Piper Aircraft PA-28-161 Cadet Airplane Maintenance Manual

2-10. Fuel Strainer...........................................................................................................................1B22 2-11. Lubrication Chart...................................................................................................................1C3 2-12. Cherrylock Rivet Removal.................................................................................................... 1C17 2-13. Identification of Aircraft Fluid Lines.....................................................................................1C18 2-14. Torque Wrench Formula........................................................................................................1C19 3-1. Inspection Areas of Exhaust System......................................................................................1D17 3-2. Typical Muffler Fatigue Areas...............................................................................................1D17 4-1. Aileron and Flap Installation................................................................................................. 1E12 4-2. Wing Installation....................................................................................................................1E13 4-3. Methods of Securing Control Cables.....................................................................................1E18 4-4. Empennage Group Installation.............................................................................................. 1E20 4-5. Windshield Installation (Typical)...........................................................................................1E23 4-6. Side Window Installation (Typical).......................................................................................1E24 4-7. Door Snubber Installation......................................................................................................1F3 4-8. Seat Back Lock......................................................................................................................1F4 4-9. Skin Materials and Thickness................................................................................................1F9 4-10. Typical Access Plates.............................................................................................................1F10 4-11. Control Surface Balance Tool................................................................................................1F11 4-12. Aileron Balance..................................................................................................................... 1F12 4-13. Rudder Balance......................................................................................................................1F13 4-14. Rudder Balance Weight......................................................................................................... 1F14 4-15. Stabilator Balance..................................................................................................................1F15 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL 1A5 LIST OF ILLUSTRATIONS (cont) Figure Aerofiche Grid No. 5-1. Control Column Assembly.....................................................................................................1G2 5-2. Correct Method of Installing Rod End Bearings................................................................... 1G3 5-3. Aileron Controls.....................................................................................................................1G5 5-4. Bellcrank Rigging Tool..........................................................................................................1G9 5-5. Stabilator Controls.................................................................................................................1G12 5-6. Stabilator Rigging Tool..........................................................................................................1G13 5-7. Stabilator Trim Controls........................................................................................................ 1G16 5-8. Methods of Securing Trim Cables.........................................................................................1G17 5-9. Rudder and Steering Pedal Assembly....................................................................................1G20 5-10. Rudder Controls.....................................................................................................................1G22 5-11. Rudder Rigging Tool..............................................................................................................1G23 5-12. Clamping Rudder Pedals........................................................................................................1G23 5-13. Rudder and Stabilator Travel Adjustment............................................................................. 1G24 5-14. Rudder Trim Control..............................................................................................................1H2 5-15. Flap Control System.............................................................................................................. 1H4 5-16. Flap Stop Adjustment............................................................................................................ 1H6 5-17. Flap Rigging Tool..................................................................................................................1H6 5-18. Fabricated Rudder Rigging Tool............................................................................................1H11 5-19. Fabricated Stabilator Rigging Tool........................................................................................1H12 5-20. Fabricated Flap Rigging Tool................................................................................................ 1H13 7-1. Nose Gear Oleo Strut Assembly............................................................................................1H21 7-2. Nose Gear Installation............................................................................................................1IH24 7-3. Clamping Rudder Pedals in Neutral Position........................................................................ 1I2 7-4. Rudder Pedals at Neutral Angle.............................................................................................1I2 7-5. Main Gear Oleo Strut Assembly............................................................................................1I4 7-6. Main Gear Installation...........................................................................................................1I6 7-7. Nose Wheel Assembly...........................................................................................................1I9 7-8. Main Wheel Assembly...........................................................................................................1I10 7-9. Wheel Brake Assembly..........................................................................................................1I12 7-10. Removal of Anchor Bolt........................................................................................................1I13 7-11. Installation of Anchor Bolt....................................................................................................1I13 7-12. Brake System Installation......................................................................................................1I15 7-13. Brake Master Cylinder (Hand/Parking Brake)...................................................................... 1I16 7-14. Brake Cylinder (Toe Brake)...................................................................................................1I21 7-15. Retainer Ring Installation Tool..............................................................................................1I24 8-1. Typical Nicks and Removal Method......................................................................................1J7 8-2. Propeller and Cowling Installation........................................................................................1J8 8-3. Engine Installation.................................................................................................................1J10 8-4. Engine Shock Mount Installation...........................................................................................1J12 8-5. Adjustment of Engine Controls............................................................................................. 1J13 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL 1A6 LIST OF ILLUSTRATIONS (cont) Figure Aerofiche Grid No. 8-6. Carburetor..........................................................................................................................1J15 8-7. T-100 Assembly and Timing Tool Kit...............................................................................1J21 8-8. Exploded View of Magneto...............................................................................................1J22 8-9. Removing Coil Wedges.....................................................................................................1J22 8-10. Index Plate and Timing Plug............................................................................................. 1J24 8-11. Installation of Bearings and Bearing Plate........................................................................1J24 8-12. Position of Magneto on T100 Too1 and oil seal Installation.............................................1K1 8-13. Timing Magneto Internally and Assembly........................................................................1K2 8-14. Stripping Tool....................................................................................................................1K6 8-15. Inserting Stripping Tool.....................................................................................................1K6 8-16. Cutting Insulation..............................................................................................................1K6 8-17. Removing Silicone Rubber from Wire..............................................................................1K6 8-18. Installation of Plug End Nut..............................................................................................1K7 8-19. Flaring Out of Shielding....................................................................................................1K7 8-20. Installation of Ferrule........................................................................................................ 1K7 8-21. Driving Tool...................................................................................................................... 1K7 8-22. Installation in Housing...................................................................................................... 1K8 8-23. Securing Wire in Housing................................................................................................. 