Cessna 182 1978 - Installation of Cotter Pins

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MODEL

182

T182

SERIES

SERVICE

MANUAL

PROVIDE

CLEARANCE

PRONG

MAY

CUT

HERE

PREFERRED

METHOD

ALTERNATE

METHOD

CASTELLATED

NUT

BOLT

TANGENT

MAXIMUM

MINIMUM

COTTER

LENGTH

APPLICATION

Figure

1-5.

Installation

Cotter

Pins

Revision

1-13

Main Page

List of Effective Pages4
Table of Contents7
General Description11
Stations11
Model 182, F182 and T182 Series11
Aircraft Specifications11
Reference Stations13
General14
Torque Procedures14
Torque Wrench Adapter Adjustment15
Torque Values - Bolts and Nuts16
Torque Value - Threaded Straight Fittings17
Torque Values Jam-Nuts and Threaded Connector17
Torque Values Hose Assemblies17
Safetying Procedures18
Safety Wire Procedures18
Torque Values - Straight Threaded Fittings18
Lockwire Safetying20
Cotter Pin Minimum Size22
Cotter Pin Temperature and Use22
Use of Cotter Pins22
Installation of Cotter Pins23
Use of Locking Clips24
Use of Lockwashers24
Use of Self-Locking Nuts24
Safetying Turnbuckle Assemblies25
Control Cable Wire Breakage and Corrosion Limitations26
Cable Broken Wire Inspection27
Testing Criteria28
Adhesives, Cements and Sealants Shelf Life and Storage28
Storage Criteria28
Ground Handling, Servicing, Cleaning, Lubrication and Inspection32
Ground Handling33
Towing33
Typical Tow Bar33
Jacking Procedure34
Tie-Down35
Flyable Storage35
Leveling35
Hoisting35
Returning Aircraft to Service36
Temporary Storage36
Inspection During Storage37
Indefinite Storage37
General Drscription40
Fuel40
Use of Fuel Additives for Cold Weather Operation40
Fuel Drains40
Fuel Additive Mixing Ratio Chart41
Engine Oil41
Carburetor Drain Plug Inspection41
Engine Induction Air Filter42
Vacuum System Filter42
Battery43
Tires43
Nose Gear Shock Strut43
Nose Gear Shimmy Damper43
Preventive Maintenance44
Cleaning Windshield and Windows44
Waxing44
Materials Required44
Interior Trim45
Painted Surfaces45
Aluminium Surfaces45
Engine and Engine Compartment45
Wing Flap Actuator46
Lubrication46
Wheels46
Upholstery and Interior46
Servicing47
General Inspection55
Inspection Requirements55
Inspection Program Selection55
Inspection Charts56
Inspection Guidelines57
Pre-Inspection Operational Checks58
Inspection Time Limits59
Special Inspections Legends68
Component Time Limits69
Cessna-Established Replacement Time Limits69
Supplier-Established Replacement Time Limits70
Progressive Care Program72
Progressive Inspection Program72
Introduction72
Inspection Time Limitations74
Procedures74
Progressive Care Program76
Inspection Chart76
Cessna Progressive Care77
Fuselage113
Windshield and Windows114
Wrap-Around Rear114
Overhead114
Repair of Windshield and Windows115
Surface Patch116
Windshield and Window Installation Techniques116
Cleaning and Waxing116
Fixed116
Cracks117
Cabin Doors117
Cabin Door Weatherstrip117
Door Latches117
Windshield and Fixed Window Installation118
Cabin Door119
Door Latch and Rotary Clutch120
Indexing Inside Handle121
Installation of Lock Assembly on Latch Assembly121
Installation of Care Assembly122
Rigging Cable Assembly122
Rigging Inside Door Handle122
Cabin Door Latch123
Replacing Lock Assembly126
Seats126
Pilot and Copilot126
Mechanical Lock Control Assembly126
Baggage Door Installation127
Front Seat Installation128
Seat Inltallation128
Infinitely Adjustable Front Seat Installation129
Seat Stop Installation130
Rear Seat131
Auxiliary Seat134
Seat Back Cam Replacement135
