Check operation, condition of lens, and security of 620
attachment.
anti-ice heat.
571001 Wing Surfaces and Tips - Inspect for skin damage, 510, 520,
loose rivets, and condition of paint. 610, 620
5-12-03 Page 5
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
571003 Wing Access Plates - Check for damage and 510, 520,
security of installation. 610, 620
571004 Wing Spar and Wing Strut Fittings - Check for 510, 520,
evidence of wear. Check attach bolts for indications 610, 620
of looseness and retorque as required.
571005 Wing Structure - Inspect spars, ribs, skins, 510, 520,
and stringers for cracks, wrinkles, loose rivets, 610, 620
corrosion, or other damage.
275001 Flaps - Check tracks, rollers, and control rods for 510, 610
security of attachment. Check rod end bearings for
corrosion. Check operation.
275003 Flap Structure, Linkage, Bellcranks, Pulleys, and 510, 610
Pulley Brackets - Check for condition, operation and
security.
275004 Flaps and Cables - Check cables for proper tension, 510, 610
routing, fraying, corrosion, and turnbuckle safety.
Check travel if cable tension requires adjustment.
282001 Fuel System - Inspect plumbing and components for 510, 610
mounting and security.
282002 Fuel Tank Vent Lines and Vent Valves - Check 510, 610
vents for obstruction and proper positioning. Check
valves for operation.
282004 Integral Fuel Bays - Check for evidence of leakage 510, 610
and condition of fuel caps, adapters, and placards.
Using quick drains, ensure no contamination exists.
282005 Fuel Reservoir - Using quick drain, ensure no 510, 610
282007 Fuel Strainer, Drain Valve, and Controls - Check 510, 610
freedom of movement, security, and proper
operation. Disassemble, flush, and clean screen
and bowl.
571002 Wing Struts and Strut Fairings - Check for dents, 510, 610
cracks, loose screws and rivets, and condition of
paint.
271003 Aileron Structure, Control Rods, Hinges, Balance 520, 620
Weights, Bellcranks, Linkage, Bolts, Pulleys, and
Pulley Brackets - Check condition, operation, and
271004 Ailerons and Hinges - Check condition, security, and 520, 620
operation.
275005 Flap Motor, Actuator, and Limit Switches - Check 610
wiring and terminals for condition and security.
Check actuator for condition and security.
5-12-03 Page 6
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
275006 Flap Actuator Threads - Clean and lubricate. Refer 610
to Chapter 12, Flight Controls - Servicing.
*** End of Operation 3 Inspection Items ***
5-12-03 Page 7
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 4
A. Description
Operation 4 consists of all 50 hour interval inspection items and those 100 or 200 hour interval
inspection items contained in the landing gear. Items from other areas are included to meet their
required time interval.
action.
service.
5-12-04 Page 1
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
611002 Spinner and Spinner Bulkhead - Remove spinner, 110
wash, and inspect for cracks and fractures.
installation.
214001 Cold and Hot Air Hoses - Check condition, routing, 120
and security.
Check belt tension.
243001 Battery - Check general condition and security. 120
Check level of electrolyte. Refer to Chapter 12,
Battery - Servicing.
243002 Battery Box and Cables - Clean and remove any 120
corrosion. Check cables for routing, support, and
security of connections.
282010 Auxiliary (Electric) Fuel Pump - Check pump and 120
fittings for condition, operation, security.
371001 Vacuum System - Inspect for condition and security. 120
371002 Vacuum Pumps - Check for condition and 120
security. Check vacuum system breather line
for obstructions, condition, and security.
371003 Vacuum System Hoses - Inspect for hardness, 120
deterioration, looseness, or collapsed hoses.
371004 Gyro Filter - Inspect for damage, deterioration and 120
contamination. Clean or replace if required.
371005 Regulator Valve and Filter - Inspect valve assembly 120
for security of installation. Visually inspect filter for
damage, deterioration and contamination. Clean or
replace if required.
5-12-04 Page 2
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
operation.
damage and service.
722002 Crankcase, Oil Sump, and Accessory Section - 120
Inspect for cracks and evidence of oil leakage.
Check bolts and nuts for looseness and retorque
as necessary. Check crankcase breather lines for
obstructions, security, and general condition.
723001 Engine Cylinders, Rocker Box Covers, and Pushrod 120
Housings - Check for fin damage, cracks, oil
leakage, security of attachment, and general
condition.
723004 Cylinder Compression - Perform differential 120
compression test. If there is weak cylinder
compression, refer to Chapter 71, IO-360-L2A
Troubleshooting, for further procedures.
730001 Engine-Driven Fuel Pump - Check for evidence 120
of leakage, security of attachment, and general
condition.
730002 Fuel Injection System - Check system for security 120
and condition. Clean fuel inlet screen, check and
clean injection nozzles and screens (if evidence of
contamination is found), and lubricate air throttle
shaft.
730003 Idle and Mixture - Run the airplane engine to 120
determine satisfactory performance. If required,
adjust the idle rpm and fuel mixture. Refer to
Chapter 73, Fuel Injection Systems - Maintenance
Practices.
5-12-04 Page 3
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
ITEM CODE TASK ZONE MECHINSP REMARKS

NUMBER
741001 Magnetos - Check external condition, security, 120
and electrical leads for condition. Check timing to
engine and internal timing if engine timing requires
adjustment.
742001 Ignition Harness and Insulators - Check for proper 120
routing, deterioration, and condition of terminals.
742002 Spark Plugs - Remove, clean, analyze, test, gap, 120
and rotate top plugs to bottom and bottom plugs to
top.
743001 Ignition Switch and Electrical Harness - Inspect for 120
damage, condition, and security.
Practices.
801001 Starter and Electrical Connections - Check security 120
and condition of starter, electrical connection, and
cable.
761001 Engine Controls and Linkage - Check general 120,225
full arc of travel.
324002 Brakes, Master Cylinders, and Parking Brake 224, 230
- Check master cylinders and parking brake
mechanism for condition and security. Check fluid
level and test operation of toe and parking brake.
Refer to Chapter 12, Hydraulic Brakes - Servicing.
251002 Seat Tracks and Stops - Inspect seat tracks for 230
condition and security of installation. Check seat
track stops for damage and correct location.
Inspect seat rails for cracks.
324001 Brakes - Test toe brakes and parking brake for 230
proper operation.
5-12-04 Page 4
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

NUMBER
anti-ice heat.
322001 Nose Gear - Inspect torque links, steering rods, 720
and boots for condition and security of attachment.
Check strut for evidence of leakage and proper
extension. Check strut barrel for corrosion, pitting,
and cleanliness. Check shimmy damper and/or
bungees for operation, leakage, and attach points
for wear and security.
322002 Nose Landing Gear Wheel Fairings - Check for 720
322003 Nose Gear Fork - Inspect for cracks, general 720
condition, and security of attachment.
322004 Nose Gear Attachment Structure - Inspect for 720
cracks, corrosion, or other damage and security of
attachment.
325001 Nose Gear Steering Mechanism - Check for wear, 720
security, and proper rigging.
324004 Tires - Check tread wear and general condition. 720, 721,
Check for proper inflation. 722
324006 Wheel Bearings - Clean, inspect and lube. 720, 721,
722
321002 Main Gear Tubular Struts - Inspect for cracks, 721,722
dents, corrosion, condition of paint or other
damage. Check axles for condition and security.
321003 Main Landing Gear Attachment Structure - Check 721, 722
for damage, cracks, loose rivets, bolts and nuts and
324005 Wheels, Brake Discs, and Linings - Inspect for 721, 722
wear, cracks, warps, dents, or other damage.
Check wheel through-bolts and nuts for looseness.
321001 Main Landing Gear Wheel Fairings, Strut Fairings, 721,722
and Cuffs - Check for cracks, dents, and condition
of paint.
***End of Operation 4 Inspection Items ***
5-12-04 Page 5
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 5
A. Description
Operation 5 consists of items to be inspected every 400 hours or 1 year, whichever occurs first.
action.
(2) This operation should be performed concurrently with one of the operations, one through four,
which falls nearest to its due point.
5-12-05 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
212001 Ventilation System - Inspect clamps, hoses, and 211
valves for condition and security.
252201 Upholstery, Headliner, Trim, and Carpeting - Check 211
324003 Brake Lines, Wheel Cylinders, Hoses, Clamps, 721,722
and Fittings - Check for leaks, condition, and
security and hoses for bulges and deterioration.
Check brake lines and hoses for proper routing and
support.
5-12-05 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 6
THERE ARE CURRENTLY NO PROGRESSIVE CARE OPERATIONS CONTAINED IN THIS SECTION.
5-12-06 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 7
A. Description
action.
_ which falls nearest to its due point.
5-12-07 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
282008 Fuel Quantity Indicators - Check for damage, 220
security of installation, and perform accuracy test.
221001 Autopilot Rigging - Refer to Autopilot - Maintenance 610
Practices.
5-12-07 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 8
5-12-08 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 9
A. Description
Operation 9 consists of items to be inspected every 500 hours.
statement of the inspection requirement and the Inspection item Code, for cross-reference to section
action.
5-12-09 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
741002 Magnetos - Clean, inspect and adjust as required. 120
Refer to Slick 4300/4600 Series Magneto
Maintenance and Overhaul Manual.
5-12-09 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 10
A. Description
Operation 10 consists of items to be inspected every 1000 hours.
action.
5-12-10 Page 1
Feb 15/2002
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MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 11
A. Description
Operation 11 consists of items to be inspected every 2 years.
action.
5-12-11 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
341102 Pitot and Static System - Inspect in accordance with 220
FAR Part 91.411.
5-12-11 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 12
A. Description
Operation 12 consists of items to be inspected beginning at the 5th year, and every 12 months
thereafter until replacement at 10 years.
action.
5-12-12 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
371006 Vacuum Manifold Check Valve - Check for proper 120
operation. Refer to Chapter 37, Vacuum System -
5-12-12 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 13
5-12-13 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 14
A. Description
Operation 14 consists of calibrating/checking the magnetic compass. This check/calibration should be
preformed every 2 years, or anytime components are added or removed from the airplane which have
the potential to effect the magnetic accuracy and/or variation of the compass calibration, or anytime
the accuracy of the compass is in question.
action.
5-12-14 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
342102 Magnetic Compass - Calibrate. 220
5-12-14 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 15
A. Description
Operation 15 consists of inspection/lubrication of the ACS brand ignition switch. This inspection/
lubrication should be performed every 2000 hours.
action.
5-12-15 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
743002 Inspect and lubricate ACS brand ignition switch. 224
Refer to Chapter 74, Ignition System - Maintenance
Practices.
5-12-15 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 16
A. Description
action.
5-12-16 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date: _
Serial Number:
Total Time:

NUMBER
221002 Autopilot Servo Capstan Assemblies. Check 610
slip-clutch torque settings. Refer to Autopilot -
221003 Autopilot Servo Actuators. Inspect for evidence of 610
corrosion and or buildup of dirt or other particulate
matter which may interfere with servo operation.
Refer to Autopilot - Maintenance Practices.
5-12-16 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
Operation 17
A. Description
Operation 17 consists of items to be inspected every 12 calendar months.
action.
5-12-17 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
262002 Cockpit Mounted Halon Type Fire Extinguisher - 211
Weigh bottle. Bottle must be reserviced by qualified
individual if more than 2 ounces is lost.
5-12-17 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 18
A. Description
action.
5-12-18 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
262004 Cockpit Mounted Halon Type Fire Extinguishers - 211
Empty, inspect for damage, and recharge.
5-12-18 Page2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 19
A. Description
action.
5-12-19 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Date:
Serial Number:
Total Time:

NUMBER
262003 Cockpit Mounted Halon Type Fire Extinguishers - 211
Perform hydrostatic test. The hydrostatic test shall
be at twelve-year intervals based on initial servicing
or date of last hydrostatic test.
5-12-19 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROGRESSIVE CARE
1. Operation 20
A. Description
Operation 20 consists of items to be inspected every year.
action.
5-12-20 Page 1
Feb 15/2002
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MODEL 172
MAINTENANCE MANUAL
CHAPTER
DIMENSIONS
AND
AREAS
MODEL 172
MAINTENANCE MANUAL

6-Title
6-List of Effective Pages 1 Aug 18/2001
6-Contents 1 Aug 18/2001
6-00-00 1 Aug 18/2001
6-10-00 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
4 Aug 18/2001
6-15-00 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
6-20-00 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
4 Aug 18/2001
6-20-02 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
4 Aug 18/2001
5 Aug 18/2001
6 Aug 18/2001
7 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
ACCESS/INSPECTION PLATES - DESCRIPTION AND OPERATION .................. 6-20-02 Page 1
General ........................................ ............................ 6-20-02 Page 1
Access/Inspection Plate Numbering ........................................ 6-20-02 Page 1
Description .................................................................. 6-20-02 Page 1
6 - CONTENTS Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DIMENSIONS AND AREAS - GENERAL
1. Scope
A. This chapter includes illustrations and statistical information concerning the Model 172 airplane.
Provided are the overall airplane dimensions, surface areas, station locations, zones and access
plate locations.
B. Dimensions and measurements are presented to aid the operator and/or maintenance personnel in
ground handling the airplane and locating components.
2. Definition
A. Airplane Dimensions and Areas.
(1) The section on airplane dimensions and areas provides airplane dimensions and identifies areas
of the airplane.
B. Airplane Stations.
(1) The section on stations provides illustrations to identify reference points on the airplane along a
three axis division.
C. Airplane Zoning.
(1) The section on zoning provides illustrations of all airplane zones.
D. Access Plates/Panels.
(1) The section on access plates/panels provides numbering of all plates and panels based on
specific airplane zones.
6-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AIRPLANE DIMENSIONS AND SPECIFICATIONS - DESCRIPTION AND OPERATION
1. General
A. Airplane dimensions and specifications have been compiled to serve as a central reference point for
airplane information. This information is presented in tabular and illustrative form below. Refer to
Figure 1 for an illustration of airplane dimensions.
AIRPLANE OVERALL
Length (Overall) 27' - 2"
Height (Maximum) 8'- 11"
Wing Span (Overall) 36' - 0"
Tail Span 11' - 4"
Landing Gear Track Width 8' - 4 1/2"
FUSELAGE DIMENSIONS
Cabin Width (Maximum Sidewall to Sidewall) 3' - 3 1/2"
Cabin Height (Floorboard to Headliner) 4' - 0"
MAXIMUM WEIGHT
Ramp
172R 2457 Pounds
172S 2558 Pounds
(And 172R Airplanes Incorporating MK172-72-01)
Takeoff
172R 2450 Pounds
172S 2550 Pounds
Landing
172R 2450 Pounds
172S 2550 Pounds
FUEL CAPACITY
Total 56.0 Gallons
Usable 53.0 Gallons
ENGINE DATA
Type Lycoming IO-360-L2A
Oil Capacity 8.0 Quarts
Oil Filter CH48110
RPM (Maximum)
172R 2400 RPM
6-10-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
172S 2700 RPM

Horsepower
172R 160 HP
172S 180 HP
PROPELLER
Type
172R McCauley 1C235/LFA7570
172S McCauley 1A170E/JHA7660
Diameter (Maximum to Minimum)
172R 75"- 74"
172S 76" - 75"
TIRE, STRUT AND WHEEL ALIGNMENT DATA
Main Tire Size
172R 6.00 X 6, 4-Ply Rating
172S 6.00 X 6, 6-Ply Rating
Main Tire Pressure
172R 28.0 PSI
172S 38.0 PSI
Nose Tire Size
172R, 172S 5.00 X 5, 6-Ply Rating
Nose Tire Pressure
172R 34.0 PSI
172S 45.0 PSI
Nose Gear Strut Pressure (Strut Extended) 45.0 PSI
Camber (Measured With Airplane Empty) 2 to 4 Degrees
Toe-In (Measured With Airplane Empty) 0.00 to 0.18"
CONTROL SURFACE TRAVELS/CABLE TENSION
SETTINGS
AILERONS
Aileron Up Travel 20 Degrees, +1 Degree
6-10-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Aileron Down Travel 15 Degrees, ±1 Degree

Aileron Cable Tension (Carry Through) 40 Pounds, ±10 Pounds
RUDDER
Rudder Travel (Measured Parallel to Water Line)
Right 16 Degrees 10 Min; ±1 Degree
Left 16 Degrees 10 Min; ±1 Degree
Rudder Travel (Measured Perpendicular to Hinge Line)
Right 17 Degrees 44 Min; +1 Degree
Left 17 Degrees 44 Min; +1 Degree
ELEVATOR
Up Travel (Relative to Stabilizer) 28 Degrees, +1 or -0 Degree
Down Travel (Relative to Stabilizer) 23 Degrees, +1 or -0 Degree
Elevator Cable Tension 30 Pounds, +10 Pounds
ELEVATOR TRIM TAB
Up Travel 22 Degrees, +1 or -0 Degree
Down Travel 19 Degrees, +1 or -0 Degree
Elevator Trim Cable Tension 20 Pounds, +0 or -5 Pounds
FLAPS
Flap Setting:
0 Degree (UP) 0 Degree
10 Degrees 10 Degrees, +0 or -2 Degrees
20 Degrees 20 Degrees, +0 or -2 Degrees
30 Degrees (FULL) 30 Degrees, +0 or -2 Degrees
Flap Cable Tension 30 Pounds, ±10 Pounds
6-10-00 Page 3
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1418
36'- 0"
PROPELLER DIAMETER
172R - 75"
182S - 76" (AND 172R AIRPLANES
INCORPORATING MK1 72-72-01)
27'- 2"
Airplane Dimensions
Figure 1 (Sheet 1)
6-10-00 Page 4
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AIRPLANE STATIONS - DESCRIPTION AND OPERATION

1. General
A. The airplane is laid out according to fuselage stations (FS) and wing stations (WS). These stations
provide fixed reference points for all components located on or within the airplane. Fuselage Stations
begin at the firewall (FS 0.00) and extend to the tailcone area (FS 230.18). Wing Stations begin at
the root (WS 23.62) and extend to the tip (WS 208.00). Both Fuselage Stations and Wing Stations
are measured in inches. For example, FS 185.50 is 185.50 inches aft of the firewall (FS 0.00).
B. For an illustration of Fuselage Stations, refer to Figure 1. For an illustration of Wing Stations, refer to
Figure 2.
6-15-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FS 3.375 FS 65.33 FS 142.00

FS 16.66 FS 108.00
05101008
Fuselage Stations
Figure 1 (Sheet 1)
6-15-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
22.875 WS
208.00 WS
208.00 WS
05223001
Wing Stations
Figure 2 (Sheet 1)
6-15-00 Page 3
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AIRPLANE ZONING - DESCRIPTION AND OPERATION

1. General
A. The Model 172 is divided into numbered zones to provide a method for locating components and/or
placards throughout the airplane. The zones are identified by a three-digit number as shown in the
example below. The first digit in the sequence denotes the major zone (300 series for aft of cabin,
500 series for left wing, etc.). The second digit in the sequence further divides the zone into submajor
zone (Zone 510 for inboard portion of the left wing and Zone 520 for outboard portion of the left wing,
etc..). The third digit further divides the submajor zones into subdivisions (if no subdivision is needed,
this digit is typically assigned as 0 (zero).
EXAMPLE
310
Major Zone Subdivision Zone
Submajor Zone
B. Major Zones.
(1) 100 - Forward side of firewall and forward.
(2) 200 - Aft side of firewall.
(3) 300 - Aft of cabin to end of airplane.
(4) 500 - Left wing.
(5) 600 - Right wing.
(6) 700 - Landing gear.
2. Description
A. For a breakdown of the airplane zones, refer to Figure 1.
6-20-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
110
720
340
110
310
(INTERIOR) 05103001
120 05103001
05103001
Airplane Zones
Figure 1 (Sheet 1)
6-20-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
224
INSTRUMENT PANEL
121 122
123 124
FIREWALL LOOKING FORWARD
0513C1003
0511T1 002
Airplane Zones
Figure 1 (Sheet 2)
6-20-00 Page 3
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INTERIOR FLOOR
05111015
Airplane Zones
Figure 1 (Sheet 3)
6-20-00 Page 4
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ACCESS/INSPECTION PLATES - DESCRIPTION AND OPERATION

1. General
A. The airplane contains both access and inspection plates on the interior and exterior of the airplane.
These plates are used to gain access to various components and to allow for inspection of airframe
areas.
NOTE: Plates which have hinges attached to them (oil door, for example) are not considered plates
and are not included in this section.
B. This section may be used in conjunction with inspection practices (Chapter 5) or standard maintenance
practices to quickly locate specific components throughout the airplane.
2. Access/Inspection Plate Numbering
A. All access/inspection plates are identified using a series of numbers and letters which specify zone,
exact panel identifier and location within the specific zone.
(1) The first three numbers of any plate identify the zone in which the plate can be found. This three-
number sequence is assigned and designated in Airplane Zoning - Description and Operation.
(2) Primary identifiers follow the three-number sequence, with the first plate identified as "A," the
second plate identified as "B" and so on.
(3) Locators follow the primary identifier and denote top, bottom, left, right or internal orientation of
the plate.
B. Using access plate 510AB as an example, the breakdown is as follows:
(1) Zone Location = 510 (inboard portion of left wing).
(2) Sequence = A (the first plate within the zone).
(3) Orientation = B (this plate is located on the bottom of the zone).
3. Description
A. Access/Inspection Plates.
(1) For location of the various access/inspection plates used on the airplane, refer to Figure 1.
6-20-02 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
VIEW LOOKING UP
610AB Wiring 610KB Wing Access

610BB Wiring 610LB Flap and Aileron Cables
610CB Strut Bolt 610MB Flap and Aileron Cables
610DB Fuel Lines, Fuel Transmitter 610NB Aileron Cables
610EB Flap Controls 620AB Auto Pilot Roll Servo
610FB Strut Bolt 620BB Aileron and Trim Cables
610GB Flap Actuator 620CB Aileron Cables
610HB Fuel Lines, Fuel Transmitter 620DB Aileron Bellcrank
610JB Wing Access
0510T1011
Access / Inspection Plates

Figure 1 (Sheet 1)
6-20-02 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
51 BB
VIEW LOOKING UP
210AB Control Yoke/Elevator Attach

210BB Brake Line, Control Cables, Wiring
210CB Control Cables
320AB Elevator Trim Actuator
510AB Wiring
510BB Wiring 510JB Wing Access, Courtesey light
510CB Strut Bolt 510KB Wing Access, Flap Bellcrank
510DB Fuel Lines, Fuel Transmitter 510LB Flap and Aileron Cables
510EB Flap Controls 510MB Flap and Aileron Cables
510FB Strut Bolt 510NB Aileron Cables
510GB Flap Actuator 520AB Aileron and Trim Cables
510HB Fuel Lines, Fuel Transmitter 520BB Aileron Cables, Aileron Bellcrank
0510T1 011
Figure 1 (Sheet 2)
6-20-02 Page 3
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1650
620AT
VIEW LOOKING DOWN LEFT SIDE VIEW
120AT External Power 310AL Elevator and Elevator Trim, Pulleys

510AT Fuel Bay 310AR Elevator and Elevator Trim,Pulleys
510BT FuelBay 310BR Control Cables
520AT Fuel Bay 610AT Fuel Bay
61OBT Fuel Bay
620AT Fuel Bay

Figure 1 (Sheet 3)
6-20-02 Page 4
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
510CT Flap Access 610CT Flap Access

510ET
510DT Flap Access 610ET
610DT Flap Access
Access
510FT Flap Access 610FT Flap Access
05251002
Access/Inspection Plates
Figure 1 (Sheet 4)
6-20-02 Page 5
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
230AT
FLOORBOARD ACCESS PLATES
230AT Brake Line

230BT Fuel Pump and Reservoir 230KT Elevator Trim Tab Pulley, ADF
230CT Fuel Pump and Reservoir Antenna
230DT Fuel Lines, Wire Bundle 230LT Fuel Lines
230ET Elevator Bellcrank, Fuel Lines 230MT Fuel Lines
230FT Fuel Selector, Elevator Bellcrank 230NT Fuel Lines
230GT Fuel Line 230PT Wire Bundle, Brake Line
230HT Fuel Line 230QT Control Cables
230RT Brake Line

Figure 1 (Sheet 5)
6-20-02 Page 6
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1653
231 BT 231 CT 231 ET

231 GT 231 KT
FLOORBOARD ACCESS PLATES
231AT Main Landing Gear Bulkhead 231GT Control Cables

231 BT Control Cables 231 HT Fuselage Access
231CT Main Landing Gear Bulkhead 231JT Control Cables
231DT Control Cables, Flap Pulleys 231KT Fuselage Access
231 ET Control Cables, Flap Pulleys
231 FT Transponder Antenna
0510T1011A

Figure 1 (Sheet 6)
6-20-02 Page 7
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CHAPTER
LIFTING
AND
SHORING
MODEL 172
MAINTENANCE MANUAL

7-Title
7-00-00 1 Aug 18/2001
7-10-00 201 Aug 18/2001
202 Aug 18/2001
7-11-00 201 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
LIFTING AND SHORING - GENERAL ............................................... 7-00-00 Page 1
Scope ......... .................................................. ......... 7-00-00 Page 1
Tools, Equipment and Materials ................................................ 7-00-00 Page 1
Definition ..................................................................... 7-00-00 Page 1
JACKING - MAINTENANCE PRACTICES ........................ .............. 7-10-00 Page 201
General ..................................................................... 7-10-00 Page 201
Tools, Equipment and Materials ........... ................................. 7-10-00 Page 201
Jacking Procedures .................... ........................... 7-10-00 Page 201
EMERGENCY LIFTING/HOISTING - MAINTENANCE PRACTICES .................... 7-11-00 Page 201
Lifting Procedures .............................. ............................... 7-11-00 Page 201
7- CONTENTS Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LIFTING AND SHORING - GENERAL

1. Scope
A. This chapter describes both standard and emergency procedures used to lift the airplane off the
ground.
2. Tools, Equipment and Material
NOTE: Equivalent substitutes may be used for the following listed items:
NAME NUMBER MANUFACTURER USE

Jack 2-170 Cessna Aircraft Company To jack wing.
Cessna Parts Department
P.O. Box 949
Wichita, KS 67201
Leg Extension 2-109 Cessna Aircraft Company To extend legs on jack.
Slide Tube 2-70 Cessna Aircraft Company To extend jack height.
Extension
Universal Tail 2-168 Cessna Aircraft Company To secure tail.
Stand
Padded Block Fabricate locally To provide cushion
between wing jack and
wing spar.
3. 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 jacking provides normal procedures and techniques used to jack the airplane off
the ground.
(2) The section on emergency lifting provides procedures, techniques and fabrication information
needed to lift the airplane by overhead means.
7-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
JACKING - MAINTENANCE PRACTICES
1. General
CAUTION: JACKING BOTH WHEELS SIMULTANEOUSLY AT BUILT-IN JACK PADS IS NOT

RECOMMENDED. WHEN USING BUILT-IN JACK PAD, FLEXIBILITY OF THE MAIN
GEAR STRUT WILL CAUSE THE MAIN WHEEL TO SLIDE INBOARD AS THE
WHEEL IS RAISED, TILTING THE JACK. IF THIS OCCURS, THE JACK MUST BE
LOWERED FOR A SECOND OPERATION.
A. Normal jacking procedures involve lifting one main wheel at a time. This procedure is best
accomplished using a floor jack in conjunction with the built-in jack pad (located directly below the
step on each strut).
2. Tools, Equipment and Materials
A. For a list of required tools, equipment and materials, refer to Lifting and Shoring - General.
3. Jacking Procedure
NOTE: When the airplane needs to be raised off the ground at all points, the following procedure should
be used.
A. Raise Airplane (Refer to Figure 201).
CAUTION: WHEN PLACED ON JACKS, THE AIRPLANE IS NOSE HEAVY. TAIL
STANDS MUST WEIGH ENOUGH TO KEEP THE TAIL DOWN UNDER
ALL CONDITIONS. ADDITIONALLY, THE TAIL STAND MUST BE STRONG
ENOUGH TO SUPPORT ANY WEIGHT WHICH MIGHT BE TRANSFERRED
TO THE TAILCONE AREA DURING MAINTENANCE, CREATING A TAIL
HEAVY CONDITION.
(1) Carefully attach tail stand to tail tie-down ring.
(2) Place wing jacks and padded blocks under front spar, just outboard of wing strut (Wing Station
118.00). Ensure that padded block (1 inch X 4 inch X 4 inch with 0.25 inch rubber pad) is resting
securely between spar and jack.
(3) Raise wing jacks evenly until desired height is reached.
B. Lower Airplane (Refer to Figure 201).
(1) Slowly lower wing jacks simultaneously until main tires are resting on ground.
(2) Remove wing jacks and pads from wing area.
(3) Detach tail stand from tie-down ring.
7-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TAILSTAND
JACK
05801001
Airplane Jacking
7-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
EMERGENCY LIFTING/HOISTING - MAINTENANCE PRACTICES

Lifting Procedure
A. The airplane may be lifted with a hoist of two-ton capacity attached by rings, which are optional
equipment installed by Service Kit, or by means of suitable slings. The front sling should be hooked to
each upper engine mount, and the aft sling should be positioned around the fuselage at the first
bulkhead forward of the leading edge of the stabilizer. If the optional hoisting rings are used, a
minimum cable length of 60 inches for each cable is required to prevent bending of the eyebolt-type
hoisting rings. If desired, a spreader jig may be fabricated to apply vertical force to the eyebolts.
7-11-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
LEVELING
AND
WEIGHING
MODEL 172
MAINTENANCE MANUAL

8-Title
8-00-00 201 Aug 18/2001
8-10-00 202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
LEVELING AND WEIGHING - GENERAL ........................................ 8-00-00 Page 1
Scope ......... .. ............................................... ......... 8-00-00 Page 1
Tools, Equipment and Material ............ ..................................... 8-00-00 Page 1
Definition ............................................................
. ....... 8-00-00 Page 1
LEVELING - MAINTENANCE PRACTICES ........................................ 8-10-00 Page 201
Leveling Procedure ...................................................... 8-10-00 Page 201
8 - CONTENTS Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LEVELING AND WEIGHING - GENERAL

1. Scope
A. This chapter provides information necessary to properly level the airplane.
B. For information on airplane weighing procedures, refer to the applicable Model 172 Pilot's Operating
Handbook and FAA Approved Airplane Flight Manual.
2. Tools, Equipment and Material

Spirit Level Commercially available Spirit level used to level
airplane.
3. Definition
(1) The section on leveling provides maintenance practices and instructions for longitudinal and
lateral leveling of the airplane. This leveling is accomplished using a spirit level of at least 18
inches in length.
(2) For information on weighing the airplane, refer to the applicable Model 172 Pilot's Operating
8-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LEVELING - MAINTENANCE PRACTICES
Leveling Procedure
A. Corresponding points on both upper door sills may be used to level the airplane laterally. The reference
points for longitudinal leveling the airplane are the two screws located on the left side of the tailcone.
(Refer to Figure 201).
8-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LEVELING REFERENCE POINTS
NOTE: CORRESPONDING POINTS ON BOTH UPPER DOOR SILLS MAY BE USED TO

LEVEL THE AIRPLANE LATERALLY.
REFERENCE POINTS FOR LONGITUDINAL LEVELING OF AIRPLANES ARE TWO

SCREWS ON LEFT SIDE OF TAILCONE AT WATERLINE ZERO.
05103001
Airplane Leveling
8-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
TOWING
AND
TAXIING
MODEL 172
MAINTENANCE MANUAL

9-Title
9-00-00 1 Aug 18/2001
9-10-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
TOWING AND TAXING - GENERAL ......... ........................................ 9-00-00 Page 1
Scope ........................................................................ 9-00-00 Page 1
Definition............... ................................. 9-00-00 Page 1
TOWING - MAINTENANCE PRACTICES ............................................ 9-10-00 Page 201
General ............................ ...................................... 9-10-00 Page 201
9 - CONTENTS Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TOWING AND TAXIING - GENERAL
1. Scope
A. This chapter describes towing procedures for movement of the airplane on the ground. For taxiing
procedures, refer to the applicable Pilots's Operating Handbook and FAA Approved Airplane Flight
Manual.
2. Definition
A. The section on towing describes towing procedures and cautions applicable to the Model 172.
9-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TOWING - MAINTENANCE PRACTICES
General
CAUTION: WHEN TOWING THE AIRPLANE, NEVER TURN THE NOSE WHEEL MORE THAN
30 DEGREES EITHER SIDE OF CENTER, OR THE GEAR WILL BE DAMAGED. DO
NOT PUSH ON CONTROL SURFACES OR ANY PORTION OF THE HORIZONTAL
STABILIZER. WHEN PUSHING ON THE TAILCONE, ALWAYS APPLY PRESSURE
AT A BULKHEAD TO AVOID DAMAGING THE SKIN.
A. Towing.
(1) Moving the airplane by hand is accomplished by using the wing struts and landing gear struts as
push points. A tow bar attached to the nose gear should be used for steering and maneuvering
the airplane on the ground. When no tow bar is available, press down on the tailcone at a
bulkhead to raise the nose wheel off the ground. With the nose wheel clear of the ground, the
airplane can be turned by pivoting about the main wheels.
9-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
WASHER
RH SIDEWALL
PANEL-AFT
BAGGAGE
SPACER
STRAP
HOLDER
TOW BAR ASSEMBLY
DETAIL A
Tow Bar Installation

9-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
PARKING, MOORING.
STORAGE AND
RETURN TO SERVICE
MODEL 172
MAINTENANCE MANUAL

10-Title
10-00-00 1 Aug 18/2001
10-10-00 201 Aug 18/2001
10-11-00 1 Aug 18/2001
2 Aug 18/2001
10-20-00 201 Aug 18/2001
10-30-00 201 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
PARKING, MOORING, STORAGE AND RETURN TO SERVICE - GENERAL ........... 10-00-00 Page 1
Scope ........................................................................ 10-00-00 Page 1
Tools, Equipment and Materials ..................... .......................... 10-00-00 Page 1
D efinition ............................................................. ....... 10-00-00 Page 1
PARKING - MAINTENANCE PRACTICES ................ ......... .................. 10-10-00 Page 201
General ........................................................... ........ 10-10-00 Page 201
Parking Instructions .................... ................. ...................... 10-10-00 Page 201
STORAGE - DESCRIPTION AND OPERATION ......... .............................. 10-11-00 Page 1
Flyable Storage ................................................... .............. 10-11-00 Page 1
Temporary Storage .......................................................... 10-11-00 Page 1
Inspection During Storage ..................................................... 10-11-00 Page 2
MOORING - MAINTENANCE PRACTICES ........................................... 10-20-00 Page 201
Mooring ............................ ......... ............................... 10-20-00 Page 201
RETURN TO SERVICE - MAINTENANCE PRACTICES ............................... 10-30-00 Page 201
Flyable Storage Return to Service ......... .......................................... 10-30-00 Page 201
Temporary Storage Return to Service ........................................... 10-30-00 Page 201
10 - CONTENTS Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PARKING, MOORING, STORAGE AND RETURN TO SERVICE - GENERAL

1. Scope
A. This chapter describes and provides maintenance instructions for parking, storing, mooring and
returning the airplane to service.
NOTE: Equivalent substitutes may be used for the following items:

Wheel Chocks Available Commercially To chock landing wheels.
Engine Air Inlet Cessna Aircraft To prevent entry of
Cover moisture and/or foreign
particles through cowling.
Pitot Tube Cover Cessna Aircraft To prevent entry of
moisture and/or foreign
particles in pitot tubes.
Static Ground Available Commercially To static ground airplane.
Cable
Rope (0.375 Available Commercially To tie down wing and tail.
inch diameter
minimum) or
equivalent
3. Definition
(1) The section on parking describes methods, procedures and precautions used when parking the
airplane.
(2) The section on storage provides information on recommended storage procedures.
Recommendations vary with the length of time the airplane is to be stored.
(3) The section on mooring describes procedures and equipment used to moor the airplane.
(4) The section on return to service describes procedures used when returning the airplane to
service from storage.
10-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PARKING - MAINTENANCE PRACTICES
1. General
A. This maintenance practice covers procedures used to park the airplane.
B. The airplane should be moored if high winds are anticipated or anytime the airplane remains outside
for extended periods of time. Refer to Mooring - Maintenance Practices for mooring procedures. Refer
to Storage - Maintenance Practices for detailed instructions regarding storage.
2. Parking Instructions
A. Hard Surface and Sod.
CAUTION: ANY TIME THE AIRPLANE IS LOADED HEAVILY, THE FOOTPRINT
PRESSURE (PRESSURE OF THE AIRPLANE WHEELS UPON THE
CONTACT SURFACE OF THE PARKING AREA OR RUNWAY) WILL BE
EXTREMELY HIGH, AND SURFACES SUCH AS HOT ASPHALT OR DAMP
SOD MAY NOT ADEQUATELY SUPPORT THE WEIGHT OF THE AIRPLANE.
PRECAUTIONS SHOULD BE TAKEN TO AVOID AIRPLANE PARKING OR
MOVEMENT ON SUCH SURFACES.
(1) Position airplane headed into wind, on level surface.

CAUTION: DO NOT SET PARKING BRAKE DURING COLD WEATHER, WHEN
ACCUMULATED MOISTURE MAY FREEZE BRAKES, OR WHEN BRAKES
ARE HOT.
(2) Set parking brake or chock main gear wheels.

(3) Install control column lock.
10-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
STORAGE - DESCRIPTION AND OPERATION

1. Flyable Storage
A. Flyable storage is defined as a maximum of 30 days nonoperational storage and/or the first 25 hours
of intermittent engine operation. During the 30-day nonoperational storage or the first 25 hours of
intermittent engine operation, every seventh day the propeller shall be rotated through five revolutions,
without running the engine. The pitot tube, static air vents, air vents, openings in the engine cowling,
and other similar openings shall have protective covers installed to prevent entry of foreign material.
After 30 days, airplane should be flown for 30 minutes or ground run-up performed until oil has reached
operating temperature (lower green arc range).
2. Temporary Storage
A. Temporary storage is defined as airplane in a nonoperational status for a maximum of 90 days. The
airplane is constructed of corrosion resistant, epoxy primed aluminum, which will last indefinitely under
normal conditions, if kept clean. However, these alloys are subject to oxidation. The first indication
of corrosion on unpainted surfaces is in the form of white deposits or spots. Corrosion on painted
surfaces shows up as the paint being discolored or blistered. Storage in a dry hangar is essential to
good preservation and should be procured, if possible. Varying conditions will alter the measures of
preservation, but under normal conditions in a dry hangar, and for storage periods not to exceed 90
days, the following methods of treatment are suggested:
(1) Fill fuel tanks with the correct grade of gasoline.
WARNING: DURING ALL FUELING PROCEDURES, FIRE FIGHTING EQUIPMENT MUST
BE AVAILABLE. TWO GROUND WIRES FROM DIFFERENT POINTS ON THE
AIRPLANE CONNECTED TO SEPARATE APPROVED GROUND STAKES
SHALL BE USED IN CASE OF ACCIDENTAL DISCONNECTION OF ONE
GROUND WIRE. ENSURE THAT FUELING NOZZLE IS GROUNDED TO THE
AIRPLANE
NOTE: Tie-down rings should be used as grounding points for all grounding wires during
refueling procedures.
(2) Clean and wax airplane thoroughly.
(3) Clean any oil or grease from tires and coat tires with a tire preservative. Cover tires to protect
against grease and oil.
(4) Either block up fuselage to relieve pressure on tires or rotate wheels every 30 days to change
supporting points and prevent flat spotting on the tires.
(5) Lubricate all airframe items and seal or cover all openings which allow moisture and/or dust to
enter.
(6) Remove battery and store in a cool, dry place; service battery periodically and charge as
required. ,
(7) Disconnect spark plug leads and remove upper and lower spark plugs from each cylinder.
(8) Using a portable pressure sprayer, atomize spray preservative oil through the upper spark plug
hole of each cylinder with the piston in a down position. Rotate crankshaft as each pair of
cylinders is sprayed.
(9) Rotate crankshaft so that no piston is at a top position. If the airplane is to be stored outside,
stop two-bladed propeller so that blades are as near horizontal as possible to provide maximum
clearance for passing airplane.
(10) Again, spray each cylinder without moving the crankshaft to thoroughly cover all interior surfaces
of the cylinder above the piston.
(11) Install spark plugs and connect spark plug leads. Apply preservative oil to the engine interior by
spraying approximately two ounces of the preservative oil through the oil filler tube.
(12) Seal all engine openings exposed to the atmosphere, using suitable plugs. Attach a red streamer
at each point that a plug is installed.
(13) If the airplane is to be stored outside, the pitot tube, static source vents, air vents openings in the
engine cowling, and other similar openings should have protective covers installed to prevent
entry of foreign material.
10-11-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(14) Attach a warning placard to the propeller to the effect that the propeller shall not be moved while
the engine is in storage.
3. Inspection During Storage
A. Inspect airplane.
(1) Inspect airframe for corrosion at least once a month and remove dust collection as frequently as
possible. Clean and wax airplane as required.
(2) Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once
a month.
NOTE: Do not move crankshaft when inspecting interior of cylinder for corrosion.
(3) If at the end of the 90 day period, the airplane is to be continued in nonoperational storage,
repeat the 90-day storage procedure.
10-11-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
MOORING - MAINTENANCE PRACTICES
1. Mooring
A. When mooring the airplane in the open, head into the wind if possible. Tie down the airplane as
follows:
(1) Secure control surfaces with the internal control lock and set brakes.
(2) Tie ropes, cables, or chains to the wing tie-down fittings, located at the upper end of each wing
strut. Secure the opposite ends of ropes, cables, or chains to ground anchors.
(3) Secure rope (no chains or cables) to forward mooring ring and secure opposite end to ground
anchor.
(4) Secure the middle of a rope to the tail tie-down ring. Pull each end of rope away at a 45 degree
angle and secure to ground anchors at each side of tail.
(5) Secure control lock on pilot control column. If control lock is not available, tie pilot control wheel
back with front seat belt.
(6) These airplanes are equipped with a spring-loaded steering system which affords protection
against normal wind gusts. However, if extremely high wind gusts are anticipated, additional
external locks may be installed.
10-20-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
RETURN TO SERVICE - MAINTENANCE PRACTICES
1. Flyable Storage Return to Service

A. Flyable storage is defined as a maximum of 30 days nonoperational storage and/or the first 25 hours of
intermittent engine operation. After flyable storage, returning the airplane to service is accomplished
by performing a thorough preflight inspection. At the end of the first 25 hours of engine operation,
drain engine oil and replace oil filter. Service engine with correct grade and quantity of engine oil.
2. Temporary Storage Return to Service
A. Temporary storage is defined as airplane in a nonoperational status for a maximum of 90 days. After
temporary storage, use the following procedures to return the airplane to service:
(1) Remove airplane from blocks and check tires for proper inflation. Check for proper nose gear
strut inflation.
(2) Check battery and install.
(3) Check that oil sump has proper grade and quantity of engine oil.
(4) Service induction air filter and remove warning placard from propeller.
(5) Remove materials used to cover openings.
(6) Remove spark plugs from engine.
(7) While spark plugs are removed, rotate propeller several revolutions to clear excess oil from
cylinders.
(8) Clean, gap and install spark plugs. Torque spark plugs to the proper value and connect spark
plug leads.
(9) Check fuel strainer. Remove and clean filter screen if necessary. Check fuel tanks and fuel lines
for moisture and sediment. Drain enough fuel to eliminate any moisture and sediment.
(10) Perform a thorough preflight inspection, then start and warm up engine.
10-30-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CHAPTER
PLACARDS
AND
MARKINGS
MODEL 172
MAINTENANCE MANUAL

11-Title
11-00-00 1 Aug 18/2001
11-00-01 1 Aug 18/2001
11-20-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
11-21-20 1 Aug 18/2001
11-21-24 1 Aug 18/2001
11-23-10 1 Aug 18/2001
11-25-10 1 Aug 18/2001
11-26-10 1 Aug 18/2001
11-27-20 1 Aug 18/2001
11-32-11 1 Aug 18/2001
11-32-12 1 Aug 18/2001
11-32-13 1 Aug 18/2001
11-32-14 1 Aug 18/2001
11-32-15 1 Aug 18/2001
11-32-20 1 Aug 18/2001
11-32-21 1 Aug 18/2001
11-32-22 1 Aug 18/2001
11-32-23 1 Aug 18/2001
11-32-24 1 Aug 18/2001
11-32-25 1 Aug 18/2001
11-32-40 1 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
PLACARDS AND MARKINGS - GENERAL .................................... .... 11-00-00 Page 1
S cope ....................................................................... 11-00-00 Page 1
D efinition .................................................................... 11-00-00 Page 1
Required Placards ......... ............................................ ... 11-00-00 Page 1
Placards Not Illustrated ...................................................... 11-00-00 Page 1
Placards and Markings as Silkscreens .......................................... 11-00-00 Page 1
Deciphering Page Number System for Internal/External Placards ............... 11-00-00 Page 1
INTERIOR/EXTERIOR PAINT - DESCRIPTION AND OPERATION .................... 11-00-01 Page 1
G eneral ..................................................................... 11-00-01 Page 1
Tools and Equipment ............................................. 11-00-01 Page 1
EXTERIOR GRAPHICS - MAINTENANCE PRACTICES ......... ............... 11-20-00 Page 201
G eneral ..................................................................... 11-20-00 Page 201
Tools and Equipment ......... . ....................... .................. 11-20-00 Page 201
Graphics Removal/Installation ....................................... 11-20-00 Page 201
Care and Cleaning of Exterior Graphics ........................................ 11-20-00 Page 203
11 -CONTENTS Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PLACARDS AND MARKINGS - GENERAL
1. Scope
A. This chapter provides information on paint, interior placards and markings, exterior placards and
markings, and external graphics.
2. Definition
A. The 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 description of each
section follows:
(1) The section on paint provides a list of paint and related materials used on the airplane.
(2) The section on exterior graphics provides instructions for removal, installation and care of the
exterior graphics.
(3) The section on interior placards provides an illustration of placards found in the interior of the
airplane.
(4) The section on exterior placards provides an illustration of placards found on the exterior of the
airplane.
3. Required Placards
A. Some placards are required to be on the airplane and are inspected in accordance with Chapter
5, Inspection Time Limits. Not all of these required placards are illustrated in this chapter. For a
comprehensive list of required placards, refer to Section 2 of the Pilot's Operating Handbook and FAA
Approved Airplane Flight Manual.
4. Placards Not Illustrated
A. This chapter does not provide a complete illustration of all placards and marking used throughout the
airplane.
5. Placards and Markings as Silkscreens
A. Some of the placards and markings used on the airplane are actually silkscreens which have been
printed on a component or panel. These placards or markings may not be available without purchasing
the component or panel on which it was printed.
(1) If a placard or marking is required and that placard or marking is part of a component or panel,
it is acceptable to reproduce the wording of the placard or marking on a decal which shall be
permanently affixed to the component or panel.
6. Deciphering Page Number System for Internal/External Placards
A. Placards and markings for the airplane are divided into two broad categories (exterior and interior).
All exterior placards or marking will be found in the "20" section of this chapter. All interior placards or
markings will be found in the "30" section of this chapter.
B. Each placard has been located and indexed according to zones established in Chapter 6, Airplane
Zoning - Description and Operation. For instance, the placard found in 11-21-20 (Engine Oil) is located
in Zone 120. By referencing the last three digits of the 11-21-20 document (120), the zone location
for each placard can be determined. Refer to the following examples:
(1) 11-26-10 = Zone 610 (Right Wing).
(2) 11-32-11 = Zone 211 (Interior).
(3) 11-27-20 = Zone 720 (Nose Gear).
(4) 11-32-40 = Zone 240 (Baggage Compartment Area).
11-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INTERIOR/EXTERIOR PAINT - DESCRIPTION AND OPERATION

1. General
A. This section provides information on paint and related chemicals used throughout the airplane.
2. Tools and Equipment
A. Refer to the following table for a list of paint and related chemicals used on the airplane:

Fuel Bay Primer BMS10-20J Type II, Crown Metro Aerospace To epoxy prime interior
Class A Dexter Aerospace surfaces of wing fuel
Materials Division bays.
East Water Street
Waukegan, IL 60085
Activator BMS10-20 Type II, Crown Metro Used with fuel tank
Class A epoxy primer.
Overall Primer/Sealer 483-928 Pratt & Lambert Applied to airplane
16116 E. 13th St. before topcoat.
Wichita, KS 67230
Hardener 120-828 Pratt & Lambert Used with primer/sealer.
Topcoat 830 Series High Solids Pratt & Lambert Used as topcoat overall
Acry Glo Color Code color.
WP-150 (Matterhorn
White)
Hardener 830-081 Pratt & Lambert Used as a catalyst for
Acry Glo.
Accelerator 830-H18 Pratt & Lambert Shorten cure time of
Acry Glo.
Wash Primer 728-014-FCA-85-K Polymer Corp. Used as pre-treatment
Epoxy 2120 Fairmont Ave. for primer.
Reading, PA 19612
Polyester PCA-1575-GP1 Polymer Corp. Used as topcoat for
landing gear.
Heat Resistant Enamel (Gray) 521-520 Pratt & Lambert Used for engine mount
and accompanying
hardware in engine
compartment.
Cloth Cheese cloth Commercially available Used with solvent to
clean airplane exterior.
11-00-01 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
EXTERIOR GRAPHICS - MAINTENANCE PRACTICES
1. General
A. This maintenance practices section provides general instructions for removing and installing exterior
graphics (decals) on the airplane. Instructions are also included for care and cleaning of the graphics.

Table 201. Graphics Application Tools

Isopropyl Alcohol None Commercially Available To prepare airplane
surface for graphics
application.
Sharpline Primer None Sharpline Converting Inc. To provide additional
1520 S. Tyler Road adhesion of graphics
Box 9608 to airplane around rivet
Wichita, KS 67277 heads.
Primer Remover Acti-Sol Sharpline To remove primer.
Dense, closed cell 1" X 2" X 2" Fabricate Locally To aid in forming graphics
foam block around rivets.
Needle None Commercially Available To puncture air bubbles.
Artist's Paint None Commercially Available To apply primer to
Brush airplane.
Squeegee None Commercially Available To aid in adhering
graphics to flat surfaces.
3. Graphics Removal/Installation
A. Remove Graphics (Refer to Figure 201).
NOTE: If a new graphic is being installed, reference marks should be made on the airplane before
removing old graphic. These marks will aid in positioning the new graphic on the airplane.
(1) Carefully separate a corner of the graphic from the airplane.
(2) Apply primer remover between graphic and airplane to loosen adhesive-backed graphic.
CAUTION: DO NOT PULL GRAPHIC OUT (PERPENDICULAR TO SURFACE) AND
AWAY FROM AIRFRAME. FAILURE TO PULL GRAPHIC STRAIGHT DOWN
(PARALLEL TO THE SURFACE ) MAY RESULT IN PAINT BEING LIFTED
FROM AIRPLANE.
(3) Pull downward on graphic (parallel to the surface) using a firm, but slow, motion.
(4) Continue to add primer remover to glued side of graphic while pulling downward on graphic.
(5) Remove and discard graphic.
(6) Remove all traces of adhesive from airplane using primer remover. Pay particular attention to
areas around rivet heads.
11-20-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DECAL
051OC1009
Decal Application
11-20-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B. Install Graphics (Refer to Figure 201).

NOTE: The graphic consists of a protective backing (paper liner), the adhesive-backed graphic
(decal), and a protective outer film (premask).
(1) Clean surface of airplane using isopropyl alcohol and primer remover as required. Ensure all
traces of old adhesive have been removed from airplane surface.
(2) Using a small artist's paint brush, apply Sharpline Primer on and around each rivet
(approximately 0.25 inch beyond the head). Allow primer to dry for 15 minutes at 75°F.
(3) Remove paper liner from backside of graphic to expose adhesive. Using reference marks made
before old graphic was removed, carefully position top of graphic to airplane.
(4) Work downward and apply graphic to airplane. Use squeegee to ensure no wrinkles/bubbles
appear on flat surfaces of airplane. Where graphic overlays rivets, graphic must be stretched
over rivet heads to avoid wrinkle development.
NOTE: At this stage, graphic should adhere to top of rivet and to surrounding airplane
structure. Air which has been entrapped around the base of the rivets will be
removed in step B.(5).
(5) When entire graphic has been applied to airplane, remove the premask (outer protective film)
from the graphic.
(6) Remove entrapped air bubbles from rivets in the following steps:
(a) Perforate the air bubble around the rivet using a small diameter needle. The air bubble
should be perforated at 8 to 12 places around the rivet head.
(b) Warm the graphic and structure around each rivet to approximately 125°F using a heat
gun. When the graphic and metal have heated up, work out all bubbles from around the
rivet head using a dense, closed cell foam block (Temperfoam or equivalent).
(7) Remove entrapped air bubbles from flat areas of the graphic by perforating bubble with a small
diameter needle and flattening with a squeegee.
(8) When all bubbles have been removed, warm the entire graphic for 10 minutes to 15 minutes at
125°F to 130°F.
(9) After surface has cooled to room temperature, remove any excess primer with primer remover.
4. Care and Cleaning of Exterior Graphics
A. The following practices should be followed to ensure maximum service life for the graphic:
(1) Wash the graphic with plain soap and water. Rinse thoroughly after washing.
(2) If a high pressure washer is used, keep nozzle at least two feet from edge of graphic to avoid
lifting graphic from surface.
(3) Do not use acetone, Methyl Ethyl Ketone (MEK), toluene, paint thinner, lacquer thinner or other
aromatic solvents to clean the graphic.
(4) Test other cleaning solutions on a small corner of the graphic before using.
(5) Do not overcoat the graphic with clear paint.
(6) Do not allow fuel to spill on graphics. If fuel spills on graphics, wipe off and rinse with water
immediately.
(7) Do not paint over graphics.
(8) Do not apply wax over graphics, especially if the wax contains any petroleum distillates.
11-20-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Cessna ENGINE OIL

ALL TEMP. USE MULTIVISC. OR
ABOVE 16 C (60 F) USE SAE 50
-1 C (30 F) TO 32C (90F) USE SAE 40
-18C (0 F) TO 21 C (70 F) USE SAE 30
OVERLAP.
TEMPERATURES
WHENOPERATING GRADEOIL
USETHE LIGHTER
USE ONLY OIL THAT COMPLIES WITH APPLICABLE PILOTS HANDBOOK

S1397-13
1 S1397-13
DETAIL A
ON OIL DOOR
Cessna ENGINE OIL Cessna MOTOROL

ALL TEMP. USE MULTIVISC. OR ALLE TEMPERATUREN: MULTIVISC. ODER
ABOVE 16'C (60'F): SAE 50 UBER 16C (60 F): SAE 50
-1C (30 F) TO 32 C (90 F)USE SAE 40 -1C (30 F)BIS 32 C (90 F): SAE 40
-18C (0F)TO 21 C (70 F)USE SAE 30 -18C (0F)BIS 21C (70F): SAE 30
WHEN OPERATING TEMPERATURES OVERLAP. WENN DIE TEMPERATURBEREICHE SICH
USE THE LIGHTER GRADE OIL. USE ONLY UBERSCHNEIDEN. DIE OLSORTE FUR DEN
OIL THAT COMPLIES WITH APPLICABLE NIEDRIGEREN TEMPERATURBEREICH
PILOT'S HANDBOOK. VERWENDEN.
1A 05050484
DETAIL A
ON OIL DOOR
GERMANY
ALLTEMP. USEMULTIVISC. OR 100A TEMPERATURA UTILICE YISCOSIDAO

16 C (60 F): SAE50
ABOVE MULTIPLE0
-1 C (30F) TO32'C (90'F): 5AE40 A MAYOR DE 16 C(60'F): SAE50
-18 C(0 F) TO21 C(70'F): SAE30 -1 C [30 F) HASTA32'C(90 F): SAE40
WHEN OPERATINGTEMPERATURES -18 C (0 F) HASTA 21 C (70 F): SAE30
OVERLAP,USETHELIGHTER CUANDO TEMPERATURASDEOPERACION SE
GRADEOIL. USEONLY OIL SOBREPONEN,UTILIZEELACIETE DENEMOR GRADO
THATCOMPLIES WITH UTILICE SOLAMENTEACEITEQUECUMPLA CON EL
APPLICABLEPILOT'S HANDBOOK.MANUAL DEOPERACION DELPILOTO APROBADO.
0505048-10
1 B 050504810
DETAIL A
ON OIL DOOR
ARGENTINA
Exterior Placards And Markings

Figure 1 (Sheet 1)
11-21-20 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1658
CAUTION 24 VOLTS D.C.
GROUND SYSTEM.
B ELECTRICAL COMPONENTS.
ATTENTION 24 VOLTS cc
BATTERY
VERKEHRTE POLAR
DETAIL B
11
FRANCE DETAIL B
BATTERY
GERMANY
BATTERY
PRECAUC ION 24 VOLT OS D.C.
11A 1205024-4
ARGENTINA
BATTERY
BATTERY
0510T1007

Figure 1 (Sheet 1)
11-21-24 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1659
12
120 POUNDS MAXIMUM
50 POUNDS MAXIMUM
BAGGAGE AFT OF BAGGAGE DOOR LATCH
MAXIMUM 120 POUNDS COMBINED

FOR ADDITIONAL LOADING INSTRUCTIONS
SEE WEIGHT AND BALANCE DATA
Aircraft Identification 654 0505043-3
UNITNO. SERIAL NO.
DETAIL A
MAXIMUM 54 KG
7 S2807-1 GEPACK IN FLUGRICHTUNG VOR DEM GEPACKRAUMTURSCHLOSS
DETAIL B MAXIMUM 22 KG
HOCHSTZULA551GE GESAMTGEPACKMASSE 54 KG
CAPACITE MAXIMALE DE BAGAGES: 54kg SIEHE MASSE- UND SCHWERPUNKTSDATEN FUR
EN AVANT DE LA PORTE DE SOUTE A BAGAGE ZUSATZLICHE BELADUNGSANWE SUNGEN
CAPACITE MAXIMALE DE BAGAGE: 22kg
EN ARRIERE DE LA PORTE DE SOUTE A BAGAGE
CAPACITE MAXIMALE: 54kg COMBINE 6A 0505043-4
POUR PLUS DE DETAILS SUR LES CONSIGNES
DE CHARGEMENT SE REPORTER AUX DONNEES DETAIL
DE MASSE ET DE CENTRAGE
ON BAGGAGE DOOR
DETAIL A
ON BAGGAGE DOOR FRANCE
CARGA MAXIMA DE 54kg NO COMPARTIMENTO
A FRENTE DO FECHO DA PORTA DE CARGA,
E DE 22kg NO COMPARTIMENTO ATRAS DO
54 KG MAXIMO FECHO DA PORTA DE CARGA.
EQUIPAJE ADELANTE DE LA TRABA DE LA CARREGAMENTO MAXIMO COMBINADO DE 54kg
PUERTA DE EQUIPAJE.
22 KG MAX I MO PARA INSTRUCOES ADICIONAIS DE CARREGAMENTO
EQUIPAJE POSTERIOR A TRABA DE LA VEJA SECAO DE PESO E BALANCEAMENTO
PUERTA DE EQUIPAJE.
MAXIMO: 54 KG COMBINADOS
ADICIONALES.
DETAIL A
ON BAGGAGE DOOR ARGENTINA 0510T1007

Figure 1 (Sheet 1)
11-23-10 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLUX VALVE
USE NON-MAGNETIC
13
B
CARBURANT FUEL
0
5C 5
DETAIL A DETAIL A
FRANCE
0505094-7 0505094-8
5D 5A
DETAIL A DETAIL A
CANADA GERMANY
0505094-9
DETAIL A DETAIL A
ARGENTINA BRAZIL

Figure 1 (Sheet 1)
11-25-10 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A B
AVGAS ONLY
4 S2608-1
DETAIL A
(COMBUSTIBLE DE AVI ACION)
GRAOO GRADO
4C 0505048-9
ARGENTINA
DETAIL A
USE SOMENTE GASOLINA
DETAIL A
BRAZIL
Figure 1 (Sheet 1)
11-26-10 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CESSNAAIR OIL SHOCK STRUT

KANSAS
CESSNA AIRCRAFTCOMPANY, WICHITA,
FILLING INSTRUCTIONS
1. VALVECAP ANDRELEASE ALLAIR.
REMOVE
2. VALVEHOUSINGASSEMBLY.
REMOVE
3. (STOPS IN
COMPRESS STRUTCOMPLETELY
CONTACTWITHOUTERBARRELHUB).
4. OILLEVEL
a. FLUIDUSED SHOULDCOMPLY WITH
MIL-H-5606.
SPECIFICATION
b. FILLSTRUTTOBOTTOM OF VALVE
INSTALLATION HOLE.
MAINTAIN OILLEVELATBOTTOMOF
VALVE INSTALLATIONHOLE.
5. STRUT.
FULLYEXTEND
6. REPLACE ASSEMBLY.
VALVEHOUSING
7. WITHSTRUT FULLYEXTENDEDANDNOSE
WHEELCLEAR OF INFLATESTRUT
GROUND,
TO45 PSI
3 0543032-2
DETAIL A
0510T1007

Figure 1 (Sheet 1)
11-27-20 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
THIS SEAT ISCERTIFIED FOR

FORWARD FACING ONLY.
9 0705097-2
DETAIL A
ON SEAT FRAME
DETAIL A
ON SEAT FRAME
GERMANY
SER INSTALADO VOLTADO PARA FRENTE
14A 0705097-4
DETAIL A
BRAZIL
MIRANDO HACIA ATRAS

ESTE ASIENTO ESTA CERTIFICADO PARA
MIRAR HACIA ADELANTE SOLAMENTE
1B 0705097-5
DETAIL A
ARGENTINA
0510T1007
Interior Placards And Markings

Figure 1 (Sheet 1)
11-32-11 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
The markings and placards installed In this airplane contain operating

limitations which must be complied with when operating this airplane Inthe
Normal Category.Other operating limitations which must be compled with
whenoperating this airplne in this category or in the Utility Category are
contained Inthe Pilot's Operating Handbook and FAA
Approved Airplane
Flight Manual.
Normal Category - No acrobatic maneuvers. Including
spins, approved.
Utility Category - No acrobatic maneuvers approved,
except those listed In the
Pilots Operating Handbook.
Baggage compartment and rear seat
must not be occupied.
Spin Recovery - Opposite rudder - forward elevator -
neutral ze controls.
Flight into known icing conditions prohibited.
This airplane is certified for the following flight operation as of date of
original airworthiness certificate:
DAY - NIGHT - VFR - IFR 0505087-23
6
DETAIL A
3940420-1
CONFIG MODULE ASSY
20
DETAIL B
ON CONFIGURATION MODULE
Figure 1 (Sheet 1)
11-32-12 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1664
. __ _ __
__ _ __ _ ~~~~~~~~~~~~~~
_
= 1
."
^ ~FliB In ba
Flu TAG-
Fl *
DETAIL A 0505087-25
ON LEFT FORWARD TRIM PANEL
All
Fl
DETAIL A
Fl
Dl
Lu
T
DETAIL A
FOREIGN CERTIFICATION
Figure 1 (Sheet 1)
11-32-13 Page
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
0705042-7 0705042-8
15 16
DETAIL A DETAIL B
ON INTERIOR LH DOOR ON INTERIOR RH DOOR
0510T1007

Figure 1 (Sheet 1)
11-32-14 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
GESCHLOSSEN VERRIEGELT OFFEN
OFFEN VERRIEGELT
18A 0705042-13 GERMANY
DETAIL A
ON INTERIOR RH DOOR
GERMANY
ON INTERIOR LH DOOR
FECHADO
ABERTO TRAVADO
DETAIL A 19B
ON INTERIOR LH DOOR DETAIL B
BRAZIL ON INTERIOR RH DOOR
BRAZIL
ABR IR TRABADA TRABADA ABRIR
18C 0705042-17 19C 0705042-18
DETAIL A DETAIL A
ON INTERIOR LH DOOR ON INTERIOR RH DOOR
ARGENTINA - ARGENTINA
0510T1007

Figure 1 (Sheet 1)
11-32-15 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B2177
DETAIL A
SAMPLE NUMBER SHOWN
GPS NOT APPROVED

FOR IFR NAVIGATION V ITESSE INDIQUEE DE
MANOEUVRE - 99 KIAS
20 3930408-1
17A 0505048-8
DETAIL C
ON TOP OF PILOTS PANEL FRANCE
DETAIL B
MANOVERGESCHWINDIGKEIT MANOVERGESCHWINDIGKET
81 (726 KG 90 KAS (862 KG)
17 0505048-2 17050504814
GERMANY
DETAIL B GERMANY
DETAIL B
MANEUVERING SPEED
105 KIAS
17C 0505048-36
DETAIL B
AIRPLANES INCORPORATING MK172-72-01
0510T 1007

Figure 1 (Sheet 1)
11-32-20 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A
WARNUNG
STEILEN SIE SICHER, DASS ALLE VEUEINIGUNGEN
EINSCHELIESS1CH iASSER AUS 4EMKRAFTSTOFF LND
DEM KRFTSTOFFSYST VOR OEM FLG ENTFERT WURDEN.
VERUNREINIGNGEN IM KRAFSTF UND EIN N1CHITACaTEN
DER SICEFHEITSANWEISJNGEN UND BETRIEBSANWEISUNGEN
VOR DEM FLUG KANN ZU KJ ICRPERLI
ERGEOFA R E ZLM
TOO FLREN.
WARNUNG
STELLEN SE SICHER . DAS DER SITZ VOR DEM ROLLEN.
OEM START UND OER LAUXNG IN SEINER LAOE VERRIEELT
IST. EIN NICHTBEACHTEN DER SICH-EREITSANWEISUNGEN
UND DES SITZVERRIEELNS KANN ZU KtIRPL1ER LIC EFAHR
ODER ZUM TOO FREN.
WARNUNG
PITOTHEIZUNG MUSS AN SEIN. WENN FLUGZEUG IN IMC
UNTER 4'C BETRIEBEN WIRD
AUSRUSTUNG FUR DEN WINTERBETRIEB ENTFERNEN.

WENN DIE AUBENTEMPERATUR -6'C UEERSTEIGT
15 0505048-1
GERMANY
DETAIL A
A REDE DE CARGA DE
NYLON DEVE ESTAR
INSTALADA PARA O
TRANSPORTE DE BAGAGEM o0505s
21 0505048-11
DETAIL A
BRAZIL
0510T1007

Figure 1 (Sheet 1)
11-32-21 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LIGHT DIM
MAP
5 0415035-1
DETAIL A
ON PILOT CONTROL WHEEL
0510T1007

Figure 1 (Sheet 1)
11-32-22 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
ON COPILOT CONTROL WHEEL

Figure 1 (Sheet 1)
11-32-23 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SEITENGLEITFLUG MIT
AUSGEFAHRENEN KLAPPEN
VERMEIDEN
DETAIL A
GERMANY
0510T1007

Figure 1 (Sheet 1)
11-32-24 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
4 0400213-5
DETAIL A
RADIO
3 0400213-4
DETAIL A

Figure 1 (Sheet 1)
11-32-25 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
EMERGENCY LOCATOR TRANSMITTER

INSTALLED AFT OF THIS PARTITION
MUST BE SERVICED IN ACCORDANCE
WITH FAR PART 91.207
1205085-4
BALISE DE DETRESSE INSTALLEE 10 1205085-4

A L'ARRIERE DE CETTE CLOISON
DOIT ETRE ENTRETENUE ncTAIi A
CONFORMEMET A LA FAR DETAIL
PART 91.207. 7 ON ACCESS PANEL IN
. ________ t7- 1 .BAGGAGE COMPARTMENT
1205085-7
10C 1o
FRANCE
DETAIL A ELT BEFINDET SICH
ONACCESS PANEL IN HINTER DIESEM ABSCHNITT
ON ACCESS PANEL IN ER MUB ENTSPRECHEND DEN
BAGGAGE COMPARTMENT GOLTIGEN VORSCHRI FTEN
.GEWARTET WERDEN 1,2 _i-
TRANSMISOR LOCALIZADOR DE 10A 1205085-5

EMERGENCIA INSTALADO
DETRAS DE ESTA DIVISION GERMANY
DEBE CUMPLIR CON EL DETAIL A
DNAR PARTE 91.207
Ioo
2s-e ON ACCESS PANEL IN
BAGGAGE COMPARTMENT
10D
ARGENTINA . -
DE-TAL3A | TRANSMISSOR LOCAL IZADOR DE
DETAIL A | EMERGtNCIA (ELT) INSTALADO
ON ACCESS PANEL IN ATR001 S DESTA DIVIS021 RIA.
BAGGAGE COMPARTMENT | EHA BATE
| CONFORME 0 RBHA 91.207. 1205086 |
10B 1205085-6
DETAIL A
BRAZIL
0510T1007

Figure 1 (Sheet 1)
11-32-40 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CHAPTER
SERVICING
MODEL 172
MAINTENANCE MANUAL

12-Title
2 Feb 15/2002
12-00-00 1 Aug 18/2001
12-10-00 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
12-11-00 301 Aug 18/2001
12-12-00 301 Aug 18/2001
12-13-00 301 Aug 18/2001
12-14-00 1 Aug 18/2001
12-14-01 301 Aug 18/2001
302 Aug 18/2001
303 Aug 18/2001
12-14-02 301 Feb 15/2002
302 Feb 15/2002
303 Feb 15/2002
12-15-00 301 Feb 15/2002
12-16-00 301 Aug 18/2001
302 Aug 18/2001
12-17-00 301 Aug 18/2001
12-18-00 301 Aug 18/2001
302 Aug 18/2001
12-20-00 1 Aug 18/2001
12-21-00 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
12-21-01 301 Aug 18/2001
302 Aug 18/2001
12-21-02 301 Aug 18/2001
302 Aug 18/2001
12-21-03 301 Aug 18/2001
302 Aug 18/2001
303 Aug 18/2001
304 Aug 18/2001
305 Aug 18/2001
306 Aug 18/2001
12-21-04 301 Aug 18/2001
12-21-05 301 Aug 18/2001
12-22-00 701 Aug 18/2001
702 Aug 18/2001
703 Aug 18/2001
704 Aug 18/2001
12-23-00 701 Aug 18/2001
702 Aug 18/2001
703 Aug 18/2001

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
CONTENTS
SERVICING - GENERAL ......................................................... 12-00-00 Page 1
Scope ................................................. ..................... 12-00-00 Page 1
Definition ................................................................... 12-00-00 Page 1
REPLENISHING - DESCRIPTION AND OPERATION ............................... 12-10-00 Page 1
General .................................................................... 12-10-00 Page 1
D escription ................................................................. 12-10-00 Page 1
Fuel Capacity Table ......................................................... 12-10-00 Page 1
Approved Fuel Table ........................................................ 12-10-00 Page 1
Engine Oil Capacity Table .................................................... 12-10-00 Page 1
NOSE LANDING GEAR SHOCK STRUT - SERVICING ............................. 12-11-00 Page 301
General .................................................................... 12-11-00 Page 301
Shock Strut Servicing Procedures ............................................ 12-11-00 Page 301
NOSE LANDING GEAR SHIMMY DAMPENER - SERVICING ........................ 12-12-00 Page 301
General .................................................................... 12-12-00 Page 301
Shimmy Dampener Servicing ................................................ 12-12-00 Page 301
HYDRAULIC BRAKES - SERVICING ...................................... ........ 12-13-00 Page 301
General .................................................................... 12-13-00 Page 301
FUEL AND ENGINE OIL - DESCRIPTION AND OPERATION ....... ................. 12-14-00 Page 1
General Page 11................
P
Fuel Precautions ............................................................ 12-14-00 Page 1
Oil Precautions ............................................................. 12-14-00 Page 1
FUEL - SERVICING .............................................................. 12-14-01 Page 301
General .................................................................... 12-14-01 Page 301
Safety and Maintenance Precautions ......................................... 12-14-01 Page 301
Fueling and Defueling ....................................................... 12-14-01 Page 301
Aviation Fuel Additive ........................................................ 12-14-01 Page 302
Fuel Loading ............................................................... 12-14-01 Page 302
ENGINE OIL - SERVICING ....................................................... 12-14-02 Page 301
General .................................................................... 12-14-02 Page 301
Oil Change Intervals ......................................................... 12-14-02 Page 301
Checking Engine Oil ................................. ..................... 12-14-02 Page 301
Changing Engine Oil ....................................................... 12-14-02 Page 301
INDUCTION AIR FILTER - SERVICING ............................................ 12-15-00 Page 301
General .................................................................... 12-15-00 Page 301
Air Filter Servicing .......................................................... 12-15-00 Page 301
VACUUM SYSTEM FILTERS - SERVICING ................ ........................ 12-16-00 Page 301
General .................................................................... 12-16-00 Page 301
Central Air Filter Servicing ................................................... 12-16-00 Page 301
Relief Valve Filter Servicing .................................................. 12-16-00 Page 301
BATTERY - SERVICING .......................................................... 12-17-00 Page 301
G eneral .................................................................... 12-17-00 Page 301
Battery Servicing ............................................................ 12-17-00 Page 301
TIRES - SERVICING ............................................................. 12-18-00 Page 301
General .................................................................... 12-18-00 Page 301
Safety Precautions and Notes ................................................ 12-18-00 Page 301
Tire Servicing ............................................................... 12-18-00 Page 301
Cold Weather Servicing ...................................................... 12-18-00 Page 302
12- CONTENTS Page 1

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
SCHEDULED SERVICING - DESCRIPTION AND OPERATION ...................... 12-20-00 Page 1

General... ................................... 12-20-00 Page 1
Description .......... .......... ................ ........................... 12-20-00 Page 1
LUBRICANTS - DESCRIPTION AND OPERATION ................................. 12-21-00 Page 1
General ........................................ ......................... 12-21-00 Page 1
Lubrication Service Notes .................................................... 12-21-00 Page 1
Definition of "As Needed" .................................................... 12-21-00 Page 1
Recommended Lubricants Table .............................................. 12-21-00 Page 1
BATTERY TERMINALS - SERVICING ............................................. 12-21-01 Page 301
G eneral .................................................................... 12-21-01 Page 301
Battery Terminal Lubrication ........................................ ......... 12-21-01 Page 301
LANDING GEAR AND PARKING BRAKE - SERVICING ............................. 12-21-02 Page 301
General ................................ ................. .......... ..... 12-21-02 Page 301
Wheel Bearing Lubrication ........................................ ........... 12-21-02 Page 301
Nose Gear Torque Link Lubrication ................... ........................ 12-21-02 Page 301
Shimmy Dampener Pivots Lubrication ......................................... 12-21-02 Page 301
Steering System Needle Bearing Lubrication .................................. 12-21-02 Page 301
Nose Gear Steering Pushrods Lubrication ..................................... 12-21-02 Page 301
Parking Brake Handle Shaft Lubrication ................... .................... 12-21-02 Page 301
FLIGHT CONTROLS - SERVICING ................................................ 12-21-03 Page 301
General ................ ................................. .......... ..... 12-21-03 Page 301
Aileron System Lubrication ................ ................................... 12-21-03 Page 301
Flap System Lubrication ........................................ ............. 12-21-03 Page 301
Elevator System Lubrication ................ ................. ............... 12-21-03 Page 301
Rudder System Lubrication ......................................... ......... 12-21-03 Page 301
ENGINE CONTROL CABLES - SERVICING ........................................ 12-21-04 Page 301
General ................ ................ ........................... .... 12-21-04 Page 301
Engine Control Cables Lubrication ............................................ 12-21-04 Page 301
HEATING AND VENTILATION CONTROL CABLES - SERVICING .................... 12-21-05 Page 301
General .................................................................... 12-21-05 Page 301
Heating And Ventilation Control Cables Lubrication ............................. 12-21-05 Page 301
AIRPLANE EXTERIOR - CLEANING/PAINTING .................................... 12-22-00 Page 701
General . . . . ...................................................... 12-22-00 Page 701
Precautions .................................. ...................... ....... 12-22-00 Page 701
Preventive Maintenance ........................................ ............. 12-22-00 Page 701
Windshield and Window Cleaners ................................. ........... 12-22-00 Page 702
Cleaning Windshield and Windows ................... ........................ 12-22-00 Page 702
Waxing and Polishing Windshield and Windows ................................ 12-22-00 Page 703
Aluminum Surface ......................................................... . 12-22-00 Page 703
Painted External Surfaces ................................................... 12-22-00 Page 703
Engine and Engine Compartment Washing ................................... . 12-22-00 Page 703
Propeller ................................................................... 12-22-00 Page 704
Tires and Wheels ......................................................... .. 12-22-00 Page 704
AIRPLANE INTERIOR - CLEANING/PAINTING ..................................... 12-23-00 Page 701
General ................................................................... 12-23-00 Page 701
Interior Cleaning Materials ................................................... 12-23-00 Page 701
Cleaning Interior Panels ..................................................... 12-23-00 Page 701
Cleaning Carpet ........................................................ ... 12-23-00 Page 701
Cleaning Seats ............................................................. 12-23-00 Page 702
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
SERVICING - GENERAL
1. Scope
A. This chapter provides instructions for the replenishment of fluids, scheduled and unscheduled
servicing applicable to the entire airplane. Personnel shall observe safety precautions pertaining
to the individual servicing application.
2. Definition
the Table of Contents will further assist in locating a particular subject. A brief description of each
section follows.
(1) The section on replenishing is subdivided into categories to group servicing information such
as systems requiring hydraulic fluid or compressed gas. A brief description of the subdivision
subjects follows.
(a) Replenishing charts for the liquids most commonly used to service the airplane are grouped
together to aid maintenance personnel in servicing.
(b) The subdivision of fuel and oil provides maintenance personnel with general servicing
procedures. Safety precautions and servicing procedures required by federal and local
regulations may supersede the procedures described.
(c) The subject on hydraulic fluid servicing provides servicing procedures for the airplane
hydraulic brake system, nose gear shimmy damper and nose gear strut.
(d) The remaining subject subdivisions provide service information on either a system, an
assembly or a component.
(2) The section on scheduled servicing includes lubrication information, external cleaning and
internal cleaning. The section is subdivided to provide individual system, assembly or
component service information.
(3) The section on unscheduled servicing provides information on deicing an airplane or portions of
an airplane.
12-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
REPLENISHING - DESCRIPTION AND OPERATION
1. General
A. This section provides maintenance personnel with servicing information for replenishing fuel and oil.
2. Description
A. For an illustration of service points located on the airplane, refer to Figure 1. This illustration may be
used in conjunction with replenishing tables to aid maintenance technicians in servicing the airplane.
B. The following tables are provided to establish replenishment capacities of various systems:
(1) Fuel Capacity (Table 1)
(2) Approved Fuels (Table 2)
(3) Engine Oil Capacity (Table 3)
3. Fuel Capacity Table
A. The following table lists airplane fuel capacity.
WARNING: ONLY AVIATION GRADE FUELS ARE APPROVED FOR USE.
Table 1. Fuel Capacity
U.S.
Fuel Capacity 56.0
Gallons
Usable Fuel 53.0
Gallons
4. Approved Fuel Table

A. The following table lists approved fuels for use in the airplane.
Table 2. Approved Fuels
TYPE OF FUEL SPECIFICATION COLOR

100 LL ASTM-D910 Blue
100 ASTM-D910 Green
5. Engine Oil Capacity Table

A. The following table lists oil capacity for the airplane. For list of approved engine oil, refer to the Pilot's
Operating Handbook and FAA Approved Flight Manual.
12-10-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
WARNING: THE U. S. ENVIRONMENTAL PROTECTION AGENCY ADVISES MECHANICS

AND OTHER WORKERS WHO HANDLE OIL TO MINIMIZE SKIN CONTACT
WITH USED OIL AND PROMPTLY REMOVE USED OIL FROM SKIN. IN A
LABORATORY STUDY, MICE DEVELOPED SKIN CANCER AFTER SKIN WAS
EXPOSED TO USED ENGINE OIL TWICE A WEEK WITHOUT BEING WASHED
OFF. SUBSTANCES FOUND TO CAUSE CANCER IN LABORATORY ANIMALS
MAY ALSO CAUSE CANCER IN HUMANS.
Table 3. Engine Oil Capacity
U.S. Quarts
Oil Capacity (total with filter, oil cooler and cooler 8.0 quarts
hoses)
12-10-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FUEL TANK
FILLER
UNDERWING
VACUUM RELIEF FUEL SUMP DRAINS
OIL FILLER
CAP AND DIPSTICK
FUEL STRAINER
INDUCTION AIR
FILTER
POWER JUNCTION BOX
NOSE LANDING
GEAR SHIMMY RECEPTACLE
GEAR SHOCK BRAKE MASTER

STRUT CYLINDERS
BATTERY
Airplane Service Points

Figure 1 (Sheet 1)
12-10-00 Page 3
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NOSE LANDING GEAR SHOCK STRUT- SERVICING
1. General
A. The nose gear shock strut requires periodic checking to ensure strut is filled with hydraulic fluid and
is inflated to the correct air pressure. This procedures provides only replenishing and servicing
instructions. For disassembly and repair procedures, refer to Chapter 32, Nose Landing Gear -
2. Shock Strut Servicing Procedures
A. The nose landing gear shock strut should be serviced every 100 hours.
B. To service the nose gear shock strut, proceed as follows:
(1) Raise airplane nose to remove pressure from shock strut.
(2) Remove valve cap and release all air.
(3) Remove valve housing assembly.
(4) Compress strut completely (stops in contact with outer barrel hub).
(5) Check and replenish oil level.
NOTE: Fluid used should comply with specification MIL-H- 5606.
(a) Fill strut to bottom of valve installation hole.

(b) Maintain oil level at bottom of valve installation hole.
(6) Fully extend strut.
(7) Reinstall valve housing assembly.
(8) With strut fully extended and nose wheel clear of ground, inflate strut to 45 PSI.
NOTE: The nose landing gear shock strut will normally require only a minimum amount of
service. Strut extension pressure should be maintained at 45 PSI. Machined surfaces
should be wiped free of dirt and dust using a clean, lint-free cloth saturated with MIL-
H-5606 or kerosene. All surfaces should be wiped free of excessive hydraulic fluid.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NOSE LANDING GEAR SHIMMY DAMPENER - SERVICING
1. General
A. This procedure provides servicing instructions for the shimmy dampener. For disassembly of shimmy
dampener, refer to Chapter 32, Nose Gear - Maintenance Practices.
2. Shimmy Dampener Servicing
A. The shimmy dampener should be serviced every 100 hours.
B. Service the shimmy dampener as follows:
(1) Remove shimmy dampener from airplane.
(2) While holding the dampener in a vertical position with fitting end pointed downward, pull fitting
end of the dampener shaft to its limit of travel.
(3) While holding dampener in this position, fill dampener through open end of cylinder with hydraulic
fluid.
(4) Push the shaft upward slowly to seal off the filler hole.
(5) Clean dampener with solvent. Be sure to keep the shaft protruding through the filler hole until
dampener is installed on the aircraft.
(6) Install dampener on aircraft.
NOTE: Keep the shimmy dampener, especially the exposed portions of the dampener piston
shaft, clean to prevent collection of dust and grit which could cut the seals in the
dampener barrel. Keep machined surfaces wiped free of dirt and dust, using a clean
lint-free cloth saturated with hydraulic fluid. All surfaces should be wiped free of
excessive hydraulic fluid.
12-12-00 Page 301

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
HYDRAULIC BRAKES - SERVICING
1. General
A. Brake master cylinders should be serviced every 100 hours.
B. Brake master cylinders are located on the pilot's rudder pedals and are filled with MIL-H-5606 hydraulic
fluid.
(1) Brake master cylinders are filled by removing the filler plug (located on topside of each master
cylinder) and filling to top of internal reservoir with MIL-H-5606 hydraulic fluid.
(2) For bleeding procedures, refer to Chapter 32, Brakes - Maintenance Practices.
12-13-00 Page 301

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FUEL AND ENGINE OIL - DESCRIPTION AND OPERATION
1. General
A. This section provides servicing procedures for the fuel and engine oil system. It is subdivided as
follows:
(1) The fuel system section includes procedures for adding fuel, defueling the airplane and mixing
anti-icing additives to the fuel.
(2) The engine oil section includes procedures for checking, adding and changing engine oil.
2. Fuel Precautions
A. Safety Precautions.
(1) The safety precautions on fueling and defueling may be superseded by local directives. However,
following is a typical list of precautions.
(a) Ground, by designated grounding cables, the fueling and/or defueling vehicle to the
airplane. Also, a static ground device shall contact the fueling or defueling vehicle and
ground.
(b) Fire fighting equipment shall be immediately available.
(c) Wear proper clothing.
1 Do not wear clothing that has a tendency to generate static electricity such as nylon
or synthetic fabrics.
2 Do not wear metal taps on shoes when working in areas where fuel fumes may
accumulate at ground level.
(d) The airplane shall be in a designated fuel loading or unloading area.
(e) High wattage, pulse transmitting avionics equipment shall not be operated in the immediate
vicinity.
B. Maintenance Precautions.
(1) Use designated equipment for fuel loading and unloading to prevent contamination.
(2) Use proper procedures when adding fuel inhibitors.
(3) Use specified type of fuel.
3. Oil Precautions
A. Maintenance Precautions.
(1) Use proper servicing procedures; do not overfill, do not mix manufacturer's brands of oil.
12-14-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FUEL- SERVICING
1. General
A. Fuel Tanks.
(1) Each wing contains an integral fuel bay, located between the front and rear spars, extending
from WS 31.38 to WS 65.125. Fuel bays should be filled immediately after each flight to lessen
condensation in the tanks and lines. A fuel filler cap is located on top of each wing and provides
a fueling/defueling point for each fuel bay.
B. Fuel Drains.
(1) Fuel drains are located at various places on the underside of each integral fuel bay and
throughout the fuel system. These drains are utilized to collect fuel samples for analysis. This
sampling is accomplished by placing the fuel sample cup up to the drain valve, and depressing
the valve with rod protruding from the cup.
NOTE: For detailed description and maintenance practices related to the fuel system, refer
to Chapter 28, Fuel - General.
2. Safety and Maintenance Precautions
WARNING: DURING ALL FUEL SYSTEM SERVICING PROCEDURES, FIRE FIGHTING
EQUIPMENT MUST BE AVAILABLE. TWO GROUND WIRES FROM TIE
DOWN RINGS ON THE AIRPLANE TO APPROVED GROUND STAKES
SHALL BE USED TO PREVENT ACCIDENTAL DISCONNECTION OF ONE
GROUND WIRE. MAKE SURE BATTERY SWITCH IS TURNED OFF, UNLESS
OTHERWISE SPECIFIED.
(1) Establish ground as follows:

(a) Ground airplane first.
(b) Ground vehicle (or hose cart) to the same ground as the airplane.
(c) Bond vehicle (or hose cart) to airplane.
(d) Bond refuel nozzle to airplane.
(2) Ensure fire fighting equipment is positioned and immediately available.
(3) Do not wear clothing that has a tendency to generate static electricity such as nylon or synthetic
fabrics.
(4) Do not wear metal taps on shoes.
(5) The airplane should be in a designated fuel loading/unloading area.
(6) High wattage, pulse transmitting avionics equipment shall not be operated in the vicinity of the
fueling/defueling operation.
B. Maintenance Precautions.
(1) Use designated equipment for fuel loading/unloading to prevent contamination.
(2) Due to the chemical composition of anti-ice additive, improper blending of fuel and anti-icing
additive may cause the deterioration of the integral fuel tanks interior finish, thus promoting
corrosion. It is very important that the proper anti-ice additive blending procedures be followed.
(3) Use authorized type of fuel and anti-ice additive.
(4) During defueling, ensure anti-ice additive blended fuel and unblended fuel are not mixed.
3. Fueling and Defueling
A. Fueling Procedures.
(1) Ground airplane and vehicle as outlined above.
(2) Ensure battery switch is turned OFF.
(3) Place protective mat around fuel filler area and remove fuel filler caps.
(4) Fuel airplane. Ensure correct grade of aviation fuel is used.
(5) Replace filler caps. Wipe up excess fuel from wing area.
(6) Remove grounding equipment.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B. Defueling Procedures.
(1) Ground airplane and vehicle as outlined above.
(2) Ensure battery switch is turned OFF.
(3) Remove fuel filler caps.
(4) Insert defueling nozzle into fuel bay and begin defueling.
(5) Remove as much fuel as possible with defueling nozzle.
(6) Drain fuel from drains located on underside of fuselage.
(7) Remove drain valves from bottom of fuel tank and drain remaining fuel.
(8) Remove grounding equipment.
4. Aviation Fuel Additive
A. When servicing fuel with anti-icing additive containing diethylene glycol monomethyl ether (DiEGME),
remember that it is harmful if inhaled, swallowed or absorbed through the skin, and will cause eye
irritation. Also, it is combustible. Before using this material, refer to all safety information on the
container.
B. In cases of acute exposure, DiEGME is an eye and mucous membrane irritant, a nephrotoxin and
central nervous system depressant. It is toxic by skin absorption. Inhalation may cause irritation
to mucous membranes, although, due to it's low volatility this is not an extreme hazard at room
temperature or below. If DiEGME contacts the eye, it may cause pain and transient injury. It is
absorbed through the skin in toxic amounts.
C. In the event DiEGME contact is experienced, the following emergency and first aid procedures should
be used.
(1) If ingested (swallowed), drink large quantities of water. Then induce vomiting by placing a finger
far back into the throat. Contact a physician immediately. If vomiting cannot be induced, take
victim immediately to the hospital or a physician. If victim is unconscious or in convulsions, take
victim immediately to the hospital or a physician. Do not induce vomiting or give anything by
mouth to an unconscious person.
(2) If eye or skin contact is experienced, flush with plenty of water (use soap and water for skin) for at
least 15 minutes while removing contaminated clothing and shoes. Call a physician. Thoroughly
wash contaminated clothing and shoes before reuse.
5. Fuel Loading
CAUTION: ENSURE THE PROPER GRADE AND TYPE OF FUEL IS USED TO SERVICE THE
AIRPLANE. REFER TO PILOT'S OPERATING HANDBOOK AND FAA APPROVED
AIRPLANE FLIGHT MANUAL FOR A LIST OF APPROVED FUELS.
A. Approved fuel for the Model 172 airplane may or may not contain an anti- ice additive. The additive
incorporates a biocidal chemical which inhibits growth of fungal and bacterial organisms in fuel storage
reservoirs. Mixing anti-ice additive and fuel during refueling involves the utilization of an aerosol or
proportioned dispenser.
B. Mixing Icing Inhibitor Procedures.
NOTE: Equivalent procedures may be substituted.

