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Piper PA-28-236 Dakota Maintenance Manual - Part Number 761-681
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Piper PA-28-236 Dakota Maintenance Manual – Part Number 761-681

Original price was: $39.95.Current price is: $24.95.

Official factory maintenance manual for the Piper PA-28-236 Dakota, covering airframe systems, scheduled inspections, servicing, air conditioning, and electrical overhaul.

SKU: PIP-PA28236-MM-761681-HD Category: Tags: , , , Vendor: Diagnostics Manuals
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Description

Factory Service & Shop Instructions for Piper PA-28-236 Dakota

The Piper PA-28-236 Dakota Maintenance Manual – Part Number 761-681 provides comprehensive airframe, system, and component maintenance procedures prepared in accordance with the General Aviation Manufacturers Association (GAMA) standard format. Covering all production model years from 1979 through 1986 and subsequent serial numbers, this technical publication serves as the authoritative shop reference for certificated aircraft mechanics, repair stations, and owner-operators performing routine servicing, periodic inspections, unscheduled condition checks, and complete component overhauls.

File Details

  • Manual Type: Aircraft Maintenance Manual (Card 1 of 3, GAMA Specification)
  • Aircraft Manufacturer: Piper Aircraft Corporation
  • Applicable Model: Piper PA-28-236 Dakota
  • Document Part Number: 761 681 (761-681)
  • Reissue & Revision Status: Reissued August 1, 1986 with Interim Revisions through February 15, 1995
  • Covered Serial Number Ranges: 28-7911001 through 28-7911395 (1979), 28-8011001 through 28-8011161 (1980), 28-8111001 through 28-8111105 (1981), 28-8211001 through 28-8211060 (1982), 28-8311001 through 28-8311025 (1983), 28-8411001 through 28-8411031 (1984), 28-8511001 through 28-8511020 (1985), 28-8611001 through 28-8611008 (1986), and serial numbers 2811001 and up
  • Engine Installation: Avco Lycoming O-540-J3A5D (235 hp at 2400 rpm)
  • Propeller Installation: Hartzell Constant Speed Hub HC-F2YR-1() with Blade F8468A-4R and F-4-21() Governor
  • Language: English
  • Page Count: 616 pages
  • Format: High-resolution digital PDF download

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “Piper PA-28-236 Dakota Maintenance Manual – Part Number 761-681” are as follows:

