Piper Warrior III Maintenance Manual
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Piper Warrior III Maintenance Manual

Piper Warrior III Maintenance Manual

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Table of Contents

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AIRPLANE MAINTENANCE MANUAL
CARD 1 OF 5
PA-28-161
(S/N's 2842001 & UP)
PIPER AIRCRAFT, INC.
PART NUMBER 761-882
November 30, 2006
1A1

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  • Page 1 AIRPLANE MAINTENANCE MANUAL CARD 1 OF 5 PA-28-161 (S/N’s 2842001 & UP) PIPER AIRCRAFT, INC. PART NUMBER 761-882 November 30, 2006...
  • Page 2 Published by Technical Publications © Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...
  • Page 3 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 4 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Nov 30/06...
  • Page 5 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 6 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Nov 30/06...

  • Page 7: Table Of Contents

    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...
  • Page 8 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Nov 30/06...

  • Page 9: Instructions For Continued Airworthiness

    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 10: Effectivity

    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 11: Pagination

    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 12: Accident/Incident Reporting

    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 13 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) EMERGENCY LOCATOR TRANSMITTER (ELT): Vendor: Artex Aircraft Supplies PH: - (800) 547-8901 14405 Keil Road NE Aurora, Oregon 97002 http://www.artex.net/ (6) ENGINE: Vendor: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • Page 14 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 15 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION PAGE 7 1A15 Nov 30/06...
  • Page 16 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Nov 30/06 1A16...

  • Page 17: Chapter/Section Index Guide

    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 18 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 19 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 20 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 21 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...
  • Page 22 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 1A22 THRU 1A24 INTENTIONALLY BLANK PAGE 14 INTRODUCTION Nov 30/06 1A22...
  • Page 23 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 3-IN-1 Engine Instrument Buttock Lines: 1E21 Calibration: 4K18 EFIS Avidyne Entegra: 3H3 Cabin Component Locator: 3H4 Access Plates and Panels: 1E22 Heat: 2C15 Mag/OAT Sensor: 3G15 Accident/Incident Reporting: 1A12 Ventilation: 2C9 Maintenance Aerofiche Grid Code: 1A11 Cable Tension vs.
  • Page 24 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Electrical (continued) Electrical Bonding: 4D11 Engine (continued) Schematics (continued) Resistance Index: 4D12 Starter: 5F13 Fresh Air Blower: 5H7 Electrical System Bench Tests: 5F16 Fuel Flow: 5J16 Servicing: 1I10 Cranking Tests: 5F16 Fuel Pressure: 5J17...
  • Page 25 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel System (continued) Inspections (continued) Fuel Tanks Per Event Jacking: 1F7 Components: 2J17 Engine: 1E2 Gascolator: 2K1 Loss of Oil: 1E2 Inspection Overtemp: 1E2 Landing Gear Fuel Tank / Wing Spar Sudden Stoppage: 1E2...