1K8 8-24. Installation of Electrical Screw..........................................................................................1K9 8-25. Installation of Insulation Sleeve........................................................................................1K9 8-26. Installation of Spring.........................................................................................................1K9 8-27. Removing Spark Plug Frozen to Bushing.........................................................................1K9 8-28. Ice Detection System.........................................................................................................1K13 9-1. Fuel System Diagram........................................................................................................2A12 9-2. Tolerances. Union Nut and Tubing Nut.............................................................................2A15 9-3. Fuel Quantity Transmitter Checking Jig............................................................................2A17 9-4. Fuel Quantity Indicators....................................................................................................2A17 9-5. Locking Fuel Cap.............................................................................................................. 2A18 9-6. Fuel Filter Bowl and Screen..............................................................................................2A19 9-7. Plunger Fuel Pump............................................................................................................2A21 9-8. Engine Primer....................................................................................................................2A23 9-9. Fabricated Fuel Quantity Transmitter Checking Jig..........................................................2B3 10-1. Instrument Panel................................................................................................................2B12 10-2. Pitot-Static System............................................................................................................ 2B16 10-3. Auxiliary Vacuum System.................................................................................................2B20 10-4. Engine Oil Pressure Gauge................................................................................................2C5 10-5. Fuel Pressure Gauge..........................................................................................................2C6 10-6. Oil Temperature Gauge..................................................................................................... 2C10 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL 1A7 LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-1 Instrument Panel (Circuit Breaker Panel)..............................................................................2C21 11-2. Lamp Bank Load....................................................................................................................2C22 11-3. Exploded View of Alternator.................................................................................................2C24 11-4. Removal of Rectifier..............................................................................................................2D3 11-5. Removal of Slip Ring End Bearing....................................................................................... 2D3 11-6. Removal of Drive End Head..................................................................................................2D3 11-7. Removal of End Head Bearing..............................................................................................2D3 11-8. Testing Rotor for Grounds.....................................................................................................2D4 11-9. Testing Rotor for Shorts.........................................................................................................2D4 11-10. Installation of Bearing............................................................................................................2D5 11-11. Installation of Rectifier.......................................................................................................... 2D5 11-12. Terminal Assembly................................................................................................................ 2D5 11-13. Slip Ring End Bearing Assembly.......................................................................................... 2D6 11-14. Testing Alternator...................................................................................................................2D6 11-15. Brush Installation...................................................................................................................2D7 11-16. Internal Wiring Diagram........................................................................................................2D7 11-17. Battery Box............................................................................................................................2D12 11-18. Application of Overvoltage Control......................................................................................2D14 11-19. Exploded View of Gear Reduction Starter Motor..................................................................2D15 11-20. Turning Motor Commutator...................................................................................................2D17 11-21. Testing Motor Armature for Shorts........................................................................................2D17 11-22. Testing Motor Fields for Grounds..........................................................................................2D18 11-23. No Load Test Hookup............................................................................................................2D18 11-24. Stall Torque Hookup..............................................................................................................2D19 11-25. Strobe Light Connections (With Fin Strobe).........................................................................2D23 11-26. Strobe Light Connections (With Rotating Beacon)...............................................................2D24 11-27. Ignition Switch.......................................................................................................................2E4 11-28. Annunciator............................................................................................................................2E19 11-29. Annunciator Internal Wiring..................................................................................................2E20 11-30. Pitot Static Heat.....................................................................................................................2E21 11-31. Alteernator..............................................................................................................................2E22 11-32. Avionics Master Switch (Optional)....................................................................................... 2E23 11-33. Starter.....................................................................................................................................2E24 11-34. Battery Master Switch............................................................................................................2F1 11-35. Air Blower..............................................................................................................................2F2 11-36. Fuel Pump..............................................................................................................................2F3 11-37. Clock, Electrical and Digital (Optional)................................................................................2F4 11-38. Engine Gages.........................................................................................................................2F5 11-39. Hourmeter (Optiuonal).......................................................................................................... 2F6 11-40. Turn and Bank........................................................................................................................2F7 11-41. Anti - Collision, Strobe Lights (Wing).................................................................................. 2F8 11-42. Anti - Collision, Strobe Lights (Tail).....................................................................................2F9 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL 1A8 LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 11-43. Recognition Lights (Optional)............................................................................................ 2F10 11-44. Instrument Flood Lights......................................................................................................2F11 11-45. Navigation Lights................................................................................................................2F12 11-46. Landing Light......................................................................................................................2F13 11-47. Instrument Panel and Switch Lights....................................................................................2F14 11-48. Pitch Trim............................................................................................................................2F15 11-49. Stall Warning.......................................................................................................................2F16 11-50. Optional Avionics................................................................................................................2F17 12-1. ELT Portable Folding Antenna............................................................................................2F24 12-2. ELT Using Fixed Aircraft Antenna.....................................................................................2F24 12-3. ELT Schematic.................................................................................................................... 2G1 12-4. Avionics Master and Emergency Switch Circuit.................................................................2G4 13-1. Cabin Heater, Defroster and Fresh Air System...................................................................2G11 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL 1A9 LIST OF TABLES Table Aerofiche Grid No. II-I Leading Particulars and Principal Dimensions................................................................... 1A22 II-II Recommended Torques.......................................................................................................1B4 II-IIA Flare Fitting Torques...........................................................................................................1B7 II-IIB Type of Lubricants...............................................................................................................1C1 II-IIC Types of Metal Corrosion....................................................................................................1C13 II-III List of Consumable Materials............................................................................................. 