REPRINT
MODEL 188 & T188 SERIES
1966 THRU 1984
SERVICE MANUAL
02054-1-13
THIS REPRINT
CONSISTS OF THE BASIC MANUAL, DATED 25 MARCH 1983,
AND INCORPORATES REVISION 1, DATED 1 AUGUST 1983.
Service Manual
1966 thru 1984 MODEL 188 & Tl88 SERIES f}
Member of GAMA
THIS REPRINT CONSISTS OF THE BASIC MANUAL, DATED 25 MARCH 1983, AND INCORPORATES REVISION 1, DATED 1 AUGUST 1983.
COPYRIGHT ·t> 1987
CESSNA AIR CRAFT COMPANY
WICHITA, KANSA S. USA
02054 - l - 13-RGI- 100- 6/97
25 MARCH 1983 REVISION 1
1 AUGUST 1983
MODEL 188 & T188 SERIES SERVICE MANUAL
LIST OF .EFFECTIVE PAGES INSERT LATEST REVISED PAGES. DESTROY SUPERSEDED PAGES. NOTE
The portion ot the text a.t!ected by the revision is indi . cated by a vertical line in the outer margins ot the page. Changes to illustrations are indicated by miniature point ing hands. Original . . . 0 . . . 2~ March 1983
Revision ... 1 . .. 1 August 1983
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 616. • The asterisk indicates pages revised, added, or deleted by the current change.
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Upon receipt o f a revision to t his book, personnel responsible for maintaining this publi cation in current status should ascertain that all previous revisions have been received and incorporated.
A
Revision
1
MODEL 188 & T188 SERIES SERVICE MANUAL
LIST OF EFFECTIVE PAGES (Cont.)
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MODEL 188 & T188 SERIES SERVICE MANUAL
TABLE OF CONTENTS
PAGE NO.
SECTION
Aerofiche / Ma"u at
GENERAL DESCRIPTION
1Al3/ l-l
GROUND HANDLING, SERVICING, CLEANING, LUBRICATION AND INSPECTION
1A21/ 2- 1
3
FUSELAGE
.. . . . . .
lCS/3-1
4
WINGS AND EMPENNAGE.
101 / 4-1
5
LANDING GEAR, WHEELS AND BRAKES.
1013/ 5- 1
6
AILE.RON CONTROL SYSTEM • .
1F7/6-1
7
WING FLAP CONTROL SYSTEM.
1F21 / 7-l
8
ELEVATOR CONTROL SYSTEM .
1G9/ 8- 1
9
ELEVATOR TRIM CONTROL SYSTEM
1021/ 9-1
10
RUDDER CONTROL SYSTEM . . . .
1H9/ 10-1
II
ENGINE (CARBURETOR) ( THRU 188023481
1H19/ ll-1
IIA
ENGINE ! F UE L IN.IECTED) .
1J2/ 11Al
11 D
ENGINE (TL'RBOCHARGEDl .
1Kl1/ 11B-1
12
FL'EL SYSTEMS . . . . . .
IJ
PROPELLERS AND GOVERNORS
287/ 13-1
14
UTILITY SYSTEMS . . . . . . .
2Cl/ 14-1
15
INSTRL'MENTS AND INSTRUMENT SYSTEMS
2C15/ 15-1
16
ELECTR ICAL SYSTEMS
2D9/ 16-1
17
STRCCTL'RAL REPAIR
2F19/ 17-1
I~
PAINTING
19
DISPERSA L SYSTE MS
211 / 19-1
20
WIRING DIAGRA MS
3A2/ 20-1
2
2A2/ 12-1
. 2H21/ 18- l
!WARNING' When periorming any inspection or maintenance that requ1res turmn~ on the master switch, installing a battery. or pulling the propeller through by hand, treat the propeller as ii the ignition switch were ON. Do not s tand, nor allow anyone else to stand. w1thin the arc of the propeller. since a loose or broken wire, or a component ma.Uunction, could cause the propeller to rotate.
MODEL 188 & T188 SERIES SERVICE MANUAL CR(l;S REFERENCE USTING OF POPULAR
NAME VS. MODEL NUMBERS AND SERIALS
All aircraft, regardless of manufacturer, are certificated under model number designations. However, popular names are often used for marketing purposes. To provide a consistent method of referring to the various aircraft, model numbers will be used in this publication unless names are required to differentiate between versions of the same basic model. The following table provides a cr oss refer ence listing of popular name vs . model nwnbers. NAME AGWAGON 230
BEGINNING
ENDD'lG
/, 966
188
188-0001
188-0317
1'1-'1-
A188
188-0001
188-0317
.e.
AGWAGON 300
SERIALS
MODELl MODEL YEAR
-----BLOCK CHANGE -------BLOCK CHANGE------- BLOCK CHANGE-------- - --- BLOCK CHANGE--- - AGWAGON "A" (230 HP} AGWAGON "A" (300 HP)
I fj6(
188
188-0318
188-0572
piM1f!:
A188
188-0318
188-0572
e_
I <t£'7
- --- - BLOCK CHANGE------- BLOCK CHANGE------ - BLOCK CHANGE------------ BLOCK CHANGE---- PM1E {)E 18800573 188A AGWAGON "B" (230 HP) 1. 969 18800832 AGWAGON "B" (300 HP)
A188A
18800573
18800832
188B
18800833
18801040
AGwagon C (300 HP)
A188B
18800833
18801040
AGtruck (300 HP)
Al88B
18800967T*
AGpickup (230 HP)
1972
18801040T
188B
18801041
18801374
AGwagon (300 HP )
Al88B
18801041
18801374
AGtruck (300 HP )
A188B
18801041T
18801374T
188B
18801375
18801824
AGwagon (300 HP)
A188B
18801375
18801824
AGtruck (300 HP )
A188B
18801375T
18801824T
188B
18801825
18802348
AGwagon (300 HP)
A188B
18801825
18802348
AGtruck (300HP)
A188B
18801825T
18802348T
AGpickup (230 HP)
AGpickup (230 HP)
AGpickup (230 HP)
1973
1974
1975
• Beginning with these serials, a ''T" may be used following the serial number which designates the aircraft has a new tubular structure and a large 37.4 cubic foot capacity hopper.
MODEL188 & T188 SERIES SERVICE MANUAL
~AME
AGwa.gon (300 HP)
MODEL YEAR 1976
AGtruck (300 HP)
AGwa.gon (300 HP)
1977
AGtruck (300HP) AGwagon (300 HP )
1978
AGtruck (300 HP )
SERIALS MODEL
BEGINNING
A188B
18802349
18802745
A188B
18802349T
18802745T
A188B
18802746
18803046
A188B
18802746T
18803046T
A188B
18803047
ENDING
18803296 ;.'~
A188B
18803047T
A188B
18803297
18803521
AGtruck (300 HP)
A188B
18803297T
18803521 T
AGhusky (310 HP)
T188C
T18803297T
T18803521T
A188B
18803522
18803721
AGtruck (300 HP)
A188B
18803522T
18803721T
AGhusky (310 HP)
T188C
T18803522T
T18803721T
Al88B
18803722
18803856
AGtruck (300HP)
A188B
18803722T
18803856T
AGhusky (310HP)
T188C
Tl8803722T
T18803856T
A188B
18803857T
18803926T
Tl88C
T18803857T
T18803 926T
A188B
18803927T
18803968T
T188C
Tl8803927T
T18803968T
Al88B
18803969T
Tl 88C
T18803969T
AGwa.gon (300 HP)
AGwagon (300 HP)
AGwagon (300HP)
1979
1980
1981
-
AGtruck (300HP)
1982
AGhusky (310HP)
AGtruck (300HP)
1983
AGhusky (310HP)
AGtruck (300 HP)
.....~
18803296T
1984 AGhusky (310 HP)
Revision
1
iii
MODEL 188 & T188 SERIES SERVICE MANUAL NOTE Cessna assigned serials are used throughout this manual. Coverage in this manual !or Argentine manufactured aircraft is determined by cross-referencing the Argentine assigned serials to the Cessna as signed serials shown in the following chart.
NAME
A~tC
188 AGpickup (230 H. P . )
SERIALS MODEL
A - 1888
BEGINNING •A-1880002 •• 18801034
ENDING • A -1880002 •• 18801034
AMC 188 AGwagon (300 H. P . )
A-1888
A~C
A-1888
188 AGwa.gon (300 H. P. )
*ARGENTINE ASSIGNED SERIALS **CESSNA ASSIGNED SERIALS ***CESSNA ASSIGNED ARGENTINE SERIALS
• •• • ••
A-Al880001 Al8801033 A-Al880003 AlSS-1035
•** A-A1880025
• •• • ••
A-Al880001 Al8801033 A-Al880016 Al8801125
***A-Al880034
MODEL 188 & T188 SERIES SERVICE MANUAL
INTRODUCTION -
This manual contains factory-recommended procedures and instructions for ground handling, ser vicing, and maintaining Cessna Model 188 and T188 Series aircraft. Besides serving as a reference for the experienced mechanic, this book also covers step-by-step procedures for the less experienced. If properly used, it will better enable the mechanic to maintain the aircraft and thereby establish a reputation for reliable service. This service manual is designed for aerofiche presentation. To facilitate the use of the aerofiche, refer to the aerofiche header for basic information. KEEPING CESSNA PUBLICATIONS CURRENT
The information in this manual is based on data available at the time for publication, and is supple mented and kept current to Cessna Dealers by Customer Care Service Information Letters, Customer Care News Letters, and Customer Care Owner Advisory Letters published by Cessna Aircraft Com pany. In addition to this information, your dealer has been supplied a group of vendor publications which describe complete disassembly, overhaul, and parts breakdowns of some of the various vendor equipment items. These vendor publications are all kept current by issuing Vendor Service Bulletins, etc., to Cessna Aircraft Company, which in turn reissues them under Cessna Vendor Service Bulletin Notices to all appropriate dealers. Further, this publication is also kept current in the following two ways: 1.
REVISIONS/CHANGES. These are issued to the dealers by Cessna Aircraft Company for this publication as requii-ed, and include only pages that require updating.
2.
REISSUE. Manual is reissued to dealers as required, and is a complete manual incorporat ing all the latest information and outstanding revisions/changes. It supersedes and re places previous issue(s).
REVISIONS/CHANGES and REISSUES can be purchased from your Cessna Dealer or directly from the Cessna Supply Division, SPA Dept. 703, Cessna Aircraft Company, 5800 East Pawnee, Wichita, Kansas 67201. All supplemental service information concerning this manual Is supplied to all appropriate Cessna Dealers so that they have the latest alithoritative recommendations for servicing these Cessna air craft. Therefore, it is recommended that Cessna owners utilize the knowledge and exrerience of the factory-trained Dealer Service Organization.
CUSTOMER CARE SUPPLIES AND PUBLICATIONS CATALOG
A Customer Care Supplies and Publications Catalog i.s available from your Cessna Dealer or directly from the Cessna Supply Division, SPA Dept. 703, Cessna Aircraft Company, 5800 East :Pawnee, Wichita, Kansas 67201. 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 quarterly and issued on Aerofiche with the quarterly Service Information Summaries. CUSTOMER COMMENTS ON MAN UAL
Cessna Aircraft Company has endeavored to furnish you with an accurate, useful, up-to-date man ual. 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 .
Revision 1
V
!WARNING' Operators. ptlots. and maintenance personnel directly concerned with aerial application of agncultural chemicals must be thoroughly familiar with all precauttonary measures . The followtng information is provided for the in divtdual who is not famtliar with these> chemicals, but who is required to perform matntenance on agricultural ~urcraft. d~?pending on exposure rate . Some are highly toxic
and can even be fatal if exposure is prolonged or treatment is delayed . Immediate treatment is
a must upon known exposure .
1 . Almost all agricultural chemtcals are toxic.
2 . Taxtc chemtcals can enter the body in dtfferent ways; inhalation when in ~por form, ingestion
when contaminated foods, dnnks. or tobacco products are consumed, and absorption when
chemtcal passes throu gh skin on contact The latter is probably most dangerous, because a
very small amount tS lethal. and the individual usually doesn 't realize he has been con
taminated.
NOTE Most common symptoms of exposure are as follows, but not necessarily in order of appearance: 1 l Mi osis, constriction of pupils of the eyes. creating a dimming of viSIOn. 21 Rhinorrhea, excesstve nasal discharge, runny nose. 3) Salivation, uncontrolled drooling of the mouth. 4 ) Constriction or tightness in chest. inability to breathe deeply enough. 5} Sometimes a cough is evtdent. 6) Sometimes, but not always, headache, fatigue, anorexia (loss of appetite), nausea, perspiration, dizziness, twitching, dreaming, irritability, and mood changes. Naturally as exposure increases symptoms worsen, and some new ones appear: 1) Cyanosis. bluish or purplish color indicating deficient oxygenation of the blood. 2} Convulsions. appearing as simtlar to an uncontrolled fit. 3) Coma . 4 ) Loss of reflexes . 5) Loss of control ove r urination and excretion. If any of these symptoms are apparent, medical aid should be sought IMMEDIATELY .
DO NOT DOCTOR YOURSELF.' rDENTIFY CHEMICAL CONTAMINATE, SO THE
PHYSICIAN CAN MAKE IMMEDIATE DIAGNOSIS AND ·PRESCRIBE PROPER TREATMENT.
3 . When handling chemicals, always wear protective equipment: Rubber gloves, rubber boots. clean cap. long-sleeved coveralls or Jump sutt. All these items should be changed daily. Do Not permit contamt nated clothing to be Laundered by someone who is unaware of the hazard in handliiig, this 1ncludes industrial laundry servtce. If handling material in an enclosed area, wear an approved resptrator or other breathing device. 4 . After use atrcraft should be washed down thoroughly, especially prior to maintenance. DO NOT steam clean. as this tends to vaporize chemicals allowtng easier and faster absorption . Drainage from wash area. must be into an area where poisomng cannot occur. DO NOT allow aircraft to be washed by untrained personnel.
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 1
GENERAL DESCRIPTION
TABLE OF CONTENTS GENERAL DESCRIPTION Model 188, A188, and T188C Series Descrlptlon . .
Page No. Aerofiche/ Manual . 1Al3/l-l . 1Al3/ 1-l . 1A13/1-l
1-1. GENERAL DESCRIPTION. 1-2. MODELS 188, A188, and Tl88C Series 1-3. DESCRIPTION. Cessna Models 188, A188, and T188C Series aircraft, described ln the manual are single- place, low-wing monoplanes , designed spec ifically for agricultural use. Two basic types of construction are uWized in the fuselage. The tail cone and empennage assemblies are of semimonoco que construction. From the tailcone forward, in· eluding the stub wings, a welded, tubular-steel structure is incorporated. Welded to the tubular structure are tabs, angles, channels, and fittings for engine mount, tailcone, landing gear, and wing and strut attachment, as well as supporting struc ture for stub wing and fuselage skin panels. Some of these panels are removable or hinged for easy access. Wlngs are of semicantllever, semimonoco que construction. A tallwheel-type landing gear and spring-steel main gear struts are provided. A canopy, with a horizontally hinged access door on each side, encloses a cockpit, provided for the pilot. Ailerons and elevators are operated by a control stick instead of control wheel. Just forward of the cockpit, a glass-fiber reinforced plastic hopper with a top-loading door is installed. A steel deflector cable is installed between the top of the canopy and the top of the vertlcal fin. The aircraft is internally corrosion-proofed, and the external finish is acid resistant. Section 19 of this manual describes op tional liqwd and dust dispersal eqwpment used on these aircraft. Power for these :urcraft is provided
Aircraft Specifications Stations . . . Torque Values . . . .
. 1A13/t-1 . 1A13/l-1 . 1A17/1-5
by six-cylinder, horizontally opposed, air-cooled Continental engines. On Model 188-Series aircraft, ·a carburetor-equipped, 230-horsepower engine drives a standard all-metal, fixed-pitch propeller, or an optional all- metal, constant-speed p r opeller. Model Al88-Series aircraft incorporate fuel-injected, 3QO-horsepower engines (285-horsepower METO rating), driving all-metal, constant-speed propellers. Beginning 1979 Model Year, a turbo powered T188C, AGhusky, is offered.
1-4. AIRCRAFT SPECIFICATIONS. Leading par ticulars of these aircraft, with dimensions based on gross weight, are given ln figure 1-L If these di mensions are used for constructing a hangar or com puting clearances, remember that such factors as tire pressures, tire sizes, and load distribution may result in some dimensions that are considerably dif- · ferent from those listed. 1-5. STATIONS. A station diagram is shown in figure 1-2 to assist in locating equipment when a written description is inadequate or impractical.
1- 1
MODEL 188 & T188 SERIES SERVICE MANUAL
GROSS WEIGHT (Restricted Category - AgTruck beginning with 1974) . . . . . (Restricted Category - AgTruck thru 1973 and A188B AgWagon) (Restricted Category - AgWagon 230) . . . . . . . . . . . (Normal Category - AgWagon 230 and 300) . (Restricted Category - AgHusky turbo) .
lb.
lb.
lb.
lb.
lb.
12, 500 Ct.
MAXIMUM OPERATING ALTITUDE (Certified).
FUEL CAPACITY
Metal Tank (Total) Not installed on 1880274& and subsequent
(Usable) . . .
Rubberized Cell (Total) .
(Usable) .
Rubberized Cell (Total) .
{Usable) .
OIL CAPACITY
Without External Filter .
With External Filter . . .
ENGINE MODEL
188 (Refer to Section 11 for Engine Data).
A 188 {Refer to Section llA for Engine Data)
Tl88C (Refer to Section llB for Engine Data)
CONTINENTAL 0-470 SERIES CONTINENTAL 10-520 SERIES CONTINENTAL TSI0-520 SERIES
PROPELLER 230 HP (Fixed-Pitch, Two- Blade) • • • . •• 230 HP (Constant-Speed, Two-Blade) • • • • • 230 HP & 300 HP (Constant-Speed, Two-Blade). 300 HP (Constant-Speed, Two-Blade) . 300 HP (Constant-Speed, Two-Blade) • 300 HP (Constant-Speed, Three-Blade) 310 HP (Constant-Speed, Three-Blade)
90" 88" 86'' 82" 80" 80" 80"
MAIN WHEEL TIRES Standard . .
Pressure .
Optional . .
Pressure .
Optional . .
Pressure .
TAIL WHEEL TffiE Standard . . Pressure . .
Optional . . .
Pressure . .
WHEEL ALIGNMENT Camber . . . . Toe In (Total Both Wheels) AILERON TRAVEL (Measured from Droop Position) Up . . . . . . . Down . . . . . Droop Position . . . . . WING FLAP TRAVEL (Thru 188-0293) . . . • . (188-0294 Thru 18800832). (Beginning 18800833) . RUDDER TRAVEL Right . . . . . . Left . . . . . . ELEVATOR TRAVEL Up . . . . . . . Do wn . . . . . ELEVATOR TRIM TAB TRAVEL Up . . Down
Figure 1-1. 1-2
4200 4000 3800 3300 4400
37 gal. 36.5 gal. 56 gal.*
54 gal.
54 gal.*
52 gal.
12 qt
13 qt
McCAULEY
McCAULEY
McCAULE Y
McCAULEY
McCAULEY
McCAULEY
McCAULEY
8. 00-6, 6- Ply Rating
35 psi
8. 50-10, 6-Ply Rating 25 psi 22 X 8. 00-8, 6-Ply Rating 35 psi
2. 80-8, 4-Ply Rating 60-70 psi 3. 50-10, 4-Ply Rating 50-60 psi
2 o to 4° 0" to . 12" l8 °:tl 0
to •: t • 3°±0.30' Down !rom 0° .
1o·.
o•
20°, 28°± 2 °
o · . to •. 2o•:~:1• o•, 5•, to•, 2o•, :1:1 • 24 o . •0° -1 o 24 · . • o• -1 ·
Aircraft Specifications (Sheet 1 of 2)
MODEL 188 & T188 SERIES SERVICE MANUAL
PRINCIPAL DIMENSIONS Wing Span (6° Dihedral) . Wing Span (9° Dihedral) . T ail Span . . . . . . . Length (Fixed-Pitch Propeller) . Length (Constant- Speed Propeller) . . . . . . Length (Constant-speed Propeller with Spinner) Fin Height (Less Flashing Beacon on Fin) . . . Fin Height (With Cable Deflector on Fin) . . . Track Width . . . . . . . . . . . . . . . . Wing Span (Turbo - Modified Conical Tips) . . . . Wing Span (Turbo - High Performance Conical Tips) Length (Turbo) . . . Tail (Turbo) . . . . Fin Height (Turbo) . Track Width (Tur bo)
484. 50" 497. 20" 131. 93" 30 6. 30 " 308.41" 315.00" None Given 96.05" 88.38" 484.40" 497. 20" 326. 53" 132.00" 98. 00" 85. 00"
BATTERY LOCATION
RH Forward Baggage Compartment
.
BATTERY LOCATION (Turbo) .
Tailcone, behind pilot's seat
* When not modified by Cessna Single-Engine Service Letter SE75- 7 and pr ior to 18801347.
*
Whe n modified by Cessna Single-Engine Service Letter SE75-7 and beg inning with 18801347.
F igure 1-1. Aircraft Specifications (Sheet 2 of 2) 1-3
MODEL 188 & T188 SERIES SERVICE MANUAL
188 SERIES 23.62
NOTE
Wing stations shown are NOT the equivalent of dimensions in inches !rom the aircraft center line. To find equivalent dimensions from air craft centerline, add 30. 00 inches to station numbers.
39.00 56.4 1 71.97 85.87
100.00 118.00
154. 00 172.00 190.00 208.00
THRU 18800832
0.00
23. 57
60.00
75.57
110. 18
.... r:o
. ~
33. 58
64. 57
111. 00
143.00
Figure 1-2. Refe renee Stations 1-4
175. 00
212. 00 233. 18
MODEL 188 8t T188 SERIES SERVICE MANUAL
1-6. BOLT TORQUES. The importance of correct application cannot be over emphasized. Under-torque can result in unnecessary wear of nuts and bolts as well as parts they are holding together. When insuf足 ficient pressures are applied, uneven loads will be transmitted throughout assembly, which may result in excessive wear or premature failure due to fatigue. Ovel'-torque can be equally damaging because of fail足 ure of a bolt or nut from overstressing threaded areas. .There are a few simple, but very important, proce足 dures that should be followed to assure that correct torque is applied: a. Calibrate torque wrench periodically to assure accuracy; and recheck frequently. b. Be sure that bolt and nut threads are clean and dry unless otherwise specified. c. Run nut down to near contact with washer or bearing surface and check "friction drag torque" required to turn nut.
d. Add friction drag torque to desired torque recommended or obtain desired torque as shown in figure 1-3. This is referred to as final torque which should register on indicator or setting for a snapover type wrench. . e. Apply a smooth even PJll when applying torque pressure. U chattering or a jerking motion occurs during final torque, back off and re-torque . C. When installing a castle nut, start alignment with cotter pin hole at minimum recommended torque, plus friction drag to:"que, and do not exceed maximum plus friction drag. U hole and nut castel足 lation do not align change washers or nut and try again. Exceeding maximum recommended torque is not recommended unless specifically allowed or recommended for that particular installation.
1-5
MODEL 188 & T188 SERIES SERVICE MANUAL
r
BOLT TORQUE VALUES BOLTS Steel Tension
Steel Tension
M$20004 thru M$20024 NAS144 thru NAS148
NAS333 thru NAS340 NAS585 thru NAS590
NAS624 thru NAS644 NAS1303 thru NA$1320 NAS172 NAS174
NA$517
AN3 thru AN20 AN42 thru AN49 AN73 thru AN81
AN173 thru AN186 M$20033 thru M$20046
M$20073 MS20074 AN509NK9 M$24694
AN525NK525
M$27039
Steel Tension
NUTS
AN310 AN315 AN363 AN365 NA$1021 M$17825 M$21045
M$20365 M$20500
NA$679
Nut-bolt size 8·36 10·32
1/ 4-28
5/16-24
3/8·24
7/ 16-20
1/2·20
9/1 6-18
5/8· 18
3/ 4-16
7/8·1 4
1· 14
1-1/8·12 1·1/4-12
Nut-bolt SIZ9
a
NAS464
r'
r
1 j·
r '
Steel Shear
Steel Tension AN310 AN315 AN363 AN365 M$17825 M$20365
MS21045 NA$1021
NAS679 NA$1291
AN320 AN364 NA$1022 M$17826 M$20364
Mon.
Maa.
Mon.
NUTS
Steel Shear AN320 AN364 NA$1022 MS17826 M$20364
r'
!"
"" i" 1'-'
12 20 50 100 160 450 480
15
25
70
140
191)
500
690
1000
1300
2500
3000
4500
7000
11 ()(10
7 12
BOO 1100 2300 2500 3700
5000 9000
30 60 95 270 290 480 660 1300 1500 2200 3000 5400
Maa.
9
15
40
85
110
300
410
600
780
1500
1800
3300
' 4200
6600
COARSE THREAD SERIES Torque Limits Torque Limits in.-lbs . in.-lbs.
12 20 40 80 160 235 400 500 700 1150 2200 3700 5500 6500
1.4aa.
15
25
50
90
185
255
480
700
900
1600
3000
5000
6500
8000
Mon
7 12 25 48 95 140 240 300 420 700 1300 2200 3300 4000
Maa.
\.
~------~----------_.------------~~ COARSE THREAD SERIES NOT USED
Revision 1
'
I'
~--~--------~------~~ ~
9
15
30
55
110
155
290
420
540
950
1800
3000
4000
5000
F1gure 1-3 Torque Values -1-6
Steel Shear
FINE THREAD SERIES
Torque Limits Torque Limits
in.- lbs. in.-lbs.
Mon
8·32 10-24
1/4·20
5/ 16· 18 3/ 8·16
7/ 16-14
1/ 2·13
9/ 16·12 5/8· 11
3/4-10 7 '8·9
1·8 1·1 '8·8
1. 1 4
BOLTS
<.:
... \.
f.J l (
MODEL 188 &. T188 SERIES SERVICE MANUAL
BOLTS
Steel Tension
AN3 thru AN20 AN42 thru AN49 AN73 thru AN81 AN173 thru AN186 MS20033 thru MS20046 MS20073 MS20074 AN509NK9 MS24694 AN525NK525 MS27039
mrrs
NUTS
Steel Tension
Steel Shear
AN310 AN315 AN363 AN365 NAS1021 MS17825 MS21045 MS20365 MS20500 NAS679
AN320 AN364 NAS1022 MS17826 MS20364
COURSE THREAD SERIES Nut bolt size
Torque Limits in-lbs MIN
8-32 10-24 1/4-20 5/16- 18 3/8-16 7/ 16-14 1/ 2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 1-1/8- 8 1-1/ 4-8
12
20
.40
80
160
235
400
500
700
1150
2200
3700
5500
6500
MAX
15 25 50 90 185 255 480 700 900 1600 3000 5000 6500 8000
Torque Limits in-lbs MIN
7
12
25
48
95
140
240
300
420
700
1300
2200
3300
4000
MAX 9
15 30 55 110 155 290 420 540 950 1800
3000
. 4000
5000
Figu re 1-3 Torque Values (Sheet 2 of 2) 1-7/ (1-8 blank)
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 2
GROUND HANDLING, SERVICING, CLEANING, LUBRICATION AND INSPECTION
lWARNINGt When performing any inspection or mainte nance that requirea turning on the master switch, installing a battery, or pulling the propeller through by hand, treat the propel ler as if the ignition switch wer e ON. Do not stand, nor allow anyone else to stand, within the arc of the propeller, since a loose or braten wire, or a component mal function, could cause the propeller to rotate.
TABLE OF CONTENTS GROUND HANDLING . Ground Movement Hoisting . Jacking . Leveling . Parking . Tie- Down Weighing Aircraft Flyable Storage . Returning Aircraft to Service Temporary Storage . . . . . Inspection During Storage . . Returning Aircraft to Service Indefinite Storage . . . . . Inspection During Storage . . Returning Aircraft to Service SERVICING . . . . . . Fuel Tanks and Cells Fuel Additives . . .
Page No. Aerofiche/Manual
. 1A21/ 2-1 . 1A21/ 2-1 . 1A21/ 2-1 . 1A23/ 2-3 . 1A23/ 2-3 . 1A22/2 -3 . 1A24/ 2-4 . 1A24/ 2-4 . 1A24/2-4 . 1A24/ 2-4 . 1A24/ 2-4 . lBl/ 2-5 . lBl/ 2-5 . l Bl/ 2- 5 . 1B2/ 2-6 . 1B3/ 2-7 . 1B3/ 2-7 . 1B3/2-7 . 1B3/ 2-7
Fuel Drains . . . . . . Engine Oil . . . . . . . Remote Engine Oil Drain Induction Air Fllter . Battery . . . . . . . . Tires . . . . . . . . . Hydraullc Brake System CLEANING . . . . . . . . . General Considerations . Windshield and Windows . Exterior Cleaning. . . . Interior Cleaning . . . . Engine and Engine Compartment Propeller . . Wheels . . . . . LUBRICATION . . . . Requirements . . Rod End Bearings INSPECTION . . . .
. 1B4/2- 8 . 1B4/2- 8 . lBS/2-9 . 1B5/2-9 . lBS/2- 9 . lBS/ 2 - 9 . lBS/2-9 . lBG/2-10 . l BG/2-10 . 1B6/2-10 . 1B6/ 2- 10 . lBG/ 2- 10 . 1B6/ 2 - 10 . 1B7/2- 11 . 1B7/ 2- ll . 1B7/ 2-11 . 1B7/2-11 . 1B7/ 2- 11 . 1Bl6/2- 20
2-1. GROUND HANDLING.
2-2. GROUND MOVEMENT. Moving the aircraft by hand is accomplished by using the wing struts and la.n ding gear struts as push points. Side pressure (or steering may be applied at the fin or stabilizer. close to the fuselage . Optional towing lugs are available. Each lug bolts to the two bottom holes in the spring struts. The lugs point inboard for attachment of tow bars.
NOTE Place padded stand at bulkhead under the stabilizer to avoid buckling fuselage skin. A b lock may be placed beneath tailwh.eel. The fuselage assembly, fr om tailcone to firewall, must NOT be supported from underside, since the skin bulkheads are not designed for this purpose.
/CAUTION \ I¢AUTION \ Do not push on control s urfaces o r outboard empennage surfaces. When pushing on tail cone, always apply pressure at a bulkhead to avoid buckling the skin.
Before attempti~ to hoist aircraft, make sure hopper is empty to av oid possible damage to the aircraft.
2-3. HOISTING. The a1rcraft may be lifted with a hoist of two-ton capacity by using a suitable sling attached to each upper engine mount at the firewall. Raise tail section of aircraft and place a suitable padded stand or block under tail section. 2-1
MODEL 188 & T188 SERIES SERVICE MANUAL
CD
0 CD CD CD
CD
REMARKS
TYPE AND NUMBER
ITEM NUMBER
Cessna "SE834-1
Adapter (Thru Serial 188-0572)
Jack
Any short jack of capable capacity
Universal tail stand
Any tail stand of capable capacity
Cessna II 1601018-1
Forward jack point (optional)
Cessna 1110004-98
Jack point (SEE CAUTION)
Cessna 111601015 - 1
Tailcone jack point fitting (optional)
Wing jacks must be of adequate strength, must be short enough to slide under front spar of wing,
and must extend far enough to raise wheels off ground.
I
Wtng Jack is inserted in tube welded to U- shaped adapter, which may be fabricated locally, or obtained from the Cessna Supply Division. Adapt~r, which !its around wing-to-Stub wing attachment at front spar, must be strong enough to SUp!X)rt aircraft. Make sure t:ul stand is strong enough t.o support any w~ight placed on it. A telescoping, adjustable tail
stand is illustrated. However, any suitable tail stand may be used.
Jacking one wing is not recommended du~ to landing gear flexibility. However, if adequate precautions against slipping are taken, it is permissible. Operate jacks evenly until desired height is reached.
(~AUTION } When using universal jack point (10004 -98), flexibility of the gear strut will cause the main wheels to slide inboard as the wheel is raised, tilting the jack. The jack must be lowered for a second operation. Jacking both wheels simultaneously with universal jack pmnts is not recommended. Umversal jack point may be used to raise only one mam wheel. DO NOT USE brake casting a~ a jack point.
I
Items (1). (4). (5) and (6) are avatlable from the Cessna Supply Diviston.
Figure 2-1. Jacking Details
2-2
Revision
1
MODEL 188 8t T1 88 SERIES SERVICE MANUAL
NOTE
To level laterally, place level across tailcone upper attach tubes, located immediately aft of pllot 's seat.
1 Station 2 Station
110. 18
143. 00
Figure 2- 2. Leveling
2-4. JACKING. Figure 2-1 may be used as a guide for jacking procedures.
(~AUTION \ When using universal jack point, flexibility
of the gear strut will cause the main 'Yheel
to slide inboard as the wheel is raised,
tilting the jack. The jack must then be
lowered for a second jacking operation.
Jacking both wheels simultaneously with
universal jack points is not recommended.
2- 5. LEVELING. Longitudinal leveling of the air craft is accomplished by installing two screws in the nutplates located on the left side of the fuselage, just aft of and below the cockpit entrance door, and plac ing a level across the screws. A level placed across
the upper tailcone-attach tubes, behind the pilot seat, is used to level the aircraft laterally. 2-6. PARK.ING. Parking precautions depend princi·· pally on local conditions. As a general pr ecaution, head aircraft into the wind, chock the wheels, install inter nal control lock and set parking brake.
!CAUT(ON \ Do not set parking brakes during cold weather when accumulated moisture may freeze the br akes or when brakes are overheated. In severe weather and high wind conditions, tie the air craft down as outlined in pa ragraph 2- 7 if a han gar is not available.
2-3
MODEL188 & T188 SERIES SERVICE MANUAL
2- 7. TIE-DOWN. When mooring the aircraft, head it into the wind, if possible. Secure control surfaces with internal control lock, and set parking brake.
I
Do not set parking brakes when they are overheated or during cold weather when accumulated moisture may freeze them.
Moor the aircraft as follows: a. Tie ropes. cables or chains to the wing tie- down fitting located on the underside of each wing. Secure opposite end to ground anchors. b. Secure a tie-down rope or chain to the tie-down fitting at the tailwheel. Secure opposite end to ground anchors located as near as possible to the tailwheel. c. Install unernal control lock on control stick. II control lock is not available, tie control stick back with seat belt. d . These aircraft are equipped with a spring-loaded tail wheel steering system which af!ords protection agautst normal wutd gusts. However, if extremely high wind gusts are anticipated, additional external locks may be installed.
2-8. WEIGHING AIRCRAFT. Handbook.
2- 9. FLYABLE STORAGE. Flyable storage is de fined as a maximum of 30 days non- oper ational stor age and/or the first 25 hours of intermittent e~ine operation. NOTE The aircraft is delivered from Cessna with a Corrosion Preventive Aircr aft Engine Oil (MlL-C-6529, Type II). This engine oil is a blend of aviation grade straight mineral oil and a corrosion preventive compound. This engine oil should be used for the first 25 hours of engine operation. In the event it is necessary to add oil during the first 25 hours of operation use only MIL- L-6082 av1ation grade straight n.ineral oil of the correct viscosity. During the 30 day non- operational storage or the first 25 hours of intermittent engine operation, every sev
Revision
1
!CAUTION} Excessive ground operation shall be avoided, 2-10. RETURNING AIRCRAFT TO SERVICE. After flyable storage, returning the aircraft to service is accomplished by performing a thorough pre-flight in spection. At the end of the first 25 hour~ of engine operation, drain engine oil, clean oil screens and change external oil filter element. Service engine with correct grade and quantity of engine oil. Refer to figure 2- 4 and paragraph 2-21 for cor rect grade of engine oiL
Refer to Pilot's
Operati~
2- 4
enth day the propeller shall be rotated through five revolutions, without running the engine . II the atr craft is stored outside. tie- down in accordance with paragraph 2-7. In addition, 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 for eign material. If at the end of thirty (30) days aircraft will not be removed fr om storage, the engine shall be started and run. The preferred method would be to fly the aircraft for thirty (30) minutes, and up to, but not exceeding normal oil and cylinder temer atures.
2-11. T E MPORARY STORAGE. Tempo!ary storage is defined as aircraft in a non- operational status for a maximum of 90 days. The aircraft is constructed of corrosion resistant alclad aluminum, which will last indefinitely under normal conditions i! 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. On painted surfaces, the paint is discolor ed or blistered. Stor age in a dry hangar is essential to good pr eservation and should be procured if possible. Varying condi tions will alter the measur es 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: a. Fill fuel tanks with correct grade of gasoline. b. Clean and wax aircr aft thoroughly. c. Clean any oil or grease from tires and coat tires with a tire preservative. Cover tires to pro tect against grease and oil. d. Either block up fuselage to relieve pressure on tires or rotate wheels every 30 days to change sup porting points and prevent flat spotting the tires. e. Lubricate all airframe items and seal or cover all openings which could allow moisture and/or dust to enter.
MODEL 188 & T1 88 SERIES SERVICE MANUAL
NOTE The aircraft battery serial number is recorded in the aircraft equipment list. To assure ac curate warranty records, the battery should be re-installed in the same aircraft from which it was removed. If the battery is returned to service in a different aircraft, appropriate record changes must be made and noWication sent to the Cessna Claims Department. f. Remove battery and store in a cool dry place; service the battery periodically and c harge as re quired. NOTE
o. Attach a warning placard to the propeller to the effect that the propeller shall not be moved while the engine is in storage. 2-12. INSPECTION DURING srORAGE. a. Inspect airframe for corrosion at least once a month and remove dust collections as frequently as possible. Clean and wax as r equired. b. Inspect the inter ior of at least one cylinder
through the spark plug hole for corrosion at least
once a month.
NOTE Do not move cr ankshaft when inspecting interior of cylinder for corrosion.
An engine treated in accordance with the fol lowing may be considered protected against normal atmospheric corrosion for a period not to exceed 90 days.
c. If at the end of the 90 day period, the aircraft is to be continued in non-oper ational storage, again per· form the procedural steps "g thru o" of paragraph 2- 11. .
g. Disconnect spark plug leads and remove upper and lower spark plugs from each cylinder.
2-13. RETURNING AIRCRAFT TO SERVICE. After temporary storage, use the following procedures to return the aircraft to service. a. Remove aircraft from blocks and check tires for proper inflation. b. Check battery and install. c. Check that oil sump has pr oper grade and quan tity of engine oil. d. Service induction air filter . and remove warning
placard from pr opeller .
e. Remove materials used to cover openings. f. Remove, clean, and gap spark plugs. g. While spark plugs are removed, rotate propel ler sever al revolutions to clear excess rust preven tive oil from cylinders. h. Install spark plugs and torque to the values spec· ified in Sections 11, U A or UB; connect plug leads. i. Check fuel strainer. Remove and clean filter screen i1 necessary. Check fuel tanks and fuel lines for moisture and sediment, drain enough fuel to elimi· nate moisture and sediment. j. Perfor m a thorough pre-flight inspection, then start and warm- up engine.
NOTE The preservative oil must be Lubricating Oil-Contact and Volatile, Corrosion In hibited, MIL- L-46002, Grade 1 or equiva lent. h. Using a portable pressure sprayer, atomize spray preservative oil through the upper spark plug hole of each cylinder with the piston in a down posi tion. Rotate crankshaft as each pair of cylinders is sprayed. i. After completing step "h. " rotate crankshaft so that no piston is at a top position. If the aircraft is to be stored outside, stop two- bladed propeller so that blades are as near horizontal as possible to pro vide maximum clearance with passing aircraft. j. Again spray each cylinder without moving the crankshaft to thoroughly cover all interior surfaces of the cylinder above the piston. k. Install spark plugs and connect spark plug leads. 1. Apply preservative oil to the engine interior by spraying approximately two ounces of the preserva tive oil through the oil filler tube. m. Seal all engine openings exposed to the atmos phere using suitable plugs or non-hygroscopic tape. Attach a red streamer at each point that a plug or tape is installed. n. If the aircraft is to be stored outside, perform the procedures outlined in paragraph 2-7 . In addi tion, 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.
2-14. INDEFINITE srORAGE. Indefinite storage is defined as aircraft in a non- operational status for an indefinite period of time. Engines treated in accor dance with the following may be considered protected against normal atmosphere corrosion, provided the procedures outlined in paragraph 2- 15 are preformed at the specified interva ls. a. Operate e~ine oil until the temper ature reaches normal operati~ r ange. Drain engine oil sump and reinstall drain plug and safety. b. Fill oil sump to normal operati~ capacity with corrosion preventive mixture recommended in the following note. Throughly mix and preheat the pr e ventive mixture (221 °F to 250°F) at the time it is added to the engine.
2-5
MODE L 188 & T188 SERIES SERVICE MANUAL
NOTE Corrosion preventive mixture consists of one part compound :'-.tiL-C - 6529, Type I. mixed with three parts new lubr icating oil of the grade recommended for service. During all spraying operations , corrosion pre ventive mixture is preheated to 221 °F to 250°F. c. Immediatly after filling the oil s ump with cor
rosion preventive mixture, fly the aircraft for a
period of time not to exceed a maximum of 30 min
utes.
d. After flight, with engine operating at 1200 to 1500 rpm and induction air filter removed, spray corrosion preventive mixture into induction airbox, at th e rate of one- half gallon per minute, until heavy smoke comes from exhaust stack, then increase the spray until the engine is stopped.
/CAUTION \ Injecting corrosion -preventive mixture too fast ca n ca use a hydrostatic lock. e. Do not rotate propeller after completing step ''d.
It
f. Remove all spark plugs and s pray corrosion preventive mixture, which has been pre-heated (221 o to 250°F) into all spark plug holes to throughly cover interior s urfaces of cylinders. NOTE To throughly cover all surfaces of the cylinder interior, move the nozzle of the spray gun !rom the top to the bottom of the cylinder. If by accident the propeller is rotated fol lowing this sprayi~ , re- spray the cylinders to ensure an unbrcken coverage on all sur faces. g. Install spark plugs or solid plugs into the lower spark plug holes and install dehydrator plugs in the upper s park plug holes. Be sure that dehydrator plugs are blue m color when installed. h. Cover spark plug lead terminals with shipping plugs (AN4060-l) or other suitable cover s. i. With throttle tn full open position, place a bag of desiccant in the carburetor intake and seal open ing with moisture resistant paper and tape. j. Place a bag of desiccant in the exhaust tail pipe(s) and seal openings w1th moisture resistant tape. k. Seal cold air inlet to the heater muff with mois ture resistant tape. I. Seal engine breather by inserting a protex plug in the breat her hose and clamping m place. m. Seal all other engine openings exposed to atmos phere us1ng su ttable plu~;s or non - hygroscopic tape. :--IOTE Attach a red streame r to each place plugs or tape tS installed. Either attach red streamers 2-6
outside of the sealed area with tape or to t he inside of the sealed area with safety wire to pr event wicking of moisture into the sealed area.
n. Drain corrosion preventive mixture from engine sump and reinstall drain plug or close drain valve. NOTE The corrosion-preventive mixture is harmful to paint and should be wiped from painted sur faces immediately. o. Attach a warning placard on the throttle control knob, to the effect that the engine contains no lubri eating oil. Placard the propeller to the effect that it should not be moved while the engine is in storage. p. Prepare airframe for storage as outlined in
paragraph 2-11 thru step "f '.
NOTE As an alternate method of indefinite storage, the aircraft may be serviced in accordance with paragraph 2-11, providi~ the aircraft is run- up at maximum intervals of 90 days and then reserviced per paragraph 2- 11.
2-15. INSPECTION DURING STORAGE. Airc raft in indefinite storage shall be inspected as follows: a. Inspect cylinder protex plugs ea ch 7 days. b. Change protex plugs if their color indicates an unsafe condition. c. II the dehydrator plugs have changed color in one half of the cylinders, all desiccant material In the engine shall be replaced with new material. d. Respray the cylinder interiors with corrosion pr~ ventive mixtur e every six months and replace desiccant and protex plugs . NOTE Before spraying, inspect the interior of one cylinder for corrosion through the s park plug hole and remove at least one rocker box cover and inspect the valve mechanism. 2-16. RETURNING AIRCRAFT TO SERVICE. Arter indefinite storage, use the following procedure to return the aircraft to service. a. Remove aircraft from blocks and check tires for correct inflation. b. Check battery and install. c. Remove a ll materials used to seal and cover openings. d. Remove warning placards posted at throttle and pr opeller. e. Remove and clean engine oil screen, then re install and safety. On aircraft that are equipped wtth an external oil filter, install new filter element. C. Remove oil sump drain plug or open drain valve
and drain sump. Install or close drain valve and
safety. Service engine with oil per F igure 2-4.
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE The corrosion-preventive mixture will mix with the engine lubricating oil, so flushing the oil system is not necessary. Draining the oil sump will remove enough of the cor rosion-preventive mixture. g. Service and install the induction air filter. h. Remove dehydrator plugs and spark plugs or plugs installed in spark plug holes and rotate pro- . peller by hand several revolutions to clear corrosion preventive mixture from cylinders. i. Clean, gap, and install spark plugs. Torque plugs to the vaiues listed in Sections 11, llA, and llB. Connect leads. j. Check fuel strainer. Remove and clean filter screen. Check fuel tanks and fuel lines for moisture and sediment, and drain enough fuel to eliminate. k. Perform a thorough pre-flight inspection, then start and warm-up engine . 1. Thoroughly clean aircraft and flight test air craft. 2-17. SERVICING. Servicing requirements are outlined 1n figure 2-4 . The following paragraphs supplement this figure by adding details not in cluded 1n the figure. 2-18. FUEL TANKS AND CELLS. Fuel tanks or cells should be filled to capacity immediately after flight to retard condensation. The recommended fuel grade for each model is listed in figure 2-4. Fuel capacity for each model configuration is listed in Section 1. 2- 19. USE OF FUEL ADDITIVES FOR COLD WEATHER OPERATION. Strict adherence to recom mended preflight draining instructions will eliminate any free water accumulations from the tank sumps. While small amounts of water may still remain in solution 1n the gasoline, it will normally be consumed and go unnoticed in the operation of the engine. One exception to this can be encountered when oper ating under the combined effect of: 1) use of certain fuels, with 2) high humidity conditions on the ground 31 followed by flight at high altitude and Low tempera ture. Under these unusual conditions small amounts of water in solution can precipitate from the fuel stream and freeze in sufficient quantities to induce partial icing of the engine fuel system. While these conditions are quite rare and will not normally pose a problem to owners and operators, they do exist in certain areas of the world and con sequently must be dealt with when encountered. The refore , to alleviate the possibility of fuel icing occurnng under these unusual conditions it is per miSSible to add ISOpropyl alcohol or ethyelene gl}·col monomethvl ether 1EGME l compound to the fuel sup pi}". See figure 2- 3 for fuel additive mixing ratio.
Ethylene glycol monomethyl ether ( EG_M~ ) compound in compliance with MIL- 1-27686 or Ph1lhps PFA 55MB, if used, must be carefully mixed with the fuel in concentrations not to exceed 0. 15% by volume.
(~AUTION \ Mixing of the EGME compound with the fuel is extremely impor tant because concentra tion in excess of that recommended (0. 15 percent by volume maximum) will result in detrimental affects to the fuel tanks, such as deterioration of protective primer and sealants and damage to 0-rings and seals in the fuel system and engine components. Use only blending equipment that is recom mended by the manufacturer to obtain proper propor tioning. Do not allow the concentrated EGME com pound to come in contact with the airplane finish or fuel cell as damage can result. Prolonged storage of the airplane will result in a water buildup in the fuel which "leeches out" the additive. An indication of this is when an excessive amount of water accumulates in the fuel tank sumps. The concentration can be checked using a differential refractometer. It is imperative that the technical manual for the differential refractometer be followed expliciUy when checking the additive concentration. Alcohol, if used, is to be blended with the fuel in a concentration of 1% by volume. Concentrations greater than 1% are not recommended since they can be detrimental to fuel tank materials. The manner in which the alcohol is added to the fuel is sigmficant because alcohol is most effective when it is completely dissolved in the fuel. To insure proper mucing the following is recommended. 1. F or best results the alcohol should be added during the fueling operation by pouring the alcohol directly on the fuel stream issuing from the fuel nozzle. 2. An alternate method that may be used is to premix the complete alco ol dosage with some fuel in a separate clean container (approximately 2-3 gallon capacity) and then transfer this mixture to the tank prior to the fuel operation.
Any high quality isopropyl alcohol may be used, such as: Anti-icing fluid ( MIL- F - 5566 ) or Isopropyl alco hol (Federal Specification TT-l-735a). Ethylene glycolmonomethyl ether (EGME) compound in compliance with MIL- 1-27686 o r Phillips PFA 55MB, if used, must be carefully mixed with the fuel in concentrations not to exceed 0. 15% by volume.
The 1ntrodu cu on of alcohol o r EGl\tE compound 1nlo the fuel prov1des lwo d!Sllnct effects : I l 1t absorbs the d 1ssolved water from the gasoline and 21 alcohol has a fre ez 1ng temperature depressant effecl. 2- 7
MODEL 188 & T188 SERIES SERVICE MANUAL
140
18
4.5
16
4.0
14
3.5
120
...., ~ 100 1 0 0
c(
..... 80 0
~ 3.0
...., 12 > i= 010
0 ~
0
c(
....,
V)
u z :::> 60
0 0
5
.....
0
.
....
I>'
2.5
u. 0
8
~0~
s5~
'+!
1
(/) 2.0 1 a:
(/) ~
:::> u 6
5 1.5
4
1.0
2
0.5
0
0.0
c(
-J
.....
20
0
EGME ·
0
10
20
30
40
50
60
70
80
90
100
110
GALLONS OF GASOLINE
Figure 2-3. Fuel Additive Mixing Ratio Chart 2-20. FUEL DRAINS. The fuel drain for the metal tank system is located in the fuel strainer. The strainer drain valve is operated by a control located adjacent to the engine oil dipstick. Access to the control is through the oil dipstick door in the upper engine cowl. In the rubberized wing tank fuel system, fuel drains are located in each wing fuel cell, in the bottom of the fuel reservoir tank and in the fuel strainer. Fuel strainer drain control is located on lower RH instrument panel (thru 18800832), in engine compartment adjacent to engine dipstick (18800833 thru 18803296) and on lower LH instrument panel (18803927) & on. Open strainer drain and remove strainer screen at the intervals specified in figure 2-4. Remove plugs and drain fuel system at the intervals specified. Also, during daily inspection of the fuel strainer, if any water is found in the strainer, there 1s a possibility the fuel tanks or lines contain water. Therefore, the fuel system should be drained to remove any water from the fuel system. On aircraft equipped w1th rubberized fuel cells, a fuel sampler cup is furnished. To activate drain valve Cor fuel sampler, place cup up to valve and depress valve with rod protruding from cup. (Refer to Section 12.)
oil
2-21. E~INE OIL. 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 poss1ble when checking the eng1ne oil. so that a true reading IS obtained. Er>.gme 011 should be dra1ned ·...,hlle engtne IS still hot. Engine oil should be changed e\·ery six months, even though less than the specliied hours have accumur.tted. Reduce these tnten·als for prolonged operations in
2-8
Revision
1
dusty areas, in cold climates where sludging cond itions exist, or where short flights and long idle per iods are encountered, which cause sludging cond itions. Always change oil, clean oil screens, and clean and I or change external filter element when ever oil on the dipstick appears dirty. Ashless dis persant oil conforming to Continental Motors Spec ification MHS-24 and all revisions or supplements thereto and conforming with current Continental Aircraft Engine Service Bulletins shall be used in the Continental Engine. NOTE New or newly overhauled engines should be operated on aviation grade straight mineral oil until the first oil change. The aircraft is delivered from Cessna with a corrosion preventive aircraft engine oil. If oil must be added during the first 25 hours, use only aviation grade straight mineral oil conforming to Specification MIL-L- 6082. After the first 2 5 hours of operation, drain engine oil sump and clean both the oil suction strainer and the oil pressure screen. If the aircraft is equipped with an oil filter, change the filter at this time. Refill sump with avia tion grade ashless dispersant oil. Refer to Continental Motors Service Bulletin M82-8, and any superseding bulletins, revisions, or supplements thereto, for further recommen dations.
MODEL 188 8t T188 SERIES SERVICE MANUAL
When changing engine oil, remove and clean oil screens, o r install a new filter element on aircraft equipped with an external oil filter. To drain the engine oil, proceed as follows: a. Operate engine until oil temperature is at nor mal operating temperature. b. Remove oil drain plug from engine sump and
allow oil to drain into a container.
c. After engine oil has drained, install and safety drain plug or close drain valve. d. Remove and clean oil screen. e. Service engine with correct quantity and grade of engine oil. NOTE Refer to inspection charts for intervals for changing oil and filter elements. Refer to figure 2-4 for correct grade of engine oil, and correct capacities. Also Section 1. 2- 22. REMOTE EN:JINE OIL DRAIN. An optional remote engine oil drain system may be installed. This system allows the engine oil to be drained from the engine without having to remove the lower engine cow ling. The installation consists of an on-off valve mounted at the base of the firewall and connected to the engine oil sump by a flexible fire resistance hose. 2-23. INDUCTION AIR FILTER. (Thru Serial 18801374.) The frequency with which the filter s hould be removed and cleaned will be determined primarily by aircraft operating conditions. A good general rule, however, is to remove and clean the filter at least every 50 hours of engine operating time and more frequently if warranted by operating conditions. Filter blockage can be considered excessive whenever the difference between the manifold pressure reading with the engine shut down on the ground and the mani fold pressure reading with the engine running on the ground at full throttle and high RPM exceeds 1. 0 in. Hg. Under extremely dusty conditions , daily maintenance of the.filter is recommended. The aircr¥t is equip ped Wlth a paper-media filte r. To service the air filter, proceed as follows: a . Remove filter from aircraft, b. Clean filter by blowing with compressed air (not over 100 psi) from direction opposite of normal air flow. Normal air flow is from outside to inside of filter. NOTE Use care to prevent damage to filter element
when cleaning with compressed air. Never
use an air pres!"•Jre g r eater than 100 psi.
c. Aft<:& cleaning as outlined in step "b", filter may be washed, 1f necessary, with a mild household de
tergent, and a warm water solution.
(~AUTION{ Do not use solvent or cleaning fluids to clean filter. Use only a mild household detergent and warm water solution. d. After washing, rinse in clean water and allow water to drain !rom filter. Dry with compressed air (not over 100 psi). e. Be sure induction air duct is clean, inspect
filter , and replace if damage is evident.
f. Install filter with gasket on aft face of filter
frame and safetywire attaching wing nuts.
2-24. INDUCTION AIR FILTER. Ever y 50 hours or more often under dusty conditions. clean air filter by tapping on a hard surface to remove loose dirt. Re place filter every 500 hours or more often if required . 2-25. BATTERY. Battery servicing involves adding distilled water to maintain the electrolyte even with the horizontal baffle plate or split ring at the bottom of the filler holes, checking cable connections, and neutralizing and cleaning off any spilled electrolyte or corrosion. Use bicarbonate of soda (baking soda) and clean water to neutralize electrolyte or corrosion followed with a thorough flushing with clean water. Do not allow bicarbonate of soda to enter battery. Brighten cable and terminal connections with a wire brush, then coat with petroleum jelly before connect ing. Check the battery every 50 hours (or at least every 30 days), more often in hot weather. Add only
distilled water, not acid, or "Rejuvenators" when
maintaining electrolyte level in the battery. ' Inspect
the battery box and clean, and remove any evidence
of corrosion. See ;Section 16 for detailed battery
removal, installation and testing.
2-2 6. TIRES. Tiree should be maintained in the air P.ressures specified in figure 1-1. When checking ttres for pressure. examine for wear, cuts, bruises and slippage. Remove oil, grease and mud from tires with soap and water. NOTE Recommended tire pressure should be main tained. Especially in cold weather, remem ber that any drop in temperature of the air inside a tire causes a corresponding drop in pressure. 2-27. HYDRAULIC BRAKE S"Y:STEM:S. Check brake master cylinders and refill with MIL-H-5606 hydraulic fluid as specified in the inspection charts. Bleed the brake system of entrapped air whenever there is a spongy response to the brake pedal. Refer to Section 5 for filling and bleeding of the brake system.
NOTE The filter assembly may be cleaned with a tr a maximum of 30 times or washed a maximum of 20 times. Filter should be replaced alter 500 hours of engine operation or one year, whichever should occur first. 2-9
MODEL 188 & T188 SERIES SERVICE MANUAL
2-28.
CLEANING.
NOTE
2-29. GENERAL CONSIDERATIONS. Keeping the :urcra!t cle:1n is import:utt. Besides maJntainin~ the tnm appearance of the aircrait, cleaning reduces the poss1bility of corros10n .lnd makes inspection and maintenance easier. 2-30. WINDSHIELD AND WINDOWS. Clean care full y w1th plenty of fresh water and a m1ld detergent. ustng the palm of the hand to feel and dislodge any caked dirt or mud. Ruboer gloves should be used to avoid hands coming in contact with any chemicals or dust on Windows o r wwdshield. A sponge. soft cloth or c ham01s may be used. but only as a means of ca rrying wate r to the plastic. Rinse thoroughly, then dry with a clean moist chamois. Do not rub the plas tic with a dry cloth since this builds up an electro static charge which attracts dust. Oil and grease may be removed by rubbing Lightly with a soft cloth moistened with Stoddard solvent. After washing, thE plastic windshield and w1ndows should be cleaned wtth an aircrait windshield cleaner . Apply the clean er w1th soft cloths, and rub with moderate pressure. Allow the cleaner to dry. then wipe it off with soft flannel cloths. A thin, even coat of wax, polished out by hand Wlth clean. soft flannel cloths. will fill in mwor scratches and help prevent further scratch ing. Do not use a canvas covt>r on the wmdshield or Windows unless a freezing rain or sleet is anticipated, s1nce the cover may scr.ltch the plastic surface.
iC.A UTION j Do not use gasohne, alcohol, benzene, acetone, carbon tetrachlonde, fire extinguisher fluid, de-1cer fluid, lacqut·r thinner or glass window c leamng spray. Tht·sc solvents wi II soften and c ra ze the plastu·. 2-31. EXTERIOR CLEANING. Do not apply wax or polish for a penod of 7 to 10 days after delivery. Th1s w11l g1ve the pamt a chance to cure by the nat ural process. Waxes and polishes seal the pa1nt from the a1r and prevent curing. Any ordinary a~to moblle paste wax may be used to polish the painted surface. U 1t 1s necessary to clean the pamted sur fa ce befor e the exp1rat1cn of the cu nng penod. use cold or lukewarm water and soap, rubbtng gently and holding 1t to a m1n1mum to avoid cracking the pa1nt film . Pnor to cleaning, 1nstall plugs or mask off all open1ngs to prevent entry of water in the en gine compartment, or pilOt and static systems. First the a:rplane tncludtng spray and dusting equip ment should be hosed down w1th clean water to flush away any loose d1rt: then wash with clean luke · warm wa ter and soap. Rubber gloves should be used to avo1d hands com1ng 1n contac t with any chem1cals on the exteno r su rface . Harsh o r abras1ve soaps o r oete rgents. wht ch could cause corros1on vr make scratches. should not bE- .1sed. Soft cleant n~ clo1hs or a chamo1s should oc 1sed to prevent sc r::~tche s when rle::ln ln-: •)r ;.>ul t::.ht:lg. To remove s tubborn oil 1nd ~rease. ·..: s e l c l·>th dampened ·Ntth naphtha •)r kerosene. A f1ne 5rade rubbtn~; compound ma\' o~ used to remove bugs and gasoltne st.atns. 2- 10
At least once a day, the aircraft should be cleaned to help prevent corrosion and s taining of the painted surfaces . 2-32. INTERIOR CLEANING. Prior to hosmg out the interior of the fuselage, remove the two panels on each side of the tubular structure and the one on each side of the tailcone. Open the two access doors aft of the firewall and remove rubber plugs from drain holes in bottom of fuselage. Remove pilot's seat. The radio, heater outlet and instrument panel should be protected to keep them dry. First hose down interior of fuselage and inside of panels, using clean water to flush away any dust and chemicals that may have collected. Care must be taken not to direct stream of water on or behind the instrument panel or radio. Do not direct stream of water at intersection of rudder cables and aft tailcone bulk head, as water could get through the seals into the stabilizer. After the interior has been hosed down it should be washed by hand with a sponge or soft cloth, using a mixture of warm water and soap. Rubber gloves should be worn during the washing process to protect hands from chemicals on the inter ior surface. A hose rinse should follow the soap and water washing process to flush away s oapy water . After a reasonable drying period remstall rubber plugs in drain holes in bottom of fuselage. Close access doors, and reinstall panels and pilot's seat. 2-33. ENGINE AND ENGINE COMPARTMENT . An engine and accessories wash-down s hould be accom plished during each 100-hour inspection to remove oil, grease, salt corrosion or other residue that might conceal component defe~s during inspection. Also, i>eriodic cleaning can be very effective in pre ventive maintenance. Precautions should be taken when working with clean ing agents such as wearing of rubber gloves, an apron or coveralls and a face shield or goggles. Use the least toxic of available cleaning agents that will satis factorily accomplish the work. These cleaning agents include: (1) Stoddard solvent (Specification P-D-680, type ll) , (2) A water base alkaline detergent cleaner (MIL- C- 25769J) mixed 1 part cleaner, 2 to 3 parts water and 8 to 12 parts Stoddard solvent or {3) A sol vent base emulsion cleaner. {MIL-C-4361B) mixed 1 part cleaner and 3 parts Stoddard solvent.
(~.A UTION} Do not use gasoline or other highly flam mable substances for wash-down. Perform all cleaning operations in well ventilated work areas. and ensure that adequate fire-fighting and saiety equipment is available. Do not smoke or expose a flame within 100 reet of the cleaning area. Co mpressed air. used for cleaning agent application or dry1ng. should be regulated to the lowest practical pr essure. Use o f a stiff bristle brush rather than a s teel brush is recommended if cleaning agents do not remove excess grease and grime during spraying.
MODEL 1 8 8 & T1 88 SERIES SERVICE MANUAL
A recommended procedure for cleaning an engine and accessories is as follows .
jCAUTION \ Do not attempt to wash an engine which is still hot o r running. Allow the engine to cool before cleaning. a. Remove engine cowling. b. Use fresh water for wash-down when the engine is contaminated with salt or corrosive chemicals. A cleaning agent such as described previously may then be used to remove oil and grease.
(CAUTION ! Care should be exercised to not direct cleaning agents or water streams at openings on the starter, magnetos, alternator, ...,,.,.urn pump or turbocharger relief valve. 2-37. c. Thoroughly rinse with clean. warm water to
remove all traces of cleaning agents.
[~AUTJON ! Cleaning agents should never be left on
engine components lor an extended period
ol time. Failure to remove them may
cause damage to components such as
Neoprene seals and silicone !ire sleeves
and could cause additional corrosion.
d. Completely dry the engine and accessories using clean, dry compressed air. e . U desired, the engine cowling may be washed with the same clean!~ agents, then rinsed thorough ly and wiped dry. C. Reinstall engine cowling.
2-34. PROPELLER. Wash hub and blades with a soft cloth and Stoddard cleaning solvent o r equt valent. then dry thoroughly with compressed air. Wipe pro peller occasionally with an Oil)' cloth. then wipe with a dry cloth. In salt water areas this wi 11 assist in corrosion proofing th propeller. Check blades and hub periodically for oxidation and corroston. When cleaning propellers, take the following pre cautions:
a. Be sure ignition switch ts off. b. Make sure engine has cooled completely. When moving propeller, DO NOT STAND IN UNE OF BLADE. c. Avoid using excessive amount of liquid cleaner as it may splatter or run down the blade and enter the propeller hub or engine. d. After cleaning, check the area around the prope . ler hub to be sure all cleaning solution is removed. See Section 13 lor information on oil filled hubs. 2-35. WHEELS. The landing gear wheels should be washed pe riodically and examined for corrosion, chipped paint , and cracks or dents in the wheel cast: ings. Sand smooth, prime and repaint minor defects. 2-36.
LUBRICATION.
2- 37. REQUIREMENTS. Lubrication requirements are specilied ln the lubr ication chart in llgure 2-5. Be!ore adding grease to fittings,wipe off all dirt. Lubricate until new grease appears around parts be ing lubricated, when wipe off excess grease. Lubri cate tailwheel every 25 hours. When operating in dusty conditions, mud or water, more frequent lubri cation is recommended.
(WARNING ' For maximum safety, check that the magneto switches are OFF, the throttle is closed, the mixture control Is in the idle cut-of! position, and the airplane is secured before rotating the propeller by hand. Do not stand within the arc of the propeller blades while turning the pro peller. g. Before starting the engine, rotate the propeller by hand no less than four complete revolutions .
2-38. ROD E.ND BEARINGS. Periodic inspection and lubrication is required to prevent corrosion of the bea ring in the rod end. At each 100 hour inspec tion, disconnect the control rods ?t the aileron and flap and inspect each rod end for corrosion. u no corrosion is found, wipe the surface of the rod end balls with a general purpose oil and rotate the ball Creely to distribute the oil over its entire surface and connect the control rods to their respective units . U corrosion is detected during the inspection, install new rod ends.
Revision 1
2-11
MODEL 188 & T188 SERIES SERVICE MANUAL
>·~·.....,...
··.: .. ···.•... ···.; ······~· ... . .; ~:·.
.
··············
AG Husky
Refer to Sheet 2 for Fuel. Oil and Hydraulic Fluid Specifications.
Figure 2-4. Revision
1
Servictng (Sheet 1 of 5)
MODEL 1 8 8 & T 1 88 SERIES SERVICE MANUAL
HYDRAULIC FLUID :
SPEC. :-10. MIL -H -5606
SPECIFIED AVIATION GRADE FUELS:
!WARNING' ONLY AVIATION GRADE F UELS ARE APPROVED FOR USE .
E NGI:-IE MODEL
APPROVED FUEL GRADES
NOTE
lOOLL (blue)
CONTINENTAL 0-470 CONTINENTAL I0-520
100 (green) (formerly 100/ 130) NOTE
1. Compliance with Continental Aircraft Engine Service Bulletins M77- 3 and M75-2,
and all supplements or revisions thereto, must be accomplished. SPECIFIED AVIATION GRADE OIL: AVERAGE AMBIENT TEMPERATURE (° F ) / OIL GRADE
1-+-
- --:1_ _....;1_
l
SAE 30
1
I
..L.
I
I
i lr-50; 2t-50 ~ SAE
SAE
SAEso I~---~------~ 1
1
•
sAf 2sw-;so --~----_. 1
Aviation grade ashless dispersant oil, conforming to Continental Motors Specification MHS- 24 , and all revisions or supplements thereto, must be used except as noted in paragraph 2-21 herein. Refer to Continental Aircraft Engine Service Bulletin M75-2 and any superseding bulletins , rev isions or supplements ther eto, !or further recom mendations. Oil capacities for the aircralt are given in the following chart . To minimize loss of oil thr ough the breather, fill to specilied oil level on dipstick for normal operation (flight of less than three hours duration). For extended flight , fill to FULL mark on dipstick. Do not operate with less than MINIMUM FOR FLIGHT quantities listed. U an exter nal oil filte r is Installed, one additional quart of oil ls required when filter ts cha nged. CAPACITY (TOTAL) 12.
CAPACITY (TOTAL WITH FILTER) 13
NORMAL OPERATION
MINIMUM F OR F LIGHT
10
9
Figure 2-4. Servicing (Sheet 2 of 5) Revision 1
2-13
MOD EL 188 & T188 SERIES SERVICE MANUAL
HYDRAULIC DISPERSAL SYSTEM SERVICE REQUffiEMENTS
···········-····················-........
--------=:··· -.-
~:~ f: (.J ) 18800573 THRU 18801374
.•{
A Change the filter when any system component has been changed because of an internal failure. B Remove and flush
reservoir tank and oil cooler and flush remainder of system when hydraulic syst em has been contaminated. Flush the system with DEXTRON type automatic transmittion fluid.
SYSTEM FLUID: Aircraft Senals 188 00573 thru 18801374: Fill rese r vo1r to 3. 00 Inches fr om the top of the filler neck us1ng Type ··A·· Automatic TransmiSSI On F luid and pr es sunze reservOir to 8-10 ps1.
Aircraft Serials Begmning with 18801375 : Fill reserv oi r to F ULL mark on dipstick with DEXR0:'-1 type automatic transmission fluid and charge to 15 psi.
F igure 2-4. Servicing (Sheet 3 of 5) 2-14 .
MODEL 188 & T188 SERIES SERVICE MANUAL
0
DAILY
FUEL FILLER SerVlce a!ter each flight . Keep full to retard condensation. details.
2
FUEL TANK DRAINS Drain off any water and sediment before first flight of the day.
4
PITOT AND STATIC PORTS Check for obstructions before first flight of the day.
9
~
Refer to paragraph 2- 18 for
. OIL FILLER CAP Whenever oil is added, check that filler cap is tight and oil filler door is secure.
10
OIL DIPSTICK Check on preflight. Add oil as necessary.
12
FUEL STRAINER Drain off any water and sediment before first flight of the day. Refer to paragraph 2-20 for details.
13
INDUCTION AIR FILTER Inspect and service under dusty conditions. Refer to paragraph 2- 23 for details.
19
PROPELLER Inspect blades at hubs for red oil (oil filled hubs.)
~15
0
Refer to paragraph 2- 21 for details.
FIRST 25 HOURS
ENGINE OIL SYSTEM Drain engine sump and r e place filter (if equipped). with ashless dispersant oil.
0
TAIL WHEEL Lubricate every 25 hours.
0
Refill sump
25HOURS
SOHOURS
5
T IRES Maintain correct tire pressure as listed in chart of Section 1. Also refer to paragraph 2-26.
14
BATTERY
13
INDUCTION AIR FILTER Clean filte r per paragraph 2-23.
15
' Check e lec trolyte level a nd clean batt ery compartment each 50 hour s or each 30 days.
Replace as required.
ENGINE OIL SYSTEM Change oil each 50 hours if engine is NOT equipped with external oil filter; if equipped with an external filter (thru 18803473 or 18803473T or Tl8803437T change oil filter each 50 hours and o il at least each 100 hours. Change oil and filter at least every 6 months even thoug h less than the recommended hour s have accumulated.
Figure 2-4. Servicing (Sheet 4 of 5) Revision 1
2- 15
MODEL 188 & T188 SERIES SERVICE MANUAL
·
o 7
I
lOOHOURS
MAlN LANDING GEAR OUTBOARD SADDLE-ATTACH BOLTS
Check bolt torques per values mdicated in Section 5.
J1
FUEL / AIR CONTROL UNIT SCREEN Remove and clean screen in bottom of fuel/ air contr ol unit on fuel injected engines, then reinstall a nd safety wire screen.
12
FUEL ST RAINER
Disassemble and clean strainer bowl and screen.
15
ENGINE OIL SYSTEM Serials 18803474 or 18803474T or Tl8803474T and on, change oil and replace filter ever y 100 hours. Change oil and replace filter al least every 6 months even though less than the recommended hours have accumulated.
18
HYDRAULIC DISPERSAL SYSTEM
Spray clean the cooling fins. Prior to 18803522.
(OJ
J
6
200 Hours
BRAKE MASTER CYLINDERS Check fluid level and refill as required with hydraulic fluid. 2- 27 for details. FUEL DRAINS Drain off any water and sediment.
Refer to paragraph
0
Srio HOURS
16
HYDRAULIC DISPERSAL SYSTEM RESERVOIR
Replace fluid, flush system and reservoir tank after first year or first 500
hours. (Refer to 1000 hour check thereafter. )
18
HYDRAULIC DISPERSAL SYSTEM FLUID COOLER
Check fins for cleanliness and blast tubes for condition.
¢
17
IOOOHOURS
HYDRAULIC DISPERSAL SYST EM RESER VOIR Change fluid and C!ush reservoir each 1000 hours or each 2 years after !irst year or 500 hours. -
8
AS REQUDlED
GROUND SERVICE RECEPTACLE Connect to 14 or 24-volt, OC, negative-ground power unit for cold weather starting and lengthy ground maintenance of the electrical system. Master switch should be turned on before connect· 1ng a generator -type ex-ternal power source: it should be turned off before connecting a battery type external power s ource. Refer to Sect iOns 11, llA and 11B.
Figure 2-4. Servicing (Sheet 5 of 5) 2- 16
Revision
1
MODE L 188 & T188 SERIES SERVICE MANUAL
METHOD OF APPLICATION
FREQUENCY (HOURS)
(@) ~ ~~
GREASE GUN
OIL CAN
SYJUNGE (FOR POWDERED GRAPlllTE)
WHERE NO INTERVAL IS SPECIF1ED, LUBRICATE AS REQUIRED AND WHEN ASSEMBLED OR INSTALLED.
NOTE
The military specifications listed below are not mandatory, but are intended as guides in choosing satisfactory materials. Products of most reputable manufacturers meet or exceed these specifications.
LUBRICANTS
rG ss-G-659 . . .
POWDERED GRAPHITE GREASE ffiGH AND LOW TEMPERATURE GREASE GENERAL PURPOSE OIL PETROLATUM LIGHT OIL
GR
MIL-G-81322A . G l .MIL-G-21164 . OG .MIL-L-7870 r L VV-P-236 . OL VV-L-800A .
MAIN GEAR
TAIL GEAR
DO NOT LUBRICATE UNDER EXTREMELY DUSTY CONDITIONS.
WHEEL BEARINGS
ENGINE CONTROLS
REFER TO SECTION 5 FOR INSTRUCTIONS
AILERON AND WING FLAP BELLCRANK ~EDLE BEARINGS
TAILWHEEL LOCK CONTROL
Figure 2-5.
Lubrication (Sheet 1 of 3) Revision 1
2-17
MODE L 188 & T188 SERIES SERVICE MANUAL
_.. BATTERY
• Every 100 Hours or each year.
ALSO REFER TO INSPECTION CHART IN THIS SECTION AND TO SECTION 9 OF THIS MANUAL
l' l
TERMrNALS SCREW THREA.ai RELEASE BUTTON & RATCHET LATCH
rl OG
ELEVATOR TRIM TAB ACTUATOR
BEARING BLOCKS BEARING BLOCKS OG
BUSHINGSJ
f '
RUDDER BARS AND PEDALS
a
··.
SPRAY VALVE CONTROL CABLE ASSEMBLY {THRU 18800791) Figure 2- 5. 2- 18
Revision
1
Lubrication (Sheet 2 of 3)
MOD EL 188 & T188 SERIES SERVICE MANUAL
GL
WORM, ~WORM
,v
GEAR, BUSHINGS & SHAFT
V A' u W ·.· :
ELECTRIC
SPRAY ~ VALVE ASSEMBL~ ' ' ·\;., ._ . v.
0
a, , I. .
INBOARD LANDING GEAR SPRING STRUT ATTACH BOLT & HOLE*
OUTBOARD LANDING GEAR SADDLE ATTACH BOLTS & HOLES*
WING STRUT-ATTACH (LOWER) BOLT & HOLE *
" \
OG
J~
O;LIT.E BEARINGS
OILITE BEARINGS CONTROL STICK
GL
_.. • :..ubricate once each year.
WING STRUT-ATTACH (UPPER) BvLT & HOLE*
* UPON INSTALLATION
===========================NOTES==========================
Sealed bearings require no lubrication. McCauley propellers are lubricated at overhaul and require no other lubrication. Do not lubricate roller chains or cables except under seacoast conditions. dry cloth.
Wipe with a clean,
Lubricate unsealed pulley bearings, rod ends, Oilite bearings, pivot and hinge points, and any other friction point obviously needing lubrication, with general purpose oil e'lery 1000 hours or oftener if required. · Paraifin wax rubbed on seat rails will ease sliding the seat !ore and a!t. Figure 2.: 5.
Lubrication (Sheet 3 of 3) Revision 1
2-19
MODEL 188 & T188 SERIES SERVICE MANUAL
I
INSPECTION REQUffiEMENTS.
As requ1red by Federal Aviation Reg_ulations, all civil aircraft of U.S. registry must undergo a
COMPLETE INSPEC T ION (ANNUAL) each twelve calendar months. In addition to the required
ANNUAL inspection, aircraft operated commercially (for hire) must also have a COMPLETE
AffiCRAFT INSPECTION every 100 hours of operation.
In lieu of the above requirements, an aircraft may be inspe cted in accordance with a progressive inspection schedule, which allows the work load to be divided into smaller operations that can be accomplished in shorter time periods.
Therefore, the Cessna Aircraft Company recommends PROGRESSIVE CARE for aircraft that are being flown 200 hours or more per year, and the 100 HOUR inspection for all other aircraft.
n
INSPECTION CHARTS.
The following charts show the recommended intervals at which items are to be inspected. As shown in the charts, there are items to be checked each 50 hours, each 100 hours, each 200 hours, and also Special Inspection items which require servicing or inspection at intervals other than 50, 100 or 200 hours. a. When conducting an inspection at 50 hours, all items marked under EAC H 50 HOURS would be
inspected, serviced or otherwise accomplished as necessary to insure continuous
airworthiness.
b . At each 100 hours, the 50 hour items would be accomplished in addition to the items
marked under EACH 100 HOURS as necessary to insure continuous airworthiness.
c. An inspection conducted at 200 hour intervals would likewise include the 50 hour
items and 100 hour items in addition to those at EACH 200 HOURS.
d. The numbers appearing in the SPECIAL INSPECTION IT EMS colwnn refer to data listed
at the end of the inspection charts. These items should be check ed at ea ch inspection
interval to insure that applicable servicing and inspection requirements are accomplished
at the specified intervals.
e. A COMPLETE AffiCRAFT INSPECTION includes all 50, 100 and 200 hour items plus those
Spec ial Inspection Items which are due at the time of the inspection.
III INSPECTION PROGRA...'vt SELECTION.
AS A GUIDE FOR SELECTING THE INSPECTION PROGRAM THAT BEST SUITS THE OPERATION OF · THE AIRCRAFT, THE FOLLOWING IS PROVIDED . 1.
IF THE AIRCRAFT IS FLOWN o . IF FLOWN FOR HIRE
LESS THAN
200
HOURS ANNUALLY.
An aircraft operating in this category must have a COMPLETE AIRCRAFT INSPECTION each 100 hours and each 12 calendar months of operation. A COMPLETE AffiCRAFT 1:-.ISPECTION consists of all 50, 100, 200 and Special Inspection Items shown in the in s pection charts as defined In paragraph II above. b . IF N OT
FLO W N
FOR HIRE
An a1rcraft operating in this category must have a COMPLETE AIRCRAFT INSPECTION each 12 calendar months (ANNUAL). A COMPLETE AffiCRAFT INSPECTION consists of all 50, 100. 200 and Special Inspection Items shown in the inspection charts as defined in paragraph II above. In addition, it is recommended that between annual inspections, all items be inspected J.t the intervals specified in the inspection charts .
2-20 .
MODEL 188 8t T188 SERIES SERVICE MANUAL 2.
IF THE A IR-CRAFT IS FLOWN M O RE THAN 200 HOURS A NNUALLY. Whether Gown for hire or oot, it is recommended that aircraft operating in this category
be placed on the CESSNA PROGRESSIVE CARE PROGRAM. However, if not placed on Progressive Car e , the inspection requirements for aircr aft in this category are the same as those defined under paragraph m 1. (a) and (b). Cessna Progres sive Care may be utilized as a total concept pr ogram which insures that the inspection intervals in the inspection charts are not exceeded. Manuals and forms which are r equired for conducting Progr essive Care in spections are available from the Cessna Service Part s Center. IV INSPECTION GUIDE LINES.
(a ) MOVABLE PARTS for : lubrication, servicing, security of attachment, binding, excessive wear, safetying, pr oper operation, pr oper adjustment, correct travel, cracked fittings, security of hinges, defective bearings, cleanliness, corrosion, deformation, sealing and tension. (b) F LUID LINES AND HOSES for : leaks, cracks, dents, kinks, chafing, pr oper radius, security,
cor rosion, deterioration, obstruction and foreign matter .
(c ) METAL PARTS for : security of attachment, cr a cks , metal distortio n, br oken spotwelds,
corrosion, condition of paint and any other apparent damage.
(d) WlRING for : security, chafi.ng, burning, defective insulation, loose or broken terminals,
beat deterioration and cor roded terminals.
(e ) BOLTS IN CRmCAL AREAS for : correct torque in acco rdance with torque values given in the
chart in Section 1, when installed or when visual inspection i.odicates the need for a
torque che ck.
NOTE Torque values listed in Section 1 are derived from oil- free cadmium- pl ated threads, and are recommended for all installation procedures contained in this book except where other values are stipulated. They are not to be used for checking tightness of installed parts during service. (f) FILTERS, SCREENS & FLUIDS for : cleanliness, contamination and/or replacement at specified
intervals .
(g) AIRCRAFT FILE . Miscellaneous data, information and licenses are a part of the aircraft file . Check that the following documents are up-to-date and in accordance with current Federal Aviation Regulations . Most of the items listed are required by the United States
Federal Aviation Regulations. Since the regulations of other nations may require
othe r documents and data, owners of exported aircraft should check with¡ their own avia tion ofiicials to determine their individual requirements. To be displayed in the aircraft at all times: 1. Airc raft Airworthiness Certificate (FAA For m 8100-2). 2. Aircraft Registration Ce rtificate (FAA Form 8050-3). 3. Aircraft Radio Statio n License, if tr ansmitter is installed (FCC P'o rm 556). To be carried in the aircraft a t all times: 1. Weight and Balanc e, and associated papers (Latest copy of the Repair and Alteration Fo rm, FAA Fo rm 337, if applicable ). 2. Aircraft Equipment List. 3. FAA Approved Flight Manual ( Begining with 1979 Mode ls) To be made available upon r equest : l. Aircraft Log Book and Engine Log Book .
2-21
MODEL 188 & T188 SERIES SERVICE MANUAL
(h) ENGINE RUN- UP
Before beginning the step-by-step inspection, start, run-up and shut down the engine in accordance with instructions in the Information Manual. During the run-up, observe the following, making note of any discrepancies or abnor malities: 1. Engine temperatures and pressures. 2. Static RPM. (Also refer to Sections 11, UA and llB of this Manual.) 3. Magnito Drop. 4. Engine response to changes in power. 5. Any unusual engine noises. 6. Fuel selector and/or shut-off valve; operate engine on each tank (or cell) position and OFF position long enough to ensur e shut-off and/ or selector valve functions properly. 7. Idling speed and mixture; proper idle cut-oU. 8. Alternator and ammeter. 9. Suction gage. 10. Fuel flow indicator. (if equipped)
After the inspection has been completed, an engine run- up should again be preformed to ensure that any descrepancies or abnormalities have been corrected.
SHOP NOTES:
2-22
MODEL 1 88 & T, 88 SERIES SER V ICE MANUAL
SPECIAL rN'SPECTION IT!:M i M POR TANT
. EACH 200 ROURS
READ AL:.. I ~ PEC ~ON REQ UIRE ME STS P ARAGRAPHS PRIOR TO
PROPELU:R
USING 'r'HESE CHARTS .
EACH 100 HOURS
EACH SO HOURS
1.
2. S'plnner bu.lkb.ead
16
3. ~.
Bolta a.ad/ or mta .
5. Hub . . • . • . .
e.
• • • •
• •
Gonroor and c onuol
ENGINE COMPARTMENT
Cb.eclt tor endeoce at oU a.ad tuel lea.lta, then clean en11re eaclD8 aDi compartment. L! a.eeeled.. pnor to 1..11apec:t1cm.
1. ~au. screen. fWer eap, dlpettclt. dniD pluc a.ad ut.eraal LUter elemem • . 2. 011 CooLer • • .
•
4. 1Dduct:10D airbcm, air ruvee, doors a.ad couttola •
5. Cold and bot air boeee
EDC1De ba!!lee •
7 . Cyllnden, roc.lter box carers aDd paab rod baual.fiiS
•
8 . Cn.nkcue. oU sump, aeeeuorr seetton :a.ad front cra.nka b21t seu .
• •
9. Hoaea, mew l ines and tltUnge •
10.
Inbke a.ad ex.bawl t rry stema
11.
li1Ut1on ba.rneea
12.
Sp;uX phlga
13.
CompH881on check .
14.
Cnnkea•e a.ad breathe r 1.111ea
15.
Electrtcu wtri..nl .
I
2
3. laduct10D air fUt.er
e.
• •
• •
•
1
17 .
EtJil.ll.e abock mounts , meum scruc:D.lre and ground s t.nps .
18 .
Cabin heat n.lves , door s &.Dod controls.
19 .
Su r ter, solenotd :w.c1 elec:tncu connec:ooD.II .
:!0 .
!SUrt.er brushes. brush leaaa
and
c ommutator
•
•
•
•
•
•
•
•
•
6
• •
• 2-2:!
MOOEt 188 & T1 88 SERIES SERV1CE MANUAL SPECIAL I:NSPECTION rrnl E.ACB %00 HOURS &A.CB 100 HOURS EACB SO HOURS
• • • •
21. Alt.arnarcr. belL .uppon bnc:ut Uld electnc:a.l. coDDaCClaaa 2%. Alt.arnator bruatw•. bru•h Leada. eom.a:aaCUDI" or slip ~ • 23. Volta«• r~r moannnc a.na eleccn=.J. Ln.da •
25.
~'lapeto
t1m1.aC • • •
28 . Cubuntor
ma dn..Ull'WC •
27 . flrew:aJJ. . 28.
•
. •
Fuel 1..111eccoa tae!• a.tr CCIIJU'Ol wuL tuel pumll. tuel m..a.a.Uold n.lYe.
tuelUAea aM DDU.Lu • • • •
29 .
30. TUrbocba.rler .
• • . • •
u . All oU llDu CD ~r . 12.
TUrtlocfta.r'ler pr. .nrt.zed na& tWa ca fllti ~
d.Ucba.rle nou.&.e• a.Dd tuel now pp
. ... e
. . • • •
I
• • • • •
•
33. TUrtlocba.rler mc-u•u,. bnaeta • ••
I
17 7
34. Turbochar ger oil line check va lves . ·
22
FUEL SYSTE lf 1•
Fuel .stnJ.n.er. c1n1n nin aDI1 ccmtral
2.
Fuel
.s~r
screeD
&Ad
bowl •
•
.
.. . . e
3.
•• 5. sc:.-.:ea.s .
• •
8.
Fuel vent nlYe•
T.
Vetlt line dn.i.D •
8.
FUel shut-otf nln aDd plac:ua.s .
..... ....
10. Electrt c: !uel pump, throttl• nrttcb ancs eleca1c cocnecctccs . ll.
2-2·
E~
• •
pnmer .
• • • • • • •
5
Tempora.r y Revision N umber 1 1 April l992
MODEL 188 & T1 88 SERIES SERVICE MANUAL
SPECIAL INSPECTION ITEM !ACH 200 HOURS EACH 100 HOURS EACH 50 HOURS
LANDING GEAR
• •
1.
Main gear wheels
2.
Main gear spring strut
3.
Main and tail gear wheel bearings
4.
Brake fluid, lines and hoses, brake assemblies and master cylinders
5.
Parking brake system
6.
Main landing gear outboard saddle - attach bolts.
7.
Tailwheel steering, cables and spring tube
8.
Tailwheel friction check (refer to Section 5) .
•• 18
•
10
•
•
.
AIRFRAME
1.
Aircraft exterior
2.
Aircraft structure
3.
Windows, windshield, doors and seals
4.
Seat belts and shoulder harnesses
5.
Seat stops, seat rails, upholstery, s tructure and mounting
6.
Control stick bearings, pulley, weight, bushings and bellcrank
7.
Instruments and markings . . .
8.
Magnetic compass compensation
9.
Instrument wiring and plumbing
10.
Instrument panel, decals and labeling.
11.
Heating and ventilating systems and controls
12.
Lines, hoses, wires and control cables . . .
13.
Electrical horn, lights, switches and circuit breakers
14.
Exterior lights . . . .
15.
Pitot and static systems .
16.
Stall warning sensing unit and pitot and stall warning heaters
17.
Radios and radio controls
18.
Antennas and cables
19 .
Battery, battery box and battery cables .
20.
Battery electrolyte . . . . . . . . . .
9
• • •
•
• 15 21 •
• 5
• •
•
• •
• • •
•
• 20
•
11
2-25
MODEL188 & T188 SERIES SERVICE MANUAL
SPECIAL INSPECTION ITEM EACH 200 HOURS EACH 100 HOURS EACH 50 HOURS
CONTROL SYSTEMS In addition to the items listed below, always check for correct direction of movement, correct travel and correct cable travel. 1. Cables (except aileron), terminals, pulleys. pulley brackets, cable guards, turnbuckles and fairleads . . . . . . . . . . . . . . . . . . . . . . .
2.
Aileron cables (188-0001 thro 18800707) for fraying or wear at pulleys or fairleads
3.
Aileron cables ( 18800708 thro 18801348) for fraying or wear at pulleys or fairleads
4. Aileron cables (Beginning with 18801349) for fraying or wear at pulleys 5. Aileron push-pull rod bolts
. . . . . . . . .
6. Chains, terminals, sprockets and chain guards 7. Trim control wheel, indicator and actuator 8. Travel stops . . . . 9. Decals and labeling . 10. Flap control lever latch, flap rollers and tracks . 11. Elevator downspring system
.........
12. Elevator trim tab actuator lubrication a nd tab free -play inspection . 13. Elevator trim tab for cracks or looseness wher e trim tab horn fastens to trim tab . . . • . • • • . • • • 14. Rudder pedal assemblies and linkage .
.
15. Skins (external) of control surfaces and tabs 16. Internal structure of control surfaces.
17. Balance weight attachment .
DISPERSAL SYSTEMS
1.
Dispersal system controls in cockpit area.
.... . .....
2. Hydraulic fluid reservoir (hydraulically-driven dispersal system) 3.
Externally mounted dispersal system components
4. Spray equipment mounted on wings 5. Fan-dnven pump . . . . . . . . 6. Hydraulic motor :wd dispersal pump
1. Hydraulic fluid filter .
8. Hydraulic flu1d cooler . 9. Quick-loader valves 2-26
• 12 •
•
•
•
•
• •
•
• • • •
• •
•
• 19 • • • • • • 13
14
•
MODEL 1 88 & T1 88 SERIES SERVICE MANUAL
SPECIA.L INSPECnoN tn:M
t.ACB 200 HOURS EACB 100 HOURS EACB 50 BOORS 10. Hopper
.. . . . . . . . . .. . . .. . . .. . . .
11. Alltomadc
fla&ma.a soleD.Old.
12 . Electric:al A&'ita.tor,
• •
rela.y, swttcbea aDd wtrUIC • •
~lay, swttchu aDd
'lrir1nC . . . . ·
•
I
SPECIA.L INSPECTION ITEMS
Flrst 25 hours: C'ha.n~Je to ub.lesa dls~en&At oU. Change otl ei.CA 50 boun 1.f engine ~ NOT equ1ppeci wtt.b uterm.! ou lUter; tt eqwppect wtt.b e~erual oU Wter, ~e Wter taell 50 houn aDd oU eadl 100 hours. Serials 188034'14, 18803414T, n88034T4T a.nd oo.. d1a.nlfe
oU ~Dd rep1a.ce tUter eae11 100 hours. 1ft either ca.se, c.b..uiiJ• oU and rep1a.ce Ulter eYery e moatb.S nea t.bo\lo!b le.sa CbaA Use recom.meaded boun ~Te accumuJaud.
2 c1au Wter per sancn• 2-2:s.
3 4 5 6
7 8
;~t
lean
Replace u nqatncL
R.epla.c:e tao.n at 11J11,Da cmtrtlaal or attar 5 rears. wldcbenr come• tlnt. O.unl1D.spec:UOilenry 50 hcaan. Refer ta SeCUOilll, 11A or 11B for 100 houz t.Dspectloa.
Ball Jouu ue to be wpectld per SE'rl-42.
Each 1000 hau.ra, or to cot.actde wtt.b eDC1M cmtrbmll.
Ea.cb 50 baun tor ceural eoadlUoa. fn_,m oi moniDiat. llltecritr of utensal rubber shaft
aula, &Ad lubrtcutaQ. These coacro&. ve aot repainbla ud seoald be npla.ced ea.cb 1500 bou.n or .oooer U reqatred. wp.ct ucn 500 boun. AI lot:IC u UU.r=l t1m1.Dc aDd aJ.aCD.tCD-CD-eDCUW C1m1DC an wtt!Wl the pnscrt!)ed
tolen=es, 1t 1.a recommended th:lt the ID2CD8t.o be cbec&ad imara:UlJ oaty u
500 hoa.r.s I..D.Ce r"\"1.11.
MacD8CD-to-eDC1AI t1m1.Dc abaild be checked wtth a t1m1DilJCbt u ncb 100·hG:1r 1.Dsl)eCt1.0D..
MacD~co-to-eDC1U C1m.1nC sba11d be wtt2Wl a tolerance at plu uro, m.11IWI two decrees.
ID the enn.c tile =acuto t.mar=.L l:1.m.1zJC ma11a an ot! more c.ba.D plu or mim.s tift
deenea wbea the bnaker pointS Qp.D to fin au.mber OD.I cyJJ.Dder, ~mcmt the macut.o
a.Dd check the macneto t.ntermL t1.miJIC. Whem.nr the mapeto ba.lns an separated.
t.be breaker poUlt uaembly sbauld aJ.waya be checked.
9
Flnt 100 hG:1n a.ad ncn 500 bQU"JJ t.berattar. Man aft.ID. U oper.ued UDder preftilUIC
wee or duaCJ' cCDd1t1oaa.
10
Chac& torque o1 ma1D gear CNtbaard aaddle-au:&dl bolts pu Sed:1oa 5 ..,ery 100 hours. Ea.dllOOO hours or Z yean wbic:bner occ:an first, remon &ad cla.D m&ta rear sprtap &Dd aaddlea, replace stums, attadl bo1t.s a.Dd auu.
11
Cb.edt electz'1)lyte lenl and clean tn.tterr compartment each 50 ha1n or ncb 30 lhys.
12
.U eaeb 500 hcurs, or euller 1! requtnd by t.aapect1aa. replace &lleroa c11rect and
Latercoanect ables .
13
l..ubricat1aa at t.he acDJ.ator la required ei.CA 1000 boars or 3 yeus. wbichenr comes flrst. Ra:fer a:1 tlcure 2-5 tor gTeue spec1!1cat1cma. Refer to Section 9 tor t~·play l.n.spect1cm.
14
~~ c:&.rtr1die :Ut.er the tint 50 boars ot open.t:toa a.Dd enry 250 boars thern.tt.er.
UDder
ez:tnme!y dirty C:ODC11t1oas. cb:l.I:ICt more fnqueD.tly.
Reftmo:ll 1
2-27
·
.
..
MPDEL 188 & T1 88 SERIES SERVICE MANUAL '-...
SPECIAL INSPECTION ITEMS (Continued from page 2-28) 24. Fuel quantity indicating system operational test is requ.ired every 12 months. Refer to Section 15 for detailed accomplishment instructions. 25. At the first 100-hour inspection on new, rebuilt or overhauled engines, remove and clean the fuel injection nozzles. Thereafter, the fuel injection nozzles must be cleaned at 300-hour intervals or more frequently if fuel stains are found. 2-54.
COMPONENT TIME LIMITS
1. General A. Most components listed throughout Section 2 should be inspected as detailed elsewhere in this sectlor and repaired, overhauled or replaced as required. Some components, however, have a time or lift limit, and must be overhauled or replaced on or before the specifred 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 tift 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. Tablt 1 lists those items which Cessna has mandated must be overhauled or replaced at specific time limits Table 2 lists component time limits which have been established by a supplier to Cessna for tht supplier's product. C. In addition to these time limits, the components listed herein are also inspected at regular time interval: set forth in the Inspection Charts, and may require overhauVreplacement before the time limit i: reached based on service usage and inspection results. 2. Cessna-Established Replacement Time Limits
,.
A. Thelollowing component time limits have been established by Cessna Aircraft Company.
·f~
Table 1: Cessna-Established Replacement Time Limits
COMPONENT
OVERHAUL
REPLACEMENT TIME
Restraint Assembly Pilot Seat
(_5 years -
"'' !J
)
~-- __.,;
· Trim Tab Actuator . /
1,000 hours or 3 years, .....~ever occurs first
" l --Pitot and Static System Hoses /
,.
~
1~~rs ~~
\..10 years 0( ~ngine overhaul,
V/h~-'iWoCCUrs first
{Note 1)
Engine Compartment Flexible Fluid Carrying Tetlon Hoses (Cessna. lnstaftedl Except Drain tioses (Drain hoses are replaced .
on condition)
~.
_..
(s}~rs or ~ngine overhaul,
Engine Compartment Flexible Fluid Carrying Rubber Hoses (Cessna Installed) Except Drain·Hoses 1 (Dr!in hoses are replaced on condition)
~~r,_occurs first
2-28A
D2054-1-13 Temporary Revision Number 5 - Apr 5/2004 0 Cessna Aircraft Company
__ ....
+-:L 'tict
-
" MODEL 188 & T188 SERfES SERVICE MANUAL
COMPONENT Engine Air Filter
REF?LACE::::.M .;.:.;E ;;;.;.NT ..-.--_ _ TIME ·
>
../
NO
Engine Mixture, Throttle, and
Propeller Controls
Check Valve (Turbocharger /
I_/"
Oil Line Check Valve)
OVERHAUL
NO NO
Every 1 ,000 hours of operation · (Note 4) '
3. Supplier-Established Replacement Time Umits <
A. The following component time limits have been established by specific suppliers and are
reproduced as follows:
Table 2: Supplier-Established Replacement Time Urn its
COMPONENT
REPLACEMENT TIME
ELT Battery
Note3
NO
Magnetos
Note 5
YES
Engine
Note6
YES
Engine Flexible Hoses (TCM-!nstalled)
Note2
NO
Auxiliary Electric Fuel Pump
Note7
YES
Propeller
Note 8
YES
. "
OVERHAUL
.... ~
. ..
12-288
02054-1-13 Temporary Revision Number 4 - Oct 7/2002 C Cessna Ail'craft Company
"
MODEL 188 & T188 SERIES SERVICE MANUAL NOTES: Note 1: This life limit is not intended to allow flexible fluid-carrying Teflon or rubber hoses in a deteriorated or damaged condition to remain in service. Replace engine compartment flexible Teflon (AE3663819BXXXX series hose) fluid-carrying hoses (Cessna installed only) every ten years or at engine overhaul, whicheve.r occurs first Replace engine compartment flexible rubber fluid-carrying hoses (Cessna installed only) every five years or at engine overhaul, whichever occurs first (this does not include drain hoses). Hoses which are beyond these limits and are in a serviceable condition, must be placed on order immediately and then be replaced within 120 days after receiving the new hose from Cessna.
,.
Note 2: ForTCM engines, refer to Teledyne Continental Service Bulletin SB97-6, or latest revision. Note 3: tefer to FAR 91207 for battery replacement time limits. Note
4j ~eplace the ~urbocharger oil line check valve every 1,0/?00o of operation (Refer to Cessna ·?
Serv1ce Bulletin SEB91·7 Revision 1 , or latest revision).
·
'
Note 5: For airplanes equipped with Slick magnetos, refer to Slick Service Bulletin SB2·80C, or la~est revision, for time limits. .
-:::::::::::::=
For airplanes equipped with TCM!Bendix magnetos, refer to Teledyne Continental Motors Service Bulletin No. 643, or latest revision, for time limits. Note 6: Refer to Textron/Lycoming Service l.nstructlon S.l. 1oosAJ. or latest revision, for time limits.
·--
No~efer to Cessna Service Bulletin SEB94-"7 ~Inc. Service Bulletin NO. 0003_..Q.t. ...
7'.
latest revisJon.
.
••·
Note 8: Refer to the applicable McCauley Service Bulletins and Overh~ual for replacement and oveJhi:!;ul Information. / ~ .
.r
Note 9: The air filter may be cleaned, refer to Section 2 of this sejvlce manual or servicing instructions. For airplanes equipped wi1h an afr filter manufactured b'~ Donaldson, fer to Donaldson Aircraft Alters Service Instructions P46'-90?5 for detailed servi~'\J instruc~s. The address for Donaldson Aircraft Alters is: \,~ Customer Service
115 E. Steels Comers AD
. Stf,lw OH. 44224
Do not overservice the air filter, overservicing Increases the risk of damage to the air filter from excessive handling. A damaged/worn air filter may expose the engine to unfiltered air and result in damage/excessive wear to the engine.
.·
·-·
Temporary Revision Number 4
7 October 2002
@ 2002 Cessna Aircraft Company
2-28(
MODEL 188 & T188 SERIES SERVICE MANUAL
STUB WING - TO-FUSELAGE FAffiiNG
FRONT SPAR UPPER CARRY-THRU TUBE
VIEW FROM LH WING. LOOKING FORWARD AND INBOARD AT FRONT SPAR UPPER CARRY-THRU TUBE (TYP RH ALSO)
NOTE Each 100 hours, inspect tubular structure on AGwagon and AGpickup aircraft in the area depicted above on both sides of aircraft.
F1gure 2- 6.
Inspection
2- 29/ (2 - 30 blank}
MODEL 188 & T188 . SERIES SERVICE MANUAL . SECTION 3
FUSELAGE
TABLE OF CONTENTS
Page No. Aerotiche/Manual
FUSELAGE . . . . . . . .
Windshield and Windows . Description Cleaning Waxing . . . . Repair . . . . Surface Patch Plug Patch Scratches Cracks . . . Windshield Removal and Installation Windows . . . . . . . . . Removal and Installation Doors . . . . . . . . . . . Removal and Installation Door Weatherstrip . . .
. 1CS/3-1 . lCS/3-1 . 1<;5/3-1 . 1C5/2-1 . 1C5/3-1 . 1CS/3-1 . 1C5/3-1 . 1C5/ 3-1 . 1CS/3-1 . 1C7/3-3 . 1C7/3-3 . 1C7/3-3 . 1C13/.3-9 . 1C13/3-9 . 1C13/3-9 . 1C13/3-9 . 1C13/ 3-9
3-1. FUSELAGE. 3-2. WINDSffiELD AND WINDOWS. 3-3. DESCRIPTION. The windshield and windows are single-piece acrylic plastic panels set in sealing strips and held by formed retaining strips secured to the fuselage with screws and rivets. Presstite No. 579.6 sealing compound, used in conjunction with a felt seal, is applied to all edges of the windshield and windows. 3-4. CLEANING. (Refer to Section 2.) 3-5. WAXING. Waxing will fill in minor scratches in clear plastic, and help protect the surface from further abrasion. Use a good grade of commercial wax, applied in a thin even coat. Bring wax to a high polish by rubbing lighUy with a clean, dry flannel cloth. 3-6 . REPAIR. Replace extensively damaged trans parent plastic, rather than repai r whenever possible, since even a carefully patched part is not the equal of a new s ection, either optically or structurally. At the first sign of crack development, drill a small hole at the extreme e nd of the crack, as s hown in figure 3-1. This serves to localize the cracks, and to p re vent further splitting by distnbuting the stra1n over a large area. If the cracks are small, stopping them with drilled holes will usually suffice until replace ment or more permanent repair can be made. The following repairs are permissible; howeve r , they are
Tallcone Seal . Description Cockpit Seals . Description Seats . . . . . Description Removal and Installation Repair of Seat Structure Safety Provisions. . . Safety Belts . . . . . Shoulder Harness Canopy Padding . . . Wire Cutters and Cable Deflectors . . Baggage Area . . . . . . Baggage Doors . . . . Description . . . . . Removal and Installation Seat Rail Inspection • • . .
. 1C13/3-9 . 1C13/3-9 . 1Cl3/3-9 . 1C13/3-9 . 1C13/3-9 . 1C13/3- 9 . 1C13/ 3-9 . 1C13/ 3-9 . 1C13/3-9 . 1C13/3-9 . 1C13/3-9 . 1C21/3-17 . 1C21/3-17 . 1C21/3-17 . 1C21/ 3-17 . 1C21/ 3-17 . 1C21/3-17 . • 1C21/ 3-17
not to be located in the pilot's line of vision during landing or normal flight. · a. SURFACE PATCH. If a surface patch is to be installed, trim away the damaged area, and round all corners. Cut a piece of plastic of sufficient size to cover the damaged area, and extend at least 3/ 4 inch on each side of the crack or hole. Bevel the edges as shown in figure 3-1. lf the section to be repaired is curved, shape the patch to the same con tour by heating it in an oil bath at a temperature of 248 o to 302 °F., or it may be heated on a hot plate until soft. Boiling water should not be used for heat ing. Coat the patch evenly with plastic solvent adhe sive, and place immediately over the hole. Maintain a uniform pressure of from 5 to 10 psi on the patch for a mi.n imum of 3 hours. Allow the patch to dry 24 to 36 hours before sanding or polishing is attempted. b. PLUG PATCH. In using inserted patches to re pair holes ln plastic structures, trim the holes to a perfect circle or oval, and bevel the edges slightly. Make the patch slighUy thicker than the material being repaired and similarly, bevel the edges. In stall patches in accordance with procedures illus trated in figure 3-1. Beat the plug until soft and press into the hole without cement, and allow to cool to make a perfect fit. Remove the plug, coat the edges with adhesive, and then reinstall in the hole. Maintain a firm, light pressure until the cem·ent has set, then sand or file the edges, level with the sur face, buff and polish. 3-7. SCRATCHES. Scratches on clear plastic sur faces can be removed by hand-sanding operations, 3-1
MODEL 188 & T188 SERIES SERVICE MANUAL
COI<tn:cr • •· · ·
.·, /..
. /f ~~ . . ·.·.. ·· 5 1'01'
·=-; ;r>
·.··"' INCORRECT
l>HII.I.EI> --~
PATCH SHOULD BE
THICKER
PATCHES
P.- \TCH A;\;D HOLE SHOt.:LD BE TRI:-.tMED WITH TAPERED EDGES
II EAT EDGES OF' P.·HCH L';\;TIL SOFT .-\;\;0 F'OHCE IT I :-.ITO HOLE. HOLD IT 1:--: PLACE t.::-JTIL COO L .-\ ;\;0 HARD TO .-\SSt.:RE PERF'ECT F'IT T ilE:'> RE:'-10\"F: P-\TC H FOR C!:::..E:-:TJ;\;G BA T H
Fig ure 3 -I .
3-2
DURING CEMEN TING. PRESSURE :'IIEED BE APPLIED ONLY ON TOP SURF'ACE . TAPER ASSURES EQUAL PRESSURE ON ALL SIDES.
~~
!!
:\FTER CE:-.tE:-.IT HAS HAROE:-;Eo. SA;\;D OR FILE EDGES LEVEL WITH St:RF'ACE
Repa1r of W1ndshteld and Windows
MODEL 188 & T188 SERIES SERVICE MANUAL
followed bv buffing and polishing, if steps following
are followed carefully.
a. Wrap a piece of No. 320 (or finer) sandpaper or abrasive cloth around a rubber pad or wood block. Rub surface around scratch with a circular motion, keeping abrasive constantly wet with clean water to prevent scratching surface more. Use minimum pressure and cover an area large enough to prevent formation of "bull's-eyes" or other optical distor tions .
I~AUTION I Do not use coarse grade abrasive. Number 320 grit or finer is recommended. b. Continue sanding operation, using progressively finer grade abrasives until scratches disappear. c. When scratches have been removed, wash area
thoroughly with clean water to remove all gritty
particles. The entire sanded area will be clouded
with minute scratches which must be removed to
restore transparency.
d. Apply fresh tallow o r buffing compound to a motor-driven buffing wheel. Hold wheel against plastic surface, moving it constantly over damaged area until cloudy appearance disappears. A 2000 foot-per- minute s urlace speed is recommended to prevent overheating and distortion. (Example: 750 rpm polishing machine with a 10-inch buffing bonnet.) NOTE Polishing can be accomplished by hand,
but will require a considerably longer
period of time to attain the same result
as produced by a buffing wheel.
e. When buffing is finished, wash area thoroughly, and dry with a soft flannel cloth. Allow surface to c ool, and inspect area to determine if full transpar ency has been restored. Apply a thin coat of hard wax and polish surlace lightly with a clean. flannel cloth.
NOTE Rubbing plastic surface with a dry cloth will build up an electrostatic charge which attracts dirt particles and may eventually cause scratching of surface. After wax has har dened, dissipate this charge by rubbing surface with a slightly damp chamois. This will also r emove dust particles which have collected while wax is hardening. f. Minute hairline scratches can often be removed by rubbing with commercial automobile body cleaner, or fine- grade rubbing compound. Apply with a soft, clean, dry cloth or imitation chamois. 3-8. CRACKS. (See figure 3-1.) a. When a crack appears, drill a hole at end of crack to pr event furthe r spreading. Hole s hwld be approximately 1/ 8- inc h in diameter, depending on length of crack, and thickness of material. b. Tempor ary repairs to flat surfaces can be ac complished by placing a thin strip of wood over each side of surface, and inserting small bolts through the wood and plastic. A cushion of sheet rubber or air craft fabric should be placed between wood and plastic on both sides. c. A temporary repair can be made by drilling small holes along both sides of crack, 1/ 4-inch to 1/2-inch apar t, and lacing edges together with soft wire. Small-stranded antenna wire makes a good temporary lacing material. This type of repair is used as a temporary measure ONLY, and as soon as facilities are available, panel should be replaced. 3-9. WINDSHIELD.
(See figure 3-2.)
3-10. REMOVAL AND INSTALLATION. a. Remove wire cutter and mounting brackets. b. Drill out all rivets securing retainer strip lower edge of windshield. c. Remove screws on sides and along top of wind shield.
SHOP NOTES:
3-3
MODEL 188 & T188 SERIES SERVICE MANUAL
4
2
Detail
Detail
6
B B
A
Detail
C 5
D
E
Detail
0
4
Detail
f 9
Detail 1. 2. 3. 4. 5. 6.
Canopy Top Windsh1eld Seal Inner Retainer Outer Ret:1.1ner Rea r Window '7. Tab 8. Fuselage Str ucture
;). Screw
10. R1•:et
E NOTE The magnetic compass is mounted on screws at the top-center of the windshield. Take necessary steps to protect the compass during re moval and installation of the wind Shield.
r1gure 3-2. W1ndsh1eld and Rear Window Installation
3-4
MODEL 188 8t T188 SERIES SERVICE MANUAL
1. Inside Handle
2
L I ;)67
3. Door
3
4
Roll Pin 4. Retainer 5. e. Nylon Washer 7. Outside Handle
5
4
~
'
-
8
2. Latch Arm
8. Strike r Plat e
9. Shim 10. Nutplate
~
A
netau
B
B
NOTE /
Detail
13
Safety hinge pins With ..018 max. dia. tag Wire.
A
C
Detail TIIRU SERIAL 18801924
3
11. 12. 13. 14. 15. 16. 17.
18
E
Detail TIIRU SERIAL 18800832
3
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Detail
24
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Det'-'1
C
BEGINNING WITII SERIAL 18801925
~ ~
BEGINNING WITH SERIAL 18800833
Deta1l
0
18. Cable Shield 19. Hinge 20. Vent Window 21. Seal 22 . Shim 23. Door Window 24. Phenolic Washer 25. Lever 26. Latch 27. Nylon Washer 28. Magnetic Catch
Figure 3-3 . Cabin Door (Sheet 1 of 2)
3- 5
MODEL 188 & T188 SERIES SERVICE MANUAL
\
Adjus t plate (5) as required to receive pin (3) without binding.
THRU 1880 3878
. 9
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jy ;{ -BEGINNING WIT H
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路. ~ 路. \i . I
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1. Openable Window
2.
Pin Guide Block
3. Pin 4. Instrument Panel 5. Door Pin Guide Plate 6. Crash Pad 7. Cable Assembly 8 . Washer
9. Pin 10. Bushing
11 . Latch Arm 12. Inside Handle 13. Cotter Pin 14. Outside Handle 15. Window 16. Bumper 17. Door Pull BEGINNING WITH 1981 MODELS 18. Hinge 19. Lever
Figure 3-3 . Cabin Door (Sheet 2 of 2) 3- 6
MODEL 188 & T188 SERIES SERVICE MANUAL
7
NOTE
Bond with EC-1300L (3M Co. ) or equivalent.
DETAIL
D 4. 5. 6. 7. 8. 9. 10.
D
A
Weatherstrip Felt Seal Pressurization Scoop Access Door Rubber Seal Tailcone Seal Extruded Seal Retainer Aft Tailcone Baggage Door
E NOTE If deflector cable mounting
bracket is removed, re-seal to canopy with RTV 102 (General Electric Co.) or equivalent.
A
DETAIL TYPICAL
579. 6 PRESSTITE SEALER Inmont Corporation.
8
2
I
DETAIL C DOOR SEALS
NOTE Bond with EC - 880 (3M Co. ) or equivalent. Spray door seals with MS - 122 (Miller-Stephenson J -+--""1 Chern. Corp.) or equivalent. Confine to seal, do not overspray. COCKPIT SEALS
Figure 3-4 .
Fuselage Seals
3- 7
MODEL 188 & T188 SERIES SERVICE MANUAL
/.
10
12
8
Detail (Typical)
A
Detail (Typtcal)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
BEGININNING WITH SERIAL 18801825
Belly Skin Seal Assembly Stiffener LH Carry Through Seal Half Assembly LH Rib Root Seal RH Rib Root Seal RH Carry Through Seal Half Assembly Reinforcement RH Rib Root Seal Half Hopper Seal RH Side Panel Seal Assembly Seal LH Side Panel Seal Assembly Figure 3-5.
3- 8
3
Cockpit Sealing
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE A magnetic compass is mounted on the center screws at the top of the windstueld. Take necessary steps to pr otect the compass during removal and replacement of the windshield. d. Pull windshield fo rward, out of side and top re tainers. e. Clean retainer strips and channels before in
stalling new windshield.
f. When installing a new windshield, check fit and carefully file or grind away any excess plastic. g. Apply felt strips and sealing compound or seal ing tape to all edges of the windshield. h. Use care not to crack windshield when installing. Start at an upper corner and gradually work wind shield into position. NOTE Machine screws and self-locking nuts may be used instead of the factory installed rivets which fasten the front retaining strip to the cowl deck. If at least No. 6 screws are used no loss of strength will result. i.
j.
Install lower retainer strip. Install wire cutter and compass.
3-11. WINDOWS.
(See figure 3-2.)
3-12. REMOVAL AND INSTALLATION. a. Remove screws or rivets as necessary to re
move the retainer strips.
b. Remove window and clean retainer strips and
channels.
c. Install felt seal, an adequate coating of sealer
and install new Window.
3-13. CABIN DOOR. (See figure 3-3.) 3-14. REMOVAL AND INSTALLATION.' Removal of the door is accomplished by removing the screws securing the hinges to the sill, or if emergency re lease is installed, by pulling the emergency release handle. The hinges have slotted holes for adjustment of the door in the fuselage opening. When fitting a new door, some trimming of the door skin at the edges and some reforming with a soft mallet may be necessary to achieve a good fit. 3-15. DOOR WEATHERSTRIP is cemented around all edges of the door. New weatherstrip may be ap plied after mating surfaces of weatherstrip and door are clean. dry and free from oil or grease. Apply a thin, even coat of adhesive to each surface and al low to dry until tacky before pressing strip in place. Minnesota Mining and Manufacturmg Co. No. EC-880 cement is recommended. 3-16. T AILCONE SEAL.
(See figure 3-4.)
3-17. DESCRIPTION. The tailcone seal is riveted to the aft side of the bulkhead just behind the pilot seat. The tailcone seal and two cockpit pressuriza tion scoops help prevent chemical residue from being
sucked from the tailcone to the cockpit area. Control cables pass through access holes in the seal. The access holes have replaceable rubber covers with holes just large enough for the control cables to pass through. A removable door provides access to the tallcone from the cockpit.
3-18. COCKPIT SEALS.
(See figure 3-5.)
3-19. DESCRIPTION. Beginning with aircraft serial -18801825 and on, a sealed cockpit system is installed to lessen the possibility of contamination of the pilot by chemicals. A seal is installed around the aft edge of the hopper and extends down the belly skin. Flexible seals, bonded to small bulkheads, are installed between the removable side panels, belly skin and hopper. 3-20. SEATS.
(See figure 3-6.)
3-21. DESCRIPTION. These seats are manually operated throughout their full range of operation. Seat stops are provided to limit fore and aft travel. 3-22. REMOVAL AND INSTALLATION. a. Remove seat stops from rails. b. Slide seat fore-and-aft to disengage seat rollers from rails. c. Lift seat out. d. Rever se the preceding steps for reinstallation. Ensure all seat stops are installed.
!WARNING
a
It is extremely important that seat stops are installed, since acceleration and deceleration could possibly permit seat to become disen gaged from seat rails and create a hazardous situation, especially during take-off and land ing.
3-23. REPAIR OF SEAT STRUCTURE. Replace . ment of defective parts is recommended in repair of seats. However, a cracked framework may be welded, provided the crack is not in an area of stress concentration (close to a hinge or bearing point). The square-tube framework is 6061 aluminwn, heat treated to a T-6 condition. Use a heliarc weld on these seats, as torch welds will destroy the heat treatment of the frame structure. Figure 3-7 out lines instructions for replacement of defective cams on th~ semi- reclining seat back. 3-24. SAFETY PROVISIONS. 3-25. SAFETY BELTS. (See figure 3-8.)
Safety belts should be replaced if frayed or cut,
latches are defective or stitching is broken. At
taching parts should be replaced if excessively
worn or defective.
3-26. SHOULDER HARNESS. (See figure 3-8.) The shoulder harness may be equipped with an inertia reel mounted on the tubular fuselage structure. Thru Aircraft Serial 18800832 a reel control is located ad 3- 9
MODEL 188 & T188 SERIES SERVICE MANUAL
5
14
8
2
2
2 12
/
:-IOTE
Seat stops (15) are installed on the LH rail on the standard seat installation.
REC UNI:NG BACK
Figure 3- 6. Seat Installation (Sheet 1 of 3) 3-10
1. Recline Handle 2. Pin 3 . Hinge Assembly 4. Torque Tube 5. Seat Back 6. Recline Cam 7. Spacer 8. Spring 9. Bushing 10. Recline Pawl 11. Roller 12. Adjustment Pin 13. Fore/ Aft Handle 14. Seat Bottom 15. Seat Stop
MODEL 188 &- T188 SERIES SERVICE MANUAL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
* Cam Bellcrank • Roller Housing Push- Pull Channel Seat Lock Actuator Tube A Seat Adjustment Pin Clamp Bra ce Spring Pin Seat Adjustment Arm Spring Clip Nut Screw Assembly Handle Bearing Block Spacer Washer Spring Seat Fr ame Splice Tube Pivot Br acket Seat Back Frame Collar Forward Torque Tube Aft Tor que Tube Brace Seat Bottom Cover Seat Back Cover
Fwd and aft seat stop 18802349 thru 18802781 Aft seat stop Beginning with 18802782 & 18803297T Fwd seat stop Beginning with 18802782 & 18803297T
NOTE Thru 18802348, seat incorporates adjustment pin (6) on LH side only. Seat stops a r e installed on the LH rail on the vertical adjust seat installation.
