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SEMINOLE PA-44-180
Maintenance manual
Table Of Contents - Piper PA-44-180 SEMINOLE Maintenance Manual
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Also See for PA-44-180 SEMINOLE
:
Information manual
(354 pages)
,
Pilot operating handbook
(344 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
Table of Contents
Gama System/Chapter Index Guide
7
List Of Illustrations
9
Table Of Contents
9
Figure No
10
Airworthiness Limitations
19
Time Limits/Maintenance Checks
22
Subject Grid No
22
Inspection Requirements 1A24
24
Preflight Checks 1A24
24
Overlimits Inspection 1A24
24
Propeller Group Inspections
25
Engine Group Inspections
25
Scheduled Maintenance Checks 1B1 9R
25
Periodic Inspections 1B1 A
25
Turbocharger Group Inspections
29
Cabin Group Inspections
29
Fuselage And Empennage Group Inspections
30
Wing Group Inspections
31
Landing Gear Group Inspections
32
Operational Inspection
33
Notes On Periodic Inspections
35
Unscheduled Maintenance Checks - Special Inspections As Required
37
Programmed Inspection 1B13
37
Special Inspections As Required Upon Condition 1B13
37
Dimensions And Areas
39
Leading Particulars And Principle Dimensions
40
Airplane Views And Dimensions
43
Station Reference Lines
44
Access And Inspection Provisions
45
Serial Number Plate
45
Access Plates And Panels Diagram
46
Lifting And Shoring
50
Jacking
52
Leveling And Weghing
54
Leveling Airplane
56
Weighing
57
Towing And Taxiing
59
Parking And Mooring
63
Locking Airplane
64
Placards And Markings Table
67
Placards And Decals Diagram
68
Servicing
71
Service Points
73
Replenishing Fuel System
74
Filling Fuel Tanks
74
Draining Fuel System
74
Oil System
74
Draining Oil Sump
75
Filling Oil Sump
75
Oil Screen (Suction)
75
Recommendations For Changing Oil
75
Oil Filter (Full Flow)
76
Scheduled Servicing
76
Landing Gear Servicing
76
Servicing Oleo Struts
76
Filling Nose Gear Oleo Strut
77
Filling Main Gear Oleo Struts
78
Inflating Oleo Struts
79
Servicing Steering Bungee
79
Brake System
79
Filling Brake System Reservoir
79
Draining Brake System
80
Tires
80
Tire Balance
80
Hydraulic System
81
Hydraulic Pump/Reservoir
81
Battery
81
Removal Of Induction Air Filter
81
Service Instructions - Air Filter Inspection And Replacement
82
Installation Of Air Filter
82
Engine Compartments Cleaning
82
Landing Gear Cleaning
83
Exterior Surfaces Cleaning
83
Windshield And Windows Cleaning
84
Headliner, Side Panels And Seats Cleaning
84
Carpets Cleaning
84
Lubrication Instructions
85
Application Of Oil
85
Application Of Grease
85
Lubrication Chart (Landing Gear, Main)
86
Lubrication Chart (Landing Gear, Nose)
88
Lubrication Chart (Control System)
90
Lubrication Chart (Cabin Door, Baggage Door & Seats)
92
Lubrication Chart (Power Plant & Propeller)
95
Thread Lubricants
97
Standard Practices/Airframe
99
Method Of Installing Rod End Bearings 1E5
99
Torque Wrenches
100
Torque Wrench Formula
100
Method Of Installing Rod End Bearings
101
Cherrylock Rivet Removal
102
Maximum Distance Between Supports For Fluid Tubing
103
Identification Of Fluid Lines
103
Aircraft Finish Care/Cleaning
105
Windshield/Windows Cleaning
105
Headlinder, Side Panels And Seats Cleaning
105
Carpets
106
Cleaning The Engine Compartment
106
Fuel System Cleaning
106
Environmental System
109
Environmental System Description And Principles Of Operation
112
Environmental System Troubleshooting
113
Janitrol Heater Troubles
113
Cabin Vent System
116
Overhead Vent Blower
116
Removal Of Blower Assembly
116
Dismantling Of Blower Assembly
117
Rebuilding Of Blower Assembly
117
Installation Of Blower Assembly
117
Blower System Wire Color Codes
118
Heating System Operational Test
118
Description Of Heater And Basic Components
119
Spark-Spray Ignition
119
Cabin Environmental System Installation
120
Heater And Combustion Air Blower Assembly
121
Fuel Regulator And Shutoff Valve
122
Duct Switch
122
Cumbustion Air Blower/Ventilating Air Blower
122
Diagramatic Cutaway Of Heater To Show Whirling Flame Action
122
Top View - Duct Switch
123
Heater Operating Controls
124
Heater Operating Procedure
124
Intake Valve And Switches View
124
Heater And Heater Components Inspection
125
Removal Of Heater
126
Installation Of Heater
127
Heater Electrical System Checks
127
Heater Electrical System Wiring Diagram
128
Primary Power Circuit (Heater)
129
Vent Blower Power Circuit Check
130
Starting Power Circuit (Heater)
130
Heater Power Circuit Check
131
Combustion Air Blower Maintenance
131
Replacing Motor Brushes
132
Spark Plug Fixture
132
Wiring - Test Setup
132
Spark Plug Removal
133
Spark Plug Gap Adjustment
133
Spark Plug Inspection And Servicing
134
Ignition Unit Removal And Installation
135
Spark Plug Installation
135
Ignition Unit Testing
136
Vibrator Removal And Installation
137
Ignition Unit Assembly View
137
Ignition Unit Inspection
138
Cycling Switch And Limit (Overheat) Switch Removal And Installation
138
Combustion Air Pressure Switch Removal And Installation
139
Fuel Regulator Removal
139
Fuel Regulator Adjustment
139
Fuel Regulator Installation
140
Heater Fuel Pump Removal
140
Heater Fuel Pump View
141
Pump Disassembly
141
Pump Cleaning
141
Pump Repair And Inspection
142
Pump Assembly
142
Heater Fuel Pump Installation
142
Duct Switch Removal And Installation
142
Heater Assembly Overhaul
143
Heater Disassembly
143
Combustion Air Blower Assembly Disassembly
144
Heater Components Cleaning
144
Design For Seal Plates, Plugs, Caps For Combustion Tube Leakage Test
145
