Piper Aircraft PA-28-236 Maintenance Manual

8 LEVELING AND WEIGHING 1C1 9 TOWING AND TAXIING 1C6 10 PARKING AND MOORING 1C10 11 REQUIRED PLACARDS 1C14 12 SERVICING 1C19 20 STANDARD PRACT - AIRFRAME 1EI 21 ENVIRONMENTAL SYSTEMS 1F12 22 AUTOFLIGHT 1H8 23 COMMUNICATIONS 1H12 24 ELECTRICAL POWER 1H21 25 EQUIPMENT/FURNISHINGS 1J17 27 FLIGHT CONTROLS 1J21 28 FUEL 2A17 32 LANDING GEAR 2B10 33 LIGHTS 2C20 34 NAVIGATION & PITOT/STATIC 2D7 37 VACUUM 2E1 39 ELECTRIC/ELECTRONIC PANELS AND MULTIPURPOSE PARTS 2E16 Introduction Page - 6 Reissued: August 1, 1986 1A7 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GAMA SYSTEM/CHAPTER INDEX GUIDE (cont) SYST SUB-SYST AEROFICHE CHAP SECTION TITLE GRID NO. 51 STRUCTURES 2E19 52 DOORS 2F13 55 STABILIZERS 2F21 56 WINDOWS 2G7 57 WINGS 2G12 61 PROPELLER 2H2 70 STANDARD PRACTICES - ENGINE 2H10 71 POWERPLANT 2H14 73 ENGINE FUEL SYSTEM 2I10 74 IGNITION 2I18 77 ENGINE INDICATING 2K2 78 EXHAUST 2K10 79 OIL 2K14 80 STARTING 2K19 91 CHARTS/WIRING DIAGRAMS 3A17 95 SPECIAL PURPOSE EQUIPMENT 3D1 Introduction Page - 7 Interim Revision: February 15, 1995 1A8 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. 6-1. Three View 1B17 6-2. Station References 1B18 6-3. Access Plates and Panels 1B19 7-1. Jacking Arrangement 1B23 8-1. Weighing Airplane 1C4 8-2. Leveling Longitudinally 1C5 8-3. Leveling Laterally 1C5 11-1. Placards and Decals 1C17 12-1. Fuel Filter Bowl and Screen 1C22 12-2. Servicing Points 1D2 12-3. Main Gear Oleo Struts (Cut-away View) 1D6 12-4. Lubrication Chart (Landing Gear, Main) 1D14 12-5. Lubrication Chart (Landing Gear, Nose) 1D15 12-6. Lubrication Chart (Control System) 1D16 thru 1D19 12-7. Lubrication Chart (Cabin Door, Baggage Door and Seat) 1D20 12-8. Lubrication Chart (Power Plant, Propeller and Control Pivot Points) 1D21 12-9. Lubrication Chart (Air Conditioning Condenser) 1D22 20-1. Torque Wrench Extension 1E5 20-2. Correct Method of Installing Rod End Bearings 1E5 20-3. Cherrylock Rivet Removal 1E6 20-4. Hose/Line Markings 1E8 20-5. Flareless Tube fittings 1E9 21-1. Cabin Heater, Defroster and Fresh Air System 1F16 21-2. Air Conditioning System Installation (Typical) 1F24 21-3. Service Valves 1G5 21-4. Test Gauge and Manifold Set 1G6 21-5. Manifold Set Operation 1G7 21-6. Leak Test Hookup 1G8 21-7. Evacuation Hookup 1G10 21-8. Charging Stand 1G12 21-9. Charging Hookup 1G14 21-10. Compressor and Fabricated Oil Dipstick 1G17 21-11. Compressor and Alternator Belt Installation 1G18 21-12. Magnetic Clutch 1G21 21-13. Condenser Air Scoop Installation 1G24 21-14. Expansion Valve 1H1 Introduction Page - 8 Reissued: August 1, 1986 1A9 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. 21-15. Components Installation 1H3 21-16. Overhead Vent System (Not Available with Air Conditioning) 1H5 23-1. Avionics Master and Emergency Switch Circuit 1H14 23-2. Communications Components ELT Schematic 1H16 23-3. Emergency Locator Transmitter Schematic (Narco) 1H16 23-4. ELT Portable Folding Antenna (Narco) 1H18 23-5. ELT Using Fixed Aircraft Antenna (Narco) 1H18 24-1. Lamp-Bank Load 1I10 24-2. Exploded View of Alternator (Chrysler) 1I12 24-3. Checking Field Coil Current Draw 1I12 24-4. Testing Field Circuit 1I12 24-5. Testing Positive Rectifiers 1I14 24-6. Testing Negative Rectifiers 1I14 24-7. Rectifier End Shield and Stator Assembly 1I14 24-8. Testing Positive Rectifiers With Test Lamp 1I16 24-9. Testing Negative Rectifiers With Test Lamp 1I16 24-10. Rectifier and Heatsink Assembly Removal 1I17 24 11. Rectifier End Shield Assembly 1I17 24-12. Testing Stator 1I18 24-13. Removal of Pulley 1I18 24-14. Removal of Bearing 1I19 24-15. Removal of Rectifier End Shield Bearing 1I19 24-16. Testing Rotor for Ground 1I20 24-17. Testing Rotor for Opens or Shorts 1I20 24-18. Installation of Grease Retainer 1I21 24-19. Installation of Rectifier End Shield Bearing 1I21 24-20. Installation of Drive End Shield Bearing 1I21 24-21 . Installation of Pulley 1I21 24-22. Installation of Insulators 1I23 24-23. Installation of Positive Rectifier Assembly 1I23 24-24. Installation of Capacitor 1I23 24-25. Installation of Battery Output Insulator 1I23 24-26. Installation of Negative Rectifier Assembly 1J1 24-27. Installation of Stator 1J1 24-28. Exploded View of Alternator (Prestolite) 1J3 24-29. Removal of Slip Ring End Bearing 1J4 24-30. Removal of Rectifier 1J4 24-31. Removal of Drive End Head 1J4 24-32. Removal of End Head Bearing 1J4 24-33. Testing Rotor for Ground 1J5 Introduction Page - 9 Reissued: August 1, 1986 1A10 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 24-34. Testing Rotor for Shorts 1J5 24-35. Installation of Bearing 1J7 24-36. Installation of Rectifier 1J7 24-37. Terminal Assembly 1J7 24-38. Slip Ring End Bearing Assembly 1J8 24-39. Testing Alternator 1J8 24-40. Brush Installation 1J9 24-41. Internal Wiring Diagram 1J9 25-1. Seat Back Lock 1J19 27-1. Rod End Installation Method 1K7 27-2. Control Column Assembly 1K9 27-3. Aileron Controls (Typical) 1K12 27-4. Aileron Rigging 1K16 27-5. Bellcrank Rigging Tool 1K16 27-6. Aileron Rigging Tool 1K17 27-7. Rudder and Steering Pedal Assembly 1K19 27-8. Rudder Controls 1K21 27-9. Rudder Rigging Tool 1K22 27-10. Clamping Rudder Pedals 1K22 27-11. Rudder Rigging 1K22 27-12. Rudder Travel Adjustments 1L2 27-13. Rudder Trim Control 1L2 27-14. Stabilator Controls 1L4 27-15. Stabilator and Stabilator Trim Travel Adjustments 1L5 27-16. Stabilator Rigging Tool 1L5 27-17. Methods of Securing Trim Cables 1L8 27-18. Stabilator Trim Control 1L9 27-19. Flap Controls 1L13 27-20. Flap Step Adjustment 1L15 27-21. Flap Rigging Tool 1L15 27-22. Flap Rigging 1L18 28-1. Fuel System Diagram 2A20 28-2. Locking Fuel Cap Assembly 2A24 28-3. Fuel Filter Bowl and Screen 2B2 28-4. Plunger Fuel Pump 2B2 28-5. Tolerances, Union Nut and Tubing Nut 2B6 28-6 Fuel Gauge 2B9 32-1. Main Gear Oleo Strut Assembly 2B17 32-2. Main Gear Installation 2B19 32-3. Nose Gear Oleo Strut Assembly 2B21 32-1. Nose Gear Installation 2C1 32-5. Clamping Rudder Pedals in Neutral Position 2C3 32-6. Rudder Pedals at Neutral Angle 2C3 Introduction Page - 10 Reissued: August 1, 1986 1A11 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont.) FIGURE NO. SUBJECT GRID NO. 32-7. Main Wheel Assembly 2C4 32-8. Nose Wheel Assembly 2C6 32-9. Standard Brake Assembly (Cleveland 30-55) 2C8 32-10. Heavy Duty Brake Assembly (Cleveland 30-65) 2C9 32-11. Removal and Installation of Anchor Bolts 2C10 32-12. Brake Disc Minimum Thickness 2C11 32-13. Brake System Installation 2C11 32-14. Brake Master Cylinder (Hand/Parking Brake) 2C13 32-15. Toe Brake Installation 2C15 32-16. Brake Cylinder 10-30 (Toe Brake) 2C16 32-17. Brake Cylinder 17000 (Toe Brake) 2C16 33-1. Strobe Light Connections 2D4 34-1. Pitot/Static System 2D11 37-1. Auxiliary Vacuum Pump Installation 2E12 51-1. Skin Materials and Thickness 2E23 51-1a. Baggage Compartment Inspection Holes Cutout Details 2F1 51-2. Surface Scratches, Abrasions or Ground-in-Dirt 2F5 51-3. Deep Scratches, Shallow Nicks and Small Holes 2F6 51-4. Mixing of Epoxy Patching Compound 2F6 51-5. Welding Repair Method 2F8 51-6. Repairing of Cracks 2F8 51-7. Various Repairs 2F9 51-8. Repair of Stress Lines 2F11 51-9. Repair of Impacted Damage 2F11 52-1. Door Snubber Installation 2F19 55-1. Empennage Group Installation 2G1 55-2. Methods of Securing Control Cables 2G2 55-3. Stabilator Balance 2G2 55-4. Rudder Balance 2G5 56-1. Windshield Installation (Typical) 2G10 56-2. Side Window Installation, Single Pane (Typical) 2G11 57-1. Wing Installation 2G15 57-2. Aileron and Flap Installation 2G20 57-3. Aileron Balance Configuration 2G24 61-1. Typical Nicks and Removal Method 2H4 61-2. Propeller Installation 2H6 61-3. Propeller Governor 2H8 61-4. Adjustment of Propeller Control 2H8 71-1. Engine Installation (PA-28-236) 2I1 71-2. Engine Mount Assembly 2I2 71-3. Cowling Installation (PA-28-236) 2I3 71-4. Carburetor Ice Detection System 2I5 71-5. Carburetor Ice Detector Probe Installation 2I7 71-6 . Rear View of Carburetor Airbox 2I9 73-1. Carburetor 2I13 Introduction Page - 11 Interim Revision: February 15, 1995 1A12 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 73-2. Engine Primer 2I14 73-3. Adjustment of Engine Controls 2I16 74-1. Height of Spring in Distributor Block Tower 2I24 74-2. Contact Points 2I24 74-3. Engine Timing Marks 2J2 74-4. Timing Light Connected to Magneto 2J2 74-5. Timing Marks on Magneto Rotor 2J4 74-6. Painted Tooth Centered in Timing Window 2J4 74-7. Timing Mark on Rotor Aligned with Pointer 2J4 74-8. Timing Light Connected to Magneto and Breakers 2J5 74-9. Cam End View of Magneto 2J7 74-10. Removing Impulse Coupling 2J9 74-11. Checking Flyweight to Stop Pin Clearance 2J9 74-12. Stop Pin Installation Dimension 2J9 74-13. Checking Flyweight Axial Wear with Drill Shank 2J10 74-14. Checking Flyweight Radial Wear with Gauge 2J10 74-15. Points of Coupling Body Wear 2J11 74-16. Acceptable and Deformed Coupling Springs 2J11 74-17. Checking Impulse Coupling for Magnetization 2J13 74-18. Orientation of Spring in Coupling Body 2J13 74-19. Lifting Inner End of Spring 2J13 74-20. Checking Harness Lead Continuity 2J15 74-21. Checking Harness Lead Insulation Resistance 2J15 74-22. Modified Pliers 2J15 74-23. Removing Spring From Lead Assembly 2J15 74-24. Assembly Tool 2J17 74-25. Using Assembly Tool 2J17 74-26. Ferrule Positioned Under Braid 2J18 74-27. Ferrule Seating Tool 2J18 74-28. Position of 11-8627 Kit and Contact Spring at Start of Installation 2J19 74-29. Position of 11-8627 Kit and Contact Spring After Installation 2J19 74-30. Lubricating Sleeve 2J19 74-31. Lubricating Ferrule Shoulder 2J19 74-32. Removing Spark Plug Frozen to Bushing 2J21 74-33 Ignition Switch Wire Positions 2J24 78-1. Exhaust System Inspection Points 2K12 80-1. Exploded View of Gear Reduction Starting Motor 2K24 80-2. Turning Starting Motor Commutator 2L2 80-3. Testing Motor Armature for Shorts 2L2 80-4. Testing Motor Fields for Grounds 2L2 80-5. No-Load Test Hookup 2L4 80-6. Stall-Torque Hookup 2L4 Introduction Page - 12 Reissued: August 1, 1986 1A13 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 95-1. Tire Balancer Fixture 3D4 95-2. Control Surface Balancing Tool 3D5 95-3. Orifice Replacement Tool 3D6 95-4. Fabricated Tool for Baggage Door Lock 3D7 95-5. Retainer Ring Tool 3D7 95-6. Fabricated Aileron Bellcrank Rigging Tool 3D8 95-7. Fabricated Rudder Rigging Tool 3D8 95-8. Fabricated Aileron and Flap Rigging Tool 3D9 95-9. Fabricated Stabilator Rigging Tool 3D10 95-10. Charging Stand 3D11 95-11. York Compressor and Fabricated Oil Dipstick 3D11 95-12. Ignition Harness Ferrule Seating Tool 3D12 95-13. Assembly Tool for Ignition Harness Insulating Sleeve Installation 3D12 —NOTE— Refer to Grid No. 3B15 for Electrical Schematic Index. Introduction Page - 13 Reissued: August 1, 1986 1A14 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CHARTS CHART NO. SUBJECT GRID NO. 601 Leading Particulars and Principal Dimensions 1B15 1201 Thread Lubricants 1D11 1202 Type of Lubricants 1D12 2001 Thread Lubricants 1E10 2002 Maximum Distance Between Supports For Fluid Tubing 1E10 2003 Types of Metal Corrosion 1E15 2101 Troubleshooting (Air Conditioner) 1F18 2102 Troubleshooting (Air Conditioning System) 1F20 2103 Temperature Pressure 1G2 2104 Aluminum Tubing Torque 1G4 2105 System Vacuum 1G10 2106 Compressor Oil Charge 1G17 2107 Blower System Wire Color Codes 1H6 2401 Troubleshooting (Alternator) 1I1 2402 Troubleshooting (Battery) 1I6 2403 Alternator Specifications 1J10 2404 Alternator Belt Tension 1J11 2405 Hydrometer Reading and Battery Charge Percent 1J13 2406 Electrical System Component Loads 1J16 2701 Troubleshooting (Surface Controls) 1K1 2702 Cable Tension Vs. Ambient Temperature 1K6 2801 Troubleshooting (Fuel System) 2A21 2802 Transmitter/Fuel Gauge Tolerances 2B9 3201 Troubleshooting (Landing Gear) 2B14 3202 Nose Gear Alignment Tolerances 2C2 3301 Troubleshooting (Electrical System) 2C23 3401 Troubleshooting (Rate of Climb Indicator) 2D12 3402 Troubleshooting (Altimeter) 2D14 3403 Troubleshooting (Airspeed Tubes and Indicator) 2D15 3404 Troubleshooting (Magnetic Compass) 2D19 3701 Troubleshooting (Vacuum System) 2E3 5101 List of Materials (Thermoplastic Repair) 2F4 6101 Propeller Torque Limits 2H7 7101 Troubleshooting (Engine) 2H17 7301 Troubleshooting (Fuel Pressure Gauge) 2I17 7401 Troubleshooting (Magneto) 2I22 7402 Coupling Torques 2J20 7701 Troubleshooting (Manifold Pressure Indicator) 2K4 7702 Troubleshooting (Tachometer) 2K5 7703 Troubleshooting (Engine Oil Pressure Gauge) 2K6 7704 Troubleshooting (Oil Temperature Indicators) 2K7 Introduction Page - 14 Interim Revision: February 15, 1995 1A15 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CHARTS (cont) CHART NO. SUBJECT GRID NO. 7705 Troubleshooting (Exhaust Gas Temperature Gauge) (Alcor) . 