15
16 13
15
14 THRU 18801052
VERTIC ALL ¥-ADJUSTABLE
Figure 3-6. Seat Installation (She et 2 of 3) 3- 11
MODEL 188 8t T188 SERIES SERVICE MANUAL
Detail
8
ARMREST INSTALLATION
'
~
Detail
A
THRU SERIAL 18802348
5
r ·
/
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M~' Detail
/
1
A "
::; 18802349 THRU 18803935
B. Detall
A
• BEGINNING WITH SERIAL 18803936 1. Articulating Ad justment Handle 2. Adjustment Pin 3. F ore / aft Adjustment Handle 4. Vertical Ad justment Handle 5 . Seat Bottom 6 . Seat Bac k 7. Bellcrank 8 . Channel 11 9 . Torque Tube INFINITELY- ADJUSTABLE 10. Seat Structure • BEGINNING WITH SERIAL 18802349 11 . Roller 12. Seat Stop 13 . Sea t Be lt Retaine r 14. Li nk
Figure 3- 6. 3-12
.
Seat Installation (Sheet 3 of 3)
MODEL 188 8t T188 SERIES SERVICE MANUAL
0SEAT BACK (REF)
CD
CLEVIS BOLT (REF)
CD
REPLACEMENT CAM
INDENT PROFILE (REF)
NOTE Ensure replacement cam conforms
to dimensions shown in Detail A
before installation.
i
\ ,. 32" (TYP)
. 060''R (TYP)
REPLACEMENT PROCEDURE: a. Remove seat from aircraft.
Detail
A
b. Remove plastic upholstery panels from a.ft side of seat back, then loosen upholstery retaining rings and upholstery material as required to expose rivets retaining old cam assembly. c. Drill out existing rivets and insert new cam assembly (2 ). Position seat back so pawl (3) en gages first cam slot as illustrated . d. Position cam so each slot bottom aligns with the 2. 50'" radius as illustrated. e. Clamp securely 1n this position and check travel of cam. Pawl must contact bottom of each cam slot. Using e xtsttng holes 1n seat frame, drill thr ough new cam and secure with MS20470AD6 nvets. f. Retnstall upholstery. upholstery panels and seat.
Figure 3-7.: Seat Cam Replacement
3-13
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
A
9~
A
Detail
8
BEGINNING WITH SERIAL 18800833 AIRCRAFT
"=""---18 lT
,, 14
&~17 ~~~-
~~ -- 7 /
Detail
f
~;RU AIRCRAFT RIAL 18800832
E
Detail SEAT MOUNTED
Shoulder H Inertia R arness C eel ove r Bolt Plate ~· Spacer Fusela Structure 8.· Washe:e 1. 2. 3 • 4. 5•
9. Nut 10. Support 11. Clamp 12. Control 13 Cont rol Cable 14 · B • ~acket 15 · Ftre Ext :ngulsher 16. Seat Be. 17
14
7 Detail
RIAL 18800832
14 Deta1l
It
C
Detail PAI." lEL MOU NTED
0
18. Floorboard · Eyebolt Figure 3- 8. 3-14
8
~ RU AIRCRAFT
Saie t v p r ovtsions . (Sheet 1 of 3)
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE
19
Deflector Cable tension from 15 to 20 LB-IN.
20
-~ ~~~~ •
0
..
·~
21
19. Blade Fuselage Structure Nutplate Winds hield Defle ctor Cable 24. Cable Bracket 25. Canopy P:ldding 26. Landing Gear Strut 27. Bracket 28. Wheel Fe nder Bra.c ket 20. 21. 22. 23.
Detail
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H ·····~·.:.·:; ~
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--
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I NOTE
.. ·· ·. ~..... ·..··
Bond padding (25) to cockpit s tructu.r e with EC -1300L
Detail Detail
J
Detail
BEGIN Nl NG wtTH SERIAL 18802349
I
J
THR U SERIAL 18802348
Figure 3- 8. Safety Provisions (Sheet 2 of 3)
3- 15
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
26
H
NOTE
Deflector cable tension from 15 to 20 lb. in.
Detail
G
BEGrNNl:-.IG WITH
SERIAL 1880 1375
19. Blade 20. 21. 22. 23.
Fuselage Structure Nut plate Windshield Deflector Cable 24. Cable Bracket 25. Cable Terminal 26. Blade Bracket
Figure 3- 8. 3- 16
Safetr Provisions (Sheet 3 of 3)
MODEL 188 & T188 SERIES SERVICE MANUAL
jacent to the seat. This control b.a.ndle has a MANUAL and AUTOMATIC position. In the AUTOMATIC posi tion, the reel allows slow movement of the pilot, loc.ld.ng only against sudden movement. Locking, automatically moves the control to the MANUAL posi tion and all movement is restricted. After the emer gency, this handle may again be moved to the AUTO MATIC position. Beginning with Aircraft Serial 18800833 a new 1. 5 g's inertia reel may be installed in the aircraft. This reel does not incorporate the manual locking and release handle. Both systems require no lubrication or adjustment. Component parts should be- replaced as outlined in Paragraph 3-25. 3-27 . CANOPY PADDING. (See figure 3- 8.) The caoopy padding consists of a l ; rt inch black ensolite cover on the crash pad, also urethane bumper pads bonded to the tubular structure above the cabin door, down the corner doorposts, across the tubular struc ture behind the pilots head, and across the lower door seal. 3-28. WIRE CUTTERS AND CABLE DEFLECTORS. (See figure 3-8. ) Wire cutter blades are installed on the landing gear struts and in front of the Windshield. A deflector cable is installed from the back of the canopy to a fitting at the forward upper end of the fin thru air craft Serial 18801374. Beginning with aircraft Serial
18801375 the deflector cable is attached to the upper end of the windshield cutter blade, which is extended to the top of the canopy. The cable tension is set at 15 to 20 pounds tension on either installation. 3-29. BAGGAGE AREA. The area aft of the firewall and forward of the hopper on aircraft Serials thru 18800832 may be equipped with a removable floo r and tie-downs. Beginning with aircraft Serial 18800833 the equipment installation in the area does not permit the floor installation. 3-30.
BAGGAGE DOORS. (See figure 3-4.)
3-31. DESCRIPTION. The baggage doors, located aft of the firewall on either side of the fuselage are hinged at the top to swing up for access to forward hopper area and baggage area prior to aircraft Serial 18800833. 3-32. REMOVAL AND INSTALLATION. a. Unlock the wing stud fasteners and remove the
fasteners common to the upper half of door hinge.
b. Remove door assembly. c. Install by reversing above procedures. When in stal.llng a new door, some trimming to fit the opening and some forming of the door edge to fair with the fuselage may be necessary thru aircraft Serial 188 00832. Beginning with aircraft Serial 18800833 these doors are a bonded assembly and forming the door edge is not permissible, as it could cause material separation. 3-33. SEAT RAIL INSPECTION. A special inspec tion of seat rails should be conducted each 50 hours. See figure 3- 9 for inspection procedures.
S HOP NOTES :
3- 17
MODEL 188 8t T188 SERIES SERVICE MANUAL
Counts as one crack. Usable if not closer than one -lnch to a similar crack.
REPLACE SEAT RAIL WHEN:
a. Anyportion of web or lower flange is cracked, (index 2). b. Any c rack in crown of rail is in any direction other than right angle to length of rail. c . Number of cracks on any one rall exceeds four, or any two cr acks (index 1) are closer than one- inch.
NCYrE
Use of seat rail cargo tie-downs is not permissible on seat rails with cracks.
F igure 3-9. Seat Rail Inspection 3-18
MODEL 188 8t T188 SERIES SERVICE MANUAL ::iECTION 4
WING:S AND EMPENNAGE
TABLE OF CONTENTS
Page No. Aerofiche/Manual
WINGS AND EMPENNAGE . Wings . . . . . Description Removal. . Repair . . Installation Adjustment (Correcting Wing Heavy Condition) . . . Wing Strut . . . . . . . . Description . . . . . . Removal and Installation Repair Stub Wing Catwalk F in . . . . . . Descriptio n .
4-1 .
. . . . . .
1D1/4-1 101/ 4-1 1D1/4-1 101/4-1 103/4-3 103/4-3
. . . . . • . .
1D3/4-3 1D3/4-3 103/4-3 1D3/4-3 103/4- 3 1D7/ 4-7 1D7/ 4-7 107/ 4-7
WINGS AND EMPENNAGE.
4-2. WlNGS.
(See figure 4-1.)
4-3 . DE:SCRlPTION. Each all-metal wing panel is a semicantilever, semimonocoque type, with two main spars and suitable ribs for attachment of the skin. Skin panels are riveted to the ribs, spars and stringers to complete the structure. Two versions of the Agwagon-Series wing are available . On car buretor equipped aircraft, and on standard fuel in jected aircraft with fuel tanks installed in the forward fuselage area, no fuel provisions are made in the wings . Optional rubberized fuel c ells are available fo r installation in the wings of fuel injected airc raft. An all- metal aileron, flap and a detachable wing tip are mounted on each wing assembly. Beginning with aircraft serial 18800573 , a stall fence and an aileron gap s eal are installed on each wing as sembly. Thru aircraft serial 18800832 optional landing and taxi lights. and also, colored navigatio n lights are avail able fo r installation on each wing ass embly. Begin ning with aircraft serial 18800833 the landing lights are in s talled on the lower nose cap, and in addition to the colored navigation light a strobe light, wing tip turning light, and forward fac ing s pray light may be installe d o n each wing assembly. 4-4. REMOVAL. Wing removal is accomplished m ost ea s ily if four men are available to handle the wing. Otherwise , the wing should be supported with a sling or maintenance stand when fa s tenings are loosened.
Removal and Installation Repair . . . . Horizontal Stabilizer . . . . Description . . . . . . Removal and Installation Repair . . . . . . Stabillzer Abrasion Boots Description Removal Installation Tailcone Description Removal . . Installation Repair
. . . . . . . . . . . . .
107/ 4-7 1D7/4-7 1D7/4-7 107/4-7 1D7/4-7 107/4-7 1D7/4-7 109/ 4-9 1D9/ 4-9 109/ 4-9 109/4-9 109/4-9 109/4-9 1010/ 4-10 lDl0/ 4-10
c . On models with wing fuel cells , drain fuel in wing being removed. Drain reservoir tank and enough fuel from cell in opposite wing to lower fuel level below crossover vent line. Observe precau tions outlined in section 12. d. Disconnect electrical wires at wing root. e . Disconnect fuel lines and crossover vent line , if installed, at wing root and cap lines. r. Disconnect pitot line (left wing only) at wing root g . Disconnect flap and aileron cables at the turn buckles in the fuselage and remove cable guards and fairleads as necessary to pull cables out to the wing root. h. Thru aircraft serial 18800832 , loosen strut fairings and slide fairings along s trut fo r acce ss to strut fittings . Beginning with aircraft serial 188 00833 , remove strut fairing for access to s trut fitting on the wing. i. Support wing , remove jury strut, and disconnec t wing strut at the fuselage fitting and wing fitting. j. Mark position of wing attachment ec centric bushings ; thes e bushings are used to r ig out "wing heaviness. " NOTE It is recommended to secure flap in str eam
lined position with tape during wing removal. to pr event damage since flap will swing freel y. k. Remove nuts , washers, bushings and bolts attaching wing s pars to stub wing . NOTE
NOTE It may be ne cessary to u s e a long drift punc h
to drive out wing attaching bolts, or to r ock wing s lightly while pulling bolts.
Di s connect a ny ag ricultural equipment as
necessar y to remove wings.
a. b.
Re move wing g ap fai r ings. Remove all wt ng ms pect10n plates.
l.
Remove wing and lay on padded s tand.
4-1
MODEL 188 & T188 SERIES SERVICE MANUAL
*
Countersink toward bolt head.
11
(P Detail
A
Detail
B
NOTE BEGINNING WITH AIRCRAFT SERIAL 18800833 wi~s are constructed with bonded leading edges.
A FUEL FILLER CAP ON OPTIONAL WING WITH FUEL SYSTEM INSTALLATION
19
23
26 â&#x20AC;¢ THRU AIRCRAFT SERIAL 18800832. BEGINNING WITH AIRCRAFT SERIAL 18800833 THE LANDING AND T AXI LIGHTS ARE COWL MOUNTED.
C
Detail BEGINNING WITH AffiCRAFT SERIAL 18800833.
Bolt 2. Washer 3. Front Spar Fitting 4. Wing 5. Bolt 6. Front Stub Wing Fitting 1. Eccentric Bushing 8. Rear Spar Fitting 9. Spacer 1.
10. Nut 11. Rear Stub Wi~ Fitti~ 12. Front Wing Gap Cover 13. Screw 14. Washer 15. Upper Wing Gap Cover 16. Lower Wing Gap Cover 17. Seal 18. F lap
Figure 4-1.
4-2
Wing Installation
19. 20. 21. 22. 23. 24. 25. 26. 27.
Airflow Fence Assembly Ailer on Aileron Gap Seal Wi~ Tip Navigation Light Landing Light Strut-Attach Fittir~ Stall Warning Unit Inspection Plate
MODEL 188 & T188 SERIES SERVICE MANUAL
4-5. REPAIR. ·Repair of a damaged wing panel may be accomplished in accordance with instructions given in Section 17. Extensive repairs of wing skin or struc ture are best accomplished by using the wing repair jig, which may be obtained from Cessna. The jig serves not only as a holding fixture. making work on the wing easier, rut also assures absolute alignment of the repaired wing.
d. Test-fly airplane. [f wing-heavy condition still exists, remove fairing strip on "lighter " wing. loosen nut. and rotate bushings simultaneously until bush ings are positioned with thick side of eccentric down. This will raise trailing edge of wing, thus increasing wing heaviness to balance heaviness in opposite wing. e. Tighten nut, install fairing strip. and repeat test flight.
4-6. INSTALLATION. a. Hold wing in position and install bushings, bolts,
washers and nuts attaching wing spars to stub wing
fittings .
b. Install wing strut at fuselage fitting and wing fitting, then install jury strut. Check straightness of strut per figure 4-2. c. Install upper and lower strut fairings. d. Route flap and aileron cables. · e. Connect electrical wires at quick-disconnects. f. Connect fuel lines and cross-over vent line, if
installed.
g. Connect pitot line (if left Wing is being installed). h. Rig aileron system (Refer to Section 6). i. Rig flap system (Refer to Section 7). j. Refuel wing cells if installed, and check for leaks. k. Check operation of all lights. l. Install Wing gap fairings and inspection plates. m. Connect any agricultural equipment previously disconnected to remove Wing.
4-8. WING STRUT. (See figure 4-2.)
4-7. ADJUSTMENT (CORRECI'ING "WING-HEAVY.. CONDITION). Il considerable control stick pressure is required to keep Wings level in normal flight, a wing-heavy condition exists. a. Remove Wing fairing strip on the wing-heavy side of aircraft: b. (See figure 4-1.) Loosen nut (10) and rotate bushings (7) simultaneously until bushings are posi tioned with thick side of eccentrics up. This will lower trailing edge of the wing, and decrease wing heaviness by increasing wing angle - of-incidence.
@AUTION! Be sure to rotate the eccentric b.lshings
simultaneously. Rotating thP.m separately
will destroy the alignment between the off
center bolt holes in the bushings, thus ex
erting a shearing force on the bolt, with
possible damage to the hole in the wing spar.
c.
Tighten nut and reinstall fairing strip.
4-9. DESCRIPTION. Each wing has a single wing strut which transmits a part of the wing load to the upper portion of the fuselage . The strut consists of a streamlined tube riveted to two end fittings for attachment at the fuselage and wing. The strut is braced by a jury strut.
REMOVAL AND INSTALLATION. a. Remove bolts and nuts securing jury strut. b. Remove screws securing strut fairings and re move fairings. · c. Support wing securely. Remove nut and bolt securing strut to wing. d. Remove nut and bolt securing strut to fuselage and remove strut. e. Reverse the preceding steps for installation. Check st.rai.ghtness of strut per figure 4-2. 4-10.
4-11. REPAIR. a. For grooves in wing strut caused by strut fair ings, the following applies. · 1. U groove exceeds . 010 inch in depth and is less than . 75 inch from a rivet center, the strut should be replaced. 2. Il groove is more than . 75 inch from a rivet center and groove depth exceeds . 025 inch, strut should be replaced. 3. II groove depth is less than . 025 inch and is more than . 75 inch from a rivet center, strut should be repaired by tapering gradually to the original sur face and burnishing out to a smooth finish. The local area should be checked with dye penetrant to insure that no crack has developed. 4. Apply brush alodine or zink chromate primer and repaint area. NOTE Il a wing strut is badly dented, cracked or
defotmed , it should be replaced.
Revision
1
4-3
MODEL 188 & T188 SERIES SERVICE MANUAL
Use washers as required for a max
imum strut curvature of . 085 inch fr om wing to fuselage thru aircraft
serials 18800966 and 18801033 thru 18801036. Use one washer as shown beginning with aircraft ser ials 188 00967 thru 18801032 and 18801037
2 1
.~ 2
1
~-- '
Detail ...-.,;~----
A
Install struts (2) with the • 386" hole for the jur y strut spacer (3) on the upper surface.
8 4
8
Detail THRU AIRCRAFT SERIAL 18800832
• Coat lightly (hole and bolt) with ELECTRO MOLY NO. 11 (MIL G-21164) grease.
•
• T o be installed as sets.
1. 2. J. 4. 5. 6. 7. 8. 9. 10. 11. 12. lJ.
Upper Strut F itting Wing St rut Spacer Lower Str ut F itting Jury Strut Eyebolt Upper Strut F ai r ing Fus e ~e Attach m ent Fitting Lower Strut F a in ~ Wi ng Attachment Fitting P lat e Seal Bracket
Detail
AffiCRAFT SERIAL 18800833.
Figure 4-2. 4 -4
8
~ BEG INNING WITH
Wing Strut
MODEL 188 & T188 SERIES SERVICE MANUAL
5
. BEGINNING WITH SERIAL 18800833
6
~RCRAF:~
4 7
Detail
A
8 ••THRU AffiCRAFT SERIALS 18800967 AND 18801033 THRU 18801035 ..B EGINNING WITH AIRCRAFT SERIALS 18800968 THRU 18801032 AND 18801036
Detail
8
12*
~'--~
11
1. Dorsal 2. Fin Assembly 3. Air Inlet Screen 4. Deflector Cable Support 5. Flashing Beacon 6. Ftn T ip 7. Upper Rudder Hinge 8. Center Rudder Hinge 9. Lower Rudder Hinge 10. Nutplate 11. Was her 12. Bolt 13 . Nut
Detail
0
Detail C
THRU AmCRAFT SERIAL 18801374
* TORQUE BOLTS 190-390 LB-IN. . TORQUE BOLT 140-225 LB-IN. ON·Affi CRAF T SERIALS 18800872 THRU 18800967 AND 18801033 THRU 18801035 Figure 4-3 .
Ver tica l Fin (Sheet 1 of 2) 4-5
MODEL 188 & T188 SERIES SERVICE MANUAL
5
6
4
E Detail
E
F 8
Detail
Detail
f
H 1 37.~ 11
e 12/~-13
11 BEGINNING WlTH AIRCRAFT SERIAL 18801375
Detail * TORQUE BOLTS 70-100 LB INCHES
e TORQUE BOLTS 140- 225 LB INCHES
Figure 4-3.
4- 6
Vertical Fin (Sheet 2 of 2)
G
MODEL 188 & T188 SERIES SERVICE MANUAL
4-llA. STUB WING CATWALK . walk, SK188- 2A is available. 4-12 .
FIN.
(See
Fo r
repa~r
of cat
i. Tighten the four bolts in the rear spar first. then tighten the four bolts in the. front spar last.
NOTE
figure 4-3 .)
4-13. DESCRIPTION. The fin is primarily of metal construction consisting of two main spars and suitable ribs for attachment of the skin. Skin panels are rivet ed to the ribs and spars. Hinge brackets are attached to the rear spar for rudder installation. The rudder also has a removable tip. 4-14 . REMOVAL AND INSTALLATION. The fin may be removed without removing the rudder. However, for access and ease of handling, the rudder may be removed if desired, following procedures outlined in Section 10. a. Thru 18801374. 1. Remove stinger and disconnect tail navigation light lead and flashing beacon lead, if installed. Dis connect rudder cables ii rudder has not been removed. 2. Disconnect deflector cable at fitting on fin. 3. Remove screws attaching dorsal to fuselage. 4. Remove tail fairing, then remove bolts attach ing fin front and rear spars to fuselage, and remove fin . 5. Reverse the preceding steps for installation. NOTE Be sure to check and reset rudder and eleva tor travel. U any stop bolts were removed or settings disturbed, the system will have to be rigged. Refer to applicable sections in this manual. 6. Tighten deflector cable to 15 to 20 pound inches and resafety. b. Beginning with 188-1375. 1. Remove stinger and disconnect tail naviga tion light lead and flashing beacon lead, if installed. Disconnect rudder cables if rudder has not been re moved. 2. Disconnect deflector cable at fittihg on fin. 3. Remove screws attaching dorsal to fuselage. 4. Remove tail fairing, then remove horizontal stabilizer at::ach bolts and lower stabilizer to gain access to the fin attach bolts. 5. Remove bolts attaching lin front and rear spars to fuselage, and remove fin. f. Installation steps are as follows: g. Adequately support the ta.ilcone at approximately station 175.00 to a height sufficient enough to raise the tailwheel above ground level. h. Set the vertical tail assembly in place and insert the eight attach bolts thru the spars and respective bulkheads. NOTE Be sure to check the washer requirements ,
assembly sequence of washers and head
direction of bolts.
Be sure to check and reset rudder and ele vator travel. U any stop bolts were removed or settings disturbed, the system will have to be rigged. Refer to applicable sections of this manual. j. Tighten deflector cable to 15 to 20 pound-inches
and resafety.
4-15. REPAIR. Repair of. the fin should be accom plished in accordance with the applicable instructions in Section 17. 4-16. HORIZONTAL STABILIZER. (See figure 4- 4.) 4-17. DESCRIPTION. The horizontal stabilizer is primarily of metal construction, consisting of two main spars and suitable ribs for attachment of the skin. Stabilizer tips are of thermo-formed plastic. A formed metal leading edge is riveted to the assem bly 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. 4-18. REMOVAL AND INSTALLATION. a. Remove elevators and rudder in accordance with procedures outlined in Sections 8 and 10. b. Remove vertical fin in accordance with proce dures outlined in paragraph 4-14. c. Disconnect elevator trim control cables at clevis and turnbuckle inside tailcone, remove pulley·s which route the aft cables into horizontal stabilizer, and pull cables out of tailcone. d. Remove bolts securing horizontal stabilizer to tailcone. e. Remove horizontal stabilizer. f. Reverse the preceding steps for installation. g. Re-rigg control systems as necessary. h. Check operation of tail navigation light and flashing beacon, if installed. 4-19. REPAIR. Repair of the stabilizer should be accomplished in accordance with the applicable in structions in Section 17. 4-20.
STABIUZER ABRASION BOOT. NOTE
An Accessory Kit (AK177-64) is available
from the Cessna Supply Division for in
stallation of abrasion boots on aircraft
not so equipped.
Revision 1
4-7
MODEL 188 & T188 SERIES SERVICE MANUAL
2
Detail
A Detail
7
8
BOLTS 70-100 LB-IN *e TORQUE INSTALL BOLT WITH NUT OUTBOARD
10
9 Detail
C Detail
15
11
12 10
1.
Nut
2. Washer 3. Bolt 4. 5.
Attach F ttti ng Bushtng
6. 7. 8. 9.
Hinge E levator Pylon Bracket Inboard Elevator Hinge Outboard Elevator Hinge 10. Stabtlizer Tip
Figure 4-4.
4- 8
Horizontal Stabilizer
11. Stabilizer Assembly 12. Mouldi~ 13. Leading Edge Fairing 14. Fair ing 15. Abrasion Boot
D
MOD EL 188 & T188 SERIES SERVICE MANUAL
4-21. DESCRIPTION. The aircraft may be equipped with two extruded rubber abrasion boots, one on the leading edge of each horizontal stabilizer. These boots are installed to protect the stabilizer leading edge !rom damage caused by rocks thrown back by the propeller. 4-22 . REMOVAL. The abrasion boots can be re
moved by loosening one end of the boot and pulling
it off the stabilizer with an even pr essure. Excess
adhesive or rubber can be removed with Methyl
Ethyl-Ketone.
4-23. INSTALLATION. Install abrasion boots as
outlined in the following procedures.
a. Trim boots to desired length. b. Mask off boot area on leading edge of stabilizer
with l-inch maski.ng tape, allowing 1/4-inch margin.
c. Clean metal surfaces of stabilizer, where boot
is to be installed with Methyl-Ethyl-Ketone.
d. Clean inside of abrasion boot with Methyl-Ethyl Ketone and a Scotch brite pad to ensure complete re moval of paraffin/talc . Then a nor mal wipedown with MEK on a cloth will leave surface suitable for bonding to the aluminum. NOTE Boots may be applied over epoxy primer, but if the surface has been painted, the paint
shall be removed from the bond area. This shall be done by wiping the surfaces with a clean, lint-free rag , soaked with solvent,
and then wiping the surfaces dry, before
the solvent has time to evaporate, with a
clean, dry lint-free rag.
e. Stir cement (EC-1300 Minnesota Mining and Manufacturing Co. ) thoroughly. f. Apply one even brush coat to the metal and the inner surface of the boot. Allow cement to air-dry for a minimum of 30 minutes, and then apply a second coat to each surface. Allow at least 30 min utes (preferably one- hour) for drying. g. After the cement has thoroughly dried, reacti vate the surface of the cement on the stabilizer and boot. using a clean, line-free cloth, heavily moisten ed with Toluol. Avoid excess rubbing which would remove the cement from the surfaces. h. Position boot against leading edge, exercising care not to trap air between boot and stabilizer. NOTE Should boot be attached "off-course". pull it up immediately with a quick motion. and reposition properly.
4-24. TAILCONE. 4-25. DESCRIPTION. The tailcone is of semimono coque-type construction, consisting of skin riveted to bulkheads, str ingers. and longerons. Four attach points, one on the forward end of each longeron, are provided to bolt the tailcone to the welded tubular structure. Attach points are provided at the aft end of the tailcone to support the horizontal stabilizer, vertical fin, and dorsal. 4- 26. REMOVAL. a. Remove side panels from tubular structure and tailcone. b. Remove access door from forward bulkhead of
tailcone.
c. Remove upper engine cowling. d. Disconnect elevator and rudder control cables
at turnbuckles .
e. Disconnect elevator tr im tab control cables in side tailcone and pull for ward through forward bulk·· head. f. Disconnect radio antenna lead from antenna and
remove clamps attaching lead to bulkheads, if in
stalled.
g . Disconnect flashing beacon and tail light wires
at quick- disconnects forward of fr ont bulkhead, if
installed.
h. Disconnect static line at tee in tailcone and re
move from forward bulkhead.
I. Disconnect deflector cable from canopy. j. If optional quick-loader system is installed, disconne ct main tube at aft end. k. Drill out rivets attaching aft section of canopy to taJ.lcone. l. Remove four bolts attaching tubular brace from canopy to tailcone. m. Jack aircraft in accordance with procedures out lined in Section 2.
/ ~AUTION \ .::iuppor t fr ont end of aircraft with hoie t hooked into engine lifting eye. Loss of tailcone weight will allow nose to drop. n. Drill out rivets attaching lower skin to tailcone forward b.llkhead. o. On serials prior to 188-0048, remove four bolts attaching tailcone to tubular structure. Tailcone may have to be held or supported while bolts are removed. Beginning with serial 188- 0048, remove four cotter pins and castle nuts from attaching studs. If shims are used, be sure to identify according to location. p. Remove tailcone by pulling aft and down. When removing tailcone. be sure quick-loader tube. anten na wire, and cables properly clear aircraft structure . q. Place tailcone on padded supports.
i. Press or roll entire surface of boot to assure positive contact between the two surfaces. j. Apply a coat of GACO N700A sealer , or equiva lent. conforming to IVIIL-C-21067 , along the trailing edges of the boots to the surface of the skin to form a neat, stra1ght fillet. k. Remove masking tape and clean stabilizer of exce s s material. 1. Mask to the edge of boot for painting stabilizer.
4- 9
MODEL 188 & T188 SERIES SERVICE MANUAL
4-27 . INSTALLATION. a. Jack aircraft in accordance with procedures out lined in paragraph 2-4 and figure 2-1.
ISAUTION] Support front end of aircraft wich hoist hooked into engine lifting eye. Loss of tailcone weight will allow nose to drop. b. On serials prior to 188-0048, position tailcone in proper location to be fastened to welded tubular structure. Beginning with serial 188-0048 , align tailcone with attaching studs in tubular structure. Be sure tube for quick-loader system is properly install ed and that it passes through forward bulkhead seal without damage to either tube or bulkhead. c. On serials prio r to 188-0048, install four bolts attaching tailcone to tubular structure. Beginning with s erial 188-0048, install cas tle nuts and cotter pins on attaching studs. If shims are used, be sure they are in proper location as identified at removaL d. Install four bolts attaching canopy brace to tail cone. e . Using existing holes as guides, either in canopy or tailcone , drill and rivet canopy to tailcone. !. · Using existing holes as guides, either in bottom skin or tailcone bulkhead, drill and rivet bottom skin
to forward bulkhead of tailcone . g. Remove jacks and hoist supporting aircraft. h. Connect: \_ 1. Elevator cables and check rigging. See Sec- I tlon 8. • 2. Rudder cables and check rigging. See ~ection 10. • 3. Elevator trim tab cables and check rigging. See :>ection 9. l. Route static line through forward bulkhead and \__: connect at tee in tailcone. • j . Connect optional quick-loading system main tube at aft end. k. Route radio antenna lead through front tailcone bulkhead, attach to antenna, and install clamps sup- \_ porting lead. Jill 1. Connect flashing beacon and tail light wires at quick-disconnect forward of frcS.Dt tailcone bulkhead, if installed. ~ m. Connect deflector cable , tighten to 15-20 pound- · inches and resafety. n. Install access door on tailcone forward bulkheadt o. Install side panels on tubular structure and tail- .... cone. ~ p. Install upper engine cowling. II'
t
4-28. REPAIR. Repair of the tailcone should be accomplished in accordance with applicable instruc- • Uons in Section 17. \.
·\...:.
4-1 0
Revision 1
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 5
LANDING GEAR, WHEELS AND BRAKES
TABLE OF CONTENTS
I
Page No. Aerofiche/ Manual Brake System Description . . . Trouble 'Shooting . Master Cylinders . Description Removal Disassembly (thru 1978 Models) . Inspection and Repair (thru 1978 Models) . Reassembly (thru 1978 Models) . Disassembly (Beginning with 1979 Models) . Inspection and Repair (Begin . ning with 1979 Models) Reassembly (Beginning with 1979 Models Installation Wheel Brakes
Description
Removal
Disassembly .
Inspection and Cleaning
Reassembly
Installation
Brake Lining Cheek .
Lining Installation
Bleeding .
Parking Brake System
Removal.
Installation
Rigging
LANDING GEAR
. 1D13/ 5-1 Description
. 1013/5-1 Trouble Shooting .
. 1D13/ 5-1 . 1014/ 5-2 Main Gear . Removal and Installation . 1014/5-2 Brake Line Bracket Installation . 1E7/5-19 Fe nders . . 1E7/5-19 Description . 1E7/5-19 . 1E7/ 5-19 Removal and Installation Main Wheels . · . 1Ell/ 5-23 Wheel and Axle Removal . 1E11/5~23 Wheel Removal . . 1Ell/5-23 Wheel Disassembly . . lEll/5-23 Wheel Cleaning and Inspection . 1EU/ 5-23 Wheel Reassembly . lEll/5-23 Wheel Installation . 1E13/5-25 Wheel Alignment . . 1E13/ 5-25 Wheel Balancing . 1E13/5-25 Tail Gear . 1E13/5-25 Description . 1E13/ 5-25 Removal and Installa~ion . 1E13/5-25 Tailwheel Casting Removal . 1E13/5-25 Tailwheel Casting Installation . 1E17/ 5-29 Tailwheel Removal . . 1E17/5-29 Tailwheel Disassembly and Reassembly . 1E18/5-30 Tailwheel Installation . . 1E18/5-30 Anti-Shimmy Adjustment . 1E18/5-30 Balancing . 1El8/5-30 TaU Wheel Lock System. • 1E18/ 5-30 Description • • . • • • 1E18/ 5-30 Removal/Installation . • 1El9/ 5-31 Rigging • . • • • • 1E19/ 5-31
5-l.
LANDING GEAR. (See figure S-1.)
5-2. DESCRIPTION. The landing gear consists of extra thick chrome-vanadium steel main landing gear springs and a spring-steel tubular tail wheel spring With a steerable tail wheel. The tail wheel steering arms are connected to the rudder cables with cables and springs. The tail wheel is steerable up to a de flection of 24 o left or right of center. In close quar
. . . . . .
1E19/5-31 1E19/ 5-31 1El9/5-31 1E20/5-32 1E20/5-32 1E20/5-32
. 1E20/ 5-32 . 1E20/5-32 . 1E20/ 5-32 . 1E20/5-32 . 1E20/5-32 . 1E20/5- 32 . 1E20/5-32 . 1E21/ 5-33 . 1E21/ 5-33 . 1E21/ 5-33 . 1E21/5-33 . 1E21/5-33 . 1E21/5-33 . 1E21/5-33 . 1E21/ 5-33 . 1E21/5-33 . 1E21/5-33 . 1E24/5-36 . 1E24/5-36 . 1E24/5-36 . 1E24/ 5-36
ters, tighter turns 'U'e possible by apt'lYing toe pre ssure to either rudder pedal, causing the tail wheel to free swivel, and enable the aircraft to be pivoted around the wheel being braked. The aircraft may also be equipped with fenders over the main gear tires. The fenders are designed to deflect mud and gravel being picked up and thrown by the tires. The fenders should never by used as a step; however, the gear support bracket may be used.
5-3. TROUBLE SHOOTING.
TROUBLE AIRCRAFT LEANS TO ONE SIDE
PROBABLE CAUSE
REMEDY
Incorrect tire inflation.
Inflate to correct pressure.
Landing gear attaching parts not tight.
Tighten loose parts and replace defective parts. Heviaion 1
5-1
MODEL 188 & T188 SERIES SERVICE MANUAL 5-3. TROUBLE SH<XYI'ING.
(Cont.)
TROUBLE
PROBABLE CAUSE
REMEDY
Landing gear spring excessively sprung.
Remove and replace.
Incorrect shimming at inboard end of spring.
Install shims as required. Refer to paragr aph 5-5 for limitations.
Bent axles.
Replace axles.
WHEEL BOUNCE EVIDENT EVEN ON SMOOTH SURFACE
Out of balance condition.
Refer to paragra ph 5-17.
TIRES WEAR EXCESSIVELY
Incorrect tire inflation.
Inflate to correct pressure.
Wheels out of alignment.
Align in accordance with paragraph 5- 16.
AIRCRAFT LEANS TO ONE SIDE (Cont).
Landing gear spring exces sively sprung.
EXCESSIVE TAILWHEEL SHIMMY
~·
Remove and replace.
Incorrect shimming at in board end of spring.
Install shims as required. Refer to paragraph 5-5 for limitations . ·
Bent axles.
Replace axles.
Dragging brakes.
Refer to paragraph 5-30.
Wheel bearings too tight.
Adjust properly.
Nut fastening s teering mech anism to fork improperly tightened.
Tighten per paragraph 5-26.
,
Incorrect tire pressure.
Inflate to correct pressure.
Refer to Section 3 for installation of wire cutters on main landing gear struts and center windshield. 5-4.
MAIN GEAR.
5-5 . REMOVAL AND INSTALLATION. a. Hoist aircraft in accordance with instructions outlined in Section 2. b. Remove fairings at upper end of gear strut. Re move access covers inboard of fairings on aircraft belly. c. Open forward baggage area doors and remove baggage floor, if installed. d . Remove brake bleeder screw and drain hydraulic brake flllid from gear being removed. e. Disconnect brake line at fuselage and remove with landing gear, or disconnect brake line at brake cylinder and strut and leave brake line with fuselage as gear is removed. Protect open lines and fittings from entry of foreign material. f. Refer to figure 5-1 and remove outboard saddle, 5-2
shim, spacers or washers, by removing attaching bolts. g. Remove bolt securing inboard end of strut and pull entire gear out of fuselage. Note any shims at inboard attachment and mark them to be sure they are replaced in the same position at gear installation. h. Reverse preceding steps to install main landing gear. Inspect outboard saddle - attach bolts and re place if damaged. Torque these bolts to values noted in figure 5-2. After connecting brake line, fill and bleed affected brake system. NOTE Shims (maximum of three) at the inboard end of the gear, are used to level the wing tips within a total tolerance of three inches.
MODEL .188 & T188 SERIES .SERVICE MANUAL 5-5A. CORROSION CONTROL ON LANDING GEAR SPRINGS. a. General (1) The main landing gear springs are made from high strength steel that is shot peened on the lower surface to increase the fatigue life of the part. (2) The shot peened layer is between 0.010 and 0.020 inch thick. (3) If the protective layer of paint is chipped, scratched, or worn away, the steel may corrode (rust) .
.NOTE: Corrosion ·pits that extend .past the shot peer layer of the gear spring will cause a significant decrease in the fatigue life of the spring. (4) Operation from unimproved surfaces Increases the possibility of damage. b. Corrosion removal and repair.
WARNING: Do not use chemical rust removers or paint strippers on landing gear springs. High-strength steel parts are very susceptible to t)ydrogen embrittlement. Acidic solutions, such as rust removers and paint strippers, can cause hydrogen embrittlement. Hydrogen embrittlement is an undetectable, time-delayed process. Since the pr9cess is time delayed, failure can occur after the part fs ret-urned to service.
'-r
(1) Examine for signs of corrosion (red rust) if damage to the paint finish of the landing gear spring Is found . (2} Carefully remove any rust by lightsanding. (a) The sanding must blend the damage into the adjacent area in an approximate 20:1 ratio. EXAMPLE: An 0.005-inch deep pit. The pit must be blended to a 0. 10-inch radius or 0.20-inch diameter. • (b) Make sure the last sanding tnarks are along an inboard-to-outboard direction, or along the long dimension of the spring. (3) After the sanding is complete, measure the depth of the remoVed material from the damaged area.
NOTE: 1'he maximum combined depth of removed material to the top and bottom or leading and trailing edge is not to be more than 0.063 inch at any two opposite points on the gear spring. This measurement limita1lon inclu des areas that have previously been damaged and repaired. (a) Make sure the depth of the damage area on the bottom of the gear spring is not more than 0.012 Inch deep. 1 If the damage is deeper than 0.012 inch deep and less than 0.063 inch deep, replace or shot _peen the gear spring. The gear spring must be removed and sent to an approved facility to be · -shot peened. g The shot peen specification Is to be Almen intensity of 0.012 to 0.016 with 330 steel shol ,
(b) Make sure the depth of any damage on the leading edgE;!, trailing edge, or top of the gear spring is not more than 0.063 inch deep. 1 If the damage is deeper than 0 .063 inch deep, replace the gear spring. (4) Touch-up paint as required.
NOTE: Additional information regarding corrosion control can be found in FAA Documents AC-43-4, Chapter 6, or AC43.13-1 B Chapter 6. c. Axle bolt hole corrosion. (1) Operation of an airplane on skis Increases the leads on the lower part of the gear spring because of the unsymmetrical and twisting loads. (a) The increased loads have produced spring fractures that originate from pits in the axle attach holes. 1 Catastrophic failures can occur from fatigue cracks as· small as 0.003 to 0.010- inch long that originated at pits.
02054-1-13 Temporary Revision 6 Jan 15/2008 © Cessna Aircraft Company
-
-·------'-
5-2A
MODEL 188 & T1 88 SERIES SERViCE MANUAL NOTE: Although operation on skis causes more loads, the criteria apply to all airplanes. (2) There is no maximum aamage'depth for pits that develop in the axle bolt holes. If pits or corrosion Is found, ream to remove it, subject to the following limitations: (a} Remove the minimum material necessary to repair the damage. (b} Make sure 1he diameter of the axle attachment holes are no more than 0.383 inch for 318- inch bolts. (c) Make sure the diameter of the axle attachment holes are no more than 0.321 inch for 5116- Inch bolts. (d) If reaming to the maximum dimension does not remove all signs of corrosion, discard the landing gear spring.
I
5-28
- -·
-·-- --
02054-1-13 Temporary Revision 6 Jan 15f2008 © Cessna Aircraft Company
MODEL 188 & T188 SERIES SERVICE MANUAL
BEGINNING WITH 18800955T
*On
aircraft serial A18803170 and A18803177 & on, fairing (5) material has been changed from ABS to Polyethylene.
5
*
18801375 & ON
NOTE
12
13
v @e_/
14
NOTE On aircraft serials 188-0001 thru 188-0409, 188-0551, and 188-0554 thru 188-0570, the brake cylinder ls located on the aft side of the axle. On aircraft serials 188-0410 thru 188-0553, except 188-0551 and 188-0571 & on, the brake cylinder is located on the forward side of the axle. On air craft equipped with the optional w~eel, the brake cylinder is at the forward side of the axle.
1. Axle 2. Wheel Alignment Shim 3. Towing Lug 4. Spring Strut 5. Brake Line Bracket
Figure 5-1.
6. Fairing 7. 8. 9. 10. 11.
Brake Line Union Brake Hose Nipple Brake Assembly
I
'()
I
/
12. 13. 14. 15. 16.
Wheel Assembly Axle Nut Dust Cover Elbow Connector
Main Landing Gear (Sheet 1 of 2) 5-3
MODEL 188 & T188 SERIES SERVICE MANUAL
.,r-:-7
5
~8
~~~ g 10 •
-v
..
...- .. ~
USED ON AIRCRAFT WITH 8. 50x10 WHEELS
16 11
-~
SHIM INSTALLED
ON A/ C 18800833 THRU 18801009 USED ON AIRCRAFT
WITH 8. 00x6 WHEELS
NOTE Beginning with aircraft serial 18800571, new
heavy-duty landing gear springs are installed
Cl$ standard equipment. Service Kits 188-20
and SK188-21 are available from the Cessna
Supply Division for installation of heavy-duty
springs on aircraft prior to 18800571.. Cess
na ·Single-Engine Service Letter No. SE~ 018 describes an improved adhesive for bond
ing main gear fretting shims, installed by the
Service Kits. NOTE * For 8. 50xl0 MLG torque nuts sym. in 50 in . .lbs. steps, until 275 .t 25 in. lbs. is reached.
Figure 5-1. Main Landing Gear (Sheet 2 of 2) 5 •4
Revision 1
12
MODEL 188 8t T188 SERIES SERVICE MANUAL
*MS20365-1216C NUTe
~
\
AN960-1216L "{ASHER
LOWER SADDLE
MS20002C7 WASHER MS20002C 12 WASHER
NAS147-94 BOLT
AN12-52A BOLT
NAS147-66 BOLT
* *
TORQUE NUTS TO 50-70 LB-FT
MODELS 188 & A188 SERIAlS 188-0001 THRU 188-0049 WHEN NOT MODIFIED PER SERVICE KIT
TORQUE NUTS TO 2300-2500 LB-fN
.A. WING TIPS MAY BE 3-INCHES TOTAL OUT OF LEVEL;
IF MORE THAN 3-rNCHES. ADD MAXIMUM OF (3) WASHERS . (FOR SERVICE PARTS. WING TIPS MAY BE 3-INCHES TOTAL OUT OF LEVEL; IF MORE THAN 3-INCHES. ADD MAXIMUM OF (1 ) WASHER .)
Figure 5-2. Main Landing Gear Spring Strut Installation (Sheet 1 of 14) 5- 5
MODEL 188 & T1 88 SERIES SERVICE MANUAL
(1613024-2 LOWER SADDLE INSTALLED) (1613019-3 LOWER SADDLE TO ORDER FOR SERVICE PARTS)O MS2000C7 WASHER
AN12-52A BOLT THRU 188-0570. EXCEPT SERIAL 188-0412 )
NAS147-94 BOLT
NAS147-66 BOLT
â&#x20AC;¢ 1641009-2 SPACER MIGHT BE INSTALLED
IN LIEU OF (3) AN960-716 WASHERS .
NAS152-88 BOLT (BEGINNING WITH SERIA L 188 -0571 AND INCLUDING SERIAL 188-0412)
* TORQUE NUTS TO 37.5-42 LB-FT *TORQUE NUTS TO 2300 - 2500 LB-IN
'-_
Figure 5- 2. 5-6
MODELS 188 & A188 SERIALS 188 - 0050 THRU 18800572
WHEN NOT MODIFIED
PER SERVICE KIT
A. WTNG TIPS MAY BE 3 -INCHES TOTAL OUT OF LEVEL; IF MORE THAN 3-INCHES. ADD MAXIMUM OF (3) WASHERS. (FOR SERVICE PARTS. ADD (1) WASHER .) O oN THE INITIAL SERVICE PARTS ORDER FOR A 1613019-3 SADDLE. SERVICE KIT SK188-35, SK188-21 OR SK1 88 -33, DEPENDING ON AffiCRAFT SERIAL. SHALL BE SUPPLIED.
Main Landing Gear Spring Strut Installation (Sheet 2 of 14)
MODEL 188 & T188 SERIES SERVICE MANUAL
~164 -2 )1641009-1 (SERVICE MS20002C 12
WASHE~@
@MS20002C7 WASHER * TORQUE NUTS TO 37.5-42 LB-FT NAS152 -88 BOLT *TORQUE NUT TO 2300-2500 LB-IN COAT LIGHTLY (HOLE & BOLT WITH ELECTRO-MOLY NO. 11 (MIL-G-21164) GREASE
NAS147-97 BOLT
.:: NAS147-69 BOLT
MODELS AGpickup AND AGwagon MODELS 188 & A188 SERIALS 18800573 THRU 18801040 WHEN NOT MODIFIED PER SERVICE KIT
Figure 5-2.
• J14109 -1 SHIMS ARE BONDED TO UPPER AND LOWER SADDLES WITH HYSOL 5095 AND 3673 THRU 1880846. BEGINNING WITH 1880847, SHIMS ARE BONDED TO UPPER AND LOWER SADDLES WITH B. F . GOODRICH A-1186B. A A MAXIMUM OF (3) AN960-1216L WASHERS MAY BE USED TO ADJUST THE WING TIPS TO WITHIN 3-INCHES OF BEING LEVEL. (FOR SERVICE PARTS, A MAXIMUM OF (1) MS20002-12 WASHER MAY BE USED TO ADJUST THE WING TIPS TO WITHIN 3 INCHES OF BEING LEVEL.
Main Landing Gear Spring Strut Installation (Sheet 3 of 14) 5-7
MODEL 188 & T188 SERIES SERVICE MANUAL
AN960-1216L WASHER (BETWEEN LANDING GEAR SPRING STRUT AND TUBULAR -STRUC TURE ) (MS20002-12 WASHER FOR SERVICE · ........._ PARTS) *MS203~-1216C NUT (THRU 18801332) MS21044N12 NUT\ (BEGINNING WITH 18801333) AN960-12 16L WASHER (THRU 18801332 )" :\ MS20002-12 WASHER (BEGINNING WITH 18801333)
\\I
LOWER SADDLE (1613024-4) (THRU 18801077) LOWER SADDLE (1613024-7) THRU 18801374) LOWER SADDLE (1613019- 3) (SERVICE PARTS THRU 18801374)
NAS152-88 BOLT
NAS1 47-70 BOLT (THRU 1880 1332 ) NAS147-72 BOLT ( BEGINNING WITH 18801333)
:\ItODE LS AGpickup A ND AGwagon SERIALS 1880 1041 THR U 18801374 WHEN NOT :'JODIFIED PER SERVICE KIT
*
TORQUE NUTS TO 37 . .~ -42 LB-FT.
*
TORQUE NUT TO 2300 - 2500 LB-IN. COAT LIGHTLY (HOLE & BOLT) WITH ELECTRO MOLY NO. 11 (MIL-G-21164) GREASE .
• J14109-1 SHIMS ARE BONDED TO UPPER AND LOWER SADDLES WITH B. F . GOODRICH A-1186B. NAS147-98 BOLT (THRU 18801332) NAS147-100 BOLT (BEGINNING WITH 18801333 )
A A MAXIMUM OF (3) AN960-1216L WASHERS MAY BE USED TO AD JUST THE WING TIPS TO WITH IN 3-INCHES OF BEING LEVEL. FOR SERVICE PARTS, A MAXI MUM OF (1) MS20002-12 WASH ER MAY BE USED TO ADJUST THE WING TIPS TO WITHIN 3 INCHES OF BEING LEVEL.
F igur e 5- 2. Main Landing Gear Spring Strut Installation (Sheet 4 of 14)
5- 8
MODEL 188 & T188 SERIES SERVICE MANUAL
......--•.v•u••vv•uG-12 WASHER (BETWEEN LANDING GEAR SPRING STRUT AND TUBULAR STRUCTURE)
MS20002C12 WASHER
MODELS AGpickup AND AGwagon BEGINNING WITH SERIAL 18801375 WHEN NOT MODIFIED PER SERVICE KIT
NAS152-88 BOLT
MS20002C8 WASHER MS20008-86 BOLT
.AA MAXIMUM OF (1) MS2002-12 WASHER MAY BE USED TO AD.TUST THE WING TIPS TO WITHIN 3 -INCHES OF BEING LEVEL. * TORQUE NUTS TO 60-70 LB-FT COAT LIGHTLY (HOLE & BOLT) WITH ELECTRO- MOLY NO. 11 (MIL-G-21164 ) GREASE
MS20008-58 BOLT
*TORQUE NUT to 2300- 2500 LB-IN COAT LIGHTLY (HOLE & BOLT) WITH ELECTRO-MOLY NO. 11 (MIL-G-21164) GREASE Figure 5-2.
Main
Landi~
Gear Spring Strut Installation (Sheet 5 of 14) 5- 9
MODEL 188 & T188 SERIES SERVICE MANUAL
AN960-1216 WASHER
j MS20002C7 @WASHER , NAS152-88 BOLT NAS147-97 BOLT
:-IAS147 -69 B0LT
* * A
:\IODELS 188 & A188 SERIALS 188-0001 THRU 188-0049 WHE~ MODIFIED PER SERVICE KIT
Figure 5-2. 5-10
TORQUE NUTS TO 50-70 LB-FT TORQUE NUTS TO 2300-2500 LB-IN WING TIPS MAY BE 3 -lNCHES TOTAL OUT OF LEVEL; IF MORE THAN 3 INCHES. ADD MAXIMUM OF (3) WASHERS (FOR SERVICE PARTS. ADD (1) WASHER.)
• J14109 - 1 SHIMS ARE BONDED TO UPPER AND LOWER SADDLES WITH HYSOL 5095 A:ID 3673
Main Landi~ Gear Spri~ Strut Installation (Sheet 6 of 14)
MODEL 188 & T188 SERIES SERVICE MANUAL
-trMS20365-1216C NUT~
\\ -
AN960-1216L WASHER
AN960-1216 WASHER
.. MS20002C7 · WASHER NAS152-88 BOLT
NAS147-97 BOLT •
Jl4109-l SHIMS ARE BONDED TO UPPER AND LOWER SADDLES WITH HYSOL 5095 AND 3673
*
TORQUE NUTS TO 50-70 LB-FT
NAS147-69 BOLl
MODELS 188 & Al88 SERIALS 188-0050 THRU 188-0317 WHEN MODIFIED PER SERVICE KIT
Figure 5-2.
*TORQUE NUTS TO 2300-2500 LB-IN .A. WING TIPS MAY BE 3-INCHES TOTAL OUT OF LEVEL; IF MORE THAN 3,.. INCHES , ADD MAXIMUM OF (3) WASHERS (FOR SERVICE PARTS. ADD (1) WASHER .)
Main Landi~ Gear Spri~ Strut Installation (Sheet 7 of 14)
5-11
MODEL 188 & T188 SERIES SERVICE M ANUAL
450-7H16-063 WASHER MS20002C12 WASHER
NAS152-88 BOLT
*TORQUE NUTS TO 2300- 2500 LB-IN *TORQUE NUTS TO 37 . 5-42 LB-FT
NAS147 -98 BOL NAS147-70 BOLT
.A WING TIPS MAY BE 3 -INCHES TOTAL OUT OF LEVEL; IF MORE THAN 3Â INCHES, ADD MAXIMUM OF (3) WASHERS. (FOR SERVICE PARTS. ADD (1) WASHERJ MODELS 188 & Al 88 SERIALS 188-0050 THRU 188- 0411 AND
188-0413 TiiRU 188-0570 WHEN MODIFIED PER SERVICE KIT
Figur e 5- 2. Main Landing Gear Spring Strut Installation (Sheet 8 of 14) 5- 12
MODEL 188 &. T188 SERIES SERVICE MANUAL
MS20002C 12 WASHER
1613019-3 LOWER SADDLE
*TORQUE NUTS TO 2300-2500 LB -IN
NAS152-88 BOLT
* TORQUE NUTS TO 37.5-42 LB-FT .A. WING TIPS MAY BE 3-INCHES TOTAL
OUT OF LEVEL; IF MORE THAN 3Â INCHES, ADD MAXIMUM OF (3) WASHERS. (FOR SERVICE PARTS ADD (1) WASHER.)
MS20002C7 WASHER
NAS147 -98 BOLT NAS147 -70 BOLT
Figure 5-2.
MODELS 188 & A188 SERIALS 188-0050 THRU 188-0411 AND 188-0413 THRU 188-0570 WHEN MODIFIED PER SERVICE KIT
Main Landing Gear Spring Strut Installation (Sheet 9 of 14)
5-13
MODEL 188 & T188 SERIES SERVICE MANUAL
*
MS21044N12 NUT
\\e
MS20002-12 WASHER
1641009-1 SPACER
MS20002C7 WASHER NAS152-88 BOLT NAS147-97 BOLT
*
TORQUE NUTS TO 50- 70 LB-FT
*TORQUE NUTS TO 2300-2500 LB-IN :-lAS147 -69 BOLT
MODELS 188 & Al88 SERIALS 188-0001 THR U 188 - 0049 WHEN :\10DIFIED PER SERVICE KIT
A WTNG TIPS MAY BE 3-INCHES TOTAL OUT OF LEVEL: IF MORE THAN 3Â INCHES. ADD MAXIMUM OF (3) WASHERS (FOR SERVICE PARTS. ADD (1} WASHER .)
. J14109-l SHIMS ARE BONDED TO UPPER AND LOWER SADDLES WITH HYSOL 5095 AND 3673
Figure 5-2. Main Landi~ Gear Spring Strut Installation (Sheet 10 of 14) 5-14
MODEL 188 & T188 SERIES SERVICE MANUAL
MS20002Cl2
S1450 - 7H1 6-063 WASHER
WASHER~ @, .
LANDING GEAR SPRffiG STRUT
@) S1450:7H16-063
/~
o A~~
WASHE~ __)-~~1016-1
~SHIM
NAS152-88 BOLT
MODELS 188 & A188 SERIALS 188-0050 THRU 188-0317 WHEN MODIFIED PER SERVICE KIT
MS20002C7 WASHER®
NAS147-98 BOLT NAS147 -70 BOLT
*TORQUE NUTS TO 2300-2500 LB-IN *
TORQUE NUTS TO 37.5 -42 LB-FT
..A. WING TIPS MAY BE 3-INCHES TOTAL
OUT OF LEVEL; IF MORE THAN 3 INCHES, ADD MAXIMUM OF (3) WASHERS . (FOR SERVICE PARTS. ADD (1) WASHER .) Figure 5-2. Main Landing Gear Spring Strut Installation (Sheet 11 of 14) 5-15
MODEL 188 8t T188 SERIES SERVICE MANUAL
~·;
*TORQUE NUTS TO 37.5-42 LB-FT MS20002C 12 WASHER
*
.TORQUE NUTS TO 2300-2500 LB-IN COAT LIGHTLY (HLE & BOLT) WITH ELECTRO MOLY NO. ll(MIL-G-21164) GREASE
•
J-14109-2 SPACERS ARE BONDED TO UPPER AND LOWER SADDLES WITH B. F. GOODRICH A-1186B
0
NAS152 - 88 BOLT
NAS147 -69 BOL
WHEN USING 1613019-3 SADDLES FOR SERVICE PARTS. ALSO USE MS20007 - 58 BOLT (2), MS20007-86 BOLT (2), MS51943-38 NUT (4), MS20002-7 WASHER (8), AND MS20002C7 WASHER (4)
..A. A MAXIMUM OF 3 AN960-1216L WASHERS MAY BE USED TO ADJUST THE WING TIPS TO WITHIN 3 -INCHES OF BEING LEVEL
MODEL AGtruck
NAS147 - 69 BOLT
SERIALS 18800967 THRU 18801032 AND 18801037 THRU 18801040
Figure 5-2. Main Landing Gear Spri~ Strut Installation (Sheet 12 of 14) 5-16
MODEL 188 & T188 SERIES SERVICE MANUAL
*MS20365-1216 NUT (THRU 18801332) MS21044Nl2 NUT (BEGINNING WITH 18801333 & SERVICE
PARTS~
-716 WASHER
TORQUE NUTS TO 37.5-42 LB-FT
..A. TORQUE NUTS TO 2300-2500 LB-IN ~ COAT LIGHTLY (HOLE & BOLT) WITH ELECTRO MOLY NO. 11 (MIL-G -21164) GREASE
â&#x20AC;¢
0
NAS152-88 BOLT
J14109-l SHIMS ARE BONDED TO UPPER AND LOWER SADDLES WITH B. F. GOODRICH A-1186B WHEN USING 1613019-3 SADDLES FOR SERVICE PARTS ALSO USE MS20007 -86 BOLT (2), MS51943 - 38 NUT (4), MS20002-7 WASHER (8), AND MS20002C7 WASHER (4)
.A A MAXIMUM OF 3 AN960-1216L WASHERS MAY BE USED TO ADJUST THE WING TIPS TO WITHIN 3-INCHES OF BEING LEVEL (THRU 18801332); (BEGINNING WITH 18801333, A MAXIMUM OF (1)
NAS147-70 BOLT (THRU 188-1332) NAS147-72 BOLT (BEGINNING WITH 18801333 )
Figure 5-2.
NAS147-98 BOLT (THRU 18801332) NAS147 - 100 BOLT (BEGINNING 18801333 )
Main Landing Gear Spri~ Strut Installation (Sheet 13 of 14) 5- 17
MODEL 188 & T1 88 SERIES SERVICE MAN·UAL
Sl450-8H16-063 WASHER /
SPRING STRUT
//~ ~
1641016-1 SHIM
/1 *
MS152 -88 BOLT
SADDLE~ ~ MS20002C8
/
WASHER
*TORQUE NUTS TO 2300-2500 LB-IN COAT LIGHTLY (HOLE & BOLT) WITH ELECTRO MOLY NO. 11 (MIL-G-21164) A
MS20002C8 WASHER MS20008-86 BOLT :VIS20008 -58 BOLT
._
TORQUE NUTS TO 65-70 LB-FT (LUBRICATE TIIREADS)
A MAXIMUM OF (1) MS20002-12 WASHERS MAY BE USED TO ADJUST TilE WING TIPS TO WITHIN 3 -INCHES OF BEING LEVEL
MODEL AGtruck BEGINNING WITII SERIAL 18801375
Figure 5-2.
5-18
Main Landi~ Gear Spring Strut Installation (Sheet 14 of 14)
MODEL 188 & T188 SERIES SERVICE MANUAL
1. 2. 3. 4.
Wire Cutter Nut Washer Upper Bracket Clamp Half
5. Spring 6. Bolt 7. Nut 8 . Washer 9. Upper Bracket 10. Lower Bracket 11. Fender 12. Bolt 13. Lower Bracket Clamp Half
Figure 5-3. Fender Installation
5-6.
BRAKE LINE BRACKET INSTALLATION. NOTE
Brackets are secured to the landing gear spring strut with 3M £2216 or equivalent. a . Mark the position of the brake line bracket so that the replacement bracket will be installed in ap proximately the same position. b. Remove all traces of the original adhesive as well as any rust, paint, or scale with a wire brush and coarse sandpaper. c. Leave surfaces slightly roughened or abraided, but deep scratches or nicks should be avoided. d. Clean the surfaces to be bonded thoroughly. If a solvent is used, remove all traces of solvent with a clean, dry cloth. Surface must be clean and dry. e. Mix the adhesive carefully according to the manufacturer's dir ections. f. Spread a coat of adhesive on the surfaces to be bonded, and place bracket in position on the spring strut. Install small clamp to hold bracket in posi tion. g. Form a small fillet of the adhesive at all edges of the bonded surfaces. Remove excess adhesive with lacquer thhmer . h. Allow the adhesive to cure thoroughly according to the manufacturer's recommendations before flex ing the gear spring. i. Repaint gear spring and bracket after curing is complete.
5-8. DESCRIPTION. Fenders may be tnstalle:i to protect the propeller by deflecting rocks dislodged by the wheels. T he fender is not intended to be used as a s tep. 5-9. REMOVAL AND INST ALLATION OF FENDER. (See figure 5- 3.) NGrE It is not necessary to remove the fenders to
perfor m main landing gear maintenance ex cept r emoval or installation of the wire cut ter s (1). (The fender brackets also function as wire cutter brackets. ) If the aircraft is flown fr om sur faces with mud snow, or ice, the fender should be checked to make sure there is no accumulation which could pre vent wheel rotation.
a. Remove nuts (2), washers {3) and clamp halves (4 and 13) fr om upper and lower bracket bolts (6). b. Remove bolts and lift fender with brackets from main gear spring. c. Details of the fender installation are shown in figure 5- 3, which may be used as a guide for dis assembly of fender, upper bracket, and lower brack et, ii required for replacement of damaged parts. d. Reverse preceding steps to install fender making sure that bolt holes are properly aligned with clamp halves and wirecutter.
5-7. FENDERS. (See figure 5-3.) 5-19
MODEL 188 & T188 SERIES SERVICE MANUAL
WHEEL AND BRAKE ASSEMBLY (8. 00 X 6)
11
NOTE Some wheel brakes have "kidney- shaped" washer installed under head of bolts (19).
29
28
*TORQUE TO 80-90 LB-IN
1.
Grease Seal Ring
2. Grease Seal Ring Beanng Cone 4. Outer Wheel Half 5. Tire 6. Tube 7. ln.ner Wheel Half 8. Bearing Cone 9 . Grease Seal Ring 3.
10. Snap Ring 11. Grease Seal Felt 12. Bearing Cup 13. Bearing Cup 14. Grease Seal Felt 15. Snap Ring 16. Washer 17. Nut 18 . Brake Disc
Figure 5-4. 5-20
Revision
1
~
19. 20. 21. 22. 23. 24. 25. 26. 27.
Thru -Bolt Pressure Plate Anchor Bolt Brake Hose Fitting Washer Nut Washer Bolt - Self Locking Bleeder Valve
Main Wheel and Brake (Sheet 1 of 3)
28. 29. 30. 31. 32. 33. 34. 35. 36. 37.
Brake Cylinder Piston 0-Ring Brake Lining Torque Plate Shim Brake Lining Back Plate Hub Cap Spacer
MODEL 188 & T188 SERIES SERVICE MANUAL '
WHEEL AND BRAKE ASSEMBLY (8. 50 X 10)
35
25
27
Figure 5- 4.
Main Wheel and Brake (Sheet 2 of 3)
5-21
MODEL 188 & T188 SERIES SERVICE MANUAL
WHEEL AND BRAKE ASSEMBLY (8. 00 X 8)
7
BEGINNING WITH 18800833
Figure 5-4. 5-22
Main Wheel and Brake (Sheet 3 of 3)
MODEL 188 & T1 88 SER IES SERVICE MANUAL
5-10. REMOVAL AND INSTALLATION OF MAIN
WHEEL AND AXLE. (See figure 5-1. )
a. Disco nnec t brake hose at wheel cylinder and
drain h ydrau lic fluid . Protect fittings fro m dirt.
b. Remove wheel in accordance with paragraph
5-11.
a. Deflate tire and break loose tire beads. b. Remove thru-bolts and s eparate wheel halves , removing tire, tube , and brake disc , and the center spacer on the optional wheel. c. Remove g rease seals and bearing cones. NOTE
NOTE Note the number and position of any wheel alignment shims next to strut. Mark these shims or tape them together so they may be reinstalled in exactly the same positio n to e nsure that wheel alignment is not disturbed. c. Re move bolts securing axle and brake torque
plate to s trut and remove axle and plate.
d. Reverse the preceding steps to install the wheel and axle, making sure that wheel alignment shims are ins talled correctly. Refer to Figure 5-l for torque requirements when 8. 50x10 wheel is installed. Refer to paragraph 5-15 for wheel installation. e. Remove plugs or caps fro m brake hose and con nect. Bleed the brake system. 5- 11.
REMOVAL OF MAIN WHE E L. NOTE
It is not necessary to remove the whee l to reline brakes or remove brake parts (other than the brake disc or to rque plate) .
a. Jack wheel, usi~ universal jack point. b. Remove outer dust cover o r hub cap. c . Remove cotter pin and axle nut. d. Remove bolts and washers securing back plate. e. Pull wheel from axle. On optional wheel, re move bearing co ne as wheel is removed. 5- 12.
DISASSEMBLY OF MAIN WHEEL. NOTE
If wheels are not out of balance ,
mark wheel
halves and tire befo re disassembly.
The bearing cups are a press fit in the wheel halves and should not be removed unless re placement is necessary. To remove the bear ing cups, heat the wheel half in boiling water for 15 minutes. Using an arbor press, if available, press out the bearing cup and press in the new one whlle the wheel is s till hot. 5-13 . CLEANING AND INSPECTION OF MAIN
WHEEL.
a. Clean all metal parts and g reas e seal felts in
s o lvent and dry thoroug hly.
b. Inspect wheel halves for c racks . Cracked whf!c>l halves must be replaced. Sand out mcks , gouges, and corroded areas. Where the protective coating has been removed, the area should be cleaned , primed, and r e painted. c. Inspec t brakes in accordance with pr ocedur es outlined in paragraph 5-45. d. Bearing cups and cones must be replaced if damaged or discolored. After cleaning, r e pac k bearing cones before installatio n. 5-14. REASSEMBLY OF MAIN WHEEL. a. Insert thru-bolts through brake disc and positio n in inner wheel half, using bolts to guide the disc. Assure that disc is botto med in wheel half. NOTE Assemble tire and wheel halves in posit ion
marked during disassembly. U a new tire
is being installed, place tube in tire with
balance mark on tube at red do t o n tire.
Refer to paragraph 5-17 for wheel balanc
ing.
b. Position tire and tube in outboard wheel half with inflatio n valve extending through hole . On o ptional
Inju r y can r esult fro m attempting to separate wheel halves with the tire inflated. Avoid damag ing wheel flanges when breaking tire beads loose.
SHOP NOTES :
5- 23
MODEL 188 & T188 SERIES SERVICE MANUAL
REFER TO FIGURE 1-1 FOR TOE -IN AND CAMBER VA LUES
PLACE CARPENTER'S ~UARE AGAINST STRAIGHTEDGE AND LET IT TOUCH WHEEL JUST BELOW AXLE NUT
ALUMINUM PLATES, APPROXIMATELY 18" ~UARE, PLACED UNDER WHEELS--~ GREASE BETWEEN PLATES NOTE
Rock wheels before checking wheel alignment.
BLOCK STRAIGHTEDGE AGAINST TffiES JUST BELOW AXLE HEIGHT
TOP VIEW OF TOE-IN CHECK
FRONT YIEW OF CAMBER CHECK
Measure toe -in at edges of wheel flange. Dilfer ence in measurements is toe - in for one wheel. (half of total toe-in.) CARPENTER'S SQUARE
Measure camber by reading protractor level held vertically against outboard flanges of wheel. POSITIVE CAMBE7 \NEGATIVE CAMBER
/ '
...
FORWARD
INBOARD •
STRAIGHTEDGE NOTE
Setting toe-in and camber within these tolerances while the cockpit, fuel tank, and hopper are empty w111 give approximately zero toe-in. and zero camber at 3300 pounds gross weight. U abnormal tire wear occurs, realign the wheels to result in the least tire wear . Circular, tapered shims are avail able for wheel alignment. Shim, Part No. 1641005 - 1, is the thickest and provides the most change in alignment. Shim, Part No. 1641005-2, provides the least change, and 1641005-3 provides me dium change. A shim may be installed in any one of six positions on either face, offering a total of 12 possible changes in alignment per shim. Always use the least number of shims possible to obtain the desired result. The maximum accumulated shim thickness measured at the thickest portion IS . 22 inch . Figure 5-5. Wheel Alignment 5-24
MODEL 188 & T188 SERIES SERVICE MANUAL
wheel install center spacer in place. Place inner wheel hal! in position and apply a light force to bring wheel halves together. Assure that tube is not pinched. Maintaining the light force , assemble a washer and nut on one thru -bolt and tighten snugly . Assemble remaining washers and nuts on thru-bolts and torque evenly to value marked on wheel.
/CAUTION l Uneven or improper torque of thru-bolt nuts may cause bolt failure, with resultant wheel failure.
to structure in fuselage. f. Replace hose and rubber bushings ii deter iorated , inspect and replace springs and parts as required. g. Reverse preceding steps to install tail gear. 5-21. REMOVAL OF TAlL WHEEL CASTING. (Be ginning with 18801935.) (See figure 5- 6.) the a. Remove tail wheel in accordance with procedures outlined in paragraph 5-20. b. Disconnect steerl~ cables from tail gear. c. Remove all parts and attachments from tall gear spring (1) and casting (2).
c. Clean and repack bearing cones. Install bearing cones and grease seals. Outer bearing cone will be installed ~ wheel is installed on optional wheel. d. Infla.ti tire ~ seat tire beads, then adjust to correct pr'essure. 5-15. INSTALLATION OF MAIN WHEEL. a. Place wheel on axle. Install outer bearing cone on optional wheel. b. Install axle nut and tighten until a slight bearing _drag is obv_!9us as ,thLw.!!_e~s turJ!ed. Bad~. <?.~ nut to nearest castellahon and mstall cotter pin. c. Install hub cap or outer dust cover. d. Place back plate in position and secure with washers and bolts. These bolts contain sell-locking threads.
3
5- 16. WHEEL ALIGNMENT. (See figure 5--5.) 5-17. WHEEL BALANCING. Since uneven tire wear is usually the cause of wheel unbalance, replacing the tire will probably correct this condition. Tire and tube manufacturing tolerances permit a specified amount of static unbalance . The lightweight point of the tire is marked with a red dot on the tire sidewall and the heavyweight point of the tube is marked with a contrasting color line (usually near the valve stem). When installing a new tire, place these marks adja c ent to each other. If a wheel becomes unbalanced during service it may be statically rebalanced. Wheel balancing eql•ipment is available !rom the Cessna Service Parts Center. 5-18. TAILGEAR. (SeefigureS-7.) 5-19. DESCRIPTION. The·tan gear is comprised of a steerable tail wheel, mounted on a tubular spring strut. The strut is mounted in rubber bushings to cushion vibration. The tail wheel is steerable in re sponse to rudder pedal action, up to a maximum de flection, after which it becomes free-swiveling. 5-20. REMOVAL AND INSTALLATION OF TAIL GEAR. a. Place suitable padded stand under ta1icone or use a jack under jack point, if installed. to raise tail gear off ground. b. Disconnect steering cables from tail gear. c. Remove stinger for access. . d. Remove cotter pins and c levts pins securing tube to spring fitting. Tap tube out through spring fitting, removing rubber bushings. e . Pull taU gear aft, out of rubber hose, cemented
(~AUTION j Do NOT place heating tape 1n direct contact with tubular. tall gear spring.
1. Ta.ilgear Spring 2. Casti~
3. Electric Heatir~ Tape 4. Drain Hole
Figure 5-6. Tail wheel Bracket Removal NOTE Tall wheel casting (2) is bonded to tubular
tall gear spring (1). The bond is too str ong
to allow casting to be removed without first
weakening the bond strength. T he only me
thods of weakening the bond are with heat of
cryogenic cold; heat being the most r-actlcal.
A temper ature of approximately 500 F is
sufficient to weaken the bond so the casting
can be removed. This 1s still a low enough
temper ature to prevent damage to the tubu
lar tall gear spring, but wtll age the alumi
num casting. Therefore, the casting will
have to be replaced. CasU~ should be re
moved from strut using electrical heating
tape (3). Heat1~ tape, P/ N 135-459, can
b<. obtained from the Cessna Supply Division. Revision 1
I
5-25
MODEL 188 & T1 88 SERIES SERVICE MANUAL
f\:
1 __
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··········-.
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_
.-·
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.-<-~~~5~ .··•..'.:.---··· 1880833 TlURU 18802745 Detail
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.
B
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A •.,_
188- 0001 THRU 18800832
Detail
Clip Bracket Tailwheel Lock Control Cable Spring Attach Fitting Grommet Washer Bushing 8. Tube 9. Hose 1. 2. 3. 4. 5. 6. 7.
10. 11. 12. 13. 14. 15. 16. 17.
B
Bolt Cotter Pin Clevis Pin Spring Fitting Spring Tie Down Ring Bolt Tailwheel Assembly
18. 19. 20. 21. 22. 23. 24. 25. 26.
F igu- e 5- 7. T ailgear Installation {Sheet 1 of 3) 5-26
Link Cable Spring Spring Eye Barrel Fork Bellcrank T ailwheel Lock Control
MODEL 188 & T188 SERIES SERVICE MANUAL
6
9 1. Grease Fitting
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12. 13. 14. 15.
16. 17. 18.
19. 20. 21.
22. 23.
24. 25. 26. 27. 28. 29. 30.
31. 32. 33. 34. 35. 36. 37. 38.
39. 40.
41.
42. 43.
Bearing Cone
Nut
Wheel Half
Tube
Tire
Gasket
Bolt
Washer
Spacer
Spacer
Bearing Cup
Bracket
Bearing Cone Steel Washer Phenolit e Washer Washer Staking Pin Spring Spacer Spring Screw Fork Assembly Bearing Cone Spacer Grease Retainer Cotter Pin Castellated Nut Washer Grease Fitting Lockwasher Axle Assembly Washer Nut Roll Pin Locking Collar Spacer Lower Dust Cap Pawl Steering Arm Assembly Spacer Upper Dust Cap Compression Spring Grease Fitting
11
10
188-0001 THRU 18802745
15
39
17
0 1 9_e;:;:~
_
-
37
18--...
36
20---- I
21
~ · ©
-
35
I
Figure 5-7 . Tailgear Installation (Sheet 2 of 3) 5-27
MODEL 188 & T188 SERIES SERVICE MANUAL
*USED ON NON- LOCKING
TAILGEAR ONLY
9
Beginni~
with
18803874, cap
screws (47) re
place setscrews
(12). Apply li
beral amount of
MIL-G-81322A
General Purpose
grease inside each
of six mounting
holes and to the
threads of each
capscrew before
installation.
II shimmy or spindle breakage are 4 experienced. prope r tailwheel ad
3 justment can eliminate these pro
blems . Shim my is caused by rela
tively rapid break in of tailwheel
bearings and friction system. This
results in loss of bear ing preload
and shimmy damptng fnction .
Spindle bolt breakage has resulted
from loosening the spindle nut to
im;:rove poor spindle character
istics caused by a galled lockplate
(32). II a galled lockplate is found.
it should be replaced with lock plate (p ·n 0742161 - 3). which is made
of AISI 4340. 1n lieu of 17 -4PH .. pro
cedures for tai lwheel adjustment are
contained in the adjustment paragraph
in thts Sectton.
1. Friction Plate Assembly 27. Washer 28. Washer 2. Upper Dust Cove r 29. Packi~ 3. Thrust Race 4. Steering Lock Bellcrank 30. Fork 31. Spr ing Latch 5. Bushing 32 . Steering
6. Washer Lockplate
7. Spring Actuator 33. 8. Tie-Down Ring 34. Lower Dust 9. Clamp Cover 10. Spindle 35. Steering Arm 11. Grease Fitting Assembly 12. Setscrew 36. Washer 13. Insert 37 . Spacer 14. Head Assembly 38. Bolt 15. Cotter Pin 39 . Washer 16. Spring Washer 17. Fnch on -Ad)u.st Spring 40. Bear!~ 41. Wheel 18. Bearing 42. Tube 19. Race 43. Tire 20. Thrust Bearing 44. Gasket 21. Radial Beanng 45. Nut 22. Thrust Race 46. Capscrews 23 . Thrust Bearing 47. Cable 24. Spacer 48. Turnbuckle 25 . Washer 49. Bellcrank 26 . Castellated :-lut
Figure 5-7. 5-28
42
* BEGDlNING WITH 18802746
Tatl.gear Installation (Sheet 3 of 3)
Beginning with aircraft serial 18803200 and all service parts, axle with grease fitting re places AN8-46 axle bolt.
MODEL 188 & T188 SERIES SERVICE MANUAL
d. Wrap electric heating tape (3) around casti~ (2) and tie with string pr ovided with tape as shown in the illustration.
I~AUTION I DO Nor place heati~ tape in direct contact with tubular tail gear spring. e. Plug heating tape into llOVolt AC outlet and heat for 20 to 30 minutes. f. Unplug heating tape and remove from casting. Remove casting from tail gear spring by striking ca sting with sharp blows, driving it off tail gear spr ing. g. Clean old adhesive off tail gear s pring with wire brush. Brush strokes should run lengthwise of tail gear spring. After old adhesive has been removed, wipe with clean rag saturated with acetone or alcohol. Immediately wipe dry with clean, lint-free cloth. NOTE U tailwheel casting (2) is not bonded to spring (1) (aircraft prior to 18801935 not modilied
per Service Letter SE75-9. ), omit following steps and simply remove casting from spring. 5- 22. ffiSTALLATION OF TAIL WHEEL CASTING.
(Beginning with 18801935. ) (See figure 5-6. )
U casting (2) was not bonded to tail gear s pring (1)
and a new bracket is to be bonded, the tail gear
spring will require a thorough cleaning to r emove
all dirt and grime from bonding surfa ce.
a. Wipe outer surface of tail gear s pring (1) and inside surface of new casting (2) with solvent, drying
immediately with a clean, lint- fr ee cloth. b. Mix EA9309- 25GR, or equivalent adhesive, in accordance with instructions on package. Spread adhesive thinly a nd evenly on outer surface of tail gear spring in a r ea that will be covered by casting (2 ).
c. Place casting (2) on tail gear spring (1) and rotate to ass ure even coverage between mating sur faces of casting (2) and tail gear spring (1). d. Align holes and install pr eviously removed hardware. Allow adhesive to cure for 24 hours at 75°F, or 30 minutes at 250° F, if hea ting equipment is available . e. Assure that drain hole (4) is open after bon ding. f. After curing, assemble balance of removed parts in accor dance with applicable paragraphs in this section. 5-23. REMOVAL OF TAIL WHEEL ASSEMBLY. a . Place suitable padded stand under aft fuselage bulkhead to raise tailwheel off the gr ound. b. Noting position of was hers, lockwasher s and spacers, remove cotter pin and axle nut. Pull axle bolt out of fork to remove tailwheel. NOTE The bearing cups are a pre s s fit in the fork and upper bracket , a nd should not be re moved unless replacement is necessary. To remove bearing cups, heat fork or bracket in boiling water for 15 minutes. Using a s uitable expanding type puller, extract bearing cup and press in new cup while fork or bracket is still hot.
BEGINNING WITH 1979
~
Each 100 hours and after cleaning of tailwheel lock control, lubricate control as follows: a. Pull handle out to the lock position. b. Insert two to four dr ops of SAElOW oil, gr aphite or equivalent in pin slot of sleeve. c. Cycle handle several times and restor e it to its normal position.
4
1. Slot 2. Sleeve 3. Tubular Structure 4. Handle (Tailwheel Lock Control) 5. Bracket 6. Mixture Control Knob
3
Ftgure 5- 8.
Lubrication of Tall wheel Lock Control 5- 29
MODE L 188 & T188 SERIES SERVICE MANUAL
5-24. DISASSEMBLY AND REASSEMBLY OF TAIL
WHEEL ASSEMBLY. (See figure 5-7.)
Figure 5-7 may be used as a guide during disassembly,
replacement of parts and reassembly of the tail wheel.
NOTE The bearing cups are a press !it in the wheel halves and should not be removed unless re placement is necessary. To remove bearing cups, heat wheel halves in boiling water for 15 minutes. Using an arbor press, if available, press out bearing cup and press in new one while wheel is still hot. a . Alter removal, deflate tire by removing valve
core .
b. Grease seals, retainers, and bearing cones need
not be removed to replace a tire, although their re
moval for cleaning, inspection, and lubrication is
recommended.
c. Remove bolts fastening wheel halves together, then separate wheel halves, removing tire, tube, and gasket between wheel halves. a. Clean all metal parts and grease seal felts in
solvent and dry thoroughly.
e. Inspect wheel halves for cracks. Cracked wheel . hal_yes must be replaced. Sand out nicks, gouges, and corroded areas. Where protective coating has · .. been removed, area should be cleaned, primed, and painted. f. Replace felt seals if alter normal cleaning they are embedded with foreign matter, the felt is not pliable, or the material is broken or does not re tain shape necessary for proper sealing. Oil felts lightly at installation. g. Bearing cups and cones should be repacked 1! damaged or discolored. Alter cleaning, repack bearing cones before installation. _ _ h. Place tube in tire. Position wheel halves in tire, with gasket in place, so that valve stem and Dolt holes-are properly aligned. i. Hold wheel halves together, making sure that tube Is not pinched, and install and tighten the bolts evenly. NOTE During reassembly, torque bolt on tailwheel assembly until gear has the following break away force, and measured at the cable attach hole . j. On the 8- inch tailwheel assemblies thru serial 18800572, torque bolt to 10 lb. ::1 lb. breakaway force. k. On the 8- inch tailwheel assemblies from serial 18800573 thru 18800618, torque bolt to 7 lb. ::1 lb. l. On the 8- inch tailwheel assemblies from serial 18800619 thru 18802745, torque bolt to 8 lb. ±2 lb. m. On the 8-inch tailwheel assemblies from serial 18800670 thru 18801034, insta'l (2) 113233 Scott springs diametncaUy opposed to each other to obtain 8 lb :2 lb break-away force. n. On the 10-mch tailwheel assemblies thru ser ials 18800572, torque bolt to 15 lb. : 1 lb. break -away force. Beginning with serial Jl3800517, friction springs are installed to obtain desired break -away 5-30
Revision 1
force. A minimum of four springs are used. -;:-On the 10-inch tailwheel assemblies from serial 18800573 thru 18800618, torque nut to 7 lb. .d lb. break- away force. p. On the 10-inch bilwheel assemblies, from serial 18800619 thru 18802745, locate springs left and right, opposite each other and torque nut to 8 lb. ±2 lb. break-away force. q. On the 10-inch tailwheel assemblies, beginning
with serial 18802746, when assembly operations on
tailwheel assembly is completed, torque nut before
lubrication to attain apprmimately 12 to 15 lb. pull
at tailwheel steering cable attach point on steering
arm ass-embly. It may be necessary to us·e washers
(PIN S1450-9S14- 012), available from the Cessna Supply Division, as required, to attain 12 to 15 lb.
pull. Refer to paragraph 5- 2 6 for adjustment of the
anti- shimmy mechanis rn.
I
NOTE The six friction adjustment springs must not engage the friction plate assembly . r. Inflate tire to seat beads, then adjust to correct pressure, specified in figure 1- 1 of this manual. 5-25. INSTALLATIO~ QF T~L WHEEL. a. Make stire spacers, washers, and.lockwashers
are in place as tailwheel is positioned in fork, then
install axle bolt.
b. Tighten axle nut until a slight bearing drag is obvious as wheel is turned. Back off nut to the near , ~st cast.ellatiq~ and _install .cc;>tter pin. c. Lubricate tailwheel at grease fitting. d. _Remove padded stand placed under bi_lc?ne. 5- 26. ADJUSTMENT OF ANTI-SHIMMY MECHANISM. (See figure 5- 7. ) · NOTE Prior to adjusting anti-shimmy mechanism, check torque on spindle nut for a reading of 12 to 15 lbs. when measured at the tailwheel steer ing cable attach point. Failure to do so could result in bearing failures and improper friction setting of anti-shimmy mechanism.
Adjustment of the anti- shimmy mechanism on the 10" taUwheel assembly is to be accomplished by turning the six setscrews clockwise, maintaining apprCilCi .~ mately equal number of turns for each screw until a friction level of 16 lb. ±1 lb. is reached when ( measured by the use of a stick-force gauge or fish scale at the tailwheel steering cable attach point on • the tailwheel steering arm. 5-27. TAIL WHEEL BALANCING. Refer to para graph 5-17 of this manual. 5-28. TAIL WHEEL LOCK SYSTEM. (See figure 5-7, sheet 3 of 3 and figure 5-8.) · 5-29. DESCRIPTION. The steerable tail wheel in corporates a manual anti- sw1vel locking system which
(
MODEL 188 8t T188 SERIES SERVICE MANUAL can be engaged to limit steering to 2. 5• left and right. A "T" handle on the fuselage structure to the left of the pilot's seat controls a spring-loaded locking lug on the tail wheel assembly. To unlock the tail wheel, the handle must be pulled aft and turned to the locking detent. Unlocking the tail wheel is accomplished by turning the handle out of the locking detent and return ing it to the full forward position.
f. Adjust turnbuckle (48) so that handle (index 4, figure 4-8) locks and unlocks tail wheel freely with out binding. g. Saletywire tur nbuckle.
5-30. REMOVAL AND INSTALLATION. (See figure 5-7, sheet 3 of 3 and figure 5-8.) The figure may be used as a guide for removal and installation of system components. Lubrication of tail wheel lock control is outlined in figure 5-8.
Throughout the brake system, when installing fittings or coMecting lines or hoses, use NS-40 RAS-4 (Snap-On Tools Corp. , Kenosha, Wis consin), MIL-T-5544 (Thread Compound, Anti seize, Graphite-Petrolatum) or equivalent sparingly to male fittings only, omitting the first two threads. Always be sure that a com pound, the residue from a previously used compound, or any other foreign material cannot enter the system.
5- 31. RIGGING. (See figure 5-7, sheet 3 of 3 and figure 5-8.) a. Referring to figure 5-8, clock handle (4) fore and-aft in the unlocked position to avoid handle con tacting hopper control micrometer crank. b. Rotate sleeve (2) until slot (1) is at top. c. Pull handle (4) up and aft and rotate to locking detent. d. Rotate tail wheel as necessary so that slot in steering lockplate (index 32 in figure 5-7, sheet 3 of 3) is facing forward. e. Referring to figure 5-7, sheet 3 of 3, attach ca ble (47) to turnbuckle (48). Attach turnbuckle to bell crank (49) on head assembly (14).
5-32. BRAKE SYSTEM. (See figure 5-10.) NOTE
5-33. DESCRIPTION. The hydraulic brake system consists of two master cylinders, each operated by its rudder pedal, brake lines connecting each mas ter cylinder to its corresponding wheel brake cylin der' ancra single disc piston type brake assembly located at each main wheel.
5-34 . TROUBLE SHOOTINJ- -- BRAKE SYSTEM.
TROUBLE .DRAGGING BRAKES.
PROBABLE CAUSE
REMEDY
Brake pedal binding.
Check and adjust pr operly•
Parking brak_e holding brake pedal down.
Check and adjust properly.
Worn or broken piston return sprq. (In master cylinder. )
Repair or replace master cylinder.
Insufficient clearance at Lock 0-Seal in master cytinder.
Adjust as shown in figure 5-9.
Restriction in hydraulic lines or restriction in compensating port in master cylinder.
Vrain brake lines and clean inside
of brake lines with filtered com pressed air. Fill and bleed brakes. If cleaning lines fails to give satis
factory results, master cylinder may be faulty and should be re paired or replaced.
BRAKES FAIL TO OPERATE.
Wor n. scored or warped brake discs.
Replace discs and linings.
Damage or accumulated dirt r e stricti~ free movement of wheel brake parts.
Clean and repair or replace parts as necessary.
Leak in system.
If master cylinders or wheel brake
assemblies are leaking, they must be repaired or replaced. 5- 31
MODEL 188 & T188 SERIES SERVICE MANUAL 5-34. TROUBLE SHOOTIN:i - - - BRAKE SYSTEM (Cont).
TROUBLE BRAKES FAlL TO OPERATE. (Cont).
PROBABLE CAUSE
RE ME DY
Air in system.
Bleed system.
Lack of fluid in master cylinders.
F ill and bleed if necessary.
Defe ctive master cylinder.
Repair or replac e master cyunaer.
5-35. BRAKE MASTER CYLINDERS. (See figure 5-9.) 5-36. DESCRIPTION. The brake master cylinders, located just forward of the r udder pedals, are actua ted by applying toe pressure on the top of rudder pe dals. A small reservoir is incor porated in e ach mas ter cylinder to supply it with hydraulicil.uid. 5-37. REMOVAL OF BRAKE MASTER CYUNDER. a. Provide drip cloth and container, then discon
nect hydraulic hose at master cylinder. Protect
hose and fitting from dirt.
b. Remove pins attaching master cylinder to rudder
pedal and structure.
c. Remove clevis and locknut at top of piston rod. d. Note location of parking brake clamps around
master cylinder, then loosen clamps.
e. Slide locking plate oCC piston rod as master cyl inder is pulled downward through parking brake clamps. Do not disturb parking brake control clamps or stops. 5- 38. DISASSEMBLY OF BRAKE MAST ER CYLINDER. (Thru 1978 Models.) (See figure 5-9.) a. Unscrew clevis (1) and jamb nut (2). b. Remove screw (18). c. Remove filler plug (17) and setsct ew (5). d. Unscrew cover (4) and remove up over piston rod (3). e. Remove piston rod (3) and compensating sleeve (16). f. Slide sleeve (16) up over rod (3). g. Unscrew nut (12) from threads of piston rod (3). h. Remove piston s pring (13) and 0 - ring (9) from piston (14). i. Remove Lock-0-Seal (15).
b. Ins tall 0 -ring (9) in groove in piston (14); insert piston spring (13) into piston, and slide assembly up on bottom threaded portion of piston rod (3). c. Run nut (12) up threads to spring (13). Tighten nut enough to obtain 0. 040± 0. 005-inch clearance be tween top of piston and bottom of Lock-0- Seal, as shown in the figure. d. Install piston return spring (11) into cylinder (10) portion of body ('1). e. Install piston rod (3) thr ough spring (11). f. Slide compensating sleeve (16) over rod (3). g. Install cover (4) and screw (18). h. Install jamb nut (2) and clevis (1). i. Install filler plug (17), making s ure vent hole is
open.
j. Install setscrew (5).
5-41. DISASSEMBLY OF BRAKE MASTER CYLINDER. (Beginning with 1979 Models.) (See figure 5-9. ) a. Unscr ew clevis (1) and jam nu t (2). b. Remove filler plug (3). c. Unscrew cover (4) and remove, up over piston
(5).
d. Remove piston (5) and s pring (8). e. Remove packing (7) and back- up ring (6) from
pisto':l (5).
5- 42. INSPECTION AND REPAIR OF BRAKE MASTER CYLINDER. (Beginning with 1979 Models.) (See fig ure 5- 9.) Repair is limited to installation of new parts anc cleaning. Use cl ean hydraulic fluid (MIL- H- 5606) as a lubr ica nt duri~ cylinder r eassembly. Replace packings and back- up rings. F iller plug (3) must be vented so pr essure cannot build up duri ng brake opera tion. Remove plug and drilll/16- inch hole, 30° from vertical, if plug is not vented. Refe r to view A- A for hole location.
5-39. INSPECTION AND REPAIR OF BRAKE MASTER CYLINDER. (Thru 1978 Models.) (See figure 5-9.) Repair is limited to installation of new components, cleaning and adjustment, Refer to applicable par a gr aph for adjustment. Use clean hydraulic fluid (MIL H-5606) as a lubricant during reassembly of the cylin der. Inspect Lock- 0-Seal (Parker Seal Co. P/N 800- 001-6), and replace, if damaged. Replace all 0-rings. Filler plug must be vented so pr essure can not build up in the reservoir duri~ brake operation. Remove plug and rill 1/16-inch hole, 30° from verti cal, if plug is not vented.
5-43. REASSEMBLY OF BRAKE MAST ER CYLINDER. a. Ins tall spring (8) into c ylinder body (9). b. Install back- up ring {6) and pa cking (7) in groove of piston (5). c. Install piston (5) in cylinder body (9). d. ln~tall cove r (4) over piston (5) and screw cover into cylinder body (9). e . Install nut (2) and clevis (1). t. Install filler plug (3}, making sure vent hole is open.
5- 40. REASSEMBLY OF BRAKE MASTER CYLINDER. (Thru 1978 Models.) (See figure 5-9.) a. Install Lock-0-Seal (15) at bottom of piston rod (3).
5- 44. INSTALLATION OF BRAKE MASTER CYLIN DER. Rever se procedures in paragraph 5-37 to in stall m<*ster cylinder. Service system after installi tion. Check parking brake operation. Refer to appli cable paragraph for servicing parking brake.
5-32
MODEL 188 & T188 SERIES SERVICE MANUAL
5-45. WHEEL BRAKES. (see figure 5-4 . ) 5-46. DESCRIPTION. A single-disc type brake is used at each main wheel. The disc is affixed to the wheel. The brake assembly floats laterally on anchor bolts which extend through a stationary torque pla~e, held by the axle bolts. 5- 47. REMOVAL OF WHEEL BRAKE. a. Disconnect and drain brake hose, and protect
hose and fitting from dirt.
b. Remove back plate. c. Pull brake assembly out of torque plate tore
move.
NOTE
.
To remove the torque plate, the wheel and axle must be removed. The brake disc is removed as the wheel is disassembled.
5-48. DISASSEMBLY OF WHEEL BRAKE. CompO nents of the wheel brake are illustrated in figure 5-4, which may be used as a guide during disassembly of the wheel. Use of compressed air applied to the brake line fitting is permissible when removing pistons from the brake cylinders. 5-49. lliSPECTION AND CLEAl't"'NG OF WHEEL
BRAKES.
a. Clean all parts except brake linings and 0-rings in dry cleaning solvent and dry thoroughly. . b. Install all new O.:rfngs. b-ring reuse is neces sary, wipe with a clean cloth saturated in hydraulic fluid, and inspect for damage.
··u
NorE Thorough cleaning is important. Dirt and
chips are the greatest single cause of mal
function in the hydraulic brake system.
c. Check brake linings for deterioration and maxi mum permissible wear. Refer to applicable .para- · graph for maximum wear limit. d. Inspect br ake cylinder bore for scoring. A scored scored cylinder will leak or cause rapid 0-rhJg wear. A scored brake cylinder should be replaced. e. If the anchor bolts are nicked or gouged, they should be sanded smooth to prevent binding. They could bind with the pressure plate or torque plate. When new anchor bolts are to be installed, press out the old bolts and inst allanew bolts with a soft mallet . f. Inspect wheel brake discs for a minimum allow able thickness of 0. 340-inch on the 164-ISA disc (8. 00x6) wheel, 0, 287 -inch on the 164-30 disc (7. SOx 10) wheel, 0.163-inch' on the 164-31 disc (7. 50xl0) wheel , and 0. 340-i.nch on the 164-27A disc (8. 00x8) wheel. 5- 50. REASSEMBLY OF WHEEL BRAKES, Lubri cate parts with the type of hydraulic fluid used in the system and assemble components with care to pre vent damage to 0-rings. Use !lgure 5- 4 as a guide d~ing assembly o! the wheel brake.
5-51. INSTALLATION OF WHEEL BRAKE. If torque plate was removed, install as wheel and brake are in stalled in accordance with paragraph 5-l 0. If brake disc was removed, install as the wheel is assembled in accordance with paragraph 5-14. a. Place brake assembly in position, sliding anchor bolts into torque plate. b. Install back plate. c. Fill and bleed br ake system. 5-52. CHECKING BRAKE LININGS. Brake linings should be replaced whe n they are worn to a minimum thickness of 3/ 32-inch. Visually compare a 3/ 32-inch drill bit, held adjacent to each lining to measur e thick ness of the lining. 5-53. INSTALLATION OF BRAKE LININGS. a. Remove bolts, washers and back plates. b. Pull brake cylinder out of torque plate and slide
pressure plate off anchor bolts.
c. P lace back plate on a table with lining side down flat . Center a 9/64- inch (or slightly smaller) punch in the rolled r ivet, and hit the punch crisply with a hammer. Punch out all rivets securing the linings to the back plates and pressure plate in the same manner.
I
NOTE A rivet setting kit, Part No. 199-00100, is available irom the Cessna Supply Division. This kit consists o! an anvil and punch.
d. Clamp the flat sides of the anvil in a vise. e. Align new lining on back pla te and place a brake rivet in one hole with rivet head in lining. Place rivet head against the anvil. f. Center rivet setting punch on lips of the rivet. While holding back plate down firmly against lining, hit punch with a hammer to set the rivet. Repeat blows on the punch until lining is firmly against the back plate. g. Realign linings on back plate and install remain ing rivets. h. Install a new lining on pr essure.plate in the same roaMer. l. Position pressure plate on anchor bolts and in stall brake cylinder, sliding anchor bolts into the torque plate. j. Install back plate with bolts and washers. Torque bolts to value specified on illustration (See Figure 5-4~ Bolts hive self-locking threads. 5- 54. BLEEDING OF BRAKE SYSTEM. Standard bleeding , with a clean hydraulic pressuresource con nected to the wheel cylinder beeder fitting, is recom mended. a. Remove master cylinder filler plug and screw a flexible hose with a s uitable fitting into the filler hole. Immer se the fre e. end of the hose in a can con taining enough hydraulic fluid to cover the end of the hose. NOTE A capped bleeder valve is provided in the wheel cylinder. Revision 1
5-33
MODEL 188 & T188 SERIES SERVICE MANUAL
1
3 4
17
5 6 7
16
15 --rr---_.1}.....,.,
9
14~~~13
3 4
12 NOTE
Filler plug (17) must be vented so pressure cannot build up in the reservoir during brake operation. Remove plug and drill 1/ 16" hole, 30° from vertical, if plug is not vented. 0. 040:0. 005-nlCH
DO NOT DAMAGE LOCK-0-SEAL
3 16
15
THRU 1978 MODELS
ASSEMBLY OF PISTON
7. Body 8. Reservoir 9. 0-Ring 10. Cylinder 11. Piston Return Spring 12. Nut
Clevis 2. Jamb Nut 3. Pis ton Rod 4. Cover 5. Setscrew 6. Cover Boss
1.
F igure 5- 9.
5-34
Brake Master Cylinder (Sheet 1 of 2)
13. 14. 15. 16. 17. 18.
Piston Spring Piston Lock-0-Seal Compensating Sleeve Filler Plug Screw
MODEL 188 & T188 SERIES SERVICE MANUAL
--, I
A®__ A
~2 3
1
4
9
5
1. 2. 3. 4. 5. 6. 7. 8. 9.
Clevis Nut Fille r Plug Cover Piston Back- up Ring Packing Spnng Cylinder Body
BEGINNING WITH 1979 MODELS
Figure 5-9.
Br ake Master Cylinder (Sheet 2 of 2) 5- 35
MODEL 188 & T188 SERIES SERVICE MANUAL
b. Connect a clean hydraulic pressure source such as a hydraulic hand pump to the bleeder valve on the lower end of the wheel cylinder. NOTE Ensure that the Cree end of the bose from the master cylinder remains immersed during the entire bleeding process. c. As fluid is pumped into the system, observe the immersed end of the hose at the master cylinder !or evidence of air bubbles being forced !rom the brake system. When bubbling has ceased, remove the bleeder source !rom the brake wheel cylinder, tight en the bleeder valve and reinstall cap over the valve. d. Remove hose !rom master cylinder and replace filler plug. 5-55 . PARKING BRAKE SYSTEM. (See figure 5-10.) The parking brake system consists of a control knob on the instrument panel, which operates a double con trol, one control routing to each master cylinder. At the master cylinders, the control operates locking plates which lock th£> master cylinder piston rods down as tot! pr essure is applied to the top of the rud der pedals, tr:lpping pressure in the system. To re lease the parki~ brake, depress the pedals after ma king sure the parking brake knob is full IN. Beginning with 1968 Models, a "T" handle parking br ake system, with the control mounted below the instrument panel, is used, and is illustrated in figure 5-10, sheet 2. This type of system uses a handle and ratchet mecha nism, connected by a cable to linkage at each master cylinder. Pulling out on the handie depresses both master cylinder piston rods, and the ratchet locks the handle in this position until the handle is turned and released. This system allows the brakes to be set or released without the necessity of first depress ing the rudder pedals.
SHOP NOTES:
5-36
5- 56. REMOVAL OF PARKING BRAKE SYSTEM COMPONENTS. (See figure 5-10.) Components of the knob-operated parking brake system are illustra ted in the figure on sheet 1. This illustration may be used as a guide for component removal. After discon necting controls at the master cylinders, and removing clamps along the control routing, the control may be removed from the instrument panel by loosening the locknut and unscrewing the knob and face plate, then pus~ng the _contr.o.l forward, through the panel. Com ponents of the cable- operated system are illustrated on sheet 2, which may be used as a guide during re moval.
5- 57. INSTALLATION OF PARKING BRAKE. Re verse the procedures outlined in the preceding para graph to install the parking brakes. Refer to the fol lowing paragraph for rigging the knob-operated sys tem. On the cable- oper ated system, no adjustment is provided. Replacement of worn or defective compo nents will restore the system to its corr ect operation. 5- 58. PAR.KIN} BRAKE SYST EM RIGGING. a. Check that end of each control housing extends through upper clamp 0.10-inch, and that each support assembly is clamped around master cylinder 0.15 inch from top of cylinder as illustrated in figure 5-l 0. b. With parking brake control full in, adjust both lower stops so that lower spr ings will return control to full In position when it is pulled out then released. c. With parking brake control full in, adjust both upper stops so that locking plates lie flat against top of master cylinder. d. Test- operate parking br ake system several times to be sure that locking plates cannot, under any circumstances, be actuated as long as the control is full in. Conversely, the locking plates must be actuated when the control knob is pulled out.
MODEL 188 & T188 SERIES SERVICE MANUAL
21
I
SEE FIGURE 5-9 FOR MASTER CYLINDER DETAILS
SEE SHEET 2 FOR CABLEÂ OPERATED SYSTEM
TO
RIGHT .
BRAKE
1. Setscrew
Lower Stop
Lower Spring
Setscrew
So Upper Stop
60 Washer
70 Upper Spring
Bo Upper Clamp
9o Control Wire 10 Control Housing 11. Locknut 120 Clevis 130 Screw 14 Leaf Spring 150 Locking Plate 20 30 4o
o
0
Welded Support Assembly
Master Cylinder Fuselage Structure Brake Line Rudder Return Spring 21. Parking Brake Control 22o Rudder and Brake Pedal
160 170 180 19o 20o
Figure 5-100
Brake System (Sheet 1 of 2) 5-37
MODEL 188 & T188 SERIES SERVICE MANUAL
' SEE SHEET 1 FOR KNOBÂ OPERATED SYSTEM
11
1 SEE FIGURE 5-9 FOR MASTER CYLINDER DETAILS
15 TO RIGHT BRAKE
TO LEFT BRAKE
Detail
A
Control Housing Cable Assembly Master Cylinder Bracket Fuselage Structure Control Handle Parking Brake Control Rudder and Brake Pedal Rudder P edal Bar Brake Une
BEGINNING WlTii 188-01403
F igure 5-1 0. Brake System (Sheet 2 of 2) 5-38
.\
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 6
AILERON CONTROL SYSTEM
Page No. Aerofiche/Manual
TABLE OF CONTENTS
AILERON CONTROL SYSTEM Description . . . . . . Trouble Shooting . . . . Control Stick and Torque Tube Assembly . . . . . . . . . Description . . . . . . . Removal and Installation . Control Stick. . . . . Torque Tube Assembly Repair . . . . . .
BeUcranks . . . . . . . . Removal and Installation Repair . . . . . . . . Ailerons . . . . . . . . . Removal and Installation Repair . . . . . . . . Cables and Pulleys . . . . . Removal and Installation Direct Cables . . . Carry- Thru Cables . Rigging . . . . . . . .
1F7/ 6-1 1F7/ 6-1 1F7/6-l lFS/ 6-2 lFS/ 6-2 lFS/6-2 lFS/6- 2 lFS/ 6-2 1F15/6-9
lFlS/6-9 lFlS/ 6-9 1F15/ 6-9 1Fl5/ 6-9 lFlS/ 6-9 1Fl5/ 6-9 1Fl6/ 6-10 1F16/ 6-10 1Fl6/ 6-l0 1F16/ 6-10 1F16/ 6-1 0
.•ri'
6-1. AILERON CONTROL SYSTEM.
The control stick and torque tube assembly trans forms lateral movement of the stick into pulling motion on the cables. Travel extremes are set by adjustable stop bolts located at the wing bellcranks.
6-2. DESCRIPTION. The aileron control system consists of push-pull rods, bellcranks, cables, pul leys and a control stick and torque tube assembly.
6-3. TROUBLE SHOOTING. NOTE Due to remedy procedures in the following trouble shooting chart it may be necessary to re-rig system, refer to para gr aph 6-16. TROUBLE LOST MOTION IN CONTROL STICK.
PROBABLE CAUSE
REMEDY
Loose control cables.
Adjust cables to proper tension.
Broken pulley or bracket, cable off pulley or worn rod end bearings.
Replace worn or broken parts, install cables correctly .
Sprung bellcrank.
Replace bellcrank.
Bearing blocks loose or defective bearings.
Secure bea.r ing blocks. Replace defective parts.
6-1
MODEL 188 & T188 SERIES SERVICE MANUAL 6- 3. TROUBLE SHOOTING (Cont). TROUBLE RESISTANCE TO CONTROL STICK MOVEMENT.
CONTROL STICK NOT CENTERED WITII AILERONS IN NEUTRAL (DROOPED) POSITION.
INCORRECT All..ERON TRAVEL.
PROBABLE CAUSE Cables too tight.
Adjust cables to proper tension.
Pulleys binding or cable off.
Replace defective pulleys. Install cables correctly.
Bellcranks distorted or damaged.
Replace bellcranks.
Defective bearings in torque tube assembly.
Replace defective parts.
Clevis bolts in system too tight.
Loosen, then tighten properly.
Aileron rudder interconnect springs improperly installed or damaged.
Install springs properly. Replace damaged springs.
Improper adjustment of cabl es.
Adjust in accordance with par agraph 6- 16.
Improper adjustment of aileron push pull rods.
Adjust pusb-pull rods to obt.;tin proper alignment.
Push pull rods not adjusted properly.
Adjust in accordance with paragraph 6- 16.
Incorrect adjustment of travel stop bolts.
Adjust in accordance with paragraph 6- 16.
6- 4. CONTROL STICK AND TORQUE TUBE ASSEM BLY . 6-5. DESCRIPTION. The control stick serves a dual purpose. When moved fore-and- aft the stick pivots in a br acket at the aft end of the t~rque tube assembly providing elevator control. When moved laterally, the stick rotates the torque tube assembly providing aileron control. The standard stick con figuration is shown in figure 6- 2 (sheet 1). The electric stick configuration is shown in figure 6- 2 (sheet 2). 6- 6. REMOVAL AND INSTALLATION. a. CONTROL STICK. 1. Remove fuselage access panels below left and right doors. . 2. Remove safety wire and relieve elevator cable tension at turnbuckles (index 17 and 20, figure 8-1). 3. Disconnect turnbuckle (index 17. figure 8- 1) at lower end of control stick. 4. (See figure 6- 2.) Remove pivot bolt se curing control stick (5) to torque tube assembly (18) . 5. Lift control stick out of aircraft using care
6-2
REMEDY
not to drop bushing (9). 6. Reverse the preceding steps for reinstalla tion. Rig elevator control system in accor dance with paragraph 6-16, safety turnbuckles and reinstall all items removed for access. b. TORQUE TUBE ASSEMBLY. 1. Complete steps 1, 2 and 3 of subparagraph
"a." 2. (See figure 8- l. ) Remove pully (19) and pull cable (18) fr ee of tor que tube (14).
3. (See figure 6-l.) Remove safety wtre and relieve cable tension at turnbuckles (3, 5 and 8). 4. On aircraft equipped with electr ical control stick, disconnect control s tick cable from socket (23) located at aft end of LH kick plate. (Refe r to figure 6- 2.) 5. (See figure 6- 2.) Remove pivot bolt securing control (5) to torque tube assembly (18). 6. Lift control stick out of aircraft using care not to drop bushing (9). 7. Reverse the preceding steps for reinstalla tion. Rig elevator control system in accordance with paragraph 6-16, safety turnbuckles and reinstall items removed for access.
MODEL 188 & T188 SERIES SERVICE MANUAL
THRU AIRCRAFT SERIAL 188- 0229
AIRCRAFT SERIAL 188-0230 THRU 18800707
BEX:iiNNING WITH AIRCRAFT SERIAL 18800708
THRU AIRCRAFT SERIAL 18801348
SEE FIGURE 6-2-- - ,
2 SEE FIGURE 6-3
6
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Cotter Pin Cable (Right Direct) Turnbuckle (Right Direct Cable) Pulley (Right Direct Cable) Turnbuckle (Carry- Thru Cable) Cable (Carry-Thru) Cable (Left Direct) Turnbuckle (Left Direct Cable) Cable Guards Pulley (Left Direct Cable) Washer Bushing Pulley (Carry-Thru Cable) Bracket Bolt Bearing Bushing Pivot Bolt
Bellcrank Bolt Push- Pull Tube Primary Travel Stop 23. Brass Washer 24. Castellated Nut 19. 20. 21. 22.
Detail
8
[CAUTION\ MAINTAIN SPECIFIED CONTROL CABLE TENSION CABLE TENSION:
30 =: 2 LBS. TiiRU AmCRAFT SERIAL 18802745,
35 + 5 LBS, BEX:iiNNING WITH AmCRAFT SERIAL
SERIAL 18802746
(AT AVERAGE TEMPERATURE FOR THE AREA)
Figure 6-1. Aileron Control System (Sheet 1 of 3) 6-3
MODEL 188 8t T188 SERIES SERVICE MANUAL
6
14
1
THRU AIRCRAFT SERIAL 18800707
BEGINNING WITH AIRCRAFT SERIAL 18800708 Detail C
0
) ,·
3
0
y ~
.23/ e
Detail I
~
Install as requtred between bellcrank (19) and wing channel to shim out excess play.
***A CASTELLATED NUT WITH PIN BEGINNING WITH AIRCRAFT SERIALS 18803158 OR SERIALS 188-0001 THRU 18803157 WHEN MODIFIED IN ACCOR DANCE WITH SK188-68.
NOTE The access plate below the bellcrank on the left wing supports the pitot mast. When re moving the bellcrank, refer to Section 15 for pitot mast removal procedure. **Safety wire bolt heads to p1lley bracket.
Figure 6-1. Aileron Control System (Sheet 2 of 3)
6-4
MODEL 188 & T188 SERIES SERVICE MANUAL
4
Detatl E
WHEN MODIFIED IN ACCORDANCE WITH SK188- 2 5
5
Detail
E BEGINNING WITH AIRCRAIT SERIALS 18801349 OR SERIALS 18800708 THRU 18801348WHEN MODIFIED IN ACCORDANCE WITH SK188- 29
Figure 6- 1. Aileron Contro l System (Sheet 3 of 3)
6-5
MODEL 188 & T188 SERIES SERVICE MANUAL
3
2 AIRCRAFT SERIAL 18800767 THRU 18801374
2
3
1. 2. 3. 4. 5. 6. 7, 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
20. 21.
22. 23. 24. 25.
THRU AIRCRAFT SERIAL 18800766
Fuse lage Structure Spring Cont rol Lock Grip (Standar d) Control Stick Spacer Contact Tab (Travel Stop) Needle Bearing Bushing Housing Neoprene Washer Aft Bearing Secondary UP Elevator Travel Stop (Stationary) Secondary Aileron Travel Stop Forwar d Bearing Aileron Control Bellcr ank Spring Attach Tab Tor que T ube Assem bly Secondary DOWN Elevator Travel Stop (Adj ustable) Bob Weight Mounti ng Plate Grip (Electr ical) Sta- Str ap Wire Bundle Electrical Socket
5
* BEGINNING WITH AIR足 CRAFT SERIAL 18800573 AffiCRAFT Nar MOD足 IFIED BY SK188- 5 Detail
A 11
16
12 NOTE Adjust bolt (14) fo r . 06 " clearance between head of bolt and bellcrank (16) befor e tight足 ening nut when bellcrank stops in the wing have been contacted.
9
Figure 6-2.
6-6
14
The maximum friction force measured at top of control stick with cables attach足 ed and rigged is 2 lbs.
Control Stick Installation (Standard) (Sheet 1 of 2)
MODEL 188 & T188 SERIES SERVICE MANUAL
BEGINNING WITH AIRCRAFT SERIAL 18801375 AND ALL AIRCRAFT EQUIPPED WITH NTGHT LI:iHTING PACKAGE
20
12
F igure 6- 2.
Contr ol Stick Ins tallation (Electric) (Sheet 2 of 2) 6- 7
MODEL 188 & T188 SERIES SERVICE MANUAL
A
7
1. 2. 3. 4. 5. 6.
Detail
A
10 12
11
BEGINNING WITH 18803853, 18803857 AND ON AND WHEN MODIFIED PER CESSNA SING LE-ENGINE SERVICE INFORMATION LETTER SESl-32 , AGSl - 4
Figure 6-3.
6-8
Aileron Installation
7. 8. 9. 10. 11. 12.
Aileron Hinge Support Leading Edge Skin Push- Pull Tube Balance Weight Bolt Nutplate P lug Button Access Plat e Cotter Pin Nut Washer
MODEL 188 8t T188 SERIES SERVICE MANUAL
AVAILABLE FROM CESSNA SERVICE PARTS CENTER (TOOL NO. SE 716) Figure 6-4. Inclinometer for Measuring Control Surface Travel 6-7. REPAIR. Worn, damaged or defective torque tube, bearings, bushings or attaching hardware should be replaced. Refer to Section 2 for lubrica tion requirements .
g. Reverse the preceding steps for reinstallation.
Rig system in accordance with paragraph 6- 16,
safety turnbuckles and r einstall all items removed
for a c cess.
6- 8. AILERON BELLCRANKS.
6-10. REPAIR. Repair consists of replacement of defective bushing or bearings. If needle bearings are dirty or in need of lubrication, refer to Section 2.
6-9. REMOVAL AND INSTALLATION. (See figure 6-1. ) a. Remove access plate adjacent to bellcrank (19). b. Remove fuselage access panels from below left and right doors. c. remove safety wire and relieve cable tension at turnbuckles (3, 5 and 8). d. Disconnect cables at bellcrank (19). e. Disconnect push-pull tube (21) at bellcrank. f. Remove pivot bolt (18) securing bellcrank to wing structure and remove bellcrank through access opening, using care not to drop bushing (17). NOTE Brass washers (23) may be used as shims
between lower end of bellcrank and wing
channel. Retain these shims. Tape open
ends of bellcrank to prevent dust and dirt
from entering bellcrank needle bearings (16).
6-11. AILERONS. 6-12. REMOVAL AND INSTALLATION. (See figure 6- 3. ) a. Disconnect push-pull tube (4) at aileron. b. Thru 18803851 and including 18803855 and 18803856, also aircraft not modified per Cessna Single - Engine Service Information Letter SE81 32, AG81- 4, remove access plates (8) and remove bolts (6). c. Beginning with 18803852 thru 18803854 and 18803857 and on and when modified per Cessna Single- Engine Service Information Letter SE81-32, · AG81-4, remove access plates (8~ cotter pins (10), nuts (11), washer s (12), and bolts (6) . c. Carefully remove aileron from wing. d. Reverse the preceding steps for reinstallation. If push- pull tube adjustment was not disturbed, re rigging of system should not be necessary. Rig system, if necessary, in accordance with paragraph 6-16. 6-13. REPAIR. Aileron repair may be accomplished as outlined in Section 17.
6- 9
MODEL 188 & T188 SERIES SERVICE MANUAL
6-14. CABLES AND PULLEYS. 6-15. REMOVAL AND INSTALLATION. (See
figure 6- 1. )
a. DIRECT CABLES. 1. Remove fuselage access panels as necessary to expose Detail A. 2. Remove access plates as necessary to expose Details B, C and D on both wings. 3. Remove safety wire and relieve cable tension at turnbuckles (3 and 8). 4. DiscoiUlect cables (2 and 7) at torque tube
bellcrank.
5. DiscoiUlect cables from the aft side of bell
cranks (19).
6. Remove cable guards and pulleys as neces sary to work cables free of aircraft.
e. Align hole in lower wing skin, holes in bell cranks (19) and threaded hole in block at upper wing skin and install rigging pins through holes. NOTE AN4 bolts, 5-1/4 inches in length may be used as rigging pins. Grind a slight taper at the threaded end of the bolt to facilitate
alignment. NOTE Thru aircraft serial 18801967, it may be necessary to "back out" the aileron bell crank "down" stop bolts ln order to insert the rigging pins. BegiiUling with serial 18801968 the rigging pin holes have been repositioned to facilitate pin insertion.
NOTE To ease routing of cables, a length of wire may be attached to the end of the cable being withdrawn from the aircraft. Leave wire in place, routed through structure; then attach the cable being installed and use wire to pull cable into position. 7. Reverse the preceding steps for reinstalla tion. 8. After cables are routed in position, install pulleys and cable guards. Ensure cables are posi tioned in pulley grooves before installing guards. 9. Re-rig system in accordance with paragraph 6-16, safety turnbuckles and reinstall all items removed for access. b. CARRY-THRU CABLE. 1. Complete steps 1 and 2 of subparagraph "a. " 2. Remove safety wire and relieve cable tension at turnbuckle (5) . 3. DiscoMect cable from forward side of bell cranks (19 ). 4. Remove fairleads (1). 5. Complete steps 6, 7, 8 and 9 of subparagraph "a...
6-16. RIGGING. (See figure 6- 1.) a. Lock control stick in neutral with the control lock, if installed. If not installed, center the con trol stick laterally and clamp in this position. b. Remove access plate and d.iscoMect push-pull tube (21) at aileron. c. -Remove fuselage access panels as necessary to expose Detail A. d. Remove sa! ety wire and relieve cable tension at turnbuckles (3, 5 and 8).
6-10
f. Adjust turnbuckles evenly to obtain tension speci fied in figure 6-1. · g. Loo8en push-pull tube (21) jam nut, manually hold aileron streamlined with flap trailing edge (flaps full UP), mount an inclinometer on aileron and set to 0°. h. With inclinometer set at 0°, lower aileron to degree of "droop" position ~illed in figure 1-1, adjust push-pull tube (21), attach tube and tighten jam nut. 1. Complete steps "g" and "h" on opposite aileron and remove rigging pi.n s. NOTE An inclinometer for measuring control sur face travel is available from the Cessna Service Parts Center. See figure 6-4. j. Remove control lock or clamp from control stick. k. Adjust primary travel stops (22) in each wing to degree of travel specified in figure 1-1. Travel is measured from "droop" position. 1. Adjust secondary travel stops (index 14, figure 6-2) to . 06 inch clearance when primary stops are contacted. m. Safety all turnbuckles and reinstall all items removed for access .
Be sure ailerons move in the correct direc tion when operated by the control stick.