Test Setup For Combustion Air Pressure Switch
145
Combustion Tube Assembly Cleaning And Assembly
146
Remaining Components Inspection
147
Check Ventilating Air And Combustion Air Motors
148
Test The Combustion Tube Assembly For Leaks
148
Test The Combustion Air Pressure Switch
149
Test The Fuel Line And Fuel Line Shroud Tube For Leaks
149
Spray Test The Nozzle
149
Exploded View Of Heater Assembly
150
Combustion Tube Assembly Repair
151
Heater Reassembly
151
Combustion Air Blower And Motor Assembly Exploded View
152
Combustion Air Blower Assembly Reassembly
153
Suggested Setup Of Heater Operation
154
Wiring Connections For Heater Operation Test
154
Test Procedure - Equipment Required/Operational Test On Test Bench
155
Fuel Nozzle Orifice Inspection
156
Heater Hourmeter Removal
157
Heater Hourmeter Installation
157
Spark Plug Gap Adjustment Tool Diagram
157
Heater Hourmeter Installation Diagram
158
Air Conditioning System Description And Principles Of Operation
159
Air Conditioning System Troubleshooting
159
Air Conditioning System Installation Diagram
165
Temperature Pressure Chart
166
Air Conditioning System Malfunction Detection
167
Servicing Air Conditioning System
168
Aluminium Tubing Torque Chart
169
Service Values
169
Test Gauge And Manifold Set
170
Manifold Set Operation
171
Leak Detection
172
Duscharging The Air Conditioning System
173
Evacuating The Air Conditioning System
173
Evacuation Hookup Diagram
174
Charging The Air Conditioning System
175
Charging Stand Method
175
Charging Stand View
176
Airplane Compressor Method
176
Charging Hookup Diagram
177
Partial Charge Of Air Conditioning System
178
Air Conditioning System Components
179
Compressor Service
179
Compressor Removal
179
Compressor Installation
179
Top Dead Center Casting Mark (Sankyo Compressor)
180
Rotation Of Clutch Front Plate (Sankyo Compressor Oil Check)
180
Compressor Oil Level Check
181
Drive Belt Tension Adjustment
182
Receiver-Dehydrator Removal
182
Receiver-Dehydrator Installation
182
Condenser
182
Condenser Installation
183
Condenser Removal And Installation
184
Expansion Valve Removal
184
Expansion Valve Installation
185
Evaporator Assembly
185
Evaporator Assembly Removal
186
Evaporator Assembly Installation
186
Evaporator Blower Motor Wire Codes
187
Pressure Relief Switch
188
Electrical Installation
188
Manifold Pressure Switch
188
Autoflight
190
Communications
193
Emergency Locator Transmitter (Elt)
194
Battery Removal And Installation
194
Communications Components Corporation Elt Schematic
195
Narco Elt 10 Portable Folding Antenna
196
Narco Elt 10 Using Fixed Aircraft Antenna
196
Narco Elt 10 Battery Removal And Installation
197
Narco Elt 10 Emergency Locator Transmitter Schematic
197
Emergency Locator Transmitter Testing
198
Elt 910 Battery Pack View
199
Artex Elt-110 - General Information
199
Artex 110 Elt Battery Removal And Installation
200
Testing The Artex Elt 110 Emergency Locator Transmitter
201
Artex E.l.t. 110 Wiring Schematic
201
Electrical Power
203
Electrical System Description And Operation
205
Electrical System Troubleshooting
205
Alternator Troubleshooting
206
Zero Output Indicated On Ammeter Regardless Of Rpm
206
Output Indicated On Ammeter Does Not Meet Minimum Values
207
Field Circuit Breaker Trips
208
Output Circuit Defective
209
Excessive Ammeter Fluctuation
210
Battery Troubleshooting
211
Discharged Battery/Battery Life Is Short
211
Cracked Cell Jars
211
Compound On Top Of Battery Melts/Electrolyte Runs Out Of Vent Plugs
211
Excessive Corrosion Inside Container
212
Battery Freezes
212
Battery Polarity Reversed
212
Battery Consumes Excessive Water
212
Dc Generation
213
Alternator System
213
Checking Alternator Belt Tension
214
Lamp Bank Load Diagram
214
Battery Box Diagram
216
Charging Circuit Service Procedures
217
Hydrometer Reading And Battery Charge Percent
217
Service Procedures 1J1
217
Servicing Battery 1J1
217
Removal Of Battery 1J1
217
Battery Box Removal And Installation
218
Installation Of Battery 1J2
218
Testing Battery 1J2
218
Charging Battery 1J2
218
Battery Box Description 1J2
218
Removal Of Battery Box 1J2
218
Installation Of Battery Box 1J2
218
Battery Box Corrosion Prevention
219
Voltage Regulators And Overvoltage Relays Removal And Installation
219
Electrical Component Location Diagram
220
Lamar Model No. B-00288-1 Regulator Diagram
220
Overvoltage Relays
220
Regulator Operation
221
Preparation For Testing Voltage Regulators
221
Regulator Resting (Lamar Model No. B-00288-1)
222
Regulator Adjustment (Lamar Model No. B-00288-1)
223
Balancing Circuit Operation Of Lamar Model No. B-00288-1 Regulator
224
Overvoltage Relay Checking
225
Alternator Voltage Regulator
225
Voltage Regulator Unit Adjustment
226
Ammeter
227
External Power Receptacle
227
Equipment/Furnishings
229
Flight Compartment
230
Rigging Instructions - Seat Back Lock And Release
230
Lumbar Seats Description
230
Lumbar Bladder Removal
231
Lumbar Bladder Installation
231
Lumbar Seat Bladder Installation
232
Fire Protection
235
Extinguishing
235
Flight Controls
239
Flight Control System Description And Operation
241
Flight Control System - Standard Procedures
241
Rod End Installation Method
242
Control Cable Inspection
243
Cable Damage
243
External Wear Patterns Of Cable
243
Internal Cable Wear
243
Corrosion Of Cables
245
Cable Maintenance
245
Cable Fittings
245
Pulleys/Pulley Wear Patterns
245
Control Surfaces Troubleshooting
246
Aileron Control System Troubles
246
Lost Motion Between Control Wheel And Aileron
246
