Piper Cherokee Service Manual

PIPER PA-28-235 · Maintenance Manual

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Overview

The Piper Cherokee Service Manual provides comprehensive maintenance information for various models of the PA-28 series, including the PA-28-235. It includes details on handling, inspection, and structural components, along with a systematic arrangement of service data for easy reference.

The manual is organized according to GAMA specifications.
Revisions are periodically distributed to keep the manual current.
Includes a complete Table of Contents and lists of illustrations and tables.
Revised material is marked with a black vertical line in the margin.
The manual covers multiple PA-28 models, including the PA-28-235.
Aerofiche cards are used for the service manual format.
Specific chapters are dedicated to structures, landing gear, and powerplant.
Revisions have been issued since the original publication date.

Document

Source

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

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Document details

Type: Maintenance Manual
Year: 1987
File size: 40 MB
Publisher: mikeg.net
Language: en

About this document

What is the Piper Cherokee Service Manual?

The Piper Cherokee Service Manual is a maintenance manual for the PIPER PA-28-235, dated 1987.

Where does the Piper Cherokee Service Manual come from?

This copy of the Piper Cherokee Service Manual was originally published by mikeg.net and is hosted on Sprinkle as a free, searchable reference copy.

What year was the Piper Cherokee Service Manual published?

The Piper Cherokee Service Manual — the PIPER PA-28-235 maintenance manual on file — is dated 1987.

Documentation completeness

3/7

Most owners only have the POH. Here's the essential set for the PIPER PA-28-235.

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

More PIPER PA-28-235manuals & documents

In this document

Introduction

The introduction outlines the purpose of the service manual and its organization.

Handling

This section provides guidelines on the proper handling of the aircraft.

Inspection

Details the inspection procedures necessary for maintaining the aircraft.

Structures

Covers the structural components of the PA-28 series aircraft.

Landing Gear

Information on the landing gear systems and maintenance procedures.

Powerplant

Details regarding the engine and related systems for the PA-28R models.

Full document text

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 PIPER AIRCRAFT CORPORATION lA1 (PART NUMBER 753586) 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 replace- ments 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 Publication Date Aerofiche Card Effectivity ORG720816 August 16, 1972 --- CR810115 January 15, 1981 1,2, 3 and 4 PR810803 August 3, 1981 1, 2, 3 and 4 PR831003 October 3, 1983 1, 2, 3 and 4 PR840423 April 23, 1984 1, 2, 3 and 4 PR860115 January 15, 1986 1 and 3 IR860730 July 30, 1986 1 IR870506 June 12, 1987 1 IR950215* February 15, 1995 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 INTRODUCTION HANDLING INSPECTION TABLE OF CONTENTS AEROFICHE CARD NO.1 INTRODUCTION ............... STRUCTURES V........................ 2A8 VI...... . ........ (PA-28R) LANDING GEAR AND VIIA VIII POWERPLANT (PA-28R) VIIIA . ........ . . . IX . XI XIII XIV AEROFACE CARD NO.3 PLANT (PA-28R) AEROFACE CARD NO. NI ACCESSORIES AND UTILITIES 1A3 AIX IIIX 1A24 IX X 2A8 VIIIA 2K2 VIIA IIA IA A Al 4A8 II I 1A4 INTENTIONALLYLEFT BLANK PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 2-1. 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 2-2. Three View of Cherokee, PA-28-140, Serial Nos. 28-7225001 and up ...... ... ......... ............. B5 2-3. Three View of Cherokee, PA-28-150. -160. -180, Serial Nos. 28-1761 to 28-4377 incl ............... ......... ...... 1B6 2-4. Three View of Cherokee. PA-28-180, Serial Nos. 28-4378 to 28-7105244 inc .............. ............... lB7 2-5. Three View of Cherokee. PA-28-180, Serial Nos. 28-7205001 to 28-7205328 incl ......................................... B8 2-6. Three View of Cherokee. PA-28-180. Serial Nos. 28-7305001 and up ........................................ 1B9 2-7. Three View of Cherokee, PA-28-235. Serial Nos. 28-10000 to 28-11039 incl ..................... .. ...... ............ 1B10 2-8. Three View of Cherokee, PA-28-235. Serial Nos. 28-11040 to 28-7110042 incl......................................... 1B11 2-9. Three View of Cherokee, PA-28-235. Serial Nos. 28-7210001 to 28-7210033 incl ......................................... 1B12 2-10. Three View of Cherokee, PA-28-235. Serial Nos. 28-7310001 and up ........................................ IB13 2-11. 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 2-12. Three View of Cherokee, PA-28R-200, Serial Nos. 28-7235001 and up .......... .... ............ ......... IB15 2-13. 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 2-14. Station Reference Lines. PA-28-140, Serial Nos. 28-7225001 and up .................................................. IC 2-15. Station Reference Lines, PA-28-150, -160. -180, Serial Nos. 28-1761 to 28-4377 incl .................................. C6 2-16. Station Reference Lines, PA-28-180. Serial Nos. 28-4378 to 28-7105244 incl ....................................... IC7 2-17. Station Reference Lines. PA-28-180. Serial Nos. 28-7205001 to 28-7205328 incl ........................................ IC8 2-18. Station Reference Lines. PA-28-180, Serial Nos. 28-7305001 and up. IC9 2-19. Station Reference Lines. PA-28-235. Serial Nos. 28-10000

