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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL AEROFICHE REVISION STATUS Revisions to this Maintenance Manual (P/N 761-882) originally published March 1, 1998 are as follows: Effectivity Publication Date Aerofiche Card Effectivity ORG980301 March 1, 1998 PR011215 December 15, 2001...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE Intro-List of Nov 30/06 Effective Pages Nov 30/06 Intro-Table of Contents Nov 30/06 Nov 30/06 Introduction Nov 30/06 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity 1A10 Serial Number Explanation 1A10 Assignment of Subject Material 1A10 Pagination 1A11 Aerofiche Effectivity 1A11 Identifying Revised Material...
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Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even though identical in appearance, may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane.
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Effectivity This maintenance manual is effective for PA-28-161 Warrior III airplane serial numbers 2842001 and up. This encompasses the following model years: NOTE: The following is provided as a general reference only. Model Year...
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Pagination The Chapter - Section (i.e. - 28-40-00) numbering system (explained above) forms the primary page numbering system for this manual. Within each Section, pages are numbered consecutively beginning with Page 1 (i.e. - 28-40-00, Page 1). Additionally, the aerofiche grid numbering system (explained below) is also used to indicate location within the manual.
MAINTENANCE MANUAL 12. Accident/Incident Reporting To improve our Service and Reliability system and aid in Piper’s compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 14. Chapter/Section Index Guide NOTE: The following GAMA Specification No. 2 standard chapters are not included in this Maintenance Manual: 22, 26, 29, 35, 36, 38, 49, 54, 60, 72, 75, 76, 81, and 83. These chapters are omitted because the subject system is either: not installed in these airplanes;...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. STANDARD PRACTICES - AIRFRAME General Corrosion Painting ENVIRONMENTAL SYSTEMS General Distribution Heating COMMUNICATIONS 2C19 General Audio Integrating Static Discharging ELECTRICAL POWER General DC Generation External Power Electrical Load Distribution...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. INDICATING / RECORDING SYSTEMS 3C15 Central Warning Systems LANDING GEAR General Main Gear Nose Gear Wheels and Brakes LIGHTS General Flight Compartment Exterior NAVIGATION AND PITOT/STATIC Flight Environmental Data...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. WINDOWS Flight Compartment Passenger Compartment WINGS 4G13 General Main Frame Auxiliary Structure Attach Fittings Flight Surfaces PROPELLER 4H21 Propeller Assembly STANDARD PRACTICES - ENGINE General POWER PLANT...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. 5E17 Distribution Indicating STARTING Cranking CHARTS & WIRING DIAGRAMS 5F21 Charts 21 & Up Wiring Diagrams (Schematics) INTRODUCTION PAGE 13 1A21 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER AIRWORTHINESS LIMITATIONS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 4 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 4-List of Nov 30/06 Effective Pages Nov 30/06 4-Table of Contents Nov 30/06 Nov 30/06 4-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 4 - AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. AIRWORTHINESS LIMITATIONS 4-00-00 Limitations Inspections Life Limited Parts Marking and Disposition 4 - CONTENTS PAGE 1 Nov 30/06...
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43.10 in a manner that does not affect part structural integrity, i.e. - no surface deformation such as vibration/etching allowed. Parts that have accumulated the life limit shall be disposed of in accordance with the applicable FARs. Piper recommends life limited parts with no time and/or cycles remaining be completely destroyed. 4-00-00...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER TIME LIMITS / MAINTENANCE CHECKS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 5 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 5-30-00 Nov 30/06 5-List of Nov 30/06 Effective Pages Nov 30/06 Nov 30/06 Nov 30/06 5-Table of Contents...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 5 - TIME LIMITS / MAINTENANCE CHECKS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 5-00-00 1C15 TIME LIMITS 5-10-00 1C17 SCHEDULED MAINTENANCE 5-20-00 1C19 Description 1C19 Definitions 1C19 Inspection Requirements...
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MAINTENANCE MANUAL GENERAL Piper Aircraft, Inc. (Piper) takes a continuing interest in having the owner get the most efficient use from his airplane, and keeping the airplane in the best mechanical condition. To that end, Piper publishes a recurring maintenance schedule which is supplemented with Service Bulletins, Service Letters and Service Spares Letters as required.
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Refer to 5-20-00 for Piper’s recommended Inspection Programs. They include the frequency and extent of the inspections required for the continued airworthiness of these airplanes. Inspections required by Flight Hour or Calendar Year, if due, are included as part of the Annual / 100 Hour Inspection and/or the Progressive Inspection Event cycles, and are listed individually in 5-30-00.
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PUBLICATIONS.) The recurring maintenance schedule for the PA-28-161 Warrior III is provided herein as an Annual / 100 Hour Inspection. A Progressive Inspection Program will be available from Piper Dealers in a separate manual form. Piper inspection programs comply with the F.A.A. Federal Aviation Regulations Parts 43, 91 and 135.
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Each bench test will be performed by a Piper Service Center, FAA Certified Repair Station with appropriate rating or by a certified mechanic. This test will be performed at the scheduled interval regardless of any bench test performed on a particular component while being repaired/overhauled before scheduled interval bench test.
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Piper Dealers: P/N 767-002 (pending) for the Warrior III (S/N’s 2842001 & up). Refer to Piper's Customer Service Information Aerofiche P/N 1753-755 for a checklist to ensure obtaining latest issue. NOTE: The 50 Hour Progressive Inspection Manual (P/N 767-002) referenced above will not be a stand-alone document.
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To help in the performance of periodic inspections, Inspection Report forms are available through Piper Dealers: P/N 230-1802 for the Warrior III (S/N’s 2842001 & up). NOTE: Service centers conducting Part 91 Annual / 100 Hour Inspections can use the Inspection Report Form (P/N 230-1802), as a working check-off list, provided they verify its currency against an up-to-date copy of the ICA (i.e.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Scheduled Maintenance Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) PROPELLER GROUP WARNING: PROPELLER MAY KICK BACK WHEN ROTATED BY HAND - USE EXTREME CAUTION.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Scheduled Maintenance (continued) Inspection NATURE OF INSPECTION Interval (Hrs) ENGINE GROUP (cont.) 14. Inspect cylinders for cracked or broken fins. (See Note 10.) ........ 15. Inspect rocker box covers for evidence of oil leaks. If found, replace gasket, torque cover screws 50 inch-pounds ............
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Scheduled Maintenance (continued) Inspection NATURE OF INSPECTION Interval (Hrs) 46. Inspect security of alternator mounting ..............47. Check condition and security of hydraulic line and fluid in brake reservoir; fill as required ................
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Scheduled Maintenance (continued) Inspection NATURE OF INSPECTION Interval (Hrs) FUSELAGE AND EMPENNAGE GROUP (cont.) 9. Inspect vertical fin for surface damage or irregularities (i.e. - skin cracks, distortion, dents, corrosion, and excessive paint build up); structural defects (i.e.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Scheduled Maintenance (continued) Inspection NATURE OF INSPECTION Interval (Hrs) 29. Inspect ELT battery for condition/date per FAR 91.207. (See Note 18.)....30. Inspect ELT installation and antenna for condition and security. Replace antenna if bent or damaged..............
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Scheduled Maintenance (continued) Inspection NATURE OF INSPECTION Interval (Hrs) LANDING GEAR GROUP 1. Check oleo struts for proper extension (Nose-3.25 in./Main-4.50 in.) and evidence of fluid leakage. (See Landing Gear, 12-10-00.) ........
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5. Aircraft papers in proper order ................NOTES 1. Refer to Piper's Customer Service Information Aerofiche P/N 1753-755 for latest revision dates to Piper Inspection Repor ts/Manuals and this maintenance manual. References to Chapter/Section are to the appropriate Chapter/Section in this manual.
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40 to 50 inch-pounds. 12. Not used. In S/N’s 2842048 thru 2842059 only, verify compliance with Piper Service Bulletin No. 1037. In S/N’s 2842001 thru 2842072 only, verify compliance with Piper Service Bulletin No. 1040. 15. Maintain cable tension as specified in Chapter 27.
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In S/N’s 2842218 thru 2842255 only, verify compliance with Piper Service Bulletin No. 1162B. In S/N’s 2842001 thru 2842178 only, for those airplanes which have not installed Piper Kit No. 767-363, perform W.S. 36.22 Right Side Wing Rib 100 Hour Inspection, 57-10-00.
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MAINTENANCE MANUAL SPECIAL INSPECTIONS WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) The following inspections are required in addition to those listed in 5-20-00. These inspections are required at intervals of: Flight hours;...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Each 1000 Hours Replace engine compartment flexible hoses (fuel, oil, etc.) as required; but not to exceed 1000 hours time-in-service, eight (8) years, or engine overhaul, whichever comes first. Overhaul or replace magnetos.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Each Ninety (90) Days Remove, drain, and clean gascolator bowl and screen. For airplanes equipped with Avidyne Entegra EFIS: if the Standby Attitude Indicator has not been operated in the previous 90 days, charge the battery of the Standby Attitude Indicator. See Standby Attitude Indicator, 34-20-00.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Each Ten (10) Years Each ten (10) years time-in-service, test fuselage and wing fluid hoses to system pressure. Visually inspect for leaks. Hoses that pass inspection may remain in service, but must be rechecked each five (5) years additional time-in-service.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Operation in High Salt or High Humidity Environment Item Inspection Inspection Interval Fuselage, Empennage, Remove floor panels and exterior 200 Hours. Wings, and Control Surfaces. access plates; inspect for corrosion using a borescope or other suitable tool.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Operation from Soft or Unusual Terrain Item Inspection Inspection Interval Landing Gear. Inspect for cracks, attachment, 100 Hours. damage, cleanliness and lubrication. Wheels. Inspect for cracks, damage, chipped 100 Hours. rims; bearings for damage, corrosion and lubrication.
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MAINTENANCE MANUAL UNSCHEDULED MAINTENANCE CHECKS WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) The following inspections are required in response to specific anomalies encountered during aircraft operation.
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Make a preliminary inspection of checking alignment and out-of-track condition of engine, wings, tail, landing gear and doors. Follow Piper and Textron-Lycoming Maintenance Manual procedures. If there are any questions regarding repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Severe Turbulence, Hard or Overweight Landing (continued) Item Inspection Inspection Interval Wings. Wing attach bolts for slippage, damage Each occurrence, and overstress. Upper and lower wing before further flight. skins for wrinkles, cracks, popped or loose rivets.
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MANUFACTURER'S MAINTENANCE MANUAL, AND FAR PART 43. PAY PARTICULAR ATTENTION TO SILT, CORROSION AND CONTAMINANTS. Follow Piper and Textron-Lycoming Maintenance Manual procedures. If there are any questions regarding repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA). Determine the water level on the aircraft. Determine which operating and/or electrical components have been exposed to the water.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flood Damage, Immersion in Water (continued) Item Inspection Inspection Interval Engine. Remove, disassemble, and inspect. If immersed, each event, Examine all parts paying particular before further flight. attention for evidence of corrosion,...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flood Damage, Immersion in Water (continued) Item Inspection Inspection Interval Electrical Systems. Replace all circuit breakers and If immersed, each event, switches. before further flight. Replace all solenoids, relays and master contactors.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flood Damage, Immersion in Water (continued) Item Inspection Inspection Interval Vacuum and Pitot-Static Replace gyros. If immersed, each event, Systems. before further flight. Replace filters. Clean and inspect all lines, and pitot and static vents.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flood Damage, Immersion in Water (continued) Item Inspection Inspection Interval Avionics Systems. Replace avionics. If immersed, each event, before further flight. Clean and inspect antennas and connectors. Insulation and Upholstery. Remove all wet insulation and upholstery.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 6 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 6-List of Nov 30/06 Effective Pages Nov 30/06 6-Table of Contents Nov 30/06 Nov 30/06 6-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 6 - DIMENSIONS AND AREAS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 6-00-00 1E17 Leading Particulars and Principal Dimensions 1E18 Station Reference Lines 1E21 Access and Inspection Provisions 1E22...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GENERAL The principal airplane dimensions are shown in Figure 1, and the leading particulars/principal dimensions are listed in Chart 1. The airplane serial number is located on the Manufacturers Aircraft Association (MAA) plate on left side of the fuselage near the leading edge of the stabilator. The engine serial number plate is located on the right side of the engine oil sump just below cylinder number 4.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Leading Particulars and Principal Dimensions CHART 1 (Sheet 1 of 2) LEADING PARTICULARS AND PRINCIPAL DIMENSIONS MODEL PA-28-161 - WARRIOR III ENGINE Manufacturer Textron Lycoming Model O-320-D3G FAA Type Certificate Rated Horsepower...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 2 of 2) LEADING PARTICULARS AND PRINCIPAL DIMENSIONS MODEL PA-28-161 - WARRIOR III LANDING GEAR Type Fixed Shock Strut Type Combination Air-Oil Fluid Required (Struts and Brakes) MIL-H-5606 Strut Exposure (under static load 1 ): Nose 3.25 ±...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Station Reference Lines To locate various airplane components that require maintenance and servicing, a method utilizing fuselage station, wing station, buttock line and waterline designations is frequently employed in this manual. Fuselage stations (F.S.), wing stations (W.S.), buttock lines (B.L.), and water lines (W.L.) are reference points measured by inches in the vertical or horizontal direction from a given reference line.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Access And Inspection Provisions CAUTION: BEFORE ENTERING THE AFT SECTION OF THE FUSELAGE, BE SURE THE AIRPLANE IS SUPPORTED AT THE TAIL SKID. The access and inspection provisions for the airplane are shown in Figure 3. The component to be serviced or inspected through each opening is identified in the illustration.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER LIFTING AND SHORING...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 7 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 7-List of Nov 30/06 Effective Pages Nov 30/06 7-Table of Contents Nov 30/06 Nov 30/06 7-10-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 7 - LIFTING AND SHORING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. JACKING 7-10-00 7 - CONTENTS PAGE 1 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL JACKING Jacking the airplane is necessary to service the landing gear and other operations. The jacking operation is normally performed using tripod jacks. In other situations (i.e. - emergency, post-accident lifting, etc.), slings or air bags may be more appropriate.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 8 - LEVELING AND WEIGHING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. WEIGHING 8-10-00 1F15 LEVELING 8-20-00 1F17 8 - CONTENTS PAGE 1 1F13 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL WEIGHING The airplane may be weighed by the following procedure (see Figure 1): Position a scale and ramp in front of each of the three wheels. Secure the scales from rolling forward and tow the airplane up onto the scales. (Refer to Towing, 9-10-00.)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL LEVELING All configurations of the airplane are provided with a means for longitudinal and lateral leveling. The airplane may be leveled while on jacks, during the weighing procedure while the wheels are on scales, or while the wheels are on the ground.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 9 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 9-List of Nov 30/06 Effective Pages Nov 30/06 9-Table of Contents Nov 30/06 Nov 30/06 9-10-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 9 - TOWING AND TAXIING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. TOWING 9-10-00 TAXIING 9-20-00 9 - CONTENTS PAGE 1 1F23 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TOWING Before towing airplane, ground personnel must be informed by a qualified pilot or other qualified personnel about tow turning limits of nose gear and any other system functions required to properly and safely move the airplane.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TAXIING Before attempting to taxi the airplane, ground personnel should be checked out by a qualified pilot or other responsible person. Engine starting and shutdown procedures should be covered as well. When it...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER PARKING AND MOORING...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 10 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 10-List of Nov 30/06 Effective Pages Nov 30/06 10-Table of Contents Nov 30/06 Nov 30/06 10-10-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 10 - PARKING AND MOORING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. PARKING 10-10-00 1G11 Parking 1G11 Locking Airplane 1G11 MOORING 10-20-00 1G13 10 - CONTENTS PAGE 1 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL PARKING Parking When parking the airplane, ensure that it is sufficiently protected against adverse weather conditions and presents no danger to other aircraft. When parking the airplane for any length of time or overnight, it is recommended that it be moored per 10-20-00.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL MOORING CAUTION: WHEN MOORING, USE SQUARE OR BOWLINE KNOTS. DO NOT USE SLIP KNOTS. The airplane is moored to ensure its immovability, protection, and security under various weather conditions. Head the airplane into the wind, if possible.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 11 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 11-List of Nov 30/06 Effective Pages Nov 30/06 11-Table of Contents Nov 30/06 Nov 30/06 11-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 11 - PLACARDS AND MARKINGS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 11-00-00 1G21 Decals 1G21 EXTERIOR PLACARDS AND MARKINGS 11-20-00 INTERIOR PLACARDS 11-30-00 Meyercord Decals 11 - CONTENTS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GENERAL Decals For proper adhesion of decals, all surfaces must be clean and free of wax, oil, etc. Porous surfaces must be sealed. Sand and clean rough surfaces to remove any residue.
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The airplane nameplate placard (Figure 1, Item 15) is located on the left side of the fuselage near the stabilator leading edge. The placard identifies the airplane by its model number and serial number. It is important to include the airplane serial number in any correspondence with your Piper Dealer’s Service Advisor (DSA).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Exterior Placards and Markings Figure 1 (Sheet 1 of 2) PAGE 2 11-20-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Exterior Placards and Markings Figure 1 (Sheet 2 of 2) 11-20-00 PAGE 3 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INTERIOR PLACARDS Interior Placards Figure 1 (Sheet 1 of 3) 11-30-00 PAGE 1 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Interior Placards Figure 1 (Sheet 2 of 3) PAGE 2 11-30-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 36991 CD PFD DISPLAY MFD DISPLAY AIR SPEED ATTITUDE SWITCHES CARB ICE GI 106 ALTITUDE SENSITIVITY OPT DME OPT ADF 330 XPNDR 11. PLACARD - REGISTRATION NUMBER (N-NUMBER) 12. PLACARD - NIGHT-DAY 13.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Meyercord Decals (PIR-PPS-65104, Rev. G.) Decals installed on the instrument panel are Meyercord type manufactured by Mark-it Company, 291 Oswalt Ave., Batavia, IL 60510. The following procedures should be followed in the event one or more of these decals must be replaced.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 12 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 12-List of Nov 30/06 Effective Pages Nov 30/06 12-Table of Contents Nov 30/06 Nov 30/06 12-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 12 - SERVICING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 12-00-00 1H17 Aircraft Finish Care 1H17 Dupont Imron 6000 Paint System 1H17 Cleaning 1H18 Cleaning 1H18 Exterior Surfaces 1H18...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 12 - SERVICING TABLE OF CONTENTS (continued) SUBJECT SECTION PAGE GRID NO. SCHEDULED SERVICING 12-20-00 Fuel System Oil System Induction Air Filter Propeller Power Plant Winterization Plate Electrical System 1I10 Tire Balance...