Resistance To Control Wheel Rotation
246
Rudder Control System Troubles
247
Control Wheels Not Synchronized
247
Incorrect Aileron Travel
247
Lost Motion Between Rudder Pedals And Rudder
247
Rudder Trim Control System Troubles
248
Stabilator Control System Troubles
248
Excessive Resistance To Rudder Pedal Movement
248
Incorrect Rudder Travel
248
Stabilator Trim Control System Troubles
249
Resistance To Stabilator Control Movement
249
Incorrect Stabilator Travel
249
Lost Motion Between Trim Control Wheel And Trim Tab
249
Aileron Controls
250
Control Column Assembly Removal
250
Flap Control System Troubles
250
Trim Control Wheel Moves With Excessive Resistance
250
Control Column Assembly Diagram
251
Control Column Assembly Installation
252
Flex (Universal) Joint Assembly Diagram
253
Aileron Control Cables Removal
254
Aileron Controls Diagram
255
Aileron Control Cables Installation
256
Aileron Bellcrank Assembly Removal
256
Aileron Bellcrank Assembly Installation
257
Bellcrank Rigging Tool View
257
Aileron Rigging View
258
Aileron Controls Rigging And Adjustment
259
Rudder Control Cables Removal
260
Rudder Control Cables Installation
260
Rudder Controls View
261
Rudder Controls Rigging And Adjustment
262
Forward Rudder Trim Controls Removal
262
Clamping Rudder Pedals View
263
Rudder Rigging Tool View
263
Rudder Rigging View
263
Ruder Travel Adjustments
264
Forward Rudder Trim Controls Installation
265
Aft Rudder Trim Controls Removal
265
Rudder Trim Controls View
266
Aft Rudder Trim Controls Installation
267
Rudder Trim Controls Rigging And Adjustment
267
Rudder Pedal Assembly Removal
268
Rudder Pedal Assembly Installation
268
Rudder Pedal Assembly View
269
Stabilator Controls
270
Stabilator Control Cables Removal
270
Stabilator Control Cables Installation
272
Stabilator Rigging View
273
Stabilator Controls Rigging And Adjustment
274
Stabilator Travel Adjustments
275
Methods Of Securing Trim Cables
275
Forward Stabilator Trim Assembly Removal
276
Stabilator Trim Controls Diagram
277
Forward Stabilator Trim Assembly Installation
278
Aft Stabilator Trim Controls Removal
279
Aft Stabilator Trim Controls Installation
279
Stabilator Trim Rigging And Adjustment
279
Wrapping Trim Barrels
280
Stabilator Trim Screw Adjustment
280
Flaps
281
Wing Flap Controls Removal
281
Flap Controls And Rigging
282
Wing Flap Controls Installation
283
Wing Flaps Rigging And Adjustment
283
Stall Warning Horn And Lift Detector
285
Lift Detector Removal
285
Lift Detector Installation
285
Lift Detector Adjustment
286
Flap Rigging Tool View
286
Gama System/Chapter Index Guide - Pa-44-180/180T
293
Three View 1B19
295
Station References 1B20
295
Access Plates And Panels 1B22
295
Jacking 1C4
295
Leveling Airplane 1C8
295
Weighing 1C9
295
Placards And Decals
295
Placards And Decals (Sheet 2 Of 2) 1C20
295
Placards And Decals (S/N 4495001 And Up) 1C21
295
Service Points 1D1
295
Lubrication Chart - Landing Gear, Main 1D15
295
Lubrication Chart - Landing Gear, Nose 1D17
295
Lubrication Chart - Control System, Part 1
295
Lubrication Chart - Cabin Door, Baggage Door
295
And Seats 1D20
295
Lubrication Chart - Control System, Part 2 1D21
295
Lubrication Chart - Control System, Part 2 (Cont.) 1D22
295
Lubrication Chart - Power Plant And Propeller 1D23
295
Torque Wrench Formula 1E4
295
Cherrylock Rivet Removal 1E6
295
Identification Of Aircraft Fluid Lines 1E8
295
Cabin Environmental System Installation 1E24
295
Heater And Combustion Air Blower Assembly 1F1
295
Diagrammatic Cutaway Of Heater To Show Whirling Flame Action 1F2
295
Fuel Regulator And Shutoff Valve 1F3
295
Top View - Duct Switch 1F3
295
Intake Valve And Switches 1F4
295
Wiring Diagram (Heater) 1F8
295
Primary Power Circuit (Heater) 1F9
295
Starting Power Circuit (Heater) 1F10
295
Spark Plug Fixture (Heater) 1F12
295
Wiring - Test Setup (Heater) 1F12
295
Spark Plug Gap Adjustment (Heater) 1F13
295
Ignition Unit Assembly (Heater) 1F17
295
Test Setup For Fuel Regulator And Shutoff Valve (Heater) 1F20
295
Heater Fuel Pump 1F21
295
Suggested Design For Seal Plates, Plugs, And Caps For Combustion Tube Leakage Test 1G1
295
List Of Illustrations (Pa-44-180/180T)
296
List Of Charts (Pa-44-180/180T)
302
Fuel
305
Fuel System Description
307
Fuel System Troubleshooting
307
Fuel System Installation Diagram
308
Failure Of Fuel To Flow
309
Fuel Quantity Gauge Fails To Operate
309
No Fuel Pressure Indication
309
Low Pressure Or Pressure Surges
310
Removal Of Fuel Cells
311
Fuel Cells Installation
311
Fuel Cells Cleaning And Inspection
311
Fuel Cell Compartment
313
Molded Nipple Fittings
313
Fuel Cells Handling And Storage
313
Fuel Cell Repair
314
Fuel Cells Testing
316
Locking Fuel Cap Disassembly
317
Locking Fuel Cap Assembly
317
Gascolator Removal
318
Gascolator Cleaning
318
Gascolator Reassembly
318
Fuel Selector Valve Removal
319
Selector Valve Disassembly
320
Selector Valve Cleaning, Inspection And Repair
320
Selector Valve Assembly
321
Selector Valve Leak Test
321
Electric Fuel Pump Removal
322
Fuel Quantity Sender Unit
322
Fuel Quantity Sender/Gauge Check
322
Sender/Fuel Quantity Gauge Tolerances
323
Fuel Gauge View
323
Fuel Pressure Gauge Check
324
Fuel Pressure Gauge And Calibration Diagram
324
Hydraulic Power
326
Hydraulic System Description
328
Schematic Diagram Of Prestolite Hydraulic System
329
Schematic Diagram Of Oildyne Hydraulic System
330
Hydraulic System Troubleshooting
331
Leading Particulars, Hydraulic System
332
Landing Gear Retraction System Fails To Operate
333
Landing Gear Extension System Fails To Operate
