Piper PA-28 Cherokee Service Manual (PA-28-140 to PA-28R-200)

CHEROKEE

SERVICE MANUAL CARD1 OF4 PA-28-140 PA-28-150 PA-28-160 PA-28-180 PA-28-235 PA-28R-180 PA-28R-200

PIPERAIRCRAFT CORPORATION (PARTNUMBER 753586)

lA1

PIPER CHEROKEESERVICE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS The Service Manual information incorporated in this set of Aerofiche cards has been arranged in accordance with the general specifications of Aerofiche adopted by the General Aviation Manufacturer's Association, (GAMA). The information compiled in this Aerofiche Service Manual will be kept current by revisions distributed periodically. These revisions will supersede all previous revisions and will be complete Aerofiche card replacements and shall supersede Aerofiche cards of the same number in the set. Conversion of Aerofiche alpha/numeric code numbers: First number is the Aerofiche card number. Letter is the horizontal line reference per card. Second number is the vertical line reference per card. Example: 2J16 = Aerofiche card number two of given set, Grid location J16. To aid in locating the various chapters and related service information desired, the following is provided: 1. A complete manual Table of Contents is for all fiche in this set. 2. A complete list of Illustrations is given and follows the Table of Contents. 3. A complete list of Tables is given for all fiche in this set and follows the list of Illustrations. 4. A complete list of paragraph titles and appropriate Grid location numbers is given at the beginning of each Chapter relating to the information within that Chapter. 5. Identification of Revised Material: Revised text and illustrations are indicated by a black vertical line along the left-hand margin of the frame, opposite revised, added or deleted material. Revision lines indicate only current revisions with changes and additions to or deletions of existing text and illustrations. Changes in capitalization, spelling, punctuation, indexing, the physical location of the material or complete page additions are not identified by revision lines. 6. Revisions to this Service Manual 753 586 issued August 16, 1972 are as follows: Effectivity ORG720816 CR810115 PR810803 PR831003 PR840423 PR860115 IR860730 IR870506 IR950215*

Publication Date

Aerofiche Card Effectivity

August 16, 1972 January 15, 1981 August 3, 1981 October 3, 1983 April 23, 1984 January 15, 1986 July 30, 1986 June 12, 1987 February 15, 1995

--1,2, 3 and 4 1, 2, 3 and 4 1, 2, 3 and 4 1, 2, 3 and 4 1 and 3 1 1 1 and 2

* INTERIM CHANGE Chapters II, III, and IV of Card 1, and Chapters VIIA and VIII of Card 2 have been revised. There are no other changes included in this interim change revision. Please discard your current cards 1 and 2, and replace them with the revised ones. DO NOT DISCARD CARDS 3 AND 4. The date on Aerofiche cards should not be earlier than the date noted for the respective card effectivity. Consult the latest card in this series for current Aerofiche card effectivity.

1A2

TABLE OF CONTENTS

AEROFICHE CARD NO.1 INTRODUCTION

INTRODUCTION

AIX IIIX 1A24

HANDLING ............... INSPECTION

IX STRUCTURES X 2A8

V........................ 2A8 VI...... . ........ (PA-28R) LANDING GEAR AND VIIA

VIIIA

POWER (PA-28R) PLANT

2K2 VIIA

VIII

AEROFACE CARD NO.3 VIIIA . ........

IX

. ..

IIA IA

PLANT (PA-28R)

.

A

Al

AEROFACE CARD NO.

4A8

XI

II NI

XIII XIV

ACCESSORIES AND UTILITIES

1A3

I

1A4 INTENTIONALLYLEFT BLANK

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS Figure 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11. 2-12. 2-13. 2-14. 2-15. 2-16. 2-17. 2-18. 2-19. 2-20.

Aerofiche Grid No. Three View of Cherokee, PA-28-140. -150, -160, -180, Serial Nos. 28-1 to 28-1760 incl., Flite Liner, Serial Nos. 28-7125174 and up............................ ...................... B4 Three View of Cherokee, PA-28-140, Serial Nos. 28-7225001 and up ...... ... ......... ............. B5 Three View of Cherokee, PA-28-150. -160. -180, Serial Nos. 28-1761 to 28-4377 incl ............... ......... ...... 1B6 Three View of Cherokee. PA-28-180, Serial Nos. 28-4378 to 28-7105244 inc .............. ............... lB7 Three View of Cherokee. PA-28-180, Serial Nos. 28-7205001 to 28-7205328 incl ......................................... B8 Three View of Cherokee. PA-28-180. Serial Nos. 28-7305001 and up ........................................ 1B9 Three View of Cherokee, PA-28-235. Serial Nos. 28-10000 to 28-11039 incl ..................... .. ...... ............ 1B10 Three View of Cherokee, PA-28-235. Serial Nos. 28-11040 to 28-7110042 incl......................................... 1B11 Three View of Cherokee, PA-28-235. Serial Nos. 28-7210001 to 28-7210033 incl ......................................... 1B12 Three View of Cherokee, PA-28-235. Serial Nos. 28-7310001 and up ........................................ IB13 Three View of Cherokee. PA-28R-180, -200, -180 Serial Nos. 28-30005 to 28-7130019 incl. -200 Serial Nos. 28-30482 to 28-7135238 incl ............... 1B14 Three View of Cherokee, PA-28R-200, Serial Nos. 28-7235001 and up .......... .... ............ ......... IB15 Station Reference Lines. PA-28-140. -150, -160, -180. Serial Nos. 28-1 to 28-1760 incl.: Flite Liner. Serial Nos. 28-7125174 and up .................................................. C4 Station Reference Lines. PA-28-140, Serial Nos. 28-7225001 and up .................................................. IC Station Reference Lines, PA-28-150, -160. -180, Serial Nos. 28-1761 to 28-4377 incl .................................. C6 Station Reference Lines, PA-28-180. Serial Nos. 28-4378 to 28-7105244 incl ....................................... IC7 Station Reference Lines. PA-28-180. Serial Nos. 28-7205001 to 28-7205328 incl ........................................ IC8 Station Reference Lines. PA-28-180, Serial Nos. 28-7305001 and up. IC9 Station Reference Lines. PA-28-235. Serial Nos. 28-10000 to 28-11039 incl .......... ............................ 1C10 Station Reference Lines, PA-28-235. Serial Nos. 28-11040 to 28-7110042 incl ........................................ 1C11

Reissued: 1/15/81

1A5 1A5

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS

(cont.)

Figure 2-21. 2-22. 2-23. 2-24. 2-25. 2-26. 2-27. 2-28. 2-29. 2-30. 2-31. 2-32. 2-33. 2-34. 2-35. 2-36. 2-37. 2-38. 2-39. 2-40. 2-41. 2-42. 2-43. 2-44. 2-45. 2-46. 2-47. 2-48. 2-49. 2-50. 2-51.

