Piper Aircraft Corporation Cherokee 140 PA-28-140 Service Manual Download

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PART NUMBER 753-586

January 31, 2008

1A1

SERVICE MANUAL

CARD 1 OF 4

PA-28-140

PA-28-150

PA-28-160

PA-28-180

PA-28-235

PA-28R-180

PA-28R-200

PIPER AIRCRAFT CORPORATION

Summary of Contents for Cherokee 140 PA-28-140

Page 1: ...PART NUMBER 753 586 January 31 2008 1A1 SERVICE MANUAL CARD 1 OF 4 PA 28 140 PA 28 150 PA 28 160 PA 28 180 PA 28 235 PA 28R 180 PA 28R 200 PIPER AIRCRAFT CORPORATION...

Page 2: ...August 3 1983 1 2 3 and 4 PR840423 April 23 1984 1 2 3 and 4 PR86115 January 15 1986 1 and 3 IR860730 July 30 1986 1 IR870506 June 12 1987 1 IR950215 February 15 1995 1 and 2 IR020228 February 28 2002...

Page 3: ...ULIC SYSTEM PA 28R 2D3 VII LANDING GEAR AND BRAKES PA 28 2E22 VIIA LANDING GEAR AND BRAKES PA 28R 2H1 VIII POWERPLANT PA 28 2K2 VIIIA POWERPLANT PA 28R 3A8 IX FUEL SYSTEM 3C8 X INSTRUMENTS 3D18 XI ELE...

Page 4: ...INTRODUCTION 01 31 08 1A4 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 5: ...10033 1B12 2 10 Three View of Cherokee PA 28 235 S N s 28 7310001 and up 1B13 2 11 Three View of Cherokee PA 28R 180 S N s 28 30005 thru 28 7130019 PA 28R 200 S N s 28 30482 thru 28 7135238 1B14 2 12...

Page 6: ...1D10 2 34 Leveling Longitudinally 1D11 2 35 Leveling Laterally 1D11 2 36 Servicing Points PA 28 140 1D19 2 37 Servicing Points PA 28 150 160 180 1D20 2 38 Servicing Points PA 28 235 1D21 2 39 Servici...

Page 7: ...19 Exhaust System Inspection Points Sheets 1 thru 2 3K9 3 20 Exhaust System Installation PA 28R 180 200 3K11 3 21 Control Wheel Inspection Points 3K12 3 22 Aileron Hinge Doubler 100 Hour Inspection 3...

Page 8: ...k Rigging Tool Application and Fabrication 2B2 5 5 Aileron Rigging Tool Application and Fabrication 2B3 5 6 Stabilator Controls 2B6 5 7 Stabilator Rigging Tool Application and Fabrication 2B8 5 8 Stab...

Page 9: ...ain Wheel Assembly 2F23 7 10 Wheel Brake Assembly 2G1 7 11 Removal of Anchor Bolt 2G2 7 12 Installation of Anchor Bolt 2G3 7 13 Brake Disc Minimum Thickness 2G5 7 14 Brake System Installation 2G5 7 15...

Page 10: ...em Installation 2J3 7A 20 Brake Master Cylinder Hand Parking Brake 2J5 7A 21 Toe Brake Installation 2J6 7A 22 Brake Cylinder Toe Brake 10 20 10 27 17000 2J8 7A 23 Brake Cylinder Toe Brake 10 30 2J10 7...

Page 11: ...13 Aligning Timing Marks 3B11 8A 14 Checking Flyweight Clearance of Impulse Coupling 3B12 8A 15 Engine Timing Marks 3B13 8A 16 Magneto Adjustment Limits 3B14 8A 17 Magneto Timing Marks 3B14 8A 18 Remo...

Page 12: ...anel PA 28 180 S N s 28 7405001 and up 3E11 10 9 Instrument Panel PA 28 235 S N s 28 10720 thru 28 11039 3E12 10 10 Instrument Panel PA 28 235 S N s 28 11040 thru 28 7210033 3E13 10 11 Instrument Pane...

Page 13: ...28 10762 4B20 11 17 Alternator and Starter System PA 28 140 S N s 28 25000 and up PA 28 150 160 180 S N s 28 3644 and up PA 28 235 S N s 10763 and up and PA 28R 4B21 11 18 Lamp Bank Load 4B23 11 19 Ch...

Page 14: ...Removal of End Head Bearing 4D22 11 76 Testing Rotor for Ground 4D23 11 77 Testing Rotor for Shorts 4D23 11 78 Installation of Bearing 4D24 11 79 Installation of Rectifier 4D24 11 80 Terminal Assembly...

Page 15: ...e and Manifold Set 4J13 14 4 Manifold Set Operation 4J14 14 5 Leak Test Hookup 4J15 14 6 Evacuation Hookup 4J17 14 7 Charging Stand 4J19 14 8 Charging Hookup 4J21 14 9 Compressor and Fabricated Oil Di...

Page 16: ...LIST OF ILLUSTRATIONS 01 31 08 1A16 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...

Page 17: ...V II Flight Control Surfaces Rigging Limits 2A13 V III Troubleshooting Chart Surface Controls 2C19 VI I Leading Particulars Hydraulic System 2D8 VI II Characteristics Hydraulic Pump Motor 2D15 VI IIA...

Page 18: ...leshooting EGT Gauge 3F23 X XVI Cylinder Head Temperature Gauge 3F24 X XVII Fuel Flow Gauge 3G1 XI I Electrical System Schematic Index 4A12 XI II Electrical System Troubleshooting 4E10 XI III Electric...

Page 19: ...PIPER CHEROKEE SERVICE MANUAL 1A19 SECTION I AIRWORTHINESS LIMITATIONS...

Page 20: ...PIPER CHEROKEE SERVICE MANUAL 1A20 THIS PAGE INTENTIONALLY BLANK...

Page 21: ...ATIONS TABLE OF CONTENTS Paragraph Section Grid No PIPER CHEROKEE SERVICE MANUAL AIRWORTHINESS LIMITATIONS I 1A22 Limitations 1A22 Inspections 1A22 Life Limited Parts Marking and Disposition 1A22 01 3...

Page 22: ...Life Limited Parts Marking and Disposition 14 CFR Part 43 10 Disposition of Life Limited Aircraft Parts requires that proper procedures are followed when removing life limited parts with time and or...

Page 23: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 I AIRWORTHINESS LIMITATIONS 1A23 THIS PAGE INTENTIONALLY BLANK...

Page 24: ...ts 1D8 2 11 Ground Handling 1D9 2 12 Introduction to Ground Handling 1D9 2 13 Jacking 1D9 2 14 Weighing 1D10 2 15 Leveling 1D10 2 16 Mooring 1D11 2 17 Locking Airplane 1D11 2 18 Parking 1D12 2 19 Towi...

Page 25: ...tem 1E3 2 50 Tires 1E4 2 51 Servicing Tires 1E4 2 51a Tire Balancer 1E4 2 52 Power Plant 1E6 2 53 Servicing Power Plant 1E6 2 54 Induction Air Filter 1E6 2 55 Removal of Air Filter 1E6 2 56 Service In...

Page 26: ...1 31 08 1B2 2 74 Draining Oil Sump 1E11 2 75 Oil Screens Suction 1E11 2 76 Oil Screen Pressure 1E11 2 77 Oil Filter Full Flow 1E12 2 78 Recommendations for Changing Oil 1E12 2 79 Lubrication Instructi...

Page 27: ...e of the airplane and station 0 WL of the fuselage vertical stabilizer and rudder is 20 5 inches below the cabin floor as measured at the rear wing spar with the airplane level The reference datum lin...

Page 28: ...SERVICE MANUAL Figure 2 1 Three Viewof Cherokee PA 28 140and PA 28 150 160 180 SerialNos 28 1 to 28 1760 incl PA 28 140Flite Liner SerialNos 28 7125174 and up Reissued 1 15 81 HANDLINGAND SERVICING 1B...

Page 29: ...PIPER CHEROKEE SERVICE MANUAL 862 1974 MODELS AND UP Figure 2 2 Three Viewof Cherokee 140 PA 28 140 SerialNos 28 7225001and up Reissued 1 15 81 HANDLING AND SERVICING 1B5 30...

Page 30: ...PIPER CHEROKEE SERVICE MANUAL 1694 Reissued 1 15 81 HANDLINGANDSERVICING 1B6...

Page 31: ...PIPER CHEROKEE SERVICE MANUAL 1836 Figure 2 4 Three Viewof Cherokee PA 28 180 SerialNos 28 4378to 28 7105244 incl HANDLING AND SERVICING Reissued 1 15 81 1B7...

Page 32: ...PIPER CHEROKEE SERVICE MANUAL 1732 Figure 2 5 Three Viewof Cherokee PA 28 180 SerialNos 28 7205001 to 28 7205328 incl HANDLINGAND SERVICING Reissued 1 15 81 1B8...

Page 33: ...PIPER CHEROKEE SERVICE MANUAL 1724 1974 MODELS AND UP Reissued 1 15 81 Figure 2 6 Three Viewof Cherokee PA 28 180 SerialNos 28 7305001 and up HANDLING AND SERVICING...

Page 34: ...PIPERCHEROKEESERVICEMANUAL 1691 63 0 1840 23 8 55 Figure 2 7 Three Viewof Cherokee PA 28 235 Serial Nos 28 10000 to 28 11039 incl Reissued 1 15 81 HANDLINGANDSERVICING 1BlO...

Page 35: ...PIPER CHEROKEE SERVICE MANUAL Figure 2 8 Three Viewof Cherokee PA 28 235 SerialNos 28 11040 to 28 7110042 incl HANDLING AND SERVICING Reissued 1 15 81 1Bll 182B I...

Page 36: ...PIPER CHEROKEE SERVICE MANUAL C330 Reissued 1 15 81 Figure 2 9 Three View of Cherokee PA 28 235 SerialNos 28 7210001 to 28 7210033 incl HANDLING AND SERVICING 1B12...

Page 37: ...PIPER CHEROKEE SERVICE MANUAL Figure 2 10 Three Viewof Cherokee PA 28 235 SerialNos 28 7310001and up Reissued 1 15 81 HANDLING AND SERVICING 1B13 886 1974 MODELS AND UP...

Page 38: ...CHEROKEE SERVICE MANUAL 1796 30 Figure 2 11 Three View of Cherokee PA 28R 180 SerialNos 28 30005 to 28 7130019incl PA 28R 200 SerialNos 28 30482 to 28 7135238incl Reissued 1 15 81 HANDLINGANDSERVICING...

Page 39: ...EROKEESERVICEMANUAL 1796 1974 MODELS AND Up 32 2 32 74 00 1 72 50 Reissued 1 15 81 Figure 2 12 Three View of Cherokee PA 28R 200 SerialNos 28 7235001and up HANDLING AND SERVICING 1B15 5 3 0 7 DIHEDRAL...

Page 40: ...iring Order Starter Delco Remy 12 Volt Prestolite 12 Volt Alternator Chrysler 35 AMP 20 Voltage Regulator Chrysler Alternator Chrysler 60 AMP 30 Voltage Regulator WICO Overvoltage Relay WICO Alternato...

Page 41: ...c System and Brakes Strut Exposure Exposure under static load Nose Main Wheel Tread Wheel Base Nose Wheel Travel Wheel Nose Wheel Main Brake Type Tires Nose Tires Main Tire Pressure Nose Tire Pressure...

Page 42: ...er 35 AMP 20 Voltage Regulator Chrysler Alternator Chrysler 60 AMP 30 Voltage Regulator WICO Overvoltage Relay WICO Fuel Pump Drive 274 150 2700 RPM See Table II IX 8 U S quarts 80 87 80 87 See Note 3...

Page 43: ...se Nose WheelTravel Wheel Nose Wheel Main Brake Type Tires Nose Tires Main Tire Pressure Nose Tire Pressure Main Fixed Combination Air Oil MIL H 5606 3 25 25 in 4 50 25 in 10 0ft 6 ft 2 65 in REFER TO...

Page 44: ...Alternator Chrysler 60 AMP 30 Voltage Regulator WICO Overvoltage Relay WICO Alternator Prestolite 60 AMP Voltage Regulator WICO Fuel Pump Drive Avco Lycoming O 360 A3A or O 360 A4A 286 180 180 2700 R...

Page 45: ...80BMM Diameter Diameter Minimum Blade Angle 9 76 0 in 76 0 in 57 thru 60 in 48 in 28 80 0 in 78 5 in 66 thru 71 in 80 0 in 78 5 in 69 thru 71 in Constant Speed Manufacturer Hub Model Blade Model Diame...

Page 46: ...25 25 in Main 4 50 25 in Wheel Tread 10 0 ft Wheel Base 6 ft 2 65 in 17 or 6 ft 6 9 in Nose Wheel Travel REFER TO SECTION VII TABLE VII I Wheel Nose Cleveland 38501 6 00 x 6 Wheel Main Cleveland40 28...

Page 47: ...lco Remy 35 AMP Voltage Regulator Delco Remy Alternator Chrysler 35 AMP 20 Voltage Regulator Chrysler Alternator Chrysler 60 AMP 30 Voltage Regulator WICO Overvoltage Relay WICO Alternator Prestolite...

Page 48: ...r Minimum I Blade Angle Low Pitch 9 Blade Angle High Pitch 9 Governor Control Governor Model Hartzell HC C2YK IBF F7666A 0 76 0 in 74 0 14 30 30 Hartzell F 2 2 F 2 7 Hartzell or HC C2YK 1B F7666A 2 74...

Page 49: ...ake Type Tires Nose Tires Main Tire Pressure Nose Tire Pressure Main ALL MODELS CONTROL SURFACES AND CABLETENSIONS Hydraulically Retractable Combination Air Oil MIL H 5606 2 75 25 in 2 0 25 in 10ft 5...

Page 50: ......

Page 51: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 II HANDLING AND SERVICING 1C3 THIS PAGE INTENTIONALLY BLANK...

Page 52: ...EE SERVICE MANUAL 1689 Figure 2 13 Station Reference Lines PA 28 140and PA 28 150 160 180 SerialNos 28 1 to 28 1760 incl PA 28 140Flite Liner SerialNos 28 7125174 and up Reissued 1 15 81 HANDLINGAND S...

Page 53: ...PIPER CHEROKEE SERVICE MANUAL 1761 1974 MODELS AND UP Figure 2 14 Station Reference Lines PA 28 140 SerialNos 28 7225001 and up Reissued 1 15 81 HANDLING AND SERVICING 1C5...

Page 54: ...PIPER CHEROKEE SERVICE MANUAL 1798 Figure 2 15 Station Reference Lines PA 28 150 160 180 SerialNos 28 1761 to 28 4377incl 1C6 Reissued 1 15 81 HANDLINGAND SERVICING...

Page 55: ...PIPER CHEROKEE SERVICE MANUAL Figure 2 16 Station Reference Lines PA 28 180 SerialNos 28 4378to 28 7105244incl Reissued 1 15 81 HANDLING AND SERVICING 1C7 C331 0...

Page 56: ...PIPER CHEROKEE SERVICE MANUAL 1710 Figure 2 17 Station Reference Lines PA 28 180 SerialNos 28 7205001 to 28 7205328 incl Reissued 1 15 81 HANDLINGANDSERVICING 1C8...

Page 57: ......

Page 58: ...PIPER CHEROKEE SERVICE MANUAL 1754 Figure 2 19 Station Reference Lines PA 28 235 SerialNos 28 10000 to 28 11039 incl Reissued 1 15 81 HANDLINGANDSERVICING 1C10...

Page 59: ...PIPER CHEROKEE SERVICE MANUAL 1906 Figure 2 20 Station Reference Lines PA 28 235 SerialNos 28 11040 to 28 7110042 incl Reissued 1 15 81 HANDLING AND SERVICING 1C11...

Page 60: ...PIPER CHEROKEE SERVICE MANUAL 1908 Figure 2 21 Station Reference Lines PA 28 235 SerialNos 28 7210001 to 28 7210033 incl Reissued 1 15 81 HANDLINGAND SERVICING 1C12...

Page 61: ......

Page 62: ...CHEROKEE SERVICE MANUAL 1731 Figure 2 23 Station Reference Lines PA 28R 180 SerialNos 28 30005 to 28 7130019 incl PA 28R 200 SerialNos 28 30482 to 28 7135238 incl Reissued 1 15 81 HANDLINGAND SERVICIN...

Page 63: ...PIPER CHEROKEE SERVICE MANUAL Reissued 1 15 81 Figure 2 24 Station Reference Lines PA 28R 200 SerialNos 28 7235001and up HANDLING AND SERVICING 1C15 1760...

Page 64: ...ENT BOLTS 13 SPINNER PROPELLER 14 COWL ASSEMBLY ENGINE 15 COWL ASSEMBLY ENGINE PA 28 140 SERIAL NO S 26 7225001 UP 1794 2 16 PANEL TORQUE TUBE AND CONTROL CABLES BATTERY 17 PLATE CONTROL CABLES MIDDLE...

Page 65: ...LLER 11 FAIRING FUEL LINES 12 COVER FUEL LINES AND SPAR ATTACHMENT BOLTS 13 DOOR OIL FILLER 14 COWL ASSEMBLY ENGINE 15 SPINNER PROPELLER 16 SEAT TOROUE TUBE AND CONTROL CABLES 17 PLATE CONTROL CABLES...

Page 66: ...1 COVER FUEL LINES AND SPAR ATTACHMENT BOLTS 12 FAIRING FUEL LINES 13 CAP STRUT FILLER 14 CAP FUEL TANK ASSEMBLY 15 FUEL TANK ASSEMBLY WING TIP 16 DOOR OIL FILLER 17 SPINNER PROPELLER 18 COWL ASSEMBLY...

Page 67: ...AIN GEAR 11 FAIRING FUEL LINES 12 COVER FUEL LINES AND SPAR ATTACHMENT BOLTS 13 DOOR OIL FILLER 14 COWL ASSEMBLY ENGINE 15 SPINNER PROPELLER 16 PLATE AILERON AND STABILATOR CONTROL CABLE FORWARD 17 PL...

Page 68: ...hickness within the tolerances permitted c Self locking Fasteners The use of self locking nuts fasteners and screws including fasteners with non metallic inserts is subject to the following limitation...

Page 69: ...ne quarter of a foot or 0 25 is needed to get at it You want to know what scale reading it will take on a one foot lever arm wrench to obtain the 30 foot pounds at the bolt C 1 x 30 or C 30 1 0 25 1 2...

Page 70: ...ng surface 4 The friction drag torque if any shall be added to the desired torque specified in Table II IV Sheet 1 This final torque should register on the indicator or be the setting for a snap over...

Page 71: ...washers and try again Do not exceed the maximum recommended torque If self locking castellated nuts are used include friction drag torque 9 Unless otherwise specified in the subject chapter section wh...

Page 72: ...5 110 200 250 120 150 75 110 45 70 7 16 20 450 500 270 300 520 630 300 400 180 280 110 170 1 2 20 480 690 290 410 770 950 450 550 280 410 160 260 9 16 18 800 1 000 480 600 1 100 1 300 650 800 380 580...

Page 73: ...ion Shear Tension Shear Tension Shear AN 310 AN 320 AN 310 AN 320 AN 310D AN 320D AN 315 MS 20364 AN 315 MS 20364 AN 315D MS 20365 MS 21083 MS 20365 MS 21083 MS 21042 MS 21245 MS 21042 MS 21245 MS 210...

Page 74: ...U S LIQ 231 0 CU IN 0 1337 CU FT 3 785 LITERS 0 8327 IMPERIAL GAL 128 FLUID OZ IN 2 540 CM 08333 FT JOULES 0 000948 BTU 0 7376 FT LB MULTIPLY BY TO OBTAIN KILOGRAMS 2 205 LB 35 27 OZ 1000 GRAMS LITERS...

Page 75: ...1 422 1 447 1 473 1 498 0 06 1 524 1 549 1 574 1 600 1 625 1 651 1 676 1 701 1 727 1 752 0 07 1 778 1 803 1 828 1 854 1 879 1 905 1 930 1 955 1 981 2 006 0 08 2 032 2 057 2 082 2 108 2 133 2 159 2 184...

Page 76: ...10 120 130 140 150 160 170 180 190 200 210 F 94 0 76 0 58 0 40 0 22 0 4 0 14 0 32 0 50 0 68 0 86 0 104 0 122 0 140 0 158 0 176 0 194 0 212 0 230 0 248 0 266 0 284 0 302 0 320 0 338 0 356 0 374 0 392 0...

Page 77: ...VI DECIMAL MILLIMETER Equivalents of Drill Sizes From 1 2 to No 80 o o o o 0000 0000 N LL 0 z N E S...

Page 78: ...1 2 27 1 2 30 TABLE II VIII HOSE CLAMP TIGHTENING INITIAL INSTALLATION Types of hose Self sealing All other hose Types of clamps Worm screw type Finger tight plus 2 complete turns Finger tight plus 1...

Page 79: ...G AROMATIC AND HEAT RESISTANTHOSE REDNUMERALS AND LETTERS RED NUMERALS LETTERSAND STRIPE E SELF SEALINGAROMATIC RESISTANTHOSE C FLAME AROMATIC AND OIL RESISTANTHOSE HOSEIDENTIFICATION MARKINGS BROWN O...

Page 80: ...enlarge the hole 4 In thin material use a small center drill to provide a guide for a larger drill on top of the rivet stem and the tapered position of the stem be drilled away to destroy the lock 5...

Page 81: ...nding gear and to perform other service operations Proceed as follows a Place jacks under jack pads on the front wing spar Refer to Figure 2 32 b Attach the tail support to the tail skid Place approxi...

Page 82: ...n jacks during the weighing procedure while the wheels are on scales or while the wheels are on the ground To level the airplane for purposes of weighing or rigging the following procedures may be use...

Page 83: ...ecure tie down ropes to the wing tie down rings and the tail skid at approximately 45 degree angles to the ground When using rope constructed of non synthetic material leave sufficient slack to avoid...

Page 84: ...ather when accumulated moisture may freeze the brakes d The aileron and stabilator controls may be secured using the front seat belt 2 19 TOWING The airplane may be moved by using the nose wheel steer...

Page 85: ...se material that may cause damage to the propeller blades 2 21 EXTERNAL POWER RECEPTACLE 2 22 OPERATION OF EXTERNAL POWER RECEPTACLE The receptacle is located on the left side of the nose section just...

Page 86: ...Lubricate controls bearing surfaces etc per Lubrication Chart 2 25 CLEANING LANDING GEAR a Struts and Torque Links Before cleaning the landing gear struts and torque links place a plastic cover or sim...

Page 87: ...ith a cloth moistened with kerosene NOTE Do not use gasoline alcohol benzene carbon tetrachloride thinner acetone or window cleaning sprays d After cleaning plastic surfaces apply a thin coat of hard...

Page 88: ...I of this manual 2 34 SERVICING HYDRAULIC PUMP RESERVOIR The fluid level of the reservoir of the combination pump and reservoir should be checked every 50 hours by viewing the fluid through the filler...

Page 89: ...ug hole If oil is visible at the bottom of the hole then all that is required is the valve be checked for unsatisfactory conditions and air added as described in paragraph 2 41 Should fluid be at any...

Page 90: ...e filler plug hole 6 Reinstall the core in the filler plug and apply thread lubricated See Thread Lubricant Oleo Strut Air Valve Kopr Kote to the threads of the filler plug and install the plug in the...

Page 91: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 II HANDLING AND SERVICING 1D19 Figure 2 36 Servicing Points PA 28 140...

Page 92: ...PIPER CHEROKEE SERVICE MANUAL II HANDLING AND SERVICING 01 31 08 1D20 Figure 2 37 Servicing Points PA 28 150 160 180...

Page 93: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 II HANDLING AND SERVICING 1D21 Figure 2 38 Servicing Points PA 28 235...

Page 94: ...PIPER CHEROKEE SERVICE MANUAL II HANDLING AND SERVICING 01 31 08 1D22 Figure 2 39 Servicing Points PA 28R...

Page 95: ...hree torque link bolts and again raise the airplane until a minimum of ten inches do not exceed twelve inches of tube exposure of strut tube is exposed with the wheel remaining on the ground With this...

Page 96: ...then fully compress and extend the strut three or four times to remove any air that may be trapped and to allow fluid to enter the bottom chamber of the housing 5 Raise the strut to full compression...

Page 97: ...o struts refer to Section VIIA WARNING DO NOT RELEASE AIR BY REMOVING THE STRUT VALVE CORE OR FILLER PLUG DEPRESS THE VALVE CORE PIN UNTIL STRUT CHAMBER PRESSURE HAS DIMINISHED CAUTION DIRT AND FOREIG...

Page 98: ...mpress the strut two or three times to remove air from the housing 5 Remove the filler plug raise the strut to full compression and fill with fluid if needed 6 Apply thread lubricant See Thread Lubric...

Page 99: ...instructions in Section VII or VIIA 2 48 FILLING BRAKE CYLINDER RESERVOIR The brake cylinder reservoir should be filled to the level marked on reservoir with the fluid specified in Table II I The rese...

Page 100: ...n balanced for the life of the tire without having any shimmy or flat spots a Tire Balancer An inexpensive balancing fixture that will balance almost any light aircraft tire can be made from the mater...

Page 101: ...on the chamfered edges of the balancer and that it is at 90 to the sides of the balancer 2 Release the tire If it is out of balance it will rotate coming to rest with the heaviest point on the bottom...

Page 102: ...an or replace in accordance with Paragraph 2 56 b On PA 28 180 Serial Nos 28 1761 and up the filter is located on the right side and midway in the engine compartment and may be removed by the followin...

Page 103: ...oil or wax In addition constant speed propellers should be inspected for absence of grease or oil leakage and freedom of rotation on the hub pilot tube To check freedom of rotation rock the blade back...

Page 104: ...should be drained daily prior to first flight and after refueling to avoid the accumulation of water or sediment Each fuel tank is equipped with an individual quick drain located at the lower inboard...

Page 105: ...positioned in the following sequence off position left tip left main right main and right tip while draining the strainer to ensure that the fuel lines between each tank outlet and fuel strainer are...

Page 106: ...less than 0 10 by volume One and one half liquid ozs per ten gallon of fuel would fall within this range A blender supplied by the additive manufacturer should be used Except for the information cont...