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Avoid abrasive cleaners, chemicals, abrasive wax, or brushes. (g) Have paint nicks or scratches touched up as soon as possible to maintain the aircraft's corrosion protection. To summarize, Piper aircraft using the new Dupont paint system need special attention in the early days of ownership. 12-00-00...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Cleaning CAUTION: IF PAINT IS LESS THAN SIX MONTHS, SEE “DUPONT IMRON 6000 PAINT SYSTEM,” ABOVE. CAUTION: DO NOT DIRECT ANY STREAM OF WATER OR CLEANING SOLUTION AT THE OPENINGS IN THE PITOT HEAD, STATIC PORTS, ALTERNATE STATIC PORTS OR FUSELAGE DRAINS.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Landing Gear (1) Struts and Torque Links Before cleaning the landing gear struts and torque links, remove wheel pants (if equipped) and place a plastic cover or similar material over the wheel and brake assembly.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Headliner, Side Panels and Seats (1) Clean headliner, side panels, and seats with a stiff brush and vacuum where necessary. WARNING: SOLVENT CLEANERS REQUIRE ADEQUATE VENTILATION. (2) Soiled upholstery, except leather, may be cleaned by using an approved air drying type cleaner or foam upholstery cleaner.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL REPLENISHING Service Points Figure 1 12-10-00 PAGE 1 1H21 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel System WARNING: OBSERVE ALL REQUIRED SAFETY PRECAUTIONS FOR HANDLING GASOLINE. Filling CAUTION: FILL THE TANKS ONLY WITH FUEL SPECIFIED ON THE PLACARD ADJACENT TO THE FILLER NECK. The fuel tanks of each wing are filled through filler necks located on the forward slope of the wings.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Draining Entirely CAUTION: WHEN DRAINING ANY AMOUNT OF FUEL, INSURE THAT NO FIRE HAZARD EXISTS BEFORE STARTING ENGINE. To drain the fuel system, open valve at inboard end of each fuel tank. Push up on drain valve arms and turn counterclockwise to hold drain in the open position.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) Recommendations for Changing Oil NOTE: Lycoming recommends changing the oil and filter each 50 hours of operation or every four months, whichever occurs first – for engines equipped with full flow cartridge filters.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Landing Gear The landing gear consists of tires, brakes and oleo strut assemblies. These should be inspected for scored piston tubes, possible hydraulic fluid leakage and security and condition of all connection points.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) There are two methods by which the strut chamber may be filled as follows: (a) Method 1: Remove valve core from filler plug at the top of strut housing. Do not remove plug.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) Fill the main gear housing by one or two methods which are as follows: (a) Method I: Remove valve core from filler plug at top of strut housing. Do not remove plug.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Brake System The brake system incorporates a hydraulic fluid reservoir through which the brake system is periodically serviced. Fluid is drawn from the reservoir by the brake cylinders to maintain the volume of fluid required for maximum braking efficiency.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Maintain tires at pressure specified in 6-00-00, Chart 1. When checking tire pressure, examine tires for wear, cuts, bruises and slippage on the wheel. Check that index mark on tire is aligned with index mark on wheel.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL SCHEDULED SERVICING Routine cleaning and lubrication of the airplane and its component parts will significantly extend its service life and reduce the frequency of repairs. Fuel System At intervals of 50 hours or 90 days, whichever comes first, clean: (1) The fuel screen/filter (i.e.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Induction Air Filter Check induction air filter each 50 hour maintenance inspection. Clean or replace if found to be dirty. Replace the filter each 100 hours time-in-service. Removal The induction air filter is located on the right side and midway in the engine compartment, and may be removed by the following procedure: (1) Open the cowling on the right side of the engine.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Electrical System Refer to Chapter 24 for more information on the electrical system. Servicing the electrical system involves: (1) Adding distilled water to battery to maintain proper electrolyte level. (2) Checking cable connections for spilled electrolyte that will lead to corrosion.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lubrication Proper lubrication procedures are valuable for prolonging the service life of the airplane and as a means of reducing the frequency of extensive and expensive repairs. The periodic application of recommended lubricants to their relevant bearing surfaces, combined with cleanliness, as detailed in the following paragraphs, ensures maximum efficiency and utmost service of all moving parts.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 THREAD LUBRICANTS Line Lubricant Brakes MIL-H-5606G Fuel MIL -T-5544, Anti-Seize, Graphite Petrolatum Landing Gear Air Valve 6PB Parker MIL-G-6032, Lubrication Grease (Gasoline and Oil Resistant) Pitot and Static TT-A-580 (JAN-A-669). Anti-Seize Compound...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 3 SPECIAL INSTRUCTIONS AND NOTES SPECIAL INSTRUCTIONS Air Filter - Inspect filter at least once every 50 hours. Under extremely adverse operating conditions, it must be inspected more frequently. The maximum filter life is 100 hours, however, do not hesitate to replace filter if inspection reveals an excessively dirty, punctured or ruptured filter.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY 1. OLEO STRUT FILLER POINT MIL-H-5606G AS REQUIRED (See Spec. Instr. 4 and Note 1) 2. UPPER TORQUE LINK BEARING MIL-PRF-23827G 100 HOURS 3. TORQUE LINK BUSHING MIL-PRF-23827G 100 HOURS 4.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY 1. OLEO STRUT FILLER POINT MIL-H-5606G AS REQUIRED (See Spec. Instr. 4 and Note 1) 2. STEERING BELLCRANK PIVOT POINT MIL-L-7870 100 HOURS (See Spec. Instr. 2) 3. SHIMMY DAMPENER PIVOT POINT (See Spec. Instr. 2)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY 1. AILERON HINGE PINS (See Spec. Instr. 9) MIL-L-7870 100 HOURS 2.. FLAP HINGE BEARINGS (See Spec. Instr. 2) MIL-L-7870 100 HOURS 3. STABILATOR HINGE PINS MIL-L-7870 100 HOURS 4.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY 1. FLAP TORQUE TUBE BEARING BLOCKS MIL-L-7870 100 HOURS (See Spec. Instr. 6) 2. FLAP CONTROL ROD END BEARINGS (See Spec. Instr. 2) MIL-L-7870 100 HOURS 3. FLAP HANDLE PIVOT POINT, LOCK MECHANISM, AND TURNBUCKLE END AND CABLE PULLEY (See Spec.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY 1. RUDDER TUBE BEARING BLOCKS CARBON DIOXIDE RELEASE AGENT (See Spec. Instr. 6 and Caution) DRY LUBRICANT MS-122N/CO 2 100 HOURS 2. TOE BRAKE CYLINDER ATTACHMENTS MIL-L-7870 100 HOURS (See Spec.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lubrication Chart - Control System, Rudder Figure 6 (Sheet 4 of 4) 12-20-00 PAGE 15 1I21 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY 1. ENGINE SUMP AIR TEMPERATURE MIL-L-6082 MIL-L-22851 50 HRS LUBRICATING OIL, (ASHLESS DISPERSANT) AIRCRAFT RECIPROCATING SAE 15W50 OR 20W50 ENGINE (PISTON) ABOVE 80°F (26.67°C) SAE 60 SAE 60 ABOVE 60°F (15.55°C)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY 1. DOOR HINGES (See Spec. Instr. 6) MIL-L-7870 100 HOURS 2. DOOR SEALS CARBON DIOXIDE RELEASE AGENT (See Spec. Instr. 6 and 10) DRY LUBRICANT MS-122N/CO 2 50 HOURS DOOR LATCH MECHANISMS (See Spec.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STANDARD PRACTICES - AIRFRAME...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 20 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 20-List of Nov 30/06 Effective Pages Nov 30/06 20-Table of Contents Nov 30/06 Nov 30/06 20-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 20 - STANDARD PRACTICES - AIRFRAME TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 20-00-00 Description Torque Wrenches Installing Rod End Bearings 1J10 Removing Cherrylock Rivet 1J11 Identification of Fluid Lines...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GENERAL Description This chapter contains general information pertaining to standard aircraft hardware installation and removal practices. For standard repair practices of a minor nature, refer to AC 43.13-1 (latest revision). If non-destructive testing is needed after repair of 4130 steel, use a magnetic particle inspection method such as Magnaflux.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Torque Wrench Formula Figure 1 Installing Rod End Bearings Install rod end bearings as shown in Figure 2. Installing Rod End Bearings Figure 2 PAGE 2 20-00-00 Nov 30/06 1J10...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Removing Cherrylock Rivets Use following procedure to remove cherrylock rivets: To remove from thick material, use a tapered steel drift pin to drive out rivet stem. (See Figure 3, View 1.) CAUTION: DRIVING OUT THE LOCKED STEM OF RIVETS INSTALLED IN THIN MATERIAL MAY DAMAGE THE MATERIAL.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Identification of Fluid Lines (Refer to Figure 4.) Aircraft fluid lines are identified by color code markers, words and geometric symbols. The markers identify each line`s function, content, primary hazard, and the direction of fluid flow.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Hose, Tube, and Line Markings Figure 4 20-00-00 PAGE 5 1J13 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Presetting Flareless Tube Fittings Figure 5 PAGE 6 20-00-00 Nov 30/06 1J14...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flareless Tube Assemblies The use of flareless tube fittings eliminates all tube flaring. An operation, referred to as presetting, is necessary prior to installing a new flareless tube assembly. Presetting is performed as follows: Cut tube to correct length.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 MAXIMUM DISTANCE BETWEEN SUPPORTS FOR FLUID TUBING Distance Between Supports (IN.) Tube O.D. (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 Support Clamps CAUTION: MAKE CERTAIN THAT CLAMPS ARE OF THE CORRECT SIZE. CLAMPS OR SUPPORTING CLIPS SMALLER THAN THE OUTSIDE DIAMETER OF THE HOSE MAY RESTRICT THE FLOW OF FLUID THROUGH THE HOSE.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL PAINTING Painting Safety WARNING: OVERSPRAY FROM CERTAIN ENAMELS, IF PUT IN WATER, IS FLAMMABLE. STORE ALL OVERSPRAY IN COVERED CONTAINERS AWAY FROM BUILDINGS WHERE SPRAYING OPERATIONS ARE CONDUCTED. WARNING: WASH ALL RAGS AND SPONGES USED TO APPLY ANY PHOSPHORIC ACID CONVERSION COATINGS (ALODINE) BEFORE DISPOSAL.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Paint Application WARNING: GROUND AIRCRAFT BEFORE PAINTING SO NO STATIC ELECTRICITY CHARGES BUILD UP AND DISCHARGE. CAUTION: PROTECT WINDSHIELD WHEN MASKING AIRCRAFT. PAINT STRIPPERS, METAL BRIGHTENERS, AND SOLVENTS WILL DAMAGE WINDSHIELD. CAUTION: BALANCE MOVABLE CONTROL SURFACES AFTER PAINTING. REFER TO APPROPRIATE MAINTENANCE MANUAL SECTIONS.
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MAINTENANCE MANUAL Paint System Compatibility Before applying new paint, find what type finish was used previously. Refer to the Piper parts catalog for correct paint number and color. Identify paint finishes by applying engine oil to a small surface area. Old nitrocellulose finishes will soften in a few minutes.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Sags and Runs - Excess paint causes wet paint film to move by gravity and presents a sagging appearance. Incorrect viscosity, air pressure, and gun handling, or inadequate surface preparation are frequent causes.
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AIRPLANE MAINTENANCE MANUAL CARD 2 OF 5 PA-28-161 (S/N’s 2842001 & UP) PIPER AIRCRAFT, INC. PART NUMBER 761-882 November 30, 2006...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL AEROFICHE REVISION STATUS Revisions to this Maintenance Manual (P/N 761-882) originally published March 1, 1998 are as follows: Effectivity Publication Date Aerofiche Card Effectivity ORG980301 March 1, 1998 PR011215 December 15, 2001...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE Intro-List of Nov 30/06 Effective Pages Nov 30/06 Intro-Table of Contents Nov 30/06 Nov 30/06 Introduction Nov 30/06 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity 2A10 Serial Number Explanation 2A10 Assignment of Subject Material 2A10 Pagination 2A11 Aerofiche Effectivity 2A11 Identifying Revised Material...
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Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even though identical in appearance, may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Effectivity This maintenance manual is effective for PA-28-161 Warrior III airplane serial numbers 2842001 and up. This encompasses the following model years: NOTE: The following is provided as a general reference only. Model Year...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Pagination The Chapter - Section (i.e. - 28-40-00) numbering system (explained above) forms the primary page numbering system for this manual. Within each Section, pages are numbered consecutively beginning with Page 1 (i.e. - 28-40-00, Page 1). Additionally, the aerofiche grid numbering system (explained below) is also used to indicate location within the manual.
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MAINTENANCE MANUAL 12. Accident/Incident Reporting To improve our Service and Reliability system and aid in Piper’s compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (11) NAVIGATION, COMMUNICATIONS, AND GPS (NAV/COM/GPS): Vendor: Garmin International PH: - (913) 397-8200 1200 East 151ST Street Olathe, KS 66062 http://www.garmin.com (12) PROPELLER: Vendor: Sensenich Corporation - (717) 569-0435 14 Citation Lane...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 14. Chapter/Section Index Guide NOTE: The following GAMA Specification No. 2 standard chapters are not included in this Maintenance Manual: 22, 26, 29, 35, 36, 38, 49, 54, 60, 72, 75, 76, 81, and 83. These chapters are omitted because the subject system is either: not installed in these airplanes;...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. STANDARD PRACTICES - AIRFRAME General Corrosion Painting ENVIRONMENTAL SYSTEMS General Distribution Heating COMMUNICATIONS 2C19 General Audio Integrating Static Discharging ELECTRICAL POWER General DC Generation External Power Electrical Load Distribution...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. INDICATING / RECORDING SYSTEMS 3C15 Central Warning Systems LANDING GEAR General Main Gear Nose Gear Wheels and Brakes LIGHTS General Flight Compartment Exterior NAVIGATION AND PITOT/STATIC Flight Environmental Data...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. WINDOWS Flight Compartment Passenger Compartment WINGS 4G13 General Main Frame Auxiliary Structure Attach Fittings Flight Surfaces PROPELLER 4H21 Propeller Assembly STANDARD PRACTICES - ENGINE General POWER PLANT...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. 5E17 Distribution Indicating STARTING Cranking CHARTS & WIRING DIAGRAMS 5F21 Charts 21 & Up Wiring Diagrams (Schematics) INTRODUCTION PAGE 13 2A21 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ENVIRONMENTAL SYSTEMS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 21 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 21-List of Nov 30/06 Effective Pages Nov 30/06 21-Table of Contents Nov 30/06 Nov 30/06 21-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 21 - ENVIRONMENTAL SYSTEMS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 21-00-00 Standard Optional DISTRIBUTION 21-20-00 Overhead Vent System Avionics Cooling Blower 2C10 HEATING 21-40-00 2C15 Description and Operation...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GENERAL Environmental control is available in a standard ram air configuration or with an optional blower. Standard Ram Air Cabin Ventilation (See 21-20-00.) S/N’s 2842001 thru 2842108 (1995 - 2000) Air inlets in the leading edge of each wing provide fresh air to individually controlled outlets in the lower cabin side panels at each seat location.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL DISTRIBUTION Overhead Vent System (S/N’s 2842109 and up (2001 and up)) The overhead vent system ( see 21-40-00, Figure 1) provides cabin ventilation and cooling. Ram Air Installation (Standard) Air enters an inlet located on the rear left side of the fuselage and is ducted through the overhead vents to the cabin.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 BLOWER SYSTEM WIRE COLOR CODES 1482-22-1 Dukes 24 VOLT MOTOR WIRES AIRCRAFT WIRES Pin Nos. Aircraft Harness Pin Nos. Ground Green AC26A Low Speed AC8A High Speed Orange AC10A Position blower fan on motor shaft and secure with set screw.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 101145 D INSTRUMENT PANEL - LOOKING AFT BLOWER FROM KNS80 OR NO. 1 KX165 REGULATOR RELAY SUPPORT PANEL (REF) AS REQUIRED FROM NO. 2 KX155A OR KX165 SEE ABOVE VIEW A - A VIEW B - B (ROTATED 90°...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 101318 K INSTRUMENT PANEL LOOKING AFT BLOWER FROM GNS-430 NO 1 BLOWER FROM GNS-430 NO 2 S/N’s 2842064 AND UP OUTLET CAPPED BLOWER BRACKET VIEW B - B (ROTATED 90° CCW) VIEW A - A...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 101901 L SYSTEM 55 ASI (REF) MFD (REF) PFD (REF) P4002 P4001 GNS-430 P4006 INSTL. P4002 P4001 GNS-430 P4006 ADI (REF) ALT (REF) GI 106 CB13 CB12 CB11 CB10 (REF) OPTIONAL DME...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL HEATING Description and Operation (See Figure 1.) CAUTION: WHEN CABIN HEAT IS OPERATED, HEAT DUCT SURFACE BECOMES HOT. THIS COULD RESULT IN BURNS IF ARMS OR LEGS ARE PLACED TOO CLOSE TO HEAT DUCT OUTLETS OR SURFACE.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Cabin Heater, Defrosters, and Overhead Vent System Figure 1 PAGE 2 21-40-00 Nov 30/06 2C16...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER COMMUNICATIONS 2C19...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 23 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 23-List of Nov 30/06 Effective Pages Nov 30/06 23-Table of Contents Nov 30/06 Nov 30/06 23-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 23 - COMMUNICATIONS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 23-00-00 Radio Master Switch AUDIO INTEGRATING 23-50-00 GMA-340 Removal and Installation System Functional Test Adjustment STATIC DISCHARGING 23-60-00 Static Wicks...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GENERAL Radio Master Switch (See 91-23-00, Figure 1.) A separate master switch for the radios is located in the switch panel in the center of the instrument panel. Both this switch and the battery master switch must be “ON” for the radios to operate.