2K8 7706 Troubleshooting (Cylinder Head Temperature Gauge) 2K9 800l Troubleshooting (Starter) 2K22 8002 Starting Motor Specifications 2L6 9101 Flare Fitting Torques 3A19 9102 Recommended Nut Torques 3A20 9103 Conversion Tables 3A23 9104 Decimal Equivalents of Drill Sizes 3B4 9105 List of Consumable Materials 3B5 9106 Electrical Wire Coding 3B13 9107 Electrical Symbols 3B14 Introduction Page - 15 Reissued: August 1, 1986 1A16 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER AIRWORTHINESS LIMITATIONS 1A17 CHAPTER 4 - AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT NO. EFFECTIVITY 4-00-00 AIRWORTHINESS LIMITATIONS 1A20 4-00-00 General 1A20 4 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1A18 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1A19 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL AIR WORTHINESS LIMITATIONS GENERAL Airworthiness limitations are FAA approved and specify inspections and maintenance required under Parts 43 and 9l of Federal Aviation Regulations. Limitations relating to fatigue life of the airplane and its components are as follows: l. Safe life of airframe structure will be released when information becomes available. 2. Safe life limit of propeller blades is unlimited. (Refer to latest revision of Hartzell Service Letter No. 6l for l500 hour overhaul.) —NOTE— Refer to the Limitations in the Pilot’s Operating Handbook and FAA Approved Airplane Flight Manual for a detail of flight limitations. Mandatory replacement times and inspection intervals of life limited parts are contained in chapter 5 of this manual. —END— 4-00-00 Page - 4-01 Reissued: August 1, 1986 1A20 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER TIME LIMITS/MAINT CHECKS 1A21 CHAPTER 5 - TIME LIMITS/MAINTENANCE CHECKS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT NO. EFFECTIVITY 5-00-00 GENERAL 1 A24 5-10-00 TIME LIMITS 1A24 5-11-00 Inspection Requirements 1A24 5-12-00 Preflight Checks 1A24 5-13-00 Overlimits Inspection 1A24 5-20-00 SCHEDULED MAINTENANCE 1B1 5-21-00 Periodic Inspections 1B1 5-22-00 Programmed Inspection 1B11 5-50-00 UNSCHEDULED MAINTENANCE CHECKS 1B11 5-51-00 Special Inspections as Required, Upon Condition 1B11 5 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1A22 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1A23 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter provides instructions for conducting inspections. These inspections are described in Inspection Requirements and Preflight Checks. Repair or replacement instructions for components found to be unserviceable at inspection are found in the section covering the applicable aircraft system. —WARNING— When working on engines ground magneto primary circuits before performing any operation. TIME LIMITS INSPECTION REQUIREMENTS Required inspection procedures are listed in Periodic Inspections. Inspection procedures are broken down into eight major groups. These are: Propeller, Engine, Cabin, Fuselage and Empennage, Wing, Landing Gear, Operational Inspection and General. The first column in each group lists the inspection or procedure to be performed. The second column is divided into four columns indicating the required inspection intervals of 50 hours, 100 hours, 500 hours, and 1000 hours. Each inspection or operation is required at each inspection interval as indicated by a circle (O). If an item is not entirely accessible or must be removed, refer to the applicable section of this manual for instructions on removal of the item. When performing inspections, use form P/N 230 8ll furnished by Piper factory service department; available through Piper dealers or distributors. Refer to latest Piper Parts Price List Aerofiche for current revision date. PREFLIGHT CHECKS —CAUTION— In addition to inspection intervals required in Periodic Inspections, preflight checks must be performed as described in the following paragraph. The airplane must be given a thorough preflight check. The pilot or mechanic must include the preflight check as a normal procedure necessary for aircraft safe operation. Refer to the Pilot’s Operating Handbook for a checklist. . OVERLIMITS INSPECTION If the airplane has been operated so that any of its components have exceeded their maximum operational limits, check with appropriate manufacturer. 5 - 13 - 00 Page - 5-01 Reissued: August 1, 1986 1A24 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SCHEDULED MAINTENANCE PERIODIC INSPECTIONS —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Nature of Inspection A. PROPELLER GROUP l. Inspect spinner and back plate................................................................................. O O O O 2. Inspect blades for nicks and cracks ......................................................................... O O O O 3. Inspect for grease and oil leaks................................................................................ O O O O 4. Lubricate propeller. (Refer to chapter l2.)............................................................... O O O O 5. Inspect spinner mounting brackets .......................................................................... O O O 6. Inspect propeller mounting bolts and safety. (Check torque if safety is broken.).................................................................................................................... O O O 7. Inspect hub parts for cracks and corrosion.............................................................. O O O 8. Rotate blades of constant speed propeller and check for tightness in hub pilot tube.................................................................................................................. O O O 9. Remove constant speed propeller; remove sludge from propeller and crankshaft................................................................................................................. O O l0. Inspect complete propeller and spinner assembly for security, chafing, cracks, deterioration, wear, and correct installation. ............................................... O O O B. ENGINE GROUP WARNING: Ground magneto primary circuit before working on engine. NOTE: Read Notes 4 and l9 prior to completing this inspection group. l. Remove engine cowl and inspect for damage ......................................................... O O O O 2. Clean and check cowling for cracks, distortion, and loose or missing fasteners................................................................................................................... O O O 3. Drain oil sump. (See Note 5 ).................................................................................. O O O O 4. Clean suction oil strainer at oil change. (Check strainer for foreign particles.)...... O O O O 5. Clean pressure oil strainer or change full-flow (cartridge type) oil filter element. (Check strainer or element for foreign particles.).................................................... O O O O 6. Inspect oil temperature sender unit for leaks and security ...................................... O O O 50 500 1000 100 Inspection Time (HRS) PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5-21-00 Page -5-02 Reissued: August 1, 19861B1 PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Nature of Inspection B. ENGINE GROUP (cont) 7. Inspect oil lines and fitting for leaks, security, chafing, dents, and cracks. (See Note 7.)............................................................................................................ O O O O 8. Clean and inspect oil radiator cooling fins.............................................................. O O O 9. Remove and flush oil radiator ................................................................................. O O 10. Fill engine with oil per lubrication chart. (Refer to chapter l2.).............................. O O O O CAUTION: Do not contaminate the vacuum pump with cleaning fluid. (Ref: Latest revision of Lycoming Service Instruction No. l22l.) 11. Clean engine ............................................................................................................ O O O 12. Inspect condition of spark plugs. (Clean and adjust gap as required, adjust per latest revision of Lycoming Service Instruction No. 1042.).............................. (See Note 14.) ......................................................................................................... O O O NOTE: If fouling of spark plugs has been apparent, rotate bottom plugs and upper plugs. 13. Inspect spark plug cable leads and ceramics for corrosion and deposits................. O O O 14. Check cylinder compression. (Ref: Latest revision of AC 43.l3-l.)........................ O O O 15. Inspect cylinders for cracked or broken fins............................................................ O O O 16 Inspect rocker box covers for evidence of oil leaks. If found, replace gasket; tighten cover screws to a torque of 50 inch-pounds. (See Note 12.)........... O O O O NOTE: Lycoming requires a valve inspection be made after every 400 hours of operation. (See Note l l.) 17. Inspect ignition harness and insulators for high tension leakage and continuity .... O O O 18. Inspect magneto points for condition and proper clearance.................................... O O O 19. Inspect magneto for oil leakage .............................................................................. O O O 20. Inspect breaker felts for proper lubrication ............................................................. O O O 21. Inspect distributor block for cracks, burned areas, corrosion, and height of contact springs ......................................................................................... O O 22. Check magnetos to engine timing ........................................................................... O O O 23. Overhaul or replace magnetos. (See Note 6.) 24. Remove air filter and tap gently to remove dirt particles. (Replace as required.).