Table Of Contents - Cessna 177 SERIES Service Manual

Table of Contents

Table Of Contents8
General Description12
Technical Data13
Reference Stations Diagram15
Recommended Nut Torques16
Ground Handling, Servicing, Cleaning, Lubrication And Inspection17
Jacking Information19
Leveling The Aircraft19
Hoisting20
Parking20
Flyable Storage20
Temporary Storage20
Returning Aircraft To Service21
Indefinite Storage21
Servicing23
Fuel Drains23
Engine Oil23
Induction Air Filter24
Vacuum System Filter25
Battery Servicing25
Tires Maintenance25
Nose Gear Shock Strut Maintenance25
Nose Gear Shimmy Dispenser Servicing26
Hydraulic Brake Systems Servicing26
Cleaning26
Required Materials26
Cleaning Instructions27
Windshield And Window Preventive Maintenance27
Interior Trim28
Painted Surfaces28
Aluminium Surfaces28
Engine And Engine Compartment28
Upholstery And Interior29
Wheel Bearings29
Aileron Rod End Bearing29
Wing Flap Actuator29
Servicing Diagram30
Lubrication Diagram34
Inspection Charts37
If The Aircraft Is Flown More Than 200 Hours Annually38
Inspection Guide Lines38
Engine Run-Up39
Propeller Inspection40
Engine Compartment Inspection40
Fuel System Inspection41
Landing Gear Inspection41
Airframe Inspection42
Control Systems Inspection43
Special Inspection Items43
Component Time Limits46
Fuselage50
Windshield And Windows Waxing50
Scratches On Windshield And Windows50
Cracks51
Repair Of Windshield And Windows51
Windshield And Fixed Window Installation52
Windshield Removal And Installation53
Windows Removal And Installation53
Cabin Doors Removal And Installation53
Cabin Doors Adjustment53
Fixed53
Side Windows53
Weatherstrip53
Cabin Door Installation54
Latches55
Indexing Inside Handle55
Baggage Door Removal And Installation55
Seats Removal And Installation55
Description55
Adjustment55
Lock55
Pilot And Copilot55
Cabin Door Latch Diagram56
Baggage Door Installation Diagram57
Seat Installation Diagrams58
Vertical Adjust/Reclining Back59
Articulating Recline/Vertical Adjust60
Seat Belt And Shoulder Harness Installation Diagrams65
Seats Repair67
Cabin Upholstery67
Soundproofing67
Removal And Installation Center67
Cabin Headliner68
Cargo Tie-Downs Diagram68
Rear View Mirror Installation68
Removal And Installation 1C7/3-668
Safety Provisions69
Upholstery Side Panels69
Safety Belts69
Shoulder Harness69
Auxiliary69
Rear View Mirror69
Wings And Empennage70
Wings Removal70
Wings Installation71
Winds Adjustment - Correctiong "Wing-Heavy" Condition71
Fin Removal And Installation71
Wing Installation Diagram72
Vertical Fin Diagram73
Landing Gear, Wheels And Brakes74
Landing Gear Troubleshooting75
Main Landing Gear76
Main Gear Installation77
Main Wheel Speed Fairing Removal And Installation78
Main Landing Gear Fairings Removal And Installation78
Main Wheel Removal79
Wing Tip Height Adjustment79
Cleveland Wheel And Brake Assembly Diagram80
Mccauley Wheel And Brake Assembly Diagram81
Main Wheel Disassembly82
Main Wheel Inspection And Repair82
Main Wheel Reassembly82
Main Wheel Disassembly (Mccauley Two-Piece Wheel)84
Main Wheel Inspection And Repair (Mccauley Two-Piece Wheel)84
Main And Nose Wheel Thru-Bolt And Capscrew Torque Values85
Wheel Alignment Diagrams86
Wheel (Cleveland)86
Main Wheel Installation87
Main Wheel And Axle Removal87
Main Wheel And Axle Installation87
Main Wheel Alignment87
Wheel (Mccauley With Hub And Capscrews)87
Nose Gear88
Wheel Balancing88
Wheels Troubleshooting88
Trouble Shooting88
Nose Gear Removal And Installation89
Nose Wheel Speed Fairing Removal And Installation89
