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Piper PA-28-161, Maintenance Manual

The Piper PA-28-161 Maintenance Manual is a comprehensive guide for maintaining and servicing the aircraft. This manual covers all aspects of maintenance and provides detailed instructions for proper care. Download the manual for free from manualshive.com to ensure your aircraft stays in top condition.

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PIPER AIRCRAFT, INC.

PA-28-161, WARRIOR III

MAINTENANCE MANUAL

PAGE 3

Nov 30/06

2B3

INDEX

Fuel System (continued)

Fuel Tanks

Components: 2J17

Gascolator: 2K1
Inspection

Fuel Tank / Wing Spar

Corrosion Inspection:
2J17

Troubleshooting: 2J13

Fuselage Stations: 1E21

G

GMA-340

Adjustment: 2D4
Audio Panel: 2D3
Functional Test: 2D3
Removal and Installation: 2D3

H

Hose Markings: 1J13
Hoses, Flexible

Specifications: 5G14

I

Ice and Rain Protection: 3C7
Ignition System

Description: 5C7
Ignition Harness: 5D3
Magnetos: 5C9

100 Hour Inspection: 5C9
500 Hour Inspection and

Cleaning: 5C11

Testing: 5C23
Timing to Engine: 5C9
Troubleshooting: 5C8

Spark Plugs: 5D8

Coupling Torque: 5D9
Inspection And Cleaning: 5D9

Inspections

Access Provisions: 1E22
Definitions: 1C19
Per Calendar Year: 1D14

Inspections (continued)

Per Event

Engine: 1E2

Loss of Oil: 1E2
Overtemp: 1E2
Sudden Stoppage: 1E2

Flaps Extended Above Max

Speed: 1E3

Flood Damage: 1E4
Hard or Overweight Landing:

1E2

Lightning Strike: 1E1
Severe Turbulence: 1E2

Per Flight Hour: 1D13
Per Specific Operation /

Operating Environment

Extreme Cold: 1D17
High Dust or Industrial

Pollution: 1D16

High Salt or High Humidity:

1D17

Soft or Unusual Terrain: 1D18

Procedure

Aft Wing Attach Fittings 100

Hour: 4E13

Control Cable Fittings: 2G15
Corrosion: 4C13
Flap Torque Tube/Push Rod:

2I24

Magnetos

100 Hour: 5C9
500 Hour: 5C11

Propeller: 1I8
Requirements: 1C21

Annual / 100 Hour Inspection:

1C21

Procedure: 1C22

Overlimits Inspection: 1C21
Progressive Inspection: 1C21

Special: 1D13
Unscheduled: 1E1

Instruments

Face-Mounted: 3J17
Rack-Mounted: 3J17

Introduction: 1A9

J

Jacking: 1F7

L

Landing Gear

Main

Installation: 3D21
Lubrication Chart: 1I16
Oleo Strut: 3D18

Nose

Alignment: 3E6

Tolerances: 3E7

Installation: 3E5
Lubrication Chart: 1I17
Oleo Strut: 3E3

Oleo Struts

Filling

Main Gear: 1I2
Nose Gear: 1I1

Inflating: 1I3
Servicing: 1I1

Repair: 3D17, 3D20, 3E2, 3E6
Troubleshooting: 3D14

Leading Particulars: 1E18
Leveling Airplane: 1F17
Life Limited Parts: 1C7
Lifting: 1F7
Lights

Exterior: 3F15

Landing/Taxi Light: 3F15
Navigation Lights: 3F15
Strobe Lights: 3F16

Fin Tip: 3F17
Power Supply: 3F17
Troubleshooting: 3F20
Wing Tip: 3F16

Interior: 3F11

Annunciator Panel Lights:

3F11

Dimmer Control: 3F11
Flood/Map Light: 3F9
Instrument and Panel: 3F11

Lamp Replacement: 3F9

Line Markings: 1J13
Locking Airplane: 1G11

Summary of Contents for PA-28-161

Page 1: ...PART NUMBER 761 882 November 30 2006 1A1 AIRPLANE MAINTENANCE MANUAL CARD 1 OF 5 PA 28 161 S N s 2842001 UP PIPER AIRCRAFT INC...

Page 2: ...1A2 Published by Technical Publications Piper Aircraft Inc 2926 Piper Drive Vero Beach Florida 32960 U S A Member General Aviation Manufacturers Association...

Page 3: ...80301 March 1 1998 All PR011215 December 15 2001 1 PR030720 July 20 2003 1 and 2 CR040415 April 15 2004 All PR040818 August 18 2004 1 3 4 and 5 CR061130 November 30 2006 1 2 3 4 and 5 COMPLETE REVISIO...

Page 4: ...PAGE 2 Nov 30 06 AEROFICHE EFFECTIVITY 1A4 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 5: ...1 Nov 30 06 Effective Pages 2 Nov 30 06 Intro Table of Contents 1 Nov 30 06 2 Nov 30 06 Introduction 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9...

Page 6: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 INTRO LIST OF EFFECTIVE PAGES THIS PAGE INTENTIONALLY BLANK 1A6...

Page 7: ...ivity 2 1A10 Serial Number Explanation 2 1A10 Assignment of Subject Material 2 1A10 Pagination 3 1A11 Aerofiche Effectivity 3 1A11 Identifying Revised Material 3 1A11 Indexing 3 1A11 List of Effective...

Page 8: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1A8 INTRO CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 9: ...IR OF PIPER AIRPLANES This manual generally does not contain hardware callouts for installation Hardware callouts are only indicated where a special application is required To confirm the correct hard...

Page 10: ...tems such as Environmental Systems Electrical Power Landing Gear etc They are assigned a number which becomes the first element of the standardized numbering system Thus the element 28 of the number 2...

Page 11: ...all fiche in this set 2 A complete subject Index for all fiche in this set 8 Identifying Revised Material A revision to a page is defined as any change to the printed matter that existed previously Re...

Page 12: ...essive Inspection Manual pending 767 002 B Vendor Publications WARNING FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION S WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT MAY...

Page 13: ...or PH 800 998 8857 7 FIRE EXTINGUISHER PORTABLE Vendor H3R Inc PH 800 249 4289 43 Magnolia Ave 4 San Francisco California 94123 2911 http www h3r com index htm 8 FUEL PUMP Vendor Weldon Pumps PH 440...

Page 14: ...Wichita KS 67226 http www mcico com index html Installation Manual and Operating Instructions Manual No 9015762 14 STARTER Vendor Sky Tec PH 800 476 7896 350 Howard Clemmons Rd FAX 817 573 2252 Granb...

Page 15: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 1A15 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 16: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 1A16 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 17: ...bined with another chapter CHAPTER SECTION TITLE GRID NO 4 AIRWORTHINESS LIMITATIONS 1C1 00 Airworthiness Limitations 5 TIME LIMITS MAINTENANCE CHECKS 1C9 00 General 10 Time Limits 20 Scheduled Mainte...

Page 18: ...23 COMMUNICATIONS 2C19 00 General 50 Audio Integrating 60 Static Discharging 24 ELECTRICAL POWER 2D9 00 General 30 DC Generation 40 External Power 50 Electrical Load Distribution 25 EQUIPMENT FURNISH...

Page 19: ...l 10 Flight Compartment 40 Exterior 34 NAVIGATION AND PITOT STATIC 3G1 10 Flight Environmental Data 20 Attitude and Direction 37 VACUUM 3I11 00 General 10 Distribution 20 Indicating 39 ELECTRICAL ELEC...

Page 20: ...ary Structure 40 Attach Fittings 50 Flight Surfaces 61 PROPELLER 4H21 10 Propeller Assembly 70 STANDARD PRACTICES ENGINE 4I9 00 General 71 POWER PLANT 4I17 00 General 10 Cowling 20 Mounts 60 Air Intak...

Page 21: ...AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 13 Nov 30 06 1A21 INTRODUCTION 79 OIL 5E17 20 Distribution 30 Indicating 80 STARTING 5F7 10 Cranking 91 CHARTS WIRING DIAGRAMS 5F21 10 Chart...

Page 22: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 14 Nov 30 06 1A22 INTRODUCTION GRIDS 1A22 THRU 1A24 INTENTIONALLY BLANK...

Page 23: ...tenance 3I1 Consumable Materials 5G15 Control Cable Inspection 2G12 Cable Fittings 100 Hour Special Inspection 2G15 Control Column Assembly 2H3 Conversion Tables Decimal Conversions 5G9 Drill Sizes 5G...

Page 24: ...4E23 Engine Controls Adjustment 4K13 Mixture 4K12 Throttle 4K12 EGT Probe Installation 5E3 Exhaust See Exhaust System Fuel Carburetor 4K11 Idle Mixture 4K11 Idle Speed 4K12 Primer 4K7 Hour Meter 5I5...

Page 25: ...ironment Extreme Cold 1D17 High Dust or Industrial Pollution 1D16 High Salt or High Humidity 1D17 Soft or Unusual Terrain 1D18 Procedure Aft Wing Attach Fittings 100 Hour 4E13 Control Cable Fittings 2...

Page 26: ...I3 Publications Piper 1A12 Vendor 1A12 R Repairs Fiberglass 4C19 Metal Wire Stitching 4D6 Safety Walk 4D5 Skin Materials and Thickness 4C8 Thermoplastic 4C21 List of Materials 4C23 Restraint System 2F...

Page 27: ...8 Magnetos 5C8 Oil Temperature Indicator 5F3 Rudder Control System 2H15 Stabilator Control System 2I2 Trim Control 2I3 Standby Alternator 2E6 Starter 5F14 Strobe Lights Tachometer 5D23 Turn and Bank I...

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Page 29: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1C1 CHAPTER 4 AIRWORTHINESS LIMITATIONS...

Page 30: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1C2 THIS PAGE INTENTIONALLY BLANK...

Page 31: ...PAGE 1 Nov 30 06 4 LIST OF EFFECTIVE PAGES 1C3 CHAPTER 4 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 4 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 4 Table of Contents 1 Nov 30 06 2 Nov 30 0...

Page 32: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4 LIST OF EFFECTIVE PAGES 1C4 THIS PAGE INTENTIONALLY BLANK...

Page 33: ...CE MANUAL PAGE 1 Nov 30 06 1C5 4 CONTENTS CHAPTER 4 AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO AIRWORTHINESS LIMITATIONS 4 00 00 1 1C7 Limitations 1 1C7 Inspections 1 1C7...

Page 34: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1C6 4 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 35: ...sposition 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 well as the disposition of life limi...

Page 36: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1C8 4 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 37: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1C9 CHAPTER 5 TIME LIMITS MAINTENANCE CHECKS...

Page 38: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1C10 THIS PAGE INTENTIONALLY BLANK...

Page 39: ...0 06 2 Nov 30 06 5 20 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9 Nov 30 06 10 Nov 30 06 11 Nov 30 06 12 Nov 30 06 13 Nov 30 06 14 Nov 30 06 15...

Page 40: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5 LIST OF EFFECTIVE PAGES 1C12 THIS PAGE INTENTIONALLY BLANK...

Page 41: ...oup 7 1D1 Cabin and Cockpit Group 9 1D3 Fuselage and Empennage Group 9 1D3 Wing Group 11 1D5 Landing Gear Group 12 1D6 Special Inspections 12 1D6 Operational Inspection 12 1D6 General 13 1D7 Notes 13...

Page 42: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1C14 5 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 43: ...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 recorded by the...

Page 44: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1C16 5 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 45: ...related structural inspection procedure required for type certification 2 Refer to 5 20 00 for Piper s recommended Inspection Programs They include the frequency and extent of the inspections require...

Page 46: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1C18 5 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 47: ...stablished Part 91 Progressive Inspection Program see 91 409 d or Part 135 Approved Aircraft Inspection Program see 135 419 The time periods given for inspections of various components are based on av...

Page 48: ...n operational test of the component and its related system should be performed to ensure proper function Serviceable parts that were issued to the component will be filed in the aircraft permanent rec...

Page 49: ...hedule This schedule is prepared in a manual form which will be available from Piper Dealers P N 767 002 pending for the Warrior III S N s 2842001 up Refer to Piper s Customer Service Information Aero...

Page 50: ...nterval columns or listed as a special inspection in 5 30 00 or both 2 Refer to the applicable chapter of this manual for instructions on how to gain access to remove any item that must be removed and...

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Page 53: ...group 1 Remove and inspect engine cowling for damage O O 2 Clean and inspect cowling for cracks distortion and loose or missing fasteners O 3 Drain oil sump See Note 6 O O 4 Clean suction oil straine...

Page 54: ...d screen O O 28 Inspect condition of flexible fuel lines O O 29 Inspect fuel system for leaks See Note 13 O 30 Inspect engine driven and electric fuel pumps for operation See Notes 7 and 27 O 31 If in...

Page 55: ...0 Inspect instruments lines and attachments See Notes 29 and 31 O 11 Inspect gyro operated instruments and electric turn and bank Overhaul or replace as required O 12 If equipped replace filters on At...

Page 56: ...igging or structural imbalance hinge damage excessive wear freedom of movement and proper lubrication and attachment points for missing or worn hardware O 16 Inspect stabilator and tab hinges horn and...

Page 57: ...knut is tight O 6 Inspect aileron rudder stabilator and stabilator trim cables terminals turnbuckles guides fittings and pulleys for safety condition and operation O 7 Inspect flaps for surface damage...

Page 58: ...nspect gear forks for damage O 14 Inspect main gear torque links for cracks O 15 Inspect oleo struts for fluid leaks and scoring O 16 Inspect gear struts attachments torque links and bolts for conditi...

Page 59: ...erformed as indicated by a O at the 50 or 100 hour inspection interval Inspections or operations i e component overhauls replacements etc required outside the 100 hour cycle are listed as special insp...

Page 60: ...area is usually due to emission of thread lubricant used during assembly of the barrel at the factory or by slight gas leakage which stops after the cylinder has been in service for awhile This condit...

Page 61: ...842203 only verify compliance with Piper Service Bulletin No 1139A See also AD 04 14 12 33 In S N s 2842176 thru 2842179 only verify compliance with Piper Service Bulletin No 1141 34 In S N s 2842001...

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Page 63: ...THIS PAGE INTENTIONALLY BLANK PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 17 Nov 30 06 1D11 5 20 00...

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Page 65: ...ther suitable tool Installation of a new wing flap will relieve this inspection requirement until such time as the replacement wing flap reaches ten years time in service Each 400 Hours At every 400 h...

Page 66: ...i e through the use of a borescope without removing the headliner providing access is obtained to all concealed areas and borescope provides sufficient detail to adequately accomplish the inspection E...

Page 67: ...ast every three 3 years See Standby Attitude Indicator 34 20 00 Each Five 5 Years Replace or overhaul engine driven and electric fuel pumps at engine overhaul or five 5 years time in service whichever...

Page 68: ...ry in the multifunction display MFD as required but at least each 10 years See Multifunction Display MFD 34 20 00 Each Twenty 20 Years No fluid hose may exceed twenty 20 years total time in service 3...

Page 69: ...ours total 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...

Page 70: ...ct for cracks attachment 100 Hours damage cleanliness and lubrication Wheels Inspect for cracks damage chipped 100 Hours rims bearings for damage corrosion and lubrication Tires Inspect for cuts wear...

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Page 72: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 1D20 5 30 00 GRIDS 1D20 THRU 1D24 INTENTIONALLY BLANK...

Page 73: ...t revisions of appropriate Each occurrence Textron Lycoming Service Bulletins before further flight and Overhaul Manual Electrical and Avionics Inspect and check harness connections Each occurrence Sy...

Page 74: ...wings tail landing gear and doors C Follow Piper and Textron Lycoming Maintenance Manual procedures If there are any questions regarding repairs or procedures contact your Piper Dealer s Service Advi...

Page 75: ...alignment Each occurrence windows and attachments for overstress before further flight cracks or damage Wing carry through member for overstress damage Stringers bulkheads keel beams for buckling cra...

Page 76: ...e further flight Tubular Structures Check for internal corrosion If immersed each event i e Engine Mounts etc Clean and represerve as required before further flight See 71 20 00 Engine Mount Corrosion...

Page 77: ...l holes and similar hidden openings and recesses are thoroughly free from contaminants Test electrical components and fuel metering devices in accordance with manufacturer s instructions to determine...

Page 78: ...blies for entrapped contaminants Clean and check for short circuits Remove electric motors and electric pumps Remove all potted solid state electrical equipment such as alternator inop switches low fu...

Page 79: ...ary Clean and inspect all heat shrouds and ducting Fuel System Perform Fuel Tank Wing Spar Corrosion If immersed each event Inspection 28 10 00 Remove and clean before further flight fuel cells and fu...

Page 80: ...Inspection 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 up...

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Page 83: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1E11 CHAPTER 6 DIMENSIONS AND AREAS...

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Page 85: ...CTIVE PAGES CHAPTER 6 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 6 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 6 Table of Contents 1 Nov 30 06 2 Nov 30 06 6 00 00 1 Nov 30 06 2 Nov 30 06 3...

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Page 87: ...L PAGE 1 Nov 30 06 1E15 6 CONTENTS CHAPTER 6 DIMENSIONS AND AREAS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO GENERAL 6 00 00 1 1E17 Leading Particulars and Principal Dimensions 2 1E18 Station Refe...

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Page 89: ...the leading particulars principal dimensions are listed in Chart 1 The airplane serial number is located on the Manufacturers Aircraft Association MAA plate on left side of the fuselage near the leadi...

Page 90: ...mp Drive Plunger Carburetor Marvel Schebler MA 4SPA Magnetos Slick Left 4371 Right 4370 Spark Plugs Shielded Spark Plug Gap Setting Refer to latest Lycoming Service Instruction No 1042 Firing Order 1...

Page 91: ...oad1 Nose 3 25 25 in Main 4 50 50 in Wheel Track 10 0 ft Wheel Base 6 ft 8 in Nose Wheel Travel Left 20 1 Right 20 1 Wheel Nose Cleveland 40 77B 5 00 x 5 or McCauley D 30500 5 00 x 5 Main Cleveland 40...

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Page 93: ...es in the vertical or horizontal direction from a given reference line The reference datum line F S 0 is located 78 4 inches ahead of the wing leading edge at the intersection of the straight and tape...

Page 94: ...TED AT THE TAIL SKID The access and inspection provisions for the airplane are shown in Figure 3 The component to be serviced or inspected through each opening is identified in the illustration All ac...

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Page 97: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1F1 CHAPTER 7 LIFTING AND SHORING...

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Page 99: ...PAGE 1 Nov 30 06 1F3 7 LIST OF EFFECTIVE PAGES CHAPTER 7 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 7 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 7 Table of Contents 1 Nov 30 06 2 Nov 30 0...

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Page 101: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 1F5 7 CONTENTS CHAPTER 7 LIFTING AND SHORING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO JACKING 7 10 00 1 1F7...

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Page 103: ...gs may be more appropriate If wing or fuselage shoring is required make sure the support is contoured to conform to the surface it is supporting Jacking A Align jacks under the wing respective pads on...

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Page 105: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1F9 CHAPTER 8 LEVELING AND WEIGHING...

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Page 107: ...1F11 8 LIST OF EFFECTIVE PAGES CHAPTER 8 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 8 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 8 Table of Contents 1 Nov 30 06 2 Nov 30 06 8 10 00 1 Nov...

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Page 109: ...RAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 1F13 8 CONTENTS CHAPTER 8 LEVELING AND WEIGHING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO WEIGHING 8 10 00 1 1F15 LEVELING 8 20...

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Page 111: ...ure 1 A Position a scale and ramp in front of each of the three wheels B Secure the scales from rolling forward and tow the airplane up onto the scales Refer to Towing 9 10 00 C Remove the ramp so as...

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Page 113: ...OTE Level the airplane laterally first then level it longitudinally A To laterally level the airplane place a spirit level across the baggage compartment floor along the rear bulkhead refer to Figure...

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Page 115: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1F19 CHAPTER 9 TOWING AND TAXIING...

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Page 117: ...1F21 9 LIST OF EFFECTIVE PAGES CHAPTER 9 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 9 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 9 Table of Contents 1 Nov 30 06 2 Nov 30 06 9 10 00 1 Nov...

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Page 119: ...AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 1F23 9 CONTENTS CHAPTER 9 TOWING AND TAXIING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO TOWING 9 10 00 1 1G1 TAXIING 9 20 00...

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Page 121: ...OVING THE AIRCRAFT FORWARD BY HAND WILL CAUSE THE AILERON CONTOUR TO CHANGE RESULTING IN AN OUT OF TRIM CONDITION CAUTION DO NOT TOW THE AIRPLANE WITH CONTROL LOCKS INSTALLED The airplane may be moved...

Page 122: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1G2 9 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 123: ...he taxi roll and perform the following checks CAUTION DO NOT OPERATE THE ENGINE AT HIGH RPM WHEN RUNNING UP OR TAXIING OVER GROUND CONTAINING LOOSE STONES GRAVEL OR ANY LOOSE MATERIAL THAT MAY CAUSE D...

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Page 125: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1G5 CHAPTER 10 PARKING AND MOORING...

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Page 127: ...G7 10 LIST OF EFFECTIVE PAGES CHAPTER 10 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 10 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 10 Table of Contents 1 Nov 30 06 2 Nov 30 06 10 10 00 1 No...

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Page 129: ...WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 1G9 10 CONTENTS CHAPTER 10 PARKING AND MOORING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO PARKING 10 10 00 1 1G11 Parking 1 1G11 Locking Airplane 1...

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Page 131: ...brake lever and depressing the knob attached to the left side of the handle C To release the parking brakes pull back on the brake lever to disengage the catch mechanism Then allow the handle to swing...

Page 132: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1G12 10 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 133: ...ock the wheels C Lock the aileron and stabilator controls by looping the pilot s seat belt around control yoke CAUTION WHEN USING ROPE CONSTRUCTED OF NON SYNTHETIC MATERIAL LEAVE SUFFICIENT SLACK TO A...

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Page 135: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1G15 CHAPTER 11 PLACARDS AND MARKINGS...

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Page 137: ...ECTIVE PAGES CHAPTER SECTION PAGE DATE 11 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 11 Table of Contents 1 Nov 30 06 2 Nov 30 06 11 00 00 1 Nov 30 06 2 Nov 30 06 11 20 00 1 Nov 30 06 2 Nov 30 06...

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Page 139: ...AL PAGE 1 Nov 30 06 1G19 11 CONTENTS CHAPTER 11 PLACARDS AND MARKINGS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO GENERAL 11 00 00 1 1G21 Decals 1 1G21 EXTERIOR PLACARDS AND MARKINGS 11 20 00 1 1H1...

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Page 141: ...or a piece of masking tape Apply cyclohexanone or equivalent to adhesive side of film Position and apply decal while adhesive is still tacky Work a roller across decal until all air bubbles are remove...

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Page 143: ...f the fuselage near the stabilator leading edge The placard identifies the airplane by its model number and serial number It is important to include the airplane serial number in any correspondence wi...

Page 144: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1H2 11 20 00 Exterior Placards and Markings Figure 1 Sheet 1 of 2...

Page 145: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 1H3 11 20 00 Exterior Placards and Markings Figure 1 Sheet 2 of 2...