................................................................................................................. O O O O 25. Drain carburetor and clean inlet line fuel strainer................................................... O O O O 26. Inspect condition of carburetor heat air-door and box. (See Note l3.) ................... O O O O 27. Inspect vent lines for evidence of fuel or oil seepage.............................................. O O O O 28. Inspect intake seals for leaks and clamps for tightness ........................................... O O O O 29. Inspect all air inlet duct hoses. (Replace as required.) ............................................ O O O O 50 500 1000 100 Inspection Time (HRS) PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5 - 21 - 00 Page -5 - 03 Reissued: August 1, 1986 1B2 PERIODIC INSPECTIONS (cont) —NOTE— Perform oll inspections or operations at each inspection interval as indicated by a circle (O). Nature of Inspection B. ENGlNE GROUP (cont) 30. Inspect condition of flexible fuel lines ................................................................... O O O 31. Replace flexible fuel lines. (See Note 6.)................................................................ O 32. Inspect fuel system for leaks.................................................................................... O O O O 33. Clean screens in electric fuel pump(s) and check operation (engine and electric).................................................................................................................... O O O O 34. Remove and clean fuel filter bowl and screen. (Clean at least every 90 days.)........................................................................................................................ O O O O 35. Inspect vacuum pump and lines............................................................................... O O O 36. Overhaul or replace vacuum pump. (See Note 6.)................................................... O 37. Inspect throttle, carburetor heat, mixture and propeller governor controls for security, travel, and operating conditions........................................................... O O O 38. Inspect exhaust stacks, connections, and gaskets. (Refer to chapter 78.) (Replace gaskets as required.) ................................................................................. O O O 39. Inspect muffler, heat exchange and baffles. (Refer to chapter 78.)......................... O O O 40. Check recommended time for replacement of muffler per chapter 78.................... O O O 41. Inspect breather tube for obstructions and security................................................. O O O 42. Inspect crankcase for cracks, leaks, and security of seam bolts.............................. O O O 43. Inspect engine mounts for cracks and loose mountings .......................................... O O O 44. Inspect all engine baffles ......................................................................................... O O O 45. Inspect all wiring connected to engine or accessories............................................. O O O O 46. Inspect rubber engine mount bushings for deterioration. (Replace as required.).................................................................................................................. O O O 47. Inspect fire wall seals .............................................................................................. O O O 48. Inspect condition and tension of alternator drive belt. (Refer to chapter 2l.).......... O O O 49. Lubricate alternator and compressor idler pulleys (if installed) per lubrication chart................................................................................................. O 50. Inspect condition of alternator and starter............................................................... O O O 51. Inspect security of alternator mounting .................................................................. O O O 52. Check air conditioning compressor oil level (See Note 8) 53. Inspect condition of compressor belt and tension. (Refer to chapter 2l.)................ O O O 54. Inspect compressor clutch security and wiring. (See Note 9.) ................................ O O O 55. Inspect security of compressor mounting ............................................................... O O O 56. Check fluid in brake reservoir. (Fill as required.).................................................... O O O O 50 500 1000 100 Inspection Time (HRS) PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5 - 21 - 00 Page -5 - 04 Reissued: August 1, 1986 1B3 PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Nature of Inspection B. ENGINE GROUP (cont) 57. Lubricate all controls. (Refer to chapter l2.)............................................................ O O O 58. Reinstall engine cowl............................................................................................... O O O O C. CABIN GROUP 1. Inspect cabin entrance door and windows for damage and operation..................... O O O 2. Inspect upholstery for tears...................................................................................... O O O 3. Inspect seats, seat belts, security brackets, and bolts............................................... O O O 4. Check trim operation ............................................................................................... O O O 5. Check rudder pedals ................................................................................................ O O O 6. Inspect parking brake and brake handle for operation and cylinder leaks......................................................................................................................... O O O 7. Inspect control wheels, column, pulleys, and cables............................................... O O O 8. Inspect flap control cable attachment bolt (See latest revision of Piper Service Bulletin 965)............................................................................................................ O O O 9. Inspect landing, navigation, cabin, and instrument lights ....................................... O O O O 10. Inspect instruments, lines and attachments.............................................................. O O O 11. Inspect gyro operated instruments and electric turn and bank. (Overhaul or replace as required.) ............................................................................................ O O O 12. Clean or replace vacuum regulator filter................................................................. O O O 13. Inspect altimeter. (Calibrate altimeter system in accordance with FAR 9l.170 if appropriate.)...................................................................................... O O O 14. Check operation of fuel selector valve .................................................................... O O O 15. Inspect condition of heater controls and ducts ........................................................ O O O 16. Inspect condition and operation of air vents............................................................ O O O 17. Inspect condition of air conditioning ducts ............................................................. O O O 18. Remove and clean air conditioning evaporator filter .............................................. O O O 50 500 1000 100 Inspection Time (HRS) PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5 - 21 - 00 Page 5 - 05 Interim Revision: February 15, 1995 1B4 PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Nature of Inspection D. FUSELAGE AND EMPENNAGE GROUP l. Remove inspection plates and panels (See Note 21.).............................................. O O O 2. Inspect baggage door, latch, and hinges.................................................................. O O O 3. Inspect battery, box, and cables. Check at least every 30 days. Flush box as required and fill battery per instructions on box ................................................. O O O O 4. Inspect electronic installation.................................................................................. O O O 5. Inspect bulkheads and stringers for damage............................................................ O O O 6. Inspect antenna mounts and electric wiring............................................................. O O O 7. Inspect air conditioning system for freon leaks....................................................... O O O 8. Inspect freon level in sight gauge of receiver-dehydrator. (Refer to chapter 2l.).... O O O O 9. Inspect air conditioning condenser air scoop rigging ............................................. O O O O l0. Inspect fuel lines, valves, and gauges for damage and operation............................ O O O l l. Clean screens in fuel pumps ................................................................................... O O O l2. Remove, drain, and clean fuel strainer bowl and screen. Drain and clean at least every 90 days............................................................................................... O O O O l3. Inspect security of all lines...................................................................................... O O O l4. Inspect vertical fin and rudder surfaces for damage................................................ O O O l5. Inspect rudder hinges, horn, and attachments for damage and operation................ O O O l6. Inspect rudder control stop to insure stop has not loosened and locknut is tight................................................................................................... O O O 17. Inspect vertical fin attachments............................................................................... O O O 18. Inspect rudder hinge bolts for excess wear. (Replace as required.)......................... O O O 19. Inspect stabilator surfaces for damage..................................................................... O O O 20. Inspect stabilator, tab hinges, horn, and attachments for damage and operation..... O O O 21. Inspect stabilator attachments. (See latest revision of Piper Service Bulletin 856)............................................................................................................ O O O 22. Inspect stabilator and tab hinge bolts and bearings for excess wear. (Replace as required.).............................................................................................. O O O 23. Inspect stabilator control stop. Ensure stop has not loosened and jam nut is tight.. O O O 23a. Inspect stabilator trim mechanism........................................................................... O O O 24. Inspect fuselage wing attach fittings for corrosion, general condition and security. (See latest revision of Piper Service Bulletin 977.)................................................. O O O 25. Inspect cables, aileron, rudder, stabilator, stabilator trim, turnbuckles, guides, and pulleys for safety, damage, and operation (See Note 22).................................. O O O 26. Inspect all cable tensions (use tensiometer). (See Note l7.).................................... O O O 27. Clean and lubricate stabilator trim drum screw....................................................... O O 28. Clean and lubricate all exterior needle bearings...................................................... O 29. Lubricate per lubrication chart. (Refer to chapter l2.)