  • Page 26: 1A11

    PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lubrication Pitot Heat: 3C9 Application of Grease: 1I13 Pitot-Static System: 3G9 Seat Belts: 2F14 Application of Oil: 1I13 Placards Inspection: 2F14 Charts Exterior: 1H1 Seats Control System: 1I18 Interior: 1H5 Lubrication Chart: 1I23...
  • Page 27 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Tires Balance: 1I10 Vacuum System Servicing: 1I4 Description and Operation: 3I17 Torque Filter: 3I21 Conversion: 5G7 Gauge: 3J7 Requirements Pump: 3I22 Flare Fittings: 5G3 Inspection: 3I22 Nuts: 5G5 Regulator: 3I24 Wrenches: 1J9...
  • Page 28 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 1B6 THRU 1B24 INTENTIONALLY BLANK PAGE 6 INDEX Nov 30/06...
  • Page 29 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER AIRWORTHINESS LIMITATIONS...
  • Page 30 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...
  • Page 31 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...
  • Page 32 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 4 - LIST OF EFFECTIVE PAGES Nov 30/06...
  • Page 33 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...
  • Page 34 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 4 - CONTENTS Nov 30/06...
  • Page 35 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...
  • Page 36 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 4-00-00 Nov 30/06...
  • Page 37 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER TIME LIMITS / MAINTENANCE CHECKS...
  • Page 38 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 1C10...
  • Page 39 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...
  • Page 40 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 5 - LIST OF EFFECTIVE PAGES Nov 30/06 1C12...
  • Page 41 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...
  • Page 42 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 5 - CONTENTS Nov 30/06 1C14...
  • Page 43 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.
  • Page 44 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 5-00-00 Nov 30/06 1C16...
  • Page 45 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.
  • Page 46 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 5-10-00 Nov 30/06 1C18...
  • Page 47 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.
  • Page 48 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.
  • Page 49 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.
  • Page 50 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.
  • Page 51 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 5-20-00 PAGE 5 1C23 Nov 30/06...
  • Page 52 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 6 5-20-00 Nov 30/06 1C24...
  • Page 53 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.
  • Page 54 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 ............
  • Page 55 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 ................
  • Page 56 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.
  • Page 57 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..............
  • Page 58 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.) ........
  • Page 59 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.
  • Page 60 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.
  • Page 61 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.
  • Page 62 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 16 5-20-00 Nov 30/06 1D10...
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  • Page 65 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;...
  • Page 66 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.
  • Page 67 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.
  • Page 68 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.
  • Page 69 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.
  • Page 70 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.
  • Page 71 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 5-30-00 PAGE 7 1D19 Nov 30/06...
  • Page 72 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 1D20 THRU 1D24 INTENTIONALLY BLANK PAGE 8 5-30-00 Nov 30/06 1D20...
  • Page 73 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.
  • Page 74 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).
  • Page 75 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.
  • Page 76 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.
  • Page 77 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,...
  • Page 78 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.
  • Page 79 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.
  • Page 80 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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  • Page 83 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER DIMENSIONS AND AREAS 1E11...
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  • Page 85 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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  • Page 87 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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  • Page 89 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.
  • Page 90 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...
  • Page 91 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 ±...
  • Page 92 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 6-00-00 Nov 30/06 1E20...
  • Page 93 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.
  • Page 94 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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  • Page 97 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER LIFTING AND SHORING...
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  • Page 99 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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  • Page 101 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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  • Page 103 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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  • Page 105 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER LEVELING AND WEIGHING...
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  • Page 107 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 8 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 8-List of Nov 30/06 Effective Pages Nov 30/06 8-Table of Contents Nov 30/06 Nov 30/06 8-10-00 Nov 30/06...
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  • Page 109 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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  • Page 111 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.)
  • Page 112 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 8-10-00 Nov 30/06 1F16...
  • Page 113 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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  • Page 115 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER TOWING AND TAXIING 1F19...
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  • Page 117 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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  • Page 119 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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  • Page 121 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.
  • Page 122 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 9-10-00 Nov 30/06...
  • Page 123 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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  • Page 125 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER PARKING AND MOORING...
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  • Page 127 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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  • Page 129 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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  • Page 131 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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  • Page 133 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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  • Page 135 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER PLACARDS AND MARKINGS 1G15...
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  • Page 137 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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  • Page 139 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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  • Page 141 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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  • Page 143 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).
  • Page 144 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...
  • Page 145 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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  • Page 147 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...
  • Page 148 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...
  • Page 149 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.
  • Page 150 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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  • Page 153 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER SERVICING 1H11...
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  • Page 155 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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  • Page 157 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...
  • Page 158 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...
  • Page 159 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...
  • Page 160 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.
  • Page 161 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.
  • Page 162 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.
  • Page 163 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL REPLENISHING Service Points Figure 1 12-10-00 PAGE 1 1H21 Nov 30/06...
  • Page 164 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.
  • Page 165 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.
  • Page 166 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.
  • Page 167 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.
  • Page 168 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.
  • Page 169 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.
  • Page 170 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.
  • Page 171 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.
  • Page 172 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 10 12-10-00 Nov 30/06...
  • Page 173 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.
  • Page 174 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.
  • Page 175 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Induction Air Filter Figure 2 12-20-00 PAGE 3 Nov 30/06...
  • Page 176 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.
  • Page 177 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Wheel Balancer Figure 3 12-20-00 PAGE 5 1I11 Nov 30/06...
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  • Page 179 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.
  • Page 180 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...
  • Page 181 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.
  • Page 182 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.
  • Page 183 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)
  • Page 184 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.
  • Page 185 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.
  • Page 186 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.
  • Page 187 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...
  • Page 188 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)
  • Page 189 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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  • Page 193 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STANDARD PRACTICES - AIRFRAME...
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  • Page 195 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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  • Page 197 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...
  • Page 198 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 20 - CONTENTS Nov 30/06...
  • Page 199 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.
  • Page 200 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...
  • Page 201 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.
