Piper ARROW III Service Manual

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Arrow Iii - Turbo Arrow Iii

ARROW

SERVICE MANUAL

CARD 1 OF 3

PA-28R-201/201T

PIPER AIRCRAFT CORPORATION

Courtesy of Bomar Flying Service

www.bomar.biz

(PART NUMBER 761 639)

1A1

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Page 1 ARROW III - TURBO ARROW III ARROW SERVICE MANUAL CARD 1 OF 3 PA-28R-201/201T PIPER AIRCRAFT CORPORATION Courtesy of Bomar Flying Service www.bomar.biz (PART NUMBER 761 639)
Page 2 CHEROKEE ARROW III SERVICE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS Service manual information incorporated in this set of Aerofiche cards is arranged in accordance with the general specifications of Aerofiche adopted by the General Aviation Manufacturer’s Association. Information compiled in this Aerofiche service manual is kept current by revisions distributed periodically. These revisions supersede all previous revisions, are complete Aerofiche card replacements, and supersede Aerofiche cards of the same number in the set.
Page 3 TABLE OF CONTENTS AEROFICHE CARD NO. 1 GRID NO. INTRODUCTION 1A13 HANDLING AND SERVICING 1A16 INSPECTION STRUCTURES 1D17 SURFACE CONTROLS HYDRAULIC SYSTEM LANDING GEAR AND BRAKE SYSTEM 1I22 AEROFICHE CARD NO. 2 VIII POWER PLANT (CONTINENTAL) VIIIA POWER PLANT (LYCOMING) 2C18 FUEL SYSTEM INSTRUMENTS...
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Page 5 LIST OF ILLUSTRATIONS Aerofiche Figure Grid No. 2-1. Three View of PA-28R-201T..................... 1A19 2-2. Three View of PA-28R-201....................1A20 2-3. Station Reference Lines of PA-28R-201T................. 1A21 2-4. Station Reference Lines of PA-28R-201 ................1A22 2-5. Access Plates and Panels....................1A23 2-6.
Page 6 LIST OF ILLUSTRATIONS (CONT) Aerofiche Fgure Grid No. 5-8. Stabilator Trim Control...................... 5-9. Rudder and Steering Pedal Assembly ................5-10. Rudder Controls......................... 5-11. Rudder Rigging Tool......................5-12. Clamping Rudder Pedals....................5-13. Rudder and Stabilator Travel Adjustments................ 1G10 5-14. Rudder Trim Control......................1G11 5-15.
Page 7 LIST OF ILLUSTRATIONS (cont) Aerofiche Figure Grid No. 7-20. Installation of Anchor Bolt....................1K16 7-21. Brake System Installation....................1K18 7-22. Brake Master Cylinder (Hand/Parking Brake)..............1K19 7-23. Toe Brake Installation......................1K20 7-24. Brake Cylinder (1700) (Toe Brake)................... 1K21 7-25. Brake Cylinder (10-27) (Toe Brake) ................. 1K21 7-26.
Page 8 LIST OF ILLUSTRATIONS (CONT) Aerofiche Figure Grid No. 8A-7. Fuel-Air Bleed Nozzle....................... 2D11 8A-8. Contact Points........................2D13 8A-9. Rotor Holding Tool Installed..................... 2D14 8A-10. Timing Kit Installed......................2D14 8A-11. Aligning Timing Marks..................... 2D15 8A-12. Checking Flyweight Clearance of Impulse Coupling ............2D15 8A-13.
Page 9 LIST OF ILLUSTRATIONS (CONT) Aerofiche Figure Grid No. 11-13. Installing End Bearing....................... 11-14. Removing Drive Pulley..................... 11-15. Removing Drive End Bealing ................... 11-16. Removing Slip Ring......................11-17. Installing Slip Ring......................11-18. Solder Points........................11-19. Installing Retainer ......................11-20. Installing Drive End Shield and Bearing (Typical)............11-21.
Page 10 LIST OF ILLUSTRATIONS (CONT) Aerofiche Flgure Grid No. 14-1. Air Conditioning System Installation................14-2. Service Valves ........................3A12 14-3. Test Gauge and Manifold Set .................... 3A13 14-4. Manifold Set Operation..................... 3A14 14-5. Leak Test Hook-Up ......................3A15 14-6. Evacuation Hook-Up......................3A17 14-7.
Page 11 LIST OF TABLES Aerofiche Table Grid No. VIII-I. Propeller Specifications..................... 2A16 VIII-II. Engine Data........................2A21 VIII-III. Troubleshooting Chart (Engine)..................2C12 VIIIA-I. Propeller Specifications..................... VIIIA-II. Engine Troubleshooting..................... IX-I. Fuel Sender Locations....................... 2E16 IX-II. Fuel Quantity Transmitter Calibration Tolerances............2E18 IX-III. Transmitter Fuel Gauge Tolerances................... 2E23 IX-IV.
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Page 13 SECTION I INTRODUCTION Aerofiche Paragraph Grid No. 1-1. General ..........................1A14 1-2. Scope of Manual........................ 1A14 1-3. Description ........................1A14 1-4. Wing ..........................1A14 1-5. Empennage ........................1A14 1-6. Fuselage..........................1A14 1-7. Landing Gear........................1A14 1-8. Hydraulic System ......................1A15 1-9.
Page 14 Cherokee aircraft, designed and manufactured as a versatile airplane for use in the personal and business aviation field, by the Piper Aircraft Corporation. 1-2. SCOPE OF MANUAL. Section II comprise the routine service part of this manual, Section III covers inspections, and Sections IV through XIV comprise maintenance instructions.
Page 15 CHEROKEE ARROW III SERVICE MANUAL 1-8. HYDRAULIC SYSTEM. The hydraulic system incorporates an electrically driven pump which is controlled by a selector lever on the instrument panel which in turn operates the retraction and extension of the landing gear. 1-9. BRAKE SYSTEM. The brake system is operated hydraulically and controlled by a hand lever connected to a single brake cylinder that operates both wheel brakes, plus individually operated toe brakes.
Page 16 * SECTION II HANDLING AND SERVICING Aerofiche Paragraph Grid No. 2-1. Introduction ........................1A18 2-2. Dimensions........................1A18 2-3. Station Reference Lines..................... 1A18 2-4. Weight and Balance Data ....................1A18 2-5. Serial Number Plate......................1A18 2-6. Access and Inspection Provisions ..................1A18 2-7.
Page 17 Aerofiche Paragraph Grid No. 2-34. Landing Gear System ......................1B16 2-35. Servicing Landing Gear................... 1B16 2-36. Oleo Struts......................... 1B16 2-37. Servicing Oleo Struts..................1B16 2-38. Filling Oleo Struts.................... 1B17 2-39. Inflating Oleo Struts..................1B18 2-40. Brake System........................1B18 2-41. Servicing Brake System................... 1B18 2-42.
Page 18 *CHEROKEE ARROW III SERVICE MANUAL SECTION II HANDLING AND SERVICING 2-1. INTRODUCTION. This section contains routine handling and servicing procedures that are most frequently encountered. Frequent reference to this section will aid the individual by providing information such as the location of various components, ground handling procedures, routine service procedures and lubrication.
Page 19 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-1. Three View of PA-28R-201T Issued: 12/15/76 HANDLING AND SERVICING 1A19...
Page 20 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-2. Three View of PA-28R-201 Issued: 12/15/76 HANDLING AND SERVICING 1A20...
Page 21 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-3. Station Reference Lines of PA-28R-201T Issued: 12/15/76 HANDLING AND SERVICING 1A21...
Page 22 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-4. Station Reference Lines of PA-28R-201 Issued: 12/15/76 HANDLING AND SERVICING 1A22...
Page 23 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-5. Access Plates and Panels Interim Revision: 2/21/95 HANDLING AND SERVICING 1A23...
Page 24 *CHEROKEE ARROW III SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS MODEL PA-28R-201 PA-28R-201T ENGINE Manufacturer Lycoming Continental Model IO-360-CIC6 TSIO-360-F FAA Type Certificate Rated Horsepower Rated Speed: Full Throttle 2700 RPM 2575 RPM @ 41.0 in. Hg Manifold Pressure...
Page 25 *CHEROKEE ARROW III SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (cont.) MODEL PA-28R-201 PA-28R-201T ENGINE (cont.) Starter - Prestolite (12-volt) MZ4206 MCL-6501 Alternator: Chrysler (60 AMP) 2642997 Prestolite (60 AMP) ALY-6422 Prestolite (65 AMP) ALX-9425A Alternator Voltage Regulator, WICO...
Page 26 *CHEROKEE ARROW III SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (cont.) MODEL PA-28R-201 PA-28R-201T LANDING GEAR (cont.) Turning Radius (Min): Nose Wheel 15 ft. 8.4 in. 15 ft. 8.4 in. Wing Tip 29 ft. 9.6 in. 29 ft. 9.6 in.
Page 27 *CHEROKEE ARROW III SERVICE MANUAL 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.
Page 28 CHEROKEE ARROW III SERVICE MANUAL TABLE II-II. RECOMMENDED NUT TORQUES (cont.) COARSE THREAD SERIES BOLT FRICTION DRAG BOLTS SIZE TORQUE (IN. -LB.) Steel Tension 8 (course thread) AN 3 THRU AN 20 AN 42 THRU AN 49 AN 73 THRU AN 81...
Page 29 CHEROKEE ARROW III SERVICE MANUAL TABLE II-II. RECOMMENDED NUT TORQUES (cont.) FINE THREAD SERIES 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...
Page 30 *CHEROKEE ARROW III SERVICE MANUAL 2-8. TORQUE REQUIREMENTS. The torque valves given in Table II-II are derived from oil-free cadmium- plated threads and are recommended for all airframe installations procedures where torquing is required, unless otherwise noted in sections where other valves are stipulated. Engine torque valves for PA-28R-201 are found in the latest revision of Avco-Lycoming Service Bulletin No.
Page 31 *CHEROKEE ARROW III SERVICE MANUAL 2-9. WALKWAY, HANDHOLD AND STEP. The walkway is made of a non-skid compound applied to paper and bonded to the wing surface. A fixed handhold is located on the right side of the fuselage near the rear window.
Page 32 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-6. Jacking Arrangement Figure 2-7. Weighing Arrangement Issued: 12/15/76 HANDLING AND SERVICING...
Page 33 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-8. Leveling Longitudinally Figure 2-9. Leveling Laterally 2-13. WEIGHING. (Refer to Figure 2-7.) The airplane may be weighed by the following procedure: a. Position a scale and ramp in front of each of the three wheels.
Page 34 *CHEROKEE ARROW III SERVICE MANUAL 2-15. MOORING. The airplane is moored to insure its immovability, protection and security under various weather conditions. In order to properly moor the airplane use the following procedures: a. Head the airplane into the wind, if possible.
Page 35 Turn aircraft MASTER SWITCH to OFF position. b. Ensure that the RED lead of PEP (Piper External Power) kit jumper cable is connected to the POSITIVE (+) terminal of the external 12-volt battery and that the BLACK lead is connected to the NEGATIVE terminal.
Page 36 *CHEROKEE ARROW III SERVICE MANUAL 2-22. CLEANING. 2-23. CLEANING ENGINE COMPARTMENT. Before cleaning the engine compartment, place a strip tape on the magneto vents to prevent any solvent from entering these units. a. Place a pan under the engine to catch waste.
Page 37 *CHEROKEE ARROW III SERVICE MANUAL 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.
Page 38 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-10. Servicing Points (PA-28R-201) Revised: 8/31/77 HANDLING AND SERVICING 1B14...
Page 39 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-11. Servicing Points (PA-28R-201T) Issued: 12/15/76 HANDLING AND SERVICING 1B15...
Page 40 *CHEROKEE ARROW III SERVICE MANUAL 2-33. SERVICING HYDRAULIC PUMP/RESERVOIR. The fluid level of the reservoir of the combination pump and reservoir should be checked every 50 hours by viewing the fluid through the filler plug hole in the hydraulic pump. Access to the pump is through the panel at the right rear side of the baggage compartment.
Page 41 *CHEROKEE ARROW III SERVICE MANUAL 2-38. FILLING OLEO STRUTS. To fill the nose or main gear oleo strut with fluid (MIL-H-5606A), whether it be the addition of a small or large amount, procede as follows: a. Raise the airplane on jacks. (Refer to Paragraph 2-12.) b.
Page 42 *CHEROKEE ARROW III SERVICE MANUAL 2-39. INFLATING OLEO STRUTS. After making certain that an 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 piston is exposed with normal static load (empty weight of the airplane plus full fuel and oil) on the gears (Refer to Paragraph 2-37.) Rock the airplane several times to ascertain that the gear settles back to the correct strut...
Page 43 *CHEROKEE ARROW III SERVICE MANUAL 2-48. INDUCTION AIR FILTER. 2-49. REMOVAL OF AIR FILTER. The location of the PA-28R-201 filter is on the left side and just in front of the firewall. The PA-28R-201T filter is located just in front of the firewall above the turbocharger. Remove filter by following procedure: a.
Page 44 *CHEROKEE ARROW III SERVICE MANUAL Figure 2-12. Fuel Strainer 2-56. FILLING FUEL TANKS. Observe all required precautions for handling gasoline. Fill the fuel tanks with the fuel as specified on the placard adjacent to the filler neck or in Table II-I. Each wing tank has a capacity of 38 1/2 U.S.
Page 45 *CHEROKEE ARROW III SERVICE MANUAL 2-58a FUEL ADDITIVES. Operating the aircraft with fuel anti-icing fuel additive, MIL-1-27686, is approved. It must be uniformly blended with the fuel while refueling, must not exceed .15% by volume of the refueled quantity and must be blended at not less than .10% volume 1 1/2 liquid oz.’s per 10 gallons of fuel would fall within this range.
Page 46 —CAUTION— When replacing the engine oil quick drain, refer to the Piper Parts Catalog for the correct part number. Installation of an incorrect drain could damage the sump or the drain itself.
Page 47 *CHEROKEE ARROW III SERVICE MANUAL 2-67. RECOMMENDATIONS FOR CHANGING OIL. The engine manufacturer recommends that the oil supply be drained and the entire sump filled with fresh oil after each 100 hours of engine operation. Always start and warm the engine to operating temperature before performing an oil change. While draining the oil, the screens should be removed from the crankcase cover and cleaned thoroughly.
Page 48 *CHEROKEE ARROW III SERVICE MANUAL a. Use recommended lubricants. Where general purpose lubricating oil is specified, but unavailable, clean engine oil may be used as a staisfactory substitute. b. Check the components to be lubricated for evidence of excessive wear and replace them as necessary.
Page 49 *CHEROKEE ARROW III SERVICE MANUAL 2-72. LUBRICATION CHARTS. The lubrication charts consists of individual illustrations for the various aircraft systems, and each component to be lubricated is indicated by a number, the type of lubricant and the frequency of application. Special instructions are listed at the beginning of the lubrication charts and with the applicable component illustration.
Page 50 *CHEROKEE ARROW III SERVICE MANUAL TABLE II-III. RECOMMENDED ENGINE LUBRICATING OILS PA-28R-201 Average Average Ambient Oil Inlet Temperatures Grade Oil Air Temperature Desired Maximum SAE 50 Above 60°F 180°F 245°F (16°C) (82°C) (118°C) SAE 40 30°F to 90°F 180°F 245°F (-1°C to 32°C)
Page 51 *CHEROKEE ARROW III SERVICE MANUAL TABLE II-IV. THREAD LUBRICANTS TYPE OF LINE TYPE OF LUBRICANT Brakes MIL-H-5606A 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 MIL-G-6032, Lubricating Grease (Gasoline and Oil Resistant)
Page 52 CHEROKEE ARROW III SERVICE MANUAL TABLE II-V. CONVERSION TABLES 1. These charts contain the various conversion data that may be useful when figuring capacities, lengths, temperatures, and various weights and measures from the English system values to the metric system values or back again.
Page 53 CHEROKEE ARROW III SERVICE MANUAL TABLE II-V. CONVERSION TABLES (cont) INCHES TO MILLIMETER INCHES 0.0000 0.0001 0.0002 0.0003 0.0004 0.0005 0.0006 0.0007 0.0008 0.0009 MILLIMETER 0.000 0.0025 0.0050 0.0076 0.0101 0.0127 0.0152 0.0177 0.0203 0.0228 0.001 0.0254 0.0279 0.0304 0.0330 0.0355...
Page 54 CHEROKEE ARROW III SERVICE MANUAL TABLE II-V. CONVERSION TABLES (cont) INCHES TO MILLIMETER INCHES 0.00 MILLIMETER 2.54 5.08 7.62 10.16 12.70 15.24 17.78 20.32 22.86 25.40 27.94 30.48 33.02 35.56 38.10 40.64 43.18 45.72 48.26 50.80 53.34 55.88 58.42 60.96 63.50...
Page 55 CHEROKEE ARROW III SERVICE MANUAL TABLE II-V. CONVERSION TABLES (cont) CENTIGRADE - FAHRENHEIT CONVERSION TABLE Example: To convert 20°C, to Fahrenheit, find 20 in the center column headed (°F - °C); then read 68.0°F, in the column (°F) to the right. To convert 20°F, to Centigrade;...
Page 56 CHEROKEE ARROW III SERVICE MANUAL TABLE II-V. CONVERSION TABLES (cont) MULTIPLY TO OBTAIN MULTIPLY TO OBTAIN CENTIMETERS 0.3937 KILOGRAMS 2.205 0.03281 35.27 1000 GRAMS CU. CENTIMETERS 0.001 LITERS 0.06102 CU. IN LITERS 1000 CU. CM. 0.0002642 U.S. GAL. 61.03 CU. IN.
Page 57 CHEROKEE ARROW III SERVICE MANUAL TABLE II-V. CONVERSION TABLES (cont) Decimal/Millimeter Equivalents of Drill Sizes From 1/2” to No. 80 Size Decimal Millimeter Size Decimal Millimeter Size Decimal Millimeter Size Decimal Millimeter Equiv. Equiv. Equiv. Equiv. Equiv. Equiv. Equiv. Equiv.
Page 58 *CHEROKEE ARROW III SERVICE MANUAL TABLE II-VI. LUBRICATION SPECIFICATION LUBRICANT SPECIFICATION PRODUCT VENDOR PA-28R-201T (Continental) Teledyne Con- BP Aero Oil D65/80 BP (North America) Ltd., Lubricating oil, aircraft reciprocating tinental Mo- 620 Fifth Ave., New York, engine (piston) grade as specified...
Page 59 *CHEROKEE ARROW III SERVICE MANUAL TABLE II-VI. LUBRICATION SPECIFICATION (cont.) LUBRICANT SPECIFICATION PRODUCT VENDOR Grease, Aircraft, General Purpose, MIL-G-81322 Mobilgrease 28 Mobil Oil Corp., Shoreham Wide Temperature Range Building, Washington, D.C. 20005 Aeroshell Grease 22 Shell Oil Company, 50 West 50th St., New York,...
Page 60 *CHEROKEE ARROW III SERVICE MANUAL TABLE II-VI. LUBRICATION SPECIFICATION (cont.) LUBRICANT SPECIFICATION PRODUCT VENDOR Hydraulic Fluid (Brakes and Shock MIL-H-5606A 3126 Hydraulic Exxon Company, U.S.A. Box 2180, Struts) Houston, Texas 77001 PED 3337 Standard Oil of California, 225 Bush St., San Francisco,...
Page 61 *CHEROKEE ARROW III SERVICE MANUAL SPECIAL LUBRICATION INSTRUCTIONS BEARINGS AND BUSHINGS - CLEAN EXTERIOR WITH A DRY TYPE SOLVENT BEFORE LUBRICATING . LUBRICATION POINTS - WIPE ALL LUBRICATION POINTS CLEAN OF OIL GREASE, OIL, DIRT, ETC., BEFORE LUBRICATING. NOTES SEE THE LATEST REVISION OF LYCOMING SERVICE INSTRUCTIONS NO. 1014 FOR USE OF DETERGENT OIL WITH LYCOMING ENGINE.
Page 62 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. MAIN GEAR PIVOT POINTS MIL-G-23827 100 HRS 2. MAIN GEAR DOOR HINGE MIL-L-7870 100 HRS MAIN GEAR TORQUE LINKS MIL-L7870 100 HRS 4. EXPOSED OLEO STRUT MAIN MIL-L-60326 100 HRS 5. MAIN GEAR WHEEL BEARINGS...
Page 63 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. NOSE GEAR STRUT HOUSING GREASE FITTING MIL-G-23827 100 HRS. 2. NOSE GEAR PIVOT POINT AND HYDRAULIC CYLINDER ROD END MIL-L-7870 100 HRS 3. NOSE GEAR DOOR RETRACTION MECHANISM MIL-L-7870 100 HRS 4.
Page 64 *CHEROKEE ARROW III SERVICE MANUAL – CAUTION – Do not lubricate control wheel shaft or bushing. Clean only using alcohol or other uitable solvent. COMPONENT LUBRICANT FREQUENCY AILERON HINGE PINS MIL-L-7870 100 HRS 2. FLAP HINGE BEARINGS MIL-L-7870 100 HRS 3.
Page 65 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. FLAP TORQUE TUBE BEARING BLOCKS MIL-L-7870 100 HRS 2. FLAP CONTROL ROD END BEARINGS MIL-L-7870 100 HRS 3. FLAP HANDLE PIVOT POINT, LOCK MECHANISM AND TURNBUCKLE END MIL-L-7870 100 HRS 4. FLAP RETURN AND TENSION CHAINS...
Page 66 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. RUDDER TUBE BEARING BLOCKS MIL-L-60326 100 HRS 2. TOE BRAKE CYLINDER ATTACHMENTS MIL-L-7870 100 HRS 3. RUDDER TUBE CONNECTIONS MIL-L-7870 100 HRS BRAKE ROD ENDS MIL-L-7870 100 HRS Figure 2-17. Lubrication Chart (Control System) (cont.)
Page 67 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. RUDDER ARM CABLE ENDS MIL-L-7870 100 HRS 2. STABILATOR TRIM SCREW AERO LUBRIPLATE OR MAG-1 FISKE BROS. REFINING CO. 100 HRS STABILATOR SCREW/TAB LINKS MIL-L-7870 100 HRS STABILATOR HINGE POINTS MIL-L-7870 100 HRS 5.