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PA-28-161, WARRIOR III MAINTENANCE MANUAL AUDIO INTEGRATING WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) GMA-340 NOTE: The GMA-340 is factory-installed in S/N’s 2842064 and...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (c) Transceiver Operational Check Perform a ramp test radio check by exercising the installed transceivers, microphone, microphone key and audio over the headphones and speaker. Verify that communications are loud and clear and push-to-talk (PTT) operation is correct.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL MARKER BEACON HIGH SENSITIVITY MARKER BEACON LOW SENSITIVITY AIRCRAFT RADIO SPKR LEVEL PILOT PA MIC SPKR LEVEL CO-PILOT PA MIC SPKR LEVEL MARKER BEACON AUDIO LEVEL MUSIC 1 MUTE TRIP LEVEL (NOT USED IN THIS INSTALLATION)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL STATIC DISCHARGING Static Wicks Description This airplane is equipped with nine (9) static wicks: one (1) each on the inboard and outboard ends of each aileron; one (1) on each outboard end of the stabilator; one (1) on the left-hand side of the rudder at the bottom;...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ELECTRICAL POWER...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 24 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 24-40-00 Nov 30/06 24-List of Nov 30/06 Effective Pages Nov 30/06 Nov 30/06 24-Table of Contents Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 24 - ELECTRICAL POWER TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 24-00-00 2D15 Description and Operation 2D15 Troubleshooting 2D15 DC GENERATION 24-30-00 2D17 Alternator Service Precautions 2D17 Alternator System...
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MAINTENANCE MANUAL GENERAL WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) This section contains instructions and schematics for correcting difficulties which may arise in the operation of the electrical system in the aircraft.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL D.C. GENERATION Alternator Service Precautions The following precautions must be observed when testing or servicing the electrical system. Failure to observe these precautions will result in serious damage to the electrical equipment. The alternator and regulator are designed for use on only one polarity system.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Exploded View of Electrosystems Alternator Figure 1 Alternator System (Electrosystems 28 vdc, 70 amp) NOTE: In S/N’s 2842257 and up, with Avidyne Entegra installed, see also Standby Alternator, below. Description (Refer to Figure 1.) The principal alternator components are: brush holder assembly, slip ring end head, rectifiers, stator, rotor, and drive end head.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Troubleshooting WARNING: ALL CHECKS AND ADJUSTMENTS OF ALTERNATOR AND COMPONENTS MUST BE MADE WITH ENGINE STOPPED. TO COMPLETE SOME CHECKS OR ADJUSTMENTS, REMOVE THESE UNITS FROM AIRPLANE AND PLACE ON A TEST STAND.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 1 of 5) TROUBLESHOOTING ALTERNATOR SYSTEM Trouble Cause Remedy Zero output indicated Open field circuit With the master switch on ammeter regardless turned on, check for battery of rpm (see alternator voltage from the airplane’s...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 2 of 5) TROUBLESHOOTING ALTERNATOR SYSTEM Trouble Cause Remedy Zero output indicated Open field winding Disconnect field terminal of on ammeter regardless in alternator. alternator from field wiring of rpm (see alternator and check for continuity test, 24-30-00).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 3 of 5) TROUBLESHOOTING ALTERNATOR SYSTEM Trouble Cause Remedy Output indicated on Open rectifier. If any of the six rectifiers ammeter does not meet pressed into the rear bell...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 4 of 5) TROUBLESHOOTING ALTERNATOR SYSTEM Trouble Cause Remedy Field circuit breaker trips. Intermittent short circuit. Internal short circuit of the (cont.) field can occur at various positions of the rotor, therefore, reconnect field, reset breaker.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 5 of 5) TROUBLESHOOTING ALTERNATOR SYSTEM Trouble Cause Remedy Ammeter indicates 70 amps Short to ground in alternator Check output wiring for short at 1400 rpm and above, ALT output wiring.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL System Check With electrical equipment off (except master switch) the ammeter will read amount of charging current demanded by battery. The amount will vary, depending on percentage of battery charge. As battery is charged, current displayed on ammeter will reduce to approximately two amperes.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Alternator Test CAUTION: ALTERNATOR SHOULD NOT BE RUN MORE THAN 2 MINUTES FOR EACH TEST POINT. NOTE: Always refer to the appropriate alternator and starter schematic wiring diagram when installing or testing the alternator.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Alternator Belt Tension Adjustment CAUTION: AN IMPROPERL\Y TENSIONED BELT WILL WEAR RAPIDLY, SLIP, AND REDUCE ALTERNATOR OUTPUT. BELT MUST BE CHECKED FOR PROPER TENSION AT INSTALLATION, AFTER FIRST 25 HOURS OPERATION, AND EACH 100 HOURS THEREAFTER.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Standby Alternator (Installed with Avidyne Entegra in S/N’s 2842257 & up.) Description The standby system provides 20 amps of power to support continued flight in the event of primary alternator failure. It turns on automatically, annunciating its operation to the pilot through the panel mounted annunciator which doubles as a standby alternator load monitor.
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Following this procedure will locate the most common system problems encountered. When calling for additional factory support, the information gained from these checks should be readily available to aid your Piper Dealer’s Service Advisor in narrowing the field of possibilities as quickly as possible. Record the various measurements in the spaces indicated.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 4 (Sheet 2 of 3) TROUBLESHOOTING STANDBY ALTERNATOR REGULATOR (BC203-2D) Trouble Cause Remedy Move to the engine compartment. Without disconnecting the field connector, measure the field voltage on the alternator. Use a thin probe or small gage wire wrapped around the probe to reach through the connector body and measure the voltage on the male blade coming out of the alternator.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 4 (Sheet 3 of 3) TROUBLESHOOTING STANDBY ALTERNATOR REGULATOR (BC203-2D) Trouble Cause Remedy If the measurements in Steps A and B are satisfactory, prepare to monitor the voltage between terminals 3 and 7 of the regulator with the engine running. Move the aircraft to a safe location for a 2000 RPM runup.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Inspection (1) 100 Hour Standby Alternator Inspection Each 100 Hours, or at each annual inspection, whichever comes first, inspect the standby alternator installation as follows: (a) Standby Alternator (BC410) Inspect security and condition of standby alternator mounting and wiring.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Overvoltage Test The BC203-2D contains internal over-voltage protection. Grounding for both regulation and overvoltage protection is achieved through terminal 7 of the regulator, through the case mounting bolts and through the grounding stud provided under the terminal strip. Overvoltage protection may...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Removal (1) Disconnect wiring harness. (2) Remove washers and nuts (4). (3) Pull standby alternator and gasket from drive pad. Installation (1) Orient standby alternator as shown in Figure 4 and place in position on drive pad.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Battery The battery is located on a shelf on the forward, right hand side of the fire wall. Access is gained by releasing the engine cowling fasteners and lifting up the cowling.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Battery Installation Figure 5 24-30-00 PAGE 21 2E13 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 5 (Sheet 1 of 2) TROUBLESHOOTING BATTERY Trouble Cause Remedy Battery installed with Battery charged backwards. Remove battery and install reversed polarity. with correct polarity. Remove battery. Connect load such as landing light, lamp, or similar load, and discharge battery.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 5 (Sheet 2 of 2) TROUBLESHOOTING BATTERY Trouble Cause Remedy Excessive corrosion Spillage from over filling. Use care in adding water. inside container. Vent lines leaking or clogged. Repair or clean.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) The battery may be charged at any rate, in amperes, not to exceed that point which would produce bubbling and gassing of the electrolyte or a cell temperature of 115° F in any case.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 6 HYDROMETER READING (SPECIFIC GRAVITY) VS. BATTERY CHARGE Hydrometer Reading Percent Charge 1.285 to 1.295 1.250 1.217 1.184 1.150 Discharged CHART 7 HYDROMETER READING (SPECIFIC GRAVITY) TEMPERATURE CORRECTION Electrolyte Temperature Correction...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Discharge The capacity of a storage battery is measured in units of ampere hours, which is the product of the electrical current in amperes multiplied by the time in hours. Although current may be obtained after the end of the time, the voltage of the battery has dropped to a point beyond which it is not very useful.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Repairs, Storage, and Service Tips The internal parts of the battery have been designed to wear at approximately the same rate, making it uneconomical to replace any of the parts with new ones. Replacing the entire battery is simpler and cheaper.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Voltage Regulator The Lamar voltage regulator is a fully transistorized unit. The components are encapsulated in epoxy, making field repair of the unit impractical. Before performing any of the following checks verify proper functioning of the alternator per manufacturer’s instructions.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) In the regulation check procedure, increase voltage to regulator and monitor both the voltmeter and bulb. (6) As the regulation point of a properly functioning control unit is approached, the bulb will blink off and on.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL EXTERNAL POWER Description The external power receptacle is located on the right side aft fuselage, aft of the wing. Operation Proceed as follows when using external power for engine start or operation of any of the airplane’s equipment: Turn the master switch OFF.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL ELECTRICAL LOAD DISTRIBUTION Component Loads See Chart 1. CHART 1 ELECTRICAL SYSTEM COMPONENT LOADS Duty Cycle Circuit / Circuit Cont. Inter. Equipment Breaker (Amps) Optional Alternator Field Anti-Collision (Strobe) Auxiliary Vacuum Pump...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER EQUIPMENT / FURNISHINGS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 25 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 25-List of Nov 30/06 Effective Pages Nov 30/06 25-Table of Contents Nov 30/06 Nov 30/06 25-10-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 25 - EQUIPMENT / FURNISHINGS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. FLIGHT COMPARTMENT 25-10-00 2F11 Pilot’s Seat Lock and Release Rigging 2F11 Lumbar Support 2F12 Description 2F12 Removal 2F12...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL FLIGHT COMPARTMENT Pilot’s Seat Lock and Release Rigging (Refer to Figure 1.) Loosen screws and loosen clamps to allow push-pull cable to move within the clamps. Place a straightedge along lower surface of seat back release bushing.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lumbar Support (Refer to Figure 2.) Description In the optional interior, the pilot and co-pilot seats incorporate a Lumbar support feature. The installation consists of an inflatable bladder attached to the seat back filler and a inflation bulb located under and on the inboard side of each pilot and co-pilot seat.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lumbar Seat Bladder Installation Figure 2 25-10-00 PAGE 3 2F13 Nov 30/06...
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Replace all belts manufactured by Pacific Scientific and the seat belt has a date stamp of 6/94 thru 8/95, if the seat belt buckle end has an old Piper logo (large stylized “P”) or no logo, and if the seat belt fitting end I.D. tag has a date stamp of 6/94 thru 8/95.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Inertial Reel Adjustment The inertial reel locking feature prevents the shoulder strap from extending and holds occupant in place. For normal movement strap will extend and retract as required. If required, adust inertial reel as follows: (1) Allow harness to wind up on reel as much as possible.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL EMERGENCY Emergency Locator Transmitter (ELT) (Artex ELT 110-4) Description The Artex ELT 110-4 transmits on 121.5 mHz and 243.0 mHz, and is designed to meet or exceed the requirements of TSO C91a and FAR Part 91. Electrical power for the ELT transmissions is totally supplied by its own self-contained battery.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Testing The transmitter operates on the emergency frequencies of 121.5 and 243.0 MHz; both of these frequencies are monitored by the various FAA installations. Before performing any operational test of the ELT, the following precautions should be observed:...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 06311-T P203 J501 LIGHT RESET 1 RESET 2 EXTERNAL ON NO CONNECTION G-SWITCH LOOP NO CONNECTION G-SWITCH LOOP NO CONNECTION 28 VDC NO CONNECTION SOURCE +28 VDC GROUND NO CONNECTION NO CONNECTION...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER FLIGHT CONTROLS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 27 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 27-30-00 Nov 30/06 27-List of Nov 30/06 Effective Pages Nov 30/06 Nov 30/06 Nov 30/06 27-Table of Contents...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 27 - FLIGHT CONTROLS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 27-00-00 Description and Operation Standard Practices and Procedures Flight Control Surface Travel Flight Control Cable Tension Control Cable Inspection...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 27 - FLIGHT CONTROLS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. STABILATOR AND TAB 27-30-00 Troubleshooting Stabilator Control Cables Removal Installation Rigging and Adjustment Stabilator Trim Controls Forward Assembly Removal...
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GENERAL Description and Operation The PA-28-161 Warrior III is controlled in flight by standard three-axis control surfaces, consisting of ailerons (roll), stabilator (pitch) and rudder (yaw). Operation of these controls is through the movement of dual control columns and dual rudder pedal sets. The individual surfaces are connected to their control components through the use of cables and push-pull tubes.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Standard Practices and Procedures The following tips may be helpful in the removal, installation, and rigging of individual control system assemblies. It is recommended, though not always necessary, to level and place the airplane on jacks during rigging and adjustment.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 CABLE TENSION VS. AMBIENT TEMPERATURE Subtract Rigging Load Correction, Pounds Flight Control Surface Travel See Chart 2 for specifications, see appropriate section for rigging instructions. Flight Control Cable Tension CAUTION: CABLE TENSIONS GIVEN IN CHART 2 APPLY ONLY TO AIRPLANES WITHOUT AUTOPILOT BRIDLE CABLE INSTALLATIONS.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 (Sheet 1 of 2) FLIGHT CONTROL SURFACE TRAVEL AND CABLE TENSION PAGE 4 27-00-00 Nov 30/06 2G10...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 (Sheet 2 of 2) FLIGHT CONTROL SURFACE TRAVEL AND CABLE TENSION 27-00-00 PAGE 5 2G11 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Control Cable Inspection Aircraft control cable systems are subject to a variety of environmental conditions and forms of deterioration that, with time, may be easy to recognize as wire/strand breakage or the not-so-readily visible types of wear, corrosion, and/or distortion.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL External Cable Wear Figure 2 External Wear Patterns Wear will normally extend along cable equal to the distance cable moves at that location. Wear may occur on one side of the cable only or on its entire circumference. Replace flexible and non-flexible cables when individual wires in each strand appear to blend together (outer wires worn 40-50 percent) as depicted in Figure 2.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Internal Cable Wear Figure 3 Corrosion Carefully examine any cable for corrosion that has a broken wire in a section not in contact with wear producing airframe components such as pulleys, fairleads, etc. It may be necessary to remove and bend the cable to properly inspect it for internal strand corrosion as this condition is usually not evident on the outer surface of the cable.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Cable Maintenance CAUTION: TO AVOID REMOVAL OF CORROSION-PREVENTATIVE COMPOUNDS AND CABLE INTERNAL LUBRICANT, DO NOT USE VAPOR DEGREASING, STEAM CLEANING, METHYLETHYLKETONE (MEK) OR OTHER SOLVENTS. CAUTION: DO NOT OIL CONTROL CABLES. Frequent inspections and preservation measures such as rust prevention treatments for bare cable areas will help to extend cable service life.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Pulley Wear Patterns Various cable system malfunctions may be detected by analyzing pulley conditions. These include such discrepancies as too much tension, misalignment, pulley bearing problems, and size mismatches between cables and pulleys. Examples of these conditions are shown in Figure 4.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL AILERON Troubleshooting See Chart 1. Control Column Removal (Refer to Figure 1.) (1) To remove either control wheel (1) with its tube (2) the following procedure may be used: (a) Separate the control wheel tube (2) from the flexible joint (4) that is located on either side of the tee bar assembly (5) by removing the nut, washer and bolt (3).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 TROUBLESHOOTING AILERON CONTROL SYSTEM Trouble Cause Remedy Lost motion between Cable tension too low. Adjust cable tension. control wheel and aileron. Linkage loose or worn. Check linkage and tighten or replace.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Control Column Assembly Figure 1 27-10-00 PAGE 3 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Loosen the connecting bolts (22) of the idler sprockets (19 and 21) to allow the chain to fit snug around the control wheel sprockets and over the idler sprockets. (g) Connect the aileron control cables (12) to the ends of the chains (7 and 8) with bolts, bushings, nuts and cotter pins (10).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL SMALL END OF TAPERED SHANK SHALL NOT EXTEND MORE THAN 0.030 INSIDE THE O.D. OR 0.062 OUTSIDE TAPER PIN (480-730) THE O.D. OF THE SPOCKET HUB. WASHER (407-564 [AN960-10]) OR (494-093 [AN975-3])
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Effectivity Control Wheel Installation 2842026 & up Figure 3 PAGE 6 27-10-00 Nov 30/06...
(3) Prime inside of control wheel with Loctite 7649 (Piper P/N 279-073). Allow to dry. (4) Install control wheel onto tube using Loctite 271 (Piper P/N 279-128). Take care to ensure screw hole in control wheel aligns with screw hole in tube.
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Aileron Control Cables Removal (Refer to Figure 4.) (1) For the removal of either the control cables in the fuselage or the wings, first remove the rear seat bottom. (2) To remove either the right or left primary control cables (14 or 15) that are located in the fuselage, the following procedure may be used: (a) Remove the two front seats from the airplane.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Aileron Controls Figure 4 27-10-00 PAGE 9 Nov 30/06...
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation (Refer to Figure 4.) (1) The installation of either the right or left primary control cable (14 or 15) that is located in the fuselage may be accomplished as follows: (a) Draw the cable through the fuselage floor tunnel.