Aerofiche Grid No. Station Reference Lines, PA-28-235, Serial Nos. 28-7210001 to 28-7210033 incl ........................................ . Station Reference Lines. PA-28-235, Serial Nos. 28-7310001 and up .................................................. Station Reference Lines, PA-28R-180,-200, -180 Serial Nos. 28-30005 to 28-7130019 incl. -200 Serial Nos. 28-30482 to 28-7135238 incl .................. Station Reference Lines, PA-28R-200, Serial Nos. 28-7235001 and up .................................................. Access Plates and Panels, PA-28-140 and Flite Liner. Serial Nos. 28-7225001 and up as noted ........................... Access Plates and Panels, PA-28-150, -160, -180 .... .............. Access Plates and Panels, PA-28-235 ................. .. ......... Access Plates and Panels, PA-28R .............................. Identification of Aircraft Fluid Lines ............................ Torque Wrench Formula ...................................... Removing Cherrylock Rivets ................................... Jacking Arrangement ......................................... Weighing Airplane ............................................. Leveling Longitudinally ....................................... Leveling Laterally ............................................ Servicing Points, PA-28-140 ................................... Servicing Points, PA-28-150,-160, -180 ....................... Servicing Points, PA-28-235 ................................... Servicing Points, PA-28R ..................................... Main Gear Oleo Struts (Cutaway View), PA-28-140; PA-28-150,-160,-180; PA-28-235 ........................... Fuel Strainer. PA-28-140; PA-28-150, -160, -180; and PA-28R...... Fuel Selector and Filter, PA-28-235 ............................ Lubrication Chart (Landing Gear, Main), PA-28-140, -150, -160, -180 and -235 ....................................... Lubrication Chart (Landing Gear, Main), PA-28R-180 and -200 ............................................... Lubrication Chart (Landing Gear, Nose), PA-28-140, -150. -160. -180 and -235 ....................................... Lubrication Chart (Landing Gear, Nose), PA-28R-180 and -200 .... Lubrication Chart (Control System) ............................ Lubrication Chart (Control System) (cont.) ...................... Lubrication Chart (Control System) (cont.) ...................... Lubrication Chart (Control System) (cont.) . ..................... Lubrication Chart (Cabin Door. Baggage Door and Seat) .........

Revised: 8/3/81

1A6

1C12 1C13 1C14 IC15 1C16 C17 C18 1C19 1D7 1C21 1D8 1D9 1D10

1 1D11 1D20

1 1D22 1d23 1D24 1E9 1E9 1E17 E18 1E19

1 I E21 1E22 1E23 1E24 IF1

PIPER CHEROKEESERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.) Figure

2-52. 2-53. 2-54 3-1 3-2 3-3 3-4 3-5 3-6 3-7 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 5-1 5-2 5-3 5-4 5-5

Aerofiche Grid No. Lubrication Chart (Power Plant, Propeller and Control Pivot Points) ....................... 1F2 Lubrication Chart (Back-Up Extender and Fuel Selector) ........................................1F3 Lubrication Chart (Air Conditioning Condenser) ...................................................... F4 Typical Muffler Fatigue Areas . ................................................... .................... 1F10 Exhaust System Inspection Points ............................................................................. 1F11 Exhaust System Inspection Points ............................................................................. F12 Exhaust System Installation, PA-28R-180,-200 ........................................................IF14 Control Wheel Inspection Points ...............................................................................1F15 Flap Control Cable Attachment Bolt Inspection........................................................ 1Fl6 Inspection of Main Landing Gear Torque Link ......................................................... 1Fl7 Aileron and Flap Installation ....................................................................................1G19 Wing Installation ..................................................................... 1G23 Methods of Securing Control Cables ........................................ .......... 1H7 Empennage Group Installation ................................................................................. 1H Windshield Installation (Typical)............................... ..........................1H16 Side Window Installation, Single Pane (Typical) ......................................................1H18 Side Window Installation, Double Pane (Typical)....................................................1H18 Door Snubber Installation . ......................................................... 1H20 Seat Back Lock ........................................ 1H24 .................. Skin Materials and Thickness .................................................................................... 1I1 Surface Scratches, Abrasions or Ground-in-Dirt.......................................................1I8 Deep Scratches, Shallow Nicks and Small Holes ................... ............. 1................... 119 Mixing of Epoxy Patching Compound .................................................... 119 Welding Repair Method ............................................................................................. Repairing of Cracks ...................................................................................................1I11 Various Repairs .......................................................................................................... 1I12 Repair of Stress Lines ...............................................................................................1I13 Repair of Impacted Damage ......................................................................................1I13 Control Surface Balance Tool ....................................................................................1I20 Aileron and Rudder Balance Configuration ..............................................................1Ii21 Stabilator Balance ......................................................................................................1122 Wing Rib Modification ..............................................................................................1I24 Balance Weight Assembly Installation ...................................................................... 1124 Fabricated Tool for Baggage Door Lock ................................................................... J Additional Drain Holes in Stabilator ........................................................................1J2 Baggage Compartment Inspection Holes Cutout Details .......................................... J5 Control Column Assembly, PA-28-140,-150,-160, -180 and 235 .............................2A15 Control Column Assembly, PA-28R ..........................................................................2A16 Aileron Controls.........................................................................................................2A20 Bellcrank Rigging Tool, PA-28-140, -150, -160, -180, -235 .....................................2A23 Bellcrank Rigging Tool, PA-28R ...............................................................................2A23

Interim Revision: February 15, 1995

1A7

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.) Figure 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9.

Aerofiche Grid No. Aileron Rigging Tool ......................................... Stabilator Rigging Tool ....................................... Stabilator Controls ....................................... .... Stabilator Trim Control (Overhead Control) ... ............. Methods of Securing Trim Cables .............................. Stabilator Trim Control (Floor Control) ......................... Rudder and Steering Pedal Assembly ........................... Rudder Controls ............................................. Rudder Rigging Tool .................................... Clamping Rudder Pedals ...................................... Rudder and Stabilator Travel Adjustments ... ................... Rudder Trim Control ......................................... Flap Controls ................... ............................. Flap Step Adjustment ......................................... Flap Rigging Tool ............................................ Fabricated Aileron Bellcrank Rigging Tool ...................... Correct Method of Installing Rod End Bearings .................. Fabricated Aileron and Flap Rigging Tool ....................... Fabricated Stabilator Rigging Tool ............................. Fabricated Rudder Rigging Tool ............................... Schematic Diagram of Hydraulic System ... .............. Hydraulic System Installation .................................. Hydraulic Pump/Reservoir. Exploded View ...................... Test and Adjustments of Hydraulic Pump ............. ............... Pump Shock Mounts ......................................... Checking Aligning Brackets of Gear Back-Up Extender Actuator ................................................ Gear Back-Up Extender Actuator .............................. Nose Gear Actuator Cylinder .................................. End Gland Locking Device .................................... Main Gear Actuating Cylinder ................................. Gear Back-Up Extender Actuator Aligning Tool .................. Nose Gear Oleo Strut Assembly ................................ Nose Gear Installation ........................................ Clamping Rudder Pedals in Neutral Position ..................... Rudder Pedals at Neutral Angle .. ........................ ... Main Gear Oleo Strut Assembly. PA-28-140, -150, -160 and -180 ................................................ Main Gear Oleo Strut Assembly, PA-28-235 ..................... Main Gear Installation ... ........................ .......... Nose Wheel Assembly ......................................... Main Wheel Assembly ........................................

