CHEROKEE SERVICE MANUAL

PIPER PA-28-160 · Maintenance Manual

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Overview

The Piper PA-28-160 Service Manual provides comprehensive maintenance and servicing information for the PA-28 series aircraft, including the PA-28-140, PA-28-150, PA-28-160, PA-28-180, PA-28-235, PA-28R-180, and PA-28R-200 models. It includes details on handling, servicing, inspection, structures, and various systems of the aircraft.

This is an interim service manual for the Piper PA-28 series.
The manual is organized into Aerofiche cards for easy reference.
Revisions to the manual are periodically issued and supersede previous versions.
The document includes a complete list of tables and illustrations.
Revised material is indicated by a vertical line in the margin.
The manual covers multiple models of the Piper Cherokee aircraft.
It includes detailed sections on handling, servicing, and inspection.
The manual is intended for maintenance personnel.

Document

Source

Originally published by aeroelectric.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.

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Document details

Type: Maintenance Manual
Year: 2004
File size: 32 MB
Publisher: aeroelectric.com
Language: en

About this document

What is the CHEROKEE SERVICE MANUAL?

The CHEROKEE SERVICE MANUAL is a maintenance manual for the PIPER PA-28-160, dated 2004.

Where does the CHEROKEE SERVICE MANUAL come from?

This copy of the CHEROKEE SERVICE MANUAL was originally published by aeroelectric.com and is hosted on Sprinkle as a free, searchable reference copy.

What year was the CHEROKEE SERVICE MANUAL published?

The CHEROKEE SERVICE MANUAL — the PIPER PA-28-160 maintenance manual on file — is dated 2004.

Documentation completeness

2/7

Most owners only have the POH. Here's the essential set for the PIPER PA-28-160.

Pilot's Operating Handbook / AFM
Checklist
Maintenance Manual
Parts Catalog (IPC)
Systems & Wiring
Service Bulletins on file
Type Certificate (TCDS)

More PIPER PA-28-160manuals & documents

In this document

Introduction

The introduction provides an overview of the service manual's structure and purpose.

Handling and Servicing

This section outlines the procedures for the proper handling and servicing of the aircraft.

Inspection

Details the inspection protocols necessary for maintaining the aircraft's airworthiness.

Structures

Covers the structural components of the aircraft and their maintenance requirements.

Surface Controls

Describes the operation and maintenance of the aircraft's surface control systems.

Hydraulic System

Provides information on the hydraulic systems used in the PA-28 series.