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) Disconnect the primary (13 or 17) and balance (18 or 19) control cables from the bellcrank assembly by removing cotter pins, nuts, washers and bolts. (5) Disconnect the aileron control rod (7) at the aft or forward end, as desired, by removing the cotter pin, nut, washer and bolt.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL With each bellcrank set at neutral, the ailerons may be checked and adjusted for neutral as follows: (1) Ascertain that the flaps are rigged in accordance with 27-50-00, and in their up locked position.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Aileron Bellcrank Rigging (Typical) Figure 5 MATERIAL - .125 X 1.0 ALUMINUM PLATE 3.90 .125 .625 .062 R (SIX PLACES) 3.15 Aileron Bellcrank Rigging Tool Figure 6 27-10-00 PAGE 13 2H13 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL RUDDER AND TAB Troubleshooting See Charts 1 and 2. CHART 1 TROUBLESHOOTING RUDDER CONTROL SYSTEM Trouble Cause Remedy Lost motion between Cable tension too low. Adjust cable tension. rudder pedals and rudder.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Rudder Control Cables Removal (Refer to Figure 1.) (1) Remove the access panel to the aft section of the fuselage. (2) Disconnect the cable(s) to be removed at the turnbuckle (12 or 13) in the aft section of the fuselage.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Rudder Controls Figure 1 27-20-00 PAGE 3 2H17 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) Install aft rubber control cables by the following procedure: (a) Position the control cable in the fuselage. (b) Connect the end of the cable (14 or 15) to the rudder horn (17) with bolt, washer, nut and cotter pin (16).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Rudder Rigging Clamping Rudder Pedals Figure 2 Figure 3 Rudder and Stabilator Travel Adjustments Figure 4 27-20-00 PAGE 5 2H19 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Check the adjustment of the rudder pedal stops by the following procedure: (1) Remove the clamp securing the rudder pedals in their neutral position, if not previously removed. (2) Push on the pilots left rudder pedal until the rudder stop (at the tail) is contacted.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Rudder Trim Control Figure 5 Fabricated Rudder Rigging Tool Figure 6 27-20-00 PAGE 7 2H21 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Rigging and Adjustment CAUTION: VERIFY FREE AND CORRECT MOVEMENT OF RUDDER. WHILE IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY,...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Rudder and Steering Pedal Assembly Figure 7 27-20-00 PAGE 9 2H23 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation (Refer to Figure 7.) (1) Assemble the torque tube assembly (1, 2, 3 and 4) as shown in Figure 7. Do not at this time install the two bolts (25) through the center of the tube assembly.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL STABILATOR AND TAB Troubleshooting See Charts 1 and 2. Stabilator Control Cables Removal (Refer to Figure 1.) (1) To remove either the forward or aft stabilator cables, remove the access panel to the aft section of the fuselage located in the baggage compartment, the two front seats, and raise the bottom of the rear seat.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 TROUBLESHOOTING STABILATOR CONTROL SYSTEM Trouble Cause Remedy Lost motion between Cable tension too low. Adjust cable tension. control wheel and stabilator. Linkage loose or worn. Check linkage and tighten or replace.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 TROUBLESHOOTING STABILATOR TRIM CONTROL SYSTEM Trouble Cause Remedy Lost motion between Cable tension too low. Adjust cable tension. trim control wheel and trim tab. Cables not in place on Install cables properly.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation (Refer to Figure 1.) (1) The forward stabilator cables (2 and 3) may be installed by the following procedure: (a) Draw the control cable through the floor tunnel. Ascertain that the right (upper) cable (2) is routed around the pulley(s) (14) in the forward area of the floor tunnel.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stabilator Controls Figure 1 27-30-00 PAGE 5 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stabilator Rigging Tool Figure 2 Fabricating Stabilator Rigging Tool Figure 3 PAGE 6 27-30-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Rigging and Adjustment CAUTION: VERIFY FREE AND CORRECT MOVEMENT OF STABILATOR. WHILE IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY,...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stabilator Trim Controls Figure 4 PAGE 8 27-30-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stabilator Trim Controls Forward Stabilator Trim Assembly (Refer to Figure 4.) (1) Removal (a) To remove the trim control wheel assembly and/or the trim control cables, first remove the panel to the aft section of the airplane.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Methods of Securing Trim Cables Figure 5 Lubricate and install the bushing in the trim control wheel and trim drum. Align the control cables and position the control wheel assembly between its mounting brackets.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (e) Install the carpet over the floor tunnel. Install the cover over the trim control wheel and secure with screws and special washers. (g) Install the floor panel and seat belt attachments aft of the main spar and secure panel with screws.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Remove blocks holding forward cables tight and holding aft cables at barrel. Set cable tension and check rigging and adjustment per Rigging and Adjustment, below. Check safety of all turnbuckles and install pulley guard pins (38).
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S-TEC Manual Electric Trim Clutch Adjustment Figure 6 S-TEC Manual Electric Trim Clutch Check & Adjustment (Refer to Figure 6.) S-Tec Manual Electric Trim is an optional system in Warrior III S/N’s 2842019 and up. When installed, a servo motor, capstan, and idler pulley assembly are attached to the left stabilator trim cable just aft of Sta.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stall Warning The stall warning system consists of a lift detector electrically connected to a stall warning horn. As stalling conditions are approached, the lift detector activates the stall warning horn. The lift detector is on the leading edge of the left wing. A tab will extend beyond the leading edge at the point where lift detector is mounted.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flight Test Procedure (PIR-FTP2001-5, Rev. E.) NOTE: Required whenever a “replacement” wing is installed. Fly airplane and at a rate of 1 KT/SEC maximum record the following warning and stall speeds: TRIM KIAS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL FLAPS Troubleshooting See Chart 1. Flap Controls Removal (Refer to Figure 1.) (1) Remove the flap torque tube assembly by the following procedure: (a) Remove the access plate located between the underside of the aft section of each wing and the fuselage by removing attaching screws.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flap Control System Figure 1 PAGE 2 27-50-00 Nov 30/06 2I20...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) Remove the flap control cable (23) by the following procedure: (a) Remove the seats floor panel. Remove the seats. (b) Disconnect the flap tension spring (22) from the cable, if not previously disconnected, by extending the flaps to relieve spring tension.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) Install the flap handle (29) with bracket (28) by placing the assembly on the floor tunnel and secure with bolts. (3) Install the flap control cable (23) by the following procedure: (a) Attach the cable and turnbuckle (25) to the flap handle arm and secure with clevis bolt, nut and cotter pin (26).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flap Stop Adjustment Figure 2 Flap Rigging Tool Figure 3 27-50-00 PAGE 5 2I23 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) Check and adjust flap neutral: (a) With a rigging tool as shown in Figure 3: NOTE.: This tool may be fabricated from dimensions given in Figure 4. To check the 0° (neutral) position of the flaps, place the flap rigging tool against the underside of the wing and flap as close as possible to the outboard end of the flap without contacting any rivets.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fabricating Flap Rigging Tool Figure 4 27-50-00 PAGE 7 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER FUEL...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 28 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 28-40-00 Nov 30/06 28-List of Nov 30/06 Effective Pages Nov 30/06 Nov 30/06 Nov 30/06 28-Table of Contents...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 28 - FUEL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 28-00-00 2J11 Description 2J11 Troubleshooting 2J11 STORAGE 28-10-00 2J15 Fuel Tank 2J15 Removal 2J15 Installation 2J15 Inspection and Repair...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 28 - FUEL TABLE OF CONTENTS (continued) SUBJECT SECTION PAGE GRID NO. INDICATING 28-40-00 Standard Installation Description Troubleshooting Fuel Quantity Transmitter Unit Removal Installation Check and Adjustment 2K10 Fuel Quantity Indication Calibration...
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1, 2, and 4. The Warrior III has two electrical fuel gages, mounted in a common instrument, located on the lower right side of the pilot’s instrument panel. The gauges are connected electrically to a transmitter unit installed in each tank.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel System Figure 1 PAGE 2 28-00-00 Nov 30/06 2J12...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 TROUBLESHOOTING FUEL SYSTEM Trouble Cause Remedy Fuel will not flow. Blocked fuel line. Flush fuel system. Blocked cap vent. Check and clean cap vent hole. Mechanical or electric fuel Check and replace if pump failure.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL STORAGE Fuel Tank Removal (1) Drain fuel from fuel tank. (See 12-10-00.) (2) Remove tank assembly screws. (3) Remove access panel at WS 54.00 and disconnect fuel line attached to tank. (4) Pull tank from wing assembly enough to remove sender wire.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Inspection and Repair (1) General WARNING: SLOSHING OF FUEL TANKS IS PROHIBITED. (a) Inspect each tank for signs of leaks (indicated by telltale stains). (b) If leaks are detected, seal with Products Research Corporation (PRC) PR1422A series or PR1433G series sealant.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel Tank Components and Fuel Tank / Wing Spar Corrosion Inspection Figure 1 28-10-00 PAGE 3 2J17 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Locking Fuel Cap (Optional) Disassembly (Refer to Figure 2.) (1) Remove the two screws from top of fuel cap. (2) Remove screw and lock washer that secures pawl to bottom of key lock. Remove pawl.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Locking Fuel Cap Figure 2 28-10-00 PAGE 5 2J19 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL DISTRIBUTION Gascolator (Refer to Figure 1.) The gascolator is located on the left forward face of the firewall. Removal CAUTION: VERIFY ALL ELECTRICAL LEADS ARE DISCONNECTED BEFORE COWL REMOVAL. (1) Check fuel shutoff is in the off position.
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(4) Install selector cover with attaching screws. (5) Install valve control handle with attaching screws. Electric Fuel Pump The Warrior III is equipped with a 28 Vdc electric fuel pump which is mounted on the left forward side of the firewall. Removal CAUTION: CHECK ALL ELECTRICAL LEADS ARE DISCONNECTED BEFORE FUEL PUMP REMOVAL.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation (1) Position fuel pump to engine mount frame and secure with bolts, washers, and nuts. (2) Connect fuel lines to pump. Connect fuel inlet line to pump. Connect the main fuel and fuel primer outlet lines to tee fitting.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Cleaning, Inspection, And Repair (1) Clean all parts with acetone or a suitable dry type solvent. If plunger assembly does not come clean or there are any rough spots, polish gently with crocus cloth.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lines and Fittings Inspection And Tightening (1) Remove aft inboard inspection panel from the lower surface of right and left wing. (2) Remove pilot’s seat and left cabin side panel. Fold back carpeting and remove the cover from fuel line(s).
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AC43.13-1. This will require cutting off swaged ferrule and adding a short length of tubing. (3) A replacement tube and union purchased from Piper will have the ferrule pre-swaged onto tube. Install tube as follows: (a) Lubricate male threads of union with MIL-L-5606 hydraulic fluid.
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Standard Installation Description The Warrior III fuel quantity gauge is a dual instrument (two indicators in one case), calibrated in fractional divisions of 0, 5, 10, 15, 20 (gallons), and F (FULL). A transmitter unit (i.e. - sender), comprising a resistance strip and a movable control arm, is installed in each fuel tank. The arm position is controlled by a float in the fuel tank.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 TROUBLESHOOTING FUEL QUANTITY INDICATORS Trouble Cause Remedy Fuel gauge fails to indicate. Broken wiring. Check and repair. Defective gauge. Replace gauge. Tripped circuit breaker. Reset circuit breaker. If breaker does not remain set, check wiring and components for short.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (3) Check and Adjustment (a) Remove transmitter unit to be checked from the fuel tank. (b) Check and adjust transmitter unit float position as follows: Fasten unit to a fabricated checking jig with washer and nuts as shown in Figure 1.
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Fuel Quantity Indication Calibration (PIR-PPS60032-12, Rev. C.) The Warrior III fuel gauge consists of individual indicators for the left and right fuel tanks contained in a common instrument. Calibrate any new or replacement gauge prior to installation using the bench test, below. Once installed, the System Functional Check, below, is used whenever the fuel quantity indication accuracy is questioned.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL RESISTANCE (OHMS) FUEL QUANTITY INDICATOR 45 OHMS RIGHT SEND LEFT SEND 5 OHM DUMMY RESISTOR 33 OHMS 23 OHMS SWITCH 28 ± 1 VDC 14 OHMS 3 OHMS LEFT NULL RIGHT NULL...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) System Functional Check (a) Level airplane, ± 1°, laterally and longitudinally. See 8-20-00. (b) Place battery switch in OFF position. (c) Completely drain fuel tank on the side(s) being checked. (See Draining Fuel System, 12-10-00.)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel Quantity Sender Jig Fabrication Figure 3 28-40-00 PAGE 7 2K15 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Optional Installation In S/N’s 2842218 and up, with the Avidyne Flight Max Entegra EFIS installed, fuel quantity information is collected by the DAU and displayed on the MFD. Whenever the MFD, DAU, or any fuel sender is...
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AIRPLANE MAINTENANCE MANUAL CARD 3 OF 5 PA-28-161 (S/N’s 2842001 & UP) PIPER AIRCRAFT, INC. PART NUMBER 761-882 November 30, 2006...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL AEROFICHE REVISION STATUS Revisions to this Maintenance Manual (P/N 761-882) originally published March 1, 1998 are as follows: Effectivity Publication Date Aerofiche Card Effectivity ORG980301 March 1, 1998 PR011215 December 15, 2001...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE Intro-List of Nov 30/06 Effective Pages Nov 30/06 Intro-Table of Contents Nov 30/06 Nov 30/06 Introduction Nov 30/06 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity 3A10 Serial Number Explanation 3A10 Assignment of Subject Material 3A10 Pagination 3A11 Aerofiche Effectivity 3A11 Identifying Revised Material...
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Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even though identical in appearance, may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Effectivity This maintenance manual is effective for PA-28-161 Warrior III airplane serial numbers 2842001 and up. This encompasses the following model years: NOTE: The following is provided as a general reference only. Model Year...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Pagination The Chapter - Section (i.e. - 28-40-00) numbering system (explained above) forms the primary page numbering system for this manual. Within each Section, pages are numbered consecutively beginning with Page 1 (i.e. - 28-40-00, Page 1). Additionally, the aerofiche grid numbering system (explained below) is also used to indicate location within the manual.
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MAINTENANCE MANUAL 12. Accident/Incident Reporting To improve our Service and Reliability system and aid in Piper’s compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (11) NAVIGATION, COMMUNICATIONS, AND GPS (NAV/COM/GPS): Vendor: Garmin International PH: - (913) 397-8200 1200 East 151ST Street Olathe, KS 66062 http://www.garmin.com (12) PROPELLER: Vendor: Sensenich Corporation - (717) 569-0435 14 Citation Lane...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 14. Chapter/Section Index Guide NOTE: The following GAMA Specification No. 2 standard chapters are not included in this Maintenance Manual: 22, 26, 29, 35, 36, 38, 49, 54, 60, 72, 75, 76, 81, and 83. These chapters are omitted because the subject system is either: not installed in these airplanes;...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. STANDARD PRACTICES - AIRFRAME General Corrosion Painting ENVIRONMENTAL SYSTEMS General Distribution Heating COMMUNICATIONS 2C19 General Audio Integrating Static Discharging ELECTRICAL POWER General DC Generation External Power Electrical Load Distribution...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. INDICATING / RECORDING SYSTEMS 3C15 Central Warning Systems LANDING GEAR General Main Gear Nose Gear Wheels and Brakes LIGHTS General Flight Compartment Exterior NAVIGATION AND PITOT/STATIC Flight Environmental Data...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. WINDOWS Flight Compartment Passenger Compartment WINGS 4G13 General Main Frame Auxiliary Structure Attach Fittings Flight Surfaces PROPELLER 4H21 Propeller Assembly STANDARD PRACTICES - ENGINE General POWER PLANT...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. 5E17 Distribution Indicating STARTING Cranking CHARTS & WIRING DIAGRAMS 5F21 Charts 21 & Up Wiring Diagrams (Schematics) INTRODUCTION PAGE 13 3A21 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ICE AND RAIN PROTECTION...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 30 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 30-List of Nov 30/06 Effective Pages Nov 30/06 30-Table of Contents Nov 30/06 Nov 30/06 30-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 30 - ICE AND RAIN PROTECTION TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 30-00-00 PITOT AND STATIC 30-30-00 30 - CONTENTS PAGE 1 Nov 30/06...
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MAINTENANCE MANUAL GENERAL The Warrior III is not approved for operation in icing conditions. Accordingly, limited ice and rain protection is provided in the form of an optional heated pitot-static mast (see 30-30-00), carburetor heat, and an optional carburetor ice detection system (see 71-60-00).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL PITOT AND STATIC The pitot heat system (optional) is activated by the PITOT HEAT switch located on the center instrument panel just above the engine power quadrant. In addition to the switch, the system incorporates a heated pitot-static head and the 10 amp PITOT HEAT circuit breaker.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER INDICATING / RECORDING SYSTEMS 3C15...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 31 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 31-List of Nov 30/06 Effective Pages Nov 30/06 31-Table of Contents Nov 30/06 Nov 30/06 31-50-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 31 - INDICATING / RECORDING SYSTEMS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. CENTRAL WARNING SYSTEMS 31-50-00 Annunciator Troubleshooting 31 - CONTENTS PAGE 1 3C19 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CENTRAL WARNING SYSTEMS Annunciator (See Figure 1.) While provisions are made for nine annunciator lights, only five, six, or seven lights are used, depending on installed options. Refer to Chart 1 for the description and function of each annunciator light.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 85372 M OPTIONAL STARTER PITOT HEAT LOW BUS ENGAGE VOLTAGE OFF/INOP VACUUM ALTERNATOR INOP PRESSURE INOP CARB ICE OPTIONAL STANDARD PITOT HEAT ALTERNATOR CARB LOW BUS STARTER PRESSURE VOLTAGE OFF/INOP ENGAGE INOP...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 (Sheet 1 of 3) TROUBLESHOOTING ANNUNCIATOR Trouble Cause Remedy All warning lights fail to illuminate. 5 amp ANNUNCIATOR PANEL Reset (push IN) circuit circuit breaker open. breaker. No current from bus.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 (Sheet 2 of 3) TROUBLESHOOTING ANNUNCIATOR Trouble Cause Remedy STARTER ENGAGE fails Blown bulb(s). Replace bulb(s). to illuminate. Blown 5 amp in line fuse Replace fuse. between starter contactor and annunciator panel.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 (Sheet 3 of 3) TROUBLESHOOTING ANNUNCIATOR Trouble Cause Remedy OIL PRESSURE fails to illuminate. Blown bulb(s). Replace bulb(s). No current to sensor. Check all wire segments and connections. Sensor activates at a too low Replace sensor.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER LANDING GEAR...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 32 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 32-40-00 Nov 30/06 32-List of Nov 30/06 Effective Pages Nov 30/06 Nov 30/06 Nov 30/06 32-Table of Contents...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 32 - LANDING GEAR TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 32-00-00 3D13 Description 3D13 Troubleshooting 3D13 MAIN GEAR 32-10-00 3D17 Main Gear Oleo 3D17 Disassembly 3D17 Cleaning, Inspection and Repair...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 32 - LANDING GEAR TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. WHEELS AND BRAKES (cont.) 32-40-00 Brakes 3E15 Brake Adjustment, Conditioning, and Lining Tolerances 3E15 Wheel Brake Assembly 3E15 Removal and Disassembly...