MODE L 188 & T188 SERIES SERVICE MANUAL SECTION 7
WING FLAP CONTROL SYSTEM
TABLE OF CONTENTS
WWG FLAP CONTROL SYSTEM . Description . . . . . Operational Check . . . . . Trouble Shooting . . . . . . Flap Lever Assembly . . . . Removal and Installation Repair. . . Flap Bellcranks . . . . . .
Page No. Aerofiche/ Manual
1F21/ 7-1 1F21/ 7-l 1F21/ 7-1 1F22/ 7-2 1F22/ 7-2 1F22/ 7- 2 1F22/7-2 1F22/ 7-2
7- 1. WING FLAP CONTROL SYSTEM . (See
figure 7- 1. )
7-2 . DESCRIPTION. The wing flap control system is comprised of push-pull rods, bellcranks, pulleys and cables, all of which link the flaps to the manu ally-operated lever mounted on the left side of the cockpit. A latch and ratchet mechanism locks the naps in various degrees of extension. 7-3. OPERATIONAL CHECK. a. Operate flaps through their full range of travel, observing for uneven or jumpy motion, binding or lost motion in system. Ensure flaps are moving through their full range of travel. b. Retract flaps and check !or full up position. Mount an inclinometer on one flap and set to 0 ° .
Removal a nd Installation Repair . . . . . . . . . Flaps . . . . . . . . . . . Removal and Installation Repair . . . . . . . . Cables and Pulleys . . . . . Removal and Installation Higging . . . . . . . . . .
1F22/ 7- 2 1G3/7- 7 1G3/7-7 1G3/ 7-7 1G3/7- 7 1G3/7- 7 1G3/7-7 1G3/7-7
NOTE An inclinometer for measur ing control surface travel Is availabl.P. from the Cessna Supply Division. See figur e 6- 4. c. Extend flaps and check for full down position
witn inclinomet er. See figure 1- 1 for flap travel. d. Remove bellcrank access plates and attempt to r ock bellcr ank to check for bearing play on both wings. e. Inspect flap rollers and tr acks for evidence of excessive wear and defective parts.
Revision 1
7- 1
I
MODEL 188 & T188 SERIES SERVICE MANUAL 7-4. TROUBLE SHOOTING. NOTE Due to remedy procedures in the following trouble shooting chart it may be necessary to re-rig system, refer to para足 graph 7-16 . TROUBLE
REMEDY
PROBABLE CAUSE
BOTH FLAPS FAIL TO EXTEND. Disconnected or broken direct cable.
Connect or replace cable.
ONE FLAP F All..S TO LOWER.
Disconnected or broken direct cable to malfunctioning flap.
Connect or replace cable.
BOTH FLAPS FAIL TO RETRACT.
Disconnected or broken retract cable.
Connect or replace cable.
BINDING IN SYSTEM AS FLAPS ARE RAISED AND LOWERED.
Cables not riding on pulleys.
Route cabl es correctly over pulleys.
Bind in bellcrank.
Lubricate bearings or replace bellcrank.
Broken or binding pulleys.
Replace defective pulleys.
Frayed cable.
Replace defe ctive cable.
Flaps binding on tracks.
Replace defective parts.
Flap lever binding.
Replace defective parts.
INCORRECT FLAP TRAVEL.
Incorrect rigging.
Rig system in accordance with paragraph 7-16.
RELEASE BUTTON STICKS.
Release mechanism needs lubri9ation.
Lubricate in accordance with Section 2.
7-5.
FLAP LEVER ASSEMBLY.
7- 6. REMOVAL AND INSTALLATION. (See figure 7- 1. ) a. Remove access panel from below left door. b. Remove safety wire and relieve cable tension at turnbuckle ( 10, 24 , 26 and 28). c. Disconnect cables (22 and 25) at lever assembly (18).
d. Remove pivot bolt and spacer (14 ), then care足 fully work lever out of fuselage structure. e. Reverse the preceding steps for reinstallation. Rig system l11 accordance with paragraph 7-16, safety turnbuckles and remsta.U all items removed for ac足 cess.
7-2
7-7. REPAIR. Repair consists of replacement of defective bushings, spacers, ratchet mechanism and associated hardware. The placar d on the lever should be replaced if it becomes illegible.
7-8. FLAP BELLCRANKS. 7-9. REMOVAL AND INSTALLATION. (See figure 7-1.) a. Remove access plate from lower wing skin ad足 jacent to bellcrank (33). b. Remove access panel from below left door. c. Lower flaps to full down position. d. Remove safety wire and relieve cable tension at turnbuckles (10 and 24 or 26 and 28).
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE All details shown are Cor LEFT wing. RIGHT wing opposite.
...·················· ...
.·· ...·•·
...·..·· .: ·· ......-: ;;.·
...··
...
".t•' __
...···
.··
. ..·- o
·. ··········...
~-··
., ····-.,..·· ..···
Detail
A
SEE FIGURE 7-2 1. Fairlead 2. Cable Guard 3. Pulley (Left Retract Cable) 4. Bracket 5. Bushing 6. Pulley (Left Direct Cable) 7. Left Direct Cable 8. Left Retract Cable 9. Right Retract Cable 10. Turnbuckle (Right Retract Cable) 11. Terminal 12. Ratchet 13. Bushing 14. Spacer 15. Release Knob 16. Latch Rod 17. Latch 18. Lever 19. Stop 20. Pulley (Transition Cable) 21. Spacer 22. Retract Cable 23. Whufletree 24. Turnbuckle (Left Retract Cable) 25. Transition Cable 26. Turnbuckle (Right Direct Cable) 27. Right Direct Cable 28. Turnbuckle (Left Direct Cable) 29. Pivot Bolt 30. Bushing 31. Push- Pull Rod 32. Brass Washer 33. Bellcrank 34. Beanng 35. Flap Assembly
...
*
THRU SERIAL 18800572
3
Detail
f
I ~AUTION \ M..c\INTAIN PROPER CONTROL CABLE TENSION. CABLE TENSION: 30 :: 5 LBS ON DIRECT CABLE, 55 ± 5 LBS ON RETRACT CABLE THRU AIRCRAFT SERIAL 188-0293. 30 .,. 5 - 0 LBS ON ALL CABLES BE GINNING WITH AIRCRAFT SERIAL 188- 0294. (AT AVERAGE TEMPERATURE FOR THE AREA.) SEE FIGURE 1-1 FOR TRAVEL.
Figure 7-1 . Wing Flap Control System (Sheet 1 of 3)
7-3
MODEL 188 & T188 SERIES SERVICE MANUAL
NOfE All details shown are !or LEFT wing . RIGHT wing opposite.
4
Detall8
I
~~8
~r 5
3
6
SERIAL 18800707
** THRU BEGINNING WITH SERIAL 18800708
3
5
8
7
Detail
C
.(
BEGINNING WITH SERIAL 18800573
Figure 7-1. Wing Flap Control System (Sheet 2 of 3)
7-4
MODEL 188 & T188 SERIES SERVICE MANUAL
14
19
20
9
/
Detail
25
0
* * THRU AIRCRAFT SERIAL 188-0293 (0, 10, 20 AND 30 ° FLAP POSITIONS) * * AIRCRAFT SERIAL 188-0294 THRU
28
7
18800832 (0, 10 AND 20 ° FLAP POSITIONS) e BEGINNING WITH AIRCRAFT SERIAL 18800833 (0, 5, 10 AND 20 ° FLAP POSITIONS)
29
/
Detail
E
4
33 ~
~- - -
Figure
:-1.
Wi~
32 • •
e e 35
• •
Install between bellcrank (3 3) and wi ng cha nnel. Install with heads down .
FlJ.p Contr ol System (Sheet 3 of 3)
7- 5
MODEL 188 & T188 SERIES SERVICE MANUAL
netail
D
AIRCRAFT SERIALS 18800573 THRU 18800832 (LOCATED AT WING STA 100. 00) BEGINNING WITH SERIALS 18800833 (LOCATED AT WING STA. 84. 23).
A '~
:~rr 5
Detail
A C
A
INBOARD
6 '~
Detail
B
9~r;r 5
Detail
OUTBOARD
NOTE Bushings (4) , rollers (3) and spacers (9) are first positioned through s lots in flap tracks, then are secured to the !lap roller supports (2) with attaching bolts, washers and nuts. Nylon plug buttons ( 11) prevent wing flap from chafing wing trailing edge. Position spacers (9) and direction of bolts (5) as required to pr ovide adequate !lap clearance at wing r oot, !lap well skin and aileron. Some lat eral movement of flap is inherent due to the width of rollers. Ttus movement should be considered when pos1tioning spacers and direction of bolts.
Figure 7-2. Wing Flap Installation
7-6
C
1. Access Plate 2. Flap Support 3. Roller Assembly 4. Bushing 5. Bolt 6. Push- Pull Rod 7. Flap Bracket 8. Bolt 9. Spacer 10. Plug Button 11. Nylon Plug Button 12. Fence
MODEL 188 & T188 SERIES SERVICE MANUAL
c . Remove safety wire, relieve cable tension and disconnect turnbuckle to cable being removed. d. Remove cable guards, pulleys and fairleads as necessary to work cable free of aircraft.
e.
Disconnect cables (7 and 8) at bellcrank (33). Disconnect push-pull rod (31) at bellcrank (33). g. Remove pivot bolt (29) and carefully work bell
crank out through access opening, using care not to
drop bushing (30).
f.
NOTE NOTE To ease routing of cables, a length of wire may be attached to the end of cable being withdrawn from the aircraft. Leave wire in place, routed through structure; then at tach the cable being installed and use wire to pull cable into position.
Brass washers (32) ·may be used as shims between lower end of bellcrank (33) and wing channel. Retain these shims. Tape open ends of bellcrank to prevent dust and dirt from entering bellcrank needle bearings. h. Reverse the preceding steps for reinstallation. Rig system in accordance with paragraph 7- 16, safety turnbuckles and reinstall all items removed for ac cess .
e.
Reverse the preceding steps for reinstallation. After cables are routed in positicn, install pul leys, fairleads and cable guards. Ensure cables are positioned in pulley grooves before installing guards . g. Re-rig flap system in accordance with paragraph 7- 16, safety turnbuckles and reinstall all items re moved for access. !.
7-10. REPAIR. Repair is limited to rep)acement of needle bearings and bushings. Cracked, bent or excessively worn bellcranks should be replaced.
7-16. RIGGING. (See figure 7-1.) 7-11.
FLAPS. NOTE
7-12. REMOVAL AND INSTALLATION. (See figure 7-2.) a. Lower flaps to full down position. b. Remove access plates ( 1) from top leading edge of flap . c. Disconnect push-pull rod (6) at flap. d. Remove bolt (5) at each aft flap track, pull flap aft and remove bolt at each forward flap track. As the flap is removed from wing, all rollers, bushings and spacers will fall free . Retain these for reinstal lation. e. Reverse the preceding steps for reinstallation. U the push-pull rod (6) adjustment was not disturbed, re-rigging should not be necessary. Rig system, if • necessary, in accordance with paragraph 7-16.
Before completing the following procedure, relieve tension on turnbuckles (10, 24, 26 and 28). DO NOT DISCONNECT TURN BUCKLES. a . Lower flaps to full DOWN position. b . Disconnect push-pull rods (31), adjust rods to 8. 83 ± • 12 inches between centers of rod ends, tighten jam nuts and reinstall. c. (THRU AIRCRAFT SERIAL 188- 0293) Place control lever (18) in the fully retracted position and tighten retract cables (8 and 9) evenly to 55 ± 5 lbs tension. Place control lever (18) in the full down position and tighten direct cables (7 and 27) evenly to 30 ± 5 lbs tension. d. (BEGINNlNG WITH AlRCRAFT SERIAL 188- 0294) Place control lever (18) in the fully retracted position and tighten retract cables (8 and 9) evenly to 30+5- 0 lbs tension. Place control lever (18) in the full down position and tighten direct cables (7 and 27) evenly to 30+5-0 lbs tension. e. Perform an operational checkout as outlined in paragraph 7-3, check that all jam nuts are tight, all turnbuckles are safetied and reinstall all items re moved for access.
7- 13. REPAIR. Repair may be accomplished in accordance with instructions outlined in Section 17. 7-14. CABLES AND PULLEYS. 7-15. REMOVAL AND INSTALLATION. (See figure 7- 1. ) a. Remove access panel from below left door. b. Remove access plates from lower wing as neces sary to expose cable to be removed.
"
7-7/ (7-8 blank)
MODEL 188 & T188 SERIES SERVICE MANUAL
SECTION 8
E LEVATOR CONT ROL SYST EM
Page No. Aer ofiche/Manual
TABLE OF CONTENTS
. . . . . . .
ELEVATOR CONTROL SYSTEM Description . . Trouble Shooting . . . . . Control Stick . . . . . . Elevators . . . . . . . . Removal and Installation Bellcrank . . . . . . . . . 8-1.
1G9/ 8-l 1G9/ 8-l 1G9/ 8-1 lGl0/ 8-2 lGl0/ 8-2 lGl0/ 8-2 lGl0/ 8-2
Removal and Installation Arm Assembly . . . . . . . Removal a nd Installation Cables and Pulley . . . . . Re moval and Installation Rigging . . . . . . . . . .
ELEVATOR CONTROL SYSTEM.
8-2. DESCRIPTION. The elevator system is com pnsed of a control stick, bellcrank, push- pull tube, arm assembly, cables and pulleys. The turnbuckle on the elevator UP cable is attached directly to the control stick below its pivot point. A transition cable attaches to the same point and is routed through the torque tube and around a pulley, where it connects to the elevator DOWN cable. Both cables, at their aft 8-3.
lGl0/ 8-2 lGl0/ 8-2 lGl0/ 8-2 lGl0/ 8-2 lGl0/ 8-2 1Gl4/ 8-6
ends, connect to the bellcrank, fr om which a push pull tube is connected to the elevator arm. The bell crank contacts two primary stops, used for travel adjustment. Secondary stops are located on the tor que tube bracket. One stop is adjustable and the other is stationary. The secondary stops are used to prevent overtravel of the control stick, resulting in excess cable stretch. Two elevator down springs are attached to the bellcr ank to exert return force fr om the elevator UP position.
TROUBLE SHOOTING. NOTE Due to remedy procedures in the following trouble shooting chart it may be necessary to re-rig system, refer to para graph 8-13. TROUBLE
NO RESPONSE TO CONTROL STICK FORE-AND-AFT MOVEMENT .
BINDING OR JUMPY MOTION FELT IN MOVEMENT OF ELE VATOR SYSTEM.
PROBABLE CAUSE
REMEDY
Forward or aft end of push- pull tube disconnected.
Attach push-pull tube correctly.
Cables disconnected.
Attach cables correctly.
Defective bellcrank or bellcrank pivot bearing.
Replace bellcrank.
Cables slack.
Adjust to tension specified in figure 8- 1.
Cables not riding correctly on pulleys.
Route cables cor rectly over pulleys.
Defective ptvot bearmg on control stick.
Replace bearing.
Balance wetght loose.
Secure balance weight.
Defective e le vator hinges.
Replace defective hinges .
Lubricauon needed.
Lubncate in accordance w1th Section 2.
Deiec u ve (Juileys o r cable guards.
Replace defecuve parts and install guards properly. 8-1
MODEL 188 & T188 SER IES SERVICE MANUAL 8-3. TROUBLE SHOOTING (Cont). TROUBLE ELEVATORS FAIL TO ATTAIN PRESCRffiED TRAVEL.
Primary travel stops incorrectly set.
Rig system in accordance with para graph 8-13.
Cables tightened unevenly.
Rig system in accordance with para graph 8-13.
Secondary travel stops interfering.
Rig system in accordance with para graph 8- 13.
8-4. CONTROL STICK. Removal, installation and
repair of control stick may be accomplished as out
lined in Section 6.
8- 5. ELEVATORS. 8-6. REMOVAL AND INSTALLATION. (See
figure 8-2.)
a. Remove scr ews securing stinger, disconnect
tail light wire and remove stinger from aircraft.
b. Disconnect trim tab push-pull tube at tab. NOTE lf the trim wheel and actuator settings are not disturbed, the trim systetti will not
need to be re- rigged. c. Remove bolts {7) attaching elevator torque tubes
{2 ) to arm (3).
d. Remove bolts (5) and remove elevators, working
the elevator trim push-pull tube out of elevator.
e . Reverse the preceding steps for reinstallation. Rig elevator and trim system, if necessary, in accor dance with paragraphs 8- 13 and 9-12. 8-7.
REMEDY
PROBABLE CAUSE
8-9. ARM ASSEMBLY. 8-10. REMOVAL AND I~TALLATION. (See
figure 8-2.)
a. Remove screws securing stinger, disconnect
tail light wire and remove stinger from aircraft.
b. Remove bolt (11) securing push-pull tube (10) to arm (3). · c . Remove bolts {7) securing elevator torque tubes (2) to arm (3). d. Remove pivot bolt (8) and slide arm assembly
from between elevator torque tubes (2).
e. Reverse the preceding steps for reinstallation. Rig system, if necessary, in accordance with para graph 8-13. 8-11. CABLES AND PULLEY. 8-12. REMOVAL AND INST ALLATION. (See
figure 8-1.)
a. Remove access panel from below left door and
access plate from below bellcrank on tailcone.
b. Remove safety Wire, relieve cable tension and disconnect turnbuckles (17 and 20). c. Disconnect cables (3 and 5) at bellcrank links {4).
BELLCRANK. NOTE
8-8. REMOVAL AND INSTALLATION. (See figure 8- 1. ) a. Remove access panel from below left door. b. Remove access plate on tailcone below bellcrank {6).
c . Remove sa!ety wire and relieve cable tension at turnbuckles ( 17 and 20). d. Disconnect cables (3 and 5) at bellcrank links {4 ). e. Disconnect down springs (8). f. Disconnect push-pull tube (11) at bellcrank (6). g. Remove pivot bolt ( 12) securing bellcrank to bracket ( 10) and remove bellcrank through access opening. h. Reverse the preceding steps for reinstallation. Rig system in accordance with paragraph 8-13. safety turnbuckles and reinstall all items removed for ac cess.
8-2
To ease routing d cables, a length of wire may be attached to the end of c;able being withdrawn from the aircraft. Leave wire in place, routed through structure; then at tach the cable being installed and use Wire to pull cable into position. d. When removing transition cable {18), disconnect turnbuckle {20), disconnect turnbuckle {17) at lower end of control stick {16) remove cable guard (21) and pulley {19) and remove cable. e . Reverse the preceding steps for reinstallation. Rig system in accordance with paragraph 8-13, safety turnbuckles and reinstall all items removed for access.
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
B
'·<.~~~'>~_...
.
·~
.
··<:·.::::::::::::::--.::·. . ··. _;:..
·-: ..
r\ ·········••··•···•..
\~\,
·. ::>> : 0<- B
A
SEE FIGURE 8-2
\(·:\\_:.·~-.:_ :~· __ -~:::;\~~ ·., •'. ::} <: ;:':~:~: >· ~~ ~~~~:::o!orDown)
\
\~~·-.
SEE FIGURE 6-2
fCAUTION! MAINTAIN PROPER CONTROL CABLE TENSION. CABLE TENSION: 30 ± 10 LBS (AT AVERAGE TE MPER ATURE F OR THE AREA. ) SE E FIGURE 1-1 FOR TRAV EL.
:
.· ,
~~:L~.--··/
.. ·: !: ~:.~:+~evator
Up)
8. Spring 9. Prinnry Travel Stop 10. Bracket 11. Push-Pull Tube 12. Pivot Bolt 13. Bolt 14. Torque Tube 15. Secondary Ad justable Down Travel Stop 16. Control Stick 17 . Turnbuckle (Elevator 18. Cable (Transition) 19. Pulley 20. Turnbuckle (Elevato r 21. Cable Guard
Block
Elevator Up) Down)
Figu r e 8-1. Elevator Control System (Sheet 1 of 2)
8- 3
MODEL 188 & T188 SERIES SERVICE MANUAL
8 7
8
10
5
7
13 Detail
A
3
*
CASTELLATED NUTS WITH CarTER PINS
BEGINNING WITH SERIAL 18800675
Figur e 8- 1. Elevato r Control Sys tem (Sheet 2 of 2)
8-4
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE
The elevator arm assembly, to which the elevators are attached, may be removed without removing the elevators. Remove stinger, disconnect rear push pull tube, remove bolts attaching elevators to arm assembly and remove pivot bolt.
A
Detail
A
5
2 8
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Trim Tab Torque Tube Arm Assembly Hinge Bracket. Bolt Balance Weight Bolt Pivot Bolt Bearing Push- Pull Tube Bolt
dJf':,
/\
10
r
,,
Detail
B
• Pnme ba lance wetght attach screv.·s wtth :\IIL·P -8585 Loctite primer and seal u·~th \IIL -S-22473 Loctite sealer to retat n screu·s
Figu re 8-2. E le\'ator lnstallatton
8- 3
MODEL 188 & T188 SERIES SERVICE MANUAL
ELEVATOR
UP CABLE
---
BELLCRANK
0
NOTE Holes are drilled off center in bellcrank stops to provide elevator travel adjust ments. go• rotation of bellcrank stop provides approximately 1• of elevator travel.
NOTE When adjusting the stops to attain correct travel, make sure bellcrank makes full contact against a flat side and not a corner of the travel stop.
ELEVATOR _ _ / DOWN CABLE
Figure 8-3. Elevator Bellcrank Travel Stop Adjustment
8-13. RIGGING. (See figure 8-1.)
NarE
I
An inclinometer for measuring control sur
face travel is available from the Cessna
Supply Division. Refer to figure 6-4.
a. Remove access panel from below left door. b. Remove access plate from below bellcrank (6). c. Remove safety wire and relieve cable tension at turnbuckles (17 and 20). NOTE The elevator travels referenced in figure 1-1 are relative to the stabilizer. Neutral position .of the elevators is the position where the elevators and stabilizer are streamlined.
8-6
Revision 1
d. With elevators streamlined, mount an inclinom eter on trailing edge and adjust to 0°. e. Check elevator degree of travel as specified in figure 1-1 and adjust primary stops (9) as necessary. f. While holding elevators against primary UP stop, with control stick just clearing stationary secondary stop, adjust turnbuckles (17 and 20) evenly to obtain proper tension. g. Move control stick forward until primary DOWN stop is contacted, then adjust clearance between tab on control stick and secondary DOWN stop (15) to 1/32 to 1/16 inch. h. Safety turnbuckles and reinstall all items re moved for access.
Be sure elevators move in the correct direc tion when operated by the control stick.
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 9 ELEVATOR TRIM TAB CONTROL SYSTEM Page No. Aerofiche/ Manual
TABLE OF CONTENTS ELEVATOR TRIM TAB CONTROL SYSTEM . Description . . . Trouble Shooting • Trim Tab . . . . Removal and Installation Trim Tab Actuator . . . . . Removal and Installation Disassembly . . . . . .
Cleaning, Inspection and Repair . . . . . . . . Rea ssembly . . . . . . Tr im Tab Free- Play Inspection Trim Tab Control Wheel . . Removal and Installation Cables and Pulleys . . . . . Removal and Installation
1G21/9-l 1G21/ 9-l 1G21/ 9- 1 1G22/ 9-2 1G22/ 9- 2 1G22/ 9- 2 1G22/ 9- 2 1G22/ 9- 2
Rigging . . . . • • . . . .
9-1. ELEVATOR TRIM TAB CONTROL SYSTEM. (See figure 9-1. )
1G22/9- 2 lHl/9- 5 lHl/ 9- 5 1H3/ 9-7 1H3/ 9- 7 1H3/ 9- 7 lHJ/ 9-7 1H3/ 9- 7
tion of the trim wheel operates the tab through roller chains, cables, an actuator and a push-pull tube. A position indicator, s e cured to the roller chain, indi cates tab position on a scale. Trim tab travel is ad justed by stop-blocks secured to the control cables.
9-2. DESCRIPTION. The elevator trim tab is lo cated on the right elevator , operated by a control wheel mounted on the left side of the cockpit. Rota 9-3. TROUBLE SHOOTING.
NOTE Due to remedy procedures in the following tr ouble shooting chart, it may be necessary tore-r ig system. Refer to paragraph 9-16. TROUBLE TRIM CONTROL WHEEL MOVES WITH EXCESSIVE RESISTANCE.
PROBABLE CAUSE
REMEDY
Cable tension too high.
Adjust cable tension.
Pulleys binding or rubbing.
Repair or r eplace defective parts.
Cables not in place on
Install cables correctly.
pull~ys.
LOST MOTION BETWEEN CONTROL WHEEL AND TRIM TAB.
Trim tab hinge binding.
Lubrica te or replace hinge.
Defective actuator.
Replace actuator.
Rusty chain.
Replace chain.
Damaged sprocket.
Replace sprocket.
Bent sprocket shaft.
Replace shaft.
Cable tension too low.
Adjust cable tension.
Broken pulley.
Replace pulley.
Ca bles not in place on pulleys.
Install cables correctly.
Wo rn trim tab actuator.
Replace actuator.
Actuator attachment loose.
Tighten.
9-1
MODEL 188 & T188 SERIES SERVICE MANUAL 9- 3. TROUBLE SHOOTING (Cant). TROUBLE
REMEDY
PROBABLE CAUSE
TRIM INDICATOR FAILS TO INDICATE CORRECT TRIM POSITION.
Pointer incorrectly positioned during rigging.
Re- rig system in accordance with paragraph 9-12.
INCORRECT TAB TRAVEL.
Stop-blocks loose or incorrectly adjusted on control cables.
Rig system in accordance with paragraph 9-12.
9-4. TRIM TAB. 9-5. REMOVAL AND INSTALLATION. (See
figure 9-1. )
a. Disconnect push- pull tube (22) at horn assem
bly (21).
NOTE U trim system is not moved and actuator screw is not turned, rigging of system should not be necessary after installation of tab.
b. Drill out rivets securing tr im tab hinge to ele vator and remove trim tab. NOTE After tab has been removed and if hinge
pin is to be r~moved, it is necessary to
spread the cr imped ends of the hinge
before driving out pin. When a pin has
been installed, crimp ends of hinge to
prevent pin from working out.
c. Reverse preceding steps for reinstallation. Rig system, li necessary, in accordance with paragraph 9-16. 9-6.
TRIM TAB ACTUATOR.
9-7. REMOVAL AND INSTALLATION. (See
figure 9- 1. )
a. Remove access plate from left side of tailcone
and from lower stde of nght stabilizer.
b. Remove safety wire and relieve cable tension at turnbuckle (17). c. Disconnect push- pull tube (22) at actuator rod
end (23).
d. Remove chain guard (25) and disengage chain (27) from sprocket (26). e. Remove screws securing clamps (28) and care fully remove actuator (24) through access opening. t. Reverse the preceding steps for reinstallation. Rig system IJl accordance with paragraph 9- 12. safety turnbuckle and reinstall all items removed for access. 9-8. DISASSEMBLY. (See figure 9- 4. ) a. Remove actuator tn accordance wtth paragraph 9-7. 9-2
b. Disassemble actuator assembly (1) as illustrated in Detail A as follows: 1. Remove chain guard (3) if not previously re
moved in step "d" of paragraph 9-7.
2. Using suitable punch and hammer, remove groove pins (8)securing sprocket (5) to screw (9) and remove sprocket from screw. 3. Unscrew threaded rod end ( 1~) and remove
rod end from actuator.
4. Remove groove pins (1 0) securing bearings
(6 and 14) at the housing ends.
5. Lightly tap screw (9) in the opposite direc tion from spr ocket end, remove bearing (14), 0-ring (13) and collar (7). 6. Lightly tap screw {9) toward the sprocket end of housing, remove bearing (6) and collar (7). 7. It is not necessary to remove retaining rings
(11).
9-9. CLEANING, INSPECTION AND REPAIR. (See figure _9 - 4.) a. DO NOT remove bearing (16) from threaded rod end (15) unless replacement of bearing is neces sary. b. Clean all component parts, except bearing (16), by washing in Stoddard solvent or equivalent. Do not clean sealed bearing (16). c. Inspect all component parts for obvious indica tions of damage such as stripped threads, cracks, deep nicks and dents. d. Check bearings (6 and 14), screw (9) and thread ed rod end (15) for excessive wear and scoring. Dimensions of the parts are as follows: BEARlliG (6) INSIDE DIAMETER 0. 373" MIN. INSIDE DIAMETER 0. 374" MAX. BEARING (14) lliSIDE DIAMETER SMALL HOLE SMALL HOLE LARGE HOLE LARGE HOLE THREADED ROD END (15) OUTSIDE DIAMETER (SHANK)
SCREW (9) OUTSIDE DIAMETER
0. 248" MIN. 0. 249" MAX.
0. 373" MIN. 0. 374" MAX.
0. 245" MIN. 0. 246" MAX.
0. 369" MIN. 0. 370" MAX.
)
)
MOD EL 188 & T188 SERIES SERVICE MANUAL
*Stake both ends thro aircraft serial 18800591 . Safety wire through pin beginning with aircraft serial 18800592
14
..~···..··...·... .
.....
; '
t · ..
\('·<:·..... ·.·.. •.·.
..·:.~
~:!.L:. :/
Detail
5
1
Deta1l
A
8
6
1. Shaft 2. Roll Pin 3. Trim Control Wheel 4. Support 5. Position Indicator 6. Forward Cable 7. Roller Chain 8. Nylon Bearing 9. Bracket 10. Spacer 11. Sprocket 12. Bolt 13. Fairlead 14. Clevis 15. Act Cable 16. Bushing 17. Turnbuckle 18. Travel Stop Block 19. Trim Tab 20. Bolt 21. Horn (c~ UTION ! 22. Push- Pull Tube 23. Rod End MAINTAIN PROPER CONTROL 24. Actuator CABLE TENSION. 25. Chain Guard , - - - - - - - - - - - - - - - - . , 26. Sprocket CABLE TENSION: 27. Roller Chain 10 TO 15 LBS (AT AVERAGE TEMPER 28. Clamp ATURE FOR THE AREA. ) 29. Cable Guard 30. Bracket SEE FIGURE l-1 FOR TRAVEL. Figure 9-1. Elevator Trim Control System (Sheet 1 of 2) 9-3
MODEL 188 & T188 SERIES SERVICE MANUAL
31. 32. 33. 34.
Castellated Nut Cotter Pin Washer Self- Locking Nut
e THRU SERIAL 18800674
19 _ _ __
*BEGINNING WITH SERIAL 18800675 *BEGINNING WITH SERIAL 18800931
*
20
27
28 Detail
C
Figure 9-1. Elevator Trim Control System (Sheet 2 of 2) 9-4
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Relative linear movement between internal threaded screw (9) and bearing (14) should be 0. 004 to 0. 010 inch at room temperature. e. Examine threaded rod end (15) and screw (9) for damaged threads or dirt particles that may impair smooth operation. f. Check sprocket (5) for broken. chipped and/or worn teeth. g. Check bearing (16) for smoothness of operation. h. DO NOT attempt to repair damaged or worn parts of the actuator assembly. Discard all defective items and install new parts during reassembly. 9-10. REASSEMBLY. (See figure 9-4.) a. Always discard the folloWing items and install new parts during reassembly. 1. Groove Pins (8 and 10) 2. 0-Ring (13) 3. Nuts (2}. b. During reassembly, lubricate collars (7), screw (9) and threaded rod end (15) in accordance with Section 2. c. Slip collar (7) and bearing (6) on screw (9). d. Press sprocket (5) into the end of screw (9), align groove pin holes and install new groove pin (8). e. Insert screw (9), with assembled parts, into housing (12) until bearing (6) is flush with the end of housing. NOTE When inserting screw (9) into housing (12), locate the sprocket (5) at the end of housing which is farther away from the groove for retaining ring (11). • New bearings (6 and 14) are not pre-drilled and must be drilled on assembly. The groove pins (10) are 1/16 inch in diameter and require a 1/16 (0. 0625) inch drilL ~HINGE
"" r
f. With bearing (6) flush with end of housing (12),
carefully drill bearing so the drill will emerge
from the hole on the opposite side of housing (12).
DO NOT ENLARGE HOLES IN HOUSING.
g . Press new groov pins (10) into the pin holes. h. Insert collar (7), new 0-ring (13) and bearing (14) into opposite end of housing (12). i. Complete steps "f" and "g" for bearing (14). j. If a new bearing (16) is required, a new bearing may be pressed into the boss. Be sure force bears against the outer race of bearing. k. Screw the threaded rod end (15) into screw (9) . 1. Install retaining rings ( 11), if they were re
moved.
m. Test actuator assembly by rotating sprocket (5) with fingers while holding threaded rod end ( 15). The threaded rod end should travel in and out smooth· ly, with no indication of binding. n. Reinstall actuator assembly in accordance with paragraph 9-7.
9-11. TRIM TAB FREE- PLAY INSPECTION. a. Place elevator and trim tab in neutral position and secure from movement. b. Determine maximum amount of allowable free play using formula shown in figure 9-2. c. Using moderate hand pressure ( up and down),
measure free-play at trailing edge of trim tab.
d. U trim tab free-play is less than maximum allow able, the system is within prescribed limits. e. If trim tab free-play is more than maximum allowable, check the following items for looseness whtle moving trim tab up and down. 1. Check push-pull tube to trim tab horn assem bly attachment for looseness. 2. Check push-pull tube to actuator assembly threaded rod end attachment for looseness. 3. Check actuator assembly threaded rod end for looseness in the actuator assembly. f. If looseness is apparent while checking steps e-1 and e-2, repair by installing new parts. g. If looseness is apparent while checking step e-3, refer to paragraph 9- 6 through 9-10.
HINGE POINT
POINT CHORD LENGTH
0
7
r
mAILING EDGE
B Detail ~ FREE -PLA Y UP
e -
*
NEUTRAL POSITION FREE-PLAY DOWN TOTAL FREE-PLAY
A
1. Measure chord length at extreme inboard end of trim tab as shown in detail A. 2. :\ltulitiply chord length by 0. 025 to obtain maximum allowable free-play. 3. ~Ieasure free-play at same point on trim tab .that chord length was measured. 4. Total free-play must not exceed maximum allow able. Refer to detail B.
Figure 9-2. Trim Tab Free - Play Inspechon 9-5
MODEL 188 & T188 SERIES SERVICE MANUAL
1. Position stop block (2) against turnbuckle and secure to cable B. 2. Position stop block (4) against clevis and secure to cable A. 3. With elevators neutral, set tnm tab to neutral (streamlined).
4. Place inclinometer on trim tab and lower to degree specified in figure 1- 1. 5. Position stop block (1) against stop block (2) and secure to cable A.
6. Raise tab to degree specified in figure 1- 1, then position stop block (3) against stop block (4) and secure to cable B.
!WARNING. Be sure when pointer indicates NOSE OOWN, that trim tab is in UP position and with NOSE UP indication, trim tab is in OOWN position.
Figur e 9-3. Elevator Trim Tab Stop Adjustment
A
Detail
A
8 9
Figure 9-4. Elevator Trim Tab Actuator Assembly
9- 6
1. Actuator Assembly 2. Nut 3. Chain Guard 4. Screw 5. Sprocket 6. Bearing 7. Collar 8. Groove Pin 9. Screw 10. Groove Pin 11. Re taining Ring 12. Housing 13. o-Ring 14. Bearing 15. Threaded Rod End 16. Beartng
-
MODEL 188 & T188 SER IES SERVICE MANUAL
9-12.
TRIM TAB CONTROL WHEEL.
9-13 . REMOVAL AND INSTALLATION. (See
figure 9- 1. )
a. Remove access plate from left side of tailcone. b. Remove access panel from below left door. c. Remove safety wire and relieve cable tension at turnbuckle (17). d. Remove screw and bolts (12) securing support (4) to bracket (9). e. Disengage chain (7) from sprocket ( 11) and re move support (4) and control wheel assembly from aircraft. !. To remove sprocket (ll) and control wheel (3) from support (4 ), drive out roll pin (2) and slide sprocket from shaft ( 1). g. Reverse the preced~ng steps for reinstallation. Rig system in accordan~ with paragraph 9- 12, safety turnbuckle and relnstall all items removed for access. 9-14. CABLES AND PULLEYS. 9-15. REMOVAL AND INSTALLATION. (See figure 9- l. ) a. Remove access pauel from under left door. b. Remove access plates from left side of tailcone and beneath actuator on right ·stabilizer. c. Remove safety wire, relieve cable tension and disconnect turnbuckle ( ~7 ) . d . Disconnect cables at clevis (14). e. Remove travel stop blocks (18). f. Remove cable guards, pulleys and fairleads- as necessary to work cables free of aircraft. Remove chain guard (25) and disengage chain (27) from sprok et (26) to ease aft cable removal. To ease forward cable removal, pull the cable which has the position indicator attached, away from sprocket (11). NOTE To ease routing of cables, a length of wire may be attached to the end of cable being withdrawn from the aircraft. Leave wire in place, routed through structure; then ·at tach the cable being installed and use wire to pull cable into position.
g. Reverse the preceding steps for reinstallation. h. Mter cables are routed in position, install pul leys, cable guards and !airleads. Ensure cables are positioned in pulley grooves before installing guards. Ensure roller chains are positioned correctly over sprockets. i. Re-rig system in accordance with paragraph
9-16, safety turnbuckles and reinstall all items re
moved for access.
9-16. RIGGING. (See figure 9-1.)
a. Remove access panel from under left door. b. Remove access plate from left side of tailcone
and beneath actuator on right stabilizer.
c. Remove safety wire and relieve cable tension at turnbuckle (17). d. Loosen stop blocks (18) on control cables. e . Disconnect push-pull tube (22) at actuator rod end (23). f. Adjust control cables to correct tension and safety turnbuckle (17). g . Rotate trim wheel (3) unW position indicator (5) is on the "TAKE-OFF" triangle. h. With elevators and trim tab in neutral position (streamlined), rotate actuator rod end (23) IN or OUT as necessary to align with push-pull tube (22) and secure. i. With tab streamlined, mount an inclinometer on trailing edge and adjust to 0°. NOTE An inclinometer for measuring control sur
face travel is avallable from the Cessna
Supply Dlvlsion. Refer to flgure 6-4.
j. Adjust travel stop blocks to degree of travel specified in figure 1-1 as outlined in figure 9- 2. k. Reinstall all items removed for access.
IWARNINGl Be sure trim tab moves in correct direction when operated by the trim control wheel.
Revision 1
9-7/(9- 8 blank)
I
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 10 RUDDER CONTROL SYSTEM Page No. Aerofiche/ Manual
TABLE OF CONTENTS RUDDER CONTROL SYSTEM Description . . . . . . Trouble Shooting . . . . Rudder Pedal Assemblies Removal and Installation Rudder . . . . . . . . . . Removal and Installation
. 1Hl2/ 10-4 Repair . . . . . . . . Cables and Pulleys . . . . . . 1Hl2/ 10-4 Removal and Installation . 1Hl2/ 10-4 Forward Cables . . . 1Hl2/ 10-4 Aft Cables . . . . . . 1Hl4/10-6 Tailwheel Steering Cables . . 1Hl4/ 10-6 Rigging . 1H14/ 10-6
1H9/ 10-1 1H9/ 10-1 1H9/ 10-1 1Hl2/ 10- 4 1Hl2/10- 4 1H12/ 10-4 1Hl2/10-4
leys. Tailwheel steering is-controlled by cables and bellcranks attached to the rudder control cables. Beginning with aircraft serial 18800573 an aileron rudder interconnect system is installed.
10- 1. RUDDER CONTROL SYSTEM. 10-2. DESCRIPTION. The rudder system consists of individual rudder pedal assemblies with return springs, rudder, rudder bellcrank, cables and pul 10-3. TROUBLE SHOOTING. NOTE
Due to remedy procedures in the following trouble shooting chart it may be necessary to re• rig system. Refer to para graph 10- 11. TROUBLE RUDDER DOES NOT RESPOND TO PEDAL MOVEMENT.
PROBABLE CAUSE Broken or disconnected cables.
BINDING OR JUMPY MOVEMENT Cables too tight. OF RUDDER PEDALS. Cables not riding properly on pulleys.
REMEDY Connect or replace cables.
Adjust cable tension. Route cables correctly over pulleys.
Binding, broken or defective pulleys or cable guards.
Replace defective pulleys and install guards properly.
Pedal bars need lubrication.
Lubricate in accordance with Section 2.
Defective rudder bar bearings.
Replace bearing blocks.
Defective rudder hinge bushings or bellcrank bearings.
Replace defective bushings or bearings.
Clevis bolts too tight.
Readjust to eliminate binding.
Rudder-aileron interconnect springs impr operly installed or damaged.
Install springs properly. Replace damaged springs.
LOST MOTION BETWEEN RUDDER PEDALS AND RUDDER.
Insufficient cable tension.
Adjust cable tension.
INCORRECT RUDDER TRAVEL.
Incorrect rigging.
Rig in accordance with para graph 10-11. 10-1
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
A D
SEE FIGURE 10-2
10
5 Detail
C
17
Detail
0 NOTE
To obta1n proper cable tension rig rudder control system as outlined in paragraph 10- 11. Refer to figure 1-1 for rudder travel.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Figure 10-1. Rudder Control Syst em 10-2
Right Rudde r Ba r Rudder Bar Ar m Cable (Right Forward) Pulley Bracket Cable Guard Turnbuckle Tur nbuckle Cable (Le ft F orwa rd) Cable (Right Aft) Cable (Left Aft) Bulkhead Cable (Tailwheel Steering) Bushing Tailwheel Steering Bellcrank Spring Rudder Bellcrank Trave l Stop Bolt
11
MODEL 188 & T188 SERIES SERVICE MANUAL
2
Plug (BEGINNING WITH AIRCRAFT SERIAL 18802090 AND ALL SERVICE PARTS)
• T HRU 18803879
* BEGINNINJ WITH 18803880 1. Kick Plate 2. Pln 3. Pedal
'•
4. Arm
Detail
A BEGINNING WITH AIRCRAFT SERIAL 18800573
Detail
8
5. Return Spri~ 6. Master Cylinder 7. Right Rudder Bar 8. Anchor 9. Bearing Block 10. Arm (Right Rudder Cable) 11. Arm (Left Rudder Cable) 12. Left Rudder Bar 13. Bolt 14. Ailer on- Rudder Interconnect Spring 15. Torque Tube Assembly 16. Spacer 17. Aileron Control Bellcrank 18, Shaft Assembly 19. Parking Brake Cable Bracket 20. Plug 21 . Shaft
BEGINNING WITH AIRCRAFT S ERIAL 188- 0318 Figure 10-2. Rudder Pedals Installation 10 -3
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
1. 2. 3. 4. 5. 6. 7.
Bolt Upper Tip Balance Weight Ground Adjustable Trim Tab Bellcrank Lower Hinge Bracket Upper Hinge Bracket
6
Detail
8
.
Figure 10-3.
Rudder Assembly
10-4. RUDDER PEDAL ASSEMBLIES.
10-6. RUDDER.
10-5. REMOVAL AND INSTALLATION. a. Seat may be removed if desired. b. Remove fuselage side access panels from under left and nght doo r s. c. (Refer to figure 10-1.) Remove safety wire and relieve cable tension at turnbuckles (7 and 8). · d. (Refer to figure 10-2.) DiscoMect cables from rudder bar arms ( 10 and 11). e. DiscoMect return springs (5) from pedal arms
10-7. REMOVAL AND INSTALLATION. (See figure 10-3. ) a. Remove fuselage access panels from below left and right doors. b. Remove screws securing stinger, discoMect tail llght wire and remove stinger. c. Remove sa!ety wire and relieve cable tension at turnbuckles (index 7 and 8, figure 10-1). d . DiscoMect control cabl es at bellcrank (17). e . With rudder supported, remove bolts (index 1, figure 10-1) then carefully remove rudder. f. Reverse the preceding steps for reinstallation. Rig system in accordance with paragraph 10-11, safety turnbuckles and reinstall all items removed for access.
(4 ). f. DiscoMect master cylinders (6) from rudder
pedals (3). g. (B EGINNI NG WITH AIRCRAFT SERIAL 188-0318) DiscoMect parking brake cable from cable bracket (19). h. (BEGINNING WITH AIRCRAFT SERIAL 18800573) DiscoMect aileron- rudder intercoMect springs ( 14) from shaft assembly (18). i. Remove bolts securing bearing blocks (9) and lift pedal assemblies out of aircraft. j. Repair o r replace parts as necessary and re verse the preceding steps for reinstallation. Refer to Section 2 fo r lubncation requ1rements. Rig sys tem tn accordance w ith paragraph 10- 11. safety turn buckles :1nd reinstall .111 Items removed for access .
10-4
10-8. REPAIR. Repair of the rudder may be accom plished as outlined in Section 17 . 10-9. CABLES AND PULLEYS. 10-10. REMOVAL AND INSTALLATION. (See
figure 10-1. )
a. FORWARD CABLES. 1. Remove fuselage a ccess panels from below
MODEL 188 & T188 SERIES SERVICE MANUAL
VERTICAL FIN ESTABUSHING NEUTRAL POSITION OF RUDDER
/
B
BLOCK RUDDER
HALF THE
---DISTANCE BE'IWEEN
STRAIGHTEDGES
WIRE
/
/
/
/
/
POINTER~ MEASURING RUDDER TRAVEL
1. 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.
2. Tape a length of soft wire to the stinger in such a manner that it can be bent to index with a point on rudder trailing edge. This point is the bottom corner of the rudder skin (disregard the fixed trim tab). 3. Using soft lead pencil, mark rudder at point corresponding to soft wire indexing point (neutral). 4. Remove straightedges. 5. Hold rudder against right, then left, rudder stop. Measure distance from pointer to pencil mark on rudder in each direction of travel. Distance should be in accordance with following chart:
MODEL
YEAR
MINIMUM TRAVEL
MAXIMUM TRAVEL
188 SERIES
THRU AffiCRAFT SERIAL 188-0317
7.49"
7.81"
188 SERIES
BEGINNING WITH AIRCRAFT SERIAL
7.30"
7.63"
188-0318
Figur e 10- 4. Checklng Rudder Travel 10-5
MODEL 188 & T1 88 SER IES SERVICE MANUAL
left and right doors. 2. Remove access plate from tailcone below bellcranks (15). 3. Remove safety wire and relieve cable tension at turnbuckles (7 and 8 ). 4. Disconnect cables (3 and 9) at rudder bar arms and at bellcranks ( 15). 5. Remove pulleys and cable guards in Detail B as necessary to work cables free of aircraft. NOTE To ease routing of cables, a length of wire may be attached to end of the cable before being withdrawn from airc raft. Leave wire in place, routed through structure; then at tach cable being installed and pull the cable into position. 6. Reverse the preceding steps for reinstalla tion. 7. After cables are routed in position, install pulleys and cable guards. Ensure cables are in pulley grooves before installing guards. Rig system in accordance with paragraph 10-11, safety turn buckles and reinstall all items removed !or acces s. b . AFT CABLES. 1. Remove screws securing stinger, disconnect tail light wire and remove stinger from ai rcraft. 2. Complete steps 1, 2 and 3 of subparagraph "a. " 3. Disconnect cables (10 and 11) at bellcranks (15).
4. Disconnect cables (10 and 11) at bellcrank (17).
5. Complete " NOTE' in step 5 of subparagraph "a. "
6. Reverse the preceding steps for reinstalla tion. Rig system in accordance with paragraph 10-11, safety turnbuckles and reinstall all items removed for access.
10-6
c. TAILWHEEL STEERING CABLES. 1. Complete step 2 of subparagraph "a." 2. Disconnect cables (13) at springs (16). 3. Remove cable guard and pulleys in Detail C
as necessary to ease removal of cables.
4. Disconnect cables (13) at tailwheel bellcrank
and work cables out of tailcone openings.
5. Reverse the preceding steps for reinstalla tion. Install pulleys and cable guards. Ensure cables are in pulley grooves before installing guards and re inStall all items removed for access. 10-11. RIGGING. a. Remove fuselage access panels from below left and right doors. b. Remove screws securing stinger, disconnect tail light wire and remove stinger from aircraft. c. Disconnect tailwheel steering cables at tailwheel bellcrank. d. (See figure 10-1.) Remove safety wire and relieve cable tension at turnbuckles (7 and 8). e. Adjust travel stop bolts (18} to obtain degree of travel specified in figure 1-1. Figure 10-4 illustrates one method of checking travel. f. (See figure 10- 2.) Adjust turnbuckles (index 7 and 8, figure 10-1) evenly so rudder pedal pivot points are approximately 5. 75 inches from th~ hopper while the rudder is offset 1.. to the right (5/ 16 inch at lower trailing edge of rudder). Check that rudder pedals clear hopper when full brake and rudder are applied in each direction. It may be necessary to rig them slightly farther than the 6 inches specified for sufficient clearance with a loaded hopper. g. Safety turnbuckles, reconnect tailwheel steering cables and reinstall all items removed for access.
!WARNING a Be sure rudder moves ln the correct direction when operated by the rudder pedals.
MODEL 188 & T188 SERIES SERVICE MANUAL
SECTION 11 ENGINE
(CARBURETOR)
(SERIAL 188-0001 THRU 18802348)
I
IWARNINGt When performing any Inspection or mainte nance that requires turning on the master switch. tnstalllng a battery, or pulling the propeller through by hand, treat the propel ler as if the ignition switch were ON. Do not stand, nor allow anyone else to stand, within the arc of the propeller, since a loose or broken wire, or a component mal function, could cause the propeller to rotate .
TABLE OF CONTENTS
Page No. Aeroflche/Manual
. 1H20/11-2' ENGINE COWLING . . . 1820/11-2 Description . . . . 1820/11-2 Removal and Installation . 1H20/11-2 Cleaning and Inspection . Repair . . . . . . . . . 1820/11-2 ENGINE . . . . . . . . . . . 1820/11-2 Description . . . . . . . 1820/11-2 Time Between Overhaul (TBO) . . 1820/11-2 Overspeed Limitations . . . 1H20/11-2 Engine Data . . . . . . . . 1821/11-3 . 1H23/11-5 Trouble Shooting . . . . . . . 1824/11-6 Static Run- Up Procedures . Removal . . . . . . . . ·. 111/11-7 . 112/11-8 Cleaning . . . . . . . . 112/11-8 Accessories Removal . . 112/11-8 Inspection . . . . . • 112/11-8 Build-Up . . . . . . 112/11-8 Installation . . . . . 113/11-9 Flexible Fluid Hoses . 113/11-9 Leak Test . . . . 113/11-9 Replacement . . . 113/11-9 Engine Baffles . . . . 113/11-9 Cleaning and Inspection Removal and Installation . 115/11-11 . 115/11-11 Repair . . . . . .· . . Engine Mount . . . . . . . . 115/11-11 . US/11-11 Removal and Installation Repair . . . . . . . . . 115/11-11 Painting Engine Mount. . 115/11-11 . 1!5/11-11 Engine Shock-Mount Pads ENGINE OIL SYSTEM . 115/ 11-11 Description . . . . . 115/11-11 Trouble Shooting . . . 116/11-12 Full-Flow Oil Filter . 118/11-14 (THRU18803473) Description . . . 118/ 11-14 Element Removal and Installation . . . . . 118/11-14 Adapter Removal . . . . 118/11-14 Disassembly, Inspection and Assembly . 1110/11-16 Adapter Installation . . . . 111 O/ 11-16
. 1110/11-16 Oil Cooler . . . . . . Remote Engine Oil Drain . 1110/11 - 16 System . . . . . . . . 1110/11-16 ENGINE FUEL SYSTEM Description . . . . . . . 1110/11-16 Carburetor Removal and Installation . . . . . . 1110/11-16 Idle Speed and Mixture Adjustment . . . . . . 1110/11-16 Electric Fuel Pump Circuit . 1111/11-17 Auxiliary Electric Fuel Pump Flow Rate Adjustment . . . . . . . . 1111/11-17 INDUCTION AIR SYSTEM . . . . . . 1111/11 - 17 Description . . . . . . . . . . 1111/11-17 Airbox Removal and Installation . 1111/11-17 Cleaning and Inspection . . 1112/11 - 18 Induction Air Filter . . . . . 1112/11-18 ];)escription . . . . . . . 1112/11-18 Removal and Installation . 1112/11 -18 Cleaning and Inspection . . 1112/11-18 IGNITION SYSTEM . • . 1112/11-18 Description . . . . 1112/11-18 Magnetos . . . . . 1112/11 - 18 Description · . . 1112/11- 18 Removal. . . . 1113/11-19 Internal Timing. . 1113/11-19 Installation and Timing to Engine . . . . 1113/11 - 19 Maintenance . . . 1114/11-20 Magneto Chec k . . ll15/11-21· Spark Plugs . . . 1115/11-21 ENGINE CONTROLS . . . 1115/11- 21 Description . . . . . 1115/11-21 Rigging . : . . . . . 1117/11-23 Throttle Control . 1117/11-23 Mixture Control . 1117/11-23 Propeller Control . 1117/11-23 Carburetor Heat Control . 1117/11 -23 STARTING SYSTEM . 1118/11 -24 Description . . . 1118/t'1-24 Trouble Shooting . 1118/11-24 Starter Motor . . 1119/11-25 Revision
1
11-1
v
MODEL 188 & T1 88 SERIES SERVICE MANUAL Removal and Installatio n Primary Maintenance . . EXHAUST SYSTEM . . . . . Description . . . . . . Removal and Inst allation Inspection . . . . . . .
. . . . . .
1119/11-25
1119/11-25
1119/11-25
1119/11-25
1119/11-25
1119/11-25
EXTREME WEATHER MAINTENANCE Cold Weat.h er . . . . . . Seacoast and Humid Areas Dusty Areas . . . . . : . Ground Service Receptacle
u . . . . .
1121/11-27 U 1121/11-27 1122/ 11-28 V 1122/11-28 1122/11-28
u
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11-1.
ENGINE COWUNG.
11-2. DESCRIPTION. The engine cowling is divided into two ma jor removable s ections. Thes e sections are fastened together and to the fuselage with quick rel eas e fa steners, allowing the removal of either sec tion individually . At the lower aft side of the lower cowling section, a removable plate provides access to the throttlP and mixb.lre c ontrol linkages and to the induction a ir components. The upper cowling section has two a ccess doors, one at the upper front provides access to the oil filler neck and one a t the left aft side provides access to the oil dipstick. 11-3. REMOVAL AND INSTALLATION. a. Unfasten the quick-release fasteners along aft end and sides to remove upper cowling section. b. Remove plate at aft end of lower cowling section
and disconnect air intake boot at airbox.
c. Disconnect Landing light wires at quick-disconnects (beginning with aircraft serial 18800833). d. Unfasten the quick-release fasteners along aft end and carefully remove lower cowling section. e. Reverse the precedi.DI steps for reinstallation. E~ure the vertical baffle seals are folded forward and the side ba!fle seals are folded upward. 11-4. CLEANING ANP INSPECTION. Wipe the inner surfaces of the cowling segments with a clean cloth saturated with cleaning solvent (Stoddard or equiv alent). If the inside surface of the cowling is coated heavily with oil or dirt, allow solvent to soak until foreign material can be removed. Wash pa.i nted surfaces of the cowling with a solution of mild soap and water and rinse thoroughly. Aftei.· washing, a coat of wax -may be applied to the painted surfaces to prolong paint llie . After cleaning, inspect cowling for dents, cracks, loose rivets and spot welds. Re pair all defects to prevent spread of damage. 11 - 5. REPAIR. If cowling skins are extensively damaged, new complete sections of the cowling should be installed. Standard insert-type patches
SHOP NOTES:
11 -2
Revisio n 1
may be used for repair 1f repair parts are formed to U fit contour r4 cowling. Small cracks may be stopdrilled and small dents straightened 1f they are rein forced on the inner surface with a doubler of the \.) same materia.l as the cowling ald.n. Damaged rein forcement angles should be replaced with new parts. - V Due to their small size, new reinforcement angles V are easier to install than to repair the damaged part.
v
11-6. ENGINE.
v
u
11-7. DESCRIPTION. The carburetor equipped engine is an air-cooled, horizontally- opposed, U direct-drive, six-cylinder Continental 0-470 series \.) engine. The cylinders, numbered from rear to front, are staggered to permit a separate throw on the u crankshaft for each coMecting rod. The right rear cyll.nder is number 1 and cylinders on the right side U are identified by·odd numbers 1, 3 and 5. The left rear cylinder is number 2 and the cylinders on the V left side are identified as 2, . 4 and 6. For repair 3.nd 0 overhaul of the engine, accessories and propeller, ,. refer to the applicable publication issued by the manu- U facturer of these items. These publications are avail-, ~ able from the Cessna Supply Division.. ~ 11-7A. TIME BETWEEN OVERHAUL (TBO). Tele- V dyne Continental Motors recommends engine overhaul V at 1200 hours operating tlme for the 0-470 series en gines employed in spraying or dusting operations. \...) Refer to Continental Aircraft Engine Service Bulletin M81- 22, and to any supersedi.ng bulletins, revisions 0 or supplements thereto, for further recommendations. At the time of overhaul, engine accessories should be U overhauled. Refer to Section 13 for propeller and U governor overhaul periods. 11-7B. OVERSPEED UMITATIONS. The engine must not be operated above spec'ified maximum con tinuous RPM. However, should inadvertent over speed occur, refer to Continental Aircraft Engine Service Bulletin M75-16, and to any superseding bulletins , revisions or supplements thereto, for further recommendations.
u
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MODEL 188 & T188 SERIES SERVICE MANUAL
11-8.
ENGINE DATA.
Aircra!t
188 AGwagon, 188AGwagon A. 188A AGwa.gon B, 1888 AGpiclrup
MODEL (Continental)
Q-470-R
Rated Hor sepower at RPM
230 at 2600
Static RPM Model 1888 (Controllable Pitch) ( Fixed Pitch ) Number of Cylinders
2565 RPM (Refer to paragraph 11 - 10 for Run-up details) 2250 RPM 6 Horizontally-Opposed
Displacement
Bore
Stroke
470 Cubic Inches 5. 00 Inches 4. 00 Inches
Compression Ratio
7.00:1
Magnetos
Right Magneto
Left Magneto
Slick No. 662
Fires 22° BTC, Lower Left, Upper Right
Fires 22° BTC, Upper Left, Lower Right
Firing Order
1-6-3- 2- 5-4
Spark Plugs
18mm {Refer to Continental Service Bulletin M77-10 for factory approved spark plugs and required gap) 330±30 LB-IN.
Torque Car buretor (Marvel-Schebler)
MA4-5
Fuel
Grade Minimum
Aviation Gasoline
lOOLL
Alternator
14-Volt, 60-Ampere
28-Volt, 60- Ampere
Starter
12- Volt, Automatic Engagement
24-Volt, Automatic Engagement
Tachometer
Mechanical Drive
Oil Sump Capacity With External Filter
12 U.S. Quarts
13 U.S. Quarts
Oil Pressure (PSI) Normal Minimum Idling Maximum (Cold Oil Starting) Connection Location
30-60 10 100 Between No. 2 and No. 4 Cyl.
Oil Temperature Normal Operating Maximum Probe Location
Within Green Arc Red Line (225 °F.) Below Oil Cooler
Cylinder Head Temperature ~ormai Operating Maximum Thermocouple Location
Within Green Arc Red Line (460 ° F .) Lower side of Number 1 Cylinder
Direction of Cranksha!t Rotation (Viewed from Rear )
Clockwise
Dry We1ght- With Accessories
438 LB (Weight is Approximate and Will Vary With Optional Accessories Installed) 11-3
MOD EL 188 8t T1 88 SERIES SERVICE MANUAL 11-8. ENGINE DATA. (Cont.) Aircraft
188 AGwagon, 188AGwagon A, 188A AGwagon B,
188B AGpickup
MODEL (Continental)
0-470-S
Rated Horsepower at RPM
230 at 2600
Static RPM Model 188B (Controllable Pitch) (Fixed Pitch)
2565 RPM (Refer to paragraph 11-10 for Run-up
details)
2250 RPM
Number of Cylinders
6 Horizontally-Opposed
Displacement
Bore
Stroke
470 Cubic Inches 5. 00 Inches 4. 00 Inches
Compression Ratio
7. 00:1
Magnetos
Right Magneto
Left Magneto
Slick' No. 662
Fires 22° BTC, Lower Left, Upper Right
Fires 22° BTC, Upper Left, Lower Right
Firing Order
1-6-3-2-5-4
Spark Plugs
18mm (Refer to Continental Service Bulletin M77-10
for factory approved spark plugs and required gap)
330±30 LB-IN.
Torque Carburetor(Marvel-Schebler)
MA4-5
Fuel
Grade Minimum
Aviation Gasoline
lOOLL
Alternator
14- Volt, 60-Ampere
28-Volt, 60- Ampere
Starter
12-Volt, Automatic Engagement
24-Volt, Automatic Engagement
Tachometer
Mechanical Drive
Oil Sump Capacity With External Filter
12 u.s. Quarts
13 U. S. Quarts
Oil Pressure (PSI) Normal Minimum Idling Maximum (Cold Oil Starting) Connection Location
30-60
10
100
Between No. 2 and No. 4 Cyl.
Oil Temperature Normal Operating Maximum Probe Location
Within Green Arc
Red Line (240 °F . )
Below Oil Cooler
Cylinder Head Temperature Normal Operating Maximum Thermocouple Location Direction of Crankshaft Rotation (Viewed fr om Rear ) Dry Weight-'Mth Accessories 11-4
Within Green Arc
Red Line 460°F,)
Lower Side of Number 1 Cylinder (1981 Models And ON)
Lower Side of Number 5 Cylinder (thru 1980 Mode ls)
Clockwtse
438 LB (Weight is Approximate and Will Vary
With Optional Accessories Installed)
MODEL 188 & T188 SERIES SERVICE MANUAL NOTE The 0-470-S engine is interchangeablewith the 0-470-R engine on aircraft serials 18800833 THRU 18801824. Refer to Cessna Single -engine Service Letter SE75-2 Dated January 17, 1975. 11- 9. TROUBLE SHOOTING. TROUBLE ENGINE FAll..S TO START.
ENGINE STARTS BUT DIES, OR WILL NOT IDLE.
REMEDY
PROBABLE CAUSE Improper use of starting procedure.
Refer to ONner's Manual
Defective aircraft fuel system.
Refer to Section 12.
Spark plugs fouled.
Remove and clean. Check gaps and insulators. Use new gaskets. Check cables to persistently fouled plugs.
Magnet o impulse coupling failure.
Repair or install new coupling.
Defective magneto switch or grounded magneto leads.
Repair or replace switch and leads.
Defective ignition system.
Refer to paragraph 11-61.
Excessive induction air leaks.
Correct cause of air leaks.
Defective carburetor.
Repair or replace carburetor.
Water in fuel system.
Drain fuel tank sumps, fuel lines, fuel strainer and carburetor.
Engine flooded.
Refer to Owner's Manual
Vaporized fuel in system.
Refer to ONner 's Manual
Improper idle speed or idle adjustment.
Refer to paragraph 11-43.
Propeller contr ol set in high pitch position (low rpm).
Use low pitch (high rpm) position for all ground operations.
Air leak in intake manifold.
Tighten loose connections or replace damaged parts.
Spark plugs fouled by oil escaping past piston rings.
Top overhaul engine.
Water in fuel system.
Drain fuel tank sumps, fuel lines¡, fuel strainer and carburetor.
Defective ignition system.
Refer to paragraph 11-61.
Spark plugs fouled or improperly gapped.
if defective.
Defective fuel system.
Refer to Section 12.
m~re
Clean and regap. Replace
11-5
MODEL 188 & T188 SERIES SERVICE MANUAL 11-9. TROUBLE SHOOTING (Cont). TROUBLE
PROBABLE CAUSE
ENGINE STARTS BUT DIES, OR WILL NOT IDLE (Cont).
Leaking float valve or float level set too high.
Replace defective parts; reset float level.
Defective carburetor.
Repair or replace carburetor.
Vaporized fuel in system .
Refer to Owner's Manual
Manual primer leaking.
Repair or replace primer.
Defective engine.
Engine repair is required.
ENGINE POWER TOO LOW ( CONSTANT SPEED )
Improper propeller governor adjustments.
( FIXED PITCH )
Refer to paragraph 11-10.
ENGINE RUNS ROUGHLY, WILL NOT ACCELERATE PROPERLY, OR LACKS POWER.
POOR IDLE CUT-OFF.
Perform static RPM check. Refer to paragraph 11-10 for details. Refer to paragraph 11-10 for applicable details.
Restriction in aircraft fuel system.
Refer to Section 12.
Badly adjusted accelerating pump or float level set too low .
Change pump adjustment. Reset float level.
Defective carburetor.
Repair or replace carburetor.
Worn or improperly rigged throttle or mixture control.
Rig properly. Replace worn linkage.
Spark plugs fouled or improperly gapped.
Clean and regap. Replace if defective.
Defective ignition system.
Refer to paragraph 11- 61.
Defective engine.
Engine repair is required.
Worn or improperly rigged mixture control•
Rig pr operly. Replace worn linkage.
Defective carburetor.
Repair or replace carburetor.
Fuel leakage through primer.
Repair or replace primer.
Fuel contamination.
Drain all fuel and flush out fuel system. Clean all screens, fuel lines, strainer and carburetor .
.
11 - 10. STATIC RUN-UP PROCEDURES. In a case of suspected low engine power, a static RPM run-up should be conducted as follows: a . Run-up engine, using take-off power and mix tw-e settings, with the aircraft facing 90° right and then left to the wind direction. b . Reco rd the RPM obtained in each run-up posi tion. NOTE Daily change s in atmospheric pressure, tem pe rature and hum1dity wtll have a slight effe ct on static run-up. 11- 6
REMEDY
c. Average the results of the RPM obtained. It should be within 50 RPM of 2565 RPM (230 HP) & 2800 RPM (300 HP). d. U the average results of the RPM obtained are lower than stated above, the following recommended checks may be performed to determine a possible deficiency. 1. Check governor control for proper rigging. It should be determined that the governor control arm travels to the high RPM stop on the governor and that the high RPM stop screw is adjusted proper ly. (Refer to Section 13 for procedures).
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE
NOTE
If verification of governor operation is neces sary the governor may be removed from the
Dur ing the following steps remove any clamps or lacings which secure controls, wires, hoses or lines to the engine, engine mount or attached brackets. Omit any of the following items which are not present on a particular engine ins talla tion.
engine and a flat plate installed over the en gine pad. Run- up engine to determine that governor was adjusted properly. 2. Check carburetor heat control (carburetor equipped engines) for proper rigging. If partially open it would cause a slight power loss. On fuel injected engines check operation of alternate air door spring or magnetic lock to make sure door will remain closed in norm.a l operation. 3. Check magneto timing, spark plugs and
ignition harness for settings and condition.
4. On fuel injection engines, check fuel injection nozzles for restriction and check for correct un metered fuel flow. 5. Check condition of induction air filter. Clean if required. 6. Perform an engine compression check (Refer to engine Manufacturer's Manual). 11-11. REMOVAL. U the engine is to be placed in storage or returned to the manufacturer for overhaul, proper preparatory steps should be taken for corro sion prevention prior to beginning the removal proce dure. Refer to Section 2 for storage preparation. The routing and-location of wires, cables, lines, hoses and controls will vary between models and op tional equipment installed, however, the following general procedure may be followed. NOTE Identify each item as it is disconnected to
aid in replacement. Plug or cap all dis
connected lines, hoses and fittings to pre
vent entry of foreign material.
a. Place all cockpit switches and fuel shut-off valve in the OFF position. b. Remove engine cowling in accordance with para graph 11- 3. c. Open battery circuit by disconnecting battery cables. Insulate cable terminals as a safety pre caution. d. Drain fuel strainer and lines with strainer drain control. NOTE The engine may be removed from the air craft with or without the engine mount at tached. The reason for the engine removal should be the governing factor as to the manner it is to be removed and at which point the controls should be disconnected. e. Drain the engine oil sump and oil cooler. Remove spinner and propeller in accordance
with Section 13. On engines with constant- speed
propellers, cover the exposed end of the crankshaft
to prevent entry of foreign matenal.
g. Disconnect hot and cold air flexible hoses. h. Remove muffler and exhaust stacks in accor
dance w1th paragraph 11 - 79.
i. Disconnect throttle and mixture control from
carburetor. Pull t hese controls free of engine and
engine mount, using care not to damage them by
bending too sharply. Note position, sizes and num
ber of attaching washers and spacers.
j . Disconnect propeller .control at governor. Pull control aft clear of e ngine. k. Disconnect carburetor beat control at atrbox and remove airbox in accor dance with paragraph 11 - 48. 1. Disconnect wires and cables as follows: 1. Tachometer drive shaft at adapter on engine.
/ ~AUTION I When disconnecting starter cable do not
permit starter terminal bolt to rotate.
Rotation of the bolt could break the con
ductor between bolt and field coils causing
the starter to be inoperative.
2. Starter electrical cable at starter. 3. Electr ical wires and wir e shielding ground at alternator. 4. Cylinder head temperature pr obe at cylinder.
lWARNINGa The magneto Is in a SWITCH ON condition
when the switch wire is disconnected.
Ground the magneto points or remove the
high t ension wires from the magneto or
spark plugs to prevent accidental firing.
5. Disconnect switch wires at magnetos. m. Disconnect lines and hoses as follows:
lWARNINGa Residual fuel and oil draining from discon nected lines and hoses constitutes a fire hazard. Use caution to pr event accumula tion of suc h fuel and oil when lines or hoses a r e disconnected. 1. 2. 3. 4. 5.
Oil temperature bulb below oil cooler.
Oil pr essure hose at firewall. Primer line to engine at firewall. Fuel hose at fuel strainer. Manifold pressure line at firewall .
f.
I¢AUTION \ If the aircraft is equipped with an engine driven hydraulic dispersal system, relieve reservoir air pressure before disconnecting hydraulic lines at engine.
11-7
MODEL 188 & T188 SERI ES SERVICE MANUAL
n. Attach a hoist to the lifting lug on top of the en gine and take up engine weight on hoist. o. Carefully check the engine again to ensure all hoses, lines, wires, cables and clamps a.r e discon nected or removed which would interfere with the engine removal. p. If the engine is to be removed from the engine mount, remove carburetor airbox, remove bolts attaching engine to mount, slowly hoist engine and pull it forward bal.a ncing the engine by hand and carefully guide the disconnected components out from the engine assembly, then remove the shock-mount assemblies. q. If engine is to be removed with engine mount attached, remove the bolts attaching engine mount to firewall, balance the engine by hand as the last of these bolts is removed, slowly hoist the engine, pulling it forward and carefully guide the disconnected components out from the engine assembly. 11-12. CLEANING. The engine may be cleaned with Stoddard solvent or equivalent, then dried thoroughly.
jCAUTIO N\ Particular care should be given to electrical equipment before cleaning. Cleaning fluids should not be allowed to enter magnetos, starter, alternator, etc. Protect these com ponents before saturating the engine with solvents. All other openings should also be covered before cleaning the engine assembly. Caustic cleaning solutions should be used cautiously and should always be properly neutralized after their use. 11-13. ACCESSORIES REMOVAL. Removal of en gine accessories for overhaul o r for engine replace ment involves stripping the engine of parts, acces sories and components to reduce it to the bare en gine . During the removal process, removed items should be examined carefully and defective parts should be tagged for repair or replacement with new components. NOTE Items easily confused with similar items
should be tagged to provide a means of
identification when being inStalled on a
new engine. All openings exposed by the
removal of an item should be closed by
installing a swtable cover or cap over
the opening. This will prevent entry of
foreign particles. If suitable covers are
not available, tape may be used to cover
the openings.
11 - 14. INSPECTION. For specific items to be in
spected refer to the engine manufacturer's manual.
a. Visuall y 111spect the eng111e for loose nuts. bolts, cracks and fin damage. b. Inspect baffles, baffle seals and brackets for
c racks , detenoration and breakage.
c. Inspect all hoses for internal swelling, chafing
through protective plys, cuts, breaks, stiffness,
damaged threads and loose connections. Excessive
ll-8
heat on hoses will cause them to become brittle and easily broken. Hoses and lines are most likely to crack or break near the end fittings and support points. d. Inspect for color bleaching of the end fittings or severe discoloration of the hoses. NOTE Avoid excessive flexing and sharp bends when examining hoses for stiffness. e. All flexible fluid carrying hoses in the engine compartment should be replaced at engine overhaul or every five years, whichever occurs first. f. For major engine repairs, refer to the manu facturer's overhaul and repair manual. 11-15. BUILD-UP. E~ine build-up consists of in stalling of parts, accessories and components to the basic engine to build up an engine Wlit ready for in stallation on the aircraft. All safety wire, lock washers, nuts, gaskets and rubber connections should be new parts. 11-16. INSTALLATION. Before installing the en gine on the aircraft, install any items that were re moved after the engine was removed from the air craft or airframe. NOTE Remove all protective covers, and identification tags as each nected or installed. Omit any present on a particular engine
plugs, caps item is con items not inStallation.
a. U engine was removed from engine-mount, hoist engine assembly to a point near the mount, route controls, lines and hoses in place as the engine is positioned near the mount. Install shock mounts and ground straps as illustrated in figure 11- 1. Install engine mount bolts and torque bolts to the torque values shown in figure 11-1. b. If engine was removed with engine- mount at tached, hoist engine assembly to a point near the firewall, route controls, lines and hoses in place as the engine is positioned near the firewall. Install mount bolts and associated hardware as illustrated in figure 11-1 and torque bolts to torque values shown in figure 11-1. c. Remove hoist. d. Route throttle control to carburetor and secure control in position with clamps. Rig control in ac cordance with paragraph 11- 67. e. Route mixture control to carburetor and secure control in position with clamps . Rig in accordance with paragraph 11-68. f . Install carburetor airbox, route carburetor heat control to airbox and secure in position with clamps. Rig control tn accor dance with paragraph 11-70. g. Route propeller governor control to governor and secure contr ol in position with clamps. Rig in accordance with Section 13.
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Throughout the aircraft fuel system, from the tanks to the carruretor, use NS-40 (RAS-4) (Snap-On-Tools Corp., Kenosha, Wisconsin), MIL-T-5544 (Thread Com pound Antiseize, Graphite Petrolatum), USP Petrolatum or engine oil as a thread lubricator or to seal a leaking connection. Apply sparingly to male threads, exercis ing extreme caution to avoid "stringing" sealer across the end of the fitting. Always ensure that a compound, the residue from a previously used compound, or any other foreign material cannot enter the system. h. Connect lines and hoses as follows : 1. Oil temperature bulb below oil cooler. 2. Oil pressure hose at firewall. 3. Primer line at firewall. 4. Fuel hose at fuel strainer. 5. Manifold pressure line at Urewall. 6. Install all clamps attaching lines and hoses to engine, engine mount or brackets.
NOTE
If the aircraft is equipped with an engine
driven hydraulic dispersal system, con
nect hoses to pump, fill and pressurize
hydraulic reservoir as outlined in Section
19.
i.
Connect wires and cables as follows : 1. Cylinder head temperature probe at lower side of cylinder. 2. Electrical wires and wire shielding ground at alternator. 3. Tachometer drive shaft at adapter on engine. Tighten drive shaft attaching nut to 100 lb-in.
When connecting starter cable, do not permit starter terminal bolt to rotate. Rotation of the bolt could break the conductor between bolt and field coils causing the starter to be inoperative. 4. Starter electrical cable at starter. 5. Install all clamps attaching wires and cables to engine, engine mount or brackets. j. Install exhaust stacks, muffler and s hrouds in accordance with paragraph 11-79. k. Install hot and cold air flexible hoses. 1. Install p ropeller and spinner in accordance with instructions outlined in Se ction 13. m. Make a magneto switch ground- out and continuity check and connect magneto switch wires .
!WARNING' Be sure magneto switch is in OFF position when connecting switch wires to magnetos. n. Serv1ce engine with pr oper grade and quantity of engine oil. Refer to Section 2 if engine is new, newly overhauled or has been l.1l storage.
o. Make sure all switches are in the OFF position and connect battery cables: p. Inspect engine installation for security, correct r outing of controls, lines, hoses and electrical wir ing, proper safetying and tightness of all components. q. Install engine cowling in accordance with para graph 11-3. r. Clean and install air filter. s. Perform an engine run-up and make final adjust ments on engine controls. 11-17. FLEXIBLE FLUID HOSES. 11-18. LEAK TEST. a. Alter eacb 50 hours of engine operation, all flex ible fluid hos es in the engine compartment should be checked for leaks as follows: 1. Examine the exter ior of hoses for evidence of leakage or wetness. 2. Hoses found leaking s hould be replaced. 3. Refer to paragraph 11-14 for detailed inspec tion procedures for flexible hoses. 11-19. REPLACEMENT. a. Hoses should not be twisted on installation.
Pressure applied to a twisted hose may cause fail
ure or loosening of the nut.
b. Provide as large a bend radius as possible. c. Hoses should have a minimum of one-hall inch
clearance from other lines, ducts, hoses or sur
rounding objects or be butterfly clamped to them.
d. Rubber hoses will take a permanent set during extended use in service. Straightening a hose with a bend having a permanent set will result in hose cracking. Care s hould be taken during removal so that hose is not bent excessively, and during reinstal lation to a s sure hose is returned to its original posi tion. e. Refer to AC 43. 13-1, Chapter 10, for additional installation procedures for flexible fluid hose assem blies. 11-20. ENGINE BAFFLES. The sheet metal baffles installed on the engine directs the flow of air around the cylinders and other engine components to provide optimum cooling. These baffles incorporate rubber asbestos composition seals at points of contact with the engine cowling and other engine components to help confine and direct the alrflow to the desired area. It is very important to engine cooling that the baffles and seals are in good condition and installed correct ly. The vertical seals must fold forward and the side seals must fold upwards. Removal and installation . of the variO\lS baffle segments is possible with the cowling removed. Be sure that any new baffle seals properly. 11-21. CLEANING AND INSPECTION. The engine baffles should be cleaned with a suitable solvent to remove oil and dirt. NOTE The rubber-asbestos sea ls are oil a nd grease resistant but should not be soaked in solvent for long periods. 11 - 9
MODEL 188 8t T188 SERIES SERVICE MANUAL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Bolt Engine Mount Structur e Washer Bar rel Nut Tubular Fuselage Structur e F irewall Bolt Bracket Spacer Pin Shock-Mount Pad 12. Ground Strap
·~· f~ ~:Z-
e1 I
·y'?F
.
Detail
A
A---
*TORQUE TO 450-500 LB-IN • TORQUE TO 160-190 LB-IN
c
2 Detail Detail
8 e
BEGINNING WIT H AIRCRAF T SERIAL 188-0078
F igure 11-1. Engine Mount Details ll-10
C
MODEL 188 & T188 SERIES SERVICE MANUAL
Inspect baffles for cracks in the metal and for loose and/ or torn seals. Repair or replace any defective parts. 11-22. REMOVAL AND INSTALLATION. Removal and inStallation of the various baffle segments is possible with the cowling removed. Be sure that any replaced baffles and seals are installed correctly and that they seal to direct the airflow in the correct direction.
ll-26. REPAIR. Refer to Section 17. 11-27.
PAINTING. Refer to Section 18.
11-28. ENGINE SHOCK-MOUNT PADS. (See figure 11- 1.) The bonded rubber and metal shock mounts a re designed to reduce transmission of engine vibrations to the air frame. The rubber pads should be wiped clean with a clean dry cloth. NOTE
11-23. REPAIR. Baffles ordinarily should be re placed if damaged or cracked. However, small plate reinforcements riveted to the baffle will often prove satisfactory both to the strength and cooling require ments of the unit. 11-24. ENGINE MOUNT. (See figure 11-1.) The engine mount is comprised of sections of tubing welded together and reinforced With welded gussets. The purpose of the mount is to support the engine and attach it to the airframe. Each engine mount pad has a small hole for a locating pin which serves as a locating dowel for the engine shock-mounts.
11-25. REMOVAL AND INSTALLATION. a. Remove engine in accordance with paragraph
ll - 11.
b. Remove bolts from upper and lower mount-to fuselage structure and carefully remove engine mount. c. Reverse the preceding steps for reinstallation. Torque bolts to 160- 190 lb-in. Reinstall engine in accordance with paragraph 11-16.
Do not clean the rubber pads and dampener assembly with any type of cleaning solvent. Inspect the metal parts for crad<s and excessive wear due to aging and deter ioration. Inspect the rubber pads for separation between the pad and metal backing, swelling, cracking or a pronounced set of the pad. Install new parts for all parts that show evidence of wear or damage. 11-29. ENGINE OIL SYSTEM. 11-30. DESCRIPTION. A wet- sump, pr essure lubricating oil system is employed on this engine. Refer to applicable engine, manufacturer's overhaul manual for specific details and descriptions.
SHOP NOTES:
11-11
MODEL 188 8t T1 88 SERIES SERVICE MANUAL 11-31. TROUBLE SHOOTING. TROUBLE NO OIL PRESSURE .
LOW OIL PRESSURE.
HIGH OIL PRESSURE.
11-12
PROBABLE CAUSE
REMEDY
No oil in sump.
Fill sump with proper grade and quantity of oil. Refer to figure 2- 4.
Oil pressure line broken, disconnected or pinched.
Replace or connect.
Oil pump defective.
Remove and inspect. Examine engine. Metal particles from damaged pump may have entered engine oil passages.
Defective oil pressure gage.
Replace gage.
Oil congealed in gage line.
Disconnect line at engine and gage; flush with kerosene. Pre- fill with kerosene and install.
Relief valve defective .
Remove and check for dirty or de fective parts. Clean and install; replace defective parts.
Low oil supply.
Replenish.
Low viscosity oil.
Drain sump and refill with proper grade and quantity of oil.
Oil pressure relief valve spring weak or br oken.
Replace weak or broken spring.
Defective oil 'Pump.
Remove and inspect. Examine engine. Metal particles from damaged pump may have enter ed engine oil passages.
Secondary result of high oil temperature.
Observe oil temperature gage for high indication. Det ermine and correct reason for high oil tern perature.
High viscosity oil.
Drain sump and refill with proper grade and quantity of oil.
Relief valve defective.
Remove and check for dirty or de fective parts. Clean and install; r eplace defective parts.
Defective oil pressure gage.
Replace oil pressure gage.
MODEL 188 & T188 SERIES SERVICE MANUAL 11-31. TROUBLE SHOOTING (Cont). TROUBLE LOW OIL TEMPERATURE.
HIGH OIL TEMPERATURE .
REMEDY
PROBABLE CAUSE Defective oil temperature gage or temperature bulb.
Check with another gage. If reading is normal, ai rcraft gage is defective. If reading is similar te mperature bulb is defective. Replace defective part/ or parts.
Oil cooler thermo·bypas s valve defective or stuck closed.
Replace valve.
Oil cooler air passages clogged.
Clean air pa ssages.
Oil cooler oil passages clogged.
Remove cooler and flush thoroughly.
Vernatherm control valve damaged or held open by solid matter.
Remove. Clean valve and seat. If still inoperative, replace.
Low oil supply.
Reple nish.
Oil viscosity too high.
Drain and f1ll sump with pr oper grade and quantity.
Prolonged high speed operation on the ground.
Hold ground running above 1500 rpm to a minimum .
Defective oil temperature gage.
Check with another gage. If second reading is normal, air craft gage is defective . Replace gage.
,
Defective oil temperature bulb.
Check for correct oU pr essure , oil level and cylinde r head tern perature. If they are correct, check oil temperature gage for being defective; 1f similar reading is observed, bulb is defective . Replace bulb.
Oil congealed in cooler.
If congealing is suspected, use exter nal heater or a heated hangar to thaw the congealed oil.
11-13
MODEL 188 & T188 SERIES SERVICE MANUAL
11-32. FULL-FLOW OIL FILTER. (1880001 THRU 18803473) (See figure 11-3.) 11-33. DESCRIPTION. An external oil filter may be installed on the engine. The filter and filter adapter replaces the regular internal oil pressure screen. In some filter installations, the filter adap ter incorporates a bypass valve, outlet valve and isolation valve. Normally, oil from the oil pump flows through the isolation valve, through the filter element, through the outlet valve, to the en.g ine oil passages. If the filter element should become block ed, the bypass valve and outlet valve will open, allow ing pressure oil to flow to the engine oil passages. The isolation valve blocks of! the filter assembly and oil then flows through the bypass valve, if excessive oil pressure should occur. In some filter installa tions the filter adapter incorporates only a bypass valve. 11-34. ELEMENT REMOVAL AND INSTALLATION. (See figure 11-3.)
NOTE
I
New filter kits are available from the Cessna Supply Division.
a . Remove engine cowling in accordance with para-· graph 11-3. . b. Remove safety wires from filter can and unscrew hollow stud (23) to detach filter assembly from adapter (5) as a Wlit. Remove filter assembly from aircraft, discarding upper gasket (13). Oil will drain from filter as assembly is removed from adapter. c. Press downward on stud (23) to remove from
filter element (18) and can (19). Discard metal
gasket (22) on stud (23).
d. Lift lid (16) from can (19) and discard lower
gasket (17).
e. Pull filter element (18) from can (19) and dis
card.
NOTE Before discarding removed filter element, re move the outer perforated paper cover; using a sharp knife, cut through the folds of the fil ter element at both ends, close to the metal caps. Then carefully unfold the pleated ele ment and examine the material trapped in the filter element for evidence of internal engine damage such as chips or particles from bear ings. In new or newly overhauled engines, ·some small particles or metallic shavings might be found. These are generally of no consequence and should not be confused with particles produced by impacting, abrasion or pressure. Evidence of internal engine damage found in the oil filter element justifies further examination to determine the cause. !. Wash lid (16), hollow stud (23) and can (19) in
cleaning solvent and dry with compressed air.
11-14
Reviaion 1
NOTES When installing a new filter element, it is im portant that all gaskets are clean, lubricated and positioned properly, and correct amount of torque is applied to filter hollow stud. If stud is under-torqued, oil leakage will occur. If stud 1s over-torqued, the filter can may be deformed, again causing oU leakage.
• Lubricate rubber grommets tn each end of new filter element, rubber gaskets (13, 17) and metal gasket (22) with a thin coating of Dow Cor~ Compound, DC-4, apply by brushing or wiping lubricant on base gasket. • Before assembly, place a straightedge across bottom of filter can. Check for a distortion or out-of-fiat condition greater than . 010 inch. Replace if either of these conditions exist. • Before assembly, cut adapter nut safety wire and try to rotate adapter by hand. If adapter can be moved, check for thread deformation in engine and adapter. eAfter iru;t.alllng a new gasket on lid (16),
turn it upside down. If gasket falls, try
a different gasket and repeat test. If
this gasket falls off, install a new lid.
g. Inspect adapter gasket seat for gouges, deep
scratches, wrench marks and mutilation. U any of
these conditions are found , install a new adapter.
h. Place new element in can and insert stud (23) with a new metal gasket (22) in place, through the can and element. 1. Position a new gasket (17) inside lower flange of lid (16). Position new gasket (13) around upper flange of lid (16). Pla-:e the lid in position. j. Install filter assembly on adapter. Holding can to prevent it from turning, tighten stud (23) and torque to 20-25 lb-ft (240-300 lb-in), using a torque wrench. k. Reinstall parts removed for access and service the rngine with proper grade and quantity of oil. One additional quart of oil is required each time the ele ment is replaced. · 1. Start engine and check for proper oil pressure. Check for oil leakage after warming up engine. m. Again check for oil leakage after engine bas been run at a high power setting (preferably a flight around the field). n. Check to make sure that the fllter has not been in contact with adjacent parts due to engine torque. o. While engine is still warm, recheck torque on stud (23), then safety stud to lower tab (21) on filter can and safety adapter to upper tab (20) on filter can. 11 - 35. ADAPTER REMOVAL. (See figure 11 - 3.) a. Remove filter assembly as outlined in paragraph 11-34. . b. Note angular position of adapter, then remove safety wire and loosen adapter nut (2).
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE
Do NOT subsitute automotive gaskets for any gaskets used in this assembly. Use only approved gaskets listed in the Parts Catalogs.
5
A similar adapter that does not contain outlet valve (3) or isolation valve (6 thru 12) is used on later models . This newer adapter is also used for all service parts. Plug (12) is re placed with a plug containing tapered threads on the newer adapter, and the tightening di mension shown does not apply to tapered threads.
ISOLATION VALVE
• THRU AIRCRAFT SERIAL 188-0226
NUT DELETED ON CURRENT INSTALLATIONS (DISCARD AT NEXT FILTER ELEMENT CHANGE)-----------------
......---- . 40" (+. 00" -. 03") 1.
0-Ring
2. 3. 4. 6. 7.
Adapter Nut Outlet Valve BYJilsS Valve Adapter Countersunk Washer Sleeve
8.
0-Ring
9. 10. 11. 12. 13. 14.
Piston
5.
15. 16. 17.
18. 19.
20. 21. 22. 23.
12
0-Ring
Spring Plug Upper Gasket Hell-Coil Non- Metallic Nut Lid Lower Gasket Filter Element Can Upper Safety Wire Tab Lower Safety Wire Thb Metal Gasket Stud
NOTE When installing plug (12), tighten to dimension shown. 20
1880001 THRU 18803473
Figure 11-3. Full-Flow Oil Filter 11-15
MODEL 188 & T188 SERIES SERVICE M ANUAL
NOTE
I
A special wrench adapter for adapter nut (2) (Part No. SE-709) is available from the Cessna Supply Division, or one may be fabri cated as shown in figure 11-4. Remove any engine accessory that interferes with removal of the adapter.
c. Unscrew adapter and remove from engine. Dis card adapter o-ring. 11-36. DISASSEMBLY, INSPECTION AND ASSEM BLY. Figure 11-3 shows the relative position of the internal parts of the filter adapter and may be used as a guide during insW.lation of parts. The bypass and outlet valves are to be installed as complete units, with the valves being staked three places. The detail parts which form the isolation valve may be replaced individually. Also use new seals, lubri cate parts with engine oil and replace any part that shows signs of excessive wear. Note that washer (6) is installed with its countersunk side toward outlet valve (3). Tighten plug (12) to a maximum of • 40 inch as shown in figure 11-3. The hell-coil type in sert (14) in the adapter may be replaced, although special tools are required. Follow instructions of the tool manufacturer for their use. If the isola tion valve should become defective, remove plug (12) and parts (6 through 11). Weld shut vent hole in plug (12). Reinstall washer (6), sleeve (7 ), 0-ring (8) and plug (12) in the adapter. Inspect threads on adap ter and in engine for damage. Clean adapter in sol vent and dry with compressed air. Ascertain that all passages in the adapter are open and free of foreign material. Also, check that bypass and outlet valves are seated properly.
Oil circulating through the engine is allowed to circu late continuously through warm-up passages to pre vent the oil from congealing when operating in low temperatures. On the standard and non-congealing oil coolers, as the oil increases to a certain tempera· ture, the thermostat valve closes, causing the oil to be routed to all of the cooler passages for cooling. Oil returning to the engine from the cooler is routed through the internally drilled oil passages. 11-39. REMOTE EN:ZINE OIL DRAIN SYSTEM. A remote engine oil drain system may be installed. Drai.n ing of the oil is usually performed after an en gine shut-down while the oil is still hot. The follow ing chart will give the approximate oil temperature and time required to drain 10 quarts of oil from the engine. OIL TEMP. 87°F 147°F 186°F
TIME REQUIRED TO DRAIN 70 Minutes 11. 4 Minutes 6. 9 Minutes
11-40. ENGINE FUEL SYSTEM. 11-41. DESCRIPTION. The engine is equipped with a carburetor mounted at the lower side of the engine . The carburetor is of the plain-tube fixed-jet type and has such features as an enclosed accelerating pump mechanism, simplified fuel passages to prevent vapor locking, idle cut-off to prevent starting of the engine accidentally and manual mixture control for leaning. For overhaul and repair of the carburetor, refer to the manufacturer's overhaul and repair manual.
11-37. ADAPTER INSTALLATION. a. Assembly adapter nut (2) and new 0-ring (1) on adapter (5) ln sequence illustrated in figure 11-3. b. Lubricate 0- ring on adapter with clean engine oil. Tighten adapter nut until 0-ring is centered in its groove on the adapter. c. Apply an anti- seize compound sparingly to the adapter threads, then simultaneously screw adapter and adapter nut into engine until 0-ring seats against engine boss without turning adapter nut (2). Rotate adapter to approximate angular position noted during removal. Do not tighten adapter nut at this time. d. Temporarily install filter assembly on adapter, and position so adequate clearance with adjacent parts is attained. Maintaining this position of the adapter, tighten adapter nut to 50-60 lb-ft (600-700 lb-in) and safety. Use a torque wrench, extension and adapter as necessary when tightening adapter nut. e . Using new gaskets, install filter assembly as outlined in paragraph 11-34. Be sure to service the engine oil system.
11-42. CARBURETOR REMOVAL AND INSTALLA TION. a. Place fuel shut-off valve in the OFF position. b. Remove engine cowling in accordance with paragraph 11-3. c. Drain fuel from strainer and lines with strainer drain control. d. Remove airbox in accordance with paragraph 11-48. e. Disconnect throttle and mixture control to con trol arms on C4rburetor. Note position, size and number of wal$'ers and spacers so that they may be reinstalled in ffie same manner. · f. Disconnect and cap or plug fuel line at carbure tor. g. Remove nuts and washers attaching carburetor to intake manifqld and remove carburetor and mount ing gasket. h. Rever se the preceding steps for reinstallation. Use new gaskets when installing carburetor. Rig controls as outlined in paragraphs 11-67 and 11-68. Check carburetor throttle arm to idle stop arm attach ment for security and proper safetying at each normal engine inspection in accordance With figure 11-7.
11-38. OIL COOLER. A non-congealing oil cooler may be installed on the aircraft. The cooler is mounted on the right forward side of the engine crank case directly in front of number five cylinder and has no external oil lines. Ram air passes through the oil cooler and is discharged into the engine compartment.
11-43. IDLE SPEED AND MIXTURE ADJUSTMENT. Idle speed and mixture adjustment should be accom plished after the engine has been warmed up. Since idle rpm may be affected by idle mixture adjustment, it may be necessary to readjust idle rpm after setting the idle mixture correctly.
11-16
Revision 1
MODEL 188 & T188 SERIES SERVICE MANUAL
ALL DIMENSIONS ARE INCHES
1-7/ 32
!
I
~~'-1-7/8
1-5/ 32 R
I
R (TYP)
....
r--2.135-l MATERIAL: 4130 (RC. 35-38)
T OOL NUMBER SE709 IS AVAILABLE FROM THE CESSNA SUPPLY DMSION.
Figure 11-4. Wrench Adapter Fabrication a . Set the throttle stop screw to obtain between 575 and 625 rpm, with throttle control pulled full out against idle stop. NOTE Engine idle speed may vary among dillerent engines. An engine should idle smoothly, without excessive vibration and the idle speed should be high enough to maintain idling oil pressure and to preclude any possibility of engine stoppage in flight when the thrott.le.is closed.
NOTE After each adjustment to the idle mixture, run engine up to approximately 2000 rpm to clear engine of excess fuel to obtain a correct idle speed. 11-44. ELECTRIC FUEL PUMP CIRCUIT. Refer to Section 16. 11-45. AUXILIARY ELECTRIC FUEL PUMP FLC!N RATE ADJUSTMENT. Refer to Section 12. 11-46. INDUCTION AIR SYSTEM.
b. Advance throttle to incrnse engine speed to 1000 rpm. c. Pull mixture control knob slowly and steadily toward the idle cut-of! position, obser.ving tacho meter, then return control full IN (RICH) position before engine stops. d. Adjust mixture adjusting screw at upper end of carburetor intake throat to obtain a sli.ght and mo mentary gain of 50 rpm maximum at 1000 rpm en gine speed as ·mixture control is moved from full IN (RICH) toward idle cut-off position. Return con trol to full IN (RICH) to prevent engine stoppage. e. If mixture is set too LEAN, engine speed Will stop immediately, thus requiring a richer mixture. Turn adjusting screw OUT (counterclockwise) for a richer mixture. f. If mixture is set too RICH, engine speed will increase above 50 rpm, thus requiring a leaner mixture. Turn adjusting screw IN (clockwise) for a leaner mixture.
NOTE Following instructions are applicable to aircraft serials thru 18800832. Beginning with aircraft serial 18801375 airbox is nonremovable. 11·47. DESCRIPTION. Ram air enters the induc tion air system through a filter at the front of the low~r cowling and is ducted to the a.irbox at the car buretor. A butterfly valve, located in the alrbox, may be operated manually from the cockpit to per mit the selection of either cold or heated air. When the induction air door is closed, heated air is drawn from a shroud on the left exhaust stack assembly·.
11-48. AmBOX REMOVAL AND INSTALLATION. a. Remove lower engine cowling in accordance with paragraph 11- 3. Revision 1
11-17
MODEL 188 & T188 SERIES SERVICE MANUAL
I
/
.
.
THESE CONTACT POINTS ARE USABLE
THESE CONTACT POINTS NEED REPLACEMENT
Figure 11-6. Magneto Contact Breakez: Points
-b. Disconnect flexible duct from left side of airbox. c. Disconnect boot from forward end of airbox. d. Disconnect carburetor heat control at arm on right side of airbox and remove clamp securing con trol to airbox. _e..!... . ~~!'ve_ m<?_unting .~!t_ ~ety. V1r_e, ~e~ov~ . _ _ bolts and gasket, remove th~ breather line mounting strap and carefully remov~ a.lrbox. f . Reverse the preceding steps for reinstallation. Rig carburetor beat control in accordance with para graph 11-70. ll-49. CLEANING AND INSPECTION. Clean and parts of the induction air box with Stoddard solvent or equivalent. Inspect for cracks, dents, loose rivets, etc. Minor cracks miy be stop"..di-illed. In case of continued or severe cracking, replace air box. Inspect gaskets and install new gaskets, if dam aged. Check manually-operated air door for ease of operation and proper riggin_g. 11-50. INDUCTION AIR FILTER. 11-51. DESCRIPTION. An induction air filter, mounted at the induction air inlet on the front of the lower eowlin.g , removes dust particles from the ram air entering the engine. 11-52. REMOVAL AND INSTALLATION. a • . (THRU AIRCRAFT SERIAL 18800572) Cut safety wire securing wing nuts and unscrew nuts ap proximately 1/4 inch. b. Unhook bolts !rom n..ount and remove filter with bolts and nuts attached. c . (BEGINNING WITH AIRCRAFT SERIAL 18800573) Cut safety wire securing wing nuts and unscrew nuts complete! y. d. Remove washers and lift filter free of bolts. e. Reverse the preceding steps for reinstallation. When tightening wing nuts, do not crush filter. Safe ll-18
Revision
1
ty wire nuts together to prevent them from loosening. 11-53. CLEANING AND INSPECTION. Clean and inspect in aceordanee with instructions 1n Section 2.
11-54. IGNITION SYSTEM. 11-55. DESCRIPTION. The Ignition system is comprised of two magnetos, two spark plugs in each cylinder, ignition wiring barness, two toggle switches mounted on the instrument panel and required wiring between the toggle switches and magnetos. · I
11-56. MAGNETQ). 11-57. DESCRIPTION. The magnetos contain a con ventional two-pole rotating magnet (rotor), mounted in ball bearings. Driven by the engine through an impulse coupling at one end, the rotor shaft operates the breaker points at the other end of the shaft. The nylon rotor gear drives a nylon distributor gear which transfers high tension current from the wedge-mount ed coil to the proper outlet in the distributor block. A coaxial capacitor is mounted in the distributor block housing to serve as the condenser as well as a radio noise suppr essor. Both nylon gears are provided with timing marks for clockwise or counterclockwise rotation. The distributor gear and distributor block have timing marks, visible through the air vent holes, for timing to the engine. A timing bole is provided ln the bottom of the magneto adjacent to the magneto flange. A timing pin or 6- penny nail can be inserted through this timing hole into the mating hole ln the rotor shaft to lock the magneto approximately in the proper firing position. The breaker assembly is accessible only after removing the screws fastening the magneto halves together and disconnecting the capacitor slip terminal. Do not separate magneto halves while it is inStalled on the engine.
I
MODEL 188 & T188 SERIES SERVICE MANUAL
11-58. REMOVAL. a. Remove engine cowling in accordance with para graph 11-3. b. Tag Cor identification and remove high tension
wires from the magneto being removed.
!WARNING' The magneto is not internally groWlded when the switch wire iS disconnected. Remove the high tension wires from magneto or d.i.s connect spark plug leads from the spark plugs. c. Disconnect switch wire from condenser terminal at magneto. Tag wire for identification so it may be installed correctly. d. Rotate propeller in direction of normal rotation Wllli No. 1 cylinder is coming up on its compression stroke. NOTE To facilitate the installation of a replacement magneto, it is good practice to position the crankshaft at the advanced firing angle for No. 1 cylinder during step "d. " Any standard timing device or method can be used, or if the magneto being removed is correctly timed to the engine, the crankshaft can be rotated to a position at which the breaker points will be just opening to fire No. 1 cylinder. e. Remove magneto retainer clamps, nuts and washers and pull magneto from crankcase mounting pad. NOTE As the magneto is removed from its moWlt ing, be sure that the drive coupling rubber buslting and retainer do not become dislodged from the gear hub and fall into the engine. NOTE For inspection of impluse coupling on aircraft serials 18800001 THRU 18801707, refer to Cessna Single engine Service Letter SE74-21, dated September 27, 1974. 11-59. INTERNAL TIMING. a. Whenever the gear on the rotor shaft or the cam (which also serves as the key for the gear) has been removed, be sure that the gear and cam are installed so the timing mark on the gear aligns with the " 0" etched on t he rotor shaft. b. When replacing breaker assembly or adjusting contact breaker points, place a timing pin (or 0. 093 inch 6-penny nail) through the timing hole in the bot tom of the magneto next to the flange and into the mating hole in the rotor shaft. Adjusting contact breaker points so they are just starting to open in this position will give the correct point setting. Tern
porarily assemble the magneto halves and capacitor
slip terminal and use a timing light to check that the
timing marks, visible through the ventilation plug
holes are approximately aligned.
NOTE The side of the magneto with the manufac turer's insignia has a red timing mark and the side opposite to the insignia has a black timing mark viewed through the vent plug holes. The distributor gear also has a red timing mark and a black timing mark. These marks are used for reference only when in stalling magneto on the engine. Do not place red and black lines together on the same side. c. Whenever the large distributor gear and rotor gear have been disengaged, they must be engaged with their timing marks aligned for correct rotation. Align the timing mark on the rotor gear with the "RH" on the distributor gear. Care must be taken to keep these two gears meshed in this position until the magneto halves are assembled. 11-60. INSTALLATION AND TIMING TO ENJINE. The magneto must be installed with its timing marks correctly aligned and with the number one cylinder on its compr ession stroke with number one piston at its advanced firing position. Refer to paragraph 11-8 for the advanced firing position of number one piston.
IWARNING. The magneto is grounded through the magneto toggle switch, therefore, any time the switch (primary) wire is disconnected from the mag neto, the magneto is in a switch ON or HOT condition. Before turning the propeller by hand, remove the high tension wires from the magneto or disconnect all spark plug leads to prevent accidental firing of the engine. To locate the compression stroke of number one cy linder, remove the lower spark plugs from each cy linder except number one cylinder. Remove the top plug from number one cylinder. Place thumb of one hand over the number one cylinder spark plug hole and rotate the crankshaft in the direction of normal rotation Wlill the compression stroke is indicated by positive pressure inside the cylinder lifting the thumb off the spark plug hole. After the compression stroke is obtained, locate number one piston at its advanced firing position. Locating the advanced firing position of number one cylinder may be obtained by use of a timing disc and pointer, Timrite, protractor and piston locating gage or external engine timing marks alignment. NOTE External engine timing marks are located on a bracket attached to the starter adapter, with a timing mark on the alternator drive pulley as the reference point.
11-19
MODEL 188 & T188 SERIES SERVICE MANUAL
In all cases, it must be definitely determined that the number one cylinder is at the correct firing position, on the compression stroke, when the crankshaft is turned in its normal direction of rotation. After the engine has been placed in the correct firing position, install and time the magneto to the engine in the fol lowing manner.
NOTE Install the magneto drive coupling retainer and rubber bushings into the magneto drive
gear hub slot. Insert the two rubber bush ings into the retainer with the chamfered edges facing toward the front of the engine. a. Turn the magneto shaft until the timing marks Visible through the ventilation plug holes are aligned (red-to-red or black-to-black) and insert a timing pin (or 0. 093 inch 6-penny nail) through the timing hole in the bottom of the magneto next to the flange and into the mating hole in the rotor shaft. This locks the magneto approximately in the firing posi tion whlle installing on the engine. NOTE If the magneto drive gear was disengaged during magneto removal, hold the magneto in the horizontal position it will occupy when installed, make certain that the drive gear coupling slot is aligned with the magneto coupling lugs. If it is not aligned, pull the magneto drive gear out of mesh with its drive gear, and rotate it to ai& aligned angle, then push it back into mesh. DO NOT WITH DRAW THE MAGNETO DRIVE GEAR FROM ITS OIL SEAL.
b. After magneto gasket is in place, position the magneto on the engine and secure, then remove the timing pin from the magneto. Be sure to remove this pin before turning the propeller. c. Connect a timing light to the capacitor terminal at the front of the magneto and to a good ground. · d. Turn propeller back a few degrees to close the contact points. NOTE Do not turn the propeller back far enough to engage the impulse coupling or the propeller will have to be turned in normal direction of rotation until the impulse coupling releases, then backed up to slightly before the firing position.
fire at the same time. i. Remove timing devices from magneto and engine j. Connect spark plug leads to their correct mag neto outlets. NOTE The No. 1 magneto outlet is the one closest to the ventilation plug on the side of the magneto haVing the manufacturer's insignia. The magneto fires at each successive outlet in clockwise direction. Connect No. 1 magneto outlet to No. 1 cylinder spark plug lead, No. 2 outlet to the next cylinder to fire , etc. Engine firing order is listed in paragraph 11-8. k. Connect toggle switch (primary) lead to the ca
pacitor terminal on the magneto.
1. Inspect magneto installation and install engine
cowling in accordance With paragraph 11-3.
11-61. MAINTENANCE. At the first 25-hour in spection and at each 100-hour inspection thereafter, the breaker compartment should be inspected. Mag neto-to-engine timing should be checked at the first 25-hour inspection, first 50-hour inspection, first 100-hour inspection and thereafter at each 100-hour inspection. U timing is 22° (plus zero, minus 2°), internal timing need not be checked. If timing is out of tolerance, remove magneto and set internal timing, then install and time to the engine. In the event the magneto internal timing marks are off more than plus or minus five degrees when the breaker points open to fire number one cylinder, remove the magneto and check the magneto internal timing. Whenever the magneto halves are separated the breaker point as sembly. should always be checked. As long as inter nal timing and magneto-to-engine tirping are Within the preceding tolerances, it is recommended that the magneto be checked internally only at 500 hour inter vals. It is normal for contact points to burn and the cam to wear a comparable amount so the magneto wUl remain in time within itself. This is accom plished by having a good area making contact on the surface between the points and the correct amount of spring pressure on the cam. The area on the points should be twenty-five percent of the area making contact. The spring pressure at the cam should be 10. 5 to 12. 5 ounces. When the contact points burn, the area becomes irregular, which is not detrimental to the operation of the points unless metal transfer is too gr eat which will cause the engine to misfire. Figure 11-6 illustrates good and bad contact points. A small dent will appear on the nylon i nsulator be tween the cam follower and the breaker bar. This is normal and does not requlre replacement.
e. Slowly advance the propeller in normal direction of rotation until timing light indicates the position of
NOTE
contact point breaking. Magneto mounting clamps may be loosened so that the magneto may be shifted to break the points at the correct firing position. f. Tighten magneto mounting nuts, recheck timing. g. Repeat steps "a" through "f" for the other mag neto. h. After both magnetos have been timed, check synchronization of both magnetos. Magnetos must
If ignition trouble should develop, spark plugs and ignition wiring should be checked first . U the trouble definitely is associated with a magneto, use the following to help ttisclose the source of trouble without overhauling the magneto.
11-20
MODEL 188 8t T188 SERIES SERVICE MANUAL
a. Moisture Check. 1. Remove magneto from engine and remove
screws securing the magneto halves t ogether, dis
connect capacitor slip terminal and remove distrib
utor. Inspect for moisture.
2. Check distributor gear finger and carbon
brush for moisture.
3. Check breaker point assembly for moisture,
espec ially on the surfaces of the breaker points.
4 . If any moisture is evident in t he preceding places , wipe with a soft, dry, clean, lint-free cloth. b. Breaker Compartment Check. 1. Check all parts of the breaker point assem
bly for security.
2. Check breaker point surfaces for evidence of e xcessive wear, burning, deep pits and carbon deposits. · Breaker points may be cleaned with a hard-finish paper. If breaker point assembly is de fective, install a new assembly. Make no attempt to st one or dress the breaker points. Clean new breaker points with clean, unleaded gasoline and hard-finish paper before installing. 3. Check capacitor mounting bracket for cracks or looseness. 4. Check the carbon brush on the distributor gear for excessive wear. The brush must extend a minimwn of 1/ 32 inch beyond the end of the gear shaft. The spring which the carbon brush contacts should be bent out approximately 20 degrees from vertical, since spring pressure on the brush holds the distributor gear shaft against the thrust bearing in the distributor cap. 5. Oil the bearings at each end of the distributor gea r s haft with a drop of SAE 20 oil. Wipe excess oil from parts. 6. Make sure internal timing is correct and re assemble magneto. install and properly time mag neto to engine. 11-62. MAGNETO CHECK. Advanced timing set tings in some cases, i s the result of the erroneous practi ce of bumping magnetos up in timing in order to reduce RPM drop on single ignition. ~VER AD VANCE TIMING BEYOND SPECIFICATIONS IN OR DER TO REDUCE RPM DROP. Too much impor tance is being attached to RPM drop o n single ignition. RPM drop on single ignition is a natural character i s tic of dual ignition design. The purpose of the fol lowing magneto check i s to determine that all cylin de rs are firing . If all cylinders are not firing, the engine will run extremely rough and cause for investi gation will be quite apparent. The amount of RPM drop i s not necessarily significant and will be influ enced by ambient air temperature, humidity, airport altitude, etc . In fact , absence of RPM drop should be caus e for suspicion that the magneto timing has been bumped up a nd is set in adva nce of the setting specified. Magneto check s s hould be perfo rmed on a comparative ba s is between individual r ight and left magneto pe rformance. a . Start and run engine until the oil and cylinder head te mperature is in the normal ope rating r ange . b. Place the pr opelle r control in the full low pitch (high rpm) po sition.
c. Advance engine speed to 1700 rpm. d. Turn the ignition switch to the "R" position and note the rpm drop, then return the switch to the " BOTH" position to clear the opposite set of plugs. e . Turn the switch to the "L" position and note the rpm drop, then return the switch to the "BOTH" position. f . The rpm drop should not exceed 150 rpm on either magneto of show greater than 50 rpm differ ential between magnetos. A smooth rpm drop-off past normal is usually a sign of a too lean or too rich mixture . A sharp rpm drop-off past normal is usually a sign of a fouled plug, a defective harness lead or a magneto out of time . If there is doubt con cerning operation of the ignition system, rpm checks at a leaner miXture setting or at higher engine speeds will usually confirm whether a deficiency exists. NOTE An absence of rpm drop may be an indication of faulty grounding of one side of the ignition system, a disconnected ground lead at mag neto or possibly the magneto timing is set too far in advance.
11-63. SPARK PLUGS. Two spark plugs are in stalled in each cylinder and screw into hellcoil type thread inserts. The spark plugs are shielded to pre vent spark plug noise in the radios and have an inter nal resistor to provide longer terminal life. Spark plug service life will vary with operating conditions. A spark plug that is kept clean and properly gapped will give better and longer service than one that is allowed to collect lead deposits and is improperly gapped. NOTE At each 100 hour inSpection, remove, clean, inspect and regap all spark plugs. Install lower spark plugs in upper portion of cylin ders and install upper spark plugs in lower portion of cylinders at each 100 hour inSpec tion. Since deterioration of lower spark plugs is usually more rapid than that of the upper plugs, rotating them helps prolong spark plug life. 11-64.
ENGINE CONTROLS.
11-65. DESCRIPTION. The throttle and propeller governor control levers are in the control quadrant mounted to the left of the pilot's seat. The mixture · control is equipped with a position-locking device which prevents vibration- induced "creeping" of the control . The carburetor heat control is located on the lower left side of the instrument panel and has no locking device. On later model aircraft, an addi tional " Palnut" type locknut was installed in back of the existing locknut at the engine end of all throttle and propeller controls that contain rcxi ends .
11-21
MODEL 188 & T188 SERIES SERVICE MANUAL
• BEGINNING WITH AIRCRAFT SERIAL 18800833
3
e spacer (17) replaces propeller control (16) when fixed pit ch p r opeller is in stalled.
n ·/
P
1. Friction Knob ~13 16 2. Index Strip 3. Spacer e 17 13 15 4. Propeller Control Knob 5. Shim 6. Spacer ~ 7. Switch Br acket 8. Plate Assembly 9. Boost Pump Switch (T hr ottle Actuated) 10. End Plate Assembly ll. Hub Assembly 12. Hub Spacer 13. Friction Disc 14. Throttle Control Lever 15. Spacer 16. Propeller Control Lever 17. Spacer 18. Spring 19. Cover 20. Screw
10
••
Salety Wire 10-32 Bolt and Lock Nut, Torque to 35 40 Lb - in.
Figure 11-7. Control Quadrant and Throttle Arm to Idle Stop Attachment 11-22
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Some controls have intricate parts that will fall out and possibly be lost if the control is pulled from the housing while the control is disconnected. 11-66. RIGGING. When adjusting any engine control, it is important to check that the control slides smooth ly throughout its full range of travel, that it locks se curely if equipped with a locking device and that the arm or lever it operates moves through its full arc of travel.
!CAUTION ! Whenever engine controls are being discon nected, pay particular attention to the exact position, size and number of attaching washers and spacers. Be sure to install attaching parts as noted when coMecting controls. 11-67. THROTTLE CONTROL. a. DiscoMect throttle control rod end from throttle arm on carburetor. Note EXACT position and size of bolt and washers for reference on reinstallation. b. In the cockpit, move throttle control lever full forward , then pull lever aft approximately 1/8-inch from full forward for cushion and tighten friction con trol knob on quadrant to prevent movement of lever. c. Move throttle control arm on the carburetor to full OPEN position (against stop), adjust rod end on throttle control to align with arm and install attaching bolt and washers. d. Release friction lock and check for full travel of arm on carburetor.
NOTE The result of rigging, in all cases, is the
throttle control must be rigged so that the
control arm on the carburetor contacts the
mechanical stops in both directions, that
the throttle lever has approximately ' 1/8 inch cushion at the control quadrant when
in full OPEN position and that the small
retaining ring on some controls, contacts
the end of the control housing at the same
time the idle stop is reached.
• Refer to the inspection chart in Section 2
for inspection, lubrication and/or replace
ment interval for the throttle control.
11-68. MIXTURE CONTROL. a. Push mixture control full IN, unlock and pull control OUT approximately 1/ 8-inch for cushion.
b. Loosen clamp securing control to engine. c. Shift control housing in its clamp so that the
mixture arm on the carburetor is full open (FULL
RICH). Tighten the clamp in this position.
d. Unlock and pull control full OUT. Check that mixture arm on carburetor is full closed (IDLE CUT· OFF). e. Check that the bolt and nut at the mixture arm on the carburetor secures the control wire and that the bolt will swivel in the arm. f. Bend the wire tip· 90 degrees to prevent wire
from being withdrawn if the locking nut should be
come loose.
NOTE When installing a new contr ol, it may be
necessary to shorten the wire and/ or
housing. The mixture arm on the car
buretor must contact the stops in each
direction and the control should have
approximately 1/8-inch cushion when
pushed full in.
• Refer to the inspection chart in Section 2
for inspection, lubrication and/ or replace
ment interval fo r the mixb.lre control.
11-69. PROPELLER CONTROL. Refer to Section 13 for rigging propeller and governor control. 11-70. CARBURETOR HEAT CONTROL. a. Loosen clamp securing control to the bracket on alrbox. b. Push control full in, then pull it out approxi mately 1/8 inch from panel for cushion. c. Shift control housing in its clamp so that the valve in the airbox is seated in the full open position. Tighten clamp in this position. d. Pull out on the control and check that the air valve inside the airbox seats in the opposite direction e. Check that the bolt and nut on the air valve lever secures the control wire and that the bolt will swivel in the lever. f . Bend the wire tip 90 degrees to prevent it from being withdrawn if the attaching nut should become loose. NOTE When installing a new control, it may be nec essary to shorten the wire and/ or control housing. The air valve must seat 1n both positions and the control should have approxi mately 1/8 inch cushion at the instrument panel when pushed full in. • Refer to the inspection chart in Section 2
for inspection, lubrication and/or replace
ment for the carburetor heat control.
11-23
MODEL 188 & T188 SERIES SERVICE MANUAL
11-71. STARTING SYSTEM. 11-72. DESCRIPTION. The aut omatically- engaged starting system employs an electrical starter motor mounted to a 90-degree adapter. A star ter solenoid is activated by a push-button on the instrument panel.
When the solenoid is"activated, its contacts close and electr ical current ener gizes the motor . Initial rota tion of the motor engages the starter through a n over running clutch in the starter adapt er, which incorpo rates worm reduction gears. The starter motor is located just aft of the right rear cylinder.
11 - 73. TROUBLE SHOOTING. TROUBLE STARTER WILL NOT OPERATE.
STARTER MOTOR RUNS, BUT DOES NOT TURN CRANKSHAFT.
PROBABLE CAUSE Defective master switch or circuit.
Install new switch or wires.
Defective starter switch or switch circuit.
Install new switch or Wir es.
Defective starter motor.
Repair or replace starter mot or.
Defective overrunning clutch or drive.
Install new starter adapt e r .
Starter motor shaft broken. STARTER MOTOR DRAGS.
STARTER EXCE SSIVELY
REMEDY
. Install new starter motor.
Low battery.
Charge or install new battery.
Starter switch or relay contacts burned or dirty.
Install s erviceable unit.
Defective starter motor power cable.
Install new cable.
Loose or dirty connections.
Remove, clean and tighten all terminal connections.
Defective etarter motor.
Check starter motor brushes, brush spring t ension, thrown solder on brush cover. Repair or install new starter motor.
Dirty or worn commutator.
Clean and turn commutator .
Worn starter pinion.
Replace starter dr ive .
Worn or broken teeth on crankshaft gears.
Replace crankshaft gear.
~OISY.
11 -24
MODEL 188 & T188 SER IES SERVICE MANUAL
11-75. REMOVAL AND INSTALLATION.
pit. The tailpipe is welded to the muffler. A shroud is attached to the left exhaust stack to provide heated air for the alternate induction air source.
a. Remove engine cowling in accordance with para graph 11-3.
11-79. REMOVAL AND INSTALLATION.
11-74. STARTER MOTOR.
