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Piper Aircraft Corporation Cherokee Series Service Manual

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PIPER AIRCRAFT CORPORATION

PART NUMBER 753-586

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

1A1

January 31, 2008

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Summary of Contents for Piper Aircraft Corporation Cherokee Series

Page 1 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 PART NUMBER 753-586 January 31, 2008...
Page 2 PIPER CHEROKEE SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Cherokee Service Manual (P/N 753-586) originally published August 16, 1972 are as follows: Revision Publication Date Aerofiche Card Effectivity ORG720816 August 16, 1972 CR810115 January 15, 1981 1, 2, 3 and 4 PR810803 August 3, 1981 1, 2, 3 and 4...
Page 3 PIPER CHEROKEE SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A19 HANDLING AND SERVICING 1A24 INSPECTION STRUCTURES 1G13 SURFACE CONTROLS HYDRAULIC SYSTEM (PA-28R) LANDING GEAR AND BRAKES (PA-28) 2E22 VIIA LANDING GEAR AND BRAKES (PA-28R) VIII POWERPLANT (PA-28) VIIIA POWERPLANT (PA-28R)
Page 4 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION 01/31/08...
Page 5 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 2-1. Three View of Cherokee, PA-28-140 and PA-28-150, -160, -180, S/N’s 28-1 thru 28-1760, PA-28-140 Flite Liner, S/N’s 28-7125174 and up ... . . 2-2.
Page 6 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 2-21. Station Reference Lines, PA-28-235, S/N’s 28-7210001 thru 28-7210033 ... . . 1C12 2-22. Station Reference Lines, PA-28-235, S/N’s 28-7310001 and up .
Page 7 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 3-1. Electric Trim Switch Inspection ......3-2.
Page 8 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 4-15. Repairing of Cracks ........1I11 4-16.
Page 9 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 6-5. Pump Shock Mounts ........2D14 6-5a.
Page 10 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 7A-3. Nose Gear Adjustment (Without Gear Up Stop) ....2H16 7A-4. Nose Gear Adjustment (With Gear Up Stop) ....2H16 7A-5.
Page 11 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 8-16. Magneto Timing Marks ........8-17.
Page 12 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 9-6. Fuel Quantity Transmitter (P/N 62037-00) ..... 3C21 9-7.
Page 13 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-7. Checking Voltage Setting Fixed Resistance Method ....4B11 11-8. Checking Voltage Setting Variable Resistance Method ... 4B11 11-9.
Page 14 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-42. Voltage Regulator Fusible Wires ......4C20 11-43.
Page 15 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 13-4. Cabin Heater, Defroster and Fresh Air System, PA-28-150, -160, -180, S/N’s 28-2478 thru 28-4377 ..4I20 13-5. Cabin Heater, Defroster and Fresh Air System, PA-28-180, S/N’s 28-4378 and up .
Page 16 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK LIST OF ILLUSTRATIONS 01/31/08 1A16...
Page 17 PIPER CHEROKEE SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. II-I. Leading Particulars and Principal Dimensions ....1B16 II-II. Not used ..........II-III.
Page 18 PIPER CHEROKEE SERVICE MANUAL LIST OF TABLES (cont.) Table Aerofiche Grid No. X-X. Engine Oil Pressure Gauge ....... . . 3F17 X-XI.
Page 19 PIPER CHEROKEE SERVICE MANUAL SECTION AIRWORTHINESS LIMITATIONS 1A19...
Page 20 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 1A20...
Page 21 PIPER CHEROKEE SERVICE MANUAL SECTION I - AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS Paragraph Section Grid No. AIRWORTHINESS LIMITATIONS 1A22 Limitations 1A22 Inspections 1A22 Life Limited Parts Marking and Disposition 1A22 01/31/08 I - TABLE OF CONTENTS 1A21...
Page 22 PIPER CHEROKEE SERVICE MANUAL AIRWORTHINESS LIMITATIONS NOTE: The Airworthiness Limitations section is FAA approved and specifies maintenance required under §§ 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. Limitations (PIR-TCDS 2A13, Rev. 48.) No limitations related to fatigue life of the airplane and its components have been established for the PA-28-140, PA-28-150, PA-28-160, PA-28-180, PA-28-235, PA-28R-180, and PA-28R-200 Cherokee family of airplanes.
Page 23 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 01/31/08 I - AIRWORTHINESS LIMITATIONS 1A23...
Page 24 PIPER CHEROKEE SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS Paragraph Grid No. 2-1. Introduction ..........2-2.
Page 25 PIPER CHEROKEE SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS (cont.) Paragraph Grid No. 2-35. Landing Gear System ........1D16 2-36.
Page 26 PIPER CHEROKEE SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS (cont.) Paragraph Grid No. 2-74. Draining Oil Sump ........1E11 2-75.
Page 27 PIPER CHEROKEE SERVICE MANUAL SECTION II HANDLING AND SERVICING 2-1. INTRODUCTION. This section contains routine handling and servicing procedures that are most frequently encountered. Frequent reference to this section will aid the individual by providing information such as the location of various components, ground handling procedures, routine service procedures and lubrication.
Page 51 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 01/31/08 II - HANDLING AND SERVICING...
Page 68 PIPER CHEROKEE SERVICE MANUAL 2-8. THREADED FASTENER INSTALLATION (PIR-PPS20015-1, Rev. S.) Fastener Lengths Fastener lengths must be long enough to prevent bearing loads on threads. The complete chamfer or end radius of the fastener or screw must extend through the nut. The specified fastener grip length can be varied by one size (longer or shorter) to meet requirements stated above.
Page 69 PIPER CHEROKEE SERVICE MANUAL 2-8a. TORQUE WRENCHES Torque wrenches should be checked daily and calibrated by means of weights and a measured lever arm to ensure that inaccuracies are not present. Checking one torque wrench against another is not sufficient and is not recommended.
Page 70 PIPER CHEROKEE SERVICE MANUAL If the fastener, screw, or nut is listed in Table II-IV, but the mating fastener is not listed, tighten only to the low end of the torque range specified for the listed fastener. In addition, the following limitations shall apply: Fastener and nut threads shall be clean and dry (free of lubricants).
Page 71 PIPER CHEROKEE SERVICE MANUAL NOTE: When the fastener is stationary and the nut is torqued, use the lower side of the torque range. When the nut is stationary and the fastener is torqued, use the higher side of the torque range.
Page 72 PIPER CHEROKEE SERVICE MANUAL TABLE II-IV. RECOMMENDED NUT TORQUES (SHEET 1 OF 2) Bolts - Steel Bolts - Aluminum AN 3 thru AN 20 MS 20004 AN 3DD Series AN 42 thru AN 49 NAS 333 thru NAS 340 AN 525 NAS 464 MS 20033 thru MS 20046 NAS 624 thru NAS 644...
Page 73 PIPER CHEROKEE SERVICE MANUAL TABLE II-IV. RECOMMENDED NUT TORQUES (SHEET 2 OF 2) Bolts - Steel Bolts - Aluminum AN 3 thru AN 20 MS 20004 AN 3DD Series AN 42 thru AN 49 NAS 333 thru NAS 340 AN 525 NAS 464 MS 20033 thru MS 20046 NAS 624 thru NAS 644...
Page 74 PIPER CHEROKEE SERVICE MANUAL TABLE II-V. CONVERSION TABLES MULTIPLY TO OBTAIN MULTIPLY TO OBTAIN CENTIMETERS 0.3937 KILOGRAMS 2.205 0.03281 35.27 1000 GRAMS CU. CENTIMETERS 0.001 LITERS 0.06102 CU. IN. LITERS 1000 CU. CM. 0.0002642 U.S. GAL. 61.03 CU. IN. 0.03532 CU.
Page 75 PIPER CHEROKEE SERVICE MANUAL TABLE II-V. CONVERSION TABLES (cont.) Example: Convert 1.5 inches to millimeters. (1) Read down inches column to 1. inches. (2) Read across top inch column to 0.5. (3) Read down and across to find millimeters (1.5 inches is 38.10 millimeters). INCHES TO MILLIMETER INCHES 0.0000...
Page 81 PIPER CHEROKEE SERVICE MANUAL Figure 2-32. Jacking Arrangement 2-11. GROUND HANDLING. 2-12. INTRODUCTION TO GROUND HANDLING. This includes jacking, weighing, leveling, mooring, parking, towing and taxiing. Handling the airplane in the manner described in the following paragraphs will minimize damage to the airplane and its equipment. CAUTION: WHEN MOVING AIRPLANE FORWARD BY HAND, AVOID PUSHING ON THE TRAILING EDGE OF THE AILERONS FOR THIS WILL RESULT IN AN OUT OF TRIM CONDITION.
Page 82 PIPER CHEROKEE SERVICE MANUAL Figure 2-33. Weighing Airplane 2-14. WEIGHING. (Refer to Figure 2-33.) For weighing purposes, place the airplane on scales as follows: Position a scale and ramp in front of each of the three wheels. Secure the scales from rolling forward and tow the airplane up onto the scales. (Refer to Paragraph 2-19.) Remove the ramp so as not to interfere with the scales.
Page 83 PIPER CHEROKEE SERVICE MANUAL Figure 2-34. Leveling Longitudinally Figure 2-35. Leveling Laterally 2-16. MOORING. The airplane is moored to ensure its immovability, protection and security under various weather conditions. In order to properly moor the airplane use the following procedures: Head the airplane into the wind, if possible.
Page 84 PIPER CHEROKEE SERVICE MANUAL 2-18. PARKING. When parking the airplane, ensure that it is sufficiently protected against adverse weather conditions and presents no danger to other aircraft. When parking the airplane for any length of time or overnight, it is recommended that it be moored as in Paragraph 2-16. Park the airplane headed into the wind, if possible.
Page 85 PIPER CHEROKEE SERVICE MANUAL 2-20. TAXIING. Before attempting to taxi the airplane, ground personnel should be checked out by a qualified pilot or other responsible person. Engine starting and shutdown procedures should be covered as well. When it is ascertained that the propeller back blast and taxi areas are clear, apply power to start the taxi roll and perform the following checks: Taxi forward a few feet and apply brakes to determine their effectiveness.
Page 86 PIPER CHEROKEE SERVICE MANUAL 2-23. CLEANING. 2-24. CLEANING ENGINE COMPARTMENT. Before cleaning the engine compartment, place a strip of tape on the magneto vents to prevent any solvent from entering these units. Place a pan under the engine to catch waste. With the engine cowling removed, spray or brush the engine with solvent or a mixture of solvent and degreaser, as desired.
Page 87 PIPER CHEROKEE SERVICE MANUAL 2-26. CLEANING EXTERIOR SURFACES. The airplane should be washed with a mild soap and water. Harsh abrasives or detergents used on painted or plastic surfaces could make scratches or cause corrosion of metal surfaces. Cover areas where cleaning solution could cause damage. Cover the mast of the PA-28R-180 gear back-up extender.
Page 88 PIPER CHEROKEE SERVICE MANUAL 2-30. SERVICING. 2-31. INTRODUCTION TO SERVICING. This includes replenishment of fuel, oil, and hydraulic fluids; the maintenance of tire pressures; and the lubrication of various items. 2-32. HYDRAULIC SYSTEM (PA-28R) 2-33. SERVICING HYDRAULIC SYSTEM. The general condition of the hydraulic pump and landing gear actuating cylinders should be checked.
Page 89 PIPER CHEROKEE SERVICE MANUAL 2-37. OLEO STRUTS. (PA-28-140; PA-28-150,-160,-180 and PA-28-235.) 2-38. SERVICING OLEO STRUTS. Air-oil struts are incorporated in each landing gear oleo to absorb the shock resulting from the impact of the wheels on the runway during landing. To obtain proper oleo action, the nose gear oleo strut must have approximately 3.25 ±...
Page 90 PIPER CHEROKEE SERVICE MANUAL There are two methods by which the strut chamber may be filled and these are as follows: Method 1: Remove the valve core from the filler plug at the top of the strut housing. Allow the plug to remain installed.
Page 91 PIPER CHEROKEE SERVICE MANUAL Figure 2-36. Servicing Points PA-28-140 01/31/08 II - HANDLING AND SERVICING 1D19...
Page 92 PIPER CHEROKEE SERVICE MANUAL Figure 2-37. Servicing Points PA-28-150, -160, -180 II - HANDLING AND SERVICING 01/31/08 1D20...
Page 93 PIPER CHEROKEE SERVICE MANUAL Figure 2-38. Servicing Points PA-28-235 01/31/08 II - HANDLING AND SERVICING 1D21...
Page 94 PIPER CHEROKEE SERVICE MANUAL Figure 2-39. Servicing Points PA-28R II - HANDLING AND SERVICING 01/31/08 1D22...
Page 95 PIPER CHEROKEE SERVICE MANUAL 2-40. FILLING MAIN GEAR OLEO STRUT. A main gear oleo strut that is partly full or one that has been completely emptied may be filled with MIL-PRF-5606 fluid as follows: Raise the airplane on jacks until the landing gear torque link assembly has almost reached its full travel.
Page 96 PIPER CHEROKEE SERVICE MANUAL Fully compress and extend (10 + 2-0 inches of strut tube exposed) the strut thus drawing fluid from the strut chambers. By watching the fluid pass through the plastic hose, it can be determined when the strut is full and no air is present in the chambers. The strut must be extended to full ten inches to allow fluid to enter the bottom chamber of strut housing.
Page 97 PIPER CHEROKEE SERVICE MANUAL 2-42. OLEO STRUTS. (PA-28R) 2-43. SERVICING OLEO STRUTS. The air-oil type oleo strut should be maintained at proper strut tube exposures for best oleo action. The nose gear strut must have approximately 2.75 inches of piston tube exposed, while the main gear strut requires approximately 2.0 inches of tube exposure.
Page 98 PIPER CHEROKEE SERVICE MANUAL Fully compress and extend the strut thus drawing fluid from the fluid container and expelling air from the strut chamber. By watching the fluid pass through the plastic hose, it can be determined when the strut is full and no air is present in the chamber. When air bubbles cease to flow through the hose, compress the strut fully and remove the hose from the valve stem.
Page 99 PIPER CHEROKEE SERVICE MANUAL 2-46. BRAKE SYSTEM. 2-47. SERVICING BRAKE SYSTEM. The brake system incorporates a hydraulic fluid reservoir through which the brake system is periodically serviced. Fluid is drawn from the reservoir by the brake cylinders to maintain the volume of fluid required for maximum braking efficiency. Spongy brake pedal action is often an indication that the brake fluid reservoir is running low on fluid.
Page 100 PIPER CHEROKEE SERVICE MANUAL 2-50. TIRES. 2-51. SERVICING TIRES. The tires should be maintained at the pressure specified in Table II-I. When checking tire pressure, examine the tires for wear, cuts, bruises and slippage on the wheel. The tire, tube, and wheel should be properly balanced when installed with the - index mark on the tire aligned with the index mark on the tube.
Page 101 PIPER CHEROKEE SERVICE MANUAL The -6 spacers were made from 1/2 inch aluminum tubing, the two lengths of spacers are suitable for balancing most any aircraft wheel. The -7 bushings may be made from one inch phenolic or aluminum using a 1-1/2 inch hole saw to cut out the smaller bushing and a 1-3/4 hole saw to cut out the larger.
Page 102 PIPER CHEROKEE SERVICE MANUAL 2-52. POWER PLANT. 2-53. SERVICING POWER PLANT. Regularly check the engine compartment for oil and fuel leaks, chaffing of lines, loose wires and tightness of all parts. For cleaning of the engine compartment, refer to paragraph 2-24. Maintenance instructions for the power plant may be found in Section VIII or VIIIA of this manual and in the appropriate manufacturers’...
Page 103 PIPER CHEROKEE SERVICE MANUAL 2-56. SERVICE INSTRUCTION. (CLEANING AND INSPECTION.) The filter should be cleaned daily when operating in dusty conditions and if any holes or tears are noticed, the filter should be replaced immediately. For type of replacement filter, refer to PA-28 Parts Catalog.
Page 104 PIPER CHEROKEE SERVICE MANUAL 2-62. FILLING FUEL TANKS. (PA-28-140; PA-28-150, -160, -180 and PA-28R.) Observe all required precautions for handling gasoline. Fill the fuel tanks with the fuel as specified in Table II-I. Each fuel tank holds a maximum of 25 U.S. gallons. To obtain the standard fuel quantity of 36 U.S.
Page 105 PIPER CHEROKEE SERVICE MANUAL Figure 2-42. Fuel Strainer Figure 2-43. Fuel Selector and Filter PA-28-140; PA-150, -160, -180 PA-28-235 PA-28R Drain each tank through its individual quick drain located at the lower inboard rear corner of the tank, making sure that enough fuel has been drained to ensure that all water and sediment is removed.
Page 106 PIPER CHEROKEE SERVICE MANUAL 2-66. DRAINING FUEL SYSTEM. Fuel may be drained from the system by opening the valve at the inboard end of each fuel tank. Push up on the arms of the drain valve and turn counterclockwise to hold the drain in the open position.
Page 107 PIPER CHEROKEE SERVICE MANUAL The engine manufacturer does not recommend oils by brand names. Use a quality brand Aviation Grade Oil of the proper season viscosity. For information on the use of detergent oil, refer to paragraph 2-77 and/or the latest revision of Lycoming Service Instruction No. 1014. 2-73.
Page 108 PIPER CHEROKEE SERVICE MANUAL 2-77. OIL FILTER. (FULL FLOW.) The oil filter element should be replaced after each 50 hours of engine operation; this is accomplished by removing the lockwire from the bolt-head at the end of the filter housing, loosening the bolt, and removing the filter assembly from the adapter.
Page 109 PIPER CHEROKEE SERVICE MANUAL Remove all excess lubricants from components to prevent collecting dirt and sand in abrasive quantities capable of causing excessive wear or damage to bearing surfaces. 2-80. APPLICATION OF GREASE. When lubricating bearings and bearing surfaces with a grease gun, ensure gun is filled with new, clean grease specified for the particular application before applying lubricant to grease fittings.
