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Piper Cherokee PA-28 Service Manual PA-28-140 -150 -160 -180 -235 PA-28R-180 -200 (Part Number 753-586)
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Comprehensive factory Piper Cherokee PA-28 Service Manual (Part Number 753-586) covering PA-28-140, PA-28-150, PA-28-160, PA-28-180, PA-28-235, PA-28R-180, and PA-28R-200. Features complete servicing, ground handling, structural repair, wing and landing gear maintenance, and control surface balancing in an instant PDF download.
SKU: PIP-PA28-SM-753586-HD
Category: Aviation Manuals
Tags: Piper Aircraft Part Number 753-586, Piper Cherokee PA-28 Service Manual, Piper Cherokee PA-28-140 180 235 Manual, Piper PA-28R Arrow Service Manual
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Description
Piper Cherokee PA-28 Service Manual PA-28-140 -150 -160 -180 -235 PA-28R-180 -200 (Part Number 753-586)
The Piper Cherokee PA-28 Service Manual PA-28-140 -150 -160 -180 -235 PA-28R-180 -200 (Part Number 753-586) is the factory-authorized technical reference engineered for aircraft mechanics, certified repair stations, and aircraft owners maintaining the classic Piper PA-28 Cherokee fleet[cite: 1]. Originally published by Piper Aircraft Corporation and updated through the manufacturer revision of January 31, 2008, this manual represents Card 1 of the official four-card aerofiche technical publication series[cite: 1]. Covering extensive factory engineering specifications, this document details handling, servicing, ground operations, structural wing splice attachments, landing gear overhaul, control surface balancing, and composite airframe repair procedures across all early and mid-production fixed-gear and retractable Cherokee models[cite: 1].
File Details
- Document Title: Piper Cherokee Service Manual (Card 1 of 4)[cite: 1]
- Part Number: 753-586 (Revision PR080131)[cite: 1]
- Brand / Manufacturer: Piper Aircraft Corporation[cite: 1]
- Applicable Aircraft Models: Piper Cherokee PA-28-140, PA-28-140 Flite Liner, PA-28-150, PA-28-160, PA-28-180, PA-28-235, PA-28R-180 Cherokee Arrow, and PA-28R-200 Cherokee Arrow II[cite: 1]
- Document Language: English[cite: 1]
- Page Count: 1024 pages
- File Format: Adobe PDF
- Original Publication Date: August 16, 1972[cite: 1]
- Latest Revision Date: January 31, 2008[cite: 1]
Chapters Covered
- Section Index & Aerofiche Revision Status: Aerofiche card effectivity schedule, comprehensive section index guide, detailed numerical list of figures, and complete list of tables[cite: 1].
- Section I — Airworthiness Limitations: FAA-approved airworthiness limitations specifying mandatory maintenance under FAR §§ 43.16 and 91.403, Type Certificate Data Sheet (TCDS 2A13 Rev. 48) fatigue life statements, and 14 CFR Part 43.10 life-limited aircraft parts marking, tracking, and destruction disposition mandates[cite: 1].
- Section II — Handling and Servicing: Principal dimensions and detailed three-view engineering drawings; fuselage station (Sta.), wing station/buttock line (BL), and water line (WL) coordinate systems; access plate and inspection panel location diagrams; required workshop tools and fabricated equipment; threaded fastener installation, grip length rules, and NAS1149 washer limitations; self-locking fastener usage criteria; torque wrench extension math formulas; Table II-III flare fitting torque values; Table II-IV recommended nut torque schedules (fine and coarse thread series, friction drag torque determination, and permissible gap closing torque); metric conversion tables (Table II-V); drill size equivalents (Table II-VI); fluid tubing support spacing (Table II-VII); hose clamp installation tightening (Table II-VIII); Cherrylock rivet removal steps; ground handling procedures (jacking, tail support ballast, longitudinal and lateral leveling, scale weighing, mooring, towing precautions, and taxiing checks); Piper External Power (PEP) operation; cleaning guidelines for engine compartments, landing gear, windshields, side windows, and upholstery; hydraulic system servicing for retractable PA-28R models (fluid checks, reservoir maintenance, and back-up extender checks); landing gear oleo strut servicing, MIL-PRF-5606 fluid filling, and static load air inflation; brake system reservoir servicing and bleeding; tire servicing and shop-built dynamic tire balancer construction; engine induction air filter cleaning; propeller inspection and lubrication; fuel system draining, tank capacities (standard 25-gallon main tanks and PA-28-235 17-gallon auxiliary tip tanks), and MIL-DTL-27686 anti-icing additive blending; electrical battery servicing; engine oil system procedures (50-hour oil changes, suction screens, pressure screens, full-flow cartridge filter inspection for metallic debris, and mineral-to-dispersant oil changeover); consumable materials list (Table II-XI); special lubrication instructions (Table II-XII); and complete component lubrication charts for main gear, nose gear, flight control assemblies, cabin and baggage doors, power plants, back-up extenders, and air conditioning condensers (Figures 2-44 through 2-54)[cite: 1].
- Section IV — Structures: Airframe structural descriptions and dimensions; complete wing group removal and installation procedures for fixed-gear (PA-28-140, -150, -160, -180, -235) and retractable (PA-28R) Cherokees; wing washout replacement specifications (0° versus 2° washout rules); wing tip removal and installation (standard tips and fiberglass tip fuel tanks); aileron and flap removal, hinge bolt inspection, and installation; eighteen-bolt main spar carry-through installation procedures, washer arrangements, and torque tightening to 360–390 in-lbs (Figure 4-2); empennage group servicing, including stabilator, stabilator trim tab, vertical fin, and rudder removal, hinge inspection, and installation; fuselage assemblies, windshield removal and dual-tape/sealant installation; single and double pane side window replacement; cabin entrance door adjustments, door hinge alignment, door seal snubber installation, latch mechanisms, and safety latches; baggage door removal, hinge riveting, and lock fabrication tools; seat back lock and release cable rigging; structural skin materials and thickness reference diagrams (Figure 4-10); metal wire stitching repair alternatives utilizing Monel and soft aluminum rivets; fiberglass repairs (surface gel coat scratch repairs, resin and catalyst formulations, and multi-layer structural fracture patch repairs); thermoplastic repairs (ABS crack stop-drilling, hot-air welding, and patch bonding); wing walkway non-skid liquid compound and pressure-sensitive safety walk installation; control surface free play checks; and static control surface balancing procedures and tolerance limits for stabilators, rudders, and ailerons (Table IV-II)[cite: 1].
As a whole, this comprehensive technical document equips aviation technicians and inspectors with the precise structural dimensions, manufacturer fastener torques, component rigging procedures, and fluid servicing data necessary to maintain airworthiness and perform major structural repairs across the Piper PA-28 airframe series[cite: 1].
In-Depth Airframe, Servicing & Structural Repair Data
The Piper Cherokee PA-28 Service Manual PA-28-140 -150 -160 -180 -235 PA-28R-180 -200 (Part Number 753-586) provides comprehensive coverage across key aircraft systems and variants[cite: 1]:
- Extensive Model Lineup: Comprehensive data tailored specifically to the two-place and four-place PA-28-140 (including Flite Liner models), four-place cruisers PA-28-150, PA-28-160, and PA-28-180, the six-cylinder heavy-hauler PA-28-235 with 84-gallon fuel capacity, and the retractable landing gear PA-28R-180 and PA-28R-200 Cherokee Arrow series[cite: 1].
- Lycoming Engine Integration: Servicing data and oil system procedures covering Avco-Lycoming O-320-E2A, O-320-E3D, O-320-A2B, O-320-B2B, O-320-D2A, O-360-A3A, O-360-A4A, O-540-B2B5, O-540-B1B5, O-540-B4B5, IO-360-B1E, IO-360-C1C, and IO-360-C1C6 engines[cite: 1].
- Landing Gear & Oleo Strut Maintenance: Detailed exposure limits under normal static load (3.25 inches for nose gear, 4.50 inches for fixed main gear, and 2.0 to 2.75 inches for retractable gear), hydraulic cylinder rebuilding, torque link greaser bolt inspection, and tire balancing instructions[cite: 1].
- Wing & Spar Carry-Through Overhaul: Step-by-step guidance for wing removal, alignment shims, forward and aft attach fittings, and eighteen-bolt main spar carry-through installation torques (360 to 390 in-lbs)[cite: 1].
- Precision Flight Control Balancing: Hinge point inspection, maximum allowable free play limits (0.15 inch for stabilator trim tab, 0.24 inch for ailerons), and static balance limits in inch-pounds using a shop-calibrated balance beam tool to prevent control surface flutter[cite: 1].
- Sheet Metal & Composite Maintenance: Structural skin thickness specifications (2024-T3 alloys), ABS thermoplastic crack welding, Monel rivet stitching repair for engine baffles, and complete fiberglass multi-layer patch reconstruction[cite: 1].
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Piper Cherokee PA-28 Service Manual PA-28-140 -150 -160 -180 -235 PA-28R-180 -200 (Part Number 753-586)” are as follows:
+753-586 – CHEROKEE SERVICE MANUAL – PA-28-140/150/160/180/235 AND PA-28R-180/200p. 1
AEROFICHE EXPLANATION AND REVISION STATUSp. 2
TABLE OF CONTENTSp. 3
+INTRODUCTIONp. 197
TABLE OF CONTENTSp. 199
INSTRUCTIONS FOR CONTINUED AIRWORTHINESSp. 201
GENERALp. 201
EFFECTIVITYp. 202
SERIAL NUMBER EXPLANATIONp. 204
ASSIGNMENT OF SUBJECT MATERIALp. 204
PAGINATIONp. 204
AEROFICHE EFFECTIVITYp. 204
IDENTIFYING REVISED MATERIALp. 205
INDEXINGp. 205
WARNINGS, CAUTIONS, AND NOTESp. 205
ACCIDENT / INCIDENT REPORTINGp. 205
+SUPPLEMENTARY PUBLICATIONSp. 205
PIPER PUBLICATIONSp. 205
VENDOR PUBLICATIONSp. 206
SECTION INDEX GUIDEp. 3
+SECTION I – AIRWORTHINESS LIMITATIONSp. 19
TABLE OF CONTENTSp. 21
+AIRWORTHINESS LIMITATIONSp. 22
LIMITATIONSp. 22
INSPECTIONSp. 22
LIFE LIMITED PARTS MARKING AND DISPOSITIONp. 22
+SECTION II – HANDLING AND SERVICINGp. 24
TABLE OF CONTENTSp. 24
2-1. INTRODUCTIONp. 27
2-2. DIMENSIONSp. 27
2-3. STATION REFERENCE LINESp. 27
2-4. WEIGHT AND BALANCE DATAp. 27
2-5. SERIAL NUMBER PLATEp. 27
2-6. ACCESS AND INSPECTION PROVISIONSp. 27
2-7. TOOLS AND TEST EQUIPMENTp. 27
2-8. THREADED FASTENER INSTALLATIONp. 68
2-8A. TORQUE WRENCHESp. 69
2-8B. TORQUE REQUIREMENTSp. 69
2-9. WALKWAY, HANDHOLD AND STEPp. 73
2-9A. METRIC CONVERSIONp. 73
2-10. REMOVAL OF CHERRYLOCK RIVETSp. 80