Page 68 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. DOOR HINGES MIL-L-7870 100 HRS 2. DOOR SEALS MIL-L-60326 50 HRS 3. DOOR LATCH MECHANISMS AERO LUBRIPLATE OR MAG-1 FISKE BROS. REFINING CO. 500 HRS 4. SEAT TRACK ROLLERS, STOP PINS AND REAR SEAT...
Page 69 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. ENGINE SUMP (LYCOMING) MIL-L-6082 100 HRS PA-28 4-201 ONLY LUBRICATING OIL, AIRCRAFT RECIPROCATING ENGINE (PISTON) GRADE AS SPECIFIED, SAE 50 ABOVE F AIR TEMP., SAE 40 30 TO 90 F AIR TEMP., SAE 30 ?0 TO 70 F AIR TEMP., SAE 20...
Page 70 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. ENGINE OIL SUMPS (CONTINENTAL) CONTINENTAL SPECIFICATION PA-284-201T ONLY MHS-24A AND SERVICE 100 HRS BULLETIN M75-2 2. OIL FILTER 50 HRS INDUCTION AIR FILTERS CLEAN AS OFTEN AS NECESSARY, EVERYDAY UNDER SEVERE...
Page 71 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. DIAPHRAGM SHAFT AND BUSHING MIL-L-7870 ABOVE 20 MIL-C-21567 BELOW 20 100 HRS. 2. BACK-UP EXTENDER LNKS AND CONTROL ARM PIVOT POINTS MIL-L-7870 100 HRS 3. BACK-UP EXTENDER SPRING ATTACHMENT POINTS MIL-L-7870 100 HRS 4.
Page 72 *CHEROKEE ARROW III SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. CONDENSER HINGE AND ACTUATORS MIL-L-7870 100 HRS 2. CONDENSER DOOR ACTUATING TRANSMISSION MIL-G-23827 500 HRS Figure 2-23. Lubrication Chart (Air Conditioning Condenser) Issued: 12/15/76 HANDLING AND SERVICING 1C24...
Page 73 *SECTION III INSPECTION Paragraph Aerofiche Grid No. 3-1. Introduction ........................3-2. Recommended Lubrication....................3-3. Inspection Periods ......................3-4. Inspection Requirements....................3-5. Preflight Inspection ......................3-6. Overlimits Inspection ......................3-7. Special Inspection......................3-8. Service Publication Compliance Requirements..............Table III-I Inspection Report..................... Revised: 2/13/89...
Page 74 When performing inspections, use the annual inspection form furnished by the Piper Service Department, available through Piper Dealers or Distributors.
Page 75 Inspection Report and must be explained in more detail to give a clearer and complete inspection. 3-8. SERVICE PUBLICATION COMPLIANCE REQUIREMENTS. Piper Service Publications are recommended and/or mandatory changes to Piper aircraft. “Piper Service Bulletins are of Special Importance and Piper considers compliance mandatory”.
Page 76 CHEROKEE ARROW III SERVICE MANUAL TABLE III-I INSPECTION REPORT. —Note— Perform all inspections or operations at each of the inspection intervals as indicated by a circle (O). (See Notes at end of report) Inspection Time (Hrs) Nature of Inspection 1000 A.
Page 77 CHEROKEE ARROW III SERVICE MANUAL TABLE III-I INSPECTION REPORT (cont) Inspection Time (HRS) Nature of Inspection 1000 B. ENGINE GROUP (CONTINENTAL) (Cont.) 7. Clean and inspect oil radiator cooling fins. Verify that there is no radiator damage........................8. Fill engine oil sump with oil per approved information cowl, or lubrication chart.
Page 78 43.Inspect all lines, hoses, air ducts, electrical leads, and engine attachments for security, proper routing, chafing, cracks, deterioration and correct installation (Refer to latest Piper Service Bulletin 561).............. 44.Check air conditioner compressor oil level (Read Note 13)........45.Inspect condition and tension of compressor drive belt (Refer to Service Manual, Section XIV) ....................
Page 79 CHEROKEE ARROW III SERVICE MANUAL TABLE III-I INSPECTION REPORT (cont) Inspection Time (Hrs) Nature of Inspection 1000 B. ENGINE GROUP (CONTINENTAL) (Cont.) 50.Complete overhaul of engine or replace with factory rebuilt.(Read Note 5) ... C. TURBOCHARGER GROUP (CONTINENTAL) -WARNING– Read Note 24 and 28 prior to completing this inspection group.
Page 80 CHEROKEE ARROW III SERVICE MANUAL TABLE III-I. INSPECTION REPORT (cont) Inspection Time (HRS) Nature of Inspection 1000 D. ENGINE GROUP (LYCOMING) 4. Clean oil suction and oil pressure strainers at oil change (Inspect strainers for foreign particles)............5. Change full flow (cartridge type) oil filter element (inspect element thoroughly for foreign particles.............
Page 81 (Refer to latest revision of Piper Service Bulletin 691) ....... .
Page 82 5. Inspect parking brake and brake handle for operation and cylinder leaks....6. Inspect control wheels, column, pulleys, chain, and cables (Read Note 23).... 7. Inspect flap control cable attachment bolt (See latest revision of Piper Service Bulletin 965)......................8. Check landing, navigation, cabin, and instrument lights..........
Page 83 CHEROKEE ARROW III SERVICE MANUAL TABLE III-I. INSPECTION REPORT (cont) Inspection Time (Hrs) Nature of Inspection 1000 E. CABIN GROUP (cont.) 15.Inspect operation of fuel selector valve..............16.Inspect condition of heater controls and ducts............17.Inspect condition and operation of air vents.............
Page 84 31.Inspect stabilator balance weight attachments and arm for security and condition . 32.Inspect emergency locator transmitter battery for replacement date per Service Manual (Read latest revision of Piper Service Letter 820)......33.Clean and lubricate all exterior needle bearings ............34.Lubricate per lubrication chart in Service Manual, Section II........
Page 85 10.Inspect forward and aft wing attach fittings for corrosion, general condition and security. (See latest revision of Piper Service Bulletin 977.)........11.Inspect wing attachment bolts and brackets (Refer to Piper Service Bulletin(s) 789A and 886) ..................12.Inspect fuel tanks and lines for leaks, water, and contamination ......
Page 86 21.Retract gear, check operation and inspect doors for clearance and operation ..22.Inspect operation of back-up gear extender system (If not disabled) (Read Piper Service Bulletin 866.) (Read Note 27)......23.Inspect actuating cylinders for leaks and security ........... 24.Inspect all hydraulic lines, hoses, electrical leads, and attaching parts for security, routing, chafing, deterioration, wear, and correct installation.
Page 87 TABLE III-I. INSPECTION REPORT (cont) NOTES: Refer to last card of the Piper Price List - Aerofiche, for a checklist of current revision dates to Piper Inspection Reports and Manuals. Piper service bulletins are of special importance and Piper considers compliance mandatory. Piper service letters are product improvements and service hints pertaining to servicing the airplane and should be given careful attention.
Page 88 S/N’s 2803001 (PA-28R-201T) and up, have no backup extender system in the landing gear system installed as standard equipment. 28. When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor service publications.
Page 89 SECTION IV STRUCTURES Paragraph Aerofiche Grid No. 4-1. Introduction ........................1D19 4-2. Description ........................1D19 4-3. Wing Group ........................1D19 4-4. Wing Flap .......................... 1D20 4-5. Removal of Wing Tip ......................1D20 4-6. Installation of Wing Flap ....................1D20 4-7. Aileron ..........................
Page 90 CHEROKEE ARROW III SERVICE MANUAL Aerofiche Paragraph Grid No. 4-36. Door (Entrance)......................... 1E10 4-37. Removal of Door....................... 1E10 4-38. Installation of Door......................1E10 4-39. Adjustment of Door......................1E10 4-40. Removal of Door Latch Mechanism ................. 1E10 4-41. Installation of Door Latch Mechanism................
Page 91 * CHEROKEE ARROW III SERVICE MANUAL SECTION IV STRUCTURES 4-l. INTRODUCTION. This section explains the removal and installation procedures for the structural surfaces of the airplane. For the removal, installation, and rigging and adjustment procedures of the controlling components of the various structural surfaces, refer to Section V.
Page 92 * CHEROKEE ARROW III SERVICE MANUAL 4-4. WING TIP. 4-5. REMOVAL OF WING TIP. a. Remove the screws holding the wing tip to the wing, being careful not to damage the wing or wing tip. b. Pull off the wing tip far enough to disconnect the position and strobe light wire assembly. The ground lead may be disconnected at the point of connection on the wing rib, and the positive lead may be disconnected at the wire terminal or unscrewed from the light assembly.
Page 93 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-1. Aileron and Flap Installation Issued: 12/15/76 STRUCTURES 1D21...
Page 94 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-2. Wing Installation Revised: 2/13/89 STRUCTURES 1D22...
Page 95 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-2. Wing Installation (cont) Revised: 11/21/80 STRUCTURES 1D23...
Page 96 * CHEROKEE ARROW III SERVICE MANUAL 4-12. INSTALLATION OF WING FLAP. (Refer to Figure 4-1.) a. Replace the wing flap by placing the flap onto its proper position and inserting the hinge bolts, bushings, washers, and nuts. b. With the flap control in the full flap position, place the bushing on the outboard side of the rod end bearing and insert and tighten the bolt.
Page 97 * CHEROKEE ARROW III SERVICE MANUAL o. If the left wing is being removed, it will be necessary to disconnect pitot tube at the elbow located within the cockpit at the wing butt line. p. Arrange a suitable fuselage cradle and supports for both wings.
Page 98 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-3. Methods of Securing Control Cables q. Service and refill the brake system with hydraulic fluid in accordance with Servicing Brake System, Section II. Bleed the system as given in Section VII and check for fluid leaks.
Page 99 Remove the stabilator by disconnecting the stabilator at its hinge points. 4-19. INSTALLATION OF STABILATOR. (Refer to Figure 4-4.) CAUTION Comply with latest revision of Piper Service Bulletin 856. NOTE A clearance of .25 +/- .06 of an inch between the stabilator and the side of the fuselage and .18 of an inch minimum between all parts of the stabilator...
Page 100 * CHEROKEE ARROW III SERVICE MANUAL 4-20. STABILATOR TRIM TAB. 4-21. REMOVAL OF STABILATOR TRIM TAB. (Refer to Figure 4-4.) a. Disconnect the stabilator trim control rod by removing the bolts that attach the control rod to the stabilator trim tab.
Page 101 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-4. Empennage Group Installation Revised: 11/21/80 STRUCTURES...
Page 102 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-4. Empennage Group Installation (cont) Revised: 11/21/80 STRUCTURES...
Page 103 * CHEROKEE ARROW III SERVICE MANUAL 4-26. VERTICAL FIN. 4-27. REMOVAL OF VERTICAL FIN. a. Remove the screws from the upper and lower tail cone fairing, the fin tip cover and the fairing at the forward base of the fin.
Page 104 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-5. Windshield Installation (Typical) Issued: 12/15/76 STRUCTURES...
Page 105 * CHEROKEE ARROW III SERVICE MANUAL 4-32. INSTALLATION OF WINDSHIELD. (Refer to Figure 4-5.) a. Be certain that the new windshield outside contours are the same as that of the old windshield. It may be found that it is necessary to cut or grind the new windshield to acquire the proper dimensions.
Page 106 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-6. Side Window Installation (Typical) 4-36. DOOR (ENTRANCE). 4-37. REMOVAL OF DOOR. a. Remove the clevis bolt, washer and bushing from the door holder assembly. b. Remove cotter pins, clevis pins and washers from serrated door hinges.
Page 107 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-7. Skin Materials and Thickness Issued: 12/15/76 STRUCTURES 1E11...
Page 108 * CHEROKEE ARROW III SERVICE MANUAL 4-41. INSTALLATION OF DOOR LATCH MECHANISM. a. Place the latch assembly into position on the door. b. Connect the latch pull rod to the inside door handle. c. Replace the screws that attach the latch plate and mechanism to the door. Install the door trim upholstery and secure with screws.
Page 109 CHEROKEE ARROW III SERVICE MANUAL Installation of the door seal snubber is as follows: 1. If the door jamb paint is flaking or is excessively scuffed, rub down with wet and dry emery cloth. Clean the surface with Prep-Sol or equivalent cleaner which will not leave an oily residue.
Page 110 CHEROKEE ARROW III SERVICE MANUAL Figure 4-7a. Door Seal Snubber Installation 4-53.REMOVAL OF BAGGAGE DOOR HINGE. a. Remove the door from the airplane as described in Removal of Baggage Door, Paragraph 4-49. b. Remove the hinge half from the airplane or door by drilling out the rivets and removing the hinge.
Page 111 Figure 4-8. Fabricated Tool for Baggage Door Lock 4-55a. BAGGAGE COMPARTMENT INSPECTION HOLE AND COVER PLATE. (See latest revision of Piper Service Bulletin 977.) a. General. Airplanes manufactured before 1979 may not have had control cable inspection access holes in the baggage compartment floor.
Page 112 CHEROKEE ARROW III SERVICE MANUAL Cutting the holes. — CAUTION — Baggage compartment flooring is made of 0.025 inch thick aluminum. Use care when cutting through flooring so as not to damage cables and wiring routed below the floor. (a) Drill a 1/4 inch hole inside of, and adjacent to, one of the scribed lines layed out for each hole.
Page 113 Paragraph 4-58 describes Fiberglass Fracture and Patch Repairs as puncture, breaks and holes that have penetrated through the structure and damaged the fiberglass cloth. A repair kit, part number 756 729 will furnish necessary material for such repairs, and is available through Piper Aircraft Dealers.
Page 114 * CHEROKEE ARROW III SERVICE MANUAL 4-58.FIBERGLASS FRACTURE AND PATCH REPAIRS. a. Remove wax, oil and dirt from around damaged area with acetone, methylethylketone or equivalent. b. Using a key hole saw, electric saber saw, or sharp knife cut away ragged edges. Cut back to sound material.
Page 115 Glidden Thinner No. 207 b. Safety Walk Material: Walkway Compound and Matting, Nonslip (included in Piper Part No. 179 872) 4-63. A P P L I C ATION OF LIQUID SAFETY WALK COMPOUND. Liquid safety walk compound shall be applied in an area free of moisture for a period of 24 hours minimum after application. Do not apply when surface to be coated is below 50°F.
Page 116 * CHEROKEE ARROW III SERVICE MANUAL 4-64. CONTROL SURFACE BALANCING. 4-65. CHECKING CONTROL SURFACE BALANCE. The movable control surfaces have been statically balanced at the time of installation at the factory and normally should not require rebalancing. Where possible the control surfaces where set with the balance weight on the heavy side of the limits, to permit limited repair or paint touch-up without adjusting the balance weight.
Page 117 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-9. Control Surface Balance Tool Issued: 12/15/76 STRUCTURES 1E21...
Page 118 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-10. Aileron Balancing 4-67. BALANCING EQUIPMENT. (Refer to Figure 4-9.) The balancing must be done using a suitable tool capable of measuring unbalance in inch-pounds from the centerline of the control surface hinge pin. A suggested tool configuration is shown in Figure 4-9.
Page 119 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-11. Rudder Balancing 4-69. BALANCING RUDDER. (Refer to Figure 4-11.) To balance the rudder, the assembly must be complete including the tip assembly and all attaching screws, the position light and wiring must be included. Place the complete assembly horizontally on knife edge supports in a draft free area in a manner that allows unrestricted movement.
Page 120 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-12. Rudder Balance Weight TABLE IV-I. BALANCE SPECIFICATIONS FLIGHT CONDITIONS STATIC BALANCE LIMITS (IN.—LBS.) SURFACE Leading Edge Heavy Trailing Edge Heavy Ailerons Stabilators Rudders -10.5 Issued: 12/15/76 STRUCTURES 1E24...
Page 121 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-13. Stabilator Balancing. 4-70. BALANCING STABILATOR. (Refer to Figure 4-13.) To balance the stabilator, the assembly must be complete including the trim tab, the tab push rod and end bearing, stabilator tips and all attaching screws.
Page 122 * CHEROKEE ARROW III SERVICE MANUAL TABLE IV-II MAXIMUM DISTANCE BETWEEN SUPPORTS FOR FLUID TUBING TUBE OD DISTANCE BETWEEN SUPPORTS (IN.) (IN.) ALUMINUM ALLOY STEEL 9-1/2 11-1/2 3/16 13-1/2 5/16 16-1/2 25-1/2 27-1/2 26-1/2 TABLE IV-III. Hose clamp tightening, (initial installation).
Page 123 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-14. Removal of Cherrylock Rivet 4-71.R E M O VAL OF CHERRYLOCK RIVETS. Should it be necessary to remove an installed cherrylock rivet, the following procedures are recommended. a. In thick material remove the lock by driving out the rivet stem, using a tapered steel drift pin (See View 1.)
Page 124 * CHEROKEE ARROW III SERVICE MANUAL Figure 4-15. Identification of Aircraft Fluid Lines Added: 5/1/80 STRUCTURES...
Page 125 * CHEROKEE ARROW III SERVICE MANUAL 4-72.STANDARDS. 4-73 TORQUE WRENCHES Torque wrenches should be checked daily and calibrated by means of weights and a measured lever arm to make sure that inaccuracies are not present. Checking one torque wrench against another is not sufficient and is not recommended.
Page 126 SECTION V SURFACE CONTROLS Paragraph Aerofiche Grid No. 5-1. Introduction ........................5-2. Description ........................5-3. Standard Procedures......................5-4. Control Column Assembly....................1F13 5-5. Removal of Control Column Assembly................1F13 5-6. Installation of Control Column Assembly................. 1F14 5-7. Aileron Controls........................ 1F16 5-8.
Page 127 * CHEROKEE ARROW III SERVICE MANUAL SECTION V SURFACE CONTROLS 5-1. INTRODUCTION. This section contains the explanation for the removal, installation, rigging and adjustment procedures for the control assemblies of the various structural surfaces. For the removal and installation of the structural surfaces of the airplane, refer to Section IV. The assemblies need not be removed in order of paragraphs since each paragraph describes the individual removal and installation of the component.
Page 128 * CHEROKEE ARROW III SERVICE MANUAL TABLE V-I CONTROL SURFACE TRAVEL AND CABLE TENSION Revised 10/l8/83 SURFACE CONTROLS...
Page 129 * CHEROKEE ARROW III SERVICE MANUAL TABLE V-I CONTROL SURFACE TRAVEL AND CABLE TENSION (cont.) Issued: 12/15/76 SURFACE CONTROLS...
Page 130 * CHEROKEE ARROW III SERVICE MANUAL TABLE V-ll. CABLE TENSION VS. AMBIENT TEMPERATURE Revised: 2/13/89 SURFACE CONTROLS 1F10...
Page 131 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-1. Control Column Assembly Revised: 5/1 /80 SURFACE CONTROLS 1F11...
Page 132 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-la. Method of Installing Rod End Bearings Added: 12/11/78 SURFACE CONTROLS 1F12...
Page 133 * CHEROKEE ARROW III SERVICE MANUAL h. After completion of each adjustment, check the turnbuckles to be sure not more than three terminal threads are visible outside the barrel. Install the locking clips, and check for proper installation by turning to remove the clips using fingers only. Both locking clips may be installed in opposite holes.
Page 134 * CHEROKEE ARROW III SERVICE MANUAL 5-6. INSTALLATION OF CONTROL COLUMN ASSEMBLY. (Refer to Figure 5-1.) a. The tee bar assembly may be installed in the airplane by the following procedure: 1. Swing the tee bar assembly into place from the right side of the cabin and secure with attaching bolts (15), washers and nuts inserted in through each side of the floor tunnel.
Page 135 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-2. Aileron Controls Revised: 11/21/80 SURFACE CONTROLS 1F15...
Page 136 * CHEROKEE ARROW III SERVICE MANUAL 5-7. AILERON CONTROLS. 5-8. REMOVAL OF AILERON CONTROL CABLES. (Refer to Figure 5-2.) a. For the removal of either the control cables in the fuselage or the wings, first remove the rear seat floor panel.
Page 137 * CHEROKEE ARROW III SERVICE MANUAL N O T E Examine cables for broken strands by wiping the cable along its length. Visually check for damage. Replace all damaged cables. 5-9. INSTA L L ATION OF AILERON CONTROL CABLES. (Refer to Figure 5-2.) a .
Page 138 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-3. Bellcrank Rigging Tool f. Remove the nut, pivot bolt (25) and washers that secure the bellcrank. The nut is visible from the underside of the wing. g. Remove the bellcrank from within the wing.
Page 139 * CHEROKEE ARROW III SERVICE MANUAL 5-12. RIGGING AND ADJUSTMENT OF AILERON CONTROLS. (Refer to Figures 5-3 thru 5-4.) NOTE Flap adjustment must be complete before starting aileron adjustment. a. To check and adjust the rigging of the aileron controls, first set the right and left aileron bellcranks at neutral position.
Page 140 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-4. Aileron Rigging Tool Figure 5-5. Stabilator Rigging Tool 5. Tighten the bolts to secure the idler cross-over sprockets. 6. Remove any rigging locks or tools previously installed. d. Check the ailerons for correct travel from neutral per dimensions given in Table V-l, by the following procedure: 1.
Page 141 * CHEROKEE ARROW III SERVICE MANUAL g . Check complete system for safety of turnbuckle, bolts, and smooth operation without binding or chafing. h . Install access plates and panels. 5-13. STA B I L ATOR CONTROLS. 5-14. REMOVAL OF STA B I L ATOR CONTROL CABLES. (Refer to Figure 5-6.) a .
Page 142 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-6. Stabilator Controls Revised: 5/1/80 SURFACE CONTROLS 1F22...
Page 143 * CHEROKEE ARROW III SERVICE MANUAL 9. Install the floor tunnel plate and trim covers by placing the tunnel plate into position for installation and secure with the attaching screws. Roll the carpet into place and install the rudder trim cover and knob.
Page 144 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-7. Methods of Securing Trim Cables 7. With the tension of the upper cable correct and the control wheel still forward, adjust the turnbuckle of the lower cable to obtain correct tension. 8. Check the full travel of the control wheel with relation to the full travel of the stabilator to determine that the stabilator contacts its stops before the control wheel contacts its stops.