............................................. O O O O 30. Inspect anti-collision light for security and operation............................................. O O O 50 500 1000 100 Inspection Time (HRS) PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5 - 21 - 00 Page 5 - 06 Interim Revision: February 15, 1995 1B5 PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Nature of Inspection D. FUSELAGE AND EMPENNAGE GROUP (cont) 31. Inspect security of Autopilot bridle cable clamps. (See Note 10.).......................... O O O 32. Inspect all control cables, air ducts, electrical leads, lines, radio antenna leads, and attaching parts for security, routing, chafing, deterioration, wear, and correct installation................................................................................... O O O 33. Inspect elt installation, condition of battery, and antenna. (See latest revision of Piper Service Letter No. 820.)............................................................... O O O 34. Reinstall inspection plates and panels ..................................................................... O O O E. WING GROUP l. Remove inspection plates and fairings.................................................................... O O O 2. Inspect surfaces and tips for damage, loose rivets, and condition of walkway................................................................................................................... O O O 3. Inspect aileron hinges and attachments .................................................................. O O O 4. Inspect aileron control stops to insure stop has not loosened and locknut is tight ...................................................................................................................... O O O 5. Inspect aileron cables, pulleys, and bellcranks for damage and operation.............. O O O 6. Inspect flaps and attachments for damage and operation ....................................... O O O 7. Inspect condition of bolts used with hinges. (Replace as required.) ....................... O O O 8. Lubricate per lubrication chart. (Refer to chapter l2.) ............................................ O O O O 9. Inspect forward and aft wing attach fittings for corrosion, general condition and security. (See latest revision of Piper Service Bulletin 977.)................................... O O O 9a. Inspect wing attachment bolts and brackets ............................................................ O O O 10. Inspect fuel tanks and lines for leaks and water. (See Note l6.) ............................. O O O 11. Fuel tanks marked for capacity ............................................................................... O O O 12. Fuel tanks marked for minimum octane rating........................................................ O O O 13. Inspect fuel cell vents. (See Note l5.) ..................................................................... O O O 14. Inspect all control cables, air ducts, electrical leads, lines, and attaching parts for security, routing, chafing, deterioration, wear, and correct installation ............................................................................................................... O O O 15. Reinstall inspection plates and fairings ................................................................... O O O F. LANDING GEAR GROUP 1. Inspect oleo struts for proper extension. (Check fuid level as required.) ............... O O O O 2. Inspect nose gear steering control and travel........................................................... O O O 3. Inspect wheels for alignment .................................................................................. O O O 4. Put airplane on jacks ............................................................................................... O O O 5. Inspect tires for cuts, uneven or excessive wear, and slippage ............................... O O O 50 500 1000 100 Inspection Time (HRS) PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5 - 21 - 00 Page 5 - 07 Interim Revision: February 15, 1995 1B6 PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection intcrval as indicated by a circle (O). Nature of Inspection F. LANDING GEAR GROUP (cont) 6. Remove wheels. Clean, check, and repack bearings ............................................... O O O 7. Inspect wheels for cracks, corrosion, and broken bolts........................................... O O O 8. Check tire pressure. ................................................................................................. O O O O 9. Inspect brake lining and disc for condition and wear.............................................. O O O 10. Inspect brake backing plates for condition and wear............................................... O O O 11. Inspect brake lines ................................................................................................... O O O 12. Inspect shimmy dampener....................................................................................... O O O 13. Inspect gear forks for damage.................................................................................. O O O 14. Inspect oleo struts for fluid leaks and scoring......................................................... O O O 15. Inspect gear struts, attachments, torque links, and bolts for condition and security.............................................................................................................. O O O 16. Inspect all hydraulic lines, electrical leads, and attaching parts for security, routing, chafing, deterioration, wear, and correct installation ................................ O O O 17. Lubricate per lubrication chaft. (Refer to chapter l2.)............................................. O O O O 18. Remove airplane from jacks ................................................................................... O O O G. OPERATIONAL INSPECTION 1. Check fuel pump and fuel tank selector................................................................... O O O O 2. Check fuel quantity, pressure, and flow readings ................................................... O O O O 3. Check oil pressure and temperature ........................................................................ O O O O 4. Check alternator output............................................................................................ O O O O 5. Check manifold pressure ......................................................................................... O O O O 6. Check carburetor heat ............................................................................................. O O O O 7. Check parking brake................................................................................................ O O O O 8. Check operation of auxiliary vacuum pump system. (If installed.) (See Note 20.).......................................................................................................... O O O 50 500 1000 100 Inspection Time (HRS) PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5 - 21 - 00 Page -5 - 08 Reissued: August 1, 1986 1B7 PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Nature of Inspection G. OPERATIONAL INSPECTION (cont) 9. Check vacuum gauge............................................................................................... O O O O 10. Check gyros for noise and roughness...................................................................... O O O O 11. Check cabin heater operation................................................................................... O O O O 12. Check magneto switch operation............................................................................. O O O O 13. Check magneto rpm variation.................................................................................. O O O O 14. Check throttle and mixture operation...................................................................... O O O O 15. Check propeller smoothness.................................................................................... O O O O 16. Check propeller governor action ............................................................................. O O O O 17. Check engine idle .................................................................................................... O O O O 18. Check electronic equipment operation .................................................................... O O O O 19. Check air conditioner compressor clutch operation ................................................ O O O O 20. Check air conditioner condenser scoop operation................................................... O O O O 21. Check operation of autopilot and automatic trim. (See Note 18.)........................... O O O O H. GENERAL 1. Aircraft conforms to FAA specification.................................................................. O O O O 2. All FAA airworthiness directives complied with .................................................... O O O O 3. All manufacturers service bulletins and letters complied with................................ O O O O 4. Check for proper flight manual................................................................................ O O O O 5. Aircraft papers in proper order................................................................................ O O O O 50 500 1000 100 Inspection Time (HRS) PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5 - 21 - 00 Page -5 - 09 Reissued: August 1, 1986 1B8 PERIODIC INS7PECTIONS (cont) NOTES: 1. All inspections or operations are required at each inspection interval as indicated by a (O). Both annual and l00 hour inspections are complete airplane inspections, and are identical in scope. The 500 and 100 hour inspections are extensions of the annual or l00 hour inspection, but require a more detailed examination of the airplane, and overhaul or replacement of some major components. Inspections must be accomplished by persons authorized by the FAA. 2. Piper service bulletins are of special importance and must be complied with promptly. 3. Piper service letters are product improvements and service hints pertaining to servicing. Service letters should be given careful attention. 4. Power plant inspections are based on the engine manufacturers operators manual. 5. Intervals between oil changes can be increased as much as 100% provided the full flow cartridge type oil filter element is replaced each 50 hours of operation and the specified octane fuel is used. If fuel other than specified octane rating for the power plant is used, refer to latest revision of Lycoming Service Letter No. Ll85 for additional information and recommended service procedures. 6. For engine overhaul, refer to the latest revision of Lycoming Service Letter No. 20l. 7. Replace flexible oil lines as required per latest revision of Lycoming Service Bulletin No. 240. 8. Do not check compressor oil level unless a freon leak has occurred. 9. Clean any traces of oil from clutch surface. 10. Check security and condition of autopilot servo bridle cables, clamps, and shear pin in accordance with the latest revision of Piper Service Letter No. 695. 