Full document text

PART NUMBER 753-586 INTERIM REVISION: FEBRUARY 27, 2004 1A1 CHEROKEE SERVICE MANUAL CARD 1 OF 4 PA-28-140 PA-28-150 PA-28-160 PA-28-180 PA-28-235 PA-28R-180 PA-28R-200 PIPER AIRCRAFT CORPORATIONCourtesy of Bomar Flying Service www.bomar.biz AEROFICHE EXPLANATION AND REVISION STATUS Service manual information incorporated in this set of Aerofiche cards has been arranged in accordance with general specifications of Aerofiche adopted by General Aviation Manufacturer’s Association, (GAMA). The information compiled in this Aerofiche Service Manual will be kept current by revisions distributed peri- odically. These revisions supersede all previous revisions and are complete Aerofiche card replacements and supersede Aerofiche cards of same number in set. Conversion of Aerofiche alpha/numeric code numbers: First number is Aerofiche card number. Letter is horizontal line reference per card. Second number is 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 list of Tables 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 begin- ning of each Chapter relating to the information within a Chapter. 5. Identification of revised material: Revised text and illustrations are indicated by a black vertical line along the left-hand mar- gin of the frame, opposite revised, added or deleted material. Revision lines indicate only cur- rent revisions with changes and additions to or deletions of existing text and illustrations. Changes in capitalization, spelling, punctuation, indexing, physical location of 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: Revision Publication Date Aerofiche C Effectivity ORG720816 August 16, 1972 All CR810115 January 15, 1981 1, 2, 3 and 4 PR810803 August 3, 1981 1, 2, 3 and 4 PR831003 August 3, 1983 1, 2, 3 and 4 PR840423 April 23, 1984 1, 2, 3 and 4 PR86115 January 15, 1986 1 and 3 IR860730 July 30, 1986 1 IR870506 June 12, 1987 1 IR950215 February 15, 1995 1 and 2 IR020228 February 28, 2002 1 and 3 IR040227* February 27, 2004 1 and 2 * PARTIAL REVISION OF SERVICE MANUAL 753-826 Revisions appear only in Aerofiche Cards 1 and 2. Accordingly, discard your existing Aerofiche Cards 1 and 2 and replace them with these dated February 27, 2004. Consult the Customer Service Information Aerofiche (P/N 1753-755) for current revision dates for this manual. PIPER CHEROKEE SERVICE MANUAL 1A2 TABLE OF CONTENTS V V I V I I V l l A V l ll A E R O F I C H E C A R D N 0 . 1 G R I D NO . I N T R O D U C T I O N . . . . . . . . . . . . . . . . . . . . . . . . 1 A 1 9 H A N D L I N G A N D S E R V I C I N G . . . . . . . . . . . . . . . . . 1A24 I N S P E C T I O N . . . . . . . . . . . . . . . . . . . . . . . . . . 1 F 6 S T R U C T U R E S . . . . . . . . . . . . . . . . . . . . . . . . 1 3 G I A E R O F I C H E C A R D N 0 . 2 S U R F A C E C O N T R O L S . . . . . . . . . . . . . . . . . . . . . 2 A 8 . . . . . . . . . . . . . . . H Y D R A U L I C S Y S T E M ( P A - ~ B S ) . 2 0 3 L A N D I N G G E A R A N D B R A K E S Y S T E M ( P ~ . 2 8 ). . . . . . . . 2 E 2 2 . . . . . . . L A N D I N G G E A R A N D B R A K E S Y S T E M m . 2 8 ~ ) 2 H 1 P O W E R PLANT ( P A . z ~ ). . . . . . . . . . . . . . . . . . . . . 2K2 A E R O F I C H E C A R D N 0 . 3 V l l l A P O W E R P L A N T ( P A . Z ~ R ) . . . . . . . . . . . . . . . . . . . . . 3 A 8 . . . . . . . . . . . . . . . . . . . . . . . . . IX F U E L S Y S T E M 3 C 8 X I N S T R U M E N T S . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 1 8 X I X I 1 X l l l X I V A E R O F I C H E C A R D N 0 . 4 E L E C T R I C A L S Y S T E M . . . . . . . . . . . . . . . . . . . . 4 A 8 E L E C T R O N I C S . . . . . . . . . . . . . . . . . . . . . . . . . 4 1 1 H E A T I N G A N D V E N T I L A T I N G . . . . . . . . . . . . . . . . . 4114 A C C E S S O R l E S A H D U T I L I T I E S . . . . . . . . . . . . . . . 4 ~ 4 1A4 INTENTIONALLY LEFT BLANK PIPER CHEROKEE SERVICE MANUAL LIST O F ILLUSTRATIONS Figure Three View of Cherokee, PA-28- 140. - 150. - 160, - 180, Serial Kos. 28- 1 to 28- 1760 incl.. Flite Liner. Serial Nos. 28-7 125 174 and up .................................................. Three View of Cherokee. PA-28-140, Serial Nos. 28-7225001 and up ...........................:............ Three View of Cherokee. PA-28- 150. - 160. - 180. Serial Nos. 28- 1761 to 28-4377 incl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three View of Cherokee. PA-28-180, Serial Nos. 28-4378 to 28-7 105244 incl.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. Three View of Cherokee. PA-28- 180, Serial Kos. 28-720500 1 to 28-7205328 incl.. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . Three View of Cherokee. PA-28-180. Serial Nos. 28-7305001 and up ........................................ Three View of Cherokee, PA-28-235. Serial Nos. 28-10000 to 28-11039incl ........................................... Three View of Cherokee, PA-28-235. Serial Nos. 28-1 1040 to 28-7 1 10042 incl.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three View of Cherokee, PA-28-235. Serial Nos. 28-7210001 to 28-7210033incl ......................................... Three View of Cherokee. PA-28-235. Serial Nos. 28-7310001 and up ........................................ Three View of Cherokee. PA-28R-180. -200. - 180 Serial Nos. 28-30005 to 28-7 130019 incl.