(1) When using aerosol cans, utilize the following procedures.
(a) Insert the fueling nozzle and fuel additive nozzle into the fuel filler.
12-14-01 Page 302

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
WARNING: ANTI-ICING ADDITIVES CONTAINING DiEGME ARE HARMFUL IF

INHALED, SWALLOWED OR ABSORBED THROUGH THE SKIN AND
WILL CAUSE EYE IRRITATION.
CAUTION: ENSURE THAT ADDITIVE IS DIRECTED INTO FLOWING FUEL

STREAM AND ADDITIVE FLOW IS STARTED AFTER FUEL FLOW
STARTS AND IS STOPPED BEFORE FUEL FLOW STOPS. DO NOT
ALLOW CONCENTRATED ADDITIVE TO CONTACT COATED INTERIOR
OF FUEL TANK OR AIRPLANE PAINTED SURFACE.
(b) Start refueling; then, direct the fuel additive into the fuel stream so as to blend the additive
simultaneously with the fuel as it fills the tank. The additive concentration range shall be
maintained in accordance with instructions in the Pilot's Operating Handbook and FAA
Approved Airplane Flight Manual.
12-14-01 Page 303

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ENGINE OIL - SERVICING

1. General
A. This section provides instructions for checking and changing engine oil.
2. Oil Change Intervals
A. Oil Change Intervals.
NOTE: Regular filter inspections can aid in the detection of premature engine wear. Refer to
Lycoming Service Bulletin 480D or latest revision.
(1) Airplanes are delivered from the factory with aviation grade straight mineral oil conforming to
MIL-L-6082. If it becomes necessary to add oil during the first 25 hours of engine operation, use
aviation grade straight mineral oil of the recommended viscosity conforming to MIL-L-6082. After
the first 25 hours, drain engine oil and change filter. Refill oil sump with aviation grade straight
mineral oil of the recommended viscosity, conforming to MIL-L-6082, and continue to use until
a total of 50 hours of engine operation have accumulated or oil consumption has stabilized. At
this time, sump shall be drained, filter changed and ashless dispersant oil added to the engine.
(2) When ashless dispersant oil is used, the oil and filter shall be changed every 50 hours or 4
months, whichever comes first.
3. Checking Engine Oil
A. Engine Oil Checking Procedures.
(1) Check engine lubricating oil with the dipstick five to ten minutes after the engine has been
stopped. The aircraft should be in as near a level position as possible when checking the engine
oil, so that a true reading is obtained.
(2) Open engine oil door on upper cowling.
(3) Withdraw dipstick from engine and wipe down with clean cloth.
(4) Reinsert dipstick, fully seat on filler neck and withdraw again.
(5) Read oil level on dipstick.
(6) If low, service engine with correct quantity and viscosity of aviation grade engine oil.
NOTE: Airplanes may be operating with MIL-L-6082 (straight mineral oil) during their initial
break-in period or after an overhaul. After break-in period, engines are lubricated
using Ashless Dispersant oil. Verify proper oil type is used when servicing engine.
(7) Reinstall dipstick on filler neck and check for proper seating.
(8) Close engine oil door.
4. Changing Engine Oil
A. Oil Changing Procedures.
(1) Operate engine until oil temperature is at a normal operating temperature.
WARNING: AVOID SKIN CONTACT WITH ENGINE OIL. ANY ENGINE OIL THAT
INADVERTENTLY GETS ON THE SKIN SHOULD BE IMMEDIATELY
REMOVED.
(2) Engine oil shall be drained while the engine is still hot, and the nose of the aircraft shall be raised
slightly for more positive draining of any sludge which may have collected in the engine oil sump.
(3) Cut safety wire, remove drain plug and allow oil to drain into container. Refer to Chapter 20,
Safetying - Maintenance Practices.
(4) After engine oil has drained, reinstall drain plug and safety wire.
12-14-02 Page 301

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
(5) Remove Suction screen from oil sump.

(a) Inspect for metal partircles
NOTE: If inspection indicates abnormal metal content, additional investigation will be

required to determine the source of metal and possible need for corrective
maintenance.
(b) Reinstall suction screen with new gasket and safety wire. (Refer to Lycoming SSP-1776
Table of Limits or latest revision, for torque requirements.)
(6) Remove external oil filter.
(a) Open the filter can and check the oil from the filter for signs of metal trapped in the filter.
(b) Carefully remove and unfold the paper element. Inspect the material trapped in the filter.
NOTE: If inspection indicates abnormal metal content, additional investigation will be
required to determine the source and possible need for corrective maintenance.
(c) Replace with new external oil filter and safety wire. Refer to Chapter 20, Safetying -
(7) Refill engine oil sump through filler neck using correct grade and quantity of oil. Refer to
Replenishing - Description and Operation for oil quantity. Refer to Figure 301 for oil grade
verses temperature chart.
(8) Install dipstick and verify proper seating on filler neck.
(9) Run engine until normal operating temperature is reached. Shut down engine and check for
leaks.
12-14-02 Page 302

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B1669
SPECIFIED AVIATION GRADE OIL:
AVERAGE AMBIENT TEMPERATURE (°F)/OIL GRADE MAXIMUM OIL

TEMPERATURE
0° 100 200 30° 40° 50° 60° 70° 80° 90° °F
S^R ~
I SAE
SAE 30 Iw-
or I
2450
Temperature Versus Oil Viscosity

12-14-02 Page 303

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
INDUCTION AIR FILTER - SERVICING
1. General
A. The induction air filter keeps dust and dirt from entering the induction system.
2. Air Filter Servicing
A. The CA3559 Induction Air Filter shall be serviced at 50 hours, is life limited and must be replaced at
100 hours. The P198281 Induction Air Filter shall be serviced at 50 hours, is life limited and must be
replaced at 500 hours. Refer to Chapter 5, Component Time Limits.
B. Servicing Procedures.
(1) To service the CA3559 Air filter:
(a) Remove filter from airplane. If damaged or split, replace filter. If filter is in serviceable
condition, proceed with following steps:
1 Clean filter by blowing with compressed air from direction opposite of normal air flow.
2 Verify air box is clean and free of debris before installing filter.
3 Install filter at entrance to air box.
(2) To service the P198281 Air filter:
(a) Remove the filter from the airplane.
|~I ~CAUTION: USE CARE NOT TO DAMAGE FILTER ELEMENT WHEN CLEANING
WITH COMPRESSED AIR.
(b) Clean filter by blowing with compressed air (not over 100 psi) from direction opposite of
normal air flow. Arrows on filter case indicate direction of normal air flow.
(c) Check bonding of the paper pleats to the face screen. The bonding holds the paper pleats
in place and if broken, the pleats are free to shift which can impair filtration. A face screen
that is loose or gapping away from the paper pleats is indicative of broken bonding and is
cause to replace the filter element.
CAUTION: DO NOT USE SOLVENT OR CLEANING FLUIDS TO WASH FILTER. USE
ONLY A WATER AND HOUSEHOLD DETERGENT SOLUTION WHEN
WASHING THE FILTER.
(d) After cleaning as outlined in step 2.B.(2)(b), the filter may be washed, if necessary, in a
solution of warm water and a mild household detergent. A cold water solution may be
used.
NOTE: The filter assembly may be cleaned with compressed air a maximum of 30 times
or it may be washed a maximum of 20 times. A new filter must be installed
after using 500 hours of engine operating time or one year, whichever should
occur first. However, a new filter must be installed anytime the existing filter
is damaged. A damaged filter may have sharp or broken edges in the filtering
panels which would allow unfiltered air to enter the induction system. Any filter
that appears doubtful, shall have a new filter installed in its place.
(e) After washing, rinse filter with clear water until rinse water draining from the filter is clear.
Allow water to drain from filter and dry with compressed air (not over 100 psi).
NOTE: The filtering panels of the filter may become distorted when wet, but they will
return to their original shape when dry.
(f) Verify airbox is clean, and inspect filter. If filter is damaged, a new filter must be installed.
(g) Install filter at entrance to airbox with gasket on aft face of filter frame and with flow arrows
on filter frame pointed in the correct (normal air flow) direction.
12-15-00 Page 301

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
VACUUM SYSTEM FILTERS - SERVICING
1. General
A. The vacuum system contains two filters which require occasional servicing. The gyro filter is located
behind the instrument panel (pilot side), and the regulator valve filter is located behind the instrument
panel near the firewall centerline.
B. Both the gyro filter and the relief valve filter should be inspected every 100 hours. Both filters must be
replaced at life limits set forth in Chapter 5, Component Time Limits.
2. Central Air Filter Servicing
A. Servicing Procedures (Refer to Figure 301).
CAUTION: DO NOT OPERATE THE VACUUM SYSTEM WITH AIR FILTER REMOVED OR
WITH A VACUUM LINE DISCONNECTED. PARTICLES OR DUST OR OTHER
FOREIGN MATTER MAY ENTER THE SYSTEM AND DAMAGE THE VACUUM
OPERATED INSTRUMENTS.
(1) Locate gyro filter behind instrument panel.
(2) Remove bolt and washer securing air filter to cover.
(3) Check for damage, deterioration and contamination. Clean (or replace) as required.
(4) Install air filter in cover and secure using bolt and washer.
3. Relief Valve Filter Servicing
A. Servicing Procedure (Refer to Figure 301).
(1) Locate regulator valve filter behind instrument panel (to the right of radio rack).
(2) Visually inspect for deterioration or damage.
(3) If filter is dirty, carefully remove from relief valve and clean using shop air.
(4) If filter is damaged, replace with new element.
(5) Reinstall filter to relief valve.
12-16-00 Page 301

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INSTRUMENT
PANEL
SCREW
ATTITUDE
INDICATOR
REGULATOR
GYRO
DETAIL A
0510T1007
A0518T1052
Vacuum System Filters

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BATTERY - SERVICING
1. General
A. This procedure provides instructions for adding water to the battery. For testing, charging and
maintenance on the battery, refer to Chapter 24, Battery - Maintenance Practices.
2. Battery Servicing
A. The battery should be serviced every 100 hours.
B. Battery servicing involves adding distilled water to maintain the electrolyte even with the horizontal
baffle plate at the bottom of the filler holes, checking the battery cable connections, and neutralizing
and cleaning off any spilled electrolyte or corrosion. Use bicarbonate of soda (baking soda) and water
to neutralize electrolyte or corrosion. Follow with a thorough flushing with a wire brush, then coat
with petroleum jelly before connecting. The battery box should also be checked and cleaned if any
corrosion is noted. Distilled water, not acid or "re-juvenators" should be used to maintain electrolyte
level. Inspect the battery in accordance with time limits spelled out in Chapter 5, Inspection Time
Limits.
12-17-00 Page 301

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TIRES - SERVICING
1. General
A. Servicing the tires by maintaining correct inflation pressure is the most important job in any tire
preventative maintenance program. Improper inflation pressure causes uneven tread wear.
(1) Under inflation, indicated by excessive wear in the shoulder area, is particularly damaging. It
increases the chance of bruising sidewalls and shoulders against rim flanges. In addition, it
shortens tire life by permitting excessive heat buildup.
(2) Over inflation is indicated by excessive wear in the center of the tire. This condition reduces
traction, increases tire growth and makes treads more susceptible to cutting.
2. Safety Precautions and Notes
(1) Tire should be allowed to cool before attempting to service.
WARNING: THE TENDENCY OF A BURSTING TIRE IS TO RUPTURE ALONG THE BEAD.

STANDING IN ANY POSITION IN FRONT OF EITHER BEAD AREA COULD
CAUSE INJURY IF THE TIRE SHOULD BURST.
(2) Personnel should stand at a 90-degree angle to the axle along the centerline of the tire during
servicing.
CAUTION: APPLYING A TIRE SEALANT TO THE TIRE MAY CAUSE WHEEL
CORROSION.
(3) The use of tire sealant is not recommended.
B. Notes.
(1) A tube-type tire that has been freshly mounted and installed should be closely monitored during
the first week of operation, ideally before every takeoff. Air trapped between the tire and the tube
at the time of mounting could seep out under the beard, through sidewall vents or around the
valve stem, resulting in an under inflated assembly.
(2) The initial stretch or growth of a tire results in a pressure drop after mounting. Consequently, tires
should not be placed in service until the have been inflated a minimum of 12 hours, pressures
rechecked, and tires reinflated if necessary.
(3) Inaccurate tire pressure gages are a major cause of improper inflation pressures. Ensure gages
used are accurate.
3. Tire Servicing
A. Check tire pressure regularly.
(1) Tire pressure should be checked when tire is cold (at least 2 or 3 hours after flight) on a regular
basis. Tire pressure should be checked prior to each flight when practical.
(2) When checking tire pressure, examine tires for wear, cuts, and bruises. Remove oil, grease and
mud from tires with soap and water.
B. Use recommended tire pressure. Consult the table below.
NOTE: Recommended tire pressures should be maintained, especially in cold weather. Any drop
in temperature of the air inside a tire causes a corresponding drop in air pressure.
Main Gear Tire Type: Pressure

6.00 x 6, 4-ply rated tire 28 PSI
Nose Gear Tire Type:
5.00 x 5, 6-ply rated tire 34 PSI
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
4. Cold Weather Servicing

A. Cold Weather Servicing.
(1) Check tires for excessive deflation.
NOTE: Tire air pressure will decrease somewhat as the temperature drops, but excessive
deflation could indicate cold weather leakage at the air valve. Avoid unnecessary
pressure checks.
(2) If it is necessary to pressure check tires in cold climates, always apply heat to air valves and
surrounding areas before unseating valves.
(3) Continue application of heat during reinflation to ensure air valve seal flexibility when valve
closes.
(4) Do not allow tires to stand in snow soaked with fuel, or on fuel covered ramp areas.
(5) If tires become frozen to parking ramp, use hot air or water to melt ice bond before attempting
to move airplane.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SCHEDULED SERVICING - DESCRIPTION AND OPERATION

1. General
A. This section provides instructions necessary to carry out scheduled servicing as well as
internal/external cleaning. It also includes instructions for lubricating specific points identified
in periodic inspection and/or preventive maintenance programs. This section does not include
lubrication procedures required for the accomplishment of maintenance practices.
2. Description
A. This section is subdivided to provide maintenance personnel with charts, text and illustrations to
prevent confusion. Also included in this section is a table containing a list of lubricants.
(1) The subdivisions are separated according to airplane systems. This aids maintenance personnel
in locating service information.
12-20-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LUBRICANTS - DESCRIPTION AND OPERATION
1. General
A. This section is designed to assist the operator in selecting recommended lubricants. For best results
and continued trouble free service, use clean and approved lubricants.
B. For a list of recommended lubricants, refer to Recommended Lubricants Table.
2. Lubrication Service Notes

A. Lubricant Application.
(1) Cleanliness is essential to good lubrication. Lubricants and dispensing equipment must be kept
clean. Use only one lubricant in a grease gun or oil can.
(2) Store lubricants in a protected area. Containers should be closed at all times when not in use.
(3) Wipe grease fittings and areas to be lubricated with clean, dry cloths before lubricating.
(4) When lubricating bearings which are vented, force grease into fitting until old grease is extruded.
(5) After any lubrication, clean excess lubricant from all but actual working parts.
(6) All sealed or prepacked antifriction bearings are lubricated with grease by the manufacturer and
require no further lubrication.
(7) Friction bearings of the porous, sintered- type are prelubricated. An occasional squirt can oiling
of such bearings with general purpose oil (MIL-L-7870) extends its service life.
(8) Lubricate unsealed pulley bearings, rod ends, pivot end hinge points and any other friction point
obviously needing lubrication, with general purpose oil (MIL-L- 7870).
(9) Paraffin wax rubbed on seat rails will ease sliding the seats fore and aft.
(10) Do not lubricate roller chains or cables except under sea coast conditions. Wipe with a clean,
dry cloth.
(11) All piano hinges may be lubricated using (PG) powered graphite (SS-G-659) when assembly is
installed.
(12) Lubricate door latching mechanism with MIL-G-81322 general purpose grease, applied sparingly
to friction points, if binding occurs. No lubrication is recommended on the rotary clutch.
3. Definition of "As Needed"
A. In the following sections, time requirements for lubrication are presented in one of two formats. When
specific time intervals for lubrication exist, those intervals are defined in Chapter 5, Inspection Time
Limits. When no time limit has been established, lubrication is on an "as needed" basis. This leaves
much of the decision making process in the hands of the airframe and powerplant mechanic, who has
been trained to make these types of decisions.
B. In an effort to standardize the decision making process, the following guidelines may be considered
to determine if a component needs lubrication. Any one of the following conditions would indicate a
need for lubrication, and may additionally indicate the need for inspection:
(1) A visual inspection which indicates dirt or wear residue near the movement contact area.
(2) An audible inspection which indicates squeaks, grinding or other abnormal sounds.
(3) A tactile (touch and feel) inspection which indicates jerky or restricted movement throughout
portions of the travel range.
4. Recommended Lubricants Table
12-21-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 1. Recommended Lubricants
SYMBOL PROCUREMENT LUBRICANT PRODUCT SUPPLIER

SPECIFICATION DESCRIPTION PART
NUMBER
GR MIL-G-81322 Grease, wide Mobil- Mobil Oil Corp.
temperature grease 28 150 E. 42nd Street
range. New York, NY 10017
Royco 22C Royal Lubricants Co., Inc.
River Road
East Hanover, NJ 07936
Aeroshell Shell Oil Co.
grease 22 One Shell Plaza
Houston, TX 77001
GH MIL-G-23827 Grease, aircraft Southwest Southwest Petro- Chem,
and instrument, Grease Inc.
gear and 16215 Division - Witco
actuator screw. 1400 S. Harrison
Olathe, KS 66061
Aeroshell Shell Oil Co.
grease 7
Royco 27A Royal Lubricants Co., Inc.
Supermil Amoco Oil Co.
grease No. 200 East Randolph Dr.
A72832 Chicago, IL 60601
Braycote Burmah-Castrol, Inc.
6275 Bray Products Div.
16815 Von Karman Ave.
Irving, CA 92714
Cas- Burmah-Castrol, Inc.
trolease A1
TG-11900 Southwest Petro-
low temp Chem,Inc.
grease EP
Brayco 885 Brumah-Castrol, Inc.
OG MIL-L-7870 Oil, general Royco 363 Royal Lubricants Co., Inc.

purpose
OG (Cont.) MIL-L-7870 Oil, general Petrotect Penreco
purpose 7870A 106 South Main Street
Butler, PA 16001
Windsor Anderson Oil & Chemical
lubeL-1018 Co., Inc.
Portland, CT 06480
12-21-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 1. Recommended Lubricants (continued)

SYMBOL PROCUREMENT LUBRICANT PRODUCT SUPPLIER
SPECIFICATION DESCRIPTION PART
NUMBER
Octoil 70 Octagon Process, Inc.
596 River Road
Edgewater, NJ 07020
PL VV-P-236 Petrolatum Available Commercially
technical
PG SS-G-659 Powdered Available Commercially
Graphite
GL MIL-G-21164 High and Low Everlube E/M Corporation
Temperature 211-G Moly Box 2200
Grease Grease Highway 52 N.W.
West Lafayette, IN 47906
Royco 64 Royal Lubricants Co., Inc.
GP NONE Number Available Commercially
10 weight,
non-detergent
oil
OL VV-L-800 Light Oil Available Commercially
12-21-00 Page 3
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BATTERY TERMINALS - SERVICING

1. General
A. It is recommended the airplane be secured in an area free of contamination from sand, dust or other
environmental conditions that may contribute to improper lubrication practices.
2. Battery Terminal Lubrication
A. Battery terminals should be lubricated when cables are installed to terminals.
B. Refer to Figure 301 for lubrication requirements of the battery terminals.
12-21-01 Page 301

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1671
ITEM ITEM LUBE

NUMBER DESCRIPTION TYPE APPLICATION
1 BATTERY
TERMINALS PL HAND
TERMINALS
PL - GREASE, PETROLATUM - V V - P-236

0518T1023
Battery Terminals Lubrication

12-21-01 Page 302

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LANDING GEAR AND PARKING BRAKE - SERVICING
1. General
A. It is recommended that the airplane be secured in an area free of contamination from sand, dust or
other environmental conditions that may contribute to improper lubrication practices.
2. Wheel Bearing Lubrication
A. Wheel bearings should be lubricated every 100 hours.
WARNING: WHEN CLEANING WHEEL BEARINGS, USE LOW PRESSURE SHOP AIR TO
DRY BEARINGS. DO NOT SPIN BEARING CONES WITH COMPRESSED AIR.
DRY BEARINGS WITHOUT LUBRICATION MAY EXPLODE AT HIGH RPM.
B. Refer to Figure 301 for lubrication requirements of the wheel bearings.
3. Nose Gear Torque Link Lubrication
A. Nose gear torque links should be lubricated every 50 hours.
B. Refer to Figure 301 for lubrication requirements of the nose gear torque links.
4. Shimmy Dampener Pivots Lubrication

A. Shimmy dampener pivots should be lubricated on an "as needed" basis and when assembled or
installed.
B. Refer to Figure 301 for lubrication requirements of the shimmy dampener pivots.
5. Steering System Needle Bearing Lubrication
A. Steering system needle bearings should be lubricated on an "as needed" basis and when assembled
or installed.
B. Refer to Figure 301 for lubrication requirements of the steering system needle bearings.
6. Nose Gear Steering Pushrods Lubrication
A. Nose gear steering pushrods should be lubricated every 100 hours using OG lubricant applied with
an oil can.
7. Parking Brake Handle Shaft Lubrication
A. The parking brake handle shaft should be lubricated on an "as needed" basis and when assembled
or installed.
B. Refer to Figure 301 for lubrication requirements of the parking brake handle shaft.
12-21-02 Page 301

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1672
NOSE GEAR MAIN GEAR
ITEM ITEM LUBE APPLICATION

NUMBER DESCRIPTION TYPE
1 WHEEL BEARINGS GR HAND

2 TORQUE LINKS GR GUN
3 SHIMMY DAMPER PIVOTS OG OIL CAN
4 NEEDLE BEARINGS GR HAND
5 PARKING BRAKE HANDLE OG OIL CAN

SHAFT
GR - GREASE, GENERAL PURPOSE - (MIL-G-81322)

OG - OIL, GENERAL PURPOSE - (MIL-L-7870)
0542T2001
0514T3001
0541T3001
Landing Gear Lubrication

12-21-02 Page 302

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLIGHT CONTROLS - SERVICING
1. General
2. Aileron System Lubrication
A. Bearings in the control column should be lubricated on an "as needed" basis and when assembled or
installed.
B. Piano hinges on the ailerons should be lubricated on an "as needed" basis and when assembled or
installed.
C. Needle bearings on the aileron bellcrank should be lubricated every 1,000 hours.
D. Rod end bearings on the aileron bellcrank should be lubricated every 1,000 hours.
E. Refer to Figure 301 for lubrication requirements of the aileron system.
3. Flap System Lubrication

A. Flap motor screw jack threads should be lubricated every 100 hours. To lubricate the jack screw,
operate flaps to full down position, clean screw threads with solvent rag, dry with compressed air and
lubricate per Figure 302.
NOTE: It is not necessary to remove actuator from airplane to clean or lubricate threads.
B. Needle bearings should be lubricated on an "as needed" basis and when assembled or installed.
C. Refer to Figure 302 for lubrication requirements of the flap system.
4. Elevator System Lubrication
A. Bearings in the trim wheel controls should be lubricated on an "as needed" basis and when assembled
or installed.
B. Trim tab piano hinges should be lubricated on an "as needed" basis and when assembled or installed.
C. The trim tab actuator should be lubricated on an "as needed" basis". If trim tab inspection reveals
excessive free play, the first item of recourse should be to lubricate and remeasure. Lubrication
is accomplished by unscrewing the jackscrew and applying lubricant to the internal portion of the
actuator. This lubrication may bring free play back with limits. If not, actuator should be overhauled.
NOTE: Carefully count and record the number of turns required to remove jackscrew from actuator.
Upon reassembly, the jackscrew should be threaded into the actuator using exactly the
same number of turns as recorded during disassembly.
D. Refer to Figure 303 for lubrication requirements of the elevator system.
5. Rudder System Lubrication
A. The rudder bar bearings and linkage point pivots should be lubricated on an "as needed" basis and
when assembled or installed.
B. Refer to Figure 304 for lubrication requirements of the rudder system.
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MODEL 172
MAINTENANCE MANUAL


BUSHINGS AND
OILITE BEARINGS OG OIL
CONTROL TUBE
UNIVERSAL JOINTS OG OIL CAN
05603001
Aileron System Lubrication

12-21-03 Page 302

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL

4 ALL PIANO PG SYRINGE

HINGES
~5 BELLCRANK
NEEDLE BEARINGS GR HAND

PG - POWDERED GRAPHITE - (SS-G-659)
05611002
05611001
Aileron System Lubrication

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MODEL 172
MAINTENANCE MANUAL

1 SCREW JACK THREADS GP OIL CAN
GP - OIL, NO. 10 WEIGHT, NONDETERGENT
05642003
Flap System Lubrication

12-21-03 Page 304

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL

ELEVATOR TRIM GL HAND

TAB ACTUATOR
GL - MOLYBDENUM DISLULFIDE GREASE - (MIL-G-21164)
05631004
Elevator Trim Lubrication

12-21-03 Page 305

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL

OILITE BEARING
(RUDDER BAR ENDS) OG OIL
ALL LINKAGE
PIVOT POINTS OG OIL
05622002
Rudder Pedals Lubrication

12-21-03 Page 306

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ENGINE CONTROL CABLES - SERVICING
1. General
2. Engine Control Cables Lubrication
A. All housed, pull-type, push-pull or vernier controls should have each outer housing lightly lubricated
internally with VV-L-800 General Purpose Lube Oil.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
HEATING AND VENTILATION CONTROL CABLES - SERVICING
1. General
2. Heating And Ventilation Control Cables Lubrication
A. All housed, pull-type, push-pull or vernier controls should have each outer housing lightly lubricated
internally with VV-L-800 General Purpose Lube Oil.
12-21-05 Page 301

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AIRPLANE EXTERIOR - CLEANING/PAINTING
1. General
A. The airplane should be washed frequently in order to maintain its appearance and minimize corrosion.
The painted area of the airplane should be polished at periodic intervals to remove chalking paint and
restore its gloss.
B. Water/detergent cleaning is the preferred method to clean the exterior surface of the airplane.
2. Precautions
A. Read and adhere to all manufacturers instructions, warnings and cautions on the cleaning/solvent
compounds used.
B. Do not use silicone based wax to polish the airplane exterior. Silicone based wax, especially if buffed
to produce a high shine, will contribute to the build up of P-static.
C. Do not park or store airplane where it might be subjected to direct contact with fluid or vapors from
methanol, denatured alcohol, gasoline, benzene, xylene, methyl ethyl ketone (MEK), acetone, carbon
tetrachloride, lacquer thinners, commercial or household window cleaning sprays, paint strippers or
other types of solvents.
D. 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, ensure they are the silver appearing, reflective type.
3. Preventive Maintenance
A. Keep all surfaces of windshields and windows clean.
B. If desired, wax acrylic surfaces.
C. Carefully cover all surfaces during any painting, powerplant cleaning or other procedure that calls for
use of any type of solvent or chemical. Table 701 lists approved coatings for use in protecting surfaces
from solvent attack.
Table 701. Approved Protective Coatings

Spray MIL-C-6799, Available Commerically Protect surfaces from
Type 1, Class II solvents.
Masking Paper WPL-3 Champion Intl. Corp. Protect surfaces from
Forest Product Division solvents.
7785 Bay Meadows Way
Jacksonville, FL 32256
Poly-Spotstick SXN Champion Intl. Corp. Protect surfaces from
solvents.
Protex 40 Mask Off Company Protect surfaces from
345 Marie Avenue solvents.
Monrovia, CA
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Aug 18/2001
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MAINTENANCE MANUAL
4. Windshield and Window Cleaners
CAUTION: DO NOT USE GASOLINE, ALCOHOL, BENZENE, ACETONE, CARBON

TETRACHLORIDE, FIRE EXTINGUISHER FLUID, DEICER FLUID, LACQUER THINNER
OR GLASS WINDOW CLEANING SPRAY. THESE SOLVENTS WILL SOFTEN AND
CRAZE THE PLASTIC.
Table 702. Windshield and Window Cleaners/Polishers

Mild soap or Commercially Available Cleaning windshields
detergent (hand and windows.
dishwashing type
without abrasives)
Aliphatic Naphtha Federal Commercially Available Removing deposits which
Type II Specification cannot be removed with
TT-N-95 mild soap solution on
acrylic windshields and
windows.
Turtle Wax (paste) Commercially Available Waxing acrylic
windshields and
windows.
Permatex Plastic Federal Permatex Company, Inc. Waxing acrylic
Cleaner No. 403D Specification Kansas City, KS 66115 windshields and
P-P-560 windows.
Soft cloth (cotton Commercially Available Applying and removing
flannel or cotton wax and polish.
terry cloth)
5. Cleaning Windshield and Windows

CAUTION: WINDSHIELDS AND WINDOWS ARE EASILY DAMAGED BY IMPROPER
HANDLING AND CLEANING TECHNIQUES.
CAUTION: DO NOT USE ANY OF THE FOLLOWING FOR CLEANING WINDSHIELDS

AND WINDOWS: METHANOL, DENATURED ALCOHOL, GASOLINE, BENZENE,
XYLENE, MEK, ACETONE, CARBON TETRACHLORIDE, LACQUER THINNERS,
COMMERCIAL OR HOUSEHOLD WINDOW CLEANING SPRAYS.
A. Refer to Table 702 for cleaning materials.
B. Windshield Cleaning Procedures.
(1) Place airplane inside hanger or in shaded area and allow to cool from heat of sun's direct rays.
(2) Using clean (preferably running) water, flood 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 dish washing liquid) in water, wash surface. Again use
only bare hands to provide rubbing force. (A clean cloth may be used to transfer soap solution
to surface, but extreme care must be exercised to prevent scratching surface.)
(4) On acrylic windshields and windows only, if soils that cannot be removed by a mild detergent
remain, 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 soil and/or scratching windshield
with any abrasive particles.
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MODEL 172
MAINTENANCE MANUAL
(5) Rinse surface thoroughly with clean fresh water and dry with a clean cloth.
6. Waxing and Polishing Windshield and Windows
CAUTION: DO NOT USE RAIN REPELLENT ON ACRYLIC SURFACES.

NOTE: Windshields and windows must be cleaned prior to application of wax. When applying and
removing wax and polish, use a clean soft cloth.
A. Refer to Table 702 for polishing materials.
B. Hand polishing wax (or other polish meeting Federal Specification P-P-560) should be applied to
acrylic surfaces. The wax has an index of refraction nearly the same as transparent acrylic and tends
to mask any scratches on windshield surface.
7. Aluminum Surfaces
A. Aluminum surfaces require a minimum of care, but should never be neglected. The airplane may
be washed with clean water to remove dirt and may be washed with non alkaline grease solvents to
remove oil and/or grease. Household type detergent soap powders are effective cleaners, but should
be used cautiously, since some of them are strongly alkaline. Many good aluminum cleaners, polishes
and waxes are available from commercial suppliers of airplane products.
8. Painted External Surfaces
A. Generally, the painted surfaces can be kept bright by washing with water and mild soap, followed by
a rinse with water and drying with cloths or a chamois. Harsh or abrasive soaps or detergents which
could cause corrosion or scratches should never be used. Remove stubborn oil and grease with a
cloth moistened with Stoddard solvent.
NOTE: Solvents must not be allowed to come into contact with the external graphics. For proper
care and cleaning of the external graphics, refer to Chapter 11, Exterior Graphics -
B. To seal any minor surface chips or scratches and protect against corrosion, the airplane should
be waxed regularly with a good automotive wax applied in accordance with the manufacturer's
instructions. If the airplane is operated in a seacoast area or other salt water environment, it must
be washed and waxed more frequently to assure adequate protection. Special care should be taken
to seal around rivet heads and skin laps, which are the areas susceptible to corrosion. A heavier
coating of wax on the leading edges of the wings and tail and on the cowl nose cap and propeller
spinner will help reduce the abrasion encountered in these areas. Reapplication of wax will generally
be necessary after cleaning with soap solutions or after chemical deicing operations.
9. Engine and Engine Compartment Washing
A. Notes and Precautions.
(1) An engine and accessories wash down should be accomplished during each 100 hour inspection
to remove oil, grease, salt corrosion or other residue that might conceal component defects
during inspection. Also, periodic cleaning can be very effective In preventive maintenance.
(2) When working with cleaning agents, protective devices (rubber gloves, aprons, face shields,
etc...) should be worn. Use the least toxic of available cleaning agents that will satisfactorily
accomplish the work.
(3) All cleaning operations should be performed in a well ventilated work area.
(4) Adequate fire fighting and safety equipment should be available.
WARNING: DO NOT SMOKE OR EXPOSE A FLAME WITHIN 100 FEET OF THE
CLEANING AREA.
(5) Compressed air, if used to apply solvent or to dry components, should be regulated to lowest
practical pressure.
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(6) Use of a stiff bristle brush (as opposed to a steel brush) is recommended if cleaning agents do
not remove excess grease and grime during spraying.
B. Cleaning Procedures.
(1) Remove engine cowling.
(2) Carefully cover the coupling area between vacuum pumps and engine drive shafts so no cleaning
solvent can reach coupling or seal.
(3) Cover open end of the vacuum discharge tubes.
(4) If engine is contaminated with salt or corrosive chemicals, first flush engine compartment with
fresh water.
CAUTION: DO NOT USE GASOLINE OR OTHER HIGHLY FLAMMABLE SUBSTANCES

FOR WASH DOWN.
CAUTION: DO NOT ATTEMPT TO WASH AN ENGINE WHICH IS STILL HOT OR

RUNNING. ALLOW ENGINE TO COOL BEFORE CLEANING.
CAUTION: CARE SHOULD BE EXERCISED TO NOT DIRECT CLEANING AGENTS

OR WATER STREAMS AT OPENINGS ON THE STARTER, MAGNETOS,
ALTERNATOR OR VACUUM PUMP.
(5) Apply solvent or cleaning agent to engine compartment. The following solutions (or their
equivalent) can be used to satisfactorily clean the engine compartment:
(a) Stoddard Solvent (Specification P-D-680, Type II).
(b) Water alkaline detergent cleaner (MIL-C-25769 mixed 1 part cleaner, with 2 to 3 parts water
and 8 to 12 parts Stoddard Solvent).
(c) Solvent based emulsion cleaner (MIL-C-4361 mixed 1 part cleaner with 3 parts Stoddard
Solvent).
(6) After applying solvent, thoroughly rinse with clean warm water.
NOTE: Cleaning agents should never be left on engine components for an extended period
of time. Failure to remove them may cause damage to components such as neoprene
seals and silicone fire sleeves, and could cause additional corrosion.
(7) Completely dry engine and accessories using clean, dry compressed air.
(8) Remove protective cover over coupling area.
(9) Remove protective cover from vacuum discharge tube.
(10) If desired, engine cowling may be washed with the same cleaning agents, then rinsed thoroughly
and wiped dry. After cleaning engine, relubricate all control arms and moving parts as required.
(11) Reinstall engine cowling.
WARNING: ENSURE MAGNETO SWITCHES ARE OFF, THROTTLE IS CLOSED,
MIXTURE CONTROL IS IN THE IDLE CUT-OFF POSITION, AND THE
AIRPLANE IS SECURED BEFORE ROTATING PROPELLER BY HAND. DO
NOT STAND WITHIN ARC OF THE PROPELLER BLADES WHILE TURNING
PROPELLER.
(12) Before starting engine, rotate propeller by hand no less than four complete revolutions.
10. Propeller
A. The propeller should be wiped occasionally with an oily cloth to remove grass and bug stains. In salt
water areas, this will assist in corrosion proofing the propeller.
11. Tires and Wheels

A. Remove oil, grease, and mud from tires and wheels with soap and water.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AIRPLANE INTERIOR - CLEANING/PAINTING
1. General
A. This section is designed to assist the operator and recommend different types of cleaning materials
and cleaning procedures for the interior of the airplane.
2. Interior Cleaning Materials

Son Of A Gun Commercially available To protect and shine
interior components
(excluding fabric
materials).
Fantastic Commercially available For general purpose
cleaning of interior
components and
recommended for
cleaning Morbern vinyl.
Aliphatic Naphtha TT-N-94 Commercially available For removing tar, asphalt,
etc., from interior.
Rug Shampoo Commercially available For cleaning carpet.
Perchloroethylene Commercially available For spot cleaning carpet
Cleaning Solvent and seats.
Stoddard Solvent Commercially available For cleaning nylon safety
belts.
Ivory Liquid (White or Commercially available For cleaning seat fabric.
colorless)
Cheer Commercially available For cleaning seat fabric.
Mr. Clean Commercially available Recommended for
cleaning Morbern vinyl.
3. Cleaning Interior Panels

A. Interior panels (headliners, sidewalls, door panels, etc.) are constructed of a heavy vinyl and may be
covered with softer Morbern vinyl. The interior panels may be cleaned using mild detergent solutions
or premixed commercial cleaners. Stubborn deposits may be removed using aliphatic naphtha. Care
should be taken to ensure cleaners are compatible with interior. If in doubt, apply a small amount of
cleaner to an inconspicuous place and test for reaction and fading.
4. Cleaning Carpet
A. The carpet is constructed using a polypropylene weave combined with a fire retardant backing. The
polypropylene provides inherent stain resistant qualities and normally requires only a minimal amount
of maintenance.
B. Ifthe carpet becomes soiled, it may be cleaned using commercially available carpet cleaning products.
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MAINTENANCE MANUAL
5. Cleaning Seats
A. Fabric covered seats of the 172R and some 172Sare constructed of a flame retardant Trevira polyester
fiber and have inherent fire retardant and stain resistant properties. Seats should be vacuumed
and cleaned on a regular basis to retain their appearance. Spills and stains should be blotted up
immediately and the fabric cleaned before stains have a chance to set up in the fabric.
B. Tables 701 (Methods for Cleaning Trevira Fabric on Seats) and 702 (Methods For Cleaning Morbern
Vinyl on Cabin Panels) have been provided on the following pages to assist in stain removal. The
tables contain two columns; one listing the stain and the other listing the method and sequence of
cleaning. For example, coffee and tea stains are removed using processes 2, 4, 5 and 1. The first
step would be application of process 2 (dishwashing liquid with warm water) to the stain. The second
step would be-application of process 4 (vinegar and water) to the stain. The third step would be
application of process 5 (laundry powder and warm water followed by blotting) to the stain. The final
step would be application of process 1 (dry cleaning solvent applied to the stain).
Table 701. Methods For Cleaning Trevira Fabric on Seats
STAIN PROCESS AND STAIN PROCESS AND

SEQUENCE SEQUENCE
Antacid (Maalox) 1 Infant Formula 2,1
Betadine (Iodine) 2,3,4,6 Ink (ball point) 8
Blood 2,3,5 Motor Oil 1,2,3,4
Catsup 2,3,5 Mud 2,1
Chewing Gum 7,1,2 Petroleum Jelly 1,2
Chocolate Syrup 5,1 Pepto Bismol 6,1
Coffee/Tea 2,4,5,1 Urine 2,3,4
Cola 2,3,4 Suntan Lotion 1,2
Cough Syrup 2 Shoe Polish 1,2,3
Egg 2,3,5,1 Vomit 2,3,4,5
Grape Drink 2,3,4,5 Wax 7,1
Ice Cream 2,3,4,5,1
1. Apply a small amount of dry cleaning solvent to the stain. Do not smoke or use near open flame.
Use adequate ventilation.
2. Mix one teaspoon of white or colorless dishwashing liquid with a cup of lukewarm water.
3. Mix one tablespoon of household ammonia with half a cup of water.
4. Mix one part household vinegar with two parts water.
5. Mix a solution of laundry powder with water and allow to remain on stain following label directions.
Rinse with warm water and blot dry.
6. Mix one part household bleach with nine parts water. Apply with dropper to stain. Rinse with water,
blot dry.
7. Chill area with an ice cube wrapped in a plastic bag. Crack gum or wax off surface of fabric.
8. Apply a small amount of rubbing alcohol to ink stain and blot to remove ink. Continue until ink is
removed.
NOTE: All solutions must be cool when applied, or heat from the solutions will set the stain.
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Table 702. Methods For Cleaning Morbern Vinyl on Cabin Panels
STAIN PROCESS AND STAIN PROCESS AND

SEQUENCE SEQUENCE
Blood 4 Mud 3,6
Candy, Ice Cream 14,6 Mustard 3,12,8,6
Chewing Gum 11,6 Paint, Latex 9,6
Crayon 3,12,8,6 Paint, Oil base 2,3
Fruit Stains 14,6 Shoe Polish 13,6
Ink (ballpoint) 1 Soft Drinks 14,6
Ketchup 3,12,8,6 Surface Mildew 8,6
Lipstick, Eyeshadow 13,6 Tar, Asphalt 10,3
Liquor, Wine 14,6 Urine 7,6
Motor Oil, Grease 13,6 Vomit 5,6
1. Apply a small amount of rubbing alcohol to ink stain and blot to remove ink. Continue until ink is
removed.
2. The use of turpentine in a well ventilated area will remove fresh paint. Dried paint must be
moistened carefully with a semi-solid gel-type stripper so that the softened paint can be gently
scraped away.
CAUTION: Direct contact with paint strippers will remove the print pattern from a vinyl. Paint
strippers are very corrosive. Take care to avoid skin and eye contact by wearing
appropriate protection.
3. Rinse with mild soap and water.
4. Rub out any spots with a clean cloth soaked in cool water. If stubborn spots remain, use household
ammonia and rinse with a clean, wet cloth.
5. Sponge the stained area with soapy water containing diluted bleach until the stain is removed.
6. Rinse thoroughly with clean, cool water.
7. Sponge with soapy water containing a small amount of household ammonia.
8. Wash with diluted bleach, use a soft brush for stubborn stains.
9. Fresh paint can be wiped off with a damp cloth. Hot, soapy water will normally remove dried latex.
10. Remove immediately, as prolonged contact will result in a permanent stain. Use a cloth lightly
dampened with mineral spirits or kerosene and rub the stain gently, working from the outer edge of
the stain towards the center in order to prevent spreading.
11. Scrape off as much as possible with a dull knife. Rubbing with an ice cube will assist and make
it easier to remove on scraping. The remaining gum should then be removed in a well ventilated
area using a cloth saturated with mineral spirits. Use light rubbing.
12. Rinse with mild detergent and water.
13. Apply a small quantity of mineral spirits using a clean soft cloth, gently rubbing. Take care not to
spread the stain by smearing it beyond its original source. Remove shoe polish as soon as possible,
as it contains a dye which will cause permanent staining.
14. Rinse thoroughly with clean, lukewarm water. Repeat as necessary. Remove any loose material
by gently scraping with a dull knife. Any soiled area remaining after drying should be gently rubbed
with a cloth spotted with a small quantity of alcohol.
NOTE: All solutions must be cool when applied, or heat from the solutions will set the stain.
12-23-00 Page 703

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MODEL 172
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* CHAPTER
STANDARD
PRACTICES-
AIRFRAME
MODEL 172
MAINTENANCE MANUAL

20-Title
2 Feb 15/2002
2 Feb 15/2002
20-00-00 1 Aug 18/2001
20-10-00 1 Aug 18/2001
2 Aug 18/2001
20-11-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
206 Aug 18/2001
20-12-00 201 Feb 15/2002
202 Feb 15/2002
203 Feb 15/2002
204 Feb 15/2002
205 Feb 15/2002
206 Feb 15/2002
207 Feb 15/2002
208 Feb 15/2002
209 Feb 15/2002
210 Feb 15/2002
20-30-00 1 Aug 18/2001
20-31-00 1 Feb 15/2002
2 Feb 15/2002
3 Feb 15/2002
20-31-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
20-31-00 701 Aug 18/2001
702 Aug 18/2001
703 Aug 18/2001
704 Aug 18/2001
705 Aug 18/2001

Feb 15/2002
[OOZ/81- 6nL 89
1OOZ./8 L 6n 8
00-90-OS-
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|~~~~~~~~~~~ I
MODEL 172
MAINTENANCE MANUAL

I
MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL
CONTENTS
STANDARD PRACTICES AIRFRAME - GENERAL .................................. 20-00-00 Page 1
Scope ............................................................... ...... 20-00-00 Page 1
Definition ......... ......... ....................................... .......... 20-00-00 Page 1
MATERIAL AND TOOL CAUTIONS - DESCRIPTION AND OPERATION .............. 20-10-00 Page 1
Mercury ......... ......... .. ......... ....................................... 20-10-00 Page 1
M aintenance Precautions .................................................... 20-10-00 Page 1
General Usage Solvents ..................................................... 20-10-00 Page 1
TORQUE DATA - MAINTENANCE PRACTICES .......... .. ......................... 20-11-00 Page 201
General .................................................................... 20-11-00 Page 201
Torque Requirements for Bolts, Screws and Nuts .............................. 20-11-00 Page 204
Torque Requirements for Hi-Lok Fasteners .................................... 20-11-00 Page 204
Torque Requirements for Electrical Current Carrying And Airframe Ground
Fasteners ................. ............................................... 20-11-00 Page 205
Torque Requirements for Rigid Tubing and Hoses .............................. 20-11-00 Page 206
SAFETYING - MAINTENANCE PRACTICES ............................................... 20-12-00 Page 201
General ......... ......... ......... ......................................... 20-12-00 Page 201
Safety W ire ............. ......... ................................... ........ 20-12-00 Page 201
Safety W ire Installation ...................................................... 20-12-00 Page 202
Cotter Pin Installation ........................................................ 20-12-00 Page 206
Safetying Turnbuckles ........................................ ............... 20-12-00 Page 208
SEALING - DESCRIPTION AND OPERATION ...................................... 20-30-00 Page 1
General ................................................................... 20-30-00 Page 1
ACCEPTABLE REPLACEMENTS FOR CHEMICALS AND SOLVENTS - DESCRIPTION
AND OPERATION .............................................................. 20-31-00 Page 1
General .................................................................... 20-31-00 Page 1
Hand-Wipe Cleaning Operations ............................................. 20-31-00 Page 1
Prim ing O perations .......................................................... 20-31-00 Page 1
Topcoat Operations ......................................................... 20-31-00 Page 2
Paint Stripping Operations ........................................ 20-31-00 Page 3
GENERAL SOLVENTS/CLEANERS - MAINTENANCE PRACTICES .................. 20-31-00 Page 201
General ......... ......... ......... ......................................... 20-31-00 Page 201
Tools, Equipment and Materials .............................................. 20-31-00 Page 201
Safety Precautions .......................................................... 20-31-00 Page 201
Description ................................................................. 20-31-00 Page 201
INTERIOR AND EXTERIOR FINISH - CLEANING/PAINTING ........................ 20-31-00 Page 701
General.................................................................... 20-31-00 Page 701
Interior and Exterior Finishes ................................................. 20-31 -00 Page 701
Paint Facility ................................................................ 20-31-00 Page 701
Sanding Surfacer ........................................................... 20-31-00 Page 701
Paint Stripping .............................................................. 20-31-00 Page 702
Hand Solvent Cleaning ............................ ....................... 20-31-00 Page 704
Maintenance of the Interior and Exterior Primary Coatings and Topcoat .......... 20-31 -00 Page 705
Feb 15/2002
iVnNVVI 30NVN31NIV4
MODEL 172
MAINTENANCE MANUAL
STANDARD PRACTICES AIRFRAME - GENERAL
1. Scope
A. This Chapter describes standard maintenance practices and safety precautions applicable to all
aspects of the airframe and related systems. Maintenance practices which are unique to a particular
system or subject are described in the appropriate chapter and section in the maintenance manual.
B. For repairs beyond the scope of this manual, refer to the 1996 and On 100 Series Structural Repair
Manual.
2. Definition
the Table of Contents will further assist in locating a particular subject. A brief definition of the subjects
and sections incorporated in this chapter is as follows.
(1) The section on Material and Tool Cautions describes general cautions and warnings applicable
to maintenance on or around the airplane.
(2) The section on Torque Data provides tables, formulas, requirements and torque limits for various
type fasteners.
(3) The section on Safetying describes the proper methods and use of safety wire/lockwire, cotter
pins and lock clip installations.
(4) The section on Solvents describes characteristics of solvents which are commonly used during
maintenance, cleaning and inspection of various airframe and related components.
(5) The section on conversion data provides tables for converting english to metric measurements.
20-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
MATERIAL AND TOOL CAUTIONS - DESCRIPTION AND OPERATION
1. Mercury
CAUTION: THERMOMETERS AND OTHER TEST EQUIPMENT CONTAINING MERCURY, MUST
NOT BE USED ON THE AIRPLANE.
A. Mercury, by the amalgamation process, can penetrate any break in the finish, paint or sealing
coating of a metal structural element. An oxide coating on a dry metallic surface will tend to inhibit
an immediate action while a bright, polished, shining or scratched surface will hasten the process.
Moisture will also promote the amalgamation process. Soils, greases or other inert contaminants,
present on the metal surfaces, will prevent the start of the action. The corrosion and embrittlement
which results from an initial penetration, can be extremely rapid in structural members under load.
Once it has begun, there is no known method of stopping it. Complete destruction of the load
carrying capacity of the metal will result.
2. Maintenance Precautions
WARNING: DURING MAINTENANCE, REPAIR AND SERVICING OF THE AIRPLANE, MANY
SUBSTANCES AND ENVIRONMENTS ENCOUNTERED MAY CAUSE INJURY IF
PROPER PRECAUTIONS ARE NOT OBSERVED.
A. Carefully read and follow all instructions, and especially adhere to all cautions and warnings provided
by the manufacturer of the product being used. Use appropriate safety equipment as required
including goggles, face shields, breathing apparatus, protective clothing and gloves. Fuel, engine oil,
solvents, volatile chemicals, adhesives, paints and strong cleaning agents may cause injury when
contacting the skin or eyes, or when vapors are breathed. When sanding composites or metals or
otherwise working in an area where dust particles may be produced, the area should be ventilated
and the appropriate respirator must be used.
3. General Usage Solvents

A. General usage solvents include the following:
Methyl Propyl Ketone
Toluene
Isopropyl Alcohol
Acetone
Methylene Chloride
1,1,1 -Trichloroethane
Naptha
Trichloroethylene
B. These chemicals/solvents are generally colorless, evaporate quicker than water, and tend to give off
vapors in higher quantities as their temperature increases. The vapors are generally heavier than
air, which causes them to collect in low lying areas or push normal oxygen and air out of a confined
area. This situation can lead to oxygen deficient atmospheres. Many general usage solvents are also
flammable.
C. Solvents are hazardous to work with because of their flammability, rate of evaporation and reaction to
oxidizers. Solvents can also be an irritant to the skin and eyes.
D. A single spark, a smoldering cigarette, or even atmospheric conditions can ignite solvent vapors. The
lower the flash point of the chemical, the more likely it is to become flammable. Generally, flash points
of less than 100°F (37.8°C) are considered flammables. Examples of solvent flash points are shown
below:
20-10-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SOLVENT FLASH POINT

Methyl Propyl Ketone 45°F
Toluene 39°F
Isopropyl Alcohol 53.6°F
Acetone 1.4°F
E. The rate of evaporation is closely tied to flammability, because normally the vapors must be present
to ignite the liquid. Vaporization also allows solvents, even those that are not flammable, to get into
the air and into the body's blood stream through the lungs.
F. Solvents can also react explosively with oxidizers (chemicals which release oxygen). A very violent
and uncontrollable reaction takes place which generates heat rapidly. For this reason, it is very
important for each person to be aware of specific chemicals in use in the work area, and to adhere
to the labeling of containers. Chemical manufacturers are required to label each container with a
diamond shaped symbol: red for flammable and yellow for oxidizers.
G. Solvents can also damage the hands and skin. Solvents dry out skin and dissolve the natural oils.
The condition can develop into an irritation, or if left untreated with continuous exposure, it may
progress to a dermatitis. Damaged skin allows other contaminants to worsen the condition, because
the contaminants have easier access to the deeper levels of the skin. In serious cases, blood
poisoning is also possible.
H. The best defense against skin irritation is not to be exposed. If exposure is unavoidable, steps should
be taken to limit exposure times. Prolonged exposure to these irritants can lead to long term liver
damage.
20-10-00 Page 2
Aug 18/2001
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TORQUE DATA - MAINTENANCE PRACTICES

1. General
A. To ensure security of installation and prevent over stressing of components during installation, the
torque values outlined in this section and other applicable chapters of this manual should be used
during installation and repair of components.
B. The torque value tables, listed in this section, are standard torque values for the nut and bolt
combinations shown. If a component requires special torque values, those values will be listed in the
applicable maintenance practices section.
C. Torque is typically applied and measured using a torque wrench. Different adapters, used in
conjunction with the torque wrench, may produce an actual torque to the nut or bolt which is different
from the torque reading. Figure 201 is provided to help calculate actual torque in relation to specific
adapters used with the torque wrench.
D. Free Running Torque Value.
(1) Free running torque value is the torque value required to rotate a nut on a threaded shaft, without
tightening. Free running torque value does not represent the torque values listed in the tables
of this section. Torque values listed in the tables represent the torque values above free running
torque.
NOTE: EXAMPLE: If final torque required is to be 150 inch-pounds and the free running
torque is 25 inch-pounds, then the free running torque must be added to the required
torque to achieve final torque of 150 + 25 =175 inch-pounds.
(2) Breakaway torque value is the value of torque required to start a nut rotating on a thread shaft,
and does not represent free running torque value. It should be noted that on some installations
the breakaway torque value cannot be measured.
E. General Torquing Notes.
(1) These requirements do not apply to threaded parts used for adjustment, such as turnbuckles
and rod ends.
(2) Torque values shown are for clean, non lubricated parts. Threads should be free of dust, metal
filings, etc. Lubricants, other than that on the nut as purchased, should not be used on any bolt
installation unless specified.
(3) Assembly of threaded fasteners, such as bolts, screws and nuts, should conform to torque values
shown in Table 201.
(4) When necessary to tighten from the bolt head, increase maximum torque value by an amount
equal to shank friction. Measure shank friction with a torque wrench.
(5) Sheet metal screws should be tightened firmly, but not to a specific torque value.
(6) Countersunk washers used with close tolerance bolts must be installed correctly to ensure proper
torquing (refer to Figure 202).
(7) For Hi-Lok fasteners used with MS21042 self-locking nuts, fastener and nut should be lubricated
prior to tightening.
(8) Tighten accessible nuts to torque values per Table 201. Screws attached to nutplates, or screws
with threads not listed in Table 201 should be tightened firmly, but not to a specific torque value.
Screws used with dimpled washers should not be drawn tight enough to eliminate the washer
crown.
(9) Table 201 is not applicable to bolts, nuts and screws used in control systems or installations
where the required torque would cause binding, or would interfere with proper operation of parts.
On these installations, the assembly should be firm but not binding.
(10) Castellated Nuts.
(a) Self-locking and non self-locking castellated nuts, except MS17826, require cotter pins and
should be tightened to the minimum torque value shown in Table 201. The torque may be
increased to install the cotter pin, but this increase must not exceed the alternate torque
values.
(b) MS17826 self-locking, castellated nuts shall be torqued per Table 201.
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NOTE: WHEN USING A TORQUE WRENCH ADAPTER WHICH

CHANGES THE DISTANCE FROM THE TORQUE WRENCH
DRIVE TO THE ADAPTER DRIVE, APPLY THE FOLLOW-
ING FORMULAS TO OBTAIN THE CORRECTED TORQUE
READING.
SHORT OPEN END

ADAPTER
WRENCH TORQUE HANDGRIP
DRIVE WRENCH CENTERLINE
ADAPTER CENTERLINE (PREDETERMINED)
DRIVE
CENTERLINE
SETSCREW
ADAPTER
FORMULA TxL = y
L+E
EXAMPLE (WITH "E" AS PLUS DIMENSION)
T= 135 IN-LB y= 135x10 =117.39
Y = UNKNOWN 10+1.5
HOSE CLAMP E = 1.5 IN Y = 117 IN-LB
ADAPTER L = 10.0 IN
LEGEND
T = ACTUAL (DESIRED) TORQUE
(INDICATED) TORQUE
E = EFFECTIVE LENGTH OF EXTENSION
ADAPTER
OPEN-END WRENCH DRIVE HANDGRIP
ADAPTER WRENCH CENTERLINE CENTERLINE
DRIVE (PREDETERMINED)
CENTERLINE
FLARE NUT WRENCH

ADAPTER
TORQUE
FORMULA TxL = WRENCH
L- E
EXAMPLE (WITH "E" AS MINUS DIMENSION)

T = 135 IN-LB y = 135x10 =1350 = 158.82
Y = UNKNOWN 10 - 1.5 8.5
SPANNER WRENCH L = 10.0 IN
ADAPTER E = 1.5 IN Y= 159 IN-LB
5598C2005
Torque Wrench and Adapter Formulas

20-11-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
EXTERNAL WRENCHING HEAD
CORRECT INSTALLATION
INSTALL WASHER WITH COUNTERSUNK
FACE NEXT TO BOLT HEAD RADIUS
INTERNAL WRENCHING HEAD
STANDARD COUNTERSUNK
WASHER WASHER
INCORRECT INSTALLATION
CAUTION: NEVER INSTALL STANDARD
WASHER OR COUNTERSUNK
WASHER IN REVERSE WHEN
USING BOLTS WITH RADIUS
UNDER THE HEAD
5598C1004
5598C1004A
Washer Installation Close Tolerance Bolts

20-11-00 Page 203

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MAINTENANCE MANUAL
(c) The end of the bolt or screw should extend through the nut at least two full threads including
the chamfer.
(11) Joints containing wood, plastics, rubber or rubberlike materials should be torqued to values
approximately 80 percent of the torque at which crushing is observed, or to the requirements of
Table 201, whichever is lower, or as specified.
2. Torque Requirements for Bolts, Screws and Nuts

A. Use Table 201 to determine torque requirements for nuts, bolts and screws. Although the table makes
reference to nuts (because nuts are typically torqued), torque values are also applicable when applying
torque to bolts and screws.
Table 201. Torque Requirements For Steel Nuts, Bolts, and Screws (In Inch-Pounds)
SIZE FINE THREADED SERIES FINE THREADED SERIES MS17826 NUTS

(TENSION TYPE NUTS) (SHEAR TYPE NUTS
EXCEPT MS17826)
Standard Alternate Standard Alternate Standard Alternate
Torque Torque Torque Torque Torque Torque
8-36 12 to 15 -- 7 to 9 -
10-32 20 to 25 20 to 28 12 to 15 12 to 19 12 to 15 12 to 20
1/4-28 50 to 70 50 to 75 30 to 40 30 to 48 30 to 40 30 to 45
5/16-24 100 to 140 100 to 150 60 to 85 60 to 100 60 to 80 60 to 90
3/8-24 160 to 190 160 to 260 95 to 110 95 to 170 95 to 110 95 to 125
7/16-20 450 to 500 450 to 560 270 to 300 270 to 390 180 to 210 180 to 225
1/2-20 480 to 690 480 to 730 290 to 410 290 to 500 240 to 280 240 to 300
9/16-18 800 to 1000 800 to 1070 480 to 600 480 to 750 320 to 370 320 to 400
5/8-18 1100 to 1300 1100 to 1600 660 to 780 660 to 1060 480 to 550 480 to 600
3/4-16 2300 to 2500 2300 to 3350 1300 to 1500 1300 to 2200 880 to 1010 880 to 1100
7/8-14 2500 to 3000 2500 to 4650 1500 to 1800 1500 to 2900 1500 to 1750 1500 to 1900
1-14 3700 to 4500 3700 to 6650 2200 to 3300 2200 to 4400 2200 to 2700 2200 to 3000
Fine Thread Tension application nuts include: AN310, AN315, AN345, MS17825, MS20365, MS21044
through MS21048, MS21078, NAS679, NAS1291
Fine Thread Shear application nuts include: AN316, AN320, MS21025, MS21042, MS21043, MS21083,
MS21245, NAS1022, S1117
Coarse Thread application nuts include: AN340, MS20341, MS20365, MS35649
3. Torque Requirements for Hi-Lok Fasteners
A. Use Table 202 to determine torque requirements for Hi-Lok fasteners.
NOTE: This table is used in conjunction with MS21042 self-locking nuts.
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Table 202. Torque Values For Hi-Lok Fasteners (Alloy Steel, 180 to 200 ksi)
NOMINAL FASTENER DIAMETER TORQUE VALUE (INCH-POUNDS)

6-32 8 to 10
8-32 12 to 15
10-32 20 to 25
1/4-28 50 to 70
5/16-24 100 to 140
3/8-24 160 to 190
7/16-20 450 to 500
1/2-20 480 to 690
4. Torque Requirements for Electrical Current Carrying And Airframe Ground Fasteners
A. Use Table 203 to determine torque requirements for threaded electrical current carrying fasteners.
(1) Torque values shown are clean, non lubricated parts. Threads shall be free of dust and metal
filings. Lubricants, other than on the nut as purchased, shall not be used on any bolt installations
unless specified in the applicable chapters of this manual.
(2) All threaded electrical current carrying fasteners for relay terminals, shunt terminals, fuse limiter
mount block terminals and bus bar attaching hardware shall be torqued per Table 203.
NOTE: There is no satisfactory method of determining the torque previously applied to a
threaded fastener. When retorquing, always back off approximately 1/4 turn or more
before reapplying torque.
B. Use Table 204 to determine torque requirements for threaded fasteners used as airframe electrical
ground terminals.
Table 203. Torque Values For Electrical Current Carrying Fasteners
FASTENER DIAMETER TORQUE VALUE (INCH-POUNDS)

6-32 8 to 12
8-32 13 to 17
10-32 20 to 30
3/16 20 to 30
1/4 40 to 60
5/16 80 to 100
3/8 105 to 125
1/2 130 to 150
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 204. Torque Values For Airframe Electrical Ground Terminals
FASTENER DIAMETER TORQUE VALUE (INCH-POUNDS)

5/16 130 to 150
3/8 160 to 190
5. Torque Requirements for Rigid Tubing and Hoses

A. Use Table 205 to determine torque requirements for tubes and hoses.
Table 205. Tubing/Hose Torque Limits (Inch-Pounds)
Hose Size Tubing O.D. Aluminum Alloy Tubing Steel Tubing

Min Max Min Max
-2 1/8 20 30 75 85
-3 3/16 25 35 95 105
-4 1/4 50 65 135 150
-5 5/16 70 90 170 200
-6 3/8 110 130 270 300
-8 1/2 230 260 450 500
-10 5/8 330 360 650 700
-12 3/4 460 500 900 1000
-16 1 500 700 1200 1400
-20 1 1/4 855 945 1520 1680
-24 1 1/2 855 945 1900 2100
20-11-00 Page 206

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SAFETYING - MAINTENANCE PRACTICES

1. General
A. Safety Wire.
(1) Inconel (Uncoated), Monel (Uncoated).
(a) Used for general safety wiring purposes. Safety wiring is the application of wire to prevent
relative movement of structural or other critical components subjected to vibration, tension,
torque, etc. Monel safety wire shall be used at temperatures up to 700°F. Inconel safety
wire shall be used at temperatures up to 1500°F. Identified by the color of the finish, monel
and inconel color is a natural wire color.
(2) Copper, Cadmium Plated and Dyed Yellow in accordance with FED-STD 595.
(a) These wires shall be used for shear and seal wiring applications. Shear applications are
those where it is necessary to purposely break or shear the wire to permit operation or
actuation of emergency devices. Seal applications are those where the wire is used with a
lead seal to prevent tampering or use of a device without indication. Identified by the color
of the finish, copper wire is dyed yellow.
(3) Inconel and monel wires can be substituted for same diameter and length of carbon steel or
corrosion resistant wire.
(4) Wires are visually identifiable by their colors: natural for inconel and monel, yellow for copper,
and blue for aluminum.
B. Cotter Pin.
(1) The selection of material shall be in accordance with temperature, atmosphere and service
limitations.
2. Safety Wire
A. Wire Size.
(1) The size of the safety wire shall be in accordance with the requirements of Table 201.
(a) 0.032 inch diameter safety wire is for general purpose use; however, 0.02 inch diameter
safety wire may be used on parts having a nominal hole diameter of less than 0.045 inch;
on parts having a nominal hole diameter between 0.045 and 0.062 with spacing between
parts of less than two inches; or on closely spaced screws and bolts of 0.25 inch diameter
and smaller.
(b) 0.02 inch diameter copper wire shall be used for shear and seal wire applications.
(c) When employing the single wire method of locking, the largest nominal size wire for the
applicable material or part which the hole will accommodate shall be used.
Table 201. Safety Wire
MATERIAL SIZE AND NUMBER (MS20995-XXX)
.015 .020 .032 .040 .041 .047 .051 .091

Ni-Cu Alloy NC20 NC32 NC40 NC51 NC91
(Monel)
Ni-Cr-Fe Alloy N20 N32 N40 N51 N91
(Inconel)
Carbon Steel F20 F32 F41 F47 F91
Corrosion C15 C20 C32 C41 C47 C91
Resistant Steel
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
Table 201. Safety Wire (continued)

MATERIAL SIZE AND NUMBER (MS20995-XXX)
Aluminum AB20 AB32 AB41 AB47 AB91

Alloy(Blue)
Copper (Yellow) CY15 CY20
3. Safety Wire Installation

A. Method (Refer to Figure 201).
CAUTION: SCREWS IN CLOSELY SPACED GEOMETRIC PATTERNS WHICH SECURE

HYDRAULIC OR AIR SEALS, HOLD HYDRAULIC PRESSURE, OR USED IN
|*I~~ ~CRITICAL AREAS SHALL USE THE DOUBLE-TWIST METHOD OF SAFETY
WIRING.
(1) Single wire method of safety wiring shall use the largest nominal size wire listed in Table 201,
which will fit the hole.
(2) The double-twist method of safety wiring shall be used as the common method of safety wiring. It
is one wire twisted on itself several times. The single wire method of safety wiring may be used in
a closely spaced, closed geometrical pattern (triangle, square, circle, etc.), on parts in electrical
systems, and in places that would make the single wire method more advisable. Closely spaced
shall be considered a maximum of two inches between centers.
(3) Use single wire method for shear and seal wiring application. Verify the wire is installed correctly
so that it can be easily broken when required in an emergency situation. For securing emergency
devices where it is necessary to break the wire quickly, use copper only.
(4) Safety wiring by the double twist method shall be done as follows:
(a) One end of the safety wire shall be inserted through one set of safety wire holes in the bolt
head. The other end of the safety wire shall preferably be looped firmly around the head
to the next set of safety wire holes in the same unit and inserted through this set of safety
wire holes. The "other end" may go over the head when the clearances around the head
are obstructed by adjacent parts.
(b) The strands, while taut, shall be twisted until the twisted part is just short of the nearest
safety wire hole in the next unit. The twisted portion shall be within 1/8 inch of the holes
in each unit. The actual number of twists will depend upon the wire diameter, with smaller
diameters being able to have more twists than larger diameters. The twisting shall keep
the wire taut without over stressing or allowing it to become nicked, kinked or mutilated.
Abrasions from commercially available twist pliers shall be acceptable.
(c) The wire shall be twisted to form a pigtail of 3 to 5 twists after wiring the last unit. The
excess wire shall be cut off. The pigtail shall be bent towards the part to prevent it from
becoming a snag. Safety wiring multiple groups by the double twist double hole method
shall be the same as the previous double twist single hole method except the twist direction
between subsequent fasteners may be clockwise or counterclockwise.
B. Spacing.
(1) When safety wiring widely spaced multiple groups by the double-twist method, three units shall
be the maximum number in a series.
(2) When safety wiring closely spaced multiple groups, thenumber of units that can be safety wired
by a 24 inch length of wire shall be the maximum number in a series.
(3) Widely spaced multiple groups shall mean those in which the fastenings are from four to six
inches apart. Safety wiring shall not be used to secure fasteners or fittings which are spaced
more than six inches apart, unless tie points are provided on adjacent parts to shorten the span
of the safety wire to less than six inches.
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MODEL 172
MAINTENANCE MANUAL
STEP 1. INSERT WIRE THROUGH BOLT A AND
BEND WIRE ACROSS BOLT HEAD).

TWIST WIRES CLOCKWISE UNTIL
THEY REACH BOLT B.
STEP 2. INSERT ONE END OF WIRE THROUGH

BOLT B. BEND OTHER END AROUND
BOLT (IF NECESSARY, BEND WIRE
ACROSS HEAD OF BOLT). TWIST
WIRES COUNTERCLOCKWISE 1/2 INCH
OR SIX TWISTS. CLIP ENDS.
BEND PIGTAIL BACK AGAINST PART.
NOTE: RIGHT THREADED PARTS SHOWN:
REVERSE DIRECTIONS FOR LEFT PARTS.
BOLT B CLOCKWISE
DOUBLE-WIRE SAFETYING
COUNTER-
CLOCKWISE
CLOCKWISE
COUNTER-
^ ^) CLOCKWISE
MULTIPLE FASTENER
APPLICATION DOUBLE -
TWIST DOUBLE-TWIST SAFETYING
0560R1025
Lockwire Safetying
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B1679
'i1I
'III
EXTERNAL SNAP RING

SINGLE-WIRE METHOD
BOLTS IN CLOSELY SPACED, CLOSED

GEOMETRICAL PATTERN, SINGLE
WIRE METHOD
SINGLE FASTENER APPLICATION

DOUBLE-TWIST METHOD
SMALL SCREWS IN CLOSELY SPACED, CLOSED

GEOMETRICAL PATTERN, SINGLE WIRE METHOD
NOTE: RIGHT THREADED

PARTS SHOWN. REVERSE
DIRECTION FOR LEFT
THREADS 5598T1003
5598T1024
5598T1024
5598T1024
Lockwire Safetying
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
91680
SAFETY WIRE a_
0560R1026
Lockwire Safetying
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MODEL 172
MAINTENANCE MANUAL
C. Tension.
(1) Parts shall be safety wired in such a manner that the safety wire shall be put in tension when
the part tends to loosen. The safety wire should always be installed and twisted so that the loop
around the head stays down and does not tend to come up over the bolt head and leave a slack
loop.
NOTE: This does not necessarily apply to castellated nuts when the slot is close to the top
of the nut, the wire will be more secure if it is made to pass along the side of the stud.
(2) Care shall be exercised when installing safety wire to ensure that it is tight but not over stressing.
D. Usage.
(1) A pigtail of 0.25 to 0.50 inch (3 to 5 twists) shall be made at the end of the wiring. This pigtail
shall be bent back or under to prevent it from becoming a snag.
(2) Safety wire shall be new upon each application.
(3) When castellated nuts are to be secured with safety wire, tighten the nut to the low side of the
selected torque range, unless otherwise specified, and if necessary, continue tightening until a
slot aligns with the hole.
(4) In blind tapped hole applications of bolts or castellated nuts on studs, the safety wiring shall be
as described in these instructions.
(5) Hollow head bolts are safetied in the manner prescribed for regular bolts.
(6) Drain plugs and cocks may be safetied to a bolt, nut or other part having a free lock hole in
accordance with the instructions described in this text.
(7) External snap rings may be locked if necessary, in accordance with the general locking principles
as described and illustrated. Internal snap rings shall not be safety wired. Refer to Figure 201.
(8) When safety wiring is required on electrical connectors which use threaded coupling rings, or on
plugs which employ screws or rings to fasten the individual parts of the plug together, they shall
be safety wired with 0.02 inch diameter wire in accordance with the safety wiring principles as
described and illustrated. It is preferable to safety wire all electrical connectors individually. Do
not safety wire one connector to another unless it is necessary to do so.
(9) Drilled head bolts and screws need not be safety wired if installed into self-locking nuts or
installed with lockwashers. Castellated nuts with cotter pins or safety wire are preferred on
bolts or studs with drilled shanks but self-locking nuts are permissible within the limitations of
MS33588.
(10) Larger assemblies, such as hydraulic cylinder heads for which safety wiring is required but not
specified, shall be safety wired as described in these instructions.
(11) Safety wire shall not be used to secure nor shall safety wire be dependent upon fracture as
the basis for operation of emergency devices such as handles, switches, guards covering
handles, etc., that operate emergency mechanisms such as emergency exits, fire extinguishers,
emergency cabin pressure release, emergency landing gear release and the like. However,
where existing structural equipment or safety of flight emergency devices require shear wire
to secure equipment while not in use, but which are dependent upon shearing or breaking
of the safety wire for successful emergency operation of equipment, particular care shall be
exercised to that wiring under these circumstances shall not prevent emergency operations of
these devices.
4. Cotter Pin Installation
A. General instruction for the selection and application of cotter pins (Refer to Figure 202).
(1) Cotter pin shall be new upon each application and selection shall be material in accordance with
temperature, atmosphere and service limitations.
(2) When nuts are to be secured to the fastener with cotter pins, tighten the nut to the low side
(minimum) of the applicable specified or selected torque range, unless otherwise specified, and
if necessary, continue tightening until the slot aligns with the hole. In no case.shall the high side
(maximum) torque range be exceeded.
(3) Castellated nuts mounted on bolts shall be safetied using the preferred method of cotter pins.
An alternate method if cotter pins are not available, is safety wire.
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MODEL 172
MAINTENANCE MANUAL
B1681
TO PROVIDE CLEARANCE
PRONG MAY BE CUT HERE
CASTELLATED NUT ON BOLT

CASTELLATED NUT ON BOLT ALTERNATE METHOD
PREFERRED METHOD
MINIMUM
MAXIMUM
COTTER PIN 6 0.028
~~LENGTH.8
60 DEGREES 10 0.044
1/4 0.044
5/16 0.044
6 DEGREES 3/8 0.072
7/16 0.072
MINIMUM
COTTER PIN ~~~~~~COTTER
PIN ~9/16 0.086
LENGTH 5/8 0.086
3/4 0.086
7/8 0.086
1 0.086
1 1/8 0.116
1 1/4 0.116
1 3/8 0.116
1 1/2 0.116
PIN APPLICATION
0560R1028
Cotter Pin Safetying

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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
(4) in the event of more than 50 percent of the cotter pin diameter is above the nut castellation, a
washer should be used under the nut or a shorter fastener should he ised. A maximum of two
washers may be permitted under a nut.
(5) The largest nominal diameter cotter pin listed in MS24665 which the hole and slots will
accommodate shall be used; but in no application to a nut, bolt or screw shall the pin size be
less than the sizes described in Figure 202.
(6) Install the cotter pin with the head firmly in the slot of the nut with the axis of the eye at right
angles to the bolt shank, and bend prongs so that the head and upper prong are firmly seated
against the bolt.
(7) In the pin applications, install the cotter pin with the axis of the eye parallel to the shank of the
clevis pin or rod end. Bend the prongs around the shank of the pin or rod end.
(8) Cadmium plated cotter pins shall not be used in applications bringing them in contact with fuel,
hydraulic fluid or synthetic lubricants.
5. Safetying Turnbuckles
A. Use of Safety Wire.
(1) Some turnbuckles are secured using safety wire. These safetying procedures are detailed
|*I ~ and illustrated in Federal Publication AC 43-13.1B (or latest revision), Safety Methods For
Turnbuckles.
B. Use of Locking Clips (Refer to Figure 203).
(1) Prior to safetying, both threaded terminals shall be screwed an equal distance into the turnbuckle
barrel. They shall be screwed in at a minimum so that no more than three threads of any terminal
are exposed outside the body.
(2) The turnbuckle shall be adjusted to its locking position with the groove on terminals and slot
indicator notch on barrel aligned. Insert the end of the locking clip into the terminal and barrel
until the "U" curved end of the locking clip is over the hole in the center of the barrel.
(a) Press the locking clip into the hole to its full extent.
(b) The curved end of the locking clip will latch in the hole in the barrel.
CAUTION: DO NOT USE A TOOL AS THE LOCKING CLIP COULD BE DISTORTED.
(c) To check proper seating of locking clip, attempt to remove pressed "U" end from barrel hole
with fingers only.
(3) Locking clips are for one time use only and shall not be reused.
(4) Both locking clips may be inserted in the same hole of the turnbuckle barrel or in opposite holes
of the turnbuckle barrel.
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B1682 STRAIGHT END
HOOK SHOULDER
_zzzfl ^) \^_ _
PULL FOR INSPECTION

BARREL CABLE
TERMINAL
PULL FOR INSPECTION
0560R1023
Safetying Turnbuckle Assemblies

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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
THIMBLE
TURNBUCKLE BARREL LOCKING CLIP
MS21251 MS21256
TYPICAL TURNBUCKLE ASSEMBLY
SWAGED
TERMINAL
METHOD OF ASSEMBLING LOCKING CLIPS, TURNBUCKLE BARREL AND TERMINALS
LOCKING
CLIP TURNBUCKLE
NOMINAL THREAD MS21256 BODY
CABLE DIA UNF-3 (NOTE) MS21251
1/16 No. 6-40 -1 -2S
3/32 No. 10-32 -3S
-2 -3L
-1 -4S
1/8 -2 -4L
5/32 1/4-28 -1 -5S
-2 -5L
-6S
3/16 5/16-24 -1 -6L
7/32 -7L
1/4 3/8-24 -2 -8L
9/32 7/16-20 -9L
5/16 1/2-20 -3 -10L
NOTE: TWO LOCKING CLIPS REQUIRED FOR EACH

TURNBUCKLE.
0560R 1024
Safetying Turnbuckle Assemblies

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MODEL 172
MAINTENANCE MANUAL
SEALING - DESCRIPTION AND OPERATION

1. General
A. A list of the various sealants used throughout the airplane can be found in the Tools, Equipment and
Materials table of the effected chapters.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ACCEPTABLE REPLACEMENTS FOR CHEMICALS AND SOLVENTS - DESCRIPTION AND OPERATION

1. General
A. In response to the Aerospace National Emissions Standards for Hazardous Air Pollutants (NESHAP),
this data is being issued to inform customers of acceptable replacements for chemicals and solvents
in the Maintenance Manual that have been restricted or prohibited by the standards.
B. For complete details of the regulatory standards, refer to Federal Register, 40 CFR Part 63 (Ad-FRL-
5636-1), RIN 2060-AG65.
C. Compliance with the standard is mandatory by September 1, 1998.
2. Hand-Wipe Cleaning Operations
NOTE: All hazardous air pollutants (HAP) or volatile organic compounds (VOC) hand-wipe cleaning
solvents must meet a composition requirement, have a vapor pressure less than or equal
to 45 MM Hg at 20°C, or meet the requirements specified in an alternative compliance plan
administered by the permitting authority and approved under Section 112 (1) of the Clean Air
Act.
Table 1. Replacement Products for Hand-Wipe Cleaning Operations
SURFACE APPROVED PRODUCT/NUMBER SUPPLIER ADDRESS

All Metals and Painted Surfaces Methyl n-propyl ketone (CAS No. Eastman Chemical Products
107-87-9) Wilcox Dr. And Lincoln St.
Kingsport, TN
Desoclean 110 (020K19) Dynamold Solvents, Incorporated
2905 Shamrock Ave.
Fort Worth, TX 76107
All Plastics Isopropyl Alcohol (TT-I-735) Available Commercially
All Rubber (Natural or Synthetic) Isopropyl Alcohol (TT-1-735) Available Commercially
and Silicone
3. Priming Operations
NOTE: Priming operations may not exceed a maximum Hazardous Air Pollutant (HAP) limit of 2.9
Ib./Gallon (350 Grams/Liter) (less water) per application. Priming operations may not exceed
a volatile organic compounds (VOC) limit of 2.9 lb./Gallon (350 Grams/Liter) (less water and
exempt solvents) per application. Compliance of this limit may be achieved through the use
of coatings which fall below content limits, or by using monthly volume-weighted averaging to
meet content limits.
Table 2. Replacement Products for Priming Operations
PRIMER APPLICATION APPROVED PRODUCT/NUMBER SUPPLIER ADDRESS

Corrosion Primer (See Notes 1,4) Corrosion Primer (513 X 419) (910 Courtaulds Aerospace
X 942) 1608 Fourth St.
Berkeley, CA 94710
Corrosion Primer (02-Y-40) DEFT, Inc.
(02-4-40 CATA) 17451 Von Karman Ave.
Irvine, CA 92714
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
Table 2. Replacement Products for Priming Operations (continued)

PRIMER APPLICATION APPROVED PRODUCT/NUMBER SUPPLIER ADDRESS
Corrosion Primer Sterling Lacquer Mfg.
(U-1201F/U-1202F) 3150 Brannon Ave.
St. Louis, MO 63139
Corrosion Primer U.S. Paint Corp.
R4001-K14 831 S. 21st St.
MAX COR St. Louis, MO 63103
Fuel Bay Primer (See Notes 2, 4) Fuel Bay Primer 10P30-5 Dexter Crown Metro Aerospace
East Water St.
Waukegan, IL 60085
Pretreatment Primer (See Notes Pretreatment Primer Sherwin-Williams
3, 4) (728-013/702-701) 630 E. 13th St.
Andover, KS 67002
NOTE 1: Any primers which meet MIL-PRF-23377 requirements may be used.

NOTE 2: This primer is restricted to the fuel bay area
NOTE 3: Any pretreatment primers which meet DOD-P-15328 may be used.

NOTE 4: Specific application techniques must be used. If alternative is sought, it can only be used if emissions
are less than or equal to HVLP or electrostatic spray application techniques. All application equipment
must be operated according to manufacturer's specifications, company procedures, or locally specified
operating procedures.
4. Topcoat Operations
NOTE: Topcoat operations may not exceed a maximum Hazardous Air Pollutant (HAP) limit of 3.5
lb./Gallon (420 Grams/Liter) (less water) per application. Topcoat operations may not exceed
a volatile organic compounds (VOC) limit of 3.5 lb./Gallon (420 Grams/Liter) (less water and
exempt solvents) per application. Compliance of this limit may be achieved through the use
of coatings which fall below content limits, or by using monthly volume-weighted averaging to
meet content limits. Topcoats which meet the requirements of MIL-C-85285 may also be used.
Table 3. Replacement Products for Topcoat Painting Operations
TOPCOAT APPLICATION APPROVED PRODUCT/NUMBER SUPPLIER ADDRESS

Basecoat (See Note 4) DeSothane 420HS Hisolids Courtaulds Aerospace
Jet Glo High Solids System 810 Sherwin-Williams
Series 630 E. 13th St.
Andover, KS 67002
Low VOC Enamel Sterling Lacquer Mfg.
24-F 20 Series Dexter Crown Metro Aerospace
Paint Stripes (See Note 4) Low VOC Acrylic 830 Series Sherwin-Williams
630 E. 13th St.
Andover, KS 67002
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
5. Paint Stripping Operations

NOTE: Unless exempted, no organic Hazardous Air Pollutant (HAP) are to be emitted from chemical
strippers or solvents. Use of organic HAP materials for spot stripping and decal removal is limited
to 190 pounds per airplane per year.
Table 4. Replacement Products for Paint Stripping Operations
APPLICATION APPROVED PRODUCT/NUMBER SUPPLIER ADDRESS

Chemical Stripping Turco T-6776 LO Turco Products, Inc.
Westminster, CA 92684
Mechanical Stripping (See Note 5) 180 Grit or finer Available Commercially
NOTE 1: Mechanical and hand-sanding operations are exempt from these requirements
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
GENERAL SOLVENTS/CLEANERS - MAINTENANCE PRACTICES

1. General
A. Solvents are used in a wide range of cleaning activities and selected solvents can be used in the
removal of oil, grease and dirt from objects without harm to metal, plastics or elastomeric parts.
NOTE: The following items are used in conjunction with various solvents to aid in cleaning parts and
components.