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Page 147: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1H5 11 30 00 PAGE 1 Nov 30 06 INTERIOR PLACARDS Interior Placards Figure 1 Sheet 1 of 3...

Page 148: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1H6 11 30 00 Interior Placards Figure 1 Sheet 2 of 3...

Page 149: ...PLACARD CARB ICE SENSITIVITY OPT 15 PLACARD ELT CAUTION 16 PLACARD HEATER DEFROSTER 17 PLACARD CIRCUIT BREAKER PANEL 18 PLACARD PHONE 19 PLACARD MIC 20 PLACARD CARB HEAT ON OFF 21 PLACARD DME SELECT O...

Page 150: ...REMOVED IMMEDIATELY 2 If panel is painted with enamel or lacquer use a clean cloth dampened with Mark It J 70 solvent to remove placard to be replaced B Installation 1 If required clean surface to rec...

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Page 153: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1H11 CHAPTER 12 SERVICING...

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Page 155: ...00 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 12 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9 Nov 30 06 10 Nov 30 06 12 20 00 1 Nov 3...

Page 156: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 12 LIST OF EFFECTIVE PAGES 1H14 THIS PAGE INTENTIONALLY BLANK...

Page 157: ...dliner Side Panels and Seats 4 1H20 Carpets 4 1H20 REPLENISHING 12 10 00 1 1H21 Fuel System 2 1H22 Filling 2 1H22 Anti Icing Fuel Additive 2 1H22 Draining Moisture 2 1H22 Draining Entirely 3 1H23 Oil...

Page 158: ...r Filter 2 1I8 Propeller 2 1I8 Power Plant 2 1I8 Winterization Plate 2 1I8 Electrical System 4 1I10 Tire Balance 4 1I10 Lubrication 7 1I13 Precautions 7 1I13 Application of Grease 7 1I13 Application o...

Page 159: ...uidelines outlined below must be followed to prevent damage to the finish and ensure long paint life 1 For the first 30 days after painting a Hand wash the aircraft often Use fresh water only b Avoid...

Page 160: ...chamois should be used to prevent scratches when cleaning or polishing A heavier coating of wax on the leading surfaces will reduce the abrasion problems in these areas 2 Cleaning A Exterior Surfaces...

Page 161: ...d soap and water solution c Rinse with low pressure spray d Lubricate gear per Lubrication Chart 12 20 00 if not already done above e Reinstall wheel pants if equipped D Windshield and Windows WARNING...

Page 162: ...ANERS REQUIRE ADEQUATE VENTILATION 2 Soiled upholstery except leather may be cleaned by using an approved air drying type cleaner or foam upholstery cleaner Carefully follow the manufacturer s instruc...

Page 163: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 1H21 12 10 00 REPLENISHING Service Points Figure 1...

Page 164: ...The additive must Be uniformly blended with fuel while refueling Not exceed 0 15 percent by volume of the refueled quantity Be blended not less than 0 10 percent by volume One and one half liquid oun...

Page 165: ...n of Lycoming Service Instruction No 1014 A Oil Sump 1 Draining NOTE Warm the engine to operating temperature to insure complete draining of the old oil To drain the oil sump provide a suitable contai...

Page 166: ...plugging and change oil every ten hours if sludge conditions are evident Resume normal oil drain periods after sludge conditions improve B Oil Filter 1 The oil filter should be replaced after each 50...

Page 167: ...D WITH COMPRESSED AIR AND OR WITH A DRY SOLVENT These measurements are taken with the airplane sitting on a level surface under normal static load empty weight of airplane plus full fuel and oil If th...

Page 168: ...er plug hole 4 Install filler plug finger tight Extend and compress the strut two or three times to remove any air that may be trapped in housing 5 Remove filler plug Raise strut to full compression a...

Page 169: ...extend strut three or four times to remove any trapped air and for fluid to enter bottom chamber of housing 5 Raise strut to full compression and fill with fluid to bottom of filler plug 6 Apply an ap...

Page 170: ...diffuses through the liner to escape through special sidewall vents This venting prevents pressure build up within the cord body which might cause tread sidewall or ply separation Discounting tire gro...

Page 171: ...aligned with index mark on wheel Apply Age Master 1 to tires to protect against ozone attack and weathering as follows 1 Clean oil and grease from all tire surfaces 2 Apply single heavy coat using bru...

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Page 173: ...ne at the carburetor 2 Select a fuel tank turn on the electric fuel pump and flush fuel through the system until it is determined there is no dirt and foreign matter in the fuel valve or tank During t...

Page 174: ...ilter housing may be cleaned by wiping with a clean cloth soaked in a suitable quick drying type solvent When housing is dry reinstall filter C Installation 1 Install filter element in screen housing...

Page 175: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 1I9 12 20 00 Induction Air Filter Figure 2...

Page 176: ...arings in wheel then using the 7 bushings 6 spacers and 5 nuts refer to Figure 1 install the wheel tire assembly on the pipe Secure the nuts finger tight so that the wheel halves touch each other Be s...

Page 177: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 1I11 12 20 00 Wheel Balancer Figure 3...

Page 178: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 1I12 12 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 179: ...reservoir is not provided around a bearing apply lubricant sparingly and wipe off excess 2 Remove wheel bearings from the wheel hub and clean thoroughly with a suitable solvent When packing with greas...

Page 180: ...UBRICATING OIL AIRCRAFT RECIPROCATING MIL L 6082 ENGINE PISTON GRADE AS SPECIFIED IN THE LATEST REVISION OF LYCOMING SERVICE INSTRUCTION NO 1014 HYDRAULIC FLUID PETROLEUM BASED MIL H 5606G GREASE AIRC...

Page 181: ...ssemble 6 Lubrication Points Wipe all lubrication points clean of old grease oil dirt etc before lubricating 7 Lycoming recommends changing oil and filter at 50 hours or four months whichever comes fi...

Page 182: ...PPER TORQUE LINK BEARING MIL PRF 23827G 100 HOURS 3 TORQUE LINK BUSHING MIL PRF 23827G 100 HOURS 4 TORQUE LINK CONNECTING BUSHING MIL PRF 23827G 100 HOURS 5 MAIN WHEEL BEARING See Spec Instr 3 MIL G 8...

Page 183: ...OURS 4 TORQUE LINK ASSEMBLY See Spec Instr 2 MIL L 7870 100 HOURS 5 NOSE WHEEL BEARING MIL G 81322E See Spec Instr 3 100 HOURS 6 NOSE GEAR STEERING ROD END BEARINGS MIL L 7870 100 HOURS See Spec Instr...

Page 184: ...L WHEEL MIL L 7870 100 HOURS See Spec Instr 2 and Caution 1 7 O RING CONTROL SHAFT BUSHING PARKER O RING LUBRICANT AS REQUIRED See Spec Instr 5 and Caution 1 8 TEE BAR PIVOT POINT MIL L 7870 100 HOURS...

Page 185: ...AP HANDLE PIVOT POINT LOCK MECHANISM AND TURNBUCKLE END AND CABLE PULLEY See Spec Instr 2 MIL L 7870 100 HOURS 4 FLAP RETURN AND TENSION CHAINS See Spec Instr 2 MIL L 7870 500 HOURS 5 AILERON BELLCRAN...

Page 186: ...KE ROD ENDS See Spec Instr 2 and Caution MIL L 7870 100 HOURS 5 NOSE GEAR STEERING ROD ENDS See Spec Instr 2 MIL L 7870 100 HOURS 6 RUDDER ARM CABLE ENDS See Spec Instr 2 MIL L 7870 100 HOURS 7 STABIL...

Page 187: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 15 Nov 30 06 1I21 12 20 00 Lubrication Chart Control System Rudder Figure 6 Sheet 4 of 4...

Page 188: ...SAE 40 SAE 40 See Spec Instr 8 14 0 TO 70 F 17 77 TO 21 11 C SAE 30 SAE 40 30 20W40 BELOW 10 F 12 22 C SAE 20 SAE 30 20W30 2 CARTRIDGE TYPE OIL FILTERS See Spec Instr 8 14 50 HRS 3 AIR FILTER See Spec...

Page 189: ...Instr 6 MIL L 7870 100 HOURS 2 DOOR SEALS CARBON DIOXIDE RELEASE AGENT See Spec Instr 6 and 10 DRY LUBRICANT MS 122N CO2 50 HOURS 3 DOOR LATCH MECHANISMS See Spec Instr 6 MIL L 7870 500 HOURS 4 SEAT...

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Page 193: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 1J3 CHAPTER 20 STANDARD PRACTICES AIRFRAME...

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Page 195: ...SECTION PAGE DATE 20 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 20 Table of Contents 1 Nov 30 06 2 Nov 30 06 20 00 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov...

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Page 197: ...k Rivet 3 1J11 Identification of Fluid Lines 4 1J12 Inspection of Flexible Hoses 4 1J12 Flareless Tube Assemblies 7 1J15 Support Clamps 8 1J16 Dye Penetrant Inspection 8 1J16 PAINTING 20 20 00 1 1J19...

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Page 199: ...Some wrenches are quite sensitive as to the way they are supported during a tightening operation Any instructions furnished by the manufacturer must be followed explicitly When it is necessary to use...

Page 200: ...C PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 1J10 20 00 00 Torque Wrench Formula Figure 1 Installing Rod End Bearings Figure 2 3 Installing Rod End Bearings Install rod end bearings as...

Page 201: ...ends 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 provide a guide for a larger bit See...

Page 202: ...onally occurs This condition is such that rubber material protrudes through the wire braid cover This condition has no effect on hose quality It is recommended that flexible hoses be inspected every 1...

Page 203: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 1J13 20 00 00 Hose Tube and Line Markings Figure 4...

Page 204: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 1J14 20 00 00 Presetting Flareless Tube Fittings Figure 5...

Page 205: ...n nut until cutting edge of sleeve grips tube This point is determined by slowly turning tube back and forth while tightening nut When tube no longer turns nut is ready for final tightening D Final ti...

Page 206: ...r anodizing from the portion of the tube at the bonding clap location All plumbing lines must be secured at specified intervals The maximum distance between supports for rigid fluid tubing is shown in...

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Page 209: ...NE PAINT MAY BE DANGEROUS TO YOUR HEALTH SERIOUS INJURY WILL RESULT IF SAFETY PRECAUTIONS ARE NOT FOLLOWED WARNING DURING TRANSIT AND STORAGE CHECK FOR SIGNS OF A BULGING CAN OTHER THAN NORMAL ODOR OR...

Page 210: ...lerons and flaps Paint flap and aileron wells wing tips and leading and trailing edges D Paint the bottom of the airplane first including bottom of horizontal tail surfaces Starting at the root and wo...

Page 211: ...ocellulose lacquers over old nitrocellulose finishes D Acrylic nitrocellulose lacquers will not adhere to nitrocellulose and epoxy finishes and to bare metal For best results apply lacquers over fresh...

Page 212: ...upational Safety and Health Act OSHA requirements regarding air circulation lighting and fire protection Lock storage facilities to prevent children and unauthorized personnel entry C Invert pigmented...

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Page 215: ...PART NUMBER 761 882 November 30 2006 2A1 AIRPLANE MAINTENANCE MANUAL CARD 2 OF 5 PA 28 161 S N s 2842001 UP PIPER AIRCRAFT INC...

Page 216: ...2A2 Published by Technical Publications Piper Aircraft Inc 2926 Piper Drive Vero Beach Florida 32960 U S A Member General Aviation Manufacturers Association...

Page 217: ...80301 March 1 1998 All PR011215 December 15 2001 1 PR030720 July 20 2003 1 and 2 CR040415 April 15 2004 All PR040818 August 18 2004 1 3 4 and 5 CR061130 November 30 2006 1 2 3 4 and 5 COMPLETE REVISIO...

Page 218: ...PAGE 2 Nov 30 06 AEROFICHE EFFECTIVITY 2A4 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 219: ...1 Nov 30 06 Effective Pages 2 Nov 30 06 Intro Table of Contents 1 Nov 30 06 2 Nov 30 06 Introduction 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9...

Page 220: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 INTRO LIST OF EFFECTIVE PAGES THIS PAGE INTENTIONALLY BLANK 2A6...

Page 221: ...ivity 2 2A10 Serial Number Explanation 2 2A10 Assignment of Subject Material 2 2A10 Pagination 3 2A11 Aerofiche Effectivity 3 2A11 Identifying Revised Material 3 2A11 Indexing 3 2A11 List of Effective...

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Page 223: ...IR OF PIPER AIRPLANES This manual generally does not contain hardware callouts for installation Hardware callouts are only indicated where a special application is required To confirm the correct hard...

Page 224: ...tems such as Environmental Systems Electrical Power Landing Gear etc They are assigned a number which becomes the first element of the standardized numbering system Thus the element 28 of the number 2...

Page 225: ...all fiche in this set 2 A complete subject Index for all fiche in this set 8 Identifying Revised Material A revision to a page is defined as any change to the printed matter that existed previously Re...

Page 226: ...essive Inspection Manual pending 767 002 B Vendor Publications WARNING FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION S WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT MAY...

Page 227: ...or PH 800 998 8857 7 FIRE EXTINGUISHER PORTABLE Vendor H3R Inc PH 800 249 4289 43 Magnolia Ave 4 San Francisco California 94123 2911 http www h3r com index htm 8 FUEL PUMP Vendor Weldon Pumps PH 440...

Page 228: ...Wichita KS 67226 http www mcico com index html Installation Manual and Operating Instructions Manual No 9015762 14 STARTER Vendor Sky Tec PH 800 476 7896 350 Howard Clemmons Rd FAX 817 573 2252 Granb...

Page 229: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 2A15 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 230: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 2A16 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 231: ...bined with another chapter CHAPTER SECTION TITLE GRID NO 4 AIRWORTHINESS LIMITATIONS 1C1 00 Airworthiness Limitations 5 TIME LIMITS MAINTENANCE CHECKS 1C9 00 General 10 Time Limits 20 Scheduled Mainte...

Page 232: ...23 COMMUNICATIONS 2C19 00 General 50 Audio Integrating 60 Static Discharging 24 ELECTRICAL POWER 2D9 00 General 30 DC Generation 40 External Power 50 Electrical Load Distribution 25 EQUIPMENT FURNISH...

Page 233: ...l 10 Flight Compartment 40 Exterior 34 NAVIGATION AND PITOT STATIC 3G1 10 Flight Environmental Data 20 Attitude and Direction 37 VACUUM 3I11 00 General 10 Distribution 20 Indicating 39 ELECTRICAL ELEC...

Page 234: ...ary Structure 40 Attach Fittings 50 Flight Surfaces 61 PROPELLER 4H21 10 Propeller Assembly 70 STANDARD PRACTICES ENGINE 4I9 00 General 71 POWER PLANT 4I17 00 General 10 Cowling 20 Mounts 60 Air Intak...

Page 235: ...AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 13 Nov 30 06 2A21 INTRODUCTION 79 OIL 5E17 20 Distribution 30 Indicating 80 STARTING 5F7 10 Cranking 91 CHARTS WIRING DIAGRAMS 5F21 10 Chart...

Page 236: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 14 Nov 30 06 2A22 INTRODUCTION GRIDS 2A22 THRU 2A24 INTENTIONALLY BLANK...

Page 237: ...tenance 3I1 Consumable Materials 5G15 Control Cable Inspection 2G12 Cable Fittings 100 Hour Special Inspection 2G15 Control Column Assembly 2H3 Conversion Tables Decimal Conversions 5G9 Drill Sizes 5G...

Page 238: ...4E23 Engine Controls Adjustment 4K13 Mixture 4K12 Throttle 4K12 EGT Probe Installation 5E3 Exhaust See Exhaust System Fuel Carburetor 4K11 Idle Mixture 4K11 Idle Speed 4K12 Primer 4K7 Hour Meter 5I5...

Page 239: ...ironment Extreme Cold 1D17 High Dust or Industrial Pollution 1D16 High Salt or High Humidity 1D17 Soft or Unusual Terrain 1D18 Procedure Aft Wing Attach Fittings 100 Hour 4E13 Control Cable Fittings 2...

Page 240: ...I3 Publications Piper 1A12 Vendor 1A12 R Repairs Fiberglass 4C19 Metal Wire Stitching 4D6 Safety Walk 4D5 Skin Materials and Thickness 4C8 Thermoplastic 4C21 List of Materials 4C23 Restraint System 2F...

Page 241: ...8 Magnetos 5C8 Oil Temperature Indicator 5F3 Rudder Control System 2H15 Stabilator Control System 2I2 Trim Control 2I3 Standby Alternator 2E6 Starter 5F14 Strobe Lights Tachometer 5D23 Turn and Bank I...

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Page 243: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 2C1 CHAPTER 21 ENVIRONMENTAL SYSTEMS...

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Page 245: ...CTIVE PAGES CHAPTER SECTION PAGE DATE 21 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 21 Table of Contents 1 Nov 30 06 2 Nov 30 06 21 00 00 1 Nov 30 06 2 Nov 30 06 21 20 00 1 Nov 30 06 2 Nov 30 06...

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Page 247: ...TER 21 ENVIRONMENTAL SYSTEMS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO GENERAL 21 00 00 1 2C7 Standard 1 2C7 Optional 1 2C7 DISTRIBUTION 21 20 00 1 2C9 Overhead Vent System 1 2C9 Avionics Cooling...

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Page 249: ...2109 and up 2001 and up Fresh air from an inlet on the left rear fuselage is ducted into overhead cabin vents In addition air inlets in the leading edge of each wing provide fresh air to individually...

Page 250: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 2C8 21 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 251: ...ve the inlet and outlet hoses from the blower assembly by removing the clamps d Remove the screws washers and nuts that secure the blower assembly to the hanger braces e Remove the screws and washers...

Page 252: ...number 1 is at pointed side of plug and receptacle 2 Avionics Cooling Blower See Figure 1 The avionics cooling blower is installed behind the instrument panel on the fuselage side wall On the right s...

Page 253: ...21 20 00 VIEW B B VIEW A A AS REQUIRED FROM NO 2 KX155A OR KX165 SEE ABOVE FROM KNS80 OR NO 1 KX165 INSTRUMENT PANEL LOOKING AFT A A B B 1 2 3 4 101145 D REGULATOR RELAY SUPPORT PANEL REF BLOWER ROTAT...

Page 254: ...318 K INSTRUMENT PANEL LOOKING AFT BLOWER A A OUTLET CAPPED OUTLET CAPPED FROM GNS 430 NO 2 FROM GNS 430 NO 1 FROM GTX 330 TRANSPONDER BLOWER 3 2 1 4 5 3 2 1 OUTLET CAPPED FROM GNS 430 NO 2 FROM GNS 4...

Page 255: ...02 P4001 P4006 A A 1 2 3 4 CB7 CB11 CB2 CB31 CB27 CB28 CB29 CB26 CB35 CB37 CB36 CB21 CB32 CB34 CB33 CB30 CB6 CB1 GTX 330 XPDR REF ADF REF CB23 CB24 CB25 CB22 CB12 CB13 CB10 CB9 CB8 CB20 CB19 CB18 CB17...

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Page 257: ...the instrument panel Defrosting is accomplished by heat outlets located on the right and left side of the glareshield Heated air is ducted directly from the heater valve box to the defroster shut off...

Page 258: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 2C16 21 40 00 Cabin Heater Defrosters and Overhead Vent System Figure 1...

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Page 261: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 2C19 CHAPTER 23 COMMUNICATIONS...

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Page 263: ...1 CHAPTER 23 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 23 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 23 Table of Contents 1 Nov 30 06 2 Nov 30 06 23 00 00 1 Nov 30 06 2 Nov 30 06 23 50 00...

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Page 265: ...MMUNICATIONS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO GENERAL 23 00 00 1 2D1 Radio Master Switch 1 2D1 AUDIO INTEGRATING 23 50 00 1 2D3 GMA 340 1 2D3 Removal and Installation 1 2D3 System Functi...

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Page 267: ...Nov 30 06 2D1 23 00 00 GENERAL Radio Master Switch See 91 23 00 Figure 1 A separate master switch for the radios is located in the switch panel in the center of the instrument panel Both this switch...

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Page 269: ...l and Installation See Rack Mounted Avionics Removal and Installation 39 10 00 B System Functional Test See Figure 1 1 On Ground The following known good equipment is required prior to performing this...

Page 270: ...nd marker audio including the marker audio mute function Check proper operation of the marker sensitivity selection using the SENS button by flying towards the outer marker position initially using HI...

Page 271: ...00 PILOT PA MIC SPKR LEVEL CO PILOT PA MIC SPKR LEVEL AIRCRAFT RADIO SPKR LEVEL MUSIC 1 MUTE TRIP LEVEL NOT USED IN THIS INSTALLATION MARKER BEACON AUDIO LEVEL MARKER BEACON LOW SENSITIVITY MARKER BE...

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Page 273: ...achment to airframe 3 Discharge points visible 4 Resistance 1 0 to 100 megohms 500 to 1 000 volt megohmmeter 5 Base resistance to airframe one 1 ohm maximum 2 Bonding Straps See also 51 80 00 To aid i...

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Page 275: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 2D9 CHAPTER 24 ELECTRICAL POWER...

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Page 277: ...ov 30 06 24 30 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9 Nov 30 06 10 Nov 30 06 11 Nov 30 06 12 Nov 30 06 13 Nov 30 06 14 Nov 30 06 15 Nov 30...

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Page 279: ...dby Alternator 13 2E5 Description 13 2E5 Troubleshooting 13 2E5 Inspection 17 2E9 Set Point Voltage Check 17 2E9 Overvoltage Test 18 2E10 Repair 18 2E10 Removal 19 2E11 Installation 19 2E11 Battery 20...

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Page 281: ...ment except the starter which receives its power direct from battery The battery relay and alternator field circuit are controlled by independent rocker type master BATT MASTR and alternator ALTR swit...

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Page 283: ...TOR ALTERNATOR AMMETER OR ACCESSORIES WILL CAUSE SEVERE DAMAGE TO UNITS AND OR WIRING CAUTION THE OUTPUT LEAD MUST NOT BE REMOVED FROM ALTERNATOR WHILE ROTOR WINDING IS ENERGIZED AND ALTERNATOR IS OPE...

Page 284: ...and a grease seal 3 The rectifiers used are rated at minimum 150 peak inverse voltage for transient voltage protection Three positive rectifiers are mounted in rectifier mounting plate while three neg...

Page 285: ...S OR ADJUSTMENTS REMOVE THESE UNITS FROM AIRPLANE AND PLACE ON A TEST STAND Troubles peculiar to the alternator system are listed in Chart 1 along with their probable causes and suggested remedies The...

Page 286: ...tage regulator and alternator field terminal Interruption of voltage through any of these points isolates the faulty component or wire which must be replaced See wiring schematic Chapter 91 Open outpu...

Page 287: ...ve wear and replace if necessary If brushes are good and field reads open replace alternator Output indicated on Faulty voltage regulator Start engine turn ON load ammeter does not meet set throttle a...

Page 288: ...ection and Testing of Components Field circuit breaker trips Short circuit in field Disconnect field wiring at circuit terminal of alternator Turn ON master switch If breaker continues to trip disconn...

Page 289: ...r switch ON Reset breaker If breaker continues to trip disconnect each leg of output circuit working from the alternator towards the circuit breaker until breaker holds when reset Replace component or...