  • Page 202 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.
  • Page 203 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...
  • Page 204 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...
  • Page 205 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.
  • Page 206 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.
  • Page 207 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 20-00-00 PAGE 9 1J17 Nov 30/06...
  • Page 208 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 10 20-00-00 Nov 30/06 1J18...
  • Page 209 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.
  • Page 210 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.
  • Page 211 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.
  • Page 212 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.
  • Page 213 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 20-20-00 PAGE 5 1J23 Nov 30/06...
  • Page 214 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 1J24 THRU 1L24 INTENTIONALLY BLANK PAGE 6 20-20-00 Nov 30/06 1J24...
  • Page 215 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...
  • Page 216 Published by Technical Publications © Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...
  • Page 217 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 218 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Nov 30/06...
  • Page 219 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 220 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Nov 30/06...
  • Page 221 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...
  • Page 222 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Nov 30/06...
  • Page 223 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 224 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 225 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 226 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 227 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) EMERGENCY LOCATOR TRANSMITTER (ELT): Vendor: Artex Aircraft Supplies PH: - (800) 547-8901 14405 Keil Road NE Aurora, Oregon 97002 http://www.artex.net/ (6) ENGINE: Vendor: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • Page 228 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 229 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION PAGE 7 2A15 Nov 30/06...
  • Page 230 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Nov 30/06 2A16...
  • Page 231 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 232 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 233 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 234 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 235 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...
  • Page 236 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 2A22 THRU 2A24 INTENTIONALLY BLANK PAGE 14 INTRODUCTION Nov 30/06 2A22...
  • Page 237 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 3-IN-1 Engine Instrument Buttock Lines: 1E21 Calibration: 4K18 EFIS Avidyne Entegra: 3H3 Cabin Component Locator: 3H4 Access Plates and Panels: 1E22 Heat: 2C15 Mag/OAT Sensor: 3G15 Accident/Incident Reporting: 1A12 Ventilation: 2C9 Maintenance Aerofiche Grid Code: 1A11 Cable Tension vs.
  • Page 238 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Electrical (continued) Electrical Bonding: 4D11 Engine (continued) Schematics (continued) Resistance Index: 4D12 Starter: 5F13 Fresh Air Blower: 5H7 Electrical System Bench Tests: 5F16 Fuel Flow: 5J16 Servicing: 1I10 Cranking Tests: 5F16 Fuel Pressure: 5J17...
  • Page 239 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel System (continued) Inspections (continued) Fuel Tanks Per Event Jacking: 1F7 Components: 2J17 Engine: 1E2 Gascolator: 2K1 Loss of Oil: 1E2 Inspection Overtemp: 1E2 Landing Gear Fuel Tank / Wing Spar Sudden Stoppage: 1E2...
  • Page 240 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lubrication Pitot Heat: 3C9 Application of Grease: 1I13 Pitot-Static System: 3G9 Seat Belts: 2F14 Application of Oil: 1I13 Placards Inspection: 2F14 Charts Exterior: 1H1 Seats Control System: 1I18 Interior: 1H5 Lubrication Chart: 1I23...
  • Page 241 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Tires Balance: 1I10 Vacuum System Servicing: 1I4 Description and Operation: 3I17 Torque Filter: 3I21 Conversion: 5G7 Gauge: 3J7 Requirements Pump: 3I22 Flare Fittings: 5G3 Inspection: 3I22 Nuts: 5G5 Regulator: 3I24 Wrenches: 1J9...
  • Page 242 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 2B6 THRU 2B24 INTENTIONALLY BLANK PAGE 6 INDEX Nov 30/06...
  • Page 243 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ENVIRONMENTAL SYSTEMS...
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  • Page 245 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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  • Page 247 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...
  • Page 248 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 21 - CONTENTS Nov 30/06...
  • Page 249 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.
  • Page 250 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 21-00-00 Nov 30/06...
  • Page 251 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.
  • Page 252 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.
  • Page 253 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°...
  • Page 254 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...
  • Page 255 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...
  • Page 256 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 6 21-20-00 Nov 30/06 2C14...
  • Page 257 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.
  • Page 258 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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  • Page 261 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER COMMUNICATIONS 2C19...
  • Page 262 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 2C20...
  • Page 263 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...
  • Page 264 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 23 - LIST OF EFFECTIVE PAGES Nov 30/06 2C22...
  • Page 265 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...
  • Page 266 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 23 - CONTENTS Nov 30/06 2C24...
  • Page 267 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.
  • Page 268 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 23-00-00 Nov 30/06...
  • Page 269 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...
  • Page 270 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.
  • Page 271 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)
  • Page 272 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 23-50-00 Nov 30/06...
  • Page 273 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;...
  • Page 274 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 23-60-00 Nov 30/06...
  • Page 275 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ELECTRICAL POWER...
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  • Page 277 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...
  • Page 278 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 24 - LIST OF EFFECTIVE PAGES Nov 30/06 2D12...
  • Page 279 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...
  • Page 280 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 24 - CONTENTS Nov 30/06 2D14...
  • Page 281 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.
  • Page 282 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 24-00-00 Nov 30/06 2D16...
  • Page 283 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.
  • Page 284 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.
  • Page 285 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.
  • Page 286 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...
  • Page 287 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).
  • Page 288 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...
  • Page 289 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.
  • Page 290 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.
  • Page 291 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.
  • Page 292 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 10 24-30-00 Nov 30/06...
  • Page 293 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.
  • Page 294 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.
  • Page 295 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.
  • Page 296 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.
  • Page 297 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.
  • Page 298 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.
  • Page 299 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.
  • Page 300 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...
  • Page 301 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.
  • Page 302 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.
  • Page 303 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Battery Installation Figure 5 24-30-00 PAGE 21 2E13 Nov 30/06...
  • Page 304 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.
  • Page 305 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.
  • Page 306 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.
  • Page 307 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...
  • Page 308 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.
  • Page 309 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.
  • Page 310 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.
  • Page 311 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.
  • Page 312 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 2E22 THRU 2E24 INTENTIONALLY BLANK PAGE 30 24-30-00 Nov 30/06 2E22...
  • Page 313 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.
  • Page 314 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 24-40-00 Nov 30/06...
  • Page 315 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...
  • Page 316 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 24-50-00 Nov 30/06...
  • Page 317 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER EQUIPMENT / FURNISHINGS...
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  • Page 319 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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  • Page 321 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...
  • Page 322 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 25 - CONTENTS Nov 30/06 2F10...
  • Page 323 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.
  • Page 324 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.
  • Page 325 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...
  • Page 326 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.
  • Page 327 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.
  • Page 328 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 6 25-10-00 Nov 30/06 2F16...
  • Page 329 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.
  • Page 330 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:...
  • Page 331 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...
  • Page 332 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 2F20 THRU 2F24 INTENTIONALLY BLANK PAGE 4 25-60-00 Nov 30/06 2F20...
  • Page 333 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER FLIGHT CONTROLS...
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  • Page 335 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...
  • Page 336 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 27 - LIST OF EFFECTIVE PAGES Nov 30/06...
  • Page 337 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...
  • Page 338 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...
  • Page 339 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.
  • Page 340 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.
  • Page 341 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.
  • Page 342 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...
  • Page 343 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...
  • Page 344 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.
  • Page 345 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.
  • Page 346 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.
  • Page 347 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.
  • Page 348 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.
  • Page 349 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 27-00-00 PAGE 11 2G17 Nov 30/06...
  • Page 350 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 2G18 THRU 2G24 INTENTIONALLY BLANK PAGE 12 27-00-00 Nov 30/06 2G18...