Nose Wheel Speed Fairing Diagram90
Speed Fairing Removal90
Nose Wheel Removal And Installation91
Nose Wheel Disassembly91
Nose Wheel Inspection And Repair92
Nose Wheel Reassembly92
Nose Wheel Disassembly (Mccauley)92
Nose Wheel Inspection And Repair (Mccauley)93
Nose Wheel Reassembly (Mccauley)93
Standard Nose Gear95
Nose Gear Shock Strut Inspection And Repair95
Nose Gear Shock Strut Diagram96
Heavy-Duty Nose Gear97
Nose Gear Shock Strut Reassembly97
Torque Link Removal97
Nose Wheel Steering System98
Shimmy Dampener Removal And Disassembly98
Shimmy Dampener Installation98
Torque Link Inspection, Repair And Installation98
Torque Links Diagram99
Brake System100
Steering Bungee Assembly100
Nose Wheel Steering Adjustment100
Shimmy Dampener Diagram100
Nose Gear Troubleshooting101
Hydraulic Brake Lines102
Brake Master Cylinder Disassembly, Inspection And Repair102
Brake Master Cylinder Installation102
Wheel Brake Removal, Disassembly And Repair102
Brake Master Cylinder Diagram103
Wheel Brake Reassembly And Installation104
Brake Lining Installation104
Brake System Bleeding104
Brake Lining Conditioning104
Brake System Diagram105
Parking Brake System106
Aileron Control System Troubleshooting107
Control Column Removal And Installation108
Control Column Repair108
Aileron Bellcrank Removal108
Aileron Control System Diagram109
Control Column Installation Diagram110
Aileron-Rudder Interconnect System Diagram111
Cables And Pulleys Removal And Installation112
Aileron Installation112
Ailerons Removal And Installation113
Rigging113
Aileron Trim Tab Removal, Installation113
Aileron Trim Tab Adjustment113
Aileron-Rudder Interconnect System114
Wing Flap Control System115
Wing Flap Control System Troubleshooting116
Flap Motor, Transmission And Actuator Assembly Removal/Installation117
Flap Control Lever Removal And Installation117
Drive Pulleys Removal And Installation117
Flap Control System Diagram118
Flap Motor, Transmission And Actuator Installation Diagram119
Bellcranks Removal And Installation120
Flaps Removal And Installation120
Flap System Schematic122
Stabilator Control System Troubleshooting124
Stabilator Removal And Installation125
Stabilator Control System Diagram126
Stabilator Installation Diagram128
Control Column Neutral Position Diagram129
Stabilator Trim Control System Troubleshooting130
Trim Tab Removal And Installation131
Trim Tab Actuator Removal And Installation131
Trim Tab Actuator Disassembly131
Stabilator Trim System Diagram132
Trim Tab Actuator Cleaning, Inspection And Repair133
Trim Tab Actuator Reassembly134
Trin Tab Free-Play Inspection134
Trim Tab Control Wheel Removal And Installation134
Stabilator Trim Travel Adjustment Diagram135
Stabilator Trim Tab Actuator Assembly Diagram135
Rudder And Rudder Trim Control Systems Troubleshooting138
Rudder Pedal Assembly Removal And Installation139
Rudder Removal And Installation139
Rudder Control System Diagram140
Rudder Pedals Installation Diagram141
Master Cylinders141
Rudder Assembly Diagram142
Checking Rudder Travel Diagram143
Rudder Trim Control System Troubleshooting144
Steering Bungee Removal And Installation144
Trim Control Wheel Removal And Installation144
Rudder Trim Control System Diagram145
Pedestal Cover Removal And Installation146
Engines147
Removal147
Installation147
Engine Cowling148
Engine Cowling Removal And Installation149
Engine Cowling Cleaning And Inspection149
Cowl Flaps Removal And Installation149
Engine Description149
Engine Data150
Time Between Overhaul152
Overspeed Limitations152
Engine Troubleshooting152
