Piper Cherokee LANCE Service Manual Download

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PIPER CHEROKEE SIX / LANCE SERVICE MANUAL

03/27/08

IV - TABLE OF CONTENTS

1E1

SECTION IV - STRUCTURES

TABLE OF CONTENTS

Paragraph

Grid No.

4-1.

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E3

4-2.

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E4

4-3.

Wing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E4

4-4.

Wing Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E4

4-5.

Wing Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E5

4-6.

Aileron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E5

4-7.

Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E6

4-7a.

Wing Rear Attach Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E9

4-8.

Empennage Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E16

4-9.

Rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E16

4-10.

Stabilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E16

4-11.

Vertical Fin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E17

4-12.

Fuselage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E18

4-13.

Landing Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E18

4-14.

Door Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E18

4-15.

Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E19

4-16.

Windows (Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E19

4-17.

Rear Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E20

4-18.

Electrical Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1E24

4-19.

Structural Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F3

4-19a.

Metal Wire Stitching Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F6

4-19b.

General Thermoplastic Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F9

4-20.

Fiberglass Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F15

4-21.

Fiberglass Touch-up and Surface Repairs . . . . . . . . . . . . . . . . . . .

1F15

4-22.

Fiberglass Fracture and Patch Repairs . . . . . . . . . . . . . . . . . . . . .

1F16

4-23.

Safety Walk Repair /Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F17

4-23a.

Pressure Sensitive Safety Walk . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F17

4-24.

Liquid Safety Walk Compound . . . . . . . . . . . . . . . . . . . . . . . . . .

1F18

4-24a.

Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F18

4-25.

Product Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F18

4-26.

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F19

4-27.

Aileron Balance Weight Modification . . . . . . . . . . . . . . . . . . . . . . . . .

1F19

4-28.

Flap Inspection and Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F19

4-29.

Stabilator Drain Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F23

4-30.

Control Surface Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F23

4-31.

Checking Control Surface Balance . . . . . . . . . . . . . . . . . . . . . . . .

1F23

4-32.

Checking Control Surface Free Play . . . . . . . . . . . . . . . . . . . . . .

1F23

4-33.

Balancing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1F23

4-34.

Balancing Stabilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1G2

4-35.

Balancing Ailerons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1G3

4-36.

Balancing Rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1G4

Summary of Contents for Cherokee LANCE

Page 1: ...PART NUMBER 753 690 March 27 2008 1A1 AIRPLANE SERVICE MANUAL CARD 1 OF 4 PA 32 260 PA 32 300 PA 32R 300 PIPER AIRCRAFT CORPORATION...

Page 2: ...987 1 PR060715 July 15 2006 1 2 3 4 PR080327 March 27 2008 1 2 3 4 PARTIAL REVISION OF SERVICE MANUAL 753 690 Revisions appear in all aerofiche cards Accordingly replace your entire existing Aerofiche...

Page 3: ...YSTEM PA 32R 300 1I22 VI LANDING GEAR AND BRAKES PA 32 260 300 2A8 VIA LANDING GEAR AND BRAKES PA 32R 300 2C5 VII POWERPLANT PA 32 260 2E14 VIIA POWERPLANT PA 32 300 32R 300 2G4 VIII FUEL SYSTEM 2I19...

Page 4: ...D3 2 13 Lubrication Chart Control System cont 1D4 2 14 Lubrication Chart Control System cont 1D5 2 15 Lubrication Chart Air Conditioning Condenser 1D6 2 16 Lubrication Chart Cabin Door Baggage Door an...

Page 5: ...nd PA 32 300 S N s 32 7940001 and up 1F4 4 3b Metal Wire Stitching Repair 1F7 4 4 Surface Scratches Abrasions or Ground in Dirt 1F9 4 4a Deep Scratches Shallow Nicks and Small Holes 1F10 4 5 Mixing of...

Page 6: ...agram of early Hydraulic System 1J1 5A la Schematic Diagram of Oildyne Hydraulic System 1J2 5A 2 Hydraulic System Installation 1J3 5A 3 Prestolite Hydraulic Pump Reservoir Exploded View 1J8 5A 4 Test...

Page 7: ...als in Neutral Position 2D3 6A 5 Rudder Pedals at Neutral Angle 2D3 6A 6 Nose Gear Doors 2D4 6A 7 Main Gear Oleo Strut Assembly 2D7 6A 8 Main Gear Installation 2D13 6A 9 Aligning Main Gear 2D19 6A 10...

Page 8: ...ing 2H9 7A 21 Forming Shielding Around Ferrule 2H10 7A 22 Ferrule Seating Tool 2H10 7A 23 Needle 2H10 7A 24 Measuring Wire From Top of Ferrule 2H11 7A 25 Installing Grommet Over Lead Assemblies 2H11 7...

Page 9: ...S N s 32 40000 to 32 40565 incl 2J24 9 2 Instrument Panel PA 32 260 S N s 32 1111 to 32 1320 2K1 9 3 Instrument Panel PA 32 300 S N s 32 40566 to 32 41018 2K2 9 4 Instrument Panel PA 32 260 S N s 32...

Page 10: ...18 Aligning Slip Ring 3B9 10 19 Installing Slip Ring 3B10 10 20 Installing Retainer 3B10 10 21 Solder Points 3B11 10 22 Installing Driver End Shield and Bearing Typical 3B12 10 23 Installing Pulley 3B...

Page 11: ...r Fresh Air System S N s 32 7400001 and up 3G1 12 4 Cabin Heater and Defroster Fresh Air System PA 32R 300 only 3G2 13 1 Air Conditioning System Installation 3G11 13 2 Service Valves 3G16 13 3 Test Ga...

Page 12: ...1G15 V III Troubleshooting Chart Surface Controls 1I13 VA I Leading Particulars Hydraulic System 1J10 VA II Characteristics Hydraulic Pump Motor 1J10 VA III Pipe Thread Specifications 1K5 VA IV Hydra...

Page 13: ...ure Indicators 2L5 IX XV Exhaust Gas Temperature Gauge Alcor 2L9 IX XVI Cylinder Head Temperature Gauge 2L10 IX XVII Fuel Flow Gauge 2L11 X I Electrical System Schematics 3A11 X II Electrical System C...

Page 14: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL INTRODUCTION 07 15 06 1A14 THIS PAGE INTENTIONALLY BLANK...

Page 15: ...MANUAL SECTION I AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS SUBJECT SECTION GRID NO AIRWORTHINESS LIMITATIONS I 1A16 Limitations 1A16 Inspections 1A16 Life Limited Parts Marking and Disposition 1A16...

Page 16: ...and Disposition 14 CFR Part 43 10 Disposition of Life Limited Aircraft Parts requires that proper procedures are followed when removing life limited parts with time and or cycles remaining on them as...

Page 17: ...1B21 2 13 Ground Handling 1B23 2 14 General 1B23 2 15 Jacking 1B23 2 16 Weighing 1B23 2 17 Leveling 1B23 2 18 Mooring 1B24 2 19 Locking Airplane 1B24 2 20 Parking 1B24 2 21 Towing 1C1 2 22 Taxiing 1C...

Page 18: ...Oleo Struts 1C8 2 52 Filling Nose Gear Oleo Strut PA 32 260 and 300 1C9 2 53 Filling Main Gear Oleo Strut PA 32 260 and 300 1C10 2 54 Filling Oleo Struts PA 32R 1C11 2 55 Inflating Oleo Struts 1C12 2...

Page 19: ...e airplane and station 0 WL of the vertical stabilizer and rudder is 20 5 inches below the cabin floor as measured at the rear wing spar with the airplane level The reference datum line is located 78...

Page 20: ...328 75 PIPER CHEROKEE SIX SERVICE MANUAL 1927 Figure 2 1 Three View of PA 32 Serial Nos 32 1 to 32 7140086 I HANDLING AND SERVICING Revised 8 14 73 1A20...

Page 21: ...1661 PIPER CHEROKEE SIX SERVICE MANUAL 1974 1978 MODELS 5 3 75 72 50 I Figure 2 la Three View of PA 32 Serial Nos 32 7200001 to 32 7840222 HANDLING AND SERVICING Revised 9 18 78 1A21...

Page 22: ...PIPER CHEROKEE SIX SERVICE MANUAL Figure 2 lb Three View of PA 32 300 Serial Nos 32 7940001 and up Revised 9 18 78 HANDLING AND SERVICING 1A22...

Page 23: ...1601 PIPER CHEROKEE SIX SERVICE MANUAL I Figure2 1c Three View of PA 32R 300 Serial Nos 32R 7680001 to 32R 7880068 Revised 9 18 78 HANDLING AND SERVICING 1A23...

Page 24: ...ntilla Left S6LN 21 Right S6LN 204 Magneto Timing 25 degrees BTC Magneto Point Clearance 0 015 0 006 in Spark Plugs shielded See Note 2 Spark Plug Gap Setting 017 to 021 in 2 Firing Order 1 4 5 2 3 6...

Page 25: ...LN 2031 Dual Mag Right S6LN 1209 with impulse coupling Magneto Timing 20 degrees BTC 20 degrees BTC Magneto Point Clearance 0 016 in 0 016 in Spark Plugs shielded See Note 2 See Note 2 Spark Plug Gap...

Page 26: ...4 32 2 0 Governor Control Hartzell Governor Model F 4 4A FUEL SYSTEM Inboard Main Fuel Tanks Two Capacity 25 U S gallons each Unusable Fuel 125 U S gallons each Outboard Tip Fuel Tanks Two Capacity ea...

Page 27: ...FUEL SYSTEM Inboard Main Fuel Tanks Two 4 2 interconnected each wing 1 Capacity 25 U S gallons each 49 U S gallons each 1 Unusable Fuel 125 U S gallons each 2 U S gallons each 1 Outboard Tip Fuel Tan...

Page 28: ...re Main 35 40 psi 38 psi 5 CONTROL SURFACE TRAVELS REFER TO TABLE V II CABLE TENSIONS REFER TO TABLE V II NOTES 1 ALSO APPLIES WHERE NOTED TO 32 300 WITH S N s 32 7940001 AND UP 2 REFER TO THE LATEST...

Page 29: ...1974MOODELS UP PIPER CHEROKEE SIX SERVICE MANUAL Figure 2 2 Station Reference Lines PA 32 260 and 300 HANDLING AND SERVICING Revised 7 28 75 lB5...

Page 30: ...PIPER CHEROKEE SIX SERVICE MANUAL 1618 Figure 2 2a Station Reference Lines PA 32R 300 HANDLING AND SERVICING Revised 7 28 75 1B6...

Page 31: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 II HANDLING AND SERVICING 1B7 Figure 2 3 Access Plates and Panels Sheet 1 of 2...

Page 32: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL II HANDLING AND SERVICING 03 27 08 1B8 Figure 2 3 Access Plates and Panels Sheet 2 of 2...

Page 33: ...al thickness within the tolerances permitted c Self locking Fasteners The use of self locking nuts fasteners and screws including fasteners with non metallic inserts is subject to the following limita...

Page 34: ...pter one quarter of a foot or 0 25 is needed to get at it You want to know what scale reading it will take on a one foot lever arm wrench to obtain the 30 foot pounds at the bolt C 1 x 30 or C 30 1 0...

Page 35: ...with the bearing surface 4 The friction drag torque if any shall be added to the desired torque specified in Table II III Sheet 1 This final torque should register on the indicator or be the setting...

Page 36: ...washers and try again Do not exceed the maximum recommended torque If self locking castellated nuts are used include friction drag torque 9 Unless otherwise specified in the subject chapter section wh...

Page 37: ...190 95 110 200 250 120 150 75 110 45 70 7 16 20 450 500 270 300 520 630 300 400 180 280 110 170 1 2 20 480 690 290 410 770 950 450 550 280 410 160 260 9 16 18 800 1 000 480 600 1 100 1 300 650 800 380...

Page 38: ...38 43 30 33 43 48 33 38 28 33 23 28 1 4 28 65 100 60 70 110 130 80 90 60 75 45 60 5 16 24 160 200 120 145 180 205 130 150 100 125 85 100 3 8 24 240 270 175 190 280 330 200 230 155 190 125 150 7 16 20...

Page 39: ...GAL U S LIQ 231 0 CU IN 0 1337 CU FT 3 785 LITERS 0 8327 IMPERIAL GAL 128 FLUID OZ IN 2 540 CM 08333 FT JOULES 0 000948 BTU 0 7376 FT LB MULTIPLY BY TO OBTAIN KILOGRAMS 2 205 LB 35 27 OZ 1000 GRAMS L...

Page 40: ...1 397 1 422 1 447 1 473 1 498 0 06 1 524 1 549 1 574 1 600 1 625 1 651 1 676 1 701 1 727 1 752 0 07 1 778 1 803 1 828 1 854 1 879 1 905 1 930 1 955 1 981 2 006 0 08 2 032 2 057 2 082 2 108 2 133 2 159...

Page 41: ...30 86 0 160 00 320 608 0 4 44 40 104 0 165 56 330 626 0 10 00 50 122 0 171 11 340 644 0 15 56 60 140 0 176 67 350 662 0 21 11 70 158 0 182 22 360 680 0 26 67 80 176 0 187 78 370 698 0 32 22 90 194 0...

Page 42: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL II HANDLING AND SERVICING 03 27 08 1B18 TABLE II V DECIMAL CONVERSIONS...

Page 43: ...16 1 2 20 1 2 19 23 5 8 22 25 1 2 3 4 24 27 1 2 1 26 1 2 30 TABLE II VII HOSE CLAMP TIGHTENING INITIAL INSTALLATION TYPES OF HOSE TYPES OF CLAMPS WORM SCREW TYPE ALL OTHER TYPES Self sealing Finger t...

Page 44: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL II HANDLING AND SERVICING 03 27 08 1B20 Figure 2 3b Hose Tube and Line Markings...

Page 45: ...rivet sleeve when removing rivets tends to enlarge hole b To remove from thin material drill away tapered portion of stem to destroy the lock Use a small center drill bit on top of the rivet stem to...

Page 46: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL II HANDLING AND SERVICING 03 27 08 1B22 Figure 2 5 Weighing the Airplane Figure 2 4 Jacking Arrangement...

Page 47: ...he three wheels b Secure the scales from rolling forward and tow the airplane up onto the scales Refer to Towing Paragraph 2 21 c Remove the ramp so as not to interfere with the scales d If the airpla...

Page 48: ...preparations for high winds include using tie down ropes on the landing gear forks and securing the rudder e Install pitot tube cover if available 2 19 LOCKING AIRPLANE The right cabin door is provide...

Page 49: ...n the pilot s seat to maintain control by use of the brakes 2 22 TAXIING Before attempting to taxi the airplane ground personnel should be checked out by a qualified pilot or other responsible person...

Page 50: ...ane the following procedure may be used a Flush away loose dirt with water b Apply cleaning solution with a rag sponge or soft bristle brush c To remove stubborn oil and grease use a cloth dampened wi...

Page 51: ...solution 2 Rinse with low pressure spray 3 Lubricate gear per Lubrication Chart if not already done above 2 29 CLEANING WINDSHIELD AND WINDOWS a Remove dirt mud etc from exterior surfaces with clean w...

Page 52: ...al service information may also be found in Section VIII Inspection intervals of the various fuel system components may be found in Section III 2 36 FILLING FUEL TANKS The fuel tanks of each wing are...

Page 53: ...e at the inboard end of each fuel tank Push up on the arms of the drain valve and turn counterclockwise to hold the drain in the open position The flush type drain valve requires the drain cup pin to...

Page 54: ...ipstick The quantity of oil required for the engines may be found in Table II I The specified grade of oil may be found in Table II VIII Recommended Lubricating Oils or on the right cowl panel or each...

Page 55: ...ions are evident Resume normal oil drain periods after sludge conditions Improve 2 47 OIL FILTER FULL FLOW a The oil filter element should be replaced after each 50 hours of engine operation this is a...

Page 56: ...tube exposure than prescribed determine whether it needs air or oil by rocking the airplane If the oleo strut oscillated with short strokes approximately one inch and the airplane settles to its norm...

Page 57: ...nd expelling air from the strut chamber By watching the fluid pass through the plastic hose it can be determined when the strut is full and no air is present in the chamber 4 When air bubbles cease to...

Page 58: ...be exposed it will allow fluid to flow from the middle chamber to the bottom chamber of the strut housing insuring that the bottom chamber is filled with fluid NOTE With the torque links disconnected...

Page 59: ...pounds f Replace the torque link bolt Tighten bolt only tight enough to allow no side play in the connection g With the airplane raised retract and extend the gear strut several times to ascertain th...

Page 60: ...and torque to 45 foot pounds e With the airplane still on jacks compress and extend the gear strut several times to ascertain that the strut actuates freely The weight of the gear fork and wheel shou...

Page 61: ...r the life of aircraft tires If a new tire is balanced upon installation it will usually remain balanced for the life of the tire without having any shimmy or flat spots a Tire Balancer An inexpensive...

Page 62: ...t point on the bottom Tape an ounce patch across the top center of the tire Rotate the tire 45 and release it again If the tire returns to the same position add a 1 ounce patch and again rotate the ti...

Page 63: ...nd fittings are free of leaks Repair and check procedures for the hydraulic pump cylinders and various components may be found in Section VA of this manual 2 65 SERVICING HYDRAULIC PUMP RESERVOIR The...

Page 64: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL II HANDLING AND SERVICING 03 27 08 1C16 THIS PAGE INTENTIONALLY BLANK...

Page 65: ...N OF GREASE When lubricating bearings and bearing surfaces with a grease gun ensure gun is filled with new clean grease specified for the particular application before applying lubricant to grease fit...

Page 66: ...S WHICH MAY BE HARMFUL TO PAINTED SURFACES The lubrication charts consist of individual illustrations for the various aircraft systems Each component to be lubricated is indicated a number the type of...

Page 67: ...E 40 0 F to 70 F SAE 30 SAE 30 SAE 40 or SAE 20W40 0 F to 90 F SAE 20W50 SAE 20W50 or SAE 15W50 Below 10 F SAE 20 SAE 30 or SAE 20W30 TABLE II IX THREAD LUBRICANTS Line Lubricant Brakes MIL PRF 5606 W...

Page 68: ...orge Washington Hwy Danbury CT 06810 PH 203 743 4447 www miller stephenson com Grease Aircraft MIL PRF 23827 Royco 27A Anderol Inc and Instrument 215 Merry Lane Gear and Actuator E Hanover NJ 07936 Sc...

Page 69: ...n Repellent Repcon UNELKO Corporation FSCM 50159 727 E 110th Street Chicago Illinois 60628 Sealant Fuel PR 1422 A 2 Sealant Products Research Co Tank Sealing Brushing Consistency 2919 Empire Avenue Bu...

Page 70: ...nes equipped with full flow cartridge type oil filters provided the specified octane fuel is used and the filter replaced each 50 hours of operation Should fuel other than the specified octane rating...

Page 71: ...LINK BEARING See Spec Instr 1 MIL PRF 23827 100 HRS 3 TORQUE LINK BUSHING See Spec Instr 1 MIL PRF 7870 100 HRS 4 TORQUE LINK CONNECTING BUSHING See Spec Instr 1 MIL PRF 23827 100 HRS 5 MAIN GEAR WHEE...

Page 72: ...EAR DOOR CONTROL ROD ENDS See Spec Instr 1 MIL PRF 7870 100 HRS 7 MAIN GEAR SIDE BRACE LINK ASSEMBLY See Spec Instr 1 and 2 MIL PRF 23827 100 HRS 8 UPPER SIDE BRACE SWIVEL FITTING See Spec Instr 1 and...

Page 73: ...PIVOT POINT See Spec Instr 1 MIL PRF 7870 100 HRS 4 TORQUE LINK ASSEMBLY See Spec Instr 2 MIL PRF 7870 100 HRS 5 NOSE WHEEL BEARINGS See Spec Instr 3 MOBIL GREASE 28 MIL PRF 81322E 100 HRS 6 NOSE GEAR...

Page 74: ...0 100 HRS 5 EXPOSED OLEO STRUT See Spec Instr 2 DRY LUBRICANT MS 122AD 100 HRS 6 NOSE WHEEL BEARINGS See Spec Instr 3 MOBIL GREASE 28 MIL PRF 81322E 100 HRS 7 NOSE GEAR DRAG LINK ASSEMBLIES See Spec I...

Page 75: ...and Caution MIL PRF 7870 or Aeroshell 7 100 HRS 7 O RING CONTROL SHAFT BUSHING PARKER O LUBE See Spec Instr 10 and Caution AS REQUIRED 8 TEE BAR PIVOT POINT See Spec Instr 1 and Caution MIL PRF 7870...

Page 76: ...SM AND TURNBUCKLE END MIL PRF 7870 100 HRS 4 FLAP RETURN AND TENSION CHAINS MIL PRF 7870 500 HRS 5 AILERON BELLCRANK PIVOT POINTS See Spec Instr 1 MIL PRF 7870 100 HRS 6 AILERON CONTROL ROD END BEARIN...

Page 77: ...CTIONS See Spec Instr 1 MIL PRF 7870 100 HRS 4 BRAKE ROD ENDS See Spec Instr 1 MIL PRF 7870 100 HRS 5 RUDDER ARM CABLE ENDS See Spec Instr 1 MIL PRF 7870 100 HRS 6 STABILATOR TRIM SCREW See Spec Instr...

Page 78: ...CING 03 27 08 1D6 COMPONENT LUBRICANT FREQUENCY 1 CONDENSER HINGE AND ACTUATORS See Spec Instr 1 MIL PRF 7870 100 HRS 2 CONDENSER DOOR ACTUATING TRANSMISSION MIL PRF 23827 500 HRS See Spec Instr 2 and...

Page 79: ...LS See Spec Instr 5 DRY LUBRICANT MS 122AD 50 HRS 3 DOOR LATCH MECHANISMS See Spec Instr 2 MIL PRF 7870 or Aeroshell 7 500 HRS 4 SEAT TRACK ROLLERS STOP PINS AND REAR SEAT LEG RETAINER CLIP AND CAM Se...

Page 80: ...pec Instr 7 50 HRS 4 PROPELLER ASSEMBLY See Spec Instr 2 and 11 AEROSHELL 6 OR MIL PRF 23827 100 HRS 5 ENGINE CONTROL AND ENVIRONMENTAL CONTROL PIVOT POINTS See Spec Instr 1 MIL PRF 7870 100 HRS 6 FRE...

Page 81: ...MIL PRF 7870 ABOVE See Spec Instr 15 20 F MIL C 21567 BELOW 20 F 100 HRS 2 BACK UP EXTENDER LINKS AND CONTROL ARM PIVOT POINTS See Spec Instr 2 MIL PRF 7870 100 HRS 3 BACK UP EXTENDER SPRING ATTACHME...

Page 82: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL II HANDLING AND SERVICING 07 15 06 1D10 THIS PAGE INTENTIONALLY BLANK...

Page 83: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 1D11 SECTION III INSPECTION HAS BEEN RELOCATED TO GRID 4C1...

Page 84: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 03 27 08 1D12 GRIDS 1D12 THRU 1D24 INTENTIONALLY BLANK...