Show full text

to 28-11039 incl .......... ............................ 1C10 2-20. 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 Aerofiche Grid No. 2-21. Station Reference Lines, PA-28-235, Serial Nos. 28-7210001 to 28-7210033 incl ........................................ . 1C12 2-22. Station Reference Lines. PA-28-235, Serial Nos. 28-7310001 and up .................................................. 1C13 2-23. 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 .................. 1C14 2-24. Station Reference Lines, PA-28R-200, Serial Nos. 28-7235001 and up .................................................. IC15 2-25. Access Plates and Panels, PA-28-140 and Flite Liner. Serial Nos. 28-7225001 and up as noted ........................... 1C16 2-26. Access Plates and Panels, PA-28-150, -160, -180 .... .............. C17 2-27. Access Plates and Panels, PA-28-235 ................. .. ......... C18 2-28. Access Plates and Panels, PA-28R .............................. 1C19 2-29. Identification of Aircraft Fluid Lines ............................ 1D7 2-30. Torque Wrench Formula ...................................... 1C21 2-31. Removing Cherrylock Rivets ................................... 1D8 2-32. Jacking Arrangement ......................................... 1D9 2-33. Weighing Airplane ............................................. 1D10 2-34. Leveling Longitudinally ....................................... 1 2-35. Leveling Laterally ............................................ 1D11 2-36. Servicing Points, PA-28-140 ................................... 1D20 2-37. Servicing Points, PA-28-150,-160, -180 ....................... 1 2-38. Servicing Points, PA-28-235 ................................... 1D22 2-39. Servicing Points, PA-28R ..................................... 1d23 2-40. Main Gear Oleo Struts (Cutaway View), PA-28-140; PA-28-150,-160,-180; PA-28-235 ........................... 1D24 2-41. Fuel Strainer. PA-28-140; PA-28-150, -160, -180; and PA-28R...... 1E9 2-42. Fuel Selector and Filter, PA-28-235 ............................ 1E9 2-43. Lubrication Chart (Landing Gear, Main), PA-28-140, -150, -160, -180 and -235 ....................................... 1E17 2-44. Lubrication Chart (Landing Gear, Main), PA-28R-180 and -200 ............................................... E18 2-45. Lubrication Chart (Landing Gear, Nose), PA-28-140, -150. -160. -180 and -235 ....................................... 1E19 2-46. Lubrication Chart (Landing Gear, Nose), PA-28R-180 and -200 .... 1 2-47. Lubrication Chart (Control System) ............................ I E21 2-48. Lubrication Chart (Control System) (cont.) ...................... 1E22 2-49. Lubrication Chart (Control System) (cont.) ...................... 1E23 2-50. Lubrication Chart (Control System) (cont.) . ..................... 1E24 2-51. Lubrication Chart (Cabin Door. Baggage Door and Seat) ......... IF1 Revised: 8/3/81 1A6 PIPER CHEROKEESERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 2-52. Lubrication Chart (Power Plant, Propeller and Control Pivot Points) ....................... 1F2 2-53. Lubrication Chart (Back-Up Extender and Fuel Selector) ........................................1F3 2-54 Lubrication Chart (Air Conditioning Condenser) ...................................................... F4 3-1 Typical Muffler Fatigue Areas . ................................................... .................... 1F10 3-2 Exhaust System Inspection Points ............................................................................. 1F11 3-3 Exhaust System Inspection Points ............................................................................. F12 3-4 Exhaust System Installation, PA-28R-180,-200 ........................................................IF14 3-5 Control Wheel Inspection Points ...............................................................................1F15 3-6 Flap Control Cable Attachment Bolt Inspection........................................................ 1Fl6 3-7 Inspection of Main Landing Gear Torque Link ......................................................... 1Fl7 4-1 Aileron and Flap Installation ....................................................................................1G19 4-2 Wing Installation ..................................................................... 1G23 4-3 Methods of Securing Control Cables ........................................ .......... 1H7 4-4 Empennage Group Installation ................................................................................. 1H 4-5 Windshield Installation (Typical)............................... ..........................1H16 4-6 Side Window Installation, Single Pane (Typical) ......................................................1H18 4-7 Side Window Installation, Double Pane (Typical)....................................................1H18 4-8 Door Snubber Installation . ......................................................... 1H20 4-9 Seat Back Lock ........................................ .................. 1H24 4-10 Skin Materials and Thickness .................................................................................... 1I1 4-11 Surface Scratches, Abrasions or Ground-in-Dirt.......................................................1I8 4-12 Deep Scratches, Shallow Nicks and Small Holes ................... 1................... ............. 119 4-13 Mixing of Epoxy Patching Compound .................................................... 119 4-14 Welding Repair Method ............................................................................................. 4-15 Repairing of Cracks ...................................................................................................1I11 4-16 Various Repairs .......................................................................................................... 