Page 290: ...resistance Check all connections and in field circuit wire terminals in field circuit for deterioration such as loose binding posts broken wire strands at terminals etc Tighten all connections and rep...

Page 291: ...s maximum continuous load with all equipment on is approximately 60 amperes for 70 ampere alternator This approximate 60 ampere value plus approximately two amperes for a fully charged battery will a...

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Page 293: ...ALTERNATOR SERVICE TEST SPECIFICATIONS ES ALU8421LS D Alternator Test CAUTION ALTERNATOR SHOULD NOT BE RUN MORE THAN 2 MINUTES FOR EACH TEST POINT NOTE Always refer to the appropriate alternator and s...

Page 294: ...erated These higher tension values should not be applied to belts which have previously been used 2 Deflection Method Check belt tension by measuring the amount of deflection caused by a predetermined...

Page 295: ...age to 20 amps or less will cause the annunciator light to cease flashing and light steadily The pilot may choose which equipment he needs for the given flight conditions by simply keeping the total l...

Page 296: ...ints If these measurements are less than 0 5 Ohm any of these three points may be used as reference for the following measurements A Resistance from battery to Terminal 7 _________Ohms B Resistance fr...

Page 297: ...lose to the value specified the charging system should be operative If not check for a broken or loose alternator belt or if the alternator is spline driven check that the spline drive shear coupling...

Page 298: ...terminals for security Try a 5 pound pull test on all crimp joints and make sure that the terminal is crimped on the wire not the insulation 11 Noise problems are also difficult to find A few tips to...

Page 299: ...se the electrical load to over 20 amps The Stby Alt On annunciator should be blinking Reduce the electrical load to less than 20 Amps The Stby Alt On annunciator should be ON steadily 11 Switch primar...

Page 300: ...6 as soon as the short occurs e The short should occur between 32 0 and 33 0 volts No short indicates the failure of the overvoltage protection circuitry of the regulator and necessity for repair or r...

Page 301: ...moval 1 Disconnect wiring harness 2 Remove washers and nuts 4 3 Pull standby alternator and gasket from drive pad H Installation 1 Orient standby alternator as shown in Figure 4 and place in position...

Page 302: ...anifold top cover with a cloth saturated with a solution of bicarbonate of soda mixed one part soda to twenty parts of water Check that cell plugs are tight do not allow soda solution to enter any cel...

Page 303: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 2E13 24 30 00 PAGE 21 Nov 30 06 Battery Installation Figure 5...

Page 304: ...anding too long Remove and charge battery if left in unused airplane three weeks or more Equipment left on accidentally Remove and charge battery Impurities in electrolyte Replace battery Short circui...

Page 305: ...SES FORMED DURING CHARGING MAY BE EXPLOSIVE IF IGNITED The National Electric Code forbids charging batteries installed in aircraft or within 10 feet of fuel tank areas The battery must be removed from...

Page 306: ...ery tools F Hydrometer Reading and Battery Charge Whenever checking the battery ascertain that all connections are clean and tight and that the fluid level is above the baffle plates If it is necessar...

Page 307: ...5 to 1 295 100 1 250 75 1 217 50 1 184 25 1 150 Discharged CHART 7 HYDROMETER READING SPECIFIC GRAVITY TEMPERATURE CORRECTION Electrolyte Temperature Correction Add to or Subtract from reading as indi...

Page 308: ...erations Operation of storage batteries beyond their ambient temperature or charging voltage limits will result in excessive cell temperatures leading to electrolyte boiling rapid deterioration of the...

Page 309: ...charged The battery will be sufficiently charged when after a 3 hour period the specific gravity does not rise any higher with the electrolyte gassing and a charging rate of 1 1 2 amperes Long batter...

Page 310: ...ECT THE VOLTMETER ACROSS THE BATTERY BECAUSE THE REGULATOR IS DESIGNED TO COMPENSATE FOR RESISTANCE CONTAINED WITHIN THE WIRING HARNESS A Testing 1 Use only a good quality adjustable dc power source C...

Page 311: ...is out of calibration and must be replaced 8 If regulator checks good check airplane for a Poor or loose connections b Poor ground on regulator housing c Shorted alternator windings d A grounded wire...

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Page 313: ...et in the fuselage Note that after inserting plug the electrical system is ON D Proceed with the normal engine starting technique NOTE Starter manufacturers recommend limiting cranking to thirty secon...

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Page 315: ...0 5 0 X X Cabin Dome Light 5 0 3 X Cockpit Flood Light 5 0 3 X Electric Clock Negl X X Engine Gauge 3 0 2 X Fuel Pump 5 5 0 Instr Panel Switch Lights 7 5 X Panel Lights 0 8 X Switch Lights 0 8 X Landi...

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Page 317: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 2F5 CHAPTER 25 EQUIPMENT FURNISHINGS...

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Page 319: ...R 25 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 25 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 25 Table of Contents 1 Nov 30 06 2 Nov 30 06 25 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 No...

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Page 321: ...T 25 10 00 1 2F11 Pilot s Seat Lock and Release Rigging 1 2F11 Lumbar Support 2 2F12 Description 2 2F12 Removal 2 2F12 Assembly 2 2F12 Installation 2 2F12 Carpets 2 2F12 Restraint System 4 2F14 Inspec...

Page 322: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 2F10 25 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 323: ...traightedge along lower surface of seat back release bushing C Adjust push pull cable by raising or lowering until lower surface of the stop assembly is parallel to straightedge D Secure push pull cab...

Page 324: ...NIMIZE DAMAGE TO SEAT BACK FILLER DURING REMOVAL USE ONE HAND TO RETAIN SEAT BACK FILLER IN PLACE WHILE GENTLY REMOVING BLADDER WITH OTHER HAND 5 Starting at either right or left edge of bladder caref...

Page 325: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 2F13 25 10 00 Lumbar Seat Bladder Installation Figure 2...

Page 326: ...belts at each position as follows a Replace all belts manufactured by Pacific Scientific and the seat belt has a date stamp of 6 94 thru 8 95 if the seat belt buckle end has an old Piper logo large st...

Page 327: ...mpletely Measure and mark the harness 24 inches from the reel center 4 Wind harness onto reel until the 24 inch mark is reached Hold reel and place cap with spring over reel shaft end 5 Align slot in...

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Page 329: ...t must be reset To reset 1 Position the remote cockpit switch to ON then immediately reposition it to ARM or 2 Position the switch on the ELT to ON then immediately reposition it to OFF B Battery Refe...

Page 330: ...should be coordinated with the closest FAA Tower or Flight Service Station CAUTION CONSULT FAA ADVISORY CIRCULAR AC 20 81 FOR DETAILED INFORMATION CONCERNING UNSHIELDED TESTING 4 Turn both the airplan...

Page 331: ...4 Wiring Schematic Figure 2 2 1 3 5 6 7 8 9 10 8 5 12 6 3 9 7 1 P203 ELT REMOTE SWITCH J501 4 2 11 AIRTEX ELT 110 4 LIGHT RESET 1 RESET 2 EXTERNAL ON NO CONNECTION G SWITCH LOOP G SWITCH LOOP NO CONN...

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Page 333: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 2G1 CHAPTER 27 FLIGHT CONTROLS...

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Page 335: ...0 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9 Nov 30 06 10 Nov 30 06 11 Nov 30 06 12 Nov 30 06 13 Nov 30 06 14 Nov 30 06 27 20 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5...

Page 336: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 27 LIST OF EFFECTIVE PAGES 2G4 THIS PAGE INTENTIONALLY BLANK...

Page 337: ...oting 1 2H1 Control Column 1 2H1 Removal 1 2H1 Installation 1 2H1 Flex Joint Replacement 5 2H5 Control Wheel 7 2H7 Aileron Control Cables 8 2H8 Removal 8 2H8 Installation 10 2H10 Aileron Bellcrank Ass...

Page 338: ...lator Trim Controls 9 2I9 Forward Assembly 9 2I9 Removal 9 2I9 Installation 9 2I9 Aft Assembly 11 2I11 Removal 11 2I11 Installation 11 2I11 Rigging and Adjustment 12 2I12 S TEC Manual Electric Trim Cl...

Page 339: ...is routed through the center of the fuselage to the main spar and out through the wings to a bellcrank in each wing A balance cable is also connected to the bellcrank As the control wheels are moved...

Page 340: ...al tension then loosen them to the High Side of the tolerance This pre stretching will aid in maintaining specified tension after flight testing G Check all cable ball ends for proper seating in retai...

Page 341: ...STALLATIONS 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 Chart 2 f...

Page 342: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 2G10 27 00 00 CHART 2 Sheet 1 of 2 FLIGHT CONTROL SURFACE TRAVEL AND CABLE TENSION...

Page 343: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 2G11 27 00 00 CHART 2 Sheet 2 of 2 FLIGHT CONTROL SURFACE TRAVEL AND CABLE TENSION...

Page 344: ...pect each section 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 clo...

Page 345: ...her outer wires worn 40 50 percent as depicted in Figure 2 C Internal Cable Wear As wear is taking place on the exterior surface of a cable the same condition is taking place internally particularly i...

Page 346: ...inspect it for internal strand corrosion as this condition is usually not evident on the outer surface of the cable Replace cable segments if internal strand rust or corrosion is found Areas especiall...

Page 347: ...afety wires clips Pay particular attention to corrosion and pitting on cable terminals turnbuckles and cable fittings Any corrosion or pitting found requires replacement of the corroded fitting and or...

Page 348: ...terns Figure 4 H Pulley Wear Patterns Various cable system malfunctions may be detected by analyzing pulley conditions These include such discrepancies as too much tension misalignment pulley bearing...

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Page 351: ...hains from the control cables where the chains and cables join by removing the cotter pins nuts bolts and bushings e Remove the tunnel cover by removing the rudder trim control knob and trim cover att...

Page 352: ...ance between pulleys and brackets Cables not in place on Install cables correctly pulleys Check cable guards Bent aileron and or hinge Repair or replace aileron and or hinge Cables crossed or routed C...

Page 353: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 2H3 27 10 00 Control Column Assembly Figure 1...

Page 354: ...e adjustable aileron tee bar stops i Set the stabilator cable tension with turnbuckles in the aft section of the fuselage and instructions given in Stabilator Controls Rigging and Adjustment 27 30 00...

Page 355: ...otrusion for proper installation NOTE Reamer may be purchased from Enstice Tool Co Palm Bay Florida 4 Install pin through tube and shaft a If pin shoulder does not protruded past tube surface install...

Page 356: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 2H6 27 10 00 Control Wheel Installation Figure 3 Effectivity 2842026 up...

Page 357: ...w the spacer and the nutplate inside the tube using acetone or naphtha Allow to dry 3 Prime inside of control wheel with Loctite 7649 Piper P N 279 073 Allow to dry 4 Install control wheel onto tube u...

Page 358: ...right as required f Remove the cotter pins used as cable guards at the pulley 10 in the forward area of the floor opening aft of the main spar g Disconnect the cable 14 or 15 from the control chain 4...

Page 359: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 9 Nov 30 06 2H9 27 10 00 Aileron Controls Figure 4...

Page 360: ...dure a Draw the control cable into the wing b Connect the cable to the forward end of the aileron bellcrank 6 using a bolt washer nut and cotter pin Allow the cable end to rotate freely on the bellcra...

Page 361: ...er to Figures 5 and 6 CAUTION VERIFY FREE AND CORRECT MOVEMENT OF AILERONS WHILE IT WOULD SEEM SELF EVIDENT FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT...

Page 362: ...the two front seats if desired and raise the bottom of the rear seat to facilitate in the necessary operation 2 Loosen the connecting bolts of the idler crossover sprockets at the control tee bar to a...

Page 363: ...1 WARRIOR III MAINTENANCE MANUAL PAGE 13 Nov 30 06 2H13 27 10 00 Aileron Bellcrank Rigging Typical Figure 5 Aileron Bellcrank Rigging Tool Figure 6 MATERIAL 125 X 1 0 ALUMINUM PLATE 062 R SIX PLACES 3...

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Page 365: ...cate torque tube bearing in need of lubrication bearings Cable tension too high Adjust cable tension Pulleys binding or Replace binding pulleys rubbing and or provide clearance between pulleys and bra...

Page 366: ...14 or 15 by the following procedure a Remove the tail cone fairing by removing its attaching screws b Disconnect the cable 14 or 15 from the rudder horn 17 by removing cotter pin nut washer and bolt 1...

Page 367: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 2H17 27 20 00 Rudder Controls Figure 1...

Page 368: ...to aid in rudder rigging With the rudder against its stop place the rigging tool against the side of the rudder and vertical stabilizer as shown in Figure 2 Be sure the tool is not contacting any riv...

Page 369: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 2H19 27 20 00 Rudder and Stabilator Travel Adjustments Figure 4 Rudder Rigging Figure 2 Clamping Rudder Pedals Figure 3...

Page 370: ...The mounting channel may be removed by removing the channel attaching screws at the inside of the channel B Installation Refer to Figure 5 1 Install the trim control mounting channel 8 on the upper si...

Page 371: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 2H21 27 20 00 Rudder Trim Control Figure 5 Fabricated Rudder Rigging Tool Figure 6...

Page 372: ...le from the lower end of the tee bar assembly Refer to Figure 1 27 30 00 5 Remove the tee bar attaching bolts with their washers and nuts which are through each side of the floor tunnel Pull the lower...

Page 373: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 9 Nov 30 06 2H23 27 20 00 Rudder and Steering Pedal Assembly Figure 7...

Page 374: ...o the idler arms 10 and secure with clevis and cotter pins 13 8 Connect the nose wheel steering push rods 21 to the rudder pedals 32 and 33 and secure with bolts and nuts 24 Check nose wheel steering...

Page 375: ...right upper stabilator control cable 2 is to be removed remove the cotter pin guards at the pulley 14 located in the forward area of the tunnel c Disconnect the cables 2 and 3 from the lower end of th...

Page 376: ...ed Lubricate system control movement properly Cable tension too high Adjust cable tension Binding control column Adjust and lubricate Pulleys binding or rubbing Replace binding pulleys and or provide...

Page 377: ...ed Lubricate system with excessive resistance properly Cable tension too high Adjust cable tension Pulleys binding or rubbing Replace binding pulleys Provide clearance between pulleys and brackets Cab...

Page 378: ...10 to the spar housing and secure with screws g In the access opening install the cotter pin cable guard at the pulley cluster 6 h Set cable tension and check Rigging and Adjustment below i Place the...

Page 379: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 2I5 27 30 00 Stabilator Controls Figure 1...

Page 380: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 2I6 27 30 00 Stabilator Rigging Tool Figure 2 Fabricating Stabilator Rigging Tool Figure 3...

Page 381: ...remove the tail cone fairing by removing the attaching screws and with the use of the rigging tool and bubble protractor turn the stops located at each stabilator hinge in or out Refer to Figure 4 27...

Page 382: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 2I8 27 30 00 Stabilator Trim Controls Figure 4...

Page 383: ...move the rear seat bottom and the front seats if desired 2 Unfasten the carpet from the aft portion of the floor tunnel and lay it forward 3 Remove the tunnel cover located between the trim control wh...

Page 384: ...drum and install the trim control wheel as given in step 1 3 Position the cable pulleys on their mounting bracket within the floor tunnel and install the clevis pin washer and cotter pin 4 Connect th...

Page 385: ...al rib 22 from the horizontal rib 16 that supports the trim assembly by removing the four attaching nuts washers and bolts i Draw the trim cable 12 from the fuselage 2 Installation Refer to Figure 4 a...

Page 386: ...28 3 5 Check that the trim screw 23 is turned down until the cotter pin stop in the top of the screw is contacting the plate 17 on the horizontal support rib 16 of the trim assembly If the stop is not...

Page 387: ...as follows 2 Remove servo motor and capstan Place servo motor and capstan in a holding fixture vice with capstan up Remove capstan cover Remove cotter pin from end of servo shaft and remove castle nu...

Page 388: ...lift detector from airplane B Installation NOTE Refer to Chapter 91 for electrical schematic of stall warning system 1 Attach electrical wires to their correct terminals on lift detector 2 Position li...

Page 389: ..._____________ __________ A Verify that the stall warning system performs within the following limits 1 Maximum stall warning begins at 5 to 10 KIAS prior to stall and continues until stall occurs 2 De...

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Page 393: ...of the control cable 23 as desired e Grasp the flap handle release the plunger 33 and allow the flap to return to the retracted position Use caution as forward pressure will be on the handle with the...

Page 394: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 2I20 27 50 00 Flap Control System Figure 1...

Page 395: ...17 with chain 20 and 30 on the torque tube 14 and secure with bolts washers and nuts 18 b Slide the tube stop fittings 13 on their respective ends of the torque tube c Check that one bearing block fit...

Page 396: ...QUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL ACCORDINGLY UPON COMPLETION OF FLAP RIGGING AND ADJUSTMENT VERIFY THAT THE FLAPS MOVE UP WHEN THE SELECTOR LEVER IS UP AND THAT THE FLAPS MOVE DOWN WHEN...

Page 397: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 2I23 27 50 00 Flap Rigging Tool Figure 3 Flap Stop Adjustment Figure 2...

Page 398: ...ssure against the trailing edge of the flap while making this adjustment After adjustment tighten jam nuts b Or with the flap handle in the flaps up position i e next to floor adjust each flap push ro...

Page 399: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 2J1 27 50 00 Fabricating Flap Rigging Tool Figure 4...

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Page 403: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 2J5 CHAPTER 28 FUEL...

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Page 405: ...Contents 1 Nov 30 06 2 Nov 30 06 28 00 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 28 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 28 20 00 1 Nov 30 06 2 Nov 30...

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Page 407: ...2 2J16 General 2 2J16 Fuel Tank Wing Spar Corrosion Inspection 2 2J16 Locking Fuel Cap 4 2J18 Disassembly 4 2J18 Assembly 4 2J18 DISTRIBUTION 28 20 00 1 2K1 Gascolator 1 2K1 Removal 1 2K1 Installation...

Page 408: ...BJECT SECTION PAGE GRID NO INDICATING 28 40 00 1 2K9 Standard Installation 1 2K9 Description 1 2K9 Troubleshooting 1 2K9 Fuel Quantity Transmitter Unit 1 2K9 Removal 1 2K9 Installation 1 2K9 Check and...

Page 409: ...he firewall From the strainer bowl a fuel line is routed to the electric fuel pump the engine driven fuel pump and then to the carburetor and fuel inlet port The electric fuel pump is installed on the...

Page 410: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 2J12 28 00 00 Fuel System Figure 1...

Page 411: ...ve stuck Check valve No fuel in tanks Check fuel level and fill Defective fuel pump Check pump for pressure build up Check diaphragm and relief valves in engine pump Check for obstructions in electric...

Page 412: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 2J14 28 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 413: ...tached to tank 4 Pull tank from wing assembly enough to remove sender wire 5 Remove tank B Installation 1 Slide tank into position and connect sender wire 2 Slide tank completely into position and att...

Page 414: ...ang channels nut plate strips A2 Inspect the exterior of the fuel tanks for leaks Inspect the interior for corrosion or sloshing compound If either condition exists clean repair or replace the fuel ta...

Page 415: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 2J17 28 10 00 Fuel Tank Components and Fuel Tank Wing Spar Corrosion Inspection Figure 1...

Page 416: ...5 Remove key lock by pushing keylock through cover Ensure that the O ring is not lost B Assembly 1 Insert key lock through cover Make sure that O ring gasket is installed under head of key lock 2 Slid...

Page 417: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 2J19 28 10 00 Locking Fuel Cap Figure 2...

Page 418: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 2J20 28 10 00 GRIDS 2J20 THRU 2J24 INTENTIONALLY BLANK...

Page 419: ...wl 5 Spread the ends of the bail wire to remove gascolator body from mounting bracket B Installation 1 Position the gascolator body to mounting bracket ensuring the word IN on top of the inlet port is...

Page 420: ...ctor cover and screw holding handle Remove side panel to access selector valve 2 Remove selector handle and cover 3 Disconnect fuel lines from selector valve 4 Remove fuel valve assembly attaching scr...

Page 421: ...Check all fuel line fittings for leakage 5 Install cowling C Disassembly Refer to Figure 2 Pump repair is limited to fuel reservoir area only since the electrical system is sealed Disassemble fuel pu...

Page 422: ...afety F Testing 1 Bench Test a Check pump is sufficiently lubricated to prevent damage if run dry for more than five minutes b Connect electrical lead of one pump to 28 volt dc power source c Using a...

Page 423: ...RING TORQUE CHECK A GALLED NUT AND UNION ARE SUSPECTED BACK OFF THE NUT AND INSPECT THREADS IF THE UNION IS SERVICEABLE LUBRICATE THREADS WITH MIL L 5606 HYDRAULIC FLUID TORQUE THE NUT TO VALUES PER S...

Page 424: ...standard AN fitting as per latest revision of AC43 13 1 This will require cutting off swaged ferrule and adding a short length of tubing 3 A replacement tube and union purchased from Piper will have...

Page 425: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 2K7 28 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 426: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 2K8 28 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 427: ...fuel in each tank Gauge removal and installation instructions are found in 39 10 00 B Troubleshooting Troubles unique to the fuel indicating system are listed in Chart 1 along with their probable cau...

Page 428: ...nsmitter in wings Float completely filled or saturated Replace fuel transmitter Gauge not properly adjusted Check gauge settings per paragraph 1 D Defective gauge Replace gauge Fuel gauge reads full I...

Page 429: ...it is not in this range adjust arm of the float assembly by gently bending it as shown in Figure 1 The entire float must be kept horizontal to the base of the fixture c Check transmitter unit for corr...

Page 430: ...rminal of the side not being tested b Connect resistance decade to the left or right sender terminal of the side being tested c Apply 28 1 Vdc through the resistance decade to the ground GND and posit...

Page 431: ...S 33 OHMS 23 OHMS 14 OHMS 3 OHMS B C D E F A SWITCH FUEL QUANTITY INDICATOR 5 OHM DUMMY RESISTOR 28 1 VDC LEFT SEND RIGHTSEND RIGHT NULL AND GAIN ADJUSTMENTS LEFT NULL AND GAIN ADJUSTMENTS SWITCH POSI...

Page 432: ...using APU connector e Adjust power supply unit to provide 28 1 Vdc Allow gauges to warm up for a minimum of three minutes f Place one U S gallon of fuel in the tank s being tested After recording read...

Page 433: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 2K15 28 40 00 Fuel Quantity Sender Jig Fabrication Figure 3...

Page 434: ...of Tolerance will be presented and the value will not be accepted F Once all points have been calibrated the operator presses Calibration Complete to cause the calibration factors to be computed and...

Page 435: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 9 Nov 30 06 2K17 28 40 00 THIS PAGE INTENTIONALLY BLANK...

Page 436: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 10 Nov 30 06 2K18 28 40 00 GRIDS 2K18 THRU 2L24 INTENTIONALLY BLANK...

Page 437: ...PART NUMBER 761 882 November 30 2006 3A1 AIRPLANE MAINTENANCE MANUAL CARD 3 OF 5 PA 28 161 S N s 2842001 UP PIPER AIRCRAFT INC...