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Description The landing gear installed in the Warrior III is a fixed, tricycle type, fitted with two 6:00 x 6 main wheels and a 5:00 x 5 nose wheel. The landing gear struts are of the air-oil type. The nose gear is steerable through a 40°...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 1 of 2) TROUBLESHOOTING LANDING GEAR Trouble Cause Remedy Nose landing gear shimmies Internal wear in shimmy Replace shimmy during fast taxi, takeoff, or dampener. dampener. landing. Worn steering horn bolt holes.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 2 of 2) TROUBLESHOOTING LANDING GEAR Trouble Cause Remedy Excessive or uneven wear Incorrect operating pressure. Inflate tire to correct on main tires. pressure. Wheel out of alignment Check wheel alignment.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL MAIN GEAR Main Gear Oleo Disassembly (Refer to Figure 1.) The main gear axle (15) and piston tube assembly (14) may be removed from the cylinder housing (7) with the gear removed from or installed on the airplane.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Main Gear Oleo Strut Figure 1 (Sheet 1 of 2) PAGE 2 32-10-00 Nov 30/06 3D18...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Main Gear Oleo Strut Figure 1 (Sheet 2 of 2) 32-10-00 PAGE 3 3D19 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) Ascertain that the bushings are installed in the upper and lower torque links and then install links. At cable end of each link, install with the use of brake line bracket, bearing washers, bolt, washer, nut and cotter pins.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Main Gear Installation Figure 2 32-10-00 PAGE 5 3D21 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation (Refer to Figure 2.) (1) The main landing gear assembly may be installed on the wing by the following procedure: (a) Position the gear up in the wing through the access opening and secure with bolts, washers and nuts.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL NOSE GEAR Nose Gear Oleo Disassembly (Refer to Figure 2.) The nose gear oleo strut assembly may be removed and disassembled from the strut housing with the gear either removed from, or installed on, the airplane.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (10) To remove the piston tube plug (21) with O-ring (20) located in the lower end of the tube, the following procedure may be used: (a) Remove the nose wheel from the fork as described in 32-40-00.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Nose Gear Oleo Strut Figure 2 32-20-00 PAGE 3 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Assembly (Refer to Figure 2.) (1) Ascertain that all parts are cleaned and inspected. (2) To install the piston tube plug, proceed as follows: (a) Lubricate the tube plug (21) and O-ring (20) with hydraulic fluid (MIL-H-5606) and install the O-ring on the plug.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Nose Gear Installation Figure 3 32-20-00 PAGE 5 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (3) Place the airplane on jack. (Refer to Jacking, Section 7-10-00.) (4) Remove the engine. (Refer to Engine - Removal, 71-00-00.) (5) Disconnect the steering rod assemblies (4 and 11) and the two centering springs (25) from the steering horn assembly (3) by removing the nuts, washers, and bolts (1 and 13).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Clamping Rudder Pedals Rudder Pedals at Neutral Figure 4 Figure 5 CHART 1 NOSE GEAR ALIGNMENT TOLERANCES Rudder Pedal Neutral Angle 14° + 3°, - 1° (Aft of Vertical) Nose Wheel Travel 20°...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (10) Ensure that the steering rods fit between the steering horn and the rudder pedals without any load on the steering rods. Adjust rod ends to obtain this no load setting. Connect the steering rods to the steering horn.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL WHEELS AND BRAKES Wheels Main Wheel (See Figure 1.) (1) Removal and Disassembly (a) Place the airplane on jacks. (Refer to Jacking, Section 7-10-00.) (b) If wheel fairing is installed, remove attaching screws, bolt and remove the fairing.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (e) The wheel halves (7 and 8) may be separated by first deflating the tire. With the tire sufficiently deflated, remove the wheel through bolts (16). Pull the wheel halves from the tire by removing the inner half (8) from the tire first, and then the other half.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Nose Wheel (See Figure 2.) (1) Removal and Disassembly (a) Jack the airplane enough to raise the nose wheel clear of the ground. (Refer to Jacking, Section 7-10-00.) (b) If wheel fairing is installed, remove four bolts, two on each side, and the small plate on top held by metal screws.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (d) The wheel halves (7 and 10) may be separated by first deflating the tire. With the tire sufficiently deflated, remove the wheel through bolts (18). Pull the wheel halves from the tire by removing the wheel half opposite the valve stem first and then the other half.
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Brakes Brake Adjustment, Conditioning, and Lining Tolerances (1) 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.
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(e) Remove lining from backing plates by drilling or punching out the old rivets. Install a new set using the proper rivets and a rivet set that will properly stake the lining and form a correct flare of the rivet. (A rivet setting kit is available through Piper Distributors as Part Number 754-165.) (4) Assembly and Installation (Refer to Figure 3.)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Anchor Bolt Figure 4 32-40-00 PAGE 7 3E17 Nov 30/06...
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (d) Position the lining back plate between the wheel and brake disc. Install the two bolts to secure the assembly. (e) Connect the brake line to the brake cylinder housing. Bleed the brake system as described in Bleeding Brakes, below.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Brake System Installation Figure 6 32-40-00 PAGE 9 3E19 Nov 30/06...
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) Disassembly (Refer to Figure 5.) (a) Remove the cylinder from its mounting bracket in accordance with instructions given in paragraph (1), above. (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.
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Toe Brake Cylinder(s) (Cleveland 10-30.) (Refer to Figures 6 and 7.) (1) Removal (a) Disconnect the upper and lower lines from the cylinder to be removed and cap the lines to prevent fluid leakage or drain the fluid from the brake reservoir and master cylinder.
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) Installation (Refer to Figure 6.) (a) Position the cylinder at its mounting points and attach with clevis pins. Safety the pins with cotter pins. (b) Connect the brake lines to the cylinder fittings.
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (d) Close the open bleeder fitting to which the pressure hose is attached. Do not remove the tube from the fluid reservoir until both brakes have been bled. Check the brakes on the side being bled for proper pedal pressure.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER LIGHTS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 33 - LIGHTS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 33-00-00 Description and Operation Lamp Replacement Guide FLIGHT COMPARTMENT 33-10-00 3F11 Instrument and Panel Lights 3F11 Annunciator Panel Lights...
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In addition to navigation lights, standard exterior lighting includes white strobe type anti-collision lights installed in each wing tip. The Warrior III also has a landing/taxi light installed in the nose below the propeller.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL FLIGHT COMPARTMENT Instrument and Panel Lights Instrument post lights, switch lights, and avionics lights are controlled by individual electronic dimmer control assemblies, located on the right side of the airplane, on the back of the firewall. They are operated by HI-LOW adjustment potentiometers located on the instrument panel below the pilot’s control...
Page 540
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Dimmer Control Potentiometer Removal (1) Place BATT MAST switch in OFF position and disengage (pull) BATTERY FEEDER circuit breaker. (2) Disengage (pull) PANEL/SWITCH LIGHTS or RADIO LIGHTS circuit breaker, as appropriate. (3) Remove dimmer control potentiometer control knob by loosening set screw with appropriate size allen wrench.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL EXTERIOR Standard exterior lighting comprises white strobe-type anti-collision lights collocated in each wing tip with navigation lights and a landing/taxi light installed in the nose below the propeller. Optional exterior lighting includes wing tip recognition lights and/or a fin tip strobe.
Page 544
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) Locate lenses over appropriate bulbs and position cover plate over lenses and light fixture. Be sure that the red lens (right wing) or green lens (left wing) is located over the forward bulb (6) Install cover plate over lenses and secure with the two screws removed in Removing Bulbs, above.
Page 545
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fin Tip Strobe Light (Optional) (1) Removal (a) Remove clamp securing lens to mounting plate on fin tip. (b) Remove lens from strobe light assembly. (c) Remove screws securing fin tip to fin.
Page 546
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 36879 AS 104296 K TO DIMMER TO GND L4A20 STROBE LIGHTS L4B20 SWITCH FACE SWITCH CONNECTIONS STROBE CABLE L4C20 BLK (SHIELDED) VIEW A VIEW B POWER SUPPLY SEE VIEW A SEE VIEW B...
Page 547
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL L4G20 STROBE LIGHTS JUMPER L4A20 STROBE L4E20 L4B20 SWITCH FACE SWITCH CONNECTIONS TAIL STROBE OPTION SEE VIEW B POWER SUPPLY SEE VIEW A POWER 1 (+) TAIL WING WING 2 (-) TRIGGER I.E.
Page 548
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Troubleshooting Strobe Lights When troubleshooting the strobe light system, it must first be determined if the trouble is in the flash tube or the power supply. Replacement of the flash tube will confirm if the tube is defective. A normally operating power supply will emit an audible tone of 1 to 1.5 KHZ.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER NAVIGATION PITOT / STATIC...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 34 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 34-50-00 Nov 30/06 34-List of Nov 30/06 Effective Pages Nov 30/06 Nov 30/06 Nov 30/06 34-Table of Contents...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 34 - NAVIGATION AND PITOT / STATIC TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 34-00-00 FLIGHT ENVIRONMENT DATA 34-10-00 Pitot / Static System Vertical Speed Indicator 3G11 Description and Operation...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 34 - NAVIGATION AND PITOT / STATIC TABLE OF CONTENTS (continued) SUBJECT SECTION PAGE GRID NO. ATTITUDE AND DIRECTION (cont.) 34-20-00 Turn Coordinator 3H20 Description and Operation 3H20 Troubleshooting 3H20 DEPENDENT POSITION DETERMINING...
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MAINTENANCE MANUAL GENERAL WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) These airplanes are equipped with conventional air, vacuum, and electrically driven flight instruments as standard equipment.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL FLIGHT ENVIRONMENT DATA Pitot-Static System The pitot air system consists of a pitot mast on the underside of the left wing with its related plumbing. Impact air pressure entering the pitot is transmitted from the pitot inlet through hose and tubing routed through the wing to the airspeed indicator (and Avidyne Entegra PFD, if installed) on the instrument panel.
Page 560
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 35493 BX PRIMARY FLIGHT DISPLAY (PFD) (REF.) AIRSPEED INDICATOR (REF.) ALTIMETER (REF.) PITOT STATIC PITOT LINE STATIC LINE ENCODER (REF.) OPTIONAL AVIDYNE ENTEGRA INSTALLATION Effectivity Pitot / Static System Installation with Avidyne Entegra...
Page 561
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Vertical Speed Indicator Description and Operation The vertical speed indicator measures rate of change in static pressure when the airplane is established in a climb or descent. A pointer and dial will show the airplane’s rate of climb or descent in feet per minute.
Page 562
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Altimeter NOTE: For airplanes equipped with the Avidyne Entegra EFIS, the primary altimeter is the Primary Flight Display (PFD). Description and Operation The altimeter indicates pressure altitude in feet above sea level. The indicator has three pointers and a dial scale.
Page 563
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 TROUBLESHOOTING ALTIMETER Trouble Cause Remedy Excessive scale error. Improper calibration adjustment. Replace instrument. Excessive pointer oscillation. Defective mechanism. Replace instrument. Altimeter sticks at altitude or Water or restriction in static...
Page 564
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Airspeed Indicator NOTE: For airplanes equipped with the Avidyne Entegra EFIS, the primary airspeed indicator is the Primary Flight Display (PFD). Description and Operation The airspeed indicator reads the speed of the airplane passing through the air. Airspeed indication is the differential pressure reading between pitot air pressure and static air pressure.
Page 565
Outside Air Temperature (OAT) Gauge Standard (See Figure 1.) (1) Description and Operation OAT’s are mounted in the pilot’s windshield in Warrior III airplanes and are simple direct measuring thermometers. Although unlit internally, the dial is finished in fluorescent luminescent paint.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL ATTITUDE AND DIRECTION Attitude Deviation Indicator (ADI) / Artificial Horizon NOTE: For airplanes equipped with the Avidyne Entegra EFIS, the primary attitude indicator is the Primary Flight Display (PFD). Description and Operation CAUTION: THE GYRO AIR FILTER MUST BE CLEAN OR REPLACED BEFORE ADJUSTING GYRO AIR PRESSURE.
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NOTE: For airplanes equipped with the Avidyne Entegra EFIS, the primary attitude indicator is the Primary Flight Display (PFD). WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) In S/N’s 2842218 and up, with the optional Avidyne Entegra Electronic Flight Instrument System...
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MAINTENANCE MANUAL Electronic Flight Instrument System (EFIS) WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS. The Avidyne Entegra Electronic Flight Instrument System (EFIS) is available as an option in S/N’s...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 101901-SHT 6-N INSTRUMENT PANEL - LOOKING FWD ALIGNMENT PIN SLOT INSTALL MFD WITH 4 CAPTIVE DZUS FASTENERS INSTALL PFD WITH 4 CAPTIVE SCREWS (TORQUE TO 31 - 32 IN-LBS) STANDBY ATTITUDE INDICATOR...
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PFD. For the Piper installation, however, there is only a single alignment pin on the top of the PFD engaging a slot in the upper rear cross bracket. (See Figure 2, Sheet 1.) (c) In para 7.5.2.2 in “Table 2 - Main RS232 Configuration Page,”...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (d) Aircraft Setup From the MFD maintenance page, depress the LSK (R2) for accessing the Aircraft Setup page. Using the right knob to select the configuration field and the left knob to change the...
Page 576
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 86.03 106.19 123.15 140.09 157.00 174.00 190.90 206.70 24.24 49.25 64.59 PITOT HEAD (REF.) 104.25 SEE DETAIL, BELOW LEFT WING - LOOKING DOWN Effectivity Component Locator with Avidyne Entegra Figure 2 (Sheet 3 of 3)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 101901-SHT 17-N ANTENNA COUPLER WIRING HARNESS INSTALLATION AVIONICS SYSTEM HARNESS ASSY PFD (REF) MFD (REF) GMA-340 P531 J732 (REF) GNS 430 #1 J730 J733 COM ANT J530 J731 GNS 430 #2 (REF)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Directional Gyro Description and Operation The directional gyro (or heading indicator) 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 and be directed against the gyro buckets.
Page 580
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 TROUBLESHOOTING DIRECTIONAL GYRO Trouble Cause Remedy Excess drift in either Setting error. Review paragraph titled direction. “Description” for gyro operation. Defective instrument. Replace instrument. High or low vacuum. If vacuum...
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PA-28-161, WARRIOR III MAINTENANCE MANUAL Magnetic Heading Systems WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) King KCS-55A Slaving Compass (with HSI) (PIR-PPS60081, Rev.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 104737 A 101259 K LEFT WING EDGE, TOP VIEW, LOOKING DOWN LEFT WING VIEW, LOOKING INBOARD F.S. 106.628 SCREW, (REF.) WASHER (3 REQ.) W.S. 207.40 (REF.) FLUX DETECTOR HARNESS SCREW, WASHER, NUT (6 REQ.)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (c) Place the aircraft on the South compass rose heading. Rotate the indicator card to South using the manual slave buttons on the slaving control. With a non-magnetic screwdriver in the N/S opening on the slaving control, adjust to remove one-half (1/2) of the existing deviation shown by the slave meter.
Page 584
(2) Magnetic Heading Compensation / Calibration (PIR-PPS60191, Rev. New.) WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION SUPPLEMENTARY PUBLICATIONS.) Accuracy of the entire heading system is dependent on the location of the flux detector and proper calibration.
Page 585
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 3 DEVIATION CHART Approx. Magnetic Actual Magnetic Heading Card Heading Heading Reading Deviation North East South West ST-180 Deviation Graphs Figure 5 34-20-00 PAGE 17 3H17 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Magnetic Compass (1) Description and Operation The magnetic compass is a self-contained instrument. The compass card is mounted on two magnets, which tend to align themselves with the Earth’s magnetic field, permitting the compass to use Earth’s magnetic north as a reference.
Page 587
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (3) Adjustment Before attempting to compensate compass, place the aircraft in simulated flight conditions. Check to see that the doors are closed, flaps in retracted position, engine running, throttle set at 1000 rpm or low idle, and aircraft in level flight attitude. Aircraft master switch, alternator switch and all radio switches should be in the ON position.
Page 588
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Turn Coordinator Description and Operation These airplanes are equipped with an electric turn coordinator, which indicates both rate of turn and rate of roll. NOTE: The conventional turn and slip indicator is available as an option.
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MAINTENANCE MANUAL DEPENDENT POSITION DETERMINING COM/NAV/GPS WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) In S/N’s 2842064 and up, single or dual Garmin GNS-430 COM/NAV/GPS systems may be installed.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) Configuration Setup Procedure Access the Configuration Mode of the unit by depressing and holding the ENT key while applying power to the unit. Release the ENT key when the display activates. After the data base pages, press the ENT key twice to display the MAIN ARINC 429 CONFIG page.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (b) Main RS-232 CONFIG Page In S/N’s 2842001 and up, deselect the cursor and rotate the inner concentric knob on the right side of the unit to display the MAIN RS232 CONFIG page. Configure both the GNS #1 and #2 as follows: NOTE: For single GNS 430 installations, all channels will be configured to the “OFF”...
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PA-28-161, WARRIOR III MAINTENANCE MANUAL Transponder WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) S/N’s 2842001 thru 2842108 A Garmin GTX-320 Transponder is installed as standard equipment. Maintenance of the GTX-320 is “on condition”...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (a) Configuration Menu The JUMP TO menu page provides the capability to select a configuration mode starting page without having to step through all of the pages. Press the CRSR key and sequence through to the desired section with the 8 and 9 keys.
Page 596
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 2 VOICE AND VOLUME Function Selection Description VOLUME VOICE MALE MESSAGE (0-5) Selected Audio Tones and Messages 0 = Toggle a continuous tone on and off 1 = Attention Tone, precedes voice messages to attract the pilot’s attention.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 4 ARINC 429 CONFIGURATION PAGE GTX 330 429 INPUT SPEED DATA CHANNEL 1 HIGH GPS/FMS CHANNEL 2 HIGH CHANNEL 3 CHANNEL 4 429 OUTPUT DATA CHANNEL 1 CHANNEL 2 GARMIN W/TIS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Non-US Registered Aircraft For entering Non-U.S. Aircraft Registration, press the CRSR key one time, then 8 or 9 to select ADDRESS HEX. Non-U.S. Aircraft Registry normally supplies a 24 bit binary code, known as the ICAO Aircraft Code for the Mode S address in lieu of directly entering the N# for U.S.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER VACUUM 3I11...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 37 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 37-List of Nov 30/06 Effective Pages Nov 30/06 37-Table of Contents Nov 30/06 Nov 30/06 37-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 37 - VACUUM TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 37-00-00 3I17 Description and Operation 3I17 Troubleshooting 3I17 DISTRIBUTION 37-10-00 3I21 Hoses and Clamps 3I21 Gyro Filter 3I21 Vacuum Pump...
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In S/N’s 2842218 and up, for airplanes equipped with the optional Avidyne Entegra EFIS: vacuum system is installed. The air driven gyro instrumentation in Warrior III airplanes gives quick and actual indication of airplane attitude, performance, and condition. Maintenance, other than described, must be done by the instrument manufacturer or an authorized repair station.
Page 608
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 1 of 2) TROUBLESHOOTING VACUUM SYSTEM Trouble Cause Remedy No vacuum gauge indication Filter clogged or dirty. Clean or replace filter. at instrument. Line from gyro to filter restricted.
Page 609
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 2 of 2) TROUBLESHOOTING VACUUM SYSTEM Trouble Cause Remedy * AUX ON selected on ground Circuit breaker open. Push circuit bleaker(s) in. check and auxiliary vacuum pump will not run.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL DISTRIBUTION The following information is intended to aid in diagnosing vacuum system service symptoms on those components which are serviced by removal and replacement - I.E. - hoses, clamps, gyro filters, vacuum pumps, and vacuum regulators.