1I12 4-17 Repair of Stress Lines ...............................................................................................1I13 4-18 Repair of Impacted Damage ......................................................................................1I13 4-19 Control Surface Balance Tool ....................................................................................1I20 4-20 Aileron and Rudder Balance Configuration ..............................................................1Ii21 4-21 Stabilator Balance ......................................................................................................1122 4-22 Wing Rib Modification ..............................................................................................1I24 4-23 Balance Weight Assembly Installation ...................................................................... 1124 4-24 Fabricated Tool for Baggage Door Lock ................................................................... J 4-25 Additional Drain Holes in Stabilator ........................................................................1J2 4-26 Baggage Compartment Inspection Holes Cutout Details .......................................... J5 5-1 Control Column Assembly, PA-28-140,-150,-160, -180 and 235 .............................2A15 5-2 Control Column Assembly, PA-28R ..........................................................................2A16 5-3 Aileron Controls.........................................................................................................2A20 5-4 Bellcrank Rigging Tool, PA-28-140, -150, -160, -180, -235 .....................................2A23 5-5 Bellcrank Rigging Tool, PA-28R ...............................................................................2A23 Interim Revision: February 15, 1995 1A7 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 5-6. Aileron Rigging Tool ......................................... 2A24 5-7. Stabilator Rigging Tool ....................................... 2B3 5-8. Stabilator Controls ....................................... .... 2B4 5-9. Stabilator Trim Control (Overhead Control) ... ............. 2B8 5-10. Methods of Securing Trim Cables .............................. 2B10 5-11. Stabilator Trim Control (Floor Control) ......................... 2B18 5-12. Rudder and Steering Pedal Assembly ........................... 2B24 5-13. Rudder Controls ............................................. 2C4 5-14. Rudder Rigging Tool .................................... 2C5 5-15. Clamping Rudder Pedals ...................................... 2C5 5-16. Rudder and Stabilator Travel Adjustments ... ................... 2C6 5-17. Rudder Trim Control ......................................... 2C8 5-18. Flap Controls ................... ............................. 2C10 5-19. Flap Step Adjustment ......................................... 2C14 5-20. Flap Rigging Tool ............................................ 2C12 5-21. Fabricated Aileron Bellcrank Rigging Tool ...................... 2C15 5-22. Correct Method of Installing Rod End Bearings .................. 2C15 5-23. Fabricated Aileron and Flap Rigging Tool ....................... 2C16 5-24. Fabricated Stabilator Rigging Tool ............................. 2C17 5-25. Fabricated Rudder Rigging Tool ............................... 2C18 6-1. Schematic Diagram of Hydraulic System ... .............. 2D5 6-2. Hydraulic System Installation .................................. 2D6 6-3. Hydraulic Pump/Reservoir. Exploded View ...................... 2D10 6-4. Test and Adjustments of Hydraulic Pump ............. ............... 2D14 6-5. Pump Shock Mounts ......................................... 2D16 6-6. Checking Aligning Brackets of Gear Back-Up Extender Actuator ................................................ 2D 17 6-7. Gear Back-Up Extender Actuator .............................. 2D21 6-8. Nose Gear Actuator Cylinder .................................. 2E2 6-9. End Gland Locking Device .................................... 2E4 6-10. Main Gear Actuating Cylinder ................................. 2E5 6-11. Gear Back-Up Extender Actuator Aligning Tool .................. 2E20 7-1. Nose Gear Oleo Strut Assembly ................................ 2F2 7-2. Nose Gear Installation ........................................ 2F6 7-3. Clamping Rudder Pedals in Neutral Position ..................... 2F8 7-4. Rudder Pedals at Neutral Angle .. ........................ ... 2F8 7-5. Main Gear Oleo Strut Assembly. PA-28-140, -150, -160 and -180 ................................................ 2F13 7-6. Main Gear Oleo Strut Assembly, PA-28-235 ..................... 2F15 7-7. Main Gear Installation ... ........................ .......... 2F19 7-8. Nose Wheel Assembly ......................................... 2F21 7-9. Main Wheel Assembly ........................................ 2F23 Revised: 4 23/84 1A8 1A8 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 7-10. Wheel Brake Assembly ........................................ 2G1 7-11. Removal of Anchor Bolt ...................................... 2G2 7-12. Installation of Anchor Bolt .................................... 2G3 7-13. Brake Disc Minimum Thickness ................................ 2G5 7-14. Brake System Installation ..................................... 2G5 7-15. Brake Master Cylinder (Hand Brake). PA-28-150. -160. Serial Nos. 28-1 to 28-250 incl ............................. 2G8 7-16. 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 ............ 2G8 7-17. 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.......................................... 2G9 7-18. Parking Valve. PA-28-150. -160. Serial Nos. 28-1 to 28-250 incl ............................................... 