Revised: 4 23/84

1A8 1A8

2A24 2B3 2B4 2B8 2B10 2B18 2B24 2C4 2C5 2C5 2C6 2C8 2C10 2C14 2C12 2C15 2C15 2C16 2C17 2C18 2D5 2D6 2D10 2D14 2D16 2D 17 2D21 2E2 2E4 2E5 2E20 2F2 2F6 2F8 2F8 2F13 2F15 2F19 2F21 2F23

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.) Figure 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16.

7-17.

7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7A-I. 7A-2. 7A-3. 7A-4. 7A-5. 7A-6. 7A-7. 7A-8. 7A-9. 7A-10. 7A-11. 7A-12. 7A-13. 7A- 14. 7A-15. 7A-16. 7A-17. 7A-18.

Aerofiche Grid No. Wheel Brake Assembly ........................................ Removal of Anchor Bolt ...................................... Installation of Anchor Bolt .................................... Brake Disc Minimum Thickness ................................ Brake System Installation ..................................... Brake Master Cylinder (Hand Brake). PA-28-150. -160. Serial Nos. 28-1 to 28-250 incl ............................. Brake Master Cylinder (Hand Parking Brake), PA-28-140. Serial Nos. 28-20002 to 28-21036 incl.: PA-28-150. -160. -180. Serial Nos. 28-251 to 28-2700 incl.: PA-28-235. Serial Nos. 28-10003 to 28-10697 incl ............ Brake Master Cylinder (Hand Parking Brake). PA-28-140. Serial Nos. 28-21037 and up: PA-28-150. -160. -180. Serial Nos. 28-2701 and up: PA-28-235. Serial Nos. 28-10698 and up.......................................... Parking Valve. PA-28-150. -160. Serial Nos. 28-1 to 28-250 incl ............................................... Toe Brake Installation ........................................ Brake Cylinder 10-20. 10-27. 17000 (Toe Brake) .................. Brake Cylinder 10-30 (Toe Brake) .............................. Bleeding Brake (Gravity) ...................................... Bleeding Brake (Pressure) ......... ............................ Orifice Replacement Tool ..................................... Retainer Ring Tool ........................................... Nose Gear Oleo Strut Assembly ............................... Nose Gear Installation ........................................ Nose Gear Adjustment (Without Gear Up Stop) .................. Nose Gear Adjustment (With Gear Up Stop) ...... ............... Clamping Rudder Pedals in Neutral Position ..................... Rudder Pedals at Neutral Angle ................................ Nose Gear Door Retraction Mechanism ............. .............. Main Gear Oleo Strut Assembly ............................... Main Gear Installation ....................................... Aligning Main Gear .......................................... Adjustment of Nose Gear Down Limit Switch .................... Adjustment of Main Gear Down Limit Switch ................... Wiring Diagram of Landing Gear Electrical Circuit ............... Throttle Warning Switches .................................... Nose Wheel Assembly.......................................... Main Wheel Assembly ........................................ Wheel Brake Assembly .................... ................... Brake Disc Minimum Thickness ................................

Revised: 8 3 81

1A9 1A9

2G1 2G2 2G3 2G5 2G5 2G8

2G8

2G9

.

.

2G11 2G12 2G14 2G 15 2G 18 2G 18 2G23 2G24 2H9 2H 12 2H 16 2H 17 2H 19 2H19 2H20 211 214 2110 2115 2115 2117 2119 2122 2123 2J1 2J3

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS

(cont.)

Figure 7A-19. 7A-20. 7A-21. 7A-22. 7A-23. 7A-24. 7A-25. 7A-26. 8-1. 8-2. 8-3. 8-4. 8-5. 8-6. 8-7. 8-8. 8-9. 8-10. 8-11. 8-12. 8-13. 8-14. 8-15. 8-16. 8-17. 8-18. 8-19. 8-20. 8-21. 8A-1. 8A-2. 8A-3. 8A-4. 8A-5. 8A-6. 8A-7. 8A-8. 8A-9. 8A-10.

Aerofiche Grid No. Brake System Installation ..................................... Brake Master Cylinder (Hand Parking Brake) ................... Toe Brake Installation ........................................ Brake Cylinder (Toe Brake) (10-20. 10-27. 17000) ................. Brake Cylinder (Toe Brake) (10-30) ............................. Bearing Installation ........................................... Nose Gear Ser ice Tolerances. PA-28R .......................... Main Gear Service Tolerances. PA-28R ....... .................. Typical Nicks and Removal Method ............................ Propeller Installation (Constant Speed). PA-28-235 ............... Propeller Installation ......................................... Adjustment of Propeller Control. PA-28-235 ................... Propeller Governor. PA-28-235 ...... ....................... Engine Installation. PA-28-140. -150. -160. -180. Serial Nos. 28-1 to 28-1760 ............................... Engine Installation. PA-28-140. -150. -160. -180. Serial Nos. 28-1761 and up...... ......... ............. Engine Shock Mount Installation. PA-28-140. Serial Nos. 28-25000 and up ........................... .... Engine Installation. PA-28-235 ................................. Adjustment of Engine Controls ................................. Carburetor. PA-28-140. -150. -160 ............................ .. Carburetor. PA-28-180. -235 ................................... Magneto Inspection ........................................... Contact Spring Inspection ..................................... Impulse Coupling ............................................ Magneto Timing Marks ....................................... Timing Pointer .............................................. Timing Kit Installed .......................................... Breaker Compartment With Cast Timing Marks .................. Removing Spark Plug Frozen to Bushing ........................ Ignition Switch Wiring Positions ........................... .... Propeller Installation ......................................... Typical Nicks and Removal Method ............................ Propeller Governor ........................................... Engine Installation. PA-28R-180 ............................... Engine Installation. PA-28R-200 ............................... Adjustment of Engine Controls ................................. Fuel Injector ................................................. Schematic Diagram of RSA Fuel Injection System ................ Fuel-Air Bleed Nozzle ......................................... Contact Points ...............................................

Revised: 8 3 81

1A10

2J3 2J5 2J6 2J8 2J10 2J11 2J20 2J23 2K8 2K8 2K9 2K 13 2K 13 2K16 2K17 2K 18 2K22 2K24 2L3 2L3 2L5 2L6 2L6 2L7 2L7 2L8 2L8 2L13 2L16 3A12 3A13 3A16 3A19 3A21 3B1 3B3 3B4 3B6 3B8

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.) Figure 8A-11. 8A-12. 8A-13. 8A-14. 8A-15. 8A-16. 8A-17. 8A-18. 8A-19. 8A-20. 8A-21. 8A-22. 8A-23. 8A-24. 8A-25. 8A-26. 8A-27. 8A-28. 8A-29. 8A-30. 8A-31. 8A-32. 9-1. 9-2. 9-3. 9-4. 9-5. 9-6. 9-7. 9-8. 9-9. 9-10. 9-11. 9-12. 9-13. 9-14. 10-1. 10-2.