+2-11. GROUND HANDLINGp. 81
2-12. INTRODUCTION TO GROUND HANDLINGp. 81
2-13. JACKINGp. 81
2-14. WEIGHINGp. 82
2-15. LEVELINGp. 82
2-16. MOORINGp. 83
2-17. LOCKING AIRPLANEp. 83
2-18. PARKINGp. 84
2-19. TOWINGp. 84
2-20. TAXIINGp. 85
+2-21. EXTERNAL POWER RECEPTACLEp. 85
2-22. OPERATION OF EXTERNAL POWER RECEPTACLEp. 85
+2-23. CLEANINGp. 86
2-24. CLEANING ENGINE COMPARTMENTp. 86
2-25. CLEANING LANDING GEARp. 86
2-26. CLEANING EXTERIOR SURFACESp. 87
2-27. CLEANING WINDSHIELD AND WINDOWSp. 87
2-28. CLEANING HEADLINER, SIDE PANELS AND SEATSp. 87
2-29. CLEANING CARPETSp. 87
+2-30. SERVICINGp. 88
2-31. INTRODUCTION TO SERVICINGp. 88
+2-32. HYDRAULIC SYSTEM (PA-28R)p. 88
2-33. SERVICING HYDRAULIC SYSTEMp. 88
2-34. SERVICING HYDRAULIC PUMP/RESERVOIRp. 88
+2-35. LANDING GEAR SYSTEMp. 88
2-36. SERVICING LANDING GEARp. 88
+2-37. OLEO STRUTS (PA-28-140, -150. -160, -180 AND PA-28-235)p. 89
2-38. SERVICING OLEO STRUTSp. 89
2-39. FILLING NOSE GEAR OLEO STRUTp. 89
2-40. FILLING MAIN GEAR OLEO STRUTp. 95
2-41. INFLATING OLEO STRUTSp. 96
+2-42. OLEO STRUTS (PA-28R)p. 97
2-43. SERVICING OLEO STRUTSp. 97
2-44. FILLING OLEO STRUTSp. 97
2-45. INFLATING OLEO STRUTSp. 98
+2-46. BRAKE SYSTEMp. 99
2-47. SERVICING BRAKE SYSTEMp. 99
2-48. FILLING BRAKE CYLINDER RESERVOIRp. 99
2-49. DRAINING BRAKE SYSTEMp. 99
+2-50. TIRESp. 100
2-51. SERVICING TIRESp. 100
2-51A. TIRE BALANCERp. 100
+2-52. POWER PLANTp. 102
2-53. SERVICING POWER PLANTp. 102
+2-54. INDUCTION AIR FILTERp. 102
2-55. REMOVAL OF AIR FILTERp. 102
2-56. SERVICE INSTRUCTION (CLEANING AND INSPECTION)p. 103
2-57. INSTALLATION OF AIR FILTERp. 103
+2-58. PROPELLERp. 103
2-59. SERVICING PROPELLERp. 103
+2-60. FUEL SYSTEMp. 103
2-61. SERVICING FUEL SYSTEMp. 103
2-62. FILLING FUEL TANKS (PA-28-140; PA-28-150, -160, -180 AND PA-28R)p. 104
2-63. FILLING FUEL TANKS (PA-28-235)p. 104
2-64. DRAINING MOISTURE FROM FUEL SYSTEM (PA-28-140, -150, -160, -180 AND PA-28R)p. 104
2-65. DRAINING MOISTURE FROM FUEL SYSTEM (PA-28-235)p. 104
2-66. DRAINING FUEL SYSTEMp. 106
2-67. ANTI-ICING FUEL ADDITIVEp. 106
+2-68. ELECTRICAL SYSTEMp. 106
2-69. SERVICING ELECTRICAL SYSTEMp. 106
2-70. LUBRICATIONp. 106
+2-71. OIL SYSTEM (ENGINE)p. 106
2-72. SERVICING OIL SYSTEMp. 106
2-73. FILLING OIL SUMPp. 107
2-74. DRAINING OIL SUMPp. 107
2-75. OIL SCREENS (SUCTION)p. 107
2-76. OIL SCREEN (PRESSURE)p. 107
2-77. OIL FILTER (FULL FLOW)p. 108
2-78. RECOMMENDATIONS FOR CHANGING OILp. 108
2-79. LUBRICATION INSTRUCTIONSp. 108
2-80. APPLICATION OF GREASEp. 109
2-81. APPLICATION OF OILp. 109
2-82. WINTERIZATION PLATEp. 109
2-83. LUBRICATION CHARTSp. 109
SECTION III – INSPECTION (MOVED TO GRID 3H1)p. 127
+SECTION IV – STRUCTURESp. 129
TABLE OF CONTENTSp. 129
4-1. INTRODUCTIONp. 131
4-2. DESCRIPTIONp. 131
4-3. WING GROUPp. 132
+4-4. WING TIPp. 132
4-5. REMOVAL OF WING TIPp. 132
4-6. INSTALLATION OF WING TIPp. 133
+4-7. AILERONp. 133
4-8. REMOVAL OF AILERONp. 133
4-9. INSTALLATION OF AILERONp. 133
+4-10. WING FLAPp. 134
4-11. REMOVAL OF WING FLAPp. 134
4-12. INSTALLATION OF WING FLAPp. 134
+4-13. WINGp. 134
4-14. REMOVAL OF WINGp. 134
4-15. INSTALLATION OF WINGp. 142
4-16. EMPENNAGE GROUPp. 146
+4-17. STABILATORp. 146
4-18. REMOVAL OF STABILATORp. 146
4-19. INSTALLATION OF STABILATORp. 148
+4-20. STABILATOR TRIM TABp. 153
4-21. REMOVAL OF STABILATOR TRIM TABp. 153
4-22. INSTALLATION OF STABILATOR TRIM TABp. 153
+4-23. RUDDERp. 153
4-24. REMOVAL OF RUDDERp. 153
4-25. INSTALLATION OF RUDDERp. 153
+4-26. VERTICAL FINp. 154
4-27. REMOVAL OF VERTICAL FINp. 154
4-28. INSTALLATION OF VERTICAL FINp. 154
4-29. FUSELAGE ASSEMBLYp. 155
+4-30. WINDSHIELDp. 155
4-31. REMOVAL OF WINDSHIELDp. 155
4-32. INSTALLATION OF WINDSHIELDp. 155
+4-33. SIDE WINDOWSp. 157
4-34. REMOVAL OF SIDE WINDOWSp. 157
4-35. INSTALLATION OF SIDE WINDOWSp. 158
+4-36. DOOR (ENTRANCE)p. 159
4-37. REMOVAL OF DOORp. 159
4-38. INSTALLATION OF DOORp. 159
4-39. ADJUSTMENT OF DOORp. 159
4-40. REMOVAL OF DOOR LATCH MECHANISMp. 159
4-41. REMOVAL AND INSTALLATION OF DOOR SEAL SNUBBERSp. 160
4-42. INSTALLATION OF DOOR LATCH MECHANISMp. 161
4-43. ADJUSTMENT OF DOOR LATCH MECHANISMp. 161
4-44. REMOVAL OF DOOR LOCK ASSEMBLYp. 161
4-45. INSTALLATION OF DOOR LOCK ASSEMBLYp. 161
4-46. REMOVAL OF DOOR SAFETY LATCHp. 161
4-47. INSTALLATION OF DOOR SAFETY LATCHp. 161
4-48. ADJUSTMENT OF DOOR SAFETY LATCHp. 162
+4-49. BAGGAGE DOORp. 162
4-50. REMOVAL OF BAGGAGE DOORp. 162
4-51. INSTALLATION OF BAGGAGE DOORp. 162
4-52. REMOVAL OF BAGGAGE DOOR LOCK ASSEMBLYp. 162
4-53. INSTALLATION OF BAGGAGE DOOR LOCK ASSEMBLYp. 162
4-54. REMOVAL OF BAGGAGE DOOR HINGEp. 162
4-55. INSTALLATION OF BAGGAGE DOOR HINGEp. 162
4-56. RIGGING INSTRUCTIONS – SEAT BACK LOCK AND RELEASEp. 163
4-57. STRUCTURAL REPAIRSp. 164
4-57A. METAL WIRE STITCHING REPAIRp. 164
+4-58. FIBERGLAS REPAIRSp. 168
4-59. FIBERGLAS TOUCH-UP AND SURFACE REPAIRSp. 168
4-60. FIBERGLAS FRACTURE AND PATCH REPAIRSp. 169
4-61. THERMOPLASTIC REPAIRSp. 170
4-62. A.B.S. THERMOPLASTIC LANDING GEAR WHEELS AND STRUT FAIRING REPAIR INSTRUCTIONSp. 174
+4-63. SAFETY WALK REPAIRp. 178
4-64. SURFACE PREPARATION FOR LIQUID SAFETY WALKp. 178
4-65. PRODUCT LISTING FOR LIQUID SAFETY WALK COMPOUNDp. 178
4-66. APPLICATION OF LIQUID SAFETY WALK COMPOUNDp. 178
4-67. SURFACE PREPARATION FOR PRESSURE SENSITIVE SAFETY WALKp. 178
4-68. APPLICATION OF PRESSURE SENSITIVE SAFETY WALKp. 179
+4-69. CONTROL SURFACE BALANCINGp. 180
4-70. CHECKING CONTROL SURFACE BALANCEp. 180
4-71. CHECKING CONTROL SURFACES FREE PLAYp. 180
4-72. BALANCING EQUIPMENTp. 182
4-73. BALANCING AILERONSp. 182
4-74. BALANCING RUDDERp. 183
4-75. BALANCING STABILATORp. 186
4-76. AILERON BALANCE WEIGHT MODIFICATIONp. 187
4-77. FLAP INSPECTION AND MODIFICATIONp. 189
4-78. STABILATOR DRAIN HOLESp. 189
4-79. BAGGAGE COMPARTMENT INSPECTION HOLE AND COVER PLATEp. 191
4-80. ELECTRICAL BONDINGp. 194
+SECTION V – SURFACE CONTROLSp. 218
TABLE OF CONTENTSp. 218
5-1. INTRODUCTIONp. 220
5-2. DESCRIPTIONp. 220
5-3. STANDARD PROCEDURESp. 221
5-3A. FLIGHT CONTROL SURFACE TRAVELp. 222
5-3B. FLIGHT CONTROL CABLE TENSIONp. 222
+5-4. CONTROL COLUMN ASSEMBLYp. 225
5-5. REMOVAL OF CONTROL COLUMN ASSEMBLYp. 225
5-6. INSTALLATION OF CONTROL COLUMN ASSEMBLYp. 228
5-6A. INSTALLATION OF UNIVERSAL JOINTp. 229
+5-7. AILERON CONTROLSp. 229
5-8. REMOVAL OF AILERON CONTROL CABLESp. 229
5-9. INSTALLATION OF AILERON CONTROL CABLESp. 232
5-10. REMOVAL OF AILERON BELLCRANK ASSEMBLYp. 233
5-11. INSTALLATION OF AILERON BELLCRANK ASSEMBLYp. 233
5-12. RIGGING AND ADJUSTMENT OF AILERON CONTROLSp. 234
5-13. ADJUSTMENT OF AILERON TRIMp. 235
+5-14. STABILATOR CONTROLSp. 238
5-15. REMOVAL OF STABILATOR CONTROL CABLESp. 238
5-16. INSTALLATION OF STABILATOR CONTROL CABLESp. 239
5-17. RIGGING AND ADJUSTMENT OF STABILATOR CONTROLSp. 241
+5-18. STABILATOR TRIM CONTROLS (OVERHEAD TRIM)p. 243
5-19. REMOVAL OF STABILATOR TRIM ASSEMBLY (FORWARD)p. 243
5-20. INSTALLATION OF STABILATOR TRIM ASSEMBLY (FORWARD)p. 245
5-21. REMOVAL OF STABILATOR TRIM CONTROLS (AFT)p. 245
5-22. INSTALLATION OF STABILATOR TRIM CONTROLS (AFT)p. 248
5-23. RIGGING AND ADJUSTMENT OF STABILATOR TRIM (OVERHEAD CONTROL)p. 250
+5-24. STABILATOR TRIM CONTROLS (FLOOR TRIM)p. 252
5-25. REMOVAL OF STABILATOR TRIM ASSEMBLY (FORWARD)p. 252
5-26. INSTALLATION OF STABILATOR TRIM ASSEMBLY (FORWARD)p. 253
5-27. REMOVAL OF STABILATOR TRIM ASSEMBLY (AFT)p. 255
5-28. INSTALLATION OF STABILATOR TRIM ASSEMBLY (AFT)p. 255
5-29. RIGGING & ADJUST. OF STABILATOR TRIM (FLOOR CONTROL)p. 256
+5-30. RUDDER AND STEERING PEDAL ASSEMBLYp. 256
5-31. REMOVAL OF RUDDER AND STEERING PEDAL ASSEMBLYp. 256
5-32. INSTALLATION OF RUDDER AND STEERING PEDAL ASSEMBLYp. 259
+5-33. RUDDER CONTROLSp. 260
5-34. REMOVAL OF RUDDER CONTROL CABLESp. 260
5-35. INSTALLATION OF RUDDER CONTROL CABLESp. 260
5-36. RIGGING AND ADJUSTMENT OF RUDDER CONTROLSp. 262
+5-37. RUDDER TRIM CONTROLSp. 265
5-38. REMOVAL OF RUDDER TRIM CONTROLSp. 265
5-39. INSTALLATION OF RUDDER TRIM CONTROLSp. 265
5-40. RIGGING AND ADJUSTMENT OF RUDDER TRIM CONTROLSp. 265
+5-41. WING FLAP CONTROLSp. 268
5-42. REMOVAL OF WING FLAP CONTROLSp. 268
5-43. INSTALLATION OF WING FLAP CONTROLSp. 269
5-43A. TORQUE TUBE/PUSH ROD DISTORTION INSPECTIONp. 271
5-44. RIGGING AND ADJUSTMENT OF WING FLAPSp. 271
+SECTION VI – HYDRAULIC SYSTEM (PA – 28R)p. 285
TABLE OF CONTENTSp. 285
6-1. INTRODUCTIONp. 286
6-2. DESCRIPTIONp. 286
6-3. TROUBLESHOOTINGp. 290
+6-4. HYDRAULIC PUMPp. 290
6-4A. ORIGINAL EQUIPMENT PRESTOLITE PUMP, P/N 96671-002 ONLYp. 290
6-5. REMOVAL OF HYDRAULIC PUMPp. 290
6-6. DISASSEMBLY OF HYDRAULIC PUMPp. 291
6-7. CLEANING, INSPECTION AND REPAIRS OF HYDRAULIC PUMPp. 291
6-8. ASSEMBLY OF HYDRAULIC PUMPp. 293
6-9. TEST AND ADJUSTMENT OF HYDRAULIC PUMPp. 294
6-10. INSTALLATION OF HYDRAULIC PUMPp. 296
6-10A. SERVICING REPLACEMENT OILDYNE PUMPp. 296
6-11. FILLING HYDRAULIC PUMP RESERVOIRp. 301
6-11A. HYDRAULIC INSTALLATION, LANDING GEARp. 301
+6-12. GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLYp. 303
6-13. REMOVAL OF GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLYp. 303
6-14. INSTALLATION OF GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLYp. 304
6-15. CHECK AND ADJUSTMENT OF GEAR BACK-UP EXTENDER ACTUATORp. 304
6-16. OPERATIONAL CHECK OF RETRACTABLE LANDING GEAR SYSTEMp. 308
+6-17. NOSE GEAR ACTUATING CYLINDERp. 309
6-18. REMOVALp. 309
6-19. DISASSEMBLYp. 310
6-20. CLEANING, INSPECTION, AND REPAIRp. 311
6-21. ASSEMBLY OF NOSE GEAR ACTUATING.CYLINDERp. 311
6-22. INSTALLATIONp. 311
+6-23. MAIN GEAR ACTUATING CYLINDERp. 312
6-24. REMOVALp. 312
6-25. INSTALLATIONp. 312
6-26. DISASSEMBLYp. 312
6-27. CLEANING, INSPECTION, AND REPAIRp. 313
6-28. ASSEMBLYp. 314
+6-29. HYDRAULIC LINESp. 314
6-30. REMOVAL AND INSTALLATION OF HYDRAULIC LINESp. 314
+SECTION VII – LANDING GEAR AND BRAKE SYSTEM (PA – 28)p. 328
TABLE OF CONTENTSp. 328
7-1. INTRODUCTIONp. 330
7-2. DESCRIPTIONp. 330
7-3. TROUBLESHOOTINGp. 330
7-4. LANDING GEAR SYSTEMp. 331
+7-5. NOSE LANDING GEARp. 331
7-6. DISASSEMBLY OF NOSE GEAR OLEOp. 331
7-7. CLEANING, INSPECTION AND REPAIR OF NOSE GEAR OLEOp. 333
7-8. NOSE GEAR OIL ORIFICE RETAINER RING INSTALLATIONp. 333
7-9. ASSEMBLY OF NOSE GEAR OLEOp. 334
7-10. REMOVAL OF NOSE LANDING GEARp. 335
7-11. CLEANING, INSPECTION AND REPAIR OF NOSE LANDING GEARp. 335
7-12. INSTALLATION OF NOSE LANDING GEARp. 335
7-13. ALIGNMENT OF NOSE GEARp. 337
+7-14. MAIN LANDING GEARp. 340
7-15. DISASSEMBLY OF MAIN GEAR OLEOp. 340
7-16. CLEANING, INSPECTION AND REPAIR OF MAIN GEAR OLEOp. 341
7-17. ASSEMBLY OF MAIN GEAR OLEOp. 341
7-18. REMOVAL OF MAIN LANDING GEARp. 348
7-19. CLEANING, INSPECTION AND REPAIR OF MAIN LANDING GEARp. 348