2G11 7-19. Toe Brake Installation ........................................ 2G12 7-20. Brake Cylinder 10-20. 10-27. 17000 (Toe Brake) .................. 2G14 7-21. Brake Cylinder 10-30 (Toe Brake) .............................. 2G 15 7-22. Bleeding Brake (Gravity) ...................................... 2G 18 7-23. Bleeding Brake (Pressure) ......... ............................ 2G 18 7-24. Orifice Replacement Tool ..................................... 2G23 7-25. Retainer Ring Tool ........................................... 2G24 7A-I. Nose Gear Oleo Strut Assembly ............................... . 2H9 7A-2. Nose Gear Installation ........................................ 2H 12 7A-3. Nose Gear Adjustment (Without Gear Up Stop) .................. 2H 16 7A-4. Nose Gear Adjustment (With Gear Up Stop) ...... ............... 2H 17 7A-5. Clamping Rudder Pedals in Neutral Position ..................... 2H 19 7A-6. Rudder Pedals at Neutral Angle ................................ 2H19 7A-7. Nose Gear Door Retraction Mechanism ............. .............. 2H20 7A-8. Main Gear Oleo Strut Assembly ............................... . 211 7A-9. Main Gear Installation ....................................... 214 7A-10. Aligning Main Gear .......................................... 2110 7A-11. Adjustment of Nose Gear Down Limit Switch .................... 2115 7A-12. Adjustment of Main Gear Down Limit Switch ................... 2115 7A-13. Wiring Diagram of Landing Gear Electrical Circuit ............... 2117 7A- 14. Throttle Warning Switches .................................... 2119 7A-15. Nose Wheel Assembly.......................................... 2122 7A-16. Main Wheel Assembly ........................................ 2123 7A-17. Wheel Brake Assembly .................... ................... 2J1 7A-18. Brake Disc Minimum Thickness ................................ 2J3 Revised: 8 3 81 1A9 1A9 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 7A-19. Brake System Installation ..................................... 2J3 7A-20. Brake Master Cylinder (Hand Parking Brake) ................... 2J5 7A-21. Toe Brake Installation ........................................ 2J6 7A-22. Brake Cylinder (Toe Brake) (10-20. 10-27. 17000) ................. 2J8 7A-23. Brake Cylinder (Toe Brake) (10-30) ............................. 2J10 7A-24. Bearing Installation ........................................... 2J11 7A-25. Nose Gear Ser ice Tolerances. PA-28R .......................... 2J20 7A-26. Main Gear Service Tolerances. PA-28R ....... .................. 2J23 8-1. Typical Nicks and Removal Method ............................ 2K8 8-2. Propeller Installation (Constant Speed). PA-28-235 ............... 2K8 8-3. Propeller Installation ......................................... 2K9 8-4. Adjustment of Propeller Control. PA-28-235 ................... 2K 13 8-5. Propeller Governor. PA-28-235 ...... ....................... 2K 13 8-6. Engine Installation. PA-28-140. -150. -160. -180. Serial Nos. 28-1 to 28-1760 ............................... 2K16 8-7. Engine Installation. PA-28-140. -150. -160. -180. Serial Nos. 28-1761 and up...... ......... ............. 2K17 8-8. Engine Shock Mount Installation. PA-28-140. Serial Nos. 28-25000 and up ........................... .... 2K 18 8-9. Engine Installation. PA-28-235 ................................. 2K22 8-10. Adjustment of Engine Controls ................................. 2K24 8-11. Carburetor. PA-28-140. -150. -160 ............................ .. 2L3 8-12. Carburetor. PA-28-180. -235 ................................... 2L3 8-13. Magneto Inspection ........................................... 2L5 8-14. Contact Spring Inspection ..................................... 2L6 8-15. Impulse Coupling ............................................ 2L6 8-16. Magneto Timing Marks ....................................... 2L7 8-17. Timing Pointer .............................................. 2L7 8-18. Timing Kit Installed .......................................... 2L8 8-19. Breaker Compartment With Cast Timing Marks .................. 2L8 8-20. Removing Spark Plug Frozen to Bushing ........................ 2L13 8-21. Ignition Switch Wiring Positions ........................... .... 2L16 8A-1. Propeller Installation ......................................... 3A12 8A-2. Typical Nicks and Removal Method ............................ 3A13 8A-3. Propeller Governor ........................................... 3A16 8A-4. Engine Installation. PA-28R-180 ............................... 3A19 8A-5. Engine Installation. PA-28R-200 ............................... 3A21 8A-6. Adjustment of Engine Controls ................................. 3B1 8A-7. Fuel Injector ................................................. 3B3 8A-8. Schematic Diagram of RSA Fuel Injection System ................ 3B4 8A-9. Fuel-Air Bleed Nozzle ......................................... 3B6 8A-10. Contact Points ............................................... 3B8 Revised: 8 3 81 1A10 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 8A-11. Rotor Holding Tool Installed .................................. 3B10 8A-12. Timing Kit Installed ............. ..................... 3B10 8A-13. Aligning Timing Marks ....................................... 3B11 8A-14. Checking Flyweight Clearance of Impulse Coupling ............. 3B12 8A-15. Engine Timing Marks . ................. . ..................... 3B13 8A-16. Magneto Adjustment Limits . .............................. . 3B14 8A-17. Magneto Timing Marks . ...................................... 3B14 8A-18. Removing Spring From Lead Assembly . . ............ 3B16 8A-19. Assembly Tool . .............................................. 3B16 8A-20. Using Assembly Tool ......................................... 