  • Page 351: Troubleshooting

    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).
  • Page 352 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.
  • Page 353 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Control Column Assembly Figure 1 27-10-00 PAGE 3 Nov 30/06...
  • Page 354 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).
  • Page 355 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])
  • Page 356 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...

  • Page 357: Removal

    (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.

  • Page 358: Removal

    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.
  • Page 359 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Aileron Controls Figure 4 27-10-00 PAGE 9 Nov 30/06...

  • Page 360: Installation

    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.

  • Page 361: Adjustment

    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.
  • Page 362 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.
  • Page 363 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...
  • Page 364 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 14 27-10-00 Nov 30/06 2H14...

  • Page 365: Troubleshooting

    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.
  • Page 366 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.
  • Page 367 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Rudder Controls Figure 1 27-20-00 PAGE 3 2H17 Nov 30/06...
  • Page 368 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).
  • Page 369 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...
  • Page 370 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.
  • Page 371 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...
  • Page 372 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,...
  • Page 373 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...
  • Page 374 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.
  • Page 375 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.
  • Page 376 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.
  • Page 377 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.
  • Page 378 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.
  • Page 379 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stabilator Controls Figure 1 27-30-00 PAGE 5 Nov 30/06...
  • Page 380 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...
  • Page 381 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,...
  • Page 382 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Stabilator Trim Controls Figure 4 PAGE 8 27-30-00 Nov 30/06...
  • Page 383 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.
  • Page 384 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.
  • Page 385 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.
  • Page 386 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).
  • Page 387 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.
  • Page 388 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.
  • Page 389 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...
  • Page 390 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 16 27-30-00 Nov 30/06 2I16...
  • Page 391 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 27-30-00 PAGE 17 2I17 Nov 30/06...
  • Page 392 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 18 27-30-00 Nov 30/06 2I18...
  • Page 393 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.
  • Page 394 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Flap Control System Figure 1 PAGE 2 27-50-00 Nov 30/06 2I20...
  • Page 395 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.
  • Page 396 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).
  • Page 397 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...
  • Page 398 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.
  • Page 399 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fabricating Flap Rigging Tool Figure 4 27-50-00 PAGE 7 Nov 30/06...
  • Page 400 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 27-50-00 Nov 30/06...
  • Page 401 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 27-50-00 PAGE 9 Nov 30/06...
  • Page 402 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 10 27-50-00 Nov 30/06...
  • Page 403 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER FUEL...
  • Page 404 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...
  • Page 405 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...
  • Page 406 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 28 - LIST OF EFFECTIVE PAGES Nov 30/06...
  • Page 407 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...
  • Page 408 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...
  • Page 409 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.
  • Page 410 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel System Figure 1 PAGE 2 28-00-00 Nov 30/06 2J12...
  • Page 411 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.
  • Page 412 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 28-00-00 Nov 30/06 2J14...
  • Page 413 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.
  • Page 414 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.
  • Page 415 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...
  • Page 416 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.
  • Page 417 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Locking Fuel Cap Figure 2 28-10-00 PAGE 5 2J19 Nov 30/06...
  • Page 418 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 2J20 THRU 2J24 INTENTIONALLY BLANK PAGE 6 28-10-00 Nov 30/06 2J20...
  • Page 419 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.
  • Page 420 (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.
  • Page 421 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.
  • Page 422 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.
  • Page 423 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).
  • Page 424 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.
  • Page 425 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 28-20-00 PAGE 7 Nov 30/06...
  • Page 426 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 28-20-00 Nov 30/06...
  • Page 427 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.
  • Page 428 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.
  • Page 429 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.
  • Page 430 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.
  • Page 431 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...
  • Page 432 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.)
  • Page 433 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...
  • Page 434 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...
  • Page 435 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 28-40-00 PAGE 9 2K17 Nov 30/06...
  • Page 436 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 2K18 THRU 2L24 INTENTIONALLY BLANK PAGE 10 28-40-00 Nov 30/06 2K18...
  • Page 437 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...
  • Page 438 Published by Technical Publications © Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...