Page 145 * CHEROKEE ARROW III SERVICE MANUAL 4 . The wheel and drum are joined by a push fit, separate these two items with their center bushing and unwrap the right cable (8). 5 . Tie the cables forward to prevent them from slipping back into the floor tunnel.
Page 146 * CHEROKEE ARROW III SERVICE MANUAL c. Set cable tension and check rigging and adjustment per Paragraph 5-22. Check safety of all turnbuckles. d. Install the tunnel cover on the tunnel and secure with screws. e. Install the carpet over the floor tunnel.
Page 147 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-8. Stabilator Trim Control Issued: 12/15/76 SURFACE CONTROLS...
Page 148 * CHEROKEE ARROW III SERVICE MANUAL 5-22. RIGGING AND ADJUSTMENT OF STA B I L ATOR TRIM. (Refer to Figure 5-8.) a . Level the airplane. (Refer to Leveling, Section II.) b . Check for proper stabilator trim cable tension as given to Table V-I. If cables were disconnected, rotate control wheel several times to allow the cables to seat and recheck tension.
Page 149 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-9. Rudder and Steering Pedal Assembly Issued: 12/15/76 SURFACE CONTROLS...
Page 150 * CHEROKEE ARROW III SERVICE MANUAL j. Disconnect the vee brace(s) (29) (two braces are used with right hand brakes) from the torque tube by removing nuts, washers and bolts (27) that secure the strap bracket (28) to the vee brace.
Page 151 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-10. Rudder Controls Revised 12/11/78 SURFACE CONTROLS...
Page 152 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-11. Rudder Rigging Tool Figure 5-12. Clamping Rudder Pedals 5-26. RUDDER CONTROLS. 5-27. REMOVAL OF RUDDER CONTROL CABLES. (Refer to Figure 5-10.) a. To remove either the forward ( 10 or 11) or aft (14 or 15) rudder cables, first remove the access panel to the aft section of the fuselage.
Page 153 * CHEROKEE ARROW III SERVICE MANUAL N O T E Examine cables for broken strands by wiping the cable along its length. Visually check for damage. Replace all damaged cables. 5 - 2 8 . I N S TA L L ATION OF RUDDER CONTROL CABLES. (Refer to Figure 5-10.) a .
Page 154 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-13. Rudder and Stabilator Travel Adjustments 5. Check safety of turnbuckles. c. Adjust the rudder pedal stops by pushing on the pilots left rudder pedal until the rudder stop is contacted. Adjust the pedal stop (on the fire wall) to provide 0.060 to 0.120 of an inch clearance.
Page 155 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-14. Rudder Trim Control b. Before attaching the assembly to the mounting channel, ascertain that the clips (11) are installed so the safety wire (12) will be on top. Also, that the threaded bushing (43 is installed on the assembly shaft (15) with the welded attachment bushing forward or toward the housing.
Page 156 (26). Check clevis bolt (26) for wear. Replace bolt if any wear is evident. *(See latest revision of Piper Service Bulletin 965.) c. Remove the flap handle (29) and bracket (28) by disconnecting the cable turnbuckle from the handle and removing the bolts securing the bracket to the floor tunnel.
Page 157 CHEROKEE ARROW III SERVICE MANUAL Figure 5-15. Flap Controls Interim Revision: 2/21/95 SURFACE CONTROLS 1G13...
Page 158 1. Attach the cable and turnbuckle (25) to the flap handle arm and secure with clevis bolt, bushing*, washer, nut and cotter pin (26). Ascertain that the turnbuckle end is free to rotate on the arm. *(See latest revision of Piper Service Bulletin 965.) 2. Route the cable through the tunnel and spar housing.
Page 159 * CHEROKEE ARROW III SERVICE MANUAL 5. Attach the cable end to the tension chain (20) and secure with bushings, clevis bolt, nut and cotter pin. If the chain is not installed because of the torque tube assembly is removed, install the assembly as per Step c instruction.
Page 160 * CHEROKEE ARROW III SERVICE MANUAL NOTE In the event of wing heaviness during flight, the flap on the side of the heavy wing can be adjusted down from neutral to remedy this condition by lengthening the control rod. Check the inspection hole in each rod end to ascertain that there are sufficient threads remaining and a wire cannot be inserted through these holes.
Page 161 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-19. Fabricated Aileron and Flap Rigging Tool Issued: 12/15/76 SURFACE CONTROLS 1G17...
Page 162 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-20. Fabricated Stabilator Rigging Tool Issued: 12/15/76 SURFACE CONTROLS 1G18...
Page 163 * CHEROKEE ARROW III SERVICE MANUAL Figure 5-21. Fabricated Rudder Rigging Tool Issued: 12/15/76 SURFACE CONTROLS 1G19...
Page 164 CHEROKEE ARROW III SERVICE MANUAL TABLE V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS) Trouble Cause Remedy AILERON CONTROL SYSTEM Lost motion between con- Cable Tension too low. Adjust cable tension. trol wheel and aileron. (Refer to Paragraph 5-12.) Linkage loose or worn.
Page 165 CHEROKEE ARROW III SERVICE MANUAL TABLE V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS) (cont.) Trouble Cause Remedy STABLIATOR CONTROL SYSTEM (cont.) Resistance to stabilator System not lubricated Lubricate system. control movement. properly. Cable tension too high. Adjust cable tension per Paragraph 5-16.
Page 166 CHEROKEE ARROW III SERVICE MANUAL TABLE V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS) (cont.) Trouble Cause Remedy AILERON CONTROL SYSTEM (cont.) Control wheels not Incorrect control Rig in accordance with synchronized. column rigging. Paragraph 5-6. Control wheels not hori- Incorrect rigging of...
Page 167 CHEROKEE ARROW III SERVICE MANUAL TABLE V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS) (cont.) Trouble Cause Remedy STABILATOR TRIM CONTROL SYSTEM Lost motion between Cable tension too low. Adjust in accordance trim control wheel with Paragraph 5-22. and trim tab. Cables not in place on Install cables accord- pulleys.
Page 168 CHEROKEE ARROW III SERVICE MANUAL TABLE V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS) (cont.) Trouble Cause Remedy STABILATOR TRIM CONTROL SYSTEM (cont.) Trim tab fails to System incorrectly Check and/or adjust reach full travel. rigged. rigging per paragraph 5-22. Trim drum incor- Check and/or adjust rectly wrapped.
Page 169 CHEROKEE ARROW III SERVICE MANUAL TABLE V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS) (cont.) Trouble Cause Remedy RUDDER CONTROL SYSTEM (cont.) Excessive resistance Pulleys binding or Replace binding pulleys to rudder pedal rubbing. and/or provide clearance movement. (cont.) between pulleys and brackets.
Page 170 CHEROKEE ARROW III SERVICE MANUAL TABLE V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS) (cont.) Trouble Cause Remedy FLAP CONTROL SYSTEM (cont.) Flaps not synchro- Incorrect rigging Adjust flaps per in- nized or fail to of system. structions in Paragraph move evenly when 5-37.
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Page 172 INTENTIONALLY LEFT BLANK...
Page 173 SECTION VI HYDRAULIC SYSTEM Paragraph Aerofiche Grid No. 6-1. Introduction ........................6-2. Description ........................6-3. Troubleshooting......................... 6-4. Hydraulic Pump......................... 1H10 6-5. Removal of Hydraulic Pump................1H10 6-6. Disassembly of Hydraulic Pump ..............1H10 6-7. Cleaning, Inspection and Repairs of Hydraulic Pump ........1H11 6-8.
Page 174 PA-28R-201/201T airplane. One pump, which has been installed in Piper airplanes for years is the Prestolite. The latest that has been installed, is the Oildyne. Both are interchangeable, and are similar in that they both have reservoirs that are an integral part of the pump. Both pumps are controlled by a selector handle located on the instrument panel to the left of the control quadrant.
Page 175 “Emergency Down” position. This method is the only way that the gear can be extended in an emergency if you have complied with Piper Service Bulletin 886A. The second way of operating the free-fall valve is that if you have not complied with Piper Service Bulletin 886A and opted to keep your gear back-up extension system operational, the first method will apply, along with the operation of a pressure sensing device incorporated in the back-up extension system.
Page 176 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-1. Schematic Diagram of Hydraulic System (Prestolite) Revised: 2/13/89 HYDRAULIC SYSTEM...
Page 177 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-la. Schematic Diagram of Hydraulic System (Oildyne) Revised: 2/13/89 HYDRAULIC SYSTEM...
Page 178 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-2. Hydraulic System Installation Revised: 2/13/89 HYDRAULIC SYSTEM 1H10...
Page 179 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-2a. Hydraulic System Installation S/N’s 2837001 (PA-28R-201) and Up, and S/N’s 2803001 (PA-28R-201T) and Up Revised: 2/13/89 HYDRAULIC SYSTEM 1H11...
Page 180 Remove the pump by removing the pump attaching bolts. WARNING When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publication. 6-6. DISASSEMBLY OF HYDRAULIC PUMP. (PRESTOLITE) (Refer to Figure 6-3.) After the hydraulic pump has been removed from the airplane, cap or plug all ports and clean the exterior of the pump with a dry type solvent to remove accumulated dust or dirt.
Page 181 * CHEROKEE ARROW III SERVICE MANUAL 4 . Draw the armature from the motor frame (9). Note the number of thrust washers (11) mounted on the drive end of the armature shaft. 5 . Remove the motor frame from the pump reservoir (13).
Page 182 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-3. Hydraulic Pump/Reservoir, Exploded View (Prestolite) Revised: 2/13/89 HYDRAULIC SYSTEM 1H14...
Page 183 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-3a. Hydraulic Pump/Reservoir, Exploded View (Oildyne) Revised: 2/13/89 HYDRAULIC SYSTEM 1H15...
Page 184 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-4. Test and Adjustments of Hydraulic Pump (Prestolite) Revised: 2/13/89 HYDRAULIC SYSTEM 1H16...
Page 185 * CHEROKEE ARROW III SERVICE MANUAL 5 . Insert the thrust ball (7) in the bearing of the head assembly (1). To hold the ball in position, place a small amount of light grease inside the bearing. 6 . Place head assembly on frame and allow brushes to extend over commutator. Remove the string securing the brushes in the holders.
Page 186 * CHEROKEE ARROW III SERVICE MANUAL TABLE VI-II. CHARACTERISTICS, HYDRAULIC PUMP MOTOR Electrical Characteristics: (Prestolite and Oildyne) Voltage 14 DC Rotation Reversible Polarity Negative ground Operating Current 18 amps, max. at 14-volts (both rotations) Operating Time 5 to 10 seconds with a current load of 100 amps at 77°F.
Page 187 The following paragraphs, 6-11 through 6-14a, on grid pages 1H16 through 1H21, are instructions directed towards owners who have opted to comply with Piper Service Bulletin 866A Part II, and keep the back-up gear extender system operational. 6-12. REMOVAL OF GEAR BACK-UP EXTENDER ACTUATOR ASSEMBLY. (Refer to Figure 6-6.) The back-up extender actuator is located under the rear seat.
Page 188 * CHEROKEE ARROW III SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Revised: 2/13/89 HYDRAULIC SYSTEM 1H20...
Page 189 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-5. Checking Aligning Brackets of Gear Back-Up Extender Actuator 6-13. INSTALLATION OF GEAR BACK-UP EXPENDER ACTUATOR ASSEMBLY. (Refer to Figure 6-6.) a. Position the gear back-up extender actuator against its mounting brackets and install attaching machine screws.
Page 190 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-6. Gear Back-up Extender Actuator Revised: 2/13/89 HYDRAULIC SYSTEM 1H22...
Page 191 2. If it is determined that the diaphragm is defective, then remove the Back-Up Extender per instructions given in paragraph 6-12 and install Piper Kit No. 761 138V, Back-Up Gear Extender Diaphragm Replacement. Instructions for installing the diaphragm are included in the kit.
Page 192 * CHEROKEE ARROW III SERVICE MANUAL NOTE This adjustment will require two persons, a qualified pilot and a mechanic to set the actuator adjustment screw (2). 1. Remove the bottom of the rear seat. 2. The pivot screw (20) should be torqued 8 to 10 inch-pounds.
Page 193 * CHEROKEE ARROW III SERVICE MANUAL c. To check adjustment of electrical switch, the following procedure may be used: 1. Place the airplane on jacks. (Refer to Jacking, Section II.) 2. Move the mixture control back to idle cut-off and the throttle to fill forward to prevent gear warning horn from sounding during adjustment.
Page 194 14 +/- 2 inches of manifold pressure or when flaps are set beyond 10° for aircraft that complied with Piper Service Bulletin 866A Part I, and have the back-up extender disabled, or s/n 2837001 and s/n 2803001 and up while the gear is not down and locked.
Page 195 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-7. Nose Gear Actuating Cylinder Revised: 2/13/89 HYDRAULIC SYSTEM...
Page 196 * CHEROKEE ARROW III SERVICE MANUAL 6-15. NOSE GEAR ACTUATING CYLINDER. 6-16. REMOVAL OF NOSE GEAR ACTUATING CYLINDER. a. Place the airplane on jacks. (Refer to Jacking, Section II.) b. Disconnect the hydraulic lines from the actuating cylinder and cover the open line ends to prevent contamination.
Page 197 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-8. End Gland Locking Device 6-20. INSTALLATION OF NOSE GEAR ACTUATING CYLINDER. a. Attach the cylinder to its attachment fitting using bolt and nut. b. Attach the operating rod end to the downlock hook using bolt. Install nut after adjustment is completed.
Page 198 * CHEROKEE ARROW III SERVICE MANUAL Figure 6-9. Main Gear Actuating Cylinder Revised: 2/13/89 HYDRAULIC SYSTEM...
Page 199 * CHEROKEE ARROW III SERVICE MANUAL 6-23. DISASSEMBLY OF MAIN GEAR ACTUATING CYLINDER. (Refer to Figure 6-9.) a . With the cylinder removed from the airplane, push the piston rod (6) (by hand) toward the clevis (9) to remove oil from the unit.
Page 200 For airplanes that have complied with Piper Service Bulletin 866A, Part II and have the gear back-up extender system operational, refer to Paragraph 6-14 for Check and Adjustment Procedures.
Page 201 * CHEROKEE ARROW III SERVICE MANUAL m. Put the gear selector switch in the down position, and ensure that the gear has extended, the pump has stopped running, and the three green safe lights are illuminated. n. Return the flap selector to the fill down position, and note that the flaps operate to the full down position, and the warning horn does not sound.
Page 202 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING Trouble Cause Remedy Landing gear retraction § Landing gear actuator § Reset circuit breaker system fails to operate. circuit breaker open. and determine cause for open circuit breaker. § Landing gear selector §...
Page 203 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy Landing gear retraction § Gear selector switch § Check ground. system fails to operate ground incomplete. (cont) § Gear selector switch § Replace switch. inoperative. § Hydraulic pump ground §...
Page 204 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy Landing gear extension § Landing gear selector § Reset circuit breaker system fails to operate. circuit breaker open and determine cause (cont) for open circuit breaker.
Page 205 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy Landing gear retraction § Hydraulic Fluid in § Fill reservoir with extremely slow. reservoir below hydraulic fluid. operating level. § Restriction in hydraulic § Isolate and check lines.
Page 206 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy Pump fails to shut off § Pressure switch § Replace switch. though gear has fully inoperative. retracted. § Pressure switch out § Replace switch. of adjustment.
Page 207 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy Pump fails to shut off § Nose gear down limit § Adjust switch actuator though the gear has switch actuator out (Refer to Adjustment fully extended. (cont) of adjustment.
Page 208 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy Pump running inter- § Check for broken or mittently after gear damaged hydraulic has retracted. (cont) lines. Gear stops part way up, § Pump high pressure §...
Page 209 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy * Landing gear fails to * Manual control rod * Form the rod to allow operate at required between override clearance through fill speeds. (Gear up at lever (manual ex- fore and aft travel.
Page 210 CHEROKEE ARROW III SERVICE MANUAL TABLE VI-III. HYDRAULIC SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy With gear selector down § Shorted gear up § Replace solenoid. and three green lights solenoid. on, gear unsafe light comes on or intermittently on. With gear selector down §...
Page 211 * CHEROKEE ARROW III SERVICE MANUAL Figure 6- 10. Gear Back-Up Extender Actuator Aligning Tool Revised: 2/13/89 HYDRAULIC SYSTEM 1I19...
Page 212 * CHEROKEE ARROW III SERVICE MANUAL GRIDS lI20 AND lI21 INTENTIONALLY LEFT BLANK Revised: 2/13/89 HYDRAULIC SYSTEM 1I20...
Page 213 SECTION VII LANDING GEAR AND BRAKE SYSTEM Aerofiche Paragraph Grid No. 7-1. Introduction ........................1I24 7-2. Description ........................1I24 7-3. Troubleshooting......................... 7-4. Landing Gear System......................7-5. Nose Landing Gear......................7-6. Disassembly of Nose Gear Oleo..................7-7. Cleaning, Inspection and Repair of Nose Gear Oleo............7-8.
Page 214 Aerofiche Paragraph Grid No. 7-39. Landing Gear Warning Switches (Throttle Switches)............7-40. Landing Gear Up/Power Reduced Warning Switch............7-41. Removal of Landing Gear Up/Power Reduced Warning Switch........7-42. Installation of Landing Gear Up/Power Reduced Warning Switch........7-43. Adjustment of Landing Gear Up/Power Reduced Warning Switch........7-44.
Page 215 Piper Service Bulletin 866A, or they will drop themselves should airspeed drop below approximately 103 KIAS, engine power off for the PA-28R-201T and 95 KIAS, engine power off for the PA-28R-201 if the back-up gear extender system is operational per compliance instructions Part II of Service Bulletin 866A.
Page 216 * CHEROKEE ARROW III SERVICE MANUAL to manually overcome system malfunctions or to meet special pilot needs such as a deliberate wheels up landing needed for emergency landings on water, or during various flight maneuvers where airspeed and power settings would normally allow the gear to extend.
Page 217 * CHEROKEE ARROW III SERVICE MANUAL g. To remove the piston tube (39) and fork (42) from the cylinder (23), first separate the upper and lower torque links (24 and 26) by removing the link connecting bolt assembly (25) and then separate the two links.
Page 218 * CHEROKEE ARROW III SERVICE MANUAL Figure 7- 1. Nose Gear Oleo Strut Assembly Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM...
Page 219 * CHEROKEE ARROW III SERVICE MANUAL Figure 7- 1. Nose Gear Oleo Strut Assembly (cont) Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM...
Page 220 * CHEROKEE ARROW III SERVICE MANUAL g. Lubricate the inner wall of the cylinder (23) with hydraulic fluid. Carefully insert the piston tube assembly into the bottom of the cylinder, allowing the orifice tube to guide itself into the fork tube, until the snap ring (38) can be installed in the annular slot at the bottom of the cylinder.
Page 221 CHEROKEE ARROW III SERVICE MANUAL Figure 7-2. Nose Gear Installation Interim Revision: 2/21/95 LANDING GEAR AND BRAKE SYSTEM...
Page 222 * CHEROKEE ARROW III SERVICE MANUAL 7-10. CLEANING, INSPECTION AND REPAIR OF NOSE LANDING GEAR a. Clean all parts with a suitable dry type cleaning solvent. b. Inspect the gear components for the following unfavorable conditions: 1. Bolts, bearings and bushings for excess wear, corrosion and damage.
Page 223 * CHEROKEE ARROW III SERVICE MANUAL c. The drag links (32 and 35) and gear tension spring arm (40) may be installed by the following procedure: 1. Ascertain that the upper and lower links (32 and 35) are assembled with the downlock hook attached and the through travel of the links checked according to Paragraph 7-10.
Page 224 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-3. Nose Gear Adjustment (PA-28R-201) e. Check the adjustment of the hydraulic actuator rod by extending the gear and removing the nut and bolt (19) from the rod end bearing (8). Extend the actuator rod (6) to maximum then retract actuator rod (6) a minimum of .10 inch from the maximum extension.
Page 225 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-4. Nose Gear Adjustment (PA-28R-201T) Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1J10...
Page 226 Dye penetrant may be required. If any of these parts are cracked, remove and replace in accordance with the latest revision of Piper Service Bulletin 724.
Page 227 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-5. Clamping Rudder Pedals in Figure 7-6. Rudder Pedals at Neutral Neutral Position Angle g. Extend a chalk line from the mark on the floor below the tail skid to a point approximately three feet forward of the nose wheel.
Page 228 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-7. Nose Gear Door Retraction Mechanism (PA-28R-201) Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1J13...
Page 229 * CHEROKEE ARROW III SERVICE MANUAL 1. ROD, DOOR RETRACTION 2. DOOR, GEAR 3. SPRING, TENSION 4. ARM ASSEMBLY 5. BOLT & NUT 6. NUT, BOLT, WASHER, BUSHING & COTTER PIN 7. ROLLER 8. BRACKET Figure 7-8. Nose Gear Door Retraction Mechanism (PA-28R-201T)
Page 230 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-9. Main Gear Oleo Strut Assembly Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1J15...
Page 231 * CHEROKEE ARROW III SERVICE MANUAL REFER TO PRECEDING PAGE FOR CALLOUTS. Figure 7-9. Main Gear Oleo Strut Assembly (cont) Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1J16...
Page 232 * CHEROKEE ARROW III SERVICE MANUAL NOTES IT MAY HAVE BEEN NECESSARY TO USE SPECIAL LANDING GEAR ATTACHMENT HARDWARE DURING ASSEMBLY OF THE AIRCRAFT DUE TO MANUFACTURING TOLERANCES. THEREFORE, SPECIAL ATTENTION SHOULD BE GIVEN WHEN REMOVING HARDWARE TO INSPECT AND ENSURE THE SAME DIAMETER HARDWARE IS USED UPON REASSEMBLY.
Page 233 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-10. Main Gear Installation (cont) Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1J18...
Page 234 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-11. Aligning Main Gear Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1J19...
Page 235 * CHEROKEE ARROW III SERVICE MANUAL 7-15. REMOVAL OF NOSE GEAR DOOR ASSEMBLY. (Refer to Figure 7-7 or 7-8.) a. The nose gear assembly on the PA-28R-201 may be removed as follows: 1. With nose gear extended, disconnect the door retraction rods (1) from the doors (2) by removing nut, bolt and washers.