3B 17 8A-21. Measuring Lead Assembly Length . ............................. 3B17 8A-22. Cutting Metallic Braid From End of Lead ....................... 3B18 8A-23. Unbraiding Metallic Shielding ................................ 3B18 8A-24. Forming Shielding Around Ferrule ...... .......... ....... 3B19 8A-25. Ferrule Seating Tool .... ... ... ..... .............. 3B19 8A-26. Needle ...................................................... 3B19 8A-27. Measuring Wire From Top of Ferrule . . ................ 3B20 8A-28. Installing Grommet Over Lead Assemblies ... ............. 3B20 8A-29. Lead Assembly Installed in Grommet . .......................... 3B20 8A-30. Wire Doubled Over For Installation of Eyelet ..... ............. 3B20 8A-31. Removing Spark Plug Frozen to Bushing ........ .............. 3B22 8A-32. Ignition Switch Wiring Positions . .............................. 3B24 9-1. Fuel System Diagram, PA-28-140, -150, -160. -180 ... .......... . 3CII 9-2. Fuel System Diagram. PA-28-235. Serial Nos. 28-10003 to 28-10719 inc ........................................... 3C12 9-3. Fuel System Diagram. PA-28-235. Serial Nos. 28-10720 and up.... 3C13 9-4. Fuel System Diagram. PA-28R................................. 3C14 9-5. Deleted ..................... 9-6. Fuel Quantity Transmitter (P N 62037-00) ......... . 3C21 9-7. Fuel Quantity Transmitter (P/N 68101-00) . ...................... 3C21 9-8. Fuel Selector and Filter. PA-28-235 . ............................ 3C24 9-9. Fuel Filter. PA-28-235 ...... ................... 3DI 9-10. Fuel Filter Bowl and Screen. PA-28-140, -150, -160, -180 and PA-28R............................................. 3D3 9-11. Plunger Fuel Pump (Early). PA-28-150, -160, -180 . .......... 3D6 9-12. Plunger Fuel Pump (Late), PA-28-140, -150, -160. -180, -235 ....... 3D6 9-13. Engine Primer ............................................... 3D12 9-14. Fabricated Fuel Quantity Transmitter Checking Jig . ............. 3D17 10-1. Instrument Panel, PA-28-140, Serial Nos. 28-25000 to 28-26956 incl.......................... .................. 3E4 10-2. Instrument Panel. PA-28-140, Serial Nos. 28-7125001 to 28-7325684 inc . .......................................... 3E5 Revised: 8/3/81 lA11 1All PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 10-3. Instrument Panel. PA-28-140. Serial Nos. 28-7425001 and up ...... 3E6 10-4. Instrument Panel ............................................. 3E7 10-5. Instrument Panel. PA-28-150. -160. -180. Serial Nos. 28-1761 to 28-4377 incl ........................................... 3E8 10-6. Instrument Panel. PA-28-180. Serial Nos. 28-4378 to 28-7205328 incl .......................................... 3E9 10-7. Instrument Panel. PA-28-180. Serial Nos. 28-7305001 to 28-7305611 incl .......................................... 3E10 10-8. Instrument Panel. PA-28-180. Serial Nos. 28-7405001 and up ...... 3E11 10-9. Instrument Panel. PA-28-235. Serial Nos. 28-10720 to 28-11039 inc ............................................. 3E12 10-10. Instrument Panel. PA-28-235. Serial Nos. 28-11040 to 28-7210033 inc ........................................... 3E13 10- 11. Instrument Panel. PA-28-235. Serial Nos. 28-7310001 to 28-7310187 incl .......................................... 3E14 10-12. Instrument Panel. PA-28-235. Serial Nos. 28-7410001 and up...... 3E15 10-13. Instrument Panel. PA-28R-180. Serial Nos. 28-30005 to 28-30879 incl ............................................ 3E16 10-14. 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 .......................................... 3E17 10-15. Instrument Panel. PA-28R-200. Serial Nos. 28-7235001 to 28-7335455 incl .......................................... 3E18 10-16. Instrument Panel. PA-28R-200. Serial Nos. 28-7435001 and up..... 3E19 10-17. Warning Light Pressure Switch ................................. 3E23 10-18. Typical Pitot Static System. PA-28-140. -150. -160. -180. -235. PA-28R-180 and 200...................................... 3F4 10-19. EGT Probe Location. PA-28R-180 and 200 ...................... 3F24 10-20. EGT Probe Location. PA-28-235 ............................... 3GI 10-21. EGT Probe Location. PA-28-150. -160. -180. S N 1761 and up..... 3G2 11-1. Generator and Starter System .................................. 4A 18 11-2. Generator Wiring Diagram .................................... 4A19 11-3. Sectional View of Generator ................................... 4A22 11-4. Current Voltage Regulator ............................. 4B7 11-5. Use of Riffler File to Clean Contact Points ...................... 4B10 11-6. Voltage Regulator Air Gap ....................... 4B 10 11-7. Checking Voltage Setting Fixed Resistance Method ............... 4B 11 11-8. Checking Voltage Setting Variable Resistance Method ............ 4B I 11-9. Adjusting Voltage Regulator Setting ............................ 4B 12 11-10. Cutout Relay Air Gap Check and Adjustment ................... 4B14 11-11. Cutout Relay Point Opening Check and Adjustment .............. 4B14 Revised: 8 3 81 1A12 1A12 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-12. Checking Cutout Relay Closing Voltage ......................... 4B15 11-13. AdJustment of Cutout Relay Closing Voltage .................. 4B15 11-14. Checking Current Regulator. Load Method ...................... 4B16 11-15. Checking Current Regulator. Jumper Lead Method ............... 4B16 11-16. 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 ............ 4B20 11-17. 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............ 4B21 11-18. Lamp-Bank Load .......... ................................. 4B23 11-19. Checking Field Circuit ...... .................................. 4B24 11-20. Testing Field Circuit .......................................... 