  • Page 439 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 440 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Nov 30/06...
  • Page 441 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 442 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Nov 30/06...
  • Page 443 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...
  • Page 444 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Nov 30/06...
  • Page 445 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 446 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 447 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 448 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 449 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) EMERGENCY LOCATOR TRANSMITTER (ELT): Vendor: Artex Aircraft Supplies PH: - (800) 547-8901 14405 Keil Road NE Aurora, Oregon 97002 http://www.artex.net/ (6) ENGINE: Vendor: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • Page 450 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 451 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION PAGE 7 3A15 Nov 30/06...
  • Page 452 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Nov 30/06 3A16...
  • Page 453 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 454 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 455 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 456 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 457 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...
  • Page 458 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 3A22 THRU 3A24 INTENTIONALLY BLANK PAGE 14 INTRODUCTION Nov 30/06 3A22...
  • Page 459 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 3-IN-1 Engine Instrument Buttock Lines: 1E21 Calibration: 4K18 EFIS Avidyne Entegra: 3H3 Cabin Component Locator: 3H4 Access Plates and Panels: 1E22 Heat: 2C15 Mag/OAT Sensor: 3G15 Accident/Incident Reporting: 1A12 Ventilation: 2C9 Maintenance Aerofiche Grid Code: 1A11 Cable Tension vs.
  • Page 460 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Electrical (continued) Electrical Bonding: 4D11 Engine (continued) Schematics (continued) Resistance Index: 4D12 Starter: 5F13 Fresh Air Blower: 5H7 Electrical System Bench Tests: 5F16 Fuel Flow: 5J16 Servicing: 1I10 Cranking Tests: 5F16 Fuel Pressure: 5J17...
  • Page 461 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel System (continued) Inspections (continued) Fuel Tanks Per Event Jacking: 1F7 Components: 2J17 Engine: 1E2 Gascolator: 2K1 Loss of Oil: 1E2 Inspection Overtemp: 1E2 Landing Gear Fuel Tank / Wing Spar Sudden Stoppage: 1E2...
  • Page 462 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lubrication Pitot Heat: 3C9 Application of Grease: 1I13 Pitot-Static System: 3G9 Seat Belts: 2F14 Application of Oil: 1I13 Placards Inspection: 2F14 Charts Exterior: 1H1 Seats Control System: 1I18 Interior: 1H5 Lubrication Chart: 1I23...
  • Page 463 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Tires Balance: 1I10 Vacuum System Servicing: 1I4 Description and Operation: 3I17 Torque Filter: 3I21 Conversion: 5G7 Gauge: 3J7 Requirements Pump: 3I22 Flare Fittings: 5G3 Inspection: 3I22 Nuts: 5G5 Regulator: 3I24 Wrenches: 1J9...
  • Page 464 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 3B6 THRU 3B24 INTENTIONALLY BLANK PAGE 6 INDEX Nov 30/06...
  • Page 465 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ICE AND RAIN PROTECTION...
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  • Page 467 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...
  • Page 468 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 30 - LIST OF EFFECTIVE PAGES Nov 30/06...
  • Page 469 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...
  • Page 470 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 30 - CONTENTS Nov 30/06...
  • Page 471 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).
  • Page 472 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 30-00-00 Nov 30/06...
  • Page 473 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.
  • Page 474 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 3C10 THRU 3C14 INTENTIONALLY BLANK PAGE 2 30-30-00 Nov 30/06 3C10...
  • Page 475 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER INDICATING / RECORDING SYSTEMS 3C15...
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  • Page 477 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...
  • Page 478 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 31 - LIST OF EFFECTIVE PAGES 3C18 Nov 30/06...
  • Page 479 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...
  • Page 480 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 3C20 THRU 3C24 INTENTIONALLY BLANK PAGE 2 31 - CONTENTS Nov 30/06 3C20...
  • Page 481 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.
  • Page 482 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...
  • Page 483 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.
  • Page 484 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.
  • Page 485 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.
  • Page 486 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 6 31-50-00 Nov 30/06...
  • Page 487 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER LANDING GEAR...
  • Page 488 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...
  • Page 489 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...
  • Page 490 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 32 - LIST OF EFFECTIVE PAGES Nov 30/06 3D10...
  • Page 491 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...
  • Page 492 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...
  • Page 493 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°...
  • Page 494 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.
  • Page 495 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.
  • Page 496 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 32-00-00 Nov 30/06 3D16...
  • Page 497 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.
  • Page 498 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...
  • Page 499 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...
  • Page 500 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.
  • Page 501 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Main Gear Installation Figure 2 32-10-00 PAGE 5 3D21 Nov 30/06...
  • Page 502 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.
  • Page 503 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 32-10-00 PAGE 7 3D23 Nov 30/06...
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  • Page 505 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.
  • Page 506 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.
  • Page 507 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Nose Gear Oleo Strut Figure 2 32-20-00 PAGE 3 Nov 30/06...
  • Page 508 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.
  • Page 509 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Nose Gear Installation Figure 3 32-20-00 PAGE 5 Nov 30/06...
  • Page 510 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).
  • Page 511 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°...
  • Page 512 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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  • Page 515: Wheels And Brakes (Cont.)