Page 438: ...3A2 Published by Technical Publications Piper Aircraft Inc 2926 Piper Drive Vero Beach Florida 32960 U S A Member General Aviation Manufacturers Association...

Page 439: ...80301 March 1 1998 All PR011215 December 15 2001 1 PR030720 July 20 2003 1 and 2 CR040415 April 15 2004 All PR040818 August 18 2004 1 3 4 and 5 CR061130 November 30 2006 1 2 3 4 and 5 COMPLETE REVISIO...

Page 440: ...PAGE 2 Nov 30 06 AEROFICHE EFFECTIVITY 3A4 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 441: ...1 Nov 30 06 Effective Pages 2 Nov 30 06 Intro Table of Contents 1 Nov 30 06 2 Nov 30 06 Introduction 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9...

Page 442: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 INTRO LIST OF EFFECTIVE PAGES THIS PAGE INTENTIONALLY BLANK 3A6...

Page 443: ...ivity 2 3A10 Serial Number Explanation 2 3A10 Assignment of Subject Material 2 3A10 Pagination 3 3A11 Aerofiche Effectivity 3 3A11 Identifying Revised Material 3 3A11 Indexing 3 3A11 List of Effective...

Page 444: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3A8 INTRO CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 445: ...IR OF PIPER AIRPLANES This manual generally does not contain hardware callouts for installation Hardware callouts are only indicated where a special application is required To confirm the correct hard...

Page 446: ...tems such as Environmental Systems Electrical Power Landing Gear etc They are assigned a number which becomes the first element of the standardized numbering system Thus the element 28 of the number 2...

Page 447: ...all fiche in this set 2 A complete subject Index for all fiche in this set 8 Identifying Revised Material A revision to a page is defined as any change to the printed matter that existed previously Re...

Page 448: ...essive Inspection Manual pending 767 002 B Vendor Publications WARNING FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION S WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT MAY...

Page 449: ...or PH 800 998 8857 7 FIRE EXTINGUISHER PORTABLE Vendor H3R Inc PH 800 249 4289 43 Magnolia Ave 4 San Francisco California 94123 2911 http www h3r com index htm 8 FUEL PUMP Vendor Weldon Pumps PH 440...

Page 450: ...Wichita KS 67226 http www mcico com index html Installation Manual and Operating Instructions Manual No 9015762 14 STARTER Vendor Sky Tec PH 800 476 7896 350 Howard Clemmons Rd FAX 817 573 2252 Granb...

Page 451: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 3A15 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 452: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 3A16 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 453: ...bined with another chapter CHAPTER SECTION TITLE GRID NO 4 AIRWORTHINESS LIMITATIONS 1C1 00 Airworthiness Limitations 5 TIME LIMITS MAINTENANCE CHECKS 1C9 00 General 10 Time Limits 20 Scheduled Mainte...

Page 454: ...23 COMMUNICATIONS 2C19 00 General 50 Audio Integrating 60 Static Discharging 24 ELECTRICAL POWER 2D9 00 General 30 DC Generation 40 External Power 50 Electrical Load Distribution 25 EQUIPMENT FURNISH...

Page 455: ...l 10 Flight Compartment 40 Exterior 34 NAVIGATION AND PITOT STATIC 3G1 10 Flight Environmental Data 20 Attitude and Direction 37 VACUUM 3I11 00 General 10 Distribution 20 Indicating 39 ELECTRICAL ELEC...

Page 456: ...ary Structure 40 Attach Fittings 50 Flight Surfaces 61 PROPELLER 4H21 10 Propeller Assembly 70 STANDARD PRACTICES ENGINE 4I9 00 General 71 POWER PLANT 4I17 00 General 10 Cowling 20 Mounts 60 Air Intak...

Page 457: ...AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 13 Nov 30 06 3A21 INTRODUCTION 79 OIL 5E17 20 Distribution 30 Indicating 80 STARTING 5F7 10 Cranking 91 CHARTS WIRING DIAGRAMS 5F21 10 Chart...

Page 458: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 14 Nov 30 06 3A22 INTRODUCTION GRIDS 3A22 THRU 3A24 INTENTIONALLY BLANK...

Page 459: ...tenance 3I1 Consumable Materials 5G15 Control Cable Inspection 2G12 Cable Fittings 100 Hour Special Inspection 2G15 Control Column Assembly 2H3 Conversion Tables Decimal Conversions 5G9 Drill Sizes 5G...

Page 460: ...4E23 Engine Controls Adjustment 4K13 Mixture 4K12 Throttle 4K12 EGT Probe Installation 5E3 Exhaust See Exhaust System Fuel Carburetor 4K11 Idle Mixture 4K11 Idle Speed 4K12 Primer 4K7 Hour Meter 5I5...

Page 461: ...ironment Extreme Cold 1D17 High Dust or Industrial Pollution 1D16 High Salt or High Humidity 1D17 Soft or Unusual Terrain 1D18 Procedure Aft Wing Attach Fittings 100 Hour 4E13 Control Cable Fittings 2...

Page 462: ...I3 Publications Piper 1A12 Vendor 1A12 R Repairs Fiberglass 4C19 Metal Wire Stitching 4D6 Safety Walk 4D5 Skin Materials and Thickness 4C8 Thermoplastic 4C21 List of Materials 4C23 Restraint System 2F...

Page 463: ...8 Magnetos 5C8 Oil Temperature Indicator 5F3 Rudder Control System 2H15 Stabilator Control System 2I2 Trim Control 2I3 Standby Alternator 2E6 Starter 5F14 Strobe Lights Tachometer 5D23 Turn and Bank I...

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Page 465: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3C1 CHAPTER 30 ICE AND RAIN PROTECTION...

Page 466: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3C2 THIS PAGE INTENTIONALLY BLANK...

Page 467: ...C3 30 LIST OF EFFECTIVE PAGES CHAPTER 30 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 30 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 30 Table of Contents 1 Nov 30 06 2 Nov 30 06 30 00 00 1 No...

Page 468: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 30 LIST OF EFFECTIVE PAGES 3C4 THIS PAGE INTENTIONALLY BLANK...

Page 469: ...INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 3C5 30 CONTENTS CHAPTER 30 ICE AND RAIN PROTECTION TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO GENERAL 30 00 00 1 3C7 PITOT AND STATIC...

Page 470: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3C6 30 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 471: ...nditions Accordingly limited ice and rain protection is provided in the form of an optional heated pitot static mast see 30 30 00 carburetor heat and an optional carburetor ice detection system see 71...

Page 472: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3C8 30 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 473: ...switch located on the center instrument panel just above the engine power quadrant In addition to the switch the system incorporates a heated pitot static head and the 10 amp PITOT HEAT circuit breake...

Page 474: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3C10 30 30 00 GRIDS 3C10 THRU 3C14 INTENTIONALLY BLANK...

Page 475: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3C15 CHAPTER 31 INDICATING RECORDING SYSTEMS...

Page 476: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3C16 THIS PAGE INTENTIONALLY BLANK...

Page 477: ...IST OF EFFECTIVE PAGES CHAPTER 31 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 31 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 31 Table of Contents 1 Nov 30 06 2 Nov 30 06 31 50 00 1 Nov 30 06...

Page 478: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 31 LIST OF EFFECTIVE PAGES 3C18 THIS PAGE INTENTIONALLY BLANK...

Page 479: ...ARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 3C19 31 CONTENTS CHAPTER 31 INDICATING RECORDING SYSTEMS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO CENTRAL WARNING SYSTEMS 31 50 00 1 3D1 Annunciato...

Page 480: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3C20 31 CONTENTS GRIDS 3C20 THRU 3C24 INTENTIONALLY BLANK...

Page 481: ...ciator light s fail to illuminate as expected refer to Chart 2 Nomenclature Color Event LOW BUS VOLTAGE RED Illuminates when the electrical system drops from bus voltage 28 Vdc to battery voltage 24 5...

Page 482: ...NATOR INOP VACUUM INOP OPTIONAL CARB ICE OPTIONAL 85372 M LOW BUS VOLTAGE PITOT HEAT OFF INOP STARTER ENGAGE ALTERNATOR INOP OIL PRESSURE STBY ALTR ON CARB ICE LOW BUS VOLTAGE PITOT HEAT OFF INOP STAR...

Page 483: ...sition Open wires from day night Check wire connections switch to dimmer box LOW BUS VOLTAGE fails Blown bulb s Replace bulb s to illuminate Blown in line fuse between bus Replace fuse bar and Low Vol...

Page 484: ...nsor activates at a too Replace See Chapter 37 not extinguish high of a setting Sensor terminals bridged Remove material between terminals Defective sensor Replace See Chapter 37 VACUUM INOP fails to...

Page 485: ...connections Sensor activates at a too low Replace sensor setting See Chapter 79 OIL PRESSURE fails to extinguish Sensor activates at a too high Replace sensor setting See Chapter 79 Sensor terminals...

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Page 487: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3D7 CHAPTER 32 LANDING GEAR...

Page 488: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3D8 THIS PAGE INTENTIONALLY BLANK...

Page 489: ...06 3 Nov 30 06 4 Nov 30 06 32 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 32 20 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06...

Page 490: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 32 LIST OF EFFECTIVE PAGES 3D10 THIS PAGE INTENTIONALLY BLANK...

Page 491: ...4 3D20 Cleaning Inspection and Repair 4 3D20 Installation 6 3D22 NOSE GEAR 32 20 00 1 3E1 Nose Gear Oleo 1 3E1 Disassembly 1 3E1 Cleaning Inspection and Repair 2 3E2 Oil Orifice Retainer Ring Install...

Page 492: ...5 3E15 Cleaning Inspection and Repair 5 3E15 Assembly and Installation 6 3E16 Hand Parking Brake Master Cylinder 8 3E18 Removal 8 3E18 Disassembly 10 3E20 Cleaning Inspection and Repair 10 3E20 Assem...

Page 493: ...ugh a 40 arc enabling a short turning radius in each direction Spring assisted push rods are attached to the rudder pedal torque tube assemblies to aid in nose wheel and rudder centering A shimmy damp...

Page 494: ...ushings or bushings Excessive or uneven wear Incorrect operating Inflate tire to correct on nose tire pressure pressure Wear resulting from Refer to preceding Trouble shimmy column for correction Nose...

Page 495: ...se Remedy Excessive or uneven wear Incorrect operating pressure Inflate tire to correct on main tires pressure Wheel out of alignment Check wheel alignment toe in or out Strut bottoms on normal Insuff...

Page 496: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 3D16 32 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 497: ...end of the cylinder housing is removed by first removing the retainer ring 13 spacer ring 12 and then the scraper ring e The O ring seal 10 located just above the scraper ring may be removed by using...

Page 498: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3D18 32 10 00 Main Gear Oleo Strut Figure 1 Sheet 1 of 2...

Page 499: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 3D19 32 10 00 Main Gear Oleo Strut Figure 1 Sheet 2 of 2...

Page 500: ...an under the main gear to catch spillage 3 If desired remove the air from the oleo chamber by depressing the air valve core pin found in the inspection hole on top of the wing After the pressure in th...

Page 501: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 3D21 32 10 00 Main Gear Installation Figure 2...

Page 502: ...e gear up in the wing through the access opening and secure with bolts washers and nuts b Reconnect the brake line at the point of disconnection 2 Service the oleo strut per Oleo Struts 12 10 00 3 Ser...

Page 503: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 3D23 32 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 504: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 3D24 32 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 505: ...steering horn attached bolt to the tube retainer nut Then remove the steering horn attaching bolt and the flat head pin thus relieving the steering horn from the top of the strut housing 6 Loosen the...

Page 506: ...ted holes cracks corrosion scratches nicks and straightness e General condition of air valve 3 Repair of the oleo is limited to smoothing out minor scratches nicks and dents and replacement of parts C...

Page 507: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 3E3 32 20 00 Nose Gear Oleo Strut Figure 2...

Page 508: ...o a snug fit 10 To install the steering horn assembly insert the flat head pin through the side of the horn and top of the strut assembly When it protrudes through the other side of the steering horn...

Page 509: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 3E5 32 20 00 Nose Gear Installation Figure 3...

Page 510: ...e use of either one or two AN960 6l6 washers is permissible on the bolt attachments of the engine mount to the fuselage Torque the bolt heads to 240 270 inch pounds 1 Install the nose gear and engine...

Page 511: ...igging and Adjustment 27 20 00 7 Clamp the rudder pedals together to align them in a lateral position See Figure 4 The rudder pedals are tilted aft of vertical when in their neutral position as shown...

Page 512: ...ing horn NOTE Check that the rod ends have sufficient thread engagement by use of the check holes in the rods 11 Check that the rudder pedal stops are adjusted in accordance with instructions given in...

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Page 514: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 10 Nov 30 06 3E10 32 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 515: ...10 00 b If wheel fairing is installed remove attaching screws bolt and remove the fairing c To remove the main wheel remove the four cap bolts that join the brake cylinder housing and the lining back...

Page 516: ...ntains the valve stem hole Insert the valve stem Position the tire and tube so the index mark on the tire is aligned with the index mark on the tube to maintain proper wheel balance b Join the two whe...

Page 517: ...ate on top held by metal screws Slide fairing up on the gear until wheel is removed c Remove wheel by the following procedure 1 Remove the nut and washer from one end of the axle rod and slide out the...

Page 518: ...e so the index mark on the tire is aligned with the index mark on the tube to maintain proper wheel balance b Join the two wheel halves aligning the wheel bolt holes Install the through bolts 18 with...

Page 519: ...ake assembly 1 Disconnect the brake line from the brake cylinder at the tube fitting 2 Remove the two cap bolts that join the brake cylinder housing and the lining back plate assembly 3 Remove the bac...

Page 520: ...wheel disc refer to Wheels Main Wheels Removal and Disassembly above e Remove lining from backing plates by drilling or punching out the old rivets Install a new set using the proper rivets and a rive...

Page 521: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 3E17 32 40 00 Anchor Bolt Figure 4...

Page 522: ...ne 8 from the fitting at the top of the cylinder and allow fluid to drain from the reservoir and line into a suitable container b Disconnect the pressure line from the fitting on the cylinder and allo...

Page 523: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 9 Nov 30 06 3E19 32 40 00 Brake System Installation Figure 6...

Page 524: ...acking gland 9 and on the outside of the piston 6 When installing teflon O ring 5 on piston it is recommended that it be installed with the use of a cone placed against the piston The cone may be cons...

Page 525: ...ssembly O ring 5 and gland 8 and if desired the return spring 14 d Remove the O rings from the piston and packing gland 3 Cleaning Inspection and Repair a Clean cylinder components with a suitable sol...

Page 526: ...the hand brake an additional 25 times or until no air is observed through the clear plastic tube g Tighten brake bleeder and remove the plastic tube h Repeat steps a through g to the left main landin...

Page 527: ...RE TIMES OR UNTIL ALL THE AIR IS RELEASED FROM THE SYSTEM DURING ALL BLEEDING FLUID LEVEL OF THE RESERVOIR MUST BE MAINTAINED a Actuate the hand brake handle until some pressure builds up in the syste...

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Page 529: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 15 Nov 30 06 3F1 32 40 00 THIS PAGE INTENTIONALLY BLANK...

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Page 531: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3F3 CHAPTER 33 LIGHTS...

Page 532: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3F4 THIS PAGE INTENTIONALLY BLANK...

Page 533: ...CHAPTER SECTION PAGE DATE 33 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 33 Table of Contents 1 Nov 30 06 2 Nov 30 06 33 00 00 1 Nov 30 06 2 Nov 30 06 33 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06...

Page 534: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 33 LIST OF EFFECTIVE PAGES 3F6 THIS PAGE INTENTIONALLY BLANK...

Page 535: ...t 1 3F11 Dimmer Control 2 3F11 Removal 2 3F11 Installation 2 3F11 Dimmer Control Potentiometer 2 3F12 Removal 2 3F12 Installation 2 3F12 EXTERIOR 33 40 00 1 3F15 Landing and Taxi Light 1 3F15 Removal...

Page 536: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3F8 33 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 537: ...t instrument panel below the pilot s control wheel The annunciator panel located on the top right of the pilot s instrument panel includes starter engage alternator inop oil pressure vacuum inop low b...

Page 538: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3F10 33 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 539: ...ulbs Replace defective bulb s and reverse removal procedure Select BATT MASTR switch ON then depress Test switch to verify lamp is functioning See Section 31 50 00 for functional Description Operation...

Page 540: ...m back of dimmer control potentiometer 6 Remove dimmer control potentiometer B Installation 1 Solder wires to proper contacts on back of new dimmer potentiometer NOTE Check that potentiometer control...

Page 541: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 3F13 33 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 542: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 3F14 33 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 543: ...ghts Individual red and white navigation lights are installed in the left wing tip The right wing tip contains individual green and white navigation lights The lights are controlled by a rocker type s...

Page 544: ...t breaker c Remove two screws securing navigation light cover and remove cover d Remove three screws securing navigation light bracket assembly e Separate light bracket assembly from wing tip by pulli...

Page 545: ...fuselage accessible through the cabin rear closeout panel 1 Removal a Be sure electrical power is removed from aircraft and or applicable system b Remove access panel to the aft section of the fuselag...

Page 546: ...igure 1 Sheet 1 of 2 GND BLK TRIGGER 2 1 POWER 1 L4C20 TAIL 2 WING WING 3 4 POWER SUPPLY SEE VIEW A SEE VIEW B NO JUMPER IN S N S 2842001 THRU 2842063 36879 AS 104296 K 3 2 1 GND VIEW A L4C20 WHT RED...

Page 547: ...0 TRIGGER POWER 1 1 2 SEE VIEW B 3 2 TAIL WING 4 WING P33 I E FIN STROBE POWER SUPPLY OFF STROBE LIGHTS FIN STROBE JUMPER L4G20 L4E20 L4A20 L4B20 SWITCH CONNECTIONS SWITCH FACE SEE VIEW A TAIL STROBE...

Page 548: ...en Pin 1 and 3 of interconnecting cable If a reading is obtained on the meter the cable is shorted and should be replaced NOTE A short of the type described in steps 1 and 2 will not cause permanent d...

Page 549: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 3F21 33 40 00 THIS PAGE INTENTIONALLY BLANK...

Page 550: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 3F22 33 40 00 GRIDS 3F22 THRU 3F24 INTENTIONALLY BLANK...

Page 551: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3G1 CHAPTER 34 NAVIGATION AND PITOT STATIC...

Page 552: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3G2 THIS PAGE INTENTIONALLY BLANK...

Page 553: ...v 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9 Nov 30 06 10 Nov 30 06 34 20 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9...

Page 554: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 34 LIST OF EFFECTIVE PAGES 3G4 THIS PAGE INTENTIONALLY BLANK...

Page 555: ...ion Indicator ADI Artificial Horizon 1 3H1 Description and Operation 1 3H1 Troubleshooting 1 3H1 Standby Attitude Indicator 2 3H2 Electronic Flight Instrument System EFIS 3 3H3 Description 3 3H3 Maint...

Page 556: ...SUBJECT SECTION PAGE GRID NO ATTITUDE AND DIRECTION cont 34 20 00 Turn Coordinator 20 3H20 Description and Operation 20 3H20 Troubleshooting 20 3H20 DEPENDENT POSITION DETERMINING 34 50 00 1 3I1 COM...

Page 557: ...T INSTALLED IN PIPER AIRCRAFT MAY RENDER THE AIRCRAFT UNAIRWORTHY SEE INTRODUCTION SUPPLEMENTARY PUBLICATIONS These airplanes are equipped with conventional air vacuum and electrically driven flight i...

Page 558: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3G8 34 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 559: ...in erratic or zero instrument readings The static air system consists of interconnected static ports on the underside and aft side of the pitot static mast The ports are connected to the airspeed indi...

Page 560: ...06 3G10 34 10 00 AIRSPEED INDICATOR REF ALTIMETER REF ENCODER REF STATIC LINE PITOT LINE PITOT STATIC PRIMARY FLIGHT DISPLAY PFD REF OPTIONAL AVIDYNE ENTEGRA INSTALLATION UP FWD 35493 BX Pitot Static...

Page 561: ...ot set on zero Aging of diaphragm Use set screw to reset when airplane is in accelerated pointer on zero Tap level flight instrument gently while resetting Pointer fails to respond Obstruction in stat...

Page 562: ...ed on the right side of the indicator dial and is set by the knob located on the lower left corner of the instrument to compensate for variation from standard sea level pressure The altimeter is a sea...

Page 563: ...rature compensator Replace instrument frequently inoperative High or low reading Improper venting Eliminate leak in static pressure system and check alignment of airspeed tube Setting knob is hard to...

Page 564: ...ions in static system are opened for maintenance the complete system must be rechecked per F A R 23 1325 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 3G14 34 10 00 CHAR...

Page 565: ...y b Remove bushing on outside of windshield by sliding it off of threaded shaft Note position of any washers or spacers c Remove gauge and inner bushing by pulling gauge through windshield from inside...

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Page 567: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 9 Nov 30 06 3G17 34 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 568: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 10 Nov 30 06 3G18 34 10 00 GRIDS 3G18 THRU 3G24 INTENTIONALLY BLANK...

Page 569: ...arked for different degrees of bank The display is stable and shows minute attitude changes of as little as one degree A rapidly wobbling and leveling pitch bar when vacuum is first applied is normal...

Page 570: ...ired periodic maintenance is listed in 5 20 00 and 5 30 00 Checkout and test procedures and Instructions for Continued Airworthiness are provided in Mid Continent Instruments Manual No 9015762 CHART 1...

Page 571: ...IRWORTHY SEE INTRODUCTION SUPPLEMENTARY PUBLICATIONS The Avidyne Entegra Electronic Flight Instrument System EFIS is available as an option in S N s 2842218 and up A Description See Figures 1 2 and 3...

Page 572: ...ITH 4 CAPTIVE SCREWS TORQUE TO 31 32 IN LBS INSTALL MFD WITH 4 CAPTIVE DZUS FASTENERS INSTRUMENT PANEL LOOKING FWD INSTRUMENT PANEL LOOKING AFT 101901 SHT 6 N STANDBY ATTITUDE INDICATOR MFD PFD STANDB...

Page 573: ...ble 2 Main RS232 Configuration Page for CHNL 3 under GNS 430 in slot 2 both Input and Output should read Crossfill instead of Off d Para 7 5 5 Autopilot Setup is not applicable to the Warrior III inst...

Page 574: ...1910 P 101901 SHT 8 N 101910 SHT 5 K FS 128 73 DC 50 ANTENNA COUPLER K17 RELAY AND SUPPRESSION DIODE VIEW A A ANTENNA COUPLER INSTALLATION LOOKING FWD STA 48 6 P303 P304 P305 REF DAU VIEW B B DAU INST...

Page 575: ...o save the changes press Cancel Changes will not take effect until the MFD has been restarted Only with Avidyne software 530 00177 000 or later e See 28 40 00 for Fuel Quantity Indication Calibration...

Page 576: ...Nov 30 06 3H8 34 20 00 LEFT WING LOOKING DOWN FS 104 25 WS 206 70 WS 190 90 WS 174 00 WS 157 00 WS 140 09 WS 123 15 WS 106 19 WS 86 03 WS 64 59 WS 49 25 WS 24 24 SEE DETAIL BELOW PITOT HEAD REF Compon...