761-681 – DAKOTA MAINTENANCE MANUAL – PA-28-236p. 1
INTRODUCTIONp. 2
VENDOR PUBLICATIONSp. 3
PIPER PUBLICATIONSp. 4
AEROFICHE EXPLANATION AND REVISION STATUSp. 5
TABLE OF CONTENTS/EFFECTIVITY CODESp. 5
INTERIM REVISIONp. 6
SERIAL NUMBER INFORMATIONp. 6
GAMA SYSTEM/CHAPTER INDEX GUIDEp. 7
LIST OF ILLUSTRATIONSp. 9
FIGURE 6-1. THREE VIEWp. 41
FIGURE 6-2. STATION REFERENCESp. 42
FIGURE 6-3. ACCESS PLATES AND PANELSp. 43
FIGURE 7-1. JACKING ARRANGEMENTp. 47
FIGURE 8-1. WEIGHING AIRPLANEp. 52
FIGURE 8-2. LEVELING LONGITUDINALLYp. 53
FIGURE 8-3. LEVELING LATERALLYp. 53
FIGURE 11-1. PLACARDS AND DECALSp. 65
FIGURE 12-1. FUEL FILTER BOWL AND SCREENp. 70
FIGURE 12-2. SERVICING POINTSp. 74
FIGURE 12-3. MAIN GEAR OLEO STRUTS (CUT-AWAY VIEW)p. 78
FIGURE 12-4. LUBRICATION CHART (LANDING GEAR, MAIN)p. 86
FIGURE 12-5. LUBRICATION CHART (LANDING GEAR, NOSE)p. 87
FIGURE 12-6. LUBRICATION CHART (CONTROL SYSTEM)p. 88
FIGURE 12-7. LUBRICATION CHART (CABIN DOOR, BAGGAGE DOOR AND SEAT)p. 92
FIGURE 12-8. LUBRICATION CHART (POWER PLANT, PROPELLER AND CONTROL PIVOT POINTS)p. 93
FIGURE 12-9. LUBRICATION CHART (AIR CONDITIONING CONDENSER)p. 94
FIGURE 20-1. TORQUE WRENCH EXTENSIONp. 101
FIGURE 20-2. CORRECT METHOD OF INSTALLING ROD END BEARINGSp. 101
FIGURE 20-3. CHERRYLOCK RIVET REMOVALp. 102
FIGURE 20-4. HOSE/LINE MARKINGSp. 104
FIGURE 20-5. FLARELESS TUBE FITTINGSp. 105
FIGURE 21-1. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEMp. 129
FIGURE 21-2. AIR CONDITIONING SYSTEM INSTALLATION (TYPICAL)p. 137
FIGURE 21-3. SERVICE VALVESp. 142
FIGURE 21-4. TEST GAUGE AND MANIFOLD SETp. 143
FIGURE 21-5. MANIFOLD SET OPERATIONp. 144
FIGURE 21-6. LEAK TEST HOOKUPp. 145
FIGURE 21-7. EVACUATION HOOKUPp. 147
FIGURE 21-8. CHARGING STANDp. 149
FIGURE 21-9. CHARGING HOOKUPp. 151
FIGURE 21-10. COMPRESSOR AND FABRICATED OIL DIPSTICKp. 154
FIGURE 21-11. COMPRESSOR AND ALTERNATOR BELT INSTALLATIONp. 155
FIGURE 21-12. MAGNETIC CLUTCHp. 158
FIGURE 21-13. CONDENSER AIR SCOOP INSTALLATIONp. 161
FIGURE 21-14. EXPANSION VALVEp. 162
FIGURE 21-15. COMPONENTS INSTALLATIONp. 164
FIGURE 21-16. OVERHEAD VENT SYSTEM (NOT AVAILABLE WITH AIR CONDITIONING)p. 166
FIGURE 23-1. AVIONICS MASTER AND EMERGENCY SWITCH CIRCUITp. 175
FIGURE 23-2. COMMUNICATIONS COMPONENTS ELT SCHEMATICp. 177
FIGURE 23-3. EMERGENCY LOCATOR TRANSMITTER SCHEMATIC (NARCO)p. 177
FIGURE 23-4. ELT PORTABLE FOLDING ANTENNA (NARCO)p. 179
FIGURE 23-5. ELT USING FIXED AIRCRAFT ANTENNA (NARCO)p. 179
FIGURE 24-1. LAMP-BANK LOADp. 195
FIGURE 24-2. EXPLODED VIEW OF ALTERNATOR (CHRYSLER)p. 197
FIGURE 24-3. CHECKING FIELD COIL CURRENT DRAWp. 197
FIGURE 24-4. TESTING FIELD CIRCUITp. 197
FIGURE 24-5. TESTING POSITIVE RECTIFIERSp. 199
FIGURE 24-6. TESTING NEGATIVE RECTIFIERSp. 199
FIGURE 24-7. RECTIFIER END SHIELD AND STATOR ASSEMBLYp. 199
FIGURE 24-8. TESTING POSITIVE RECTIFIERS WITH TEST LAMPp. 201
FIGURE 24-9. TESTING NEGATIVE RECTIFIERS WITH TEST LAMPp. 201
FIGURE 24-10. RECTIFIER AND HEATSINK ASSEMBLY REMOVALp. 202
FIGURE 24-11. RECTIFIER END SHIELD ASSEMBLYp. 202
FIGURE 24-12. TESTING STATORp. 203
FIGURE 24-13. REMOVAL OF PULLEYp. 203
FIGURE 24-14. REMOVAL OF BEARINGp. 204
FIGURE 24-15. REMOVAL OF RECTIFIER END SHIELD BEARINGp. 204
FIGURE 24-16. TESTING ROTOR FOR GROUNDp. 205
FIGURE 24-17. TESTING ROTOR FOR OPENS OR SHORTSp. 205
FIGURE 24-18. INSTALLATION OF GREASE RETAINERp. 206
FIGURE 24-19. INSTALLATION OF RECTIFIER END SHIELD BEARINGp. 206
FIGURE 24-20. INSTALLATION OF DRIVE END SHIELD BEARINGp. 206
FIGURE 24-21. INSTALLATION OF PULLEYp. 206
FIGURE 24-22. INSTALLATION OF INSULATORSp. 208
FIGURE 24-23. INSTALLATION OF POSITIVE RECTIFIER ASSEMBLYp. 208
FIGURE 24-24. INSTALLATION OF CAPACITORp. 208
FIGURE 24-25. INSTALLATION OF BATTERY OUTPUT INSULATORp. 208
FIGURE 24-26. INSTALLATION OF NEGATIVE RECTIFIER ASSEMBLYp. 210
FIGURE 24-27. INSTALLATION OF STATORp. 210
FIGURE 24-28. EXPLODED VIEW OF ALTERNATOR (PRESTOLITE)p. 212
FIGURE 24-29. REMOVAL OF SLIP RING END BEARINGp. 213
FIGURE 24-30. REMOVAL OF RECTIFIERp. 213
FIGURE 24-31. REMOVAL OF DRIVE END HEADp. 213
FIGURE 24-32. REMOVAL OF END HEAD BEARINGp. 213
FIGURE 24-33. TESTING ROTOR FOR GROUNDp. 214
FIGURE 24-34. TESTING ROTOR FOR SHORTSp. 214
FIGURE 24-35. INSTALLATION OF BEARINGp. 216
FIGURE 24-36. INSTALLATION OF RECTIFIERp. 216
FIGURE 24-37. TERMINAL ASSEMBLYp. 216
FIGURE 24-38. SLIP RING END BEARING ASSEMBLYp. 217
FIGURE 24-39. TESTING ALTERNATORp. 217
FIGURE 24-40. BRUSH INSTALLATIONp. 218
FIGURE 24-41. INTERNAL WIRING DIAGRAMp. 218
FIGURE 25-1. SEAT BACK LOCKp. 228
FIGURE 27-1. ROD END INSTALLATION METHODp. 240
FIGURE 27-2. CONTROL COLUMN ASSEMBLYp. 242
FIGURE 27-3. AILERON CONTROLS (TYPICAL)p. 245
FIGURE 27-4. AILERON RIGGINGp. 249
FIGURE 27-5. BELLCRANK RIGGING TOOLp. 249
FIGURE 27-6. AILERON RIGGING TOOLp. 250
FIGURE 27-7. RUDDER AND STEERING PEDAL ASSEMBLYp. 252
FIGURE 27-8. RUDDER CONTROLSp. 254
FIGURE 27-9. RUDDER RIGGING TOOLp. 255
FIGURE 27-10. CLAMPING RUDDER PEDALSp. 255
FIGURE 27-11. RUDDER RIGGINGp. 255
FIGURE 27-12. RUDDER TRAVEL ADJUSTMENTSp. 259
FIGURE 27-13. RUDDER TRIM CONTROLp. 259
FIGURE 27-14. STABILATOR CONTROLSp. 261
FIGURE 27-15. STABILATOR AND STABILATOR TRIM TRAVEL ADJUSTMENTSp. 262
FIGURE 27-16. STABILATOR RIGGING TOOLp. 262
FIGURE 27-17. METHODS OF SECURING TRIM CABLESp. 265
FIGURE 27-18. STABILATOR TRIM CONTROLp. 266
FIGURE 27-19. FLAP CONTROLSp. 270
FIGURE 27-20. FLAP STEP ADJUSTMENTp. 272
FIGURE 27-21. FLAP RIGGING TOOLp. 272
FIGURE 27-22. FLAP RIGGINGp. 275
FIGURE 28-1. FUEL SYSTEM DIAGRAMp. 296
FIGURE 28-2. LOCKING FUEL CAP ASSEMBLYp. 300
FIGURE 28-3. FUEL FILTER BOWL AND SCREENp. 302
FIGURE 28-4. PLUNGER FUEL PUMPp. 302
FIGURE 28-5. TOLERANCES, UNION NUT AND TUBING NUTp. 306
FIGURE 28-6. FUEL GAUGEp. 309
FIGURE 32-1. MAIN GEAR OLEO STRUT ASSEMBLYp. 317
FIGURE 32-2. MAIN GEAR INSTALLATIONp. 319
FIGURE 32-3. NOSE GEAR OLEO STRUT ASSEMBLYp. 321
FIGURE 32-4. NOSE GEAR INSTALLATIONp. 325
FIGURE 32-5. CLAMPING RUDDER PEDALS IN NEUTRAL POSITIONp. 327
FIGURE 32-6. RUDDER PEDALS AT NEUTRAL ANGLEp. 327
FIGURE 32-7. MAIN WHEEL ASSEMBLYp. 328
FIGURE 32-8. NOSE WHEEL ASSEMBLYp. 330