    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.
  • Page 516 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.
  • Page 517 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.
  • Page 518 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.

  • Page 519: Brakes

    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.
  • Page 520 (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.)
  • Page 521 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Anchor Bolt Figure 4 32-40-00 PAGE 7 3E17 Nov 30/06...

  • Page 522: Hand/Parking Brake Master Cylinder

    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.
  • Page 523 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Brake System Installation Figure 6 32-40-00 PAGE 9 3E19 Nov 30/06...

  • Page 524: Disassembly

    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.

  • Page 525: Toe Brake Cylinder(S)

    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.

  • Page 526: Installation

    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.

  • Page 527: Brake System Leak Check

    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.
  • Page 528 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 14 32-40-00 Nov 30/06 3E24...
  • Page 529 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 32-40-00 PAGE 15 Nov 30/06...
  • Page 530 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 16 32-40-00 Nov 30/06...
  • Page 531 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER LIGHTS...
  • Page 532 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK...
  • Page 533 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 33 LIST OF EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 33-List of Nov 30/06 Effective Pages Nov 30/06 33-Table of Contents Nov 30/06 Nov 30/06 33-00-00 Nov 30/06...
  • Page 534 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 33 - LIST OF EFFECTIVE PAGES Nov 30/06...
  • Page 535 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...
  • Page 536 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 33 - CONTENTS Nov 30/06...
  • Page 537 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.
  • Page 538 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 33-00-00 Nov 30/06 3F10...
  • Page 539 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.
  • Page 541 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 33-10-00 PAGE 3 3F13 Nov 30/06...
  • Page 542 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 33-10-00 Nov 30/06 3F14...
  • Page 543 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.
  • Page 549 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 33-40-00 PAGE 7 3F21 Nov 30/06...
  • Page 550 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 3F22 THRU 3F24 INTENTIONALLY BLANK PAGE 8 33-40-00 Nov 30/06 3F22...
  • Page 551 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER NAVIGATION PITOT / STATIC...
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  • Page 553 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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  • Page 555 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...
  • Page 556 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...
  • Page 557 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.
  • Page 558 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 34-00-00 Nov 30/06...
  • Page 559 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.
  • Page 566 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 34-10-00 Nov 30/06 3G16...
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  • Page 568 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 3G18 THRU 3G24 INTENTIONALLY BLANK PAGE 10 34-10-00 Nov 30/06 3G18...
  • Page 569 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.
  • Page 570 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...
  • Page 571 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...
  • Page 572 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...
  • Page 573 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,”...
  • Page 574 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 101901-SHT 4,8-N 101910 P INSTRUMENT PANEL (REF.) 48.6 62.88 128.73 101901-SHT 8-N DC-50 ANTENNA COUPLER K17 RELAY AND SUPPRESSION DIODE VIEW A-A ANTENNA COUPLER INSTALLATION - LOOKING FWD (STA 48.6) 101910-SHT 5-K P303, P304, &...
  • Page 575 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)
  • Page 577 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 101901-SHT 12-N AVIONICS SYSTEM HARNESS ASSY P551 P552 PFD (REF) MFD (REF) SYSTEM P732 J732 P730 P43011 P43061 P530 J731 (REF) P731 GNS 430 #1 (REF) J733 P43012 J530 P43016 J730 P733...
  • Page 578 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)
  • Page 579 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...
  • Page 581 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.
  • Page 582 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.)
  • Page 583 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...
  • Page 586 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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  • Page 590 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 3H22 THRU 3H24 INTENTIONALLY BLANK PAGE 22 34-20-00 Nov 30/06 3H22...
  • Page 591 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.
  • Page 592 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.
  • Page 593 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”...
  • Page 594 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”...
  • Page 595 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.
  • Page 597 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...
  • Page 598 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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  • Page 601 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER VACUUM 3I11...
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  • Page 603 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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  • Page 605 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...
  • Page 606 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 37 - CONTENTS Nov 30/06 3I16...
  • Page 607 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.
  • Page 610 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 37-00-00 Nov 30/06 3I20...
  • Page 611 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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  • Page 621 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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  • Page 625 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ELECTRICAL / ELECTRONIC PANELS 3J11...
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  • Page 627 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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  • Page 629 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...
  • Page 630 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 39 - CONTENTS Nov 30/06 3J16...
  • Page 631 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.
  • Page 632 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Instrument Panel (Typical) Figure 1 PAGE 2 39-10-00 Nov 30/06 3J18...
  • Page 633 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.
  • Page 635 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 39-10-00 PAGE 5 3J21 Nov 30/06...
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  • Page 637 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...
  • Page 638 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...
  • Page 639 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...
  • Page 642 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.
  • Page 645 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...
  • Page 646 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...
  • Page 648 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 (-) (-)
  • Page 649 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...
  • Page 650 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 3K12 THRU 3L24 INTENTIONALLY BLANK PAGE 14 39-20-00 Nov 30/06 3K12...