7-20. INSTALLATION OF MAIN LANDING GEARp. 350
+7-21. WHEELSp. 350
7-22. REMOVAL AND DISASSEMBLY OF NOSE WHEELp. 350
7-23. INSPECTION OF NOSE WHEEL ASSEMBLYp. 352
7-24. ASSEMBLY AND INSTALLATION OF NOSE WHEELp. 352
7-25. REMOVAL AND DISASSEMBLY OF MAIN WHEELp. 352
7-26. INSPECTION OF MAIN WHEEL ASSEMBLYp. 353
7-27. ASSEMBLY AND INSTALLATION OF MAIN WHEELp. 354
7-28. BRAKE SYSTEMp. 354
+7-29. WHEEL BRAKE ASSEMBLYp. 354
7-30. BRAKE ADJUSTMENT AND LINING TOLERANCEp. 354
7-31. REMOVAL AND DISASSEMBLY OF WHEEL BRAKE ASSEMBLYp. 355
7-32. CLEANING, INSPECTION AND REPAIR OF WHEEL BRAKE ASSEMBLIESp. 358
7-33. ASSEMBLY AND INSTALLATION OF WHEEL BRAKE ASSEMBLYp. 358
+7-34. BRAKE MASTER CYLINDERp. 358
7-35. REMOVAL OF BRAKE MASTER CYLINDERp. 358
7-36. DISASSEMBLY OF BRAKE MASTER CYLINDERp. 360
7-37. CLEANING, INSPECTION AND REPAIR OF BRAKE MASTER CYLINDERp. 361
7-38. ASSEMBLY OF BRAKE MASTER CYLINDERp. 361
7-39. INSTALLATION OF BRAKE MASTER CYLINDER (HAND BRAKE)p. 364
+7-40. PARKING VALVEp. 365
7-41. REMOVAL OF PARKING VALVEp. 365
7-42. DISASSEMBLY OF PARKING VALVEp. 365
7-43. CLEANING, INSPECTION AND REPAIR OF PARKING VALVEp. 365
7-44. ASSEMBLY OF PARKING VALVEp. 365
7-45. INSTALLATION OF PARKING VALVEp. 367
+7-46. BRAKE CYLINDER (TOE BRAKE)p. 367
7-47. REMOVAL OF BRAKE CYLINDERp. 367
7-48. DISASSEMBLY OF BRAKE CYLINDERp. 367
7-49. CLEANING, INSPECTION AND REPAIR OF BRAKE CYLINDERp. 368
7-50. ASSEMBLY OF BRAKE CYLINDERp. 370
7-51. INSTALLATION OF BRAKE CYLINDERp. 371
+7-52. BRAKE BLEEDING PROCEDURESp. 371
7-53. BRAKE BLEEDING PROCEDURE (GRAVITY)p. 371
7-54. BRAKE BLEEDING PROCEDURE (PRESSURE)p. 371
7-55. BRAKE SYSTEM LEAK CHECKp. 373
7-56. BLEEDING OF THE BRAKES AFTER A UNIT HAS BEEN CHANGEDp. 373
+SECTION VIIA – LANDING GEAR AND BRAKE SYSTEM (PA-28R)p. 379
TABLE OF CONTENTSp. 379
7A-1. INTRODUCTIONp. 382
7A-2. DESCRIPTIONp. 382
7A-3. TROUBLESHOOTINGp. 384
7A-4. LANDING GEAR SYSTEMp. 384
+7A-5. NOSE LANDING GEARp. 384
7A-6. DISASSEMBLY OF NOSE GEAR OLEOp. 384
7A-7. CLEANING, INSPECTION AND REPAIR OF NOSE GEAR OLEOp. 385
7A-8. ASSEMBLY OF NOSE GEAR OLEOp. 385
7A-9. REMOVAL OF NOSE LANDING GEARp. 388
7A-10. CLEANING, INSPECTION AND REPAIR OF NOSE LANDING GEARp. 391
7A-11. INSTALLATION OF NOSE LANDING GEARp. 392
7A-12. ADJUSTMENT OF NOSE LANDING GEAR (WITHOUT GEAR UP STOP)p. 393
7A-13. ADJUSTMENT OF NOSE LANDING GEAR (WITH GEAR UP STOP)p. 395
7A-13A. ADJUSTMENT OF NOSE LANDING GEAR (WITH GEAR UP STOP)p. 395
7A-14. ALIGNMENT OF NOSE LANDING GEARp. 396
7A-15. REMOVAL OF NOSE GEAR DOOR ASSEMBLYp. 398
7A-16. CLEANING, INSPECTION AND REPAIR OF NOSE GEAR DOOR ASSEMBLYp. 399
7A-17. INSTALLATION OF NOSE GEAR DOOR ASSEMBLYp. 399
7A-18. ADJUSTMENT OF NOSE GEAR DOORSp. 399
+7A-19. MAIN LANDING GEAR SYSTEMp. 400
7A-20. DISASSEMBLY OF MAIN GEAR OLEOp. 400
7A-21. CLEANING, INSPECTION AND REPAIR OF MAIN GEAR OLEOp. 400
7A-22. ASSEMBLY OF MAIN GEAR OLEOp. 401
7A-23. REMOVAL OF MAIN LANDING GEARp. 404
7A-24. CLEANING, INSPECTION AND REPAIR OF MAIN LANDING GEARp. 407
7A-24A. MAIN LANDING GEAR TRUNNION REPAIRp. 409
7A-25. INSTALLATION OF MAIN LANDING GEARp. 410
7A-26. ADJUSTMENT OF MAIN LANDING GEARp. 411
7A-27. ALIGNMENT OF MAIN LANDING GEARp. 413
7A-28. REMOVAL OF MAIN GEAR DOOR ASSEMBLYp. 415
7A-29. CLEANING, INSPECTION AND REPAIR OF MAIN GEAR DOOR ASSEMBLYp. 415
7A-30. INSTALLATION OF MAIN GEAR DOOR ASSEMBLYp. 415
7A-31. ADJUSTMENT OF MAIN GEAR DOOR ASSEMBLYp. 416
+7A-32. LANDING GEAR LIMIT SWITCHESp. 416
7A-33. ADJUSTMENT OF NOSE GEAR UP LIMIT SWITCHp. 416
7A-34. ADJUSTMENT OF NOSE GEAR DOWN LIMIT SWITCHp. 417
7A-35. ADJUSTMENT OF MAIN GEAR UP LIMIT SWITCHp. 418
7A-36. ADJUSTMENT OF MAIN GEAR DOWN LIMIT SWITCHp. 418
7A-37. ADJUSTMENT OF LANDING GEAR SAFETY SWITCH (SQUAT SWITCH)p. 420
7A-38. ADJUSTMENT OF GEAR BACK-UP EXTENDER ACTUATOR SWITCHp. 420
+7A-39. LANDING GEAR WARNING SWITCHES (THROTTLE SWITCHES)p. 420
7A-40. LANDING GEAR UP/POWER REDUCED WARNING SWITCHp. 420
7A-41. REMOVAL OF LANDING GEAR UP/POWER REDUCED WARNING SWITCHp. 420
7A-42. INSTALLATION OF LANDING GEAR UP/POWER REDUCED WARNING SWITCHp. 420
7A-43. ADJUSTMENT OF LANDING GEAR UP/POWER REDUCED WARNING SWITCHp. 421
7A-44. GEAR DOWN/SELECTOR HANDLE UP WARNING SWITCHp. 422
7A-45. REMOVAL OF GEAR DOWN/SELECTOR HANDLE UP WARNING SWITCHp. 422
7A-46. INSTALLATION OF GEAR DOWN/SELECTOR HANDLE UP WARNING SWITCHp. 422
7A-47. ADJUSTMENT OF GEAR DOWN/SELECTOR HANDLE UP WARNING SWITCHp. 422
+7A-48. WHEELSp. 423
7A-49. REMOVAL AND DISASSEMBLY OF NOSE WHEELp. 423
7A-50. INSPECTION OF NOSE WHEEL ASSEMBLYp. 423
7A-51. ASSEMBLY AND INSTALLATION OF NOSE WHEELp. 423
7A-52. REMOVAL AND DISASSEMBLY OF MAIN WHEELp. 425
7A-53. INSPECTION OF MAIN WHEELASSEMBLYp. 426
7A-54. ASSEMBLY AND INSTALLATION OF MAIN WHEELp. 426
7A-55. BRAKE SYSTEMp. 426
+7A-56. WHEEL BRAKE ASSEMBLYp. 426
7A-57. BRAKE ADJUSTMENT AND LINING TOLERANCEp. 426
7A-58. REMOVAL AND DISASSEMBLY OF WHEEL BRAKE ASSEMBLYp. 426
7A-59. CLEANING, INSPECTION AND REPAIR OF WHEEL BRAKE ASSEMBLIESp. 428
7A-60. ASSEMBLY AND INSTALLATION OF WHEEL BRAKE ASSEMBLYp. 428
+7A-61. BRAKE MASTER CYLINDER (HAND PARKING BRAKE)p. 428
7A-62. REMOVAL OF BRAKE MASTER CYLINDERp. 429
7A-63. DISASSEMBLY OF BRAKE MASTER CYLINDERp. 430
7A-64. CLEANING, INSPECTION AND REPAIR OF BRAKE MASTER CYLINDERp. 430
7A-65. ASSEMBLY OF BRAKE MASTER CYLINDERp. 430
7A-66. INSTALLATION OF BRAKE MASTER CYLINDERp. 431
+7A-67. BRAKE CYLINDER (TOE BRAKE)p. 433
7A-68. REMOVAL OF BRAKE CYLINDERp. 433
7A-69. DISASSEMBLY OF BRAKE CYLINDERp. 433
7A-70. CLEANING, INSPECTION AND REPAIR OF BRAKE CYLINDERp. 434
7A-71. ASSEMBLY OF BRAKE CYLINDERp. 435
7A-72. INSTALLATION OF BRAKE CYLINDERp. 436
7A-73. BLEEDING PROCEDUREp. 436
7A-74. BEARING REPLACEMENTp. 436
7A-75. NOSE GEAR SERVICE TOLERANCESp. 446
7A-76. MAIN GEAR SERVICE TOLERANCESp. 449
+SECTION VIII – POWER PLANT (PA – 28)p. 452
TABLE OF CONTENTSp. 452
8-1. INTRODUCTIONp. 454
8-2. DESCRIPTIONp. 454
8-3. STANDARD PRACTICES – ENGINEp. 456
8-4. TROUBLESHOOTINGp. 456
+8-5. PROPELLERp. 457
8-6. REMOVAL OF PROPELLER (FIXED PITCH)p. 457
8-7. CLEANING. INSPECTION AND REPAIR OF PROPELLERp. 457
8-8. INSTALLATION OF PROPELLER (FIXED PITCH)p. 457
8-9. REMOVAL OF PROPELLER (CONSTANT SPEED)p. 460
8-10. CLEANING, INSPECTION AND REPAIR OF PROPELLER (CONSTANT SPEED)p. 460
8-11. INSTALLING PROPELLER (CONSTANT SPEED)p. 461
8-12. BLADE TRACKp. 461
+8-13. PROPELLER GOVERNOR (PA-28-235)p. 462
8-14. REMOVAL OF PROPELLER GOVERNORp. 462
8-15. INSTALLATION OF PROPELLER GOVERNORp. 462
8-16. RIGGING AND ADJUSTMENT OF PROPELLER GOVERNOR (PA-28-235)p. 462
+8-17. ENGINEp. 464
8-17A. REMOVAL OF ENGINE COWLINGSp. 464
8-17B. INSTALLATION OF ENGINE COWLINGSp. 464
8-17C. INSTALLATION OF BUSHINGS AND PINS FOR FIBERGLAS TYPE COWLINGSp. 464
8-18. REMOVAL OF ENGINE (PA-28-140, -150, -160, -180)p. 464
8-19. INSTALLATION OF ENGINE (PA-28-140, -150, -160, -180)p. 465
8-20. INSTALLATION OF ENGINE SHOCK MOUNTS (PA-28-140, SERIAL NOS. 28-2500 AND UP)p. 469
8-21. REMOVAL OF ENGINE (PA-28-235)p. 470
8-22. INSTALLATION OF ENGINE (PA-28-235)p. 471
8-23. INSTALLATION OF OIL COOLERp. 473
8-24. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLSp. 473
8-25. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLS (PA-28-140, S/N’S 28-25000 AND UP), (PA-28-180, S/N’S 28-4378 AND UP), (PA-28-235, S/N’S 28-11040 AND UP)p. 475
+8-26. CARBURATORp. 476
8-27. CARBURETOR MAINTENANCEp. 476
8-28. THROTTLE ARMp. 476
8-29. ADJUSTMENT OF IDLE MIXTUREp. 476
8-30. ADJUSTMENT OF IDLE SPEEDp. 478
+8-31. MAGNETO (BENDIX)p. 478
8-32. INSPECTION OF MAGNETOSp. 478
8-33. REMOVAL OF MAGNETOSp. 480
8-34. TIMING PROCEDUREp. 481
8-35. INSTALLATION AND TIMING PROCEDUREp. 483
8-36. MAGNETO (SLICK)p. 485
+8-37. HARNESS ASSEMBLYp. 485
8-38. INSPECTION OF HARNESSp. 485
8-39. REMOVAL OF HARNESSp. 485
8-40. INSTALLATION OF HARNESSp. 486
+8-41. SPARK PLUGSp. 486
8-42. REMOVAL OF SPARK PLUGSp. 486
8-43. INSPECTION AND CLEANING OF SPARK PLUGSp. 488
8-44. INSTALLATION OF SPARK PLUGSp. 488
+8-45. LUBRICATION SYSTEMp. 488
8-46. OIL PRESSURE RELIEF VALVEp. 488
+8-47. SWITCHINGp. 489
8-48. REMOVAL OF IGNITION SWITCHp. 489
8-49. INSTALLATION OF IGNITION SWITCHp. 489
+SECTION VIIIA – POWER PLANT (PA-28R)p. 506
TABLE OF CONTENTSp. 506
8A-1. INTRODUCTIONp. 508
8A-2. DESCRIPTIONp. 508
8A-3. TROUBLESHOOTINGp. 508
+8A-4. PROPELLERp. 509
8A-5. REMOVAL OF PROPELLERp. 509
8A-6. CLEANING, INSPECTION AND REPAIR OF PROPELLERp. 509
8A-7. INSTALLING PROPELLERp. 511
8A-8. BLADE TRACKp. 512
+8A-9. PROPELLER GOVERNORp. 512
8A-10. REMOVAL OF PROPELLER GOVERNORp. 512
8A-11. INSTALLATION OF PROPELLER GOVERNORp. 512
8A-12. RIGGING AND ADJUSTMENT OF PROPELLER GOVERNORp. 513
+8A-13. ENGINEp. 514
8A-14. REMOVAL OF ENGINEp. 514
8A-15. INSTALLATION OF ENGINEp. 515
8A-16. INSTALLATION OF OIL COOLERp. 522
8A-17. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLSp. 522
8A-18. INDUCTION AIR FILTERp. 524
+8A-19. ALTERNATE AIR DOORp. 524
8A-19A. 50 HOUR INSPECTIONp. 524
8A-19B. 100 HOUR INSPECTIONp. 524
+8A-20. FUEL INJECTORp. 525
8A-21. FUEL INJECTOR MAINTENANCEp. 525
8A-22. ADJUSTMENT OF IDLE SPEED AND MIXTUREp. 527
8A-23. FUEL-AIR BLEED NOZZLEp. 528
8A-24. REMOVAL OF FUEL-AIR BLEED NOZZLEp. 528
8A-25. CLEANING AND INSPECTION OF FUEL-AIR BLEED NOZZLEp. 528
8A-26. INSTALLATION OF FUEL-AIR BLEED NOZZLEp. 528
8A-27. IGNITION SYSTEM MAINTENANCEp. 529
+8A-28. MAGNETOp. 529
8A-29. INSPECTION OF MAGNETOp. 529
8A-30. REMOVAL OF MAGNETOp. 531
8A-31. TIMING PROCEDURE (INTERNAL TIMING)p. 531
8A-32. INSTALLATION AND TIMING PROCEDURE (TIMING MAGNETO TO ENGINE)p. 534
+8A-33. HARNESS ASSEMBLYp. 537
8A-34. INSPECTION OF HARNESSp. 537
8A-35. REMOVAL OF HARNESSp. 537
8A-36. MAINTENANCE OF HARNESSp. 537
8A-37. INSTALLATION OF HARNESSp. 543
+8A-38. SPARK PLUGSp. 543
8A-39. REMOVAL OF SPARK PLUGSp. 543
8A-40. INSPECTION AND CLEANING OF SPARK PLUGp. 545
8A-41. INSTALLATION OF SPARK PLUGSp. 545
+8A-42. LUBRICATION SYSTEMp. 545
8A-43. OIL PRESSURE RELIEF VALVEp. 545
+8A-44. SWITCHINGp. 546
8A-45. REMOVING IGNITION SWITCHp. 546
8A-46. INSTALLATION OF IGNITION SWITCHp. 546
+SECTION IX – FUEL SYSTEMp. 554
TABLE OF CONTENTSp. 554
9-1. INTRODUCTIONp. 556
9-2. DESCRIPTIONp. 556
9-3. TROUBLESHOOTINGp. 563
+9-4. MAIN FUEL TANKS MAIN FUEL TANKS (PA-28-140, -150, -160, -180, -235 AND PA-28R) .p. 563
9-5. REMOVAL OF MAIN FUEL TANKSp. 563
9-6. INSPECTION AND REPAIR OF MAIN FUEL TANKp. 563
9-6A. SLOSHED FUEL TANK 100 HOUR INSPECTIONp. 563
9-7. INSTALLATION OF MAIN FUEL TANKp. 564
+9-8. TIP FUEL TANKS (PA-28-235)p. 564
9-9. REMOVAL OF TIP TANKp. 564
+9-10. FUEL TANK REPAIR (FIBERGLAS)p. 564
9-11. INSTALLATION OF TIP TANKp. 564
+9-12. FUEL QUANTITY TRANSMITTER UNITp. 564