Page 85: ...tural Repairs 1F3 4 19a Metal Wire Stitching Repair 1F6 4 19b General Thermoplastic Repairs 1F9 4 20 Fiberglass Repairs 1F15 4 21 Fiberglass Touch up and Surface Repairs 1F15 4 22 Fiberglass Fracture...

Page 86: ...aragraph Grid No PIPER CHEROKEE SIX LANCE SERVICE MANUAL IV TABLE OF CONTENTS 03 27 08 1E2 4 37 Rigging Instructions Seat Back Lock and Release 1G5 4 38 Removal and Installation of Door Seal Snubbers...

Page 87: ...ctural surfaces of the airplane For the removal installation and rigging and adjustment procedures of the controlling components of the various structural surfaces refer to Section V NOTE When torquin...

Page 88: ...working through the access disconnect the fuel line fuel quantity transmitting wire the position light wire strobe light wire and two bolts which hold tank to wing tip 4 Remove the screws from around...

Page 89: ...4 6 AILERON CAUTION CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS a Removal 1 Disconnect the aileron push rod at the inboard end of the aileron 2 Remove the eight bo...

Page 90: ...lly lowering flaps and removing the bolt and bushing from the bearing at the aft end of the control rod CAUTION TO PREVENT DAMAGE AND CONTAMINATION OF FUEL HYDRAULIC AND OTHER LINES CAP OR PLUG ALL LI...

Page 91: ...for installation a few inches away from the fuselage 3 Prepare the various lines cables and electrical leads for inserting into the wing or fuselage when the wing is slid into place Ensure that the f...

Page 92: ...le guards at pulley brackets 15 Connect flaps by placing flap handle in the full UP position place the bushing on the outside of the rod end bearings insert and tighten bolts 16 Check the rigging and...

Page 93: ...inspect the areas that were under bracket for any signs of corrosion 2 If corrosion is found repair or replace parts as necessary Coat the area with primer and allow to dry 3 If no corrosion is found...

Page 94: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL IV STRUCTURES 03 27 08 1E10 Figure 4 1 Wing Installation PA 32 260 and PA 32 300 Serial Nos 32 40000 to 32 7840222 inclusive...

Page 95: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 IV STRUCTURES 1E11 Figure 4 1 Wing Installation PA 32 260 and PA 32 300 Serial Nos 32 40000 to 32 7840222 inclusive cont...

Page 96: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL IV STRUCTURES 03 27 08 1E12 Figure 4 1a Empennage Group Installation...

Page 97: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 IV STRUCTURES 1E13 Figure 4 1a Empennage Group Installation cont...

Page 98: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL IV STRUCTURES 03 27 08 1E14 Figure 4 1b Wing Installation PA 32R 300 and PA 32 300 Serial Nos 32 7940001 and up...

Page 99: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 IV STRUCTURES 1E15 Figure 4 1b Wing Installation PA 32R 300 and PA 32 300 Serial Nos 32 7940001 and up cont...

Page 100: ...DAMAGE OR EXHIBIT CRACKS a Removal CAUTION AT EACH REMOVAL OF THE STABILATOR CONDUCT STABILATOR ATTACH BRACKETS CORROSION INSPECTION SPECIAL INSPECTIONS PROCEDURES The complete stabilator assembly can...

Page 101: ...e antenna cable before removing it from the fin 4 Separate the stabilator trim cable at turnbuckle and remove the cable from the trim mechanism 5 Remove the one bolt at the leading edge of the fin 6 R...

Page 102: ...om the light assembly and remove c Install the landing light assembly in reverse of removal instructions 4 14 DOOR LOCK ASSEMBLY a Remove door latch assembly by removing door trim upholstery and remov...

Page 103: ...outboard edges of the windshield 4 Apply white PRC PR307 sealing compound Product Research Corporation in the upper and outboard windshield 5 Slide the windshield aft and up into place Use caution not...

Page 104: ...el assembly Refer to Line A Figure 4 2 3 Insert router into jaws of drill chuck Install guide on router The router should protrude from the rounded end of the guide by no more than l9 inch Adjust rout...

Page 105: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 IV STRUCTURES 1E21 Figure 4 2 Rear Door Window Replacement...

Page 106: ...in its recess in the door Gently press outer edges of the window so that tape will contact the inner surface of the outer panel assembly 6 Insert 16 wall grip nuts with screws installed through holes...

Page 107: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 IV STRUCTURES 1E23 THIS PAGE INTENTIONALLY BLANK...

Page 108: ...ation of moveable components of the aircraft 3 No self tapping screws used for bonding purposes 4 Exposed conducting frames or parts of electrical or electronic equipment should have a low resistance...

Page 109: ...ights Mounted on Non Conductive Material 003 Avionics Black Boxes 003 NOTE Harnesses should be installed and connected for this check internal chassis wiring through the connector to ground is permiss...

Page 110: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL IV STRUCTURES 03 27 08 1F2 THIS PAGE INTENTIONALLY BLANK...

Page 111: ...y Circular 43 13 1 To assist in making repairs Figure 4 3 for PA 32 260 and 300 or Figure 4 3a for PA 32R 300 identifies the type and thickness of skin structure used Never make a skin replacement or...

Page 112: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL IV STRUCTURES 03 27 08 1F4 Figure 4 3a Skin Material and Thickness PA 32R 300 and 32 300 S N 32 7940001 and up...

Page 113: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 IV STRUCTURES 1F5 Figure 4 3a Skin Material and Thickness PA 32R 300 and 32 300 S N 32 7940001 and up cont...

Page 114: ...d of Joining 1 Substitute two rivets in lieu of each staple where stitching was previously used or is specified Maintain a minimum of 75 inch spacing between rivets 2 When materials being joined inclu...

Page 115: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 IV STRUCTURES 1F7 Figure 4 3b Metal Wire Stitching Repair...

Page 116: ...right Polish Co Inc Irvin Cal 92713 Cleaners Fantastic Spray Obtain Locally Perchlorethylene VM P Naphtha Lighter Fluid ABS Solvent Cements Solarite 11 Series Solar Compounds Corp Linden N J 07036 Sol...

Page 117: ...nd thermoplastic b Surface Scratches Abrasion or Ground in Dirt Refer to Figure 4 4 1 Shallow scratches and abraded surfaces are usually repaired by following directions on containers of conventional...

Page 118: ...CHEROKEE SIX SERVICE MANUAL Figure 4 4a Deep Scratches Shallow Nicks and Small Holes 825 THOROUGHLY MIX USING FIGURE EIGHT MOTION Figure 4 5 Mixing of Epoxy Patching Compound Added 12 4 79 STRUCTURE...

Page 119: ...e thermoplastic part first determine what caused the crack and alleviate that condition to prevent it recurring after the repair is made 2 Drill small stop holes at each end of the crack 3 If possible...

Page 120: ...870 PIPER CHEROKEE SIX SERVICE MANUAL Figure 4 6 Welding Repair Method 827 DOUBLER PLATE BONDED TO NDERSIDE OF DAMAGED AREA STOP HOLES Figure 4 7 Repairing of Cracks Added 12 4 79 STRUCTURE 1F12...

Page 121: ...PIPER CHEROKEE SIX SERVICE MANUAL 831 COMPOUND Figure 4 8 Various Repairs STRUCTURE Added 12 4 79 1F13...

Page 122: ...enamels depending on which is preferred by the repair facility or customer See NOTE NOTE It is extremely important that solvent formulations be considered when selecting a paint because not all lacque...

Page 123: ...nished with repair kit 4 21 FIBERGLASS TOUCH UP AND SURFACE REPAIRS a Remove wax oil and dirt from around the damaged area with acetone Methylethylketone or equivalent and remove paint to gel coat b T...

Page 124: ...the patch immediately place another small amount of gel coat on one edge of the patch and cover with cellophane Then using a squeegee or the back of a razor blade squeegee level with area surrounding...

Page 125: ...squeegee or broad knife work out all air bubbles in the patch Work from center to edge pressing patch firmly against the structure Allow patch to cure for 15 to 20 minutes m As soon as the patch begi...

Page 126: ...the remaining protective liner as the safety walk is being applied from front to back of wing area 4 Roll firmly with a long handled cylindrical brush in both lengthwise directions Make sure all edge...

Page 127: ...rib Refer to Figure 4 11 The hole pattern in the new balance weight bracket is the same as the old bracket with the exception of two holes When replacing the old bracket with the new one it is permis...

Page 128: ...PIPER CHEROKEE SIX SERVICE MANUAL Figure 4 11 Wing Rib Modification Figure 4 12 Balance Weight Assembly Installation STRUCTURE Issued 8 17 72 1F20...

Page 129: ...CHB PIPER CHEROKEE SIX SERVICE MANUAL 0 _ TO MODIFY EXISTING ANCHOR NUT SEE SKETCHC SKETCH B SKETCH A 1 CUTOUTDETAIL RIGHT AND LEFT SIDE BOLT AN23 18 SKETCH C EXISTING DIMENSION Figure 4 113 Flap Modi...

Page 130: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL IV STRUCTURES 03 27 08 1F22 Figure 4 14 Additional Drain Holes in Stabilator...

Page 131: ...NTROL SURFACES FREE PLAY The following checks are recommended before balancing to ascertain the amount of free play in the stabilator stabilator trim tab and aileron a Stabilator Check the stabilator...

Page 132: ...ing edge support vertically until the beam is parallel with the control surface chord line d Remove the tool from the control surface and balance the tool itself by adding or removing nuts or washers...

Page 133: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 IV STRUCTURES 1G1 Figure 4 15 Control Surface Balance Tool...

Page 134: ...raft free area that allows unrestricted movement Place tool shown in Figure 4 15 on stabilator with beam perpendicular to hinge centerline Do not place tool on trim tab Calibrate tool as described in...

Page 135: ...ovable weight and determine the static balance If the static balance of the ailerons is not within the limits shown in Table IV II proceed as follows a Nose Heavy This condition is highly improbable r...

Page 136: ...bed in Balancing Equipment above Read scale when bubble level has been centered by adjustment of moveable weight and determine static balance limit This value shall be within the limits given in Table...

Page 137: ...he clamps b Place a straightedge along the lower surface of bushing 5 of the seat back release c Adjust the push pull cable 6 by raising or lowering it until the lower surface of the stop assembly 7 i...

Page 138: ...doorjamb is masked off with tape as shown in Figure 4 19 View D 3 Apply adhesive to the doorjamb with a small brush on the area indicated in Figure 4 19 View D 4 Apply adhesive to the inside surface o...

Page 139: ...OR JAMB PIPER CHEROKEE SIX SERVICE MANUAL G K B NOTES 1 ORIENTSNUBBER FLATWITH THIS SURFACE 2 BUTTJOINT OCCURSAT DOOR DRAIN AREA 3 DO NOT STRETCHSNUBBERAROUND CORNERS SNUBBER OUTBD FWD SNUBBER SCUFFPL...

Page 140: ...NUAL 8970 NOTE TRIM SNUBBER TO CLEAR ALL DOOR LATCHPINS AS REQUIRED STRIKER PLATE UNDER SNUBBER CUT VIEW H H VIEW I I VIEW J TRIM SNUBBER TO CLEAR BAGGAGE DOOR LATCH HANDLE VIEW K VIEW L L Figure 4 19...

Page 141: ...d PA 32 300 S N s 32 15 32 21 32 40000 thru 32 7340081 if one or more of the following conditions is encountered it they may be corrected by installing Piper Kit No 760 729V a The cabin door top latch...

Page 142: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1G1O...

Page 143: ...1H6 5 14 Installation of Stabilator Control Cables 1H7 5 15 Rigging and Adjustment of Stabilator Controls 1H9 5 16 Stabilator Trim Controls 1H10 5 17 Removal of Stabilator Trim Assembly Forward 1H10 5...

Page 144: ...ANCE SERVICE MANUAL V TABLE OF CONTENTS 03 27 08 1G12 SECTION V SURFACE CONTROLS TABLE OF CONTENTS cont Paragraph Grid No 5 35a Torque Tube Push Rod Distortion Inspection 1I6 5 36 Rigging and Adjustme...

Page 145: ...be positioned in three locations of 10 25 and 40 degrees 5 2 STANDARD PRACTICES AND PROCEDURES This section explains the removal installation and rigging and adjustment procedures for the control ass...

Page 146: ...ATIONS IF AN AUTOPILOT USING BRIDLE CABLES HAS BEEN INSTALLED CONSULT THE APPROPRIATE AUTOPILOT VENDOR PUBLICATION FOR CORRECT CABLE TENSIONS WITH AUTOPILOT BRIDLE CABLES ATTACHED a See Table V II for...

Page 147: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 V SURFACE CONTROLS 1G15 TABLE V II FLIGHT CONTROL SURFACES RIGGING LIMITS PIR PPS50005 1 Rev K...

Page 148: ...ts the chains at the top of the tee bar 5 4 Disconnect the control chains from the control cables where the chains and cables join by removing the cotter pins nuts bolts and bushings 5 If the control...

Page 149: ...then set cable tension with the turnbuckles located under the floor panel aft of the main spar as instructed in paragraph 5 11 Before safetying the turnbuckle check that when the ailerons are neutral...

Page 150: ...T BUSHING NUT COTTER PIN I CONTROL CABLE STABILATOR 12 CONTROL CABLE AILERON 13 PULLEY 14 BOLT WASHERS 4 NUT 15 BOLT WASHERS 2 NUT 16 BOLT WASHER NUT COTTER PIN 17 SPROCKET RIGHT CONTROL WHEEL 18 SPRO...

Page 151: ...or cable turnbuckles in the aft section of the fuselage 3 Relieve tension from the aileron control cables 22 and chains 14 and 16 at the turnbuckle 6 that connects the chains at the top of the tee bar...

Page 152: ...OLWHEEL 10 PLATE CONTROLWHEEL 11 WASHER CONTROLWHEEL 12 SPACER STOP 13 SPROCKET LEFT CONTROLWHEEL 14 CHAIN LEFT ROLLER 15 IDLER SPROCKET AFT 16 CHAIN RIGHT ROLLER 17 PIN 18 IDLER SPROCKET FORWARD 19 B...

Page 153: ...ct Method of Installing Rod End Bearings FWD 0 098 DIA SEE SAFE HOLE TO ENSURE PROPER SHAFT INSERTION TAPER PIN 480 730 WASHER 407 564 AN960 10 OR 494 093 AN975 3 NUT 484 835 MS20364 1032C SHAFT P N 6...

Page 154: ...to have both control wheels neutral to set the chain turnbuckle to neutralize the wheels and then set cable tension with the turnbuckles located under the floor panel aft of the main spar as instructe...

Page 155: ...ng the rudder trim knob and the cover attachment screws 2 Remove the lower selector cover and disconnect the fuel selector control lever from the selector torque tube by removing the attachment pin lo...

Page 156: ...12 TURNBUCKLE RIGHT PRIMARY 13 CABLE RIGHT WING PRIMARY 14 CABLE RIGHT FUSELAGE PRIMARY 15 CABLE LEFT FUSELAGE PRIMARY 16 TURNBUCKLE LEFT PRIMARY 17 CABLE LEFT WING PRIMARY 18 CABLE RIGHT BALANCE 19 C...

Page 157: ...he cable from the wing 5 8 INSTALLATION OF AILERON CONTROL CABLES Refer to Figure 5 2 a The installation of either the right or left primary control cable 14 or 15 that is located in the fuselage may...

Page 158: ...attachments and seats 5 9 REMOVAL OF AILERON BELLCRANK ASSEMBLY Refer to Figure 5 2 a Remove the floor panel located directly aft of the main spar by removing the center seats seat belt attachments an...

Page 159: ...D LEFT NOTE Flap rigging and adjustment must be completed before starting aileron rigging and adjustment a To check and adjust the rigging of the aileron controls first set the right and left aileron...

Page 160: ...the tool even with the trailing edge of the aileron This tool may be fabricated from dimensions given in Figure 5 19 3 With the aileron control rod connected between the bellcrank and aileron check th...

Page 161: ...rrect travel from neutral per dimensions given in Table V II by the following procedure 1 Center the bubble of a protractor over the surface of an aileron at neutral position and note the reading 2 Mo...

Page 162: ...ar housing by removing the block attachment screws Also remove the cotter pin cable guard at the pulley cluster 6 in the aft area of the opening 5 Remove the fuel selector panel cover by removing the...

Page 163: ...nd secure with screws 9 Set cable tension and check rigging and adjustment per paragraph 5 15 10 Install the tunnel plate directly aft of the tee bar assembly and secure with screws 11 Put the floor c...

Page 164: ...AFT 6 PULLEY FORWARD CLUSTER 7 PULLEY AFT 8 BOLT WASHER NUT COTTERPIN 9 BOLT WASHER NUT 10 BLOCK CABLE RUB 11 GUARD CABLE 12 BOLT WASHER 7 NUT 13 BOLT WASHER 11 NUT 14 PULLEY FORWARD 15 BOLT WASHER NU...

Page 165: ...tor travel by placing a rigging tool on the upper surface of the stabilator as shown in Figure 5 6 This tool may be fabricated from dimensions given in Figure 5 20 4 Set on a bubble protractor the num...

Page 166: ...qual Readjust turnbuckles if incorrect 9 Reinstall access panels 5 16 STABILATOR TRIM CONTROLS 5 17 REMOVAL OF STABILATOR TRIM ASSEMBLY FORWARD Refer to Figure 5 8 a To remove the trim control wheel a...

Page 167: ...Remove the cable rub blocks 39 located in the floor opening on the aft side of the main spar by removing the block attachment screws 9 Remove the trim plate located on top of the forward end of the a...

Page 168: ...ER NUT 16 RIB HORIZONTAL SUPPORT 17 PLATE RIB 18 GUARD 19 BUSHING BARREL 20 BARREL TRIM II PIPER CHEROKEE SIX SERVICE MANUAL 1643 8 21 CLIP DIAGONAL RIB 22 RIB DIAGONAL SUPPORT 23 SCREW TRIM 24 BOLT W...

Page 169: ...tall the cover over the control wheel and secure with screws unless the control cables have yet to be installed b The trim control cables 8 and 9 may be installed by the following procedure 1 Draw the...

Page 170: ...the diagonal rib 22 from the horizontal rib 16 that supports the trim assembly by removing the four attachment nuts washers and bolts i Draw the trim cable 12 from the fuselage 5 20 INSTALLATION OF S...

Page 171: ...m wheel l until the aft end of the turnbuckle 10 of the right trim cable 8 is approximately two inches forward of the double pulleys 13 at the top of the rear bulkhead at station 259 0 e Check that th...

Page 172: ...wer end of the tee bar aft h Disconnect the control cable 19 ends from the arms on the torque tube 3 by removing the cotter pins washers nuts and bolts 20 i Disconnect the rudder trim from the torque...

Page 173: ...r rods 11 and clevis rods 15 to the idler arms 10 and secure with clevis and cotter pins 13 i Connect the steering rods 21 to the rudder pedals 32 and 33 and secure with bolts and nuts 24 Check steeri...

Page 174: ...CLEVIS PIN COTTER PIN 17 CLEVIS END 18 TOE BRAKE PEDAL 19 CONTROL CABLE RUDDER 20 BOLT WASHER NUT COTTER PIN 21 BUNGEE NOSE WHEEL STEERING 22 JAM NUT 23 ROD END BUNGEE 24 BOLT NUT 25 BOLT WASHER NUT 2...

Page 175: ...cable guard pin 9 at the pulley 8 cluster in the aft area of the opening by removing a cotter pin from one end of the guard 5 Remove the fuel selector panel cover by removing the rudder trim knob and...

Page 176: ...ning it with a cotter pin 6 Install the cable guard plate 10 under the pulley cluster 12 located in the aft area of the aft floor tunnel and secure with screws 7 Set cable tension and check rigging an...

Page 177: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 V SURFACE CONTROLS 1H21 Figure 5 10 Rudder Controls...

Page 178: ...dder 2 With the rudder against its stop place a rigging tool against the side of the rudder and vertical stabilizer as shown in Figure 5 11 Ascertain that the tool is not contacting any rivets If no g...

Page 179: ...anding behind the airplane and sighting the rudder with the vertical stabilizer or the center of the trim screw 5 Check safety of turnbuckles c Check that when the rudder contacts its stops the cleara...

Page 180: ...nut on the side of the floor tunnel To remove the forward screw lift the floor carpet on the right side of the tunnel adjacent to the channel and remove the access plate on the side of the tunnel Sec...

Page 181: ...oles in the bushing and channel align and then install the clevis pin and cotter pin 5 Should two thru holes be located in the aft end of the mounting channel the pin must be installed through the hol...

Page 182: ...EVIDENT FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL ACCORDINGLY UPON COMPLETION OF RUDDER TRIM RIGGING AND ADJUSTMENT VERIFY THAT THE RUDDER MOVES...

Page 183: ...at the spar or return chain 32 as desired 7 Disconnect the control cable from the chain 20 by removing cotter pin nut and clevis bolt 21 8 Remove the tube support blocks 16 and 33 by removing the blo...

Page 184: ...SHER NUT 16 BLOCK BEARING 17 SPROCKET TENSION SPRING 18 BOLT WASHER NUT 19 BRACKET BEARING BLOCK 20 CHAIN TENSION SPRING 21 CLEVIS BOLT BUSHING NUT COTTER PIN 22 SPRING TENSION 23 CABLE FLAP CONTROL 2...

Page 185: ...on each end of the torque tube and slide the stop fitting 13 in place Align the bolt hole of the crank and stop fitting with the holes in the torque tube and install bolts The holes in the stop fittin...

Page 186: ...AND CORRECT MOVEMENT OF FLAPS WHILE IT WOULD SEEM SELF EVIDENT FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL ACCORDINGLY UPON COMPLETION OF FLAP RIGG...

Page 187: ...ide of the wing and flap as close as possible to the outboard end of the flap without contacting any rivets The tool must be positioned parallel with the wing ribs with the aft end of the tool even wi...

Page 188: ...scertain that there are sufficient threads remaining and a wire cannot be inserted through these holes Do not raise the flap of the other wing above neutral k Check the flap for full down travel to th...

Page 189: ...R 1 0 PIPER CHEROKEE SIX SERVICE MANUAL MATERIAL 125X 3 531 X 1 0 ALUM PLATE I 3 531 062R 125 625 t 250 250 2 781 Figure 5 18 Fabricated Aileron Bellcrank Rigging Tool Issued 8 17 72 SURFACE CONTROLS...

Page 190: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL V SURFACE CONTROLS 07 15 06 1I10 Figure 5 19 Fabricated Aileron and Flap Rigging Tool...

Page 191: ...82 ALUM BAR PIPER CHEROKEE SIX SERVICE MANUAL 932 SURFACEPARALLELTO BASELINE STABILATOR CONTOUR 25 SET BACK BASELINE BASE LINE 0 LEADING EDGE Figure 5 20 Fabricated Stabilator Rigging Tool Revised 6 1...

Page 192: ...281 20 PIPER CHEROKEE SIX SERVICE MANUAL STEELOR HARD ALUMINUM 125 X 200 X 6 187 PLATE Figure 5 21 Fabricated Rudder RiggingTool Issued 8 17 72 SURFACE CONTROLS 1112...