  • Page 651 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...
  • Page 652 Published by Technical Publications © Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...
  • Page 653 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 654 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Nov 30/06...
  • Page 655 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 656 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Nov 30/06...
  • Page 657 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...
  • Page 658 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Nov 30/06...
  • Page 659 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...
  • Page 661 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 662 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 663 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) EMERGENCY LOCATOR TRANSMITTER (ELT): Vendor: Artex Aircraft Supplies PH: - (800) 547-8901 14405 Keil Road NE Aurora, Oregon 97002 http://www.artex.net/ (6) ENGINE: Vendor: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • Page 664 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 665 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION PAGE 7 4A15 Nov 30/06...
  • Page 666 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Nov 30/06 4A16...
  • Page 667 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 668 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 669 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 670 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 671 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...
  • Page 672 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 4A22 THRU 4A24 INTENTIONALLY BLANK PAGE 14 INTRODUCTION Nov 30/06 4A22...
  • Page 673 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 3-IN-1 Engine Instrument Buttock Lines: 1E21 Calibration: 4K18 EFIS Avidyne Entegra: 3H3 Cabin Component Locator: 3H4 Access Plates and Panels: 1E22 Heat: 2C15 Mag/OAT Sensor: 3G15 Accident/Incident Reporting: 1A12 Ventilation: 2C9 Maintenance Aerofiche Grid Code: 1A11 Cable Tension vs.
  • Page 674 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Electrical (continued) Electrical Bonding: 4D11 Engine (continued) Schematics (continued) Resistance Index: 4D12 Starter: 5F13 Fresh Air Blower: 5H7 Electrical System Bench Tests: 5F16 Fuel Flow: 5J16 Servicing: 1I10 Cranking Tests: 5F16 Fuel Pressure: 5J17...
  • Page 675 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel System (continued) Inspections (continued) Fuel Tanks Per Event Jacking: 1F7 Components: 2J17 Engine: 1E2 Gascolator: 2K1 Loss of Oil: 1E2 Inspection Overtemp: 1E2 Landing Gear Fuel Tank / Wing Spar Sudden Stoppage: 1E2...
  • Page 676 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lubrication Pitot Heat: 3C9 Application of Grease: 1I13 Pitot-Static System: 3G9 Seat Belts: 2F14 Application of Oil: 1I13 Placards Inspection: 2F14 Charts Exterior: 1H1 Seats Control System: 1I18 Interior: 1H5 Lubrication Chart: 1I23...
  • Page 677 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Tires Balance: 1I10 Vacuum System Servicing: 1I4 Description and Operation: 3I17 Torque Filter: 3I21 Conversion: 5G7 Gauge: 3J7 Requirements Pump: 3I22 Flare Fittings: 5G3 Inspection: 3I22 Nuts: 5G5 Regulator: 3I24 Wrenches: 1J9...
  • Page 678 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 4B6 THRU 4B24 INTENTIONALLY BLANK PAGE 6 INDEX Nov 30/06...
  • Page 679 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STRUCTURES...
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  • Page 681 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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  • Page 683 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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  • Page 685 (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.
  • Page 686 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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  • Page 689 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.
  • Page 694 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 6 51-10-00 Nov 30/06 4C16...
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  • Page 697 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...
  • Page 703 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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  • Page 717 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER DOORS 4D15...
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  • Page 719 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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  • Page 721 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...
  • Page 722 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 52 - CONTENTS Nov 30/06 4D20...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 52-10-00 PAGE 5 Nov 30/06...
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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...
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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 737 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER 53 - FUSELAGE TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. MAIN 53-20-00 4E13 Aft Wing Attach Fittings 100 Hour Inspection 4E13 Background 4E13 Procedure 4E13 Aft Wing Attach Fittings Replacement...
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  • 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.
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  • Page 743 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STABILIZERS 4E17...
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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...
  • Page 746 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 55 - LIST OF EFFECTIVE PAGES Nov 30/06 4E20...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 55 - CONTENTS Nov 30/06 4E22...
  • 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...
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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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 55-20-00 PAGE 7 4F11 Nov 30/06...
  • Page 762 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 55-20-00 Nov 30/06 4F12...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 55-30-00 PAGE 3 4F15 Nov 30/06...
  • Page 766 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 55-30-00 Nov 30/06 4F16...
  • 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...
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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...
  • Page 774 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 56 - LIST OF EFFECTIVE PAGES Nov 30/06...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 56 - CONTENTS Nov 30/06...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 56-10-00 PAGE 3 Nov 30/06...
  • Page 780 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 56-10-00 Nov 30/06 4G10...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 56-20-00 Nov 30/06 4G12...
  • Page 783 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER WINGS 4G13...
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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...
  • Page 786 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 57 - LIST OF EFFECTIVE PAGES Nov 30/06 4G16...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 57 - CONTENTS Nov 30/06 4G18...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 57-00-00 Nov 30/06 4G20...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 57-10-00 PAGE 5 Nov 30/06...
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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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 57-20-00 Nov 30/06...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 6 57-40-00 Nov 30/06 4H10...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 57-50-00 Nov 30/06 4H18...
  • Page 813 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 57-50-00 PAGE 9 4H19 Nov 30/06...
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  • Page 815 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER PROPELLERS 4H21...