1C20 II-1V Conversion Tables...............................................................................................................1D3 II-V Thread Lubricants................................................................................................................1D7 II-VI Hose Clamp Tightening.......................................................................................................1D7 II-VII Maximum Distance Between Supports For Fluid Tubing...................................................1D8 II-VIII Decimal-Millimeter Equivalents of Drill Sizes.................................................................. 1D9 III-I Inspection Report................................................................................................................ 1D18 IV-I Balancing Specifications.....................................................................................................1F7 V-I Control Surface Travel and Cable Tension..........................................................................1F24 V-II Cable Tension vs. Ambient Temperature............................................................................ 1G1 V-III Troubleshooting Chart (Surface Controls)..........................................................................1H7 VII-I Landing Gear Troubleshooting............................................................................................1I22 VIII-I Propeller Torque Limits.......................................................................................................1J8 VIII-II Engine Troubleshooting...................................................................................................... 1K15 IX-I Transmitter/Fuel Gauge Tolerances.....................................................................................2A16 IX-II Fuel Quantity Transmitter Calibration Tolerance................................................................2A16 IX-III Fuel System Troubleshooting..............................................................................................2B1 X-I Vacuum System...................................................................................................................2B13 X-II Directional Gyro Indicator...................................................................................................2B21 X-III Gyro Horizon Indicator....................................................................................................... 2B22 X-IV Rate of Climb Indicator.......................................................................................................2B23 X-V Altimeter..............................................................................................................................2B24 X-VI Airspeed Tubes and Indicator..............................................................................................2C2 X-VII Magnetic Compass .............................................................................................................2C3 X-VIII Tachometer.......................................................................................................................... 2C4 X-IX Engine Oil Pressure Gauge..................................................................................................2C5 X-X Fuel Pressure Gauge............................................................................................................2C7 X-XI Turn and Bank Indicator......................................................................................................2C8 X-XII Fuel Quantity Indicator........................................................................................................2C9 X-XIII Oil Temperature Indicator................................................................................................... 2C11 XI-I Index Electrical System Schematics....................................................................................2C19 XI-II Alternator Specifications.....................................................................................................2D8 XI-III Alternator Belt Tension.......................................................................................................2D8 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL 1A10 LIST OF TABLES (cont.) Table Aerofiche Grid No. XI-IV Hydrometer Reading and Battery Charge Percent.............................................................. 2D10 XI-V Starting Motor Specifications..............................................................................................2D20 XI-VI Troubleshooting Chart (Electrical System).........................................................................2E6 XI-VII Lamp Replacement Guide...................................................................................................2E15 XI-VIII Electrical System Component Loads.................................................................................. 2E16 XI-IX Electrical Wire Coding........................................................................................................2E17 XI-X Electrical Symbols...............................................................................................................2E18 XIV-I Blower System Wire Color Codes...................................................................................... 2G16 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL 1A11 SECTION I INTRODUCTION Paragraph Aerofiche Grid No. 1-1 General................................................................................................................................. 1A13 1-2 Scope of Manual................................................................................................................... 1A13 1-3 Description........................................................................................................................... 1A13 1-4 Wing..................................................................................................................................... 1A13 1-5 Empennage........................................................................................................................... 1A13 1-6 Fuselage................................................................................................................................ 1A13 1-7 Landing Gear........................................................................................................................ 1A13 1-8 Brake System....................................................................................................................... 1A13 1-9 Engines................................................................................................................................. 1A13 1-10 Propeller............................................................................................................................... 1A13 1-11 Fuel System.......................................................................................................................... 1A14 1-12 Flight Controls..................................................................................................................... 1A14 1-13 Radio.................................................................................................................................... 1A14 1-14 Cabin heater, Defroster, and Fresh Air System.................................................................... 1A14 1-15 Instrument and Autopilot System......................................................................................... 1A14 1-16 Warnings, Cautions, and Notes............................................................................................ 1A14 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 INTRODUCTION 1A12 SECTION I INTRODUCTION 1-1. GENERAL. This manual contains service and maintenance instructions for the PA-28-161 Cadet. This aircraft is designed and manufactured as a versatile airplane 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 thru XIV comprise the maintenance instructions. The service instructions include ground handling, servicing and inspection. The maintenance instructions for each system include description, removal, inspection, installation,corrective maintenance and testing of components along with troubleshooting. 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 operation, refer to the Pilot's Operating Manual or Information Manual. 1-3. DESCRIPTION. The Cadet is a single-engine, low wing monoplane, of all-metal construction, with a seating capacity of four. Paragraphs 1-4 through 1-12 provide descriptions of the major components and systems. 1-4. WING. The laminar flow wing is of all-metal stressed-skin, full cantilever, tapered, low-wing design. Each tapered wing panel is bolted to a spar box assembly in the fuselage. The wing tips are made of tough resilient fiberglass and are easily removed. The ailerons are statically balanced and cable and push rod controlled. 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 and rudder are statically balanced and cable operated. 1-6. FUSELAGE. The fuselage consists of three basic units: the engine section, the cabin section, and sheet- metal tail cone. 1-7. LANDING GEAR. The tricycle landing gear is of the fixed type, consisting of shock absorbing air-oil type oleo struts. 1-8. BRAKE SYSTEM. The brake system is hydraulically operated and controlled by a hand lever connected to a single brake cylinder that operates both wheel brakes, plus individually operated toe brakes. 1-9. ENGINE. The engine installed in the airplane is a Avco-Lycoming direct drive, wet sump, horizontally opposed, air cooled model. The four cylinder engine is carburetor equipped. The engine model, rated horsepower and other related information may be found in Table II-I of Section II. 1-10. PROPELLER. The airplane is equipped with an all-metal fixed pitch propeller. Propeller specifications may be found in Table II-I of Section II. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 INTRODUCTION 1A13 1-11. FUEL SYSTEM. The fuel system consists of two aluminum tanks in the leading edge of the wings, a fuel strainer bowl with filter screen, one electric auxiliary pump and one engine driven pump. Fuel drains are provided throughout the system to remove any fuel contamination. 1-12. FLIGHT CONTROLS. The flight controls are conventional, consisting of dual control wheels which operate the ailerons and stabilator, and dual pedals which operate the rudder. 1-13. RADIO. Provisions are provided for the installation of various radio equipment along with microphone and headset jacks, loudspeaker and other radio navigation equipment. 1-14. 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 is picked up from air inlets in the leading edge of each wing. The air passes through the wings to individually controlled outlets located just forward of each front seat. Rear seat vents are available as optional equipment. 1-15. INSTRUMENT AND AUTOPILOT SYSTEM. Provisions for instrument installation include panels for engine instruments and advanced instruments, as well as for an Autopilot System. 1-16. WARNINGS, CAUTIONS, and NOTES are used throughout this manual to emphasize important operating information. — WARNINGS — Operating procedures, practices, etc., which may result in personal injury or loss of life if not carefully followed. — CAUTION — Operating procedures, practices, etc., which if not strictly observed may result in damage to equipment. — Notes — An operating procedure, condition, etc., which is essential to emphasize. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 INTRODUCTION 1A14 THIS PAGE INTENTIONALLY LEFT BLANK PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 INTRODUCTION 1A15 SECTION II HANDLING AND SERVICING Paragraph Aerofiche Grid No. 2-1. Introduction..............................................................................................................................1A19 2-2. Dimensions.............................................................................................................................. 1A19 2-3. Station Reference Lines............................................................................................................1A19 2-4. Weight and Balance Data......................................................................................................... 1A19 2-5. Serial Number Plate..................................................................................................................1A19 2-6. Access and Inspection Provisions............................................................................................ 1A19 2-7. Tools and Test Equipment........................................................................................................ 1A19 2-8. Torque Requirements................................................................................................................1B3 2-9. Walkway, Handhold and Step...................................................................................................1B8 2-10. Ground Handling......................................................................................................................1B8 2-11. Introduction to Ground Handling.............................................................................................1B8 2-12. Jacking......................................................................................................................................1B8 2-13. Weighing...................................................................................................................................1B9 2-14. Leveling....................................................................................................................................1B9 2-15. Mooring....................................................................................................................................1B10 2-16. Locking Airplane......................................................................................................................1B11 2-17. Parking......................................................................................................................................1B11 2-18. Towing......................................................................................................................................1B11 2-19. Taxiing......................................................................................................................................1B11 2-20. External Power Receptacle (Optional).....................................................................................1B12 2-21. Operation of External Power Receptacle................................................................................. 1B12 2-22. Cleaning....................................................................................................................................1B12 2-23. Cleaning Engine Compartment................................................................................................ 1B12 2-24. Cleaning Landing Gear.............................................................................................................1B12 2-25. Cleaning Exterior Surfaces.......................................................................................................1B13 2-26. Cleaning Windshield and Windows......................................................................................... 1B13 2-27. Cleaning Headliner, Side Panels and Seats..............................................................................1B13 2-28. Cleaning Carpets...................................................................................................................... 1B15 2-29. Servicing...................................................................................................................................1B15 2-30. Introduction to Servicing..........................................................................................................1B15 2-31. Landing Gear System...............................................................................................................1B15 2-32. Servicing Landing Gear............................................................................................................1B15 2-33. Oleo Struts................................................................................................................................1B15 2-34. Servicing Oleo Struts................................................................................................................1B15 2-35. Filling Nose Gear Oleo Strut....................................................................................................1B16 2-36. Filling Main Gear Oleo Strut....................................................................................................1B16 2-37. Inflating Oleo Struts.................................................................................................................1B18 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1A16 Paragraph Aerofiche Grid No. 2-38. Brake System....................................................................................................................... 1B18 2-39. Servicing Brake System.......................................................................................................1B18 2-40. Filling Brake Cylinder Reservoir.........................................................................................1B18 2-41. Draining Brake System........................................................................................................1B18 2-42. Tires......................................................................................................................................1B18 2-43. Servicing Tires.....................................................................................................................1B18 2-44. Power Plant..........................................................................................................................1B18 2-45. Servicing Power Plant..........................................................................................................1B18 2-46. Induction Air Filter...............................................................................................................1B20 2-47. Removal of Air Filter...........................................................................................................1B20 2-48. Service Instructions (Inspection and Replacement).............................................................1B20 2-49. Installation of Air Filter........................................................................................................1B20 2-50. Propeller...............................................................................................................................1B20 2-51. Servicing Propeller...............................................................................................................1B20 2-52. Fuel System..........................................................................................................................1B20 2-53. Servicing Fuel System......................................................................................................... 1B20 2-54. Filling Fuel Tanks................................................................................................................ 1B21 2-55. Anti-Icing Fuel Additive......................................................................................................1B21 2-56. Fuel Drain Valve and Strainer..............................................................................................1B21 2-57. Draining Fuel System...........................................................................................................1B21 2-58. Electrical System..................................................................................................................1B22 2-59. Servicing Electrical System.................................................................................................1B22 2-60. Lubrication...........................................................................................................................1B22 2-61. Oil System (Engine).............................................................................................................1B22 2-62. Servicing Oil System........................................................................................................... 1B22 2-63. Filling Oil Sump...................................................................................................................1B23 2-64. Draining Oil Sump...............................................................................................................1B23 2-65. Oil Screens (Suction)...........................................................................................................1B23 2-66. Oil Screens (Pressure)..........................................................................................................1B23 2-67. Oil Filter (Full Flow)............................................................................................................1B23 2-68. Recommendations for Changing Oil....................................................................................1B24 2-69. Lubrication Instructions.......................................................................................................1B24 2-70. Application of Oil................................................................................................................ 1B24 2-71. Application of Grease.......................................................................................................... 1B24 2-72. Winterization Plate...............................................................................................................1B24 2-73. Lubrication Chart.................................................................................................................1B24 2-74. Corrosion Control................................................................................................................ 