Page 110 PIPER CHEROKEE SERVICE MANUAL TABLE II-IX. RECOMMENDED ENGINE LUBRICATING OILS Average Average Ambient Oil Inlet Temperatures Grade Oil Air Temperature Desired Maximum SAE 50 Above 60° F 180° F 245° F (16° C) (82° C) (118° C) SAE 40 30° F to 90° F 180°...
Page 111 PIPER CHEROKEE SERVICE MANUAL TABLE II-XI. LIST OF CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR Adhesive Carboline F-l Carboline Co. 328 Hanley Ind. Ct. St. Louis, MO 63144 Scotch Grip 210 3M Co. Adhesive Coatings (Rubber Adhesive) and Sealers Div. 3M Center St.
Page 112 PIPER CHEROKEE SERVICE MANUAL TABLE II-XI. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION PRODUCT VENDOR Oil, Lubricating, MIL-PRF-7870 General Purpose, Low Temperature Oil, Engine (Piston) Mineral Grade MIL-PRF-6082 Ashless Dispersant MIL-L-22851 Grades O-Ring Lubricant Parker O-Lube Parker Hannifin Corp. O-Ring Division 2360 Palumbo Drive Lexington, KY 40509 PH: 859-269-2351...
Page 113 PIPER CHEROKEE SERVICE MANUAL TABLE II-XII. SPECIAL INSTRUCTIONS 1. BEARINGS AND BUSHINGS - Clean exterior with a quick drying solvent before lubricating. 2. LUBRICATION POINTS - Wipe all lubrication points clean of old grease, oil, dirt, etc., before lubricating. 3. WHEEL BEARINGS - Disassemble and clean with a quick drying solvent. Ascertain that grease is packed between the roller and cone.
Page 114 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. OLEO STRUT FILLER POINT (See Spec. Instr. 4) MIL-PRF-5606 AS REQUIRED 2. UPPER TORQUE LINK BEARING (See Spec. Instr. 1) MIL-PRF-23827 100 HRS 3. TORQUE LINK BUSHING (See Spec. Instr. 1) MIL-PRF-7870 100 HRS 4.
Page 115 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. MAIN GEAR PIVOT POINTS (See Spec. Instr. 1 and 2) MIL-PRF-23827 100 HRS 2. MAIN GEAR DOOR HINGE (See Spec. Instr. 2) MIL-PRF-7870 100 HRS 3. MAIN GEAR TORQUE LINKS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS 4.
Page 116 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. OLEO STRUT FILLER POINT (See Spec. Instr. 4) MIL-PRF-5606 AS REQUIRED 2. STEERING BELLCRANK PIVOT 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.
Page 117 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. NOSE GEAR STRUT HOUSING GREASE FITTING (See Spec. Instr. 2) MIL-PRF-23827 100 HRS. 2. NOSE GEAR PIVOT POINT AND HYDRAULIC CYLINDER ROD END (See Spec. Instr. 2) MIL-PRF-7870 100 HRS 3. NOSE GEAR DOOR RETRACTION MECHANISM (See Spec. Instr. 2) MIL-PRF-7870 100 HRS 4.
Page 118 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. AILERON HINGE PINS (See Spec. Instr. 1 and 12) MIL-PRF-7870 100 HRS 2. FLAP HINGE BEARINGS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS 3. STABILATOR HINGE PINS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS 4.
Page 119 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. FLAP TORQUE TUBE BEARING BLOCKS (See Spec. Instr. 2) MIL-PRF-7870 100 HRS 2. FLAP CONTROL ROD END BEARINGS (See Spec. Instr. 1) MIL-PRF-7870 100 HRS 3. FLAP HANDLE PIVOT POINT, LOCK MECHANISM AND TURNBUCKLE END MIL-PRF-7870 100 HRS...
Page 120 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. RUDDER TUBE 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 4.
Page 121 PIPER CHEROKEE SERVICE MANUAL COMPONENT 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-7870 100 HRS 4.
Page 122 PIPER CHEROKEE SERVICE MANUAL 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-7870 500 HRS 4.
Page 123 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. ENGINE SUMP (See Spec. Instr. 8 and 9) MIL-PRF-6082 50 HRS SEE TABLE II IX 2. CARTRIDGE TYPE OIL FILTER (See Spec. Instr. 8) 50 HRS 3. AIR FILTERS (See Spec. Instr. 7) 50 HRS 4.
Page 124 PIPER CHEROKEE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. DIAPHRAGM SHAFT AND BUSHING MIL-PRF-7870 ABOVE (See Spec. Instr. 15) 20°F MIL-C-21567 BELOW 20°F 100 HRS 2. BACK-UP EXTENDER LINKS AND CONTROL ARM PIVOT POINTS (See Spec. Instr. 2) MIL-PRF-7870 100 HRS 3.
Page 125 PIPER CHEROKEE SERVICE MANUAL 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) Figure 2-54. Lubrication Chart (Air Conditioning Condenser) 01/31/08 II - HANDLING AND SERVICING...
Page 126 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK II - HANDLING AND SERVICING 01/31/08...
Page 127 PIPER CHEROKEE SERVICE MANUAL SECTION INSPECTION (MOVED TO GRID 3H1)
Page 128 PIPER CHEROKEE SERVICE MANUAL GRIDS 1F8 THRU 1G12 INTENTIONALLY BLANK...
Page 129 PIPER CHEROKEE SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS Paragraph Grid No. 4-1. Introduction ..........1G15 4-2.
Page 130 PIPER CHEROKEE SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS (cont.) Paragraph Grid No. 4-42. Installation of Door Latch Mechanism ..... 1H21 4-43.
Page 133 PIPER CHEROKEE SERVICE MANUAL 4-6. INSTALLATION OF WING TIP. PA-28-140; PA-28-150, -160, -180 and PA-28R: Place the wing tip in a position that the navigation light leads may be connected. Connect the ground lead to the wing rib by use of a screw and nut, and the positive lead to the position light by connecting the wire terminals or screwing the connectors together.
Page 134 PIPER CHEROKEE SERVICE MANUAL 4-10. WING FLAP. CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. 4-11. REMOVAL OF WING FLAP. (Refer to Figure 4-1.) Extend the flaps to their fullest degree and remove the bolt and bushing from the rod end bearing by use of an angle or offset screwdriver.
Page 137 PIPER CHEROKEE SERVICE MANUAL 10. Disconnect flaps from the torque tube by fully lowering flaps and removing the bolt and bushing from the bearing at the aft end of the control rod. CAUTION: TO PREVENT DAMAGE AND CONTAMINATION OF FUEL, HYDRAULIC AND OTHER LINES, CAP OR PLUG ALL LINE ENDS WHICH ARE SEPARATED DURING WING REMOVAL.
Page 138 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK IV - STRUCTURES 01/31/08 1G22...
Page 141 PIPER CHEROKEE SERVICE MANUAL PA-28R: Disconnect battery. Close the fuel valve and drain the fuel from the wing to be removed. (Refer to Draining Fuel System, Section II.) Drain the brake lines and reservoir. (Refer to Draining Brake System, Section II.) Drain the hydraulic lines of the landing gear of the wing to be removed by separating the lines and elbows at the actuating cylinder.
Page 142 PIPER CHEROKEE SERVICE MANUAL 18. Remove wing jacks. 19. Remove the front and rear spar to fuselage attach nuts, washers and bolts, discard nuts. (Note number and position of washers at each attach point for reinstallation.) WARNING: DO NOT DRIVE BOLTS IN OR OUT OF THE MAIN SPAR ATTACHING BOLT HOLES (SKETCHES C AND D IN FIGURE 4-2).
Page 143 PIPER CHEROKEE SERVICE MANUAL WARNING: DO NOT DRIVE BOLTS IN OR OUT OF THE MAIN SPAR ATTACHING BOLT HOLES (SKETCHES C AND D IN FIGURES 4-2). TAKE EXTRA CARE IN REMOVING AND REPLACING THESE BOLTS TO PRECLUDE DAMAGING THE BOLT HOLES. NOTE: Top spar cap shims must be in place prior to installing bolts, below.
Page 144 PIPER CHEROKEE SERVICE MANUAL 14. Connect the aileron balance and control cables at the turnbuckles that are located within the fuselage aft of the spar. After the left balance cable has been inserted through the bracket assembly and connected, install a cotter pin cable guard into the hold that is provided in the bracket assembly.
Page 145 PIPER CHEROKEE SERVICE MANUAL Insert the number of washers required between the forward face of the wing fitting and aft face of the fuselage fitting. The maximum number of washers allowed is one of AN960C-516L and one AN960C-516. It is also acceptable to have the faces of the fitting against each other. After the required washers are inserted between the plates, install the bolt and check to ensure that...
Page 146 PIPER CHEROKEE SERVICE MANUAL 20. Service and fill the fuel system in accordance with Servicing Fuel System, Section II. Open the fuel valve and check for leaks and flow. 21. Check the operation of all electrical equipment, pitot and static systems. 22.
Page 147 PIPER CHEROKEE SERVICE MANUAL Figure 4-3. Methods of Securing Control Cables Disconnect trim indicator cable at trim screw and trim tab control arm from the trunnion or screw link by removing nut, washers, bushings and bolt. Disconnect the trim assembly from the aft bulkhead of the fuselage by removing the attaching nuts, washers and bolts of the horizontal and diagonal support brackets.
Page 148 PIPER CHEROKEE SERVICE MANUAL Disconnect the trim assembly from the aft bulkhead of the fuselage by removing the attaching nuts, washers and bolts of the horizontal and diagonal support brackets. 10. Move the trim assembly up through the tail cone fairing cutout in the stabilator and remove, with cable, from the airplane.
Page 149 PIPER CHEROKEE SERVICE MANUAL PA-28-140; PA-28-150, -160, -180, Serial Nos. 28-2171 and up; PA-28-235, Serial Nos. 28-10606 and up; and PA-28R: Insert the stabilator in position and install attaching hinge bolts, washers and nuts. Move the trim assembly through the cutout in the stabilator and attach the brackets of the assembly to the aft bulkhead with bolts, washers and nuts.
Page 150 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK IV - STRUCTURES 01/31/08 1H10...
Page 153 PIPER CHEROKEE SERVICE MANUAL 4-20. STABILATOR TRIM TAB. 4-21. REMOVAL OF STABILATOR TRIM TAB. (Refer to Figure 4-4.) Disconnect the stabilator trim control rod by removing the bolts that attach the control rod to the stabilator trim tab. Remove the stabilator trim hinge pins by cutting one end of the wire pins and removing. The stabilator trim tab can now be removed.
Page 159 PIPER CHEROKEE SERVICE MANUAL lent, between the edges of the outer (heavy gauge) and inner (light gauge) windows, prior to installation. Apply Behr-Manning sealant number PRC 5000 or equivalent, completely around the outer surface of the attachment flanges. Insert the window assembly in the frame and install the retainer moldings. Secure the window and retainer moldings in position by installing the attachment screws.
Page 161 PIPER CHEROKEE SERVICE MANUAL 4-42. INSTALLATION OF DOOR LATCH MECHANISM. Place the latch assembly into position on the door. Connect the latch pull rod to the inside door handle. Replace the screws that attach the latch plate and mechanism to the door. Install the door trim upholstery and secure with screws.
Page 162 PIPER CHEROKEE SERVICE MANUAL 4-48. ADJUSTMENT OF DOOR SAFETY LATCH. (PA-28-140; PA-28-150,-160,-180, Serial Nos. 28-991 and up; PA-28-235 and PA-28R.) To adjust the door safety latch remove the two screws from latch plate found at the top of the door opening.
Page 163 PIPER CHEROKEE SERVICE MANUAL 4-56. RIGGING INSTRUCTIONS - SEAT BACK LOCK AND RELEASE. (Refer to Figure 4-9.) Loosen screws (1 and 2) and ascertain that clamps (3 and 4) are in a relaxed condition. (Push-pull cable (6) is able to move within the clamps.) Place a straightedge along the lower surface of bushing (5) of the seat back release.
Page 164 PIPER CHEROKEE SERVICE MANUAL 4-57. STRUCTURAL REPAIRS. Structural repair methods used may be made in accordance with the regulations set forth in Federal Aeronautics Manual 18 or FAA Advisory circular 43.13-1A. To assist in making repairs, Figure 4-10 identifies the type and thickness of skin structure used. Never make a skin replacement or patch from a material thinner than the original skin.
Page 165 PIPER CHEROKEE SERVICE MANUAL Figure 4-10. Skin Materials and Thickness 01/31/08 IV - STRUCTURES...
Page 166 PIPER CHEROKEE SERVICE MANUAL Figure 4-10. Skin Materials and Thickness (cont.) IV - STRUCTURES 01/31/08...
Page 167 PIPER CHEROKEE SERVICE MANUAL Figure 4-10a. Metal Wire Stitching Repair 01/31/08 IV - STRUCTURES...
Page 168 PIPER CHEROKEE SERVICE MANUAL 4-58. FIBERGLASS REPAIRS. The repair procedure in this manual will describe the methods for repair of fiberglass reinforced structures. Paragraph 4-59 describes Fiberglass Touch-Up and Surface Repairs such as blisters, open seams, delamination, cavities, small holes and minor damages that have not harmed the fiberglass cloth material.
Page 169 PIPER CHEROKEE SERVICE MANUAL After repair has cured for 24 hours, sand patched area using a sanding block with fine wet sandpaper. Finish by priming, again sanding and applying color coat. 4-60. FIBERGLASS FRACTURE AND PATCH REPAIRS. Remove wax, oil and dirt from around damaged area with acetone, methylethylketone or equivalent. Using a key hole saw, electric saber saw, or sharp knife cut away ragged edges.
Page 170 PIPER CHEROKEE SERVICE MANUAL Mix catalyzed resin and work into patch with fingers. Smooth carefully and work into any crevices. Cover with cellophane and squeegee smooth. Allow to cure completely before removing cellophane. Let cure and resand. Brush or spray a coat of catalyzed resin to seal patch. Sand patch, finish by priming, again sanding and applying color coat.
Page 181 PIPER CHEROKEE SERVICE MANUAL TABLE IV-II. BALANCING SPECIFICATIONS Maximum Limits - Flight Conditions (PIR - PPS50015, Rev. AF) STATIC BALANCE LIMITS (INCH-POUNDS) SERIAL NOS. HEAVY SIDE HEAVY SIDE SURFACE MODEL AFFECTED LEADING EDGE TRAILING EDGE STABILATORS PA-28-140 THRU 28-7325614 PA-28-140 28-7425001 AND UP PA-28-150 PA-28-160...
Page 182 PIPER CHEROKEE SERVICE MANUAL 4-72. BALANCING EQUIPMENT (Refer to Figure 4-19). The balancing must be done using a suitable tool capable of measuring unbalance in inch-pounds from the centerline of the control surface hinge pin. See the tool configuration in Figure 4-19. Other tool configurations may be used if accuracy is maintained and recalibration capability is provided.
Page 183 PIPER CHEROKEE SERVICE MANUAL 4-74. BALANCING RUDDER. (Refer to Figure 4-20.) To balance the rudder, the assembly must be complete including the tip assembly with all attaching screws and the position light wiring. Place the complete assembly horizontally on knife edge supports in a draft-free area in a manner that allows unrestricted movement.
Page 184 PIPER CHEROKEE SERVICE MANUAL Figure 4-19. Control Surface Balance Tool IV - STRUCTURES 01/31/08 1I20...
Page 190 PIPER CHEROKEE SERVICE MANUAL Figure 4-25. Additional Drain Holes in Stabilator (Typical) IV - STRUCTURES 01/31/08...
Page 191 PIPER CHEROKEE SERVICE MANUAL 4-79. BAGGAGE COMPARTMENT INSPECTION HOLE AND COVER PLATE. General. Airplanes manufactured before 1979 may not have had control cable inspection access holes in the baggage compartment floor. The following is a method of fabricating inspection access holes in the floor of the baggage compartment, if desired.
Page 194 PIPER CHEROKEE SERVICE MANUAL 4-80. ELECTRICAL BONDING General. (PIR-PPS55006, Rev. U.) All electrical and electronic equipment and specified components shall be installed in such a manner as to provide a continuous low resistance path (bonds) from the equipment enclosure/component to the airplane structure. Bonds must be installed to ensure that the structure and equipment are electrically stable and free from the hazards of lightning, static discharge, electrical shock, etc.
Page 195 PIPER CHEROKEE SERVICE MANUAL TABLE IV-III. ELECTRICAL BONDING RESISTANCE INDEX Maximum Allowable Component Resistance Value in Ohms Engine Mount(s) .003 Generator(s) .010 Ailerons .003 Elevator / Stabilator .003 Rudder .003 Alternator(s) .010 Trim Tab(s) Conventional Hinge .003 Piano Hinge .010 Instrument Panel Inserts .010 Exterior Lights Mounted on Non-Conductive Material...
Page 196 PIPER CHEROKEE SERVICE MANUAL GRIDS 1J8 THRU 1J24 INTENTIONALLY BLANK IV - STRUCTURES 01/31/08...
Page 197 PIPER CHEROKEE SERVICE MANUAL INTRODUCTION...
Page 198 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...
Page 199 PIPER CHEROKEE SERVICE MANUAL INTRODUCTION TABLE OF CONTENTS Paragraph Grid No. Instructions for Continued Airworthiness General Effectivity Serial Number Explanation Assignment of Subject Material Pagination Aerofiche Effectivity Identifying Revised Material Indexing Warnings, Cautions, and Notes Accident / Incident Reporting Supplementary Publications PIPER Publications Vendor Publications 1K10...
Page 200 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION - TABLE OF CONTENTS 01/31/08...