I ~AUTION I When disconnecting starter electrical cable, do not permit terminal bolt to rotate. Ro tation of the bolt could br eak the conductor between bolt and field coils causing the starter to be inoperative. b. Disconnect battery cables and insulate as a
safety precaution.
c. Disconnect electrical cable at $rter motor. d. Remove nuts and washers secui.ing motor to starter adapter and remove motor. ffiefer to engine manufacturer's overhaul manual for adapter removal. e. Reverse the preceding steps for reinstallation. Install a new o- ring seal on motor, then install motor. Be sure motor drive engages with the adapter drive when installing. 11-76. PRIMARY MAINTENANCE . . The starting circuit should be inspected at regular intervals, the frequency of which should be determined by the amount of service and conditions under which the equipment is operated. Inspect the battery and wir ing. Check battery for fully charged condition, proper electrolyte level with approved water and terminals for cleanliness. Inspect wiring to be sure that all connections are clean and tight and that the wiring insulation is sound. Check that the brushes slide freely in their holders and make full contact on the commutator. When brushes are worn to one-half of their original length, install new brushes (compare brushes with new brushes). Check the commutator for uneven wear, excessive glazing or evidence of excessive arcing. If the commutator is only slightly dirty, glazed or discolored, it may ~e cleaned with a strip of No. 00 or No. 000 sandpaper. If the commu tator is rough or worn, it should be turned in a lathe and the mica undercut. Inspect the armature- shaft for rough·bearing surfaces. New brushes should be properly seated when installing by wrapping a strip of No. 00 sandpaper around the commutator (with sanding side out) 1-1/4 to 1-1/2 times maximum. Drop brushes on sandpaper covered commutator and turn armature slowly in the direction of normal ro tation. Clean sanding dust from motor after sanding operations.
11-77. EXHAUST SYSTEM. 11-78. DESCRIPTION. The exhaust system consists of two exhaust stack assemblies, for the left and right bank of cylinders. Each cylinder has a riser pipe
attached to the exhaust port. The three risers at each bank of cylinders are joined together into a collector pipe forming an exhaust stack assembly. The center riser on each bank is detachable, but the fr ont and aft risers are welded to the collector pipe. Each exhaust stack assembly connects to the muffler beneath the engine. The muffler is enclosed in a shroud which captures exhaust heat which is used to heat the cock
a. Remove engine cowling in accordance with para graph 11-3. -b. Disconnect ducts from heater shroud on muffler assembly. c. Disconnect duct from carburetor heat shroud on left exhaust stack assembly. NOTE On serials 188-0001 and ON, if equipped with ·sK182-78 kit, the carburetor heat shroud is attached to the engine mounts and must be removed before removing the exhaust system.
d. Remove nuts, bolts and clamps attaching stack
assemblies to the mufller.
e. Loosen nuts attaching exhaust stacks to the
cylinders and remove muffler assembly.
f. Remove nuts attaching exhaust stack assemblies to the cylinders and remove exhaust stacks and gas kets. g. Reverse the preceding steps for reinstallation. . Install a new copper-asbestos gasket between each riser and its mounting pad on each cylinder, regard less of apparent condition of those removed. Torque exhaust stack nuts at cylinders to 100-110 pound inches. 11-80. INSPECTION. Since exhaust systems of this type are subject to burning, cracking and general deterioration from alternate thermal stresses and vibrations, inspection is important and should be accomplished every 100 hours of operation. Also, a thorough inspection of the engine exhaust system should be made to detect cracks causing leaks which could result tn loss of engine power. To inspect the engine exhaust system, proceed as follows: a. Remove engine cowling as required so that ALL surfaces of the exhaust assemblies can be visually inspected. NOTE Especially check the areas adjacent to welds and slip joints. Look for gas deposits tn sur rounding areas, Indicating that exhaust gases are escaping through a crack or hole or around the slip joints. b. After visual inspection, an air leak check s!tould' be made on the exhaust system as follows: 1. Attach the pressure side of an industrial vacuum cleaner to the tailpipe opening, using a rub ber plug to effect a seal as r equired. NOTE The inside of the vacuum cleaner hose should be Cree of any contamination that might be blown into the engine exhaust system.
Revision 1
11-25
MODEL 188 8t T188 SERIES SERVICE MANUAL
7
1. 2. 3. 4. 5. 6. 7.
Tailpipe Clamp Half Stack Assembly Riser Shroud Cabin Heat Wet Muffler Weld Assembly 8. Clamp 9. Support 10. Ball-joint
BEGINNING WITH AIRCRAFT SERIALS 18800797, 18800799, 18800800, 18800802, 18800805 T HRU 18802706 AND 188027 10.
Detail
NOTE
When cabin heating system is not tnstalled, cabtn heater duct is routed overboard to help cool the muffler.
Figure 11-8. 11-26
A
MINIMUM CLEARANCE BE1WEEN EXHAUST STACK AND COWL TO BE . 62 "
Exhaust System (Sheet 1 of 2)
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
8
Beginning Serial 18802707
BEGINNING WITH AIRCRAFT SERIAL 18802707 THRU 18802709 AND 18802711 AND ON. Detail
Detail
A
C
Figure 11-8.
E~ust
2. With vacuum cleaner operating, all joints
in the exhaust system may be checked manually by
feel, or by using a s oap and water solution and
watching fo r bubbles. All joints should be free of
air leaks.
NOTE
Begining with aircraft serials 18800833 the ball joint should be inspected in ac足 c ordance with Cessna Single Engine Service Letter SE 78-42 . 11-81. EXTREME WEATHER MAINTENANCE. 11-82. COLD WE ATHER. Cold weather s tarting will be made easier by the installation of an engine primer system and a groWld service receptacle.
System (Sheet 2 ol 2)
The primer system is manually-operated from the cockpit. Fuel is supplied by a line from the fuel strainer to the plUDger. Operating the primer for~es fuel to the intake valve port of each cylinder. With an external power receptacle installed, an external power source may be connected to assist in cold weather or low battery starti.og. Refer to paragraph 11-85 for use of the external power receptacle. The following may also be used to assist engine start足 ing in extreme cold weather. After the last flight of the day, drain the engine oil into a clean container so the oil can be preheated. Cover the engine to pre足 vent ice or snow fr om collecting inside the cowling. When pr eparing the aircraft for flight or engine run足 up after these conditions have been followed , preheat the drained eggine oil.
Revision 1
11-27
MODEL 188 & T188 SERIES SERVICE MANUAL
!WARNING' Do not heat the oil above 121 °C (250° F). A flash fire may result. Before pulling the propeller through, ascertain that the mag neto toggle switches are in the OFF position to prevent accidental firing of the engine. Alter preheating the engine oil, gasoline may be mixed with the heated oil in a ratio of 1 part gasoline to 12 parts engiile oil before pouring into the engine oil sump. I! the free air temperature is below minus 29 °C (- 20 oF). the erurtne compartment should be pre heated by a ground heater. Pre-heating the engine compartment is accompllshed by inducing heated air up through opening in lower cowl assembly; thus heat Ing both the oil and c ylinders. Alter the engine com partment has been preheated, inspect all engine drain and vent lines for presence of ice. Alter this proce :iure has been complied with, pull propeller through several revolutions by hand before attempting to start the engine .
Due to the desludging effect of the diluted o ll, engine operation should be observed c losely during the initial warm-up of the engine . Engines that have considerable amount of operational hours accumulated s ince their last dilution period may be seriously affected by the dilution process. This will be caused by the diluted oil dis lodging sludge and carbon deposits within
11-28
Revision
1
the engine . This residue will collect in the oil sump and possibly clog the screened inlet to the oil sump. Small deposits may actually enter the oil pump and be trapped by the main oil filter scr een. Partial or complete loss of engine lubrication may r~~lt from either condition. If these con dttlons are anticipated after oil dilution, the e ngine should be run for seve ral min utes at normal operating temperatures and then stopped and inspected for evidence of sludge and carbon deposits in the oil sump and o ll filter screen. Future occurrence of this condition can be prevented by diluting the oil prior to each engine oil change. This will also prevent the accumulation of the sludge and cubon deposits. 11-83. SEACOAST AND HUMID AREAS. In salt water areas special care should be taken to keep the engine, accessorie s and airframe clean to pre vent oxidation. In humid areas, fuel and oil should be checked frequently and drained of condensation to prevent corrosion.
11-84. DUSTY AREAS. Dust induced Into the intake system of the engine is pr obably the greatest single cause of early engine wear. Whe n operating in high dust conditions, service the induction air fllter da ily as outlined in ·Section 2. Also change engine oil and lubricate airframe items more often than specified. 11 - 85. GROUND SERVICE RECEPTACLE. Refer to Section 16.
)
) )
MODEL 188 & T188 SERIES SERVICE MANUAL
SECTION llA
ENGINE
(FUEL INJECTED)
!WARNING. When performing any inspection or mainte nance that requires turning on the master switch, installing a battery, or pulling the propeller through by hand, treat the propel ler as if the ignition switch were ON. Do not stand, nor allow anyone else to stand, within' the arc af the propeller, since a loose or broken wire, or a component mal function, could cause the propeller to rotate.
TABLE OF CONTENTS
Page No. Aerollche/Manual
. 1J2/11A-2 ENGINE COWLING . . .
Description . . . .
. 1J2/11A-2 . 1J2/11A-2 Removal and Installation
Cleaning and Inspection
. 1J2/11A-2 Repair . . . . . . . .
. 1J2/11A-2 . 1J2/11A-2 ENGINE . . . . . . . . . . . 1J2/11A-2 Description . . . . . . Time Between Overhaul (TBO) . . 1J2/UA-2 . 1J2/11A-2 Overspeed Limitations . 1J2/11A-2 Engine Data . .
. 1J4/11A-4 Trouble Shooting . . .
. 1J6/11A-6 Removal . . . . . . .
. 1J7/11A-7 Cleaning . . . . . . .
. 1J7/11A-7 Accessories Removal .
. 1J7/11A-7 Inspection . . . . . .
Build-Up . . . . . .
. 1J7/11A-7 . 1J7/11A-7 Installation . . . . .
Pivoting Engine !or Maintenance . 1J8/11A- 8 . 1J8/11A-8 Flexible Fluid Hoses
. 1J8/11A-8 Pressure Test . 1J8/UA-8 Replacement
. lJS/llA-8 Engine Baffles . . .
. 1J8/11A-8 Engine Mount . . .
Removal and Installation . 1J8/11A-8 Preparations !or Swing Mount . 1J8/11A-8 Usage . . . . . . . . . Swing Mount Attachment to Flrewall . . . . . . . . lJll /llA-11 . lJll/llA-11 ENGINE SHOCK-MOUNT PADS . 1J11/11A·ll ENGINE OIL SYSTEM Description . . . . .
. lJU/llA-11 . 1Jll/11A-11 Trouble Shooting . . .
. lJll/llA-11 FULL FLOW OIL FILTER Description . . . . . . lJll/llA-11 Removal and Installation . lJU/itA-11 ENGINE FUEL SYSTEM. . . . 1Jll/11A-ll Description . . . . . . . lJll/llA-11 Fuel-Air Control Unit . 1Jl3/11A-13 Removal and Installation . 1Jl3/11A-13 Cleaning and Inspection . 1J13/11A-13 Adjustments . . . . . . . 1Jl3/11A-13
Rigging Throttle Operated Microswitcb . . . . . Electric Fuel Pump Circuit Auxiliary Electric Fuel Pump Flow Rate Adjustment Fuel Manifold Valve Removal . . . . . Cleaning . . . . . . Installation . . . Fuel DU!charge Nozzles . Removal. . . . . . Cleaning and Inspection . Installation . . Fuel Injection Pump
Removal
Installation . .
Adjustment . .
INDUCTION AIR SYSTEM . Description . . . . . Alrbox Removal and Installation Cleaning and Inspection . Installation of' Inlet Duct . Inductio'l Air Filter . . . Alternate Air Control . Rigging . . . . IGNITION SYSTEM . ENGINE CONTROLS . . Description . . . . Rigging . . . . . . Throttle Control Mixture Conlrol Propeller Control Alternate Alr Control . STARTING SYSTEM . . . . EXHAUST SYSTEM . . . . Description . . . . . . . Removal and Installation . Inspection . . . . . . . . . . . EXTREME WEATHER MAlNTENANCE Cold Weather . . . . . . Seacoast and Humid Areas . Dusty Areas . . . . . . . Ground Service Receptacle
. 1J13/11A-13 . 1J13/11A-13 . 1J13/11A-13 . 1J13/UA-13 . 1J13/11A-13 · . 1Jl3/11A-13 . lJlS/llA-15 . 1J15/11A-15 . 1Jl6/11A-16 . 1Jl6/UA-16 . 1J16/11A-16 . 1J16/11A-16 . 1Jl6/11A-16 . 1J16/11A-16 . lJ'lS/llA-16 . 1J18/11A-18 . 1J18/11A-18 . lJlS/llA-18 . lJlS/UA-18 . 1J18/ 11A-18 . 1J18/ 11A-l8 . 1Jl8/11A-18 . . 1J19/ 11A-19 . 1J19/UA-19 . 1Jl9/UA-19 . 1J19/11A-19 . 1J19/11A-19 . 1J19/UA-19 . 1J20/11A-20 . lKS/llA-29 . 1K5/ 11A-29 . 1K5/UA-29 . 1K5/11A-29 . 1K5/11A-29 . 1K5/11A-29 . 1K6/11A-30 . 1K6/11A-30 . 1K6/11A-30 . 1K6/11A-30 . 1K6/11A-30 . 1K6/11A-30
Revision 1
I
llA-1
u
MODEL 188 & T188 SERIES SERVICE MANUAL
v llA-1.
ENGINE COWLING.
llA-2. DESCRIPTION.
(Refer to Section 11).
llA-3 . REMOVAL AND INSTALLATION. NOTE
On aircraft serials 18801375 THRU 18801750 when the new solid rubber fo rward engine shock mounts are installed, refer to Cessna Single- Engine Service Letter SE75-4, dated January 31, 1975. a. (ALL AIRCRAFT). Unfasten the quick- release fasteners along aft end and sides to remove upper cowling section. b. (THRU AIRCRAFT SERIAL 18800832). Remove plate at aft end of lower cowling section and disconnect air intake boot at airbox. c . (BEGINNING WITH AIRCRAFT SERIAL 18800833) . Remove plate at aft end of lower cowling section , disconnect alternate air rod assembly at alternate air door- arm ball joint, loosen clamp securing hose to adapter, slide hose from adapter flange and disconnect landing light wires at quick disconnects. d. (ALL AIRCRAFT). Unfasten the quick-release fasteners along aft end and carefuliy remove lower cowling section. e. Reverse the preceding steps for reinstallation. Ensure the vertical baffle seals are folded forward and the side baffle seals are folded upward. llA-4. CLEANING AND INSPECTION. Refer to Section 11.
llA-5.
REPAIR. (Refer to Sectlon 11).
llA-6. ENGINE. llA-7. DESCRIPTION . The fuel-injected engine is "' an air-cooled, horizontally-opposed, direct- drive, six-cyllnder Continental I0-520 series engine. The cyllnders, numbered from rear to front, are stagge.._, ed to permit a separate throw on the crankshaft for each connecting rod. The right rear cylinder is l.J number 1 and the cylinders on the right side are identified by odd numbers 1, 3 and 5. The left rear '-" cyllnder is number 2 and the cylinders on the left side are identified as numbers 2, 4 and 6. Fo r repau:" and overhaul of the engine , accesso ries and propell~ refer to the applicable piblic ation issued by the mam· factUrer of these items . These publications are avan-1 able from the Cessna Supply Division.
""'"'
11A-7A. TIME BE1WEEN OVERHAUL (TEO). Tel.._,. dyne Continental Motors recommends engine overhaul at 1200 hours operating time for the 10-520-D series engines employed in spraying or dusting operations. Refer to Continental Aircraft Engine Service Bulletin......, M81-22 , and to any superseding bulletins, r evisions "-., or supplements thereto, for further recommendations. At the tlme of overhaul, e~ine accessories should b.....,. overhauled. Refer to Section 13 for propeller and governor overhaul periods. G 11A-7B. OVERSPEED LIMITATIONS. The engine must not be operated above specified muimum contlnuous RPM. However, should inadvertent over speed occur, refer to Continental Aircraft Engine \.) Service Bulletin M75-16, and to any superseding bulletins, revisions or supplements thereto, for further recommendations.
v
u
llA-8. ENGINE DATA.
'-'
Aircraft
A188 AGwagon, A188 AGwagon A, A188A Agwagon B, A188B AGwagon C, A188B AGtruck
Model (Continental)
I0-520-n
BHP Maximum for Take-Off (5 Minutes) at RPM BHP Maximum Except Take-Off RPM (Max. Continuous)
300 2850 285. 2700
Static RPM Model A 188B (Controllable pitch
2800 RPM (Refer to paragraph 11-10 for details)
Number of Cylinders
6-Horizontally Opposed
Displacement Bore Stroke
520 Cubic Inches 5. 25 Inches 4. 00 Inches
u
Compression Ratio
8 . 5:1
u
llA-2
Revision
1
u ()
v
u
MODEL 188 & T188 SERIES SERVICE MANUAL
Magnetos Right Magneto
Left Magneto
Slick No. 662 thru 1979 Models
Slick No. 6210 beginning with 1980 Models
Fires 22° BTC, Lower Left, Upper Right
Fires 22° BTC, Upper Left, Lower Right
Firing Order
1-6-3- 2- 5-4
Spark Plugs
18mm (Refer to Continental Service Bulletin M77-10 for factory approved spark plugs and required gap) 330±30 LB-IN.
Torque Fuel Metering System Unmetered Fuel Pressure Nozzle Pressure Fuel
Grade - Minimum
Continental Fuel Injection 9. 0 to 11.0 PSI at 600 RPM 31.0 to 33.0 PSI at 2850 RPM 3. 5 to 4. 0 PSI at 600 RPM 17.5 to 18.5 PSI at 2850 RPM Aviatton lOOLL/100 Grade
(115/145 Aviation Gr ade With Lead
Content Limited To A Maximum of
4. 6cc Tetraethyl Lead Per Gallon).
Alternator
14-Volt, 60-Ampere
28-Volt, 60-Ampere
Starter
14-Volt, Automatic Engagement
24-Volt, Automatic Engagement
Oil Sump Capacity With External Filter
12 U.s. Quarts
13 U.S. Quarts
Tachometer
Mechanical Drive
Oil Pressure (PSI) Normal Minimum Idling Maximum (Cold Oil Starting) Connection Location
30 to 60
10
100
Between No. 2 and No. 4 Cylinders
Oil Temperature Normal Operating Maximum Probe Location
Within Green Arc
Red Line (240° F)
Below Oil Cooler
C ylinder Head Temperature Normal Operating Maximum Thermocouple Location
Within Green Arc
Red Line (460° F)
Lower Side of Number 1 Cylinder
Lower Side Number 5 Cylinder (Serial 18803047 &: on)
Direction of Crankshaft Ro tation (Viewed !rom Rear)
Clockwise
Dry Weight - With Accessories
474 LB (Weight is Approximate and
Will Vary With Optional Accessories
Installed)
llA-3
MODEL 188 & T188 SERIES SERVICE MANUAL llA-9. TROUBLE SHOOTING. TROUBLE ENGINE FAILS TO START.
PROBABLE CAUSE
REMEDY
Improper use of starting procedure.
Refer to Information Manual
Defective aircraft fuel system.
Refer to Section 12.
Spark plugs fouled.
Remove and clean. Check gaps and insulators . Use new gaskets. Check cables to persistently fouled plugs.
Magneto impulse coupling failure.
Repair or install new coupling.
Defective magneto switch or groWlded magneto leads.
Repair or replace switch and leads.
t---
ENGINE STARTS BUT DIES, OR WlLL NOT IDLE.
llA-4
Defective ignition system.
Refer to paragraph 11-61.
Excessive induction air leaks.
Correct cause of air leaks.
Dirty screen in fuel control unit, or defective fuel control Wlit.
Clean screen. Replace defective fuel control unit.
Defective electric fuel pump.
Refer to Section 12.
Defective fuel manifold valve, or dirty screen.
Remove and clean. Replace if defective.
Clogged fuel injection lines or discharge nozzles.
if defective.
Clean lines and nozzles. Replace
Fuel pump not permitting fuel from auxiliary pump to by-pass.
Replace engine-driven pump.
Vaporized fuel in system.
Refer to Information Manual.
Idle stop screw or idle mixture incorrectly adjusted.
Refer to paragraph llA-37.
Propeller control set in high pitch position (low rpm) .
Use low pitch (high rpm) position for all ground operation.
Air leak in intake manifold.
Tighten loose connections or replace damaged parts.
Spark plugs fouled by oil escaping past piston rings.
Top overhaul engine.
Water in fuel system.
Drain fuel tank sumps, fuel lines and fuel strainer.
Defective ignition system.
Refer to paragraph 11-61.
Dirty screen in fuel control unit. or defective fuel contr ol unit.
Clean screen. Replace fuel contr ol unit if defective.
Defective manifold valve or clogged screen.
Replace if defective . Clean screen.
MODEL 188 8t T1 88 SERIES SERVICE MANUAL llA-9 . TROUBLE SHOOTING (Cont). TROUBLE ENGINE STARTS BUT DIES, OR WILL NOT IDLE (Cont).
ENGINE RUNS ROUGHLY, WILL NOT ACCELERATE PROPERLY, OR LACKS POWER.
POOR IDLE CUT-OFF.
PROBABLE CAUSE
REMEDY
Restricted fuel injection lines or discharge nozzles.
Clean lines and nozzles. Replace if defective.
Defective engine-driven fuel pump.
Replace engine-driven fuel pump.
Vaporized fuel in system.
Refer to Information Manual.
Manual primer leaking.
Repair or replace primer.
Defective engine.
Engine repair is required.
Defective aircraft fuel system.
Refer to Section 12.
Spark plugs fouled or impr operly gapped.
Clean and regap. Replace if defective.
Propeller control in high pitch (low rpm) position.
all ground ope rations.
Use low pitch (high rpm) for
Restriction in aircraft fuel system.
Refer to Section 12.
Restriction in fuel injection system.
Clean system. Replace any defective units.
Engine-driven fuel pump pressure improperly adjusted.
Refer to paragraph llA-52.
Worn or improperly rigged throWe or mixture control.
Rig properly. Replace worn linkage.
Spark plugs fouled or improperly gapped.
Clean and regap. Replace if defective.
Defective ignition system.
Refer to paragraph 11 Â 61.
Defective engine.
Engine repair is required.
Worn or improperly rigged mixture control.
Rig properly. Replace worn linkage.
Defective manifold valve.
Replace.
Fuel leakage through primer.
Repair or replace primer.
Auxiliary fuel pump ON.
Turn to OFF position.
Defective fuel control unit.
Replace unit.
Fuel c ontamination.
Drain all fuel and flush out fuel system. Clean all screens, fuel lines, strainer, discharge nozzles, manifold valve and fuel pump.
llA- 5
MO DEL 188 & T188 SER IES SERVICE MANUAL
llA- 10. REMOVAL . U the engine is to be placed in storage or retur ned to the manufacturer for overhaul, pr oper preparatory steps s hould be taken for corro sion pr evention prior to beginning the removal pr oce dure . Refer to Section 2 for storage pr eparation . The r outing and location oi wires, ca bles, lines, hoses and controls will vary between models and op tional equipment installed, however, the following general procedure may be followed .
m. Disconnect wires and ca bles as follows: 1. Tachometer drive s ha!t at adapter on engine
I~AUTION ! When disconnecting starter cable do not per mit starter terminal bolt to rotate. Rotation of the bolt could br eak the con ductor between bolt and field coils caus ing the s tarte r to be inoperative.
NOTE Identify each item as it is disconnected to aid 1n replacement. Plug or cap all dis connected lines, hoses and fittings to pre vent entry of foreign material. a. Place all cockpit s witches and fuel s hut- off valve in the OFF position. b. Remove engine cowling in accor dance with para graph llA-3. c. Open battery circuit by disconne cting battery
cables. Insulate cable terminals a s a safety pre
caution.
d. Drain fuel strainer and lines with strainer drain control. NOTE The engine ma y be removed from the air craft with or without the engine mount at tached. The reason for the engine removal should be the governing factor as to the manner it is to be removed and at which point the controls should be d11connected. e. Drain the engine oil sump and oil cooler. Remove spinner and pr opeller in accordance with Section 13. g. Discormect hot a nd cold air flexible hoses. h. Remove muffle r and e xhaust stacks in accor dance with par ag r aph 11-79, i1 engine is to be re moved from engine mount. f.
2. Starter e lectrical cable at starter . 3. Elect rical wires and wire shielding ground
at alternator.
4. Cylinder head temperature thermocouple at cylinder.
IWARNING t The magneto is in a SWlTCH ON condition whe n the switch wire is disconnect ed. Gr ound the ma gneto points or remove the high tension wires from the magneto or spark plugs to prevent accidental fir ing. 5. Disconnect switch wir es at magnet os. n. Disconne ct lines and hos es as follows:
IWARNING t Residual fuel and oil d.r aining fr om discon nected lines and hoses constitutes a fi r e hazard. Use caution to pr event accumula tion oi such fuel and oil when lines or hoses are disconnected. 1. 2. 3. 4. 5. 6. 7.
OU temperatur e bulb below oil cooler . Oil pressure hose at firewall. Primer line to engine at firewall . Fuel hose at fuel str ainer . Manifold pressure line at firewall. Fuel pr essure hose at firewall. Fuel vapor return hose at fi rewall.
NOTE
/CAUTION !
During the following steps remove any clamps or lacings which s ecure controls, wires, hoses or lines to the engine, engine mount or attached brackets . Omit any of the following items which are not pr esent on a particular engine installation.
If the aircraft is equipped with an engine driven hydraulic dispersal system, relieve reservoir air pressure befor e disconnecting hydraulic lines at engine.
i. (THRU AIRCRAFT SERIAL 18800832) Disconnect throttle and mixture control at airbox bellcranks. Note position. sizes and number of attaching washer s. j. (BEGINN1NG WlTH AIRCRAFT SERIAL 18800833) Disconnect engine controls at throttle and mixture control arms . Note pos ition, s izes and number of attac hing wa shers. k. Pull throttle a nd muctu.r e controls free of engine and engine mount, usmg care not to damage them by bending too s harply. l. Disconnect pr ope ller control at governor. Pull control aft clear of engrne .
llA-6
o. Attach a hoist to the lifting lug on top of the en gine and take up engine weight on hoist. p. Carefully check the engine again to ensure all hoses, lines, wi r es, cables and clamps are discon ne cted or removed whic h would interfer e with the engine removal. q. I! the engine is to be removed from the engine mount. r emove inducti on airbox, remove bolts attaching engine to mount, s lowly hoist engine and pull it forward balancing the engine by hand and carefully gmde the discormected components out from the engine a s sembly, t hen remove the s hock- mount asse mblie s.
MODEL 188 8t T188 SERIES SERVICE MANUAL r. If engine is to be removed with engine mount at tached, remove the bolts attaching engine mount to upper portion of firewall, remove bolts attaching mount to lugs protruding through lower portion of firewall, balance the engine by hand as the last of these bolts is removed, slowly hoiSt the engine, pull ing it forward and carefully guide the disconnected components out from the engine assembly.
h. Route propeller governor control to governor
and secure control in position with clamps. Rig in
accordance with Section 13.
NOTE Throughout the aircraft fuel system, from the tanks/cells to the engine-driven pump, use NS-40 {RAS-4) (Snap-on-Tools Corp., Kenosha, Wisconsin), MIL-T- 5544 (Thread Compound Antlseize, Graphite Petrolatum), USP Petrolatum or engine oil as a thread lubricator or to seal a leaking connection. Apply sparingly to male threads, exercising extreme caution to avoid "stringing" sealer across the end of the fitting. Always ensure that a compound, the residue from a prev iously used compound, or any other foreign material cannot enter the system.
llA-11. CLEANING. Refer to Section 11. 11A-12. ACCESSORIES REMOVAL. Refer to Sec
tion 11.
llA-13. INSPECTION. Refer to Section 11. 11A-14. BUILD- Up. Refer to Section 11. 11A-15. INSTALLATION. Before installing the en
gine on the aircraft, install any items that were re
moved after the engine was removed from the air
craft or airframe.
NOTE Remove all pr otective covers, plugs, caps and identification tags as each item is con nected or installed. Omit any items not present on a particular engine installation. a. If engine was removed from engine-mount, hoist engine assembly to a point near the mount, route controls, lines and hoses in place as the engine is positioned near the mount. Install shock mounts and ground straps as illustrated in figure 11A-1. Install engine-mount bolts and torque bolts to the torque values shown in figure llA-1. b. If engine was removed with engine-mount at tached, hoist engine assembly to a point near the firewall , route controls, lines and hoses in place as the engine is positioned near the firewall. Install mount bolts and associated hardware as illustrated in figur e llA-1 and torque bolts to torque, values shown in figure llA- 1. c. Remove hoist. d. (THRU AIRCRAFT SERIAL 18800832) Route throttle and mixture controls to airbox bellcranks and secure controls in position With clamps. Ri.g in accordance with paragraphs UA-63 and llA-64 respectively. e . (BEGINNING WITH AIRCRAFT SERIAL 18800833) Route controls to throttle and mixture arms, secure controls to position bracket and safety wire controls in position. Rig in accordance with paragraph llA-63 and llA-64 respectively. f. (THRU AIRCRAFT SERIAL 18800832) If engine was removed from engine mount, install induction airbox in accordance with paragraph llA- 55. g. (BEGINNING WITH AIRCRAFT SERIAL 18800833) If engine was removed from engine mount, install in duction air flexible duct to throttle body and secure duct with clamp.
1.
Connect lines and hoses as follows : 1. Oil temperature bulb below oil cooler. 2. Oil pressure hose at firewall.
3, Primer line at firewall.
4. Fuel bose at fuel strainer. 5. Manifold pressure line at firewall. 6. Fuel pressure hose at firewall. 7. Fuel vapor return hose at firewall. 8. Install all clamps attaching hoses to engine, engine mount or brackets. NOTE If the aircraft is equipped with an engine driven hydraulic dispersal system, con nect hoses to pump, fill and pressurize hydraulic reservoir as outlined in Section 19.
Connect wires and cables as follows: 1. Cylinder head temperature thermocouple at
lower side of cylinder.
2. Electrical wires and wire shielding ground at alternator. 3. Tachometer drive shaft at adapter on engine. Tighten drive shaft attaching nut to 100 lb-in. j.
When connecting starter cable, do not permit starter terminal bolt to rotate. Rotation of the bolt could break the conductor between bolt and field coils causing the starter to be inoperative. 4. Starter electrical cable at starter. 5. Install all clamps attaching wires and cables to engine, engine-mount or brackets. k. Install exhaust stacks, muffler and shrouds in accordance with paragraph 11-79. 1. Install hot and cold air flexible hoses. m. Install propeller and spinner in accordance with instructions outlined in Section 13.
llA-7
MODEL 188 & T188 SERIES SERVICE MANUAL
n. Make a magneto switch ground-out and continuity check and connect magneto switch wires.
IWAR NINGl Be sure magneto switch is in OFF position when connecting switch wires to ma.g netos.
o. Service engine with proper grade and quantity of engine oil. Refer to Section 2 if engine is new , new ly overhauled or has been iri storage. p. Make sure all switches are in the OFF position and connect battery cables. q. Inspect engine installation for security, correct routing of controls, 1\nes, hoses and electrical wir ing, proper safetying and tightness of all components. r. Install engine cowling in accordance With para graph llA-3. s. Clean and install air filter . t. Perform an engine run-up and make final adjust ments on engine controls. llA-16. PIVOTING ENGINE FOR MAINTENANCE. Access to the engine components and accessories on the back of the engine may be gained by swinging the engine forward and downward, pivoting about the lower engine mount bolts at the lugs protruding through t he firewall. Attach a suitable hoist to the hoisting lug on top of the engine and take-up engine weight with the hoist. NOTE The working space needed will determine
just how many items will have to be dis
connected before the engine can be pivoted
away from the firewall. A very small
space may require that only a few items
be disconnected or unclamped. A larger
working space will require most of the
items listed in paragraph 11A-10 to be
disconnected. Always be sure that lines,
hoses, electrical wires and controls are
not stretched or broken. Cap or plug all
disconnected lines, hoses and fittings.
After disconnecting and/or unclamping items to per mit swinging the engine down as much as needed, re move the bolts from the engine mount upper attach ment points and loosen the pivot bolts at the bottom of the engine mount. Slowly lower the hoist, watch ing for any additional items that may need to be dis connected or unfastened. The induction airbox will have to be removed for maximum access on aircraft prior to serial number 18800833. llA-17. FLEXIBLE FLtnD HOSES. llA- 18. PRESSURE TEST. a. After each 50 hours of engine operation, all flexible fluid hoses in the engine compartment should be pressure tested as follows: 1. Place mixture contr ol in the idle cut-off posi tion. 2. Operate the auxiliar y fuel pump in the high position. llA-8
3. Examine the exterior of hoses for evidence
of leakage or wetness .
4. Hoses found leaking should be replaced. 5. After pressure testing fuel hoses, allow suf ficient time for excess fuel to drain overboard from the engine manifold before attempting an engine start 6. Refer to paragr aph 11-14 for detailed inspec tion procedures for flexible hoses. llA-19 . REPLACEMENT. Refer to Section 11. llA- 20. ENGINE BAFFLES. Refer to Section 11.
llA-21. ENGINE MOUNT. {See figure llA- 1.) The engine-mount is comprised of sections of tubing weld ed together and reinforced With welded gussets. The purpos e of t he mount Is to support the engine and attach It to the airframe. Each engine-mount pad has a small hole for a locating pin which serves as a lo cating dowel for the engine shock mounts. Beginning with Aircraft Serial 18801825, a s wing engine mount designed to provide access to the rear of engine is installed. The mount hinges on the right side with the overcenter arm s uppor ting the left lower mount leg. llA-22 . REMOVAL AND INSTALLATION. a. Remove engine in accordance with paragraph llA-10. b. Remove bolts from upper and. lower mount- to fuselage strocture and carefully r emove engine mount. c. Reverse the pr eceding steps for reinstallation. Torque bolt s to 160- 190 lb-ln. Reinstall engine in accordance with paragraph llA-15. llA- 23. PREPARATIONS FOR SWIN:; MOUNT USAGE. (Refer to figure llA-1, sheet 2.) a. Disconnect the following items: 1. Propeller control at governor, at oll pan bracket (remove 2 bolts securing bracket to oil pan) and at attachment to intake manifold. 2. Main fuel line clamps from the engine mount leg. 3. Vapor return line. 4. Intake induction air hose (disconnect or remove). 5. Wiring clamps (as required). 6. If optional hydraulic pump is installed, re move the bolts securing pump to engine and allow pump to hang free of engine. b. Remove LH upper and lower firewall mount bolts. c. Loosen nuts on RH upper and lower firewall mount bolts. NOTE Engine will sag approximately 1/ 4" when disengaged from firewall lug. d . Safety swing arm (16) to overcenter position using pin (14).
MODEL 188 & T188 SERIES SERVICE MANUAL
4 / ,
~
' '-.., <if< I '
1
*
Detail
A
1.
Lockwashe r
3.
Pin Barrel Nut Spacer Ground Strap Bracket Engine Mount Structure Washer Firewall Tubular Fuselage Structure Shim Lug Pin Drift Pin (Bullet) Swmg Arm
2. Shock- Mount Pad 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Detail
NOTE On aircraft serials 18801375 THRU
C
* TORQUE TO 450- 500 LB-IN â&#x20AC;¢
TORQUE TO 160- 190 LB-lN
18802001 when the new solid rubber forwa rd engine mounts are installed refer to Cessna Single-engine Servi~e Letter SE75 -4, dated January 31 1975. ,
Figure llA- 1.
Engine Mount Details {Sheet 1 of 2) llA-9
MODEL 188 & T188 SERIES SERVICE MANUAL
Typical mount- to-firewall attachment hardware is as shown in Detail D.
DRAIN HOLE
SWING MOUNT
Detail
0 BEGINNING WITH AIRCRAFT SERIAL 18801825
Figure 11 A-1 Engine Mount Details (Sheet 2 of 2) llA- 10
MODEL 188 8t T188 SERIES SERVICE MANUAL
llA-24. SWING MOUNT ATTACHMENT TO FffiE WALL. (See figure UA-1, sheet 2.} a. Remove pin (14) attaching swing arm (16) to
overcenter position.
b. Align engine mount holes to firewall lugs using
bullet-shaped drift pin (1 5}.
f~AUTION\ Care must be exercised when swinging the engine back to firewall or damage may result. c. Lift the lower engine mount leg onto the firewall lug using screwdriver to assist. d. Install LH upper and lower firewall bolts.
T o rque bolts to value specified in paragraph llA·
22"c".
e. T orque RH upper and lower firewall bolts to
value specified in paragraph 11 A-22"c".
f. Connect items which were disconnected or re
moved in step "a" of paragraph llA-23. Ensure all
connections are correctly made, secured, and free
from binding. llA-25. ENGINE SHOCK-MOUNT PADS. (See figure llA-1. ) The bonded rubber and metal shock mounts are designed to reduce transmission of engine vibrations to the airframe. The rubber pads should be wiped clean with a clean dry cloth.
NOTE Teledyne Continental Motors recommends that the spin-on filter be inspected. Refer to Continental Aircraft Engine Service Bulletin M74-2, dated 16 January 1974. d. Before installing oil filter (6) lightly lubricate filter gasket (8} with a thin coating of Dow Corning Compoond, DC-4, apply by brushing or wiping lubri cant on to base gasket. e. Install spin-on filter, (6), on the stud and torque to 18-20 lb-ft or 3/4 to 1 full turn after gasket makes contact. C. Safety wire filter to adapter. g. Install all parts removed for access and service the engine with the proper grade and quantity of en gine oil. One additional quart of oil is required each time the filter element is changed. h. Start engine and check !or proper o il pressure.
Check for oil leakage after warming up the engine.
1. Again check for oil leakage after engine has been run at high power setting (preferably a flight around the field}. j. Check to make sure filter can has not been mak ing contact with any adjacent parts due to engine torque. k. While engine is still warm, recheck filter (6), to assure proper tightness. UA-32.
ENGINE FUEL SYSTEM.
NOTE UA-33. DESCRIPTION. The fuel injection system Do not clean the rubber pads and dampener assembly with any tpye of cleaning solvent. Inspect the metal parts for cracks and excessive wear due to aging and deterioration. lnspect the rubber pads for separation between the pad and metal backing, swelling, cracking or a pronounced set of the pad. Install new parts for all parts that show evidence of wear or damage. llA-26. ENGINE OIL SYSTEM. llA-27. DESCRIPTION. (Refer to Section 11.}
18 a low pressure system of injecting fuel into the intake valve port of each cylinder. It is a multi
nozzle, continuous-flow type which controls fuel flow to match engine airflow. Any change in throttle posi tion, engine speed, or a combination of both, causes changes in fuel flow in the correct relation to engine airflow. A manual mixture control and a fuel flow indicator are provided for leaning at any combination of altitude and power setting. The fuel flow indicator is calibrated in gallons per hour and indicates approxi mately the gallons of fuel consumed per hour. The continuous-flow system uses a typical rotary vane fuel pump. There are no running parts in this system ex cept for the engine-driven fuel pump.
llA-28. TROUBLE SHOOTING. (Refer to Section 11 . } NOTE llA-29. FULL-FLOW OIL FILTER. 18803474 &t ON (See figure 11A-2.) 11A-30. DESCRIPTION. An external oil filter may be installed on the engine. The filter and filter adapter replace the regular engine oil pressure screen. The fllter is a throw-away type spin-on filter which has an internal bypass valve. llA-31. REMOVAL AND INSTALLATION. (See figure llA-2. ) a. Remove engine cowling in accordance with para graph llA-3. b. Remove safety wire (7) from filter, (6). c. Unscrew filter from adapter , (3) .
Throughout the aircraft fuel system, from the fuel tank/cells to the engine-driven fuel pump, use RAS-4 (Snap-On Tools Corp., Kenosha, Wisconsin}, MIL-T- 5544 (Thread Compound, Antiseize, Graphite- Petrolatum) or equivalent, as a thread lubricant or to seal a leaking connection. Apply sparingly to male fittings only, omitting the first two threads . Always ensure that a compound, the residue from a previously used compound or any other foreign material cannot enter the system. Throughout the fuel injection system, from the engine-driven pump through the dis c harge nozzles, use only a fuel soluble lubri cant, such as engine lubricating oil, on fitting threads. Do not use any other form of thread compound on the injection system fittings. llA-11
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Do NOT substitute automotive gaskets for any gaskets used in this assembly. Use only approved gaske ts listed in the Parts Catalogs.
2
3
1.
0-Ring
2. 3. 4. 5. 6. 7. 8. 9.
Adapter Nut Adapter Threaded Insert Stud Filter Safety VVire Filter Gasket Plug
Figure llA- 2 . llA-12
Full- Flow Oil Filter
MODEL 188 & T188 SERIES SERVICE MANUAL
llA-34. FUEL-AIR CONTROL UNIT. This unit oc cupies the position ordinaril y used for a carwretor, at the intake manifold inlet. The function of this unit Is to control eng ine air intake and to set the metered fuel pressure for proper fuel-air ratio. There are three control elements in this unit, one for air and two for fuel. One of the fuel control elements is for fuel mixture and the other is for fuel metering . Fue I enters the control unit through a strainer and passes to the metering valve. The position of the metering valve controls this fuel passed to the manifold valve and nozzles. A linkage connecting the metering valve to the air throttle proportions airflow to fuel flow. The position of the mixture valve determines the amount of fuel returned to the fuel pump. The fuel control portion of the fuel-air control unit is enclosed in a shroud and is blast-air cooled to help prevent vapor lock. llA-35. REMOVAL AND INSTALLATION. a. Place all cockpit switches and fuel shut- off valve in the OFF position. b. Remove lower cowl section in accordance with
paragraph llA-3.
c . Remove induction airbox in accordance wlth
paragraph llA-55.
NCYrE Cap all disconnected hoses, lines and fittings . d. The three fuel lines which attach to the fuel con trol unit are routed inside flexible tubing to help cool the fuel. Loosen the tubing clamps at the control unit and slide the tubing back to gain access to the fuel line fittings. e. Disconnect the fuelllnes at the control unit. f. Loosen the hose clamps which secure the control unit to the right and left intake manifolds. g. Remove the control unit. h. Cover the open ends of the intake manifold pip ing to prevent the entry of foreign matter. i. Reverse the preceding steps for reinstallation. Use new gaskets when installing control unit. Rig throttle and mixture controls in accordance with para graph llA- 63 and llA-64 respectlvely. Rig throttle operated microswitch in accordance with Section 12. llA-3 6. CLEANING AND INSPECTION. a . Check control connection, levers and linkage for secunty, safetying and for lost motion due to wear. b. Remove the fuel screen assembly and clean in cleaning solvent. Reinstall and safety. c . Check the air control body for cracks and control unit for overall condition. llA-37. ADJUSTMENTS. The idle speed adjustment is a conventional s pring-loaded screw located in the
air throttle lever. The idle mixture adjustment is the locknut at the metering valve end of the linkage. Tightening the nut to shorten the linkage provides a richer mixture. A leaner mixture is obtained by backing off the nut to lengthen the linkage . Adjust mixture control to obtain a slight and momentary gain of 50 rpm maximum at 1000 rpm engine speed as mixture contr ol is moved slowly from full RICH toward idle cut-off. If mixture is set too LEAN, engine speed will drop immediately, thus requiring enrichment. If mixture is set too RICH, engine speed will increase above 50 rpm, thus requiring leaning. Idle speed is approximately 600 rpm. Refer to figure llA-4. llA-38. RIGGING THROTTLE- OPERATED
MICROSWITCH. Refer to Section 16.
llA-39. ELECTRIC FUEL PUMP CIRCUIT . Refer to Section 12. llA-40. AUXILIARY ELECTRIC FUEL PUMP
FLOW RATE ADJUSTMENT. Refer to Section 12.
llA-41. FUEL MANIFOLD VALVE (FUEL DISTRIB· UTOR). Metered fuel flows to the fuel manifo ld valve, which provides a central point for distrib uting fuel to the individual cylinders. An internal diaphragm, operated by fuel pressure , raises or lowers a plunger to open and close the individual cylinder supply ports simultaneously. A needle valve in the plunger ensures that the plunger fully opens the outlet ports before fuel flow starts and closes the ports simultaneously for positive engine shut-down. A fine-mesh sc r een is included in the fuel manifold valve. llA-42.
REMOVAL. NOI'E
Cap all disconnected lines, hoses and fittings. a. Disconnect the fuel lines and the six fuel injec tion lines at the fuel manifold. b. Remove the two crankcase bolts which secure the fuel manifold and remove the fuel manifold. llA-43. CLEANING. a. Remov~ fue l manifold valve from engine and re move safety wire from cover attaching screws. b. Hold the top cover down against internal spring until all four cover attaching screws have been re-· moved, then gently llft off the cover. Use care not to damage the spring-loaded diaphragm below cover. c . Remove the upper spring and lift the diaphragm assembly straight up.
llA-1:!
MODEL 188 & T188 SERIES SERVICE MANUAL
VAPOR EJECTOR
TO MANIFOLD VALVE
VAPORSE
PART THROTTLE P<l3ITION .....____ ADJUSTABLE ORIFICE
FUEL INLET
SlllELD CALIBRATED ORIFICE --~~lll
SCREEN
A
LEGEND:
INJECTION MIXTURE OUTLET
r - 1 REUEF L _ J VALVE PRESSURE
m:1 ยงJ MET ERED FUEL ~
PUMP PRESSURE
-
INLET PRESSURE
c::J
RETURN FUEL
Figure llA-3. 11 A-14
DETAIL
Fuel Injection Schematic
A
MODEL 188 & T188 SERIES SERVICE MANUAL
• SPRING (Beginning with aircraft s e rial 18800730)
IDLE MIXTURE ADJUSTMENT
Figure llA-4. Idle Speed and Idle Mixture Adjustment
NOTE
U the valve attached to the diaphragm is
stuck in the bore of the body, grasp the
center nut, rotate and lift at the same
time to work gently out of the body.
I~AUTION \ Do not attempt to remove needle or spring from inside plunger valve. Removal of these items from the valve will disturb the calibration of the valve. d. Using clean gasoline, flush out the chamber be low the screen. e. Flush above the screen and inside the center bore making sure that outlet passages are open. Use only a gentle stream of compressed air tp remove dust and dirt and to dry.
fcA UTION \ The filter screen is a tight fit in the body and may be damaged if removal is attempted. It should be removed only if a new screen is to be installed. f. Clean diaphragm, valve and top cover in the same manner. Be sure the vent hole in the top cover is open and clean. g. Carefully replace diaphragm and valve. Check that valve works freely in body bore. h. Position diaphragm so that horizontal hole in plunger valve is 90 degrees from the fuel 1nlet port in the valve body. i. Place upper spring in posttlon on dlaphragm. j. Place cover in position so that vent hole in cover 1s 90 degrees from inlet port 1n \'alve body. Install cover attaching screws and tlghten to 20.::1 lb- in. Install safety wire on cover screws. k. Install fuel manifold valve assembly on engine
and reconnect all lines and hoses to valve. 1. Inspect installation and install cowling. llA-44. INSTALLATION. a. Secure the fuel manifold to the crankcase with
two crankcase bolts.
b. Connect the fuel lines and the six fuel injection
lines. Inspect completed installation.
UA- 45. FUEL DISCHARGE NOZZLES. From the fuel manifold valve, individual, identical size and length fuel lines carry metered fuel to the fuel dis charge nozzles located in the cylinder heads. The outlet of each nozzle is directed into the intake port of each cylinder. The nozzle body contains a drilled central passage with a counterbore at each end. The lower end is used as a chamber for fuel-air mixture before the spray leaves the nozzle. The upper bore contains an orifice for calibrating the nozzles. Near the top, radial hol es connect the upper counterbore with the outside of the nozzle body for alr admission. These radial holes enter the counterbore above the orifice and draw outside air through a cylindrical screen fitted over the nozzle body. This screen pre vents dirt and foreign material from entering the nozzle. A press- fit shield is mounted on the nozzle body and extends over the greater part of the filter screen, leaving a small opening at the bottom of the shield. This provides an air bleed into the nozzle which aids in vaporizing the fuel by breaking the high vacuum in the intake manifold a t idle rpm and keeps the fuel lines filled . The nozzles are calibrated in several ranges. All nozzles furnished for one engine are the same range and are identified by a number and a suffix letter stamped on the flat portion of the nozzle body. When replacing a fuel discharge nozzle be sure it is of the same calibrated range as the rest of the nozzles in the engine, When a complete set of nozzles is being installed, the number must be the same as the one removed, but the suffix letters may be di!ferent, as long as they are the same for all nozzles being installed on a particular engine. llA- 15
MODEL 188 & T188 SERIES SERVICE MANUAL
llA-46.
REMOVAL.
e. Tag and disconnect all lines and fittings attach ed to the fuel pump. NOTE NOTE
Plug o r cap all disconnected lines and fittings. a. Disconnect the fuel injection lines at the fuel dis charge nozzles. Remove nozzles with a 1/ 2 inch deep well socket wrench. llA-47. CLEANING AND INSPECTION. To clean nozzles , immerse in clean solvent and use compress ed air to dry them. When cleaning, direct air through the nozzle in the direction opposite of normal fuel flow. Do not remove the nozzle shield or distort it in any way. Do not use a wire or other meta.i object to clean the orifice or metering jet. After cleaning, check the shield height from the hex portion of the nozzle. The bottom of the shield should be approximately 1/16 inch above the hex portion of the nozzle. llA-48. INSTALLATION. a. Insta.il nozzles in the cylinders and tighten to a
torque value 55 to 65 lb-tn.
b. Connect the fuel lines at discharge nozzles. c. Check installation for crimped lines, loose fit
tings, etc.
llA-49. FUEL INJECTION PUMP. The fuel pump is a pos1tive-displacement, r otating vane type, con nected to the accessory drive section of the engine. Fuel enters the pump at the swirl well of the pump vapor separator. Here, vapor is separated by a swirling motion so that only liquid fuel is fed to the pump. The vapor is drawn from the top center of the swirl well by a small pressure jet of fuel and is fed into the vapor return line, where it is returned to the aircraft fuel system. Since the pump is engine-driven, changes in engine speed affects tota.i pump now pro portionally. A check valve allows the auxiliary fuel pump pressure to bypass the engine-driven fuel pump for starting, or in the event of engine-driven fuel pump fa1lure. The pump supplies more fuel than is required by the engine; therefore, a spring-loaded, diaphragm type relief valve is provided, with an ad justable orifice installed in the fuel passage to the relief valve to maintain desired fuel pressure for en gine power setting. The adjustable orifice allows the exact desired pressure setting at full throttle. The fuel pump is equipped with a manual mixture control to provide positive mixture control throughout the range required by the injection system. This control limits output of the pump from full rich to idle cut-off. Non-adjustable mechanical stops are located at these positions. llA-50. REMOVAL. a . Place full shut-off valve in OFF position and mixture control in IDLE CUT-OFF position. b. Remove upper cowling section in accordance with paragraph llA- 3. c. Loosen the clamps and slide the flexible tubes free of the horns on the fuel pump shroud to gain ac cess to the fuel lines. d. Remove the alternator drive belt.
llA-16
Plug or cap all disconnected lines, hoses and fittings. f. Remove the shroud surrounding the fuel pump. g. Remove the nuts and washers attaching the fuel
pump to the engine.
h. Remove fuel pump and gasket.
fWARNINGt Residual fuel draining from lines and hose constitutes a fire hazard. Use caution to prevent accumulation of fuel when lines or hoses are disconnected. i. U a replacement pump is not being installed im
mediately, a temporar y cover should be installed on
the fuel pump mount pad.
UA-51. INSTALLATION. a. Position a new gasket and fuel pump on the
mounting studs with fuel pump inlet to the left. Be
sure pump drive aligns with drive in the engine.
b. Secure pump to engine with plain washers, in ternal tooth lock washers and nuts. Tighten nuts evenly. c. Install cooling shroud on fuel pump. d. Install all fittings and connect all lines. e. Install the flexible ram air tube on the air horn of the fuel pump shroud and install clamp. f. Replace the alternator drive belt and tighten the nuts on the adjusting arm so that the drive belt has proper tension. Refer to Section 16. g. Inspect complete installation. llA- 52. ADJUSTMENT. During the 1967 model year an adjustable orifice is added to the engine driven fuel pump so that the pressures for the full throtUe position may be obtained. This adjustable orifice allows the exact desir ed pr essure setting and eliminates changing of the fixed orifice to obtain the pressure required. The adjustable orifice applies to the FULL throttle setting only. Adjustment of the idle position is still obtained through the relief valve. This new pump is used as spare parts and is furnish ed if a new pump is ordered. Adjustment of the pumps not incorporating the adjustable orifice is sWl pe r formed as ouUined in Cessna Service Kit No. SK320 2J, using the pressures specified in paragraph llA- 8. To adjust the pump incorporating the adjustable orifice proceed as follows: a . Remove engine cowling as required in accor dance with paragraph llA-3. NOTE Inspect the slot- headed adjustable orifice
needle valve (located just below the fuel
MODEL 188 & T188 SERIES SERVICE MANUAL
ENGINE -DRIVEN FUEL PUMP
NOTE
FUEL METERING UNIT
Pressur e indicator, hose and fittings are available from the Cessna Ser vice Parts Center .
EXISTING FUEL PUMP OUTLET HOSE
22-870- 012 PRESSURE INDICATOR
--- - - AN917-10 TEE
CM2944-2-93 TEST HOSE
CM2944-4-8. 5 TEST HOSE Figure llA-5.
AN816-2D
NIPPLE
F uel Inje ction Pump Adjustment Test Harness
pump inlet fitting) to see if it is epoxy seale d or safety wired to the brass nut. If the needle valve is epoxy sealed, Conti nental Aircraft Engine Service Bulletin No. 70-10 must be complied with before calibration of the unit can be performed. b . Disconnect the engine-driven fuel pump outlet fitting or the fuel metering unit inlet fitting and " tee" the te st gage into the fuel injection system as illus trated in figure llA-5. NOTE Cessna Service Kit No. SK320-2J provides a te st gage, lines and fittings for connect ing the test gage into the system to per form a ccurate calibration of the engine driven fuel pump. c. The test gage MUST be vented to atmosphere and MUST be held as near to the level of the engine- driven fuel pump as possible. Bleed the test gage line prior to taking readings. NOTE The test gage should be checked fo r a ccuracy at least every 90 days or anytime an error is sus pected . The ta chometer accuracy s hould also be deter mined prior to making any ad just ment s to the pump. d. Start engine and war m -up thor oughly. Set mix ture control to full rich position and pr ope lle r con trol fu ll forwa rd (low pitch, high rp m).
e. Adjust engine idle speed to 600±25 rpm and
check test gage for 9- 11 PSI. Refer to figure llA-4
for idle mixture adjustment.
NOTE Do not adjust idle miXture until idle pump
pr essure is obtained.
!WARNING
a
DO NOT make fuel pump pressure adjust
ments while engine is operating.
f. If the pump press ure is not 9 to 11 PSI, sto p en gine and turn the fuel pump relief valve adjustment, on the centerline of the fuel pump clockwise {CW) to increase pr essure and counterclockwise (CCW) to decrease pr essure . g. Maintaining idle pump pressure and idle RPM, obtain correct idle mixture in accordance with para graph llA- 37. h. Completion of the preceding steps have provided : 1. Correct idle pump pressure. 2. Correct fuel flow. 3. Correct fuel metering cam to throttle plate orientation. i. Advance to full throttle and maximum rated en gine speed with the mixture control in full rich posi tion and pr opeller control in full forward (low pitch, high rpm). j. Check test gage for pr e ssures specified in para graph llA- 8. U pressure is incorrect, stop e ngine a nd adjust pressure by loo sening locknut and turning the slotheaded needle valve located just below the fuel pump inlet fitting c lockwise (CW) to increase pressure and counte r clockwise (CCW) to decrease pr essure.
llA- 17
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE I! at static run-up. rated RPM cannot be
achieved at full throttle, adjust pump pressure slightly below limits making certain the correct pressures are obtained when rated RPM is achieved during take off roll. k. After correct pressures are obtained. safety
adjustable orifice and orifice lockout.
l. Remove test equipment. run e n gine to check
for leaks and install cowling.
llA- 53,
INDUCTION AIR SYSTEM.
llA-54. DESCRIPTION. Ram air enters the induction air system through a filter at the front of the lower cowling. Thru aircraft serial 18800832 this air is ducted to the airbox at the fuel-air control unit. A spring loaded alternate air door is incorporated in the airbox and will open by engine suction if the air filter should become clogged. This permits unfiltered induction air to be drawn from within the engine compartment. Beginning with aircraft serial 18800833 the induction air is ducted to the fuel-air control unit through an adapter which is mounted on the lower cowl assembly. An alternate air door is incorporated in the adapter assembly and is manually-operated by a locking control in the cockpit. Unlocking and pulling the control out will allow unfiltered induction air to be drawn from within the engine compartment if the air filter should become clogged. Beginning with aircraft serial 18802860 the alternate air door is replaced with a rotary air valve. Operation of the rotary air valve from the cockpit is the same as the alternate _air door. llA- 55. AIRBOX REMOVAL AND
INSTALLATION.
{THRU AIRCRAFT SERIAL 18800832.)
a. Remove lower cowling section in accordance with paragraph llA-3. b. Disconnect throttle and mixture controls at bellcranks. c . Disconnect electrical wiring at air temperature inlet probe, and tape ends as a safety precaution. d. Disconnect drain Une at airbox. e . Remove safety wire from mounting bolts, remove bolts securing airbox to fuel-air control unit and remove airbox and gasket. f. Reverse the preceding steps for reinstallation. Use a new gasket each time removal is necessary. g . Rig throttle and mixture controls i.n accordance with paragraphs llA- 63 and llA-64 respectively. b. Connect and adjust throttle-operated auxiliary fuel pump microswitch in accordance with Section 12. llA-56. CLEANING AND INSPECTION. Thru aircraft serial 18800832 clean metal parts of the induction airbox with Stoddard solvent or equ1valent. Inspect for cracks. dents. loose nvets. etc. M1n or cracks may be stop-drilled. In case of llA-18
Revision 1
continued or severe cracking. replace airbox. Inspect gaskets and install new gaskets, if damaged. Inspect alternate spring-loaded door !or freedom of operation and complete closing. Beginning with aircraft seria l 18800833 .u se the (,_ preceding cleaning and inspe ction procedures applied to the adapter assembly instead of the airbox. Check manually operated air door or rotary air valve for ease of operation and proper rigging. Rotary air valve is factory lubricated with a dry lubricant, stiff operating valve should be removed and replaced. 11A-56A. INSTALLATION OF INLET DUCTS. When [ duct assembly to le~th. the support wire ~ should be cut back far enough to bend back (minimum bend radius 1/8 inch) under the clamp and protrude 1/ 4 inch. Do not break the bond between the wire and the fabric. Before tightening the clamps , make sure ~ there is no twist or torque on the hose. If the hose is wrapped with MIL- Y-ll40 cord in place of the wire support, the same installation procedure applles except; MIL- Y- 1140 has no minimum bend radius requirement.
t
cutt1~
The mi.n imum bend radius for wire supported hose
in the plane of bend is as follows :
1. Neoprene, one ply hose - 1/ 4 diameter of the
maximum hose dimension.
2. Neoprene, two ply hose and sillicone, one ply hose¡- 1/3 diamet'er of the maximum hose dimension. 4. Silllcone, two ply hose - 1/2 diameter of the maximum hose dimension. UA- 57. INDUCTION AIR Fll..TER. a. (THRU AIRCRAFT SERIAL 18801374.) (Refer to Section 11.) b. (BEGINNING WITH AIRCRAFT SERIAL 18801375. ) (See figure llA-6, sheet 6.) Disengage camloc-type studs (12) of cover assembly (11) until filter (6) can be removed. Replace filter and engage studs to install. c. (BEGINNING WITH AIRCRAFT SERIAL 18802860.) (See figure llA-6, sheet 7.} Remove wing nut (49) of cover assy. (50). Replace filter (51) and cover assy. to install. llA-58. ALTERNATE AIR CONTROL. (BEXiiNNING WITH AIRCRAFT SERIAL 1880083.3. } (See figure 11A-6, sheet 5.) NOTE Cowling must be properly installed prior
to rigging of alternate a ir control.
a.
Loosen jam nuts at both ends of rod assembly
(42).
.
b. Disconnect ball joint (43) from ball on arm assembly (44). c . Adjust ball joint (43) on rod asst'mbly (42) until sufficient threads are engaged. d. Screw rod {42) into rod end (38) to obtain approx1mately 8.65 inches between center of ball socket and center of rod end. e. Connect ball joint (43) to ball on arm assembly (44) and tighten jam nuts.
l
MODEL 188 & T188 SERIES SERVICE MANUAL
C. In the cockpit. push alternate a ir control full IN and check that alternate air door (45} is fully closed. g . If door (45) is NOT fully closed. loosen clamps securing control (37} to engine mount (39) and support assembly ( 41) and slide control through clamps until door is fully closed. Tighten clamps. h . In the cockpit, unlock alternate a i r control. pull control full OUT {approximately 3 inches} and check that alternate air door (45) is fully open.
NOTE After completion of step "h" the alternate air control should be properly rigged. however. in some cases. it may become necessary to shorten the cqntrol housing in o rder for the bellcrank (3f11 to reach full travel. If so. proceed to step· 'T'.
NOTES After completion of step "c" the alternate air control should be properly rigged. however in some cases. it becomes necessary to shorten the control housing in order for the air valve (52) to reach full open. The result of rigging. in all cases. is the alternate air valve (52) must be fully OPEN when the control in the cockpit is pulled a maximum of 3 inches. Also the valve is fully CLOSED when the control is pushed in and that no binding of the system is experienced. llA-60. IGNITION SYSTEM. Refer to Section 11. llA-61.
Loosen clamp-bolt at bellcrank (36), straighten control wire and slide wire from clamp-bolt. J. In the cockpit. using care not to lose ball
beanng from the control at instrument panel.
unlock and pull control OUT until wire is out-of
stght inside housing at the engine end of control.
Cut the ho using off as required to allow bellcrank
to attain full travel and reinstall wire in clamp
bolt. Bend w ire to a. goo angle as a safety
precaution.
k . Check operation of air door in both directions
making sure the control in the cockpit does not
pull out more than 3 inches maximum.
ENGINE CONTROLS.
i.
llA-62. DESCRIPTION. The throttle and propeller governor control levers are in the control quadrant mounted to the left of the pilot's seat. The mixture control is equipped with a position locking device which prevents vibration-induced "creeping" of the control. The alternate air control is located on the lower left side of the instrument panel. On the later model aircraft. an additional "Palnut" type locknut was installed in back of the existing locknut at the engine end of all throttle and propeller controls that contain rod ends. NOTE
NOTES The result of rigging. in all cases. is the alternate air door (45) must be fully OPEN when the control in the cockpit i.s pulled out a maximum of 3 inches. that the door is fully CLOSED when the control is pushed in and that no binding of the system is experienced. Refer to the inspection chart in Section 2
for inspection and/ or replacei'T'ent
interval for the alternate air control.
Some controls have intricate parts that will fall out and possibly be lost if the control is pulled from the housing while the control is disconnected. llA- 63. RIGGING. When adjust ing any engine control. it is important to check that the control slides smoothly throughout its full range of travel. that it locks securely if equipped with a locking device and that the arm or lever it operates moves through its full arc of travel.
/CA UTION ! llA-59. RIGGING, ALTERNATE AIR ROTARY VALVE (BEGINNING WITH AIRCRAFT SERIAL 18802860) Refer to figure llA- 6, sheet 7. NOTE Cowling must be removed prior rigging of alternate air control.
to
a. In the cockpit push alternate air controls full IN and check that alternate air valve (52) is fully closed. b. If au valve (52) is not fully closed. loosen locking nut (54) retainmg control wire (55) to valve ann (56) and move valve to c losed position. Tighten nut. c. ln the cockpit. unlock alternate air control. pull control full OUT (appro x imately 3 tnches) and check a1r valve (52) IS fully o pen.
Whenever engine controls are being disconnected. pay particular attention to the exact position. size and number of attaching washers and spacers. Be sure to install attaching parts as noted when connecting controls. llA-64. THROTTLE CONTROL. a . (THRU AIRCRAFT SERIAL 18800832.) (See to figure llA- 6, sheets 1, 2 and 3.)
fcAUTION ! Whenever throttle control is disconnected at the engine. pay particular attention to the EXACT position. size and number o f attaching bolts and washers. Be sure to install attaching parts as noted when reconnecting contr ols. Revision
1
llA- 19
MODEL 18 8 & 11 88 SERIES SERVIC E MANUAL
1. Dtsconnect throttle control (21 ) r od end
from bellcrank ( 4 ) on airbox ( 13).
2. Dis connect throttle control rod assembly (18) from c ontrol arm ( 17) on throttle body. 3. Adj ust throttle control rod assembly (18) to 1ts shortest length and reconnect rod to arm on throttle body. 4. In the cockpit. push throttle control lever full forward . then pull lever aft approximately 1/ 8 mch from full forward for cushio~:~. and tighten friction control knob on quadrant to prevent movement of lever. 5. Move control arm (17) on throttle body to full OPEN position (against stop). adjust throttle control (21) rod end to align with bellcrank (4) and install attaching bolt and washers. 6. Release friction lock, move thr ottle lever
aft and check that control arm on throttle body
contacts s to p at idle position.
7. Tig h ten all jam nuts and ensure sufficient threads are engaged in rod ends.
5. Release friction lock. pull throttle lever aft and check that control arm (17) contacts stop at idle position. 6. Check that sufficient threads are engaged in throttle control (21) rod end and tighten jam nut . NOTE Refer to the inspection chart in Section 2 for inspection, lubrication and/ or replace ment interval for the throtUe control. llA-65. MIXTURE CONTROL. a . (THRU AIRCRAFT SERIAL 18800832.) (See
figure llA-6, sheets 1, 2 and 3.)
/CAUTION \ Whenever·mixture control is disconnected at the engine. pay particular attention to the EXACT position. size and number of attaching bolts and washers. Be sure to install attaching parts as noted when reconnecting controls.
NOTES The result of rigging, in all cases. is the throttle control must be rigged so that the control arm (17) on the throttle body contacts the mechanical stops in both directions. that the throttle lever has approximately 1/ 8-inch cushion at the control q\ladrant when in full OPEN position and that the small retaining ring at the engine end of the control just clears the end of control housing when the idle stop is reached. Refer to the inspection chart in Section 2
for inspection and/or replacement
·· interval for the throttle control.
b. (BEGINNING WITH AIRCRAFT SERIAL 18800833.) (See figure llA-6, sheet 4.)
f~AUTION \
1. Disconnect mixture control (22) rod end from bellcrank (3) on airbox (13~. 2. Disconnect mixture control rod assembly (20) from control arm (16). 3. Adjust rod assembly (20) to dimensions shown in VIEW A-A. sheet 2 and connect rod assembly (20) to control arm (16). 4. In the cockpit. carefully pull mixture control OUT until retaining ring at the engine end of the control contacts control housing. tben push control IN until retaining ring just olears housing. Maintain this position. 5. Move control arm (16) against idle cut-off stop (24) and adjust mixture control (22) rod end to align with bellcrank (3) and connect in this position. 6. Push mixture control full IN and check that control arm (16) is .against FULL RICH stop. Tighten all jam nuts and ensure sufficient tbreads are engaged in rod ends.
Whenever throttle control is disconnected at the engine. pay panicular attention to the EXACT position. size and number of attaching bolts and washers. Be sure to install attaching parts as noted when reconnecting controls. 1. Disconnect throttle control (21) rod end fr o m arm (17). 2. In the cockpit. push throttle control lever full forward . then pull lever aft approximately 1/ 8 inch from full forward for cushion and tighten friction control k.nob on quadrant to prevent m o vement o f lever. 3. Be sure control (22) is attached to the bracket (2 6 ) pr operly and safety wire / retainer is mstalled. 4 . :Vlove contro l a rm (17) on throttle body (30) to full O P EN pos ition (aga inst s top ). adjust thro ttle con tr ol (21 ) rod end to a lign with a r m ( 17) and m stall attachmg bol t a nd washers.
llA-20
Revision 1
NOTES The result of rigging, in all cases, is the mixture control must be rigged so that tbe control arm (16) contacts the stops in both directions. tbat the mix:ture control has approximately 1/8-inch cushion when pushed full IN and that the small retaining ring at the engine end o f the control just clears the end of control housing when the idle cut-off stop is reached.
e
Refer to the inspection chart 'in Section 2
for inspection, lubrication and / or replace
ment interval for the mixture control.
b . (BEG INNING WITH AIRCRAFT SERIAL . 18800833 . ) (See figure llA-6 , sheet 4. )
MODEL 188 & T18S SERIES SERVICE MANUAL
(~AUTION} Whenever mixture control is disconnected at the engine. pay particular attention to the EXACT position. size and number of attaching bolts and washers. Be sure to install attaching parts as noted when reconnecting controls. Disconnect mixture control (22) rod end from arm ( 16). 2. In the cockpit. push mixture control IN. unlock and pull control OUT approximately 1/8 inch for cushion. 3. Be sure control (21) is attached to the bracket (26) properly and safety wire/ retainer is installed. 4 . Place control arm ( 16) against the FUI.J,. RICH s top . adjust mixture control (22) rod end .-Jc align wtth ann and install attaching bolt and washers. 1.
5. Unlock and pull mixture control OUT and check that control ann (16) is against IDLE CUT-off stop.
~· Check that sufficient threads are engaged
. tn mtxture control (22) rod end and tighten jam nut. NOTE Refer to the inspection chart in Section 2 for inspection, lubrication and / or replace ment interval for the mixture control.
SHOP NOTES:
Revision 1
llA-21
MODEL 188 & T188 SERIES SERVICE MANUAL
2
I
THRU AffiCRAFT SERIAL 188 -0504
I I '
,~
-~,j 10
2
14
If
BEGINNING WITH AIR
CRAFT SERIAL 188-0505
NOTE
.THRU AffiCRAFT SERIAL 188 - 0442
• Use as required to shim out excess play . *BEGINNING WITH AIR
CRAFT SERIAL 188-0443 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20 . 21. 22. 23. 24.
Safety wire all roll pins (1) to shaft (9).
Pin Spacer Mixture Bellcrank Throttle Bellcrank Auxiliary Fuel Pump Switch Striker Bushing Gasket Alternate Air Inlet Shaft Washer Shaft Boss Housing Airbox Stud Bracket Mixture Arm Throttle Arm Throttle Rod Nut Mixture Rod Throttle Control Mixture Control Clamp Idle Cut-Qff Stop
25 . Safety Wire 26. Bracket 27. Bracket 28. Spring 29. Support 30. Throttle Body 31. Propeller Control 32. Firewall 33 . Adapter Assembly 34. Clamp 35. Duct Assembly 36. Bellcrank 37. Alternate Air Control 38. Rod End 39 . Engine Mount 40. Bearing 41. Support Assembly 42. Rod Assembly 43. Ball Joint 44. Arm Assembly 45. Alternate Air Door 46. Duct Assembly 47. Retamer 48. Bolt
Figure 11A-6. Engine Controls (Sheet l of 7) llA-2 2
MODEL 188 & T188 SERIES SERVICE MANUAL
AIRCRAFT SERIAL 188-0429 THRU 188- 0504
THRU AIRCRAF T SERIAL 188-0428
A 1----22
,/
21
20
" 10 10
A
to
18
AIRCRAFT SERIAL 188- 050 5 THRU 18800707
16
~"
:\.
路~
10
10
. 038"
~/~
(MIN.)
ALL VIEWS AFT LOOKING FORWAR D
13/
(
.
路 路~
20
路. .~ \ @;
VIEW A-A
O F MIXTURE ROD 9
4
2 10 10
Figur e l l A-6 .
Engine Contr ols (Sheet 2 of 7)
11A- 23
MODEL 188 & T188 SERIES SERVICE MANUAL
AIRCRAFT SERIAL 18800708 TIIRU 18800832 AND ALL AIRCRAFT MODIFIED IN ACCORDANCE WITH SERVICE LETTER SE71-3 AND SE71-3, S UPPLEMENT 1
. 40 (Min.) II
3
MIXTURE ROD LOOKING IN BOARD, RIGHT HAND SIDE
10 AFT VIEW LOOKING FOR WARD, RIGHT HAND SIDE NOTE
e•
**
Use . 032 " and . 016 " washer s as requir ed to r educe shaft end play to a maximum of . 016 ". Thru aircraft serial 18800791
•• Beginning with air craft serial 18800792 Figure llA- 6, Engine Contr ols (Shee t 3 of 7) llA-24
MODEL 188 & T188 SERIES SERVICE MANUAL
RIGHT HAND SIDE LOOKING INBOARD
*
SE::
*BRACKET ASSEMBLY
TiiRU AffiCRAFT
18801041
netau A AffiCRAFT SERIALS 18801041 THRU 18801638, 18801643, 18801644 , 1880 1647, AND 18801650 AND AffiCRAFT MODIFIED BY CESSNA SINGLE ENGINE SERVICE LETTER SE73 - l. 30 TORQUE TO 100 to 120 LB -IN
16
17
* NOTE On aircraft serials 18800833 thru 18801629 10 18801643 , and 18801644, equipped with the 300 H. P. I0-520 D engine, at the 100 hour inspection if the safety wire used to secure the throttle or mixture control is broken or deteriorated refer to Cessna Single -engine Service Letter SE74 -20 Dated September 20, 1974.
•
AffiCRAFT SERIALS 18800833 THRU 18801638, 181301643 , 18801644, 18801647 AND 18801650: SAFETY WIRE TiiROTTLE AND MIXTURE CONTROL TO BRACKET ASSEMBLY.
27
22 I I
\"
netatt A . BEGINNING WITH AffiCRAFT SERIALS 18801639 THRU 18801642, 18801645, 18801646, 18801648, 18801649 AND 18801651 AND ON AND ALL SPARES.
BEGINNING WITH AIR CRAFT SERIAL 18800833 Figure 11A-6. Engine Controls (Sheet 4 of 7) llA-25
MODEL 188 & T188 SERIES SERVICE MANUAL
LEFT HAND SIDE LOOKING INBOARD ll
~32
;\ \
~
-
-..
0
A
Beginning with Aircraft Serial 18800955 thru 18801374
39
35
41
A 45
AffiCRAFT SERIAL 18800833 THRU 18801374 Figure llA- 6 . l lA- 26
Engine Controls ( Sheet 5 of 7)
BEGINNING WITH AffiCRAFT SERIAL 18801043, AND 18800Â 833 WHEN MODIFIED PER CESSNA SINGLE -ENGINE SERVICE LETTER SE75-5, DATED FEBRUARY 7 , 1975. Detail
B
MODEL 188 & T188 SERIES SERVICE MANUAL
c!
* NOTE
..
·~
On aircraft equipped with the 300 H. P. I0 520-D engine, serial numbers 18801375 THRU
18801824, Refer to Cessna Single-engine
Service Letter SE74-23, dated October 4,
1974 and on aircraft serial numbers 188 00833 THRU 18801374, refer to Cessna
Single -engine Service Letter SE75 -5, dated
February 7, 1975 for induction air duct improvement .
I
8
:
I
*•
• Refer to Section 2 for service
requirements of filter (10).
9
11 NOTE
18
On aircraft serials 18801375 THRU
18802001 when the new solid rubber
forward engine mounts are mstalled, refer to Cessna Single-engine Service Letter SE75-4, dated January 31, 1975.
1. Duct Assembly
11. Door Assembly ' ~
2. Airbox Assembly 12. Bushing Assembly 3. Clamp 4. Hose 5. RH Support 6. Bracket 7. Adapter 8. Engine :-.Aount 9. Control 10. Filter
15
13. Control Wire 14. Arm 15. Cover Assembly 16. Stud 17. Drain Assembly 18. Seal Retamer 19 . Seal 20. Spa::er Figure llA-6 .
-...;;:~~~~~~9
~
~---- 11
AffiCRAFT SERIAL 18801375 THRU 18802859
Engine Controls (Sheet 6 of 7) l l A-27
MODEL 188 & T188 SERIES SERVICE MANUAL
53
A
With Valve Closed
52
53
A·A · Wlth Valve Open
49. 50. 51.
52. 53. 54. 55. 56.
Wing Nut Cover Assembly Filter Air Valve Control Housing Locking Nut Control Wire Arm
BEGINNING WITH AIRCRAFT SERIAL 18802860
Figure llA-6. llA-28
Engine Co ntrol (sheet 7 of 7)
MODEL 188 & T188 SERIES SERVICE MANUAL
1. Discormect mixture control (22) rod end from arm (16). 2. In the cockpit, push mixture control IN, wt
lock and pull control OUT approximately 1/8-inch
for cushion.
3. Be sure control (21) IS attached to the bracket (26) properly and safety wire / retainer is installed. 4. Place control arm ( 16) against the FULL RICH stop, adjust mixture control (22) rod end to align with arm and install attaching bolt and washers. 5. Unlock and pull mixture control OUT and check that control arm (16) is against IDLE CUT-OFF stop. 6. Check that sufficient threads are engaged in
mixture control (22) rod end and tighten jam nut.
NOTE Refer to the inspection chart in Section 2 for inspection, lubrication and/or replace ment interval for the mixture control. llA-66. 13.
PROPELLER CONTROL. Refer to Section
11A-67. ALTERNATE Am CONTROL. (BEGINNING WITII AIRCRAFT SERIAL 18800833 .) (See figure llA-6. sheet 5 ) NOTE Cowling must be properly installed prior to rigging of alternate air control. a. Loosen jam nuts at both ends of rod assembly (42). b. Discormect ball joint (43) from ball on arm assembly (44 ). c . Adjust ball joint (43) on rod assembly (42) until sufficient threads are engaged. d. Screw rod (42) into rod end (38) to obtain approxi. ma tely 8. 65 inches between center of ball socket and center of rod end. e. Cormect ball joint (43) to ball on arm assembly (44 ) and tighten jam nuts. f. In the cockpit, push alternate air control full lN and check that alternate air door (45) is fully closed. g. II door (45) is NOT fully closed, loosen clamps securing control (37) to eng~ne mount (39) and support assembly (41 ) and slide control through clamps until door is fully closed. Tighten clamps. h. In the cockpit, unlock alternate air control, pull control full OUT (approximately 3 inches) and check that alternate air door (45) is fully open. NOTE After completion of step "h'' the alternate
a1r control should be proper!y rigged,
however, in come cases, it may become
necessary to shorten the control housing
10 order for the bellcrank (36) to reach
ful l travel. If so, proceed to step "i".
i . Loosen clamp- bolt at bellcrank (36), straighten control wire and slide wire from clamp- bolt. j. In the cockpit, using care not to lose ball bear ing from the control at instrument panel, unlock and pull control OUT until wire is out-of-sight inside housing at the engine end of control. Cut the housing off as required to allow bellcrank to attain full travel and reinstall wire in clamp- bolt. Bend wire to a 90° angle as a safety precaution. k. Check operation of air door in both directions
making sure the control in the cockpit does not pull
out more than 3 inches maximum .
NOTE The result of rigging, in all cases, is the alternate air door (45) must be fully OPEN when the control in the cockpit is pulled out a maximum of 3 inches, that the door is fully CLOSED when the control is pushed in and that no binding of the system is experienced. • Refer to the inspection chart in Section 2
for inspection, lubrication and/or replace
ment interval for the alternate air control.
UA-68. STARTING SYSTEM.
Refer to Section 11.
llA-69. EXHAUST SYSTEM. llA-70. DESCRIPTION. The exhaust system con sists of two exhaust stack assemblies, for the left and right bank of cylinders. Each cylinder has a riser pipe attached to the exhaust port. The three risers at each bank of cylinders are joined together into a collector pipe forming an exhaust stack assem bly. The center riser on each bank is detachable, but the front and aft risers are welded to the collector pipe. Each exhaust stack assembly cormects to the muffler beneath the engine. The muffler is enclosed in a shroud which captures exhaust heat which is used to heat the cockpit. The tailpipe is welded to the muffler. llA-71. REMOVAL AND INSTALLATION. a. Remove engine cowling in accordance with para graph llA-3. b. Discormect ducts from heater shroud on muffler assembly. c. Remove nuts, bolts and clamps attaching stack assemblies to the muffler. d . Loosen nuts attaching exhaust stacks to the cylinders and remove muffler assembly. e. Remove nuts attaching exhaust stack assemblie s to the cylinders and remove exhaust stacks and gas kets. f. Reverse the preceding steps for reinstallation. Install a new copper-asbestos gasket between each riser and its mounting pad on each cylinder, regard less of apparent condition of those removed. Torque exhaust stack nuts at cylinders to 100-110 pound inches.
llA:-29
MODEL 188 & T188 SERIES SERVICE MANUAL
llA-72. INSPECTION. Since exhaust systems of this type a re subject to burning, cracking and general deterioration from alternate thermal stresses and vibrations, inspection is important and should be accomplished every 100 hours of operation. Also, a thorough inspection of the engine exhaust system should be made to detect cracks causing leaks which could result in loss of engine power. To inspect the engine exhaust system, proceed as follows: a. Remove engine cowling as requi red so that ALL surfaces of t he exhaust asse mblies can be visually inspected.
2. With vacuum cleaner operating, aU joints in the exhaust system may be checked manually by feel, or by using a soap and water solution and watching for bubbles. All joints should be free of air leaks. NOTE Begining with aircraft serials 18800833 the ball joint should be inspected in ac cordance with Cessna Single Engine Service Letter SE 78-42.
NOTE Especially check the areas adjacent to welds and slip joints. Look for gas deposits in sur rounding area, indicating that exhaust gases are escaping through a crack or hole or around the slip joints. b. After visual inspection, an air leak check should be made on the exhaust system as follows: 1. Attach the pressure side of an industrial vacuum cleaner to the tailpipe opening, using a rub ber plug to effect a s eal as required. NOTE The inside of the vacuum c leaner hose should be free of any contamination that might be blown into the engine exhaust system.
SHOP NOTES:
llA-30
llA-73. EXTREME WEATHER MAINTENANCE .
Refer to Section 11.
llA-74. COLD WEATHER.
Refer to Section ll.
llA-75. SEACOAST AND HUMID AREAS. Section 11.
Refer to
llA-76. DUSTY AREAS. Refer to Section 11. llA-77. GROUND SERVICE RECEPTACLE
Refer to Section 16.
SECTION liB ENGINE (TURBOCHARGED)
lWARNINGl When performing any inspection or mainte nance that requires turning on the master switch, installing a battery, or pulllng the propeller through by hand, treat the propel ler as if the ignition switch were ON. Do not stand, nor allow anyone else to stand, within the arc of the propeller, since a loose or broken wire, or a component mal function, could cause the propeller to rotate. NOTE For additional infor mation covering tur bocharger and component maintenance, overhaul and trouble shooting refer to the manufacturers' overhaul manua l.
TABLE OF CONTENTS
Page No. Aerofiche/Manual
ENGINE COWLING . .
. 1Kl2/11B-2 Description . . .
. 1K12/11B-2 Removal and Installation ·
. 1K12/11B- 2 Cleaning and Inspection
. 1K12/11B- 2 Repair . . . . . . . .
. 1K12/11B-2 ENGINE . . . . . . . . . . . 1K12/11B-2 Description . . . . . . . 1K12/11B-2 Time Between Overhaul (TBO) . . IKI2/11B-2 Overspeed Limitation . . . . 1K12/11B-2 Engine Data . . . . . . . . 1K12/11B-2 Trouble Shooting . . . . . . 1K14/11B-4 Static Run-Up Procedures . . 1K20/11B-10 Removal and Installation. . 1K20/11B-:10 Inspection . . . . . . . 1K20/11B- 10 Cleamng . . . . . . . 1K20/11B-10 Accesso nes Removal . . 1K20/11B-10 Inspection . . .
. • . 1K20/11B- 10 Build Up . . . . . .
. 1K20/11B-10 Flexible Fluid Hoses
. 1K20/11B-10 Baffles . . .
. 1K20/11B-10 Mount . . . .
. 1K20/11B-10 Painting .
. 1K20/11B-10 OIL SYSTEM . . . 1K20/ 11B-10 FUEL SYSTEM . . . 1K20/ 11B-10 Desc ription . . 1K20/11B-10 Fuel-Air Contro l Unit. . 1K20/11B-10 Removal and Installat ion . 1K20/11B-10 Adjustments, Cleaning and Inspection . . . . . . . . 1K20/11B-10 Throttle Rigging . . . . . . 1K20/11B- 10 Rigging Throttle Operated Micro switch . . . . . . . 1K20/11B-10 Fuel Manifold Valve . . . . 1K20/11B- 10 Removal. Cleaning and Installatio n . . . . . 1K20/ 11B-10
Fuel Discharge Nozzles . . . Cleaning, Inspection and Installation . Fuel Injection Pump Description Removal . . . . Installation . . Adjustment . . Idle Speed and Idle Mixture
Adjustment . . . . . .
INDUCTION AIR SYSTEM . . . . .
Description . . . . . . . . .
Airbox Removal and Installation
Cleaning and Inspection . . ·Induction Air Filter Replacement . Alternate Air Valve Control Rigging . . . . . PROPELLER CONTROL STARTING SYSTEM (;OOLING SYSTEM . EXHAUST SYSTEM . Description . .
Inspection . . .
TURBOCHARGING SYSTEM Removal and Installation Operation . . . . . . . Fuel Pressure and Waste Gate Adjustments . . . . . . . . EXTREME WEATHER MAINTENANCE Cold Weather . . . . . . Dusty Areas . . . . . . . Ground Service Receptacle
1K20/11B- 10 1K20/11B-10 1K21/11B-ll 1K21/11B- 11 1K21/11B- i.1 1K21/11B-ll 1K21/11B- ll" 1K23/ 11B-13 1K23/11B-13 1K23/11B-13 1K23/11B-13 lLl/llB-15 1L1/ 11B-15 lLl/llB-15 lLl/llB- 15 lLl/llB- 15 lLl/llB-15 1L1/11B- 15 lLl/llB- 15 1L1/11B-15 lLl/llB-15 1L2/ 11B-16 1L2/ 11B- l6 1L7/11B- 21 1L7/ 11B-21 1L7/11B-21 1L7/ 11B-21 1L7/ 11B-21
Revision 1
llB-1
MODEL 188 & T188 SERIES SERVICE MANUAL
11 B-1.
ENGINE COWUNG.
11B-2.
DESCRIPTION.
(Refer to Section llA.)
llB-3. REMOVAL AND INSTALLATION. Unfastern the quick release fasteners along rear edge of top section, and both left and right sides to remove top section. To remove either side panel, unfasten the corresponding side quick fasteners, and the lower fasteners along lower edge of left panel connecting right and left lower cowl sections. 11B-4. CLEANING AND INSPECTION. Section 11A. )
llB-5 .
REPAIR.
llB-6.
ENGINE.
(Refer to
(Refer to Section 17.)
llB-7. DESCRIPTION. An air-cooled, horizontally opposed, direct-drive, fuel-injected, six - cylinder turbocharged, Continental TSI0-520- T series engine, driving a constant speed propeller, is used to power the aircraft. The cylinders, numbered from rear to front are staggered to permit a separate throw on the crankshaft for each connecting rod. The right rear sylincer is number 1 and cylinders on the right llB-9.
side are ider.tified by odd numbers 1, 3 ana 5. The left rear cylinder is number 2 and cylinders on the left side are identified by even numbers 2, 4 and 6. Refer to paragraph llB-8 for engine data. For re pair and overhaul of the engine, accessories and pro peller, refer to the appropriate publications issued by their manufacturer's. These publications are available from the Cessna Supply DiviSion. llB-8. TIME BETWEEN OVERHAUL (TBO). Tele dyne Continental Motors recommends engine overhaul at 1200 hours operating time for the TSI0-520-T series engines employed in spraying or dustlng oper ations. Refer to Continental Aircraft Engine Service Bulletin M81-22 , and to any superseding bulletins , revisions or supplements thereto, for further recom mendations. At the time of overhaul, engine acces sories should be overhauled. Refer to Section 13 for propeller and go·:ernor overhaul periods . 11B-8A. OVERSPEED UMITATIONS The engine
must not be operated above specified maximum con
tinuous RPM. However, should inadvertent over
speed occur, refer to Continental Aircraft Engine
Service Bulletin M75- 16, and to any superseding
bulletins, revisions or supplements thereto, for
further recommendations.
ENGINE DATA.
Aircraft
T188C Ag Husky
Model (Continental)
TSI0-520-T
BHP Rated
Continuous
310 2700 RPM
BHP Maximum Cruise
230 2500 RPM
Manifold Pressure at Sea Level
39. 5" Hg.
Displacement Bore Stroke
520 Cubic Inches
5.25"
4.00"
Compression Radio
7. 5 : 1
Magnetor
Timing , 0 BTC (-1° +1°)
Slick No. 6210 (2 each) Impulse Rlght 22°, fires Upper Right - Lower Left Left 22°, fires Upper Left - Lower Right
Engine Firing Order
1- 6- 3- 2-5-4
Spark Plugs
18MM (Refer to Continental Service Bulletin M77-10, latest edition, for factory approved plug and required gap).
Torque
330 :: 30 In/ Lbs.
118- 2
Revision
1
I
MODEL 188 & T188 SERIES SERVICE MANUAL
11 B-8 .
ENGINE DATA (Cont);
Fuel Metering System
Unmetered Fuel Pressure
Nozzle Pressure
Continental Fuel Injection 5. 5 to 6. 5 PSI at 600 RPM 33. 5 to 37. 5 PSI at 2700 RPM 4. 0 to 4. 5 PSI at 600 RPM 16. 5 to 18.0 PSI at 2700 RPM
Fuel
Grade Minimum
Aviation lOOLL/100 Grade (115/145 Aviation Grade with Lead Content limited to 4. 6cc Tetraethyl Lead per gallon).
Alternator
28Vdc, 60 Amp
Starter
24 Vdc, Automatic engagement
Oil Capacity
13 U.S. Quarts
Tachometer
Mechanical Drive
Oil Pressure (PSI) Normal Minimum Idling Maximum Cold Source
30- 60
10
100
Between No. 2 and No. 4 Cylinder bases
from left main oil galley.
Oil Temperature Normal Maximum Probe Location
Within Green Arc Red Line (240°F) Below oil cooler adaptor plate
Cylinder Head Temperature Normal Maximum Thermocouple Location
Within Green Arc Red Line (460°F) Number 2 cylinder head
DirectiOn of Rotation (Viewed from Rear)
Clockwise
Dr v We1g ht - With Accesso ries
473. 7 LB Approximate
SHOP NOTES:
118-3
MODEL 188 & T188 SERIES SERVICE MANUAL llB-10.
TROUBLE SHOOTING. TROUBLE
ENGI).;E FAILS TO START.
PROBABLE CAUSE Engine flooded or improper use of starting procedure.
Refer to the Information Manual for correct starting procedures.
Defective aircrait fuel system.
Refer to Section 12.
Fuel tanks empty.
Service fuel tanks.
Spark plugs fouled or defective.
Remove, clean, inspect and regap. Use new gaskets. Check cables to presistently fouled plugs. Re place if defective.
Magneto impulse coupling failure.
Repair o-:- install new coupling.
Defective magneto switch or grounded magneto leads.
Repair or replace switch and leads.
Defective ignition system.
Refer to paragraph 11-61.
Induction air
ENGI~E STARTS BUT DIES. OR WILL NOT IDLE PROPERLY.-
11B-4
Revision 1
REMEDY
leak~e.
Correct
ca~se
of air leakage.
Clo~,rged fuel screen in fuel control unit or defective unit.
Remove and clean. defectivE' unit.
Replace
Clogged fuel screen in fuel manifold \¡alve or defective valve.
Remove and clean screen. ¡Replace defective valve.
Clogged fuel injection lines or discharge nozzles.
Remove and clean lines and nozzles. Replace defective units.
Defective auxiliary fuel pump.
Refer to Section 12.
Engine-dri ven fuel pump not permitting fuel from auxiliary pump to bypass.
Install new engine -driven fuel pump.
Vaporized fuel in system. (Most likely t6 occur in hot weather with a hot engine. l
Refer to the Information Manual for correct starting procedures.
Propeller cont r ol in high pitch (low rpm) position.
Use low pitch (high rpm) position for all ground operations.
Imprope r idle speed or idle mixture adjustment.
Refer to paragraph llB-39.
Defective aircrait fuel system.
Refer to Section 12.
Spark plugs fouled or defective.
Re move, clean, inspe ct and regap. Use new gaskets. Check cables to persistently fouled plugs. Replace if defective.
Water in fuel system.
Drain fuel tank sumps, lines and fuel strainer.
Defecttve I!?:Oition system.
Refer to paragraph 11-61.
I
MODEL 188 & T188 SERIES SERVICE MANUAL llB-10. TROUBLE SHOOTrNG (Cont) . TROUBLE ENGINE STARTS BUT DIES, OR WILL NOT IDLE PROPERLY (CONT).
ENGINE HAS POOR ACCEL ERATION. RUNS ROUGHLY AT SPEEDS ABOVE IDLE OR LACKS POWER.
PROBABLE CAUSE
REMEDY
Induction air leakage.
Correct cause of air leakage.
Clogged fuel screen in fuel control unit or defective unit.
Remove and clean. defective unit.
Replace
Clogged fue l screen ln fuel mani fold valve or defective valve.
Remove and clean. defective valve.
Replace
Restricted fuel injection lines or discharge nozzles.
Remove , clean lines and nozzles. Replace defective units.
Defective engine driven fuel pump.
Install and calibrate new pump.
Vaporized fuel in syst em. (Most likely to occur in hot weather with a hot engine.)
Refer to Information Manual.
Obstructed air intake.
Remove obstruction; service air filter, if necessary.
Discharge nozzle air vent manifolding restr icted or defective.
Check for bent lines or loose con nections . Tighten loose connec tions. Remove restrictions and replace defective components.
Defective engine.
Check compression and listen for unusal engine noises. Check oil filter for excessive metal. Repair e ngine as required.
Idle mixture too lean.
Refer to paragraph 118-39.
Propeller control in high pitch (low rpm) position.
Use low pitch (high rpm) position for all ground operations.
~ncorrect fuel-air mixture, worn contr o l linkage or restricted air filter.
Replace worn elements of control linkage. Service air filter.
Defective ignition system.
Refer to paragraph 11 - 61.
MaUunctioning turbocharger.
Check operation, listen for unusual noise. Tighten loose connections.
Impr oper fuel- air mixtur e.
C heck intake manifo ld connections for leaks. Tighten loose connec tions. Check fuel controls and link age for setting and adjust ment.
llB- 5
I I
MODEL 188 & T188 SERIES SERVICE MANUAL 118-10. TROUBLE SHOOTING (Cont).
TROUBLE ENGINE HAS POOR ACCEL足 ERATION. RUNS ROUGHLY AT SPEEDS i\BOVE IDLE OR LACKS POWER (CONT).
POOR IDLE CUT -OFF.
E:-lG INE LACKS POWER. RE 足 DUCTION I ~ ~1AXIMUM ~tANIFOLD PRESSURE OR C RrTICAL ALTITL' DE.
118-6
PROBABLE CAUSE
REMEDY
Spark plugs fouled or defective.
Remove, clean, inspect and regap. Use new gaskets. Check cables to persistently fouled plugs. Replace if defectin:.
Fuel pump pressure 1 mproperly adjusted.
Refer to paragraph 118- 55 .
Restriction in fuel inJection system.
Clean out restriction. defective items.
Propeller out of balance.
Check and balance propeller.
Defective engine.
Check compression, check oil filter for excessive metal. Listen for unusual noises. Repair engine as required.
Exhaust system leakage.
Refer to paragraph llA-60 .
Turbocharger wheels rubbing.
Replace turbocharger.
Improperly adjusted or defective waste -gJ.te
Refer to paragraph 118-55.
Leak in turbocharger discharge pressur e system.
Correct cause of leaks. Repair or replace damaged parts.
Overboost Valve Defective
Replace Valve
Mixture control linkage im足 properly rigged.
Refer to Figure llA -5.
Defective or dirty fuel manifold valve.
Remove and clean manifold valve.
Fuel contamination.
Drain a ll fuel and flush out fuel system. Clean all screens. fuel strainers, fuel manifold valves. nozzles and fuel lines.
Defective mixture control valve in fuel pump.
Replace fuel pump.
Inco rrectly adjusted throttle control. "sticky" linkage or dirty :1.1r filter.
Check movement of linkage by mov足 ing control through range of travel. :Vtake proper adjustments and re place worn components. Service air filte r.
Overboost Valve Defective
Replace Valve
Replace
.
MODEL 188 & T188 SERIES SERVICE MANUAL llB-10.
TROUBLE SHOOTING (Cont). TROUBLE
ENGINE LACKS POWER, HEDUCTION IN MAXIMUM
MANIFOLD PRESSURE OR
CRITICAL ALTITUDE (C ONT).
BLACK SMOKE EXHAUST.
HIG H CYLINDER HEAD TEM PERATU RE.
PROBABLE CAUSE
REMEDY
Defective ignition system.
Inspect spark plugs for fouled
electrodes, heavy carbon de-
posits, erosion of electrodes,
impr operly adjusted electrode gaps and cracked porcelains. Test plugs for r egular firing under pressu r e. Replace dam aged or misfiring plugs.
Improperly adjusted wastegate.
Refer to paragraph llB-55.
Loose or damaged e:ochaust system.
lnsi)E'ct entire exhaust system to turbocharger for cracks and leaki ng connections. Tighten connections and replace damage d parts.
Loose o r damaged manifolding.
Inspect entire manifolding system for possible leakage at connections. Replace damaged components, tighten all connections and clamps .
Fuel discharge nozzle defective.
Inspect fue l discharge nozzle· vent manifolding fo r leaking coMections. Tighten a nd repair as required. Check for restricted nozzles and lines and clean and replace as necessary.
Malfunctioning turoocharger.
Check for unusual noise in turbo charger. If malfunction is sus pected, remove exhaust and/or air inlet connections and c heck ro tor assembly, for possible rubbing in housing, damaged rotor blades or defective bearings. Replace turbocharger if damage is noted.
Turbo coking, oil forced through seal of turbine housing.
Clean or change turboc harger.
Oil Check Valve Defective
Replace Valve
Defec tive cylinder head tempera-
Refer to Section 15.
ture indicating system. Engine baffles loose, bent o r missing.
Install baffles properly. replace if defective.
Repair or
Dt rt accu mutated on cylinde r cooling fins.
Clean thoroughly.
Incorrect grade of fuel.
Drain and refill with proper fuel.
118-7
MODEL 188 & T188 SERIES SERVICE MANUAL llB-10.
TROUBLE SHOOTING ( Contl.
TROt.:BLE
L· :·MBLE TO GET RATED POWER BECA USE :\tANIFOLD PRESSU RE IS LOW.
PROBABLE C'A I!SE
Overboost Valve Defective A1r Filter Obstructed
Improperly adjusted wastegate
Leak i n i ntake system.
Leak tn exhaust
T URBOCHARG ER :-IOISY WITH PLE ~ TY OF POWER.
E;..; GI~E POWER I~CREASES SLOWLY OR SEVERE ~A N I FOLD PRESSU RE fL UCTU A T IOt"S WH EN THROTT L E A D\·A~CED RAPIDLY.
E:-."Gr..: E POWER INCREA SES RAPIDLY A~D :\1ANIFOLD PRESSURE OV ERBOOSTS \\-. HF'I THROTTLE AD \ -\ :".C' F D RA PIDLY .
118 -8
sy ~t em.
Turbocharger ove1· speeding fro m defec tive o r t mpr op~rly adjusted Wastegate
REMEDY
Replace Valve Check - Replace if Obstructed Adjust wastegate . Refer to paragraph llB-55.
Check for c racks and other ob vi ous jefects. Replace defective compcnents. Tighten clamps and connections.
Check for cracks and loose connections. Replace defective c omponents. Ti ghten all clamps and connections.
Refer to paragraph llB- 56 . Replace if defective.
Overboost Valve Defective
ReplacE- Valve
Overboos t Va lve Defective
Replace Valve
Overboost Va lve Defective
Replace Valve
MODEL 188 & T188 SERIES SERVICE MANUAL llB-10.
TROUBLE SHOOTING (Cont). TROUBLE
FUEL PRESSURE DECREASES DURING CUMB, WHILE :'\iANIFOLD PRESSURE REMAINS CONSTANT.
PROBABLE CAUSE
REMEDY
Compressor dischaq;e pressure line to fuel pump aneroid rest ricted.
Check and c lean out rc ::>trictions.
Leaking o r otherwisE' defective engine-driven fuel pump aneroid.
Replace t•ngine-driven fuel pump.
Leak in intake system.
Check for cracks and other obvious defects. Tighten all hose clamps and fittings. Replace defective components.
Leak in exhaust system.
Check for cracks a nd other obvious defects. Tighten all clamps and fittings. Replace defectivE: components.
Overboost Valve Defective
Replace Valve
Intake air filter obstructed.
Service air filter. Refer to Section 2 fo r servicing instructions.
Improperly adj usted wastegate
Adjust wastegat e . Refer to paragraph llB- 55.
ll:!fective engine-driven fuel !JUmJ aneroid mechanism.
Replace engine-driven fuel pump.
Obstruction o r leak in compressor discharge pressure line to engine driven fuel pump.
Check for leaks or obstruction. Clean out lines and tighten all connections.
fL'EL FLOW INDICATOR DOES ~OT REGISTER CHANGE IN POWER SETTINGS AT HIGH ALTITUDES.
)ftoisture freezing 1n indicator line.
Disconnect lines, thaw ice and clean out lines.
SUDDEN POWER DECREASE ACCOMPANIED BY LOUD NOISE OF RUSHING AIR.
Intake system atr leak from hose becoming detached.
Check hose condition. Install hose and hose clamp securely.
Oil Gage Line Contaminated
Check and Clean or Replace
ABNORMAL MANIFOLD PRESSURE DECREASE DURING CLIMB AT ALTITUDES BELOW NORMAL PART THROTTLE CRITICAL ALTITUDE
fL'EL FLOW DOES NOT DE CREASE AS MANIFOLD PRESSURE DECREASES AT PART - THROTTLE CRITICAL ALTITUDE.
:'.1ANIFOLD PRESSURE GAGE WILL NOT PE :\-lAIN STEADY AT CONSTANT POWER SETTINGS. OR IS SL UGGISH. INDICATIO~
llB-9
MODEL 188 & T188 SERIES SERVICE MANUAL
llB-11. STATIC RUN-UP PROCEDURES. Ina case
llB-19.
ENGINE BAFFLES. (Refer to Section 11).
llB-20.
ENGINE MOUNT. (Refer to Section llA).
of suspected low engine power, a static run-up shoold
be conducted as follows: a. Run-up engine, using takeoff power and mixture
settings, with the aircraft facing 90° right and then
left to the wind direction.
b. Record the RPM obtained in each run-up position.
Daily changes in atmospheric pressure,
temperature and humidity will have a
slight effect on static run-up.
c. Average the results of the RPM obtained. It
should be within 50 RPM of 2700 RPM, 2700 RPM
must not be exceeded at any time.
d. If the average results of the RPM obtained are lower than stated above, the following recommended checks may be performed to determine a possible deficiency. 1. Check governor control for proper rigging. It should be determined that the governor control arm travels to the high RPM stop on the governor and that the high RPM stop screw is adjusted proper ly. (Refer to Section 13 for procedures).
NOTE If verification of governor operation is
necessary the governor may be removed
from the engine and a flat plate installed
over the engine pad. Run-up engine to
determine that governor was adjusted
correctly.
2. Check magneto timing, spark plugs and igni tion harness for settings and condition. 3. Check fuel injection nozzles for restriction and check for correct unmetered fuel flow. 4. Check condition o! induction air !ilter. Clean if required. 5. Perform an engine compression check (Refer to engine manufacturer's manual). llB-12. REMOVAL AND INSTALLATION. (Refer to Section llA). llB-13. INSPECTION. (Refer to Section llA ). llB-14. CLEANING. (Refer to Section 11). (Refer to
11B-16. INSPECTION. (Refer to Section 11 ). 118- 17.
8t;ILD t:P.
(Refer to Section 11 ).
11B-18. FLEXIBLE FLt:ID HOSES. (Refer to Section 2 ).
118 -10.
llB-22.
(Refer to
ENGlliE OIL SYSTEM. (Refer to Section
11).
NOTE
11 B-15. ACCESSORIES REMOVAL. Section ll ).
llB-21. PAINTING ENGINE MOUNT. Section 19).
llB-23.
ENGlliE FUEL STiiTEM.
llB-24. DE;:)CRIPTION. The fuel injection system is a low pressure system of injecting fuel into the intake valve port of each cylinder. It is a multi nozzle, continuous-flow type which controls fuel flow to match engine airflow. Any change in throttle position. engine speed. or a combination of both. causes changes in fuel flow in the correct relation to engine airflow. A manual mixture control and a fuel flow indicator are provided. The fuel flow indicator is calibrated in gallons per hour and indicates approxi· mately the gallons of fuel consumed per hour. The continuous-flow system uses a typical rotary vane fuel pump. There are no running parts in this system ex cept for the engine-driven fuel pump. The four major components of the system are: the fuel injection pump, fuel-air control unit, fuel manifold valve and the fuel discharge nozzles. The fuel injection pump incorporates an adjustable aneroid sensing unit which is pressurized from the discharge side of the turbo charger compressor. Turbocharger discharge air pressure is also used to vent the fuel discharge noz zles and the vent port of the fuel-flow gage. llB-25. FUEL- AIR CONTROL UNIT. (Refer to Section llA. llB-26. REMOVAL AND INSTALLATION. (Refer to Section llA. ) llB-27. ADJUSTMENTS.CLEANING AND INSPEC TION. (Refer to Section llA.) llB-28.
THROTTLE RIGGING. (Refer to
Section llA.) llB-29. RIGGING THROTTLE OPERATED MICRO SWITCH. (Refer to Section 12.) 118-30. FUEL MANIFOLD VALVE. (Refer to Section llA.) 118-31. REMOVAL, CLEANING, AND INSTALLA TION. ( Refer to Section llA. ) llB-32. FUEL DISCHARGE NOZZLES. ( Refer to Section llA. l 118-33. CLEANING, INSPECTION, AND INSTALLA TION. ( Refer to Section llA. l
MODEL 188 & T188 SERIES SERVICE MANUAL
llB-34.
FUEL INJECTION PUMP.
UB-35. DESCRIPTION. The fuel pump is a positive displacement. rotating vane type. It has a splined shalt for connection to the accessory drive section of the engine. Fuel enters the pump at the swirl well of the pump vapor separator. Here, vapor is separated by a swirling motion so that only liquid fuel is fed to the pump. The vapor is drawn from the top center of the swirl well by a small pressure jet of fuel and is fed into the vapor return line where it is returned to the fuel tank. Since the pump is engine-driven. changes in engine speed affect total pump flow propor tionally. A check valve allows the auxiliary fuel pump pressure to bypass the engine-driven pump for start ing . or in the event of engine-driven fuel pump failure in flight . The pump supplies more fuel than is re quired by the engine; therefore. a relief valve is pro vided to maintain a constant fuel pump pressure. The engine-driven fuel pump is equipped with an aneroid. The aneroid and relief valve are pressurized from the discharge side of the turbocharger compressor to mamtain a proper fueVair ratio at altitude. The aneroid is adjustable for fuel pump outlet pressure at full thro ttle and the relief valve is adjustable for fuel pump outlet pressure at idle. llB-36. REMOVAL. a. Place full shut-off valve in OFF position and
mixture control in IDLE CUT-OFF position.
b. Remove upper cowling section in accordance with paragraph llB-3. c. Loosen the clamps and slide the flexible tubes free of the horns on the fuel pump shroud to gain ac cess to the fuel lines. d. Remove the alternator drive belt. e. Tag and disconnect all lines and fittings attached to 'the fuel pump.
NOTE Plug o r cap all disconnected lines , hoses and fittings .
llB-37. INSTALLATION. a. Position a new gasket and fuel pump on the
mounting studs with fuel pump inlet to the left. Be
sure pump drive aligns with drive in the engine.
b. Secure pump to engine with plain washers. in
ternal tooth lockwashers and nuts. Tighten nuts
evenly.
c . Install cooling shroud on fuel pump. d. Install all fittings and connect all lines . e. Install the flexible ram air tube on the air horn of the fuel pump shroud and install clamp. f. Replace the alternator drive belt and tighten the nuts on the adjusting arm so that the drive belt has proper tension. Refer to Section 16. g. Inspect complete installation. llB-38. ADJUSTMENT. Adjustments of the fuel in jection pump requires special equipment and proce dures. Adjustment to the aneroid applies only to the full throttle setting. Adjustment of the idle position is obtained through the relief valve. To adjust the pump to the pressures specified in paragraph llB-8, proceed as follows: • a. Remove engine cowling in accordance with para graph llB-3. b. Disconnect the existing engine-driven fuel pump pressure hose at the fuel metering unit and connect the test gage pressure hose and fittings into the fuel injection system as s hown in figure llB-1. Gage MUST be vented to atmosphere. NOTE Cessna Service Kit No. SK320-2J provides
a test gage, line and fittings for connecting the test gage into the system to perform accurate calibration of the engine-driven fuel pump. c. The test gage MUST be held as near to the level of the engine driven fuel pump as possible. Bleed air from test gage line prior to taking readings.
NOTE Remove the shroud surrounding the fuel pump. g . Remove the nuts and washers attaching the fuel pump to the engine. h. Remove fuel pump and gasket. f.
!WARNING' Residual fuel draining from lines and hose constitutes a fire hazard. Use caution to prevent accumulation of fuel when lines or hoses are disconnected. i. If a replacement pump is not being installed im mediately, a temporary cover should be installed on the fuel pump mount pad.
The test gage should be checked for accuracy at least every 90 days or anytime an error is suspected. The tachometer accuracy should also be determined prior to making any ad justments to the p.~mp. d. Start engine and warm-up thoroughly. tiet mix ture control to full rich position and propeller control full forward (low pitch, high rpm) . e . Adjust engine idle speed to 600 ± 25 rpm and check test gage for 5. 5 - 6. 5 PSI.
NOTE Do not adjust idle mixture until idle pump
pressure is obtained.
llB-11
MODEL 188 & T188 SERIES SERVICE MANUAL
IWARNINGl DO Nar make fuel pump pressure ad just
ments while engine is operating. C. If the pump pressure is not 5. 5 - 6. 5 PSI . s top engine and turn the pump relief valve adjustment. on the centerline of the fuel pump clockwise (CW) to in crease pre s sure and counterclockwise (CCW) to de crease pres sure. g . Maintaining idle pump pressure and idle RPM. obtain correct idle mixture in accordance with para graph llB-40 . h. Co mpleuon of the preceding steps have pr ovided: 1. Correct idle pump pres sure. 2 . Correct fuel flow. 3. Correc t fuel metering c am to throttle plate orientation. i. Advanc e to full throttle and maximum rated en gine speed with the mixture control in full rich posi
FUEL METERING UNIT
tion and pr opeller control in full forward (low pitch. high rpm). j. Check test gage for pressures specified in para graph 118-8. U pr essure is incorrect, stop engine and adjust pr essure by loosening locknu t and tur ning the adjusting screw located at rear of aneroid counter clockwise (CCW) to increas e pressure and clockwis e (CW) to decrease pressure. NOTE
If a t s tatic run-up. rated RPM cannot be
achieved at full throttle, adjust pump pres sure s lightly below limits making cer tain the correct pressures are o btained when rated RPM is achieved during take - off r oll. k. After cor rect pressures are obtained, tighten locknut. 1. Remove test equipment. run e ngine to check fo r leaks and install cowling.
EXISTING FUEL PUMP OUTLET HOSE
ENGINE DRIVEN FUEL PUMP
'
I
. - - - -NIPPLES
I TEE
PRESSURE INDICATOR
TEST HOSE
TEST HOSE
~OT E
WH E:-1 A DJUSTING UNME TERED FUEL PReSSUR E . TEST EQ UIPME NT MAY B E TE ED" !:-ITO T HE E!'JG I~ E-DRIVE:-1 Ft; E L Pl':\lP OUTLET HOSE AT TH E F l' EL PDIP OR AT THE FUE L ~IETERI~G L':-llT.
Figur e llB- 1. Fuel In je ction Pump Adjustment Test Harness 11 B-1 2
MODEL 188 & T188 SERIES SERVICE MANUAL
llB-39. IDLE SPEED AND IDLE MIXTURE ADJu::iT MENT. (See figure 11 B-2. ) The idle speed adjust ment is a conventional spring-loaded screw located in the air throttle lever. The idle mixture adjustment is the locknut at the metering valve end of the linkage. Tightening the nut to shorten the linkage provides a n cher mixture. A leaner mixture is obtained by backing off the nut to lengthen the linkage. Idle ·speed and mixture adjustment should be accomplished after the engine has been warmed up. Since idle rpm may be afiected by idle mixture adjustment, it may be necessary to readjust idle rpm after setting the idle mixture correctly. · a. Set the throttle stop screw to obtain 600 :t 25 rpm, with thr ottle control pulled full out against idle stop.
e. U mixture is set too LEAN, engine speed will drop immediately, thus requiring a richer mixture. Tighten adjusting nut (clockwise) for a richer mixture f. U mixture is set too RICH. engine speed will in crease above 50 rpm, thus requiring a leaner mix ture. Back off adjusting nut (counterclockwise) for a leaner mixture . NOTE After each adjustment to the idle mixture, run engine up to approximately 2000 rpm to clear engine of excess fuel to obtain a correct idle speed. UB- 40.
NOTE Engine idle speed may vary among different engines. An engine should idle smoothly, without excessive vibration and the idle speed should be high enough to maintain idling oil pressure and to preclude any possibility of engine s toppage in flight when the throttle is closed. b. Advance throttle to increase engine speed to 1000 rpm. c . Pull mixture control !mob slowly and steadily toward the idle cut-off position, observing tacho meter. then return control full IN (RICH) position before engine stops. d. Adjust mixture adjusting nut to obtain a slight and momentary gain of 25 to 50 rpm at 1000 rpm engme speed as mixture control is moved from full IN (RICH) toward idle cut-off position. Return con trol to full IN (RICH) to prevent engine stoppage.
INDUCTION AIR SVSTEM.
llB-41. DESCRIPTION. The engine air induction system receives air from a scoop on the left side of the cowling. It passes through an automative type air filter into a duct assembly containing the rotary alternate air valve, and into the compressor section of the turbocharger. The centrifugal compressor increases air pressure forcing it to flow through the fuel air control into the intake manifold, and then the cylinders. A maximum power loss of five (5) inches may be a direct result of the completely blocked air filter, and alternate rotary air valve open situation. UB-42. AIRBOX REMOVAL AND INSTALLATION. a. Remove the lower left hand engine cowl section. b. Disconnect: 1. Throttle and mixture controls at bellcranks. 2. Electrical wiring from inlet air temperature probe at connections, and tape ends.
IDLE SPEED ADJUSTMENT
!_!OLE •DXTURE ADJUSTMENT
Figure llB- 2. Idle Speed and Idle Mixture Adjustment
llB-13
MODEL 188 & T1 88 SERIES SERVICE MANUAL
3
1. Wing Nut 2. Air Filter Housing 3. Seal 4. Filter Elemenl 5. Back Plate :\lounts .,6. Gasket '· Rolary A1r VJ.lve
8. Alternate Air Control Housing 9. Clamp 10. Inlet Air Duct 11. Rotary Air Valve Arm 12. Alternate Air Control Wire 13. Attaching Bolts 14. Air filter Housing Back Plate
figure 11 B- 3. IIB-14 "
Induction Ai r Syste m Installation
MODEL 188 & T188 SERIES SERVICE MANUAL
3. Drain line at airbox. c . Remove safety wire from mounting bolts and bolts securing airbox to fuel-air control unit, and remove airbox with its gasket. d. Reverse the preceding steps for installation. using all new gaskets, align per figure llB- 4. e . Rig throttle and mixture controls according to paragraph llA-53. C. Connect air inlet temperature probe wiring. llB- 43 . CLEANING AND INSPECTION. ( Refer to Section liA .) llB-44. INDUCTION AIR FILTER REPLACEMENT. a. Remove left hand engine cowling. b. Remove wing nut on air filter , and remove
filter cover.
c . Change filter element according to criteria in ::iection 2 o r more often in dusty climates.
exhaust crossover pipe and heat exchanger section, is available for cabin heat and windshield defrost air. llB-51. INSPECTION. Since exhaust systems of this type are subject to burning , cracking and gen eral deterioration from alternate thermal stresses and vibrations, inspection is important and should be accomplished every 100 hours of operation. Also, a thorough inspection of the engine exhaust system should be made to detect cracks causing leaks which ' could result in loss of engine power. To inspect the engine exhaust system, proceed as follows: a. Remove engine cowling as required so that ALL surfaces of the exhaust assemblies can be visually inspected. NOTE Especially check the areas adjacent to welds and slip joints. Look for gas deposits in surrounding area. indicating that exhaust gases are escaping· through a crack or hole or around the sllp joints.
1
11B-44A. INSTALLATION OF INLET DUCTS (Refer to Section llA). · llB-45. ALTERNATE AIR VALVE CONTROL RIGGING. (See figure llA-5.) a. Pull Alternate Air Control out approximately 3. 375". b. Remove engine cowling as necessary for access. It is possible to rig the r otary air valve with the cowling installed. c . Rotate valve sleeve until alternate air port is fully open. d. Clamp contro l housing so s leeve arm (56) clears housing (53) end by at least 1/ 8". e. Connect control wire (55) to arm (56) . f. Push alternate air control in and insure approxi mate 1/ 8" cushion.
llB-46 . PROPELLER CONTROL. Section 13. )
llB-47.
STARTING
~y:)TEM.
(Refer to
(Refer to Section 11.)
llB-48. COOUNG ::iy:)TEM. Ram air fo~ cooling enters through an intake opening in the front portion of the engine cowling. It is directed around the cyl inders with ba.!fles, and is exhausted through fixed cooling air exits on both side cowlings at the a!t end. A third exit is located underneath on the rear sections of both left and right cowlings. A cooling lip is in stalled in the lower outlet which facilitates engine coaling by directing airflow outward from the aircraft contour at tbat point. llB-49.
EXHAUST Si'STEM. (See figure llB-7. )
llB-50. DE::>CRIPTION. The exhaust gases from each c ylinder pass thru riser assemblies into an ex haust manifold. T his manifold connects the risers to the turrocharger turbine inlet, and to the ground adjustable wastegate . As the gases pass through the turbine. some of its energy turns the turbine wheel which in turn drives the compressor wheel. The waste gate shunts a preset percent of exhaust to the tailpipe . thereby, controlling turboc harger speed, i.e. output. A heater, consisting of a shroud around the
b.
After visual inspection, an air leak check should
be made on the exhaust system as follows:
'
1. Attach the pressurs side of an industrial vacuum cleaner to the tailpipe opening, using a rubber plug to effect a seal as required. NOTE The inside of the vacuum cleaner hose should be free of any contamination that might be blown into the engine exhaust system. 2. With vacuum cleaner operating, all joints In the exhaust system may be checked manually by feel, or by us·ing a soap and water solution and watching for. bubbles. All joints should be free of air leaks. NOTE At annual inspection of aircraft, LH exhaust tee & exhaust risers should be removed and a visual Inspection made of internal hea. ex changer. UB-52. TURBOCHARGING SWTEM. A turbo charged engine exhibits some different character istics from a normally aspirated engine. F ollowing \ is a description pointing to some of the differing characteristics. This turbocharged configuration differs also, because of the inflight-flxed waste gate·. Please read the following carefully to insu~e com plete understanding of the operationa l characteristics,_ a. Induction air is taken in through an opening in the left side of the cowling, ducted thr ough an auto motive type paper air filter, th r ough the rotary air valve (closed position) and into the compressor sec tion of the turbocharger, where it is compr essed by the turbine driven centr ifugal compressor. b. The pressurized air is directed through the throttle body where it is metered according to throttle valve setting, into the induction manifold, and into the individual c ylinders. Revision 1
ll B- 15\.