9-13. REMOVAL OF FUEL QUANTITY TRANSMITTER UNITp. 564
9-14. INSTALLATION OF FUEL QUANTITY TRANSMITTER UNITp. 565
9-15. FUEL QUANTITY TRANSMITTER/GAUGE CHECKp. 565
9-16. CHECK AND ADJUSTMENT OF FUEL QUANTITY TRANSMITTER UNITp. 565
9-16A. FUEL QUANTITY SENDING UNIT (P/N 548-671) CALIBRATIONp. 566
+9-17. FUEL VALVESp. 568
9-18. FUEL SHUTOFF VALVE (PA-28-140, -150, -160, -180, AND PA-28R)p. 568
9-19. REMOVAL OF FUEL SHUTOFF VALVEp. 568
9-20. DISASSEMBLY OF FUEL SHUTOFF VALVEp. 568
9-21. CLEANING, INSPECTION AND REPAIR OF FUEL SHUTOFF VALVEp. 569
9-22. ASSEMBLY OF FUEL SHUTOFF VALVEp. 569
9-23. INSTALLATION OF SHUTOFF VALVEp. 569
+9-24. FUEL SELECTOR VALVE AND FILTER (PA-28-235)p. 569
9-25. FUEL SELECTOR VALVE OPERATIONp. 569
9-26. REMOVAL OF FUEL SELECTOR VALVE AND FILTERp. 569
9-27. (RESERVED)p. 554
9-28. CLEANING FILTER ASSEMBLYp. 571
9-29. INSTALLATION OF FUEL SELECTOR AND FILTER VALVEp. 572
+9-30. FUEL FILTER BOWL AND SCREEN (PA-28-140, -150, -160, -180 AND PA-28R)p. 573
9-31. REMOVAL OF FUEL FILTER BOWL AND HOUSINGp. 573
9-32. INSTALLATION OF FUEL FILTER BOWL AND SCREENp. 573
9-33. CLEANING AND INSPECTION OF FILTER BOWL SCREENp. 574
9-34. ELECTRIC FUEL PUMPSp. 574
+9-35. PLUNGER FUEL PUMPS (PA-28-140, -150, -160, -180 AND -235)p. 574
9-36. REMOVAL OF FUEL PUMPSp. 574
9-37. DISASSEMBLY OF FUEL PUMPp. 575
9-38. CLEANING, INSPECTION AND REPAIR OF FUEL PUMPp. 577
9-39. RESISTANCE CHECK (PLUNGER TYPE PUMP)p. 577
9-40. ASSEMBLY OF FUEL PUMPp. 577
9-41. ADJUSTMENT OF ELECTRIC FUEL PUMP (BENCH TEST)p. 578
9-42. ADJUSTMENT OF ELECTRIC FUEL PUMP (IN AIRPLANE)p. 578
9-43. INSTALLATION OF FUEL PUMPSp. 579
+9-44. ROTARY FUEL PUMPS (WELDON) (PA-28R)p. 580
9-45. REMOVAL OF FUEL PUMPp. 580
9-46. REPAIR OF FUEL PUMPp. 580
9-47. ADJUSTMENT OF ELECTRIC FUEL PUMP (BENCH TEST)p. 581
9-48. ADJUSTMENT OF ELECTRIC FUEL PUMP (IN AIRPLANE)p. 581
9-49. INSTALLATION OF FUEL PUMPp. 582
+9-50. ENGINE PRIMER PUMPp. 582
9-51. REMOVAL OF ENGINE PRIMERp. 582
9-52. DISASSEMBLY, CLENAING, AND ASSEMBLY OF ENGINE PRIMERp. 582
9-53. INSTALLATION OF ENGINE PRIMER PUMPp. 583
9-54. PRIME JETSp. 583
9-55. CLEANING FUEL SYSTEMp. 583
+SECTION X – INSTRUMENTSp. 589
TABLE OF CONTENTSp. 589
10-1. GENERALp. 592
10-1A. SERVICE REPLACEMENTp. 592
10-2. NON-ELECTRICAL INSTRUMENTSp. 592
+10-3. VACUUM SYSTEMp. 592
10-4. VACUUM SYSTEM SERVICE TIPSp. 592
10-5. TROUBLESHOOTINGp. 594
+10-6. SUCTION GAUGEp. 615
10-7. GENERALp. 615
10-8. TROUBLESHOOTINGp. 615
+10-9. VACUUM REGULATOR VALVEp. 615
10-10. GENERALp. 615
10-11. TROUBLESHOOTINGp. 615
10-12. ADJUSTMENT OF VACUUM REGULATOR VALVE (WITHOUT VACUUM WARNING LIGHTS)p. 615
10-13. ADJUSTMENT OF VACUUM REGULATOR VALVE (WITH VACUUM WARNING LIGHTS)p. 616
10-14. ADJUSTMENT OF VACUUM WARNING LIGHT PRESSURE SWITCHp. 616
10-15. ADJUSTMENT OF VACUUM TURN AND BANK INDICATOR REGULATOR VALVEp. 618
10-16. REMOVAL AND REPLACEMENT OF REGULATOR VALVEp. 618
+10-17. VACUUM PUMPp. 618
10-18. GENERALp. 618
10-19. TROUBLESHOOTINGp. 618
10-20. REMOVAL OF VACUUM PUMPp. 619
10-21. REPLACING PUMP FITTINGSp. 619
10-22. INSTALLATION OF VACUUM PUMPp. 619
10-23. INSTRUMENT AIR SYSTEMp. 621
+10-24. DIRECTIONAL GYROp. 621
10-25. GENERALp. 621
10-26. TROUBLESHOOTINGp. 623
10-27. REMOVAL AND REPLACEMENTp. 624
+10-28. GYRO HORIZONp. 624
10-29. GENERALp. 624
10-30. TROUBLESHOOTINGp. 625
10-31. REMOVAL AND REPLACEMENTp. 626
+10-32. RATE OF CLIMB INDICATORp. 626
10-33. GENERALp. 626
10-34. TROUBLESHOOTINGp. 626
10-35. REMOVAL AND REPLACEMENTp. 627
+10-36. SENSITIVE ALTIMETERp. 627
10-37. GENERALp. 627
10-38. TROUBLESHOOTINGp. 628
10-39. REMOVAL AND REPLACEMENTp. 629
+10-40. AIRSPEED INDICATORp. 629
10-41. GENERALp. 629
10-42. TROUBLESHOOTINGp. 630
10-43. REMOVAL AND REPLACEMENTp. 630
+10-44. MAGNETIC COMPASSp. 631
10-45. GENERALp. 631
10-46. ADJUSTMENT OF COMPASSp. 631
10-47. TROUBLESHOOTINGp. 632
+10-48. MANIFOLD PRESSURE GAUGEp. 633
10-49. GENERALp. 633
10-50. TROUBLESHOOTINGp. 633
10-51. REMOVAL AND REPLACEMENTp. 633
+10-52. TACHOMETER INDICATORp. 633
10-53. GENERALp. 633
10-54. TROUBLESHOOTINGp. 634
10-55. REMOVAL AND REPLACEMENTp. 634
+10-56. ENGINE OIL PRESSURE GAUGEp. 634
10-57. GENERALp. 634
10-58. TROUBLESHOOTINGp. 635
10-59. REMOVAL AND REPLACEMENTp. 635
+10-60. FUEL PRESSURE GAUGEp. 635
10-61. GENERALp. 635
10-62. TROUBLESHOOTINGp. 636
10-63. REMOVAL AND REPLACEMENTp. 637
+10-64. TURN AND BANK INDICATORp. 637
10-65. GENERALp. 637
10-66. TROUBLESHOOTINGp. 637
+10-67. ELECTRICAL INSTRUMENTSp. 638
10-68. REMOVAL AND REPLACEMENTp. 638
+10-69. FUEL QUANTITY INDICATORp. 638
10-70. GENERALp. 638
10-71. TROUBLESHOOTINGp. 638
10-72. REMOVAL AND REPLACEMENTp. 639
+10-73. OIL TEMPERATURE INDICATORp. 639
10-74. GENERALp. 639
10-75. TROUBLESHOOTINGp. 639
10-76. REMOVAL AND REPLACEMENTp. 639
+10-77. AMMETERp. 639
10-78. GENERALp. 639
10-79. TROUBLESHOOTINGp. 639
10-80. REMOVAL AND REPLACEMENTp. 639
+10-81. REMOVAL AND REPLACEMENT OF FACE MOUNTED INSTRUMENTSp. 639
10-82. GENERALp. 640
+10-83. REMOVAL AND REPLACEMENT OF CLUSTER MOUNTED INSTRUMENTSp. 640
10-84. GENERALp. 640
+10-85. EXHAUST GAS TEMPERATURE GAUGE (ALCOR)p. 640
10-86. GENERALp. 640
+10-87. CLEANING AND INSPECTIONp. 641
10-88. TROUBLESHOOTINGp. 641
+10-89. CYLINDER HEAD TEMPERATURE GAUGEp. 645
10-90. GENERALp. 645
10-91. TROUBLESHOOTINGp. 645
10-92. REMOVAL AND REPLACEMENTp. 645
+10-93. FUEL FLOW GAUGEp. 645
10-94. GENERALp. 645
10-95. TROUBLESHOOTINGp. 646
10-96. REMOVAL AND REPLACEMENTp. 646
10-97. PIPER AUTOCONTROL SYSTEMp. 646
+10-98. ANNUNCIATOR PANELp. 646
10-99. GENERALp. 646
10-100. TROUBLESHOOTINGp. 646
10-101. REMOVAL AND REPLACEMENTp. 646
+SECTION III – INSPECTIONp. 648
TABLE OF CONTENTSp. 650
GENERALp. 652
TIME LIMITSp. 654
SCHEDULED MAINTENANCEp. 656
DESCRIPTIONp. 656
DEFINITIONSp. 656
+INSPECTION REQUIREMENTSp. 659
ANNUAL / 100 HOUR INSPECTIONp. 659
PROGRESSIVE INSPECTIONp. 659
OVERLIMITS INSPECTIONp. 659
ANNUAL / 100 HOUR INSPECTION PROCEDUREp. 660
+INSPECTION REPORT (PA-28-140/150/160/180/235)p. 662
PROPELLER GROUPp. 662
ENGINE GROUPp. 662
CABIN AND COCKPIT GROUPp. 664
FUSELAGE AND EMPENNAGE GROUPp. 665
WING GROUPp. 667
LANDING GEAR GROUPp. 668
FLOAT GROUPp. 668
SPECIAL INSPECTIONSp. 669
OPERATIONAL INSPECTIONp. 669
GENERALp. 669
NOTESp. 670
+INSPECTION REPORT (PA-28R-180/200)p. 676
PROPELLER GROUPp. 676
ENGINE GROUPp. 676
CABIN AND COCKPIT GROUPp. 678
FUSELAGE AND EMPENNAGE GROUPp. 679
WING GROUPp. 681
LANDING GEAR GROUPp. 682
SPECIAL INSPECTIONSp. 683
OPERATIONAL INSPECTIONp. 683
GENERALp. 683
NOTESp. 684
+SPECIAL INSPECTIONSp. 688
+REQUIREMENTSp. 688
PER FLIGHT HOURp. 688
PER CALENDAR YEARp. 693
PER SPECIFIC OPERATION / OPERATING ENVIRONMENTp. 695
HIGH DUST OR INDUSTRIAL POLLUTIONp. 695
HIGH SALT OR HIGH HUMIDITYp. 695
EXTREME COLDp. 696
SOFT OR UNUSUAL TERRAINp. 696
+PROCEDURESp. 697
ELECTRIC TRIM SWITCH INSPECTIONp. 697
AIR INDUCTION INLET HOSE 10 HOUR INSPECTIONp. 699
SPINNER/BULKHEAD 25 HOUR INSPECTIONp. 700
FUEL SELECTOR VALVE 50 HOUR LEAK CHECKp. 701
STABILATOR BALANCE WEIGHT TUBE ASSEMBLY 200 HOUR INSPECTIONp. 701
FUEL SELECTOR VALVE 400 HOUR INSPECTIONp. 704
INDUCTION AIR INLET DUCT AND ALTERNATE HEAT DUCT INSPECTIONp. 704
WING RIB ASSEMBLY W.S. 49.25 INSPECTIONSp. 706
WING SPAR INSPECTIONp. 709
LANDING LIGHT SEAL INSPECTIONp. 712
STABILATOR ATTACH FITTINGS CORROSION INSPECTIONp. 713
FLAP CONTROL CABLE ATTACHMENT BOLT INSPECTIONp. 714
AFT WING ATTACH FITTINGS 100 HOUR INSPECTIONp. 715
FUEL TANK/WING SPAR CORROSION INSPECTIONp. 720
CAST MAIN LANDING GEAR STRUT CYLINDER 100 HOUR INSPECTIONp. 720
NOSE GEAR DRAG LINK 500 HOUR INSPECTION AND BOLT REPLACEMENTp. 721
CONTROL CABLE INSPECTIONp. 722
EXHAUST SYSTEM INSPECTIONp. 725
FIELD CHECK OF PA-28-180 & PA-28R-200 MUFFLER ASSEMBLIESp. 730
CONTROL WHEEL 100 HOUR INSPECTIONp. 731
AILERON HINGE DOUBLER 100 HOUR INSPECTIONp. 731
MAIN LANDING GEAR TORQUE LINK INSPECTIONp. 733
UPPER NOSE GEAR OLEO BEARING INSPECTIONp. 734
RUDDER BAR ASSEMBLY 100 HOUR INSPECTIONp. 734
REAR SEAT QUICK DISCONNECT MECHANISM INSPECTIONp. 737
MAIN LANDING GEAR TORQUE LINK GREASER BOLT INSPECTIONp. 737
WING AFT SPAR-TO-FUSELAGE ATTACHMENT HARDWARE 100 HOUR INSPECTIONp. 739
+UNSCHEDULED MAINTENANCE CHECKSp. 744
LIGHTNING STRIKEp. 744
ENGINE OVERSPEED, OVERTEMP, OVERTORQUE, OR SUDDEN STOPPAGEp. 745
SEVERE TURBULENCE, HARD OR OVERWEIGHT LANDINGp. 745
FLAPS EXTENDED ABOVE MAXIMUM FLAP EXTENSION SPEED (VFE)p. 746
FLOOD DAMAGE, IMMERSION IN WATERp. 747
SERVICE PUBLICATIONS LISTp. 754
+SECTION XI – ELECTRICAL SYSTEMp. 775
TABLE OF CONTENTSp. 775
11-1. INTRODUCTIONp. 784
11-2. DESCRIPTIONp. 784
11-3. TROUBLESHOOTINGp. 784
+11-4. GENERATOR SYSTEM (DELCO-REMY)p. 787
11-5. DESCRIPTION OF GENERATOR SYSTEMp. 787
11-6. CHECKING GENERATOR SYSTEMp. 787
11-7. ADJUSTMENTS, TESTS AND MAINTENANCE OF GENERATOR SYSTEMp. 788
11-8. TEST AND MAINTENANCE OF GENERATOR (DELCO-REMY)p. 789
11-9. INSPECTION OF GENERATORp. 789
11-10. SHUNT GENERATOR OUTPUTp. 790
11-11. CHECKING DEFECTIVE GENERATORSp. 791
11-12. NO OUTPUTp. 791
11-13. UNSTEADY OR LOW OUTPUTp. 792
11-14. EXCESSIVE OUTPUTp. 793
11-15. NOISY GENERATORp. 793
11-16. DISASSEMBLY, REPAIR AND REASSEMBLYp. 794
11-17. FIELD COIL REMOVALp. 794
11-18. INSPECTION AND REPAIR OF PARTSp. 794
11-19. FIELD COIL SERVICEp. 794
11-20. ARMATURE SERVICEp. 795
11-21. POLARIZING GENERATORp. 795
11-22. GENERATOR SERVICE TEST SPECIFICATIONSp. 796
+11-23. REGULATORp. 797
11-24. DESCRIPTION OF REGULATORp. 797
11-25. CUTOUT RELAYp. 797
11-26. VOLTAGE REGULATORp. 798
11-27. CURRENT REGULATORp. 799
11-28. RESISTANCESp. 799
11-29. TEMPERATURE COMPENSATIONp. 800
11-30. REGULATOR POLARITYp. 800
11-31. REGULATOR MAINTENANCEp. 800
11-32. MAINTENANCE INSTRUCTIONSp. 800
11-33. CLEANING CONTACT POINTSp. 801
11-34. REGULATOR CHECKS AND ADJUSTMENTSp. 802
11-35. VOLTAGE REGULATORp. 802
11-36. CUTOUT RELAYp. 805
11-37. CURRENT REGULATORp. 806
11-38. REPAIRSp. 808
11-39. REGULATOR SPRING REPLACEMENTp. 808
11-40. RADIO BY-PASS CONDENSERSp. 808
11-41. REGULATOR ARMATURE REPLACEMENTp. 808
11-42. HIGH POINTS ON REGULATOR PERFORMANCE AND CHECKSp. 808
11-43. REGULATOR SERVICE TEST SPECIFICATIONSp. 809
+11-44. ALTERNATOR SYSTEM (CHRYSLER)p. 810
11-45. DESCRIPTION OF ALTERNATOR SYSTEMp. 810
11-46. ALTERNATOR SYSTEM TEST PROCEDUREp. 813
11-47. BENCH TESTING ALTERNATORp. 815
11-48. FIELD CURRENT DRAWp. 815
11-49. TESTING ALTERNATOR INTERNAL FIELD CIRCUIT FOR A GROUNDp. 816
11-50. INSPECTIONp. 816
11-51. TESTING RECTIFIERS (POSITIVE)p. 816
11-52. TESTING RECTIFIERS (NEGATIVE)p. 818
11-53. REMOVING AND INSTALLING RECTIFIERSp. 819
11-54. REMOVING RECTIFIERSp. 820
11-55. INSTALLING RECTIFIERSp. 820
11-56. TESTING STATOR COILS FOR GROUNDp. 823
11-57. TESTING ALTERNATOR CAPACITORSp. 823