Page 236 * CHEROKEE ARROW III SERVICE MANUAL 2. The arm assembly may be installed by placing the arms on either side of the bracket (8) and securing with bolt, bushings, nut, washer and cotter pin (6). 3. Install the gear door(s) by positioning the hinge halves of the door and cowl and inserting the hinge pin.
Page 237 * CHEROKEE ARROW III SERVICE MANUAL 7-21. CLEANING, INSPECTION AND REPAIR OF MAIN GEAR OLEO. a. Clean all parts with a suitable dry type cleaning solvent. b. Inspect the landing gear oleo assembly component for the following: 1. Bearings and bushings for excess wear, corrosion, scratches and overall damage.
Page 238 * CHEROKEE ARROW III SERVICE MANUAL 7-23. REMOVAL OF MAIN LANDING GEAR. (Refer to Figure 7-10.) a. Place the airplane on jacks. (Refer to Jacking, Section II). b. The side brace link assembly may be removed by the following procedure: 1.
Page 239 * CHEROKEE ARROW III SERVICE MANUAL d. Check the general condition of each limit switch and its actuator, and wiring for fraying, poor connections or conditions that may lead to failures. e. Check the side brace link through center travel by attaching the upper and lower links, setting them on a surface table and ascertaining that when the stop surfaces of the two links touch, linkage is not less than .062 nor more than .125 of an inch through center.
Page 240 * CHEROKEE ARROW III SERVICE MANUAL NOTE When installing a new wing, it will be necessary to back drill two (2) holes 0.250 inch and countersink 100° x .499 through the spar cap. (Screw head should be flush with spar.) Use hole in the support bracket has a guide in the drilling.
Page 241 * CHEROKEE ARROW III SERVICE MANUAL Adjust the turnbuckle of the downlock mechanism by first ascertaining that the gear is down and locked and then move the retraction fitting outboard until it contact the stop slot of the side brace link.
Page 242 * CHEROKEE ARROW III SERVICE MANUAL 7-27. ALIGNMENT OF MAIN LANDING GEAR a. Place a straightedge no less than twelve feet long across the front of both main landing gear wheels. Butt the straightedge against the tire at the hub level of the landing gear wheels. Jack the airplane up just high enough to obtain a six and one-half inch dimension between the centerline of the strut piston and the centerline of the center pivot bolt of the gear torque links.
Page 243 * CHEROKEE ARROW III SERVICE MANUAL TABLE VII-I. TOE-IN—TOE-OUT CORRECTION CHART TOE-IN TOE-OUT SHIM WASHERS WASHERS AN 174 ANGLE WASHERS UNDER HEAD UNDER NUT BOLT AN960-416 AN960-416 (3) 0°33’ AN960-416 AN960-416 AN960-416 (2) 0°48’ AN960-416L AN960-416 AN960-416 AN960-416 1 °04’...
Page 244 * CHEROKEE ARROW III SERVICE MANUAL 7-30. INSTALLATION OF MAIN GEAR DOOR ASSEMBLY. a. Install the door by positioning the hinge halves of the door and wing, and inserting the hinge pin. It is recommended a new pin be used. Bend the end of the pin to secure in place.
Page 245 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-12. Adjustment of Nose Figure 7-13. Adjustment of Main Gear Gear Down Limit Switch Down Limit Switch 7-34. ADJUSTMENT OF NOSE GEAR DOWN LIMIT SWITCH. The gear down limit switch is mounted on the horizontal support tube of the engine mount that runs between the tight attachment points of the gear housing and upper drag link.
Page 246 . Extend and then compress the strut to ascertain that the switch will actuate within the last quarter of an inch of oleo extension. WA R N I N G Applicable to airplanes that are in compliance with Piper Service Bulletin 886A, Part II. 7-38. ADJUSTMENT OF GEAR BACK-UP EXTENDER ACTUATOR SWITCH. The back-up gear extender actuator switch is mounted on the extender unit located under the bottom section of the rear seat.
Page 247 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-14. Flap Torque Tube Cam Gear Warning Switch Installation Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM...
Page 248 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-15. Throttle Warning Switches 7-41. REMOVAL OF LANDING GEAR UP/POWER REDUCED WARNING SWITCH. a. Loosen the quadrant cover by removing the cover attaching screws from each side and at the bottom of the cover.
Page 249 * CHEROKEE ARROW III SERVICE MANUAL Advance and retard the throttle to ascertain that the switch actuates at the desired throttle lever setting. The airplane may also be down to ascertain that the horn and light will actuate when the throttle is reduced below approximately 14 inches of manifold pressure with gear up.
Page 250 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-16. Nose Wheel Assembly 7-48. REMOVAL AND DISASSEMBLY OF MAIN WHEEL. (Refer to Figure 7-17.) a. Place the airplane on jacks. (Refer to Jacking, Section II.) b. To remove the main wheel, remove the four cap bolts that join the brake cylinder housing and the lining back plate assemblies.
Page 251 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-17. Main Wheel Assembly 7-49. INSPECTION OF MAIN WHEEL ASSEMBLY. The inspection of the main wheel is the same as that given for the nose wheel, Paragraph 7-46. 7-50. ASSEMBLY AND INSTALLATION OF MAIN WHEEL. (Refer to Figure 7- 17.) a.
Page 252 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-18. Wheel Brake Assembly 7-51. BRAKE SYSTEM. 7-52. WHEEL BRAKE ASSEMBLY. 7-53. BRAKE ADJUSTMENT AND LINING TOLERANCE. No adjustment of the brake lining clearance is necessary as they are self adjusting. Inspection of the lining is necessary and it may be inspected visually while installed on the airplane.
Page 253 * CHEROKEE ARROW III SERVICE MANUAL e. The piston(s) may be removed by injecting low air pressure in the cylinder fluid inlet and forcing the piston from the housing. f. Check anchor bolt for wear. g. Remove anchor bolt by the following procedure: 1.
Page 254 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-19. Removal of Anchor Bolt Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1K15...
Page 255 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-20. Installation of Anchor Bolt Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1K16...
Page 256 * CHEROKEE ARROW III SERVICE MANUAL 7-59. DISASSEMBLY OF BRAKE MASTER CYLINDER. (Refer to Figure 7-22.) a. Remove the cylinder from its mounting bracket as per paragraph 7-58. b. To disassemble the cylinder, first remove the piston rod assembly by removing the snap ring (11) from the annular slot at the rod end of the cylinder.
Page 257 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-21. Brake System Installation Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1K18...
Page 258 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-22. Brake Master Cylinder (Hand/Parking Brake) 7-63. BRAKE CYLINDER (TOE BRAKE) 7-64. REMOVAL OF BRAKE CYLINDER. (Refer to Figure 7-23.) a. Disconnect the upper and lower lines from the cylinder (14) to be removed and cap the lines to prevent fluid leakage or drain the fluid from the brake reservoir and master cylinder.
Page 259 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-23. Toe Brake Installation Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1K20...
Page 260 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-25. Brake Cylinder (10-27) (Toe Brake) Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1K21...
Page 261 * CHEROKEE ARROW III SERVICE MANUAL 7-66. CLEANING, INSPECTION AND REPAIR OF BRAKE CYLINDER a. Clean cylinder components with a suitable solvent and dry thoroughly. b. Inspect interior walls of cylinder for scratches, burrs, corrosion, etc. c. Inspect general condition of fitting threads.
Page 262 * CHEROKEE ARROW III SERVICE MANUAL NOTE Fluid level in the reservoir must be maintained to prevent air from entering in the line. g. Tighten both wheel bleeders. h. Pull hand brake until a firm handle is maintained. 7-71. BRAKE BLEEDING PROCEDURE (Pressure). (Refer to Figure 7-26.) a.
Page 263 * CHEROKEE ARROW III SERVICE MANUAL 7-72. BRAKE SYSTEM LEAK CHECK. a. Pull for a good firm hand brake and lock parking brake mechanism system to stand for approximately 10 minutes; then by gripping the parking brake handle, it should not be able to be pulled aft further than the original set.
Page 264 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-26. Bleeding Brakes Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM...
Page 265 CHEROKEE ARROW III SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING CHART (LANDING GEAR) Trouble Cause Remedy Red gear unsafe light out Indicator lamp burned Replace lamp. while gear is in transit. out. Indicator light ground Check ground circuit. incomplete. Indicator light circuit Check wiring.
Page 266 CHEROKEE ARROW III SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING CHART (LANDING GEAR) (cont) Trouble Cause Remedy Red gear unsafe light Light circuit wire Check wiring. operates on and off after loose. gear has retracted. Hydraulic system Refer to Hydraulic losing pressure.
Page 267 CHEROKEE ARROW III SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING CHART (LANDING GEAR) (cont) Trouble Cause Remedy Red gear unsafe light and Micro switch at throttle Adjust micro switch. horn fail to operate when out of adjustment. throttle is near closed and landing gear is re- Micro switch at throttle Replace switch.
Page 268 CHEROKEE ARROW III SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING CHART (LANDING GEAR) (cont) Trouble Cause Remedy Green gear down lights Micro switch out of Adjust micro switch. blink momentarily before adjustment. the down lock is engaged on roller. Nose landing gear...
Page 269 CHEROKEE ARROW III SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING CHART (LANDING GEAR) (cont) Trouble Cause Remedy Nose gear fails to steer Steering arm roller Replace defective properly. (cont) sheared at top of roller. strut. Steering bellcrank loose Readjust and tighten. on attachment plate.
Page 270 CHEROKEE ARROW III SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING CHART (LANDING GEAR) (cont) Trouble Cause Remedy Excessive or uneven Incorrect operating Inflate tire to correct wear on main tires. pressure. pressure. Wheel out of alignment Check wheel alignment. (toe in or out).
Page 271 CHEROKEE ARROW III SERVICE MANUAL TABLE VII-II. TROUBLESHOOTING CHART (LANDING GEAR) (cont) Trouble Cause Remedy Red gear unsafe light and Warning light and horn Check wiring. horn fail to operate when circuit wire broken. selector is moved to up position with gear extended and throttle retarded.
Page 272 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-27. Nose Gear Service Tolerances Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM...
Page 273 * CHEROKEE ARROW III SERVICE MANUAL TABLE VII-III. NOSE GEAR SERVICE TOLERANCES Manufacturers Service Service Fig. No Part No Nomenclature Dimension Dimension Tol. Remarks 67146-00 Drag link, upper ID .6235 ID .6230 .6245 .6250 452 474 Bearing, upper drag * * ID .4385 ID .4395...
Page 274 * CHEROKEE ARROW III SERVICE MANUAL TABLE VII-III. NOSE GEAR SERVICE TOLERANCES (cont) Manufacturers Service Service Fig. No Part No Nomenclature Dimension Dimension Tol. Remarks 67054-03 Trunnion assembly ID .302 ID .302 0015 assist spring fining .303 .3035 95061-144 Bearing, assist spring ID .240...
Page 275 * CHEROKEE ARROW III SERVICE MANUAL Figure 7-28. Main Gear Service Tolerances Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1L12...
Page 276 * CHEROKEE ARROW III SERVICE MANUAL TABLE VII-IV. MAIN GEAR SERVICE TOLERANCES Manufacturers Service Service Fig. No Part No Nomenclature Dimension Dimension Tol. Remarks 67514-0 Link, upperside brace ID .3645 .3625 63900-89 Bushing, upperside * * ID .249 ID .248 .004...
Page 277 * CHEROKEE ARROW III SERVICE MANUAL TABLE VII-IV. MAIN GEAR SERVICE TOLERANCES (cont) Manufacturers Service Service Fig. No Part No Nomenclature Dimension Dimension Tol. Remarks 402 927 Bolt, side brace link OD .3742 OD .3740 NAS 464 616 assembly + .0000 -.0005...
Page 278 * CHEROKEE ARROW III SERVICE MANUAL GRIDS 1L15 THRU 1L24 INTENTIONALLY LEFT BLANK Revised: 2/13/89 LANDING GEAR AND BRAKE SYSTEM 1L15...
Page 279 ARROW III - TURBO ARROW III ARROW SERVICE MANUAL CARD 2 OF 3 PA-28R-201/201T Courtesy of Bomar Flying Service www.bomar.biz PIPER AIRCRAFT CORPORATION (PART NUMBER 761 639)
Page 280 CHEROKEE ARROW III SERVICE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS Service manual information incorporated in this set of Aerofiche cards is arranged in accordance with the general specifications of Aerofiche adopted by the General Aviation Manufacturer’s Association. Information compiled in this Aerofiche service manual is kept current by revisions distributed periodically. These revisions supersede all previous revisions, are complete Aerofiche card replacements, and supersede Aerofiche cards of the same number in the set.
Page 281 TABLE OF CONTENTS AEROFICHE CARD NO. 1 GRID NO INTRODUCTION 1A13 HANDLING AND SERVICING 1A16 INSPECTION STRUCTURES 1D17 SURFACE CONTROLS HYDRAULIC SYSTEM LANDING GEAR AND BRAKE SYSTEM 1I22 AEROFICHE CARD NO. 2 VIII POWER PLANT (CONTINENTAL) VIIIA POWER PLANT (LYCOMING) 2C18 FUEL SYSTEM INSTRUMENTS...
Page 282 LIST OF ILLUSTRATIONS (cont) Aerofiche Figure Grid No. 8-1. Engine Cowling Installation....................2A13 8-3. Propeller Installation ......................2A14 8-4. Propeller Blade Minor Repair ................... 2A16 8-5. Propeller Governor......................2A17 8-6. Engine Installation......................2A20 8-7. Schematic Diagram of Turbocharger System..............2A23 8-8.
Page 283 LIST OF ILLUSTRATIONS (cont) Aerofiche Figure Grid No. 8A-7. Fuel-Air Bleed Nozzle....................... 2D11 8A-8. Contact Points........................2D13 8A-9. Rotor Holding Tool Installed..................... 2D14 8A-10. Timing Kit Installed......................2D14 8A-11. Aligning Timing Marks..................... 2D15 8A-12. Checking Flyweight Clearance of Impulse Coupling ............2D15 8A-13.
Page 284 LIST OF ILLUSTRATIONS (cont) Aerofiche Figure Grid No. 11-13. Installing End Bearing....................... 11-14. Removing Drive Pulley..................... 11-15. Removing Drive End Bearing................... 11-16. Removing Slip Ring......................11-17. Installing Slip Ring......................11-18. Solder Points........................11-19. Installing Retainer ......................11-20. Installing Drive End Shield and Bearing (Typical)............11-21.
Page 285 LIST OF TABLES Aerofiche Table Grid No. VIII-I. Propeller Specifications..................... 2A16 VIII-II. Engine Data ........................2A21 VIII-III. Troubleshooting Chart (Engine)..................2C12 VIIIA-I. Propeller Specifications..................... VIIIA-II. Engine Troubleshooting..................... IX-I. Fuel Sender Locations....................... 2E16 IX-II. Fuel Quantity Transmitter Calibration Tolerances............2E18 IX-III. Transmitter Fuel Gauge Tolerances...................
Page 286 THIS PAGE INTENTIONALLY LEFT BLANK Revised: 2/13/89...
Page 287 SECTION VIII POWER PLANT [CONTINENTAL] Aerofiche Paragraph Grid No. 8-1. Introduction ........................2A11 8-1a. Standard Practices - Engine....................2A11 8-2. Description ........................2A12 8-3. Troubleshooting......................... 2A12 8-4. Engine Cowling......................... 2A12 8-5. Removal of Engine Cowling..................... 2A12 8-6. Cleaning, Inspection and Repair of Engine Cowling............2A12 8-7.
Page 288 Aerofiche Paragraph Grid No. 8-35. Magnetos ........................... 8-36. Inspection of Magnetos ..................... 8-37. Removal of Magnetos......................2B10 8-38. Magneto Timing Procedure (Internal Timing) ..............2B11 8-39. Magneto Installation and Timing Procedure (Magneto to Engine)........2B13 8-40. Harness Assembly......................2B14 8-41. Inspection of Harness......................
Page 289 (PA-28R-201T) WARNING When servicing or inspecting vendor equipment installed in Piper Aircraft, it is the user’s responsibility to refer to the applicable vendor publication. 8-1. INTRODUCTION. The purpose of this section is to provide instructions for the removal, minor repair, service and installation of the engine and components.
Page 290 CHEROKEE ARROW III SERVICE MANUAL 8-2. DESCRIPTION. The PA-28R-201T is powered by a Teledyne Continental TSIO-360-F turbocharg e d , overhead valve, air cooled, horizontally opposed, direct drive, wet sump engine rated at 200 hp from sea level to 12,000 feet density altitude.
Page 291 CHEROKEE ARROW III SERVICE MANUAL Figure 8-1. Engine Cowling Installation 8-7. INSTALLATION OF ENGINE COWLING. (Refer to Figure 8-1.) a. Position the bottom cowl and secure with screw fasteners to the fuselage and engine mount. b. Position and connect the upper nose cowl to the lower cowl.
Page 292 CHEROKEE ARROW III SERVICE MANUAL Figure 8-3. Propeller Installation Revised: 8/31/77 POWER PLANT - CONTINENTAL 2A14...
Page 293 CHEROKEE ARROW III SERVICE MANUAL 8-10. CLEANING, INSPECTION AND REPAIR OF PROPELLER. NOTE Do not attempt to disassemble the propeller any further than stated in this manual. For internal repairs and replacement of parts, the propeller should be referred to the Hartzell Factory or Certified Repair Station.
Page 294 CHEROKEE ARROW III SERVICE MANUAL Figure 8-4. Propeller Blade Minor Repair TABLE VIII-I. PROPELLER SPECIFICATIONS Blade Angle Low Pitch (High RPM) 14.4° ± 0.2° High Pitch (Low RPM) 29° ± 1.0° Propeller RPM Setting Engine Static High RPM 2575 RPM max.
Page 295 CHEROKEE ARROW III SERVICE MANUAL Figure 8-5. Propeller Governor 8-12. CHECKING PROPELLER BLADE TRACK. Blade track is the ability of one blade tip to follow the other, while rotating, in almost the same plane. Excessive difference in blade track - more than .0625 inch may be an indication of bent blades or improper propeller installation.
Page 296 CHEROKEE ARROW III SERVICE MANUAL 8-15. INSTALLATION OF PROPELLER GOVERNOR. a. Clean the mounting pad and the governor drive shaft thoroughly. b. Coat the mounting gasket with Dow Corning release agent or equivalent. c. Lubricate the drive shaft with engine oil and install the governor on the mounting pad.
Page 297 CHEROKEE ARROW III SERVICE MANUAL 8-17. ENGINE. 8-18. REMOVAL OF ENGINE. (Refer to Figure 8-6.) a. Turn off all electrical switches in the cockpit and disconnect the battery ground wire at the battery. b. Move the fuel selector valve in the cockpit to the OFF position.
Page 298 CHEROKEE ARROW III SERVICE MANUAL Figure 8-6. Engine Installation Revised 12/11/78 POWER PLANT - CONTINENTAL 2A20...
Page 299 CHEROKEE ARROW III SERVICE MANUAL TABLE VIII-II. ENGINE DATA Model (Teledyne Continental) TSIO-360F or TSIO-360FB Type Certificate Number E9CE Number of Cylinders 6 Horizontally Opposed Bore (Inches) 4.44 Stroke (Inches) 3.88 Displacement (Cubic Inches) Compression Ratio 7.5:1. Type of Propeller Drive, Flanged...
Page 300 CHEROKEE ARROW III SERVICE MANUAL 8-19. INSTALLATION OF ENGINE. (Refer to Figure 8-6.) Prior to installing the engine, be sure to install all items that were removed after the engine was removed from the aircraft WARNING Prior to installation of the engine, ensure that Teledyne Continental Service Bulletin M86-11 is complied with.
Page 301 CHEROKEE ARROW III SERVICE MANUAL Figure 8-7. Schematic Diagram of Turbocharger System Revised: 8/31/77 POWER PLANT - CONTINENTAL 2A23...
Page 302 CHEROKEE ARROW III SERVICE MANUAL 8-20. ENGINE SHOCK MOUNTS. 8-21. REPLACEMENT OF ENGINE SHOCK MOUNTS. (Refer to Figure 8-6.) a. Remove the engine cowling per Paragraph 8-5. b. Relieve the engine weight on the mounts using a one-half ton hoist attached to the engine lifting points.
Page 303 CHEROKEE ARROW III SERVICE MANUAL Density Controller The density controller is designed to allow the engine to develop full rated power no matter what ambient temperature and pressure conditions are. This controller regulates wastegate bleed oil only at full throttle position to maintain a constant air density at the injector inlet.
Page 304 CHEROKEE ARROW III SERVICE MANUAL Overboost An overboost condition means that manifold pressure is exceeding the limits at which the engine was tested and FAA certified and can be detrimental to the life and performance of the engine. Overboost can...
Page 305 4. Remove the bolts that attach the turbocharger to the mounting bracket and remove the turbocharger assembly. WARNING Comply with instructions of latest revision of Piper Service Bulletin No. 844. NOTE Piper considers service bulletins of utmost importance and compliance mandatory.
Page 306 CHEROKEE ARROW III SERVICE MANUAL d. Place turbine housing insulation blanket in proper position and safety blanket to turbocharger attaching hardware. e. Position the exhaust tailpipe and exhaust bypass screw to the turbine outlet, aligning the tailpipe with the hole cut out in the lower cowl provided for it.
Page 307 CHEROKEE ARROW III SERVICE MANUAL Figure 8-8. Induction System Installation 8-31. CLEANING INDUCTION AIR FILTER. The air filter element should be cleaned as often as it becomes dirty, everyday under severe dust conditions. The filter element should be replaced if any holes or tears exist.
Page 308 CHEROKEE ARROW III SERVICE MANUAL 8-32. INSTALLATION OF AIR FILTER. (Refer to Figure 8-8.) a. Properly position the filter element in the box assembly and secure the cover assembly with the stud fasteners. NOTE Check filter element for proper position by ensuring that the slightly raised section in the bottom of the box assembly is completely inside the filter element inner ring.