Page 201 PIPER CHEROKEE SERVICE MANUAL INTRODUCTION Instructions for Continued Airworthiness WARNING: INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) FOR ALL NON-PIPER APPROVED STC INSTALLATIONS ARE NOT INCLUDED IN THIS MANUAL. WHEN A NON-PIPER APPROVED STC INSTALLATION IS INCORPORATED ON THE AIRPLANE, THOSE PORTIONS OF THE AIRPLANE AFFECTED BY THE INSTALLATION MUST BE INSPECTED IN ACCORDANCE WITH THE ICA PUBLISHED BY THE OWNER OF THE STC.
Page 202 PIPER CHEROKEE SERVICE MANUAL Effectivity This service manual is effective for PA-28-140/150/160/180/235 and PA-28R-180/200 Cherokee airplanes, serial numbers 28-1 thru 28-7725290 and serial numbers 28R-30001 thru 28R-7635462. This encompasses the following model years: NOTE: The following is provided as a general reference only. Model Sub-Model Serial Numbers...
Page 203 PIPER CHEROKEE SERVICE MANUAL Model Sub-Model Serial Numbers Model Year PA-28-180 28-671 thru 28-820 1962 “B” 28-821 thru 28-1440 1963 28-1441 thru 28-1760A 1964 “C” 28-1761 thru 28-1891 28-1892 thru 28-2792 1965 28-2793 thru 28-3674 1966 28-3675 thru 28-4377 1967 “D”...
Page 204 PIPER CHEROKEE SERVICE MANUAL Serial Number Explanation Example (1961-1970): 28 671 28R 30001 TYPE CERTIFICATE DESIGNATION SEQUENCE NUMBER (No Model Year Designation) (No Model Code) Example (1971 and Up): 28 77 25 163 28R 71 30 001 TYPE CERTIFICATE DESIGNATION SEQUENCE NUMBER MODEL YEAR MODEL CODE...
Page 205 PIPER CHEROKEE SERVICE MANUAL Identifying Revised Material Revisions, additions and deletions are identified by a vertical line (i. e. - change bar) along the left- hand margin of the page opposite only that portion of the printed matter that was changed. Changes in capitalization, spelling or punctuation are not identified by revision lines.
Page 206 PIPER CHEROKEE SERVICE MANUAL B. Vendor Publications: WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. ALTERNATOR: Vendor Address: Kelly Aerospace, Power Systems (888) 461-6077 Airport Complex FAX: (334) 227-8596 P.
Page 207 PIPER CHEROKEE SERVICE MANUAL ENGINE: Vendor Address: Lycoming Engines (717) 323-6181 652 Oliver Street FAX: (717) 327-7101 Williamsport, PA 17701 http://www.lycoming.com/ Overhaul Manual: DIRECT DRIVE MODELS - P/N 60294-7 Parts Catalog: O, IO, LIO-320 Series Engines - P/N PC-103 O-320 A & E Series Engines - P/N PC-203-1 O-320 B &...
Page 208 PIPER CHEROKEE SERVICE MANUAL (10) MAGNETOS: Vendor Address: Teledyne Continental Motors (251) 438-3411 P.O. Box 90 (800) 718-3411 Mobile, AL 36601 FAX: (251) 432-7352 http://www.tcmlink.com Service Support Manual: S-1200 Series High Tension Magnetos, P/N x42001 Service Support Manual: S-20 / S-200 Series High Tension Magnetos, P/N x42002 or, if installed: Vendor Address: Slick Aircraft Products...
Page 209 PIPER CHEROKEE SERVICE MANUAL (12) PROPELLER GOVERNOR: Vendor Address: See listing under Propeller, Hartzell above. Governor Maintenance: Manual No. 130B (13) STARTER: Vendor Address: Sky-Tec (800) 476-7896 350 Howard Clemmons Rd. FAX: (817) 573-2252 Granbury, Texas 76048 http://www.skytecair.com Electro Systems, Inc. See listing under Alternator, above.
Page 210 PIPER CHEROKEE SERVICE MANUAL GRIDS 1K14 THRU 1L24 INTENTIONALLY BLANK INTRODUCTION 01/31/08 1K14...
Page 211 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 PART NUMBER 753-586 January 31, 2008...
Page 212 PIPER CHEROKEE SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Cherokee Service Manual (P/N 753-586) originally published August 16, 1972 are as follows: Revision Publication Date Aerofiche Card Effectivity ORG720816 August 16, 1972 CR810115 January 15, 1981 1, 2, 3 and 4 PR810803 August 3, 1981 1, 2, 3 and 4...
Page 213 PIPER CHEROKEE SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A19 HANDLING AND SERVICING 1A24 INSPECTION STRUCTURES 1G13 SURFACE CONTROLS HYDRAULIC SYSTEM (PA-28R) LANDING GEAR AND BRAKES (PA-28) 2E22 VIIA LANDING GEAR AND BRAKES (PA-28R) VIII POWERPLANT (PA-28) VIIIA POWERPLANT (PA-28R)
Page 214 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 5-1. Control Column Assembly, PA-28-140, -150, -160, -180 and -235 . . 2A16 5-2. Control Column Assembly, PA-28R ......2A17 5-2a.
Page 215 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 7-6. Main Gear Oleo Strut Assembly, PA-28-235 ....2F15 7-7. Main Gear Installation .
Page 216 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 7A-17. Wheel Brake Assembly ........7A-18.
Page 217 PIPER CHEROKEE SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. V-I. Cable Tension Vs. Ambient Temperature ..... . 2A12 V-II.
Page 218 PIPER CHEROKEE SERVICE MANUAL SECTION V - SURFACE CONTROLS TABLE OF CONTENTS Paragraph Grid No. 5-1. Introduction ..........2A10 5-2.
Page 219 PIPER CHEROKEE SERVICE MANUAL SECTION V - SURFACE CONTROLS TABLE OF CONTENTS (cont.) Paragraph Grid No. 5-30. Rudder and Steering Pedal Assembly ......2B22 5-31.
Page 220 PIPER CHEROKEE SERVICE MANUAL SECTION V SURFACE CONTROLS 5-1. INTRODUCTION. This section contains removal, installation, rigging, adjustment and trim procedures for ailerons, flaps (less trim), stabilator and rudder flight control surfaces. Also included are similar procedures for the control column and rudder and steering pedal assembly. For removal, installation, and repair of structural surfaces of the airplane, refer to Section IV.
Page 221 PIPER CHEROKEE SERVICE MANUAL 5-3. STANDARD PROCEDURES. The following tips may be helpful in the removal, installation and rigging of the various assemblies: It is recommended, though not always necessary, to level and place the airplane on jacks during rigging and adjustment. Remove turnbuckle barrels from cable ends before withdrawing the cables through the structures.
Page 222 PIPER CHEROKEE SERVICE MANUAL TABLE V-I. CABLE TENSION VS. AMBIENT TEMPERATURE -10 -8 Subtract Rigging Load Correction, Pounds 5-3a. FLIGHT CONTROL SURFACE TRAVEL. See Table V-II for specifications, see appropriate 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.
Page 223 PIPER CHEROKEE SERVICE MANUAL TABLE V-II. FLIGHT CONTROL SURFACES RIGGING LIMITS (PIR-PPS-50005-1, Rev. K.) 01/31/08 V - SURFACE CONTROLS 2A13...
Page 224 PIPER CHEROKEE SERVICE MANUAL TABLE V-II. FLIGHT CONTROL SURFACES RIGGING LIMITS (cont.) V - SURFACE CONTROLS 01/31/08 2A14...
Page 225 PIPER CHEROKEE SERVICE MANUAL 5-4. CONTROL COLUMN ASSEMBLY. 5-5. REMOVAL OF CONTROL COLUMN ASSEMBLY. (Refer to Figure 5-1 or 5-2.) To remove either control wheel (l) with tube (2), the following procedure may be used: Separate the control wheel tube (2) from the flexible joint (4) that is located on either side of the tee bar assembly (5) by removing the nut, washer and bolt (3).
Page 226 PIPER CHEROKEE SERVICE MANUAL Figure 5-1. Control Column Assembly (Typical) PA-28-140, -150, -160, -180, -235 V - SURFACE CONTROLS 01/31/08 2A16...
Page 227 PIPER CHEROKEE SERVICE MANUAL Figure 5-2. Control Column Assembly PA-28R 01/31/08 V - SURFACE CONTROLS 2A17...
Page 228 PIPER CHEROKEE SERVICE MANUAL 5-6. INSTALLATION OF CONTROL COLUMN ASSEMBLY. (Refer to Figure 5-1 or 5-2.) The tee bar assembly may be installed in the airplane by the following procedure: Swing the tee bar assembly into place from the right side of the cabin and secure with attaching bolts (15), washers and nuts inserted in through each side of the floor tunnel.
Page 229 PIPER CHEROKEE SERVICE MANUAL Connect the control wheel tube (2) to the flexible joint (4) of the tee bar assembly. If the control cables and/or chains have not been removed or loosened, place the ailerons in neutral and install the control tube on the flexible joint to allow the control wheel to be neutral. Install bolt, washer and nut (3) and tighten.
Page 230 PIPER CHEROKEE SERVICE MANUAL Figure 5-3. Aileron Controls (Typical) V - SURFACE CONTROLS 01/31/08 2A20...
Page 231 PIPER CHEROKEE SERVICE MANUAL To remove either the right or left primary control cables (14 or 15) that are located in the fuselage, the following procedure may be used: Remove the two front seats from the airplane. Remove the tunnel cover located aft of the tee bar assembly by the following procedure: (a) PA-28-140;...
Page 232 PIPER CHEROKEE SERVICE MANUAL Disconnect the cable from the aft end of the aileron bellcrank by removing the cotter pin, nut, washer and bolt. Draw the cable from the wing. 5-9. INSTALLATION OF AILERON CONTROL CABLES. (Refer to Figure 5-3.) The installation of either the right or left primary control cable (14 or 15) that is located in the fuselage may be accomplished as follows: Draw the cable through the fuselage floor funnel.
Page 233 PIPER CHEROKEE SERVICE MANUAL If the left cable was removed, install the cotter pin cable guard at the pulley (10) located within the fuselage, aft of the main spar. Check rigging and adjustment per paragraph 5-12. Install the access plate on the underside of the wing. Replace the rear seat bottom or floor panel and the two front seats.
Page 234 PIPER CHEROKEE SERVICE MANUAL 5-12. RIGGING AND ADJUSTMENT OF AILERON CONTROLS. (Refer to Figures 5-4 and 5-5.) CAUTION: VERIFY FREE AND CORRECT MOVEMENT OF AILERONS. WHILE IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY, UPON COMPLETION OF AILERON RIGGING AND ADJUSTMENT, VERIFY THAT THE RIGHT AILERON MOVES UP AND THE LEFT AILERON MOVES DOWN WHEN THE CONTROL WHEEL IS TURNED RIGHT;...
Page 235 PIPER CHEROKEE SERVICE MANUAL Loosen the connecting bolts of the idler cross-over sprockets at the control tee bar to allow the chain to fit snug around the control wheel sprockets, and- over the idler sprockets. Ascertain that both bellcranks are at neutral position. Adjust the turnbuckles, located in the access opening just aft of the main spar, of the primary and balance cables to their proper cable tension and maintain neutral-center position of the control wheels.
Page 236 PIPER CHEROKEE SERVICE MANUAL Figure 5-4. Bellcrank Rigging Tool Application and Fabrication V - SURFACE CONTROLS 01/31/08...
Page 237 PIPER CHEROKEE SERVICE MANUAL Figure 5-5. Aileron Rigging Tool Application and Fabrication 01/31/08 V - SURFACE CONTROLS...
Page 238 PIPER CHEROKEE SERVICE MANUAL 5-14. STABILATOR CONTROLS. 5-15. REMOVAL OF STABILATOR CONTROL CABLES. (Refer to Figure 5-6.) To remove either the forward or aft stabilator cables, first remove the access panel to the aft section of the fuselage located in the baggage compartment, the two front seats, and the baggage area floor panel on the PA-28-140 airplanes or the bottom of the rear seat on the PA-28-150, -160, -180;...
Page 239 PIPER CHEROKEE SERVICE MANUAL 5-16. INSTALLATION OF STABILATOR CONTROL CABLES. (Refer to Figure 5-6.) The forward stabilator cables (2 and 3) may be installed by the following procedure: Draw the control cable through the floor tunnel. Ascertain that the right (upper) cable (2) is routed around the pulley(s) (14) in the forward area of the floor tunnel.
Page 240 PIPER CHEROKEE SERVICE MANUAL Figure 5-6. Stabilator Controls V - SURFACE CONTROLS 01/31/08...
Page 241 PIPER CHEROKEE SERVICE MANUAL 5-17. RIGGING AND ADJUSTMENT OF STABILATOR CONTROLS. CAUTION: VERIFY FREE AND CORRECT MOVEMENT OF STABILATOR. WHILE IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY, UPON COMPLETION OF STABILATOR RIGGING AND ADJUSTMENT, VERIFY THAT THE REAR EDGE OF THE STABILATOR MOVES UP WHEN THE WHEEL IS PULLED BACK;...
Page 242 PIPER CHEROKEE SERVICE MANUAL Figure 5-7. Stabilator Rigging Tool Application and Fabrication V - SURFACE CONTROLS 01/31/08...
Page 243 PIPER CHEROKEE SERVICE MANUAL Check the full travel of the control wheel with relation to the full travel of the stabilator to determine that the stabilator contacts its stops before the control wheel contacts its stops. With the control wheel in the fore and aft positions, the travel distance from the point where the stabilator contacts its stops and the control wheel contacts its stops should be approximately equal.
Page 244 PIPER CHEROKEE SERVICE MANUAL Figure 5-8. Stabilator Trim Control (Overhead Control) V - SURFACE CONTROLS 01/31/08 2B10...
Page 245 PIPER CHEROKEE SERVICE MANUAL 5-20. INSTALLATION OF STABILATOR TRIM ASSEMBLY. (FORWARD.) (Refer to Figure 5-8.) If the trim crank and pulley assembly has been removed, install assembly and secure with attachment screws. Install the forward stabilator trim cable using the following procedure: Attach a line to the right end of the control cable and pull the cable forward to the crank assembly.
Page 246 PIPER CHEROKEE SERVICE MANUAL Figure 5-9. Methods of Securing Trim Cables (b) Disconnect the trim indicator cable (17) from the trim screw trunnion (12) by removing attaching nut, washer and screw. Remove the cotter pin cable guard at the cable pulley (10) located directly below the trunnion.
Page 247 PIPER CHEROKEE SERVICE MANUAL (g) Remove the snap ring, washer and thrust washer from the bottom of the barrel. (h) Disconnect the diagonal and horizontal trim assembly support ribs from one another by removing their four attaching nuts, washers and bolts. (i) Loosen the bolts where the horizontal ribs attach to the fuselage bulkhead, raise the aft end of the ribs, and move the barrel (21) aft far enough to unwrap the trim cable from around the barrel and idler pulleys (18).
Page 248 PIPER CHEROKEE SERVICE MANUAL 5-22. INSTALLATION OF STABILATOR TRIM CONTROLS. (AFT.) (Refer to Figure 5-8.) PA-28-150,-160, -180, Serial Nos. 28-1 to 28-1410 incl. (The exception being airplanes with Piper Kit No. 756 930, Stabilator Trim Modification, installed. Airplanes with this kit installed, refer to step c.) The trim mechanism may be assembled and attached to the aft bulkhead of the fuselage as follows:...
Page 249 PIPER CHEROKEE SERVICE MANUAL Install the forward portion of the cable as given in paragraph 5-20. Wrap the trim cable around the barrel (21) and idler pulley (18). To do this, hold the barrel next to the aft end of the support braces and wrap, bringing the end of the long length (The long length should be the left end of the cable.) aft to the left side of the trim barrel, around the bottom groove of the idler pulley, then continuing to wrap in this direction until all grooves are filled.
Page 250 PIPER CHEROKEE SERVICE MANUAL Route the cable ends into the fuselage and attach the ends to the mating end of the forward cable. Remove the blocks holding the forward cable tight and the aft cables at the barrel. 10. Set cable tension and check rigging and adjustment per paragraph 5-23. Check safety of turnbuckles.
Page 251 PIPER CHEROKEE SERVICE MANUAL 10. Check the bubble of the protractor over the neutral tab and then check tab travels as given in Table V-II. The degree of travel on the protractor is determined by taking the difference between the protractor reading at neutral and up, and neutral and down. The bubble must be centered at each reading with the airplane level.
Page 252 PIPER CHEROKEE SERVICE MANUAL 5-24. STABILATOR TRIM CONTROLS. (FLOOR TRIM.) 5-25. REMOVAL OF STABILATOR TRIM ASSEMBLY. (FORWARD.) (Refer to Figure 5-10.) To remove the trim control wheel assembly and/or the trim control cables, first remove the panel to the aft section of the airplane. If the aft trim cable (12) is not to be removed, block the cables at the pulleys (13) in the upper aft section of the fuselage to prevent them from unwrapping from the trim drum.
Page 253 PIPER CHEROKEE SERVICE MANUAL 5-26. INSTALLATION OF STABILATOR TRIM ASSEMBLY. (FORWARD.) (Refer to Figure 5-10.) The trim control wheel with drum may be installed by the following procedure: Wrap the right trim cable on the trim drum by inserting the swaged ball of the cable in the slot provided in the side (right side) of the drum that mates with the control wheel, and looking at this side, wrap the drum with three wraps of the cable in a clockwise direction.
Page 254 PIPER CHEROKEE SERVICE MANUAL Figure 5-10. Stabilator Trim Control (Floor Control) V - SURFACE CONTROLS 01/31/08 2B20...
Page 255 PIPER CHEROKEE SERVICE MANUAL 5-27. REMOVAL OF STABILATOR TRIM ASSEMBLY. (AFT.) (Refer to Figure 5-10.) Remove the access panel to the aft section of the fuselage. Block the trim cables at the first set of pulleys (33) forward of the cable turnbuckles (10 and 11) in the aft section of the fuselage by a method shown in Figure 5-9.