Page 612
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Vacuum Pump NOTE: In S/N’s 2842218 and up, for airplanes equipped with the optional EFIS: no vacuum system is installed. A single engine-driven dry-air pump is mounted on the accessory section at the rear of the engine. The vacuum pump is a rotar y vane, positive displacement type.
Page 613
(1) If required, install fittings on pump per Replacing Pump Fittings, below. CAUTION: ONLY PUMP MOUNTING GASKET AUTHORIZED AND APPROVED FOR USE ON AIRBORNE VACUUM PUMP IS AIRBORNE GASKET B3-1-2, PIPER PART NUMBER 751-859. USE OF ANY OTHER GASKET MAY RESULT IN OIL SEEPAGE OR LEAKAGE AT MOUNTING SURFACE.
Page 614
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Vacuum Regulator One (1) vacuum regulator is incorporated in the system to control vacuum pressure to gyro instruments. The regulator is located under the instrument panel. Service Tips (1) Vacuum regulators seldom need replacement. Symptoms that suggest replacement are: (a) Chatter as indicated by rapid fluctuation of vacuum gauge needle or an audible sound.
Page 615
The auxiliary vacuum pump installation has a 24 Vdc pump motor and relay. The VAC OFF AUX ON switch is located on the extreme left instrument panel on the Warrior III. CAUTION: REPLACE AUXILIARY VACUUM PUMP/MOTOR ASSEMBLY WITH A NEW, WORKING UNIT, OR SEND UNIT TO VENDOR FOR REPAIR.
Page 616
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation WARNING: BE SURE BATTERY MASTER SWITCH IS OFF. CAUTION: NEVER INSTALL A PUMP THAT HAS BEEN DAMAGED OR DROPPED. CAUTION: THE ELAPSED TIME INDICATOR IS MATCHED TO THE PUMP/MOTOR ASSEMBLY AND MUST BE REMOVED AND REPLACED WITH THE PUMP/MOTOR ASSEMBLY.
Page 617
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Auxiliary Vacuum Pump Installation (Optional) Figure 2 37-10-00 PAGE 7 Nov 30/06...
Page 618
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL JUMPER MOTOR V7A14 FILTER 373-19 373-17 F7-64-1 RELAY 373-15 373-13 PUMP V6A20 (FRONT VIEW) VAC OFF AUX ON SWITCH (REAR VIEW) V5A20 V4A20 MANIFOLD JUMPER ETI ASSEMBLY V3C20 V3B20 V1A20 V3A20 V2A20...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INDICATING The following information is intended to aid in diagnosing vacuum system service symptoms on those components which are serviced by removal and replacement (i.e. - vacuum gauges and switches). Vacuum (Suction) Gauge The suction gauge is mounted on the left side of instrument panel.
Page 622
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Vacuum Switch A vacuum switch is mounted on the vacuum regulator. It activates the VACUUM INOP annunciator light when the suction from the vacuum pump drops below 3.5 psig. Removal (1) Disconnect the two electrical leads.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ELECTRICAL / ELECTRONIC PANELS 3J11...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 39 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 39-List of Nov 30/06 Effective Pages Nov 30/06 39-Table of Contents Nov 30/06 Nov 30/06 39-10-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 39 - ELECTRICAL / ELECTRONIC PANELS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. INSTRUMENT AND CONTROL PANELS 39-10-00 3J17 General 3J17 Face-Mounted Instruments 3J17 Removal 3J17 Installation 3J17 Rack-Mounted Avionics...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INSTRUMENT AND CONTROL PANELS General Face-Mounted Instruments Most instruments are face-mounted and secured to the instrument panel by screws from the front of the panel. Most instruments are removed out the back of the panel, but a few are removed through the front of the panel.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Instrument Panel (Typical) Figure 1 PAGE 2 39-10-00 Nov 30/06 3J18...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) Installation NOTE: Inspect the front of the panel-mounted avionics tray/rack to verify it is not significantly inset from the panel. If so, correct the tray/rack installation before proceeding. NOTE: The high insertion forces required to seat a unit with “high density” connectors tend to limit the effectiveness of the first seating attempt.
Page 634
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Switches All switches are rocker-type and are located centrally in the instrument panel. CAUTION: ALTHOUGH SMALL SWITCH ASSEMBLIES ARE EASIER TO REMOVE IF WIRING IS FIRST DISCONNECTED, THE LIMITED WORK SPACE BEHIND THE PANEL CAN RESULT IN BURNED WIRE INSULATION.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL ELECTRICAL & ELECTRONIC EQUIPMENT The following illustrations depict the location and installation of various electrical/electronic components. Index Component Figure 1, Sheet No. Annunciator Box Assembly Annunciator Dimmer Assembly Avionics Cooling Blower Battery Contactor...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 85360 T 101911 V 104304 J 8, 11 2, 10 9, 10 ITEM NUMBERS ARE KEYED TO FIGURE SHEET NUMBER Electrical/Electronic Component Locator Figure 1 (Sheet 1 of 12) PAGE 2 39-20-00...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL F1E20 F1C20 LIFT SENSOR LOOKING INBOARD STALL HORN UNDER INSTRUMENT PANEL LOOKING LEFT FROM AIRCRAFT CENTERLINE ROTATED 180° Electrical/Electronic Component Locator Figure 1 (Sheet 2 of 12) 39-20-00 PAGE 3 Nov 30/06...
Page 640
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TO BATTERY CONTACTOR NIPPLE BATTERY GROUND WIRE P1A4 STARTER CONTACTOR NIPPLE Q2C20 TO STARTER K2A4 SLEEVE (K2B4) ENGINE GROUND FUEL PUMP S/N’S 2842001 THRU 2842217 TO BATTERY CONTACTOR BATTERY GROUND WIRE NIPPLE...
Page 641
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL FUSE ASSY BATTERY CONTACTOR M2C20 P1D4 M1B20 P4AA20 BLACK TO STARTER CONTACTOR S/N’S 2842001 THRU 2842217 BATTERY CONTACTOR M1B20 L11B20 P1D4 FUSELAGE HARNESS ASSEMBLY P4A20 BLACK TO STARTER CONTACTOR S/N’S 2842218 AND UP...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (P312) CONTROLLER (3) RADIO (P313) PANEL (P314) SWITCH LIGHT DIMMER INSTALLATION UNDER INSTRUMENT PANEL, RIGHT SIDE, LOOKING FORWARD Electrical/Electronic Component Locator Figure 1 (Sheet 5 of 12) PAGE 6 39-20-00 Nov 30/06...
Page 643
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (BLACK) P2C20 ALTR OUT (BLUE) SWITCH S/N’s 2842001 THRU 2842217 (RED) VOLTAGE REGULATOR (GREEN) (RED) (W2D20) (W2B20) PRIMER SWITCH RELAY GROUND BLOCKS ALTR OUT SWITCH (RED WIRE) (W2D20) (W2B20) TRIM MONITOR (REF) S/N’s 2842218 AND UP...
Page 644
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL R-4AMM PITOT HEAT SENSOR ASSY. P-AMM (OPT) GND WIRES TO DIMMER CONTROLS CONTROL ASSY GROUND BLOCK GROUND BLOCK S/N’S 2842001 THRU 2842217 (J310) PITOT HEAT SENSOR ASSY. (J311) AVIONICS COOLING BLOWER LOW VOLTAGE MONITOR ASSY.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL W.L. 47.450 BRACKET (REF.) STANDBY ALTERNATOR REGULATOR FORWARD OF INSTRUMENT PANEL, RIGHT SIDE, LOOKING OUTBOARD CURRENT LIMITER CURRENT SENSOR ASSY. (TO STANDBY ALTERNATOR) (SP1A10 TO AMMETER SHUNT) (TO VOLTAGE REGULATOR) LOOKING AFT AT LEFT SIDE FIREWALL...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL ANNUNCIATOR BOX ASSEMBLY S/N’s 2842001 THRU 2842217 128.737 FRAME ASSEMBLY - RIGHT LOOKING AFT CABIN FLOOR FUSELAGE HARNESS ANNUNCIATOR DIMMER ASSEMBLY (W12A20N) (P302) (J302) S/N’s 2842218 AND UP 128.737 FRAME ASSEMBLY - RIGHT...
Page 647
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (E7T22) (E7S22) EXCEEDANCE HORN BRACKET BRAKE CHANNEL UNDER INSTRUMENT PANEL, LOOKING INBOARD, FROM LEFT S/N’s 2842218 AND UP FUSELAGE HARNESS CABIN FLOOR S/N’s 2842218 AND UP 128.737 FRAME ASSEMBLY - LEFT WITH AVIDYNE ENTEGRA...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL EGT SENSOR (PROBE) (YELLOW) (WHITE) (RED) (TO DAU) (GREEN) FRONT LEFT CYLINDER, LOOKING INBOARD S/N’s 2842218 AND UP TO ALT (P3A4) TO BUS (P3B4) SHUNT TO CURRENT LIMITER (SP1A10) AMMETER AMMETER (-) (-)
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL W6B20N M3C20 W6A20 OIL PRESSURE SWITCH C NC FIREWALL OIL PRESSURE SENDER LOOKING DOWN Electrical/Electronic Component Locator Figure 1 (Sheet 12 of 12) 39-20-00 PAGE 13 3K11 Nov 30/06...
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AIRPLANE MAINTENANCE MANUAL CARD 4 OF 5 PA-28-161 (S/N’s 2842001 & UP) PIPER AIRCRAFT, INC. PART NUMBER 761-882 November 30, 2006...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL AEROFICHE REVISION STATUS Revisions to this Maintenance Manual (P/N 761-882) originally published March 1, 1998 are as follows: Effectivity Publication Date Aerofiche Card Effectivity ORG980301 March 1, 1998 PR011215 December 15, 2001...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE Intro-List of Nov 30/06 Effective Pages Nov 30/06 Intro-Table of Contents Nov 30/06 Nov 30/06 Introduction Nov 30/06 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity 4A10 Serial Number Explanation 4A10 Assignment of Subject Material 4A10 Pagination 4A11 Aerofiche Effectivity 4A11 Identifying Revised Material...
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Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even though identical in appearance, may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane.
Page 660
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Effectivity This maintenance manual is effective for PA-28-161 Warrior III airplane serial numbers 2842001 and up. This encompasses the following model years: NOTE: The following is provided as a general reference only. Model Year...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Pagination The Chapter - Section (i.e. - 28-40-00) numbering system (explained above) forms the primary page numbering system for this manual. Within each Section, pages are numbered consecutively beginning with Page 1 (i.e. - 28-40-00, Page 1). Additionally, the aerofiche grid numbering system (explained below) is also used to indicate location within the manual.
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MAINTENANCE MANUAL 12. Accident/Incident Reporting To improve our Service and Reliability system and aid in Piper’s compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (11) NAVIGATION, COMMUNICATIONS, AND GPS (NAV/COM/GPS): Vendor: Garmin International PH: - (913) 397-8200 1200 East 151ST Street Olathe, KS 66062 http://www.garmin.com (12) PROPELLER: Vendor: Sensenich Corporation - (717) 569-0435 14 Citation Lane...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 14. Chapter/Section Index Guide NOTE: The following GAMA Specification No. 2 standard chapters are not included in this Maintenance Manual: 22, 26, 29, 35, 36, 38, 49, 54, 60, 72, 75, 76, 81, and 83. These chapters are omitted because the subject system is either: not installed in these airplanes;...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. STANDARD PRACTICES - AIRFRAME General Corrosion Painting ENVIRONMENTAL SYSTEMS General Distribution Heating COMMUNICATIONS 2C19 General Audio Integrating Static Discharging ELECTRICAL POWER General DC Generation External Power Electrical Load Distribution...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. INDICATING / RECORDING SYSTEMS 3C15 Central Warning Systems LANDING GEAR General Main Gear Nose Gear Wheels and Brakes LIGHTS General Flight Compartment Exterior NAVIGATION AND PITOT/STATIC Flight Environmental Data...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. WINDOWS Flight Compartment Passenger Compartment WINGS 4G13 General Main Frame Auxiliary Structure Attach Fittings Flight Surfaces PROPELLER 4H21 Propeller Assembly STANDARD PRACTICES - ENGINE General POWER PLANT...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. 5E17 Distribution Indicating STARTING Cranking CHARTS & WIRING DIAGRAMS 5F21 Charts 21 & Up Wiring Diagrams (Schematics) INTRODUCTION PAGE 13 4A21 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STRUCTURES...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 51 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 51-List of Nov 30/06 Effective Pages Nov 30/06 51-Table of Contents Nov 30/06 Nov 30/06 51-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 51 - STRUCTURES TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 51-00-00 Description INVESTIGATION, CLEANUP AND AERODYNAMIC SMOOTHNESS 51-10-00 4C11 Corrosion Control 4C11 Forms of Corrosion 4C11 Conditions Affecting Corrosion...
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(see Figure 1) is riveted. NOTE: The Warrior III Parts Catalog, P/N 761-897, provides detailed views of the individual structural components. Windows include a single pane windshield and six side windows. All windows are single pane. A storm window is located in the forward lower section of the left window and can be opened inward when the latch is released.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Skin Materials and Thickness Figure 1 PAGE 2 51-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INVESTIGATION, CLEANUP AND AERODYNAMIC SMOOTHNESS Corrosion Control Corrosion is the deterioration of metal by chemical or electrochemical attack. Water which is allowed to remain on the aircraft and industrial pollution are the major causes of corrosion in aircraft. The two general types of corrosion are: -- Direct chemical attack (i.e.
Page 690
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) A clean aircraft will resist corrosion better than a dirty one. Cleaning frequency depends on several factors, including geographical location, type of operation, etc. Remove soil as soon as possible, especially when in a high temperature area.
Page 691
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Inspection CAUTION: INSPECTION FOR CORROSION MUST BE PERFORMED BY PERSONS FAMILIAR WITH CORROSIVE PROBLEMS AND REMEDIES. NOTE: Some areas of the airplane have been treated with a corrosion inhibiting compound which requires re-treatment at five (5) year intervals. See Each Five (5) Years, Per Calendar Year, 5-30-00.
Page 692
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) Evaluate corrosion damage to determine type and extent of repairs required. Proceed as follows: (a) Light Corrosion: discoloration or pitting. Remove by light hand sanding or a small amount of chemical treatment.
Page 693
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (10) Check and clean drain holes regularly. (11) Battery compartment and vent openings are especially prone to corrosion due to spilled electrolyte. Fumes from overheated battery electrolyte will spread to adjacent areas and cause rapid corrosion of unprotected surfaces.
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Also covered are Fracture and Patch Repairs such as puncture, breaks and holes that have penetrated through the structure and damaged the fiberglass cloth. A repair kit, Piper P/N 766-222, that contains the necessary material for such repairs, is available through Piper Distributors.
Page 698
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (8) Pour out a small amount of resin, add catalyst and mix thoroughly, using a cutting motion rather than stirring. Use no fibers. (9) Using the tip of a putty knife or fingertips, fill the hole to about .062 of an inch above the surrounding surface with the gel coat mixture.
Page 699
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (13) As soon as the patch begins to set up, but while still rubbery, take a sharp knife and cut away extra cloth and mat. Cut on outside edge of feathering. Strip cut edges of structure. Do this before cure is complete, to save extra sanding.
Page 700
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Surface Scratches - Abrasions or Ground in Dirt Figure 1 Deep Scratches, Shallow Nicks and Small Holes Figure 2 PAGE 4 51-70-00 Nov 30/06 4C22...
Page 701
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 LIST OF MATERIALS (THERMOPLASTIC REPAIRS) Items Descriptions Suppliers Buffing and Rubbing Automotive Type - DuPont #7 DuPont Company Compounds Ram Chemical #69 x 1 Ram Chemicals Mirror Glaze #1 Mirror Bright Polish Co., Inc.
Page 702
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Mixing of Epoxy Patching Compound Figure 3 Welding Repair Method Figure 4 PAGE 6 51-70-00 Nov 30/06 4C24...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Cracks (See Figure 5.) (1) Before repairing a crack in the thermoplastic part, first determine what caused the crack and alleviate that condition to prevent it from recurring after the repair is made.
Page 704
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Various Repairs Figure 6 PAGE 8 51-70-00 Nov 30/06...
Page 705
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stress Lines (See Figure 7.) (1) Stress lines produce a whitened appearance in a localized area and generally emanate from the severe bending or impacting of the material (see Figure 8). (2) To restore the material to its original condition and color, use a hot air gun or similar heating device and carefully apply heat to the affected area.
Page 706
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Repair of Impacted Damage Figure 8 PAGE 10 51-70-00 Nov 30/06...
Page 707
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Pressure Sensitive Safety Walk Installation (PIR-PPS45010, Rev. F.) Pressure sensitive safety walk (i.e. - non-skid) is installed on the right wing root, right inboard flap end, and the top of the boarding step to provide a secure non-slip path to the cabin door.
Page 708
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Metal / Wire Stitching Repair (See Figure 9.) (PIR-PPS20024, Rev. A.) CAUTION: METAL/WIRE STITCHING (AND THE ALTERNATE METHOD OF JOINING DESCRIBED BELOW) SHALL ONLY BE USED FOR NON-STRUCTURAL, NON-LOAD CARRYING APPLICATIONS. A metal/wire stitching process is used to staple fabric and rubber seal materials to engine baffles and some composite materials.
Page 709
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Metal / Wire Stitching Repair Figure 9 51-70-00 PAGE 13 Nov 30/06...
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Page 713
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL ELECTRICAL BONDING General (See also 23-60-00.) (PIR-PPS55006, Rev. T.) All electrical and electronic equipment and specified components shall be installed in such a manner as to provide a continuous low resistance path (bonds) from the equipment enclosure/component to the airplane structure.
Page 714
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 ELECTRICAL BONDING RESISTANCE INDEX Maximum Allowable Component Resistance Value in Ohms Engine Mount(s) .003 Generator(s) .010 Ailerons .003 Elevator / Stabilator .003 Rudder .003 Alternator(s) .010 Trim Tab(s) Conventional Hinge .003...
Page 715
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL VOLT METER AIRCRAFT STRUCTURE SURFACE COMPONENT SURFACE BONDING STRAP Adjust rheostat (R1) so that ammeter (A) reads 10 Amps. 28 VDC SOURCE Resistance in milliohms is then the reading on the volt meter (i.e. - millivolts (MV)) divided by the amps (10) set on the ammeter.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER DOORS 4D15...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 52 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 52-List of Nov 30/06 Effective Pages Nov 30/06 52-Table of Contents Nov 30/06 Nov 30/06 52-10-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 52 - DOORS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. PASSENGER/CREW 52-10-00 4D21 Cabin Door 4D21 Removal 4D21 Installation 4D21 Adjustment 4D21 Door Latch Mechanism (Lower Latch) 4D21 Removal 4D21...