Page 577: ...F AVIONICS SYSTEM HARNESS ASSY 101901 SHT 12 N 101901 SHT 13 N ADF OR GI 106 OPT DME OPTIONAL L5 L6 L7 55X SYSTEM GMA 340 PFD REF MFD REF GNS 430 2 REF GNS 430 1 REF J530 J731 J733 J732 J730 ADI REF A...

Page 578: ...GTX 330 TRANSPDR REF ADF RECEIVER OPT J530 J731 J733 J732 J730 ADI REF ADF OR GI 106 OPT FWD TO GROUND BLOCK REF COM ANT TO COM2 DATALINK ANT LOOKING AFT LOOKING DOWN AVIONICS SYSTEM HARNESS ASSY MFD...

Page 579: ...and the magnetic compass necessitating resetting the gyro Even while maintaining a given heading the compass card tends to precess drift due to internal friction spin axis error air turbulence and air...

Page 580: ...e following 1 Relief valve improperly 1 Adjust relief valve adjusted 2 Incorrect gauge reading 2 Replace gauge 3 Pump failure 3 Repair or replace 4 Vacuum line kinked or 4 Check and repair Check leaki...

Page 581: ...detector into position on its mounting bracket and secure with brass screws and washers 3 ea 2 Connect wiring harness to the connector on top of the flux detector 3 Reinstall the left wing tip NOTE En...

Page 582: ...the North compass rose heading Rotate the indicator card to North using the manual slave buttons on the slaving control With a non magnetic screwdriver in the N S opening on the slaving control cente...

Page 583: ...ors in excess of 10 are the fault of the instrument replace instrument After installing a new instrument repeat procedures 1 and 2 f After all adjustments are completed the indicator shall read within...

Page 584: ...for the gyro to erect and synchronize 2 Prior to actual alignment of the flux sensor turn the aircraft to both north and east headings Apply power to electrical equipment such as navigation and beacon...

Page 585: ...161 WARRIOR III MAINTENANCE MANUAL PAGE 17 Nov 30 06 3H17 34 20 00 Approx Magnetic Actual Magnetic Heading Card Heading Heading Reading Deviation North East South West CHART 3 DEVIATION CHART ST 180 D...

Page 586: ...hragm Replace instrument collapsed Card does not move when The gears that turn compensating Replace instrument compensating screws are turned magnets are stripped Compass swings erratically Normal Non...

Page 587: ...lign airplane with magnetic north Note heading being indicated on magnetic compass may not be North and enter on compass deviation correction card h Align airplane with successive magnetic 30 headings...

Page 588: ...n a coordinated turn the small airplane will remain deflected indicating the turn 2 A metal ball sealed in a curved glass tube filled with dampening fluid provides a sensitive indication of yaw slip s...

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Page 590: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 22 Nov 30 06 3H22 34 20 00 GRIDS 3H22 THRU 3H24 INTENTIONALLY BLANK...

Page 591: ...ied avionics shop in accordance with the GARMIN Series 400 Maintenance Manual Garmin P N 190 00140 05 Information provided in this manual is intended solely to aid the removal and installation of the...

Page 592: ...or Rotating the outer concentric knob on the right side of the unit changes the selected data field Rotating the inner concentric knob changes the data within the selected field To accept entry of the...

Page 593: ...cursor and rotate the inner concentric knob on the right side of the unit to display the MAIN LIGHTING page Change only the SOURCE setting to display an output of PHOTO and key of PHOTO d Deselect the...

Page 594: ...l and Installation See 39 10 00 C S N s 2842201 and up A Garmin GTX 330 Transponder is installed as standard equipment Maintenance of the GTX 330 is on condition only and with the exception of swappin...

Page 595: ...TEMPERATURE Page select NO for SENSOR INSTALLED d MODE S Address ICAO Aircraft Address Code and FLIGHT ID Entry Page When the unit is turned on for the first time or an invalid address is recognized...

Page 596: ...E MESSAGE 0 5 Selected Audio Tones and Messages 0 Toggle a continuous tone on and off 1 Attention Tone precedes voice messages to attract the pilot s attention 2 Leaving Altitude when altitude monitor...

Page 597: ...429 OUTPUT DATA CHANNEL 1 OFF CHANNEL 2 GARMIN W TIS GARMIN W SKYWATCH CHART 4 ARINC 429 CONFIGURATION PAGE CHART 6 OPERATION CONFIGURATION VS RATE 500 FORMAT FEET VFR ID 1200 ALTITUDE ALERT DEVIATIO...

Page 598: ...inary code to hexadecimal as follows 1 24 bit binary code 11100100011111101101101 2 Separate for hex conversion 1110 0100 0111 1110 1110 1101 3 Apply the hexadecimal values found in Chart 7 E 4 7 E E...

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Page 601: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3I11 CHAPTER 37 VACUUM...

Page 602: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3I12 THIS PAGE INTENTIONALLY BLANK...

Page 603: ...E 37 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 37 Table of Contents 1 Nov 30 06 2 Nov 30 06 37 00 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 37 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06...

Page 604: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 37 LIST OF EFFECTIVE PAGES 3I14 THIS PAGE INTENTIONALLY BLANK...

Page 605: ...1 3I21 Vacuum Pump 2 3I22 Inspection 2 3I22 Removal 3 3I23 Installation 3 3I23 Replacing Pump Fittings 3 3I23 Vacuum Regulator 4 3I24 Service Tips 4 3I24 Removal and Replacement 4 3I24 Adjustment 4 3I...

Page 606: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3I16 37 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 607: ...tation in Warrior III airplanes gives quick and actual indication of airplane attitude performance and condition Maintenance other than described must be done by the instrument manufacturer or an auth...

Page 608: ...strument Replace instrument sluggish operation of instruments High system pressure Vacuum regulator incorrectly Adjust regulator adjusted Vacuum regulator sticking Clean screen and check or dirty scre...

Page 609: ...Leak in vacuum system Tighten clamps and check check and little or no vacuum hoses Replace if is indicated AUX ON necessary annunciator will not light Restriction in hose lines Inspect and repair hose...

Page 610: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 3I20 37 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 611: ...p air Remove from aircraft as required CAUTION DO NOT WIGGLE HOSE FROM SIDE TO SIDE DURING INSTALLATION WIGGLING COULD CAUSE PARTICLES TO BE CUT FROM INNER WALL OF HOSE WHICH WOULD DAMAGE THE PUMP E W...

Page 612: ...riginal equipment in S N s 2842001 thru 2842165 Beginning with S N s 2842165 later and for all service replacement requirements Aero Accessories Tempest pumps are installed A Inspection Aero Accessori...

Page 613: ...hose clamps 5 Reinstall engine cowling D Replacing Pump Fittings CAUTION WHEN REPLACING ANY OF THE THREADED FITTINGS DO NOT USE PIPE DOPE THREADLUBE OR TAPE PIPE DOPE TAPE PARTICLES INGESTED BY THE V...

Page 614: ...connect and mark electrical wires 3 Remove mounting nut Remove regulator valve 4 Install regulator valve in reverse order of removal C Adjustment WARNING DO NOT ATTEMPT ADJUSTMENT OF VACUUM REGULATOR...

Page 615: ...annunciator extinguishes Check that the vacuum gauge reads between 4 8 and 5 2 in hg 3 Press VAC OFF AUX ON annunciator switch to cycle it to the off position Check that AUX ON annunciator goes out an...

Page 616: ...cure excess lead wire 4 Remove top engine cowling 5 Mount pump motor assembly to bracket with band clamps Do not tighten clamps NOTE Rotate pump motor assembly within clamps for easier installation 6...

Page 617: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 3J3 37 10 00 Auxiliary Vacuum Pump Installation Optional Figure 2...

Page 618: ...17 373 15 373 19 373 13 F7 64 1 RELAY V6A20 EMI FILTER PUMP SWITCH VAC OFF AUX ON FRONT VIEW REAR VIEW V5A20 V4A20 MANIFOLD V3B20 V3C20 V1A20 ETI ASSEMBLY 20 5 D C BUS V3A20 V2A20 W4B REGULATOR V7A14...

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Page 620: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 10 Nov 30 06 3J6 37 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 621: ...vacuum gauge malfunctions in a manner to cause an incorrect reading in normal cruise conditions the gauge must be checked by comparing its reading with a gauge of known accuracy If the gauge is confi...

Page 622: ...when the suction from the vacuum pump drops below 3 5 psig A Removal 1 Disconnect the two electrical leads 2 Unscrew switch unit from vacuum regulator 3 Cover hole in vacuum regulator to prevent fore...

Page 623: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 3J9 37 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 624: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 3J10 37 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 625: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3J11 CHAPTER 39 ELECTRICAL ELECTRONIC PANELS...

Page 626: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3J12 THIS PAGE INTENTIONALLY BLANK...

Page 627: ...of 1 Nov 30 06 Effective Pages 2 Nov 30 06 39 Table of Contents 1 Nov 30 06 2 Nov 30 06 39 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 39 20 00 1 Nov 30 06 2 Nov 30...

Page 628: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 39 LIST OF EFFECTIVE PAGES 3J14 THIS PAGE INTENTIONALLY BLANK...

Page 629: ...S SUBJECT SECTION PAGE GRID NO INSTRUMENT AND CONTROL PANELS 39 10 00 1 3J17 General 1 3J17 Face Mounted Instruments 1 3J17 Removal 1 3J17 Installation 1 3J17 Rack Mounted Avionics 1 3J17 Removal 1 3J...

Page 630: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3J16 39 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 631: ...slid gently forward to expose the connections at the rear b Remove the screws that secure the instrument in the panel cutout c Remove the instrument from the panel 2 Installation a Place the instrumen...

Page 632: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 3J18 39 10 00 Instrument Panel Typical Figure 1...

Page 633: ...ircuit breakers are installed in the lower right instrument panel and are of the single hole mounting pushbutton type with manual reset Should a circuit breaker be replaced or added exercise extreme c...

Page 634: ...AT POINT OF CONNECTION IN ANY CASE IT S BETTER TO DAMAGE THE SWITCH AND REPLACE IT RATHER THAN DAMAGE THE WIRING HARNESS LEADS A Removal 1 Disconnect positive battery cable 2 Gain access to the switc...

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Page 636: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 3J22 39 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 637: ...Box Assembly 9 Annunciator Dimmer Assembly 9 Avionics Cooling Blower 7 Battery Contactor 4 Control Assembly 7 DAU 10 EGT Probe 11 Exceedance Horn 10 Fuse Assembly 11 Lift Sensor 2 Light Dimmer 5 Low...

Page 638: ...II MAINTENANCE MANUAL PAGE 2 Nov 30 06 3J24 39 20 00 ITEM NUMBERS ARE KEYED TO FIGURE SHEET NUMBER 9 10 11 3 2 10 85360 T 101911 V 104304 J 2 12 9 10 8 2 8 11 3 11 4 5 7 10 6 Electrical Electronic Com...

Page 639: ...NTENANCE MANUAL PAGE 3 Nov 30 06 3K1 39 20 00 LIFT SENSOR LOOKING INBOARD F1E20 F1C20 STALL HORN F1A20 F1B20 UNDER INSTRUMENT PANEL LOOKING LEFT FROM AIRCRAFT CENTERLINE ROTATED 180 Electrical Electro...

Page 640: ...GROUND WIRE NIPPLE K2B4 ENGINE GROUND TO FUEL PUMP LOOKING AFT AT LEFT SIDE LOWER FIREWALL ENGINE GROUND K2B4 NIPPLE GROUND WIRE STARTER CONTACTOR NIPPLE SLEEVE TO STARTER TO FUEL PUMP TO BATTERY CON...

Page 641: ...BLACK RED LOOKING OUTBOARD FROM CENTERLINE P 1 C 4 M1B20 L11B20 P1D4 P4A20 TO STARTER CONTACTOR S N S 2842218 AND UP BATTERY CONTACTOR BATTERY CONTACTOR P1D4 P 1 C 4 M2C20 M1B20 P4AA20 FUSE ASSY TO ST...

Page 642: ...II MAINTENANCE MANUAL PAGE 6 Nov 30 06 3K4 39 20 00 SWITCH PANEL RADIO P312 P313 P314 LIGHT DIMMER INSTALLATION UNDER INSTRUMENT PANEL RIGHT SIDE LOOKING FORWARD CONTROLLER 3 Electrical Electronic Com...

Page 643: ...OUT SWITCH RED WIRE W2D20 W2B20 VOLTAGE REGULATOR G B 3 G B 3 G B 4 G B 4 ENCODER REF TRIM MONITOR REF GROUND BLOCKS RED BLUE BLACK LEFT SIDE ELECTRICAL PANEL UNDER INSTRUMENT PANEL LOOKING OUTBOARD...

Page 644: ...e 1 Sheet 7 of 12 R 4AMM P AMM PITOT HEAT SENSOR ASSY OPT GND WIRES TO DIMMER CONTROLS CONTROL ASSY GROUND BLOCK GROUND BLOCK J310 J311 LOW VOLTAGE MONITOR ASSY PITOT HEAT SENSOR ASSY GB1 GB2 GB3 AVIO...

Page 645: ...REGULATOR FORWARD OF INSTRUMENT PANEL RIGHT SIDE LOOKING OUTBOARD BRACKET REF W L 47 450 CURRENT LIMITER J326 P326 CURRENT SENSOR ASSY SP1A10 TO AMMETER SHUNT TO VOLTAGE REGULATOR TO STANDBY ALTERNATO...

Page 646: ...ABIN FLOOR FUSELAGE HARNESS ANNUNCIATOR DIMMER ASSEMBLY W12A20N P302 J302 128 737 FRAME ASSEMBLY RIGHT LOOKING AFT S N s 2842218 AND UP 128 737 FRAME ASSEMBLY RIGHT LOOKING AFT ANNUNCIATOR BOX ASSEMBL...

Page 647: ...KET EXCEEDANCE HORN BRAKE CHANNEL UNDER INSTRUMENT PANEL LOOKING INBOARD FROM LEFT E7T22 E7S22 S N s 2842218 AND UP FUSELAGE HARNESS CABIN FLOOR DAU 128 737 FRAME ASSEMBLY LEFT LOOKING AFT S N s 28422...

Page 648: ...P3A4 EGT SENSOR PROBE YELLOW WHITE TO DAU GREEN TO BUS P3B4 TO CURRENT LIMITER SP1A10 SHUNT FUSE ASSEMBLY P400 RED FRONT LEFT CYLINDER LOOKING INBOARD LOOKING AFT AND DOWN AT LEFT UPPER FIREWALL S N s...

Page 649: ...161 WARRIOR III MAINTENANCE MANUAL 3K11 39 20 00 C NC NO FIREWALL OIL PRESSURE SWITCH OIL PRESSURE SENDER M3C20 W6B20N W6A20 FWD LOOKING DOWN Electrical Electronic Component Locator Figure 1 Sheet 12...

Page 650: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 3K12 39 20 00 PAGE 14 Nov 30 06 GRIDS 3K12 THRU 3L24 INTENTIONALLY BLANK...

Page 651: ...PART NUMBER 761 882 November 30 2006 4A1 AIRPLANE MAINTENANCE MANUAL CARD 4 OF 5 PA 28 161 S N s 2842001 UP PIPER AIRCRAFT INC...

Page 652: ...4A2 Published by Technical Publications Piper Aircraft Inc 2926 Piper Drive Vero Beach Florida 32960 U S A Member General Aviation Manufacturers Association...

Page 653: ...80301 March 1 1998 All PR011215 December 15 2001 1 PR030720 July 20 2003 1 and 2 CR040415 April 15 2004 All PR040818 August 18 2004 1 3 4 and 5 CR061130 November 30 2006 1 2 3 4 and 5 COMPLETE REVISIO...

Page 654: ...PAGE 2 Nov 30 06 AEROFICHE EFFECTIVITY 4A4 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 655: ...1 Nov 30 06 Effective Pages 2 Nov 30 06 Intro Table of Contents 1 Nov 30 06 2 Nov 30 06 Introduction 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9...

Page 656: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 INTRO LIST OF EFFECTIVE PAGES THIS PAGE INTENTIONALLY BLANK 4A6...

Page 657: ...ivity 2 4A10 Serial Number Explanation 2 4A10 Assignment of Subject Material 2 4A10 Pagination 3 4A11 Aerofiche Effectivity 3 4A11 Identifying Revised Material 3 4A11 Indexing 3 4A11 List of Effective...

Page 658: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4A8 INTRO CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 659: ...IR OF PIPER AIRPLANES This manual generally does not contain hardware callouts for installation Hardware callouts are only indicated where a special application is required To confirm the correct hard...

Page 660: ...tems such as Environmental Systems Electrical Power Landing Gear etc They are assigned a number which becomes the first element of the standardized numbering system Thus the element 28 of the number 2...

Page 661: ...all fiche in this set 2 A complete subject Index for all fiche in this set 8 Identifying Revised Material A revision to a page is defined as any change to the printed matter that existed previously Re...

Page 662: ...essive Inspection Manual pending 767 002 B Vendor Publications WARNING FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION S WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT MAY...

Page 663: ...or PH 800 998 8857 7 FIRE EXTINGUISHER PORTABLE Vendor H3R Inc PH 800 249 4289 43 Magnolia Ave 4 San Francisco California 94123 2911 http www h3r com index htm 8 FUEL PUMP Vendor Weldon Pumps PH 440...

Page 664: ...Wichita KS 67226 http www mcico com index html Installation Manual and Operating Instructions Manual No 9015762 14 STARTER Vendor Sky Tec PH 800 476 7896 350 Howard Clemmons Rd FAX 817 573 2252 Granb...

Page 665: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 4A15 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 666: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 4A16 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 667: ...bined with another chapter CHAPTER SECTION TITLE GRID NO 4 AIRWORTHINESS LIMITATIONS 1C1 00 Airworthiness Limitations 5 TIME LIMITS MAINTENANCE CHECKS 1C9 00 General 10 Time Limits 20 Scheduled Mainte...

Page 668: ...23 COMMUNICATIONS 2C19 00 General 50 Audio Integrating 60 Static Discharging 24 ELECTRICAL POWER 2D9 00 General 30 DC Generation 40 External Power 50 Electrical Load Distribution 25 EQUIPMENT FURNISH...

Page 669: ...l 10 Flight Compartment 40 Exterior 34 NAVIGATION AND PITOT STATIC 3G1 10 Flight Environmental Data 20 Attitude and Direction 37 VACUUM 3I11 00 General 10 Distribution 20 Indicating 39 ELECTRICAL ELEC...

Page 670: ...ary Structure 40 Attach Fittings 50 Flight Surfaces 61 PROPELLER 4H21 10 Propeller Assembly 70 STANDARD PRACTICES ENGINE 4I9 00 General 71 POWER PLANT 4I17 00 General 10 Cowling 20 Mounts 60 Air Intak...

Page 671: ...AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 13 Nov 30 06 4A21 INTRODUCTION 79 OIL 5E17 20 Distribution 30 Indicating 80 STARTING 5F7 10 Cranking 91 CHARTS WIRING DIAGRAMS 5F21 10 Chart...

Page 672: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 14 Nov 30 06 4A22 INTRODUCTION GRIDS 4A22 THRU 4A24 INTENTIONALLY BLANK...

Page 673: ...tenance 3I1 Consumable Materials 5G15 Control Cable Inspection 2G12 Cable Fittings 100 Hour Special Inspection 2G15 Control Column Assembly 2H3 Conversion Tables Decimal Conversions 5G9 Drill Sizes 5G...

Page 674: ...4E23 Engine Controls Adjustment 4K13 Mixture 4K12 Throttle 4K12 EGT Probe Installation 5E3 Exhaust See Exhaust System Fuel Carburetor 4K11 Idle Mixture 4K11 Idle Speed 4K12 Primer 4K7 Hour Meter 5I5...

Page 675: ...ironment Extreme Cold 1D17 High Dust or Industrial Pollution 1D16 High Salt or High Humidity 1D17 Soft or Unusual Terrain 1D18 Procedure Aft Wing Attach Fittings 100 Hour 4E13 Control Cable Fittings 2...

Page 676: ...I3 Publications Piper 1A12 Vendor 1A12 R Repairs Fiberglass 4C19 Metal Wire Stitching 4D6 Safety Walk 4D5 Skin Materials and Thickness 4C8 Thermoplastic 4C21 List of Materials 4C23 Restraint System 2F...

Page 677: ...8 Magnetos 5C8 Oil Temperature Indicator 5F3 Rudder Control System 2H15 Stabilator Control System 2I2 Trim Control 2I3 Standby Alternator 2E6 Starter 5F14 Strobe Lights Tachometer 5D23 Turn and Bank I...

Page 678: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 4B6 INDEX GRIDS 4B6 THRU 4B24 INTENTIONALLY BLANK...

Page 679: ...4C1 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL CHAPTER 51 STRUCTURES...

Page 680: ...4C2 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 681: ...7 Nov 30 06 8 Nov 30 06 51 70 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9 Nov 30 06 10 Nov 30 06 11 Nov 30 06 12 Nov 30 06 13 Nov 30 06 14 Nov...

Page 682: ...PAGE 2 Nov 30 06 51 LIST OF EFFECTIVE PAGES 4C4 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 683: ...1 4C11 Inspection 3 4C13 Corrosion Removal and Control 3 4C13 Corrosion Prone Areas 4 4C14 REPAIRS 51 70 00 1 4C19 Fiberglass Repairs 1 4C19 Touch up and Surface Repairs 1 4C19 Fracture and Patch Repa...

Page 684: ...PAGE 2 Nov 30 06 4C6 51 CONTENTS PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 685: ...through The spar box is an integral part of the fuselage structure which provides in effect a continuous main spar with splices at each side of the fuselage There are also fore and aft attachments at...

Page 686: ...PAGE 2 Nov 30 06 4C8 51 00 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL Skin Materials and Thickness Figure 1...

Page 687: ...PAGE 3 Nov 30 06 4C9 51 00 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 688: ...PAGE 4 Nov 30 06 4C10 51 00 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 689: ...d inspection Insulating is necessary between two contacting dissimilar surfaces 2 to 3 coats of zinc chromate on each surface plus if one of the surfaces is magnesium a 0 003 inch thick piece of vinyl...

Page 690: ...e areas is generally not dangerous however it shows a need for maintenance and the possibility of corrosive attack in more critical areas Any surface corrosion on highly stressed steel parts is potent...

Page 691: ...nsive removal of inspection access covers b Detailed inspection must include above referenced areas along with areas requiring removal of inspection plates and panels to thoroughly inspect internal ca...

Page 692: ...ate conversion coating before paint is applied will help prevent corrosion 4 Areas exposed to exhaust gases may have their finish damaged by deposits These deposits may result in an aggressive attack...

Page 693: ...and paint coatings 13 Electrical components and connectors must be checked Inspection frequency is based on operational environment and past trouble 14 Skin joints and lap overs are two areas that ca...

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Page 695: ...PAGE 7 Nov 30 06 4C17 51 10 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 696: ...PAGE 8 Nov 30 06 4C18 51 10 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 697: ...d dirt from around the damaged area with acetone Methylethylketone or equivalent and remove paint to gel coat 2 The damaged area may be scraped with a fine blade knife or a power drill with a burr att...