FIGURE 32-9. STANDARD BRAKE ASSEMBLY (CLEVELAND 30-55)p. 332
FIGURE 32-10. HEAVY DUTY BRAKE ASSEMBLY (CLEVELAND 30-65)p. 333
FIGURE 32-11. REMOVAL AND INSTALLATION OF ANCHOR BOLTSp. 334
FIGURE 32-12. BRAKE DISC MINIMUM THICKNESSp. 335
FIGURE 32-13. BRAKE SYSTEM INSTALLATIONp. 335
FIGURE 32-14. BRAKE MASTER CYLINDER (HAND/PARKING BRAKE)p. 337
FIGURE 32-15. TOE BRAKE INSTALLATIONp. 339
FIGURE 32-16. BRAKE CYLINDER 10-30 (TOE BRAKE)p. 340
FIGURE 32-17. BRAKE CYLINDER 17000 (TOE BRAKE)p. 340
FIGURE 33-1. STROBE LIGHT CONNECTIONSp. 352
FIGURE 34-1. PITOT/STATIC SYSTEMp. 359
FIGURE 37-1. AUXILIARY VACUUM PUMP INSTALLATIONp. 384
FIGURE 51-1. SKIN MATERIALS AND THICKNESSp. 395
FIGURE 51-1A. BAGGAGE COMPARTMENT INSPECTION HOLES CUTOUT DETAILSp. 397
FIGURE 51-2. SURFACE SCRATCHES, ABRASIONS OR GROUND-IN-DIRTp. 401
FIGURE 51-3. DEEP SCRATCHES, SHALLOW NICKS AND SMALL HOLESp. 402
FIGURE 51-4. MIXING OF EPOXY PATCHING COMPOUNDp. 402
FIGURE 51-5. WELDING REPAIR METHODp. 404
FIGURE 51-6. REPAIRING OF CRACKSp. 404
FIGURE 51-7. VARIOUS REPAIRSp. 405
FIGURE 51-8. REPAIR OF STRESS LINESp. 407
FIGURE 51-9. REPAIR OF IMPACTED DAMAGEp. 407
FIGURE 52-1. DOOR SNUBBER INSTALLATIONp. 415
FIGURE 55-1. EMPENNAGE GROUP INSTALLATIONp. 421
FIGURE 55-2. METHODS OF SECURING CONTROL CABLESp. 422
FIGURE 55-3. STABILATOR BALANCEp. 422
FIGURE 55-4. RUDDER BALANCEp. 425
FIGURE 56-1. WINDSHIELD INSTALLATION (TYPICAL)p. 430
FIGURE 56-2. SIDE WINDOW INSTALLATION, SINGLE PANE (TYPICAL)p. 431
FIGURE 57-1. WING INSTALLATIONp. 435
FIGURE 57-2. AILERON AND FLAP INSTALLATIONp. 440
FIGURE 57-3. AILERON BALANCE CONFIGURATIONp. 444
FIGURE 61-1. TYPICAL NICKS AND REMOVAL METHODp. 448
FIGURE 61-2. PROPELLER INSTALLATIONp. 450
FIGURE 61-3. PROPELLER GOVERNORp. 452
FIGURE 61-4. ADJUSTMENT OF PROPELLER CONTROLp. 452
FIGURE 71-1. ENGINE INSTALLATION (PA-28-236)p. 469
FIGURE 71-2. ENGINE MOUNT ASSEMBLYp. 470
FIGURE 71-3. COWLING INSTALLATION (PA-28-236)p. 471
FIGURE 71-4. CARBURETOR ICE DETECTION SYSTEMp. 473
FIGURE 71-5. CARBURETOR ICE DETECTOR PROBE INSTALLATIONp. 475
FIGURE 71-6 . REAR VIEW OF CARBURETOR AIRBOXp. 477
FIGURE 73-1. CARBURETORp. 481
FIGURE 73-2. ENGINE PRIMERp. 482
FIGURE 73-3. ADJUSTMENT OF ENGINE CONTROLSp. 484
FIGURE 74-1. HEIGHT OF SPRING IN DISTRIBUTOR BLOCK TOWERp. 492
FIGURE 74-2. CONTACT POINTSp. 492
FIGURE 74-3. ENGINE TIMING MARKSp. 494
FIGURE 74-4. TIMING LIGHT CONNECTED TO MAGNETOp. 494
FIGURE 74-5. TIMING MARKS ON MAGNETO ROTORp. 496
FIGURE 74-6. PAINTED TOOTH CENTERED IN TIMING WINDOWp. 496
FIGURE 74-7. TIMING MARK ON ROTOR ALIGNED WITH POINTERp. 496
FIGURE 74-8. TIMING LIGHT CONNECTED TO MAGNETO AND BREAKERSp. 497
FIGURE 74-9. CAM END VIEW OF MAGNETOp. 499
FIGURE 74-10. REMOVING IMPULSE COUPLINGp. 501
FIGURE 74-11. CHECKING FLYWEIGHT TO STOP PIN CLEARANCEp. 501
FIGURE 74-12. STOP PIN INSTALLATION DIMENSIONp. 501
FIGURE 74-13. CHECKING FLYWEIGHT AXIAL WEAR WITH DRILL SHANKp. 502
FIGURE 74-14. CHECKING FLYWEIGHT RADIAL WEAR WITH GAUGEp. 502
FIGURE 74-15. POINTS OF COUPLING BODY WEARp. 503
FIGURE 74-16. ACCEPTABLE AND DEFORMED COUPLING SPRINGSp. 503
FIGURE 74-17. CHECKING IMPULSE COUPLING FOR MAGNETIZATIONp. 505
FIGURE 74-18. ORIENTATION OF SPRING IN COUPLING BODYp. 505
FIGURE 74-19. LIFTING INNER END OF SPRINGp. 505
FIGURE 74-20. CHECKING HARNESS LEAD CONTINUITYp. 507
FIGURE 74-21. CHECKING HARNESS LEAD INSULATION RESISTANCEp. 507
FIGURE 74-22. MODIFIED PLIERSp. 507
FIGURE 74-23. REMOVING SPRING FROM LEAD ASSEMBLYp. 507
FIGURE 74-24. ASSEMBLY TOOLp. 509
FIGURE 74-25. USING ASSEMBLY TOOLp. 509
FIGURE 74-26. FERRULE POSITIONED UNDER BRAIDp. 510
FIGURE 74-27. FERRULE SEATING TOOLp. 510
FIGURE 74-28. POSITION OF 11-8627 KIT AND CONTACT SPRING AT START OF INSTALLATIONp. 511
FIGURE 74-29. POSITION OF 11-8627 KIT AND CONTACT SPRING AFTER INSTALLATIONp. 511
FIGURE 74-30. LUBRICATING SLEEVEp. 511
FIGURE 74-31. LUBRICATING FERRULE SHOULDERp. 511
FIGURE 74-32. REMOVING SPARK PLUG FROZEN TO BUSHINGp. 513
FIGURE 74-33. IGNITION SWITCH WIRE POSITIONSp. 516
FIGURE 78-1. EXHAUST SYSTEM INSPECTION POINTSp. 528
FIGURE 80-1. EXPLODED VIEW OF GEAR REDUCTION STARTING MOTORp. 540
FIGURE 80-2. TURNING STARTING MOTOR COMMUTATORp. 542
FIGURE 80-3. TESTING MOTOR ARMATURE FOR SHORTSp. 542
FIGURE 80-4. TESTING MOTOR FIELDS FOR GROUNDSp. 542
FIGURE 80-5. NO-LOAD TEST HOOKUPp. 544
FIGURE 80-6. STALL-TORQUE HOOKUPp. 544
FIGURE 95-1. TIRE BALANCER FIXTUREp. 607
FIGURE 95-2. CONTROL SURFACE BALANCING TOOLp. 608
FIGURE 95-3. ORIFICE REPLACEMENT TOOLp. 609
FIGURE 95-4. FABRICATED TOOL FOR BAGGAGE DOOR LOCKp. 610
FIGURE 95-5. RETAINER RING TOOLp. 610
FIGURE 95-6. FABRICATED AILERON BELLCRANK RIGGING TOOLp. 611
FIGURE 95-7. FABRICATED RUDDER RIGGING TOOLp. 611
FIGURE 95-8. FABRICATED AILERON AND FLAP RIGGING TOOLp. 612
FIGURE 95-9. FABRICATED STABILATOR RIGGING TOOLp. 613
FIGURE 95-10. CHARGING STANDp. 614
FIGURE 95-11. YORK COMPRESSOR AND FABRICATED OIL DIPSTICKp. 614
FIGURE 95-12. IGNITION HARNESS FERRULE SEATING TOOLp. 615
FIGURE 95-13. ASSEMBLY TOOL FOR IGNITION HARNESS INSULATING SLEEVE INSTALLATIONp. 615
LIST OF CHARTSp. 15
CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMENSIONSp. 39
CHART 1201. THREAD LUBRICANTSp. 83
CHART 1202. TYPE OF LUBRICANTSp. 84
CHART 2001. THREAD LUBRICANTSp. 106
CHART 2002. MAXIMUM DISTANCE BETWEEN SUPPORTS FOR FLUID TUBINGp. 106
CHART 2003. TYPES OF METAL CORROSIONp. 111
CHART 2101. TROUBLESHOOTING (AIR CONDITIONER)p. 131
CHART 2102. TROUBLESHOOTING (AIR CONDITIONING SYSTEM)p. 133
CHART 2103. TEMPERATURE PRESSUREp. 139
CHART 2104. ALUMINUM TUBING TORQUEp. 141
CHART 2105. SYSTEM VACUUMp. 147
CHART 2106. COMPRESSOR OIL CHARGEp. 154
CHART 2107. BLOWER SYSTEM WIRE COLOR CODESp. 167
CHART 2401. TROUBLESHOOTING (ALTERNATOR)p. 186
CHART 2402. TROUBLESHOOTING (BATTERY)p. 191
CHART 2403. ALTERNATOR SPECIFICATIONSp. 219
CHART 2404. ALTERNATOR BELT TENSIONp. 220
CHART 2405. HYDROMETER READING AND BATTERY CHARGE PERCENTp. 222
CHART 2406. ELECTRICAL SYSTEM COMPONENT LOADSp. 225
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS)p. 234
CHART 2702. CABLE TENSION VS. AMBIENT TEMPERATUREp. 239