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-200 Serial Xos. 28-30482 to 28-7 135238 incl.. . . . . . . . . . . . . . . . . Three View of Cherokee, PA-28R-200, Serial Nos. 28-7235001 and up.. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . Station Reference Lines. PA-28- 140. - 150, - 160, -1 80. Serial Nos. 28- 1 to 28- 1760 incl.: Flite Liner. Serial Nos. 28-7 125 174 and up ................................................... Station Reference Lines. PA-28- 140. Serial Nos. 28-722500 1 and up .................................................. Station Reference Lines. PA-28- 150. - 160. - 180. Serial Sos. 28-1761 to 28-4377incl. ................................... Station Reference Lines, PA-28-180. Serial Nos. 28-4378 to 28-7 105244 incl.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Station Reference Lines. PA-28-180. Serial Nos. 28-720500 1 to 28-7205328 incl.. . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . .. . Station Reference Lines. PA-28- 180. Serial Nos. 28-730500 1 and up ..........................................;....... Station Reference Lines. PA-28-235. Serial Nos. 28-10000 to 28-1 1039 incl.. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Station Reference Lines. PA-28-235. Serial Nos. 28-1 1040 to 28-71 10042 incl.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aerofiche Grid KO. Reissued: 1 i15: 8 1 PIPER CHEROKEE SERVICE MANUAL LIST O F ILLUSTRATIONS (cont.) Figure 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 Kos . 28-30005 t o 28-7 130019 incl . -200 Serial Nos . 28-30482 t o 28-7135238 incl .................. Station Reference Lines . PA.28R.200 . Serial Kos . 28-7235001 and up .................................................. Access Plates and Panels . PA-28-140 and Flite Liner . Serial Nos . 28-722500 1 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. -1 60. .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. . ....................................... .I60 -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: 8i3181 PIPER CHEROKEE SERVICE MANUAL Figure LIST OF lLLUSTRATIONS (cont.) Aerofiche Grid No . ....................... Lubrication Chart (Power Plant. Propeller and Control Pivot Points) IF2 ........................................ Lubrication Chart (Back-up Extender and Fuel Selector) IF3 ...................................................... Lubrication Chart (Air Conditioning Condenser) IF4 Typical Muffler Fatigue Areas ................................................................................... IF10 ............................................................................. Exhaust System Inspection Points 1 1 1 ............................................................................. Exhaust System Inspection Points IF12 ..................................................... Exhaust System Installation. PA.28R.180.. 200 1 F14 ............................................................................... Control Wheel Inspection Points IF15 ........................................................ Flap Control Cable Attachment Bolt Inspection IF16 ......................................................... Inspection of Main Landing Gear Torque Link IF17 ..................................................................................... Aileron and Flap Installation IG19 ........................................................................................................ Wing Installation 1G23 ......................................................................... Methods of Securing Control Cables lH7 .................................................................................. Empennage Group Installation 1H11 ............................................................................... Windshield Installation (Typical) l H l 6 ................................ Side Window Installation, Single Pane (Typical) . . . . . . . . . . . . . . . . . . . . . . . HI 8 ..................................................... Side Window Installation, Double Pane (Typical) 1H18 .......................................................................................... Door Snubber Installation 1H20 .......................................................................................................... Seat Back Lock 1H24 .................................................................................... Skin Materials and Thickness 111 .................................................. Surface Scratches, Abrasions or Ground-in-Dirt 1 I8 ...................................................... Deep Scratches, Shallow Nicks and Small Holes 119 ...................................................................... Mixing of Epoxy Patching Compound 119 ............................................................................................ Welding Repair Method 1111 Repairing of Cracks ................................................................................................... 1111 ......................................................................................................... Various Repairs 1112 ............................................................................................... Repair of Stress Lines 1113 Repair of Impacted Damage ...................................................................................... 1113 .................................................................................... Control Surface Balance Tool 1120 .............................................................. Aileron and Rudder Balance Configuration 1121 ..................................................................................................... Stabilator Balance -1122 .............................................................................................. Wing Rib Modification 1124 ...................................................................... Balance Weight Assembly Installation 1124 ................................................................... Fabricated Tool for Baggage Door Lock 1JI ......................................................................... Additional Drain Holes in Stabilator 152 .......................................... Baggage Compartment Inspection Holes Cutout Details lJ5 ............................. 