Page 107: ...e drain up and turning counterclockwise This will hold the drain in the open position It is recommended the engine be warmed to operating temperature to ensure complete draining of the old oil 2 75 OI...

Page 108: ...ution since the cleaning action of some additive oils will tend to loosen sludge deposits and cause plugged oil passages When an engine has been operating on straight mineral oil and is known to be in...

Page 109: ...ROPERLY LUBRICATED If specific lubrication instructions for certain components are not available observe the following precautions a Apply oil sparingly never apply more than enough to coat bearing su...

Page 110: ...F 12 C 71 C 99 C TABLE II X THREAD LUBRICANTS Line Lubricant Brakes MIL PRF 5606 WARNING DO NOT PERMIT MIL T 5544 ANTI SEIZE COMPOUND TO ENTER SYSTEM APPLY TO FITTING THREADS ONLY Air Conditioning Ref...

Page 111: ...PH 203 743 4447 www miller stephenson com Grease Aircraft MIL PRF 23827 Royco 27A Royal Lubricants Co and Instrument River Road Gear and Actuator E Hanover NJ 07936 Screw Grease General MIL PRF 81322...

Page 112: ...llent Repcon UNELKO Corporation FSCM 50159 727 E 110th Street Chicago Illinois 60628 Sealant Fuel PR 1422 A 2 Sealant Products Research Co Tank Sealing Brushing Consistency 2919 Empire Avenue Burbank...

Page 113: ...nes equipped with full flow cartridge type oil filters provided the specified octane fuel is used and the filter replaced each 50 hours of operation Should fuel other than the specified octane rating...

Page 114: ...100 HRS 3 TORQUE LINK BUSHING See Spec Instr 1 MIL PRF 7870 100 HRS 4 TORQUE LINK CONNECTING BUSHING See Spec Instr 1 MIL PRF 23827 100 HRS 5 MAIN GEAR WHEEL BEARINGS See Spec Instr 3 MOBIL GREASE 28...

Page 115: ...HRS 5 MAIN GEAR WHEEL BEARINGS See Spec Instr 3 MOBIL GREASE 28 MIL PRF 81322E 100 HRS 6 MAIN GEAR DOOR CONTROL ROD ENDS See Spec Instr 1 MIL PRF 7870 100 HRS 7 MAIN GEAR SIDE BRACE LINK ASSEMBLY See...

Page 116: ...T POINT See Spec Instr 1 MIL PRF 7870 100 HRS 3 SHIMMY DAMPENER PIVOT POINT See Spec Instr 1 MIL PRF 7870 100 HRS 4 TORQUE LINK ASSEMBLY See Spec Instr 2 MIL PRF 7870 100 HRS 5 NOSE WHEEL BEARINGS See...

Page 117: ...c Instr 2 DRY LUBRICANT MS 122AD 100 HRS 6 NOSE WHEEL BEARINGS See Spec Instr 3 MOBIL GREASE 28 MIL PRF 81322E 100 HRS 7 NOSE GEAR DRAG LINK ASSEMBLIES See Spec Instr 1 MIL PRF 7870 100 HRS 8 NOSE GEA...

Page 118: ...UIRED 8 TEE BAR PIVOT POINT See Spec Instr 1 and Caution MIL PRF 7870 100 HRS 9 CONTROL COLUMN CHAIN See Spec Instr 2 and Caution MIL PRF 7870 500 HRS 10 CONTROL COLUMN FLEX JOINTS AND SPROCKET See Sp...

Page 119: ...L PRF 7870 100 HRS 3 FLAP HANDLE PIVOT POINT LOCK MECHANISM AND TURNBUCKLE END MIL PRF 7870 100 HRS 4 FLAP RETURN AND TENSION CHAINS MIL PRF 7870 500 HRS 5 AILERON BELLCRANK pivot points See Spec Inst...

Page 120: ...E BEARING BLOCKS See Spec Instr 2 DRY LUBRICANT MS 122AD 100 HRS 2 TOE BRAKE CYLINDER ATTACHMENTS See Spec Instr 1 MIL PRF 7870 100 HRS 3 RUDDER TUBE CONNECTIONS See Spec Instr 1 MIL PRF 7870 100 HRS...

Page 121: ...LUBRICANT FREQUENCY 1 RUDDER ARM CABLE ENDS See Spec Instr 1 MIL PRF 7870 100 HRS 2 STABILATOR TRIM SCREW See Spec Instr 2 LUBRIPLATE 907 100 HRS 3 STABILATOR SCREW TAB LINKS See Spec Instr 1 MIL PRF...

Page 122: ...nd Seats COMPONENT LUBRICANT FREQUENCY 1 DOOR HINGES See Spec Instr 2 MIL PRF 7870 100 HRS 2 DOOR SEALS See Spec Instr 5 DRY LUBRICANT MS 122AD 50 HRS 3 DOOR LATCH MECHANISMS See Spec Instr 2 MIL PRF...

Page 123: ...Spec Instr 7 50 HRS 4 PROPELLER ASSEMBLY See Spec Instr 2 and 13 AEROSHELL 6 OR MIL PRF 23827 100 HRS 5 ENGINE CONTROL AND ENVIRONMENTAL CONTROL PIVOT POINTS See Spec Instr 1 MIL PRF 7870 100 HRS 6 F...

Page 124: ...20 F MIL C 21567 BELOW 20 F 100 HRS 2 BACK UP EXTENDER LINKS AND CONTROL ARM PIVOT POINTS See Spec Instr 2 MIL PRF 7870 100 HRS 3 BACK UP EXTENDER SPRING ATTACHMENT POINTS See Spec Instr 2 MIL PRF 787...

Page 125: ...ERVICING 1F5 COMPONENT LUBRICANT FREQUENCY 1 CONDENSER HINGE AND ACTUATORS See Spec Instr 1 MIL PRF 7870 100 HRS 2 CONDENSER DOOR ACTUATING TRANSMISSION MIL PRF 23827 500 HRS See Spec Instr 2 and 17 F...

Page 126: ...PIPER CHEROKEE SERVICE MANUAL II HANDLING AND SERVICING 01 31 08 1F6 THIS PAGE INTENTIONALLY BLANK...

Page 127: ...PIPER CHEROKEE SERVICE MANUAL 1F7 SECTION III INSPECTION MOVED TO GRID 3H1...

Page 128: ...PIPER CHEROKEE SERVICE MANUAL 1F8 GRIDS 1F8 THRU 1G12 INTENTIONALLY BLANK...

Page 129: ...Stabilator 1H6 4 19 Installation of Stabilator 1H8 4 20 Stabilator Trim Tab 1H13 4 21 Removal of Stabilator Trim Tab 1H13 4 22 Installation of Stabilator Trim Tab 1H13 4 23 Rudder 1H13 4 24 Removal of...

Page 130: ...ing Repair 1H24 4 58 Fiberglass Repairs 1I4 4 59 Fiberglass Touch Up and Surface Repairs 1I4 4 60 Fiberglass Fracture and Patch Repairs 1I5 4 61 Thermoplastic Repairs 1I6 4 62 A B S Thermoplastic Land...

Page 131: ...s A storm windowis located in the forward lower section of the left window and can be opened inward when the latch is released The cabinentrance door is located on the right side of the fuselage above...

Page 132: ...wing being carefulnot to damage the wingor wing tip 2 Pull off the wing tip far enough to disconnect the position light wireassembly The ground lead may be disconnected at the point of connection on...

Page 133: ...aileron control rod at the aileron attachment point by removing the nut washers and bolt from the rod end bearing To simplify installation note location of washers removed b Remove the attaching screw...

Page 134: ...ING 4 14 REMOVAL OF WING Refer to Figure 4 2 a PA 28 140 PA 28 150 160 180 and PA 28 235 1 Disconnect battery 2 Close the fuel valve and drain the fuel from the wing to be removed Refer to Draining Fu...

Page 135: ...N960 10 20365 1032C PA 28 181 ONLY AN3 11A AN960 1 0 MS20365 1032C 63900 19 2 REQ 2 REQ SKETCHB A322 SKETCH C BOLT AN3 12A WASHER AN960 10 6 REQ NUT MS20365 1032C AN3 13A AN960 10 MS20365 1032C 63900...

Page 136: ...TO AGREE WITH SKETCH E 2 1 10 MODIFIED DEMENSION 81 EXISTING DIMENSION NUT AN310 3 WASHER AN960 10 COTTER PIN MS24665 132 MODIFIED CUTOUTDETAIL RIGHT ANDLEFT SIDE SKETCHE 2 Figure 4 1 Aileron and Fla...

Page 137: ...necessary to disconnect the pitot and static tubes at the elbows located within the cockpit at the wing butt line 15 Arrange a suitable fuselage cradle and supports for both wings 16 Remove wing jack...

Page 138: ...PIPER CHEROKEE SERVICE MANUAL IV STRUCTURES 01 31 08 1G22 THIS PAGE INTENTIONALLY BLANK...

Page 139: ......

Page 140: ...ASHER UNDERNUT 1 AN960 616 1 96352 3 1 AN960 616 1 96352 3 1 AN960 616 1 96352 3 1 AN960 616 1 96352 3 2 AN960 616 2 AN960 616 2 AN960 616 2 AN960 616 1 AN960 616 2 AN960 616 2 AN960 616 2 AN960 616 1...

Page 141: ...move the cotter pin from the pulley bracket assembly to allow the left aileron balance cable end to pass between the pulley and bracket 11 Disconnect flaps from the torque tube by fully lowering flaps...

Page 142: ...0 41 L W and P N 62010 42 R W All airplanes not indicated in the above serial number listing are equipped with wing panels modified to 2 of washout P N 62015 04 L W and P N 62015 03 R W During the ser...

Page 143: ...inimum from the fitting to the end of the bolt Add washers AN960 516 as required minimum of one to leave a maximum of one and one half visible thread or minimum of the bolt chamfer exposed after the n...

Page 144: ...Ground run aircraft to verify proper operation of fuel and brake systems b PA 28R 1 Ascertain that the fuselage is solidly positioned on the support cradle 2 Place the wing in position for installati...

Page 145: ...age 11 Connect the hydraulic brake line onto the fitting located within the cockpit at the leading edge of the wing and torque B nuts 12 Connect the landing gear hydraulic lines at the fittings within...

Page 146: ...n to distribute weight on top of the bulkheads so as not to damage the fuselage skin NOTE Should it be necessary to move the rudder to its extreme left or right for clearance do so with the use of the...

Page 147: ...ng assembly and remove the fairing separately 2 Block the trim cable at the barrel of the trim screw assembly to prevent the cable from unwrapping 3 Remove the access panel to the aft section of the f...

Page 148: ...bilator Trim Modification installed Airplanes with either kit installed refer to step b 1 Insert the stabilator in position and install attaching hinge bolts washers and nuts 2 Move the trim assembly...

Page 149: ...5 Remove the cable block from the trim control cable within the fuselage 6 Set stabilator control cable tension and check rigging and adjustment according to Rigging and Adjustment of Stabilator Secti...

Page 150: ...PIPER CHEROKEE SERVICE MANUAL IV STRUCTURES 01 31 08 1H10 THIS PAGE INTENTIONALLY BLANK...

Page 151: ...UAL SKETCH A 908 SKETCH B 908 868 907 SKETCHC BOLT AN3 11 NUT AN310 3 SKETCH D Figure4 4 EmpennageGroup Installation 1H11 Reissued 1 15 81 STRUCTURES C335 1791 Al16 SKETCH F SKETCH E A109 BOLT AN3 5A...

Page 152: ......

Page 153: ...upper tail cone fairing assembly and remove the fairing b Remove the rudder tip by removing the attaching screws and disconnect the tail position light wire at the quick disconnect located at the tip...

Page 154: ...fin b Remove the rudder per instructions given in Paragraph 4 24 c Disconnect the leads from the antenna terminals optional and attach a line to the leads to assist in reinstallation d Disconnect the...

Page 155: ...1 REMOVAL OF WINDSHIELD a Remove the collar molding from around the bottom of the windshield and the trim strip from between the windshield halves by removing the attaching screws b Remove the windshi...

Page 156: ...ITE WHITE SEALANT SEALANT WHITE I VINYL BLACK 1800 WHITE SEALANT BLACK VINYL TAPE Reissued 1 15 81 898 966 WHITE SEALANT VINYL BLACK VINYL TAPE BLACK VINYL TAPE Figure4 5 WindshieldInstallation Typica...

Page 157: ...stall and se cure i Seal with sealant any areas around windshield that mayallow water to pen etrate past the windshield j Remove excess exposed sealer to tape 4 33 SIDE WINDOWS 4 34 REMOVAL OF SIDE WI...

Page 158: ...anning vinyl foam tape number 560 or equivalent on both sides of the window around the outer edges 3 Apply Behr ManningSealant number PRC5000 or equivalent completely around the outer surface of the w...

Page 159: ...e door into position and install the washers clevis bolts and cotter pins on the door hinges b For adjustment of door refer to Paragraph 4 39 c Hook up and install the clevis bolt bushing and washer i...

Page 160: ...ed as required with toluol Apply adhesive ina continuous coat of 002 to 010 of an inch thick 5 Apply a continuous coat of adhesive of the same thickness to the seal 6 With the adhesive applied to the...

Page 161: ...160 180 Serial Nos 28 1 to 28 990 incl 1 Remove the latch assembly by removing the two knobs and the small trim plate at the aft end of the latch 2 Remove the two screws from the inside trim plate an...

Page 162: ...52 REMOVAL OF BAGGAGE DOOR LOCK ASSEMBLY a With the door open remove the nut from the back of the lock assembly by use of a special made wrench This tool may be fabricated from the dimensions given in...

Page 163: ...ing 5 of the seat back release c Adjust the push pull cable 6 by raising or lowering it until the lower surface of the stop assembly 7 is parallel to the straightedge d Secure the push pull cable in t...

Page 164: ...ND THE ALTERNATE METHOD OF JOINING DESCRIBED BELOW SHALL ONLY BE USED FOR NON STRUCTURAL NON LOAD CARRYING APPLICATIONS A metal wire stitching process is used to staple fabric and rubber seal material...

Page 165: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 IV STRUCTURES 1I1 Figure 4 10 Skin Materials and Thickness...

Page 166: ...PIPER CHEROKEE SERVICE MANUAL IV STRUCTURES 01 31 08 1I2 Figure 4 10 Skin Materials and Thickness cont...

Page 167: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 IV STRUCTURES 1I3 Figure 4 10a Metal Wire Stitching Repair...

Page 168: ...ly A hypodermic needle may be used to inject gel into small cavities not requiring fiberglass millings mixed with the gel d Work the mixture of resin fibers and catalyst into the damaged area using th...

Page 169: ...ast replace the amount of reinforcements removed in order to maintain the original strength If damage occurred as a stress crack an extra layer or two of cloth may be used to strengthen area i Lay pat...

Page 170: ...thermoplastic parts they can be removed with a hot air gun capable of supplying heat in the temperature range of 300 to 400 F Use care not to overheat the material Hold the nozzle of the gun about 1 4...

Page 171: ...motive Type DuPont 7 DuPont Company Wilmington Del 19898 Ram Chemical 69 x 1 Mirror Glaze 1 Fantastic Spray Perchlorethylene VM P Naptha Lighter Fluid Ram Chemicals Gardena Cal 90248 Mirror Bright Pol...

Page 172: ...made 2 Drill small stop holes at each end of the crack 3 If possible a double plate should be bonded to the reverse side of the crack to provide extra strength to the part 4 The crack should be V groo...

Page 173: ...CHEROKEE SERVICE MANUAL 871 Figure 4 12 Deep Scratches Shallow Nicks and Small Holes 826 THOROUGHLYMIX USING FIGUREEIGHT MOTION Figure 4 13 Mixing of Epoxy Patching Compound Reissued 1 15 81 119 STRUC...

Page 174: ...ion of the repair and surrounding area before applying any paint 2 It is recommended that parts be cleaned prior to painting with a commercial cleaner or a solution made from one fourth cup of deterge...

Page 175: ...PIPER CHEROKEE SERVICE MANUAL B70 Figure 4 14 Welding Repair Method 827 HOLES Figure 4 15 Repairing of Cracks 1I11 DOUBLER PLATE TO I Revised 10 3 83 STRUCTURES...

Page 176: ...PIPER CHEROKEE SERVICE MANUAL 831 830 828 DAMAGED AREA Figure 4 16 Various Repairs STRUCTURES I 1112...

Page 177: ...PIPER CHEROKEE SERVICE MANUAL 827 STRESS LINES Figure 4 17 Repair of Stress Lines 829 PROFILE VIEW INDICATING DAMAGED AREA Figure 4 18 Repair of Impacted Damage 1113 STRUCTURES Revised 10 3 83...

Page 178: ...mpound as follows a Mix and thin the liquid safety walk compound in accordance with the manufacturer s instructions on the container b Coat the specifiedsurfaceswith a smooth unbroken film of the liqu...

Page 179: ...e sensitive safety walk as follows a Peel back the full width of the protective liner approximately 2 inches from the leadingedgeof the safety walk b Apply the safety walk to the wing area begin at th...

Page 180: ...ral positions 4 71 CHECKINGCONTROLSURFACESFREEPLAY The following checks are recommended before balancing to ascertain the amount of free play in the stabilator stabilator trim tab and aileron a Stabil...

Page 181: ...40 PA 28R 200 28R 7435001 AND UP 5 TO 40 PA 28 235 NON STRETCHED STABILATOR 5 TO 14 PA 28 235 28 7310001 TO 28 7310176 5 TO 40 PA 28 235 28 7410001 AND UP 5 TO 40 RUDDERS PA 28 140 UP TO 28 7325614 0...

Page 182: ...balancing the tool the movable weight must be at the bar s hinge centerline d After balancing the tool reattach it to the control surface per Figures 4 20 and 4 21 Keep the beam positioned 90 from th...

Page 183: ...centerline Calibrate the tool as described in Paragraph 4 72 Read the scale when the bubble level has been centered by adjustment of the movable weight and determine the static balance limit If the s...

Page 184: ...PIPER CHEROKEE SERVICE MANUAL IV STRUCTURES 01 31 08 1I20 Figure 4 19 Control Surface Balance Tool...

Page 185: ...PIPER CHEROKEE SERVICE MANUAL A12r HOLDING FIXTURE BALANCING TOOL REFERTO FIG 4 19 LEVELSUPPORT Figure 4 20 Aileron and Rudder BalanceConfiguration STRUCTURES Revised 10 3 83 1121...

Page 186: ...a mannerthat allowsunrestrictedmovement Place the tool on the stabilator with the beam perpendicularto the hingecenterline Donot placethe tool on thetrim tab Calibrate the tool as describedinParagrap...

Page 187: ...new one it is per missible to use the new bracket as a hole template to drill the two new holes at their proper location To install the balance weight assembly the following procedure may be used a R...

Page 188: ...PIPER CHEROKEE SERVICE MANUAL 969 50R Figure 4 22 Wing Rib Modification 885 RIVETS MS20470AD3 3 Figure 4 23 Balance Weight Assembly Installation Reissued 1 15 81 STRUCTURES 1124...

Page 189: ...ith the following instructions a Remove the clevis bolt and related parts from the inboard flap hinge at taching point b The skin on the flap must be modified in accordance with Figure 4 1 c Remove th...

Page 190: ...PIPER CHEROKEE SERVICE MANUAL IV STRUCTURES 01 31 08 1J2 Figure 4 25 Additional Drain Holes in Stabilator Typical...

Page 191: ...side of the reference centerline Joining these two points will form the centerlines of each inspection hole e Measure two points on each side of each centerline of both holes at distances of 8 48 inch...

Page 192: ...gage compartment floor b Drill a 0 120 inch hole in baggage compartment floor at each position layed out in step a c Attach cover to flooring with No 8 X 0 38 corrosion resistant steel sheet metal scr...

Page 193: ...99 2 28 R TYP 2 00 R o TYP M 0 0 120 HOLETHRU N0 8X38 CRESTRUSS RECESSED HEADSHEET METAL SCREWS 16 REQD 10 98 8 48 AFT V 19 11 Figure 4 26 BaggageCompartment Inspection Holes Cutout Details Interim R...

Page 194: ...of moveable components of the aircraft 3 No self tapping screws used for bonding purposes 4 Exposed conducting frames or parts of electrical or electronic equipment should have a low resistance bond o...

Page 195: ...Mounted on Non Conductive Material 003 Avionics Black Boxes 003 NOTE Harnesses should be installed and connected for this check internal chassis wiring through the connector to ground is permissible...

Page 196: ...PIPER CHEROKEE SERVICE MANUAL IV STRUCTURES 01 31 08 1J8 GRIDS 1J8 THRU 1J24 INTENTIONALLY BLANK...

Page 197: ...PIPER CHEROKEE SERVICE MANUAL 1K1 INTRODUCTION...

Page 198: ...PIPER CHEROKEE SERVICE MANUAL 1K2 THIS PAGE INTENTIONALLY BLANK...

Page 199: ...hiness 1K5 General 1K5 Effectivity 1K6 Serial Number Explanation 1K8 Assignment of Subject Material 1K8 Pagination 1K8 Aerofiche Effectivity 1K8 Identifying Revised Material 1K9 Indexing 1K9 Warnings...

Page 200: ...PIPER CHEROKEE SERVICE MANUAL INTRODUCTION TABLE OF CONTENTS 01 31 08 1K4 THIS PAGE INTENTIONALLY BLANK...

Page 201: ...plication is required To confirm the correct hardware used refer to the PA 28 140 150 160 180 235 PA 28R 180 200 Cherokee Parts Catalog P N 753 582 and FAR 43 for proper utilization Genuine PIPER part...

Page 202: ...26401 thru 28 26946 1970 D Fliteliner 28 7125001 thru 28 7125641 1971 E Cruiser Fliteliner 28 7225002 thru 28 7225602 1972 F Cruiser Fliteliner 28 7325001 thru 28 7325674 1973 Cruiser Fliteliner 28 7...

Page 203: ...039 1967 C 28 11040 thru 28 11226 1968 28 11227 thru 28 11255 1969 D 28 11301 thru 28 11378 1970 E 28 7110001 thru 28 7110028 1971 F 28 7210001 thru 28 7210023 1972 Charger 28 7310001 thru 28 7310176...

Page 204: ...ormation compiled in this Aerofiche Service Manual will be kept current by revisions distributed periodically These revisions will supersede all previous revisions and will be complete Aerofiche card...

Page 205: ...ersons Cautions call attention to methods and procedures which must be followed to avoid damage to equipment Notes call attention to methods which make the job easier Warnings and Cautions shall be lo...

Page 206: ...nter One S TEC Way 23500 W 105th St M D 45 Mineral Wells Texas 76067 Olathe Kansas 66061 1950 PH 940 325 9406 http www bendixking com http www s tec com Rockwell Collins Inc 400 Collins Road N E Cedar...

Page 207: ...O 320 Series P N 60297 30 O HO IO AIO HIO TIO 360 Series P N 60297 12 O 540 IO 540 Series P N 60297 10 NOTE The above Lycoming publications can be ordered as a set on CD ROM from Avantext See www avan...

Page 208: ...2256 http www unisonindustries com Installation Operation F1100 MASTER SERVICE MANUAL and Maintenance Instructions 11 PROPELLER Vendor Address Sensenich Corporation PH 717 569 0435 14 Citation Lane FA...

Page 209: ...048 http www skytecair com or Electro Systems Inc See listing under Alternator above 14 VACUUM PUMP Vendor Address Aero Accessories Inc PH 800 822 3200 1240 Springwood Avenue Gibsonville NC 27249 http...

Page 210: ...PIPER CHEROKEE SERVICE MANUAL INTRODUCTION 01 31 08 1K14 GRIDS 1K14 THRU 1L24 INTENTIONALLY BLANK...

Page 211: ...PART NUMBER 753 586 January 31 2008 2A1 SERVICE MANUAL CARD 2 OF 4 PA 28 140 PA 28 150 PA 28 160 PA 28 180 PA 28 235 PA 28R 180 PA 28R 200 PIPER AIRCRAFT CORPORATION...

Page 212: ...August 3 1983 1 2 3 and 4 PR840423 April 23 1984 1 2 3 and 4 PR86115 January 15 1986 1 and 3 IR860730 July 30 1986 1 IR870506 June 12 1987 1 IR950215 February 15 1995 1 and 2 IR020228 February 28 2002...

Page 213: ...ULIC SYSTEM PA 28R 2D3 VII LANDING GEAR AND BRAKES PA 28 2E22 VIIA LANDING GEAR AND BRAKES PA 28R 2H1 VIII POWERPLANT PA 28 2K2 VIIIA POWERPLANT PA 28R 3A8 IX FUEL SYSTEM 3C8 X INSTRUMENTS 3D18 XI ELE...

Page 214: ...dder Trim Control 2C9 5 17 Flap Controls 2C12 5 18 Flap Rigging Tool Application and Flap Step Adjustment 2C14 5 19 Correct Method of Installing Rod End Bearings 2C16 5 20 Not Used 5 21 Not Used 5 22...

Page 215: ...Brake Installation 2G12 7 20 Brake Cylinder 10 20 10 27 17000 Toe Brake 2G14 7 21 Brake Cylinder 10 30 Toe Brake 2G15 7 22 Bleeding Brake Gravity 2G18 7 23 Bleeding Brake Pressure 2G18 7 24 Orifice R...

Page 216: ...allation 2K9 8 4 Adjustment of Propeller Control PA 28 235 2K13 8 5 Propeller Governor PA 28 235 2K13 8 6 Engine Installation PA 28 140 150 160 180 S N s 28 1 thru 28 1760 2K16 8 7 Engine Installation...

Page 217: ...ticulars Hydraulic System 2D8 VI II Characteristics Hydraulic Pump Motor 2D15 VI IIA Pipe Thread Specifications 2D21 VI III Hydraulic System Troubleshooting 2E9 VII I Nose Gear Alignment Tolerances 2F...

Page 218: ...ron Controls 2A24 5 13 Adjustment of Aileron Trim 2B1 5 14 Stabilator Controls 2B4 5 15 Removal of Stabilator Control Cables 2B4 5 16 Installation of Stabilator Control Cables 2B5 5 17 Rigging and Adj...