Seat Belt and Shoulder Harness Installation136
Cabin Headliners138
Seat Repair138
Soundproofing138
Cabin Upholstery138
Shoulder Harnesses139
Glider Tow-Hook139
Rear View Mirror139
Seat Rail Inspection139
Cargo Tie-Downs Installation140
Rear View Mirror Installation141
Cargo Net Installation141
Wings and Empennage143
Wing Installation144
Adjustment (Correcting Wing-Heavy Condition)146
Wing Struts146
Fin147
Horizontal Stabilizer147
Stabilizer Abrasion Boots147
Wing Strut148
Vertical Fin149
Horizontal Stabilizer150
Landing Gear and Brakes151
Troubleshooting - Landing Gear152
Main Landing Gear153
Main Gear Strut Removal/Installation153
Step Bracket153
Landing Gear Fairings153
Main Landing Gear Fairing155
Main Wheel and Tire Assembly156
Disassembly of Cleveland Main Wheel and Tire Assembly156
Main Wheel Speed Fairing Installation156
Main Wheel Speed Fairing Removal156
Inspection and Repair of Cleveland Main Wheel and Tire Assembly157
Reassembly of Cleveland Main Wheel and Tire Assembly157
Step Installation157
Inspection and Repair of Mccauley Wheel and Tire Assembly158
Reassembly of Mccauley Main Wheel and Tire Assembly158
Disassembly of Mccauley Main Wheel and Tire Assembly158
Main Wheel and Brake Assembly160
Main Wheel Alignment164
Top View of Toe-In Check164
Front View of Camber Check164
Shim Chart165
Removal of Main Wheel Axle166
Installation of Main Wheel Axle166
Wheel Balancing166
Nose Gear166
Nose Gear Installation167
Nose Gear Removal167
Troubleshooting - Nose Gear167
Nose Wheel Speed Fairing Removal169
Nose Wheel Speed Fairing Installation169
Nose Wheel Removal170
Nose Wheel Disassembly170
Nose Wheel Inspection and Repair170
Nose Wheel Reassembly/Installation170
Nose Gear Shock Strut Disassembly171
Nose Wheel Speed Fairing171
Nose Gear Shock Strut Inspection and Repair172
Nose Wheel and Tire Assembly172
Nose Gear Shock Strut Breakdown173
Nose Gear Shock Strut Assembly174
Nose Gear Shock Strut Reassembly176
Torque Links177
Removal of Torque Links177
Installation of Torque Links177
Shimmy Damper177
Nose Wheel Steering System178
Installation of Shimmy Damper178
Disassembly and Reassembly of Shimmy Damper178
Removal of Shimmy Damper178
Steering Bungee Assembly179
Removal and Installation of Nose Wheel Steering System Components180
Rigging of Nose Wheel Steering System180
Brake System180
Trouble Shooting - Brake System182
Brake Master Cylinder182
Brake Master Cylinder Removal182
Removal/Disassembly of Wheel Brake185
Brake Master Cylinder Installation185
Wheel Brake Assemblies185
Hydraulic Brake Lines185
Reassembly/Installation of Wheel Brake186
Checking Brake Lining Wear186
Installation of Brake Lining186
Bleeding Brake System186
Parking Brake System187
Brake Disc Minimum Allowable Thickness Chart187
Inspection and Repair of System Components188
Aileron Control System189
Control Column190
Pilot's Control Column190
Control Column Installation192
Copilot's Control Column194
Aileron Bellcrank194
Aileron Installation194
Inclinometer for Measuring Control Surface Travel196
Ailerons196
Cables and Pulleys196
Rigging197
Wing Flap Control System198
Operational Check198
Flap Motor and Transmission Assembly201
Flap Control Lever201
Drive Pulleys201
Flaps201
Flap Motor and Transmission Installation202
Flap Control Lever and Follow-Up Installation203
Flap Installation204
Cables and Pulley205
Rigging-Flaps205
Flap System Schematic205
Rigging-Flap Control Lever and Follow-Up207
Elevator Control System208
Elevators209
Bellcrank209