11. Remove the rocker box covers after every 400 hours of engine operation, and check for freedom of valve rockers when valves are closed. Check for evidence of abnormal wear or broken parts in the area of the valve tips, valve keeper, springs, and spring seat. If any indications are found, the cylinder and all components must be removed (including the piston and connecting rod assembly). Inspect for further damage. Replace any parts that do not conform to limits shown in the latest revision for Lycoming Service Table of Limits No. SSPl776. 12. Check cylinders for evidence of excessive heat. This condition is indicative of internal damage to the cylinder. If found, determine and correct its cause before the aircraft is returned to service. Heavy discoloration and appearance of seepage at the cylinder head and barrel attachment area is usually due to emission of thread lubricant used during assembly, or by slight gas leakage which stops after the cylinder has been in service for awhile. This condition is neither harmful nor detrimental to engine performance and operation. If proven that leakage exceeds these conditions, replace the cylinder. 13. Check throttle body attaching screws for tightness. The correct torque for these screws is 40 to 50 inch-pounds. 14. When using alternate fuels, refer to latest revision of Lycoming Service Letter No. L185 for additional information and recommended service procedures. 15. Replace fuel tank vent line flexible connections as required. Time in service must not exceed 1000 hours. 5 - 21 - 00 Page - 5 - 10 Reissued: August 1, 1986 1B9 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PERIODIC INSPECTIONS (cont) NOTES (cont): 16. Replace flexible fuel tank supply hose at time of engine overhaul. 17. Maintain cable tensions specified in chapter 27. 18. Refer to list of vendor and Piper publications in the front of the maintenance manual for appropriate subject manual part number. 19. Refer to Lycoming Service Bulletin 469. 20. The airborne auxiliary vacuum pump/motor (4A3-1) must be removed from service at 500 hours operating time as indicated on the elapsed time indicator, or at l0 years of installed time in the aircraft, whichever comes first. —NOTE— 100 Hour/Annual Inspection Report printed copies are available through Piper service sales - under Piper part number 230 811. refer to latest revision of Piper Parts Price List Aerofiche (last card in set) for latest revision to this report. 21. If not already installed, add access panels per instructions in Chapter 51. See latest revision of Piper Service Bulletin 977. 22. Special care should be taken to inspect stabilator control cables beneath aft baggage compartment floor. Add access panels per instructions in Chapter 51 to ease this inspection. 5 - 21 - 00 Page 5 - 11 Interim Revision: February 15, 1995 1B10 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PROGRAMMED INSPECTION The programmed inspection permits best aircraft utilization by scheduling inspections through use of planned inspection schedules. This programmed inspection schedule is available in manual form from Piper service sales under Piper part number 76l 734. UNSCHEDULED MAINTENANCE CHECKS SPECIAL INSPECTIONS AS REQUlRED (ON CONDITION) Special inspections supplement scheduled inspections as outlined in periodic inspections, to include inspections required at intervals not compatible with airframe operating time or inspection intervals. These include: l. Inspections required because of special conditions or incidents that are required to ensure further safe flight. 2. Hard or Overweight Landing. This inspection must be performed after rough landing or after landing while aircraft is known to exceed design landing weight. Check following areas and items: a. Wings - for wrinkled skins and loose or missing rivets. b. Fuel leaks around fuel tanks. c. Wing spar webs, bulkheads, wing and fuselage stringers, and skins for any signs of overstress or damage. d. An alignment check to clarify any doubt of damage. 3. Severe Turbulence Inspection. Check same items and locations as for Hard or Overweight Landings as well as the following: a. Top and bottom fuselage skins for loose or missing rivets and wrinkled skins. b. Empennage skins and attachments. 4. Engine overspeed, sudden stoppage, loss of oil, overtemperature, and lightning strike. Check with Avco Lycoming for necessary corrective action. —END— 5 - 51 - 00 Page - 5 - 12 Reissued: August 1, 1986 1B11 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER DIMENSIONS AND AREAS 1B12 CHAPTER 6 - DIMENSIONS AND AREAS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT NO. EFFECTIVITY 6-10-00 DIMENSIONS 1B15 6-20-00 STATION REFERENCE LINES 1B18 6-30-00 ACCESS AND INSPECTION PROVISIONS 1B19 1B13 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 6 - Cont./Effec. Page - 1 Reissued: August 1, 1986 THIS PAGE INTENTIONALLY LEFT BLANK 1B14 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL DIMENSIONS Airplane dimensions and specifications are shown in figure 6-1 and listed in chart 601. CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS MODEL PA-28-236 ENGINE Manufacturer Avco-Lycoming Model 0-540-J3A5D Rated horsepower at propeller rpm 235 hp/2400 rpm Oil sump capacity l2 U.S. qts. Fuel, aviation grade, minimum l00/ 130 Magneto, Bendix D6LN-203l, 303l, 3000 Magneto timing 23° btc Approved spark plugs Refer to the latest issue of Avco Lycoming Service Instructions No. 1042 Spark plug gap 0.017 to 0.021 Firing order 1-4-5-2-3-6 Carburetor, Marvel-Schebler MA4-5 Starter, Prestolite, l2 Volt MZ4206 Alternator, Prestolite (60 Amp) ALY-64221 Alternator, Chrysler (60 Amp) 36566242 Alternator, Chrysler (60 Amp) 41118103 PROPELLER (CONSTANT SPEED) Manufacturer Hartzell Hub, model HC-F2YR-l( ) Blade, model F8468A-4R Diameter max./min. 80.0 In. Governor control Hartzell Governor model F-4-2l( ) 1Airconditioned aircraft 2Non-Airconditioned aircraft s/n: 28-7911001 to 28-7911087 3Non-Airconditioned aircraft s/n: 28-7911088 and up 6 - 10 - 00 Page - 6 - 01 Reissued: August 1, 1986 1B15 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (CONT) FUEL SYSTEM CAPACITY Left wing tank 38.5 gal. Right wing tank 38.5 gal. Total 77 gal. Total unusable 5 gal. LANDING GEAR Type Fixed Shock strut type Combination air-oil Wheel tread 10.0 Ft. Wheel base 6 Ft. 6.06 Inches Turning radius, nose wheel l3 Ft. Nose wheel travel 30° +/- l° left & right Wheel, nose McCauley D30665 or Cleveland 40-56, 6:00x6 Wheel, main Cleveland 40-86B, 6:00 x 6 Wheel, main, heavy duty Cleveland 40-90A, 6:00 x 6 Brake type, standard Cleveland 30-55, single disc, single piston Brake type, heavy duty Cleveland 30-65, single disc, double piston Tires, nose 6:00 x 6, 6 ply rating Tires, main 6:00 x 6, 6 ply rating Tires, main, heavy duty 6:00 x 6, 8 ply rating Tire pressure, nose 28-30 psi Tire pressure, main 35-40 psi Tire pressure, main, heavy duty 35-40 psi 6 - 10 - 00 Page - 6 - 02 Reissued: August 1, 1986 1B16 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 6-l. Three View 6 - 10 - 00 Page - 6 - 03 Reissued: August 1, 1986 1B17 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STATION REFERENCE LINES To facilitate location of various components which require maintenance and servicing, a method utilizing fuselage station (F. S.), wing station or buttock line (BL), and water line (WL) is frequently used in this manual. (Refer to figure 6-2.) Fuselage stations, buttock lines, and water lines are reference points measured in inches in a vertical or horizontal direction from a given reference line. Fuselage station 0 is 78.4 inches forward of wing leading edge or 44.5 inches forward of lower edge of firewall. Station 0 BL of wing and stabilator is centerline of airplane. Station 0 WL of fuselage, vertical stabilizer, and rudder is 20.5 inches below the cabin floor as measured at rear wing spar with airplane level. The reference datum is located 78.4 inches forward of wing leading edge at the intersection of the straight and tapered section. Figure 6-2. Station Reference Lines 6 - 20 - 00 Page - 6 - 04 Reissued: August 1, 1986 1B18 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ACCESS AND INSPECTION PROVISIONS —CAUTION— Before entering aft section of fuselage, be sure airplane is supported at tail skid. Airplane access and inspection panels are shown in figure 6-3. All access plates and panels are secured by either metal fasteners or screws. To enter aft section of fuselage, open baggage compartment door and remove access panel. Figure 6-3. Access Plates and Panels 6 - 30 - 00 Page 6 - 05 Interim Revision: February 15, 1995 1B19 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER LIFTING AND SHORING 1B20 CHAPTER 7 - LIFTING AND SHORING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT NO. EFFECTIVITY 7-l0-00 JACKING lB23 7 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1B21 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1B22 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 7-l. Jacking Arrangement JACKING Jacking airplane is necessary to service landing gear and to perform other service operations. Proceed as follows: —CAUTION— Be sure to apply sufficient tail support ballast to prevent airplane from tipping forward. 1. Place jacks under jack pads on front wing spar. (Refer to figure 7-1.) 2. Attach tail support to tail skid. Place approximately 250 pounds ballast on base of tail support to hold tail down. 3. Raise jacks until all three wheels are off ground. —END— 7 - 10 - 00 Page - 7 - 01 Reissued: August 1, 1986 1B23 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1B24 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER LEVELING AND WEIGHING 1C1 CHAPTER 8 - LEVELING AND WEIGHING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION SUBJECT SUBJECT NO EFFECTIVITY 8-l0-00 LEVELING lC4 8-20-00 WEIGHING lC4 8 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1C2 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1C3 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LEVELING To level the airplane for purposes of weighing or rigging, proceed as follows: l. To longitudinally level airplane. Partially withdraw two leveling screws immediately below the left front side window. (Refer to figure 8-2.) Place level on screw heads and adjust jacks until level is centered. If airplane is either on scales or on noor, block main gear oleos to full extension. Deflate nose wheel until propcr position is reached. 2. To laterally level airplane. Place level across spar box assembly located under rear seat. (Refer to figure 8-3.) Raise or lower one wing tip by deflating appropriate tire on high side of airplane or adjust either jack until bubble of level is centered. WEIGHING (figure 8-1) Weigh airplane as follows: 1. Position scale and ramp in front of each wheel. 2. Secure scales from rolling forward and tow airplane up onto scales. 3. Remove ramp so as not to interfere with scales. 