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Page 723
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL PASSENGER / CREW Cabin Door Removal (1) Remove the clevis bolt, washer and bushing from the door holder assembly. (2) Remove cotter pins, clevis pins and washers from door hinges. (3) Remove the door from the airplane.
Page 724
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Door Lock Assembly Removal (1) Remove the door trim upholstery by removing the attachment screws. (2) Loosen the nut on the lock assembly and remove the lock by turning it sideways. Installation (1) Install the lock in the door by turning it sideways and placing it through the opening provided.
Page 725
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Door Snubber Seal Installation Figure 1 52-10-00 PAGE 3 4D23 Nov 30/06...
Page 726
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) Apply adhesive to inside surface of snubber. (5) Position snubber with protruding leg facing outboard beginning at lower center of door jamb and work progressively around jamb applying pressure to snubber to remove any trapped air and to ensure a proper bond.
Page 727
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Page 729
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CARGO Baggage Door Removal With the door open remove the hinge pin from the hinge and remove the door. Installation Place the door in position so that the hinge halves are properly matched and install the hinge pin. It will not be necessary to replace the hinge pin with a new pin if it is free of bends and wear.
Page 730
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fabricated Tool for Baggage Door Lock Figure 1 PAGE 2 52-30-00 Nov 30/06...
Page 731
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Page 733
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER FUSELAGE...
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Page 735
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 53 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 53-List of Nov 30/06 Effective Pages Nov 30/06 53-Table of Contents Nov 30/06 Nov 30/06 53-20-00 Nov 30/06...
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Page 738
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 53 - CONTENTS Nov 30/06 4E12...
Page 739
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL MAIN Aft Wing Attach Fittings 100 Hour Inspection Background Should the seals for the windows and doors not be maintained, leaks may develop which, if not corrected, will allow an ingress of water. This water contamination will wet the insulation around the aft wing attach fittings creating a highly corrosive environment.
Page 740
(a) If corrosion is superficial and there is no metal flaking and/or pitting, clean and paint fittings, using a good quality aircraft primer. (b) If serious corrosion is found, consult the Piper Illustrated Parts Catalog (P/N 761-897) for replacement part numbers and obtain and install new parts before next flight. See Aft Wing Attach Fittings Replacement, below.
Page 741
NOTE: The following is basic guidance. More extensive disassembly may be required to remove the rear attach fitting(s). Thoroughly access the job before beginning to determine if additional steps or parts may be required. Consult the Piper Illustrated Parts Catalog (P/N 761-897) for additional parts as required.
Page 742
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Page 743
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STABILIZERS 4E17...
Page 744
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Page 745
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 55 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 55-List of Nov 30/06 Effective Pages Nov 30/06 55-Table of Contents Nov 30/06 Nov 30/06 55-00-00 Nov 30/06...
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Page 747
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 55 - STABILIZERS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 55-00-00 4E23 Description 4E23 Repairs 4E23 Control Surface Balancing 4E23 Checking Balance 4E23 Balancing Equipment STABILATOR 55-20-00 Checking Free Play...
Page 748
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Page 749
The stabilator also incorporates a one channel main spar that runs the full length of the stabilator and hinges to the aft bulkhead assembly of the fuselage. NOTE: The Warrior III Parts Catalog, P/N 761-897, provides detailed views of the individual structural components.
Page 750
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Empennage Installation Figure 1 (Sheet 1 of 2) PAGE 2 55-00-00 Nov 30/06 4E24...
Page 751
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Empennage Installation Figure 1 (Sheet 2 of 2) 55-00-00 PAGE 3 Nov 30/06...
Page 752
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Balancing Equipment (Refer to Figure 2.) 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 configuration is shown in Figure 2.
Page 753
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Control Surface Balancing Tool Figure 2 55-00-00 PAGE 5 Nov 30/06...
Page 754
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Page 755
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL STABILATOR CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. LIMITED REPAIRS TO STABILATOR BOTTOM SKINS ARE AUTHORIZED ONLY AS PROVIDED IN THIS MANUAL. Checking Free Play...
Page 756
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (8) Disconnect the trim assembly from the aft bulkhead of the fuselage by removing the attaching nuts, washers and bolts of the horizontal and diagonal support brackets. (9) Move the trim assembly up through the tail cone fairing cutout in the stabilator and remove, with cable, from the airplane.
Page 757
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Methods of Securing Control Cables Figure 1 55-20-00 PAGE 3 Nov 30/06...
Page 758
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Balancing Stabilator Figure 2 Balancing (See Control Surface Balancing, 55-00-00, and Figure 2.) (PIR-PPS50015, Rev. AC.) WARNING: ALL CONTROL SURFACES THAT HAVE BEEN REPLACED, REPAINTED, OR REPAIRED AS AUTHORIZED IN THIS MANUAL, MUST BE BALANCED BEFORE INSTALLATION.
Page 759
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stabilator Attach Brackets (Typical) Figure 3 Attach Brackets Corrosion Control Inspection (Refer to Figure 3.) During each annual inspection, and each time the stabilator is removed, use the following method to inspect stabilator attach brackets for rust and corrosion between the steel attach fittings and the adjacent fuselage structure.
Page 760
NOTE: This repair is authorized only as a temporary measure until replacement parts (i.e. - skins) can be obtained and installed. Repair of minor cracks in Warrior III stabilator skin surfaces is authorized, but limited as follows: CAUTION: BEAD CRACK REPAIRS ON TOP SURFACE STABILATOR SKINS ARE NOT AUTHORIZED.
Page 761
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Page 762
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Page 763
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL VERTICAL STABILIZER Vertical Fin (Refer to 55-00-00, Figure 1.) Removal (1) 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 764
NOTE: This repair is authorized only as a temporary measure until replacement parts (i.e. - skins) can be obtained and installed. Repair of minor cracks in Warrior III vertical fin skin surfaces is authorized, but limited as follows: (1) Cracks of no more that 0.5 inch at the ends of the skin stiffening beads;...
Page 765
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Page 767
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL RUDDER CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. LIMITED REPAIRS TO RUDDER SKINS ARE AUTHORIZED ONLY AS PROVIDED IN THIS MANUAL. Rudder (Refer to 55-00-00, Figure 1.) Removal (1) Remove the screws from around the upper tail cone fairing assembly and remove the fairing.
Page 768
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Balancing Rudder Figure 1 Balancing (See Control Surface Balancing, 55-00-00, and Figure 1.) (PIR-PPS50015, Rev. AC.) WARNING: ALL CONTROL SURFACES THAT HAVE BEEN REPLACED, REPAINTED, OR REPAIRED AS AUTHORIZED IN THIS MANUAL, MUST BE BALANCED BEFORE INSTALLATION.
Page 769
NOTE: This repair is authorized only as a temporary measure until replacement parts (i.e. - skins) can be obtained and installed. Repair of minor cracks in Warrior III rudder skin surfaces is authorized, but limited as follows: (1) Cracks of no more that 0.5 inch at the ends of the skin stiffening beads;...
Page 770
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 4F20 THRU 4F24 INTENTIONALLY BLANK PAGE 4 55-40-00 Nov 30/06 4F20...
Page 771
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER WINDOWS...
Page 772
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Page 773
PIPER AIRCRAFT, INC. PA-28-181, WARRIOR III MAINTENANCE MANUAL CHAPTER 56 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 56-List of Nov 30/06 Effective Pages Nov 30/06 56-Table of Contents Nov 30/06 Nov 30/06 56-10-00 Nov 30/06...
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Page 775
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 56 - WINDOWS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. FLIGHT COMPARTMENT 56-10-00 Windshield Removal Installation PASSENGER COMPARTMENT 56-20-00 4G11 Side Windows 4G11 Removal 4G11 Installation 4G11 56 - CONTENTS...
Page 776
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Page 777
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL FLIGHT COMPARTMENT Windshield (Refer to Figure 1.) Removal (1) Remove the collars from around the bottom of the windshield and the trim strip from between the windshield halves by removing the attaching screws.
Page 778
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Windshield Installation (Typical) Figure 1 PAGE 2 56-10-00 Nov 30/06...
Page 779
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Page 780
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Page 781
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL PASSENGER COMPARTMENT Side Windows (Refer to Figure 1.) These airplanes are equipped with single pane side windows. Removal (1) Remove retainer molding from around the top and sides of window by removing attachment screws.
Page 782
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Page 783
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER WINGS 4G13...
Page 784
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Page 785
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 57 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 57-List of Nov 30/06 Effective Pages Nov 30/06 57-Table of Contents Nov 30/06 Nov 30/06 57-00-00 Nov 30/06...
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Page 787
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 57 - WINGS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 57-00-00 4G19 Description 4G19 Repairs MAIN FRAME 57-10-00 4G21 Wing Spar Inspection 4G21 W.S. 36.22 Right Side Wing Rib 100 Hour Inspection...
Page 788
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Page 789
NOTE: The major subassemblies of the wing may be removed individually or the wing may be removed as a unit. To remove a wing, a fuselage supporting cradle is required. NOTE: The Warrior III Parts Catalog, P/N 761-897, provides detailed views of the individual structural components.
Page 790
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Page 791
PA-32’s operating in a severe environment and with considerable damage histories. Piper understands that the majority of aircraft are, have been, and will continue to be operated well within the aircraft’s design parameters during all of their operational life.
Page 792
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (c) Usage Class “C” - EXTREME Aircraft which have been damaged due to operations from extremely rough runways, flight in extreme damaging turbulence or other accident/incident which required major repair or replacement of wing(s), landing gear or engine mount.
Page 793
W.S. 36.22 Right Side Wing Rib 100 Hour Inspection In S/N’s 2842001 through 2842178, for airplanes which have not installed Piper Kit No. 767-363, each 100 hours, inspect the rib at W.S. 36.22 in the right wing for cracks.
Page 794
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Effectivity 2842001 thru 2842178 with W.S. 36.22 Right Side Rib Inspection Kit No. 767-363 not installed Figure 1 PAGE 4 57-10-00 Nov 30/06 4G24...
Page 795
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Page 797
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL AUXILIARY STRUCTURE Wing Tip Removal (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 landing light and navigation and strobe light wire assemblies.
Page 798
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Page 799
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL ATTACH FITTINGS Wing NOTE: The major subassemblies of the wing may be removed individually or the wing may be removed as a unit. To remove a wing, a fuselage supporting cradle is required.
Page 800
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Wing Installation Figure 1 (Sheet 1 of 2) PAGE 2 57-40-00 Nov 30/06...
Page 801
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Wing Installation Figure 1 (Sheet 2 of 2) 57-40-00 PAGE 3 Nov 30/06...
Page 802
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL WARNING: DO NOT DRIVE OUT SPAR TO FUSELAGE ATTACH BOLTS. TAKE EXTREME CARE NOT TO DAMAGE BOLTS OR BOLT HOLES. NUMBER BOLTS AND BOLT HOLES TO ENSURE THAT, IF REUSED, THE SAME BOLTS ARE REINSTALLED IN THE SAME HOLES.
Page 803
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CAUTION: BE CERTAIN THAT ALL BOLTS, NUTS AND WASHERS ARE INSTALLED IN ACCORDANCE WITH FIGURE 1 (I.E. - THE BOLT LEGEND AND SKETCHES A, B, C, AND D). (8) Torque the bolt heads on the upper main spar cap and the nuts on the lower main spar cap as specified in Figure 1, bolt legend.
Page 804
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Page 805
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL FLIGHT SURFACES Ailerons (Refer to Figure 1.) CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. LIMITED REPAIRS TO AILERON SKINS ARE AUTHORIZED ONLY AS PROVIDED IN THIS MANUAL.
Page 806
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Aileron and Flap Installation Figure 1 PAGE 2 57-50-00 Nov 30/06 4H12...
Page 807
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Balancing Aileron Figure 2 Balancing (Refer to Figure 2.) NOTE: Read Control Surface Balancing, below, before proceeding. The aileron assembly must be complete including static wicks and all attaching screws. (1) Position the aileron on the balancing fixture in a draft free area and in a manner which allows unrestricted movement of the aileron.
Page 808
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TYPICAL BEAD 0.5 INCH MAX. 0.25 INCH FORE AND AFT TYPICAL CRACK CONTROL SURFACE SKIN CRACK LIMIT LINE Skin Bead Repair Figure 3 Skin Bead Repair (Refer to Figure 3.) CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS.
Page 809
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Control Surface Balancing Checking Free Play (1) Set the aileron in its neutral position and secure. (2) Obtain a straightedge long enough to extend from the ground up to a few inches above the aileron trailing edge.
Page 810
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Control Surface Balancing Tool Figure 4 PAGE 6 57-50-00 Nov 30/06 4H16...
Page 811
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flaps (Refer to Figure 1.) CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. Removal (1) Extend the flaps to their fullest degree and remove the bolt and bushing from the rod end bearing.
Page 812
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Page 814
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Page 815
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER PROPELLERS 4H21...
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Page 817
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 61 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 61-List of Nov 30/06 Effective Pages Nov 30/06 61-Table of Contents Nov 30/06 Nov 30/06 61-10-00 Nov 30/06...
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Page 819
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 61 - PROPELLERS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. PROPELLER ASSEMBLY 61-10-00 Propeller Removal Cleaning, Inspection and Repair Installation Blade Track 61 - CONTENTS PAGE 1 Nov 30/06...
Page 820
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Page 821
OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) The Warrior III is equipped with a Sensenich fixed pitch all metal propeller. Removal (See Figure 2.) WARNING: PROPELLER MAY KICK BACK WHEN ROTATED BY HAND - USE EXTREME CAUTION.
Page 823
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Cleaning, Inspection, and Repair (1) Clean the spinner back plate and propeller surfaces with a non-corrosive solvent, and inspect for nicks, scratches, corrosion and cracks. (2) Nicks in the leading edges of the blades should be filed out and all edges rounded, as cracks sometimes start from such places.
Page 824
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Page 825
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Page 826
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Page 827
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STANDARD PRACTICES - ENGINE...
Page 828
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Page 829
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 70 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 70-List of Nov 30/06 Effective Pages Nov 30/06 70-Table of Contents Nov 30/06 Nov 30/06 70-00-00 Nov 30/06...
Page 830
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Page 831
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 70 - STANDARD PRACTICES - ENGINE TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 70-00-00 4I15 70 - CONTENTS PAGE 1 4I13 Nov 30/06...
Page 832
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Page 833
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GENERAL Review the following suggestions before working on the power plant. To insure proper reinstallation and/or assembly, tag and mark all parts, clips, and brackets as to their location prior to their removal and/or disassembly.
Page 834
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Page 835
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER POWER PLANT 4I17...
Page 836
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Page 837
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 71 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 71-List of Nov 30/06 Effective Pages Nov 30/06 71-Table of Contents Nov 30/06 Nov 30/06 71-00-00 Nov 30/06...
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Page 839
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 71 - POWER PLANT TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 71-00-00 4I23 Description 4I23 Troubleshooting 4I23 Static RPM Equipment Test Procedure Allowable Tolerance Engine 4J11 Removal 4J11 Installation...
Page 840
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 71 - CONTENTS Nov 30/06 4I22...
Page 841
In addition to the previously mentioned components, each engine installed in the Warrior III is equipped with a 28 volt 70 ampere alternator, providing the airplane with a 28 Vdc electrical system. A shielded ignition, vacuum pump drive, fuel pump and starter are also provided.
Page 842
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 1 of 5) TROUBLESHOOTING ENGINE Trouble Cause Remedy Failure of engine to start. Lack of fuel. Check fuel system for leaks. Fill fuel tank. Clean dirty lines, strainers, or fuel cocks.
Page 843
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 2 of 5) TROUBLESHOOTING ENGINE Trouble Cause Remedy Failure of engine to idle Leak in the induction system. Tighten all connections in properly. (cont.) the induction system. Replace any parts that are defective.
Page 844
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 3 of 5) TROUBLESHOOTING ENGINE Trouble Cause Remedy Failure of engine to develop Throttle lever out of adjustment. Adjust throttle lever. full power. Leak in induction system. Tighten all connections and replace defective parts.
Page 845
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 4 of 5) TROUBLESHOOTING ENGINE Trouble Cause Remedy High oil temperature. Insufficient air cooling. Check air inlet and outlet for deformation or obstruction. Insufficient oil supply. Fill oil sump to proper level.
Page 846
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 (Sheet 5 of 5) TROUBLESHOOTING ENGINE Trouble Cause Remedy Inaccurate pressure readings Cold weather. In extremely cold weather, after initial engine start. until engine has warmed to normal operating temperature, oil pressure...
Page 847
This section describes the ground test procedure for determining the maximum static rpm value for the fixed pitched propeller Warrior III. A simplified test procedure is provided first to test static rpm under limited conditions. In the event that the test conditions do not fall within the limits of Chart 710x, proceed to the expanded test procedure.
Page 848
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (d) Allow oil temperature to reach at least 80 degrees F. (e) Record the test static rpm using the Vu-thru tachometer and engine oil temperature. NOTE: If wind speed exceeds 10 knots, record static rpm and oil temperature into the wind, left crosswind, downwind, and right crosswind.
Page 850
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 3 STATIC RPM EXPANDED TEST (SEA LEVEL ± 500 FT PRESSURE ALTITUDE ONLY) PAGE 10 71-00-00 Nov 30/06...
Page 851
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 4 STATIC RPM VS. ENGINE OIL TEMPERATURE 71-00-00 PAGE 11 Nov 30/06...
Page 852
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 5 PSYCHROMETRIC CHART PAGE 12 71-00-00 Nov 30/06 4J10...
Page 853
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Engine Removal (Refer to Figure 1.) CAUTION: PLACE A TAIL STAND UNDER THE TAIL OF THE AIRPLANE BEFORE REMOVING THE ENGINE. (1) Turn off all electrical switches in the cockpit and then disconnect the battery ground wire at the battery.
Page 854
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Engine Installation Figure 1 PAGE 14 71-00-00 Nov 30/06 4J12...
Page 855
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (3) Assemble the engine shock mounts as shown in Figure 2, 71-20-00. Note the position of each mount carefully. The upper right and lower left mounts are installed the same. The upper left and lower right are installed the same.
Page 856
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Page 857
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL COWLING Cowling Installation Figure 1 71-10-00 PAGE 1 4J15 Nov 30/06...