Page 309 CHEROKEE ARROW III SERVICE MANUAL WARNING When servicing or inspecting vendor equipment installed in Piper Aircraft, it is the user’s responsibility to refer to the applicable vendor publication. Figure 8-8a. Magneto Assembly Revised: 2/13/89 POWER PLANT - CONTINENTAL...
Page 310 CHEROKEE ARROW III SERVICE MANUAL Figure 8-9. Contact Spring Inspection. c. Should the trouble appear definitely associated with the magneto, the most effective measure is to install a replacement magneto which is known to be in satisfactory condition and send the suspected unit to the overhaul shop for test and repair.
Page 311 CHEROKEE ARROW III SERVICE MANUAL Figure 8-10. Contact Points. NOTE No attempt should be made to stone or dress contact points. Should contact assembly have bad points or show excessive wear, the complete contact assembly should be replaced. Check the condition of the cam follower felt. Squeeze felt tightly between thumb and forefinger. If fingers are not moistened with oil, re-oil using 2 or 3 drops of Bendix 10-86527 lubricant.
Page 312 CHEROKEE ARROW III SERVICE MANUAL Figure 8-11. Impluse Coupling Figure 8-12. Flyweight Clearance of Impulse Coupling n. Check the clearance between each flyweight and each stop pin as follows: 1. Bend the end of a stiff piece of wire into a right angle 0.125 inch long (maximum).
Page 313 CHEROKEE ARROW III SERVICE MANUAL Figure 8-13. Rotor Holding Tool Installed Figure 8-14. Timing Kit Installed 8-38. MAGNETO TIMING PROCEDURE (INTERNAL TIMING). When installing or adjusting breaker points and before timing the magneto to the engine, it is important that the internal timing of the magneto be correct.
Page 314 CHEROKEE ARROW III SERVICE MANUAL Figure 8-15. Cast-in Timing Marks Figure 8-16. Fabricated Pointer 5. Install the Bendix 11-8149 Pointer Assembly on the cam screw and align pointer with the zero degree mark on the timing plate. 6. Loosen adjusting knob of rotor holding tool and turn rotating magnet in normal direction of rotation until pointer indexes with the respective 10°...
Page 315 CHEROKEE ARROW III SERVICE MANUAL Figure 8- 17. Engine Timing Marks 2. Turn rotating magnet in direction of rotation until painted chamfered tooth of distributor gear is just becoming visible in timing window. Continue turning rotating magnet until line on end of cam is aligned with mark at top of breaker housing.
Page 316 CHEROKEE ARROW III SERVICE MANUAL 3. Remove the inspection hole plug from the magneto. Turn the magneto coupling until the painted chamfered tooth on the distributor gear is approximately centered in the inspection hole. Hold the magneto in its approximate installed position. Note carefully the position of the coupling drive lugs.
Page 317 CHEROKEE ARROW III SERVICE MANUAL Figure 8-18. Removing Spring From Lead Assembly 3. Depress PRESS-TO-TEST push-button switch. 4. Observe that INDICATOR lamp flashes and GAP fires intermittently as long as PRESS-TO-TEST switch is held depressed. 5. Whenever INDICATOR lamp flashes and gap fails to fire, lead under test is defective.
Page 318 CHEROKEE ARROW III SERVICE MANUAL 8-43. MAINTENANCE OF HARNESS. a. To replace contact springs, spring retainer assemblies or insulating sleeves, proceed as follows: 1. Using a Bendix 11-7073 Needle or a mechanical pencil with the lead retracted, hook the end of the contact spring as shown in Figure 8-18.
Page 319 CHEROKEE ARROW III SERVICE MANUAL Figure 8-19. Assembly Tool Figure 8-20. Assembly Tool Application Figure 8-21. Measuring Lead Assembly Length Revised: 8/31/77 POWER PLANT - CONTINENTAL 2B17...
Page 320 CHEROKEE ARROW III SERVICE MANUAL CAUTION Insure before every cutting or stripping procedure that braid has not worked back on lead by grasping lead in one hand and sliding the other hand firmly along lead toward the outlet plate. If braid is improperly located on lead, the lead may be trimmed to the wrong length.
Page 321 CHEROKEE ARROW III SERVICE MANUAL Figure 8-22. Ferrule Seating Tool Figure 8-23. Measuring Wire From Top of Ferrule Figure 8-24. Needle Figure 8-25. Installing Grommet Over Lead Assemblies Revised: 8/31/77 POWER PLANT - CONTINENTAL 2B19...
Page 322 CHEROKEE ARROW III SERVICE MANUAL Figure 8-26. Lead Assembly Installed in Grommet Figure 8-27. Wire Doubled Over For Installation of Eyelet 17. Install the clamps and cable ties, as necessary, to secure the lead to the engine. CAUTION Leads should be dressed away from hot spots, such as manifolds and sharp edges which cause chafing.
Page 323 CHEROKEE ARROW III SERVICE MANUAL Figure 8-28. Ignition Schematic Revised: 8/31/77 POWER PLANT - CONTINENTAL 2B21...
Page 324 CHEROKEE ARROW III SERVICE MANUAL 8-45. SPARK PLUGS. 8-46. REMOVAL OF SPARK PLUGS. a. Loosen the coupling nut on the harness lead and remove the terminal insulator from the spark plug barrel well. (A crows foot adapter is needed to remove the lower spark plugs.)
Page 325 CHEROKEE ARROW III SERVICE MANUAL Figure 8-29. Removing Frozen Spark Plug 8-47. INSPECTION AND CLEANING OF SPARK PLUG. a. Visually inspect each spark plug for the following non-repairable defects: 1. Severely damaged shell or shield threads nicked up, stripped or cross-threaded.
Page 326 CHEROKEE ARROW III SERVICE MANUAL Figure 8-30. Lubrication System Maintenance Points. 8-49. LUBRICATION SYSTEM. 8-50. DESCRIPTION. The oil system is a wet sump, force feed system with a capacity of 8 quarts. A conventional dipstick is provided for determining the oil quantity.
Page 327 CHEROKEE ARROW III SERVICE MANUAL 8-51. OIL FILTER REPLACEMENT. (Refer to Figure 8-30.) The oil filter element should be replaced after each 50 hours of engine operation. The filter element is mounted on the lower portion of the engine accessory case.
Page 328 CHEROKEE ARROW III SERVICE MANUAL Figure 8-31. Schematic Diagram of Fuel Injection System Revised:8/31/77 POWER PLANT - CONTINENTAL...
Page 329 CHEROKEE ARROW III SERVICE MANUAL Figure 8-32. Fuel Injector Nozzle Assembly 8-55. FUEL INJECTOR NOZZLE ASSEMBLY. 8-56. REMOVAL OF FUEL INJECTOR NOZZLES. a. Remove the cowling side access panels. b. Disconnect the fuel line and remove the ram air line from the nozzle.
Page 330 CHEROKEE ARROW III SERVICE MANUAL Figure 8-33. Engine Controls Revised: 8/31/77 POWER PLANT - CONTINENTAL...
Page 331 CHEROKEE ARROW III SERVICE MANUAL 8-59. ENGINE AND PROPELLER CONTROLS. 8-60. RIGGING THROTTLE, MIXTURE AND GOVERNOR CONTROLS. (Refer to Figure 8-33.) a. Rig the throttle control as follows: 1. Place the quadrant throttle lever full forward. 2. With the control arm on the fuel-air control unit in the full throttle position. rig the throttle quadrant lever to provide a minimum of .032 inches clearance from the forward stop.
Page 332 CHEROKEE ARROW III SERVICE MANUAL Figure 8-34. Idle Speed and Mixture Adjustment Points b. Exhaust Bypass Check: Ascertain that the exhaust bypass adjusting screw has from eight to nine threads showing below the jam nut. This screw is preset at the factory and should not require any adjustment, unless it is known that critical altitude is not correct;...
Page 333 CHEROKEE ARROW III SERVICE MANUAL d. Check and Adjustment of Idle Fuel Pressure: NOTE The following setup procedure is accomplished with the boost pump OFF and the engine thoroughly warmed up. 1. Back off the idle speed adjusting screw two turns. (Refer to Figure 8-34.) 2.
Page 334 CHEROKEE ARROW III SERVICE MANUAL Figure 8-35. Sectional View of Altitude Compensating Fuel Pump Assembly g. Adjustment for Full Power Performance: (Refer to Figure 8-35.) CAUTION Before attempting full power checks, be sure that the brakes are properly maintained and set, and that the ground conditions will not permit the wheels to slip during full power check.
Page 335 CHEROKEE ARROW III SERVICE MANUAL h. Rechecking System: 1. Recheck the idle settings per instructions c, d, e and f, and adjust as required. 2. Recheck Full Power Fuel Flow settings per instruction g, and adjust as required. 3. With engine operating at 2575 RPM (40.8 to 41.0 in. Hg manifold pressure), lean the mixture to obtain 21 gph fuel flow readings.
Page 336 CHEROKEE ARROW III SERVICE MANUAL Figure 8-36. Exhaust Bypass Screw CHART VIII-I. METERED FUEL ASSEMBLY CALIBRATION Revised 12/11/78 POWER PLANT - CONTINENTAL 2C10...
Page 337 CHEROKEE ARROW III SERVICE MANUAL CHART VIII-II. LIMITS - FUEL FLOW VS. BRAKE H.P. Revised: 8/31/77 POWER PLANT - CONTINENTAL 2C11...
Page 338 CHEROKEE ARROW III SERVICE MANUAL TABLE VIII-III. TROUBLESHOOTING CHART (ENGINE) Trouble Cause Remedy Engine will not No fuel gauge pres- Check fuel control for proper position, auxiliary start. sure - no fuel to pump “ON” and operating, feed valves open. Fuel engine.
Page 339 CHEROKEE ARROW III SERVICE MANUAL TABLE VIII-III. TROUBLESHOOTING CHART (ENGINE) (cont.) Trouble Cause Remedy Engine has poor Idle mixture too Readjust idle mixture. acceleration. lean. Incorrect fuel-air Tighten loose connections. Service air cleaner. mixture, worn con- trol linkage or restricted air cleaner.
Page 340 CHEROKEE ARROW III SERVICE MANUAL TABLE VIII-III. TROUBLESHOOTING CHART (ENGINE) (cont.) Trouble Cause Remedy Engine lacks Defective ignition Inspect spark plugs for fouled electrodes, heavy power, reduction system. carbon deposits, erosion of electrodes, improperly in maximum man- adjusted electrode gaps and cracked porcelains.
Page 341 CHEROKEE ARROW III SERVICE MANUAL TABLE VIII-III. TROUBLESHOOTING CHART (ENGINE) (cont.) Trouble Cause Remedy Low fuel pressure. Restricted flow to Check mixture control for full travel. Check for fuel metering valve. restrictions in fuel filters and lines; adjust control and clean filters. Replace damaged parts.
Page 342 CHEROKEE ARROW III SERVICE MANUAL TABLE VIII-III. TROUBLESHOOTING CHART (ENGINE) (cont.) Trouble Cause Remedy High fuel Restricted re- Replace pump. pressure. circulation pas- (cont.) sage in fuel in- jector. Air leakage in fuel Locate cause of leakage and eliminate. gauge vent pres- surization line.
Page 343 CHEROKEE ARROW III SERVICE MANUAL TABLE VIII-III. TROUBLESHOOTING CHART (ENGINE) (cont.) Trouble Cause Remedy Low oil pressure Leaking oil seal Check for oil in turbocharger exhaust outlet. Re on engine gauge. in turbocharger. place turbocharger. (cont.) Defective check valve Disassemble and clean valve or replace.
Page 344 SECTION VIIIA POWER PLANT [LYCOMING] Aerofiche Paragraph Grid No. 8A-1. Introduction ........................2C19 8A-1a. Standard Practices-Engine....................2C19 8A-2. Description ........................2C20 8A-3. Troubleshooting......................... 2C20 8A-4. Propeller ..........................2C20 8A-5. Removal of Propeller......................2C20 8A-6. Cleaning, Inspection and Repair of Propeller..............2C22 8A-7.
Page 345 LYCOMING (PA-28R-201) WARNING When servicing or inspecting vendor equipment installed in Piper Aircraft, it is the user’s responsibility to refer to the applicable vendor publication. 8A-1. INTRODUCTION. This section covers the power plant used in PA-28R-201 airplanes and is comprised of instructions for the removal, minor repair, service and installation of the propeller, propeller governor, engine, induction system, fuel injector, fuel air bleed nozzle, ignition system and lubrication system.
Page 346 CHEROKEE ARROW III SERVICE MANUAL h. Anti-seize lubrication should be applied to all loose-fit spline drives which are external to the engine and have no other means of lubrication. For certain assembly procedures, molybdenum disulfide in either paste or powdered form mixed with engine oil or grease may be used.
Page 347 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-1. Propeller Installation (Hartzell) Revised: 5/1/80 POWER PLANT - LYCOMING 2C21...
Page 348 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-2. Propeller Blade Minor Repair NOTE Nuts with studs will have to be backed out evenly so that propeller may be pulled forward (approx. 1/4-inch at a time) until all studs are disengaged from the engine crankshaft flange.
Page 349 CHEROKEE ARROW III SERVICE MANUAL 8A-7. INSTALLING PROPELLER. a. Assure master switch and magneto switches are in the off position. b. Make certain the fuel selector is in the off position and the mixture control is in idle cut-off. c. Wipe crankshaft and the interior of the propeller hub to assure no foreign matter entered the propeller mechanism.
Page 350 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-3. Propeller Governor 8A-12. RIGGING AND ADJUSTMENT OF PROPELLER GOVERNOR. (Refer to Figure 8A-3.) a. Start engine, park 90° to wind direction and warm in normal manner. b. To check high RPM, low pitch setting, move the propeller control all the way forward. At this position the governor speed control arm (1) should be against the high RPM fine adjusting screw (2).
Page 351 CHEROKEE ARROW III SERVICE MANUAL TABLE VIIIA-I. PROPELLER SPECIFICATIONS Hartzell McCauley Blade Angle* Low Pitch (High RPM) 14.0° ± 0.2° 12.5° ± 0.2° *Measured at 30 inch station. High Pitch (Low RPM) 29.0° ± 2° 27.5° ± 0.5° Propeller RPM Setting Engine Static High RPM 2700 RPM Max.
Page 352 CHEROKEE ARROW III SERVICE MANUAL 1. UPPER COWL ASSEMBLY 2. LOWER COWL ASSEMBLY 3. OIL FILLER DOOR ASSEMBLY 4. FASTENER ASSEMBLY 5. PIN PLATE ASSEMBLY 6. PLATE ASSEMBLY, BUSHING, RETAINING RING, WASHERS, NUTS Figure 8A-3a. Engine Cowling Installation 8A-14. REMOVAL OF ENGINE.
Page 353 CHEROKEE ARROW III SERVICE MANUAL NOTE Where a question may arise as where to reconnect hose, line or wire, the item at the separation should be identified (tagged) to facilitate reinstallation. Open fuel, oil, vacuum lines and fittings should be covered to prevent contamination.
Page 354 CHEROKEE ARROW III SERVICE MANUAL Figure 8A4. Engine Installation (PA-28R-201) Revised: 10/18/83 POWER PLANT - LYCOMING...
Page 355 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-4. Engine Installation (PA-28R-201) (cont) Revised: 11/21/80 POWER PLANT - LYCOMING...
Page 356 CHEROKEE ARROW III SERVICE MANUAL n. Connect the oil cooler. o. Connect the magneto “P” leads. Check that magneto switch is “OFF.” p. Connect the fuel pump supply and vent line. q. Install the injector. Connect the throttle and mixture cables to the injector. Check adjustment of the control by referring to Paragraph 8A-16.
Page 357 CHEROKEE ARROW III SERVICE MANUAL Figure 8A4a. Adjustment of Engine Controls 2. Adjust the linkage by rotating the rod end on the cable to obtain 0.010 to 0.030O fan inch spring back on instrument panel stop when in full throttle position.
Page 358 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-5. Fuel Injector CAUTION Never wash the filter element in any liquid or soak it in oil. Never attempt to blow off dirt with compressed air. c. The filter housing can be cleaned by wiping with a clean cloth soaked in a suitable dry type solvent.
Page 359 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-6. Schematic Diagram of RSA Fuel Injection System Revised: 8/31/77 POWER PLANT - LYCOMING...
Page 360 CHEROKEE ARROW III SERVICE MANUAL 3. Check all fuel lines for tightness and evidence of leakage. A slight fuel stain adjacent to the air bleed nozzles is not cause for concern. 4. Check throttle and mixture control rod ends and levers for tightness and lock.
Page 361 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-7. Fuel - Air Bleed Nozzle THIS SPACE INTENTIONALLY LEFT BLANK Revised: 11/21/80 POWER PLANT - LYCOMING 2D11...
Page 362 8A-27. INSPECTION OF MAGNETO. WARNING When servicing or inspecting vendor equipment installed in Piper Aircraft, it is the user’s responsibility to refer to the applicable vendor publication. NOTE Comply with latest revision of Bendix Service Bulletin No. 608 at first o p p o r t u n i t y, but no later than next magneto overhaul.
Page 363 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-8. Contact Points NOTE No attempt should be made to stone or dress contact points. Should contact assembly have bad points or show excessive wear, the complete contact assembly should be replaced. g. Check the condition of the cam follower felt. Squeeze felt tightly between thumb and forefinger. If fingers are not moistened with oil, re-oil using 2 or 3 drops of Scintilla 10-391200 lubricant.
Page 364 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-9. Rotor Holding Tool Installed Figure 8A-10. Timing Kit Installed 8A-28. REMOVAL OF MAGNETO. Before removing the magneto, make sure magneto switches are off. a. Remove the harness assembly terminal plate from the magneto.
Page 365 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-11. Aligning Timing Marks Figure 8A-12. Checking Flyweight Clearance of Impulse Coupling 4. Install the 11-8693 Timing Plate Assembly and the 11-8149 Pointer Assembly of the 11 - 8 1 5 0 Scintilla Timing Kit to breaker compartment of magneto. (Refer to Figure 8A-10.) Align pointer assembly with the 0 mark on timing plate.
Page 366 CHEROKEE ARROW III SERVICE MANUAL 3. Secure distributor block to housing with studs and washers. Tighten studs finger tight. Loosen the 11-8465 Rotor Holding Tool and turn rotating magnet in reverse direction of rotation until timing light indicates contact assembly had just opened and check to make certain timing marks align within tolerance indicated above.
Page 367 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-13. Engine Timing Marks Figure 8A-14. Magneto Adjustment Limits b. At this point, the engine is ready for assembly of the magnetos. Remove the inspection plugs from both magnetos and turn the drive shafts in direction of normal rotation (counterclockwise facing the coupling), until the first painted chamfered tooth on the distributor gear is aligned in the center of the inspection window.
Page 368 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-15. Magneto Timing Marks Figure 8A-16. Removing Spring From Lead Assembly d. After both magnetos have been timed, check, as described below, to ascertain that both magnetos are set to fire together. e. Back off the crankshaft a few degrees; the timing lights should go out. Bring the crankshaft slowly back in direction of normal rotation until the timing mark and the hole in the starter housing are in alignment.
Page 369 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-17. Assembly Tool Figure 8A-18. Using Assembly Tool Figure 8A-19. Measuring Lead Assembly Length Revised: 8/31/77 POWER PLANT - LYCOMING 2D19...
Page 370 CHEROKEE ARROW III SERVICE MANUAL 8A-33. REMOVAL OF HARNESS. a. Disconnect the clamps that secure the wires to the engine and accessories. b. Loosen the coupling nuts at the spark plugs and remove the insulators from the spark plug barrel well.
Page 371 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-20. Cutting Metallic Braid From End Figure 8A-21. Unbraiding Metallic Shielding of Lead Figure 8A-22. Forming Shielding Around Ferrule Figure 8A-23. Ferrule Seating Tool Figure 8A-24. Needle Revised: 8/31/77 POWER PLANT - LYCOMING 2D21...
Page 372 CHEROKEE ARROW III SERVICE MANUAL 6. Cut lead assembly to the length determined in Step 5. Mark ferrule on spark plug end of lead with a metal stamp, scribe or rubber stamp to correspond with correct cylinder number. 7. Starting at spark plug location, thread new cable through grommets and clamps as necessary for correct routing of cut end of cable to magneto location.
Page 373 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-25. Measuring Wire From Top of Figure 8A-26. Installing Grommet Over Lead Ferrule Assemblies Figure 8A-27. Lead Assembly Installed in Grommet Figure 8A-28. Wire Doubled Over for Installation of Eyelet Revised: 8/31/77 POWER PLANT - LYCOMING...
Page 374 CHEROKEE ARROW III SERVICE MANUAL 8A-35. INSTA L L ATION OF HARNESS. Before installing harness on magneto, check mating surfaces for cleanliness. Spray entire face of grommet with a light coat of Plastic Mold Spray, SM-OOTH Silicone Spray or equivalent. This will prevent harness grommet from sticking to magneto distributor block.
Page 375 CHEROKEE ARROW III SERVICE MANUAL Figure 8A-29. Removing Spark Plug Frozen to Bushing d. Removal of seized spark plugs in the cylinder may be accomplished by application of liquid carbon dioxide by a Conical metal funnel adapter with a hole at the apex just large enough to accommodate the funnel of a CO2 bottle.
Page 376 8A-42. ENGINE OIL QUICK DRAIN VALVE. When replacing the engine oil quick drain, refer to the Piper Parts Catalog for the correct part number. Installation of an incorrect drain could lead to damage of the sump or the drain itself.
Page 377 CHEROKEE ARROW III SERVICE MANUAL TABLE VIIIA-II. ENGINE TROUBLESHOOTING Trouble Cause Remedy Failure of engine to Lack of fuel. Check fuel system for start. leaks. Fill fuel tank. Clean dirty lines, strain- ers or fuel valves. Check fuel selector valve for proper tank.
Page 378 CHEROKEE ARROW III SERVICE MANUAL TABLE VIIIA-II. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy Failure of engine to Internal failure. Check oil screens for start. (cont.) metal particles. If found, complete over- haul of engine may be indicated. Failure of engine to Incorrect idle mixture.
Page 379 CHEROKEE ARROW III SERVICE MANUAL TABLE VIIIA-II. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy Low power and uneven Leaks in induction Tighten all connections. running. (cont.) system. Replace defective parts. Defective spark plugs. Clean and gap or re- place spark plugs.