MODEL 188 & T188 SERIES SERVICE M ANUAL
J
c. The air and fue l mixture is rur ned in the cylin de rs, and ex haus ted th r ough the risers and manifold to the turbine section of the tu r bocharger, or through the preset wastegate bypass as pr eviously explained in the exhaust system section.
')
NOTE For additional information covering turbo charger and component mainte nance, over haul and trouble shooting refer to the manu fa cturers' overhaul manuaL
} )
I
llB-53. REMOVAL AND INSTALLATION. (See J figure llB- 5. ) I a . Remove top, left hand, and right hand sections of engine cowling for access. J b. Disconnect duct from compressor inlet elbow, and hose from compressor outlet. I c. Disconnect clamp on turbine exhaus t pi pe, and pull pipe out of slip-joint at waste gate.
'
d . Cover both intake and exhaust ports to prevent
fo reign m a terial ent ry.
e . Disconnect and cap o il pressure and retu r n lines
at tur bocharger connections. Cover oil ports.
f. Disconnect the inlet air temperatur e probe wiring at connectors. g . Remove four mou nt bolts from turbine inlet mount pad. h. To install, reverse above pr ocedures. NOTE If throttle body was removed, r ei nstall according to dim ensions in figure llB-4.
llB-54. OP ERATION. T he turbocharger is capable of pr oducing mor e manifold pressure than required for maximu m power, (39. 5 In. Hg at sea level). Therefore an overboost va lve is installed in the in duction system just prior to the thr ottle body. It is adju sted to begin unseating at 38. 5 In. Hg and will allow a m anifo ld pres sure of 39. 5 In. Hg at sea level.
1.
Left Rear Oil Sump Mount Bolt Br acket Rear Left Oil Sump Mount Bolt Throttle Intake Manifold Connection 6. Throttle Arm 7. Pressure Relief Valve Mount Adapter
2. 3. 4. 5.
')
Figure llB- 4.
~
~
Throttle Body Installation Dimensions
/ ~AUTION}
I
•
P a rallel to Oil - - - Su mp Mount
This adjustment should not be changed. II in thorough trouble shooting it is determined that the valve is malfunctioning, it should be replaced. Adequate adjustment is provided with the wastegate adjustment bolt.
the adju s ting bol t out will cause a decr eas e in mani fold pr e s sur e, because mor e ex haust is bypassed. A s chedule of m axi mu m allowable manifold pr essure versus a ltitude is e.x hibited in the a ircraft cockpi t, a and is as follows: Density Altitude
Maximum Manifold Pressure
Sea Level
39 . 5InHg
1
The intention of this system is to pr ovide the o pe r ator 1 with a tu r bocharged engine with normally aspi rated characteristics. i.e. full throttle fo r takeoff. climb. "' and othe r flight conditions where needed. without con cern for an overboost.
2500 Feet 5000 Feet
, A wastegate adjustment bolt is provided to adjust the full throttle manifold pr essure. Although the adjust ' ment is not completely linear. an approximation of 1/ 8 inch travel of adJustment bolt (3 to 4 turns) causes I approximately 0 . 5 In. Hg change in manifold pr essure.
7500 Feet
38. 8 In Hg '
38. 1 In Hg 37.3 In Hg
Maximum Allowable Manifold Pressure
' Turning the adjusting bolt in gives an increase in , manifold pressure, because less exhaust gases are bypassed through the wastegate . Conversely. turning 11 B - 16 .
-~
•
The wastegate adju stment bolt should be adjusted to provide full throttle manifold pressure in accordance with the above values.
IVIVUC::L I 00 01.
I I 00
.;:, r::n u :..;, .:J t:n
Y 1\., C:: 1\111"\ I"VI"\L.
I
'
f
l
16
1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12. 13. 14. 15. 16.
Exhaust Manifold. Crossover Pipe. Turbocharger Mount Bolts Exhaust Divider Turbine Exhaust Clamp Tail Pipe Bypass Slip Joint Gate Valve Gate Valve Adjustment Turbine Housing Oil Fitting to Bearing Housing Compressor Outlet Compressor Inlet Exhaust Risers Compressor Housing Gate Valve Mounting Bolts
16
13 View
A-A
NOTE Refer to "Bolt Torque Values" in Section 1 of this manual for torque requirements of bolts (3), (5), and (16) used in this install ation.
Figure llB-5. Turbocharger Installation Revision
1
llB- 17
,
MODEL 188 & T188 SERIES SERVICE MANUAL
10
11
15
1. 2. 3. 4.
5. 6. 7. 8. 9. 10 . 11 . 12 . 13. 14. 15. 16. 17. 18. 19. 20. 21.
Air mtake Air Filter Rotary Air Valve Turbocharger Compressor Section Induction Relief Valve Thro ttle Body Throttle Valve Exhaust Manifold LH Intake Manifold LH Crossover Tube (Intake Balance) Exhaust Manifold RH Intake Manifo ld RH Exhaust Crossover Pipe Wastegate Valve Ad just ing Bolt Tailpipe Wastega[e Va lve Turbocharr;te r Turbine Section Turbine Wheel ( Radial Inward Flow) Tu rboc harge r :\L11n ::>hait Turboc harge r Bearing Housing Co mpressor Wheel (Centrliugal)
LEGEND:
¢:l
RAM AIR
~ COMP R.:.:SS ED .-\IR
. . EXHA U!:>T AIR
'L-------------------------------------------------------~------------------------~
,
, 11 B-18.
Figure 11 B- 6. Turbocharger System Schematic
MODEL 188 & T188 SERIES SERVICE MANUAL
r i !. Exhaust Tee
T1 8803297T T1 8803799T T1 8803805T Tl 8803812T
THRU THRU THR U THRU
T18803797T , T18803802T . Tl 88038 10T . Tl8 80381 6T
2. 3. 4. 5. 6. 7 8. 9.
Exhaust Rise r s Crossover Pipe Exhaust Divider Wastegate Valve Wastegate Valve Adjusting Bolt Turbocharger Mounting Flange Tailpipe Heater Shroud (Optional)
l )
I
F igure 118- 7. Exhaust System (Sheet 1 oC 2)
llB- 19
MODEL 188 & T188 SERIES SERVICE MANUAL
i
1
1. Exhaust T ee 2. Exhaust Risers 3. Crossover Pipe 4. Exhaust Divider 5. Wastegate Valve 6. Wastegate Valve Adj usting Bolt 7. T urbocharger Mounting Flange 8. Tailpipe 9. Heater Shroud (Optional)
T18803798T, Tl8803803T, T18803804T, T18803811T & T18803817T & ON
i Figure 11 B-7.
llB-20
Exhaust System (Sheet 2 of 2)
MODEL 188 & T188 SERIES SERVICE MANUAL
118-55. FUEL PRESSURE AND WASTEGATE AD JUSTMENTS. It is recommended that when making any wastegate or fuel system adjustments on T188 aircraft that the following steps be performed in the sequence presented to obtain correct settings for fuel pressure and wastegate position.
b. Adjust the wastegate one full turn closed to allow for slight manifold pressure variations encountere_, in the following procedures. c. Install the unmetered fuel pressure test set, \..1 P/N SK320- 2J.
v
NOTE
()
NOTE Run the engine to allow temperatures to reach the nor mal operating ra.nge before proceeding.
Prior to performing the following steps,
ensure that the tachometer, fuel flow and
manifold pressure gages are. indicating
accurately.
a . Start the engine and very slowly open the throttle until it 1s full open o r until manifold pressure reaches the pressure shown in the Maximum Allowable Mani fold Pressure table. Shut the engine down and adjust the wastegate position as necessary to oblain the pre scribed pressure with full open throttle. NOTE Use caution not to overboost. All throtlle
movements should be made slowly to allow
adequate time for the turbocharger to spool
up o r down.
V
d. Adjust the unmetered fuel pressure in accor- V dance with the procedures in paragraph llB-37 . V e. The following must be adhered to: 1. The low RPM unmetered fuel pressure ana_, only the low unmetered fuel pressure is to be adjuF' • ed with the fuel pump relief valve adjustment. Furw ther, the low RPM unmetered fuel pressure is to \_ set first and not readjusted once set. 2. The high RPM (2700) unmetered fuel pr es-....., sure is to be adjusted with the slot headed needle valve on the end of the aneroid. At no time during._ the high unmetered fuel pressure adjustment is the fuel pump relief valve to be adjusted. '-' 3. At no time is the fuel pump r elief valve ad"' justment to be bottomed out.
v 0
fcAUTION ! A slight overboosting of manifold pressure beyond established maximums may be en countered occasionally under certain atmospheric conditions and is not considered detrimental to the engine as long as it is momentary. This overboost condition is corrected by retarding the throttle until the maximum power setting is attained. However, if overboosting at full throttle persists the wastegate should be adjusted to lower the maximum attainable manifold pressure to the limit as shown on the schedule of maximum allowable manifold pressure versus altitude. If the overboost exceeds 4 inches, the overboost control valve should be replaced. AN OYERBOOST EXCEEDING 4 INCHES beyond established maximums is excessive and can result in engine damage. It is recommended that overboosting of this nature be reported to your Cessna Dealer, who will be glad to determine what, if any, corrective action needs to be taken.
u (J
u
u
118-56. EXTREME WEATHER MAINTENANCE. Refer to Section 11.
llB-58.
118-57. COLD WEATHER. Refer to Section 11.
118-59. GROUND SERVICE RECEPTACLE Refer to Section 16.
DUSTY AREAS Refer to Section 11.
v u u llB-2 1/(118-22 bla~
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 12
FUEL SYSTEMS
TABLE OF CONTENTS
Page No. Aerofiche/Manual
FUEL SYSTEM Description . . . . . . . . Precautions . . . . . . . . Trouble Shooting (Carbureted Engine) . . . . . . . . . Trouble Shooting (Fuel-Injected Engine) . . . . . . . Fuel Vent (Metal Tank) . . . Description . . . . . . Checking . . . . . . . Fuel Vents (Rubberized Cell) Description . Checking . . . . . . . Fuel Tank (Metal) . . . . . . Description . . . . . . Removal and Installation Fuel Cells . . . . . . . Description . . . . General Precautions Removal . . . . . Installation . . . . Removal and Installation of Fuel Shut-Off Valve (Metal Tank) . Removal and Installation of Fuel Shut- Off Valve (Rubberized Cell) Vented Fuel Filler Caps (thru 18803296) . . . . . . . . . Description . . . . . . . Metal "Flush Type" Filler Caps . . . . Inspection . . . . . Cleaning . . . . . . Reassembly . . . . Red Plastic "Flush Type" Filler Caps . . . . . .
Inspection Cleaning Reassembly . . Vented Fuel Filler Caps (18803297 & ON) . . . Description . . . . Inspection, Cleaning and Repair . . . . . .
Fuel Quantity Transmitters .
Fuel Reservoir . . . .
Description . . . . . . Removal and Installation Fue1 Strainer (Metal Tank) . . Description . . . . . . Removal and Installation Disassembly and Reassembly Fuel Strainer (Rubberized Cell) . Description . . . . . . . . Removal and Installation . . Disassembly and Reassembly Auxiliary Fuel Pump . . . . Description . . . . . . Removal and Installation (Metal Tank) . . . . . Removal and Installation (Rubberized Cell) . . . Electric FUel Pump Circuit (A188 Series) . . . . . . . . . . . Description . . . . . . . . Rigging Throttle Microswitch Auxiliary Fuel Pump Rate Adjustment . . . . . Emergency Boost Check . Priming System Description . . . . . .
. 2A2/12-1 . 2A2/12-1 . 2A3/12-2 . 2A3/12-2 . 2A4/12-3 . 2A15/12-14 . 2A15/12-14 . 2A15/12-14 . 2A15/ 12-14 . 2A15/12-14 . 2A15/12-14 . 2A16/12-15 . 2A16/12-15 . 2A16/12-15 . 2A16/12-15 . 2A16/12-15 . 2A16/12-15 . 2A16/12-15 . 2A18/12-17 . 2Al8/ 12-17 . 2Al8/ 12-17 . 2Al8/ 12-17 . 2A18/ 12-17 . . . .
2Al8/ 12-17 2Al8/ 12-17 2Al8/12-17 2A19/ 12- 18
. 2A20/12-19
12-1. FUEL SYSTEM. The fuel system, as defhed by this manual, is that portion of the entire system
up to and including the fuel line connected to the engine driven fuel pump. The Auxiliary fuel pump and the applicable throttle rigging procedures are covered in this section. 12-2. DESCRIPTION. On standard fuel instal lations, the fuel supply is contained in a rigid metal tank, enclosed in a plastic vapor barrier, and mounted immediately behind the firewall in the air craft fuselage. The Specification Chart, figure 1-1, gives fuel capacities .. Fuel nows through a finger screen in the tank outlet to a shut-off valve, through the fuel strainer, to the carburetor. On fuel-injected engines. fuel nows from the shut-oU valve, through an auxiliary electric fuel pump, through the fuel stramer, to the engine driven fuel pump. The fuel strainer is equipped with
. 2A20/12-19 . 2A21/12-20 . 2A21/12-20 . 2A21-12-20 . 2A21/12-20 . 2A21/12 -20 . 2A21/12-20 . 2A21/12-20 . 2A21/12-20 . 2A21/12-20 . 2A22/12-21 . 2A22/12-21 . 2A22/12-21 . 2A22/12-21 . 2A22/12-21 . 2A22/12-21 . 281/12-24 . 281/12-24 . 281/12-24 . 281/12-24 . 281/12.!24 . 281/ 12-24 . 282/ 12-25 . 282/ 12-25 . 283/ 12-26 . . . .
283/ 12-26 283/ 12-26 284/ 12-271 284/ 12- 27
remotely-controlled drain valve with the control handle located adjacent to the oil dipstick in the en gine compartment. Access to the control handle is gained through the oil dipstick door in the upper en gine cowling. The fuel tank is vented through an overboard vent line connected to a fitting in the filler neck. Another fitting in the top of the tank is used for the vapor return line on fuel-injected engines, and is capped on carburetor- equipped engines. A fuel quantity transmitter, located in the bottom of the tank, is electrically connected to the fuel quantity indicator' located in the instrument cluster panel in the cockpit. The fuel quantity indicator is discussed in Section 15. Schematic diagrams are illustrated in figure 12-1. System details are illustrated in suc ceeding figures. <1.
On optional fuel system installation, cells are located in the Wings, with a reservoir between the cell!
Revision 1
12-1
MODEL 188 & T188 SERIES SERVICE MANUAL
1n the fuselage. In thts system, fuel flows from the rubberi zed cells tn the w1ngs. through a reservo1r tank . to a shut - off valve. through an electnc aw(ll tary fuel pump. and a stramer to the engme dn ven fuel pump. wh1ch 1s cover ed 1n the engine section of the manual. The cells a re tndivldually vented over board through a check valve located in each cell. A crossover vent line 1s tnt er cormected between each cell and the reser vOir fo r positive ventilation. Two fuel quanttty transmitters, one per cell, are elec trtcally cormected to the mdividual fuel quantity indicators. wh1ch are located in the instrument panel. The fuel strainer incorporates a quick-drain valve with the control located on the r ighthand instrument pane 1 thru serial 18800832. Beginning with serial 18800833, the strainer drain control handle is located adjacent to the Oil dipstick in the engine compartment. Access to :he control handle is gained through the oil dipstick door in the upper e ngine cowling.
should be observed. a. While engaged in fueling operations, repai r , or disassembly of systems, make cer tain that aircraft is pr oper ly GROUNDED to pr event static electricity build-up . b. Spillage constitutes a fire hazard. Be cautious when disconnecting fuel lines or hoses because ac cummulation increases fire hazard. c . Cover open lines and connections to prevent entrance of for eign materials, and prevent pos sibility of damaging thr eads of fittings.
12- 3 . PRECAUTIONS . During maintenance on fuel system. the follow1ng general and safety pr ecautions 12-4 .
TROUBLE SHOOTING.
TROUBLE ~0
FUEL TO CARBURETOR
Ft:EL STARVATI0!'-1 AFTER STARTI~G
12 - 2
NOTE Use NS- 40RAS-4 (Snap-On Tool Cor p., Kenosha, Wisconsin) MIL- T - 5544 (Thread Compound), Antiseize, Graphite Peholatum , or equivalent as th r ead lubr icant :u .·.i sealer t hrough out the entire fuel system . Apply s paringly to male fittings , omitting the fi r st two threads, to prevent entry i nto fu el syst em .
(Carbureted Engine).
REMEDY
PROBABLE CAUSE Fuel shut-off valve not turned on.
T urn fuel shut-off valve on.
Fuel tank empty.
Servic e with proper grade and amount of fuel.
Plugged fuel strainer .
Remove and clean straine r and screen .
Inlet fitting or inlet screen in ca rburetor plugged.
Clean and/ or replace.
Fuel tank out let,sc reen plugged.
Remove and clean screen and flush out fuel tank.
Defective fuel s hut -off valve .
Remove and repair or replace valve.
Fuel line disconnected or br oken.
Connect or repair fuel lines.
Fuel line plugged.
Clean out or replace fuel line.
Partial fuel flow fr om the p r eceding causes.
Use the pr eceding remedies.
Plugged fuel \'ent.
See paragraph 12 -8.
Water tn fuel.
Drain fuel strainer.
.
MODEL 188 & T188 SERIES SERVICE MANUAL 12-4.
TROUBLE SHOOTING (Cont). TROUBLE
NO FUEL QUANTITY INDICATION
12-5. TROUBLE SHOOTING.
REMEDY
PROBABLE CAUSE Fuel tank empty.
Service with proper grade and amount of fuel.
Circuit breaker open or de足 fective.
Reset.
Loose connections or open circuit.
Tighten connections; repair or re place wiring .
Defective fuel quantity indi足 cator or tr ansmitter.
Refer to Section 15.
Replace if defective.
(Fuel- Injected Engine) . NOTE
This trouble shooting chart should be used in conjunction with the engine trouble shooting chart in Section l.lA. TROUBLE NO FUEL FLOW TO ENGINE 足 DRIVEN FUEL PUMP
FUEL STARVATION AFTER STARTING
NO FUEL FLOW WHEN ELECT RlC PU:\1P IS TUfu~ED ON
PROBABLE CAUSE
REMEDY
Fuel shut- off valve not turned on.
Turn fuel shut- off valve on.
Fuel tank or cells empty.
Service with proper grade and amount of fue l.
Fuel line disconnected or br oken.
Connect or repair fuel lines.
Fuel tank outlet screen plugged.
Remove and clean screen and flush out fuel tank.
Defective fuel shut- off valve.
Remove and repair or replace shu t- off valve.
Plugged fuel strainer.
Clean strainer and screen.
Defective check valve in electric fuel pump.
Repair or replace electric fuel pump.
Fue 1 line plugged.
Clean out or replace fuel line.
Partial fuel flow fr om the preceding causes.
Use the pre ceding remedies.
Malfunction of engine-driven fuel pump or fuel injection system.
Refe r to Section llA.
Fuel vent line(s) plugged.
Refer to paragraph 12-8 o r 12 足 11.
Water in fuel.
Drain strainer, tank or cells. and lines.
Defective fuel pump switch.
Replace defective switch.
Defective throttle switch.
Replace defective switch.
Open or defective circuit breaker.
Reset; replace if defective.
12-3
MODEL 188 & T188 SERIES SERVICE MANUAL 12-5. TROUBLE SHOOTING (Cont). TROUBLE NO FUEL FLOW WHEN ELECTRIC PUMP IS 'MJRNED ON (Cont).
Loose coMections or open circuit.
Tighten coMections; repair or replace wiring.
Defective electric fuel pump.
Replace defective pump.
Defective engine-driven fuel pump by- pass or defective fuel injection system.
Refer to Section llA.
Fuel tank or cells empty.
Service with pr oper grade and amount of fuel.
Circuit breaker open or defective.
Reset. Replace if defective.
Loose coMections or open circuit.
Tighten coMections; repair or replace wiring.
Defective fuel quantity indicator or transmitter.
Replace defective indicator or transmitter.
Obstructed filter in fuel inlet strainer of metering unit.
Remove and clean.
Manifold valve.
Replace.
Fuel flow indicator.
Replace.
NO FUEL QUANTITY niDICATION
FLUCTUATING FUEL PRESSURE INDICA Â TIONS. (Al88B : 300 HP)
SHOP NOTES:
12 -4
REMEDY
PROBABLE CAUSE
MODEL 188 & T188 SERIES SERVICE MANUAL
FUEL QUANTITY INDICATOR FILLER C AP
VENT
S HUT . OFF
VALVE
KNOB
FUEL SHUT-OFF VALVE
-----Orl®
STRA INER
DRA I N
KNOB
ENG INE PRIMER
THROTTLE
LEVER
CODE f.t«j«~J FU EL SUPPLY
c::::J V ENT
MIX TU RE
C ONTROl
KNOB
..
MECH AN ICAL liNKAG E
-s_.
TO EN G INE CYL INDERS
ELECTRICAL CONNECTION
NOTE
This schemauc 1s applicable to the fue l sys tem for engines equipped with a carburetor .
F igur e 12-1. Fuel Sys tem Sche matic {Sheet 1 of 4) 12-5
MODE L 188 & T188 SERIES SERVICE MANUAL
FUEL QUANTITY
INDICA TOR
Fi l l ER C AP
VE N T FUEL S HUT -OFF VAL VE
S HUT Â OF F VAlVE KNOB
- - ------[)tJllb FUEL PUMP SWITCH
AUXILIARY FUEL PUMP TO BUS
ENGINE FUEL PUMP MIXTURE CONTRO L KNOB
~--VALVE
MECH AN ICA L LINKAGE
-s-
FU El FLO W INDIC A TOR FUEL NOZZLE
o--o
::-lOTE
This schematic is applicable to the fuel syst em fo r fuel-injected engines . Refer to Section llA for the fuel inJectio n s ystem schematic .
ftgure 12-1. 12 - 6
.
Fuel System Schematic (Sheet 2 of 4)
ELECTRICAL CONNECTION ELECTRICAL SCHEMATIC
MODEL 188 &. T188 SERIES SERVICE MANUAL
fUEl QUANTITY INDICATORS
LEF T
LEFT W ING CELL
0
0
RIGHT
RIGHT WING CELL CH EC K
FUEL QUANTITY TRANSMITTERS
..l SCREEN VENT
CHE CK VAL VE
THRU 18800572 NOT E
This schemat ic is applicable to the fuel system !or fuel-injected engines. Refer to Section llA for the fuel injection s ys tem schematic.
FUEL SHUT - OFF VALVE
AUX. FUEL PUMP
SHUT- OFF V AL V E KNOI
- - -- -Q)
STRA INER DRA IN KN O B
FUEL PUMP
SWIT CH
CODE MIXT URE
(.·-: _.,.,,,:::;} FUEl SUPPLY
c:::::::J V E NT EX C ESS FUEl AND VAPOR
RE TURN FUEL FUEl flO W
MECHANICAL
LI NKAGE
-z.._
G AGE
ElECTRIC Al
CO NNE CTIO N
FUEL NOZZl ES
F igure 12-1. Fuel System Schematic (Sheet 3 of 4) 12-7
MODEL 188 & T188 SERIES SERVICE MANUAL
FUEL QUANTITY INOICA TORS
0
0
lffT
LEFT WING CELL
RIGHT
RI GHT WIN G CEL L CHECK
VENT
BEGINNING WITii 18800573
FUEL RESERVOIR
WIT H OR AIN VALVE
NOTE This schematic is applicable to the fuel
system for fuel-injected engine-equipped
aircraft with optional fuel cell installation.
The AGtruck installation iS standard. Re fer to Section llA for the fuel injection system schematic.
STRAINER ORAIN KNOB
~
- ---~
VALVE
S H UT-OF F
VALV E
KNOB
~..
lJ-' - -
1880573 ~u 1880832
BEGINNING WITH 1880833
FUEL PU M P SWITCH
--.-~-F
1--1
UEl _ _ S_U_P_P l-
l fVER
c:=::::J VENT
,
'I«J-~
\ -)
AIR THROTTLE
FUEl
MECHAN IC AL
LINKAGE
FUEL HOW GAGE
~ ElE CT RICAl
CONNECTION
fUEl
NOZZlES
Figure 12-1. Fuel System Schematic (Sheet 4 of 4) 12-8
MIXTURE
L._)
~ EJtCESS FUEL
ANO v A.POR
fZl'2l RETURN
'~- - _1u1--
y -., THR0 T;LE
MODEL 188 & T188 SERIES SERVICE MANUAL
0-RING
TV-- UNION
~t FlliGERSCREEN ·
SUPPORT- ·· VAPOR
..,>>
BARRIER-~:" N1JT
DRAIN TUBE
..
--'fV
/![
NUTSl
u : " - - - INSERT
INSERT~ ~
--.-...,Jj
VAPOR BARRIER
NOTE
:::;
(;_ .
v~
Top of union is forced through hole in vapor barrier. Retain lower portion of union while tightening lock nut.
.·
SEE FIGURE 12- 8
····......
UNION
. ·· · ··(.::~::}:::>···
:; ·
····....
.,.
.
··.... *Vapor barrier drain: Prior to 188-0318 • Vapor barrier drain: 188-0318 & on
..··.·::~· .. .···
---.......--.......,. ...... .· .... ..
..._..
•
SEE FIGURE 12-9
15
SERIAL NO. 188-0235 & ON AND ALL SERVICE PARTS PRIOR TO SERIAL NO. 188-0235
1. Primer Lines 2. "On-Off'' Control 3. "On-Off" Control Handle 4. Primer 5. Overboard Vent Line 6. Fuel Lme
A THRU 188-0395 8 188- 0396 & ON
NOTE This installation is a pplicable to engines equipped with carburetors. 7. Fuel Hose 8. Doubler 9. Fuel Tank 10. Gasket 11 . Fuel Quantity Transmitter
12. 13. 14. 15. 16. 17.
Ground Strap Cork Washer Screw Float Arm Float Nut Ring
Figure 12-2. Fuel System (Sheet 1 of 5) 12-9
MODEL 188 & T188 SERIES SERVICE MANUAL
4
4
3
3
SEE FIGURE 12-8
SEE SHEET 1
SEE FlGURE
12-3
SEE F IGURE 12-8
...,__ __ _ SEE FIGURE
12-3
2
SEE FlGURE 12-8
7
1
--%
SEE FIGURE_/
y
12-9
c
Detail
12
10 '
10
11
13
15
PRIOR TO SERIAL
NO. A 188-0318
Deta1l
NOTE This installation is applicable to fuel injection engines.
C
1. Check Valve 2. Vapor Return Line 3. "ON- OFF" Control ·L "ON-OFF" Contro l Handle 5. Overboard Vent Line 6. Vapor Barrier Drain Line
7. Strainer 8. Pump Bracket 9. Clamp 10 . Fuel Line 11. Union 12. Elbow
Figure 12-2. 12-1 0
SERIAL NO. Al88- 0318 & ON Detail
0
13. 0-Ring 14. Pump Drain Line 15. Electric Auxiliary Fuel Pump 16. Fuel Hose 17. Nut 18. Spacer 19. Vapor Return Check Valve
Fuel System (Sheet 2 of 5)
E
MODEL 188 & T188 SERIES SERVICE MANUAL
3
2 4----1
3
REFER TO FIGURE 12Â 8
REFER TO FIGURE 12-9
\ Detail
f
THRU 18800572
1. 2. 3. 4. 5. 6. 7.
Scoop Vent Line Fuel Cell Shut-Qff Valve Control Strainer Drain Control Vapor Return Check Valve FingerStra iner
Figure 12-2.
8. 9. 10. 11. 12. 13.
Reservoir Shut -Off Valve Drain Valve Auxiliary Pump Auxiliary P ump Drain Line Strainer
Fuel System (Sheet 3 of 5) 12- ll
MODEL 188 & T188 SERIES SERVICE MANUAL
'
... ...
'' '
15
2
Detail
4
14
11¢
H
18800573 thru 18801216, on aircraft equip ped with a hy draulic-driven
.AI
13/ ~
dispersal sys REFER TO
FIGURE 12-8
Detail
tem and wing fuel tanks, split hose length wise and bond to fuel line with 3M EC-800, EC -1300 or EC -1300L.
G 10
7
10
REFER TO
FIGURE 12-9
1.
2.
3. 4. 5. 6. ~
I.
8.
BEGI~~G
WITH 18801737
9. Auxiliary Pump Drain Line 10. 11. 12. 13. 14. 15 .
0 - Ring Shut - Off Valve Bracket Drain Valve Clamp Vapor Return Check Valve
18800573 THRU 18803296
Figure 12 - 2. 12-12
Scoop Vent Line Fuel Cell ReservOi r Shut-Orr Valve Control Str:ltner Drain Control .-\uxtlt:lry Pump Fuel Str:ltne r
Fuel System (Sheet 4 of 5)
MODEL 188 & T188 SERIES SERVICE MANUAL
REFER TO FIGURE 12-4
1
2
J
Detail
J
REFER TO FIGURE 12-9
10 1. Scoop
2 . Vent Line 3 . Fuel Cell 4. Reservotr 5. Shut - Off Valve Control 6. Strainer Drain Control 7. Auxiliary Pump 8. Fuel Stratner
9. 10. 11. 12. 13. 14. 15.
Auxiliary Pump Drain Line 0-Ring Shut-Off Valve Bracket Drain Valve Clamp Vapor Return Check Valve
Figure 12-2.
7
10
BEGINNING WITH 18803297
Fuel System (Sheet 5 of 5) 12- 13
MODEL 188 & T1 88 SERIES SERVICE MANUAL
3
Vapor return line fitting is capped on carburetor- equipped engine.--
----..
!WARNING' PURGE METAL FUEL TANKS WITH STEAM FOR 30 MIN UTES PRIOR TO REPAffi OF TANKS.
1.
Rubber Pad
2. Strap
NOTE
3. Vapor Return Fitting 4. Cap 5. Filler Neck 6. Vent Fitting 7. Fuselage Structure 8. Spacer
The fuel tank is enclosed in a plastic vapor barrier that is equipped with a zipper. Prior to Serial 188-0318, a single drain tube is installed ln the bottom of the plastic bag, im mediately aft of the fuel shut-off valve. Beginning With Serial 188-0318, three drain tubes are installed in the bot tom of the plastic bag, one on either side, and one immedi ately aft of the shut-off valve. F igure 12-3.' Fuel Tank Installation
12-6.
FVEL VENT.
(METAL TANK.)
Any fuel vent or crossover line found plugged or restricted shall be corrected prior to re turning aircraft to service.
12-7. DESCRIPTION. A vent line is installed in the fille r neck of the fuel tank . The vent line extends overboard down through the lower fuselage sktn.
12-9.
12-8. CHEC KING FUEL VENT. Field experience has demo nstrated that vents can become plugged, wtth possible fuel s tarvation of the engine, or col lapse of the tank. The fo llowmg procedure may be used to check the vent. a. Attach a rubber hose to the end of the vent li ne below the fu selage s kin. b . Remove iiller cap and blow th rough hose. If atr can be blown tnto tank, ve nt ltne is open.
12-10. DESCRIPTION. A vent line is installed in the outboard end of each fuel cell. The vent line ex tends from the cell to a scoop mounted on the lower wtng skin. The mboard end of the vent line extends into the fuel cell, then is offset downward from cell upper surface. A vent valve ts tnstalled on the in board end of the vent line inside the cell and a cross over line is connected from each cell to the reser voi r tank fo r pOSitive ventilation.
SOTE
12-11. CHECKING FUEL VENT. (RUBBERIZED :::E LL. ) Field expenence has demonstrated that vents can become plugged, wtth possible fuel starva tion uf the eng ine, or collapse of fuel cel ls. Also, the bleed hole tn the vent valve assembly could pos Sibly become plugged, alloWing pressure fro m ex
Remember that a plugged \'ent line can cau:>e ct the r iue l starvati on and collapstng of fuel tank ur the pr essunzat ion of the tank by fue l expansiOn. 12-14
FUEL VENTS. (RUBBERIZED CELL. )
MODEL 188 & T188 SERIES SERVICE MANUAL
panding fuel to pressurize the cells. The following procedure may be used to check the vent and bleed hole in the valve assembly.
f. Disconnect s traps securing fuel tank and re
move tank.
g. Rever se the preceding steps for installation.
a. Remove plate on lower side of wing, immedi
ately aft of tie-down ring for access.
b. Working through plate opening, remove clamp
and vent line from wing scoop.
c. Attach a rubber tube to the end of the vent line. d. Blow into tube to slightly pressurize the cell.
II air can be blown into cell, the vent line is open.
e. Alter cell is s lightly pressurized, insert end of
tube into a container of water and watch for a con
tinuous stream of bubbles, which indicates the bleed
hole in valve assembly is open and relieving pres
sure. f. Alter completion of step ··e .. , blow into tube aga1n to slightly pressur ize the cell and loosen, but do not remove, filler cap on opposite wing to check cell crossover line. II pressure escapes from filler cap, crossover line is open. g. Repeat steps "a" through ··e .. for fuel vent be neath opposite wing ; step 'T" will not require an add itional check.
12 - 15. FUEL CELLS.
NOTE Remember that a plugged vent line or bleed hole can cause either fuel starvation and col lapsmg of fuel cell, or the pressurizing of the cell by fuel expansion. h. Any fuel vent or crossover line found plugged or restric ted shall be corrected prior to returning air craft to service. 12-12.
FUEL TANK.
(METAL .)
12-13. DESCRIPTION. A rigid metal tank Is install ed immediately behind the firewall in the fuselage. The tank is enclosed in a plastic vapor barrier with dratn lines in the event of a fuel leak and a zipper for acce:>s to component parts of the tank assembly. 12 - 14 . REMOVAL AND INSTALLATION . a. Loosen wing strut upper fairings and remove panel above tank. Open side panels aft of firewall. b. Open fuel shut-of! valve and drain fuel through stratner. To expedite draining of fuel, close shut orr valve and disconnect line from bottom of valve. Us1ng suitable funnel and hose, open shut-off valve and drain fuel from tank. c . Disconnect overboard vent line at filler neck and vapor return line if applicable. NOTE The plas tic barrier enclosing the fuel tank is equ 1pped with a zipper which may be opened for access. d. Dtsconnect vapor drain lines. e. Disconnect electrical lead at transmitter and g r ound strap at firewall.
12-16. DESCRIPTION. Rubberized, bladder-type fuel cells are installed in the inboard bay of each wing panel. These cells are secured by snap fasten ers to prevent collapse of the flexible cells . NOTE For fuel cell repair Information, refer to Cessna Service News Letter, dated August 28, 1970. For minor repair. a fuel cell repair kit is available from Goodyear. com plete with required materials and instructions.
12-17. GENERAL PRECAUTIONS . When storing,
inspecting or handling rubberized, bladder-type
fuel cells, the following precautions should be ad
hered to:
a. Fold cells as smoothly and lightly as possible
with a minimum number of folds. Place protective
wadding between folds.
b. Wrap cell in moisture -proof paper and place in a suitable container. Do not crowd cell in container. Use wadding to prevent movement. c. Stack boxed cells to allow access to oldest cells first . Do not allow stacks to crush bottom boxes. Leave cells in boxes until used. d. Storage must be cool, +30 • F to +85 oF, and free of exposure to sunlight, dirt, and damage. e. Used cells must be cleaned with soap and warm water prior to s torage. Dry and package as outlined in the preceding s teps. C. Do not carry cells by fittings. Maintain original cell contours or folds when refolding for boxing.
12-18. FUEL CELL REMOVAL. (See figure 12-4. ) a. Drain fuel from applicable cell. NOTE Prior to removal of cell, drain, purge with fresh air , and swab out to remove all traces of fuel. b. Remove wing root fairings and disconnect fuel lines at wing root. c . Remove clamps from cell bosses at wing root ;:.nd carefully work fuel strainers from bosses. DO NOT ATTEMPT TO REMOVE UPPER FORWARD LINE AT THIS TIME. d . Disconnect e lectrical lead and ground strap from fuel quantity transmitter. Remove sc rews attaching transmitter and carefully work transmitter from fuel cell and wing rib. DO NOT BEND FLOAT ARM. (Refer to Section 15 for transmitter calibra tion.)
12-15
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Beginning with Serial No. 18800939 and all SerVice Parts. a vented fuel cell cap is installed.
·-~'
*FUEL SAMPLER CUP (REFER TO PARAGRAPH 2 - 18.
B
)
./
1. Screw 2. Cap 3. 0-Ring 4. Adapter 5. Chain 6. Gaskt>t 7 . Fuel Cell 8. Hanger 15 9. Clamp 10. Drain Valve 11. Finger Stra iner 12. Protec to r 13. Nut 14. Fuel Quantity Transmitter 15. Ground Strap 16. Fitting 17. Vent Ltne 18. Hose 19. Vent Valve
' 12
r
13
Detatl A
• SERIAL NO. A 18~ - 0446 & ON
A Figure 12-4. e . Re move sc r ews attac hing dra1n adapter to lowe r .,;u riace of w1n~ . , , Wor ktnl! th r oul!h iill('r :1eck opemng , remove cl amps a nach1ng c r ossove r line se cl\ ons . Work 1nner sec t1on >i c r ossover li ne and O\'l? r board \'ent line from cell. ~. Carefu llv wor k oute r se cu on of cr ossovp r line :;o m uppe r f~ r 'oA.·ard boss noted 1n step "c" . h. Re move rue! f1lle r adap te r and ~a:;kets by re12-16
Fuel Cell Installation movtng screws attac hing adapter to wing and fue l cell. 1. Work tng thr ough fi lle r neck openi ng, loosen fa s tene rs. Use care when pulling cell free, to p re vent tea ring ru bber . J. Collapse and care fully fo ld ce ll fo r r emoval, work ing ce ll out thr ough filler opemng tn uppe r wtl'lg surface. L'se car e to preve nt damage to cell.
MODEL 188 & T188 SERIES SERVICE MANUAL
12-19.
FUEL CELL INSTALLATION.
a. All filings, trimmings, loose washers, bolts,
nuts, etc. must be removed from fuel cell compart
ment before installing fuel cell.
b. All sharp edges and protruding rivets must be rounded off and taped over for protection to fuel cell. c. Inspect cell compartments just prior to installa tion of a cell for the conditions mentioned in the pr e ceding steps. d. Install fuel drain adapter. e. Check to insure cell is warm enough to be flex
ible and fold as necessary to fit through fuel cell ac
cess opemng.
C. Place fuel cell in compartment, develop it out to its full size and attach fasteners, then reverse the pro cedures outlined in paragraph 12-18 for installation. g. Install all new gaskets when installing fuel cell.
Gaskets to be installed dry. Do not use sealer or
adhestve .
h. IC screw-type clamps are to be used, apply a
maximum o f 20 pound-inches torque to clamp screws.
A light application of ·tflO engine oil to the metal tube
aids the installation into the nipple fittings.
i. When installing filler adapter, cover plate, and
fuel quantity transmitter to the wing and fuel cell,
tighten attaching screws evenly. The s ealing or com
presston surfaces must be assembled when absolutely
dr y (NO SEALING PASTE TO BE USED).
j. After installation has been completed, cell should
be inspected for final fit within compartment, making
certain that cell is extended out to the structure and
no corners are folded in.
k. The final inspection, prior to closing the cell, should be a close check to insure that cell is free of foretgn matter such as lint, dust. oil, or any install atiOn equtpment. If a cell is not thoroughly clean, it should be c leaned with a lint-free cloth. soaked in water . alcohol. o r kerosene. NO OTHER SOLVENT SHALL BE USED. NOTE Throughout the atrcraft fuel system, from the cells to the engine-driven pump, use NS-40 (RAS-4) (Snap-On-Tools Corp., Kenosha, Wis consin), MIL- T-5544 (Thread Compound, Anti seize. Graphite-Petrolatum) or equivalent compound as a thread lubricant or to seal a leaktng connection. Apply sparingly to male fittings only, omitting the first two threads. Always insure that a compound, the residue from a pre viously used compound. o r any other foretgn matertal c annot enter the system. 12-20. RE~OVAL AND INSTALLATION OF FUEL SHUT-OFF VALVE. (METAL TANK). a . Dratn fuel tank as outlined in paragraph 12-14. b. Dtsconnect control fr o m valve handle . c . Disconnect fuel line from valve and unscrew valve fro m botto m of tank. d. Reverse the preceding steps fo r installatiOn. 12-21. RE:"\tOVAL AND U\STALLATION OF F UEL SHt:T -OFF VALVE. (RUBBERIZED CELL). a. Drat n fuel from wt ng cells at ce ll dratn plugs .
IWARNINGt Refer to page iv prior to fuel system component maintenance. b. Remove plate immediately aft of hopper on
lower fuse lage skin.
c. With shut- off valve in "ON" position, drain fuel from reservoir tank and lines with strainer drain control. To expedite fuel drain ing, r emove plug from bottom of reservoir tank. d. Disconnect control from valve handle. e . On aircraft thru serial 18800572 , disconnect fuel line from valve, and rellX>ve valve from bottom of reservoir tank. f. Beginning with aircraft 18800573 disconnect fuel line and control fr om valve. g. Disconnect control from strainer. h. Remove screw securing strainer. i. Disconnect a ll fue l lines and e lectrical connec tions from fuel pump. j. Loosen clamp securing pump. k. Remove shut- off valve, fuel strainer and pump from aircraft as a unit. 1. Reverse preceding steps for installation. 12-22. VENTED FUEL FILLER CAPS. 18803296.)
(THRU
12 - 23. DESCRIPTION. The filler cap assemblies may be constructed of either metal or red plastic. Both cap asse m blies incorpora te a vent safety valve that provides vacuum and positive pressure relief for their respective fuel tanks. It is important that both type caps to be cleaned on as required basis, if pro per flller cap sealing is to be maintained. 12-24. METAL "FLUSH- TYPE" FILLER CAPS. Except for minor differences in construction and weight, :netal fuel filler caps perform the same function as red plastic fuel filler caps. The caps are interchangeable and will fit the same adapter assembly. 12-25. INSPECTION. NOTE
U fuel collects in the handle well it could in dicate stem 0 - ring leakage. Fuel collecting around perimeter of cap could indicate cap 0-ring or check valve leakage. a . Remove fue l cap from adapter (8), remove safe ty chain (11) from cap and cover o r plug fuel opening to keep out foreign matter . b. Remove nut (10) and, observing position of lock plate (6) in relation to stem (14) disassemble cap. c. Note resiliency of 0-rings (3 & 13) and condition of grooves. II the 0 - rings (3 & 13) have deteriorated they must be replaced. 12-26. CLEANING. a. Using a cotton swab and Stoddard solvent o r equivalent, g ently lift edges of rubber umbrella (5) and c lean stainless steel seat and umbrella removing 12-17
MODEL 188 & T1 88 SERIES SERVICE MANUAL
1. Handle 2. Fuel Cap Body 3. 0-Ring 4. Check Valve (Vent) 5. Umbrella 6. Fuel Cap Lock Plate 7. Washer 8. Adapter Assembly 9. Placard 10. Nut 11. Safety Chain 12. Lug 13. 0-Ring 14. Stem 15. Spring 16. Split Washer 17. Handle Pin
2
3
15
.*Metal caps that have a letter "M" cast in the body (2) under the handle (1), have the 0-ring retention groove machined to ensure a positive fit for the 0-ring (3).
9
THRU 18803296
Figure
12~5.
Fuel Filler Cap- Metal
all contaminates . Using a second swab wipe seat and umbrella tho r oughly. removing all cotton fibers. Repeat until swabs show no discolotation. b. U 0-ring grooves appear contaminated, clean with Stoddard solvent or equivalent and cottom swabs. c. Ascertam that all vent holes in check valve are
unobstructed.
d . Clean cap body and lock plate. check for defects. e. U the umbrella continues to leak or is deterio
rated it must be replaced.
· f. To remove umbrella, lubricate the umbrella stem with (MIL- H- 5606) hydraulic fluid to prevent tearing the stem. g . To replace the umbrella. lubricate the umbrella stem wtth (MlL-H-5606) hydraulic fluid and use a small blunt tool to insert the retaining knob on the umbrella s tem tnto the check valve body co prevent damagtng the stem. 12-27 . REASSE:\1BLY. a. Place spht washer (16) tn c ap well correctly.
12-18
Revision
1
b. With handle (1) and 0 - ring (13) installed on stem (14), insert stem (14) through split washer (16; on cap body (2). c. Place spring (15) on stem (14). d. Position cap handle (1) to full "OPEN" position. e. Place lock plate (6) on threaded end of stem (14) and align all three lugs (12) with three guide bosses on the cap body (2) . f. Check that square hole in bottom of lock plate (6) is aligned with square surface on threaded end of stem (14).
NOfE It is possible to install the lock plate (6) 180°
out of the desired position, if the alignment procedures in steps "d" and ''f" are not fol lowed. rt the cap will not fit when assembled remove the lock plate (6) and reassemble after rotating it 180°.
MODEL 188 & T188 SERIES SERVICE MANUAL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Cap handle Fuel Cap body Outer Seal Check Valve(Vent) Umbrella Rubber Fuel Cap Lock Plate Lock Plate Vents(4) Adapter Assembly Placard Safety Chain Cotter Key Metal Plates Stem 0-Ring Stem Spr111g Split Washer Handle Pin
THRU 18803296
10
Figure 12-6. g. and h. and
Fuel Filler Cap - Red Plastic
Compress the lock plate (6) and fuel cap body (2) secure with washer (7) and nut (10). Connect fuel cap assembly to safety chain (11) reinstall in tank.
12-28. RED PLASTIC "FLUSH-TYPE" FILLER CAPS. A red plastic " Flush-Type" vented filler cap m ay be used. Extra care is required when reinstalling plastic filler caps in the fuel filler adapter assembly. An improperly installed filler cap could cause a loss of fuel !rom the tanks during flight. 12-29.
INSPECTION. NOTE
around perimeter of cap could indicate cap outer seal or check valve leakage .
a. Remove fuel cap from adapter (8), remove safe ty chain (10) from cap and cover or plug fuel opening to keep out foreign matter. b. Rotate cap handle (1) to the "OPEN" position, compress cap body (2) and lock plate (6) to expose the . 125 inch diameter handle pin (17). c. Using a small wire push out the handle pin (17) . d. Note resi.lience oi 0-ring (13) and outer seal (3) and condition of grooves. If the 0-ring (13) or the outer seal (3) have deteriorated they must be replaced. e. Note condition of tabs on lock plate (6) for signs of abnormal wear , if such wear is evident replace the complete cap assembly.
lf fuel collects in the handle well it could inÂ
dicate stem 0-ring leakage . Fuel collectilli;
~vision 1
12-19
MODEL 188 & T188 SERIES SERVICE MANUAL
12-30. CLEANING. a. Using a cottorn swab and Stoddard solvent or equivalent, gently lilt edges of rubber umbrella (5) and clean stainless steel 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. b. U 0-ring or outer seal grooves appear contami nated, clean with Stoddard solvent or equivalent and cotton swabs. c. Ascertain that all vent holes in check valve are
unobstructed.
d. Clean cap body and lock plate, check for defects. e. U the umbrella continues to leak or is deterio
rated it must be replaced.
f. To remove umbrella, lubricate the umbrella
stem with (MIL-H-5606) hydraulic fluid to prevent
tearing the stem.
g. To replace umbrella, lubricate the umbrella
stem with (MIL-H-5606) hydraulic fluid and use a
small blunt tool to insert the retaining knob on the
umbrella stem into the check valve body to prevent
damaging the stem.
12-31.
REASSEMBLY. NOTE
U fuel was observed leaking around the cap periphery prior to disassembly and the leak age was not due to a bad 0-ring or outer seal an additional split washer (16) may be added for a total of two, prior to reassemblying cap. To make sure that these washers are not in stalled upside down, check to see that edges of the split parallel the respective sides of the cap well. The addition of a washer under the cap handle will increase the effort required to uncap the fuel tank.
a.
Install spring (15) on stem (14). b. Install fuel cap body (2) on stern (14). c. Check that three metal plates (12) on top rim of lock plate (6) are aligned with three guide bosses on fuel cap body (2).
It is possible to install the handle pin in the
pin hole 180° out of the desired position, if
the alignment procedure in step "c" is not
followed. U the handle (1) is not installed
properly the FWD arrow on the cap will not align with the arrow on the placard (9) when the cap is reinstalled. d. Compress cap body (2) and lock plate (6), install split washer(s) (16) as required. e. Install cap handle (1) on stern (14) so that the handle (1) will be in the open ;x>sition. f. Insert handle p1n (17) through handle (1) and stern (14). g. Connect fuel cap assemblv to safetv chJ.in (10) and re install fuel cap. :-.take ~erta tn that the arrow on the fuel cap body (2) a.nd the ar r ow on the placard (9) align. 12-20
Revision 1
12-32. VENTED FUEL FILLER CAPS. (18803297 & ON. ) 12-23. DESCRIPTION. Both fuel filler caps incor porate a vent and safety valve that provides both vacuum and positive pressure relief. 12-34. INSPECTION , CLEANING AND REPAIR. a. Remove the fuel filler cap from the adapter
assembly.
b. Disconnect the safety chain from the cap and
cover or plug the tank opening to keep out foreign
matter.
c. Check condition of gasket and frictionless
washer, replace as required .
d. Using cotton swabs and Stoddard solvent or equivalent, gently lift edges of rubber umbrella and clean seat and umbrella removing all contaminates. Using a second swab wipe seat and umbrella thorough ly, removing all cotton fibers. Repeat untii swabs show no discoloration. e. U the umbrella continues to leak or is deterio rated, remove and replace. To remove the umbrella, lubricate the umbrella stern with (MIL-H-5606) hy draulic fluid to prevent tearing the stern. When in stalling the new umbrella, lubricate the stem with (MIL-H- 5606) hydraulic fluid and use a small blunt tool to insert the retaining knob on the umbrella, into the check valve body. f. Connect fuel cap to safety chain and reinstall
cap in the adapter assembly.
12-35. FUEL QUANTITY TRANSMITTERS. Fuel quantity transmitters are installed in the top of fuel tanks an/ or cells. A complete description, along with procedures for removal, installation and ad justment are co~tained in Section 15. 12-36. FUEL RESERVOIR (RUBBERIZED CELL
INSTALLATION) .
12-37. DESCRIPTION. A fuel reservoir is installed in the lower fuselage immediately forward of the con trol stick. The reservoir has six fuel line connec tions; two from the right fuel cell. two from the left fuel cell, one to the ~ut - off valve and a vapor return line from the engine. =.:.A drain valve with strainer is installed in the bottom of the reservoir for draining trapped water and sediment from the fuel system. 12-38. REMOVAL AND INSTALLATION (See figure 12-2, Sheets 3 and 4).
!WARNING' Refer to page vi prior to fuel system com ponent maintenance. a. Remove plate imr:1ediately aft of hopper on lower fuselage skin. b. Drain all fuel from cells at sump dratn plugs. Drain fuel from reservoir and lines with stratner drain contr ol. T o expediate draining of fuel. remove dra1n valve from bottom of reservoir . c. Disconnec t fue 1 lines at reservoir.
I·
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE ; Check valve (2) opens at approximately 4. 0 PSI vacuum, and . 5 PSI pressure. 1. Umbrella Rubber 2. Check Valve (Vent) 3. Gasket 4. Frictionless Washer 5. Fuel Cap Body
5
2
18803297 & ON
4
3
Figure 12-7. Vented Fuel Filler Cap d. On aircraft prior to 18800573, disconnec t control from shut- off valve handle, loosen clamps attaching reservoir bracket clips to fuselage structure and slide clamps from clip legs; remove reservoir. e. Beginning with aircraft 18800573, remove four bolts attaching reservoir to brackets and lilt out. C. Reverse the preceding steps for installation. 12-39.
FUEL STRAINER.
(METAL TANK).
12-40. DESCRIPTION. The fuel strainer is located on the r ight lower side of the firewall and Is readily accessible by removing the lower rear engine cowling cover. The quick-drain control is located at the left rear side of the engine adjacent to the oil dipstick and is accessible through the oil dipstick door.
NOTE The fuel strainer can be disassembled. cleaned and reassembled without removing the assembly from the aircraft. (Refer to paragraph 12-42.) 12-41. REMOVAL AND INSTALLATION. a. With shut-off valve io ''OFF'' position. drain strainer with the quick-drain control. b. Remove lower rear engine cowling cover for access. c . Disconnect all fuel lines and quick-drain control. d . Remove volts attaching assembly to bracket. e. Reverse the prf;cedlDg steps for installation.
12-42. DISASSEMBLY AND ASSEMBLY. (See figure 12-6.) a. With shut-off valve in "OFF" position. drain
strainer with the quick-drain control.
b. Remove lower rear engine cowling cover for
access.
c. Remove safety wire. out. and washer at bottom of filter bowl and remove bowl. d . Carefully unscrew s tandpipe and remove. e. Remove filter screen and gasket. Wash filter screen and bowl in solvent (Federal Specification P -S-661. or equivalent) and dry with compressed air. f. Using a new gasket between filter screen and top assembly, install screen and standpipe. Tighten standpipe only finger tight. g . Using all new O'¡rings. install bowl. Note that step-washer at bottom of bowl is installed so that step seats against 0-ring. h. With shut-off valve in "ON" position. check for leaks and proper operation. i. Safety wire bottom nut to top assembly. Wire must have right band wrap, at least 45 degrees. 12-43. FUEL STRAINER. (RUBBERIZED CELL). 12-44. DESCRIPTION. The fuel strainer is located in the lower fuselage immediately forward of the
left rudder pedals. The strainer is equipped with a quick-drain valve which provides a means of draining trapped water and sediment from the fuel system. Fuel strainer drain control is located on lower RH instr ument panel (thru 18800832), in engine compartment adjacent to engine oil dipstick (18800833 thru 18803926) & on lower LH instrument panel (18803927) & on. Revision 1
12-21
MODEL 188 & T188 SEPUES SERVICE MANUAL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
"ON-OFF" Control Cover Retainer Gasket Rotary Valve Body 0-Ring Fuel Tank Finger Strainer Bracket Setscrew Retaining Ring Lever Assembly Swivel Bushing Elbow Line (Valve to Electric Fuel Pump) Hose (Valve to Electric Fuel Pump) Hose (Valve to Strainer) Une (Valve to Strainer)
Arrow must point down
~
j
I
13
. -
ff-..
A
PRIOR TO SERIAL NO. 188-0275
1--- --- Â
12
SERIAL NO. 188-0275 & ON AND ALL SERVICE PARTS
PRIOR TO SERIAL NO .
NO. Al88-Q318
17
I
A188- 0318 & ON
22 20. 21. 22. 23. 24. 25. 26.
Rotor Spring Ball Packing Seal Washer Body
~24 BEGINNING WITH SERIAL 18802746
/%'
1
7~.-
24~ . ~~~~ THRU SERIALS 18802745
Figure 12-8. Fuel Shut-Off Valve 12- 22
26
MODEL 188 & T188 SERIES SERVICE MANUAL
Primer line fitting installed here with carburetor- equipp ed engine. Hole plugged on fuel Injected engine.-- ....
*
THRU SERIAL 18802556
*BEGINNING WITH SERIAL 18802557
./ I'
(!
I
I
(
12
I
I I
/
/'
// / ~
I
2
*
;/;"
/ 2
'
/
/
/
NOTE
I/ /
SAFETY WIRE HOLE
• SERIAL NO. Al88-0446 & ON 1. Spring
2. Washer 3. Plunger 4. T op
5. Dr:un Control
6. 7. 8. 9. 10. 11.
Plate 0-Ring Gasket Filter Retainer Ring Standpipe
F igure 12-9.
Fuel Strainer
12. 13. 14. 15. 16.
0 - Ring Bowl 0-Ring Nut Drain Tube
12-23
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE The fuel strainer can be disassembled, cleaned and reassembled without remov ing the assembly from the aircraft. (Refer to paragraph 12-46.) 12-45. REMOVAL AND INSTALLATION. a. Remove plate immediately aft of hopper on the lower fuselage skin for access.
IWARNINGt
I
Refer to procedures outlined on page vi prior to performing maintenance to fuel system components.
b. On aircraft thru serial 1880572 place shut-off valve in "OFF" position and drain fuel from strainer and Hnes with quick drain control. c. Disconnect all fuel lines and controls from
strainer.
d. Disconnect all fuel lines and electrical connec tions from fuel pump. e. Remove screws securing strainer. f. Loosen clamp securing pump. g. Remqve pump and strainer as a unit. h. Reverse the preceding steps for installation. i. Beginning with aircraft 18800573 drain fuel from wing cells at cell drain plugs. j. Place shut-off valve in "ON" position, drain fuel from reservoir tank and lines with strainer drain control. To expedite fuel draining, remove plug from botto~ of reservoir tank. k. Disconnect control and fuelllne from shut-off valve. 1. Disconnect control from strainer. m. Remove screws securing strainer. n. Disconnect all fuel lines and electrical connec tions from fuel pump. o. Loosen clamp securing pump. p: Remove shut-off valve, fuel strainer and pump from aircraft as a unit. q. Reverse the preceding steps for installation.
12-46. DISASSEMBLY AND ASSEMBLY. (See fig ure 12-9). a. With shut-off valve in "OFF" position, drain fuel from bowl and lines with quick-drain control.
. IWARNINGa
I
Refer to procedures outlined on page vi prior to performing maintenance to fuel system components.
b. Remove plate immediately aft of hopper on the lower fuselage skin for access. c. Remove drain tube, safety wire, nut, and washer at bottom of filter bowl and remove bowl (13). d. Carefully unscrew standpipe (11) and remove. e. Remove filter (9) and gasket (8) . Wash filter and bowl in so lvent (Federal Specification P-S-661 , o r equi valent) and dr y wtth co mpressed atr. f. Using a new gasket between filter and top assem bly, install filter and standptpe. Tighten standpipe only finger tight. 12-24
Revision
1
g. Using all new 0-rings, install bowl (13). Note that step-washer at oottom of bowl is installed so that step seats against 0-rlng. Install strainer drair tube. h. With shut-off valve in "ON" position, check for leaks and proper operation of quick-drain valve. I. Safety wire oottom nut to top· assembly. Wire ' must have right hand wrap, at least 45 degrees. 12-47. AUXILIARY FUEL PUMP. 12-48. DESCRIPTION. The electric auxiliary fuel pump is a 35 gallon-per-hour pump, supplying a pressure of 23 - 24 psi. On metal tank installations, the pump is mounted on the aft side of the firewall. On rubberized cell installations , the pump is located in the lower fuselage, immediately forward of the rudder pedals. An integral bypass and check valve incorporated in the pump assembly permits fuel flow \ through the pump, even when the pump is not oper attng, but prevents reverse flow. A separate over- \ board drain line from the pump prevents entry of fuel into the electric motor in the event of an internal( leak. 12-49. REMOVAL AND INSTALLATION. (METAL TANK INSTALLATION). a. Remove side panels just aft of firewall. b. With shut-off valve in "OFF" position, drain fuel from pui:np and lines with strainer drain control. c. Disconnect all fuel lines and electrical connec tions from pump. ~ d. Loosen clamps securing pump. e. Remove fuel pump. f. Reverse the preceding steps for installation. 12-50. REMOVAL AND INSTALLATION . (RUBBER IZED CELL INSTALLATION). a. Remove plate immediately aft of hopper on the lower fuselage skin for access.
!WARNING' Refer to procedures outlined on page vi prior to performing maintenanc • to fuel system components.
1
I'· ,
b. On aircraft thru serial 1880572 place shut-off valve in "OFF" position and drain fuel from strainer and lines with quick drain control. c. Disconnect all fuel lines and electrical connec tions from fuel pump. d. Disconnect all fuel lines and contro l from strainer. e. Remove screws securing strainer and loosen clamp securing pump. C. Remove pump and strainer from aircraft as a 11 unit. g. Reverse the pr eceding steps Cor installation. h. Beginning with aircraft 1880573 drain fuel from wing cells at cell drain plugs. i. Place shut- off valve in "ON" position, drain fuel fro m reservoir tank and lines with strainer drain contro l. To expedite fuel draining, remove plug fror. bottom of reservoir tank. j. Disconnect cootrol and fuel line from shut- off valve.
MODEL 188 & T188 SERIES SERVICE MANUAL
k.
Disconnect contro l from strainer. Remove screws securing strainer. m. Disconnect all fuel lines and electrical connec
tione fro m fuel pump.
n . Loosen clamp securing pump. o . Remove shut-off valve, fuel strainer and pump
from aircraft as a unit.
p . Reverse the preceding steps for installation. I.
12-51. ELECTRIC FUEL PUMP CIRCUIT. A188-SERIES). (Refer to figure 12-1).
(MODEL
12-52. DESCRIPTION. The electric auxiliary fuel pump, which supplies fuel flow for starting and for engine operation if the engine-driven fuel pump should fail , is contro lled by the auxiliary fuel pump switch, mounted o n the instrument panel. The switch is a three-position toggle switch. The down position, labeled START, is used for starting the engine. With the switch in this position and the starter button push ed in, the auxiliary fuel pump will operate at a flow rate that provides the proper fuel mixture for start ing as the eng ine is being turned over with the starter. NOTE T he auxiliary fuel pump will no t operate with the switch in the START position until the starter button is pushed in. The up position of the switch, labeled EMERGENCY, is used for engine operation if the engine-driven fuel pump should fail, or for vapor purging in extremely hot weather . When the switch is in this position, the auxiliary fuel pump can operate at two flow rates de pending on the setting of the throttle . With the throttle at a cruise setting, the auxiliary pump is opera ting at maximum capacity, supplying sufficient fue l flo w to maintain flight with the engine-driven pump inoperative . When throttle is moved toward the closed position, as during let-down, landing, and taxiing, a mechanically-actuated switch electrically reduces the auxiliary fuel pump flow r.ate by means of a resistor in the pump power circuit. This action automati cally prevents an excessively rich mixture during the se periods of reduced engine speed. The auxiliary fuel pump is not to be on EMERGENCY .during normal operation because, with the engine dri ven pump funct ioning, a fuel-air ratio consider ably n cher than best power is produced. If fuel vapor 1S affecting e ngine operation, the vapor may be purged by turning the auxiliary fuel pump switch to EMERGENCY and leaning the mixture as required to prevent an excessively r ich mixture. Successful vapor purging is evidenced by smooth engine oper ation and s teady and normal fuel flow indi cations with the auxiliary fuel pump switch OFF. NOTE If the auxiliary fuel pump swit ch is a cciden
ta lly turned to EMERGENCY (With mas ter sWitch on) with the engine stopped, Intake mamfolds Wi ll be flooded unless the mllcture is 10 1dle cut -off.
On aircraft 18800833 thru 18801374, the fuel pump switch is a split-rocker type; the right half positions are "HI, " "LO" and off and the left hall positions are "MAX HI" and off. The right half of the switch in corporates an intermediate "LO" position used for normal starting, and a "ffi" position (when the top of the switch i s fully depressed) for vapor purging during hot engine starts. Maximum fuel flow is pro duced when the left half of the switch is held in the spring-loaded "MAX HI" position. In the "MAX HI" position, an interlock within the switch automatically trips the right half of the switch to its "HI'' position. When the spring-loaded left half of the switch is re leased, the right half will remain in the ''HI'' position unW manually returned -to the off position. With the right half of the switch in the "LO" position, and the starter button depr essed, the auxiliary fuel pump will operate at a low flow rate (providing proper fuel mixture for starting) as the engine is being turned over with the starter. NOTE The auxiliary fuel pump will not operate in the "LO" position until the starter button is depressed. With the right half of the switch in the "HI" position, the pump operates at one of the two flow rates that are dependent upon the setting of the throttle. With the throttle open to a cruise setting, the pump is op erating at a high capacity to. supply sufficient fuel flow to maintain flight. When the throttle is moved toward the closed position (as during letdown, land ing and taxiing), the fuel pump flow rate is automati cally reduced, preventing an excessively rich mix ture during these periods of reduced engine speed. When the engine-driven fuel pump is functioning and the auxiliary fuel pump is turned on " HI'', a fuel/air ratio considerably richer than best power is pro duced unles s the mixture is leaned. If the auxiliary fuel pump switch is accidentally placed on "HI" (with master switch on) with the engine stopped and the mixture rich, the intake manifolds will be flooded. On Aircraft 18801375 thru 18801824, the switching circuits to the electric fuel pump are simplified. The new switch appears identical to the red-yellow inter locking switch pr eviously used. The right-hand yel low rocker switch does not have the center "ON" posi tion which was interconnected to the starter circuit, but it still has the low and high bOOst, depending on throttle position. The throttle- actuated switch func tions off the throttle quadrant as described in the preceding paragraph. Closing the throttle adds more resistance to the low boost circuit. The left- hand red rocker switch functions as before (''OFF" - "MO MENTARY ON") for high boost operation. The mo mentary high boost function controlled by the red rocker switch, bypasses the throttle switch circuit and provides full fuel pump capac1ty , regardless of throttle position.
12-25
MODEL 188 & T188 SERIES SERVICE MANUAL
On aircraft beginning with 18801825, the yellow right hall of the switch is labeled "START," and its upper "ON" position is used for normal starting, minor va por purging and continued engine operation in the e vent of an engine- driven pump failure. With the r ight hal! of the switch in the "ON" position, the pu mp operates at one of two flow rates that are de pendent upon the setting of the throttle. With the throttle open to a cruise setting, the pump operates at a high enough capacity to supply sufficient fuel flow to maintain flight with an inoperative engine driven fuel pump. When the throttle is moved toward the closed position (as during letdown, landing and taxllng), the fuel pump flow rate is automatically re duced, preventing an excessively rich mixture during these periods of reduced engine speed. NOTE II the engine- driven fuel pump is functioning and the auxiliary fuel pump switch is placed in the "ON" position, a fuel/air ratio con siderably richer than best power is pr oduced unless the mixture is leaned. Therefore , this switch should be turned off during take of(.
(~AUTION I II the auxiliary fuel pump switch is acciden tally placed in the "ON" position with the master switch on and the engine stopped, the intake manifolds will be flooded.
The red left hall of the switch Is labeled "EMERG," and its upper "HI" position is used in the event of an engine- driven fuel pump fa ilure during take- off or high power operation. The "HI" position may also be used for extreme vapor purging. Maximum fuel flow is produced when the left hall of the switch is held in the spring-loaded "HI" position. In this position. an interlock within the switch automatically trips the right hal! of the switch to the "ON" position. When the spring-loaded left hall of the switch is releas~d. the right half will remain in the "ON" position until manually returned to the "OFF" position. 12-53. RIGGING THROTTLE MICROSWITCH. a. With engine running, advance the throttle to obtain a man1fold pressure of over: 20" Hg on normally aspirated and fuel injected engines , and 25" Hg on turbocharged engines. b. Slowly r etard the throttle , and mark the throttle position at: 20" Hg on normally aspirated and fuel injected engines. and 25" Hg on turbocharged models. c. Stop the engine. and adjust the switch located at the bottom of the throttle quadrant to actuate o n the previously marked positions. NOTE Sw1tch bracket may have to be modified on
the aft end to allow pro per adjustment.
12-26
12- 54. AUXILIARY FUEL PUMP RATE ADJUST MENT.
IWARNINGt Large amounts of raw fuel are drained from the engine compartment during engine stopped test. Therefore , a suitable drip pan should be placed under engine compartment and all safety precautions observed to prevent igni tion of fumes. NOTE On 12V Aircraft, adjust AMOR 20-1. 5 resis tor to 1. 0 ± . 25 OHMS, and AMOR 20-5 to 2. 0 ± . 25 OHMS pr ior to installation. On 24V Aircraft, adjust AMOR 20-10 resistor to 3. 5 ± . 5 OHMS prior to installation. a. Make the following adju stments with engine
stopped, and using external power:
1. Apply 13. 75 VDC ± . 25V on 12V aircraft,
and 28. 8 VDC ± . 25V on 24V aircraft, to the bus.
2. Set Mixture: FULL RlCH. 3. Set Throttle: FULL OPEN. 4. Turn boost pump rocker switch (yellow} ON. 5. Adjust number one resistor until a fuel flow of 14. 7 - 16.0 gallons/hr. is indicated. 6. Retard thr ottle to IDLE. Pump should change to slower speed as the throttle passes the marked position. 7. Adjust number two resistor until an appr ox imate 4 gallons/hr flow is indicated. This reading will be on the low end red line or appr oximately one red llne - width - above the low end red line . NOTE On 24V aircraft, low setting is made by ad justing number two resistor to minimum resistance position. Gage reading will be just above the lower red line (~. 5 psi). This is maximum available low position. 12-55. EMERGENCY BOCX3T CHECK. With ex ternal power applied, and bus voltage on 12V air craft at 13. 75 VDC ± . 25V, and on 24V aircraft at 28. 8 VDC ± . 25V, make the following check. I. Engine: Stopped. 2. Set \1ixture: F ULL RlCH. 3. SPt Throttle: FULL OPEN. 4. EMERGENCY fuel switch (RED): HELD ON . 5. The fuel flow gage must indicate a noticeable increase in fuel flow.
IWARNINGt Large amounts o f raw fuel are drained from the engine compartment during engine stopped test . Therefore. a suita ble drip pan should be placed under engine compartment and all s afety pr ecautio ns observed to prevent igni t iOn of fumes .
MODEL 188 & T188 SERIES SERVICE MANUAL
12-56.
PRIMING SYSTEM.
12-57. DESCRIPTION. A manually operated priming system is installed on carburetor engines only. Fuel IS supplied by a line from the fuel strainer to the plunger -type primer. Operating the primer forces fuel to the aft end of each intake manifold, thus priming the entire length of the intake mamfold for each bank of cylinders. Replacement of the pr imer is accomplished by disconnecting the fuel lines at the primer and removing the primer from the in strument panel. Before installing a pr imer, check it for correct pumping action and positive fuel shut off in the locked position. Primer lines should be replaced when crushed or broken and should be properly clamped to prevent fat1gue due to vibration and chafing.
12-27/ (12-28 blank
MOD EL 188 & T188 SERIES SERVICE MANUAL SECTION 13
PROPELLERS AND GOVERNOR
!WARN ING'
When performing any inspection or mainte nance that requires turning on the master switch, installing a battery, or ·pulling the propeller through by hand, treat the propel ler as if 'the ignition switch were ON. Do not stand, nor allow anyone else to stand, within the arc of the propeller, since a loose or broken wire, or a component ma.l. function, could cause the propeller to rot~.
TABLE OF CONTENTS PROPELLERS . . . Description . . Repair . . . . Trouble Shooting Fixed-Pitch . . Removal and Installation Constant-Speed . Removal. . Installation
Page No. Aerofiche/Manual . 2B7/13-1 . 287/13-1 . 2B7/13-1 . 288/13-2 . 289/13-3 . 289/13-3 ·. 289/13-3 . 289/13-3 . 289/13-3
13-1. PROPELLERS. 13-2. DESCRIPTION. Aircraft equipped with the 230 HP engine may have an all-metal, fixed pitch propeller or an all-metal, constant-speed, governor regulated propeller installed. Aircraft equip,t>ed with the 300 HP engine have an all-metal, constant-speed, governor- regulated propeller installed. The constant speed is single-acting, in which engine oil pressure, boosted and regulated by the governor, is used to ob tain the correct blade pitch for the engine load. En fine lubricating oil is supplied to the power piston in the propeller hub through the crankshaft. The amount and pressure of the oil supplied is controlled by the engine-driven governor. An increase or decrease in throttle setting or a change in aircraft attitude will affect the balance which maintains a given RPM. U the throttle is opened further or if aircraft speed is increased, engine RPM will try to increase . The governor senses this and directs oil pressure to the forward side of the piston. The blades will be moved to a higher pitch setting and engine speed will remain constant. Conversely, if the throttle opening or the aircraft speed is decreased, the eng ine RPM w111 try to decrease. The governor senses this and allows oil to drain from the forward side
Tlme Between Overhaul . PROPELLER GOVERNOR . Oeser iption · . . . . Trouble Shooting ·. . . . Removal . . . . . . . Installation . . . . . . High-RPM Stop Adjustment Rigging Governor Control . Time Between Overhaul . .
. 2B18/13-12 . 2818/13-12 . 2B18/13-12 . 2818/13-12 . 2818/13- 12 . 2818/13-12 . 2818/13-12 . 2819/ 13-13 1 . 2819/ 13-13
of the piston. Spring tension and centrifugal twist ing inoment Will move th~ blades to a lower pitch to maintain the selected engine speed. During the 1969 model year, a new threadless blade propeller is installed on aircraft equipped with the 230 HP engine. With this type blades , the propeller balance weights are moved to ·a bracket on the propeller cyl inder nearer the center llne of the propeller. During the 1976 model year, a three - blad~ constant-speed propeller is optlonal, and some constant ~spe ed AG Aircraft propellers have oil filled hubs. Figures 13-1 and 13 - 2 illustrate the different propellers used on the aircraft.
13~3. REPAIR. Metal propeller repair first involves evaluating the damage and dete rmining whether the repair will be a major or tritnor one. Federal Avia tion Regulations, Part 43 (FAR 43), and Federal Aviation Agency, Advisory Circular No. 43. 13 (FAA AC No. 43.13), define major and minor repairs, al terations and who may accomplis h them . When mak ing repair s or alterations to a pr opeller FAR 43, FAA AC No. 43 . 13 and the propeller manufacturer's instructions must be observed.
Revision 1
13-1
MOD EL 188 & T188 SERIES SERVICE MANUAL 13-4. TROUBLE SHOOTING. TROUBLE FAILURE TO CHANGE PITCH.
FAILURE TO CHANGE PITCH FULLY.
SLUGGISH RESPONSE TO PROPELLER CONTROL.
STATIC RPM TOO LOW.
TOO HIGH OR
ENGINE SPEED WU..L NOT STABILIZE.
OIL LEAKAGE AT PROPELLER MOUNTING FLANGE.
OIL LEAKAGE AT ANY OTHER PLACE.
13-2
REMEDY
PROBABLE CAUSE Governor control disconnected or broken.
Connect or replace control .
Governor not correct for propeller. (Sensing wrong.)
Replace governor.
Defective governor.
Replace governor.
Defective pitch changing mechanism i.nSide propeller or excessive propeller blade friction.
Propeller repair or replacement is required.
Improper rigging of governor control.
Check that governor control arm and control have full travel. Rig control and arm as required.
Defective governor.
Replace governor.
Excessive friction in pitch changing mechanism inside propeller or excessive blade friction.
Propeller repair or r eplacement is required.
Improper propeller governor adjustments .
Perform static RPM check Refer to section 11 for procedures.
Sludge in governor.
Remove and clean.
Air trapped in propeller actuating cylinder .
Trapped air should be purged by exercising the propeller several times prior to take-off after propeller has been re installed or has been idle for an extended period.
Excessive friction in pitch changing mechanism inside propeller or excessive blade friction.
Propeller repair or replacement is requir ed.
Defective governor.
Replace governor.
Damaged 0- ring seal between engine crankshaft flange and propeller.
0- ring seal.
Remove propeller and install
Foreign material between engine crankshaft flange and propeller mating surfaces or mounting nuts not tight.
Remove propeller and clean mating surfaces; install new 0- ring and tighten mounting nuts evenly to torque value in figure 13-2.
Defective seals, gaskets. threads, etc . , or mcorrect assembly.
Propeller repair o r replacement is required.
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Torque propeller nuts to 660 to 780 inch- lbs
1. Bolt 2. Washer 3. Propeller 4. Dowel 5. Engine Crankshaft 6. Washer 7. Nut
Figure 13-1.
Fixed-Pitch Propeller
13- 5. FIXED- PITCH. 13-6. REMOVAL AND INSTALLATION. (See
figure 13- 1. )
a. Remove bolts, washers and nuts attaching pro peller to crankshaft flange. b. Pull propeller forward to remove from engine. c. Reverse the preceding steps far reinstallation.
Clean mating surfaces of propeller and crankshaft,
position propeller on dowel pins and install attaching
hardware. Torque bolts evenly to 660-780 lb-in.
Us.e torque wrench adapter, Cessna No. 509006-9.
I
13-7. CONSTANT-SPEED.
13-8. RE:viOVAL. (See figure 13-2.) a. Remove spinner attaching screws and remove spinner, spinner support and spacers. b. Remove cowling as required for access to ·pro peller attaching nuts. c. Loosen all nuts attaching propeller about 1/4 inch and pull propeller forward until halted by nuts.
13-9. INSTALLATION. (See figure 13- 2.) a . If the spiliner bulkhead was removed, position it so the propeller blades will emerge from the spinner and install spinner bulkhead attaching lugs and screws.
- .. - (c.AUTION\
-
Avoid scraping metal from bore of spinner bulkhead and wedging scrapings between e ngine flange and pr opeller. Trim the in side diameter of the bulkhead as necessary when installing a new spinner bulkhead. b. Clean propeller hub cavity and mating surfaces of. propeller and crankshaft. c. Lightly lubricate a new 0-ring and the crank shaft pilot with clean engine oil and install the o- ring in the propeller hub. ·
!WARNING
a
Be sure magneto ls grounded before turning engine.
NOTE As the propeller is separated from the engine crankshaft flange, oil will drain from the pro peller and engine cavities. d. Remove propeller attaching nuts and pull pro peller forward to remove from engine crankshaft. e. U desired, the spinner bulkhead can be removed by removing screws and nuts attaching lugs to bulk l:!_e~ch_~ote direction lug attaching screws are in stalled.
d. Align propeller mounting studs and dowel pins with proper holes in engine crankshaft flange and slide propeller carefully over crankshaft pilot until mating surfaces of. propeller and crankshaft flange are approximately 1/4 inch apart. e. Install propeller attaching washers and nuts and work propeller aft as far as i>ossible, then tighten nuts evenly and torque to 660- 780 lb-in. Use torque wrench adapter, Cessna No. 509006-9. f. Install any spacers used between spinner support
Revision 1
13 -3
I
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Torque propeller mounting nuts (15) to 660-780 lb-in.
,
THREADED PROPELLERS ARE INSTALLED ON ALL AIRCRAFT EQUIPPED WITH 300 HP ENGINES (SERIALS 188-0001 THRU 18803721), AND ON AIRCRAFT EQUIPPED WITH 230 HP ENGINES THRU SERIAL 188-0537.
4
18
NOTE
â&#x20AC;¢ Install screws with heads aft and washers under nut through aircraft serial 188-0537. Install screws w1th heads fotward and washers under screw heads beginning with aircraft serial 1880538. 1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Spinner Spinner Support
Spacer Cylinder Screw Propeller Stud Dowel Pin 0-Ring Fillet Engine Crankshaft Spinner Bulkhead Lug Washer Nut Tube SafetyWire Ring Oil Filler Plug
Detail
DETAIL ""A" APPLIES TO CYLINDER (4) ATTACHMENT WHEN MODIFIED PER SERVICE LETTER SE71 -18 AND MS-71-12
NOTE
Additional spacers (3), Cessna Part Number 0752620-3, may be required when installing a new spinner (1) to ensure a snug fit between spinner (1) and support (2). DO NOT use more than a total of 14 spacers in this mstallation.
Figure 13-2. Revision 1
I j
i
TWO BL\DED (THREADED)
13 - -!
A
18
Constant- Speed Propeller (Sheet 1 of 6)
'r
r
MODEL 188 & T188 SERiES SERVICE MANUAL NOTE
Torque pr opeller mounting nuts
(17) to 660- 780 lb- in.
21
NOTE
14 Because of dowel pin location, lugs (15) are reversed on 230 HP en gine propeller installa tions. The 300 HP en gine propeller installa tlon is shown.
THREADLESS PROPELLERS ARE INSTALLED ON ALL AIRCRAFT EQUIPPED WITH 230 HP ENGINES BEGIN NING WITH SERIAL 188-0538 & ALL 300 HP ENGINES
BEGINNING WITH SERIAL 18803722 & ALL AIRCRAFT
MODIFIED PER CESSNA SERVICE KITS SK188-76 OR
SK188-77. NOTE Additional spacers (3) , Cessna Part Number 0752 620-3, may be required when installing a new spinner (1) to ensure a snug fit between spinner. (1) and support (2). DO NOT use more than a total of 14 spacers in ~his installation.
1. Spinner
2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13. 14. 15. 16.
9
17. 18. DETAIL "A" APPLIES TO CYLINDER (4) ATTACHMENT WHEN MODIFIED PER SERVICE LETTER SE71-18. Detail
A
1'9. 20. 21.
22. 23.
Spinner Support Spacer Cylinder Screw Safety Wire Ring T ube Balance Weight Bracket Balance Weight Hub Dowel Pin 0-Rlng Stud Lug Washer Nut Engine Crankshaft Spinner Bulkhead Fillet Screw Washer Nut
TWO BLADED (THREADLESS) Figure 13-2. Constant-Speed Propeller (Sheet 2 of 6) Revision 1
13-5
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE
NOTE Additional spacers (4), Cessna part number 0752620-3, may be required when installing a new spinner (l) to ensure a snug fit between spinner (1) and spinner _upport (3). DO NOT use more than a total of 14 spacers in this installation.
1. 2. 3. 4. 5. 6.
Propeller Spinner Screw Spinner Support Spacer Cylinder Sc rew
7. 8. 9. 10. 11. 12. 13.
See Applicable Vender Publications for in depth Inspection/ Repair Requirements.
Stud Lug Nut Screw Spinner Bulkhead Crankshaft 0 Ring
14. 15, 16. 17. 18. 19, 20.
THRU 18803721 THREE BUDED (THREADED)
F igure 13-2. Constant-Speed Propeller (Sheet :, of 6) 13-6
Revision 1
Dowel Pin Hub Tube Safety Wire Ring Washer Oil Filler Plug
MODEL 188 &. T188 SERIES SERVICE MANUAL
2 Blade Propeller
3 Blade Propeller
1. Relief Hole 2. Ferrule 3. Retainer Nut 4. Hub 5. Retainer Ring 6. Crack 7. Crack 8. Blade Shank 9. 0 ' Rings 10. Sealant 11. Sealant 12. Sealant
8
IWARNINGt 4
9
II leakage is coming from the sealant between the blade shank and steel fer rule (location 10), the actual source of the leak could be either a cracked blade or a breakdownorthe sealant on the inboard end of the blade/fer rule seam (loc.a tion 12). II leakage is coming from location 10 or from a crack in the hub or blade, the aircraft must remain GROUNDED until repairs can be accomplished.
POSSIBLE LEAK POINTS I . Leak at (10) is either from sealant failure (location 12, internal) or crack in threaded retention area such as (6). 2. Leak a t s urface of (4)'hub is indication of cracked hub. 3. Leak at (7) is indication of cracked blade shank, (not necessarily location indicated) . 4. Leak at (5) or (9) is indication of bad O'Ring (9). 5. Leak around piston housing mount indicates deteriorated gasket. NOTE Clear sealant is applied externally (location 10) to prevent water from entering blade/ferrule joint, however, red propeller oil can penetrate small intentional perforations in this seal if a crack developes in the blade (area 6). Deterioration of the sealant at location 10 will not be the~ or~ of leakage.
OIL FILLED HUB INSPECTION Figur e 13-2 . Cons tant- Speed Propeller. (Sheet 4 of 6) 13-7
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE
19
Additional spacers (6) , Cessna part number 0752620-3, may be required when installing a new spinner (1) to ensure a snug fit between spinner (1) and spinner support (5). DO NOT use more than a total of 14 spacers in this installation.
4
NOTE
1
Torque propeller mounting nuts (21) to 660-780 lb-in.
USED WITH AIR CONDITIONER
Det ail
A
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Beginning with 18803722 THREE BLADED (THREADLESS) Figure 13 -2.
13- 8
Revision 1
Spinner Fillet Screw Washer Spinner Support Spacer Cylinder Safety Wire Screw R ing Tube Hub Blade
Pro peller Installation (Sheet 5 of 6)
14. 15. 16. 17. 18. 19. 20. 21.
22. 23. 24. 25.
0-Ring Retainer Stud Dowel Pin 0 - Ring Crankshaft Washer Nut Spinner Bulkhead Bolt Washer Nut
MODEL 188 & T188 SERIES SERVICE MANUAL
~
NOTE
Additional spacers (4), Cessna part number 0752620-3, may be required when installing a new spinner (1) to ensure a snug Cit between spinner (1) and spinner support (3). DO NOT use more than a total of 14 spacers in this installation.
13
14
15
10
2
1. Spinner
2. Scr ew 3. 4. 5. 6. 7. 8. 9. 10.
NOTE Torque propeller mounting nuts (15) to 660-780 lb-in.
MODEL Tl88
Spinner Support Spacer Cylinder Screw Tube Safe ty Wire R ing Stud
Beginni~
11. Dowel Pin 12. 0 - Ring 13. Crankshaft 14. Washer 15. Nut 16. Spinner Bulkhead 17. Bolt 18. Washer 19. Nut
With T18803297T
THREE BLADED (THREADLESS) Figure 13-2. Propeller Installation (Sheet 6 of 6)
Reruion 1
13-9
MODEL 188 & T188 SERIES SERVICE MANUAL
THRU AIRCRAFT SERIAL 18800832
1
6
3 1. Propeller Governor · 2. High-Speed Stop Screw 3. Governor Arm Extension 4. Nut 5. Rod End 6. Governor Control 7. Oil Pan Bolt (Ref) 8 . Bracket 9. Safety Wire 10. Balance Tube (Ref) 11 . Lever 12. Washer
4
A
~......
,
......
'-
J /
'r ""---- ------,. ""'
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.-\ffiCRAFT SERL.1.LS 18800833 THRU 18801824
Detail
F tgure 13-3. Governor and Control Adjustmems (Sheet 1 of 2) 13-10 .
)I
B
MODEL 188 & T188 SERIES SERVICE MANUAL
*Both dimensions 33â&#x20AC;¢ and 0. 35" must exist while holding arm/lever (11) against the high pitch stop (2).
*0. 35-in.
11
3
Detail
C
BEGINNING WITH AIDCRAFT SERIAL 18801825
Figure 13 -3. Governor and Control Adjustments (Sheet 2 of 2) 13-11
MODEL 18 8 & T188 SERIES SERVICE MANUAL
f. Install spacers and spinner support on propeller cylinder. If spacers are not centered mechanically (piloted) , visually center and hold them until spinner support is forced firmly in place. g. Hold spinner snug against spinner support and check alignment o! holes in spinner with holes in spinner rulkhead. Add or remove spacers from pro peller cylinder until holes are within . 050 of align ment. h. Push hard on spinner to align holes and install screws and washers(tf required) in 3 or more equal spaces around the spinner bulkhead. Relax pr essure on the spinner and install the remaining screws and washers (if required) . i. Tighten all screws uniformly around t he spinner.
13-10. TIME BETWEEN OVERHAUL (T BO). Pro
peller overhaul shall coincide with engine overhaul,
but interval shall not exceed 1200 hours, Refer to
Sections 11, llA, and llB for engine overhaul r ec
ommendations.
13-11. PROPELLER GOVERNOR. 13 - 12. DESCRIPTION. The propeller gover nor is a single-acting, centrifugal type, which boosts oil pres sure from the engine and directs it to the propeller where the oil is used to increase blade pitch. A single- acting gover nor uses oil pr essure to effect a pitch change in one direction only; a pitch change in the opposite direction results fr om a combination of centrifugal twisting moment of rotating blade s and compressed springs. Oil pressure is boosted in the governor by a gear type oil pump. A pilot valve, fly weight and speeder spr ing act together to open and close governor oil passages as required to maintain a constant engine speed. NOTE Outward physical appear ance of specific gov ernors is the same, but internal parts deter mine whether it uses oil pressure to increase or decrease blade pitch. The propellers used on these aircraft require governors which "sense" in a certain manner. "Sensing"' is determined by the type pilot valve installed inside the governor. Si.r-ce the basic governor may be set to "sense" oppositely, it is impor tant to ascertain that the governor is correct for the propeller being used. 13-13. TROUBLE SHOOTING. When trouble shoot ing the propelle r - governor combination, it is recom mended. that a governor known to be in good condition be installed to check whether the propeller or the governor i s at fault. Removal and replacement, rig ging, high- speed stop adjustment, desludging and re placement of the governor mounting gasket are not major repairs and may be accomplished in the field. Repairs to propeller governors are classed as pro peller major repairs in Federal Aviation Regulations, which also define who may accomplish such repairs.
13-12
Revision
1
13-14. REMOVAL. a. Remove cowling and engine baffles as required for access to governor. b. Disconnect governor control from governor arm or extension arm . NOTE Note position of all washers so that washers may be install ed in the same position on re installation. c. Remove four sets of nuts and washers securing
governor to engine and pull governor from mounting
studs.
d. Remove gasket fr om between governor and engine mounting pad. 13-15. INSTALLATION. a. Wipe governor and engine mounting pad clean b. Install a new gasket on the mounting studs. In
stall gasket with r aised surface of the gasket screen
toward the governor.
IWARNINGl Be sure magneto is grounded befor e turning engine.
c. Position governor on mounting studs, aligning governor drive splines with splines in the engine and install mounting nuts and washers. Do not for ce spline engagement. Rotate engine crankshaft slightly and splines will engage smoothly when properly aligned. d. Connect governor control to governor ar m or arm extension and rig control as outlined in par agraph 1 13- 16. e. Reinstall all items removed for access. 13 - 16. HIGH-RPM STOP ADJUSTMENT. a. Remove engine cowling and baffle as required for access. b. Remove safety wire and loosen the high- speed stop screw locknut. c. Turn the stop ~rew IN to decrease maximum rpm and OUT to in~ease maximum rpm. One full turn of the stop screw causes a change of approxi mately 25 rpm. d. Tighten stop screw locknut and make propeller control linkage adjustment as necessary to maintain full travel. e. Install baffle and cowling. f. Test operate propeller and governor. NOTE It is possible for either the propeller low
pitch (high-rpm ) stop or the governor high
rpm stop to be the high- rpm limiting factor.
It is desirable for the governor stop to
limit the high- rpm at the maximum rated
MODEL 188 & T188 SERIES SERVICE MANUAL
rpm fo r a particular aircraft. Due to cli matic conditions, field elevation, low-pitch blade angle and other considerations, an engine may not reach rated rpm on the ground. It may be necessary to readjust the governor stop after test flying to obtain maximum rated rpm when airborne. 13-17. RIGGING PROPELLER GOVERNOR CON TROL . a. Disconnect governor control from governor arm or extension arm. b. Place propeller governor control, in cabin, full forward, then pull back approximately 1/ 8 inch and lock in this position. This will allow "cushion" to assure full contact of the governor arm with the governor high- rpm stop screw . c. Place governor arm against high- rpm stop screw. d . Loosen jam nuts and adjust control rod end until attaching holes align while governor arm is against high- rpm stop screw. Be sure to maintain sufficient thread engagement of the control and rod end. If necessary, shift control in the clamps to achieve this. e . Attach rod end to the governor arm or arm ex tension. Be sure all washers are installed correctly. Beginning with Aircraft Serial 18801825, rotate governor internal head so that control end fitting clears the governor body as shown in figure 13-3, sheet 2, with the arm in the full forward po~ition :
f. Operate the control to see that the governor arm bottoms out against the low pitch stop and bottoms out against or a maximum of . 12" from the high pitch stop on the governor before reaching the end of con trol cable travel.
NOTE Some governors are equipped with an offset extension to the governor arm. The offset extension has an elongated slot to per mit further adjustment. The preceding steps may still be used as an outline in the rigging procedure. • Refe r to the inspection chart in Section 2
for inspection and/ or replacement inter
val for the propeller control.
13 - 18. TIME BETWEEN OVERHAUL (TBO). Propeller governor overhaul shall coincide with engine overhaul. Refer to Sections 11, llA and UB for engine time between overhaul (TBO) periods. The governor ove r haul manual is available from the Cessna Suppl y Division.
Revision 1
13- 13/ (13-14 blank)
I
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 14
UTILITY SYSTEMS
TABLE OF CONTENTS
I
HEATING SYSTEM . .
Description . . .
Operation . . . .
VENTILATING SYSTEM
Description . . .
Operation . . . .
DEFOGGING SYSTEM.
Description . . .
Operation . . . .
FRESH AIR INSTALLATION (Beginning with 1880833) . . Description . . . . . . Operation . . . . . . . · . FRESH AIR INSTALLATION (Beginning with 18801825) . .
Page No.
Aerofiche/Manual
. . . . . . . . .
2Cl /14-l 2C1/14-1 2Cl/14-l 2C1/14-l 2C1/14-1 2C1/14-l 2C1/14-l 2C1/14-l 2Cl/14-1
. 2C1/14-l . 2C1/14-l . 2Cl/ 14-1
. 2C6/ 14-6
. 2C6/ 14-6
. . . .
2C6/ 14-6 2C6/ 14-6 2C6/ 14- 6 2C12/ 14-12
. . . • .
2C12/14-·t2 2C12/14-12 2C12/14-12 2C12/14-12 2C12/14-12
. 2C6/14-6
14-1. HEATING SYSTEM. (See figure 14-1.) 14-2. DESCRIPTION. The heating system is com prised of the heat exchange section of the exhaust muffler, a shut-off valve, mounted on the right for- · ward side of the firewall, a push-pull control on the instrument panel, outlets, and flexible ducts con necting the system. 14:..3. HEATER OPERATION. Ram air is ducted through an engine ba!fle and heat exchange section of the exhaust mutner, to the shut-off valve at the fire wall. The heated air flows from the firewall shut-off valve into a tee where it is distributed to both sides of the cockpit area. The shut-off valve, operated by the "CABIN HEAT" control, located on the instru ment panel, regulates the volume of heated air enter ing the system. Pulling the heater control full out supplies maximum now, shutting off flow completely whl!n the control is pushed full in. 14-4. VENTILATING SYSTEM. and 14-5.)
Oeser iption . . . . . .
Operation . . . . . . .
FRESH AIR INSTALLATION
(Beginning with 18802746) . Description . . . . . . Operation . . . . . . . Removal, Installation and Repair. AUXIUARY CABIN AIR INSTALLATION (Beginning with 18801825) . . . . Description . . . . . . . . Operation . . . . . . . . . Trouble Shooting . . . . . • Removal, Installation and Repair .
(See figures 14-2
14- 5. DESCRIPTION. The venWating system is comprised of a fresh air scoop door located on the underside of the left stub wing on aircraft serials thru 18800985 and not modified per kit SK188-27. Beginiling with aircraft serial 18800986 and aircraft modified per kit SK188-27. the air scoop door is lo cated on the right hand fuselage forward of the canopy . .\ push-pull control on the right side of the control panel, an outlet and flexible ducting connecting the system. 14-6. VENTO...ATING SYSTEM OPERATION. Fresh air from the scoop door is routed through ducting to
the cockpit area. The scoop door, operated by the "CABIN AIR" control, located on the instrument panel, regulates the volume of fresh air entering tb cockpit. Pulling the "CABIN AIR" control full out supplies maximum flow, shutting off now completely when the control is pushed full ln.
14-7. DEFcx:;GING SYSTEM. 14-5.)
(See figures 14-3 and
14-8. DESCRIPTION. The defogging system is com prised of a defroster nozzle mounted immediately forward of the instrument cluster panel, just aft of the windshield in the cockpit, and flexible ducts con necting the system to the heating and ventilating systems. 14-9. DEFOGGING SYSTEM OPERATION. Ram air is ducted through an engine baffle and heat exchange section of the exhaust muffler, to a tee in the aircraft heating system, where a part of the heated air is rout ed to the defroster nozzle in the cockpit. Fresh air is ducted from the scoop door on the underside of the left wing stub to a connection in the ventilation sys tem, where a part of the fresh air is routed to the defroster nozzle on aircraft serials thru 1880098 5 and not modified per kit SK188-27. By the use of "CABIN AIR" and the "CABIN HEAT" controls, the temperature and flow of air in the defogging system can be regulated. Beginning with aircraft serial· 18800986 and aircraft modified pe.r kit SK188-27, the defroster air comes directly from the tee to the defroster nozzle and is not comected to the fresh air duct. Defogging is managed by the "CABIN HEAT" control increasing or decreasing the air flow. 14-10. FRESH AIR INSTALLATION. with 18800833.) (See figure 14-4.)
(Seginning
14-11. DESCRIPTION. The installation is comprised of an air inlet in the leading edge of the vertical fin, a plenum area in the vertical fin, dueling, routed to the cockpit area, and a louver assembly, located in a bracket assembly in the right-hand cockpit area, ad jacent to the ash tray. 14-12. OPERATION. Ram air enters the inlet on the leading edge of the vertical fin, and routes through the plenum area ln the vertical fin. A collector at the botReviaion 1
14 -1
MODEL 188 8t T188 SERIES SERVICE MANUAL
NOTE
Detail
U warm air valve seat (7) is re moved, it must be sealed per Section 17 upon reinstallation.
A
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1. Hose - T o Muffler
2. Valve Body 3. Valve
4. Control Arm 5. 6. 7. 8. 9. 10. 11.
12 . 13. 14.
Spacer Firewall Valve Seat Heat Control Fuselage Structure Lacing Hose Support CushiOn Mu!fler Baffle
THRU SERIAL 18802745
Figure 14-1. 14-2
Detail
Heating System Installation (Sheet 1 of 2)
8
MODEL 188 & T188 SERIES SERVICE MANUAL
BEGINNING WITII 18803297T I 0 00000 0
•
o,'o·<:-:<~~0 ~·00
I
000
\
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• •
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1 1 .., .., 00
lo 2. 3. 40 5o 6. 7
0
80 90 lOo 110
12. 130
14. 15 o
Duct Door Assembly Filler Strip
Inlet Assembly
Bracket
Plate
Spring
Filler Plate
Slide
Plate Heat Inlet Clamp Cabin Heat Control Tube Interconnect
Detail
o
netail C
0
B
BEGINNING WTTII T188C SERIAL 18803297T & Al88 SERIAL 18802746
Figure 14-1.
-:?.:
Detail
A
Heating System Installation (Sheet 2 of 2) 14-3
MODEL 188 & T188 SERIES SERVICE MANUAL
4
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2
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Detail 188- 0001 THRU 18800832
1. Control
2. Clamp Spring ~u t 4. Fuselag e Structure
3.
5. Lacing 6. Clip 7 . Hose 8. Inlet Body
9 . Gasket 10. Clamp Bolt 11. Door 12. Wing Skin
Figure 14- 2. Ventilation System Installation 14 - 4
A
~
«9
~ 10 ~<
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE If warm air valve seat (7), figure 14- 1, is removed, it must be sealed per Section 17 upon installation.
7
6
A
SEE FIGURE 14-1
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SEE FIGURE 14-
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HEATING SYSTEM
. . DEFOGGING SYSTEM ~ VENTILATING SYSTEM
BEGINNING WITH 18800573 THRU 18800985 AND AmCRAFT NOT MODIFIED PER KIT SK1 88-27 1. Baffle 2. Heater Valve 3. Tee 4. Defroster Hose
5. 6. 7. 8. 9.
Cabin Heat Control Nozzle Cabin Air Control Clamp Union
10. Lower Cover Plate
11. Rivet
13
12. Washer 13. Upper Cover Plate
Figure 14- 3. Heating, Ventilating and Defogging Systems. 14-5
MODEL 188 & T188 SERIES SERVICE MANUAL
7
18800833 THRU 18801824
* Lacing attaches ducting to structural tubing. 1. Gasket 2. Louver Assembly 3. Grommet
4. 5. 6. 7.
Clamp Inlet Screen Deflector Aluminum Foil
8. Collector 9. Duct 10. Lacing
Figure 14-4, Fresh Air Installation tom of the fin is attached to a duct which routes tnt! air to a louver assembly in the ccckpit. The louver can be opened or closed or partially opened by the pilot to provide fresh air to the cockpit. 14-13. FRESH AIR INSTALLATION. with 18801825.) (See figure 14-7. )
(Beginning
14-14. DESCRIPTION. The installation is com prised of two fresh air scoops mounted in the canopy top, a plenum chamber and rotatable air guide mount ed in the air vent housing which is connected directly to the two fresh air scoops in the canopy top. The two fresh air scoop doors can be opened or closed individually by control levers mounted on either end of the air vent housing. A drain spout Is installed in the bottom of the housing with plastic tubing connected and routed to an outs1de dr:un hole in the lower right hand fusel3.$re inboard of the stub wing root.
14- 6
Revision
1
14-15. OPERATION: Ram air enters the cockpit through the two fresh air scoops mounted in the canopy top. The f.::-esh air is distributed over the pilot's head and upper torso and is directed by the rotatable air guide in the air vent housing. 14 - 15A. FRESH AIR INSTALLATION. with 18802746.) (See figure 14- 8.)
(Beginning
14-15B. DESCRIPTION. The fresh air unit in the canopy top includes an air scoop (8), fwd and aft plenums (1) and (13). rotatable air guides (2) and an air inlet butterfly (6). The butterfly (6) can be opened or closed. or adjusted as desired. by a lever (14) located above the pilot's head. 14-15C. OPERATION. In flight, ram air enters the scoop (8), flows through the air guides (2), located in the plenums (1) and (13 ) and is diffused across the top
MODEL 188 & T188 SERIES SERVICE MANUAL
4
5
VENTILATING SYSTEM
13
18800833 THRU 18801824
1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Fresh Air Scoop Actuator Lever Control Cable Seal Cup Assembly Screen Clamp Fresh Air Duct Heater Duct Defroster Duct Tee Assembly Defroster Nozzle Cabin Heat Control
DEFROSTER SYSTEM
Figure 14-5.
Ventilating and Defroster Installation 14-7
M.ODEL 188 8t T188 SERIES SERVICE MANUAL
10
8
1. Housing Assembly 2. Drain Line 3. Clamp 4. Stay -Strap 5. Grommet 6. Lever Assembly 7. Screw 8. Air Guide Assembly
9. 10. 11. 12. 13. 14. 15.
Cover Air Vent Door Assembly Seal Canopy Top Skin Stud Nut Door Control Link
23. Figure 14-6. Fresh Air lnstallation
14-8
16. 17. 18. 19. 20. 21. 22.
Cotter Pin Washer Actuator Assembly Washer Spring Washer Spacer Bolt Union
MODEL 188 & T188 SERIES SERVICE MANUAL
14
6
Detail
13
A 3
Detail
B 18801825 THRU 18802745
1. 2. 3. 4.
5. 6. 7. 8. 9. 10. 11. 12 . 13. 14. 15. 16.
Duct Clamp Screen Cup Assembly Seal Nut Washer Lever Cotter Pin Door Assembly Pin Clamp Control Assembly Control Support Plate Clamp Screw
14-7 .
Auxiliary Cabin Air Installation
14-9
MODEL 188 & T188 SERIES SERVlCE MANUAL
1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Fwd Cabin Top Plenum Assembly Air Guide Assembly Wire Casing Clamp Butterfly Support Alr Inlet Butterfly Inlet Bulkhead Assembly Cabin Top Air Inlet Screen Washer Control Guide Grommet Aft Cabin Top Plenum Assembly Control Lever Knob Control Wire Control Lever Doubler Door Asselllbly Clamp Auxiliary Air Control Lever
21. 22. 23. 24.
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
36. 37.
Seal Cup Assembly Inlet Screen Clamp Duct Louver Gasket Control Support Plate Clamp Door Assembly Link Lever Seal Housing Louver Sta Strap Duct
B
c
... ... ·......
··. ·. ··-.· . ··.- ·... ...
BEGINNlNG WITH 18802746
Figure 14- 8. Cabtn Ventilation System (Sheet 1 of 2) 14- tO
Revision
1
I
MODEL 188 & T188 SERIES SERVICE MANUAL
25 THRU 18803929
16 15 Detail
A
BEniNNING WITH
18803930
____a
28 29
37~ T ~ . 36 ~ 35
19
BEGINNING WITH
18803466
Detail
C
Detail
B
Figure 14-8. Cabin Ventilation System (Sheet 2 of 2) Revision 1
14Â 11
I
MOD EL 188 & T1 88 SERIES SERVICE MANUAL
o! the cockptt. The air guides may be rotated to direct the air, as desired, in the cockpit. 14-15D. REMOVAL, INSTALLATION AND REPAIR. If adjustments or replacement of broken parts is
required, the cabin top must be removed from the canopy before the fresh air unit can be disassembled. See figure 14-8 for detail parts. The magnetic com pass and wire cutter (if installed) must be removed during removal of the cabin top. Re move all bolts and rivets attaching the cabin top to the canopy, take care when removing the windshield attaching bolts to prevent cracking the windshield. Before replacing the cabin top, remove the existing seal strip and old sealant from matlng surfaces. Install new seal strip and apply new sealant to clean dry surfaces. 14-16. AUX1LIARY CABIN AIR INSTALLATION. (Beginning with 1881825. ) (See figure 14-7.) 14-17. DESCRIPTION. The auxiliary cabin air in stallation is comprised of an air inlet scoop, duc1ing, a louvered circular air outlet and a push-pull type control. 14-18. OPERATION. Outside air is taken in through the air inlet scoop mounted in the right hand fuselage forward of the cockpit. The fresh air is ducted to the circular air outlet l~ated in the auxiliary control panel below the right hand side of the main control panel. The au inlet scoop is opened or closed by op eration of the push-pull type auxiliary air control in stalled between the main and auxiliary control panels on the right hand side of the cockpit.
SHOP NOTES :
14-12
Revision
1
.14-1!!: TROUBLE SHOO!JNG • .¥ost of.th~_op~ra tional troubles in the heating and ventilating systems are caused by sticking or binding of the shut -off valve, air scoop door controls; damaged air ducting, or defects in the exhaust muffler. In most cases, the shut-of! valve, air scoop door or their controls can be freed by proper lubrication. Damaged or broken parts will be repaired or replaced. When checking rigging of controls, ensure valves respond freely to control movement, move in the correct di rection, a.n d move through their full range of travel and seal properly. Check that heater hose a r e prop erly secured and replace hose that are burned, fray ed, or crushed. If fumes are detected in the cabin, a thorough inspection of the exhaust muffler should be accomplished. Refer to Section 11 for the exhaust system inspection. Since any holes or cracks may . permit exhaust fumes to enter the cabin, replacement of defective parts is imperative because fumes con stitute an extreme danger. Seal any gaps in shut-off valve at the firewall with Pro-Seal lt700 (Coast Pro Seal Co., Los Angeles, California) compound, or equivalent compound. 14- 20. REMOVAL, INSTALLATION AND REPAIR. Figures 14-1 through 14-7 may be used as ltllides for removal, installation and repair of components. Burned, frayed or crushed hose should be replaced with new hose. Cut hose to length and install in the original routing. Trim the hose winding shorter than the hose to allow hose clamps to be fitted. A defec tive shut-off valve or air scoop door will be repaired or replaced. Check for proper operation and correct rigging of the shut-off valve and air scoop door after repair or installation.
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 15
INSTRUMENTS AND INSTRUMENT SYSTEMS
TABLE OF CONTENTS
Page No.
Aerofiche/Manual
INSTRUMENT AND INSTRUMENT SYSTEMS . . . . . . General . . . . . Instrument Panel . Description Instruments . . . Removal . . . Installation . Pitot and Static System Description . . . Maintenance . . . Static System Inspection and Leakage Test . . . Pitot System Inspection and Leakage Test . . . . Blowing out Lines . . . Removal and Installation Trouble Shooting Pitot Static System Pitot Tube Heater Airspeed Indicator Altimeter . . Engine Indicators Tachometer . . . . Description . . Manifold Pressure Gage Description . . Trouble Shooting . .
. 2C15/15-1 . 2C15/15-1 . 2C15/15-1 . 2C15/15-1 . 2C18/15-4 . 2C18/ 15-4 . 2C18/15-4 . 2C18/15-4 . 2C18/15-4 . 2C18/15-4 . 2C18/15-4 . 2C19/15-5 . 2C19/ 15-5 . 2Cl9/ 15-5 . 2Cl9/ 15-5 . 2C19/ 15-5 . 2C21/15-7 . 2C21/15-7 . 2C22/15- 8 . 2C22/15-8 . 2C22/15-8 . 2C22/15-8 . 2C22/15-8 . 2C22/15-8
15-1. INSTRUMENTS AND INSTRUMENT SYSTEMS. 15-2. GENERAL. This section describes typical instrument installations and their respective opera ting systems . Emphasis is placed on trouble shoot ing and corrective measures only. It does NOT deal with specific instrument repairs since this usually requires special equipment and data and should be handled by instrument specialists. Federal Aviation Regulations require malfwtctioning instrument be sent to an approved instrument overhaul and repair station or returned to manufacturer for servicing. Our concern here is with preventive maintenance on various instrument systems and correction of system faults which result in instrument malfwtctions. The descnptive matertal, maintenance and trouble shoot ing information in this section is intended to help the mechanic determ1ne mallwtctions and correct them, up to the defective instrument itseli, at which point an mstrwnent techntctan should be called in. Some
Cylinder Head Temperature Gage . . . . . . Description . . Trouble Shooting Oil Pressure Gage . Description . . Trouble Shooting Oil Temperature Gage Description . . . Fuel Quantity Indicating Systems . . . . . . . Description . . . . Removal and Installation (Met.a l Tank) . . . . . Removal and Installation (Rubberized Cell) . . . Transmitter Calibration . Trouble Shooting (Calibration) . . Magnetic Compass . . Description . . . Turn and Slip Indicator Description . . Trouble Shooting . Turn Coordinator . . Description . . . Trouble Shooting . Stall Warning System . . . Outside Air Temperature Gage .
. 2C23/15-9 . 2C23/15-9 . 2C23/15-9 . 2C24/15-10 . 2C24/15-10 . 2C24/ 15-10 . 2C24/15-10 . 2C24/15-10 . 2C24/15-10 . 2C24/15-10 . 2C24/15-10 . 2D1/15-ll . 2D1/15 - ll . 201/15-11 . 2D2/15-12 . 2D2/15-12 . 2D2/15-12 . 2D2/15-12 . 2D2/15-12 . 2D3/15-13 . 2D3/15-13 . 2D3/15-13 . 2D4/15- 14 . 2D4/15-14
instruments, such as fuel quantity and oil pressure gages, are so simple and inexpensive, repairs usu ally will be more costly than a new instrument. On the other hand, aneroid and gyro instruments usu ally a.r e well worth repairing. The words " replace instrument" in the text, therefore, should be taken only in the sense of physical replacement in aircraft. Whether replacement is to be with a new instrument; an exchange one, or original instrument is to be re paired must be decided on basis of individual circum stances. 15-3. INSTRUMENT PANEL. (See figure 15-1.) 15-4. DESCRIPTION. The instrument panel is com prised of two sections; the cluster panel above, which contains engine instruments and the main panel below which contains flight instruments, circuit breaker, switches, and various controls.
15-1
MODEL 188 & T188 SER IES SERVICE MANUAL
3 4
THRU AIRCRAFT
SERIAL 18800832
NOTE
Instruments and cont rols on main panel and cluster may vary.
3
Ammeter is relocated to the cluster panel on optional wing fuel cell instal lation.
BEGINNING WITH
AffiCRAFT SERAIL 18800833
1. 2. 3. 4. 5. 6. 7.
Figure 15-l. 15-2
Main Panel Magnetic Compass Clus ter Panel Pad Retainer Ball Seat Panel Retainer Ball Typical Instrument Panel
•
MODEL 188 & T188 SERIES SERVICE MANUAL NOTE Apply 579. 6 sealant (or equivalent) sparingly to static source washer and flange at point of contact with tailcone skin when installing. Check orifice for restrictions after riveting.
o ~4
B
A ..........................._..........
Detail
.... _...........
.. ....·
-····.·
Detail
~5
B
THRU
A
I )
18801921
~/15 '.:1 -
16
. b·v
:;,dJ
neta11
B
BEGINNING WITII 18801922
·····J·-··..:.:...•....~. . . ····~
c
3
1. Altimeter 2. Airspeed Indicator 3. Pitot Line 4. Static Source Line 5. Static Source Sump 6. Tee 7. Grommet 8. Lacing 9. Access Cover 10. Body 11. Heater Element 12. Tube 13. Stem 14. Nose Fitting 15 . Coupling 16. Tube
9 3
STANDARD PITOT MAST Detail F1 gure 15-2.
C
HEATED PITOT MAST Detail
C
Pitot-Static System
15-3
MODEL 188 & T188 SERIES SERVICE MANUAL
15-5. INSTRUMENTS. 15-6. REMOVAL . Most instruments are secured to the panel with s crews inserted through the panel face. To remove this type instrument, disconnect plumbing or wiring, remove the mounting s crews, then remove instrument from behind the panel. Other instruments are held in place by metal brackets that seat against the panel from behind. To remove this type instru ment, disconnect wiring or plumbing, remove nuts securing the bracket to the instrument, then remove instrument from the front side of the panel. The same procedures apply to the cluster after the plastic cover has been removed for access . In all instances when an instrument has been removed, the lines or wires disconnected from it s hould be protected. Cap open lines and cover pressure connections on the in struments to prevent thread damage and the entrance of foreign matter. Wire terminals should be insu lated or tied up so they will not ground accidentally or short-circuit on another terminal. 15-7. INSTALLATION. Generally, installation pro cedure is the reverse of the removal procedure. Make sure mounting s crew nuts are tightened firmly, but do not overtighten them, particularly on instru ments having plastic cases. The same rule generally applies to connecting plumbing and wiring. U thread lubricant or sealer is used on plumbing, it should be applied sparingly and only on the male threads. 15-8. PITOT AND STATIC SYSTEM. (See figure 15-2.) 15-9. DESCRIPTION. The pitot system conveys ram air pressure from the pitot mast, mounted beneath the left wing, through plastic tubing to the airspeed indicator. The static system vents the altimeter, which is connected to the airspeed indicator, through a source button located on each side of the tailcone aft of the c ockpit. A static line sump is installed at each s ource button to collect condensation in the sys tem. A pitot mast heater may be installed. The heating element is controlled by a switch on the in~ strument panel a nd power is supplied by the electrical system. 15- 10. MAINTENANCE. Proper maintenance of pitot and static s ystem is essential for proper opera tion of altimeter , ve rtical s peed and airspeed indi cators . Leaks, moisture and obstructions in pitot system will result in false airspeed indications, while static system malfunctions will affect readings of all three instruments . Under instrument flight condi tions , these instrume nt e rrors could be hazardous . Cleanliness and securit y are the principal rules for system maintenance . The pitot tube and static ports MUST be kept clean and unobstructed. 15-11. STATIC PRESSURE SYSTEM INSPECTION AND LEAKAGE TEST. The following procedur e out lines inspection a nd testing of s tatic pressure system, assuming altimeter has been tested and inspected in accordance with current F ederal Aviation Regulations. a . Ensure static syste m is free from entrapped moisture a nd restri ctions . 15-4
b. Ensure no alterations or defor mations of air frame s urface have been made which would affect the relations hip between air pressure in static pr es sure system and true ambient static air pr essure for any flight configuration. c. Seal one static source port with pressure sensi tive tape. This seal must be air tight. d . Attach a source of suction to the remaining static pressure source opening. Figure 15-3 shows one method of obtaining suction. e. Slowly appl y suction until altimeter indicates a 1000-foot increase in altitude.
/~AUTION I When applying or releasing suction, do not exceed range of vertical speed indicator or airspeed indicator . f. Cut off suction source to maintain a "closed"
system for one minut e. Leakage shall not exceed
100 feet of altitude loss as indicated on altimeter .
g. II leakage rate is within tolerance, slowly re lease suction source and remove tape from static port. NOTE U leakage rate exceeds the maximum allowable, first tighten all connections, then repeat leak age test. U leakage rate still exceeds the maxi mum allowable, use following procedure. h. Disconnect static pr essure lines from air speed indicator and ve r tical speed indicator . Use suitable fittings to connect lines together so altimeter is the only instrument still connected into static pressure system. i . Repeat leakage test to check whether static pres sure system or the bypassed instruments are cause of leakage. If instruments a r e at fault, they must be repaired by an " appropriately rated repair station" or replaced. U static pressure system is at fault, use following pr ocedure to locate leakage . j . Attach a source of positive pressure to static source opening. Figure 15-3 shows one method of obtaining positive pr essure .
/CAUTION ! Do not apply positive pressure with airspeed indicator or vertical speed indicator connect ed to static pressure system. k. Slowly apply positive pressure until altimeter indicates a 500-Coot decrease in altitude and main tain this altimet er indication while checking for leaks. Coat line connections and static source flange with LEAK- TEC o r a solution of mild soap and water, watc hing for bubbles t o locate leaks. 1. Tighten leaking connections . Repair or replace parts foWld defective. m . Reconnect air speed and vertical speed indicat ors into static pr essure system a nd r epeat leakage test per s teps "'c:" thru "g" .
MODEL 188""& T1·88 SERI£S SERVICE MANUAL
15-12. PITOT SYSTEM INSPECTION AND LEAKAGE TEST. To check pitot system for leaks, place a piece of tape over small hole in lower aft end of pitot tube, fasten a piece of rubber or plastic tubing over pitot tube, cl ose opposite end of tubing and slowly roll up tube until airspeed indicator registers in cruise range. Secure tube and after a few minutes recheck airspeed indicator. Any leakage will have reduced the pres sure in system, resulting in a lower airspeed indica tion. Sl owly unroll tubing before removing it, so press ure is reduced gradually. Otherwise instru ment may be damaged. If test reveals a leak in sys tem, check all connections for tightness. 15- 13. BLOWING OUT LINES. Although the pitot s ystem is designed to drain down t o pitot tube open ing, condensation may collect at other points in sys tem and produc e a partial obstruction. To clear the line, disconnect it at airspeed indicator. Using low pressure air, blow from indicator end of line toward the pitot tube.
(CAUTION \ Neve r blow through pitot or static lines toward the instruments.
Like the pitot lines, static pressure lines must be kept clear and connections tight. Static source sumps collect moisture and keeps system clear. However, when necessary, disconnect static line at first instru ment to which it is connected, then blow line to clear with low pressure air. Check all static pressure line connections for tightness. If hose or hose connec tions a r e used, che ck for general condition and clamps for s ecurity. Repla ce hose which have cracked, hardened or show other signs of deterioration. 15-14. REMOVAL AND INSTALLATION OF COM PONENTS. (Refer to figure 15-2). To remove the pitot mast, lower t he access cover, then disc onnect line and heater wires (if installed). Pitot and static lines are removed in the usual manner, after r e mov ing access plates. Installation of the tubing will be simpler if a guide wire is drawn in as tubing is being remove d. When r eplacing components of the pitot and static pr essur e systems, use anti seize compound sparingly on male threads , avoid excess compound which might enter lines. Tighten connections firmly, but avoid overtightening and distorting the fittings. U twisting ol plastic tubing is encountered when tight ening fittings , VV-P-236 (USP Petrolatum), may be a pplied sparingly between tubing and fittings.
15- 15. TROUBLE SHOOTING -- PITOT-STATIC SYSTEM. TROUBLE
LOW OR SLUGGISH AIRSPEED INDICATION.
INCORRECT OR SLUGGISH RESPONSE.
PROBABLE CAUSE
REMEDY
Normal altimeter and vertical speed leak or obstruction in pitot line.