Detergent Commercially available General cleaning.
ScotchBrite Pads Type A Minnesota Mining and Mfg. Co. Light abrasion of metal
3M Center surfaces.
St. Paul, MN 55101
Sandpaper 320 Grit Commercially available Light abrasion of metal
surfaces.
Rymple Cloth Commercially available Wiping and applying
cleaning agents.
Wiping cloth white, Commercially available Wiping and applying
oil free, absorbent cleaning agents.
3. Safety Precautions
A. Solvents are composed of a group of chemicals that often prove toxic. Anyone engaged in
maintenance, repair and operation of airplane and airplane accessories may be exposed to these
chemicals.
B. To help avoid the effects of these toxic substances, work only a clean, well-lighted and well-ventilated
area. Rubber gloves and protective clothing should be worn. Avoid breathing spray vapors as they
are highly toxic.
C. When working with toxic substances, always be alert for symptoms of poisoning. If symptoms are
observed, immediate removal of the victim from the contaminated area is most important.
4. Description
A. Solvents exhibit a selective solvent action which permits its use in the removal of oil, grease or dirt. For
selection of proper solvent, refer to Table 201. For the cleaning of metal, plastics or rubber, proceed
as follows:
(1) Metal.
NOTE: Prior to bonding or priming, lightly abrade surface with either a ScotchBrite pad or
sandpaper prior to cleaning.
(a) Wipe off all excess oil, grease or dirt from surface.
(b) Apply solvent to a clean cloth by pouring solvent on the cloth from a safety can or other
approved container. The cloth should be well saturated but not to the point of dripping.
(c) Wipe the surface with the moistened cloth as required to dissolve or loosen soil. Work on
small enough area so the surface being cleaned remains wet.
(d) With a clean dry cloth, immediately wipe the surface while the solvent is still wet. Do not
allow the surface to evaporate dry.
(e) Repeat steps (b) through (d) until there is no discoloration on the drying cloth.
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MODEL 172
MAINTENANCE MANUAL
(2) Plastic or Rubber.

NOTE: If cleaning a bonding surface, lightly abrade the bonding surface with sandpaper prior
to cleaning.
(a) Remove heavy soil from surface by washing with a water detergent solution.
(b) Apply solvent to a clean cloth by pouring solvent onto cloth from a safety can or other
approved container. The cloth should be well saturated but not to the point where dripping.
(c) Wipe the surface with the moistened cloth as required to dissolve or loosen soil. Work on
a small enough area so that the surface being clean remains wet.
(d) Using a clean dry cloth, immediately wipe the surface while the surface is still wet. Do not
allow the surface to evaporate dry.
(e) Repeat steps (b) through (d) until there is no discoloration on the drying cloth.
Table 201. General Solvents
CLEANER/ FED- TYPE USE/ DESCRIPTION CAUTION/ WARNING

SOLVENT ERAL CLASSIFI- FUNCTION
SPECIFI- CATION
CATION
Dry PD680 Type I -100°F General cleaning solvent. FLAMMABLE.
Type II -140°F Dry cleaning of textile
materials. Grease
removal.
1,1,1 O- T-620 Type I - Spot removing from USE WITH ADEQUATE
Inhibited Regular fabrics. General cleaning VENTILATION.
Technical Type II - with solvent. Cleaning of AVOID PROLONGED
Trichloroethane dauber assembled equipment. BREATHING OF VAPOR.
Type III - AVOID PROLONGED
Aerosol CONTACT WITH SKIN.
Turco Seal Cleaning/Degreasing
Solvent Turco metal parts.
Products
Penwalt 2331 Preparing metal plate for ACID ACTIVATED
painting. SOLVENT, DO NOT
USE ON PLASTICS.
Carbon P-C- Use in soak tank REMOVES PAINT. AVOID
Removing 111A tofacilitate removal of CONTACT WITH SKIN.
Compound carbon, gum, oil and other
surface contaminants
except rust or corrosion
from engine and other
metal parts.
Cleaning P-C-535 Heavy duty electro
Compound cleaner used for removal
of soils from ferrous
metal surfaces prior to
electroplating or other
treatments.
Cleaning MIL-C- Type I - Used full strength for
Compound, 5410 Viscous overhaul of unfinished
Unfinished Emulsion aluminum surfaces.
Aluminum
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 201. General Solvents (continued)

SPECIFI- CATION
CATION
Type II -Clear Use full strength or diluted
Liquid with mineral spirits and
water for maintenance
of airplane unfinished
aluminum surfaces.
Trichloro- O-T- Type I Cleaning of metal parts. REMOVES PAINT
ethylene 634B -Regular Degreasing of metal AND DAMAGES
Type II -Vapor parts. Special purpose PLASTICS. USE ONLY
Degreasing solvent. WITH ADEQUATE
VENTILATION. HIGH
CONCENTRATIONS
OF VAPOR ARE
ANESTHETIC AND
DANGEROUS TO LIFE.
VERY TOXIC.
Polish, Metal MIL- Type I -Liquid Metal polish for use FLAMMABLE.
Aluminum P-6888C Type IIPaste on airplane aluminum
surfaces.
Naphtha, TT-N-958 Type I For use with organic DO NOT USE WITH
Aliphatic coatings only. ACRYLIC PLASTICS.
FLAMMABLE.
Type II Cleanerfor acrylic plastics VAPOR HARMFUL.
and may be used in AVOID PROLONGED OR
placeof Type I General REPEATED BREATHING
cleaningagent. OR CONTACT WITH
SKIN.
Methyl Ethyl TT-M- Paint and adhesive FLAMMABLE.
Ketone 261 D thinner, cleaning agent.
Isopropyl TT-1-735 Grade B For use with organic USE DISCRIMINATELY
Alcohol -0.4% water coatings and as an WITH ACRYLIC
anti-icing fluid. General PLASTICS.
Solvent for synthetic
rubbers.
Wax, MIL-W- A waterproof wax that can DO NOT USE SOLVENTS
Airplane, 18723C be dissolved or dispersed THAT MAY DAMAGE
Waterproof with an organic solvent. PAINT OR FINISH FOR
Solvent Type REMOVAL OF WAX.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 201. General Solvents (continued)

SPECIFI- CATION
CATION
Clean- MIL-C- Type I Use full strength for RUBBER OR
ing Corn- 5410B -Viscous maintenanceof unfinished SYNTHETIC RUBBER
pound,Alu- Emulsion aluminum surfaces. GLOVES AND EYE
minum PROTECTIONSHOULD
BE USED WHEN
Type II - Clear Use full strength or diluted HANDLING THE
Liquid with mineral spirits and COMPOUND.
water for maintenance WASH FROM SKIN
of unfinished aluminum IMMEDIATELY WITH
surfaces. WATER OR A
SOLUTION OF SODIUM
BICARBO-NATE AND
APPLY GLYCERIN OR
PETROLEUM JELLY.
WASH FROM EYES AS
PER MANUFACTURER'S
INSTRUCTIONS AND
REPORT TO NEAREST
MEDICAL FACILITY.
Toluene TT-T- Use as a solvent or thinner FLAMMABLE VAPOR.
548D for organic coatings, VAPOR HARMFUL.
various resins, and
chlorinated rubber. Also
used to dilute cellulose
lacquers and dopes.
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MAINTENANCE MANUAL
INTERIOR AND EXTERIOR FINISH - CLEANING/PAINTING
1. General
A. Interior and exterior finish cleaning/painting consists of general information and instructions for
applying chemical film treatments, primer and topcoats to the airplane.
2. Interior and Exterior Finishes
A. Detail aluminum parts are chemically pretreated and epoxy primed prior to assembly. The chem-film
pretreatment and the epoxy primer are primary coatings and must be maintained and preserved for
corrosion control. Exterior assemblies that are to be topcoated receive ScotchBrite, hand solvent
cleaning and another overall application of epoxy primer. The airplane exterior then receives an overall
topcoat of polyurethane paint.
CAUTION: ALL PLASTIC AND FIBERGLASS PARTS, EXCEPT BUSHINGS, BEARINGS,
GROMMETS AND CERTAIN PURCHASED ANTENNA COVERS WHICH ARE
NOT COLORED OR PAINTED, SHALL BE COLORED OR PAINTED TO MATCH
ADJACENT SURFACE. THE HEAD OF THE PITOT TUBE MUST BE OPEN
AND FREE FROM PAINT AND OTHER FOREIGN OBJECTS. THE SURFACE
ADJACENT TO STATIC PORT MUST BE SMOOTH AND FREE FROM ALL
PAINT IMPERFECTION. DO NOT PAINT PITOT TUBE, FUEL CAPS, TRIM TAB
PUSHRODS WHERE THEY OPERATE IN AN ACTUATOR, OLEO STRUT SLIDING
SURFACES, STANDARD POLISHED SPINNERS, EXHAUSTS, STALL WARNING
VANES, CHROMED ITEMS (HANDLES, LOCKS, ETC.) OR THE TIE-DOWN LUGS
(LOCATED ON STRUTS) OR LIGHT LENS. PAINT THE LANDING GEAR BARRELS
AND TORQUE LINKS TO MATCH THE OVERALL COLOR.
3. Paint Facility
A. Painting facilities must include the ability to maintain environmental control of temperature at a
minimum of 65°F (18°C). All paint equipment must be clean. Accurate measuring containers should
be available for mixing protective coatings. Use of approved respirators while painting is a must
for personal safety. All solvent containers should be grounded to prevent static buildup. Catalyst
materials are toxic, therefore, breathing fumes or allowing contact with skin can cause serious
irritation. Material stock should be rotated to allow use of older materials first, because its useful life
is limited. All supplies should be stored in an area where temperature is higher than 50°F (10°C), but
lower than 90°F (32°C). Storage at 90°F (32°C) is allowable for no more than sixty days, providing it
is returned to room temperature for mixing and use.
(1) Areas in which cleaning or painting are done shall have adequate ventilation and shall be
protected from uncontrolled spray, dust, or fumes.
(2) Areas for prolonged storage of cleaned parts and assemblies awaiting painting shall be free from
uncontrolled spray, dust, or fumes, or else positive means of protecting part cleanliness such as
enclosed bins or wrapping in kraft paper shall be provided.
(3) Areas in which cleaning or painting are done shall be periodically cleaned and dusted.
(4) Compressed air used for dusting and paint spraying shall be free from oil, water and particulate
matter.
4. Sanding Surfacer
A. Purpose and Requirements.
(1) Surfacer is applied over fiberglass and ABS assemblies to provide aerodynamic contour,
smoothness and to seal porous surfaces. Application of surfacer also provides a good surface
for a polyurethane finish.
(2) The objective of a surfacer is to fill local depressions, pits, pin holes and other small surface
defects so a smooth surface is obtained for paint. The total surfacer thickness shall not be greater
than 15 mils (0.38 mm). Only enough surfacer shall be applied to obtain a smooth surface for
paint. If less thickness will provide a smooth surface, this is better. A thick layer of surfacer is
less flexible and may crack in service.
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MAINTENANCE MANUAL
(3) To complete the airplane's polyurethane finish over surfacer, begin by applying the intermediate
coat. Apply topcoat (polyurethane enamel) using same procedure.
(4) Should a repair be required (cracked or chipped paint) to areas where surfacer is applied,
sanding surfacer should be removed to expose fiberglass or Kevlar. It may be necessary
to remove all sanding surfacer on that individual assembly and/or component to obtain a
satisfactory finish. For additional information, refer to Cleaning.
(5) Sanding surfacer methods.
(a) Do not intermix vendor material or substitute material. Also, do not substitute instructions.
Select and use one vendor's material and use the corresponding instructions.
B. Cleaning.
CAUTION: DO NOT USE CHEMICAL STRIPPERS ON ABS PLASTIC AND FIBERGLASS
ASSEMBLIES. PAINT STRIPPER SOLVENT WILL DAMAGE THESE ASSEMBLIES.
CAUTION: SANDING OF PAINT AND/OR SANDING SURFACER MUST BE VERY CAREFULLY

ACCOMPLISHED. DO NOT SAND INTO THE FABRIC LAYERS OF COMPOSITE
ASSEMBLIES AS THIS WILL RESULT IN LOSS OF STRENGTH.
(1) Remove paint covering sanding surfacer by sanding. Paint should be removed well beyond
damaged area. For best results, it is recommended to remove all paint covering sanding surfacer
of that individual composite component.
(2) Remove sanding surfacer by sanding from individual component to expose fabric.
(3) Scuff sand area to be refinished with 320 grit paper. Do not over expose fabric.
(4) Clean surface with Methyl n-Propyl Ketone. Follow manufacturer's instructions for final cleaning
prior to sanding surfacer application.
5. Paint Stripping
A. Mechanical Stripping
(1) Mechanical methods of stripping include power sanding with a disc or jitterbug type sander,
grinder, hand sanding, and wire brushing.
(a) Ensure mechanical methods do not damage surfaces being stripped. Damage may
include, but is not limited to, cutting fibers of composite structures or scratches in the
surface of metallic surfaces.
CAUTION: DO NOT USE LOW CARBON STEEL BRUSHES ON ALUMINUM,

MAGNESIUM, COPPER, STAINLESS STEEL OR TITANIUM SURFACES.
STEEL PARTICLES MAY BECOME EMBEDDED IN THE SURFACES,
AND LATER RUST OR CAUSE GALVANIC CORROSION OF THE METAL
SURFACES.
(2) Mechanical stripping must be used for stripping composite or plastic surfaces.
(3) Mechanical stripping is recommended for surfaces which might entrap chemical strippers and
result in corrosion.
(4) Mechanical stripping is required for painted surfaces masked during chemical stripping.
B. Chemical Stripping.
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WARNING: ALL PAINT STRIPPERS ARE HARMFUL TO EYES AND SKIN. ALL OPERATORS
SHOULD WEAR GOGGLE-TYPE EYEGLASSES, RUBBER GLOVES, APRONS
AND BOOTS. IN CASE OF CONTACT WITH SKIN, FLUSH WITH WATER. IN CASE
OF CONTACT WITH EYES, FLUSH EYES THOROUGHLY WITH WATER AND
CONSULT PHYSICIAN IMMEDIATELY. PAINT STRIPPING SHOULD BE DONE IN
A WELL VENTILATED AREA.
WARNING: USE OF A HEATER WITH AN OPEN FLAME IN AN AREA IN WHICH STRIPPING

WITH A METHYLENE CHLORIDE TYPE STRIPPER IS USED PRODUCES
HYDROCHLORIC ACID FUMES. IF ACID IS DEPOSITED ON AIRPLANE IT WILL
CORRODE ALL SURFACES.
(1) Thoroughly clean airplane surfaces to remove all grease and other dirt which might keep stripping
agent from attacking paint.
(2) All seams and joints must be protected by applying a tape, resistant to strippers, to every
joint to prevent stripping chemicals from entering the skin joints. Chemicals used for stripping
polyurethane paint are very difficult to remove from joints, and may promote corrosion or
deteriorate bonding agents used in assembly of airplane.
(3) Mask following surfaces using plastic sheeting or waxed paper and plastic tape so as to make
a safety margin of at least one-half inch (13 mm) between protected surface and surface to be
stripped.
NOTE: Do not use masking tape.
(a) Mask all windows and transparencies.

CAUTION: ACRYLIC WINDOWS MAY BE SOFTENED OR OTHERWISE DAMAGED
BY PAINT STRIPPER, SOLVENT OR PAINT. USE WATER AND GREASE-
PROOF BARRIER MATERIAL AND POLYETHYLENE COATED TAPE TO
PROTECT WINDOWS.
1 Place barrier material over window and seal around periphery with polyethylene
backed masking tape.
2 Cut second sheet of barrier material an inch (26 mm) or more larger than window.
3 Place second sheet of barrier material over window and seal with polyethylene tape.
(b) Mask all rubber and other non metals.
(c) Composites if possible, shall be removed from airplane prior to stripping.
(d) Mask all honeycomb panels and all fasteners which penetrate honeycomb panels.
(e) Mask all pivots, bearings and landing gear.
(f) Titanium, if used on airplane, must be protected from strippers.
(g) Mask all skin laps, inspection holes, drain holes, or any opening that would allow stripper
to enter airplane structure.
CAUTION: DO NOT ALLOW PAINT STRIPPER TO CONTACT HIGH HEAT

TREATED STEEL PINS, SUCH AS PINS ATTACHING LANDING GEAR
COMPONENTS. PAINT STRIPPERS MAY INDUCE HYDROGEN
EMBRITTLEMENT IN HIGH HEAT TREATED STEEL.
(4) Apply approved stripper by spray or brush method.
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WARNING: USE NORMAL SAFETY PRECAUTIONS WHEN USING FLAMMABLE

MATERIALS DURING CLEANING AND PAINTING PROCEDURES.
WARNING: PAINT STRIPPER SOLUTION IS HARMFUL TO EYES AND SKIN. WEAR
GOGGLES, RUBBER GLOVES, APRON AND BOOTS WHEN WORKING
WITH PAINT STRIPPER. ALSO WEAR APPROPRIATE RESPIRATOR
WHEN APPLYING "SPRAY-ON" STRIPPERS. THE CHEMICAL SUPPLIER
BULLETINS AND INSTRUCTIONS SHOULD BE CLOSELY FOLLOWED FOR
PROPER MIXING OF SOLUTION, APPLICATION METHODS AND SAFETY
PRECAUTIONS.
(a) If using spray method, apply a mist coat to area to be stripped, then when paint begins to
lift, apply a second heavy coat.
(b) If applying with brush, brush across the surface only once, in one direction.
(5) Allow stripper coating to lay on the surface until paint lifts.
(6) After paint begins to lift, use a propylene bristle brush to agitate stripper to allow deeper
penetration of stripper.
(7) Remove lifted paint with a plastic squeegee. Dispose of residue in accordance with local
regulations.
(8) Inspect all surfaces for incomplete paint removal.
(a) Repeat previous procedural steps as necessary until all paint is removed.
(9) After stripping airplane, thoroughly rinse to remove any stripping residue.
(10) Remove tape applied to protect joints and other masked areas.
(11) Carefully remove remaining paint at skin joints and masked areas by sanding with a hand or
jitterbug type sander.
(12) If necessary to remove paint from inside skin joints, refer to Cleanout of Skin Joints.
(13) If corrosion is encountered, refer to Structural Repair Manual, Chapter 51, Corrosion/Repair, for
corrosion treatment.
C. Cleanout of Skin Joints.
(1) Install a surface conditioning disc on a pneumatic drill.
(2) Taper edge of disc to an edge which will allow edge to fit into skin joint seam.
(a) Run disc against a piece of coarse abrasive paper or a mill file until edge is tapered.
CAUTION: EXCESSIVE PRESSURE OR DWELL TIME WILL CAUSE SCRATCHES
OR GROOVES IN METAL. ENSURE DOUBLER AT BOTTOM OF JOINT
IS NOT DAMAGED OR GOUGED IN ANY WAY BY THIS PROCESS.
(3) Using tapered surface conditioning disc, remove paint and other material from joint seams.
(4) Carefully, and using as low speed as possible, remove paint and all other material from joint.
NOTE: Surface conditioning disc will wear rapidly, it will be necessary to resharpen (retaper)
disc frequently.
6. Hand Solvent Cleaning
WARNING: WORK IN A WELL VENTILATED AREA FREE FROM SOURCES OF IGNITION. USE
ONLY APPROVED SOLVENTS AND MATERIALS.
CAUTION: AIRPLANE SHALL BE GROUNDED DURING SOLVENT WIPE.
A. Surface Cleaning.
(1) Apply solvent to a clean wiping cloth by pouring from a safety can or other approved container.
The cloth should be well saturated with solvent. Avoid dipping wipers into open solvent
containers as this contaminates the solvent.
(2) Wipe the surface with the wet cloth as required to dissolve or loosen soils. Work on a small
enough area so that the area being cleaned remains wet with solvent.
(3) With a clean dry cloth, immediately wipe dry the area being cleaned. Do not allow the surface
to evaporate dry.
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(4) Repeat steps (1) through (3) as required and change cloths often.
7. Maintenance of the Interior and Exterior Primary Coatings and Topcoat
A. Rework and repair primary coatings on airplane interior and exterior surfaces for protection and
corrosion control.
(1) Minor scratches or defects, which do not penetrate the epoxy primer or which penetrate the
primer and expose bare metal, with the total area of exposed bare metal less than the size of a
dime, touch up as follows:
(a) Hand solvent clean and sand with 320 grit or finer sandpaper.
(b) Clean with compressed air, hand solvent clean again, then wipe with a tack rag.
(c) Mix and reapply epoxy primer (MIL P-23377 or equivalent) as directed by the primer
manufacturer or supplier.
(d) On a properly prepared surface, mix and apply polyurethane topcoat as directed by the
paint manufacturer or supplier.
(2) Major defects which expose bare metal to an area larger than the size of a dime, touch up as
follows:
(a) Hand solvent clean and sand with 320 grit or finer sandpaper.
(b) Clean with compressed air, hand solvent clean again, then wipe with a tack rag.
(c) Apply a spray wash primer or (preferred method) brush chem film primer. Mask the area
to minimize the amount of primer from spreading over the existing epoxy primer. Let cure
according to the product manufacturers recommendations.
(d) Mix and apply epoxy primer (MIL P-23377 or equivalent) to the affected area within four
hours.
(e) If an exterior painted surface, mix and apply polyurethane topcoat as directed by the paint
manufacturer or supplier.
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FUEL, WEATHER AND HIGH-TEMPERATURE SEALING - MAINTENANCE PRACTICES
1. General
A. Procedures for application of sealants are provided for various types of sealing required for the

NOTE: Specified sealants, cleaning solvents, parting agents, adhesion inhibitors and equipment are
listed for use. Suitable substitutes may be used for sealing equipment only.
SEALANTS TYPE I, CLASS A- 1/2, OR A-2 - MIL-S-8802

Sealants GC-408 Goal Chemical Sealant Corp. Fuel, pressure and
3137 East 26th Street weather sealant brush
Los Angeles, CA 90023 application.
Pro-Seal 890 Courtaulds Aerospace
5426 San Fernando Rd.
Glendale, CA 91209
PR-1440 Courtaulds Aerospace
SEALANTS TYPE I, CLASS B-1/4, QUICK REPAIR - MIL-S-83318

Sealant GC-435 Goal Chemical Sealant Corp. Fuel, pressure and
weather sealant. For
limited repairs requiring
rapid curing sealant.
SEALANTS TYPE I, CLASS B-1/2, B- 2 OR B-4 - MIL-S-8802

Sealants PR-1440 Courtalds Aerospace Fuel pressure and
weather sealant,
suitable for application
by extrusion gun and
spatula.
AC-236 Advanced Chemistry And
Technology
CS 3204 Flamemaster Corporation
Pro Seal 890 Courtalds Aerospace
SEALANTS TYPE I, CLASS C-20, C-48 OR C-80

Sealant Pro-Seal 890 Courtaulds Aerospace Fuel, pressure and
weather sealant. Suitable
for faying surface sealing.
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SEALANTS TYPE IV
Sealant Dapco 2100 D. Aircraft Inc. Firewall and wire bundle
Anaheim, CA 92807 sealing.
Pro Seal 700 Courtaulds Aerospace Firewall sealing (except
wire bundles).
Q3-6077 Dow Corning Wire bundle firewall
sealing.
SEALANT TYPE VIII, CLASS B-1/2 ORB2 - MIL-S-8784

Sealant PR-1428 Class Courtaulds Aerospace Low adhesion access
door, fuel, pressure and
weather sealing.
PR-1081 Class Courtaulds Aerospace
SEALANT TYPE VI
Sealant FA-0606 125 HB Fuller Water and weather-tight
acrylic latex sealant for
windows and metal lap
joints.
SEALANT TYPE XI
Sealant EP-7191T- Fiber Resin Corp. Permanently pliable
0877 extruded tape for fixed
windows.
CLEANING SOLVENTS
1, 1, 1 - Federal Commercially Available Presealing cleaning.
Trichloroethane Specification
Technical O-T-620
Inhibited (Methyl
Chloroform)
Methyl Propyl Commercially Available Cleaning organic coating.
Ketone
Naphtha Type II Federal Commercially Available Presealing cleaning.
Specification
TT-N-95
Cleaning MIL-C-38736 Commercially Available Presealing cleaning.
compound
Isopropyl alcohol Federal Commercially Available Cleaning plastic. (Except
Specification plastic transparencies)
TT-I-735
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PARTING AGENTS
Silicone compound MIL-S-8660 Commercially available Prevent sealant sticking.
Petrolatum Federal Commercially available Prevent sealant sticking.
technical Specification
VV-P-236
EQUIPMENT
Pneumatic sealing Semco Semco Packaging and Injection sealing.
gun. Number Applications Systems, Division of
250 with Courtaulds Aerospace
accessories 5454 San Fernanco Rd.
(or equivalent) Glendale, CA 91209
Hand-operated Semco Semco Packaging and Injection sealing.
sealing gun Number 850 Applications Systems, Division of
Courtaulds Aerospace
Nozzles, Semco Packaging and Application of sealant.
Applications Systems, Division of
Courtaulds Aerospace
Round 1/16 orifice Semco No.
420
440
Duckbill Semco No.
8615
Duckbill Semco No.
8648
Comb Semco No.
8646
Polyethylene Commercially available Application of sealant.
cartridges with
plungers and caps
for sealant gun.
Metal spatulas with Commercially available Mixing sealant.
either stainless
steel or glass
plates.
Plastic lined cups, Commercially available Mixing sealant.
wax-free with caps
Sealant fairing tools Commercially available To fair-in sealant.
Cheesecloth, Commercially available Cleaning.
lint-free
Plastic scraper, Commercially available Removing old sealant.
45- degree cutting
edge.
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EQUIPMENT
Durometer Rex Model Rex Gauge Company, Inc. Testing cure of sealant.
1500 (or 3230 West Lake Avenue
equivalent) P.O. Box 46
Glenview, IL 60025
Gloves, lightweight Commercially available Removing old sealant.
lint-free white
cotton
Nylon bristle Commercially available Removing old sealant.
brushes
Pipe cleaners Commercially available Cleaning.
Funnel brushes Commercially available Cleaning.
3. Definition of Sealing Terms

A. The following definitions are included to provide a basic concept of the special terms used in sealing.
This list is not all inclusive but the more common terms are listed.
(1) Absolute Sealing - There can be no leakage allowed. All openings of any nature through the seal
plane are positively sealed. This is the first level of sealing. (All holes, slots, joggles, fasteners
and seams must be sealed.)
(2) Accelerator (Activator) - Curing agent for sealants.
(3) Application Time - The length of time sealant remains workable or suitable for application to
structure by brush, extrusion gun, spatula or roller.
(4) Base Compound - The major component of a two-part sealing compound which is mixed with the
accelerator prior to application to produce a fuel, temperature, pressure, weather and/or firewall
sealing material.
(5) Brush Coat - Apply an overcoat or continuous film of appropriate sealing compound by use of a
brush.
(6) Fay Seal or Faying Surface Seal - A seal barrier created by the sandwiching of sealant between
mating surfaces of structure. Special attention must be taken to avoid metal chips or dirt at the
faying surface.
(7) Fillet Seal - Sealant material applied at the seam, joint or fastener after the assembly has all
permanent fasteners installed and shall conform to the dimension in applicable figure.
(8) Hole - An opening that has no appreciable depth, such as a tool hole. Holes that penetrate the
seal plane must be metal filled with a fastener, gusset or patch.
(9) Injection Seal - Filling of channels by forcing sealant into a void or cavity after assembly.
(10) Integral Tank - Composition of structure and sealant material which forms a tank that is capable
of containing fuel without a bladder.
(11) Intermediate Seal - The second level of sealing. All holes, slots, joggles and seams in the seal
plane must be sealed. A minor amount of leakage is tolerable and permanent fasteners are not
required to be sealed.
(12) Post-Assembly Seal - A seal that is applied after the structure is assembled. (Fillet and injection
seals.)
(13) Preassembly Seal - Sealant material that must be applied during or prior to the assembly of the
structure. (Faying surface and pre-pack seals.)
(14) Pre-Pack Seal - A preassembly seal used to fill voids and cavities; can be a primary seal used
to provide seal continuity when used in conjunction with a fillet seal. It can be used as a backup
seal to support a fillet across a void. Fill the entire cavity to be prepacked. Usage as a primary
seal should be kept to a minimum.
(15) Primary Seal - Sealant material that prevents leakage and forms a continuous seal plane. This
seal is in direct contact with fuel, vapor, air, acid, etc. With few exceptions, it is in the form of a
fillet seal.
(16) Sealant - A compound applied to form a seal barrier.
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(17) Seal Plane - A surface composed of structure, sealant and fasteners on which the continuity of
seal is established.
(18) Shank Sealing - Sealant compound shall be applied to the hole or to both the shank and the
under head area of the fastener in sufficient quantity that the entire shank is coated and a small
continuous bead of sealant is extruded out around the complete periphery of each end of the
fastener when installed. The fastener shall be installed within the application time of the sealing
compound used.
(19) Squeeze-Out Life - Length of time sealant remains suitable for structure assembly in faying
surface seal application.
(20) Tack-Free Time - Tack-free time is a stage, during the cure of the sealant compound, after which
the sealant compound is no longer tacky. When the sealant compound is pressed firmly with the
knuckles, but no longer adheres to the knuckles, the sealant compound is tack-free.
4. Materials
A. Type of Sealants - Sealants are categorized by type of usage. Type I sealants are separated into
classes to differentiate the materials according to method of application. Dash numbers following
the class designation indicate the minimum application time (in hours) for Class A and Class B, and
minimum work life (in hours) for Class C. Refer to Table 201 for application time, curing rate, etc., for
Type I sealants.
(1) Type I - Fuel, pressure, and weather sealant.
(a) Class A - Sealant which is suitable for brush application.
(b) Class B - Sealant which is suitable for application by extrusion gun, spatula, etc.
(c) Class C - Sealant which is suitable in faying surface applications.
(d) Quick Repair Sealant - This material is for use only in making repairs when an extremely
rapid curing sealant is required. A possible application includes sealing a leaking fuel tank
on an airplane which must be dispatched within a few hours.
CAUTION: QUICK REPAIR SEALANT MUST BE APPLIED WITHIN ITS WORKING LIFE
OF 15 MINUTES. ATTEMPTS TO WORK QUICK REPAIR SEALANT BEYOND
WORKING LIFE WILL RESULT IN INCOMPLETE WETTING OF SURFACE AND
WILL RESULT IN A FAILED SEAL.
(2) Type VIII - Low Adhesion Access Door Sealant. This Class B sealant is designed for sealing
faying surfaces where easy separation of the joined surfaces is required. The sealant has low
adhesion and forms a gasket that molds itself to fill all irregularities between two surfaces.
The sealant is exceptionally resistant to fuels, greases, water, most solvents and oils including
hydraulic oil.
NOTE: Time periods presented below are based on a temperature of 77F (25°C) and 50
percent relative humidity. Any increase in either temperature or relative humidity may
shorten these time periods and accelerate the sealant cure.
Table 201. Curing Properties of Type I Sealant
CLASS APPLICATION WORK LIFE TACK-FREE CURING RATE

TIME (HOURS, (HOURS, TIME (HOURS, (HOURS,
MINIMUM) MINIMUM) MAXIMUM) MAXIMUM)
A-1/2 1/2 10 40
A-2 2 40 72
B-1/2 1/2 4 6
B-2 2 40 72
B-4 4 48 90
C-24 8 24 96 168 (7 days)
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Table 201. Curing Properties of Type I Sealant (continued)

C-48 12 48 120 336 (14 days)
C-80 8 80 120 504 (21 days)
5. General Requirements
A. When working with sealants observe the following requirements.
(1) Unmixed sealants shall not be more than two months old when received. These sealants shall
not be more than six months old when used.
(2) Unmixed sealants stored at temperatures exceeding 80°F (27°C) shall be used within five weeks.
(3) Sealants which have been premixed, degassed and flash frozen shall be maintained at -40°F
(-40°C) or lower and shall not be received more than two weeks beyond the date of mixing.
These sealants shall not be used more than six weeks after the date of mixing.
(4) Frozen sealant shall be thawed before being used. If sealant were applied at a temperature
below 60°F (15°C), it would not be sufficiently pliable for proper application and adhesion could
be critically reduced by condensation of moisture. On the other hand, although sealant must
extrude freely for proper application, it would be subject to excessive slumping if applied at a
temperature above 80°F (27°C). Frozen sealant may be thawed by any suitable means which
does not cause contamination or overheating of the sealant and does not shorten the application
time of the sealant to an impractical period. Examples: Thawing by exposure to ambient air
temperature, accelerated thawing by exposure in a constant temperature bath (using clean, hot
water), accelerated thawing in a microwave oven. In any case, thawing temperature and time
shall be adjusted to give a thawed sealant temperature between 60°F, and 80°F (15°C and 27C)
at the time the sealant is applied.
(5) Mixed, frozen sealants which have thawed shall not be refrozen.
(6) Complete preassembly operations, such as fitting, filing, drilling, countersinking, dimpling and
deburring, prior to cleaning and sealant application.
(7) Surfaces must be clean and dry, free from dust, lint, grease, chips, oil condensation or other
moisture and all other contaminating substances prior to the application of sealant.
(a) All exposed bonding primer or bonded assemblies which are to be sealed shall be cleaned
using Scotch Brite followed by solvent cleaning using Trichloroethane.
NOTE: Bond primer shall not be removed; just lightly scuffed with Scotch Brite.
(8) Sealant materials may be applied to unprimed or primed surfaces. Nonchromated or epoxy
primers shall have good adhesion to the substrate material and shall have aged at least 48
hours prior to sealant application. Adhesive bonding primer shall be scotchbrited and cleaned
before applying sealant.
(9) Sealants shall not be applied when the temperature of either the sealant or the structure is below
60°F (15°C).
(10) Sealant applied by the fillet or brush coat methods shall always be applied to the pressure side
of a joint if possible.
(11) After application, sealants shall be free of entrapped air bubbles and shall not exhibit poor
adhesion. All fillets shall be smoothed down and pressed into the seam or joint with a filleting
tool before the sealant application time has expired.
(12) Where fasteners have been shank or under head sealed, extruded sealant shall be evident
around the complete periphery of the fastener to indicate adequate sealing. Sealant extruded
through a hole by a rivet shall be wiped from the end of the rivet before bucking. Threaded
fasteners which have been shank or under head sealed shall not be retorqued after the expiration
of the application time of the sealant. Prior to torquing, sealant shall be removed from the
threads. In torquing, turn the nut rather than the bolt, if possible.
(13) Pressure testing shall not be accomplished until the sealant is cured.
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(14) Sealant shall not be applied over ink, pencil or wax pencil marks. If these materials extend into
the sealing area, they must be removed.
(15) If sealing is to be accomplished over primer and the primer is removed during the cleaning
process, it is permissible to seal directly over the cleaned area and then touch up the exposed
areas after the sealant has been applied and is tack free.
(16) Sealed structure shall not be handled or moved until sealant is tack free (sealant may be
dislodged or have the adhesion damaged). Excessive vibration of structure, such as riveting,
engine run up, etc. is not permitted.
(17) Drilling holes and installing fasteners through a fay sealed area shall be performed during the
working life of the faying sealant or the entire shank and area under fastener head shall be fay
sealed.
6. Sealant Curing
A. Room Temperature.
(1) Room temperature curing properties are based on a temperature of 77°F, +5 or -5°F (25°C, +3
or - 3°C) and a relative humidity of 50 percent unless otherwise indicated.
(2) Room temperature curing properties of Type I sealants are given in Table 201.
(3) Curing properties of Type VIII, Class B sealants are the same as for Type I, Class B. Adhesion
to aluminum should be (peel) less than two pounds per inch width (1.4 N per 10 mm width).
B. Accelerated Curing.
(1) Accelerated curing of sealant can be accomplished in several ways. The procedure to be used
is dependent on the type of sealant and other factors.
(2) The cure of Type I sealants can be accelerated by an increase in temperature and/or relative
humidity. Warm circulating air at a temperature not to exceed 140°F (60°C) may be used to
accelerate cure. Heat lamps may be used if the surface temperature of the sealant does not
exceed 140°F (60°C). At temperatures above 120°F (49°C), the relative humidity will normally be
so low (below 40 percent) that sealant curing will be retarded. If necessary, the relative humidity
may be increased by the use of water containing less than 100 parts per million total solids and
less than 10 parts per million chlorides.
7. Mixing of Sealants
A. Requirements.
(1) Sealants shall be mixed or thinned in accordance with the manufacturers recommendations and
thoroughly blended prior to application. All mixed sealant shall be as void free as possible.
(2) Prior to mixing, the sealing compound base and its curing agent, both in their respective original
unopened containers, shall be brought to a temperature between 75°F and 90°F (24°C and 32°C)
along with all required mixing equipment.
B. Sem-Kit Mixing. (Refer to Figure 201)
WARNING: THE CARTRIDGE SHOULD BE HELD FIRMLY, BUT MUST NOT BE

SQUEEZED, AS THE DASHER BLADES MAY PENETRATE THE CARTRIDGE
AND INJURE THE HAND.
(1) Pull dasher rod to the FULL OUT position so that the dasher is at the nozzle end of the cartridge.
(2) Insert ramrod in the center of the dasher rod against the piston and push the piston in
approximately one inch (25 mm).
NOTE: Extra force will be needed on the ramrod at the beginning of accelerator injection into
the base material.
(3) Move the dasher rod in approximately one inch (25 mm), then push piston in another inch (25
mm). Repeat this action until accelerator is distributed along the entire length of the cartridge.
NOTE: The accelerator has been fully injected into the cartridge when the ramrod is fully
inserted into the dasher rod.
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B2152
FOUR-BLADE
DASHER
DASHER ROD
RAMROD
NOTE: CARTRIDGE IS DISPOSABLE AFTER USE.
0580T1005
Two-Part Sealant Cartridge
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(4) Remove and properly discard the ramrod.

NOTE: Mixing the accelerator and base material can be accomplished manually, or as an
alternate method, with the use of a drill motor.
(5) Manual Mixing.

(a) Begin mixing operation by rotating the dasher rod in a clockwise direction while slowly
moving it to the FULL OUT position.
NOTE: Do not rotate the dasher rod counterclockwise; the four blade dasher inside the
cartridge will unscrew and separate from the dasher rod.
(b) Continue clockwise rotation and slowly move the dasher rod to the FULL IN position.
1 A minimum of five full clockwise revolutions must be made for each full out stroke and
for each full in stroke of the dasher rod. Approximately sixty strokes are necessary
for a complete mix.
NOTE: If streaks are present in the sealant (viewing through the side of the
cartridge), the sealant is not completely mixed.
(c) End mixing operation with the four blade dasher at the bottom of the cartridge.
(d) Hold cartridge upright; unscrew dasher rod from the four blade dasher by gripping the
cartridge at the four blade dasher and turn the dasher rod counterclockwise. Remove
dasher rod.
(e) Screw appropriate nozzle into the cartridge. If sealant gun is to be used, install cartridge
in gun.
(6) Drill motor mixing.
NOTE: A tapered rotary file or a 25/64 inch drill bit may be used with a drill motor to turn the
dasher rod.
(a) Insert the rotary file/drill bit into the dasher rod approximately 1/2 inch (13 mm).
WARNING: THE CARTRIDGE SHOULD BE HELD FIRMLY, BUT NOT SQUEEZED,
AS THE DASHER BLADES MAY PENETRATE THE CARTRIDGE AND
INJURE THE HAND.
(b) Verify the drill motor will rotate the dasher rod clockwise (looking toward the nozzle end of
the cartridge).
(c) With the cartridge held firmly in one hand and the drill motor in the other, rotate the dasher
rod at approximately 50 revolutions-per-minute while moving the dasher rod to FULL IN
and FULL OUT positions.
1 Mix sealant for at least 50 strokes (a stroke is one complete full in and full out stroke
of the dasher rod).
(d) End mixing operation with the four blade dasher at the bottom of the cartridge.
(e) Hold cartridge upright; remove drill motor and rotary file/drill bit from the dasher rod;
unscrew dasher rod from the four blade dasher by gripping the cartridge at the four blade
dasher and turn the dasher rod counterclockwise. Remove dasher rod.
(f) Screw appropriate nozzle into the cartridge. If sealant gun is to be used, install cartridge
in gun.
8. Cleaning
A. All surfaces to which sealant is to be applied shall be clean and dry.
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B. Remove all dust, lint, chips, shavings, etc. with a vacuum cleaner where necessary.
C. Cleaning shall be accomplished by scrubbing the surface with clean cheesecloth moistened with
solvent. The cloth shall not be saturated to the point where dripping will occur. For channels and
joggles, pipe cleaners and/or funnel brushes may be used instead of cheesecloth.
(1) The solvents to be used for the cleaning in the integral fuel tank are MIL-C-38736 or TT-M-261
for the first or preliminary cleaning. For the final cleaning, 0-T-620, 1, 1, 1 - Trichloroethane,
Technical, Inhibited only must be used.
D. The cleaning solvent should never be poured or sprayed on the structure.
E. The cleaning solvent shall be wiped from the surfaces before evaporation using a piece of clean, dry
cheesecloth in order that oils, grease, wax etc., will not be redeposited.
F. It is essential that only clean cheesecloth and clean solvent be used in the cleaning operations.
Solvents shall be kept in safety containers and shall be poured onto the cheesecloth. The cheesecloth
shall not be dipped into the solvent containers and contaminated solvents shall not be returned to the
clean solvent containers.
G. Final cleaning shall be accomplished immediately prior to sealant application by the person who is
going to apply the sealant.
(1) The area which is to be sealed shall be thoroughly cleaned. A small clean paint brush may
be needed to clean corners, gaps, etc. Always clean an area larger than the area where the
sealant is to be applied. Never clean an area larger than 30 inches (0.8 m) in length when
practical. When the area is being scrubbed with a moistened cloth in one hand, another clean
dry cloth shall be held in the other hand and shall be used to dry the structure. The solvent must
be wiped from the surfaces before it evaporates.
(2) The above procedure shall be repeated until there is no discoloration on the clean drying cloth.
Marks resulting from wax or grease pencils must be removed from parts prior to sealing.
H. Allow all cleaned surfaces to dry a minimum of 5 minutes before the application of sealant materials.
I. Sealant shall be applied as soon as possible after cleaning and drying the surfaces to be sealed.
Do not handle the parts between the cleaning and sealing operations. Sealant application personnel
handling cleaned surfaces shall wear clean white gloves to prevent surface contamination. In the
event contamination does occur, the surfaces shall be recleaned.
J. Safety precautions should be observed during the cleaning and sealing operation. Cleaning solvents
are toxic and flammable in most cases. Fresh air masks and/or adequate ventilation are required for
all closed areas. The structure shall be electrically grounded before starting any cleaning or sealing
operation.
9. Sealing Application
A. General.
(1) All new sealing shall be accomplished using the type of sealing material required for the area
being sealed. All sealant repairs shall be accomplished using the same type of sealing material
as that which is being repaired.
(2) Application time of the sealing compound shall be strictly observed. Material which becomes
too stiff and difficult to work or which does not wet the surface properly shall be discarded even
though the application time has not expired.
(3) For an illustration of the integral fuel bay and sealing techniques, refer to Figure 202.
(4) Prior to sealant application, all surfaces to be sealed shall be cleaned per paragraph 8 Cleaning.
B. Faying Surface Sealing - The application of a faying surface seal shall be made only when new
structure is being added to the airplane and requires a faying surface seal or when the structure
and/or parts have been disassembled for reasons other than a faulty seal. Fay sealed joints must
be closed and fastened before expiration of the work life given in Table 201. Excess sealant
must squeeze out of a fay sealed joint when attachment is made. Countersinking and reaming of
holes through a fay sealed joint is permissible when every other hole is held firm by temporary or
permanent holding fasteners. Spring loaded plunger type clecos are inadequate to create sufficient
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MAINTENANCE MANUAL
B2153
INSPECTION
COVER
(TYPICAL)
UPPER TRAILING
UPPER
SKIN
FUEL BAY
(LEFT SHOWN,
RIGHT OPPOSITE
TRAILING EDGE
LOWER
SKIN
0526T1010
0526T1009
0526T 1011
Integral Fuel Bay Sealing

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MAINTENANCE MANUAL
FAYING SURFACE SEAL
TYPICAL RIB
SECTION
FAY SEAL
SEALANT EXTRUDED
CONTINUOUSLY
55982007

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B2155
NOTE: THE EXAMPLES SHOW TYPICAL CROSS SECTIONS OF SEALING METHODS AND
TECHNIQUES USED IN THE FUEL BAY AREA. IN MOST CASES, WING SKIN AND RIB
THICKNESS COMBINED IS APPROXIMATELY 0.070 INCH (1.8 mm). MINIMUM SEALANT
APPLICATION AT ANY POINT SHOULD NOT BE LESS THAN 0.060 INCH (1.5 MM).

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INJECTION IS COMPLETE
WHEN SEALANT EMERGES
FROM THIS SIDE
0598T 1002

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pressure for sealant squeeze-out. Fabrication and changes done after sealing are not recommended
and shall be held to a minimum. Fasteners installed after the sealant has cured to replace temporary
fasteners shall be installed wet with sealing compound.
NOTE: Preassembly operations such as fitting, filing, drilling, dimpling and deburring shall be
completed prior to cleaning and sealing application.
(1) Immediately prior to final closure of the joint, sealant shall be applied to one mating surface of the
joint with a sealant gun, spatula, roller or other suitable tool. Sufficient sealant shall be applied
so that the space between the assembled faying surfaces is completely filled with sealant and a
small excess is squeezed out in a continuous bead around the periphery of the joint when the
joint is secured (refer to Figure 202, Sheet 2).
(2) Place parts in assembly position and install the fasteners within the application time of the faying
surface sealant. When assembly with permanent type fasteners is not feasible, temporary
fasteners (clecos or bolts) may be used, but when the temporary fasteners are used, they must
be replaced by permanent type fasteners prior to the expiration of the work life of the faying
surface sealant. Removal of each individual temporary fastener shall be followed immediately
by the installation of the permanent fastener.
(3) When a fillet seal is required around the periphery of a fay sealed joint, it is not necessary to
remove the sealant squeeze out where the fillet is to be applied, provided that the material which
was squeezed out has been shaped into a small fillet configuration prior to the expiration of the
application time. When the squeeze-out has been shaped, a final or full bodied seal can be
applied over the shaped squeeze-out without waiting for the squeeze-out to cure. If the squeezed
out material was not shaped before the expiration of its application time, it shall be cured to a
tack-free condition and then removed, by use of a plastic tool, from locations where a fillet is to
be applied.
(4) Immediately after the assembly is completed and all permanent type fasteners have been
installed, remove uncured sealant which extrudes onto the exterior of the airplane using clean
rags moistened with TT-T-548, Toluene or Methyl Propyl Ketone.
C. Injection Sealing.
(1) Sealant shall be injected into the channel, joggle, void or cavity from one point only, using a
sealant gun, in such a manner that no air is entrapped and the channel, joggle, void or cavity is
completely filled and sealant is observed emerging from the prescribed opening (refer to Figure
202, Sheet 4). If multiple exits or channels exist, block each channel exit after it is filled, without
stopping the injection, so that sealant extrudes into all necessary channels.
(2) Remove excess sealant before the expiration of its application time and smooth flush with the
surface using a suitable tool.
D. Fillet Sealing.
(1) Fastener considerations:
(a) Do not fillet seal any parts until they are held completely together by permanent fasteners.
(b) Prior to filleting the periphery of bolted structure and fittings, it is necessary that all bolts,
accomplishing the attachment, be properly torqued.
(2) The sealant shall be applied using a sealant gun or spatula.
(3) When using a sealant gun for fillet sealing, the nozzle tip shall be pointed into the seam or joint
and shall be maintained nearly perpendicular to the line of travel. A continuous bead of sealant
shall precede the tip and the tip size, shape and rate of travel shall be such that sufficient sealant
shall be applied to produce the required fillet.
(4) Fillets shall be shaped or formed to meet the size and shape requirements as shown in applicable
figures using the nozzle tip and/or fairing tools to press against the sealant while moving parallel
to the bead. Exercise caution to prevent folds and entrapment of air during application and
shaping of the fillet and work out any visible air bubbles. The fillet shall be formed so that the
highest portion of the fillet is centered over the edge of the structure or fitting. Lubrication in
any form shall not be used for smoothing purposes. In all cases, fillet size shall be kept as near
minimum as practical.
(5) Where it is more convenient or fillet slumping is encountered, the fillet may be applied in two
stages. A small first fillet should be applied which is allowed to cure to a tack-free state, followed
by a second application of sealant sufficient to form the final fillet conforming to the specified
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MODEL 172
MAINTENANCE MANUAL
dimensions for a fillet seal. If the first fillet has cured, it must be cleaned before the second
application of sealant is made. If the fillet has only cured to a tack-free state, it shall be wiped
lightly with a gauze pad or cheesecloth pad dampened with cleaning solvent.
(6) Allow the sealant to cure to a tack-free condition prior to the airplane being moved, handled
and/or worked on.
(7) In cases where a fillet seal connects to an injection seal, the full bodied fillet shall extend past
the end of the injection and then taper out.
(8) Lap joint and seam fillets shall be as shown in Figure 202, Sheet 3 .
(9) Butt joint fillets shall be as shown in Figure 202, Sheet 3.
(10) Bolts shall be fillet sealed as shown in Figure 202, Sheet 3. The area for sealing shall consist of
the area of the structure surrounding the base of the fastener end plus the entire exposed area
of the fastener. An optional method of sealing threaded fasteners is to apply a brush coat of Type
I, Class A sealant. Where brush coating is used as the method of sealing threaded fasteners,
the sealant must be worked around each fastener with a stiff brush and considerable care to be
effective. A simple pass of the brush with the sealant is not sufficient to produce an effective
seal.
(11) Dome type nutplates shall be fillet sealed as shown in Figure 202, Sheet 3. The area for sealing
shall consist of the area of the structure surrounding the base of the fastener and from there up
over the rivets to the dome.
(12) Hole filling and slot fillets shall be as shown in Figure 202, Sheet 3.
(a) Tooling holes shall be plugged with a shank sealed soft rivet and then brush coated with
Type I, Class A sealant.
10. Sealant Repair
A. Materials - Repairs, in general, shall be accomplished with the same type of material as that being
repaired.
NOTE: Type I, Class B-1/2 is recommended for use during cold weather to obtain an accelerated
cure.
NOTE: Type I, Quick Repair sealant may be used as a repair for sealant in fuel tanks if desired for
fast cure and rapid dispatch.
B. Temperature Requirements.
(1) The structure shall be above 60°F (15°C) before the sealant is applied and shall remain above
60°F (15°C) until the sealant is tack-free.
NOTE: For outside operations only, the temperature of the structure may be allowed to drop
below 60°F (15°C) but not below 58°F (14°C), after application for a period of time
not to exceed 48 hours; however, the structure must be subsequently heated to
above 60°F (15°C) and the sealant allowed to become tack-free before the tanks are
refueled.
(2) The maximum air temperature allowed to come in contact with the curing sealant is 120°F (49°C).
C. Fillet and Fastener Sealing Repairs.
(1) Repair of damaged or faulty sealant applications shall be accomplished as follows:
(a) Remove all damaged or faulty sealant to ensure solid residual material.
(b) Sealant shall be cut to produce a smooth continuous scarfed face. The sealant shall be
completely removed in the affected areas. The cutting tools should only be made from
nonmetallic materials that are softer than aluminum.
(c) Inspect repair areas for clean and smooth cuts. Loose chunks or flaps of sealant on the
cut areas shall be removed.
(d) Clean the area to be sealed, including the scarfed face of the old seal, per paragraph ,8
Cleaning.
(e) Apply new fillet seals. Slight overlapping of the fresh material over the existing fillet is
permissible. A large buildup of sealant shall not be allowed.
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(f) Rework of a fillet which has been oversprayed or brushed with primer shall be accomplished
by a scarfed joint and removal of the fillet having primer on it, in the area of the repair. The
primer shall not be sandwiched between the old and new sealants.
(g) If the primer is removed during the cleaning operation, it is permissible to apply the new
fillet seal directly over the clean bare metal and then touch up with the proper primer all
exposed areas of bare metal after the sealant has been applied.
D. Faying Surface Sealing Repair - After determining the area which contains the faulty and/or leaking
faying surface seal, the repair shall be accomplished by applying a fillet seal along the edge of the
part adjacent to the faying surface seal long enough to fully cover the area of the faulty and/or leaking
seal.
E. Brush Coat Sealing Repair - Repair of damaged or leaking brush coat seals shall be accomplished by
removing the discrepant brush coat. Clean the area of sealant removal and the surrounding structure
and sealant per paragraph 8, Cleaning. Apply a new brush coat of sealant.
F. Integral Fuel Tank Sealing Using PR-1826 Class B Rapid Curing Sealant.
(1) Remove damaged section of sealant with a sharp plexiglass scraper. Taper all cuts in old sealant
at 45-degree angles.
(2) Thoroughly clean with solvent and abrade old areas which are to be over coated. Clean one
small area at a time, then dry with a clean cloth before the solvent evaporates.
NOTE: Always pour solvent on the cloth to maintain a clean solvent supply.
NOTE: In fuel tanks which have been in operation, the sealant will be soaked and should be
dried in area of the repair with a vapor proof heat lamp or hot air blower before new
sealant is applied.
(3) After the surface has been cleaned and dried, apply a heavy layer of PR- 1826 Adhesion
Promoter with a clean brush or gauze pad. Allow adhesion promoter a minimum of 30 minutes
to dry.
NOTE: Care must be taken to obtain a uniform thin coat of adhesion promoter. Thin enough
to cover the surface, but not heavy enough to run.
(4) Mix PR-1826 Class B sealant according to instructions supplied with the material.
(5) Apply PR-1826 Class B sealant, 0.125 to 0.375 inch (3.2 to 9.5 mm) thick, to the repair area
with a spatula or paddle shaped tool. Firmly press sealant in place and form to desired shape.
Overlap PR-1826 Class B sealant over old sealant from 0.125 to 0.25 inch (3.2 to 6.4 mm).
NOTE: Sealant may be applied up to 8 hours after the application of adhesion promoter. After
8 hours, the surface should be recleaned and adhesion promoter reapplied.
(6) Allow sealant to cure a minimum of 2 hours at 77°F (25°C) before refueling. Curing time is based
solely on temperature and will be halved for every 18°F (10°C) increase, and doubled for every
18°F (10°C) decrease from the standard 77°F (25°C).
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CONVERSION DATA - DESCRIPTION AND OPERATION

1. General
A. This section contains information converting the more commonly used measuring units found in this
manual from the North American system to the metric system.
B. Tables have been prepared for the convenience of the user. In addition, formulas, examples and a
table of conversion factors are included for individual computations.
2. Formulas for Conversion Computations
A. Work and Energy.
(1) Mechanical Energy Formula - Refer to conversion factors in Figure 1 to convert inch-pounds and
foot-pounds into metric measure of centimeter kilograms and meter kilograms.
(2) Figure 2 is a table containing conversion data for converting inch-pounds to centimeter kilograms,
centimeter kilograms to inch-pounds, foot-pounds to meter kilograms, meter kilograms to foot-
pounds.
B. Distance and Length.
(1) Formula - One multiplied by 2.540 = centimeter; inch = 2.54 cm. One multiplied by 25.40 =
millimeter; inch = 25.40 mm.
NOTE: Reference conversion factors in Figure 1.
(2) Figure 3 is a table containing conversion data for converting inches to millimeters. Procedure
for converting inches to millimeters by using figure as follows: Example, convert 0.032 inches to
millimeters.
(a) Read down inch column to 0.003.
(b) Read across top inch column to 0.0002.
(c) Locate where these two columns intersect (0.0032 inch is 0.0812 millimeters).
(3) Figure 4 is a table containing conversion data for converting fraction of an inch to decimal
equivalent and to millimeter. Locate fraction of an inch figure and move to the right horizontally
to locate decimal equivalent figure in the decimal equivalent column and millimeter numeral
in the millimeter column.
C. Temperature.
(1) Formula: °F = 9/5 (°C +32) °C = 5/9 (°F -32)
(2) Figure 5 is a table containing conversion data for converting temperature from either Celsius to
Fahrenheit or Fahrenheit to Celsius.
(a) Select the desired number in the middle column of the three column presentation, if the
number you selected is in degrees Celsius, read degrees Fahrenheit equivalent in right
column of the three-column presentation.
(b) Select the desired number in the middle column of the three-column presentation. If the
number selected is in degrees Fahrenheit, read degrees Celsius equivalent in the left
column of the three-column presentation.
D. Drill Sizes and Tap Sizes.
(1) Figure 6 is a table containing conversion data for converting standard and millimeter drill sizes to
decimal equivalents. Also included is a chart for determining tap size when a hole ID is known.
(a) To find decimal equivalent of a standard drill size, go down the chart to the standard drill
size and read decimal equivalent in the right column.
(b) To find standard drill size for a known decimal equivalent size, go down decimal column to
decimal size and read drill size in the left column.
(c) To find decimal equivalent of a millimeter drill size, go down the chart to the millimeter drill
size and read decimal equivalent in the right column.
(d) To find millimeter drill size for a known decimal equivalent size, go down the chart to the
decimal equivalent size and read millimeter drill size in the left column.
(e) To find a tap size, go down the hole ID chart to the size hole to be tapped and read the tap
size in the left column.
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MAINTENANCE MANUAL
MULTIPLY BY TO OBTAIN
CENTIMETERS 0.3937 INCHES

0.03281 FEET
CUBIC 0.001 LITERS
CENTIMETERS 0.06102 CUBIC INCHES
0.0002642 U.S. GALLONS
CUBIC FEET 28,320 CUBIC CENTIMETERS
1,728 CUBIC INCHES
7.481 U.S. GALLONS
28.32 LITERS
CUBIC INCHES 16.39 CUBIC CENTIMETERS
0.01639 LITERS
0.004329 U.S. GALLONS
0.01732 QUARTS
CUBIC 1,000,000 CUBIC CENTIMETERS
METERS 35.31 CUBIC FEET
61,023 CUBIC INCHES
264.2 GALLON
999.97 LITERS
FEET 0.3048 METERS
12,000 MILS
304.8 MILLIMETERS
0.3333 YARDS
FOOT-POUNDS 0.1383 METER-KILOGRAMS
0.001285 BRITISH THERMO UNIT
0.000000376 KILOWATTS PER HOUR
FLUID OUNCE 8 DRAM
29.6 CUBIC CENTIMETERS
GALLON, 277.4 CUBIC INCHES
IMPERIAL 1.201 U.S. GALLON
4.546 LITERS
U.S. DRY 0.1556 CUBIC FEET
1.164 U.S. GALLON, LIQUID
4.405 LITERS
U.S. LIQUID 0.1337 CUBIC FEET
3.785 LITERS
0.8327 IMPERIAL GALLON
128 FLUID OUNCES
INCHES 2.540 CENTIMETERS
.08333 FEET
Conversion Factors
Figure 1 (Sheet 1)
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MAINTENANCE MANUAL
MULTIPLY BY TO OBTAIN
JOULES 0.000948 BRITISH THERMO UNIT

0.7376 FOOT-POUNDS
KILOGRAMS 2.205 POUNDS
35.27 OUNCES
1000 GRAMS
LITERS 1000 CUBIC CENTIMETERS
61.03 CUBIC INCHES
0.03532 CUBIC FEET
0.2642 U.S. GALLON
0.22 IMPERIAL GALLON
1.057 QUARTS
METERS 39.37 INCHES
3.281 FEET
1000 MILLIMETERS
METER-KILOGRAM 7.233 FOOT-POUNDS
9.807 JOULES
OUNCES, 0.0625 POUND, AVOIRDUPOIS
AVOIRDUPOIS 28.35 GRAMS
437.5 GRAINS
OUNCES, FLUID 29.57 CUBIC CENTIMETERS
1.805 CUBIC INCHES
POUND, 453.6 GRAMS
AVOIRDUPOIS 7000 GRAINS
16.0 OUNCES
SQUARE INCH 6.4516 SQUARE CENTIMETERS
POUND PER 0.0703 KILOGRAM-CENTIMETER
SQUARE INCH SQUARED
(PSI)
STATUTE MILE 1.609 KILOMETER
0.0684 NAUTICAL MILE
NAUTICAL MILE 1.151 STATUTE MILE
QUART 0.9463 LITER
MILLIMETER 1000 MICRON
MICRON 0.001 MILLIMETER
0.00003937 INCH
INCH POUNDS 11.521 METER GRAMS
INCH OUNCES 0.72 METER GRAMS
Conversion Factors
Figure 1 (Sheet 2)
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MAINTENANCE MANUAL
INCH-POUNDS TO CENTIMETER-KILOGRAMS
INCH- CENTIMETER- INCH- CENTIMETER- INCH- CENTIMETER-
POUNDS KILOGRAMS POUNDS KILOGRAMS POUNDS KILOGRAMS
5 5.76 45 51.84 85 97.82
10 11.52 50 57.60 90 103.68
15 17.28 55 63.36 95 109.44
20 23.04 60 69.12 100 115.20
25 28.80 65 74.88 105 120.96
30 34.56 70 80.64 110 126.72
35 40.32 75 86.40 115 132.48
40 46.08 80 92.16 120 138.24
CENTIMETER-KILOGRAMS TO INCH-POUNDS
CENTIMETER- INCH- CENTIMETER- INCH- CENTIMETER- INCH-
KILOGRAMS POUNDS KILOGRAMS POUNDS KILOGRAMS POUNDS
50 43.4 300 260.4 550 477.4
100 86.8 350 303.8 600 520.8
150 130.2 400 347.2 650 564.2
200 173.6 450 390.6 700 607.6
250 217.0 500 434.0
FOOT-POUNDS TO METER-KILOGRAMS
FOOT- METER- FOOT- METER- FOOT- METER-
POUNDS KILOGRAMS POUNDS KILOGRAMS POUNDS KILOGRAMS
2.5 .346 67.5 9.332 165 22.813
5.0 .691 70.0 9.678 170 23.504
7.5 1.037 72.5 10.024 175 24.195
10.0 1.383 75.0 10.369 180 24.887
12.5 1.728 77.5 10.715 185 25.578
15.0 2.074 80.0 11.060 190 26.269
17.5 2.419 82.5 11.406 195 26.960
20.0 2.765 85.0 11.752 200 27.652
22.5 3.111 87.5 12.097 205 28.343
25.0 3.456 90.0 12.443 210 29.034
27.5 3.802 92.5 12.789 215 29.726
30.0 4.148 95.0 13.134 220 30.417
32.5 4.493 97.5 13.480 225 31.108
35.0 4.839 100.0 13.826 230 31.800
37.5 5.185 102.5 14.517 235 32.491
40.0 5.530 105.0 15.208 240 33.182
42.5 5.876 110.0 15.900 245 33.873
45.0 6.222 120.0 16.591 250 34.565
47.5 6.567 125.0 17.282 255 35.256
50.0 6.913 130.0 17.974 260 35.947
52.5 7.258 135.0 18.665 265 36.639
55.0 7.604 140.0 19.356 270 37.330
57.5 7.950 145.0 20.047 275 38.021
60.0 8.285 150.0 20.739 280 38.713
62.5 8.641 155.0 21.430 285 39.404
65.0 8.987 160.0 22.121 290 40.095
295 40.786
300 41.478
Torque Conversion Chart

Figure 2 (Sheet 1)
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METER-KILOGRAMS TO FOOT-POUNDS
METER- FOOT- METER- FOOT- METER- FOOT-
KILOGRAMS POUNDS KILOGRAMS POUNDS KILOGRAMS POUNDS
1 7.23 8 57.86 15 108.49
2 14.46 9 65.89 16 115.72
3 21.69 10 72.32 17 122.95
4 28.93 11 79.56 18 130.19
5 36.16 12 86.79 19 137.42
6 43.39 13 94.02 20 144.65
7 50.63 14 101.26 21 151.89
22 159.12
Torque Conversion Chart

Figure 2 (Sheet 2)
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INCHES- 0.0000 0.0001 0.0002 0.0003 0.0004 0.0005 0.0006 0.0007 0.0008 0.0009
MILLIMETER
0.000 0.0025 0.0050 0.0076 0.0101 0.0127 0.0152 0.0177 0.0203 0.0228
0.001 0.0254 0.0279 0.0304 0.0330 0.0355 0.0381 0.0406 0.0431 0.0457 0.0482
0.002 0.0508 0.0533 0.0558 0.0584 0.0609 0.0635 0.0660 0.0685 0.0711 0.0736
0.003 0.0762 0.0787 0.0812 0.0838 0.0863 0.0889 0.0914 0.0939 0.0965 0.0990
0.004 0.1016 0.1041 0.1066 0.1092 0.1117 0.1143 0.1168 0.1193 0.1219 0.1244
0.005 0.1270 0.1295 0.1320 0.1346 0.1371 0.1397 0.1422 0.1447 0.1473 0.1498
0.006 0.1524 0.1549 0.1574 0.1600 0.1625 0.1651 0.1676 0.1701 0.1727 0.1752
0.007 0.1778 0.1803 0.1828 0.1854 0.1879 0.1905 0.1930 0.1955 0.1981 0.2006
0.008 0.2032 0.2057 0.2082 0.2108 0.2133 0.2159 0.2184 0.2209 0.2235 0.2260
0.009 0.2286 0.2311 0.2336 0.2362 0.2387 0.2413 0.2438 0.2463 0.2489 0.2514
INCHES- 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
MILLIMETER
0.00 0.025 0.050 0.076 0.101 0.127 0.152 0.177 0.203 0.228
0.01 0.254 0.279 0.304 0.330 0.355 0.381 0.406 0.431 0.457 0.482
0.02 0.508 0.533 0.558 0.584 0.609 0.635 0.660 0.685 0.711 0.736
0.03 0.762 0.787 0.812 0.838 0.863 0.889 0.914 0.939 0.965 0.990
0.04 1.016 1.041 1.066 1.092 1.117 1.143 1.168 1.193 1.219 1.244
0.05 1.270 1.295 1.320 1.346 1.371 1.397 1.422 1.447 1.473 1.498
0.06 1.524 1.549 1.574 1.600 1.625 1.651 1.676 1.701 1.727 1.752
0.07 1.778 1.803 1.828 1.854 1.879 1.905 1.930 1.955 1.981 2.006
0.08 2.032 2.057 2.082 2.108 2.133 2.159 2.184 2.209 2.235 2.260
0.09 2.286 2.311 2.336 2.362 2.387 2.413 2.438 2.463 2.489 2.514
Inches to Millimeter (0.0001 to 10 inches)

Figure 3 (Sheet 1)
20-50-00 Page 6
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INCHES - 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
MILLIMETER
0.0 0.254 0.508 0.762 0.016 1.270 1.524 1.778 2.032 2.286
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 5.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
INCHES- 0.00 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
MILLIMETER
0 2.54 5.08 7.62 10.16 12.70 15.24 17.78 20.32 22.86

1 25.40 27.94 30.48 33.02 35.56 38.10 40.64 43.18 45.72 48.26
2 50.80 53.34 55.88 58.42 60.96 63.50 66.04 68.58 71.12 73.66
3 76.20 78.74 81.28 83.82 86.36 88.90 91.44 93.98 96.52 99.06
4 101.60 104.14 106.68 109.22 111.76 114.30 116.84 119.38 121.92 124.46
5 127.00 129.54 132.08 134.62 137.16 139.70 142.24 144.78 147.32 149.86
6 152.40 154.94 157.48 160.02 162.56 165.10 167.64 170.18 172.72 175.26
7 177.80 180.34 182.88 185.42 187.96 190.50 193.04 195.58 198.12 200.66
8 203.20 205.74 208.28 210.82 213.36 215.90 218.44 220.98 223.52 226.06
9 228.60 231.14 233.68 236.22 238.76 241.30 243.84 246.38 248.92 251.46
Inches to Millimeter (0.0001 to 10 inches)

Figure 3 (Sheet 2)
20-50-00 Page 7
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DECIMAL MILLI- DECIMAL MILLI-

FRACTION EQUIV. METER FRACTION EQUIV. METER
1/64 0.015 0.396 33/64 0.515 13.096
1/32 0.031 0.793 17/32 0.531 13.493
3/64 0.046 1.190 35/64 0.546 13.890
1/16 0.062 1.587 9/16 0.562 14.287
5/64 0.078 1.984 37/64 0.578 14.684

3/32 0.093 2.381 19/32 0.593 15.081
7/64 0.109 2.778 39/64 0.609 15.478
1/8 0.125 3.175 5/8 0.625 15.875
9/64 0.140 3.571 41/64 0.640 16.271

5/32 0.156 3.968 21/32 0.656 16.668
11/64 0.171 4.365 43/64 0.671 17.065
3/16 0.187 4.752 11/16 0.687 17.462
13/64 0.203 5.159 45/64 0.703 17.859

7/32 0.218 5.556 23/32 0.718 18.256
15/64 0.234 5.953 47/64 0.734 18.653
1/4 0.250 6.350 3/4 0.750 19.050
17/64 0.265 6.746 49/64 0.765 19.446

9/32 0.281 7.143 25/32 0.781 19.843
19/64 0.296 7.540 51/64 0.796 20.240
5/16 0.312 7.937 13/16 0.812 20.637
21/64 0.328 8.334 53/64 0.828 21.034

11/32 0.343 8.731 27/32 0.843 21.431
23/64 0.359 9.128 55/64 0.859 21.828
3/8 0.375 9.525 7/8 0.875 22.225
25/64 0.390 9.921 57/64 0.890 22.621

13/32 0.406 10.318 29/32 0.906 23.018
27/64 0.421 10.715 59/64 0.921 23.415
7/16 0.437 11.112 15/16 0.937 23.812
29/64 0.453 11.509 61/64 0.953 24.209

15/32 0.468 11.906 31/32 0.968 24.606
31/64 0.484 12.303 63/64 0.984 25.003
1/2 0.500 12.700 1 1.000 25.400
Fraction to Decimal to Millimeter Conversion
Figure 4 (Sheet 1)
20-50-00 Page 8
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
READ KNOWN
READ LEFT COLUMN TEMPERATURE IN THIS READ RIGHT COLUMN
TO CONVERT TO COLUMN (FAHRENHEIT TO CONVERT TO
CELSIUS OR CELSIUS) FAHRENHEIT
C F C F C F C F
-73.3 -100 -148.0 -51.1 -60 -76.0 -28.9 -20 -4.0 -6.7 20 68.0
-72.8 -99 -146.2 -50.6 -59 -74.2 -28.3 -19 -2.2 -6.1 21 69.8
-72.2 -98 -144.4 -50.0 -58 -72.4 -27.8 -18 -0.4 -5.6 22 71.6
-71.7 -97 -142.6 -49.4 -57 -70.6 -27.2 -17 1.4 -5.0 23 73.4
-71.1 -96 -140.8 -48.9 -56 -68.8 -26.7 -16 3.2 -4.4 24 75.2
-70.6 -95 -139.0 -48.3 -55 -67.0 -26.1 -15 5.0 -3.9 25 77.0
-70.0 -94 -137.2 -47.8 -54 -65.2 -25.6 -14 6.8 -3.3 26 78.8
-69.4 -93 -135.4 -47.2 -53 -63.4 -25.0 -13 8.6 -2.8 27 80.6
-68.9 -92 -133.6 -46.7 -52 -61.6 -24.4 -12 10.4 -2.2 28 82.4
-68.3 -91 -131.8 -46.1 -51 -59.8 -23.9 -11 12.2 -1.7 29 84.2
-67.8 -90 -130.0 -45.6 -50 -58.0 -23.3 -10 14.0 -1.1 30 86.0
-67.2 -89 -128.2 -45.0 -49 -56.2 -22.8 -9 15.8 -0.6 31 87.8
-66.7 -88 -126.2 -44.4 -48 -54.4 -22.2 -8 17.6 0.0 32 89.6
-66.1 -87 -124.6 -43.9 -47 -52.6 -21.7 -7 19.4 0.6 33 91.4
-65.6 -86 -122.8 -43.5 -46 -50.8 -21.1 -6 21.2 1.1 34 93.2
-65.0 -85 -121.0 -42.8 -45 -49.0 -20.6 -5 23.0 1.7 35 95.0
-64.4 -84 -119.2 -42.2 -44 -47.2 -20.0 -4 24.8 2.2 36 96.8
-63.9 -83 -117.4 -41.7 -43 -45.4 -19.4 -3 26.6 2.8 37 98.6
-63.3 -82 -115.6 -41.1 -42 -43.6 -18.9 -2 28.4 3.3 38 100.4
-62.8 -81 -113.8 -40.6 -41 -41.8 -18.3 -1 30.2 3.9 39 102.2
-62.2 -80 -112.0 -40.0 -40 -40.0 -17.8 0 32.0 4.4 40 104.0
-61.7 -79 -110.2 -39.4 -39 -38.2 -17.2 1 33.8 5.0 41 105.8
-61.1 -78 -108.4 -38.9 -38 -36.4 -16.7 2 35.6 5.6 42 107.6
-60.6 -77 -106.6 -38.3 -37 -34.6 -16.1 3 37.4 6.1 43 109.4
-60.0 -76 -104.8 -37.8 -36 -32.8 -15.6 4 39.2 6.7 44 111.2
-59.4 -75 -103.0 -37.2 -35 -31.0 -15.0 5 41.0 7.2 45 113.0
-58.9 -74 -101.2 -36.7 -34 -29.0 -14.4 6 42.8 7.8 46 114.8
-58.3 -73 -99.4 -36.1 -33 -27.4 -13.9 7 44.6 8.3 47 116.6
-57.8 -72 -97.6 -35.6 -32 -25.6 -13.3 8 46.4 8.9 48 118.4
-57.2 -71 -95.8 -35.0 -31 -23.8 -12.8 9 48.2 9.4 49 120.2
56.7 -70 -94.0 -34.4 -30 -22.0 -12.2 10 50.0 10.0 50 122.0
-56.1 -69 -92.2 -33.9 -29 -20.2 -11.7 11 51.8 10.6 51 123.8
-55.6 -68 -90.4 -33.3 -28 -18.4 -11.1 12 53.6 11.1 52 125.6
-55.0 -67 -88.6 -32.8 -27 -16.6 -10.6 13 55.4 11.7 53 127.4
-54.4 -66 -86.8 -32.2 -26 -14.8 -10.0 14 57.2 12.2 54 129.2
-53.9 -65 -85.0 -31.7 -25 -13.0 -9.4 15 59.0 12.8 55 131.0
-53.3 -64 -83.2 -31.1 -24 -11.2 -8.9 16 60.8 13.3 56 132.8
-52.8 -63 -81.4 -30.6 -23 -9.4 -8.3 17 62.6 13.9 57 134.6
-52.2 -62 -79.6 -30.0 -22 -7.6 -7.8 18 64.4 14.4 58 136.4
-51.7 -61 -77.8 -29.4 -21 -5.8 -7.2 19 66.2 15.0 59 138.2
Fahrenheit and Celsius (Centigrade) Temperature Conversion

Figure 5 (Sheet 1)
20-50-00 Page 9
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
C F C F C F C F
15.6 60 140.0 37.8 100 212.0 60.0 140 284.0 82.2 180 356.0
16.1 61 141.8 38.3 101 213.8 60.6 141 285.8 82.8 181 357.8
16.7 62 143.6 38.9 102 215.6 61.1 142 287.6 83.3 182 359.6
17.2 63 145.4 39.4 103 217.4 61.7 143 289.4 83.9 183 361.4
17.8 64 147.2 40.0 104 219.2 62.2 144 291.2 84.4 184 363.2
18.3 65 149.0 40.6 105 221.0 62.8 145 293.0 85.0 185 365.0
18.9 66 150.8 41.1 106 222.8 63.3 146 294.8 85.6 186 366.8
19.4 67 152.6 41.7 107 224.6 63.9 147 296.6 86.1 187 368.6
20.0 68 154.4 42.2 108 226.4 64.4 148 298.4 86.7 188 370.4
20.6 69 156.2 42.8 109 228.2 65.0 149 300.2 87.2 189 372.2
21.1 70 158.0 43.3 110 230.0 65.6 150 302.0 87.8 190 374.0
21.7 71 159.8 43.9 111 231.8 66.1 151 303.8 88.3 191 375.8
22.2 72 161.6 44.4 112 233.6 66.7 152 305.6 88.9 192 377.6
22.8 73 163.4 45.0 113 235.4 67.2 153 307.4 89.4 193 379.4
23.3 74 165.2 45.6 114 237.2 67.8 154 309.2 90.0 194 381.2
23.9 75 167.0 46.1 115 239.0 68.3 155 311.0 90.6 195 383.0
24.4 76 168.8 46.7 116 240.8 68.9 156 312.8 91.1 196 384.8
25.0 77 170.6 47.2 117 242.6 69.4 157 314.6 91.7 197 386.6
25.6 78 172.4 47.8 118 244.4 70.0 158 316.4 92.2 198 388.4
26.1 79 174.2 48.3 119 246.2 70.6 159 318.2 92.8 199 390.2
26.7 80 176.0 48.9 120 248.0 71.1 160 320.0 93.3 200 392.0
27.2 81 177.8 49.4 121 249.8 71.7 161 321.8 93.9 201 393.8
27.8 82 179.6 50.0 122 251.6 72.2 162 323.6 94.4 202 395.6
28.3 83 181.4 50.6 123 253.4 72.8 163 325.3 95.0 203 397.4
28.9 84 183.2 51.1 124 255.2 73.3 164 327.2 95.6 204 399.2
29.4 85 185.0 51.7 125 257.0 73.9 165 329.0 96.1 205 401.0
30.0 86 186.8 52.2 126 258.8 74.4 166 330.8 96.7 206 402.8
30.6 87 188.6 52.8 127 260.6 75.0 167 332.6 97.2 207 404.6
31.1 88 190.4 53.3 128 262.4 75.6 168 334.4 97.8 208 406.4
31.7 89 192.2 53.9 129 264.2 76.1 169 336.2 98.3 209 408.2
32.2 90 194.0 54.4 130 266.0 76.7 170 338.0 98.9 210 410.0
32.8 91 195.8 55.0 131 267.8 77.2 171 339.8 99.4 211 411.8
33.3 92 197.6 55.6 132 269.6 77.8 172 341.6 100.0 212 413.6
33.9 93 199.4 56.1 133 271.4 78.3 173 343.4 100.6 213 415.4
34.4 94 201.2 56.7 134 273.2 78.9 174 345.2 101.1 214 417.2
35.0 95 203.0 57.2 135 275.0 79.4 175 347.0 101.7 215 419.0
35.6 96 204.8 57.8 136 276.8 80.0 176 348.8 102.2 216 420.8
36.1 97 206.6 58.3 137 278.6 80.6 177 350.6 102.8 217 422.6
36.7 98 208.4 58.9 138 280.4 81.1 178 352.4 103.3 218 424.4
37.2 99 210.2 59.4 139 282.2 81.7 179 354.2 103.9 219 426.2

Figure 5 (Sheet 2)
20-50-00 Page 10
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
C F C F C F C F
104.4 220 428.0 148.9 300 572.0 260.0 500 932.0 371.1 700 1292.0
105.0 221 429.8 151.7 305 581.0 262.8 505 941.0 373.9 705 1301.0
105.6 222 431.6 154.4 310 590.0 265.6 510 950.0 376.7 710 1310.0
106.1 223 433.4 157.2 315 599.0 268.3 515 959.0 379.4 715 1319.0
106.7 224 435.2 160.0 320 608.0 271.1 520 968.0 382.2 720 1328.0
107.2 225 437.0 162.8 325 617.0 273.9 525 977.0 385.0 725 1337.0
107.8 226 438.8 165.6 330 626.0 276.7 530 986.0 387.8 730 1346.0
108.3 227 440.6 168.3 335 635.0 279.4 535 995.0 390.6 735 1355.0
108.9 228 442.4 171.1 340 644.0 282.2 540 1004.0 393.3 740 1364.0
109.4 229 444.2 173.9 345 653.0 285.0 545 1013.0 396.1 745 1373.0
110.0 230 446.0 176.7 350 662.0 287.8 550 1022.0 398.9 750 1382.0
110.6 231 447.8 179.4 355 671.0 290.6 555 1031.0 401.7 755 1391.0
111.1 232 449.6 182.2 360 680.0 293.3 560 1040.0 404.4 760 1400.0
111.7 233 451.4 185.0 365 689.0 296.1 565 1049.0 407.2 765 1409.0
112.2 234 453.2 187.8 370 698.0 298.9 570 1058.0 410.0 770 1418.0
112.8 235 455.0 190.6 375 707.0 301.7 575 1067.0 412.8 775 1427.0
113.3 236 456.8 193.3 380 716.0 304.4 580 1076.0 415.6 780 1436.0
113.9 237 458.6 196.1 385 725.0 307.2 585 1085.0 418.3 785 1445.0
114.4 238 460.4 198.9 390 734.0 310.0 590 1094.0 421.1 790 1454.0
115.0 239 462.2 201.7 395 743.0 312.8 595 1103.0 423.9 795 1463.0
115.6 240 464.0 204.4 400 752.0 315.6 600 1112.0 426.7 800 1472.0
116.1 241 465.8 207.2 405 761.0 318.3 605 1121.0 429.4 805 1481.0
116.7 242 467.6 210.0 410 770.0 321.1 610 1130.0 432.2 810 1490.0
117.2 243 469.4 212.8 415 779.0 323.9 615 1139.0 435.0 815 1499.0
117.8 244 471.2 215.6 420 788.0 326.7 620 1148.0 437.8 820 1508.0
118.3 245 473.0 218.3 425 797.0 329.4 625 1157.0 440.6 825 1517.0
118.9 246 474.8 221.1 430 806.0 332.2 630 1166.0 443.3 830 1526.0
119.4 247 476.6 223.9 435 815.0 335.0 635 1175.0 446.1 835 1535.0
120.0 248 478.4 226.7 440 824.0 337.8 640 1184.0 448.9 840 1544.0
120.6 249 480.2 229.4 445 833.0 340.6 645 1193.0 451.7 845 1553.0
121.1 250 482.0 232.2 450 842.0 343.3 650 1202.0 454.4 850 1562.0
123.9 255 491.0 235.0 455 851.0 346.1 655 1211.0 457.2 855 1571.0
126.7 260 500.0 237.8 460 860.0 348.9 660 1220.0 460.0 860 1580.0
129.4 265 509.0 240.6 465 869.0 351.7 665 1229.0 462.8 865 1589.0
132.2 270 518.0 243.3 470 878.0 354.4 670 1238.0 465.6 870 1598.0
135.0 275 527.0 246.1 475 887.0 357.2 675 1247.0 468.3 875 1607.0
137.8 280 536.0 248.9 480 896.0 360.0 680 1256.0 471.1 880 1616.0
140.6 285 545.0 251.7 485 905.0 362.8 685 1265.0 473.9 885 1625.0
143.3 290 554.0 254.4 490 914.0 365.6 690 1274.0 476.7 890 1634.0
146.1 295 563.0 257.2 495 923.0 368.3 695 1283.0 479.4 895 1643.0

Figure 5 (Sheet 3)
20-50-00 Page 11
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
C F C F C F C F
482.2 900 1652.0 593.3 1100 2012.0 704.4 1300 2372.0 815.6 1500 2732.0
485.0 905 1661.0 596.1 1105 2021.0 707.2 1305 2381.0 818.3 1505 2741.0
487.8 910 1670.0 598.9 1110 2030.0 710.0 1310 2390.0 821.1 1510 2750.0
490.6 915 1679.0 601.7 1115 2039.0 712.8 1315 2399.0 823.9 1515 2759.0
493.3 920 1688.0 604.4 1120 2048.0 715.6 1320 2408.0 826.7 1520 2768.0
496.1 925 1697.0 607.2 1125 2057.0 718.3 1325 2417.0 829.4 1525 2777.0
498.9 930 1706.0 610.0 1130 2066.0 721.1 1330 2426.0 832.2 1530 2786.0
501.7 935 1715.0 612.8 1135 2075.0 723.9 1335 2435.0 835.0 1535 2795.0
504.4 940 1724.0 615.6 1140 2084.0 726.7 1340 2444.0 837.8 1540 2804.0
507.2 945 1733.0 618.3 1145 2093.0 729.4 1345 2453.0 840.6 1545 2813.0
510.0 950 1742.0 621.1 1150 2102.0 732.2 1350 2462.0 843.3 1550 2822.0
512.8 955 1751.0 623.9 1155 2111.0 735.0 1355 2471.0 846.1 1555 2831.0
515.6 960 1760.0 626.7 1160 2120.0 737.8 1360 2480.0 848.9 1560 2840.0
518.3 965 1769.0 629.4 1165 2129.0 740.6 1365 2489.0 851.7 1565 2849.0
521.1 970 1778.0 632.2 1170 2138.0 743.3 1370 2498.0 854.4 1570 2858.0
523.9 975 1787.0 635.0 1175 2147.0 746.1 1375 2507.0 857.2 1575 2867.0
526.7 980 1796.0 637.8 1180 2156.0 748.9 1380 2516.0 860.0 1580 2876.0
529.4 985 1805.0 640.6 1185 2165.0 751.7 1385 2525.0 862.8 1585 2885.0
532.2 990 1814.0 643.3 1190 2174.0 754.4 1390 2534.0 865.6 1590 2894.0
535.0 995 1823.0 646.1 1195 2183.0 757.2 1395 2543.0 868.3 1595 2903.0
537.8 1000 1832.0 648.9 1200 2192.0 760.0 1400 2552.0 871.1 1600 2912.0
540.6 1005 1841.0 651.7 1205 2201.0 762.8 1405 2561.0 873.9 1605 2921.0
543.3 1010 1850.0 654.4 1210 2210.0 765.6 1410 2570.0 876.7 1610 2930.0
546.1 1015 1859.0 657.2 1215 2219.0 768.3 1415 2579.0 879.4 1615 2939.0
548.9 1020 1868.0 660.0 1220 2228.0 771.1 1420 2588.0 882.2 1620 2948.0
551.7 1025 1877.0 662.8 1225 2237.0 773.9 1425 2597.0 885.0 1625 2957.0
554.4 1030 1886.0 665.6 1230 2246.0 776.7 1430 2606.0 887.8 1630 2966.0
557.2 1035 1895.0 668.3 1235 2255.0 779.4 1435 2615.0 890.6 1635 2975.0
560.0 1040 1904.0 671.1 1240 2264.0 782.2 1440 2624.0 893.3 1640 2984.0
562.8 1045 1913.0 673.9 1245 2273.0 785.0 1445 2633.0 896.1 1645 2993.0
565.6 1050 1922.0 676.7 1250 2282.0 787.8 1450 2642.0 898.9 1650 3002.0
568.3 1055 1931.0 679.4 1255 2291.0 790.0 1455 2651.0 901.7 1655 3011.0
571.1 1060 1940.0 682.2 1260 2300.0 793.3 1460 2660.0 904.4 1660 3020.0
573.9 1065 1949.0 695.0 1265 2309.0 796.1 1465 2669.0 907.2 1665 3029.0
576.7 1070 1958.0 687.8 1270 2318.0 798.9 1470 2678.0 910.0 1670 3038.0
579.4 1075 1967.0 690.6 1275 2327.0 801.7 1375 2687.0 912.8 1675 3047.0
582.2 1080 1976.0 693.3 1280 2336.0 804.4 1480 2696.0 915.6 1680 3056.0
585.0 1085 1985.0 696.1 1285 2345.0 807.2 1485 2705.0 918.3 1685 3065.0
587.8 1090 1994.0 698.9 1290 2354.0 810.0 1490 2714.0 921.1 1690 3074.0
590.6 1095 2003.0 701.7 1295 2363.0 812.8 1495 2723.0 923.9 1695 3083.0