Page 219: ...Removal of Rudder Control Cables 2C2 5 35 Installation of Rudder Control Cables 2C2 5 36 Rigging and Adjustment of Rudder Controls 2C4 5 37 Rudder Trim Controls 2C7 5 38 Removal of Rudder Trim Control...

Page 220: ...hain is wrapped around the sprockets and around a double sprocket on the vertical post of the control column The chain is connected to the primary aileron control cable which is routed through the cen...

Page 221: ...nal threads are visible outside the barrel Install the locking clips and check for proper installation by trying to remove the clips using fingers only Both locking clips may be installed in opposite...

Page 222: ...priate section for rigging instructions 5 3b FLIGHT CONTROL CABLE TENSION CAUTION CABLE TENSIONS GIVEN IN TABLE V II APPLY ONLY TO AIRPLANES WITHOUT AUTOPILOT BRIDLE CABLE INSTALLATIONS IF AN AUTOPILO...

Page 223: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 V SURFACE CONTROLS 2A13 TABLE V II FLIGHT CONTROL SURFACES RIGGING LIMITS PIR PPS 50005 1 Rev K...

Page 224: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2A14 TABLE V II FLIGHT CONTROL SURFACES RIGGING LIMITS cont...

Page 225: ...ains at the top of the tee bar 5 4 Disconnect the control chains from the control cables where the chains and cables join by removing the cotter pins nuts bolts and bushings 10 5 Remove the tunnel cov...

Page 226: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2A16 Figure 5 1 Control Column Assembly Typical PA 28 140 150 160 180 235...

Page 227: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 V SURFACE CONTROLS 2A17 Figure 5 2 Control Column Assembly PA 28R...

Page 228: ...and then set cable tension with the turnbuckles located under the floor panel aft of the main spar as instructed in paragraph 5 12 Before safetying the turnbuckle check that when the ailerons are neu...

Page 229: ...rusion for proper installation NOTE Reamer may be purchased from Enstice Tool Co Palm Bay Florida d Install pin through tube and shaft 1 If pin shoulder does not protrude past sprocket hub install an...

Page 230: ...Figure 5 3 Aileron Controls Typical PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2A20...

Page 231: ...the pulley attaching bolt 21 5 Move the cable guard 20 under the pulley cluster 9 located just aft of the lower portion of the tee bar by removing the cotter pin from the exposed end of the guard and...

Page 232: ...by the following procedure a PA 28 140 PA 28 150 160 180 and PA 28R Place the tunnel plate into position for installation and secure with the attachment screws Roll the carpet into place and install...

Page 233: ...end as desired by removing the cotter pin nut washer and bolt f Remove the nut pivot bolt 25 and washers that secure the bellcrank The nut is visible from the underside of the wing g Remove the bellc...

Page 234: ...he aft side of the bellcrank stop The bellcrank must be moved to allow a snug fit of the tool between the bellcrank arm and rib To do so it may be necessary to loosen a primary control cable or the ba...

Page 235: ...ch reading When measuring down travel from the neutral position maintain a light up pressure at the center of the aft edge of the aileron When measuring up travel from the neutral position maintain a...

Page 236: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2B2 Figure 5 4 Bellcrank Rigging Tool Application and Fabrication...

Page 237: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 V SURFACE CONTROLS 2B3 Figure 5 5 Aileron Rigging Tool Application and Fabrication...

Page 238: ...fuel selector torque tube by removing the attaching pin located at the bottom of the lever Remove the tunnel plate located just aft of the tee bar by laying back enough tunnel carpet to remove the pla...

Page 239: ...or tunnel plate and trim covers by the following procedure a PA 28 140 PA 28 150 160 180 and PA 28R Place the tunnel plate into position for installation and secure with the attaching screws Roll the...

Page 240: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2B6 Figure 5 6 Stabilator Controls...

Page 241: ...ctor the number of degrees down travel as given in Table V II and again place it on the rigging tool Lower the trailing edge of the stabilator and determine that when it contacts its stops the bubble...

Page 242: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2B8 Figure 5 7 Stabilator Rigging Tool Application and Fabrication...

Page 243: ...from the panel b Remove the spring clip from the stabilator trim crank handle and remove the handle c Remove the headliner trim panel light panel from around the trim crank assembly by the following p...

Page 244: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2B10 Figure 5 8 Stabilator Trim Control Overhead Control...

Page 245: ...ecting the electrical leads and in stalling attaching screws i Replace the trim handle and secure with the snap ring 5 21 REMOVAL OF STABILATOR TRIM CONTROLS AFT Refer to Figure 5 8 a PA 28 150 160 18...

Page 246: ...10603 to 28 10605 incl The exception being those airplanes with Piper Kit No 756 896 Stabilator Trim Modification installed Airplanes with this kit installed refer to step c 1 Remove the tail cone fa...

Page 247: ...buckles 8 in the aft section of the fuselage by the method shown in Figure 5 9 b Remove the cable guard pin from the pulleys located within the fuselage at station 228 30 c Disconnect the links 19 loc...

Page 248: ...back around the bottom groove of the trim pulley and forward to the inside of the fuselage c Draw the cable end forward and connect it with its mating end within the fuselage d Ascertain that the cabl...

Page 249: ...end of the cable to the indicator wire and at the same time make adjustments given in paragraph 23 12 Install tail cone fairing and secure with screws 13 Install access panel to the aft section of the...

Page 250: ...vel the airplane Refer to Leveling Section II 2 Check for proper stabilator trim cable tension as given in Table V II If the cables were disconnected rotate control crank 1 several times to allow the...

Page 251: ...al support rib 20 of the trim assembly If the stop is not contacting the plate and the links between the screw 11 and the trim control arm 15 are not disconnected disconnect the two by removing the co...

Page 252: ...tion not to damage trim indicator wire 2 3 Unwrap the left cable 9 from the drum 4 The wheel and drum are joined by a push fit separate these two items with their center bushing and unwrap the right c...

Page 253: ...wheel and secure with screws unless the control cables have yet to be installed b The trim control cables may be installed by the following procedure 1 Draw the cable s through the floor tunnel 2 Wrap...

Page 254: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2B20 Figure 5 10 Stabilator Trim Control Floor Control...

Page 255: ...n the slot of the barrel Bring the upper cable through the diagonal slot in the flange at the upper end of the barrel and wrap down in a counterclockwise direction Bring the lower cable through the di...

Page 256: ...disconnect the two by removing the connecting nut washers and bolt 24 With the turnbuckle still at the two inch dimension from the pulley turn the screw down until the pin contacts the plate f Check t...

Page 257: ...the arm to the trim Remove the cotter pin and clevis pin from the rudder trim mechanism and remove the mechanism from the mounting channel Remove the screw from the engine control bracket assembly an...

Page 258: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2B24 Figure 5 11 Rudder and Steering Pedal Assembly...

Page 259: ...h Connect the ends of the brake cylinder rods 11 and clevis rods 15 to the idler arms 10 and secure with clevis and cotter pins 13 i Connect the steering rods 21 to the rudder pedals 32 and 33 and sec...

Page 260: ...tter pin nut washer and bolt 2 8 Draw the cable from the floor tunnel d The aft rudder control cables may be removed by the following procedure 1 Remove the tail cone fairing by removing its attaching...

Page 261: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 V SURFACE CONTROLS 2C3 Figure 5 12 Rudder Controls...

Page 262: ...SSED AND THAT THE RUDDER MOVES LEFT WHEN THE LEFT PEDAL IS DEPRESSED a To check and set the correct degree of rudder travel the following procedure may be used 1 Check the rudder travel by swinging th...

Page 263: ...ermined by standing behind the airplane and sighting the rudder with the vertical stabilizer or the center of the trim screw 5 Check safety of turnbuckles c On fixed landing gears check that when the...

Page 264: ...st the rudder pedal stops by pushing on the pilot s left rudder pedal until the rudder stop is contacted Adjust the pedal stop on the fire wall to provide 0 060 to 0 120 of an inch clearance Repeat th...

Page 265: ...ed bushing 4 is installed on the assembly shaft 15 with the welded attachment bushing forward or toward the housing c Attach the housing lug to the arm provided on the rudder pedal torque tube and sec...

Page 266: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2C8 Figure 5 15 Rudder Trim Control Installation PA 28 140 150 160 180 235...

Page 267: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 V SURFACE CONTROLS 2C9 Figure 5 16 Rudder Trim Control...

Page 268: ...6 Disconnect the flap return spring 32 at the spar or return chain 30 as desired 7 Disconnect the control cable from the chain 20 by removing cotter pin nut and clevis bolt 21 8 Remove the tube suppo...

Page 269: ...d with the bearing block on it between the mounting bracket and sliding the other end into the previously attached bearing block 6 Position the remaining bearing block and secure with bolts washers an...

Page 270: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2C12 Figure 5 17 Flap Controls...

Page 271: ...s 5 43a TORQUE TUBE PUSH ROD DISTORTION INSPECTION If flaps have been extended at or above VFE inspect the flap torque tube arms and pushrods for evidence of distortion a If the paint is cracked or pe...

Page 272: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2C14 Figure 5 18 Flap Rigging Tool Application and Flap Stop Adjustment...

Page 273: ...e of the wing and flap as close as possible to the outboard end of the flap without contacting any rivets The tool must be positioned parallel with the wing ribs with the aft end of the tool even with...

Page 274: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2C16 Figure 5 19 Correct Method of Installing Rod End Bearings...

Page 275: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 V SURFACE CONTROLS 2C17 THIS PAGE INTENTIONALLY BLANK...

Page 276: ...PIPER CHEROKEE SERVICE MANUAL V SURFACE CONTROLS 01 31 08 2C18 THIS PAGE INTENTIONALLY BLANK...

Page 277: ...Resistanceto control wheelrotation Systemnot lubricated properly Lubricate system Cable tension too high Control columnhori zontal chainimproperly adjusted Pulleysbindingor rubbing Cablesnot in place...

Page 278: ...igin accordancewith paragraph 5 6 Rigin accordance with paragraph 5 12 Adjust in accordance with paragraph 5 12 Aileronbellcrankstops not adjusted properly Adjust in accordance with paragraph 5 12 Cor...

Page 279: ...lubricated Lubricate system ntrol movement properly Cable tension too high Adjust cable tension per paragraph 5 17 Bindingcontrol column Adjust and lubricate per paragraph 5 6 Pulleysbinding or Replac...

Page 280: ...with paragraph 5 29 Install cablesaccord ing to paragraphs5 26 and 5 28 Broken pulley Linkageloose or worn Replacepulley Checklinkageand tighten or replace Trim control wheel moves with excessive res...

Page 281: ...m position Trim indicator unit not adjustedproperly Adjust in accordance with paragraph 5 29 OVERHEADTRIM Lost motion between trim control crank and trim tab Cabletension too low Cablesnot in placeon...

Page 282: ...pulleys Trim tab hingebinding Cablescrossedor routed incorrectly Refer to paragraphs 5 20 and 5 22 Lubricate hinge If necessary replace Check routing of control cables Trim tab failsto reach full tra...

Page 283: ...edal movement System not lubricated properly Rudder pedal torque tube bearingin need of lubrication Lubricate system Lubricate torque tube bearings Cable tension too high Pulleysbinding or rubbing Cab...

Page 284: ...gin accordance with paragraph3 36 RUDDERTRIM CONTROLSYSTEM Trim control knob moveswith excessive resistance System not lubricated properly Lubricate system FLAPCONTROL SYSTEM Flaps fail to extend or r...

Page 285: ...lic Installation Landing Gear 2D19 6 12 Gear Back Up Extender Actuator Assembly 2D21 6 13 Removal of Gear Back Up Extender Actuator Assembly 2D21 6 14 Installation of Gear Back Up Extender Actuator As...

Page 286: ...stments and Checks for the operation of the repaired sys tem CAUTION Prior to starting anyinvestigation of the hydraulic sys tem place the airplane on jacks Refer to Jacking Section II 6 2 DESCRIPTION...

Page 287: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VI HYDRAULIC SYSTEM 2D5 Figure 6 1 Schematic Diagram of Hydraulic System...

Page 288: ...EAR DOWN 4 MANIFOLD GEARUP PRESSURE SWITCH 6 GEARBACK UP EXTENDER ACTUATOR 7 MAST ACK UP EXTENDER 8 ACTUATING CYLINDER LEFT 9 LEVER EMERGENCY EXTENDER 10 ACTUATING CYLINDER NOSE 11 FITTING RESTRICTOR...

Page 289: ...up position at airspeeds below approximately 105 MPHwith engine power off The devicealso prevents the gear from retracting at airspeeds below approximately 85 MPHwith full power though the selector sw...

Page 290: ...uires disassembly it is recommended that it be overhauled by a recommended overhaul shop However if this cannot be achieved minor repairs of the pump such as replacement of gaskets and motor component...

Page 291: ...etween the end of the armature 8 and motor head Do not misplace this bearing 4 Draw the armature from the motor frame 9 Note the number of thrust washers 11 mounted on the drive end of the armature sh...

Page 292: ...7 BALL THRUST 8 ARMATURE 9 FRAME MOTOR 10 SLEEVE 11 WASHER THRUST 12 SCREW VENT AND FILLER 13 RESERVOIR 14 SEAL 15 CASE VALVE AND SEAR 16 BASE PUMP 17 BOLT 18 SCREWS 8 REQ 9 10 11 13 14 15 18 5 16 17...

Page 293: ...tation and end play thrust of the armature within the assembly A minimum of 005 of an inch end play is allowable Should this be incorrect adjust by adding or removing thrust washers 11 on drive end of...

Page 294: ...e blue lead and the high pressure reading should not drop more than 300 psi in five minutes High pressure may not be selected until after five minutes 7 Connect the green lead to the positive terminal...

Page 295: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VI HYDRAULIC SYSTEM 2D13 Figure 6 4 Test and Adjustments of Hydraulic Pump...

Page 296: ...rvoir of the combination pump and reservoir should be checked every 50 hours by checking the dipstick indication Access to the pump is through the access panel in the aft wall of the baggage compartme...

Page 297: ...black blue and green forward and reverse harness wires 5 Check fluid level in pump Fill per instructions given in Section II 6 Install baggage compartment access panel TABLE VI II CHARACTERISTICS HYDR...

Page 298: ...bly 1 If bracket was removed from was removed from pump mount install bracket to pump mount with four MS24693 S298 screws 2 Position pump assembly on bracket so that tapped holes in oildyne adapter al...

Page 299: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VI HYDRAULIC SYSTEM 2D17 Figure 6 5a Hydraulic Pump Reservoir Sheet 1 of 2...

Page 300: ...PIPER CHEROKEE SERVICE MANUAL VI HYDRAULIC SYSTEM 01 31 08 2D18 Figure 6 5a Hydraulic Pump Reservoir Sheet 2 of 2...

Page 301: ...e of the pump and ascertain that fluid is visible up to the bottom of the filler plug hole Should fluid be below the hole add fluid MIL H 5606A through the filler hole until full Reinstall the filler...

Page 302: ...PIPER CHEROKEE SERVICE MANUAL VI HYDRAULIC SYSTEM 01 31 08 2D20 Figure 6 6 Checking Aligning Brackets of Gear Back up Extender Actuator and Fabrication of the Aligning Tool...

Page 303: ...phragm housing 10 by releasing clamps and sliding the hoses from their elbows The hoses should be tagged for ease of reassembly d Place a shop cloth under the actuator hydraulic valve 25 to absorb flu...

Page 304: ...ng the forward hose 13 to the diaphragm assembly 10 so that no strain is placed on the teflon bushing 15 and diaphragm shaft 16 thus causing friction in movement d Connect the hydraulic lines 5 and 26...

Page 305: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VI HYDRAULIC SYSTEM 2D23 Figure 6 7 Gear Back up Extender Actuator Sheet 1 of 2...

Page 306: ...PIPER CHEROKEE SERVICE MANUAL VI HYDRAULIC SYSTEM 01 31 08 2D24 Figure 6 7 Gear Back up Extender Actuator Sheet 2 of 2...

Page 307: ...emergency gear extension lever moved to the up override position 6 Loosen the adjustment screw 2 by turning counterclockwise until spring 24 tension is free WARNING WHILE MAKING ADJUSTMENTS DO NOT LA...

Page 308: ...able landing gear system Refer to Paragraph 6 16 6 16 OPERATIONAL CHECK OF RETRACTABLE LANDING GEAR SYSTEM a Maximum Gear Extend Place the gear selector in the down position at 150 MPH 130 Kts In appr...

Page 309: ...up nor down 3 The Red gear warning light will indicate an unsafe condition It will indicate when the throttle setting is less than 14 2 inches of manifold pressure while the gear is not down and lock...

Page 310: ...lt and nut b Attach the operating rod end to the downlock link using bolt Install nut after adjustment is completed c Connect the hydraulic lines to the cylinder fittings d Check the adjustment of the...

Page 311: ...nd exterior surfaces of the piston for scratches burrs corrosion etc 2 Threaded areas for damage 3 Rod end fitting and swivel fitting of cylinder for wear and corrosion c Repairs to the cylinder and l...

Page 312: ...sing bolt and nut b Attach the operating rod end and downlock spring swivel fitting to the upper side brace retraction fitting by using bolt washer and nut Ascertain swivel fitting is free to rotate c...

Page 313: ...owing 1 Interior walls of cylinder and exterior surfaces of piston for scratches burrs corrosion etc 2 Threaded areas for damage 3 End fitting retainer slot for excess wear 4 Rod end fitting and swive...

Page 314: ...t in the cylinder body 7 and slot in the end gland 1 Rotate gland to completely wrap lock ring into assembly f Align port in end gland and cylinder body g Check smoothness of operation of piston and s...

Page 315: ...eaker open Landing gear actuator circuit wires broken Landing gear selector circuit wires broken Safety squat switch out of adjustment Squat switch inoper ative Pressure switch inoperative Pump retrac...

Page 316: ...circuit should be further Landing gear retraction system fails to oper ate cont Gear selector switch ground incomplete Check ground Gear selector switch inoperative Hydraulic pump ground incomplete Hy...

Page 317: ...gm Referto the latest revisionof PiperService LetterNo 810 Can be checked by using override Landing gear exten sion system fails to operate Landing gear actuator circuit breaker open Reset circuit bre...

Page 318: ...ear selector switch it may be assumed that the gear control circuit is operating properly and the actuator circuit should be further checked Gear selector switch ground incomplete Gear selector switch...

Page 319: ...selector circuit breaker opens Pressure switch out of adjustment Mechanical restriction or obstruction in hyd raulic system to allow pressure to build up and shut off pump be fore gear has retracted...

Page 320: ...p retraction sole noid sticking inboard solenoid Internal leakage of system Replace switch Replace solenoid Check back up exten sion unit valve for internal leakage Check gear actuating cylinders for...

Page 321: ...off though the gear has fully extended Pump extension sole noid sticking out board solenoid Replace solenoid Nose gear down limit switch actuator out of adjustment Nose gear down limit switch failed M...

Page 322: ...pump and re place check valve Internal leakage of system Check auxiliary retrac tion unit valve for internal leakage Check gear actuating cylinders for internal leakage External leakage of system Che...

Page 323: ...draulic lines Hydraulic fluid in reservoir below operating level Fill reservoir with hydraulic fluid All gears fail to free fall Gear free falls at air speeds above that required Back up extension uni...

Page 324: ...ints of the over ride lever or actuator arm Binding of diaphragm shaft caused by build up of sand or dirt Clean free and lub ricate all pivot points Clean all moving parts Landing gear will not retrac...

Page 325: ...ith gear selector down and three green lights on pump motor circuit breaker opens With in transit light on pump operates on and off With in transit light on pump motor circuit breaker opens Shorted ge...

Page 326: ...PIPER CHEROKEE SERVICE MANUAL VI HYDRAULIC SYSTEM 01 31 08 2E20 THIS PAGE INTENTIONALLY BLANK...

Page 327: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VI HYDRAULIC SYSTEM 2E21 THIS PAGE INTENTIONALLY BLANK...

Page 328: ...ain Landing Gear 2F10 7 15 Disassembly of Main Gear Oleo 2F10 7 16 Cleaning Inspection and Repair of Main Gear Oleo 2F11 7 17 Assembly of Main Gear Oleo 2F11 7 18 Removal of Main Landing Gear 2F18 7 1...

Page 329: ...Parking Valve 2G11 7 42 Disassemblyof Parking Valve 2G11 7 43 Cleaning Inspection and Repair of Parking Valve 2G11 7 44 Assembly of Parking Valve 2G11 7 45 Installation of Parking Valve 2G13 7 46 Bra...

Page 330: ...e also incorporated on the push rods of later models 1974 models and up These springsmake lighter and smoother ground steeringpossible The two main wheels are equipped with a singledischydraulic brake...

Page 331: ...he fluid by slowly compressing the piston tube If it is desirable to ex tract more fluid from the strut chamber remove the filler plug insert the si phon hose and drain fluid from the upper area of th...

Page 332: ...STRUT HOUSING 5 BEARING BOTTOM 6 CAP VALVE 7 PLUG FILLER 8 TUBE METERING 9 CYLINDER 10 RING RETAINER 11 SNAP RING 12 BEARING 13 0 RING PACKING 14 0 RING OR QUAD RING 15 WASHER CACK UP 17 WIPER STRIP 1...

Page 333: ...IONAND REPAIROF NOSEGEAROLEO a Clean all parts with a suitabledry type cleaningsolvent b Inspect the landing gearoleo assemblycomponent for the following 1 Cylinder tube assemblyfor corrosion scratche...

Page 334: ...upper and lower bearings 3 and 5 are installed in the strut housing Bearings are a press fit with the grooves in the inner and outer races in the up position i Position washer 2 and strut assembly ret...

Page 335: ...identification and reinstallation g Remove the nose gear and engine mount by removing the five bolts 16 which attach the mount to the firewall 7 11 CLEANING INSPECTION AND REPAIR OF NOSE LANDINGGEAR a...

Page 336: ...PIPER CHEROKEE SERVICE MANUAL VII LANDING GEAR AND BRAKE SYSTEM 01 31 08 PA 28 2F6 Figure 7 2 Nose Gear Installation...

Page 337: ...tely three feet forward of the nose wheel Allow the line to passunder the wheel at the center lineof the tire Snap the chalk line f Ascertain that the rudder is properly rigged and the rudder cableten...

Page 338: ...the gear fork or torque links m When the wheel is turned to its extreme right or left travel there should be 06 to 12 of an inch clearancebetween the nose wheel steering stops This is due to the stop...

Page 339: ...N s 28 1761 thru 28 7305601 3 PA 28 235 S N s 28 10487 thru 28 7310187 4 PA 28R 180 S N s 28R 7130001 and up 5 PA 28R 200 Models previous to 1974 14 degrees 3 All 1974 Models and up 1 Nose Wheel Trave...

Page 340: ...by removing any one of the three cotter pins nuts washers and bolts Note arrangement of the components for reinstallation Carefullyslidethe piston tube from the cylinderhousing 4 The scraper ring 15 l...

Page 341: ...g apply Permatex Forma Gasket 6 Sealantbeneath the flangeof the cylinderhead 4 4 Insert The tube of the metering assembly through the openingin the top of the housing and into the orifice Use caution...

Page 342: ...ruts Section II i Actuate the gear several times by hand to be certain it operates freely NOTE Links should be loose enough to allow free action of the gear but also resist side play To eliminate side...

Page 343: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VII LANDING GEAR AND BRAKE SYSTEM PA 28 2F13 Figure 7 5 Main Gear Oleo Strut Assembly PA 140 150 160 and 180...

Page 344: ...PIPER CHEROKEE SERVICE MANUAL 1698 SEE NOTE Figure 7 5 Main Gear Oleo Strut Assembly PA 28 140 150 160 and 180 cont 1 15 81 2F14 LANDING GEAR AND BRAKE Reissued SYSTEM...

Page 345: ...7310003 UP 2 1 CAP VALVE 2 PLUG FILLER 3 0 RING 4 HEAD CYLINDER 5 DELETED 6 TUBE METERING 7 0 RING 8 ORIFICE ASSEMBLY 9 SRUT HOUSING 10 WASHER 12 NUT 12 WASHER 13 TORQUE LINKS 14 O RING OR QUADRING 1...

Page 346: ...PIPERCHEROKEE SERVICE MANUAL 1999 1 2 3 4 6 7 8 9 13 SEE NOTE Figure 7 6 Main Gear OleoStrut Assembly PA 28 235 cont Reissued 1 15 81 2F 16 LANDING GEAR AND BRAKESYSTEM...

Page 347: ...INTENTIONALLY LEFTBLANK 2F17...

Page 348: ...ing attaching screws e Unhook the hydraulic brake line inside the wing assembly This is accessible through the access plate Cap the line by use of a threaded cap or wrapping with plastic f Remove the...

Page 349: ...LVE CAP 3 BOLT 4 AIR VALVE 5 CYLINDER 6 BOLT 7 BRAKE LINE HOSE 8 BOLT WASHER NUT COTTER PIN 9 OLEO ASSEMBLY 10 TORQUE LINK ASSEMBLY 11 TOROUE LINK ASSEMBLY 12 STUB AXLE Figure 7 7 Main Gear Installati...

Page 350: ...AND DISASSEMBLYOF NOSE WHEEL Refer to Figure 7 8 a Jack the airplane enough to raise the nose wheel clear of the ground Refer to Jacking Section II b If wheel fairing is installed remove four bolts tw...

Page 351: ...ficiently deflated remove the wheel through bolts 4 Pull the wheel halves from the tire by removing the wheel half opposite the valve stem first and then the other half e The wheel bearing assemblies...

Page 352: ...ace the wheel fairing by turning sideways and slipping it up over the fork assembly d Place the spacer tubes one on each side of the wheeland install unit in fork Align and slide the axle tube through...

Page 353: ...from each wheel half by first removing the retainer rings 7 or 12 or snap rings 17 that secure the grease seal retainers 18 or 20 and then the retainers grease seals 13 or 19 and bearing cone II The b...

Page 354: ...lide the wheel on the axle and secure with retainer nut Tighten the nut to allow no side play yet allow the wheelto rotate freely Safety the nut with a flat head pin washer and cotter pin Reinstall th...

Page 355: ...ove the brake assembly first disconnect the brake line from the brake cylinder at the tube fitting b Remove the two cap bolts that jointhe brake cylinder housing and the lining back plate assembly Rem...