Repair or replace damaged line.
Both instruments leaks or in static line.
Repair or replace line.
ob~truction
15-16. TROUBLE SHOOTING -- PITOT TUBE HEATER.
TROUBLE T UBE DOES NOT HEAT OR CLEAR ICE .
PROBABLE CAUSE
REMEDY
Switch turned " OFF. "
Turn switch " ON."
Circuit breaker "Open".
Reset br eaker .
Break in wiring.
Repair wir ing.
Heating element burned out .
Replace element.
15-5
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Air bulb with check valves may be obtained locally from a surgical supply company. This is the type used in measuring blood pressure.
THICK-WALLED SURGICAL HOSE~
PRESSU RE
~
\/ PRESSURE BLEED-OFF SCREW (CLOSE D ) \
/'
"""
~
.•/
AIR BULB WITH CHECK~ VALVES \
CLAMP~ '- -
THICK-WALLED SURGICAL HOSE
CLAMP
CHECK VALVE
SUCTION
CHECK VALVE
TO APPLY SUCTION: 1. Squeeze air bulb to expel as much air as possible.
2. Hold suction hose firmly against static pressure source opening. 3. Slowly release air bulb to obtain desired suction, then pinch hose st,ut tightly to trap suction in system . '
4. Arter leak test, release suction slowly by intermittently allowing a small amount of air to enter static system. To do this, tilt end of suction hose away from opening, then immediately tilt it back against opening. Continue to admit this small amount of air intermittently until all suction is released, then remove test equipment. TO APPLY PRESSURE :
(~AUTION } Do not apply positive pressure with airspeed indicator connected into static system. 1. Hold pressure hose firmly against static pressure source opening.
2. Slowly squeeze air bulb to apply desired pressure to static system. Desired pressure may be maintained by repeatedly squeezing bulb to replace any air escaping through leaks. 3. Release pressure by slowly opening pressure bleed-off screw, then remove test equipment.
Figure 15-3. 15-6
Static System Test Equipment
MODEL 188 & T188 SERIES SERVICE MANUAL 15-17. TROUBLE SHOOTING-- AIRSPEED INDICATOR. NOTE Refer to paragraph 15-13 before blowing out pitot or static lines. REMEDY
PROBABLE CAUSE
TROUBLE HAND FAILS TO RESPOND.
INCORRECT INDICATION OR HAND OSCILLATES.
HAND VIBRATES.
Pitot pressur e connection not properly connected to pressure line from pitot tube.
Repair or replace dama.g ed line, tight en connections.
Pitot or static lines clogged .
Blow out lines.
Leak in pitot or static lines.
Repair or replace damaged lines, tighten connections.
Defective mechanism.
Replace instrument.
Leaking diaphragm.
Replace instrume nt.
Excessive vibration caus ed by loose mounting scr ews.
Tighten mounting screws.
Excessive tubing vibration.
Tighten clamps and connections.
15-18. TROUBLE SHOOTING-- ALTIMETER. NOTE Refer to paragraph 15- 13 be!or e blowing out pitot or static lines. TROUBLE
PROBABLE CAUSE
REMEDY
'
INSTRUMENT FAILS TO OPERATE.
INCORRECT INDICATION.
HAND OSCILLATES.
Static line plugged.
Blow out lines.
Detective mechanism.
Replace instrument.
Hands not engaged.
Reset hands with. knob.
Leaking diaphragm.
Replac e instrument .
Pointers out of calibr ation.
Replace instrument.
Static pressure irr egular.
Blow out lines, tighten connections.
Leak in airspeed or vertical speed indicator installations.
Blow out lines, tighten cormections.
15- 7
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE
15- 19. ENGINE INDICATORS.
Befor e r e placing a tachometer cable in hous ing, coat lower two thirds with AC Type ST 640 speedometer cable grease or Lubriplate No. 110. Insert cable in housing as fa r as possible, then slowly rotate to make sure it is seated in the engine fittin~. Insert cable in tachometer , making sure it is seated in drive shaft, then reconnect housing and torque to 50 pound-inches (at instrument).
15-20. TACHOMETER. 15-21. DESCRIPTION. The tachometer is a me chanical indicator driven at half crankshaft speed by a flexible shaft. Most tachometer difficulties will be found in the drive-shaft. To function properly, the shalt housing must be free of kinks, dents and sharp bends. There should be no bend on a radius shorter than six inches and no bend within three inches of either terminal . II a tachometer is noisy or the pointer oscillates , check cable housing for kinks, s harp bends and damage. Disconnect cable at tach ometer and pull it out of housing. Check cable for worn spots, breaks and kinks.
15-22. MANIFOLD PRESSURE GAGE . 15-23. DESCRIPTION. The manifold pr essure gage is a barometric instrument which indicates the ab solute pressure in the intake manifold in inches of mercury. The fuel flow and manifold pressure indi cators are in one instrument case, however, each instrument operates independently.
15-24. TROUBLE SHOOTING. TROUBLE
PROBABLE CAUSE
EXCESSIVE ERROR AT EXISTING Pointer shlfted. BAROMETRIC PRESSURE. Leak in vacuum bellows.
J ERKY MOVEMENT OF POINTER.
REMEDY Replace instrument. Replace instrument .
Loose pointer.
Replace instrument.
Leak in pressure line.
Repair or replace dama ged line, tighten connections.
Condensate or fuel in line.
Blow out line.
Exces s ive internal friction.
Replace instrument.
Rocker shaft screws tight.
Replace instrument.
Link springs too tight.
Replace instrument.
'
SL UGGISH OPERATION OF POINTER.
EXCESSIVE POINTER VIBRA TION .
15- 8
Di rty pivot bearings.
Replace instrument.
Defective mechanism.
Replace inst r ument.
Leak in pressure line.
Repair or replace damaged line, tighten connections.
For eign matter in line.
Blow out line.
Damping needle dirty.
Replace instrument .
Leak in
Repair or replace damaged line, tighten connections .
pressure~ line.
Tight rocker pivot bearings.
Replace instrument.
Excessive pane l vibration.
Replace defective shock panel mounts.
MODEL 188 & T188 SERIES SERVICE MANUAL 15-24. TROUBLE SHOOTING (Cont). TROUBLE
REMEDY
PROBABLE CAUSE
IMPROPER CALIBRATION.
Faulty mechanism.
Replace instrument.
NO POINTER MOVEMENT.
Faulty mechanism.
Replace instrument.
Broken pr essure line.
Repair or replace damaged line.
15-25. CYLINDER HEAD TEMPERATURE GAGE. 15-26. DESCRIPTION. The temperature bulb reg ulates electrical power through the cylinder head temperature gage . The gage and bulb require little or no maintenance other than cleaning, making sure lead is properly supported and all connections are clean, tight and properly insulated.
.
NOTE
.
A Cylinder Head Temperature Gage Calibra tlon Unit, SK182-43 ls available and may be ordered throug h the Cessna Supp1y Division.
15-27. TROUBLE SHOOTING. TROUBLE
PROBABLE CAUSE
REMEDY
No current to circuit.
Repair electrical circuit.
Defective gage, bulb or circuit.
Repair or replace defective items.
GAGE FLUCTUATES RAPIDLY.
Loose or broken wire per mitting alternate make and break of gage circuit.
Repair or replace defective wire.
GAGE READS TOO HIGH ON SCALE .
High V<?ltage.
Check "A" terminal.
Gage off calibration.
Replace gage .
Low voltage.
Check voltage supply and "D" terminal.
Gage off calibration.
Replace gage.
Break in bulb.
Replace bulb.
Break in bulb lead.
Replace bulb.
Internal break in gage.
Replace gage.
Defective gage mechanism.
Replace gage.
Incorrect calibration.
Calibrate system.
GAGE INOPERATIVE.
GAGE READS TOO LOW ON SCALE.
GAGE READS OFF SCALE AT HIGH END.
OBVIOUSLY INCORRECT READING .
Revision 1
15- 9
MODEL 188 & T188 SERIES SERVICE MANUAL main oil gallery. The oil pressure line from the in strument to t he engine should be filled with ke rosene, especially during cold weather operation, to attain an immediate oil indication.
15- 28. OIL PRESSURE GAGE. 15-29. DESCRIPTION. The Bourdon tube-type oil pre ssur e gage is a dir ect - reading instrument, opera ted b y a p r e s sure pickup line connected to the engine 15-30. TROUBLE SHOOTING.
TROUBLE
GAGE DOES NOT REGISTER.
PROBABLE CAUSE
REMEDY
Pressure line clogged .
Clean line.
Pressure line broken.
Repair or replace damaged line.
Fractured Bourdon tube.
Replace instrument.
Gage pointer loose on staff.
Replace instrument.
Damaged gage movement.
Replace instrument .
Foreign matter in line.
Clean line.
Foreign matter in Bourdon tube.
Repla ce instrument.
Bourdon tube stretched .
Repla ce instrument.
GAGE DOES NOT REGISTER PROPERLY.
Faulty mechanism.
Repla ce instrument.
GAGE HAS ERRATIC OPERATION.
Worn or bent movement.
Repla ce instrument.
Foreign matter in Bourdon tube.
Replace instr ument.
Dirty or corroded movement.
Replace instrument.
Pointer bent·and rubbing on dial, dial screw or glass.
Replace instrument.
Leak in pressure line.
Repair or r eplace damaged line.
GAGE POINTER F All.S TO RETURN TO ZERO.
FUEL QUANTITY INDICATING SYSTEMS.
15-31. OIL TEMPERATURE GAGE .
15-33.
15-32. DESCRIPTION. The oil temperature gage is a Bourdon tube-type pressure inst rument connected by armored capillary tubing to a temperature bulb in the engine. The temperature bulb, capillary tube and gage are filled with fluid and sealed. Expansion and contraction of fluid in the bulb with temperature changes operates the gage. Checking capillar y tube for damage and fittings for security is the only main tenance required. Since the tube's inside diameter is quite small. small dents and kinks which would be qu1te acceptable in larger tubing may partially or completely close off capillary, making the gage in operative.
15- 34 . DESCRIPTION. The magnetic type fuel quan tit y indicators are used in conjunction with a float operated variable-resistance transmitter in each fuel cell. The full position of float pr oduced a minimum resistance through the transmitter, permitting maxi mum current flow through the fuel quantity indicator and maximum pointer deflection. As fuel level is lowered, resistance in the transmitter is increased producing a decreased current flow through the fuel' quantity indicator and a smaller pointer deflection.
15-10
15-35. REMOVAL AND INSTALLATION (METAL TANK.) a . Drain fuel as outlined in Section 12.
MODEL 188 & T188 SERIES SERVICE MANUAL
b. Open zipper in vapor barrier enclosl~ tank as
necessary for access .
c . Disconnect electrical lead at transmitter and
ground strap at firewall.
d. Remove transmitter attaching screws and care fully remove transmitter, DO NOT BEND FLOAT ARM. e. To install transmitter, use new gaskets and reverse preceding steps. f. Fill fuel tank. Check for leaks and correct fuel quantity indication. 15-36. REMOVAL AND INSTALLATION (RUBBER IZED CELL). a. Drain fuel from cells. b. Remove wing root fairings. c . Disconnect electrical lead and ground strap from transmitter. d. Remove screws attaching transmitter and care fully work transmitter from cell and wing rib. DO NOT BEND FLOAT ARM. e. Install transmitter by reversing preceding steps. No gasket paste should be used.
15-37. TRANSMITTER CALffiRATION. Chances of transmitter calibration changing in normal service is remote, however, it is possible that float arm or float arm stops may become bent i! transmitter is removed fr om cell. Transmitter calibration is ob tained by adjusting float travel. Float travel is limited by float arm stops.
!WARNING
a
Use extreme caution while working with el ec trical components of the fuel system. The possibility of electrical spar ks around an "empty" fuel cell creates a hazardous situa tion. Before installing transmitter. attach electrical wires and place master switch in "ON" position. Allow float arm to rest against lower float arm stop and read indicator. The pointe r shwld be on E (e mpty ) position. Adjust the floa t arm against lower 11top so pointer indicator is on E. Raise float until ar m Is against upper stop and adjust float a rm to oermit indicator pointer to be on F (full).
NOTE Be sure grounding is secure in accord ance with Section 12. 15-38.
TROUBLE SHOOTING. TROUBLE
PROBABLE CAUSE
FAILURE TO INDICATE .
No power to indicator or trans mitter. (Point er stays below E.)
Check and reset br eaker, repair or r eplace defective wiring.
Grounded wire. (Pointer stays above F.)
Repair or replace defective Wire.
Low voltage.
Correct voltage.
Defective indicator.
Replace indicator.
Defective indicator.
Replace indicator.
Defective transmitter.
Recalibrate or replace.
Low or high voltage.
Correct voltage.
Defective indicator.
Replace indicator.
Low voltage.
Correct voltage.
Loose or broken wiring on indicator or transmitter.
Repair or replace defective wire.
Defective indicator or trans mitter.
Replace indicator or trans mitter.
Defective master switch.
Replace switch.
SYSTEM OFF CALI BRATION.
STICKY OR SLUGGISH INDICATOR OPERATION.
ERRATIC READINGS.
REMEDY
15 - 11
MODEL 188 & T188 SER IES SERVICE MANUAL
3 Detail
A
1. Mounting Bracket 2. Shock Mount 3. Compass 4. Compass Light
Figure 15 -4. Magnetic Compass. 15-39. MAGNETIC COMPASS. (Refer to figure 15-4. ) 15-40. DESCRIPTION. The magnetic compass is liquid-filled, with expansion pr ovisions to compen sate for temperature changes. lt is equipped with compensating magnets adjustable from the front of the case. The compass is internally lighted, con trolled by the instrument lights rheostat switch. No maintenance is r equired on the compass except an occasional check on a compass rose and replacement of lamp . Removal of the compass may be accom
pllshed by removing the s cr ews s e curing compass to canopy structure a s shown in figure 15- 4 . The light wir es have quick-dis connects located near the com pass to facilitate compass removal and inStallation. ·15-41.
TURN-AND- SLIP INDICATOR.
15 -42. DE SCRIPTION. The turn- and-slip indicator is operated by the aircr aft electrical system and oper at es ONLY when the master switch is on. Its circuit is protected by an automatically-resetting circuit breaker.
15-43. TROUBLE SHOOTING. TROUBLE
INDICATOR POINTER FAILS TO RESPOND.
15-12
PROBABLE CAUSE
REMEDY
Automatic resetting circuit breaker defective.
Re place circuit br eaker.
Master switch "OFF" or switch defective .
Repla ce defective switch.
Broken or grounded lead to indicator.
Repair or replace defective wir ing.
Indicator not grounded.
Repair or replace defective wire.
Defective mechanism.
Replace instrument.
MODEL 188 & T1 88 SERIES SERVICE MANUAL 15-43. TROUBLE SHOOTING (Cont). TROUBLE
PROBABLE CAUSE
REMEDY
Defective mechanism.
Replace instrument.
Low voltage.
Correct voltage.
POINTER DOES NOT INDICATE PROPER TURN.
Defective mechanism.
Replace instrument.
HAND DOES NOT SIT ON
Gimbal and rotor out of balance.
Replace instrument.
Hand incor rectly sits on r od.
Replace instrument.
Sensitivity spring adjustm e nt pulls hand off zer o.
Replace instrument.
Oil in indicat or becomes too thick.
Replace instrument.
Insufficient bearing end play.
Replace inst rument.
Low voltage.
Corre ct voltage.
High voltage.
Corr ect voltage.
HAND SLUGGISH IN RE TURNING TO ZERO.
ZERO.
IN COLD TEMPERATURES. HAND FAILS TO RESPOND OR IS SLUGGISH .
NOISY GYRO.
Loose or defective rotor .bearings.
15- 44. TURN COORDINATOR. 15-4 5. DESCRIPTION. The turn coordinator is an electrically operated, gyroscopic, roll - rate turn indicator. Its gyro simultaneously ser)SeS rate of 15-46.
Replace instrument.
motion roll and yaw axes which is pr ojected on a s ingle indicator . T he gyro is a non-tumbling type re quiring no caging mechanis m a nd incor porates an a. c. brushless spin motor with a solid state inver ter.
TROUBLE SHOOTING. TROUBLE
PROBABLE CAUSE
INDICA TOR DOES NOT RETURN TO CENTER.
Friction caused by contamination in the indicator damping.
Replace instrument .
Friction in gimbal assembly.
Replace instrument .
Low voltage.
Measure voltage at instrument . Cor rect voltage.
Inverter frequency change d.
Replace instrument.
Faulty bearings.
Repla ce instrument.
DOES NOT INDICATE A STANDARD RATE TURN (TOO SLOW).
NOISY MOTOR.
REMEDY
.
15-13
MODEL 188 8t T188 SERIES SERVICE MANUAL 15-46. Trouble Shooting (Cont).
ROTOR DOES NOT START.
Faulty electrical connection.
Check continuity and voltage. Correct voltage or replace faulty wire.
Inverter malfunctioning.
Replace instrument .
Motor shorted.
Repla ce instrument .
Bearings frozen.
.
Repla ce instrument.
•·. IN COLD TEMPERATURES, HAND FAILS TO RESPOND OR IS SLUGGISH.
NOISY GYRO.
Oil in indicator becomes too thick.
Replace instrument:
Insufficient bearing e nd play.
Replace instrument .
Low voltage.
Check voltage at instrument . Correct voltage.
High voltage .
Check voltage to instrument. Correct voltage.
Loose or defec tive rotor bearings.
Replace instrument.
15-47. STALL WARNING SYSTEM. Refer to Sec tion 16 for description and maintenance procedures. The wiring diagram for the stall warning system appears in Section 20.
outside air temperature gage is mounted through the canopy top a s s hown in figure ·l5-5. The gage re quires no maintenance except keeping the mounting secure and occas ionally replacing the sealing grom mets.
15-48. OUTSIDE AIR TEMPERATURE GAGE. An
3
8~
2
~4~: Detail
A
Washer Sealing Gromm et Canopy Top 4. Gage
Figure 15-5. Outstde Air Te mperature Gage 15-14
MOD EL 188 & T 188 SERIES SERVI CE MAN UAL SECTION 16 ELECTRICAL SYSTEMS
!WARNING' When performing any inspection or maintenance that requires turning on the master switch, installing a battery, or pulling the propeller through by hand , treat the propeller as if the ignition switch were ON . Do not stand, nor allow anyone else to stand, within the arc of the pro peller, since a loose or broken wire , or a component malfunction , could cause the propeller to rotate. Page No. TABLE OF CONTENTS Aerofiche/ Manual
I
. 2D9/16- 1 ELECTRICAL SYSTEM General . . . . . 2D9/16-1 Master Switch . . 2D10/ 16- 2 Desc r iption . 2D10/16- 2 Ammeter . . . . 2D10/16-2 Description . 2010/ 16- 2 Battery Power System . . 2D10/ 16-2 Battery . . . . . . . 2D10/ 16-2 Description . . . . 2D10/16-2 Trouble Shooting . . 2D10/ 16- 2 . 2D13/ 16- 5 Removal and Installation . . 2D14/ 16-6 Cleaning . . . . 2D14/16- 6 Testing . . 2014/ 16- 6 Servicing . 2D14/ 16-6 Charging . . 2D15/ 16-7 Battery Box . 2015/16-7 Description Removal and Installation . 2D15/ 16- 7 Maintenance . . . 2D15/ 16-7 Battery Contactor . . . . . 2D24/ 16-16 Description . . . . . . . 2D24/16-16 Removal and Installation . 2D24/16-16 Battery Contactor Closing Circuit . . . . . . . 2D24/ 16-16 Description . . . . . . · . 2D24/16- 16 . 2D24/ 16- 16 Radio Protection Diode . . . 2D24/ 16-16 Description . . . . . . . 2D24/ 16-16 Ground Service Receptacle . 2D24/ 16-16 Description . . . . . . . 2E1/16-17 Trouble Shooting . . . . . 2E5/ 16-21 Removal and Installation Alternator . . . . . . . . . 2E5/ 16-21 Description . . . . . . . 2E5/ 16-21 Trouble Shooting . . . . . 2E6/ 16-22 Removal and Installation . 2El6/ 16-32 Voltage Regulator . . . . . 2E16/ 16- 32 Description - 14 Volt . . . 2E16/ 16-32 . 2El6/ 16-32 Description - 28 Volt . . Description - 28 Volt, 100 . 2E16/ 16-32 Amp Alternator . . . . Adjustment. . . . . . . . . 2E16/ 16-32 Over-Voltage Warning Circuit . 2E16/16-32 Thru 18803046 . . . . . Description . . . . . . . . 2E16/ 16-32 Adjustment . . . . . . . . 2E16/ 16-32 Removal and Installation . . 2 E20/16-36 Over-Voltage Warning Circuit (14V) (18800833 Thru 18803046~ 2E20/ 16-36 Description . . . . . . . 2 E20/ 16-36 Alternator Failure Warning Circuit Thi'\1 1977 Models . . . 2E20/ 16-36 16-1.
E LECTRICAL SYSTEM.
16-2. GENERAL.
This section contains service in
Description . . . . . . Removal and Installation Electric Fuel Pump Circuit . Auxiliary Electric Fuel Pump Flow Rate Adjustment. Aircraft Lighting System . . Description . . . . . . Trouble Shooting . . . . Landing and Taxi Lights (Wing Mounted). . . . . . . . . . Description . . . . . . . Removal and Installation . Landing and Taxi Lights (Cowl Mounted). . . . . . . . . Description . . . . . . Removal and Installation Navigation Lights . . . . . . Description . . . . . . Removal and Installation Anti-Collision Strobe Lights . Description . . . . . . Operational Requirements Thru 18803046 . . . . Removal and Installation Flashing Beacon . . . . . . Description . . . . . . Removal and Installation Insti'\Iment Lighting . . . . . Description . . . . . . Removal and Installation Transistorized Light Dimming . Description . . . . . . Removal and Installation Wing Tip Turning Lights. . . Description . . . . . . . Removal and Installation Forward Facing Spr ay Lights Description . . . . . . Removal and Installation Hopper Quantity Light . Description . . Compass Light . . . Description . . Stall Warning System Description . . Pitot and Stall Warning Heaters Description . . . . . . Cigar Lighter . . . . . . . . Description . . . . . . . Removal and Installation . Electrical Load Analysis Chart
. . . . . . . .
2E20/16- 36
2E20/16-36
2E20/16-36
2E20/16-36
2E20/16-36
2E20/16-36
2E20/16- 36
2E21/16- 37
. 2E24/ 16-40 . 2E24/ 16-40 . 2F1/ 16-41 . . . . . . . .
2F1/16- 41 2Fl/16-41 2F1/16-41 2Fl/16- 41 2Fl/l~- 41
2F1/16- 41 2F1/16- 41 2F1/16-41
. 2F1/ 16-41 . 2Fl/ 16- 41 . 2F1/16-41 . 2Fl/16- 41 . 2F1/16- 41 . 2Fll / 16-51 . ZFll/16-51 . 2Fll/16-51 . 2F11/16- 51 . 2Fll/16-51 . 2Fll/16-51 . 2F11/16-51 . 2Fll/16-51 . 2Fll/16-51 . 2 Fll/16-51 . 2F11/16- 51 . 2Fll/16-51 . 2Fll/16-51 . 2Fll/16-51 . 2F11/16-51 . 2 Fll/16-51 . 2 Fll/16-51 . 2Fll/16-51 . 2F12/16-52 . 2F12/16-52 . 2F12 / 16-52 . 2F12/16-52 . 2F12/1~-52 . 2F15/16- 55
formation necessary to maintain the aircraft electri cal system components. Electrical energy for the aircraft is supplied by a 14-volt or optional 28-volt. Revision 1
16-1
I
MODEL 188 & T188 SERIES SERVICE MANUAl direct-current, stngle-wire, negative ground electri cal system. A single 12 or optional 24 - volt battery supplies power for starting. furnishes power for al ternator excitation and furnishes a reserve source of power in the event of alternator failure. An engine driven alternator is the normal sou rce of power dur ing flight and matntains a battery charge controlled by a volt"ge regulator. An external power source receptacle is offered as optional equipment to supple ment the battery-alternator system for starting and gr ound operation. 16-3. MASTER SWITCH. 16-4. DESCRIPTION. The operation of the battery and alternator is controlled by the master switch. Thru aircraft serial 188-0572, the master switch is a pull type with double-pole, single-throw contacts. The switch, when operated, connects the battery con tactor coil to ground and the alternator field circuit to the .battery. activating the power systems. Begin ning with air craft serial 188-0573 a new type master switch is installed. This switch is an interlocking split rocker with the battery mode on the right side and the alternator mode on the left side. This ar rangement allows the battery to be on the line without the alternator, however, operation of the alternator without the battery on the line is not possible. The switch is labeled BAT and ALT. A new master switch is installed with the 100 amp alternator. This switch is also a interlocking split rocker with the exception it is equipped with a set of contacts in the off position, a Jumper wire to ground. This grounds the alternator field in the off position preventtng the alternator from
maintaining residual voltage. A diode is also incor porated on the· switch to prevent spiking when the switch is operated. 16-5. AMMETER. 16-6. DESCRIPTION. The ammeter is connected between the battery and the afrcraft ws. The am meter indicates the amount of current flow either to or from the battery. With a low battery and the en gine operating a.t cruise speed the ammeter wtll show the full alternator output when all electrical equip ment is off. When the battery is fully charged and cruise RPM is maintained with all electrical equip ment off, the ammeter will show a minimum charg ing rate. 16-7.
BATTERY POWER SYSTEM.
16-8. BATTERY. 16-9. DESCRIPTION. Thru 1977 Models the 14-volt aircraft are equipped with a 12-volt battery with an approximate 25 ampere-hour capacity. A larger, heavy duty, 12-volt, 33 ampere-hour battery is ocrer ed as optional equipment. On aircraft with the 28-volt electrical system, a 24-volt, 17 a mpere-hour capacity batte r y is utilized. Beginning with 1978 Models the aircraft has a 28-volt system and the battery Is 24 volts with approximately 12.75 ampere-hour capacity also the optional battery is 24 - volts with approximate ly 15.5 ampere-hour capacity. On the A188B the battery is located just aft of the firewall on the right hand side of the fuselage. On the T188C the battery is located in the tail cone on the right hand side.
16-10. TROUBLE SHOOTING. TROUBLE BATTERY WILL NOT SUPPLY POWER TO BUS OR IS INCAP ABLE OF CRANKING ENGINE
16-2
PROBABLE CAUSE
REMEDY
Battery discharged.
1. Measure voltage at "BAT'' terminal of battery cont.actor with master switch and a suit able load such as a taxi light turned on. Normal battery will indicate 11. 5 volts or more on a 14 volt system or 23 vo~ts or more on a 28 volt system. If voltage is low proceed to step 2. · If voltage is normal, pro ceed to step 3.
Battery faulty.
2. Check fluid level in cells and charge 12-volt batte r y at 14 volts or 24-volt battery at 28 volts for approximate! y 30 minutes or until battery voltage rises to 14 volts on 12-volt bat ter y or 28 volts on 24-volt bat tery. If tester indicates a good battery, the maUunction may be assumed to be a discharged bat tery. If the tester indicates a faulty battery, replace the battery .
MODEL 188 & T188 SERIES SERVICE MANUAL
4
10
2
5
6
13
7
12
1
18800573 TIIRU 18800832 14
15
16
188-0318 TIIRU 188-0572
2
10
4
3
5
6
7
8
9
188-0275 THRU 188-0317
188-0001 THRU 188-0274 1. Bus Bar 2. Landing Light 3. Navtgatlon Lights 4. Beacon 5. Instrument Lights 6. Radio
7. Fuel Pump 8. Pitot Heat 9. Generator 10. TaXl Ltght 11. Generator Field 12 . Alternator
13. Spray Valve 14 . Alternator Regulator 15 . Turn Coordtnator 16 . Stall Warmng 17. Landing and Taxi Lights 18. Beacon and Strobe Lights
19. Left Hand Spray Light 20. 21. 22 . 23 .
Right Hand Spray Light Agitator Automatic Flag Strobe 24. Air Conditioner
Figure 16-1. Circuit Breaker Instaltltlon (Sheet 1 of 2) 16- 3
MODEL 188 & T188 SERIES SERVICE MAN UAL
16
5
20
6
7
15
19
23
4
21
13
17
3
14
12
BEGINNING WITH 18803047
16
5
20
19
6
7
15
22
23
4
3
17
1
1
18801825 THRU 18803046
12
16
5
20
19
18
3
22
6
7
15
21
13
17
1
14
18800833 THRU 18801824 Figure 16 - 1. Circuit Breaker Installation (Sheet 2 of 2 ) 16-4
MODEL 188 & T188 SERIES SERVICE MANUAL 16-10. TROUBLE SHOOTING. (Cont.) TROUBLE BATTERY WILL NOT SUPPLY POWER TO BUS OR IS INCAP ABLE OF CRANKING ENGINE (Cont.)
PROBABLE CAUSE
REMEDY
Faulty contactor or wiring. between contactor and master switch.
3. Measure voltage at master switch terminal (smallest) on contactor with master switch closed. Normal indication is zero volts. U voltage reads zero, proceed to step 4. U a voltage reading is obtained, check wiring between contactor and master switch. Also check master switch.
Open coil on contactor.
4. Check continuity between "BAT" terminal and master switch terminal of contactor. Normal indication on 14 volt aircraft is 16-24 ohms. Nor mal indication on 28 volt air crait is 50-70 ohms. U ohm meter indicates an open coil, replace contactor. U ohm meter indicates a good coil, proceed to step 5.
Faulty contactor contacts.
5. Check voltage on "BUS" side of contactor with master switch closed. Meter nor mally indicates battery voltage. U voltage is zero or intermit tent, replace contactor. U voltage is normal, proceed to step 6.
Faulty wiring between con tactor and bus.
16-11. REMOVAL AND INSTALLATION (See figure 16-2.) a. Al88B THRU 18803721 1. Remove cover on right hand side of fuselage at the w1ng leading edge for access to battery. 2. Remove battery box cover. 3. Disconnect the ground cable from the nega tive battery termmaL
When mstalling or removing the battery always observe the proper polarity wtth the a1rcra!t electrical system (negative to ground). Reversing the polanty, even momentanly, may result in fa1lure of semiCOnductor dev1ces (alternator diodes. radio protectiOn diode :lnd rad1o transistors). 4. D1sconnect the cable from the pos1ttve termi nal of the batter y. 5. Lift the batterv out of the batter y box. 6. Reverse the precedwg s te ps for retnstalla t10n.
6. Inspect wiring between con tactor and bus. Repair or replace wiring.
b. Tl88C THRU Tl8803721 T 1. Remove cover on right hand side of tailcone for access to battery. 2. Remove battery box cover. 3. Disconnect the ground cable from the nega tive battery terminaL
When installing or removing the battery always observe the proper polarity with the aircraft electrical system (negative to ground). Reversing the polanty, even momentarily, may result in failure of semiconductor devices (alte rnator diodes. radio protection dtode and rad10 transistors) . 4. Disconnect the cable from the positive termi nal of the battery. 5. Lift the battery out of the battery box. 6. Reverse the preceding steps for retnstalla t10n.
16-5
MODEL 188 & T188 SERIES SERVICE MANUAL
c. Al88B AND Tl88C BEGINNING WITH 18803722 & Tl8803722T. 1. On Al88B remove cover on right hand side of fuselage at wing leading edge for access to battery. 2. On Tl88C remove cover on right hand side of tailcone for access to battery. 3. Disconnect the ground cable from the negative battery terminal.
BATTERY HYDROMETER READINGS 1. 280 1. 250 1. 220 1. 190 1. 160
Specific Specific Specific Specific Specific
Gravity Gravity Gravity Gravity Gravity
100C0 Charged 75'i- Charged 50e>C' Charged 251Q Charged Practically Dead NOTE
I¢ AUTIONj When installing or removing the battery always observe the proper polarity with the aircraft electrical system (negative to ground). Reversing the polarity, even momentarily, may result in failure of semiconductor devices (alternator diodes, radio protection d.iode and radio transistors). 4. Cut sta-strap and remove cover from JX>Sitive cable, then disconnect cable. 5. Remove battery hold down bolts and remove battery. 6. Remove clamp and remove drain tube from
battery.
7. Remove battery. 8. Reverse the preceding steps for reinstalla
tion, using new sta-strap on positive terminal cover.
16-12. CLEANING. For maximum efficiency, the battery and connections should be kept clean at all times. a. Remove the battery in accordance with preced ing paragraph.
b. Tighten battery cell filler caps to prevent the
cleaning solution from entering the cells.
c. Wipe battery cable ends, battery terminals a~d entire surface of the battery with a clean cloth mOIS tened with a solution of bicarbonate of soda (baking soda) and water. d. Rinse with clear water, wipe off excess water
and allow battery to dry.
e. Brighten up cable ends and battery terminals
with emergy cloth or a wire brush.
f. Install the battery according to the preceding
paragraph.
g. Coat the battery terminals and the cable ends
with petroleum jelly.
16 - 13. TESTING. The specific graVlty check met~ od of testing the battery is preferred when the condi tion of the battery is in a questionable state-of - charge. However, when the aircraft has been operated for a period of time with an alternator .output voltage wh1ch is known to be correct. the quest1on of battery capa bility may be answered more correctly w1th a load type tester. u testing the bauery IS deemed neces sary. the specific i!rav1ty should be checked first and compared with the following chart.
16-6
All readings shown are for an electrolyte temperature of 80~ Fahrenheit. For higher temperatures the readings will be slightly lower. For cooler temperatures the read ings will be slightly higher. Some hydrome ters have a built-in temperature compensa tion chart and a thermometer. U this type tester ts used, disregard this chart. U a specific gravity reading indicates that the battery is not fully c harged. the battery should be charged at approximately 20 amperes for 30 minutes, or until the battery voltage rises to 15 volts. 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 connec tors between plates of a cell, etc. 16-14. SERVICING. A batte r y being charged and discharged with use will decompose the water from the electrolyte by electrolysis. Add distilled water as necessary to maintain the elect rolyte level even w1th the horizontal baffle plate 1nside the battery. When "dry charged" batteries are put into service, fill as directed with electrolyte. However, as the electrolyte level falls below normal with use add only distilled water to maintain the proper level. The bat tery electrolyte contains approximately 25Cf. sulphuric acid by volumnc. Any change in this volumne will hamper the proper operation of the battery.
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 pub lished by the Association of American Battery :\1anufacturers. 16-15. CHARGING. When the battery is to be charg ed, the level of electrolyt~ should be checked and ad JUSted by adding distilled water to cover the tops of the internal battery plates. The battery cables and connections should be cled.n.
MODEL188 & T188 SERIES SERVICE MANUAL
!WARNING' When a battery is charging. hydrogen and oxy gen gases are generated. Accumulation ol these gases can create a hazardous explosive condition. Always keep sparks and open Clarne away !rom the battery. Allow unrestricted ventilation of the battery area during charging. The main points of consideration during a battery charge are excessive battery temperature and violent gassing. Under a reasonable rate of charge (20 am peres or less) the battery temperature should not rise over 125 • F , nor should gassing be so violent that acid is blown from the vents. 16-16.
BAT;'iERY BOX.
(THRU 18803721.)
16-17. DESCRIPTION. The battery box completely encloses the battery, and thru 1976 models, is paint ed with acid proof paint. Beginning with 1977 models the box is not constructed of metal and does not re quire painting. A vent tube attached to the bottom of the box allows battery gasses and spilled electrolyte to escape overboard. On the A188B the battery box is riveted to ·angle assemblies then bolted to a bracket assembly riveted in the tailcone.
16-18. REMOVAL AND INSTALLATION . (See figure 16-2. ) a. Remove battery using paragraph 16- 11 as a guide. b. Remove bolts from brackets that battery box is riveted to. c. Remove box and drill out rivets holding box to brackets. d. Rivet brackets on new box and re install. e. When battery box is installed all rivets and scratches inside the box should be painted with acid proof lacquer part no. CES1054-381, available from the Cessna Supply Division.
I
16- 19. MAINTENANCE. The battery box should be inspected and cleaned periodically. The box and cover should be cleaned with a strong solution of bicarbonate of soda (baking soda) and water. Hard deposits may- be removed with a wire brush. When all corrosive deposits have been removed from the box, flush it thoroughly with clean water.
!WARNING. Do not allow acid deposits to come in contact with skin or clothing. Serious acid burns may r esult unless the al!ected area is washed immediately with soap and water. Clothing will be ruined upon contact with battery acid.
Revision 1
16-7
MODEL 188 & T188 SERIES SERVICE MANUAL
A
. THRU 18801766
22
- Â2
3 BEGINNING 18801767
wrrn
5
5
16
10
15
12-VOLT. 33 AMP HOUR BATTERY
1. 33 Amp-Hour Battery 2. Pin - Lock 3. Box :\ssy- Upper 4. Box Assv - Lower 5. Nut 6. Lockwasher P osit1ve Batterv Cable 8. Diode 9. Washer 10. Bolt
..
11. Batter y Contactor 12. Master Switch Wire 13. Power Cable to Bus 14. Gnd Ser Recpt Cable 15. Angle Assembly 16. Negative Ground Strap 17. Angle .- \ssembly 18. Wire to Gnd Ser Recpt 19. Resistor - . 75 Ohm 20. Fuse - 7. 5 .-\mp
21. 22. 23. 24,
25. 26. 27. 28. 29.
Screw Fuse Nylon Nut Nylon Washer Bracket Nylon Spacer Insulating Washers Solder Terminal Wire to Battery
F!!!;ure 16-2. Battery and Electnc:.l l Equipment InstallatiOn (Sheet 1 of 8) 16-8
MODEL 188 & T1 88 SERIES SERVICE MANUAL
23
BEGINNING WITII 18801767
â&#x20AC;¢ THRU 18801766
18 On late models, the battery and box are rotated 180 degrees.
12-VOLT. 25 AMP HOUR BATTERY 1. 24 Amp - Hour Battery 2. Lid Assembly 3. Box Assembly 4. Pin 5. Angle Assembly 6. Bolt 7. :-iegative Ground Strlp 8. Clamp 9. Tube - Drain 10. Angle Assembly
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Nut Lockwasher Positive Battery Cable Diode Washer Master Switch Wire Power Cable to Bus Gnd Ser Recpt Cable Wire to Gnd Ser Recpt Resistor - . 75 Ohm
21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Fuse - 7. 5 Amp Screw Fuse Nylon Nut Nylon Washer Bracket Nylon Spacer Insulating Washers Solder Terminal Wire to Battery
Ftgure 16-2. Battery and Electrical Equipment Installation (Sheet 2 of 8} 16- 9
MODEL 188 & T188 SERIES SERVICE MANUAL
A
â&#x20AC;¢
THRU 18801766
5 20
/ / /
!----15
/
27
A
"~1
netatl BEGINNING WITii -6 18801767
*
THRU 1977 MODELS
24-VOLT, 15. 5 AMP HOUR BATTERY
THRU 1976
1. Wire to Gnd Serv Recpt. 2. Resistor - . 75 Ohm 3. Fuse- 7. 5 Amp 4. Battery - 24 Volt 5. Ltd Assembly 6. Box Assembly - Batt 7 . Clamp 8. Tube - Dratn 9. Angle Assembly 10. Wire to Master Switch 11. Bolt 12 . Cable to Gnd Serv Recpt 13. Cable to Battery Contactor 14. Battery C ontactor 15. Dtode 16. Nut
17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Positive Battery Cable Lockwasher Screw Fuse Nylon Nut Nylon Washer Bracket Nylon Spacer Insulating Washers Solder Terminal Wire to Battery
Figure 16-2. Battery and Electrical Equipment Installation (Sheet 3 of 8) 16- 10
7 16
MODEL 188 & T188 SERIES SERVICE MANUAL
â&#x20AC;¢
BEGINNING WITii 1978 MODELS
8
15~-
3
8 13
24-VOLT. 12.75 AND 15.5 AMP HOUR BATTERY
BEGINNING WITii 1977
1. Battery Box Cover 2. Battery 3. Battery Box 4. Bolt 5. Drain Tube 6. Clamp 7. Nylon Nut 8. Nylon Washer 9. Fuse 10. Bracket 11. Resistor 12. Diode 13. Solder Terminal 14 . Spacer 15. Screw 16. Cover 17. Sta -strap 18 . Nut
25
19. Lockwasher 20. Battery Positive Cable 21. Diode Assembly 22. Wire (to Master Switch) 23. Cable (to Starter Contactor) 24 . Battery Contactor 25. Wlre (to Fuse)
23
Figure 16-2. Battery and Electrical Equipment Installation (Sheet 4 of 8) 16- 11
MODEL 188 & T188 SERIES SERVICE MANUAL
~3 I
5
4
~6
13
~15
7
16 8
12 11
~
I
,~ ~
...... __
10 Detail
--
Detail
B
18
t19 I
3
A
1. Nylon Cover
2. 3. 4. 5. 6. 7.
8. 9. 10. 11.
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
22. 23. 24. 25.
Sta-Strap
Nut
Lockwasher
Cable (to Starter Contactor)
Washer
Battery Contactor
Battery Positive Cable
Diode Assembly
Wire (to Master SWitch)
Wire (to Fuse)
Cable (to External Power)
Clock Fuse
Contactor Closing Circuit Fuse
Mica Washer
Bracket
Spacer
Solder Terminal
Diode
Battery Box Cover
Clip
Battery
Battery Box
Battery Box Support
Battery Negative Strap
T188C ONLY
24
A
Ftgure 16-2. Battery and Electrical Equtpment lnstallatwn (Sheet 5 of 8) 16-12
MODEL 188 & T188 SERIES SERVICE MANUAL
2 4
~~~~~-++--7
8
14
See sheet 1
1. 2. 3. 4.
5. 6. 7.
8. 9.
A
10. Mount Bolt 11. Elbow Battery Cover 12. Aircraft Skin Battery Positive Terminal Cover 13. Clamp 14. Contactor Cover Sta-strap 15. Cable to Ground SeiVice Pos1tive Cable Clamp Drain Tube Ground Cable Al88B
Figure 16-2. Battery and Electrical Equipment Installation (Sheet 6 of 8)
16- 13
MODEL 188 & T1 88 SERIES SERVICE MANUAL
36
30
35v ·" 33
17
Detatl
22
Detatl
16. 17. 18. 19.
20.
A
21.
22. 23. 24. 25.
Diode Assembly Jumper Wire Nut Washer Wire (to Ground Service) W1re (to Starter Contact or ) Battery Contactor W1r e (to Master Switch) Pos1t1ve Cable W1re (to D1ode Board)
A188B AND T1 88C Figure 16-2. Battery and Electr ical Equipment InstallatiOn (Sheet 7 of 8) 16- 14
8
MODEL 188 & T188 SERIES SERVICE MANUAL
See sheet 7
8
,.
USED ON ALL T HREE
CONTACTORS
• THRU 18803862
• BE.x:;INNING WITH 18803863
13
1. Contactor Cover 2. Positive Termmal Cover 3. Sta-strap 4. Battery Cover 5. Clamp 6. Positive Cable 7. Batter y 8. Drain Tube 9. Ground Strap 10. Elbow 11. Aircraft Skin 12. Clamp 13. Mount 14. Bolt
T188C
12
Figure 16-2. Battery and Electrical Equipment Installation (Sheet 8 of 8) 16- 15
MODEL 188 & T188 SERIES SERVICE MAN UAL
I
Inspect the cleaned box and cover for physical dam age and for areas lacking proper acid proofing. A badly damaged or corr oded box should be replaced. U the box or lid require acid proofing. paint the area with acid-proof black lacquer, part no. CES1054-381, available from the Cessna Supply Division. 16-20.
BATTERY CONTACTOR.
16-21. DESCRIPTION. The battery contactor is bolted to the firewall adjacent to the battery box on the A188B and thru 18803721T on the battery box on the T188C. Beginning with T18803721T the contactor is mounted on a bracket adjacent to the battery. The contactor is a solenoid plunger type, which is actu ated by turning the master switch on. When the mas ter switch is off, the battery is disconnected from the electrical syst~m. A silicon diode is used to elimi nate spiking of the transistorized radio equipment. The cathode (+) terminal of the diode connects to the battery terminal of the battery contactor. The anode (- ) terminal of the diode connects to the same termi nal on the contactor as the master switch wire . This t>laces the diode directly across the contactor solenoid coil so that inductive spikes orginating in the coil are clipped when the master switch is opened. Beginning with 18801069 a vented contactor is installed.
16-25.
RADIO PROTECTION DIODE.
16-26. DESCRIPTION. A silicon diode is installed across the winding of the battery contactor to sup press the inductive "kick" created when the contactor is de- energized. The diode is shown in figure 16- 2. Reducing the inductive peak voltage flowing back onto the bus system prevents possible damaging of the transistors in any radio equipment turned on. 16-27. GROUND SERVICE RECEPTACLE. 16-28. DESCRIPTION. (See figure 16- 3.) A ground service is offered as optional equipment to permit use of external power for cold weather starting or when performing lengthy electrical maintenance . A reverse polarity protection system is utilized where by ground power must pass through an external power contactor to be connected to the bux. A silicon junc tion diode is connected in series with the coil on the external power contactor so that i! the ground power source is inadvertently connected with a reverse polarity, the external power contactor will not close. This feab.lre protects the diodes in the alternator, and other semi-conductor devices, used in the air craft from possible reverse polarity damage. NOTE
16-22. REMOVAL AND INSTALLATION. (See figure 16-2.) a. Disconnect ground cable from negative battery
terminal. Pull cable clear of battery.
b. Remove the nut, lockwasher and the two plain
washers securing the battery cables to the battery
contactor .
c. Remove the nut, lockwasher atld the two plain
washe r s securing the wire which is routed to the
master switch.
d. Remove the bolt, washer and nut securing each
side of the battery contactor to the fi r ewall on the
A188B and the battery box/bracket on the T188C.
The contactor will now be free for removal.
e. To replace the contactor, reverse this proce
dure.
16-23.
BATTERY CONTACTOR CLOSING CIRCUIT .
. 16-24. DESCRIPTION. Beginning with aircraft se rial 188-0318. An inline fuse and a resistor are in stalled from the positive side of the battery to the small lug on the ground service receptacle. (See figure 16- 2. ) When the aircraft battery is low and an external power source is being used to start the engine, ensure that the master switch is "ON" before dtsconnecting external power.
Maintenance of the electronic installation cannot be performed when using external power. Application of external power opens the relay supplying voltage to the electronic bux. For lengthy ground testing of electron ic systems, connect a well regulated and filtered power supply directly to the battery side of the batter y contactor. Adjust the supply for 14 or 28-volts, depending on 14 or 28- volt system, and close the master switch. NOTE On Aircraft Serials 18803047 thru 18803071
refer to Cessna Single-engine Service Let
ter SE78-19, dated March 27, 1978.
The follow1ng check, to verify the condition of the battery, should be made after start and removal of the external power source. 1. Master Switch - OFF. 2. Taxi and Landing Light Switches- ON. 3. Engine RPM - REDUCE to idle. 4. Master Switch - ON (with taxi and landing lights on). 5. Engine RPM - INCREASE to apprOximately 1500 RPM. 6. Ammeter and Low-Voltage Warning Light CHECK. NOTE If the ammeter does not show a charge or
the low-voltage warning light does not go
out, the battery should be removed from
the airplane and properly se r viced prtor
to flight.
16-16
Revision 1
MODEL 188 &. T188 SERIES SERVICE MANUAL 16-29. TROUBLE SHOOTING. TROUBLE
PROBABLE CAUSE
REMEDY
STARTER ENGAGES WHEN GROUND POWER IS CON NECTED.
Shorted or reversed diode in split bus -bar system.
Check wiring t~ and condition of diode mounted on the split bus relay bracket adjacent to the magneto switch. Correct wiring. Replace diode board assembly.
GROUND POWER WlLL NOT CRANK ENGINE.
Ground service connector wired incorrectly.
1. Check for voltage at all three terminals of external power contactor with ground power connected and master switch off. U voltage is pre sent on input and coil termin als but not on the output ter minal, proceed to step 4. U voltage is present on the input terminal but not on the coil terminal, proceed to step 2. U voltage is present on all three terminals, check wiring between contactor and bus. 2. Check for voltage at small terminal of ground service re ceptacle. U voltage is not pre sent, check ground service plug wiring. U voltage is present, proceed to step 3.
Open or mls -wired ell ode on ground service diode board assembly.
3. Check polarity and continuity of diode on ctiode board at rear of ground service receptacle . U diode is open or improperly wired, replace diode board assembly.
Faulty external power con tactor.
4. Check resistance from small (coil) terminal of external power contactor to gr ound (master switch off and ground power unplugged). Normal indication is 16- 24 ohms. U resistance indicates an open coil, replace contactor. U resistance is normal, proceed to step 5.
Faulty contacts in external power contactor.
5. With master switch off and ground power applied, c heck for voltage drop between two large terminals of external power (turn on taxi light for a load). Normal indication is zero volts. U voltage is intermittently pres ent or present all the time, r eplace contactor.
16- 17
MODEL 188 & T188 SERIES SERVICE MANUAL
Ground servtce receptacle is located on right hand side of aircraft at aircraft serial 188- 0318 and on.
3
A
7
2
8 9
10 11
15
~18 ~19
7
Detail
A
THRU 18803856
14
B
Detail BEGINNING WITH 18801767 (Refer to figure 16-1 for prior installation) 1. Power Cable 2. Nipple 3. ~ut 4. Star Lockwasher 5. Washer 6. Ground Strap 7. Bracket 8. Receptacle
9. Screw 10. Receptacle 11. Doubler Assembly 12. Stud - Locktng 13. Door Assembly 14. Placard 15. Closing Circutt Wire 16. Resistor - . 75 Ohm
17. Fuse ~ylon Nut :>/ylon Washer Nylon Spacer Insulating Washers Solder Termmal 23. Diode 24. Wire tO Battery
18.
19. 20. 21. 22.
Figure 16-3. Ground Ser vice Receptacle Instalbtwn (Sheet 1 of 3) 16-18
& T188 SERIES SERVICE MANUAL MODEL1_8 __ a_____________
7 10
10
5
11
12
13
Detail
A
B EX:Z INNlNG W1TH 18803857T
1
2. 3' 4.• 5 6.
1" ... e Skin Fuse'""1:> bly Door Ass em
Doubler
Receptacle t Bracke G r ound Strap
7. Nut
8
9: Washer
Lockwasher
pie
~-
10. · 1 P
w 1· re to
11.. Power 12 13. Screw
F se
ca ub1e
. (Sheet 2 of J) Fu;u r e 16- 3. Gr ound S ernce R eceptac 1e lnstallatlOn 16 - 19
MODEL 188 & T188 SERIES SERVICE MANUAL
*SERIAL Tl8803697T THRU Tl 8803721T &. AIRCRAFT MODIFIED PER C ESSNA SERVICE LETTER SE80- 60 DATED MAY 27. 1980.
1s e
e BEGINNING WITH T1 880:l722T 6
12
14 1
\_ ....Â
.. /
BEGINNING WITH 1979 MODELS Tl88C ONLY
l. Tailcone
2. Door Assembly 3. Doubler 4. Screw 5. Receptacle 6. Bracket 7. Was her 8. G r ound Strap
9. Nut 10. Lockwas her 11. Nipple 12. W1r e t o F us e 13. Powe r Cable 14. Ground Cable 15. Plate 16. Wire Ha r ne ss Band
F igu r e 16-3. Gr ound Ser vice Receptacle Installation (Sheet 3 of 3)
16-20
MODEL 188 & T188 SERIES SERVICE MANUAL
16-30. REMOVAL AND INSTALLATION. (See figure 16- 2. )
a. Open battery box and disconnect the ground cable from the negative terminal of the batter y and pull the cable from the battery box. b. Remove the rubber nipples, nuts, washers and ground strap from the studs of the receptacle. Then remove the cable/ cables and the battery contactor closing cir cuit wire . · c. Remove the screws and nuts holding the recep tacle. The receptacle will then be Cree from the bracket. d. To install a ground service receptacle, reverse this procedure. Be sure to place the ground strap on the negative stud of .the receptacle. 16-31. ALTERNATOR. 16-32. DESCRIPTION. The alternators used on the aircraft are belt driven, three phase with integral silicon diode rectlfiers. Thru 18803046 the alternator s are rated at 14 volts at 60 amperes, 28 volts at 60 amperes or 28 volts at 100 amperes continuous output, depending on 12 or 24 volt system. Beginning With 188 03047 the alternators are 28 volts at 60 amperes or 28 volts at 95 ampe r es continuous output. The alternator ls mounted on the left slde of the engine accessory sec -
tlon. For maintenance of the alternator , refer to the Cessna Alter nator Charging Systems Service/Parts Manual.
jCAUTION \ Due to the high torque requirements of the 100 ampere alternator, at low rpm, night lighting such as spray lights, should not be turned on with the engine operating be low 1000 rpm as alternator drive belt slippage may occur causing short belt life or breakage.
j~AUTION \ The alternator is very susceptible to reverse polarity current because of the silicon diodes. The diodes, having a very high resistance to reverse current flow, are used without any cutout relay such as used on a generator sys tem. The alternator diodes are arranged with their cathodes connected to the aircraft bus bar which is positive and no back current will flow. If the polarity of the battery is reversed the diodes will offer no resistance to the cur rent flow . The current rating of the diodes is exceeded and diode failure may result.
SHOP NOTES:
16-21
MODEL 188 & T1 88 SERIES SERVICE MANUAL 16-33. TROUBLE SHOOTING THE ALTERNATOR SYSTEM (14 VOLT SYSTEM)
TROUBLE AMMETER ll'<'DICATES HEAVY DISCHARGE WITH ENGINE NOT RUNNING OR ALTERNA TOR CIRCUIT BREAKER OPENS WHEN MASTER SWITCH IS TURNED ON.
PROBABLE CAUSE Shorted radio noise filter or sho rted wire.
REMEDY 1. Remove cable from output terminal of alternator . Check resistance from end of cable to ground (MASTER SWITCH MUST BE OFF). If resistance does not indicate a direct short, proceed to step 4. If resistance indicates a direct short, proceed to step 2.
2. Remove cable connections from radio noise filter. Check resistance from the filter input terminal to ground. Normal in dication is infinite resistance. U reading indicates a direct short, replace filter . If no short is evident, proceed to step 3.
3. Check resistance from ground to the free ends of the wires which were connected to the radio noise filter (or alternator if no !lOise filter is installed). Normal indica tion does not show a direct short. U a short exists in wires, repair or replace wiring. Shorted diodes in alternator.
ALTERNATOR SYSTEM \.\'ILL KOT KEEP BAT TERY CHARGED.
16-22
Regulator faulty or improp erly adJusted.
4. Check resistance from output terminal of alternator to alterna tor case. Reverse leads and check again. Resistance reading may show continuity in one direc tion but should show an infinite reading in the other direction . If an Infinite reading is not ob tained in at least one direction, repair or replace alternator. 1. Start engine and adjust for 1500 RPM . Ammeter should indicate a heavy charge rate with all electri cal equ1pment turned off. Rate should taper off in 1-3 minutes. A voltage check at the bus should in dicate a reading consistant with the voltage vs temperature chart in the Cessna Alternator Charging Systems Serv1ce Parts Manual. I! charge rate tapers o!f very quickly and volt age is normal, check battery for malfunction. I! ammeter shows a low charge rate or any discharge rate, and voltage is low, proceed to step 2.
MODEL 188 & T188 SERIES SERVICE MANUAL 16-33. TROUBLE SHOOTING THE ALTERNATOR SYSTEM (14 VOLT SYSTEM)( Cont.)
PROBABLE CAUSE
TROUBLE ALTERNATOR SYSTEM WILL NOT KEEP BAT TERY CHARGED (Contl.
Regulator faulty or improp erly adjusted. (Cont.)
ff~ UTION I Before performing step 4, remove radios from the panel.
Faulty w1nng between alter nator and regulator, or faulty alternator.
REMEDY 2. Stop engine, remove cowl, and remove cover from voltage regulator. Turn master switch ON/ OFF several times and ob serve field relay in regulator. Relay should open and close with master switch and small arc should be seen as contacts open. If relay is inoperative, proceed to step 3. U relay operates, proceed to step 4. 3. Check voltage at "S" terminal of regulator with master switch closed. Meter should indicate bus voltage . U voltage is present, re place regulator. U voltage is not present, check wiring between regulator and bus. 4. Remove plug from regulator and start engine. Momentaril y jumper the " A+" and "F" termi nals together on the plug. Ship's ammeter should show heavy rate of charge. U heavy charge rate is observed, replace regulator. II heavy charge rate is not ob served, proceed to step 5. 5. Check resistance from "F" terminal of regulator to "F" ter minal of alternator. Normal indication is a very low r esis tance. II reading indicates no, or poor contmuity, repair or replace wiring from regulator to alternator. 6. Check res1stance from " F" termmal of alternator to alter nator case . Normal indication is 6-7 ohms. If resistance is high or low, repair or replace alternator. 7. Check resiStance from case of alternator to a1rframe gr ound. Normal indication is ver y low resistance. If reading indicates no. or poor continuity, repair or replace alternator ground wiring.
16- 23
MODEL 188 & T188 SERIES SERVICE M A NUAL 16-33. TROUBLE SHOOTING THE ALTERNATOR SYSTEM (14 VOLT SYSYEM) (Cont.)
TROUBLE ALTERNATOR SYSTEM WILL NOT KEEP BAT TERY CHARGED. (Coot) .
PROBABLE CAUSE Faulty wiring between alter nator and regulator, or faulty alternator. (Coot).
REMEDY 6. Check resistance from "F" terminal of alternator to alter nator case. Normal indication on 12-volt systems is 6-7 ohms or 11-12 ohms on 24-volt systems. If resistance is high or low, re pair or replace alternator. 7. Check resistance from case of alternator to airframe ground. Normal indication is very low re sistance. If reading indicates no, or poor continuity, repair or replace alternator ground wiring. Check bus voltage with engine run ning. Normal indication agrees wtth voltage vs temperature chart in the Cessna Alternator Chaqpng Systems Service/ Parts Manual. Observe ships ammeter, ammeter should in dicate near zero after a few mtnutes of engine operation. Replace regulator.
ALTERNATOR OVERCHARGES BATTERY - BATTERY USES EXCESSIVE WATER.
Regulator faulty or improp er ly adjusted.
OVE.RoVOLTAGE WARNING LIGHt-STAYS ON. (24- VOLT).
Faulty regulator.
Reset over-voltage relay by turning master switch (ALT side) off and on. Check regulator by r eplacement. Replace regulator.
Over-voltage relay out of adjustment.
Warning light comes on without over-voltage. Adjust over-volt relay assembly.
Faulty over-voltage relay.
Repair or replace. Substitute relay.
Faulty field wiring.
Test wiring - look for field wire shorted to primary voltage. Repair.
Regulator faulty or improperly adjusted. Faulty sensor switch.
1. With engine running turn off and on battery portion of the master switch. If the light stays on shut down engine then turn on the "'BAT" and "ALT" portions of the master switch. Check for . voltage at the "S" terminal of the voltage regulator. If voltage is present adjust or replace regula tor. If voltage is not present check master switch and wirmg for short or open condition. If wiring and switch are normal replace sensor.
OVER-VOLTAGE WARNING LIGHT ON. (12 VOLT)
16-24
MODEL 188 & T188 SERIES SERVICE MANUAL 16-34. TROUBLE SHOOTING THE ALTERNATOR SYSTEM (28 VOLT SYSTEM)• a. ENGINE NOT RUNNING . TROUBLE
PROBABLE CAUSE
REMEDY
Shorted diode in alternator .
Tu r n ofi Battery Swit ch and re move "B" Lead from a lternator . Check r esistance fr om " B" Ter minal of a lternator to alter nator case. Re ve rse leads a nd check again. Resistance r eading may show contirruity in one direc tion but should show a n infinite reading in the other di rection. U an infinite readi ng is not ob tained in a t least one di r ection, repair or r epla ce alternator .
Short in Over -Voltage sensor. THRU 18803046
Disconnect Over- Voltage Sensor plug and recheck . U circuit breaker stays i n replace Ove r Voltage Sensor.
Short in alternator voltage regulator.
Disconnect r egulator plug and recheck. U circuit breaker stays in, r e place regulator .
Short in alternator field.
Disconnect "F" terminal wir e a nd recheck. U circuit b r eake r stays in, replace alte rnator .
ALTERNATOR CIRCUIT BREAKER OPENS WHEN BATTERY ANDALTER NA TOR SWITCHES ARE TURNED ON; OVER VOLTAGE LIGHT DOES NOT COME ON.
Defective circuit breaker.
Replace circuit breaker .
ALTERNATOR REGULA TOR CIRCUIT BREAKER OPENS WHEN BATTERY AND
Shorted field in alterrator .
Check resistance from " F " terminal of alternator to alternator case, if resistance is less than 5 ohms repair/ replace.
AMMETER INDICATES HEAVY DISCHARGE OR ALTERNATOR CIRCUIT BREAK ER OPENS. (Battery Switch ON,
Alternator Switch OF'F, all other electrtcal switches OF F .)
ALTERNATOR REGULATOR CIRCUIT BREA K ER OP ENS WHEN BATTERY AND ALTERNATOR SWITCHES ARE TURNED ON.
b.
ENGINE RUNNING.
ALTERNATOR S~TCHES
ARE TURNED ON, OVER VOLTAGE LIGHT DOES NOT COME ON
/CAUTION ! This maUunctton frequently causes a shorted regulator which will result in an over voltage condition when system is again operated.
16- 25
MODEL 188 & T188 SERIES SERVI CE MANUAL 16-34. TROUBLE SHOOTING THE ALTERNATOR SYSTEM (28 VOLT SYSTEM) (Cont. ) b . ENGINE RUNNING (Cont.) TROUBLE
PROBABLE CAUSE
REMEDY
ALTERNATOR MAKES
ABNORMAL WHINING
NOISE.
Shorted diode in alternator.
Turn off Battery Switch and remove "B" Lead from alternator. Check res1stance from "B" Terminal of alter nator to alternator case. Re verse leads and check again. Resistance reading may show continuity in one direction but should show an infinite reading in the other direction. U an infinite reading is not obtained in at least one direction, repair or replace alterna.tor.
OVER-VOLTAGE LIGHT DOES NOT GO OUT WHEN ALTER NATOR AND BATTERY SWITCHES ARE TURNED ON.
Shorted regulator.
Replace regulator.
Defective over-voltage sensor. THRU 18803046
Replace sensor .
Regulator faulty or high resistance in field circuit.
With engine not running turn off au electrical loads and turn on battery and alternator switches. Measure bus voltage to ground, then measure voltage from terminal of alternator to ground. U there is more than 2 volts difference check field circuit wiring shown on alter nator system wiring diagram in Section 19 . Clean all contacts. Replace components until there is less than 2 volts difference between bus voltage and field voltage.
AFTER ENGINE START WITH ALL ELECTRICAL EQUIPMENT TURNED OFF CHARGE RATE DOES NOT TAPER OFF IN 1-3 MINUTES
NOTE Also refer to battery power system trouble shooting chart. ALTERNATOR SYSTEM WILL NOT KEEP BATTERY CHARGED.
16-26
Alternator output voltage insuffictent..
1. Connect voltmeter between D.C. Bus and ground. Turn off all electncal loads. Turn on Battery Switch, start engme and adjust fo r 1500 RPM, voltage should read approximately 24 volts. Turn on alternator switch, volt age should read between 27. 4 and 28 .0 volts. Ammeter should indtcate a heavy charge rate which should taper off m 1-3 mmutes. If charge rate tapers off very
MODEL 188 & T188 SERIES SERVICE MANUAL 16-34. TROUBLE SHOOTING THE ALTERNATOR SYSTEM (28 VOLT SYSYEM) (Cont.) b. ENGINE RUNNING (Cont. ) TROUBLE ALTERNATOR SYSTEM WILL NOT KEEP BATTERY CHARGED. (Cont. )
PROBABLE CAUSE Alternator output voltage insufficient (cont).
REMEDY quickly and voltage is normal, check battery for malfunction. U ammeter shows a low charge rate or any discharge rate, and voltage does not rise when alternator switch ls turned on proceed to Step 2. · 2. Stop engine, turn off au switches. Connect voltmeter between "F" terminal of alternator and ground. Do NOT start engine. Turn on battery switch and alternator switch. Battery voltage should be present at "F" terminal, less 1 volt drop thru regulator, if not refer to Step 3 . 3. Starting at "F" terminal of alternator trace circuit
to voltage regulator, at "B" terminal of regulator trace circuit to over-voltage sensor, to master switch, to Bus Bar. Replace component which does not have voltage present at output. Refer to alternator system wiring diagram in Section 19 . Alternator field winding open.
1. U voltage is present turn off alternator and battery switches. Check resistance from "F" terminal of alternator to alter nator case, turning alternator shaft during measurement. Normal indication is 12 20 ohms. U resistance is high or low, repair or replace alternator. U at refer to Step 2.
2 . Check resistance from case of alternator to airframe g rwnd. Normal indication is very low reststance. U reading tndicates no, or poor continuity, repatr or replace alternator ground wiring.
16- 27
MODEL 188 & T188 SERIES SERVICE MANUAL
NON- SHOCKMOUNTED 188-0001 THRU 188 0049 EXCEPT WHEN MODIFIED PER SK2 10- 84
1 SHOCKMOUNT ED 188- 0050 THRU 18801424 EXCEPT WHEM MODIFIED PER SK210-84
8
IWARNING a
6
7
On Models manufactured prior to mid 1971 should alternator thru-bolt loosening or breaking occur, Cessna Service Letter SE71-40 dated November 24 , 1971 should be complied with. On models manufactured after mid 1971 a new high strength thru bolt and a K shaped retainer are installed. Torque bolts 45 to 55 pound-inches.
1. Bolt 2. Washer 3. Arm -Ad justing 4. Belt -Alte rnator 5. Alternator Assembly 6. Nut 7. Support Assembly 8 . Bushing -Rubber
9, Bushing 10. :'vtount - Bonded 11. Safety Wire
- J· ."'>._ c
.'
••
'
2
/'
7
~ ~
NON- SHOCKMOUNTED 2 6
18802257 THRU 18803240 EXCEPT WHEN MODIFIED PER SK210-84
Ftgure 16-4. Alternator InstallatiOn (Sheet 1 of 4) 16-28
6
NON- SHOCKMOUNTED 18801425 THRU 18802256 EXCEPT WHEN MODIFIED PER SK210-84
MODEL 188 & T188 SERIES SERVICE MANUAL
3
4
5
13 NON -SHOCKMOUNTED
100 AMP ALTERNATOR
e
TORQUE BOLT TO 165
:t:
10 LB-IN
THRU 1977 MODELS 1. Nut 2. Washer 3. Safety Wi re 4. Bolt 5. Washer 6. Arm -Adjusting 7 . Washer 8. Bolt
9. Drive Belt Washer Bolt Engine Engine Mount Support 14. Lock Washer 15 . Washer 16. Alternator 10. 11. 12. 13.
Fig ure 16-4 . Alternator Installation (Sheet 2 of 4) 16- 29
MODEL 188 & T1 88 SERIES SERVICE MANUAL
1
2
. /~ . 'Q..
4 8
*TORQUE TO 450-500 IN. LB. * TURQUE TO 720-1200 IN. LB. NON -SHOC~MOUNTED 95 AMP ALTERNATOR
BEGINNING WITH 18803047
1. Arm -Adjusting Washer
2. 3. 4. 5.
Bolt Safety Wire Drive Belt
6. Support 7. Nut 8. Alternator F~.gure
16-30
Revision
1
16- 4. Alternator lnsUllatwn (Sheet 3 of 4)
MODEL 188 & T188 SERIES SERVICE MANUAL
3
, 6
*
TORQUE TO 720-1000 IN. LB.
*
TORQUE TO 165 ± 10 IN. LB.
•
TORQUE TO 450-500 IN LB.
*TORQUE TO 200-270 IN. LB.
188-0001 THRU 18803240 WHEN MODIFIED PER SK210- 84 AND BEGINNING WITH 18803241
1. Washer
2. Bolt 3. Alternator 4. 5. 6. 7.
Arm- Adjusting Drive Belt Suppor t Nut
Figure 16- 4. P. lternator Installation (Sheet 4 of 4) ~vision
1
16-3 1
MODEL 188 & T188 SERIES SERVICE MANUAL
16-35. REMOVAL AND INSTALLATION. (See figure 16-4. ) a. Ensure that master switch is off, then disconnect and label wiring for alternator. b. Remove safety wire from adjusting arm bolts and remove bolts. c. Remove drive belt . d. Remove lower alternator mount bolt and remove alternator . e. Reverse the preceding steps for reinstallation. f. After reinstallation of the alternator, adjust belt tension to obtain 3/ 8" deflection at the center of the belt when applying 12 pounds of pressure to the belt. After the belt is adjusted and the bolt is safety wired tighten the lower support assembly bolt to the follow ing torque values : LB. -IN. TORQUE
ALTERNATOR ·
100 to 140
Shock mounted
I ~A UTION] Do not force belt over pulleys. The belt is to be installed on the sheaves with the arrow sym bol shown on the 0. D., pointing in the direction of rotation. This is toward the left or 2-4-6 side of the engine when viewing the top of the belt. On new aircraft or whenever a new belt is install ed, belt tension should be checked within 10 to 25 hours of operation. NOTE When tightening the alternator belt, apply
pry bar pressure o nly to the end of the
alternator nearest the belt pulley.
16- 36. VOLTAGE REGULATOR. 16- 37. DESCRIPTION.- 14 VOLT. The alternator voltage regulator contains two relays. One relay is actuated by the aircraft master switch and connects the regulator to the battery. The second relay is a two- stage, voltage sensitive device which is used to co ntrol the current applied to the field wmding of thf alternator. When the upper set of contacts on the voltage regulator relay are closed, full bus voltage is applied to the held. This condition will exist when the battery is being heavily charged or when a very heavy load is applied to the system. When the upper contacts open, as the voltage begins to rise toward normal bus vo ltage, the voltage to the alternator field is reduced through a resistor netwo rk in the base of the regulator thus reducing the output from the alternator. As the voltage continues to rise, assummg a very light load on the system, the lower co ntacts will close and ground the alternato r field and shut the alternator completely off. Under lightly load ed conditions the voltage relay will vibrate between the intermediate charge rate and the lower (co mpletely off) contacts. Under a moderate load, the relay will vibrate ~tween the intermediate charge rate and the up per {full output) contacts. Begmnmg w1th 1974 16-32
models a 14-volt solid state regulator is installed. The field relay ln this regulator is replaced by a circuit board. The regulator is a remove and re place item and not repairable in the field. the reg ulator may be adjusted. Refer to Cessna Alternator Charging Systems Service/Parts Manual. The voltage relay is temperature compensated so that the battery is supplied with the proper charging volt age for all operating temperatures. With the battery fully charged (ship's ammeter indicating at or near zero) and a moderate load applied to the system (a taxi light turned on) the voltage at the bus bar should be within the range shown according to the voltage vs temperature chart in the Cessna Alternator Charg1ng Systems Service/ Parts Manual. 16-38. DESCRIPTION.- 28 VOLT. The 28 volt regu lator is transistorized and controls the alternator output in a similar manner to a mechanical voltage regulator by regulating the alternator field current. The regulation is acco mplished electronically with the use of transistors and diodes rather than by a vibrating armature relay. The voltage sensing com ponent is a zener diode whjch had the characteristic of a sudden change in its resistance when a specified voltage is reached. A bench adjustment procedure ls outlined in the Cessna Alternator Charging Systems Service/Parts Manual. A Cessna Alternator Charg ing System Test Box Assembly (PN. 9870000-1) is available through the Cessna Service/Parts Center for use in isolating failures in the 28 - volt transistor ized voltage regulator (C611002-0105) and the 28 volt Alternator. 16-39. DESCRIPTION. - 28 VOLT. 100 AMP ALTER NATOR. The regulator is mounted on the alternator, is transistorized, and controls the alternator output by regulating the alternator field current . 16-40. ADJUSTMENT. For adjustment of the volt age regulator refer to Cessna Alternator Charging Systems Service/ Parts Manual. 16-41. OVER-VOLTAGE WARNING CIRCIDT (AIRCRAFT SERIAL 188-0001 THRU 18803046, 28 - VOLT SYSTEM) 16-42. DESCRIPTION. The o ver-voltage warning system consists of a relay assembly and an mcllcato r light. The relay is vo ltage sensit1 ve, opemng the al ternator field circuits and turmng on a red warmng light if excessive voltage is present. The over voltage relay IS mounted on the lower left hand fire wall thru aircraft senal 18800832 and on the bulkhead forward of the instrument p:mel at the center line. beginning with a1rcraft senal 18800833 . 16-43. ADJUSTMENT. (THRU 18801997) a. Remove relay fr o m the rurcraft according to the following paragraph. b. Attach a variable, well regulated and filtered power supply to term1nals "B" (poSitive) and "G'' (negative ). c. AdJuSt power supply toward 31.5 volts and listen fo r a ··click'' inside the relay as it pulls in . Note the voltage at wh1ch pull- m occurs .
MODEL 188 8t T188 SERIES SERVICE MANUAL
E
F B
Detail BEGINNING WITH 18803297
6
14 VOLT VOLTAGE REGULATOR Detail (THRU 18801374)
A Detail B 18801375 THRU 18803046 1. Wtre to :vtaster Switch 2. Wire to Regulator 3. Shield - Ground 4. ~ut 5. Lockwasher 6. Ftlter -Radio ~oise 7. Screw 8. VoltaJle Regulator - 14 Volt 9. Plug Assv 10 . Wt re to Alternat or Gr ound 11. Wtre to Alternator Fteld 12. Wire tO Alternator ..A-·· Ft.e;ure 16-5.
Volta~e
13 . 14. 15 . 16. 17. 18. 19. 20. 21. 22 . 23 . 24. 25 .
28 VOLT VOLTAGE REGULATOR Detail (THRU 18801374)
A
Detail
Voltage Regulator - 28 Volt Wi re - Ground Wire to Over-Voltage Relay Over-Voltage Relay Wire to Over - Voltage Lamp Wire to Voltage Regulator Capacitor Wire to Warmng Assembly Wtre to Shunt Alternator Warmng Assembly Heat Stnk D10de Wtre to Alternator
B 18801375 THRU 18803296 26. 27. 28. 29. 30 . 31. 32. 33 . 34. 35 . 36. 37.
Voltage Regulator - 28 Volt Wire (Red) Wire (Purple ) Wire (Green) Wire (Black) Alternator Adjustment Screw Lock Clip Bolt Over- Voltage Sensor Sta -Strap Wire Bundle
Regulator and Over-Voltage Relay Installation (Sheet 1 o! 3) 16-33
MODEL 188 & T188 SERIES SERVICE MANUAL
* BEGINNING WITH 18801998
9
14 VOLT OVER-VOLTAGE SENSOR
24 VOLT OVER-VOLTAGE RELAY 18801998 THRU 18803046
Detail
c
Detail
0
5
14
~
17
;
~1
18 24 VOLT OVER -VOLTAGE RELAY (THRU 18801997) Detail
17
C
F~ure 16-5. Voltage Regulator and CNer-Voltage Relay Installation (Sheet 2 of 3)
16-34
MODEL 188 & T188 SERIES SERVICE MANUAL
22
Detail
E
/
32 28 VOLT VOLTAGE REGULATOR (100 AMP ALTERNATOR INSTALLATION) Detail
F ~gure
16-5.
Volt~e
F
Regulator and 0-rer-Voltage Relay Installation (Sheet 3 of 3)
16- 35
MODEL 188 & T1 88 SERIES SERVICE MANUAL
d. AdJUSt relay as required to obtain a 31. 5 volt pull-in. Seal adjusting screw. e. Reinstall relay on aircraft. 16-44. REMOVAL AND INSTALLATION. (See figure 16- 5. ) a. Open battery box and disconnect ground cable from the negative battery terminal. Pull cable clear of battery box. b. Tape and lable wires connected to the three ter minals on relay before removal. Remove screws and locking washers holding wires on relay connec tions. c. Remove screws and locknuts securing relay to firewall. The relay will now be free for removal. d. To replace relay, reverse this procedure. fcAUTION \
Observe polarity when replacing capacitor on relay. 16- 45. OYER-VOLTAGE WARNING CIRCUIT. (AIRCRAFT SERIAL 18800833 THRU 18803046, 14-VOLT SYSTEM). 16-46. DESCRIPTION. The over- voltage warning system consists of an over-voltage sensor switch and a red warning light labeled, "HIGH VOLTAGE", on the instrument panel. When an over-voltage tripoff occurs the over- voltage sensor turns off the alternator system and the red warning light comes on. The ammeter will show a discharge. Turn off both sections of the Master Switch to recycle the over-voltage sensor. If the over-voltage condition was transient, the normal alternator charging will resume and no further action is necessary. If the over - voltage tripout recurs, then a generating sys tem malfunction has occurred such that the electrical accessories must be operated from the aircraft bat tery only. Conservation of electrical energy must be practiced until the flight can be terminated. The over-voltage red warning light filament may be tested at any time by turning off the " Alternator" portion of the Master Switch and leaving the "Battery" portion turned o n. This test does not induce an over- voltage condition on the electrical system. The sensor is preset and not adjustable. The sensor is located on the nght hand side of the instrument panel, attached to the W1re bundle with a sta-strap. A capacitor is also 10stalled at the same location, connected be tween the circuit breaker and the switch, to prevent
S HOP N OTES:
lfi- Jfi
nuisance trip-outs caused by voltage spikes or· tran sients. (¢A UTION !
Gro\Uld.ing the orange lead or interconnecting and black leads will destroy the sensor.
oran~e
16- 47. ALTERNATOR FAILURE WARNING CIRCUIT THRU 1977 MODELS. 16- 48. DESCRIPTION. A silicon, j\Ulction, power diode is wired in series with the alternator output lead. A 28-volt reed type relay is connected across the diode . On normal operation the diode is in for ward conduction and the relay sees about 1-volt drop across the diode and remains de- energized. If the alternator output should fail, bus voltage will exceed alternator output energizing the relay and directing power to the alternator out warning lights on the in strument panel. The diode assembly is mo\Ulted on the left hand side of the firewall. 16-49. REMOVAL AND INSTALLATION. (See figure 16- 5. ) a. Disconnect the four leads from the alternator
warning assembly and tag wires for reinstallation.
b. Remove screws, spacers and nuts securing the
warning assembly to the firewall and remove assem
bly.
c. Remove the four screws securing the diode assembly, then remove the bolt securing the wires on the forward side of the diode and the nut and washers on the aft side and remove assembly. d. For reinstallation reverse the preceding steps. e. When installing new diode on heat sink, coat bottom surface of diode hex with Dow-Corning DC-4 or a similar heat sink compound. Torque diode to 50 lb. inches. 16-50. ELECTRIC FUEL PUMP CIRCUIT. (See Section 12.) 16-51. AUXILIARY ELECTRIC FUEL PUMP FLOW RATE ADJUSTMENT. See Section 12. 16-52. AIRCRAFT LIGHTING SYSTEM. 16-53. DESCRIPTION. The aircraft lighting system consists of landing and taxi lights, navigation lights. anti-collision strobe lights, flashing beacon, instru ment lighting, wing tip turning lights, forward facing spray lights, hopper quantity light and compass light.
MODEL 188 & T1 88 SERIES SERVICE MANUAL 16-54.
TROUBLE SHOOTING.
TROUBLE
PROBABLE CAUSE
LANDING AND TAXI LIGHTS OUT.
LANDING OR T AXl LIGHT OUT.
ALL NAV LIGHTS OUT.
ONE NAV LIGHT OUT.
REMEDY
Short circuit in wiring.
1. Inspect circuit breaker. u circuit breaker is open, proceed to step 2. U circuit breaker is OK. proceed to step 3.
Defective wiring.
2. Test each circuit separat'ely until short is located. Repair or replace wiring.
Defective switch.
3. Check voltage at lights wHh master and landing and taxi light switches ON. Should read bat tery voltage. Replace switch.
Lamp burned out.
l. Test lamp with ohmmeter or new lamp. Replace lamp.
Open circult in wiring.
2. Test wiring for continuity. Repair or replace wiring.
Short circuit in wiring.
1. Inspect circuit breaker. If circuit breaker is open, proceed to step 2 . If circuit breaker is OK, proceed to step 3.
Defective wiring.
2. Isolate and test each nav light circuit until short is located. Repair or replace wiring.
Defective switch.
3. Check volt4ge at nav light with master and nav light switches on. Should read battery voltage. Re place switch.
Lamp burned out.
l.
Open circuit in wiring.
2. Test wiring for continwty.
Inspect lamp. Replace lamp.
Repair or replace wiring.
IWARNINGl The a nti- collision system is a high voltage device. Do not remove or touch tube assembly while in operation. Wait at least 5 minutes a.!ter turning of! power before starting work. BOTH ANTI-COLLISION STROBE LIGHTS WILL NOT LIGHT.
Open circuit breaker.
1. Check, if open reset. u circuit breaker continues to open proceed to step 2.
16- 37
MODEL 188 & T188 SERIES SERVICE M ANUAL 16-54.
TROUBLE SHOOTING (Cont.) TROUBLE
PROBABLE CAUSE
BOTH ANTI-cOLLISION STROBE LIGHTS WILL NOT LIGHT.
Open circuit b r eaker. Cont.
REMEDY
2. Disconnect red wire be tween aircraft power supply (battery/ external power) and strobe power supplies, one at a time. U clrcui t breaker opens on one strobe power supply, replace strobe power supply. II circuit breaker opens on both strobe power supplies proceed to s tep 3. II circuit breaker does not open proceed to step 4. 3. Check aircraft wiring. Repair or replace as neces sary. 4. Inspect strobe power sup ply ground wire for contact with wing structure.
(~AUTION }
Extreme care should be taken when exchanging flash tube. The tube is fragile and can easily be cracked ln a place where it will not be obvious visually. Make sure the tube is seated properly on the base of the nav light assembly and is centered in the dome. NOTE
When checking defective power supply and flash tube, units from opposite wing may be used. Be sure power leads are protected properly when unit is removed to prevent short circuit. ONE ANTI-COLLISION STROBE UGIIT WlLL NOT LIGHT.
Defective Strobe Power Supply, or flash tube.
1. Connect voltmeter to red lead between aircraft power supply (battery/ external power) and strobe power supply, connecting negative lead to wing structure. Check for 12/ 24 volts. II OK proceed to step 2. II not, check ai rcraft power supply (batteryI external power).
2. Replace flash tube with known good flash tube. II system still does not work, replace strobe power supply.
16-38
MODEL188 & T188 SERIES SERVICE MANUAL 16- 54. TROUBLE SHOOTING. (Cont. ) TROUBLE
PROBABLE CAUSE
REMEDY
Short circuit in wiring.
1. Inspect circuit breaker. If circuit breaker is open, pr oceed to step 2. If circuit breaker is OK, proceed to step 3.
Defective wiring.
2. Test circuit unW short is lo足 cated. Repair or replace wiring .
Lamp burned out.
3. Test lamp with ohmmeter or a new lamp. Replace lamp. If lamp is good, proceed to step 4.
Open circuit in wiring.
4. Test circuit from lamp to flasher for continuity. Uno continuity is present, repair or replace wiring. If continuity is present, proceed to step 5.
Defective switch.
5. Check voltage at flasher with master and bea con switch on . Should read battery voltage. Replace switch . If voltage is present, proceed to step 6.
Defective flasher .
6. Install new flasher .
FLASHING BEACON CONSTANTLY LIT.
Defective flasher .
1. Install new flasher.
INSTRUMENT LIGHT S WILL NOT LIGHT.
Short circuit wiring.
1. Inspect circuit breaker. If cir cuit breaker is open, proceed to step 2. If circuit breaker is OK, proceed to step 3.
Defective wiring.
2. Test circuit unW short is locat足 ed. Repair or replace wiring .
FLASHING BEACON DOES NOT LIGHT.
3. Rest for open circuit. Repair or replace wiring. If no short or open circuit is found, proceed to step 4. Faulty section in dimming potentiometer.
4. Lights will work when control is placed in brighter position. Re足 place potentiometer.
Faulty light dimming transistor .
5. Test both transistors with new transistor . Replace faulty transis足 tor.
16-39
MODEL 188 & T188 SERIES SERVICE MANUAL 16-54.
TROUBLE SHOOTING (Cont.)
TROUBLE
PROBABLE CAUSE
REMEDY
INSTRUMENT LIGHTS WILL NOT LIGHT (Cont. )
Faulty selector switch.
6 . Inspect.
INSTRUMENT lJGHTS WILL NOT DIM.
Open resistor wiring in minimum intensity end of potentiometer.
1. Test for continuity. Replace resistor or repair wiring.
Shorted transistor .
2. Test transistor by substitution.
Replace switch.
Replace defective transistor. ONE WING TIP TURNING LIGHT OUT.
BOTH WING TIP TURNING LIGHTS OUT.
ONE SPRAY LAMP OUT.
BOTH SPRAY LAMPS OUT.
ONE SPRAY LAMP WILL NOT EXTEND OR RETRACT .
BOTH SPRAY LAMPS WILL NOT EXTEND OR RETRACT.
16- 55. ED.)
16-40
Lamp burned out.
Replace lamp.
Defective wiring.
Repair or replace wiring.
Spray light circuit breaker open.
Reset.
Defective wiring.
Repair or replace wiring.
Defective spray light switch.
Replace switch.
Defective switch on grip.
Replace switch.
Defective relay.
Replace relay.
Lamp burned out.
Replace lamp.
Defective wiring.
Repair or replace wiring.
Defective relay .
Replace relay.
Defective wiring .
Repair or replace wiring .
Defective power switch.
Replace switch.
Defective switch on grip.
Replace switch.
Defective wiring.
Repair o r replace wiring.
Defective power unit relay.
Replace relay .
Defective power unit.
Replace power unit.
Defective switch.
Replace switch .
LANDING AND TAXI LIG HTS (WING MOUNTÂ
16-56. DESCRIPTION. The landing and taxi lights may be mou?ted in the leading edge of the left wing.
MODEL 188 8t T188 SERIES SERVICE MANUAL A clear plastic cover provides weather protection for the lamps and is shaped to maintain the leading edge curvature of the wing. The tanding lamp is mounted on the inboard side and adjusted to throw tts beam farther forward than the taxi light. Both lights are controlled by a single switch. An additional landing and taxi light installation may be installed in the right wing on serials thru 188-0274 . Beginning with serial 188-0275 thru 18800832, the optional land ing and taxi lights installation includes lights on both wings. 16- 57. REMOVAL AND INSTALLATION. (See figure 16-6.) a. Remove the screws securing the landing light window assembly. The assembly will then be free for removal. b. Remove the four attaching screws from the bracket assembly and remove the bracket.
16-62. DESCRIPTION. The navigation lights are located on each wing tip and the stinger. Lights are controlled by a switch on the instrument panel. 16-63. REMOVAL AND INSTALLATION. For re moval and installation of the navigation lights see figure 16-7. 16-64. ANTI-COLLISION STROBE LIGHTS. 16-65. DESCRIPTION. A white strobe light may be installed on each wing tip with the navigation lights. The strobe lights are vibration resistant and operate on the principle of a capacitor discharge into a zenon tube producing an extremely high intensity flash. Energy is supplied to the strobe lights from power supplies mounted on each wing tip rib.
!WARNING'
NOTE Do not reposition the landing and taxi light adjustment screws. If readjustment is re quired, see figure 16-6. c. Remove the two screws securing the wiring to the lamp contacts and remove the lamp. d. Install new lamp and reassembly. 16-58. ED).
16-66. OPERATIONAL REQUIREMENTS. (Thru 18803046).
!WARNING'
LANDING AND TAXI LIGHTS (COWL MOUNT
16-59. DESCRIPTION. Beginning with aircraft serial 18800833 the landing and taxi lights are mounted in the lower hail of the cowl nose cap. The landing hght on the left side and the taxi light on the right side. Lights are solid mounted although additional adjustment may be made by adding washers under the bracket assembly mounting screws. 16-60. REMOVAL AND INSTALLATION. (See figure 16-6, sheet 2 and 3). a. 18800833 THRU 18801040 1. Remove lower half of engine cowl. Then re move the screws securing the winng to the landing and tax1 lamps. 2. Remove tinnerman screws (6) securing aft bracket and remove lamp. 3. Install new lamp and reassemble. b. BEGINNING WITH 18801041 1. Remove lower half of eng1ne cowl. Then re move screws securing wiring to the landing and taxi lamps . 2. Remove screws (9) securing lamp assembly to reta1ner (2) and remove assembly. 3. Remove screws (10) and disassemble lamp assembly. 4. Install new lamp and reassemble.
NOTE When lamps are removed note position of washe rs and spacers for remstallat10n. 16-61.
The anti collision system is a high voltage device. Do not remove or touch the tube assembly while in operation. Wait at least 5 minutes after turning off power before proceeding with any maintenance.
NAVIGATION LIGHTS.
The capacitors in the strobe light power supplies must be reformed if not used for a period of six (6) months. The following procedure must be used. Connect the power supply, red wire to plus, black to ground to 6 volt DC source. Do Not connect strobe tube. Turn on 6 volt supply. Note current draw after one minute. If less than 1 ampere, continue operation for 24 hours. Turn off DC power source. Then con nect to the proper voltage, 12/ 24 volt. Connect tube to output of strobe power supply and allow to operate, !lashing, for 15 minutes. Remove strobe tube. Oper ating power supply at 12/ 24 volts, note the current drain after one mmute. If less than 0. 5 amperes. operate for 6 hours. If current draw is greater than 0. 5 amperes, reject the unit. 16- 67. REMOVAL AND INSTALLATION. See figure 16-7. for removal and installation. 16-68.
FLASHING BEACON.
16-69. DESCRIPTION. A flashing beacon light may be installed on the vertical fin tip. The flashing beacon is an iodine- vapor lamp electrically switched by a solid- state flasher assembly mounted in the tailcone. The switching frequency of the flasher operates the beacon ai approximately 45 flashes per minute. Beginning with aircraft serial 18801041 a resistor is added to the system to prevent pulsing of the lighting when the flasher is operating. 16-70. REMOVAL AND INSTALLATION. See figure 16-7 as a guide for removal and Installation of the flash1ng beacon. 16-41
MODEL 188 & T188 SERIES SERVICE MANUAL
2
4
5
3 VIEW
6
A-A 4
LEFT W ING
6 A-A -
3
RIGHT WING
2
5
DIMENSION NO. 1
2 3 4
5 6
0
S ERIAL THRU SERIAL 188-0274 ~8 8-0275 & ON .70 . 60 . 70 . 60 1. 15 . 75
VIEW
1. 10 . 77 . 57 . 55 . 97 . 73
THRU AlRCRAFT SERIA L 18800832
1. Window 2. AdJusting Screw
3. Lamp 4. Spnng
Figure 16- 6. Landing and Tax1 Light Installation (Sheet 1 of 3) 16-42
5. Bracket 6. Screw
MODEL 188 & T188 SERIES SERVICE MANUAL
1
AIRCRAFT SERIAL 18800833 THRU 18801040
1. Lower Nose Cap
Retainer Plate Lamp Bracket 6. Tinnerman Screw 7. Screw 2. 3. 4. 5.
Detail
A
NOTE Should further adJustment be des1red washers may be added between plate (3) and retainer (2).
Figure 16- 6. Land1ng and Taxi Light Installation (Sheet 2 of 3) 16-43
MODEL 188 & T188 SERIES SERVICE M ANUAL
10
BEGINNING WITH AIRCRAFT SERIAL 18801041
1. Lower Nose Cap 2 . Retai ner 3. Spacer 4. Washer 5. Plate
Detail
A
On aircraft serials 18801375 THRU 18802001 when the new solid rubber forward engine mounts are installed, refer to Cessna Single -engine Service Letter SE75-4. dated January 31. 1975 . 6. Lamp 7. Gasket 8. Br acket 9. Screw 10. Screw
Figur e 16-6. Landing and Taxi Light Installation (Sheet 3 of 3) 16-44
MODEL 188 & T188 SERIES SERVICE MANUAL
1~ LATF. MODELS Detail
G 15
1 4 - -
.__17
13
THRU 188-0317
Detail
8
'
BEGINNING WITH 18801041
Detail
B
188-0318 THRU 18801040
8
1. 2. 3. 4. 5. 6. 7. 8. 9.
Detail Shield Dome Gasket Lamp Clamp Assembly Plate - Mounting Socket Assembly Nutplate Support - Cable Deflector
10. 11. 12. 13. 14. 15. 16. 17. 18.
Tip Assembly Fin Clip Housing - Cap Housing - Plug Screw Flasher Assembly Mount Nut Resistor (1. 5 ohm)
Figure 16- 7. Night
Lighti~
A
Detail BEGINNING WJTH 18800833
•
THRU 18803296
Installation (Sheet 1 of 5) 16- 45
MODEL 188 & T 188 SERIES SERVICE MANUAL
9
Detatl
J
BEGINN1NG WITH 18803297
Detail
I
BEGINNING WIT H 18803604 NOI'E When installing lamp be sure socket assembly is installed in mounting plate so lamp may be installed with filament perpen dicular to the longitudinal axis of the aircraft. On Aircraft 18803047 thru
18803603, refer to Cessna Single- Engine Customer Care Service 111formation Letter SESO- 53, Dated 12 May, 1980. Figure 16-7 . Night Lighting Installation (Sheet 2 of 5) 16-46
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
C
Detail
0
25 32
26 24 Detail
0
Detail
0
AIRCRAFT SERIAL 18800833 THRU 18803046
23
THRU 18803967
36 19. Bracket 20. Wire 21. Lamp Socket 22. Gasket 23. Lamp 24. Lens
25, 26. 27. 28. 29. 30.
Lans Retainer Screw Cap Grounding Washer Insulating Washer Spring
31. 32. 33. 34. 35. 36.
Wing Tip Contact Insulator Wing Tip Rib Power Supply Ground Wire
Figure 16-7. Night Lighting Installation (Sheet 3 of 5) 16-47
MODEL 188 & T188 SERIES SERVICE MANUAL
31
27 28
31
Detail
32 Detail
0
24
BEGINNING WITH 18803868
0
22
THRU 18803867
3.1
32 Detail
0
22
BEGINNING WITH 18803868
44
I Deta 11
C
26
35
BEGINNING WI'ni AffiCRAFT SERIAL 18803047
Figure 16- 7. Night Lighting Installation (Sheet 4 of 5) 16-48
E
Detail BEGINNING WITH AIRCRAFT
SERIAL 18800833
MODEL 188 & T188 SER IES SERVICE MANUAL
~~·---
~
64 51
65
38
f
Detail BEGINNING WITH AIRCRAFT SERIAL 18800833
51
54
47 Detail 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.
H
Retainer R1ng Wing Panel Drive Housing Assembly Lamp Screw P ower Unit Wing Tip Shroud Reflector Bracket Wire (T o Turn Lig ht ) Lockwashe r Nut Wt r e (T o Wing Root Pl ug)
59 51. Diode 52. Wire (To Wing Root P lug) 53. Wire (To Drive Assembly) 54. Wire 55. Jumper Wire 56. Wtre (To Wing Root Plug) 57. Washer 58. Relay 59. Mounting Bracket 60. Sc r e w
T HRU 18803296
eew1
G
ROTATED 180° 61. 62. 63. 64 . 65.
Nylon Cover Sta-strap Wire (to Circuit Breaker) Wire (to Stick Gnp Switch) Contactor
F1g ure 16-7. Night Lighting Installation (Sheet 5 of 5) 16- 49
MODEL 188 & T188 SERIES SERVICE MANUAL
9
10
d d
5
fl~
~
0
8
8 Detail
~
A
Detail
1. Screw 2. Washer 3. Transistor 4. Mica Washer 5. Heat Sink 6. Cabin Skin 7. Housing ::>ocket 8. Rheostat 9. Instrument Panel 10. Knob Figure 16- 8. Transistorized Light Dimming 16-50
B
~
10
MODEL 188 & T188 SERIES SERVICE MANUAL
16-71. INSTRUMENT LIGHTING. 16- 72. DESCRIPTION. Instrument lighting is pro vided by 13 lamps mounted within the structure of the crash pad. Nine of the lamps furnish lighting to the Instrument panel through slots In the bottom of the crash pad. The other four lamps are directed up ward to light the instrument cluster. Glare is elimi nated by a thermo-formed plastic shield mounted atop the c rash pad. On aircraft serial 188- 0318 and on, a light was added above the elevator trtm tab con trol wheel. The intensity of the Instrument and clus ter lights is controlled by individual rheostats mount ed on the instrument panel. 16-73. REMOVAL AND INSTALLATION. (See figure 16-8.) a. Thru aircraft serial 18800832 to gain access to the instrument lamp socket assemblies, reach through the lightening holes in back of the instrument panel. Beginning with serial 18800833 the crash pad is hinged. b. Pull light socket from the mounting support. c. Remove the defective bulb and replace. 16-74. TRANSISTORIZED I.JGHT DIMMING. 16-75. DESCRIPTION. . A remotely located two circuit transistorized dimming assembly is installed in the aircraft beginning with 1972 models. One cir cuit controls the radio dial lights, lower instrument lights, and trim light. The other circuit controls the map light, upper instrument lights and compass light. Power is supplied from the bus bar through a circuit breaker to the off- on switch, then to the dimming assembly. Two rheostats on the instruments panel control the output of the dimming assembly and in turn control the lighting. 16-76. REMOVAL AND INSTALLATION. Figure 15-8 may be used as a guide for removal and in stallation. 16- 77. WING TIP TURNING LIGHTS. 16-78. DESCRIPTION. The wing tip turning lights are mounted in a fiber glass housing attached to the lower side of each wing tip. Lamps are 24-volt, 250 watt and controlled by a switch on the control stick grip. 16-79. REMOVAL AND INSTALLATION. (See figurel6 - 7.) a. Remove screws securing shroud to wing tip and
remove shroud.
b. Remove screws securing wiring to lamp contacts. c. Remove screws from lamp retainer ring and re
move lamp.
d . Install new lamp and reassembly. 16-80.
FORWARD FACING SPRAY UGHTS.
16-81. DESCRIPTION. The forward facing spray lights consists of a retractable 600 watt, 24- volt lamp mounted on the under side of each wing at sta tion 196.50. The !amps are extended o r retracted by a split-rocker type switch located on the left hand s1de of the instrument panel. The nght hand s1de of
the switch controls the right hand light and the left hand side controls the left hand light. A second r ocker type switch mounted on the panel controls power to the lamps on the top position and beginning with 18801425 the lower position controls power to the automatic flagman. Lamps may be turned on in the retracted position and extended to any degree desired. Conversion from spray lights to wing tip turning lights is controlled by a switch on the control stick grip. 16-82. REMOVAL AND INSTALLATION. a. To remove lamp extend the light approximately 60 degrees. b . Remove lamp retainer ring and remove lamp
from inner canopy and disconnect the wires from
the lamp.
c. To remove light assembly, support assembly
and remove screws securing assembly to retainer
band.
d. Lower the light assembly from wing and place
on a stand of suitable height.
e. Tag and remove the wires from the terminal
block.
f. Remove the two screws securing the power unit to the housing. g. To install reverse the preceding steps. 16- 83. HOPPER QUANTITY LIGHT. 16-84 . DESCRIPTION. A quantity light may be mounted on the hopper to provide illumination of the contents of the hopper so the pilot can determine the amount of chemical remaining during night spraying operation. The light is controlled by the interior light switch and a dimming rheostat located on the left side of the instrument panel. 16-85. COMPASS LIGHT. 16-86. DESCRIPTION. The compass light is con tained within the individual unit. The intensity of the compass light is controlled by the instrument cluster rheostat mounted on the instrument panel. 16-87. STALL WARNING SYSTEM. 16-88. DESCRIPTION. The stall warning circuit is comprised of a warning horn and an actuating switch. The switch is installed in the leading edge of the left wing and is actuated by airflow over the surface of the wing. The switch will close as a stall condition is approached, actuating the warning horn. The stall warning unit should actuate the stall warrung horn · approximately five to ten miles per hour above the airplane stall speed. Install the lip of the warning unit approximately one-sixteenth of an inch below the centerline of the wing skin cutout. Test fly the air craft to determine if the unit actuates the warning horn at the desired speed. U the unit actuates the warning horn at a speed in excess of ten miles per hour above stall speed, loosen the mounting screws and move the unit down. U the unit actuates the horn five miles per hour below stall speed, loosen the mounting screws and move the unit up.
16- 51
MODEL 188 & T188 SERIES SERVICE MANUAL
16- 89.
PITOT AND STALL WARNING HEATERS .
16-90. DESCRIPTION. (See figure 16-10.) Electrical heater units are incorporated in some pitot tubes and stall warning switch units. The heat足 ers offset the possibility of ice formations on the pitot tube and stall warning actuator switch. The heaters are integrally mounted in the pitot tube and the stall warning actuator SWitch. Both heaters are operated by the pitot heat switch. 16- 91. CIGAR IJGHTER (THRU 18803872). 16- 92. DESCRIPTION. The cigar lighter is equip足 ped with an extra circuit protection device. The cigar lighter has a special thermal- actuated cutout which is attached to the rear of the cigar lighter socket. The cutout will open the circuit il the lighter becomes jammed in the socket or held in the heat
SH OP NOTES:
16-52
position too long. The cutout may be reset by in足 serting a small probe into the . 078 diameter hole in the cutout and pushing lightly until a click is heard. /"fAUTION \
Make sure master switch is "OFF" before inserting probe into cutout on cigar lighter to reset. 16-93. REMOVAL AND INSTALLATION. a. Ensure that the master switch is "OFF." b. Remove cigar lighter element. c. Disconnect wire on back of lighter. d. Remove shell that screws on socket back of panel. e. The socket will then be free for removal. C. To install a cigar lighter, reverse this pro足 cedure.
MODEL 188 & T1 88 SERIES SERVICE MANUAL
r------2
3 4
THRU AIRCRAFT SERIAL 18800832
.'~2
1. Shield - Instrument L1ghtmg 2. Screw 3. Socket - Typical 4. Support - Instrument Lighting 5. Rheostat - Instrument Panel 6. Rheostat - Instrument Cluster 7. Knob
8, 9. 10. 11. 12. 13. 14.
Bulb - Typical Tinnerman Nut Panel Hinge Fastener Panel Light Clamp
F tgu re 16-9. Instrument Lighting Installation 16- 53
MODEL 188 8t T188 SERIES SERVICE MANUAL
18 Detan A BEGINNING WITH 6 1979 MODELS
2
A
Detail THRU 1978 MODELS
9
10
~...
10
~1
~
14 13
Detatl
C
1. Screw
2. 3. 4. 5. 6.
Fuselage Skin Nut Star Lockwasher Insulator-Washer Bracket Assy
~12
. ""
STANDARD PITOT MAST
HEAT ED PITOT MAST
Detail 7. 8. 9. 10.
8
Stall Warning Horn Pitot Line Access Cover Body 11. Heater Element 12 . Tube
Detail 13. 14. 15. 16. 17. 18.
B
Stem Nose Ft tttng Tinnerman Nut Wing Leading Edge Stall Warning Transmitter Cover
Figur e 16-10. Stall Warning and Pi tot Heat Systems 16-54
MODEL 188 & T1 88 SERIES SERVICE MANUAL ELECTRICAL LOAD ANALYSIS CHART ELECTRICAL EQUIPMENT
AIRCRAFT SERIALS 188-0001 THRU 188-03 17
AMPS REQD
STANDARD EQUIPMENT {Running Lo...c' Battery Conta.ctor Fuel Quantity Indicator OPTIONAL ACCESSORIES
{Running Load)
Cess na Transceiver 300 (RT- 524A) .
Cylinder Head Temperature Indicator Flashing Beacon Light Heated Stall Warning & Pitot Indicator, T & B Light, Compass Lights, Instrument Panel Lights, Position ITEMS NOT CONSIDERED RUNNING LOAD Auxiliary Fuel Pump (Al88 Only) Stall Warning Horn Taxi and Landing Lights.
ELECTRICAL EQUIPMENT STANDARD EQUIPMENT (Running Load) Battery Contactor. Fuel Quantity Indicator OPTIONAL ACCESSORIES (Running Load)
Cessna 300 Transceiver (RT-524A).
(Thru Serial 18802745)
Cessna 400 Transceiver (RT-532A) .
(Thro Serial 18801824)
Cylinder Head Temperature Ind.
Flashing Beacon Light Heated Stall Warning & Pitot. Indicator, Turn& Bank . Indicator. Turn Coordinator . Lig ht , Compass Lights, Instrument Panel Lights, Position Air Conditioning Lights, Wing Str obe Light. Overhead Flood ITEMS NOT CONSIDERED RUNNING LOAD
Auxiliary Fuel Pump (A188 Only).
Cigar Lighter Stall Warning Horn Taxi and Landing Lights DISPERSAL SYSTEMS Electric Spray Valve Electnc Agitator . Contactor Spray Valve NIGHT SPRAY LIGHTING Ho pper Light . Wing Tip Turning Light Spray Light Taxi and Landing Light Spray Light Contactor.
0. 6 0.2
3.2 0.2 7. 0 10.0 0.2 0.08 2.6 5.6 3.0 0 . 25 15 . 6
AMPS. REQD 18803459 THRU THRU 188-0318 18803458 18803296 14 VOLT 28 VOLT 28 VOLT
BEGIN WITH 18803297 28 VOLT
BEGIN WITH 18803522 28 VOLT
BEGIN WITH 18803722 28 VOLT
0.5 0.1
0. 5 0. 1
0. 5 0. 1
0.5 0. 1
. 04 6.0 4 . 05 0. 2 0.3 0.04 1.7 2.5 6.7 3. 0 0.2
0. 6 0.2
0.4 0. 12
3.2
2. 1
1.1
1.1
0.2 7. 0 10.0 0. 2 0. 8 9.08 3.0 5.6
0.04 6. 0 4.05 0.2 0. 3 0.04 1.4 2. 0
0.04 6.0 4.05 0. 15 0.3 0.04 1.7 2.5
0.04 6.0 4.05 0.15 0.3 0. 04 1.5 2. 5
. 04 6. 0 4.05 0. 15 0.3 0.04 1.5 2.5
3.0 10.0 0. 25 15. 6
3.0 7. 0 0. 15 7. 14
3.0 10.0 0. 15 7. 14
3.0 10.0 0. 15 7. 14
3. 0 10.0 0. 15 7. 14
3.0 10. 0 0. 15 3. 6 (ea)
30.0 14.0 0.6
15.0 7.0 0. 5
15.0 7.0 0. 5
15. 0 7.0 0.5
15.0 7. 0 0.5
15.0 7. 0 0.5
N/A N/ A N/A N/ A N/ A
0. 5 36. 0 48.0 20.0
0.5 36. 0 48.0 20 . 0
1.0
0. 7 42 .0 42.0 20.0 0. 5
0.5 42 .0 42 .0
1.0
0. 7 32 . 0 42 . 0 20. 0 0. 5
20. 0 0. 5
â&#x20AC;¢ Replace taxi and landing lights noted under 9. 4. 3 16-55
MODEL 188 8t T188 SERIES SERVICE MANUAL ELECTRICAL LOAD ANALYSIS CHART ELECTRICAL EQUIPMENT
STANDARD EQUIPMENT (Running Load)
Battery Contactor
Fuel Quantity Indicator
OPTIONAL ACCESSORIES (Running Load)
Flashing Beacon Light
Indicator, Turn & Bank
Indicator, Turn Coordinator
Lights, Instrument Panel
Lights, Position
Air Conditioning
Lights, Wing Strobe
Light, Overhead Flood
ITEMS NOT CONSIDERED RUNNING LOAD Auxiliary Fuel Pump (Al88 Only) . Taxi and Landing Lights. DISPERSAL SYSTEMS Electric Spray Valve Electric Agitator . Contactor Spray Valve NIGHT SPRAY UGHTING Hopper Light . Wing Tip Turning Light Spray Light Taxi and Landing Light Spra y Light Conta.ctor.
16-56
BEGIN WITH 18803857 28 VOLT
0. 5 0. 1
6.0 0.2 0. 3 1.7
2.5 6.7 3.0 0.2
3.0 3. 6 (ea) 15. 0 7.0 0. 5 0. 5 42 . 0 42.0 20.0 0. 5
MODEL 188 & T188 SERIES SERVICE MANUAL
SECTION 17
STRUCTURAL REPAIR
TABLE OF CONTENTS
Page No. Aerofiche/Manual
REPAIR CRITERIA . . EQUIPMENT AND TOOLS . Support Stands . . . . Alignment Jigs . . . . WING TWIST AND STABILIZER ANGLE- OF -INCIDENCE CONTROL SURFACE BALANCING REPAIR MATERIALS. WING . . . . ·. . . Wing Skin . . . Wing Stringers . Wing Ribs . . . Wing Spars Wing Leading Edge Bonded Leading Edge Repair. Ailerons. . . . . . . Wing Flaps . . . . . ELEVATORS AND RUDDER FIN AND STABILIZER . . FUSELAGE (Except Tubular Structure) Firewall . . . . . . . . . . . .
. . . .
2F19/17-l 2F19/17-1 2FI 9/17- 1 2F19/17-l
. . . . . . . . . . . . . .
2F19/17 - l 2F22/ 17-4 2F22/17-4 2F22/17-4 2F22/17-4 2F22 / 17- 4 2F22/17 - 4 2F22/17-4 2G4/17 -10 2G4/17-10 2G4/17-10 2G4/17-10 2G4/ 17-10 2G4/17-10
Engine Cowling. . . . . . . . . BONDED FORWARD ACCESS DOORS . FUSELAGE TUBULAR STRUCTURE GENERAL CONSIDERATIONS ENGINE MOUNT . . . . . General Considerations . Support Cradle Damage . Mounting Lugs and Fittings BAFFLES . . . . . . . . HOPPER . . . . . . . . . . CATWALK . . . . . . . . . REPAIR OF GLASS- FIBER CONSTRUCTED COMPONENTS SUBSTITUTING BLIND RIVETS FOR SOLID RIVETS . . . . . General Considerations . Blind Rivet Substitution : Determining Quantity of Substitute Blind Rivets FASTENER SUBSTITUTION . . .
2G5/17 -ll 2G5/17 - ll 2G5/17 - ll 2G5/17- ll 2G24/17- 30 2G24/17- 30 2G24/17- 30 2G24/17- 30 2G24/17 - 30 2H8/17 - 38 2H8/17 -38 2Hl3/17 - 43 2H13/17-43 2H13/17- 43 2Hl3/17-43 2H13/17-43 2H13/ 17-43
. 2G5/17-ll
17-l. REPAIR CRITERIA. 17-2. Although this section outlines repair premis sible on structure of the aircraft, the decision of whether to repair or replace a maJOr unit of structure will be influenced by such factors as time and labor available, and by a comparison of labor costs with the price of replacement assemblies. Past experience indicates that replacement. in many cases, is less costly than major repair. Certainly, when the air craft must be restond to its airworthy condition in a limited length of time, replacement is preferable. 17-3. Restoration of a damaged airc raft to its orig inal design strength, shape, and alignment involves careful evaluation of the damage. followed by exact ing workmanship in performing the repairs. This section suggests the extent o! structural repair prac ticable and supplements Federal Aviation Regulations, Part 43. Consult the factory when in doubt about a repair not specifically mentioned here. 17-4. EQUIPMENT AND TOOLS. 17 - 5. SUPPORT STA.''-i'DS. Padded, reinforced saw horse or tripod type support stands, sturdy enough to support any assembly placed upon them, should be used to store a removed wing or tailcone. The fuse lage assembly, from the tailcone to the firewall,
must NOT be supported from the underside, since the skin bulkheads are not designed for this ploU'pose. Adapt support stands to fasten to the wing attach points or landing gear attach points when supporting a fuse lage. 17-6. ALIGNMENT JIGS. Whenever a repair is to be made which could affect structural alignment, suitable jigs should be used to assure correct align ment of major attach points as shown in figure 17- 1. Wing and fuselage jigs are available from the factory. 17-7. WING TWIST AND STABILIZER ANGLE-OF. . INCIDENCE. Wing twist (washout) and horizontal stabilizer angle- of- incidence are shown in the follow ing. chart. Stabilizers do not have twist. Wings have no twist from the root to the lift strut station. All twist in the wing panel occurs between this station and the tip rib. See figure 17-2 for wing twist measurement. WING
-
Twist (washout)
STABILIZER
Angle -of -incidence
. -4. 30 '
Revision
1
17 -1
I
MODEL 188 & T188 SERIES SERVICE MANUAL
AFT;;
<t. OF HOLE AT
Detail
C
<t. OF HOLE AT MIDPOINT
Detail
8
Detail AGwagon AGpickup
A
STRUT ATTACH
POINTS AGtruck
STA. 23.70 L. B. L. 22. 51 R. B. L. 22.51 W. L. 19. 34
STRUT ATTACH POINTS AGwagon and AGpickup ST A. 23.90 L. B. L. 20.00 · R. B.L. 20. 00 W. L. 19. 34
c
-
FIREWALL UPPER ATTACH POINTS STA. . 07 L. B. L. 18. 44 R. B. L. 18. 44 W. L . 11.77
T AILCONE UPPER ATTACH POINTS STA. 110.97 L.B.L. 15.09 R.B.L. 15.09 W. L. 24.80
~~~=~-20.00W. L.
FIREWALL LOWER
ATTACH POINTS STA . . 07 L. B. L. 16. 19 R. B. L. 16. 19 W. L. -18.25
WING FORWARD ATTACH POINTS STA. 33.58 L. B. L. 52.75 R. B. L. 52. 75 W. L. -9.25
(REF)
TAILCONE LOWER
ATTACH POINTS
STA. 110.97 L. B. L. 13.65 R. B. L. 13.65 W. L. - 7. 85
WING REAR ATTACH POINTS STA. 64. 57 L. B. L. 52.77 R. B. L. 52.77 W. L. -10. 27
<t. OF HOLE AT MIDPOINT
De tail
0
AG truc k
<t. OF HOLE AT MIDPOINT
Ftg ure 17 - 1. S tructural AI ig nme nt (Sheet 1 o f 2)
17-2
0
Deta tl AGwagon AGpickup
MODEL 188 & T188 SERIES SERVICE MANUAL
STA . =STATION LINE. A vertical plane whtch is perpendicular to water line planes and buttock line planes. For reference purpose here . zero station line is the front face of the firewall . Station lines are given in inches aft (positive number) or forward (negative number) of zero station line.
B. L. = BUTTOCK LINE. A plane which is parallel to the vertical center plane of the aircralt. Zero buttock line is the vertical plane passing through the centerline of the aircraft. Buttock lines are given in inches right (R. B. L.) or left (L. B. L. ) as viewed from the rear of the ai r craft.
BUTTOCK LINE
W. L. =WATER UNE. A plane which is parallel to a horizontal plane . Water lines are given in inches above (positive number ) or below (negative number) zero water line.
NOTE
These definitions apply to the attach points shown on sheet 1 of this illustration.
Figure 17-1. Structural Alignment (Sheet 2 of 2) Revision 1
17-3
MODEL 188 & T188 SERIES SERVICE MANUAL
17-8. CONTROL SURFACE BALANCING. A balanc Ing fixture and mandrels are required to determine the static balance moment of a control surface . A Flight Control Surface Balancing Fixture Kit (P /N 5180002 - 1) is available from the Cessna Supply Dlvlslon (ref. figure 17 -3) . 17-9. REPAIR MATERIALS. 17-10. Thickness of material on which a repair is
to be made can easily be determined by measuring with a micrometer. ln general, material used in Cessna aircraft covered in this manual is made from 2024 aluminum alloy, heat treated to a -T3, -T4, or -T42 condition. If the type of material cannot be readily determined, 2024-T3 may be used in making repairs, since the strength of -T3 is greater than -T4 or -T42 (-T4 and -T42 may be used interchange ably, but they may not be substituted for -T3). When necessary to form a part with a smaller bend radius than the standard cold bending radius for 2024- T4, use 2024-0 and heat treat to 2024-T42 after forming. The repair material used in making a repair must equal the gage of the material being repaired unless otherwise noted. It is often practical to cut repair pieces from service parts listed in the Parts Catalog. A few components (empennage tips, for example) are fabricated from thermo-for med plastic or glass fiber constructed materials.
17-16. REPAIRABLE DAMAGE . Figure 17- 4 out lines typical repair to be employed in pataching skin. Before installing a patch, trim the damaged area to form a rectangular pattern, leaving at least a one half inch radius 'at each corner, and de-burr. The sides of the hole should lie span- wise or chord- wise. A circular patch may also be used. If the patch is in an area where flush rivets are used, make a flush patch type of repair; if in an area where flush rivets are not used, make an overlapping type of repair. Where optimum appearance and airflow are desired, the flush patch may be used. Careful workmanship will eliminate gaps at butt-joints; however, an epoxy type filler may be used at such joints. 17-17. DAMAGE NECESSITATING REPLACEMENT OR PARTS. If a skin is badly damaged, repair should be made by replacing an entire skin panel, from one structural member to the next. Repair seams should be made to lie along existing structural member s and each seam should be made exactly the same in regard to rivet size, spacing, and pattern as the manufactured seams at the edges of the orig inal sheet. If the manufactured seams are different, the stronger should be copied. If the repair ends at a structural member where no seam is used, enough repair panel should be used to allow an extra row of staggered rivets, with sufficient edge margin, to be installed.
17- 11. WING. 17-18. WING STRINGERS. 17-12. The wing assemblies are a semicantilever type employing semimonocoque type of structure. Basically, the internal structure consists of built-up front and rear spar assemblies, formed sheet metal nose, .intermediate, and trailing edge r ibs. stressed skin, riveted to the r ib and spar structures, com pletes the wing structure. 17-13. ACCESS openings (hand hol es with removable cover plates) are located in the underside of the wing between the wing root and tip section. These openings afford access to aileron bellcranks, flap bellcranks, electrical wiring, strut attaching fittings, control cables and pulleys, and control disconnect points.
17-19. NEGLIGIBLE DAMAGE. 17-15.
Refer to paragraph
17-20. REPAIRABLE DAMAGE . Figure 17-5 out lines a typical wing stringer repair. Two such re pairs may be used to splice a new section of stringer material in position, without the filler material . 17-21. DAMAGE NECESSITATING REPLACE'MENT OF PARTS. If a stringer is so badly damaged that more than one section must be spliced, replacement is recommended. 17-22. WING RIBS.
17-14.
WING SKIN.
17-15. NEGLIGIBLE DAMAGE . Any smooth dents in the wing skin that are free from cracks, abrasions and sharp corners, which are not stress wrinkles and do not interfere with any inte rnal structure or mechanism, may be considered as negligible damage . In areas of low stress intensity, cracks, deep scratches or dents, sharp dents, which after trim ming or stop drilling can be enclosed by a two-inch circle, can be considered negligible if the damaged a rea is at least one diameter of the enclosing circle away from all existing rivet lines and material edges. stop-drilling 1s considered a temporary repair and a permanent repair should be made as soon as practi cable.
17-23. NEGLIGIBLE DAMAGE. 17-15. 17-24. REPAIRABLE DAMAGE. lines typical Wing rib repairs.