Page 858
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Page 859
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL MOUNTS Engine Shock Mounts (Refer to Figure 1.) Assemble the engine shock mounts on the engine mount as shown in Figure 1. Note the position of each mount carefully. The upper right...
Page 860
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Engine Mount Corrosion Inspection, Immersion in Water The following guidance is general in nature and should be applied or varied to fit the individual situation based on water level during immersion, length of time immersed, length of time since exposure, etc.
Page 861
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Engine Mount Corrosion Inspection Figure 2 71-20-00 PAGE 3 4J19 Nov 30/06...
Page 862
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Page 863
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL AIR INTAKES Carburetor Ice Detector (See Figure 1.) Description The optional carburetor ice detection system is an advisory system only and is designed to alert the pilot to impending engine power loss or stoppage due to ice/frost accumulation inside the carburetor.
Page 864
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Carburetor Ice Detector Figure 1 PAGE 2 71-60-00 Nov 30/06 4J22...
Page 865
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (2) Installation (a) If plug is installed, remove plug from carburetor housing just below throttle valve on the forward side of carburetor. CAUTION: DO NOT BEND PROBE COMPONENTS. (b) Open throttle valve and carefully screw in probe. When installed, index mark on probe housing must face carburetor air inlet.
Page 866
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (b) Procedure Turn ON the power supply and verify supply voltage with the multimeter. Voltage should be between 24-30 volts for 28VDC power supply. Turn the instrument power switch to the ON position. Verify that the RED warning light illuminates and no radiated light is emitted from the probe.
Page 867
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (b) Adjustment Turn ON the power supply and verify supply voltage with the multimeter. Voltage should be between 24-30 volts for 28Vdc power supply. Turn the instrument power switch to the ON position. Verify that the RED warning light illuminates and no radiated light emitted from the probe.
Page 868
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Page 869
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ENGINE FUEL AND CONTROL...
Page 870
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Page 871
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 73 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 73-List of Nov 30/06 Effective Pages Nov 30/06 73-Table of Contents Nov 30/06 Nov 30/06 73-10-00 Nov 30/06...
Page 872
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Page 873
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 73 - ENGINE FUEL AND CONTROL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. DISTRIBUTION 73-10-00 Engine Primer Pump Removal Disassembly, Cleaning, and Assembly Installation Prime Jets 4J10 Removal 4J10 Cleaning...
Page 874
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Page 875
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL DISTRIBUTION Engine Primer Pump (Refer to Figure 1.) Removal (1) Disconnect the fuel lines from the primer behind the instrument panel. (2) Loosen the locknut (12) from behind the panel. (3) Unscrew the knurled face nut (10), and withdraw the pump handle (9) and piston (7) from the cylinder (5).
Page 876
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (7) Place a suitable container under disconnected primer line to catch discharged fuel. Operate the pump to check for proper operation. (8) If pump is operating satisfactorily, connect primer line inside engine compartment.
Page 877
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Page 878
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Page 879
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CONTROLLING WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) Carburetor Maintenance The carburetor requires little attention between overhauls. Check the following items during recommended inspection periods of the engine.
Page 880
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (3) Turn the idle mixture adjusting screw (1) located near the rear of the carburetor, clockwise, leaning the fuel mixture. Continue to do this until the engine begins to run roughly, at which time the engine speed will decrease.
Page 881
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Engine Controls Adjustment Figure 2 73-20-00 PAGE 3 4K15 Nov 30/06...
Page 882
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Page 883
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Page 884
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Page 885
INDICATING Fuel Pressure Gauge The fuel pressure gauge on the PA-28-161, Warrior III is mounted in a 3-in-1 gauge on the instrument panel. Pressure information is transmitted electrically to the fuel pressure gauge by a sender unit clamped to the upper left engine mount. The sender unit is connected by an independent fuel line, to a tee fitting at the carburetor inlet, where it can sense the pressure of fuel entering the carburetor.
Page 886
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 3-IN-1 Engine Instrument Calibration (Fuel Pressure) Figure 1 PAGE 2 73-30-00 Nov 30/06 4K20...
Page 887
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Page 888
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Page 889
AIRPLANE MAINTENANCE MANUAL CARD 5 OF 5 PA-28-161 (S/N’s 2842001 & UP) PIPER AIRCRAFT, INC. PART NUMBER 761-882 November 30, 2006...
Page 891
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL AEROFICHE REVISION STATUS Revisions to this Maintenance Manual (P/N 761-882) originally published March 1, 1998 are as follows: Effectivity Publication Date Aerofiche Card Effectivity ORG980301 March 1, 1998 PR011215 December 15, 2001...
Page 892
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Page 893
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE Intro-List of Nov 30/06 Effective Pages Nov 30/06 Intro-Table of Contents Nov 30/06 Nov 30/06 Introduction Nov 30/06 Nov 30/06...
Page 894
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Page 895
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity 5A10 Serial Number Explanation 5A10 Assignment of Subject Material 5A10 Pagination 5A11 Aerofiche Effectivity 5A11 Identifying Revised Material...
Page 896
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Page 897
Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even though identical in appearance, may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane.
Page 898
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Effectivity This maintenance manual is effective for PA-28-161 Warrior III airplane serial numbers 2842001 and up. This encompasses the following model years: NOTE: The following is provided as a general reference only. Model Year...
Page 899
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Pagination The Chapter - Section (i.e. - 28-40-00) numbering system (explained above) forms the primary page numbering system for this manual. Within each Section, pages are numbered consecutively beginning with Page 1 (i.e. - 28-40-00, Page 1). Additionally, the aerofiche grid numbering system (explained below) is also used to indicate location within the manual.
Page 900
MAINTENANCE MANUAL 12. Accident/Incident Reporting To improve our Service and Reliability system and aid in Piper’s compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
Page 902
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (11) NAVIGATION, COMMUNICATIONS, AND GPS (NAV/COM/GPS): Vendor: Garmin International PH: - (913) 397-8200 1200 East 151ST Street Olathe, KS 66062 http://www.garmin.com (12) PROPELLER: Vendor: Sensenich Corporation - (717) 569-0435 14 Citation Lane...
Page 903
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION PAGE 7 5A15 Nov 30/06...
Page 904
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Page 905
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 14. Chapter/Section Index Guide NOTE: The following GAMA Specification No. 2 standard chapters are not included in this Maintenance Manual: 22, 26, 29, 35, 36, 38, 49, 54, 60, 72, 75, 76, 81, and 83. These chapters are omitted because the subject system is either: not installed in these airplanes;...
Page 906
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. STANDARD PRACTICES - AIRFRAME General Corrosion Painting ENVIRONMENTAL SYSTEMS General Distribution Heating COMMUNICATIONS 2C19 General Audio Integrating Static Discharging ELECTRICAL POWER General DC Generation External Power Electrical Load Distribution...
Page 907
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. INDICATING / RECORDING SYSTEMS 3C15 Central Warning Systems LANDING GEAR General Main Gear Nose Gear Wheels and Brakes LIGHTS General Flight Compartment Exterior NAVIGATION AND PITOT/STATIC Flight Environmental Data...
Page 908
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. WINDOWS Flight Compartment Passenger Compartment WINGS 4G13 General Main Frame Auxiliary Structure Attach Fittings Flight Surfaces PROPELLER 4H21 Propeller Assembly STANDARD PRACTICES - ENGINE General POWER PLANT...
Page 909
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SECTION TITLE GRID NO. 5E17 Distribution Indicating STARTING Cranking CHARTS & WIRING DIAGRAMS 5F21 Charts 21 & Up Wiring Diagrams (Schematics) INTRODUCTION PAGE 13 5A21 Nov 30/06...
Page 910
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Page 916
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Page 917
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER IGNITION...
Page 918
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Page 919
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 74 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 74-List of Nov 30/06 Effective Pages Nov 30/06 74-Table of Contents Nov 30/06 Nov 30/06 74-10-00 Nov 30/06...
Page 920
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Page 921
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 74 - IGNITION TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. ELECTRICAL POWER SUPPLY 74-10-00 Ignition System Description Troubleshooting Replacement Magnetos Overhaul Magnetos 100 Hour Inspection Removal 5C11 500 Hour Inspection and Cleaning...
Page 922
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Page 923
MAINTENANCE MANUAL ELECTRICAL POWER SUPPLY Ignition System WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) Description Ignition of the fuel charge in each cylinder is accomplished by two spark plugs independently excited by one of two Slick 4300 series magnetos.
Page 924
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 TROUBLESHOOTING MAGNETOS Trouble Cause Remedy Failure of engine to start. Defective spark plugs. Clean and adjust or replace spark plugs. Defective ignition wire. Check with electric tester and replace defective wires.
Page 925
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Magnetos 100 Hour Inspection Every 100 hours or at annual inspection, whichever comes first, perform the following checks. WARNING: BE SURE IGNITION SWITCH IS IN THE “OFF” POSITION AND THE CONDENSER P-LEAD IS GROUNDED.
Page 926
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL WARNING: DO NOT ROTATE PROPELLER WHEN IGNITION SWITCH IS IN THE “ON” POSITION. THE MAGNETOS WILL FIRE THE SPARK PLUGS IF THE PROPELLER IS ROTATED - FATAL INJURY IS POSSIBLE. (d) Turn ignition switch ON.
Page 927
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Removal CAUTION: ASCERTAIN THAT THE PRIMARY CIRCUIT OF THE ENGINE IS GROUNDED BEFORE WORKING ON THE ENGINE. Before removing the magnetos, make sure the magneto switches are OFF. WARNING: THE MAGNETO IS NOT INTERNALLY GROUNDED, WHEN THE GROUND LEAD IS DISCONNECTED THE MAGNETO IS HOT.
Page 928
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (d) Inspect impulse coupling pawl latching ends (see Figure 4). If rounded, peened, or excessively worn, replace impulse coupling. NOTE: Stringers, inclusions, and heat checks may appear on the surfaces of impulse coupling components.
Page 929
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Contact Points Figure 6 (5) Inspect coil for visible radial cracks. Replace coil if cracks evident. Inspect coil for primary and secondary circuit resistance and continuity, as follows: primary coil - .50 to 1.2 ohms;...
Page 930
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (c) Inspect the distributor block for cracks or other physical damage. Replace, as required. (d) Inspect the brass electrode posts for signs of physical wear. Replace block assembly, as required, but note that during normal operation, the post will experience an electrical- metal transfer with the distributor gear electrode.
Page 931
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Slick T-100 Assembly and Timing Tool Kit Figure 8 74-10-00 PAGE 9 5C15 Nov 30/06...
Page 932
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Exploded View of 4300 Series Magneto Figure 9 PAGE 10 74-10-00 Nov 30/06 5C16...
Page 933
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Disassembly (see Figures 8 and 9.) NOTE: Use of the Slick T-100 Assembly and Timing Kit (Figure 8) is strongly recommended. The tools contained in this kit will greatly facilitate magneto disassembly/assembly and help prevent damage to parts.
Page 934
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (9) Remove bearings from shaft and discard CAUTION: DO NOT DISASSEMBLE BEARING CAP ASSEMBLY SLICK PART NUMBER M-3485. THIS ASSEMBLY HOLDS A DOUBLE-SHIELDED BEARING CAPTIVE IN THE BEARING CAP AND IS PRE-LUBRICATED AT THE FACTORY WITH SPECIAL GREASE THAT TOLERATES THE OZONE RICH ENVIRONMENT WITHIN THE MAGNETO.
Page 935
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installing Bearings Figure 11 (2) Install rotor shaft assembly (see Figure 11.) (a) Place magneto frame in T-125 assembly fixture (flange down). (b) Position rotor shaft assembly in the magneto frame. (c) Insert rotor and frame assembly plug (T-102) into the T-handle.
Page 936
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) Install Woodruff Key by pressing Woodruff Key into the key slot of the rotor shaft. In the left magnetos only (i.e. - impulse coupled), assemble impulse coupling: (a) Assemble inner eye of the impulse spring into the grooves in the impulse hub.
Page 937
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (d) Insert T-150 "E" Gap Gauge between the pole laminations in the rotor shaft and the pole laminations in the frame. Read the magneto data plate for magneto rotation. For old style rotor (i.e. - no slots on the magnet head), insert flat end of T-150 "E"...
Page 938
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (12) Distributor gear assembly (a) Install carbon brush into spring. Insert small end of carbon brush tapered end of spring. Turn carbon brush clockwise until shoulder of carbon brush seats spring. (b) Install carbon brush assembly into distributor gear.
Page 939
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (18) Connect condenser wire (a) Connect condenser wire to the remaining terminal of the contact assembly. (b) Attach the terminal with the lead pointing left. (19) Insert the top boss of the distributor housing into its mating pilot on the magneto frame.
Page 940
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) Turn the engine crankshaft in the normal direction of rotation until the No. 1 cylinder is in the full-advance firing position. (a) Cover spark plug hole of number one cylinder with thumb. Rotate crankshaft until pressure is felt on thumb.
Page 941
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Page 942
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Page 943
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL DISTRIBUTION Ignition Harness Inspection (1) Check lead assemblies for nicks, cuts, mutilated braiding, badly worn section or any other evidence of physical damage. Inspect spark plug sleeves for chafing or tears, and damage or stripped threads on coupling nuts.
Page 944
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stripping Tool Inserting Stripping Tool Figure 1 Figure 2 Cutting Insulation Removing Silicone Rubber from Wire Figure 3 Figure 4 PAGE 2 74-20-00 Nov 30/06...
Page 945
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation of Plug Endnut Flaring out the Shielding Figure 5 Figure 6 Installation of Ferrule Driving Tool Figure 7 Figure 8 74-20-00 PAGE 3 Nov 30/06...
Page 946
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Assembly (1) Cut a piece of harness wire to length required. Do not stretch wire when measuring it. (2) On magneto end, make a final mark one inch from wire end. Another mark must be made 0.9375 inch from spark plug end of wire.
Page 947
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation of Harness Cap Securing Wire in Harness Cap Figure 9 Figure 10 Installation of Electrode Screw Installation of Insulator Screw Figure 11 Figure 12 74-20-00 PAGE 5 Nov 30/06...
Page 948
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Installation (1) Before installing harness on magneto, check mating surfaces for cleanliness. (2) Place har ness ter minal plate on magneto and tighten nuts around plate alternately to seat cover squarely on magneto.
Page 949
PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (4) Removal of seized spark plugs in cylinder is done by application of liquid carbon dioxide (CO 2 ) by a conical metal funnel adapter with a hole at the apex just large enough to accommodate the funnel of a 20 lb bottle.
Page 950
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL SWITCHING Ignition Switch Removal (1) Make sure ignition switch is in OFF position. (2) Gain access to and disconnect power lead (+) from battery. (3) Remove retaining nut from switch and pull switch from back of instrument panel.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ENGINE INDICATING 5D15...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 77 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 77-List of Nov 30/06 Effective Pages Nov 30/06 77-Table of Contents Nov 30/06 Nov 30/06 77-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 77 - ENGINE INDICATING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 77-00-00 5D21 Description 5D21 Removal and Installation 5D21 POWER 77-10-00 5D23 Tachometer Indicator 5D23 Description 5D23 Troubleshooting 5D23...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GENERAL WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) Description NOTE: In S/N’s 2842218 and up, for airplanes equipped with the Avidyne Entegra...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL POWER Tachometer Indicator NOTE: In S/N’s 2842218 and up, for airplanes equipped with the Avidyne Entegra EFIS, engine data is collected by the Data Acquisition Unit (DAU) and is displayed on the Multi-Function Display (MFD) and Primary Flight Display (PFD).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL TEMPERATURE Exhaust Gas Temperature (EGT) Gauge NOTE: In S/N’s 2842218 and up, for airplanes equipped with the Avidyne Entegra EFIS, engine data is collected by the Data Acquisition Unit (DAU) and is displayed on the Multi-Function Display (MFD) and Primary Flight Display (PFD).
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Cleaning and Inspection CAUTION: DO NOT CONNECT OHMMETER ACROSS METER. IT WILL BURN OUT THE MOVEMENT OF THE METER. Unless mechanical damage is evident, broken glass, bent or broken pointer, or broken case, the following checks should be performed before removing the instrument.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL EGT Probe Installation Figure 1 77-20-00 PAGE 3 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER EXHAUST...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 78 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 78-List of Nov 30/06 Effective Pages Nov 30/06 78-Table of Contents Nov 30/06 Nov 30/06 78-00-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 78 - EXHAUST TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. GENERAL 78-00-00 5E13 100 Hour Inspection 5E13 78 - CONTENTS PAGE 1 5E11 Nov 30/06...
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100 hour period. The system should also be checked carefully before winter operation when cabin heat will be used. NOTE: Piper recommends PA-28 airplanes be fitted with a new muffler at or near 1000 hours time-in-service.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Exhaust System Inspection Points Figure 1 PAGE 2 78-00-00 Nov 30/06 5E14...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 5E17...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 79 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 79-List of Nov 30/06 Effective Pages Nov 30/06 79-Table of Contents Nov 30/06 Nov 30/06 79-20-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 79 - OIL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. DISTRIBUTION 79-20-00 5E23 Oil Cooler 5E23 INDICATING 79-30-00 Description Oil Pressure Indicator Sender Switch Oil Temperature Indicator Bulb 79 - CONTENTS...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL DISTRIBUTION Oil Cooler When installing fittings in the oil cooler, care should be used to prevent excessive torque being applied to the cooler. When a rectangular fitting boss is provided, backup wrench should be used, employing a scissor motion, so that no load is transmitted to the cooler.
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The oil pressure display is included in the 3-In-1 gauge on the instrument panel, and reads the amount of oil pressure available at the pressurized oil passage. Refer to Figure 1 for data required to calibrate the Warrior III oil pressure display. (2) Troubleshooting See Chart 1.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Switch (1) Removal (a) Gain access to the switch from under the pilot’s (left) instrument panel. (b) Disconnect electrical connector. NOTE: There will be some residual oil in the line leading to the sender and switch.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Oil Temperature Indicator (1) Description The oil temperature indicator is part of the combination engine gauge which also includes the oil pressure gauge and the cylinder head temperature gauge. This instrument will display a temperature indication of the engine oil in degrees Fahrenheit.
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 3-IN-1 Engine Instrument Calibration (Oil Pressure, Oil Temperature) Figure 1 PAGE 4 79-30-00 Nov 30/06...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STARTING...
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PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 80 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 80-List of Nov 30/06 Effective Pages Nov 30/06 80-Table of Contents Nov 30/06 Nov 30/06 80-10-00 Nov 30/06...
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