Aerofiche Grid No. Rotor Holding Tool Installed .................................. Timing Kit Installed ............. ..................... Aligning Timing Marks ....................................... Checking Flyweight Clearance of Impulse Coupling ............. Engine Timing Marks . ................. . ..................... Magneto Adjustment Limits . .............................. . Magneto Timing Marks . ...................................... Removing Spring From Lead Assembly . . ............ Assembly Tool . .............................................. Using Assembly Tool ......................................... Measuring Lead Assembly Length . ............................. Cutting Metallic Braid From End of Lead ....................... Unbraiding Metallic Shielding ................................ Forming Shielding Around Ferrule ...... .......... ....... Ferrule Seating Tool .... ... ... ..... .............. Needle ...................................................... Measuring Wire From Top of Ferrule . . ................ Installing Grommet Over Lead Assemblies ... ............. Lead Assembly Installed in Grommet . .......................... Wire Doubled Over For Installation of Eyelet ..... ............. Removing Spark Plug Frozen to Bushing ........ .............. Ignition Switch Wiring Positions . .............................. Fuel System Diagram, PA-28-140, -150, -160. -180 ... .......... . Fuel System Diagram. PA-28-235. Serial Nos. 28-10003 to 28-10719 inc ........................................... Fuel System Diagram. PA-28-235. Serial Nos. 28-10720 and up.... Fuel System Diagram. PA-28R................................. Deleted ..................... Fuel Quantity Transmitter (P N 62037-00) ......... . Fuel Quantity Transmitter (P/N 68101-00) . ...................... Fuel Selector and Filter. PA-28-235 . ............................ Fuel Filter. PA-28-235 ...... ................... Fuel Filter Bowl and Screen. PA-28-140, -150, -160, -180 and PA-28R............................................. Plunger Fuel Pump (Early). PA-28-150, -160, -180 . .......... Plunger Fuel Pump (Late), PA-28-140, -150, -160. -180, -235 ....... Engine Primer ............................................... Fabricated Fuel Quantity Transmitter Checking Jig . ............. Instrument Panel, PA-28-140, Serial Nos. 28-25000 to 28-26956 incl.......................... .................. Instrument Panel. PA-28-140, Serial Nos. 28-7125001 to 28-7325684 inc . ..........................................

Revised: 8/3/81

lA11 1All

3B10 3B10 3B11 3B12 3B13 3B14 3B14 3B16 3B16 3B 17 3B17 3B18 3B18 3B19 3B19 3B19 3B20 3B20 3B20 3B20 3B22 3B24 3CII 3C12 3C13 3C14 3C21 3C21 3C24 3DI 3D3 3D6 3D6 3D12 3D17 3E4 3E5

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.) Figure 10-3. 10-4. 10-5. 10-6. 10-7. 10-8. 10-9. 10-10. 10- 11. 10-12. 10-13. 10-14.

10-15. 10-16. 10-17. 10-18. 10-19. 10-20. 10-21. 11-1. 11-2. 11-3. 11-4. 11-5. 11-6. 11-7. 11-8. 11-9. 11-10. 11-11.

Aerofiche Grid No. Instrument Panel. PA-28-140. Serial Nos. 28-7425001 and up ...... Instrument Panel ............................................. Instrument Panel. PA-28-150. -160. -180. Serial Nos. 28-1761 to 28-4377 incl ........................................... Instrument Panel. PA-28-180. Serial Nos. 28-4378 to 28-7205328 incl .......................................... Instrument Panel. PA-28-180. Serial Nos. 28-7305001 to 28-7305611 incl .......................................... Instrument Panel. PA-28-180. Serial Nos. 28-7405001 and up ...... Instrument Panel. PA-28-235. Serial Nos. 28-10720 to 28-11039 inc ............................................. Instrument Panel. PA-28-235. Serial Nos. 28-11040 to 28-7210033 inc ........................................... Instrument Panel. PA-28-235. Serial Nos. 28-7310001 to 28-7310187 incl .......................................... Instrument Panel. PA-28-235. Serial Nos. 28-7410001 and up...... Instrument Panel. PA-28R-180. Serial Nos. 28-30005 to 28-30879 incl ............................................ Instrument Panel. PA-28R-180. Serial Nos. 28-30880 to 28-7130019 incl.: PA-28R-200. Serial Nos. 28-30482. 28-35001 to 28-35830 incl. and 28-7135001 to 28-7135238 incl .......................................... Instrument Panel. PA-28R-200. Serial Nos. 28-7235001 to 28-7335455 incl .......................................... Instrument Panel. PA-28R-200. Serial Nos. 28-7435001 and up..... Warning Light Pressure Switch ................................. Typical Pitot Static System. PA-28-140. -150. -160. -180. -235. PA-28R-180 and 200...................................... EGT Probe Location. PA-28R-180 and 200 ...................... EGT Probe Location. PA-28-235 ............................... EGT Probe Location. PA-28-150. -160. -180. S N 1761 and up..... Generator and Starter System .................................. Generator Wiring Diagram .................................... Sectional View of Generator ................................... Current Voltage Regulator ............................. Use of Riffler File to Clean Contact Points ...................... Voltage Regulator Air Gap ....................... Checking Voltage Setting Fixed Resistance Method ............... Checking Voltage Setting Variable Resistance Method ............ Adjusting Voltage Regulator Setting ............................ Cutout Relay Air Gap Check and Adjustment ................... Cutout Relay Point Opening Check and Adjustment ..............

Revised: 8 3 81

1A12 1A12

3E6 3E7 3E8 3E9 3E10 3E11 3E12 3E13 3E14 3E15 3E16

3E17 3E18 3E19 3E23 3F4 3F24 3GI 3G2 4A 18 4A19 4A22 4B7 4B10 4B 10 4B 11 4B I 4B 12 4B14 4B14

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.) Figure 11-12. 11-13. 11-14. 11-15. 11-16.

11-17.

11-18. 11-19. 11-20. 11-21. 11-22. 11-23. 11-24. 11-25. 11-26. 11-27. 11-28. 11-29. 11-30. 11-31. 11-32. 11-33. 11-34. 11-35. 11-36. 11-37. 11-38. 11-39. 11-40. 11-41. 11-42. 11-43. 11-44. 11-45. 11-46.

Aerofiche Grid No. Checking Cutout Relay Closing Voltage ......................... AdJustment of Cutout Relay Closing Voltage .................. Checking Current Regulator. Load Method ...................... Checking Current Regulator. Jumper Lead Method ............... Alternator and Starter System. PA-28-140. Serial Nos. 28-20000 to 28-24999 incl.: PA-28-150. -160. Serial Nos. 28-508 to 28-3643 incl.: PA-28-180. Serial Nos. 28-671 to 28-3643 incl.: PA-28-235. Serial Nos. 28-10002 to 28-10762 incl ............ Alternator and Starter System. PA-28-140. Serial Nos. 28-25000 and up: PA-28-150. -160. -180. Serial Nos. 28-3644 and up: PA-28-235. Serial Nos. 10763 and up and PA-28R............ Lamp-Bank Load .......... ................................. Checking Field Circuit ...... .................................. Testing Field Circuit .......................................... Testing Rectifiers (Positixe) .................................... Testing Rectifiers (Negative) ................................... C-3928 Fixtures and Adapters .................................. Removing Rectifiers ..... .............................. ..... Installing Rectifiers ..... ...................................... Soldering Rectifier Lead ....................................... Testing Stator Coils ......................................... Removing End Bearing ........................................ Installing End Bearing ..... ............................ .... Removing Drive Pulley ....................................... Removing Drive End Bearing .................................. Removing Slip Ring ...................... .................. Aligning Slip Ring .......................................... Installing Slip Ring ........................................... Installing Retainer ........................................... Solder Points ................................................ Installing Drive End Shield and Bearing (Typical) ................ Installing Pulley ..................... ...................... Meter Connections for Alternator Performance Test .............. Voltage Regulator ............................................ Checking Air Gap ............................................ Voltage Regulator Fusible Wires ............................... Voltage Regulator Resistance Units ............................. No-Load Test Hookup ........................................ Lock Torque Test Hookup ................................... Resistance Test Hookup .......................................