Static Run-Up Procedures154
Engine Removal155
Accessories Removal156
Engine Inspection156
Engine Build-Up156
Engine Installation156
Flexible Fluid Hoses Pressure Test157
Flexible Fluid Hoses Replacement157
Engine Baffles Description157
Engine Oil System158
Engine Baffles Cleaning And Inspection158
Engine Baffles Removal And Installation158
Engine Mount Removal And Installation158
Engine Mount Details Diagram159
Engine Oil System Troubleshooting160
Full-Flow Oil Filter Removal And Installation162
Filter Adapter Removal163
Filter Adapter Disassembly, Inspection And Reassembly163
Oil Cooler164
Carburetor164
Induction Air System164
Filter Adapter Installation164
Airbox Removal And Installation165
Ignition System165
Magneto Outlet Diagram165
Ignition System Troubleshooting166
Magnetos Description167
Magneto Removal And Installation167
Internal Timing167
Magneto Replacement Interval169
Magneto-To-Engine Timing169
Magneto Maintenance172
Engine Controls173
Magneto Check173
Throttle Control174
Mixture Control175
Carburetor Heat Control175
Starting System175
Starting System Troubleshooting176
Exhaust System177
Starting System Primary Maintenance177
Starter Motor Removal And Installation177
Extreme Weather Maintenance177
Dusty Contitions179
Seacoast And Humid Areas179
Ground Service Receptacle179
Hand Cranking179
Fuel System180
Fuel System Troubleshooting181
Fuel Vents182
Checking Vents182
Fuel System Schematic183
Fuel System Diagram185
Fuel Vent System Diagram187
Fuel Vents Removal And Installation188
Removal And Installation (Thru Serial 17701633)188
Removal And Installation (Beginning With Serial 17701634)188
Fuel Bay Caps190
Drain Fittings Removal And Installation190
Classification Of Fuel Leaks190
Fuel Bay Purging191
Integral Fuel Bay Sealant191
Mixing Sealant191
Sealing During And After Structural Repair191
Fuel Bay Sealing Diagram192
Sealing Fuel Leaks194
Curing Time194
Fuel Quantity Transmitters194
12-19. Testing Integral Fuel Bay194
Fuel Reservoir Tank Removal And Installation195
Fuel Selector Valve195
Fuel Shut-Off Valve Removal And Installation195
Fuel Strainer195
Fuel Strainer Disassembly And Assembly196
Fuel Strainer Removal And Installation196
Fuel Selector Valve And Shut-Off Valve Diagram196
Fuel Strainer Diagram197
Priming System198
Auxiliary Fuel Pump198
Electric Fuel Pump Diagram198
Removal And Installation198
Strainer198
Auxiliary Fuel Pump Disassembly And Assembly199
Propeller And Governor Description200
Fixed-Pitch Propeller Removal200
Propeller Installation (Fixed-Pitch)201
Constant-Speed Propeller202
Propeller And Governor Troubleshooting203
Propeller Installation (Constant-Speed)205
Governor Description206
Governor Troubleshooting206
Governor Removal206
Time Between Overhaul (Tbo)206
Governor Installation207
High Rpm Stop Adjustment207
Time Between Overhaul (Tbo) (Governor)209
Utility Systems210
Heating System Operation210
Heating System Troubleshooting210
Heating System Removal, Repair And Installation210
Heating And Defrosting Systems Diagram211
Ventilating System Diagrams212
Defroster System215
Ventilating System215
Instrument And Instrument Systems216
Instrument Panel Diagram217
Instrument Panel Removal And Installation219
Instruments Removal And Installation219
Pitot And Static Systems219
Static Pressure System Inspection And Leakage Test219
Shock Mounts219
Maintenance219
Pitot Static Systems Diagram220
Pitot System Inspection And Leakage Test222
Blowing Out Lines (Pitot System)222
Pitot System - Removal And Installation Of Components222
Pitot Static System Troubleshooting223