Page 193: ...sistance to control System not lubricated Lubricate system wheel rotation properly Cable tension too high Adjust cable tension Refer to paragraph 5 11 Control column hori Adjust chain tension zontal c...

Page 194: ...cordance with paragraph 5 5 or 5 5B Rig in accordance with paragraph 5 11 Adjust in accordance with paragraph 5 11 Aileron bellcrank stops not adjusted properly Adjust in accordance with paragraph 5 1...

Page 195: ...rol movement System not lubricated properly Lubricate system Cable tension too high Binding control column Pulleys binding or rubbing Cables not in place on pulleys Cables crossed or routed incorrectl...

Page 196: ...h paragraph 5 21 Install cables accord ing to paragraphs 5 18 and 5 20 Broken pulley Linkage loose or worn Replace pulley Check linkage and tighten or replace Trim control wheel moves with excessive r...

Page 197: ...ted properly Adjust in accordance with paragraph 5 21 RUDDER CONTROL SYSTEM Lost motion between rudder pedals and rudder Cable tension too low Linkage loose or worn Adjust cable tension per paragraph...

Page 198: ...rrectly Install cables cor rectly Check cable guards Check routing of control cables Rudder pedals not neutral when rudder is streamlined Incorrect rudder travel Rudder cables incorrectly rigged Rudde...

Page 199: ...CONTROL SYSTEM Flaps fail to extend or retract Flaps not synchro nized or fail to move evenly when retracted Control cable broken or disconnected Incorrect rigging of system Replace or reconnect contr...

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Page 201: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1121...

Page 202: ...18 5A 14 Check and Adjustment of Gear Back Up Extender Actuator 1J20 5A 14a Operational Check of Retractable Landing Gear System 1J22 5A 15 Nose Gear Actuating Cylinder 1J23 5A 16 Removal of Nose Gear...

Page 203: ...witch is placed in either the up or down position the pump directs fluid through the particular pressure line to each individual actuating cylinder As fluid pressure increases at one side of a cylinde...

Page 204: ...nce on the nose gear The lever must be held in the downward position for emergency extension This same lever when held in the raised position can be used to override the system and gear position is co...

Page 205: ...500 psi SHUTTLE VALVE DELIVERED PRESSURE 400 to 800 psi PRESSURE SWITCH OFF at 1800 100 psi ON at 200 to 400 psi or OFF at 1400 100 psi ON at 200 to 400 psi APPLIES TO PUMPNO 105476A ONLY APPLIES TO P...

Page 206: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL VA HYDRAULIC SYSTEM 07 15 06 1J2 Figure 5A 1a Schematic Diagram of Oildyne Hydraulic System...

Page 207: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VA HYDRAULIC SYSTEM 1J3 Figure 5A 2 Hydraulic System Installation...

Page 208: ...ENT PRESTOLITE PUMP 5A 5 REMOVAL OF HYDRAULIC PUMP The hydraulic pump with reservoir incorporated is located in the nose section of the fuselage Access to the pump is through the access panel in the n...

Page 209: ...components with a dry type cleaning solvent and dry thoroughly c Inspect pump components for scratches scores chips cracks and wear d Inspect motor for worn brushes minimum of 218 brush remains betwee...

Page 210: ...reedom of rotation and end play thrust of the armature within the assembly A minimum of 005 inch end play is permissible Adjust to this tolerance if necessary by adding or removing thrust washers 11 o...

Page 211: ...may be bled by alternately connecting blue lead and green lead to the positive terminal of the power supply until all air is exhausted 6 Connect blue lead to positive terminal of power supply Pump sh...

Page 212: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL VA HYDRAULIC SYSTEM 07 15 06 1J8 Figure 5A 3 Prestolite Hydraulic Pump Reservoir Exploded View...

Page 213: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VA HYDRAULIC SYSTEM 1J9 Figure 5A 4 Test and Adjustments of Prestolite Hydraulic Pump...

Page 214: ...38998 004 Hydraulic Pump High Pressure 2000 to 2500 psi 2000 to 2500 psi 2400 200 psi Low Pressure 650 150 psi 650 150 psi 600 200 psi Flow Rate 1000 psi 45 cu in per min 45 cu in per min 60 cu in per...

Page 215: ...green lead from the power supply and permit the pressure to drop before disconnecting the hydraulic lines 5A 10 INSTALLATION OF PRESTOLITE HYDRAULIC PUMP Refer to Figure 5A 3 a Insert grommet 22 in p...

Page 216: ...of the forward baggage compartment To remove pump 1 Disconnect the pump electrical leads from the pump solenoid relays and the ground wire from the battery shelf 2 Disconnect the hydraulic lines from...

Page 217: ...acket b Assembly 1 If bracket was removed from pump mount install bracket to pump mount with four MS24693 S298 screws 2 Position pump assembly on bracket so that tapped holes in Oildyne adapter align...

Page 218: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL VA HYDRAULIC SYSTEM 07 15 06 1J14 Oildyne Hydraulic Pump Reservoir Figure 5A 5 Sheet 1 of 2...

Page 219: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VA HYDRAULIC SYSTEM 1J15 Oildyne Hydraulic Pump Reservoir Figure 5A 5 Sheet 2 of 2...

Page 220: ...bonded to the new reservoir base using Scotch Grip 2210 or Contact Adhesive B 10161 rubber cement b Assembly 1 Locate the cushion pad and bond it to the bottom surface of the reservoir using Scotch Gr...

Page 221: ...ender System can do so by installing Piper Kit No 765 199 5A 12 REMOVAL OF GEAR BACK UP EXTENDER ACTUATOR ASSEMBLY Refer to Figure 5A 7 The back up extender actuator is located under the center seat f...

Page 222: ...screw through the ring of the diaphragm housing ensure that the attaching holes in the housing and mounting bracket align without using force Should they misalign it may be necessary to reform the ma...

Page 223: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VA HYDRAULIC SYSTEM 1J19 Figure 5A 7 Gear Back Up Extender Actuator...

Page 224: ...spar box linkage Refer to Figures 5A 7 detail B and 5A 2 Note 1 i Install floorboard and center seats 5A 14 CHECK AND ADJUSTMENT OF GEAR BACK UP EXTENDER ACTUATOR Refer to Figure 5A 7 a If diaphragm...

Page 225: ...adjustment screw 2 by turning counterclockwise until spring 24 tension is free WARNING WHILE MAKING ADJUSTMENTS DO NOT LAY TOOLS IN AREA EXPOSED BY THE REMOVAL OF FLOORBOARD THIS MAY INTERFERE WITH A...

Page 226: ...ny time during extension d Turn master switch OFF 6 Check gear operation in the normal manner with the use of the gear selector switch The emergency extension lever must be held in the up override pos...

Page 227: ...tch on and off observe ammeter for indication 2 The red gear warning light will indicate an unsafe condition It will indicate when the gear is in an intermediate position neither fully up nor down In...

Page 228: ...AND REPAIR OF NOSE GEAR ACTUATING CYLINDER a Clean the cylinder parts with a suitable dry type solvent and dry thoroughly b Inspect the cylinder assembly for the following 1 Interior walls of the cyl...

Page 229: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VA HYDRAULIC SYSTEM 1K1 Figure 5A 8 Nose Gear Actuating Cylinder...

Page 230: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL VA HYDRAULIC SYSTEM 07 15 06 1K2 Figure 5A 9 End Gland Locking Device Main Gear Figure 5A 10 Main Gear Actuating Cylinder...

Page 231: ...ing nut and bolt f Remove the cylinder from the wheel well 5A 23 DISASSEMBLY OF MAIN GEAR ACTUATING CYLINDER Refer to Figure 5A 10 NOTE The following instructions apply to actuators P N 96860 000 i e...

Page 232: ...piston assembly d Lubricate the areas around the O rings with hydraulic fluid park o lube or vaseline slide the end gland on the piston rod and the piston into the cylinder housing 7 e Insert the hoo...

Page 233: ...number of turns specified for hand tight engagement one turn both fitting and boss should be gauged per MIL P 7105 The fitting is to be wrench tightened not to exceed the number of turns shown in colu...

Page 234: ...t panel should light up until the gear is fully retracted The hydraulic pump should stop operating after full gear retraction c Place gear selector switch in DOWN position The gear should extend and l...

Page 235: ...f Safety Switch Section VIA Squat switch inoperative Replace switch Pressure switch Replace switch inoperative Pump retraction solenoid Replace solenoid inoperative inboard solenoid NOTE If the retrac...

Page 236: ...reaker circuit breaker open and determine cause for open circuit breaker Landing gear actuator Check wiring circuit wires broken Landing gear selector Check wiring circuit wires broken Pump extension...

Page 237: ...cause for overload Pressure switch out of Remove and readjust or adjustment replace switch Mechanical restriction Place airplane on jacks or obstruction in hydraulic and run retraction system to allo...

Page 238: ...xternal leakage Check for broken or damaged hydraulic lines or hoses Pump relief valve out Replace pump of adjustment Pump fails to shut off Pump extension solenoid Replace solenoid though the gear ha...

Page 239: ...eck for broken or damaged hydraulic lines Gear stops part way up Pump high pressure Replace pump but pump continues to run relief valve out of adjustment Internal leakage of Check back up extension sy...

Page 240: ...nect hoses at after selecting up at an of gear back up extender back up extender and airspeed above actuator speed actuator clean out hoses and head Also upon trying to override it is found that only...

Page 241: ...ch See Section auto extension off light switch actuator VA Paragraph 5A 2 for fails to operate out of adjustment switch location by moving mounting bracket at attachment slot Adjust switch until actua...

Page 242: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL VA HYDRAULIC SYSTEM 07 15 06 1K14 Figure 5A 11 Gear Back Up Extender Actuator Aligning Tool...

Page 243: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VA HYDRAULIC SYSTEM 1K15 THIS PAGE INTENTIONALLY BLANK...

Page 244: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL VA HYDRAULIC SYSTEM 07 15 06 1K16 GRIDS 1K16 THRU 1L24 INTENTIONALLY BLANK...

Page 245: ...PART NUMBER 753 690 March 27 2008 2A1 AIRPLANE SERVICE MANUAL CARD 2 OF 4 PA 32 260 PA 32 300 PA 32R 300 PIPER AIRCRAFT CORPORATION...

Page 246: ...987 1 PR060715 July 15 2006 1 2 3 4 PR080327 March 27 2008 1 2 3 4 PARTIAL REVISION OF SERVICE MANUAL 753 690 Revisions appear in all aerofiche cards Accordingly replace your entire existing Aerofiche...

Page 247: ...YSTEM PA 32R 300 1I22 VI LANDING GEAR AND BRAKES PA 32 260 300 2A8 VIA LANDING GEAR AND BRAKES PA 32R 300 2C5 VII POWERPLANT PA 32 260 2E14 VIIA POWERPLANT PA 32 300 32R 300 2G4 VIII FUEL SYSTEM 2I19...

Page 248: ...ylinder 17000 Toe Brake 2B18 6 16 Bleeding Brake Gravity 2B20 6 17 Bleeding Brake Pressure 2B20 6A l Nose Gear Oleo Strut Assembly 2C12 6A 2 Nose Gear Installation 2C14 6A 2a Nose Gear Service Toleran...

Page 249: ...1 Aligning Timing Marks 2H2 7A 12 Checking Flyweight Clearance of Impulse Coupling 2H3 7A 13 Engine Timing Marks 2H4 7A 14 Magneto Timing Marks 2H5 7A 15 Removing Spring From Lead Assembly 2H7 7A 16 A...

Page 250: ...er 2I5 7A 53 Removing Spark Plub Frozen to Bushing 2I8 8 1 Fuel System PA 32 260 2I21 8 2 Fuel System PA 32 300 2I22 8 3 Fuel System PA 32 300 S N s 32 7940001 and up PA 32R 300 ALL 2I23 8 3a Fuel Qua...

Page 251: ...r Fuel Quantity Gauge Tolerance PA 32R 300 and 32 300 above S N 32 7940001 2J7 VIII III Troubleshooting Chart Fuel System 2J12 IX I Vacuum System 2J20 IX II Directional Gyro Indicator 2K14 IX III Gyro...

Page 252: ...of Nose Landing Gear 2A14 6 10a Excessive Nose Wheel Shimmy 2A15 6 11 Installation of Nose Landing Gear 2A15 6 12 Alignment of Nose Landing Gear 2A17 6 13 Main Landing Gear 2A19 6 14 Disassembly of Ma...

Page 253: ...nder 6 36 Cleaning Inspection and Repair of Brake Master Cylinder 6 37 Assembly of Brake Master Cylinder 6 38 Installation of Brake Master Cylinder Brake Cylinder Toe Brake 6 40 Removal of Brake Cylin...

Page 254: ...the parking brake pull back on the handle A brake fluid reservoir is installed on the left forward face of the engine firewall 6 3 TROUBLESHOOTING Troubles peculiar to the landing gear are listed in T...

Page 255: ...slot in the bottom of the cylinder tube Then remove piston tube and fork assembly by sliding out from the bottom of the cylinder tube i To remove the bearing assembly from the piston tube release the...

Page 256: ...6 CAP VALVE 7 PLUG FILLER 8 TUBE METERING 9 CYLINDER 10 RING RETAINER 11 SNAP RING 12 BEARING 13 O RING PACKING 14 O RING OR OQUD RING 15 WASHER BACK UP 16 WIPER STRIP 17 TUBE PISTON 18 O RING 19 PLU...

Page 257: ...still allowing the links to rotate freely h Ascertain that the upper and lower bearings 3 and 5 are installed in the strut housing Bearings are a press fit with the grooves in the inner and outer race...

Page 258: ...ee assemblies 25 at the nose gear hom assembly by removing the cotter pins nuts washers and bolts f Disconnect the oil lines vacuum lines fuel lines hoses and wires which are secured to the mount with...

Page 259: ...igure 6 2 1 Should any looseness be present at the shimmy dampener 5 steering horn 10 or steering horn attachment pin 12 install Piper Kit No 760 863V 2 If Piper Kit No 760 863V is not immediately ava...

Page 260: ...D 3 RIGHT STEERING CONTROL ROD 4 BOOT 5 SHIMMY DAMPENER 6 BUSHING STOP 7 AIR VALVE 8 AIR VALVE CAP 9 BOLT NUT 10 HORN ASSY 11 BOLT 12 PIN WASHER COTTER PIN OR BOLT WASHER NUT 13 BOLT WASHER NUT 14 BOL...

Page 261: ...on the floor below the tail skid to a point approximately three feet forward of the nose wheel Allow the line to pass under the wheel at the center of the tire Snap the chalk line f Clamp the rudder p...

Page 262: ...to its extreme right or left travel there should be 06 to 12 of an inch clearance between the nose wheel steering stops This is due to the stops on the rudder making contact ahead of the nose gear st...

Page 263: ...Disconnect the torque link assembly by removing any one of the three cotter pins nuts washers and bolts Note arrangement of the components for reinstallation Carefully slide the piston tube from the...

Page 264: ...gear oleo components for the following 1 Bearing surfaces of housing for excess wear corrosion scratches and overall damage 2 Retaining ring for cracks burrs etc 3 Cylinder tube for corrosion scratch...

Page 265: ...head assembly into the top of the housing and secure with cap bolts Safety bolts with MS20995 C32 wire b Assemble the components of the piston tube 18 on the tube by placing in order the retainer rin...

Page 266: ...9 STRUT HOUSING SHIM WASHER 163311 03 005 PERLINK HINGE MAY BE USED IF REQUIRED 10 WASHER IF BOTH LINK HINGES REQUIRE SHIMS MAKE SURE TO INSTALL THE SHIMS 11 NUT 12 WASHER ON THE SAME SIDE OF EACH HIN...

Page 267: ...UT HOUSING 21 SPACER NOTE LINKS SHOULD BE LOOSE ENOUGH TO ALLOW FREEACTION 10 WASHER 22 NUT WHEEL RETAINER OF THE GEAR BUT ALSO RESIST SIDE PLAY TO ELIMINATE 11 NUT 23 PIN CLEVIS SIDE PLAY ONE SHIM WA...

Page 268: ...l hose to the air valve and drain the fluid by slowly compressing the piston tube If it is desirable to extract more fluid from the chamber remove the filler plug insert the siphon hose and drain flui...

Page 269: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VI LANDING GEAR AND BRAKE SYSTEM PA 32 260 300 2B1 Figure 6 7 Main Gear Installation...

Page 270: ...e wheel assembly by use of an object of near equal diameter NOTE Be certain not to damage the axle tube end in any way This will make removal and installation extremely difficult 3 Remove the spacer t...

Page 271: ...r the cotter pin and flat head pin that safeties the wheel nut and the wheel nut Slide the wheel from the axle d The wheel halves I and 2 may be separated by first deflating the tire With the tire suf...

Page 272: ...G 9 WHEEL THROUGH BOLT 10 WASHER 11 NUT 12 GREASE SEAL RETAINER 1 WHEEL ASSEMBLY 5 2 WHEEL HALF INNER 3 BEARING CUP 4 WHEEL HALF OUTER 5 BEARING CUP 6 BEARING CONE 7 RETAINER 8 RETAINER 9 RETAINING RI...

Page 273: ...ble II I Section II b Lubricate the bearing cones II and install the cones grease seals 14 and seal retainer rings 12 or 15 Secure retainer with snap ring 13 c Slide the wheel on the axle and secure w...

Page 274: ...OF NOSE AND MAIN WHEEL ASSEMBLIES Repairs are limited to blending out small nicks scratches gouges and areas of slight corrosion plus the replacement of parts which are cracked or badly corroded NOTE...

Page 275: ...WHEEL BRAKE ASSEMBLY 6 29 BRAKE ADJUSTMENT AND LINING TOLERANCE No adjustment of the brake lining clearance is necessary as they are self adjusting Inspection of the lining is necessary and it may be...

Page 276: ...LINDER BODY ANCHOR BOLT HOLDING FIXTURE STEP A ANCHOR BOLT CYLINDER BODY HOLDING FIXTURE STEP B STEP C PRESS CYLINDER BODY HOLDING FIXTURE STEP D Figure 6 9a Removal and Installation of Anchor Bolts A...

Page 277: ...heck the brake disc for wear grooves scratches or pits Minimum service thickness of Disc 164 22A used on Wheel Assembly 40 90A is 345 A heavy duty brake and wheel assembly is optional on PA 32R 300 Th...

Page 278: ...may be removed by prying loose with a screwdriver or a thin flat wedge Install the snap on type by positioning onto the pins and applying pressure to snap into positon NOTE To condition the organic b...

Page 279: ...e cylinder housing f Bleed the brake system as described in paragraph 6 45 6 33 BRAKE MASTER CYLINDER Hand Parking Brake 6 34 REMOVAL OF BRAKE MASTER CYLINDER Hand Brake Refer to Figure 6 11 a To remo...

Page 280: ...D RUDDER PEDAL 4 RIGHT BRAKE CYLINDER 5 LEFT BRAKE CYLINDER 6 BRAKE HANDLE 7 HANDLE RELEASE BUTTON 8 MASTER CYLINDER ASSEMBLY 9 TORQUE TUBE 10 RUDDER PEDAL PADS 11 BOLT ASSEMBLY 12 CLEVIS PIN 13 LINE...

Page 281: ...y may be disassembled by first removing the small snap ring 2 securing the retainer bushing 3 spring 4 piston 6 seal 7 gland 9 and if desired the large return spring 13 d Remove the 0 rings from the p...

Page 282: ...tainer bushing 3 Secure these pieces with small ring 2 on the end of the rod c Insert the piston rod assembly in the cylinder 1 and secure packing gland with snap ring 11 d Install the cylinder per pa...

Page 283: ...RM TRIM CONTROL ATTACHMENT 4 CLEVIS PIN WASHER COTTER PIN 5 CLEVIS ASSEMBLY 6 CLEVIS PIN 7 ARM IDLER 8 JAM NUT PIPER CHEROKEE SIX SERVICE MANUAL 1609 Figure 6 13 Toe Brake Installation LANDING GEAR AN...

Page 284: ...the snap ring 10 from the annular slot in the cylinder housing 1 Draw the piston rod assembly from the cylinder The piston rod assembly may be disassembled by first removing the roll pin 12 and then t...

Page 285: ...eral condition of the fitting threads of the cylinder d Check the piston and valve for scratches burrs corrosion etc e Repairs to the cylinder are limited to polishing out small scratches burrs etc an...

Page 286: ...1 WASHER WIPER 15 ROLL PIN 4 SPRING 8 GLAND 12 ROD Figure 6 15a Brake Cylinder 10 30 Toe Brake 1 2 3 4 56 7 8 9 10 11 12 13 14 1 HOUSING 5 O RING 9 0 RING 13 WASHER 2 RETAINING RING 6 PISTON 10 O RING...

Page 287: ...n 15 washer 14 spring 11 washer 9 packing gland 7 seal 5 piston assembly 3 spring 2 and roll pin 12 3 Insert the piston rod assembly in the cylinder 1 and secure with the snap ring 10 4 Install the cy...

Page 288: ...PIPER CHEROKEE SIX SERVICE MANUAL Figure 6 16 Bleeding Brake Gravity Figure 6 17 Bleeding Brake Pressure LANDING GEAR AND BRAKE SYSTEM Issued 8 17 72 2B20...

Page 289: ...ke pedals in the cockpit to insure pedals are pulled full aft f Pull the hand brake handle pumping the master cylinder very slowly approximately 25 times until fluid is observed passing through the cl...

Page 290: ...e hand lever e Repeat this procedure if necessary on the other gear f Drain excess fluid from the reservoir to fluid level line with a syringe 6 48 BRAKE SYSTEM LEAK CHECK a Pull for a good firm hand...

Page 291: ...for this will allow air to enter the system Repeat the pumping and bleeding approximately 10 or more times or until all the air is released from the system During all bleeding fluid level of the rese...

Page 292: ...r adjust bearings wheel bearings Worn torque link bolts Replace bolts and or and or bushings bushings Excessive or uneven Incorrect operating Inflate tire to correct wear on nose tire pressure pressur...

Page 293: ...ake off or landing Loose torque links Adjust side play Worn or loose wheel Replace and or adjust bearings wheel bearings Worn torque link bolts Replace bolts and or and or bushings bushings Excessive...

Page 294: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL VI LANDING GEAR AND BRAKE SYSTEM 07 15 06 PA 32 260 300 2C2 THIS PAGE INTENTIONALLY BLANK...

Page 295: ...THIS PAGE INTENTIONALLY LEFT BLANK 2C3...

Page 296: ...THIS PAGE INTENTIONALLY LEFT BLANK 2C4...

Page 297: ...ar Door Assembly 6A 16 Installation of Nose Gear Door Assembly 6A 17 Adjustment of Nose Gear Doors 6A 18 Main Landing Gear System 6A 19 Disassembly of Main Gear Oleo 6A 20 Cleaning Inspection and Repa...

Page 298: ...Gear Up Power Reduced Warning Switch 2D23 6A 39 Removal of Landing Gear Up Power Reduced Warning Switch 2D23 6A 40 Installation of Landing Gear Up Power Reduced Warning Switch 2D23 6A 41 Adjustment o...