Revised: 8 3 81

1A13 1A13

4B15 4B15 4B16 4B16

4B20

4B21 4B23 4B24 4B24 4C2 4C3 4C4 4C4 4C5 4C6 4C7 4C9 4C9 4C10 4C10 4C 11 4C11 4C12 4C12 4C13 4C14 4C 14 4C17 4C19 4C19 4C20 4C20 4D2 4D3 4D3

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS

(cont.)

Figure 11-47. 11-48. 11-49. 11-50. 11-51. 11-52. 11-53. 11-54. thru 11-70. 11-71. 11-72. 11-73. 11-74. 11-75. 11-76. 11-77. 11-78. 11-79. 11-80. 11-81. 11-82. 11-83. 11-84. 11-85. thru 11-143. 11-144. 12-1. 12-2. 12-3. 13-1.

13-2. 13-3.

Aerofiche Grid No. Exploded View of Gear Reduction Starting Motor ................ Turning Starting Motor Commutator ........................... Testing Motor Armature for Shorts ............................. Testing Motor Field for Grounds ............................. No-Load Test Hookup ..... . ....................... Stall Torque Hookup ......................................... Terminal Block ............................................ For Index to these Figures, see Table XI-I, Index - Electrical System Schematics Exploded View of Alternator .................................. Removal of Slip Ring End Bearing ............................. Removal of Rectifier .......................................... Removal of Drive End Head .................................. Removal of End Head Bearing ................ .... .. ..... Testing Rotor for Ground ..................................... Testing Rotor for Shorts ..................................... Installation of Bearing ..................................... Installation of Rectifier ....................................... Terminal Assembly ........................................... Slip Ring End Bearing Assembly ............................... Testing Alternator ............................................ Brush Installation ............................................ Internal Wiring Diagram ...................................... For Index to these Figures. see Table XI-I, Index - Electrical System Schematics Strobe Light Connections ..................................... Two Year Magnesium Battery Connections ......... ......... Five Year, Lithium Battery Connections ... .... .................. Communications Components ELT Schematic ................... Cabin Heater. Defroster and Fresh Air System, PA-28-140. Serial Nos. 28-2002 to 28-24999 incl.. and PA-28-150, -160, -180, Serial Nos. 28-1 to 28-1760 incl ............... ... .................. Cabin Heater. Defroster and Fresh Air System, PA-28-140, Serial Nos. 28-25000 and up ..................... Cabin Heater. Defroster and Fresh Air System, PA-28-150. -160, -180. Serial Nos. 28-1761 to 28-2477 incl ..............................................

Revised: 10 3,83

lA14

1A14

4D8 4D I 4D I 4D I 4D13 4D13 4F5 4F11 thru 4G17 4D20 4D21 4D21 4D22 4D22 4D23 4D23 4D24 4D24 4E I 4E2 4E2 4E3 4E3 4G20 thru 4H 24 4E9 413 414 4111

4117 4118 4119

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS (cont.) Figure 13-4. 13-5. 13-6. 13-7. 13-8. 13-9. 13-10. 13-11. 14-1. 14-2. 14-3. 14-4. 14-5. 14-6. 14-7. 14-8. 14-9. 14-10. 14-11. 14-12. 14-13. 14-14. 14-15.

14-16.

Aerofiche Grid No. Cabin Heater. Defroster and Fresh Air System. PA-28-150. -160. -180, Serial Nos. 28-2478 to 28-4377 incl.............................................. Cabin Heater. Defroster and Fresh Air System. PA-28-180. Serial Nos. 28-4378 and up ...................... Cabin Heater. Defroster and Fresh Air System. PA-28-235. Serial Nos. 28-10003 to 28-10675 incl ............ Cabin Heater. Defroster and Fresh Air System. PA-28-235. Serial Nos. 28-10676 to 28-11039 incl ............ Cabin Heater. Defroster and Fresh Air System, PA-28-235. Serial Nos. 28-11040 to 28-7210033 incl. .......... Cabin Heater. Defroster and Fresh Air System. PA-28-235. Serial Nos. 28-7310001 and up................... Cabin Heater. Defroster and Fresh Air System. PA-28R ................................................. Overhead Vent System. ........................................ Air Conditioning System Installation ............................ Service Valves ............................................... Test Gauge and Manifold Set .................................. Manifold Set Operation ....................................... Leak Test Hookup ........................................... Evacuation Hookup .......................................... Charging Stand ...... ........................................ Charging Hookup ...................................... ...... Compressor and Fabricated Oil Dipstick .......................... Compressor and Alternator Belt Installation ..................... Magnetic Clutch ............................................. Condenser Air Scoop Installation ............................ Expansion Valve ............................................. Components Installation ...................................... Control Head - Diode Mounting Board, Diode Location and Number. PA-28-140. Serial Nos. 28-7125472 to 28-7325057; PA-28-180. Serial Nos. 28-7205092 to 28-7305071; PA-28R-200. 28R-7235001 to 28R-7335057 .................. Air Conditioning Wiring Schematic, PA-28-140. Serial Nos. 28-7125472 thru 28-7225131 incl.: PA-28-180, Serial Nos. 28-7205092 thru 28-7205144 incl........

Revised: 10 3 83

1A15

1A15

4120 4121 4122 4123 4124 4.11 4J2 4.13 4J7 4J 12 4J13 4J 14 4.115 4J 17 4J 19 4J21 4K I 4K5 4K7 4K11 4K13 4K15

4K16 4K18

PIPER CHEROKEE SERVICE MANUAL

LIST OF ILLUSTRATIONS

(cont.) Aerofiche Grid No.

Figure 14-17.

14-18.

Air Conditioning Wiring Schematic, PA-28-140. Serial Nos. 28-7225132 to 28-7225612; PA-28-180. Serial Nos. 28-7205145 to 28-7205328; PA-28R-200. Serial Nos. 28R-7235001 to 28R-7235330........ Air Conditioning Wiring Schematic, PA-28-140. Serial Nos. 28-7325001 and up: PA-28-180. Serial Nos. 28-7305001 and up: PA-28R-200. Serial Nos. 28-7335001 and up ..................