11-58. REMOVING NEEDLE BEARING FROM END SHIELDp. 824
11-59. INSTALLING NEEDLE BEARING IN END SHIELDp. 824
11-60. REMOVING DRIVE PULLEYp. 825
11-61. REMOVING DRIVE END BEARINGp. 825
11-62. REPLACING SLIP RINGSp. 826
11-63. REMOVING SLIP RINGSp. 827
11-64. INSTALLATION OF SLIP RINGSp. 827
11-65. INSTALLING GREASE RETAINERp. 830
11-66. INSTALLING DRIVE END BEARINGp. 830
11-67. INSTALLING PULLEYp. 830
11-68. ASSEMBLING END SHIELD SUB-ASSEMBLIESp. 831
11-69. BENCH RUN-UP TESTp. 831
11-70. BENCH HOT STABILATION OUTPUT TESTp. 833
+11-71. VOLTAGE REGULATOR SERVICING (CHRYSLER)p. 834
11-72. AIR GAP ADJUSTMENTp. 834
11-73. CONTACT CLEARANCE ADJUSTMENTp. 835
11-74. VOLTAGE REGULATOR FUSIBLE WIRE REPLACEMENTp. 836
+11-75. VOLTAGE REGULATOR (WICO)p. 836
11-76. CHECKING VOLTAGE REGULATORp. 836
+11-77. OVER VOLTAGE RELAY (WICO)p. 837
11-78. CHECKING OVER VOLTAGE RELAYp. 837
11-79. CHECKING GENERATOR OR ALTERNATOR BELT TENSIONp. 838
+11-80. STARTING MOTOR (DELCO-REMY)p. 838
11-81. OPERATION OF STARTING MOTORp. 838
11-82. CHECKING STARTING MOTORp. 840
11-83. TEST AND MAINTENANCE OF STARTING MOTORSp. 841
11-84. INSPECTIONp. 841
11-85. NO LOAD TESTp. 841
11-86. LOCK-TORQUE TESTp. 842
11-87. RESISTANCE TESTp. 843
11-88. DISASSEMBLYp. 843
11-89. COMPONENT INSPECTION AND REPAIRp. 844
11-90. ASSEMBLYp. 845
11-91. STARTING MOTOR SERVICE TEST SPECIFICATIONSp. 845
+11-92. STARTING MOTORS PRESTOLITEp. 846
11-93. DESCRIPTIONp. 846
11-94. OPERATIONp. 846
11-95. MAINTENANCEp. 846
11-96. OVERHAULp. 849
11-97. REMOVALp. 849
11-98. DISASSEMBLYp. 849
11-99. BRUSHESp. 850
11-100. ARMATUREp. 850
11-101. FIELD COILSp. 851
11-102. BRUSH HOLDERSp. 851
11-103. GEAR AND PINION HOUSINGp. 851
11-104. BENDIX DRIVEp. 851
11-105. ASSEMBLYp. 851
11-106. BENCH TESTSp. 852
11-107. STARTING MOTOR CONTROL CIRCUITp. 853
11-108. STARTING MOTOR SERVICE TEST SPECIFICATIONSp. 853
+11-109. BATTERYp. 854
11-110. SERVICING BATTERYp. 854
11-111. REMOVAL OF BATTERYp. 854
11-112. INSTALLATION OF BATTERYp. 854
11-113. CHARGING BATTERYp. 855
11-114. BATTERY BOX CORROSION PREVENTIONp. 855
11-115. STARTING THROUGH EXTERNAL POWERp. 856
+11-116. ALTERNATOR SYSTEM (RRESTOLITE)p. 857
11-117. CHECKING ALTERNATOR SYSTEMp. 857
11-118. ALTERNATOR NOMENCLATUREp. 858
11-119. ALTERNATOR SERVICE PRECAUTIONSp. 858
11-120. DESCRIPTION OF ALTERNATORp. 858
11-121. OVERHAUL OF ALTERNATORp. 859
11-122. DISASSEMBLY OF ALTERNATORp. 860
11-123. INSPECTION AND TESTING OF COMPONENTSp. 861
11-124. ASSEMBLY OF ALTERNATORp. 863
11-125. TESTING OF ALTERNATORp. 864
11-126. ALTERNATOR SERVICE TEST SPECIFICATIONSp. 865
11-127. CHECKING ALTERNATOR BELT TENSIONp. 866
+11-128. INSTRUMENT AND PANEL LIGHTSp. 866
11-129. REMOVAL OF DIMMER CONTROL ASSEMBLYp. 866
11-130. INSTALLATION OF DIMMER CONTROL ASSEMBLYp. 866
+11-131. ANNUNCIATOR PANELp. 867
11-132. DESCRIPTIONp. 867
11-133. REMOVAL OF OIL PRESSURE SENSORp. 867
11-134. INSTALLATION OF OIL PRESSURE SENSORp. 867
11-135. REMOVAL OF VACUUM SENSORp. 867
11-136. INSTALLATION OF VACUUM SENSORp. 868
+11-137. ANTI-COLLISION LIGHT (ROTATING BEACON)p. 868
11-138. REMOVALp. 868
11-139. INSTALLATIONp. 868
+11-140. ANTI-COLLISION (STROBE)p. 868
11-141. DESCRIPTIONp. 868
11-142. REMOVAL OF WING TIP STROBE LIGHTp. 868
11-143. INSTALLATION OF WING TIP STROBE LIGHTp. 869
11-144. REMOVAL OF FIN TIP STROBE LIGHTp. 869
11-145. INSTALLATION OF FIN TIP STROBE LIGHTp. 869
11-146. REMOVAL OF STROBE POWER SUPPLYp. 869
11-147. INSTALLATION OF STROBE POWER SUPPLYp. 870
11-148. TROUBLESHOOTING PROCEDUREp. 870
+TABLE XI-I. INDEX – ELECTRICAL SYSTEM SCHEMATICSp. 779
FIGURE 11-54. ELECTRICAL SYSTEM SCHEMATIC, PA-28-140, S/N’S 28-20000 THRU 28-24999p. 898
FIGURE 11-55. ELECTRICAL SYSTEM SCHEMATIC, PA-28-140, S/N’S 28-25000 THRU 28-7325052p. 899
FIGURE 11-56. ELECTRICAL SYSTEM SCHEMATIC, PA-28-150, -160, S/N’S 28-1 THRU 28-507p. 900
FIGURE 11-57. ELECTRICAL SYSTEM SCHEMATIC, PA-28-150, -160, S/N’S 28-508 THRU 28-670p. 901
FIGURE 11-58. ELECTRICAL SYSTEM SCHEMATIC, PA-28-150, -160, -180, S/N’S 28-671 THRU 28-1760p. 902
FIGURE 11-59. ELECTRICAL SYSTEM SCHEMATIC, PA-28-150, -160, -180, S/N’S 28-1761 THRU 28-3643p. 903
FIGURE 11-60. ELECTRICAL SYSTEM SCHEMATIC, PA-28- 150, – 160, – 180, S/N’S 28-3644 THRU 28-4377p. 904
FIGURE 11-61. ELECTRICAL SYSTEM SCHEMATIC, PA-28-180, S/N’S 28-4378 THRU 28-5227p. 905
FIGURE 11-62. ELECTRICAL SYSTEM SCHEMATIC, PA-28-180, S/N’S 28-5228 THRU 28-7305063p. 906
FIGURE 11-63. ELECTRICAL SYSTEM SCHEMATIC, PA-28-235, S/N’S 28-10003 THRU 28-10719p. 907
FIGURE 11-64. ELECTRICAL SYSTEM SCHEMATIC, PA-28-235, S/N’S 28-10720 THRU 28-10762p. 908
FIGURE 11-65. ELECTRICAL SYSTEM SCHEMATIC, PA-28-235, S/N’S 28-10763 THRU 28-11039p. 909
FIGURE 11-66. ELECTRICAL SYSTEM SCHEMATIC, PA-28-235, S/N’S 28-11040 THRU 28-7310038p. 910
FIGURE 11-67. ELECTRICAL SYSTEM SCHEMATIC, PA-28R-180, S/N’S 28-30005 THRU 28-30879p. 911
FIGURE 11-68. ELECTRICAL SYSTEM SCHEMATIC, PA-28R-180, -200, S/N’S 28-30880 THRU 28-7335054p. 912
FIGURE 11-69. LANDING GEAR BACK-UP ACTUATOR OVERRIDE MECHANISMp. 913
FIGURE 11-70. LANDING GEAR BACK-UP ACTUATOR OVERRIDE MECHANISMp. 913
+THE FOLLOWING SYSTEM SCHEMATICS ARE FOR 1973 MODELS AND UPp. 779
FIGURE 11-107. A/C AIR BLOWER, PA-28-140, S/N’S 28-7425001 & UP; PA-28-180, S/N’S 28-7405001 & UP; PA-28R-200, S/N’S 28-7435001 & UP; PA-28-235, S/N’S 28-7410001 & UPp. 930
FIGURE 11-85. ALTERNATOR, STARTER, CABIN LIGHT, CIGAR LIGHTER AND EXTERNAL POWER RECEPTACLE, PA-28-140, S/N’S 28-25000 THRU 28-7325052p. 916
FIGURE 11-86. ALTERNATOR, STARTER, CABIN LIGHT, CIGAR LIGHTER AND EXTERNAL POWER RECEPTACLE, PA-28-140, S/N’S 28-7325053 THRU 28-7425454p. 917
FIGURE 11-125. ALTERNATOR, STARTER, CABIN LIGHT, CIGAR LIGHTER AND EXTERNAL POWER RECEPTACLE, PA-28-140, S/N’S 28-7525001 & UPp. 935
FIGURE 11-87. ALTERNATOR, STARTER, CABIN LIGHT, CIGAR LIGHTER AND EXTERNAL POWER RECEPTACLE, PA-28-180, S/N’S 28-5228 THRU 28-7305063; PA-28-235, S/N’S 28-11040 THRU 28-7310038p. 918
FIGURE 11-88. ALTERNATOR, STARTER, CABIN LIGHT, CIGAR LIGHTER AND EXTERNAL POWER RECEPTACLE, PA-28-235, S/N’S 28-7310039 THRU 28-7310187p. 919
FIGURE 11-89. ALTERNATOR, STARTER, CABIN LIGHTER, CIGAR LIGHTER AND EXTERNAL POWER RECEPTACLE, PA-28-180, S/N’S 28-7305064 THRU 28-7405290; PA-28R-200, S/N’S 28-7335055 THRU 28-7435331; PA-28-235, S/N’S 28-7410001 THRU 28-7410120p. 920
FIGURE 11-126. ALTERNATOR, STARTER, CABIN LIGHTER, CIGAR LIGHTER AND EXTERNAL POWER RECEPTACLE, PA-28-180, S/N’S 28-7505001 & UP; PA-28R-200, S/N’S 28-7535001 & UP; PA-28-235, S/N’S 28-7510001 & UPp. 936
FIGURE 11-144. ANTI-COLLISION LIGHTp. 944
FIGURE 11-92. AVIONICS, PA-28-140, S/N’S 28-7325053 THRU 28-7425454p. 923
FIGURE 11-93. AVIONICS, PA-28-180, S/N’S 28-7305064 THRU 28-7305611; PA-28R-200, S/N’S 28-7335055 THRU 28-7335455; PA-28-235, S/N’S 28-7310039 THRU 28-7310187p. 923
FIGURE 11-94. AVIONICS, PA-28-180, S/N’S 28-7405001 THRU 28-7405290; PA-28-235, S/N’S 28-7410001 THRU 28-7410120p. 924
FIGURE 11-95. AVIONICS, PA-28R-200, S/N’S 28-7435001 THRU 28-7435331p. 924
FIGURE 11-128. AVIONICS, PA-28-140, S/N’S 28-7525001 & UP; PA-28-180, S/N’S 28-7505001 & UP; PA-28-235, S/N’S 28-7510001 & UPp. 938
FIGURE 11-129. AVIONICS, PA-28R-200, S/N’S 28-7535001 & UPp. 938
FIGURE 11-97. ENGINE GAUGES, PA-28-180, S/N’S 28-7305064 THRU 28-7305611; PA-28R-200, S/N’S 28-7335055 THRU 28-7335455p. 925
FIGURE 11-98. ENGINE GAUGES, PA-28-235, S/N’S 28-7310039 THRU 28-7410120p. 926
FIGURE 11-96. ENGINE GAUGES, PA-28-140, S/N’S 28-7325053 THRU 28-7425454; PA-28-180, S/N’S 28-7405001 THRU 28-7405290; PA-28R-200, S/N’S 28-7435001 THRU 28-7435331p. 925
FIGURE 11-133. ENGINE GAUGES, PA-28-235, S/N’S 28-7510001 & UPp. 940
FIGURE 11-134. ENGINE GAUGES, PA-28-140, S/N’S 28-7525001 & UP; PA-28-180, S/N’S 28-7505001 & UPp. 941
FIGURE 11-135. ENGINE GAUGES, PA-28R-200, S/N’S 28-7535001 & UPp. 941
FIGURE 11-139. FIN STROBE ANTI-COLLISION LIGHTp. 943
FIGURE 11-110. FUEL PUMP, PA-28-140, S/N’S 28-7325053 THRU 28-7520004; PA-28-180, S/N’S 28-7305064 THRU 28-7505004; PA-28R-200, S/N’S 28-7335055 THRU 28-7535004; PA-28-235, S/N’S 28-7310039 THRU 28-7510004p. 931
FIGURE 11-124. FUEL PUMP, PA-28-140, S/N’S 28-7525005 & UP; PA-28-180, S/N’S 28-7505005 & UP; PA-28R-200, S/N’S 28-7535005 & UP; PA-28-235, S/N’S 28-7510005 & UPp. 934
FIGURE 11-99. INSTRUMENT LIGHTS, PA-28- 140, S/N’S 28-7325053 THRU 28-7325684p. 926
FIGURE 11-100. INSTRUMENT LIGHTS, PA-28-140, S/N’S 28-7325053 THRU 28-7425454p. 927
FIGURE 11-130. INSTRUMENT LIGHTS, PA-28-140, S/N’S 28-7525001 & UPp. 939
FIGURE 11-101. INSTRUMENT LIGHTS, PA-28-180, S/N’S 28-7305064 THRU 28-7305611p. 927
FIGURE 11-102. INSTRUMENT LIGHTS, PA-28-180, S/N’S 28-7405001 THRU 28-7405290p. 928
FIGURE 11-103. INSTRUMENT LIGHTS, PA-28R-200, S/N’S 28-7335055 THRU 28-7335455p. 928
FIGURE 11-104. INSTRUMENT LIGHTS, PA-28R-200, S/N’S 28-7435001 THRU 28-7435331p. 929
FIGURE 11-105. INSTRUMENT LIGHTS, PA-28-235, S/N’S 28-7310039 THRU 28-7310187p. 929
FIGURE 11-106. INSTRUMENT LIGHTS, PA-28-235, S/N’S 28-7410001 THRU 28-7410120p. 930
FIGURE 11-131. INSTRUMENT LIGHTS, PA-28-180, S/N’S 28-7505001 & UP; PA-28-235, S/N’S 28-7510001 & UPp. 939
FIGURE 11-132. INSTRUMENT LIGHTS, PA-28R-200, S/N’S 28-7535001 & UPp. 940
FIGURE 11-90. LANDING GEAR, PA-28R-200, S/N’S 28-7335055 THRU 28-7335455p. 921
FIGURE 11-91. LANDING GEAR, PA-28R-200, S/N’S 28-7435001 THRU 28-7435331p. 922
FIGURE 11-127. LANDING GEAR, PA-28R-200, S/N’S 28-7535001 & UPp. 937
FIGURE 11-111. LANDING LIGHT, PA-28-140, S/N’S 28-7325053 THRU 28-7425454; PA-28-180, S/N’S 28-7305064 THRU 28-7405290; PA-28R-200, S/N’S 28-7335055 THRU 28-7435331; PA-28-235, S/N’S 28-7310039 THRU 28-7410120p. 931
FIGURE 11-142. LANDING LIGHT, PA-28-140, S/N’S 28-7525001 & UP; PA-28-180, S/N’S 28-7505001 & UP; PA-28R-200, S/N’S 28-7535001 & UP; PA-28-235, S/N’S 28-7510001 & UPp. 944
FIGURE 11-112. NAVIGATION LIGHTS, PA-28-140, S/N’S 28-7325053 THRU 28-7425454; PA-28-180, S/N’S 28-7305064 THRU 28-7405290; PA-28R-200, S/N’S 28-7335055 THRU 28-7435331; PA-28-235, S/N’S 28-7310039 THRU 28-7410120p. 931
FIGURE 11-140. NAVIGATION LIGHTS, PA-28-140, S/N’S 28-7525001 & UP; PA-28- 180, S/N’S 28-7505001 & UP; PA-28R-200, S/N’S 28-7535001 & UP; PA-28-235, S/N’S 28-7510001 & UPp. 943
FIGURE 11-109. OVERHEAD FLOOD LIGHT, PA-28-140, S/N’S 28-7425001 THRU 28-7425454; PA-28-180, S/N’S 28-7405001 THRU 28-7405290; PA-28R-200, S/N’S 28-7435001 THRU 28-7435331; PA-28-235, S/N’S 28-7410001 THRU 28-7410120;p. 931
FIGURE 11-141. OVERHEAD FLOOD LIGHT, PA-28-140, S/N’S 28-7525001 & UP; PA-28-180, S/N’S 28-7505001 & UP; PA-28R-200, S/N’S 28-7535001 & UP; PA-28-235, S/N’S 28-7510001 & UPp. 944