CHART 2801. TROUBLESHOOTING (FUEL SYSTEM)p. 297
CHART 2802. TRANSMITTER/FUEL GAUGE TOLERANCESp. 309
CHART 3201. TROUBLESHOOTING (LANDING GEAR)p. 314
CHART 3202. NOSE GEAR ALIGNMENT TOLERANCESp. 326
CHART 3301. TROUBLESHOOTING (ELECTRICAL SYSTEM)p. 347
CHART 3401. TROUBLESHOOTING (RATE OF CLIMB INDICATOR)p. 360
CHART 3402. TROUBLESHOOTING (ALTIMETER)p. 362
CHART 3403. TROUBLESHOOTING (AIRSPEED TUBES AND INDICATOR)p. 363
CHART 3404. TROUBLESHOOTING (MAGNETIC COMPASS)p. 367
CHART 3701. TROUBLESHOOTING (VACUUM SYSTEM)p. 375
CHART 5101. LIST OF MATERIALS (THERMOPLASTIC REPAIR)p. 400
CHART 6101. PROPELLER TORQUE LIMITSp. 451
CHART 7101. TROUBLESHOOTING (ENGINE)p. 461
CHART 7301. TROUBLESHOOTING (FUEL PRESSURE GAUGE)p. 485
CHART 7401. TROUBLESHOOTING (MAGNETO)p. 490
CHART 7402. COUPLING TORQUESp. 512
CHART 7701. TROUBLESHOOTING (MANIFOLD PRESSURE INDICATOR)p. 520
CHART 7702. TROUBLESHOOTING (TACHOMETER)p. 521
CHART 7703. TROUBLESHOOTING (ENGINE OIL PRESSURE GAUGE)p. 522
CHART 7704. TROUBLESHOOTING (OIL TEMPERATURE INDICATORS)p. 523
CHART 7705. TROUBLESHOOTING (EXHAUST GAS TEMPERATURE GAUGE) (ALCOR)p. 524
CHART 7706. TROUBLESHOOTING (CYLINDER HEAD TEMPERATURE GAUGE)p. 525
CHART 8001. TROUBLESHOOTING (STARTER)p. 538
CHART 8002. STARTING MOTOR SPECIFICATIONSp. 546
CHART 9101. FLARE FITTING TORQUESp. 566
CHART 9102. RECOMMENDED NUT TORQUESp. 567
CHART 9103. CONVERSION TABLESp. 570
CHART 9104. DECIMAL EQUIVALENTS OF DRILL SIZESp. 575
CHART 9105. LIST OF CONSUMABLE MATERIALSp. 576
CHART 9106. ELECTRICAL WIRE CODINGp. 584
CHART 9107. ELECTRICAL SYMBOLSp. 585
CHAPTER 4 – AIRWORTHINESS LIMITATIONSp. 17
TABLE OF CONTENTSp. 18
AIR WORTHINESS LIMITATIONSp. 20
GENERALp. 20
CHAPTER 5 – TIME LIMITS/ MAINT CHECKSp. 21
TABLE OF CONTENTSp. 22
GENERALp. 24
TIME LIMITSp. 24
INSPECTION REQUIREMENTSp. 24
PREFLIGHT CHECKSp. 24
OVERLIMITS INSPECTIONp. 24
SCHEDULED MAINTENANCEp. 25
PERIODIC INSPECTIONSp. 25
PROGRAMMED INSPECTIONp. 35
UNSCHEDULED MAINTENANCE CHECKSp. 35
SPECIAL INSPECTIONS AS REQULRED UPON CONDITIONp. 35
CHAPTER 6 – DIMENSIONS AND AREASp. 36
TABLE OF CONTENTSp. 37
DIMENSIONSp. 39
STATION REFERENCE LINESp. 42
ACCESS AND INSPECTION PROVISIONSp. 43
CHAPTER 7 – LIFTING AND SHORINGp. 44
TABLE OF CONTENTSp. 45
JACKINGp. 47
CHAPTER 8 – LEVELING AND WEIGHINGp. 49
TABLE OF CONTENTSp. 50
LEVELINGp. 52
WEIGHINGp. 52
CHAPTER 9 – TOWING AND TAXIINGp. 54
TABLE OF CONTENTSp. 55
TOWINGp. 57
TAXIINGp. 57
CHAPTER 10 – PARKING AND MOORINGp. 58
TABLE OF CONTENTSp. 59
PARKINGp. 61
MOORINGp. 61
CHAPTER 11 – REQUIRED PLACARDSp. 62
TABLE OF CONTENTSp. 63
EXTERIOR PLACARDS AND MARKINGSp. 65
INTERIOR PLACARDS AND MARKINGSp. 66
CHAPTER 12 – SERVICINGp. 67
TABLE OF CONTENTSp. 68
GENERALp. 69
FUEL SYSTEMp. 69
FILLING FUEL TANKSp. 69
DRAINING MOISTURE FROM FUEL SYSTEMp. 69
DRAINING FUEL SYSTEMp. 70
OIL SYSTEMp. 70
SERVICING OIL SYSTEMp. 70
DRAINING OIL SUMPp. 71
FILLING OIL SUMPp. 71
OIL SCREEN (SUCTION)p. 71
RECOMMENDATIONS FOR CHANGING OILp. 71
OIL FILTER (FULL FLOW)p. 72
SCHEDULED SERVICINGp. 72
FUEL SYSTEMp. 72
SERVICING FUEL SYSTEMp. 72
LANDING GEARp. 73
SERVICING LANDING GEARp. 73
SERVICING OLEO STRUTSp. 75
FILLING NOSE GEAR OLEO STRUTp. 75
FILLING MAIN GEAR OLEO STRUTp. 76
INFLATING OLEO STRUTSp. 79
BRAKE SYSTEMp. 79
SERVICING BRAKE SYSTEMp. 79
FILLING BRAKE CYLINDER RESERVOIRp. 79
DRAINING BRAKE SYSTEMp. 79
TIRESp. 79
SERVICING TIRESp. 79
POWER PLANTp. 80
SERVICING POWER PLANTp. 80
ENGINE AIR FILTERp. 80
SERVICING PROPELLERp. 80
SERVICING ELECTRICAL SYSTEMp. 81
BATTERYp. 81
BATTERY BOX CORROSION PREVENTIONp. 81
LUBRICATIONp. 81
LUBRICATION INSTRUCTIONSp. 81
APPLICATION OF OILp. 82
APPLICATION OF GREASEp. 82
LUBRICATION CHARTp. 82
CHAPTER 20 – STANDARD PRACTICES/AIR FRAMEp. 97
TABLE OF CONTENTSp. 98
GENERALp. 100
STANDARD PRACTICES — AIRFRAMEp. 100
TORQUE WRENCHESp. 100
METHOD OF INSTALLING ROD END BEARINGSp. 101
REMOVAL CHERRYLOCK RIVETSp. 102
IDENTIFICATION OF FLUID LINESp. 103
FLARELESS TUBE ASSEMBLIESp. 103
LUBRICATION OF GASKETS AND SEALSp. 107
LUBRICATION OF THREADSp. 107
AIRCRAFT FLNISH CAREp. 107
CLEANING- GENERALp. 107
CLEANING INTERIOR SURFACESp. 107
HEADLINER, SIDE PANELS, AND SEATSp. 107
CARPETSp. 107
CLEANING EXTERIOR SURFACESp. 108
WINDSHIELD AND WINDOWSp. 108
LANDING GEARp. 109
ENGINE COMPARTMENTp. 109
FUEL SYSTEMp. 109
CONDITIONS AFFECTING CORROSIONp. 110
INSPECTIONp. 110
CORROSION REMOVAL AND CONTROLp. 110
AREAS PRONE TO CORROSIONp. 112
PAINTINGp. 113
PAINTING SAFETYp. 113
PAINT APPLICATIONp. 114
PAINTING SEQUENCEp. 114
COLOR MATCHINGp. 115
POLYURETHANE PAINT SAFETYp. 115
DUPONT IMRON METHODp. 116
RANDOLPH RANTHANE METHODp. 117
ALUMIGRIP METHODp. 118
TITANINE POLYURETHANE METHODp. 119
AMERON METHODp. 119
APPLICATION OF ACRYLICSp. 120
TRIM AND REGISTRATION NUMBERSp. 121
PAINT SYSTEM COMPATIBILITYp. 121
COMMON PAINT TROUBLESp. 122
STORAGEp. 122
PAINTING FACILITYp. 122
WAXINGp. 123
DECALSp. 123
CHAPTER 21 – ENVIRONMENTAL SYSTEMp. 125
TABLE OF CONTENTSp. 126
GENERALp. 128
HEATINGp. 128
DESCRIPTION AND OPERATIONp. 128
HEATER MAINTENANCEp. 128
COOLINGp. 130
DESCRIPTION AND OPERATIONp. 130
SERVICING COOLING SYSTEMp. 138
MALFUNCTION DETECTIONp. 138
SPECIAL SERVLCING PROCEDURESp. 140
SYSTEM SERVICING PRECAUTIONSp. 140
SERVICE VALVESp. 141
SERVICE VALVE REPLACEMENTp. 142
TEST GAUGE AND MANIFOLD SETp. 143
CHECKING THE SYSTEM FOR LEAKSp. 143
LEAK CHECKp. 145
METHOD Ip. 145
METHOD IIp. 146
DISCHARGINGp. 146
EVACUATING THE SYSTEMp. 147
CHARGING THE SYSTEMp. 148
WITH A CHARGING STANDp. 149
USING THE AIRPLANE COMPRESSOR TO CHARGE THE SYSTEMp. 150
ADDITION OF PARTIAL CHARGE TO SYSTEMp. 151
COMPRESSORp. 152
COMPRESSOR SERVICEp. 152
COMPRESSOR REMOVALp. 152
COMPRESSOR INSTALLATIONp. 153
CHECKING COMPRESSOR OILp. 153
REPLACEMENT OF COMPRESSOR DRIVE BELTp. 154
ADJUSTMENT OF DRIVE BELT TENSIONp. 156
MAGNETIC CLUTCH REMOVALp. 157
MAGNETIC CLUTCH INSTALLATIONp. 157
REFRIGERANT LINES AND ROUTINGp. 158
RECEIVER-DEHYDRATORp. 159
RECEIVER-DEHYDRATOR REMOVALp. 159
RECEIVER-DEHYDRATOR INSTALLATIONp. 159
CONDENSERp. 159
CONDENSER REMOVALp. 159
CONDENSER INSTALLATIONp. 160
CONDENSER DOOR ACTUATORp. 160