Page 256 PIPER CHEROKEE SERVICE MANUAL 5-29. RIGGING AND ADJUSTMENT OF STABILATOR TRIM. (FLOOR CONTROL.) PA-28-180, Serial Nos. 28-4378 and up; PA-28-235, Serial Nos. 28-10720 and up; and PA-28R. (Refer to Figure 5-10.) Level the airplane. (Refer to Leveling, Section II.) Check for proper stabilator trim cable tension as given in Table V-II. If cables were disconnected, rotate control wheel several times to allow the cables to seat and recheck tension.
Page 257 PIPER CHEROKEE SERVICE MANUAL Remove the tunnel plate located just aft of the tee bar assembly by the following procedure: PA-28-140; PA-28-150, -160, -180 and PA-28R. Remove the rudder trim control knob, trim cover attaching screws and trim cover. Roll back the carpet from the tunnel and remove the tunnel plate that is located just aft of the tee bar assembly by removing the plate attaching screws.
Page 258 PIPER CHEROKEE SERVICE MANUAL Figure 5-11. Rudder and Steering Pedal Assembly V - SURFACE CONTROLS 01/31/08 2B24...
Page 259 PIPER CHEROKEE SERVICE MANUAL 5-32. INSTALLATION OF RUDDER AND STEERING PEDAL ASSEMBLY. (Refer to Figure 5-11.) Assemble the torque tube assembly (1, 2, 3 and 4) as shown in Figure 5-11. Do not at this time install the two bolts (25 and 26) through the center of the tube assembly. Place the upper support blocks (7) on the ends of the torque tube assembly.
Page 260 PIPER CHEROKEE SERVICE MANUAL 5-33. RUDDER CONTROLS. 5-34. REMOVAL OF RUDDER CONTROL CABLES. (Refer to Figure 5-12.) To remove either the forward (10 or 11) or aft (14 or 15) rudder cables, first remove the access panel to the aft section of the fuselage. Disconnect the desired cable at the turnbuckle (12 or 13) in the aft section of the fuselage.
Page 261 PIPER CHEROKEE SERVICE MANUAL Figure 5-12. Rudder Controls 01/31/08 V - SURFACE CONTROLS...
Page 262 PIPER CHEROKEE SERVICE MANUAL For PA-28-235 only: Place the fuel selector lever on the selector torque tube and secure with pin and cotter pin. 11. Install the lower and upper selector covers and secure with screws. 12. Install the rear seat or floor panel and install the seats. The aft rudder control cables may be installed by the following procedure: Position the control cable in the fuselage.
Page 263 PIPER CHEROKEE SERVICE MANUAL Adjust the turnbuckles in the aft section of the fuselage to obtain proper cable tension as given in Table V-II and to allow the rudder to align at neutral position. Adjust cables evenly to prevent undue strain on aircraft components. Neutral position can be determined by standing behind the airplane and sighting the rudder with the vertical stabilizer or the center of the trim screw.
Page 264 PIPER CHEROKEE SERVICE MANUAL Figure 5-14. Rudder and Stabilator Travel Adjustments On 1974 models (PA-28-140 S/N’s 28-7425001 to 28-7425444, PA-28-180 S/N’s 28-7405001 to 28-7405280, PA-28-235 S/N’s 28-7410001 to 28-7410110, and PA-28R-200 S/N’s 28R-7435001 to 28R-7435323), adjust the rudder pedal stops by pushing on the pilot's left rudder pedal until the rudder stop is contacted.
Page 265 PIPER CHEROKEE SERVICE MANUAL 5-37. RUDDER TRIM CONTROLS. 5-38. REMOVAL OF RUDDER TRIM CONTROLS. (Refer to Figures 5-15 and 5-16.) Remove the cover (1) from over the trim control assembly by removing attaching screws. Remove the rudder trim knob (2) and the cover attaching screws. Rotate the trim knob to the extreme left (counterclockwise) trim position.
Page 266 PIPER CHEROKEE SERVICE MANUAL Figure 5-15. Rudder Trim Control Installation - PA-28-140/150/160/180/235 V - SURFACE CONTROLS 01/31/08...
Page 267 PIPER CHEROKEE SERVICE MANUAL Figure 5-16. Rudder Trim Control 01/31/08 V - SURFACE CONTROLS...
Page 268 PIPER CHEROKEE SERVICE MANUAL 5-41. WING FLAP CONTROLS. 5-42. REMOVAL OF WING FLAP CONTROLS. (Refer to Figure 5-17.) The flap torque tube assembly may be removed by the following procedure: Remove the access plate located between the underside of the aft section of each wing and the fuselage by removing attaching screws.
Page 269 PIPER CHEROKEE SERVICE MANUAL Remove the cotter pin cable guard from the flap cable pulley (24) located inside the floor tunnel just ahead of the spar housing. Remove the cable rub blocks located in the floor opening on the aft side of the spar housing by removing the attaching screws.
Page 270 PIPER CHEROKEE SERVICE MANUAL Figure 5-17. Flap Controls V - SURFACE CONTROLS 01/31/08 2C12...
Page 271 PIPER CHEROKEE SERVICE MANUAL The flap control cable (23) may be installed by the following procedure: Attach the cable and turnbuckle (25) to the flap handle arm and secure with clevis bolt, nut and cotter pin (26). Ascertain that the turnbuckle end is free to rotate on the arm. Route the cable through the tunnel and spar housing.
Page 272 PIPER CHEROKEE SERVICE MANUAL Figure 5-18. Flap Rigging Tool Application and Flap Stop Adjustment V - SURFACE CONTROLS 01/31/08 2C14...
Page 273 PIPER CHEROKEE SERVICE MANUAL To adjust the flap up stop and step lock, loosen the jam nut of the right torque tube stop screw, located in the floor opening along the outer end of the flap torque tube, and turn the stop screw to obtain approximately .60 of an inch between the stop fitting and the bearing block as measured along the top side of the screw.
Page 274 PIPER CHEROKEE SERVICE MANUAL Figure 5-19. Correct Method of Installing Rod End Bearings V - SURFACE CONTROLS 01/31/08 2C16...
Page 275 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 01/31/08 V - SURFACE CONTROLS 2C17...
Page 276 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK V - SURFACE CONTROLS 01/31/08 2C18...
Page 285 PIPER CHEROKEE SERVICE MANUAL SECTION VI - HYDRAULIC SYSTEM TABLE OF CONTENTS Paragraph Grid No. 6-1. Introduction ..........6-2.
Page 287 PIPER CHEROKEE SERVICE MANUAL Figure 6-1. Schematic Diagram of Hydraulic System 01/31/08 VI - HYDRAULIC SYSTEM...
Page 290 PIPER CHEROKEE SERVICE MANUAL TABLE VI-I. LEADING PARTICULARS, HYDRAULIC SYSTEM Hydraulic Pump 96671-002 (Prestolite) 38998-004 (Oildyne) High Pressure 1600 to 2000 psi 2400 ± 200 psi Low Pressure 650 ± 150 psi 600 ± 200 psi Flow Rate @ 1000 psi 45 cu.
Page 291 PIPER CHEROKEE SERVICE MANUAL 6-6. DISASSEMBLY OF HYDRAULIC PUMP. (Refer to Figure 6-3.) After the hydraulic pump has been removed from the airplane, cap or plug all ports and clean the exterior of the pump with a dry type solvent to remove accumulated dust or dirt. To disassemble any one of the three main components of the pump, proceed as follows: The base (16) of the pump may be removed from the case (15) as follows: Cut the safety wire and remove the bolts (17) with washers that secure the base to the pump...
Page 293 PIPER CHEROKEE SERVICE MANUAL 6-8. ASSEMBLY OF HYDRAULIC PUMP. (Refer to Figure 6-3.) The pump motor may be assembled and installed on the pump reservoir assembly as follows: Position the motor frame (referring to Figure 6-3, identified as No. 9) on the reservoir (No. 13).
Page 294 PIPER CHEROKEE SERVICE MANUAL 6-9. TEST AND ADJUSTMENT OF HYDRAULIC PUMP. (Refer to Figure 6-4.) Test Equipment: Hydraulic pump and mounting base. Pressure gauge (0 to 1000 psi). Pressure gauge (0 to 3000 psi). Hoses with fittings to connect between base and gauges. Power supply (14V DC).
Page 295 PIPER CHEROKEE SERVICE MANUAL Figure 6-4. Test and Adjustments of Hydraulic Pump 01/31/08 VI - HYDRAULIC SYSTEM 2D13...
Page 296 PIPER CHEROKEE SERVICE MANUAL 6-10. INSTALLATION OF HYDRAULIC PUMP. Install the rubber shock mounts through the mounting holes of the pump. Insert a bushing through the holes of each shock mount. Position the pump on its mounting flange. Install mounting bolt with washer and tighten.
Page 297 PIPER CHEROKEE SERVICE MANUAL Installation (Refer to Figure 6-5a.) Position assembled pump, bracket, and pump mount on pump deck in airplane. Secure pump assembly to deck by installing the three AN3-10 bolts with one MS35489-64 washer under each bolt head and three No. 5712-45 (Piper P/N 494 192) washers between Piper mount assembly and pump deck.
Page 298 PIPER CHEROKEE SERVICE MANUAL Field Service NOTE: No field repair of Oildyne hydraulic pumps is authorized. Any faulty hydraulic pump must be replaced; or, returned to Piper, via the local piper distributor, for repairs. Field service of the hydraulic pump is limited to removal, cleaning, and inspecting the hydraulic fluid reservoir.
Page 299 PIPER CHEROKEE SERVICE MANUAL Figure 6-5a. Hydraulic Pump/Reservoir (Sheet 1 of 2) 01/31/08 VI - HYDRAULIC SYSTEM 2D17...
Page 300 PIPER CHEROKEE SERVICE MANUAL Figure 6-5a. Hydraulic Pump/Reservoir (Sheet 2 of 2) VI - HYDRAULIC SYSTEM 01/31/08 2D18...
Page 301 PIPER CHEROKEE SERVICE MANUAL Reservoir (3) and Pump-Adapter (2) (Keyed to Figure 6-5a.) CAUTION: DO NOT DISASSEMBLE PUMP ASSEMBLY FROM PUMP ADAPTER. DAMAGE TO VALVES AND CHANGES TO PRESSURE SETTINGS, WHICH ARE NON-ADJUSTABLE, WILL OCCUR. (a) Disassembly Remove screw and O-ring securing the reservoir to the adapter assembly. Remove reservoir and reservoir seal.
Page 302 PIPER CHEROKEE SERVICE MANUAL Figure 6-6. Checking Aligning Brackets of Gear Back-up Extender Actuator and Fabrication of the Aligning Tool VI - HYDRAULIC SYSTEM 01/31/08 2D20...
Page 303 PIPER CHEROKEE SERVICE MANUAL 6-12. GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLY. NOTE: The following instructions apply to actuators P/N 96860-000 (i.e. - SFA232-3 and SFA232-4) only. Disassembly, Assembly, and Cleaning, Inspection and Repair instructions for later model actuators P/N 96860-002 and 96860-003 (i.e. - SFA232-5) are found in Cleveland Wheel and Brakes publication: Component Maintenance Manual - CMSFA232-5 (011-00504) available from the vendor.
Page 304 PIPER CHEROKEE SERVICE MANUAL 6-14. INSTALLATION OF GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLY. (Refer to Figure 6-7.) Position the gear back-up extender actuator against its mounting brackets and install attaching machine screws. Do not tighten screws. NOTE: With the base attached and before installing the attaching screw through the ring of the diaphragm housing, ensure that the attaching holes in the housing and mounting bracket align without using force.
Page 305 PIPER CHEROKEE SERVICE MANUAL Figure 6-7. Gear Back-up Extender Actuator (Sheet 1 of 2) 01/31/08 VI - HYDRAULIC SYSTEM 2D23...
Page 306 PIPER CHEROKEE SERVICE MANUAL Figure 6-7. Gear Back-up Extender Actuator (Sheet 2 of 2) VI - HYDRAULIC SYSTEM 01/31/08 2D24...
Page 307 PIPER CHEROKEE SERVICE MANUAL Adjustment of the gear back-up extender actuator is preset to allow the hydraulic valve (25) of the actuator to open when the airspeed is reduced below 105 MPH with the engine power OFF. This adjustment is accomplished by setting the tension of springs (24) on the actuator with adjustment screw (2).
Page 308 PIPER CHEROKEE SERVICE MANUAL To check adjustment of electrical switch, the following procedure may be used: Place the airplane on jacks. (Refer to Jacking, Section II.) Move the mixture control back to idle cut-off and the throttle to full forward to prevent gear warning horn from sounding during adjustment.
Page 309 PIPER CHEROKEE SERVICE MANUAL Gear Up: Set maximum climb power. Maintain approximately 70 MPH (61 Kts) for approximately 15 seconds. Move the gear selector up. The gear should stay down and locked. Increase the airspeed at the rate of 1 MPH (1 Kt) per second. The gear should begin to retract between 80 and 90 MPH (70 and 78 Kts) at zero density altitude.
Page 310 PIPER CHEROKEE SERVICE MANUAL 6-19. INSTALLATION. Attach the cylinder to its attachment fitting using bolt and nut. Attach the operating rod end to the downlock link using bolt. Install nut after adjustment is completed. Connect the hydraulic lines to the cylinder fittings. Check the adjustment of the cylinder rod end.
Page 311 PIPER CHEROKEE SERVICE MANUAL 6-20. DISASSEMBLY. (Refer to Figure 6-8.) With the cylinder removed from the airplane, remove the fitting from the piston rod (6) end of the cylinder (7). Mark the position of the fitting to facilitate reinstallation. On Syncro Devices nose gear actuating cylinders remove the snap ring (1) from the annular slot in the end of the housing.
Page 312 PIPER CHEROKEE SERVICE MANUAL 6-23. MAIN GEAR ACTUATING CYLINDER. 6-24. REMOVAL. Place the airplane on jacks. (Refer to Jacking, Section II.) Disconnect the hydraulic lines from the actuating cylinder and cover the open line ends to prevent contamination. Disconnect the gear downlock spring from the swivel fitting at the upper end of the spring. Remove the downlock spring swivel fitting and disconnect the cylinder operating rod end from the upper side brace retraction fitting by removing the attaching nut.
Page 313 PIPER CHEROKEE SERVICE MANUAL 6-27. CLEANING, INSPECTION AND REPAIR. Clean the cylinder parts with, a suitable dry type solvent and dry thoroughly. Inspect the cylinder assembly for the following: Interior walls of cylinder and exterior surfaces of piston for scratches, burrs, corrosion, etc. Threaded areas for damage.
Page 314 PIPER CHEROKEE SERVICE MANUAL 6-28. ASSEMBLY. (Refer to Figure 6-10.) Install O-ring (5) on the exterior of the end gland (1). Install O-ring (3) and back-up ring (2) in the interior of the end gland. Install O-ring (8) on the body of the piston assembly. Lubricate the areas around the O-rings with hydraulic fluid, park-o-lube or vaseline, slide the end gland on the piston rod and the piston into the cylinder housing (7).
Page 326 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VI - HYDRAULIC SYSTEM 01/31/08 2E20...
Page 327 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 01/31/08 VI - HYDRAULIC SYSTEM 2E21...
Page 336 PIPER CHEROKEE SERVICE MANUAL Figure 7-2. Nose Gear Installation VII - LANDING GEAR AND BRAKE SYSTEM 01/31/08 (PA-28)
Page 339 PIPER CHEROKEE SERVICE MANUAL TABLE VII-I. NOSE GEAR ALIGNMENT TOLERANCES (PIR-PPS-50005-1, Rev. K.) Rudder Pedal Neutral Angle (Aft of Vertical) (See Figure 7-4.) 8 degrees, 15 minutes 1. PA-28-140, S/N’s 28-20002 thru 28-20520 2. PA-28-150, -160, -180, S/N’s 28-1 thru 28-1760 3.
Page 342 PIPER CHEROKEE SERVICE MANUAL Install the hydraulic brake line. If removed, install the landing gear as described in paragraph 7-19. Service the oleo strut as given in Oleo Struts, Section II. 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.
Page 343 PIPER CHEROKEE SERVICE MANUAL Figure 7-5. Main Gear Oleo Strut Assembly; PA-140, -150, -160, and -180 01/31/08 VII - LANDING GEAR AND BRAKE SYSTEM (PA-28) 2F13...
Page 348 PIPER CHEROKEE SERVICE MANUAL 7-18. REMOVAL OF MAIN LANDING GEAR. (Refer to Figure 7-7.) Place the airplane on jacks. (Refer to Jacking, Section II.) Place a drip pan under the main gear to catch spillage. If desired, remove the air from the oleo chamber by depressing the air valve core pin found in the inspection hole on top of the wing.
Page 374 PIPER CHEROKEE SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING - LANDING GEAR Trouble Cause Remedy Nose landing gear Internal wear in Replace shimmy shimmies during fast taxi, shimmy dampener. dampener. takeoff or landing. Shimmy dampener or Replace necessary bracket loose at parts and bolts. mounting.
Page 375 PIPER CHEROKEE SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING - LANDING GEAR (cont.) Trouble Cause Remedy Main landing gear Tire out of balance. Check balance and replace shimmies during fast taxi, tire if necessary. takeoff or landing. Worn or loose wheel Replace and/or adjust bearings.
Page 379 PIPER CHEROKEE SERVICE MANUAL SECTION VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R) TABLE OF CONTENTS Paragraph Grid No. 7A-1. Introduction ..........7A-2.
Page 380 PIPER CHEROKEE SERVICE MANUAL SECTION VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R) TABLE OF CONTENTS (cont.) Paragraph Grid No. 7A-32. Landing Gear Limit Switches ....... 2I14 7A-33.
Page 381 PIPER CHEROKEE SERVICE MANUAL SECTION VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R) TABLE OF CONTENTS (cont.) Paragraph Grid No. 7A-61. Brake Master Cylinder (Hand Parking Brake) ....7A-62.