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, -1 50, -1 60, -1 80, -235 2A23 Bellcrank Rigging Tool, PA-28R ............................................................................... 2A23 Interim Revision: February 15. 1995 lA7 PIPER CHEROKEE SERVICE MANUAL LIST O F ILLUSTRATIOXS (cont.) Figure 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 Bellcran k 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 1 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 ................................ Kose Gear Oleo Strut Assembly ........................................ Nose Gear Installation Clamping Rudder Pedals in Neutral Position ..................... Rudder Pedals at Keutral Angle ................................ Main Gear Oleo Strut Assembly . PA.28-140 . -1 50. -160 and -180 ................................................ ..................... Main Gear Oleo Strut Assembly . PA-28-235 ........................................ Main Gear Installation ......................................... Nose Wheel Assembly Main Wheel Assembly ........................................ Aerofiche Grid K O. Revised: 4 23 ! 84 P I P E R C H E R O K E E SERVICE MAKUAL Figure LIST O F ILLUSTRATIONS (cont.) Aerofiche Grid No . U'heel Brake Assembl! ......................................... ...................................... R e m o ~ a lof Anchor Bolt .................................... lnstallation of Anchor Bolt ................................ Brake Disc Minimum Thickness ..................................... Brake Slestem lnstallation Brake Master Cylinder (Hand Brake). PA-28- 150. -160 . .............................. Serial S o s . 28-1 t o 28-250 incl Brake Master Cylinder (Hand Parking Brake) . PA-28- 140. Serial S o s . 28-20002 t o 28-21 036 incl .. PA-28- 150. - 160. .180. Serial Nos . 28-25 1 t o 28-2700 incl ..PA.28.135 . Serial Nos . 28- 10003 t o 28- 10697 incl ............. Brake Master C!. linder (Hand Parking Brake). PA-28.140 . Serial Nos . 28-21037 and up: PA.28-150 . .I60 . .180. Serial 3 0 s . 28-2701 and up: PA-28.235 . Serial Nos . 28-10698and up .......................................... Parking Valve . PA-28- 150. - 160. Serial Nos . 28- 1 to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-350incl ........................................ Toe Brake lnstallation Brake C!. linder 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 lnstallation Nose Gear Adjustment (Without Gear Up Stop) .................. ..................... Nose Gear Adjustment (With Gear Up Stop) ..................... Clamping Rudder Pedals in Neutral Position ................................ Rudder Pedals a t Keutral Angle ......................... Nose Gear Door Retraction Mechanism ................................ 3lain Gear Oleo Strut Assembly ........................................ Main Gear lnstallation .......................................... Aligning Main Gear .................... Adjustment of S o s e Gear Down Limit Switch Adjustment of Main Gear Down Limit Switch ................... \+'iring Diagram of Landing Gear Electrical Circuit ............... .................................... Throttle Warning Switches S o s e Wheel Assembly ......................................... ........................................ Main Wheel Assembly ........................................ k'heel Brake Assembly ................................ Brake Disc Minimum Thickness Revised: 8 3 81 P I P E R C H E R O K E E S E R V I C E M A N U A L . LIST O F I L L U S T R A T I O N S (cont.) ..................................... Brake System lnstallation Brake Master C!. linder (Hand Parking Brake) ................... ........................................ Tort Brake lnstallation Brake Cylinder (Toe Brake) ( 10.20 . 10.27 . 17000) ................. Brake C!.linder (Toe Brake) ( 10-30) ............................. ........................................... Bearing Installation 50Se Gear S e n ice Tolerances . PA.28R .......................... Main Gear Service Tolerances. PA-28R ......................... Typical Nicks and Removal Method ............................ Propeller lnstallation (Constant Speed). PA-28-235 ............... ......................................... Propeller lnstallation ..................... Adjustment of Propeller Control . PA-28-235 Propeller Governor . PA.28.235 ................................. Engine Installation . PA-28- 140. .I50 . .160. .I80 . Serial T o s . 28-1 t o 28-1760 ................................ Engine Installation . PA.28.140 . .I50 . .160. .I80 . Serial Nos . 28-1761 and u p ................................ Engine Shock Mount Installation . PA.28.140 . Serial Nos . 28-25000 a n d up ............................... ................................. Engine Installation . PA-18-35 ................................. Adjustment of Engine Controls .. .............................. Carburetor. PA-28- 140.. 150 160 ................................... . Carburetor . PA-38- 180 -235 ........................................... Magneto Inspection ..................................... Contact Spring lnspection ............................................ Impulse Coupling ....................................... Magneto Timinz Marks ............................................... Timing Pointer .......................................... Timing Kit Installed .................. Breaker Compartment With Cast Timing Marks ........................ Removing Spark Plug Frozen t o Bushing ............................... Ignition Su-itch Wiring Positions ......................................... Propeller lnstallation ............................ Typical Nicks and R e r n o ~ . a1 Method ........................................... Propeller Governor ............................... Engine Installation . PA-28R- 180 ...................... Engine Installation . PA-28R-200 ........ ; ................................. Adjustment of Engine Controls ................................................. Fuel Injector Schematic Diagram of R S A Fuel Injection S ~ s t e m................ ......................................... Fuel-Air Bleed Nozzle ............................................... Contact Points Aerofiche Grid No . Revised: 8 3 81 PIPER CHEROKEE SERVICE MAKUAL Figure LIST O F ILLUSTRATIONS (cont.) Aerofiche Grid No . .................................. Rotor Holding Tool Installed Timing Kit Installed .......................................... Aligning Timing Marks ....................................... Checking Fllweight 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 .......................................... h'eedle ...................................................... ........................... 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 Xos . 28-10003 to 28- 10719 incl ........................................... . . .... . Fuel System Diagram PA-28-235 Serial Fr'os 28-10720 and up Fuel System Diagram . PA-28R ................................. Deleted ..................................................... ....................... Fuel Quantity Transmitter ( P ' X 62037-00) Fuel Quantity Transmitter (P! N 68 10 1-00) ....................... ............................. Fuel Selector and Filter . PA-28-235 ........................................ . Fuel Filter PA-28-235 Fuel Filter Bowl and Screen . PA-28- 140. - 150. - 160. -1 80 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 t o ............................................. 28-26956 incl Instrument Panel. PA-28- 140. Serial Nos . 28-7 12500 1 to ........................................... 28-7325684 incl Revised: 8 / 3 / 8 1 PIPER CHEROKEE SERVICE MANUAL . - - . LIST O F ILLCSTRATIONS (cont.) Instrument Panel . PA.28.140 . Serial 3 0 s . 28-7425001 and u p ...... Instrument Panel ............................................. lnstrument Panel . PA-28- I50. .160. .I80 . Serial No3. 28- 1761 to 28-4377 incl ............................................ lnstrument Panel . PA-28- 180. Serial Nos . 28-4378 to 28-7205328 incl ........................................... lnstrument Panel . PA-28- 180. Serial Nos . 28-730500 1 to 28-730561 1 incl ........................................... Instrument Panel . PA-28- 180. Serial Nos . 28-7405001 and up ...... Instrument Panel . PA.28.235 . Serial Nos . 28-10720 to 28-11039incl ............................................. Instrument Pancl . PA.28.235 . Serial Nos . 28-1 1040 to ........................................... 28.7110033incl lnstrurnent Panel . PA.28.235 . Serial Nos . 28-73 1000 1 to ........................................... 28-73 10 187 incl . ...... Instrument Panel . PA.28.235 . Serial Nos 28-7410001 and up lnstrument Panel . PA.28R.180 . Serial Nos . 28-30005 to ............................................. 28-30879 incl lnstrument Panel . PA-28R- 180. Serial Nos . 28-30880 to 28-71 30019 incl .. PA.28R.200 . Serial S o s. 28.30482 . 28-3500 1 to 28-35830 incl . and 28-7 135001 to 28-7135238incl ........................................... lnstrument Panel . PA.28R.200 . Serial Nos . 28-7235001 to ........................................... 28-7335455incl . ..... Instrument Panel . PA.28R.200 . Serial Nos 28-7435001 and up ................................. \Yarning Light Pressure Switch T!.pical Pitot Static System . PA-28- 140. .150. - 160. .180. .I35 . 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 176 1 and up Generator and Starter System .................................. .................................... Generator Wiring Diagram ................................... Sectional View of Generator .................................... Current Voltage Regulator ...................... Use of Riffler File to Clean Contact Points .................................... L'oltase Regulator Air Gap ............... Checking Voltage Setting Fixed Resistance Method ............ Checking Voltage Setting Variable Resistance Method ............................ Adjus~ingVoltage Regulator Setting .................... Cutout Relay Air Gap Check and Adjustment .............. Cutout Relay Point Opening Check and Adjustment Aerofiche Grid No . P I P E R C H E R O K E E SERVICE M A X U A L LIST OF ILLL'STRATIONS (cont.) Aerofiche Grid No . Checking Cutout Rela> Closing Voltage ......................... .Adju?;tment of Cutout Relay Closing Voltage .................... Chccking Current Regulator . Load Method ...................... Checking Current Regulator . J u m p e r Lead Method ............... Alternator and Starter S!.stem. PA-28- 140. Serial S o s . 28-20000 to 28-24999 incl ..PA-28- 150. - I60 . Serial \as . 28-508 to 28-3643 incl ..PA-28- 180. Serial S o s. 28-67 1 t o 28-3643 incl ..PA-28.235 . Serial Nos . 28-10002 t o 28-10762 incl ............. Alternator and Starter System . PA.28-140 . Serial S o s . 78-35000 and up: PA.28-150 . .160. .I80 . Serial Nos . 28-3644 and up: PA.28-235 . Serial S o s . 10763 and up and PA-28R ............ ............................................ Lamp-Bank Load Checking Field Circuit ........................................ .......................................... Test ins Field Circuit .................................... Testing Rectifiers (Positi\r) ................................... Testing Rectifiers (Segative) .................................. C-3998 Fixtures and Adapters .......................................... Remo\.ing Rectifiers ........................................... Installing Rectifiers ....................................... Soldering Rectifier Lead .......................................... Te4ting Stator Coils ........................................ Remo\.ing End Bearing ......................................... Installing End Bearing ....................................... Removing Drive Pulley .................................. Removing Dri\.e 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 \!oltage Regulator ............................................ Checking Alr Gap ............................................ ............................... Voltage Regulator Fusible Wires ............................. i'oltage R e p l a t o r Resistance Units ........................................ So-Load Test Hookup Lock Torque Test Hookup .................................... ....................................... Resistance Test Hookup Revised: 8 3 81 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure 11.47 . 1 1.48 . 1 1.49 . 1 1.50 . 11.51 . 1 1.52 . 11.53 . 11.54 . t hru 1 1.70 . 11.71 . 1 1.72 . 11.73 . 1 1.74 . 11.75 . 1 1.76 . 1 1.77 . 1 1.78 . 1 1.79 . 11.80 . 11.81 . 11.82 . 11.83 . 1 1.84 . 11.85 . thru 1 1.143 . 1 1- 144. 12- 1 . 12.2 . 1 2.3 . 13- 1 . ................ 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 X1-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 ........................................ lnstallation of Rectifier ........................................... Terminal Assembly ............................... Slip Ring End Bearing Assembly ............................................ Testing Alternator ........... .............................. Brush Installation .. ...................................... Internal Wiring Diagram For Index to these Figures . see Table XI.1. 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 Kos . 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 .............................................. Aerofiche Grid K O. 4D8 4d11 4d11 Revised: 10 3 83 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure 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 740s . 28- 10003 to 28-10675 incl ............. Cabin Heater . Defroster and Fresh Air System . PA.28.235 . Serial Nos . 28- 10676 to 28- 1 1039 incl ............. Cabin Heater . Defroster and Fresh Air System . PA.28.235 . Serial Nos . 28- 1 1040 to 28-72 10033 incl ........... Cabin Heater . Defroster and Fresh Air System . PA.28.235 . Serial Nos . 28-73 10001 and up ................... Cabin Heater . Defroster and Fresh Air System . PA-28R ................................................. Overhead Vent System ........................................ ............................ Air Conditioning System lnstallation ............................................... 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 lnstallation Magnetic Clutch ............................................. ............................... Condenser Air Scoop Installation ............................................. Expansion Valve ...................................... Components lnstallation Control Head .Diode Mounting Board . Diode Location and Sumber. PA-28- 140. Serial Nos . 28-7 125472 to 28-7325057; PA-28- 180. Serial Nos . 28-7205092 t o 28-730507 1 : PA.28R.200 . 28R-7235001 to 28R-7335057 .................. Air Conditioning Wiring Schematic. PA-28- 140. Serial Nos . 28-7 125472 thru 28-7225 13 1 incl ..PA-28- 180. Serial Nos . 28-7205092 thru 28-7205 144 incl ........ Aerofiche Grid KO. Revised: 10 3 83 PIPER CHEROKEE SERVICE M A K U A L LIST O F ILLUSTRATIONS (cont.) Figure Aerofiche Grid KO. 14- 17. Air Conditioning Wiring Schematic. PA-28- 140. Serial Kos. 28-72251 32 to 28-722561 2; PA-28- 180. Serial Kos. 28-7205 145 to 28-7205328; PA-28R-200. Serial Nos. 28R-7235001 to 28R-7235330 . . . .. . .. 4K 19 14- IS. 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 . . . . . . . . . . . . . . . . . . 4K20 Revised: 10 3 '8.7 PIPER CHEROKEE SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No . 11.1 . Leading Particulars and Principal Dimensions ................. ...................................... 11.11 . Consumable Materials ................................. Il.111 . Recommended Nut Torques . ........................................*.......... Il.1V Deleted .......................................... I1.V . Conversion Tables II.VI . Decimal ' Millimeter Equivalents of Drill Sizes ................. Il.VI1 . Maximum Distance Between Supports for Fluid Tubing ......... ..................................... II~VIII. Hose Clamp Tightening . ....................... II.IX Recommended Engine Lubricating Oils .......................................... 1I.X . Thread Lubricants 1l.Xl . Summary of Recommended Lubricants used on PA-28 ......................................... Series Aircraft 111.1 . Inspection Report . PA-28- 140. .150. .160. -180; ............................................. PA-28-235 111.11 . Inspection Report . PA.28R .................................. 1V.I . List of Materials (Thermoplastic Repair) ...................... IV.11 . Balancing Specifications ..................................... V.1 . Control Surface Travel and Cable Tension .................... V-I I . Cable Tension Vs . Ambient Temperature ...................... . ..................... V.111 Troubleshooting Chart (Surface Controls) VI.1 . Leading Particulars . Hydraulic System ........................ V1.11 . Characteristics. Hydraulic Pump Motor ....................... ........................... . VI.111 Hydraulic System Troubleshooting VI1.1 . Nose Gear Alignment Tolerances ............................. V11.11 . Landing Gear Troubleshooting ............................... VI 1A.I . Landing Gear Troubleshooting ............................... ........................ VIIA.11 . PA-28R Nose Gear Service Tolerances ........................ . VIIA.111 PA-28R Main Gear Service Tolerances V111.l . Propeller Torque Limits ..................................... VIII.11 . Engine Troubleshooting Chart ............................... VIIIA.1 . Engine Troubleshooting Chart ............................... 1X.1 . TransmitterjFuel Gauge Tolerances .......................... .............. IX.11 . Fuel Quantity Transmitter Calibration Tolerances ................................ . IX.111 Fuel System Troubleshooting X.1 . Vacuum System ............................................ X.11 . Directional Gyro Indicator .................................. Revised: 8 . 3 : 81 PIPER CHEROKEE SERVICE MANUAL LIST O F TABLES (cont.) Table Aerofiche Grid KO. ..................................... Gyro Horizon Indicator R l t e of Climb Indicator ..................................... .................................................. .i. !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: 1 0 . 3:83 SECTION I INTRODUCTION Aerofiche Grid S o . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . Scope of Manual Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Empennage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuselage Landing Gear (Fixed) . . . . . . . . . . . . . . Landing G e a r (Retractable) . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System (PA 2 8 R ) Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engines . . . . . . . . . . . . . . . . . . . Propellers Fuel System . . . . . . . . . . . . . . . . Flight Controls . . . . . . . . . . . . . . . . . Radio . . . . . . . . . . . . . . . . . . . . . . . . Cabin Heater. Defroster. and F r e s h A i r System . . . . . . . . . . Instrument and Autopilot System Reissued: 1 / 15 /8 1 PIPER CHEROKEE SERVICE MANUAL . -- -- - SECTION I INTRODUCTION t WARNING When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user's responsibility to refer to the applicable vendor publication. I-I . GENERAL. This manual contains service and maintenance instructions for PA-28- 140. ( -150. -160. -180. -235 and P.4-28R-180 200 Cherokees. desisned 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 I1 and I11 comprise the senice 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 t o general information. Section I1 gives leading particulars apd 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 sinzle-engine. low-wing monoplane of all metal construction. The standard PA-28-140 is a t n o place. with third and fourth family seats I available as optional equipment. The PA-28-150. -160. -180. -235 and PA-?BR-I80 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. Revised: 1/ 15/ 86 INTRODUCTION 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 landing gear is of the fixed type, consisting of shock absorbing air-oil type oleo struts. 1-8. LANDING GEAR. (Retractable) The tricycle landing gear is a hydraulically operated, fully retractable unit consisting of shock absorbing air-oil type oleo struts. 1 1-9. HYDRAULIC SYSTEM. (PA-2RR-I80 200) The hYdraulic.system incorporates an electrically driven pump uhich is controlled by a lever on the instrument panel uhich 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 - 1 1 . 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. - 1 50. -160. - I 80 and the six-c!.linder engine in the P.4-28-235 are carburetor I 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 11-1 of Section 11. 1 - 1 2. PROPELLERS. The PA-28-140. -150. -160. -180 and -235 models are equipped nith 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. I The constant speed propellers are controlled by a governor mounted on the engine. The governor is in turn controlled b!. a lever on the power quadrant. Propeller specifications ma! be found in Table 11-1 of Section 11. 1-13. Ft'EL SYSTEM. The fuel system on the PA-28-140. -150. -160. -180 and 1 PA-2XR-I80 200 consists of tu.o aluminum tanks in the leading edge of the uings. a strainer b o ~ lwith fuel screen. one electrical ausiliar! pump and one engine driven pump. The fuel s!,stem for the PA-28-235 consists of two aluminum tanks in the wings plus an ausiliar! fiberglass tank in each nin? tip. There also is a combination fuel selector and filter. electrical ausiliary fuel pump(s) and one engine driven pump. Revised: 10 3 83 INTRODUCTION P I P E R C H E R O K E E SERVICE MANUAl, 1-14. FLIGHT CONTROLS. The flight controls are conventional equipment, consisting of 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 A N D 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 28-2477 incl.. and PA-28-235. Serial 5 0 s . 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 t o the individual seat location. On the PA-28-1 50. - 160. - 180. Serial Nos. 28-2478 and up: PA-28-235. Serial Nos. 28- 10676 1 and up. and PA-ZXR-180 200. fresh air is picked up from a n 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 Lent is located in the top or bottom of the fuselage to take exhaust air from the cabin interior. 1-1 7. INSTRUMENT AND 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 lA23 INTENTIONALLY LEFT BLANK SECTION 11 HANDLING AND SERVICING Pa rag rap h ................................................. Introduction Dimensions .................................................. ....................................... Station Reference Lines ..................................... Weight and Balance Data .......................................... Serial Kumber 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 .................................................... ............................. 2-3 1 . Introduction to Servicing ................................... Hydraulic System (PA-28R) ........................... 2.33 . Servicing Hydraulic System ................... 2.34 . Servicing Hydraulic Pump I Reservoir Aerofiche Grid No . Revised: 8 / 3 / 81 PIPER CHEROKEE SERVICE MANUAL Paragraph Aerofiche Grid No . Landing Gear System ......................................... 2.36 . Servicing Landing Gear .............................. Oleo Struts (PA-28- 140. -1 50. .I60 .. 180 and PA-28-235) .......... ................................. . 2.38 Senicing Oleo Struts .......................... 2.39 . Filling Nose Gear Oleo Strut ......................... . 2.40 Filling Main Gear Oleo Strut ................................. . 2.41 lnflating 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 3 8 . Filling Brake Cylinder Reservoir ....................... ............................... 2.49 . Draining Brake System Tires ........................................................ ...................................... . - 5 I Servicing Tires ................................................. Power Plant ................................ 2.53 . Servicing Power Plant ........................................... lnduction Air Filter 2.55 . Removal of Air Filter ................................ 2.56 . Service instruction (Cleaning and Inspection) ............ 2.57 . Installation of Air Filter .............................. .................................................... Propeller 2.59 . Servicing Propeller ................................... ................................................. Fuel Sxstem ................................ . 2-6 1 Senicing 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 . .. .......................... .I60 180 and PA-28R) ..... . 