CONDENSER ASSEMBLY RIGGING INSTRUCTIONSp. 160
EXPANSION VALVEp. 162
EXPANSION VALVE REMOVALp. 162
EXPANSION VALVE INSTALLATIONp. 162
EVAPORATORp. 163
EVAPORATOR REMOVALp. 163
EVAPORATOR INSTALLATIONp. 163
PRESSURE RELIEF SWITCH (RANCO)p. 164
ELECTRICAL INSTALLATIONp. 164
ADJUSTMENT OF THROTTLE SWITCHp. 165
FUSE REPLACEMENTp. 165
CABIN VENT SYSTEMp. 165
OVERHEAD VENT BLOWERp. 165
DESCRIPTIONp. 165
REMOVAL OF BLOWER ASSEMBLYp. 165
DISASSEMBLY OF BLOWER ASSEMBLYp. 165
REASSEMBLY OF BLOWER ASSEMBLYp. 167
INSTALLATION OF BLOWER ASSEMBLYp. 167
CHAPTER 22 – AUTOFLIGHTp. 169
TABLE OF CONTENTSp. 170
GENERALp. 171
AUTOPILOTp. 171
NON-PIPER AFCS EQUIPMENT CONTACTSp. 171
PIPER AFCS EQUIPMENTp. 172
CHAPTER 23 – COMMUNICATIONSp. 173
TABLE OF CONTENTSp. 174
GENERALp. 175
AVIONICS MASTER AND EMERGENCY SWITCHp. 175
DESCRIPTION AND OPERATIONp. 175
DATA TRANSMISSION AND AUTOMATIC CALLINGp. 176
EMERGENCY LOCATOR TRANSMITTERp. 176
DESCRIPTIONp. 176
BATTERY REMOVAL AND INSTALLATION (COMMUNICATIONS COMPONENTS CORPp. 176
BATTERY REMOVAL AND INSTALLATION (NARCOp. 178
DESCRIPTION, OPERATION, AND TESTING OF PILOT’S REMOTE SWITCHp. 178
TESTING EMERGENCY LOCATOR TRANSMITTERp. 180
CHAPTER 24 – ELECTRICAL POWERp. 182
TABLE OF CONTENTSp. 183
GENERALp. 185
DESCRIPTION AND OPERATIONp. 185
TROUBLESHOOTINGp. 185
DC GENERATIONp. 193
DESCRIPTION OF ALTERNATOR SYSTEMp. 193
CHECKING ALTERNATOR SYSTEMp. 194
SERVICE PRECAUTIONSp. 195
OVERHAUL OF ALTERNATORp. 196
ALTERNATOR SYSTEM (CHRYSLER)p. 196
BENCH TESTING ALTERNATORp. 196
ROTOR FIELD COIL CURRENT DRAWp. 196
TESTING ALTERNATOR INTERNAL FIELD CIRCUITp. 196
INSPECTIONp. 198
TESTING OF RECTIFIER ASSEMBLIESp. 198
TESTING OF POSITIVE RECTIFIERS USING C-3829 TESTERp. 198
TESTING OF NEGATIVE RECTIFIERS USING C-3829 TESTERp. 200
TESTING OF RECTIFIER ASSEMBLIES USING TEST LAMPp. 200
REMOVAL OF RECTIFIER AND HEATSINK ASSEMBLYp. 202
TESTING OF STATORp. 203
REMOVAL OF PULLEY AND BEARINGp. 203
TESTING OF ROTORp. 204
SLIP RINGSp. 205
ASSEMBLY OF ALT ERNATORp. 205
ALTERNATOR SYSTEM (PRESTOLITEp. 211
DESCRIPTION OF ALTERNATORp. 211
DISASSEMBLY OF ALTERNATORp. 211
INSPECTION AND TESTING OF COMPONENTSp. 214
ASSEMBLY OF ALTERNATORp. 215
TESTING ALTERNATORp. 217
PRECAUTIONSp. 218
ALTERNATOR SERVICE TIPSp. 219
ALTERNATOR SERVICE TEST SPECIFICATIONSp. 219
CHECKING ALTERNATOR BELT TENSIONp. 220
BATTERYp. 221
SERVICING BATTERYp. 221
REMOVAL OF BATTERYp. 221
INSTALLATION OF BATTERYp. 222
TESTING BATTERYp. 222
CHARGING BATTERYp. 222
BATTERY BOX CORROSION PREVENTIONp. 222
CHECKING VOLTAGE REGULATORp. 223
CHECKING OVERVOLTAGE RELAYp. 224
EXTERNAL POWERp. 224
OPERATION OF EXTERNAL POWER RECEPTACLEp. 224
ELECTRICAL SYSTEM LOAD DISTRIBUTIONp. 225
CHAPTER 25 – EQUIPMENT/FURNISHINGSp. 226
TABLE OF CONTENTSp. 227
FLIGHT COMPARTMENTp. 228
RIGGING INSTRUCTIONS – SEAT BACK LOCK AND RELEASEp. 228
SHOULDER HARNESS INERTIA REEL ADJUSTMENTp. 229
CHAPTER 27 – FLIGHT CONTROLSp. 230
TABLE OF CONTENTSp. 231
GENERALp. 233
TROUBLESHOOTINGp. 233
STANDARD PROCEDURESp. 241
CONTROL COLUMN ASSEMBLYp. 241
REMOVAL OF CONTROL COLUMN ASSEMBLYp. 241
INSTALLATION OF CONTROL COLUMN ASSEMBLYp. 243
AILERON AND TABp. 244
AILERON CONTROL CABLESp. 244
REMOVAL OF AILERON CONTROL CABLESp. 244
INSTALLATION OF AILERON CONTROL CABLESp. 246
AILERON BELLCRANK ASSEMBLYp. 247
REMOVAL OF AILERON BELLCRANK ASSEMBLYp. 247
INSTALLATION OF AILERON BELLCRANK ASSEMBLYp. 247
RIGGING AND ADJUSTMENT OF AILERON CONTROLSp. 248
RUDDER AND TABp. 251
RUDDER AND STEERING PEDAL ASSEMBLYp. 251
REMOVAL OF RUDDER AND STEERING PEDAL ASSEMBLYp. 251
INSTALLATION OF RUDDER AND STEERING PEDAL ASSEMBLYp. 253
RUDDER CONTROL CABLESp. 256
REMOVAL OF RUDDER CONTROL CABLESp. 256
INSTALLATION OF RUDDER CONTROL CABLESp. 256
RIGGING AND ADJUSTMENT OF RUDDER CONTROLSp. 257
RUDDER TRIM CONTROLSp. 257
REMOVAL OF RUDDER TRIM CONTROLSp. 257
INSTALLATION OF RUDDER TRIM CONTROLSp. 258
RIGGING AND ADJUSTMENT OF RUDDER TRIM CONTROLSp. 258
STABILATOR AND TABp. 258
STABILATOR CONTROL CABLESp. 258
REMOVAL OF STABILATOR CONTROL CABLESp. 258
INSTALLATION OF STABILATOR CONTROL CABLESp. 260
RIGGING AND ADJUSTMENT OF STABILATOR CONTROLSp. 263
STABILATOR TRIM ASSEMBLY (FORWARD)p. 264
REMOVAL OF STABILATOR TRIM ASSEMBLY (FORWARD)p. 264
INSTALLATION OF STABILATOR TRIM ASSEMBLY (FORWARD)p. 265
STABILATOR TRIM ASSEMBLY (AFTp. 267
REMOVAL OF STABILATOR TRIM ASSEMBLY (AFTp. 267
INSTALLATION OF STABILATOR TRIM ASSEMBLY (AFTp. 268
RIGGING AND ADJUSTMENT OF STABILATOR TRIMp. 268
FLAPSp. 269
WING FLAP CONTROLSp. 269
REMOVAL OF WING FLAP CONTROLSp. 269
INSTALLATION OF WING FLAP CONTROLSp. 271
RIGGING AND ADJUSTMENT OF WING FLAPSp. 273
STALL WARNINGp. 274
STALL WARNING HORN, INDICATOR, AND DETECTORp. 274
REMOVAL OF LIFT DETECTORp. 274
INSTALLATION OF LIFT DETECTORp. 274
ADJUSTMENT OF LIFT DETECTORp. 274
CHAPTER 28 – FUELp. 293
TABLE OF CONTENTSp. 294
GENERALp. 295
DESCRIPTIONp. 295
TROUBLESHOOTINGp. 295
STORAGEp. 299
FUEL TANKp. 299
REMOVAL OF FUEL TANKp. 299
INSPECTION AND REPAIR OF FUEL TANKp. 299
INSTALLATION OF FUEL TANKp. 299
LOCKING FUEL CAPp. 299
DISASSEMBLY OF LOCKING FUEL CAPp. 299
ASSEMBLY OF LOCKING FUEL CAPp. 299
DISTRIBUTIONp. 300
FUEL SELECTOR VALVEp. 300
REMOVAL OF FUEL SELECTOR VALVEp. 300
INSTALLATION OF FUEL SELECTOR VALVEp. 301
FUEL FILTER BOWL AND SCREENp. 301
REMOVAL OF FUEL FILTER BOWL AND SCREENp. 301
INSTALLATION OF FUEL FILTER BOWL AND SCREENp. 301
CLEANING AND INSPECTION OF FILTER BOWL SCREENp. 301
FUEL PUMP (ELECTRIC)p. 301
REMOVAL OF ELECTRIC FUEL PUMPp. 301
DISASSEMBLY OF ELECTRIC FUEL PUMPp. 303
CLEANING, INSPECTION AND REPAIR OF ELECTRIC FUEL PUMPp. 303
RESISTANCE CHECK (PLUNGER TYPE PUMP)p. 303
ASSEMBLY OF FUEL PUMPp. 304
ADJUSTMENT OF ELECTRIC FUEL PUMP (BENCH TEST)p. 304
ADJUSTMENT OF ELECTRIC FUEL PUMP (IN AIRPLANE)p. 304
INSTALLATION OF ELECTRIC FUEL PUMPp. 305
LINES AND FITTINGSp. 305
INSPECTION AND TIGHTENING OF FUEL LINE UNION FITTINGSp. 305
REPLACEMENT OF FITTINGSp. 306
INDICATINGp. 307
FUEL QUANTITYp. 307
REMOVAL OF FUEL QUANTITY TRANSMITTER UNITp. 307
INSTALLATION OF FUEL QUANTITY TRANSMITTER UNITp. 307
FUEL QUANTITY SENDER/GAUGE CHECK (INSTALLED)p. 308