Page 356: ...bolt by the followingprocedure 1 Position cylinder assemblyon a holding fixture Refer to Figure 7 11 2 Use a suitable arbor press to removethe anchor bolt from the cylinder body 923 PRESS CYLINDER BO...

Page 357: ...anchor bolt Refer to Figure 7 12 Step B 3 Use a suitable arbor press and apply pressure on the spot face directly over the anchor bolt hole Refer to Figure 7 12 Step C A122 STEPA PRESS HOLDING FIXTUR...

Page 358: ...rt number 754 165 7 33 ASSEMBLYAND INSTALLATIONOF WHEEL BRAKE ASSEMBLY Refer to Figure 7 10 a Lubricate the piston O ringwith fluid MIL H 5606and installon piston Slidethe piston in cylinder housing u...

Page 359: ...e Disc Minimum Thickness 1786 1 BRAKE RESERVOIR 2 RIGHT BRAKE AND RUDDER PEDAL 3 LEFT BRAKE AND RUDDER PEDAL 4 RIGHT BRAKE CYLINDER 5 LEFT BRAKE CYLINDER 6 BRAKE HANDLE 7 HANDLE RELEASE BUTTON 8 MASTE...

Page 360: ...03to 28 10679incl Refer to Figure 7 16 1 Remove the cylinder from the airplane per Paragraph 7 35 2 Cut the safety wireand remove screw 10 that securesthe plug 1 in the end of the cylinder 9 3 Remove...

Page 361: ...utside of the brake cylindercap 3 2 Install new O ring 10 on the piston head 11 and slideonto the guidepin 12 3 Slidethe O ring 9 onto the smallend of the guide pin 4 Fit the guide pin with piston hea...

Page 362: ...G 14 PARKING VALVE Hand Brake to 28 250 incl 1 CYLINDER ACTUATOR PLUG A600 2 0 RING 3 0 RING 4 CYLINDER ACTUATOR SHAFT 5 CYLINDER ACTUATOR PISTON 6 PISTON 7 ROLLPIN 8 SPRING 9 CYLINDER 10 SCREW 9 Figu...

Page 363: ...150 160 180 Serial Nos 28 251 to 28 2700inch PA 28 235 Serial Nos 28 10003to 28 10697incl Refer to Figure 7 16 NOTE Use a small amount of hydraulic fluid MIL H 5606 on the 0 rings and componentparts...

Page 364: ...land 9 with 0 rings 10 seal 7 piston 6 with 0 ring spring 4 and retainer bushing 3 Secure these pieces with snap ring 2 on the end of the rod 3 Insert the piston rod assembly in the housing 1 and secu...

Page 365: ...ve O ring packings from the end fitting and piston 7 43 CLEANING INSPECTION AND REPAIR OF PARKINGVALVE a Clean the valve components in a suitable dry type cleaning solvent b Inspect the valve for the...

Page 366: ...EE SERVICE MANUAL 1884 9 CLEVIS PIN WASHER COTTER PIN 10 CLEVIS PIN WASHER COTTER PIN 11 SPRING RETURN 12 BRACKET 13 BRACE ASSEMBLY 14 CYLINDER ASSEMBLY HYDRAULIC 15 TUBE ASSEMBLY LEFT 16 CLEVIS PIN C...

Page 367: ...ing bracket per Paragraph 7 47 2 Todisassemblethe cylinder firstremove the pistonrod assemblybyremovingthe snap ring 10 from the annular slotin the cylinderhousing 1 Drawthe piston rod assembly from t...

Page 368: ...ING 5 O RING 6 PISTON 7 SEAL 8 FITTING 9 O RING 10 O RING 11 SPRING 12 PISTON ROD 13 WASHER 14 ROLL PIN Figure 7 20 Brake Cylinder Toe Brake 7 49 CLEANING INSPECTION AND REPAIR OF BRAKE CYLINDER a Cle...

Page 369: ...EEVE 4 SPRING Revised 10 3 83 5 O RING 6 PISTON 7 O RING 8 GLAND 9 O RING 10 O RING 11 WASHER WIPER 12 ROD 13 SPRING 14 WASHER 15 ROLL PIN Figure 7 21 Brake Cylinder 10 30 Toe Brake THIS SPACE INTENTI...

Page 370: ...seal 5 piston assembly 3 and spring 2 3 Insert the piston rod assembly in the cylinder 1 and securewith the snap ring 10 4 Install the cylinder per paragraph 7 51 c Cleveland cylinder number 10 30 Re...

Page 371: ...ight brake cylinder very slowly approximately 12 times This will purge air from the toe brake cylinder system Watch for any air forced through the clearplastictube duringthis operation to insure air h...

Page 372: ...r is left inthe system If air bubbles are evident fillingof the systemshall becontinueduntil allthe air is out of the systemand a steady flow of fluid is obtained Should the brake handle remainspongy...

Page 373: ...should not be able to be pulled aft further than the originalset Should the handle be able to be pulled towards the panel and feel spongy a leak ispresent at some point in the system Thisleak may appe...

Page 374: ...Loose torque links Adjust side play Worn torque link bolts Replace bolts and or and or bushings bushings Excessive or uneven wear Incorrect operating Inflate tire to correct on nose tires pressure pre...

Page 375: ...nd replace shimmies during fast taxi tire if necessary takeoff or landing Worn or loose wheel Replace and or adjust bearings wheel bearings Loose torque links Adjust side play Worn torque link bolts R...

Page 376: ...G cont Trouble Cause Remedy Strut bottoms on normal landing or taxiing on rough ground Insufficient air and or fluid in strut Service strut with air and or fluid Defective internal parts Replace defec...

Page 377: ...PIPER CHEROKEE SERVICE MANUAL I MATERIAL STEEL Figure 7 24 Orifice Replacement Tool Reissued 1 15 81 2G23 LANDING GEAR AND BRAKE SYSTEM I...

Page 378: ...PIPER CHEROKEE SERVICE MANUAL 904 HANDLE 50 DIA 4 00 3 WELD 125 7 50 Reissued 1 15 81 Figure 7 25 Retainer Ring Tool 2 G 24 LANDINGGEARAND BRAKESYSTEM...

Page 379: ...r Up Stop 2H17 7A 14 Alignment of Nose Landing Gear 2H18 7A 15 Removal of Nose Gear Door Assembly 2H20 7A 16 Cleaning Inspection and Repair of Nose Gear Door Assembly 2H21 7A 17 Installation of Nose G...

Page 380: ...Reduced Warning Switch 2I18 7A 43 Adjustment of Landing Gear Up Power Reduced Warning Switch 2I19 7A 44 Gear Down Selector Handle Up Warning Switch 2I20 7A 45 Removal of Gear Down Selector Handle Up W...

Page 381: ...and Repair of Brake Master Cylinder 2J4 7A 65 Assembly of Brake Master Cylinder 2J4 7A 66 Installation of Brake Master Cylinder 2J5 7A 67 Brake Cylinder Toe Brake 2J7 7A 68 Removal of Brake Cylinder...

Page 382: ...mit switchactuates the switchto the NC circuit and inserieswith the NC circuit of the up limit switch allowsthe intransit light to come on The intransit light will remain on until the gear is up and a...

Page 383: ...lock the extension lever in the up overrideposition thus bypassing the automatic portion of the system A flashingwarning light is mounted below the gear selector lever to indicate whenever the lock is...

Page 384: ...l strut chamber pressure has diminished remove the filler plug and with a small hose siphon as much hydraulic fluid from the strut as possible d To remove the complete cylinder and fork assembly from...

Page 385: ...scratches and over all damage 2 Retaining pins for wear and damage 3 Lock rings for cracks burrs etc 4 Cylinder and orifice tube for corrosion scratches nicks and excess wear 5 Upper and lower cylinde...

Page 386: ...26 17 SNAP RING 18 ROLL PIN 19 WASHER STOP 20 BUSHING UPPER 21 HOUSING STRUT 22 BUSHING LOWER 23 OLEO CYLINDER 24 LINK UPPER TORQUE 25 BOLT WASHER BUSHINGS NUT AND COTTER PIN 26 LINK LOWER TORQUE 27 P...

Page 387: ...E SERVICE MANUAL 1716 27 29 30 31 38 39 40 41 42 1736 Reissued 1 15 81 Figure 7A I Nose Gear Oleo Strut Assembly cont 2H9 LANDING GEAR AND BRAKE SYSTEM 1733 10 11 12 13 14 15 16 17 18 19 19 43 20 21 2...

Page 388: ...h links The torque link bolt assemblies should be lubricated and installed with the flat of the bolt head hex adjacent to the milled stop on the wide end of the link Tighten the bolts only tight enoug...

Page 389: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VIIA LANDING GEAR AND BRAKE SYSTEM PA 28R 2H11 Figure 7A 2 Nose Gear Installation Sheet 1 of 2...

Page 390: ...PA 28R 200 1968 THRU 1971 67147 AE 55 ENGINE MOUNT 4 STEERING BELLCRANK WASHERS 62833 10 3 REQ SEE NOTE 13 BOLT AN6 14A WASHER MS35335 35 UNDER HEAD BEARING 65003 15 NUT MS21042 6 VIEW C LOOKING AFT P...

Page 391: ...ight side of the oleo housing 54 and lower drag link 32 by removing the cotter pin nut and washer from the bolt 29 that connects the drag link to the housing Slide the arm and spacer washer from the b...

Page 392: ...he distance exceed the required through center traveland bolt and bushing are tight replace one or both draglinks f The shimmy dampener requires no serviceother than routine inspection In caseof damag...

Page 393: ...center locked position e Retract the gear and connect the gear downlock spring 42 between the downlock hook 43 and the upper drag link 35 f Extend the gear and connect the two gear tension springs 15...

Page 394: ...PIPER CHEROKEE SERVICE MANUAL VIIA LANDING GEAR AND BRAKE SYSTEM 01 31 08 PA 28R 2H16 Figure 7A 4 Nose Gear Adjustment With Gear Up Stop Figure 7A 3 Nose Gear Adjustment Without Gear Up Stop...

Page 395: ...quare with the longest end along the bottom of the fuselage and the shortest end running up through the centerline of the wheel axle Measure up along the square from the bottom of the fuselage 6 25 0...

Page 396: ...lock hook k Adjust shimmy dampener by turning nose wheel against stops and adjusting the rod end of the dampener for adequate travel to both extremes l Install engine cowling retract and cycle landing...

Page 397: ...tube to check the neutral angle for the model being serviced as given in Table VII I n On earlier models one end of each rod must be disconnected and the jam nuts loosened to make any adjustments Do n...

Page 398: ...oor s from the cowl bend the end of the hinge pin straight and from the other end pull out the pin c The bellcrank assembly 4 of the door retraction mechanism may be removed by removing the attached h...

Page 399: ...nk between its mounting bushing and inserting the insulator sleeve and bushing tube Install a cotter pin through each attachment bushing and the pivot tube New tubes will require a 0 070 hole drilled...

Page 400: ...n the tube and pushing out the upper bearing 18 retainer pins 17 Slide off the upper bearing 18 lower bearing 20 with O rings 19 and 21 wiper 22 washer 23 and snap ring 24 i To remove the orifice tube...

Page 401: ...and install pins 17 without force The outer surface of the pins must not protrude beyond the outer diameter of the bearing 18 g Lubricate the wall of the cylinder oleo housing 11 and tube 25 and caref...

Page 402: ...PIPER CHEROKEE SERVICE MANUAL VIIA LANDING GEAR AND BRAKE SYSTEM 01 31 08 PA 28R 2H24 Figure 7A 8 Main Gear Oleo Strut Assembly Sheet 1 of 2...

Page 403: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VIIA LANDING GEAR AND BRAKE SYSTEM PA 28R 2I1 Figure 7A 8 Main Gear Oleo Strut Assembly Sheet 2 of 2...

Page 404: ...sconnect the gear door actuating rod 38 at the gear housing 3 Remove the access plate located on the underside of the wing aft of landing gear 4 If not previously disconnected disconnect the lower sid...

Page 405: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VIIA LANDING GEAR AND BRAKE SYSTEM PA 28R 2I3 Figure 7A 9 Main Gear Installation Sheet 1 of 2...

Page 406: ...PIPER CHEROKEE SERVICE MANUAL VIIA LANDING GEAR AND BRAKE SYSTEM 01 31 08 PA 28R 2I4 Figure 7A 9 Main Gear Installation Sheet 2 of 2...

Page 407: ...ons or conditions that may lead to failures e Check side brace link through center travel by attaching the upper and lower links setting them on a surface table and ascertaining that when the stop sur...

Page 408: ...PIPER CHEROKEE SERVICE MANUAL VIIA LANDING GEAR AND BRAKE SYSTEM 01 31 08 PA 28R 2I6 Figure 7A 9a Main Landing Gear Trunnion Repair...

Page 409: ...dd a 191 inch hole in the location shown on Figure 7A 9a and deburr the hole c Enlarge the former 191 inch hole to 500 inch diameter and remove material from web as shown on Figure 7A 9a Deburr edges...

Page 410: ...ne each AN960 416 and AN960 416L washer per bolt 5 Push the retainer tube into the arm of the housing and secure with bolt 6 Check that the gear rotates freely in its support fittings and recheck thru...

Page 411: ...he stop slot of the side brace link Hold the fitting in this position and turn the turnbuckle barrel until the downlock hooks make contact with the lock pin Safety the turnbuckle g For easier adjustme...

Page 412: ...PIPER CHEROKEESERVICEMANUAL Figure A 10 Aligning Main Gear Reissued 1 15 81 2110 LANDINGGEAR AND BRAKESYSTEM RIVET BRACKET SKETCH B...

Page 413: ...lane up just high enough to obtain a six and one half inch dimension between the centerline of the strut piston and the centerline of the center pivot bolt of the gear torque links Refer to Figure 7A...

Page 414: ...spacers to go in the same direction f Recheck wheel alignment If the alignment is correct safety the castellated nut with cotter pin g If a new link on the top left main gear had to be installed or it...

Page 415: ...inges and brackets c Inspect the door retraction rod and end bearing for damage and corrosion d Repairs to a door may be replacement of hinge repair of fiberglass and painting 7A 30 INSTALLATION OF MA...

Page 416: ...7A 33 ADJUSTMENT OF NOSEGEAR UPLIMIT SWITCH The gearup limitswitchis mounted on a bracket on the engine mount above the point wherethe rightsideof the upper drag link attaches to the engine mount a To...

Page 417: ...SWITCH The gear down limit switch is mounted on the horizontal support tube of the engine mount that runs between the right attachment points of the gear housing and upper drag link a Ascertain that...

Page 418: ...rtain that the main gear downlock is properly adjusted as described in paragraph 7A 26 b Raise the airplane on jacks Refer to Jacing Section II c Ascertain that the landing gear is down and pressure i...

Page 419: ...u i I N 3 a G O u o O 6 o...

Page 420: ...or the extender as found in Section VI 7A 39 LANDING GEAR WARNINGSWITCHES THROTTLE SWITCHES 7A 40 LANDINGGEARUP POWERREDUCEDWARNINGSWITCH The gear up power reduced warning switch Switch A is within th...

Page 421: ...and the propeller control at a desired low pitch setting c Retard the throttle to a manifold pressure of approximately 14 inches This setting should be an airspeed above 110MPH d In some manner mark...

Page 422: ...er and removing the two screws that secure the bracket 7A 46 INSTALLATION OF GEAR DOWN SELECTOR HANDLE UP WARNING SWITCH a Connect the electrical leads tothe switch Leads attach to terminals C and NC...

Page 423: ...st removing the snap rings 1 or 16 that secure the grease seal retainers and then the retainers grease seals 4 or 13 and bearing cones 6 or 12 The bearing cups 5 or 11 should be removed by tapping out...

Page 424: ...e 7A 15 Nose Wheel Assembly NOTE On aircraft models which use the ClevelandWheelAssembly torque nuts to 90 inch pounds Those aircraft models which use the McCauley Wheel Assembly torque nuts to 140 15...

Page 425: ...cks Refer to Jacking Section II b To remove the main wheel remove the four cap bolts that join the brake cylinder housing and the lining back plate assemblies Remove the back plate from between brake...

Page 426: ...gs 3 or 12 Secure with snap rings 1 or 14 c Slide the wheel on the axle and secure with retainer nut Tighten the nut to allow no side play yet allow the wheel to rotate freely Safety the nut with a co...

Page 427: ...e 7A 17 Wheel Brake Assembly c Slide the brake cylinder housing 3 from the torque plate d Remove pressure plate 8 by sliding it off anchor bolts 15 of the housing e The pistons may be removed by injec...

Page 428: ...vet set that will properly stake the lining and form a correct flair of the rivet f After replacing brake linings condition them by performing a minimum of six light pedal effort braking applications...

Page 429: ...ine into a suitable container b Disconnect the pressure line from the fitting at the bottom of the cylinder and allow fluid to drain from the cylinder line c Disconnect the end of the cylinder rod fro...

Page 430: ...corrosion etc c Inspect the general condition of the fitting threads of the cylinder d Check the piston and valve for scratches burrs corrosion etc e Repairs to the cylinder are limitedtopolishing out...

Page 431: ......

Page 432: ...ABLE ATTACHMENT 2 ARM RUDDER CABLE ATTACHMENT 3 ARM TRIM CONTROL ATTACHMENT 4 CLEVIS PIN WASHER COTTER PIN 5 CLEVIS ASSEMBLY 6 CLEVIS PIN 7 ARM IDLER 8 JAM NUT 1 1 Figure 7A 21 Toe Brake Installation...

Page 433: ...mblyby removing the snap ring 10 from the annular slot in the cylinder housing 1 Draw the piston rod assembly from the cylinder 3 The piston rod assemblymay be disassembledby first removingthe roll pi...

Page 434: ...ING 5 O RING 6 PISTON 7 SEAL 8 FITTING 9 O RING 10 O RING 11 SPRING 12 PISTON ROD 13 WASHER 14 ROLL PIN Figure 7A 22 Toe Brake Cylinders 7A 70 CLEANING INSPECTIONAND REPAIR OF BRAKECYLINDER a Clean th...

Page 435: ...pin 15 washer 14 spring 11 washer 9 packing gland 7 seal 5 piston assembly 3 and spring 2 and roll pin 12 3 Insert the piston rod assembly in the cylinder 1 and securewith the snap ring 10 4 Install t...

Page 436: ...ecessary to bleed the brake system refer to Section VII paragraphs 7 52 through 7 55 7A 74 BEARING REPLACEMENT Refer to Figure 7A 24 When it becomes necessary to replace a bearing in any link attachme...

Page 437: ...he bosshole c Press fit new bearing s P N 67026 07 tight against boss and line ream bearing s to 31 dimension d The 089 greaseholes willrequire a needle type adapter on the greasegun nozzle 1738 089 G...

Page 438: ...r open circuit breaker Yellow transit light on though gear has re tracted One or more up limit switches failed Isolate and replace switch Nose gear up limit switch out of ad justment Main gear not re...

Page 439: ...ight operates on and off after gear has re tracted Light circuit wire loose Check wiring Hydraulic system losing pressure Gear up switch out of adjustment Refer to Hydraulic System Section VI Check ge...

Page 440: ...Green gear down lights will go out and not dim when position light switch is turned on though gear is down and locked Gear warning light and horn fail to operate when throttle is near closed and land...

Page 441: ...E When replacing diode connect banded end cathode to terminal ends of wires G2R G2Q and G2K on mount ing block Gear warning light and horn fail to stop when throttle is closed and gear has extended Ge...

Page 442: ...sure switch open Throttle micro swich B out of adjustment Throttle micro switch B failed Gear not fully retracted Landing gear not re tracting completely Replace switch Replace switch Adjust switch Re...

Page 443: ...Replace bolts and or bushings Excessive or uneven wear on nose tire Incorrect operating pressure Inflate tire to correct pressure Wear resulting from shimmy Refer to proceedings for correction Nose g...

Page 444: ...arm roller sheared at top of strut Replace defective roller Incorrect rigging of nose gear steering Check nose gear steer ing adjustment Nose gear fails to straighten when landing gear retracts Main...

Page 445: ...Wheel out of alignment toe in or out Lower side brace link out of adjustment allowing gear to slant in or out Check wheel alignment Check gear adjustment Strut bottoms on normal landing or taxiing on...

Page 446: ...L 7A 75 NOSE GEAR SERVICE TOLERANCES 1770 24 2 7 8 11 12 13 14 19 15 16 17 19 20 21 19 22 23 19 19 25 1 2 1 2 6 18 5 9 10 11 12 3 4 Figure 7A 25 Nose Gear Service Tolerances PA 28R 2J20 LANDINGGEARAND...

Page 447: ...pue6L80 Bu uo dn s S3 0 LL 6 L 9...

Page 448: ...OO pue 06 u 6u S S 6 8 LL 9 91 S L...

Page 449: ...NBUSHINGS14843 16 NO 8 OR 11 ARE TO BE REPLACED THEYSHOULD BE LINE REAMED TO 376 375 THE BUSHINGS SHOULD BE A PRESSFIT HOWEVER IF THEY ARE LOOSE THEY MAY BE IN STALLEDUSINGLOCTITE Figure 7A 26 Main Ge...

Page 450: ...9 9 9L 0 s 18 00 a 06 06 06 S9 6 SOS 6 99 uo S Z SZ 00 00 00 68 Z S Z LL 6 8 L 9 N 6 d S33MOi...

Page 451: ...f service trunnion P N 67926 040 or 67926 041 installed then 67026 17 Bushing trunnion ID 4975 4990 18 400 810 Bolt trunnion side OD 497 0 0 OD 497 0 0 004 AN28 50A brace attaching 0 002 0 004 19 6771...

Page 452: ...8 16 Rigging and Adjustment of Propeller Governor PA 28 235 2K12 8 17 Engine 2K14 8 17a Removal of Engine Cowlings 2K14 8 17b Installation of Engine Cowlings 2K14 8 17c Installation of Bushings and P...

Page 453: ...Timing Procedure 2L9 8 36 Magneto Slick 2L11 8 37 Harness Assembly 2L11 8 38 Inspection of Harness 2L11 8 39 Removal of Harness 2L11 8 40 Installation of Harness 2L12 8 41 Spark Plugs 2L12 8 42 Remova...

Page 454: ...sign with the two major parts head and barrel screwedand shrunk together Theheadsare madefrom analuminumalloy castingwith a fully machinedcombustion chamber The cylinderbarrel whichis machinedfroma ch...

Page 455: ...then enters a drilled passage in the accessory housing which feeds the oil to a threaded connection on the rear face of the accessoryhousing where a flexible line leads the oil to the external oil coo...

Page 456: ...st fit snuglyinholesdrilledinstuds and boltsfor lockingpurposes Cotter pins should be installed so the head fits into the castellation of the nut and unless otherwisespecified bend one end of the pin...

Page 457: ...application of oil or wax may be applied to the surfaces to prevent corrosion 8 8 INSTALLATION OF PROPELLER Fixed Pitch a Insure magneto switch is OFF b Place the generator or alternator drive belt i...

Page 458: ...and Removal Method SPINNER PROPELLER PROPELLER BULKHEAD ASSEMBLY SPINNER O RING GOVERNOR CONTROL CABLE CONTROL KNOB HOSE MANIFOLD GAUGE GAUGE MANIFOLD PRESSURE Figure 8 2 Propeller Installation Consta...

Page 459: ...HMENT 4 WASHER 5 PLATE 6 BULKHEAD FORWARD SPINNER 7 CUFF SPINNER 8 Low PITCH STOP 9 JAM NUT 10 PROPELLER HUB 11 PROPELLER BLADE 12 SPINNER BACK PLATE 13 STARTER RING 14 RING SEAL 15 NUT FLYWHEEL 16 ST...

Page 460: ...s to determine whether they turn freely on the hub pivot tube This can be done by rocking the blades back and forth through the slight freedom allowed by the pitch change mechanism If they appear tigh...

Page 461: ...0995 C41 safety wire j Install the spinner torque cap bolts 35 to 40 inch pounds 8 12 BLADE TRACK Blade track is the ability of one blade tip to follow the other while rotating in almost the same plan...

Page 462: ...tion raise the governor enough to install washers and start mounting nuts Torque nuts even e Connect the control cable end to the governor control arm The ball stud is installed in the inner hole of t...

Page 463: ...ter setting the proper high RPM adjustment run the self locking nut on the fine adjustment screw against the base projection to lock 5 Ascertain that the governor control arm is adjusted to the proper...

Page 464: ...mein service d Locatepins inuppercowling NOTE It shouldnot be necessaryto replacethe pins unless bushingin lowercowlinghas worn enoughto allow damageto the pin Any noticeablenotchingor cut ting of the...

Page 465: ...for any attachments remaining to obstruct its removal t Drain the engine oil if desired and close the drain u Remove the four engine mount assemblies and swing the engine free being careful not to dam...

Page 466: ...AET 6 OIL COOLER LINES 7 OIL COOLER 8 BAFFLING 9 TOP COWL 10 PROPELLER 11 SPINNER MOUNTING PLATE 12 SPINNER ASSEMBLY 13 LANDING LIGHT 14 PAPER AIR FILTER 15 LANDING LIGHT AIR FILTER ATTACHMENT BOLT 16...

Page 467: ...ROPELLER 13 SPINNER SUPPORTPLATE 14 SPINNER 15 HEATERANDMUFFLER ASSEMBLY 16 AIRFILTER 17 FRESHAIRINTAKE 18 POWERPLANT ASSEMBLY 19 PLATEASSEMBLY BUSHING RETAINING RING WASHERS NUTS NOTE A maximumof 3 A...

Page 468: ...OLT WASHER SHOCKMOUNT SPACER ENGINEMOUNT SHOCKMOUNT ENGINEMOUNTINGLUG TORQUE 450 500 IN LBS SPACER WASHER SECTIONB B SECTIOND D Figure 8 8 Engine Shock Mount Installation PA 28 140 Serial Nos 28 25000...

Page 469: ...II r Connect the battery ground wire at the battery s Open the throttle and fuel valve completely Turn on the electric fuel pump and check the fuel line for leaks t Install the engine cowlings and re...

Page 470: ...t the primer line at the tee connection g Disconnect the mechanical fuel pump inlet line that is connected to the right side of the pump h Disconnect the starter leads at the starter and their attachm...