4B24 11-21. Testing Rectifiers (Positixe) .................................... 4C2 11-22. Testing Rectifiers (Negative) ................................... 4C3 11-23. C-3928 Fixtures and Adapters .................................. 4C4 11-24. Removing Rectifiers ..... .............................. ..... 4C4 11-25. Installing Rectifiers ..... ...................................... 4C5 11-26. Soldering Rectifier Lead ....................................... 4C6 11-27. Testing Stator Coils ......................................... 4C7 11-28. Removing End Bearing ........................................ 4C9 11-29. Installing End Bearing ..... ............................ .... 4C9 11-30. Removing Drive Pulley ....................................... 4C10 11-31. Removing Drive End Bearing .................................. 4C10 11-32. Removing Slip Ring ...................... .................. 4C 11 11-33. Aligning Slip Ring .......................................... 4C11 11-34. Installing Slip Ring ........................................... 4C12 11-35. Installing Retainer ........................................... 4C12 11-36. Solder Points ................................................ 4C13 11-37. Installing Drive End Shield and Bearing (Typical) ................ 4C14 11-38. Installing Pulley ..................... ...................... 4C 14 11-39. Meter Connections for Alternator Performance Test .............. 4C17 11-40. Voltage Regulator ............................................ 4C19 11-41. Checking Air Gap ............................................ 4C19 11-42. Voltage Regulator Fusible Wires ............................... 4C20 11-43. Voltage Regulator Resistance Units ............................. 4C20 11-44. No-Load Test Hookup ........................................ 4D2 11-45. Lock Torque Test Hookup ................................... 4D3 11-46. Resistance Test Hookup ....................................... 4D3 Revised: 8 3 81 1A13 1A13 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-47. Exploded View of Gear Reduction Starting Motor ................ 4D8 11-48. Turning Starting Motor Commutator ........................... 4D I 11-49. Testing Motor Armature for Shorts ............................. 4D I 11-50. Testing Motor Field for Grounds ............................. 4D I 11-51. No-Load Test Hookup ..... . ....................... 4D13 11-52. Stall Torque Hookup ......................................... 4D13 11-53. Terminal Block ............................................ 4F5 11-54. For Index to these Figures, see Table XI-I, Index - Electrical 4F11 thru System Schematics thru 11-70. 4G17 11-71. Exploded View of Alternator .................................. 4D20 11-72. Removal of Slip Ring End Bearing ............................. 4D21 11-73. Removal of Rectifier .......................................... 4D21 11-74. Removal of Drive End Head .................................. 4D22 11-75. Removal of End Head Bearing ................ .... .. ..... 4D22 11-76. Testing Rotor for Ground ..................................... 4D23 11-77. Testing Rotor for Shorts ..................................... 4D23 11-78. Installation of Bearing ..................................... 4D24 11-79. Installation of Rectifier ....................................... 4D24 11-80. Terminal Assembly ........................................... 4E I 11-81. Slip Ring End Bearing Assembly ............................... 4E2 11-82. Testing Alternator ............................................ 4E2 11-83. Brush Installation ............................................ 4E3 11-84. Internal Wiring Diagram ...................................... 4E3 11-85. For Index to these Figures. see Table XI-I, Index - Electrical 4G20 thru System Schematics thru 11-143. 4H 24 11-144. Strobe Light Connections ..................................... 4E9 12-1. Two Year Magnesium Battery Connections ......... ......... 413 12-2. Five Year, Lithium Battery Connections ... .... .................. 414 12-3. Communications Components ELT Schematic ................... 4111 13-1. 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 ............... ... .................. 4117 13-2. Cabin Heater. Defroster and Fresh Air System, PA-28-140, Serial Nos. 28-25000 and up ..................... 4118 13-3. Cabin Heater. Defroster and Fresh Air System, PA-28-150. -160, -180. Serial Nos. 28-1761 to 28-2477 incl .............................................. 4119 Revised: 10 3,83 lA14 1A14 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 13-4. Cabin Heater. Defroster and Fresh Air System. PA-28-150. -160. -180, Serial Nos. 28-2478 to 28-4377 incl.............................................. 4120 13-5. Cabin Heater. Defroster and Fresh Air System. PA-28-180. Serial Nos. 28-4378 and up ...................... 4121 13-6. Cabin Heater. Defroster and Fresh Air System. PA-28-235. Serial Nos. 28-10003 to 28-10675 incl ............ 4122 13-7. Cabin Heater. Defroster and Fresh Air System. PA-28-235. Serial Nos. 28-10676 to 28-11039 incl ............ 4123 13-8. Cabin Heater. Defroster and Fresh Air System, PA-28-235. Serial Nos. 28-11040 to 28-7210033 incl. .......... 4124 13-9. Cabin Heater. Defroster and Fresh Air System. PA-28-235. Serial Nos. 28-7310001 and up................... 4.11 13-10. Cabin Heater. Defroster and Fresh Air System. PA-28R ................................................. 4J2 13-11. Overhead Vent System. ........................................ 4.13 14-1. Air Conditioning System Installation ............................ 4J7 14-2. Service Valves ............................................... 4J 12 14-3. Test Gauge and Manifold Set .................................. 4J13 14-4. Manifold Set Operation ....................................... 