CHAPTER 32 – LANDING GEARp. 310
TABLE OF CONTENTSp. 311
GENERALp. 313
DESCRIPTIONp. 313
TROUBLESHOOTINGp. 313
MAIN GEARp. 316
MAIN GEAR OLEOp. 316
DISASSEMBLY OF MAIN GEAR OLEOp. 316
CLEANING, INSPECTION, AND REPAIR OF MAIN GEAR OLEOp. 316
ASSEMBLY OF MAIN GEAR OLEOp. 318
MAIN LANDING GEAR ASSEMBLYp. 318
REMOVAL OF MAIN LANDING GEARp. 318
CLEANING, INSPECTION, AND REPAIR OF MAIN LANDING GEARp. 320
INSTALLATION OF MAIN LANDING GEARp. 320
NOSE GEARp. 320
NOSE GEAR OLEOp. 320
DISASSEMBLY OF NOSE GEAR OLEOp. 320
CLEANING, INSPECTION, AND REPAIR OF NOSE GEAR OLEOp. 322
NOSE GEAR OIL ORIFICE RETAINER RING INSTALLATIONp. 323
ASSEMBLY OF NOSE GEAR OLEOp. 323
NOSE LANDING GEAR ASSEMBLYp. 324
REMOVAL OF NOSE LANDING GEARp. 324
CLEANING, INSPECTION, AND REPAIR OF NOSE LANDING GEARp. 324
INSTALLATION OF NOSE LANDING GEARp. 324
ALIGNMENT OF NOSE GEARp. 326
WHEELS AND BRAKESp. 327
MAIN WHEEL ASSEMBLYp. 327
REMOVAL AND DISASSEMBLY OF MAIN WHEEL ASSEMBLYp. 327
INSPECTION OF MAIN WHEEL ASSEMBLYp. 329
ASSEMBLY AND INSTALLATION OF MAIN WHEELp. 329
NOSE WHEEL ASSEMBLYp. 329
REMOVAL AND DISASSEMBLY OF NOSE WHEEL ASSEMBLYp. 329
INSPECTION OF NOSE WHEEL ASSEMBLYp. 331
ASSEMBLY AND INSTALLATION OF NOSE WHEEL ASSEMBLYp. 331
BRAKE ASSEMBLYp. 331
BRAKE ADJUSTMENT AND LINING TOLERANCEp. 331
REMOVAL AND DISASSEMBLY OF BRAKE ASSEMBLYp. 331
CLEANING, INSPECTION, AND REPAIR OF BRAKE ASSEMBLYp. 332
ASSEMBLY AND INSTALLATION OF BRAKE ASSEMBLYp. 336
MASTER CYLINDER (HAND BRAKEp. 336
REMOVAL OF MASTER CYLINDER (HAND BRAKE)p. 336
DISASSEMBLY OF MASTER CYLINDER (HAND BRAKE)p. 336
CLEANING, INSPECTION, AND REPAIR OF MASTER CYLINDER (HAND BRAKE)p. 337
ASSEMBLY OF MASTER CYLINDER (HAND BRAKE)p. 337
INSTALLATION OF MASTER CYLINDER (HAND BRAKE)p. 338
BRAKE CYLINDER (TOE BRAKE)p. 338
REMOVAL OF BRAKE CYLINDER (TOE BRAKE)p. 338
DISASSEMBLY OF BRAKE CYLINDERp. 338
CLEANING, INSPECTION, AND REPAIR OF BRAKE CYLINDERp. 341
ASSEMBLY OF BRAKE CYLINDER (TOE BRAKE)p. 341
INSTALLATION OF BRAKE CYLINDER (TOE BRAKE)p. 341
BLEEDING BRAKESp. 341
BRAKE BLEEDING PROCEDURE (GRAVITY)p. 341
BRAKE BLEEDING PROCEDURE (PRESSURE)p. 342
BRAKE SYSTEM LEAK CHECKp. 312
BLEEDING OF THE BRAKES AFTER A UNIT HAS BEEN CHANGEDp. 312
CHAPTER 33 – LIGHTSp. 344
TABLE OF CONTENTSp. 345
GENERALp. 346
DESCRIPTION AND OPERATIONp. 346
TROUBLESHOOTINGp. 346
FLIGHT COMPARTMENTp. 349
INSTRUMENT PANEL LIGHTSp. 349
DIMMER CONTROL ASSEMBLYp. 349
REMOVAL OF DIMMER CONTROL ASSEMBLYp. 349
INSTALLATION OF DIMMER CONTROL ASSEMBLYp. 349
ANNUNCIATOR PANELp. 349
DESCRIPTION AND OPERATIONp. 349
EXTERIORp. 350
GENERALp. 350
LANDING LIGHTp. 350
REMOVAL AND INSTALLATION OF LANDING LIGHTp. 350
ROTATING BEACONp. 351
REMOVAL OF ROTATING BEACONp. 351
INSTALLATION OF ROTATING BEACONp. 351
ANTI-COLLISION LIGHT (STROBEp. 351
WING TIP STROBE LIGHTp. 351
REMOVAL OF WING TIP STROBE LIGHTp. 351
INSTALLATION OF WING TIP STROBE LIGHTp. 351
STROBE POWER SUPPLYp. 353
REMOVAL OF STROBE POWER SUPPLYp. 353
INSTALLATION OF STROBE POWER SUPPLYp. 353
TROUBLESHOOTING PROCEDUREp. 353
CHAPTER 34 – NAVIGATION AND PITOT/STATICp. 355
TABLE OF CONTENTSp. 356
GENERALp. 357
DESCRIPTION AND OPERATIONp. 357
REMOVAL AND INSTALLATION OF FACE MOUNTED INSTRUMENTSp. 357
GYRO FITTING INSTALLATION PROCEDURE (EDO-AIRE)p. 358
REMOVAL AND REPLACEMENT OF CLUSTER MOUNTED INSTRUMENTSp. 360
RATE OF CLIMB INDICATORp. 360
SENSITIVE ALTIMETERp. 361
AIRSPEED INDICATORp. 363
GYRO HORIZONp. 364
GENERALp. 364
AIR DRIVEN ATTITUDE HORIZONp. 364
TROUBLESHOOTINGp. 365
DIRECTIONAL GYRO – AIR DRIVEN/ELECTRICp. 365
GENERALp. 365
AIR DRIVEN DIRECTIONAL GYROp. 366
ELECTRICALLY DRIVEN DIRECTIONAL GYROp. 366
TROUBLESHOOTINGp. 366
MAGNETIC COMPASSp. 367
ADJUSTMENT OF COMPASSp. 367
TURN AND BLANK/PICTORIAL RATE INSTRUMENTSp. 368
GENERALp. 368
TROUBLESHOOTINGp. 368
CHAPTER 37 – VACUUMp. 373
TABLE OF CONTENTSp. 374
GENERALp. 375
DESCRIPTION AND OPERATIONp. 375
TROUBLESHOOTINGp. 375
DISTRIBUTIONp. 378
VACUUM SYSTEM SERVICE TIPSp. 378
VACUUM PUMPp. 379
REMOVAL OF VACUUM PUMPp. 379
REPLACING PUMP FITTINGSp. 380
INSTALLATION OF VACUUM PUMPp. 380
VACUUM REGULATOR VALVEp. 381
ADJUSTMENT OF VACUUM REGULATOR VALVEp. 381
REMOVAL AND REPLACEMENT OF REGULATOR VALVEp. 381
INDICATINGp. 382
VACUUM GAUGEp. 382
REMOVAL OF VACUUM SENSORp. 382
INSTALLATION OF VACUUM SENSORp. 382
AUXILIARY VACUUM PUMP (SERIAL NUMBERS 8611001 AND UP)p. 383
AUXILIARY VACUUM PUMP, ENGINE OFF OPERATIONAL CHECKp. 383
REMOVAL OF AUXILIARY PUMPp. 385
INSTALLATION OF AUXILIARY VACUUM PUMPp. 386
CHAPTER 39 – ELECTRIC/ELECTRONIC PANELS AND MULTIPURPOSE PARTSp. 388
TABLE OF CONTENTSp. 389
MULTIPURPOSE ELECTRICAL AND ELECTRONIC PARTSp. 390
ELECTRICAL SWITCHES AND CIRCUIT BREAKERSp. 390
REMOVAL OF ELECTRICAL SWITCHESp. 390
CHAPTER 51 – STRUCTURESp. 391
TABLE OF CONTENTSp. 392
GENERALp. 393
DESCRIPTIONp. 393
STRUCTURAL REPAIRSp. 393
BAGGAGE COMPARTMENT INSPECTION HOLE AND COVER PLATEp. 393
FIBERGLASS REPAIRSp. 394
FIBERGLASS TOUCH-UP AND SURFACE REPAIRSp. 398
FIBERGLASS FRACTURE AND PATCH REPAIRSp. 398
THERMOPLASTIC REPAIRSp. 399
SAFETY WALK REPAIRp. 406
SURFACE PREPARATIONp. 406
PRODUCT LISTING FOR LIQUID SAFETY WALK COMPOUNDp. 406
APPLICATION OF LIQUID SAFETY WALK COMPOUNDp. 408
SURFACE PREPARATION FOR PRESSURE SENSITIVE SAFETY WALKp. 408
APPLICATION OF PRESSURE SENSITIVE SAFETY WALKp. 408
CHAPTER 52 – DOORSp. 409
TABLE OF CONTENTSp. 410
GENERALp. 411
PASSENGER/CREWp. 411
CABIN DOORp. 411
REMOVAL OF DOORp. 411
INSTALLATION OF DOORp. 411
ADJUSTMENT OF DOORp. 411
DOOR LATCH MECHANISMp. 411
REMOVAL OF DOOR LATCH MECHANISMp. 411
INSTALLATION OF DOOR LATCH MECHANISMp. 412
ADJUSTMENT OF DOOR LATCH MECHANISMp. 412
DOOR LOCK ASSEMBLYp. 412
REMOVAL OF DOOR LOCK ASSEMBLYp. 412
INSTALLATION OF DOOR LOCK ASSEMBLYp. 412
DOOR SAFETY LATCHp. 412
REMOVAL OF DOOR SAFETY LATCHp. 412
INSTALLATION OF DOOR SAFETY LATCHp. 412
ADJUSTMENT OF DOOR SAFETY LATCHp. 413
DOOR SNUBBERp. 413
REMOVAL AND INSTALLATION OF DOOR SNUBBERp. 413
CARGOp. 416
BAGGAGE DOORp. 416
REMOVAL OF BAGGAGE DOORp. 416
INSTALLATION OF BAGGAGE DOORp. 416
BAGGAGE DOOR LOCK ASSEMBLYp. 416