Figure 5 (Sheet 4)
20-50-00 Page 12
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
C F C F C F C F
926.7 1700 3092.0 1037.8 1900 3452.0 1148.9 2100 3812.0 1260.0 2300 4172.0
929.4 1705 3101.0 1040.6 1905 3461.0 1151.7 2105 3821.0 1262.8 2305 4181.0
932.2 1710 3110.0 1043.3 1910 3470.0 1154.4 2110 3830.0 1265.6 2310 4190.0
935.0 1715 3119.0 1046.0 1915 3479.0 1157.2 2115 3839.0 1268.3 2315 4199.0
937.8 1720 3128.0 1048.9 1920 3488.0 1160.0 2120 3848.0 1271.1 2320 4208.0
940.6 1725 3137.0 1051.7 1925 3497.0 1162.8 2125 3857.0 1273.9 2325 4217.0
943.3 1730 3146.0 1054.4 1930 3506.0 1165.6 2130 3866.0 1276.7 2330 4226.0
946.1 1735 3155.0 1057.2 1935 3515.0 1168.3 2135 3875.0 1279.4 2335 4235.0
948.9 1740 3164.0 1060.0 1940 3524.0 1171.1 2140 3884.0 1282.2 2340 4244.0
951.7 1745 3173.0 1062.8 1945 3533.0 1173.9 2145 3893.0 1285.0 2345 4255.0
954.4 1750 3182.0 1065.6 1950 3542.0 1176.7 2150 3902.0 1287.8 2350 4262.0
957.2 1755 3191.0 1068.3 1955 3551.0 1179.4 2155 3911.0 1290.6 2355 4271.0
960.0 1760 3200.0 1071.1 1960 3560.0 1182.2 2160 3920.0 1293.3 2360 4280.0
962.8 1765 3209.0 1073.9 1965 3569.0 1185.0 2165 3929.0 1296.1 2365 4289.0
965.6 1770 3218.0 1076.7 1970 3578.0 1187.8 2170 3938.0 1298.9 2370 4298.0
968.3 1775 3227.0 1079.4 1975 3587.0 1190.6 2175 3947.0 1301.7 2375 4307.0
971.1 1780 3236.0 1082.2 1980 3596.0 1193.3 2180 3956.0 1304.4 2380 4316.0
973.9 1785 3245.0 1085.0 1985 3605.0 1196.1 2185 3965.0 1307.2 2385 4325.0
976.7 1790 3254.0 1087.8 1990 3614.0 1198.9 2190 3974.0 1310.0 2390 4334.0
979.4 1795 3263.0 1090.6 1995 3623.0 1201.7 2195 3983.0 1312.8 2395 4343.0
982.2 1800 3272.0 1093.6 2000 3632.0 1204.4 2200 3992.0 1315.6 2400 4352.0
985.0 1805 3281.0 1096.1 2005 3641.0 1207.2 2205 4001.0 1318.3 2405 4361.0
987.8 1810 3290.0 1098.9 2010 3650.0 1210.0 2210 4010.0 1321.1 2410 4370.0
990.6 1815 3299.0 1101.7 2015 3659.0 1212.8 2215 4019.0 1323.9 2415 4379.0
993.3 1820 3308.0 1104.4 2020 3668.0 1215.6 2220 4028.0 1326.7 2420 4388.0
996.1 1825 3317.0 1107.2 2025 3677.0 1218.3 2225 4037.0 1329.4 2425 4397.0
998.9 1830 3326.0 1110.0 2030 3686.0 1221.1 2230 4046.0 1332.2 2430 4406.0
1001.7 1835 3335.0 1112.8 2035 3695.0 1223.9 2235 4055.0 1335.0 2435 4415.0
1004.4 1840 3344.0 1115.6 2040 3704.0 1226.7 2240 4064.0 1337.8 2440 4424.0
1007.2 1845 3353.0 1118.3 2045 3713.0 1229.4 2245 4073.0 1340.6 2445 4433.0
1010.0 1850 3362.0 1121.1 2050 3722.0 1232.2 2250 4082.0 1343.3 2450 4442.0
1012.8 1855 3371.0 1123.9 2055 3731.0 1235.0 2255 4091.0 1346.1 2455 4451.0
1015.6 1860 3380.0 1126.7 2060 3740.0 1237.8 2260 4100.0 1348.9 2460 4460.0
1018.3 1865 3389.0 1129.4 2065 3749.0 1240.6 2265 4109.0 1351.7 2465 4469.0
1021.1 1870 3398.0 1132.2 2070 3758.0 1243.3 2270 4118.0 1354.4 2470 4478.0
1023.9 1875 3407.0 1135.0 2075 3767.0 1246.1 2275 4127.0 1357.2 2475 4487.0
1026.9 1880 3416.0 1137.8 2080 3776.0 1248.9 2280 4136.0 1360.0 2480 4496.0
1029.4 1885 3425.0 1140.6 2085 3785.0 1251.7 2285 4145.0 1362.8 2485 4505.0
1032.2 1890 3434.0 1143.3 2090 3794.0 1254.4 2290 4154.0 1365.6 2490 4514.0
1035.0 1895 3443.0 1146.1 2095 3803.0 1257.2 2295 4163.0 1368.3 2495 4523.0

Figure 5 (Sheet 5)
20-50-00 Page 13
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
C C F
1371.1 2500 4532.0 1398.9 2550 4622.0 1426.7 2600 4712.0

1373.9 2505 4541.0 1401.7 2555 4631.0 1429.4 2605 4721.0
1376.7 2510 4550.0 1404.4 2560 4640.0 1432.2 2610 4730.0
1379.4 2515 4559.0 1407.2 2565 4649.0 1435.0 2615 4739.0
1382.2 2520 4568.0 1410.0 2470 4658.0 1437.8 2620 4748.0
1385.0 2525 4577.0 1412.8 2575 4667.0 1440.6 2625 4757.0
1387.8 2530 4586.0 1415.6 2580 4676.0 1443.3 2630 4766.0
1390.6 2535 4595.0 1418.3 2585 4685.0 1446.1 2635 4775.0
1393.3 2540 4604.0 1421.1 2590 4694.0 1448.9 2640 4784.0
1396.1 2545 4613.0 1423.9 2595 4703.0 1451.7 2645 4793.0

Figure 5 (Sheet 6)
20-50-00 Page 14
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
STANDARD DRILL SIZES

DRILL DECIMAL DRILL DECIMAL DRILL DECIMAL DRILL DECIMAL DRILL DECIMAL
80 0.0135 45 0.0820 12 0.1890 S 0.3480 55/64 0.8594
79 0.0145 44 0.0860 11 0.1910 T 0.3580 7/8 0.8750
1/64 0.0156 43 0.0890 10 0.1935 23/64 0.3594 57/64 0.8906
78 0.0160 42 0.0935 9 0.1960 U 0.3680 29/32 0.9062
77 0.0180 3/32 0.0937 8 0.1990 3/8 0.3750 29/64 0.9219
76 0.0200 41 0.0960 7 0.2010 V 0.3770 15/16 0.9375

75 0.0210 40 0.0980 13/64 0.2031 W 0.3860 61/64 0.9531
74 0.0225 39 0.0995 6 0.2040 25/64 0.3906 31/32 0.9687
73 0.0240 38 0.1015 5 0.2055 X 0.3970 63/64 0.9844
72 0.0250 37 0.1040 4 0.2090 Y 0.4040 1 1.0000
71 0.0260 36 0.1065 3 0.2130 13/32 0.4062

70 0.0280 7/64 0.1093 7/32 0.2187 Z 0.4130
69 0.0292 35 0.1100 2 0.2210 27/64 0.4219
68 0.0310 34 0.1110 1 0.2280 7/16 0.4375
1/32 0.0313 33 0.1130 A 0.2340 29/64 0.4531
67 0.0320 32 0.1160 15/64 0.2344 15/32 0.4687

66 0.0330 31 0.1200 B 0.2380 31/64 0.4843
65 0.0350 1/8 0.1250 C 0.2420 1/2 0.5000
64 0.0360 30 0.1285 D 0.2460 33/64 0.5156
63 0.0370 29 0.1360 E 0.2500 17/32 0.5312
62 0.0380 28 0.1405 1/4 0.2500 35/64 0.5469

61 0.0390 9/64 0.1406 F 0.2750 9/16 0.5625
60 0.0400 27 0.1440 G 0.2610 37/64 0.5781
59 0.0410 26 0.1470 17/64 0.2656 19/32 0.5937
58 0.0420 25 0.1495 H 0.2660 39/64 0.6094
57 0.0430 24 0.1520 I 0.2720 5/8 0.6250

56 0.0465 23 0.1540 J 0.2770 41/64 0.6406
3/64 0.0469 5/32 0.1562 K 0.2811 21/32 0.6562
55 0.0520 22 0.1570 9/32 0.2812 43/64 0.6719
54 0.0550 21 0.1590 L 0.2900 11/16 0.6875
53 0.0595 20 0.1610 M 0.2950 45/64 0.7031

1/16 0.0625 19 0.1660 19/64 0.2968 23/32 0.7187
52 0.0635 18 0.1695 N 0.3020 47/64 0.7344
51 0.0670 11/64 0.1719 5/16 0.3135 3/4 0.7500
50 0.0700 17 0.1730 O 0.3160 49/64 0.7656
49 0.0730 16 0.1770 P 0.3230 25/32 0.7812

48 0.0760 15 0.1800 21/64 0.3281 51/64 0.7969
5/64 0.0781 14 0.1820 Q 0.3320 13/16 0.8125
47 0.0785 13 0.1850 R 0.3390 53/64 0.8281
46 0.0810 3/16 0.1875 11/32 0.3437 27/32 0.8437
Drill and Tap Decimal Conversion

Figure 6 (Sheet 1)
20-50-00 Page 15
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
MILLIMETER DRILL SIZES

mm DECIMAL mm DECIMAL mm DECIMAL mm DECIMAL mm DECIMAL
.35 0.0138 2.10 0.0827 4.60 0.1811 7.50 0.2953 12.50 0.4921
.40 0.0157 2.15 0.0846 4.70 0.1850 7.60 0.2992 13.00 0.5118
.45 0.0177 2.20 0.0866 4.75 0.1870 7.70 0.3031 13.50 0.5315
.50 0.0197 2.25 0.0886 4.80 0.1890 7.75 0.3051 14.00 0.5512
.55 0.0217 2.30 0.0905 4.90 0.1929 7.80 0.3071 14.50 0.5709
.60 0.0236 2.35 0.0925 5.00 0.1968 7.90 0.3110 15.00 0.5906
.65 0.0256 2.40 0.0945 5.10 0.2008 8.00 0.3150 15.50 0.6102
.70 0.0276 2.45 0.0965 5.20 0.2047 8.10 0.3189 16.00 0.6299
.75 0.0295 2.50 0.0984 5.25 0.2067 8.20 0.3228 16.50 0.6496
.80 0.0315 2.55 0.1004 5.30 0.2087 8.25 0.3248 17.00 0.6693
.85 0.0335 2.60 0.1024 5.40 0.2126 8.30 0.3268 17.50 0.6890
.90 0.0354 2.65 0.1043 5.50 0.2165 8.40 0.3307 18.00 0.7087
.95 0.0374 2.70 0.1063 5.60 0.2205 8.50 0.3346 18.50 0.7283
1.00 0.0394 2.75 0.1083 5.70 0.2244 8.60 0.3386 19.00 0.7480
1.05 0.0413 2.80 0.1102 5.75 0.2264 8.70 0.3425 19.50 0.7677
1.10 0.0433 2.90 0.1142 5.80 0.2283 8.75 0.3445 20.00 0.7874
1.15 0.0453 3.00 0.1181 5.90 0.2323 8.80 0.3465 20.50 0.8071
1.20 0.0472 3.10 0.1220 6.00 0.2362 8.90 0.3504 21.00 0.8268
1.25 0.0492 3.20 0.1260 6.10 0.2401 9.00 0.3543 21.50 0.8465
1.30 0.0512 3.25 0.1280 6.20 0.2441 9.10 0.3583 22.00 0.8661
1.35 0.0531 3.30 0.1299 6.25 0.2461 9.20 0.3622 22.50 0.8858
1.40 0.0551 3.40 0.1339 6.30 0.2480 9.25 0.3642 23.00 0.9055
1.45 0.0571 3.50 0.1378 6.40 0.2520 9.30 0.3661 23.50 0.9252
1.50 0.0591 3.60 0.1417 6.50 0.2559 9.40 0.3701 24.00 0.9449
1.55 0.0610 3.70 0.1457 6.60 0.2598 9.50 0.3740 24.50 0.9646
1.60 0.0629 3.75 0.1477 6.70 0.2638 9.60 0.3780 25.00 0.9843
1.65 0.0650 3.80 0.1496 6.75 0.2658 9.70 0.3819
1.70 0.0669 3.90 0.1535 6.80 0.2677 9.75 0.3839
1.75 0.0689 4.00 0.1575 6.90 0.2716 9.80 0.3858
1.80 0.0709 4.10 0.1614 7.00 0.2756 9.90 0.3898
1.85 0.0728 4.20 0.1654 7.10 0.2795 10.00 0.3937

1.90 0.0748 4.25 0.1674 7.20 0.2835 10.50 0.4134
1.95 0.0768 4.30 0.1693 7.25 0.2855 11.00 0.4330
2.00 0.0787 4.40 0.1732 7.30 0.2874 11.50 0.4528
2.05 0.0807 4.50 0.1771 7.40 0.2913 12.00 0.4724

Figure 6 (Sheet 2)
20-50-00 Page 16
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TAP HOLE SIZES
HOLE ID
TAP
SIZE MINIMUM MAXIMUM
0-80 0.0616 0.0619

1-64 0.0746 0.0749
1-72 0.0746 0.0749
2-56 0.0876 0.0879
2-64 0.0876 0.0879
3-48 0.1011 0.1014

3-56 0.1006 0.1009
4-40 0.1146 0.1149
4-48 0.1141 0.1144
5-40 0.1276 0.1279
5-44 0.1271 0.1274

6-32 0.1411 0.1414
6-40 0.1406 0.1409
8-32 0.1671 0.1674
8-36 0.1666 0.1669
10-24 0.1941 0.1944

10-32 0.1931 0.1934
12-24 0.2201 0.2204
12-28 0.2196 0.2199
1/4-20 0.2551 0.2555
1/4-28 0.2536 0.2540

5/16-18 0.3181 0.3185
5/16-24 0.3166 0.3170
3/8-16 0.3811 0.3815
3/8-24 0.3791 0.3795
7/16-14 0.4446 0.4450

7/16-20 0.4426 0.4430
1/2-13 0.5076 0.5080
1/2-20 0.5051 0.5055
9/16-12 0.5701 0.5705
9/16-18 0.5681 0.5685

5/8-11 0.6331 0.6335
5/8-18 0.6306 0.6310
3/4-10 0.7592 0.7596
3/4-16 0.7562 0.7566
7/8-9 0.8852 0.8856

7/8-14 0.8822 0.8826
1-8 1.0112 1.0116
1-14 1.0072 1.0076

Figure 6 (Sheet 3)
20-50-00 Page 17
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
AIR
CONDITIONING
MODEL 172
MAINTENANCE MANUAL

21-Title
21-00-00 1 Aug 18/2001
21-20-00 1 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
21-21-00 201 Aug 18/2001
202 Aug 18/2001
21-40-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
AIR CONDITIONING - GENERAL ............................ ... ................ 21-00-00 Page 1
Scope ........................... . ................................... ........ 21-00-00 Page 1
Definition ......... . ................... .... ...............................
..... 21-00-00 Page 1
FRESH AIR DISTRIBUTION - DESCRIPTION AND OPERATION ...................... 21-20-00 Page 1
General ............................................... .............. ....... 21-20-00 Page 1
D escription ................................................................... 21-20-00 Page 1
System Operation ............................................................. 21-20-00 Page 1
FRESH AIR DISTRIBUTION - MAINTENANCE PRACTICES ......................... 21-20-00 Page 201
General ............................................... ............ ........ 21-20-00 Page 201
Air Outlet Valve Removal/Installation ............ ............................. 21-20-00 Page 201
AVIONICS COOLING FAN - MAINTENANCE PRACTICES ............................ 21-21-00 Page 201
Cooling Fan Removal/Installation ............................................... 21-40-00 Page 201
HEATING AND DEFROSTING - MAINTENANCE PRACTICES ......................... 21-40-00 Page 201
General .................................................................. .. 21-40-00 Page 201
System Operation ............................................................. 21-40-00 Page 201
System Troubleshooting ....................................................... 21-40-00 Page 201
Heat Exchanger Removal/Installation ........................................... 21-40-00 Page 201
Shutoff Valve Removal/Installation .............................................. 21-40-00 Page 203
Control Cable Removal/Installation ............................................. 21-40-00 Page 203
Distribution System Components Removal/Installation ........................... 21-40-00 Page 203
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AIR CONDITIONING - GENERAL

1. Scope
A. This chapter describes those units and components which furnish a means of ventilating and heating
the cockpit/cabin area.

Type II Sealant PR1488 Courtaulds Aerospace To secure cabin duct to
5426 San Fernando Rd. various air outlets.
Glendale, CA 91209
Type IV Sealant Pro-Seal 700 Courtaulds Aerospace To seal shutoff valve to
firewall.
Type IV Sealant GC- 1900 Courtaulds Aerospace To seal shutoff valve to
firewall.
3. 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 fresh air distribution describes that portion of the system used to induct and
distribute fresh air throughout the cockpit/cabin area.
(2) The section on avionics cooling describes those components used to provide forced air cooling
to the rear of the avionics racks.
(3) The section on heating describes those components used to generate and distribute heat for the
cockpit/cabin area.
21-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FRESH AIR DISTRIBUTION - DESCRIPTION AND OPERATION
1. General
A. The cockpit/cabin area is ventilated with fresh air by means of external wing root openings, an
adjustable air scoop, and internal ducting.
2. Description
A. Fresh air enters into the cabin from one of five sources. Four of those sources are located in the
leading edge area of the wing (two left and two right) and the fifth source is located on the right side
of the fuselage, between the firewall and the forward door post.
(1) Each wing leading edge area contains two inlet scoops. One inlet scoop feeds an air valve
located at the wing leading edge/windshield intersection; and the other inlet scoop (located in
the wing-to-fuselage fairing) feeds a pair of air valves located near the mid torso area (front seat)
and overhead area (rear seat).
(2) Fresh air may also be introduced by an adjustable door located on the fuselage. This air is routed
directly into the heated air plenum and is distributed through the heated air distribution system.
3. System Operation
A. The amount of fresh air entering the cabin can be controlled by any of the six air valves. Rotating the
air valve will vary the airflow from fully closed to fully open.
B. Air flow into the cabin can also be controlled by the CABIN AIR control cable. Pulling the control aft
allows the maximum amount of fresh air to flow through the heated air distribution system. Pushing the
control forward closes the door and allows no fresh air to flow through the heated distribution system.
NOTE: Air temperature in the heated air distribution system can be altered by use of the CABIN
HT control in conjunction with the CABIN AIR control. With the CABIN AIR control fully
aft and the CABIN HT control full forward, only ambient temperature air fill flow through
the heated air distribution system. As the CABIN HT control is gradually pulled out, more
and more heated air will blend with ambient temperature air and be distributed through the
heated air distribution system. Either one or both of the controls may be set at any position
from full open to full closed.
21-20-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FRESH AIR DISTRIBUTION - MAINTENANCE PRACTICES

1. General
A. Fresh air outlet valves are located in the cockpit/cabin area at upper corners of the windshield, in the
sidewalls just aft of the instrument panel, and above the passenger seat. Air outlet valve removal/
installation is typical at each location.
2. Air Outlet Valve Removal/Installation
A. Remove Air Outlet Valve (Refer to Figure 201).
(1) Remove retaining ring from air outlet valve.
(2) Remove upholstery panel. Refer to Chapter 25, Interior Upholstery - Maintenance Practices.
(3) Remove clamp securing ducting hose to air outlet valve adapter.
(4) Remove air outlet valve and adapter.
B. Install Air Outlet Valve (Refer to Figure 201).
(1) Install air outlet valve and valve adapter to ducting. Secure with clamp.
(2) Install upholstery panel. Refer to Chapter 25, Interior Upholstery - Maintenance Practices.
(3) Install retaining ring to air outlet valve.
21-20-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1691
PLENUM CAP
DUCT
DUCT AIR OUTLET
AIR
INLET
ASSEMBLY
AIR DETAIL A
PLENUM CAP
Fresh Air Distribution

21-20-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1692
FITTING
SCOOP
AIR VALVE
OUTLET DUCT
DETAIL B
RIGHT SIDE SHOWN
LEFT SIDE OPPOSITE
DOOR ASSEMBLEY
DETAIL C
Fresh Air Distribution

21-20-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AVIONICS COOLING FAN - MAINTENANCE PRACTICES
1. General
A. The avionics cooling fan is located behind the instrument panel and is used to force cool various
components in the radio stack. Maintenance is limited to removal and installation of the cooling fan
and associated ductwork.
2. Cooling Fan Removal/Installation
A. Remove Cooling Fan (Refer to Figure 201).
(1) Ensure airplane master and avionics switches are in the OFF position.
(2) Disconnect the negative lead from the battery terminal. Refer to Chapter 24, Battery -
(3) Remove bolts securing cooling fan to firewall.
(4) Disconnect electrical connector from avionics cooling fan.
(5) Disconnect flexible ducts from cooling fan.
(6) Remove cooling fan from airplane.
B. Install Cooling Fan (Refer to Figure 201).
(1) Connect flexible ducts to cooling fan. Secure using tie wraps.
(2) Connect electrical connector to cooling fan.
(3) Install cooling fan to firewall using existing hardware.
(4) Reconnect negative lead to battery terminal. Refer to Chapter 24, Battery - Maintenance
Practices.
(5) Test cooling fan for proper operation in the following steps:
(a) Place master switch in the BATT position.
(b) Place the avionics master switch to the ON position and audibly confirm that avionics
cooling fan is running.
(6) Place avionics master switch and master switch to the OFF positions.
21-21-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ELECTRICAL CONNECTOR
FLEXIBLE DUCT
(TO AVIONICS STACK)
FIREWALL
AVIONICS COOLING FAN
Avionics Cooling Fan Installation

21-21-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
HEATING AND DEFROSTING - MAINTENANCE PRACTICES

1. General
A. The heating and defrosting system is comprised of the heat exchange section of the exhaust muffler, a
shut-off valve mounted on the firewall, a push-pull control on the instrument panel, outlets, and flexible
ducting connecting the system.
2. System Operation
A. Ram air enters the engine compartment through cowling inlets located aft of the propeller. A portion
of this air is directed toward an exit point in the rear engine baffle. This air is directed, via ducting, to
the heat exchange section of the exhaust muffler. As air passes into the heat exchange and around
the exhaust muffler, it picks up heat from the engine exhaust. This heated air exits the heat exchange
and is directed, via ducting, to a firewall shutoff valve. The shutoff valve is cable controlled from the
cockpit, and controls the amount of heated air entering the cockpit area distribution plenum. From the
plenum, various ducts distribute the heated air to floorboard and defroster outlets.
NOTE: The cockpit area distribution plenum is also plumbed to receive outside fresh air from the
right hand external air scoop (door). This arrangement allows a combination of fresh air
and heated air to be mixed and distributed throughout the system
3. System Troubleshooting
A. Most of the operational troubles in the heating, defrosting and ventilating systems are caused by
sticking or binding air valves and their controls, damaged air ducting or defects in the exhaust muffler.
In most cases, valves or controls can be freed by proper lubrication. Damaged or broken parts
must be repaired or replaced. When checking controls, ensure that valves respond freely to control
movement, that they move in the correct direction, and that they move through their full range of travel
and seal properly. Check that hoses are properly secured, and replace hoses that are burned, frayed
or crushed.
B. If fumes are detected in the cabin, a thorough inspection of the exhaust system should be
accomplished. Since any holes or cracks may permit exhaust fumes to enter the cabin, replacement
of defective parts is imperative, because fumes constitute an extreme danger.
4. Heat Exchanger Removal/Installation
A. Remove Exchanger (Refer to Figure 201).
(1) Remove engine cowling. Refer to Chapter 71, Cowling - Maintenance Practices.
(2) Remove c-clamps securing flexible duct to heat exchanger.
(3) Remove sheet metal screws securing heat exchanger to itself.
(4) Carefully remove exchanger from around muffler.
NOTE: Anytime heat exchanger is removed from around muffler, muffler should be carefully
examined and inspected for leaks or cracks. Refer to Chapter 5, Inspection Time
Limits for normal inspection time frame. Refer to Chapter 78, Exhaust System -
Maintenance Practices for inspection criteria of the muffler.
B. Install Exchanger (Refer to Figure 201).
(1) Carefully wrap heat exchanger around muffler.
(2) Secure heat exchanger to itself using sheet metal screws.
(3) Secure flexible duct to heat exchanger using c-clamps.
(4) Install engine cowling. Refer to Chapter 71, Cowling - Maintenance Practices.
5. Shutoff Valve Removal/Installation
A. The shutoff valve is riveted to the firewall and is not removed from the airplane during normal
maintenance. If valve is replaced, firewall should be sealed using Type IV sealant upon reattachment
of shutoff valve to firewall. For a list of Type IV sealants, refer to Air Conditioning - General.
21-40-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B B
VALVE SEAT
DETAIL A
VALVE SPRING
VALVE PLATE
CONTROL ARM SCREW

VALVE BODY
DETAIL C VALVE GUIDE
NOZZLE
DEFROSTER HOSE
C05141020
Heating and Defrosting installation

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MAINTENANCE MANUAL
6. Control Cable Removal/Installation

A. Remove Control Cable (Refer to Figure 201).
(2) Carefully straighten end of cabin heat control cable.
(3) Loosen clamp bolt on control arm and withdraw cable from control arm.
(4) Loosen screws securing clamp bolt to firewall.
(5) From inside the cabin, gain access to the backside of the CABIN HT control cable.
(6) Loosen nut on backside of control cable.
(7) Carefully withdraw cable from instrument panel and firewall.
B. Install Control Cable (Refer to Figure 201 ).
(1) Thread end of control cable through hole in instrument panel and through hole in firewall.
(2) Secure CABIN HT control cable to backside of instrument panel using existing jam nut.
(3) Thread end of control cable through the clamp bolt.
(4) Tighten clamp bolt and test control cable to ensure full range of travel.
(5) When full range of travel has been established, bend end of control cable around clamp bolt
area.
7. Distribution System Components Removal/Installation
A. The majority of heated air distribution system components are riveted to the airframe and do not
require replacement during normal maintenance. Ducts are secured to these components using
c-clamps. If ducts become damaged or worn, they should be replaced with new hose of equal length.
B. Ducts are typically attached to various outlets using Type II sealant. For a list of Type II sealants, refer
to Air Conditioning - General.
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MAINTENANCE MANUAL
* CHAPTER
AUTO
FLIGHT
.
MODEL 172
MAINTENANCE MANUAL

22-Title
22-List of Effective Pages 1
22-00-00 1 Aug 18/2001
22-10-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
206 Aug 18/2001
207 Aug 18/2001
208 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
AUTO FLIG HT - G ENERAL ......................................................... 22-00-00 Page 1
Scope and Definition .......................................................... 22-00-00 Page 1
AUTOPILOT - MAINTENANCE PRACTICES ......................................... 22-10-00 Page 201
General .................................................................... 22-10-00 Page 201
Roll Servo Removal/Installation ................................................ 22-10-00 Page 201
Pitch Servo Removal/Installation ............................................... 22-10-00 Page 201
Pitch Trim Servo Removal/Installation........................................... 22-10-00 Page 205
Servo Inspection .............................................................. 22-10-00 Page 206
KAP 140 Autopilot Controller Removal/Installation ................................ 22-10-00 Page 207
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AUTO FLIGHT - GENERAL

1. Scope and Definition
A. This chapter contains a single section which deals with removal and installation of the autopilot and
roll servo.
22-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AUTOPILOT - MAINTENANCE PRACTICES
1. General
A. A single axis autopilot featuring heading hold is installed on IFR equipped airplanes. Heading hold is
based on directional gyro input and can incorporate VOR, GPS or Localizer input on demand.
B. A dual axis autopilot is available as an option. The two axis system provides both vertical speed and
altitude hold selection. Altitude alerting and altitude preselection are optional features with the two
axis autopilot system.
2. Roll Servo Removal/Installation
A. Remove Roll Servo (Refer to Figure 201).
(1) Remove access panel 620AB. Refer to Chapter 6, Access/Inspection Plates - Description and
Operation.
(2) Loosen roll servo cable turnbuckle.
(3) Disconnect electrical connector from roll servo.
(4) Remove cable guard and cable.
(5) Remove screws securing roll servo to bracket.
(6) Remove roll servo from airplane.
B. Install Roll Servo (Refer to Figure 201).
(1) Position roll servo to bracket and secure with screws.
(2) Connect electrical connector to roll servo.
NOTE: Removal of servo mount requires disconnecting the servo cable. Consequently, servo
cable rigging is required upon reinstallation of the servo mount.
(3) Install roll servo cable on roll servo.
NOTE: System rigging should be accomplished with aileron and bellcrank in neutral position.
NOTE: Wrap cable around servo drum approximately 1.25 turns each direction from swaged
ball (drum ball detent facing inboard).
NOTE: When installing cable guard, ensure that the legs of the cable guard do not touch the
cable. Be sure that feet of cable guard straddle notches around perimeter of mount.
(4) Adjust roll servo cable tension with turnbuckle to obtain cable tension of 15 pounds, ±3 pounds
(66.7 N, ±13.34 N).
(5) Turn power ON to autopilot controller.
(6) Move heading bug on directional gyro left and right of current heading to verify proper deflection
of ailerons.
3. Pitch Servo Removal/Installation
A. Remove Pitch Servo (Refer to Figure 201).
(1) Remove access plates 31 OAR, 340AL and 340AR. Refer to Chapter 6, Access/Inspection Plates
- Description and Operation.
(2) Disconnect electrical connector from pitch servo.
(3) Release cable tension, loosen pitch servo cable at turnbuckle.
(5) Remove bolts securing pitch servo to bracket assembly.
(6) Remove pitch servo from airplane.
B. Install Pitch Servo (Refer to Figure 201).
(1) Position pitch servo to bracket assembly in the install position and secure with bolts.
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MAINTENANCE MANUAL
(NOTE)
CABLE GUARD
LEG
CABLES MUST NOT
AILERON LOCATION OF
DETAIL A
A0000214
Autopilot Servo Installation

22-10-00 Page 202

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MODEL 172
MAINTENANCE MANUAL
B240
CABLE GUARD LEG

(TYPICAL) PITCH TRIM SERVO
NOTE: CABLES MUST NOT

CONTACT CABLE
GUARD LEGS.
CABLES
LOCATION OF
SWAGED BALL
VIEW B-B
CABLE ELEVATOR
CLAMP BLOCK BELLCRANK
CABLE
CABLE ASSY
CLAMP BLOCK
DETAIL B
A0000240
B0560T1018
B-B0560T1019

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CABLE GUARD LEG
CABLE GUARD
(NOTE)
VIEW C-C
NOTE: CABLES MUST NOT

CONTACT CABLE
GUARD LEGS.
TURNBUCKLE
CABLES
DETAIL C
A0000241

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MAINTENANCE MANUAL
(2) Connect electrical connector to pitch servo.

(3) Install pitch servo cable on pitch servo actuator.

NOTE: System rigging should be accomplished with elevator and bellcrank in neutral
position.
NOTE: Wrap cable around pitch servo drum approximately 1 turn each direction from swaged
ball (ball location on bottom of capstan in approximately 7 o'clock position).
(4) Adjust pitch servo cable tension with turnbuckle to obtain cable tension of 15 pounds, ±3 pounds
(66.7 N, ±13.34 N).
(5) Install access plates 310AR, 340AL and 340AR. Refer to Chapter 6, Access/Inspection Plates -
Description and Operation.
(6) Turn autopilot on and operationally test in accordance with the manufacturers installation manual.
Refer to Introduction, List of Manufacturers Technical Publications.
4. Pitch Trim Servo Removal/Installation
A. Remove Pitch Trim Servo (Refer to Figure 201).
(1) Remove access plates 310AR, 340AL and 340AR. Refer to Chapter 6, Access/Inspection Plates
- Description and Operation.
(2) Disconnect electrical connector from pitch trim servo.
(3) Release cable tension, loosen pitch trim servo cable at turnbuckle.
(5) Remove bolts securing pitch trim servo to bracket assembly.
(6) Remove pitch trim servo from airplane.
B. Install Pitch Trim Servo (Refer to Figure 201).
(1) Position pitch trim servo to bracket assembly in the install position and secure with bolts.
(2) Connect electrical connector to pitch trim servo.
(3) Install pitch trim servo cable on pitch trim servo actuator.
(4) Adjust pitch trim servo cable tension with turnbuckle to obtain cable tension between 15 and 20
pounds (66.7 N to 88.9 N).
(5) Install access plates 310AR, 340AL and 340AR. Refer to Chapter 6, Access/Inspection Plates -
(6) Turn autopilot on and operationally test in accordance with the manufacturers installation manual.
Refer to Introduction, List of Manufacturers Technical Publications.
C. Check pitch trim rigging.
(1) Streamline the elevator and trim tab. Mount an inclinometer to trim tab and set to 0 degrees.
Manually run trim tab to up and down limits and record limits of travel.
(2) Position observer at bottom aft access opening in tailcone. Apply power to the aircraft and run
electric trim to full nose-up position until the observer notices clutch slippage. With servo clutch
still slipping, apply an additional 1/4 turn of the manual trim wheel nose-up (test load condition).
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MAINTENANCE MANUAL
(3) In this condition, observer needs to verify that the stop blocks do not slip on the trim tab cables.
(4) Release the trim wheel and disengage the autopilot. Manually run the trim to full nose-up position
and check trim tab deflection with an inclinometer. Additional trim tab deflection (compared with
the values recorded in step C.1.) indicates slippage of the stop blocks. Rerig trim system, check
torque on stop block bolts, then repeat pitch trim rigging check.
(5) If swaged ball needs adjustment, make adjustments by repositioning cable assembly chain on
gear teeth of actuator sprocket. One chain link corresponds to approximately 17 degrees of
travel on the capstan. Re-tension cable and repeat pitch trim rigging check.
(6) Repeat procedure for the full nose-down trim condition.
5. Servo Inspection
A. Inspect Servo
(1) Remove servo cover.
CAUTION: Any disassembly/assembly of the servo MUST be done at a static-safe
workstation. The inspector and bench should be grounded.
(a) Remove the two screws that hold the cover on the unit, and carefully slide the cover off
over the wiring harness.
(b) Place the servo (without the cover) on the bench so that the inner parts of the unit will not
be damaged.
(2) Inspect solenoid/clutch.
(a) Inspect the operation of the solenoid. The plunger should move freely in and out of the
solenoid body. There should be no dirt, contamination, or corrosion around the solenoid
plunger. This could impede the actuation of the solenoid.
(b) The release spring should pull the plunger out of the solenoid and against its stop freely
and without hesitation. With hands clear of the solenoid plunger and spring, the pinion
gear should spin with no interference from the clutch gears.
(3) Perform general inspection.
(a) Inspect the electrical wiring for evidence of wear or damage to the insulation. This could
cause electrical shorting and unit malfunction.
(b) Inspect the entire servo for any loose hardware or other abnormalities.
(4) Perform additional inspection for the pitch servo.
(a) Position the servo so that the baseplate is on the bottom side of the unit.
(b) While holding on to the top section of the motor, gently rotate the motor. It should rotate
freely side to side a slight amount before touching and beginning to deflect the trim-sensing
strain gauge beam.
(5) Install cover.
(a) Carefully slide the cover back on over the wiring harness and onto the unit to its original
position.
(b) Install the screws using a low-strength thread-locking compound such as Loctite 222 or
Loctite 242.
(6) Remove the servo capstan assembly and check the slip-clutch torque setting (Refer to KAP-140
Installation Manual).
(a) Set servo clutch plate torque using the table below:
Servo Clutch Plate Torque

Roll 55 ±5 inch pounds
Pitch 18 ±2 inch pounds
Pitch Trim 30 +3 inch pounds
(b) Record setting information and date by permanently marking placard on internal face of
servo clutch housing.
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6. KAP 140 Autopilot Controller Removal/Installation

A. Remove Autopilot Controller (Refer to Figure 202).
(1) Ensure that power is OFF to autopilot controller.
(2) Loosen mounting screw on face of autopilot controller.
(3) Pull autopilot controller aft and remove from mounting tray.
B. Install Autopilot Controller (Refer to Figure 202).
(1) Slide autopilot controller forward into mounting tray.
(2) Tighten mounting screw on face of autopilot controller.
(3) Test static system for leaks.
(4) Turn power ON to autopilot controller.
(5) Functionally test autopilot operation per manufacturer's instructions.
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MAINTENANCE MANUAL
AUTOPILOT
LOCATION
DETAIL A
A0000215
KAP140 Autopilot Installation

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MAINTENANCE MANUAL
* CHAPTER
COMMUNICATIONS
MODEL 172
MAINTENANCE MANUAL

23-Title
23-00-00 1 Aug 18/2001
23-10-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
23-50-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
23-60-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
COMMUNICATIONS - GENERAL ................................................... 23-00-00 Page 1
S cope ............................ ................................. ......... 23-00-00 Page 1
Tools and Equipment ......... ...... ......... ............................. 23-00-00 Page 1
Definition ......... ............................................................ 23-00-00 Page 1
NAV/COM - MAINTENANCE PRACTICES ........................................... 23-10-00 Page 201
General ...................................................................... 23-10-00 Page 201
Nav/Com Radio Removal and Installation ....................................... 23-10-00 Page 201
Antenna Removal/Installation .................................................. 23-10-00 Page 201
AUDIO PANEL - MAINTENANCE PRACTICES .................... .... ............... 23-50-00 Page 201
General ....
........ ................................................................. 23-50-00 Page 201
Audio Panel Removal/Installation ........... ............................... 23-50-00 Page 201
Intercom Jacks Removal/Installation ........................................... 23-50-00 Page 201
Marker Beacon Antenna Removal/Installation .................................... 23-50-00 Page 204
STATIC WICKS - MAINTENANCE PRACTICES ....................................... 23-60-00 Page 201
General ............................................... ............... ........ 23-60-00 Page 201
Tools and Equipment .......................................................... 23-60-00 Page 201
Static Wicks Removal/Installation ............................. ......... 23-60-00 Page 201
Bonding Straps Removal/Installation ............................................ 23-60-00 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
COMMUNICATIONS - GENERAL
1. Scope
A. This chapter describes and provides maintenance instructions for equipment which furnishes a
means of communicating from one part of the airplane to another, and between the airplane and
other airplanes or ground stations
B. Additional information on communications equipment can be found in the Wiring Diagram Manual
supplied with the airplane.
C. Technical publications available from the manufacturer of the various components and systems which
are not covered in this manual must be utilized as required for maintenance of those components and
systems.

Type I, Class B-2 PR1440 Courtaulds Aerospace To fay seal antenna to fuselage.
Sealant 5426 San Fernando Rd.
Glendale, CA 91209
Bonding meter Keithley Model 580 Keithley Instruments, Inc. To check electrical bonding
Instrument Division connections.
28775 Aurora Rd.
Cleveland, OH 44139
Megohmmeter Model 2850 Associated Research, To check resistance of static
Inc. wicks.
3773 W. Belmont Ave.
Chicago, IL 60618
3. Definition
A. Information contained in this chapter provides the basic procedures which can be accomplished at
the flight line level; such as, removal and installation of components and system operation.
B. This chapter is divided into sections to aid maintenance personnel in locating information. A brief
description of each section is as follows:
(1) The speech communication section describes radio equipment used for reception and
transmission of voice communication.
(2) The audio integrating system section describes that portion of the system which controls
the output of the communications and navigation receivers into the pilot and passengers
headphones and speakers, and the output of the pilot's microphone into the communications
transmitters.
(3) The static discharging section describes the static discharge wicks used to dissipate static
electricity.
23-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NAV/COM - MAINTENANCE PRACTICES
1. General
A. Navigation and communication functions are combined in a single Nav/Com unit, mounted in the
center avionics stack. Airplane may be equipped with dual nav/coms, and removal/installation for
both units is identical.
B. This maintenance practice section provides instructions for removal and installation of the nav/com
units and removal/installation of the com antennas.
2. Nav/Com Radio Removal and Installation
A. Remove Nav/Com (Refer to Figure 201).
(1) Ensure avionics master switch is in OFF position and Nav/Com is turned OFF.
(2) On face of Nav/Com, turn recessed mounting screw counterclockwise until locking paw releases
unit from back of mounting tray.
(3) Grasp Nav/Com and gently pull aft out of mounting tray.
B. Install Nav/Com (Refer to Figure 201).
(1) Slide Nav/Com forward into mounting tray.
NOTE: Ensure that Nav/Com positively seats into the electrical connections at back of
mounting tray.
(2) Turn recessed mounting screw on face of Nav/Com clockwise until Nav/Com is secured to
mounting tray.
(3) Place MASTER switch in the BATT position and avionics master switch in the ON position.
(4) Turn Nav/Com power ON and verify electronic display illuminates.
(5) Place Master, Avionics and Nav/Com switches in the OFF position.
3. Antenna Removal/Installation
NOTE: Antenna removal/installation is typical for both antennas.
A. Remove Antenna (Refer to Figure 201).
(1) Ensure all electrical power to airplane is off.
(2) Gain access to topside of wing.
(3) Remove four screws securing com antenna to topside of fuselage.
(4) Pull antenna away from fuselage far enough to disconnect coax connector.
NOTE: It may be helpful to secure coax cable to airplane structure to prevent cable from
falling down into headliner area.
B. Install Antenna (Refer to Figure 201).
(1) Connect coax connector to corn antenna.
(2) Secure base of corn antenna to topside of fuselage using existing hardware.
(3) Fillet seal interface area of antenna base and fuselage using Type I, Class B-2 sealant. Refer to
Communications - General for a list of Type I sealants.
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DETAIL A 0585C1040
23-1 0-00 Page 202

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SCREW
WASHER
COM ANTENNA
GASKET FUSELAGE
SKIN
NUTPLATE
DOUBLER
ELECTRICAL
CONNECTOR
NAV/COM Installation
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MAINTENANCE MANUAL
AUDIO PANEL - MAINTENANCE PRACTICES

1. General
A. The audio panel is installed in the center of the instrument panel and incorporates audio integrating
functions, intercom functions and marker beacon indicators in a single unit.
B. Maintenance practices for the audio panel consist of removal/installation of the audio panel, intercom
jacks and marker beacon antenna.
C. For removal/installation of the overhead speaker, refer to Chapter 25, Interior Upholstery -
2. Audio Panel Removal/Installation
A. Remove Audio Panel (Refer to Figure 201).
(1) Ensure avionics master switch is in OFF position.
(2) On face of audio panel, turn recessed mounting screw counterclockwise until locking paw
releases unit from back of mounting tray.
(3) Grasp audio panel and gently pull out from mounting tray.
B. Install Audio Panel (Refer to Figure 201).
(1) Slide audio panel forward into mounting tray.
NOTE: Ensure audio panel seats positively into electrical connections at back of mounting
tray.
(2) Turn recessed mounting screw on face of audio panel clockwise until audio panel is secured to
mounting tray.
3. Intercom Jacks Removal/Installation
A. Remove Pilot/Front Passenger Intercom Jacks (Refer to Figure 201).
(1) Ensure avionics and master switches are in the OFF position.
(2) To gain access to backside of jacks, remove interior sidewall panel located between instrument
panel and forward doorpost. Refer to Chapter 25, Interior Upholstery - Maintenance Practices.
(3) Loosen and remove jamnuts securing jacks to interior panel.
(4) Carefully label all wires to microphone jack (small plug) and headphone jack (large plug).
(5) Cut wires near solder point at each jack.
B. Install Pilot/Front Passenger Intercom Jacks (Refer to Figure 201).
(1) Remove all traces of old solder from jacks.
(2) Reconnect and solder wires to jacks. Ensure all wires are soldered to correct pins on jacks.
(3) Secure jacks to sidewall panel using jamnuts.
(4) Reinstall sidewall panel. Refer to Chapter 25, Interior Upholstery - Maintenance Practices.
C. Remove Rear Passenger Intercom Jacks (Refer to Figure 201).
(2) Remove rear seat. Refer to Chapter 25, Rear Seats - Maintenance Practices.
(3) Remove rear sidewall panel. Refer to Chapter 25, Interior Upholstery - Maintenance Practices.
(4) Carefully label all wires to microphone jack (small plug) and headphone jack (large plug).
(5) Cut wires near solder point at each jack.
(6) Loosen and remove jamnuts securing jacks to rear sidewall panel.
D. Install Rear Passenger Intercom Jacks (Refer to Figure 201).
(1) Remove all traces of old solder from jacks.
(2) Reconnect and solder wires to jacks. Ensure all wires are soldered to correct pins on jacks.
(3) Secure jacks to sidewall panel using jamnuts.
(4) Reinstall rear sidewall panel. Refer to Chapter 25, Interior Upholstery - Maintenance Practices.
(5) Reinstall rear seat. Refer to Chapter 25, Rear Seats - Maintenance Practices.
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AUDIO PANEL
LOCKING SCREW
MODEL 172
MAINTENANCE MANUAL
B1697
CONSOLE
(TYPICAL) JACK
HEADPHONE
JACK
DETAIL C
COAX CABLE
CONNECTOR
MARKER BEACON
ANTENNA
DETAIL D
D0518T1035
Audio Panel Installation

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MAINTENANCE MANUAL
4. Marker Beacon Antenna Removal/Installation

A. Remove Marker Beacon Antenna (Refer to Figure 201).
(2) Remove baggage compartment lower access panel. Refer to Chapter 25, Interior Upholstery -
(3) Remove aft floorboard access/inspection plate to gain access to marker beacon antenna
connections.
(4) Disconnect coax cable from antenna.
(5) Remove screws securing antenna to belly of fuselage.
NOTE: Antenna may free fall to ground when last retaining screw is removed. Use additional
personnel to prevent antenna from striking ground.
B. Install Marker Beacon Antenna (Refer to Figure 201 ).
(1) Position marker beacon antenna to belly of fuselage.
(2) Secure to belly from inside of fuselage using existing hardware.
(3) Attach coax connector to antenna.
(4) Reinstall access/inspection plate to floor of airplane.
(5) Reinstall baggage compartment lower access panel. Refer to Chapter 25, Interior Upholstery -
23-50-00 Page 204

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MAINTENANCE MANUAL
STATIC WICKS - MAINTENANCE PRACTICES

1. General
A. Maintenance of the static (discharger) wicks consists of removal/replacement of the wick assembly and
ensuring that bonding straps are properly connected between control surfaces and primary structure.
B. Static wicks are mounted on the trailing edges of the ailerons, rudder and the elevators. Bonding
straps are secured to flight control surfaces and electrically connect those surfaces to the primary
structure.
A. For a list of applicable tools and equipment, refer to Communications - General.
3. Static Wicks Removal/Installation

A. Remove Static Wick (Refer to Figure 201).
(1) Carefully drill out mounting rivets which attach static wick to structure. Ensure holes are not
drilled oversize.
(2) Remove static wick from the airplane skin.
B. Install Static Wick (Refer to Figure 201).
(1) Clean surface of airplane skin where static wick will attach to skin. Remove all traces of
contaminants (including paint/primer) using scotchbrite and P-D-680 solvent.
(2) Secure static wick to airplane skin using rivets.
(3) Repaint at base of new wick (if required).
(4) Rebalance control surfaces. Refer to 1996 and On Single Engine Structural Repair Manual.
4. Bonding Straps Removal/Installation

A. Bonding straps are provided to ensure that electrical potential between primary and secondary
structure remains nearly equal. If bonding straps are removed, they should be reinstalled using
hardware called out in the 172R Illustrated Parts Catalog.
B. The maximum allowable resistance (in ohms) for bonding straps is 0.0025 ohms.
C. Primary and secondary structure should be cleaned using scotchbrite pad and P-D-680 solvent
before installing bonding hardware. Aluminum surfaces should be chemically protected (alodine or
equivalent) before attaching bonding hardware to surface.
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STATIC WICK SCREW
SPACER
SCREW
NUT
Static Discharger Installation

23-60-00 Page 202

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MAINTENANCE MANUAL
* CHAPTER
ELECTRICAL
POWER
MODEL 172
MAINTENANCE MANUAL

24-Title
24-00-00 1 Aug 18/2001
2 Aug 18/2001
24-20-00 101 Aug 18/2001
102 Aug 18/2001
103 Aug 18/2001
104 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
24-30-00 101 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
24-60-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
24-61-00 201 Aug 18/2001
202 Aug 18/2001
24-61-01 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
24-70-00 1 Aug 18/2001
2 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
ELECTRICAL POWER - GENERAL ................................................. 24-00-00 Page 1
Scope ........... ............................ ................................
24-00-00 Page 1
Tools, Equipment and Materials ..................... .......................... 24-00-00 Page 1
ALTERNATOR -TROUBLESHOOTING .............................................. 24-20-00 Page 101
Troubleshooting ............................................................... 21-20-00 Page 101
ALTERNATOR - MAINTENANCE PRACTICES ....................................... 21-20-00 Page 201
General ............................................................... ....... 21-20-00 Page 201
Alternator Removal/Installation ................................................. 24-20-00 Page 201
BATTERY - TROUBLESHOOTING ................................................. 24-30-00 Page 101
Troubleshooting ........... .............................................. 24-30-00 Page 101
BATTERY - MAINTENANCE PRACTICES ............................................ 24-30-00 Page 201
General ......... ......... ......... ........................................... 24-30-00 Page 201
Battery Removal/Installation .......................................... ........ 24-30-00 Page 201
Cleaning the Battery .......................................................... 24-30-00 Page 201
Adding Electrolyte or Water to the Battery ................................... ... . 24-30-00 Page 201
Charging the Battery .......................................................... 24-30-00 Page 203
Testing the Battery ........................................................... 24-30-00 Page 203
POWER JUNCTION BOX - MAINTENANCE PRACTICES ............................. 24-60-00 Page 201
General ................... ................................................... 24-60-00 Page 201
Power Junction Box Removal/Installation ............... . ..................... 24-60-00 Page 201
Component Removal/Installation ............................................... 24-60-00 Page 201
CIRCUIT BREAKER - MAINTENANCE PRACTICES ......... ......................... 24-61-00 Page 201
General ... ................................................................... 24-61-00 Page 201
Circuit Breaker Removal/Installation ... ............ ......................... 24-61-00 Page 201
ESSENTIAL BUS DIODES - MAINTENANCE PRACTICES ............................ 24-61-01 Page 201
General ................................................. ..................... 24-61-01 Page 201
Essential Bus Diode Removal/Installation ....................................... 24-61-01 Page 201
Essential Bus Diode Isolation Inspection (For Power Junction Boxes That Contain
Primary Bus Fuses. ) ................... .................................... 24-61-01 Page 201
Essential Bus Diode Isolation Inspection (For Power Junction Boxes That Contain
Primary Bus Circuit Breakers) ............................................... 24-61-01 Page 203
ELECTRICAL LOAD ANALYSIS - DESCRIPTION AND OPERATION .................. 24-70-00 Page 1
General .................. .............. ...................................... 24-70-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ELECTRICAL POWER - GENERAL

1. Scope
A. This chapter describes the electrical units and components which generate, control and supply
electrical power for the airplane systems. This includes such items as alternator, battery and relays.
B. Electrical energy for the aircraft is supplied by a 28-volt, direct current, single-wire, negative ground
electrical system. A single 24-volt battery supplies power for starting and furnishes a reserve source
of power in the event of alternator failure. A power junction box is mounted on the forward left side of
the firewall and incorporates electrical relays, an alternator control unit (ACU), an ammeter transducer,
an external power receptacle and additional fuses and circuits within a single box. An engine-driven
alternator is the normal source of power during flight and maintains a battery charge controlled by the
ACU. The external power receptacle is for ground operation of the electrical equipment and battery
conservation when starting the engine.
C. Electrical power is supplied through two electrical busses which are fed through two 30A fuses or two
30A circuit breakers in the J-box. These electrical buses power two avionics buses through 15A circuit
breakers. The two avionics buses are controlled by a single avionics master switch.
D. The operation of the battery and alternator system is controlled by a master switch. The operation
of the battery and alternator system is controlled by the master switch. The switch is an interlocking
split rocker with the right half controlling the battery and the left half controlling the alternator.
This arrangement allows the battery to be on line without the alternator, however, operation of the
alternator without the battery is not possible. The battery switch, when operated, connects the
battery contactor coil to ground so that the contacts close and powers the system with the battery
only. The alternator portion of the switch, when activated, applies positive voltage to the ACU and to
the alternator contactor coil simultaneously which subsequently applies field voltage to the alternator
field and powers the electrical system using the alternator. The switch is labeled BAT and ALT below
the switch and is located on the left side of the switch panel.
E. The ammeter is driven by a transducer located in the power junction box. The meter indicates the
amount of current flowing either to or from the battery. With a low battery and the engine operating at
cruise speed, the ammeter will show the full alternator output. When the battery is fully charged and
cruise is maintained with all electrical equipment off, the ammeter will show a minimum charging rate.
F The battery is a 24-volt, 12 Amp-hour, flooded lead-acid type. The battery is installed on the front-left
side of the firewall below the power junction box.

Digital Multimeter Model 75, 77, 87 or John Fluke Mfg. Co. General electrical use.
equivalent 6920 Seaway Blvd.
Everett, WA 98206
Variable Power Supply Available Commercially Supply external power.
Battery Charger TDMC-81 Cessna Aircraft Company Charge battery.
Cessna Parts Distribution
Department 701, CPD 2
5800 East Pawnee Road
Wichita, KS 67218-5590
Hydrometer (1.100 to Available Commercially Test specific gravity of
1.310 specific gravity electrolyte.
range)
24-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Small syringe Available Commercially Service battery.

Nonmetallic Brush (Acid Available Commercially Cleaning battery cells.
Resistant)
Adhesive 41-30 Mid-West Industrial Used to secure battery
Chemical Company vent drain tubes to battery
1509 Sublette case elbows
St. Louis, MO 63110
Rubber Gloves, Rubber Available Commercially Clean battery.
Apron, and Protective
Goggles.
Cleaning Cloth Available Commercially Clean battery.
Test Set TE03 Precision Airmotive Test J-box.
Corporation
3220 100th Street
Southwest #E
Everett, WA 98204
NOTE: Only test sets with a serial number of 1 through 800 and 1001 and up are approved for use.
24-00-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ALTERNATOR - TROUBLESHOOTING
1. Troubleshooting
Engine not running

TROUBLE PROBABLE CAUSE REMEDY
ALTERNATOR FIELD CIRCUIT Shorted diodes in alternator STEP 1: Turn off battery switch and
BREAKER TRIPS WHEN remove "B" lead (alternator feeder
BATTERY AND ALTERNATOR wire) and filter capacitor lead from
SWITCHES ARE TURNED ON BAT terminal on alternator. If
circuit breaker no longer trips
when alternator switch is turned
on, check filter capacitor for
short. Replace filter capacitor
as necessary. If filter capacitor is
ok, and circuit breaker trips when
alternator switch is turned on,
reinstall the "B" lead and proceed
to step 2.
Short in alternator "B" lead. STEP 2: Inspect "B" lead for short
to ground. Repair or replace "B"
lead as necessary. If no problem
with "B" lead is found, proceed to
step 3.
Short in alternator field winding. STEP 3: Disconnect field wire
from FLD terminal on alternator.
If circuit breaker no longer trips,
replace alternator. Otherwise
reinstall the field wire and proceed
to step 4.
Short in field wire. STEP 4: Inspect field wire for short
to ground between alternator and
ACU. Repair or replace field wire as
necessary. If no problem with the
field wire is found, proceed to step
5.
Defective ACU. STEP 5: Disconnect the ACU
connector in the J-box. If the circuit
no longer trips, replace the ACU.
Otherwise, reconnect the ACU
connector and proceed to step 6.
Short in alternator relay. STEP 6: Disconnect the red wire
from the small terminal of the
alternator relay. If the circuit
breaker no longer trips, replace
alternator relay. Otherwise,
reinstall the red wire and proceed
to step 7.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Short in J-box wire. STEP 7: Disconnect the PB018

J-box connector. If the circuit
breaker no longer trips, look for
a short to ground in the red wire
that goes from pin C of JB018 to
the alternator relay and the ACU.
Repair and replace as necessary.
If nothing is found, proceed to step
8.
Short in wire between J-box and STEP 8: Look for a short in the
alternator switch. alternator switch wire between the
alternator switch and the J-box.
Repair and replace as necessary.
If nothing is found, proceed to step
9.
Defective circuit breaker. STEP 9: Replace the alternator
field circuit breaker.
Engine running
ALTERNATOR FIELD CIRCUIT Defective ACU. STEP 1: Disconnect ACU
BREAKER TRIPS WHEN connector in J-box. If circuit
BATTERY AND ALTERNATOR breaker no longer trips, replace
SWITCHES ARE TURNED ON. ACU. Otherwise, proceed to step
(DOES NOT TRIP WHEN ENGINE 2.
IS NOT RUNNING)
Short between field wire and STEP 2: Look for short between
alternator "B" lead. field wire and alternator "B" lead.
Repair or replace as necessary.
ALTERNATOR MAKES Broken lead on filter capacitor. STEP 1: Repair or replace filter
ABNORMAL WHINING NOISE, capacitor.
NOISE CHANGES PITCH WHEN
RPM CHANGES AND GOES
AWAY WHEN ALTERNATOR IS
TURNED OFF
Grounding problem. STEP 2: Check for proper
grounding at alternator, J-box,
and ground block. If ok, then check
for any loose connections in J-box
or alternator. If ok, proceed to step
3.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Shorted diode in alternator. STEP 3: Turn off battery switch

and remove cable from "BAT'
terminal of alternator. Disconnect
negative battery cable. Using a
digital multimeter with the diode
function selected, place negative
lead on "BAT" terminal of alternator
and positive lead on case or
"GND" terminal and a reading
of approximately 0.8 to 1.0 should
be seen. If a reading of about half
is seen then suspect a shorted
diode in alternator. Reverse the
test leads and the meter should
indicate an open circuit. If the
resistance function of the meter is
selected or if using older analog
meters the readings will be different
but one direction should yield
an open circuit and the other
a numerical value in very high
resistance (usually greater than 1
Megaohm). If using the resistance
function and a setting on very
high resistance (greater than 1
Megaohm), then the meter may
show leakage, although the diodes
are fine. Since the alternator has
an internal capacitor, readings
taken with meters selected on
resistance may be unstable. If
readings are not ok, then replace
alternator.
LOW VOLTAGE LIGHT DOES NOT Broken terminal on alternator "B" STEP 1: Replace terminal on "B"
GO OUT WHEN ALTERNATOR lead. lead.
AND BATTERY SWITCHES ARE
TURNED ON
Defective ACU. STEP 2: With engine running
and alternator switch on, check
bus voltage (bus voltage can be
displayed on the clock). ACU
should turn low voltage light on
if voltage in J-box is at or below
24.5 volts. If light remains on and
clock displays at or above 26 volts,
replace ACU. Otherwise, proceed
to step 3.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Loss of power to ACU and STEP 3: With engine not running

alternator relay. and alternator switch on, check
voltage at small terminal of
alternator relay where red wire
attaches. If zero volts, check for
open wire, defective alternator
switch, or defective alternator field
circuit breaker. If nothing is found,
proceed to step 4.
Defective relay. STEP 4: With engine not running
for battery voltage at both large
terminals of alternator relay. If
battery voltage is present at
only one large terminal, replace
alternator relay. Otherwise,
proceed to step 5.
Defective alternator. STEP 5: With engine not running
field voltage at FLD terminal of
alternator. Field voltage should
be approximately 2 volts less than
battery voltage. If field voltage is
ok, replace alternator. Otherwise,
proceed to step 6.
Open in field wire. STEP 6: If there is no voltage
at FLD terminal, check for open
in field wire between alternator
and ACU. Repair or replace as
necessary. If nothing is found,
proceed to step 7.
Defective ACU. STEP 7: Replace ACU.
AFTER ENGINE START WITH Defective ACU. STEP 1: Check bus voltage. If 29
ALL ELECTRICAL EQUIPMENT volts or higher, replace ACU.
TURNED OFF, CHARGE RATE
DOES NOT TAPER OFF IN 1-3
MINUTES
ALTERNATOR WILL NOT KEEP Alternator output voltage STEP 1: This problem should be
BATTERY CHARGED insufficient. accompanied by a low voltage
light that won't go out. Refer to
the section above concerning this
problem.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ALTERNATOR - MAINTENANCE PRACTICES
1. General
A. A 60 amp alternator is installed on the forward side of the engine, below and to the right of the
crankshaft.
2. Alternator Removal/Installation
A. Remove Alternator (Refer to Figure 201).
(1) Remove upper and lower cowl.
(2) Disconnect battery cables.
(3) Disconnect electrical connectors from alternator.
(4) Remove safety wire from adjusting bolt. Remove bolt.
(5) Remove alternator mounting bolt.
(6) Remove drive Micro-V-Belt from alternator pulley.
(7) Remove alternator from airplane.
B. Install Alternator (Refer to Figure 201).
(1) Position alternator on mounting bracket and install mounting bolt and nut. Do not tighten at this
time.
(2) Place drive Micro-V-Belt on alternator pulley.
(3) Install adjusting bolt.
CAUTION: ANY AIRPLANE WITH A NEW ALTERNATOR BELT INSTALLED, INCLUDING
NEW AIRPLANES, BELT TENSION SHOULD BE RE-CHECKED WITHIN THE
FIRST 10 TO 25 HOURS OF OPERATION.
(4) Apply a torque wrench to the nut on alternator pulley and adjust the belt tension so the belt slips
at 7 to 9 foot-pounds of torque with a used belt, or 11 to 13 foot-pounds of torque with new
Micro-V-Belt.
(5) Torque the adjusting bolt to 160-185 inch-pounds and safety wire.
(6) Torque the alternator mounting bolt to 235-255 inch-pounds.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ADJUSTING BOLT
WASHER
ALTERNATOR ASSEMBLY
BRACKET ASSEMBLY
MOUNTING BOLT
Alternator Installation
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BATTERY - TROUBLESHOOTING
1. Troubleshooting

BATTERY WILL NOT Battery discharged. STEP 1: Place MASTER switch
SUPPLY POWER and TAXI LIGHT switch in ON
TO BUS OR IS position. Measure battery voltage
INCAPABLE OF across battery terminals. A
CRANKING ENGINE normally charged battery will
indicate 23 volts or more. If voltage
is low, proceed to Step 2. If voltage
is normal, proceed to Step 3.
Faulty battery. STEP 2: Check fluid level in
battery cells and charge battery
at 28 volts for approximately 30
minutes or until the battery voltage
rises to 28 volts. If tester indicates
a good battery, the problem was
a discharged battery. If the tester
indicates a faulty battery, replace
the battery.
Faulty wiring or electrical connection STEP 3: With master switch
between battery terminal and master closed, measure voltage at
switch. master switch terminal on bus bar
contactor. Normal indication is
zero volts. If voltage reads zero,
proceed to Step 4. If a voltage
reading is otained, check wiring
between battery terminal and
master switch. Also check master
switch.
Open coil on contactor. STEP 4: Check continuity between
battery terminal and master switch
terminal on bus bar contactor.
Normal indication is 50 to 70
Ohms. If ohmmeter indicates an
open coil, replace contactor. If
ohmmeter indicates a good coil,
proceed to Step 5.
Faulty bus bar contacts. STEP 5: Check voltage on bus
side of contact with master switch
closed. Meter normally indicates
battery voltage. If voltage is zero
or intermittent, replace contactor.
If voltage is normal, proceed to
Step 6.
Faulty wiring between battery terminal STEP 6: Inspect wiring between
and bus. contactor and bus. Repair or
replace wiring as necessary.
24-30-00 Page 101

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BATTERY - MAINTENANCE PRACTICES
1. General
A. The battery is a 24-Volt, 12 Amp-hour, flooded lead-acid type. The battery is installed on the front-left
side of the firewall below the power junction box.
NOTE: The 12 Amp-hour rating is based on a five hour discharge rate.
2. Battery Removal/Installation
A. Remove Battery (Refer to Figure 201).
(1) Remove upper and lower engine cowl.
(3) Disconnect battery drain at hose clamp.
(4) Remove battery hold down strap.
(5) Remove battery.
B. Install Battery (Refer to Figure 201).
(1) Place battery in tray and secure with battery hold down strap.
(2) Connect battery drain with hose clamp.
(3) Connect battery cables. Torque to 10 In. Ibs.
(4) Install upper and lower engine cowl.
3. Cleaning the battery

A. For maximum efficiency the battery and connections should be kept clean at all times.
(1) Remove the battery and connections in accordance with the preceding paragraph.
(2) Tighten battery cell filler caps to prevent the cleaning solution from entering the cells.
(3) Wipe the battery cable ends, battery terminals and the entire surface of the battery with a clean
cloth moistened with a solution of bicarbonate of soda (baking soda) and water.
(4) Rinse with clear water, wipe off excess water and allow battery to dry.
(5) Brighten up cable ends and battery terminals with emery cloth or a wire brush.
(6) Install the battery according to the preceding paragraph.
(7) Coat the battery terminals with petroleum jelly or an ignition spray product to reduce corrosion.
4. Adding electrolyte or water to the battery
CAUTION: Do not add any type of "battery rejuvenator" to the electrolyte. When acid has been spilled
from a battery, the acid balance may be adjusted by following instructions published by the
Association of American Battery Manufacturers.
A. A battery being charged and discharged with use will decompose the water from the electrolyte by
electrolysis. When the water is decomposed hydrogen and oxygen gases are formed which escape
into the atmosphere through the battery vent system. The acid in the solution chemically combines
with the plates of the battery during discharge or is suspended in the electrolyte solution during charge.
Unless the electrolyte has been spilled from a battery, acid should not be added to the solution. The
water, however, will decompose into gases and should be replaced regularly. Add distilled water as
necessary to maintain the electrolyte level with the horizontal baffle plate or the split ring on the filler
neck inside the battery. Water should be added only to a fully charged battery. When "dry charged"
batteries are put into service fill as directed with electrolyte. When the electrolyte levels falls below
normal with use, and only distilled water to maintain the proper level. The battery electrolyte contains
approximately 25% sulphuric acid by volume. Any change in this volume will hamper the proper
operation of the battery.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A
BATTERY CABLE
BATTERY GROUND CABLE
BATTERY
BATTERY TRAY
FIREWALL
DETAIL A
0510T1007
A0518T1023
Battery Installation
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
5. Charging the battery

WARNING: When a battery is being charged, hydrogen and oxygen gases are generated.
Accumulation of these gases can create a hazardous explosive condition. Always
keep sparks and open flame away from the battery. Allow unrestricted ventilation of
the battery area during charging.
WARNING: The main points of consideration during a battery charge are excessive battery
temperature and violent gassing. Cell temperature should not rise to over 115
degrees F (46 degrees C). Reduce charging rate if this occurs. Under a reasonable
rate of charge gassing should not be so violent that acid is blown from vents.
A. Remove the battery from the aircraft and place in a well ventilated area for charging. The level of the
electrolyte should be checked and adjusted by adding distilled water to cover the tops of the internal
battery plates. Water should only be added after battery is fully charged.
B. Because the battery is 24 volts, there are 12 cells connected in series as opposed to only 6 cells in 12
volt units. There is a greater chance for cell damage to occur if the battery is completely discharged
by leaving some electrical system on. If this should occur, the battery must be removed from the
aircraft, placed in a well ventilated area during charging, and given a supplemental charge. Charge
at a constant current rate of 1.5 amps until the terminal charge voltage remains constant for at least
three consecutive hours. If a constant current charger is not available, a constant potential charger
with voltage adjustment capabilities can be used. With an ammeter in series, manually adjust voltage
of charger so that approximately 1.5 amps are flowing at all times. Frequent adjustment may be
necessary for the first part of charge. A second alternative of a constant potential charge of 28.8 volts
could be used; however, the charging time under this system must be 48 to 72 hours. This long, slow
charge will tend to equalize all cells and bring the battery back to a useful state. Failure to utilize this
charge can leave the battery with one or more weak cells which will drastically reduce service life.
C. When activating new dry charged batteries, ensure that the proper strength of electrolyte is used. The
specific gravity of this electrolyte must be 1.285 +0.005 or -0.005 when measured at 80 degrees F +5
or -5 degrees F (27 degrees C +3 or -3 degrees C). The battery should then be charged as stated on
the installation instructions supplied with the battery. When installing the new battery into the aircraft,
the battery box maintenance cleaning procedure outlined below should be followed.
D. While Cessna aircraft batteries are manufactured with lower percentage antimony grids than that used
in the past, the phenomenon of "local action" or self-discharge still occurs in these newer batteries.
This is normal and should be expected in any wet lead acid battery. To maintain a battery if it is left
unused in or out of the aircraft for a period of 30 days, the maintenance charge should be equivalent
to that charge defined above for a discharged battery. If an aircraft is to be setting for periods of
time exceeding 30 days, the battery should be removed, stored in a cool, dry place, and given the
maintenance charge at intervals not exceeding 30 days.
6. Testing the battery

A. The specific gravity of the battery may be measured with hydrometer to determine the state of battery
charge. If the hydrometer reading is low, slow-charge the battery and retest. Hydrometer readings
of the electrolyte must be compensated for the temperature of the electrolyte. Some hydrometers
have a built-in thermometer and conversion table. Table 201 shows the battery condition for various
hydrometer readings with an electrolyte temperature of 80 degrees F (27 degrees C).
Table 201. Battery Hydrometer Readings
READINGS BATTERY CONDITION

1.280 Specific Gravity 100% Charged
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 201. Battery Hydrometer Readings (continued)

READINGS BATTERY CONDITION
1.160 Specific Gravity Practically dead
Note: All readings shown are for an electrolyte temperature of 80 Degrees F (27 Degrees C). For higher
temperatures the readings will be slightly lower. For cooler temperatures the readings will be slightly higher.
Some hydrometers will have a built-in temperature compensation chart and a thermometer. If this type tester
is used, disregard this chart.
B. If the specific gravity indicates the battery is not fully charged, the battery should be charged at
approximately 28 volts for 30 minutes, or until the battery voltage rises to 28 volts. Refer to charging
the battery for battery charging instructions for a completely discharged battery. After charging, a load
type tester will give more meaningful results. A specific gravity check can be used after charging but
the check cannot spot cells which short under load, broken connectors between plates of a cell, etc.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
POWER JUNCTION BOX - MAINTENANCE PRACTICES

1. General
A. The power junction box is mounted on the forward-left side of the fire wall and incorporates electrical
relays, an alternator control unit, an ammeter transducer, an external power receptacle and additional
fuses and circuits within a single box.
2. Power Junction Box Removal/Installation
A. Remove Power Junction Box (Refer to Figure 201).
(1) Disconnect battery.
(2) Disconnect power junction box electrical connectors.
(3) Remove screws securing power junction box to firewall.
(4) Remove power junction box.
B. Install Power Junction Box (Refer to Figure 201).
(1) Position power junction box on firewall and secure with screws.
(2) Connect power junction box electrical connectors.
(3) Connect battery.
3. Component Removal/Installation
A. General Precautions and Notes.
CAUTION: ENSURE ALL ELECTRICAL POWER IS REMOVED FROM AIRPLANE AND

BATTERY IS DISCONNECTED BEFORE WORKING ON JUNCTION BOX
COMPONENTS.
(1) Individual components such as relays, transducers and alternator control unit may be replaced
on an as-needed basis. Refer to the Model 172R Illustrated Parts Catalog for replacement part
numbers.
(2) Before disconnecting wires, identify and tag for reinstallation purposes.
(3) Torque values for ground and current-carrying studs may be found in Chapter 20, Torque Data -
24-60-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A
FIREWALL
WASHER
POWER
JUNCTION
BOX
EXTERNAL
POWER
RECEPTACLE
DETAIL A
0510T1007
A0558T1001
Power Junction Box Installation

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1700
ALTERNATOR
CONTROL
UNIT ALTERNATOR SPARE FUSE
CURRENT
BATTERY
RELAY (K3)
ELECTRICAL
CONNECTORS
(J1 AND J2)
VIEW A-A
0558T1002
Power Junction Box Installation

24-60-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CIRCUIT BREAKER - MAINTENANCE PRACTICES
1. General
A. The circuit breaker panel is located on the left lower instrument panel, below the pilot's control wheel.
The circuit breaker panel contains electrical circuit breakers, the ignition/magneto switches, the master
switch, the avionics master switch and light switches.
2. Circuit Breaker Removal/Installation
A. Remove Circuit Breaker (Refer to Figure 201).
(2) In the cockpit/cabin area, remove screws securing circuit breaker panel to lower instrument
panel.
(3) Disconnect and label wires from circuit breaker.
(4) Remove nut and washer securing circuit breaker to circuit breaker panel.
(5) Remove circuit breaker.
B. Install Circuit Breaker (Refer to Figure 201).
(1) Place circuit breaker in circuit breaker panel and secure with washer and nut.
(2) Remove labels and connect wires to circuit breakers
(3) Place circuit breaker panel on lower instrument panel and secure with screws.
(4) Connect battery cables.
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MODEL 172
MAINTENANCE MANUAL
BREAKER
CIRCUIT BREAKER
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Aug 18/2001
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ESSENTIAL BUS DIODES - MAINTENANCE PRACTICES

1. General
A. The essential bus diodes are located on the circuit breaker panel on the lower instrument panel below
the pilot's control wheel. The diodes provide power to the essential bus from the two primary buses
and at the same time isolate the two primary buses.
2. Essential Bus Diode Removal/Installation

A. Remove Essential Bus Diode (Refer to Figure 201).
(1) Remove circuit breaker panel. Refer to Chapter 24, Circuit Breaker - Maintenance Practices.
(2) Unsolder wire from diode. Refer to Model 172R Serial Numbers 17280001 And On And
172S Serial Numbers 172S8001 And On Wiring Diagram Manual, Chapter 20, Soldering -
(3) Remove nut and washer from diode.
(4) Remove diode.
B. Install Essential Bus Diode (Refer to Figure 201).
(1) Install diode.
(2) Secure diode with nut and washer.
(3) Solder wire to diode. Refer to Model 172R Serial Numbers 17280001 And On And 172S Serial
Numbers 172S8001 And On Wiring Diagram Manual, Chapter 20, Soldering - Maintenance
Practices.
(4) Install circuit breaker panel. Refer to Chapter 24, Circuit Breaker - Maintenance Practices.
3. Essential Bus Diode Isolation Inspection (For Power Junction Boxes That Contain Primary Bus
Fuses)
NOTE: If TE04 test box is available use it for this test, otherwise follow the steps below.
A. Inspect Essential Bus Diodes (Refer to Figure 201).
CAUTION: DO NOT REMOVE ANY FUSES WITH BATTERY MASTER SWITCH ON.
(1) Position Battery Master, Taxi Light, and Landing Light switches to the ON position.
(2) Verify operation of Landing and Taxi Lights.
(3) Position Battery Master, Taxi Light, and Landing Light switches to the OFF position.
(4) Remove screws securing power junction box cover and remove cover.
(5) Remove fuse labeled BUS 1.
(7) If BOTH Landing Lights and Taxi Lights illuminate, then replace both Essential Bus Diodes.
(9) Reinstall BUS 1 fuse into the Power Junction Box.
NOTE: If fuse is pitted, arced, or does not fit snugly into fuse receptacle, then replace with
new fuse of same type. Do not replace with fuse with thinner blades.
(10) Remove fuse labeled BUS 2.
(14) Reinstall BUS 2 fuse into the Power Junction Box.
NOTE: If fuse is pitted, arced, or does not fit snugly into fuse receptacle, then replace with
new fuse of same type. Do not replace with fuse with thinner blades.
NOTE: Any time the diodes are replaced, repeat this test to make sure the new diodes are
functioning properly.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
DIODE
DIODE
VIEW A-A
VIEW LOOKING AFT
Essential Bus Diode Inspection

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(15) Reinstall Junction Box Cover with screws.

4. Essential Bus Diode Isolation Inspection (For Power Junction Boxes That Contain Primary Bus
Circuit Breakers)
NOTE: If TE04 test box is available use it for this test, otherwise follow the steps below.
A. Inspect Essential Bus Diodes (Refer to Figure 201).
CAUTION: DO NOT REMOVE ANY BUS WIRES FROM CIRCUIT BREAKERS WITH BATTERY
MASTER SWITCH ON.
(2) Verify operation of Landing and Taxi Lights.
(4) Remove screws securing power junction box cover and remove cover.
(5) Remove hex nut and lock washer that holds bus wire to circuit breaker 1 then remove the wire
terminal from circuit breaker stud labeled AUX and isolate the end of bus wire.
(9) Reinstall the bus wire back to the circuit breaker 1 terminal using the same hex nut and washer
that was removed and torque nut to 20 to 25 inch-pounds.
(10) Remove hex nut and lock washer that holds bus wire to circuit breaker 2 then remove the wire
terminal from circuit breaker stud labeled AUX and isolate the end of bus wire.
(14) Reinstall the bus wire back to the circuit breaker 2 terminal using the same hex nut and washer
that was removed and torque nut to 20 to 25 inch-pounds.
NOTE: Any time the diodes are replaced, repeat this test to make sure the new diodes are
functioning properly.
(15) Reinstall Junction Box Cover with screws.
24-61-01 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ELECTRICAL LOAD ANALYSIS - DESCRIPTION AND OPERATION

1. General
A. The following chart provides a load analysis of various components used on the airplane.
Component Draw at 24.0 VDC Draw at 28.0 VDC

(In Amps) (In Amps)
Master Switch ON 1.5 1.6
Master & Avionics ON 3.4 3.8
#1 Comm w/GS (Receive mode) 0.5 0.5
#1 Comm w/GS (Transmit mode) 2.4 2.4
#2 Comm w/o GS (Receive mode) 0.5 0.5
#2 Comm w/o GS (Transmit mode) 2.4 2.4
ADF Receiver 0.5 0.5
Annunciator (engine off) 0.1 0.1
Beacon (50% duty cycle) 1.2 1.3
Courtesy Lights (left, right, aft cabin) 1.7 1.8
Flap Motor 1.1 1.2
Fuel Pump 2.0 2.0
Glareshield Light 0.9 0.9
GPS (KLN 89/89B) 1.0 1.0
GPS (KLN 94) 1.1 1.2
Landing Light 8.0 8.8
Nav & Map Light 2.3 2.4
Panel Lights 0.8 0.9
Pedestal Light 0.1 0.1
Pitot Heat 5.3 6.2
Radio Lights 0.5 0.6
Left & Right Strobes (Peak Values) 3.8 3.8
Taxi Light 8.0 8.8
Transponder 1.0 1.2
Autopilot (Single Axes) 1.5 1.5
Autopilot (Dual Axes) 2.5 2.5
Audio Panel (KMA-26) 1.5 1.5
Audio Panel (KMA-28) 0.3 0.4
MFD (KMD-540) 0.8 0.8
24-70-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Component Draw at 24.0 VDC Draw at 28.0 VDC

(In Amps) (In Amps)
Power Port (*Current input at 10 Amp 5.4* 5.5*
output.)
Storm Scope (WX-500) 0.9 0.9
24-70-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
EQUIPMENT/
FURNISHINGS
MODEL 172
MAINTENANCE MANUAL

25-Title
25-00-00 1 Aug 18/2001
25-10-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
25-10-04 201 Aug 18/2001
202 Aug 18/2001
25-11-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
25-21-00 201 Aug 18/2001
202 Aug 18/2001
25-22-00 201 Feb 15/2002
202 Feb 15/2002
203 Feb 15/2002
204 Feb 15/2002
205 Feb 15/2002
206 Feb 15/2002
25-50-00 201 Aug 18/2001
202 Aug 18/2001
.25-60-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
25-80-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

|~~~~~~~~~~~ I
MODEL 172
MAINTENANCE MANUAL

I
MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL
CONTENTS
EQUIPMENT/FURNISHING - GENERAL ........................................... 25-00-00 Page 1
Scope ..................................................................... 25-00-00 Page 1
Definition ................................................................... 25-00-00 Page 1
FRONT SEATS AND RAILS - MAINTENANCE PRACTICES ......................... 25-10-00 Page 201
General.................................................................... 25-10-00 Page 201
Seat Removal/Installation .................................................... 25-10-00 Page 201
Seat Rail Removal/Installation ............................................... 25-10-00 Page 201
MAP COMPARTMENT - MAINTENANCE PRACTICES .............................. 25-10-04 Page 201
General ................................................................... 25-10-04 Page 201
Map Compartment Removal/Installation ....................................... 25-10-04 Page 201
SEAT BELTS/RESTRAINTS - MAINTENANCE PRACTICES ......................... 25-11-00 Page 201
General .................................................................... 25-11-00 Page 201
Seat Belt/Restraints Removal and Installation .................................. 25-11-00 Page 201
Restraint Testing ............................................................ 25-11-00 Page 201
REAR SEAT - MAINTENANCE PRACTICES ....................................... 25-21-00 Page 201
General .................................................................... 25-21-00 Page 201
Rear Seat Removal/Installation ............................................... 25-21-00 Page 201
INTERIOR UPHOLSTERY - MAINTENANCE PRACTICES .......................... 25-22-00 Page 201
General .................................................................... 25-22-00 Page 201
Cabin Panels Removal/Installation ............................................ 25-22-00 Page 201
Door Panels, Carpet and Rubber Mat Removal/Installation ...................... 25-22-00 Page 201
CARGO TIE-DOWNS - MAINTENANCE PRACTICES ............................... 25-50-00 Page 201
General .................................................................... 25-50-00 Page 201
EMERGENCY LOCATOR TRANSMITTER - MAINTENANCE PRACTICES ............ 25-60-00 Page 201
General .................................................................... 25-60-00 Page 201
Transmitter Removal/Installation .............................................. 25-60-00 Page 201
Panel Mounted Rocker Switch Removal/Installation ............................ 25-60-00 Page 201
Antenna Removal/Installation ................................................ 25-60-00 Page 201
Battery Pack Removal/Installation ............................................ 25-60-00 Page 204
Emergency Locator Transmitter Test ...................................... .... 25-60-00 Page 204
SOUNDPROOFING AND INSULATION - MAINTENANCE PRACTICES .............. 25-80-00 Page 201
General .................................................................... 25-80-00 Page 201
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
EQUIPMENT/FURNISHING - GENERAL
1. Scope
A. This chapter describes the interior equipment and furnishings used throughout the airplane.
Emergency locator transmitter information is also included in this chapter.