Page 299: ...k hook disengages the down limit switch actuates to the NC circuit and in series with the NC circuit of the up limit switch allows the gear unsafe light to come on The gear unsafe light will remain on...

Page 300: ...dless of airspeed power combinations An override latch mechanism is installed which allows the pilot to latch the extension lever in the up override position thus bypassing the automatic portion of th...

Page 301: ...uid from the strut as possible d To remove the complete cylinder and fork assembly from the oleo housing 21 cut safety wire 2 at the top of the unit and remove cap bolts 1 that attach steering arm 11...

Page 302: ...and dents and replacement of parts 6A 8 ASSEMBLY OF NOSE GEAR OLEO Refer to Figure 6A l a Ascertain that parts are cleaned and inspected b To install the piston tube plug 40 first lubricate the tube...

Page 303: ...e link yet be free enough to rotate j Ascertain that the upper and lower oleo housing bushings 20 and 22 are installed if reusing original housing If new housing is being installed bushings are not to...

Page 304: ...TUBE 17 SNAP RING 18 ROLL PIN 19 WASHER STOP 20 BUSHING UPPER 21 HOUSING STRUT 22 BUSHING LOWER 23 OLEO CYLINDER 24 LINK UPPER TORQUE 25 BOLT WASHER BUSHINGS NUT AND COTTER PIN 26 LINK LOWER TORQUE 2...

Page 305: ...21 22 23 27 28 29 30 31 Figure 6A 1 Nose Gear Oleo Strut Assembly cont Issued 7 28 75 LANDING GEAR AND BRAKE SYSTEM 2C13...

Page 306: ...D END BEARING 32 DRAG LINK LOWER 33 BOLT WASHER NUT AND COTTER PIN 34 BOLT WASHER NUT AND COTTER PIN 35 DRAG LINK UPPER 36 BOLT AND NUT ASSEMBLY 37 BOLT WASHER AND NUT 38 JAM NUT 39 SPRING DOWNLOCK 40...

Page 307: ...19 20 16 PIPER CHEROKEE SIX SERVICE MANUAL Nose Gear Service Tolerances LANDING GEAR AND BRAKE SYSTEM Added 12 15 80 2C15...

Page 308: ...r 502 503 002 Draglink Bushing 501 501 Bushing 376 376 002 375 377 Bushing 645 640 002 640 647 Upper Drag 2505 2515 002 Brace Bearing 2495 2495 Upper Drag 189 193 004 Brace Bushing 191 189 Drag Link 3...

Page 309: ...ushing 385 395 010 390 385 14976 16 Bushing 260 270 010 265 260 452 445 Steering Cam 502 512 010 Bearing 502 82732 99 Nose Gear 241 241 010 Arm Bushing 246 251 65003 30 Down Lock 193 196 003 Bushing 1...

Page 310: ...Assy 6285 Main Attach Fitting 6295 Drag Link Upper 4385 4375 Tolerances Service Dimension 312 314 4370 4385 302 3035 312 314 3745 3760 4415 4425 3775 3795 6285 6295 4385 4405 6230 6250 Service Tol 00...

Page 311: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VIA LANDING GEAR AND BRAKE SYSTEM PA 32R 300 2C19 Figure 6A 2B Main Gear Service Tolerances...

Page 312: ...4925 4935 8 14843 16 Side Brace Link 376 374 Notes 1 4 Bushing 375 9 AN26 25 Link Stud OD 373 373 004 400 761 Attaching Bolt 0 002 0 004 10 67025 02 Upper Side Brace Link 4945 4925 4935 11 14843 16 Si...

Page 313: ...Trunnion Bearing 313 315 Notes 1 2 4 314 21 67037 06 Strut Assembly 4385 4395 0025 4370 4370 22 67026 07 Strut Bearing 313 313 002 Notes 1 4 314 315 23 67012 00 Torque Link 312 312 002 001 0 002 0 24...

Page 314: ...used 1 Disconnect the rod end of the hydraulic cylinder 42 from the downlock hook 40 by removing nut and bolt that connects these two units This will require manually unlocking the nose gear to allow...

Page 315: ...links and ascertaining that when the stop surfaces of the two links touch linkage is not less than 125 nor more than 250 of an inch through center Should the distance exceed the required through cent...

Page 316: ...the right side of the gear oleo housing 25 secure and safety A washer is installed on the bolt between the lower drag link and the arm d Connect the gear downlock spring 39 between the downlock 40 an...

Page 317: ...o the UPposition Retainthe emergencyextension leverin the UPOverrideposition d Check the adjustment of the gear up stop by placing a carpenters square with the longest end along the bottom of the fuse...

Page 318: ...ally and longitudinally Refer to Leveling Section II f From the center point of the tail skid extend a plumb bob and mark the contact point on the floor g Extend a chalk line from the mark on the floo...

Page 319: ...inimum of 3 8 inch thread engagement Reinstall the rods and tighten the jam nuts n To check the nose gear steering for its 22 5 2 maximum right and left travel mark on each side of the nose wheel an a...

Page 320: ...cleaning solvent b Inspect doors for damage loose or damaged hinges and brackets c Inspect door retraction link assemblies and arms for damage and wear d Check the door tension springs for wear and te...

Page 321: ...ressure has diminished remove the filler plug and with a thin hose siphon as much hydraulic fluid from the strut as possible d Disconnect brake line at the joint located in the wheel well e To remove...

Page 322: ...INTENTIONALLY LEFT BLANK 2D6...

Page 323: ...T 12 ORIFICE TUBE 13 PLATE ORIFICE 14 SNAP RING 15 LINK ASSEMBLY UPPER 16 LINK ASSEMBLY LOWE R 17 RETAINER PIN BEARING 18 BEARING UPPER 19 O RING OUTER 20 BEARING LOWER 21 O RING INNER 22 WIPER STRIP...

Page 324: ...PIPER CHEROKEE SIX SERVICE MANUAL 27 Figure GA 7 Main Gear Oleo Strut Assembly cont Issued 7 28 75 LANDING GEAR AND BRAKE SYSTEM 2D8 2D8...

Page 325: ...e tube 12 insert orifice plate 13 into the bottom of the tube and secure with snap ring 14 e To install tube 12 in oleo housing 11 insert the tube up through the housing With the end of the tube expos...

Page 326: ...er and bolt 47 and bushing and spring swivel 20 3 Disconnect lower side brace link 33 from gear housing 13 by removing attachment nut washer and bolt 7 Note bushings on each side of end bearing 4 Disc...

Page 327: ...s 48 pounds pull at 7 9 inches Measurement is taken from the inner side of each hook d Check the general condition of each limit switch and its actuator and wiring for fraying poor connections or cond...

Page 328: ...INTENTIONALLY LEFT BLANK 2D12...

Page 329: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VIA LANDING GEAR AND BRAKE SYSTEM PA 32R 300 2D13 Figure 6A 8 Main Gear Installation...

Page 330: ...INGS ARE INSTALLED IN UPPER 38 ROD GEAR DOOR SIDE BRACE LINK 67025 02 THEY MUST BE LINE 39 BOLT WASHERS NUT AND COTTER PIN REAMED TO 376 375 THE BUSHING MUST BE 40 FORK GEAR PRESS FIT IF LOOSE ON INST...

Page 331: ...each up through the access opening and insert the tube into the support fitting 1 through the hole in the web 4 Position the gear housing up in the wheel well and install the forward support fitting 1...

Page 332: ...casting with the flat side of the bearing and tighten the jam nut f Adjust the turnbuckle of the downlock mechanism by first ascertaining that the gear is down and locked and then move the retraction...

Page 333: ...to obtain a six and one half inch dimension between the centerline of the strut piston and the centerline of the center pivot bolt of the gear torque links Devise a support to hold the straightedge in...

Page 334: ...nstalled or it had to be reversed during the alignment check it will be necessary to check the gear safety switch squat switch bracket for engagement and locking in place If the large machine surface...

Page 335: ...RIVET SKETCHA BRACKET SKETCH B PIPER CHEROKEE SIX SERVICE MANUAL Figure 6A 9 Aligning Main Gear Revised 9 18 78 LANDING GEAR AND BRAKE SYSTEM 2D19...

Page 336: ...ment of hinge repair of fiberglass and painting 6A 29 INSTALLATION OF MAIN GEAR DOOR ASSEMBLY a Install the door by positioning the hinge halves of the door and wing and inserting the hinge pin It is...

Page 337: ...ill go out when the gear has retracted and the pump has shut off 6A 32 ADJUSTMENT OF NOSE GEAR DOWN LIMIT SWITCH The gear down limit switch is mounted on the horizontal support tube of the engine moun...

Page 338: ...ook assembly and place a 030 of an inch feeler gauge between the horizontal surface of the hook that is next to the switch the surface that contacts the downlock pin and the rounded surface of the pin...

Page 339: ...g switch Switch A is within the control quadrant below the throttle control lever Refer to Figure 6A 12 This switch will actuate the warning horn and red light simultaneously when the landing gear is...

Page 340: ...d In some manner mark the throttle lever in relation to its position next to the mounting bracket e With the airplane on the ground and the throttle positioned to the mark loosen the screws that secu...

Page 341: ...to the switch Leads attach to terminals C and NC b Position the switch against its mounting bracket and secure c Ascertain that switch actuates by moving throttle control lever aft and then forward d...

Page 342: ...AP RING 17 WASHER 14 18 BOLT 19 RUBBER BUSHING Figure 6A 13 Nose Wheel Assembly 6A 47 INSPECTION OF NOSE WHEEL ASSEMBLY a Visually check all parts for cracks distortion defects and excess wear b Check...

Page 343: ...o 140 150 inch pounds NOTE On McCauley Nose Wheel Assemblies only bushing 19 is required to prevent tube movement b Lubricate the bearing cones 6 and 12 and install the cones grease seals 4 or 13 felt...

Page 344: ...ause for open circuit breaker Red gear unsafe light on though gear has re tracted One or more up limit switches failed Isolate and replace switch Nose gear up limit switch out of ad justment Main gear...

Page 345: ...safe light operates on and off after gear has re tracted Light circuit wire loose Check wiring Hydraulic system losing pressure Gear up switch out of adjustment Refer to Hydraulic System Section VA Ch...

Page 346: ...ng gear selector circuit breaker open Reset circuit breaker and determine cause for open circuit breaker Check wiring Reset circuit breaker and determine cause for open circuit breaker Micro switch A...

Page 347: ...tion on ground Above condition in the air Red gear unsafe light and horn fail to shut off at full throttle Gear selector at up position and gear extended Hydraulic pump shuts off but red gear unsafe l...

Page 348: ...not dim when position light switch is turned on though gear is down and locked Green gear down lights blink momentarily before the down lock is engaged on roller Failed instrument panel light control...

Page 349: ...link bolts and or bushings Check balance and re place tire if nec essary Replace and or adjust wheel bearings Replace bolts and or bushings Excessive or uneven wear on nose tire Incorrect operating pr...

Page 350: ...d or bolt worn Shimmy dampener galling or binding Readjust and tighten Replace bearing and or bolt Replace Nose gear fails to straighten when landing gear extends Steering arm roller sheared at top of...

Page 351: ...erating pressure Inflate tire to correct pressure Wheel out of alignment toe in or out Lower side brace link out of adjustment allowing gear to slant in or out Check wheel alignment Check gear adjustm...

Page 352: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2E12...

Page 353: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2E13...

Page 354: ...2E21 7 13 Rigging and Adjustment of Propeller Governor 2E22 7 14 Engine 2E24 7 15 Removal of Engine 2E24 7 16 Installation of Engine 2F1 7 17 Installation of Oil Cooler 2F1 7 18 Adjustment of Throttl...

Page 355: ...INTENTIONALLY LEFT BLANK 2E15...

Page 356: ...shooting the engine ground the magneto primary circuit before performing any checks on the engine 7 3 PROPELLER 7 4 REMOVAL OF PROPELLER Fixed Pitch a Insure master and magneto switches are off b Move...

Page 357: ...d forth through the slight freedom allowed by the pitch change mechanism If they appear tight and are properly lubricated the pitch change mechanism should be removed so that each blade can be checked...

Page 358: ...PIPER CHEROKEE SIX SERVICE MANUAL Figure7 1 Propeller System Installation Constant Speed Figure 7 2 Typical Nicks and Removal Method POWER PLANT Issued 8 17 72 2E18...

Page 359: ...PIPER CHEROKEE SIX SERVICE MANUAL I5 1 SCREW SPINNER ATTACHMENT Figure 7 2a Propeller Installation II PROPELLER BLADE 12 SPINNER BACK PLATE 13 STARTER RING POWER PLANT 2E19...

Page 360: ...making sure the extended bushing goes into the proper mounting hole i Install the six hexagon head propeller hub mounting bolts and torque perTable VII I j Check propeller blade track as given in Par...

Page 361: ...governor control arm c Remove the governor mounting stud nuts It will be necessary to raise the governor as the nuts are being removed before the nuts can be completely removed d Remove the mounting...

Page 362: ...rclockwise direction to increase engine speed NOTE One revolution of the fine adjustment screw will increase or decrease the engine speed approximately 20 RPM 3 Reinstall upper engine cowl and repeat...

Page 363: ...EAR STRUT 7 FITTING OIL DRAIN 8 ENGINE 9 OIL COOLER 10 TUBE ENGINEVENT 11 MOUNT ENGINE 12 COOLING SHROUD FUEL PUMP PIPER CHEROKEE SIX SERVICE MANUAL NOTE A maximum of 3 AN960 616 washers can be used t...

Page 364: ...t primer line at the tee connection g Disconnect the mechanical fuel pump inlet line connected to the right side of the pump h Disconnect the starter lead i Disconnect alternator leads j Disconnect th...

Page 365: ...the latest revision of Lycoming Service Instructions No 1241A for information on pre oiling the engine to prevent a possible high speed bearing failure 7 17 INSTALLATION OF OIL COOLER a When installi...

Page 366: ...ightened to align with the control cable casing after tightening the swivel fitting c Check security of cable casing attachments d Pull throttle and mixture knobs in cockpit full aft to ascertain that...

Page 367: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 VII POWER PLANT PA 32 260 2F3 Figure 7 4a Adjustment of Engine Controls Figure 7 4b Throttle Mixture Control Ball Joint Inspection...

Page 368: ...FILTER a The filter should be cleaned daily when operating in dusty conditions If any holes or tears are noticed the filter must be replacedimmediately b Remove the filter element and shakeoff loose...

Page 369: ...ove and discard lock tab c Examine the screw to determine if there is a hole through the head of the screw If not drill a 1 16 inch diameter hole through the head of the screw d Reinstall the screw to...

Page 370: ...direction until the engine begins to run roughly once more At this point the fuel mixture will be too rich and engine speed will decrease again e Now advance the screw to a midway position between th...

Page 371: ...INTENTIONALLY LEFT BLANK 2F7...

Page 372: ...inspection or when a magneto has been removed from the engine the following checks may be per formed Each step in the check list is keyed by number to a part shown in Fig ure 7 6 1 Inspect distributor...

Page 373: ...and flyweight the fit is too loose and coupling should be replaced Refer to Figure 7 7 10 Check impulse coupling for excess wear on the contact edges of body and flyweights 11 Check that the impulse c...

Page 374: ...removed from the engine to de termine E gap b To determine E gap find neutral position of the magneto drive by rotating drive coupling in a left hand direction until the red or white chamfered tooth o...

Page 375: ...agneto is type which has cast in timing marks 200 series see Fig ure 7 10 main breaker may be adjusted with magneto on engine as follows turn engine crankshaft until notch in cam is alignedwith mark a...

Page 376: ...being worked on by checking the engine dataplate a Remove the top spark plug from No one cylinder Place the thumb of one hand over the spark plug hole and rotate the crankshaft in direction of normal...

Page 377: ...direction opposite to that of nor mal rotation d Turn on the switch of the timing light Turn the crankshaft very slowly in direction of normal rotation until the timing mark on the front face of the...

Page 378: ...iming as previouslydescribedto make sure that both mag netos are set to fire together If timing is correct both timing lights will go on simultaneously when the 25 degree mark aligns with the centerli...

Page 379: ...insulator b Remove the spark plug from the engine In the course of engine operation carbon and other combustion products will be deposited on the end of the spark plug and will penetrate the lower thr...

Page 380: ...seized plug e Do not allow foreign objects to enter the spark plug hole 7 30 INSPECTION AND CLEANING OF SPARK PLUG a Visually inspect each spark plug for the following non repairable defects 1 Severe...

Page 381: ...ket is properly seated on the spark plug hexagon as damage to the plug could result if the wrench is cocked to one side when pres sure is applied b Carefully insert the terminal insulator in the spark...

Page 382: ...INTENTIONALLY LEFT BLANK 2F18...

Page 383: ...s Improper operation of magneto breaker points Prime with two or three strokes of primer Leave ignition OFF and mixture control in idle cut off open throttle and unload engine by cranking for a few se...

Page 384: ...arburetor Reverse magneto switch wires Demagnetize impulse couplings Replace spark plugs or dry out removed plugs Open mixture control Check and replace or repair Disconnect fuel line and check fuel f...

Page 385: ...cases Check primer Read justment of carburetor indicated Mixture too lean indi cated by overheating or backfiring Leaks in induction system Defective spark plugs Improper grade of fuel Magneto breake...

Page 386: ...uneven running engine cont Restriction in exhaust system Check for loose muffler baffles Improper ignition tim ing Check magnetos for timing and synchronization Failure of engine to develop full power...

Page 387: ...ough running engine cont Defective mounting bushings Install new mounting bushings Lead deposit on spark plug Malfunctioning engine Clean or replace plugs Check entire engine Low oil pressure Insuffic...

Page 388: ...d oil Remove and clean oil strainers Examine sump for metal particles and if found overhaul of engine is indicated Replace Replace gauge Excessive blow by Improper engine operation Low grade of oil Us...

Page 389: ...place with oil conform ing to specifications Use mineral base oil Climb to cruise altitude at full power and operate at 75 cruise power setting until oil consumption stabilizes Overpriming Cold weathe...

Page 390: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2G2...

Page 391: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2G3...

Page 392: ...ture Controls Serial Nos 32 40000 to 3240565 incl 7A 15a Adjustment of Throttle and Mixture Controls Serial Nos 3240566 and up and 32R 7680001 and up 7A 16 Induction Air Filter 2G16 7A 17 Alternate Ai...

Page 393: ...39 Magneto Installation and Timing Procedure Timing Magneto to Engine 2H14 7A 40 Magneto Timing Procedure Internal Timing 2H17 7A 41 Impulse Coupling Removal 2H21 7A 42 Inspection of Impulse Coupling...

Page 394: ...y a governor mounted on the engine supplying oil through the propeller shaft at various pressures 7A 2 TROUBLESHOOTING Troubles peculiar to the power plant are listed in Table VIIA I along with their...

Page 395: ...PIPER CHEROKEE SIX SERVICE MANUAL SCREW SPINNER ATTACHMENT Figure 7A 1 Propeller Installation Issued 8 17 72 POWER PLANT 2G7...

Page 396: ...n be done by rocking the blades back and forth through the slight freedom allowed by the pitch change mechanism If they appear tight and are properly lubricated the pitch change mechanism should be re...

Page 397: ...or of propeller hub for proper seating of O ring Wipe inside of hub to remove any traces of dirt Check to see that O ring is covered with grease g Install rear spinner bulkhead h Slide propeller caref...

Page 398: ...nt damagecausedby foreignmatter 7A 10 INSTALLATIONOF PROPELLERGOVERNOR a Clean the mounting pad thoroughly making very certain that there are no foreign particles in the recessaround the driveshaft b...

Page 399: ...against the base projection to lock 5 Ascertain that the governor control arm 1 is adjusted to the proper angle on the control wheel 3 as shown in Figure 7A 3 d With the high RPM adjustment complete...

Page 400: ...positive and ground leads at the injector The injector may be removed if desired f Disconnect the governor control cable at the governor and cable attachment clamps g Disconnect the heater hose at the...

Page 401: ...gainst head in the engine mount and slide half of the mount assembly on the bolt Refer to Figure 7A 4 for proper shock mount assembly Repeat this procedure for the other three attachment points NOTE S...

Page 402: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL VIIA POWER PLANT 03 27 08 PA 32 300 32R 300 2G14 Figure 7A 4 Engine Installation...

Page 403: ...ment of alternate air control v Install the propeller Refer to Figure 7A 1 z On PA 32 300 fixed gear aircraft install the bottom cowling by attaching the bottom cowl to the firewall aa Connect the ele...

Page 404: ...just the linkage by rotating the clevis end of the cable to obtain 0 062 to 0 125 of an inch spring back when the control is in the forward position 3 Reconnect the clevisend to the control arm and sa...

Page 405: ...in 0 010 to 0 030 of an inch spring back on the instrument panel stop when in full rich position 3 Reconnect the clevis end to the control arm and safety c Check security of cable casing attachments d...

Page 406: ...eck that the air door seals are tight and hinge is secure b Actuate the door to determine that it is not sticking or binding and the control cable has free travel c Check that when the air door is ful...

Page 407: ...WDIVIDER DIAPHRAGM 1 8 INCH O D STAINLESS STEEL LINE NOZZLE ONE PER CYLINDER FLOW DIVIDERVALVE II THROTTLE VALVE Figure 7A 5 Schematic Diagram of RSA Fuel Injection System Issued 8 17 72 POWER PLANT 2...

Page 408: ...screw so that the engine idlesat 550 600 RPM If the RPMchanges appreciably after making the mixture adjustment during the succeedingsteps readjust the idle speed to the desired RPM d When the idling s...

Page 409: ...e linkage any looseness in this linkage would cause erratic idling In all cases allowance should be made for the effect of weather conditions and field altitude upon idling adjustment 7A 21 FUEL AIR B...

Page 410: ...or excessively burned areas should be discarded Examine the cam follower felt for proper lubrication If neces sary points can be cleaned by using any hard finished paper Clean breaker compartment wit...

Page 411: ...riveted to its spring Examine the contact points for ex cessive wear or burning Figure 7A 8 shows how the average contact point will look when surfaces are separated for inspection Desired contact su...

Page 412: ...n paragraph 7A 30 At this instant the timing light should go out If it does the magneto is properly timed to the engine If the timing light does not go out removal of the magneto for internal timing c...

Page 413: ...aft at 12 o clock with respect to name plate on housing Tighten adjusting knob of 11 8465 Rotor Holding Tool until pressure is applied on housing flange preventing magnet from turning 3 Loosen and rot...

Page 414: ...way up and points just opening At this position the ref erence line on the distributor block should line up between the L and LB marks on the gear On single contact magnetos the line should favor the...

Page 415: ...mbly procedures e On the magneto employing the im Figure 7A 12 Checking Flyweight pulse coupling check clearance be Clearance of Impulse Coupling tween each flyweight and each stop pin as follows 1 Be...

Page 416: ...he front face of the starter housing Refer to Figure 7A 13 NOTE The advance timing mark on the top face of the starter ring gear is marked at both 20 and 25 BTC When timing the magnetos to the engine...