1C11 2-75. Form of Corrosion................................................................................................................1C11 2-76. Conditions Affecting Corrosion...........................................................................................1C11 2-77. Inspection.............................................................................................................................1C12 2-78. Corrosion Removal and Control..........................................................................................1C12 2-79. Areas Prone to Corrosion.....................................................................................................1C14 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1A17 Paragraph Aerofiche Grid No. 2-80. Repainting............................................................................................................................1C15 2-81. Product Listing For Urethane Enamel Aircraft Finish.........................................................1C15 2-82. Preparation of Epoxy Zinc Chromate Primer.......................................................................1C15 2-83. Preparation and Application of Du Pont Imron Urethane Enamel...................................... 1C16 2-84. Product Listing For Randolph Paint Finish..........................................................................1C16 2-85. Preparation and Application of Zinc Chromate Primer....................................................... 1C16 2-86. Finish Painting With Randolph Paint (B5420/D7784)........................................................ 1C16 2-87. Repairs................................................................................................................................. 1C17 2-88. Removal of Cherrylock Rivets.............................................................................................1C17 2-89. Standard Practice - Airframe................................................................................................1C19 2-90. Torque Wrenches..................................................................................................................1C19 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1A18 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 Figure 2-1 and are listed in Table II-I. 2-3. STATION REFERENCE LINES. In order to facilitate the location of various components of the airplane which require maintenance and servicing, a method utilizing fuselage station (Sta.), wing station or buttock line (BL), and waterline (WL) designations is frequently employed in this manual. (Refer to Figure 2-2.) Fuselage stations, buttock lines, and waterlines are reference points measured by inches in the vertical or horizontal direction from a given reference line which indicates station locations of structural members of the airplane. Station 0 of the fuselage is 44.5 inches ahead of the lower edge of the firewall; station 0 (BL) of the wing and stabilator is the centerline of the airplane; and station 0 (WL) of the fuselage vertical stabilizer and rudder is 20.5 inches below the cabin floor as measured at the rear wing spar with the airplane level. The reference datum line is located 78.4 inches ahead of the wing leading edge at the intersection of the straight and tapered section. 2-4. WEIGHT AND BALANCE DATA. When figuring various 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. 2-5. SERIAL NUMBER PLATE. The serial number plate is located on the left side of the fuselage near the leading edge of the stabilator. The serial number should always be used when referring to the airplane on service or warranty matters. 2-6. ACCESS AND INSPECTION PROVISIONS. The access and inspection provisions for the airplane are shown in Figure 2-3. The component to be serviced or inspected through each opening is identified in the illustration. All access plates and panels are secured by either metal fasteners or screws. To enter the aft section of the fuselage, remove the upholstery panel. — Caution — before entering the aft section of the fuselage, be sure the airplane is supported at the tail skid. 2-7. TOOLS AND TEST EQUIPMENT. Because of the simplicity and easy accessibility of components, few special tools outside normal shop tools will be required. Tools that are required may be fabricated from dimensions given in the section that pertains to a particular component. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1A19 12' 11.75" 2' 6" 5' 3" 4 35' 10' 23' 9.6'' 7'3.6" STATIC GROUND LINE 6' 8" Figure 2-1. Three View PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1A20 Figure 2-2. Station Reference Lines PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVING 1A21 BL 53.12 BL 6.16 BL 77.87 BL 53.37 BL 71.17 WS 108.20 BL 19.73 BL 14.94 BL 22.25 WS 208.05 STA 258.72 THERORETICAL TIP STA 278.40 WS 211.57 BL 00.00 STA 280.90 WL 100.10 STA 7.00 WS 57.00 WS 88.75 STA 108.63 WL 96.50 WL 53.35 WL 0.386 STA 108.17 WL 40.00 STA 108.64 STA 191.00 WL 80.94 WL 51.75 STA 256.80 WL 38.00 STA 256.13 WL 67.85 STA 80.80 WL 45.00 STA 288.63 STA 228.30 STA 156.00 STA 128.73 WL 7.984 STA 44.50 STA 30.79 STA 62.88 STA 49.88 WL 52.79 STA 7.08 STA 138.88 WL 101.13 TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS ENGINE Manufacturer Avco-Lycoming Model O-320-D3G FAA Type Certificate 274 Rated Horsepower 160 Rated Speed: Full Throttle 2700 RPM Oil, SAE Number See Table II-II Oil Sump Capacity 8 U.S. qts Fuel, Aviation Grade, Specified Minimum Octane 100 LOW LEAD Carburetor, Marvel-Schebler MA-4SPA Magnetos, Slick Left 4051, 4251 Right 4050, 4250 Magneto Timing 25° BTC Spark Plugs (Shielded) and Spark Plug Gap Setting SEE NOTE — Note — Refer to the latest issue of Avco-Lycoming Service Instruction No. 1042. Firing Order 1-3-2-4 Tachometer Drive, Ratio to Crankshaft 0.5:1 Starter: Prestolite, 12 Volt MZ4218 Alternator: Prestolite (60 AMP) ALX-8421LS Alternator Voltage Regulator, LAMAR B-00371-1 Fuel Pump Drive Plunger MODEL PA-28-161 CADET PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1A22 TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (cont) MODEL PA-28-161 CADET PROPELLER Fixed Pitch: Manufacturer Sensenich Model 74 DM6-0-60 Diameter 74 in. Diameter, Minimum 72 in. FUEL SYSTEM Inboard (Main Tanks) Two Capacity (each) 25 U.S. gal. Unusable Fuel (each tank) 1 U.S. gal. Total Capacity 50 U.S. gal. Total Unusable Fuel 2 U.S. gal. LANDING GEAR Type Fixed Shock Strut Type Combination Air-Oil Fluid Required (Struts and Brakes) MIL-H-5606 Strut Exposure (under static load): Nose 3.25 +/- .25 in. Main 4.50 +/- .50 in. Wheel Tread 10.0 ft. Wheel Base 6 ft. 8 in. Nose Wheel Travel 30° +/- 1° Left 30° +/- 1° Right Wheel, Nose Cleveland 40-77B, 5:00 x 5 Wheel, Main Cleveland 40-28, 6:00 x6 Brake Type Cleveland 30-55 Tires, Nose 5:00 x 5, 4 ply rating Tires, Main 6:00 x 6, 4 ply rating Tire Pressure, Nose 30 psi Tire Pressure, Main 24 psi PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1A23 TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (cont) MODEL PA-28-161 CADET CONTROL SURFACE TRAVELS REFER TO SECTION V TABLE V-I. CABLE TENSIONS REFER TO SECTION V TABLE V-I. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1A24 TABLE 11-1. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS FOOTNOTES 1. The specified minimum octane aviation grade fuel for the PA-28-l61 Cadet is 100 octane Low Lead. When using alternate fuels, refer to the latest revision of Lycoming Service Letter No. L185. END PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1B1 Figure 2-3. Access Plates and Panels 1. TIP, STABILATOR 2. TIP, RUDDER 3. FAIRING, FIN 4. TAIL CONE, CONTROL CABLE AND TRIM SCREW 5. TIP, WING 6. COVER, BELLCRANK AND CONTROL CABLES 7. FAIRING, MAIN GEAR STRUT ASSEMBLY 8. FAIRING, FLAP TORQUE TUBE AND AILERON CABLES 9. CAP, FUEL TANK FILLER 10. CAP, STRUT FILLER 11. FAIRING, FUEL LINES 12. COVER, FUEL LINES AND SPAR ATTACHMENT BOLTS 13. COVER, CONTROL CABLES 14. COWL ASSEMBLY, ENGINE 15. SPINNER, PROPELLER 16. SEAT, , TORQUE TUBE AND CONTROL CABLES 17. PLATE, CONTROL CABLES, MIDDLE 18. PLATE, AILERON AND STABILATOR CONTROL CABLE, FORWARD 19. COVERS, AILERON AND STABILATOR CONTROL CABLE 20. PANEL, AFT AREA OF FUSELAGE, STROBE LIGHT POWER SUPPLY 21. PLATE, CONTROL CABLES AND PULLEYS, REAR 22. COVER, FLAP CONTROL 23. EMERGENCY LOCATOR TRANSMITTER 24. BATTERY 6 7 8 9 10 3 11 12 13 14 15 16 17 18 19 20 21 22 23 24 UPPER SURFACE LOWER SURFACE 8 7 12 11 10 9 6 5 19 2066 13 1 2 1 4 5 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1B2 2-8. TORQUE REQUIREMENTS. Proper torque application cannot be overemphasized. Undertorqued assemblies can result in premature failure due to fatigue from uneven loads, as well as causing unnecessary wear of nuts, bolts, and other parts. Overtorqued assemblies can be equally harmful by causing failure of a bolt or nut by overstressing the threaded areas. The torque values given in Table II-II are derived from oil-free cadmium-plated threads and are recommended for all airframe installation procedures where torquing is required, unless otherwise noted in sections where other values are stipulated. Engine torque values are found in the latest revision of Avco- Lycoming Special Service Publications No. SSP1776, and propeller torque values are found in Section VIII of this manual. Table II-IIA lists the torque values for flared fittings of various sizes and material. Important procedures for torquing assemblies on Piper Aircraft are as follows: a. Frequently check and/or calibrate the torque wrench. b. Make sure bolt/screw and nut threads are clean and dry, unless otherwise required. If the threads are to be lubricated and no torque is specified, reduce recommended nut torque (plus the friction drag torque) by 50%. c. Unless otherwise specified the charted torque values should be used. Should a bolt or nut be listed and not its mating fastener, use the lower torque. d. When using "self-locking fasteners" and hardware with thread sizes 10 through 7/16" add the specified friction drag torque to the designated torque. Assume a friction drag torque of zero for non self-locking fasteners. For other bolt sizes, the friction drag torque is determined as follows: 1. Turn nut to "near contact" with the bearing surface (NOT IN CONTACT). 2. Attach a scale type torque wrench and determine the torque required to turn the nut on the bolt before it contacts the bearing surface. Add this value to the specified torque for the total torque value to be applied. e. When torquing castellated nuts remember the following: 1. Determine maximum torque value (friction + max. torque) and do not exceed when aligning slot and hole, change washers if necessary. 2. When using castellated nuts on movable joints, tighten nuts only to remove looseness in the joint before installing cotter pin. f. Use the latest information from LYCOMING for torquing power plant parts. g. On critical installations the nut should be permanently marked red after torquing and not be further tightened or disturbed. — NOTE — When flared fittings are being installed, ascertain that the male threads are properly lubricated. Torque the fittings in accordance with Table II-IIA. For more details on torquing, refer to FAA Manual AC 43-13-1A. — CAUTION — Do not overtorque fittings. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1B3 TABLE II-II. RECOMMENDED NUT TORQUES TORQUES: The importance of correct application cannot be overemphasized. Undertorque can result in unnecessary wear of nuts and bolts as well as the parts they are holding together. When insufficient pressures are applied, uneven loads will be transmitted throughout the assembly which may result in excessive wear or premature failure due to fatigue. Overtorque can be equally damaging because of failure of a bolt or nut from overstressing the thread areas. The following procedures should be followed to assure that the correct torque is applied: 1. Torque (self-locking fasteners) Add the friction torque from Table A for sizes 8 through 7/16" to the recommended torque from Table B to get the final torque. This would be the actual reading on the torque wrench. 2. Torque (castellated and non-self-locking nuts) Use only the torque given in Table B. Unless otherwise specified, when castellated nuts are used with a cotter pin on moving joints, do not torque the nut. Turn the nut onto the bolt until proper grip is established and alignment with the cotter pin hole is achieved. Then install the cotter pin. GENERAL REQUIREMENTS: 1. Calibrate the torque wrench periodically to assure accuracy; recheck frequently. 2. Ascertain that the bolt and nut threads are clean and dry (unless otherwise specified by the manufacturer). If the bolt or nut is specified to be lubricated prior to tightening, the torque range should be reduced 50 percent. 3. Use a bolt length long enough to prevent bearing loads on the threads. The complete chamfer or end radius of the bolt or screw must extend through the nut. 4. Unique torques specified in the text of this manual supersede the torques given in Tables A and B. 5. Refer to the latest revision of Lycoming SSP 1776 for torques on parts used on Lycoming engines. 6. A maximum of two AN960 washers may be added under the bolt heads or nuts to correct for variations in material thickness within the tolerances permitted. 7. Limitations of the use of self-locking nuts, bolts and screws including fasteners with non-metallic inserts are as follows: A. Fasteners incorporating self-locking devices shall not be reused if they can be run up using only fingers. They may be reused if hand tools are required to run them up, providing there is no obvious damage to the self- locking device prior to installation. B. Bolts 5/16 inch diameter and over with cotter pin holes may be used with self-locking nuts. Nuts with non-metallic locking devices may be used in this application only if the bolts are free from burrs around the cotter pin hole. C. Do not use self-locking nuts at joints which subject either the nut or the bolt to rotation. D. Never tap or rethread self-locking fasteners. Do not use nuts, bolts or screws with damaged threads or rough ends. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING 1B4 TABLE II-II. RECOMMENDED NUT TORQUES (cont) TABLE B * APPLICABLE TO COARSE THREADS ONLY BOLTS Steel Tension AN 3 thru AN 20 AN 42 thru AN 49 AN 73 thru AN 81 AN 173 thru AN 186 MS 20033 thru MS 20046 MS 20073 MS 20074 AN 509 NK9 MS 24694 AN 525 NK525 MS 27039 NUTS Steel Tension Steel Shear AN 310 AN 320 AN 315 AN 364 AN 363 NAS 1022 AN 365 MS 17826 NAS 1021 MS 20364 MS 17825 MS 21045 MS 20365 MS 20500 NAS 679 COURSE THREAD SERIES NUT-BOLT TORQUE LIMITS TORQUE LIMITS SIZE IN-LBS IN-LBS MIN. MAX. MIN. MAX. 8-32 12 15 7 9 10-24 20 25 12 15 1/4-20 40 50 25 30 5/16-18 80 90 48 55 3/8-16 160 185 95 110 7/16-14 235 255 140 155 1/2-13 400 480 240 290 9/16-12 500 700 300 420 5/8-11 700 900 420 540 3/4-10 1,150 1,600 700 950 7/8-9 2,200 3,000 1,300 1,800 1-8 3,700 5,000 2,200 3,000 1-1/8-8 5,500 6,500 3,300 4,000 1-1/4-8 6,500 8,000 4,000 5,000 BOLT FRICTION DRAG SIZE TORQUE (IN LBS) 8* 15 10 18 1/4 30 5/16 60 3/8 80 7/16 100 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B5 BOLTS BOLTS BOLTS Steel Tension Steel Tension Aluminum AN 3 thru AN 20 MS 20004 thru MS 20024 AN 3DD thru AN 20DD AN 42 thru AN 49 NAS 144 thru NAS 158 AN 173DD thru AN 186DD AN 73 thru AN 81 NAS 333 thru NAS ~0 AN 509DD AN 173 thru AN 186 NAS 583 thru NAS 590 AN 525D MS 20033 thru MS 20046 NAS 624 thru NAS 644 MS 27039D MS 20073 NAS 1303 thru NAS 1320 MS 24694DD MS 20074 NAS 172 AN 509 N K9 NAS 174 MS 24694 NAS 517 1 Steel shear bolt MS 27039 NAS 464 NUTS NUTS NUTS Steel Tension Steel Shear Steel Tension Steel Shear Alum. Tension Alum. Shear AN 310 AN 320 AN 310 AN 320 AN 365D AN 320D AN 315 AN 364 AN 315 AN 364 AN 310D AN 364D AN 363 NAS 1022 AN 363 NAS 1022 NAS 1021D NAS 1022D AN 365 MS 17826 AN 365 MS 17826 NAS 1021 MS 20364 MS 17825 MS 20364 MS 17825 MS 20365 MS 21045 MS 21045 MS 20365 NAS 1021 MS 20600 NAS 679 NAS 679 NAS 1291 FINE THREAD SERIES Nut-bolt Torque Limits Torque Limits Torque Limits Torque Limits Tonque Limits Torque Limits size in-lbs in-lbs in-lbs in-lbs in-lbs in-lbs Min. Max. Min. Max Min. Max. Min. Max. Min. Max. Min. Max. 8-36 12 15 7 9 5 10 3 6 10-32 20 25 12 15 25 30 15 20 10 15 5 10 1/4-28 50 70 30 40 80 100 50 60 30 45 15 30 5/16-24 100 140 60 85 120 145 70 90 40 65 25 40 3/8-24 160 190 95 110 200 250 120 150 75 110 45 70 7/16-20 450 500 270 300 520 630 300 400 180 280 110 170 1/2-20 480 690 290 410 770 950 450 550 280 410 160 260 9/16-18 800 1,000 480 600 1,100 1,300 650 800 380 580 230 360 5/8-18 1,1000 1,300 660 780 1,250 1,550 750 950 550 670 270 420 3/4-16 2,300 2,500 1,300 1,500 2,650 3,200 1,600 1,900 950 1,250 560 880 7/8-14 2,500 3,000 1,500 1,800 3.550 4,350 2,100 2,690 1,250 1,900 750 1,200 1-14 3,700 4,500 2,200 3,300 4,500 5,500 2,700 3,300 1,600 2,400 950 1,500 1-1/8-12 5,000 7,000 3,000 4,200 6,000 7,300 3,600 1,400 2,100 3,200 1,250 2,000 1-1/4-12 9,000 11,000 5,400 6,600 11,000 13,400 6,600 8,000 3,900 5,000 2,300 3,650 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B6 Table 11-11. Recommended Torques (cont) TORQUE INCH-POUND TUBING ALUMINUM - ALLOY STEEL TUBING HOSE END FITTING O.D. TUBING FLARE - AND FLARE AND lNCHES 10061 OR AND 10078 AND 10061 HOSE ASSEMBLIES MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM 1/8 ---- ---- ---- ---- ---- ---- 3/16 ---- ---- 90 100 70 100 1/4 40 65 135 150 70 120 5/16 60 80 180 200 85 180 3/8 75 125 270 300 100 250 1/2 150 250 450 500 210 420 5/8 200 350 650 700 300 48O 3/4 300 500 900 1000 500 850 1 500 700 1200 1400 700 1150 1-1/4 600 900 ---- ---- ---- ---- 1-/2 600 900 ---- ---- ---- ---- 1-3/4 ---- ---- ---- ---- ---- ---- 2 ---- ---- ---- ---- ---- ----- THIS SPACE INTENTIONALLY LEFT BLANK PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B7 TABLE II-IIA. FLARE FITTING TORQUES 2-9. WALKWAY, HANDHOLD AND STEP. The walkway is made of a non-skid material applied to the wing surface. A fixed handhold is located on the right side of the fuselage near the rear window. A step is available as optional equipment and is installed just aft of the trailing edge of the right flap. 2-10. GROUND HANDLING. 2-11. INTRODUCTION TO GROUND HANDLING. Ground handling covers all essential information governing the handling of the airplane while on the ground. This includes jacking, weighing, leveling, mooring, parking, towing and taxiing. When the airplane is handled in the manner described in the following paragraphs, the chance of possible damage to the airplane and its equipment will be prevented. 2-12. JACKING. Jacking the airplane is necessary to service the landing gear and to perform other service operations. Proceed as follows: a. Place jacks under jack pads on the front wing spar. (Refer to Figure 2-4.) b. Attach the tail support to the tail skid. Place approximately 250 pounds of ballast on the base of the tail support hold down the tail. — CAUTION — Be sure to apply sufficient tail support ballast; otherwise the airplane will tip forward. c. Raise the jacks until all three wheels are clear of the surface. Figure 2-4. Jacking Arrangement PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B8 Figure 2-5. Weighing Arrangement 2-13. WEIGHING. (Refer to Figure 2-5.) The airplane may be weighed by the following procedure: a. Position a scale and ramp in front of each of the three wheels. b. Secure the scales from rolling forward and tow the airplane up onto the scales. c. Remove the ramp so as not to interfere with the scales. d. If the airplane is to be weighed for weight and balance computations, level the airplane per instructions given in Paragraph 2-14. 2-14. LEVELING. All configurations of the airplane are provided with a means for longitudinal and lateral leveling. The airplane may be leveled while on jacks, during the weighing procedure while the wheels are on scales, or while the wheels are on the ground. To level the airplane for purposes of weighing or rigging, the following procedures may be used: a. To longitudinally level the airplane, partially withdraw the two leveling screws located immediately below the left front side window. (Refer to Figure 2-6). Place a level on these screw heads and adjust the jacks until the level is centered. Should the airplane be either on scales or on the floor, first block the main gear oleos to full extension; then deflate the nose wheel until the proper position is reached. 2061 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B9 Figure 2-6. Leveling Longitudinally Figure 2-7.Leveling Laterally b. To laterally level the airplane, place a level across the spar box assembly behind the pilots seat. (Refer to Figure 2-7.) Raise or lower one wing tip by deflating the appropriate tire on the high side of the airplane or adjust either jack until the bubble of the level is centered. 2-15. MOORING. The airplane is moored to ensure its immovability, protection, and security under various weather conditions. The following procedure gives the instructions for proper mooring of the airplane: a. Head the airplane into the wind, if possible. b. Block the wheels. c. Lock the aileron and stabilator controls using the front seat belt or control surface blocks. d. Secure tie-down ropes to the wing tie-down rings and the tail skid at approximately 45 degree angles to the ground. When using rope constructed of non-synthetic material, leave sufficient slack to avoid damage to the airplane when the ropes contract due to moisture. — CAUTION — Use square or bowline knots. Do not use slip knots. — NOTE — Additional preparations for high winds include using tie-down ropes from the landing gear forks and securing the rudder. 896 9092 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B10 2-16. LOCKING AIRPLANE. The cabin door is provided with a key lock on the outside. The ignition switch and cabin door require the same key 2-17. PARKING. When parking the airplane, ensure that it is sufficiently protected against adverse weather conditions and presents no danger to other aircraft. When parking the airplane for any length of time or overnight, it is recommended that it be moored as in Paragraph 2-15. a. To park the airplane, head it into the wind, if possible. b. Set the parking brake by pulling back the brake lever and depressing the knob attached to the left side of the handle; then release the handle. To release the parking brake, pull back on the brake lever to disengage the catch mechanism, and allow the handle to swing forward. c. The aileron and stabilator may be locked by using the front seat belt. — NOTE — Care should be taken when setting brakes that are overheated or during cold weather when accumulated moisture may freeze the brakes. 