Spray Adhesive Airtac2 Advanced Materials Group To adhere soundproofing
2542 East Del Amo Blvd. and insulation to fuselage
Box 6207 structure.
Carson, CA
3. Definition
A. The 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 subjects
and sections incorporated in this chapter is as follows:
(1) The section on Flight Compartment covers those items installed in the cabin area, including
seats, seat restraints systems, carpets and interior panels.
(2) The section on emergency equipment covers the emergency locator transmitter installed behind
the aft baggage compartment.
(3) The section on soundproofing and insulation covers the material used to deaden sound
throughout the airplane.
25-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FRONT SEATS AND RAILS - MAINTENANCE PRACTICES

1. General
A. This maintenance practices section covers removal and installation for the front seats and seat rails.
For removal/installation of seat belts and harnesses, refer to Seat Belts/Restraints - Maintenance
Practices. For removal/installation of the rear seats, refer to Rear Seat - Maintenance Practices.
2. Seat Removal/Installation
A. Remove Seats (Refer to Figure 201).
(1) Remove seat stops from front and rear of each seat track.
(2) Unlatch seat from seat track and move seat forward on seat track until forward roller clears seat
track.
(3) Move seat backward on seat track until rear rollers clear seat track.
(4) Remove seat from airplane.
B. Install Seats (Refer to Figure 201).
(1) Position rear roller of seat on seat track.
(2) Move seat forward on seat track until front roller can be installed on seat track.
(3) Install seat stops to front and rear of seat track.
WARNING: IMPROPERLY INSTALLED SEAT STOPS COULD ALLOW SEAT MOVEMENT
DURING FLIGHT MANEUVERS, RESULTING IN SERIOUS INJURY OR
DEATH.
(4) Test seat through full range of motion to ensure proper operation. Ensure seat stops are properly
installed.
3. Seat Rail Removal/Installation

A. Remove Seat Rails (Refer to Figure 202).
(1) Remove bolts securing seat rails to fuselage.
B. Install Seat Rails (Refer to Figure 202).
(1) Install seat rails to fuselage using bolts.
25-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
HEAD
REST
HARNESS
GUIDE
SEAT
BACK
PAN
BACK
HEIGHT
ADJUSTMENT
CRANK
SEAT
LOCK BASE
ASSEMBLY
DETAIL A
A0519T1036
Seat Installation
25-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B
SPACERS
DETAIL E
WASHERS
WASHERS
FORWARD
AFT FOOT
HALVES
BUSHING
A0519T1036
DETAIL C B0519T1037
DETAIL D C0519T1038
D0519T1039
Seat Installation
25-10-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SPACER
BOLT
SPACER
WARNING: IT IS EXTREMELY IMPORTANT THAT PILOT'S SEAT STOPS ARE INSTALLED,

SINCE ACCELERATION AND DECELERATION COULD POSSIBLY PERMIT SEAT
TO BECOME DISENGAGED FROM SEAT RAILS AND CREATE A HAZARDOUS
SITUATION, ESPECIALLY DURING TAKEOFF AND LANDING.
Seat Stop Installation

25-10-00 Page 204

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
MAP COMPARTMENT - MAINTENANCE PRACTICES

1. General
A. This maintenance practices section consists of removal and installation of the map compartment.
2. Map Compartment Removal/Installation
A. Remove Map Compartment (Refer to Figure 201).
(1) Remove interior screws securing map compartment to instrument panel structure.
B. Install Map Compartment (Refer to Figure 201).
(1) Place map compartment in position and secure to instrument panel structure using screws.
25-10-04 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
MAP
COMPARTMENT
SCREWS
PIANO
HINGE
HINGE
MAP WIRE
COMPARTMENT CLOSURE
05193003
Map Compartment Installation

25-10-04 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SEAT BELTS/RESTRAINTS - MAINTENANCE PRACTICES
1. General
A. The airplane is equipped with retraction-style reels which allow the seat belts to retract and stow
in position when not in use. This maintenance practices section covers removal and installation for
restraints used in both the front and rear positions.
NOTE: The restraint system components are non-repairable field items. If any component in the
restraint system is not operating properly, the system must be replaced.
2. Seat Belt/Restraints Removal and Installation

NOTE: Seat belt/restraint assembly removal/installation is typical for restraints in all locations.
A. Remove Restraints (Refer to Figure 201).
(1) Remove access covers (if installed) to gain access to the restraint assembly attaching hardware.
(2) Remove nuts, bolts, washers and spacers securing restraint assemblies to fuselage or to seats.
(3) Remove assemblies from airplane.
B. Install Restraints (Refer to Figure 201).
(1) Install restraint assemblies to fuselage or to seat. Ensure spacers (if installed) are positioned
correctly.
(2) Install access covers (if equipped).
(3) Check system for security of installation and proper operation.
3. Restraint Testing
A. The restraint system should be inspected in accordance with time intervals set forth in Chapter 5,
Inspection Time Limits. In addition to these scheduled inspections, the restraint assemblies have a
time life associated with them. Refer to Chapter 5, Component Time Life for these limits.
25-11-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PLATE
BRACKET
WASHER BOLT
A
PLUG BUTTON
BOLT
WASHERS B
NUT
DETAIL D
D
BOLT
DETAIL C
DETAIL A C
A109
C0519T1047
Seat Belts and Restraints Installation

25-11-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BOLT
NUT
DETAIL H
ASSEMBLY
H
DETAIL E
WASHER
A108
G0519T1049
H1219T1003
Seat Belts and Restraints Installation

25-11-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
REAR SEAT- MAINTENANCE PRACTICES
1. General
A. This section provides instruction for removal and installation of the rear seat.
2. Rear Seat Removal/Installation

A. Remove Rear Seat (Refer to Figure 201).
(1) Remove bolts and washers securing seat frame to fuselage.
(2) Remove seat from airplane.
B. Install Rear Seat (Refer to Figure 201).
(1) Install seat to fuselage and secure using bolts and washers.
25-21-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
HARNESS
SEAT
BACK
BASE
B
WASHER
DETAIL A
ROD
SEAT BACK
ADJUSTMENT
HANDLE
Aft Bench Seat Installation

25-21-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INTERIOR UPHOLSTERY - MAINTENANCE PRACTICES
1. General
A. This section provides general instructions for removal and installation of the interior panels, carpet
and rubber mat.
2. Cabin Panels Removal/Installation
A. Interior panels are typically attached to fuselage structure using screws. Refer to Figure 201 for an
exploded view of the interior panels, headliner and overhead console.
3. Door Panels, Carpet and Rubber Mat Removal/Installation
A. Cabin door panels are typically attached to the fuselage and door structure using small screws. Carpet
and rubber mats are attached to the floorboard using Velcro. Refer to Figure 202 for a view of the side
panels, carpet and rubber mat.
25-22-00 Page 201

Feb 15/2002
(L eeLa4S) LO aJn6!-
30
-13NVd
HOO VOVJL
/l3a
13NVd 3G
ln0O3SO
MODEL 172
MAINTENANCE MANUAL
B1705
LIGHT
LIGHT SWITCH
OVERHEAD CONSOLE
DETAIL C
C0519T1050
Cabin Interior Trim And Overhead Console Installation

25-22-00 Page 203

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B3271
DOORPOST MOLDING
GRILL COVER
DOORPOST MOLDING
DETAIL D
LEFT SIDE SHOWN
RIGHT SIDE OPPOSITE
172080984 THRU 172081074 AND
172S087704 THRU 172S08908
D0719T1012
Cabin Interior Trim And Overhead Console Installation

25-22-00 Page 204

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
REAR PANEL DOOR PANEL FORWARD SIDE PANEL
VIEW A-A
ACCENT TRIM
FORWARD SIDE PANEL DOOR PANEL REAR PANEL
(/ oVIEW B-B
0510T1007
AA0519T1042
ACCENT TRIM BB0519T1042
Cabin Side Panel And Floorboard Upholstery Installation

25-22-00 Page 205

Feb 15/2002
3i1V-d di nos
-IVnNVA 30NVN31NIVIAI
MODEL 172
MAINTENANCE MANUAL
CARGO TIE-DOWNS - MAINTENANCE PRACTICES

1. General
A. Cargo tie-downs are provided for the airplane to accommodate a variety of loading positions. These
tie-downs are secured directly to the floorboard through nutplates or indirectly to the floorboard through
seat rails. Refer to Figure 201 for an illustration of these tie- downs.
25-50-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CARGO TIE-DOWN RING
CARGO TIE-DOWN
LUG SLIDE ASSEMBLY
SEAT RAIL
Cargo Tie-Downs Installation

25-50-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
EMERGENCY LOCATOR TRANSMITTER - MAINTENANCE PRACTICES
1. General
A. This section provides maintenance practices for the emergency locator transmitter.
2. Transmitter Removal/Installation
A. Remove Transmitter (Refer to Figure 201).
(1) Gain access to transmitter through the left side baggage compartment door.
(2) Remove tie-downs bolts and plastic closeout from lower baggage area (Zone 240). Refer to
Airplane Zoning - Description and Operation.
(3) Disconnect coaxial antenna cable from transmitter.
(4) Disconnect remote connector from transmitter.
(5) Disengage attach strap from around transmitter and remove transmitter from airplane.
B. Install Transmitter (Refer to Figure 201).
CAUTION: ENSURE THAT DIRECTION OF FLIGHT ARROW ON TRANSMITTER IS POINTING
TOWARD NOSE OF AIRPLANE.
(1) Position transmitter inbracket and secure using attach strap.

(2) Reconnect remote connector to transmitter.
(3) Reconnect coaxial antenna cable to transmitter.
(4) Perform an operational test of the transmitter in accordance with Emergency Locator Transmitter
Test.
(5) Install tie down bolts and plastic close out panel.
3. Panel Mounted Rocker Switch Removal/Installation
WARNING: DISCONNECT CONNECTOR FROM THE ELT TRANSMITTER BEFORE
PERFORMING AIRCRAFT MAINTENANCE IN AREA OF THE PANEL REMOTE
MOUNTED SWITCH. FAILURE TO REMOVE THE CONNECTOR COULD CAUSE
INADVERTENT BLOWING OF THE ELT'S INTERNAL FUSE.
A. Remove Switch (Refer to Figure 201).
(1) Ensure all electrical power to the airplane is off.
(2) Gain access to backside of remote mounted switch. Compress locking tabs on either side of
switch and, at same time, pull switch aft and away from instrument panel.
(3) Disconnect electrical connector from switch.
B. Install Switch (Refer to Figure 201).
(1) Reconnect electrical connector to remote mounted switch.
(2) Grasp edges of remote mounted switch and insert into instrument panel cutout. Ensure locking
tabs engage and that switch is secure.
4. Antenna Removal/Installation
A. Remove Antenna (Refer to Figure 201).
(1) Disconnect coax cable from transmitter.
(2) Remove all tie straps securing coax cable to fuselage.
(3) On outside of airplane, remove six internal locking screws attaching antenna (with integral base
and coax cable) to fuselage.
| (4) Remove antenna from inside airplane.
B. Install Antenna (Refer to Figure 201).
(1) From inside of airplane, position antenna (with integral base and coax cable) to fuselage.
(2) From outside of airplane, secure antenna base to fuselage using internal locking screws.
(3) Connect coax cable to transmitter.
(4) Secure coax cable to fuselage using tie straps.
25-60-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INTERNAL
LOCKING
SKIN
DOUBLER
ANTENNA
ANCHOR
MASTER SWITCH
REMOTE CONNECTOR
(TO REMOTE MOUNTED SWITCH)
TRANSMITTER
BATTERY PACK
BASE PLATE
NEOPRENE WASHER
ATTACH STRAP
MOUNTING BRACKET
DETAIL A
Emergency Locator Transmitter Installation
25-60-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL B
REMOTE MOUNTED SWITCH
T
0 T
RESET
TOTAL HOURS
DETAIL C B0585C1040
Emergency Locator Transmitter Installation

25-60-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
5. Battery Pack Removal/Installation

A. Remove Battery Pack (Refer to Figure 201).
(1) Place transmitter switch in OFF position.
(2) Remove transmitter from airplane.
(3) Remove screws attaching base plate to transmitter.
(4) Disconnect battery pack and transmitter electrical connectors.
(5) Remove battery pack from transmitter.
B. Install Battery Pack (Refer to Figure 201).
WARNING: DISPOSE OF UNSERVICEABLE BATTERY PACK PROPERLY. DO NOT

INCINERATE OR COMPACT.
CAUTION: BATTERY PACKS ARE NOT INTERCHANGEABLE AND TRANSMITTERS CAN

ONLY USE THE RECOMMENDED BATTERY PACK, AS THE OPERATING
LIFE AND/OR SIGNAL STRENGTH OF THE TRANSMITTER WILL BE
SERIOUSLY DEGRADED. IN SOME CASES, CHANGES IN THE MECHANICAL
CONFIGURATION MAY MAKE THE TRANSMITTER PRONE TO FAILURE DUE TO
VIBRATION AND CORROSION.
(1) Place battery pack in transmitter.

(2) Connect battery pack electrical connectors.
(3) Attach base plate and gasket to transmitter using screws.
WARNING: ENSURE NEW BATTERY PACK EXPIRATION DATE IS ENTERED IN
AIRPLANE RECORDS. IT IS ALSO RECOMMENDED THAT EXPIRATION
DATE BE PLACE IN EMERGENCY LOCATOR TRANSMITTER OWNER'S
MANUAL FOR QUICK REFERENCE.
(a) Stamp new replacement date on outside of transmitter. The date should be noted on switch
nameplate, on side of unit and in instruction nameplate on top of unit.
(4) Install transmitter to airplane.
6. Emergency Locator Transmitter Test

A. Operational Test Using Control Tower Monitoring.
(1) Request permission from control tower and/or flight service station to test emergency locator
transmitter system.
(2) Activate emergency locator transmitter system by placing remote mounted switch to the ON
position.
(3) Contact control tower and/or flight service station to confirm proper emergency locator
transmitter system operation.
(4) Momentarily place the remote mounted switch to the RESET position.
(5) place the remote mounted switch in the AUTO position.
B. Operational Test Using Local Monitoring.
(1) Verify that test is performed on the hour to five minutes after the hour.
(2) Position a small, hand held AM radio tuned to any frequency, within six inches of the emergency
locator transmitter antenna.
NOTE: Using the airplane's VLF receiver or ADF will not properly check power of radiated
signal.
(3) Activate emergency locator transmitter system by placing the remote mounted switch in the ON
position for no more than three sweeps of the audio signal.
(a) Verify that signal has been detected on the AM radio. If signal is not detected, proceed to
Operational Test Using Master Switch On The ELT Unit
| (4) Momentarily place the remote mounted switch to the RESET position.
25-60-00 Page 204

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(5) place the remote mounted switch in the AUTO position.

C. Operational Test Using Master Switch On The ELT Unit.
(1) Verify that test is performed on the hour to five minutes after the hour.
(2) Momentarily place master switch to the ON position.
(3) Verify the signal is detected by either the Control Tower, Flight Service Station or AM radio.
(4) If signal is detected, suspect blown internal PICO fuse.
(5) If signal is not detected, suspect defective transmitter.
WARNING: REMOVE REMOTE CONNECTOR FROM ELT BEFORE PERFORMING AIRCRAFT
MAINTENANCE IN AREA OFTHE PANEL REMOTE MOUNTED SWITCH. FAILURE
TO REMOVE THE CONNECTOR COULD CAUSE INADVERTENT BLOWING OF
THE ELT'S INTERNAL FUSE.
D. G Switch Operation Check.
(1) Remove transmitter from airplane.
(2) Hold transmitter firmly in one hand, and make a throwing motion followed by a sudden reversal
of the transmitter.
(a) Verify that G switch has been actuated.
(3) Reset the G switch.
(4) Reinstall transmitter in airplane.
25-60-00 Page 205

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SOUNDPROOFING AND INSULATION - MAINTENANCE PRACTICES

1 General
A. The airplane utilizes soundproofing and insulation throughout the fuselage area. This material is glued
into place using spray adhesive. Anytime old material is being replaced, care should be taken to
ensure all traces are removed from fuselage skin before reapplication. For a list of spray adhesives,
refer to Equipment/Furnishing - General.
B. For an illustration of soundproofing and insulation locations, refer to Figure 201 and Figure 202.
25-80-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
05191029
Soundproofing Installation
25-80-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
05191030
25-80-00 Page 203

MODEL 172
MAINTENANCE MANUAL
* CHAPTER
FIRE
PROTECTION
.
MODEL 172
MAINTENANCE MANUAL

26-Title
26-00-00 1 Aug 18/2001
26-20-00 1 Aug 18/2001
2 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
FIRE PROTECTION - GENERAL .................................................... 26-00-00 Page 1
Scope and Definition ......... ............................... ......... ......... 26-00-00 Page 1
HAND FIRE EXTINGUISHER - DESCRIPTION AND OPERATION .............. .... 26-20-00 Page 1
Description and Operation ......... ............................................ 26-20-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FIRE PROTECTION - GENERAL

A. This chapter contains a single section which describes the portable fire extinguisher used in the cabin.
26-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
HAND FIRE EXTINGUISHER - DESCRIPTION AND OPERATION
1. Description
A. A portable, hand operated fire extinguisher is mounted on the floor between the pilot and copilot
seats for use in the event of a fire. The extinguishing agent is Halon 1211 and may be used on
solid combustible, electrical or liquid fires. Servicing of the extinguisher can be handled by most
fire equipment dealers. The fire extinguisher is mounted within a quick release, clamp type bracket
assembly. (Refer to Figure 1).
2. Operation
A. For operation of the fire extinguisher, refer to Section 7 of the Pilot's Operating Handbook.
26-20-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
COPILOTSEAT
FIRE EXTINGUISHER
DETAIL A
MOUNTING BRACKET
Fire Extinguisher Installation

Figure 1 (Sheet 1)
26-20-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
FLIGHT CONTROLS
MODEL 172
MAINTENANCE MANUAL

27-Title
27-00-00 1 Aug 18/2001
27-00-01 201 Aug 18/2001
202 Aug 18/2001
27-10-00 101 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
206 Aug 18/2001
207 Aug 18/2001
27-20-00 101 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
27-30-00 101 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
27-31-00 101 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
206 Aug 18/2001
207 Aug 18/2001
208 Aug 18/2001
209 Aug 18/2001
210 Aug 18/2001
211 Aug 18/2001
27-50-00 101 Aug 18/2001
102 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
206 Aug 18/2001
207 Aug 18/2001
27-51-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
FLIGHT CONTROLS - GENERAL ................................................... 27-00-00 Page 1
General ................................................. 27-00-00 Page 1
Tools, Equipment and Material ................................................. 27-00-00 Page 1
Definition .................................................................... 27-00-00 Page 1
CONTROL CABLE WIRE BREAKAGE AND CORROSION LIMITATIONS ............... 27-00-00 Page 201
Examination of Control Cables ................................................. 27-00-01 Page 201
AILERON CONTROL SYSTEM - TROUBLESHOOTING ............................... 27-10-00 Page 101
AILERON CONTROL SYSTEM - MAINTENANCE PRACTICES ........................ 27-00-00 Page 201
General ............................................................ 27-10-00 Page 201
Control Yoke Removal/Installation .............................................. 27-10-00 Page 201
Aileron Removal/Installation .................................................... 27-10-00 Page 201
Aileron Bellcrank Removal/Installation .......................................... 27-10-00 Page 206
Adjustment/Test ............................................................... 27-10-00 Page 206
Cable and Pulleys Removal/Installation ......................................... 27-10-00 Page 207
RUDDER CONTROL SYSTEM - TROUBLESHOOTING ............................... 27-20-00 Page 101
Troubleshooting .............................................................. . 27-20-00 Page 101
RUDDER CONTROL SYSTEM - MAINTENANCE PRACTICES ........................ 27-20-00 Page 201
General .................................................................... 27-20-00 Page 201
Rudder Pedal Assembly Removal/Installation ................................... 27-20-00 Page 201
Rudder Removal/Installation .................................................. 27-20-00 Page 201
Rudder Control Adjustment/Test ............................................... 27-20-00 Page 201
ELEVATOR CONTROL SYSTEM - TROUBLESHOOTING ............................. 27-30-00 Page 101
ELEVATOR CONTROL SYSTEM - MAINTENANCE PRACTICES ...................... 27-30-00 Page 201
General ................................................ 27-30-00 Page 201
Forward Elevator Bellcrank Removal/Installation ................................. 27-30-00 Page 201
Aft Elevator Bellcrank Removal/Installation ...................................... 27-30-00 Page 201
Elevator Removal/Installation ................................................. 27-30-00 Page 201
Elevator Control Adjustment/Test ............................................... 27-30-00 Page 204
ELEVATOR TRIM CONTROL - TROUBLESHOOTING ................................. 27-30-00 Page 101
Troubleshooting ....................... .................................... 27-30-00 Page 101
ELEVATOR TRIM CONTROL - MAINTENANCE PRACTICES ......................... 27-31-00 Page 201
General ................................................. 27-31-00 Page 201
Trim Tab Actuator Removal/Installation ......................................... 27-31-00 Page 201
Trim Tab Actuator Disassembly/Assembly ....................................... 27-31-00 Page 201
Trim Tab Actuator Cleaning, Overhaul/Inspection and Repair ..................... 27-31-00 Page 207
Trim Tab Free Play Inspection ................................................. 27-31-00 Page 208
Trim Tab Control Wheel Removal/Installation .................................... 27-31-00 Page 208
Trim Tab Control Adjustment/Test. ............................................. 27-31-00 Page 208
FLAP CONTROL SYSTEM - TROUBLESHOOTING ................................... 27-50-00 Page 101
FLAP CONTROL SYSTEM - MAINTENANCE PRACTICES ............................ 27-50-00 Page 201
General ........................................................... 27-50-00 Page 201
Flap Motor and Transmission Assembly Removal/Installation ..................... 27-50-00 Page 201
Flap Removal/Installation ...................................................... 27-50-00 Page 201
Flap Drive Pulley Removal/Installation .......................................... 27-50-00 Page 206
Flap Control System Adjustment/Test ........................................... 27-50-00 Page 206
Operational Check .......................................................... 27-50-00 Page 207
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLAP FOLLOW UP AND INDICATING SYSTEM - MAINTENANCE PRACTICES ........ 27-51-00 Page 201
Description and Operation ..................................................... 27-51-00 Page 201
Follow Up and Indicating System Removal/Installation ............................ 27-51-00 Page 201
System Rigging ............................................................... 27-51-00 Page 201
27- CONTENTS Page 2

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLIGHT CONTROLS - GENERAL
1. General
A. This chapter provides maintenance of components which furnish a means of manually controlling the
flight attitude characteristics of the airplane, including flaps.

Tensiometer Available commercially To measure and obtain
cable tension.
Inclinometer SE716 Cessna Aircraft To measure control
Company surface deflection.
Cessna Distrubution
Department 701, CPD
25800 East Pawnee
Road
Wichita, KS
67218-5590
Polyurethane Tape Y8761 3M To prevent flap chafing.
3M Center
Minneapolis, MN 55144
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 aileron section provides information on control wheels, cables, linkage and aileron
assemblies.
(2) The rudder section provides information on rudder pedals, cables, linkage and rudder assembly.
(3) The elevator section provides information on control column, cables, linkage and elevator
assemblies.
(4) The flap section provides information on the flap actuator, cables, linkage, and the flap
assemblies.
27-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTROL CABLE WIRE BREAKAGE AND CORROSION LIMITATIONS - MAINTENANCE PRACTICES

1. Examination of Control Cables.
A. Control cable assemblies are subject to a variety of environmental conditions and forms of
deterioration. Some deterioration, such as wire or strand breakage, is easy to recognize. Other
deterioration, such as internal corrosion or cable distortion, is harder to identify. The following
information will aid in detecting these cable conditions.
B. Broken Wire Examination (Refer to Figure 201).
(1) Examine cables for broken wires by passing a cloth along length of cable. This will detect broken
wires, if cloth snags on cable. Critical areas for wire breakage are those sections of cable which
pass through fairleads, across rub blocks, and around pulleys. If no snags are found, then no
further inspection is required. If snags are found or broken wires are suspected, then a more
detailed inspection is necessary which requires that the cable be bent in a loop to confirm broken
wires. Loosen or remove cable to allow it to be bent in a loop as shown. While rotating cable,
inspect bent area for broken wires.
(2) Wire breakage criteria for cables in flap, aileron, rudder, and elevator systems are as follows:
(a) Individual broken wires at random locations are acceptable in primary and secondary
control cables when there are no more than six broken wires in any given ten-inch cable
length.
C. Corrosion.
(1) Carefully examine any cable for corrosion that has a broken wire in a section not in contact
with wear-producing airframe components, such as pulleys, fairleads, rub blocks, etc. It may be
necessary to remove and bend cable to properly inspect it for internal strand corrosion, as this
condition is usually not evident on outer surface of cable. Replace cable if internal corrosion is
found. If a cable has been wiped clean of its corrosion-preventive lubricant and metal-brightened,
the cable shall be examined closely for corrosion. For description of control cable corrosion, refer
to Chapter 51, Corrosion and Corrosion Control - Maintenance Practices
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MODEL 172
MAINTENANCE MANUAL
BROKEN WIRE UNDETECTED BY

WIPING CLOTH ALONG CABLE
BROKEN WIRE DETECTED VISUALLY

WHEN CABLE WAS REMOVED
AND BENT
DO NOT BEND INTO LOOP SMALLER

THAN 50 CABLE DIAMETERS
NORMAL TECHNIQUE FOR

BENDING CABLE AND
CHECKING FOR BROKEN WIRES
5561C1119
Cable Broken Wire Examination

27-00-01 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AILERON CONTROL SYSTEM - TROUBLESHOOTING
1. Troubleshooting
A. Actions listed in the Remedy column can be found in Aileron Control System - Maintenance Practices,
unless otherwise noted.

LOST MOTION IN Loose control cables. Adjust cables to proper tension.
CONTROL WHEELS
Broken pulley or bracket, cable off Replace worn or broken parts,
pulley or worn rod end bearings. install cables correctly.
Sprung bellcrank. Replace bellcrank.
Loose chains. Adjust chain tension.
RESISTANCE TO Cables too tight. Adjust cables to proper tension.
CONTROL WHEEL
MOVEMENT
Pulleys binding or cable off track. Replace defective pulleys. Install
cables correctly.
Bellcrank distorted or damaged. Replace bellcrank.
Defective U-joints. Replace defective U-joints.
Clevis bolts in system too tight. Loosen, then tighten properly and
safety.
Rusty chain or chain binding with Replace chain or defective parts.
sprocket.
CONTROL WHEELS Improper adjustment of chains or Adjust in accordance with Aileron
NOT LEVEL WITH cables. With control wheel centered, Control System - Maintenance
AILERONS NEUTRAL aileron bellcrank stop bushing should Practices (Adjustment/Test).
be centered in slot (both left and right
bellcranks).
Improper adjustment of aileron Adjust in accordance with Aileron
push-pull rods. If chains and cables Control System - Maintenance
are properly rigged and bellcrank stop Practices (Adjustment/Test).
bushings are not centered in slots,
push-pull rods are adjusted incorrectly.
DUAL CONTROL Chains improperly adjusted. Adjust in accordance with Aileron
WHEELS NOT Control System - Maintenance
COORDINATED Practices (Adjustment/Test).
INCORRECT Push-pull rods not adjusted properly. Adjust in accordance with Aileron
AILERON TRAVEL Control System - Maintenance
Practices (Adjustment/Test).
Worn bellcrank stop bushings or Replace worn parts.
bellcrank slots.
27-10-00 Page 101

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AILERON CONTROL SYSTEM - MAINTENANCE PRACTICES
1. General
A. The ailerons receive input from the pilot or copilot control wheel through a series of sprockets, chains,
pulleys, cables, bellcranks and pushrods. For an overview of the system, refer to Figure 201. For a
breakdown of system components, refer to Figure 202, Figure 203 and Figure 204.
2. Control Yoke Removal/Installation
A. Remove Control Yoke (Refer to Figure 202).
(1) Disconnect battery cables and insulate terminals as a safety precaution.
(2) Remove center pedestal cover.
(3) Remove rudder bar shields, carpeting and plates as necessary for access to lower end of control
yoke.
(4) Remove avionics equipment and associated hardware as required.
(5) Remove engine and cabin air controls as required.
(6) Remove right hand forward side upholstery panel.
(7) Remove bolt from each end of parking brake assembly and swing assembly away from working
area.
(8) On upper right side of control yoke, remove bolt attaching bearing to yoke. On left side of control
yoke (Figure 202, Detail B), remove similar bolt securing spacer and roller to upper yoke.
(9) Remove instrument panel and structure as required to allow yoke to slide out under right side of
instrument panel.
(10) Remove safety wire/clip and disconnect direct cable turnbuckles.
(11) Remove bolts attaching control wheel tubes to universal joints.
(12) Remove bolt attaching push-pull tube to control yoke.
(13) Remove pivot bolt from base of control yoke and carefully work control yoke out from under right
hand side of instrument panel.
B. Install Control Yoke (Refer to Figure 202).
(1) Place control yoke in position under instrument panel.
(2) Secure control yoke to structure with pivot bolt.
(3) Connect elevator push-pull tube to control yoke.
(4) Connect control wheel tubes to universal joints using bolt.
(5) Reconnect direct cable turnbuckles and safety.
(6) Reinstall instrument panel structure and instrument panel.
(7) Reinstall engine and cabin air control cables.
(8) Reattach spacers, rollers, bushings and bearings on upper left and upper right control yoke.
(9) Reinstall parking brake assembly to structure.
(10) Rig aileron cables. Refer to Adjustment/Test.
(11) Check and/or rig elevator control system.
(12) Check and/or rig all engine and cabin air controls.
(13) Check all avionics and/or electrical equipment which may have been disconnected or become
inoperative while performing the preceding steps.
(14) Reinstall all items removed for access.
3. Aileron Removal/Installation
A. Remove Aileron (Refer to Figure 203 and Figure 204).
(1) Disconnect aileron pushrod at aileron.
(2) Disconnect electrical bonding straps.
(3) Remove screws and nuts attaching aileron hinges to trailing edge of wing.
(4) Using care, pull aileron out and down to slide hinges from under wing skin and auxiliary spar
reinforcements.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
REFER TO FIGURE 204
REFER TO FIGURE 203
DETAIL C
DETAIL K DETAIL J
DETAIL G
051 0T1007
A0561 4001
F0561C1006
G0561C1010
Aileron Control System

27-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A CONTROL
LATEST REVSION
BUSHING
BEARING
SHAFT
CONTROL SECONDARY
YOKE
SECONDARY CABLE
TURNBUCKLE
PRIMARY CABLE
SPACER
TURNBUCKLE
Control Yoke Installation

MODEL 172
MAINTENANCE MANUAL
B107
BUSHING
CARRY THROUGH
CABLE TURNBUCKLE BOLT PIVOT BOLT
PIVOT BOLT
STOP
BUSHING
SPACER
CARRY THROUGH
CABLE
SPACER
DIRECT CABLE
BRASS WASHER BELLCRANK

LOWER WING CHANNEL
SKIN
DETAIL A
LEFT SIDE SHOWN A05613001
(RIGHT SIDE TYPICAL) A05613002
Aileron Bellcrank Installation

27-10-00 Page 204

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
I
B223
HINGE PIN
DETAIL A
AILERON HINGE
Aileron Installation
27-10-00 Page 205

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B. Install Aileron (Refer to Figure 203 and Figure 204).

(1) Position aileron hinges between skin and auxiliary spar reinforcements and install screws and
nuts attaching hinges to trailing edge of wing.
NOTE: Ensure hinge pins are secured using screws and nuts.
(2) Reconnect electrical bonding straps.

(3) Attach aileron pushrod to aileron.
(4) Check aileron travel. Refer to Adjustment/Test below.
4. Aileron Bellcrank Removal/Installation
NOTE: Left and right aileron bellcrank removal/installation is typical.
A. Remove Aileron Bellcrank (Refer to Figure 203).
(1) Remove access plate inboard of bellcrank on underside of each wing.
(2) Relieve control cable tension by loosening carry through cable turnbuckle.
(3) Disconnect control cables from bellcrank.
(4) Disconnect aileron push rod at bellcrank.
(5) Remove nuts, washers and bolts securing bellcrank stop bushing and bellcrank to wing structure.
(6) Remove bellcrank through access opening, using care that bearing bushing is not dropped from
bellcrank.
B. Install Aileron Bellcrank (Refer to Figure 203).
(1) Install bellcrank to structure, ensuring bushings are in place.
(2) Install brass washers between lower end of bellcrank and wing channel to shim out excess
clearance.
(3) Connect aileron push rod to bellcrank.
(4) Connect control cables to bellcrank. Ensure required spacers and bushings are properly
installed.
(5) Adjust cable tension. Refer to Adjustment/Test.
(6) Safety turnbuckle. Refer to Chapter 20, Safetying - Maintenance Practices.
5. Adjustment/Test
A. Rig Aileron Cables.
(1) Verify primary cable is in aft groove of cable drum and wrapped once around drum. The primary
cable lock is installed at bottom of drum and direct cable lock is installed at top.
(2) With control wheels neutral, ensure that chain ends are approximately equally spaced from
center of sprockets.
(3) Keeping control wheels neutral, tighten secondary cable turnbuckles so control wheels are level
in neutral position (synchronized), with enough tension on cables to remove slack from chains
without binding. Results of adjusting turnbuckles are as follows:
(a) Loosening secondary cable turnbuckles and tightening direct cable turnbuckles at center
of control yoke will move inboard sides of both control wheels down.
(b) Tightening either primary control cable turnbuckle and loosening secondary cable
turnbuckles at center of control yoke will move outboard side of applicable control wheel
down.
(4) Tape a bar across both control wheels to hold them in neutral position.
(5) Adjust direct cable turnbuckles below control yoke and single carry through turnbuckle at aileron
bellcrank so bellcrank stop bushings are centered in both bellcrank slots with 40 pounds, +10 or
-10 pounds of tension on aileron carry through cable. Disregard tension on direct cables which
will be different than tension on carry through cable.
(6) Adjust push rods at each aileron until ailerons are neutral with reference to trailing edge of wing
flaps. Be sure wing flaps are fully up when making this adjustment.
(7) Remove bar from control wheels.
27-10-00 Page 206

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(8) Check ailerons for correct travel using an inclinometer. Make adjustments if necessary and check
that the bushing travel stops are properly centered in the bellcranks.
NOTE: For aileron rigging specifications, refer to Chapter 6, Airplane Dimensions and
Specifications - Description and Operation.
(9) Safety all turnbuckles. Refer to Chapter 20, Safetying - Maintenance Practices.
(10) Install all items removed for access.
WARNING: ENSURE AILERONS MOVE IN CORRECT DIRECTION WHEN OPERATED BY
CONTROL WHEEL.
(11) Check aileron for correct travel.
6. Cables And Pulleys Removal/Installation

A. Cables And Pulleys Removal.
(1) Remove access plates, wing root fairings, and upholstery as required.
(2) Disconnect cables from aileron bellcranks and remove cable guards and pulleys as necessary
to work cables free of aircraft.
NOTE: To ease routing of cables, a length of wire may be attached to end of cable before
being withdrawn from aircraft. Leave wire in place, routed through structure; then
attach cable being installed and use to pull cable into position.
B. Cables And Pulleys Installation.
(1) Route cable, install pulleys and cable guards.
NOTE: Ensure cable is positioned in pulley groove before installing guard.
(2) Rig aileron system in accordance with applicable paragraph in this section, safety turnbuckles,
and install access plates, fairings, and upholstery.
27-10-00 Page 207

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
RUDDER CONTROL SYSTEM - TROUBLESHOOTING
1. Troubleshooting
A. Actions listed in the Remedy column can be found in Rudder Control System - Maintenance Practices,
unless otherwise noted.

RUDDER DOES NOT Broken or disconnected cables. Connect or replace cables.
RESPOND TO PEDAL
MOVEMENT
BINDING OR JUMPY Cables too tight. Ensure distance from firewall to
MOVEMENT OF pivot shaft is 6.50 inches.
RUDDER PEDALS
Cables not riding properly on pulleys. Route cables correctly over
pulleys.
Binding, broken or defective pulleys or Replace defective pulleys and
cable guards. install guards properly.
Pedal bars need lubrication. Lubricate as required.
Defective rudder bar bearings. If lubrication fails to eliminate
binding, replace bearing blocks.
Defective rudder hinge bushings. Replace defective bushings.
Clevis bolts too tight Readjust to eliminate binding.
Steering rods not adjusted properly. Re-rig system. Refer to Rudder
Control Adjustment/Test.
LOST MOTION Insufficient cable tension. Ensure distance from firewall to
BETWEEN RUDDER pivot shaft is 6.50 inches.
PEDALS AND
RUDDER
INCORRECT Incorrect rigging. Re-rig system. Refer to Rudder
RUDDER TRAVEL Control Adjustment/Test.
27-20-00 Page 101

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
RUDDER CONTROL SYSTEM - MAINTENANCE PRACTICES
1. General
A. Rudder control is maintained through use of conventional rudder pedals which also control nose wheel
steering. The system is comprised of rudder pedals, cables and pulleys, all of which link the pedals
to the rudder and nose wheel steering. For an illustration of the rudder system, refer to Figure 201.
2. Rudder Pedal Assembly Removal/Installation

A. Remove Rudder Pedal Assembly (Refer to Figure 201).
(1) Remove upholstery from area below instrument panel as necessary.
(2) Disconnect master cylinders at pilot rudder pedals.
(3) Disconnect parking brake cables at master cylinders.
(4) Remove rudder pedals and brake links.
(5) Relieve cable tension at clevis adjustments.
(6) Disconnect cables, return springs, trim bungee and steering tubes from rudder bars.
(7) Remove bolts securing bearing blocks and work rudder bars out of area below instrument panel.
B. Install Rudder Pedal Assembly (Refer to Figure 201).
NOTE: Rudder bar assemblies should be checked for excessive wear before installation. The
bearing blocks are nylon and require no lubrication unless binding occurs. A few drops of
(1) Position rudder bars in area below instrument panel and secure bearing blocks with bolts.
(2) Reconnect cables, return springs, trim bungee and steering tubes to rudder bars.
(3) Set distance from pivot shaft to firewall at 6.50 inches.
(4) Install rudder pedals and brake links.
(5) Connect parking brake cables at master cylinders.
(6) Connect master cylinders at pilot rudder pedals.
(7) Install upholstery to tunnel area as necessary.
3. Rudder Removal/Installation
A. Remove Rudder (Refer to Figure 201).
(1) Disconnect shackles at rudder bellcrank.
(2) Disconnect tail navigation light quick-disconnect at bottom of rudder.
(3) With rudder supported, remove hinge bolts (including electrical bonding strap) and lift rudder
free of vertical fin.
B. Install Rudder (Refer to Figure 201).
(1) Install rudder (with electrical bonding strap) to vertical fin. Torque nuts to 50 to 70 inch pounds
plus free running torque.
(2) Reconnect tail navigation light quick-disconnect at bottom of rudder.
(3) Attach shackles to rudder bellcrank.
NOTE: Do not over tighten. Shackle must pivot freely.

4. Rudder Control Adjustment/Test
A. Rig Rudder Controls.
NOTE: For rudder travel angles, refer to Chapter 6, Airplane Dimensions and Specifications -
(1) Using a digital inclinometer, adjust travel stops on rudder to obtain proper rudder travel.
27-20-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
RIGHT
REAR
CABLE
CABLE
PIVOT SHAFT
CABLE
FIREWALL
6.50 INCHE
AFT RUDDER BA
BEARING BLOCK
SINGLE RETURN SPRIN
MASTER
DETAIL B BRACKET
Rudder Control Installation

27-20-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ANTI-RATTLE
SPACER
CABLE SPACER
GUARD BRAKE LINK
DETAIL D
TURNBUCKLE
DETAIL J
PULLEY
BRAKE TORQUE
TUBE
DETAIL E
DETAIL H
BELLCRANK
RUDDER
BAR
SHACKLE
E05623003
K0561C1013
Rudder Control Installation

27-20-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(2) As an alternate means of establishing travel limits, refer to Figure 202 in conjunction with the
following steps:
(a) Establish neutral position of rudder by clamping straightedge (such as wooden 2 X 4) on
each side of fin and rudder, and blocking trailing edge of rudder half the distance between
straightedges as shown in Figure 202.
(b) Tape a length of soft wire to one elevator in such a manner that it can be bent to index with
a point on rudder trailing edge just above the lower rudder tip (disregard fixed trim tab).
(c) Using soft led pencil, mark rudder at point corresponding to soft wire indexing point
(neutral).
(d) Remove straightedges.
(e) Hold rudder against right, then left rudder stops. Measure the distance from pointer to
pencil mark on rudder in each direction of travel. Distance should be between 5.29 inch
and 5.91 inch.
(3) After rudder travel has been established, disconnect nose wheel steering tubes from nose strut.
(4) Establish rudder neutral position by clamping straight edge such as wooden 2x4 on each side of
vertical stabilizer and rudder and blocking trailing edge of rudder half the distance between the
straightedges.
(5) Adjust cables at clevis to align rudder and pedals in neutral position to 6.50 inches from firewall
to pedal pivot shafts. Cable tension is automatically set by return springs on the rudder bar.
NOTE: Due to thickness of insulation of firewall, it is recommended that a piece of 0.0625
inch welding rod be ground to a sharp point and notched at the 6.50 inch dimension.
Pierce insulation on firewall and use notch to measure proper dimension.
(6) Tie down or weight tail to raise nose wheel free of ground.
(7) Center nose gear against external stop.
NOTE: Do not compress springs when extending steering tubes.
(8) Extend steering tubes until free play is removed.

(9) Adjust steering tube rod ends to 1.00 inch between steering arm assembly and bolt hole and
tighten jam nuts.
(10) Adjust steering tube clevises to align with rod end bearings.
NOTE: Extend steering tubes to seat rods against internal springs, but do not attempt to
preload these springs by shortening rod end clevises after alignment. Preload is built
into steering tubes.
(11) Install clevises on rod ends.
(12) Safety clevises, remove tail stand and straight edges and install all items removed for access.
WARNING: ENSURE THAT RUDDER MOVES IN CORRECT DIRECTION WHEN
OPERATED BY RUDDER PEDALS.
(13) Flight test airplane to determine if ground adjustment of fixed trim tab is necessary.
NOTE: Do not rig rudder off-center unless trim tab does not provide adequate correction.
27-20-00 Page 204

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
STEP 1: ESTABLISHING NEUTRAL STEP 2: MEASURING

POSITION OF RUDDER. RUDDER TRAVEL.
RUDDER
5.29 INCH TO
5.91 INCH
BLOCK RUDDER HALF WIRE POINTER

THE DISTANCE BETWEEN
STRAIGHTEDGES
05621009
05621009
Rudder Travel Adjustment

27-20-00 Page 205

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ELEVATOR CONTROL SYSTEM - TROUBLESHOOTING
1. Troubleshooting
NOTE: Due to remedy procedures in the following troubleshooting chart, it may be necessary to rerig
system.

NO RESPONSE TO Forward or aft end of push- pull tube Attach push-pull tube correctly.
CONTROL WHEEL disconnected.
FORE AND AFT
MOVEMENT
Cables disconnected. Attach cables and rig system.
BINDING OR JUMPY Defective forward or rear bellcrank Move to check for play or binding.
MOTION FELT IN pivot bearing. Replace bellcrank.
MOVEMENT OF
ELEVATOR SYSTEM
Cables slack. Adjust to specified tension per
rigging procedure.
Cables not riding correctly on pulleys. Open access plates and observe
pulleys. Route cables correctly
over pulleys.
Nylon bearing on instrument panel Disconnect universal joint and
binding. check for binding. Replace bearing
if binding is felt.
Defective control yoke pivot bearing. Disconnect elevator push-pull tube
at lower end of control yoke and
check that control yoke moves
freely. Replace bearing if found
defective.
Defective elevator hinges. Move elevators by hand checking
hinges. Replace defective hinges.
Clevis bolts too tight. Readjust to eliminate bolt binding.
Lubrication needed. Lubricate in accordance with
Chapter 12, Flight Controls -
Lubrication.
Defective pulleys or cable guards. Replace defective parts and install
guards properly.
ELEVATORS FAIL TO Stops are incorrectly set. Check elevator travel with
ATTAIN PRESCRIBED inclinometer. Re-rig system if
TRAVEL required.
Cables tightened unevenly. Re-rig system.
Interference at instrument panel. Re-rig system.
27-30-00 Page 101

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ELEVATOR CONTROL SYSTEM - MAINTENANCE PRACTICES
1. General
A. The elevators are operated by power transmitted through forward and aft movement of the control
yoke. This power reaches the elevators through a system consisting of a push-pull tube, cables and
bellcranks. The elevator control cables, at their aft ends, are attached directly to a bellcrank, installed
between the elevators. This bellcrank serves as an interconnect between the elevators and as a
bearing point for travel stop bolts. A trim tab is installed on the right elevator and is described later in
this chapter. For an illustration of the elevator control system, refer to Figure 201.
2. Forward Elevator Bellcrank Removal/Installation
A. Remove Forward Elevator Bellcrank (Refer to Figure 201).
(1) Remove front seats and carpet. Refer to Chapter 25, Front Seats - Maintenance Practices and
Interior Upholstery - Maintenance Practices.
(2) Remove floorboard access panels. Refer to Chapter 6, Access/Inspection Plates - Description
and Operation.
(3) Relieve cable tension at turnbuckles and disconnect cables from forward bellcrank.
(4) Disconnect push-pull tube from forward bellcrank.
(5) Remove pivot bolt and remove forward bellcrank.
B. Install Forward Elevator Bellcrank (Refer to Figure 201 ).
(1) Place forward bellcrank in position and install pivot bolt.
(2) Connect push-pull tube to forward bellcrank.
(3) Install cables to forward bellcrank and re-rig system. Refer to Elevator Control Adjustment/Test.
(4) Install floorboard access panels. Refer to Chapter 6, Access/Inspection Plates - Description and
Operation.
(5) Install seats and carpet. Refer to Chapter 25, Front Seats - Maintenance Practices and Interior
Upholstery - Maintenance Practices.
3. Aft Elevator Bellcrank Removal/Installation
A. Remove Aft Elevator Bellcrank (Refer to Figure 201).
(1) Remove rudder. Refer to Rudder Control System - Maintenance Practices.
(2) Relieve cable tension at turnbuckles and disconnect cables from rear bellcrank.
(3) Remove bolts securing elevators to bellcrank.
(4) Remove bellcrank pivot bolt and slide bellcrank out from between tube assemblies.
NOTE: It may be necessary to remove one of the stabilizer attach bolts for clearance when
removing the bellcrank pivot bolt.
B. Install Aft Elevator Bellcrank (Refer to Figure 201).
(1) Place bellcrank in position and install pivot bolt. Replace any extra components removed to
facilitate aft bellcrank removal.
(2) Install bolts securing elevators to bellcrank.
(3) Connect cables to rear bellcrank and re-rig system. Refer to Elevator Control Adjustment/Test.
(4) Install rudder. Refer to Rudder Control System - Maintenance Practices.
4. Elevator Removal/Installation
A. Remove Elevator Halves (Refer to Figure 202).
NOTE: This procedure is written for the right elevator with attached trim tab. Left elevator removal/
installation is similar.
(1) Disconnect push-pull channel from elevator trim tab horn.

(2) Remove bolts securing tube assembly to aft bellcrank.
(3) With elevator supported, remove bolts from elevator hinge brackets and remove elevator half.
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MODEL 172
MAINTENANCE MANUAL
BELLCRANK
PUSH/PULL
TUBE
TURNBUCKLE
A05633002
D05631015
E05631003
Elevator Control System

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1715
ELEVATOR AFT
TRIM TAB BELLCRANK
(NOTE 1)
TRIM TAB HORN (NOTE 2) TUBE
ASSEMBLY
TRAVEL
PUSH-PULL STOP
CHANNEL DETAIL A BOLT /
JAMNU /G
ELEVATOR TIP
ELEVATOR TRIM TAB (NOTE 2)
A (NOTE 2)
ELEVATOR
NOTE 1: INSTALL UPPER BOLT WITH HEAD TO

THE RIGHT AND LOWER BOLT WITH
HEAD TO THE LEFT. THE CABLE END
CLEVISES MUST BE FREE TO SWIVEL.
NOTE 2: DO NOT PAINT CABLE TERMINALS,

BOLTS OR ENDS OF ELEVATOR BELL-
D
CRANK
BOLT
SCREW )
C05631007
Elevator Installation
27-30-00 Page 203

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MODEL 172
MAINTENANCE MANUAL
B. Install Elevator Halves (Refer to Figure 202).

(1) Attach elevator to horizontal stabilizer at hinge points using bolts.
(2) Attach tube assembly of elevator to aft bellcrank.
(3) Connect push-pull channel (opening down) to elevator trim tab horn.
5. Elevator Control Adjustment/Test
A. Rig Elevator (Refer to Figure 202 and Figure 203).
(1) Lock elevator control in neutral position by installing neutral rigging tool.
(2) Streamline elevators to neutral with horizontal stabilizer.
NOTE: Neutral position is measured with the bottom of the elevator balance area flush with
the bottom of the stabilizer.
(3) Holding elevators in neutral position, adjust turnbuckles equally to obtain 30 pounds, +10 or -10
pounds of cables tension.
(4) Mount an inclinometer on elevator and, keeping elevator streamlined with stabilizer, set
inclinometer to 0 degrees.
(5) Remove control column neutral rigging tool and adjust travel stop bolts to range of travel specified
in Chapter 6, Airplane Dimensions and Specifications - Description and Operation.
(6) Check that control yoke does not contact instrument panel in full UP position or firewall in the
full DOWN position.
WARNING: ENSURE THAT ELEVATORS MOVE IN THE CORRECT DIRECTION WHEN
OPERATED BY CONTROLS.
(7) Safety turnbuckles and travel stop bolts: check remainder of elevator control system for security
and reinstall all items removed for access.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NEUTRAL RIGGING TOOL
INSTRUMENT PANEL
PILOT CONTROL COLUMN
SUPPORT
0.46 INCH 0.62 INCH
0.19 INCH
RADIUS
(TYPICAL)
0.35 INCH
RADIUS
DETAIL A
NOTE: FABRICATE FROM 0.125 INCH STEEL PLATE AND

0.209 INCH DIAMETER DRILL ROD ACCORDING
TO DIMENSIONS SHOWN.
05601005
A0560C1004
Control Column Neutral Rigging Tool

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ELEVATOR TRIM CONTROL - TROUBLESHOOTING
1. Troubleshooting
NOTE: Due to remedy procedures in the following chart, it may be necessary to re-rig the system after
trouble has been corrected.

TRIM CONTROL Cable tension too high. Adjust tension from 15 to 20
WHEEL MOVES WITH foot-Lbs at average temperature
EXCESSIVE FORCE. for the area.
Pulleys binding or rubbing. Repair or replace as necessary.
Cables not in place on pulley. Install cables correctly.
Trim tab hinge binding. Disconnect actuator and move tab
to check resistance. Lubricate or
replace hinge as necessary.
Defective trim tab actuator. Remove chain from actuator
sprocket and operate actuator
manually. Replace actuator if
defective.
Rusty chain. Replace rusty chain.
Damaged sprocket. Replace damaged sprocket
Bent sprocket shaft. Observe motion of sprockets.
Replace bent sprocket shaft.
LOST MOTION Cable tension too low. Adjust tension from 15 to 20
BETWEEN CONTROL foot-Lbs at average temperature
WHEEL AND TRIM for the area.
TAB.
Broken pulley. Replace defective pulley.
Cables not in place on pulleys. Install cables correctly.
Worn trim tab actuator. Remove and replace worn
actuator.
Actuator attachment loose. Tighten.
TRIM INDICATOR Indicator incorrectly engaged on wheel Reset indicator.

FAILS TO INDICATE track.
CORRECT TRIM
POSITION.
INCORRECT TRIM Stop blocks loose or incorrectly Adjust stop blocks on cables.
TAB TRAVEL adjusted.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ELEVATOR TRIM CONTROL - MAINTENANCE PRACTICES

1. General
A. The elevator trim tab, located on the right elevator, is controlled by a trim wheel mounted in the
pedestal. Power to operate the tab is transmitted from the trim control wheel by means of chains,
cables and an actuator. A mechanical pointer, adjacent to the trim wheel indicates tab position. A
nose up setting results in a tab down position. For an illustration of tab system components, refer to
Figure 201.
2. Trim Tab Actuator Removal/Installation
A. Remove Trim Tab Actuator (Refer to Figure 201 and Figure 202).
(1) Remove baggage compartment aft wall for access to elevator trim control cable stop blocks.
Refer to Chapter 25, Interior Upholstery - Maintenance Practices.
CAUTION: POSITION A SUPPORT STAND UNDER TAIL TIE-DOWN RING TO PREVENT
TAILCONE FROM DROPPING WHILE PERSON IS WORKING INSIDE.
(2) Remove safety wire and relieve cable tension at turnbuckle.

(3) At the elevator hinge gap, disconnect push-pull channel from actuator.
(4) Remove access plate 320AB. Refer to Chapter 6, Access/Inspection Plates - Description and
Operation.
(5) Remove chain guard.
(6) Remove chain from actuator sprocket.
(7) Remove screws attaching actuator clamps to bracket, and carefully work actuator out through
access opening.
B. Install Trim Tab Actuator (Refer to Figure 201 and Figure 202).
(1) Place actuator in position and attach actuator clamps to bracket using screws.
(2) Install chain to actuator sprocket.
(3) Install chain guard.
(4) Install access plate 320AB. Refer to Chapter 6, Access/Inspection Plates - Description and
Operation.
(5) At the elevator hinge gap, connect push-pull channel to actuator.
(6) Rig trim system. Refer to Trim Tab Control Adjustment/Test.
3. Trim Tab Actuator Disassembly/Assembly
A. Disassemble Trim Tab Actuator (Refer to Figure 203).
(1) Remove trim tab actuator. Refer to Tim Tab Actuator Removal/Installation.
(2) Using suitable punch and hammer, remove groove pins securing sprocket to screw and remove
sprocket.
(3) Unscrew threaded rod end and remove rod end from actuator.
(4) Remove groove pins securing bearings at the housing ends.
(5) Lightly tap screw toward the sprocket end of housing, remove forward bearing and collar.
(6) Lightly tap screw in the opposite direction from sprocket end, remove aft bearing, O-ring and
collar.
NOTE: It is not necessary to remove retaining rings.

B. Assemble Trim Tab Actuator (Refer to Figure 203).
NOTE: Discard groove pins, O-rings and nuts removed in disassembly, and install new parts during
reassembly.
NOTE: During reassembly lubricate collars, screw and threaded rod end.
(1) Install collar and forward bearing on screw.

(2) Press sprocket into the end of screw and align groove pin holes and install new groove pins.
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MODEL 172
MAINTENANCE MANUAL
F
D
DETAIL L AFT
DETAIL M LEFT CABLE
RIGHT
FORWARD RIGHT
CABLE AFT DETAILB
DETAIL K CABLE DETAIL J
E
DETAIL P
F05633001
NOTE: SAFETY WIRE

ROLL PIN FORWARD
R05631 001
Elevator Trim Tab Control System

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TAB UP
TAB UP
TAB DOWN
TAB UP
TAB UP
DETAIL N
TAB DOWN
TAB UP
DETAIL H
C05631017
E05631017
H05631017
N05631017
Elevator Trim Tab Control System

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MODEL 172
MAINTENANCE MANUAL
ACTUATOR
CHAIN GUARD
DETAIL A
A05633001
Elevator Trim Tab Actuator Installation

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ACTUATOR
ASSEMBLY
THREADED
ROD END
DETAIL A HOUSING
RETAINING
RING
BEARING
COLLAR
GROOVE PIN
DETAIL B
Elevator Trim Tab Actuator Cleaning, Inspection and Repair

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TRIM TAB
DETAIL C
HINGE POINT TRAILING EDGE
FREE-PLAY UP
NEUTRAL POSITION
FREE-PLAY DOWN
TOTAL FREE-PLAY
C0563C1012
Elevator Trim Tab Actuator Cleaning, Inspection and Repair

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MODEL 172
MAINTENANCE MANUAL
(3) Insert screw with assembled parts into housing until forward bearing is flush with end of housing.
NOTE: When inserting screw into housing, locate the sprocket at the end of housing which
is farther away from the groove for retaining ring.
NOTE: The bearings are not pre-drilled and must be drilled on assembly. The groove pins
are 3/32 (0.094 inch) diameter, therefore, requiring a 3/32 (0.094 inch) drill.
(4) With bearings flush with end of housing, carefully drill bearing so the drill will emerge from the
hole on the opposite side of housing.
NOTE: Do not enlarge holes in housing.
(5) Press new groove pins into holes.

(6) Insert collar, new O- ring and aft bearing into opposite end of housing.
(7) Repeat steps 3, 4 and 5 for bearing on opposite end of actuator.
(8) If a new bearing is required, a new bearing may be pressed into the boss. Ensure that force
bears against the outer race of bearing.
(9) Screw the threaded rod end into screw.
(10) Install retaining rings if they were removed.
(11) Test actuator assembly by rotating sprocket with fingers while holding threaded rod end. The
threaded rod end should travel in and out smoothly, with no indication of binding.
4. Trim Tab Actuator Cleaning, Overhaul/Inspection and Repair
A. Clean, Inspect and Repair Trim Tab Actuator (Refer to Figure 203).
(1) Do not remove bearing from threaded rod end unless replacement of bearing is necessary.
(2) Clean all component parts, except bearing, by washing in Stoddard solvent or equivalent. Do
not clean sealed bearing.
(3) Inspect all component parts for obvious indications of damage such as stripped threads, cracks,
deep nicks and dents.
(4) Check bearings, screw and threaded rod end for excessive wear and scoring. Refer to Table
201 for dimensions.
Table 201. Actuator Wear Limits
COMPONENT MAXIMUM DIMENSION MNIMUM DIMENSION

Forward End Bearing 0.374 Inch 0.373 Inch
Inside Diameter
Aft End Bearing Inside 0.249 Inch (Small Hole) 0.248 Inch (Small Hole)
Diameter
Aft End Bearing Inside 0.374 Inch (Large Hole) 0.373 Inch (Large Hole)
Diameter
Threaded Rod End 0.246 Inch (Shank) 0.245 Inch (Shank)
Outside Diameter
Threaded Rod End 0.370 Inch (Threads) 0.369 Inch (Threads)
Outside Diameter
NOTE: Relative linear movement between internal threaded screw and bearing should be
0.004 to 0.010 inch at room temperature.
(5) Examine threaded rod end and screw for damaged threads or dirt particles that may impair
smooth operation.
(6) Check sprocket for broken, chipped and/or worn teeth.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(7) Check bearing for smoothness of operation.

(8) Do not attempt to repair damaged or worn parts of the actuator assembly. Discard all defective
items and install new parts during reassembly.
5. Trim Tab Free Play Inspection
A. Inspect Trim Tab Free Play (Figure 203).
(1) Place elevator and trim tab in neutral position and secure elevator from movement with elevator
gust lock.
(2) Determine maximum amount of allowable free play.
(a) Measure chord length at extreme inboard end of trim tab as shown in Detail C.
(b) Multiply chord length by 0.025 to obtain maximum allowable free-play.
(c) Measure free-play at same point on trim tab that chord length was measured.
(d) Total free-play must not exceed maximum allowable as calculated in step (2)(b).
(3) Using moderate hand pressure (up and down, measure free play at trailing edge of trim tab.
(4) If trim tab free play is less than maximum allowable, the system is within prescribed limits.
(5) If trim tab free play is more than maximum allowable, check the following items for looseness
while moving trim tab up and down.
(a) Check push-pull channel to trim tab horn assembly attachment for looseness.
(b) Check push-pull channel to actuator assembly threaded rod end attachment for looseness.
(c) Check actuator assembly threaded rod end for looseness in the actuator assembly.
(6) If looseness is apparent while checking steps (a) and (b), repair by installing new parts.
(7) If looseness is apparent while checking step (c), threaded rod end is out of tolerance and must
be replaced.
6. Trim Tab Control Wheel Removal/Installation
A. Remove Trim Tab Control Wheel (Refer to Figure 204).
(1) Relieve cable tension at turnbuckle.
(2) Remove pedestal cover.
(3) Remove screws attaching control wheel retainer.
(4) Remove retainer and pointer, using care not to drop trim control wheel.
B. Install Trim Tab Control Wheel (Refer to Figure 204).
(1) Install retainer and pointer with screws.
(2) Install pedestal cover.
(3) Set cable tension at turnbuckle. Refer to Trim Tab Control Adjustment/Test.
7. Trim Tab Control Adjustment/Test.
CAUTION: POSITION A SUPPORT STAND UNDER TAIL TIE-DOWN RING TO PREVENT
TAILCONE FROM DROPPING WHILE PERSON IS WORKING INSIDE.
A. Set Trim Tab Control Cable Tension (Refer to Figure 205).
(1) Remove rear baggage compartment panel and access plates as necessary.
(2) Loosen travel stop blocks on cables.
(3) Disconnect actuator from trim tab push-pull channel.
(4) Check cable tension and adjust turnbuckle as necessary.
NOTE: If chains or cables are being installed, permit actuator screw to rotate freely as chains
and cables are connected.
(5) Rotate trim wheel full forward. Ensure pointer does not restrict wheel movement. If necessary,
reposition pointer using a thin screwdriver to pry trailing leg of pointer out of groove.
(6) With elevator and trim tab both in neutral, place inclinometer on tab and set at zero.
(7) Rotate actuator screw in or out as required to place tab up with a maximum of two degrees over
travel, with actuator screw connected to push-pull channel.
(8) Rotate trim wheel to position tab up and down, readjusting actuator screw as required to obtain
overtravel in both directions.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PEDESTAL
RETAINER
TRIM
FORWARD REAR
CHAIN CHAIN
DETAIL A
Elevator Trim Tab Wheel Installation
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B1723
CABLE A STOP BLOCK 1 TURNBUCKLE STOP BLOCK 4
CABLE B STOP BLOCK 2 STOP BLOCK 3
TURNBUCKLE
CABLE A STOP BLOCK 2
CABLE B STOP BLOCK 1 STOP BLOCK 3
CONFIGURATION WITH OPTIONAL DUAL AXIS AUTOPILOT
Elevator Trim Tab Travel Adjustment

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(9) Position stop blocks (standard configuration) (Refer to Figure 205).

(a) With elevators in neutral, set trim tab to neutral (streamlined).
(b) Position stop blocks (2) and (3) approximately 0.25 inch forward and aft of turnbuckle
respectively, and secure to cable A.
(c) Place inclinometer on trim tab and run tab to DOWN TRAVEL limit of 19° , +1° or -0° .
(d) Position stop block (4) against stop block (3) and secure to cable B.
(e) Run trim tab to UP TRAVEL limit of 22 ° , +1° or -0° , place stop block (1) against stop block
(2) and secure to cable B.
(10) Position stop blocks (configuration with optional dual-axis autopilot) (Refer to Figure 205).
(a) With elevators in neutral, set trim tab to neutral (streamlined).
(b) Position stop block (3) approximately 1.0 inch forward of turnbuckle, and secure to cable A.
(c) Place inclinometer on trim tab and run tab to UP TRAVEL limit of 22 °, +1 or -0° .
(d) Position stop block (2) against stop block (3) and secure to cable B.
(e) Run trim tab to DOWN TRAVEL limit of 19° , +1° or -0° , place stop block (1) against stop
block (2) and secure to cable A.
(f) Check pitch trim rigging.
1 Streamline the elevator and trim tab. Mount an inclinometer to trim tab and set to 0
degrees. Manually run trim tab to up and down limits and record limits of travel.
2 Position observer at bottom aft access opening in tailcone. Apply power to the aircraft
and run electric trim to full nose-up position until the observer notices clutch slippage.
With servo clutch still slipping, apply an additional 1/4 turn of the manual trim wheel
nose-up (test load condition).
3 In this condition, observer needs to verify that the stop blocks do not slip on the trim
tab cables.
4 Release the trim wheel and disengage the autopilot. Manually run the trim to full
nose-up position and check trim tab deflection with an inclinometer. Additional trim
tab deflection (compared with the values recorded in step C.1.) indicates slippage
of the stop blocks. Rerig trim system, check torque on stop block bolts, then repeat
pitch trim rigging check.
5 If swaged ball needs adjustment, make adjustments by repositioning cable assembly
chain on gear teeth of actuator sprocket. One chain link corresponds to approximately
17 degrees of travel on the capstan. Re-tension cable and repeat pitch trim rigging
check.
6 Repeat procedure for the full nose-down trim condition.
(11 ) Check trim wheel pointer travels the same distance from ends of slot in cover. Reposition trailing
leg of pointer if necessary.
WARNING: ENSURE TRIM TAB MOVES IN CORRECT DIRECTION WHEN OPERATED BY

TRIM WHEEL. NOSE DOWN TRIM CORRESPONDS TO TAB UP POSITION.
(12) Safety turnbuckle and reinstall all items removed to gain access to components.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLAP CONTROL SYSTEM - TROUBLESHOOTING
1. Troubleshooting
NOTE: Due to remedy procedures in the following chart, it may be necessary to re-rig the system after
trouble has been corrected.

BOTH FLAPS FAIL TO Open circuit breaker. Reset and check continuity.
MOVE Replace breaker if defective.
Defective switch. Place jumper across switch.
Replace if defective.
Defective motor. Remove and bench test motor.
Broken or disconnected wires. Run a continuity check of wiring.
Connect or repair wiring.
Defective or disconnected Connect transmission. Remove,
transmission. bench test and replace
transmission if defective.
Defective limit switch. Check continuity of switches.
Replace switches found defective.
BINDING IN SYSTEM Cables not riding on pulleys. Check visually. Route cables
AS FLAPS ARE correctly over pulleys.
RAISED AND
LOWERED.
Bind in drive pulleys. Check drive pulleys in motion.
Replace drive pulleys found
defective.
Broken or binding pulleys. Check pulleys for free rotation or
breaks. Replace defective pulleys.
Frayed cable. Check visually. Replace defective
cable.
Flaps binding on tracks. Observe flap tracks and rollers.
Replace defective parts.
LEFT FLAP FAILS TO Disconnected or broken cable. Check cable tension. Connect or
MOVE replace cable.
Disconnected push-pull rod. Check visually. Attach push- pull
rod.
INCORRECT FLAP Incorrect rigging. Rig correctly. Refer to Flap Control
TRAVEL System Adjustment/Test.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL

Defective operating switch. Check continuity of switches.
Replace switches found defective.
FLAPS FAIL TO Defective or disconnected flaps UP Check continuity of switch.
RETRACT operating switch. Connect or replace switch.
FLAPS FAIL TO Defective or disconnected flaps DOWN Check continuity of switch.
EXTEND operating switch. Connect or replace switch.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLAP CONTROL SYSTEM - MAINTENANCE PRACTICES

1. General
A. The wing flap control system is comprised of an electric motor and transmission assembly, drive
pulleys, push-pull rods. cables and a follow up control. Power from the motor and transmission
assembly is transmitted to the flaps by a system of drive pulleys, cables and push-pull rods. Electrical
power to the motor iscontrolled by two microswitches mounted on a floating arm assembly, a cam lever
and a follow up control. As the flap control lever is moved to the desired flap setting, the attached cam
trips one of the microswitches, activating the flap motor. As the flaps move to the position selected,
the floating arm is rotated by the follow up control until the active microswitch clears the cam breaking
the circuit and stopping the motor. To reverse flap direction, the control lever is moved in the opposite
direction causing the cam to trip the second microswitch, which reverses the flap motor. The follow up
control moves the cam until it is clear of the second switch, shutting off the flap motor. Limit switches
at the flap actuator assembly control flap travel as the flaps reach the full UP or DOWN positions.
B. For a schematic of the flap system, refer to Figure 201.
2. Flap Motor and Transmission Assembly Removal/Installation

A. Remove Flap Motor and Transmission Assembly (Refer to Figure 202).
(1) Lower flaps.
(2) Disconnect electrical power.
(3) Remove access plate 610GB. Refer to Chapter 6, Access/Inspection Plates - Description and
Operation.
(4) Remove bolt securing actuating tube to drive pulley.
(5) Screw actuating tube in toward transmission as far as possible by hand.
(6) Remove bolt securing flap motor hinge to wing. Retain brass washer between hinge and wing
structure for use on reinstallation.
(7) Disconnect electrical connectors from motor and limit switches.
(8) Carefully work assembly from wing through access opening.
B. Install Flap Motor and Transmission Assembly (Refer to Figure 202).
(1) Carefully work assembly into wing through access opening.
NOTE: If hinge assembly was removed from the transmission for any reason, ensure that
short end of hinge is reinstalled toward the top.
(2) Connect electrical connectors to motor and limit switches.
(3) Secure flap motor hinge to wing with bolt and brass washer.
(4) Screw actuating tube out towards bellcrank.
(5) Install bolt securing actuating tube to drive pulley.
(6) Install access plate 610GB. Refer to Chapter 6, Access/Inspection Plates - Description and
Operation.
(7) Connect electrical power.
(8) Verify proper operation of flaps. Refer to Flap System Adjustment/Test for rigging instructions.
3. Flap Removal/Installation
A. Remove Flaps (Refer to Figure 202).
NOTE: The flap track slot width should be 0.5735 inches ±0.03 inches. Any width not within these
limits constitutes replacement of the flap track.
NOTE: It is permissible to apply 3M Y8671 (or equivalent) polyurethane tape on upper flap skins
as required to prevent chafing against wing trailing edge.
(1) Place Master Switch in the BATT position and lower flaps using flap selector switch.
(2) Return BATT portion of the Master Switch to the OFF position.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FWD
FLAP MOTOR AND
TRANSMISSION
DRIVE PULLEY DRIVE PULLEY SETSCREW
FLAP MOTOR
TURNBUCKLES ACTUATING
LEFT
TO LEFT TO RIGHT
WING FLAP WING FLAP
VIEW LOOKING DOWN
0525C1007
Flap System Schematic

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B
D FLAP
DRIVE PULLEY RETRACT CABLE
DIRECT CABLE
FLAP FLAP
CONTROL
CONTROL
SPACER
PULLEY
BOLT
Flap System Installation

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
0.12 INCH, +0.05 OR -0.05 INCH

WITH FLAPS IN FULL UP POSITION.
BOLT
WING STRUCTURE
BOLT
ASSEMBLY
SWITCH ACTUATING COLLAR

SETSCREW /
DOWN LIMIT SWITCH DRIVE PULLEY
ACTUATING TUBE RETRACT CABLE
DIRECT CABLE
DETAIL D AA05641007

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLAP
BRACKET
DETAIL G
NYLON PLUG BUTTON
DETAIL E
ACCESS PLATE
SPACER
BUSHING
ROLLER
ASSEMBLY
SPACER
FLAP INBOARD
BUSHING
E05251002
SUPPORT

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MODEL 172
MAINTENANCE MANUAL
(3) Remove access plates 510CT. 510DT. 510ET and 510FT from leading edge of flap. Refer to
Chapter 6, Access/Inspection Plates - Description and Operation.
(4) Disconnect push-pull rod at flap bracket.
(5) Remove bolts at each flap track. As flap is removed from wing, all washers, rollers and bushings
will fall free. Retain for reinstallation.
B. Install Flaps (Refer to Figure 202).
(1) Install flap to flap tracks using hardware removed in step (A.) (5.) above.
(2) Connect push- pull rod to flap bracket.
NOTE: If push-pull rod adjustment was not disturbed, flap re-rigging should not be required.
(3) Reinstall access plates 510CT. 510DT. 510ET and 510FT to leading edge of flap. Refer to
(4) Place Master Switch in the BATT position and raise flaps using flap selector switch.
(5) Return BATT portion of the Master Switch to the OFF position.
4. Flap Drive Pulley Removal/Installation
NOTE: Left and right flap drive pulley removal/installation is typical.

A. Remove Flap Drive Pulley (Refer to Figure 202).
(1) In the cockpit/cabin area, remove overhead center console.
(2) Remove safety wire and loosen flap adjustment turnbuckles.
(3) Remove access plate 610GB. Refer to Chapter 6, Access/Inspection Plates - Description and
Operation.
(4) Remove bolt securing flap push-pull rod to drive pulley and gently lower right flap.
(5) Remove bolt securing actuating tube to drive pulley and gently lower left flap.
(6) Remove cable locks securing control cables to drive pulley. Tag cables for identification.
(7) Remove bolt attaching drive pulley to wing structure.
(8) Remove drive pulley through access opening, without dropping bushing. Retain brass washer
from between drive pulley and wing structure, for use during reinstallation.
B. Install Flap Drive Pulley (Refer to Figure 202).
(1) Install drive pulley and bushing through access opening, install brass washer and secure to wing
structure with bolt.
(2) Remove identification tags and install cable locks securing control cables to drive pulley.
(3) Raise left flap and install bolt securing actuating tube to drive pulley.
(4) Raise right flap and install bolt securing flap push- pull rod to drive pulley.
(5) Rig system. Refer to Flap Control Adjustment/Test.
(6) Install access plate 610GB. Refer to Chapter 6, Access/Inspection Plates - Description and
Operation.
(7) Install overhead center console.
5. Flap Control System Adjustment/Test
A. Rig Flap Control System (Refer to Figure 202).
(1) In the cockpit/cabin area, remove overhead console.
(2) With flaps in UP position, disconnect follow up cable by removing clevis attaching follow up cable
to bellcrank.
(3) Remove safety wire, relieve cable tension, disconnect turnbuckles and gently lower left flap.
(4) Disconnect push- pull rods at drive pulleys in both wings and gently lower right flap.
(5) Disconnect actuating tube from drive pulley.
(6) Adjust both push- pull rods to 8.83 inches, +0.12 or -0.12 inch between centers of rod end
bearings and tighten locknuts on both ends. Connect push-pull rods to flaps and drive pulleys.
NOTE: If control cables are not connected to left and right drive pulleys, actuating tube and
push-pull rods must be disconnected before installing cables. If drive pulleys are not
installed, attach control cables before installing drive pulleys in the wings.
27-50-00 Page 206

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(7) Screw actuating tube in toward transmission by hand to 0.12 inch, +0.05 or -0.05 inch between
switch actuating collar and transmission.
NOTE: Temporarily connect cables at turnbuckles and test flaps by hand to ensure both flaps
extend and retract together. If they will not, the cables are incorrectly attached to the
drive pulleys. Ensure that the right drive pulley rotates clockwise when viewed from
below, as the flaps are extended. Place identification tag on cables, and disconnect
turnbuckles again.
(8) Loosen setscrew securing actuating tube to switch actuating collar and hold collar to maintain
0.12 inch, +0.05 or -0.05 inch while holding right flap up, and adjust actuating tube in or out as
necessary to align with attachment hole in drive pulley.
(9) Apply Loctite grade CV sealant to threads of setscrew and torque to 60 inch- pounds.
(10) Disconnect push-pull rod at drive pulley to allow connecting actuating tube to drive pulley.
(11) Manually hold right flap in full up position and readjust push pull rod to align with attachment
hole in drive pulley. Connect push-pull rod and tighten jamnuts.
(12) With flaps in full up position, loosen setscrew and slide up limit switch adjustment block on
support to just activate switch and shut off electrical power to motor at this position. Tighten
setscrew.
(13) Manually hold left flap full up and connect control cables at turnbuckles. Remove reference tags
previously installed.
(14) With flaps up, adjust turnbuckles to obtain 30 pounds, +10 or -10 pounds tension on cables.
Adjust retract cable first.
(15) Disconnect push-pull rod at left drive pulley.
(16) Run motor to extend flaps approximately 20 degrees and check tension on each flap cable.
(17) If necessary readjust turnbuckles to maintain 30 pounds, +10 or -10 pounds tension on each
cable and safety turnbuckles.
(18) Fully retract right flap.
(19) Manually hold left flap in up position and readjust push-pull rod to align with attaching hole in
drive pulley.
(20) Connect push-pull rod and tighten locknuts.
(21) Mount an inclinometer in right flap and adjust to zero degrees.
(22) Run flaps to full down position and adjust down limit switch to stop motor and flap at 30 degrees,
+0 or -2 degrees. Repeat check on left flap. Recheck limit switch through several flap cycles.
(23) Reconnect and re rig the flap follow up system.
(24) Perform an operational check of the system. Refer to procedures on page 208
(25) Recheck all items for proper safetying and replace items removed for access.
6. Operational Check
A. Check Procedures:
(1) Operate flaps through their full range of travel, observing for uneven travel or jumpy motion,
binding or lost motion. Ensure flaps are moving together through their full range of travel.
(2) Check for positive shut-off of motor at flap travel extremes to prevent damage to actuator
assembly.
(3) With flap full UP, mount an inclinometer on one flap and set to 0 degrees. Lower flaps to full
DOWN position and check flap angle as specified in Chapter 6, Airplane Dimensions and
Specifications - Description and Operation. Repeat same procedure for the opposite flap.
27-50-00 Page 207

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLAP FOLLOW UP AND INDICATING SYSTEM - MAINTENANCE PRACTICES

A. The flap follow up and indicating system consists of a sheathed cable assembly, pointers and micro
switches. One end of the cable is attached to the flap operating switch operating arm. The other end
is clamped to the flap direct cable, above the headliner in the rear cabin area. Motion of the flap cable
is transmitted through the follow up control to the pointer, attached to the switch mounting arm. Pointer
moves along a scale as the flaps are extended or retracted. When the motion of the switch mounting
arm with the attached operating switches positions the "active" operating switch to clear the cam on
flap lever, flap motor circuit is broken and flaps stop at selected position.
2. Follow Up and Indicating System Removal/Installation
A. Figure 201 may be used as a guide for removal and installation of the flap follow up and indicating
system.
NOTE: If the knob on the flap selector lever becomes loose, remove knob and clean threads on
lever with MEK or equivalent. After threads have thoroughly dried, prime threads and allow
to dry. Secure knob to lever using loctite (MIL-S-22473) or equivalent. Allow loctite to cure
for approximately 30 minutes before returning to service.
3. System Rigging
A. Rigging Procedures (Refer to Figure 201).
NOTE: The flaps must be properly rigged before rigging the follow up system.
(1) Disconnect spring from switch mounting arm (Detail C).
(2) With flaps and flap lever in full UP position and holding flap position indication to a clearance
of 0.03 inch maximum with top of instrument panel opening, pull center cable of flap follow up
cable (Detail B) to remove slack. Thread cable thru the clamp bolt (Detail C).
(3) Lubricate the slots of guide and bellcrank (Detail B) with LPS 3 or equivalent.
(4) Connect spring to switch mounting arm (Detail C).
(5) Adjust switches in slotted holes of mounting arm until cam is centered between switch rollers.
(6) Mount an inclinometer on one flap and set to 0 degrees. Turn master switch ON and move flap
lever to 10 degree position.
(7) Observe inclinometer reading when flap stops. Adjust flaps DOWN operating switch in slotted
holes on mounting arm as required to obtain flap travel of 10 degrees, + 0 or -2 degrees.
(8) Adjust flaps UP operating switch to obtain positive clearance with cam when flaps DOWN
operating switch has just opened in the 10 degree position.
(9) Repeat steps 6 thru 7 for the 20 degree flap position. Travel should be 20 degrees, +0 or -2
degrees.
(10) Run flaps to full DOWN position (30 degrees, +0 or -2 degrees). Ensure that flaps DOWN
operating switch remains closed as flap motor limit switch stops flaps in full DOWN position.
(11) Check flaps through several cycles, recheck all components for security, and replace items
removed for access.
27-51-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
BELLCRANK
GUIDE
WASHER
WASHER
SPACER
CLAMP
DETAIL B
A05641001
B05641003
Flap Indicator Installation

27-51-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SUPPORT
SPACER
WASHER
SPACER
OPERATING
CLAMP BOLT
INSULATOR
SWITCH
DETAIL C
C05641002
Flap Indicator Installation

27-51-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
FUEL
.
MODEL 172
MAINTENANCE MANUAL

28-Title
28-00-00 1 Aug 18/2001
2 Aug 18/2001
28-20-00 1 Feb 15/2002
2 Feb 15/2002
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206 Feb 15/2002
207 Feb 15/2002
208 Feb 15/2002
209 Feb 15/2002
210 Feb 15/2002
211 Feb 15/2002
212 Feb 15/2002
213 Feb 15/2002
214 Feb 15/2002
215 Feb 15/2002
216 Feb 15/2002
28-21-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
206 Aug 18/2001
207 Aug 18/2001
208 Aug 18/2001
209 Aug 18/2001
210 Aug 18/2001
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217 Aug 18/2001
218 Aug 18/2001
219 Aug 18/2001

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

|~~~~~~~~~~~ I
MODEL 172
MAINTENANCE MANUAL

I
MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL
CONTENTS
FUEL - GENERAL ............................................................... 28-00-00 Page 1
Scope ....................... ............................................ . 28-00-00 Page 1
Definition ......... .. ........................................................ 28-00-00 Page 2
FUEL STORAGE AND DISTRIBUTION - DESCRIPTION AND OPERATION .......... 28-20-00 Page 1
General .................................................................... 28-20-00 Page 1
FUEL STORAGE AND DISTRIBUTION - MAINTENANCE PRACTICES ............... 28-20-00 Page 201
G eneral .................................................................... 28-20-00 Page 201
Fuel Drain Valve Removal/Installation ......................................... 28-20-00 Page 201
Fuel Level Sender and Indicator Removal/Installation ........................... 28-20-00 Page 201
Fuel Reservoir Removal/Installation ........................................... 28-20-00 Page 205
Fuel Selector Valve Removal/Installation ...................................... 28-20-00 Page 205
Fuel Shutoff Valve Control Cable/Arm Adjustment .............................. 28-20-00 Page 209
Electric Auxiliary Fuel Pump Removal/Installation .............................. 28-20-00 Page 209
Fuel Bay Vents Adjustment/Test ...................................... ........ 28-20-00 Page 209
Vented Fuel Filler Cap Adjustment/Test ....................................... 28-20-00 Page 210
Fuel Quantity Calibration .................................................... 28-20-00 Page 210
Fuel Strainer Disassembly/Cleaning/Assembly ................................. 28-20-00 Page 211
FUEL BAY SEALING - MAINTENANCE PRACTICES ............................... 28-21-00 Page 201
General .................................................................... 28-21-00 Page 201
Tools and Equipment ........................................................ 28-21-00 Page 201
Definition of Sealing Terms ................................................... 28-21-00 Page 204
Materials ................................................................... 28-21-00 Page 205
General Requirements ...................................................... 28-21-00 Page 206
Sealant Curing .............................................................. 28-21-00 Page 207
Mixing of Sealants .......................................................... 28-21-00 Page 207
Cleaning ................................................................... 28-21-00 Page 209
Sealing Application .......................................................... 28-21-00 Page 210
Sealant Repair .............................................................. 28-21-00 Page 215
Classification of Fuel Leaks .................................................. 28-21 -00 Page 217
Sealing Fuel Leaks .......................................................... 28-21-00 Page 217
Testing Integral Fuel Bay ..................................................... 28-21-00 Page 217
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
FUEL - GENERAL
1. Scope
A. This chapter provides information on systems and componnets associated with fuel storage, fuel
distribution, refueling and fuel quantity indicating.