4. If airplane is to be weighed for weight and balance computations, level airplane per Leveling. Figure 8-l. Weighing Airplane 8 - 20 - 00 Page - 8 - 01 Reissued: August 1, 1986 1C4 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 8-2. Leveling Longitudinally Figure 8-3. Leveling laterally END 8 - 20 - 00 Page - 8 - 02 Reissued: August 1, 1986 1C5 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS SPACE INTENTIONALLY LEFT BLANK CHAPTER TOWING AND TAXIING 1C6 CHAPTER 9 - TOWING AND TAXIING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT NO. EFFECTIVITY 9-10-00 TOWING 1C9 9-20-00 TAXIING IC9 9 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1C7 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 9 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1C8 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL TOWING —CAUTION— Do not turn nose gear in either direction beyond its steering radius limits This will result in damage to nose gear and steering mechanism. —CAUTION— Do not tow airplane with control locks installed —CAUTION— When moving airplane forward by hand, avoid pushing on trailing edge of control surfaces. This will cause control surface contour to change resulting in an out-of-trim condition. Move airplane using a nose wheel steering bar or power equipment that will not damage or cause excess strain. TAXIING Before taxiing airplane, ground personnel must be checked out by a qualified pilot or other responsible person. Engine starting and shutdown procedures must also be covered. Ensure that propeller back blast and taxi areas are clear. Apply power to start taxi roll and perform the following checks: l. Taxi forward a few feet and apply brakes to determine their effectiveness. 2. Taxi with propeller set in low pitch, high rpm setting. 3. While taxiing, make slight turns to check effectiveness of steering. 4. Observe wing clearances when taxiing near buildings or other stationary objects. If possible, station a guide outside airplane to observe. 5. Avoid holes and ruts when taxiing on uneven ground. 6. Do not operate engine at high rpm when running up or taxiing over loose ground, stones, gravel, or any material that may damage propeller blades. —END— 9 - 20 - 00 Page - 9 - 01 Reissued: August 1, 1986 1C9 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER PARKING AND MOORING 1C10 CHAPTER 10 - PARKING AND MOORING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT NO. EFFECTIVITY 10-10-00 PARKING 1C13 10-20-00 MOORING 1C13 10 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1C11 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1C12 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PARKING —CAUTION— Be careful when setting brakes. Accumulated moisture may freeze brakes that are overheated or exposed to cold weather. When parking airplane, ensure it is sufficiently protected against adverse weather conditions and presents no danger to other aircraft. When parking airplane for any length of time, it should be moored. To park airplane, proceed as follows: l. Head airplane into wind. 2. Set parking brake by pulling back brake lever and depressing knob attached to left side of handle, then release handle. To release parking brake, pull back on brake lever to disengage catch mechanism. Allow handle to swing forward. 3. Lock aileron and stabilator with front seat belt. MOORING —CAUTION— Additional preparations for high winds include using tie-down ropes from the landing gear forks, and securing the rudder. —CAUTION— Use square or bowline knots. Do not use slip knots. Moor airplane to ensure immovability, protection, and security. Moor airplane as follows: l. Head airplane into wind. 2. Block wheels. 3. Lock aileron and stabilator controls with front seat belt or control surface blocks. 4. Secure tie-down ropes to wing tie-down rings and tail skid at approximately 45 degree angles. When using rope constructed of non-synthetic material, leave sufficient slack to avoid damage to airplane when ropes contract due to moisture. 5. Install pitot tube cover, if available. Cover Kit 760 297 is available from Piper dealers. —END— 10 - 20 - 00 Page - 10 - 01 Reissued: August 1, 1986 1C13 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER REQUIRED PLACARDS 1C14 CHAPTER 11- REQUIRED PLACARDS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT NO. EFFECTIVITY 11-20-00 EXTERIOR PLACARDS AND MARKINGS 1C17 11-30-00 INTERIOR PLACARDS AND MARKINGS 1C18 11 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1C15 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1C16 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL EXTERIOR PLACARDS AND MARKINGS Figure 11 - l. Placards and Decals 11 - 20 - 00 Page - 11 - 01 Reissued: August 1, 1986 1C17 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INTERIOR PLACARDS AND MARKINGS 13. PLACARD - RUDDER TRIM 43. PLACARD - WARNING 21. PLACARD - HEATER AND DEFROST 44. PLACARD - PITCH TRIM 22. PLACARD - CLIMATE CONTROL CENTER 45. PLACARD - WARNING, ELT 23. PLACARD - CIRCUIT PROTECTOR, LOWER 46. PLACARD - ALTITUDE REPORTER INSTALLED 24. PLACARD - CIRCUIT PROTECTOR, UPPER 47. PLACARD - MIKE AND PHONE 25. PLACARD - LANDING CHECKLIST 48. PLACARD - MIKE JACK (WITH CONSOLE MIKE, JACK) 26. PLACARD - TAKE-OFF CHECKLIST 54. PLACARD - WARNING 27. PLACARD - ANNUNCIATOR, PRESS TO TEST 55. PLACARD - AUTOFLITE ll 28. PLACARD - MANEUVERING LIMITATIONS 56. PLACARD - OMNI COUPLER SWITCH 29. PLACARD - MANEUVERING SPEED 57. PLACARD - VENT FAN 30. PLACARD - FUEL 58. PLACARD - RADIO POWER ON-OFF 31. PLACARD - CROSSWIND COMPONENT 59. PLACARD - EMERGENCY BUS SWITCH 32. PLACARD - AIR CONDITIONING DOOR LIGHT 61. PLACARD - CAUTION 34. PLACARD - CAR8URETOR HEAT 63. PLACARD - CARB. ICE DEFROSTER 40. PLACARD -.INSTRUMENT LIGHTS, 64. PLACARD - SENSITIVITY BLACK BACKGROUND 65. PLACARD - ENGINE CONTROLS 41. PLACARD - INSTRUMENT LIGHTS, PANEL, 74. PLACARD - NAV 1 OFF NAV 2 BLACK BACKGROUND 75. PLACARD - ON-OFF (TOGGLE TRIM) 76. PLACARD - CAUTION (REDUCE AMP LOAD) Figure l l-l. Placards and Decals (cont) 11 - 30 - 00 Page - 11 - 02 Reissued: August 1, 1986 1C18 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER SERVICING 1C19 CHAPTER 12 - SERVICING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT NO. EFFECTIVITY 12-00-00 GENERAL 1C21 12-11-00 Fuel System 1C21 12-11-00 Filling Fuel Tanks 1C21 12-11-00 Draining Moisture From Fuel System 1C21 12-11-00 Draining Fuel System 1C22 12-12-00 Oil System 1C22 12-12-00 Servicing Oil System 1C22 12-12-00 Draining Oil Sump 1C23 12-12-00 Filling Oil Sump 1C23 12-12-00 Oil Screen (Suction) 1C23 12-12-00 Recommendations for Changing Oil 1C23 12-12-00 Oil Filter (Full Flow) 1C24 12-20-00 SCHEDULED SERVICING 1C24 12-2l-00 Fuel System 1C24 12-2l-00 Servicing Fuel System 1C24 12-22-00 Landing Gear 1D1 12-22-00 Servicing Landing Gear 1D1 12-22-00 Servicing Oleo Struts 1D3 12-22-00 Filling Nose Gear Oleo Strut 1D3 12-22-00 Filling Main Gear Oleo Strut 1D4 12-22-00 Inflating Oleo Struts 1D7 12-23-00 Brake System 1D7 12-23-00 Servicing Brake System 1D7 12-23-00 Filling Brake Cylinder Reservoir 1C7 12-23-00 Draining Brake System 1C7 12-24-00 Tires 1D7 12-24-00 Servicing Tires 1D7 12-25-00 Power Plant 1D8 12-25-00 Servicing Power Plant 1D8 12-25-00 Engine Air Filter 1D8 12-25-00 Servicing Propeller 1D8 12-26-00 Servicing Electrical System 1D9 12-26-00 Battery 1D9 12-26-00 Battery Box Corrosion Prevention 1D9 12-27-00 Lubrication 1D9 12-27-00 Lubrication Instructions 1D9 12-27-00 Application of Oil 1D10 12-27-00 Application of Grease 1D10 12-27-00 Lubrication Chart 1D10 12 - Cont./Effec. Page - 1 Reissued: August 1, 1986 1C20 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter contains routine handling and servicing procedure. Frequent reference to this chapter will provide information such as location of various components, ground handling procedures, routine service procedures, and lubrication. When any system or component requires service other than routine procedures, refer to appropriate section for that component. FUEL SYSTEM FILLING FUEL TANKS —CAUTION— Observe all safety precautions for handing gasoline. Fill fuel tanks through filler necks located on forward slope of each wing. Each wing tank holds 38.5 U.S. gallons. Fill tanks with the type fuel specified on placard adjacent to filler neck. DRAINING MOISTURE FROM FUEL SYSTEM —CAUTION— Be careful when draining any amount of fuel to ensure no fire hazard exists before starting engine. The fuel system must be drained daily before first flight and after refueling to avoid accumulation of water and sediment. Each fuel tank is equipped with a quick drain located at lower inboard rear corner of the tank. The fuel strainer with a quick drain valve (refer to figure l2-l) is located on lower left side of the fire wall. Drain fuel tanks and strainer as follows: l. Drain each tank through its individual quick drain. Make sure enough fuel has been drained to ensure all water and sediment are removed. 2. Place a container under fuel strainer drain. Drain fuel strainer by opening quick drain on strainer. 3. Examine contents of container placed under fuel strainer drain for water and sediment. Dispose of contents. 12 - 11 - 00 Page - 12 - 01 Reissued: August 1, 1986 1C21 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure l2-l. Fuel Filter Bowl and Screen DRAINING FUEL SYSTEM Drain fuel from system by opening valve at inboard end of each fuel tank. Push up on arms of drain valve and turn counterclockwise to hold drain in open position. Flush type drain valves require a pin to hold the valve open. Fuel remaining in system is drained through filter bowl. Drain an individual tank by closing selector valve and draining as necessary. OIL SYSTEM SERVICING OIL SYSTEM —CAUTION— Do not introduce any trade additive into the basic lubricant unless recommended by the engine manufacturer. Engine oil level is checked before each flight and changed after each 50 hours of engine operation. During oil change, oil screen(s) must be removed and cleaned. Intervals between oil changes can be increased by 100% on engines equipped with full flow (cartridge type) oil filters provided element is replaced each 50 hours of operation. If fuel other than specified is used, refer to latest revision of Lycoming Service Letter No. Ll85 for additional information and recommended service procedures. The engine manufacturer does not recommend oils by brand names. Use a quality brand aviation grade oil of proper viscosity. For information on use of detergent oil, refer to Recommendations for Changing Oil and latest revision of Lycoming Service Instruction No. l0l4. 12 - 12 - 00 Page - 12 - 02 Reissued: August 1, 1986 1C22 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL DRAINING OIL SUMP —NOTE— Engine should be warm to ensure proper oil draining. Drain oil as follows: l. Remove engine cowl. 2. Open oil drain valve located on underside of engine by pushing arms of drain up and turning counterclockwise. This will hold drain in open position. 3. Drain oil into suitable container and dispose. FILLING OIL SUMP Fill oil sump with oil to mark on engine dipstick. The quantity of oil required for the engine is found in chapter 6. The specified grade of oil is found in chart 1202, Type of Lubricants, or on the engine oil filler access door. To service engine with oil, open quick release access door on top of cowl and remove oil filler cap with dipstick. OIL SCREEN (Suction) The oil suction screen, located on bottom aft end of engine sump is installed horizontally. To remove, proceed as follows: 1. Cut safety wire and remove hex head plug. 2. Clean screen at each oil change to remove any accumulation of sludge and check for metal filings or chips. If metal particles are found in screen, the engine must be examined for internal damage. 3. After cleaning and inspection, to eliminate possible damage, place screen inside recess in hex head plug. 4. Insert the screen into housing. 