Page 389 PIPER CHEROKEE SERVICE MANUAL Figure 7A-2. Nose Gear Installation (Sheet 1 of 2) 01/31/08 VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R) 2H11...
Page 390 PIPER CHEROKEE SERVICE MANUAL 67147 AE 76426 BH (BOLT, AN26-25 (BOLT, AN6-14A WASHER, NAS1149F0663P WASHER, MS35335-35 (UNDER HEAD) (UNDER HEAD) BEARING, 65003-15 BEARING, 65003-15 NUT, AN320-6 NUT, MS21042-6 COTTER PIN, MS24665-285 WASHERS, 62833-10 WASHERS, 62833-10 (3 REQ., SEE NOTE) (3 REQ., SEE NOTE) (STEERING BELLCRANK) (ENGINE MOUNT) (ENGINE MOUNT)
Page 393 PIPER CHEROKEE SERVICE MANUAL The drag links (32 and 35) and gear tension spring arm (53) may be installed by the following procedure: Ascertain that the upper and lower links (32 and 35) are assembled with the downlock hook attached, and the through travel of the links checked according to paragraph 7A-10. Position the link assembly to allow the bolt holes in the links to align with the bolt holes in the gear housing and the engine mount.
Page 394 PIPER CHEROKEE SERVICE MANUAL Figure 7A-3. Nose Gear Adjustment (Without Gear Up Stop) Figure 7A-4. Nose Gear Adjustment (With Gear Up Stop) VIIA - LANDING GEAR AND BRAKE SYSTEM 01/31/08 (PA-28R) 2H16...
Page 395 PIPER CHEROKEE SERVICE MANUAL When adjustment requires less than 0.010 of an inch, the rod end bearing need not be disconnected and therefore all that will be required is to loosen the jam nut, place a wrench on the flat at the end of the piston rod and turn to obtain the correct adjustment.
Page 396 PIPER CHEROKEE SERVICE MANUAL Loosen the jam nut on the rubber bumper stop and turn in approximately three (3) turns. NOTE: Some aircraft are equipped with a large 1 l/8” diameter flat rubber stop. If these stops have washers of any type between the jam nut and the threaded receptacle, remove these washers and discard.
Page 397 PIPER CHEROKEE SERVICE MANUAL Figure 7A-5. Clamping Rudder Pedals Figure 7A-6. Rudder Pedals in Neutral Position at Neutral Angle Adjust the rod end bearings of each steering control rod to align the nose wheel with the chalk line and to bring the rudder pedals into neutral angle fore and aft. On 1974 models install the steering push rods on the pilot's rudder pedals.
Page 398 PIPER CHEROKEE SERVICE MANUAL 7A-15. REMOVAL OF NOSE GEAR DOOR ASSEMBLY. (Refer to Figure 7A-7.) With the nose gear extended, disconnect the door retraction rod (1) from the gear door (2) by removing nut, bolt and washers. The bottom cowl may be removed to facilitate easier removal. To remove the door(s) from the cowl, bend the end of the hinge pin straight and from the other end pull out the pin.
Page 399 PIPER CHEROKEE SERVICE MANUAL 7A-16. CLEANING, INSPECTION AND REPAIR OF NOSE GEAR DOOR ASSEMBLY. Clean all parts with a suitable cleaning solvent. Inspect doors for cracks or damage, loose or damaged hinges and brackets. Inspect door retraction rods for damage and rod end bearing for corrosion. Check the door tension spring for wear and tension below minimum allowable tolerance.
Page 400 PIPER CHEROKEE SERVICE MANUAL 7A-19. MAIN LANDING GEAR SYSTEM. 7A-20. DISASSEMBLY OF MAIN GEAR OLEO. (Refer to Figure 7A-8.) The main gear oleo assembly may be removed and disassembled from the gear oleo housing with the gear removed from or installed on the airplane.
Page 401 PIPER CHEROKEE SERVICE MANUAL 7A-22. ASSEMBLY OF MAIN GEAR OLEO. (Refer to Figure 7A-8.) Ascertain that all parts are cleaned and inspected. To install the piston tube plug (26), first lubricate the plug “O” ring (27) with hydraulic fluid (MIL- PRF-5606) and install it on the plug.
Page 402 PIPER CHEROKEE SERVICE MANUAL Figure 7A-8. Main Gear Oleo Strut Assembly (Sheet 1 of 2) VIIA - LANDING GEAR AND BRAKE SYSTEM 01/31/08 (PA-28R) 2H24...
Page 403 PIPER CHEROKEE SERVICE MANUAL Figure 7A-8. Main Gear Oleo Strut Assembly (Sheet 2 of 2) 01/31/08 VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R)
Page 404 PIPER CHEROKEE SERVICE MANUAL 7A-23. REMOVAL OF MAIN LANDING GEAR. (Refer to Figure 7A-9.) Place the airplane on jacks. (Refer to Jacking, Section II.) The side brace link assembly may be removed by the following procedure: With the gear in the extended position, disconnect the gear downlock spring (18). Disconnect the rod end (46) of the actuating cylinder (24) from the retraction fitting (21) of the upper side brace link (28) by removing the nut, washer and bolt (47) with bushing and spring swivel (20).
Page 405 PIPER CHEROKEE SERVICE MANUAL Figure 7A-9. Main Gear Installation (Sheet 1 of 2) 01/31/08 VIIA - LANDING GEAR AND BRAKE SYSTEM (PA-28R)
Page 406 PIPER CHEROKEE SERVICE MANUAL Figure 7A-9. Main Gear Installation (Sheet 2 of 2) VIIA - LANDING GEAR AND BRAKE SYSTEM 01/31/08 (PA-28R)
Page 407 PIPER CHEROKEE SERVICE MANUAL 7A-24. CLEANING, INSPECTION AND REPAIR OF MAIN LANDING GEAR. Clean all parts with a suitable dry type cleaning solvent. Inspect the gear components for the following unfavorable conditions: Bolts, bearing and bushings for excess wear, corrosion and damage. Gear housing, side brace links, torque links and attachment plates for cracks, bends or misalignment.
Page 408 PIPER CHEROKEE SERVICE MANUAL Figure 7A-9a. Main Landing Gear Trunnion Repair VIIA - LANDING GEAR AND BRAKE SYSTEM 01/31/08 (PA-28R)
Page 409 PIPER CHEROKEE SERVICE MANUAL 7A-24a.MAIN LANDING GEAR TRUNNION REPAIR. (Refer to Figure 7A-9a.) NOTE: This procedure applies only to PA-28R-180 S/N’s 28R-30005 thru 28R-7130007 and PA-28R- 200 S/N’s 28R-35001 thru 28R-7135131 which had Trunnion Assemblies part numbers 67735- 00V (left) and -0lV (right) factory installed. These repair instructions will apply if cracks are discovered in the trunnion web during a routine landing gear system 100-hour or annual inspection.
Page 410 PIPER CHEROKEE SERVICE MANUAL 7A-25. INSTALLATION OF MAIN LANDING GEAR. (Refer to Figure 7A-9.) NOTE: When assembling components of the landing gear, lubricate bearings, bushings and friction surfaces with proper lubricant as described in Section II. Insert a gear support bearing (53 or 54) in each support fitting (1 or 16) and secure with snap rings (2).
Page 411 PIPER CHEROKEE SERVICE MANUAL 7A-26. ADJUSTMENT OF MAIN LANDING GEAR. Place the airplane on jacks. (Refer to Jacking, Section II.) Level the airplane laterally and longitudinally. (Refer to Leveling, Section II.) Disconnect the gear door actuating rods at either the door or the housing, as desired, by removing the rod attachment bolt.
Page 426 PIPER CHEROKEE SERVICE MANUAL then the outer half. The wheel bearing assemblies may be removed from each wheel half by first removing the snap rings (1 or 14) that secure the grease seal retainers (2 or 13), and then the retainers, grease seals (4 or 11) and bearing cones (6 or 10).
Page 427 PIPER CHEROKEE SERVICE MANUAL Figure 7A-17. Wheel Brake Assembly Slide the brake cylinder housing (3) from the torque plate. Remove pressure plate (8) by sliding it off anchor bolts (15) of the housing. The pistons may be removed by injecting low air pressure in the cylinder fluid inlet and forcing the pistons from the housing.
Page 428 PIPER CHEROKEE SERVICE MANUAL 7A-59. CLEANING, INSPECTION AND REPAIR OF WHEEL BRAKE ASSEMBLIES. Clean the assembly with a suitable solvent and dry thoroughly. Check the walls of the cylinder housing and pistons for scratches, burrs, corrosion, etc., that may damage O-rings. Check the general condition of the brake bleeder screw and lines.
Page 429 PIPER CHEROKEE SERVICE MANUAL Figure 7A-18. Brake Disc Minimum Thickness Figure 7A-19. Brake System Installation 7A-62. REMOVAL OF BRAKE MASTER CYLINDER. (Refer to Figure 7A-19.) To remove the brake master cylinder (8) first disconnect the inlet supply line (13) from the fitting at the top of the cylinder and allow fluid to drain from the reservoir and line into a suitable container.
Page 436 PIPER CHEROKEE SERVICE MANUAL 7A-72. INSTALLATION OF BRAKE CYLINDER. (Refer to Figure 7A-21.) Position the cylinder (14) at its mounting points and attach with clevis pin. Safety the pins with cotter pins. (See 16, Figure 7A-21.) Connect the brake lines to the cylinder fittings. Bleed the brakes per Paragraph 7A-73.
Page 451 PIPER CHEROKEE SERVICE MANUAL TABLE VIIA-III. PA-28R MAIN GEAR SERVICE TOLERANCES (cont.) Manufacturer Service Service Fig. No. Part No. Nomenclature Dimension Dimension Tolerance Remarks 67716-04 Trunnion housing, .7508 .749 +0.0 .003 67716-05 side brace attachment .7513 .752 67026-05 Bushing, trunnion .499 .498 .004...
Page 452 PIPER CHEROKEE SERVICE MANUAL SECTION VIII - POWER PLANT (PA-28) TABLE OF CONTENTS Paragraph Grid No. 8-1. Introduction ..........8-2.
Page 453 PIPER CHEROKEE SERVICE MANUAL SECTION VIII - POWER PLANT (PA-28) TABLE OF CONTENTS (cont.) Paragraph Grid No. 8-31. Magneto (Bendix) ........8-32.
Page 465 PIPER CHEROKEE SERVICE MANUAL f. Disconnect the cabin heat and defroster tubes from the muffler. g. Disconnect the primer line at the tee connection. h. Disconnect the throttle and mixture cables at the carburetor and carburetor heat control. The carburetor may be removed if it is found desirable. i.
Page 469 PIPER CHEROKEE SERVICE MANUAL Connect the generator or alternator leads and secure cables with clamps. Connect the oil pressure line, tachometer drive cable, oil temperature lead and the engine vent tube to the aft end of the engine. Connect the vacuum pump line at the pump. Secure the ignition harness, hoses and lines at the aft end of the engine using koroseal lacing.
Page 473 PIPER CHEROKEE SERVICE MANUAL Connect the battery ground wire at the battery. Open the throttle and fuel valve completely; turn on the electric fuel pump and check the fuel lines for leaks. Install the engine cowlings and remove the tail stand. NOTE: To avoid a possible high speed bearing failure resulting from a lack of lubrication during initial starts, refer to the latest revision of Avco-Lycoming Service Instruction No.
Page 474 PIPER CHEROKEE SERVICE MANUAL Figure 8-10. Adjustment of Engine Controls Figure 8-10a. Throttle/Mixture Control Ball Joint Inspection VIII - POWER PLANT (PA-28) 01/31/08 2K24...
Page 475 PIPER CHEROKEE SERVICE MANUAL Check security of cable casing attachments. Pull throttle and mixture knobs in cockpit full aft to ascertain that the idle screw contacts its stop and the mixture control arm contacts its lean position. 8-25. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLS. (PA-28-140, Serial Nos. 28-25000 and up;...
Page 481 PIPER CHEROKEE SERVICE MANUAL Figure 8-16. Magneto Timing Marks Figure 8-17. Timing Pointer 8-34. TIMING PROCEDURE. (Internal Timing) (-20 and -200 Series Magnetos) When installing new or adjusting breaker points and before timing the magneto to the engine, it is important that the internal timing of the magneto be correct.
Page 483 PIPER CHEROKEE SERVICE MANUAL CAUTION: IF CAM SCREW WAS REMOVED, BE SURE TO REPLACE FLAT WASHER, LOCK WASHER AND SCREW. TORQUE TO 25 INCH-POUNDS. With internal timing checked, the magneto may be timed to the engine. (Refer to paragraph 8-35.) 8-35.
Page 485 PIPER CHEROKEE SERVICE MANUAL NOTE: The crankshaft should not be rotated more than 10 degrees in direction opposite normal rotation as the pawl on the impulse coupling will engage with the stop pin and late timing will be indicated through the impulse coupling mechanism. If this should happen, rotate crankshaft in normal direction until sharp click is heard;...
Page 499 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 PART NUMBER 753-586 January 31, 2008...
Page 500 PIPER CHEROKEE SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Cherokee Service Manual (P/N 753-586) originally published August 16, 1972 are as follows: Revision Publication Date Aerofiche Card Effectivity ORG720816 August 16, 1972 CR810115 January 15, 1981 1, 2, 3 and 4 PR810803 August 3, 1981 1, 2, 3 and 4...
Page 501 PIPER CHEROKEE SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A19 HANDLING AND SERVICING 1A24 INSPECTION STRUCTURES 1G13 SURFACE CONTROLS HYDRAULIC SYSTEM (PA-28R) LANDING GEAR AND BRAKES (PA-28) 2E22 VIIA LANDING GEAR AND BRAKES (PA-28R) VIII POWERPLANT (PA-28) VIIIA POWERPLANT (PA-28R)
Page 502 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 3-1. Electric Trim Switch Inspection ......3-2.
Page 503 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 8A-17. Magneto Timing Marks ........3B14 8A-18.
Page 504 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 10-12. Instrument Panel, PA-28-235, S/N’s 28-7410001 and up ..3E15 10-13. Instrument Panel, PA-28R-180, S/N’s 28-30005 thru 28-30879 ..3E16 10-14.
Page 505 PIPER CHEROKEE SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. III-I. Inspection Report, PA-28-140, -150, -160, -180; PA-28-235 ..3H15 III-II. Inspection Report, PA-28R ....... . . III-III.
Page 506 PIPER CHEROKEE SERVICE MANUAL SECTION VIIIA - POWER PLANT (PA-28R) TABLE OF CONTENTS Paragraph Grid No. 8A-1. Introduction ..........3A10 8A-2.
Page 518 PIPER CHEROKEE SERVICE MANUAL Figure 8A-4. - Engine Installation (PA-28R-180) (cont.) POWER PLANT Interim Revision: 2/28/02 3A20...
Page 519 PIPER CHEROKEE SERVICE MANUAL Figure 8A-5. - Engine Installation (PA-28R-200) 01/31/08 VIIIA - POWER PLANT (PA-28R) 3A21...
Page 520 PIPER CHEROKEE SERVICE MANUAL Figure 8A-5. - Engine Installation (PA-28R-200) (cont.) VIIIA - POWER PLANT (PA-28R) 01/31/08 3A22...
Page 522 PIPER CHEROKEE SERVICE MANUAL 8A-16. INSTALLATION OF OIL COOLER. When installing fittings in the oil coolers, care should be used to prevent excessive torque being applied to the cooler. When a rectangular fitting boss is provided, a backup wrench should be used, employing a scissor motion, so that no load is transmitted to the cooler.
Page 523 PIPER CHEROKEE SERVICE MANUAL Figure 8A-6. Adjustment of Engine Controls Figure 8A-6a. Throttle/Mixture Control Ball Joint Inspection 01/31/08 VIIIA - POWER PLANT (PA-28R)
Page 524 PIPER CHEROKEE SERVICE MANUAL 8A-18. INDUCTION AIR FILTER. The filter should be cleaned daily when operating in dusty conditions. If any holes or tears are noticed, the filter must be replaced immediately. Remove the filter element and shake off loose dirt by rapping on a hard flat surface, being careful not to damage or crease the sealing ends.
Page 525 PIPER CHEROKEE SERVICE MANUAL Figure 8A-7. Fuel Injector 8A-20. FUEL INJECTOR. 8A-21. FUEL INJECTOR MAINTENANCE. In general, little attention is required between injector overhauls. However, it is recommended that the following items be checked during periodic inspection of the engine. Check tightness and lock of all nuts and screws which fasten the injector to the engine, torquing all nuts to 135-150 inch-pounds.
Page 527 PIPER CHEROKEE SERVICE MANUAL 8A-22. ADJUSTMENT OF IDLE SPEED AND MIXTURE. Start the engine and warm up in the usual manner until oil and cylinder head temperatures are normal. Check magnetos. If the “mag-drop” is normal, proceed with idle adjustment. Set throttle stop screw so that the engine idles at 550-600 RPM.
Page 530 PIPER CHEROKEE SERVICE MANUAL Figure 8A-10. Contact Points to Figure 8A-10 center). Neither are small pits or mounds, if not too pronounced. If there is a possibility of pit becoming deep enough to penetrate pad, Figure 8A-10, right, reject contact assembly.
Page 533 PIPER CHEROKEE SERVICE MANUAL line on the distributor block should line up between the L and LB marks on the gear. On single contact magnetos the line should favor the L mark, if possible. If the distributor block was removed from the housing, the distributor gear alignment and internal check may be accomplished as followed:...
Page 535 PIPER CHEROKEE SERVICE MANUAL NOTE: The advance timing mark on the top face of the starter ring gear is marked at both 20° and 25° BTC. Use only the 20° BTC mark when timing the magnetos to the engine. NOTE: Verify correct engine timing for the airplane being worked on by checking the engine dataplate.
Page 543 PIPER CHEROKEE SERVICE MANUAL NOTE: If the crimping tool is not available, a satisfactory connection can be made by soldering with Kester Flux 709 or equivalent and a non-corrosive solder. After soldering, clean solder joints using denatured alcohol. 16. Install clamps and cable ties as necessary to secure lead to the engine. 8A-37.