Sealant Type 1 CS-3204 Flame Master To seal fuel tank area.
Class A-1/2 Chem Seal Div.
Class A-2 11120 Sherman Way
Sun Valley, CA 91352
Sealant Type 1 Pro-Seal 890 Courtaulds Aerospace To seal fuel tank area.
Class A-2 5426 San Fernando Rd.
Glendale, CA 91209
Sealant Type 1 PR-1440 Courtaulds Aerospace To seal fuel tank area.
Class A-1/2
Class A-2
Class B-2
Sealant Type 1 Pro-Seal 890 Courtaulds Aerospace To seal fuel tank area.
Class B-1/2
Class B-2
Class B-1/2
Class B-2
Class B
Sealant Type 1 CS-3204 Flame Master, Chem Seal Div. To seal fuel tank area.
Class B-1/2
Class B-2
Sealant Type PR-1428 Courtaulds Aerospace To seal fuel tank access
VIII Class B-1/2 panels.
Class B-2
Sealant Type FR-1081 Fiber Resin Corp. To seal fuel tank access
VIII Class B-1/2 170 W. Providencia Ave. panels.
Class B-2 Burbank, CA 91502
Pressure Commercially Available To regulate input pressue.
Regulator
Fahrenheit Commercially Available To monitor test area
Thermometer temperature.
Leak Detector Eldorado LD-4 Eldorado Chemical Co. Inc. To locate source of leak.
14350 Lookout Road P.O.
Drawer 34837
San Antonio, TX 78265-4837
28-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL

Cleaner Methel Ethyl Commercially Available To clean surfaces prior to
Ketone (MEK) sealing.
Scotchbrite Pad N/A Commercially Available To remove loose primer.
Fuel Quantity 0580001-1 Cessna Aircraft Company To calibrate fuel quantity
Test Box system.
680 Loctite To improve the installation of
the fuel strainer fittings.
3. Definition
A. This chapter is divided into sections and subsections to assist maintenance personnel in locating,
specific systems and information. For locating information within the chapter, refer to the Table of
Contents at the beginning of the chapter.
28-00-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FUEL STORAGE AND DISTRIBUTION - DESCRIPTION AND OPERATION