Page 380 CHEROKEE ARROW III SERVICE MANUAL TABLE VIIIA-II. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy Figure of engine to Faulty ignition. Tighten all connections. develop full power. Check system with (cont.) tester. Check ignition timing. Rough engine. Cracked engine mount. Replace or repair mount.
Page 381 CHEROKEE ARROW III SERVICE MANUAL TABLE VIIIA-II. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy High oil temperature. Insufficient oil supply. Fill oil sump to proper (cont.) level with specified oil. Low grade of oil. Replace with oil con- forming to specifica- tions.
Page 382: Fuel System
SECTION IX FUEL SYSTEM Aerofiche Paragraph Grid No. 9-1. Introduction ........................9-2. Description ........................9-3. Troubleshooting......................... 2E14 9-4. Fuel Tanks.......................... 2E14 9-5. Removal of Fuel Tanks...................... 2E14 9-6. Inspection and Repair of Fuel Tank................... 2E14 9-7. Installation of Fuel Tank....................2E14 9-8.
Page 383 CHEROKEE ARROW III SERVICE MANUAL SECTION IX FUEL SYSTEM 9-1. INTRODUCTION. The fuel system components covered in this section consist of the fuel tanks, selector valves, filter screens, fuel pumps and quantity transmitter units. Instructions are given for remedying difficulties which may arise in the normal operation of the fuel system. The instructions are organized so the mechanic can refer to: Removal, Repair, Installation and Adjustment of each part of the system.
Page 384 CHEROKEE ARROW III SERVICE MANUAL A fuel tank selector allows the pilot to control the flow of fuel to the engine, and is located on the left side wall below the instrument panel. It has three positions: OFF, LEFT TANK and RIGHT TANK. The arrow on the handle of the selector points to the tank which is supplying fuel to the engine.
Page 385 CHEROKEE ARROW III SERVICE MANUAL Figure 9-1. Fuel System Diagram (PA-28R-201) Issued: 12/15/76 FUEL SYSTEM 2E11...
Page 386 CHEROKEE ARROW III SERVICE MANUAL Figure 9-1a. Fuel System Diagram (PA-28R-201) S/N 2837001 and up Revised: 2/13/89 FUEL SYSTEM 2E12...
Page 387 CHEROKEE ARROW III SERVICE MANUAL Figure 9-2. Fuel System Diagram (PA-28R-201T) Revised: 2/13/89 FUEL SYSTEM 2E13...
Page 388 If peeling has occurred and separated material is found, the fuel tank should be removed and resloshed in accordance with the instructions included with each can of Randolph Sloshing Sealer, 802, Piper part number 757 572V. (Approved under Mil. Spec. MIL-L-G0478.) One gallon of sloshing compound is required per tank.
Page 389 CHEROKEE ARROW III SERVICE MANUAL Figure 9-3. Fuel Sender Units Installation Revised: 2/13/89 FUEL SYSTEM 2E15...
Page 390 S/N: 28R-7737162 and up PA-28R-201T Outboard Inboard S/N: 28R-7703381 and up Note: Fuel quantity sender Piper P/N: 550 504 requires fiber washer insulators. Refer to Figure 9-3, View B-B. Figure 9-4. Engine Primer System Placard (PA-28R-201T) Revised: 2/13/89 FUEL SYSTEM 2E16...
Page 391 Reaching through the access opening, disconnect the electrical lead(s) from the sender unit(s). NOTE The inboard and outboard senders are different units in that one unit (Piper P/N 550 504) requires fiber insulating washers. When removing the bolts and washers from this unit, be careful not to damage the fiber insulating washers and make sure when reinstalling the sender, to use the correct bolts and washers.
Page 392 CHEROKEE ARROW III SERVICE MANUAL d. Fill the fuel tank with fuel. During filling check for proper fuel quantity gauge readings. Check for any leaks around the sender unit attachment surface by looking through the access opening on the lower surface of the wing.
Page 393 CHEROKEE ARROW III SERVICE MANUAL Figure 9-5. Fuel Quantity Indicator 9-12. FUEL SELECTOR VALVE. 9-13. REMOVAL OF FUEL SELECTOR VALVE. a. Remove three screws holding selector cover and the screw holding the handle. It will be necessary to remove side panel to gain access to the selector valve.
Page 394 CHEROKEE ARROW III SERVICE MANUAL Figure 9-6. Fuel Filter Bowl and Screen 9-17. INSTALLATION OF FUEL FILTER BOWL AND SCREEN. a. Position the top of the filter bowl to the bracket and connect the fuel lines. b. Spread the bail wire ends and insert them through the holes in the side of the mounting bracket and the top of the filter bowl.
Page 395 CHEROKEE ARROW III SERVICE MANUAL Figure 9-7. Aux Fuel Pump Variable Resistor c. Disconnect the wire from the auxiliary pump circuit breaker. d. From an external power source containing a voltmeter, connect the negative lead to ground and the positive lead to the slide resistor high terminal.
Page 396 CHEROKEE ARROW III SERVICE MANUAL 9-20b. AUXILIARY FUEL PUMP SYSTEM OPERATIONAL CHECK. a. Install a calibrated fuel pressure gauge in the fuel line between the electric fuel pump and the engine and disconnect the electrical leads to the manifold pressure switch located on the firewall.
Page 397 CHEROKEE ARROW III SERVICE MANUAL TABLE IX-III. TRANSMITTER/FUEL GAUGE TOLERANCES Tolerance Actual Fuel in Gauge Reading (Plus or Minus) Tank (U. S. Gal) (U.S. Gal) (Needle-Widths) Full 32.5 22.5 12.5 Zero Plus 0 - Minus 1 0 Empty Empty Dot 9-21.
Page 398 CHEROKEE ARROW III SERVICE MANUAL 9-24. ADJUSTMENT OF ELECTRIC FUEL PUMP (BENCH TEST). a. Ascertain that the pump is sufficiently lubricated to prevent damage if run dry for a period greater than five minutes. b. Connect the electric leads to a 14-volt dc power source.
Page 399 CHEROKEE ARROW III SERVICE MANUAL 9-28. INSPECTION AND TIGHTENING OF FUEL LINE UNION FITTINGS. a. Remove the aft inboard inspection panel from the lower surface of the right and left wing. b. Remove the pilot’s seat and left cabin side panel. Fold back the carpeting that covers the forward side of the spar box and remove the cover from the fuel line(s).
Page 400 AC43.13-1A, paragraph 392. This will require cutting off the swaged ferrule and adding a short length of tubing. c. If a replacement tube and union purchased from Piper is being used, the ferrule is pre-swaged onto the tube. Install the pre-fabricated tube as follows: 1.
Page 401 CHEROKEE ARROW III SERVICE MANUAL TABLE VIX-IV. TROUBLESHOOTING CHART. (FUEL SYSTEM) Trouble Cause Remedy Failure of fuel to flow. Fuel line blocked. Flush fuel system. Fuel vent cap blocked. Check and clean vent hole in cap. Mechanical or electrical Check and replace if fuel pump failure.
Page 402 CHEROKEE ARROW III SERVICE MANUAL TABLE VIX-IV. TROUBLESHOOTING CHART. (FUEL SYSTEM) (cont) Trouble Cause Remedy No fuel pressure Fuel selector valve Check fuel selector indication. stuck. valve. Fuel tanks empty. Check fuel tanks and fill. Defective pump. Replace pump. Defective gauge.
Page 403 SECTION X INSTRUMENTS Aerofiche Paragraph Grid No. 10-1. General ..........................10-2. Non-Electrical Instruments....................10-3. Vacuum System Description and Operation..............10-4. Vacuum System Service Tips .................... 10-5. Hoses and Clamps ......................10-6. Vacuum Gauges......................... 10-7. Gyro Filters........................10-8. Vacuum Regulator......................2F10 10-9.
Page 404 Aerofiche Paragraph Grid No. 10-36. Airspeed Indicator ......................10-37. General ..........................10-38. Troubleshooting......................... 10-39. Removal and Replacement....................10-40. Magnetic Compass ......................10-41. General ..........................10-41a. Adjustment of Compass ....................10-42. Troubleshooting......................... 10-43. Manifold Pressure Gauge....................10-44. General ..........................10-45. Troubleshooting......................... 10-46.
Page 405 10-81. Cylinder Head Temperature Gauge................... 2G13 10-82. General ..........................2G13 10-83. Troubleshooting......................... 2G14 10-84. Removal and Replacement....................2G14 10-85. Piper Auto Control System....................2G14 10-86. Annunciator Panel......................2G14 10-87. General ..........................2G14 10-88. Troubleshooting......................... 2G14 10-89. Removal and Replacement....................2G14...
Page 406 INSTRUMENTS WARNING When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publications. 10-1. GENERAL. The instrumentation is designed to give a quick and actual indication of the attitude, performance and condition of the airplane.
Page 407 10-7. GYRO FILTERS. (Refer to Table 10-1 for Troubleshooting Instructions.) CAUTION Service gyro filters per Piper recommended scheduled basis, but no later than 100 hours, or sooner as conditions may require. Operations in dusty conditions, or if heavy concentrations of smoking occur in the aircraft, are conditions that warrant sooner inspection considerations.
Page 408 CHEROKEE ARROW III SERVICE MANUAL CAUTION The central filter combined with a differential vacuum gauge will give a decline in panel gauge indication when filter is clogged and vacuum declines below recommended adjustment settings. Filters should be replaced when gauge indication declines below the recommended adjustment setting;...
Page 409 CHEROKEE ARROW III SERVICE MANUAL Figure 10-1, Instrument Panel (Typical) Revised: 2/13/89 INSTRUMENTS 2F11...
Page 410 CHEROKEE ARROW III SERVICE MANUAL Figure 10-1a. Instrument Panel (PA-28R-201 S/N 2837001 and up) Revised: 2/13/89 INSTRUMENTS 2F12...
Page 411 CHEROKEE ARROW III SERVICE MANUAL Figure 10-1b. Instrument Panel (PA-28R-201T S/N 2803001 and up) Revised: 2/13/89 INSTRUMENTS 2F13...
Page 412 CHEROKEE ARROW III SERVICE MANUAL Figure 10-2. Pitot Static System Revised: 2/13/89 INSTRUMENTS 2F14...
Page 413 CAUTION The only pump mounting gasket authorized and approved for use on the AIRBORNE vacuum pump is AIRBORNE gasket B3-1-2, Piper Part Number 751 859. Any other gasket could result in oil seepage or leakage at the mounting flange.
Page 414 CHEROKEE ARROW III SERVICE MANUAL Figure 10-3. Vacuum-Auxiliary Vacuum Installation Revised: 2/13/89 INSTRUMENTS 2F16...
Page 415 CHEROKEE ARROW III SERVICE MANUAL 1. Press battery master switch ON. Check the VAC OFF annunciator illuminates. 2. Press VAC OFF/AUX ON annunciator switch. Ensure that AUX ON annunciator illuminates and VAC OFF annunciator goes out. Observe that the vacuum gauge indicates between 4.8 and 5.2 in.
Page 416 CHEROKEE ARROW III SERVICE MANUAL 3. Secure all excess lead wire. 4. Now remove the top engine cowling. 5. Mount auxiliary vacuum pump/motor assembly with band clamps. Do not tighten the clamps at this time because adjustments may be necessary.
Page 417 CHEROKEE ARROW III SERVICE MANUAL TABLE X-I. TROUBLESHOOTING CHART (VACUUM SYSTEM) Trouble Cause Remedy No vacuum gauge indication Open vacuum line. Locate and repair. at instrument. Faulty instrument. Replace. No vacuum gauge indication Faulty gauge or Replace gauge or at instrument of source.
Page 418 CHEROKEE ARROW III SERVICE MANUAL TABLE X-I. TROUBLESHOOTING CHART (VACUUM SYSTEM) (cont) Trouble Cause Remedy Vacuum correct but pilot Regulator sticky. Clean regulator. reports erratic indication of complete loss in flight. Oil in pump due to leaky Replace pump. engine flange seal or cleaning fluid blown into pump while cleaning engine.
Page 419 CHEROKEE ARROW III SERVICE MANUAL 10-16. SUCTION GAUGE. 10-17. GENERAL. The suction gauge is mounted in the right side of the instrument panel to the left and up from the cigar lighter. This gauge is calibrated in inches of mercury and has a direct pressure line and vent line.
Page 420 CHEROKEE ARROW III SERVICE MANUAL 10-20. DIRECTION GYRO. 10-21. GENERAL. The directional gyro is a flight instrument incorporating an air driven gyro stabilized in the vertical plane. The gyro is rotated at high speed by lowering the pressure in the air tight case and simultaneously allowing atmospheric air pressure to enter the instrument against the gyro buckets.
Page 421 CHEROKEE ARROW III SERVICE MANUAL TABLE X-III. GYRO HORIZON INDICATOR (cont) Trouble Cause Remedy Instrument tumbles in Low vacuum. Reset regulator. flight. Dirty filter. Clean or replace filter. Line to filter restricted. Replace line. Plug missing or loose Replace or tighten plug.
Page 422 CHEROKEE ARROW III SERVICE MANUAL 10-30. TROUBLESHOOTING. TABLE X-IV. RATE OF CLIMB INDICATOR Trouble Cause Remedy Pointer does not set on Aging of diaphragm. Reset pointer to zero by zero. means of setting screw. Tap instrument while resetting. Pointer fails to respond.
Page 423 CHEROKEE ARROW III SERVICE MANUAL TABLE X-IV. RATE OF CLIMB INDICATOR (cont) Trouble Cause Remedy Pointer cannot be reset Diaphragm distorted. Replace instrument. to zero. Instrument reads very low Case of instrument Replace instrument. during climb or descent. broken or leaking.
Page 424 CHEROKEE ARROW III SERVICE MANUAL TABLE X-V. ALTIMETER (cont) Trouble Cause Remedy Altimeter sticks at Water or restriction Remove static lines altitude or does not in static line. from all instruments, change with change of blow line clear from altitude.
Page 425 CHEROKEE ARROW III SERVICE MANUAL TABLE X-V. ALTIMETER (cont) Trouble Cause Remedy Barometric scale and Slippage mating Replacement instrument. reference markers out parts. of synchronism. Barometric scale and Drift in mechanism. Refer to latest revision reference markers out of AC43.13-1A.
Page 426 CHEROKEE ARROW III SERVICE MANUAL TABLE X-VI. AIRSPEED TUBES AND INDICATOR (cont) Trouble Cause Remedy Instrument reads high. Pointer not on zero. Replace instrument. Leaking static system. Find leak and correct. Instrument reads low. Pointer not on zero. Replace instrument.
Page 427 CHEROKEE ARROW III SERVICE MANUAL e. Head aircraft on magnetic West and do same as step d, adjusting E-W adjusting screw. Head aircraft in successive magnetic 30° headings and record compass readings on appropriate deviation card. Deviations must not exceed ± 10° on any heading.
Page 428 CHEROKEE ARROW III SERVICE MANUAL TABLE X-VII. MAGNETIC COMPASS (cont) Trouble Cause Remedy Compass swings Normal. erratically when radio transmitter is keyed. 10-43. MANIFOLD PRESSURE GAUGE. 10-44. GENERAL. The manifold pressure gauge is a vapor proof, absolute pressure type instrument. Pressure from the intake manifold of the engine is transmitted to the instrument through a line.
Page 429 CHEROKEE ARROW III SERVICE MANUAL 10-47. TACHOMETER INDICATOR. 10-48. GENERAL. The tachometer is connected to the engine accessory by a flexible cable and provides an indication of crankshaft speed in revolutions per minute. The instrument has a recording mechanism for recording the time that the engine is in actual operation.
Page 430 CHEROKEE ARROW III SERVICE MANUAL 10-51. ENGINE OIL PRESSURE GAUGE. 10-52. GENERAL. The oil pressure gauge is mounted in the cluster on the instrument panel. This gauge will indicate the amount available at the pressurized engine oil passage. 10-53. TROUBLE SHOOTING.
Page 431 CHEROKEE ARROW III SERVICE MANUAL 10-57. TROUBLESHOOTING. TABLE X-XI. FUEL PRESSURE GAUGE Trouble Cause Remedy No fuel pressure indication. Fuel valve stuck. Check valve. No fuel in tanks. Check fuel, full. Defective fuel pump. Check pump for pressure buildup. Check diaphragm and relief valve in engine pump.
Page 432 CHEROKEE ARROW III SERVICE MANUAL 10-59. ELECTRICAL INSTRUMENTS. 10-60. TURN AND BANK INDICATOR. 10-61. GENERAL. The turn and bank indicator is an electrical instrument. The turn portion of the indicator is driven by a permanent magnet DC governor controlled gyro motor. Damping action is provided by a precision air dashpot.
Page 433 CHEROKEE ARROW III SERVICE MANUAL 10-66. TROUBLESHOOTING. TABLE X-XIII. FUEL QUANTITY INDICATORS Trouble Cause Remedy Fuel gauge fails to indicate. Broken wiring. Check and repair Gauge not operating. Replace. Fuel gauge indicates empty Incomplete ground. Check ground connections at when tanks are full.
Page 434 CHEROKEE ARROW III SERVICE MANUAL 10-70. TROUBLESHOOTING. TABLE X-XIV. OIL TEMPERATURE INDICATORS Trouble Cause Remedy Instrument fails to show Broken or damaged bulb. Check engine unit and any reading. Wiring open. wiring to instrument. Excessive scale error. Improper calibration Repair or replace.
Page 435 CHEROKEE ARROW III SERVICE MANUAL 10-78. REMOVAL AND REPLACEMENT OF CLUSTER MOUNTED INSTRUMENTS. 10-79. GENERAL. A cluster, located on the instrument panel, contains five individual instruments. Removal of these instruments can be accomplished by the following procedure: a. Remove the face panel by pulling from retaining channels at top and bottom.
Page 436 Defective sender. Replace sender. 10-84. REMOVAL AND REPLACEMENT. (Refer to Paragraph 10-78 of this section.) 10-85. PIPER AUTOCONTROL SYSTEM. (See AutoControl Service Manual.) 10-86. ANNUNCIATOR PANEL. 10-87. GENERAL. The annunciator panel for both the PA-28R-201 and the PA-28R-201T consists of three amber lights and a push-button test switch located on the upper left center portion of the instrument panel.
Page 437: Electrical System
SECTION XI ELECTRICAL SYSTEM Aerofiche Paragraph Grid No. 11-1. Introduction ........................2G18 11-2. Description ........................2G18 11-3. Troubleshooting......................... 2G18 11-4. Alternator System......................2G18 11-5. Alternator System (Chrysler) .................... 2G20 11-6. Alternator System Test Procedure..................2G20 11-7. Bench Testing Alternator....................2G20 11-8.
Page 438 Aerofiche Paragraph Grid No. 11-39. Assembly of Alternator ..................... 2H15 11-40. Testing of Alternator......................2H17 11-41. Alternator Service Test Specifications ................2H17 11-42. Checking Alternator Belt Tension (PA-28R-201 only)............. 2H19 11-43. Voltage Regulator (Wico)....................2H19 11-44. Checking Voltage Regulator....................2H19 11-45.
Page 439 Aerofiche Paragraph Grid No. 11-79. Removal of Tail Navigation Light..................11-80. Installation of Tail Navigation Light................. 11-81. Anti-Collision (Strobe)...................... 11-82. Description ........................11-83. Removal of Wing Tip Strobe Light................... 11-84. Installation of Wing Tip Strobe Light................11-85. Removal of Strobe Power Supply ..................11-86.
Page 440 SECTION XI ELECTRICAL SYSTEM WARNING When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publication. 11-1. Introduction. This section contains instructions and schematics for correcting difficulties which may arise in the operation of the electrical system in PA-28R-201 and PA-28R-201T airplanes.
Page 441 CHEROKEE ARROW III SERVICE MANUAL The alternator has no armature or commutator and only a small pair of carbon brushes, which make contact with a pair of copper slip rings. The rotating member of the alternator, known as the rotor, is actually the field windings.
Page 442 Figure 11-2. Lamp-Bank Load 11-5. ALTERNATOR SYSTEM (Chrysler). WARNING When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publication. 11-6. ALTERNATOR SYSTEM TEST PROCEDURE. a. Start engine and set throttle for 1000 to 1200 rpm.
Page 443 CHEROKEE ARROW III SERVICE MANUAL Figure 11-3. Checking Field Circuit Figure 11-4. Testing Field Circuit 11-9. TESTING ALT E R N ATOR INTERNAL FIELD CIRCUIT FOR A GROUND. To test the alternator internal field circuit for a short circuit foreground, proceed as follows: a.
Page 444 CHEROKEE ARROW III SERVICE MANUAL Figure 11-5. Testing Rectifiers (Positive) 11-11. TESTING RECTIFIERS (POSITIVE). (Refer to Figure 11-5.) Special test box tool C-3829 has been developed to test the diode rectifiers without opening the “Y” connection as is necessary where the test lamp method is used.
Page 445 CHEROKEE ARROW III SERVICE MANUAL Figure 11-6. Testing Rectifiers (Negative) NOTE Any tools called out by a “C” or “SP” number in this section may be purchased from: Miller Special Tools A Division of Utica Tool Company, Inc. 32612 Park Lane Garden City, Michigan 48135 Phone: (313) 522-6717 11-12.
Page 446 CHEROKEE ARROW III SERVICE MANUAL Figure 11-7. C-3928 Fixture and Adapters Figure 11-8. Removing Rectifiers NOTE A common cause of an open or a shorted rectifier is a defective capacitor or a battery that has been installed in reverse polarity. If the battery is installed properly and the rectifiers are open, test the capacitor with a condenser tester.
Page 447 CHEROKEE ARROW III SERVICE MANUAL Figure 11-9. Installing Rectifiers 11-14. REMOVING RECTIFIERS. After cutting the lead from the malfunctioning rectifier, position the fixture with the rectifier to be removed over the fixture anvil. Position the removing adapter SP-3821 around the rectifier. Rotate the threaded screw clockwise. As the screw approaches the removing adapter, guide its shank into the hole in the end of the screw.