REMOVAL OF BAGGAGE DOOR LOCK ASSEMBLYp. 416
INSTALLATION OF BAGGAGE DOOR LOCK ASSEMBLYp. 416
BAGGAGE DOOR HINGEp. 416
REMOVAL OF BAGGAGE DOOR HINGEp. 416
INSTALLATION OF BAGGAGE DOOR HINGEp. 416
CHAPTER 55 – STABILIZERSp. 417
TABLE OF CONTENTSp. 418
STABILATOR AND TABp. 419
STABILATORp. 419
REMOVAL OF STABILATORp. 419
INSTALLATION OF STABILATORp. 419
STABILATOR TRIM TABp. 420
REMOVAL OF STABILATOR TRIM TABp. 420
INSTALLATION OF STABILATOR TRIM TABp. 420
CHECKING STABILATOR SURFACES FREE PLAYp. 420
BALANCINGp. 423
BALANCING EQUIPMENTp. 423
BALANCING STABILATORp. 423
VERTICAL STABILIZERp. 423
VERTICAL FINp. 423
REMOVAL OF VERTICAL FINp. 423
INSTALLATION OF VERTICAL FINp. 424
RUDDER AND TABp. 424
RUDDERp. 424
REMOVAL OF RUDDERp. 424
INSTALLATION OF RUDDERp. 424
BALANCINGp. 425
BALANCING RUDDERp. 425
CHAPTER 56 – WINDOWSp. 427
TABLE OF CONTENTSp. 428
FLIGHT COMPARTMENTp. 429
WINDSHIELDp. 429
REMOVAL OF WINDSHIELDp. 429
INSTALLATION OF WINDSHIELDp. 429
CABINp. 429
SIDE WINDOWSp. 429
REMOVAL OF SIDE WINDOWSp. 429
INSTALLATION OF SIDE WINDOWSp. 431
CHAPTER 57 – WINGSp. 432
TABLE OF CONTENTSp. 433
GENERALp. 434
DESCRIPTIONp. 434
AUXILIARY STRUCTUREp. 434
WING TIPp. 434
REMOVAL OF WING TIPp. 434
INSTALLATION OF WING TIPp. 434
REPAIR OF WING TIPp. 434
ATTACH FITTINGSp. 438
WING TO FUSELAGE ATTACH FITTINGSp. 438
REMOVAL OF WINGp. 438
INSTALLATION OF WINGp. 439
FLIGHT SURFACESp. 442
AILERONp. 442
REMOVAL OF AILERONp. 442
INSTALLATION OF AILERONp. 443
CHECKING AILERON FREE PLAYp. 443
BALANCINGp. 443
BALANCING AILERONp. 443
BALANCING EQUIPMENT AND PROCEDUREp. 443
WING FLAPp. 445
REMOVAL OF WING FLAPp. 445
INSTALLATION OF WING FLAPp. 445
CHAPTER 61 – PROPELLERp. 446
TABLE OF CONTENTSp. 447
GENERALp. 448
PROPELLER ASSEMBLYp. 448
MAINTENANCE OF PROPELLERp. 448
REMOVAL OF PROPELLERp. 448
CLEANING, INSPECTION, AND REPAIR OF PROPELLERp. 449
INSTALLATION OF PROPELLERp. 449
CHECKING PROPELLER BLADE TRACKp. 451
CONTROLLINGp. 451
PROPELLER GOVERNORp. 451
REMOVAL OF PROPELLER GOVERNORp. 451
INSTALLATION OF PROPELLER GOVERNORp. 451
RIGGING AND ADJUSTMENT OF PROPELLER GOVERNORp. 452
CHAPTER 70 – STANDARD PRACTICES ENGINESp. 454
TABLE OF CONTENTSp. 455
STANDARD PRACTICES – ENGINEp. 456
CHAPTER 71 – POWER PLANTp. 458
TABLE OF CONTENTSp. 459
GENERALp. 460
DESCRIPTIONp. 460
TROUBLESHOOTINGp. 460
ENGINEp. 467
REMOVAL OF ENGINEp. 467
PRE-OILING ENGINEp. 467
INSTALLATION OF ENGINEp. 468
COWLINGp. 471
MAINTENANCE OF COWLINGp. 471
REMOVAL OF COWLINGp. 471
CLEANING, INSPECTION, AND REPAIR OF COWLINGp. 472
INSTALLATION OF COWLINGp. 472
MOUNTSp. 472
ENGINE SHOCK MOUNTSp. 472
REPLACEMENT OF ENGINE SHOCK MOUNTSp. 472
AIR INTAKESp. 472
CARBURETOR ICE DETECTORp. 472
REMOVAL OF ICE DETECTOR PROBEp. 474
INSTALLATION OF ICE DETECTOR PROBEp. 474
FUNCTIONAL CHECK OF ICE DETECTOR PROBEp. 474
CARBURETOR ICE DETECTION SYSTEM TESTp. 476
CARBURETOR AIRBOXp. 477
REMOVAL OF CARBURETOR AIRBOXp. 477
INSTALLATION OF CARBURETOR AIRBOXp. 477
CHAPTER 73 – ENGINE FUEL SYSTEMp. 478
TABLE OF CONTENTSp. 479
GENERALp. 480
DISTRIBUTIONp. 480
CARBURETOR MAINTENANCEp. 480
THROTTLE ARMp. 480
ADJUSTMENT OF IDLE MIXTUREp. 480
ADJUSTMENT OF IDLE SPEEDp. 481
ENGINE PRIMER (OPTIONAL)p. 482
REMOVAL OF ENGINE PRIMERp. 482
DISASSEMBLY, CLEANING, AND ASSEMBLY OF ENGINE PRIMERp. 482
INSTALLATION OF ENGINE PRIMERp. 483
PRIMER JETSp. 483
CONTROLLINGp. 483
ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLSp. 483
INDICATINGp. 484
FUEL PRESSURE GAUGEp. 484
CHAPTER 74 – IGNITIONp. 486
TABLE OF CONTENTSp. 487
GENERALp. 489
DESCRIPTION AND OPERATIONp. 489
TROUBLESHOOTINGp. 489
ELECTRICAL POWER SUPPLYp. 491
MAGNETOp. 491
INSPECTION OF MAGNETOp. 491
INSTALLATION AND TIMING (MAGNETO TO ENGINE)p. 493
INTERNAL TIMING OF MAGNETOp. 497
IMPULSE COUPLINGp. 500
REMOVAL OF IMPULSE COUPLINGp. 500
INSPECTION OF IMPULSE COUPLINGp. 500
INSTALLATION OF IMPULSE COUPLINGp. 504
DISTRIBUTIONp. 506
IGNITION HARNESSp. 506
INSPECTION OF HARNESSp. 506
MAINTENANCE OF HARNESSp. 508
SPARK PLUGSp. 513
REMOVAL OF SPARK PLUGSp. 513
INSPECTION AND CLEANING OF SPARK PLUGSp. 514
INSTALLATION OF SPARK PLUGSp. 515
SWITCHINGp. 515
IGNITION SWITCHp. 515
REMOVAL OF IGNITION SWITCHp. 515
INSTALLATION OF IGNITION SWITCHp. 515
CHAPTER 77 – ENGINE INDICATINGp. 518
TABLE OF CONTENTSp. 519
GENERALp. 520
POWERp. 520
MANIFOLD PRESSURE GAUGEp. 520
TACHOMETER INDICATORp. 521
ENGINE OIL PRESSURE GAUGEp. 522
TEMPERATUREp. 522
OIL TEMPERATURE INDICATORp. 522
EXHAUST GAS TEMPERATURE GAUGE (ALCOR)p. 523
REMOVAL OF EGT PROBE AND GAUGEp. 523
CLEANING AND INSPECTION OF EGT GAUGEp. 523
INSTALLATION OF EGT PROBE AND GAUGEp. 524
CYLINDER HEAD TEMPERATURE GAUGEp. 524
CHAPTER 78 – EXHAUSTp. 526
TABLE OF CONTENTSp. 527
GENERALp. 528
INSPECTION OF EXHAUST SYSTEMp. 528
CHAPTER 79 – OIL SYSTEMp. 530
TABLE OF CONTENTSp. 531
GENERALp. 532
DISTRIBUTIONp. 532
OIL COOLERp. 532
REMOVAL OF OIL COOLERp. 532
INSTALLATION OF OIL COOLERp. 532
INDICATINGp. 532
OIL PRESSURE SENSORp. 532
REMOVAL OF OIL PRESSURE SENSORp. 532
INSTALLATION OF OIL PRESSURE SENSORp. 533
CHAPTER 80 – STARTINGp. 535
TABLE OF CONTENTSp. 536
GENERALp. 537
DESCRIPTION AND OPERATIONp. 537
TROUBLESHOOTINGp. 537
CRANKINGp. 540
MAINTENANCE OF STARTING SYSTEMp. 540
OVERHAUL OF STARTING MOTORp. 541
REMOVAL OF STARTING MOTORp. 541
DISASSEMBLY OF STARTING MOTORp. 541
BRUSHESp. 541
ARMATUREp. 543
FIELD COILSp. 543
BRUSH HOLDERSp. 543
GEAR AND PINION HOUSINGp. 543
BENDIX DRIVEp. 543
ASSEMBLY OF STARTING MOTORp. 544
BENCH TESTp. 545
STARTING MOTOR CONTROL CIRCUITp. 545
STARTING MOTOR SERVICE TEST SPECIFICATIONp. 546
EXTERNAL POWER RECEPTACLEp. 546
CHAPTER 91 – CHARTS/WIRING DIAGRAMSp. 564
TABLE OF CONTENTSp. 565
GENERALp. 566
TORQUE REQUIREMENTSp. 566
FLARE FITTING TORQUESp. 566
RECOMMENDED NUT TORQUESp. 567
CONVERSION TABLESp. 570
DECIMAL EQUIVALENTS OF DRILL SIZESp. 575
LIST OF CONSUMABLE MATERIALSp. 576
ELECTRICAL SCHEMATICSp. 584
ELECTRICAL WIRE CODINGp. 584
ELECTRICAL SYMBOLSp. 585
ELECTRICAL SCHEMATIC INDEXp. 586
CHAPTER 95 – SPECIAL PURPOSE EQUIPMENTp. 604
TABLE OF CONTENTSp. 605
GENERALp. 606
TOOLS AND TEST EQUIPMENTp. 606
TIRE BALANCER BUILDING INSTRUCTIONSp. 607