True Airspeed Indicator Troubleshooting223
Trouble Shooting--Pitot Static System223
Static System Test Equipment224
Altimeter Troubleshooting225
Vertical Speed Indicator Troubleshooting225
Trouble Shooting -Altimeter225
Vacuum System226
Pitot Tube Heater Troubleshooting226
Pitot Tube Alignment226
Trouble Shooting - Pitot Tube Heater226
Pitot Tube Alignment Template227
Vacuum System Troubleshooting228
Gyros Troubleshooting228
Vacuum System Diagram230
Standby Vacuum System Description232
Vacuum Pump Troubleshooting232
Removal And Installation Of Vacuum System Components232
Vacuum Relief Valve Adjustment232
Engine Indicators233
Standby Vacuum Pump Troubleshooting233
Low Vacuum Warning System233
Tachometer233
Standby Vacuum System Diagram234
Oil Pressure Gauge Troubleshooting236
Oil Temperature Gauge237
Carburetor Air Temperature Gauge237
Engine Instrument Installation (Leigh System)238
Fuel Pressure Indicator Troubleshooting240
Manifold Pressure Gauge Troubleshooting241
Cylinder Head Troubleshooting Gage Troubleshooting242
Fuel Quantity Indicating System Removal And Installation243
Fuel Quantity Indicating System Troubleshooting243
Stall Warning And Outside Air Temperature Gage Installation244
Ground Strap Installation244
Transmitter Adjustment245
Stewart Warner Gage Transmitter Calibration245
Rochester Fuel Gage Transmitter245
Fuel Quantity Indicating System Operational Test245
Oil Temperature Indicating System Resistance Table246
Cylinder Head Temperature Indicating System Resistance Table247
Hourmeter248
Magnetic Compass248
Electric Clock248
Outside Air Temperature Gage248
Stall Warning System Troubleshooting249
Turn Coordinator249
Turn-And-Slip Indicator Troubleshooting250
Wing Leveler Control System Diagram251
Wing Leveler Description252
Economy Mixture Indicator Troubleshooting252
Economy Mixture Indicator Calibration252
Economy Mixture Indicator Removal And Installation252
Electrical Systems253
Electrical Power Supply System254
Split Bus Bar254
Master Switch254
General254
Split Bus Power Relay254
16-11. Ammeter254
Split Bus Power Relay Installation255
Bus Bar And Circuit Breaker Installation256
Battery And Electrical Equipment Installation Diagram257
Battery Description259
Battery Power System Troubleshooting259
Battery Removal And Installation260
Battery Cleaning260
Adding Electrolyte Or Water To The Battery260
Testing The Battery260
Battery Hydrometer Readings261
Charging The Battery261
Battery Box261
Battery Contactor261
Battery Contactor Closing Circuit262
Ground Service Receptacle Troubleshooting262
Ground Service Receptacle Installation263
Alternator Power System264
Alternator Description264
16-36. Description264
Alternator Power System Troubleshooting265
Trouble Shooting The Alternator System (Thru 1977 Models)265
Trouble Shooting The Alternator System267
Alternator Field Circuit Protection270
16-42. Alternator Voltage Regulator270
Alternator Installation271
Voltage Regulator Installation272
Alternator Voltage Regulator Removal And Installation273
Over-Voltage Warning System273
Aircraft Lighting System Troubleshooting273
Landing And Taxi Lights Removal And Installation279
Landing And Taxi Lights Adjustment279
Removal And Installation (Beginning With 1973 Models And When Modified Per Sk177-24)279
1971 Models)279
Flashing Beacon Light Installation Diagram286
Landing And Taxi Lights (Dual Cowl Mounted) Removal And Installation287
Navigation Lights Removal And Installation287
Flashing Beacon Light287
Instrument Lighting287
Anti-Collision Strobe Lights287