Page 417: ...iming lights operate in the reverse manner as de scribed above the light goes out when the breaker points open d After both magnetos have been timed check as described below to as certain that both ma...

Page 418: ...voltage tester to outer shielding braid of a single lead Connect plug terminal Turn tester ON and apply 10 000 volts The insulation resistance should be 100 megohms minimum Proceed to check other lea...

Page 419: ...efective component and reassemble as follows a Fabricate a tool as shown Figure 7A 15 Removing Spring in Figure 7A 16 for instal From Lead Assembly ling the insulating sleeves over cable terminals b P...

Page 420: ...ace one of the lead assemblies proceed as follows 1 Remove clamps and brackets from applicable lead assembly Cut cable ties from assembly and discard 2 Cut off condemned lead flush with outer surface...

Page 421: ...assembly to the length determined in step 5 Mark ferrule on spark plug end of lead with a metal stamp scribe or rubber stamp to correspond with correct cylinder number 7 Starting at spark plug locati...

Page 422: ...nd install tapered end of ferrule under the unbraided strands of shielding Form strands of shielding evenly around tapered ferrule as shown in Figure 7A 21 and pull lead assembly back through cable ou...

Page 423: ...er as shown in A of Figure 7A 27 Slide eyelet over doubled wire until it is firmly seated in recess of grommet outlet 15 Using the AB groove of Scintilla 11 4152 Crimping Tool or equivalent crimp eyel...

Page 424: ...single cam operates the main breakers for both magneto circuits Suppression of contact point arching and conducted radio interference is accomplished by feed thru capacitors which are mounted in the...

Page 425: ...ot open point contacts more than 0625 of an inch for examination of contact surfaces Excessive spreading of the breaker points will overstress and damage the contact spring Desired contact surfaces ha...

Page 426: ...DURE Timing Magneto to Engine WARNING DO NOT ATTACH HARNESS SPARK PLUG ENDS TO THE SPARK PLUGS UNTIL ALL MAGNETO TO ENGINE TIMING PROCEDURES AND MAGNETO TO SWITCH CONNECTIONS ARE ENTIRELY COMPLETED NO...

Page 427: ...eto drive end The timing tooth of each large distributor gear is marked with red paint Refer to Figure 7A 31 NOTE If magneto has counterclockwise rotation then the marks on the L side of the K are use...

Page 428: ...tter B is in the window turn the magneto shaft 1 1 2 times in the direction of rotation and check again to be sure the K is in the window on the data plate side and the red distributor tooth appears i...

Page 429: ...pounds Recheck timing once more and if satisfactory disconnect the timing light and remove the adapter leads o Reinstall the plugs in the timing inspection holes and torque to 12 15 inch pounds Loose...

Page 430: ...tool to shaft Check to insure proper location of keyway and tighten adjusting screw of holding tool to lock rotor in position i Loosen rotor holding tool and turn magnet in direction of rotation unti...

Page 431: ...ights should go out within one degree or half the width of R mark on rotor If breakers are not properly synchronized reset right breaker q Check right main breaker contact for 0 016 004 inch point ope...

Page 432: ...LEFT MAGNETO HIGH TENSION OUTLETS LEFT MAIN BREAKER CONTACT ASSEMBLY RIGHT MAGNETO HIGH TENSION OUTLETS 1 RIGHT MAIN CONTACT ASSEMBLY 2 LEFT MAIN CONTACT ASSEMBLY 3 SCREW 4 LOCK WASHER 5 FLAT WASHER...

Page 433: ...e the body and spring together Uncoil spring from body and pry spring eye from body recess to disengage spring c Thread protective cap of 11 702 1 puller securely on end of shaft Engage puller over pr...

Page 434: ...oked wire and make certain that a feeler gauge of 0 015 of an inch minimum thickness will pass between the stop pin and the highest point of the flyweight NOTE A true and accurate check of the clearan...

Page 435: ...lyweights against the gauge If the inner end of either flyweight heel touches the gauge replace the cam assembly If parts are near limits check clearance between flyweight and gauge with a 003 inch fe...

Page 436: ...ormed Coupling Springs i Inspect spring for cracks particularly at the ends and around spring eyes Inspect coils of spring for excessive wear If grooves or ridges are worn in coils or cracks are found...

Page 437: ...from the outside toward the center when viewed from the spring recess side of the body Refer to Figure 7A 43 Insert eye of outer end of spring into hole drilled in inner rim of body e Using heavy glov...

Page 438: ...less than 9 or more than 15 inch pounds 7A 44 HARNESS ASSEMBLY 7A 45 INSPECTION OF HARNESS a Inspect cover for cracks or other damage Inspect lead assemblies for abrasions mutilated braid or other phy...

Page 439: ...t indicator lamp flashes and GAP fires simultaneously as long as the PRESS TO TEST switch is held depressed Whenever indicator lamp flashes and GAP fails to fire lead under test is defective and must...

Page 440: ...assembly off end of lead assembly d Replace defective component and reassemble as follows 1 Fabricate a tool as shown in Figure 7A 16 for installing the insulating sleeves over cable terminals 2 Slid...

Page 441: ...t of Installation COAT PIPER CHEROKEE SIX SERVICE MANUAL 11 3699 11 8626 SPRING INSERTION GUIDE DISTRIBUTOR BLOCK Figure 7A 50 Position of 11 8627 Kit and Contact Spring after Installation LUBRICATE F...

Page 442: ...y seated 9 Thread the pre stripped end of conductor through grommet Place a new eyelet on conductor and crimp per instructions given in second paragraph of Maintenance of Harness 7A 46 f When lead bei...

Page 443: ...reads lb in 5 8 24 90 95 3 4 20 110 120 7A 47 SPARK PLUGS 7A 48 REMOVAL OF SPARK PLUGS a Loosen the coupling nut on the harness lead and remove the terminal insulator from the spark plug barrel well N...

Page 444: ...e removed NOTE Spark plugs should not be used if they have been dropped d Removal of seized spark plugs in the cylinder may be accomplished by application of liquid carbon dioxide by a conical metal f...

Page 445: ...carbon and foreign deposits c Test the spark plug both electrically and for resistance d Set the electrode gap at 0 017to 0 021 inches 7A 50 INSTALLATION OF SPARK PLUGS Before installing spark plugs a...

Page 446: ...INTENTIONALLY LEFT BLANK 2110...

Page 447: ...le and unload engine by crank ing for a few seconds Turn ignition switch on and proceed to start in a normal manner Incorrect throttle Open throttle to one setting eighth of its range Defective spark...

Page 448: ...metal particles If found complete over haul of engine may be indicated Adjust mixture Tighten all connections in the induction system Replace any parts that are defective Adjust throttle stop to obtai...

Page 449: ...ment of fuel injector by authorized personnel is indicated Tighten all connections Replace defective parts Clean and gap or re place spark plugs Fill tank with fuel of recommended grade Clean points...

Page 450: ...gine Cracked engine mount Replace or repair mount Defective mounting bushings Uneven compression Plugged fuel injector nozzle Install new mounting bushings Check compression Clean or replace nozzle Lo...

Page 451: ...ner High oil temperature See High Oil Temper ature in Trouble column High oil temperature Insufficient air cooling Check air inlet and out let for deformation or obstruction Fill oil sump to proper le...

Page 452: ...use Remedy Excessive oil consump tion cont Failing or failed bear ings Check sump for metal particles Worn piston rings Incorrect installation of piston rings Install new rings Install new rings Use m...

Page 453: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2117...

Page 454: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2118...

Page 455: ...val of Outboard Fuel Tank PA 32R 300 and 32 300 S N s 32 7940001 and up 2J2 8 12 Installation of Outboard Fuel Tank PA 32R 300 and 32 300 S N s 32 7940001 and up 2J3 8 13 Inspection of Fuel System 2J3...

Page 456: ...gallons for a total capacity of 98 U S gallons These tanks form an integral part of the wing surface when installed Fuel flow is indicated on the gauge located in the instrument panel A fuel quantity...

Page 457: ...IX SERVICE MANUAL CARBURETOR TROTTLE T MIXTURE R FUEL SELECTOR ENGINE FUEL LEFT MAIN TANK RIGHT TIP TANK ELECTRIC FUEL PUMP FUEL QUANTITY GAUGES FUEL QUANTITY GAUGES Figure 8 1 Fuel System PA 32 260 I...

Page 458: ...PER CHEROKEE SIX SERVICE MANUAL NOZZLES VALVE FUEL SELECTOR ENGINE FUEL LEFT MAIN TANK FUEL FLOW GAUGE LEFT TIP TANK RIGHT MAIN TANK RIGHT TIP TANK ELECTRIC FUEL FUEL QUANTITY GAUGES Figure 8 2 Fuel S...

Page 459: ...OKEE SIX SERVICE MANUAL 1604 FLOW DIVIDER FUEL INJECTOR LEFT TANKS SIGHT GAUGE RIGHT TANKS PRESSURE GAUGE Figure 8 3 Fuel System PA32 300 Serial No 32 7940001 and up PA 32R 300 All Revised 12 4 79 FUE...

Page 460: ...1 Allow sealant to cure 72 hours 2 Leak check repair by filling the fuel tanks with 1 5 psi clean dry air and a applying a water and soap solution or b submerging seams in clean water a minimum of one...

Page 461: ...32 260 and 300 a Slide the main tank partly into position and connect the sender wire b Slide the tank completely into place and secure with screws around its perimeter c Connect fuel line on inboard...

Page 462: ...e of wing slide hose on interconnecting fuel line and fuel vent line into position and tighten clamps c Connect fuel line on inboard side of tank d Fill fuel tanks and check for leaks unrestricted fue...

Page 463: ...s for leaks If fuel tanks leak follow instructions given in Paragraph 8 5 or 8 6 If fuel line connections leak tighten clamps or replace hose connections after first draining tanks 8 14 FUEL QUANTITY...

Page 464: ...sions of fuel quantity sending unit checking fixture 2 Ascertain that with the float just touching the top of a 0 27 inch spacer block the resistance of the sending unit is 3 5 ohms Should the resista...

Page 465: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 VIII FUEL SYSTEM 2J5 Figure 8 3a Fuel Quantity Sender Checking Fixture...

Page 466: ...r levers in the OFF position Completely drain fuel tanks that relate to the fuel quantity senders and gauge to be checked Refer to Draining Fuel System Section II b Level airplane laterally refer to L...

Page 467: ...should be centered on the O radial mark plus 0 minus 1 needle width g If the needle does not read within the above tolerance remove the sender wire from the rear of the gauge and check the resistance...

Page 468: ...OF FUEL SELECTOR VALVES IS AUTHORIZED MAINTENANCE IS LIMITED TO REMOVAL AND REPLACEMENT OF THE WHOLE UNIT a Drain fuel from tanks Refer to Draining Fuel System Section II b Remove center seats seat b...

Page 469: ...ends of filter disc center with stoppers to prevent dirt from entering 2 Wash metallic filter disc in acetone gasoline carbon tetrachloride trichlorethylene permachor or Bendix cleaner Wash nylon fil...

Page 470: ...be raised and lowered to allow the fuel to rinse any contamination still remaining in the tank out the drain c After the valve is installed and the aircraft refueled the fuel inlet line to the inject...

Page 471: ...cated in the left side of the opening d Remove the safety wire that secures the cover l on the pump e Turn the cover on the pump in a counterclockwise direction and remove f Usually the fuel pump filt...

Page 472: ...valve valve Fuel quantity gauge fails Broken wire Check and repair to operate Gauge inoperative Replace gauge Fuel sender float partially or Replace sender completely filled with fuel Circuit breaker...

Page 473: ...ANCE SERVICE MANUAL 07 15 06 VIII FUEL SYSTEM 2J13 Trouble Cause Remedy CAUTION DO NOT TIGHTEN SENDER UNIT TERMINAL SCREW IN AN ATTEMPT TO STOP LEAK Fuel sender leaks through the Bad sender unit Repla...

Page 474: ...2K10 9 14 Vacuum Pump 2K10 9 l 5 General 2K10 9 16 Troubleshooting 2K10 9 17 Removal and Replacement 2K11 9 17a Replacing Pump Fittings 2K11 9 17b Instrument Air System 2K13 9 18 Directional Gyro 2K13...

Page 475: ...49 Engine Oil Pressure Gauge 2K24 9 50 General 2K24 9 51 Troubleshooting 2L1 9 52 Removal and Replacement 2L1 9 53 Fuel Pressure Gauge 2L1 9 54 General 2L1 9 55 Troubleshooting 2L2 9 56 Removal and R...

Page 476: ...lcor 2L7 9 79 General 2L7 9 80 Removal of EGT Probe and Gauge 2L7 9 81 Cleaning and Inspection 2L7 9 82 Installation of EGT Probe and Gauge 2L8 9 83 Troubleshooting 2L9 9 84 Cylinder Head Temperature...

Page 477: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 03 27 08 IX INSTRUMENTS 2J17 THIS PAGE INTENTIONALLY BLANK...

Page 478: ...th a means to diagnose vacuum system service symptoms on those components which are serviced by removal and replacement These items include hoses clamps gyro filters vacuum regulating valves and vacuu...

Page 479: ...ould read from 4 9 inches to 5 1 inches of mercury vacuum d At 1200 RPM the vacuum gauge reading should be more than four inches of mercury c Gyro Filters 1 Gyro filters must be serviced on a schedule...

Page 480: ...st a known test gauge cruise RPM only 2 All modes of regulator malfunction tend to increase the vacuum power applied to the gyros Thus although excess vacuum is applied a loss of vacuum does not occur...

Page 481: ...n of vacuum pump or regulator valve Vacuum lines restricted or broken Check system Low vacuum system pressure Vacuum regulator valve incorrectly adjusted Adjust regulator valves in accordance with Adj...

Page 482: ...r clogged or dirty Clean or replace filter Line from gyro to filter restricted Check line No vacuum gauge indica tion at instrument or source Low vacuum system pressure Faulty gauge and or malfunction...

Page 483: ...lace pump Vacuum correct on ground but will not maintain pressure at altitude Vacuum pump mal functioning Replace pump Regulator sticky Clean regulator Vacuum correct but pilot reports pressure errati...

Page 484: ...ESSURE FUEL FLOW GAUGE 17 ENGINE CLUSTER 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 TACHOMETER VACUUM CIGAR LIGHTER DEFROSTER CABIN HEAT MIXTURE CONTROL PROPELLERCONTROL AUTOFLITE CONTROL T...

Page 485: ...ECTOR PANEL 15 MAGNETIC COMPASS 16 NAV COMM TRANSCEIVERS 17 TRANSPONDER 18 ADF RADIO 19 DME 20 LIGHTER 22 ENGINE GAUGES 23 NAV COUPLER 24 PITCHTRIM SWITCH 25 MAGNETO STARTERSWITCH 26 MANIFOLD PRESSURE...

Page 486: ...ETIC COMPASS 16 NAV COMM TRANSCEIVERS 17 TRANSPONDER 18 ADFRADIO 19 DME 20 LIGHTER 20 21 AUTOCONTROL 22 ENGINE GAUGES 23 NAVCOUPLER 24 PITCH TRIMSWITCH 25 MAGNETO STARTER SWITCH 26 MANIFOLDPRESSURE FU...

Page 487: ...E RADIO 20 CIGAR LIGHTER 19 37 38 21 AUTOCONTROL 22 ENGINE I USTRUUMENT CLUSTER 23 HA COUPLER 24 TRANSMITTER S ELCTOR 25 PITC TRIM SWITCH 26 MAGETO ANO STARTE R SWITCH 27 CONTROL LOC K 28 MANIFOLD P E...

Page 488: ...RANSPONDER 18 ADF RADIO 19 DME RADIO 20 CIGAR LIGHTER 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 AUTOCONTROL ENGINE INSTRUMENT CLUSTER NAV COUPLER TRANSMITTER SELECTOR PITCHTRIM SWITC...

Page 489: ...RANSPONDER 18 ADF RADIO 19 DME RADIO 20 CIGAR LIGHTER 21 AUTOCONTROL 22 ENGINE INST CLUSTER 23 RADIO COUPLER 24 TRANSMITTER SELECTOR 25 PITCH TRIM SWITCH 26 MAGNETO AND STARTER SWITCH 27 CONTROL LOCK...

Page 490: ...TIC COMPASS 16 NAV COMM TRANSCEIVERS 17 TRANSPONDER 18 ADF RADIO 20 CIGAR LIGHTER 29 TACHOMETER 31 CLIMATE CONTROL CENTER 21 AUTOCONTROL 30 MICROPHONE 38 CIRCUIT BREAKER COVER 22 ENGINE INST CLUSTER 3...

Page 491: ...RADIO 20 DME RADIO 21 CIGAR LIGHTER 22 23 24 25 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 AUTOPILOT ENGINE INSTRUMENTCLUSTER NAV COUPLER NAV SELECTORSWITCH MAGNETO AND STARTERSWITCH MANIFOLD...

Page 492: ...O 21 CIGAR LIGHTER 22 AUTOPILOT 23 ENGINE INSTRUMENT CLUSTER 24 NAV COUPLER 25 NAV SELECTOR SWITCH 26 PITCH TRIM SWITCH 27 MAGNETO AND STARTER SWITCH 28 MANIFOLD PRESSURE FUEL FLOW GAUGE 29 FUEL SYSTE...

Page 493: ...BLOWER CONTROLS 22 CIGAR LIGHTER 23 MASTER AND ACCESSORY SWITCH PANEL 26 VOR LOC COUP 2 NAV SELECTOR 28 MAGNETO AND 29 PITCH TRIM SW 30 MANIFOLD PRE FLOW GAUGE 31 FUEL PRESSURE AND QUANTITY 38 MIXTUR...

Page 494: ...emove the protective cap from the valve depending on which type is installed NOTE Do not attempt adjustment of this valve with the engine in operation b Start the engine after allowing time for warm u...

Page 495: ...engine with four plain washers lock washers and retaining nuts Torque the nuts 40 to 50 inch pounds 4 Connect the hoses to the pump and secure with hose clamps 5 Reinstall the engine cowling e Install...

Page 496: ...BIN VINTS AND STORMWINDOWMUST BE CLOSED 2 ALTIMETER HEATER AND DEFROSTER MUST BE ON PULL AFT TOOPEN 3 AIRSPEED INDICATOR 4 VALVE ASSEMBLY ALTERNATE AIR 5 TUBE ASSEMBLY STATIC 6 TUBE ASSEMBLY PITOT 7 H...

Page 497: ...ce is located below the instrument panel in front of the pilot The alternate static source is part of the standard system and has a shutoff valve which closes the port when it is not needed A placard...

Page 498: ...ective mechanism Replace 9 21 REMOVAL AND REPLACEMENT Refer to Paragraph 9 74 of this section 9 22 GYRO HORIZON 9 23 GENERAL The gyro horizon is essentially an air driven gyroscope rotating in a horiz...

Page 499: ...ument Instrument loose in panel Vacuum too high Defective mechanism Instrument not level in panel Aircraft out of trim Normal if it does not exceed 1 16 inch Low vacuum Remedy Check pump and tubing Cl...

Page 500: ...ough air thisshould not be considered a malfunction 9 28 TROUBLESHOOTING TABLEIX IV RATEOF CLIMBINDICATOR Trouble Cause Remedy Pointer does not set on zero Pointer failsto respond Agingof diaphragm Ob...

Page 501: ...9 29 REMOVAL AND REPLACEMENT Refer to Paragraph 9 74 of this section 9 30 SENSITIVE ALTIMETER 9 31 GENERAL The altimeter indicates pressure altitude in feet above sea level The indicator has three po...

Page 502: ...of lubrication Out of engagement Not tight when altimeter was reset Case gasket hardened Replace instrument Replace instrument Eliminate leak in static pressure system and check alignment of airspeed...

Page 503: ...R 23 1325 9 33 REMOVAL AND REPLACEMENT Refer to Paragraph 9 74 of this section 9 34 AIRSPEED INDICATOR 9 35 GENERAL The airspeed indicator provides a means of indicating the speed of the airplane pass...

Page 504: ...Leaking static system Pointer not on zero Leaking static system Pitot head not aligned correctly Water in pitot line Remedy Check for leak and seal Replace instrument Replace instrument Find leak and...

Page 505: ...ator switch and all radio switches should be in the ON position All other cockpit controlled electrical switches should be in the OFF position a Set adjustment screws of compensator on zero Zero posit...

Page 506: ...pivot fric tion or broken jewel Replace instrument Liquid leakage Loose bezel screws Replace instrument Broken cover glass Defectivesealing gaskets Replace instrument Replace instrument Replace instr...

Page 507: ...when engine is running Sluggishor jerky pointer movement Pointer shifted Line leaking Defective instrument Replace instruments Tighten line connections Replace instrument Dull or discolored marking A...

Page 508: ...the way to stop more noticeable in cold weather Excessive clearance in speed cup Excessive lubricant in instruments Replace instrument Replace instruments Pointer jumps at idle Tachometer cable breaks...

Page 509: ...adjustment Air in line or rough engine relief Engine relief valve open Replace instrument Replace instrument Disconnect line and fill with light oil Check for leaks If trouble persists clean and adjus...

Page 510: ...ric pump Check bypass valve Air leak in intake lines Replace gauge Pressure low or pressure surges Obstruction in inlet side of pump Trace lines and locate obstruction Faulty bypass valve Replace Faul...

Page 511: ...ns if the aircraftis rolled right and left rapidly the indicator will move indicating a turn but if the aircraft is held in a bank by applyingrudder the indicator willcome back to zero indicatingno tu...

Page 512: ...el cell and this position is transmitted electrically to the indicator gauge to show the amount of fuel in the cell 9 64 TROUBLESHOOTING TABLE IX XIII FUEL QUANTITY INDICATORS Trouble Cause Remedy Fue...

Page 513: ...e scale error Pointer fails to move as engine is warmed up Broken or damaged bulb Wiring open Improper calibration adjustment Broken or damaged bulb or open wiring Check engine unit and wiring to inst...

Page 514: ...ts is performed a Remove the face panel by removing the screws from around the perimeter of the panel b With the face panel removed the mounting screws for the individual instruments will be exposed R...

Page 515: ...the leads to the gauge are defective in any way they should be replaced When replacing leads it is very important to use the same type and length of wire as the resistance of the leads is critical fo...

Page 516: ...l probe in the following manner 1 Locate the hole for the probe in the exhaust stack of the number six cylinder The 129 inch hole is located 2 25 inches from the mating side of the mounting flange 2 C...

Page 517: ...ge probe or wiring Check probe and lead wires for chafing breaks or shorting between wires and or metal structure Adjusting potentio meter turned off scale Reset potentiometer Fluctuating reading Loos...

Page 518: ...re Defective sender Replace sender 9 87 REMOVAL AND REPLACEMENT Refer to Paragraph 9 76 of this section 9 88 FUEL FLOW GAUGE 9 89 GENERAL The fuel flow gauge is a non electric pressure gauge mounted i...

Page 519: ...ressure and the vacuum system The ALT warning light will illuminate when alternator output is zero the VAC light when the pressure difference is below 3 5 in Hg and the OIL light when the oil pressure...

Page 520: ...INTENTIONALLY LEFT BLANK 2L12 THRU 2L24...