Page 471: ...que the nuts to 450 to 500 inch pounds e If the airplane involved is equipped with a constant speed propeller connect the propeller control cable at the propeller governor and the manifold pressure li...

Page 472: ...BLY NOTE A maximum of 3 AN960416 17 washers can be used to permit a max of 2 5 threads exposed on the bolt Torque to 230 240 Inch pounds 10 SPINNER BULKHEAD ASSEMBLY 11 PROPELLER SPINNER ASSEMBLY 12 C...

Page 473: ...t pounds another fitting should be used e When attaching lines to the cooler a backup wrench should be used f After installation inspect the cooler for distorted end cups g Run up engine After run up...

Page 474: ...PIPER CHEROKEE SERVICE MANUAL VIII POWER PLANT PA 28 01 31 08 2K24 Figure 8 10 Adjustment of Engine Controls Figure 8 10a Throttle Mixture Control Ball Joint Inspection...

Page 475: ...the throttle control cable from the control arm Loosen the jam nut that secures the clevis end b Adjust the linkage by rotating the clevis end on the cable to obtain 0 010 to 0 030 of an inch spring...

Page 476: ...8 28 THROTTLEARM a Remove screw securing the throttle arm to the carburetor Do not remove the throttle arm b Removeand discard lock tab c Examine the screw to determine if there is a hole through the...

Page 477: ...le mixture adjusting screw 1 located near the rear of the carburetor clockwise leaning the fuel mixture Continue to do this until the engine begins to run roughly at which time the engine speed willde...

Page 478: ...act springs Top of spring must not be more than 422 inches below top of tower as shown in Figure 8 14 If broken or corroded they should be replaced 2 Inspect oil felt washer It should be saturated wit...

Page 479: ...wear on the contact edges of body and flyweights 11 Checkthat the impulse couplingflyweight axle rivets are tight and there are no cracks in body 12 Look at the lead conduits A few broken strands won...

Page 480: ...to is hot Re moving the harness assembly terminal plate first and installing them last minimizes the danger of starting the engine accidentally when the ground lead is re moved from the magneto b Disc...

Page 481: ...agneto drive by rotating drive coupling in a left hand direction until the red or white chamfered tooth on the distributor drive gear appears through the timing inspection hole At the same location th...

Page 482: ...made by wrapping a piece of soft wire tightly around the head of cam securing screw and bending it to extend over timing marks e If magneto is type which has cast in timing marks 200 series see Fig u...

Page 483: ...spark plug hole In this position both valves of No 1 cylinder are closed Turn the crankshaft opposite to its normal direction of rotation until it is approximately 35 degrees BTC on the compression s...

Page 484: ...r Without al lowing the magneto gear to turn from this position assemble the left magneto to the accessory housing and secure with washers and nuts Tighten nuts only finger tight g Connect the other p...

Page 485: ...ion or any other evidence of physical damage Inspect spark plug sleeves for chafing or tears and damaged or stripped threads on coupling nuts Check compression spring to see if it is broken or distort...

Page 486: ...LUGS 8 42 REMOVAL OF SPARK PLUGS a Loosen the coupling nut onthe harness lead and remove the terminal insu lator from the spark plug barrel well NOTE When withdrawing the ignition cable lead connectio...

Page 487: ...as soon as they are removed NOTE Spark plugs should not be used if they have been drop ped d Removal of seized spark plugs inthe cylinder may be accomplished by ap plication of liquid carbon dioxide...

Page 488: ...m electrodes should be set at 015 to 018 of an inch only 8 44 INSTALLATION OF SPARK PLUGS Before installing spark plugs ascer tain that the threads within the cylinder are clean and not damaged a Appl...

Page 489: ...n the oil pressure gauge If the pressure is above 90 psi stop engine loosen the adjusting lock nut and back off the adjusting screw oneor two fullturns Tighten lock nut and retest Ifpressure istoo low...

Page 490: ...N 28 7505001 AND UP PA 28 235 S N 28 7510001 AND UP J2A K1B GND C236 PA 28 140 S N 28 25000 AND UP PA 28 180 S N 28 4378 TO 28 7405290 PA 28 235 S N 28 11040 TO 7410120 B Figure 8 21 Ignition Switch...

Page 491: ...magneto breaker points Internal failure Prime with two or three strokes of primer Open throttle and un load engine by turn ing in counter clock wise direction Open throttle to one tenth of its range C...

Page 492: ...ose ground Demagnetize impulse couplings Replace spark plugs or dry out removed plugs Open mixture control Check and replace or repair Failure of engine to idle properly Incorrect carburetor idle adju...

Page 493: ...peration red exhaust flame and black smoke Checkprimer Read d justment of carb uretor indicated Mixture too lean in dicated by overheat ing or backfiring Leaks in induction system Defective spark plug...

Page 494: ...Check for loose muffler baffles Check magnetos for trimming and synchronization Failure of engine to develop full power Throttle lever out of adjustment Adjust throttle lever Leak in induction system...

Page 495: ...ressure gauge Air lock or dirt in relief valve Leak in suction line or pressure line High oil temperature Repair or replace engine mount Remove propeller and have it checked for balance Check propelle...

Page 496: ...air inlet and out let for deformation or obstruction Insufficient oil supply Clogged oil lines or screens Failing or failed bear ing Defectivethermo stats Defective temper ature gauge Excessive blow b...

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Page 498: ......

Page 499: ...PART NUMBER 753 586 January 31 2008 3A1 SERVICE MANUAL CARD 3 OF 4 PA 28 140 PA 28 150 PA 28 160 PA 28 180 PA 28 235 PA 28R 180 PA 28R 200 PIPER AIRCRAFT CORPORATION...

Page 500: ...August 3 1983 1 2 3 and 4 PR840423 April 23 1984 1 2 3 and 4 PR86115 January 15 1986 1 and 3 IR860730 July 30 1986 1 IR870506 June 12 1987 1 IR950215 February 15 1995 1 and 2 IR020228 February 28 2002...

Page 501: ...ULIC SYSTEM PA 28R 2D3 VII LANDING GEAR AND BRAKES PA 28 2E22 VIIA LANDING GEAR AND BRAKES PA 28R 2H1 VIII POWERPLANT PA 28 2K2 VIIIA POWERPLANT PA 28R 3A8 IX FUEL SYSTEM 3C8 X INSTRUMENTS 3D18 XI ELE...

Page 502: ...spection Points Sheets 1 thru 2 3K9 3 20 Exhaust System Installation PA 28R 180 200 3K11 3 21 Control Wheel Inspection Points 3K12 3 22 Aileron Hinge Doubler 100 Hour Inspection 3K13 3 23 Inspection o...

Page 503: ...Fuel Quantity Transmitter P N 68101 00 3C21 9 7a Fuel Quantity Transmitter P N 548 671 3C22 9 8 Fuel Selector and Filter PA 28 235 3C24 9 9 Fuel Filter PA 28 235 3D1 9 10 Fuel Filter Bowl and Screen...

Page 504: ...2 28 35001 thru 28 35830 and 28 7135001 thru 28 7135238 3E17 10 15 Instrument Panel PA 28R 200 S N s 28 7235001 thru 28 7335455 3E18 10 16 Instrument Panel PA 28R 200 S N s 28 7435001 and up 3E19 10 1...

Page 505: ...Fuel System Troubleshooting 3D15 X I Vacuum System 3D24 X II Directional Gyro Indicator 3F5 X III Gyro Horizon Indicator 3F7 X IV Rate of Climb Indicator 3F8 X V Altimeter 3F10 X VI Airspeed Tubes an...

Page 506: ...ine 3A16 8A 15 Installation of Engine 3A17 8A 16 Installation of Oil Cooler 3A24 8A 17 Adjustment of Throttle and Mixture Controls 3A24 8A 18 Induction Air Filter 3B2 8A 19 Alternate Air Door 3B2 8A 1...

Page 507: ...s 3B15 8A 37 Installation of Harness 3B21 8A 38 Spark Plugs 3B21 8A 39 Removal of Spark Plugs 3B21 8A 40 Inspection and Cleaning of Spark Plug 3B23 8A 41 Installation of Spark Plugs 3B23 8A 42 Lubrica...

Page 508: ...e fuel pump fuel injector and dry paper type induction air filter An alternate air door that will open automatically in the event of air stoppage through the filter or may be operated manually with th...

Page 509: ...pivot tube This can be done by rocking the blades back and forth through the slight freedom allowed by the pitch change mechanism If they appear tight and are properly lubricated the pitch change mech...

Page 510: ...P 2 JAM NUT 3 PROPELLER HUB 4 SPINNER 5 PROPELLER BLADE 6 SPINNER BACK PLATE 7 STARTER RING 8 O RING SEAL 9 GREASE FITTING 10 WASHER II NUT 12 SAFETY WIRE 13 STUD 14 NUT FLYWHEEL Figure 8A 1 Propeller...

Page 511: ...r to make sure it is mounted properly on the engine crankshaft flange One of the bushings on the crankshaft is stamped with an O mark and it must be inserted in the starter ring gear hole likewise ide...

Page 512: ...ing excess blade track should be removed and inspected for bent blades or for parts of sheared O ring or foreign particles which have lodged between hub and crankshaft mounting faces Bent blades will...

Page 513: ...means of the fine adjustment screw 2 for 2700 RPM To do this loosen the high RPM fine adjustment screw lock nut and turn the screw in a clockwise direction to decrease engine speed or in a countercloc...

Page 514: ...s Remove the top cowl 3 Disconnect thelanding light lead at the quickdisconnect at the left rear side of the bottom cowl 4 Disconnect the nose gear door rods by removing the nuts washers and bolts 5 R...

Page 515: ...connect the injector line at the flow divider v Disconnect the alternator leads and the cable attachment clamps w Attach a one half ton minimum hoist to the hoisting straps and relieve the tension fro...

Page 516: ...3A18 INTENTIONALLY LEFT BLANK...

Page 517: ...8 MAGNETO RIGHT 9 SHOCK MOUNT SEE SKETCH A 10 FLOW DIVIDER 11 OIL FILLER 12 LIFTING STRAP 13 STARTER RING GEAR 14 OIL FILTER 15 PROPELLER GOVERNOR 16 INJECTOR INLET HOSE 17 FUEL INJECTOR 18 OIL COOLE...

Page 518: ...PIPER CHEROKEE SERVICE MANUAL POWER PLANT Interim Revision 2 28 02 3A20 Figure 8A 4 Engine Installation PA 28R 180 cont...

Page 519: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VIIIA POWER PLANT PA 28R 3A21 Figure 8A 5 Engine Installation PA 28R 200...

Page 520: ...PIPER CHEROKEE SERVICE MANUAL VIIIA POWER PLANT PA 28R 01 31 08 3A22 Figure 8A 5 Engine Installation PA 28R 200 cont...

Page 521: ...o paragraph 8A 17 s Connect the heater hose to the muffler t Install the air filter box filter and box cover Checkadjustment of the alternate air door by referring to Paragraph 8A 19 u Connect the gov...

Page 522: ...hrottle may be adjusted as follows 1 At the carburetor disconnect the clevis end of the throttle control cable from the control arm Loosen the jam nut that secures the clevis end 2 Adjust the linkage...

Page 523: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 VIIIA POWER PLANT PA 28R 3B1 Figure 8A 6 Adjustment of Engine Controls Figure 8A 6a Throttle Mixture Control Ball Joint Inspection...

Page 524: ...ould there be an air stoppage through the filter system 8A 19a 50 HOUR INSPECTION a Check that air door seals are tight and hinge is secure b Ascertain that the spring tension of the door is tight eno...

Page 525: ...itional 1 3 to 1 2 turn 3 Check all fuel lines for tightness and evidence of leakage A slight fuel stain adjacent to the air bleed nozzles is not cause for concern 4 Check throttle and mixture control...

Page 526: ...AA IDLE VALVE LEVER CONNECTED TO THROTTLE LEVER LINKAGE MANUAL MIXTURE CONTROL ANDIDLE CUT OFF LEVER CONSTANTHEAD IDLE SPRING CONSTANT EFFORT SPRING AIR DIAPHRAGM FUEL DIAPHRAGM BALL SERVO VALVE I It...

Page 527: ...hile leaning out indicates an excessively rich idle mixture An immediate decrease in RPM if not preceded by a momentary increase indicates the idle mixture is too lean e If the above indicates that th...

Page 528: ...d Nozzle OF FUEL AIR BLEED NOZZLE a Clean the nozzle with acetone or equivalent and blow out all foreign par ticles with compressed air in the direction opposite that of fuel flow Do not use wire or o...

Page 529: ...this not be possible a visual inspection may disclose the source of trouble Remove the harness outlet plate from the magneto Inspect for the presence of moisture and foreign matter on the rubber gromm...

Page 530: ...lubricant Allow approximately 30 minutes for felt to absorb the oil Blot off the excess with a clean cloth Too much oil may foul contact points and cause excessive burning h Check the capacitor mount...

Page 531: ...ng the engine accidentally when the ground lead is removed from the magneto b Disconnect the ground lead at the magneto c Remove the nuts and washers and draw the magneto from the engine 8A 31 TIMING...

Page 532: ...n This adjustment shall be made by rotating cam in opposite direction of rotation until contacts just open While holding cam in this exact position push cam on magnet shaft as far as possible with the...

Page 533: ...utor block to housing with studs and washers Tighten studs finger tight Loosen the 11 8465 Rotor Holding Tool and turn rotating magnet in reverse direction of rotation until timing light indicates con...

Page 534: ...of Impulse Coupling 8A 32 INSTALLATION AND TIMING PROCEDURE Timing Magneto to En gine Although only the left magneto is equipped with an impulse coupling the timing procedure in the following paragrap...

Page 535: ...st painted chamfered tooth on the distributor gear is aligned in the center of the inspection window Refer to Figure 8A 16 Being sure that the gear does not move from this position install gaskets and...

Page 536: ...r as de scribed above the light goes out when the breaker points open d After both magnetos have been timed check as described below to as certain that both magnetos are set to fire together e Backoff...

Page 537: ...istance should be 100 megohms minimum Proceed to check other leads of harness in same manner d Minor repair of the harness assembly such as replacement of contact springs spring retainer assemblies in...

Page 538: ...in Figure 8A 20 Screw the cable terminal into the tool 230 Figure 8A 18 Removing Spring From Lead Assembly c Work insulating sleeve and spring retainer assembly into position over the cable and unscre...

Page 539: ...elet of lead with a pair of pliers and pull short length of con ductor out of grommet and cable outlet plate 4 Using a 3 inch long 0 270 inch diameter drift applied atouter surface of plate drive out...

Page 540: ...ician s scissors carefully remove 1 250 inch of outer braid from end of lead Refer to Figure 8A 22 CAUTION Use care not to nick or cut insulation when removing braid 9 Using a scribe or similar pointe...

Page 541: ...ll Position the Scintilla 11 7074 Ferrule Seat ing Tool Figure 8A 25 over the wire and firmly seat the ferrule by tapping the seating tool with a hammer or by using an arbor press 12 Measure 1 2 inch...

Page 542: ...e 8A 30 Slide eyelet over doubled wire until it is firmly seated in recess of grommet outlet 15 Using the AB groove of Scintilla 11 4152 Crimping Tool or equiva lent crimp eyelet to wire Approximately...

Page 543: ...plate alternately to seat cover squarely on magneto Torque nuts to 18 to 22 inch pounds b Route ignition wires to their respective cylinders c Clamp the harness assembly in position d Connect the lea...

Page 544: ...ter torque require ment c Place spark plugs in a tray that will identify their position in the engine as soon as they are removed NOTE Spark plugs should not be used if they have been dropped d Remova...

Page 545: ...install gasket and spark plugs Torque 360 to 420 inch pounds CAUTION MAKE CERTAIN THE DEEP SOCKET IS PROPERLY SEATED ON THE SPARK PLUG HEXAGON AS DAMAGE TO THE PLUG COULD RESULT IF THE WRENCH IS COCK...

Page 546: ...ning nut from the switch on the forward side of the instrument panel and withdraw the switch from the panel d Mark the wires and note their position on the switch then disconnect the wires 8A 46 INSTA...

Page 547: ...g Incorrect throttle setting Defective spark plugs Defective ignition wire Defective battery Improper operation of magneto breaker Lack of sufficient fuel flow Openthrottle and unload engine by engagi...

Page 548: ...ys tem Replace any parts that are defective Incorrect idle adjust ment Uneven cylinder com pression Faulty ingition system Insufficient fuel pres sure Adjust throttle stop to obtain correct idle Check...

Page 549: ...park plug terminal connectors Tighten all connections Replace defective parts Clean and gap or re place spark plugs Fill tank with fuel of recommended grade Clean points Check internal timing of mag n...

Page 550: ...timing Rough engine Cracked engine mount Defective mounting bushings Uneven compression Replace or repair mount Install new mounting bushings Check compression Low oil pressure Insufficient oil Fill...

Page 551: ...bstruction Insufficient oil supply Low grade of oil Clogged oil lines or strainers Excessive blow by Failing or failed bearing Defective temperature gauge Fill oil sump to proper level with specified...

Page 552: ...Incorrect installation of piston rings Failure of rings to seat new nitrided cylin ders Check sump for metal particles Install new rings Install new rings Use mineral base oil Climb to cruise altit ud...

Page 553: ...3C7 INTENTIONALLYLEFTBLANK...

Page 554: ...itter Gauge Check 3C19 9 16 Check and Adjustment of Fuel Quantity Transmitter Unit 3C19 9 16a Fuel Quantity Sending Unit P N 548 671 Calibration 3C20 9 17 Fuel Valves 3C22 9 18 Fuel Shutoff Valve PA 2...

Page 555: ...ustment of ElectricFuel Pump In Airplane 3D8 9 43 Installation of Fuel Pumps 3D9 9 44 Rotary Fuel Pumps Weldon PA 28R 3D10 9 45 Removal of Fuel Pump 3D10 9 46 Disassembly Repair and Assembly of Fuel P...

Page 556: ...strainer bowl to the electricfuel pump engine driven fuel pump and then to the carburetor injector inlet port Two electrical fuel quantity gaugesare mounted within the instrument cluster Each gaugeis...

Page 557: ...FUEL TANK SELECTOR VALVE FUEL TANK SELECTOR VALVE FUEL STRAINER RIGHT MAIN TANK LEFT MAIN TANK PRIMER FUEL PRESSURE GAUGE CARBURETOR ENGINE FUEL PUMP ELECTRIC FUEL PUMP Figure9 1 Fuel SystemDiagram P...

Page 558: ...LE MIXTURE FUEL SELECTOR CONTROL ENGINE FUEL PUMP LEFT TIP TANK LEFT MAIN TANK RIGHT MAIN TANK FUEL PUMPS FUEL QUANTITY GAUGES Figure9 2 Fuel System Diagram PA 28 235 SerialNos 28 10003 to 28 10719 in...

Page 559: ...BURETOR ENGINE FUEL SELECTOR CONTROL RIGHT MAIN TANK RIGHT TIP TANK ELECTRIC FUEL PUMP FUEL QUANTITY GAUGES Figure 9 3 Fuel System Diagram PA 28 235 Serial Nos 28 10720 and up Reissued 1 15 81 3C13 LE...

Page 560: ...T TANK U DRAIN FUEL PRESSURE GAUGE FUEL QUANTITY GAUGE FUEL SELECTOR LEFT TANK U DRAIN GASCOLATOR FUEL FLOW GAUGE VENT FLOW ELECTRIC FUEL PUMP ENGINE DRIVEN FUEL PUMP FUELINJECTOR Figure9 4 Fuel Syste...

Page 561: ...3C15 INTENTIONALLYLEFTBLANK...

Page 562: ...3C16 INTENTIONALLY LEFT BLANK...

Page 563: ...leaking fuel must be removed and repaired as authorized herein or replaced WARNING SLOSHING OF FUEL TANKS PROHIBITED a Remove tank s as described above b Fuel tanks which have previously been sloshed...

Page 564: ...assembly 9 10 FUEL TANK REPAIR Fiberglass The wing tip tanks are constructed of Fiberglass Minor repair of the tank can be accomplished with the use of Fiberglass Repair Kit No 756 729 This kit along...

Page 565: ...in the amount of five U S gallon increments until the tank is full and observe the gauge readings NOTE It will be permissible to adjust the float assembly to obtain specified tolerances This adjustmen...

Page 566: ...t must be used only with Rochester fuel quantity gauges Refer to Service Spares Letter No 406 for appropriate fuel quantity gauge sensor systems a See above for fuel quantity sending unit transmitter...

Page 567: ...stop A resistance of 45 2 ohms should be indicated at this position 4 Check for dead spots by slowly moving the float arm from the bottom stop to the upper stop and back Watch the ohmmeter indicator i...

Page 568: ...acard plate c Disconnect right and left fuel inlet lines from fuel valve assembly d Disconnect fuel outlet line from fuel valve assembly e Remove fuel valve assembly by removing attaching screws 9 20...

Page 569: ...24 FUEL SELECTOR VALVE AND FILTER PA 28 235 only 9 25 FUEL SELECTOR VALVE OPERATION When the fuel selector handle is not in a positive selector detent position more than one fuel port will be open at...

Page 570: ...PIPER CHEROKEE SERVICE MANUAL IX FUEL SYSTEM 01 31 08 3C24 Figure 9 8 Fuel Selector and Filter PA 28 235...

Page 571: ...etand replaceif necessary e Filter discsmay be cleanedas follows 1 Plug open ends of filter disc center with stoppers to prevent dirt fromentering 2 Wash metallic filter disc in acetone gasoline carbo...

Page 572: ...that selector handle engagesleft indent position whenit is againstthe safety stop on consolecover e Fill the fuel tanks and check all connectionsfor leaks f Install the rear seat g Install the access...

Page 573: ...re loosen the bail nut move the bail wire to the side and remove the bowl e Remove the housing of the filter bowl by spreading the ends of the bail wire allowing the housing to be lifted from the brac...

Page 574: ...he attaching screws depending on the type installed Be certain all electrical leads are disconnected prior to removal 2 Ascertain that the fuel shutoff valve is in the off position 3 Disconnect the fu...

Page 575: ...so as not to damage it 2 Remove the three screws securing the plunger spring cup inside the pump Remove the cup and gasket 3 Pull the plunger spring and plunger assembly from the pump with fingers CA...

Page 576: ...NGER SPRING 10 PLUNGER 11 PUMP BODY Figure9 11 PlungerFuel Pump Early PA 28 150 160 180 C349 9 8 7 6 5 3 2 1 1 COVER 2 COVER GASKET 3 MAGNET 4 FILTER 5 RETAINER 6 WASHER 7 O RING 8 CUP VALVE 9 SPRING...

Page 577: ...he O ring 5 Check the condition of the cover gasket and plunger spring cup gasket c Repair of the pump is limited to replacementof parts found defective during inspection 9 39 RESISTANCE CHECK PLUNGER...

Page 578: ...RIC FUEL PUMP BENCHTEST a Ascertain that the pump is sufficiently lubricated to prevent damage if run dry for a period greater than five minutes b Connect the electrical lead of one pump to a 14 volt...

Page 579: ...and replace and secure the access panel 9 43 INSTALLATION OF FUEL PUMPS a Install the fuel pump on PA 28 140 150 160 and 180 airplanes by the following procedure 1 Position the fuel pump tothe engine...

Page 580: ...s or any defects which might cause the seal to wear Any defect would be cause for pump replacement 4 Replace the seal on the shaft and press into place 5 Install the pump end assemblyto the motor init...

Page 581: ...ssure is obtained h Disconnect the power source from the pump and lock the adjustment screw with the locknut Remove the fuel lines from the pump 9 48 ADJUSTMENT OF ELECTRIC FUEL PUMP IN AIRPLANE a Wit...

Page 582: ...9 50 ENGINE PRIMER PUMP 9 51 REMOVAL OF ENGINE PRIMER Refer to Figure 9 13 a Disconnect the fuel lines from the primer behind the instrument panel b Loosen the locknut 12 from behind the panel c Unscr...

Page 583: ...bon remover solution long enough to loosen any dirt and blow clean with air pressure Do not use sharp objects or wire brush to clean the jet tube c Install the jet finger tight to assure that the thre...

Page 584: ...3D14 INTENTIONALLYLEFTBLANK...

Page 585: ...cap Check and replace if necessary Check position of selector and adjust if required Replace fuel valve Fuel gauge fails to operate Broken wire Gauge inoperative Check and repair Replace Float partial...

Page 586: ...k valve Check fuel level and fill Check pump for pres sure build up Check diaphragm and relief valves in engine pump Check for obstructions in electric pump Check by pass valve Air leak in intake line...

Page 587: ...Figure 9 14 Fabricated Fuel Quantity Transmitter Checking Jig 01 31 08 IX FUEL SYSTEM 3D17 PIPER CHEROKEE SERVICE MANUAL...

Page 588: ...PIPER CHEROKEE SERVICE MANUAL IX FUEL SYSTEM 01 31 08 3D18 THIS PAGE INTENTIONALLY BLANK...

Page 589: ...tor Valve With Vacuum Warning Lights 3E22 10 14 Adjustment of Vacuum Warning Light Pressure Switch 3E22 10 15 Adjustment of Vacuum Turn and Bank Indicator Regulator Valve 3E24 10 16 Removal and Replac...

Page 590: ...10 49 General 3F15 10 50 Troubleshooting 3F15 10 51 Removal and Replacement 3F15 10 52 Tachometer Indicator 3F15 10 53 General 3F15 10 54 Troubleshooting 3F16 10 55 Removal and Replacement 3F16 10 56...

Page 591: ...Mounted Instruments 3F22 10 84 General 3F22 10 85 Exhaust Gas Temperature Gauge Alcor 3F22 10 86 General 3F22 10 87 Cleaning and Inspection 3F23 10 88 Troubleshooting 3F23 10 89 Cylinder Head Tempera...

Page 592: ...se vacuum system service symptoms on those components which are serviced by removal and replacement These items include hoses clamps gyro filters vacuum regulating valves and vacuum gauges a Hoses and...

Page 593: ...ad from 4 9 inches to 5 1 inchesof mercury vacuum d At 1200 RPM the vacuumgaugereading shouldbe morethan four inches of mercury c Gyro Filters 1 Gyro filters must be servicedon a scheduledbasis not to...