4J 14 14-5. Leak Test Hookup ........................................... 4.115 14-6. Evacuation Hookup .......................................... 4J 17 14-7. Charging Stand ...... ........................................ 4J 19 14-8. Charging Hookup ...................................... ...... 4J21 14-9. Compressor and Fabricated Oil Dipstick .......................... 4K I 14-10. Compressor and Alternator Belt Installation ..................... 4K5 14-11. Magnetic Clutch ............................................. 4K7 14-12. Condenser Air Scoop Installation ............................ 4K11 14-13. Expansion Valve ............................................. 4K13 14-14. Components Installation ...................................... 4K15 14-15. 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 .................. 4K16 14-16. 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........ 4K18 Revised: 10 3 83 1A15 1A15 PIPER CHEROKEE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure 14-17. 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........ 14-18. 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 Aerofiche Grid No. 4K19 4K20 PIPER CHEROKEE SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. 11-I. Leading Particulars and Principal Dimensions ................. IB16 11-11. Consumable Materials ......... ............................. IC3 11-111. Recommended Nut Torques ................................. 1C22 II-IV. Deleted ........................................ 1l-V. Conversion Tables .......................................... IC24 II-VI. Decimal Millimeter Equivalents of Drill Sizes ........................ ID5 II-VII. Maximum Distance Between Supports for Fluid Tubing ......... D6 II-VIII. Hose Clamp Tightening .................................... ID6 II-IX. Recommended Engine Lubricating Oils ....................... IE 15 II-X. Thread Lubricants .................................... ...... 1E15 II-XI. Summary of Recommended Lubricants used on PA-28 Series Aircraft ......................................... E16 111-I. Inspection Report, PA-28-140. -150. -160. -180; PA-28-235 ..................... ........................ 1F18 111-11. Inspection Report. PA-28R .................................. IG3 IV-I. List of Materials (Thermoplastic Repair) ...................... 117 IV-II. Balancing Specifications ................................. .... 1117 V-l. Control Surface Travel and Cable Tension .................... 2A 11 V-ll. Cable Tension Vs. Ambient Temperature ...................... 2A13 V-Ill. Troubleshooting Chart (Surface Controls) ..................... 2C19 VI-1. Leading Particulars. Hydraulic System ........................ 2D8 VI-lI. Characteristics, Hydraulic Pump Motor ....................... 2D13 VI-III. Hydraulic System Troubleshooting ........................... 2E9 VII-I Nose Gear Alignment Tolerances ............................. 2F9 VII-II. Landing Gear Troubleshooting ............................... 2G20 VIIA-I. Landing Gear Troubleshooting ............................... 2J 12 VIIA-II. PA-28R Nose Gear Service Tolerances ....................... 2J21 VIIA-III. PA-28R Main Gear Service Tolerances ........................ 2J24 VIII-I. Propeller Torque Limits ..................................... 2K10 VIII-II. Engine Troubleshooting Chart ............................... 2L17 VIIIA-I. Engine Troubleshooting Chart ........................... .... 3CI IX-1. Transmitter/Fuel Gauge Tolerances .......................... 3C20 IX-II. Fuel Quantity Transmitter Calibration Tolerances .............. 3C21 IX-III. Fuel System Troubleshooting ............................... 3D15 X-l. Vacuum System ............................................ 3D24 X-ll. Directional Gyro Indicator .................................. 3F5 Revised: 8 3 81 1A17 1A17 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. 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 Aerofiche Grid No. ....................... 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. 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 ... ... . 1A20 ... ..1A20 ... . 1A20 ... . 1A20 ... ..1A20 ... . 1A21 . 1A21 .... A21 .... A21 . .. 1A21 1A21 .... 1A21 ..... 1A21 ... . 1A22 ... . 1A22 . .. 1A22 .. 1A22 Reissued:1/15/81 1A19 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. 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. Revised: 1/15/86 INTRODUCTION 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. Revised: 10 3 83 INTRODUCTION 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 Aerofiche Grid No. 2-1. Introduction ......... ........................................ 1B3 2-2. Dimensions .................................................. 1B3 2-3. Station Reference Lines ....................................... 1B3 2-4. Weight and Balance Data ..................................... 1B3 2-5. Serial Number Plate .......................................... 1C20 2-6. Access and Inspection Provisions ............................... 1C20 2-7. Tools and Test Equipment ..................................... 1C20 2-8. Torque Requirements ......................................... IC20 2-8a. Torque Wrenches ............................................. 1C21 2-9. Walkway. Handhold and Step ................................. C24 2-10. Removal of Cherrylock Rivets ................................. 1D8 2-11. Ground Handling ........................................... 1D9 2-12. Introduction to Ground Handling ...................... 1D9 2-13. Jacking ............................................. D9 2-14. Weighing ........................................... ID10 2-15. Leveling ............................................ ID10 2-16. Mooring............................................ 