Page 521: ...PART NUMBER 753 690 March 27 2008 3A1 AIRPLANE SERVICE MANUAL CARD 3 OF 4 PA 32 260 PA 32 300 PA 32R 300 PIPER AIRCRAFT CORPORATION...

Page 522: ...3 1 2 3 IR860430 April 30 1986 1 IR860730 July 30 1986 1 IR870506 July 12 1987 1 PR060715 July 15 2006 1 2 3 4 PR080327 March 27 2008 1 2 3 4 PARTIAL REVISION OF SERVICE MANUAL 753 690 Revisions appea...

Page 523: ...YSTEM PA 32R 300 1I22 VI LANDING GEAR AND BRAKES PA 32 260 300 2A8 VIA LANDING GEAR AND BRAKES PA 32R 300 2C5 VII POWERPLANT PA 32 260 2E14 VIIA POWERPLANT PA 32 300 32R 300 2G4 VIII FUEL SYSTEM 2I19...

Page 524: ...rcuit 3A23 10 6 Testing Rectifiers Positive 3A24 10 7 Testing Rectifiers Negative 3B1 10 8 C 3928 Fixtures and Adapters 3B2 10 9 Removing Rectifiers 3B2 10 10 Installing Rectifiers 3B3 10 11 Soldering...

Page 525: ...matic NARCO 3F10 11 3 ELT Portable Folding Antenna NARCO 3F11 11 4 ELT Using Fixed Aircraft Antenna NARCO 3F11 11 5 Communications Components ELT Schematic 3F16 12 1 Cabin Heater Defroster and Fresh A...

Page 526: ...de Mounting Board Diode Location and Number S N s 32 7240056 to 32 7340042 3H19 13 16 Air Conditioning Wiring Schematic S N s 32 7240056 to 32 7340042 3H20 13 17 Air Conditioning Wiring Schematic S N...

Page 527: ...X III Electrical System Troubleshooting 3D1 X IIIA Electrical Symbols 3D17 X IV Electrical Wire Coding 3D18 XII I Blower System Wire Color Codes 3G5 XIII I Temperature Pressure Chart 3G13 XIII II Alum...

Page 528: ...Bearing from End Shield 3B 10 17 Installing Needle Bearing in End Shield 3B7 10 18 Removing Drive Pulley 3BS 10 19 Removing Drive End Bearing 3BS 10 20 Replacing Slip Rings 3B9 10 21 Removing Slip Ri...

Page 529: ...Specifications 3C10 10 45 Cranking Motors Prestolite 3C 01 10 46 Descriptio 3C10 10 47 Operation 3C10 10 48 Maintenance 3C1 10 49 Overhaul C12 10 50 Removal 3C1 10 51 Disassembl 3C13 10 52 Brushes 3C1...

Page 530: ...ator Panel 10 72 Removal of Oil Pressure Sensor 10 73 Installation of Oil Pressure Sensor 10 74 Removal of Vacuum Sensor 10 75 Installation of Vacuum Sensor 10 76 Ignition Switch 10 77 Removal of Igni...

Page 531: ...500001 to 32 7600033 incl and PA 32 300 Serial Nos 32 7540001 to 32 7640142 incl 10 52 3E12 Alternator Starter Forward Baggage Light Cigar Lighter and External Power Receptacle PA 32R 300 Serial Nos 3...

Page 532: ...001 to 32 7440182 incl 10 48 3E10 Instrument Navigation and Radio Lights PA 32 260 Serial Nos 32 7500001 to 32 7800008 incl and PA 32 300 Serial Nos 32 7540001 to 32 7840202 incl 10 54 3E Instrument N...

Page 533: ...os 32R 7880001 to 32R 7880068 incl 10 65 3E21 Stall Warning PA 32 260 Serial Nos 32 7400001 to 32 7800008 incl and PA 32 300 Serial Nos 32 7440001 and up 10 41 3E8 Stall Warning PA 32R 300 Serial Nos...

Page 534: ...electrical system for security and operation of its components 10 3 ELECTRICAL POWER SUPPLY The electrical power is supplied by one 12 volt battery and a 14 volt direct current alternator The alternat...

Page 535: ...NAL POWER RECEPTACLE EXTERNAL POWER SOLENOID PIPERCHEROKEE SIX SERVICE MANUAL Figure 10 la Alternator and Starter System PA 32 260 Serial Nos 32 1 to 32 855 inclusive Revised 6 18 76 ELECTRICAL SYSTEM...

Page 536: ...PIPER CHEROKEE SIX SERVICE MANUAL Figure 10 lb Alternator and Starter System PA 32 260 Serial Nos 32 856 to 32 1111 and PA 32 360 Serial Nos 32 40000 to 32 40566 3A16 Revised 8 3 81 ELECTRICAL SYSTEM...

Page 537: ...ILTER ALTERNATOR ALTERNATOR CIRCUIT PROTECTOR 60AMP AMMETER VOLTAGE REGULATOR BATTERY SWITCH BAT OVERVOLTAGE RELAY IGN F 6 REE NOTE MECHANICAL INTERLOCKNOT USEDON PA 32 260 S N 32 1112 TO 32 7300066 A...

Page 538: ...ERNATOP BATTERY SWITCH AMMETER VOLTAGE REGULATOR OVERVOLTAGE RELAY I SEE NOTE SEE NOTE NOTE GROUND NOT USED IN PA 32R 300 Figure 10 2a Alternator and Starter System PA 32 260 Serial Nos 32 7500001 to...

Page 539: ...B FILTER ALTERNATOR AMMETER VOLTAGE REGULATO I BATTERY SWITCH OVERVOLTAGE RELAY 1 BAT G REG SEE NOTE SEE NOTE F NOTE GROUND NOTUSED ON PA 32R 300 Figure 10 2b Alternator and Starter System PA 32 260...

Page 540: ...not prevent their continued tripping and indicates a breakdown of wiring or equipment in the generator circuit Unlike previous systems the ammeter does not indicate battery discharge but displays the...

Page 541: ...it of electrical equipment is switched on the cur rents will add up and the total including the battery will appear on the ammeter 10 4 ALTERNATOR SYSTEM TEST PROCEDURE CHRYSLER a Start engine and set...

Page 542: ...ammeter to determine the current flowing through the rotor coil and connected circuit and record the amount Slowly rotate the rotor with the pulley while watching the meter The current will be a litt...

Page 543: ...spect the brush holder and insulatedwasher Re place if damaged The stack of parts attaching the insulated brush holder assen blv to the end shield must aiwavs be installed in the proper sequence as fo...

Page 544: ...wires in the heat sink at the rectifiers The meter reading for each of the rectifiers should be the same Always contact the connection nearest the rectifiers Do not break the sealing on the rectifier...

Page 545: ...s are the same for the negative case rectifiers in the end shield as they are for the positivecase rectifiers in the heat sink However the meter will read at the opposite end of the scale NOTE If all...

Page 546: ...on all Chrysler built alternators A press is not required when using the new C 3928 tool kit for removing or installing rectifiers Three diode rectifiers are pressed into the heat sink and three in t...

Page 547: ...lling support on the fixture anvii PIPER CHEROKEE SIX SERVICE MANUAL Figure 10 10 Installing Rectifiers from the fixture and position SP 3820 10 13 INSTALLING RECTIFIERS Start the new rectifier as squ...

Page 548: ...ed properly NOTE Clean all wires before soldering Form the rectifier lead around the connector being very careful not to crack the seal To protect the rectifier from over heating grip the rectifier le...

Page 549: ...will be rough and pitted NOTE After soldering to quickly cool the soldered connection touch a dampened cloth against it This will aid in forming a solid joint With the rectifier properly installed te...

Page 550: ...alternators to suppress any transient peak voltage that may occur It is essential therefore to test the capacitor when servicing the alternator This is especially true where diode rectifiers test ope...

Page 551: ...used as a support for end shields without the grease retainer counterbore 10 17 INSTALLING NEEDLE BEARING IN END SHIELD Refer to Figure 10 14 Support the end shield on the C 3925 tool and press the b...

Page 552: ...er on the early production alternators was attached to the end shield by three stud nuts and washers All late retainers are of spring steel construction and three integral fingers snap over a shoulder...

Page 553: ...nd the slip rings were pressed on and the ring cemented to the rotor fan Later rotor shafts were knurled and the slip rings were pressed on the knurled surface of the shaft The early slip rings have a...

Page 554: ...of the old ring f Scrape the face of the fan to be sure it is smooth g Clean the shaft surface on the area that contacts the inner diameter of the ring and also the ends of the rotor coil leads 10 21...

Page 555: ...assembly in an arbor press Pull up on the guide wire being careful to guide the insulated field lead into the slip ring groove 7 While guiding the insulated field lead through the groove press the sli...

Page 556: ...ot grounded lightly clean slip ring surface with 00 sandpaperand assemblealternator b NewStyle Refer to Figure 10 21 1 Position the slip ringon the rotor shaft so the solderlugs alignwith the rotor co...

Page 557: ...require no service position the beanng and the drive end shield assembly on the rotor shaft and while supporting the parts on the end of the rotor shaft press the bearing and end shield assembly in p...

Page 558: ...mbient conditions and consists of four checks which are to be made quickly to avoid heating of the windings These are as follows NOTE For test c and d external field excitation may be used but must be...

Page 559: ...se no external load shall be applied An external D C power source may be used to polarize the field but must be removed as soon as the alternator is self sustaining Maintain 14 volts at no load by adj...

Page 560: ...ttery will appear on the ammeter Using the example that the airplane s maximum continuous load with all equipment on is approximately 48 amperes for the 60 ampere alternator This approximate 48 ampere...

Page 561: ...these precautions will result in serious damage to the electrical equipment a Disconnect the battery before connecting or disconnecting test instruments except voltmeter or before removing or replacin...

Page 562: ...ee phase windings The stator has been treated with a special epoxy varnish for high temperature resistance e The rotor contains the slip ring end bearing inner race and spacer on the slip ring end of...

Page 563: ...end head d Remove the nuts lock washers flat washers and insulators from the output and auxiliary terminal studs Note carefully the correct assembly of the insulator washers and bushings Using the sp...

Page 564: ...type of continuity tester Refer to Figure 10 24f There must not be any continuity between the slip rings and the rotor shaft or poles To test for shorted turns in the rotor winding connect a voltmeter...

Page 565: ...erminal or any stator lead and the other test bulb or ohmmeter probe to the stator frame If the test bulb lights or the ohmmeter indicates continuity the stator is grounded To test for open windings c...

Page 566: ...Figure 10 24i CAUTION Use an arbor press do not hammer Reconnect the stator leads to the rectifiers When soldering these connections use pliers as a heat dam on the lead between the solder joint and t...

Page 567: ...mbly and retaining screws Spin the rotor and check for interference between the brush holder and rotor Check between the field terminal and ground with an ohmmeter The ohmmeter must indicate the amoun...

Page 568: ...volt alternators installed as standard equipment on PA 32 airplanes equipped with air conditioning ALTERNATOR SPECIFICATIONS I Alternator Model ALY 6409 ALY 6422 Voltage 12 volts Rated Output 60 amper...

Page 569: ...e regulator may be tested by the following procedure a Be sure that the battery is fully charged and in good condition b Check the alternator according to the manufacturer s instructions to determine...

Page 570: ...ecting the regulator while the circuit energized 6 Open circuit operation of the alternator The battery disconnected 10 30 OVER VOLTAGE RELAY 10 31 CHECKING OVER VOLTAGE RELAY The relay may be tested...

Page 571: ...he belt at the small pulley and is accomplished as follows a Apply a torque indicating wrench to the nut that attaches the pulley to the generator and turn it in a clockwise direction Observe the torq...

Page 572: ...gine is running Others use a small anti drift pin and spring inside the pinion which provides enough friction to keep the pinion from drifting into mesh Never operate the motor for more than 30 second...

Page 573: ...ery to ground battery to master relay master relay to starter solenoid starter solenoid to starter and engine return ground wire to airframe See schematics for your airplane If during inspection a fau...

Page 574: ...m of operation by turning it on the screw shaft The armature should be checked for freedom of operation by turning the pinion Tight dirty or worn bearings bent armature shaft or loose pole shoe screw...

Page 575: ...and d Failure to operate with no current draw indicates 1 Open field circuit This can be checked after disassembly byinspecting internal connections and tracing circuit with a test lamp 2 Open armatur...

Page 576: ...d frame to the field frame assembly Discard the tang lock washers d Separate the commutator end frame armature assembly field frame and drive housing e Remove and disassemble the drive from the armatu...

Page 577: ...e commutator and other test probe on the armature core or shaft the armature is grounded If the commutator is worn dirty out of round or has high insulation the commutator should be turned down and un...

Page 578: ...CRANKING MOTORS Prestolite 10 46 DESCRIPTION The gear reduction starting motor consists of six major components The Commutator End Head Assembly The Armature The Frame and FieldAssembly theGear Housin...

Page 579: ...shaft is supported in the gear housing by a closed end roller bearing and in the pinion housing by a graphitized bronze bearing When the armature turns the reduction gear the Bendix drive pinion mesh...

Page 580: ...ed 1 Voltage loss from insulated battery post to starting motor terminal 0 3 volt maximum 2 Voltage loss from battery ground post to starter frame 0 1 volt maximum NOTE If voltage loss is greater than...

Page 581: ...ssemble the drive and do not dip it in cleaning solvent d To remove the roller bearings from the gear housing use an arbor press and the correct bearing arbor DO NOT HAMMER OUT Each part should be cle...

Page 582: ...he field coils for grounds Refer to Figure 10 30 by placing one testprobe on the frame and the other onthe starter terminal Be sure the brushes are not accidentally touching the frame If the lamp ligh...

Page 583: ...out 1 1 4 to 1 1 2 times maximum Drop brushes on sandpaper covered commutator and turn the armature slowly in the directionof rotation Dust should be blown out of the motor after sanding NOTE The spri...

Page 584: ...CIRCUIT a Inspect the control circuit wiring between the battery solenoid and manual starting switches for breaks poor connections and faulty insulation Tighter all connections and make sure solenoid...

Page 585: ...ring cleaning of the box The battery should be checked for fluid level but must not be filled above the baffle plates A hydrometer check should be performed to determine the percent of charge in the b...

Page 586: ...the PA 32R 300 model remove the external access panel and the floor panel located in the forward baggage compartment c Cut the safety wire and remove the wing nuts that secure the battery box cover d...

Page 587: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3C19...

Page 588: ...p Pulsating Carb Rotary Fuel Inj t Engine Gages Elec Turn Bank Pitot Heat Pitot and Pressure Mast Heat X Cigar Lighter Master Solenoid X Starter Solenoid Radio See Mfg s Installation Manual X Baggage...

Page 589: ...applied until all bubbling action has ceased CAUTION Do not allow soda solution to enter battery c d to dry e f Rinse the battery and box with clean water and dry On metal battery boxes paint the box...

Page 590: ...ument lights are controlled by a 5 amp circuit breaker through a transistorized dimmer The dimmer control is located in the middle of the instrument panel just above the pedestal In earlier model airp...

Page 591: ...flows through a 5 amp fuse located above the diode heat sink to the resistor and diode creating a no flow condition which does not allow the warning light to light The test button is used to check the...

Page 592: ...e ignition switch retaining nut from the switch on the forward side of the instrument panel and withdraw the switch from the panel d Mark the wires and note their position on the switch then disconnec...

Page 593: ...s through entire field circuit to alternator field terminal Mea sure voltage from ground to the follow ing points in se quence buss bar out put circuit breaker 60A field circuit breaker 5A field termi...

Page 594: ...o the following points in sequence buss bar output circuit breaker 60A am meter and alternator battery post Interruption of voltage through any of these points isolates the faulty component or wire wh...

Page 595: ...e place if necessary If brushes are okay and field reads open re place alternator Start engine turn on load Ref alternator test procedure set throttle at 2300 RPM Check voltage at buss bar convenient...

Page 596: ...the six recti fiers pressed into the rear bell housing of the alternator open up internally it will result in a definite limitation on the current that can be drawn from the alternator After Having ch...

Page 597: ...on master switch Reset breaker and if breaker fails to retrip this isolates short circuit to field of alternator itself Check brush holders for shorting against frame If there are no obvious signs of...

Page 598: ...itch Reset breaker and if breaker con tinues to trip proceed to disconnect each leg of output circuit work ing from the alternator towards the circuit breaker until breaker can be reset and will hold...

Page 599: ...gns of damage due to reversed charging NOTE This type of con dition can only occur in a case where a discharged battery has been removed from the airplane and put on a charger with the polarity revers...

Page 600: ...lator STARTER Replace voltage regu lator Motor fails to operate Low battery charge Checkand rechargeif necessary Defective or improper wiring or loose connections Defective starter solenoid or con tro...

Page 601: ...er between the brush and commu tator with the sanded side next to the brush Pull sandpaper in the direction of rotation being careful to keep it in the same contour as the commutator CAUTION Do not us...

Page 602: ...d Worn rough or im properly lubricated motor or starter gearing Disassemble clean in spect and relubricate replacing ball bear ings if worn Same remedies listed for these troubles Excessive arcing of...

Page 603: ...ATTERY Discharged battery Battery worn out Replace battery Charging rate not set right Reset Remove and recharge battery if left in un used airplane 3 weeks or more Remove and recharge Replace Check w...

Page 604: ...and charg ing rate too high Spillage from over filling Replace Reduce charging rate by adjusting voltage regulator Drain and keep at proper level and adjust volt age regulator Use care in adding water...

Page 605: ...TEM TROUBLESHOOTING cont Trouble Cause Remedy and then charged cor rectly and tested Battery consumes ex cessive water Charging rate too high if in all cells Correct charging rate Cracked jar one cell...

Page 606: ...anel All the warning lights fail to extinguish after engine is running OIL warning light fails to operate Test switch grounded out Bulb burned out No current to sensor Check terminals and replace swit...

Page 607: ...extinguish too high setting Sensor terminals Remove material bridged between terminals Defective sensor Replace LT warning light fails Bulb burned out Replace operate No current from bus Check all wir...

Page 608: ...A966 12 INTENTIONALLY LEFT BLANK PIPER CHEROKEE SIX SERVICE MANUAL B1115 GIF 2 8 PA 32R 300 ONLY Figure 10 32b Terminal Block Revised 9 18 78 ELECTRICAL SYSTEM 3D16...

Page 609: ...ELECTRICAL SYMBOLS BATTERY KNIFE CONNECTORS BUS BAR SWITCH PUSH TYPE TYPE USPULL TYPE CIGAR LIGHTER CONDUCTORS SHIELDED CONNECTOR VALVE CONDUCTORS CROSSINGS AND JUNCTIONS OF CONDUCTORS THE DOT AT THE...

Page 610: ...ing AC AIR CONDITIONING C CONTROL SURFACE E 200 Series Right Wing E ENGINE INSTRUMENT F FLIGHT INSTRUMENT E 300 Series Aft Fuselage G LANDING GEAR E 400 Series Forward Fuselage H HEATER VENTILATING DE...

Page 611: ...INTENTIONALLY LEFT BLANK 3D19...

Page 612: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3D20...

Page 613: ...PIPER CHEROKEESIXSERVICEMANUAL STARTER FUSE I STARTER 1 UTs UPPERTERMinAL BLOCK LT8 LOWER TERMINAL BLOCK REAdINGLIGHTS Figure 10 33 Electrical SystemSchematic PA 32 260 SerialNos 32 1 to 32 375 incl E...

Page 614: ...10AMP STARTER KIC CIGARLIGHTER H NAVLIGHTS HFRADIO LF RADIO FUSE FUSE FUSE SAP ISAMP AMP LANDING LIGHT FUEL PUMP FUSE FUSE 10AMP 10 AMP I FUELPUMP NOTES 1 UTB UPPERTERMINAL BLOCK LTB LOWER TERMINAL BL...

Page 615: ...CIgARLIGHTER NOTES Figure 10 33b Electrical System Schematic PA 32 260 Serial Nos 32 856 to 32 1111 and PA 32 300 Serial Nos 32 40000 to 32 40566 ELECTRICAL SYSTEM Revised 12 4 79 3E2 3E1...

Page 616: ...CHEROKEE SIX SERVICE MANUAL Figure 10 33c Electrical System Schematic PA 32 260 Serial Nos 32 1112 to 32 7300066 and PA 32 300 Serial Nos 32 40567 to 32 7340191 ELECTRICAL SYSTEM Revised 12 4 79 10 5...

Page 617: ...PIPERCHEROKEESIXSERVICEMANUAL Figure 10 35 Courtesy Lights 1627 PA 32 300 SERIAL NOS 32 794000 AND UP n Figure 10 36 Engine Gauges ELECTRICALSYSTEM Added 9 18 78 3E5...

Page 618: ...MAIN IN TIP AE Q A A SEE NOTE 4 00 4 30 70 O 0 3 05 E NOTE SEE NOTE SEE NOTE IN 10 6 SENSOR 20 TE 20MP 20 20 Figure 10 37 Engine Gauges 1630 PASSENGE READING L GHTS 01 AMP FWD CABIN 2 NOTES PAS S E N...

Page 619: ...R SWITCH FORWARD BAGGAGE L STARTER 8 ACC 15 AMP MECHANICAL INTERLOCK STARTER PA 32 260 Serial Nos 32 7400001 to 7400061 Incl PA 32 300 Serial Nos 32 7440001 to7440182 Incl Figure 10 39 Alternator Star...

Page 620: ...7400001 TO 32 7800008 STALL WARNING HORN PA 32 260 Serial Nos 32 760001 up PA 32 300 Serial Nos 32 7640001 up NOTE USED ON PA 32 260 SERIAL NOS 32 7500001 TO 32 7800008 PA 32 260 SERIAL NOS 32 740000...

Page 621: ...ND PA 32 300 SERIAL NOS 32 7840001 AND UP SEE NOTE PITOT HEAT 15 AMP PA 32 260 SERIAL NOS 32 7400001 TO 32 7800008 PA 32 300 SERIAL NOS 32 7440001 AND UP Figure 10 44 Pitch Trim Figure 10 45 Pitot Hea...

Page 622: ...MP NAVIGATION LIGHTS 5 AMP TERMINAL UPPER PANEL LIGHTS INSTRUMENT LIGHTS DIMMER TO START 6 ACC C B RADIO LIGHTS DIMMER PA 32 260 Serial Nos 32 7400001 to 7400061 Incl PA 32 300 Serial Nos 32 7440001 t...

Page 623: ...MP 20 20 SEE ADF INSTALLATION SEE MARKER BEACON INSTALLATION _ ______ ______ OAMP SEE DME INSTALLATION SEE GLIDE SLOPE INSTALLATION TRANSPONDER AMP RP6 2C SEE TRANSPONDER INSTALLATION COMM NAV II 1O A...

Page 624: ...PA 32 260 Serial No 32 7500001 to 32 7600033 Icn PA 32 300 Serial Nos 32 7540001 to 32 7640142 Incl Figure 10 52 Alternator Starter Forward BaggageLight Cigar Lighter and External Power Receptacle EL...