FIGURE 11-113. PITCH TRIM, PA-28-140, S/N’S 28-7325053 THRU 28-7325684; PA-28-180, S/N’S 28-7305064 THRU 28-7305611; PA-28R-200, S/N’S 28-7335055 THRU 28-7335455; PA-28-235, S/N’S 28-7310039 THRU 28-7310187p. 932
FIGURE 11-114. PITCH TRIM, PA-28-140, S/N’S 28-7425001 & UP; PA-28-180, S/N’S 28-7405001 & UP; PA-28R-200, S/N’S 28-7435001 & UP; PA-28-235, S/N’S 28-7410001 & UPp. 932
FIGURE 11-115. PITOT HEAT, PA-28-140, S/N’S 28-7325053 THRU 28-7425454p. 932
FIGURE 11-116. PITOT HEAT, PA-28-180, S/N’S 28-7305064 THRU 28-7305611; PA-28-235, S/N’S 28-7310039 THRU 28-7310187p. 932
FIGURE 11-117. PITOT HEAT, PA-28-180, S/N’S 28-7405001 THRU 28-7405290; PA-28-235, S/N’S 28-7410001 THRU 28-7410120p. 933
FIGURE 11-137. PITOT HEAT, PA-28-140, S/N’S 28-7525001 & UP; PA-28-180, S/N’S 28-7505001 & UP; PA-28-235, S/N’S 28-7510001 & UPp. 943
FIGURE 11-118. PITOT AND PRESSURE HEAD HEATER, PA-28R-200, S/N’S 28-7335055 THRU 28-7435331p. 933
FIGURE 11-143. PITOT AND PRESSURE HEAD HEATER, PA-28R-200, S/N’S 28-7535001 & UPp. 944
FIGURE 11-119. RADIO LIGHTS, PA-28-140, S/N’S 28-7425001 & UP; PA-28-180, S/N’S 28-7405001 & UP; PA-28R-200, S/N’S 28-7435001 & UP; PA-28-235, S/N’S 28-7410001 & UPp. 933
FIGURE 11-108. ROTATING BEACON, PA-28-140, S/N’S 28-7325053 & UP; PA-28-180, S/N’S 28-7305064 & UP; PA-28R-200, S/N’S 28-7335055 & UP; PA-28-235, S/N’S 28-7310039 & UPp. 930
FIGURE 11-120. STALL WARNING, PA-28-140, S/N’S 28-7325053 THRU 28-7525350; PA-28-180, S/N’S 28-7305064 THRU 28-7505269; PA-28R-200, S/N’S 28-7335055 THRU 28-7535393; PA-28-235, S/N’S 28-7310039 THRU 28-7510145p. 933
FIGURE 11-138. STALL WARNING, PA-28-140, S/N’S 28-7625001 & UP; PA-28R-200, S/N’S 28-7635001 & UP; PA-28-235, S/N’S 28-7610001 & UPp. 943
FIGURE 11-121. TURN & BANK, PA-28-140, S/N’S 28-7325053 & UPp. 934
FIGURE 11-122. TURN & BANK, PA-28-180, S/N’S 28-7405001 & UP; PA-28-235, S/N’S 28-7410001 & UPp. 934
FIGURE 11-123. TURN & BANK, PA-28R-200, S/N’S 28-7335055 & UPp. 934
+SECTION XII – ELECTRONICSp. 945
TABLE OF CONTENTSp. 945
12-1. INTRODUCTIONp. 946
12-2. EMERGENCY LOCATOR TRANSMITTER (GARRETT MFG. LTD.)p. 946
12-3. DESCRIPTIONp. 946
12-4. BATTERY REMOVAL AND INSTALLATION (2 YEAR MAGNESIUM)p. 946
12-5. BATTERY REMOVAL AND INSTALLATION (NARCO)p. 949
12-6. TESTING EMERGENCY LOCATOR TRANSMITTERp. 951
12-7. PILOT’S REMOTE SWITCHp. 952
12-8. TESTING PILOT’S REMOTE SWITCHp. 952
12-9. INADVERTENT ACTIVATIONp. 953
12-10. EMERGENCY LOCATOR TRANSMITTER (COMMUNICATIONS COMPONENTS CORP.)p. 954
12-11. DESCRIPTIONp. 954
12-12. BATTERY REMOVAL AND INSTALLATIONp. 954
12-13. PILOT’S REMOTE SWITCHp. 955
12-14. TESTING EMERGENCY LOCATOR TRANSMITTERp. 955
12-15. TESTING PILOT’S REMOTE SWITCHp. 955
12-16. INADVERTENT ACTIVATIONp. 955
12-17. AUTOFLIGHT – GENERALp. 956
12-18. NON-PIPER A.F.C.S. EQUIPMENT CONTACTSp. 956
12-19. PIPER A.F.C.S. EQUIPMENTp. 956
12-20. RACK-MOUNTED AVIONICSp. 957
+SECTION XIII – HEATING AND VENTILATION SYSTEMp. 958
TABLE OF CONTENTSp. 958
13-1. INTRODUCTIONp. 959
13-2. DESCRIPTIONp. 959
13-3. HEATER MAINTENANCEp. 960
13-4. OVERHEAD VENT SYSTEMp. 960
+SECTION XIV – ACCESSORIES AND UTILITIESp. 972
TABLE OF CONTENTSp. 972
14-1. AIR CONDITIONING INSTALLATIONp. 974
14-2. DESCRIPTIONp. 974
14-3. AIR CONDITIONING SYSTEM OPERATIONp. 974
14-4. MALFUNCTION DETECTIONp. 977
14-5. SPECIAL SERVICING PROCEDURESp. 978
14-6. SERVICE VALVESp. 980
14-7. SERVICE VALVE REPLACEMENTp. 980
14-8. TEST GAUGE AND MANIFOLD SETp. 981
14-9. CHECKING THE SYSTEM FOR LEAKSp. 981
14-10. LEAK CHECK – METHOD Ip. 983
14-11. LEAK CHECK – METHOD IIp. 984
14-12. DISCHARGINGp. 984
14-13. EVACUATING THE SYSTEMp. 985
14-14. CHARGING THE SYSTEMp. 986
14-15. WITH A CHARGING STANDp. 987
14-16. USING THE AIRPLANE COMPRESSOR TO CHARGE THE SYSTEMp. 988
14-17. ADDITION OF PARTIAL CHARGE TO SYSTEMp. 989
14-18. COMPRESSOR SERVICEp. 990
14-19. COMPRESSOR REMOVALp. 991
14-20. COMPRESSOR INSTALLATIONp. 991
14-21. CHECKING COMPRESSOR OILp. 992
14-22. REPLACEMENT OF COMPRESSOR AND/OR ALTERNATOR DRIVE BELTSp. 993
14-23. ADJUSTMENT OF DRIVE BELT TENSIONp. 995
14-24. MAGNETIC CLUTCHp. 999
14-25. MAGNETIC CLUTCH REMOVALp. 999
14-26. MAGNETIC CLUTCH INSTALLATIONp. 1000
14-27. REFRIGERANT LINES AND ROUTINGp. 1000
14-28. RECEIVER-DEHYDRATORp. 1001
14-29. RECEIVER-DEHYDRATOR REMOVALp. 1001
14-30. RECEIVER-DEHYDRATOR INSTALLATIONp. 1001
14-31. CONDENSERp. 1001
14-32. CONDENSER ASSEMBLY REMOVALp. 1001
14-33. CONDENSER INSTALLATIONp. 1002
14-34. CONDENSER DOOR ACTUATORp. 1002
14-35. CONDENSER ASSEMBLY RIGGING INSTRUCTIONSp. 1004
14-36. EXPANSION VALVEp. 1005
14-37. EXPANSION VALVE REMOVALp. 1005
14-38. EXPANSION VALVE INSTALLATIONp. 1005
14-39. EVAPORATOR ASSEMBLYp. 1006
14-40. EVAPORATOR ASSEMBLY REMOVALp. 1006
14-41. EVAPORATOR ASSEMBLY INSTALLATIONp. 1006
14-42. PRESSURE RELIEF SWITCH (RANCO)p. 1007
14-43. ELECTRICAL INSTALLATIONp. 1008
14-44. ADJUSTMENT OF THROTTLE SWITCHp. 1008
14-45. FUSE REPLACEMENT (PA-28-140, 28-7125472 TO 28-7325057, PA-28-180, 28-7205092 TO 28-7305071, PA-28R-180, 28R-7235001 TO 28R-7335057.)p. 1009
14-46. FUSE REPLACEMENT (PA-28-140, 28-7325058 AND UP, PA-28-180, 28-7305072 AND UP, PA-28R-200, 28R-7335058 AND UP.)p. 1009
14-47. RESTRAINT SYSTEMp. 1020
14-48. OVERHEAD VENT BLOWERp. 1020
14-49. DESCRIPTIONp. 1020
14-50. REMOVAL OF BLOWER ASSEMBLYp. 1020
14-51. DISASSEMBLY OF BLOWER ASSEMBLYp. 1021
14-52. REASSEMBLY OF BLOWER ASSEMBLYp. 1021
14-53. INSTALLATION OF BLOWER ASSEMBLYp. 1021
14-54. PORTABLE FIRE EXTINGUISHERp. 1022
+LIST OF ILLUSTRATIONSp. 5
FIGURE 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 UPp. 28
FIGURE 2-2. THREE VIEW OF CHEROKEE, PA-28-140, S/N’S 28-7225001 AND UPp. 29
FIGURE 2-3. THREE VIEW OF CHEROKEE, PA-28-150, -160, -180, S/N’S 28-1761 THRU 28-4377p. 30
FIGURE 2-4. THREE VIEW OF CHEROKEE, PA-28-180, S/N’S 28-4378 THRU 28-7105244p. 31
FIGURE 2-5. THREE VIEW OF CHEROKEE, PA-28-180, S/N’S 28-7205001 THRU 28-7205328p. 32
FIGURE 2-6. THREE VIEW OF CHEROKEE, PA-28-180, S/N’S 28-7305001 AND UPp. 33
FIGURE 2-7. THREE VIEW OF CHEROKEE, PA-28-235, S/N’S 28-10000 THRU 28-11039p. 34
FIGURE 2-8. THREE VIEW OF CHEROKEE, PA-28-235, S/N’S 28-11040 THRU 28-7110042p. 35
FIGURE 2-9. THREE VIEW OF CHEROKEE, PA-28-235, S/N’S 28-7210001 THRU 28-7210033p. 36
FIGURE 2-10. THREE VIEW OF CHEROKEE, PA-28-235, S/N’S 28-7310001 AND UPp. 37
FIGURE 2-11. THREE VIEW OF CHEROKEE, PA-28R-180 S/N’S 28-30005 THRU 28-7130019, PA 28R -200 S/N’S 28-30482 THRU 28-7135238p. 38
FIGURE 2-12. THREE VIEW OF CHEROKEE, PA-28R-200, S/N’S 28-7235001 AND UPp. 39
FIGURE 2-13. STATION REFERENCE LINES, PA-28-140ANF PA-28-150, -160, -180, S/N’S 28-1 THRU 28-1760; PA -28 -140 FLITE LINER, S/N’S 28-7125174 AND UPp. 52
FIGURE 2-14. STATION REFERENCE LINES, PA-28-140, S/N’S 28-7225001 AND UPp. 53
FIGURE 2-15. STATION REFERENCE LINES, PA-28-150, -160. -180, S/N’S 28-1761 THRU 28-4377p. 54
FIGURE 2-16. STATION REFERENCE LINES, PA-28-180, S/N’S 28-4378 THRU 28-7105244p. 55
FIGURE 2-17. STATION REFERENCE LINES, PA-28-180, S/N’S 28-7205001 THRU 28-7205328p. 56
FIGURE 2-18. STATION REFERENCE LINES, PA-28-180, S/N’S 28-7305001 AND UPp. 57
FIGURE 2-19. STATION REFERENCE LINES, PA-28-235, S/N’S 28-10000 THRU 28-11039p. 58
FIGURE 2-20. STATION REFERENCE LINES, PA-28-235, S/N’S 28-11040 TO 28-7110042p. 59
FIGURE 2-21. STATION REFERENCE LINES, PA-28-235, S/N’S 28-7210001 THRU 28-7210033p. 60
FIGURE 2-22. STATION REFERENCE LINES, PA-28-235, S/N’S 28-7310001 AND UPp. 61
FIGURE 2-23. STATION REFERENCE LINES, PA-28R-180 S/N’S 28-30005 THRU 28-7130019; PA-28R-200 S/N’S 28-30482 THRU 28-7135238p. 62
FIGURE 2-24. STATION REFERENCE LINES, PA-28R-200, S/N’S 28-7235001 AND UPp. 63
FIGURE 2-25. ACCESS PLATES AND PANELS, PA-28-140 AND FLITE LINER, S/N’S 28-7225001 AND UP AS NOTEDp. 64
FIGURE 2-26. ACCESS PLATES AND PANELS, PA-28-150, -160, -180p. 65
FIGURE 2-27. ACCESS PLATES AND PANELS, PA-28-235p. 66
FIGURE 2-28. ACCESS PLATES AND PANELS, PA-28Rp. 67
FIGURE 2-29. IDENTIFICATION OF AIRCRAFT FLUID LINESp. 79
FIGURE 2-30. TORQUE WRENCH FORMULAp. 68
FIGURE 2-31. REMOVING CHERRYLOCK RIVETSp. 80
FIGURE 2-32. JACKING ARRANGEMENTp. 81
FIGURE 2-33. WEIGHING AIRPLANEp. 82
FIGURE 2-34. LEVELING LONGITUDINALLYp. 83
FIGURE 2-35. LEVELING LATERALLYp. 83
FIGURE 2-36. SERVICING POINTS, PA-28-140p. 91
FIGURE 2-37. SERVICING POINTS, PA-28-150,-160, -180p. 92
FIGURE 2-38. SERVICING POINTS, PA-28-235p. 93
FIGURE 2-39. SERVICING POINTS, PA-28Rp. 94
FIGURE 2-40. MAIN GEAR OLEO STRUTS (CUTAWAY VIEW), PA-28-140; PA-28-150,-160,-180; PA-28-235p. 95
FIGURE 2-41. TIRE BALANCERp. 100
FIGURE 2-42. FUEL STRAINER, PA-28-140; PA-28-150, -160, -180; AND PA-28Rp. 105
FIGURE 2-43. FUEL SELECTOR AND FILTER, PA-28-235p. 105
FIGURE 2-44. LUBRICATION CHART (LANDING GEAR, MAIN), PA-28-140, -150, -160, -180 AND -235p. 114
FIGURE 2-45. LUBRICATION CHART (LANDING GEAR, MAIN), PA-28R-180 AND -200p. 115
FIGURE 2-46. LUBRICATION CHART (LANDING GEAR, NOSE), PA-28-140, -150, -160, -180 AND -235p. 116
FIGURE 2-47. LUBRICATION CHART (LANDING GEAR, NOSE), PA-28R-180 AND -200p. 117
FIGURE 2-48. LUBRICATION CHART (CONTROL SYSTEM, SHEETS 1 THRU 4)p. 118
FIGURE 2-51. LUBRICATION CHART (CABIN DOOR. BAGGAGE DOOR AND SEAT)p. 122
FIGURE 2-52. LUBRICATION CHART (POWER PLANT, PROPELLER AND CONTROL PIVOT POINTS)p. 123
FIGURE 2-53. LUBRICATION CHART (BACK-UP EXTENDER AND FUEL SELECTOR)p. 124
FIGURE 2-54. LUBRICATION CHART (AIR CONDITIONING CONDENSER)p. 125
FIGURE 3-1. ELECTRIC TRIM SWITCH INSPECTIONp. 698
FIGURE 3-2. AIR INDUCTION INLET HOSE INSPECTIONp. 699
FIGURE 3-3. SPINNER AND SPINNER BULKHEAD INSPECTIONp. 700
FIGURE 3-4. STABILATOR BALANCE WEIGHT TUBE INSPECTIONp. 703
FIGURE 3-5. FUEL SELECTOR VALVE INSPECTIONp. 705
FIGURE 3-6. WING RIB ASSEMBLY INSPECTIONp. 707
FIGURE 3-7. WING RIB ASSEMBLY DATE STAMP IDENTIFICATIONp. 708
FIGURE 3-8. STABILATOR ATTACH FITTING CORROSION INSPECTIONp. 713
FIGURE 3-9. FLAP CONTROL CABLE ATTACHMENT BOLT INSPECTIONp. 714
FIGURE 3-10. WING ATTACH FITTINGSp. 716
FIGURE 3-11. DRAIN HOLE INSTALLATIONp. 717
FIGURE 3-12. FUEL TANK AND WING SPAR CORROSION INSPECTIONp. 719
FIGURE 3-13. MAIN GEAR STRUT CYLINDERp. 721
FIGURE 3-14. CONTROL CABLE INSPECTIONp. 722
FIGURE 3-15. EXTERNAL CABLE PATTERNSp. 723
FIGURE 3-16. INTERNAL CABLE PATTERNSp. 724
FIGURE 3-17. PULLEY WEAR PATTERNSp. 726
FIGURE 3-18. TYPICAL MUFFLER FATIGUE AREASp. 727
FIGURE 3-19. EXHAUST SYSTEM INSPECTION POINTS, (SHEETS 1 THRU 2)p. 728
FIGURE 3-20. EXHAUST SYSTEM INSTALLATION, PA-28R-180,-200p. 730
FIGURE 3-21. CONTROL WHEEL INSPECTION POINTSp. 731
FIGURE 3-22. AILERON HINGE DOUBLER 100 HOUR INSPECTIONp. 732
FIGURE 3-23. INSPECTION OF MAIN LANDING GEAR TORQUE LINKSp. 733
FIGURE 3-24. UPPER NOSE GEAR OLEO BEARING INSPECTIONp. 735