Page 545 PIPER CHEROKEE SERVICE MANUAL 8A-40. INSPECTION AND CLEANING OF SPARK PLUG. Visually inspect each spark plug for the following non-repairable defects: Severely damaged shell or shield threads nicked up, stripped or cross-threaded. Badly battered or rounded shell hexagons. Out-of-round or damaged shielding barrel. Chipped, cracked or broken ceramic insulator portions.
Page 554 PIPER CHEROKEE SERVICE MANUAL SECTION IX - FUEL SYSTEM TABLE OF CONTENTS Paragraph Grid No. 9-1. Introduction ..........3C10 9-2.
Page 563 PIPER CHEROKEE SERVICE MANUAL 9-3. TROUBLESHOOTING. Troubles peculiar to the PA-28 fuel system are listed in Table IX-III along with their probable causes and suggested remedies. When troubleshooting, check from the power supply to the items affected. If no trouble is found by this method, the trouble probably exists inside individual pieces of equipment; they may then be removed from the airplane and an identical unit or units, tested and known to be good, installed in their place.
Page 564 PIPER CHEROKEE SERVICE MANUAL 9-7. INSTALLATION OF MAIN FUEL TANK. Slide the main tank partly into position and connect the sender wire. Slide the tank completely into place and secure with screws around its perimeter. Connect fuel line on inboard side of tank. The flexible hose from the fuel tank must not be twisted during installation on applicable models.
Page 565 PIPER CHEROKEE SERVICE MANUAL 9-14. INSTALLATION OF FUEL QUANTITY TRANSMITTER UNIT. Position the transmitter and gasket to the fuel tank and secure with machine screws or bolts and washers. Torque bolts to 25 inch-pounds. (Tip tank installation, install ground wire under head of mounting screw.) Safety the machine screws with MS20995-C32 wire.
Page 566 PIPER CHEROKEE SERVICE MANUAL TABLE IX-I. TRANSMITTER/FUEL GAUGE TOLERANCES MAIN TANK TIP TANK Actual Fuel in Gauge Reading Actual Fuel in Gauge Reading Tank (U.S. Gal) (U.S. Gal) Tank (U.S. Gal) (U.S. Gal) Full 22 to Full* Full 15 to Full* 17 to 24 7 to 12 12 to 17...
Page 567 PIPER CHEROKEE SERVICE MANUAL Figure 9-6. Fuel Quantity Transmitter Figure 9-7. Fuel Quantity Transmitter (P/N 62037-00; AC Sparkplug) (P/N 68101-00; Stewart Warner) TABLE IX-II. FUEL QUANTITY TRANSMITTER CALIBRATION TOLERANCES (P/N’s 62037-00 or 68101-00 only.) UNIT POSITION RESISTANCE P/N 62037-00 Empty .00 to 0.5 ohms (Metal Float) Full...
Page 568 PIPER CHEROKEE SERVICE MANUAL 9-17. FUEL VALVES. 9-18. FUEL SHUTOFF VALVE. (PA-28-140, -150, -160, -180 and PA-28R.) 9-19. REMOVAL OF FUEL SHUTOFF VALVE. Remove two screws holding the fuel valve placard plate and the screw holding the fuel shutoff valve handle.
Page 569 PIPER CHEROKEE SERVICE MANUAL 9-21. CLEANING, INSPECTION AND REPAIR OF FUEL SHUTOFF VALVE. Aircraft equipped with fuel selector valve P/N 11383-04, must be cleaned, inspected, and repaired per Fuel Selector Valve 400 Hour Inspection (see Special Inspections, Procedures). No cleaning, inspection, or repair is recommended for other fuel selector valves.
Page 570 PIPER CHEROKEE SERVICE MANUAL Figure 9-8. Fuel Selector and Filter (PA-28-235) IX - FUEL SYSTEM 01/31/08 3C24...
Page 573 PIPER CHEROKEE SERVICE MANUAL Figure 9-10. Fuel Filter Bowl and Screen (PA-28-140, -150, -160, -180 and PA-28R) 9-30. FUEL FILTER BOWL AND SCREEN. (PA-28-140, -150, -160, -180 and PA-28R.) (Refer to Figure 9-10.) 9-31. REMOVAL OF FUEL FILTER BOWL AND HOUSING. Ascertain that the fuel shutoff is in the off position.
Page 574 PIPER CHEROKEE SERVICE MANUAL 9-33. CLEANING AND INSPECTION OF FILTER BOWL SCREEN. Follow steps a, b and d of paragraph 9-31 for removal of the filter bowl. Remove the gasket and screen from the filter housing. Clean the screen and bowl with acetone or a suitable dry type solvent. If damaged, replace screen. Replace the screen followed by a new gasket.
Page 581 PIPER CHEROKEE SERVICE MANUAL Install new O-rings. CAUTION: SEAL ALL PIPE THREADS WITH LUBON #404. DO NOT APPLY TO THE FIRST TWO THREADS OR SEALANT MAY ENTER FUEL SYSTEM. Replace fittings. Torque to 230-360 in.-lb. 9-47. ADJUSTMENT OF ELECTRIC FUEL PUMP (BENCH TEST). Ensure that the pump is sufficiently lubricated to prevent damage.
Page 582 PIPER CHEROKEE SERVICE MANUAL 9-49. INSTALLATION OF FUEL PUMP. Place fuel pump inside cover assembly and secure with cap screws, washers and plate. WARNING: IF O-RINGS FECTIVE OR IF INLET FITTING IS NOT PROPERLY INSTALLED, AIR WILL BE DRAWN INTO FUEL LINE, CAUSING ENGINE TO RUN VERY LEAN OR STOP RUNNING.
Page 587 PIPER CHEROKEE SERVICE MANUAL Figure 9-14. Fabricated Fuel Quantity Transmitter Checking Jig 01/31/08 IX - FUEL SYSTEM 3D17...
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Page 589 PIPER CHEROKEE SERVICE MANUAL SECTION X - INSTRUMENTS TABLE OF CONTENTS Paragraph Grid No. 10-1. General ..........3D22 10-1a.
Page 590 PIPER CHEROKEE SERVICE MANUAL SECTION X - INSTRUMENTS TABLE OF CONTENTS (cont.) Paragraph Grid No. 10-36. Sensitive Altimeter ........10-37.
Page 591 PIPER CHEROKEE SERVICE MANUAL SECTION X - INSTRUMENTS TABLE OF CONTENTS (cont.) Paragraph Grid No. 10-73. Oil Temperature Indicator ........3F21 10-74.
Page 592 PIPER CHEROKEE SERVICE MANUAL SECTION X INSTRUMENTS 10-1. GENERAL. The instrumentation in the Cherokee is designed to give a quick and actual indication of the attitude, performance and condition of the airplane. Maintenance, other than described in these sections, shall be done by the instrument manufacturer or an authorized repair station.
Page 594 PIPER CHEROKEE SERVICE MANUAL NOTE: The latest systems which employ a central filter in combination with a differential vacuum gauge will indicate a decline in panel gauge reading when the filter becomes clogged and vacuum declines below the recommended value. The filters should be replaced when gauge reading declines below the recommended value;...
Page 595 PIPER CHEROKEE SERVICE MANUAL TABLE X-I. TROUBLESHOOTING - VACUUM SYSTEM (cont.) Trouble Cause Remedy No vacuum gauge indica- Hose from instrument to Check all lines and tion at instrument. gauge leaking or re- connections. stricted. No vacuum gauge indica- Faulty gauge Mal- Check operation of tion at either instru- functioning, regulator...
Page 596 PIPER CHEROKEE SERVICE MANUAL TABLE X-I. TROUBLESHOOTING - VACUUM SYSTEM (cont.) Trouble Cause Remedy NOTE: Aircraft S/N’s: 28-7125001, 28-7105001, 28-7110001, 28S-7105001, 28R-7130001 and 28R- 7135001 and above. No vacuum gauge indication Filter clogged or dirty. Clean or replace filter. at instrument. Line from gyro to filter restricted.
Page 597 PIPER CHEROKEE SERVICE MANUAL TABLE X-I. TROUBLESHOOTING - VACUUM SYSTEM (cont.) Trouble Cause Remedy Vacuum correct but Regulator sticky. 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.
Page 618 PIPER CHEROKEE SERVICE MANUAL Recheck the high vacuum light by restarting the engine and increasing the RPM. Determine if the high light indicates high vacuum at 5.2 +0.2 -0. If further adjustment is necessary, return to step f. After proper adjustment to the high vacuum light has been made, shut down the engine. Readjust the vacuum regulator by setting throttle at a medium RPM.
Page 619 PIPER CHEROKEE SERVICE MANUAL 10-20. REMOVAL OF VACUUM PUMP. Remove the top portion of the engine cowling. (Refer to Section VIII.) Loosen the hose clamp and remove the hose from the pump fitting. Remove the four retaining nuts, lock washers and plain washers used to secure the pump to the engine;...
Page 620 PIPER CHEROKEE SERVICE MANUAL Before installing any fittings on the pump, check for any external damage. CAUTION: DO NOT APPLY VISE PRESSURE TO THE OUTSIDE DIAMETER OR OVERALL LENGTH OF THE PUMP. When a vise is used to hold the pump while installing fittings, suitable caution must be exercised to avoid pump damage.
Page 621 PIPER CHEROKEE SERVICE MANUAL 10-22a. INSPECTION - AERO ACCESSORIES TEMPEST PUMPS ONLY. (Refer to Figure 10-17a.) These vacuum pumps are available as service replacements. They feature a wear indicator inspection port on the back cover which allows direct observation of pump vane wear. Beginning at 500 hours time- in-service, and each 100 hours thereafter, remove the inspection port plug and observe vane wear as shown in Figure 10-17a.
Page 624 PIPER CHEROKEE SERVICE MANUAL 10-27. REMOVAL AND REPLACEMENT. Refer to Paragraphs 10-4 and 10-82 of this section. 10-28. GYRO HORIZON. 10-29. GENERAL. The gyro horizon is essentially an air driven gyroscope rotating in a horizontal plane and is operated by the same principal as the directional gyro.
Page 626 PIPER CHEROKEE SERVICE MANUAL 10-31. REMOVAL AND REPLACEMENT. Refer to Paragraphs 10-4 and 10-82 of this section. 10-32. RATE OF CLIMB INDICATOR. 10-33. GENERAL. The rate of climb indicator measures the rate of change in static pressure when the airplane is climbing or descending.
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Page 648 PIPER CHEROKEE SERVICE MANUAL SECTION INSPECTION...
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Page 650 PIPER CHEROKEE SERVICE MANUAL SECTION III - INSPECTION TABLE OF CONTENTS Paragraph Grid No. General Time Limits Scheduled Maintenance Description Definitions Inspection Requirements 3H12 Annual / 100 Hour Inspection 3H12 Progressive Inspection 3H12 Overlimits Inspection 3H12 Annual / 100 Hour Inspection Procedure 3H13 Inspection Report (PA-28-140/150/160/180/235) 3H15...
Page 651 PIPER CHEROKEE SERVICE MANUAL SECTION III - INSPECTION TABLE OF CONTENTS (continued) Paragraph Grid No. Soft or Unusual Terrain Procedures Electric Trim Switch Inspection Air Induction Inlet Hose 10 Hour Inspection Spinner/Bulkhead 25 Hour Inspection Fuel Selector Valve 50 Hour Leak Check Stabilator Balance Weight Tube Assembly 200 Hour Inspection Fuel Selector Valve 400 Hour Inspection Induction Air Inlet Duct and Alternate Heat Duct Inspection...
Page 652 PIPER CHEROKEE SERVICE MANUAL INSPECTION General Piper Aircraft, Inc. (Piper) takes a continuing interest in having the owner get the most efficient use from his airplane, and keeping the airplane in the best mechanical condition. To that end, Piper publishes a recurring maintenance schedule which is supplemented with Service Bulletins, Service Letters and Service Spares Letters as required.
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Page 654 PIPER CHEROKEE SERVICE MANUAL Time Limits A. Refer to Section I for the FAA-approved airworthiness limitations section. It sets forth each mandatory replacement time, structural inspection interval, and related structural inspection 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 continued airworthiness of these airplanes.
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Page 656 PIPER CHEROKEE SERVICE MANUAL Scheduled Maintenance WARNING: GROUND THE MAGNETO PRIMARY CIRCUIT (P LEAD), BEFORE PERFORMING ANY MAINTENANCE OPERATION ON THE ENGINE. This section provides instructions for conducting inspections - see Tables III-I (PA-28-140/150/ 160/180/235) and III-II (PA-28R-180/200). Repair or replacement instructions for those components found to be unserviceable during inspections will be found in the applicable airplane system section.
Page 657 PIPER CHEROKEE SERVICE MANUAL B. Checks - Can be performed by pilots and/or mechanics who are qualified on this aircraft and consists of examinations in the form of comparisons with stated standards for the purpose of verifying condition, accuracy and tolerances. C.
Page 658 PIPER CHEROKEE SERVICE MANUAL H. Time - as used in this manual. (1) Time-in-service for aircraft components, unless otherwise specified, is a cumulative total of flight hours or calendar time calculated from the time a new or overhauled component was first installed in any aircraft, and including: (a) the aircraft time that elapses from the initial installation to the first removal, if any;...
Page 659 The Progressive Inspection programs are designed to permit the best utilization of the aircraft through the use of a planned inspection schedule. These schedules are prepared in a manual form, which 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.
Page 660 PIPER CHEROKEE SERVICE MANUAL Annual / 100 Hour Inspection Procedure A. Scheduled Maintenance (i.e. - Tables III-I (PA-28-140/150/160/180) and III-II (PA-28R-180/200) (1) The required periodic inspection procedures are listed in Tables III-I ( PA-28-140/150/160/180) and III-II (PA-28R-180/200). These inspection procedures are broken down into major groups which include Propeller, Engine, Cabin and Cockpit, Fuselage and Empennage, Wing, Landing Gear, Special Inspections, Operational Inspection, and General.
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Page 662 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) A. PROPELLER GROUP WARNING: USE EXTREME CAUTION WHEN ROTATING PROPELLER BY HAND;...
Page 663 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) B. ENGINE GROUP (CONT.) 9. Fill engine with oil per information on cowling or in Lubrication Chart, Sec.
Page 664 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) B. ENGINE GROUP (CONT.) 34. Inspect throttle, carburetor heat, mixture, and propeller governor controls for security, travel and operating condition.
Page 665 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) C. CABIN AND COCKPIT GROUP (CONT.) 8. Inspect parking brake and brake handle for operation and cylinder leaks .... 9.
Page 666 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) D. FUSELAGE AND EMPENNAGE GROUP (CONT.) 10. Inspect refrigerant level in sight gauge of receiver-dehydrator. Refer to Section XIV ......................
Page 667 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) D. FUSELAGE AND EMPENNAGE GROUP (CONT.) 30. Inspect security of Autopilot servo bridle cable clamps. (See Note 14.) ....31.
Page 668 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) E. WING GROUP (CONT.) 17. Inspect all control cables, air ducts, electrical leads, lines, and attaching parts for security, routing, chafing, deterioration, wear, and correct installation.
Page 669 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) H. SPECIAL INSPECTIONS See Special Inspections, Requirements, below. OPERATIONAL INSPECTION NOTE: Refer to Note 19 prior to starting engine or taxiing airplane.
Page 670 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 K. NOTES 1. Refer to Piper's Customer Service Information Aerofiche P/N 1753-755 for latest revision dates to Piper Inspection Reports/Manuals and this service manual. References to Section are to the appropriate Section in this manual. WARNING: INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) FOR ALL NON-PIPER APPROVED STC INSTALLATIONS ARE NOT INCLUDED IN THIS MANUAL.
Page 671 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 K. NOTES (CONT.) 9. Not used. 10. Check cylinders for evidence of excessive heat indicated by burned paint on the cylinders. This condition is indicative of internal damage to the cylinder and, if found, its cause must be determined and corrected before the airplane is returned to service.
Page 672 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 K. NOTES (CONT.) 21. If not accomplished already, create access panels for inspection (refer to Sec. IV, Para. 4-79). Inspect stabilator control cables. In PA-28-140 S/N’s 28-20001 thru 28-7725290, PA-28-150, -160, -180 S/N’s 28-1 thru 28- 4377, PA-28-235 S/N’s 28-10001 thru 28-11039, for airplanes with the original equipment “butterfly”...
Page 673 PIPER CHEROKEE SERVICE MANUAL TABLE III-I - INSPECTION REPORT - PA-28-140/150/160/180/235 K. NOTES (CONT.) In PA-28-140 S/N’s 28-20001 thru 28-7725290, PA-28-150, -160 S/N’s 28-1 thru 28-4377, 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 not installed Piper Kit No. 760-910 or a new greaser bolt P/N 79543-002 and have accumulated 500 hours time-in-service: perform Main Landing Gear Torque Link Greaser Bolt Inspection (see Special Inspections, Procedures).
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Page 676 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) A. PROPELLER GROUP WARNING: USE EXTREME CAUTION WHEN ROTATING PROPELLER BY HAND;...
Page 677 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) B. ENGINE GROUP (CONT.) 9. Fill engine with oil per information on cowling or in Lubrication Chart, Section II .......................
Page 678 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) B. ENGINE GROUP (CONT.) 33. Inspect throttle, alternate air, mixture, and propeller governor controls for security, travel, and operating condition.
Page 679 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) C. CABIN AND COCKPIT GROUP (CONT.) 9. Inspect control wheels, column, pulleys, cables, and fittings. (See Note 14.) ..10.
Page 680 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) D. FUSELAGE AND EMPENNAGE GROUP (CONT.) 11. Inspect air conditioner condenser air scoop for condition and rigging. (See Note 16.) .......................
Page 681 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) D. FUSELAGE AND EMPENNAGE GROUP (CONT.) 30. Inspect ELT battery for condition and date per FAR 91.207 ........ 31.