Page 448 CHEROKEE ARROW III SERVICE MANUAL Figure 11-10. Soldering Rectifier Lead NOTE Clean all wires before soldering. Form the rectifier lead around the connector, being very careful not to crack the seal. To protect the rectifier from overheating, grip the rectifier lead between the rectifier and the point being soldered with a pair of long nose pliers.
Page 449 CHEROKEE ARROW III SERVICE MANUAL Figure 11-11. Testing Stator Coils 11-16. TESTING STATOR COILS FOR GROUND. The stator coils are insulated form the core. A break in the installation, allowing the bare wire to touch the core, will ground the coil and result in no output.
Page 450 CHEROKEE ARROW III SERVICE MANUAL Figure 11-12. Removing End Bearing Figure 11-13. Installing End Bearing 11-18. REMOVING NEEDLE BEARING FROM END SHIELD. (Refer to Figure 11-12.) If inspection indicates that the needle bearing is faulty, it may be replaced. The bearing is a press fit in the end shield. To protect the end shield, it is necessary to support it with tool C-3925 while pressing the bearing out with tool C-3770-A.
Page 451 CHEROKEE ARROW III SERVICE MANUAL Figure 11-14. Removing Drive Pulley Figure 11-15. Removing Drive End Bearing 11-20. REMOVING DRIVE PULLEY. The drive pulley is an interference fit on the rotor shaft. The pulley is removed with puller C-4068. The use of this puller set to remove the pulley will prevent damage to the pulley.
Page 452 CHEROKEE ARROW III SERVICE MANUAL Figure 11-16. Removing Slip Ring Figure 11-17. Installing Slip Ring 11-23. REMOVING SLIP RINGS. (Refer to Figure 11-16.) a. Unsolder the rotor coil (field) leads from the solder lugs. b. Remove grease retainer with a pair of diagonal pliers.
Page 453 CHEROKEE ARROW III SERVICE MANUAL Figure 11-18. Solder Points Figure 11-19. Installing Retainer CAUTION Under no circumstance use acid core solder. A short circuit may result and corrosion will definitely occur. 11-25. INSTALLING GREASE RETAINER. (Refer to Figure 11-19.) If the solder connection where the rotor field coil lead is soldered to the insulated brush ring lug has a sharp point or if the blob solder is excessive, smooth with a scraper or file before installing the grease retainer insulator.
Page 454 CHEROKEE ARROW III SERVICE MANUAL Figure 11-20. Installing Drive End Shield and Figure 11-21. Installing Pulley Bearing (Typical) 11-27. INSTALLING PULLEY. (Refer to Figure 11-21.) Install pulley on the rotor shaft using an arbor press before the rectifier end shield is assembled to the drive end shield.
Page 455 CHEROKEE ARROW III SERVICE MANUAL NOTE New through bolt locking tabs should be installed at each alternator disassembly. Torque through bolts evenly to 25 inch pounds and bend both ears of the locking tabs against bolt head. Check proper belt tension.
Page 456 CHEROKEE ARROW III SERVICE MANUAL Figure 11-22. Meter Connections for Alternator Performance Test 11-31. CHECK ALTERNATOR BELT TENSION. If properly installed, tensioned and checked periodically, the alternator drive belt will give very satisfactory service. However, an improperly tensioned belt will wear rapidly and may slip and reduce alternator output.
Page 457 11-32. ALTERNATOR SYSTEM (PRESTOLITE). WARNING When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publication. a. Bearings: These units have a sealed ball bearing at the drive end and a two-piece roller bearing at the slip ring end.
Page 458 CHEROKEE ARROW III SERVICE MANUAL Figure 11-23. Exploded View of Alternator. 11-35. DESCRIPTION OF ALTERNATOR. (Refer to Figure 11-23.) The principal components of the alternator are the brush holder assembly (1), the slip ring end head (2), the rectifiers (3), the stator (4), the rotor (5) and the drive end head (6).
Page 459 CHEROKEE ARROW III SERVICE MANUAL Figure 11-24. Removal of Slip Ring End Figure 11-25. Removal of Rectifier Bearing 11-36. OVERHAUL OF ALT E R N ATOR. When repairing the alternator, complete disassembly may not be required. In some cases, it will only be necessary to perform those operations which are required to effect the repair.
Page 460 CHEROKEE ARROW III SERVICE MANUAL Figure 11-26. Removal of Drive End Head Figure 11-27. Removal of End Head Bearing g. On PA-28R-201 models, to remove the drive end head from the rotor shaft, use a puller that grips on the bearing retainer plate as shown in Figure 11-26. Do not attempt to remove by supporting the end head and pressing on the shaft as this may result in distortion of the end head or stripping of the retainer plate screws.
Page 461 CHEROKEE ARROW III SERVICE MANUAL Figure 11-28. Testing Rotor for Ground Figure 11-29. Testing Rotor for Shorts c. Stator: The stator can be tested for open or grounded windings with a 12-volt test bulb, described in the rectifier section, or an ohmmeter, in the following manner. Separate the stator from the slip ring end head just far enough to insert a fold of rags or blocks of wood.
Page 462 CHEROKEE ARROW III SERVICE MANUAL Figure 11-30. Installation of Drive End Head Figure 11-31. Installation of Rectifier CAUTION Use an arbor press, do not hammer. Reconnect the stator leads to the rectifiers. When soldering these connections, use pliers as a heat dam on the lead between the solder point and the rectifier.
Page 463 CHEROKEE ARROW III SERVICE MANUAL Figure 11-32. Terminal Assembly 11-40. TESTING OF ALTERNATOR. a. Wiring connections for bench testing the alternator are shown in Figure 11-34. Refer to the individual specification pages for output test figures. Adjust the carbon pile, if necessary, to obtain the specified voltage.
Page 464 CHEROKEE ARROW III SERVICE MANUAL Figure 11-33. Slip Ring End Bearing Figure 11-34. Testing Alternator Assembly TABLE XI-II. ALTERNATOR SPECIFICATIONS Aircraft Model PA-28R-201 PA-28R-201T Alternator Model ALY 6422 ALX 9425A Voltage 12-volts 12-volts Rated Output 60 amperes 65 amperes Ground Polarity...
Page 465 CHEROKEE ARROW III SERVICE MANUAL Figure 11-35. Brush Installation Figure 11-36. Internal Wiring Diagram 11-42. CHECK ALT E R N ATOR BELT TENSION. PA-28R-201. For aircraft with air conditioning installed, see Paragraph 14-22, Section XIV, Replacement of Compressor and/or Alternator Drive Belts.
Page 466 11-47. STARTING MOTORS. (Prestolite) WARNING When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publication. 11-48. DESCRIPTION. On PA-28R-201 airplanes, the gear reduction starting motor consists of six major components: the commutator end head assembly, the armature, the frame and field assembly, the gear housing, the pinion housing, and the Bendix drive assembly.
Page 467 CHEROKEE ARROW III SERVICE MANUAL Figure 11-37. Exploded View of Gear Reduction Staring Motor (PA-28R-201) When the engine reaches a predetermined speed, centrifugal action forces the detent pin out of the notch in the screw shaft and allows the pinion to demesh from the flywheel.
Page 468 CHEROKEE ARROW III SERVICE MANUAL Figure 11-38. Exploded View of Starting Motor (PA-28R-201T) c. On PA-28R-201 airplanes, no lubrication is required on the starter motor except at the time of overhaul. Then lubricate the entire shaft under Bendix drive, fill grooves in armature shaft at drive end and pack gear box with 1.3 to 2.0 ounces of lithium soap base grease No.
Page 469 CHEROKEE ARROW III SERVICE MANUAL Figure 11-39. Turning Starting Motor Figure 11-40. Testing Motor Armature for Commutator Short 11-53. DISASSEMBLY. a. Disassembly of starter motor used on PA-28R-201 airplanes is as follows: 1. Remove the frame screws from the commutator end head and pull end head and armature from frame.
Page 470 CHEROKEE ARROW III SERVICE MANUAL Figure 11-41. Testing Motor Field for Grounds Figure 11-42. No-Load Test Hook-Up 11-54. BRUSHES. Check the brushes to see that they slide freely in their holders and make full contact on the commutator. If worn to half their original length or less, they should be replaced.
Page 471 CHEROKEE ARROW III SERVICE MANUAL Figure 11-43. Stall - Torque Hook-Up 11-58. GEAR AND PINION HOUSING. (PA-28R-201) Inspect housings for cracks and bearings for excessive wear. Remove rust, paint or grease from mounting surfaces. 11-59. BENDIX DRIVE. (PA-28R-201) The Bendix drive should be wiped clean with a dry cloth. The pinion should turn smoothly in one direction and should lock in the other direction.
Page 472 CHEROKEE ARROW III SERVICE MANUAL c. On PA-28R-201, check the position of the pinion to be sure the unit will mesh properly with the flywheel ring rear. See specifications of unit for correct dimensions. Refer to paragraph 11-63. 11-61. BENCH TESTS.
Page 473 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-III. STARTING MOTOR SERVICE TEST SPECIFICATIONS Aircraft Model PA-28R-201 PA-28R-201T Motor Model MZ4206 MCL-6501 Min. Brush Tension 32 oz. 32 oz. Max. Brush Tension 40 oz. 40 oz. No-Load Test (77°F) (75°F) Volt Max. Amps Min.
Page 474 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-IV. HYDROMETER READING AND BATTERY CHARGE PERCENT Hydrometer Reading Percent of Charge 1280 1250 1220 1190 1160 Very little useful capacity 1130 or below discharged 11-69. BATTERY BOX CORROSION PREVENTION. The battery should be checked for spilled electrolyte or corrosion at least each 50 hour inspection or at least every 30 days, whichever comes first.
Page 475 CHEROKEE ARROW III SERVICE MANUAL 5. Turn master switch ON and check ammeter for battery charging current. b. When starting with a power cart and the airplane’s battery is nearly depleted, the procedure in step a. need not be followed. The capacity of a power cart is sufficient to start an aircraft with a low battery. If a 6-volt battery is available, it can be connected in series with the 12-volt external battery to supply 18-volts for starting.
Page 476 CHEROKEE ARROW III SERVICE MANUAL 11-79. REMOVAL OF TAIL NAVIGATION LIGHT. a. Remove the two screw securing the lens and lens retainer. b. Remove the bulb. NOTE To remove the complete tail light assembly, unsolder the electrical lead from the base of the light assembly and disconnect the remaining electrical lead at the connector.
Page 477 CHEROKEE ARROW III SERVICE MANUAL Figure 11-44. Strobe Light Connections (Earlier Models) Revised: 2/13/89 ELECTRICAL SYSTEM...
Page 478 CHEROKEE ARROW III SERVICE MANUAL Figure 11-44a. Strobe Light Connections (Later Models) Revised: 2/13/89 ELECTRICAL SYSTEM...
Page 479 CHEROKEE ARROW III SERVICE MANUAL 11-87. TROUBLESHOOTING PROCEDURE. The strobe light functions as a condenser discharge system. A condenser in the power supply is charged to approximately 450 volts dc discharged across the Xenon flash tube at intervals of approximately 50 flashes per minute. The condenser is parallel across the Xenon flash tube which is designated to hold off the 450 volts dc applied until the flash tube is triggered by an external pulse.
Page 480 CHEROKEE ARROW III SERVICE MANUAL 11-88. INSTRUMENT AND PANEL LIGHTS. The instrument and panel lights are broken up into three groups; Lower Panel Light, Upper Panel Lights, and Compass Light. The instrument lights are controlled by a 5 amp circuit breaker through a transistorized dimmer. A second dimmer control is connected to a variable resistor which controls the light intensity for all the avionic equipment.
Page 481 If during inspection, a fault is found with any aluminum cable or wiring, Piper considers it mandatory that it be replaced with copper wire with suitable terminals. 11-97. IGNITION SWITCH. (Refer to Figure 11-44b.) 11-98.
Page 482 CHEROKEE ARROW III SERVICE MANUAL Figure 11-44b. Ignition Switch Revised: 2/13/89 ELECTRICAL SYSTEM 2I12...
Page 483 CHEROKEE ARROW III SERVICE MANUAL Figure 11-45. Terminal Block Revised: 2/13/89 ELECTRICAL SYSTEM 2I13...
Page 484 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING Trouble Cause Remedy ALTERNATOR Zero output indicated Open field circuit. With master switch turned on ammeter regardless on, check for battery voltage of rpm (refer to alternator from airplane’s main buss system test procedure).
Page 485 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy ALTERNATOR (cont) Zero output indicated on Interruption of voltage ammeter regardless of through any of these rpm (refer to alternator points isolates the faulty system test procedure).
Page 486 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy ALTERNATOR (cont) Outlet indicated on Faulty voltage regulator. Start engine, turn on load ammeter does not (Ref. alternator test meet minimum values procedure), set throttle specified in alternator at 2300 rpm.
Page 487 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy ALTERNATOR (cont) Output indicated on Open rectifier. If any of the six rectifiers ammeter does not pressed into the rear bell meet minimum values housing of the alternator...
Page 488 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy ALTERNATOR (cont) Field circuit breaker Short circuit in field Disconnect field wiring at trips. (cont) winding of alternator. terminal of alternator. Turn on master switch. Reset...
Page 489 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy ALTERNATOR (cont) Output circuit defective. Short circuit in output Disconnect wiring at circuit. battery post of alternator. Turn on master switch. Disconnect each leg of output circuit, working from the alternator towards the bus bar.
Page 490 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy ALTERNATOR (cont) Excessive ammeter Excessive resistance in Check all connections and fluctuation. field circuit. wire terminals in field circuit for deterioration such as loose binding posts, broken wire strands at terminals, etc.
Page 491 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy STARTER Motor fails to operate. Low battery charge. Check and recharge if necessary. Defective or improper Refer to electrical wiring wiring or loose diagram and check all connections.
Page 492 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy STARTER (cont) Motor fails to operate. Binding, worn, or CAUTION (cont) improperly seated brush, or brushes with Do not use coarse sandpaper excessive side play. or emery cloth. After seating,...
Page 493 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy STARTER (cont) Excessive arcing of Binding, worn, or See information above motor brushes. improperly seated dealing with this trouble. brush or brushes with excessive side play.
Page 494 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy BATTERY (cont) Battery life is short. Overcharge due to level Maintain electrolyte. of electrolyte being below top of plates. Sulfation due to disuse. Replace. Impurities in electrolyte.
Page 495 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy BATTERY (cont) Battery freezes. Discharged battery. Replace. Water added and battery Always recharge battery for not charged immediately. 1/2 hour following addition of water in freezing weather.
Page 496 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy ANNUNCIATOR PANEL (cont) OIL warning light fails Bulb burned out. Replace. to operate. No current to sensor. Check all wire segments and connections. Sensor activates at a Replace.
Page 497 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-V. ELECTRICAL SYSTEM TROUBLESHOOTING (cont) Trouble Cause Remedy ANNUNCIATOR PANEL (cont) VAC warning light fails Sensor activates at a Replace. to operate. (cont) too low setting. Defective sensor. Replace. VAC warning light fails Sensor activates at a Replace.
Page 498 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-VI. ELECTRICAL SYMBOLS Revised: 2/13/89 ELECTRICAL SYSTEM...
Page 499 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-VII. ELECTRICAL WIRE CODING CIRCUIT FUNCTION LETTER CIRCUITS AUTOPILOT CONTROL SURFACE ENGINE INSTRUMENT FLIGHT INSTRUMENT LANDING GEAR HEATER - VENTILATING & DEICING LIGHTING POWER FUEL & OIL RADIO POWER RADIO AUDIO & INTERPHONE IGNITION...
Page 500 CHEROKEE ARROW III SERVICE MANUAL TABLE XI-VIII. INDEX - ELECTRICAL SYSTEM SCHEMATICS Aerofiche Figure Grid No. 11-46. Anti-Collision Lights, PA-28R-201................... 11-47. Fuel Pump, PA-28R-201....................11-48. Landing Light........................11-49. Navigation Lights......................11-50. Overhead Flood Lights...................... 11-51. Pitch Trim.......................... 11-52. Pitot Heat...........................
Page 501 CHEROKEE ARROW III SERVICE MANUAL Figure 11-46. Anti-Collision Lights Figure 11-47. Fuel Pump PA-28R-201 PA-28R-201 and 201T Figure 11-48. Landing Light, Figure 11-49. Navigation Lights PA-28R-201 and 201T PA-28R-201 and 201T Revised: 2/13/89 ELECTRICAL SYSTEM...
Page 502 CHEROKEE ARROW III SERVICE MANUAL Figure 11-50. Overhead Flood Lights Figure 11-51. Pitch Trim, PA-28R-201 and 201T PA-28R-201 and 201T Figure 11 -52. Pitot Heat, PA-28R-201 and 201T Figure 11-53. Radio Lights, PA-28R-201 and 201T Revised: 2/13/89 ELECTRICAL SYSTEM...
Page 503 CHEROKEE ARROW III SERVICE MANUAL Figure 11-54. Rotating Beacon, Figure 11-55. Stall Warning, PA-28R-201 and 201T PA-28R-201 and 201T Figure 11-56. Turn and Bank, Figure 11-57. A/C Blower, PA-28R-201 and 201T PA-28R-201 and 201T Revised: 2/13/89 ELECTRICAL SYSTEM...
Page 504 CHEROKEE ARROW III SERVICE MANUAL Figure 11-58. Avionics, PA-28R-201 and 201T Figure 11-59. Engine Gauges, PA-28R-201 Revised: 2/13/89 ELECTRICAL SYSTEM 2J10...
Page 505 CHEROKEE ARROW III SERVICE MANUAL Figure 11-60. Engine Gauges, PA-28R-201T Figure 11-61. Instrument Lights, PA-28R-201 Revised: 2/13/89 ELECTRICAL SYSTEM 2J11...
Page 506 CHEROKEE ARROW III SERVICE MANUAL Figure 11-62. Instrument Lights, PA-28R-201T Revised: 2/13/89 ELECTRICAL SYSTEM 2J12...
Page 507 CHEROKEE ARROW III SERVICE MANUAL Figure 11-63. Alternator and Starter, PA-28R-201 Revised: 2/13/89 ELECTRICAL SYSTEM 2J13...
Page 508 CHEROKEE ARROW III SERVICE MANUAL Figure 11-64. Alternator and Starter, PA-28R-201T (Early Models) Revised: 2/13/89 ELECTRICAL SYSTEM 2J14...
Page 509 CHEROKEE ARROW III SERVICE MANUAL Figure 11-64a. Alternator and Starter Schematic (PA-28R-201 S/N’s 2837001 & up, PA-28R-201T S/N’s 2803001 & up) Revised: 2/13/89 ELECTRICAL SYSTEM 2J15...
Page 510 CHEROKEE ARROW III SERVICE MANUAL Figure 11-65. Fuel Pump, PA-28R-201T Revised: 2/13/89 ELECTRICAL SYSTEM 2J16...
Page 511 CHEROKEE ARROW III SERVICE MANUAL Figure 11-66. Landing Gear, PA-28R-201/201T Revised: 2/13/89 ELECTRICAL SYSTEM 2J17...
Page 512 CHEROKEE ARROW III SERVICE MANUAL Figure 11-66a. Landing Gear, Without Backup Extender Functional or Installed PA-28R-201 and 201T Revised: 2/13/89 ELECTRICAL SYSTEM 2J18...
Page 513 ELECTRONICS Aerofiche Paragraph Grid No. 12-1. Introduction to Autoflight....................2J20 12-2. Non-Piper A.F.C.S. Equipment Contacts................2J20 12-3. Piper A.F.C.S. Equipment Contacts .................. 2J20 12-4. Introduction to Emergency Locator Transmitter............... 2J21 12-5. Emergency Locator Transmitter..................2J21 12-6. Description ........................2J21 12-7.
Page 514 2144 Michelson Drive Irvine, California 92715 (714) 851-0119 12-3. PIPER A.F.C.S. EQUIPMENT. In the case of early models, Piper autopilot equipment bears the Piper name and the appropriate Piper Autopilot/Flight Director Service Manual shall be used. NOTE If a Roll Axis-only Autopilot is installed, or if no Autopilot is installed, consult the Piper Pitch Trim Service Manual - 753 771 for manual electric pitch trim service information.
Page 515 CHEROKEE ARROW III SERVICE MANUAL The following is a complete listing of Piper A.F.C.S. equipment service literature. It is imperative to correctly identify the Autopilot system by “faceplate” model name in order to consult the appropriate service manual. Each manual identifies the revision level and revision status as called out on the Master Parts Price List- Aerofiche published monthly by Piper.
Page 516 CHEROKEE ARROW III SERVICE MANUAL SECTION XII ELECTRONICS 12-4. INTRODUCTION. This section of the manual contains information necessary to perform operational checks of the Emergency Locator Transmitter (ELT), with and without a pilot’s remote switch. Included are the appropriate removal and installation instructions to facilitate battery replacement.
Page 517 CHEROKEE ARROW III SERVICE MANUAL 12-8. REMOVAL AND INSTALLATION (NARCO). The ELT is located on the right side of the airplane tail section ahead of the stabilator. 1. Remove the access panel at fuselage station 228.30. 2. Set the ON/OFF/ARM switch on the transmitter to OFF.
Page 518 CHEROKEE ARROW III SERVICE MANUAL 12-9. PILOT’S REMOTE SWITCH. A pilot’s remote switch, located on the left side panel, is provided to allow the transmitter to be controlled from inside the cabin. The pilot’s remote switch is placarded ON, AUTO/ARM and OFF/RESET. The switch is normally left in the AUTO/ARM position. The aircraft master switch must be ON to turn the transmitter OFF.
Page 519 CHEROKEE ARROW III SERVICE MANUAL d. A transmitter which is functioning properly should emit a characteristic downward swept tone. e. When the test is completed, ascertain the transmitter ON/ARM/OFF switch is in the ARM position. f. Place the access panel on the right side of the fuselage aft of sta. 228.30.
Page 520 CHEROKEE ARROW III SERVICE MANUAL 12-12. INADVERTENT ACTIVATION. The remote switch allows the pilot to turn off the transmitter inadvertently activated by impact or improper switch position. The pilot simply selects the momentary OFF, RESET position. The transmitter shuts off and the spring loaded switch automatically returns to the ARM position.