Chapters Covered

  • Chapter 4 – Airworthiness Limitations: FAA-approved Part 43 and Part 91 inspection requirements, structural fatigue safe-life parameters, and Hartzell propeller blade safe-life limits.
  • Chapter 5 – Time Limits / Maintenance Checks: Inspection requirements for 50-hour, 100-hour/annual, 500-hour, and 1000-hour intervals across Propeller, Engine, Cabin, Fuselage/Empennage, Wing, Landing Gear, and Operational groups; overlimits inspections for hard or overweight landings, severe turbulence encounters, and engine sudden stoppage; programmed inspection scheduling under P/N 761 734.
  • Chapter 6 – Dimensions and Areas: Chart 601 leading particulars and principal dimensions; 3-view engineering drawings; station reference datum lines including fuselage stations (FS), buttock lines (BL), and water lines (WL); exterior access and inspection plate locations.
  • Chapter 7 – Lifting and Shoring: Main gear jack pad arrangements on front wing spars, tail skid support cradles, and mandatory 250-pound tail ballast procedures.
  • Chapter 8 – Leveling and Weighing: Longitudinal leveling screw locations below left front window, lateral leveling across rear seat spar box, wheel scale positioning, and ramp tare procedures.
  • Chapter 9 – Towing and Taxiing: Nose gear towing bar limits, maximum turning angles, tractor towing safety, and engine run-up precautions over loose gravel.
  • Chapter 10 – Parking and Mooring: Parking brake ratchet operation, gust lock installations using front seat belts, and 45-degree three-point tie-down procedures.
  • Chapter 11 – Required Placards: Complete exterior decal mapping and internal instrument panel, console, circuit breaker, and emergency bus switch markings.
  • Chapter 12 – Servicing: Fuel system draining, 77-gallon capacity specifications, MIL-I-27686 anti-icing fuel additive blending; Lycoming 12-quart oil sump draining, suction screen cleaning, full-flow cartridge filter replacement; nose and main landing gear air-oil oleo strut fluid servicing (Methods I and II), 250 psi nitrogen inflation, Cleveland brake reservoir replenishment; dry-air induction filter cleaning; constant speed propeller lubrication; battery box neutralization; comprehensive airframe lubrication schedules.
  • Chapter 20 – Standard Practices – Airframe: Torque wrench adapter formulas, rod end bearing alignment, Cherrylock blind rivet extraction, fluid line color coding and markings, flareless tube fitting presetting, metal corrosion removal, chemical surface treatments, and exterior finishing specifications (DuPont Imron, Randolph Ranthane, Alumigrip, Titanine, Ameron Jet-Glo, and Randacryl).
  • Chapter 21 – Environmental Systems: Exhaust manifold heater muff and defroster ducting; cabin ventilation and overhead blower servicing; complete vapor-cycle air conditioning maintenance including York compressor service, magnetic clutch replacement, condenser door actuator rigging, Ranco pressure relief switch testing, system leak detection, evacuation down to 26-28 inches Hg, and charging stand procedures.
  • Chapter 22 – Autoflight: Automated Flight Control Systems (AFCS) vendor cross-references and Piper AutoControl, AutoFlite, and Pitch Trim service literature mapping.
  • Chapter 23 – Communications: Avionics master and emergency bus switch circuits; Narco and Communications Components Corp (CCC) Emergency Locator Transmitter (ELT) battery replacement, testing intervals, and radiation sweep restrictions.
  • Chapter 24 – Electrical Power: 14-volt DC single-wire negative ground electrical distribution; 12-volt battery testing and charging; voltage regulator and overvoltage relay checks; Chrysler (3656624, 4111810) and Prestolite (ALY-6422) 60-amp alternator complete teardown, rotor field coil current draw checks, C-3829 diode rectifier testing, stator diagnostics, and drive belt tensioning.

Together, these chapters equip the technician with unambiguous technical data, exact assembly clearances, and verified testing procedures. Rather than relying on generic shop manuals, mechanics working with the Piper PA-28-236 Dakota Maintenance Manual can verify manufacturer torque limits, fluid grades, and structural rigging dimensions specifically established for the Lycoming O-540-powered Dakota airframe.

Airframe Inspection Schedules, Servicing & Rigging Procedures

The periodic inspection program outlined in the Piper PA-28-236 Dakota Maintenance Manual provides structured checklists broken down across eight distinct operational zones. From verifying torque link bolt security to checking stabilator control cable tensions beneath the aft baggage floor per Piper Service Bulletin 977 and 856, every task is matched to 50, 100, 500, or 1000-hour intervals. Detailed conditional inspection procedures guide mechanics through post-incident airworthiness checks following hard landings, heavy turbulence, or engine overspeed, detailing precise spar web, bulkhead, and skin wrinkle inspection zones.

Chapter 12 provides thorough handling procedures for all recurring fluid services. It details nose gear strut servicing to maintain 3.25 inches (+/- 0.25 in) of exposed piston tube and main gear oleo strut servicing to maintain 4.50 inches (+/- 0.50 in) under normal static load. Technicians will find step-by-step instructions for both gravity and pressure filling methods using MIL-H-5606 hydraulic fluid, followed by nitrogen inflation to 250 psi (+/- 25 psi). Induction air filtration procedures outline cleaning parameters using Donaldson D-1400 compound, while power plant servicing includes detailed oil change guidelines for mineral and ashless dispersant grades under Lycoming Service Instruction 1014.

Environmental Systems & Vapor-Cycle Air Conditioning Overhaul

A major technical highlight within this Piper PA-28-236 Dakota service manual is the comprehensive coverage of the cabin climate and optional vapor-cycle cooling installations. In addition to exhaust shroud heater maintenance and carbon monoxide contamination thresholds (limited to less than 1 part in 20,000), Chapter 21 provides unmatched depth on R-12 refrigeration servicing. Detailed schematics illustrate the York compressor installation, magnetic clutch shimming, and receiver-dehydrator placement aft of the baggage compartment.

IMAGES PREVIEW

Piper PA-28-236 Dakota Maintenance Manual - Part Number 761-681 — PDF page 1 preview
Piper PA-28-236 Dakota Maintenance Manual - Part Number 761-681 — PDF page 41 preview
Piper PA-28-236 Dakota Maintenance Manual - Part Number 761-681 — PDF page 74 preview

Mechanics will find precise rigging instructions for the electrically actuated condenser scoop door on the fuselage belly, requiring 5.00 inches (+/- 0.50 in) of door travel, a 0.16-inch trailing edge gap, and a 0.12-inch mechanism preloading adjustment on the closed limit switch. The manual outlines step-by-step system leak checks with electronic halogen detectors at 50 psi static charge, vacuum dehydration targeting 26 to 28 inches of mercury, and exact refrigerant recharging procedures using the Kent-Moore J23500 charging stand or aircraft engine run-up methods.

DC Electrical Generation, Alternator Diagnostics & Overhaul

Chapter 24 provides complete shop overhaul instructions for the 14-volt charging system, covering both Prestolite ALY-6422 and Chrysler 60-amp alternators. Technicians have access to comprehensive troubleshooting charts addressing tripped 5-amp ALT FIELD circuit breakers, ammeter fluctuations, and shorted output diodes. Step-by-step test benches detail rotor current draw (4.5 to 6.5 amperes at 12 volts for Chrysler; 2.4 to 4.0 amperes for Prestolite), slip ring resistance ranges (1.5 to 2.0 ohms normal, up to 3.0 ohms hot), and stator continuity checks.

Bench teardown guides illustrate specialized pullers (C-4068, C-4201, C-3858), bearing press fitting limits (up to 6800 pounds maximum pressure), and diode testing using the Kent-Moore C-3829 tester or test lamp assemblies. Additional sections guide the technician through proper alternator and compressor drive belt tensioning across Gates and Deco belts, pulley misalignment measurements relative to the ring gear datum, and avionics emergency bus switch verification.

Professional Shop Capability & Instant PDF Delivery

Whether you are performing an annual inspection, tracking down an intermittent electrical fault, rebuilding oleo shock struts, or calibrating flight control stops, the Piper PA-28-236 Dakota Maintenance Manual – Part Number 761-681 delivers the exact engineering specifications required to maintain your aircraft to FAA standards. Relying on original factory documentation ensures correct rigging angles, proper thread lubricants (such as Parker 6PB and MIL-T-5544), and strict compliance with airframe service bulletins, safeguarding both flight safety and aircraft asset value.

Delivered as an instant PDF download, this manual eliminates costly delays and shipping fees. The digital file is fully indexed, easy to navigate, and viewable across any computer, laptop, tablet, or mobile device. Operators and maintenance shops can easily print specific chapters, inspection checklists, or full wiring diagrams to carry directly into the hangar or keep beside the aircraft on the ramp.

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