Revised: 10 3/83

1A16

1A16

4K19

4K20

PIPER CHEROKEE SERVICE MANUAL

LIST OF TABLES Table 11-I. 11-11. 11-111. II-IV. 1l-V. II-VI. II-VII. II-VIII. II-IX. II-X. II-XI. 111-I. 111-11. IV-I. IV-II. V-l. V-ll. V-Ill. VI-1. VI-lI. VI-III. VII-I VII-II. VIIA-I. VIIA-II. VIIA-III. VIII-I. VIII-II. VIIIA-I. IX-1. IX-II. IX-III. X-l. X-ll.

Aerofiche Grid No. Leading Particulars and Principal Dimensions ................. Consumable Materials ......... ............................. Recommended Nut Torques ................................. Deleted ........................................ Conversion Tables .......................................... Decimal Millimeter Equivalents of Drill Sizes ........................ Maximum Distance Between Supports for Fluid Tubing ......... Hose Clamp Tightening .................................... Recommended Engine Lubricating Oils ....................... Thread Lubricants .................................... ...... Summary of Recommended Lubricants used on PA-28 Series Aircraft ......................................... Inspection Report, PA-28-140. -150. -160. -180; PA-28-235 ..................... ........................ Inspection Report. PA-28R .................................. List of Materials (Thermoplastic Repair) ...................... Balancing Specifications ................................. .... Control Surface Travel and Cable Tension .................... Cable Tension Vs. Ambient Temperature ...................... Troubleshooting Chart (Surface Controls) ..................... Leading Particulars. Hydraulic System ........................ Characteristics, Hydraulic Pump Motor ....................... Hydraulic System Troubleshooting ........................... Nose Gear Alignment Tolerances ............................. Landing Gear Troubleshooting ............................... Landing Gear Troubleshooting ............................... PA-28R Nose Gear Service Tolerances ....................... PA-28R Main Gear Service Tolerances ........................ Propeller Torque Limits ..................................... Engine Troubleshooting Chart ............................... Engine Troubleshooting Chart ........................... .... Transmitter/Fuel Gauge Tolerances .......................... Fuel Quantity Transmitter Calibration Tolerances .............. Fuel System Troubleshooting ............................... Vacuum System ............................................ Directional Gyro Indicator ..................................

Revised: 8 3 81

1A17 1A17

IB16 IC3 1C22 IC24 ID5 D6 ID6 IE 15 1E15 E16 1F18 IG3 117 1117 2A 11 2A13 2C19 2D8 2D13 2E9 2F9 2G20 2J 12 2J21 2J24 2K10 2L17 3CI 3C20 3C21 3D15 3D24 3F5

PIPER CHEROKEE SERVICE MANUAL

LIST OF TABLES (cont.) Table

X-lll. X-IV. X-V. X-VI.

X-VII. X-VIII. X-IX. X-X. X-XI. X-XII. X-XIII. X-XIV. X-XV. X-XVI. X-XVII.

XI-I. XI-lI. XI-lll.

XI-IV. XI-V. XIV-I. XIV-II. XIV-III.

XIV-IV. XIV-V.

Aerofiche Grid No. Gyro Horizon Indicator.............. Rate of Climb Indicator..............

....................... ....................... meter ........................... ....................... Airspeed Tubes and Indicator......... ....................... Magnetic Compass .................. ....................... Manifold Pressure Indicator.......... ....................... Tachometer ........................ ....................... Engine Oil Pressure Gauge ........... ....................... Fuel Pressure Gauge................. ....................... Turn and Bank Indicator............. ....................... Fuel Quantity Indicators .................................... Oil Temperature Indicators .................................. Troubleshooting EGT Gauge ................................ Cylinder Head Temperature Gauge ........................... Fuel Flow Gauge ......... ................................. Electrical System Schematic Index............................ Electrical System Troubleshooting .......................... Electrical System Component Loads .......................... Electrical Symbols.......................................... Electrical Wire Coding ..................................... Temperature Pressure Chart ................................. Aluminum Tubing Torque................................... Compressor Oil Change ..................................... Air Conditioning System Troubleshooting ..................... Blower System Wire Color Codes ............................

Revised: 10 383

1A18

3F7 3F8 3F10 3F 12 3F14 3F15 3F 16 3F 17 3F18 3F19 3F20 3F21 3F23 3F24 3GI 4A12 4E10 4F8 4F9 4F10 4.18 4JII 4.124 4K21 4L6

SECTION I INTRODUCTION Aerofiche Grid No. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 1-10. 1-11. 1-12. 1.-13. 1-14. 1-15. 1-16. 1-17.

General ....... Scope of Manual ..... Description ....... Wing ........ Empennage ....... Fuselage ....... Landing Gear (Fixed) .... Landing Gear (Retractable) .... Hydraulic System (PA-28R) .... Brake System ...... Engines ........ Propellers . ...... Fuel System ............. Flight Controls ............. Radio ....... Cabin Heater, Defroster, and Fresh Air System Instrument and AutoPilot System ...

Reissued:1/15/81

1A19

. 1A20 ..1A20 . 1A20 . 1A20 ..1A20 . 1A21 1A21 . A21 .... A21 .... . .. 1A21 1A21 1A21 .... 1A21 ..... . 1A22 ... ... . 1A22 1A22 . .. 1A22 . ... ... ... ... ... ...

PIPER CHEROKEE SERVICE MANUAL SECTIONI INTRODUCTION WARNING When servicing or inspecting vendor equipment installed in Piper aircraft,it is the user'sresponsibilityto referto the applicablevendor publication. 1-1. GENERAL. This manual contains serviceand maintenanceinstructionsfor PA-28-140. -150. -160. -180. -235 and PA-28R-180 200 Cherokees. designed and manufactured as versatile airplanes in the personal and business aviation field. by the Piper Aircraft Corporation . Vero Beach. Florida. 1-2. SCOPE OF MANUAL. Sections II and III comprise the service part of this manual, whereas Sections IV through XIII comprise the maintenance instructions. The service instructions include ground handling, servicing and inspections. The maintenance instructions for each system include troubleshooting, removal and installation of components, and corrective maintenance and testing; each major system of the airplane is covered in a separate section. Only qualified personnel should perform the operations described in this manual. The description of the airplane included in this section is limited to general information. Section II gives leading particulars and principal dimensions, while each major

system is described in its appropriate section of the manual. For a more detailed description of the airplane, refer to the Owner's Handbook, or Pilot's Information Manual for the particular airplane. 1-3. DESCRIPTION. The Cherokee PA-28 is a single-engine. low-wing monoplane of all metal construction. The standard PA-28-140 is a two place. with third and fourth family seats available as optional equipment. The PA-28-150. -160. -180. -235 and PA-28R-180 200 are four place airplanes. Paragraphs 1-4 through 1-17 provide descriptions of the major components and systems. 1-4. WING. The laminar flow wing is of all-metal stressed-skin, full cantilever, low-wing design, consisting of two wing panels bolted to a spar box assembly in the fuselage. The wing tips are removable. The ailerons are cable and push rod controlled and are dynamically balanced. The trailing edge wing flaps are manually operated. 1-5. EMPENNAGE. The empennage consists of the fin, rudder, stabilator and stabilator trim tabs. The stabilator is dynamically balanced.