Page 698: ...m formed to a similar contour may be placed over the area The aluminum should also be covered with cellophane 6 Prepare a patch of fiberglass mat and cloth to cover an area two inches larger than the...

Page 699: ...cleaners have proven most effective in removing surface dirt 2 Preliminary cleaning of the damaged area with perchlorethylene or V M P Naphtha will generally ensure a good bond between epoxy compound...

Page 700: ...PAGE 4 Nov 30 06 4C22 51 70 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL Deep Scratches Shallow Nicks and Small Holes Figure 2 Surface Scratches Abrasions or Ground in Dirt Figure 1...

Page 701: ...res a hot air gun and ABS rods To weld the gun should be held to direct the flow of hot air into the fusion repair zone heating the damaged area and rod simultaneously The gun should be moved continuo...

Page 702: ...PAGE 6 Nov 30 06 4C24 51 70 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL Mixing of Epoxy Patching Compound Figure 3 Welding Repair Method Figure 4...

Page 703: ...tch should be made of the same material and cut slightly larger than the section being repaired 2 When appearances are important large holes cracks tears etc should be repaired by cutting out the dama...

Page 704: ...PAGE 8 Nov 30 06 4D2 51 70 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL Various Repairs Figure 6...

Page 705: ...mended that parts be cleaned prior to painting with a commercial cleaner or a solution made from one fourth cup of detergent mixed with one gallon of water 3 The paint used for coating thermoplastic c...

Page 706: ...PAGE 10 Nov 30 06 4D4 51 70 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL Repair of Impacted Damage Figure 8...

Page 707: ...pplying the safety walk wipe the applicable surface with a clean dry cloth ensuring that no moisture remains on the surface B Application Procedure 1 Do not apply when surface temperature is below 50...

Page 708: ...Rivet Method 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 j...

Page 709: ...PAGE 13 Nov 30 06 4D7 51 70 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL Metal Wire Stitching Repair Figure 9...

Page 710: ...PAGE 14 Nov 30 06 4D8 51 70 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 711: ...PAGE 15 Nov 30 06 4D9 51 70 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 712: ...PAGE 16 Nov 30 06 4D10 51 70 00 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 713: ...ircraft C No self tapping screws used for bonding purposes D Exposed conducting frames or parts of electrical or electronic equipment should have a low resistance bond of less than 2 5 millohms to str...

Page 714: ...tor to ground is permissible for this grounding Battery Ground Point 010 Static wick mounting plates TCO Model B 4 P N 452 094 1 00 NOTE Where jumper wires or cables are used to accomplish a proper bo...

Page 715: ...SURFACE AIRCRAFT STRUCTURE SURFACE BONDING STRAP 28 VDC SOURCE AMMETER VOLT METER MV A R1 Adjust rheostat R1 so that ammeter A reads 10 Amps Resistance in milliohms is then the reading on the volt me...

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Page 717: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4D15 CHAPTER 52 DOORS...

Page 718: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4D16 THIS PAGE INTENTIONALLY BLANK...

Page 719: ...R 52 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 52 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 52 Table of Contents 1 Nov 30 06 2 Nov 30 06 52 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 No...

Page 720: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 52 LIST OF EFFECTIVE PAGES 4D18 THIS PAGE INTENTIONALLY BLANK...

Page 721: ...Lower Latch 1 4D21 Removal 1 4D21 Installation 1 4D21 Adjustment 1 4D21 Door Lock Assembly 2 4D22 Removal 2 4D22 Installation 2 4D22 Door Safety Latch Upper Latch 2 4D22 Removal 2 4D22 Installation 2...

Page 722: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4D20 52 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 723: ...ents may be made by tapping out the serrated door hinge bushings and rotating them to obtain the hinge centerline location that will provide proper door fit 3 To ensure long life of door seals and imp...

Page 724: ...e found at the top of the door opening 2 Remove the plate and turn the loop assembly in or out to make necessary adjustments 3 Replace the latch plate and secure with the two attachment screws 5 Door...

Page 725: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4D23 52 10 00 Door Snubber Seal Installation Figure 1...

Page 726: ...is 30 45 minutes at 75 F However adhesive that has set may be reactivated by a clean rag moistened with Toluol or MEK 6 It takes approximately 1 day for bond to cure Do Not allow door to close during...

Page 727: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 4E1 52 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 728: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 4E2 52 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 729: ...l may be fabricated from the dimensions given in Figure 1 2 Remove the lock assembly through the front of the door B Installation 1 Place the lock into position for installation 2 Install the nut on t...

Page 730: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4E4 52 30 00 Fabricated Tool for Baggage Door Lock Figure 1...

Page 731: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4E5 52 30 00 THIS PAGE INTENTIONALLY BLANK...

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Page 733: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4E7 CHAPTER 53 FUSELAGE...

Page 734: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4E8 THIS PAGE INTENTIONALLY BLANK...

Page 735: ...06 53 LIST OF EFFECTIVE PAGES 4E9 CHAPTER 53 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 53 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 53 Table of Contents 1 Nov 30 06 2 Nov 30 06 53 20 00...

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Page 737: ...06 4E11 53 CONTENTS CHAPTER 53 FUSELAGE TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO MAIN 53 20 00 1 4E13 Aft Wing Attach Fittings 100 Hour Inspection 1 4E13 Background 1 4E13 Procedure 1 4E13 Aft W...

Page 738: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4E12 53 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 739: ...ive environment B Procedure Each 100 hours inspect to determine condition of the aircraft window and door seals the condition of the aft wing attach fittings the insulation material around the affecte...

Page 740: ...and it will be necessary to inspect all windows doors and exterior panels leading to the cabin 1 Check door seals for deterioration cracks and voids in adhesive 2 Check window seals for voids cracks...

Page 741: ...the spar 8 With all the rivets removed remove wing attach fitting from the aircraft Discard fitting 9 Clean and inspect the areas that were under bracket for any signs of corrosion a If corrosion is...

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Page 743: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4E17 CHAPTER 55 STABILIZERS...

Page 744: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4E18 THIS PAGE INTENTIONALLY BLANK...

Page 745: ...ective Pages 2 Nov 30 06 55 Table of Contents 1 Nov 30 06 2 Nov 30 06 55 00 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 55 20 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 No...

Page 746: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 55 LIST OF EFFECTIVE PAGES 4E20 THIS PAGE INTENTIONALLY BLANK...

Page 747: ...ABILATOR 55 20 00 1 4F5 Checking Free Play 1 4F5 Stabilator 1 4F5 Removal 1 4F5 Installation 2 4F6 Stabilator Trim Tab 2 4F6 Removal 2 4F6 Installation 2 4F6 Balancing 4 4F8 Attach Brackets Corrosion...

Page 748: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4E22 55 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 749: ...revision of FAA Advisory Circular 43 13 1 Specific limited repair procedures are described herein in 55 20 00 55 30 00 and 55 40 00 To assist in making repairs Figure 1 51 00 00 identifies the type an...

Page 750: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4E24 55 00 00 Empennage Installation Figure 1 Sheet 1 of 2...

Page 751: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4F1 55 00 00 Empennage Installation Figure 1 Sheet 2 of 2...

Page 752: ...3 Calibrate the tool a Avoiding rivets place the balancing tool on the control surface with the tool s hinge centerline directly over the hinge line of the control surface b Adjust the movable trailin...

Page 753: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 4F3 55 00 00 Control Surface Balancing Tool Figure 2...

Page 754: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 4F4 55 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 755: ...ssive free play 2 Stabilator Refer to Figure 1 and 55 00 00 Figure 1 A Removal CAUTION AT EACH REMOVAL OF THE STABILATOR CONDUCT ATTACH BRACKETS CORROSION CONTROL INSPECTION BELOW CAUTION BEFORE ENTER...

Page 756: ...im cable ends into the fuselage 3 Attach the stabilator control cables to the stabilator balance arm with clevis bolts bushings washers nuts and cotter pins 4 Connect the ends of the fore and aft trim...

Page 757: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4F7 55 20 00 Methods of Securing Control Cables Figure 1...

Page 758: ...lete assembly on knife edge supports in a draft free beam perpendicular to hinge centerline Do not place tool on trim tab Calibrate tool as described in Control Surface Balancing Balancing Equipment 5...

Page 759: ...lower tail cone fairing assembly B Remove the aft fuselage closeout plate assembly on the applicable models C Inspect the steel stabilator attach fittings 4 places and adjacent fuselage structure for...

Page 760: ...SURFACE STABILATOR SKINS ARE NOT AUTHORIZED 1 Repairs are authorized in bottom surface stabilator skins only 2 Cracks of no more that 0 5 inch at the ends of the skin stiffening beads 2 No more than t...

Page 761: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 4F11 55 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 762: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 4F12 55 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 763: ...at attaches the leading edge of the fin to the fuselage 8 Remove the nuts washers and bolts that secure the fin spar to the aft bulkhead and remove the vertical fin B Installation 1 Insert the vertica...

Page 764: ...the skin stiffening beads 2 No more than two cracks per surface side 3 Cracks are limited to either end of a bead refer to Figure 1 but not on the same bead B Proceed as follows 1 Only cracks confined...

Page 765: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4F15 55 30 00 THIS PAGE INTENTIONALLY BLANK...

Page 766: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 4F16 55 30 00 THIS PAGE INTENTIONALLY BLANK...

Page 767: ...otter pins nuts washers bushings and bolts 5 Remove the cotter pins nuts washers and bolts from the upper and lower rudder hinge pivot points 6 Pull the rudder up and aft from the vertical fin B Insta...

Page 768: ...cular to hinge centerline Calibrate tool as described in Control Surface Balancing Balancing Equipment 55 00 00 Read scale when bubble level has been centered by adjustment of moveable weight and dete...

Page 769: ...nds of the skin stiffening beads 2 No more than two cracks per surface side 3 Cracks are limited to either end of a bead refer to Figure 2 but not on the same bead 4 For wrap around skins two crack re...

Page 770: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 4F20 55 40 00 GRIDS 4F20 THRU 4F24 INTENTIONALLY BLANK...

Page 771: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4G1 CHAPTER 56 WINDOWS...

Page 772: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4G2 THIS PAGE INTENTIONALLY BLANK...

Page 773: ...FECTIVE PAGES 4G3 CHAPTER 56 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 56 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 56 Table of Contents 1 Nov 30 06 2 Nov 30 06 56 10 00 1 Nov 30 06 2 No...

Page 774: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 56 LIST OF EFFECTIVE PAGES 4G4 THIS PAGE INTENTIONALLY BLANK...

Page 775: ...ov 30 06 4G5 56 CONTENTS CHAPTER 56 WINDOWS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO FLIGHT COMPARTMENT 56 10 00 1 4G7 Windshield 1 4G7 Removal 1 4G7 Installation 1 4G7 PASSENGER COMPARTMENT 56...

Page 776: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4G6 56 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 777: ...sion between the two windshield sections at the center post 4 Apply 1 5 in 9 mil black vinyl tape covering the previously applied vinyl foam tape and sealing the joint between the windshield and airfr...

Page 778: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4G8 56 10 00 Windshield Installation Typical Figure 1...

Page 779: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4G9 56 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 780: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 4G10 56 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 781: ...Insert the window into the frame install the retainer moldings and attachment screws but do not tighten Take care not to damage or dislocate the vinyl foam tape 4 Apply polyurethane urethane acrylic...

Page 782: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4G12 56 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 783: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4G13 CHAPTER 57 WINGS...

Page 784: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4G14 THIS PAGE INTENTIONALLY BLANK...

Page 785: ...able of Contents 1 Nov 30 06 2 Nov 30 06 57 00 00 1 Nov 30 06 2 Nov 30 06 57 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 57 20 00 1 Nov 30 06 2 Nov 30 06 57 40 00 1 N...

Page 786: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 57 LIST OF EFFECTIVE PAGES 4G16 THIS PAGE INTENTIONALLY BLANK...

Page 787: ...Right Side Wing Rib 100 Hour Inspection 3 4G23 AUXILIARY STRUCTURE 57 20 00 1 4H3 Wing Tip 1 4H3 Removal 1 4H3 Installation 1 4H3 Repair 1 4H3 ATTACH FITTINGS 57 40 00 1 4H5 Wing 1 4H5 Removal 1 4H5 I...

Page 788: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4G18 57 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 789: ...ture which provides in effect a continuous main spar with splices at each side of the fuselage There are also fore and aft attachment points at the front and rear spars NOTE The major subassemblies of...

Page 790: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4G20 57 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 791: ...B Procedure First determine the airplane s usage class second determine the recurring inspection intervals and third when required accomplish the wing spar inspection 1 Determining Usage Class NOTE Ai...

Page 792: ...in Hours in Example Severe Service Normal Service Factored Service Hours 17 1 800 4000 1035 17 2 1000 50000 3941 17 Results 1 Initial inspection not required at this time Will require initial inspecti...

Page 793: ...elow 2 If any cracks are found prior to further flight replace the spar or wing with a new or serviceable unit shown to be free of cracks when subjected to the inspections specified in this paragraph...

Page 794: ...IPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 4G24 57 10 00 W S 36 22 Right Side Rib Inspection Figure 1 Effectivity 2842001 thru 2842178 with Kit No 767 363 not installe...

Page 795: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 4H1 57 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 796: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 4H2 57 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 797: ...e wing tip to ascertain that it is free of cracks severe nicks and minor damage If repair is required refer to Repair below B Installation a Place the wing tip in a position that the landing light and...

Page 798: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4H4 57 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 799: ...age or wing 9 If the left wing is being removed remove the cotter pin from the pulley bracket assembly to allow the left aileron balance cable end to pass between the pulley and bracket 10 Disconnect...

Page 800: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4H6 57 40 00 Wing Installation Figure 1 Sheet 1 of 2...

Page 801: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4H7 57 40 00 Wing Installation Figure 1 Sheet 2 of 2...

Page 802: ...repare the various lines control cables etc for inserting into the wing or fuselage when the wing is slid into place Insure that the bushing is in place in the fuselage forward wing attach fitting See...

Page 803: ...ng the electrical harness to secure it in position and install the terminal strip dust cover 13 Remove the cap from the fuel line and connect it at the fitting located aft of the spar at the wing butt...

Page 804: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 4H10 57 40 00 THIS PAGE INTENTIONALLY BLANK...

Page 805: ...dge of the aileron and remove the aileron B Installation WARNING ALL CONTROL SURFACES THAT HAVE BEEN REPLACED REPAINTED OR REPAIRED AS AUTHORIZED IN THIS MANUAL MUST BE BALANCED BEFORE INSTALLATION SE...

Page 806: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4H12 57 50 00 Aileron and Flap Installation Figure 1...

Page 807: ...e when the bubble level has been centered by adjustment of the movable weight and determine the static balance 5 If the static balance is not within the limits specified in Figure 2 proceed as follows...

Page 808: ...5 inch at the ends of the skin stiffening beads b No more than two cracks per surface side c Cracks are limited to either end of a bead see Figure 3 but not on the same bead d For wrap around skins t...

Page 809: ...uld be installed The surface should be painted and trim servo tabs should be in the neutral position NOTE Because paint is a considerable balance factor it is recommended that existing paint be remove...

Page 810: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 4H16 57 50 00 Control Surface Balancing Tool Figure 4...

Page 811: ...nuts washers bushing and hinge bolts that hold the flap to the wing assembly 3 Pull the flap straight back off the wing B Installation 1 Replace the wing flap by placing the flap onto its proper posit...

Page 812: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 4H18 57 50 00 THIS PAGE INTENTIONALLY BLANK...

Page 813: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 9 Nov 30 06 4H19 57 50 00 THIS PAGE INTENTIONALLY BLANK...

Page 814: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 10 Nov 30 06 4H20 57 50 00 THIS PAGE INTENTIONALLY BLANK...

Page 815: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4H21 CHAPTER 61 PROPELLERS...

Page 816: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4H22 THIS PAGE INTENTIONALLY BLANK...

Page 817: ...F EFFECTIVE PAGES 4H23 CHAPTER 61 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 61 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 61 Table of Contents 1 Nov 30 06 2 Nov 30 06 61 10 00 1 Nov 30 06...

Page 818: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 61 LIST OF EFFECTIVE PAGES 4H24 THIS PAGE INTENTIONALLY BLANK...

Page 819: ...CE MANUAL PAGE 1 Nov 30 06 4I1 61 CONTENTS CHAPTER 61 PROPELLERS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO PROPELLER ASSEMBLY 61 10 00 1 4I3 Propeller 1 4I3 Removal 1 4I3 Cleaning Inspection and...

Page 820: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4I2 61 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 821: ...TARY PUBLICATIONS The Warrior III is equipped with a Sensenich fixed pitch all metal propeller A Removal See Figure 2 WARNING PROPELLER MAY KICK BACK WHEN ROTATED BY HAND USE EXTREME CAUTION SWITCH OF...

Page 822: ...2 Nov 30 06 4I4 61 10 00 CHART 1 PROPELLER TORQUE LIMITS Propeller Installation Figure 2 Description Required Torque Dry Propeller Mounting Nuts 280 300 inch pounds Spinner Backplate Attachment Screw...

Page 823: ...starter housing are aligned 5 Install propeller by indexing number one propeller blade over O mark on ring gear support 6 Place the doubler in position Install and tighten each propeller bolt with wa...

Page 824: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 4I6 61 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 825: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 4I7 61 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 826: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 4I8 61 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 827: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4I9 CHAPTER 70 STANDARD PRACTICES ENGINE...

Page 828: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4I10 THIS PAGE INTENTIONALLY BLANK...

Page 829: ...GE 1 Nov 30 06 4I11 70 LIST OF EFFECTIVE PAGES CHAPTER 70 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 70 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 70 Table of Contents 1 Nov 30 06 2 Nov 30...

Page 830: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 70 LIST OF EFFECTIVE PAGES 4I12 THIS PAGE INTENTIONALLY BLANK...

Page 831: ...IPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 4I13 70 CONTENTS CHAPTER 70 STANDARD PRACTICES ENGINE TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO GENERAL 70 00 00 1 4I15...

Page 832: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4I14 70 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 833: ...dropped into the engine the assembly process must stop and the item removed even though this may require considerable time and labor Insure that all parts are thoroughly clean before assembling 5 Neve...

Page 834: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4I16 70 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 835: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4I17 CHAPTER 71 POWER PLANT...

Page 836: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4I18 THIS PAGE INTENTIONALLY BLANK...

Page 837: ...ntents 1 Nov 30 06 2 Nov 30 06 71 00 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9 Nov 30 06 10 Nov 30 06 11 Nov 30 06 12 Nov 30 06 13 Nov 30 06...

Page 838: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 71 LIST OF EFFECTIVE PAGES 4I20 THIS PAGE INTENTIONALLY BLANK...

Page 839: ...t 7 4J5 Test Procedure 7 4J5 Allowable Tolerance 8 4J6 Engine 13 4J11 Removal 13 4J11 Installation 13 4J11 COWLING 71 10 00 1 4J15 MOUNTS 71 20 00 1 4J17 Engine Shock Mounts 1 4J17 Engine Mount Corros...

Page 840: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4I22 71 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 841: ...st system is stainless steel with two mufflers A shroud is provided to supply heat for both the cabin and carburetor The lubrication system is the pressure wet sump type The oil pump is located in the...

Page 842: ...ustment Defective ignition wire Check with electric tester and replace any defective wires Magneto not operating properly Check timing of magnetos Internal failure Check oil sump screen for metal part...

Page 843: ...exhaust flame and black smoke Mixture too lean indicated by Check fuel lines for dirt or overheating or backfiring other restrictions Check fuel supply Leaks in induction system Tighten all connectio...

Page 844: ...ngine mount s Unbalanced propeller Remove propeller and have it checked for balance Bent propeller blades Check propeller blade track Defective mounting bushings Install new mounting bushings Lead dep...

Page 845: ...haul engine Improper engine operation Check entire engine Excessive oil consumption Leakage through engine fuel Replace fuel pump O ring pump vent Engine breather or vacuum Check engine compression pu...

Page 846: ...eadings up to 100 psi do not necessarily indicate malfunctioning Overpriming during initial Cold weather Rotate the crankshaft engine start by hand in the counterclockwise direction with throttle FULL...

Page 847: ...ground test procedure for determining the maximum static rpm value for the fixed pitched propeller Warrior III A simplified test procedure is provided first to test static rpm under limited condition...

Page 848: ...nd left crosswind downwind and right crosswind Average the four test static rpm values f With OAT and relative humidity read static rpm from Chart 3 g With the oil temperature and OAT read delta rpm f...

Page 849: ...e 10 Knots Tested Static RPM ________________ Average Oil Temp __________________ Rpm ______________ See Chart 3 Delta rpm subtract ______________ See Chart 4 BASELINE Static rpm ______________ Tested...

Page 850: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 10 Nov 30 06 4J8 71 00 00 CHART 3 STATIC RPM EXPANDED TEST SEA LEVEL 500 FT PRESSURE ALTITUDE ONLY...

Page 851: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 11 Nov 30 06 4J9 71 00 00 CHART 4 STATIC RPM VS ENGINE OIL TEMPERATURE...

Page 852: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 12 Nov 30 06 4J10 71 00 00 CHART 5 PSYCHROMETRIC CHART...

Page 853: ...ct the engine oil cooler lines from the cooler 11 Disconnect the magneto P leads at the magnetos Insert a protective cover over the connection 12 Disconnect the engine oil temperature lead at the aft...

Page 854: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 14 Nov 30 06 4J12 71 00 00 Engine Installation Figure 1...

Page 855: ...sing koroseal lacing 10 Connect both lines to the oil cooler Use a back up wrench on the cooler fitting 11 Connect the mechanical fuel pump supply line at the pump 12 Connect the magneto P leads to th...

Page 856: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 16 Nov 30 06 4J14 71 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 857: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 4J15 71 10 00 COWLING Cowling Installation Figure 1...

Page 858: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4J16 71 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 859: ...er right B Swing the engine into place positioning the engine mounting lugs so they align with the engine mount attachment points C Position the shock mount bolts through the mounting lugs and secure...

Page 860: ...plastic tube 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...

Page 861: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4J19 71 20 00 Engine Mount Corrosion Inspection Figure 2...

Page 862: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 4J20 71 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 863: ...ed light must flash ON then OFF indicating all components are operating normally C Normal Maintenance 1 With increasing time of operation on the engine a slight film of fuel residue may form on the pr...

Page 864: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4J22 71 60 00 Carburetor Ice Detector Figure 1...

Page 865: ...t Testing Individual testing of either the instrument or probe may be performed using a previously tested and accepted probe or instrument respectively CAUTION DO NOT ATTEMPT TO TEST PROBE OR INSTRUME...

Page 866: ...Place the probe in an area without direct light c Turn the instrument power switch to the ON position d Turn the sensitivity adjustment knob clockwise until the RED warning light extinguishes e Turn t...

Page 867: ...sor so it faces directly towards the probe radiated light source 6 Repeat steps 3 through 5 until optimum sensitivity is achieved 7 Return the sensitivity adjustment knob back to full counter clockwis...

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Page 869: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4K3 CHAPTER 73 ENGINE FUEL AND CONTROL...

Page 870: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 4K4 THIS PAGE INTENTIONALLY BLANK...