Page 625: ...PTICAL EXTERNA POWER PIPERCHEROKEE SIXSERVICE MANUAL 1637 ALTERNTOR PA 32 260 Serial Nos 32 7700001TO 32 7800008 PA 32 300 Serial Nos 32 7740001 and up Figure10 53 Alternator Starter CigarLighterand E...

Page 626: ...E USED ON PA 32 260 INSTRUMENT SERIAL NOS 32 7600021 TO 32 7800008 LIGHTS USED ON PA 32 300 DIMMER SERIAL NOS 32 7640105 TO 32 7340202 RADIO LIGHTS DIMMER 400n J PA 32 260 SERIAL NOS 32 7500001 TO32 7...

Page 627: ...AMP 75 AMP LOWER PANEL LIGHTS CENTER EXTRUSION LIGHTS TO START ACC C B RADIO LIGHTS I DIMMER INSTRUMENT LIGHTS DIMMER ft NOTE 1 PA 32 300 SERIAL NOS 32 7940275 AND UP Figure 10 54a Instrument Navigati...

Page 628: ...INTENTIONALLY LEFT BLANK 3E16...

Page 629: ...IAL NOS 32R 7680001 TO 32R 7 85 0 0 6 8 Figure 10 55 Engine Instruments e PA 32R 300 SERIAL NOS 32 R 7680001 TO 32R 7880068 Figure 10 56 ER READING LIGHTS Passenger Reading Lights Revised 9 18 78 ELEC...

Page 630: ...NAL POWER RECEPTACLE ECHAN ICAL INTERLOCK PIPER CHEROKEE SIX SERVICE MANUAL r ALTERNATOR FIELD 5 AMP ANNUNCIATOR LIGHTS 5AMP Figure 10 57 Alternator Starter Forward Baggage Light Cigar Lighter and Ext...

Page 631: ...TARTER SWITCH EXTERNAL POWRER EXTERNAL POWER RECEPTACLE MECHANICAL INTERLOCK a ACC TO RADIO DIMMER CIGAR LIGHTER LIGHTS PA 32 R 300 SERIAL NOS 32R 7780001 TO 32R 7880068 CIRCUIT Figure 10 58 Alternato...

Page 632: ...CHEROKEE SIX SERVICE MANUAL 2600 STALL WARNING 5 AMP TALL WARNING ANTI COLLISION 10 AMP 20 TERMINAL 8 3 PA 32R 300 SERIAL NOS 32R 7680001 TO 32 R 7880068 PA 32R 300 SERIAL NOS 32R 7680001 TO 32R 7880...

Page 633: ...PressureHeadHeat 2601 18 O 2 A FUEL PUMP 1 0 AM P O2 D 18 FUEL PA 32R 300 SERIAL NOS 32 R 7680001 TO 32 R 788006 Figure 10 64 Fuel Pump STROBE 5 BEACON L4 ANTI COLLISION 1O 10 AMP L4E SWITCH POWER 7...

Page 634: ...TS 5 AMP NAVIGATION LIGHTS 7 5 AMP CONSOLE LIGHTS NOTE USED ON PA 32R 300 SERIAL NOS 32R 76S0392 TO 32 R 780063 INSTRUMENT LIGHTS DIMMER 0 PA 32R 300 SERIAL NOS 32R 7680001 TO 32R 7810068 Figure 10 66...

Page 635: ...H ON LATER MODELS 3 AUTOMATICGEARDOWNACTUATOR SWITCIH SHOWNIN LOWAIRSPEED POSITION 4 REPLACES FLASHER LOCATED BETWEEN WIRES G5C G5D ON S N 32R 7880C33 TO32R 7880068 5 WIRE G3H G2F C2D G2H MOVED TC TER...

Page 636: ...HTS BAGGAGE LIGHT CIGAR 1632 1632 I TO STARTERSWITCH TO STARTER SWITCH LIGHTS PA 32R 300 SERIAL NOS 32R 7880001 TO 32R 7880068 Figure 10 68 Forward BaggageLight INTENTIONALLY LEFT BLANK Revised 8 3 81...

Page 637: ...ionics Master Switch optional I B197 iPIPER CHEROKEE SIX SERVICE MANUAL ELECTRICAL SYSTEMBUS B195 OFF ON OPTIONAL AVIONICS MASTER SWITCH EMERGENCY AVIONICS BUS SWITCH AVIONICS BUS PA 32 300 32 8040001...

Page 638: ...KEE SIX SERVICE MANUAL AC AIR BLOWER Figure 10 73 A C Air Blower Figure 10 74 Anti Collision Wings and Fin Strobe FIN STROBE PA 32 300 SERIAL NO 32 7940275 AND UP Figure 10 75 Anti Collision Fin Strob...

Page 639: ...B195 PIPER CHEROKEE SIX SERVICE MANUAL ENGINE INSTR 5 AMP Figure 10 76 Engine Gauges ELECTRICAL SYSTEM Added 12 4 79 3F3...

Page 640: ...3F4 THRU 3F6 INTENTIONALLY LEFT BLANK...

Page 641: ...5 Battery Removal and Installation NARCO 3F10 I 1 6 Testing Emergency Locator Transmitter 3F12 11 7 Pilot s Remote Switch 3F14 11 8 Testing Pilot s Remote Switch 3F14 11 9 Inadvertent Activation 3F15...

Page 642: ...replacement options if any As of the 2006 revision Artex Aircraft Supplies 14405 Keil Rd NE Aurora OR 97022 www artex net offered a line of replacement batteries Alternatively installation of a new a...

Page 643: ...the end cap screws n Place transmitter into its mounting bracket replace rear mounting bracket by pushing plastic knob into place o Connect the pilot s remote switch harness to the transmitter p Conne...

Page 644: ...so that a water tight seal will be retained Do not remove this sealant h Connect new battery pack terminals to the bottom of the circuit board i Reinsert the control head section into battery pack be...

Page 645: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 XI ELECTRONICS 3F11 Figure 11 3 ELT Portable Folding Antenna Narco Figure 11 4 ELT Using Fixed Aircraft Antenna Narco...

Page 646: ...N The transmitter operates on the emergency frequencies of 121 5 and 243 MHz both of these frequencies are monitored by the various FAA installations Permission should be obtained from the FAA FCC Rep...

Page 647: ...eceiver and or control tower During cold weather there may be a slight delay before transmission occurs d A transmitter which is functioning properly should emit a characteristic downward swept tone e...

Page 648: ...her reasons move the switch upward to the ON RESET position and leave it in that position as long as transmission is desired CAUTION Under normal conditions the switch must be set to ARM 11 8 TESTING...

Page 649: ...d that the ELT be replaced at the earliest opportunity after inadvertent activation Note however that the problem may not be in the transmitter Check the following 1 Proper spacing of antennas so as t...

Page 650: ...hich secure the antenna to the radome assembly and remove the antenna 1l 13 ANTENNA INSTALLATION a Secure the antenna and gasket assembly to the radome with the appropriate screws and washers b Place...

Page 651: ...l manufacturer of the A F C S equipment installed in any particular airplane This includes mechanical service such as adjusting bridle cable tension servo removal installation servo clutch adjustments...

Page 652: ...to correctly identify the AutoPilot system by faceplate model name in ordertoconsulttheappropriateservice manual Each manual identifies the revision level and revision status as called out on the Mas...

Page 653: ...et from the panel If so correct the tray rack installation before proceeding NOTE The high insertion forces required to seat a unit with high density connectors tend to limit the effectiveness of the...

Page 654: ...PIPER CHEROKEE SIX SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3F20...

Page 655: ...2 3 12 4 General Description Heater Maintenance Overhead Vent Blower 12 5 Description 12 6 Removal of Blower Assembl 12 7 Disassembly of Blower Assembly 12 8 Reassembly of Blower Assembl 12 9 Installa...

Page 656: ...resh air for the cabin interior is picked up from air inlets in the leading edge of each wing at the intersection of the tapered and straight section and passed to outlets located beside the front and...

Page 657: ...ING SYSTEMS 1 DEFROSTEROUTLET 2 FRESHAIR INLET 3 FRESHAIR OUTLET 4 CABIN HEAT OUTLET 5 DEFROSTERAIR CONTROL 6 HEATERAIR CONTROL 7 CABIN AIR EXHAUST Figure 12 1 Cabin Heater Defroster and Fresh Air Sys...

Page 658: ...R INLET 6 HEATER AIR CONTROL 3 FRESH AIR OUTLET 7 CABIN AIR EXHAUST 4 CABIN HEAT OUTLET 1974 MODELS UP PIPER CHEROKEE SIX SERVICE MANUAL 1900 2 SERIALNOS 32 7100001 TO 32 7340191 Figure 12 2 Cabin Hea...

Page 659: ...RHEAD VENT BLOWER 4 BULKHEAD ASSEMBLY 5 OVERHEAD FRESH AIR DUCT 6 CABIN AIR EXHAUST 7 FRESH AIR OUTLET 8 DEFROSTER OUTLET 9 CABIN HEAT OUTLET 10 DEFROSTER AIR CONTROL 11 HEATER AIR CONTROL Figure 12 3...

Page 660: ...IN AIR EXHAUST 6 FRESH AIR OUTLET 7 DEFROSTER OUTLET 8 CABIN HEAT OUTLET 9 HEATER AND DEFROSTER AIR CONTROLS 10 MUFFLER AND HEAT SHROUD 11 AIR BOX 12 DEFROSTER VALVE FRESH AIR DEFROSTER AIR HEATED AIR...

Page 661: ...and nuts that secure the blower assembly to the hangar braces e Remove the screws and washers which secure the blower assembly to the retainer and hangars f Remove the blower assembly from the aircraf...

Page 662: ...and nuts h Position the hose duct on the blower assembly and secure it with screws washers and nuts The screws must be installed with their heads inside the duct i After cleaning the surfaces of all o...

Page 663: ...arness Pin Nos Ground 2 Brown Brown Low Speed Medium Speed High Speed Red 2 Black Yellow Red Black Yellow Red Orange AC26A Black White Red I Yellow Orange NOTE Pin number I is at the pointed side of t...

Page 664: ...INTENTIONALLY LEFT BLANK 3G6...

Page 665: ...INTENTIONALLY LEFT BLANK 3G7...

Page 666: ...sor to Charge the System 3G24 13 17 Addition of Partial Charge to System 3H2 13 18 Compressor Service 3H2 13 19 Compressor Removal 3H3 13 20 Compressor Installation 3H3 13 20a Compressor Mounting Brac...

Page 667: ...o 13 39 Evaporator Assembly 3H16 13 40 Evaporator Assembly Removal 3H16 13 41 Evaporator Assembly Installation 3H17 13 42 Pressure Relief Switch Ranco 3H18 13 43 Electrical Installation 3H18 13 44 Adj...

Page 668: ...mpressor is de clutched and the condenser door is automatically retracted 13 3 AIR CONDITIONING SYSTEM OPERATION The air conditioning system in this aircraft is a recirculating independent unit It fil...

Page 669: ...R DEYDRTO 10 EVAPORATOR 11 BLOWER MOTOR 12 CONDENSER 13 COVER ASSEMBL 14 BELCRRAN ASSE LY PIPER CHEROKEE SIX SERVICE MANUAL 5 SKETCH A 10 11 COMPRESSOR AND ALTERNATOR ASS Y SEE SKETCH A FREON LINES CO...

Page 670: ...asier with the knowledge that the temperature and pressure of Refrigerant 12 is in close proximity between the pressures of twenty and eighty pounds per square inch psi A glance at the temperature pre...

Page 671: ...re F 21 15 10 2 4 6 8 10 12 14 16 18 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 47 49 52 53 57 62 66 72 86 105 109 113 117 122 126 129 132 134 137 140 144 148 152 156 160...

Page 672: ...ds upon the pressure temperature relationship of pure refrigerant As long as the system contains only pure refrigerant plus a specified amount of compressor oil which is mixed with the refrigerant it...

Page 673: ...mpressor If any doubt exists about the cleanliness of the compressor oil replace it with new oil 6 Never reuse oil removed from the system Discard it 7 When Loctite Refrigerant Sealant has been used o...

Page 674: ...e valves in servicing is not recommended NOTE If a Schrader service valve is not serviceable the core assembly must be replaced 13 7 SERVICE VALVE REPLACEMENT The valves on the compressor are sealed w...

Page 675: ...anifold See Figures 13 3 and 134 The center port of the manifold set is used for charging or evacuation procedures or any other service that may be necessary Both the high and low side of the manifold...

Page 676: ...L H CLOSED CLOSED DIAGRAM A CRACKED CLOSED CLOSED CRACKED DIAGRAM C CRAC CKED DIAGRAM D Figure 13 4 Manifold Set Operation ACCESSORIES AND UTILITIES Issued 8 17 72 PIPER CHEROKEE SIX SERVICE MANUAL 3...

Page 677: ...e low side manifold valve and open the high side manifold valve d Open the refrigerant container service valve and allow the pressure at the low side gauge to reach 50 psi at which time close the high...

Page 678: ...completion of repair of any leaks proceed to check the system in accordance with one of the methods outlined for any other leaks h If no further repair is required on the system it is now ready to eva...

Page 679: ...m evacuated to remove any trapped aft and moisture which has entered it A vacuum pump capable of pulling 29 inches of mercury or better should be used As we lower the pressure in the air conditioning...

Page 680: ...f Continue to operate the vacuum pump until 26 to 28 inches of vacuum is attained on the low pressure gauge then extend the operation for another 25 minutes g If the system cannot maintain 26 to 28 i...

Page 681: ...TH A CHARGING STAND This is the preferred method of charging the systen NOTE The following instructions apply to Kent Moore J23500 charging stand Refer to Figure 13 7 a With the system discharged and...

Page 682: ...With the system evacuated as outlined in paragraph 13 13 connect the refrigerant charging hose to the manifold refer to Figure 13 8 and purge the charging hose of air b Place the refrigerant containe...

Page 683: ...ds of refrigerant does not fill the system j Shut off the air conditioning system and airplane engine Then remove the charging lines from the Schrader valves with care due to the refrigerant remaining...

Page 684: ...ation j When the sight glass stays clear of bubbles add an additional 1 4 pound of refrigerant to the system Engine should be operating at 1000 RPM NOTE This should be done with OAT at 70 F or higher...

Page 685: ...rque to 13 17 ft pounds Safety all bolts with 032 safety wire b Check the oil level in the compressor in accordance with instructions given in paragraph 13 21 c Place drive belt over clutch pulley and...

Page 686: ...d the level should not go above 12 ounces Suniso No 5 Texaco Capellae Texaco Capallae wax free Napa Temp Refrigerant Oil No 9500 or equivalent 500 viscosity refrigerant oil must be used g Reinstall th...

Page 687: ...ler assemblies if necessary and the alternator lower mounting bolts in order to install the belts e Check the belt and pulley alignment of the compressor and or alternator by the following method 1 A...

Page 688: ...INTENTIONALLY LEFT BLANK 3H6...

Page 689: ...ON FOR COMPRESSORBELT ALIGNMENT MISALIGNMENT DIMENSION CHECK NOMINAL DIMENSION FOR ALTERNATOR BELT ALIGNMENT 5 MISALIGNMENT DIMENSION CHECK STRAIGHT EDGE DATUM LINE FORWARD SURFACE OF RING GEAR DATUM...

Page 690: ...INSTL BRACKET ASSY P N 79584 2 ADD OR REMOVE SHIMS P N 62833 82 AS REQUIRED TO ALIGN IDLER IN BELT PLANE 936 POI POINT D PRESENT INSTL INSURE THERE IS POSITIVE CLEARANCE BETWEEN JAM NUT AND MOUNTING B...

Page 691: ...ting bolts are of adequate length For present installations which incorporate the new bracket assembly P N 79584 02 proceed to step h Older installations must still follow steps 1 thru 5 until the new...

Page 692: ...Only the service valves located on the evaporator assembly should be used for testing d Shut down engine and recheck both belt tensions If compressor belt tension falls as low as 60 pounds retension t...

Page 693: ...rom burrs d Slide the pulley assembly 2 over the field assembly and onto the crankshaft now torque the field assembly 85 to 120 inch pounds Then secure pulley assembly with washer and new self locking...

Page 694: ...ECEIVER DEHYDRATOR REMOVAL This unit is mounted on the inboard side of the evaporator assembly housing a Discharge the system of all refrigerant See Paragraph 13 12 b Uncouple the refrigerant lines at...

Page 695: ...embly remove the screws in the side mounting frame 13 33 CONDENSER INSTALLATION a Install the condenser core to the frame assembly with the hose fittings forward and up b Place the condenser and frame...

Page 696: ...or to the fuselage skin b Adjust side push rods so that a verticallymeasured gapof 16 of an inch existsalong the trailing edge of the door at the instant the forward edge of the door becomes flush wit...

Page 697: ...NKASSY CONDENSER 3 PUSH ROD ASSY 4 BELLCRANK ASSY MECHANISM 5 OPEN LIMITSWITCH 6 CLOSED LIMITSWITCH 7 CONDENSER 8 CONDENSER DOOR 9 PUSH ROD 10 TRANSMISSION MOTOR ASSY 944 PIPER CHEROKEE SIX SERVICE MA...

Page 698: ...ORATOR ASSEMBLY The evaporator assembly consists of the evaporator core receiver dehydrator expansion valve circulating fan and pressure switch together with necessary housing and plumbing The housing...

Page 699: ...ss hole in the bulkhead 13 41 EVAPORATOR ASSEMBLY INSTALLATION a Cement gasket in place on the flanges of the evaporator housing and attach the large end of the mounting gasket to the back of the hous...

Page 700: ...switch is located in the line between the receiver and expansion valve NOTE Before the relief switch is removed the air conditioning system must be discharged See Paragraph 13 12 13 43 ELECTRICAL INS...

Page 701: ...Head Diode Mounting Board Diode Location and Number Serial Nos 32 7240056 to 32 7340042 NOTE Control head will be replaced when needed with new parts used in aircraft Serial Nos 32 7340043 and up Refe...

Page 702: ...ER CHEROKEE SIX SERVICE MANUAL 2779 REL OPEN CLOSE OPEN LIMIT LIMIT RELAY Figure 13 16 Air Conditioning Wiring Schematic Serial Nos 32 7240056 to 32 7340042 Revised 8 14 73 ACCESSORIES AND UTILITIES 3...

Page 703: ...DITIONING FAN SWITCH IN OFF POSITION THROTTLENOTWIDE OPEN AIR CONDITIONING SWITCH IN ON DOOR POSITION FREONPRESSURE BELOW LIMIT THERMOSTAT CALL MOTOR ING FOR COOLING AND CONDENSERDOOR CLOSED 21 USEDON...

Page 704: ...9 THERMOSTAT PRESS SW COMPRESSOR CLUTCH OPEN S4 LIMIT SW OPEN 4 2 DOOR MOTOR NOTES 11 SHOWN WITH AIR CONDITIONING FAN SWITCH IN OFF POSITION THROTTLE NOT WIDE OPEN AIR CONDITIONING SWITCH IN ON POSITI...

Page 705: ...ying where harness web passes in and out of adjustable buckle end If excessively worn replace c Inspect shoulder harness keeper nylon bushing If excessively worn or missing replacement of that half of...

Page 706: ...de the operating head This interrupts the flow of extinguishant thus retaining part of the charge for dealing with a flash back or re ignition should they occur without waste or leakage A partly or to...

Page 707: ...ng on suction to suction line If line and compressor capillary bulb OK suction service valve replace expansion valve Restriction in liquid Check for kinked hoses line from condenser and stopped up fil...

Page 708: ...st its capillary by holding in charge hand If suction pressure does not charge replace expansion valve Restriction anywhere in Locate restriction and liquid line Restriction will repair show frost Hig...

Page 709: ...element defective comfort control panel Blower motor disconnected Check current flow to or burned out blower motor Repair or replace if inoperative Mechanical Loose or broken drive belt Replace drive...

Page 710: ...ver condenser coils fins clogged with dirt or bugs Evaporator filter clogged Clean with cleaning solvent to remove cigarette tars Refrigeration Insufficient refrigerant in Recharge system until in sys...

Page 711: ...lts required 13 22 and 13 23 Noisy clutch Remove clutch for service or replacement as necessary 13 24 Compressor noisy Check mountings and repair remove compressor for service or replacement 13 18 Com...

Page 712: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL XIII ACCESSORIES AND UTILITIES 07 15 06 3I6 GRIDS 3I6 THRU 3L24 INTENTIONALLY BLANK...

Page 713: ...PART NUMBER 753 690 March 27 2008 4A1 AIRPLANE SERVICE MANUAL CARD 4 OF 4 PA 32 260 PA 32 300 PA 32R 300 PIPER AIRCRAFT CORPORATION...

Page 714: ...4A2 Published by Technical Publications 1965 2008 Piper Aircraft Inc 2926 Piper Drive Vero Beach Florida 32960 U S A Member General Aviation Manufacturers Association...

Page 715: ...2 3 PR810803 August 3 1981 1 2 3 PR831104 November 4 1983 1 2 3 IR860430 April 30 1986 1 IR860730 July 30 1986 1 IR870506 July 12 1987 1 PR060715 July 15 2006 1 2 3 4 PR080327 March 27 2008 1 2 3 4 PA...

Page 716: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL AEROFICHE EFFECTIVITY 07 15 06 4A4 THIS PAGE INTENTIONALLY BLANK...

Page 717: ...on 4A9 Assignment of Subject Material 4A9 Pagination 4A9 Aerofiche Effectivity 4A9 Identifying Revised Material 4A10 Indexing 4A10 Warnings Cautions and Notes 4A10 Accident Incident Reporting 4A10 Sup...

Page 718: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL INTRODUCTION TABLE OF CONTENTS 07 15 06 4A6 THIS PAGE INTENTIONALLY BLANK...

Page 719: ...e a special application is required To confirm the correct hardware used refer to the PA 32 260 300 PA 32R 300 Parts Catalog P N 753 689 and FAR 43 for proper utilization Genuine PIPER parts are produ...

Page 720: ...7100001 thru 32 7100028 1971 Cherokee Six 260 E 32 7200001 thru 32 7200045 1972 32 7300001 thru 32 7300065 1973 32 7400001 thru 32 7400051 1974 32 7500001 thru 32 7500043 1975 32 7600001 thru 32 7600...

Page 721: ...the set The Aerofiche Effectivity page at the front of this manual lists the current revision for each card in this set B Conversion of Aerofiche alpha numeric grid code numbers First number is the A...

Page 722: ...ction begins with an individual Table of Contents 10 Warnings Cautions and Notes These adjuncts to the text are used to highlight or emphasize important points when necessary Warnings call attention t...

Page 723: ...AIRCRAFT UNAIRWORTHY 1 AIR CONDITIONING COMPRESSOR Vendor Address Climate Control Inc PH 217 422 0055 2120 North 22nd Street FAX 217 422 4323 Decatur Illinois 62526 2 AIR CONDITIONING EVAPORATORS AND...

Page 724: ...ndor Address Lycoming Engines PH 717 323 6181 652 Oliver Street FAX 717 327 7101 Williamsport PA 17701 http www lycoming com Overhaul Manual DIRECT DRIVE MODELS P N 60294 7 Parts Catalog O 540 B E and...