Page 594: ...ion tend to increase the vacuum power applied to the gyros Thus although excess vacuum is applied a loss of vacuum does not occur 3 The gyros themselves act as a limiting device to keep the vacuum pow...

Page 595: ...w vacuum system Vacuum regulator valve Adjust regulator valves pressure incorrectly adjusted in accordance with Adjustments of this section Leaking of the system Check all lines and lines or fittings...

Page 596: ...lator valve in incorrectly adjusted accordance with adjustments in this section Line from gyros to filter restricted Repair line Line from pump to gyros leaking Check all lines and fittings Replace or...

Page 597: ...icky Clean regulator pilot reports pressure erratic or shows complete loss in flight Oil in pump due to Replace pump Ieaky engine seal or cleaning fluid blown into pump while cleaning engine Pressure...

Page 598: ...IVER 16 DME RECEIVER 17 SUCTION GAUGE 18 CIGAR LIGHTER 19 PHONEJACKS 20 AUTOCONTROL III AUTOPILOT 21 OMNI COUPLER 22 PITCH CONTROL 23 MAGNETO SWITCHES STARTER 24 INSTRUMENT CLUSTER 25 RPM CRUISE CHART...

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Page 601: ...OR 5 AUTONAV RADIO 6 SUPERHOMER RADIO 7 TACHOMETER 8 VACUUM GAUGE 9 INSTRUMENT CLUSTER 10 TURN AND BANK INDICATOR 11 CLOCK 12 STALL WARNING LIGHT 13 ALTIMETER INDICATOR 14 RATE OF CLIMB INDICATOR 4 5...

Page 602: ...D INDICATOR 8 TACHOMETER 9 VACUUM INDICATOR 10 COMMUNICATIONS AND NAVIGATION TRANSCEIVERS 11 ENGINE AND FUEL SYSTEM INSTRUMENT CLUSTER 12 OME CONTROL AND INDICATOR Figure 10 5 Instrument Panel PA 28 1...

Page 603: ...RS 15 ADF RECEIVER AND INDICATOR 16 DME CONTROL AND INDICATOR 17 CIGAR LIGHTER 18 HEAT AND DEFROST CONTROLS 19 AUTOCONTROL III AUTOPILOT 20 ENGINE INSTRUMENT CLUSTER 21 OMNI COUPLER 22 MAGNETO SWITCHE...

Page 604: ...i...

Page 605: ......

Page 606: ...ETER 17 SUCTION GAUGE 18 RADIO 19 MIXTURE CONTROL 20 AUTOFLITE 21 PROPELLER CONTROL 22 THROTTLE CONTROL 23 AUDIO SELECTOR 24 _CARBURETOR HEAT 25 ROTATING BEACON 26 LANDING LIGHT 27 NAV AND INST LIGHTS...

Page 607: ...ONTROL AND INDICATOR 15 CIGAR LIGHTER 16 VACUUM INDICATOR 17 HEAT AND DEFROST CONTROLS 18 AUTOCONTROL III AUTOPILOT 19 ENGINE INSTRUMENT CLUSTER 20 OMNI COUPLER 21 MAGNETO SWITCHES AND STARTER 22 FUEL...

Page 608: ...ZZ __...

Page 609: ......

Page 610: ...RS 15 ADF RECEIVER AND INDICATOR 16 DME CONTROL AND INDICATOR 17 CIGAR LIGHTER 18 HEAT AND DEFROST CONTROLS 19 AUTOCONTROL III AUTOPILOT 20 ENGINE INSTRUMENT CLUSTER 21 OMNI COUPLER 22 MAGNETO SWITCHE...

Page 611: ...GAR LIGHTER 18 HEAT ANDDEFROST CONTROLS 19 AUTOCONTROL III AUTOPILOT 20 ENGINE INSTRUMENT CLUSTER 21 OMNI COUPLER 22 MAGNETOSWITCHES AND STARTER 23 FUEL SYSTEM CLUSTER 24 MANIFOLD PRESSURE FUEL FLOW I...

Page 612: ......

Page 613: ...0...

Page 614: ...3E20 INTENTIONALLYLEFTBLANK...

Page 615: ...panel 10 11 TROUBLESHOOTING For troubleshooting of the vacuumregulator refer to Table X I 10 12 ADJUSTMENTS OF VACUUMREGULATORVALVE WithoutVacuumWarning Lights a Loosen the locking nut or remove the...

Page 616: ...sureand counterclockwiseto decreasethe pressure e Restart the engineand repeat the check f After the system pressure has been adjusted to this recommended setting retighten the regulator screwjam nut...

Page 617: ...and loosenthe regulatorjam nut e Start the engineand set the throttle at 1400 to 1600 RPM Whilereadingthe suction gauge turn valve adjustment screw of the vacuum regulator clockwise to increase the s...

Page 618: ...on gauge NOTE Do not attempt adjustment of any system in this airplane with the engine in operation without a qualified pilot or other responsible person at the controls b Start the engine and operate...

Page 619: ...RT NUMBER 751 859 USE OF ANY OTHER GASKET MAY RESULT IN OIL SEEPAGE OR LEAKAGE AT THE MOUNTING SURFACE 3 Secure the pump to the engine with four plain washers lock washers and retaining nuts Torque th...

Page 620: ...nough vise pressure to hold the pump firmly c The ports of the AIRBORNE pump have been treated with a dry film lubricant and the AIRBORNE fittings are cadmium plated thus eliminating any need for thre...

Page 621: ...tubing routed through the wing along with the pitot line An alternate static air source is located below the instrument panel in front of the pilot The alternate static source is part of the standard...

Page 622: ...C358 5 1 ALTIMETER INDICATOR 2 AIRSPEED INDICATOR 3 PITOT HEAT SWITCH 4 VERTICAL SPEED INDICATOR 5 PITOT HEAD Figure 10 18 Typical Pitot Static System PA 28 140 150 160 180 235 PA 28R 180and 200 INSTR...

Page 623: ...ect check for the following a Reliefvalveim properly adjusted b Incorrect gauge reading c Pump failure d Vacuumline kinked or leaking Replaceinstrument a Adjust b Replacegauge c Repairor replace d Che...

Page 624: ...nal gyro Due to the gyroscopic inertia the spin axis continues to point in the vertical direction providing a constant visual reference to the attitude of the airplane relative to pitch and roll axis...

Page 625: ...ent Instrument loose in panel Vacuumtoo high Defectivemechanism Instrument not levelin panel Aircraft out of trim Normal if it does not exceed 1 16 inch Lowvacuum Remedy Checkpump and tubing Cleanor r...

Page 626: ...ssumed level flight In rough air this should not be considered a malfunction 10 34 TROUBLESHOOTING TABLE X IV TROUBLESHOOTING RATE OF CLIMB INDICATOR Trouble Cause Remedy Pointer does not set Aging of...

Page 627: ...REMOVALANDREPLACEMENT Refer to Paragraph10 81of this section 10 36 SENSITIVEALTIMETER 10 37 GENERAL The altimeter indicates pressure altitude in feet above sea level The indicator has three pointers a...

Page 628: ...referencemarkers out of synchronismwith pointers Improper calibration adjustment Defectivemechanism Improperventing Wronglubrication or lack of lubrication Out of engagement Not tight when altimeter...

Page 629: ...MOVALANDREPLACEMENT Refer to Paragraph 10 81of this section 10 40 AIRSPEEDINDICATOR 10 41 GENERAL The airspeed indicator providesa means of indicating the speedof the airplane passing through the air...

Page 630: ...Leakingstatic system Pointer not on zero Leakingstatic system Pitot head not aligned correctly Waterin pitot line Remedy Check for leak and seal Replaceinstrument Replaceinstrument Find leak and corr...

Page 631: ...lternator switchand all radio switchesshould be in the ONposition All other cockpit controlled electricalswitches should be in the OFF position a Set adjustment screwsof compensator on zero Zero posit...

Page 632: ...vot fric tion or brokenjewel Replaceinstrument Liquid leakage Loosebezel screws Replaceinstrument Brokencover glass Defectivesealing gaskets Discoloredmarkings Age Replaceinstrument Replaceinstrument...

Page 633: ...ument Dullor discolored marking Age Replaceinstrument Incorrect reading Moistureor oil in line Disconnect linesand blow out 10 51 REMOVALAND REPLACEMENT Referto Paragraph 10 81of thissection 10 52 TAC...

Page 634: ...to stop more noticeablein cold weather Pointerjumps at idle Tachometer cablebreaks Excessiveclearancein speedcup Excessivelubricant in instruments Speedcup hitting ro tating magnet Cablebent too shar...

Page 635: ...ir in line or rough enginerelief Enginereliefvalve open Replaceinstrument Replaceinstrument Disconnectline and fill with light oil Check for leaks If trouble persists clean and adjust reliefvalve Clea...

Page 636: ...Checkbypassvalve Airleak in intake lines Defectivegauge Replacegauge Pressurelow or pressure surges Obstruction in inlet side of pump Tracelines and locate obstruction Faulty bypassvalve Faulty diaph...

Page 637: ...aft is rolled right and left rapidly the indicator will move indicating a turn but if the aircraft is heldin a bank and rudder is applied the indicator willcome back to zero indicatingno turn 10 66 TR...

Page 638: ...fuel cell and this position is transmitted electricallyto the indicator gauge to showthe amount of fuel in the cell 10 71 TROUBLESHOOTING TABLEX XIII FUEL QUANTITYINDICATORS Trouble Cause Remedy Fuel...

Page 639: ...move as engineis warmedup Brokenor damagedbulb Wiringopen Improper calibration adjustment Broken or damagedbulb or open wiring Check engineunit and wiringto instrument Repair or replace Checkengineuni...

Page 640: ...ents Removalof these instruments can be accomplishedby the followingprocedure a Remove the face panel by removing the screws from around the perimeter of the panel b With the face panel removed the cl...

Page 641: ...to the fourth graduation or approximately1500 F Before making this check make sure that the adjustment screw located at the rear of the instrument case is in the center of its travel If this screw ha...

Page 642: ...ERVICE MANUAL C314 PROBE SEENOTE LEFTSIDEVIEW NOTE 129 HOLE IN NO 2 CYLINDER EXHAUST STACK REFER TO TOPVIEWFORCORRECT LOCATION Figure 10 19 EGT PROBE LOCATION PA 28R 180and 200 5 81 3F24 INSTRUMENTS R...

Page 643: ...E SERVICE MANUAL C316 ENGINECENTERLINE 45 TOPVIEW EGT 2 00 NOTE 129 HOLE IN NO 2 CYLINDER EXHAUST STACK REFER TOTOPVIEWFORCORRECT LOCATION Figure 10 20 EGT PROBELOCATION PA 28 235 3G1 Reissued 1 15 81...

Page 644: ...ENGINE CENTERLINE TOP VIEW EGTPROBE SEENOTE LEFT SIDEVIEW NOTE 129 HOLE IN NO 4 CYLINDEREXHAUST STACK IN LINE WITHCENTERLINE OFENGINE Figure 10 21 EGT PROBELOCATION PA 28 150 160 180 S N 1761and up 15...

Page 645: ...esender Replacesender 10 92 REMOVALANDREPLACEMENT Refer to Paragraph10 83of this section 10 93 FUEL FLOWGAUGE 10 94 GENERAL The fuel flow gauge is a non electric pressure gauge mounted in the bottom h...

Page 646: ...ghtsand a push button test switch located on the upper left center portion of the instrument panel Refer to Figure 10 4b The panel monitors alternator output oil pressure and the vacuum system The ALT...

Page 647: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 X INSTRUMENTS 3G5 GRIDS 3G5 THRU 3G24 INTENTIONALLY BLANK...

Page 648: ...PIPER CHEROKEE SERVICE MANUAL 3H1 SECTION III INSPECTION...

Page 649: ...PIPER CHEROKEE SERVICE MANUAL 3H2 THIS PAGE INTENTIONALLY BLANK...

Page 650: ...Cockpit Group 3H17 Fuselage and Empennage Group 3H18 Wing Group 3H20 Landing Gear Group 3H21 Float Group 3H21 Special Inspections 3H22 Operational Inspection 3H22 General 3H22 Notes 3H23 Inspection R...

Page 651: ...Tank Wing Spar Corrosion Inspection 3K1 Cast Main Landing Gear Strut Cylinder 100 Hour Inspection 3K1 Nose Gear Drag Link 500 Hour Inspection and Bolt Replacement 3K2 Control Cable Inspection 3K3 Exha...

Page 652: ...d 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 653: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3H6 THIS PAGE INTENTIONALLY BLANK...

Page 654: ...procedure required for type certification B Refer to the remainder of this section for Piper s recommended Inspection Programs They include the frequency and extent of the inspections required for the...

Page 655: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3H8 THIS PAGE INTENTIONALLY BLANK...

Page 656: ...acement of components should be performed at the given periods The condition of various components can then be used as criteria for determining subsequent periods applicable to the individual airplane...

Page 657: ...vidual performing the test E Bench Test Means removal of component from the aircraft to inspect for cleanliness impending failure need for lubrication repair or replacement of parts and calibration to...

Page 658: ...ircraft time that elapses from each subsequent installation to each subsequent removal if any or c the calendar time elapsed since the installation NOTE Dates stamped on individual components at the t...

Page 659: ...ich are available from Piper Dealers P N 761 497 for the PA 28 140 150 160 180 235 Cherokee Series and the PA 28 140 Fliteliner and P N 761 500 for the PA 28R 180 200 Refer to Piper s Customer Service...

Page 660: ...100 hour cycle it will be listed as a special inspection below 2 Refer to the applicable section of this manual for instructions on how to gain access to remove any item that must be removed and is n...

Page 661: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3H14 THIS PAGE INTENTIONALLY BLANK...

Page 662: ...installed inspect hub parts for cracks and corrosion O 8 In PA 28 235 only if constant speed propeller installed rotate blades of propeller and check for tightness in hub pilot tube Refer to Section V...

Page 663: ...and continuity O 17 Check magneto points for proper clearance O 18 Inspect magnetos for oil seal leakage See Note 34 O 19 Inspect breaker felts for proper lubrication O 20 Inspect magnetos to engine t...

Page 664: ...rication Chart Section II Disregard if sealed bearing is installed O 45 Inspect condition of alternator and starter O 46 Inspect security of alternator and mounting O 47 Inspect condition and tension...

Page 665: ...Notes 15 25 O 19 PA 28 235 only check operation of fuel drain O 20 PA 28 235 only inspect fuel valve drain lever cover for security Verify door opens and closes freely and prevents operation of lever...

Page 666: ...O 18 Inspect vertical fin attachments for security O 19 Inspect rudder control stops to ensure stops have not loosened and locknuts are tight O 20 Inspect rudder hinge bolts for excess wear Replace as...

Page 667: ...inge damage excessive wear freedom of movement and proper lubrication and attachment points for missing or worn hardware O 4 Inspect aileron hinges and attachments See Note 24 O 5 Inspect aileron cont...

Page 668: ...els clean inspect and repack bearings O 8 Inspect wheels for cracks corrosion and broken bolts O 9 Check tire pressure O O 10 Inspect brake lining and disc for condition and wear O 11 Inspect brake ba...

Page 669: ...moothness O O 15 Check propeller governor action O O 16 Check engine idle O O 17 Check electronic equipment operation O O 18 Check operation of autopilot including automatic pitch trim and manual elec...

Page 670: ...ecting of critical components b The 100 hour inspection is a complete inspection of the airplane identical to an annual inspection NOTE A log book entry should be made upon completion of any inspectio...

Page 671: ...m 13 Clean any traces of oil from the clutch surface 14 Examine cables for broken strands by wiping them with a cloth for their entire length Visually inspect the cable thoroughly for damage not detec...

Page 672: ...uipped with forged main landing gear strut cylinders P N 65489 002 on both left and right sides perform Cast Main Landing Gear Strut Cylinder 100 Hour Inspection see Special Inspections Procedures 27...

Page 673: ...500 hours time in service perform Main Landing Gear Torque Link Greaser Bolt Inspection see Special Inspections Procedures 34 Inspect magnetos a For airplanes equipped with Slick Magnetos inspect magn...

Page 674: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 III INSPECTION 3I3 THIS PAGE INTENTIONALLY BLANK...

Page 675: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3I4 THIS PAGE INTENTIONALLY BLANK...

Page 676: ...8 Rotate blades and check for tightness in hub pilot tube Refer to Section VIIIA O 9 Inspect complete propeller and spinner assembly for security chafing cracks deterioration wear and correct installa...

Page 677: ...high tension leakage and continuity O 17 Check magneto points for proper clearance O 18 Inspect magneto for oil seal leakage See Note 33 O 19 Inspect breaker felts for proper lubrication O 20 Inspect...

Page 678: ...if sealed bearing is installed O 44 Inspect condition of alternator and starter O 45 Inspect security of alternator and mounting O 46 Inspect condition and tension of alternator drive belt See Checki...

Page 679: ...Verify door opens and closes freely and prevents operation of lever when closed O O 20 Inspect condition of heater controls and ducts O 21 Inspect condition and operation of air vents O 22 If installe...

Page 680: ...es i e skin cracks distortion dents corrosion and excessive paint build up structural defects i e loose or missing rivets misrigging or structural imbalance hinge damage excessive wear freedom of move...

Page 681: ...gging or structural imbalance hinge damage excessive wear freedom of movement and proper lubrication and attachment points for missing or worn hardware O 4 Inspect aileron hinges attachments balance w...

Page 682: ...nspect brake lining and disc for condition and wear O 11 Inspect brake backing plates for condition and wear O 12 Inspect brake and hydraulic lines for condition and security O 13 Inspect shimmy dampe...

Page 683: ...Check engine idle O O 17 Check electronic equipment operation O O 18 If installed check operation of autopilot including automatic pitch trim and manual electric trim See Note 20 O O 19 Check air con...

Page 684: ...aintenance lubrication and servicing as well as inspecting of critical components b The 100 hour inspection is a complete inspection of the airplane identical to an annual inspection NOTE A log book e...

Page 685: ...ir entire length Visually inspect the cable thoroughly for damage not detected by the cloth Replace any damaged or frayed cables a See Special Inspections Procedures Control Cable Inspection below or...

Page 686: ...s 28R 35001 thru 28R 7335089 for airplanes which have not modified the original equipment rudder bar assembly per Figure 3 25 perform Rudder Bar Assembly 100 Hour Inspection see Special Inspections P...

Page 687: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3I16 THIS PAGE INTENTIONALLY BLANK...

Page 688: ...ed with Manual Electric Pitch Trim which have not installed Piper Kit No 760 517V or 761 039 before each flight conduct Electric Trim Switch Inspection see Special Inspections Procedures Each 10 Hours...

Page 689: ...in the area of the valve tips valve keepers springs and spring seats If any indications are found the cylinder and all of its components must be removed including the piston and connecting rod assemb...

Page 690: ...PA 28 180 S N s 28 671 thru 28 7505259 and PA 28 235 S N s 28 10001 thru 28 7710089 for those airplanes which have installed either Piper Kit No 760 910V or main landing gear torque link greaser bolt...

Page 691: ...0 and 235 airplanes check upper nose gear oleo bearing for condition Each 1200 Hours Overhaul engine at 1200 1400 or 2000 hours time in service see Lycoming Service Instruction No 1009 latest revision...

Page 692: ...replace Hartzell propellers each five 5 or six 6 years or each 2000 or 2400 hours Refer to latest revision of Hartzell Service Letter No 61 to determine specific requirements for individual engines E...

Page 693: ...ces Manual No 202A Each Twelve 12 Months Lubricate Hartzell constant speed propeller every 100 Hours or annually whichever comes first If annual usage is significantly less than 100 Hours lubricate pr...

Page 694: ...r condition and security Inspection of structure concealed by headliner may be accomplished by alternate means i e through the use of a borescope without removing the headliner providing access is obt...

Page 695: ...alt or High Humidity Environment Item Inspection Inspection Interval Fuselage Empennage Remove floor panels and exterior 200 Hours Wings and Control Surfaces access plates inspect for corrosion using...

Page 696: ...terval Hydraulic Pneumatic Check all fittings and attachments for First 100 Hour then and Environmental security and leaks as required d Operation from Soft or Unusual Terrain Item Inspection Inspecti...

Page 697: ...ght 4 To replace the switch install Piper Kit No 761 039 b Disabling the Switch Should a switch malfunction occur in a location where parts service facilities are not available the aircraft may be flo...

Page 698: ...uttons with open ends of spring facing up Spring coils must be concentric with micro switch buttons and shoulders and must not rest upon them 8 Place knob in position and depress slightly so that the...

Page 699: ...ng bonded properly to the hose interior wall especially in the vicinity of Koroseal ties or clamps b In PA 28R 180s S N s 28R 30479 thru 28R 31092 and PA 28R 200s S N s 28R 35000 thru 35256 less 28R 3...

Page 700: ...follows NOTE Installation of Piper Kit No 760 410V or removal of the spinner and spinner bulkhead entirely relieve this inspection requirement a Remove spinner and inspect for cracks in the areas sho...

Page 701: ...nutes Drain fuel selector for one minute collecting contents in a graduated container Close drain valve Contents collected must be less than 1 2 fluid ounce d If fuel collected exceeds one half fluid...

Page 702: ...is repetitive inspection requirement as well as those of AD 70 26 04 h Inspect stabilator mounting points for possible stabilator side movement Should side movement be evident install combination of A...

Page 703: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3J8 Figure 3 4 Stabilator Balance Weight Tube Inspection...

Page 704: ...e area where the 0 ring seats Should the stem be worn or damaged so that the 0 ring will not seal replace valve e With a 10X magnifying glass inspect valve ports for cracks if cracks are visible repla...

Page 705: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3J10 Figure 3 5 Fuel Selector Valve Inspection...

Page 706: ...rs time in service 1 Place the airplane on jacks per Sec II Para 2 13 2 In both the right and left wings a Inspect the Aft Rib Assembly at W S 49 25 for any evidence of cracks see Figure 3 6 b Inspect...

Page 707: ...13 2 In both the right and left wings a Remove the Main Landing Gear Side Brace by removing the five 5 bolts that fasten it to the wing structure Retain hardware for reassembly b Inspect the Rib Asse...

Page 708: ...he crack a If so install the appropriate kit see above b If this cannot be accomplished replace the cracked Rib Assembly 4 If no cracks are detected reassemble reinstall any parts or components previo...

Page 709: ...t s design parameters during all of their operational life HOWEVER Piper also realizes that some small number of aircraft engage in operations which are defined herein as severe or extreme and those a...

Page 710: ...ough runways flight in extreme damaging turbulence or other accident incident which required major repair or replacement of wing s landing gear or engine mount d Usage Class D Unknown Aircraft and or...

Page 711: ...ct Wing Spar Inspection each 1600 hours time in service d Each 3000 Hours In PA 28 235 s only for airplanes in Usage Class A i e normal usage beginning at 30 600 hours total time in service and each 3...

Page 712: ...sult 10 LANDING LIGHT SEAL INSPECTION WARNING TURN MAGNETOS SWITCHES AND MASTER SWITCH OFF BEFORE WORKING NEAR PROPELLER In PA 28 140 150 160 180 s where the landing light is located in the air filter...

Page 713: ...ped c Inspect the steel attach fittings 4 places for the stabilator and adjacent fuselage structure for rust and or corrosion See Figure 3 8 d If rust and or corrosion is found repair or replace as re...

Page 714: ...d bracket assembly to gain access to the control cable attachment bolt c On aircraft having the flap handle and trim wheel mounted together proceed as follows 1 Loosen the trim wheel attachment bolt 2...

Page 715: ...ft wing attach fittings for evidence of flaking paint and or corrosion Flaking paint may be a symptom of hidden corrosion a If corrosion exists 1 If corrosion is superficial and there is no metal flak...

Page 716: ...insulation has been cut out in all directions around each attach fitting 4 Locate the two 0 191 inch drain holes one beneath each rear attach fitting in the bottom fuselage skin and ensure each is cl...

Page 717: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3J22 Figure 3 11 Drain Hole Installation...

Page 718: ...s found repair or replace parts as necessary Coat the area with primer and allow to dry 11 If no corrosion is found coat the area with primer Allow time to dry 12 Install new wing attach fitting and a...

Page 719: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3J24 Figure 3 12 Fuel Tank and Wing Spar Corrosion Inspection...

Page 720: ...ardless of serviceability 6 Inspect the spar spar angles cap and ribs behind and adjacent to the fuel tank If corrosion is detected conduct a thorough inspection of the entire wing 7 Remove the lacing...

Page 721: ...7A 2 that functions as a hinge pin for the two parts Discard bolt and cotter pin regardless of condition Nut and washers may be reused depending on condition c Inspect bearings in the drag links for...

Page 722: ...which passes over a pulley or through a fairlead remove cable from aircraft to the extent necessary to expose that particular section Examine cables for broken wires by passing a cloth along length o...

Page 723: ...50 percent as depicted in Figure 3 15 c Internal Cable Wear As wear is taking place on the exterior surface of a cable the same condition is taking place internally particularly in the sections of th...

Page 724: ...trations of corrosive fumes vapors and liquids can accumulate NOTE Check all exposed sections of cable for corrosion after a cleaning and or metal brightening operation has been accomplished in that a...

Page 725: ...n smooth rotation freedom from flat spots dirt and paint spray Periodically rotate pulleys which turn through a small arc to provide a new bearing surface for the cable Maintain pulley align ment to p...

Page 726: ...t separation of components Removal of the tail pipe and stacks is required for inspection of the muffler baffle Remove or loosen all exhaust shields carburetor and cabin heat muffs shrouds heat blanke...

Page 727: ...onoxide indicator by heading the airplane into the wind warming the engine on the ground advancing the throttle to full static RPM with cabin heat valves open and taking readings of the heated airstre...

Page 728: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 III INSPECTION 3K9 Figure 3 19 Exhaust System Inspection Points Sheet 1...

Page 729: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3K10 Figure 3 19 Exhaust System Inspection Points Sheet 2...

Page 730: ...hroud Rework the end plates to give a 03 min gap after assembly d Prior to reassembly the two top screw holes in the upper shroud assembly should be slotted as necessary to allow the screws to be inst...

Page 731: ...to detect and replace any cracked control wheels c Inspect the front bottom and back of the control wheels using an ordinary 3x magnifying glass and light NOTE Do not confuse any surface irregulariti...