334
Landing Gear Retraction Extremely Slow
335
Pump Stops During Gear Retraction
335
Pump Stops During Gear Extension
335
Pump Fails To Shut Off Though Gear Has Fully Retracted
335
Pump Fails To Shut Off Though The Gear Has Fully Extended
336
Pump Running Intermittently After Gear Has Retracted
337
Gear Stops Part Way Up, But Pump Continues To Run
337
All Gears Fail To Free Fall
337
Hydraulic Pump Motor Characteristics
338
With Gear Unsafe Light On, Pump Operates On And Off
338
With Gear Unsafe Light On, Pump Motor Circuit Breaker Opens
338
Prestolite Hydraulic Pumps Removal
339
Prestolite Hydraulic Pump Disassembly
339
Exploded View Of Prestolite Hydraulic Pump/Reservoir
340
Prestolite Hydraulic Pump Cleaning, Inspection, Repair
341
Prestolite Hydraulic Pump Assembly
341
Prestolite Hydraulic Pump Test And Adjustment
342
Prestolite Hydraulic Pump Installation
344
Oildyne Hydraulic Pump Removal
345
Oildyne Hydraulic Pump Field Service
345
Disassembly Of Oildyne Hydraulic Pump From Bracket
345
Disassembly Of Motor Assembly From Oildyne Pump-Adapter Assembly
345
Oildyne Hydraulic Pump View
346
Assembly Of Reservoir To Oildyne Pump-Adapter Assembly
348
Installation Of Motor Assembly To Oildyne Pump-Adapter Assembly
348
Installation Of Piper Bracket To Oildyne Hydraulic Pump Assembly
348
Oildyne Hydraulic Pump Installation
348
Landing Gear Free Fall Valve Assembly
349
Free-Fall Valve Assembly Removal
349
Free-Fall Valve Assembly Installation
349
Nose Gear Actuating Cylinder Removal
349
Nose Gear Actuating Cylinder Disassembly
350
Nose Gear Actuating Cylinder Cleaning, Inspection And Repair
350
Nose Gear Actuating Cylinder Assembly
351
Nose Gear Actuating Cylinder Installation
351
Main Gear Actuating Cylinder Removal
351
Main Gear Actuating Cylinder View
352
Main Gear End Gland Locking Device View
352
Main Gear Actuating Cylinder Disassembly
353
Main Gear Actuating Cylinder Cleaning, Inspection And Repair
353
Main Gear Actuating Cylinder Assembly
353
Main Gear Actuating Cylinder Installation
353
Hydraulic Lines Removal And Installation
354
Hydraulic System Testing
354
Hydraulic Lines Installation Diagram
355
Ice And Rain Protection
358
Ice And Rain Protection System Description And Operation
361
Airfoils
362
Ice And Rain Protection System Troubleshooting
362
Pneumatic Deice System Troubles
363
Deicers Do Not Inflate
363
Deicers Inflate Slowly
363
Deicers Deflate Slowly
363
Deicers Innate. Indicator Light Does Not Function
364
Deicer Boots Don't Hold Their Form In Flight To System Inadequate
364
Pneumatic Deice System Installation Diagram
365
Deicer System Inspection
366
Deicer System Operating Pressures
367
Deicer System Operation Check
367
Electrical Tests
368
Pressure Leaks Testing
368
Deicer System Component Maintenance And Replacement
368
Control Valves Replacement
369
Pneumatic Boots Removal
369
Boots Repair
370
Scuff Damage
370
Tube Area Damage
370
Loose Surface Ply In Dead Area (Non-Inflatable Area)
371
Loose Surface Ply In Tube Area
371
Damage To Fabric Back Ply Of Deicer During Removal
371
Vulcanized Repairs
371
Deice Control Panel Installation View
372
Installing Pneumatic Boots
373
Leading Edges Preparation
373
Materials And Supplies For Cold Repair
374
Deicer Boot Preparation
376
Mounting Boot On Leading Edge
376
Adhesion Test
377
Deicer Boot Maintenance
378
Icex Application
378
Resurfacing Conductive Cement
379
Pneumatic System Final Test And Adjustment
380
Pitot And Static
381
Windows And Windshields
381
Heated Windshield Panel Removal
381
Heated Windshield Panel Installation
381
Propeller Deice System Description And Operation
382
Propeller Deice System Troubleshooting
382
Ammeter Shows Zero Current All Phases Of The Timer Cycle
383
Ammeter Shows Normal Current Part Of Cycle, Zero Current Rest Of Cycle
383
Ammeter Shows Normal Current Part Of Cycle, Low Current Rest Of Cycle
384
Ammeter Shows Low Current Over Entire Cycle
384
Ammeter Shows Excess Current Over Entire Cycle
385
Ammeter Shows Normal Current Part Of Cycle/Excess Current Rest
385
Ammeter Does Not "Flick" Approximately Every 90 Seconds
386
Ammeter Flicks Between 90 Second Phase Periods
386
Radio Noise Or Interference With Deicers On
387
Cycling Sequence Not Correct
388
Rapid Brush Wear Or Frequent Breakage
388
Electric Prop Deice System Installation Diagram
389
Using The Ammeter
391
Deicer System 50 Hour Inspection
391
Deicer System 100 Hour Inspection
392
Suggested Use Of Dial Indicator
393
Centering Of Brushes On Slip Rings
393
Modular Brush Assembly Alignment
394
Modular Brush Assemblies
395
Brush Module Replacement
395
Measuring Bush Assemblies
395
Brush Module Assembly Diagrams
396
Slip Ring Assemblies Alignment
397
Slip Ring Assemblies Replacement
397
Propeller Deicer Boots
398
Resistance Check Of Deicer Boots
398
Removal Of Boots/Installation Of Boots
398
Blade Preparation
398
Installation Of Deider Bots
399
Cement Application
400
Required Materials For Repair Of Propeller Deicer
400
Deicer And Required Materials Installation
401
Sealer Preparation And Application
401
Typical Deicer Boot Sealer Application
402
Wrinkled Deicer View
402
Wrinkled Deicers
403
Deicer Electrical Check
403
Deicer Wiring Harness Installation
404
Balancing
404
Deicer Final Electric Check
404
Deicer Final Functional Check
404
Deicer Wiring Harness Installation Diagram
405
Timer Test
406
Wing Ice Detection Light Removal
406
Wing Ice Lighting System Diagram
407
Wing Ice Detection Light Installation
408
Carburetor Ice Detector Description
408