2-18. TOWING. The airplane may be moved by using the nose wheel steering bar that is stowed in the baggage area or power equipment that will not damage or cause excess strain to the nose gear steering assembly. Towing lugs are incorporated as part of the nose gear fork. — CAUTION — When towing with power equipment, do not turn the nose gear in either direction beyond its steering radius limits as this will result in damage to the nose gear and steering mechanism. — CAUTION — Do not tow the airplane with control locks installed. In the event towing lines are necessary, lines (rope) should be attached to both main gear struts as high up on the tubes as possible. Lines should be long enough to clear the nose and/or tail by not less than 15 feet, and a qualified person to ride in the pilot's seat to maintain control by use of the brakes. 2-19. TAXIING. Before attempting to taxi the airplane, ground personnel should be checked out by a qualified pilot or other responsible person. Engine starting and shutdown procedures should be covered as well. When it is ascertained that the propeller back blast and taxi areas are clear, apply power to start the taxi roll and perform the following checks: a. Taxi forward a few feet and apply brakes to determine their effectiveness. b. While taxiing, make slight turns to determine the effectiveness of steering. c. Observe wing clearances when taxiing near buildings or other stationary objects. If possible, station a guide outside the airplane to observe. d. When taxiing on uneven ground, avoid holes and ruts. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B11 e. Do not operate the engine at high RPM when running up or taxiing over ground containing loose stones, gravel, or any loose material that may cause damage to the propeller blades. 2-20. EXTERNAL POWER RECEPTACLE (OPTIONAL) 2-21. OPERATION OF EXTERNAL POWER RECEPTACLE. The external power receptacle is located on the right side of the fuselage forward of the wing. When using external power for starting or operation of any of the airplane's equipment, the following procedure should be followed: a. Turn aircraft MASTER SWITCH and all electrical equipment OFF. b. Ascertain that the RED lead of PEP (Piper External Power) kit jumper cable goes to the POSITIVE (+) terminal of external 12-volt battery and the BLACK lead goes to the NEGATIVE (-) terminal. c. Insert the plug of the jumper cable into the socket located on the aircraft fuselage. d. Turn the aircraft MASTER SWITCH ON and proceed with NORMAL engine starting technique. e. After the engine has been started, turn the MASTER SWITCH and all electrical equipment OFF and remove the jumper cable plug from the aircraft. f. Turn the aircraft MASTER SWITCH to the ON position and check the alternator ammeter for an indication of output. Do not attempt any flight if there is no indication of alternator output. 2-22. CLEANING. 2-23. CLEANING ENGINE COMPARTMENT. Before cleaning the engine compartment, place strips of tape on the magneto vents to prevent any solvent from entering these units. a. Place a pan under the engine to catch waste. b. With the engine cowling removed, spray or brush the engine with solvent or a mixture of solvent and degreaser, as desired. It may be necessary to brush areas that were sprayed where heavy grease and dirt deposits have collected in order to clean them. — CAUTION — Do not spray solvent into the alternator, starter, air intake, and alternate air inlets. c. Allow the solvent to remain on the engine from five to ten minutes; then rinse the engine clean with additional solvent and allow to dry. — CAUTION — Do not operate engine until excess solvent has evaporated or otherwise been removed. d. Remove the protective covers from the magnetos. e. Lubricate controls, bearing surfaces, etc., per Lubrication Chart. 2-24. CLEANING LANDING GEAR. Before cleaning the landing gear, place a plastic cover or similar material over the wheel and brake assembly. a. Place a pan under the gear to catch waste. b. Spray or brush the gear area with solvent or a mixture of solvent and degreaser, as desired. It may be necessary to brush areas that were sprayed where heavy grease and dirt deposits have collected in order to clean them. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B12 c. Allow the solvent to remain on the gear from five to ten minutes; then rinse the gear with additional solvent and allow to dry. d. Remove the cover from the wheel and remove the catch pan. e. Lubricate the gear per Lubrication Chart. 2-25. CLEANING EXTERIOR SURFACES. The airplane should be washed with a mild soap and water. Harsh abrasives or detergents used on painted or plastic surfaces could make scratches or cause corrosion of metal surfaces. Cover areas where cleaning solution could cause damage. To wash the airplane, the following procedure may be used: a. Flush away loose dirt with water. b. Apply cleaning solution with a rag, sponge or soft bristle brush. c. To remove stubborn oil and grease, use a cloth dampened with naptha. d. Where exhaust stains exist, allow solution to remain on the surface longer. e. Any good automotive wax may used to preserve the painted surfaces. Soft cleaning cloths or a chamois should be used to prevent scratches when cleaning or polishing. A heavier coating of wax on the leading surfaces will reduce the abrasion problems in these areas. 2-26. CLEANING WINDSHIELD AND WINDOWS. a. Remove dirt, mud, etc., from exterior surfaces with clean water. b. Wash with mild soap and warm water, or an aircraft plastic cleaner using a soft cloth or sponge and a straight rubbing motion. Do not rub surfaces harshly. c. Remove oil and grease with a cloth moistened with kerosene. — NOTE — Do not use gasoline, alcohol, benzene, carbon tetrachloride, thinner, acetone, or window cleaning sprays. d. After cleaning plastic surfaces, apply a thin coat of hard polishing wax. Rub lightly with a soft cloth. Do not use a circular motion. e. A severe scratch or mar in plastic can be removed by using jeweler's rouge to rub out the scratch. Smooth both side and apply wax. f. To improve visibility through windshield and windows during flights through rain, a rain repellent such as REPCON should be applied to the windshield and windows. The surfaces of the windshield and windows treated becomes so smooth that water beads up and readily flows off the surface. Apply this product in accordance with the manufacturer's instructions. (Refer to Table II-III. Consumable Materials for Specifications and Manufacturer's address.) 2-27. CLEANING HEADLINER, SIDE PANELS, AND SEATS. a. Clean headliner, side panels, and seats with a stiff bristle brush and vacuum where necessary. b. Soiled upholstery, except leather, may be cleaned by using an approved air drying type cleaner or foam upholstery cleaner. Carefully follow the manufacturer's instructions. Avoid soaking or harsh rubbing. — CAUTION — Solvent cleaners require adequate ventilation. c.Leather material should be cleaned with saddle soap or mild soap and water. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B13 Figure 2-8. Servicing Points 1. FILLER, FUEL TANK, LEFT 12. TIRE, NOSE WHEEL 2. DRAIN, FUEL TANK, LEFT 13. CARBURETOR, ENGINE 3. FILTER, VACUUM REGULATOR 14. FILTER, INDUCTION AIR 4. RESERVOIR, BRAKE SYSTEM 15. SCREEN, OIL PRESSURE, ENGINE 5. SCREEN OR CARTRIDGE FILTER, 16. DRAIN, FUEL MANIFOLDS, L AND R OIL PRESSURE, ENGINE 17. FILLER, OLEO SHOCK STRUT, L AND R 6. FILLER/INDICATOR, OIL, ENGINE 18. DRAIN, FUEL TANK, RIGHT 7. FILTER, FUEL PUMP, ELECTRIC 19. TIRE, MAIN WHEEL, L AND R 8. SCREEN, FUEL DRAIN 20. FILLER, FUEL TANK, RIGHT 9. FILLER, OLEO SHOCK STRUT, NOSE 21. FILTER, INSTRUMENTS 10. DRAIN, FUEL, ENGINE 22. BATTERY 11. SCREEN, OIL SUCTION, ENGINE 1 2 3 4 5 6 7 8 8 10 11 12 13 14 15 16 17 18 20 21 19 22 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B14 2-28. CLEANING CARPETS. Use a small whisk broom or vacuum to remove dirt. For soiled spots, use a non- inflammable dry-cleaning fluid. 2-29. SERVICING 2-30. INTRODUCTION TO SERVICING. (Refer to Figure 2-8). Servicing the airplane includes the replenishment of fuel, oil, hydraulic brake fluid, tire pressures, lubrication requirements and other required items. 2-31. LANDING GEAR SYSTEM. 2-32. SERVICING LANDING GEAR. The landing gear consists of tires, brakes and oleo strut assemblies. These should be inspected for proper gear extension, scored piston tubes, possible hydraulic fluid leakage, security, and condition of all connection points. Check the brake linings for wear and frayed edges, and brake discs for scoring. Replace, if necessary. Minor servicing is described in the following paragraphs, and for detailed service and overhaul instructions, refer to Section VII. 2-33. OLEO STRUTS. 2-34. SERVICING OLEO STRUTS. Air-oil struts are incorporated in each landing gear oleo to absorb the shock resulting from the impact of the wheels on the runway during landing. To obtain proper oleo action, the nose gear oleo strut must have approximately 3.25 ± .25 inches of piston tube exposed, while the main gear struts require approximately 4.50 ± .50 inches of tube exposure. — CAUTION — Do not exceed these tube exposures. These measurements are taken with the airplane setting on a level surface under normal static load (empty weight of airplane plus full fuel and oil). If the strut has less tube exposed than that prescribed, determine whether it needs air or oil by raising the airplane on jacks. With the strut extended, remove the cap from the air valve at the top of the housing and depress the valve core to allow air to escape from the strut piston until it is fully compressed. Allow the foam from the air-oil mixture to settle and then determine if oil is visible up to the bottom of the filler plug hole. If oil is visible at the bottom of the hole, then all that is required is the valve be checked for unsatisfactory conditions and air added as described in Paragraph 2-37. Should fluid be at any level below the bottom of the filler plug hole, the oleo should be checked for leaks, etc., and oil added as described in Paragraph 2-35 for the nose gear, or Paragraph 2-36 for the main gear. For repair procedures of the landing gear and/or oleo struts, refer to Section Vll. — WARNING — Do not release air by removing the strut valve core or filler plug. Depress the valve core pin until strut chamber pressure has diminished. — CAUTION — Dirt and foreign particles form around the filler plugs of the landing gear struts, therefore, before attempting to remove these plugs, the tops of the struts should be cleaned with compressed air and/or with a quick drying solvent. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B15 2-35. FILLING NOSE GEAR OLEO STRUT. To fill the nose gear oleo strut with hydraulic fluid (MIL-H-5606), whether it be only the addition of a small amount or if the unit has been completely emptied and will require a large amount, it should be filled as follows: a. Raise the airplane on jacks until the nose wheel is completely clear of the ground. (Refer to Paragraph 2-12.) b. Place a pan under the gear to catch spillage. c. If not previously accomplished, remove the engine cowl and relieve air from the strut housing chamber by removing the cap from the air valve and depressing the valve core. d. There are two methods by which the strut chamber may be filled and these are as follows: Method I: 1. Remove the valve core from the filler plug at the top of the strut housing. Allow the plug to remain installed. 