Page 732: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 III INSPECTION 3K13 Figure 3 22 Aileron Hinge Doubler 100 Hour Inspection...

Page 733: ...inspect as follows a Inspect each main landing gear torque link for cracks in areas shown in Figure 3 23 These cracks may form just behind the large boss which attaches to the strut or to the wheel a...

Page 734: ...d If loading grooves are not visible is will be necessary to lower oleo assembly to remove bearing The bearing should be removed checked lubricated and installed with the bearing loading grooves faci...

Page 735: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3K16 Figure 3 24 Upper Nose Gear Oleo Bearing Inspection...

Page 736: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 III INSPECTION 3K17 Figure 3 25 Rudder Bar Assembly 100 Inspection...

Page 737: ...the above inspection after adjustment replace the retention clips per parts catalog c Parts Availability If replacement parts are not immediately available the aircraft may be operated with the seat...

Page 738: ...NOTE For bolts shown in Sketch A Piper recommends they be replaced even if no cracks are found 2 When replacing bolts shown in Sketch B replace with P N 79543 002 e If the struts were deflated above...

Page 739: ...ut of round condition exists outside of allowable limits The specified hole size for each fitting is 0 3745 0 3765 inch diameter b If the holes meet the requirements specified above check the gap betw...

Page 740: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 III INSPECTION 3K21 THIS PAGE INTENTIONALLY BLANK...

Page 741: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3K22 THIS PAGE INTENTIONALLY BLANK...

Page 742: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 III INSPECTION 3K23 THIS PAGE INTENTIONALLY BLANK...

Page 743: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3K24 THIS PAGE INTENTIONALLY BLANK...

Page 744: ...re further flight Engine See latest revisions of appropriate Each occurrence Lycoming Service Bulletins before further flight and Overhaul Manual Electrical and Avionics Inspect and check harness conn...

Page 745: ...INOR OR APPARENTLY SUPERFICIAL DAMAGE MAY INDICATE A MORE SEVERE CONDITION SOMEWHERE ELSE IN THE STRUCTURE 1 Place aircraft in a normal level attitude 2 Make a preliminary inspection of checking align...

Page 746: ...urther flight Propeller for evidence of ground strike i e hard or overweight landing Fuselage Loose or missing rivets door alignment Each occurrence windows and attachments for overstress before furth...

Page 747: ...t Tubular Structures Check for internal corrosion If immersed each event i e Engine Mounts etc Clean and represerve as required before further flight See Engine Mount Corrosion Inspection Immersion in...

Page 748: ...lar hidden openings and recesses are thoroughly free from contaminants Test electrical components and fuel metering devices in accordance with manufacturer s instructions to determine fitness for futu...

Page 749: ...pped 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 fuel warning swit...

Page 750: ...Clean and inspect all heat shrouds and ducting Fuel System Perform Fuel Tank Wing Spar Corrosion If immersed each event Inspection Remove and clean before further flight fuel cells and fuel cells wing...

Page 751: ...rval Avionics Systems Replace avionics If immersed each event before further flight Clean and inspect antennas and connectors Insulation and Upholstery Remove all wet insulation and upholstery If imme...

Page 752: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 III INSPECTION 3L9 THIS PAGE INTENTIONALLY BLANK...

Page 753: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3L10 THIS PAGE INTENTIONALLY BLANK...

Page 754: ...ication PA 28 AltiMaticAP SL 638A Edo Aire Mitchell SL No ML 35 PA 28 Lycoming SL 653 Serrated Throttle Lever and Shaft PA 28 Piper II AP SL 695 Edo Aire Mitchell SL No ML 38 PA 28 140 1964 SL 425 Lyc...

Page 755: ...SL 494 757 165 Cherokee Landing Gear Inspection 1967 1969 SL 535A Rudder Trim Locking Pin Securing 1967 1977 SB 642 Air Filter Seal Inspection 1968 SB 281 R C Allen Service Bulletin No 1 Artificial H...

Page 756: ...61 1964 SB 287 Tailpipe Replacement SB 360 760 640 Air Induction Hose System Mod SB 774 760 455 Baggage Door Latch Replacement SL 425 Lycoming SB 298 AC Fuel Pump Vent Restrict SL 442 AC Fuel Pump Rep...

Page 757: ...Cowl Drain Insp Mod 1964 1973 SB 387 760 742 Alternator Installation Mod 1966 1967 SB 811A 765 186 Ammeter Replacement SL 494 757 165 Throttle Clamp Replacement 1966 1972 SB 357A Alternator Output Wi...

Page 758: ...Servo Spacer Bushing Install SL 577 Servo Bridle Cable Clamp Replacement 1964 1965 SB 223 756 906 Fuel Quantity Gauge Sender Unit Mod SL 457 756 963 Plastic Spinners on Cherokee C 1964 1966 SB 234 75...

Page 759: ...rborne SL 56 Air Filter Inspection Cleaning SL 761 760 795 Magnetic Compass Relocation Kit SL 793 Flap Warning Placard SL 845 763 828 Engine Breather Tube Winterization Kit VSP 174 Lycoming SB 569 Cra...

Page 760: ...4 SL 734 760 857 Bendix ADF T 12 1973 1975 SB 436 Operating Limitations Placard Inspection 1974 SL 700 760 842 Toe Brake System Modification SL 715 760 876 ELT Switch Cover Modification 1974 1975 SB 4...

Page 761: ...0 Fuel System Instructions and Mod 1964 1972 SL 620 760 729 Forward Cabin Door Reinforcement 1964 1973 SB 360 760 634 Air Induction Hose System Mod SB 387 760 742 Alternator Installation Mod SB 395 Wa...

Page 762: ...ntenna Protector Installation SB 393 760 794 Rear Seat Belt Attachment Mod 1972 1976 SB 533 Fuel Gauge Calibration Inspection 1973 SL 647 760 740 Seat Back Stop Modification 1973 1974 SL 720 Fuel Plac...

Page 763: ...SB 769 760 542 Landing Gear Back up Actuator Override Mech SB 789A 764 998 Aft Wing Spar Modification SB 789A 765 106 Aft Inboard Wing Access Panel Retrofit SB 805A Hartzell SB No 142B O Ring Deterior...

Page 764: ...r Drive Assembly SB 326 Fuel Valve Selector Handle 2 Tank Inspection SL 566 760 508 Autopilot Servo Spacer Bushing Install SL 568 Engine Mount Tubes Inspection SL 571 760 531 Flap Handle Assembly Modi...

Page 765: ...aft Retirement 1970 1971 SB 337 760 532 Vertically Adjustable Seat Frame Tube Replace SL 607 Emergency Gear Lever Knob 1971 SB 339 Owner s Handbook Revision 1971 1973 SL 626 Landing Gear Bolt Lubricat...

Page 766: ...1976 SL 836 Narco ADF 140 141 Antenna Inspection Mod cont 1975 1977 SB 623 Diode Assembly Inspection SB 804 765 157 Battery Strap Installation 1976 SB 543 Starter Magneto Switch Inspection Replacemen...

Page 767: ...PIPER CHEROKEE SERVICE MANUAL III INSPECTION 01 31 08 3L24 THIS PAGE INTENTIONALLY BLANK...

Page 768: ...PART NUMBER 753 586 January 31 2008 4A1 SERVICE MANUAL CARD 4 OF 4 PA 28 140 PA 28 150 PA 28 160 PA 28 180 PA 28 235 PA 28R 180 PA 28R 200 PIPER AIRCRAFT CORPORATION...

Page 769: ...August 3 1983 1 2 3 and 4 PR840423 April 23 1984 1 2 3 and 4 PR86115 January 15 1986 1 and 3 IR860730 July 30 1986 1 IR870506 June 12 1987 1 IR950215 February 15 1995 1 and 2 IR020228 February 28 2002...

Page 770: ...ULIC SYSTEM PA 28R 2D3 VII LANDING GEAR AND BRAKES PA 28 2E22 VIIA LANDING GEAR AND BRAKES PA 28R 2H1 VIII POWERPLANT PA 28 2K2 VIIIA POWERPLANT PA 28R 3A8 IX FUEL SYSTEM 3C8 X INSTRUMENTS 3D18 XI ELE...

Page 771: ...0000 thru 28 24999 PA 28 150 160 S N s 28 508 thru 28 3643 PA 28 180 S N s 28 671 thru 28 3643 PA 28 235 S N s 28 10002 thru 28 10762 4B20 11 17 Alternator and Starter System PA 28 140 S N s 28 25000...

Page 772: ...l of End Head Bearing 4D22 11 76 Testing Rotor for Ground 4D23 11 77 Testing Rotor for Shorts 4D23 11 78 Installation of Bearing 4D24 11 79 Installation of Rectifier 4D24 11 80 Terminal Assembly 4E1 1...

Page 773: ...e and Manifold Set 4J13 14 4 Manifold Set Operation 4J14 14 5 Leak Test Hookup 4J15 14 6 Evacuation Hookup 4J17 14 7 Charging Stand 4J19 14 8 Charging Hookup 4J21 14 9 Compressor and Fabricated Oil Di...

Page 774: ...I Electrical System Troubleshooting 4E10 XI III Electrical System Component Loads 4F8 XI IV Electrical Symbols 4F9 XI V Electrical Wire Coding 4F10 XIV I Temperature Pressure Chart 4J8 XIV II Aluminum...

Page 775: ...CoilRemoval 11 18 Inspectionand Repair of Parts 11 19 FieldCoilService 11 20 Armature Service 11 21 PolarizingGenerator 11 22 Generator ServiceTest Specifications Delco Remy r Delco Remy Descriptionof...

Page 776: ...d Shield 11 60 RemovingDrivePulley 11 61 RemovingDriveEnd Bearing 11 62 ReplacingSlipRings 11 63 RemovingSlipRings 11 64 Installation of SlipRings 11 65 InstallingGreaseRetainer 11 66 InstallingDriveE...

Page 777: ...ingMotor ServiceTest Specification Prestolite 4D14 11 109 Battery 4D15 11 110 ServicingBattery 4D15 11 111 Removalof Battery 4D15 11 112 Installationof Battery 4D15 11 113 ChargingBattery 4D16 11 114...

Page 778: ...ht Rotating Beacon 4E5 11 138 Removal 4E5 11 139 Installation 4E5 11 140 Anti CollisionLight Strobe 4E5 11 141 Description 4E5 11 142 Removalof WingTip Strobe Light 4E5 11 143 Installationof WingTip S...

Page 779: ...228 thru 28 7305063 11 62 4G3 Electrical System Schematic PA 28 235 S N s 28 10003 thru 28 10719 11 63 4G5 Electrical System Schematic PA 28 235 S N s 28 10720 thru 28 10762 11 64 4G7 Electrical Syste...

Page 780: ...4G24 Alternator Starter Cabin Lighter Cigar Lighter and External Power Receptacle PA 28 180 S N s 28 7505001 up PA 28R 200 S N s 28 7535001 up PA 28 235 S N s 28 7510001 up 11 126 4H16 Anti Collision...

Page 781: ...S N s 28 7510005 up 11 124 4H14 Instrument Lights PA 28 140 S N s 28 7325053 thru 28 7325684 11 99 4H6 Instrument Lights PA 28 140 S N s 28 7325053 thru 28 7425454 11 100 4H7 Instrument Lights PA 28 1...

Page 782: ...7335055 thru 28 7435331 PA 28 235 S N s 28 7310039 thru 28 7410120 11 112 4H11 Navigation Lights PA 28 140 S N s 28 7525001 up PA 28 180 S N s 28 7505001 up PA 28R 200 S N s 28 7535001 up PA 28 235 S...

Page 783: ...eater PA 28R 200 S N s 28 7535001 up 11 143 4H24 Radio Lights PA 28 140 S N s 28 7425001 up PA 28 180 S N s 28 7405001 up PA 28R 200 S N s 28 7435001 up PA 28 235 S N s 28 7410001 up 11 119 4H13 Rotat...

Page 784: ...generator or alternator are both connected to the bus bar from which all electrical equipment is powered with the exception of the starter which receives its power from the load side of the battery Th...

Page 785: ...NLY FOR DETAILED SCHEMATIC SEE TABLE XI I VOLTAGE REGULATOR BAT F GENERATOR T CIRCUIT PROTECTOR 35AMP T SHIE i MASTER I MASTER SWITCH CONTACTOR _ BATTERY AMMETER TO BUSBAR SELINOID STARTER SWITCH Figu...

Page 786: ...IS IS A TYPICAL WIRING DIAGRAM FOR GENERAL REFERENCE ONLY FOR DETAILED SCHEMATIC SEETABLE XI I REGULATOR I I I F BATTERY LOAD GENERATOR Figure 11 2 Generator WiringDiagram Typical 4A19 A143 BAT GEN A...

Page 787: ...enerator regulator operation any of several basic conditions may be found a Fully Charged Battery and Low Charging Rate This indicates normalgen erator regulator operation Regulator settingmay be chec...

Page 788: ...uit operation or high resistance in the charging circuit Where burned resistances windings or contacts are found always check wiring before installing a new reg ulator Otherwise the new regulator may...

Page 789: ...OR Delco Remy 11 9 INSPECTION OF GENERATOR a At periodic intervals the generator should be inspected to determine its con dition The frequency with which this should be done will be determined by the...

Page 790: ...asive material which when held against a revolving commutator disintegrates so that particles are carried under the brushes and wear their contacting faces to the contour of the commutator in a few se...

Page 791: ...and a test lamp as follows to locate the trouble leads must be disconnected from generator terminals b Raise the grounded brush from the commutator and insulate with a piece of cardboard Check for gr...

Page 792: ...wn to specifications to prevent overloading by readjustment of the regulator f Short circuits in the armature are located by use of a growler The ar mature is placed in the growler and slowly rotated...

Page 793: ...he field is internallygrounded If the field has become grounded because the insulation on a field lead has worn away repair can be made by reinsulating the lead It is also possible to make repair wher...

Page 794: ...r field should not be cleaned in any degreasing tank or by use of degreasing compounds since this might damage insulation so that a short or ground would subsequently develop Sealed ball bearings do n...

Page 795: ...hacksaw blade held above it the blade will vibrate above the area of the armature core in which the short is located Copper or brush dust in the slots between the commutator bars sometimes causes shor...

Page 796: ...24 oz Field Current 80 F Amps 1 62 to 1 72 Volts 12 Cold Output Amps 35 Volts 14 0 Approx RPM 3100 COLD OUTPUT Cold output data applies to generators at 80 degrees F and with brushes well seated Vari...

Page 797: ...flat steel armature is attached to the frame by a flexible hinge so that it is centered just above the stationary contact points When the generator is not operating the ar mature contact points are h...

Page 798: ...d to ground through them c When the generator voltage reaches the value for which the voltage regu lator is adjusted the magnetic field produced by the two windings shunt and se ries overcomes the arm...

Page 799: ...ints open resistance is inserted into the generator field circuit so that the generator output is reduced c As soon as the generator output starts to fall off the magnetic field of the current regulat...

Page 800: ...igned for use with po sitive grounded systems Usingthe wrong polarity regulator on an installation will cause the regulator contact points to pit badlyand give short life As a safeguard against instal...

Page 801: ...After any tests oradjustments thegenerator on the airplane must be polar ized after leads are connected but before the engine is started as follows After reconnecting leads momentarily connect a jump...

Page 802: ...e devel oped 11 34 REGULATOR CHECKSAND ADJUSTMENTS 11 35 VOLTAGE REGULATOR Two checks and adjustments are required on the voltage regulator air gap and voltage setting a Air Gap To check air gap push...

Page 803: ...eed until generator voltage is re duced to 4 volts Move voltmeter lead back to BAT terminal of regulator Bring generator back to specified speed and note voltage setting Method 2 Connect a variable re...

Page 804: ...at the BAT terminal as shown in Figure 11 7 rather than at the GEN terminal even though these terminals are in the same circuit An examin ation of the wiring diagram Figure 11 2 will show that regula...

Page 805: ...rocedure In using the vari able resistance method it is necessary to readjust the variable resis tance after each voltage adjustment to assure that 8 to 10 amperes are flowing Cycle generator after ea...

Page 806: ...field circuit Refer to Figure 11 12 Use a 25 ohm 25 watt resistor Operate generator at medium speed with vari able resistance turned all in Slowly decrease turn out the resistance un til cutout relay...

Page 807: ...steps c and d in paragraph 11 32 If current regulator is not temperature compen sated disregard 15 minute warm up period d Cycle generator and note current setting e Adjust in same manner as describe...

Page 808: ...ching the armature to the regulator frame Support the frame to avoid bending Center punch the rivet heads and drill out with a 3 32 inch drill Attach the new armature with screws lockwashers and nuts...

Page 809: ...must be polarized as explained in paragraph 11 32 step e in order to avoid damage to the equipment i It is recommended that following replacement or repair of a generator or regulator they be adjuste...

Page 810: ...he voltageregulatoris the only control needed An additional latching circuit is used to help keep the master solenoidclosedwhen the battery voltage is low and the enginestarter is being operated This...

Page 811: ...REGULATOR 6 ALTERNATORSOURCE POWER RELAY ENERGIZINGCIRCUIT PA 28 140 Serial Nos 28 20000to 28 24999incl PA 28 150 160 Serial Nos 28 508to 28 3643incl PA 28 180 Serial Nos 28 671to 28 3643incl PA 28 23...

Page 812: ...XI I RADIO ALTERNATOR ALTERNATOR SOURCE POWE RELAY ENERGIZING CIRCUIT PA 28 140 Serial Nos 28 25000and up PA 28 150 160 180 Serial Nos 28 3644and up PA 28 235 Serial Nos 10763and up and PA 28R Figure...

Page 813: ...e alternator or 48 amperes for the 60 ampere alternator This approximate 30 or 48 ampere value plus approximately two amperes for a fully charged battery will appear contin uously under these flight c...

Page 814: ...11 18 On airplanes with a 60 ampere alternator without night flying equipment load required by test can be simulated by connecting a lamp bank load consisting of 8 landing lights wired in parallel fro...

Page 815: ...or coil and connected circuit and record the amount Slowly rotate the rotor with the pulley while watching the meter The current will be a little less while ro tating the rotor than when stationary Ho...

Page 816: ...her lockwasher and at taching screw 11 50 INSPECTION Inspect the condition of the alternator components paying special attention to the condition of the slip rings for indications of oil being burnt o...

Page 817: ...rrosion protection The reading on the meter will indicate 1 7 or over for good rectifiers Where two of the rectifiers are good and one is shorted the reading taken at the good rectifiers will show low...

Page 818: ...ame for the negativecaserectifiersin the end shield as they are for the positive case rectifiersin the heat sink However the meter willread at the opposite end of the scale NOTE If all three of the ne...

Page 819: ...lled It is not rec ommended to reinstall rectifiers once they have been removed The tool kitcan beused on all Chrysler built alternators A press is not required when using the C 3928 tool kit for remo...

Page 820: ...assembly installing support on the fixture anvil C362 FIXTURE INSTALLING SUPPORT Figure 11 25 Installing Rectifiers from the fixture and position SP 3820 11 55 INSTALLING RECTIFIERS Start the new rec...

Page 821: ...fier in place until it bottoms heting grip the rectifier bottoms itea be felt Remove the end shield assem bly from the fixture and inspect to see that rectifier is installed properly NOTE Clean all wi...

Page 822: ...t cold will be rough and pitted NOTE After soldering to quickly cool the soldered connec tion touch a dampened cloth against it This will aid in forming a solid joint With the rectifier properly insta...

Page 823: ...rnators to suppress any transient peak voltage that may occur It is essential therefore to test the capacitor when servicing the alternator This is especially true where diode rectifiers test open or...

Page 824: ...end is used as a support for end shields without the greaseretainer counterbore 11 59 INSTALLING NEEDLE BEARING IN END SHIELD Refer to Figure 11 29 Support the end shieldon the C 3925tool and press t...

Page 825: ...he retainer on the early production alternators was attached to the end shieldby three stud nuts and washers All late retainers are of spring steel construction and three integralfingerssnap over a sh...

Page 826: ...le The early rotor shaft was smooth and the slip rings were pressed on and the ring cemented to the rotor fan Later rotor shafts were knurled and the slip rings were pressedon the knurled surfaceof th...

Page 827: ...e old ring f Scrapethe face of the fan to be sure it is smooth g Clean the shaft surface on the area that contacts the inner diameter of the ring and alsothe ends of the rotor coil leads 11 64 INSTALL...

Page 828: ...ly in an arbor press Pullup on the guidewirebeing careful to guide the insulated field lead into the slipringgroove 7 Whileguidingthe insulated field lead through the groove press the slip ringon the...

Page 829: ...when installing slip ring If rotor is not grounded lightlycleanslipring surfacewith 00 sandpaper and assemblealternator b New Style Refer to Figure 11 36 1 Position the slip ring on the rotor shaft s...

Page 830: ...all early production Snap the springsteel retainer fingersin placeon all later production models If the rotor and its components require no service position the bearingand the drive end shield assemb...

Page 831: ...lder terminal insulating washer lock washer and terminal attaching screw Install the ground brush and attaching screw Rotate the pulley slowly by hand tobe sure that the rotor fans do not hit the rect...

Page 832: ...f supply to positive of the alternator Monitor rectifier reverse current which shall be not more than 1 milliampere 2 With the alternator at rest apply 15 volts to the field circuit and mon itor field...

Page 833: ...h a suitable driving mechanism During this test the following shall be monitored Refer to Figure 11 39 for meter connections a Alternator output voltage b Alternator output current c Field current d A...

Page 834: ...attery positive post and the remaining lead to the regulator IGN terminal b Connect a jumper wire from the battery negative post to the regulator Field terminal c Insert a 048 inch gauge betweenthe ar...

Page 835: ...n 2 volt nor more than 7 volt If the transfer voltage is less than 2 volt it is permissible toincrease the air gap but not to exceed 005 inch 057 g If the transfer voltage is greater than 7 volt the a...

Page 836: ...field repair of the unit impractical and if it does not meet the specifications it must be replaced The regulator may be tested by the following procedure a Be sure that the battery is fully charged...

Page 837: ...zed 6 Open circuit operation of the alternator The battery disconnected 11 77 OVER VOLTAGE RELAY Wico 11 78 CHECKING OVER VOLTAGE RELAY The relay may be tested with the use of a good quality accurate...

Page 838: ...ER 375 USED 7 9 RUBBER 500 NEW 13 15 RUBBER 500 USED 9 11 PLASTIC 328 NEW 11 13 PLASTIC 328 USED 7 9 11 80 STARTING MOTOR Delco Remy 11 81 OPERATION OF STARTING MOTOR When the starting motor switchis...

Page 839: ...THIS PAGE INTENTIONALLYLEFT BLANK 4C24...

Page 840: ...th an AN 3 copper cable assembly The new cable should be installed in accordance with AC 43 13 2A b Inspect the wiring for frayed insulation or other damage Replace anywir ing that is damaged Inspect...

Page 841: ...Also con nect a voltmeter as illustrated from the motor terminal to the motor frame An RPM indicator is necessary to measure armature speed Obtain the specified voltage by varying the resistance unit...

Page 842: ...ted replace the field coil assemblyand check for improved per formance 11 86 LOCK TORQUE TEST Refer to Figure 11 45 The lock torque test requires the equipment illustrated A variable resistance with a...

Page 843: ...ons for disassem bling a typical Bendix drive starting motor a Remove the cover band if present and detach the field coil leads from the brush holders b If gear reduction remove the drive housing and...

Page 844: ...er the leads in the riser bars and turn the commutator down in a lathe Then undercut the insulation be tween the commutator bars 031 of an inch 3 Grounds in the armature can be detected by the use of...

Page 845: ...will return to the de meshed position 11 91 STARTING MOTOR SERVICE TEST SPECIFICATIONS Delco Remy specifications for 12 volt starting motors installed as standard equipment on PA 28 series airplanes a...

Page 846: ...onze bearing When the armature turns the reduction gear the Bendixdrive pinion meshes with the flywheel ring gear by inertia and action of the screw threads within the Bendix sleeve A detent pin engag...

Page 847: ...E If a solderlessterminal on an aluminum cableis loose cor roded or otherwiseunsatisfactory it is recommendedthat the complete cable assembly be replaced instead of replacing or repairing the solderle...

Page 848: ...um 2 Voltage loss from battery ground post to starter frame 0 1 volt maximum NOTE If voltage loss is greater than the above limits add itional tests should be made over each part of the cir cuit to lo...

Page 849: ...ul 11 98 DISASSEMBLY a Remove the frame screws from the commutator end head and pull end head and armature from frame Lift the brushes and lock in elevated position with brush springs Use a puller to...

Page 850: ...ugh bearing surfaces and rough or damaged splines b To test the armature for grounds a set of test probes connected in series with a 110 volt light should be used Touch one probe to a commutator segme...

Page 851: ...ion should turn smoothly in one direction and should lock in the other di rection Replace drive if it fails to check as above or if the pinion teeth are ex cessively worn or damaged 11 105 ASSEMBLY a...

Page 852: ...e 11 51 If current is too high check the bearing alignment and end play to make sure there is no binding or interference Two or three sharp raps on the frame with a rawhide hammer will often help to a...

Page 853: ...l starting switch is released it should be removed and tested to specifications If either opening or closing voltages are not to specifications replace the solenoid 11 108 STARTINGMOTORSERVICETEST SPE...

Page 854: ...aced instead of replacingor repairingthe solderlessterminal Should replacementof the complete assemblynot be prac tical it is permissibleto replacethe aluminumcableassembly witha copper cable assembly...

Page 855: ...box on the terminals or around the battery the battery should be removed and both the box and battery cleaned by the followingprocedure a Remove the box drain cap from the under side of the fuselagea...

Page 856: ...all of the airplane selectricalequipment is turned OFF 3 Connect the external battery to the external power receptacle turn master switchONand start engineusingnormal starting procedure 4 Turn master...

Page 857: ...he battery will appear on the ammeter Using the example that the airplane s maximum continuous load with all equipment on is approximately 48 amperesfor the 60 amperealternator This approximate48 ampe...

Page 858: ...lure to observe these precautions will result in serious damageto the electricalequipment a Disconnect the battery before connecting or disconnectingtest instruments except voltmeter or before removin...