INTRODUCTION

Revised: 1/15/86

1A20

PIPER CHEROKEE SERVICE MANUAL

1-6. FUSELAGE. The fuselage consists of three basic units: The engine section, the cabin section, and the sheet-metal tail cone.

1-7. LANDING GEAR. (Fixed) The tricycle landinggearis of the fixed type, consistingof shock absorbingair-oiltype oleo struts. 1-8. LANDINGGEAR.(Retractable)The tricycle landinggearis a hydraulicallyoperated, fully retractableunit consistingof shock absorbingair-oiltype oleo struts. 1-9. HYDRAULIC SYSTEM. (PA-28R-180 200) The hydraulic system incorporates an electrically driven pump which is controlled by a lever on the instrument panel which in turn operates the retraction and extension of the landing gear. 1-10. BRAKE SYSTEM. The brake system operated hydraulically is controlled by a hand lever connected to a single brake cylinder that operates both wheel brakes. On later models, the hand lever plus individually operated brakes and cylinder control the brakes. Dual toe brakes may be installed as optional equipment. 1-11. ENGINES. The engines installed in the PA-28 series airplanes are Avco-Lycoming direct drive, wet sump. horizontally opposed. air cooled models. The four-cylinder engines in the PA-28-140. -150.-160. -180 and the six-cylinder engine in the PA-28-235 are carburetor equipped while the four-cylinder engine in the PA-28-180 200 is fuel injector equipped. The engine model. rated horsepower and other related information for each engine may be found in Table 11-1of Section II. 1-12. PROPELLERS. The PA-28-140. -150. -160. -180 and -235 models are equipped with an all-metal fixed pitch propeller. A constant speed propeller may be installed as optional equipment on the PA-28-235. and is installed as standard equipment on the PA-28R-180 200. The constant speed propellers are controlled by a governor mounted on the engine. The governor is in turn controlled by a lever on the power quadrant. Propeller specifications may be found in Table 11-1of Section 11. 1-13. FUEL

SYSTEM. The fuel system on the PA-28-140. -150. -160. -180 and

PA-28R-180 200 consists of two aluminum tanks in the leading edge of the wings. a strainer bowl with fuel screen. one electrical auxiliary pump and one engine driven pump. The fuel system for the PA-28-235 consists of two aluminum tanks in the wings plus an auxiliary fiberglass tank in each wing tip. There also is a combination fuel selector and filter, electrical auxiliary fuel pump(s) and one engine driven pump.

INTRODUCTION

Revised: 10 3 83

1A21

PIPER CHEROKEE SERVICEMANUAL

1-14. FLIGHT CONTROLS. The flight controls are conventional equipment, consistingof a control wheel which operates the ailerons and stabilator, and pedals which operate the rudder. Duplicate controls are provided for the copilot. 1-15. RADIO. Provisions are provided for the installations of microphone and headset jacks, loudspeaker, and panel space for radios. 1-16. CABIN HEATER. DEFROSTER AND FRESH AIR SYSTEM. Heated air for the cabin and defroster is obtained directly from the exhaust system muffler shroud. Fresh air for the PA-28-140. PA-28-150.-160. -180. Serial Nos. 28-1 to 28-2477incl.. and PA-28-235. Serial Nos. 28-10003 to 28-10675 incl.. is obtained through an intake located on the left forward side of the fuselage. directing air to the forward section of the cockpit. Additional intakes are located on each side of the fuselage. venting air to the individual seat location. On the PA-28-150. -160. -180. Serial Nos. 28-2478 and up: PA-28-235. Serial Nos. 28-10676 and up. and PA-28R-180 200. fresh air is picked up from an inlet in the leading edge of each wing. The air passed through the wings to indivually controlled outlets located just forward of each seat. An air ent is located in the top or bottom of the fuselage to take exhaust air from the cabin interior.

1-17. INSTRUMENTAND AUTOPILOT SYSTEM. Provisions for instrument installation include panels for engine instruments and advanced instruments, as well as for an Autopilot System.

Revised: 10 3 83

INTRODUCTION

1A22

1A23 INTENTIONALLY LEFT BLANK

SECTION II HANDLING AND SERVICING Paragraph 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-8a. 2-9. 2-10. 2-11.

2-21. 2-23.

2-30. 2-32.

Aerofiche Grid No. Introduction ......... ........................................ Dimensions .................................................. Station Reference Lines ....................................... Weight and Balance Data ..................................... Serial Number Plate .......................................... Access and Inspection Provisions ............................... Tools and Test Equipment ..................................... Torque Requirements ......................................... Torque Wrenches ............................................. Walkway. Handhold and Step ................................. Removal of Cherrylock Rivets ................................. Ground Handling ........................................... 2-12. Introduction to Ground Handling ...................... 2-13. Jacking ............................................. 2-14. Weighing ........................................... 2-15. Leveling ............................................ 2-16. Mooring............................................ 2-17. Locking Airplane .................................... 2-18. Parking ............................................ 2-19. Towing ............................................. 2-20. Taxiing .......................... ................ External Power Receptacle .................................... 2-22. Operation of External Power Receptacle ................ Cleaning .................................................... 2-24. Cleaning Engine Compartment ........................ 2-25. Cleaning Landing Gear ............................... 2-26. Cleaning Exterior Surfaces............................ 2-27. Cleaning Windshield and Windows .................... 2-28. Cleaning Headliner, Side Panels and Seats.............. 2-29. Cleaning Carpets .................................... Servicing.................................................... 2-31. Introduction to Servicing ............................. Hydraulic System (PA-28R) ................................... 2-33. Servicing Hydraulic System ........................... 2-34. Servicing Hydraulic Pump / Reservoir ...................

Revised: 8/3/81

A24

1A 24

1B3 1B3 1B3 1B3 1C20 1C20 1C20 IC20 1C21 C24 1D8 1D9 1D9 D9 ID10 ID10 1D11 1D12 1D12 D13 1D13 1D13 ID13 1D14 1D14 D 15 1D15 ID15 1D16 D 16 D 16 1D16 1D16 1D16 1D17

PIPER CHEROKEE SERVICE MANUAL

Paragraph 2-35. 2-37.

2-42.

2-46.

2-50. 2-52. 2-54.

Aerofiche Grid No. Landing Gear System ................................... 2-36. Servicing Landing Gear ........................ Oleo Struts (PA-28-140. -150. -160. -180 and PA-28-235) .... 2-38. Servicing Oleo Struts ............. 2-39. Filling Nose Gear Oleo Strut ...... 2-40. Filling Main Gear Oleo Strut ...... 2-41. Inflating Oleo Struts .............. Oleo Struts (PA-28R) ...................... 2-43. Servicing Oleo Struts ............. 2-44. Filling Oleo Struts ................ 2-45. Inflating Oleo Struts .............. Brake System ............................. 2-47. Servicing Brake System............ 2-48. Filling Brake Cylinder Reservoir.... 2-49. Draining Brake System............ Tires..................................... 2-51. Servicing Tires ................... Power Plant.............................. 2-53. Servicing Power Plant............. Induction Air Filter . ................... 2-55. Removal of Air Filter ............. 2-56. Service Instruction (Cleaning and Ins pection)............ 2-57. Installation of Air Filter .......... .............