Carburetor Ice Detector Troubleshooting
408
Ice Detector Probe Removal
409
Ice Detector Probe Installation
409
Ice Detector Probe Functional Check
410
Ice Detection System Diagram
410
Lift Detectors
410
Heated Pitot And Heated Left Detector Installation
411
Functional Check Of Lift Detectors
412
Landing Gear
415
Landing Gear Description And Operation
418
Landing Gear Troubleshooting
418
Red Gear Unsafe Light Out While Gear Is In Transit
419
Red Gear Unsafe Light On Though Gear Has Retracted
419
Red Gear Unsafe Light On
419
Though Gear Is Down And Locked
419
Red Gear Unsafe Light Operates On And Off After Far Has Retracted
420
Red Gear Unsafe Light Out Though Gear Is Down And Locked
420
Red Gear Unsafe Light And An Green Lights Out
420
Red Gear Unsafe Light And Horn Fail To Operate
420
Red Gear Unsafe Light And Horn Fail To Stop
421
Above Condition On Ground
421
Above Condition In The Air
421
Hydraulic Pump Shuts Off But Red Gear Unsafe Light Remains On
421
Green Gear Down Lights Dim Though Position Light Switch Is Off
422
Green Gear Down Light Fails To Go Out With Gear In Transit
422
Nose Landing Gear Shimmies During Fast Taxi, Takeoff Or Landing
422
Excessive Or Uneven Wear On Nose Tire
422
Nose Gear Fails To Steer Properly
423
Nose Gear Fails To Straighten When Landing Gear Extends
423
Nose Gear Fails To Straighten When Landing Gear Retracts
423
Main Landing Shimmies During Fast Taxi, Takeoff Or Landing
423
Excessive Or Uneven Wear On Main Tires
424
Strut Bottoms On Normal Landing Or Taxiing On Rough Found
424
Landing Gear Doors Fail To Completely Close
424
Main Gear Oleo Disassembly
425
Main Gear Oleo Cleaning, Inspection And Repair
425
Main Gear Oleo Strut Assembly View
426
Main Gear Oleo Assembly
427
Main Gear Service Tolerances
428
Main Landing Gear Removal
431
Main Landing Gear Cleaning, Inspection And Repair
431
Main Landing Gear Installation
432
Main Landing Gear Adjustment
435
Toe-In, Toe-Out Correction
436
Main Landing Gear Alignment
436
Main Gear Door Removal
437
Main Gear Door Cleaning, Inspection And Repair
437
Main Gear Door Installation
437
Aligning Main Gear Diagram
438
Nose Gear Oleo Disassembly
439
Nose Gear Oleo Cleaning, Inspection And Repair
439
Nose Gear Oleo Strut Assembly Diagram
440
Nose Gear Oleo Strut Assembly Procedure
441
Nose Gear Installation Diagram
442
Nose Landing Gear Removal
443
Nose Landing Gear Cleaning, Inspection And Repair
443
Nose Gear Service Tolerances
444
Nose Landing Gear Installation
447
Nose Gear Downlock And Eccentric Bushing Removal
448
Nose Gear Downlock And Eccentric Bushing Installation
449
Nose Gear Adjustment
451
Nose Landing Gear Alignment
452
Clamping Rudder Pedals In Neutral Position
453
Rudder Pedals At Neutral Angle
453
Nose Gear Door Removal
454
Nose Gear Doors Cleaning, Inspection And Repair
455
Nose Gear Doors Installation
455
Nose Gear Doors Adjustment
455
Mechanical Nose Gear Door Mechanism View
455
Wheels And Brakes
456
Nose Wheel Removal And Disassembly
456
Nose Wheel Inspection
456
Nose Wheel Assembly And Installation
456
Nose Wheel Assemblies Diagram
457
Main Wheel Removal And Installation
458
Main Wheel Inspection
458
Main Wheel Assembly And Installation
458
Nose And Main Wheel Assemblies Repair
459
Main Wheel Assembly View
459
Brake Adjustment And Lining Tolerance
460
Wheel Brake Assembly Removal And Disassembly
460
Wheel Brake Assembly Diagrams
461
Wheel Brake Assembly Cleaning, Inspection And Repair
463
Wheel Brake Assembly Assembly And Installation
463
Brake Installation Diagram
464
Parking Brake Valve Removal
465
Parking Brake Valve Disassembly
465
Brake Cylinder View
466
Parking Brake Valve Cleaning, Inspection And Repair
467
Parking Brake Valve Assembly
467
Parking Brakve Valve Installation
467
Brake Cylinder Removal
468
Brake Cylinder Disassembly
468
Brake Cylinder Cleaning, Inspection And Repair
468
Brake Cylinder Repair
468
Brake Cylinder Installation
469
Brake Cylinder Bleeding
469
Toe Brake Installation Diagram
470
Main Gear Up Limit Switch Adjustment
471
Main Gear Down Limit Switch Adjustments
471
Nose Gear Up And Down Limit Switches Adjustment
471
Landing Gear Safety (Squat) Switch Adjustment
473
Landing Gear Warning (Throttle) Swithe Location
473
Landing Gear Up/Power Reduced Warning Switch Adjustment
473
Landing Gear Up/Power Reduced Warning Switch Replacement
474
The Gear Retracting System Functional Test
474
Throttle Warning Switches Views
475
Lights
480
Lighting Description And Operation
481
Lighting Troubleshooting
481
Dimmer Control Assembly Removal
481
Dimmer Control Assembly Installation
481
Landing/Taxi Light Removal
482
Landing/Taxi Light Installation
482
Tail Lights Removal
483
Tail Lights Installation
483
Recognition Lights
483
Anti-Collision Strobe Lights
484
Strobe Light Removal
484
Strobe Light Installation
484
Strobe Light System Troubleshooting
484
Strobe Power Supply Removal
485
Strobe Power Supply Installation
485
Navigation And Pitot/Static
489
Pitot Air System And Static Air System Description And Operation
491
Rate Of Climb Indicator
491
Pitot-Static System Installation View
492
Rate Of Climb Troubleshooting
493
Altimeter Troubleshooting
494
Airspeed Indicator
495
Airspeed Tubes And Indicator Troubleshooting
495
Magnetic Compass Adjustment
496
Magnetic Compass Troubleshooting
497
Directional Gyro - Air Driven/Electric
498
Directional Gyro Troubleshooting
499
Gyro Fitting Installation Procedure
499
Gyro Horizon
500
Air Driven Attitude Horizon
500
Electrically Driven Attitude Horizon
500