Elevator Installation211
Elevator Bellcrank Installation211
Elevator Bellcrank Travel Stop Adjustment212
Control Column Neutral Position Rigging Tool212
Arm Assembly213
Elevator Trim Tab Control System214
Trim Tab215
Trim Tab Actuator215
Elevator Trim Tab Travel Stop Adjustment218
Trim Tab Free Play Inspection219
Trim Tab Control Wheel219
Pedestal Cover219
Trim Tab Free-Play Inspection220
Elevator Trim Tab Actuator Assembly221
Electric Elevator Trim Installation222
Clutch Adjustment222
Electric Trim Installation223
Rigging - Electric Trim Assist224
Voltage Regulator Adjustment225
Rudder and Rudder Trim Control Systems226
Rudder Pedal Assembly227
Rudder227
Rudder Control System228
Rudder Pedals Installation229
Сables and Pulleys231
Rudder Installation231
Checking Rudder Travel232
Rudder Trim and Nosewheel Steering System233
Rudder Trim Control System234
T182 Rudder Trim Control System235
Engine238
Table of Contents239
Engine Cowling239
Description240
Cowl Flaps240
Rigging240
- Overspeed Limitations242
- Time between Overhaul242
- Cowl Flaps Installation243
- Static Run-Up Procedures247
- Build-Up249
- Engine Baffles250
- Flexible Fluid Hoses250
- Leak Test250
- Engine Mount251
- Engine Oil System251
- Engine Shock-Mount Pads251
- Painting251
- Full-Flow Oil Filter254
- Filter Adapter256
- Oil Filter Adapter Wrench Fabrication257
- Full Flow Oil Filter258
- Carburetor259
- Engine Fuel System259
- Idle Speed and Mixture Adjustments259
- Oil Cooler259
- Airbox260
- Induction Air Filter260
- Induction Air System260
- Installation of Inlet Ducts260
- Installation and Timing to Engine262
- Internal Timing262
- Magnetos262
- Maintenance263
- Magnito Contact Breaker Points264
- Engine Controls265
- Magneto Check265
- Spark Plugs265
- Throttle Control265
- Carburetor Heat Control266
- Mixture Control266
- Propeller Control266
Starting System266
Description267
Trouble Shooting267
Primary Maintenance268
Starter Motor268
Exhaust System268
Description268
Economy Mixture Indicator (EGT)269
Inspection269
- Seacost and Humid Areas271
- Extreme Weather Maintenance271
Cold Weather271
Hot Weather271
Engine (Turbocharged)272
Extreme Weather Maintenance272
- Cowl Flap Installation274
- Engine Data275
- Turbocharger - Airflow Schematic276
- Accessories Removal281
- Cleaning281
- Engine Mount Details283
- Airbox Removal and Installation285
- Filter Removal and Installation285
- Ignition System285
- Carburetor Heat and Air Filter Installation286
- Magneto-To-Engine-Timing287
- Throttle and Waste Gate Control289
- Throttle to Carburetor and Waste Gate Installation290
- Waste Gate Assembly291
- Exhaust System Installation293
- Turbocharger294
- Turbocharger Installation295
- Cold/Hot Weather296
- Dusty Areas296
- Ground Service Receptacle296
- Seacoast and Humid Areas296
- Fuel System297
- Fuel System Schematic299
- Fuel Cell Installaton305
- Description307
  - Fuel Cell Removal307
  - Fuel Cell Repair/Installation307
  - Fuel Cells307
- General Precautions307
  - Vented Fuel Filler Caps307
  - Fuel Filler Cap - Plastic or Metal308
  - Metal Flush-Type Filler Caps308
  - Fuel Filler Cap - Metal309
  - Cleaning LSE Fuel, Filler Caps310
  - Fuel Filler Cap - LSE310
- Cleaning311
- Inspection311
  - Leak Testing Metal or Red Plastic Filler Caps311
  - Red Plastic Flush-Type Filler311
- Fuel Quantity Transmitter312
- Fuel Vents312
- Cleaning Inspection and Repair313
- Fuel Selector Valve313
- Fuel Strainer314
- Fuel Vent Location314
- Reassembly314