2-58. 2-58. 2-60.

2-68. 2-70. 2-71.

Propeller. Propeller ....................................................

2-59. Servicing Propeller................................. Fuel System ................................................ 2-61. Servicing Fuel System ................................ 2-62. Filling Fuel Tanks (PA-28-140. -150, -180 and PA-28R) ....................................... 2-63. Filling Fuel Tanks (PA-28-235) ........................ 2-64. Draining Moisture From Fuel System (PA-28-140, -150, -160. -180 and PA-28R) ...................... 2-65. Draining Moisture From Fuel System (PA-28-235) .... 2-66. Draining Fuel System ................................ 2-67. Anti-Icing Fuel Additive ............................. Electrical System ............................................. 2-69. Ser icing Electrical System ............................ Lubrication .................................................. Oil System (Engine) .......................................... 2-72. Servicing Oil System ................................. 2-73. Filling Oil Sump ....................................

Reissued: 1/15/81

1B1

1D17 1D17 1D17 1D17 ID18 1 D24 1E1 IE2 IE2 IE3 IE4 IE4 1E4 1E4 IE5 IE5 IE5 IE5 IE5 IE5 IE5 1E6 1E7 1E7 1E7 IE7 IE7 IE8 IE8 1E8 IE8 IE10 IE10 IEIO IE1O 1E11 1E11 1E11 IEII

PIPER CHEROKEE SERVICE MANUAL Aerofiche Grid No. 2-74. 2-75. 2-76. 2-77. 2-78. 2-79. 2-80. 2-81. 2-82. 2-83.

Reissued:1/15/81

Draining Oil Sump .......... ... . (Suction.) .. Oil Screens. ....... (Pressure.) Oil Screen. ....... (Full Flow.) Oil Filter. for Changing Oil Recommendations ...... Lubrication Instructions . Application of Oil .......... ........ Application of Grease ......... Winterization Plate . .... . Lubrication Chart .

IB2

IE12 1E12

.

1E12 IE12 E13 1E13 IE13 IE14 1E14

.

1E14

PIPER CHEROKEE SERVICE MANUAL

SECTION II HANDLING AND SERVICING 2-1. INTRODUCTION. This section contains routine handling and servicing procedures that are most frequently encountered. Frequent reference to this section will aid the individual by providing information such as the location of various components, ground handling procedures, routine service procedures and lubrication. When any system or component requires service other than the routine procedures as outlined in this section, refer to the appropriate section for that component.

2-2. DIMENSIONS. The principal airplane dimensions are shown in Figures 2-1 through 2-12 and are listed in Table II-I.

2-3. STATION REFERENCE LINES. In order to facilitate the location of various components of theairplanewhichrequiremaintenance and servicing, a method utilizing fuselage station (Sta.), wing station or buttock line (BL), and water line (WL) designations is frequently employed in this manual. (Refer to Figures 2-13 thru 2-24.) Fuselage stations, buttock lines, and water lines are reference points measured by inches in the vertical or horizontal direction from a given reference line which indicates station locations of structural members of the airplane. Station 0 of the fuselage is 78.4 inches aheadof thewing leading edge or 49.5 inches ahead of the lower edge of the firewall; station 0 (BL) of the wing and stabilator is the centerline of the airplane; and station 0 (WL) of the fuselage vertical stabilizer and rudder is 20.5 inches below the cabin floor as measured at the rear wing spar with the airplane level. The reference datum line is located 78.4 inches ahead of the wing leading edge at the intersection of the straight and tapered section. 2-4. WEIGHT AND BALANCEDATA. Whenfiguringvarious weight and balance computations, the empty, static and gross weight, and center of gravity of the airplane may be found in the Weight and Balance Form of the Airplane Flight Manual.

HANDLING AND SERVICING

Reissued: 1/15/81

1B3

PIPER CHEROKEE SERVICE MANUAL

I

C329

63.75" -

Figure 2-1. Three-Viewof Cherokee PA-28-140and PA-28-150-160-180,Serial Nos. 28-1 to 28-1760 incl. PA-28-140Flite Liner, Serial Nos. 28-7125174 and up HANDLING AND SERVICING

Reissued: 1/15/81

1B4

PIPER CHEROKEE SERVICE MANUAL

862

*1974 MODELS

AND UP

30'

Figure 2-2. Three-View of Cherokee 140 PA-28-140, SerialNos. 28-7225001 and up

Reissued: 1/15/81

HANDLING AND SERVICING

1B5

PIPER CHEROKEE SERVICE MANUAL

1694

Reissued: 1/15/81

HANDLINGAND SERVICING

1B6

PIPER CHEROKEE SERVICE MANUAL

1836

Figure 2-4. Three-Viewof Cherokee PA-28-180,Serial Nos. 28-4378 to 28-7105244 incl. HANDLING AND SERVICING Reissued:1/15/81

1B7

PIPER CHEROKEE SERVICE MANUAL

1732

Figure 2-5. Three-View of Cherokee PA-28-180, SerialNos. 28-7205001 to 28-7205328 incl.

HANDLINGAND SERVICING Reissued: 1/15/81

1B8

PIPER CHEROKEE SERVICE MANUAL

1724

1974 MODELS AND UP

Figure 2-6. Three-View of Cherokee PA-28-180, Serial Nos. 28-7305001 and up

Reissued: 1/15/81

HANDLING AND SERVICING

PIPER CHEROKEESERVICEMANUAL

1691

63.0"

1840

23' 8.55"

Figure 2-7. Three-View of Cherokee PA-28-235, Serial Nos. 28-10000 to 28-11039 incl.

HANDLINGAND SERVICING

Reissued: 1/15/81

1BlO

PIPER CHEROKEE SERVICE MANUAL

182B

I

Figure 2-8. Three-View of Cherokee PA-28-235,Serial Nos. 28-11040 to 28-7110042 incl. HANDLING AND SERVICING

Reissued:1/15/81

1Bll

PIPER CHEROKEE SERVICE MANUAL

C330

Figure 2-9. Three-View of Cherokee PA-28-235, SerialNos. 28-7210001 to 28-7210033 incl. HANDLING AND SERVICING

Reissued: 1/15/81

1B12

PIPER CHEROKEE SERVICE MANUAL

886

*1974 MODELS

AND UP

Figure 2-10. Three-View of Cherokee PA-28-235, Serial Nos. 28-7310001 and up

HANDLING AND SERVICING

Reissued: 1/15/81

1B13

PIPER CHEROKEE SERVICE MANUAL

1796

30'

Figure 2-11. Three-View of Cherokee PA-28R-180,Serial Nos. 28-30005 to PA-28R-200,SerialNos. 28-30482 to 28-7130019 incl. 28-7135238 incl. Reissued: 1/15/81

HANDLINGAND SERVICING

1B14

PIPER CHEROKEESERVICEMANUAL

1796

*1974

MODELS

AND Up

5' 3.0"

32' 2.32"

7° DIHEDRAL

11.83"

74.00"