5. When certain that screen is properly seated, tighten and safety plug with MS-20995-C4l safety wire. RECOMMENDATIONS FOR CHANGING OIL (Refer to latest revision of Lycoming Service Instruction No. l0l4 and Lycoming Service Letter No. Ll85.) —CAUTION— Do not add ashless dispersant oil to mineral oil or switch to dispersant oil Dispersant oil will loosen sludge deposits and can plug screens and lubrication parts in the engine and cause failure or serious damage. In engines that have been operating on straight mineral oil for several hundred hours, a change to ashless dispersant oil must be made with caution. The cleaning action of some ashless dispersant oils will tend to loosen sludge deposits and cause plugged oil passages. When an engine has been operating on straight mineral oil and is known to be in excessively dirty condition, switch to ashless dispersant oil should be deferred until after engine is overhauled.. 12 - 12 - 00 Page - 12 - 03 Reissued: August 1, 1986 1C23 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL OIL FILTER (Full Flow) l. Replace oil filter after each 50 hours of engine operation. Remove safety wire from bolthead at end of filter housing. Loosen bolt and remove filter assembly from adapter. 2. Remove filter element for inspection before discarding filter, using a Champion cutter tool CT470, available from Champion Spark Plug Co., Toledo, OH 43601. Examine maternal trapped in filter element for evidence of engine damage, such as chips or particles from bearings. Evidence of internal damage found in filter element justifies further investigation to determine cause. 3. Install new filter. Tighten to a torque of l8 to 20 foot-pounds. Attach safety wire to bolt through loops on side of housing to drilled head of thermostatic valve. Be sure safety wire is replaced at both attaching bolthead and thermostatic oil cooler bypass valve. Use MS-20995-C4l safety wire. SCHEDULED SERVICING FUEL SYSTEM SERVICING FUEL SYSTEM —CAUTION— Assure that additive is directed into flowing fuel stream. Additive flow must start after and stop before fuel flow. Do not permit concentrated additive to come in contact with aircraft painted surfaces or interior surfaces of fuel tanks. —CAUTION— Some fuels have anti-icing additives pre-blended No further blending should be performed on these fuels. —CAUTION— Fuel additives cannot be used as a substitute for preflight draining of fuel system drains. 1. Clean fuel screens or filters at intervals of 50 hours or 90 days, whichever comes first. Fuel filter unit screens and bowl are located on left side panel next to pilot seat. Screen of electric fuel pump is located on firewall (left side). Clean screen located in inlet side of carburetor. 2. Disconnect fuel line at carburetor to flush fuel tanks and selector valve. 3. Select a fuel tank. Turn ON electric fuel pump and flush fuel through system until there is no dirt and foreign matter in fuel valve or tank. —NOTE— Agitation of fuel within the tank will help pick up and remove any dirt. 4. Repeat this procedure for each tank. 5. Clean all filters when all tanks are flushed. —NOTE— The PA -28-236 aircraft is approved for operation with an anti- icing fuel additive. The anti-icing additive must meet specification MIL-I27686, must be uniformly blended with fuel while refueling, must not exceed 0.15% by volume of refueled quantity, and to ensure its effectiveness must be blended at not less than 0.10% by volumn (one and one-half liquid ozs. per ten gallon of fuel). A blender supplied by the additive manufacturer should be used. Except for the information contained in this section, the manufacturers mixing or blending instructions must be carefully followed. 12 - 21 - 00 Page - 12 - 04 Reissued: August 1, 1986 1C24 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LANDING GEAR SERVICING LANDING GEAR The landing gear consists of tires, brakes, oleo strut assemblies and on some models wheel fairings. These are inspected for proper gear extension, scored piston tubes, hydraulic fluid leakage, security, condition of all connection points, and fairings for cracks. Cheek brake linings for wear and frayed edges, and brake discs for scoring. Replace as necessary. Minor servicing is described in this chapter. For detailed service and overhaul instructions refer to chapter 32. THIS SPACE INTENTIONALLY LEFT BLANK 12 - 22 - 00 Page - 12 - 05 Reissued: August 1, 1986 1D1 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure l2-2. Servicing Points 12 - 22 - 00 Page - 12 - 05 Reissued: August 1, 1986 1D2 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SERVICING OLEO STRUTS Air-oil struts are incorporated in each landing gear oleo to absorb shock resulting from landing. —CAUTION— Do not exceed these tube exposures. Approximately 3.25 +/- 0.25 inches of piston tube on nose gear and 4.5 +/- 0.50 inches of piston tube on main gear must be exposed to ensure proper oleo action. —WARNING— Do not release air by removing strut valve core or filler plug. Depress valve core pin until strut chamber pressure has diminished. —CAUTION— Dirt and foreign particles form around filler plugs of landing gear struts, therefore, before attempting to remove these plugs, tops of struts should be cleaned with compressed air and a dry solvent. Take piston tube measurements with airplane setting on a level surface under normal static load (empty weight of airplane plus full fuel and oil). If strut has less tube exposed than prescribed, determine whether it needs air or oil. 1. Raise airplane on jacks. 2. With strut extended, remove cap from air valve at top of housing. Depress valve core to allow air to escape from strut piston until fully compressed. 3. Allow foam from air-oil mixture to settle and determine if oil is visible up to bottom of filler plug hole. a. If oil is visible at bottom of hole, check valve and add air as described in Inflating Oleo Struts. b. If fluid is below bottom of filler plug hole, check oleo for leaks, etc. c. Add oil as described in Filling Nose Gear Oleo Strut for nose gear or Filling Main Gear Oleo Strut for main gear. —NOTE— For repair procedures of landing gear and oleo struts, refer to chapter 32. FILLING NOSE GEAR OLEO STRUT Fill nose gear oleo strut with hydraulic fluid (MIL-H-5606) as follows: 1. Jack airplane until nose wheel is completely clear of ground. (Refer to chapter 7.) 2. Place a pan under gear to catch spillage. 3. Remove engine cowl if not previously accomplished. Remove cap from air valve and depress valve core to relieve air from strut housing chamber. 12 - 22 - 00 Page - 12 - 07 Reissued: August 1, 1986 1D3 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 4. There are two methods used to fill the strut chamber. These are as follows: a. Method I. (1) Remove valve core from filler plug at top of strut housing. Allow plug to remain installed. (2) Attach one end of clear plastic hose to valve stem of filler plug and submerge other end in a container of hydraulic fluid. Check that end of hose on valve stem is tight and fluid container is approximately equal in height to top of strut housing. (3) Fully compress and extend strut, drawing fluid from fluid container and expelling air from strut chamber. (4) When air bubbles cease to flow through hose, compress strut fully and remove hose from valve stem. (5) With strut compressed, remove filler plug to determine that fluid level is visible up to bottom of filler plug hole. (6) Install core in filler plug and apply thread lubricant (Parker #6PB) to threads of filler plug. Install plug in top of strut housing. Tighten plug to a torque of 350 to 400 inch-pounds. b. Method II. (1) Remove filler plug from top of strut housing. (2) Raise strut piston until fully compressed. (3) Pour fluid from a clean container through filler opening until it reaches bottom of filler plug hole. (4) Install filler plug finger tight. Extend and compress strut two or three time to remove any air that may be trapped in housing. (5) Remove filler plug. Raise strut to full compression and fill with fluid if needed. (6) Apply thread lubricant (Parker #6PB) to threads of filler plug. Reinstall filler plug and tighten to a torque of 350 to 400 inch-pounds. 5. With airplane raised, compress and extend gear strut several times to ensure that strut moves freely. —NOTE— The weight of gear fork and wheel should extend strut. 6. Clean off overflow of fluid. Inflate strut as described in Inflating Oleo Struts. 7. Check that fluid is not leaking from around strut piston at bottom of housing. FILLING MAIN GEAR OLEO STRUT Fill main gear oleo strut with MIL-H-5606 fluid as follows: 1. Raise airplane on jacks until landing gear torque link assembly has almost reached its full travel. (Refer to chapter 7.) 2. Place a pan under gear to catch spillage. 3. Remove cap on top of wing if not previously accomplished to gain access to top of strut housing. Remove cap from air valve and depress valve core to relieve air from strut housing chamber. 12 - 22 - 00 Page - 12 - 08 Reissued: August 1, 1986 1D4 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —CAUTION— With torque links disconnected, piston tube is free to slide from strut housing. 4. Remove any one of three torque link bolts. Again raise airplane until a minimum of ten inches (do not exceed twelve inches of tube exposure) of strut tube is exposed with wheel remaining on ground. Fluid will flow from middle chamber to bottom chamber of strut housing, ensuring that bottom chamber is filled with fluid. 5. Fill main gear housing by either of two methods as follows: a. Method I. (l) Remove valve core from filler plug at top of strut housing. Allow plug to remain installed. (2) Attach one end of clear plastic hose to valve stem of filler plug and submerge other end in container of hydraulic fluid. (3) Fully compress and extend (l0 +2 -0 inches of strut tube exposure) strut drawing fluid from strut chambers. Watch fluid pass through plastic hose. Stop procedure when strut is full and no air is present in chambers. The strut must be extended to ten inches to allow fluid to enter bottom chamber of strut housing. (4) When air bubbles cease to flow through hose, compress strut fully and remove hose from valve stem. (5) With strut fully compressed, remove filler plug to determine that fluid level is visible up to bottom of filler plug hole. (6) Reinstall core in filler plug and apply thread lubricant (Parker #6PB) to threads of filler plug. Install plug in top of strut housing. Tighten plug to a torque of 350 to 400 inch-pounds. b. Method II. (l) Remove filler plug from top of strut housing. (2) Raise strut to full compression. (3) Pour fluid from clean container through filler opening until it is visible at top of strut chamber. If housing has been completely emptied, allow sufficient time for fluid to drain through orifice from upper chamber into middle chamber. (4) Lower gear until wheel touches ground (10 +2 -0 inches of strut exposure). Fully compress and extend strut three or four times to remove any air that may be trapped and to allow fluid to enter bottom chamber of housing. (5) Raise strut to full compression. If needed, fill with fluid to bottom of filler plug. (6) Apply thread lubricant (Parker #6PB) to threads of filler plug. Reinstall filler plug and tighten to a torque of 350 to 400 inch-pounds. 6. Replace torque link bolt. Tighten bolt tight enough to allow no side play in connection. 