  - Fuel Selector Valve and Controls315
  - Auxiliary Electric Fuel Pump319
- Description319
- Fuel Leak Classification319
- Priming System319
  - Auxiliary Fuel Pump on Turbo Equipped Airplanes320
  - Fuel Bay Purging320
  - Integral Fuel Bay Sealant320
  - Mixing Sealant321
  - Sealing During and after Structural Repair321
  - Typical Fuel Bay Sealing322
  - Accelerated Curing Time323
  - Normal Cure Time323
  - Normal Work Time323
  - Sealing Fuel Leaks323
  - Integral Fuel Bay Quick-Repair Sealant324
  - Surface Preparation324
  - Testing Integral Fuel Bay324
  - Fuel Quantity Transmitters325
  - Integral Fuel Bay Components325
- Fuel Quantity Transmitter327
  - Propeller and Governor329
  - Propeller Installation332
  - Governor335
  - Governor and Control Adjustments336
  - High-RPM Stop Adjustment336
  - Rigging Propeller Governor Control336
  - Utility Systems338
- Description339
- Heating System339
- Operation339
- Removal. Installation and Repair339
- Trouble Shooting339
- 14-2A340
- Defrosting System340
- Description340
- Operation340
- Removal, Installation and Repair340
- Trouble Shooting340
- Ventilating System340
  - Heating and Defrosting Systems341
  - Oxygen Systems346
- Description349
- Maintenance Precautions349
- Oxygen System349
- Trouble Shooting349
- Cylinder - Regulator350
- Oxygen Cylinder General Information350
- Servicing Oxygen Cyl- Inder-Regulator350
- Installation of Oxygen Cylinder-Regulator351
- Removal of Oxygen Cyl- Inder-Regulator351
- Description352
- Installation (Beginning with F18266718)352
- Installation (Thru 18266715 and F18200169)352
- Oxygen Filler Valve352
- Oxygen Lines352
- Removal (Beginning with F18266716)352
- Removal (Thru 18266715 and F18200169)352
- Description353
- Inspection/Test of Oxygen353
- Installation of Pilot And/Or Copilot Outlet Valve Assembly353
- Outlet Valve Assemblies353
- Oxygen Gage353
- Oxygen System Functional Test353
- Removal of Passenger Outlet Valve Assembly353
- Removal of Pilot And/Or Copilot Outlet Valve Assembly353
- Cleaning354
- Description354
- Functonal Test354
- Heated Windshield Panel354
- Inspection354
- Installation354
- Oxygen Masks354
- Removal354
- Description355
- Portable Oxygen Cascades355
- Propeller De-Ice System (B.F. Goodrich 2-Bladed)355
- Windshield Anti-Ice Installation356
- Slip Ring Alignment357
- Timer Test357
- Trouble Shooting357
  - B. F. Goodrich 2-Bladed Propeller De-Ice System358
  - Installation and Alignment of Brush Block Assembly362
  - Replacement of De-Ice Boots362
- Description363
- Propeller De-Ice System (Mcauley 3-Bladed)363
- Mccauley 3-Bladed Propeller De-Ice System364
- Slip Ring Alignment367
- Timer Test367
- Trouble Shooting367
  - Angular Brush Alignment368
  - Brush Face Alignment368
- Of Brush Block Assy368
  - Ice Detector Light369
  - Installation of Ice-Detector Light369
  - Removal of Ice-Detector Light369
- Replacement of De-Ice Boots369
- Control Surface Static Dischargers371
- Description371
  - Resistance Check371
  - Instruments and Instrument Systems372
  - Instrument Panel373
- Description375
  - Flight Instrument Panel375
  - Instruments375
  - Pitot and Static Systems375
  - Shock-Mounts375
  - Blowing out Lines376
  - Pitot System Inspection and Leakage376
  - Static Pressure System Inspection and Leakage Test376
  - Pitot-Static Systems377
  - Alternate Static Air System378
  - Encoding Altimeter Installation379
  - Removal and Installation of Components380
  - Troubleshooting - Pitot-Static System380