General
A. The airplane is equipped with a wet wing fuel storage system. The system consists of two integral fuel
tanks (one in each wing), a three position selector valve, a fuel reservoir tank, an electrically-driven
auxiliary fuel pump, a fuel shutoff valve and a fuel strainer.
B. Components beyond the fuel strainer include the engine-driven fuel pump, the fuel injection servo and
the fuel distribution valve. These components are considered part of the powerplant and are covered
in Chapter 73, Fuel Injection System - Description and Operation.
C. A schematic of the entire fuel system is shown to aid in system understanding. Refer to Figure 1.
28-20-00 Page 1
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B1730
FUEL QUANTITY INDICATORS
FUEL FUEL
QUANTITY QUANTITY
TRANSMITTER TRANSMITTER
LEFT
FUEL RIGHT
TANK FUEL
SELECTOR l|;|j|M-. _ TANK
VALVE
VENT
(WITH SCREEN
CHECK
VALVE) DRAIN
DRAIN VALVES
VALVES (5 TOTAL)
(5 TOTAL)
DRAIN
VALVE
FUEL RESERVOIR
TANK FUEL RESERVOIR
TANK DRAIN
AUXILIARY
FUEL PUMP
AUXILIARY
FUEL SHUTOFF FUEL PUMP
VALVE KNOB
VALVE KNOB FUEL SHUTOFF SWITCH
VALVE
ENGINE DRIVEN
FUEL
STRAINERSTRAINER ]•. FUEL PUMP
FUEL INJECTION
~~~DRAIN SERVO
VALVE
_________ FUEL DISTRIBUTION
LEGEND VALVE
FUEL SUPPLY FUEL FLOW

INDICATOR
VENT
MECHANICAL
LINKAGE
ELECTRICAL
CONNECTION
0591R1001
Fuel System Schematic

Figure 1 (Sheet 1)
28-20-00 Page 2
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
FUEL STORAGE AND DISTRIBUTION - MAINTENANCE PRACTICES

1. General
A. This section provides information on removal, installation and adjustment of fuel system components.
For an illustration of the fuel system, refer to Figure 201.
2. Fuel Drain Valve Removal/Installation
NOTE: Drain valve removal and installation is typical for all fuel drains on both wing tanks.
A. Remove Fuel Drain Valve (Refer to Figure 202).
(1) Defuel airplane. Refer to Chapter 12, Fuel - Servicing.
(2) Using a fuel sampler cup, press fuel drain valve up to ensure fuel bay is completely drained.
(3) Cut safety wire and remove fuel drain valve from fuel bay.
B. Install Fuel Drain Valve (Refer to Figure 202).
(1) Install fuel drain valve in fuel bay. Tighten drain valve until O-ring compresses and forms a fuel-
tight seal.
~
1| (2) Install safety wire on drain valve to structure. Refer to Chapter 20, Safetying - Maintenance
Practices.
(3) Add small amount of fuel to fuel bay and check fuel drain valve for leaks.
3. Fuel Level Sender and Indicator Removal/Installation
NOTE: Fuel level sender removal/installation is typical for left and right fuel bays.
A. Check the fuel level sender for proper operation before replacing the fuel quantity indicator. The
resistance must be 6 ohms +5 or -5 ohms when empty, and 90 ohms +5 or -5 ohms when full.
B. Remove Fuel Level Sender (Refer to Figure 203).
(1) Defuel airplane. Refer to Chapter 12, Fuel - Servicing.
(2) Remove access panels 510DB and 51 OHB (left wing) or 610DB and 61 OHB (right wing) to gain
access to the sender. Refer to Chapter 6, Access/Inspection Plates - Description and Operation.
(3) Disconnect wire ring terminals from fuel level sender.
(4) Disconnect fuel level sender ground wire from rib.
CAUTION: DO NOT BEND FUEL LEVEL SENDER FLOAT ARM.
(5) Remove screws attaching fuel level sender to bracket and carefully work from fuel bay.
C. Install Fuel Level Sender (Refer to Figure 203).
(1) Install new gaskets on fuel level sender.
(2) Install five (5) insulating bushings into the mounting screw holes with the shoulder to the outside
of the transmitter.
CAUTION: DO NOT BEND FUEL LEVEL SENDER FLOAT ARM.
(3) Carefully work fuel level sender into fuel bay and secure with screws. Torque screws to 20 inch-
pounds.
(4) Connect the larger ring terminal to fuel level sender center stud (stud #1). Torque nut to 12
inch-pounds.
(5) Connect fuel level sender ground wire to the small stud (stud #2).
(6) Install access panels 510DB and 51 OHB (left wing) or 610DB and 61 OHB (right wing). Refer to
(7) Check fuel quantity calibration. Refer to Fuel Quantity Calibration in this section.
D. Remove Indicator (Refer to Figure 203).
(1) Ensure all electrical power is OFF.
(2) Gain access to backside of fuel quantity indicator and disconnect electrical connector.
(3) Remove screws securing indicator to instrument panel and remove indicator from airplane.
28-20-00 Page 201

Feb 15/2002
v 11V13a
v
iVnNVIV 3ONVN31NIVV/
MODEL 172
MAINTENANCE MANUAL
B1476
WS WS
23.62 71.62
2362 REAR SPAR 7162
FRONT SPAR
B DETAIL A
LOOKING UP AT BOTTOM OF WING
RIGHT SIDE SHOWN
(LEFT SIDE TYPICAL)
LOWER WING SKIN
DRAIN VALVE BOSS
FUEL DRAIN VALVE
DETAIL B 0510T1007
A0516R1016
B1516R1017
Fuel Drain Valve Installation

28-20-00 Page 203

Feb 15/2002
( IeeqiS) CO eaJn6!j
JapuaS l|aA- l|anj
(VOIldA1l 3GIS lHOID)
NMOHS 3lIS 1i33
3C3aN3S 13A31 133
ni
MODEL 172
MAINTENANCE MANUAL
E. Install Indicator (Refer to Figure 203).

NOTE: If the indicator or fuel level senders are being replaced, the system must be calibrated using
procedures found in Fuel Quantity Calibration.
(1) Connect electrical connector to indicator.

(2) Place indicator in position and secure to instrument panel using screws.
(3) Restore electrical power to airplane and ensure fuel quantity gauge reads correctly.
4. Fuel Reservoir Removal/Installation
A. Remove Fuel Reservoir (Refer to Figure 204).
(1) Defuel the airplane. Refer to Chapter 12, Fuel - Servicing.
(2) Remove copilot seat and carpet. Refer to Chapter 25, Front Seats and Rails - Maintenance
Practices and Chapter 25, Interior Upholstery - Maintenance Practices.
(3) Remove access panel directly aft of copilot rudder pedals to gain access to reservoir.
(4) Place container under fuel drain in bottom of fuselage, and drain fuel from reservoir.
(5) Disconnect reservoir vent tube.
(6) Disconnect reservoir inlet tube.
(7) Disconnect reservoir outlet tube.
(8) Remove screws securing reservoir to airplane structure.
(9) Remove reservoir from airplane.
B. Install Fuel Reservoir (Refer to Figure 204).
(1) Position fuel reservoir in airplane and secure with screws.
(2) Connect reservoir outlet tube.
(3) Connect reservoir inlet tube.
(4) Connect reservoir vent tube.
(5) Ensure fuel reservoir drain is closed.
(6) Place fuel shutoff valve in the ON position.
(7) Check fuel reservoir connections for any fuel leaks.
(8) Turn on auxiliary fuel pump and note positive fuel pressure on fuel pressure gage.
(9) Install access panel to floorboard.
(10) Install carpet and copilot seat. Refer to Chapter 25, Front Seats and Rails - Maintenance
5. Fuel Selector Valve Removal/Installation
A. Remove Fuel Selector (Refer to Figure 205).
(1) Defuel the airplane. Refer to Chapter 12, Fuel - Servicing.
(2) Remove button plug on top of fuel selector valve handle to expose screw.
(3) Remove screw and lift up on handle to disconnect it from fuel selector valve shaft.
(4) Remove metal placard from pedestal to gain access to valve, plumbing and universal joints.
(5) Remove carpet as required to gain access to inspection plates aft of pedestal structure.
(6) Disconnect fitting at base of shaft assembly from valve shaft.
(7) Disconnect and cap fuel lines to valve.
(8) Remove screws attaching valve to mounting bracket and withdraw valve.
B. Install Fuel Selector (Refer to Figure 205).
(1) Attach selector valve to mounting bracket.
(2) Connect fuel lines to valve.
(3) Reconnect valve shaft assembly.
(4) Fuel airplane and check fuel lines for leaks. Refer to Chapter 12, Fuel - Servicing.
(5) Install carpet and inspection plates.
(6) Install metal placard to center pedestal.
(7) Install fuel selector valve handle to shaft, secure with screw and reinstall button plug.
28-20-00 Page 205

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B1480
TO VENT
MOUNT
(TYPICAL)
FROM
\ / SELECTOR
VALVE
DRAIN
TO AUXILIARY VALVE
FUEL PUMP
DETAIL A 051T1007
A0516T1004
Fuel Reservoir Installation

28-20-00 Page 206

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
81737
FUEL
SUPPLY
LINE
FUEL VENT FUEL
LINE SHUTOFF
KNOB
FUEL
RESERVOIR
ELECTRIC
FUEL PUMP
FUEL
i-ir-ti-iHA
FUEL DETAIL A
STRAINER
0510T1007
A0516T1007
Fuel System Details

28-20-00 Page 207

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B3263
LOCK NUT
WASHER
(NAS1149F0363P)
'^^.j^~ j^ ~ CLAMP
FUEL SHUTOFF
VALVE CABLE
DETAIL B
B0516T1014
Fuel System Details

28-20-00 Page 208

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
6. Fuel Shutoff Valve Control Cable/Arm Adjustment

A. Preliminary (Refer to Figure 205).
(1) Remove copilot seat. Refer to Chapter 25, Front Seats and Rails - Maintenance Practices.
(2) Pull the footwell carpet away from the copilot's rudder pedal shields, to expose the screws
attached the shield.
(3) Remove screws from pedal shields.
(4) Remove pedal shields from airplane.
B. Adjust Fuel Shutoff Cable and Control Arm to swivel smoothly (Refer to Figure 205).
(1) Remove lock nut.
NOTE: Lock nuts may be reused unless they can be run up finger tight. When fiber type
self locking nuts are reused, check the fiber carefully to make sure it has not lost its
locking function or become brittle.
(2) Remove existing washers and replace with one (1) NAS1149F0316P Washer and one (1)
NAS1149F0363P Washer.
(3) Install lock nut, tightening to a minimum of 15 inch pounds to secure control cable.
(4) Lubricate swivel clamp using a dry film lubricant such as Molykote 321.
(5) Make sure the control arm will swivel smoothly.
(6) Operate the fuel shutoff control cable knob, inspecting for a smooth swivel of the fuel shutoff
valve control cable/arm connection.
NOTE: If the fuel shutoff valve control assembly is binding or kinked, adjust control assembly
until smooth operation is achieved. If adjusting does not produce a smooth operation,
then replace the assembly and adjust control assembly until smooth operation is
achieved.
C. Install the copilot's rudder pedal shields secure with screws.
D. Install footwell carpet.
E. Install the copilot's seat. Refer to Chapter 25, Front Seats and Rails - Maintenance Practices.
7. Electric Auxiliary Fuel Pump Removal/Installation
A. Remove Electric Auxiliary Fuel Pump (Refer to Figure 205).
(1) Set MASTER ALT/BAT switch to the OFF position.
(2) Turn the fuel selector handle to the OFF position.
(3) Disconnect the battery ground cable from the battery.
(4) Remove copilot seat and carpet. Refer to Chapter 25, Front Seats and Rails - Maintenance
(5) Remove access plates (230BT and 230CT). Refer to Chapter 6, Access/Inspection Plates -
(6) Disconnect electrical connection (P1) from electric auxiliary fuel pump (UF005).
(7) Disconnect fuel lines, and drain line from electric auxiliary fuel pump.
(8) Loosen clamps securing electric auxiliary fuel pump and remove pump from airplane.
(9) Remove all fuel fittings from electric auxiliary fuel pump and discard inlet and outlet fuel fitting's
O-rings.
B. Install Electric Auxiliary Fuel Pump (Refer to Figure 205).
(1) Put new O-rings on the inlet and outlet fuel fittings.
(2) Install inlet and outlet fuel fittings into electric auxiliary fuel pump and tighten. Refer to Chapter
20, Torque Data - Maintenance Practices.
(3) Install fuel drain fitting into electric auxiliary fuel pump and tighten. Refer to Chapter 20, Torque
Data - Maintenance Practices.
(4) Place the electric auxiliary fuel pump into mounting clamps.
(5) Loosely tighten mounting clamps.
(6) Connect fuel lines to inlet and outlet fittings and tighten with your hand.
28-20-00 Page 209

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
(7) Tighten mounting clamps. Refer to Chapter 20, Torque Data - Maintenance Practices.
(8) Tighten fuel lines onto fittings. Refer to Chapter 20, Torque Data - Maintenance Practices.
(9) Connect electrical connection to electric auxiliary fuel pump.
(10) Turn the fuel selector handle to the ON position.
(11) Check electric auxiliary fuel pump and fuel fittings for fuel leaks.
(12) Connect the battery ground cable to the battery.
(13) Loosen fuel supply hose at fuel injection servo inlet.
(14) Set mixture control to OFF.
(15) Set throttle control to IDLE STOP.
(16) Set MASTER ALT/BAT switch to the ON position.
(17) Set FUEL PUMP switch to ON.
(18) Operate electric auxiliary fuel pump sufficient time to bleed air from fuel lines and prime the
electric auxiliary fuel pump.
(19) Set FUEL PUMP switch to OFF.
(20) Tighten fuel supply hose at fuel injection servo inlet. Refer to Chapter 20, Torque Data -
(21) Set FUEL PUMP switch to ON.
(22) Operate electric auxiliary fuel pump and check all fuel fittings for leaks.
(23) Set FUEL PUMP switch to OFF.
(24) Install access plates (230BT and 230CT). Refer to Chapter 6, Access/Inspection Plates -
(25) Install carpet and copilot seat. Refer to Chapter 25, Front Seats and Rails - Maintenance
8. Fuel Bay Vents Adjustment/Test

NOTE: If stoppage of either the fuel vent or vent bleed hole occurs with the engine running, it can lose
power, and eventually stop due to fuel starvation. If the above stoppage occurs with the engine
not running, fuel expansion can pressurize the fuel bays causing fuel spillage.
A. Test Fuel Bay Vents (Refer to Figure 206).
(1) Attach a rubber tube to the end of vent line beneath the wing.
(2) Blow into tube to slightly pressurize fuel bay. If air can be blown into the fuel bay, vent line is
open.
(3) After tank is slightly pressurized, insert end of rubber tube into a container of water and watch
for a continuous stream of bubbles which indicates the valve assembly bleed hole is open and
relieving pressure.
(4) After completion of step 8.A.(3), blow into tube again to slightly pressurize the fuel bay and
loosen, but do not remove filler cap on opposite wing to check fuel bay crossover line. If pressure
escapes from filler cap, crossover line is open.
(5) If fuel vent check valve is unserviceable, complete the following steps. Refer to Figure 207.
(a) Defuel the airplane. Refer to Chapter 12, Fuel - Servicing.
(b) Access the wing fuel vent check valve by opening the wing fuel bay access plates
(510KB and 610KB) on the upper surface. Refer to Chapter 6, Inspection/Access Plates -
(c) Remove the unserviceable wing fuel vent check valve and replace it with a new fuel vent
check valve ensuring the bypass hole on the valve flap is installed at the top of the fuel bay.
(d) Reinstall and seal the wing fuel bay access plate. Ensure complete sealing of access plate.
Refer to Chapter 28, Fuel Bay Sealing - Maintenance Practices.
(e) Perform the test detailed above to ensure the new fuel vent check valve functions properly.
(f) Fill the fuel tank and inspect for leaks. If leaks are apparent, defuel, disassemble, and
reseal until no leaks are evident. Refer to Chapter 28, Fuel Bay Sealing - Maintenance
Practices.
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MODEL 172
MAINTENANCE MANUAL
WARNING: THE FUEL VENT LINE PROTRUDING BENEATH THE WING NEAR THE WING
STRUT MUST BE CORRECTLY ALIGNED TO AVOID POSSIBLE ICING OF
THE VENT TUBE.
(6) Ensure the fuel vent line protruding beneath the wing is correctly aligned as shown in Figure 206.
(7) Any fuel vent component found plugged or restricted must be corrected prior to returning aircraft
to service.
9. Vented Fuel Filler Cap Adjustment/Test
A. Inspect, Clean and Repair Vented Fuel Filler Cap (Refer to Figure 208).
(1) Remove vented fuel filler cap from the adapter assembly. Disconnect the safety chain and cover
or plug the tank opening to keep out foreign matter.
(2) Check condition of gasket and frictionless washer. Replace as required.
(3) Using cotton swabs and solvent, gently lift edges of rubber umbrella and clean seat and umbrella
removing all contaminates. Using a second swab wipe seat and umbrella thoroughly, removing
all cotton fibers. Repeat until swabs show no discoloration.
(4) If the umbrella continues to leak or is deteriorated, remove and replace. To remove the umbrella,
lubricate the umbrella stem with hydraulic fluid (MIL-H-5606) to prevent tearing the stem. When
installing the new umbrella, lubricate the stem with hydraulic fluid (MIL-H-5606) and use a small
blunt tool to insert the retaining knob on the umbrella, into the check valve body.
(5) Connect fuel cap to safety chain and reinstall cap in the adapter assembly.
10. Fuel Quantity Calibration
NOTE: Anytime a fuel level sender (transmitter) or indicator is replaced, the fuel quantity system must
be calibrated to establish both empty and full reading levels.
A. Prepare Airplane.
(1) Drain fuel from wing tanks only. Do not drain fuel from drains located on underside of fuselage.
Refer to Chapter 12, Fuel - Servicing.
(2) Place the airplane at 2 degree nose up and wings level attitude. Refer to Chapter 8, Leveling -
Maintenance Practices for location of level points.
(3) Remove fuel quantity indicator from instrument panel.
(4) Install the 0580001-1 test box between the indicator and the airplane's electrical connector.
NOTE: Internal lighting for the fuel quantity indicator will not work with test box connected
between it and the airplane.
B. Calibrate The System (Refer to Figure 203).
(1) Apply 28.0 VDC, +0.5 or -0.5 VDC, to airplane and turn master switch to the ON position.
(2) Place both switches on the test box to the NORM position.
(3) Place 2.0 gallons of fuel in each wing tank.
NOTE: A non-magnetic screwdriver must be used when adjusting the potentiometers on the
fuel quantity indicator.
(4) Adjust the "Empty" potentiometer on each side of indicator until pointer for each tank is in the
middle of the red radial line.
(5) Verify that L LOW FUEL R message is illuminated on annunciator panel.
(6) Fill both wing tanks to capacity.
(7) Adjust the "Full" potentiometer on each side of indicator until pointer for each tank is at the full
indication.
(8) Verify that L LOW FUEL R message extinguishes on annunciator panel.
(9) Proceed to step 8.C. and verify proper operation of the circuitry.
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MODEL 172
MAINTENANCE MANUAL
C. Verify Proper Operation of Warning Circuitry.

NOTE: Use the airplane digital clock in the timer mode to time the annunciators. The timing interval
for this test is from switch actuation until the annunciator begins to flash. The annunciators
will flash for approximately 10 seconds before they illuminate steady.
(1) Place the NORM/OPEN switch on the text box to OPEN and begin timing.
(2) Observe the indicator. Fuel quantity pointers must go to the Power Off position (below 0). The
annunciator panel message L LOW FUEL R must illuminate between 0 to 75 seconds.
(3) Return the NORM/OPEN switch to the NORM position. The indicators must read full and the
message L LOW FUEL R must be extinguished.
(4) Reset timer.
(5) Turn the SHORT/NORM/100+OHM switch to the 100+OHM position. Begin timing.
(7) Return the SHORT/NORM/100+OHM switch to the NORM position. The indicators must read
full and the message L LOW FUEL R must be extinguished.
(8) Reset timer.
(9) Turn the SHORT/NORM/100+OHM switch to the SHORT position. Begin timing.
(11) Return the SHORT/NORM/100+OHM switch to the NORM position. The indicators must read
full and the message L LOW FUEL R must be extinguished.
(12) Reset time and return clock to clock mode.
(13) Turn Master Switch OFF.
(14) Remove test box from airplane.
(15) Reconnect fuel quantity indicator to electrical connector.
(16) Reinstall fuel quantity indicator in instrument panel.
D. Turn Master Switch ON. Observe that fuel quantity indicators register FULL and that annunciators are
extinguished.
E. Turn master switch OFF.
11. Fuel Strainer Disassembly/Cleaning/Assembly
A. Disassemble And Clean Fuel Strainer (Refer to Figure 209).
(1) Turn off fuel selector valve.
(2) Disconnect and remove the safety wire, nut, and washer at bottom of filter bowl and remove
bowl.
(3) Carefully unscrew standpipe and remove.
(4) Remove filter screen and gasket.
(5) Wash filter screen and bowl in solvent and dry with compressed air.
B. Assemble Fuel Strainer (Refer to Figure 209).
(1) Using a new gasket between filter screen and top assembly, install screen and standpipe.
Tighten standpipe only finger tight.
(2) Using all new O-rings, install bowl. Torque nut 25 to 30 inch-pounds.
NOTE: Step-washer at bottom of bowl is installed so that step seats against O-ring. It is
permissible to use O-ring lubrication for this step.
(3) Safety wire bottom nut to top assembly. Wire must have right hand wrap, at least 45 degrees.
(4) Turn on fuel selector valve and check for leaks. Check for proper operation.
(5) Bleed the air from the fuel strainer.
(a) Loosen fuel supply hose at fuel injection servo inlet.
(b) Set mixture control to OFF.
(c) Set throttle control to IDLE STOP.
(d) Set FUEL PUMP switch to ON.
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MAINTENANCE MANUAL
(e) Operate electric auxiliary fuel pump until the air is removed from fuel lines and prime the
electric auxiliary fuel pump.
(f) Set FUEL PUMP switch to OFF.
(g) Tighten fuel supply hose at fuel injection servo inlet. Refer to Chapter 20, Torque Data -
12. Auxiliary Fuel Pump Serviceability Test (Airplanes 17280001 and On and Airplanes 172S8001 and
On)
A. Auxiliary Fuel Pump Test (Refer to Table 201).
WARNING: OBEY ALL FUEL SYSTEM FIRE AND SAFETY PROCEDURES.
WARNING: REMOVE ALL FLAMMABLE SOURCES FROM THE AIRPLANE AND ALL VAPOR
HAZARD AREAS.
(1) Remove the fuel supply hose from the engine driven fuel pump inlet fitting.
(2) Install a T-fitting on the fuel supply hose.
(3) Connect a calibrated fuel pressure test gage and locally purchased fuel shutoff valve to the T-
fitting.
(4) Direct the fuel shutoff valve to drain the fuel into a container.
(5) Use a regulated electric power source to supply the 24 VDC electric power to the aircraft and a
multimeter to measure the electric current.
(a) Turn on the auxiliary fuel pump and adjust the fuel shutoff valve to get a pressure value as
shown in Table 201 for the applicable part number to test.
(b) Monitor the current draw of the auxiliary fuel pump electric motor.
(c) Measure the fuel pump current draw and output. The output will be 1 gallon in 2.5 minutes.
NOTE: To help determine an acceptable pump output, the output will be 1 gallon in 2.5
minutes (24 GPH).
NOTE: The Dukes Model 5100-00-1 auxiliary fuel pumps that are capable to give a
minimum flow rate of 23.5 GPH at 23 PSI and have a maximum current draw of
3.0 amps at 24 volts DC are considered serviceable. Dukes Models 5100-00-3
and 5100-00-4 auxiliary fuel pumps that are capable to give a minimum flow
rate of 23.5 GPH at 14 PSI and have a maximum current draw of 3.0 amps at
24 volts DC are considered serviceable.
(6) If the fuel pump fails to meet the noted requirements, replace it with a pump that meets the
requirements.
(7) If the fuel pump meets the requirements, it is considered serviceable.
Table 201. Dukes Model 5100 Serviceability Requirements
PUMP PART FUEL FLOW FUEL FLOW SUPPLIED MAXIMUM FUEL

NUMBER VOLUME PRESSURE VOLTAGE PUMP CURRENT
(MINIMUM)
5100-00-1 (or-1RX) 23.5 GPH 23 PSI 24 Volts DC 3.0 Amps
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Feb 15/2002
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MODEL 172
MAINTENANCE MANUAL
B1482
FUEL VENT
CHECK VALVE
LEFT FUEL B
VENT LINE
DETAIL A
BYPASS PORT
(NOTE)
FUEL VENT
CHECK VALVE DETAIL C
LINE ASSEMBLY - VENT
NOTE: IF THE PRESSURE TEST INDICATES THE

BYPASS PORT IS BLOCKED, THE CHECK
VALVE MUST BE REPLACED. INSTALL NEW
VALVE WITH THE HINGE/BYPASS PORT
FACING THE TOP OF THE FUEL BAY. (REQUIRED) DETAIL 1007
B1226R1004
C0516T1015
Wing Fuel Tank Vent Check Valve

28-20-00 Page 215

Feb 15/2002
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MODEL 172
MAINTENANCE MANUAL
TOP
GASKET
O-RING
FILTER
STANDPIPE -
BOWL
O-RING
NUT
O-RING
DRAIN VALVE
DETAIL A 0510T1007
A0516T1010
Fuel Strainer Assembly

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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
FUEL BAY SEALING - MAINTENANCE PRACTICES
1. General
A. The fuel bays may need to be resealed if a leak has developed, or if the wing has been repaired. This
procedures provides instructions for sealing fuel bays, classifying fuel leaks and testing fuel bays after
repair.
NOTE: Specified sealants, cleaning solvents, parting agents, adhesion inhibitors and equipment are
listed for use. Suitable substitutes may be used for sealing equipment only.
SEALANTS TYPE I, CLASS A- 1/2, OR A-2 - MIL-S-8802

3137 East 26th Street weather sealant brush
Los Angeles, CA 90023 application.
5426 San Fernando Rd.
Glendale, CA 91209
MC-236 Morton Aerospace
Polymer Systems
9341 Anaconda Ave.
Garden Grove, CA 92641
SEALANTS TYPE I, CLASS B-1/4, QUICK REPAIR - MIL-S-83318

Sealant GC-435 Goal Chemical Sealant Corp. Fuel, pressure and
weather sealant. For
limited repairs requiring
rapid curing sealant.

weather sealant spatula,
faying seals application.
Class B-1/2
Class B-2
Class B-2
Class B-4
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MODEL 172
MAINTENANCE MANUAL

PR-1826 Courtaids Aerospace
MC-236 Morton Aerospace
Polymer Systems
SEALANTS TYPE I, CLASS C- 20, C-48 OR C-80

Sealant Pro-Seal 890 Courtaulds Aerospace Fuel, pressure and
weather sealant. Suitable
for faying surface sealing.
SEALANT TYPE VIII

Sealant PR-1428 Class Courtaulds Aerospace Used in areas for access.
B2
PR-1081 Class Courtaulds Aerospace
B2
CLEANING SOLVENTS
1, 1, 1 - Federal Commercially Available Presealing cleaning.
Trichloroethane Specification
Technical O-T-620
Inhibited (Methyl
Chloroform)
Methyl-Ethyl- Federal Commercially Available Cleaning organic coating.
Ketone Specification
TT-M-261
Naphtha Type II Federal Commercially Available Presealing cleaning.
Specification
TT-N-95
Cleaning MIL-C-38736 Commercially Available Presealing cleaning.
compound
Isopropyl alcohol Federal Commercially Available Cleaning plastic
Specification transparencies.
TT-1-735
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PARTING AGENTS
Silicone compound MIL-S-8660 Commercially available Prevent sealant sticking.
Petrolatum Federal Commercially available Prevent sealant sticking.
technical Specification
VV-P-236
EQUIPMENT
Pneumatic sealing Semco Semco Packaging and Injection sealing.
gun. Number Applications Systems,
250 with Division of Courtaulds Aerospace
accessories 5454 San Fernanco Rd.
(or equivalent) Glendale, CA 91209
Hand-operated Semco Semco Packaging and Injection sealing.
sealing gun Number 850 Applications Systems,
Division of Courtaulds Aerospace
Nozzles, Semco Packaging and Application of sealant.
Applications Systems,
Division of Courtaulds Aerospace
420
440
Duckbill Semco No.
8615
Duckbill Semco No.
8648
Comb Semco No.
8646
Polyethylene Commercially available Application of sealant.
cartridges with
plungers and caps
for sealant gun.
Metal spatulas with Commercially available Mixing sealant.
either stainless
steel or glass
plates.
Plastic lined cups, Commercially available Mixing sealant.
wax-free with caps
Sealant fairing tools Commercially available To fair-in sealant.
Cheesecloth, Commercially available Cleaning.
lint-free
Plastic scraper, Commercially available Removing old sealant.
45-degree cutting
edge.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Durometer Rex Model Rex Gauge Company, Inc. Testing cure of sealant.
1500 (or 3230 West Lake Avenue P.O. Box
equivalent) 46
Glenview, IL 60025
Gloves, lightweight Commercially available Removing old sealant.
lint-free white
cotton
Nylon bristle Commercially available Removing old sealant.
brushes
Pipe cleaners Commercially available Cleaning.
Funnel brushes Commercially available Cleaning.
3. Definition of Sealing Terms

A. The following definitions are included to provide a basic concept of the special terms used in sealing.
This list is not all inclusive but the more common terms are listed.
(1) Absolute Sealing - There can be no leakage allowed. All openings of any nature through the seal
plane are positively sealed. This is the first level of sealing. (All holes, slots, joggles, fasteners
and seams must be sealed.)
(2) Accelerator (Activator) - Curing agent for sealants.
(3) Application Time - The length of time sealant remains workable or suitable for application to
structure by brush, extrusion gun, spatula or roller.
(4) Base Compound - The major component of a two-part sealing compound which is mixed with the
accelerator prior to application to produce a fuel, temperature, pressure, weather and/or firewall
sealing material.
(5) Brush Coat - Apply an overcoating or continuous film of appropriate sealing compound by use
of a brush.
(6) Fay Seal or Faying Surface Seal - A seal barrier created by the sandwiching of sealant between
mating surfaces of structure. Special attention must be taken to avoid metal chips or dirt at the
faying surface.
(7) Fillet Seal - Sealant material applied at the seam, joint or fastener after the assembly has all
permanent fasteners installed and shall conform to the dimension in applicable figure.
(8) Hole - An opening that has no appreciable depth, such as a tool hole. Holes that penetrate the
seal plane must be metal filled with a fastener, gusset or patch.
(9) Injection Seal - Filling of channels by forcing sealant into a void or cavity after assembly.
(10) Integral Tank - Composition of structure and sealant material which forms a tank that is capable
of containing fuel without a bladder.
(11) Intermediate Seal - The second level of sealing. All holes, slots, joggles and seams in the seal
plane must be sealed. A minor amount of leakage is tolerable and permanent fasteners are not
required to be sealed.
(12) Post-Assembly Seal - A seal that is applied after the structure is assembled. (Fillet and injection
seals.)
(13) Preassembly Seal - Sealant material that must be applied during or prior to the assembly of the
structure. (Faying surface and pre-pack seals.)
(14) Pre-Pack Seal - A preassembly seal used to fill voids and cavities; can be a primary seal used
to provide seal continuity when used in conjunction with a fillet seal. It can be used as a backup
seal to support a fillet across a void. Fill the entire cavity to be prepacked. Usage as a primary
seal should be kept to a minimum.
(15) Primary Seal - Sealant material that prevents leakage and forms a continuous seal plane. This
seal is in direct contact with the fuel, vapor, air, acid, etc. With few exceptions, it is in the form of
a fillet seal.
(16) Sealant - A compound applied to form a seal barrier.
(17) Seal Plane - A surface composed of structure, sealant and fasteners on which the continuity of
seal is established.
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MODEL 172
MAINTENANCE MANUAL
(18) Shank Sealing - Sealant compound shall be applied to the hole or to both the shank and the
underhead area of the fastener in sufficient quantity that the entire shank is coated and a small
continuous bead of sealant is extruded out around the complete periphery of each end of the
fastener when installed. The fastener shall be installed within the application time of the sealing
compound used.
(19) Squeeze-Out Life - Length of time sealant remains suitable for structure assembly in faying
surface seal application.
(20) Tack-Free Time - Tack-free time is a stage, during the cure of the sealant compound, after which
the sealant compound is no longer tacky. When the sealant compound is pressed firmly with the
knuckles, but no longer adheres to the knuckles, the sealant compound is tack-free.
4. Materials
A. Type of Sealants - Sealants are categorized by type of usage. Type I sealants are separated into
classes to differentiate the materials according to method of application. Dash numbers following
the class designation indicate the minimum application time (in hours) for Class A and Class B, and
minimum work life (in hours) for Class C. Refer to Table 201 for application time, curing rate, etc., for
Type I sealants.
(1) Type I - Fuel, pressure, and weather sealant.
(a) Class A - Sealant which is suitable for brush application.
(b) Class B - Sealant which is suitable for application by extrusion gun, spatula, etc.
(c) Class C - Sealant which is suitable in faying surface applications.
(d) Quick Repair Sealant - This material is for use only in making repairs when an extremely
rapid curing sealant is required. A possible application includes sealing a leaking fuel tank
on an airplane which must be dispatched within a few hours.
CAUTION: QUICK REPAIR SEALANT MUST BE APPLIED WITHIN ITS WORKING LIFE
OF 15 MINUTES. ATTEMPTS TO WORK QUICK REPAIR SEALANT BEYOND
WORKING LIFE WILL RESULT ININCOMPLETE WETTING OF SURFACE AND
WILL RESULT IN A FAILED SEAL.
(2) Type VIII - Low Adhesion Access Door Sealant. This Class B sealant is designed for sealing
faying surfaces where easy separation of the joined surfaces is required. The sealant has low
adhesion and forms a gasket that molds itself to fill all irregularities between two surfaces.
The sealant is exceptionally resistant to fuels, greases, water, most solvents and oils including
hydraulic oil.
NOTE: Time periods presented below are based on a temperature of 77°F and 50 percent
relative humidity. Any increase in either temperature or relative humidity may shorten
these time periods and accelerate the sealant cure.
Table 201. Curing Properties of Type I Sealant

A-1/2 1/2 10 40
A-2 2 40 72
B-1/2 1/2 4 6
B-2 2 40 72
B-4 4 48 90
C-24 8 24 96 168 (7 days)
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MODEL 172
MAINTENANCE MANUAL
Table 201. Curing Properties of Type I Sealant (continued)

C-48 12 48 120 336 (14 days)
C-80 8 80 120 504 (21 days)
5. General Requirements
A. When working with sealants observe the following requirements.
(1) Unmixed sealants shall not be more than two months old when received. These sealants shall
not be more than six months old when used.
(2) Unmixed sealants stored at temperatures exceeding 80°F shall be used within five weeks.
(3) Sealants which have been premixed, degassed and flash frozen shall be maintained at -40°F or
lower and shall not be received more than two weeks beyond the date of mixing. These sealants
shall not be used more than six weeks after the date of mixing.
(4) Frozen sealant shall be thawed before being used. If sealant were applied at a temperature
below 60°F, it would not be sufficiently pliable for proper application and adhesion could be
critically reduced by condensation of moisture. On the other hand, although sealant must
extrude freely for proper application, it would be subject to excessive slumping if applied at a
temperature above 80°F Frozen sealant may be thawed by any suitable means which does
not cause contamination or overheating of the sealant and does not shorten the application
time of the sealant to an impractical period. Examples: Thawing by exposure to ambient air
temperature, accelerated thawing by exposure in a constant temperature bath (using clean, hot
water), accelerated thawing in a microwave oven. In any case, thawing temperature and time
shall be adjusted to give a thawed sealant temperature between 60°F, and 80°F at the time the
sealant is applied.
(5) Mixed, frozen sealants which have thawed shall not be refrozen.
(6) Complete preassembly operations such as fitting, filing, drilling, countersinking, dimpling and
deburring prior to cleaning and sealant application.
(7) Surfaces must be clean and dry, free from dust, lint, grease, chips, oil condensation or other
moisture and all other contaminating substances prior to the application of sealant.
(a) All exposed bonding primer or bonded assemblies which are to be sealed shall be cleaned
using Scotch Brite followed by solvent cleaning using Trichloroethane.
NOTE: Bond primer shall not be removed; just lightly scuffed with Scotch Brite.
(8) Sealant materials may be applied to unprimed or primed surfaces. Nonchromated or epoxy
primers shall have good adhesion to the substrate material and shall have aged at least 48
hours prior to sealant application. Adhesive bonding primer shall be scotchbrited and cleaned
before applying sealant.
(9) Sealants shall not be applied when the temperature of either the sealant or the structure is below
60 F.
(10) Sealant applied by the fillet or brush coat methods shall always be applied to the pressure side
of a joint if possible.
(11) After application, sealants shall be free of entrapped air bubbles and shall not exhibit poor
adhesion. All fillets shall be smoothed down and pressed into the seam or joint with a filleting
tool before the sealant application time has expired.
(12) Where fasteners have been shank or underhead sealed, extruded sealant shall be evident
around the complete periphery of the fastener to indicate adequate sealing. Sealant extruded
through a hole by a rivet shall be wiped from the end of the rivet before bucking. Threaded
fasteners which have been shank or underhead sealed shall not be retorqued after the
expiration of the application time of the sealant. Prior to torqueing, sealant shall be removed
from the threads. In torqueing, turn the nut rather than the bolt, if possible.
(13) Pressure testing shall not be accomplished until the sealant is cured.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(14) Sealant shall not be applied over ink, pencil or wax pencil marks. If these materials extend into
the sealing area, they must be removed.
(15) If sealing is to be accomplished over primer and the primer is removed during the cleaning
process, it is permissible to seal directly over the cleaned area and then touch up the exposed
areas after the sealant has been applied and is tack free.
(16) Sealed structure shall not be handled or moved until sealant is tack free (sealant may be
dislodged or have the adhesion damaged). Excessive vibration of structure, such as riveting,
engine run up, etc. is not permitted.
(17) Drilling holes and installing fasteners through a fay sealed area shall be performed during the
working life of the faying sealant or the entire shank and area under fastener head shall be fay
sealed.
6. Sealant Curing
A. Room Temperature.
(1) Room temperature curing properties are based on a temperature of 77°F, +5°F or -5°F and a
relative humidity of 50 percent unless otherwise indicated.
(2) Room temperature curing properties of Type I sealants are given in Table 201.
(3) Curing properties of Type VIII, Class B sealants are the same as for Type I, Class B. Adhesion
to aluminum should be (peel) less than two pounds per inch width.
B. Accelerated Curing.
(1) Accelerated curing of sealant can be accomplished in several ways. The procedure to be used
is dependent on the type of sealant and other factors.
(2) The cure of Type I sealants can be accelerated by an increase in temperature and/or relative
humidity. Warm circulating air at a temperature not to exceed 140°F may be used to accelerate
cure. Heat lamps may be used if the surface temperature of the sealant does not exceed 140°F.
At temperatures above 120°F, the relative humidity will normally be so low (below 40 percent)
that sealant curing will be retarded. If necessary, the relative humidity may be increased by the
use of water containing less than 100 parts per million total solids and less than 10 parts per
million chlorides.
7. Mixing of Sealants
A. Requirements.
(1) Sealants shall be mixed or thinned in accordance with the manufacturer's recommendations and
thoroughly blended prior to application. All mixed sealant shall be as void free as possible.
(2) Prior to mixing, the sealing compound base and its curing agent, both in their respective original
unopened containers, shall be brought to a temperature between 75°F and 90°F along with all
required mixing equipment.
B. Hand Mixing of Sealant.
(1) Weigh into clean, wax-free containers the correct amount of base and curing agent, per
manufacturer's instructions, immediately prior to mixing. An alternate method is to mix the
sealant on a flat plate with a spatula. The scales and weighing process must be controlled
within +2 or -2 percent to ensure good quality.
(2) Do not allow the accelerator to come into contact with the sides of the container.
(3) Materials shall be accurately weighed on scales that are calibrated and maintained for required
accuracy.
(4) Mix the components until the color is uniform taking care not to trap air in the sealant.
(5) Transfer the sealant to another clean container and complete the mix.
C. Sem-Kit Mixing.
WARNING: THE CARTRIDGE SHOULD BE HELD FIRMLY, BUT MUST NOT BE
SQUEEZED, AS THE DASHER BLADES MAY PENETRATE THE CARTRIDGE
AND INJURE THE HAND.
(1) Pull dasher rod to the FULL OUT position so that the dasher is at the nozzle end of the cartridge.
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MAINTENANCE MANUAL
(2) Insert ramrod in the center of the dasher rod against the piston and push the piston in
approximately one inch.
NOTE: Extra force will be needed on the ramrod at the beginning of accelerator injection into
the base material.
(3) Move the dasher rod in approximately one inch, then push piston in another inch. Repeat this
action until accelerator is distributed along the entire length of the cartridge.
NOTE: The accelerator has been fully injected into the cartridge when the ramrod is fully
inserted into the dasher rod.
(4) Remove and properly discard the ramrod.
NOTE: Mixing the accelerator and base material can be accomplished manually, or as an
alternate method, with the use of a drill motor.
(5) Manual Mixing.
(a) Begin mixing operation by rotating the dasher rod in a clockwise direction while slowly
moving it to the FULL OUT position.
NOTE: Do not rotate the dasher rod counterclockwise; the four-blade dasher inside the
cartridge will unscrew and separate from the dasher rod.
(b) Continue clockwise rotation and slowly move the dasher rod to the FULL IN position.
1 A minimum of five full clockwise revolutions must be made for each full-out stroke and
for each full-in stroke of the dasher rod. Approximately sixty strokes are necessary
for a complete mix.
(c) End mixing operation with the four-blade dasher at the bottom of the cartridge.
(d) Hold cartridge upright; unscrew dasher rod from the four-blade dasher by gripping the
cartridge at the four-blade dasher and turn the dasher rod counterclockwise. Remove
dasher rod.
(e) Screw appropriate nozzle into the cartridge. If sealant gun is to be used, install cartridge
in gun.
(6) Drill motor mixing.
NOTE: A tapered rotary file or a 25/64 inch drill bit may be used with a drill motor to turn the
dasher rod.
(a) Insert the rotary file/drill bit into the dasher rod approximately 1/2 inch.
WARNING: THE CARTRIDGE SHOULD BE HELD FIRMLY, BUT NOT SQUEEZED,
AS THE DASHER BLADES MAY PENETRATE THE CARTRIDGE AND
INJURE THE HAND.
(b) Verify the drill motor will rotate the dasher rod clockwise (looking toward the nozzle end of
the cartridge).
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MODEL 172
MAINTENANCE MANUAL
(c) With the cartridge held firmly in one hand and the drill motor in the other, rotate the dasher
rod at approximately 50 revolutions-per- minute while moving the dasher rod to FULL IN
and FULL OUT positions.
1 Mix sealant for at least 50 strokes (a stroke is one complete full-in and full-out stroke
of the dasher rod).
(d) End mixing operation with the four-blade dasher at the bottom of the cartridge.
(e) Hold cartridge upright; remove drill motor and rotary file/drill bit from the dasher rod;
unscrew dasher rod from the four- blade dasher by gripping the cartridge at the four-blade
dasher and turn the dasher rod counterclockwise. Remove dasher rod.
(f) Screw appropriate nozzle into the cartridge. If sealant gun is to be used, install cartridge
in gun.
8. Cleaning
A. All surfaces to which sealant is to be applied shall be clean and dry.
B. Remove all dust, lint, chips, shavings, etc. with a vacuum cleaner where necessary.
C. Cleaning shall be accomplished by scrubbing the surface with clean cheesecloth moistened with
solvent. The cloth shall not be saturated to the point where dripping will occur. For channels and
joggles, pipe cleaners and/or funnel brushes may be used instead of cheesecloth.
(1) The solvents to be used for the cleaning in the integral fuel tank are MIL-C-38736 or TT-M-261
for the first or preliminary cleaning. For the final cleaning, 0-T-620, 1, 1, 1 - Trichloroethane,
Technical, Inhibited only must be used.
D. The cleaning solvent should never be poured or sprayed on the structure.
E. The cleaning solvent shall be wiped from the surfaces before evaporation using a piece of clean, dry
cheesecloth in order that oils, grease, wax etc. will not be redeposited.
F. It is essential that only clean cheesecloth and clean solvent be used in the cleaning operations.
Solvents shall be kept in safety containers and shall be poured onto the cheesecloth. The cheesecloth
shall not be dipped into the solvent containers and contaminated solvents shall not be returned to the
clean solvent containers.
G. Final cleaning shall be accomplished immediately prior to sealant application by the person who is
going to apply the sealant.
(1) The area which is to be sealed shall be thoroughly cleaned. A small clean paint brush may be
needed to clean corners, gaps, etc. Always clean an area larger than the area where the sealant
is to be applied. Never clean an area larger than 30 inches in length when practical. When the
area is being scrubbed with a moistened cloth in one hand, another clean dry cloth shall be held
in the other hand and shall be used to dry the structure. The solvent must be wiped from the
surfaces before it evaporates.
(2) The above procedure shall be repeated until there is no discoloration on the clean drying cloth.
Marks resulting from wax or grease pencils must be removed from parts prior to sealing.
H. Allow all cleaned surfaces to dry a minimum of 5 minutes before the application of sealant materials.
I. Sealant shall be applied as soon as possible after cleaning and drying the surfaces to be sealed.
Do not handle the parts between the cleaning and sealing operations. Sealant application personnel
handling cleaned surfaces shall wear clean white gloves to prevent surface contamination. In the
event contamination does occur, the surfaces shall be recleaned.
J. Safety precautions should be observed during the cleaning and sealing operation. Cleaning solvents
are toxic and flammable in most cases. Fresh air masks and/or adequate ventilation are required for
all closed areas. The structure shall be electrically grounded before starting any cleaning or sealing
operation.
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9. Sealing Application
A. General.
(1) All new sealing shall be accomplished using the type of sealing material required for the area
being sealed. All sealant repairs shall be accomplished using the same type of sealing material
as that which is being repaired.
(2) Application time of the sealing compound shall be strictly observed. Material which becomes
too stiff and difficult to work or which does not wet the surface properly shall be discarded even
though the application time has not expired.
(3) For an illustration of the integral fuel bay and sealing techniques, refer to Figure 201.
(4) Prior to sealant application, all surfaces to be sealed shall be cleaned per paragraph 8.
B. Faying Surface Sealing - The application of a faying surface seal shall be made only when new
structure is being added to the airplane and requires a faying surface seal or when the structure
and/or parts have been disassembled for reasons other than a faulty seal. Fay sealed joints
must be closed and fastened before expiration of the work life given in Table 201. Excess sealant
must squeeze out of a fay sealed joint when attachment is made. Countersinking and reaming of
holes through a fay sealed joint is permissible when every other hole is held firm by temporary or
permanent holding fasteners. Spring loaded plunger type clecos are inadequate to create sufficient
pressure for sealant squeeze-out. Fabrication and changes done after sealing are not recommended
and shall be held to a minimum. Fasteners installed after the sealant has cured to replace temporary
fasteners shall be installed wet with sealing compound.
NOTE: Pre- assembly operations such as fitting, filing, drilling, dimpling and deburring shall be
completed prior to cleaning and sealing application.
(1) Immediately prior to final closure of the joint, sealant shall be applied to one mating surface of the
joint with a sealant gun, spatula, roller or other suitable tool. Sufficient sealant shall be applied
so that the space between the assembled faying surfaces is completely filled with sealant and a
small excess is squeezed out in a continuous bead around the periphery of the joint when the
joint is secured (refer to Figure 201, Sheet 2 ).
(2) Place parts in assembly position and install the fasteners within the application time of the faying
surface sealant. When assembly with permanent type fasteners is not feasible, temporary
fasteners (clecos or bolts) may be used, but when the temporary fasteners are used, they must
be replaced by permanent type fasteners prior to the expiration of the work life of the faying
surface sealant. Removal of each individual temporary fastener shall be followed immediately
by the installation of the permanent fastener.
(3) When a fillet seal is required around the periphery of a fay sealed joint, it is not necessary to
remove the sealant squeeze out where the fillet is to be applied, provided that the material which
was squeezed out has been shaped into a small fillet configuration prior to the expiration of the
application time. When the squeeze-out has been shaped, a final or full bodied seal can be
applied over the shaped squeeze-out without waiting for the squeeze-out to cure. If the squeezed
out material was not shaped before the expiration of its application time, it shall be cured to a
tack-free condition and then removed, by use of a plastic tool, from locations where a fillet is to
be applied.
(4) Immediately after the assembly is completed and all permanent type fasteners have been
installed, remove uncured sealant which extrudes onto the exterior of the airplane using clean
rags moistened with TT-T-548, Toluene or TT-M-261, Methyl- Ethyl-Ketone.
C. Injection Sealing.
(1) Sealant shall be injected into the channel, joggle, void or cavity from one point only, using a
sealant gun, in such a manner that no air is entrapped and the channel, joggle, void or cavity is
completely filled and sealant is observed emerging from the prescribed opening (refer to Figure
201, Sheet 4). If multiple exits or channels exist, block each channel exit after it is filled, without
stopping the injection, so that sealant extrudes into all necessary channels.
(2) Remove excess sealant before the expiration of its application time and smooth flush with the
surface using a suitable tool.
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MAINTENANCE MANUAL
INSPECTION
COVER
UPPER TRAILING
UPPER
SKIN
FUEL BAY
(LEFT SHOWN,
RIGHT OPPOSITE)
TRAILING EDGE
SKIN STIFFENER
LOWER
SKIN
0526T1010
0526T1009
0526T1011

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MAINTENANCE MANUAL
FAYING SURFACE SEAL
TYPICAL RIB
SECTION
FAY SEAL
SEALANT EXTRUDED (SEALANT
CONTINUOUSLY
NOTE: THE FOLLOWING EXAMPLES SHOW TYPICAL CROSS SECTIONS OF SEALING METHODS
AND TECHNIQUES USED IN THE FUEL BAY AREA. IN MOST CASES, WING SKIN AND RIB
THICKNESS COMBINED IS APPROXIMATELY 0.070 INCH. MINIMUM SEALANT
APPLICATION AT ANY POINT SHOULD NOT BE LESS THAN 0.060 INCH.
55982007

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MAINTENANCE MANUAL
5598C1010
6280C 1003

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MAINTENANCE MANUAL
INJECTION IS COMPLETE
WHEN SEALANT EMERGES
FROM THIS SIDE
5598C1009

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D. Fillet Sealing.
(1) Fastener considerations:
(a) Do not fillet seal any parts until they are held completely together by permanent fasteners.
(b) Prior to filleting the periphery of bolted structure and fittings, it is necessary that all bolts,
accomplishing the attachment, be properly torqued.
(2) The sealant shall be applied using a sealant gun or spatula.
(3) When using a sealant gun for fillet sealing, the nozzle tip shall be pointed into the seam or joint
and shall be maintained nearly perpendicular to the line of travel. A continuous bead of sealant
shall precede the tip and the tip size, shape and rate of travel shall be such that sufficient sealant
shall be applied to produce the required fillet.
(4) Fillets shall be shaped or formed to meet the size and shape requirements as shown in applicable
figures using the nozzle tip and/or fairing tools to press against the sealant while moving parallel
to the bead. Exercise caution to prevent folds and entrapment of air during application and
shaping of the fillet and work out any visible air bubbles. The fillet shall be formed so that the
highest portion of the fillet is centered over the edge of the structure or fitting. Lubrication in
any form shall not be used for smoothing purposes. In all cases, fillet size shall be kept as near
minimum as practical.
(5) Where it is more convenient or fillet slumping is encountered, the fillet may be applied in two
stages. A small first fillet should be applied which is allowed to cure to a tack-free state, followed
by a second application of sealant sufficient to form the final fillet conforming to the specified
dimensions for a fillet seal. If the first fillet has cured, it must be cleaned before the second
application of sealant is made. If the fillet has only cured to a tack-free state, it shall be wiped
lightly with a gauze pad or cheesecloth pad dampened with cleaning solvent.
(6) Allow the sealant to cure to a tack-free condition prior to the airplane being moved, handled
and/or worked on.
(7) In cases where a fillet seal connects to an injection seal, the full bodied fillet shall extend past
the end of the injection and then taper out.
(8) Lap joint and seam fillets shall be as shown in Figure 201, Sheet 3.
(9) Butt joint fillets shall be as shown in Figure 201, Sheet 3.
(10) Bolts shall be fillet sealed as shown in Figure 201, Sheet 3. The area for sealing shall consist of
the area of the structure surrounding the base of the fastener end plus the entire exposed area
of the fastener. An optional method of sealing threaded fasteners is to apply a brush coat of Type
I, Class A sealant. Where brush coating is used as the method of sealing threaded fasteners,
the sealant must be worked around each fastener with a stiff brush and considerable care to be
effective. A simple pass of the brush with the sealant is not sufficient to produce an effective
seal.
(11) Dome-type nutplates shall be fillet sealed as shown in Figure 201, Sheet 3. The area for sealing
shall consist of the area of the structure surrounding the base of the fastener and from there up
over the rivets to the dome.
(12) Hole filling and slot fillets shall be as shown in Figure 201, Sheet 3.
(a) Tooling holes shall be plugged with a shank sealed soft rivet and then brush coated with
Type I, Class A sealant.
10. Sealant Repair

A. Materials - Repairs, in general, shall be accomplished with the same type of material as that being
repaired.
NOTE: Type I, Class B-1/2 is recommended for use during cold weather to obtain an accelerated
cure.
NOTE: Type I, Quick Repair sealant may be used as a repair for sealant in pressure vessels and
fuel tanks if desired for fast cure and rapid dispatch.
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B. Temperature Requirements.
(1) The structure shall be above 60°F before the sealant is applied and shall remain above 60°F
until the sealant is tack-free.
NOTE: For outside operations only, the temperature of the structure may be allowed to drop
below 60°F but not below 58°F, after application for a period of time not to exceed 48
hours; however, the structure must be subsequently heated to above 60°F and the
sealant allowed to become tack-free before the tanks are refueled.
(2) The maximum air temperature allowed to come in contact with the curing sealant is 120°F.
C. Fillet and Fastener Sealing Repairs.
(1) Repair of damaged or faulty sealant applications shall be accomplished as follows:
(a) Remove all damaged or faulty sealant to ensure solid residual material.
(b) Sealant shall be cut so as to produce a smooth continuous scarfed face. The sealant shall
be completely removed in the affected areas. The cutting tools should only be made from
nonmetallic materials that are softer than aluminum.
(c) Inspect repair areas for clean and smooth cuts. Loose chunks or flaps of sealant on the
cut areas shall be removed.
(d) Clean the area to be sealed, including the scarfed face of the old seal, per paragraph 8.
(e) Apply new fillet seals. Slight overlapping of the fresh material over the existing fillet is
permissible. A large buildup of sealant shall not be allowed.
(f) Rework of a fillet which has been oversprayed or brushed with primer shall be accomplished
by a scarfed joint and removal of the fillet having primer on it, in the area of the repair. The
primer shall not be sandwiched between the old and new sealants.
(g) If the primer is removed during the cleaning operation, it is permissible to apply the new
fillet seal directly over the clean bare metal and then touch up with the proper primer all
exposed areas of bare metal after the sealant has been applied.
D. Faying Surface Sealing Repair - After determining the area which contains the faulty and/or leaking
faying surface seal, the repair shall be accomplished by applying a fillet seal along the edge of the
part adjacent to the faying surface seal long enough to fully cover the area of the faulty and/or leaking
seal.
E. Brush Coat Sealing Repair - Repair of damaged or leaking brush coat seals shall be accomplished by
removing the discrepant brush coat. Clean the area of sealant removal and the surrounding structure
and sealant per paragraph 8. Apply a new brush coat of sealant.
F Integral Fuel Tank Sealing Using PR-1826 Class B Rapid Curing Sealant.
(1) Remove damaged section of sealant with a sharp plexiglass scraper. Taper all cuts in old sealant
at 45 degree angles.
(2) Thoroughly clean with solvent and abrade old areas which are to be over coated. Clean one
small area at a time, then dry with a clean cloth before the solvent evaporates.
NOTE: Always pour solvent on the cloth to maintain a clean solvent supply.
NOTE: In fuel tanks which have been in operation, the sealant will be soaked and should be
dried in area of the repair with a vapor- proof heat lamp or hot air blower before new
sealant is applied.
(3) After the surface has been cleaned and dried, apply a heavy layer of PR-1826 Adhesion
Promoter with a clean brush or gauze pad. Allow adhesion promoter a minimum of 30 minutes
to dry.
NOTE: Care must be taken to obtain a uniform thin coat of adhesion promoter. Thin enough
to cover the surface, but not heavy enough to run.
(4) Mix PR-1826 Class B sealant according to instructions supplied with the material.
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MAINTENANCE MANUAL
(5) Apply PR-1826 Class B sealant, 1/8 to 3/16 of an inch thick, to the repair area with a spatula or
paddle shaped tool. Firmly press sealant in place and form to desired shape. Overlap PR-1826
Class B sealant over old sealant from 1/8 to 1/4 of an inch.
NOTE: Sealant may be applied up to 8 hours after the application of adhesion promoter. After
8 hours, the surface should be recleaned and adhesion promoter reapplied.
(6) Allow sealant to cure a minimum of 2 hours at 77° Fbefore refueling. Curing time is solely based
on temperature and will be halved for every 18° F increase, and doubled for every 18° F decrease
from the standard 77° F
11. Classification of Fuel Leaks

A. Fuel leaks are classified into one of four categories based on the observed size of the leaks.
Dependent on where the leak is located, immediate corrective action may be required prior to flight.
Leaks may be classified as follows and are illustrated in Figure 202:
(1) Stains - An area of 0.75 inch or less in diameter.
(2) Seep - An area from 0.75 inch to 1.50 inch in diameter.
(3) Heavy Seep - An area from 1.50 inch to 4.00 inch in diameter.
(4) Running Leak -- Size varies with location and intensity of leak.
B. The following leaks require corrective action before further flight:
(1) Running leaks in any area.
(2) Stains, seeps or heavy seeps in an enclosed area.
NOTE: An enclosed area is defined as the wing leading edge and the section of wing inboard
or outboard of the fuel bays.
C. The following leaks require correction when the airplane is grounded for other maintenance:
(1) Stains, seeps or heavy seeps not in an enclosed area.
12. Sealing Fuel Leaks
A. Determine Source of Leak.
(1) Fuel can flow along a seam or structure of the wing for several inches, making the leak source
difficult to find. A stained area is an indication of the leak source.
(2) Fuel leaks can be found by testing the complete bay as described in Testing Integral Fuel Bay.
(3) Another method of detecting the source of a fuel leak is to remove access doors and blow with
an air nozzle from the inside of the bay in the area of the leak while soap bubble solution is
applied to the outside wing skin.
B. Repair Leak.
(1) Remove existing sealant in the area of the leak.
(2) Clean the area and apply a filet seal. Press sealant into leaking area with a small paddle, working
out all air bubbles.
(3) If leakage occurs around a rivet or bolt, replace the rivet or loosen bolt, retorque and reseal
around nutplate.
(4) Apply Type VIII sealant to access doors, fuel quantity transmitter, etc., as required and reinstall
to structure.
(5) Allow sealant to completely cure.
(6) Test fuel bay for leakage. Refer to Testing Integral Fuel Bay.
13. Testing Integral Fuel Bay
A. The fuel system consists of two vented, integral fuel tanks (one in each wing). The following procedure
should be used only after sealant has fully cured.
(1) Remove vent line from vent fitting and cap fitting.
(2) Disconnect fuel lines from bay.
(3) To one of the bay fittings, attach a water manometer capable of measuring 20 inches of water.
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MODEL 172
MAINTENANCE MANUAL
SEEP HEAVY
SEEP
0.75 TO
1.50 TO
4.00 INCHES
STAIN
0.75 INCH
MAXIMUM
RUNNING
LEAK
SIZE WILL VARY

WITH LOCATION
AND INTENSITY
OF LEAK.
FUEL WILL USUALLY

FLOW IN THIS AREA
ALONG SKIN CONTOUR
AFTER IT IS WIPED DRY.
FUEL USUALLY DRIPS

AT THIS POINT.
05161006
Classification of Fuel Leaks

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MODEL 172
MAINTENANCE MANUAL
(4) To the other bay fitting, connect a well-regulated supply of air (0.5 PSI maximum, or 13.8 inches
of water). Nitrogen may be used where the bay might be exposed to temperature changes while
testing.
(5) Make sure filler cap is installed and sealed.
(6) Apply pressure slowly until 0.5 PSI is obtained.
(7) Apply a soap solution as required.
(8) Allow 15 to 30 minutes for pressure to stabilize.
(9) If bay holds for 15 minutes without pressure loss, seal is is acceptable.
(10) Reseal and retest if any leaks are found.
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MAINTENANCE MANUAL
* CHAPTER
INDICATING/
RECORDING
SYSTEMS
MODEL 172
MAINTENANCE MANUAL

31-Title
31-00-00 1 Aug 18/2001
31-10-00 201 Aug 18/2001
202 Aug 18/2001
31-20-00 201 Aug 18/2001
31-30-00 201 Aug 18/2001
202 Aug 18/2001
31-50-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
INDICATING/RECORDING SYSTEMS - GENERAL ................................... 31-00-00 Page 1
Sco pe ................................................................... .... 3 1-00-00 Pag e 1
Definitio n ........................................... .......................... 3 1-00-00 Pag e 1
INSTRUMENT AND CONTROL PANELS - MAINTENANCE PRACTICES ............... 31-10-00 Page 201
Panel Removal/ Installation ........................................ ............ 31-10-00 Page 201
DIGITAL CLOCK - MAINTENANCE PRACTICES ............................... ...... 31-20-00 Page 201
Description and Operation ........................................ ............. 31-20-00 Page 201
Clock Removal/Installation ..................................................... 31-20-00 Page 201
HOUR METER - MAINTENANCE PRACTICES ...................................... . 31-30-00 Page 201
Descriptio and Operation ...................................................... 31-30-00 Page 201
Hour Meter Removal/Installation ................................................ 31-30-00 Page 201
ANNUNCIATOR PANEL - MAINTENANCE PRACTICES ............................... 31-50-00 Page 201
Annunciator Panel Removal/Installation ........................................ 31-50-00 Page 202
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INDICATING/RECORDING SYSTEMS - GENERAL
1. Scope
A. This chapter contains information on those systems and components used to indicate and/or record
various parameters of the engine, airframe or related flight operations. Also included in this chapter
is information on the instrument panels that house the indicating/recording systems.
2. Definition
the Table of Contents will assist in locating a particular subject. A brief definition of the sections
(1) The section on instrument and control panels provides general removal and installation
instructions for the various panels used in the cockpit.
(2) The section on indicating provides information on the digital clock.
(3) The section on recording provides information on the hour meter.
(4) The section on annunciation provides information on the multi-system panel annunciator.
31-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INSTRUMENT AND CONTROL PANELS - MAINTENANCE PRACTICES

A. The instrument panel is divided into sections to facilitate easy removal and installation of particular
components without removing the entire panel.
(1) The pilot side of the instrument panel is broken up into three separate panels, with the flight
instruments grouped in a panel, the avionics dials and tachometer located in a panel, and the
indicating/recording instruments grouped in a third panel.
(2) The switch panel is located below the pilot side instrument panel and houses the majority of
switches and circuit breakers in a single location.
(3) The copilot side of the instrument panel houses the Hobbs meter and remote ELT activation
switch, and is designed to allow for panel expansion.
NOTE: For an overview of the various sub panels which make up the instrument panel, refer
to Figure 201.
2. Panel Removal and Installation
A. The individual panels may be removed by unscrewing the perimeter screws located on each panel.
The flight instrument sub-panel has been designed to be moved aft without disconnecting the electrical
or mechanical connections to that panel.
B. If entire panels are being removed, it may be necessary to disconnect various electrical and/or
mechanical connections prior to removing the panel.
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MODEL 172
MAINTENANCE MANUAL
1743
PILOT'S PILOT'S PILOT'S COPILOT'S

OUTBOARD CENTER INBOARD RADIO PANEL
CIRCUIT BREAKER CONTROLS VENTILATING

PANEL
Instrument Panels
31-10-00 Page 202

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MAINTENANCE MANUAL
DIGITAL CLOCK - MAINTENANCE PRACTICES

A. The digital clock is located in upper left side of the instrument panel and incorporates clock,
temperature and voltage readings in a single unit. For removal/installation of the OAT/Clock, refer to
Chapter 34, Outside Air Temperature Gauge - Maintenance Practices.
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MAINTENANCE MANUAL
HOUR METER - MAINTENANCE PRACTICES

A. The hour (Hobbs) meter is located in the upper right corner of the instrument panel and provides
indication of flight hours based on engine operation.
B. The hour meter receives power through the WARN circuit breaker located on the lower instrument
panel. The hour meter is grounded through the Oil Pressure Switch, and anytime oil pressure exceeds
20 PSI a ground is sent from the switch to the hour meter, completing a circuit and activating the hour
meter.
2. Hour Meter Removal/Installation
A. Remove Hour Meter (Refer to Figure 201).
(1) Gain access to backside of instrument panel and hold nuts while loosening screws.
(2) Disconnect electrical connectors leading into hour meter.
B. Install Hour Meter (Refer to Figure 201).
(1) Connect electrical connectors to hour meter.
(2) Install hour meter to panel and secure using screws and nuts.
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MAINTENANCE MANUAL
B1745
HOUR METER
NUT
INSTRUMENT
PANEL
SCREW
DETAIL A
Hour Meter Installation

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MAINTENANCE MANUAL
ANNUNCIATOR PANEL - MAINTENANCE PRACTICES

A. The annunciator panel is a multi-system display which provides visual warning and caution information
related to various systems and fuel levels throughout the airplane. The annunciator presents this visual
information in either amber (caution) or red (warning) messages. Refer to Table 201 for a breakdown
of messages and their inputs.
B. Table 201 is provided to give a basic overview of the annunciator system and its inputs. This table
should be used in conjunction with the Wiring Diagram Manual to aid in system troubleshooting.
Table 201. Annunciator Panel Messages and Inputs
MESSAGE COLOR MEANING SOURCE OF SIGNAL
L LOW FUEL Amber Low fuel condition detected in Left fuel quantity system.
the left tank.
LOW FUEL R Amber Low fuel condition detected in Right fuel quantity
the right tank. system.
L LOW FUEL R Amber Low fuel condition detected Left and right fuel quantity
in both the left and right fuel systems.
tanks.
L LOW FUEL and Amber Short, open or increasing Left fuel transmitter or
left fuel gauge resistance over time. electrical line between
needle parked transmitter and fuel
below 0 gauge.
LOW FUEL R and Amber Short, open or increasing Right fuel transmitter or
right fuel gauge resistance over time. electrical line between
needle parked transmitter and fuel
below 0 gauge.
L LOW FUEL Amber Short, open or increasing Left and right transmitters
R and both fuel resistance over time. or electrical lines
gauge needles between transmitters
parked below 0 and fuel gauge.
OIL PRESS Red Oil pressure less than 20 PSI. Oil pressure switch
(SN001) supplying
ground to annunciator.
L VAC Amber Vacuum less than 3.0 In.Hg. Left vacuum switch
(SN012) supplying
VAC R Amber Vacuum less than 3.0 In.Hg. Right vacuum switch
(SN011) supplying
L VAC R Amber Vacuum less than 3.0 In.Hg. Right vacuum switch
and left vacuum switch
supplying ground to
annunciator.
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MAINTENANCE MANUAL
Table 201. Annunciator Panel Messages and Inputs (continued)

MESSAGE COLOR MEANING SOURCE OF SIGNAL
VOLTS Red Voltage less than 24.5 VDC, Ground from the
+0.35 or -0.35 VDC. alternator control unit
to the annunciator panel.
PITCH TRIM Red Autopilot pitch trim failure. Autopilot flight computer.
2. Annunciator Panel Removal/Installation

A. Remove Annunciator Panel (Refer to Figure 201).
(1) Ensure electrical power to airplane is OFF.
(2) Gain access to backside of annunciator panel and disconnect electrical connector.
(3) Remove screws securing annunciator panel to instrument panel and remove from airplane.
B. Install Annunciator Panel (Refer to Figure 201).
(1) Connect electrical connector to annunciator panel.
(2) Position annunciator panel to instrument panel and secure using screws.
(3) Restore electrical power to airplane.
(4) Check annunciator panel for proper operation.
31-50-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ELECTRICAL
CONNECTOR
ANNUNCIATOR PANEL
INSTRUMENT
PANEL
SCREW
DETAIL A
0585T1040
A0518T1022
Annunciator Panel Installation

31-50-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
LANDING
GEAR
MODEL 172
MAINTENANCE MANUAL
^~~~* ~LIST OF EFFECTIVE PAGES

32-Title
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Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

|~~~~~~~~~~~ I
MODEL 172
MAINTENANCE MANUAL

I
MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL
CONTENTS
LANDING GEAR - GENERAL ..................................................... 32-00-00 Page 1
Scope ...................................................................... 32-00-00 Page 1
Definition ......... .. ........... ................................ .......... 32-00-00 Page 1
MAIN LANDING GEAR - TROUBLESHOOTING .................................... 32-10-00 Page 101
Troubleshooting ............................................................. 32-10-00 Page 101
MAIN LANDING GEAR - MAINTENANCE PRACTICES ............................. 32-10-00 Page 201
General .................................................................... 32-10-00 Page 201
Main Landing Gear Fairings Removal/Installation .............................. 32-10-00 Page 201
Main Landing Gear Removal/Installation ...................................... 32-10-00 Page 203
Step Bracket Removal/Installation ............................................ 32-10-00 Page 203
Alignment Inspection/Check .................................................. 32-10-00 Page 204
NOSE LANDING GEAR - TROUBLESHOOTING ................................... 32-20-00 Page 101
NOSE LANDING GEAR - MAINTENANCE PRACTICES ............................. 32-20-00 Page 201
Description and Operation ................................................... 32-20-00 Page 201
Nose Wheel Speed Fairing Removal/Installation ............................... 32-20-00 Page 201
Nose Landing Gear Removal/Installation ...................................... 32-20-00 Page 201
Torque Link Removal/Installation ................... .......................... 32-20-00 Page 209
Shimmy Damper Removal/Disassembly/Installation ............................ 32-20-00 Page 209
Shock Strut Disassembly/Inspection/Assembly ................................. 32-20-00 Page 210
Steering Rod Assembly ..................................................... 32-20-00 Page 211
MAIN LANDING GEAR WHEEL AND AXLE - MAINTENANCE PRACTICES .......... 32-40-00 Page 201
General .................................................................... 32-40-00 Page 201
Main Wheel Removal/Installation ............................................. 32-40-00 Page 201
Main Wheel Axle Removal/Installation ................................ ...... 32-40-00 Page 201
Main Wheel Disassembly/Assembly ................... ....................... 32-40-00 Page 201
Main W heel Inspection/Check ................................................ 32-40-00 Page 204
Wheel Balancing ............................................................ 32-40-00 Page 204
NOSE LANDING GEAR WHEEL - MAINTENANCE PRACTICES ..................... 32-41-00 Page 201
General .................................................................... 32-41-00 Page 201
Nose Landing Gear Wheel Removal/Installation ............................... 32-41-00 Page 201
Nose Landing Gear Wheel Disassembly/Assembly ............................ 32-41-00 Page 201
Nose Landing Gear Wheel Inspection/Check .................................. 32-41-00 Page 203
BRAKES - TROUBLESHOOTING ................................................. 32-42-00 Page 101
BRAKE SYSTEM - MAINTENANCE PRACTICES ................................... 32-42-00 Page 201
Brake Line Removal ......................................................... 32-42-00 Page 201
Brake Assembly and Line Removal/Installation ................................. 32-42-00 Page 201
Brake Component Inspection ................................................. 32-42-00 Page 201
New Brake Lining Conditioning ............................................... 32-42-00 Page 205
Master Cylinder Removal/Disassembly/Installation ............................. 32-42-00 Page 205
Brake System Bleeding ...................................................... 32-42-00 Page 207
Parking Brake System ....................................................... 32-42-00 Page 207
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LANDING GEAR - GENERAL
1. Scope
A. This chapter contains maintenance information concerning the landing gear and associated
components which provide a means of supporting, braking and steering the airplane during takeoff,
landing, taxiing, towing and parking.
2. Definition
the Table of Contents will assist in locating a particular subject. A brief definition of the sections
(1) The section on main landing gear provides troubleshooting, maintenance practices and
adjustment instructions for the main landing gear.
(2) The section on nose landing gear provides troubleshooting, maintenance practices and
inspection/checks for the nose landing gear.
(3) The section on wheels and brakes provides description/operation, troubleshooting, maintenance
practices and adjustment/test instructions for the main gear brake system.
(4) The section on nose gear steering provides troubleshooting, maintenance practices and
adjustment/test instructions for the nose gear steering system and related components.
32-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
MAIN LANDING GEAR - TROUBLESHOOTING
1. Troubleshooting

AIRPLANE LEANS TO ONE SIDE. Incorrect tire pressure. Ensure tire is inflated to correct air
pressure.
Landing gear attaching parts not Tighten loose parts or replace
tight. defective parts with new parts.
Landing gear tubular strut Replace tubular strut. Refer to
excessively sprung. Main Landing Gear - Maintenance
Practices.
Bent axle. Replace axle. Refer to Main
Landing Gear Wheel and Axle -
TIRES WEAR EXCESSIVELY. Incorrect tire pressure. Ensure tire is inflated to 28 PSI air
pressure.
Main wheels out of alignment. Check main wheel alignment.
Refer to Main Landing Gear Wheel
and Axle - Maintenance Practices.
Landing gear tubular strut Replace tubular strut. Refer to
excessively sprung Main Landing Gear - Maintenance
Practices.
Bent axle. Replace axle. Refer to Main
Landing Gear Wheel and Axle -
Dragging brakes. Adjust brakes. Refer to Brakes -
Wheel bearings excessively tight. Properly install wheel bearings.
Refer to Main Landing Gear Wheel
and Axle - Maintenance Practices.
TIRE BOUNCE EVIDENT ON Tire out of balance. Balance tire. Refer to Main
SMOOTH SURFACE. Landing Gear Wheel and Axle -
32-1 0-00 Page 101

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
MAIN LANDING GEAR - MAINTENANCE PRACTICES
1. General
A. The airplane is equipped with fixed, tubular spring steel main gear struts bolted into the lower
fuselage belly. Attached to the outboard end of each strut is a die-cast aluminum wheel and disc
brake assembly.
B. Maintenance practices provide instructions for fairing, strut and step removal/installation. Also
included in this section are procedures for checking main wheel alignment.
C. For wheel and tire maintenance, refer to Main Landing Gear Wheel and Axle - Maintenance Practices.
For brake maintenance, refer to Brakes - Maintenance Practices.
2. Main Landing Gear Fairings Removal/Installation
A. Remove Main Wheel Speed Fairings (Refer to Figure 201).
(1) Remove screws securing brake fairing to main wheel speed fairing.
(2) Remove screws attaching main wheel speed fairing to attach plate, which is bolted to axle.
(3) Remove bolt securing outboard side of main wheel speed fairing to axle nut.
(4) Loosen scraper, if necessary, and work main wheel speed fairing from wheel.
B. Remove Brake Fairing (Refer to Figure 201).
(1) Remove screws from lower side of brake fairing.
(2) Work brake fairing from landing gear.
C. Remove Cap Fairing (Refer to Figure 201).
(1) Remove screws and clamp securing cap fairing to tubular strut fairing.
(2) Remove cap fairing and clamp.
D. Remove Tubular Strut Fairing (Refer to Figure 201).
(1) Remove screws securing step to step bracket.
(2) Remove screws from lower side of tubular strut fairing.
(3) Carefully separate tubular strut fairing along aft edge and work over step bracket.
(4) Pull tubular strut fairing out of fuselage fairing and remove from tubular strut.
E. Remove Fuselage Fairing (Refer to Figure 201).
(1) Remove main landing gear wheel. Refer to Main Landing Gear Wheel And Axle - Maintenance
Practices.
(2) Remove main wheel speed fairing attach plate.
(3) Remove brake torque plate.
(4) Remove screws securing fuselage fairing to fuselage.
(5) Slide fuselage fairing down tubular strut and work over main landing gear axle.
F. Install Fuselage Fairing (Refer to Figure 201).
(1) Work fuselage fairing over main landing gear axle and slide up to fuselage. Secure with screws.
(2) Install brake torque plate.
(3) Install main wheel speed fairing attach plate.
(4) Install main landing gear wheel. Refer to Main Landing Gear Wheel And Axle - Maintenance
Practices.
G. Install Tubular Strut Fairing (Refer to Figure 201).
(1) Place tubular strut fairing over tubular strut, position over step bracket and into fuselage fairing.
Secure with screws.
(2) Install step to step bracket.
H. Install Cap Fairing (Refer to Figure 201).
(1) Place cap fairing and clamp over tubular strut. Secure with screws and clamp.
I. Install Brake Fairing (Refer to Figure 201).
(1) Place brake fairing over landing gear.
(2) Install screws to lower side of brake fairing.
32-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FUSELAGE
FAIRING
BUSHING
STRUT
LANDING GEAR
BULKHEAD
TUBULAR BRAKE
STRUT FAIRING
STEP
BRAKE CLAMP
LINE MAIN LANDING
STIFFENER
MOUNTING
PLATE
BRAKE
MAIN WHEEL DETAIL A

SPEED FAIRING
DETAIL B
Main Landing Gear Installation
32-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
J. Install Main Wheel Speed Fairings (Refer to Figure 201).

(1) Work speed fairing over wheel. Adjust scraper if necessary.
(2) Install bolt securing outboard side of main wheel speed fairing to axle nut.
(3) Install screws attaching main wheel speed fairing to attach plate, which is bolted to axle.
(4) Install screws securing brake fairing to main wheel speed fairing.
3. Main Landing Gear Removal/Installation
A. Remove Main Landing Gear (Refer to Figure 201).
(1) Remove interior seat, carpet and access panels as required to gain access to landing gear
components in the fuselage belly.
(2) Jack airplane. Refer to Chapter 7, Jacking - Maintenance Practices.
(3) Remove screws attaching fuselage fairing to fuselage. Remove screws at splice in fuselage
fairing and remove from strut fairing.
(4) Drain hydraulic fluid from brake line on strut.
(5) Disconnect hydraulic brake line at fitting where brake line emerges from fuselage skin. Cap or
plug disconnected fittings.
(6) Remove nut, washer and bolt attaching inboard end of tubular strut to the inboard landing gear
bulkhead fitting.
(7) Pull tubular strut from fitting and bushing. Use care when removing strut to prevent damage to
hydraulic brake line.
NOTE: The tubular strut is a compression fit in the bushing in the outboard landing gear
forging.
B. Install Main Landing Gear (Refer to Figure 201).
(1) Install all parts removed from strut.
(2) Apply Dow Corning Compound DC-7 to approximately 11 inches on upper end of tubular strut.
NOTE: Avoid use of Dow Corning DC-7 on surfaces to be painted. DC-7 contains silicone
which is harmful to painted areas.
(3) Slide tubular strut into place through bushing in outboard strut fitting and into inboard strut fitting.
(4) Align tubular strut in inboard fitting and install bolt through fitting and strut. Install washer and
nut on bolt and tighten to torque value of 100 foot-pounds, +8 or -8 foot-pounds.
(5) Connect hydraulic brake line to fitting. Fill and bleed brake system.
(6) Install fuselage fairing.
(7) Remove airplane from jacks
(8) Reinstall access panels, carpet and seats as required.
4. Step Bracket Removal/Installation
A. Remove Step Bracket (Refer to Figure 201).
(1) Remove main landing gear fairings. Refer to Main Landing Gear Fairings Removal/Installation.
(2) Remove step bracket.
(a) Using long handled pliers or other similar tool, apply upward force to step bracket.
CAUTION: DO NOT CONTINUE HEATING TUBULAR STRUT TO THE POINT
WHERE PAINT OR EPOXY BLISTERS.
(b) Apply heat to epoxy using heat gun, until epoxy softens and upward force of pliers breaks
step bracket away from landing gear strut. Quickly remove heat.
32-10-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B. Install Step Bracket (Refer to Figure 201).
NOTE: The step bracket is secured to the tubular gear strut with EA9309, EC2216, EC2214,
EC3445 or a similar epoxy base adhesive.
(1) Mark position of the bracket so that the new step bracket will be installed in approximately the
same position on the strut.
(2) Remove all traces of the original bracket and adhesive as well as any rust, paint or scale with a
wire brush and coarse sandpaper.
(3) Leave surfaces slightly roughened or abraded, but deep scratches or nicks should be avoided.
(4) Clean surfaces to be bonded together thoroughly. If a solvent is used remove all traces of the
solvent with a clean, dry cloth. It is important that the bonding surfaces be clean and dry.
(5) Check fit of step bracket on the tubular strut. A small gap is permissible between bracket and
tubular strut.
(6) Mix adhesive in accordance with manufacturer's directions.
(7) Spread a coat of adhesive on bonding surfaces, and place step bracket in position on the tubular
strut. Clamp bracket to strut to ensure a good, tight fit.
(8) Form a small fillet of the adhesive at all edges of the bonded surfaces. Remove excess adhesive
with lacquer thinner.
(9) Allow adhesive to cure thoroughly according to manufacturer's recommendations before flexing
the tubular gear strut or applying loads to the strut.
(10) Paint tubular strut and step bracket after adhesive is completely cured.
(11) Install main landing gear fairings.Refer to Main Landing Gear Fairings Removal/Installation.
5. Alignment Inspection/Check
A. Check Main Wheel Alignment (Refer to Figure 202).
(1) Toe-in limitations are 0.00 inch to 0.18 inch.
(2) Camber limitations are 2 degrees to 4 degrees.
NOTE: There is no adjustment for the main landing gear strut. If wheel alignment is out of
these limits, a new tubular spring strut will have to be installed.
32-10-00 Page 204

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PERPENDICULAR
NOTE: ENSURE FLOOR IS LEVEL IN WORK AREA. SUSPEND PLUMB BOB FROM TAIL
TIE-DOWN RING (AFT), AND FROM FORWARD INSPECTION COVER PLATE.
COVER PLATE IS LOCATED JUST AFT OF NOSE GEAR ON BOTTOM OF FUSELAGE.
PLUMB BOB SHOULD BE ATTACHED TO THE FORWARD-MOST SCREW OF THE
INSPECTION PLATE.
STRAIGHTEDGE
PERPENDICULAR
05411003
05411003
Main Wheel Alignment Check

32-10-00 Page 205

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TOP VIEW OF TOE-IN CHECK
CARPENTER'S
SQUARE
FWD
STRAIGHTEDGE
MEASURE TOE-IN AT EDGES OF WHEEL FLANGE.

DIFFERENCE IN MEASUREMENTS IS TOE-IN FOR
ONE WHEEL. (HALF OF TOTAL TOE-IN.)
FRONT VIEW OF CAMBER CHECK
POSITIVE NEGATIVE
CAMBER
INBD
MEASURE CAMBER BY READING PROTRACTOR LEVEL

HELD VERTICALLY AGAINST OUTBOARD FLANGES
OF WHEEL.
NOTE: THESE PROCEDURES ARE SPECIFICALLY FOR CHECKING MAIN WHEEL ALIGNMENT.
NO PROVISIONS ARE MADE FOR ALIGNING THE NOSE WHEEL. FOR CAMBER AND
TOE-IN SPECS, REFER TO CHAPTER 6, AIRPLANE DIMENSIONS AND SPECIFICATIONS.
05411004
05411004
Main Wheel Alignment Check

32-10-00 Page 206

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NOSE LANDING GEAR - TROUBLESHOOTING
1. Troubleshooting

NOSE WHEEL Nose strut attaching bolts loose. Tighten nose strut attaching bolts.
SHIMMY.
Loose or worn nose wheel steering Tighten linkage. Replace defective
linkage. parts with new parts.
Nose wheel out of balance. Balance nose wheel. Refer to
Nose Landing Gear - Maintenance
Practices.
Wheel bearings too loose. Properly install wheel bearings.
Defective shimmy damper. Repair or install new damper.
Shimmy damper fluid low. Service shimmy damper. Refer to
Chapter 12, Nose Gear Shimmy
Damper - Servicing.
Loose torque links. Add shims, or install new parts as
required.
NOSE STRUT DOES Defective strut seals. Install new seals. Refer to Nose
NOT HOLD AIR Landing Gear - Maintenance
PRESSURE. Practices.
Defective or loose air filler valve. Check gasket and tighten loose
valve. Install new valve if defective.
HYDRAULIC FLUID Defective strut seals. Install new seals. Refer to Nose
LEAKAGE FROM Landing Gear - Maintenance
NOSE STRUT. Practices.
32-20-00 Page 101

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NOSE LANDING GEAR - MAINTENANCE PRACTICES

A. The airplane incorporates a steerable nose wheel linked through the rudder pedals to provide ground
control. Major components of the nose landing gear are as follows:
(1) Shock Strut - The shock strut is comprised of upper and lower machined cylinders which contain
a mixture of oil and air. This construction provides for variable shock-absorbing rates
(2) Torque Links - Torque links provide a mechanical link between the upper and lower portions of
the shock strut and serve to keep the nose wheel aligned with the airframe.
(3) Nose Wheel Steering - Nose wheel steering is accomplished through use of the rudder pedals.
Spring loaded steering rod assemblies connect the nose gear steering arm assembly to arms
on the rudder pedals. Steering is afforded up to approximately 10 degrees each side of neutral,
after which brakes may be used to gain a maximum deflection of 30 degrees right or left of center.
(4) Shimmy Damper - The shimmy damper offers resistance to shimmy by forcing hydraulic fluid
through small orifices in a piston. The damper is connected between the shock strut and the
steering arm assembly.
2. Nose Wheel Speed Fairing Removal/Installation

A. Remove Nose Wheel Speed Fairing (Refer to Figure 201).
(1) Remove bolt securing cover plate to lower torque link and remove cover plate. Replace bolt.
(2) Weight or tie down tail of airplane to raise nose wheel from floor.
(3) Remove nose wheel axle stud.
(4) Remove bolt securing speed fairing and tow bar spacers to strut.
(5) Slide speed fairing up and remove nose wheel. Loosen scraper as necessary.
(6) Rotate speed fairing 90 degrees to centerline of airplane and work fairing down over the fork to
remove.
B. Install Nose Wheel Speed Fairing (Refer to Figure 201).
(1) With speed fairing 90 degrees to center line of airplane, work fairing up over nose gear fork.
(2) Slide fairing up and install nose wheel in fork. Install axle stud.
(3) Position speed fairing over nose wheel and tighten axle stud nut until a slight bearing drag is
obvious when the wheel is rotated. Back off nut to the nearest castellation and install cotter pin.
(4) Install bolt, tow bar spacers, washers and nut attaching fairing to strut.
CAUTION: ALWAYS CHECK SCRAPER CLEARANCE AFTER INSTALLING SPEED
FAIRING. SET CLEARANCE BETWEEN TIRE AND SCRAPER FOR A
MINIMUM OF 0.25 INCH TO A MAXIMUM OF 0.50 INCH. ELONGATED HOLES
ARE PROVIDED IN THE SCRAPER FOR ADJUSTMENT.
(5) Adjust wheel scraper clearance.

(6) Lower nose of airplane to floor.
(7) Remove lower torque link attach bolt.
(8) Position cover plate over speed fairing and secure with lower torque link attach bolt.
3. Nose Landing Gear Removal/Installation
A. Remove Nose Landing Gear (Refer to Figure 202).
(1) Remove cowling. Refer to Chapter 71, Cowling - Removal/Installation.
(3) Disconnect nose wheel steering tubes from nose gear steering collar.
CAUTION: ENSURE STRUT IS COMPLETELY DEFLATED PRIOR TO REMOVING BOLT
OR ROLL PIN AT TOP OF STRUT.
(4) Remove strut clamp cap and shims from lower strut fitting.
(5) Deflate strut completely and telescope strut to its shortest length.
(6) Remove bolt from top of strut.
32-20-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL B
COVER
WASHER
WASHER
NOSE
WASHER
BOLT
Nose Wheel Speed Fairing Installation

32-20-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BOLT
UPPER NOSE
STRUT
ASSEMBLY TUBE
LOWER STRUT
BOLT
SHIMMY
DAMPENER
SHIMMY
DAMPENER D
ARM
BOLT
STRUT
CLAMP
CAP
STEERING ARM
ASSEMBLY
WHEEL
ASSEMBLY
05421006
Nose Landing Gear Installation

32-20-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
UPPER NOSE
UPPER NOSE
LOWER STRUT DETAIL A

FITTING
BALL
SHIM
CHECK
CLEVIS CLAMP
CAP
DETAIL C
DETAIL B
0511 T1006
A05421008

32-20-00 Page 204

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
UPPER
TORQUE SHIM
GREASE
FITTING NUT
BUSHING
GREASE
SPACER
BUSHING
GREASE
FITTING
LINK
SHIM
SPACER
DETAIL D
D05421011

32-20-00 Page 205

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(COLLAR) 1.00 ROD
VIEW A-A
ORIFICE
PISTON
SUPPORT
UPPER
STRUT
NO. 40
HOLE
UPPER
STRUT
VIEW B-B
RETAINING B
RING
STEERING
ASSEMBLY
END
ROD
END
SHIM TO
(AS SHEET 5
REQUIRED)
DETAIL E
E05421010

32-20-00 Page 206

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FROM SHEET 4
LOCK
RING
BEARING
STRUT
PACKING
SUPPORT
RING
RING RING
PACKING
RETAINING RING LOCK

RING RING
SCRAPER
C TOW BAR
LOCK RING SPACER
RING
VIEW C-C
RETAINING
SPACER
TOW BAR
SPACER
FORK
METERING
PIN
05421010
C-C05421010

32-20-00 Page 207

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BARREL
SNAP
PISTON
PISTON
ROLL
PIN
BEARING
DETAIL F
F0542T1003

32-20-00 Page 208

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(7) Pull the strut assembly down from upper attach forging.
B. Install Nose Landing Gear (Refer to Figure 202).
(1) Before inflating nose gear strut, insert top of strut in upper attach forging and attach with bolt.
(2) Telescope strut to mate strut clamp cap with lower strut fitting on firewall.
(3) Install shims and strut clamp cap attaching strut to lower strut fitting.
NOTE: When installing cap, check gap between cap and strut fitting before attaching bolts
are tightened. Gap tolerance is 0.010 inch minimum and 0.016 inch maximum. If gap
exceeds maximum tolerance, install shims as required. Replace cap if gap is less
than minimum, using shims to obtain proper gap. Install shims as equally as possible
between sides.
(4) Inflate and service shock strut. Refer to Chapter 12, Nose Landing Gear Shock Strut - Servicing.
(5) Rig nose wheel steering tubes. Refer to Chapter 27, Rudder Control System - Maintenance
Practices.
(6) Remove weights or tie down from tail, and lower nose wheel to floor.
(7) Install cowling. Refer to Chapter 71, Cowling - Removal/Installation.
4. Torque Link Removal/Installation

A. Remove Torque Links (Refer to Figure 202, Detail D ).
WARNING: COMPLETELY DEFLATE SHOCK STRUT BEFORE REMOVING TORQUE

LINKS
(1) Disconnect upper and lower attaching bolts, spacers, shims and nuts.
(2) Remove torque links.
B. Install Torque Links (Refer to Figure 202, Detail D).
NOTE: If the safety lug and stop lug were removed from the upper torque link during disassembly,
they must be reinstalled and the retaining bolts tightened from 20 to 25 In-lbs. After
torqueing bolts, safety them into position by bending the tips of the safety lug.
(1) With shock strut completely deflated, install upper and lower torque link assemblies.
(2) Install bolt attaching upper and lower assemblies.
(3) Tighten nuts at both ends of torque links snugly, then tighten to align next castellation with cotter
pin hole in bolt.
(4) Check upper and lower torque link for looseness. If looseness is apparent, shims may be
installed to take up slack. This will assist in preventing nose wheel shimmy.
(5) Fill and inflate shock strut to proper pressure.
5. Shimmy Damper Removal/Disassembly/Installation

A. Remove Shimmy Damper (Refer to Figure 202, Detail F).
(1) Remove cotter pin, nut, washers and bolt attaching piston shaft clevis to bracket welded on
bottom of upper strut tube.
(2) Remove cotter pin, nut, spacer and bolt attaching housing to steering arm assembly.
(3) Remove shimmy damper.
B. Disassemble/Reassemble Shimmy Damper (Refer to Figure 202, Detail F).
(1) The shimmy damper should be disassembled using Detail F as a guide. When reassembling
damper, all new O-rings should be used. All parts should be lubricated before reassembly
using clean hydraulic fluid. When damper is completely assembled, it should be serviced using
procedures set forth in Chapter 12, Nose Landing Gear Shimmy Damper - Servicing.
C. Install Shimmy Damper (Refer to Figure 202, Detail F).
(1) Attach shimmy damper housing to steering arm assembly with bolt, spacer, nut and cotter pin.
32-20-00 Page 209

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(2) Attach shimmy damper piston rod clevis to bracket welded on bottom of upper strut tube with
bolt,washers (as required) and nut.
6. Shock Strut Disassembly/Inspection/Assembly

A. Dissemble Shock Strut (Refer to Figure 202, Detail E).
NOTE: The following procedures apply to the nose gear shock strut after it has been removed from
the airplane and the speed fairings and nose wheel have been removed. In may cases,
separation of the upper and lower strut will permit inspection and parts installation without
removal or complete disassembly of the strut.
WARNING: ENSURE SHOCK STRUT IS COMPLETELY DEFLATED BEFORE
REMOVING LOCK RING IN LOWER END OF UPPER STRUT, OR BEFORE
DISCONNECTING TORQUE LINKS.
(1) Remove shimmy damper.

(2) Remove torque links. Note position of washers, shim and spacers.
(3) Remove lock ring from groove inside lower end of upper strut. A small hole is provided at the
lock ring groove to facilitate removal of the lock ring.
NOTE: Hydraulic fluid will drain from strut halves as lower strut is pulled from upper strut.
(4) Using a straight, sharp pull, separate upper and lower struts. Invert lower strut and drain
hydraulic fluid.
(5) Remove lock ring and bearing at upper end of lower strut assembly. Note top side of bearing.
(6) Slide packing support ring, scraper ring, retaining ring and lock ring from lower strut, noting
relative position and top side of each ring. Wire or tape together, if desired.
(7) Remove O-ring and back-up rings from packing support ring.
(8) Remove bolt securing tow bar spacers.
NOTE: Bolt attaching tow bar spacers also holds bushing and base plug in place.
(9) Remove bolt attaching fork to strut barrel, and remove base plug and metering pin from lower
strut.
(10) Remove O-rings and metering pin from base plug.
NOTE: Lower strut barrel and fork are a press fit, drilled on assembly. Separation of these
parts is not recommended, except for installation of a new part.
(11) Remove retaining ring securing steering arm assembly on upper strut, and remove steering arm
assembly, shims (if installed) and washer. If shims are installed, note number and position of
each shim.
(12) Push orifice support from upper strut and remove O-ring.
(13) Remove filler valve from orifice support.
B. Inspect/Repair Strut.
(1) Thoroughly clean all parts in cleaning solvent and inspect them carefully.
(2) All worn or defective parts and all O-rings and back-up rings must be replaced with new parts.
(3) Sharp metal edges should be smoothed with No. 400 emery paper, then cleaned with solvent.
C. Reassemble Shock Strut (Refer to Figure 202, Detail E).
NOTE: All parts should be clean and lubricated with hydraulic fluid before reassembly. All O-rings
should be new.
(1) Install washer and shims (if removed earlier).

(2) Lubricate needle bearings in steering collar. Install collar and retaining ring.
32-20-00 Page 210

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(3) Check steering collar for snug fit against washer. Shims of variable thickness are available form
Cessna to provide a snug fit for collar against washer. Refer to the Model 172 Illustrated Parts
Catalog for shim numbers.
(4) Install rod ends in steering collar and adjust rod ends to dimensions specified in View A-A.
(5) Install O-rings and filler valve in orifice piston support, and install orifice piston support in upper
strut.
(6) Install O-ring and metering pin with O-ring in base plug. Secure with nut.
NOTE: If base plug is to be replaced, new part will need to be line-drilled to accept NAS75-5
bushing.
(7) Install bushing (if removed) in base plug, and install base plug assembly in lower strut.
(8) Align holes of bushing, hole in lower strut, and hole in fork. Install tow bar spacer under head of
bolt, and install bolt through fork, lower strut and bushing which is installed in base plug. Install
tow bar spacer on threaded end of bolt, install and tighten nut.
(9) Install lock ring, retaining ring and scraper ring on lower strut, making sure they are installed in
same positions as they were removed.
(10) Install O-rings and back-up rings in packing support ring; slide packing support ring over lower
strut.
(11) Install bearing and lock ring at upper end of lower strut assembly. Note top side of bearing.
(12) Install upper strut assembly over lower strut assembly.
(13) Install lock ring in groove in lower end of upper strut. Position lock ring so that one of its ends
covers the small access hole in the lock ring groove (View C-C).
(14) Install torque links, positioning washers, shims and spacers exactly in positions as removed.
(15) Install shimmy damper.
(16) After shock strut assembly is complete, install strut on airplane.
(17) Fill and inflate strut. Refer to Chapter 12, Nose Landing Gear Shock Strut - Servicing.
7. Steering Rod Assembly

A. Adjustment Criteria (Refer to Figure 202, Detail C and Detail E).
(1) Before attaching nose wheel steering rods to the rod ends protruding from the steering arm
assembly, adjust rod ends to the dimension specified in View A-A of detail E. Because nose
wheel steering and rudder systems are interconnected, adjustment to one system might affect
the other system and should be taken into consideration.
32-20-00 Page 211

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
MAIN LANDING GEAR WHEEL AND AXLE - MAINTENANCE PRACTICES

1. General
A. Main landing gear wheel maintenance practices provide removal/installation instructions for left main
wheel. Removal/installation for right main wheel is typical unless otherwise noted.
2. Main Wheel Removal/Installation
NOTE: Wheel removal is not necessary to reline brakes or to remove brake parts, other than the brake
disc on the torque plate.
A. Remove Main Wheel (Refer to Figure 201).
(1) Jack airplane. Refer to Chapter 7, Jacking - Maintenance Practices.
(2) Remove speed fairing if installed. Refer to Main Landing Gear - Maintenance Practices.
(3) Remove hub caps, cotter pin and axle nut.
(4) Remove bolts securing brake back plate to brake cylinder. Remove back plate.
(5) Pull wheel from axle.
B. Install Main Wheel (Refer to Figure 201).
(1) Place wheel assembly on axle.
(2) Install axle nut and tighten axle nut until a slight bearing drag is obvious when the wheel is
rotated. Back off nut to nearest castellation and install cotter pin.
(3) Place brake back plate in position and secure with bolts.
(4) Install hub cap.
(5) Install speed fairing. Refer to Main Landing Gear - Maintenance Practices.
3. Main Wheel Axle Removal/Installation
A. Remove Main Wheel Axle (Refer to Figure 201).
(1) Remove main wheel speed fairing. Refer to Main Landing Gear - Maintenance Practices.
(2) Remove main landing gear wheel.
(3) Disconnect, drain and cap or plug hydraulic brake line at the wheel brake cylinder.
(4) Remove bolts attaching brake torque plate and speed fairing mounting plate to axle.
(5) Remove cotter pin, nut, washer and bolt attaching axle to tubular strut.
(6) Remove axle from spring strut.
B. Install Main Wheel Axle (Refer to Figure 201).
(1) Apply epoxy primer to faying surfaces of axle and tubular strut.
(2) Install axle onto tubular strut while primer is still wet.
NOTE: Axle is installed with tapered edge on bottom.
(3) Install bolt, washer and nut attaching axle to tubular strut. After tightening nut, install cotter pin.
(4) Install brake components and speed fairing mounting plater to axle.
(5) Install wheel on axle.
(6) Connect hydraulic brake line to wheel brake cylinder.
(7) Fill and bleed hydraulic brake system. Refer to Brakes - Maintenance Practices.
(8) Install main wheel speed fairing. Refer to Main Landing Gear - Maintenance Practices.
4. Main Wheel Disassembly/Assembly

A. Disassemble Main Wheel (Refer to Figure 202).
WARNING: SERIOUS INJURY CAN RESULT FROM ATTEMPTING TO SEPARATE WHEEL

HALVES WITH TIRE AND TUBE INFLATED.
(1) Completely deflate tire and tube and break loose tire bead. Extreme care must be exercised to
prevent tire tool damage when removing tire from wheel halves.
(2) Remove thru-bolts holding wheel halves together.
32-40-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A
TUBULAR
STRUT
MAIN LANDING
GEAR AXLE
BRAKE
BACKPLATE TIRE
AXLE NUT
COTTER PIN
HUB CAP
DETAIL A
0510T1 007
A05413001
Main Wheel Installation
32-40-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BEARING CONE
TIRE
TUBE
WASHER
BEARING CUP
WHEEL HALF
GREASE SEAL
BEARING CUP FELT
GREASE SEAL
RETAINER
DETAIL A RETAINING
RING
A05411001
Main Wheel Assembly

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(3) Separate and remove wheel halves from tire and tube.
(4) From each wheel half, remove retaining rings, grease seal retainers, grease seal felts, grease
seal retainers and bearing cones.
NOTE: Bearing cups (races) are a press fit in wheel halves, and should not be removed
unless a new part is to be installed. To remove bearing cups, heat wheel half in
boiling water for 30 minutes, or in an oven, not to exceed 250°F. Using an arbor press,
if available, press out bearing cup and press in a new bearing cup while wheel half is
still hot.
B. Assemble Main Wheel (Refer to Figure 202).
(1) Install bearing cone, grease seal retainer, grease seal felt, grease seal retainer and retaining
ring into each wheel half.
(2) Insert tube in tire, aligning index marks on tire and tube.
(3) Place wheel half into tire and tube (side opposite valve stem). With washer under head of thru-
bolt, insert bolt through wheel half.
(4) Place other wheel half into other side of tire and tube, aligning valve stem in valve slot. Ensure
tube is not pinched between wheel halves before torqueing nuts.
CAUTION: UNEVEN OR IMPROPER TORQUE OF THE NUTS CAN CAUSE FAILURE OF
THE BOLTS WITH RESULTANT WHEEL FAILURE.
CAUTION: DO NOT USE IMPACT WRENCHES ON THRU-BOLTS OR NUTS.
(5) Insert washers and nuts on thru-bolts. Dry torque nuts to 90 inch- pounds, +2 or -2 inch-pounds.
(6) Inflate tire to seat tire beads, then adjust pressure to proper inflation.
5. Main Wheel Inspection/Check.
A. Inspect Main Wheel (Refer to Figure 202).
(1) Clean all metal parts and grease seal felts in solvent, and dry thoroughly.
NOTE: A soft bristle brush may be used to remove hardened grease, dust or dirt.
(2) Inspect wheel halves for cracks or damage.
(3) Inspect bearing cones, cups, retaining rings, grease seal retainers, grease seal felts and grease
seal retainers for wear or damage.
(4) Inspect thru-bolts for cracks in bolt head.
(5) Replace cracked or damaged wheel half.
(6) Replace damaged retainer rings and seals.
(7) Replace worn or damaged bearing cups and cones.
(8) Replace any worn or damaged thru-bolts.
(9) Remove any corrosion or small nicks.
(10) Repair reworked areas of wheel by cleaning thoroughly, then applying one coat of clear lacquer
paint.
(11) Pack bearings with MIL-G-81322 wheel bearing grease.
6. Wheel Balancing
A. Since uneven tire wear is usually the cause of wheel unbalance, replacing the tire will probably correct
this condition. Tire and tube manufacturing tolerance permits a specified amount of static unbalance.
The light weight point of this tire is marked with a red dot on the tire sidewall and the heavy weight
point of the tube is marked with a contrasting color line (usually near the inflation valve stem). When
installing a new tire, place these marks adjacent to each other. If a wheel shows evidence of unbalance
during service, it may be statically balanced but not dynamically balanced.
32-40-00 Page 204

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NOSE LANDING GEAR WHEEL - MAINTENANCE PRACTICES

1. General
A. Nose landing gear wheel maintenance practices consist of nose wheel removal/installation, nose
wheel disassembly/assembly and nose landing gear wheel inspection/check.
2. Nose Landing Gear Wheel Removal/Installation
A. Remove Nose Landing Gear Wheel (Refer to Figure 201).
(2) Remove nose wheel axle stud.
(3) Pull nose wheel assembly from fork and remove axle tube from nose wheel. Airplanes equipped
with speed fairing, loosen wheel scraper as necessary.
B. Install Nose Landing Gear Wheel (Refer to Figure 201).
(1) Install axle tube in nose wheel.
(2) Install nose wheel assembly in fork and install nose wheel axle stud.
(3) Tighten axle stud until a slight bearing drag is obvious when wheel is rotated. Back the nut off
to the nearest castellation and insert cotter pins.
(4) Airplanes equipped with speed fairings, check scraper clearance. Refer to Nose Landing Gear
- Maintenance Practices.
3. Nose Landing Gear Wheel Disassembly/Assembly
A. Disassemble Nose Landing Gear Wheel (Refer to Figure 201).
(1) Completely deflate tire and tube and break loose tire beads. Extreme care must be exercised to
prevent tire tool damage when removing tire from wheel halves.
WARNING: SERIOUS INJURY CAN RESULT FROM ATTEMPTING TO SEPARATE WHEEL

HALVES WITH TIRE AND TUBE INFLATED.
(2) Remove thru-bolts and washers.
(3) Separate and remove wheel halves from tire and tube.
(4) Remove retaining rings, grease seal retainer, felt grease seal, grease retainer and bearing cone
from each wheel half.
NOTE: Bearing cups are a press fit in wheel half and should not be removed unless a new
part is to be installed. To remove bearing cups, heat wheel half in boiling water for 30
minutes, or in an oven, not to exceed 250°F. Using an arbor press, press out bearing
cup and press in new bearing cup while wheel half is still hot.
B. Assemble Nose Landing Gear Wheel (Refer to Figure 201).
(1) Assemble bearing cone, grease seal retainer, felt grease seal, grease seal retainer and retaining
ring into both wheel halves.
(2) Insert tube in tire, aligning index marks on tire and tube.
(3) Place wheel half into tire and tube. With washer under head of thru bolt, insert bolt through
wheel half.
(4) Place other wheel half into other side of tire and tube, aligning valve stem in valve slot. Ensure
tube is not pinched between wheel halves before torqueing nuts.
CAUTION: UNEVEN OR IMPROPER TORQUE OF THE NUTS CAN CAUSE FAILURE OF
THE BOLTS WITH RESULTANT WHEEL FAILURE.
CAUTION: DO NOT USE IMPACT WRENCHES ON THRU-BOLTS OR NUTS.
(5) Insert washers and nuts on thru- bolts. Dry torque nuts to 90 inch-pounds, +2 or -2 inch-pounds.
(6) Inflate tire to seat tire beads, then adjust pressure to proper inflation.
32-41-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
RETAINING RING
GREASE SEAL RETAINER
FELT GREASE SEAL
NUT
WHEEL HALF
GREASE
SEAL
RETAINER
BEARING
CONE
WHEEL HALF
BEARING CUP
CUP
WASHER
BOLT
BEARING CONE
DETAIL A GREASE SEAL RETAINER
FELT GREASE SEAL
GREASE SEAL RETAINER
RETAINING RING
A05421001
Nose Landing Gear Wheel Assembly

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
4. Nose Landing Gear Wheel Inspection/Check

A. Inspect Nose Landing Gear Wheel (Refer to Figure 201).
(1) Clean all metal parts and felt grease seals in Stoddard solvent or equivalent, and dry thoroughly.
(2) Inspect wheel halves for cracks or damage.
(3) Inspect bearing cones, cups, retaining rings, and seals for wear or damage.
(4) Inspect thru- bolts and nuts for cracks in threads or radius of bolt heads.
(5) Replace cracked or damaged wheel half.
(6) Replace damaged retaining rings and seals.
(7) Replace any worn or cracked thru-bolts or nuts.
(8) Replace worn or damaged bearing cups or cones.
(9) Remove any corrosion or small nicks.
(10) Repair reworked areas of wheel by cleaning thoroughly, then applying one coat of clear lacquer
paint.
32-41-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BRAKES - TROUBLESHOOTING
1. Troubleshooting

DRAGGING BRAKES. Brake pedal binding. Check and adjust properly. Refer
to Brakes - Maintenance Practices.
Parking brake linkage holding brake Check and adjust properly. Refer
pedal down. to Brakes - Maintenance Practices.
Worn or broken piston return spring in Repair, or install new master
master cylinder. cylinder. Refer to Brakes -
Restriction in hydraulic lines or Drain brake line and clean inside of
restrictions in compensating port in brake line with filtered compressed
master cylinder. air. If cleaning lines fails to give
satisfactory results, the master
cylinder may be faulty and should
be repaired.
Worn, scored or warped brake disc. Install new disc and brake linings.
Refer to Brakes - Maintenance
Practices.
Damaged or accumulated dirt Clean and repair or install new
restricting free movement of wheel parts as necessary. Refer to
brake parts. Brakes - Maintenance Practices.
BRAKES FAIL TO Leak in system. If brake master cylinders or wheel
OPERATE. cylinder assemblies are leaking,
repair, or install new parts. Refer
to Brakes - Maintenance Practices.
Air in system. Bleed system. Refer to Brakes -
Lack of fluid in master cylinders. Fill and bleed system. Refer to
Brakes - Maintenance Practices.
Defective master cylinder. Repair or install new parts as
necessary. Refer to Brakes -
32-42-00 Page 101

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
BRAKE SYSTEM - MAINTENANCE PRACTICES

A. The hydraulic brake system is comprised of two master cylinders, located immediately forward of
the pilot's rudder pedals, brake lines and hoses, and single-disc, floating cylinder brake assemblies
located at each main landing gear wheel.
B. The parking brake system is comprised of a pull-type handle and mechanical connections which are
linked to the rudder pedal assembly. Pulling aft on the brake handle applies mechanical pressure to
the rudder pedals, activating the brakes and locks the handle in place. Turning the handle 90 degrees
will release the parking brake and allow for normal operation through the rudder pedals.
C. Brake operation is accomplished by pushing on the upper part of each rudder pedal. This motion is
mechanically transmitted to the respective brake master cylinder, and through fluid-carrying lines out
to the brake assembly where fluid pressure acts to exert friction (through brake pads) against brake
discs.
D. For an illustration of brake system, refer to Figure 201. For an illustration of the brake master cylinder,
refer to Figure 202.
2. Brake Line Removal
A. Brake lines in the system are mostly metal, with flexible rubber lines installed near the master cylinders.
Rigid lines may be replaced in sections using pre-formed parts available from Cessna. Flexible lines
should be inspected for cracks, deterioration wear and damage, and are also available in replacement
assemblies through Cessna.
3. Brake Assembly and Line Removal/Installation
A. Remove Brake Assembly (Refer to Figure 201).
(1) Ensure parking brake is OFF.
(2) Disconnect brake line at brake assembly.
(3) Remove bolts securing back plate and remove brake assembly.
NOTE: If torque plate needs to be removed, wheel must be removed from axle. If brake disc
is to be removed, the tire and wheel assembly must be removed, deflated and split.
(4) Inspect components. Refer to Brake Component Inspection below.
B. Install Brake Assembly (Refer to Figure 201).
(1) Position brake assembly in place and secure using bolts. Torque from 80 to 90 In-lbs.
(2) Reconnect brake line and bleed brakes.
C. Remove Brake Lining (Refer to Figure 201).
(1) Remove back plate.
(2) Pull brake cylinder out of torque plate and slide pressure plate off anchor bolts.
(3) Place back plate on a table with lining side down flat. Center a 9/64-inch punch in the roller rivet,
and hit the punch sharply with a hammer. Punch out all rivets securing the linings to the back
plate and pressure plate in the same manner.
D. Install Brake Lining (Refer to Figure 201).
(1) Install new lining on back and pressure plates. Secure to plates using rivets.
(2) Position pressure plate on anchor bolts and place cylinder in position so that anchor bolts slide
into the torque plate.
(3) Install back plate with bolts and washers. Torque from 80 to 90 In-lbs.
(4) Burn in brake lining. Refer to procedure below.
4. Brake Component Inspection

A. Brake components should be inspected as follows:
(1) Clean all parts except brake linings and O-rings in dry cleaning solvent and dry thoroughly.
32-42-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INSTRUMENT
PANEL ASSEMBLY LOWER
INSTRUMENT
CABLE
POSITIONING PIN
POSITIONING RACK
RUDDER
TUBE PEDALS
ASSEMBLY
BELLCRANK
BRACKET
DETAIL B
SPRING
BRACKET PULLEY
A-A05141011
B05141011
Brake System Installation

32-42-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BRAKE LINE
LINE
DETAIL C
BRAKE
LINE
BRAKE
LINE BRAKE
LINE
DETAIL D
BRAKE
MASTER
CYLINDER
BRAKE
LINES
BRAKE
HOSE DETAIL E
C05141009
D05141009
E05143002

32-42-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NOSE GEAR MAIN GEAR
ITEM ITEM LUBE

1 WHEEL BEARINGS GR HAND

2 TORQUE LINKS GR GUN
3 SHIMMY DAMPER PIVOTS OG OIL CAN
5 PARKING BRAKE HANDLE OG OIL CAN

SHAFT

0542T2001
0514T3001
0541T3001

32-42-00 Page 204

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(2) Install all new O-rings. Ensure all components are clean and lubricated with brake fluid before
reinstallation.
(3) Check brake linings for deterioration and wear. Minimum allowable thickness is 3/32-inch.
(4) Inspect brake cylinder bore for scoring. A scored cylinder will leak or cause rapid O-ring wear.
Install a new brake cylinder if the bore is scored.
(5) If the anchor bolts on the brake assembly are nicked or gouged, they must be sanded smooth
to prevent binding with the pressure plate or torque plate. When new anchor bolts are installed,
press out old bolts and install new bolts with a soft mallet.
(6) Inspect wheel brake disc for thickness. Minimum thickness is 0.205 inch.
5. New Brake Lining Conditioning
A. Non-asbestos organic lining:
(1) Taxi airplane for 1500 feet with engine at 1700 RPM, applying brake pedal force as needed to
develop a 5 to 9 knot taxi speed.
(2) Allow brakes to cool for 10 to 15 minutes.
(3) Apply brakes and check to see if a high throttle static run up may be held with normal pedal
force. If so, burn-in is completed.
(4) If static run up cannot be held, allow brakes to completely cool then repeat steps 1 through 3 as
needed to successfully hold.
B. Iron-based metallic lining:
(1) Perform two consecutive full stop braking applications from 30 to 35 knots. Do not allow the
brake discs to cool substantially between stops.
NOTE: Light brake usage can cause the glaze to wear off, resulting in reduced brake
performance. In such cases, the lining may be conditioned again following the
instructions set forth in this conditioning procedure.
6. Master Cylinder Removal/Disassembly/Installation

A. Remove Master Cylinder (Refer to Figure 201).
(1) Remove front seats and rudder bar shield to access the brake master cylinders.
(2) Remove bleeder screw at wheel brake assembly and drain hydraulic fluid from brake cylinders.
(3) Disconnect parking brake and disconnect brake master cylinders from rudder pedals.
Disconnect hydraulic hose from brake master cylinders and remove cylinders.
(4) Plug or cap hydraulic fittings, hose and lines to prevent entry of foreign material.
B. Disassemble Master Cylinder (Refer to Figure 202).
(1) Unscrew clevis and nut from piston.
(2) Remove filler plug.
(3) Unscrew cover and remove from piston.
(4) Remove piston and spring.
(5) Remove packing and back-up ring from piston.
C. Inspect and Repair Master Cylinder.
(1) Repair is limited to installation of new parts and cleaning. Use clean hydraulic fluid as a lubricant
during reassembly of the cylinders. Replace packing and back-up ring. Filler plug must be vented
so pressure cannot build up during brake operation. If plug is not vented, drill a 1/16-inch hole,
30 degrees from vertical. Refer to Figure 202, View A-A for vent location.
D. Reassemble Master Cylinder (Refer to Figure 202).
(1) Install spring in cylinder body.
(2) Install back-up ring and packing in groove of piston.
(3) Install piston in cylinder body. Install cover over piston and screw cover into cylinder body.
(4) Install nut and clevis on piston.
(5) Install filler plug. Ensure vent hole is open.
E. Install Master Cylinder (Refer to Figure 201).
(1) Connect hydraulic hoses to brake master cylinders and install cylinders.
(2) Connect brake master cylinders to rudder pedals and connect parking brake linkage.
32-42-00 Page 205

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BACK-UP
RING
SPRING
FILLER
PLUG
COVER
BODY
CYLINDER
BODY
BACK-UP
RING
PACKING
SPRING
PISTON
VIEW A-A
05141012
A-A05141012
Brake Master Cylinder

32-42-00 Page 206

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(3) Install bleeder screw at wheel brake assembly.

(4) 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) Install seat and rudder bar shield.

7. Brake System Bleeding
A. 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.
8. Parking Brake System
A. Figure 201, Detail A may be used as a guide in removal and installation of parking brake components.
32-42-00 Page 207

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
LIGHTS
MODEL 172
MAINTENANCE MANUAL

33-Title
33-00-00 1 Aug 18/2001
33-10-00 201 Aug 18/2001
202 Aug 18/2001
33-11-00 201 Aug 18/2001
202 Aug 18/2001
33-12-00 201 Aug 18/2001
202 Aug 18/2001
33-13-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
33-14-00 201 Aug 18/2001
202 Aug 18/2001
33-15-00 201 Aug 18/2001
202 Aug 18/2001
33-40-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
33-41-00 201 Aug 18/2001
202 Aug 18/2001
33-43-00 201 Aug 18/2001
202 Aug 18/2001
33-44-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
LIGHTING - GENERAL ................................ ............................. 33-00-00 Page 1
Scope ...................................................................... 33-00-00 Page 1
Definition ..................................................................... 33-00-00 Page 1
FLOOD LIGHTING - MAINTENANCE PRACTICES .......... ......................... 33-10-00 Page 201
General ........... ......... ......... ............................ ........ 33-10-00 Page 201
Floodlight Bulb Removal/Installation ............................................ 33-10-00 Page 201
Floodlight Removal/Installation ........................................ ......... 33-10-00 Page 201
Floodlight Switch Removal/Installation ................... ....................... 33-10-00 Page 201
GLARESHIELD LIGHTING - MAINTENANCE PRACTICES ............................ 33-11 -00 Page 201
General ...................................................................... 33-11-00 Page 201
Glareshield Light Removal/Installation ........................................ 33-11-00 Page 201
Glareshield Light Power Supply Removal/Installation ................. .. .......... 33-11-00 Page 201
PEDESTAL LIGHTING - MAINTENANCE PRACTICES ......... ....................... 33-12-00 Page 201
General ............................ .3.........3.................... ........ 33-12-00 Page 201
Pedestal Light Bulb Replacement ............................................... 33-12-00 Page 201
INSTRUMENT LIGHTING - MAINTENANCE PRACTICES ............................. 33-13-00 Page 201
G eneral ...................................................................... 33-13-00 Page 201
Flight Instrument Light Bar Replacement ........................................ 33-13-00 Page 201
Engine Instrument Light Bulb Replacement ...................................... 33-13-00 Page 201
Dimming Module Removal/Installation .................................................. 33-13-00 Page 201
RADIO LIGHTING - MAINTENANCE PRACTICES .................................... 33-14-00 Page 201
General ...................................................................... 33-14-00 Page 201
Dimming Module Removal/Installation ........................... ............ 33-14-00 Page 201
Dimming Control Removal/Installation ........................................... 33-14-00 Page 201
PILOT CONTROL WHEEL LIGHTING - MAINTENANCE PRACTICES .................. 33-15-00 Page 201
G eneral ...................................................................... 33-15-00 Page 201
Map Light Removal/Installation .................................... .......... 33-15-00 Page 201
Map Light Rheostat Remove/Installation ......... ............................. 33-15-00 Page 201
NAVIGATION AND STROBE LIGHTS - MAINTENANCE PRACTICES ...... ............ 33-40-00 Page 201
Navigation Lights Removal/Installation ......................................... 33-40-00 Page 201
Strobe Lights Removal/Installation ......... ................................. 33-40-00 Page 201
VERTICAL FIN BEACON - MAINTENANCE PRACTICES ..................................... 33-41-00 Page 201
Beacon Removal/Installation ................................................ .. 33-41-00 Page 201
LANDING/TAXI LIGHTS - MAINTENANCE PRACTICES ............................... 33-43-00 Page 201
Light Removal/Installation ......... .. ......... . ................. .......... 33-43-00 Page 201
Light Adjustm ent ......... .. ..................................... . 33-43-00 Page 201
COURTESY WING LIGHTS - MAINTENANCE PRACTICES ........................... 33-44-00 Page 201
Courtesy Wing Light Removal/Installation ..................................... . .. 33-44-00 Page 201
33- CONTENTS Page 1

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LIGHTING - GENERAL
1. Scope
A. This chapter provides information on internal and external lighting.
2. 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.
33-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FLOOD LIGHTING - MAINTENANCE PRACTICES

1. General
A. Cabin flood lighting is available from three individually switched lights mounted in the overhead
console.
2. Floodlight Bulb Removal/Installation
CAUTION: Bulb may break if excessive pressure is applied when removing and installing.
NOTE: Removal/Installation is typical for all three bulbs.

A. Remove Bulb (Refer to Figure 201, Detail B).
(1) Remove bulb lens by pressing lens holder in and turning left.
(2) Remove bulb by pressing in and turning to left.
B. Install Bulb (Refer to Figure 201, Detail B).
(1) Install bulb by pressing in and turning right.
(2) Install bulb lens by pressing lens holder in and turn to right.
3. Floodlight Removal/Installation
A. Remove Floodlight (Refer to Figure 201).
NOTE: Removal/Installation is typical for all three floodlights.

(1) Remove screws securing overhead console to structure.
(2) Disconnect electrical connectors from light assembly.
(3) Remove light assembly from overhead console.
B. Install Floodlight (Refer to Figure 201).
(1) Install light assembly in overhead console.
(2) Connect electrical connector
(3) Secure overhead console to structure with screws.
4. Floodlight Switch Removal/Installation
A. Remove Floodlight Switch (Refer to Figure 201).
(1) Remove screws securing overhead console to structure.
(2) Disconnect electrical connectors from switch.
(3) Remove switch from overhead console.
B. Install Floodlight Switch (Refer to Figure 201).
(1) Install switch in overhead console.
(2) Connect electrical connector
(3) Secure overhead console to structure with screws.
33-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LENS LIGHT
HOLDER BULB
DETAIL B
LIGHT
SWITCH
LIGHT
ASSEMBLY
OVERHEAD CONSOLE
DETAIL A
Flood Lighting Installation
33-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
GLARESHIELD LIGHTING - MAINTENANCE PRACTICES
1. General
A. A single white neon tube installed under the glareshield provides overall lighting for the instrument
panel. A glareshield dimming control is mounted below and to the left of the throttle.
2. 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.
3. 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 panel.
B. Install Glareshield Light Power Supply (Refer to Figure 201).
(1) Secure power supply to back of instrument panel with screws.
(2) Connect electrical connector to power supply.
33-11-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
GLARESHIELD LIGHT
VIEW A-A
GLARESHIELD DIMMING CONTROL
Glareshield Lighting Installation

33-11-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PEDESTAL LIGHTING - MAINTENANCE PRACTICES
1. General
A. A single bulb-type light is installed on the pedestal. This light provides illumination of the fuel selector.
2. 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.
33-12-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
0585C1040
A05181012
Pedestal Lighting Installation

33-12-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INSTRUMENT LIGHTING - MAINTENANCE PRACTICES
1. General
A. Flight instruments are individually lighted by a replaceable light bar installed at the top of the
instrument. Engine instruments are individually lighted by replaceable light bulbs. Both flight and
engine instruments are connected to a dimming module and a single dimming control.
2. Flight Instrument Light Bar Replacement
A. Replace Flight Instrument Light Bar (Refer to Figure 201).
(1) Remove flight instrument.
(2) Remove screws securing light bar to flight instrument.
(3) Replace light bar and secure with screws.
(4) Install flight instrument.
3. Engine Instrument Light Bulb Replacement
A. Replace Engine Instrument Light Bulbs (Refer to Figure 201).
(1) Remove engine instrument.
(2) Remove screws securing light cover plate.to bottom of instrument.
(3) Replace light bulbs.
(4) Secure light coverplate to bottom of instrument with screws.
(5) Install engine instrument.
4. Dimming Module Removal/Installation
A. Remove Dimming Module (Refer to Figure 201).
(1) Disconnect dimming module electrical connector.
(2) Remove screws securing dimming module to structure.
(3) Remove dimming module.
B. Install Dimming Module (Refer to Figure 201).
(1) Secure dimming module to structure with screws.
(2) Connect dimming module electrical connector.
33-13-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
TYPICAL FLIGHT INSTRUMENT LIGHTING
REPLACEABLE
LIGHT BULB
LEMENTS
VIEW A-A
DETAIL C
TYPICAL ENGINE
INSTRUMENT LIGHTING
AA051 8C1037
Instrument Lighting Installation

33-13-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INSTRUMENT LIGHTS
DIMMER
ALT
DETAIL D
VOLTAGE REGULATOR
DIMMING MODULE
ELECTRICAL
CONNECTOR
DETAIL E
Instrument Lighting Installation

33-13-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
RADIO LIGHTING - MAINTENANCE PRACTICES

1. General
A. 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.
2. Dimming Module Removal/Installation

A. For Dimming Module Removal/Installation, refer to Instrument Lighting - Maintenance Practices,
located in this chapter.
3. Dimmer Control Removal/Installation
A. Remove Dimmer Control (Refer to Figure 201).
(1) Remove nut securing dimmer control to back of instrument panel.
(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 panel and secure with nut.
33-14-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
B
R PUSH PULL
B ALT
RADIO LIGHT DIMMER

DETAIL
Radio Lighting Installation
33-14-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PILOT CONTROL WHEEL LIGHTING - MAINTENANCE PRACTICES
1. General
A. A map light is installed on the lower surface of the pilot's control wheel.
2. 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.
3. Map Light Rheostat Removal/Installation

A. 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.
B. Install Map Light Rheostat (Refer to Figure 201).
(1) Connect electrical wires to rheostat and place in control wheel.
(2) Install jamnut and thumbwheel.
33-15-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
RHEOSTAT
JAMNUT
SETSCREW
THUMBWHEEL
2618X1 153
Control Wheel Lighting Installation

33-15-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NAVIGATION AND STROBE LIGHTS - MAINTENANCE PRACTICES

A. 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.
2. Navigation Lights Removal/Installation
A. Remove Wingtip Navigation Lights (Refer to Figure 201).
NOTE: Removal is typical for both the left and right bulbs.
(1) Ensure electrical power to airplane is OFF

(2) Remove screws securing lens retainer to wingtip.
(3) Remove lens from navigation portion of assembly.
(4) 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 ).
(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.
3. Strobe Lights Removal/Installation
A. Remove Strobe Light Assembly (Refer to Figure 201).
NOTE: Removal/installation is typical for both the FR003 right strobe light and FL005 left strobe
light.
(2) Remove screws securing lens retainer to wingtip.
(3) Remove lens from in front of flash tube assembly.
(4) 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.
33-40-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
B A
WING TIP
CAP
ELECTRICAL LEADS
WASHER
INSULATED SCREW
SPRING
LENS DETAIL A
RETAINER
LENS
GASKET WING TIP
RECEPTACLE
POWER
MOUNT
SCREW
ELECTRICAL
DETAIL C LEADS DETAIL B
A05181028
C05181029
Navigation and Anti-Collision Strobe Light Installation

33-40-00 Page 202

Aug 18/2001
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 contact 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: Removal and installation is typical for both the UL001 left and UR001 right power supply.

(2) Remove wingtip.
(3) Disconnect electrical connectors from both ends of power supply.
(4) Remove ground wires as required.
(5) Remove screws securing power supply to wing, and remove power supply from wing.
D. 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.
33-40-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
VERTICAL FIN BEACON - MAINTENANCE PRACTICES

A. 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. The flashing beacon is activated by placing the circuit breaker/switch to the BCN position. This position
supplies power to the light, which uses internal circuitry to flash on and off at approximately 20 cycles
per minute.
2. Beacon Removal/Installation
A. 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.
B. 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.
33-41-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LENS ASSEMBLY
CLAMP RING ASSEMBLY SCREW
LAMP ASSEMBLY
SCREW
BASE ASSEMBLY
PLATE ASSEMBLY
SCREW
CAP ASSEMBLY
4
Flashing Beacon Light Installation
33-41-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LANDING/TAXI LIGHTS - MAINTENANCE PRACTICES

A. The airplane is equipped with both landing and taxi lights mounted on the left wing leading edge.
(1) The taxi light is controlled by the circuit breaker/switch.
(2) The landing light in controlled by the circuit breaker/switch.
2. Light Removal/Installation
NOTE: Removal and installation is typical for both the landing and taxi lights.
A. Remove Light (Refer to Figure 201).
(1) Remove screws securing lens assembly to leading edge of wing.
(2) Remove screws and brackets which hold lights in position.
(3) Disconnect electrical connectors from backside of lights.
B. Install Light (Refer to Figure 201).
(1) Reconnect electrical connectors to taxi and landing lights.
(2) Secure lights to assembly using brackets and screws.
(3) Reinstall lens assembly to leading edge of wing.
3. Light Adjustment
A. If lights are aimed too high or too low to provide effective coverage during operation, washers may be
added between spacers and plate (aft of the actual light) to reorient the beam. Proper aim points are
as follows:
(1) Park airplane on a flat, level surface in front of a light reflecting object (hangar door, etc...).
Ensure waterline of airplane is level and wings are level.
(2) Position airplane so that distance from light reflecting surface to rivet line on bottom of front spar
is 3.0 feet.
(3) Turn lights on and measure distance from the ground to the center of the beam (which will be
shining on the light reflecting surface.
(4) Distance shall be as noted:
(a) Landing Light = 74.41 inches from the ground.
(b) Taxi Light = 73.29 inches from the ground.
(5) If center of beam does not fall within guidelines, add washers behind plates to obtain correct
measurement.
33-43-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A
SPACER SPACER
LANDING
LIGHT
SPACER
BRACKET
SCREW BRACKET
BRACKET
NUTPLATE
LIGHT
BRACKET
LENS SCREW
ASSEMBLY
DETAIL A
051 T1007
A05283001
Landing and Taxi Light Installation

33-43-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
COURTESY WING LIGHTS - MAINTENANCE PRACTICES

A. 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.
2. Courtesy Wing Light Removal/Installation
A. 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.
B. 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.
33-44-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TINNERMAN
GROMMET SCREW
TINNERMAN
NUT
LAMP
TINNERMAN
NUT LENS
COVER
NOTE: RIGHT WING SHOWN,

TINNERMAN LEFT WING TYPICAL
SCREW
DETAIL A
051 T1 007
A05281001
Courtesy Wing Light Installation

33-44-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
NAV IGATION
MODEL 172
MAINTENANCE MANUAL
*i^~ ~LIST OF EFFECTIVE PAGES

34-Title
34-00-00 1 Aug 18/2001
34-11-00 201 Feb 15/2002
202 Feb 15/2002
203 Feb 15/2002
204 Feb 15/2002
205 Feb 15/2002
206 Feb 15/2002
207 Feb 15/2002
34-12-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
34-20-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
34-21-00 201 Aug 18/2001
202 Aug 18/2001
34-50-00 201 Aug 18/2001
202 Aug 18/2001
34-51-00 201 Aug 18/2001
202 Aug 18/2001
34-52-00 201 Aug 18/2001
202 Aug 18/2001
34-53-00 201 Aug 18/2001
202 Aug 18/2001

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

|~~~~~~~~~~~ I
MODEL 172
MAINTENANCE MANUAL

I
MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL
CONTENTS
NAVIGATION - GENERAL ........................................................ 34-00-00 Page 1
Scope ...................................................................... 34-00-00 Page 1
D efinition ................................................................... 34-00-00 Page 1
PITOT/STATIC SYSTEM - MAINTENANCE PRACTICES ............................ 34-11-00 Page 201
Pitot Tube Removal/Installation ............................................... 34-11-00 Page 201
Pitot Tube Heater Insulation Replacement ..................................... 34-11-00 Page 201
Vertical Speed Indicator Removal/Installation .................................. 34-11-00 Page 205
Alternate Static Source Valve Removal and Installation ......................... 34-11-00 Page 205
Blind Encoder Removal/Installation ........................................... 34-11-00 Page 205
Altimeter Removal/Installation ................................................ 34-11-00 Page 206
Airspeed Indicator Removal/Installation ................... .................... 34-11-00 Page 206
Pitot System Leak Test ...................................................... 34-11-00 Page 206
Static System Leak Test ..................................................... 34-11-00 Page 206
Blow ing O ut Lines ........................................................... 34-11-00 Page 207
OUTSIDE AIR TEMPERATURE INDICATOR - MAINTENANCE PRACTICES.......... 34-12-00 Page 201
OAT Probe Removal/Installation .............................................. 34-12-00 Page 201
Clock/OAT Indicator Removal/Installation ...................................... 34-12-00 Page 201
ATTITUDE AND DIRECTION - MAINTENANCE PRACTICES ........................ 34-20-00 Page 201
General .................................................................... 34-20-00 Page 201
Precautions ................................................................ 34-20-00 Page 201
Horizon Gyro General Operation Notes ................... .................... 34-20-00 Page 201
Attitude Indicator Removal/Installation ................... ..................... 34-20-00 Page 201
Directional Gyro Removal/Installation ................... ...................... 34-20-00 Page 203
Directional Gyro Operational Test ............................................. 34-20-00 Page 203
Turn Coordinator Removal/Installation ......................................... 34-20-00 Page 203
COMPASS INSTALLATION - MAINTENANCE PRACTICES .......................... 34-21-00 Page 201
General .................................................................... 34-21-00 Page 201
Compass Removal/Installation .............................................. 34-21-00 Page 201
NAV/COM - MAINTENANCE PRACTICES ................... ...................... 34-50-00 Page 201
General .................................................................... 34-50-00 Page 201
Nav Antenna Removal/Installation ............................................ 34-50-00 Page 201
Nav Antenna Coupler Removal/Installation .................................... 34-50-00 Page 201
Nav Indicator Removal/Installation ................... ......................... 34-50-00 Page 201
GPS - MAINTENANCE PRACTICES ............................................... 34-51-00 Page 201
G eneral .................................................................... 34-51-00 Page 201
GPS Removal/Installation .................................................... 34-51-00 Page 201
GPS Antenna Removal/Installation ........................................... 34-51-00 Page 201
ADF - MAINTENANCE PRACTICES ............................................... 34-52-00 Page 201
General .................................................................... 34-52-00 Page 201
ADF Removal/Installation .................................................... 34-52-00 Page 201
ADF Antenna Removal/Installation ............................................ 34-52-00 Page 201
TRANSPONDER - MAINTENANCE PRACTICES ................................... 34-53-00 Page 201
General .................................................................... 34-53-00 Page 201
Transponder Removal/Installation ............................................. 34-53-00 Page 201
Transponder Antenna Removal/Installation .................................... 34-53-00 Page 201
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
NAVIGATION - GENERAL
1. Scope
A. This chapter describes the navigation systems, units, and components which provide airplane
navigational information. Included are pitot/static temperature, gyros, compass, VOR and indicators.
For King KAP140 Autopilot information refer to Chapter 22.
2. Definition
the table of Contents will further assist in locating a particular subject. A brief definition of the sections
(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, compass, 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.
34-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PITOT/STATIC SYSTEM - MAINTENANCE PRACTICES

A. The pitot system conveys ram air pressure to the airspeed indicator. The static system vents 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 panel and powered by the electrical system. An alternate static source valve is
installed on the instrument panel for use when the external static source is malfunctioning. Refer