Dome And Instrument Lights Installation Diagram288
Courtesy Lights Installation Diagram289
Transistorized Light Dimming Installation Diagram290
Dome Light291
Compass And Radio Dial Lighting291
Transistorized Light Dimming291
Control Wheel Map Light291
Courtesy Lighting291
Removal And Installation (Thru 1970 Models)291
Control Wheel Map Light Installation Diagram292
Heated Pitot Installation Diagram294
Cigar Lighter Removal And Installation295
Emergency Locator Transmitter296
Emergency Locator Transmitter Installation Diagram297
Emergency Locator Transmitter Removal And Installation298
Antenna Removal And Installation298
Magnesium Six Cell Battery Pack Removal And Installation298
Lithium Four Cell Battery Pack Removal And Installation298
"G" Switch Operational Check299
"G" Switch Troubleshooting299
Emergency Locator Transmitter (Beginning With 1978 Models)301
Electrical Load Analysis Chart305
Structural Repair309
Equipment And Tools For Structural Repair310
Repair Materials310
Wing Angle-Of-Incidence310
Wing Skin Damage310
Damage Necessitating Replacement Of Parts311
Wing Stringers Damage311
Wing Ribs Damage311
Ailerons Damage311
Wing Leading Edge Damage312
Stabilator Damage312
Rudder Damage312
Fin Damage / Fuselage Damage312
Landing Gear Bulkheads313
Replacement Of Hi-Shear Rivets313
Firewall Damage313
Engine Mount313
Engine Mount Radial Support Damage314
Engine Cowling Repair314
Repair Of Cowling Skins314
Repair Of Glass-Fiber Constructed Components314
Support Stands View315
Checking Wing Twist316
Control Surface Balancing317
Control Surface Balance Requirements321
Skin Repair322
Stringer And Channel Repair328
Rib Repair332
Wing Spar Repair334
Leading Edge Repair335
Flap Leading Edge Repair336
Access Hole Installation337
Firewall Angle Repair338
Exterior Painting339
Painting Of Formed Abs Plastic Parts340
Painting Facilities341
Clean Up342
Pre-Priming / Priming342
Pre-Painting342
Painting Allover White Or Color342
Touch-Up343
Repair Of Dents343
Wiring Diagrams344
Battery Circuit Wiring Diagram347
Alternator System Wiring Diagram348
Circuit Breakers Wiring Diagram349
Ground Service Receptacle Wiring Diagram350
Magneto System Wiring Diagram356
Starter Wiring Diagram358
Fuel Pump Wiring Diagram359
Fuel Gage And Transmitter Wiring Diagram360
Hourmeter Wiring Diagram361
Carburetor Air Temperature Wiring Diagram362
Cylinder Head Temp Wiring Diagram363
Oil Temperature Wiring Diagram364
Oil Pressure Wiring Diagram366
Turn And Bank Wiring Diagram368
Brittain Wing Leveler Wiring Diagram369
Turn Coordinator Wiring Diagram370
Encoding Altimeter Wiring Diagram373
Blind Encoder Wiring Diagram374
Clock Wiring Diagram375
Ammeter Wiring Diagram376
Instrument Lights Wiring Diagram378
Landing Taxi Lights Wiring Diagram379
Landing Light Wiring Diagram380
Dual Landing Light Wiring Diagram381
Landing Light And Taxi Light Wiring Diagram382
Navigation Lights Wiring Diagram383
Dome And Courtesy Lights Wiring Diagram384
Flashing Beacon Wiring Diagram386
Map Light, Control Wheel Wiring Diagram388
Wing Tip Strobe Light Wiring Diagram390
Post Lighting Wiring Diagram394
Electro Luminescent Panel Wiring Diagram396
Cigar Lighter Wiring Diagram398
Pitot Heat Wiring Diagram399
Flap System Wiring Diagram400
Starter System Wiring Diagram408
Aux. Fuel Pump Wiring Diagram409
Cylinder Head Temperature Wiring Diagram413
Turn Coordinator Bank Wiring Diagram415
Ldg/Taxi Light And Landing Light Wiring Diagram418
Dome Light Wiring Diagram420
Courtesy Lights Wiring Diagram421
Maplight Control Wheel Wiring Diagram423