Attitude Horizon Operational Limitations
501
Attitude Horizon Troubleshooting
501
Turn And Bank/Pictoral Rate Instruments
501
Gyro Installation Inspection
502
Oxygen
504
Oxygen System Description And Operation
505
Fixed - Oxygen System Diagram
506
Crew/Passenger System
507
Portable - Oxygen System Diagram
507
Oxygen System Troubleshooting
508
Fixed Oxygen System Inspection, Maintnenance And Overhaul Time Limits
509
Test Apparatus For Testing Oxygen System
510
Oxygen Tubing Installation
511
Oxygen System Components Cleaning And Purging
512
Swageloc Fitting Installations
513
Application Of Teflon Tape Thread Sealant
515
Oxygen System Limits
515
Oxygen System Leak Tests
516
Oxygen System Components
516
Oxygen Cylinder Removal
516
Oxygen System Maintenance Manual
517
Recharge Valve Removal
517
Recharge Valve Installation
517
Oxygen Cylinder Installation
518
Pressure Gauge Removal And Installation
518
Outlets Removal
518
Outlets Intallation
519
Oxygen On/Off Control Removal And Installation
519
Oxygen System Refilling
519
Filling Pressure For Certain Ambient Temperatures
520
Portable - Oxygen System
521
Testing For Leaks
521
Portable Oxygen System Maintenance
522
Portable Oxygen System Component Limits
522
Vacuum
525
Vacuum System Description And Operation
526
Vacuum System Installation Diagram
527
Vacuum System Troubleshooting
528
Vacuum Regulator View
529
Vacuum System Service Tips
530
Vacuum Gauge
532
Face Mounted Instruments Removal And Installation
532
Vacuum Regulator Valve
532
Vacuum Regulator Valve Adjustments
533
Regulator Valve Removal And Replacement
533
Vacuum Pump Removal And Installation
533
Electrical/Electronic Panels And Multipurpose Parts
536
Face Mounted Instruments Removal And Replacement
537
Annunciator Panel
537
Annunciator Troubleshooting
537
Annunciator Panel Installation Diagram
539
Annunciator Panel Light Bulbs Replacement
541
Vacuum/Gyro Air Sensor Switch Removal And Installation
541
Overboost Sensor Switch Removal And Installation
541
Electric Clock
541
Electric Clock Installation Diagram
542
Instrument Panel Mounted Clock Removal
544
Instrument Panel Mounted Clock Installation
544
Control Wheel Mounted Clock Removal And Installation
544
Electrical Switches And Circuit Breakers
544
Electrical Switches Removal
545
Electrical Switches Installation
545
Circuit Breakers Removal
545
Circuit Breakers Installation
545
Structures
548
Structural Repairs
549
Baggage Compartment Inspection Hole And Cover Plate
549
Baggage Compartment Inspection Holes Farbication Procedure
549
Layout Cut Lines
549
Cutting The Holes
550
Installing Covers
550
Fiberglass Repairs
550
Skin Material And Thickness
551
Baggage Compartment Inspection Hole Cutout Details
553
Minor Scratch And Crack Repair
554
Hole Repair
554
Fiberglass Fracture And Patch Repairs
554
Adding Layers To Undamaged Areas
555
General Thermoplastic Repairs
556
List Of Materials For Thermoplastic Repair
556
Surface Praparation
556
Surface Scratches
556
Deep Scratches, Shallow Nicks, And Small Holes
557
Cracks In Thermoplastic Parts
558
Mixing Of Epoxy Patching Compound
558
Welding Repair Method
559
Repairing Of Cracks
559
Various Repairs Diagram
560
Repairing Major Damage
561
Stress Lines
561
Painting The Repair
561
Safety Walk Repair - Surface Preparation
561
Product Listing For Liquid Safety Walk Compound
562
Repair Of Impacted Damage
562
Repair Of Stress Lines
562
Application Of Liquid Safety Walk Compound
563
Surface Preparation For Pressure Sensitive Safety Walk
563
Application Of Pressure Sensitive Safety Walk
563
Doors
583
Door Removal
584
Door Installation
584
Door Adjustment
584
Door Latch Mechanism Removal And Installation
584
Door Installation Diagram
585
Door Latch Mechanism Adjustment
586
Door Lock Assembly Removal
586
Door Lock Assembly Installation
586
Door Auxiliary Latch Removal, Installation And Adjustment
586
Door Seal Snubber
587
Door Snubber Installation Diagram
587
Baggage Door Removal
588
Baggage Door Installation
588
Fabricated Tool For Baggage Door Lock
588
Baggage Door Lock Assembly Removal
589
Baggage Door Lock Assembly Installation
589
Emergency Exit Removal And Installation
589
Emergenxy Exit Door Testing
589
Emergency Exit Installation Diagram
590
Stabilizers
594
Stabilator Removal And Installation
595
Stabilator Trim Tab Removal And Installation
595
Stabilator Balance
595
Stabilator Installation Diagram
596
Balancing Equipment
597
Stabilator Balance Configuration
597
Vertical Fin Installation Diagram
598
Vertical Stabilizers
599
Vertical Fin Removal And Installation
599
Rudder Removal And Installation
599
Rudder Trim Tab Removal And Installation
599
Rudder Installation Diagram
600
Rudder Balance
601
Windows
605
Windshield Removal And Installation
606
Side Windows Removal And Installation
606
Windshield Installation Diagram
607
Emergency Exit Window Removal And Installation
608
Side Window Installation Diagram
609
Wings
612
Wings Description
613
Wing Tip Removal
613
Wing Tip Repair
613
Wing Tip Installation
613
Wing Attachment
614
Wing Removal
614
Wing Installation Diagram
615
Wing Installation
617
Aileron Removal
618
Aileron Installation
618
Aileron Balance
618
Aileron And Flap Installation Diagrams
619
Aileron Balancing
621
Balancing Equipment And Procedure
621
Wing Flap Removal
622
Wing Flap Installation
622
Propeller
625
Propeller Removal
626
Propeller Cleaning, Inspection And Repair
626
Propeller Installation
626
Propeller: Typical Nicks And Removed Method
627
Propeller Torque Limits
627
Propeller Installation Diagram (Two And Three Blade Propellers)