Page 682 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) E. WING GROUP (CONT.) 15. Inspect fuel tanks for minimum octane markings ..........16.
Page 683 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) G. SPECIAL INSPECTIONS See Special Inspections, Requirements, below. H. OPERATIONAL INSPECTION NOTE: Refer to Note 19 prior to starting engine or taxiing airplane.
Page 684 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 NOTES 1. Refer to Piper's Customer Service Information Aerofiche P/N 1753-755 for latest revision dates to Piper Inspection Reports/Manuals and this service manual. References to Section are to the appropriate Section in this manual. WARNING: INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) FOR ALL NON-PIPER APPROVED STC INSTALLATIONS ARE NOT INCLUDED IN THIS MANUAL.
Page 685 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 NOTES Not used. 10. Check cylinders for evidence of excessive heat indicated by burned paint on the cylinders. This condition is indicative of internal damage to the cylinder and, if found, its cause must be determined and corrected before the airplane is returned to service.
Page 686 PIPER CHEROKEE SERVICE MANUAL TABLE III-II - INSPECTION REPORT - PA-28R-180/200 NOTES 23. Inspection of hydraulic pump brushes applies only to Prestolite pumps. When the brushes wear out, replace pump with a new Oildyne pump - replacement brushes are no longer available. For airplanes which have not installed Piper Kits No.
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Page 688 PIPER CHEROKEE SERVICE MANUAL Special Inspections WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) A. Requirements The following inspections are required in addition to those listed in Scheduled Maintenance, above. These inspections are required at intervals of: Flight hours;...
Page 689 PIPER CHEROKEE SERVICE MANUAL Each 200 Hours For airplanes with flaps which have accumulated ten (10) years time-in-service, conduct the following special inspection each 200 hours: Inspect the interior of the wing flap for evidence of dissimilar metal corrosion where aluminum sheet metal is in contact with steel flap brackets. Use a borescope or other suitable tool.
Page 690 PIPER CHEROKEE SERVICE MANUAL Each 500 Hours (cont.) In PA-150/160/180 S/N’s 28-1761 and up; PA-28-235’s: and PA-28R’s: replace teflon bushings in nose of lower engine cowling. Clean and lubricate stabilator trim drum screw. For PA-28R-180 and -200, and for PA-28-235’s with optional constant speed propeller, remove the constant speed propeller, remove sludge from propeller and crankshaft.
Page 691 PIPER CHEROKEE SERVICE MANUAL Each 1000 Hours Replace engine compartment flexible hoses (fuel, oil, etc.) as required; but not to exceed 1000 hours time-in-service, eight (8) years, or engine overhaul, whichever comes first. Overhaul or replace magnetos, as required, and at engine overhaul. In no case may Slick magneto's time- in-service exceed engine TBO.
Page 692 PIPER CHEROKEE SERVICE MANUAL Each 2000 Hours (cont.) Overhaul engine at 1200, 1400, or 2000 hours time-in-service (see Lycoming Service Instruction No. 1009, latest revision). At engine overhaul or each 2000 hours, whichever comes first, overhaul or replace alternator. Recommended Time-Between-Overhaul (TBO) / Reconditioning of Sensenich fixed-pitch metal propellers is 2000 hours, if propeller does not receive damage requiring immediate attention.
Page 693 PIPER CHEROKEE SERVICE MANUAL (2) Per Calendar Year Each Thirty (30) Days Inspect battery, box or shelf, and cables. Flush box as required and fill battery per instructions on box and in Electrical System, Section XI. If installed, check portable fire extinguisher for condition and charge. Verify nozzle is unobstructed and safety seal is intact.
Page 694 PIPER CHEROKEE SERVICE MANUAL Each Four (4) Years For airplanes equipped with TCM/Bendix Magnetos: overhaul or replace TCM/Bendix magnetos at engine overhaul, or each four (4) years time-in-service, whichever comes first. Each Five (5) Years Overhaul or 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.
Page 695 PIPER CHEROKEE SERVICE MANUAL (3) Per Specific Operation / Operating Environment (a) Operation in High Dust or Industrial Pollution Environment CAUTION: DISCONNECT LINES FROM PITOT/STATIC SYSTEM BEFORE CONDUCTING THIS INSPECTION. Item Inspection Inspection Interval Engine Air Filter. Clean and inspect. Daily.
Page 696 PIPER CHEROKEE SERVICE MANUAL (b) Operation in High Salt or High Humidity Environment (continued) Item Inspection Inspection Interval Instruments and Wiring. Inspect for proper seal of cases and 100 Hours. corrosion. Interior. Inspect upholstery, seat belts, seats and 100 Hours. rugs for corrosion and integrity.
Page 697 PIPER CHEROKEE SERVICE MANUAL B. Procedures (1) ELECTRIC TRIM SWITCH INSPECTION. In PA-28-180s S/N’s 28-4378 thru 28-7105122; PA-28-235s S/N’s 28-11040 thru 28-7110011; PA-28R-180s S/N’s 28R-30005 thru 28R-7130005; PA-28R-200s S/N’s 28R-35001 thru 28R- 7135102; for airplanes equipped with Manual Electric Pitch Trim which have not installed Piper Kit No.
Page 698 PIPER CHEROKEE SERVICE MANUAL Inspect spring to determine if coils consist of 2 l/4 turns or 2 l/2 turns. If coils consist of 2 l/4 turns as shown in Figure 3-1, proceed to Step 7. If coils consist of 2 l/2 turns, modify spring by cutting l/4 turn from top of coils before proceeding.
Page 699 PIPER CHEROKEE SERVICE MANUAL (2) AIR INDUCTION INLET HOSE 10 HOUR INSPECTION. NOTE: Installation of Piper Kit No. 760-328V or 760-334V, as appropriate, relieves this inspection requirement. In PA-28R-180s S/N’s 28R-30004 thru 28R-30478, for airplanes which have not installed Piper Kit No. 760-328V per Piper Service Bulletin No. 297, each 10 hours time-in-service visually inspect the air induction inlet hose, P/N 63633-43 (Figure 3-2), for deterioration, broken or frayed cord wrapping, evidence of hose partially collapsed, indication of...
Page 700 PIPER CHEROKEE SERVICE MANUAL (3) SPINNER/BULKHEAD 25 HOUR INSPECTION. In PA-28R-180s S/N’s 28R-30001 thru 28R-31266, less 28R-31072; and in PA-28R-200s S/N’s 28R-35001 thru 28R-35713, less 28R-35699, 28R-35701, 28R-35703, 28R-35706, 28R-35707, 28R-35708, and 28R-35710; for airplanes which have not installed Piper Kit No. 760-410V per Piper Service Bulletin No. 309, each 25 hours time-in-service inspect the spinner and spinner bulkhead as follows: NOTE: Installation of Piper Kit No.
Page 701 PIPER CHEROKEE SERVICE MANUAL (4) FUEL SELECTOR VALVE 50 HOUR LEAK CHECK. In PA-28-235s S/N’s 28-10001 thru 28-74100093; for airplanes which have not installed Piper Kit No. 757-148 (with the 1-H65-2 valve) or 760-895: each 50 hours check the fuel selector valve for internal leaks using the following procedure.
Page 702 PIPER CHEROKEE SERVICE MANUAL (c) Disconnect stabilator cables at the balance weight tube assembly. NOTE: Do not misplace the bushing fitted in the tube/cable attachment lugs. (d) Remove the stabilator balance weight tube assembly attachment bolts as shown in Figure 3-4 and inspect bolts for wear.
Page 703 PIPER CHEROKEE SERVICE MANUAL Figure 3-4. Stabilator Balance Weight Tube Inspection III - INSPECTION 01/31/08...
Page 704 PIPER CHEROKEE SERVICE MANUAL (6) FUEL SELECTOR VALVE 400 HOUR INSPECTION. In PA-28-140s S/N’s 28-20002 thru 28-26783 and 28-26945 thru 28-7125595; PA-28- 150/160/180s S/N’s 28-l thru 28-7105179; PA-28R-180s S/N’s 28R-30001 thru 28R-7130007; and PA-28R-200s S/N’s 28R-35001 thru 28R-7135163 for airplanes with the original equipment fuel selector valve still installed: each 400 hours time-in-service, annually, or whenever the selector is difficult to rotate, inspect and lubricate the fuel selector valve...
Page 705 PIPER CHEROKEE SERVICE MANUAL Figure 3-5. Fuel Selector Valve Inspection III - INSPECTION 01/31/08 3J10...
Page 706 PIPER CHEROKEE SERVICE MANUAL (8) WING RIB ASSEMBLY W.S. 49.25 INSPECTIONS. The left and right rib assemblies PA-28R-180/200’s, aft of the main spar at W.S. 49.25 can, under certain conditions, crack. The cracking is typically observed vertically along the bend radius of the flange common to the main spar and the main landing gear side brace attach fitting (see Figure 3-6).
Page 707 PIPER CHEROKEE SERVICE MANUAL (b) 500 Hour Wing Rib Inspection. Except as described above, each 500 hours time-in-service: Place the airplane on jacks per Sec. II, Para. 2-13. In both the right and left wings: Remove the Main Landing Gear Side Brace, by removing the five (5) bolts that fasten it to the wing structure.
Page 708 PIPER CHEROKEE SERVICE MANUAL If a crack is detected, identify the path of the propagation, and determine if trimming, as shown in Figure 3-7, will remove all the material affected by the crack. If so, install the appropriate kit (see above). If this cannot be accomplished, replace the cracked Rib Assembly.
Page 709 PIPER CHEROKEE SERVICE MANUAL (9) WING SPAR INSPECTION. WARNING: FAILURE TO FULLY COMPLY WITH THIS INSPECTION COULD SERIOUSLY AFFECT THE STRUCTURAL INTEGRITY; SAFETY AND AIRWORTHINESS OF THE AIRCRAFT. (a) Background On March 30, 1987, a PA-28 engaged in pipeline patrol operations suffered an inflight wing separation resulting in a fatal accident.
Page 710 PIPER CHEROKEE SERVICE MANUAL Usage Class “B” - Severe Aircraft which have engaged in severe usage, involving contour or terrain following operations, (such as power/pipeline patrol, fish/game spotting, aerial application, aerial-advertising, police patrol, livestock management or other activities) where a significant part of the total flight time has been spent below one-thousand (1000) feet AGL altitude.
Page 711 PIPER CHEROKEE SERVICE MANUAL Inspection Requirements. Next 50 Hours: For airplanes in “Usage Class D” (i.e. - unknown usage), conduct Wing Spar Inspection and establish usage class for next inspection based on current aircraft operations. Each 800 Hours: In PA-28-235’s only, for airplanes in “Usage Class B”...
Page 712 PIPER CHEROKEE SERVICE MANUAL Visually inspect, using a 10-power (minimum) magnifying glass and a dye- penetrant method or equivalent, for cracks in the wing lower spar cap from the wing skin line outboard of the outboard row of wing attach bolt holes to an area midway between the second and third row of bolt holes from the outboard row.
Page 713 PIPER CHEROKEE SERVICE MANUAL (11) STABILATOR ATTACH FITTINGS CORROSION INSPECTION. At each annual or 100 hour inspection or anytime the stabilator is removed: (a) Remove upper and lower tailcone fairing assembly. (b) Remove the aft fuselage closeout plate assembly, if so equipped. (c) Inspect the steel attach fittings (4 places) for the stabilator and adjacent fuselage structure for rust and/or corrosion.
Page 714 PIPER CHEROKEE SERVICE MANUAL (12) FLAP CONTROL CABLE ATTACHMENT BOLT INSPECTION. (See Figure 3-9.) Each 100 hours time-in-service, or annually, whichever comes first, inspect the flap control cable attachment bolt as specified below. Should any evidence of wear be detected replace the bolt.
Page 715 PIPER CHEROKEE SERVICE MANUAL (13) AFT WING ATTACH FITTINGS 100 HOUR INSPECTION. (a) Background Should the seals for the windows and doors not be maintained, leaks may develop which, if not corrected, will allow water ingress. This water contamination will wet the insulation around the aft wing attach fittings creating a highly corrosive environment.
Page 716 PIPER CHEROKEE SERVICE MANUAL If using insulation other than Piper original material, be sure that the insulation is flame resistant and conforms to FAR part 23.853. If the insulation material has not been wet, or if new material is being installed, ensure a six (6) inch clearance in the insulation has been cut out in all directions around each attach fitting.
Page 717 PIPER CHEROKEE SERVICE MANUAL Figure 3-11. Drain Hole Installation III - INSPECTION 01/31/08 3J22...
Page 718 PIPER CHEROKEE SERVICE MANUAL (c) Removal and Installation Procedure (if required). (See Figure 3-10.) NOTE: If both fittings are to be changed, remove and replace one fitting at a time. Remove electrical power from aircraft by disconnecting the battery. Place jacks under wings and tail - tie down to stabilize aircraft. Remove seats, removable floorboards and interior panels necessary to gain access to the rear wing attach fittings.
Page 719 PIPER CHEROKEE SERVICE MANUAL Figure 3-12. Fuel Tank and Wing Spar Corrosion Inspection III - INSPECTION 01/31/08 3J24...
Page 720 PIPER CHEROKEE SERVICE MANUAL (14) FUEL TANK/WING SPAR CORROSION INSPECTION. Paragraphs (a) and (b) are keyed to Figure 3-12 (i.e. – (a)1 corresponds to A1 in figure). (a) Each seven calendar years time-in-service, remove the fuel tanks and conduct inspections as specified below.
Page 721 PIPER CHEROKEE SERVICE MANUAL (c) If a crack is detected, prior to further flight, replace the "cast" main gear strut cylinder with the "forged" main gear strut cylinder per Section VII. (d) If no cracks are detected, thoroughly clean the surfaces and touch-up paint and primer removed during the inspection process.
Page 722 PIPER CHEROKEE SERVICE MANUAL (17) CONTROL CABLE INSPECTION. Aircraft control cable systems are subject to a variety of environmental conditions and forms of deterioration that, with time, may be easy to recognize as wire/strand breakage or the not- so-readily visible types of wear, corrosion, and/or distortion. The following data may help in detecting the presence of these conditions: (a) Cable Damage.
Page 723 PIPER CHEROKEE SERVICE MANUAL (b) External Wear Patterns. Wear will normally extend along cable equal to the distance cable moves at that location. Wear may occur on one side of the cable only or on its entire circumference. Replace flexible and non-flexible cables when individual wires in each strand appear to blend together (outer wires worn 40-50 percent) as depicted in Figure 3-15.
Page 724 PIPER CHEROKEE SERVICE MANUAL (d) Corrosion. Carefully examine any cable for corrosion that has a broken wire in a section not in contact with wear producing airframe components such as pulleys, fairleads, etc. It may be necessary to remove and bend the cable to properly inspect it for internal strand corrosion as this condition is usually not evident on the outer surface of the cable.
Page 725 PIPER CHEROKEE SERVICE MANUAL (f) Cable Fittings. 100 Hour Standard Inspection. Check swaged terminal reference marks for any indication of cable slippage within fitting. Inspect fitting assembly for distortion and/or broken strands at the terminal. Check that all bearings and swivel fittings (bolted or pinned) pivot freely to prevent binding and subsequent failure.
Page 726 PIPER CHEROKEE SERVICE MANUAL Figure 3-17. Pulley Wear Patterns CAUTION: WHEN REMOVING OR INSTALLING COUPLING CLAMP, SLIDE CLAMP OVER END OF PIPE BEFORE ASSEMBLY / DISASSEMBLY. EXCESSIVE SPREADING CAN LEAD TO PREMATURE FAILURE OF CLAMP. NOTE: When installing an exhaust clamp having an alignment pin be certain that the pin engages the mating holes in exhaust pipe and muffler to prevent separation of components.
Page 727 PIPER CHEROKEE SERVICE MANUAL If any component is inaccessible for a thorough visual inspection, accomplish one of the following: (a) Accomplish a submerged pressure check of the muffler and exhaust stack at 2 psi air pressure. (b) Conduct a ground test using a carbon monoxide 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 airstream inside the cabin at each outlet (including rear seat heat outlet, if installed).
Page 728 PIPER CHEROKEE SERVICE MANUAL Figure 3-19. Exhaust System Inspection Points (Sheet 1) 01/31/08 III - INSPECTION...
Page 729 PIPER CHEROKEE SERVICE MANUAL Figure 3-19. Exhaust System Inspection Points (Sheet 2) III - INSPECTION 01/31/08 3K10...
Page 730 PIPER CHEROKEE SERVICE MANUAL (19) FIELD CHECK OF PA-28R-180 and PA-28R-200 MUFFLER ASSEMBLIES. (Refer to Figure 3-20.) (a) Remove end clips. (b) Check for any movement between the heater muff end plates and the muffler pipes in the directions shown on Figure 3-20. If there is no movement, the muffler assembly is acceptable.
Page 731 PIPER CHEROKEE SERVICE MANUAL (20) CONTROL WHEEL 100 HOUR INSPECTION. (Refer to Figure 3-21.) NOTE: Installation of “ram’s horn” control wheels (P/N 78729-002 (.75 inch dia. shaft) or 79276-000 (1.25 inch dia. shaft)) eliminates this repetitive inspection requirement. PA-28-140 S/N’s 28-20001 thru 28-7725290, PA-28-150, -160, -180 S/N’s 28-1 thru 28- 4377, PA-28-235 S/N’s 28-10001 thru 28-11039, for airplanes with the original equipment “butterfly”...
Page 732 PIPER CHEROKEE SERVICE MANUAL Figure 3-22. Aileron Hinge Doubler 100 Hour Inspection 01/31/08 III - INSPECTION 3K13...
Page 733 PIPER CHEROKEE SERVICE MANUAL (22) MAIN LANDING GEAR TORQUE LINK INSPECTION NOTE: Installation of the service replacement improved torque link P/N 78032-000 relieves this repetitive inspection requirement. The new links must be installed in pairs and each pair will require two washers P/N 63312-002. In PA-28-140 S/N’s 28-20001 thru 28-7225496, PA-28-150, -160, -180 S/N’s 28-03, 28-1 thru 28-7205293;...