  • Page 816 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 4H22...
  • 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...
  • Page 818 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 61 - LIST OF EFFECTIVE PAGES Nov 30/06 4H24...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 61 - CONTENTS Nov 30/06...
  • 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 822 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHART 1 PROPELLER TORQUE LIMITS Description Required Torque (Dry) Propeller Mounting Nuts 280-300 inch-pounds Spinner Backplate Attachment Screws 30-35 inch-pounds Spinner Attachment Screws 20-25 inch-pounds Propeller Installation Figure 2 PAGE 2 61-10-00...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 61-10-00 Nov 30/06...
  • Page 825 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 61-10-00 PAGE 5 Nov 30/06...
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  • Page 827 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER STANDARD PRACTICES - ENGINE...
  • Page 828 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 4I10...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 70 - LIST OF EFFECTIVE PAGES 4I12 Nov 30/06...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 70 - CONTENTS Nov 30/06 4I14...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 70-00-00 Nov 30/06 4I16...
  • Page 835 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER POWER PLANT 4I17...
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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...
  • Page 838 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 71 - LIST OF EFFECTIVE PAGES 4I20 Nov 30/06...
  • 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 849 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL STATIC RPM WORKSHEET Aircraft Model: _____________________ Aircraft S/N: _____________________ Date: _____________________ OAT: _____________________ Relative Humidity (Temp ) (Dew PT ___________________% Wind above 10 Knots Tested Static RPM: ________________ Average Oil Temp: __________________...
  • 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.
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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...
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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...
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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.
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  • Page 869 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER ENGINE FUEL AND CONTROL...
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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...
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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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 73 - CONTENTS Nov 30/06...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 73-10-00 PAGE 3 4K11 Nov 30/06...
  • Page 878 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 73-10-00 Nov 30/06 4K12...
  • 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...
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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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK 73-30-00 PAGE 3 4K21 Nov 30/06...
  • Page 888 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 4K22 THRU 4L24 INTENTIONALLY BLANK PAGE 4 73-30-00 Nov 30/06 4K22...
  • 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 890 Published by Technical Publications © Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Nov 30/06...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Nov 30/06...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Nov 30/06...
  • 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 901 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL (5) EMERGENCY LOCATOR TRANSMITTER (ELT): Vendor: Artex Aircraft Supplies PH: - (800) 547-8901 14405 Keil Road NE Aurora, Oregon 97002 http://www.artex.net/ (6) ENGINE: Vendor: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Nov 30/06 5A16...
  • 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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 5A22 THRU 5A24 INTENTIONALLY BLANK PAGE 14 INTRODUCTION Nov 30/06 5A22...
  • Page 911 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL 3-IN-1 Engine Instrument Buttock Lines: 1E21 Calibration: 4K18 EFIS Avidyne Entegra: 3H3 Cabin Component Locator: 3H4 Access Plates and Panels: 1E22 Heat: 2C15 Mag/OAT Sensor: 3G15 Accident/Incident Reporting: 1A12 Ventilation: 2C9 Maintenance Aerofiche Grid Code: 1A11 Cable Tension vs.
  • Page 912 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Electrical (continued) Electrical Bonding: 4D11 Engine (continued) Schematics (continued) Resistance Index: 4D12 Starter: 5F13 Fresh Air Blower: 5H7 Electrical System Bench Tests: 5F16 Fuel Flow: 5J16 Servicing: 1I10 Cranking Tests: 5F16 Fuel Pressure: 5J17...
  • Page 913 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Fuel System (continued) Inspections (continued) Fuel Tanks Per Event Jacking: 1F7 Components: 2J17 Engine: 1E2 Gascolator: 2K1 Loss of Oil: 1E2 Inspection Overtemp: 1E2 Landing Gear Fuel Tank / Wing Spar Sudden Stoppage: 1E2...
  • Page 914 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Lubrication Pitot Heat: 3C9 Application of Grease: 1I13 Pitot-Static System: 3G9 Seat Belts: 2F14 Application of Oil: 1I13 Placards Inspection: 2F14 Charts Exterior: 1H1 Seats Control System: 1I18 Interior: 1H5 Lubrication Chart: 1I23...
  • Page 915 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL Tires Balance: 1I10 Vacuum System Servicing: 1I4 Description and Operation: 3I17 Torque Filter: 3I21 Conversion: 5G7 Gauge: 3J7 Requirements Pump: 3I22 Flare Fittings: 5G3 Inspection: 3I22 Nuts: 5G5 Regulator: 3I24 Wrenches: 1J9...
  • Page 916 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL GRIDS 5B6 THRU 5B24 INTENTIONALLY BLANK PAGE 6 INDEX Nov 30/06...
  • Page 917 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL CHAPTER IGNITION...
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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...
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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 PIPER AIRCRAFT, INC. PA-28-161, WARRIOR III MAINTENANCE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 74 - CONTENTS Nov 30/06...
  • 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.
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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.
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  • Page 953 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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  • Page 957 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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  • Page 959 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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  • Page 961 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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  • Page 963 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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  • Page 965 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).
  • Page 966 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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  • Page 975 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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  • Page 977 100 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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  • Page 985 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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  • Page 987 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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  • Page 989 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.
  • Page 990 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.
  • Page 991 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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