  - True Airspeed Indicator380
  - Static System Test Equipment381
  - Troubleshooting - Altimeter382
  - Troubleshooting - Pitot Tube Heater383
  - Troubleshooting - Vertical Speed Indicator383
  - Vacuum System383
  - Vacuum System Installation384
  - Troubleshooting - Vacuum System387
  - Maintenance Practices388
  - Removal of Vacuum Pump388
  - Troubleshooting - Gyros388
  - Troubleshooting - Vacuum Pump388
  - Installation of Vacuum Pump389
  - Low-Vacuum Warning Light389
  - Mounting Pad Inspection389
  - Vacuum Relief Valve Adjustment389
  - Standby Vacuum System390
  - Dampening Screw Adjustment393
  - Engine Indicators393
  - Manifold Pressure Gage393
  - Tachometer393
  - Troubleshooting - Fuel Pressure Gage394
  - Cylinder Head Temperature Gage395
  - Oil Pressure Gage395
  - Carburetor Air Temperature Gage396
  - Oil Temperature Gage396
  - Fuel Quanity Indicating System397
  - Removal and Installation of Transmitter397
  - Hourmeter398
  - Transmitter Adjustment398
  - Compass, O.A.T. Gage and Hourmeter Installation399
  - Rochester Gage Transmitter400
  - Stewart Warner Gage Transmitter Calibration400
  - Fuel Quantity Indicating System Operational Test402
  - Calibration404
  - Magnetic Compass404
  - Stall Warning Horn and Transmitter405
  - Turn Coordinator405
  - Turn-And-Slip Indicator405
  - Electric Clock406
  - Outside Air Temperature Gage406
  - Electrical Systems407
  - Electrical Power Supply System408
  - Master Switch408
  - Split Bus Bar408
  - Split Bus Power Relay408
  - Switch and Circuit Breaker Installation409
  - Troubleshooting the Battery Power System413
  - Battery and Electrical Equipment Installation414
  - Battery Hydrometer Reading420
- Removal Installation420
- Adding Electrolyte or Water to the Battery420
- Testing the Battery420
- Cleaning the Battery420
- Charging the Battery421
- Battery Box421
- Maintenance of Battery Box421
- Battery Contactor421
- Battery Contactor Closing Circuit422
Ground Service Receptacle422
- Ground Service Receptacle Installation423
- Alternator426
- Alternator Power System426
- Troubleshooting the Alternator System426
- Engine Not Running429
- Alternator Control Unit435
- Alternator Field Circuit Protection435
- Alternator Voltage Regulator435
- Alternator Installation436
- Over-Voltage Warning System439
- Voltage Regulator/Alternator Control Unit439
- Aircraft Lighting System443
- Landing and Taxi Lights446
- Adjustment of Landing and Taxi Light447
- Anti-Collision Strobe Lights447
- Flashing Beacon447
- Navigation Lights447
- Landing and Taxi Light Installation448
- Navigation and Anti-Collision Strobe Light Installation449
- Flashing Beacon Light Installation451
- Electroluminescent Panel Lighting454
- Instrument Lighting454
- Instrument Post Lighting454
- Overhead Console454
- Control Wheel Map Light455
- Dome Light455
- Map Light455
- Transistorized Light Dimming455
- Overhead Console, Dome Light and Courtesy Light Installation456
- Instrument Panel Glareshield Lighting Installation458
- Transistorized Light Dimming/Electroluminescent Inverter Installation459
- Control Wheel Map Light Installation460
- Cigar Lighter462
  - Pedestal Lighting462
  - Pitot and Stall Wrning Heaters462
- Removal Installation462
- Stall Warning System462
  - Pitot Heat and Stall Warning Installation465
  - Cigar Lighter Installation466
- Checkout Interval467
- Description467
- Emergency Locator Transmitter (Thru 18265360)467
- Operation467