Page 734 PIPER CHEROKEE SERVICE MANUAL (23) UPPER NOSE GEAR OLEO BEARING INSPECTION. (Refer to Figure 3-24.) NOTE: Installation of the service replacement upper nose gear oleo bearing P/N 452-419 relieves this 500 hour inspection requirement. PA-28-150, -160, -180 S/N’s 28-1 thru 28-90, 28-92 thru 28-365, 28-367 thru 28-764, 28- 766 thru 28-886, 28-888 thru 28-1109, 28-1111 thru 28-1146, 28-1148 thru 28-1154, 28-1156 thru 28-1206, 28-1209 thru 28-1218, 28-1220 thru 28-1223, 28-1225 thru 28-1227, 28-1229, 28-1232, 28-1233, 28-1235 thru 28-1237, 28-1239 thru 28-1245, 28-1248 thru 28-1251, 28-...
Page 735 PIPER CHEROKEE SERVICE MANUAL Figure 3-24. Upper Nose Gear Oleo Bearing Inspection III - INSPECTION 01/31/08 3K16...
Page 736 PIPER CHEROKEE SERVICE MANUAL Figure 3-25. Rudder Bar Assembly 100 Inspection 01/31/08 III - INSPECTION 3K17...
Page 737 PIPER CHEROKEE SERVICE MANUAL (25) REAR SEAT QUICK DISCONNECT MECHANISM INSPECTION (See Figure 3-26.) NOTE: This inspection incorporates the requirements of Piper Service Letter No. 763 as referenced in AD 75-24-2. (a) Inspection. In PA-28-180 S/N’s 28-7105001 thru 28-7505046, PA-28-235 S/N’s 28- 7110001 thru 28-7510016, PA-28R-180 S/N’s 28R-7130001 thru 28R-7130013 and PA- 28R-200 S/N’s 28R-7135001 thru 28R-7535041: each 100 hours or at each annual...
Page 738 PIPER CHEROKEE SERVICE MANUAL Figure 3-26. Retention Clip Adjustment Figure 3-27. Main Landing Gear Torque Link Greaser Bolt Inspection (d) If any cracks are found, replace the bolt: When replacing bolts shown in Sketch “A,” install Piper Kit No. 760-910V. NOTE: For bolts shown in Sketch “A,”...
Page 739 PIPER CHEROKEE SERVICE MANUAL (27) WING AFT SPAR-TO-FUSELAGE ATTACHMENT HARDWARE 100 HOUR INSPECTION Each 100 hours time-in-service, inspect the aft wing spar-to-fuselage attachment hardware for both the right and left wings, as follows: NOTE: Perform the following with weight on wheels (i.e. - not on jacks). (a) Remove the lower wing-to-fuselage fairing in the area of the wing aft spar.
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Page 744 PIPER CHEROKEE SERVICE MANUAL Unscheduled Maintenance Checks WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) The following inspections are required in response to specific anomalies encountered during aircraft operation.
Page 745 PIPER CHEROKEE SERVICE MANUAL B. Engine Overspeed, Overtemp, Loss of Oil, or Sudden Stoppage Item Inspection Inspection Interval Engine. See latest revisions of appropriate Each occurrence, Lycoming Service Bulletins before further flight. and Overhaul Manual. Propeller. Refer to latest Sensenich Repair Manual. Each occurrence, (Sudden Stoppage only.) Remove and recondition before...
Page 746 PIPER CHEROKEE SERVICE MANUAL C. Severe Turbulence, Hard or Overweight Landing (continued) Item Inspection Inspection Interval Wheel Wells and Landing Buckling, cracks, overstress, wing skin Each occurrence, Gear attach points. buckling, and side brace for before further flight. (Not required for damage and condition.
Page 747 PIPER CHEROKEE SERVICE MANUAL Flood Damage, Immersion in Water A. These guidelines are general in nature and should be applied or varied to fit the individual aircraft according to water level, length of time of exposure and other variables. Only those areas that might not be obvious to the mechanic are addressed.
Page 748 PIPER CHEROKEE SERVICE MANUAL Flood Damage, Immersion in Water (continued) Item Inspection Inspection Interval Engine. Remove, disassemble, and inspect. If immersed, each event, Examine all parts paying particular before further flight. attention for evidence of corrosion, rust or contaminants imbedded on bearing surfaces, piston, mounting flanges or any aluminum, magnesium or bronze surface that may be porous.
Page 749 PIPER CHEROKEE SERVICE MANUAL Flood Damage, Immersion in Water (continued) Item Inspection Inspection Interval Electrical Systems. Replace all circuit breakers and If immersed, each event, switches. before further flight. Replace all solenoids, relays and master contactors. Replace battery. Disassemble all connectors; clean and inspect for corrosion.
Page 750 PIPER CHEROKEE SERVICE MANUAL Flood Damage, Immersion in Water (continued) Item Inspection Inspection Interval Vacuum and Pitot-Static Replace gyros. If immersed, each event, Systems. before further flight. Replace filters. Clean and inspect all lines, and pitot and static vents. Clean and check all regulating valves. Remove and inspect engine driven and auxiliary vacuum pumps.
Page 751 PIPER CHEROKEE SERVICE MANUAL Flood Damage, Immersion in Water (continued) Item Inspection Inspection Interval Avionics Systems. Replace avionics. If immersed, each event, before further flight. Clean and inspect antennas and connectors. Insulation and Upholstery. Remove all wet insulation and upholstery. If immersed, each event, Thoroughly clean and dry (or replace) before further flight.
Page 752 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 01/31/08 III - INSPECTION...
Page 753 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK III - INSPECTION 01/31/08 3L10...
Page 754 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST This table is a cumulative list of Piper service publications (i.e. - Service Bulletins and Service Letters) applicable to the airplane models covered by this manual, with the following exceptions: A. Service publications which have been fully incorporated into this manual are not listed, B.
Page 755 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28-140 1964-1973 SB 395 Warning - Improper Use of Rudder Pedals (cont.) SB 789A 764-998 Aft Wing Spar Modification SB 789A 765-106 Aft Inboard Wing Access Panel Retrofit SL 620 760-729 Forward Cabin Door Reinforcement...
Page 756 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28-140 1973-1974 SL 734 760-857 Bendix ADF-T-12 (cont.) 1974 SL 700 760-842 Toe Brake System Modification SL 715 760-876 ELT Switch Cover Modification 1974-1975 SB 450 Fuel Gascolator Quick Drain Valve Inspection...
Page 757 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28-150 1961-1967 SL 845 763-828 Engine Breather Tube Winterization Kit (cont.) SL 864 III 763-874 Turn & Slip Indicator Conversion 1961-1970 SB 317 760-451 Vertical Fin Rib Inspection SB 326...
Page 758 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28-160 1961-1967 SB 896 Shoulder Harness Installation and Usage (cont.) SB 1022 Inspection of Induction Air Filter / Purolator SB SB 1026 Airborne SL 48 / Dry Air Pump Flexible Couplings SB 1041 Airborne SL 56 / Air Filter Inspection &...
Page 759 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28-180 1962-1967 SB 313 Magneto Filter Terminals (cont.) SL 864 III 763-874 Turn & Slip Indicator Conversion 1962-1970 SB 317 760-451 Vertical Fin Rib Inspection SB 322 760-477 Vacuum Pump Adapter Drive Assembly...
Page 760 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28-180 1968-1969 SL 535A Rudder Trim Locking Pin - Securing (cont.) 1968-1970 SB 305 Carburetor Drain Plugs Inspection 1968-1975 SB 548 Engine Control Rod End Bearing Inspection SL 758 761-065 Bendix Ignition Switches Inspection...
Page 761 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28-235 1964-1966 SB 237 757-085 Rudder Trim Installation Mod (cont.) SB 240 Corrosion Inspection - Aileron, Stabilator, Rudder SB 285 760-251 Fuel Selector Control Stop Assembly SB 313 Magneto Filter Terminals 1964-1967...
Page 762 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28-235 1966-1972 SB 357A Alternator Output Wire Terminal Replacement (cont.) 1966-1977 SB 811A 765-186 Ammeter Replacement 1967 SB 376 760-682 Fuel Selector Control System Mod 1967-1968 SB 281 R.C.
Page 763 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28R-180 1967-1969 SB 295 Control Wheel Retaining Pin (cont.) SB 774 760-456 Baggage Door Latch Replacement 1967-1970 SB 316 Flight Manual Weight and Balance Data Revision SB 317 760-451 Vertical Fin Rib Inspection...
Page 764 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28R-180 1967-1971 SL 988 764-377 Nose Landing Gear Modification (cont.) VSP-155 Cleveland SB 7076 - Inspect/Repl Gear Actuator VSP-174 Lycoming SB 569 - Crankshaft Retirement 1968 SB 281 R.C.
Page 765 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28R-200 1969-1977 SB 738 Nose Landing Gear Actuator Rod End Inspection (cont.) SB 805A Hartzell SB No. 142B - O-Ring Deterioration SB 836A Aluminum Wire Inspection / Replacement SB 866A 765-303...
Page 766 PIPER CHEROKEE SERVICE MANUAL TABLE III-III. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-28R-200 1975-1976 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 &...
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Page 768 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 PART NUMBER 753-586 January 31, 2008...
Page 769 PIPER CHEROKEE SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Cherokee Service Manual (P/N 753-586) originally published August 16, 1972 are as follows: Revision Publication Date Aerofiche Card Effectivity ORG720816 August 16, 1972 CR810115 January 15, 1981 1, 2, 3 and 4 PR810803 August 3, 1981 1, 2, 3 and 4...
Page 770 PIPER CHEROKEE SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A19 HANDLING AND SERVICING 1A24 INSPECTION STRUCTURES 1G13 SURFACE CONTROLS HYDRAULIC SYSTEM (PA-28R) LANDING GEAR AND BRAKES (PA-28) 2E22 VIIA LANDING GEAR AND BRAKES (PA-28R) VIII POWERPLANT (PA-28) VIIIA POWERPLANT (PA-28R)
Page 771 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 11-1. Generator and Starter System ....... 4A18 11-2.
Page 772 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-39. Meter Connections for Alternator Performance Test ... . . 4C17 11-40. Voltage Regulator ........4C19 11-41.
Page 773 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 13-4. Cabin Heater, Defroster and Fresh Air System, PA-28-150, -160, -180, S/N’s 28-2478 thru 28-4377 ..4I20 13-5. Cabin Heater, Defroster and Fresh Air System, PA-28-180, S/N’s 28-4378 and up .
Page 774 PIPER CHEROKEE SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. XI-I. Electrical System Schematic Index ......4A12 XI-II.
Page 779 PIPER CHEROKEE SERVICE MANUAL TABLE XI-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS Subject Figure GRID NO. Electrical System Schematic, PA-28-140, S/N’s 28-20000 thru 28-24999 ....... . 11-54 4F11 Electrical System Schematic, PA-28-140, S/N’s 28-25000 thru 28-7325052 .
Page 780 PIPER CHEROKEE SERVICE MANUAL TABLE XI-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS (cont) Subject Figure GRID NO. Alternator, Starter, Cabin Light, Cigar Lighter and External Power Receptacle, PA-28-140, S/N’s 28-7325053 thru 28-7425454 ......11-86 4G21 Alternator, Starter, Cabin Light, Cigar Lighter and External Power Receptacle, PA-28-140, S/N’s 28-7525001 &...
Page 781 PIPER CHEROKEE SERVICE MANUAL TABLE XI-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS (cont) Subject Figure GRID NO. Engine Gauges, PA-28-235, S/N’s 28-7510001 & up ........11-133 4H20 Engine Gauges, PA-28-140, S/N’s 28-7525001 &...
Page 782 PIPER CHEROKEE SERVICE MANUAL TABLE XI-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS (cont) Subject Figure GRID NO. Landing Gear, PA-28R-200, S/N’s 28-7435001 thru 28-7435331 ......11-91 Landing Gear, PA-28R-200, S/N’s 28-7535001 &...
Page 783 PIPER CHEROKEE SERVICE MANUAL TABLE X-I. INDEX - ELECTRICAL SYSTEM SCHEMATICS (cont) Subject Figure GRID NO. Pitot Heat, PA-28-140, S/N’s 28-7325053 thru 28-7425454 ......11-115 4H12 Pitot Heat, PA-28-180, S/N’s 28-7305064 thru 28-7305611;...
Page 817 PIPER CHEROKEE SERVICE MANUAL Figure 11-21. Testing Rectifiers (Positive) The meter reading for each of the rectifiers should be the same. Always contact the connection nearest the rectifiers. Do not break the sealing on the rectifier lead wire or on the top of the rectifiers. The sealing material is used for corrosion protection.
Page 872 PIPER CHEROKEE SERVICE MANUAL Figure 11-145. Strobe Light Connections 01/31/08 XI - ELECTRICAL SYSTEM...
Page 897 PIPER CHEROKEE SERVICE MANUAL TABLE XI-V. ELECTRICAL WIRE CODING (PIR-PPS55006, Rev. V.) Circuit Function Letter Circuit AUTOPILOT AIR CONDITIONING CONTROL SURFACE ENGINE INSTRUMENT FLIGHT INSTRUMENT LANDING GEAR HEATER, VENTILATING & DEICING IGNITION STARTER LIGHTING MISC. EQUIP. - (Cigar Lighter, Hour Meter, etc.) DC POWER FUEL &...
Page 945 PIPER CHEROKEE SERVICE MANUAL SECTION XII - ELECTRONICS TABLE OF CONTENTS Paragraph Grid No. 12-1. Introduction ..........12-2.
Page 948 PIPER CHEROKEE SERVICE MANUAL Figure 12-2. ELT Portable Folding Antenna (Narco) Figure 12-3. ELT Using Fixed Aircraft Antenna (Narco) XII - ELECTRONICS 01/31/08...
Page 956 PIPER CHEROKEE SERVICE MANUAL 12-17. AUTOFLIGHT. - GENERAL. Due to the wide variety of A.F.C.S. (Automated Flight Control System) options, it is mandatory to follow the service literature published by the individual manufacturer of the A.F.C.S. equipment installed in any particular airplane. This includes mechanical service such as; adjusting, bridle cable tension, servo removal &...
Page 957 PIPER CHEROKEE SERVICE MANUAL 12-20. RACK-MOUNTED AVIONICS (PIR-PPS60237, Rev. New.) Late-model avionics are rack-mounted, front-removable units generally secured to the instrument panel tray/rack by a single jackscrew located in the center of their faceplate. If installed, they should be removed and installed as follows: Removal Insert an appropriate size (generally 3/32 inch) allen wrench into the jackscrew access hole in the faceplate.
Page 972 PIPER CHEROKEE SERVICE MANUAL SECTION XIV- ACCESSORIES AND UTILITIES TABLE OF CONTENTS Paragraph Grid No. 14-1. Air Conditioning Installation ....... 14-2.
Page 973 PIPER CHEROKEE SERVICE MANUAL SECTION XIV- ACCESSORIES AND UTILITIES TABLE OF CONTENTS (cont.) Paragraph Grid No. 14-39. Evaporator Assembly ........4K14 14-40.
Page 974 PIPER CHEROKEE SERVICE MANUAL SECTION XIV ACCESSORIES AND UTILITIES 14-1. AIR CONDITIONING INSTALLATION. 14-2. DESCRIPTION. This installation consists of a compressor with its special bracketry, an evaporator, a condenser, a receiver-dehydrator, circulating fan, thermal expansion valve, and related plumbing. The evaporator filters, dehumidifies and cools the air. The evaporator is mounted in a fabricated housing along with the receiver-dehydrator, circulating fan, thermal expansion valve and related plumbing.
Page 991 PIPER CHEROKEE SERVICE MANUAL 14-19. COMPRESSOR REMOVAL. (The removal of the compressor requires a complete system discharge.) See Paragraph 14-12. Be certain the circuit protector is off for the air conditioning system. Remove the engine cowling and right front baffles. Disconnect the electrical leads to the magnetic clutch on the compressor.
Page 1006 PIPER CHEROKEE SERVICE MANUAL 14-39. EVAPORATOR ASSEMBLY. The evaporator assembly consists of the evaporator core, receiver-dehydrator, expansion valve, circulating fan and pressure switch together with necessary housing and plumbing. The housing is fabricated of Cycolac type material. The condensed moisture is dumped overboard through a hose clamped to a fitting on the bottom of the evaporator housing.
Page 1020 PIPER CHEROKEE SERVICE MANUAL 14-47. RESTRAINT SYSTEM. Inspections. Shoulder Harness: (a) Inspect ends and attachment points for condition and security. (b) Inspect harness web material for condition and wear over its entire length. Particularly look for wear and fraying where harness web passes in and out of inertial reel. If excessively worn, replace.
Page 1021 PIPER CHEROKEE SERVICE MANUAL Remove the inlet and outlet hoses from the blower assembly by removing the clamps. Remove the screws, washers and nuts that secure the blower assembly to the hangar braces. Remove the screws and washers which secure the blower assembly to the retainer and hangars. Remove the blower assembly from the aircraft.
Page 1022 PIPER CHEROKEE SERVICE MANUAL TABLE XIV-V. BLOWER SYSTEM WIRE COLOR CODES MOTOR WIRES AIRCRAFT WIRES Pin. 15920-01 E362Q F0018075FA Nos. General Singer Leece- Aircraft Industries Controls Neville Harness Nos. Ground Brown Brown Black AC26A Low Speed Yellow Yellow Black Medium Speed Black White High Speed...
Page 1023 PIPER CHEROKEE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 01/31/08 XIV - ACCESSORIES AND UTILITIES...
Page 1024 PIPER CHEROKEE SERVICE MANUAL GRIDS 4L8 THRU 4L24 INTENTIONALLY BLANK XIV - ACCESSORIES AND UTILITIES 01/31/08...

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