628
Blade Track
629
Propeller Controlling
629
Propeller Governor Removal
629
Propeller Governor Installation
629
Propeller Control Adjustment Diagram
630
Engine Synchrophaser
631
Test Equipment
631
Synchrophaser System Installation Diagrams
633
Propeller Governor Ground Test
635
Pulse Generator Assembly Diagram
635
Prop-Synch Switch Removal And Installation
636
Pulse Generators Removal
636
Pulse Generator Backup Test
637
Pulse Generators Installation And Coordinated Timing
638
Pulse Generators Post Installation Check
639
Pulse Generators Flight Check
639
Propeller Unfeathering System
640
Accumulator Service
640
Power Plant
644
Power Plant Description
645
Power Plant Troubleshooting
645
Failure Of Engine To Start
646
Failure Of Engine To Idle Properly
646
Low Power And Uneven Running
647
Failure Of Engine To Develop Full Power
648
Rough Engine
648
Low Oil Pressure
649
High Oil Temperature
649
Excessive Oil Consumption
650
Poor Acceleration
650
Low Fuel Pressure
651
Fluctuating Fuel Pressure
651
White Smoke Emitting From Exhaust
651
Engine Removal
652
Engine And Shock Mount Installation Diagrams
654
Engine Installation
657
Engine Pre-Oiling
657
Cowling Maintenance
658
Engine Cowling Removal And Installation
658
Engine Cowling Cleaning, Inspection And Repair
658
Engine Cowl Flaps Operation And Adjustment
658
Engine Cowling Installation Diagram
659
Cowl Flap Installation Diagram
659
Engine Shock Mounts Installation
660
Air Intakes/Induction System
660
Pa-44-180 Air Filter Housing Removal And Installation
660
Pa-44-180 Carburetor Air Box Inspection, Removal And Installation
660
Pa-44-180 Induction System Diagram
661
Pa-44-180 Carburetor Heat Shroud Removal And Installation
662
Pa-44-180T Sniffle Valve Maintenance
662
Pa-44-180T Air Inlet Filter Housing Inspection And Maintenance
663
Pa-44-180T Compressor Inlet Duct And Alternate Air Door Inspection
663
Pa-44-180T Induction System Diagram
664
Compressor To Carburetor Intake Assembly
665
Engine Fuel System
668
Carburetor Maintenance
669
Idle Mixture Adjustment
670
Idle Speed Adjustment
670
Engine Primer Installation
671
Manual Primer
671
Primer Removal, Disassembly, Cleaning And Assembly
671
Primer Installation
671
Engine Primer System Diagram
672
Fuel System Schematic
672
Electric Primer System Diagram
673
Engine Primer System Diagram (Pa-44-180T)
674
Electric Primer
675
Primer Jets
675
Throttle, Mixture And Carburetor Heat Controls Adjustment
675
Fuel Pressure Gauge
677
Fuel Pressure Sender Testing
678
Fuel Pressure Gauge Troubleshooting
679
Ignition
682
Ignition Description And Operation
683
Magneto Troubleshooting
683
Magneto Inspection
684
Height Of Spring In Distributor Block Tower
686
Contact Points
686
Magneto Installation Timing Procedure
687
Engine Timing Marks
688
Timing Light Connected To Magneto - Diagram
688
Timing Marks On Magneto Rotor
689
Painted Tooth Centered In Timing Window
690
Timing Mark On Rotor Aligned With Pointer
690
Magneto Timing Procedure (Internal Timing)
691
Timing Light Connected To Magneto And Breakers - Diagram
693
Cam End View Of Magneto
694
Impulse Coupling Removal
695
Impulse Coupling Inspection
695
Checking Flyweight To Stop Pin Clearance
696
Stop Pin Installation Dimension
696
Checking Flyweight Axial Wear With Drill Shank
697
Checking Flyweight Radial Wear With Gauge
697
Points Of Coupling Body Wear
698
Acceptable And Deformed Coupling Springs
698
Impulse Coupling Installation
699
Checking Impulse Coupling For Magnetization
700
Orientation Of Spring In Coupling Body
700
Lifting Inner End Of Spring
700
Ignition Harness Inspection
701
Harness Maintenance
701
Checking Harness Lead Continuity
702
Checking Harness Lead Insulation Resistance
702
Modified Pliers
702
Removing Spring From Lead Assembly
702
Assembly Tool
704
Ferrule Positioned Under Braid
705
Ferrule Seating Tool
705
Position Of 11-8627 Kit And Contact Spring At Start Of Installation
706
Position Of 11-8627 Kit And Contact Spring After Installation
706
Lubricating Sleeve
706
Lubricating Ferrule Shoulder
706
Removal Of Spark Plug
707
Coupling Torques
707
Removing Spark Plug Frozen To Bushing
708
Spark Plugs Inspection And Cleaning
709
Spark Plugs Installation
709
Magneto And Starter Switches
710
Engine Indicating
713
Engine Instrument Lines Installation Diagram
714
Cluster Mounted Instruments Removal And Replacement
716
Manifold Pressure Gauge
716
Manifold Pressure Gauge Troubleshooting
717
Tachometer Indicator
717
Tachometer Troubleshooting
718
Electric Tachometer Installation
719
Tach Indicator Removal And Installation
719
Emi Filter Removal And Installation
719
Magnetic Pickup Removal And Installation
719
Cylinder Head Temperature Gauge Troubleshooting
722
Cylinder Head Temperature Gauge Calibration
723
Exhaust Gas Temperature Gauge Cleaning And Inspection
724
Exhaust Gas Temperature Gauge Troubleshooting
725
Egt Probe Installation (Pa-44-180)
726
Egt Probe Removal (Pa-44-180T)
726
Egt Probe Installation (Pa-44-180T)
728
Exhaust
731
Leak Test Of Muffler
732
Oil
735
Oil Cooler Installation
736
Oil Pressure Senders Removal
736
Oil Pressure Sender Test
736
Oil Pressure Senders Installation
737
Engine Oil Pressure Gauge
737
Oil Pressure Sender Test Specifications
737
Oil Pressure Gauge Troubleshooting
738
Oil Pressure Gauge Calibration
738
Oil Temperature Gauge Calibration
740
Oil Temperature Gauge Troubleshooting
740
Starting
744
Starting Motor Description Of Operation
745
Starter Troubleshooting
745
Starter Fails To Operate
745
Low Motor And Cranking Speed