Page 859: ...d The stator contains a speciallead whichis connected to the center of the three phase windings The stator has been treated with a special epoxy varnish for high temperature resistance e The rotor co...

Page 860: ...unit from the stator and slipringendhead d Remove the nuts lock washers flat washers and insulators from the output and auxiliary terminal studs Note carefully the correct assemblyof the insulator was...

Page 861: ...ter or any type of continuity tester Refer to Figure 11 76 There must not be any continuity between the slip rings and the rotor shaft or poles To test for shorted turns in the rotor winding connect a...

Page 862: ...probe to the auxiliaryterminal or any stator lead and the other test bulb or ohmmeter probe to the stator frame If the test bulb lights or the ohmmeter indicates continuity the stator is grounded To t...

Page 863: ...he specialtools illustrated in Figure 11 79 CAUTION Use an arbor press do not hammer Reconnect the stator leads to the rectifiers Whensolderingthese connections use pliers as a heat dam on the lead be...

Page 864: ...the brush and holder assemblyand retaining screws Spin the rotor and check for interference between the brush holder and rotor Check between the field terminal and ground with an ohmmeter The ohmmeter...

Page 865: ...rs installedas standard equipment on PA 28airplanesequipped with air conditioning ALTERNATOR SPECIFICATIONS PRESTOLITE Alternator Model Voltage ALY 6422 12 volts Rated Output 60 amperes Ground Polarit...

Page 866: ...a varibleresistor that controls the intensity of the instrument lights On 1974model aircraft there is a second control knob connected to a varible resistor which controls the light intensity for all...

Page 867: ...rent flowsthrough a 5 amp fuse located near the diode heat sink to the resistor and diode creating a no flow condition whichdoes not allow the warninglight to light The test button is used to check th...

Page 868: ...ow be removed 11 139 INSTALLATION a Installlight bulb in bayonet socket b Replacelensand clampand secureby tighteningscrewon clamps 11 140 ANTI COLLISION STROBE 11 141 DESCRIPTION The lightsare locate...

Page 869: ...e in middle of mounting plate 11 145 INSTALLATION OF FINTIP STROBELIGHT a Insert new electricalplug down through hole in mounting plate and position strobe light assemblyin place b Positionlensin plac...

Page 870: ...5 KHZ If there is no sound emitted check the systemaccordingto the followinginstructions When troubleshooting the system utilize the appropriate schematic at the back of this section a Ascertain the i...

Page 871: ...be replaced 4 Check continuity between Pins 1 and 2 1 and 3 2 and 3 of the interconnecting cable If continuity existsbetween any of theseconnections the cableis shorted and should be replaced d Check...

Page 872: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 XI ELECTRICAL SYSTEM 4E9 Figure 11 145 Strobe Light Connections...

Page 873: ...s Brushes excessively worn Clean and tighten all electrical connections When brush wears down to 1 2 inch replace with a new one CAUTION Do not use abra sives of any des cription in seat ing the brush...

Page 874: ...commutators Dirty commutator Scored or pitted com mutator Shorted or open arm ature coils Improper operation of the voltage regulator Clean the commutator with a cloth moistened in a dry type cleanin...

Page 875: ...output low above Generator field mag netized in the wrong direction Generating system is overloaded Improper operation of generator reverse current relay Replace voltage reg ulator Use remedy under G...

Page 876: ...d to the follow ing points in se quence buss bar out put circuit breaker 40A 60A field circuit breaker 5A field terminals of master switch voltage regu lator and alternator field terminal Interruption...

Page 877: ...y component or wire which must be replaced See wiring schematic Open field winding in alternator Disconnect field termi nal of alternator from field wiring and check for continuity from field terminal...

Page 878: ...rocedure set throttle at 2300 RPM Check voltage at buss bar convenient check point remove cigar lighter and check from center contact to ground Voltage should be 13 5 volts minimum If voltage is below...

Page 879: ...up internally it will result in a definite limitation on the current that can be drawn from the alternator After having checked the previous causes of low output it can be assum ed that a faulty rect...

Page 880: ...r and if breaker fails to retrip this isolates short circuit to field of alternator itself Check brush holders for shorting against frame If there are no obvious signs of a physical short circuit at f...

Page 881: ...reaker and if breaker continues to trip proceed to dis connect each leg of out put circuit working from the alternator towards the circuit breaker until breaker can be reset and will hold Replace com...

Page 882: ...rging NOTE This type of condition can only occur in a case where a dis charged battery has been removed from the airplane and put on a charger with the polarity reversed This reversal in polarity cann...

Page 883: ...on cont Highfield circuit resistance If problem persists jump acrossterminals of the followingcom ponents one at atime until the faulty unit is isolated a Field 5 amp al ternator circuit protector b A...

Page 884: ...Replace faulty unit Brushes should be a free fit in the brush boxes without excessive side play Binding brushes and brush boxes should be wiped clean with a gasoline undoped moistened cloth A new brus...

Page 885: ...bearing free from sand or metal particles Dirty commutator Shorted grounded or open armature Grounded or open field circuit If commutator is rough or dirty smooth and polish with number 0000 sandpaper...

Page 886: ...ate Binding worn or im properly seated brush or brushes with ex cessive side play Same remedies listed for these troubles See information above dealing with this trouble Dirty commutator rough pitted...

Page 887: ...n accidentally Impurities in electrolyte Short circuit ground in wiring Broken cell partitions Overcharge due to level of electrolyte being below top of plates Sulfation due to disuse Impurities in el...

Page 888: ...ing rate too high Reduce charging rate by adjusting voltage regu lator or replace tran sistorized regulator Drain and keep at proper level and adjust voltage regulator Use care in adding water Repair...

Page 889: ...II ELECTRICALSYSTEMTROUBLESHOOTING cont Trouble Cause Remedy BATTERY cont y consumes Charging rate too high Correct chargi excessivewater if in all cells Cracked jar one cell Replace battery only ELE...

Page 890: ...el All the warninglights fail to extinguish after engineisrunning OIL warninglight failsto operate Test switchgrounded out Bulbburned out No current to sensor Sensoractivatesat a too low setting Defec...

Page 891: ...ght fails to operate ALTwarninglight fails to extinguish Sensoractivatesat a too highsetting Sensorterminals bridged Defectivesensor Bulbburned out No current from bus to resistor Blownfuse Replace Re...

Page 892: ...E L45 06B Q7B 012 LIG Q4B 10 Q4B Q3A 74E PA 28 140 SERIAL NOS 28 25000 TO 28 7425454 INCLUSIVE PA 28 180SERIAL NOS 28 4378 TO 28 7405290 INCLUSIVE 3 PA 28 235 SERIAL NOS 28 11040 TO 28 7410120 INCLUSI...

Page 893: ...ERIAL NOS 28 10003 TO 28 11039 INCLUSIVE PA 28 140 SERIAL NOS 28 20002 TO 28 24999 INCLUSIVE PA 28 150 PA 28 160 AND PA 28 130 SERIAL NOS 28 1411 TO 2 4377 INCLUSIVE PA 28 150 PA 28 160 AND PA 28 180...

Page 894: ...28 235 SERIAL NOS 28 7510001 AND UP PA 28 140 SERIAL NOS 28 7525001 UP 012 PA 28 180 SERIAL NOS 28 7505001 UP Figure 11 53 Terminal Block cont ELECTRICALSYSTEM 012 012 PA 28 R 200 SERIAL NOS 28 R 753...

Page 895: ...ting Carb Rotary Fuel Inj t Engine Gages Elec Turn Bank Pitot Heat X Cigar Lighter Master Solenoid X Starter Solenoid X LandingGear Pump Circuitbreaker Solenoid X Gear Down Lights X AutoPilot Avg Radi...

Page 896: ...DIODE DIODE LIGHT PRESSURE SOLENOID CONNECTOR PIN SWITCH INSULATEDCONNECTOR NNECTORS WINGROOT CONNECTOR PIN KNIFE DISCONNECT NOISE FILTER SHIELDEDCONDUCTORS USH BUTTON SWITCH CONDUCTORS CONDUCTORS CRO...

Page 897: ...C CONTROL SURFACE E ENGINE INSTRUMENT F FLIGHT INSTRUMENT G LANDING GEAR H HEATER VENTILATING DEICING J IGNITION K STARTER L LIGHTING M MISC EQUIP Cigar Lighter Hour Meter etc P DC POWER Q FUEL OIL Q...

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Page 945: ...Transmitter 4I7 12 7 Pilot s Remote Switch 4I8 12 8 Testing Pilot s Remote Switch 4I8 12 9 Inadvertent Activation 4I9 12 10 Emergency Locator Transmitter Communications Components Corp 4I10 12 11 Des...

Page 946: ...e aircraft Refer to Paragraph 12 4or 12 5 12 4 BATTERYREMOVALANDINSTALLATION 2 year magnesiumbattery refer to Figure 12 1 The ELT is located on mounting brackets on the right sideof the fuselageaft of...

Page 947: ...ransmitter p Connect the antenna coax to the transmitter mounting bracket by NOTE Before installingaccessplate ascertainthat transmitter switch is in the ARMposition It may alsobe advisableto test the...

Page 948: ...PIPER CHEROKEE SERVICE MANUAL XII ELECTRONICS 01 31 08 4I4 Figure 12 2 ELT Portable Folding Antenna Narco Figure 12 3 ELT Using Fixed Aircraft Antenna Narco...

Page 949: ...Do not remove this sealant h Connect new battery pack terminals to the bottom of the circuit board i Reinsertthecontrol head sectioninto batterypack beingcarefulnot to pinchanywiresandreplace the four...

Page 950: ...enna conducted RF 2 Rigidityof the transmitter installation CAUTION Under normal conditions the pilot s remote switch must be set to ARMposition 347 COMMUNICATIONS COMPONENTSCORP REMOTI RESET ELT E BL...

Page 951: ...est should be coordinated with the closestFAA Toweror Flight ServiceStation Consult FAA Advisory Circular AC 20 81 for detailed information concerningabovecaution a Removethe accessplate on the right...

Page 952: ...ot s remote switch is placarded ON RESET and ARM NORMALPOSITION The switchis normallyleft in the down or ARM position To turn the transmitter off move the switch to the ON RESET position for one secon...

Page 953: ...e reset by gainingaccessto the ELT Refer to Paragraphs 12 4 or 12 5 Put the ON ARM OFFswitch in the OFF position To reset for automatic operation return switchto the ARMposition SeeNote b In aircraft...

Page 954: ...ch e Remove the forward mounting bracket by pulling the black plastic knob out Removethe transmitter fromthe airplane f Remove the six Phillips headscrews securing the transmitter cover Remove the cov...

Page 955: ...s heard NOTE If the aircraft is not fitted with a communicationsreceiver request that the tower listen for your test b Set the pilot s remote switchto the ONposition Holdthe switchin this position for...

Page 956: ...AutoPilot Flight Director Service Manual shall be used NOTE If a Roll Axis only AutoPilot is installed or if no AutoPilot is installed consult the Piper Pitch Trim Service Manual 753 771 for manual el...

Page 957: ...ly inset from the panel If so correct the tray rack installation before proceeding NOTE The high insertion forces required to seat a unit with high density connectors tend to limit the effectiveness o...

Page 958: ...SECTION XIII HEATING AND VENTILATING Aerofiche Grid No Introduction Description Heater Maintenance OverheadVent System Revised 10 3 83 4114 13 1 13 2 13 3 13 4 4115 4115 4116 4116...

Page 959: ...nt The heater outlet in the cabin is located between the two front seats Control for the heater system is located on the right panel below the instruments The windshield is kept clear of frost ice and...

Page 960: ...controls are pushed in the valvesshould close off all air passageand vent the air into the engine compartment Refer to Figures 13 1 thru 13 9for an illustration of the heater system 13 4 OVERHEADVENTS...

Page 961: ...H AIR INLET HEATER OUTLET 7 FRESH AIR INLET 8 CABIN HEAT CONTROL BOX FLEXIBLE HOSE 10 DEFROSTER CONTROL BOX Figure 13 1 Cabin Heater Defroster and Fresh Air System PA 28 140 Serial Nos 28 20002 to 28...

Page 962: ...13 2 Cabin Heater PA 28 140 Serial Reissued 1 15 81 4 Defroster and Fresh Air System Nos 28 25000 and up I18 HEATING AND VENTILATING SYSTEM 1 FRESH AIR CONTROL 4 DEFROSTER AIR OUTLET 2 DEFROSTER CONT...

Page 963: ...PIPER CHEROKEE SERVICE MANUAL 1826 Figure 13 3 Cabin Heater Defroster and Fresh Air System PA 28 150 160 180 Serial Nos 28 1761 to 28 2477 incl Reissued 1 15 81 4119 HEATING AND VENTILATING SYSTEM...

Page 964: ...ONTROL 4 DEFROSTER AIR OUTLET 2 DEFROSTER CONTROL 5 FRESH AIR INLET 3 HEATER CONTROL 3 CABIN EXHAUST OUTLET Figure 13 4 Cabin Heater Defroster and Fresh Air System PA 28 150 160 180 Serial Nos 28 2478...

Page 965: ...FRESH AIR CONTROL 2 DEFROSTER CONTROL CABIN HEAT 3 HEATER CONTROL Figure 4 DEFROSTERAIR OUTLET 5 FRESHAIR INLET 6 CABIN EXHAUST OUTLET Figure 13 5 Cabin Heater Defroster and Fresh Air System PA 28 18...

Page 966: ...EATER DEFROSTER OUTLET FRESH AIR INLET CABIN CABIN HEAT OUTLET CABIN AIR AND HEAT CONTROLS CABIN AIR EXHAUST OUTLET Figure 13 6 Cabin Heater Defroster and Fresh Air System PA 28 235 Serial Nos 28 1000...

Page 967: ...7 Cabin Heater PA 28 235 Serial Nos Reissued l 15 81 Defroster and Fresh Air System 28 10676 to 28 11039 incl 4123 HEATING AND VENTILATING SYSTEM 1 FRESH AIR CONTROL 4 DEFROSTER AIR OUTLET 2 DEFROSTER...

Page 968: ...SH AIR CONTROL 4 DEFROSTER AIR OUTLET 2 DEFROSTER CONTROL 5 FRESH AIR INLET 3 HEATER CONTROL 6 CABIN EXHAUST OUTLET Figure 13 8 Cabin Heater Defroster and Fresh Air System PA 28 235 Serial Nos 28 1104...

Page 969: ...at 1 Fr AirControl 4 Defroster Air Outlet 2 DefrosterControl 5 Fresh Air Inlet 3 Heater Control 6 Cabin ExhaustOutlet 7 HeatDuct Figure 13 9 Cabin Heater Defroster and Fresh Air System PA 28 235 Seria...

Page 970: ...HEAT 1 FRESH AIR CONTROL 4 DEFROSTER AIR OUTLET 2 DEFROSTER CONTROL 5 FREST AIR INLET 3 HEATER CONTROL 6 CABIN EXHAUST OUTLET Figure 13 10 CabinHeater DefrosterandFresh Air System PA 28R 180 and200 R...

Page 971: ...S I...

Page 972: ...ne Compressor to Charge the System 4J20 14 17 Addition of Partial Charge to System 4J21 14 18 Compressor Service 4J22 14 19 Compressor Removal 4J23 14 20 Compressor Installation 4J23 14 21 Checking Co...

Page 973: ...4K16 14 45 Fuse Replacement PA 28 140 S N s 28 7125472 to 28 7325057 PA 28 180 S N s 28 7205092 to 28 7305071 PA 28R 180 S N s 28R 7235001 to 28R 7335057 4K17 14 46 Fuse Replacement PA 28 140 S N s 2...

Page 974: ...design is such that there is no increase in drag to the aircraft during its take off flight conditions During maximum power demands the compressor is de clutched and the condenser door is automaticall...

Page 975: ...0 b 4...

Page 976: ......

Page 977: ...sier with the knowledge that the temperature and pressure of Refrigerant 12 is in close proximity between the pressuresof twenty and eighty pounds per square inch psi A glanceat the temperature pressu...

Page 978: ...nds upon the pressure temperature relationship of pure refrigerant As long as the system contains only pure refrigerant plus a specified amount of compressor oil which is mixed with the refrigerant it...

Page 979: ...the compressor If any doubt exists about the cleanlinessof the compressoroil replaceit with new oil 6 Neverreuseoilremovedfrom the system Discardit 7 When Loctite Refrigerant Sealanthas beenused on a...

Page 980: ...compressor However use of thesevalvesin servicingis not recommended NOTE If a Schrader service valve is not serviceable the core assemblymust be replaced 14 7 SERVICEVALVEREPLACEMENT The valveson the...

Page 981: ...manifold See Figures 14 3and 144 The center port of the manifoldset is used for chargingor evacuationprocedures or any other servicethat may be necessary Both the high and low side of the manifold hav...

Page 982: ...PIPER CHEROKEE SERVICE MANUAL 1257 DIAGRAM A DIAGRAM B DIAGRAM C DIAGRAM D Figure 14 4 Manifold Set Operation Reissued 1 15 81 ACCESSORIES AND UTILITIES 4J14...

Page 983: ...e c Closethe low sidemanifoldvalveand open the highsidemanifoldvalve d Open the refrigerant container servicevalveand allow the pressure at the low side gaugeto reach 50 psi at whichtime closethe high...

Page 984: ...ion of repair of any leaks proceed to check the systemin accordance with one of the methods outlined for any other leaks h If no further repair is required on the system it is now ready to evacuate in...

Page 985: ...ng 29 inchesof mercury or better should be used As we lowerthe pressurein the air conditioningsystem we lower the boiling temperature of the water moisture that may be present Then we are able to pull...

Page 986: ...ontinue to operate the vacuum pump until 26 to 28 inches of vacuum is attained on the low pressuregauge then extend the operation for another 25 minutes g If the system cannot maintain 26 to 28 inches...

Page 987: ...15 WITHA CHARGINGSTAND This isthe preferred method ofchargingthe system NOTE The following instructions apply to Kent Moore J23500 charging stand Referto Figure 14 7 a With the system dischargedand ev...

Page 988: ...e a With the system evacuated as outlined in Paragraph 14 13 connect the refrigerant charging hose to the manifold refer to Figure 14 8 and purge the charging hose of air b Place the refrigerant conta...

Page 989: ...j Shut off the air conditioningsystemand airplaneengine Then removethe charging linesfrom the Schradervalveswith care due to the refrigerantremainingin the hose NOTE A shop cloth should be used to di...

Page 990: ...t to the system Engineshould be operating at 1000 RPM NOTE This should be done with OAT at 700F or higher with the air conditioner operating k Shut off the air conditioner and engine Remove the chargi...

Page 991: ...ing the compressor to the engine mounting brackets 14 20 COMPRESSOR INSTALLATION NOTE In PA 28 140 S N s 28 7125472 and up as required use one 1 NAS1149F0663P washer and or one 1 NAS1149F0632P washer...

Page 992: ...s marked with a stamped K ndicating the key position The oil levelshould be measured from the lowest point in the crankcase Usethe long endof the dipstick SeeFigure 14 9 e With the compressor in the i...

Page 993: ...to the proper pulley sheavesas shownin Figure 14 10 CAUTION Do not force the belts into the pulley sheaves Remove the idler assemblies if necessary and the alternator lower mounting bolts in order to...

Page 994: ...shimmingthe alternator and or the alternator idler pulley in the forward direction On later installations shims can be transferred as required from forward or aft of the alternator mounting lugs to ac...

Page 995: ...nsion specifiedfor a new belt isto compensate for the initial stretch that takes place as soon as it is operated These higher tension valuesshould not be applied to belts whichpreviouslyhave been used...

Page 996: ...4K4 INTENTIONALLYLEFTBLANK...

Page 997: ...AM NUT MOUNTING BRACKET REMOVE SHIMS P N AS REQUIRED FOR COMPRESSOR BELT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 RING GEAR COMPRESSORIDLER PULLEY COMPRESSOR COMPRESSOR ALTERNATOR RING GEAR COMPRESSO...

Page 998: ...CES POINT C and RELATIVE BELT PULLEY CONTACT 14 EDGE FWD POINT A A POINT B ADD SHIMS P N 62833 41 AS REQUIRED FOR PROPER ALTERNATORBELTALIGNMENT PRESENTINSTL BRACKETASSY P N79584 2 ADDORREMOVE SHIMSP...

Page 999: ...UNC 2Bbolt in the threaded portion of the hub and tighten The pressure exertedby the bolt on the end of the compressorcrankshaft willforce off the rotor pulley assembly 2 without damageto the clutch...

Page 1000: ...ture face e Spin the pulley by hand to check for any interference between the field 4 and rotor pulley assemblies 2 A rubbing noise can be heard as the pulley rotates if there is interference The roto...

Page 1001: ...e fitting on top Alignthe fittings to the proper line before securingthe mounting bracket NOTE Torque the fittings SeeTable XIV I b Evacuateand rechargethe systemin accordancewithparagraph 14 13and 14...

Page 1002: ...adNo 576 purchasedfrom PrestoliteEngineeringCompany See Figure 14 12 WARNING Wheneverit is necessaryto removeand replacethe cabinrear panel it should bereplaced and sealedin the originalmanner to prev...

Page 1003: ...on DetailA SEAL ALL AROUND FORWARD AND AFT COVERSWITH PERMAGUM BEAD NO 576 17SS PURCHASED FROM PRESTOUTE ENGINEERING COMPANY 10 Present Installation Detail B LIMITSWITCH 44 ACTUATING TRANSMISSION ASSY...

Page 1004: ...e of the door at the instant the forward edge becomes flush with fuselage c When the above adjustments have been completed assure that the door actuator assembly 1 is fullyretracted and that the door...

Page 1005: ...he capillarycoilfrom the outlet line Do not kink the capillarytube c Uncoupleall related tube fittings SeeParagraph14 5 B 7 NOTE If this part is not serviceable it must be replacedwith a new part 14 3...

Page 1006: ...vaporator housing f Remove the screws attaching the support bracket and evaporator housing to the mounting panel Remove the assembly through the access hole in the bulkhead 14 41 EVAPORATOR ASSEMBLY I...

Page 1007: ...g the cabin After removing and replacing the rear panel conduct a carbon monoxide test on the ground and in flight with and without the air conditioner operating Presence of CO shall not exceedone par...

Page 1008: ...urerelief switch and the condenseractuating motor 14 44 ADJUSTMENTOF THROTTLESWITCH The throttle switchis mounted forward and below the throttle arm The switchmust be adjusted so it willactuate at the...

Page 1009: ...7325058 and up PA 28 180 28 7305072 and up PA 28R 200 28R 7335058 and up There are three fuses located behind the air conditioning system control panel A 20 amp circuit breaker mounted in the circuit...

Page 1010: ...SHOWN WITHACON THROTTLE NOT FULL OPEN CONDENSER DOOROPEN THERMO STAT CALLINGFOR COOING FREON PRESSURE BELOW LIMIT HIGH BLOWER SPEED SELECTED Figure 14 16 Air Conditioning Wiring Schematic PA 28 140Se...

Page 1011: ...OPEN THERMO STATCALLING FOR COOLING FREON PRESSUREBELOW LIMIT HIGH BLOWER SPEEDSELECTED Reissued 1 15 81 Figure 14 17 Air ConditioningWiring Schematic PA 28 140Serial Nos 28 7225132 to 28 7225612 PA...

Page 1012: ...Panel Rear of Cabin Rearof Cabin Intrument Panel Instrument Panel ThrottleQuadrnt R Transmission Assy Rearof Cabin Intrument Panel Transmission Assy LATER 5AF3 S2 COND ON SW OPEN 4 3 RELAY2 CONDITIONI...

Page 1013: ...ystem Evacuateand recharge system 14 13and 14 14 Cleanbugsand dirt fromcondenser fins Straightenfins if bent Checkthat capillary bulb is securely clampedto suction line If capillary bulb OKreplace exp...

Page 1014: ...xpansionvalve inlet screenclogged Inoperativeexpansion valve Valvestuck closedor capillary bulbhas lostits charge Add refrigerant Installnew dryer Evacuate andrecharge 14 13and 14 14 Remove screen Cle...

Page 1015: ...essor Remedy Doorwillnot close when air conditioner switchis in OFF position Systemproduces no cooling Faulty relay K 2 Replacerelay Electrical Blownfuse in control head Opencircuit breaker Brokenor d...

Page 1016: ...igerant line Leak in system Reissued 1 15 81 Checkthermostat and cabin comfort control panel Checkcurrent flow to blowermotor Repair or replace if inoperative Replace drivebelts and or tighten to spec...

Page 1017: ...l Repair as necessary Systemwillnot produce sufficientcooling Electrical Blowermotor sluggish in operation Removeblowermotor for serviceor re placement Mechanical Compressorclutch slipping Obstructed...

Page 1018: ...n receiverdehydrator Excessivemoisture in system Air in system Reissued 1 15 81 Cleanwith cleaning solventto remove cigarettetars Rechargesystemuntil bubbles disappearin receiverdehydrator and gaugere...

Page 1019: ...eration Excessivechargein system Lowchargein system Excessivemoisture in system Reissued 1 15 81 Tightenor replaceas required 14 22and 14 23 Removeclutch for serviceor replace ment asnecessary 14 24 C...

Page 1020: ...sible 2 On end of reel pry off plastic cover over spring Make sure spring does not come out of plastic cover Set aside plastic cover 3 Unwind the harness completely Measure and mark the harness 24 inc...

Page 1021: ...b Position the cover over the motor plate with the motor wires protruding through the cover grommet c With the holes in the cover matching the holes in the motor plate secure the two parts together w...

Page 1022: ...e is no obvious physical damage or condition to prevent operation Determine fullness by weighing or hefting 2 100 Hour Annual Each 100 hours or annually whichever comes first weigh the extinguisher Re...

Page 1023: ...PIPER CHEROKEE SERVICE MANUAL 01 31 08 XIV ACCESSORIES AND UTILITIES 4L7 THIS PAGE INTENTIONALLY BLANK...

Page 1024: ...PIPER CHEROKEE SERVICE MANUAL XIV ACCESSORIES AND UTILITIES 01 31 08 4L8 GRIDS 4L8 THRU 4L24 INTENTIONALLY BLANK...

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Piper Aircraft Corporation Cherokee 140 PA-28-140, Service Manual

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