FIGURE 3-25. RUDDER BAR ASSEMBLY 100 INSPECTIONp. 736
FIGURE 3-26. RETENTION CLIP ADJUSTMENTp. 738
FIGURE 3-27. MAIN LANDING GEAR TORQUE LINK GREASER BOLT INSPECTIONp. 738
FIGURE 4-1. AILERON AND FLAP INSTALLATIONp. 135
FIGURE 4-2. WING INSTALLATIONp. 139
FIGURE 4-3. METHODS OF SECURING CONTROL CABLESp. 147
FIGURE 4-4. EMPENNAGE GROUP INSTALLATIONp. 151
FIGURE 4-5. WINDSHIELD INSTALLATION (TYPICAL)p. 156
FIGURE 4-6. SIDE WINDOW INSTALLATION, SINGLE PANE (TYPICAL)p. 158
FIGURE 4-7. SIDE WINDOW INSTALLATION, DOUBLE PANE (TYPICAL)p. 158
FIGURE 4-8. DOOR SNUBBER INSTALLATIONp. 160
FIGURE 4-9. SEAT BACK LOCKp. 163
FIGURE 4-10. SKIN MATERIALS AND THICKNESSp. 165
FIGURE 4-10A. METAL WIRE STITCHING REPAIRp. 167
FIGURE 4-11. SURFACE SCRATCHES, ABRASIONS OR GROUND-IN-DIRTp. 172
FIGURE 4-12. DEEP SCRATCHES, SHALLOW NICKS AND SMALL HOLESp. 173
FIGURE 4-13. MIXING OF EPOXY PATCHING COMPOUNDp. 173
FIGURE 4-14. WELDING REPAIR METHODp. 175
FIGURE 4-15. REPAIRING OF CRACKSp. 175
FIGURE 4-16. VARIOUS REPAIRSp. 176
FIGURE 4-17. REPAIR OF STRESS LINESp. 177
FIGURE 4-18. REPAIR OF IMPACTED DAMAGEp. 177
FIGURE 4-19. CONTROL SURFACE BALANCE TOOLp. 184
FIGURE 4-20. AILERON AND RUDDER BALANCE CONFIGURATIONp. 185
FIGURE 4-21. STABILATOR BALANCEp. 186
FIGURE 4-22. WING RIB MODIFICATIONp. 188
FIGURE 4-23. BALANCE WEIGHT ASSEMBLY INSTALLATIONp. 188
FIGURE 4-24. FABRICATED TOOL FOR BAGGAGE DOOR LOCKp. 189
FIGURE 4-25. ADDITIONAL DRAIN HOLES IN STABILATORp. 190
FIGURE 4-26. BAGGAGE COMPARTMENT INSPECTION HOLES CUTOUT DETAILSp. 193
FIGURE 4-27. MILLIVOLT DROP TESTp. 195
FIGURE 5-1. CONTROL COLUMN ASSEMBLY, PA-28-140,-150,-160, -180 AND -235p. 226
FIGURE 5-2. CONTROL COLUMN ASSEMBLY, PA-28Rp. 227
FIGURE 5-2A. UNIVERSAL, OR FLEX, JOINT INSTALLATIONp. 229
FIGURE 5-3. AILERON CONTROLSp. 230
FIGURE 5-4. BELLCRANK RIGGING TOOL APPLICATION AND FABRICATIONp. 236
FIGURE 5-5. AILERON RIGGING TOOL APPLICATION AND FABRICATIONp. 237
FIGURE 5-6. STABILATOR CONTROLSp. 240
FIGURE 5-7. STABILATOR RIGGING TOOL APPLICATION AND FABRICATIONp. 242
FIGURE 5-8. STABILATOR TRIM CONTROL (OVERHEAD CONTROL)p. 244
FIGURE 5-9. METHODS OF SECURING TRIM CABLESp. 246
FIGURE 5-10. STABILATOR TRIM CONTROL (FLOOR CONTROL)p. 254
FIGURE 5-11. RUDDER AND STEERING PEDAL ASSEMBLYp. 258
FIGURE 5-12. RUDDER CONTROLSp. 261
FIGURE 5-13. RUDDER RIGGING TOOL APPLICATION AND FABRICATIONp. 263
FIGURE 5-14. RUDDER AND STABILATOR TRAVEL ADJUSTMENTSp. 264
FIGURE 5-15. RUDDER TRIM CONTROL INSTALLATION – PA-28-140/150/160/180/235p. 266
FIGURE 5-16. RUDDER TRIM CONTROLp. 267
FIGURE 5-17. FLAP CONTROLSp. 270
FIGURE 5-18. FLAP RIGGING TOOL APPLICATION AND FLAP STOP ADJUSTMENTp. 272
FIGURE 5-19. CORRECT METHOD OF INSTALLING ROD END BEARINGSp. 274
FIGURE 6-1. SCHEMATIC DIAGRAM OF HYDRAULIC SYSTEMp. 287
FIGURE 6-2. HYDRAULIC SYSTEM INSTALLATIONp. 288
FIGURE 6-3. HYDRAULIC PUMP/RESERVOIR. EXPLODED VIEWp. 292
FIGURE 6-4. TEST AND ADJUSTMENTS OF HYDRAULIC PUMPp. 295
FIGURE 6-5. PUMP SHOCK MOUNTSp. 296
FIGURE 6-5A. HYDRAULIC PUMP/RESERVOIRp. 299
FIGURE 6-6. CHECKING ALIGNING BRACKETS OF GEAR BACK-UP EXTENDER ACTUATOR AND FABRICATION OF THE ALIGNING TOOLp. 302
FIGURE 6-7. GEAR BACK-UP EXTENDER ACTUATORp. 305
FIGURE 6-8. NOSE GEAR ACTUATOR CYLINDERp. 310
FIGURE 6-9. END GLAND LOCKING DEVICEp. 313
FIGURE 6-10. MAIN GEAR ACTUATING CYLINDERp. 313
FIGURE 7-1. NOSE GEAR OLEO STRUT ASSEMBLYp. 332
FIGURE 7-2. NOSE GEAR INSTALLATIONp. 336
FIGURE 7-3. CLAMPING RUDDER PEDALS IN NEUTRAL POSITIONp. 338
FIGURE 7-4. RUDDER PEDALS AT NEUTRAL ANGLEp. 338
FIGURE 7-5. MAIN GEAR OLEO STRUT ASSEMBLY, PA-28-140, -150, -160 AND -180p. 343
FIGURE 7-6. MAIN GEAR OLEO STRUT ASSEMBLY, PA-28-235p. 345
FIGURE 7-7. MAIN GEAR INSTALLATIONp. 349
FIGURE 7-8. NOSE WHEEL ASSEMBLYp. 351
FIGURE 7-9. MAIN WHEEL ASSEMBLYp. 353
FIGURE 7-10. WHEEL BRAKE ASSEMBLYp. 355
FIGURE 7-11. REMOVAL OF ANCHOR BOLTp. 356
FIGURE 7-12. INSTALLATION OF ANCHOR BOLTp. 357
FIGURE 7-13. BRAKE DISC MINIMUM THICKNESSp. 359
FIGURE 7-14. BRAKE SYSTEM INSTALLATIONp. 359
FIGURE 7-15. BRAKE MASTER CYLINDER (HAND BRAKE), PA-28-150, -160, S/N’S 28-1 THRU 28-250p. 362
FIGURE 7-16. BRAKE MASTER CYLINDER (HAND/PARKING BRAKE), PA-28-140, S/N’S 28-20002 THRU 28-21036; PA-28-150, -160, -180, S/N’S 28-251 THRU 28-2700; PA-28-235, S/N’S 28-10003 THRU 28-10697p. 362
FIGURE 7-17. BRAKE MASTER CYLINDER (HAND/PARKING BRAKE), PA-28-140, S/N’S 28-21037 AND UP; PA-28-150, -160, -180, S/N’S 28-2701 AND UP; PA-28-235, S/N’S 28-10698 AND UPp. 363
FIGURE 7-18. PARKING VALVE, PA-28-150, -160, S/N’S 28-1 THRU 28-250p. 365
FIGURE 7-19. TOE BRAKE INSTALLATIONp. 366
FIGURE 7-20. BRAKE CYLINDER 10-20. 10-27. 17000 (TOE BRAKE)p. 368
FIGURE 7-21. BRAKE CYLINDER 10-30 (TOE BRAKE)p. 369
FIGURE 7-22. BLEEDING BRAKE (GRAVITY)p. 372
FIGURE 7-23. BLEEDING BRAKE (PRESSURE)p. 372
FIGURE 7-24. ORIFICE REPLACEMENT TOOLp. 377
FIGURE 7-25. RETAINER RING TOOLp. 378
FIGURE 7A-1. NOSE GEAR OLEO STRUT ASSEMBLYp. 386
FIGURE 7A-2. NOSE GEAR INSTALLATIONp. 389
FIGURE 7A-3. NOSE GEAR ADJUSTMENT (WITHOUT GEAR UP STOP)p. 394
FIGURE 7A-4. NOSE GEAR ADJUSTMENT (WITH GEAR UP STOP)p. 394
FIGURE 7A-5. CLAMPING RUDDER PEDALS IN NEUTRAL POSITIONp. 397
FIGURE 7A-6. RUDDER PEDALS AT NEUTRAL ANGLEp. 397
FIGURE 7A-7. NOSE GEAR DOOR RETRACTION MECHANISMp. 398
FIGURE 7A-8. MAIN GEAR OLEO STRUT ASSEMBLYp. 403
FIGURE 7A-9. MAIN GEAR INSTALLATIONp. 406
FIGURE 7A-9A. MAIN LANDING GEAR TRUNNION REPAIRp. 408
FIGURE 7A-10. ALIGNING MAIN GEARp. 412
FIGURE 7A-11. ADJUSTMENT OF NOSE GEAR DOWN LIMIT SWITCHp. 417
FIGURE 7A-12. ADJUSTMENT OF MAIN GEAR DOWN LIMIT SWITCHp. 417
FIGURE 7A-13. WIRING DIAGRAM OF LANDING GEAR ELECTRICAL CIRCUITp. 419
FIGURE 7A-14. THROTTLE WARNING SWITCHESp. 421
FIGURE 7A-15. NOSE WHEEL ASSEMBLYp. 424
FIGURE 7A-16. MAIN WHEEL ASSEMBLYp. 425
FIGURE 7A-17. WHEEL BRAKE ASSEMBLYp. 427
FIGURE 7A-18. BRAKE DISC MINIMUM THICKNESSp. 429
FIGURE 7A-19. BRAKE SYSTEM INSTALLATIONp. 429
FIGURE 7A-20. BRAKE MASTER CYLINDER (HAND PARKING BRAKE)p. 431
FIGURE 7A-21. TOE BRAKE INSTALLATIONp. 432
FIGURE 7A-22. BRAKE CYLINDER (TOE BRAKE) (10-20. 10-27. 17000)p. 434
FIGURE 7A-23. BRAKE CYLINDER (TOE BRAKE) (10-30)p. 436
FIGURE 7A-24. BEARING INSTALLATIONp. 437
FIGURE 7A-25. NOSE GEAR SERVICE TOLERANCES, PA-28Rp. 446
FIGURE 7A-26. MAIN GEAR SERVICE TOLERANCES, PA-28Rp. 449
FIGURE 8-1. TYPICAL NICKS AND REMOVAL METHODp. 458
FIGURE 8-2. PROPELLER INSTALLATION (CONSTANT SPEED) PA-28-235p. 458
FIGURE 8-3. PROPELLER INSTALLATIONp. 459
FIGURE 8-4. ADJUSTMENT OF PROPELLER CONTROL, PA-28-235p. 463
FIGURE 8-5. PROPELLER GOVERNOR, PA-28-235p. 463
FIGURE 8-6. ENGINE INSTALLATION, PA-28-140,-150,-160,-180, S/N’S 28-1 THRU 28-1760p. 466
FIGURE 8-7. ENGINE INSTALLATION, PA-28-140, -150, -160, -180, S/N’S 28-1761 AND UPp. 467
FIGURE 8-8. ENGINE SHOCK MOUNT INSTALLATION. PA-28-140, S/N’S 28-25000 AND UPp. 468
FIGURE 8-9. ENGINE INSTALLATION, PA-28-235p. 472
FIGURE 8-10. ADJUSTMENT OF ENGINE CONTROLSp. 474
FIGURE 8-10A. THROTTLE/MIXTURE CONTROL BALL JOINT INSPECTIONp. 474
FIGURE 8-11. CARBURETOR, PA-28-140, -150, -160p. 477
FIGURE 8-12. CARBURETOR, PA-28-180, -235p. 477
FIGURE 8-13. MAGNETO INSPECTIONp. 479
FIGURE 8-14. CONTACT SPRING INSPECTIONp. 480
FIGURE 8-15. IMPULSE COUPLINGp. 480
FIGURE 8-16. MAGNETO TIMING MARKSp. 481
FIGURE 8-17. TIMING POINTERp. 481
FIGURE 8-18. TIMING KIT INSTALLEDp. 482
FIGURE 8-19. BREAKER COMPARTMENT WITH CAST TIMING MARKSp. 482
FIGURE 8-20. REMOVING SPARK PLUG FROZEN TO BUSHINGp. 487
FIGURE 8-21. IGNITION SWITCH WIRING POSITIONSp. 490
FIGURE 8A-1. PROPELLER INSTALLATIONp. 510
FIGURE 8A-2. TYPICAL NICKS AND REMOVAL METHODp. 511
FIGURE 8A-3. PROPELLER GOVERNORp. 514
FIGURE 8A-4. ENGINE INSTALLATION, PA-28R-180p. 517
FIGURE 8A-5. ENGINE INSTALLATION, PA-28R-200p. 519
FIGURE 8A-6. ADJUSTMENT OF ENGINE CONTROLSp. 523
FIGURE 8A-6A. THROTTLE/MIXTURE CONTROL BALL JOINT INSPECTIONp. 523
FIGURE 8A-7. FUEL INJECTORp. 525
FIGURE 8A-8. SCHEMATIC DIAGRAM OF RSA FUEL INJECTION SYSTEMp. 526
FIGURE 8A-9. FUEL-AIR BLEED NOZZLEp. 528
FIGURE 8A-10. CONTACT POINTSp. 530
FIGURE 8A-11. ROTOR HOLDING TOOL INSTALLEDp. 532
FIGURE 8A-12. TIMING KIT INSTALLEDp. 532
FIGURE 8A-13. ALIGNING TIMING MARKSp. 533
FIGURE 8A-14. CHECKING FLYWEIGHT CLEARANCE OF IMPULSE COUPLINGp. 534
FIGURE 8A-15. ENGINE TIMING MARKSp. 535
FIGURE 8A-16. MAGNETO ADJUSTMENT LIMITSp. 536
FIGURE 8A-17. MAGNETO TIMING MARKSp. 536
FIGURE 8A-18. REMOVING SPRING FROM LEAD ASSEMBLYp. 538
FIGURE 8A-19. ASSEMBLY TOOLp. 538
FIGURE 8A-20. USING ASSEMBLY TOOLp. 539
FIGURE 8A-21. MEASURING LEAD ASSEMBLY LENGTHp. 539
FIGURE 8A-22. CUTTING METALLIC BRAID FROM END OF LEADp. 540
FIGURE 8A-23. UNBRAIDING METALLIC SHIELDINGp. 540
FIGURE 8A-24. FORMING SHIELDING AROUND FERRULEp. 541
FIGURE 8A-25. FERRULE SEATING TOOLp. 541
FIGURE 8A-26. NEEDLEp. 541
FIGURE 8A-27. MEASURING WIRE FROM TOP OF FERRULEp. 542
FIGURE 8A-28. INSTALLING GROMMET OVER LEAD ASSEMBLIESp. 542
FIGURE 8A-29. LEAD ASSEMBLY INSTALLED IN GROMMETp. 542
FIGURE 8A-30. WIRE DOUBLED OVER FOR INSTALLATION OF EYELETp. 542
FIGURE 8A-31. REMOVING SPARK PLUG FROZEN TO BUSHINGp. 544
FIGURE 8A-32. IGNITION SWITCH WIRING POSITIONSp. 546
FIGURE 9-1. FUEL SYSTEM DIAGRAM, PA-28-140, -150, -160. -180p. 557
FIGURE 9-2. FUEL SYSTEM DIAGRAM, PA-28-235, S/N’S 28-10003 THRU 28-10719p. 558
FIGURE 9-3. FUEL SYSTEM DIAGRAM, PA-28-235, S/N’S 28-10720 AND UPp. 559
FIGURE 9-4. FUEL SYSTEM DIAGRAM, PA-28Rp. 560
FIGURE 9-6. FUEL QUANTITY TRANSMITTER (P/N 62037-00)p. 567
FIGURE 9-7. FUEL QUANTITY TRANSMITTER (P/N 68101-00)p. 567
FIGURE 9-7A. FUEL QUANTITY TRANSMITTER (P/N 548-671)p. 568
FIGURE 9-8. FUEL SELECTOR AND FILTER, PA-28-235p. 570
FIGURE 9-9. FUEL FILTER, PA-28-235p. 571
FIGURE 9-10. FUEL FILTER BOWL AND SCREEN, PA-28-140, -150, -160, -180 AND PA-28Rp. 573
FIGURE 9-11. PLUNGER FUEL PUMP (EARLY), PA-28-150, -160, -180p. 576
FIGURE 9-12. PLUNGER FUEL PUMP (LATE), PA-28-140, -150, -160. -180, -235p. 576
FIGURE 9-13. ENGINE PRIMERp. 582
FIGURE 9-14. FABRICATED FUEL QUANTITY TRANSMITTER CHECKING JIGp. 587
FIGURE 10-1. INSTRUMENT PANEL, PA-28-140, S/N’S 28-25000 THRU 28-26956p. 598
FIGURE 10-2. INSTRUMENT PANEL, PA-28-140, S/N’S 28-7125001 THRU 28-7325684p. 599
FIGURE 10-3. INSTRUMENT PANEL, PA-28-140, S/N’S 28-7425001 AND UPp. 600
FIGURE 10-4. INSTRUMENT PANELp. 601
FIGURE 10-5. INSTRUMENT PANEL, PA-28-150, -160, -180, S/N’S 28-1761 THRU 28-4377p. 602
FIGURE 10-6. INSTRUMENT PANEL, PA-28-180, S/N’S 28-4378 THRU 28-7205328p. 603
FIGURE 10-7. INSTRUMENT PANEL, PA-28-180, S/N’S 28-7305001 THRU 28-7305611p. 604
FIGURE 10-8. INSTRUMENT PANEL, PA-28-180, S/N’S 28-7405001 AND UPp. 605
FIGURE 10-9. INSTRUMENT PANEL, PA-28-235, S/N’S 28-10720 THRU 28-11039p. 606