2.65 Draining Moisture From Fuel System (PA-28-235) 2.66 . Draining Fuel Svstern ................................ 2.67 . Anti-Icing Fuel Additive ............................. Electrical System ............................................. 2.69 . Sert icing Electrical System ............................ .................................................. Lubrication 011Sj.stem (Engine) .......................................... ................................. 2.72 . S e n icing Oil System 2.73 . Filling Oil Sump .................................... 1E8 1E8 Reissued: 1 / 15/8 1 PIPER CHEROKEE SERVICE MANUAL Aerofiche Grid No . Reissued: 1 / 15/8 1 Draining Oil Sump . . . . . . . . . . . Oil Screens (Suction.) . . . . . . . . . . Oil Screen ( P r e s s u r e ) . . . . . . . . . . . . . . . Oil F i l t e r (Full Flow.) Recommendations for Changing Oil . . . Lubrication Instructions . . . . . . . . . . . . . . . . . . Application of Oil . . . . . . . . Application of G r e a s e Winterization Plate . . . . . . . . . Lubrication C h a r t . . . . . . . . . . PIPER CHEROKEE SERVICE MANUAL SECTION I1 HA NDLING AND SERVICING 2 - 1 . INTRODUCTION. This section contains routine handling and servicing procedures that a r e most frequently encountered. Frequent reference to this section will aid the individual by providing information such a s the locatioo of various components, ground handling procedures, routine service procedures and lubrication. When any system o r component requires service other than the routine procedures a s outlined in this section, r e f e r 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 11-1. 2 - 3 . STATION REFERENCE LINES. In order to facilitate the location of vari- ous components of the airplane which require maintenance and servicing, a method utilizing fuselage station (Sta.), wing station o r 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 o r horizontal direction from a given reference line which indicates station locations of structural members of the airplane. Sta- tion 0 of the fuselage is 78 - 4 inches ahead of the wing leading edge o r 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 stab- ilizer and rudder is 20.5 inches below the cabin floor a s measured a t the r e a r wing s p a r with the airplane level . The reference datum line is located 78.4 inches ahead of the wing leading edge a t the intersectionof the straight and tapered sec- tion. 2-4. WEIGHT AND BALANCE DATA. 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 t h e d i r p l a n e Flight Manual. Reissued: 1/ 15181 HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL Figure 2- 1. Three-View of Cherokee PA-28-140 and PA-28- 15@160-180, Serial Nos. 28-1 to 28-1 760 incl. PA-28-140 Flite Liner, Serial Nos. 28-7 125 174 and up Reissued: 1/ 15/8 1 HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL m 1862 *I974 MODELS AND UP ' 6' 1.92 Figure 2-2. Three-View of Cherokee 140 PA-28-1 40, Serial Nos. 28-7225001 and up Reissued: 1 / 15/8 1 HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL - PA - 20-150,- 160 Figure 2-3. Three-View of Cherokee PA-28-150-160-180,Serial Nos. 28-1761 to 28-4377 incl. Reissued: 1/ 1 518 1 HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL Figure 2-4. Three-View of Cherokee PA-28-1 80, Serial Nos. 28-4378 to 28-7105244 incl. Reissued: 1 / 15/8 1 HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL Figure 2-5.Three-View of Cherokee PA-28-180, Serial Nos. 28-7205001to 28-7205328incl. Reissued: 1 / 1518 1 HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL -12' 10.50" -1724 +I974 MODELS AND UP -.- -. . - .-- -- - -. * 32' 2.50" . i n 1 C . . S - k . > / \ -i-- --=.-- - *i ! 6' 6.9" Figure 2-6. Three-View of Cherokee PA-28-180, Serial Nos. 28-7305001 and up Reissued: 1 / 15/8 1 HANDLING A N D SERVICING PIPER CHEROKEE SERVICE MANUAL Figure 2-7. Three-View of Cherokee PA -28-235, Serial Nos. 28- 10000 to 28-11039 incl . Reissued: 1 / 15/8 1 .HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL Figure 2-8. Three-View of Cherokee PA-28-235,Serial Nos. 28-11040 to 28-7110042 incl. Reissued: 1 / 1518 1 HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL Figure 2-9. Three-View of Cherokee PA-28-235, Serial Nos. 28-721 000 1 to 28-72 10033 incl. Reissued: 1/15/81 - HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL Figure 2-10. Three-View of Cherokee PA-28-235, Serial Nos. 28-73 10001 and up r Reissued 1/ 15/8 1 886 12' 10.5" '1974 MODELS AND UP \ - 1 8 - 1 ' 8 , ! j ' 6' 6.06" HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL +--I' 5.50"-+ IFigure 2- 1 1 . Three-View of Cherokee PA-28R-180, Serial Nos. 28-30005 to 28-7 1300 19 incl. PA-28R-200, Serial Nos. 28-30482 to 28-7135238 incl. Reissued: 1 / 1518 1 HANDLING AND SERVICING PIPER CHEROKEE SERVICE MANUAL Figure 2- 12. Three-View of Cherokee PA-28R-200, Serial Nos. 28-7235001 and up Reissued: 1 / 15/8 1 HANDLING A N D SERVICING 1B15 TABLE 11-1. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS MODEL PA-28- 140 ENGINE Manufacturer Model FAA Type Certificate Rated Horsepower Rated Speed: Full Throttle Oil, SAE Number Oil Sump Capacity Fuel, Aviation Grade (Minimum Octane) Fuel, Aviation Grade (Specified Octane) Fuel,- Aviation Grade (Alternate) Fuel Injector, Bendix Magnetos, Scintilla: Left Right Magneto Timing Magneto Point Clearance Spark Plugs (Shielded): Refer to the latest revision of Lycoming Service Instruction No. 1042. Firing Order Starter: Delco-Remy, 12 Volt Prestolite, 12 Volt Alternator, Chrysler (35 AMP) 20 Voltage Regulator, Chrysler Alternator, Chrysler (60 AMP) 30 Voltage Regulator, WICO Overvoltage Relay, WICO Alternator, Prestolite (60 AMP) Voltage Regulator, WICO Fuel Pump Drive PROPELLER Fixed Pitch: Manufacturer Model I Refer 10 Grid IT? for foot Notes: Revised: 10 3 83 Avco-Lycoming 0-320-E2A or 0-320-E3D 2450 RPM - 2700 RPM ' See Table 11-IX 8 U.S. quarts 80187 80187 See Note 37 Scintilla or Slick S4LN-21 or 405 1 S4LN-204 or 4050 25' BTC 0.01 8 2 0.006 1109657 MZ4204 209861 5 or 2642996 2098613 or 87-87102-2 1 32 2642997 or 2642210 X 16300B X16799B ALY-6422 3' X 16300B Plunger Sensenich M74DM -- .- HANDLING AND SERVICING

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