1D11 2-17. Locking Airplane .................................... 1D12 2-18. Parking ............................................ 1D12 2-19. Towing ............................................. D13 2-20. Taxiing .......................... ................ 1D13 2-21. External Power Receptacle .................................... 1D13 2-22. Operation of External Power Receptacle ................ ID13 2-23. Cleaning .................................................... 1D14 2-24. Cleaning Engine Compartment ........................ 1D14 2-25. Cleaning Landing Gear ............................... D 15 2-26. Cleaning Exterior Surfaces............................ 1D15 2-27. Cleaning Windshield and Windows .................... ID15 2-28. Cleaning Headliner, Side Panels and Seats.............. 1D16 2-29. Cleaning Carpets .................................... D 16 2-30. Servicing.................................................... D 16 2-31. Introduction to Servicing ............................. 1D16 2-32. Hydraulic System (PA-28R) ................................... 1D16 2-33. Servicing Hydraulic System ........................... 1D16 2-34. Servicing Hydraulic Pump / Reservoir ................... 1D17 Revised: 8/3/81 A24 1A 24 PIPER CHEROKEE SERVICE MANUAL Paragraph 2-35. Landing Gear System ................................... 2-36. Servicing Landing Gear ........................ 2-37. 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 .............. 2-42. Oleo Struts (PA-28R) ...................... 2-43. Servicing Oleo Struts ............. 2-44. Filling Oleo Struts ................ 2-45. Inflating Oleo Struts .............. 2-46. Brake System ............................. 2-47. Servicing Brake System............ 2-48. Filling Brake Cylinder Reservoir.... 2-49. Draining Brake System............ 2-50. Tires..................................... 2-51. Servicing Tires ................... 2-52. Power Plant.............................. 2-53. Servicing Power Plant............. 2-54. Induction Air Filter . ................... 2-55. Removal of Air Filter ............. 2-56. Service Instruction (Cleaning and Ins 2-57. Installation of Air Filter .......... pection)............ ............. 2-58. Propeller. 2-58. Propeller .................................................... 2-59. Servicing Propeller................................. 2-60. 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 ............................. 2-68. Electrical System 2-68. Electrical System ............................................. 2-69. Ser icing Electrical System ............................ 2-70. Lubrication .................................................. 2-71. Oil System (Engine) .......................................... 2-72. Servicing Oil System ................................. 2-73. Filling Oil Sump .................................... Reissued: 1/15/81 1B1 Aerofiche Grid No. 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. Draining Oil Sump .......... IE12 Oil Screens. (Suction.) .. . ... 1E12 Oil Screen. (Pressure.) ....... 1E12 Oil Filter. (Full Flow.) ....... IE12 Recommendations for Changing Oil . E13 Lubrication Instructions . ...... 1E13 Application of Oil .......... IE13 Application of Grease ........ IE14 Winterization Plate ......... 1E14 Lubrication Chart . . . .... . 1E14 Reissued:1/15/81 2-74. 2-75. 2-76. 2-77. 2-78. 2-79. 2-80. 2-81. 2-82. 2-83. IB2 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 vari- ous 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. Sta- tion 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 stab- ilizer 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 sec- tion. 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 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 Reissued: 1/15/81 HANDLING AND SERVICING 1B4 C329 63.75" - I PIPER CHEROKEE SERVICE MANUAL 862 *1974 MODELS AND UP Figure 2-2. Three-View of Cherokee 140 PA-28-140, SerialNos. 28-7225001 and up Reissued: 1/15/81 HANDLING AND SERVICING 1B5 30' 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 Reissued: 1/15/81 Figure 2-6. Three-View of Cherokee PA-28-180, Serial Nos. 28-7305001 and up 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. Reissued: 1/15/81 HANDLINGAND SERVICING 1BlO PIPER CHEROKEE SERVICE MANUAL 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 182B I PIPER CHEROKEE SERVICE MANUAL C330 Reissued: 1/15/81 Figure 2-9. Three-View of Cherokee PA-28-235, SerialNos. 28-7210001 to 28-7210033 incl. HANDLING AND SERVICING 1B12 PIPER CHEROKEE SERVICE MANUAL Figure 2-10. Three-View of Cherokee PA-28-235, Serial Nos. 28-7310001 and up Reissued: 1/15/81 HANDLING AND SERVICING 1B13 886 *1974 MODELS AND UP PIPER CHEROKEE SERVICE MANUAL 1796 30' Figure 2-11. Three-View of CherokeePA-28R-180,Serial Nos. 28-30005 to 28-7130019 incl. PA-28R-200,SerialNos. 28-30482 to 28-7135238 incl. Reissued: 1/15/81 HANDLINGAND SERVICING 1B14 PIPER CHEROKEESERVICEMANUAL 1796 *1974 MODELS AND Up 32' 2.32" 74.00" <1 72.50" Reissued: 1/15/81 Figure 2-12. Three-View of Cherokee PA-28R-200, SerialNos. 28-7235001 and up HANDLING AND SERVICING 1B15 5' 3.0" 7° DIHEDRAL 11.83" PIPER CHEROKEE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS PA-28-140 Avco-Lycoming O-320-E2A or O-320-E3D 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 Refer to Grid IC2 for foot Notes: Revised: 10 3 83 274 140 or 150 2450 RPM - 2700 RPM See Table II-IX 8 U.S. quarts 80/87 80/87 See Note 37 Scintilla or Slick S4LN-21 or 4051 S4LN-204 or 4050 25° BTC 0.018 + 0.006 1-3-2-4 1109657 MZ4204 2098615 or 2642996 2098613 or 87-87102-21 32 2642997 or 2642210 X16300B X16799B ALY-6422 31 X16300B Plunger Sensenich M74DM HANDLING AND SERVICING 1B16 MODEL ENGINE Manufacturer Model

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