Page 871: ...CHAPTER SECTION PAGE DATE 73 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 73 Table of Contents 1 Nov 30 06 2 Nov 30 06 73 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 73 20 00 1 Nov 30 06...

Page 872: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 73 LIST OF EFFECTIVE PAGES 4K6 THIS PAGE INTENTIONALLY BLANK...

Page 873: ...val 1 4J9 Disassembly Cleaning and Assembly 1 4J9 Installation 1 4J9 Prime Jets 2 4J10 Removal 2 4J10 Cleaning 2 4J10 Installation 2 4J10 CONTROLLING 73 20 00 1 4J13 Carburetor 1 4J13 Maintenance 1 4J...

Page 874: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4K8 73 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 875: ...er parts with acetone or a dry type solvent 3 To assemble primer a Install new O rings to the piston 7 and lubricate with light motor oil b Install check ball 1 ball spring 2 and screw 3 to the cylind...

Page 876: ...jet 2 Using a deep socket and light pressure remove the jet from the cylinder B Cleaning CAUTION DO NOT USE SHARP OBJECTS OR WIRE BRUSH TO CLEAN THE JET TUBE 1 Soak in carbon remover solution long en...

Page 877: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4K11 73 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 878: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 4K12 73 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 879: ...k all fuel lines for tightness and evidence of leakage 3 Check throttle and mixture control rods and levers for travel tightness and safety 4 Clean the fuel inlet screen Refer to Figure 1 5 Remove the...

Page 880: ...and the mixture control is rotated forward against its full rich stop the cockpit control levers of the throttle and mixture should be within 0 03 to 0 12 of an inch of the instrument panel stop A Th...

Page 881: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4K15 73 20 00 Engine Controls Adjustment Figure 2...

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Page 883: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 4K17 73 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 884: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 4K18 73 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 885: ...e indication Fuel valve stuck Check valve No fuel in tanks Check fuel fill Defective fuel pump s Check pump s for pressure buildup Check diaphragm and relief valves in engine driven pump Check for obs...

Page 886: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 4K20 73 30 00 3 IN 1 Engine Instrument Calibration Fuel Pressure Figure 1...

Page 887: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 4K21 73 30 00 THIS PAGE INTENTIONALLY BLANK...

Page 888: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 4K22 73 30 00 GRIDS 4K22 THRU 4L24 INTENTIONALLY BLANK...

Page 889: ...PART NUMBER 761 882 November 30 2006 5A1 AIRPLANE MAINTENANCE MANUAL CARD 5 OF 5 PA 28 161 S N s 2842001 UP PIPER AIRCRAFT INC...

Page 890: ...5A2 Published by Technical Publications Piper Aircraft Inc 2926 Piper Drive Vero Beach Florida 32960 U S A Member General Aviation Manufacturers Association...

Page 891: ...80301 March 1 1998 All PR011215 December 15 2001 1 PR030720 July 20 2003 1 and 2 CR040415 April 15 2004 All PR040818 August 18 2004 1 3 4 and 5 CR061130 November 30 2006 1 2 3 4 and 5 COMPLETE REVISIO...

Page 892: ...PAGE 2 Nov 30 06 AEROFICHE EFFECTIVITY 5A4 PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 893: ...1 Nov 30 06 Effective Pages 2 Nov 30 06 Intro Table of Contents 1 Nov 30 06 2 Nov 30 06 Introduction 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9...

Page 894: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 INTRO LIST OF EFFECTIVE PAGES THIS PAGE INTENTIONALLY BLANK 5A6...

Page 895: ...ivity 2 5A10 Serial Number Explanation 2 5A10 Assignment of Subject Material 2 5A10 Pagination 3 5A11 Aerofiche Effectivity 3 5A11 Identifying Revised Material 3 5A11 Indexing 3 5A11 List of Effective...

Page 896: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5A8 INTRO CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 897: ...IR OF PIPER AIRPLANES This manual generally does not contain hardware callouts for installation Hardware callouts are only indicated where a special application is required To confirm the correct hard...

Page 898: ...tems such as Environmental Systems Electrical Power Landing Gear etc They are assigned a number which becomes the first element of the standardized numbering system Thus the element 28 of the number 2...

Page 899: ...all fiche in this set 2 A complete subject Index for all fiche in this set 8 Identifying Revised Material A revision to a page is defined as any change to the printed matter that existed previously Re...

Page 900: ...essive Inspection Manual pending 767 002 B Vendor Publications WARNING FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION S WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT MAY...

Page 901: ...or PH 800 998 8857 7 FIRE EXTINGUISHER PORTABLE Vendor H3R Inc PH 800 249 4289 43 Magnolia Ave 4 San Francisco California 94123 2911 http www h3r com index htm 8 FUEL PUMP Vendor Weldon Pumps PH 440...

Page 902: ...Wichita KS 67226 http www mcico com index html Installation Manual and Operating Instructions Manual No 9015762 14 STARTER Vendor Sky Tec PH 800 476 7896 350 Howard Clemmons Rd FAX 817 573 2252 Granb...

Page 903: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 5A15 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 904: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 5A16 INTRODUCTION THIS PAGE INTENTIONALLY BLANK...

Page 905: ...bined with another chapter CHAPTER SECTION TITLE GRID NO 4 AIRWORTHINESS LIMITATIONS 1C1 00 Airworthiness Limitations 5 TIME LIMITS MAINTENANCE CHECKS 1C9 00 General 10 Time Limits 20 Scheduled Mainte...

Page 906: ...23 COMMUNICATIONS 2C19 00 General 50 Audio Integrating 60 Static Discharging 24 ELECTRICAL POWER 2D9 00 General 30 DC Generation 40 External Power 50 Electrical Load Distribution 25 EQUIPMENT FURNISH...

Page 907: ...l 10 Flight Compartment 40 Exterior 34 NAVIGATION AND PITOT STATIC 3G1 10 Flight Environmental Data 20 Attitude and Direction 37 VACUUM 3I11 00 General 10 Distribution 20 Indicating 39 ELECTRICAL ELEC...

Page 908: ...ary Structure 40 Attach Fittings 50 Flight Surfaces 61 PROPELLER 4H21 10 Propeller Assembly 70 STANDARD PRACTICES ENGINE 4I9 00 General 71 POWER PLANT 4I17 00 General 10 Cowling 20 Mounts 60 Air Intak...

Page 909: ...AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 13 Nov 30 06 5A21 INTRODUCTION 79 OIL 5E17 20 Distribution 30 Indicating 80 STARTING 5F7 10 Cranking 91 CHARTS WIRING DIAGRAMS 5F21 10 Chart...

Page 910: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 14 Nov 30 06 5A22 INTRODUCTION GRIDS 5A22 THRU 5A24 INTENTIONALLY BLANK...

Page 911: ...tenance 3I1 Consumable Materials 5G15 Control Cable Inspection 2G12 Cable Fittings 100 Hour Special Inspection 2G15 Control Column Assembly 2H3 Conversion Tables Decimal Conversions 5G9 Drill Sizes 5G...

Page 912: ...4E23 Engine Controls Adjustment 4K13 Mixture 4K12 Throttle 4K12 EGT Probe Installation 5E3 Exhaust See Exhaust System Fuel Carburetor 4K11 Idle Mixture 4K11 Idle Speed 4K12 Primer 4K7 Hour Meter 5I5...

Page 913: ...ironment Extreme Cold 1D17 High Dust or Industrial Pollution 1D16 High Salt or High Humidity 1D17 Soft or Unusual Terrain 1D18 Procedure Aft Wing Attach Fittings 100 Hour 4E13 Control Cable Fittings 2...

Page 914: ...I3 Publications Piper 1A12 Vendor 1A12 R Repairs Fiberglass 4C19 Metal Wire Stitching 4D6 Safety Walk 4D5 Skin Materials and Thickness 4C8 Thermoplastic 4C21 List of Materials 4C23 Restraint System 2F...

Page 915: ...8 Magnetos 5C8 Oil Temperature Indicator 5F3 Rudder Control System 2H15 Stabilator Control System 2I2 Trim Control 2I3 Standby Alternator 2E6 Starter 5F14 Strobe Lights Tachometer 5D23 Turn and Bank I...

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Page 917: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5C1 CHAPTER 74 IGNITION...

Page 918: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5C2 THIS PAGE INTENTIONALLY BLANK...

Page 919: ...v 30 06 74 10 00 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 7 Nov 30 06 8 Nov 30 06 9 Nov 30 06 10 Nov 30 06 11 Nov 30 06 12 Nov 30 06 13 Nov 30 06 14 Nov 30 06 15 Nov 30...

Page 920: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 74 LIST OF EFFECTIVE PAGES 5C4 THIS PAGE INTENTIONALLY BLANK...

Page 921: ...ment Magnetos 1 5C7 Overhaul 1 5C7 Magnetos 3 5C9 100 Hour Inspection 3 5C9 Removal 5 5C11 500 Hour Inspection and Cleaning 5 5C11 Disassembly 11 5C17 Assembly 12 5C18 Testing 17 5C23 Installation 17...

Page 922: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5C6 74 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 923: ...ling is wound When the engine crankshaft reaches the proper position for starting the spring in the impulse coupling is released to spin the rotating magnet and produce the spark required to fire the...

Page 924: ...ck magneto breaker internal timing of magnetos Failure of engine to idle Faulty ignition system Check entire ignition properly system Low power and uneven Defective spark plugs Clean and gap or replac...

Page 925: ...linder with thumb Rotate crankshaft until pressure is felt on thumb 2 Rotate crankshaft slowly until the advance timing mark on the starter ring gear is in alignment with the small hole located at the...

Page 926: ...the corresponding reference mark on the magneto If this measurement is more than 1 8 inch remove the magneto paragraph B and inspect adjust the contact breaker points per paragraphs C 4 5 and E 9 10...

Page 927: ...internal engine contamination C 500 Hour Inspection and Cleaning Each 500 hours remove magneto per paragraph B above and disassemble magneto as necessary per procedures in paragraph D below Inspect a...

Page 928: ...ance for pawls with two bosses is 150 inch for left hand rotation couplings and 140 inch for right hand rotation couplings If the feeler gauge passes between the full width of the boss es and the pawl...

Page 929: ...roken glass or for glass separation from the retaining steel rings Replace if required c Inspect the condenser for signs of corrosion Replace if required d Inspect the condenser P lead stud for twisti...

Page 930: ...s f Ensure the distributor block surfaces are free of all oil and carbon dust prior to reassembly g Inspect distributor gear teeth for wear and general integrity Replace block assembly as required h I...

Page 931: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 9 Nov 30 06 5C15 74 10 00 Slick T 100 Assembly and Timing Tool Kit Figure 8...

Page 932: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 10 Nov 30 06 5C16 74 10 00 Exploded View of 4300 Series Magneto Figure 9...

Page 933: ...ong screws and single short screw from distributor housing b Separate distributor housing from magneto frame c Disconnect condenser lead from contact breaker assembly 4 Remove the distributor block as...

Page 934: ...coil 11 Remove air vent pressure vent plug from magneto 12 Remove oil seal from magneto E Assembly NOTE The following parts MUST BE REPLACED at engine overhaul refer to Slick Service Bulletin No SB 2...

Page 935: ...end of rotorshaft first e Place T 151 cam and rotor set onto the end of the rotor shaft and turn T handle until the shaft bottoms in magneto frame f Install bearing clamps and the hold down screws g T...

Page 936: ...the nut and lightly lap its bottom surface with emory cloth c Verify that the coupling is free by snapping it through 3 or 4 times 7 Install coil a Place the frame on the T 125 assembly fixture Inser...

Page 937: ...ion magnetos e Rotate the magneto frame on the T 125 assembly fixture until the T 150 E Gap Gauge rests against the pole lamination in the magneto frame Rotate the magneto frame clockwise for left han...

Page 938: ...tation of the magneto look at data plate on the rotor gear so that it points up toward the high tension lead of the coil Secure rotor shaft to prevent rotation during assembly Alignment of rotor gear...

Page 939: ...st stand drive pulley in the same direction of rotation stated on the magneto data plate b The impulse coupling should engage the stop pin in the magneto frame below approximately 200 RPM If the impul...

Page 940: ...t on magneto flange Install magneto carefully so drive coupling lugs mate with slots of drive bushings Install holding washers lockwashers and nuts NOTE Do not tighten completely Allow for turning mag...

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Page 942: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 20 Nov 30 06 5D2 74 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 943: ...s assembly such as replacement of contact springs spring retainer assemblies insulating sleeves or of one lead assembly is done with harness assembly mounted on engine To replace more than one lead as...

Page 944: ...RAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5D4 74 20 00 Cutting Insulation Figure 3 Stripping Tool Figure 1 Inserting Stripping Tool Figure 2 Removing Silicone Rubber from Wire...

Page 945: ...RCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 5D5 74 20 00 Installation of Plug Endnut Figure 5 Flaring out the Shielding Figure 6 Installation of Ferrule Figure 7 Driving Tool...

Page 946: ...ted CAUTION DO NOT REUSE THE M 1458 DRIVE FERRULE 9 On spark plug end of wire install M 1458 male tapered drive ferrule over silicone insulation and under shielding to within 0 0625 inch from flange o...

Page 947: ...161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 5D7 74 20 00 Installation of Harness Cap Figure 9 Securing Wire in Harness Cap Figure 10 Installation of Electrode Screw Figure 11 Installation of I...

Page 948: ...R WILL BE BROKEN BY A ROTARY TWISTING OF COLLAR AVOID UNDUE DISTORTION OF COLLAR AND POSSIBLE SIDE LOADING OF BARREL INSULATOR 1 Loosen coupling nut on harness lead and remove terminal insulator from...

Page 949: ...ssthreaded b Badly battered or rounded shell hexagons c Out of round or damaged shielding barrel d Chipped cracked or broken ceramic insulator portions e Badly eroded electrodes worn to approximately...

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Page 953: ...ires to ignition switch as shown in Figure 1 2 Check for proper operation of ignition switch as follows a Remove P lead from right magneto b Attach P lead of right magneto to ohmmeter and to airframe...

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Page 955: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5D15 CHAPTER 77 ENGINE INDICATING...

Page 956: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5D16 THIS PAGE INTENTIONALLY BLANK...

Page 957: ...LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 77 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 77 Table of Contents 1 Nov 30 06 2 Nov 30 06 77 00 00 1 Nov 30 06 2 Nov 30 06 77 10 00 1 Nov 30 06...

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Page 959: ...ION PAGE GRID NO GENERAL 77 00 00 1 5D21 Description 1 5D21 Removal and Installation 1 5D21 POWER 77 10 00 1 5D23 Tachometer Indicator 1 5D23 Description 1 5D23 Troubleshooting 1 5D23 TEMPERATURE 77 2...

Page 960: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5D20 77 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 961: ...ne Entegra EFIS engine data is collected by the Data Acquisition Unit DAU and is displayed on the Multi Function Display MFD and Primary Flight Display PFD See Electronic Flight Instrument System 34 2...

Page 962: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5D22 77 00 00 THIS PAGE INTENTIONALLY BLANK...

Page 963: ...ng engine operating time The time recorder will be accurate i e records 1 00 hour in 60 minutes at 75 power setting under standard sea level conditions B Troubleshooting See Chart 1 CHART 1 TROUBLESHO...

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Page 965: ...oting chart it must be replaced If leads to gauge are defective they must be replaced Because the resistance of the electrical leads is critical for proper gauge operation they must be replaced with t...

Page 966: ...h propane torch to dull red The meter should read up to the fourth graduation or approximately 1500 F Before making this check make sure that the adjustment screw which is located in the rear of the i...

Page 967: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 5E3 77 20 00 EGT Probe Installation Figure 1...

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Page 971: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5E7 CHAPTER 78 EXHAUST...

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Page 973: ...06 78 LIST OF EFFECTIVE PAGES 5E9 CHAPTER 78 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 78 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 78 Table of Contents 1 Nov 30 06 2 Nov 30 06 78 00 00...

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Page 975: ...AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 5E11 78 CONTENTS CHAPTER 78 EXHAUST TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO GENERAL 78 00 00 1 5E13 100 Hour Inspection 1...

Page 976: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5E12 78 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 977: ...ng holes in exhaust pipe and muffler to prevent separation of components A Removal of the tail pipe and stacks are required for inspection of the muffler baffles B Remove or loosen all exhaust shields...

Page 978: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5E14 78 00 00 Exhaust System Inspection Points Figure 1...

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Page 981: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5E17 CHAPTER 79 OIL...

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Page 983: ...5E19 CHAPTER 79 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 79 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 79 Table of Contents 1 Nov 30 06 2 Nov 30 06 79 20 00 1 Nov 30 06 2 Nov 30 06 79 3...

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Page 985: ...E21 79 CONTENTS CHAPTER 79 OIL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO DISTRIBUTION 79 20 00 1 5E23 Oil Cooler 1 5E23 INDICATING 79 30 00 1 5F1 Description 1 5F1 Oil Pressure 1 5F1 Indicator 1...

Page 986: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5E22 79 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 987: ...thread fitting is used it should be installed only far enough to seal with sealing compound C Apply Lubon No 404 to all male pipe thread fittings do not allow sealant to enter the system D Oil line ro...

Page 988: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5E24 79 20 00 THIS PAGE INTENTIONALLY BLANK...

Page 989: ...n the engine is not running the switch closes the circuit to the annunciator light and opens the circuit to the hour meter As soon as the engine starts and the pressure sensor senses oil pressure it t...

Page 990: ...tighten c Using a back up wrench on union tee snug switch to tee d Join electrical connector e Perform operational check Ensure fittings do not leak Trouble Cause Remedy CHART 1 TROUBLESHOOTING OIL PR...

Page 991: ...ter housing on the engine accessory section provides a signal to the indicator 1 Removal a Remove safety wire from electrical connector and temperature bulb b Remove electrical connector c Unscrew and...

Page 992: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 5F4 79 30 00 3 IN 1 Engine Instrument Calibration Oil Pressure Oil Temperature Figure 1...

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Page 995: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5F7 CHAPTER 80 STARTING...

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Page 997: ...PAGES 5F9 CHAPTER 80 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE 80 List of 1 Nov 30 06 Effective Pages 2 Nov 30 06 80 Table of Contents 1 Nov 30 06 2 Nov 30 06 80 10 00 1 Nov 30 06 2 Nov 30 06...

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Page 999: ...ABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO CRANKING 80 10 00 1 5F13 Description 1 5F13 Troubleshooting 1 5F13 Starter 1 5F13 Removal 1 5F13 Installation 1 5F13 Cranking Tests 4 5F16 Bench Tests 4 5...

Page 1000: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5F12 80 CONTENTS THIS PAGE INTENTIONALLY BLANK...

Page 1001: ...ER USE JUMPER CABLES to test voltage to the starter The toothed jaws of jumper cables are meant to bite into soft leaded terminals on car batteries and simply WILL NOT provide enough contact with the...

Page 1002: ...cloth A new brush should be run in until at least 50 seated however if facilities are not available for running in brushes then the brush should be properly seated by inserting a strip of No 0000 san...

Page 1003: ...n speed lubricated motor or starter inspect and relubricate replacing ball bearings if worn See electrical causes See remedies listed for listed under Starter fails Starter fails to operate to operate...

Page 1004: ...mplete C A voltage loss test should be made to locate any high resistance connections that would impair starting motor electrical efficiency Using a low reading voltmeter scale while cranking engine o...

Page 1005: ...as shown in Figure 2 2 See specifications in Chart 2 C If torque and current are not within specifications overhaul or replace the starter No Load Current Test Figure 1 Stall Torque Test Figure 2 Mod...

Page 1006: ...ground connection B Check the voltage loss across the switch contacts during normal starting If loss is in excess of 0 2 volts per 100 amperes the solenoid should be replaced C If solenoid fails to o...

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Page 1009: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5F21 CHAPTER 91 CHARTS WIRING DIAGRAMS...

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Page 1011: ...0 06 22 Nov 30 06 23 Nov 30 06 24 Nov 30 06 25 Nov 30 06 26 Nov 30 06 27 Nov 30 06 28 Nov 30 06 91 21 20 1 Nov 30 06 2 Nov 30 06 91 23 00 1 Nov 30 06 2 Nov 30 06 91 23 50 1 Nov 30 06 2 Nov 30 06 CHAPT...

Page 1012: ...06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 91 34 10 1 Nov 30 06 2 Nov 30 06 91 34 20 1 Nov 30 06 2 Nov 30 06 3 Nov 30 06 4 Nov 30 06 5 Nov 30 06 6 Nov 30 06 91 77 40 1 Nov 30 06 2 Nov 30 06 91 79 30 1 No...

Page 1013: ...r 5I7 Antenna Coupler 5J11 Auxiliary Vacuum Pump 3J4 Avionics Master Switch 5H9 5I4 Battery Switch 5H19 Clock 5I5 Data Acquisition Unit DAU 5I11 5J15 Emergency Locator Transmitter ELT 5I11 Engine Gaug...

Page 1014: ...NTENTS continued SUBJECT SECTION PAGE GRID NO WIRING DIAGRAMS SCHEMATICS continued Subject Grid No Primary Flight Display PFD 5J10 Radio Master Switch 5H9 Stall Warning 5H21 5I11 Standby Alternator 5H...

Page 1015: ...ut not its mating fastener use the lower torque in Chart 2 for the listed nut or bolt NOTE If normal operation requires movement between any of the components being clamped together tighten the nut or...

Page 1016: ...o not torque as described above Tighten nuts only enough to remove looseness in the joint and install the cotter pin G Unless otherwise specified when parts are used on Lycoming engines using Piper fu...

Page 1017: ...que torques specified in the text of this manual supercede the torques given in Charts A and B 5 Refer o the latest revision of Lycoming Service Table Limits SSP1776 for torques on parts used on Lycom...

Page 1018: ...21045 MS 21045 MS 20365 NAS 1021 MS 20500 NAS 679 NAS 679 NAS 1291 Nut bolt Torque Limits Torque Limits Torque Limits Torque Limits Torque Limits Torque Limits size in lbs in lbs in lbs in lbs in lbs...

Page 1019: ...5 3 456 27 5 3 802 30 4 148 32 5 4 493 35 4 839 37 5 5 185 40 5 530 42 5 5 876 45 6 222 47 5 6 567 50 6 913 52 5 7 258 55 7 604 57 5 7 950 60 8 295 62 5 8 641 65 8 987 67 5 9 332 70 9 678 72 5 10 024...

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Page 1021: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 5G9 91 10 00 CHART 4 DECIMAL CONVERSIONS...

Page 1022: ...2 22 270 518 0 23 3 10 14 0 137 78 280 536 0 17 8 0 32 0 143 33 290 554 0 12 22 10 50 0 148 89 300 572 0 6 67 20 68 0 154 44 310 590 0 1 11 30 86 0 160 00 320 608 0 4 44 40 104 0 165 56 330 626 0 10 0...

Page 1023: ...1556 CU FT 1 164 U S GAL LIQ 4 405 LITERS 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...

Page 1024: ...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 15...

Page 1025: ...037 0 9398 23 64 0 3593 9 1262 13 64 0 2031 5 1594 35 0 110 2 794 64 0 036 0 9144 T 0 358 9 1281 7 0 201 5 1054 7 64 0 1093 2 7781 65 0 035 0 899 S 0 346 8 7884 8 0 199 5 0546 36 0 1065 2 7051 66 0 0...