- Transmitter Life to 75 Milliwatts Output467
- Antenna468
  - Emergency Locator Transmitter Installation468
  - Lithium 4 Cell469
  - Removal and Installation of Antenna469
  - Removal and Installation of Lithium Four Cell Battery-Pack469
  - G-Switch Operational Check470
- Trouble Shooting470
- Checkout Interval471
- Description471
- Emergency Locator Transmitter (Beginning with 18265361)471
- Operation471
- Anten472
- Battery Pack472
- Transmitter472
  - Removal and Installation of Battery Pack475
  - G Switch Operational Check476
- Electrical Load Analysis Chart477
- Structural Repair480
- Equipment and Tools481
- Wing Twist and Stabilizer Angle-Of-Incidence481
- Wing481
- Wing Skin481
- Bonded Leading Edges Repair482
- Wing Stringers/Ribs/Spars482
- Wing Leading Edges482
- Wing Auxiliary Spars482
- Aileron Balancing483
- Wing Flaps483
- Elevators and Rudder483
- Fin and Stabilizer483
- Cracks in Corrugated Aileron Skins484
- Crack in Corrugated Elevator Skins485
- Cracks in Corrugated Flap Skins485
- Bulkheads486
- Repair after Hard Landing486
- Firewall Damage486
- Engine Mount Support Cradle Damage486
- Rivets487
- Replacement of Hi-Shear Rivets487
- Substitution of Rivets487
- Repair of Glassfiber-Constructed Components487
- Wing and Fuselage Support Stands491
- Repair of Glass-Fiber Constructed Components491
- Checking Wing Twist492
- Control Surface Balancing493
- Control Surface Balance Requirements497
- Skin Repair499
- Stringer and Channel Repair505
- Rib Repair509
- Wing Spar Repair511
- Auxiliary Spar Repair515
- Leading Edge Repair516
- Flap Leading Edge Repair517
- Bonded Leading Edge Repair518
- Corrugated Skin Repair519
- Access Hole Installation520
- Firewall Angle Repair521
- Painting of Formed ABS Plasticic Parts523
- Interior Parts523
- Exterior Parts523
- Imron Modified Urethane524
- Enmar Modified Urethane524
- Clean up525
- Facility525
- Pre Priming526
- Priming526
- Pre Painting526
- Repair of Dents527
- Refinishing Engine Mounts527
- Touch-Up527
- Masking for Stripes527
- Wiring Diagrams528
- Circuit Function and Specific Circuit Code Letters530
- Cross Reference Listing of Serial Request Numbers531
- Battery and External Power Systems532
- Alternator System, 60 AMP535
- Starter System542
- Cylinder Head Temperature544
- Fuel Quantity Indicator545
- Carburetor Air Temp546
- Turn and Bank Indicator549
- Encoding Altimeter550
- Blind Encoder551
- Clock552
- Dome and Courtesy Lights553
- Flashing Beacon Light556
- Electro Luminiscent Panel557
- Lighting Instrument and Oxygen560
- Post Lights563
- Map Light, Control Wheel565
- Wing Tip Strobe Lights566
- Landing Lights567
- Heated Pitot Tube and Heated Stall Warning569
- Electric Trim573
- Battery Circuit576
- Alternator System577
- Circuit Breakers578
- Magneto System584
- Cylinder Head Temp and Oil Temperature592
- Fuel Quantity Indicators593
- Digital Clock596
- Dome Light and Courtesy Lights597
- Instrument: Oxygen Lights601
- Heated Pitot Tube: Heated Stall Warning612
- Electric Elevator Trim614
- Vacuum out Warning System625
- Standby Vacuum Pump626
- Fuel Pump638
- Electric Primer639
- Instrument Lights652
- Map Light Control Wheel655
- Landing Light658
- Map Light - Control Wheel661
- Heated Pitot Tube663
- Heated Stall Warning663
- Air Conditioner664
- Prof Anti-Ice System666
- Windshield Anti-Ice System667
- Prof Anti-Icing 3 Blade668

Cessna 182 1978 - Installation of Cotter Pins

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