747
Excessive Arcing Of Motor Brushes
747
Excessive Wear And Arcing Of Motor Brushes
747
Starting System Maintenance
748
Exploded View Of Gear Reduction Starter Motor
748
Starting Motor Overhaul
749
Starting Motor Removal
749
Starting Motor Disassembly
749
Brushes Check
749
Armature Check
750
Field Coils Check
750
Brush Holders Check
750
Gear And Pinion Housing Check/Bendix Drive Check
750
Turning Motor Commutator
751
Testing Motor Armature For Shorts
751
Testing Motor Fields For Grounds
751
No Load Test Hookup
751
Starting Motor Assembly
752
Bench Tests
752
Starting Motor Control Circuit Check
752
Starting Motor Specifications
753
Stall Torque Hookup
753
Turbines
756
Turbocharger Troubleshooting
757
Manifold Pressure Low Or Fluctuating
757
Aircraft Cannot Reach Critical Altitude
757
Oil Leakage
758
Engine Overboosts
758
Turbocharger Output Low Or Operates Sluggishly
758
Turbocharger Rotating Assembly Binding Or Dragging
759
Turbocharger Seal Leakage At Turbine End
759
Turbocharger Seal Leakage At Compressor End
760
Pressure Relief Valve Fails To Open
760
Excessive Noise Or Vibration
760
Engine Will Not Deliver Rated Power
760
Turbocharger Nomenclature
761
Turbocharger Removal And Installation
763
Schematic Diagram Of Typical Turbocharger System
764
Turbocharger Prelubrication
765
Turbocharger Installation Diagram
766
Initial Run-In Procedure Precautions
767
Routine Turbocharger Maintenance/Inspection
767
Absolute Pressure Relief Valve
767
Absolute Pressure Relief Valve Removal
768
Absolute Pressure Relief Valve Installation
768
Exhaust Bypass Valve Adjustment
768
Charts And Wiring Diagrams
788
Torque Requirements
789
Flare Fitting Torques
789
Recommended Nut Torques
790
Decimal Conversions
792
Decimal/Millimeter Equivalents Of Drill Sizes
793
Tire Balancer Building Instructions
794
Tire Balancer Fixture View
794
List Of Consumable Materials
795
Metric Conversion Tables
800
Centigrade-Fahrenheit Conversion Table
801
Inches To Millimeter
802
Control Surface Balancing Tool
804
Fabricated Aileron Bellcrank Rigging Tool
805
Fabricated Aileron And Flap Rigging Tool
806
Fabricated Stabilator Rigging Tool
807
Fabricated Rudder Rigging Tool
807
Electrical Wire Coding
808
Electric Symbols (Old Style)
809
Electric Symbols (New Style)
810
Electrical System Component Load
812
Electrical Schematic Index
814
Annunciator Panel Diagrams
818
Pitot Heat Diagram
822
Windshield Heat Diagram
822
Propeller Deice Diagram
824
Surface Deice Diagram
825
Heated Lift Detector Diagram
825
Alternator And Starter Diagram
827
Alternator Diagram
828
Starters Diagram
829
Power Distribution And Control Diagram
830
Power Monitor And Control Diagram
831
Starter And Ignition Control Diagram
832
Avionics Bus Power Diagrams
833
Optional Avionics Master Switch Diagram
834
Engine Gauges Diagrams
837
Fuel And Ampere Indicators Diagram
839
Cylinder Head Temperature And Oil Pressure/Temperature Indicators
840
Electric Tachometer Installation Diagram
841
Electric Tachometer Diagram
842
Left And Right Engine Magnetos Diagram
843
Primer Solenoids Diagram
843
Fuel Pumps Diagram
843
Engine Hour Meter Diagram
845
Air Conditioning System Diagram
848
Heater System Diagram
849
Cabin Heat Diagram
850
Optional Blower Motor Diagram
851
Vent Blower Diagram
851
Panel Mounted Clock Diagram
854
Control Wheel Mounted Clock Diagram
854
Turn And Bank Diagram
854
Optional Turn Coordinator Diagram
855
Electric Turn And Bank Diagram
855
Hydraulic Pump And Landing Gear Control And Warning
858
Hydraulic Pump Diagram
859
Landing Gear Position Indicators Diagram
860
Anti-Collision Lights Diagram
863
Strobe Lights Diagram
863
Position Lights Diagrams
864
Landing Light Diagram
865
Dual Landing Lights Diagram
865
Wing (Ice) Inspection Light Diagram
867
Recognition Lights Diagram
868
Flood Lights Diagrams
871
Cockpit Flood Lights Diagram
871
Avionics And Instrument Lights Diagram
872
Panel And Switch Lighting Diagram
873
Propeller Synchrophaser System Diagram
876
Landing Gear Warning Diagram
878
Stall Warning Diagram
879
Stall Detection Diagram
880
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Table of Contents
Troubleshooting
Environmental system troubleshooting
113
Air conditioning system description and principles of operation
159
Electrical system description and operation
205
Alternator troubleshooting
206
Battery troubleshooting
211
Control surfaces troubleshooting
246
Fuel system description
307
Hydraulic System Troubleshooting
331
Airfoils
362
Propeller deice system description and operation
382
Wing ice detection light installation
408
Landing gear description and operation
418
Lighting description and operation
481
Anti-collision strobe lights
484
Rate of climb troubleshooting
493
Altimeter troubleshooting
494
Airspeed indicator
495
Magnetic compass troubleshooting
497
Directional gyro troubleshooting
499
Attitude horizon operational limitations
501
Oxygen system troubleshooting
508
Vacuum System Troubleshooting
528
Face mounted instruments removal and replacement
537
Power plant description
645
Fuel pressure gauge troubleshooting
679
Ignition description and operation
683
Manifold pressure gauge troubleshooting
717
Tachometer troubleshooting
718
Cylinder head temperature gauge troubleshooting
722
Exhaust gas temperature gauge troubleshooting
725
Oil pressure gauge troubleshooting
738
Oil temperature gauge calibration
740
Starting motor description of operation
745
Turbocharger troubleshooting
757
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