Page 521 CHEROKEE ARROW III SERVICE MANUAL NOTE: AIRCRAFT POWER USED TO SHUT OFF THE ELT WITH REMOTE SWITCH. Figure 12-1. ELT Schematic (Typical) Revised: 2/13/89 ELECTRONICS...
Page 522 CHEROKEE ARROW III SERVICE MANUAL Figure 12-2. ELT Portable Folding Antenna (Narco) Figure 12-3. ELT Using Fixed Aircraft Antenna (Narco) ELECTRONICS...
Page 523 SECTION XIII HEATING AND VENTILATING Aerofiche Paragraph Grid No. 13-1. Introduction ........................13-2. Description ........................13-3. Heater Maintenance......................13-4. Overhead Vent System ...................... Revised: 2/13/89 HEATING AND VENTILATING...
Page 524 (on PA-28R-201) be inspected regularly. (Refer to the latest revision Piper Service Bulletin 691 for Muffler Assembly Inspection Procedure.) The heater exchanger must be removed in order to inspect the tailpipe on PA-28R-201T, the heat muff must be removed before the manifold assembly can be inspected on PA-28R-201.
Page 525 CHEROKEE ARROW III SERVICE MANUAL Figure 13-1. Cabin Heater and Defroster (PA-28R-201) Revised: 2/13/89 HEATING AND VENTILATING...
Page 526 CHEROKEE ARROW III SERVICE MANUAL Figure 13-2. Cabin Heater and Defroster (PA-28R-201T) Revised: 2/13/89 HEATING AND VENTILATING...
Page 527 CHEROKEE ARROW III SERVICE MANUAL Figure 13-3. Overhead Vent System and Fresh Air System “NOT AVAILABLE WITH AIR CONDITIONING” Revised: 2/13/89 HEATING AND VENTILATING...
Page 528 INTENTIONALLY LEFT BLANK 2K10 THRU 2L24 2K10...
Page 529 ARROW III - TURBO ARROW III ARROW SERVICE MANUAL CARD 3 OF 3 PA 28R-201/201T Courtesy of Bomar Flying Service www.bomar.biz PIPER AIRCRAFT CORPORATION (PART NUMBER 761 639)
Page 530 CHEROKEE ARROW III SERVICE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS Service manual information incorporated in this set of Aerofiche cards is arranged in accordance with the general specifications of Aerofiche adopted by the General Aviation Manufacturer’s Association. Information complied in this Aerofiche service manual is kept current by revision distributed periodically. There revisions supersede all previous revisions and are complete Aerofiche card replacements and supersede Aerofiche cards of the same number in the set.
Page 531 TABLE OF CONTENTS AEROFICHE CARD NO. 1 GRID NO. INTRODUCTION lA13 HANDLING AND SERVICING lA16 INSPECTION STRUCTURES lD17 SURFACE CONTROLS HYDRAULIC SYSTEM LANDING GEAR AND BRAKE SYSTEM lI22 AEROFICHE CARD NO. 2 VIII POWER PLANT (CONTINENTAL) VIIIA POWER PLANT (LYCOMING) 2C18 FUEL SYSTEM INSTRUMENTS...
Page 532 LIST OF ILLUSTRATIONS (cont.) Aerofiche Figure Grid No. 14-1. Air Conditioning System Installation................14-2. Service Valves ........................3A12 14-3. Test Gauge and Manifold Set ................... 3A13 14-4. Manifold Set Operation..................... 3A14 14-5. Leak Test Hook-Up ......................3A15 14-6. Evacuation Hook-Up......................3A17 14-7.
Page 533 SECTION XIV ACCESSORIES AND UTILITIES Aerofiche Paragraph Grid No. 14-1. Air Conditioning Installation..................... 14-2. Description ........................14-3. Air Conditioning System Operation.................. 14-4. Malfunction Procedures..................... 14-5. Special Servicing Procedures.................... 14-6. Service Valves ........................14-7. Service Valves Replacement....................3A10 14-8. Test Gauge and Manifold Set .................... 3A10 14-9.
Page 534 Aerofiche Paragraph Grid No. 14-41. Evaporator Assembly lnstallation..................14-42. Pressure Relief Switch (Ranco)..................14-43. Electrical Installation......................14-44. Air Conditioning Throttle Switch..................14-45. Fuse Replacement......................14-46. Shoulder Harness Inertia Reel Adjustment ............... 3B10 14-47. Overhead Vent Blower ...................... 3B10 14-48. Description ........................3B10 14-49.
Page 535 CHEROKEE ARROW III SERVICE MANUAL SECTION XIV ACCESSORIES AND UTILITIES PA-28R-201 & PA-28R-201T 14-1. AIR CONDITIONING INSTALLATION. 14-2. DESCRIPTION. These installations consist of a compressor with its special bracketry, an evaporator, a condenser, a receiver-dehydrator, circulating fan, thermal expansion valve, and related plumbing.
Page 536 CHEROKEE ARROW III SERVICE MANUAL Figure 14-1. Air Conditioning System Installation Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 537 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-I. TEMPERATURE PRESSURE CHART Evaporator Pressure Evaporator High Pressure Ambient Gauge Reading Temperature Gauge Reading Temperature °F. °F. 10.1 11.2 12.3 13.4 14.6 15.8 17.1 18.3 19.7 22.4 23.1 23.8 24.6 25.3 26.1 26.8 27.6...
Page 538 CHEROKEE ARROW III SERVICE MANUAL NOTE The air conditioning system should be operated at least once a month to prevent sticking valves and keep the system lubricated. 14-4. MALFUNCTION DETECTION. The detection of system malfunction largely depends on the mechanic’s ability to interpret the gauge pressure readings into system problems. A system operating normally...
Page 539 CHEROKEE ARROW III SERVICE MANUAL 14-5. SPECIAL SERVICING PROCEDURES. The air conditioning system should be serviced by a qualified shop with trained personnel. The following procedure and precautions should be observed. The efficiency of this system depends upon the pressure-temperature relationship of pure refrigerant. As long as the system contains only pure refrigerant plus a specified amount of compressor oil (which is mixed with the refrigerant) it is considered to be chemically stable.
Page 540 CHEROKEE ARROW III SERVICE MANUAL Figure 14-2. Service Valves NOTE A very strong acid (HCL) is formed when R-12 comes in contact with moisture. A new receiver-dehydrator should be opened and connected to the system only when ready to charge the system with refrigerant.
Page 541 CHEROKEE ARROW III SERVICE MANUAL Figure 14-3. Test Gauge and Manifold Set 14-7. SERVICE VALVE REPLACEMENT. The valves on the York compressor are sealed with a gasket placed in the valve port boss. Lubricate the gasket with refrigerant oil of the type used in the compressor, place the valves with the tube fitting aft and secure with .312 bolts, torque to 15-23 inch pounds.
Page 542 CHEROKEE ARROW III SERVICE MANUAL Figure 14-4. Manifold Set Operation Revised: 2/13/89 ACCESSORIES AND UTILITIES 3A14...
Page 543 CHEROKEE ARROW III SERVICE MANUAL Figure 14-5. Leak Test Hookup 14-9. CHECKING THE SYSTEM FOR LEAKS. There are several methods of doing this operation, depending on the type of equipment which is available. Two methods of performing this check will be covered in the following paragraphs.
Page 544 CHEROKEE ARROW III SERVICE MANUAL 14-11. LEAK CHECK - METHOD II. a. Remove the access panel at the rear of the cabin to gain access to the service valves. b. Remove the protective cap on the high pressure Schrader valve fitting and connect a charging hose with a shutoff valve arrangement to the fitting.
Page 545 CHEROKEE ARROW III SERVICE MANUAL Figure 14-6. Evacuation Hookup System Vacuum Temperature °F 27.99 COMPOUND GAUGE 28.89 READING IN INCHES 29.40 OF MERCURY VACUUM 29.71 29.82 29.88 NOTE For each 1,000 feet of elevation above sea level, the compound gauge reading will be about one inch lower, numerically.
Page 546 CHEROKEE ARROW III SERVICE MANUAL b. Connect the manifold gauge set to the airplane service valves. (Refer to Figure 14-6.) c. The high and low manifold hand valves should be in the closed position. (Refer to Figure 14-3 and 14-4.) d.
Page 547 CHEROKEE ARROW III SERVICE MANUAL Figure 14-7. Charging Stand NOTE If bubbling occurs in sight glass, reopen the cylinder base valve momentarily to equalize drum and cylinder pressure. e. Connect the heating element plug to a 110-volt outlet. f. Turn cylinder sight glass to match pressure reading on cylinder pressure gauge. This scale should be used during entire charging operation.
Page 548 CHEROKEE ARROW III SERVICE MANUAL Figure 14-8. Charging Hookup a. With the system evacuated as outlined in paragraph 14-13, connect the refrigerant charging hose to the manifold (refer to Figure 14-8) and purge the charging hose of air. b. Place the refrigerant container on a scale to observe the amount of refrigerant entering the system.
Page 549 CHEROKEE ARROW III SERVICE MANUAL NOTE A shop cloth should be used to divert escaping refrigerant when disconnecting the charging hose from the Schrader valve. Recap the valve. 14-17. ADDITION OF PARTIAL CHARGE TO SYSTEM. It is possible to top off this system with refrigerant by the following method.
Page 550 CHEROKEE ARROW III SERVICE MANUAL 14-19. COMPRESSOR REMOVAL. (The removal of the compressor requires a complete system discharge.) See paragraph 14-12. a. The removal instructions for the York compressor are as follows: 1. Be certain the circuit protector is off for the air conditioning system.
Page 551 6. The compressor should never be operated with less than 6 ounces of oil. When oil is added, the level should not go above 10 ounces. Piper refrigerant oil PMS-L2000 or equivalent 500 viscosity refrigerant oil must be used.
Page 552 7. Remove the dipstick and count the number of increments of oil. The acceptable oil level in increments is 7 to 10. This represents between 2.6 and 4.4 fluid ounces. 8. When oil is added, Piper refrigerant oil PMS-L2000 or equivalent 500 viscosity refrigerant oil must be used.
Page 553 CHEROKEE ARROW III SERVICE MANUAL Figure 14-8a. Top Dead Center Casting Mark (Sankyo Compressor) Figure 14-8b. Rotation of Clutch Front Plate (Sankyo Compressor Oil Check) Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 554 CHEROKEE ARROW III SERVICE MANUAL Figure 14-9. York Compressor and Fabricated Oil Dipstick (PA-28R-201) e. Check the belt and pulley alignment of the compressor and/or alternator by the following method: 1. A daturm line must be established for checking belt and pulley alignment. A nominal dimension must be established between the forward edge of the compressor belt and the forward machined surface of the ring gear.
Page 555 CHEROKEE ARROW III SERVICE MANUAL Figure 14-9a. Compressor and Alternator Belt Installation (Lycoming) Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 556 CHEROKEE ARROW III SERVICE MANUAL Figure 14-9a. Compressor and Alternator Belt lnstallation (Lycoming) (cont.) Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 557 CHEROKEE ARROW III SERVICE MANUAL g. Alternator Belt Alignment: (Refer to Figure 14-9a.) 1. With the alternator belt installed, align the idler pulley in the belt plane by adding or removing shims, P/N 62833-82 as required. Refer to paragraph 14-23 for belt tension adjustment.
Page 558 CHEROKEE ARROW III SERVICE MANUAL Figure 14-10. Magnetic Clutch (York Compressor) 14-24. MAGNETIC CLUTCH. (York Compressor) 14-25. MAGNETIC CLUTCH REMOVAL. (Refer to Figure 14-10.) a. Remove the self-locking capscrew and washer (1) from the compressor shaft. b. Insert a 5/8 -11 UNC-2B bolt in the threaded portion of the hub and tighten. The pressure exerted by the bolt on the end of the compressor crankshaft will force off the rotor pulley assembly (2) without damage to the clutch or compressor.
Page 559 CHEROKEE ARROW III SERVICE MANUAL d. Slide the pulley assembly (2) over the field assembly and onto the crankshaft, now torque the field assembly 85 to 120 inch pounds. Then secure pulley assembly with washer and new self-locking capscrew (1). Torque the capscrew to 180 to 240 inch-pounds.
Page 560 CHEROKEE ARROW III SERVICE MANUAL 14-31. CONDENSER. The condenser is mounted in a frame assembly located in the bottom of the fuselage between stations 156.00 and 191.00. 14-32. CONDENSER ASSEMBLY REMOVAL. a. Discharge the system. (See paragraphs 14-5 and 14-12.) b.
Page 561 CHEROKEE ARROW III SERVICE MANUAL Figure 14-11. Condenser Air Scoop Installation Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 562 CHEROKEE ARROW III SERVICE MANUAL Figure 14-12. Expansion Valve b. Adjust the push rods (9) so that a vertically measured gap of .16 of an inch exists along the trailing edge of the door at the instant the forward edge of the door becomes flush with the fuselage skin.
Page 563 CHEROKEE ARROW III SERVICE MANUAL 14-39. EVA P O R ATOR ASSEMBLY. The evaporator assembly consists of the evaporator core, receiver d e h y d r a t o r, expansion valve, circulating fan and pressure switch together with necessary housing and plumbing.
Page 564 CHEROKEE ARROW III SERVICE MANUAL Figure 14-13. Components Installation 14-42. PRESSURE RELIEF SWITCH (Ranco). The pressure relief switch automatically prevents the system from over pressurization by breaking the electrical circuit to the magnetic clutch, stopping the compressor until pressure is reduced. The switch is located in the line between the receiver and expansion valve, and set to cut out at 350 ±...
Page 565 CHEROKEE ARROW III SERVICE MANUAL Figure 14-14. Adjustment of Air Conditioning Throttle Switch (PA-28R-201) 14-46. SHOULDER-HARNESS INERTIAL REEL ADJUSTMENT. a. Allow the harness to wind up on the reel as much as possible. b. On the end of the reel, pry off the plastic cap over the spring, making sure the spring does not come out of the plastic cap, and set cap aside.
Page 566 CHEROKEE ARROW III SERVICE MANUAL Figure 14-15. Air Conditioning Wiring Schematic Revised: 2/13/89 ACCESSORIES AND UTILITIES 3B14...
Page 567 CHEROKEE ARROW III SERVICE MANUAL 14-49. REMOVAL OF BLOWER ASSEMBLY. a. Remove the access door from the aft wall of the baggage area. b. With the master switch off, disconnect the plug assemblies at the blower assembly. c. Remove the inlet and outlet hoses from the blower assembly by removing the clamps.
Page 568 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-IV. TROUBLESHOOTING CHART (AIR CONDITIONER) Gauge Indication Probable Causes Remedy High discharge pressure. Overcharge of refrigerant. Purge excess refrigerant. Air in system. Check for leaks. Bleed charge from system. Evacuate and recharge system 14-13 and 14-14.
Page 569 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-IV. TROUBLESHOOTING CHART (AIR CONDITIONER) (cont) Gauge Indication Probable Causes Remedy Low suction pressure. Low air supply through Repair blower or blower (Accompanied by icing evaporator. motor. Clean stoppage evaporator.) in air ducts. Very dirty evaporator Clean and flush with fins and coils.
Page 570 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-IV. TROUBLESHOOTING CHART (AIR CONDITIONER) (cont) Gauge Indication Probable Causes Remedy High suction pressure. Magnetic clutch Check electrical circuit (cont) slipping. for correct voltage to clutch coil. Clean clutch surfaces of oil. Leaking or broken Replace compressor.
Page 571 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-IV. TROUBLESHOOTING CHART (AIR CONDITIONER) (cont) Trouble Cause Remedy System produces no Electrical (cont) cooling. (cont) Thermostat sensing Check thermostat and element defective. cabin comfort control panel. Blower motor disconnected Check current flow to or burned out.
Page 572 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-IV. TROUBLESHOOTING CHART (AIR CONDITIONER) (cont) Trouble Cause Remedy System produces no Compressor shaft seal Replace compressor, cooling. (cont) leaking. 14-18. Clogged screen or Repair as necessary. screens in receiver dehydrator or expansion valve; plugged hose or coil.
Page 573 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-IV. TROUBLESHOOTING CHART (AIR CONDITIONER) (CONT) Trouble Cause Remedy Excessively noisy Electrical system. (cont) Compressor noisy. Check mounting and repair; remove compressor for service or replacement, 14-18. Compressor oil level Fill with correct amount low.
Page 574 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-IV. TROUBLESHOOTING CHART (AIR CONDITIONER) (cont) Trouble Cause Remedy System will not produce Mechanical sufficient cooling. (cont) Clogged screen in Purge system and replace expansion valve. expansion valve, 14-35. Expansion valve Purge system; replace thermal bulb has expansion valve, 14-35.
Page 575 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-V. BLOWER SYSTEM WIRE COLOR CODES AIRCRAFT MOTOR WIRES WIRES 15920 01 E362Q F0018a75FA General Singer Leece- Aircraft Nos. Industries Controls Neville Harness Nos. See Note 2 Ground Brown Brown Black AC26A Low Speed...
Page 576 14-54. DESCRIPTION AND OPERATION. A fixed and/or portable oxygen system is available on this aircraft. Scott Aviation manufacturers the major components for these systems and should be contacted along with the Piper Customer Service for any further information not covered herein. For specific parts information refer to the Piper Parts Catalog.
Page 577 CHEROKEE ARROW III SERVICE MANUAL 14-55. TROUBLESHOOTING. (Refer to Table XIV-VI) 14-56. FIXED OXYGEN SYSTEM. 14-57. INSPECTION AND MAINTENANCE. Due to the nature of the process used to test compressed gas tanks, servicing and hydrostatic tests must be conducted by a DOT or manufacturer (Scott Aviation) approved shop.
Page 578 CHEROKEE ARROW III SERVICE MANUAL Figure 14-16. Fixed - Oxygen System Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 579 CHEROKEE ARROW III SERVICE MANUAL Figure 14-17. Test Apparatus For Testing Oxygen System Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 580 CHEROKEE ARROW III SERVICE MANUAL Figure 14-18. Oxygen Tubing Installation Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 581 CHEROKEE ARROW III SERVICE MANUAL CAUTION When the six inch requirement cannot be complied with, one inch is allowed as long as the electric cables and other lines are supported at least every two inches; and, the oxygen tube(s) is protected by rubber neoprene hose fastened in place with cable ties at the location the specific item crosses or is near the oxygen tube(s).
Page 582 CHEROKEE ARROW III SERVICE MANUAL 2. Method II. a. For tubing, flush with naphtha per specifications TT-N-95. b. Blow clean and dry off all solvent with clean, dry, filtered air. c. Flush with isopropyl alcohol. d. Rinse thoroughly with fresh water.
Page 583 CHEROKEE ARROW III SERVICE MANUAL Figure 14-19. Installation of Swageloc Fittings Revised: 2/13/89 ACCESSORIES AND UTILITIES...
Page 584 CHEROKEE ARROW III SERVICE MANUAL (1) Slide tube in fitting until it bottoms, turn nut to finger tight position and tighten one quarter turn with wrench. (2) Snug slightly with wrench. 14-60. APPLICATION OF TEFLON TAPE THREAD SEALANT. All male pipe (tapered) threads of the oxygen system should be sealed with 3M No.
Page 585 CHEROKEE ARROW III SERVICE MANUAL 14-61. LEAK TESTS. Solutions recommended for leak testing are Leak-Tec Formula #16-OX and that available from Scott Aviation. Refer to the List of Consumable Materials for consumer information. 1. Remove royalite covers in baggage compartment and with the oxygen system turned off, disconnect low pressure supply line and connect it to a regulated cylinder charged with dry nitrogen.
Page 586 CHEROKEE ARROW III SERVICE MANUAL 2. When working in the tail cone of the aircraft, attach a tail stand to the tail. 3. With immediate area clear of flammables (grease, hydraulic fluid, fuel) and with the oxygen system OFF, connect the mask or tube to an outlet to exhaust any pressure in the system.
Page 587 CHEROKEE ARROW III SERVICE MANUAL 14-66. INSTALLATION OF OXYGEN CYLINDER. 1. Before mounting cylinder to shelf, connect control cable to control valve-regulator. If the shelf has been removed, reinstall it before continuing. Install Teflon tape per Section 14-60 application instructions.
Page 588 CHEROKEE ARROW III SERVICE MANUAL 14-69. INSTALLATION OF OUTLETS. 1. Apply Teflon tape to male threads of the affected fitting. Refer to Section 14-60 instructions. 2. Connect outlet to low pressure line. 3. Position trim panel and secure with screws.
Page 589 CHEROKEE ARROW III SERVICE MANUAL CHART VIII-IV. FILLING PRESSURE FOR CERTAIN AMBIENT TEMPERATURES Ambient Temperature Filling Pressure Ambient Temperature Filling Pressure 1650 (PSI) 1975 (PSI) 1700 2000 1725 2050 1775 2100 1825 2150 1875 2200 1925 2250 NOTE: Filling pressure are for 1850 PSI at 70°F. Table assumes 25°F rise due to heat of comprssion with max fill rate.
Page 590 CHEROKEE ARROW III SERVICE MANUAL d. When the pressure gauge on the recharge unit or in the aircraft reaches 1800 to 1850 psi, close the pressure regulator valve on the recharge unit Disconnect the filler hose from the filler valve;...
Page 591 CHEROKEE ARROW III SERVICE MANUAL 14-75. REMOVAL OF OXYGEN UNIT. WARNING Do not use grease or any grease type fittings on any hardware that connects to the oxygen bottle or system hardware. When working with the system make sure hands, clothing, and tools are free of oil, grease, and dirt when working with the oxygen system.
Page 592 CHEROKEE ARROW III SERVICE MANUAL 14-78. MAINTENANCE. a. Check the cylinder to be sure it is securely mounted. b. Check the cylinder for the ICC identification number and for the date of the last FAA inspection and test. c. If cylinder is completely empty, it must be completely disassembled and inspected in an FAA or manufacturer approved facility before recharging.
Page 593 CHEROKEE ARROW III SERVICE MANUAL TABLE XIV-IV. TROUBLESHOOTING CHART (AIR CONDITIONER) (CONT) Trouble Cause Remedy No indication of pressure on Cylinder empty or leak in Charge system and check pressure gauge. system has exhausted for leaks. pressure. Pressure gauge or regulator Return unit to manufacturer defective.
Page 594 INTENTIONALLY LEFT BLANK 3C18 THRU 3L24...

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