FIGURE 10-10. INSTRUMENT PANEL, PA-28-235, S/N’S 28-11040 THRU 28-7210033p. 607
FIGURE 10-11. INSTRUMENT PANEL, PA-28-235, S/N’S 28-7310001 THRU 28-7310187p. 608
FIGURE 10-12. INSTRUMENT PANEL, PA-28-235, S/N’S 28-7410001 AND UPp. 609
FIGURE 10-13. INSTRUMENT PANEL, PA-28R-180, S/N’S 28-30005 THRU 28-30879p. 610
FIGURE 10-14. INSTRUMENT PANEL, PA-28R-180, S/N’S 28-30880 THRU 28-7130019; PA-28R-200, S/N’S 28-30482, 28-35001 THRU 28-35830 AND 28-7135001 THRU 28-7135238p. 611
FIGURE 10-15. INSTRUMENT PANEL, PA-28R-200, S/N’S 28-7235001 THRU 28-7335455p. 612
FIGURE 10-16. INSTRUMENT PANEL, PA-28R-200, S/N’S 28-7435001 AND UPp. 613
FIGURE 10-17. WARNING LIGHT PRESSURE SWITCHp. 617
FIGURE 10-17A. VACUUM PUMP VANE WEAR INSPECTIONS – AERO ACCESSORIES ONLYp. 620
FIGURE 10-18. TYPICAL PITOT STATIC SYSTEM, PA-28-140, -150, -160, -180, -235, PA-28R-180 AND 200p. 622
FIGURE 10-19. EGT PROBE LOCATION, PA-28R-180 AND 200p. 642
FIGURE 10-20. EGT PROBE LOCATION, PA-28-235p. 643
FIGURE 10-21. EGT PROBE LOCATION, PA-28-150, -160, -180, S N 1761 AND UPp. 644
FIGURE 11-1. GENERATOR AND STARTER SYSTEMp. 785
FIGURE 11-2. GENERATOR WIRING DIAGRAMp. 786
FIGURE 11-3. SECTIONAL VIEW OF GENERATORp. 789
FIGURE 11-4. CURRENT VOLTAGE REGULATORp. 798
FIGURE 11-5. USE OF RIFFLER FILE TO CLEAN CONTACT POINTSp. 801
FIGURE 11-6. VOLTAGE REGULATOR AIR GAPp. 801
FIGURE 11-7. CHECKING VOLTAGE SETTING FIXED RESISTANCE METHODp. 802
FIGURE 11-8. CHECKING VOLTAGE SETTING VARIABLE RESISTANCE METHODp. 802
FIGURE 11-9. ADJUSTING VOLTAGE REGULATOR SETTINGp. 803
FIGURE 11-10. CUTOUT RELAY AIR GAP CHECK AND ADJUSTMENTp. 805
FIGURE 11-11. CUTOUT RELAY POINT OPENING CHECK AND ADJUSTMENTp. 805
FIGURE 11-12. CHECKING CUTOUT RELAY CLOSING VOLTAGEp. 806
FIGURE 11-13. ADJUSTMENT OF CUTOUT RELAY CLOSING VOLTAGEp. 806
FIGURE 11-14. CHECKING CURRENT REGULATOR, LOAD METHODp. 807
FIGURE 11-15. CHECKING CURRENT REGULATOR, JUMPER LEAD METHODp. 807
FIGURE 11-16. ALTERNATOR AND STARTER SYSTEM, PA-28-140, S/N’S 28-20000 THRU 28-24999; PA-28-150, -160, S/N’S 28-508 THRU 28-3643; PA-28-180, S/N’S 28-671 THRU 28-3643; PA-28-235, S/N’S 28-10002 THRU 28-10762p. 811
FIGURE 11-17. ALTERNATOR AND STARTER SYSTEM, PA-28-140, S/N’S 28-25000 AND UP; PA-28-150, -160, -180, S/N’S 28-3644 AND UP; PA-28-235, S/N’S 10763 AND UP AND PA-28Rp. 812
FIGURE 11-18. LAMP-BANK LOADp. 814
FIGURE 11-19. CHECKING FIELD CIRCUITp. 815
FIGURE 11-20. TESTING FIELD CIRCUITp. 815
FIGURE 11-21. TESTING RECTIFIERS (POSITIVE)p. 817
FIGURE 11-22. TESTING RECTIFIERS (NEGATIVE)p. 818
FIGURE 11-23. C-3928 FIXTURES AND ADAPTERSp. 819
FIGURE 11-24. REMOVING RECTIFIERSp. 819
FIGURE 11-25. INSTALLING RECTIFIERSp. 820
FIGURE 11-26. SOLDERING RECTIFIER LEADp. 821
FIGURE 11-27. TESTING STATOR COILSp. 822
FIGURE 11-28. REMOVING END BEARINGp. 824
FIGURE 11-29. INSTALLING END BEARINGp. 824
FIGURE 11-30. REMOVING DRIVE PULLEYp. 825
FIGURE 11-31. REMOVING DRIVE END BEARINGp. 825
FIGURE 11-32. REMOVING SLIP RINGp. 826
FIGURE 11-33. ALIGNING SLIP RINGp. 826
FIGURE 11-34. INSTALLING SLIP RINGp. 827
FIGURE 11-35. INSTALLING RETAINERp. 827
FIGURE 11-36. SOLDER POINTSp. 828
FIGURE 11-37. INSTALLING DRIVE END SHIELD AND BEARING (TYPICAL)p. 829
FIGURE 11-38. INSTALLING PULLEYp. 829
FIGURE 11-39. METER CONNECTIONS FOR ALTERNATOR PERFORMANCE TESTp. 832
FIGURE 11-40. VOLTAGE REGULATORp. 834
FIGURE 11-41. CHECKING AIR GAPp. 834
FIGURE 11-42. VOLTAGE REGULATOR FUSIBLE WIRESp. 835
FIGURE 11-43. VOLTAGE REGULATOR RESISTANCE UNITSp. 835
FIGURE 11-44. NO-LOAD TEST HOOKUPp. 841
FIGURE 11-45. LOCK TORQUE TEST HOOKUPp. 842
FIGURE 11-46. RESISTANCE TEST HOOKUPp. 842
FIGURE 11-47. EXPLODED VIEW OF GEAR REDUCTION STARTING MOTORp. 847
FIGURE 11-48. TURNING STARTING MOTOR COMMUTATORp. 850
FIGURE 11-49. TESTING MOTOR ARMATURE FOR SHORTSp. 850
FIGURE 11-50. TESTING MOTOR FIELD FOR GROUNDSp. 850
FIGURE 11-51. NO-LOAD TEST HOOKUPp. 852
FIGURE 11-52. STALL TORQUE HOOKUPp. 852
FIGURE 11-53. TERMINAL BLOCKp. 892
FIGURES 11-54 THRU 11-70 SEE TABLE XI-I, INDEX – ELECTRICAL SYSTEM SCHEMATICSp. 14
FIGURE 11-71. EXPLODED VIEW OF ALTERNATORp. 859
FIGURE 11-72. REMOVAL OF SLIP RING END BEARINGp. 860
FIGURE 11-73. REMOVAL OF RECTIFIERp. 860
FIGURE 11-74. REMOVAL OF DRIVE END HEADp. 861
FIGURE 11-75. REMOVAL OF END HEAD BEARINGp. 861
FIGURE 11-76. TESTING ROTOR FOR GROUNDp. 862
FIGURE 11-77. TESTING ROTOR FOR SHORTSp. 862
FIGURE 11-78. INSTALLATION OF BEARINGp. 863
FIGURE 11-79. INSTALLATION OF RECTIFIERp. 863
FIGURE 11-80. TERMINAL ASSEMBLYp. 864
FIGURE 11-81. SLIP RING END BEARING ASSEMBLYp. 865
FIGURE 11-82. TESTING ALTERNATORp. 865
FIGURE 11-83. BRUSH INSTALLATIONp. 866
FIGURE 11-84. INTERNAL WIRING DIAGRAMp. 866
FIGURES 11-85 THRU 11-144 SEE TABLE XI-I, INDEX – ELECTRICAL SYSTEM SCHEMATICSp. 14
FIGURE 11-145. STROBE LIGHT CONNECTIONSp. 872
FIGURE 12-1. TWO YEAR MAGNESIUM BATTERY CONNECTIONSp. 947
FIGURE 12-2. ELT PORTABLE FOLDING ANTENNA (NARCO)p. 948
FIGURE 12-3. ELT USING FIXED AIRCRAFT ANTENNA (NARCO)p. 948
FIGURE 12-4. EMERGENCY LOCATOR TRANSMITTER SCHEMATIC (NARCO)p. 949
FIGURE 12-5. COMMUNICATIONS COMPONENTS ELT SCHEMATICp. 950
FIGURE 13-1. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-140, S/N’S 28-2002 THRU 28-24999, AND PA-28-150, -160, -180, S/N’S 28-1 THRU 28-1760p. 961
FIGURE 13-2. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-140, S/N’S 28-25000 AND UPp. 962
FIGURE 13-3. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-150. -160, -180, S/N’S 28-1761 THRU 28-2477p. 963
FIGURE 13-4. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-150, -160, -180, S/N’S 28-2478 THRU 28-4377p. 964
FIGURE 13-5. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-180, S/N’S 28-4378 AND UPp. 965
FIGURE 13-6. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-235, S/N’S 28-10003 THRU 28-10675p. 966
FIGURE 13-7. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-235, S/N’S 28-10676 THRU 28-11039p. 967
FIGURE 13-8. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-235, S/N’S 28-11040 THRU 28-7210033p. 968
FIGURE 13-9. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28-235, S/N’S 28-7310001 AND UPp. 969
FIGURE 13-10. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM, PA-28Rp. 970
FIGURE 13-11. OVERHEAD VENT SYSTEMp. 971
FIGURE 14-1. AIR CONDITIONING SYSTEM INSTALLATIONp. 975
FIGURE 14-2. SERVICE VALVESp. 980
FIGURE 14-3. TEST GAUGE AND MANIFOLD SETp. 981
FIGURE 14-4. MANIFOLD SET OPERATIONp. 982
FIGURE 14-5. LEAK TEST HOOKUPp. 983
FIGURE 14-6. EVACUATION HOOKUPp. 985
FIGURE 14-7. CHARGING STANDp. 987
FIGURE 14-8. CHARGING HOOKUPp. 989
FIGURE 14-9. COMPRESSOR AND FABRICATED OIL DIPSTICKp. 993
FIGURE 14-10. COMPRESSOR AND ALTERNATOR BELT INSTALLATIONp. 997
FIGURE 14-11. MAGNETIC CLUTCHp. 999
FIGURE 14-12. CONDENSER AIR SCOOP INSTALLATIONp. 1003
FIGURE 14-13. EXPANSION VALVEp. 1005
FIGURE 14-14. COMPONENTS INSTALLATIONp. 1007
FIGURE 14-15. CONTROL HEAD – DIODE MOUNTING BOARD, DIODE LOCATION AND NUMBER, PA-28-140, S/N’S 28-7125472 THRU 28-7325057; PA-28-180, S/N’S 28-7205092 THRU 28-7305071; PA-28R-200, 28R-7235001 THRU 28R-7335057p. 1008
FIGURE 14-16. AIR CONDITIONING WIRING SCHEMATIC, PA-28-140, S/N’S, 28-7125472 THRU 28-7225131 PA-28-180, S/N’S 28-7205092 THRU 28-7205144p. 1010
FIGURE 14-17. AIR CONDITIONING WIRING SCHEMATIC, PA-28-140, S/N’S 28-7225132 THRU 28-7225612; PA-28-180, S/N’S 28-7205145 THRU 28-7205328; PA-28R-200, S/N’S 28R-7235001 THRU 28R-7235330p. 1011
FIGURE 14-18. AIR CONDITIONING WIRING SCHEMATIC, PA-28-140, S/N’S 28-7325001 AND UP; PA-28-180, S/N’S 28-7305001 AND UP; PA-28R-200, S/N’S 28-7335001 AND UPp. 1012
+LIST OF TABLESp. 17
TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONSp. 40
TABLE II-III. FLARE FITTING TORQUE VALUESp. 70
TABLE II-IV. RECOMMENDED NUT TORQUESp. 72
TABLE IL-V. CONVERSION TABLESp. 74
TABLE II-VI. DECIMAL/MILLIMETER EQUIVALENTS OF DRILL SIZESp. 77
TABLE II-VII. MAXIMUM DISTANCE BETWEEN SUPPORTS FOR FLUID TUBINGp. 78
TABLE II-VIII. HOSE CLAMP TIGHTENINGp. 78
TABLE II-IX. RECOMMENDED ENGINE LUBRICATING OILSp. 110
TABLE II-X. THREAD LUBRICANTSp. 110
TABLE II-XI. CONSUMABLE MATERIALSp. 111
TABLE.II-XII. SPECIAL INSTRUCTIONSp. 113
TABLE III-I. INSPECTION REPORT, PA-28-140, -150, -160, -180; PA-28-235p. 662
TABLE III-II. INSPECTION REPORT, PA-28Rp. 676
TABLE III-III. SPECIAL PUBLICATIONS LISTp. 754
TABLE IV-I. LIST OF MATERIALS (THERMOPLASTIC REPAIR)p. 171
TABLE IV-II. BALANCING SPECIFICATIONSp. 181
TABLE V-L. CABLE TENSION VS. AMBIENT TEMPERATUREp. 222
TABLE V-II. FLIGHT CONTROL SURFACES RIGGING LIMITSp. 223
TABLE V-ILL. TROUBLESHOOTING CHART (SURFACE CONTROLS)p. 277
TABLE VI-I. LEADING PARTICULARS, HYDRAULIC SYSTEMp. 290
TABLE VI-LI. CHARACTERISTICS, HYDRAULIC PUMP MOTORp. 297
TABLE VI-IIA. PIPE THREAD SPECIFICATIONSp. 303
TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTINGp. 315
TABLE VII-I. NOSE GEAR ALIGNMENT TOLERANCESp. 339
TABLE VII-II. LANDING GEAR TROUBLESHOOTINGp. 374
TABLE VIIA-I. LANDING GEAR TROUBLESHOOTINGp. 438
TABLE VIIA-II. PA-28R NOSE GEAR SERVICE TOLERANCESp. 447
TABLE VIIA-III. PA-28R MAIN GEAR SERVICE TOLERANCESp. 450
TABLE VIII-I. PROPELLER TORQUE LIMITSp. 460
TABLE VIII-II. ENGINE TROUBLESHOOTING CHARTp. 491
TABLE VIIIA-I. ENGINE TROUBLESHOOTING CHARTp. 547
TABLE IX-I. TRANSMITTER/FUEL GAUGE TOLERANCESp. 566
TABLE IX-II. FUEL QUANTITY TRANSMITTER CALIBRATION TOLERANCESp. 567
TABLE IX-III. FUEL SYSTEM TROUBLESHOOTINGp. 585
TABLE X-L. VACUUM SYSTEMp. 594
TABLE X-LL. DIRECTIONAL GYRO INDICATORp. 623
TABLE X-LLL. GYRO HORIZON INDICATORp. 625
TABLE X-IV. RATE OF CLIMB INDICATORp. 626
TABLE X-V. ALTIMETERp. 628
TABLE X-VI. AIRSPEED TUBES AND INDICATORp. 630
TABLE X-VII. MAGNETIC COMPASSp. 632
TABLE X-VIII. MANIFOLD PRESSURE INDICATORp. 633
TABLE X-IX. TACHOMETERp. 634
TABLE X-X. ENGINE OIL PRESSURE GAUGEp. 635
TABLE X-XI. FUEL PRESSURE GAUGEp. 636
TABLE X-XII. TURN AND BANK INDICATORp. 637
TABLE X-XIII. FUEL QUANTITY INDICATORSp. 638
TABLE X-XIV. OIL TEMPERATURE INDICATORSp. 639
TABLE X-XV. TROUBLESHOOTING EGT GAUGEp. 641
TABLE X-XVI. CYLINDER HEAD TEMPERATURE GAUGEp. 645
TABLE X-XVII. FUEL FLOW GAUGEp. 646
TABLE XI-I. ELECTRICAL SYSTEM SCHEMATIC INDEXp. 779
TABLE XI-LI. ELECTRICAL SYSTEM TROUBLESHOOTINGp. 873
TABLE XI-LLL. ELECTRICAL SYSTEM COMPONENT LOADSp. 895
TABLE XI-IV. ELECTRICAL SYMBOLSp. 896
TABLE XI-V. ELECTRICAL WIRE CODINGp. 897
TABLE XIV-I. TEMPERATURE PRESSURE CHARTp. 976
TABLE XIV-II. ALUMINUM TUBING TORQUEp. 979
TABLE XIV-III. COMPRESSOR OIL CHANGEp. 992
TABLE XIV-IV. AIR CONDITIONING SYSTEM TROUBLESHOOTINGp. 1013
TABLE XIV-V. BLOWER SYSTEM WIRE COLOR CODESp. 1022
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