2. Attach one end of a clear plastic hose to the valve stem of the filler plug and submerge the other end in a container of hydraulic fluid. Ascertain that the end of the hose on the valve stem is tight and the fluid container is approximately equal in height to the top of the strut housing. 3. Fully compress and extend the strut thus drawing fluid from the fluid container and expelling air from the strut chamber. By watching the fluid pass through the plastic hose, it can be determined when the strut is full and no air is present in the chamber. 4. When air bubbles cease to flow through the hose, compress the strut fully and remove the hose from the valve stem. 5. With the strut compressed, remove the filler plug to determine that the fluid level is visible up to the bottom of the filler plug hole. 6. Reinstall the core in the filler plug and the plug in the top of the strut housing. Torque the plug from 350 to 400 inch-pounds. Method 2: 1. Remove the filler plug from the top of the strut housing. 2. Raise the strut piston until it is fully compressed. 3. Pour fluid from a clean container through the filler opening until it reaches the bottom of the filler plug hole. 4. Install the filler plug finger tight, and extend and compress the strut two or three times to remove any air that may be trapped in the housing. 5. Remove the filler plug; raise the strut to full compression and fill with fluid if needed. 6. Reinstall the filler plug and torque from 350 to 400 inch-pounds. e. With the airplane raised, compress and extend the gear strut several times to ascertain that the strut actuates freely. The weight of the gear fork and wheel should extend the strut. f. Clean off overflow of fluid, and inflate the strut as described in Paragraph 2-37. g. Check that fluid is not leaking from around the strut piston at the bottom of the housing. 2-36. FILLING MAIN GEAR OLEO STRUT. To fill a main gear oleo strut with fluid that is partly full or one that has been completely emptied, proceed as follows: a. Raise the airplane on jacks until the landing gear torque link assembly has almost reached its full travel. (Refer to Paragraph 2-12.) b. Place a pan under the gear to catch spillage. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B16 c. If not previously accomplished, remove the cap on top of the wing to gain access to the top of the strut housing and relieve air from the strut housing chamber by removing the cap from the air valve and depressing the valve core. d. Remove any one of the three torque link bolts, and again raise the airplane until a minimum of ten inches (do not exceed twelve inches of tube exposure) of strut tube is exposed with the wheel remaining on the ground. With this amount of tube exposed, it will allow fluid to flow from the middle chamber to the bottom chamber of the strut housing ensuring that the bottom chamber is filled with fluid. —CAUTION— With the torque links disconnected, the piston tube is free to slide from the strut housing. e. Fill the main gear housing by one of two methods which are as follows: Method 1: 1. Remove the valve core from the filler plug at the top of the strut housing. Allow the plug to remain installed. 2. Attach one end of a clear plastic hose to the valve stem of the finer plug and submerge the over end in a container of hydraulic fluid. 3. Fully compress and extend (10 ± 2 inches of strut tube exposed) the strut thus drawing fluid from the strut chambers. By watching the fluid pass through the plastic hose, it can be determined when the strut is full and no air is present in the chambers. The strut must be extended to full ten inches to allow fluid to enter the bottom chamber of strut housing. 4. When air bubbles cease to flow through the hose, compress the strut fully and remove the hose from the valve stem. 5. With the strut fully compressed, remove the filler plug to determine that the fluid level is visible up to the bottom of the filler plug hole. 6. Reinstall the core in the filler plug and the plug in the top of the strut housing Torque the plug from 350 to 400 inch-pounds. Method 2: 1. Remove the filler plug from the top of the strut housing. 2. Raise the strut to full compression. 3. Pour fluid from a clean container through the filler opening until it is visible at the top of the strut chamber. If the housing has been completely emptied or nearly so, allow sufficient time for the fluid to drain through the orifice from the upper chamber into the middle chamber. 4. Lower the gear until the wheel touches the ground (10 ±2 inches of strut exposure), and then fully compress and extend the strut three or four times to remove any air that may be trapped and to allow fluid to enter the bottom chamber of the housing. 5. Raise the strut to full compression and if needed, fill with fluid to the bottom of the filler plug. 6. Reinstall the filler plug; torque from 350 to 400 inch-pounds f. Replace the torque link bolt. Tighten bolt only tight enough to allow no side play in the connection. g. With the airplane raised, compress and extend the gear strut several times to ascertain that the strut actuates freely. The weight of the gear fork and wheel should extend the strut. h. Clean off overflow of fluid and inflate the strut as described in Paragraph 2-37. i. Check that fluid is not leaking around the strut piston at the bottom of the housing. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B17 2-37. INFLATING OLEO STRUTS. After making certain that the oleo strut has sufficient fluid, attach a strut pump to the air valve and inflate the oleo strut. The strut should be inflated until the correct inches of piston is exposed with normal static load (empty weight of airplane plus full fuel and oil on the gears.) (Refer to. Paragraph 2-34.) Rock the airplane several times to ascertain that the gear settles back to the correct strut position. (If a strut pump is not available. the airplane may be raised and line pressure from a high pressure air system used. Lower the airplane and while rocking it, let air from the valve to bring the strut down to the proper extension.) Before capping the valve, check for valve core leakage. 2-38. BRAKE SYSTEM. 2-39. SERVICING BRAKE SYSTEM. The brake system incorporates a hydraulic fluid reservoir through which the brake system is periodically serviced. Fluid is drawn from the reservoir by the brake cylinders to maintain the volume of fluid required for maximum braking efficiency. Spongy brake pedal action is often an indication that the brake fluid reservoir is running low on fluid. Instructions for filling the reservoir are given in Paragraph 2-40. When found necessary to accomplish repairs to any of the brake system components, or to bleed the system, these instructions may be found in Section VII. 2-40. FILLING BRAKE CYLINDER RESERVOIR. The brake cylinder reservoir should be filled to the level marked on reservoir, with the fluid specified in Table II-I. The reservoir, located on the left side of the fire wall in the engine compartment, should be checked at every 50-hour inspection and replenished as necessary. No adjustment of the brakes is necessary, though they should be checked periodically per instructions given in Section VII. 2-41. DRAINING BRAKE SYSTEM. To drain the brake system, connect a hose to the bleeder fitting on the bottom of the cylinder and place the other end of the line in a suitable container. Open the bleeder and slowly pump the hand brake lever and the desired brake pedal until fluid ceases to flow. To clean the brake system, flush with denatured alcohol. 2-42. TIRES. 2-43. SERVICING TIRES. The tires should be maintained at the pressure specified in Table II-I. When checking tire pressure, examine the tires for wear, cuts, bruises and slippage on the wheel. The tire, tube, and wheel shall be properly balanced when installed by aligning the red dot on the tire with the silver arrow on the tube. 2-44. POWER PLANT. 2-45. SERVICING POWER PLANT. Regularly check the engine compartment for oil and fuel leaks, chafing of lines, loose wires and tightness of all parts. For cleaning of the engine compartment, refer to Paragraph 2-23. Maintenance instructions for the power plant may be found in Section VIII of this manual and in the appropriate manufacturer's manuals. PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B18 Figure 2-9. Induction Air Filter 1. CARBURETOR AIR INTAKE DUCT 2. AIR FILTER BOX SEAL 3. COVER PLATE 4. RETAINER 5. FILTER ELEMENT 6. RETAINER 7. HOUSING 8. AIR FILTER BOX SEAL 9. CARBURETOR AIR FILTER BOX ASSEMBLY 10. SPRING 11. WASHER 12. FASTENER 3076 1 2 3 4 5 6 7 8 9 10 11 12 PIPER AIRCRAFT PA-28-161 CADET AIRPLANE MAINTENANCE MANUAL Issued: FEBRUARY 28, 1989 HANDLING AND SERVICING 1B19 2-46. INDUCTION AIR FILTER. 2-47. REMOVAL OF AIR FILTER. The induction air filter is located on the right side and midway in the engine compartment, and may be removed by the following procedure: a. Open the cowling on the right side of the engine. b. Loosen the four quarter turn fasteners and separate the filter housing. b. When returning existing filter element to service, shake filter to remove dirt particles. c. Remove the filter element from its screen housing by removing the four screws. d. Inspect filter per instructions in Paragraph 2-48. 2-48. SERVICE INSTRUCTIONS (INSPECTION AND REPLACEMENT). a. The wet-type polyurethane foam air filter must be inspected at least once every 5O hours. Under extremely adverse operating conditions, it must be inspected more frequently. The maximum filter life is 100 hours, however, do not hesitate to replace filter if inspection reveals an excessively dirty, punctured or ruptured filter. Refer to the PA-28-161 CADET Parts Catalog for filter part number.. c. Inspect filter housing for damage and condition of seal. d. The filter housing may be cleaned by wiping with a clean cloth soaked in a suitable quick drying type solvent. When housing is dry, reinstall filter. 2-49. INSTALLATION-OF AIR FILTER. After replacement and/or inspection. Install filter element in screen housing. Ensure the two retainers are properly positioned around the filter element according to Figure 2-9. 2-50. PROPELLER. 2-51. SERVICING PROPELLER. The propeller surfaces along with the spinner and back plate should be cleaned and inspected frequently for nicks, scratches, corrosion and cracks. Minor nicks and scratches on the propeller may be removed per instructions given in Section VIII. The rear face of each propeller blade should be painted when necessary with a flat black paint to retard glare. To prevent corrosion. wipe surfaces with a light oil or wax. 2-52. FUEL SYSTEM. 2-53. SERVICING FUEL SYSTEM. At intervals of 50 hours or 90 days, whichever comes first, clean the fuel strainer screen located in the fuel bowl, mounted on the lower left side of the firewall. There is a screen in the electric fuel pump, located at the lower left side of the engine compartment, and a screen in the inlet side of the carburetor