Refer to paragraph Figure 17-6 out
17-25. DAMAGE NECESSITATING REPLACE'MENT OF PARTS. Leading and traUing edge ribs that are extensively damaged should be replaced. However, due to the necessity of unfastening so much skin in o rder to replace ribs, they should be repaired if practicable. Center ribs. between the front and rea; spars should always be repaired if practicable. 17-26. WING SPARS. 17-27. NEGLIGIBLE DAMAGE . Due to the stresses
17-4
MODEL 188 & T188 SERIES SERVICE MANUAL
GRIND
~~
(
----+------- ~I --I
--- .i~i- -1 -.----------'~
A orB
l eo
c - - - . -1
1
i -Â - ----------- ....
f
_l_ lF=====~r~~,~ ~========~~~h~=====4¡------~~ I I
!
I
MODEL
I
c
A
B
THRU 1880832
2.00 2.00 .79
1. 00 1. 00 1. 00
29 .50 29. 50 20. 00
39. 00 100.00 207.00
1880833 AND ON
2.00 2.00 . 66
1. 00 1. 00 1. 00
29.50 29.50 20.00
39.00 100.00 207 . 00
WING STATION
ALL WING TWIST OCCURS BETWEEN STA. 100.00
AND STA. 207.00.
(Refer to paragr aph 17 - 11).
MEASURING WING 1WIST U damage has occurred to a wing, it is advisable to check the twist. The following method can be used with a mmimum of equtpment, whtch mcludes a straightedge (32" minimum length of angle, or equivalent), three modified bolts for a specific wmg, and a pr otractor head with level. 1. Check chart for applicable dimension for bolt length (A or B).
2. Grmd bolt shanks to a r ounded point as illustrated, checking length penodically. 3. Tape two bolts to straightedge according to dimension C. 4. Locate inboard wing station to be checked and make a pencil mar k approximately one-hall inch art of leadtng edge skin. 5. Holding stratghtedge paralle l to wing station (staytng as clear as possible from "cans"), place longe r bolt on pencil mark and set protractor head against lower edge of straightedge. 6. Set bubble
10
level to center and lock protractor to hold this reading.
7. Omitting st~tp 6, repe:lt procedure for outboard wing station, using dimensions specliied in chart. to see that pr otractor bubble tS still centered. 8.
Proper tW1St is present in wing if protra ctor readings are the same (parallel). may be lowe r ed from wmg. 10 inch maximum to attain parallelism.
Check
Forward or aft bolt
Figure 17-2. Measunng Wing l'w1st 17-5
MODEL 188 & T188 SERIES SERVICE MANUAL
GENERAL NOTES
1. Balance control surfaces in a draft- free area. 2. Place hinge bolts through control surface hinges, and position on knife edge balancing mandrels.
Be sure hinge bolt shank rests on knife edge.
3. Make sure all control surfaces are in their approved flight configuration: painted, trim tabs installed. all foreign matter removed from inside of control surface , elevator trim tab push-pull rod installed, and all tips Installed. 4. Place balancing mandrels on a table or othe r suitable flat surface. 5. Adjust trailing edge support to fit control surface being balanced while center of balancing beam is
directly over hinge line. Remove balancing beam and balance the beam itself by moving the adjust
able weight (fastened by bolt & washer). Fine balance may be accomplished by use of washers at
long screw on end of beam.
6. When positioning balancing beam on control sur face, avoid r ivets to provide a smooth surface
for the beam, and keep the beam 90° to the binge line of the control surface.
7. Paint is a considerable weight factor. In order to keep balance weight to a minimum, it is
recommended that existing paint be removed before adding paint to a control surface. Increase
in balance weight will also be limited by the amount of space available and clearance with
adjacent parts. Good workmanship and standard repair practices should not result in unrea
sonable balance weight.
8. The approximate amount of weight needed may be determined by taping loose weight at the
balance weight area.
9. Lighten balance weight by drilling off part of weight. 10. Make balance wetght heavier by fusing bar stock solder to weight after removal from control surface. The ailerons should have balance weight increased by ordering additional weight and gang channel listed in the Parts Catalog, and installing next to existing inboard weight the mmimum length necessary for correct balance, except that a length which contains at least two attaching screws must be used. If necessary, lighten new weight and/ or existing weights for correct balance.
~110002
"
MU ORHS
Figure 17-3. Control Surface Balancing (Sheet 1 of 4) 17-6
MODEL 188 & T188 SERIES SERVICE MANUAL
BEAM ASSEMBLY CENTERLINE ON BEAM MUST BE AUG NED WITH CONTROL SURFACE IDNGE CENTERUNE
HANGER ASSEMBLY
-
----*~ --- -
ADD WASHERS AS NECESSARY STO FINE BALANCE THE BEAM ASSEMBLY
-
~
Adjust vertically until beam parallels control surface
chord line (except ailerons).
READ CONTROL SURFACE MOMENT AT CENTER OF WEIGHT ADJUSTABLE WEIGHT HANGAR ASSEMBLY
(TO BE IN PROPER PQ)ITION)
E=======~~~~~ --~0~ LINE
FLAT SURFACE RUDDERS AND ELEVATORS
"""
~ \
I I \
\ \
\
\
~0°...._
~
\
\
Refer to chart for correct range of underbalance. - •
BALANCING MANDREL
l
Set control surface on balancing mandrels, with hinge bolts resting on mandrels. Posi tion balancing beam with mid - point directly over, and 90° to, hinge line.
Figure 17-3. Control Surface Balancing (Sheet 2 of 4) 17 - 7
MODEL 188 & T188 SERIES S ERVICE MANUAL
AILERONS
NOTE
Refer to chart for correct range of underbalance.
*DETAIL
A-A m:NGE LINE HORIZONTAL PLANE
*NOTE
Balance aileron wlth chord line level at wing station 100.
Figure 17-3. Control Surface Balanc ing (Sheet 3 of 4) 17-8
MODEL 188 & T188 SERIES SERVICE MANUAL
CONTROL SURFACE BALANCE REQUIREMENJ'S
NOTE
e
B&l.ance limits for contr ol surfaces are expr essed for "Appr oved Flight" configuration. "Approved Flight" configuration is that condition o! the control surface as prepared for flight o! the airplane whether it be painted or unpainted.
e "Approved
Flight" limits must never be exceeded when the surface Is in its ltnal configuration
fo r flight.
DEFINITIONS: UNDERBALANCE is defined as the condition that exists when surface is trailing edge heavy
and is defined by symbol (+). U the balance beam sllding weight must be on the leading edge
side of the hinge line (to balance the control surface), the control surface is considered to
be underbalanced.
OVERBALANCE is defined as the condition that exists when surface is leading edge heavy and is defined by symbol (-). U the balance beam sliding weight must be on the trailing edge side of the hi~e line (to balance the control surface), the control surface is considered to be overbalanced.
CONTROL SURFACE
AP P ROVED FIJGHT CONFIGURATION BALANCE lJMITS (Inch-Pounds)
AILERON
+1. 97 to +17 . 08
RUDDER
0.0 to +11.4
RIGHT ELEVATOR
LEFT ELEVA TOR
Figure 17-3.
0. 0 to -+29. 8
O.Oto+25.4
Control Surface Balancing (Sheet 4 of 4) 17-9
MODEL 188 & T188 SERIES SERVICE MANUAL
which wing spars encounter, very little damage can be considered negligible. All cracks, stress wrinkles, deep scratches, and sharp dents must be repaired. Smooth dents, light scratches, and abrasions may be consider ed negligible. 17-28. REPAIRABLE DAMAGE. Figure 17-7 out lines typical spar repairs. It is often practical to cut repair pieces from spare parts listed in Parts Catalogs. Service Kits are available for certain types of spar r epairs . 17-29. DAMAGE NECESSITATlNG REPLACEMENT OF PARTS. Damage so extensive that repair is not feasible requires replacement of a complete wing spar. Also refer to paragraph 17- 2. 17-30. WING LEADING EDGE. 17-31. NEGLIGIBLE DAMAGE. Refer to paragraph 17- 15. 17- 32. REPAIRABLE DAMAGE. A typical leading edge skin repair is shown in figure 17- 8. An epoxy type filler may be used to fill gaps at butt joints. To facilitate repair, extra access holes may be installed in the locations noted in figure 17-9 . If the damage would requir e a repair which could not be made be tween adjacent ribs, refer to the following paragraph.
17- 40. DAMAGE NECESSITATING REPLACEMENT OF PARTS. If the damage would require a repair which could not be made between adjacent ribs, complete skin panels should be r eplaced. Ribs and spar s may be repaired, but replacement is generally pr eferable. Where extensive damage has occurred, replace ment of the aileron assembly is recommended. After repair and/ or repainting, balance in accordance with figure 17-3. 17-41. WING FLAPS. 17- 42. NEGLIGIBLE DAMAGE . Refer to paragr aph 17-15. 17- 43. REPAIRABLE DAMAGE. Flap r epair s should be similar to aileron repairs discussed in paragraph
17- 44. A flap leading edge r epair is shown in figure 17- 8. 17-44. BALANCING. Since the flap is not consider ed a movable control surface, no balancing is re quired. 17- 45. DAMAGE NECESSITATING REPLACEMENT OF PARTS. Flap r epairs which require replacement of part s should be similar to aileron repair s discuss ed in paragraph 17-40. 17-46. ELEVATORS AND RUDDER.
17-33. DAMAGE NECESSITATING REPLACEMENT OF PARTS. For extensive damage, complete lead ing edge skin panel s should be r eplaced. To facili tate replacement, extra access holes may be installed in the locations noted in figure 17-9. 17- 34. BONDED LEADING EDGE REPAIR. 17- 35. 17-15.
NEGLIGIBLE DAMAGE. Refer to paragraph
17-36. REPAIRABLE DAMAGE. (See figur e 17-16.) Cut out damaged area as shown, to the edge of un damaged ribs. Using a corresponding section from a new leading edge skin, overlap ribs and secure to wing using rivet pattern shown in the figure. Blind rivets may be used in unaccessible areas. 17- 37 . AILERONS. 17- 38. NEGLIGIBLE DAMAGE. Refer to paragraph 17- 15. 17-39. REPAIRABLE DAMAGE. The leading edge skin r epair shown in figure 17- 8 should be used to
repair damage to aileron leading edge skins. The flush-type skin patches shown in figure 17-4 may be used as a guide to repair damage to flat surface be tween corrugations, when damaged area includes corrugations refer to figure 17- 15. It is recom mended that material used for repair be cut from spare parts of the same gu.age and corrugation spac ing. Following repair the aileron must be balanced. If damage would require a repair which couldn't be made between adjacent ribs, see the following para graph. 17-10
17- 47. NEGLIGIBLE DAMAGE. Refer to paragraph 17-15. The exception to negligible damage on the elevator surfa ces is the fr ont spar, where a crack appearing in the web at the hi.n ge fittings or in the structure which supports the overhanging balance wieght is not considered negligible . Cracks in the overhanging tip r ib, in the area at t he front spar in tersection with the web of the rib, also cannot be con sidered negligible. 17- 48. REPAffiABLE DAMAGE . Skin patches shown in figure 17-4 may be used to repair skin between corrugations. Refer to figur e 17- 15 for damage which includes corrugations. It is recommended that mate rial used for repair be cut from spare parts of the same gua.ge and corrugation spacing. If the damaged area would require a repair which could not be made between adjacent ribs, see the following paragraph. 17- 49. DAMAGE NECESSITATING REPLACEMENT OF PARTS. If the damaged area would require a re pair which could not be made between adjacent ribs, complete skin panels should be replaced. Ribs and spars may be repair ed, but replacement is generally preferable. Where extensive damage has occurred, replacement of the entire assembly is recommended. After repair and/ or repainting, balance in accordance with figure 17-3. 17- 50. FIN AND STABU..IZER. 17-51. NEGLIGIBLE DAMAGE . Refer to paragraph 17- 15.
MODEL 188 & T188 SERIES SERVICE MANUAL
17-52. REPAIRABLE DAMAGE. Skin patches shown in figure 17-4 may be used to repair skin damage. Access to the dorsal area of the fin may be gained by removing the horizontal closing rib at the bottom of the fin. Access to the internal fin structure is best gained by removing skin attaching rivets on o ne side of the rear spar and ribs, and springing back the skin. Access to the stabilizer structure may be gained by removing skin attaching rivets on one side oi the rear spar and ribs, and springing back the skin. If the damaged area would require a repair · which could not be made between adjacent ribs, or a repair would be located in an area with compound curves, see the following paragraph. 17-53. DAMAGE NECESSITATING REPLACEMENT OF PARTS. lf the damaged area would require a patch which would not be made between adjacent ribs, or the repair would be located in an area with com pound curves, complete skin panels should be re placed. Ribs and spars may be repaired, but re placement is generally preferable. Where damage is extensive, replacement of the entire assembly is recommended. 17-54. FUSELAGE. (Except tubular structure.) 17-55. The fuselage tailcone is of semlmonocoque construction, consisting of formed bulkheads, longi tudln.al stringers, reinforcing channels, and skin platings. The fuselage skins and supporting struc tures which surround the tubular structure, from the tailcone to the firewall, are not stress members but are essentially just covering. The tubular structure is discussed later in this section. 17-56. NEGLIGIBLE DAMAGE. Refer to paragraph 17-15. Mild corrosion appearing upon alclad surfaces does not necessarily indicate incipient failure of the base metal. However, corrosion of all types should be carefully considered, and approved remedial ac tion taken. Small cans appear in the skin structure of all metal airplanes. It is strongly recommended, however, that wrinkles which appear to have origin ated from other sources, or which do not follow the general appearance of the remainder oi the skin panels, be thoroughly investigated. Wrinkles over stringers which disappear when the rivet pattern is removed may be considered negligible. However, the stringer rivet holes may not align perfectly with the skin holes because of a permanent "set" in the stringer. If this is apparent, replacement of the stringer will usually restore the original strength charactenstics of the area. Wrinkles occuring on open areas which disappear when the r ivets at the edge of the sheet are removed, or a wrinkle which is hand-removable, may often be repaired by the addi tion of a 1/ 2 x 1/ 2 x . 060-inch 2024-T4 extruded an gle, riveted over the wrinkle and extended to within 1/16 to 1/8-inch of the nearest structural members. Rivet pattern should be identical to the existing manu factured seam at the edge of the sheet. Neglible dam age to stringers, formed slun fla~es, bulkhead chan nels, and like parts is similar to that for the wing stringers and ribs, outlined In par agraph 17-19.
17-57. REPAIRABLE DAMAGE. Fuselage skin re pairs may be accomplished in the same manner as wing skin repairs outlined in paragraph 17-16. Stringers, formed skin flanges, bulkhead channels, and simUar parts may be repaired as shown in figure 17-5. 17-58. DAMAGE NECESSITATING REPLACEMEN'l OF PARTS. Fuselage skin major repairs may be accomplished in the same manner as the wing re pairs outlined in paragraph 17-17. Damaged fittlng1 should be replaced. 17-59. FIREWALL DAMAGE may be repaired by removing the damaged material and splicing in a new section of material. The new portion should be lapped over the old material, sealed with Pro Seal 11700 (Coast Pro-Seal Co., Chemical Division, 2235 Beverly Blvd, Los Angeles, California), com• pound or equivalent, and secured with stainless steel rivets. Damaged or deformed angles and stiffeners may be repaired as shown in figure 17-10, or they may be replaced. A severely damaged fire wall should be replaced as a unit. Seal around all holes and openings in fi rewall with Pro-Seal 1#700 compound or equivalent. 17-60. ENGINE COWLING. 17-61. REPAIR OF COWLING SKINS. lf extensively damaged, complete sections of colwing should be re placed. Standard insert-type skin patches, however, may be used if repair parts are formed to fit. Small cracks may be stop-drilled and dents straightened if they are reinforced on the inner side with a doubler of the same material. 17-62. REPAIR OF REINFORCEMENT ANGLES. Cowl reinforcement angles, if damaged, should be replaced. Due to their small size they are easier to replace than to repair. 17-63. BONDED FORWARD ACCESS .DOORS. 17-64. REPAIRABLE DAMAGE. Bonded doors may
be repaired by the same method used for rivited
structure. Rivets are a satisfactory substitute for bonded seams on the assemblies. The strength of the bonded seams may be replaced by a single 3/ 32 , 2117 -AD rivet per running inch of bonded seam. The standard repair procedures outlined in AC 43. 13-1 are also applicable to bonded doors . 17-66. FUSELAGE TUBULAR STURCTURE. 17-67. The fuselage tubular structure, illustrated in figure 17-11, is fabricated of chrome- molybdenum 4130 steel aircraft tubing welded together . Gussets, channels, angles, tabs and fittings, also of 4130 steel, are welded to the tubular assembly to complete the structure. The structure is not heat treated. 17 -68. GENERAL CONSIDERATIONS. Federal Aviation Regulations, Part 43, list persons author ized to perform repairs and outlines standards of performance. Given In these standards of perfor 17-11
MODEL 188 & T188 SERIES SERVICE MANUAL
~-
PATCHES AND DOUBLERS 2024-T3 ALCLAD MS20470AD4 RIVETS 24 REQD
r--
!
6. 50 DIA.-----t
~ 4 · 00 DIA =-1
# ~-----7. ~
I
PATCH
~DOUBLER :=:}'
50 DIA.
SECTION T HRU PATCH 3. 00 DIA. HOLE
PATCH REPAffi FOR 3 INCH DIAMETER HOLE MS20470AD4 RIVETS 16 REQD
t - 4. 00 DIA . 3.00 DIA.-
1-+
-1 ·I I
PATCH
EXISTING SKIN 2. 00 OIA. HOLE
SECTION THRU PATCH PATCH REPAIR FOR 2 INCH DIAMETER HOLE
2. 50 DIA.
MS20470AD4 RIVETS
8 REQD
EXISTING
SKIN
PATCH (NO DOUBLER REQD)
-i 1. 00 DIA. HOLE
~
1.75 DIA.
SECTION THRU PATCH
PATCH REPA1R FOR 1 INCH Dl.Al\1ETER HOLE
c=J
ORIGINAL PARTS
IIlliilllillTIJ
RE PAm PARTS
-
REPAIR PARTS IN CROSS SECTION
OVERLAPPING
CIRCULAR PATCH
Figure 17-4. Skin Repair (Sheet 1 of 6)
17-12
MODEL 188 & T188 SERIES SERVICE MANUAL
SECTION THRU ASSEMBLED PATCH
A-A EDGE MARGIN = 2 X RIVET DlA. PATCH -
2024-T3 ALCLAD
1/ 2" RADIUS
1/ 2" RADIUS EDGE MARGIN = 2 X RIVET DlA.
OOUBLER -
2024- T3 ALCLAD
RIVET TABLE
c=J
-
ORIGINAL PARTS
OVERLAPPING RECÂ TANGULAR PATCH
!H::~:;q REPAIR PARTS REPAIR PARTS IN CROSS SECTION
SKIN GAGE
RIVET DIA.
.020 . 025 . 032 .040 .051
1/ 8 1/ 8 1/8 1/ 8 5/ 32
Figure 17-4. Skin Repair (Sheet 2 of 6)
17-13
MODEL 188 & T188 SERIES SERVICE MANUAL
EXISTING SKIN DOUBLER_/ SECTION THRU ASSEMBLED PATCH
NOTE For optimum appearance and airflow, use !lush rivets, dim pled skin and patch, a nd counter sunk doubler.
A-A ---+-- EDGE MARGIN = 2 X RIVET DIA. PATCH -
2024-T3 ALCLAD
1/ 2" RADIUS --o.t...
EDGE MARGIN = 2 X RIVET' DIA .
CLEAN OUT DAMAGED AREA SKIN
.......;1---+-:..- EDGE MARGIN :
2 X RNET DIA.
DOUBLER ALCLAD
2024-T3
1/ 2" RADIUS
ORIGINAL PARTS
I
I
FLUSH RECTANGULAR PATCH
(CIRCULAR FLUSH PATCH IS SIMILAR)
REPAIR PARTS REPAIR PARTS IN CROSS SECTION
Figure 17 - 4. 17-14
Skm Repair (Sheet 3 of 6)
RI VET TABLE SKIN GAGE
. 020 .025 ' 032 . 040 .0 51
RIVET DIA. 1/8 1/ 8 1/8 1/ 8 5/ 32
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Countersink doublers, and dimple skin and patch.
A-A
EDGE DISTANCE
2D MIN.
t
!
i~
. 50 R. MIN. TYPICAL
I
I I I
RI YET TR BLE SKIN GAGE
RIVET DIA.
.020 .025 .032 .040 . 051
1/8 1/ 8 1/ 8 1/8 5/ 32
PATCH 2024-T3 ALCLAD
FLUSH PATCH AT STRINGER/ BULKHEAD INTERSECTION
c=)
ORIGINAL PARTS
F':' ::-fj
REPAIR PARTS
-
REPAIR PARTS IN CROSS SECTION
NOTE This procedure is not rec ommended in areas where s tringers a r e nveted to bulkheads.
Figure 17-4. Skin Repa1r (Sheet 4 of 6)
17 - 15
MODEL 188 & T188 SERIES SERVICE MANUAL
OOUBLERSh EXISTING SKIN
8D
1/ 4 B (BUT NOT LESS THAN 4D)
_
r-
I
A-A SECTION THRU ASSEMBLED PATCH
CARRY EXISTING RIVET PATTERN THRU PATCH
PITCH TYPICA L F OR
PATCH SKIN & OOUBLER
(4-8D)
EXISTING SKIN 0. 5" MIN. RADIUS
TYPICAL
'-::iii~-----+
RIVET TABLE SKIN GAGE . 020 . 025 . 032 .040 .051
RIVET DIA.
r---t- SPACER
2024-T3 ALCLAD
1/8 1/ 8 1/ 8
1/ 8
5/ 32
OVERLAPPING PATCH AT STRINGER/ BULKHEAD INTERSECTION
I
I ORIGINAL PARTS
H ::~:::::1
REPAIR PARTS
-
REPAIR PARTS IN CROSS SECTION
...__--PATCH 2024-T3 ALCLAD
Figure 17-4. Skin Repa1r (Sheet 5 of 6)
17-16
EDGE DISTANCE 2D MIN.
MODEL 188 8t T188 SERIES SERVICE MANUAL
FUSELAGE SKIN
CLEAN OUT DAMAGED AREA
A-A PICK UP EXISTING SKIN RIVET PATTERN
10 RlVETS EACH SIDE OF DAMAGED AREA FILLER -
2024-T4 ALCLAD \_DOUBLER- 2024-T4 ALCLAD
MS20470AD4 RIVETS
c=J ~ :::::::: -
ORIGiNAL PARTS
:I REPAffi
PARTS
REPAffi PARTS IN CROSS SECTION
F1gure 17-4. Skin Repair (Sheet 6 of 6)
17 - 17
MODEL 188 & T188 SERIES SERVICE MANUAL
DOUBLER -
2024-T4 ALCLAD
RIVET SPACING TO MATCH
6 RIVETS EACH SIDE OF DAMAGED AREA
STRINGER
CLEAN OUT DAMAGED AREA
FILLER -
2024-T4 ALCLAD
J', A-A
MS20470AD4 RIVETS
SKIN
ORIGINAL PARTS REPAffi PARTS -
REPAffi PARTS IN CROSS SECTION
Figure 17-5. Stringer and Channel Repair (Sheet 1 of 4) 1
1
MODEL 188 & T188 SERIES SERVICE MANUAL
FILLER -
2024-T4 ALCLAO
A-A STRIP -
2024-T3 ALCLAO
1/ 4" EDGE MARGIN
STRINGER - - PICK UP EXISTING SKIN RIVETS
c=::J c=J -
ORIGINAL PARTS REPAIR PARTS
A
SKIN
REPAIR PARTS IN CROSS SECTION
Figure 17-5. Stringer and Channel Repair (Sheet 2 of 4) 17 - 19
MODEL 188 & T188 SERIES SERVICE MANUAL
/ OOUBLER -
2024-Tl ALCLAD
~SKIN
D
ORIGINAL PARTS
~ REPAIR PARTS ~ -
REPAIR PARTS IN CROSS SECTION
Figure 17-5. Stringer and Channel Repair (Sheet 3 of 4) 17-20
MODEL 188 8t T188 SERIES SERVICE MANUAL
F ILLER- 2024-T4 ALCLAD DOUBLER- 2024- T3 ALCLAD
A-A CLEAN OUT DAMAGED AREA
2 ROWS RIVETS OUTBOARD OF LIGHTENING HOLE CHANNEL
A~
I
I
A~
c:=J
ORIGINAL PARTS
b~:::: 'id REPAffi PARTS -
REPAffi IN CROSS SECTION
Figure 17-5. Str inger and Channel Repair (Sheet 4 of 4) 17-21
MODEL 188 & T188 SERIES SERVICE MANUAL
STOPDRILL CRACK IF CRACK DOES NOT EXTEND TO EDGE OF PART
DOUBLER 2024-T3 AL CLAD - - ,
A-A
MS20470AD4 RIVETS ORIGINAL PARTS
L..-- .J)
RE PAJR PARTS REPAIR
PA RTS~
C ROSS SECTION
Figure 17- 6 . 17 - 22
Rib and Bulkhead Re pair (Sheet 1 of 2)
MODEL 188 & T188 SERIES SERVICE MANUAL
1/4" EDGE MARGIN
~-~ONE
ROW RIVETS AROUND DAMAGED AREA
- ._ _,J ORIGINAL PARTS
f', ~
<
I REPAIR PARTS
A-A
REPAlR PARTS IN CROSS SECTION Figure 17-6.
Rib and Bulkhead Repair (Sheet 2 of 2)
17-23
MODEL 188 & T188 SERIES SERVICE MANUAL
'
FILLER -
2024- T 4 ALCLAD
~
a-FILLER -
----'"~_':Z.:~~~:~,. :.
2024-T4 ALCLAD
~/f.!%f.~l~~;.~m>.~ CLEAN OUT DAMAGED AREA
3/8" RADIUS
ANGLE 2024-T4 ALCLAD SPAR
3/ 8" EDGE MARGIN (TYPICAL)
~
ORIGINAL PARTS
A
'~
J
r .:':./·~·>J
REPAIR PARTS
-
REPAIR PARTS IN CROSS SECTION
Figure 17 -7. Wing Spar Repair (Sheet 1 of 3) 17 -24
A-A
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE
F1LLER -
This repair applies to e ither fr ont or rear spar if tht: s par is a single channel.
2024-T4 ALCLAD
•
• •
1/ 4" EDGE MARGIN (TYP. ) CLEAN OUT DAMAGED AREA
ANGLE - - --.._ 2024-T4 ALCLAD 7/ 8 X 7/ 8 X .064
1/ 4" MINYMUM EDGE MARGIN
3/ 4" RIVET SPACING (TYPICAL ALL PARTS)
DOUBLER -
3 ROWS RIVETS EACH SIDE OF DAMAGED AREA
2024 - T4 ALCLAD
'--- - 1/ 4" EIXiE MARGIN (TYP.)
MS20470AD4 RIVETS
r=J ORIGINAL PARTS [:, :::d REPAffi PARTS -
REPAffi PARTS IN CROSS SECTION
A-A
F igure 17-7. Wing Spar Repair (Sheet 2 of 3)
17 - 25
MODEL 1 88 8t T188 SERIES SERVICE MANUAL
FILLER ALCLAD
2024-T4
3/ 4" RIVET SPACING
A-A \---
-ANGLE -
MS204 70AD4 RIVETS - - - '
ORIGINAL PARTS
@»&"'~ -
)
REPAIR PARTS REPAIR PARTS IN CROSS SECTION
Figure 17 - 7. 17-26
Wing Spar Repa1r (Sheet 3 of 3)
2024-T4 ALCLAD
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTES : 1. Dimple leading edge skin and filler material ; countersink the doubler. 2. Use MS20426AD4 rivets to install doubler. 3. Use MS20426AD4 rivets to install filler, except where bucking is impossible. Cherry (blind) rivets where regular rivets cannot be bucked.
Use CR162-4
4. Contour must be maintained; after repair has been completed, use epoxy !lller as necessary and sand smooth before painting. 5. Vertical size is llmited by ability to install doubler clear of front spar . 6. Lateral size is limited to seven inches across trimmed out area. 7. Number of repairs is limited to one in each bay.
1" MAXIMUM RIVET
SPACING (TYPICAL)
'
v u
(J ....... ,
'V
<::.- ' ,
c.' -,(' ..;(
'c/V /
'-'
"--5/ 16" MINIMUM EDGE MARGIN (TYPICAL)
TRIM OUT DAMAGED AREA
PAffi DOUBLER 2024-T3 ALCLAD . 040" TmCKNESS
0
ORIGINAL PARTS
0
REPAIR PARTS
....___ . ,.,LLER MATERIAL 2024-TJ ALCLAD SAME THICKNESS AS SKIN
F 1gure 17-8.
LEADING EDGE SKIN
Leading Edge Repair 17-27
MODEL 188 & T188 SERIES SERVICE MANUAL
S-1443-1 DOUBLER
VIEWED F ROM INSIDE WING LOOKING DOWN AT TOP OF LOWER WING SIGN. #40 (.098) HOLE (10 REOO)
LOWER WING SKIN (REF)
5.062 S- 225- 4F COVER
MS20426A03 RIVETS
NOTE PARTS ARE AVAlLABLE F ROM T HE CESSNA SERVICE PARTS CENTER.
S-1022Z- 8 - 6 SCREWS
PRECAUTIONS 1. Add the minimum number of access holes necessary. 2. Any circular or rectangular access hole which is used with approved optional equipment installa tions may be added in lieu of the access hole illustrated. 3. Use landing light installations instead of a dding access holes where possible. Do not add access holes at outboard end of wing; remove wing tip instead. 4. Do not add an access hole in the same bay where one is already located. 5. Locate new access holes near the center of a bay (spanwise). 6. Locate new access holes forward of the front spars as close to the front spar as practicable. 7. Locate new access holes aft of the front spar between the first and second stringers aft of the spar. When installing the doubler, rotate it so the two straight edges are closest to the stringers. 8. Alternate bays, with new access holes staggered forward and aft of the front spar, are pr e
ferable.
9. A maximum of five new access holes in each wtng IS permissible; ii more are required, contact
the Cessna Service Department.
10. When a complete leading edge skin is being replaced, the wing should be supported in such a manner so that wing alignment is maintained.
a.
Establish exact location for inspection cover and insc r ibe centerlines.
b.
Determine position of doubler on wing skin and center over centerlines. Mark the ten rivet hole locations and drill to size shown.
c. Cutout access hole, using dimensiOn shown. d.
Flex doubler and msert through acc ess hole. and n vet m place.
e.
Pos1t1on cover and secure. using screws as shown.
Figure 17 - 9. Access Hole Installation 17-28
MODEL 188 & T188 SERIES SERVICE MANUAL
1/ 4" EDGE MARGIN CLEAN OUT DAMAGED AREA
ANGLE -
10 RIVETS EACH SIDE OF DAMAGED AREA
A-A
2024 - T4 ALCLAD
__,....._........~
FIREWALL ANGLE FILLER -
2024-T4 ALCLAD
....-Â- - FffiEWALL
C=:J
ORIGINAL PARTS REPAIR PARTS
-
REPAIR PARTS IN CROSS SECTION
Figure 17-10. Firewall Angle Repair 17-29
MODEL 188 & T188 SERIES SERVICE MANUAL
mance are instructions for repair of tubular members, including cluster repairs, split- sleeve reinforce ments, welded-patch repairs, splicing by inner sleeve method, splicing by outer sleeve method and splicing by using larger diameter replacement tube. 17-68. NEGLIGffiLE DAMAGE. Negligible damage
Service Department. Figure 17-lllists the size and wall thickness of each tube used in the structure, along with size and wall thickness of repair tube for each. Structural alignment, shown in figure 17-1, must be maintained, NOTE
of fuselage tubing should be limited to small smooth
dents, shallow scratches, and minor bowing of tulr ing, not in the middle third of the tube. 17-69. REPAIRABLE DAMAGE. Dents at a cluster may be repaired by a finger type welded patch. Dented, cracked, or otherwise damaged tubes may be repaired by a welded split- sleeve reinforcement, after straightening the damaged part and stop drill ing cracks with a No. 40 (. 98) drill. Dents or holes 1n tubes which are not 1n the middle third of the tube and do not result in the patch overlapping a joint may be repaired by a welded patch, one gage thicker, U the dents are not deeper than one-tenth of the tube diameter, do not involve more than one-fourth of the tube circumference, and are not longer than the tube diameter; U dents are free from cracks, abrasions and sharp corners; and if the dented tubing can be substantially reformed without cracking before ap plication of the patch. Holes must not be longer than tube diameter and must not involve more than one fourth of tube circwnference. 17-70. DAMAGE NECESSITATING REPLACEMENT OF PARTS. U extenSive damage has occurred, it is recommended that the complete fuselage tubular structure assembly be replaced. Where damage ex ceeds that specified as negligible or repairable, par tial replacement is required. Three methods of splicing in partial replacement tubes are acceptable, all of which are standard procedures outiined 1n Federal Aviation Regulations, Part 43. Splicing by the inner sleeve method is recommended where a smooth tube surface is desired. Splicing by using a larger diameter replacement tube requires the least amount of cutting and welding, but cannot be used where the damaged tube is cut too near adjacent clusters or where brackets and the like require the same size tube, Splicing by the outer sleeve method requires the greatest amount of welding and should be used only where the other splicing methods are not suitable. U it should become necessary to re pair a major attach point fitting, consult the Cessna
SHOP NOTES:
17-30
Refer to Section 18 for required priming after a welded repair has been accomplished. 17 -71. ENGINE MOUNT. 17-72. DESCRIPTION. The mount for the aircraft engine is constructed of 4130 chrome-molybdenum steel tubing. A truss structure, fastened to the fire wall at four points, supports a cradle arrangement. This cradle arrangement, With its supporting lugs, forms the base for rubber shock mounted engine sup ports. Engine mounts are illustrated in figure 17-12. 17-73. GENERAL CONSIDERATIONS. All welding on the engine mount should be of the highest quality since the tendency of vibration is to accentuate any minor defect present and cause fatigue cracks. En gine mount members are preferably repaired by using a large diameter replacement tube, telescoped over the stub of the original member using fishmouth and rosette type welds. However, reinforced 30-degree scarf welds in place of the fishmouth welds are con sidered satisfactory for engine mount repair work. 17 -74. ENGINE MOUNT SUPPORT CRADLE DAM AGE . Minor damage such as a crack adjacent to an engine attachlng lug may be repaired by rewelding the cradle tube and extending a gusset past the dam aged area. Extensively damaged parts should be re placed. 17-75. DAMAGE INVOLVING ENGINE MOUNTING LUGS AND ENGINE MOUNT TO FUSELAGE ATTACH ING FITTINGS. Engine mounting lugs and engine mount to fuselage attaching fittings should not be re paired but should be replaced. 17-76. BAFFLES ordinarily should be replaced U damaged or cracked. However , small plate rein forcements riveted to the baffle will often prove satisfactory both to the strength and cooling require ments of the un.it.
MODEL 188 & T188 SERIES SERVICE MANUAL
TAILCONE FITTINGS
LANDING GEAR flTTINGS NOTE
This illustration shows the complete fuselage tubular str uctu r e assembly, whtch may be re placed as a unit. Refer to Sheets 3 thru 6 for tndividual tube diameters and wall thicknesses.
Figure 17-11.
Fuselage Tubular Structure (Sheet 1 of 6) 17-31
MODEL 188 & T188 SERIES SERVICE MANUAL
AGtruck ONLY
NOTE
Tubes not called out on this sheet
for the AGtruck are the same as
those called out on Sheets 3, 4 , 5
and 6.
11
WlliG STRUT F1TTINGS
15
6
ENGINE MOUNT FITTINGS
LANDING GEAR FITTINGS
â&#x20AC;¢ Beginning with atrcra!t serial 18801425
Figure 17-11. 17 -32
Fuselage Tubular Structure (Sheet 2 of 6)
MODEL 188 & T188 SERIES SERVICE MANUAL
11
11 11
15 11
11
••
22 • 6 13
9
4
NOTE
Tube diameters and wall thicknesses for the
original tubes, inside sleeves, and outside
sleeves are listed in the chart on Sheet 6
Figure 17-11.
21
2
D Beginning with aircraft serial 18803377 0 Thru aircraft serial 18800807 •• Beginning with aircraft serial 18800808
• Beginning with aircraf t serial 18800079
•• Beginning with aircraft serial 18800137
*Aircraft serial 18800833 thru 18803376
• Beginning with aircraft serial 18801425
• Beginning with airc r aft serial 18801825
* Thru aircraft serial 18801659
* * Beginning with aircraft serial 18801660
Fuselage Tubular Structure (Sheet 3 of 6) 17 -33
MODEL 188 & T188 SERIES SERVICE MANUAL
1 11
1
1 1
11
5
1 1511
9
5
2
5
9
24
9
9
9
9 /
.............
. . ......... /
.....
··.....
··.....
9 1
4
•10 16 25 25 16
25 NOTE Tube diameter s and wall thicknesses for the original tubes, inside sleeves, and outside sleeves are listed in the chart on Sheet 6.
Figur e 17- 11. 17-34
Fuselage Turular Structure (Sheet 4 of 6)
5
MODEL188 & T188 SERIES SERVICE MANUAL
. 11 11
7
1 1
2
2 7 7
2
·.·· .....
·..
15
16
18 ,
NOTE Tube diamete r s and wall thiCknesses !o r the original tubes , ins1de sleeves, and outside sleeves ar e listed in the chart on Sheet 6.
Figur e 17 - 11.
Fuse lage Tubular Structure (Sheet 5 of 6)
17 -35
-
MODEL 188 & T188 SERIES SERVICE MANUAL
OUTSIDE
SLEEVE
ORIGINAL
INSIDE
SLEEVE
TUBE NUMBER
TUBE DIAMETER
1
1/ 2
. 035
5/8
. 035
3/ 8
. 049
2
5/ 8
. 035
3/ 4
. 035
1/2
. 058
3
5/ 8
. 049
3/ 4
. 058
1/ 2
.058
4
5/ 8
. 058
3/ 4
. 058
1/ 2
. 058
5
3/ 4
. 035
7/ 8
. 035
5/ 8
. 058
6
3/ 4
. 049
7/ 8
. 049
5/ 8
. 058
7
3/ 4
. 058
7/ 8
. 058
5/ 8
. 058
8
3/ 4
.065
7/8
. 058
1/ 2
.065
9
7/ 8
.049
1
. 049
3/ 4
.065
10
7/ 8
. 058
1
. 058
3/ 4
.065
WALL
THICKNESS
TUBE DIAMETER
WALL
THICKNESS
TUBE DIAMETER
WALL
THICKNESS
11
1
. 049
1 1/ 8
. 049
7/ 8
. 083
12
1
. 058
1 1/ 8
. 058
7/ 8
. 083
13
1
. 065
1 1/ 8
. 058
7/ 8
.083
14
1 1/ 8
. 049
1 1/4
. 049
1
. 083
15
1 1/ 8
. 058
1 1/ 4
. 058
1
. 095
16
1 1/ 4
. 049
1 3/ 8
. 049
1 1/ 8
. 083
17
1 1/ 4
. 065
1 3/ 8
. 058
1
.095
18
1 1/ 4
. 095
1 1/ 2
. 095
1
. 095
19
1 1/4
. 120
1 1/ 2
.120
1
• 095
20
1 1/4
.125
1 1/ 2
.125
1
. 095
21
1 3/ 8
. 058
1 1/ 2
. 058
1 1/ 4
. 083
22
1 3/ 8
. 083
1 5/ 8
.125
1 1/ 8
. 095
23
1 3/ 8
.095
1 5/ 8
• 095
1 1/8
.095
24
1 1/ 2
. 049
1 5/ 8
. 049
1 3/ 8
.083
25
1 5/ 8
.065
1 3/ 4
. 058
1 3/ 8
.125
26
1 5/ 8
• 095
1 7/ 8
. 095
1 3/ 8
.125
27
1 7/ 8
. 083
2 1/ 8
. 095
1 5/ 8
.125
,058 NOT APPLICABLE
NOT APPLICABLE 3/ 8 . 049
1 5/ 8 1 3/ 8 . 058 . 083 1 1/ 2 29 TUBE NUMBERS REFER TO CORRESPONDING NUMBERS LISTED ON PRECEDING PAGES. 28
Figure 17- 11. 17-36
Fuselage Tubular Structure (Sheet 6 of 6)
MODEL 188 & T188 SERIES SERVICE MANUAL
4
3
ORIGINAL TUBE NUMBER
TUBE WALL DIAMETER THICKNESS
REPLACE MENT TUBE DIAMETER
WALL T HICKNESS
I 1/ 4
7/ 8 3/ 4
5/8 1 3/ 8
1<;!. . . .
MODEL 188 & T188 SERIES SERVICE MANUAL
17-77. REPAIR OF HOPPER.
(See figure 17-13.)
d. Prepare a sufficient number of glass-fiber cloths to restore original thickness of damaged area. Trim the first piece of cloth to fit two inches beyond the chamfered area, then trim each succeeding piece slightly smaller than the preceding one. Trim the final inside cloth (type 128 or equivalent) to overlap the other laminations as illustrated. e. Mix the adhesive according to directions fur
nished.
f. Coat chamfered area, and two inches beyond chamfer, with the adhesive. Place the first pre cut piece of cloth in position on the coated area, then work additional adhesive into the fabric to impreg nate it completely. g. Apply subsequent patches, each slightly smaller
than the preceding one, using same laminating tech
nique, unW original thickness has been restored.
Use sufficient adhesive to assure a resin- rich sur
face and to preclude any wicking of the fabric.
h. Coat prepared surface on outside of hopper with
the adhesive and apply one layer of cloth, using same
teclmique.
1. Allow repair to cure a minimwn of 12 hours at 70°F, or four hours at 130°F, Proportionally longer curing time is required in cooler temperature. j. U the surface of the repaired area inside the hopper is rough enough to trap chemicals, sand smooth and apply additional adhesive to assure a smooth resin- rich surface, then allow to cure.
17-78. The hopper is constructed of glass-fiber re inforced plastic. An extensively damager hopper , or one which has damage to stiffening beads, fittings , or metal components embedded in the plastic, should be replaced. With these exceptions, cracked punctured, or otherwise damaged areas may be repaired. Any repairs must restore at least the original strength to the repaired area. Although repairs may be made without removing the hopper, it is generally more practicable to remove it.
!WARNING' The hopper must be thoroughly cleaned of
toxic materials. Extreme care must be
used to avoid inhalation or ingestion of
material removed from the hopper lami
nate.
NOTE A laminating kit (SK188-1), a filler kit
(SK188-2), and a sealer kit (SK188-3)
are available from the Cessna Service
Parts Center. Two types of glass-fiber
cloth are included in the laminating kit.
Type HG63 is a coarser, thicker cloth
than type 128. Type HG63 is used for
all laminations except the final one, for
which type 128 is used. The sealer kit
is the same adhesive contained in the
laminating kit, but is packaged separately.
17-79. REPAIR OF CATWALK.
(See figure 17-14.)
17-80. The catwalk is constructed of glass-fiber re inforced plastic skins, bonded to an aluminum honey comb core. An adhesive-backed wing walk with rough surface is then applied to the catwalk. An extensively damaged catwalk should be replaced. Damaged areas may be repaired in accordance with the following in structions. Any repairs must restore at least the original strength to the repair ed area. It is not neces sary to remove the catwalk for repairs, although the wing walk must be removed by carefully peeling it
a, Cut and trim out all damaged material, leaving an opening that is without square corners. b. Chamfer inside edges to approximately 15 de grees as illustrated. c. Remove the whitesurfacing material inside hop per by sanding with a coarse abrasive for two inches beyond the cham!ered area. Remove surface glo ss. on outside of hopper in the same manner.
___£"DAMAGED AREA
---------------------------------------
~
15°
------------:::::=-'- 1- 1/2"~ MAX. IN
INNER SURFACE OF HOPPER
7
TYPE 128 OR EQUTVALENT (FINAL LAMINATION ONLY)
_/
-r:t(--:;?-- - - - - - - - -
ANY DIRECTION
ijtiB
~
y
GLASS- FIBER LAMINATIONS (TYPE HG63 OR EQUIVALENT)
Figure 17- 13. Hopper Repair 17 - 38
~
MODEL 188 & T188 SERIES SERVICE MANUAL
back as required to expose the damaged area. Pre vent damage to the wing walk material and protect the adhesive backing from sanding dust and other foreign matter. Damage to the catwalk is divided into the following categories: CLASS I: Cracks or punctures penetrating outer skin only, without apparent'delamination between skin and honeycomb core or damage to core. CLASS n: Cracks, punctures, or locally crushed areas, accompanied by delamination between outer skin and honeycomb core, but without delamination between core and inner skin. CLASS ill: Class ll damage accompanied by damage - to honeycomb core, with or without delamination between core and inner skin, but without damage to inner skin. CLASS IV: Puncture of total composite, accompanied by delamination between honeycomb and both skins. NOTE
I
A laminating kit (SK188-1), a filler kit
(SK188- 2), and a sealer kit (SK188-3)
are available from the Cessna Supply
Division. Two types of glass- fiber
cloth are included in the laminating.kit. Type HG63 is a coarser, thicker cloth than type 128. Type HG63 is used for all laminations except the final one, for which type 128 is used. The sealer kit is the same adhesive contained in the laminating kit, but is packaged separately.
REPAIR OF CLASS I DAMAGE. The purpose at re pairing Class I damage is to seal the catwalk to p re vent deterioration from moisture. It is assumed that structural integrity is not involved. a. Thoroughly clean the area with acetone, ketone, or other similar solvent that leaves no residue . b. Remove surface gloss in damaged area, and for at least one inch by sanding with a coarse abrasive . c. Prepare a piece of glass-fiber cloth (type 128 or equivalent} to fit one inch beyond the damaged area. d. ML"t the adhesive according to directions fur
nished.
e. Work some of the adhesive into the crack or puncture, and brush a thin film over the sanded area, after making sure it is free from sanding dust. f . Place the pre- cut cloth in position, then work additional adhesive into the fabric to impregnate it completely and seal the damaged area. Use sufficient adhesive to assure a resin-rich surface. g. Leave repaired area exposed until adhesive is no longer tacky (about four hours}, then smooth edges ii necessary. Reinstall wing walk. h. Allow repair to cure a minimum of 12 hours at 70°F, or four hours at 130°F. Proportionally longer curing time is required in cooler temperature. REPAIR OF CLASS ll DAMAGE. a. Thoroughly clean the area with acetone, ketone,
or other similar solvent that leaves no re.sidue.
b. Establish and mark each delaminated area, then mark a smooth contour which encompasses all dam.:. age. NOTE An easy and reliable way to establish de laminated areas is to tap all suspected areas with a heavy coin, listening to the sound made by the coin. A solid sound results where areas are not delaminated, but a lighter sound is readily detected in delaminated areas. c. Remove outer skin in area marked. Scribe the · marked area smoothly, without sharp corners, then cut through the skin by r .e peatedly dragging the end tooth of a hacksaw blade along the scribed line. Once an edge of the skin in the damaged area has been lift ed, the skin may then be removed by peeling it back to break the bond with the honeycomb, thus leaving the honeycomb undamaged. d. Remove surface gloss for two inches beyond
opening by sanding with a coarse abrasive.
e. Prepare two pieces of glass-fiber cloth (type HG63 or equivalent), one to fit the open area and the other to fit twq inches beyond the open area. Pre pare one additional piece of cloth (type 128 or equiv alent) also to fit two inches beyond the open area. This is the cloth to be applied next to the wing walk. f. Mix the filler material according to directions furnished . g. Fill all exposed honeycomb, flush with the top of the core, with this putty-like mixture. h. Mix the adhesive according to directions fur nished. 1. Brush a thin film of adhesive over the sanded area and a relatively wet coat over the honeycomb area. j . Place the piece of glass-fibercloth that was pre-cut to the size of the opening in position, then work additional adhesive into the fabric to impreg nate it completely. Apply the second and third pieces of pre- cut fabric to overlap the open area two inches, using same laminating technique. Use sufficient ad hesive to assure a resin-r~ch surface. k. Leave repaired area exposed until adhesive is no longer tacky (about·four hours), then smooth edges if necessary. Reinstall wing walk. 1. Allow repair to cure a minimum of 12 hours at 70°F, or four hours at 130°F. Proportionally longer curing time is required in cooler temperature. REPAIR OF CLASS ill DAMAGE.
a. Thoroughly clean the area with acetone, k·etone or other similar solvent that leaves no residue. b . Carefully remove outer skin. Also determine the extent at delamination (U any) between undamaged honeycomb cor e and inner skin by careful probing, since the outer skin must· also be removed to repair these areas. Remove any damaged honeycomb core. c. If any delamination between core and inner skin was found, mix the adhesive according to directions furnished, then apply this adhesive by working it down ~through the honeycomb core. Use sufficient Reviaion 1
17-39
MODEL 188 & T188 SERIES SERVICE MANUA.l CLASS II
CLASS I
TYPE 128 OR EQUIVALENT (FINAL LAMINATION ONLY) TYPE 128 OR EQUIVALENT
FILL HONEYCOMB WITH FILLER MATERIAL
'\__DAMAGED AREA
CLASS
m
CLASS IV /TYPE 128 OR EQUIVALENT (FINAL LAMINATION ONLY)
TYPE 128 OR EQUIVALENT (FINAL LAMINATION ONLY)
I
FILL HONEYCOMB AND CAVITY WITH FILLER MATERIAL AFTER REPAIRING ANY DELAMINATION OF INNER SKIN
ALUMINUM PATCH
0 ~~~
m
GLASS- FIBER CLOTH HONEYCOMB CORE
Ftgure 17-14. Catwalk Repatrs 17-40
FILL CAVITY WITH FILLER MATERIAL AFTER ALUMINUM PATCH HAS BEEN INSTALLED
MODEL 188 8t T188 SERIES SERVICE MANUAL
1/4" MINIMUM EDGE MARGIN USE EXJSTING RIVET PATTERN AND RIVET SIZE
CUT OUT DAMAGED AREA
~
CJ
PATCH MAY OVERLAP OR BE INSERTED UNDER EXlSTING AILERON SKIN
ORIGINAL PART
. . REPAIR PATCH IN CROSS SECTION
A-A Figure 17-15.
Cor rugated Skin Repair 17-41
MODEL 188 & T188 SERIES SERVICE MANUAL
Q) Use rivet pattern at wing station
23. 62 for repair from wing sta tion 23.62 to w1~ station 85. 87. Use rivet pattern at wing station 100. 50 for lap splice patterns from wt~ station 100. 50 to 190. 00. See figure 1-2 for wing stations.
(Duse rivet spacing similar to the pattern at wing station 100. 50 at leading edge ribs between lap splice~.
Select number of flush rivets to be used at each wing station leading edge rib from table. RIBS:
Blind rivets may be substituted for solid rivets in proportionally in creased numbers in accordance with the table. SPARS:
Blind rivets may be installed in wing spars only in those locations where blind rivets were used du ring original manufacture , ie fuel bay areas of front spars on air craft with integral fuel bays. For additional instructions on blind rivet substitutions, refer to paragraphs 17-82 thru 17-85.
NUMBERS OF FLUSH RIVETS IN DIMPLED S KIN RE QUIRED IN REPLACEMENT LEADING EDGE SKIN WING
STATION RIB
CR2248-4
18 15 11 10 10
22 18 13 12 12
118 136 154 172 190
EXISTING TA CK RIVET _ _.........
BLnm
SOLID MS20426-4
EXISTING RIVET PATTERN TYPICAL LEADING EDGE SE CTION
Figure 17 -16. 17-42
Bonded Leading Edge Repair
MODEL 188 & T188 SERIES SERVICE MANUAL
adhesive to provide generous fillets at the core-to skin junction, to repair the delamination. d. Mix the filler material according to directions
furnished, fill the exposed honeycomb core and
cavity, and complete the repair per Class 11, steps
"d" thru "1."
REPAIR OF CLASS rv DAMAGE. a. .Thoroughly clean the area With acetone, ketone,
or other similar solvent that leaves no residue.
b. Carefully remove outer skin, honeycomb core, and inner skin to remove all damage and delamination. Remove additional outer skin and honeycomb core as necessary to provide a two-inch bearing area around periphery of opening in inner skin. c. Cut out an aluminum patch (. 025" minimum thick ness) to overlap the inner skin opening one inch. Trim a piece of glass- fiber cloth to overlap the inner skin opening two inches. Cut a hole in the cloth to match the opening in the inner skin. d. Mix the adhesive according to directions fur
nished.
e. Brush the adhesive around opening in inner skin. Place the ring of cloth in position and thoroughly wet with the adhesive to provide a "bed" for the alumi num patch. . f. Clean the aluminum patch with acetone, ketone, or other similar solvent that leaves no residue, and brush the contacting area of the patch with the adhe sive. Place the patch in position. g. Mix the filler material according to directions furnished. h. Fill the cavity, flush with the top of the honey comb core, with this putty- like mixture. U a large area is being repaired, be sure to restore original wing contour. 1. Complete the repair per Class U, steps "d" thru "1." 17- 81. REPAIR OF GLASS-FIBER CONSTRUCTED COMPONENTS. Glass-fiber constructed components on the aircraft may be repaired as stipulated in Ser vice Kit SK182-12. Observe the resin manufacturer's recommendations concerning mixing and application of the resin. Epoxy resins are preferable for making repairs, since epoxy compounds are usually more stable and predictabh: than polyester and, in addition,
give better adhesion. 17- 82. SUBSTITUTING BLIND RIVETS FOR SOUD RIVETS. 17- 83. GENERAL CONSIDERATIONS. Where re placement of s olid r ivets is difficult due to limited acces s for proper driving and bucking, blind rivets may be used within the guidelines of these pr o cedures. BUnd rivets should not be used in main wing spars unless specified in a Cess na Service Kit, or when approved by the Ces s na Service Department. CR162, CR163, CR762 and CR763 rivets should not be used 1n structural load carryiAg members s uch as wing s pars, r ibs, stri ngers aod doublers or fuselage · bulkheads, longerons and fUting attachments. If there is any question concerning the us e of these rivets contact the Ce ssna Service Department. 17- 84. BLIND RIVET SUBSTITUTION. Blind r ivets may be subs tituted for solid rivets on a one- for:.one basis, e ither the same size or larger, provided that restr ictions outlined in paragraph 17-83 are met, shear stre ngth of the blind rivet is equivalent or greater than the solid rivet (see figure 17-17), and the rivet edge margin, spacing and grip length is in accordance with figure 17-18. When substitution on a one-for -one basis 1s not possible, refer to para graph 17- 85. 17-85. DETERMINING QUANTITY OF SUBSTITUTE BLIND RIVETS. Whe n shear strength cannot be maintained with a one-for -one substitution, additional blind rivets will be required. Determine the tot al number of blind rivets required by using figure 17- 17 with the following calculation~ shear strength of the solid rive t s ize multiplied by the number of solid r ivets in the row being replaced. Divide this total s hear str ength by the shear strength of the substitute blind rivet size. Round off the answer to the next highest whole number of substitute blind rivets re quired for that row. Maintain edge margin, spacing and grip length specified in figure 17- 18. 17-86. FASTENER SUBSTITUTION. For approved fastener substitutions, See figure 17-19.
SHOP NOTES :
Reviaion 1
17-43
I
MODEL 188 & T188 SERIES SERVICE MANUAL
PROTRUDI NG HEAD RIVETS IN SINGLE SHEAR srJ2 inch diameter
118 inch d~meter 0
Thick· neu of
0
.... ~
~~ VIa:
1/)
Thinnest :i Sheet
:io
0
II)
<
<
0
~ CJI
~~ <a:
:3 ....
InN
0
zo
a:
.016
. . ... ... . ... . ... .. . - . ......
.020
...
.025 .032 .040
.050 .063
.071 .080 .090
.100 .125
-.....
357 374 396 388
.. -.....
186 233 277 321 388
186 233 277 321 396 388
199 267 368 427 480 547 554
.... -... ... ..
388 388
............
388 ... .. ... ..
388 388 ......
388 ...
.........
-- ...
388
--
388 388
388
-... -... --- ...
0
<
M
~
N
M
a: 0
II)
<
.... ~
~~ In a:
0
1/)
:i o
:i
3/16 inch diametei'
M
<D .... a:
0
0
0
.... ~ VI
~~a:
<
~CJI ~~
M
InN
~~
M
a:
~
0
0
:i
(I')
:io
:3 .... a: 0
~0>
:::-or
(1')::::
<a:
zo
- - - -
---
----
-- -- - -
- - - -- - - --
Sel ect Shear strength of rivet for the thickness of the thinnest sheet c:J. ma · ter lal
bel ~
M
.... .... a: ~
0
- - -- - -- --- - -- -...... .. -.. -- -- -- 4'n 572
186 ... . ... . . ... . . ..... ... . .. ... ... ...... ... ...... ... ... ... ... 216 288 ... .. 245 .. .. .. ... ... . .. ... 228 .... .. . ... 318 ...... .. 286 286 305 377 330 445 445 473 395 551 368 368 428 503 - ..... 450 575 425 425 567 603 804 544 544 636 519 593 506 506 650 687 836 643 643 815 596 596 596 735 798 862 753 763 912 609 596 785 866 639 ... ... 596 ... 823 823 976 837 940 .... 596 660 .. ... 596 862 862 1042 596 596 ... 976 .. 862 862 1115 696 ... ... 1013 ...... 862 862 1128 725 596 596 ... .. ... 596 .. 1104 ..... ... .. 862 799 -- .. ... SHEA R STR ENGTH OF RIVETS IN PO UNDS
NOTE
joined.
Figur e 17-17. Rivet She ar Strength (Sheet 1 of 2) 17-44
II)
<
--
738 847 972 1053 1142 1242 1298 1403
.M ODEL 188 & T188 SERIES SERVICE MANUAL
FLUSH HEAD RIVETS IN SINGLE SHEAR (DIMP LED)
1/8 inch dilmeter 0
Thick· nea of Thinnest
~
N
~
i
0
~~
ifi
N Ill
,.... a: 0
Sheet
.01 6 .020 .025 .032 .040
.050 .063
.071 .080 .090
.100 .125
--...... -- .. --- 299 ....... . . - 360 ....... ...... - 41 3 -- .. -- .. 451 484
---... .. -.. --... ........... ---.. .... ..
0
Ill
c(
159 236 377 380 388 388 388 388
159 236 327 360 388 388
388 388
~~ • ~ -~ ~ ~ a: a: zo 0 i N N
I")
..... . . .. 246 281 330
386 456
..... -..
.. -.... . --..
0
Ill
c(
~~ ~fi
N
~,
0
zo
c(
268
258
389 439
389 439
511 581
511 581
596 596
596 596
--- -- --- -----
~
N
•~
-~ ~a:
:ea:
........
--- ---.. ----
.. ... -.
0
-. - ... -.. ... -- --- --- --- 474 -- ... --.. 568 --- ... -- 635 --- --- 893 736 756
546
........
3/16 inch di~
5132 inch dilmeter
~
a:
0
-~~ ·
i ifi
0
Ill
c(
N Ill
,.... a: 0
~~
N
• ~
-~
~a: zo
a:
0
. --.. -... - ... -- -·-- ... 8 --- -- - --- 41 -... - -- ... - ---.. 465
334
376
722
436 506
839 940
592 703
1012 1045 1074 1098
---...
--- SHEAR STRENGTH OF RIVETS IN POUNDS
--.... - -- ----398.. -398-... 485
485
577
577
684
684
768
768
882
862
536
618 716 845 928 1013 111 2
- - ... - ... - ..
FLUSH HEAD RIVETS IN SINGLE SHEAR (COUNTERSUNK)
1/8 inch d iameter 0
Thick·
,_
of Thinnest
Sheet
.016 .020
.025 .032 .040
c( Ill N
~
i
. . . 163 221 272
.063
309 340 363
.071
373
.050 .080 .090
.100 .125
-. . . . ..
.......
- ...... -- . ..
0
CD
c(
~~ "',....a: ~5 N
0
. . - ..
-
-
159 236 327 380 388 388 388
388
159 236 327
0
~
~~
~II)~~ •
zo
~
N N
I")
a:
<a:
0
II)
!5
0
Ill
c( N
<D ,.... a:
0
166 212 266 344
441 504
388
. . ..... . .
554 388 . . ...... ..
- .. -..
...
0
~~ • ;;:;~ ~
c(
c(
zo
~
~~
~
N
<a:
a: 0
~
II)
i5
--... . . .. -...... .. -...... ... ... -.. ... -..... .. .. . -- ... --- -- ... ...... ... .. - ...... -- . -- - ... -- 21 7 250 --... -- .. .. -.. - ..... - .. - - .. -.. 343 -.- . -- 284 348 . -- -- - 281 418 ... -- -... -... 328 439 - - -- .. 363 442 479 258 258 410 557 -.. . . - ... --.. 536 523 369 368 533 682 -........ 398 593 542 439 439 608 753 --- .. 485 619 560 511 511 693 833 --..... 5n 641 575 561 581 7fJ7 912 .. ..... .. 684 664 .. .. .. 596 596 837 940 ... - .. 788 721 .. - 596 596 ... ..... .. 1009 ... .... 862
.......... . . ........ .. .. ..
360 388
388
0
c( Ill N
.. - .. . . .. -
- -- - - ... ... --- .. -... - ...
3/16 inch diameter
5132 inch dilmeter
Ill
N
~,
<D .....
-N 1/)N
0
zo
a:
<a:
N
• N
I")
a: 0
... .-.. .. ....... -. -... -- - ... - ..... -..... .. -.. .. --- --- .. . . .... . -- .. -..... . .. - 379 503 . -- 473 639
398 485
577 684
788 862
606 688
817 897
794
990
1093 1013 1196 1128 1296 900
SHEAR STRENGTH OF RIVETS IN POUNDS
Figure 17-17 . Rivet Shear·Stre ngth (Sheet 2 of 2) 17-45
MODEL 188 & T188 SERIES SERVICE MANUAL
GRIP LENGTH SELECTION TABLE GRIP LENGTH MI N. MAX.
1/ 8 DIA. DASH NO.
5132 DIA. DASH NO.
3/ 18 DIA. DASH NO.
.020
.062
4-1
&- 1
6-1
.063
.125
4-2
&-2
6-2
.126
.187
4-3
6-3
6-3
.188
.250
4-4
s-.
a...
.251
.312
4-5
6-5
tr5
.313
.375
4-6
!HI
6-6
.378
.437
4-7
6-7
6-7
.438
.500
4-6
6-8
6-8
.501
.562
4-9
&-9
6-9
.563
.825
6-10
6-10
.626
.687
6-11
6-11
.688
.750
6-12
TWO-ROW RIVET LAYOUT
SINGLE-ROW RIVET LAYOUT
1
1. Rivet Location (Typical) 2. Edge Margin: 2 to 2 1/ 2 rivet diameters between rtvet center and edge c1 material. 3 . Rtvet Pitch: 6 to 8 rtvet diameters between rtvets tn same row and no closer than 3 rtvet diameters. 4. Transver se Pitch: 75% of rtvet pitch between rows and no c loser than 2 1/ 2 diameters.
!',
'\
.'\
\ ''
v- -
"\.
',\, ' ' ' ._
4
""'·
"\
\.
- -
THREE-ROW RIVET LAYOUT
Figure 17 - 18. Rivet Grip Length and Layout 17-46
\
'\....
-t .,...
MODEL 188 & T188 SERIES SERVICE MANUAL
Replace
In thickness (or thicker)
With
MS20470AD3
. 025 . 020
NAS1398B4, NAS139804 NAS1738B4, NAS173804, NAS1768D4 , CR3213-4, CR3243-4
MS20470AD4
. 050 . 040
NAS1398B4, NAS139804 NAS1398B5, NAS139805, NAS1738B4, NAS1738E4, NAS176804, CR3213-4 NAS1738B5, NAS1738E5, NAS1768D5, CR3213-5, CR3243-4 CR3243-5
. 032 . 025 MS20470AD5
. 063 . 050 . 040 . 032
NAS1398B5, NAS1398D5 NAS139886, NAS1398D6, NAS1398B5, NAS1738E5, CR3213-5 NAS1738B6, NAS1738E6, NAS1768D5, CR3213-6, CR3243-5 CR3243-6
. 050
NAS1398B6 NAS1398D6 NAS1738B6, NAS1738D6, NAS176806, CR3213-6 CR3243-6
MS20426AD3 (Countersunk)
. 063 . 040
NAS1399B4, NAS1399D4 NAS1769D4, CR321~-4
(See Note 1)
. 025
NAS1769B4, NAS1739E4, CR3242-4
MS20426AD4 (Countersunk)
. 080 . 063 . 050 . 040
NAS139984, NAS139904 NAS1739B4, NAS1739D4 , CR3212-4 NAS1769D4 CR3242-4
(See Note 1)
. 050 . 040 . 032
CR3212-5 NAS1739B5, NAS173905, NAS1769D4 CR3242-5
MS2042 6AD4 (Dlmpled)
. 063
NAS1739B4, NAS173904
MS20426AD5 (Countersunk)
. 090 . 080 . 071 . 063 . 050
NAS139985, NAS139905 CR3212-5 NAS1739B5, . NAS1739E5 . NAS1769D5 CR3242-5
(See Note 1)
. 063 . 040 . 032
NAS1739B6, NAS1739D6, NAS176906, CR3212-6 CR3242-6 AN509-10 Screw wlth MS20365 Nut
MS20426AD5 (Dimpled)
. 071
NAS1739B5, NAS1739D5
MS20426AD6 (Countersunk)
. 090 . 071 . 063 . 032
NAS173986, NAS1739D6, CR3212 -6 NAS176906 CR3242-6 AN 509- 10 Screw with MS20365 Nut
MS20470AD6
. 080 . 071 . 063
Figure 17 - 19. Fastener Substitution Table (Sheet 1 of 2) Revision
1
17-47
MODEL 188 & T188 SERIES SERVICE MANUAL
Replace
In thickness (or thicker)
MS20426AD6 (Dimpled) eNAS178
e
NAS1054
With
. 090 . 032 NAS179
NAS1739B6, NAS1739D6 AN509-10 Screw with MS20365 Nut
(See Note 3) (See Note 3)
e NAS1054 e NAS14XX
(See (See (See (See
e NAS529 *NAS1446 *NAS7034 =:NAS464 CNAS1103 CNAS1303 C NAS6203 =AN173
Note 3) Notes 3 and 4) Note 3)
Note~)
NAS179, NAS528 (See Note 4)
e NAS14XX
NAS1080C NAS1080E NAS1080G
e NAS529
NAS524A
NOTE 1: Rework required.
(See Note 5)
NAS179, NAS528 NAS1080C, NAS1080E, NAS1080G NAS524A NAS1080C, NAS1080A6 NAS1080K AN364, MS20364, MS21042
AN305, MS20305 , MS21044 , MS21045
e NAS14XX e NAS529 *NAS1446 *NAS7034 O NAS464 D NAS1103 ONAS1305 ONAS6203
NAS1080C, NAS1080E NAS524A NAS1080C, NAS1080A6 NAS1080K AN364, MS20304, MS21042
e NAS529 *NAS1446 *NAS7034 O NAS464 0 NAS1103 O NAS1303 ONAS6203
NAS524A NAS1080C, NAS1080A6 NAS1080K AN364, MS20364, MS21042
:::JNAS1446
NAS1080C, NAS1080A6
Counter sink oversize to accommodate oversize rivet.
NOTE 2: Do not use blind rivets in high-vibration ueas or to pull heavy sheets or extrusions together. High vibration ueas include the nacelle or engine compartment including the firewall. Heavy sheets or extrusions include spar caps. NOTE 3: See appropriate tables for nominal diameters available. NOTE 4: Available in over size fOr repair of elongated holes. interference fit. NOTE
s: NAS1446 oversize only permitted as a
Ream holes to provide a. 001 lnch
replacement for NAS529.
â&#x20AC;¢ Steel shank fastener designed for drive-on collars. *Steel shank fastener designed for squeeze-on collars. Cor the tool and extended shank of the fastener.
Installation requires su!fic ient space
= Threaded fastener.
I"-"
Figure 17-19. Fastener Substitution Table (Sheet 2 of 2) Revision 1
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 18 EXTERIOR PAINTING Page No. Aerofiche/ Manual
TABLE OF CONTENTS MATERIALS • . • • . General . • . . . . . • • Application .1nd Mixture Etch Primer . . . • Epoxy Primer • • . White Epoxy Topcoat . Polyurethane Topcoat . Touch Up Urethane to Metal. Urethane to Paint. Application of Colors Acrylic . . . • .
.2H21/18-1 . 2H22/18-2 .2H22/ 18-2 • .2H22/18-2 .2H22/18-2 .2H22/ 18-2 .2H23/18-3 .2H23/18-3 .2H23/ 18-3
MATERIAL
NO/TYPE
PAINT
URETHANE Jet Glo DUPONT LUCITE ACRYLIC LACQUER EPOXY 5400
PRIMER
ETCH PRIMER 818-012 and ETCH PRIMER EX-ER-7 and T-ER-4 825-8136 and VG8392
THINNER
ACTIVATOR
Epoxy • • • • • . •• Polyurethane . • . . • Primi~
. 2H23/ 18- 3 • 2H23/ 18-3
Tubular Steel Structure • • • 2H23/ 18-3 Tubular Steel Components . .2H23/18-3 E~ine Mounts • . . • • 2H23/18-3 Open-End Tubi~ . • • • • 2H23/18-3 Detalled Parts • • • . •• 2H23/18-J Assemblies • • • • • • 2H23/ 18-3 REFINSHING ENJINE MOUNTS .2H24/18-4 VHT Enamel . • • ••• • • • 2H24/ 18- 4
AREA OF APPLICATION Standard Exterior Serial 18802840
Beginni~
Used for color stripe on Epoxy thru aircraft sertal188-0251. Standard, used on aircraft exterior on thr AGpickup Thru 18802839. Used to prime aircraft exterior for application of Urethane 643-6-20 topcoat.
Used to prime aircraft exterior for application of Epoxy 5400 topcoat. Used to prime aircraft exterior for application of Urethane 643-6-20 topcoat.
54 SERIES
Used to prime aircraft exterior for application of Epoxy 5400 topcoat.
110-650, ll0-655 or T-10399
Used to thin Jet Glo series urethane ·topcoats.
T-3871 or TOLUENE
Used to thin 825-8136 primer.
T-6487 ADDUCT
Used to thin Epoxy 5400.
X-310A
Used to catalyze 643-6-20.
570-520 ACTIVATOR
Used to catalyze Jet Glo.
120-475 ACCELER ATOR
Used to shorten cure time of Jet Glo.
Revision 1
18-1
MODEL 188 & T188 SERIES SERVICE MANUAL NOTE The materials required and called out In this Section may be obtained from the Cessna Supply Division. 18-1. GENERAL. Detail parts are wash primed or chemically treated, epoxy primed. Assemblies and sub-assemblies are then epoxy primed after assem bly. The exter ior of the aircraft receives an overall topcoat of white epoxy after wash prime and epoxy prime coats are applied. The stripe color is then applied over the white epoxy base coat. The follow ing procedures outline mixing and application of wash prime, epoxy prime, epoxy topcoat, and stripe color (in that order). Where external finish has been re moved to bare metal, apply the wash prime, epoxy prime, epoxy topcoat and (if applicable) the stripe color. Agwagons prior to serial number 188-0251 were delivered with an acrylic stripe over the epoxy base coat. Serial number 188-0251 and on were de livered with an epoxy stripe over the epoxy basecoat. Beginning with serial 18800833 aircraft may have the optional urethane topcoat and stripe and beginning with aircraft serial 18802840 the AGwagon will have urethane topcoat and str ipe standard. Refer to air craft finish and trim plate for type of paint. NOTE Epoxy and urethane finishes are very difficult to remove with thiMer or solvent. Usually they must be sanded or a paint remover must be used. 18-2. MIXTURE AND APPLICATION OF ETCH PRIMER. a. Mix 1 part of P6002 primer and 1 1/2 parts R7K44 reducer. b. Allow mixture to stand for a minimum of 30 minutes before spraying. NOTE
Wash primers should be mixed only in quantities required for use within siX (6) hours and then only in a stainless steel container . Mixed primer shall be dis carded if not used within six (6) hours. Air pressure at the gun should be approx Imately 40 psi. Keep the gun 6 to 8 inch- · es from the work and perpendicular to the surface being primed. DO NOT PAINT WITH AN ARCING MOTION. Finishes should be applied in an uniform wet coat. c. Apply the etch primer in one well atomized wet even coat to . 0003 to . 0005 inch dry film thickness. d. Allow primer to dry until a firm pressure with the fingernail will not penetrate the coating (approXlmately 30 min.:tes) .
18-3. MIXTURE AND APPLICATION OF EPOXY
PRIMER.
a . Mix two (2) parts 825- 8136 primer and one part
VG 8392 activator. Mix thoroughly and allow to stand
for 1 hour before spraying. Epoxy primer has a pot
life of eight (8) hours.
b. Primer may be thinned with T-3871 thinner up
to 40% for spraying viscosity. Exact thiMing can
be varid to fit the available equipment.
c. Apply the epoxy primer to a dry film thickness of a.pproximatly • 0007 inches. d. Allow the primer to air dry at least two hours before application of th~ topcoat. 18-4. MIXTURE AND APPLICATION OF WHITE
EPOXY TOPCOAT.
a. Mix required amount of epoxy with VG8339 acti vator in a 1:1 ratio. NOTE These mixtures shall set for a minimum of 45 minutes, then be agitated, before spraying. b. Reduce mixture approximately 10 to 15% to spraying viscosity with T-3871 thiMer. Thinning ratio may be varied to fit the available spraying equipment. c. Apply one wet even coat to completely cover the epoxy pr imer. Allow to dry for 30 minutes and ap ply second coat. d. Let air-dry for eight hours at 70°F. , or force dry for four hours at 130°F. 18-5. MIXTURE AND APPLICATION OF POLY URETHANE TOPCOAT. a. Mix the required amount of urethane Jet Glo Series with Jet Glo Catalyst 578-520 in a 1 to 1 ratio. Mix thoroughly and allow to stand for approximately 30 minutes before spraying. Jet Glo urethane has a potllfe of six i§) hours. If faster cure time is desired 120-975 acce~ator may be added to the mixed ma terial in quantfty of 1/2 to 1 fl. oz. per gallon. If 120-975 is used no induction time is necessary. Pot life is shortened to 1- 2 hours. b. Urethane may may be thinned with Jet Glo thiMer T-10399 to obtain a spraying viscosity. 110-650 or 110-655 may be used also. c. Apply one wet even coat to completely cover the epoxy primer. Allow sufficient time for this coat to tack and apply a second coat. d. Jet Glo Urethane finishes usually requue 12 16 hours air dry at 75 °F to become tape free and are not fully cured till seven (7) days. Accelerated with 120-975 tape free time is 4- 6 hours. e. Overall dry film thickness should be about 2. 0 mil.
NOTE NOTE Primer shall be coated within four (4)
hours of application.
18-2
Revision 1
I
All materials shall be mixed by adding the
MODEL 188-& T188 SERIES SERVICE MANUAL
appropriate activator to the base with vig orous stirring. Thinners shall be added after base and activator have been mixed in the proper ratio.
b. Thin paint with T -794 5 thinner to spray viscqsit (approximately one to one). c. Inspect for overspray and apply "burndown",
T-7945 thinner, to any area showing overspray.
When an induction time is noted the mixed material must be allowed to stand for a minimum of the time indicated before spraying. Failure to comply with this re quirement can cause the finish to fail in later service.
18-9. MIXTURE AND APPLICATION OF CESSNA EPOXY COLOR (5400 Series.) a. Thor oughly stir and mix in original container
to make sure all pigments are in solution.
b. Mix required amount of epoxy with T-6487 ad
duct. Ratto is one part paint to one part T-6487 ad
duct.
Pot lifes indicated are at 75 °F. higher temperatures will shorten the pot We. Do not use any material that shows any in dication of premature gelation (lumps, ski~, markedly increased viscos_ icy, ect.) even if the pot life has not expire¥ 18-6. TOUCH UP OF URETHANE FINISHES TO BARE METAL. a. Clean all surfaces to be finished with Naphtha. Saturate a clean lint free cloth in Naphtha and wring out so no thinner is dripping from the cloth. Wipe the aircraft surface using the Naphtha saturated cloth and immediatly followillt, wipe the surface with a dry, lint free cloth. NOTE It Is important that the Naphtha is wiped before 1t evaporates. Change cloths often so the aircraft surface Is thoroughly clean ed and the surface Is not contaminated from the use of a dirty ·rag. Always use clean Naphtha for the final cleaning. Be sure the Naphtha Is disposed of when con taminated.
18-7. TOUCH UP PAINTING OF URETHANE FINISHES. a. Because urethane finishes cannot be burnt in, they should be applied in sections when being touched up. All sections should be marked off to skin laps, edges, or strip lines. The defect in the section should be removed by sanding with 320 sanding paper. U possible, avoid sanding through the primer to bare metal. If the defect is such that a surfacer ls needed to repair the defect, an epoxy surfacer ts recommended. b. Minor defects to bare metal one (1) square inch and larger should be repaired with wash primer, epoxy primer and urethane topcoat. c. After the defect has been removed and the epoxy surfacer has sufficiently cured, scuff sand the entire surface of the section to break the surface glase of the finish. All surfaces to be painted should be tack ed off prior to application of the urethane finish. The urethane finish should be applied in two or three wet uniform coats for best results. 18-8. MIXTURE AND APPLICATION OF CESSNA ACRYLIC COLOR (Dupont Lucite Acrylic Lacquer.) a. Thoroughly stir (Dupont Luclte Acrylic Lac quer) to make sure all pigments are in solution.
18-10. MIXTURE AND APPLICATION OF POLY URETHANE COLOR. a . Thor oughly stir and mix in original container
to make sure all pigments ue in solution.
b. Mix required amount of 643-6-20 urethane with X-310A Converter. Ratto is three parts paint to one part X-310A converter. For Jet Glo Urethane Colors follow instructions in paragraph 18- 5. 18-11. PRIMING OF WELDED TUBULAR STEEL STRUCTURE. The welded tubular steel section of the aircraft is a sealed, air-tight unit, pr otected with one coat of epoxy primer. After a welded re pair has been made on any part of this structure, the repair section shall be primed per paragraph 18-3. This also applies to any welded or brazed parts of the aircraft. 18-12. PRIMING OF TUBULAR STEEL COMPO NETS. Steel tubing parts which are not welded shut and cannot be spr ayed on the inside shall be dipped in Red Iron Oxide Primer, and then sprayed on the outside with epoxy primer per paragraph 18-3. An example would be the flap control lever. 18-13. PRIMING OF ENGINE MOUNT. The engine mount shall be primed with high temperature, Zinc Rich primer. 18-14. PRIMING OF OPEN-END TUBING. If a re pair necessitates the replacement of an open-end steel tubing where barrel nuts are employed, the tubing shall be oiled on the inside. After installation of the nut, seal the open end of the tube with Prers tite 579. 6 sealer (Presstite Engineering Company), then brush epoxy primer on the seal and tube. 18-15. PRIMING OF DETAIL PARTS. All alumi num and alumunized steel detail parts shall receive one coat of wash primer per paragraph 18-2, and . one coat of epoxy primer per paragraph 18-3 before assembly. 18-16. PRIMING OF ASSEMBLIES. All assemblies or sub-assemblies of metal shall receive a second coat of epoxy primer on all surfaces not exposed on the exterior of the aircraft. This coat shall cover all bare rivets, fasteners and any areas which may have been scratched or chipped during assembly.
Revision 1
18- 3
MODEL 188 8t T188 SERIES SERVICE MANUAL
18-17. REFINlSHING ENGINE MOUNTS. After completing a repair as directed in Section 17. finish the enure engine m•>unt with P/ N CCM44A. Zinc Rich Primer, (55x10) (K000486). Apply as follows: a . Scuff sand or grit blast entire area to bare metal. b. Wipe with solvent such as lacquer. c . Thin primer 25% to 30% with No. 2 thinner. and
mlx thoroughly .
d. Spray to a film thickness of 0 . 001'' to 0.0015". e. Material may be force dried at 180• to 200°F for 10 to 15 minutes. 18- 18. VERY HIGH T EMPERATURE ENAMEL. After completing the priming operation as directed ln paragraph 18-17, apply VHT Wbite Enamel P/N CES1054-812A to those areas of the mount that are tn close proximity to the exhaust system components. VHT Enamel may be applted to the overall mount, butts expenaive and only required in areas shown in figure 18- 1. Apply very high temperature enamel ae follows: a. Surface Preparation . 1. Clean burnt area to bare metal by sanding or grit blasting. 2. Wipe clean with a llnt free cloth soaked in lacquer thinner or toluene. b . Appllcation. 1. Apply a thin even coat, just enough to thor
oughly c~lor . Excessive build-up is not recom mended . . If heavy coating is required. apply in stages with each being cured befo re next application . 2. VHT Enamel requires no primer . c . Curing . 1. VHT Enamel will air dry in 15 to 30 minutes. · and m.1y be used immediately, U handled with reason· 'able care. Curing can be accomplished by the inher ent heat of operation near engine manifolds and ex hausts . 2. Operation and/or curing under continually rising heat to 850° F will provide a superior coating resistant to most solvents and fuels . d. Cleaning VHT Finish . VHT Enamel coated sur faces are best cleaned with soap and water . Obsti nate stains may be rem ::>ved with moderate cleant-rs . NOTE Do 1'4ot Use solvents for cleaning unless coating has been cured as recommended .
NOTE All engine mounts can be spotted with VHT Enamel in those areas where in close prox imity to high temperature exhaust system components.
VRT. Enamel, 6" minimum length
Figure 18-1. Typical Engine Mounts. 18-4
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 19
DISPERSAL SYSTEM
TABLE OF CONTENTS
Page No. AeroCiche/ Manual
DISPERSAL SYST E MS . . 211/ 19-1
SPRAY SYST EMS . . . . . 211/ 19- 1
Trouble Shooting . . . 213/ 19-3
Ho pper . . . . . . . 213/19-3
Removal and Installation . 2I3/19-3
Repair . . . . . . . . . 2I3/ 19-3
Internal Sealing . . . . . 2I3/ 19-3
Pump Assembly . . . . . . . 2I8/ 19-8
Removal and Installation . 2I8/ 19-8
Flow Control. . . . . . . . 2I8/ 19- 8
Rigging . . . . . . . . 2I8/ 19-8
E mergency Dump Control . . 2I8/ 19-8
Fan Brake . . 2120/ 19-18
Rigging . . . 2120/ 19-18
Plumbing . . . . . 2121/ 19-19
Y-Strainer . 2121/19- 19
Inspection . . . 2121/19- 19 Boom Assemblies . . . . . 2123/19- 21 Streamlined Boom Assemblies . 2123/ 19- 21
Removal and Installation. . 2123/ 19-21
Setting Boo m Chord Angle
of Incidence . 2123/ 19-21
Ins pection . . . 2123/ 19-21
Nozzles . . . • . . . • 2123/ 19-21
Disassembly. . . . 2123/ 19-21
Rotary Atomizer . . . . 2123/ 19-21
Pressure Gage . . . . . 2123/ 19- 21
Quick- Loader Systems . . 2123/ 19-21
DUST DISPERSAL SYSTEMS . . 2I24/ 19-22
Trouble Shooting . . . . . 2124/19-22
Hopper . . . . • . . . . . . . . 2124/19-22
Gate Box and Spreader Assembly. . 2124/ 19-22
Gate Box Control . . . . . . . . . 2I24/ 19-22
Removal and Installation . . . 2124/ 19-22
Rigging . . . . . . • . . . • 2J6/ 19-26 CLEANrnG DISPERSAL EQUIPMENT . . 2J6/ 19-2 6 HYDRAUUCALLY-OPERATED
DISPERSAL SYSTEM . . . 2J8/ 19-28
Operatio n . . . . . . . . . 2J13/ 19-33
Servicing . . . . . . . . . 2J13/ 19-33
Hydraulic Fluid Filter . . . ZJ13/ 19-33
HydrauUc Cooler . . . . . . 2J13/ 19-33
Component Removal and Installation. • . 2J13/ 19- 33
Rigging . . . . . . . 2J13/ 19- 33
Hydraulic Res ervoir . 2J13/ 19-33
Desc ription . . . 2J13/ 19-33
Re moval . . . . . 2J 13/ 19-33
Dis assembly . . . . 2K4/ 19- 48
Inspection of Parts . 2K4/ 19-48
Assembly . . . . 2K5/ 19- 49
Installation . . . 2K5/ 19-49
Rigging . . . . . 2K8/ 19-52
Air Flller Valve . 2K8/19-52
Removal . . . 2K8/19- 52
Installation . . . • . 2K8/19-52 . 2K8/ 19-52
Spray Pump Strainer . . . . . 2K8/ 19-52
Description . . . . . . . 2K8/ 19-52·
Removal and Installation ELECTRICALLY-OPERAT ED SPRAY VALVE SYSTEM • . • • . . . . . . 2K8/ 19- 52
Removal and Installation . . . . . 2K8/ 19- 52
Rigging . . . . . . . . . . . . . 2K8/ 19-52
ELECTRICALLY-DRIVEN AGITATOR
INSTALLATION . . . . 2K8/ 19- 52
. Rigging . . • . . . . 2K8/ 19-52
. 2K11/ 19- 55
AUTOMATIC FLAGMAN . 2K11/ 19-55
Description . . . . . . . 2Kll/ 19-55
Removal. . . . . . Installation . . . . . 2K11/ 19-55
. 2Kll/ 19-55
Inspection and Maintenance BOOM PRESSURE VALVE AND
CONTROL KNOB . . . . . . . 2K11/ 19- 55 1
Description . . . . . • . • . . • 2K11/ 19- 55
Removal (Ag Wagon thru 18801682) . 2K13/ 19-57
Removal (Ag Truck thru 18801682) . 2K13/ 19- 57
Installation (Thru 18801682) . . . 2K13/ 19-57
Description (Beginning with
18801683) . . . . . . . . . . . 2K13/ 19-57
Removal (All Models beg inning
with 18801683) . . . . • . . . . 2K13/ 19-57
Installation (All Models beginning
with 18801683) . . . . . . . . . 2K13/ 19-57
Valve Control Linkage . . . . . . 2K14/ 19- 58
Description . . . • • . . . . 2K14/ 19- 58
Re moval and Installation and
• 2K14/ 19-58
Rigging . . . • • MANUAL CONTROL VALVES . 2 K14/ 19-58
Description . . . . . . . 2K14/ 19-58
Removal and Installation . 2K14/ 19-58
. 2K14/ 19-58
Disassembly (Ball Type) . 2Kl4/ 19-58
Reassembly (Ball Type) Adjustment • . • . . . • 2K14/ 19-58
ELECTRIC SPRAY VALVE . . 2K14/ 19- 58
Description . . . . . . • 2K17/ 19-61
Removal and Installation . 2K17/ 19-61
Disassembly (Ball Type) . 2Kl7/ 19-61
Assembly (Ball Type) . • 2K17/ 19- 61
Butterfly Valve Dis assembly and
Reassembly • . • • . • . . . . 2K17/ 19-61
Butterfly Valve Seal Replacement. . 2K18/19-62
In.s pectton and Replacement of
Butterfly Valve Inser t . . . 2K1 8/19-62
Butterfly Valve Adjustment . 2K19/ 19- 63
Electric Butter fly Valve
Dl.sass e mbly . • . . . • • 2K21/ 19- 65
Electric Butter fly Valve
Reassembly . . . . . . . 2K21/ 19- 65
Electr ic Butter fly Valve Disk
Chltch Rigging . . . . . . . 2K21/ 19-65
19-1. DISPERSAL SYSTEMS. All Agricultural Air._ c raft , Al 88 Se rie s, are offered with both a liquid and d ry dispersal system. Each system oper ates inde pendently of the other, excepting the hopper, gate box, and emergenc y dump. Either system may be re moved without distu r bing the operation of the othe r.
19-2. SPRAY SYSTEMS. Liquid Chemical spray sys tems components include a hopper , pump assembly, discharge tu be , Y-strainer, flow pressure gage , and boom assembly. Cockpit co ntrols are provided Co r a flow contro l valve; an emergency dump gate, and a pump brake. The pump may be electr ically or ram air driven. Revision 1 19-1
I
MODEL 188 8t T188 SERIES SERVICE MANUAL IWARNINGt Operators , pilots , and maintenance personnel directly concerned with aerial application of agricultural chemicals must be thoroughly familiar with all precautionary measures . The following information is provided for the in dividual who is not familiar with these chemicals, but who is required to perform maintenance on agricultural aircraft. 1. Almost all agricultural chemicals are toxic, depending on exposure rate . Some are highly toxic and can even be fatal if exposure is prolonged or treatment is delayed . Immediate treatment is a must upon known exposure . 2. Toxic chemicals can enter the body in differ ent ways ; inhalation when in vapor form, ingestion when contaminated foods , drinks, or tobacco products are consumed, and absorption when chemical passes through skin on contact. The latter is probably most dangerous, because a very small amount is lethal, and the individual us ually doesn't realize he has been con tamirated . NOTE Most common symptoms of exposu r e are as follows, but not necessar ily in order of appearance : 1) Miosis , constriction of pupils of the eyes, creating a dimming of vision. 2) Rhinorrhea, excessive nasal discharge, runny nose . 3) Salivation, uncontrolled drooling of the mouth. 4) Constriction or tightness in chest, inability to breathe deeply e nough. S) Sometimes a cough is evident. 6) Sometimes, but not always, headache, fatigue, anorexia (loss of appetite), nausea, perspiration, dizziness, twitching, dreaming, irritability, and mood changes . Naturally as exposure increases symptoms worsen, and some new ones appear: 1) Cyanosis, bluish or purplish color indicating deficient oxygenation of the blood. 2) Convulsions, appearing as similar to an uncontrolled fit. 3) Coma. 4) Loss of reflexes . S) Loss of control over u rination a nd excretion. lf any of these symptoms are appar ent, medical aid should be sought IMMEDIA TELY.
DO NOT DOCTOR YOURSE LF. IDENTIFY CHEMICAL CONTAMINATE, SO THE PHYSICIAN CAN MAKE IMMEDIATE DIAGNOSIS AND PRESCRIDE PROPER TREATMENT. 3 . When handling chemicals, always wear protective equipment: Rubber gloves, rubber boots, clean cap, long- sleeved coveralls or jump suit. All these ite ms should be changed daily . Do Not permit contaminated clothing to be launder ed by someone who is unaware of the hazard in handling, this includes industrial laundry service. If handling material in an enclosed area, wear a n approved res pirator or other breathing device . 4. After use a ir craft s hould be was hed down thoroughly , especially prior to maintenance . DO NOT steam clean, a s this tends to vaporize chemicals allowing easier and faste r absorption. Drainage from wa sh area, must be into an area where poisoning cannot occur . DO NOT allow aircraft to be washed by untrained personnel.
19-2
MODEL 188 & T188 SERIES SERVICE MANUAL
PERSONAL SAFETY WARNING (Cont) of~
5.
An adequate area for personal hygiene is a must, shower, sink, soap and plenty for ~rotection .
6.
Carrying foods, drinks, or cigarettes in pockets or work area is extremely dangerrus, as these items can become the medium of ingestion for the contaminates.
7.
Additional information may be obtained by contacting the local Crunty Agent or Chemical supplier.
19-3. TROUBLE SHOOTING. When trouble ls en countered with dispersal equipment, check that con trols operate without binding or lost motion, that they are rigged properly, and that they are not damaged. Trace any leakage of chemicals to its source and correct the cause. On models employing a hopper relief valve, check the valve periodically to assure it functions satisfactorily. A major source of trruble is clogged stra.i ners and other components, caused by inadequate flushing and cleaning. Refer to the manu facturer's instruction manual and Cessna Service Kit number SK188 -28 for trouble shooting dispersal equipment. Refer to the Cessna Parts Catalog for replacement parts.
NOTE The hopper is removable from the aircraft, but no provisions are made for flight with the hopper removed. 19-4. HOPPER. A hopper, With a top loading door, is located forward of the cockpit on all AG aircraft. Hopper capacity Is 200-gallons, except for the AG truck. which holds 280-gallons. Prior to 1880083, hoppers are made of glass -fiber reinforced plastic. Beginning with 1880083, hoppers are made ol Dere kane. A clear area wtth graduations marked on the rear of the hopper enables the pilot to observe mater tal level on the ground or tn flight. A clear area with marked graduations is also located on each side of the hopper. Prior to serial 188-0413, a quick-disconnect adapter is installed at the bottom of the hopper for attachment of a spray system pump assembly or a gate box. Beginning with serial 188-0413, a glass-fiber flange is incorporated on the bottom of the hopper, elimin ating the need for a quick-disconnect flange and adap ter. Begmning with serial 188-0028, a hopper with a larger opening and a larger adapter is available for spec1al requirements. A pump assembly with a large bottom plate is required to attach to this hopper. A steel baffle in all hoppers reduces sloshing and adds strength to the hopper. Prior to serial 188-0275, a spring-loaded relief valve, connected to an air vent, is provided at the upper rear of the hopper to prevent collapse of the hopper during emergency Jettison of material. Beginning with serial 188-0275. a vacuum relief tube IS provided at this location. A filler open ing is located at the lower rear of the hopper for use
This is
with quick-loader valves, when installed. Beginning with serial 18800573, a spring-loaded flapper check valve is installed at this opening. Holes 1n the filler cap 1n the top loading door provide an additional air bleed for the hopper. Removal, installation and main tenance are the same on all hoppers except for re moval and installation of dispersal equipment on the glass-flange hopper. Refer to paragraph 19-7 for sealing instructions during hopper installation. Hop per repair is ouWned in Section 17. Beginning with serial 18800833, a hopper quantity light Is mounted on the aft lower surface of the hopper to provide illu mination so the pilot can determine the amount of material remaining during night spraying operations. Details of this llght installation are outlined in Section 16. 19-5. HOPPER REMOVAL AND INSTALLATION. a. Drain and flush hopper thoroughly, observing precautions outlined on page iv. b. Remove side panels on both sides of hopper. c. Remove fairing strip at upper rear of hopper. d. Loosen wing strut upper fairings and slide fair ings along strut. e. Remove metal fuel tank cover, lf installed. f. Remove nuts from strut-attach bolts; drive bolts forward until threaded ends are flush with aft end of fittings to allow clearance for hopper removal. g. Thru 188-0274, disconnect hose at vacuum re lief valve door. Beginning with 188-0275, remove vacuum relief tube. h. Disconnect quick-loader valve lines at hopper, if installed. i. Disconnect controls at control valve. j. Disconnect discharge tube at pump or valve. k. Remove fairings at bottom of hopper. 1. Unclamp or unbolt pump or gate box, and remove . m. Remove bolts attaching hopper to aircraft struc ture. (Refer to paragraph 19-7.) n. Remove s tructural tubing at front of hopper, if . large hopper is installed. o. Lift hopper straight up out of aircraft. p. Reverse pr eceding steps for installation. Rig controls as outlined in applicable paragraphs. Refer to paragr aph 19-7 for sealing procedures. 19 -6. REPAIR OF HOPPER. (Refer to Section 17.) 19-7. INTERNAL SEALING OF HOPPER. All bolts, nuts, latch.es, doublers, filler neck, etc. that are located mside the hopper are sealed wtth an epoxy type sealant during installation to pr event leakage
19-3
MODEL 188 & T188 SERIES SERVICE MANUAL
11 12
'9
I
5
Detail
A
15
~
NOTE Beginning with Serial No. 188 - 0400, a check valve ls added at the inlet for the quick-loader system .
1. 2. 3. 4. S. 6. 7. 8. 9. 10.
Doubler Hopper Flange Gasket Cover Cotter Pin Pin Hinge Halves Top Loader Door Late:: Assembly 11. Seal 12. Cap 13. Tubular Structure 14. Clamp 15. Overhead Vent Tube 16. Hose 17. Vacuum Relief Valve* 18. Catch Assembly 19. Baffle 20. Seal 21. Fairing 22. Latch SEE SHEET 2 23. Seal 24. Adapter THRU SERIAL NO. 188-0274
Figure 19-1. Hopper Assembly (Sheet 1 of 4) 19-4
Revision 1
B
* SK Optional Service Kit 188-16, available from the Cessna Sup ply Division, replaces vacuum relief valve (17) with an overflow tube.
MODEL 188 & T1 88 SERIES SERVICE MANUAL
5
3
12
16
17
LARGE-OPENING HOPPER BEGINNING WITH SERIAL NO, 188-0028
11
SEE SHEET 1
Detail
~~ ~ 1.
2. 3. 4. 5. 6. 7.
Baffle Pin Cotter Pin Hinge Halves Latch Assembly Top Loader Door Cap
18
18
19
• THRU SERiAL NO, 188-0412
.,.......\ '\a*
19
C
BEGINNING WITH SERIAL NO. 188- 0413
17
8. 9. 10. 11. 12. 13.
Hopper Gasket Vacuum Relief Tube Catch Assembly Fairing Hook
14. 15. 16. 17. 18. 19. 20.
Clamp Assembly Roll Pin Adapter Seal Fairing Outlet Cover Plate Hopper ~ange
Figure 19-1. Hopper Assembly (Sheet 2 of 4) and corrosion caused by spray and dust materials. The vent tube installed at the right rear of the hop?er Is sealed to the hopper with EC 16!75 type sealant and the bolts attaching the tube !lange to the hopper are sealed with epoxy. Whenever 1t becomes necessary to break a seal, such as durtng parts replacement or hopper removal, parts must be resealed at installa tion . A sealtng kit (SK188-3 ), available from the
I
Cessna Supply Division, Is recommended for all
resealing except the adapter at the bottom of the
hopper. When installing the adapter, the area be
tween the adapter and the outer surface of the hopper
must be sealed, and a fillet seal must be applied be
tween the adapter and the bottom edge of the hopper.
The sealant for these areas should be EC 16758 mixed
~with EC1675A accelerator in a ratio of 8.8 parts
Reviaion
1
19 - 5
MODEL 188 & T188 SERIES SERVICE MANUAL
37 . 4 CU. FT. HOPPER
INSTALLED IN AGtruck
BEGI NNING WITif
18800955T
* * 0
18800955T thru 18801118T BegiMing with 18801) 19T 18800955T thru 18801045T
2
I
Seal strip (17) bonded to """ .A !airing (14) wi th EC -1300L ~ or EC-880 (3M Co.", St. ,â&#x20AC;¢ Paul, MiMesota 55101 ) at 18801825 & on. 1 OPENINGS FOR
STRUCTURAL
TUBING - --+- -
----,
12 13
Deta1l 1.
2. 3. 4. 5. 6.
7. 8.
Baffle
A*
9. 10. Hinge Halves 11. Latch Assembly 12. Top Loader Doo r 13. Cap 14. Hopper 15. Gasket 16.
Pin
Vacuum Relief T ube C:1tch As sembly Adapter Gasket Cove r 15 Fai ring Seal Hopper Flange 17. Seal Strip Figure 19 -1.
19 - 6
Hopper Asse mbly (Shee t 3 of 4)
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 .
14 . 15. 16. 17. 18. 19 .
A
Hinge HaU Hinge Pin Door Latch Catch Gasket Vacuum Relief Tube Cover Gasket Seal Strip Cover Fairing Fa1r1ng Seal Fairing Seal Fairing Outlet Cove r Plate Fai r ing Assembly Baffle Hoppe r Body
14 F igure 19 - 1.
Hopper Assembly (Sheet 4 of 4) 19-7
"'-"·
MODEL 188 & T188 SERIES SERVICE MANUAL
accelerator to 100 parts base by volume. These materials are available from the Cessna Supply Division. The adapter attaching bolts must be sealed inside the hopper with epoxy. any exist ing sealant at the adapter must be removed be fore applying new sealant. Any surface to be re sealed on the hopper must be cleaned with acetone, Methyl Ethyl Keytone, or a similar solvent, and dried with a clean cloth before the solvent evapor ates, to assure a residue-free surface for max imum adhesion of the sealant. NOTE
I
Early adapters at the bottom oi the hopper were originally sealed with epoxy. However, later hoppers ue sealed with the EC 1675 type sealant, which should be used when installing an adapter on the euly hoppers.
19-8. PUMP ASSEMBLY. Component parts of the pump assembly Include a bottom plate for attachment to the hopper adapter flange, a rem1vable strainer, an emergency dump gate, a now-control valve, and a centrifugal pump. The pump ls driven by a two blade wood fan mounted on a strut or on an angle drive which extends down Into the airstream. The fan is equipped with a one-piece, steel -drum brake. The fan brake, flow-control valve, and emergency dump gate are controlled from the cockpit by the pilot. 19-9. REMOVAL AND INSTALLATION. a . Disconnect fan brake control, emergency dump control, and connecting rod at flow-control valve. b. Disconnect discharge tube at pump assembly. c. Unclamp or unbolt pump assembly and remove from hopper. d. Install pump assembly by reversing the preced ing steps, rigging controls as outlined in applicable paragraphs in this section. 19-10. FLOW CONTROL. (See figure 19-3. ) Mate
nal flow from the hopper is controlled by a handle in
the cockpit. The handle is moved along a fixed micro
meter screw mechamsm to a flow rate position that
is determmed by an adjustable stop on the micro
meter screw. A crank on the micrometer screw may
be operated from the cockpit to set the stop. On the
··sTRUT MASTER" system, the gatebox flow hand
control serves as an emergency dump control. The
rubber boot at the fuselage unders1de should be check
ed frequently for damage which would allow chemicals
to enter the cockpit. The ""STRUT MASTER"" system
employs a separate spray valve control. This con
trol is Installed in the left door jamb next to the en
gme throttle. The control handle actuates a flexible
contr ol which 1S attached to the spray valve arm at
the gate box.
RIGGING.
Flow Control illustnted in figure 19-3:
a. Pull control handle (15) to full AFT pOSition . b. Push lever on flow control valve to full FOR WARD pOSition . c. Attach connect:ng rod (1 2 ) to bottom of arm (13 ). d. Adjust rod end (22 ) as requ1red to align with hole m control valve lever or to gate box door link 19-11.
19 -8
Revision 1
age. Install bolt, washer, nut and cotter pin.
Spray Valve Control illustrated in figure 19-4
a. Pull control handle (7) to full AF T position. b. Push lever on spray valve to full FORWARD
position.
c. Attach control cable assembly (12) to bottom of
handle (7) and spray valve lever.
d. Adjus t control cable assembly as required to
allow control handle to actuate spray valve lever to
full O~EN and full CLOSED position.
NOTE Support assembly (16) may be moved forward or aft on discharge tube for further adjustment. Before attempting repairs to the dispersal system, make sure that hopper is clean and empty. Due to extreme toxicity of Agricultural Chemicals Personal Safety must come first. NOTE A major source of trouble. in dispersal
systems is clogged strainers and other
components, caused by inadequate clean
ing.
19-12 . EMERGENCY DUMP CONTROL. On all dry and liquid dispersal systems, except the "BOOM MASTER", the emergency dump gate is controlled by the Flow Control handle, described in paragraph 19-10. Raise adjustable stop which allows control han~e to be pushed to the full FORWARD position, operung the gate box door fully to jettison the contents of the hopper . Pulling the control full AFT will close the gate box door in flight. Rig this control accord ing to instructions outlined in paragraph 19-11. On "BOOM MASTER" systems through Serial No. 188 -0317, a tee handle , mounted under the left side of the instrument panel, controls the emergency dump _gate. The emergency dump gate must be closed by hand once the control handle has been pulled. On Serials 188 -0001 thru 188 -0003, with origmal con trols, no rigging is provided: If the control assembly is the correct length, rigging is automatic . From Serial No. 188-0004 thru 188-0317, a Bowden type control is used. Rigging is accomplished as follows: a. Loosen clamps securing control housmg. b. Open emergency dump door. (Attach control if not already attached. ) c. Tighten clamp nearest door end of control housing. d. Close emergency dump door. e. Push tee handle to full FORWARD position. f. Shift housing in its clamps as necessary to en able wire to pass through hole in clamp-bolt at tee handle, and tighten remaining clamps. g. Tighten clamp-bolt at tee handle . h. Bend wire tip 90 degrees to prevent wtre from be1ng withdrawn if attaching nut should become loose. 1. When instalhng new control, 1t may be necessary to shorten w1re and / or housinlZ. Begmning with Serial No. 188-0318, a ring handle, mounted on the left side of the c rash pad, controls
MODEL 188 & T188 SERIES SERVICE MANUAL
27 BEGINNING WITH 18800805
10 11
1
2
1. Cotter Pin 2. Brake Drum 3. Brake Spring 4. E Sprmg 5. Anchor Stud 6. Brake Shoe 7 . Spacer 8. Key 9. Pump Shaft 10. Beanng 11 . Spacer 12 . Cam & Lever Kit 13 . Roll Pin 14 . Setscrew 15 . .Pump Bracket 16 . Gasket 17 . Seal 18. Soacer 19. Imoeller 20 . Sp1nner 2 1. Fan 22 . Reta1ner 23 . Washer 24 . Lo::k Washer 25. Pump Housu1g 26. Hose Coupler 27 . Dust Cap 28. Inlet Fitting 29 . Gasket 30. Elbow
rtr:--tfl7----.
~
Figure 19 - 2.
Strutmaster Pump and Valve Installation 19 -9
MODEL 188 & T188 SERIES SERVICE MANUAL
188-0001 THRU 188-0003
EMERGENCY DUMP CONTROL
2
1
2 4
188-0004 THRU 188-0317
6 CLAMP-BOLT
/ .......
*See figu r e 19-1 for Installations be
gtnrung with Senal
No. 188-0318.
-"
.;
·····
· ::····•••:::Y ... .
······.o:··········
.-
...,
.
..:....········
Detail
8 23•
~
B
..\
r
11
~
,., :
-: -:
..·, ............)·..~.
..· :···············..
·.:...···
-'····:.......
··.. ············ ...........·······
.··.······
..···
....~
·.
'
.
·.
.. .
2. 3. Lever 4. Control 5. C~mp
6. Handle 7. Control 8. Pin 9. Clevis 10. Bushing 11. Boot 12. Connecting Rod 13. Arm 14. Grtp 15. Handle 16. Actuator 17. Crank 18. 19. 20. 21. 22 . 23. 24. 25. 26.
/-'~\\''.
~:!~~;·sL.•,.
1.
(;;~}
* THRU 18803721
• BEGINNING WITH 18803722 THRU 18803860 CEMENT ITEM 2(23) TO (15) WITH (3M) EC- 2216 ·-· : ·:::..••••••••~!>· ••••••• OR EQUIVALENT.
· .~· ·
\ ~....
c
··/········ ..........
..
-Q-Beginning with 18803861
11
• Beginning Serial 18802746
.......··
EMERGENCY DUMP CONTROL
Detail
0 I ~.
NOTE Pin 18 Support 1'1110 13 32" · spacers are Mic r ometer Stop (Typical) used at rod end (22) on dust system. Rod End Knob HOPPER CONTROL Spnne; Connects to flow-control valve lever on spray system. Houswg Assembly Connects to gate-box door linkage on dust system . 27. Pin 'f Stop
--
Figure 19-3. Dtspersal Equtpment Controls 19-10
*
MODEL 188 & T188 SERIES SERVICE MANUAL
··..
H
SEE FIGURE 19-3
1~
21
1~
t-3
4
~5
\~:\
~5
...···················
,--------, STRUT MASTER INSTALLATION (WITH STRUT MOUNTED PUMP)
Detai! G
. F
........
26
7
0ew1 H
1. 2. 3.
4. 5. 6. 7. 8. 9. 10. 11.
12. 13. 14. 15 . 16. 17.
18. 19. 20. 21.
22 . 23 . 24. 25. 26.
Spray Pressure Line Union Nut Washer Elbow Hose Assembly Handle Control Arm Arm Stop Bracket Shalt Bracket Control Cable Assembly Clamp Bracket Clamp Support Assembly Bracket Spacer Clamp Grommet Slrtp Control Cable Assembly Bracket Clamp Placard Lever Assembly
10
BEGINNING WITH SERIAL NO. 188-0318
16 Detail
E
Detail
f
Figure 19-4. Liquid Disper sal System (Sheet 1 of 4)
19 - 11
I MODEL 188 8t T188
SERIES SERVICE MANUAL
M .·· .·
BOOM MASTER INSTALLATION WITH ANGLE DRIVE PUMP
SEE SHEET 1
····~::~~
....
....···...
1
SEE FIGURE 19-3
.:::.·_:........
··.. SEE SHEET 1\ ..., ··~:•::,..
···... ···. .... : ·.:.·· ,, ,,,,, ,,,, , ~··_,;,:.
.··
.
~~--:....~~~···· ... ~· ····· .. ~~~t, ·:."" .. .. ····... ··.....
:::
:··.... .
..
6
L Detail 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12 . 13. 14. 15.
16. 17. 18.
NOTE
L
Safety wire (10) to be . 032 dia. corrosion resistant wire.
Plate Control Cable Assembly Grommet Clamp Arm Tubular Structure Clamp Support Assembly Handle Safety Wire Grommet Spacer Placard Cras h Pad Cable Assembly Toggle Clamp Clamp Support Assembly
I
(
13
I
\
~ ..:...___14 . '~1 1
/
"""
16
~
"\ Detail
___
K
.-/·
I
)
7 Figure 19-4. Liquid Dispersal System (Sheet 2 of 4) 19-12
BEGINNING WITii SERIA L NO. 188-0318
MODEL 188 & T188 SERIES SERVICE MANUAL
3
2
5
Detail
N
3
8
5
N Detail
7
)J u
P
4
7
gru~
9
6
Detail Q
28
··..··..
···. . ...... ·· . .··
......··· ...··
Detail
R
R
~--- - - ~ --. .
.... ...
'"'
·:····,:····:···--.... ······~..••...
·····
6
~
5
4 *TORQUE TO
10-12 LB FT Detail
16 1.
2. 3. -1.
5. 6.
4
Support Boo m Support Clamp Assembly Hose Boom :--lozzle
T
BEGlNNlNG WITH SERIAL NO. 188-0498 7. 8.
9.
10. 11.
12. 13.
Nipple Adapter Extension Tube Spray Pressure Gage Cap 0- Ring Hose Coupler
~ lJ
?~ 1
t
tr~
:~
"'l>
14. Fitting 15. Y-Strainer 16. Discharge Tube 17. 'Hanger Bracket 18. Latch 19. Strainer 20. Retainer
21. End Cap 22. Diaphragm 23 . Nozzle Body 24. Strainer 25. Core 26. Onfice 27. Nut 28. Drain Cock
Figure 19- 4. Liquid Dispersal System (Sheet 3 of 4) 19-13
MODEL 188 8t T188 SERIES SERVICE MANUAL
3
2
"
5
'J~a
9
10
Detau A
Detail
0
' Detau C 8 STREAMEDLINED BOOM INSTALLATION
1. Support 2. Boom Mount 3. Socket 4. Bolt 5. Clevis 6. Nut
7. 8. 9. 10. 11. 12.
Support Boom Plug Clamp Fitting Nozzle
13. 14. 15. 16. 17. 18.
Spacer Hanger Cap Coupling Clamp Y-Strainer Assembly
Figure 19- 4. Liquid Dispersal System (Sheet 4 of 4) 19-13A
MODEL 188 & T188 SERIES SERVICE MANUAL
COUPLER ASSEMBLY
'
... BOOM SUPPORT BRACKET
.125 INDEX HOLE (T O BE USED ON OUTBOARD LOCATION ONLY)
.125 PLATE (6. 00 in x 3. 00 in)
F igure 19-4A. Boom Chord Angle of Incidence 19-13B
:MODEL 188 & T188 SERIES SERVICE MANUAL
CLAMPS OR BOLTS TO HOPPER OUTLET
5
.... ·. . ....
...... ··..................
.....................
~ ...-···~..........
····t···... :. ·· ·
....___ _ SEE FIGURE 19-3
.··
MODEL 1401 (54068) INSTALLATION TIIRU SERIAL 188-0317
··-..
;;
..
.. ..........~·········/
MODEL 1452 (54070) INSTALLATION
BEGINNING WlTH SERIAL 188-0318 AND ALL SERVICE PARTS
•..•'' ' /
.·· >SEE FIGURE 19-3
.. ..>::::~-·~-.~.
1. Strut Assembly
2. RH Wing Panel 3. Hanger 4. Connecting Rod 5. Boot 6. Strut Assembly 7. LH Wing Panel 8. Hanger 9. Center Section 10. Agitator 11 . Gate Box
6 CLAMPS OR BOLTS TO HOPPER OUTLET SWATHMASTER (MEDIUM VOLUME) INSTALLATIONS
Figure 19-5. Dry Dispersal Systems (Three Piece) 19- 14
·:
MODEL 188 & T188 SERIES SERVICE MANUAL
4
CLAMPS OR BOLTS TO HOPPER OUTLET
2
.·
..·..
6
3
2 ··.. ~1
,......
~l~ . ;::
../ .
;//.//
CLAMPS OR BOLTS ... ·.. ···~ ·.' • ...-;·:" ·_:~ . . .' TO HOPPER OUTLET .................... ··. . . ' : .._.,..•/ · ·· . .. .. . · ". .... ........ ~ ·-,.,.., ........., .. ~..-·
\\ '-.... ~ / '\ .......... /'•/ . \ ...
,
\<: ~: .~ (/~
· ~\{· .. ··
. ......
•
1. 2. 3. 4. 5. 6. 7. 8.
Support Brace Spreader CoMecting Rod Boot Adjustable Door Agitator Gate Box
.
·:
/
5
I:;,L.~~--1
. .... ·
. . . _~:...,...-2
··..............~.....
\<··.:. .. ._,... -- \\ \'\-
·'
\. \\ ·.;
6 THESE INSTALLATIONS AVAILABLE THRU SERIAL 18800832
VANE TYPE
(ffiGH VOLUME)
INSTALLATIONS
Figure 19-6. Dry Dispersal Systems (One Piece) 19-15
i MODEL 188 It T1 88 SERIES SERVICE MANUAL .... .•
Begtnnt~
serlal 18802746 (1977 Model) New Stainless Steel Model wtth Larger Throat is available
···
,- ·::-~ ··. ···.-;-_..: ~
~~~,, #~~ ::~
3
•
..
..
............
5
........ \
7
THINLINE INSTALLATION AVAILABLE BEGINNING WITH SERIAL 18800730
NOTE A typical installation is shown. Aircraft may be equipped wtth a gate box with the followt~ op tions: With Agitator Less Agitator With Prop-dr iven Agitator Beginning with Serial 18800833, gate box may be equipped with a 12 volt or 24 volt electric-driven agitator.
1. Gate Box Assembly 2. Propeller 3. Spreader Assembly
4. Brace 5. Hopper Control 6. Quick- Disconnect Oust Cap
Figure 19- 7, Dry Dispersal Systems (Thlnline) 19-16
Detail
A
7. Boom Support 8. Eye Bolt 9. Spacer
MODEL 188 & T188 SERIES SERVICE MANUAL
AUTOMATIC FLAGMAN (Mounted on right stubwing)
NOTE Keep water out of solenoid (1). When not in use or while standing in rain. place tape over solenoid plunger hole to keep out moisture. NOTE Clean out solenoid each 50 hours or more often if operating under dirty field condi tions; c lean contact points of electric swttch each 100 hours.
!WARNING a
NOTE CIRCUIT BREAKERS '·~
DO NOT USE TiiE AUTOMATIC
FLAGMAN WHEN DISPENSING
FLAMABLE MATERIALS, AS
TiiE SOLENOID COULD CAUSE
A FIRE. 1. Solenoid Spacer Dispenser Flag Card Stop Support Tab Lid Block Nose Cone ··u·· Channel Seal 11. Bracket 12. Bracket 13. Plate 14. Electrical Lead 15. Grommet 16. Tubing 17. Support 18. Support 19 . Socket and Housing 20. Clamp
2. 3. 4. 5. 6. 7. 8. 9. 10.
CONTACT~
,~ ~
Cement seal (10) to nose cone (9) with EC -800 or EC -1300 (3M Corporation).
( ~: \~
BUTT~N~ f/
SPRAY VALVE (OPEN) (CLOSE)
,,\ ,,1
'\
~
\
I'
··.\. ~ } I'
A~,.- ~~ /
-~
:· ) · I
L-.-~- ··.
NOTE
Trigger operation is dependent upon position of selector switch, located on instrument panel (shown below). When lower portion of switch is de pressed, trigger operates Automatic Flagman. When upper portion of switch is depressed. trigger operates spray lights and turn lights . Refer to Section 16 for description and operation of lights.
SPQAY'DT
LI~HT$
~
OFF
G
AUTt>
G
E
FLAG
I<
PISTOL GRIP TRIGGER
Figure 19-8. Automatic Flagman Installation 19-17
IMODEL 188 8t T188 SERIES SERVICE MANUAL
1. Fan 2 . Brake Drum 3. Pump Shaft 4 . Brake Shoes 5. Cam (Brake Actuator ) S. Brake Arm 7. P u mp Hous ing B. Pump Seal 9. Pump Impeller
9
Figure 19-9. Fan Brake Installation the empergency dump gate.
(See figure 19-4.) Rigging of this control is accomplished as follows: a. Loosen clamps securing control housing. b. Open emergency dump door. (Attach contr ol (2) and cable assembly (15) 11 not already attached.) c. Tighten clamp nearest door end ol control housing. d. Close emergency dump door . e. Push ring handle (9) to full IN position. f. Adjust cable assembly (15) at emergency dump door as necessary to enable ring handle to open emergency dump door. g. Tighten remaining clamps. h. Close emergency dump door . NOTE The emergency dump gate must be closed by hand once the control handle has been pulled. 19-13. FAN BRAKE. A pilot controlled fan brake lever is mounted on the right side of the cockpit. The control lever actuates the fan brake arm on the pump assembly through a flexible control cable. (Prior to Serial No. 1880318)A notch on the cockpit control mounting bracket provides a FAN STOP posi 足 tion. Pushing forward on the lever releases the brake on the pump assembly, allowing the fan to rotate. This installation Is s hown ln figure 19- 4 ( Begi nmng With Serial No. 1880318) Pulling back on the lever gradually engages the brake , caus1ng fan
l i-18
to stop. A lodt position Is reached when lever is pulled back to a hor izontal p osition. Pushing the lever forward r elease s the brake shoe from the brake drum, allowing the fan to rotate. A knurled knob on the control handle can be rotated cloclcwl.se to tighten the control cable, or counter 足 clockwise to loose n cable tension. As cable wears, tension may be readjusted by rotating knurled knob CLOCKWISE . This installation is shown In figure . 19- 9. 19-14 . RIGGING. (Prior to Serial No. 188-0318.) Adjustable rod ends are provided at each end of the fan brake contr ol for r igging. With lower end of con足 trol disconnected, a ne utral position of the fan brake lever can be felt. With cockpit control lever pushed forward, adjust rod e nd so control removes slack from the spring connected to fan brake lever , but fan still rotates freely. Pull cockpit control lever back to FAN STOP position and check that fan wlll not ro足 tate.
RIGGING. (Begtnnl~ with Serial No. 188- 0318, See figu re 19-4.) a. Push fan brake lever on pump assembly to full DOWN position, allowing fan to r otate fr eely. b. Push cockpit control lever (26) full FORWARD. c. Rotate knurled knob on cockpit control lever fully COUNTERCLOCKWISE. d. Attac h cable assembly to cockpit control lever. e. Loosen clamps securing control hous1ng.
MODEL 188 & T188 SERIES SERVICE MANUAL
Detail
A 3
2
A
,'-..... Detail
8 4
~\
· ·<:·: .~.;:~*~~~"· ;; .
c
Detail
C
Shims (11 ) are used under clamp assemblies (10) only when 1-3/ 8 inch diameter booms are installed.