Page 725: ...ww whelen com 13 MAGNETOS Vendor Address Teledyne Continental Motors PH 251 438 3411 P O Box 90 800 718 3411 Mobile AL 36601 FAX 251 432 7352 http www tcmlink com Service Support Manual S 1200 Series...

Page 726: ...al No 113B Aluminum Blade Overhaul Manual No 133C Propeller Owner s Manual and Logbook Manual No 115N 15 PROPELLER GOVERNOR Vendor Address See listing under Propeller Hartzell above Governor Maintenan...

Page 727: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 INTRODUCTION 4A15 THIS PAGE INTENTIONALLY BLANK...

Page 728: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL INTRODUCTION 07 15 06 4A16 THIS PAGE INTENTIONALLY BLANK...

Page 729: ...TION 4C1 IV STRUCTURES 1E1 V SURFACE CONTROLS 1G11 VA HYDRAULIC SYSTEM PA 32R 300 1I22 VI LANDING GEAR AND BRAKES PA 32 260 300 2A8 VIA LANDING GEAR AND BRAKES PA 32R 300 2C5 VII POWERPLANT PA 32 260...

Page 730: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL INTRODUCTION 07 15 06 4A18 GRIDS 4A18 THRU 4A24 INTENTIONALLY BLANK...

Page 731: ...Engine Oil Cooler Check 4F1 3 11 Main Landing Gear Torque Link Greaser Bolt Inspection 4F3 3 12 Stabilator Attach Brackets 4F7 3 13 Left Fuselage Frame 4F9 3 14 Engine Mount 4F11 3 15 Aft Wing Attach...

Page 732: ...X LANCE SERVICE MANUAL LIST OF TABLES 07 15 06 4B2 III I Inspection Report PA 32 260 and 300 4C17 III II Inspection Report PA 32R 300 4D7 III III Service Publication List 4I1 LIST OF TABLES Table Aero...

Page 733: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 LIST OF TABLES 4B3 THIS PAGE INTENTIONALLY BLANK...

Page 734: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL LIST OF TABLES 07 15 06 4B4 GRIDS 4B4 THRU 4B24 INTENTIONALLY BLANK...

Page 735: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 4C1 SECTION III INSPECTION...

Page 736: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 4C2 THIS PAGE INTENTIONALLY BLANK...

Page 737: ...C17 Cabin and Cockpit Group 4C19 Fuselage and Empennage Group 4C20 Wing Group 4C22 Landing Gear Group 4C23 Float Group 4C24 Special Inspections 4C24 Operational Inspection 4C24 General 4D1 Notes 4D2 I...

Page 738: ...Landing Gear Torque Link Greaser Bolt Inspection 4F2 Fuel Quantity Sender Check 4F2 Wing Spar Inspection PA 32 260 300 Only 4F3 Stabilator Attach Brackets Corrosion Inspection 4F7 Left Fuselage Frame...

Page 739: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III TABLE OF CONTENTS 4C5 THIS PAGE INTENTIONALLY BLANK...

Page 740: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III TABLE OF CONTENTS 07 15 06 4C6 THIS PAGE INTENTIONALLY BLANK...

Page 741: ...the registered owner s is responsible for forwarding these Bulletins and Letters to the operating location s or person s Changes in aircraft registration may take a substantial amount of time to be re...

Page 742: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4C8 THIS PAGE INTENTIONALLY BLANK...

Page 743: ...ctural inspection procedure required for type certification 2 Refer to paragraph 8 for Piper s recommended Inspection Programs They include the frequency and extent of the inspections required for the...

Page 744: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4C10 THIS PAGE INTENTIONALLY BLANK...

Page 745: ...cement of components should be performed at the given periods The condition of various components can then be used as criteria for determining subsequent periods applicable to the individual airplane...

Page 746: ...individual performing the test E Bench Test Means removal of component from the aircraft to inspect for cleanliness impending failure need for lubrication repair or replacement of parts and calibrati...

Page 747: ...the aircraft time that elapses from each subsequent installation to each subsequent removal if any or c the calendar time elapsed since the installation NOTE Dates stamped on individual components at...

Page 748: ...be available from Piper Dealers P N 767 019 for the Piper PA 32 260 300 S N s 32 1 up and P N 767 018 for the Piper PA 32R 300 S N s 32R 7680003 up Refer to Piper s Customer Service Information Aerof...

Page 749: ...ll be listed as a special inspection below 2 Refer to the applicable section of this manual for instructions on how to gain access to remove any item that must be removed and is not completely accessi...

Page 750: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4C16 THIS PAGE INTENTIONALLY BLANK...

Page 751: ...nstant speed propeller installed inspect hub parts for cracks and corrosion See Note 31 O 9 If constant speed propeller installed rotate blades and check for tightness in hub pilot tube Refer to Secti...

Page 752: ...age and continuity O 17 Inspect magneto points for proper clearance Maintain clearance at 0 018 006 for 20 and 200 series 0 016 for 1200 series O 18 Inspect magnetos for oil seal leakage See Note 28 O...

Page 753: ...ty of alternator and mounting O 45 Inspect engine mounted accessories for condition and security O 46 Inspect condition and tension of alternator drive belt See Checking Alternator Belt Tension Sectio...

Page 754: ...nd 91 413 respectively O 17 Inspect and test ELT per FAR 91 207 See Testing ELT Section XI O 18 Inspect operation of fuel selector valve See Note 29 O 19 Inspect fuel valve drain lever cover for secur...

Page 755: ...nts corrosion and excessive paint build up structural defects i e loose or missing rivets misrigging or structural imbalance hinge damage excessive wear freedom of movement and proper lubrication and...

Page 756: ...spection plates and fairings O 2 Inspect wing surfaces and tips for damage loose rivets and condition of walkway O 3 Inspect ailerons for surface damage or irregularities i e skin cracks distortion de...

Page 757: ...ce of fluid leakage See Landing Gear System Section II O O 2 Inspect nose gear steering control and travel O 3 Remove wheel fairings O 4 Inspect wheel alignment O 5 Put airplane on jacks Refer to Sect...

Page 758: ...oil pressure and temperature O O 4 Check alternator output O O 5 Check manifold pressure O O 6 Check carburetor heat alternate air O O 7 Check parking brake O O 8 Check vacuum gauge O O 9 Check gyros...

Page 759: ...tions complied with See Table III III O O 4 Current and correct Pilot s Operating Handbook or Airplane Flight Manual is in the airplane O O 5 Appropriate entries made in the Aircraft and Engine Log bo...

Page 760: ...hould be made upon completion of any inspections 3 Piper Service Bulletins are of special importance and Piper considers compliance mandatory In all cases see Service Bulletin Service Letter Index P N...

Page 761: ...nks not approved For airplanes with fuel tanks which have previously been sloshed perform Sloshed Fuel Tank 100 Hour Inspection in Section VIII 15 Refer to Pilot s Operating Manual POM Pilot s Operati...

Page 762: ...accumulated 500 hours time in service or more inspect vacuum pump vane wear per Vacuum Pump Vane Wear Inspection see Special Inspections Procedures 28 Inspect magnetos a For airplanes equipped with S...

Page 763: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4D5 THIS PAGE INTENTIONALLY BLANK...

Page 764: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4D6 THIS PAGE INTENTIONALLY BLANK...

Page 765: ...and check for tightness in hub pilot tube O 9 Inspect complete propeller and spinner assembly for security chafing cracks deterioration wear and correct installation O B ENGINE GROUP WARNING IF MAGNE...

Page 766: ...24 O 19 Inspect breaker felts for proper lubrication O 20 Inspect magneto to engine timing O 21 Remove air filter and clean per Paragraph 7A 16 Replace as required O O 22 Inspect air induction system...

Page 767: ...ng See Note 9 O 48 If installed inspect A C compressor mounting for cracks corrosion and security O 49 Check fluid in brake reservoir Fill as required O O 50 Inspect and lubricate all engine controls...

Page 768: ...plates and panels O 2 Inspect aft wing attach fittings per Aft Wing Attach Fittings 100 Hour Inspection See Special Inspections Procedures O 3 Inspect fwd baggage door latch and hinge for damage opera...

Page 769: ...for surface damage or irregularities i e skin cracks distortion dents corrosion and excessive paint build up structural defects i e loose or missing rivets misrigging or structural imbalance hinge da...

Page 770: ...ge pins for condition and security O 5 Inspect aileron control stops to ensure stops have not loosened and locknuts are tight O 6 Inspect aileron cables and cable terminals turnbuckles fittings guides...

Page 771: ...ition and wear See Paragraph 6 31 O 10 Inspect brake backing plates for condition and wear O 11 Inspect brake and hydraulic lines for condition and security O 12 Inspect shimmy dampener operation O 13...

Page 772: ...n O O 19 If installed check operation of Autopilot including automatic pitch trim and manual electric trim See Note 16 O O 20 If installed check air conditioner compressor clutch operation O O 21 If i...

Page 773: ...ould be made upon completion of any inspections 3 Piper Service Bulletins are of special importance and Piper considers compliance mandatory In all cases see Service Bulletin Service Letter Index P N...

Page 774: ...I 15 Refer to Section 4 of the Pilot s Operating Handbook for preflight and flight check list 16 Refer to Pilot s Operating Handbook Supplement for preflight and flight check and for intended function...

Page 775: ...TCM Bendix Magnetos inspect magneto s per the procedures in the Periodic Maintenance section of the applicable Service Support Manual available from Teledyne Continental Motors Inc PH 800 718 3411 or...

Page 776: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4D18 THIS PAGE INTENTIONALLY BLANK...

Page 777: ...day before the first flight and after the last flight perform Daily Engine Oil Cooler Leak Check Inspection see Special Inspections Procedures Each 10 Hours In PA 32 260 S N s 32 1 thru 32 7500039 an...

Page 778: ...in Landing Gear Torque Link Greaser Bolt Inspection see Special Inspections Procedures In PA 32 260 S N s 32 1 thru 32 7800008 and PA 32 300 S N s 32 40000 thru 32 7840202 for those airplanes which ha...

Page 779: ...first remove interior cabinets panels and headliner and conduct detailed inspection of aircraft structure skin bulkheads stringers etc for condition and security Inspection of structure concealed by h...

Page 780: ...y for airplanes in Usage Class A i e normal usage beginning at 30 600 hours total time in service and each 3000 hours thereafter conduct Wing Spar Inspection see Special Inspections Procedures NOTE In...

Page 781: ...fuel senders Piper P N 68101 002V each 500 hours or annually whichever comes first perform Fuel Quantity Sender Check see Special Inspections Procedures Lubricate Hartzell constant speed propeller eve...

Page 782: ...l tank removal whichever comes first Each 2000 hours or seven 7 years whichever occurs first remove interior cabinets panels and headliner and conduct detailed inspection of aircraft structure skin bu...

Page 783: ...and Inspect and replace if necessary 100 Hours Instrument Air Filters Pitot Static system Check for obstruction Reverse 100 Hours or flow to lines as required Landing Gear Oleos Clean Before each flig...

Page 784: ...time complete revolutions and Each 30 days fly aircraft for 30 minutes each 30 days or ground run until oil temperature is in the green arc Avoid excessive ground run Engines with less than Each day p...

Page 785: ...liness and lubrication Wheels Inspect for cracks damage chipped 100 Hours rims bearings for damage corrosion and lubrication Tires Inspect for cuts wear inflation and Daily deterioration Wheel Wells I...

Page 786: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4E4 THIS PAGE INTENTIONALLY BLANK...

Page 787: ...heat muffs shrouds heat blankets etc as required to permit inspection of the complete system Perform the necessary cleaning operations and inspect all external surfaces for dents cracks and missing pa...

Page 788: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4E6 Figure 3 1 Typical Muffler Fatigue Areas...

Page 789: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4E7 Figure 3 2 Exhaust System Inspection Points...

Page 790: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4E8 Figure 3 2 Exhaust System Inspection Points cont...

Page 791: ...rim wheel cover 3 Remove flap handle mounting bracket attachment bolts 4 Raise flap handle and bracket assembly to gain access to the control cable attachment bolt 5 Remove and inspect cable attachmen...

Page 792: ...bolt 6 Remove and inspect cable attachment bolt for possible wear If an AN23 10 bolt is installed or if wear is detected replace existing bolt with new Clevis Bolt AN23 11 Piper Part Number 400 673 7...

Page 793: ...beginning at 800 hours and each 500 hours thereafter inspect as follows a Inspect each main landing gear torque link for cracks in areas shown in Figure 3 4 These cracks may form just behind the larg...

Page 794: ...USE ANY COMMERCIAL PAINT REMOVER OR CAUSTIC SODA TO REMOVE PAINT WASH PART IN GASOLINE TO REMOVE ANY WAX g Inspect tube for cracks in this area by use of the dye penetrant method 1 Should cracks be de...

Page 795: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4E13 Figure 3 5 Stabilator Balance Weight Tube Assembly Inspection...

Page 796: ...rols to ensure freedom of movement and that stabilator contacts both upper and lower stops n Install bulkhead close out plate and tail cone assembly o Make proper log book entry 6 AILERON HINGE DOUBLE...

Page 797: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4E15 Figure 3 6 Aileron Hinge Doubler 100 Inspection...

Page 798: ...an be installed simply to relieve this repetitive inspection requirement even though no cracks have been detected Keep in mind however that a general visual inspection of the rudder bar assembly for c...

Page 799: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4E17 Figure 3 7 Rudder Bar Assembly 100 Inspection...

Page 800: ...quick disconnect mechanism for each rear seat as follows 1 With one hand grasp the lower rear portion of the seat and lift up 2 The rear seat legs should disengage from the retention mechanism with a...

Page 801: ...t WARNING OBSERVE ALL SAFETY PRECAUTIONS REQUIRED WHEN HANDLING GASOLINE a Position aircraft on relatively level ground with a minimum of one 1 gallon in each tank Drain fuel tank sumps and fuel selec...

Page 802: ...OUR CONTROL WHEEL INSPECTION NOTE Installation of ram s horn control wheels P N 78729 002 75 inch dia shaft or 79276 000 1 25 inch dia shaft eliminates this repetitive inspection requirement In PA 32...

Page 803: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4E21 Figure 3 9 Control Wheel Inspection...

Page 804: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4E22 THIS PAGE INTENTIONALLY BLANK...

Page 805: ...t the cooler end fins especially the fins adjacent to the hose connection boss If there is evidence of oil seepage wipe clean with a rag and observe if oil seepage continues in the root of the fins or...

Page 806: ...normal operating temperature by conducting this inspection immediately after a flight or a ground run Remove top cowling b Inspect coolers visually for signs of leakage paying particular attention to...

Page 807: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4F1 Figure 3 10 Engine Oil Cooler Inspection...

Page 808: ...Sketch A Piper recommends they be replaced even if no cracks are found 2 When replacing bolts shown in Sketch B replace with P N 79543 002 e If the struts were deflated above re inflate the struts per...

Page 809: ...ed on more than five hundred 500 inspections of PA 28 and PA 32 airplanes with more than 5000 hours total time in service and extensive wing fatigue and fracture analysis by Piper the following inspec...

Page 810: ...the airplane s operating history it is recommended that the initial inspection be conducted in accordance with the Next 50 Hours inspection requirement below b Usage Class B Severe Aircraft which have...

Page 811: ...next 50 hours time in service 2 Inspection Requirements a Next 50 Hours For airplanes in Usage Class D i e UNKNOWN usage conduct Wing Spar Inspection and establish usage class for next inspection base...

Page 812: ...in the wing lower spar cap from the wing skin line outboard of the outboard row of wing attach bolt holes to an area midway between the second and third row of bolt holes from the outboard row 1 If n...

Page 813: ...s c Inspect the steel attach fittings 4 places for the stabilator and adjacent fuselage structure for the presence of rust and or corrosion See Figure 3 12 d If rust and or corrosion is present repair...

Page 814: ...stic cover located on the floor just in front of the pilot seat tracks and remove surrounding carpeting to gain access to the Station 73 04 fuselage frame assembly c Using a dye penetrant method inspe...

Page 815: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4F9 Figure 3 13 Left Fuselage Frame...

Page 816: ...n the engine mount firewall or airframe structure they must be repaired and Piper Kit No 766 253 must be installed PRIOR TO FURTHER FLIGHT h Minor cracks in the engine mount may be repaired on the air...

Page 817: ...lation around the aft wing attach fittings creating a highly corrosive environment b Procedure Each 100 hours inspect to determine condition of the aircraft window and door seals the condition of the...

Page 818: ...flight See paragraph 4 7a 3 Upon completion of the inspection and after replacement or refurbishment of fittings treat the aft attach fittings area using DINOL AV 8 corrosion compound P N 89500 800 T...

Page 819: ...rated Parts Catalog P N 753 689 for replacement part numbers and obtain and install new parts before continued operation 5 If sealing windows use P N 279 058 Sealant Bostik 1100 FS or equivalent 6 If...

Page 820: ...rts and methods A1 Inspect the entire spar and all spar angles behind each fuel tank with special attention to the area of the inboard upper and lower spar caps If corrosion is detected accomplish a t...

Page 821: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4F15 Figure 3 17 Fuel Tank Corrosion Inspection PA 32 32R EARLY...

Page 822: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4F16 Figure 3 18 Fuel Tank Corrosion Inspection PA 32 32R LATE...

Page 823: ...cracks Ref Figure 3 19 If no cracks are found by visual inspection proceed to Liquid Penetrant Inspection per latest revision of AC 43 13 1 to check for cracks Strip the paint and primer from the area...

Page 824: ...annually whichever comes first time in service 1 Place the airplane on jacks per Section II 2 In both the right and left wings a Inspect the Aft Rib Assembly at W S 49 25 for any evidence of cracks s...

Page 825: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4F19 Figure 3 20 Wing Rib Inspection...

Page 826: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4F20 Figure 3 21 Wing Rib Date Stamp...

Page 827: ...cracked Rib Assembly 4 If no cracks are detected reassemble reinstall any parts or components previously removed 5 Verify proper functioning of landing gear 6 Verify gear are down and locked and remov...

Page 828: ...for evidence of distortion a If the paint is cracked or peeling anywhere along the torque tube arm or pushrod torsional movement has occurred b Remove the paint and inspect for cracks 1 In the welds a...

Page 829: ...tion which passes over a pulley or through a fairlead remove cable from aircraft to the extent necessary to expose that particular section Examine cables for broken wires by passing a cloth along leng...

Page 830: ...worn 40 50 percent as depicted in Figure 3 23 c Internal Cable Wear As wear is taking place on the exterior surface of a cable the same condition is taking place internally particularly in the sectio...

Page 831: ...apors and liquids can accumulate NOTE Check all exposed sections of cable for corrosion after a cleaning and or metal brightening operation has been accomplished in that area e Cable Maintenance CAUTI...

Page 832: ...able or fitting Any evidence of corrosion or cracking however minute is cause for replacement A logbook entry documenting the replacement of a cable terminal turnbuckle or other cable fitting relieves...

Page 833: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4G3 Figure 3 25 Pulley Wear Patterns...

Page 834: ...e thru each inspection hole and feed it up to the high point of the engine mount tube 3 Using a syringe inserted into the end of the plastic tube pump linseed oil into the upper end of the engine moun...

Page 835: ...time in service each 100 hours thereafter inspect vacuum pump vane wear as follows a Remove the inspection port plug and observe vane wear as shown in Figure 3 26 b As vanes wear they slide outboard i...

Page 836: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4G6 GRIDS 4G6 THRU 4G24 INTENTIONALLY BLANK...

Page 837: ...light latest revision of Hartzell Manual No 115N McCauley Propellers see latest revision of McCauley SB 177 Engine See latest revisions of appropriate Each occurrence Lycoming Service Bulletins before...

Page 838: ...ine Mount and Inspect for distortion and Each occurrence Attachments damage Replace or repair before further flight as required C Severe Turbulence Hard or Overweight Landing CAUTION MINOR OR APPARENT...

Page 839: ...and overstress Upper and lower wing before further flight skins for wrinkles cracks popped or loose rivets Remove access plates and inspect for internal damage to ribs stringers and sparwebs and fuel...

Page 840: ...e Manual procedures If there are any questions regarding repairs or procedures contact your Piper Dealer s Service Advisor DSA C Determine the water level on the aircraft Determine which operating and...

Page 841: ...Engine Remove disassemble and inspect If immersed each event Examine all parts paying particular before further flight attention for evidence of corrosion rust or contaminants imbedded on bearing sur...

Page 842: ...eplace battery Disassemble all connectors clean and inspect for corrosion Replace all corroded or pitted connectors Inspect for wire corrosion at connector Check all harness assemblies for entrapped c...

Page 843: ...nspect all heat shrouds and ducting Fuel System Perform Fuel Tank Wing Spar Corrosion If immersed each event Inspection Special Inspections Procedures before further flight Remove and clean fuel cells...

Page 844: ...Interval Avionics Systems Replace avionics If immersed each event before further flight Clean and inspect antennas and connectors Insulation and Upholstery Remove all wet insulation and upholstery If...

Page 845: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4H9 THIS PAGE INTENTIONALLY BLANK...

Page 846: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4H10 GRIDS 4H10 THRU 4H24 INTENTIONALLY BLANK...

Page 847: ...Mod 1965 1966 SB 233 Brake Disc Assembly SB 239 757 095 Windshield Collars Replacement SB 240 Balance Weight Assembly Corrosion Inspection SB 259 Storm Window Placard SB 285 760 251V Fuel Selector Con...

Page 848: ...olator SB SB 1026 Dry Air Pump Flexible Couplings Inspection SB 1041 Airborne Air Filter Elements Inspec Cleaning SL 566 Autopilot Servo Spacer Bushing Installation SL 612A Fuel Leakage Fuel Sender Un...

Page 849: ...SL 836 Narco ADF 140 141 Antenna Inspec Mod 1976 1977 SB 541 Throttle Attachment Inspection SB 565 Horizontal Situation Indicator Edo Aire Mod 1977 SB 538 Engine Control Cable Inspection SB 543 Starte...

Page 850: ...duction Air Filter Inspec Purolator SB SB 1026 Dry Air Pump Flexible Couplings Inspection SB 1041 Airborne Air Filter Elements Inspec Cleaning SB 1134 Servo Metered Fuel Pressure Port Leakage SL 566 A...

Page 851: ...Dimmer Control Assembly Mod 1974 1976 SB 519A Fuel Selector Valve Inspection and Replacement SL 756 Dual Glideslope Indicator Placard SL 762 761 009V ELT Remote Switches Modification 1975 SB 449A Alte...

Page 852: ...186 Ammeter Replacement SB 896 Shoulder Harness Installation Usage SB 1022 Induction Air Filter Inspec Purolator SB SB 1023 Landing Gear Cylinders Inspec Parker Hannifin SB SB 1026 Dry Air Pump Flexib...

Page 853: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL 07 15 06 III INSPECTION 4I7 THIS PAGE INTENTIONALLY BLANK...

Page 854: ...PIPER CHEROKEE SIX LANCE SERVICE MANUAL III INSPECTION 07 15 06 4I8 GRIDS 4I8 THRU 4L24 INTENTIONALLY BLANK...

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