Page 1026: ...and year hose manufacturer s identification Uses Hose is approved for use in aircraft hydraulic pneumatic coolant fuel and oil systems Operating Temperatures Sizes 3 thru 12 Minus 65 F to plus 250 F S...

Page 1027: ...ize Compound Exxon Oil Company Royco 44 Royal Lubricants Co Anti Seize Compound TT A 580 Armite Product Armite Laboratories White Lead Base JAN A 669 Anti Seize Thread Fel Pro C5 A Fel Pro Incorporate...

Page 1028: ...ompany Braycote 627S Mobil Grease 27 Mobil Oil Corporation B P Aero Grease 31B B P Trading Limited Grease Aircraft MIL G 3278 Unitemp E P Texaco Incorporated Instrumentation Gear and Actuator RPM Avia...

Page 1029: ...ell Oil Company Grease High MIL G 3545 High Temp Grease Texaco Incorporated Temperature Marfak All Purpose Shellaire Grease HT Shell Oil Company Alvania E P Grease 2 Aeroshell Grease 5 Grease 77 Mobil...

Page 1030: ...hers High and Low Refining Company Temperature Hot Melt Adhesive Stick Form 1 2 in Sears Roebuck and Polyamids and Hot diameter 3 in long Company or most Melt Gun hardware stores Hydraulic Fluid MIL H...

Page 1031: ...ing Aircraft MIL L 6082 Castrolaero 113 Castrol Oils Inc Reciprocating Engine Grade 1065 piston grade as specified Chevron Aviation Oil 65 ChevronTexaco Corp Mobil Aero White Band Mobil Oil Corp AVREX...

Page 1032: ...pper thick PR 1422 A 2 Sealant Products Research Brushing Consistency Company PR 1422 B 2 Sealant Trowling Consistency PR 1431G Faying Surface Seal Type 1 PR 1321 B 1 2 Access Panel Sealant PR 1560 MK...

Page 1033: ...arch Co Silicone Compound MIL S 8660 DC 4 DC 6 Dow Corning MIL C 21567 Compound G 624 General Electric Co Silicone Products Department Solvents Methyl Ethyl Ketone MEK Local Suppliers Methylene Chlori...

Page 1034: ...Foam Tape 1 8 in x 1 in 501 Series Type II Norton Tape Division Vinyl Black Plastic 2 in x 9 mil and or 1 1 2 in x 9 mil Corrosion Retardant MIL C 16173 D LPS 3 Heavy Duty Holt Lloyd Corp Compounds Pi...

Page 1035: ...www phillips66aviation com Corrosion Reaction Consultants Inc Limekin Pike Dresher PA 19025 D Dextrex Chemical P O Box 501 Detroit MI 48232 Dow Corning Corporation Alpha Molykote Plant 64 Harvard Aven...

Page 1036: ...et Pittsburgh PA 15219 412 565 2000 Royal Lubricants Company River Road E Hanover NJ 07936 201 887 3100 S Schnee Moorhead Chemicals Inc PO Box 171305 Irving TX 75017 1305 800 878 7876 www schneemorehe...

Page 1037: ...1 91 10 00 CIRCUIT FUNCTION LETTER CIRCUIT A AUTOPILOT C CONTROL SURFACE E ENGINE INSTRUMENT F FLIGHT INSTRUMENT G LANDING GEAR H HEATER VENTILATING DEICING L LIGHTING P POWER Q FUEL OIL RP RADIO POWE...

Page 1038: ...CEPTACLE PLUG MATED PLUG RECEPTACLE GROUND TO CHASSIS WITH TERMINAL GROUND OR CIRCUIT RETURN GROUNDS FUSE A DIODES GENERAL ZENER UNIDIRECTIONAL ZENER BIDIRECTIONAL T P SHIELDED TWO CONDUCTOR W GROUND...

Page 1039: ...ATURE ACTUATED OPENS ON RISING TEMPERATURE OR t t t t NOTE t symbol equals operating temperature of the device NORMALLY OPEN NORMALLY OPEN HELD CLOSED SELECTOR OR MULTI POSITION SWITCH NORMALLY CLOSED...

Page 1040: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 26 Nov 30 06 5H4 91 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 1041: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 27 Nov 30 06 5H5 91 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 1042: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 28 Nov 30 06 5H6 91 10 00 THIS PAGE INTENTIONALLY BLANK...

Page 1043: ...MAINTENANCE MANUAL PAGE 1 Nov 30 06 5H7 91 21 20 Fresh Air Blower Optional Figure 1 1 3 BLOWER VB1B14 LO 2 VB1A14 10A FRESH AIR BLOWER HIGH 2 R34 1 4 3 VB1D14 VB1C14 VB1E14 AC26A14N GRN YEL ORN RED 4...

Page 1044: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5H8 91 21 20 THIS PAGE INTENTIONALLY BLANK...

Page 1045: ...R III MAINTENANCE MANUAL PAGE 1 Nov 30 06 5H9 91 23 00 Radio Master Switch Figure 1 AVIONICS BUS ELECTRICAL BUS PR2B 20 PR2A 20 PR1A 10 PR1B 10 A3 A4 X2 AVIONICS MASTER CONTACTOR AVIONICS MASTER SWITC...

Page 1046: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5H10 91 23 00 THIS PAGE INTENTIONALLY BLANK...

Page 1047: ...BLU WHT BLU ORG P3401 J3406 2 1 3 J3407 1 2 3 4 J3408 1 3 2 1 2 3 4 J3409 R CABIN SIDEWALL UPHOLSTERY PNL GMA 340 INSTRUMENT PANEL P3402 L CABIN SIDEWALL UPHOLSTERY PANEL 101900 SHT 19 J L PIPER AIRCR...

Page 1048: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 5H12 91 23 50 PAGE 2 Nov 30 06 THIS PAGE INTENTIONALLY BLANK...

Page 1049: ...H 8 5 9 B 1 2 1 4 3 5 P9C 20 P8C 20 4 3 8 5 AUX 6 6 P2 R2 W2B 20 W2D 20 W2C 20 1 4 A P8B 20 P8A 20 P9B 20 P9A 20 P5G 20 P5D 20 6 P5C 20 5A 1A 9 7 P6A 20 P5A 20 P5B 20 P6B 20 P5F 20 11 12 P6C 20 P6D 2...

Page 1050: ...G18 K2A4 J300 ENGINE COMPARTMENT CIRCUIT BREAKER PANEL FIREWALL 2 3 32 5 4 6 P301 FWD FUSELAGE L SIDEWALL PANEL TO J400 SEE 91 77 40 FIGURE 1 SHEET 1 P400 33 P2C20 J1C18 J2C18 R MAG L MAG SOLENOID FUE...

Page 1051: ...0 P3501 6 15 1 MIC KEY P43021 4 2 XMTR INTERLOCK 2 MIC KEY P3401 30 2 MIC KEY P43022 4 1 XMTR INTERLOCK SUPPRESSION SHIELD JB5 N DME SUPPRESSION J4503 6 XPDR SUPPRESSION P3301 31 SUPPRESSION SHIELD JB...

Page 1052: ...X 1B P43012 49 MFD 429 IN 4A P530 48 MFD 429 IN 4B P530 68 K17 429 TX A ROLL STR K17 5 K17 429 TX B ROLL STR K17 6 1 GPS 429 TX 1A P43011 46 PFD 429 RX 1B P732 40 PFD 429 RX 1A P732 41 1 GPS 429 TX 1B...

Page 1053: ...0 06 5H17 91 24 30 3 4 7 6 1 2 5 TB7 J326 P O MAIN BUS STBY ALTR SENSE 101902 SHT 21 U 1 2 3 BLU ORG WHT TO STBY ALTR SWITCH P2N20 P3C20 P300 SP7A20 SP16A22 SP4A22 SP8A20N TO J316 4 CB39 REF GB4 R Sta...

Page 1054: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 5H18 91 24 30 THIS PAGE INTENTIONALLY BLANK...

Page 1055: ...ANCE MANUAL PAGE 1 Nov 30 06 5H19 91 24 40 External Power Figure 1 TO STARTER CONTACTOR EXTERNAL POWER CONTACTOR P1D 4 4 P1C 4 BATTERY CONTACTOR EXTERNAL POWER RECEPTACLE P4AA 20 P4A 20 4 P2 R2 4 1 2...

Page 1056: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5H20 91 24 40 THIS PAGE INTENTIONALLY BLANK...

Page 1057: ...8 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 5H21 91 27 30 Stall Warning Figure 1 ELECTRICAL BUS STALL WARNING 5 A F1A 20 F1B 20 13 13 F1E 20 F1C 20 STALL WARNING HORN P1 R1 8 LIFT DETECTOR F...

Page 1058: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5H22 91 27 30 THIS PAGE INTENTIONALLY BLANK...

Page 1059: ...06 5H23 91 28 20 Fuel Pump Figure 1 IN LINE FILTER FUEL PUMP ELECTRICAL BUS Q2A 20 Q2B 20 2 FUEL PUMP SWITCH 5A 1 3 4 4 P1 R1 Q2C 20 FUEL PUMP Q2F 20 Q2J 20 1 3 5 Q2D 20 1 1 3 2 2 2 Q2G 20 10 10 P1 R1...

Page 1060: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5H24 91 28 20 THIS PAGE INTENTIONALLY BLANK...

Page 1061: ...INTENANCE MANUAL PAGE 1 Nov 30 06 5I1 91 28 40 Fuel Quantity Figure 1 28V GND LEFT RIGHT ELECTRICAL BUS FUEL GAUGE Q3E 20N Q1A 20 3A Q3A 20 Q4A 20 Q3C 20 Q4C 20 14 14 1 1 P1 R1 R2 P2 Q4B 20 Q3B 20 10...

Page 1062: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5I2 91 28 40 THIS PAGE INTENTIONALLY BLANK...

Page 1063: ...L2A 20 1 1 2 2 3 3 4 4 WHT WHT BLK BLK WHT WHT GRN GRN PITOT SENSOR ASSY S N S 2842001 THRU 2842007 ONLY H2B 18 7 1 2 A 9 D19A 20 D19B 20 1 2 1 2 H2D 18 H3A 18 DN20A 20 100W 70W PTT H3B 18 H2C 18 H3C...

Page 1064: ...S MAIN 1A P6A20 TO P316 16 TO P315 8 W11A20 W8C20 H2B16 H1C16 H2C16 P311 WHT BLK TO STROBE LT SW PITOT SENSOR ASSY WHT WHT WHT WHT GRN GRN BLK BLK 3 5 4 1 H1B16 H1B16 5 4 6 ON H1A14 PITOT STATIC TO CB...

Page 1065: ...ock Figure 1 BATTERY FEEDER BATTERY CONTACTOR STARTER CONTACTOR P1A 4 ELECTRICAL BUS 70 A M2A 20 M1B 20 P1C 4 M2C 20 5 7 7 5 M3A 20 P1D 4 4 2 1 P2 R2 M2B 20N PWR GND 0 0 0 0 1 C NC W6B 20N 1 2 TO P3 P...

Page 1066: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5I6 91 31 30 THIS PAGE INTENTIONALLY BLANK...

Page 1067: ...3 W2A 20 DN16A 22 DN12A 22 W4A 20 W4B 20 DN11A 22 P6C 20 DN22A 22 DN13A 22 TO OIL PRESSURE SWITCH W6A 20 5 2 1 6 5 4 DAY NIGHT C TO DIM RELAY DN17B 22 DN17A 22 PRESS TO TEST P304 P304 1 1 3 3 P304 2 2...

Page 1068: ...7 8 9 1 2 3 J3 J3A OIL PRESSURE LOW BUS VOLTAGE ALTERNATOR INOP 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 VACUUM INOP IN2071A DIODES ANNUNCIATOR LIGHT ASSEMBLY 1 2 3 LIGHT SCHEMATIC START...

Page 1069: ...14 TO K4 PIN X2 22 B2 A2 A1 K5 B2 A2 C2 C1 R5 C3 K3 X2 X1 15 16 17 20 19 21 X1 X2 D3 D2 C3 C2 B3 B2 A3 A2 A1 1 2 3 4 5 6 R9 B2 B3 B1 A2 A3 A1 8 R8 9 K2 K4 X1 X2 B2 B3 R2 A2 A1 A3 R1 11 C2 C3 R3 C1 R4...

Page 1070: ...ANNUNCIATOR PANEL W4B20 DN1C22 DN3B22 DN1B22 TO ELECTRIC TRIM MASTER SWITCH DN31A22 DN16A22N DN32A22 DN30A22 2 2 GPS 1 1 P304 OIL PRESS CARB ICE LOW BUS VOLT VACUUM INOP TO CARB ICE DETECT DN22A22 P6...

Page 1071: ...EAT SWITCH TO P311 2 C NC P OIL PRESS SWITCH AFT ENGINE FIREWALL NO P6A22 P5A22 P7A22 7 9 36 J530 MFD 13 15 14 12 11 16 OIL PRESS E 5 3 4 ALT INOP D 6 2 1 GB4 A 101902 SHT 12 J M TO AVIONICS HARNESS D...

Page 1072: ...T PANEL LIGHTS OVERHEAD L2A20 P300 L6A20 19 21 20 24 25 23 22 28 31 17 26 27 W1A20 TO PITOT HEAT SWITCH TO P311 2 W9A20 C NC P OIL PRESS SWITCH AFT ENGINE FIREWALL NO P6A22 P5A22 P7A22 7 9 36 J530 MFD...

Page 1073: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 7 Nov 30 06 5I13 91 31 50 THIS PAGE INTENTIONALLY BLANK...

Page 1074: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 8 Nov 30 06 5I14 91 31 50 THIS PAGE INTENTIONALLY BLANK...

Page 1075: ...C PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 5I15 91 33 10 Flood Light Figure 1 ELECTRICAL BUS FLOOD LIGHT 5A P1 R1 L2A 20 L2B 20 7 7 L2D 20 FLOOD LIGHT WHT BLK GND FLOOD LIGHT CONTROL...

Page 1076: ...IRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5I16 91 33 10 Overhead Lights Figure 2 Sheet 1 of 2 ELECTRICAL BUS DOME LIGHT L6A 20 8 8 P1 R1 L6C 20 5A GND DOME LIGHT 85423 F 10...

Page 1077: ...016 047 MFD C102 5 6 K R104 R103 5 6 K ANNUN DIMMER ASS Y Q 101 MJ11015 R101 5 6 K R102 047 MFD 5 6 K C101 L6B18 P302 MAIN BATTERY M1B20 P4A20 EMPENNAGE PITOT HEAT STATIC HEAT H1D16 H2D16 31 17 L4D18...

Page 1078: ...IOR III MAINTENANCE MANUAL PAGE 4 Nov 30 06 5I18 91 33 10 A D B C F RADIO LIGHTS DIMMER ASSY L8D 20 ELECTRICAL BUS RADIO LIGHTS L8A 20 5K 2 1 L8C 20N 5A L8E 20 L8B 20 AVIONICS DIMMING LIGHTS BUS 85423...

Page 1079: ...HTS CLOCK OPT ALTIMETER AIRSPEED INDICATOR VERTICAL SPEED INDICATOR TURN COORDINATOR VAC ENG GAUGE TACH FUEL QTY A D B C F COMPASS INSTRUMENT PANEL POST LIGHTS DIMMER ASSY L5C 20N L5D 20 L5E 20 L5A 20...

Page 1080: ...A20 L10B20 L10E20 L10D20 PANEL CB16 5 PANEL SWITCH LIGHTS B D C F SWITCH LTS DIMMER A CB17 5 RADIO AVIONICS B D C F RADIO LTS DIMMER A P312 P313 P314 AFT ENGINE FIREWALL INSTRUMENT PANEL 5K 2 1 L10A20...

Page 1081: ...Lights Figure 5 Sheet 1 of 3 A D B C F SWITCH LIGHTS DIMMER ASSY L7B 20N L7C 20 L7D 20 ELECTRICAL BUS PANEL SWITCH LIGHTS 5K 2 1 7 1 2A BATT MASTER ALT LANDING LIGHT NAV LIGHTS STROBE LIGHT 2 1 L7F 2...

Page 1082: ...F 1 BATTERY MASTER L3A16 2 3 4 5 6 OFF 1 NAV LIGHT SWITCH ON L1A18 L5A18 TO NAV LT SW TO LDG LT SW TO PITOT HEAT SW 91 30 30 FIGURE 1 SHEET 2 L3E16N 6 4 5 A ON B 1 OFF 2 RECOG LTS SW 3 L4B18 L3D18 L4A...

Page 1083: ...STBY ALT FIELD P2H20 P2N20 ON 2 3 OFF 1 6 2 1 3 4 5 STROBE LTS FIN STROBE 1 3 2 OFF ON ALTERNATOR SW 3 2 ON OFF 1 BATTERY MASTER L3A16 2 3 4 5 6 OFF 1 NAV LIGHT SWITCH ON L1A18 L5A18 TO NAV LT SW TO...

Page 1084: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 10 Nov 30 06 5I24 91 33 10 THIS PAGE INTENTIONALLY BLANK...

Page 1085: ...ITE POSITION LIGHT LEFT NAV LIGHT 1 BLUE BLUE 3 2 RED NAV LIGHT L1C20 11 3 NAV LIGHTS SWITCH 5A 2 1 2 1 3 POWER SUPPLY 1 BLUE BLUE 3 3 2 L4B20 L1G20 L4C20 1 2 7 12 P2 R1 L4D20 R2 P1 12 2 1 1 2 3 L1A20...

Page 1086: ...L1G20 L4C20 7 L4D20 R1 P1 12 12 L4B20 2 1 3 1 2 3 L1A20 5A L4A20 5A NAV LIGHTS ANTI COLL LIGHTS WITH FIN STROBE LIGHT OPTIONAL 6 4 5 3 2 1 3 1 2 FIN STROBE LIGHT 2 1 3 L4E20 L4F20 P33 1 1 R35 P35 L4H2...

Page 1087: ...61 WARRIOR III MAINTENANCE MANUAL PAGE 3 Nov 30 06 5J3 91 33 40 Landing Light Figure 2 ELECTRICAL BUS L3A 20 5A 2 1 3 LANDING LIGHT L3B 20 1 1 2 2 P1 R1 L3D 20 2 2 1 1 L3C 20 LANDING LIGHT SWITCH LAND...

Page 1088: ...WING 1 2 LEFT WING RECOGNITION LIGHTS AUTHORIZED SERVICE REPLACEMENT IN S N S 2842109 THRU 2842194 85423 F 104295 F ELECTRICAL BUS L14A 20 5A RECOG LIGHTS L14B 20 R2 P2 L14C 20 9 9 2 1 3 RECOGNITION...

Page 1089: ...R FUEL QTY SENSOR Q3B20 F1C20 L1G18 L1C18 8 R RECOGNITION LT R NAV LIGHT BLU BLU 1 9 7 L RECOGNITION LIGHT L WING HARNESS L LANDING LIGHT R LANDING LIGHT L3H18 2 PITOT STATIC MAST 1 P100 P329 P330 3 2...

Page 1090: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL 91 33 40 5J6 PAGE 6 Nov 30 06 THIS PAGE INTENTIONALLY BLANK...

Page 1091: ...161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 5J7 91 34 10 9 5 6 8 7 1 4 3 2 P729 CONNECTOR TO MAG OAT E G C D H F B J734 WHT BLU BLU WHT BLU WHT BLU ORN WHT ORN WHT ORN BLU 101753 C Magnetomet...

Page 1092: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5J8 91 34 10 THIS PAGE INTENTIONALLY BLANK...

Page 1093: ...R AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 1 Nov 30 06 5J9 91 34 20 Turn and Bank Indicator Figure 1 5A 2 1 F2B 20 F2C 20 F2A 20 TURN BANK ELECTRICAL BUS F2A 20N 2 1 IND 85423 F 1042...

Page 1094: ...429 CH 2 RX A BEZEL DIMMING 16 AWG RED 28VDC INPUT A4 GND GND 28VDC INPUT DAU TRAY MAG OAT 422 TX MAG OAT PWR GND MAG OAT 24VDC OUT PFD CH_1D1 CH_1D2 MAG OAT 422 RX MAG OAT 422 RX CH_1D0 MAG OAT 422...

Page 1095: ...ND ARINC 429RX 2A ARINC 429RX 2B 23 65 45 ARINC 429RX 1B 25 SHIELD GND LIGHTING 28 VDC 28 VDC 28 VDC 18 GND GND 24 61 62 GND 60 42 41 40 20 AWG BLK 20 AWG RED MFD CB3 CIRCUIT BREAKER PANEL R INSTRUMEN...

Page 1096: ...A22 FG4A22 G JB8 GB3 B 2 1 101902 SHT 12 H 106096 A 101902 SHEET 12 U S N S 2842218 THRU 2842244 BEFORE COMPLIANCE WITH SB1162 STANDBY ATTITUDE INDICATOR STANDBY BATTERY STANDBY ATTITUDE INDICATOR STB...

Page 1097: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 5 Nov 30 06 5J13 91 34 20 THIS PAGE INTENTIONALLY BLANK...

Page 1098: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 6 Nov 30 06 5J14 91 34 20 THIS PAGE INTENTIONALLY BLANK...

Page 1099: ...8 VDC POWER A 4 20 1 P403 J400 GS VDC SIGNAL J1 J3 2 3 1 B A 2 4 1 Q3A20 Q3A20N P6A22WH P6A22BL Q5A22WH Q5A22BL E3A22WH E3A22BL E3K22 ENGINE COMPARTMENT DAU OIL TEMP SENSOR TACH GENERATOR BLU BLK RED...

Page 1100: ...232 TRANSMIT COM2 SHIELD 1 23 5 10 28 FUEL QTY LEFT HI FUEL QTY LEFT LO FUEL FLOW EXC FUEL FLOW LO 20 28 VDC POWER B ACFT GND 1 J2 J3 J2 J3 P305 P304 P305 P304 P406 ENGINE COMPARTMENT J331 OIL PRESSUR...

Page 1101: ...ure 1 A B 28V GND OIL TEMP FUEL PRESS OIL PRESS ELECTRICAL BUS ENGINE GAUGE Q8A 20N Q6A 20 Q5A 20 5 5 Q5B 20N P1 R1 OIL PRESS SENDER Q7A 20 FUEL PRESS SENDER Q6D 20N Q5B 20 Q6B 20 3 3 P2 R2 OIL TEMP S...

Page 1102: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5J18 91 79 30 THIS PAGE INTENTIONALLY BLANK...

Page 1103: ...18 3 3 R1 P1 K1B 18 STARTER SWITCH P1A 4 K2A 4 K2B 4 TO EXTERNAL POWER RECEPTACLE TO ANNUNCIATOR PANEL STE1 20 5A 5A 5A P4AA 20 P4A 20 4 P2 R2 4 1 2 3 BATTERY SWITCH 1 TO COURTESY LIGHT SWITCH L9A 20...

Page 1104: ...PIPER AIRCRAFT INC PA 28 161 WARRIOR III MAINTENANCE MANUAL PAGE 2 Nov 30 06 5J20 91 80 10 GRIDS 5J20 THRU 5L24 INTENTIONALLY BLANK...

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