~·
CLAMPS OR BOLTS /;::~ TO HOPPER OUTLET
* TiiRU SERIAL NO. 188-0274 ALS() REFER T0 SHEET 1A
\ \ _.,/ "
REFER TO FIGURE 19-3 • s ERIAL NO. 188- 0275 T HRU 188-0497
~: =~upp<>~t -
3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
'e. NOTE
Spring .,~.,... , ---- Spacer \ Nozzle ~ Nipple Outboard Boom Clamp Hose Clamp Assembly Shim Inboard Boom 16. Hanger Brackets Plug 17. Latch 18. Cap Spray Pressure Gage 19. 0 - Ring Pump Assembly
5
. . . . . . . . .. ·
0 20. 21. 22. 23.
(REF ER
. ,,,,:,!,~.... .
TO~~
Strainer Spray Pressur e Gage Line Y-Strainer Dischar ge Tube
24 . Gasket 25. Arm
Figure 19-10. Spray Syst em (Typical) f. Attach control cable assembly (22) to bracket (17) on fan brake lever. g. Adjust cable assembly attached to ran br ake
lever on pump assembly, and tighten clamp (19).
h. Pull cockpit control lever back to LOCK POSI TION and c heck that fan will not rotate. i. Final minor adjustments can be made by rotating knurled knob in direction necessary to obtain proper cable tens1on. 19-15. SPRAY SYSTEM PLUMBING . (See figure 19-9.) Chemicals flow from the pump now-control valve throu~th a dischar~~;e tube to the Y-strainer as sembly, then through the booms to the nozzles. Prior to Aircraft 188-0275, the spr ay pressure gage line is
connected to a fltttng installed ln the discharge tube. On Aircraft 188-0275 thru 188-0497, the spray pres s ur e gage line is connected to a fitting installed in the left Inboard boom. Beginning with Aircraft 188 0498, the s pray pressure gage line Is connected to a fitting installed in the Y- strainer assembly. 19.- 16. Y-STRAINER. The Y -s trainer assembly functions both as a strainer and a connector to each boom asse mbly. Removal and replacement may be accomplished while usi~ figure 19-11 as a guide. 19-17. INSPECTION. Inspect cap and latch for tightness. Inspect 0-r ing for corrOSIOn and wear , and pr oper seating. Clean strainer frequently and
19-19
MODEL 188 & T188 SERIES SERVICE MANUAL
TRANSLAND 120350
23
20
Detail
18
0
CESSNA ltl608065-1
TRANSLAND â&#x20AC;¢20841
Figure 19-11. Y-Strainer Installation 19-20
MODEL 188 & T188 SERIES SERVICE MANUAL
check hose co nnections for tightness and deteriora
tion. See figure 19- 11 fo r component parts of the
Y-strainer assembly.
19- 19. INSPECTION. Inspect hose connectio ns fo r tightness and deterioratio n. Check booms for cor rosion.
19-18. BOOM ASSEMBI.JES are shown in figure 19-4, which may be used as a guide for removal and re placement. For quick removal of individual booms: a. Loosen clamps and disconnect hoses, o r release quick-disconnects attaching boom assembly to Y strainer assembly. b. Remove bolt , washer, and nut from clamp
halves, then pull upper and lower clamp tabs from
slots in clamp retainers, and pull boom aft.
19- 20. NOZZLES. The booms are equipped wit h non- adjustable nozzles. Fluid pressure moves a spring- loaded diaphragm in the nozzle to allow liquid to enter the core of the nozzle . where it is diffused and emitted as spray. Hold nipple and turn nozzle , using wrench pad on nozzle body, to remove .
19-18A. STREAMLINED BOOM ASSEMBI.JES (BE
GINNING WITH 18803872.) (See figure 19- 4.)
· 19-18B. REMOVAL AND INSTALLATION- STREA~i LINED BOOM ASSEMBLIES. (See figure 19- 4, sheet' 4 of 4). For quick removal of individual booms: a. Disconnect coupling (16) from y- strainer assem bly (18). b. Remove nuts (6) and bolts (4) then remove boom
(8).
c. For installation, install bolts (4) through clevises (5) and boom supports (7), and install nuts (6). d. Index booms in accordance with paragraph 19-18C. 19-18C. SETTING BOOM CHORD ANGLE OF INCI
DENCE. (See figures 19-4, sheet 4 of 4 and 19-4A. )
a. With booms installed, loosen nuts (6) and bolts (4) on one boom (8). b. Loosen clamps (17). c. Disconnect coupling (16). d . Insert indexing pin (MS20392-1C33) in indexing
hole in the outboard boom support (7) and rotate
boom (8) until indexing pin is contacted by clevis (5).
e. Tighten nut (6) on bolt (4) at outboard boom sup port.
C. Using a C-clamp, secure a . 125 plate outboard
of the boom support , shown in figure 19-4A.
g . Attach an inclinometer to the plate as shown and
set to 0° .
NOTE An inclinometer is available from the Cessna Supply Division, See figure 6-4. h. Being careful not to move the dial on the inclino meter , remove c-clamps , plate, and inclino meter from outboard location and move to next inboard boom support. l. Wlth plate and inclinometer installed, read the degree of angle and make necessary adjustments by rotating boom so angle of incidence reads o·. j. Tighten nut (~) and bolt (4) at this location. k. Repeat procedure for the two inboard boom sup ports. l. 1lghten hose clamps (17). m . Connect coupling (16). n. Remove indexing pin. o . Repeat steps a . through n. fo r opposite boom.
NOTE Nozzle direction may be changed by r o tating the booms in thelr clamps. 19-21. DISASSEMBLY. When disassembling a nozzle, hold nozzle with outlet up and carefully disasse mble, noting exact relationship of parts fo r reassembly. 19- 22. ROTARY ATOMIZER OPTION. Figure 19- 19 shows the rotary atomizer available with the 1979 Model Year airplane. The atomizers replace nozzles in this application . Refer to Vendor Publi- ~ cations for complete description, operation, and maintenance. Vendor publications are available ·thru the Cessna Supply Division. 19-23. ~RESSURE GAGE. A direct-reading pres sure gage is mounted in the instrument cluster above the panel pad in the cockpit. The gage is connected by tubing to a fitting on the pump discharge tube, left inboard boom, or the Y-strainer assembly, and indicates boom pressure. To r emove gage from instrument panel, disconnect tube from back of gage and unscrew be_z el attaching gage to panel. 19-24. QUICK- LOADER SYSTEMS. Three quick loader installations are available as optional equip ment. The left-hand, right- hand, and dual installa tions are shown in figure 19- 16. A manually oper ated valve controls flow of material into the hopper. On the dual installation, be sure that o nly the valve being used is opened. Removal and installatio n of the quick-loader system may be accomplished wh1le usir.g the lllustration as a guide. Inspect hose con nections for tightness and deterioration. Check the valves for proper operation. Seal all inside corners , edges , and open ings in and around boxes (3) with General E lectric RTV 102, Dow Co rning 732 RTV, or equivalent sealant.
ISAUTION! In freezing weather, d r ain the hopper and quick- loader valves. Leave valves open to pr event damage.
Revision 1
19-21
MODEL 188 & T188 SERIES SERVICE M ANUAL
2
1
3
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 .
Nozzle Diaphram Spring Seat Strainer Orifice Spray Pattern Nut Retainer Cor e End Cap Assembly Retainer
Figure 19- 12. Spray Nozzle 19-25. DUST DISPERSAL SYSTEMS. Various sys tems have been available as optional equipment. Major components of the systems include a hopper, gate box with agitator and gate-control mechanism, cockpit control handle and connecting rod, and spreader assembly. The installations illustrated on figure 19-5 includes a center section, left and right wing panels. The one-piece assemblies are shown in figure 19-7. The spreaders are equipped with ad justable side doors on the inboard sides of the spreader. The "THINLINE" model, figure 19- 7, improves aircraft performance by creating less drag, and is a high volume unit. 19- 26.
TROUBLE SHOOTING.
See paragraph 19-3.
19- 27 . HOPPER. The same hopper that is used for the liquid spray system is also used for the dust dis persal system. Instead of the pump assembly used with the spray s ystem. a gate box with agitator is clamped o r bolted to the bottom of the ho pper. 19 - 28. GATEBOX AND SPREADER ASSEMBLY. The gatebox is available 1n three conftgurat1ons. without an ag1tator, w1th ram a1r fan driven ag1tator, o r w1th an electriC driven ag1ataor (12 or 28 volt). The gate (gatebox outlet door) is controlled by a 19-22
handle in the cockpit. Ram air nows underneath the gate box whe r e it picks up the chemical and carries it into the spr eader, whe r e it is dispersed through vanes or wing panels of the spreader.
!WARNING ' Insure that ga te control handle and micro meter screw stop is FULL AFT and stop is DOWN holding handle, before working under airc raft. 19-29. GATEBOX CCNTROL. Material flow through the gate box is controlled by a handle in the cockpit. The handle is moved along a fixed micrometer screw to a flow rate position that is determined by an ad justable stop on the micrometer screw. A crank on the micrometer screw may be operated from the cockpit to set the stop. The hopper control handle is also used as an emergency dump lever. This is accomplished by nipping the adjustable stop out of position so the handle may be p..tShed to the full for ward position. Frequently check the rubber boot on the fuselage underside for damage whtch could per mi t chemicals to enter the cockpit.
19-30.
REMOVAL AND INSTALLATION.
MODEL 188 & T188 SERIES SERVICE MANUAL
7
*
Seal 4 bolts attaching cover (13) and 1 bolt attaching hook (15) with EP-711 82 (Coast Pro-Seal; Compton, California).
THRU 18802745 1. Agitator Assembly 2. Gasket 3. Cap 4. Flange Fitting 5. Flapper Valve Assembly 6 . Seal 7. Propeller Blade 8. Support 9. Gear Reducer 10. Coupling and Key 11 . Gate Box Asse mbly 12. Cap 13 . Cover 14. Agitator SuppJrt 15. Hook
Figure 19-13. Gatebox Assembly (Sheet 1 of 2) ~-
19-22A
MODEL 188 & T188 SERIES SERVICE MANUAL
3 5
10
18 19
NOTE Cover (8) is installed when fan drtve assembly and agiator ar e not installed.
BEGINNING WITH 18802746 AND Tl 8803297
Covers (11) and (12) are in stalled when !lapper valve assembly and flange fitting are not tnstalled. Ftgure 19-13. Gatebox Assembly (Sheet 2 of 2) I9-22B
1. Fan Assembly 2. Bracket 3. Speed Reducer 4. Coupling 5. Seal 6. Gatebox Assembly 7. Aglator Assembly 8. Cover 9, Cover 10. Bolt 11. Cover 12. Cover 13. Shaft Support 14. Retainer (Gate Seal) 15. Seal 16. Support (Gate Seal) 17. Flapper Valve Assembly 18. Bracket Support 19. Gasket 20. Flange Fitti~ 21. Cap
MODEL 188 8t T188 SERIES SERVICE MANUAL
1
View A. Gate Closed
..
_, ~~~ _ 3
_,.1
'·
12
1
View B. Gate Open
3
5 I. Gatebox 2. Gate Seal 3. Control Rod 4 . Gatebox Rod Assembly 5. Gate Assembly 6. Gate Hinge F ork 7. Bell Crank Assembly B. Door ~ount Bolts 9 . Gatebox Door 10. Gate Seal ~ount Bolts I I. Se:il Retatner 12 . Bolt
NOTE
Lube all bearing and pivot surfaces with E Iectro Molly. No. 11.
• Approximately 2 Inches
*
Approximately 11 .6 Inches D1 mensions are approximate. may be changed when using dry chemtcals. Figure 19-14.
Rigging Gate Assembly 19-23
MODEL 188 & T188 SERIES SERVICE MANUAL
10
.. ' ' .
' ........ - -
,.. k
••
··•······••
12
1\:q\ \ \ ':\ \ ;\: \]:\ :\ ~ Spreader Assembly IWARNINGl
Due to EXTREME toxic nature of most agricultural chemicals use caution when working on dispersal system. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Gate Box Agitator Drive Fan Control Rod Gate Box Rod Assembly Agitator Gate Hinge Fork Bellcrank As sembly Control Arm Control Handle Micrometer Screw Micrometer Screw Stop Spreader Latch Rear Spreade r :\1ount Bolts
• Belly Skin Clearance Necessary at this Point in Rigging
Figure 19-15. Gatebox Installation 19 -24
MODEL 188 & T188 SERIES SERVICE MANUAL
...········-··-·-.:·~·····...
·.·.··..
.
1
··•···....
..:'· .
.·.~~· ...... ..i-<·....
·. .
....;.··_:::_·._ ;. ·. .
..
..' - .• . . ·. ·. ·, li:':: : : . ~-
~
-.,
..... ····.. .-. ·~ ... ••
~
>···..· -.-
..
...
......\ ....... ····...·.. ...... ·.
. ..
···-·..·..····.·,·.:~.~-~_::~ ·
. :::· ....: ~..
.,.
·... ·...
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.·
.·
. .- · ·~· ··
.·1··
-;···
•••••
.:
.•
~-:::::>····
..·
..
..·...
·~
···...
...............
... ..• : .
SEE FIGURE 19-2 - -...1
NOTE T hree configur ations of the optional quick-loader system are available: a right side, lelt side, or dual installation. Tee (8) replaces elbows (7) in the dual-loading system.
3 1. Hopper 2. Cover 3. Box 4. Loader Valve 5. Clamp 6. Hose 7. Elbow 8. Tee 9 . Tube 10. Sprtng 11. Stiffener 12. Control Handle
3
11
NOTE Beginning with 18800573, a spring-loaded flapper check valve is added to the hopper at the side loading valve system outlet.
5 Detail
A 4
Figure 19- 16. Qu ick -Loader Systems 19-25
MODEL 188 & T188 SERI ES SERVICE M ANUAL
NOTE Insure th.at hopper is clean and drained prior to wor king under aircraft on the dispersal system. Even small amounts oL agricultural chemicals can be dangerous. a. In cockpit place gatebox door control in FULL FORWARD position. Micrometer screw stop must be lifted to allow control to move to the dump position. b. Disconnect two gate box rod assemblies (4) from gate assembly (5 ), allowing door (9) to swing fr ee. (See figure 19-15. ) c. Remove four door mount bolts (8) allowing removal of door (9) from gate box. exposing agitator . d. U seal is to be replaced, remove nine bolts (10) securing seal retainer (11) and seal (2) to door (9). NOTE Seal is of cast urethane compound material, and is self lubricating. It Is secured by the retainer only. Bronze bushings on agitator shalt require occasional oiling. e. U repair or removal of agitator is required,
proceed to step "h".
r. Place door in opening of gate box, and install
four mount bolts (8). Loosen two gate hinge fork
nuts (6) as new seal will be thicker th.an old one.
U reinstalling same seal, above step may be
omitted.
g. Connect gate box rod assemblies (4) to door
brackets (5). Since rod ends are not normally
adjusted from the 11. 6 inch length, re-adjustment
is not necessary. however. for ease of operation
rods may be lengthened, when dry chemicals are
used.
h. Remove four speed reducer mount bolts on ag1tator drive. and if electrically driven, remove applicable wiring . Mark wires to aid installation. Remove speed reducer. separating drive coupllng halves. This will allow agitator removal from bearing at non-drive end of gate box. To r eassemble reverse above steps. Lube agitator bearing surfaces with Electro Molly, No. 11. 19-31. RIGGING. NO!E To set up gatebox, see figure 19-14,
and loosen nine seal mount bolts (10) and
four door mount bolts (8). This will allow
seal to form itself in the seat as the gate
ls closed.
a. Gate box assembly must be set up prior to rig g ing the controls.
To accomplish this, drop sprea der down for access. See figure 19-15, remove eight screws along rear edge of gate. Loosen two rear spreader mount bolts (13), and open spreader latches (12).
19-26
fcAUTION\ Exercise caution, as mount latches are
open, because spreader will drop down
and possibly forward, if not supported.
b. Referring to figure 19-14, set up 2-inch dimen sion at gate hinge forks (6) and the 11. 6- inch dimen sion on gate box assemblies (4). c. In cockpit, move gate box control handle (item 9, figure 19- 15) to the FULL AFT position. NO!E Ensure that clearance is maintained between control arm and aircraft belly skin. d. Referring to figure 19- 15, align control rod (3) with arm on bellcrank assembly (7). e. Install hardware in removal sequence, ensuring that sufficient belly clearance is maintained and that bellcrank is locked overcenter. f. Referring to figure 19-14, tighten nine gate seal mount bolts (10) and four door mount bolts. (8). g. Operate handle ln cockpit to ensure smooth operation thr oughout limits of movemenL Overcen ter should be felt as the handle reaches FULL AFT traveL h. Check seating of gate box seal by pouring water lnto the hopper with the gate closed. There should be no seepage around seal. NO!E II leakage is evident, adjust hinge fork
bolts or gate box rod as required to seal.
i.. Raise fr ont of spr eader, latch two front mount latches, and lnstall eight mount screws. Tighten two rear mount bolts (item 13, ftgure 19-15) at rear of spreader.
19-32. CLEANING DISPERSAL EQUIPMENT. It ls important that dispersal equipment be kept clean. Since there are literally thousands of trade formulations for chemicals that may be used ln aerial application, it is impractical to list clean ing compounds for all types. Follow manufacturer Instructions when given. However, a solution of household ammonia and water, or a solution of powdered, activated charcoal, ~undry detergent, and water will generally suffice. Mix the ammonia solution in a ratio of one quart of household am monia to one gallon of water. Prepare about live gallons and pour Into the hopper, agitate vigorously to clean the hopper, then fill the hopper w1th water. With spray nozzles removed, start the engine and operate at 1500 rpm, release the fan brake and empty the hopper through the system. This wil l take 10 to 15 mtnutes. Follow by nnsutg w1th clean water. Mix the charcoal solution 1n a rat10 of 1 ' 4 pound of activated charcoal and 1/ 8 to 1/ 4 pound of laundry detergent to 10 gallons of water. The same cleamng and flushing procedure may be used wtth this solutiOn. When operating the system, be sure
MODEL 188 & T188 SERIES SERVICE MANUAL
All fiLLU
fNGINl-OIIVIN PUMP
VALVE
t
HO,EI
.OFFÂ ON.
L-------~
18801041 FILTU THRU
HYOIAULIC MOTOR
18801424
COCKPIT CONTIOL
IIOOM 'IISSUU GAGE
SPlAY PUMP
SPlAY VALVE
PAnt OF FLOW FROM RESERVOlR PRESSURIZED UNES WHE N: (1) Engine and engine - driven pump running (2) Cockpit cont r ol: OFF (3) Hydraulic motor: INOPERATIVE (4) Relief valve: CLOSED
18800573 THRU 18801374
All
INGINf. OIIVIN PUMP
fiLLII V AL VI
.A .:: T
HO,EI
I
18801041
fiLTER HYDRAUliC MO TOR
THRU
18801424
..
.OFF-O N.
L-------~
..
COCKPIT CO NTR OL
IIO O M PU SSUU G AGE
SPlAY PUMP
...
[=:J
SPlAY VAlV E
PATH OF FLOW FROM RESERVOIR PRESSURIZED UNES WHEN: (I) Eng~ne and e~ne -drlven pump runmng (2) Cockpit control: ON (3) HydrauUc motor: OPERATIVE (4) Relief valve: CLOS ED
Figure 19-17.
18800573 THRU 18801374
Hydraulically-operated Dispersal System Schematic (Sheet 1 of 4) 19 - 27
MODEL 188 & T188 SERIES SERVICE MAN UAL
All lNGINl- OIIVl N ,UM,
Flllll
t ON - OFF V .AlVl
18801041
FILTER
THRU
18801424
HTOI AULIC MOTO I
COCK' IT COHTIOL
IIOOM 'llSSUil GAOl
S'IAT VALVE
PATH OF FLOW FROM RESERVOIR PRESSURlZ£0 LINES WHEN: (I) Engine and englne - dnven pump running (2) Cockpit control: ON (3) HydrauUc motor: INOPERATIVE (4) Reller valve: OPEN
18800573 THRU 18801374
Figure 19-17. Hydraulically-Operated Dispersal System Schematic (Sheet 2 of 4)
LEGENDS FOR SCHEMATICS ILLUSTRATED ON SHEETS 3 AND 4 AND FIGURE 19-18.
CD CONDITION: Engine and engine -driven pump running (1)
CD CONDITION: Engine and engine-driven pump running (1)
(2) Cockpit control : ON (3) Hydraulic motor: OPERATIVE (4) Relief valve: CLOSED
CD
CONDITION: (1) Engine and engine-driven pump running (2) Cockpit control: ON (3) Hydraulic motor: INOPERATIVE (4) Relief valve: OPEN
to be located in an area where the solutions will not cause damage to vegetation or personnel.
!WARNINGl A.!ter us1ng herb1c1des lplant killers), It 1s 1mperauve that equ1pment be thoroughly cleaned before us1ng other chem1cals that are not harmful to plants. A very small res1due from some herbicides can severely damage crops. Also remove all hose con nections 1n the spray system and replace w1th new hoses. Some operators will prefer 19-28
(2) Cockpit control: OFF (3) Hydraulic motor: INOPERATIVE (4) Relief valve: CLOSED
0
CONDITIO~:
(1) Engtne and engine-driven pump running
(2) (3) (4) (5)
Cockpit control: ON Hydraulic motor: OPERATIVE Relief valve: CLOSED Boom Pressure valve control: OPEN
to keep two sets of boom and nozzle assem blies, one exclusively for herbicides. 19-33. HYDRAULICALLY- OPERATED DISPERSAL SYSTEMS. (See figure 19-21.) Engine driven hyd raulic spray systems are available for a1rcraft equtp ped with constant speed-propellers. The systems are composed of a pressurized hydraulic reservoir, an engtne-driven pump, mounted on the accessory pad of the engine, an ON- OFF valve, pressure relief valve, a hydraulic fluid cooler (prior to Serial 18803522), hydraulic pump, hydraulic motor, cockpit control, and associated lines and fittings. The systems are installed in the baggage area, immedi
MODEL 188 8t T188 SERIES SERVICE MANUAL SYSTEM ON- OFF LEVER
(:::J
mnmm
PRESSURE I
, ,-- _,,:.. ..
STATIC PRESSURE
I
FLUID FLOW PATH
I I I ON
~
I
RAY MATERIAL RETURN FROM SPRAY VALVE
\
\
I
\
\
\
\
' , ...\
"----"
OFF
REFER TO SHEET 2 FOR CONDITION
STRAINER
HYDRAULIC FLUID COOLER
HYDRAULIC MOTOR
RETURN TO GATE BO X
I ~
SEAL DRAIN
ENGINE DR IV EN PUMP
II flll£1
TO SPRA Y BOOM
lOOM PRESSURE SCREEN CONTROL KNOB SYSTEM ON- OFF LEVER
lf*·~jJ PRESSURE
mmmn ~
STATIC PRESSURE FLUID FLOW PATH
REFER TO SHEET 2 FOR CONDITION
HY DRAUL IC FLUID COO LER SPRAY PUMP
ENG INE DRI VEN PUMP
IR FILL£R
~
BOOM PRESSURE SCREEN CONTROL KNOB
Y- STRAINER
18801375 T HRU 18803 521
Figur e 19-17. Hydraulically- Oper ated Dispersa l System Schematic (Sheet 3 of 4) 19- 29
MODEL 188 & T188 SERIES SERVICE MANUAL
SYSTEM ON - O FF LE V ER
c:J
PRESSUU
IIIIIIIIIII s TA Tl c ~
p RE s s u u
PRA Y MA TERIAL RETU RN FROM SPRAY V ALVE
FLUID FLOW PATH
REFER TO SHEET 2 FOR CONDITION
STRAINER
HYDRA ULIC flU ID COOLER
SP RAY PUMP
HAFT DRAIN
EN GI NE DRIVE N PU MP
IR fllL U
SCREEN
c=J miliiiiii ~
I
~
llOOM PRESSURE CONTROL KNOll
TO S PRA Y BO OM Y-S TRAINER
SY STEM O N- OFF lE V ER PRESSURE STATI C PRE SSU RE
PRA Y MATERIAL RETURN FRO M SPRAY V ALVE
FLUID FLOW P ATH
STRA INER
HY DRAULIC FlUI D COOLE R
HYDRAULIC MOTOR
', OOMI PRESS . I V AL V E! I I I
ENGIN E DRIVE N
PU MP
IR
REFER TO SHEET 2 FOR CONDITION
SPRAY PUMP
RETURN TO GA TE llOx
FILLER ~• ~-
..
·~
SC REEN
ll OO M PRE SS URE CO NTR O L KNOll
TO SPRA Y ISO O M Y-S TRA I NER
18801375 THRU 1880352 1 Figure 19-17. 19-30
Hydrau lically - Operated Dispersal System Schematic (Sheet 4 of 4)
MODEL 188 & T188 SERIES SERVICE MANUAL
SYSTEM ON OFF LEVU PRESSURE I
liiiiiliiiD
-
, , - ~=~ ..
I
STATIC PRESSURE
'
'' '' \
I
SPRAY MATERIAL RETURN FROM SPRAY VALVE
...........__.. ' ' OFF \
FLUID FLOW PATH
HOPPER
ON
\
HYDRAULIC MOTOR
RELIEF VALVE
SPRAY PUMP
RETURN TO GATE BOX ENGINE DRIVEN PUMP
FilTER BYPASS VALVE
Y-STRAINER
..
, - - - - - - - - - - _ , SYSTEM ON-OFF LEVU
Mt\ll IIIIl1IIliJ
PRESSURE
,
~--
I
I
I 0
S TA TIC P R ES S U RE
-FLUID FLOW PATH
HOPPER
I I I I
I
I
ON '
1
.....____....,
OFF
RELIEF VALVE
SPRAY PUMP
RETURN TO GATE aox
ENGINE- ,.~... ""~' DRIVEN PUMP
FILTER 8YPASS VALVE
MOTOR SHAF I SEAL DRAIN I I
... """ ~ lOOM PRESSURE O IL FillER . DIPSTICK & SCREEN CONTROL KNOI
TO SPRAY lOOM Y-STRAINER
BEGINNING WITH 18803522 Figure 19-18. Hydraulically-Operated Dispersal System Schematic (Sheet 1 of 2) 19-31
MODEL 188 & T188 SERIES SERVICE MANUAL
SYSTEM ON - OFF LEVU (·.·.-.'-~
:- J
,c:i)o•
PUSSURE
IIIIIIIIIIJ
S T A Tl C P I E5 S U RE
-
FLUID FLOW PATH
I
I
OFF
HOPPER
p
SPRAY MATERIAL RETURN FROM SPRAY VALVE
RELIEF VALVE
RETURN TO GATE BOX
ENG INE DR IV EN PUMP
MOTOR SHAFT ' SEAL DltAIN
I
ov>...,.,.._.,.,
... """ ~
FILTER BYPASS VALVE
OIL FillER , BOOM PRESSURE DIPSTICK & SCREEN CONTROL KNOB
TO SPRAY BOOM Y- STRAINER
SYSTEM ON - OFF LEVER
c::::::J
P RE S S U 1tE
rna
STATIC PRESSURE
-FLUID FLOW PATH I
I
HYDitAULIC MOTOit
RELIEF VAlVE
' OM\
SPRAY PUMP
PRESS . 1 VAL VEt
ENG INE
DR IV EN
PUM P
Alit
Fll TER BYPASS VALVE
Fi llER~ ~
OIL FILLER . BO OM PIESSUR DIPST IC K & SCREEN CONTR O L KNOB
Y- STRA I NER
BEGINNING WITH 18803522
F igur e 19-18. 19 - 32
Hydraulically- Operated Disper sal System Schematic (Sheet 2 of 2)
MODEL 188 & T188 SERIES SERVICE MANUAL
ately aft of the firewall. The systems cannot be in stalled in aircraft equipped with a baggage compart ment fl oorboard. On aircraft Serials 18800833 thru 18803521, air scoops, mounted in the wing root fair ings, receive ram air, which is routed to a hydr:tulic fluid cooler. After passing through the cooler, the heated air is routed overboard through an opening immediately below the cooler. Beginning with Serial 18803522, air scoops, mounted in the wing root fair ings, receive ram air, which is routed to a shroud, surrounding the hydraulic fluid reservoir. Cooling fins are machined into the reservoir ooter rube to cool the fluid in the reservoir. The heated air is routed oot of the shroud through a square opening in the shroud. On aircraft serials 18801041 through 18801374, a hydraulic fluid fUter is installed in the system between the reservoir and the engine-driven pump. Beginning with 18801375, the reservoir, ON OFF valve, pressure relief valve, filter and filter bypass valve are contained in a single unit. 19-34. SYSTEM OPERATION. (See figures 19-17 and 19-18.) Hydraulic fluid is routed through the system as illustrated in the schematic diagrams. These schematics may be used for trouble shooting the systems under various operating conditions. The systems are "closed", therefore no other systems are affected if malfunctions are encountered. 19-35. SERVICING. Prior to serial 18801375, the
hydraulic fluid reservoir is pressurized to 8-10ps1.
(~AUTION \ Depress air valve core to relieve pressure before !Uling reservoir or removing sys tem components. Fill the reservoir to 3. 00 inches from the top of the
filler neck using Type "A" Automatic Transmission
Clwd and install filler plug. Pressurize reservoir to
8-10 psL Beginning with serial18801375, fill reser voir to FULL mark on dipstick with DEXRON type auto matic transmission fluid and charge to 15 psi. 19-36. HYDRAULIC FLUID FILTER. (See figure 19-21 , Sheet 9). A hydraulic fluid filter is installed at the firewall between the reservoir and the engine driven pump on aircraft serials 18801041 thru 18801374. The filter contains a throw -away element which can be removed by unscrewing the cartridge from the head. To install a replacement cartridge, apply a film of oil to the seal and hand-turn the cartridge until seal con tacts head. After contact, tighten 1/ 4 turn only. Start system and check !or leaks. The cartridge should be changed after the first 50 hours of operation and each 250 hours thereafter. Under extremely dirty conditions, change more frequently. The filter head is equipped with a bypass which will open and allow fiu1d flow in event the filter becomes clogged . Beginning Wlth serial 18801375, the filter is installed in an inverted position on the reservoir assembly. The cartndge is screwed Into a standpipe In the reser vo1r. A bypass is contained at the bottom o! an adja cent standpipe.
(~AUTIONl Before removing the cartridge from the filter mounted on the reservoir assembly, allow sufficient time for fluid to drain from the cartridge into the reservoir. 19- 37. HYDRAULIC FLUID COOLER. (See figure 19-21.) On aircraft serials 18800573 thru 18803522, a hydraulic fluid cooler is installed in the return line to the fluid reservoir. The cooler is the same type as the one used as the engine oil cooler. All fluid passes through the cooler as it returns to the reser voir, thus maintaining the most efficient hydraulic system operation. Heat transfer in the cooler is affected by routing ram air from inlet ports in the sb.lb wing leading edge, through the cooli.ng fins, and exhausting it behind the engine firewall, through an opening in the aircraft belly skin. 19-38. REMOVAL AND INSTALLATION. Figure
19-21 may be used as a guide for removal and
installation of system components.
/~AUTION \ Depress air valve core to relieve pressure before filling reservoir or removing sys tem components. As motor is pulled away from pump, coupling will separate. Use caution to prevent brass bushing from falling out. 19-39. RIGGING. With cockpit control pushed full IN, move a.r m on ON-OFF valve to full FORWARD position. Pull control knob out approximately 1/8" to obtain cushion. Adjust rod end on control to en gage valve arm . Install pin, washers and cotter pin. Move control knob in and out several times to check valve arm for freedom of movement. 19-40. HYDRAULIC RESERVOffi ASSEMBLY. (See figure 19-23.) 19-41. DESCRIPTION. Beginning with serial 18801375, a pressurized hydraulic reservoir as sembly Is mounted aft of the firewall on the left for ward side of the baggage area. · The assembly is comprised of a reservoir, oil filler wtth screen and dipstick, on- off valve, relief valve, air filler valve and a filter with a bypass valve. The CUter element is screwed into a standpipe in the reservoir body as sembly. The filter bypass valve Is installed at the bottom of an adjacent s tandpipe. The bypass valve is preset and should not be adjusted. The air valve core must be depressed to relieve system pressure before filling the reservoir, replacing the filter element or removing a system component. When removing the filter element, allow sufficient time for fluid to drain fro m th~ element Into the reservoir. The relief valve, located 1n the reservoir body assembly, is preset and should not be adjusted. 19-42. REMOVAL. (See figure 19-21, sheet 8 of 11) a. Remove side panels on left side o! aircraft, aft o! ifrewall. 19-33
MODEL 188 & T188 SERIES SERVICE MAN UAL
5
6
6
Detail (
Detail 8
0eta11 A
_..---,, (.' .. . >:: ·-~::··..... '""' .
7
SEE FIGURE 19-20
··...···.,·.,
8
....··
'~, ' ·"· ~~
...··
__
9
10
..·· ··:~: ~--
· · ·,..··'(~:>> '""'- STRUTMASTER OR HYDRAUUC DIS PERSAL SYSTEM
..
·
~
~
INSTALLATION---~-'
\.) ..._,. .
.
c ' ····-···-·····--···-·-...._ 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Pump-to-Strainer Tube Y Strainer Bracket Forward Boom Support Rear Boom Support Boom Mount Boom Cap Assembly Outboard Boom Center Boom Inboard Boom Contro ls Boom Pressure Hose
....
19-34
-·-·-.,_
·--....._
5
Detail O F ~g ure
,
5
.
6
~.,~,E
19-19. Rotar y Atomizer Spray System Installation
.
""···~...·--··t:;!J,..., ..-··- --····'
MODEL 188 & T188 SERIES SERVICE MANUAL
7
1. 2. 3. 4. 5. 6. 7.
8. 9. 10.
Shutoff Screw Wing Nut Check Valve Plug Self- Locking Nut Compression Spring Diaphragm Follower . Lock Ring
Diaphragm Main Body Assembly Pipe Reducer Bushing
11. 0-Rlng 12. 0-Rirlg
13. Orifice Plate 14. 15.
0-Ring 0-Ring
16. Output Cup End 17. Washer 18. Nut 19. Bandit Clamp 20. Hose 21. Fan Shaft 22. Fan Assembly 23. Adapter Screen 24. Screw 25. Body 26. Screw 27. Spring 28. Cup 29. Gasket 30 . Washer 31. Nut 32. Cage 33. End Plate 34. Bolt
25
Figure 19-20. Rotary Atomizer Assembly 19-35
MODEL 188 & T188 SERIES SERVICE MANUAL
3
8
9
Detail
A
FILL TO 3. 00 INCHES FROM TOP USING TYPE "A" AUTOÂ MATIC TRANSMISSION FLUID AND PRESSURIZE TO 8-10 PSI.
12 Detail
8
18800573 THRU 18800832 Detail 1. 2. 3. 4. 5.
Detail
0
Reservoi r Air F iller Valve Fluid Filler Valve Engine-Dnven Pump Gatebox
6. Hydraulic Fluid Cooler 7. Boom Pressure Gage 8. Placard 9. Spray Pump Control 10. Hydraulic Motor 11. ON/ OFF Valve
12. 13. 14. 15. 16.
Clamp Hal! Valve Handle Clevis Clamp Relief Valve
F igure 19-21. Hydraulically- Operated Dispersal Systems (Sheet 1 of 14) 19-36
MODEL 188 & T188 SERIES SERVICE MANUAL
BOOM PRESSURE GAGE
SHUT- OFF VALVE
ll:l:::::. fr""7"'-:....:._-Q REFER TO SHEET 5
REFER TO SHEET 3
18800833 THRU 18801374
FAUUNG LEADING EDGE
c03
Detail
A
Figure 19-21. Hydraulically-Operated Dispersal Systems (Sheet 2 of 14) 19-37
MODEL 188 & T188 SERIES SERVICE MANUAL
r----THRU 18800851 BEGINNING WITH 18800852
I
I
I
/ /
/
v
,
~ Detail
1. Oil Cooler 2. Shroud Assembly 3. Clamp 4. RH Ram Air Hose 5. LH Ram Air Hose 6. Reservoir 7. Hydr aulic Motor 8. Support Assembly 9. Control 10. Shut-O!C Valve 11. Reinfor cement Plate 12. Cove r 13. Screen 14. Retainer
8 18800833 THRU 18801040
Figure 19-21. Hydraulically-Operated Dispersal Systems (Sheet 3 of 14) 19- 38
MODEL 188 & T188 SERIES SERVICE MANUAL
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
Female Coupling Coupling Gasket Vent Line Nipple Housing Impeller Spacer Seal Gasket Bearing Cage Key Shaft Retaining Ring Bearing Spacer Cap
40
32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49 .
Support Plastic Insert Coupling Hook Pin Clamp Bushing Hydraulic Motor Spacer Spacer Assembly Gate Box Male Coupling Dust Cap Female Coupling Manual Valve Clamp Hose Shim
18800805
THRU
18801040
45
<"
-~
18800573 THRU 18801040
44
/
~~
~~ -'
'1J / /
/ ' Deta1l
/
I
/
/ 48
C 15
Figure 19- 21. Hydrauli cally-Operated Dispersal Systems (Sheet 4 of 14) 19-39
MODEL 188 & T188 SERIES SERVICE MANUAL
NOTE Refer to sheet 4 Cor callouts.
18801041 THRU 18801374
32 '
;
l±27
*
. I
*TANG DRIVE
26
• SPLINE DRIVE
•
43 29
30
44
25 24 23
NOTE
/
<..
22 21 48
~
Lubricate splines of shaft • (27) with MIL-G-21164 upon installation.
~ ~/ F1gure 19-21. Hydraulically- Operated Dispersal Systems (Sheet 5 of 14) 19- 40
MODEL 188 8t T188 SERIES SERVICE MANUAL
NOTE
Refer to s heet 4 for callouts.
46
NOTE
Lubricate splines of shaft â&#x20AC;¢ (27) with
MI L-C-21164 upon installation.
BEGINNING WlTH 18801375
43
44
15
~A* *
T HRU 18803721
Figure 19-21. Hydraulically-Operated Dispersal Systems (Sheet 6 of 14) 19- 41
MODEL 188 8t T188 SERIES SERVICE MANUAL
1
5
1. 2. 3. 4. 5. 6. 7. 8. 9.
~6 Deta1l
Gasket Tube Assembly Clamp Hose Safety Wire Plug Tube Assembly Coupler Assembly Coupli~ Adaptor
A
BEGINNING WI'IH 18803722
Figure 19-21. Hydraulically- Operated Dispersal Systems (Sheet 7 of 14) 19- 42
MODEL 188 & T188 SERIES SERVICE MANUAL
RETRACTABLE HANDLE-~ '
57 18802746
new1 E
IWARNING ' MAKE SURE HOPPER CONTROL STOP (54) IS IN LOCK POSITION BEFORE WORKING UNDER AffiCRAFT. â&#x20AC;¢
Beginning with 18801825
49
Detail
0
49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70.
Bellcrank Half Gatebox Shaft Arm Assembly Connecting Rod Micr ometer Hopper Control Stop Bracket Stop Spray Valve Control Arm Shaft Crank Assembly Hopper Control Handle Actuato r Assem bly Control Rod Boot Bellcrank Baffle Double r Control Rod Ball Valve Adapter Boot
Figure 19- 21. Hydr aulically-Operated Dispersal Syst ems (Sheet 8 of 14)
-
19-43
MODEL 188 & T188 SERIES SERVICE MANUAL
15
16
15 1213 1011 \ \
9
"),.\~
~neta11 A 16
5
-~ I :l,
3. 4. 5. 6. 7. 8. 9. 10. 11 . 1:l. 13. 14 . 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Retainer Assembly Cover Plate Reinforcement Plate Otl Cooler Shroud Adapter Fltttng Duct Washer Bypass Pin Bypass Spring Bypass Poppet Bypass Retainer Locking Nut Support Head Cartridge Motor and Pump Relief Valve Shut-off Control Clamp Hall (Typ) Shut- off Valve Valve Assembly Plug 0-Ring Reservoir Tubular Structure Fuel Une Sta-Strap Hose Bracket
28
*Split (18800573 thru 18801216) hose lengthwise and bond to fuel lint! wtth 3M EC -800, EC -1300 or EC - 1300L .
18801041 THRU 18801374 Beginning with 18801217 Figure 19-21. Hydraullcally-Operated Dispersal Systems (Sheet 9 of 14) 19-44
MODEL 188 & T188 SERIES SERVICE MANUAL
*Lay tape on threads close to end of fitting. Hold in place and
wrap in direction of threads . Apply enough tension while winÂ
ding so tape forms into thread grooves . Once around
plus 1/ 2" overlap is sufficient. After wrap is completed,
maintain tension and tear tape by pulling apart in direction
it was applied. Ragged end will keep tape in place.
U sheared or cut, tape may unwind. Press tape into threads.
8
Detail
REFER TO SHEET 2
A
6~
~/
I I I
Detail
B \,_
Detail
E
!.~ /
18801375 THRU 18803521
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Boom Pressure Control Knob On -Ott Lever On-Off Control Boom Pressure Control Leading Edge Fairing Reservoir Screen Air Scoop Motor and Pump Boom Pressure Valve Filter Assembly
Figure 19-21. Hydraulically-Operated Dispersal Systems (Sheet 10 of 14) 19- 45
MODEL 188 & T188 SERIES SERVICE MANUAL
15
I!Jffi
Detail
A
FIREWALL
·~
8
l:"(v'
"
9
4-- 3
10
· ~
5
~~ /
Beginning with Serial 18803522
A
TUBULAR STRUCTURE
1. Shroud 2. Reservoir 3. Return Tube 4. Bypass Tube 5. Filter 6. Suction Tube 7. Hydraulic Motor 8. Motor Seal Dr ain Tube 9. Bypass Outlet 10. Bypass Inlet
11. 12. 13. 14. 15. 16. 17. 18. 19.
Control Valve Inlet Duct Clamp Mounting Bracket Suction Tube Bracket Hose Hydraulic Pump Seal Drain Tube
Figure 19-21. Hydraulically- Operated Disper sal Systems (Sheet 11 of 14) 19-46
MODEL 188 & T188 SERIES SERVICE MANUAL
(REFER TO SHEET 13)
A
NOTE
3
Setscrews (11) are primed with Grade T primer and sealed in adapter (12) with Loctite Grade CV sealer.
1.
2. 3. 4. 5. 6.
13
7. 8.
14
9. 10. 11. 12. 13. 14 .
15. 16. 17 . 18 . 19 . 20. 21 . 22 . 23 .
NOTE
Universal Joint Shaft Spool Shaft Handle Nut Pac king Bracket Was her Packing Nut
Universal joints (14) are wrapped with three !.ayers of tape (Polyken 230 or Polyken 231 : Kendall - Polyken Division, Chicago, Illinois) or (Tuck 92T: Tech nical Tape Corp. , Shawnee Mission, Kansas).
9
18
U removed , pins (13) must be s afety wir ed upon installation .
Figure 19-21. Hydr aulically-Operated Dispersal Systems (Sheet 12 of 14) 19-47
MODEL 188 & T188 SERIES SERVICE M ANUAL
15
Detail
C
Beginning Serial 18802349
~
19 Detail
-足
11
12
0
Thru 18802348 Detail
f
Figur e 19-21. Hydraulically-Operated Dispersal Systems (Sheet 13 of 14) b. begiruting with aircraft serial 18803522, remove inlet hoses to shroud, enclosing reservoir, and re足 move shroud halves. c. Depress air valve core in body assembly of reservoir to relieve system pressure. d. Disconnect motor seal drain line at elbow at bottom of reservoir and install flex hose to drain fluid from reservoir. Route flex hose to a container placed under one of the openings in aircraft belly. NOTE I.f filler cap is not removed, litUe fluid will be lost while connecting flex hose. However, sufficient care must be exercised to avoid excessive fluid loss.
e. Either pressurize reservoir with air compressor to approximately 10 psi or remove filler cap to expe足 dite fluid draining. f. Disconnect ON-OFF valve control at the valve and at clamp on reservoir lug. g. Disconnect all lines at reservoir. h. Remove screw, washer and nut from clamp at bottom of reservoir. i. Remove reservoir from aucrait. 19-43. DISASSEMBLY. (See figure 19-23. ) a. Remove nuts 169}, washers (68} and packings (67} from studs (63). b. Reinstall nuts loosely on studs and slightly pressurize reservoir to fa cilitate disassembly. 19-48
c. Remove end cap (66), packing (65} and spacers (61), d. Remove ftlter bypass assembly ( 1 thru 6) from fitting (7}. e. Remove filter (33), cap (34}, elbow (39} and dip足 stick (40). f. Pull body assembly (53) from reservoir tube (64). removing baffle (58). g. Remove relief valve assembly (26) . h. Remove two-way valve assembly (43 thru 49}. i. Remove fitting (27), nut (28}, 0-ring (29) and ball (31). NOTE Use caution not to lose seats (30} and (32) j. Remove remaining parts from body assembly as necessary, using the figure as a guide.
NOTE Studs (63), return tubes (55} and (62}, suction tube (57} and bypass valve fitting (7} may also be removed, if necessary. 19-44. INSPECTION OF PARTS. a. Wash all parts in cleaning solvent (Federal Specification P-S-661 or equivalent} and dry with filtered air. b. Inspect all threaded surfaces for serviceable
MODEL 188 & T188 SERIES SERVICE MANUAL
21
Detail
A
NOTE Threads of valve (6) are primed with Grade T primer and sealed with Loctite Grade CV sealer when packing nut (23) is installed. Install valve (6) with arrow pointing down as shown.
Figure 19-21. Hydraulically-Operated Dispersal Systems (Sheet 14 of 14) condition and cleanliness. c. Inspect all parts for scratches, scores, chips,
cracks and indication of excessive wear.
d. Inspect teflon seats (30 and 32, figure 19-23).
Replace if worn or damaged.
19-45. REASSEMBLY. (See figure 19-23. ) NOI'E Use all new packings, back-up rings and 0-rings for reassembly. Before assembly, lubricate all rings with Petrolatum or DEX RON-type automatic transmission fluid. Lubricate all threads with Petrolatum. If return tubes (55) and (62), and suctiom tube (57) were removed, they should be primed
with Grade T Primer and sealed with hy
draulic sealant (Catal~ 169, Loctite Cor
poration) upon installation.
a. Install relief valve assembly (26). NOI'E The relief valve is preset and should not
be adjus ted.
b. Install seat (32) , if removed, ball (31), seat (30) , 0-ring (29), nut (28) and fitting (27).
NOI'E Note position of slot in ball (31) to assure positioning of shaft (48). Do not overtorque fitting (27). This would bind ball (31), preventing operation. c. Assemble and install two-way valve assembly (43 thru 49), and assure that lug of shaft (48) fits in slot of ball (31). d. Install filter (33) and remaining packings and fittings in reservoir body (53). · e. Install packing (54). f. Install reservoir tube (64), spacers (60) and baffle (58). g. Assemble and install Iilter bypass assembly (1 thru 6) on bypass valve Citting (7). h. Install spacers (61) on studs (63). i. Install packing ( 65) on end cap (66); install end cap on studs (63). j. Install packings (67), washers (68) and nuts (69). k. Torque nuts (69) to 190 to 210 lb-in.
L Install packing (72), nut (71) and elbow (70).
19-46. INSTALLATION. (See figure 19-21.) a. Install reservoir and attach to tubular structure with bolts and washers or clamp. b . Beginning with aircraft serial 18803522, install shroud and inlet hoses. c. Attach ON-OFF valve control at the valve and at 19- 49
MODEL 188 & T1 88 SERIES SERVICE MANUAL
@AUTION} DO NOT OVERTORQUE
FITTING (27).
TWO-WAY VALVE
43 44
-~ -----,
1. Ptn
2. Spring 3. Poppet 4. Nut Retuner 8 ...... Locknut Bypass Valve Fitting Packing Packing 10. Fitting 11. Packing 12. Union 13. Snap Ring 14. Washer 6 I 15. Screen 5~ 16. Reinforcing Wire 17. Orifice Plate 18. 0-Ring 19. Washer 3~ 20 . Spring 21. Pilot Body 22. 0-Ring 23. 0-Ring 24 . Back -up Washer 1 25 . Spring 26. Relief Valve Assembly* 27. Fitting 44. Lever Assembly 28. Nut 45. Adaptor 29. 0-Ring 46. Ring 30. Seat 47. Washer 31. Ball 48. Shaft 32. Seat 49. Packing 33. Fnter 50. Packing 34 . Cap 51. Fitting 35 . Union 52 . Air Filler 36. Packing 53 . Body Assembly 37. Packing 54. Packing 38. Nut 55. Return Tube 39. Elbow 56. Packing 40. Dipstick 57. Suction Tube 41. Packing 58. Baffle 42 . Screen 59 . Insert 43. Ptn 60. Spacer
5. 6. 7. 8. 9.
r
"CD
62
4--e
65
2--1
~
66 I
I
L~-_jJ •Torque to 190-210 lb-in. 61. Spacer 62 . Return Tube *850 PSI (Thru 18802348) 63. Stud 1000 PSI (Beginning with 64 . Reservoir Tube 18802349) 65. Packing 66. End Cap NOTE 67 . Packing 68. Washer •69 . Nut U return tubes (55) and (62), and suction tube (57) were removed, they should be 70. Elbow 71. Nut pri med with Grade T Primer and s ealed 72. Packing with Locttte Catalog 169 sealant upon in stallation.
F igure 19-23. Hydraulic Reservoir Assembly 19- 51
MODEL 188 & T188 SERIES SERVICE MANUAL
the clamp on reservoir body lug. d. Connect all lines at reservoir. e. Fill reservoir to FULL mark on dipstick with DEXRON-type automatic transmission fluid, and pressurize to 15 psi. 19-47. RIGGING. (See figure 19-21 , sheet 9.) a. Remove on-off control from lever at reservoir and shut valve off. b. Push bottom of on-off control in cockpit to full forward position. c. Attach control to valve lever at reservoir. d . Check operation of control for freedom of move ment. 19-48. AIR FILLER VALVE. Due to the deterior ating effect that hydraulic fluid has on rubber, the air !iller valve should be inspected under criteria given in Section 2. 19-4 9. REMOVAL. (See figure 19-23. ) a . Depressurize reservoir by depressing air filler valve core (52), and remove core after pressure ls released. b. Remove reservoir filler cap (41) and screen (42). Thread a piece of safety wire through air filler valve stem, reservoir. and oil filler por t. c. Cut air filler valve stem (52), and remove in ternal portion with safety wire. 19-50. INSTALLATION. a. Wet new air !iller valve stem around groove with clean hydraulic fluid (DEXRON Automatic Transmis sion Fluid), and wrap safety wire around threaded end. b. Insert safety wire wrapped valve stem through filler port , and align with air valve mount port. Pull valve stem through port with long nosed pliers or with tire valve installing tool. NOTE Use care when mstalling air valve stem. Re move safet y wtre while holding stem, and pull stem through orifice carefully, because metal edge of reservo ir top may cut through valve s tem creating a hazard condition. e . Remstall filler sc reen (42) and cap (41). pres sunze reservoir to approximately 15 psi with clean atr source , and mstall air valve cap. 19-51. SPRAY PUMP STRAINER. 19-22 .)
(See figure
19-52 . DESCRIPTION. A strainer may be mounted between the gate box outlet and the spray pump of liquid dispersal s ystems to strain out undissolved liquid dispersal materials and to catch foreign ob jects before they reach the spray pump. Removal of the strainer screen for cleaning or daily inspec tion is acco mphshed by cutting the safety wire and turmng the handle at the botto m of the strainer in a counterclockwise direction. U necessary, a sc rew driver o r suitable tool positio ned through the handle will give added leverage for loosening the strainer cap and screen. 19-52
19-53. REMOVAL AND INSTALLATION. a. Remove clamp and hose . b. Unscrew filter assembly from coupler. c . Reverse preceding steps !or installation. 19-54. ELECTRICALLY- OPERATED SPRAY VALVE SYSTEM. (See figure 19- 24.) An electrically- operated spray valve is available to replace the manual valve on the remote pump spray system. The spray handle and push-pull control of the manual system are replaced by an electrical switch mounted on the control stick. The vernier setting of the valve is accomplished by a stop on the valve actuated from the cockpit through a flexible drive shaft. 19-55. REMOVAL AND INSTALLATION. Ftgure 19-24 may be used as a guide for removal and installation of system components. 19-56. RIGGING. (See figure 19-24.) a. Disconnect flexible control (4) at aft end of valve (13). b. Rotate stop (18) to full FORWARD position. c. Turn on master switch. d. Using switch (9) on control stock, actuate arm on valve (13) to full FORWARD position (FULL OPEN), then turn master switch off. e. Rotate nut on forward end of shaft (16) until stop (18) rests against valve arm. f. In cockpit, turn knurled knob on shaft to move stop (5) to full AFT position to line up with ''20" on placard (FULLY-OPEN) mounted adjacent to control. g. Connect flexible control at aft end of valve (13). 19-57. ELECTRICALLY-DRIVEN AGITATOR IN STALLATION. (See figure 19- 25.) Beginning with ser ial18800833, an electric-driven agitator is available. The previou s optional agitators for the gate box, which are still available, were air driven fans causing some drag loss and operational vibration. The electric-driven agitator is a part of the gate box assembly and is available in 12 or 24 volts. Activation of the agitator motor is controlled by a microswitch attached to the metering gate con trol. When the hopper is opened for dry dispersal, the agitator automatically functions. 19-58. RIGGING . (See figure 19- 25. ) a. Move gate box control handle to full aft position (gate box closed). b. Adjust switch roller to contact bellcrank as lever is moved forward to open gate box. c. Electric motor should start as gate box opens.
MODEL 188 8t T188 SERIES SERVICE MANUAL
6
Thru 1880832 Det ail
A 7 Det a il
.,.........
..·~··'''
.
B
..
.... .. ..··.·· B ~
9
10
Detail Thru 18801374
13 Detail
C Beginning 18801375
0
1. Instrument Panel 2. Relay 3. Control Stick 4. Control 5. Stop 6. Support 7. Bracket 8. Switch Mount 9. Microswitch
10. 11. 12. 13. 14. 15. 16. 17. 18.
Control Stick Grip Clamp Electric Moto r Valve Spacer Support Shaft Counter sunk Screw Stop
19. Support Assembly 20 . Contactor 21. Resistor
Figure 19-24. Electrically-Operated Spr ay Valve Disper sal System 19- 53
MODEL 188 & T188 SERIES SERVICE MANUAL
BELLCRANK
~ ~
VIEW FROM LEFT AFT SIDE OF GATE BOX, LOOKI NG TO THE RIGHT NOTE
Replace gear reducer lubricant with DEXRON type automatir transmission flu id upon com  pletion of maintenance or when binding or stiffness is noted during operation .
8 BEGINNING WITH 18802746 AND Tl8803297 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Gear Reducer Coupling Electric Motor Clamp Bracket Hopper Flange Gate Box Flange Bearing Gate Box Sway Brace
Figure 19-25. Electrically-Driven Agitator Installation 19- 54
MODEL 188 & T188 SERIES SERVICE MANUAL
19-59. AUTOMATIC FLAGMAN. (See figure
19-8. )
19-60. DESCRIPTION. The Automatic Flagman dispenser 1s located on top of the nght stub w1ng, Just o utSlde of the catwalk. The urut eJects a disposable paper streamer attached to a piece of cardboard
wh ich serves as a we ight. The flag lands 1n the
center of the swath be ing sprayed upon actuation
of an electnc solenoid by the pressmg of a trig ger on the control stick. Air pr essure IS fed in
from the slipstream through a hole m the fr ont of
the nose cone and 1s transmitted onto the flags 1n
dispenser and feeds them to the rear. hold1ng them firmly aga1nst the rear stops.
IWARN INGl DO NOT USE THE AUTOMATIC FLAGMAN WHEN USING SULPHUR DUSTS AS THE SOLENOID COULD CAUSE A FIRE IN THE DUST.
19-61. REMOVAL. (See figure 19-8.) a . Remove screws and washers attaching nose cone (9) to bracket (11). b. Remove (13) screws attaching nose cone (9 ) to
dispenser (3) ; remove nose cone .
c. Disconnect electrical leads ( 14 ) at socket and
housmg ( 19 ) and remove bolts and nut s attaching
solenoid ( 1) ; remove solenoid.
d. Remove bolts and washers attachmg dispenser to bracket (12). e. Remove bolts attaching supports (5) to support (18) : remove dispenser (3). f. Remove two access covers under stub wing and
disconnect electncal leads at terminals.
g. Pull tub1ng (16) and leads (14) out through grom met 115 ). INSTALLATION. (See figure 19-8. ) a . Place dispenser (3) on r ight stub w1ng and in stall bolts and washers attaching dispenser to bracket 19- 62.
( 12 ).
b. Install bolts attaching supports (5) to support ( 18). c. PoSltlon nose cone (9) and install screws and washers attaching nose cone to bracket (11); install ( 13) screws attaching nose cone to dispenser. d . Install solenoid (1) on dispenser. e. Remove two access covers under stub wing, route tubing (16) and leads ( 14) through grommet ( 15); co nnect leads at terminals inside stub wing. f. Connect electrical leads at socket and housing(l9) ·
19-63. INSPECTION AND MAINTENANCE. a. The inside surface of the dispenser is waxed and contains a smooth, dirt-free finish. Care should be taken to prevent entry of foreign material o r water. The inside of the dispenser should be waxed occasionally .
b. Keep water from entering and running down into the solenoid. lf the solenoid should fail because of excessive foreign material or water , it can be taken apart, cleaned and reassembled. The plunger should have a shiny outside surface . lf this should become rusted it should be taken apart and polished with very flne sandpaper. The use of liquid fertilizers, which may come in contact with the solenoid, will . adversel y alfect its operation. Protect th~ sol~no1d by spraying the inside with silicone spray 1f us1ng liquid fertilizers. Generall y, the solenoid should be cleaned each 50 hours or more often if under dirt y field conditions. c. The contact points of the electrical switch should be cleaned each 100 hours.
(~AUTIO N} Be sure that switching of the solenoid is so as not to have continuous current to the solenoid or it will burn out . A momentary button on top of the control Stick will burn up solenoids when erroneously activated by pilots placing hard hats on top of the stick while away from the aircralt. NOTE This information supplements vendor instructions stowed in the a1rcra1t.
19-64. BOOM PRESSURE VALVE AND CONTROL
KNOB. (See figure 19-21, sheets 9 and 10.)
19-65. DESCRIPTION. (18801375 thru 18801682), a boom pr essure valve in the hydrauli c system is used to regulate dispersal system boom pressure to a pre scribed setting. When the hydraulic system 1s op erating and Mte boom pressure valve IS ~los~d, all pressure betng developed in the system 1s d1rected to the hydraulic motor and the motor dnves the spray pump at m:uumum output. This condtllon would re sult by rotat ing the boom pressure control knob, lo cated below the left side of. the instrument panel, to an index setting of 9. If less boom pressure is re quired, the boom pressure control knob can be ro tated back to any index from 9 to 0. The 1ndex num bers do not indicate a specific pressure but are for index purposes only, and are useful in establishing similar pressures on successive spray runs . A s top bolt normally lim1ts the amount the boom pressure valve IS open, as indicated by an wdex settmg of 0. Under some conditions where the operat o r 1s us1ng 22 nozzles w1th small onfices, he may want to back out the stop bolt to allow more opemng of the boom pressure valve for a greater reductton of boom pres sure . The s t op bolt is attached to the boom pres sure valve bracket and is accessible by removing the left fuselage s ide panel.
19- 55
MODEL 188 & T1 88 SER IES SERVICE MANUAL
TRANSLAND 21100 INSTALLATION
Shims (7) to be used upon installation Two shims a r e required for AGtruck and four shims are required for AGpickup and AGwagon. NOTE Other than clamp (10) and suppor t washer (11), this unit is sold only as a complete assembly. The illustration is provided only to facilitate disassembly and assembly.
1. 2.
Lower Quick - Disconnect Hall Pin
5
3. Clamp Assembly 4. Hook 5. Upper Quick-Disconnect Hall 6. Strip 7. Shim 8. Cap 9. Support 10. Clamp 11. Support Washer 12. Tube 13. Washer
4-l
~--1 2
3
2
3
Figure 19- 26. Quick- Disconnect Fan - Driv~ Ins tallation 19- 56
MODEL 188 & T188 SERIES SERVICE MANUAL
19-66. REMOVAL. (AgWagon) (thru 18801682) a . Remove s1de panels on left side of aircraft, alt of fl rewall. b. Depress air valve core 1n body ass embly of hy draulic reservOir to relieve system pressure. c. D1sconnect and cap o r plug hoses at elbows on
valve.
d. Back out stop bolt to clear shalt assembly. e. Loosen lock nuts and run nut up to cap; slide
valve 1nboard through bracket to remov e.
19-67. REMOVAL. (AgTruck) (thru 18801682) a. Remove s1de panels on left s1de of aircraft, alt of firewall. b. Depress air valve core in body assembly of hy draulic reservoir to relieve system pressure. c. Disconnect and cap or plug hoses at elbows on
valve.
d. Back out stop bolt to clear shalt assembly . e. Loosen set screws in shalt assembly. f. Slide valve downward through slot in bracket to r emove. 19- 68.
INSTALLATION. (thru 18801682) NOTE
Install valve so direction of arrow and direction of flow are the same. a. With valve in closed position and with light valve seat contact, assemble shalt assembly with stop tab m most outboard positic.n (same side as arrow on valve. ) b. Install valve without plumbing tn mounting br ack et assembly w1th stop tab on lower alt side of stop bolt (maximum rotation apprOlomately 30° out of BL plane or when valve contacts outboard side of bracket.) Assure that end of stop bolt is l-inch from 1nboard edge of bracket. c. Connect cable assembly wtth spline assembled such that control knob in cockpit IS in a position nearest number 9 on pl:1card. d. Connect hoses and check alignment of valve. e. Tighten set screws on AgTruck model. f. Tighten stop bolts. 19-69. DESCRIPTION. (Beginning with 18801683.) A boom pressure valve 1n the hydraulic system is used to regulate system boom pressure to a pre scnbed setttng . When the hydraulic system is oper ating and the boom pressure valve 1s closed, all pressure beu~g developed 1n the system 1s directed to the hydraulic motor and the motor dnves the spra}' pump at maximum output. Ttus cond1t1on would re sult by rotatu1g the boom pressure control knob, located below the left s1de of the Instrument panel, to an tndex setting of 9. U less boom pressure 1s requ1red, the boom pressure control knob can be r otated back to any Index from 9 to 0. The tndex numbers do not 1nd1cate a spec1hc pressure but are fo r 1ndex pu rposes only, and are useful in establlsh lng s1mtlar pressures on success1ve spray runs. A
stop is located at the bottom aft side of support (9) as shown in figure 19-21, sheets 10 and 11. This stop is used to limit the travel of handle (18) when rotated to increase boom pressure. 19-70. REMOVAL. (All Models Beginning with 18801683.) a. Remove side panels on left side of aircraft, aft
of fi rewall .
b. Depress air valve core in body assembly of
hydraulic reservoir to relieve system pressure.
c. Disconnect and cap or plug lines at elbows on
valve.
d. Referring to sheets 10 and 11 of figure 19- 7,
disconnect valve control linkage (7) at spools (16).
e. Loosen setscrews (11) at adapter (12); remove
linkage from valve (6).
NOTE Setscrews (11) and packi~ nut (23) are in
stalled after bei~ primed with Grade T
Primer and sealed with Grade CV Loctite.
f. Remove packing nut (23 ), nuts ( 19) and washers (22) attachi~ valve (6) to bracket (21); remove valve (6).
g . To remove remainder of linkage (7), loosen setscrew (11) from handle (18) and pull linkage for ward from support (9 ). 19-71. INSTALLATION. (All Models, Beginning with 18801683.) a. Install valve (6) with arrow pointi~ down, on bracket (21) with nuts (19), washers (22) and packing nut (23) as shown on sheet 11 of figure 19-21.
NOTE After installi~ valve (6), and nuts (19) and
washers (22), prime threads of valve with
Grade T primer and seal with Grade CV
Loctite before installi~ packing nut (23).
Turn packing nut finger tight at this time.
b. Install lines ( 1) and (2) at elbows on valve (6) . c . Install forward hal! of linkage assembly (7) by threading adapter ( I 2) onto valve assembly (6) and tightening setscrews ( 11) (after priming with Grade T primer and sealing with Loctite Grade CV) into valve stem flats. d. Install aft haU of linkage assembly (7) in support assembly (9). e. With short end of handle ( 18) pointing to the
number ''9'' position on support (9), lightly seat val\•.e
assembly (6) closed (clockwise); 1nstall setscrew ( II)
into handle ( 18). f . Install adJustment screws and nuts into two spools ( 16).
NOTE U necessary, rotate valve seating counter
clockwise for proper hole alignment of
spools.
19-57
MODEL 188 & T1 88 SERIES SERVICE MANUAL
g. Tighten packing nut only enough so that linkage
works freely when rotated by handle ( 18).
h. Check that DEXRON type automatic transmission fluid is to FULL mark on dipstick in reservoir and pressunze to 15 psi. i. Install side panels on left side of aircralt aft of fi rewaII. ' 19-72. BOOM PRESSURE VALVE CONTROL LINK AGE. (See figure 19-21, sheet 12.} 19-73. DESCRIPTION. Beginning with 18801683, a two-part, solid shaft hnkage is employed to control the boom pressure valve. The control handle is lo cated below the left side of the instrument panel. The valve is attached to a bracket which is welded to the structural tubing on the left side of the aircraft, outboa r d of the hopper. 19-74. REMOVAL, INSTALLATION AND RIGGING. Refer to paragraph 19- 70, steps "d", "e" and "g", and paragraph 19-71 , steps "c" thru "g" and "i". NCYfE II uruversal JOmts (14) were disconnected or
removed, pins ( 13) will have to be salety Wired, and universal joints will have to be wrapped w1th three layers of Polyken 230 or Polyken 231, ( Kendall-Polyken Division, Chicago, Illinms) or Tuck 92T, (Tecluucal Tape Corp., Shawnee Missi on, Kansas) . Al so, 1! spools ( 16) were removed, pins ( 13) will have to be safety wired. 19-75.
REMOVAL AND INSTALLATION. NOTE
If the adjus t ment sc rcw tS not disturbed,
s u c tton adJUStment should not be requtred.
a. b. c. d. e. box
Completel y dr :un hopper. Dt sco nnect contro l rod at valve control lever. Dlsconnect hose coupler at forward end of valve. Remove hose and clamps at aft end of valve. Re move bolts attachtng valve to adaptor at g ate and rerrove ~ asket n r seal. f. Reverse preceding steps fo r valve tnstallatlon.
19- 78. DISASSE:vtBLY. ( BALL TYPE VALVES) See figure 19-27 fo r valve disas sembl y.
19-58
If the adJustment screw is not disturbed.
suction adjustment should not be requ1red. 19-79. REASSEMBLY. (See figu r e 19-27.)
(BALL TYPE VALVES)
a. Install ball (26) , pa..:kings (27), support assembly (29) with packing (28) and lever (30). b. Cbeck ball (26) and seals (23), (35) and (38) Cit as follows: 1. Install adaptor (21 ), seal (23). adaptor (33 ) and seal (35) less packings , bolts and washers. 2. Applying equal forces ag;unst adaptors (21 ) and (33), measure gaps between adaptors (21) and (33) and valve body (25). 3. Install shims (24) and (36) as required to a thickness of . 002- inch less than each gap measure ment. 4. Install stde cover (40) and seal (37). 5. During assembly, for measuring gap between valve body and two adapters, set valve assembly up right. with hose adapter down on nat surface and cam-lo::k adapter up. Place a 5 to 6 pound weight 0:1 top to give ..equal forces " for seal-to-ball seating. then measure gap. 6. Install s hims (3 8) as required to a thickness of approximately . 002 -inch less than the gap measure ment. c. Disassemble comp::>nents and install packtngs (22), (34) and (39). d. Assemble all components and 1nstall attachtng bolts and washers . SHIM CHART
MANUAL CONTROL VALVE.
19-76. DESCRIPTION. A three-way control valve is tnstalled between the pump. the hopper and the noz zles. The valve tS controlled by the spray valve con trol lever tn the cockptt. This valve permits a by pass for pressure control and also prov1des r eclr cu latton through the hopper for a mo re consistant muc ture o f the spray matenal. Also tncorp::>rated mto the contro l valve IS a bleed-back valve to relieve boom pres sure after the control valve ts closed to prevent nozzle ..drtp". 19-77.
NOfE
SIZE
PART NO.
LARGE SMA LL LARGE SMALL
1608075-1 160807 5-3 1608075-2 1608075-4
THICKNESS . 005 . 005 . 014 . 01 4
19- 80. ADJUSTMENT. U suck-back adjustment is required due to nozzle ..drip.. , an adjustment screw is incorporated on the aft side of the control valve. Sl:rewing in on the adjustment screw d~creases sue tio:t. Unscrewing the adjustment screw wtll increase the suction . Screw should be "backed-out.. until noz zles stop ..dripp1ng". Back adjustment screw o·Jt se ven turns from CL<:x:;ED position for maximum "suck back. " (See figure 19-27, item 32.) 19-81. ELECTRIC SPRAY VALVE ASSEMBLY.
I ~AUTION\ An electric motor dynamic braking system ts pr ovided on the Cessna valve through a se ries of relay and limit sWitch circuttry 1n the aircralt. DO NOT electrically operate valve assembly except through this ci r cuitry.
MODEL 188 & T1 88 SERIES SERVICE MANUAL
AGRINAUTICS !177505 VALVE
Valve seal repair kit !#K'7520, available from the Cessna Supply Division, may be used to overhaul Agrinautics 1#77505 valve.
1. Dust Cap Hose Coupler TRANSLAND 1120383 VALVE Cap 0 - Ring Shim Main Seal 1 Valve Ball Pipe Plug 9. Washer 10. Shaft 11. Valve Arm Refer to paragr apg 19 79 for pr ocedures 12. 0 - Ring to be followed dur ing assembly or Cessna 13. Roll Pin 111608056 - 1 valve. 14. Stat-Q-Seal 15. Adjusting Sc r ew Shims (24) and (36) are listed by size, 16. Valve Body part number a nd thickness in para 17. 0 -Ring graph 19- 79. 18. Lower Shim 19. Cover Plate 20. Bypass Seal 21. Coupler Adaptor 33 22. Packing 23. Seal 24. Shim 25. Body Assembly 26. Valve Ball 27. Packing 28. Packing 29. Shaft Support Assembly 30. Lever 24 31. Pin 32. Adjusting Screw 33. Adaptor 34. Packing 35. Seat 36. Shim 37. Seal 38. Shim 39. Packing 39 40 40. Side Cover CESSNA i/ 1608056-1 VALVE
2. 3. 4. 5. 6. 7. 8.
Figure 19- 27. Manual Control Valves Revision 1
19-59
MODEL 188 & T1 88 SERIES SERVICE MANUAL
Seal end plug (17) with Loctite Catalog No. 92. Avoid exces sive use. Seal retaining plug only.
A A 1/ 4-ln bolt
VALVE OPEN POSITION
12
14-s:;:J 15__. '
16
Detatl
~
10 ·
t
Q_/ J:;j
17
~-~~
Tool mserted thru 9 .:=; motor mount to 8 -.... y .:!::- ~ turn worm gear.~ ~ ~""' l.. ,.,
7
j30.
~~t,;
~
•
•
/
18 ~-
From the time the switch actuates and ''clicks,·· until a solid stop is contacted, the r e should be . 35"-. 45" overtr avel as shown Is view A -A.
· / .f..~ 19 20 22
Grea se worm, worm gear, bearing, bushings and shaft asse mbly tang with Electro Moly No. 11 (MIL-G-2 1164).
1
27 28
~A
29
L Coupler Adapter 2 . Packmg 3. Seal 4. Shim 5. Body Assembly 6. Valve Ball 7 . Motor 8. Drive Support Assembly 9. Wo rm Gear 10. Valve Co ntrol Support
11. Leal Actuator Assembly 12. Switch 13. Valve Adjustment Control Arm 14 . Actuator 15. Actuator Pin 16. Adjustment Guide 17. End Plug 18. Shalt Assembly 19. Packing
Figure 19-28. Electric Spray Valve Assembly 19- 60
20. 21. 22 . 23. 24. 25 . 26. 27. 28 . 29. 30.
Packing Adjusting Screw Adapter Packing Seal Shim Seal Shim Packing Side Cover Worm Gear Pin
MODEL 188 & T188 SERIES SERVICE MANUAL
19-82. DESCRIPTION. An electric three-way spr ay valve assembly is avrulable for mounting between the ~mp . the hopper and the nozzles. The valve is con trolled by a flex1ble shalt and a knob in the cockpit. Th1s valve permtts a bypass for pressure control and also provides recirculation through the hopper for a mo re c ooststent miXture of the spray material Also mco r porated 1nto the cootrol valve IS a bleed- back valve to relieve boom pressure alter the control valve IS closed to prevent nozzle "drip". 19-83. REMOVAL AND lNST ALLATION. NOfE If the adJustment screw is not disturbed,
suction adjustment should not be required. a. b. and c. d. e. box
Completely drain hopper. Disconnect plugs at motor, remove sta-strap remove wiring. Disconnect hose coupler at forward end of valve. Remove hose and clamps at aft end of valve. Remove bolts attaching valve to adaptor at gate and remove gasket or seal. !. Reverse preceding steps for valve installation.
19-84. DISASSEMBLY. (BALL TYPE VALVES)
(See figure 19-28 for valve disassembly).
NOTE If adJustment screw (21) 1s not disturbed, suction adJustment should not be required.
19-85. ASSEMBLY. (BALL TYPE VALVES)
(See figure 19-28.)
a. Install ball (6). packing (20) . support assembly (8) w1th packtng (19). valve control support (1 0) and worm gear (9) . b. Check ball (6) and seals (3), (24) and (26) fit as follows: 1. Install adaptor (1), seal (3), adaptor (22)
and seal (24) less packings, bolts and washers.
2. Applying equal forces against adaptors (1) and (22), measuring gaps between adaptors (I) and (22) and valve body (5). 3. Install shims (4) and (25) as required to a thickness or . 002-inch less than each gap measure
ment.
4. Install side cover (29) and seal (26). 5. During assembly, !or measuring gap between valve body and two adapter s, set valve assembly up nght, with hose adapter down on flat surface and cam-lock adapter up. Place a 5 or 6 pound weight on top to give "equal forces"' l or seal-to -ball seating. then measure gap. 6. Install sh1 ms (27 ) as requ1red to a thickness of apprmnmately . 002 -inch less than the gap measure ment. c. D1sassemble components and 1nstall packwgs 12). 123 ) and (28) . d. Assemble all components and mstall attaching oolts and washers.
SHIM CHART SIZE
PART NO.
THICKNESS
LARGE SMALL LARGE SMALL
1608075-1 1608075-3 1608075-2 1608075-4
. 005 .005 .014 . 014
NOTE T he instructions outlined in paragraph 19-86 should be followed if Single-Engine Service Letters SE78-31 and/or SE78-59 have not been complied with. To comply with these Ser vice Letters, refer to paragraphs 19-87 and 19- 88 19- 86. BUT TERFLY VALVE DISASSEMBLY AND
REASSEMBLY. (See figure 19-29.)
NOTE The manual and the electric valves contain identical parts. Therefore, the following procedures apply to both valves. a . Remove bolts and washers from coupler adapter (2) and hose adapter (15). b. Remove coupler adapter (2 ), 0-ring packings ( 3) and ( 5), and shims (4). c. Remove hose adapter (15), 0-ring packings ( 3) and (15), and shims (4).
-c-AU - T-IO _N_,m 1 Do not intermix total shim thickness from
end-to-end. Insert must be centered to
operate freely .
d. Remove seal-attaching screws (14), existing seal (13) and retainer (12). If existing seal does not meet ins~ection criterion, or is questionable, discard old seals a nd install new seals (13). This will c omply with Single- Engine Service Lett~r SE78-31. NOTE If seals are replaced per Service Letter,
follow instructions outlined in the Service
Letter. If seals are not r eplaced, proceed
as follows.
e. Check to see that butterfly halves (11), seals ( 13), shaft (8) and seal retainer screws are sealed ( Locrite Sealant P / N 59231.) To ensure proper sealing, close butterfly valve until seat is contacted. Tighten screws (14) 1/ 4 to 1/ 2 turn alter seating to prevent deform1ng seals. NOTE The following procedure must be followed in assembling the spray valve. 19- 61
MODEL 188 & T188 SERIES SERVICE MANUAL
f. Temporarily install adapters (2 ) and (15) in valve body (1 7 ), making sure that packings ( 5) are in place. DO NOT INSTALL BOLTS at this time. g. Set ~alve upright on one adapter, and place a
10-lb wetght on top to compress the packing.
h. Using a thickness gage, measure clearance between adapters (2) and (15) and valve body (17). These dimensions are equal to shim (4) size required to properly assemble the valve.
NOTE Shims (4) are available inthicknesses of 0. 005-inch and 0 . 014-inch. Use c ombina
tions of shims to most nearly meet the
dimensions measured for each gap.
i. Remove weight and adapters (2 and 15), and install b olts (1 ) and washers. Tighten bolts to nor mal torque value. Refer to the chart in Section 1 of this manual for proper torque. j. Attach hopper adapter (7 ) to aircraft hopper, after lubricating fitting with MIL-G-81322A, general purpose grease. k. Connect coopling and hose to respective adapters. Check sys tem after curing time of sealant has lapsed.
19- 87. BUTTERFLY SPRAY VALVE S EAL RE PLACEMENT. (See figure 19-29.) NOTE The following procedures will comply with Single- Engine Service Letter SE78- 31. a. Remo ve bolts and washers from coopler adapter (2 ) and hos e adapter (15). b. Rem ove coupler adapter (2 ), 0-ring packing (3) and (5), a nd s hims (4 ). c. Remove hose adapter (1 5), 0-ring packings (3) and (5), a nd s hims (4 ).
/CAUTION \ Do not tnte r mix total shim thickness from end-to - e nd. d. Rem ove seal- a ttaching screws (1 4 ) and nuts, existing s e al (13 ), and retainer ( 12 ). Disca rd ( 13 ) when removed. e. Ins tall new butte rfl y seal (13 ) in r eve r s e o r der of procedures outlined in s tep "d", coati ng the screw threads w1th Loctite Sealant (Part Number 59231. ) To ensure p r oper s ealing, close butterfly to where sea l ( 13 ) fi rs t contacts insert (6); tighten s crews (1 4 ).
[f~ UTION] Tighte n sc r ews 1/ 4 to 1/ 2 turn afte r seating to prev ent deform ing of sea l. f. Tempo ranl y 1nSt.Jll adapte r s (2 ) and d 5) in valve body 117 1, ma.long sure that packings (5) are in plac e . DO :-lOT 1:-ISTALL BOLTS a t thiS tim e . g. Set valve up on one end and apply a 10- lb weight on top to compress packing. h. Us1ng a thickness gage , measure c lea r ance be
19- 62
tween adapters (2) and ( 15) and valve body (17). These dimensions are equal to shim (4 ) size required to properly assembly the valve. NOTE Shims ( 4) are available in thicknesses of 0. 005-inch and 0. 014-inch. Use combin ations of shims to most nearly meet the dimensions measured for each gap. i. Remove weight and adapters (2 and 15), and in
s tall bolts ( 1) and washers. Tighten bolts to normal
torque value. Refer to the chart in Section 1 of this
manual for proper torque.
j . Attach hopper adapter (7) to aircraft hopper,
after lubricating fitting with MIL-G- 81322A general
purpose grease.
k. Connect coupling and hose to respective adapters.
Check system after curing time of sealant has lapsed.
19-88. INSPECTION AND REPLACEMENT OF BUTTERFLY VALVE INSERT. (See figure 19-29.) NOTE The following procedures will c omply with Single- Engine Service Letter SE78-59. a. Remove bolts and washers from coupler adapter (2) and hose adapter (15). b. Remove coupler adapter (2), 0-ring packings (3) and (5) and shims (4). c. Remove hose adapter (15), 0-ring packings ( 3) and (5) and shims (4).
I¢AUTIO N! Do not intermix total shim thickness from end-to - end.
NOTE If Single-Engine Service Letter SE78-31 has
been complied with, seals ( 13) have been
replaced. If the Servic e Letter has not been
complied with follow procedures ouUined in
Steps "d" and "e" of paragraph 19-86.
d. Remove cover (9 ), packings, butte rfly valve assembly and insert (6 ). e. Squeeze insert (6). If it can be readily deformed, it is a standard grade polyethylene, and must be re placed. The high- density polyethylene is extremely rigid, and cannot be deformed. f. If insert (6) is found to be of the proper material o r if a new one is installed, inspect the insert land (20)-to-shaft s eal and hole conditi on as follows : 1. Inspect shaft holes in insert (6) for nicks and s ize . The hole s hould be 0. 623 .,. 0. 000, - . 003-inch. Th1s pr ovides a 0. 002 - inch to 0 . 00 5- inch inte rference fi t on the butte rfly s haft (21 ). Ove rs ize holes or nicks ca n resul t in va lve leakage. 2. Inspect and remove any burrs from butterfly s haft (21 ). 3. Ca r efully slide shaft (21) through inse rt (6 ).
MODEL 188 & T188 SERIES SERVICE MANUAL
16
0eta11A (Showing Valve Positioning)
15 8
Valve Open (Spray Position)
16
1. 2. 3. 4. 5. 6. 7. 8. 9. 19 10. 11. 12. 13.
Bolt Coupler Adapter 0 - ring Shim Packing Insert Hopper Adaptor Butterfly Valve Cap Control Arm (Manual) Butterfly Halves Seal Retainer Seal
8
Valve Closed (Recirculate Position)
14. Seal Attaching Screw 15. Hose Adaptor 16. Suck Back Adjustment Screw 17. Valve Body 18. Grease Fitting 19. Dust Cap 20. Insert Land 21. Shaft
Figure 19-29. Manual Butterfly Spray Valve 4. Visually inspect shaft-to-land seal for a snug fit. I! a 0. 001 - inch shim can be slid between shaft (21) and land (20), excessive leakage will result. 5. Remstall or replace insert as required. g. Pos1tion valve body (17 ) with hopper adapter (7 ) away from you , and the suck-back adjls tment screw (16) to your right. h. Slide insert (6) into valve body (17 ), so that straight land (20) on the inside of insert is toward you, and curved land is pointing away and to the right. Shaft holes in insert should be aligned verti cally in valve body (17 ), and with the lower bearing. i. Carefully slide shaft (21 ) through insert (6), and into lower bearing. j. Install butterfly seal assemblies into the shaft. Coat screws and slot edge of seals with LoctHe Sealant Part Number 59231, if required, prior to assembly. k. Remove 0 - rings (3) and s hims (4) from adapters (2) and (15 ), and slide into valve body ( 17 ), w1th pack ings ( 5) in place. l. Stand valve on one end and place a 10-lb. weight on the top end.
m. Using a thickness gage, measure gap between each adapter (2 ) and (15) and valve body (17). n. Subtract 0. 010-inch from measurements obtained in s tep "m", and install shims equal to that number (1608075-1 shims are 0.014- inch and 1608075-2 shims are 0. 005-inch.) o. Reinstall 0-.Mngs (3) and adapters (2) and (15). p. Install cap (9) and contr ol arm (10). q. Reinstall and tighten bolts and washers attaching adapters (2) and (15). . r. Equally tighten bolts attac hing adapters to proper torque values. Refer to chart in Section 2 of this manual. s, Attach hopper adapter (7) to aircraft hopper, after lubricating fitting with MIL- G- 81322A general purpose grease. t. Connect coupling and hose to respective adapters. Check system after curing time of sealant has lapsed. 19-89. ADJUSTMENT. 1f "suck-back" adjustment is required due to nozzle ''drip", an adjustment screw (See figure 19-27) is incorporated on the aft s1de of the control valve. Screwing in the adjust 19-63
MODEL 188 & T188 SERIES SERVICE MANUAL
*
THRU SERIAL 18803290
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.
• USED ON 1608 132-1 s pray valve . • Used on 1608160-1 spray valve.
11 15
·7~
*9
7
16
I
.
es B
I Detail
17
10
18
7
B
8
Motor Motor Support Disk Clutch Housing Assembly Shim Shim Race Worm Gear Spacer Packing Washer Pin Stop Arm Torsional Spring Support Shalt Shalt Stop Bearing Pin Bearing End Plug Wor m Assembly Shim Packing Packing Shalt Butterfly Half Shalt Assembly Butterfly Half Seal Butterfly Assembly Bolt Coupler Adapter 0 - ring
Shim Packing Insert Valve Body Suck- back Adjustment Screw 40. Packing 41. Shim 42 . 0-ring 43. Hose Adapte r 44. Bolt
Det:ul
A 30
31'-ti
!~ · .~~
f'X::: '"\....1~~ 36 , ~ > ' ·\-_) 0 ~ -35
-.
~~
~ 32
34 33
45.
Figure 19- 30. Electnc Butterfly Spray Valve 19- 64
37
".J
Plug Button
MODEL 188 & T188 SERIES SERVICE MANUAL
ment screw will incr ease the suction. The screw should be ''backed-out" until the nozzle ceases "dripping". Back adjustment screw out seven turns from CLOSED position for maximum "suck- back." To adjust limit switching, use slotted 1/4-inch bolt shown in Detail "B" in figure 19-28. Use fabricated bolt tool on worm shaft assembly tang so tha. 35 tnch to . 45-inch overtravel dimension, when switch activates, does not alldw cam to contact the positive stops tn either direction when valve is in operation. 19-90. ELECTRIC BUTTERFLY VALVE DISASSEM BLY. (See figure 19-30.) a. Remove bolts and washers from coupler adapter (33) and hose adapter (43). b. Remove coupler adapter (33), 0-rings and pac king (34) and (36), and shims (35). c. Remove hose adpater (43), 0-rings and packings (42) and (37), and shims (41) .
/ ~AUTION \ Do not intermix total shim thickness from end-to-end. Insert must be centered to operate freely. d. Remove seal-attaching screws, seal (30) and butterfly halves (27) and (29). U seal does not meet inspection criter ion, or is questinable, discard old seal and install new seal. e. Check to see that rutterfly halves (27) and (29), shaft (26) and seal retainer screws are sealed (Loc tite Sealant P/N 59231). To ensure proper sealing, close butterfly valve until seat is contacted Tighten screws 1/4 to 1/2 turn after seating to pre;ent de forming seals.
NOTE To replace seals and/or inserts. refer to paragraph 19-82 of 19-83. 19-92. ELECTRIC BUTTERFLY VALVE DISK
CLUTCH RIGGING. (See figure 19-30.)
a. Aircraft switch in OFF position. b. Install an ammeter in series with the spray valve motor assembly. c. Monitor the current necessary to run the valve from CLOSED to OPEN position. The motor should draw 8 amps, once stop arm (13) reaches stop assem bly (17). d. U the current draw of the motor is not as speci fied in step "c", adjustment of the disk clutch is ne cessary. e. Remove safety wire from clutch housing assem bly. f. Holding clutch housing assembly (4), adjust plug assembly. Turn plug clockwise (from motor end, looking towards housing assembly). Turn clockwis e for a higher current draw, or turn clunterclockw1s e for a lower current draw.
[~AUTION \ A current draw in excess of 8 amps will
result in damage to the motor assembly.
g. Repeat step "c" after each adjustment of the clutch assembly. h. After proper adjustment has been attained, safety clutch assembly as shown in detail C.
19-91. ELECTRIC BUTTERFLY VALVE REASSEM BLY. (See figure 19-30. ) a. Temporarily install adapters (33) and (43) less 0 - rings (34) and (42), bolts (32) and (44) and w~hers. Install adapters against packings (36) and (40). b. Set valve upright on one adapter, and place a 10 lb. weight on top adapter to compress the packings. c. Usmg a thickness gage, measure clearance be tween adapters (33) and (43) and valve body (38) .
NOTE Shims are available in thlckness es of 0. 005 inch and 0. 014-inch. Use combinations of shims to most nearly meet the dimensions measured from each gap. d. Remove weight and adapters (33) and (43) and in stall bolts (32) and (44) and washer s. NOTE On 1608 132 - 1 Spray Valve s Shims (2 3) . {5) and (6) are us ed as required to al ign wo rm (22) a nd wo rm gear (8) and to line up wo rm gea r o n shaft (26). On 1608160- 1 Spray Valves Shuns (2 3) and ( 5) are used as requ1red to align wo rm (22 ) and wo rm gear (8).
19- 65
MODEL 188 & T188 SERIES SERVICE MANUAL
4
8
â&#x20AC;¢
Seal bolt heads with SACO 326 (American Mtneral Spints: Wic hita , Kansas) . Mix by adding 2 parts of A to 1 part o{ B by wetght. 1.
Door
2. Gasket 3. Eyebolt 4. Plate 5. Gasket 6. Gasket/ Seal
7. 8. 9. 10 . 11.
Br acket Valve Assembly Gasket Adapter Contr ol
12. 13 . 14 . 15. 16. 17.
Hose Clevi s Bolt Suppor t Outlet Gasket
Figure 19-31. Aus tralian Dump P late Installation
19-66
MODEL 188 & T188 SERIES SERVICE MANUAL SECTION 20
TABLE OF CONTENTS
WIRING DIAGRAMS
THRU 1977 MODEL
Page No. Aerofiche/ Manual
Circuit Function and Specific Circuit Code Letters . . . . . 3A3/20- 2 DC. POWER Battery and External Power System. 3A6-20-5 Battery and External Power System (24V, 60 AMP) . . . . . . . . . 3A8/20-7 Alternator System (14V, 60 AMP~ . 3A10/20-9 24 Volt, 60 AMP Regulator, Alternator & Warning Lt . . . â&#x20AC;¢ 3All/ 20-10 Alternator System (14V, 60 AMP) . 3A12/20-11 Alternator System (14V, 60 AMP) . 3A13/ 20-12 Alternator System (14V, 60 AMP) . 3Al4/20-13 24 Volt 60 AMP Regulator, Alternator & Warning Lt. . . . . 3A16/20-15 Alternator System (24V, 60 AMP) . 3A17/20-16 Alternator System (24V, 60 AMP) . 3A18/20-17 Alternator System (14V, 100 AMP) . 3A20/20-19 Alternator System (24V, 100 AMP) . 3A21/20- 20 Bus Bar . . . . . . . . . . . . . 3A23/20-22 Bus Bar . . . . . . . . . . . . . 3B1/20-24 Battery and External Power System. 3B3/ 20-26 IGNITION Magneto . . . . . . . 384/20-27 ENGINE CONTROL Starter System . . . . 385/20-28 Starter System (24V) . 386/20-29 FUEL AND OIL Fuel Pump System . . 3B7/20-30 Fuel Pump System (24V) . . . 388/20-31 Fuel Pump System (12V and 24V) . . 389/20- 32 Fuel Pump System (12V and 24V). . 3810/20-33 Fuel Pump System (12V and 24V). . 3812/ 20-35 ENGINE INSTRUMENTS Fuel Quantity Indicator . . . . . . 3813/20-36 Fuel Quantity Indicator (24V). . . . 3814/20-37 Fuel Quantity Indicator, Wing Tank. 3815/20-38 Fuel Quantity Indicator, Wing Tank (24V) . . . . . . . . . . . . . 3816/20-39 Cylinder Head Temperature . . . . 3817/ 20- 40 Cylinder Head Temperature (2 4V) . 3818/ 20-41 FUGHTINSTRUMENTS Turn and Bank Indicator. . . . 3Bl9/20-42 Turn and Bank Indicator (24V) . 3820/20-43 Brittain Wing Leveler . 3B21 / 20-44 Turn Coordinator (12V) . 3822/20-45 Turn Coordinator (24V) . 3B23/20-4 6 OTHER INSTRUMENTS Ammeter . . . . . . . 3824/20-47
LIGHTING Compass and Instrument Lighting. Compass and Instrument Lighting (24V) . . . . . . Landing Lights . . . . . . . . . Landing Lights . . . . . . . . . Landing Lights (24V) . . . . . . Landing and Taxi Lights (12V and 24V) . . . . . . . . Navigation Lights . . . . . . Navigation Lights (24V) . . . . . Flashing Beacon Light. . . . . . Flashing Beacon Light (24V) . . . Wing Tip Strobe Lights (12V and 24V) . . . . . . . . . . . . Flashi~ Beacon Light (12V and 24V). . . . . . . . . . . Flashing Beacon Light . . . . Map and Auxillary Instrument Light (12V and 24V) . . . . . Compass and Instrument Lighting (12V and 24V) . . . . . . . . Compass and Instrument Lighting (12V and 24V) . Turn Lights . . . . . . . . . Spray Lights (24V) . . . . . . . Spray Lights (24V) . . . . . . . Hopper Light. . . . . . . . . . HEATING, VENTING AND DE-ICING Heated Pltot Tube & Heated Stall Warning System . Cigar Lighter . . . . .
Cigar Lighter (24V) . . .
Air Conditioner . . . .
WARNING AND EMERGENCY Stall Warning System (Non-Heated) . . . . Stall Warning System (Non-Heated( (2 4V) . . MISCELLANEOUS SECTION Electric Spray Valve (12V) Electric Spray Valve (12V) Electric Spray Valve (24V) Agitator (12V and 24V) Electric Spray Valve . Automatic Flagman . . Automatic Flag man . . Agitator (12V and 24V) Electric Spray Valve
. 3C1/20-48 . . . .
3C2/ 20- 49 3C3/20-50 3C4/20-51 3C5/20- 52
. . . . .
3C6/20-53 3C7/ 20- 54 3C9/20-56 3C10/20-57 3Cll/20-58
. 3Cl2/ 20-59 . 3C14/20- 61 . 3C15/20-62 . 3C16/20-63 . 3C17/20- 64 . . . . .
3C18/20-65 3C20/20-67 3C22/20-69 3C23/20-70 3C24/20-71
. . . .
301/20-72 3D2/20-73 3D3/20-74 304/20-75
. 305/20-76 . 306/20- 77 . . . . . . . . .
3D7/20-78 3D8/20-79 3010/20-81 3011/20-82 3012/20-83 3014/20-85 3D15/20-8.6 3016/20-87 3D17/20-88
Beginning With 1978 Models 0 C POWER
Bus Bar . . . . . . . . . . . Alternato r System (60 AMP&. 95 AMP} . . . . . . . . . . Alternator System (60 AMP&. 95 AMP}. . . . . . . . . . Battery and External Power Syste m. Battery and External Power Syste m.
3019/ 20-90 3020/ 20-91 3021 / 20-92 3023/20- 94 3D24/20-95
Alternato r System (60 AMP & 95 AMP). . . . . . . . . . . . Alternator System (60 AMP & 95 AMP) . . . . . . . . . . . . Battery and External Power System. Battery and External Power System. Battery and External Power System (Tl88C} . . . . . . . . . . . .
3E 1/ 20- 96 3E2/20-97 3E3/20- 98 3E4/20-99 3E 5/20-1 00 20-1
MODEL 188 & T188 SERIES SERVICE MANUAL
Alternator System (60 AMP &. 95 AMP) . . . . . . . . . . 3E6/20-101 Alternator System (60 AMP & 95 AMP) . . . . 3E7/20-102 IGNITION Magneto . . . . . 3E8/ 20-103 ENGINE CONTROL Starter System . . 3E9/20-104 Starter System . . 3E10/20-105 FUEL AND OIL Fuel Pump . . . . 3Ell/20- 106 ENGINE INSTRUMENTS Fuel Quantity Indicator, Wing Tank . 3E12/20-107 Cylinder Head Temperature . 3E13/20-108 FLIGHT INSTRUMENTS Turn Coordinator & Turn and Bank Indicator . 3E14/20-109,-~ LIGHTING ~~ Landing and Taxi Lights . 3El5/20-110 Navigation Lights . . . . . 3El6/20-lll Wing Tip Strobe Lights . . 3El7/20-112 Flashing Beacon Light . . 3El8/20-113 Map and Auxiliary Instrument Light . · . . . . . . . . . . 3El9/20-114 Compass and Instrument Lighting . . 3E20/ 20-115
Compass and Instrument Lighting. Turn & Spray Lights
Turn & Spray Lights . . . .
Turn & Spray Lights . . . .
Hopper Light . . . . . . .
Map and Auxiliary Instrument
Light . . . . . .
Turn & Spray Lights
Turn & Spray Lights
HEATING, VENTING Cigar Lighter . . . Alr Conditioner. . . Air Conditioner. . . WARNING AND EMERGENCY Stall Warning System (Non-Heated). . . . . MISCELLANEOUS SECTION Electric Spray Valve Automatic Flagman. Automatic Flagman. Agitator . . . . . . Electric Spray Valve Electric Spray Valve Automatic Flagman . Electric Spray Valve
. . . . .
3E21/ 20-116 3E23/ 20-11 8 3E24/20-119 3F2/20-121 3F3/20-122
. 3F4/20-123 . 3F5/20-124 . 3F6/20-125 . 3F8/20-127 . 3 F9/20-12 8 . 3F10/20- 129 . 3Fll/20- 130 . . . . . . . .
3F12/ 20-131 3Fl3/20-132 3F14/20-133 3Fl6/20-135 3F17/ 20-136 3Fl9/20-138 3F20/20-139 3F21/20-140
CffiCUIT FUNCTION AND SPECIFIC CIRCUIT CODE LEITERS
I
A- Armament B - Photographic C - Control Surface CA - Automatic Ptlot
CC- Wing Flaps
CD - Elevator Trim il
D - Instrument (Other Than Fli~t or Engine Instrument) DA- Ammeter DB - Flap Position Indicator DC - Clock DD - Voltmeter DE - Outside Air Temperature DF - Flight Hour Meter E - ··Engine Instrument EA - Carburetor Air Tempe~ture EB - Fue l Quantity Gage and Transmitter EC - Cylinder Head Temperature ED - Oii Pressure EE - Oil Temperature EF - Fuel Pressure EG - Tachometer EH - Torque Indicator EJ - Instrument Cluster EL- Fuel Flow F - Flight Instrument FA - Bank and Turn FB - Pitot Static Tube Heater and Stall Warning Heater FC - Stall Warning FD - Speed Control System FE - Indicator Lights G - Landing Gear GA - Actuator GB - Retraction GC - Warm ng Devi ce (Horn) GO - Light Switches GE - Indicator Lights 20- 2
Revision 1
H- Heating, Air Conditioning, Ventilating & De- Icing
HA HB HC HD-
Antl-tch~
Cabin Heater Cigar Lighter De-tee HE - Air Conditioners HF - Cabin Ventilation J - Ign.l.tion
JA - Magneto
K - Engine Control
KA - Starter Control
KB - Propeller Synchronizer
L- Lighting
+A - Cabtn·
LB -· llistruptent
LC- Landing
LD - Navigation
LE- Taxi
LF - Rotating Beacon
LG'- Radio
LH- De-ice
W - Fuel Selector
LK - Tail Floodlight
M - Miscellaneous MA- Cowl Flaps MB - Electrically Operated Seats MC - Smoke Generator MD - Spray Equipment ME - Cabin Pressurization Equipment MF - Chern Oz - Indicator P - D. C. Power PA - Battery Circuit PB - Generator Circuits PC - External Power Source Q - Fuel and Oil QA - Auxilliary Fuel Pump QB - Oil Dilution QC - Engine Primer
MODEL 188 & T188 SERIES SERVICE MANUAL
QD - Main Fuel Pumps QE - Fuel Valves R - Radio (Navigation and Communication) RA - Instrument Landing RB - Command RC - Radio Direction Finding RD- VHF RE- Homing RF - Marker Beacon RG - Navigation RH - High Frequency RJ - Interphone RK- UHF RL - Low Frequency
FUNCTION CIRCUITS
RM - Frequency Modulation RP - Audio System and Audio Amplifier RR - Distance Measuring Equipment (DME) RS - Airborne Public Address System s- Radar U - Miscellaneous Electronic UA - ldentUication - Friend or Foe W - Warning and Emergency WA - Flare Release WB - Chip Detector WC - Fire Detection System WD - Low Level Fuel WE- Vacuum Warning System X - A. C. Power
BASE COLOR (or eoltd)
GAUGE
STRIPE COLOR
16
Red
Nooe
18
Red
Black
Re d
White
20
Red
Green
22
Red
Yellow
16
Black
None
18
Black
White
Mlke Ground
22
Black
None
Radio Lights Dt m
18
Yellow
None
Mike AudLo
22
Tan
None
Tan (Shielded)
None
A+ Power
Ground
Mike Key
22
White
Black
Radio Speaker
20
Green
None
Headphones
22
Blue
None
22
Gray
Red
22
Gray
Green
Dev + Dev
• ••
e "Dev+" and "Dev- "
circuits are for use with autopilots and any associated omni indicator circuit to which it connects. Where additional colors are required, red/ white may be used for "Dev+" and red/black for "Dev- " .
NOTE All other color coded wires are for general use in multi conductor radio and autopilot harness assemblies. Effectivity of diagrams are designated as follows: Eff thru (SRXXXX) denotes effectivity to the serial number prior to the (SRXXXX) serial. (S RXXXX) & on denotes effecttvity fo r the (SRXXXX) sertal and on. Diagrams and/o r portions of. may be tndividually serialized and not designated by a (S RXXXX) number. 20- 3
M ODE L 188 & T188 SER IES .S ERVICE MANUAL CROSS REFERENCE USTING OF SERIAL REQUEST NUMBERS LISTED ON DIAGRAMS VS. AIRCRAFT SERIAL NUMBERS. SR NO.
AlRCRAFT SERIAL NO.
SR NO.
AIRCRAFT SERIAL NO.
SR 4767
188-0001
SR 8297
18802447
SR 6037
18800573
SR 8299
18802779
SR 6222
18800546
SR 8457
18803047
SR 6765
18800833
SR 8552
18802811
SR 6879
18800833
SR 8598
18803047
SR 7201
18801069
SR 8629
18803015
::lR 7402
18801375
SR 8635
18802796
SR 7639
18801510
SR 8763
18803047
SR 7669
18801825
SR 8777
18803,297
SR 7684
18801617
SR 8821
18803026
SR 7803
18801607
SR 8822
18803284
SR 7848
18801767
SR 8861
18803047
SR 7 887
18801857
SR 8938
18803050
SR 8139
18802746
SR 8968
18803219
SR 8153
18802130
SR 9014
18803246
SR 8260
18802230
SR 9142
18803255
SR 9109
18803522
SR 9253
18803405
SR 9429
18803373
SR 9444
18803473
SR 9629
18803722
SR 9948
18803857
SR10096
18803927
SR10637
18803969
20-4
Revision 1
& 18802901T
I
MODEL 188 & T188 SERIES SERVICE MANUAL
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\(o\0043
TEMPORARY REVISION NUMBER 6 DATE January 15 2008
.
.
.
MANUAL TITLE
Model 188 & T188 Series 1966 Thru 1984 Service Manual
MANUAL NUMBER :- PAPER COPY
D2054-1-13
MANUAL NUMBER - AEROFICHE
D2054-1-13AF
TEMPORARY REVISION NUMBER
D2054-1TR6
MANUAL DATE
25 March 1983
REVISION NUMBER ___ 1_ _ DATE
1 August 1983
This Temporary Revision consists of the following pages, which affect antl replace existing pages in the .paper copy manual and supersede aeroflche information . " ,. ..
SECTION
5 5
PAGE 2A
2B
AEROFICHE. FICHE/FRAME Added Added
SECTION
PAGE
AEROFICHE FICHE/FRAME
REAS.ON FOR TEMPORARY REVJSION 1. ro add a corrosion inspection of the main landing gear. '\.......-
fiLING INSTRUCTIONS FOR THIS TEMPORARY REVlSION
1. For Paper PublicatiQns, file this cover sheet behind the p ublication's title page to identify the inclusion of the Temporary Revision into the manual. Insert the new pageS into 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 ~me (page) affected by the T empor~ry Revision. TtJis will be a visual identifier: that the information on the frame (page) is no longer valid and the Temporary Revision should be referenced. For uadded· pages in a Temporary Revision, draw a vertical line between the applicable frames. line should be wide.enf>ugo to show on the edges of the-pages. Temporary Revisions should be collected and maintained in a notebook or binder near the aeroflche library fOr quick reference. 3. For CD publications, mark the temporary revision part number on th.e CD label with permanent red marker. This will be a visual identifier that the temporary revision must be referenced when the content of the CD is being used, Temporary revisions should be collected and maintained in a notebook or binder near the CD library for quick reference.
© Cessna Aircraft Company
'
.. I
'
TEMP_ORARY REVISION NUMBER 5 DATE 5 April 2004 MANUAL TITLE
Model 188 & T188 Series 1966 Thru1984 Service MaP!ual
MANUAL NUMBER- PAPER COPY
02054-1-13
MANUAL NUMBER - AEROFICHE
0205~ 1-13AF
TEMPORARY REVISION NUMBER
02054-1TR5
MANUAL DATE
25 March 1983
REVISION NUMBER _.1.__ DATE
1 August 1983
Thi~ Temporary Revision consists of the following pages. which affect and replace existing pages
in lhe paper copy manual and supersede aerofiche information. SECTION
2 2-":
..
PAGE 24 28A
AEROFICHE FICHE/FRAME
PAGE
SECTION
AEROFICHE FICHE/FRAME
.. .
1/820 Added
-~
•.
,. ,, ...
..
REASON FOR TEMPORARY REVISION
\
1. To add the cleaning interval of the engine fuel injection nozzles. '
FlUNG INS!RUCTIONS FOR THIS TEMPORARY REVISION
.
.
~:
.
~·,
1. For Paper Publications, file this cover sheet behind the. PQ~Iication's title page_to identify th~ ~ • · inclusion of the Temporary Revision into the manual. ln~art the new pages iQt_9.the,pyt>llcatt<:>n at the appropriate locations and Femove and discard the superseded pages~~ ~..~ i •,,~:'
.
2. For Aerofiche Publications, draw a line with permanent red ink mai:ker, through ~~y ae[Pflche { frame (page) affected by the Temporary Revision. This will be a visual identifier ttfanhe infOrmation on the frame (page) is no longer valid and the Temporary Revision should b.e 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.
•
0 Cessna Afrcraft Company
.l
. ...
.........
;· I'
I
'
'-.-r
TEMPQRARY REVISION NUMBER 4 DATE 7 October 2002 MANUAL TITLE
Model1.88 & T188 Series 1966 Thru1984 Service Manual
MANUAL NUMBER- PAPER COPY
0201*1-13
MANUAL NUMBER- AERORCHE
D2054-1·13AF
TEMPORARY REVISION NUMBER
D2054-1TR4
MANUAL DATE
25 March 1983
REVISION NUMBER _..1_ _ DATE
1 Auqust1983
This Temporary Revision consists of the following pages, which affect and replace existing pages in the paper copy manual and supersede aerofiche Information. SECTION 2 2
2 2 2 15 15
PAGE
AEROFICHE 'FICHE/FRAME
24 24A/Deleted 28A
288 28C 12C 120
SECTION
PAGE
AEROFICHE FICHE/FRAME
1/820
NA
Added
Added
Added
Added
Added
REASON FOR TEMPORARY REVISION 1. To add a Component Time Limits section and a fuel quantity indicating system operational test FILING INSTRUCTIONS FOR TH~ TEM{»ORARY REVISION 1.
For Paper Publications, file this cover sheet behind the publication's title page to identify the inclusion of the Temporary Revision into the manual. Insert the new pages into the publication at the-~ppropriate locations and remove and discard the superseded pages.
2 . For A'erofiche 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 tne 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. Une should be wide enough to show on the edges of the pages. Temporary Revisions should he collected and maintained ln a notebook or binder near the aerofiche library for quick reference.
'
.:·
COPYRIGHT@ 2002 CESSNA AIRCRAfT COMPANY WICHITA, KANSAS, USA .
-.
.
.
.
...
. ....
TEMPORARY REVISION NUMBER 3 \._
DATED 7 January 2000
·
MANUAL TITLE
MODEL 188 & T188 SERIES 1966 THRU1984 SERVICE MANUAL
. MANUAL NUMBER - PAPER COPY 02054-1-13
AEROFICHE
TEMPORARY REVISION NUMBER .PAPER COPY D2054-1TR3 MANUAL DATE 25 MARCH 1983 REVISION NUMBER _1_
D2054-1-13AF AEROFICHE N/A
DATE 1 AUGUST 1983
~· This Temporary Revision consists of the following pages, which affect existing pages in the } paper copy manual and supersede aerofiche information.
-- 1
'
·:
- SECTION 2 2 17 17
PAGE
AEROFICHE FICHE/FRAME
24A 28A10A108 -
Added
Added
Added
Added
SECTION
PAGE
AEROFICHE FICHE/FRAME
REASON FOR TEMPORARY REVISION To include the inspection requirements of Cessna Service Bulletin SE899-18. To provide additional information forthe stop drilling of cracks that originate at the trailing edge of control surfaces with corrugated skins. . FILING INSTRUCTIONS FOR THIS TEMPORARY REVISION For Paper Publications: · · R le this cover sheet behind the publication's title page to identify the inclusion of the Temporary Revision into the manual. Insert the new pages into the publication at the appropri.at~ locations. Draw a line, with a permanent red ink marker, through any superceded information. For Aerofiche Publications: Draw a line through any aerofiche frame (page) affected by tha..Temporary Revision with a permanent red ink marker. 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 "adde_d" . pages in a Temporary Revision, draw a vertical line between the applicable frames whtch~s,. 1, wide enough to show on the edges of the pages. Temporary Revisions should be collecte.~~.· and maintained in a notebook or binder near the aeroflche library for quick reference . ~· <!:·~ · .
, ,., I~·
\.....
I
\
l
. COPYRIGHT © 2000 CESSNA AIRCRAFT COMPANY WICHITA, KANSAS, USA
·
.
..
MPDEL 188 & T1 88 SERIES SERVICE MANUAL '-...
SPECIAL INSPECTION ITEMS (Continued from page 2-28) 24. Fuel quantity indicating system operational test is requ.ired every 12 months. Refer to Section 15 for detailed accomplishment instructions. 25. At the first 100-hour inspection on new, rebuilt or overhauled engines, remove and clean the fuel injection nozzles. Thereafter, the fuel injection nozzles must be cleaned at 300-hour intervals or more frequently if fuel stains are found. 2-54.
COMPONENT TIME LIMITS
1. General A. Most components listed throughout Section 2 should be inspected as detailed elsewhere in this sectlor and repaired, overhauled or replaced as required. Some components, however, have a time or lift limit, and must be overhauled or replaced on or before the specifred 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 tift 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. Tablt 1 lists those items which Cessna has mandated must be overhauled or replaced at specific time limits Table 2 lists component time limits which have been established by a supplier to Cessna for tht supplier's product. C. In addition to these time limits, the components listed herein are also inspected at regular time interval: set forth in the Inspection Charts, and may require overhauVreplacement before the time limit i: reached based on service usage and inspection results. 2. Cessna-Established Replacement Time Limits
,.
A. Thelollowing component time limits have been established by Cessna Aircraft Company.
·f~
Table 1: Cessna-Established Replacement Time Limits
COMPONENT
OVERHAUL
REPLACEMENT TIME
Restraint Assembly Pilot Seat
(_5 years -
"'' !J
)
~-- __.,;
· Trim Tab Actuator . /
1,000 hours or 3 years, .....~ever occurs first
" l --Pitot and Static System Hoses /
,.
~
1~~rs ~~
\..10 years 0( ~ngine overhaul,
V/h~-'iWoCCUrs first
{Note 1)
Engine Compartment Flexible Fluid Carrying Tetlon Hoses (Cessna. lnstaftedl Except Drain tioses (Drain hoses are replaced .
on condition)
~.
_..
(s}~rs or ~ngine overhaul,
Engine Compartment Flexible Fluid Carrying Rubber Hoses (Cessna Installed) Except Drain·Hoses 1 (Dr!in hoses are replaced on condition)
~~r,_occurs first
2-28A
D2054-1-13 Temporary Revision Number 5 - Apr 5/2004 0 Cessna Aircraft Company
__ ....
+-:L 'tict
-
" MODEL 188 & T188 SERfES SERVICE MANUAL
COMPONENT Engine Air Filter
REF?LACE::::.M .;.:.;E ;;;.;.NT ..-.--_ _ TIME ·
>
../
NO
Engine Mixture, Throttle, and
Propeller Controls
Check Valve (Turbocharger /
I_/"
Oil Line Check Valve)
OVERHAUL
NO NO
Every 1 ,000 hours of operation · (Note 4) '
3. Supplier-Established Replacement Time Umits <
A. The following component time limits have been established by specific suppliers and are
reproduced as follows:
Table 2: Supplier-Established Replacement Time Urn its
COMPONENT
REPLACEMENT TIME
ELT Battery
Note3
NO
Magnetos
Note 5
YES
Engine
Note6
YES
Engine Flexible Hoses (TCM-!nstalled)
Note2
NO
Auxiliary Electric Fuel Pump
Note7
YES
Propeller
Note 8
YES
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OVERHAUL
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. ..
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02054-1-13 Temporary Revision Number 4 - Oct 7/2002 C Cessna Ail'craft Company
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MODEL 188 & T188 SERIES SERVICE MANUAL NOTES: Note 1: This life limit is not intended to allow flexible fluid-carrying Teflon or rubber hoses in a deteriorated or damaged condition to remain in service. Replace engine compartment flexible Teflon (AE3663819BXXXX series hose) fluid-carrying hoses (Cessna installed only) every ten years or at engine overhaul, whicheve.r occurs first Replace engine compartment flexible rubber fluid-carrying hoses (Cessna installed only) every five years or at engine overhaul, whichever occurs first (this does not include drain hoses). Hoses which are beyond these limits and are in a serviceable condition, must be placed on order immediately and then be replaced within 120 days after receiving the new hose from Cessna.
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Note 2: ForTCM engines, refer to Teledyne Continental Service Bulletin SB97-6, or latest revision. Note 3: tefer to FAR 91207 for battery replacement time limits. Note
4j ~eplace the ~urbocharger oil line check valve every 1,0/?00o of operation (Refer to Cessna ·?
Serv1ce Bulletin SEB91·7 Revision 1 , or latest revision).
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Note 5: For airplanes equipped with Slick magnetos, refer to Slick Service Bulletin SB2·80C, or la~est revision, for time limits. .
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For airplanes equipped with TCM!Bendix magnetos, refer to Teledyne Continental Motors Service Bulletin No. 643, or latest revision, for time limits. Note 6: Refer to Textron/Lycoming Service l.nstructlon S.l. 1oosAJ. or latest revision, for time limits.
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No~efer to Cessna Service Bulletin SEB94-"7 ~Inc. Service Bulletin NO. 0003_..Q.t. ...
7'.
latest revisJon.
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Note 8: Refer to the applicable McCauley Service Bulletins and Overh~ual for replacement and oveJhi:!;ul Information. / ~ .
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Note 9: The air filter may be cleaned, refer to Section 2 of this sejvlce manual or servicing instructions. For airplanes equipped wi1h an afr filter manufactured b'~ Donaldson, fer to Donaldson Aircraft Alters Service Instructions P46'-90?5 for detailed servi~'\J instruc~s. The address for Donaldson Aircraft Alters is: \,~ Customer Service
115 E. Steels Comers AD
. Stf,lw OH. 44224
Do not overservice the air filter, overservicing Increases the risk of damage to the air filter from excessive handling. A damaged/worn air filter may expose the engine to unfiltered air and result in damage/excessive wear to the engine.
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Temporary Revision Number 4
7 October 2002
@ 2002 Cessna Aircraft Company
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MODEL .188 & T188 SERIES .SERVICE MANUAL 5-5A. CORROSION CONTROL ON LANDING GEAR SPRINGS. a. General (1) The main landing gear springs are made from high strength steel that is shot peened on the lower surface to increase the fatigue life of the part. (2) The shot peened layer is between 0.010 and 0.020 inch thick. (3) If the protective layer of paint is chipped, scratched, or worn away, the steel may corrode (rust) .
.NOTE: Corrosion ·pits that extend .past the shot peer layer of the gear spring will cause a significant decrease in the fatigue life of the spring. (4) Operation from unimproved surfaces Increases the possibility of damage. b. Corrosion removal and repair.
WARNING: Do not use chemical rust removers or paint strippers on landing gear springs. High-strength steel parts are very susceptible to t)ydrogen embrittlement. Acidic solutions, such as rust removers and paint strippers, can cause hydrogen embrittlement. Hydrogen embrittlement is an undetectable, time-delayed process. Since the pr9cess is time delayed, failure can occur after the part fs ret-urned to service.
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(1) Examine for signs of corrosion (red rust) if damage to the paint finish of the landing gear spring Is found . (2} Carefully remove any rust by lightsanding. (a) The sanding must blend the damage into the adjacent area in an approximate 20:1 ratio. EXAMPLE: An 0.005-inch deep pit. The pit must be blended to a 0. 10-inch radius or 0.20-inch diameter. • (b) Make sure the last sanding tnarks are along an inboard-to-outboard direction, or along the long dimension of the spring. (3) After the sanding is complete, measure the depth of the remoVed material from the damaged area.
NOTE: 1'he maximum combined depth of removed material to the top and bottom or leading and trailing edge is not to be more than 0.063 inch at any two opposite points on the gear spring. This measurement limita1lon inclu des areas that have previously been damaged and repaired. (a) Make sure the depth of the damage area on the bottom of the gear spring is not more than 0.012 Inch deep. 1 If the damage is deeper than 0.012 inch deep and less than 0.063 inch deep, replace or shot _peen the gear spring. The gear spring must be removed and sent to an approved facility to be · -shot peened. g The shot peen specification Is to be Almen intensity of 0.012 to 0.016 with 330 steel shol ,
(b) Make sure the depth of any damage on the leading edgE;!, trailing edge, or top of the gear spring is not more than 0.063 inch deep. 1 If the damage is deeper than 0 .063 inch deep, replace the gear spring. (4) Touch-up paint as required.
NOTE: Additional information regarding corrosion control can be found in FAA Documents AC-43-4, Chapter 6, or AC43.13-1 B Chapter 6. c. Axle bolt hole corrosion. (1) Operation of an airplane on skis Increases the leads on the lower part of the gear spring because of the unsymmetrical and twisting loads. (a) The increased loads have produced spring fractures that originate from pits in the axle attach holes. 1 Catastrophic failures can occur from fatigue cracks as· small as 0.003 to 0.010- inch long that originated at pits.
02054-1-13 Temporary Revision 6 Jan 15/2008 © Cessna Aircraft Company
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5-2A
MODEL 188 & T1 88 SERIES SERViCE MANUAL NOTE: Although operation on skis causes more loads, the criteria apply to all airplanes. (2) There is no maximum aamage'depth for pits that develop in the axle bolt holes. If pits or corrosion Is found, ream to remove it, subject to the following limitations: (a} Remove the minimum material necessary to repair the damage. (b} Make sure 1he diameter of the axle attachment holes are no more than 0.383 inch for 318- inch bolts. (c) Make sure the diameter of the axle attachment holes are no more than 0.321 inch for 5116- Inch bolts. (d) If reaming to the maximum dimension does not remove all signs of corrosion, discard the landing gear spring.
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02054-1-13 Temporary Revision 6 Jan 15f2008 © Cessna Aircraft Company