to Figure 201 for pitot/static system schematic.
B. Proper maintenance of pitot and static system is essential for proper operation of altimeter, vertical
speed and airspeed indicators. Leaks, moisture and obstructions will affect readings of all three
instruments. Under instrument flight conditions, these instrument errors could be hazardous.
Cleanliness and security are the principal rules for system maintenance. The pitot tube and static
ports must be kept clean and unobstructed.
(1) The pitot/static system shall be tested using time limits set forth in Chapter 5, Inspection Time
Limits, or anytime components or lines within the system are opened. Refer to FAR 91.411.
2. Pitot Tube Removal/Installation
A. Remove Pitot Tube (Refer to Figure 202).
(1) Remove screws securing pitot tube to wing and remove pitot tube.
(2) Disconnect ram air tube from pitot.
(3) Disconnect electrical connectors from pitot heater and from pitot heat ground.
B. Install Pitot Tube (Refer to Figure 202).
CAUTION: DO NOT BLOW THROUGH PITOT LINES TOWARD INSTRUMENT AS DAMAGE
WILL OCCUR TO INSTRUMENTS.
CAUTION: THE PITOT TUBE ASSEMBLY SHALL BE KEPT CLEAN AND ALL SYSTEM
COMPONENTS ARE TO BE FREE OF OBSTRUCTION AND LEAKS FOR PROPER
OPERATION.
(1) Connect ram air tube to pitot.
(2) Connect electrical connectors to pitot heater and to pitot heat ground.
(3) Check system for leaks. Refer to step 10, Pitot System Leak Test.
3. Pitot Tube Heater Insulation Replacement
A. Remove Pitot Tube (Refer to Figure 202).
(1) Remove electrical power from airplane. Position PITOT HEAT/OFF switch to OFF.
(2) Access pitot tube assembly in left wing.
(3) Remove screws securing pitot assembly to wing structure.
CAUTION: WHEN REMOVING FROM THE WING, DO NOT DISCONNECT PITOT RAM
AIR TUBE FROM THE PITOT TUBE ASSEMBLY.
(4) Remove pitot tube assembly.
B. Remove and discard any existing nylon spiral wrap insulation (Refer to Figure 202).
C. Cut new H990000 Nylon Spiral Wrap into 2 pieces: 4.0 inches and 8.0 inches.
D. H990000 Nylon Spiral Wrap Installation:
34-11-00 Page 201

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B227
A
HEATED PITOT TUBE AIRSPEED ALTIMETER

INDICATOR
2180 0 9
lo
VERTICAL SPEED _
INDICATOR //,s
ALTERNATE STATIC AIR SOURCE s' /

(VENTED TO COCKPIT)
STATIC
SUMP
ELECTRICAL
CONNECTOR
0-~~~ ~~~ALTERNATE STATIC AIR SOURCE KNOB

0OA'~~~ ~(MOUNTED ON INSTRUMENT PANEL)
LEGEND
\///// PITOT
STATIC SOURCE STATIC

(VENTED TO OUTSIDE)
0595T1001
Pitot/Static System Schematic

34-11-00 Page 202

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
PITOT LINE
(TO AIRSPEED
INDICATOR)
CONNECT
MAST BODY
B
HEATER ELEMENT
DETAIL A
SCREW
ALTERNATE AIR CONTROL VALVE CONTROL KNOB
NUT INSTRUMENT PANEL

INSERT
TEE ^i^^ .^ (TYPICAL)
STATIC LINES
(TO STATIC
INSTRUMENTS)
MOUNTING TRAY
KNURLED KNOB -- INSERT
STATIC SUMP
ELECTRICAL
CONNECTOR STATIC PORT
ELBOW
BLIND ENCODER
0510T1007
DETAIL A0518R1046
B0518T1040
Pitot/Static System Installation

34-11-00 Page 203

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B3262
PITOT TUBE
HEATER ASSEMBLY
WIRE LEADS
4 INCH PIECE OF \ /
H990000 NYLON \ RAM AIR
SPIRAL WRAP TUBE
8 INCH PIECE IF
H990000 NYLON
SPIRAL WRAP
0.10 INCH
CLEARANCE
PITOT TUBE DETAIL C

ASSEMBLY
C0518R 1070
Pitot/Static System Installation

34-11-00 Page 204

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
CAUTION: PITOT TUBE HEATER ASSEMBLY WIRE LEADS OPERATE AT HIGH

TEMPERATURES. THE PITOT HEATER ASSEMBLY WIRE LEADS MUST
NOT CONTACT THE PITOT RAM AIR TUBING, WIRE BUNDLES, OR ANY HEAT
SENSITIVE COMPONENTS.
(1) Starting 0.10 inch from the pitot ram air tube assembly heater, work the 4.0 inch piece of spiral
wrap around the pitot air tube. Trim as required.
(2) Work the 8.0 inch piece of spiral wrap around the pitot ram air tube. Trim as required.
E. Install the pitot tube assembly.
CAUTION: DO NOT BLOW THROUGH PITOT LINES TOWARD INSTRUMENT OR DAMAGE
WILL OCCUR TO INSTRUMENTS.
CAUTION: THE PITOT TUBE ASSEMBLY SHALL BE KEPT CLEAN AND ALL SYSTEM
COMPONENTS ARE TO BE FREE OF OBSTRUCTION AND LEAKS FOR PROPER
OPERATION.
F Install access cover plate.
G. Restore electrical power to airplane as required.
4. Vertical Speed Indicator Removal/Installation

A. Remove Vertical Speed Indicator (VSI).
(1) Gain access to the back of the VSI by removing screws securing flight instrument subpanel to
instrument panel.
(2) Disconnect static tube and electrical connector from VSI.
(3) Remove screws securing VSI to flight instrument subpanel.
(4) Remove VSI from airplane.
B. Install Vertical Speed Indicator (VSI).
(1) Position VSI on flight instrument subpanel and secure with screws.
(2) Connect static tube and electrical connector to VSI.
(3) Secure flight instrument subpanel to instrument panel with screws.
(4) Check system for leaks. Refer to step 10, Static System Leak Test.
5. Alternate Static Source Valve Removal and Installation
A. Remove Alternate Static Source Valve (Refer to Figure 202).
(1) Reach behind stationary control panel and loosen nuts securing two static tubes to alternate
static source valve. Disconnect static tubes from alternate static source valve.
(2) Remove screws securing alternate static source valve to stationary control panel.
(3) Remove alternate static source valve from airplane.
B. Install Alternate Static Source Valve (Refer to Figure 202).
(1) Position alternate static source valve behind stationary control panel and secure static tubes
using nuts.
(2) Secure alternate static source valve to stationary control panel with screws.
6. Blind Encoder Removal/Installation
A. Remove Blind Encoder located under dash on copilot side (Refer to Figure 202).
(1) Loosen knurled knob and remove encoder from mount.
(2) Disconnect static tube and electrical connector and remove encoder from airplane.
B. Install Blind Encoder.
(1) Connect static tube and electrical connector to encoder.
(2) Place encoder on mount and secure with knurled knob.
34-11-00 Page 205

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
7. Altimeter Removal/Installation
A. Remove Altimeter.
(1) Gain access to back of altimeter by removing screws securing flight instrument subpanel to
instrument panel.
(2) Disconnect static tube and electrical connector from altimeter.
(3) Remove screws securing altimeter to flight instrument subpanel.
(4) Remove altimeter from airplane.
B. Install Altimeter.
(1) Position altimeter on flight instrument subpanel and secure with screws.
(2) Connect static tube and electrical connector to altimeter.
(4) Check system for leaks. Refer to 10, Static System Leak Test.
8. Airspeed Indicator Removal/Installation

A. Remove Airspeed Indicator.
(1) Gain access to back of airspeed indicator by removing screws securing flight instrument
subpanel to instrument panel.
(2) Disconnect static tube and electrical connector from airspeed indicator.
(3) Remove screws securing airspeed indicator to flight instrument subpanel.
(4) Remove airspeed indicator from airplane.
B. Install Airspeed Indicator.
(1) Position airspeed indicator on flight instrument subpanel and secure with screws.
(2) Connect static tube and electrical connector to airspeed indicator.
9. Pitot System Leak Test

A. Testing Procedures.
(1) Place a piece of tape over small hole in lower aft end of pitot tube.
(2) Fasten a piece of rubber or plastic tubing over pitot tube and close opposite end of tube.
(3) Slowly roll up tube until airspeed indicator registers in cruise range.
(4) Secure tube to prevent air pressure from changing and recheck airspeed in one minute. Any
leakage will have reduced the pressure in system, resulting in a lower airspeed indication.
NOTE: If test reveals a leak in system, all connections, hoses and fittings should be checked
and tightened (as required) before performing another test.
(5) If no leaks are indicated, slowly unroll tubing, allowing pressure in instrument to slowly return to
ambient.
10. Static System Leak Test

A. Testing Procedures.
(1) Ensure static system is free from entrapped moisture and restrictions.
(2) Ensure no alterations or deformations of airframe surface have been made which would affect the
relationship between air pressure in static pressure system and true ambient static air pressure
for any flight configuration.
(3) Close static pressure alternate source control.
(4) Attach a source of suction to static pressure source opening.
(5) Slowly apply suction until altimeter indicates a 1,000 foot increase in altitude.
(6) Cut off suction source to maintain a "closed" system for one minute.
34-11-00 Page 206

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
(7) If altimeter loss has not exceeded 100 feet after one minute, the system checks good and suction
may be slowly released until system returns to ambient. If altimeter loss exceeds 100 feet,
tighten all connections and repeat leak test. If rate still exceeds maximum allowable, perform
the following:
(a) Disconnect static pressure lines from airspeed indicator and vertical speed indicator. Use
suitable fittings to connect lines together so altimeter is the only instrument still connected
into static pressure system.
(b) Repeat leakage test to check whether static pressure system or the bypassed instruments
are cause of leakage. If instruments are at fault, they must be repaired by an approved
repair station or replaced. If static pressure system is at fault, proceed as follows:
CAUTION: Do not apply positive pressure with airspeed indicator or vertical speed
indicator connected to static pressure system.
1 Attach a source of positive pressure to static source opening.
2 Slowly apply positive pressure until altimeter indicates a 500 foot decrease in altitude
and maintain this altimeter indication.
3 Coat line connections and static source flange with solution of mild soap and water,
watching for bubble to locate leaks.
4 Tighten leaking connections. Repair or replace parts found defective.
5 Reconnect airspeed and vertical speed indicators into static pressure system and
repeat steps 10.A.(3) thru 10.A.(7).
11. Blowing Out Lines
CAUTION: DO NOT BLOW THROUGH PITOT OR STATIC LINES TOWARD INSTRUMENT AS
DAMAGE WILL OCCUR TO INSTRUMENT.
A. Pitot Lines.
(1) Although pitot system is designed to drain down to pitot tube opening, condensation may collect
at other points in the system and produce a partial obstruction. To clear line, disconnect at
airspeed indicator. Using low pressure air, blow from indicator end of line toward pitot tube.
B. Static lines.
(1) Static lines must be kept clear and connections tight. All models have a static source sump which
collects moisture and keeps system clear. If necessary, disconnect static line at first instrument
to which it is connected, then blow line clear using low-pressure air.
34-11-00 Page 207

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
OUTSIDE AIR TEMPERATURE INDICATOR - MAINTENANCE PRACTICES

A. 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 panel.
(2) The cockpit-mounted indicator is located in the upper left portion of the instrument panel. 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: 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.
B. 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.
2. 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 panels 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 -
(2) Install terminal pins into electrical connector.
(3) Reconnect electrical connector to backside of OAT/Clock indicator.
(4) Reroute probe wiring in cabin area, and insert probe and ground lug through roof skin.
(5) 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.
(6) Reinstall interior panels and overhead console. Refer to Chapter 25, Interior Upholstery -
Maintenance Practices, Figure 201.
3. Clock/OAT Indicator Removal/Installation

A. Remove Indicator (Refer to Figure 201).
(1) Remove fuse F4 from the power junction box.
(2) Remove screws securing instrument sub panel to airplane structure.
(3) Withdraw sub panel aft to gain access to electrical connector.
(4) Remove electrical connector from OAT indicator.
(5) Remove screws securing OAT indicator to sub panel.
B. Install Indicator (Refer to Figure 201).
(1) Secure OAT indicator to instrument sub panel using screws.
(2) Connect electrical connector to backside of OAT Indicator.
(3) Reinstall instrument sub panel to airplane structure.
(4) Reinstall fuse F4 to power junction box.
34-12-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
HEX
NUT
WITH O-RING
INSERT
GROUND CABIN
LUG UPPER
SKIN
DETAIL B
ELECTRICAL
OAT/CLOCK CONNECTOR
INDICATOR
INSTRUMENT
PANEL
SCREW
0510T1007
A0518R1067
Outside Air Temperature Installation

34-12-00 Page 202

Aug 18/2001
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.
34-12-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ATTITUDE AND DIRECTION - MAINTENANCE PRACTICES
1. General
A. Three gyroscopic instruments that indicate attitude and direction, are mounted in the instrument panel.
Included are the attitude indicator, the directional gyro and the turn coordinator.
2. Precautions
A. Gryoscopic instruments are very sensitive. They have precision bearings on the gyroscope rotor,
pivots, and the yoke shaft. Careless handling while the instrument is out of the aircraft, and dirt and
other contaminates can damage the bearings. Special precautions should be followed when handling,
installing, removing, or shipping any gyroscopic instruments.
(1) During removal of instruments, place cushioning material between the instruments and the
control column.
(2) Do not vibrate or shake panel or instruments.
(3) Do not drop, shake, place on hard surface, or bump gyroscope against any other object.
(4) Do not remove any wires, labels, tie straps, or any parts original to the gyro.
(5) Visually check the gyro for any external damage. There should be no scratches, dents, or dings
on any part of the gyro. Do not install any gyros that have scratches, dents, or dings.
(6) Any instruments that are to be shipped, should have all female ports plugged with removable
port plugs, and all male receptacles capped with removable plastic caps.
(7) Pack all gyros in styrofoam or other cushioning material for storage and transportation. When
shipping gyroscope pack in original box if possible.
(8) Shipping plugs should be kept in the air ports except when the instrument is installed in an aircraft
or being tested.
3. Horizon Gyro General Operation Notes

A. The horizon gyro (attitude) is an instrument that requires air flow to move the gyro rotor for normal
operation. The airflow is provided by the vacuum system. Any abnormalities (vacuum system or
other) that effect the function and movement of the gyro rotor, can effect indicating accuracy and
performance.
B. The horizon gyro requires approximately 4.5 to 5.5 inches Hg to adequately spin the rotor. The gyro
reaches rated performance in a minimum of 3 minutes of rotor spin time with rated vacuum applied.
C. The gyro rotor may continue to spin for approximately 15 minutes after air to the system is removed.
While the rotor is spinning down, it will normally start to show a change in the roll and/or pitch indication,
and when completely stopped will remain in a roll and/or pitch indication until the system is started
again.
D. If a gyro has been shut down and started again before the rotor has been allowed to stop, it requires
considerably more time to erect to the correct pitch and roll indication.
4. Attitude Indicator Removal/Installation
A. Remove Attitude Indicator (Refer to Figure 201).
(1) Gain access to the back of the attitude indicator by removing screws securing flight instrument
sub-panel to instrument panel.
(2) Disconnect vacuum hoses and electrical connector from attitude indicator.
(3) Remove screws securing attitude indicator to flight instrument sub-panel.
(4) Remove attitude indicator.
B. Install Attitude Indicator (Refer to Figure 201).
(1) Position attitude indicator on flight instrument sub-panel and secure with screws.
(2) Connect vacuum hoses and electrical connector to attitude indicator.
(3) Secure flight instrument sub-panel to instrument panel with screws.
34-20-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
INSTRUMENT
PANEL
SCREW
REGULATOR
VALVE (WITH
VACUUM
GYRO (ELECTRIC)
DIRECTIONAL
FIREWALL
GYRO
DETAIL A
A0518T1052
Attitude and Direction Instruments

34-20-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
5. Directional Gyro Removal/Installation

A. Remove Directional Gyro (Refer to Figure 201).
(1) Gain access to the back of the directional gyro by removing screws securing flight instrument
CAUTION: Be sure to place cushioning material between the directional gyro and the
control column before removal. Placing the sub-panel on the control column
without any cushioning protection can damage the directional gyro and/or the
other instruments in the sub-panel. Take extra care when removing sub-panel
so as not to scrape or bump the gyro.
(2) Disconnect vacuum hoses and electrical connector from directional gyro.
(3) Remove screws securing directional gyro to flight instrument sub-panel.
(4) Remove directional gyro.
B. Install Directional Gyro (Refer to Figure 201).
(1) Position directional gyro on flight instrument sub-panel and secure with screws.
(2) Connect vacuum hoses and electrical connector to directional gyro.
6. Directional Gyro Operational Test

A. Test Directional Gyro.
NOTE: Acceptable limits for gyro drift in flight is 4° in either direction from a heading, during a ten
minute period.
(1) Start airplane and verify proper operation of the vacuum system. Suction gauge should read 4.5
to 5.5 in. Hg.
(2) Align airplane into the wind.
(3) Allow directional gyro to stabilize for at least one minute.
(4) Set directional gyro to the north.
(5) Verify that dial or pointer drift does not exceed 4 ° within a 10 minute period.
(6) If dial or pointer drift is unacceptable, repair system and/or replace gyro.
7. Turn Coordinator Removal/Installation
A. Remove Turn Coordinator (Refer to Figure 201).
(1) Gain access to the back of the turn coordinator by removing screws securing flight instrument
(2) Disconnect electrical connector from turn coordinator.
(3) Remove screws securing turn coordinator to flight instrument sub-panel.
(4) Remove turn coordinator.
B. Install Turn Coordinator (Refer to Figure 201).
(1) Position turn coordinator on flight instrument sub-panel and secure with screws.
(2) Connect electrical connector to turn coordinator.
34-20-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
COMPASS INSTALLATION - MAINTENANCE PRACTICES

1. General
A. A lighted, magnetic compass is installed on top of the glareshield at the airplane centerline.
2. Compass Removal/Installation
A. Remove Compass (Refer to Figure 201).
(1) Remove screws securing compass to compass base.
(2) Disconnect electrical connector.
B. Install Compass (Refer to Figure 201).
(1) Connect electrical connector.
(2) Secure compass to compass base with screws.
(3) Check compass accuracy on compass rose.
34-21-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
COMPASS
BEZEL
COMPASS
BASE
DETAIL A
0510T1007
A0514T1007
Compass Installation
34-21-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
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.
2. 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.
3. 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 Figurre 201).
(1) Place nav antenna coupler on fuselage and secure with screws.
(2) Connect antenna coax connectors to nav antenna coupler.
4. Nav Indicator Removal/Installation
A. Remove Nav Indicator.
(1) Remove screws securing right instrument sub-panel to instrument panel.
(2) Disconnect electrical connector from nav indicator.
(3) Remove screws secureing nav indicator to right instrument sup-panel.
(4) Remove nav indicator.
B. Install Nav Indicator.
(1) Place nav indicator on right instrument sub-panel and secure with screws.
(2) Install electrical conector to nav indicator.
(3) Secure right instrument sub-panel to instrument panel with screws.
34-50-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
NAV
B ANTENNA
FIN CAP ASSEMBLY
ANTENNA BASE
COAX CONNECTOR
DETAIL A
NAV ANTENNA
COUPLER
SCREW
Nav Antenna Installation

34-50-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
GPS - MAINTENANCE PRACTICES
1. General
A. The KLN89B orthe optional KLN94GPS is installed in the avionics panel radio rack. The GPS antenna
is mounted above the cabin, in the general proximity of the comm antennas.
2. 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.
3. 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 connecter to GPS antenna.
(3) Secure GPS antenna to fuselage skin with screws.
34-51-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
GPS ANTENNA
GPS SCREW
GASKET
DETAIL B
COAX
CONNECTOR
0510T1007
A0518T1003
GPS Installation
34-51-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ADF - MAINTENANCE PRACTICES
1. General
A. The KR87 ADF receiver is installed in the avionics panel radio rack. The ADF antenna is installed on
bottom of the cabin, along the centerline of the airplane.
2. ADF Removal/Installation
A. Remove ADF (Refer to Figure 201).
(2) Pull ADF from radio rack.
B. Install ADF (Refer to Figure 201).
(1) Place ADF in radio rack and slide forward, engaging fixed electrical plug.
3. ADF Antenna Removal/Installation
A. Remove ADF Antenna (Refer to Figure 201 ).
(1) Remove screws securing ADF antenna to fuselage skin.
(2) Disconnect antenna connector from ADF antenna.
(3) Remove antenna and gasket.
B. Install ADF Antenna (Refer to Figure 201).
(1) Connect antenna connector to ADF antenna.
(2) Secure ADF antenna to fuselage skin with screws.
34-52-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
U.
INDICATOR
SKIN
DOUBLER
LOCKING SCREW
DETAIL A
ADF ANTENNA
ANTENNA
SCREW CONNECTOR
DETAIL B
ADF Installation
34-52-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TRANSPONDER - MAINTENANCE PRACTICES
1. General
A. The KT76C transponder is installed in the avionics panel radio rack. The transponder antenna is
installed on the bottom of the cabin, just forward of the baggage area.
2. Transponder Removal/Installation
A. Remove Transponder (Refer to Figure 201).
(2) Pull transponder from radio rack.
B. Install Transponder (Refer to Figure 201).
(1) Place transponder in radio rack and slide forward, engaging fixed electrical plug.
3. Transponder Antenna Removal/Installation

A. Remove Transponder Antenna (Refer to Figure 201).
(1) Remove the aft cabin panel, gaining access to the tailcone and transponder antenna.
(2) Remove nuts and washers securing transponder antenna to tailcone.
(3) From outside the airplane, remove coax connector which will allow the antenna to fall away from
the airplane.
B. Install Transponder Antenna (Refer to Figure 201).
(1) From outside the airplane, connect coax connector to the transponder antenna.
(2) From the tailcone, insert antenna studs through mounting holes and secure with nuts and
washers.
34-53-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
COAX
DOUBLER
SCREW
DETAIL
Transponder Installation
34-53-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
VACUUM
MODEL 172
MAINTENANCE MANUAL

37-Title
37-00-00 1 Aug 18/2001
37-10-00 101 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
VACUUM - GENERAL ............................................... ............... 37-00-00 Page 1
S cope ............................ ............................... ......... 37-00-00 Page 1
Definition ..................................................................... 37-00-00 Page 1
VACUUM SYSTEM TROUBLESHOOTING ......... ........ ............... ....... 37-10-00 Page 101
Troubleshooting ......... ...................................................... 37-10-00 Page 101
VACUUM SYSTEM - MAINTENANCE PRACTICES ......... .......................... 37-10-00 Page 201
Vacuum Pump Removal/Installation .................. ........................... 37-10-00 Page 201
Regulator Valve Filter Removal/Installation ............ ........ ................. 37-10-00 Page 203
Gyro Filter Removal/Installation ............................................... 37-10-00 Page 203
Vacuum Gauge Removal/Installation ........................... ................ 37-10-00 Page 203
Regulator Valve Filter Removal/Installation ...................................... 37-10-00 Page 203
Gyro Filter Removal/Installation ................................................ 37-10-00 Page 203
Vacuum Gauge Removal/Installation .......................................... 37-10-00 Page 205
Vacuum Pressure Adjustment/Test .............................................. 37-10-00 Page 205
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
VACUUM - GENERAL
1. Scope
A. This chapter describes those units and components used to provide vacuum necessary to operate
the artificial horizon and directional gyros.
2. Definition
A. This chapter consists of a single section which describes those components used to distribute and
indicate vacuum air.
37-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
VACUUM - TROUBLESHOOTING
1. Troubleshooting

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.
LOW PRESSURE. Vacuum regulator leaking. Replace safety valve.
Vacuum pump failure. Substitute known good pump and
check pump pressure. Replace
vacuum pump as required.
37-10-00 Page 101

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
VACUUM SYSTEM - MAINTENANCE PRACTICES

A. The vacuum system consists a filter, vacuum gauge, vacuum instruments, regulator valve, vacuum
manifold, two low vacuum annunciator switches, two engine driven vacuum pumps and associated
plumbing.
B. Vacuum air originates in the cabin and is pulled through the system by the engine driven vacuum
pumps. This air is filtered at the cabin inlet source by the gyro filter before passing through the vacuum
gauge and gyro instruments. The pressure of the vacuum is regulated by the regulator valve, located
on the aft side of the firewall. After passing through the firewall, vacuum air is drawn through the
vacuum manifold, past the low vacuum annunciator switches and into the pumps themselves. After
leaving the pumps, vacuum air is expelled into the engine compartment.
C. Vacuum pressure is measured by the cockpit- mounted vacuum gauge and by the engine
compartment-mounted low vacuum pressure annunciator switches.
(1) The cockpit-mounted gauge provides direct reading of system vacuum in In. Hg.
(2) The engine compartment-mounted switches are tied into the panel annunciator warning system.
If annunciator switches sense a vacuum below 3.0 In. Hg., the VAC annunciator illuminates in
the cockpit. If the left vacuum switch activates, the message will read L VAC. If the right vacuum
switch activates, the message will read VAC R. If both switches activate, the message will read
L VAC R.
NOTE: Maintenance practices for the panel-mounted annunciator can be found in Chapter
31, Annunciator Panel - Maintenance Practices.
2. Vacuum Pump Removal/Installation
NOTE: Removal/Installation is typical for both vacuum pumps.
A. Remove Vacuum Pump (Refer to Figure 201).
(2) Disconnect hoses from inlet and outlet ports of vacuum pump. Cap hoses and vacuum pump
ports to prevent entry of foreign matter.
(3) Remove nuts, lock washers, and flat washers securing vacuum pump to engine.
(4) Remove vacuum pump from mounting studs on engine.
(5) Remove elbow from pump and retain if reusable.
NOTE: Discard any twisted fittings or nuts with rounded corners.

B. Install Vacuum Pump (Refer to Figure 201).
(1) Prior to installing a new vacuum pump, purge all lines in system to remove carbon particles or
other pump components that may have been deposited in lines by previous vacuum pump.
CAUTION: THE PUMP HOUSING SHOULD NEVER BE PLACED DIRECTLY IN A VISE,
SINCE CLAMPING ACROSS CENTER HOUSING WILL CAUSE AN INTERNAL
FAILURE OF CARBON ROTOR. PROTECT PUMP MOUNTING FLANGE WITH
SOFT METAL OR WOOD. NEVER INSTALL A VACUUM PUMP THAT HAS
BEEN DROPPED.
(2) Position vacuum pump in a jaw protected vise with drive coupling downward.
(3) Install elbow in pump hand tight. Use only a box wrench to tighten fittings to desired position.
Do not make more than 1.5 turns beyond hand tight position.
NOTE: Do not use teflon tape, pipe dope, or thread lubricants of any type, and avoid over-
tightening connections.
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MAINTENANCE MANUAL
A
ATTITUDE
INDICATOR
REGULATOR
VALVE (WITH
VACUUM
MANIFOLD
ELBOW
LEFT LOW VACUUM

VACUUM GAGE
ELBOW
VACUUM
PUMP
FILTER
DETAIL A
Vacuum System Installation

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(4) Position new mounting pad gasket on mounting studs on engine.

NOTE: Do not use any cork type gaskets when installing vacuum pump.
(5) Ensure that mating surfaces are clean and free of any old gasket material.
(6) Position vacuum pump on mounting studs.
(7) Secure pump to engine with flat washers, new lock washers, and nuts. Torque mounting nuts to
70 inch-pounds, ±10 inch-pounds. Tighten and torque nuts in a cross pattern.
(a) To torque the nuts, fabricate torque wrench adapter using Figure 202 as a guide. Weld a
3/8 drive to a 7/16 wrench with a 12 point cut-out in the box end of the wrench. The wrench
length should be 2.25 inches from center of box end to center of drive.
(8) Connect hose to inlet and outlet ports of vacuum pump.
(9) Connect drain hose to elbow. Position tube so that exhaust is not directed at magnetos or
electrical wiring.
(10) Run up engine and note positive indication on vacuum gauge. Refer to Pilot's Operating
(11) Install upper engine cowling. Refer to Chapter 71, Cowling - Maintenance Practices.
3. Vacuum Manifold and Annunciator Switches Removal/Installation

A. Remove Vacuum Manifold and Annunciator Switches (Refer to Figure 201 ).
(2) Remove hoses from vacuum manifold.
(3) Disconnect electrical wires from left low vacuum switch or right low vacuum switch.
(4) Loosen B-nut securing vacuum manifold to nipple in firewall.
(5) Remove vacuum manifold from airplane.
B. Install Vacuum Manifold and Annunciator Switches (Refer to Figure 201 ).
(1) Position vacuum manifold on nipple in firewall and secure with B-nut.
(2) Connect electrical wires to left low vacuum switch or right low vacuum switch.
(3) Connect hoses to vacuum manifold.
4. Regulator Valve Filter Removal/Installation

A. Remove Regulator Valve Filter (Refer to Figure 201).
(1) Gain access to regulator valve, located behind the radio stack.
(2) Carefully stretch the foam element filter over the top retaining bezel, and remove filter from
regulator valve.
B. Install Regulator Valve Filter (Refer to Figure 201).
(1) Install the regulator valve filter by stretching the foam element over the top retaining bezel, and
ensuring that it seats properly.
5. Gyro Filter Removal/Installation

A. Remove Gyro Filter (Refer to Figure 201).
(1) Remove bolt and retainer from mount and remove gyro filter.
B. Install Gyro Filter (Refer to Figure 201).
(1) Position gyro filter and retainer on mount and secure with bolt.
6. Vacuum Gage Removal/Installation
NOTE: The vacuum gauge, and ammeter are incorporated into a single instrument. For information on
the ammeter, refer to Chapter 24, DC Power Indicating - Maintenance Practices.
A. Remove Vacuum Gauge (Refer to Figure 201).
(1) Disconnect vacuum and air hoses from vacuum gauge.
(2) Disconnect electrical connector from ammeter.
(3) Remove screws securing vacuum gauge, to instrument panel and remove vacuum gauge.
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FABRICATED TORQUE WRENCH

ADAPTOR
2.25 INCHES
3/8 DRIVE
DETAIL A
7/16 WRENCH
VIEW A-A
Vacuum Pump Torque Wrench Adapter

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MAINTENANCE MANUAL
B. Install Vacuum Gauge (Refer to Figure 201).

(1) Install vacuum gauge, to instrument panel and secure with screws.
(2) Connect electrical connector to ammeter.
(3) Connect vacuum and air hoses to vacuum gauge.
7. Vacuum Manifold Testing

A. The vacuum manifold should 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 testing procedures.
8. Vacuum Pressure Adjustment/Test
NOTE: Prior to adjustment, the entire pneumatic system should be inspected and tested for leaks,
restrictions and malfunctioning components. Failure to correct all system anomalies will lead
to reduced dry air pump service life.
A. Prepare System for Test (Refer to Figure 201).
(1) From under the instrument panel, remove the gyro (central air) filter from the system.
B. Check and Adjust Regulator Valve.
CAUTION: DO NOT EXCEED MAXIMUM ENGINE TEMPERATURES DURING THE

FOLLOWING CHECK/ADJUSTMENT OF THE REGULATOR VALVE.
NOTE: Suction should fall between 4.5 In. Hg. and 5.5 In. Hg. (green marking range on gauge)
Optimal setting is 5.3 In. Hg.
(1) Start engine and run up to 1900 RPM. Refer to Pilot's Operating Handbook and FAA Approved
Airplane Flight Manual.
(2) Ensure suction gauge reads between 5.3 In. Hg. and 5.5 In. Hg.
(3) If suction reading falls outside of range, adjust regulator valve in the following steps:
(a) Bend locking tab upward on lower surface of regulator valve.
(b) Turn adjustment screw, located on lower surface of regulator valve, in desired direction to
increase or decrease pressure as required.
(c) Bend locking tab downward to secure adjustment screw in place when desired pressure
has been set.
(4) Run up to 2200 RPM and ensure gauge reading does not exceed 5.5 In. Hg.
(5) Shut down engine.
(6) Reattach filter element to gyro (central air) filter.
(7) Run engine for a final time at 2200 RPM and observe reading on suction gauge. if reading falls
noticeably after reinstalling filter, filter should be replaced.
(8) Reduce engine speed to 800 RPM. Ensure suction remains within green operating range and
that L VAC R lights are extinguished on the annunciator panel.
(9) Reduce engine speed to idle (approximately 600 RPM).
(10) Verify that suction gauge reading falls below 3.0 In. Hg, +0.5 or -0.5 In. Hg., and that L VAC R
annunciator lights illuminate on the annunciator panel.
NOTE: If engine produces more than 3.0 In. Hg. at idle, the L VAC R lights can be checked
with engine off.
(11) Slowly increase engine speed to 800 RPM. Verify that L VAC R lights extinguish on the
annunciator panel and that suction falls within normal operating range.
(12) Shut down engine.
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* CHAPTER
STANDARD PRACTICES
AND STRUCTURES-
GENERAL
MODEL 172
MAINTENANCE MANUAL

51-Title
51-00-00 1 Aug 18/2001
51-10-00 1 Aug 18/2001
51-11-00 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
4 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
STRUCTURES - GENERAL ........... .................... ................. 51-00-00 Page 1
Sco pe ........................................................................ 51-00-00 Page 1
Definitio n .................................................................. .. 51-00-00 Page 1
STRUCTURES - DESCRIPTION AND OPERTION .................................... 51-10-00 Page 1
Description ................................................................... 51-10-00 Page 1
CORROSION - DESCRIPTION AND OPERATION ........................... ......... 51-11-00 Page 1
General ..................................................................... 51-11-00 Page 1
Characteristics of Corrosion ......... ........................................... 51-11-00 Page 1
Types of Corrosion ........................................................... 51-11-00 Page 1
Typical Corrosion Areas ....................................................... 51-11-00 Page 3
Corrosion Detection .......................................................... 51-11-00 Page 4
Corrosion Damage Limits .................. . ................................... 51-11-00 Page 4
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
STRUCTURES - GENERAL
1. Scope
A. This chapter provides a description of general airplane structures and corrosion characteristics. For
repair of structural members and repair techniques used throughout the airplane, refer to the Single
Engine Structural Repair Manual 1996 and On.
2. 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.
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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 members of the cabin section are constructed of
formed bulkhead channels. Bulkheads are formed "U" channel sections. Principal material is 2024-
0 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 panel 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.
C. 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 panels. The skin panels
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 panels. The rudder trim tab is constructed of
a spar, ribs, and skin; all riveted together.
D. 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.
E. The engine mount is constructed of welded 4130 steel tubing.
F. 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.
51-10-00 Page 1
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CORROSION - DESCRIPTION AND OPERATION

1. General
A. 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.
2. Characteristics of Corrosion
A. 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 contact
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 contact (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 joints, around rivets, bolts and screws.
3. 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 passive 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 contact 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 Page 1
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MAINTENANCE MANUAL
SIMPLIFIED CORROSION CELL
UNBROKEN PAINT FILM
NO CONTACT BETWEEN ELECTROLYTE AND ANODE AND CATHODE
ELECTRON CONDUCTOR METAL
CORROSION ELIMINATION BY APPLICATION OF ORGANIC FILM 26821017
Corrosion Identification
Figure 1 (Sheet 1)
51-11-00 Page 2
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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, cadmium 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 joints 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.
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(c) After thorough cleaning of the exterior cable surface, apply a light coat of lubricant (VV-L-
800) 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.
5. Corrosion Detection
A. 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
joints are indications of corrosive build-up which is well advanced.
(b) In many cases the inspection area is obscured by structural members, 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.
6. 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, contact Cessna Propeller
Aircraft Product Support 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).
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* CHAPTER
DOORS
MODEL 172
MAINTENANCE MANUAL

52-Title
52-00-00 1 Aug 18/2001
52-10-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
206 Aug 18/2001
207 Aug 18/2001
52-30-00 201 Aug 18/2001
202 Aug 18/2001

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CONTENTS
DOORS - GENERAL ............................................................... 52-00-00 Page 1
Scope ........................................................................ 52-00-00 Page 1
D efinition ..................................................................... 52-00-00 Page 1
CABIN DOORS - MAINTENANCE PRACTICES ...................................... 52-10-00 Page 201
General .................................................................... . 52-10-00 Page 201
Cabin Door Removal/Installation ................................................ 52-10-00 Page 202
Cabin Door Weatherstrip Remove/Installation ................. ................ 52-10-00 Page 202
Installation of Lock to Latch Assembly ........................................... 52-10-00 Page 202
Install Latch Assembly to Door ................................................. 52-10-00 Page 206
Upper Cabin Door Cable Installation ............................................ 52-10-00 Page 206
Upper Cabin Door Cable Rigging ............................................... 52-10-00 Page 206
Inside Door Handle Rigging ....................................... ............ 52-10-00 Page 207
BAGGAGE DOOR - MAINTENANCE PRACTICES .................................... 52-30-00 Page 201
General ...................................................................... 52-30-00 Page 201
Baggage Door Removal/Installation ............................................. 52-30-00 Page 201
Baggage Door W eatherstrip .................................................... 52-30-00 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DOORS - GENERAL
1. Scope
A. This chapter provides maintenance information on doors. Provided are removal/installation
instructions and rigging procedures.
2. Definition
(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.
52-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CABIN DOORS - MAINTENANCE PRACTICES

1. General
A. A cabin door is installed on each side of the airplane, consisting of an outer sheet skin chemically
bonded to a formed inner pan assembly. Left and right door assemblies are similar in construction
and operation, with the pilot (left) door incorporating an additional exterior lock.
B. All following procedures refer to the left door unless otherwise noted. Procedures apply to, and are
typical for the right door.
C. The cabin door latch consists of a two-piece nylon latch base, exterior handle, spring-loaded latch
bolt/pull-bar assembly, and a spring-loaded catch/trigger pin assembly. The interior handle base plate
assembly is directly connected to the cabin door latch by means of an adjustable push rod assembly.
This push rod assembly has one clamp on the main rod. This clamp is used to operate a cable
assembly that drives a cable pin from the upper aft end of the cabin door into the aft upper door sill.
When the cabin door is open, the door latch exterior handle should be extended (out), held in this
position by means of the spring-loaded latch catch engaged with the latch bolt through the beveled
hole in the bolt. The push rod assembly will be moved forward, and the attached cable assembly will
be retracted from the upper door sill with the cable pin recessed in the pin guide, located in the upper
aft corner of the door. The interior handle, being directly connected by means of the push rod, will be
moved approximately 15° aft of the vertical position. Closing the cabin door drives the trigger pin over
the nylon actuator attached to the cover plate, located on the rear doorpost. As the trigger pin is driven
forward, it disengages the latch catch from the latch bolt. The extended extension springs, attached
to the latch handle and bolt/pull-bar assembly, compress, pulling the latch handle in, and driving the
latch bolt over the latch striker, located on the rear doorpost. Pushing the exterior handle flush with
the fuselage skin, the push rod assembly, attached to the latch bolt/pull-bar assembly, moves aft,
which also drives the cable pin from the pin guide in the door into the upper aft door sill receptacle.
The interior door handle has now moved from approximately 15° aft of vertical to approximately 45 °
forward of vertical. Pushing the interior handle to the horizontal position, flush with the arm rest, will
overcenter the door latch, securing the door for flight. The cabin door latch assembly also incorporates
a locking arm and locking pin, used with a key lock to secure the aircraft after use. With the cabin door
closed, and the exterior latch handle flush, actuating the key lock drives the locking pin into the exterior
latch handle, locking the aircraft. It is important to note that since the cabin door latch assembly and
the interior handle base plate assembly are directly connected by the push rod assembly, that any
amount of force applied to the outside handle is subsequently applied to the inside handle. If the push
rod assembly is not properly adjusted, it is possible to lock one's self out of the aircraft by applying
too much force to the exterior handle when closing the cabin door. Therefore, it is important to adhere
to all of the rigging and adjustment specifications pertaining to the preload forces of the interior door
handle. Refer to the rigging and adjusting procedures in the following paragraphs.
A. Doors.
(1) The door assembly contains two forward mounted hinges, handles to open and close door from
inside and outside the airplane, two locking pins which engage the door at upper and aft doorpost
locations for positive closure and an integral latch assembly.
B. Latch Mechanism.
(1) The cabin door latch consists of a two-piece nylon latch base, exterior handle, spring-loaded
latch bolt/pull-bar assembly, and a spring-loaded catch/trigger pin assembly. The inside handle
is directly connected to the outside handle by means of a fixed length push rod assembly.
(2) The pushrod which connects inside and outside handles is also connected to a cable and pin
assembly by means of a welded stud. This cable and pin assembly is routed on the inside of
the aft door frame, and engages a receptacle in the upper aft fuselage door frame. Opening or
closing the door moves both the latch bolt and the upper pin simultaneously.
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MODEL 172
MAINTENANCE MANUAL
(3) The inside handle has three positions (OPEN, CLOSE or LOCK). The outside handle has two
positions (OPEN or CLOSE). When the inside handle is placed in the LOCK (fully stowed)
position, the door cannot be opened from the outside.
NOTE: The left door also incorporates a locking arm and locking pin, used with a key lock
to secure the airplane after use. With the cabin door closed, and the outside handle
flush, actuating the key lock drives the locking pin into the outside handle, locking the
airplane.
(4) As the cabin door is closed, a trigger pin in the latch mechanism contacts the door post striker
plate. As the trigger pin is driven forward, it disengages the latch catch from the latch bolt. This
process releases the spring-loaded exterior handle, allowing it to seat in its stowed position,
and driving the latch bolt aft into the latch striker. This process also moves the inside handle
from the OPEN to the CLOSE position. As the inside handle is moved farther forward and down
into the LOCK position, the latch bolt moves farther aft to fully seat in the latch striker, and the
pin assembly of the upper aft doorpost is driven upward into position, thus locking the door at
two points. An internal overcenter cam, which has engaged between the CLOSE and LOCK
positions, ensures a positive lock of both door pins during all phases of flight.
(5) When the inside handle is moved upward from the LOCK to the CLOSE position, the overcenter
mechanism is disengaged and the upper aft doorpost pin is retracted into its cable. As the
handle is moved further aft to the OPEN position, the latch bolt disengages from the striker
plate, allowing the door to open.
3. Cabin Door Removal/Installation
A. Remove Cabin Door (Refer to Figure 201).
(1) Open cabin door.
(2) Remove clevis pin from door stop spring.
(3) Remove screws securing hinges to fuselage.
(4) Remove cabin door from airplane.
B. Install Cabin Door (Refer to Figure 201).
(1) Position cabin door hinges to fuselage and secure with screws.
(2) Install clevis pin to door stop spring.
NOTE: If fitting a new door assembly, some trimming of the door flange may be required.
4. Cabin Door Weatherstrip Removal/Installation
A. Remove Cabin Door Weatherstrip (Refer to Figure 201).
(1) Using a non-metallic scraper, remove weatherstrip and adhesive from door assembly.
(2) Remove all adhesive residue from bond surface with solvent.
B. Install Cabin Door Weatherstrip (Refer to Figure 201).
(1) Cut new weatherstrip to length, using old weatherstrip as guide.
(2) Cut small notch in butt ends of new weatherstrip to allow for drainage.
(3) Position splice with notch at door low point and apply a thin, even coat of EC-1300L or equivalent
adhesive to both surfaces.
(4) Allow adhesive to dry until tacky before pressing weatherstrip into place on door. Do not stretch
weatherstrip around door corners.
5. Installation of Lock to Latch Assembly

A. Install Cabin Door Lock to Latch (Refer to Figure 201).
(1) Assemble locking arm with pin assembly by placing one washer on each side of locking arm.
Swage pin so that there is a minimal amount of looseness between parts. Cut excessive material
from pin.
(2) Place pin into 0.125 inch diameter hole of base assembly.
(3) Align .099 inch hole of locking arm with .094 inch hole in latch base and install pin.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AS REQUIRED
FOR GOOD SEAL
WEATHERSTRIP
SEAL
(TYPICAL ENTIRE
PERIMETER)
DOOR
STRUCTURE
WEATHERSTRIP
SEAL
DOOR
STRUCTURE
NOTCH
DETAIL E
A-A05111003
E05111003
Cabin Door Installation

52-10-00 Page 203

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CABLE CLAMP
PIN
PUSH-PULL
ROD
SPACER D
ASSEMBLY
NUT
CAM
ASSEMBLY S
ARM Cabin Door Installation
CAM
ASSEMBLY
OUTSIDE

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LOCK
ASSEMBLY
SPRING
HINGE
E DETAIL B
05111004
A05111005
B05111005

52-10-00 Page 205

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(4) Assemble cam assembly to locking arm. Cam should be on latch side of locking arm. Use 3
washers between cam and locking arm.
6. Install Latch Assembly to Door
A. Install Latch Assembly to Door (Refer to Figure 201).
NOTE: Install with latch in CLOSED position.

(1) Install latch assembly between door pan and door skin.
(2) Cable assembly should be forward of latch base attach plate, and inboard of latch base cup.
(3) Extend latch handle through cutout in door skin. This will pull latch bolt back far enough to allow
latch to fall into place.
(4) Push latch assembly aft so that bolt and push rod extend through their respective holes.
(5) Trip push rod so that bolt is fully extended and handle is flush.
(6) Secure latch to door pan with screws through base assembly and two screws through aft flange
of door pan.
(7) Ensure door skin fits properly around latch assembly, then drill eleven 0.128 inch diameter holes
to align with latch base.
NOTE: Do not oversize holes in the latch base and do not rivet base to skin at this time.
7. Upper Cabin Door Cable Installation
A. Install Upper Cabin Door Cable Assembly (Refer to Figure 201).
(1) On pin end of cable assembly, attach clamp and nut one inch from end of casing.
(2) Insert pin end of cable between door pan and door skin at aft end of door. Push pin end of cable
to top of door.
(3) Remove plug button and align pin of cable with pin guide, and insert pin through guide. Access
is gained through a 0.875 inch diameter hole after removal of plug button.
(4) Align clamp on cable casing through hole located one inch below 0.875 inch access hole and
install screw.
(5) Check operation of cable. If sluggish operation of cable is encountered, add washers as required
to facilitate smoother cable operation.
8. Upper Cabin Door Cable Rigging
A. Rig Cabin Door Latch Cable Assembly (Refer to Figure 201).
(1) Pull excess slack out of cable. Attach clamp and nut to cable so that it aligns with 0.193 inch
diameter hole in door pan, and attach.
NOTE: Ensure door latch is in OPEN position before proceeding.
(2) Cut casing of cable assembly approximately two inches from clamp bolt on push rod assembly.
(3) Insert core of cable through clamp.
(4) Pull core through clamp bolt so that pin extends approximately 0.125 inch from door pan contour.
(5) Cut core approximately one inch forward of push rod clamp.
(6) Secure two nuts to push rod clamp bolt.
(7) Operate latch several times to ensure latch works freely. If latch binds up and will not work
freely, remove cable core from clamp and operate latch. If cable operates easily without cable
attachment, check cable for possible adjustments to facilitate ease of operation.
(8) Once cable operates freely, install cover assembly and recheck cable for operation.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
9. Inside Door Handle Rigging

A. Rig Inside Door Handle (Refer to Figure 201).
NOTE: This procedure must be done with door installed and completely fitted to fuselage, and the
interior door panels removed.
(1) From inside airplane, close door and place inside handle to LOCK position. A force of 6 to 12
pounds should be required to engage the overcenter cam and the handle should stow flush with
the arm rest.
(2) If the overcenter cam engages but the inside handle does not fit flush with the arm rest, proceed
as follows:
(a) Check sheathing on cable for interference against clamp bolt. With handle in LOCK
position, the cable sheathing should be within approximately 0.125 inch of the clamp bolt
but should not be touching it. If sheathing is touching clamp bolt, loosen clamps and
reposition sheathing to provide non-interference with clamp bolt.
(b) Loosen bolt and nut securing spacer in pivot base plate. Reposition spacer to allow push-
pull rod to rest against spacer. Retighten bolt and nut.
(c) Move inside handle to LOCK position. If handle does not fit flush with armrest, remove
screw securing inside handle to shaft assembly, reclock handle on shaft assembly and
reinstall screw.
(3) If the overcenter cam does not appear to engage when inside handle is placed in the LOCK
position and the door can be opened from the outside, proceed as follows:
(a) Check sheathing on cable for interference against clamp bolt. With handle in LOCK
position, the cable sheathing should be within approximately 0.125 inch of the clamp bolt
but should not be touching it. If sheathing is touching clamp bolt, loosen clamps and
reposition sheathing to provide non-interference with clamp bolt.
NOTE: In some cases, it may be necessary to remove a small section of sheathing to
allow for non-interference with clamp bolt and full retraction of pin into the upper
door post when door is in OPEN position.
(b) Place inside handle in the OPEN position.

(c) Loosen four screws securing pivot base plate to door.
(d) Move pivot base plate reward to lengthen effective arm of push-pull rod.
(e) Retighten screws securing pivot base plate to door.
(f) From inside airplane, close door and place inside handle to LOCK position. A force of 6 to
12 pounds should be required to engage the overcenter cam, and the handle should stow
flush with the arm rest.
(g) If inside handle does not fit flush with arm rest, it may be necessary to reposition spacer
and/or reclock inside handle on shaft assembly to achieve flush fit between arm rest and
inside handle.
NOTE: Recheck clamps that secure cable to door. There must not be any slippage
between cable sheathing and clamps.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BAGGAGE DOOR - MAINTENANCE PRACTICES
1. 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.
2. Baggage Door Removal/Installation

A. Remove Baggage Door (Refer to Figure 201).
(1) Open baggage door.
(2) Disconnect door-stop chain.
(3) Remove upholstery panel from door.
(4) Remove bolts securing door to hinges.
B. Install Baggage Door (Refer to Figure 201).
(1) Position baggage door to hinges and secure with bolts.
(2) Install upholstery panel to door.
(3) Connect door stop chain.
(4) Close baggage door and check for binding.
3. Baggage Door Weatherstrip
A. A rubber weather strip is cemented around the edge of the baggage door, and seals the door to the
fuselage structure when the door is closed.
B. The baggage door weatherstrip can be replaced using the following steps:
(1) Remove the baggage door.
(2) Using a nonmetallic scraper, remove the existing seal and adhesive from the baggage door.
(3) Remove adhesive residue and clean door seal area with DeSoclean 110 Solvent.
(4) Using the old seal as a guide or the door seal area of the baggage door, measure and cut the
new seal to length.
(5) Apply a thin, even coat of RTV157 Adhesive around the circumference of the door seal area of
the baggage door.
(6) Press the new seal into the adhesive. Allow the adhesive to cure per the manufacturer's
instructions, ensuring that the seal is completely adhered to the door with no gaps between the
seal and the door.
NOTE: Do not stretch the seal around the corners of the door.
(7) Reinstall the baggage door.
C. Baggage door weatherstrip inspection.
(1) Place a 4 X 11 inch piece of paper between the baggage door frame and the baggage door.
Close the baggage door. Slowly pull on the paper to ensure there is seal tension. Move the
paper around the perimeter of the door to test the door seal tension.
(2) Remove the paper from the door frame. Ensure the baggage door is closed. Pour a gallon of
water over the door and tailcone door frame. After the water has finished dripping, open the door
and inspect for leaks.
(3) If any leaks are found, towel dry the upholstery with a clean dry towel. Reposition the seal as
required to ensure no leaks around the seal area of the baggage door.
NOTE: It is permissible to build-up the area using U064158 Aerodynamic Filler Compound
before repositioning the seal, if necessary. Sand and touch-up paint area to match.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
SPACER
STRIKER
PLATE
DETAIL C
DOOR
BOLT
BAGGAGE
DOOR HINGE
DETAIL B
Baggage Door Installation

52-30-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
STABILIZERS
MODEL 172
MAINTENANCE MANUAL

55-Title
55-00-00 1 Aug 18/2001
55-10-00 201 Aug 18/2001
202 Aug 18/2001
55-30-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
STABILIZER - GENERAL ......... ......... ................................ ......... 55-00-00 Page 1
Scope ......... .................................................. ......... 55-00-00 Page 1
D efinition ......... .................................................... ....... 55-00-00 Page 1
HORIZONTAL STABILIZER - MAINTENANCE PRACTICES ............. .... .......... 55-10-00 Page 201
General..................................................................... 55-10-00 Page 201
Horizontal Stabilizer Removal/Installation ......... ........................... 55-10-00 Page 201
VERTICAL STABILIZER FIN - MAINTENANCE PRACTICES ......................... 55-30-00 Page 201
General ................................ ..................................... 55-30-00 Page 201
Vertical Stabilizer Fin Removal/Installation ......... ............................. 55-30-00 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
STABILIZERS - GENERAL
1. Scope
A. This chapter provides maintenance information on the horizontal and vertical stabilizer.
2. Definition
A. The section on horizontal stabilizer provides instructions for removal and installation of the horizontal
stabilizer.
B. The section on vertical stabilizer fin provides instructions for removal and installation on the vertical
stabilizer fin.
55-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
HORIZONTAL STABILIZER - MAINTENANCE PRACTICES
1. 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 support the elevators.
B. This section provides removal and installation instructions for the horizontal stabilizer.
2. 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: Note the order in which any spacers or shims are removed for reinstallation.
(7) Remove horizontal stabilizer.

B. Install Horizontal Stabilizer (Refer to Figure 201).
(1) Install horizontal stabilizer to fuselage using bolts.
NOTE: Reinstall any spacers and shims in the exact order in which they were removed.
(2) Reroute cables into tailcone and install pulleys.

(3) Reconnect elevator trim control cables at clevis and turnbuckle inside tailcone.
(4) Install vertical stabilizer. Refer to Vertical Stabilizer - Maintenance Practices.
(5) Install rudder. Refer to Chapter 27, Rudder Control System - Maintenance Practices.
(6) Install elevators. Refer to Chapter 27, Elevator Control System - Maintenance Practices.
55-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
STABILIZER
HORIZONTAL
STABILIZER
FORWARD RIGHT
FAIRING
FORWARD LEFT
FAIRING
STABILIZER
TIP
OUTBOARD
ELEVATOR
HINGE
DETAIL A BUSHING
DETAIL C
INBOARD
ELEVATOR
05321004
A05321003
B05321003
C05321002
Horizontal Stabilizer Installation

55-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
VERTICAL STABILIZER FIN - MAINTENANCE PRACTICES
1. 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.
2. 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) Connect elevator cable to elevator bellcrank.
(5) Secure dorsal to fin using screws.
(6) Reconnect all electrical, navigation, and antenna leads.
(7) Install upper left and upper right fairings.
(8) Install rudder. Refer to Chapter 27, Rudder Control System - Maintenance Practices.
55-30-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
RUDDER
NOTE: FAIRING AND DORSAL HINGE
FIN ARE RIVETED TO
FUSELAGE. FIN TIP
DORSAL
FAIRING RUDDER
ASSEMBLY
NUTPLATES
UPPER
RIGHT
FAIRING
RUDDER
HINGE
SHIM
FUSELAGE FAIRING
Vertical Stabilizer Fin Installation
55-30-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
WINDOWS
MODEL 172
MAINTENANCE MANUAL

56-Title
56-00-00 1 Aug 18/2001
2 Aug 18/2001
56-00-01 1 Aug 18/2001
2 Aug 18/2001
56-10-00 201 Aug 18/2001
202 Aug 18/2001
56-20-00 201 Aug 18/2001
202 Aug 18/2001
56-30-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
W INDOW S - GENERAL ......... ..................... .............................. 56-00-00 Page 1
Scope ........................................................................ 56-00-00 Page 1
D efinition .................................................................... 56-00-00 Page 2
WINDSHIELD AND WINDOWS - DESCRIPTION AND OPERATION .............. 56-00-01 Page 1
General...................................................................... 56-00-01 Page 1
Cleaning Instructions .......................................................... 56-00-01 Page 1
Windowshield and Window Preventive Maintenance .............................. 56-00-01 Page 1
Windshield and Window Installation Techniques ................................. 56-00-01 Page 2
W indshield Rain Repellent................................................ 56-00-01 Page 2
WINDSHIELD - MAINTENANCE PRACTICES........................................ 56-10-00 Page 201
G eneral .................................................................... 56-10-00 Page 201
Rear Windshield Removal/Installation ........................................... 56-20-00 Page 201
Side W indow Removal/Installation ......... ......................... ........ 56-20-00 Page 201
CABIN DOOR WINDOWS - MAINTENANCE PRACTICES ........................... 56-30-00 Page 201
General .................................................................... 56-30-00 Page 201
Cabin Door Window Removal/Installation ....................... .......... 56-30-00 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
WINDOWS - GENERAL
1. Scope
A. This chapter provides information on windows used throughout the airplane.

Mild Soap or Commercially Available To clean windshields and
Detergent (hand windows.
dishwashing type
without abrasives)
Aliphatic Naphtha Type II Commercially Available To remove deposits
Federal from windshields and
Specification windows.
TT-N-95
Novus Number 1 Commercially Available To clean acrylic
windshields and
windows.
Novus Number 2 Commercially Available To remove minor
surface scratches in
acrylic windshields and
windows.
Novus Number 3 Commercially Available To remove heavy
scratches and abrasions
in acrylic windshields and
windows.
Mirror Glaze MGH-7 Meguiars Mirror Bright Polish To clean and polish
210 N First Ave. acrylic windshields and
Arcadia, CA 91006 windows.
Soft cloth, such Commercially Available To apply and remove wax
as: Cotton flannel and polish.
or cotton terry
cloth
Windshield U000926 Fiber Resin Corp. To seal windshield.
sealant Tape 170 W. Providencia Ave. P.O. Box
4187
Burbank, CA 91502
Repcon rain 6850-00-139- Unelko Corporation To repell rain from
repellent 5297 7428 East Karen Drive windshield.
Scottsdale, Arizona 85260
3. Definition
(1) The section on windshields and windows provides installation notes and precautions applicable
to the entire chapter.
56-00-00 Page 1
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MODEL 172
MAINTENANCE MANUAL
(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.
56-00-00 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
WINDSHIELDS AND WINDOWS - DESCRIPTION AND OPERATION
1. General
A. This section provides instructions and tips for cleaning and installing windshields and windows used
in the airplane.
A. For a list of required tools, equipment and materials, refer to Windows - General.
3. 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-ETHYL-KETONE (MEK), 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: When applying and removing wax and polish, use a clean, soft cloth, such as cotton
or cotton flannel.
4. Windshield and Window Preventive Maintenance
NOTE: Utilization of the following techniques will help minimize windshield and window crazing.
A. 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 contact with or vapors from:
methanol, denatured alcohol, gasoline, benzene, xylene, MEK, acetone, carbon tetrachloride,
lacquer thinners, commercial or household window cleaning sprays, paint strippers, or other
types of solvents.
(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.
56-00-01 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
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.
56-00-01 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
WINDSHIELD - MAINTENANCE PRACTICES
1. General
A. This section provides instructions for removal and installation of the window as well as repair
techniques applicable to acrylic windshields and windows.
2. 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: IF WINDSHIELD IS TO BE REINSTALLED, BE SURE TO PROTECT
WINDSHIELD DURING REMOVAL.
(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.
B. 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.
3. 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.
56-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
OUTER
RETAINER
FELT
SEAL INNER
RETAINER
DETAIL A
D0511T3002
Windshield Installation
56-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CABIN WINDOWS - MAINTENANCE PRACTICES

1. General
A. 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.
2. 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.
3. Side Window Removal/Installation
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.
56-20-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
REAR
SIDE
05124001
Cabin Windows Installation

56-20-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CABIN DOOR WINDOWS - MAINTENANCE PRACTICES

1. General
A. 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 -
2. 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.
56-30-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
LATCH
BRACKET
LATCH
ASSEMBLY
ASSEMBLY
ARM
DETAIL A
0510T1007
A05113001
B05111002
Cabin Door Window Installation

56-30-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
WINGS
MODEL 172
MAINTENANCE MANUAL

57-Title
57-00-00 1 Aug 18/2001
57-10-00 201 Feb 15/2002
202 Feb 15/2002
203 Feb 15/2002
204 Feb 15/2002
205 Feb 15/2002
206 Feb 15/2002

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

|~~~~~~~~~~~ I
MODEL 172
MAINTENANCE MANUAL

I
MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL
CONTENTS
W INGS - GENERAL .............................................................. 57-00-00 Page 1
Scope ........... .................... ...............................
...... 57-00-00 Page 1
Tools, Equipment and Materials ......... ..................................... 57-00-00 Page 1
Definition ................................................................... 57-00-00 Page 1
WINGS AND WING STRUTS - MAINTENANCE PRACTICES ........................ 57-10-00 Page 201
Description and Operation ......................... ........................ 57-10-00 Page 201
Wing and Strut Removal/Installation .......................................... 57-10-00 Page 201
Adjustment (Correcting Wing Heavy Conditions) ............................... 57-10-00 Page 204
Strut Damage and Repair Criteria ............................................ 57-10-00 Page 205
Wing Tip Removal/Installation .............. ....................... .......... 57-10-00 Page 205
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
WINGS - GENERAL
1. Scope
A. 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.

Grease MIL-G-21164 E/M Corporation To lubricate wing attach
Box 2200 fittings and bolts upon
Highway 52 N.W. reinstallation.
West Lafayette, IN 47906
3. Definition
A. This chapter contains a single section on wing removal, installation and adjustment.
57-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
WINGS AND WING STRUTS - MAINTENANCE PRACTICES

A. Each metal wing is a strut braced type, with two main spars and suitable ribs for the attachment of the
skin. Skin panels 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 supported 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.
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 supported 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) Support 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.
57-10-00 Page 201

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B234
WASHERS
LOWER NUT
REAR ECCENTRIC
FAIRING A BUSHINGS
FAIRING DETAIL A
WING
FLAP
NAVIGATION AND
BOLT STROBE LIGHTS
NUT
DETAIL B 052T2001
A0520T1003
80520T1002
Wing Installation
57-10-00 Page 202

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B233
SCREW
NOTE: LUBRICATE BOLT AND HOLE
PRIOR TO INSTALLATION
ccv / \ UPPER
A
FAIRING
TIE-DOWN
SCREW 0 cRING
LOWER
FAIRING
SPA C ER
BOLT
(NOTE)
B
WING STRUT
WING STRUT \
^S^/ ~ O_~ WING
ATTACHMENT
FITTING
,( / \ TIE-DOWN
RING -
FUSELAGE
ATTACHMENT DETAIL A
FITTING
BOLT 0520T1006
DETAIL B (NOTE) 0520T1006

A0520T1006
B0520T1006
Wing Installation
57-10-00 Page 203

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B. Install Wing and Strut (Refer to Figure 201).

(1) Hold wing in position and insta!! bolts, bushings, washers and nuits attrnhing 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) Route flap and aileron cables, using guide wires.

(6) Reconnect all fuel, electrical and mechanical connections removed above.
(7) Rig flap system. Refer to Chapter 27, Flap Control System - Maintenance Practices.
(8) Rig aileron systems. Refer to Chapter 27, Aileron Control System - Maintenance Practices.
(9) Refuel wing tank.
(10) Check operation of all mechanical, electrical and fuel systems.
(11) Install wing root fairings.
(12) Install all removed access/inspection plates and upholstery.
3. Adjustment (Correcting Wing Heavy Conditions)
NOTE: 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.
A. 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
IN THE 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.
(4) 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.
(5) Torque nut from 300 to 500 inch pounds, install fairing strip and repeat flight test.
57-10-00 Page 204

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
4. Strut Damage and Repair Criteria

A. For wing strut damage and repair criteria, refer to the Single Engine Structural Repair Manual Chapter
| 57, Wing Damage Classification.
5. 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.
57-10-00 Page 205

Feb 15/2002
l'o3llino)3: 30VdS
iVnNVW 3ONVN31NIVIA
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
PROPELLERS
MODEL 172
MAINTENANCE MANUAL

61-Title
61-00-00 1 Aug 18/2001
61-10-00 201 Feb 15/2002
202 Feb 15/2002
Added 203 Feb 15/2002

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL

|~~~~~~~~~~~ I
MODEL 172
MAINTENANCE MANUAL

I
MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL
CONTENTS
PROPELLERS - GENERAL ....................................................... 61-00-00 Page 1
Scope .................................................................... . 61-00-00 Page 1
Definition ................................................................... 61-00-00 Page 1
PROPELLER - MAINTENANCE PRACTICES ...................................... 61-10-00 Page 201
Propeller and Spinner Removal/Installation .................................... 61-10-00 Page 201
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
PROPELLERS - GENERAL
1. Scope
A. This chapter provides instructions on propeller and spinner.
2. Definition
A. This chapter contains a single section on removal and installation of the propeller and spinner.
61-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PROPELLER - MAINTENANCE PRACTICES

A. The airplane is equipped with a two bladed, fixed pitch metal propeller. Maintenance practices consist
of propeller/spinner removal and installation. For information beyond the scope of this section, refer
to the applicable McCauley Service Manual.
2. Propeller and Spinner Removal/Installation
A. Remove the Propeller and Spinner (Refer to Figure 201).
WARNING: EXERCISE CARE WHEN WORKING WITH THE PROPELLER. ENSURE
MAGNETO SWITCH IS IN THE OFF POSITION BEFORE TURNING
PROPELLER.
(1) Remove the cowling and nosecap. Refer to Chapter 71, Cowling - Maintenance Practices.
(2) Remove screws securing the spinner to the forward and aft bulkheads. Remove the spinner.
(3) Cut and discard safety wire from the propeller mounting bolts.
(4) Remove the mounting bolts, forward bulkhead, propeller, aft bulkhead and spacer from
crankshaft.
NOTE: A dowel pin holds the propeller, aft bulkhead and spacer together when removed.
(5) The propeller mounting bolts must be magnetic particle inspected, refer to ASTM E-1414 or
liquid penetrant inspected, refer to ASTM E-1417, or replaced at every overhaul. The propeller
mounting bolts must be replaced when the propeller is involved in a blade strike.
(6) Remove the spacer and the aft bulkhead from the propeller.
(a) Support the propeller by setting it between two sand filled bags placed as close to the hub
as possible with the spacer down. Allow two (2) inches of clearance for the spacer and aft
bulkhead to separate from the hub.
(b) Select a rod of proper diameter and is six (6) inches long. Insert rod into propeller hub
dowel pin holes. Using a hammer, lightly tap dowels in a alternating pattern to free the
spacer and bulkhead from propeller hub. The dowels will remain in the spacer.
(c) If the tapered end of dowels were installed in the propeller hub, remove dowels from spacer
by inserting the rod into dowel pin holes in spacer. Using a hammer, lightly tap dowels in
a alternating pattern to remove dowels from spacer.
B. Aft bulkhead and spacer assembly.
CAUTION: THE SPACER AND PROPELLER ARE BALANCED AS A PAIR AND MUST BE
INSTALLED TOGETHER. DO NOT EXCHANGE SPACERS OR PROPELLERS
FROM OTHER AIRPLANES.
(1) Position spacer on a arbor press table with hub mating surface facing up.
(2) If dowels were removed from spacer, install dowels with tapered end into spacer.
(a) Lightly oil each dowel and press into spacer.
(b) Engage dowel into spacer enough to hold dowel firmly. Extension of both dowels above
face of spacer must be the same after pressing.
NOTE: Final dowel location will be made when spacer is installed in propeller hub.
(c) Position propeller hub on arbor press table with spacer mating surface facing up.
(d) Place bulkhead over hub aligned with dowel holes.
(e) Align serial number on spacer with serial number on propeller hub.
(f) Press spacer down against hub and allow the bulkhead to rotate against the dowels for
adjustment.
C. Install the Propeller and Spinner (Refer to Figure 201).
61-10-00 Page 201

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B1786 /<
A SPACER
DOWEL
FORWARD BULKHEAD
ASSEMBLY
WASHER o
SPINNER \
AFT BULKHEAD
ASSEMBLY
PROPELLER
PROPELLER MOUNTING BOLT
SCREWS
DETAIL A
0510T1007
A0555R3001
Propeller and Spinner Installation

61-10-00 Page 202

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
CAUTION: THE SPACER AND PROPELLER ARE BALANCED AS A PAIR AND MUST BE
INSTALLED TOGETHER. DO NOT EXCHANGE SPACERS OR PROPELLERS
FROM OTHER AIRPLANES.
(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) Install the spacer, aft bulkhead, propeller and forward bulkhead to crankshaft with mounting bolts
finger tight.
(3) 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.
(4) Rotate the aft bulkhead until the spinner screws can be installed with little effort.
(5) Identify on the propeller, spinner, forward and aft bulkheads index marks for screw alignment.
(6) 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.
(7) 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 -
(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.
F. 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.
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.
61-10-00 Page 203

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
POWER
PLANT
MODEL 172
MAINTENANCE MANUAL

71-Title
71-00-0 1 Aug 18/2001
71-00-01 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
4 Aug 18/2001
5 Aug 18/2001
101 Aug 18/2001
102 Aug 18/2001
103 Aug 18/2001
104 Aug 18/2001
105 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
71-10-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
71-20-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
71-60-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
71-70-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
POWERPLANT - GENERAL ........... ....................... .................. 71-00-00 Page 1
S cope ........................................................................ 71-00-00 Page 1
D efinition .................................................................. .. 71-00-00 Page 1
ENGINE - DESCRIPTION AND OPERATION ......................................... 71-00-00 Page 1
IO-360-L2A - TROUBLESHOOTING ................................................. 71-00-01 Page 101
Troubleshooting Chart ......................................................... 71-00-01 Page 101
IO-360-L2A - MAINTENANCE PRACTICES ........................................... 71-00-01 Page 201
General ...................................................................... 71-00-01 Page 201
Engine Removal/Installation .................................................... 71-00-01 Page 201
Engine Cleaning .............................................................. 71-00-01 Page 203
Engine Storage ............................................................... 71-00-01 Page 203
COWLING - MAINTENANCE PRACTICES ........................................... 71-10-00 Page 201
Cowling Removal/Installation ................................................... 71-10-00 Page 201
Cowling Shock Mounts ........................................................ 71-10-00 Page 201
Cowling Repair ............................................................... 71-10-00 Page 201
ENGINE MOUNT - MAINTENANCE PRACTICES ..................................... 71-20-00 Page 201
Engine Mount Procedures ..................................................... 71-20-00 Page 201
Engine M ount Repairs ......................................................... 71-20-00 Page 201
AIR INDUCTION SYSTEM - MAINTENANCE PRACTICES ............................ 71-60-00 Page 201
Air Induction System Removal/Installation ....................................... 71-60-00 Page 201
172S Engine Induction Air Filter Maintenance Practices .......................... 71-60-00 Page 201
DRAIN LINES - MAINTENANCE PRACTICES ........................................ 71-70-00 Page 201
Maintenance Practices ........................................................ 71-70-00 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
POWERPLANT- GENERAL
1. Scope
A. 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.
2. Definition
(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.
71-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ENGINE - DESCRIPTION AND OPERATION

A. The Textron Lycoming IO-360-L2A is a direct drive, four cylinder, fuel injected, horizontally opposed,
air cooled engine. The cylinders, numbered from front to rear, are staggered to permit a separate
throw 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. For information beyond the scope of this chapter, refer to applicable engine manuals listed in
Introduction - List of Supplier Publications.
Table 1. IO-360-L2A Technical Description
172R Rated Horsepower at 2400 160

RPM
172S* Rated Horsepower at 2700 180
RPM
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 0.028 to 0.080 inch
tappets collapsed)
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
71-00-01 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
Table 1. IO-360-L2A Technical Description (continued)

Normal 100°F to 245°F
Maximum 245°F
Dry Weight - without alternator or 278 Lbs
vacuum pumps
*And 172R Airplanes Incorporating MK172-72-01
71-00-01 Page 2
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
OIL PRESSURE
RELIEF VALVE
LOW OIL
PRESSURE OIL
SWITCH COOLER
ALTERNATOR
DIPSTICK
OIL
FILTER
CRANKCASE
FUEL BREATHER
DISTRIBUTION LINE
VALVE
FLOW TRANSDUCER
Engine Installation
Figure 1 (Sheet 1)
71-00-01 Page 3
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FUEL FLOW ENGINE

STARTER TRANSDUCER
RING GEAR
HEAT
MUFFLER (WITH
HEAT SHROUD)
AIR
FILTER
INLET
DUCT
DRAIN
LINES
0550C1006
Engine Installation
Figure 1 (Sheet 2)
71-00-01 Page 4
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BAFFLE
MAGNETOS
ENGINE
DRIVEN
ILLUSTRATED)
PIPE
CONTROL
UNIT
FUEL
STRAINER
DRAIN
0550C1007
Engine Installation
Figure 1 (Sheet 3)
71-00-01 Page 5
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
IO-360-L2A - TROUBLESHOOTING
1. Troubleshooting Chart
A. The following chart has been provided to aid maintenance technicians in system troubleshooting. This
chart should be used in conjunction with Chapter 74, Ignition System - Troubleshooting to provide 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: If low power is suspected, the following static run-up procedures may by used in conjunction
with the troubleshooting chart to develop a diagnosis:
B. 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
(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 obtained on the two run-ups. RPM should be from 2065 to 2165
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) Check operation of alternate air door and ensure door remains closed in normal operation.
(b) Check magneto timing, spark plugs and ignition harness for settings and condition.
(c) Check fuel injection nozzles for restriction and check for correct unmetered fuel flow.
(d) Check condition of induction air filter. Clean or replace as required.
(e) Perform engine compression check.
ENGINE WILL NOT START No fuel to engine. Check fuel level in tanks, check
(NO FLOW INDICATED ON mixture control for proper
FUEL GAUGE). position, fuel boost pump on and
operating, fuel valves open, fuel
filters clean and unblocked.
ENGINE WILL NOT START Engine flooded. Reset throttle, clear engine of
(SUFFICIENT FUEL FLOW excess fuel and attempt re-start.
INDICATED ON FUEL
GAUGE).
ENGINE WILL NOT START No fuel to engine. Loosen line at fuel injector
(SUFFICIENT FUEL FLOW nozzle. If there is no fuel flow
INDICATED ON FUEL with fuel flow showing on gauge,
GAUGE) (Cont.). replace the flow divider valve.
Grounded ignition switch Check for grounded switch
wires. wires.
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MAINTENANCE MANUAL

Magneto improperly timed to Retime magnetos. Refer to
engine. Chapter 74, Ignition System -
Magneto internal timing Refer to applicable Bendix
incorrect, weak capacitor, or supplier Publications.
improperly adjusted breaker
points.
Fouled spark plugs. Remove and clean, check gaps
and insulators. Reinstall with
new gaskets. Check ignition
harness.
Weak spark, magneto coils Remove and bench test
burned out, moisture in magnetos, ignition harness and
distributor, spark plugs.
Leak in intake manifold. Check hose connections,
gaskets and tighten hose
clamps and flange attaching
bolts.
ENGINE WILL NOT RUN AT Idle stop screw or idle Refer to Chapter 73, Fuel
IDLING SPEED. mixture lever incorrectly Injection System - Maintenance
adjusted. Practices.
Air leak in intake manifold. Tighten loose connections or
replace damaged parts.
Weak magneto capacitor. Install new capacitor.
Spark plugs fould by oil Top overhaul engine.
escaping past piston rings.
ROUGH IDLING. Improper idle mixture Refer to Chapter 73, Fuel

adjustment. Injection System - Maintenance
Practices.
Manual mixture control set Use full rich mixture for all
for lean mixture. 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 Check mounts, tighten or install
mounts. new parts.
ROUGH IDLING (Cont.) Burned or warped exhaust Top overhaul engine.
valves and/or seats. Scored
valve stems.
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MAINTENANCE MANUAL

Hydraulic tappet sticking or Listen for tappet noise. Refer
worn. to applicable engine overhaul
manual in Introduction - List of
Supplier's Publications.
ENGINE DOES NOT Idle mixture too lean. Refer to Chapter 73, Fuel
ACCELERATE PROPERLY. Injection System - Maintenance
Practices.
Worn throttle or mixture Install new parts as required.
linkage.
ENGINE RUNS ROUGH AT Loose or deteriorated engine Check, tighten or install new
HIGH SPEED. mount pads. parts.
Propeller out of balance or Remove and repair.
track.
Spark plug gasket leaking, Install new parts.
improper gap, or damaged
insulator.
Ignition cable insulator Test cables for leakage and
deteriorated. install new parts as necessary.
Improper mixture. Check mixture control setting.
CONSTANT MISFIRING AT Valve spring broken. Install new spring.

HIGH RPM.
Valve warped or burned. Top overhaul engine.
Hydraulic tappet worn or Remove, clean or install new
dirty. parts.
SLUGGISH OPERATION Injectors clogged. Test and clean injectors.
AND LOW POWER.
Worn valve seats. Top overhaul engine.
Worn or stuck piston rings. Top overhaul engine.
LOW FLOW ON FUEL Line to flow transducer Check line for bends, kinks or
FLOW GAUGE. clogged or restricted, obstructions.
Restricted flow to flow divider Check mixture control for full
valve. travel. Check for clogged fuel
filters.
LOW FLOW ON FUEL Inadequate flow from pump. Worn pump or pump plunger
FLOW GAUGE (Cont.). shaft. Install new parts.
Interference with mixture Check mixture control for
control. freedom of movement.
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Aug 18/2001
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MAINTENANCE MANUAL

HIGH PRESSURE ON FUEL Restricted flow beyond flow Check for restricted nozzles or
FLOW GAUGE. divider valve. flow divider valve. Clean nozzles
or install new valve.
FLUCTUATING PRESSURE Vapor in system. Excessive If not cleared with boost pump,
ON FUEL FLOW fuel temperature. drain fuel pressue line.
INDICATOR.
Fuel leak in line from flow Check line, replace as required.
divider to flow transducer.
ENGINE DOES NOT STOP Mixture control valve leaking Check mixture control, should
WITH MIXTURE CONTROL in idle cutoff position. be in full idle cutoff. Check fuel
IN IDLE CUTOFF. boost pump off.
HIGH OIL TEMPERATURE. Oil cooler fins clogged. Clean thoroughly.

Oil cooler oil passages Remove and flush cooler.
restricted.
Oil cooler bypass valve Remove cooler, and clean valve
damaged or held open. and seat.
Low oil supply. Replenish.
Oil viscosity too high. Use correct grade of oil.
Prolonged high speed Avoid prolonged ground
operation on ground. operation above 1500 RPM.
Dirty/clogged oil filter. Replace filter.
HIGH CYLINDER HEAD Low fuel grade. Use correct grade of fuel.
TEMPERATURE.
Excessive carbon deposits in Top overhaul engine.
cylinder head and on piston.
Clogged cylinder fins. Clean thoroughly.
Leaking exhaust valves. Top overhaul engine.
LOW OIL PRESSURE. Low oil supply. Add oil.

Viscosity too low. Use correct grade oil.
Sludge or foreign material in Remove and clean valve.
relief valve.
Defective oil pressure gauge. Install new gauge.
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MODEL 172
MAINTENANCE MANUAL

Restricted oil transducer Check line from front of
line. crankcase to pressure
transducer for kinks or
restrictions.
Internal leak, damaged Major overhaul engine.
gasket or bearing.
OIL LEAK AT FRONT OF Crankshaft oil seal leaking. Install new seal.
ENGINE.
OIL LEAK AT PUSHROD Damaged housing seal. Install new seals.

HOUSING.
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.
EXCESSIVE OIL Low grade of oil. Use specified grade of oil.

CONSUMPTION.
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.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
IO-360-L2A - MAINTENANCE PRACTICES
1. General
A. This section provides instructions to remove and install the engine and mount from the firewall. For
maintenance beyond the scope of this chapter, refer to applicable engine publications which are listed
in Introduction - List of Supplier Publications.
2. Engine Removal/Installation
A. Remove Engine and Mount.
NOTE: The following procedure removes the engine and mount from the firewall. If only the engine
is being removed, some modification to the steps will be required to accomplish engine
removal.
(1) Place all cabin switches and the fuel shutoff valve in the OFF position.
(2) Remove engine cowling.
NOTE: The following steps can be accomplished from the right side of the airplane.
(3) Disconnect positive and negative battery leads from battery.

(4) Loosen c-clamp securing flexible duct to firewall-mounted heater valve. Remove flexible duct
from heater valve.
WARNING: DISCONNECTING THE P LEAD WIRE FROM THE MAGNETOS WILL
REMOVE THE ELECTRICAL GROUND FROM THE MAGNETO CIRCUIT,
RESULTING IN HOT MAGNETOS. A SEPARATE GROUND WIRE MUST BE
RUN TO THE MAGNETOS OR THE HIGH TENSION WIRES REMOVED FROM
THE SPARK PLUGS TO PREVENT ACCIDENTAL ENGINE START WHEN
THE PROPELLER IS ROTATED.
(5) Disconnect "P lead" wires on magnetos.
(6) Disconnect electrical connector JN004 from EGT Probe UN005.
(7) Disconnect fuel outlet line at the fuel strainer.
(8) Disconnect throttle and mixture cables at fuel/air control unit. Note position of washers and
spacers for later reassembly.
(9) Disconnect vacuum hoses (2) at firewall-mounted manifold/check valve.
(10) Disconnect and label electrical wires on low vacuum annunciator switches, low oil pressure
transducer and alternator.
NOTE: The following steps can be accomplished from the left side of the airplane.
(11) Loosen and remove tachometer drive cable clamps in engine area. Disconnect tachometer drive
cable from rear of accessory case.
(12) Cut tie wraps (sta straps) securing the various wire bundles to the engine mount.
(13) On bottom side of engine, loosen and remove clamps securing starter wires to sump area.
(14) Remove starter wires from starter.
(15) Disconnect ground strap from engine mount.
(16) Disconnect electrical connector JN001 from fuel flow transducer UN003.
(17) Disconnect electrical connector JN005 from low oil pressure switch SN001.
(18) Disconnect electrical connector JN004 from oil pressure transducer U1006.
NOTE: To remove electrical connector JN004 from baffle area, it will be necessary to remove
two screws on backside of upper right baffles and separate baffles from each other.
(19) Loosen clamps securing battery vent tube to drain line cluster. Withdraw vent tube through
clamps.
(20) Remove bolt and spacer securing drain line cluster to firewall.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
(21) Loosen and remove ram air tubes (2) on backside of upper left baffle.
(22) Place stand under tail tie-down to allow for tail heavy condition which will occur when engine is
removed from airframe.
(23) Attach hoist to lifting strap on top of engine. Begin to take up engine weight using hoist.
NOTE: Do not raise engine higher than necessary. Raising the engine too high places a
strain on the attach bolts and hinders their removal.
(24) Remove bolts attaching engine and engine mount to firewall. Note sequence of nuts, washers
and flat washers. Slowly raise engine using hoist until engine and mount slide freely from bolts.
NOTE: It may be necessary to access bolt heads from inside the cockpit to keep them from
turning.
B. Install Engine and Mount.
(1) Hoist engine into position and secure mount to firewall using hardware removed in above
steps. Refer to Engine Mount - Maintenance Practices for specific washer, nut and flat washer
sequencing.
(2) Torque firewall bolts from 160 to 190 In lbs.
(3) Remove stand from under tail tie-down.
(4) Install and secure ram air tubes (2) to backside of upper left baffle.
(5) Secure drain line cluster to firewall using bolt and spacer.
(6) Route battery vent tube through drain line clamps and tighten clamps.
(7) Pass wires from electrical connector JN004 through baffle cutout area. Secure baffle pieces to
each other using screws.
(8) Connect electrical connector JN004 to oil pressure transducer U1006.
(9) Connect electrical connector JN005 to low oil pressure switch SN001.
(10) Connect electrical connector JN00 to fuel flow transducer UN003.
(11) Connect ground strap to engine mount.
(12) Install starter wires to starter, and secure wires to sump area using clamps.
(13) Secure various wire bundles to engine mount using tie wraps.
(14) Connect tachometer drive cable to back of accessory case.
(15) Reconnect tagged wires to respective low vacuum annunciator switches.
(16) Reconnect vacuum lines (2) to firewall-mounted manifold/check valve.
(17) Reconnect throttle and mixture control cables to fuel air control unit.
(18) Reconnect fuel outlet line at the fuel strainer.
(19) Connect electrical connector JN004 to EGT Probe UN005.
(20) Reconnect P leads to magnetos. If required, reconnect high tension wires to spark plugs.
(21) Connect flexible duct to firewall-mounted heater valve.
(22) Check all controls and lines for security of installation and freedom of movement. Ensure all fuel
fittings are tight and leak-free.
(23) Reconnect positive and negative leads to battery.
(24) Reinstall engine cowling.
(25) Run engine.
3. Engine Cleaning
A. The engine may be cleaned using stoddard solvent or equivalent chemicals. Care should be taken
to ensure that all openings are capped or plugged to prevent solvent entry into engine. All electrical
accessories (starters, alternators, etc...) should be covered before cleaning solvent is applied.
4. Engine Storage
A. If the engine is being removed for storage purposes, it may need to be preserved. Refer to Chapter
10, Storage - Description and Operation for preservation techniques.
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MODEL 172
MAINTENANCE MANUAL
COWLING - MAINTENANCE PRACTICES

A. The engine cowling consists of upper and lower sheet metal halves and upper and lower composite
nose pieces. The cowling 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.
2. Cowling Removal/Installation
A. Remove Cowling (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 Cowling (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.
3. Cowling Shock Mounts
A. 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 cowling openings. If required, sheet aluminum
may be used as shim stock to provide proper cowling contour.
4. Cowling Repair
A. For repair procedures to the cowling, refer to the Structural Repair Manual.
71-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
PIN HINGE
UPPER COWL
UPPER NOSE CAP
INDUCTION
AIR
ASSEMBLY
A0552T3001
DETAIL
Engine Cowling Installation
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
DETAIL A
ENGINE
COWLING QUICK-RELEASE
FASTENER
COWL FUSELAGE
SNUBBER
BRACKET
SCREW
MAXIMUM GAP SEAL
0.125 INCH
MOUNT
ENGINE BRACKET
SNUBBER
SHIM FIREWALL
SNUBBER
NOSE CAP SUPPORT
DETAIL B
DETAIL C
NOTE: SHIM CAN BE INSTALLED AS REQUIRED (MAXIMUM 4) BETWEEN SNUBBER

SUPPORT AND SNUBBER TO OBTAIN A MAXIMUM GAP OF 0.125 INCH BETWEEN
SNUBBER AND COWL SNUBBER BRACKET.
0510T1007
A0511T1006
B05521002
C05521002
Engine Cowling Shock Mount Installation

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MODEL 172
MAINTENANCE MANUAL
ENGINE MOUNT- MAINTENANCE PRACTICES

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.
(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.
B. 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.
C. Removal Notes.
(1) Specific instructions for removing the engine mount have been included earlier in this chapter
under IO-360-L2A - Maintenance Practices.
3. Engine Mount Repairs

A. The engine mount may be repaired using procedures described in the Single Engine 1996 and On
Structural Repair Manual.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
1789
WASHER ENGINE
ENGINE
MOUNT M
MOUNTING
NUT
UPPER RIGHT HAND SHOCK MOUNT
BOLT
WASHER
MOUNTING
DAMPER
WASHER
LOWER RIGHT HAND SHOCK MOUNT
Engine Shock Mount Installation

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
BOLT
DAMPER
WASHER
ENGINE
WASHER ENGINE
UPPER LEFT HAND SHOCK MOUNT
WASHER
WASHER
NUT
ENGINE
SPACER
MOUNTING
MOUNTING
WASHER
BOLT
LOWER LEFT HAND SHOCK MOUNT
Engine Shock Mount Installation
71-20-00 Page 203

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MODEL 172
MAINTENANCE MANUAL
MOUNT
WASHER
DETAIL A
051 OT1007
A05511001
Firewall Engine Mount Installation

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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
AIR INDUCTION SYSTEM - MAINTENANCE PRACTICES

A. Ram air to the engine enters the induction air box through the induction filter, located in the forward
part of the lower engine cowling. From the induction air box, the air isdirected to the inlet of the fuel/air
control unit and, ultimately, through individual intake runners into their respective cylinders.
B. For a more comprehensive description of how the air induction system relates to fuel injection, refer
to Chapter 73, Fuel Injection System - Description and Operation.
2. Air Induction System Removal/Installation
A. Remove System Components (Refer to Figure 201).
(1) Loosen fasteners securing air filter bracket to lower cowl. Remove air filter bracket and air filter.
(2) Remove lower cowl. Refer to Cowling - Maintenance Practices.
(3) Loosen clamps on duct to disconnect filter box from induction air elbow.
(4) To remove induction air elbow, loosen clamps at inlet adapter and at drain line. Slide induction
air elbow down and away from inlet adaptor.
B. Install System Components (Refer to Figure 201).
(1) Position induction air elbow to inlet adaptor and secure using clamp.
(2) Secure drain line to induction air elbow using clamp.
(3) Install lower cowl. Refer to Cowling - Maintenance Practices.
(4) Secure air filter and air filter bracket to lower cowl using quick release fasteners.
3. 172S Engine Induction Air Filter Maintenance Practices
A. The induction air filter keeps dust and dirt from entering the induction system. The value of maintaining
the air filter in a good clean condition can never be overstressed. More engine wear is caused through
the use of a dirty or damaged air filter than is generally believed. The frequency with which the
filter should be removed, inspected and cleaned will be deteremined primarily by aircraft operating
conditions. A good general rule, however, is to remove, inspect and clean the filter at least every
100 hours of engine operating time, and more frequently if warranted by operating condtions. Under
extremely dusty conditions, daily servicing of the filter is recommended. To service the induction filter,
proceed as follows:
(1) Remove the filter from airplane.
NOTE: Use care to prevent damage to filter element when cleaning filter with compressed
air.
(2) Clean filter by blowing with compressed air (not over 100 psi) from direction opposite of normal
air flow. Arrows on filter case indicate direction of normal air flow.
(3) Check bonding of the paper pleats to the face screen. The bonding holds the paper pleats to
the face screen. The bonding holds the paper pleats in place and if broken, the pleats are free
to shift which can impair filtration. A face screen that is loose or gapping away from the paper
pleats is indicative of broken bonding and is caused to replace the filter element.
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MAINTENANCE MANUAL
HINGE
SPRING DOOR
DETAIL B
ALTERNATE AIR DOOR
FILTER INDUCTION
BOX AIR ELBOW INLET
DUCT
DRAIN
CLAMPS
DETAIL A
Induction Air Installation

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MAINTENANCE MANUAL
CAUTION: Do not use solvent or cleaning fluids to wash filter. Use only a water and
household detergent solution when washing the filter.
(4) After cleaning as outlined in step "b", the filter may be washed, if necessary, in a solution of warm
water and a mild household detergent. A cold water solution may be used.
NOTE: The filter assembly may be cleaned with compressed air a maximum of 30 times
or it may be washed a maximum of 20 times. A new filter should be installed after
using 500 hours of engine operating time or one year, whichever should occur first.
However, a new filter should be installed anytime the existing filter is damaged. A
damaged filter may have sharp or broken edges in the filtering panels which would
allow unfiltered air to enter the induction system. Any filter that appears doubtful,
shall have a new filter installed in its place.
(5) After washing, rinse filter with clear water until rinse water draining from filter is clear. Allow water
to drain from filter and dry with compressed air (not over 100 psi).
NOTE: The filtering panels of the filter may become distored when wet, but they will return to
their original shape when dry.
(6) Be sue airbox is clean, and inspect filter. If filter is damaged, a new filter should be installed.
(7) Install filter at entrance to airbox with gasket on aft face of filter frame and with flow arrows on
filter frame pointed in the correct direction.
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MODEL 172
MAINTENANCE MANUAL
DRAIN LINES - MAINTENANCE PRACTICES

A. 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.
2. 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.
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MODEL 172
MAINTENANCE MANUAL
DETAIL C DETAIL B
INLET DRAIN HOSE INLET DRAIN LINE BREATHER
Engine Drain Lines Installation

71-70-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
ENGINE
FUEL AND
CONTROL
MODEL 172
MAINTENANCE MANUAL

73-Title
73-00-00 1 Aug 18/2001
73-00-01 1 Aug 18/2001
2 Aug 18/2001
3 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
204 Aug 18/2001
205 Aug 18/2001
73-30-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
ENGINE FUEL AND CONTROL - GENERAL ......................................... 73-00-00 Page 1
Scope ........................................................................ 73-00-00 Page 1
Definition ..................................................................... 73-00-00 Page 1
FUEL INJECTION SYSTEM - DESCRIPTION AND OPERATION ....................... 73-00-01 Page 1
General...................................................................... 73-00-01 Page 1
Operation .................................................................... 73-00-01 Page 1
FUEL INJECTION SYSTEM - MAINTENANCE PRACTICES ........................... 73-00-01 Page 201
General ...................................................................... 73-00-01 Page 201
Precautions .................................................................. 73-00-01 Page 201
Fuel/Air Control Unit Removal/Installation ....................................... 73-00-01 Page 201
Fuel Distribution Valve Removal/Installation ..................................... 73-00-01 Page 202
Injection Nozzle Removal/Installation ........................................... 73-00-01 Page 202
Injection Nozzle Flow Test ..................................................... 73-00-01 Page 202
Idle and Mixture Adjustment .................................................... 73-00-01 Page 203
Injector Nozzle Cleaner ........................................................ 73-00-01 Page 205
Fuel Strainer Cleaner .......................................................... 73-00-01 Page 205
Air Throttle Shaft Lubrication ................................................... 73-00-01 Page 205
FUEL FLOW INDICATOR - MAINTENANCE PRACTICES ............................. 73-00-01 Page 201
General .................................................................. . 73-00-01 Page 201
EGT/Fuel Gauge Removal/Installation .......................................... 73-00-01 Page 201
Transducer and Line Removal/Installation ....................................... 73-00-01 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ENGINE FUEL AND CONTROL - GENERAL
1. Scope
A. 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.
2. Definition
(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.
73-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FUEL INJECTION SYSTEM - DESCRIPTION AND OPERATION
1. General
A. 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.
2. 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.
3. 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, passes through
the fuel distribution valve, and is routed to individual injection nozzles at each cylinder.
NOTE: For a schematic of the entire fuel system, refer to Chapter 28, Fuel Storage and Distribution
- Description and Operation, Figure 1.
B. 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.
73-00-01 Page 1
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MODEL 172
MAINTENANCE MANUAL
FUEL
STRAINER
FUEL
METERING
IDLE VALVE LEVER

MANUAL MIXTURE
THROTTLE LEVER
LINKAGE
CONSTANT EFFORT
SPRING
PRESSURE BELOW FLOW DIVIDER 1/8 INCH STAINLESS

THROTTLE STEEL LINE
METERED FUEL
PRESSURE (P2) TO FUEL
FLOW GAUGE
PRESSURE
05162001
Fuel Injection System Schematic

Figure 1 (Sheet 1)
73-00-01 Page 2
Aug 18/2001
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 passed 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.
73-00-01 Page 3
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
FUEL INJECTION SYSTEM - MAINTENANCE PRACTICES
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 Removal/Installation
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
NAS1149F0363P washer or use a thin, NAS1149F0332P 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.
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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. Fuel Distribution Valve Removal/Installation
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.
5. Injection Nozzles Removal/Installation
A. Remove Injection Nozzles.
(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.
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 verify
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.
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MAINTENANCE MANUAL
7. Idle and Mixture Adjustment

A. 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 600 +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 (10 - 20) 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 20 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 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 10-15 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: 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 20 RPM rise on lean out.
(7) Run engine to full throttle and back to idle to verify that the setting has not changed.
(8) Re-cowl engine and run until oil temperature is 150 degrees F (minimum) to verify settings have
not changed.
NOTE: Small changes in the idle speed and RPM are acceptable. Any large variations should
be investigated.
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MODEL 172
MAINTENANCE MANUAL
A
IDLE SPEED ADJUSTMENT
INLET FUEL PRESSURE TAP
AND STRAINER
IDLE
MIXTURE
ADJUSTMENT
IDLE VALVE
ART USED BY PERMISSION DETAIL A 0510T1007

OF PRECISION AIRMOTIVE A05561002
Idle and Mixture Adjustment

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MODEL 172
MAINTENANCE MANUAL
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.
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 O-rings, install fuel strainer to control unit. Torque 65 to 70 In-lbs.
(4) Reinstall fuel inlet hose. Torque 25 to 50 In-lbs.
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.
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MODEL 172
MAINTENANCE MANUAL
FUEL FLOW INDICATOR - MAINTENANCE PRACTICES
1. General
A. Engine fuel flow is measured by use of an engine compartment mounted transducer and a cockpit
mounted indicator. Component of the system include the Fuel Flow Transducer, the cockpit mounted
EGT/Fuel Flow Gauge, wiring to connect the two electrical components and rigid fuel line running
from the fuel distribution valve to the transducer.
B. Maintenance is limited to removal and installation of the components.
2. EGT/Fuel Flow Gauge Removal/Installation
NOTE: The Fuel flow gauge is incorporated on the right half of the dual-function EGT/Fuel Flow Gauge,
mounted on the left side of the instrument panel.
A. Remove Fuel Flow Gauge.
(2) Remove screws securing gauge to instrument panel.
(3) Carefully withdraw gauge from bottom side of instrument panel and disconnect electrical
connector from gauge.
B. Install Fuel Flow Gauge.
(1) Connect electrical connector to gauge.
(2) Install gauge in instrument panel using screws.
(3) Restore electrical power to airplane and ensure gauge is connected and functioning properly.
3. Transducer and Line Removal/Installation
A. Remove Transducer (Refer to Figure 201).
(3) Disconnect electrical connector from fuel flow transducer.
(4) Disconnect rigid line leading from fuel distribution valve to transducer.
(5) Remove transducer from baffle.
(6) Remove fitting from the transducer.
B. Install Transducer (Refer to Figure 201).
(1) Install fitting and o-ring in the transducer.
(2) Install fuel flow transducer to baffle.
(3) Connect rigid line leading from fuel distribution valve to transducer. Torque 25 to 50 In-lbs.
(4) Connect electrical connector to fuel flow transducer.
(5) Reinstall upper cowling. Refer to Chapter 71, Cowling - Maintenance Practices.
(6) Restore electrical power to airplane and ensure gauge is connected and functioning properly.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A
FUEL DISTRIBUTION FUEL FLOW TRANSDUCER

VALVE
ENGINE BAFFLE
NUT
RIGID FUEL LINE
CLAMP
DETAIL A
Fuel Flow Indicating Installation
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MODEL 172
MAINTENANCE MANUAL
* CHAPTER
IGNITION
MODEL 172
MAINTENANCE MANUAL

74-Title
74-00-00 1 Aug 18/2001
74-10-00 101 Aug 18/2001
102 Aug 18/2001
201 Aug 18/2001
202 Aug 18/2001
601 Aug 18/2001
602 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
IGNITION SYSTEM - GENERAL ........... ............................ ......... 74-00-00 Page 1
Scope ................... .. ..... .. ......... .. ...........................
.... 74-00-00 Page 1
Definition .................................................................. .. 74-00-00 Page 1
IGNITION SYSTEM - TROUBLESHOOTING ......................................... 74-10-00 Page 101
General .................................................................. .. 74-10-00 Page 101
IGNITION SYSTEM - MAINTENANCE PRACTICES .................................. 74-10-00 Page 201
Magneto Removal/Installation ......................................... ......... 74-10-00 Page 201
Check Magneto Timing ........................................................ 74-10-00 Page 202
IGNITION SWITCH - INSPECTION/CHECK .......................................... 74-30-00 Page 601
ACS Ignition Switch Inspection and Lubrication .................................. 74-30-00 Page 601
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
IGNITION SYSTEM - GENERAL

1. Scope
A. This chapter covers the ignition system used on the 10-360 L2A engine.
NOTE: Refer to the following table for tools, equipment and material used throughout the chapter.

Luberex Grease 10-1206 Cessna Aircraft Company To lubricate ignition
Cessna Parts Distribution switch components.
Department 701, CPD
25800 East Pawnee
Wichita, KS 67218-5590
Ignition Switch A3770 Cessna Aircraft To rebuild ignition switch.
Parts Kit
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
Aug 18/2001
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.
ENGINE WILL NOT START Defective ignition switch. Check switch continuity.
Spark plugs defective, Clean, regap and test plugs.
improperly gapped or fouled Replace if defective.
by moisture or deposits.
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 -
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.
ENGINE WILL NOT IDLE Spark plugs defective, Clean, regap and test plugs.
OR RUN PROPERLY. improperly gapped or fouled Replace if defective.
by moisture or deposits.
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Aug 18/2001
MODEL 172
MAINTENANCE MANUAL

Defective ignition harness. If no defects are found by a
visual inspection, check with
a harness tester. Replace
defective parts.
Defective magneto. Refer to Ignition System -
Impulse coupling pawls Listen for loud clicks as impulse
remain engaged. coupling operates. Remove
magneto and determine cause.
Replace defective magneto.
Spark plugs loose. Check and install properly.
74-1 0-00 Page 102

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
IGNITION SYSTEM - MAINTENANCE PRACTICES

A. The engine utilizes two Unison/Slick 4371 series, impulse-coupled magnetos to fire dual plugs in
each cylinder. Maintenance of the magnetos is limited to removal, installation and engine-to-magneto
timing.
B. For complete description, operation, troubleshooting, maintenance, overhaul and lubrication
requirements of the magnetos, refer to Unison 4300/6300 Series Magneto Maintenance and
Overhaul Manual.
C. For inspection time requirements of the magnetos, refer to Chapter 5, Inspection Time Limits. For
inspection procedures, refer to Unison 4300/6300 Series Magneto Maintenance and Overhaul
Manual.
2. Magneto Removal/Installation
NOTE: Removal and installation for both magnetos is typical.
A. Remove Magneto.
(1) Remove engine cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices.
WARNING: BEFORE ROTATING PROPELLER, REMOVE A COMPLETE SET OF UPPER
OR LOWER SPARK PLUGS FROM CYLINDERS TO PREVENT ACCIDENTAL
FIRING OF ENGINE.
(2) As a convenient reference point for reinstallation of the magneto, rotate propeller to locate
number one cylinder near TDC.
(3) Disconnect P" lead and ground wire from magneto. Remove screws securing high tension outlet
cover to the magneto.
(4) Remove nuts, washers and clamps securing magneto to engine accessory housing. Note
approximate position of the magneto for reinstallation.
B. Install Magneto.
(1) If magneto was rotated, or a new magneto is being installed, perform the following steps:
(a) Insert timing pin into back of magneto distributor housing.
(b) Rotate magneto until timing pin is locked into magneto.
(2) Install magneto to accessory case. Secure loosely to accessory case using nuts, washers and
clamps. If timing pin was inserted, remove pin from magneto.
(3) Attach high tension outlet cover to magneto. Attach ground wire to magneto.
(4) Time magneto in the following steps:
(a) Ensure cylinder number 1 is still at 25 ° BTDC.
(b) Connect a standard timing light between a suitable engine ground and the P lead terminal
of the magneto.
(c) Rotate entire magneto opposite normal rotation direction until timing light just comes on
(indicating that breaker points are beginning to open).
(d) Hold magneto in position and tighten against accessory case using nuts, washers and
clamps.
(5) After magneto is timed, reconnect P lead to magneto. Torque P lead nut from 13 to 15 In-lbs.
(6) Reinstall spark plugs.
(7) Install cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices
74-10-00 Page 201

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
3. Check Magneto Timing

A. Timing Procedures.
NOTE: This procedure is used when the magneto is already installed on the engine and timing is
being checked.
WARNING: BEFORE ROTATING PROPELLER, REMOVE A COMPLETE SET OF UPPER
OR LOWER SPARK PLUGS FROM CYLINDERS TO PREVENT ACCIDENTAL
FIRING OF ENGINE.
(2) Ensure ignition switch is OFF. Turn the propeller slowly in the normal direction of rotation until
number one cylinder passes through TDC and a distinctive "click" is heard from the impulse
couplings on the magnetos.
(3) Turn propeller backward to approximately 30 ° BTDC, and then slowly forward to 25° BTDC.
(4) Loosen mounting clamps securing magneto to accessory case.
(5) Connect a standard timing light between a suitable engine ground and the P lead terminal of the
magneto.
(6) Turn ignition switch to the ON position.
(7) Rotate entire magneto opposite normal rotation direction until timing light just comes on
(indicating that breaker points are beginning to open).
(8) Hold magneto in position and tighten against accessory case using nuts, washers and clamps.
(9) Turn ignition switch to the OFF position.
(10) Reinstall spark plugs.
(11) Install cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices
74-10-00 Page 202

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
IGNITION SWITCH - INSPECTION/CHECK

1. Description
A. The following inspection and lubrication procedures are designed for the ACS brand ignition switch
and should be accomplished every 2000 hours.
A. Refer to Ignition System - General for a list of required tools, equipment and materials.
3. ACS Ignition Switch Inspection and Lubrication

NOTE: Refer to Figure 601 for the following steps.
A. Switch Removal.
(1) Disconnect battery.
(2) Remove switch assembly from instrument panel by loosening locknut on the forward side of
panel and removing decorative nut on aft side of panel.
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 contacts and the three movable contact cups using alcohol on a cotton tip swab.
D. Switch Inspection.
(1) Inspect movable contact cups and switch contacts on the terminal board assembly for excessive
wear or corrosion and for loose contacts or terminals. If the silver plating on the contact 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 contacts on the contact 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 contacts and the three movable
contact cups. Ensure all contact 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 panel 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) Verify 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.
74-30-00 Page 601

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
A SWITCH
CONTACTS
CONTACT CUPS
SPRING
TERMINAL
BOARD
SWITCH BODY
SCREW
ACS Ignition Switch Inspection/Lubrication

74-30-00 Page 602

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
* CHAPTER
ENGINE
CONTROLS
MODEL 172
MAINTENANCE MANUAL

76-Title
76-00-00 1 Aug 18/2001
76-10-00 201 Aug 18/2001
202 Aug 18/2001
203 Aug 18/2001
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MAINTENANCE MANUAL
CONTENTS
ENGINE CONTROLS - GENERAL ................................................. 76-00-00 Page 1
Scope ...................................................................... 76-00-00 Page 1
Definition ..................................................................... 76-00-00 Page 1
THROTTLE CONTROL - MAINTENANCE PRACTICES ............................... 76-10-00 Page 201
General ...................................................................... 76-10-00 Page 201
Throttle Control Removal/Installation ........................... ................. 76-10-00 Page 201
Throttle Control Adjustment/Test ................................................ 76-10-00 Page 203
Throttle Control Inspection/Check .............................................. 76-10-00 Page 203
FUEL MIXTURE CONTROL - MAINTENANCE PRACTICES .......................... 76-11-00 Page 201
General ..................................................................... 76-11-00 Page 201
Fuel Mixture Control Removal/Installation ...................................... 76-11-00 Page 201
Fuel Mixture Control Adjustment/Test .......................................... 76-11-00 Page 203
Fuel Mixture Control Inspection/Check .......................................... 76-11-00 Page 203
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ENGINE CONTROLS - GENERAL

1. Scope
A. This chapter describes those controls used to regulate engine power.
2. 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.
76-00-00 Page 1
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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: 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.
2. Throttle Control Removal/Installation
A. Remove Throttle Control (Refer to Figure 201).
(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 panel.
(6) Carefully pull throttle control through firewall and instrument panel, and remove from airplane.
B. 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 panel
and then place washer and retaining nut over rod end.
(2) Route throttle control rod end through firewall and position throttle control in instrument panel.
(3) Secure throttle control in instrument panel by tightening retaining nut against washer and
instrument panel.
NOTE: To prevent damage to the instrument panel finish and markings, ensure the control
housing does not rotate against the instrument panel 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.
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 contacted.
(2) Push throttle control knob full in and check that full power stop on throttle body is contacted.
(3) Check that throttle has approximate 0.125 inch cushion at each stop.
(4) Work throttle control in and out several times to check for binding.
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MODEL 172
MAINTENANCE MANUAL
INSTRUMENT
PANEL
LOCKWASHER
FIREWALL LOCKWASHER
ROD END
BOLT
DETAIL A
Throttle Control Installation

76-10-00 Page 202

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MAINTENANCE MANUAL
B. Adjust Throttle Control (Refer to Figure 201).

(1) Disconnect throttle control rod end from the throttle body.
(2) Loosen jamnut and adjust throttle control rod end to obtain desired setting.
(3) Tighten jamnut.
(4) Connect throttle control rod end to throttle body.
4. Throttle Control Inspection/Check
A. Inspect 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. Check bolt, castellated nut, cotter pin
and rod end for security and condition. 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.
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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: 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 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.
2. Fuel Mixture Control Removal/Installation
A. 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 panel.
(6) Carefully pull throttle control through firewall and instrument panel, and remove from airplane.
B. 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 panel, 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 panel by tightening retaining nut against washer and
instrument panel.
NOTE: To prevent damage to the instrument panel finish and markings, ensure the control
housing does not rotate against the instrument panel 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 verify that mixture arm on throttle body is fully open (rich).
(2) Pull fuel mixture control full out and verify that mixture arm on throttle body is fully closed (lean).
(3) Check that fuel mixture control has approximate 0.125 inch cushion at each stop.
(4) Work fuel mixture control in and out several times to check for binding.
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MAINTENANCE MANUAL
INSTRUMENT
PANEL
JAMNUTS WASHER
WITH WASHERS
COTTER PIN
CABLE
LARGE WASHER
WASHER MIXTURE
DETAIL A BOLT
Fuel Mixture Control

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MAINTENANCE MANUAL
B. Adjust Fuel Mixture Control.

(1) Disconnect fuel mixture control rod end from throttle body.
(2) Loosen jamnut and adjust rod end to obtain desired setting.
(3) Tighten jamnut.
(4) Connect rod end to throttle body.
4. 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. 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.
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* CHAPTER
ENGINE
INDICATING
MODEL 172
MAINTENANCE MANUAL

77-Title
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77-20-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
ENGINE INDICATING - GENERAL .................................................. 77-00-00 Page 1
Sco pe ............................................................. ......... 77-00-00 Page 1
Definition ......... ............................................................ 77-00-00 Page 1
TACHOMETER - MAINTENANCE PRACTICES ...................................... 77-10-00 Page 201
Description and Operation ...................................................... 77-10-00 Page 201
Tachometer and Drive Cable Removal/Installation ................................ 77-10-00 Page 201
EGT SYSTEM - MAINTENANCE PRACTICES ......... ........................... 77-20-00 Page 201
EGT Indicator Removal/Installation ............ .............................. 77-20-00 Page 201
Probe Removal/Installation ..................................................... 77-20-00 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
ENGINE INDICATING - GENERAL

1. Scope
A. This chapter describes those components used to measure and indicate engine output.
2. Definition
A. This chapter isdivided 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.
77-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
TACHOMETER - MAINTENANCE PRACTICES

A. Engine speed is measured by a cockpit mounted indicator which incorporates both RPM and hour
meter functions. Maintenance is limited to removal/installation of the tachometer and drive cable.
2. Tachometer and Drive Cable Removal/Installation
A. Remove Tachometer and Drive Cable (Refer to Figure 201).
(1) On backside of instrument panel, disconnect drive cable from tachometer.
(2) Disconnect electrical connector J1014 from backside of tachometer.
(3) Remove screws securing tachometer to instrument panel and remove tachometer.
(4) Remove upper engine cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices.
(5) Disconnect drive cable at rear of accessory case.
(6) Remove two screws securing firewall shield to firewall.
(7) Withdraw drive cable through firewall.
B. Install Tachometer and Drive Cable (Refer to Figure 201).
(1) Install drive cable through firewall.
(2) Connect drive cable to accessory case housing.
(3) Install firewall shield to firewall using screws.
(4) Install tachometer to instrument panel using four screws.
(5) Connect electrical connector J1014 to tachometer.
(6) Connect drive cable to backside of tachometer.
(7) Reinstall upper engine cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices.
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MAINTENANCE MANUAL
TACHOMETER DRIVE CABLE ASSEMBLY
ENGINE TACHOMETER
DETAIL A
Tachometer Installation
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MODEL 172
MAINTENANCE MANUAL
EGT SYSTEM - MAINTENANCE PRACTICES

A. The exhaust gas temperature (EGT) system is used to measure temperature of exhaust gas as it
leaves the lower portion of the muffler. This reading provides a relative indication of the fuel/air mixture
for the pilot. The cockpit mounted EGT indicator also incorporates fuel flow readings on the right hand
portion of the instrument.
B. The system is comprised of a cockpit mounted EGT indicator with movable pointer and an exhaust
mounted probe.
C. Maintenance of the EGT system is limited to removal/installation of the various components.
2. EGT Indicator Removal/Installation
A. Remove EGT Indicator (Refer to Figure 201).
(1) Gain access to the backside of the indicator.
(2) Disconnect electrical connector from indicator.
(3) Remove screws securing indicator to instrument panel and withdraw indicator from airplane.
B. Install EGT Indicator (Refer to Figure 201).
(1) Place indicator in instrument panel and secure using screws.
(2) Connect electrical connector to indicator.
3. Probe Removal/Installation
A. Remove Probe (Refer to Figure 201).
CAUTION: EXHAUST SYSTEM REACHES EXTREMELY HOT TEMPERATURES WHICH
CAN CAUSE BODILY INJURY. ENSURE EXHAUST SYSTEM HAS COOLED
TO TEMPERATURES LOW ENOUGH TO BE SAFE IN WHICH TO WORK AND
THAT PROTECTIVE CLOTHING IS WORN BEFORE REMOVING PROBE AND
DURING MAINTENANCE PROCEDURES.
(2) Cut the tie-strap securing the electrical wire. Disconnect probe at electrical connector.
(3) Remove probe from muffler tailpipe.
B. Install Probe (Refer to Figure 201 ).
(1) Install probe to muffler tailpipe.
(2) Connect probe at electrical connector. Secure electrical wire with tie-strap.
(3) Reinstall engine cowling. Refer to Chapter 71, Engine Cowling - Maintenance Practices.
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MODEL 172
MAINTENANCE MANUAL
PROBE
DETAIL A
EGT INDICATOR
NUT INSTRUMENT PANEL

LOCKWASHER
0510T1007
AA051T 1049
DETAIL B
EGT Installation
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MAINTENANCE MANUAL
* CHAPTER
EXHAUST
MODEL 172
MAINTENANCE MANUAL

78-Title
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203 Aug 18/2001

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MAINTENANCE MANUAL
EXAUST - G EN ERAL ......... ..................................................... 78-00-00 Page 1

Scope and Definition .......................................................... 78-00-00 Page 1
EXHAUST SYSTEM - MAINTENANCE PRACTICES .................................. 78-10-00 Page 201
D escription ................................................................... 78-10-00 Page 201
Exhaust System Removal/Installation ........................................... 78-10-00 Page 201
M uffler Inspection ................................ . .................... 78-10-00 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
EXHAUST - GENERAL

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
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
EXHAUST SYSTEM - MAINTENANCE PRACTICES
1. Description
A. 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.
B. Maintenance practices for the exhaust system consist of removal, installation and testing of the
exhaust system for leaks.
2. Exhaust System Removal/Installation

A. Remove Exhaust System (Refer to Figure 201).
(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.
3. 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.
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RISER
05552001
Exhaust System Installation

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(b) With vacuum cleaner operating, all joints 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.
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MAINTENANCE MANUAL
* CHAPTER
OIL
MODEL 172
MAINTENANCE MANUAL

79-Title
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202 Aug 18/2001
79-30-00 201 Aug 18/2001
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203 Aug 18/2001
79-31-00 201 Aug 18/2001
202 Aug 18/2001

Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
CONTENTS
OIL - GENERAL ......... ......... ......... ....................................... 79-00-00 Page 1
S cope ........................................................... ......... 79-00-00 Page 1
Definition ............................................................. ....... 79-00-00 Page 1
OIL COOLER - MAINTENANCE PRACTICES ...................................... 79-20-00 Page 201
General .................................................................. .. 79-20-00 Page 201
Oil Cooler Removal/Installation ............ .......................... 79-20-00 Page 201
OIL PRESSURE INDICATORS - MAINTENANCE PRACTICES ........................ 79-30-00 Page 201
Oil Pressure Indicator and Transducer Removal/Installation ...................... 79-30-00 Page 201
Low Oil Pressure Switch Removal/Installation .................................. 79-30-00 Page 201
OIL TEMPERATURE INDICATOR - MAINTENANCE PRACTICES ...................... 79-31-00 Page 201
Description and Operation ................................................ . 79-31-00 Page 201
Oil Temperature Sending Unit Removal/Installation ............................... 79-31-00 Page 201
Oil Temperature/Oil Pressure Indicator Removal/Installation ....................... 79-31-00 Page 201
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
OIL - GENERAL
1. Scope
A. 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.
2. 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.
79-00-00 Page 1
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
OIL COOLER - MAINTENANCE PRACTICES

1. General
A. This section provides maintenance instructions for removal and installation of the externally mounted
oil cooler.
2. Oil Cooler Removal/Installation
A. Remove Oil Cooler (Refer to Figure 201).
(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.
79-20-00 Page 201

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MAINTENANCE MANUAL
A
OIL
COOLER
ELBOW
WASHER
HOSE
BOLT
CAP
DETAIL A
Oil Cooler Installation

79-20-00 Page 202

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MAINTENANCE MANUAL
OIL PRESSURE INDICATORS - MAINTENANCE PRACTICES

A. Oil pressure is measured at two distinct points on the engine and provides both indicator readings
and low oil pressure annunciation.
(1) The oil pressure indicator system is comprised of an oil pressure line, a transducer and a cockpit
mounted combination pressure/temperature indicator. Oil for the system is tapped at the upper
right side of the case. This oil is routed, via rigid line, to a transducer mounted on the rear baffle
area. This transducer produces an electrical signal which is routed to the cockpit mounted oil
pressure/oil temperature indicator.
(2) The low oil pressure annunciation system is comprised of a pressure switch and associated
wiring. The switch is mounted 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 instrument panel mounted
annunciator. This causes the OIL PRESS light to illuminate on the annunciator. When oil
pressure is greater than 20 PSI, the ground switches to the Hobbs meter, activating the meter
and extinguishing the OIL PRESS light.
2. Oil Pressure Indicator and Transducer Removal/Installation

A. Remove Oil Pressure Indicator (Refer to Figure 201).
(1) Ensure electrical power to airplane is off.
(2) Remove screws securing indicator to instrument panel.
(3) Unscrew electrical connector from backside of indicator.
(4) Carefully withdraw indicator from backside of instrument panel.
B. Install Oil Pressure Indicator (Refer to Figure 201).
(1) Connect electrical connector to backside of indicator.
(2) Position indicator to instrument panel.
(3) Secure to panel using screws.
(4) Run engine and check operation of indicator.
C. Remove Transducer (Refer to Figure 201).
(2) Disconnect oil pressure line at transducer.
(3) Disconnect electrical connector from transducer.
(4) Remove nut securing transducer to rear of baffle and remove transducer.
D. Install Transducer (Refer to Figure 201).
(1) Install o-ring and fitting to transducer.
(2) Install transducer to rear baffle and secure using nut.
(3) Connect electrical connector to transducer.
(4) Connect oil line at transducer.
(6) Run engine and check for leaks and operation of transducer.
3. Low Oil Pressure Switch Removal/Installation
A. Remove Switch (Refer to Figure 201).
(1) Ensure electrical power to airplane is off.
(3) Disconnect electrical connector from switch.
(4) Unscrew switch from engine case.
B. Install Switch (Refer to Figure 201).
(1) Using U544006 sealant (or equivalent) on threads, hand tighten new switch.
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MAINTENANCE MANUAL
ELECTRICAL
CONNECTOR
ELECTRICAL
SWITCH
Oil Pressure Indication Installation

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CAUTION: DO NOT USE TEFLON TAPE.
CAUTION: CLEAN ANY SEALER OR OTHER DEBRIS FROM THE SWITCH FITTING
BEFORE INSTALLATION. ENSURE FOREIGN MATERIAL IS REMOVED AND
CLEAR OF THE PRESSURE HOLE IN THE END OF THE SWITCH FITTING.
(2) Use a 7/16 inch wrench to tighten switch approximately 1 to 1 1/2 turns (not to exceed 60 inch
pounds) beyond hand tight.
CAUTION: DO NOT USE EXCESSIVE TORQUE ON PLASTIC SWITCH CONNECTION
HOUSING WHEN HAND TIGHTENING.
CAUTION: USE ONLY THE HEX FITTING TO FINAL TIGHTEN. EXCESSIVE TORQUE
WILL DAMAGE THE SWITCH. DO NOT ROUND THE CORNERS OF THE HEX
FITTING.
(3) Connect electrical connector to switch.

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MODEL 172
MAINTENANCE MANUAL
OIL TEMPERATURE INDICATOR - MAINTENANCE PRACTICES

A. The oil temperature system consists of a sending unit, a combination oil temperature/oil pressure
indicator and wire connecting the two components. Oil temperature is measured in the accessory
case area and provides cockpit readings in °F.
2. Oil Temperature Sending Unit Removal/Installation
A. Remove Oil Temperature Sending Unit (Refer to Figure 201).
(1) Remove upper engine cowling. Refer to Chapter 71, Cowling - Maintenance Practices.
(2) Disconnect ring terminal wiring at sending unit.
(3) Loosen and remove sending unit from accessory case.
B. Install Oil Temperature Sending Unit (Refer to Figure 201).
(1) Reinstall sending unit to accessory case.
(2) Attach ring terminal wire to sending unit. Torque jamnut to 20 Inch Pounds, maximum.
(3) Run engine and check for leaks and proper indicator operation.
3. Oil Temperature/Oil Pressure Indicator Removal/Installation
A. For removal and installation of the Oil Temperature/Oil Pressure Indicator, refer to Oil Pressure
Indicators - Maintenance Practices.
79-31-00 Page 201

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MODEL 172
MAINTENANCE MANUAL
VIEW A-A
JAMNUTS
SENDING UNIT
DETAIL
AS2335C
Oil Temperature Installation

79-31-00 Page 202

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MODEL 172
MAINTENANCE MANUAL
* CHAPTER
STARTING
MODEL 172
MAINTENANCE MANUAL

80-Title
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80-10-00 201 Feb 15/2002
202 Feb 15/2002

Feb 15/2002
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MAINTENANCE MANUAL

|~~~~~~~~~~~ I
MODEL 172
MAINTENANCE MANUAL

I
MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL

MODEL 172
MAINTENANCE MANUAL
CONTENTS
STARTING - GENERAL .......................................................... 80-00-00 Page 1
Scope and Definition ........................................................ 80-00-00 Page 1
STARTER - MAINTENANCE PRACTICES .................. ..................... 80-10-00 Page 201
Starter Removal/Installation .................................................. 80-10-00 Page 201
Bendix Drive Starter Assembly Cleaning and Lubrication ....................... 80-10-00 Page 201
Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
STARTING - GENERAL

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
Aug 18/2001
MODEL 172
MAINTENANCE MANUAL
STARTER - MAINTENANCE PRACTICES

A. The airplane is installed 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 panel operates the starter solenoid. When
the solenoid is operated, its contacts 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.
2. Starter Removal/Installation
A. Remove The Starter (Refer to Figure 201).
(1) Remove the upper and lower engine cowling. Refer to Chapter 71, Engine Cowling -
(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 securing the alternator attach bracket to the starter.
(8) Remove the four (4) bolts attaching the starter to the crankcase and remove the starter from the
engine.
B. Install The Starter (Refer to Figure 201).
(1) Using the four (4) bolts, attach the starter to the engine crankcase.
(2) Attach the alternator attach bracket to the starter with the bolt.
(3) Safety wire the bolt to the attach bracket. Refer to Chapter 20, Safetying - Maintenance
Practices).
(4) Reconnect the positive lead to the starter. Make sure the protective boot fully covers the stud
on the starter.
(5) Attach the left front baffle to the engine assembly.
(6) Attach the negative terminal to the battery.
(7) 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).
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.
NOTE: The silicone spay product code 8034 is available from Textron/Lycoming, 652 Oliver
Street, Wiliamsport PA 17701 U.S.A. Phone number (717) 323-6181.
80-10-00 Page 201

Feb 15/2002
MODEL 172
MAINTENANCE MANUAL
B1804
ALTERNATOR
STARTER
ENGINE SUMP
VIEW A-A
Starter Installation
80-10-00 Page 202

Feb 15/2002

172 MM 1996 and On

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Cessna

TEMPORARY REVISION NUMBER 5-1

MANUAL TITLE Model 172 Series 1996 And On Maintenance Manual

MANUAL DATE 2 December 1996 REVISION NUMBER 6 DATE 18 August 2001

COMPONENT TIME LIMITS

2. Cessna-Mandated Replacement Time Limits

CHAPTER COMPONENT PART NUMBER REPLACEMENT OVERHAUL

172RMM06 Temporary Revision Number 5-1 - Nov 1/2001 5-11-00 Page 1

Table 1. Cessna-Mandated Replacement Time Limits (continued)

3. Supplier Established Replacement Time Limits

Table 2. Supplier Established Replacement Time Limits

CHAPTER COMPONENT PART NUMBER REPLACEMENT OVERHAUL

172RMM06 Temporary Revision Number 5-1 - Nov 1/2001 5-11-00 Page 2

Table 2. Supplier Established Replacement Time Limits (continued)

172RMM06 Temporary Revision Number 5-1 - Nov 1/2001 5-11-00 Page 3

TEMPORARY REVISION NUMBER 61-1

MANUAL TITLE Model 172 Series 1996 And On Maintenance Manual

MANUAL DATE 2 December 1996 REVISION NUMBER 6 DATE 18 August 2001

PROPELLER - MAINTENANCE PRACTICES

2. Propeller and Spinner Removal/nstallation

WARNING: EXERCISE CARE WHEN WORKING WITH THE PROPELLER. ENSURE

Propeller and Spinner Installation

172RMM07 REVISION 7 15 FEBRUARY 2002

LIST OF EFFECTIVE PAGES

INTRODUCTION - LIST OF EFFECTIVE PAGES Page 1

REVISION DATE DATE PAGE REVISION DATE DATE PAGE

REVISION DATE DATE PAGE REVISION DATE DATE PAGE

REVISION DATE DATE PAGE REVISION DATE DATE PAGE

REVISION DATE DATE PAGE REVISION DATE DATE PAGE

SERVICE BULLETIN LIST

Service Title Service Manual

SERVICE BULLETIN LIST Page 1

Service Title Service Manual

SERVICE BULLETIN LIST Page 2

Service Title Service Manual

SERVICE BULLETIN LIST Page 3

Service Title Service Manual

SERVICE BULLETIN LIST Page 4

NAME MODEL SERIALS

| 3. Coverage and Format

8. Using the Maintenance Manual

5 Time Limits/Maintenance Checks

(6) A typical page number:

22-10-00 Page 202 Second Page of

Auto Flight Auto Pilot

Table 1. Basic Manual - Original Issue - 2 December 1996

Revision Date Revision Date

LIST OF REVISIONS Page 1

LIST OF CHAPTERS Page 1

LIST OF EFFECTIVE PAGES

5 - LIST OF EFFECTIVE PAGES Page 1

RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE DATE

RECORD OF TEMPORARY REVISIONS l

TEMPORARY PAGE ISSUE DATE

RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE DATE

RECORD OF TEMPORARY REVISIONS