7. With airplane raised, retract and extend gear strut several times to ensure that strut moves freely. —NOTE— The weight of gear fork and wheel should extend strut. 8. Clean off overflow of fluid and inflate strut as described in Inflating Oleo Struts. 9. Check that fluid is not leaking around strut piston at bottom of housing. 12 - 22 - 00 Page - 12 - 09 Reissued: August 1, 1986 1D5 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 12-3. Main Gear Oleo Struts (Cut-away View) 12 - 22 - 00 Page - 12 - 10 Reissued: August 1, 1986 1D6 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INFLATING OLEO STRUTS Prior to engine operation, air or nitrogen pressure in each landing gear assembly must be adjusted to either applicable pressure or visible piston extension (pressure servicing method is preferred). l. Ensure oleo strut has sufficient fluid and torque link is properly connected. 2. Attach strut pump to air valve and inflate oleo strut. a. Inflate strut until correct length of piston is exposed with normal static load. b. If pressure servicing method is used, pistons must be fully extended. (l) Inflate struts to 250 +/- 25 psi. (2) Rock airplane several times to ensure gear settles back to correct strut position. (3) Check for valve core leakage before capping valve. BRAKE SYSTEM SERVICING BRAKE SYSTEM The brake system incorporates a hydraulic fluid reservoir through which brake system is periodically serviced. Fluid is drawn from the reservoir by brake cylinders to maintain the volume of fluid required for maximum braking efficiency. Spongy brake pedal action is often an indication that brake fluid reservoir level is low. Instructions for filling reservoir are given in Filling Brake Cylinder Reservoir. For repairs to any brake system component or system bleed procedures, refer to chapter 32. FILLING BRAKE CYLINDER RESERVOIR Fill brake cylinder reservoir to level marked on reservoir, with MIL-H-5606 fluid: l. Locate reservoir on left side of firewall in engine compartment. 2. Check reservoir at every 50 hour inspection and replenish as necessary. —NOTE— No adjustment of brakes is necessary. 3. Check brakes periodically per instructions in chapter 32. DRAINING BRAKE SYSTEM Drain brake system as follows: 1. Connect hose to bleeder fitting on bottom of cylinder. Place other end of line in suitable container. 2. Open bleeder. Slowly pump hand brake lever and desired brake pedal until fluid ceases to flow. 3. Clean brake system by flushing with denatured alcohol. TIRES SERVICING TIRES Maintain tires at pressure specified in chapter 6. l. Check tire pressure. 2. Examine tires for wear, cuts, bruises, and slippage on wheel. 3. Tire, tube, and wheel must be properly balanced when installed and index mark on tire must align with index mark on tube. 12 - 24 - 00 Page - 12 - 11 Reissued: August 1, 1986 1D7 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL POWER PLANT SERVICING POWER PLANT Check engine compartment regularly for oil and fuel leaks, chafing of lines, loose wires, and tightness of parts. For engine compartment cleaning, refer to chapter 20. ENGINE AIR FILTER —CAUTION— Do not use solvents or gasoline to clean air filter. l. Removing Engine Air Filter a. Remove front cowl scoop. b. Unfasten quarter-turn fastener securing filter. 2. Cleaning Engine Air Filter Check induction air filter during each preflight inspection. Clean or replace if dirty. Replace filter after one year, ten cleanings, or 500 flight hours, whichever comes first. To clean filter: a. Blow compressed air through filter in opposite direction of normal airflow to remove light dust contaminants. Air pressure must be less than l00 psi. Keep nozzle at least one inch from filter to prevent damage. b. If filter is excessively dirty, flush filter with running water (less than 40 psi) and soak in a solution of Donaldson D-1400 compound and water. Rinse until clear water comes through filter. —CAUTION— Do not use a light bulb to dry filter. c. Dry filter thoroughly before inspection. Mechanical dryers may be used provided heated air is circulated and maintained below l80° F. d. Inspect filter medium for holes or tears and ensure frame provides a good air seal. Replace filter if defects are found. 3. Installation of Engine Air Filter Install filter in reverse order of removal. SERVICING PROPELLER Clean and inspect spinner, backplate, and propeller surfaces regularly for nicks, scratches, corrosion, and cracks. Remove minor nicks and scratches per instructions in chapter 6l. When necessary, paint the face of each blade with a flat paint to retard glare. Wipe surfaces with a light oil or wax to prevent corrosion. Inspect constant speed propellers for grease or oil leakage and freedom of rotation on hub pilot tube. Check freedom of rotation by rocking blade back and forth through the slight freedom allowed by the pitch change mechanism. Lubricate the propeller at 100 hour intervals in accordance with the lubrication chart. Additional service information is found in chapter 6l. 12 - 25 - 00 Page - 12 - 12 Reissued: August 1, 1986 1D8 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SERVICING ELECTRICAL SYSTEM Electrical system servicing involves adding distilled water to battery to maintain correct electrolyte level, checking cable connections, and checking for any spilled electrolyte that could lead to corrosion. Check security of all electrical connections as well as operation of all lights, general condition of generator or alternator and starter. Inspect electrical wires for chafing and bare wires. For detailed information on this system, refer to chapter 24. BATTERY BATTERY BOX CORROSION PREVENTION Check battery for spilled electrolyte or corrosion at each 50 hour inspection or every 30 days, whichever comes first. If corrosion is found, remove, clean, and install battery and box as follows: l. Remove box drain cap from underside of fuselage and drain off any electrolyte that overflowed into box. (On aircraft s/n 8611005 and up, no cap is installed.) —CAUTION— Do not allow soda solution to enter battery. 2. Neutralize corrosion effects by applying a solution of baking soda and water mixed to a consistency of thin cream. Apply this mixture until all bubbling action has ceased. 3. Rinse battery and box with clean water and dry. 4. Place cap over battery box drain. 5. Install battery. (Refer to chapter 24 for additional service information.) LUBRICATION LUBRICATION INSTRUCTIONS Periodic application of recommended lubricants to bearing surfaces, as detailed in the following paragraphs, will ensure maximum efficiency of all moving parts. Lubrication instruction regarding locations, time intervals, and type of lubricants used is found in lubrication chart. To ensure best possible results from application of lubricants, observe precautions as follows: l. Use recommended lubricants. Where general purpose lubricating oil is specified, but unavailable, use clean engine oil as a substitute. 2. Check components to be lubricated for evidence of excessive wear and replace as necessary. 3. Remove all excess lubricant from components to prevent collection of dirt and sand capable of causing excessive wear or damage to bearing surfaces. 12 - 27 - 00 Page - 12 - 13 Reissued: August 1, 1986 1D9 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL APPLICATION OF OIL Observe the following precautions whenever specific instructions for lubrication of mechanisms is not available: l. Apply oil sparingly. Do not use more than required to coat bearing surfaces. 2. Control cables are sufficiently coated by manufacturer, additional protection is unnecessary. —CAUTION— Be careful not to add too much oil. Excess oil will be thrown off during operation and can cause pitting and burning of magneto points. 3. Squeeze magneto cam follower felts at regular inspection periods. If oil appears on fingers, do not add oil. If felt is dry, moisten with light oil. APPLICATION OF GREASE —CAUTION— Be very careful when greasing the constant speed propeller hub. Too much pressure can blow clamp gaskets. Be careful when lubricating bearings and bearing surfaces with a grease gun. Ensure that gun is filled with new, clean grease of the grade specified for application before applying lubricant to fittings. l. Apply lubricant sparingly and wipe off any excess when a reservoir is not provided around a bearing. 2. Remove wheel bearings from wheel hub and clean thoroughly with a suitable solvent. Be sure lubricant enters space between rollers in retainer ring when repacking with grease. Do not pack grease into wheel hub. 3. When greasing the constant speed propeller hub, remove one grease fitting and apply grease to other fitting until fresh grease appears at hole of removed fitting. LUBRICATION CHART Each airplane part to be lubricated, as depicted on the lubrication chart, is indicated by a frequency symbol which shows time intervals between lubrications. Application symbols with frequency symbols show how lubrication is applied. A parts nomenclature key, identifies part to be lubricated. Within frequency symbol is a code letter which identifies type of lubricant to be used and a special instructions number which gives instruction for lubricating a particular component. 12 - 27 - 00 Page - 12 - 15 Reissued: August 1, 1986 1D10 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 1201. THREAD LUBRICANTS TYPE OF LINE TYPE OF LUBRICANT Brakes MIL-H-5606 Freon TT-A-580 or MIL-T-5544, anti-seize compound Fuel MIL-T-5544, anti-seize, graphite petrolatum Landing Gear (Air Valve) 6PB Parker Oil MIL-G-6032, lubricating grease (gasoline and oil resistant) Pitot and Static TT-A-580 (JAN-A-669), anti-seize compound (white lead base) 12 - 27 - 00 Page - 12 - 15 Reissued: August 1, 1986 1D11 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CAUTION— Lubricant engine fittings only with the fluid contained in the particular lines. PREFERRED PRODUCT LUBRICANT SPECIFICATION AND VENDOR LUBRICATING OIL, GENERAL PURPOSE, LOW MIL-L-71170 TEMPERATURE LUBRICATING OIL AIRCRAFT RECIPROCATING Mil-L-6082 ENGINE (PISTON) GRADE AS SPECIFIED (MINERAL SAE 60 ABOVE 80° F AIR TEMP. GRADE) SAE 50 ABOVE 60° F AIR TEMP. SAE 40 30° TO 90° F AIR TEMP. SAE 30 0° TO 70°3 AIR TEMP. SAE 20 BELOW 10° F AIR TEMP. LUBRICATING OIL, AIRCRAFT RECIPROCATING MIL-L-22851 ENGINE (PISTON) GRADE AS SPECIFIED (ASHLESS SAE 15w 50 OR SAE 20w 50 ALL TEMP. DISPERSANT SAE 60 ABOVE 80° F AIR TEMP. GRADE) SAE 40 OR SAE 50 ABOVE 60° AIR TEMP. SAE 40 30° F TO 90° F AIR TEMP. SAE 30, SAE 40 OR SAE 20~ 40 0’ TO 70’ F AIR TEMP. SAE 20w 50, OR SAE 15— 50 0° TO 90°F AIR TEMP. SAE 30, OR SAE 20w 30 BELOW 0°F AIR TEMP. HYDRAULIC FLUID PETROLEUM BASE MIL-H-5606 GREASE, AIRCRAFT AND INSTRUMENT, GEAR MIL-G-23827 AND ACTUATOR SCREW GREASE, AIRCRAFT HIGH TEMPERATURE TEXACO MARFAK ALL PURPOSE GREASE, MOBIL GREASE 77 (OR MOBILUX EP2), SHELL ALVANIA EP GREASE 2 PARKER O-RING LUBRICANT AERO LUBRIPLATE OR FISKE BROS. AERO SHELL GREASE ~7, MAG #l REFINING CO. FLUOROCARBON RELEASE AGENT DRY MS-122 LUBRICANT GREASE- LUBRICATION GENERAL MIL-G-7711 PURPOSE AIRCRAFT SILICONE, COMPOUND MIL-C-21567 12 - 27 - 00 Page - 12 - 16 Reissued: August 1, 1986 1D12 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 1202. TYPE OF LUBRICANTS CHART 1202. TYPE OF LUBRICANTS (cont.) PREFERRED PRODUCT LUBRICANT SPECIFICATION AND VENDOR GREASE, AIRCRAFT WIDE-TEMPERATURE MIL-G-81322 MOBIL GREASE 28 AEROSHELL GREASE 22 ROYCO 22S