Piper CHEROKEE WARRIOR PA-28-151 1995 Maintenance Manual

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AIRPLANE

MAINTENANCE MANUAL

CARD 1 OF 3

PA-28-151 CHEROKEE WARRIOR

PA-28-161 WARRIOR II

PA-28-161 WARRIOR III

PIPER AIRCRAFT CORPORATION

(PART NUMBER 761 539

FEBRUARY 28, 1995

1A1

Island Enterprises

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Piper CHEROKEE WARRIOR PA-28-151 1995

Page 1 AIRPLANE MAINTENANCE MANUAL CARD 1 OF 3 PA-28-151 CHEROKEE WARRIOR PA-28-161 WARRIOR II PA-28-161 WARRIOR III PIPER AIRCRAFT CORPORATION (PART NUMBER 761 539 FEBRUARY 28, 1995 Island Enterprises...
Page 2 Published by Technical Publications Piper Aircraft Corporation 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member of GAMA General Aviation Manufacturers Association Island Enterprises...
Page 3 PIPER CHEROKEE WARRIOR SERVICE MANUAL SERIAL NUMBER INFORMATION PA-28-151, WARRIOR- 1974 Serial Numbers 28-7415001 to 28-7415713 inclusive PA-28-151, WARRIOR- 1975 Serial Numbers 28-7515001 to 28-7515459 inclusive PA-78-151, WARRIOR- 1976 Serial Numbers 28-7615001 to 28-7615445 inclusive PA-28-151, WARRIOR- 1977 Serial Numbers 28-7715001 to 28-7715314 inclusive...
Page 4 PIPER CHEROKEE WARRIOR SERVICE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS The Service Manual information incorporated in this set of Aerofiche cards has been arranged in accordance with the general specifications of Aerofiche adopted by the General Aircraft Manufacturer’s Association, (GAMA). The i n f o r m ation compiled in this Aerofiche Service Manual will be kept current by revisions distributed periodically.
Page 5 TABLE OF CONTENTS AEROFICHE CARD NO.1 GRID NO. INTRODUCTION............1A13 HANDLING AND SERVICING........1A16 INSPECTION ..............1D15 STRUCTURES............1E5 SURFACE CONTROLS ..........1G10 HYDRAULIC SYSTEM (Not Applicable) LANDING GEAR AND BRAKE SYSTEM....1I10 VIII POWER PLANT............1J19 AEROFICHE CARD NO.2 FUEL SYSTEM............2A10 INSTRUMENTS ............2B11 ELECTRICAL SYSTEM ..........2D4 ELECTRONICS ............2J11 XIII HEATING AND VENTILATING........2K5...
Page 6 PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF ILLUSTRATIONS Aerofiche Figure Grid No. 2-1. Three View ............................1A20 2-2. Station Reference Lines........................1A21 2-3. Access Plates and Panels ........................2-4. Jacking Arrangement........................2-5. Weighing Arrangement ........................1B10 2-6. Leveling Longitudinally ........................
Page 7 PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Aerofiche Figure Grid No. 5-2. Control Cable Inspection Technique ....................1G14 5-3. Cable Weat Patterns.......................... 1G15 5-4. Internal Cable Wear.......................... 1G16 5-5. Pulley Wear Patterns......................... 1G17 5-6. Control Column Assembly....................... 1G21 5-7.
Page 8 PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Aerofiche Figure Grid No. 8-8. T-100 Assembly and Timing Tool Kit....................1K13 8-9. Removing Coil Wedges ........................1K14 8-10. Index Plate and Timing Plug ......................1K15 8-11. Installation of Bearings and Bearing Plate ..................
Page 9: Table Of Contents
PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Aerofiche Figure Grid No. 10-8. Warrior III Instrument Cluster - Oil Temperature, Fuel Pressure, and Oil Pressure Gauge..... 2C18 10-9. Warrior III Fuel Quantity Gauge ...................... 2C20 10-10. Exhaust Gas Probe Installation......................
Page 10 PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Aerofiche Figure Grid No. 11-47. Lamar 14 Vdc System Overvoltage Check..................2F21 11-48. Lamar 28 Vdc System Overvoltage Check..................2F21 11-49. Exploded View of Gear Reduction Starter Motor ................
Page 11 PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. II-I. Leading Particulars and Principal Dimensions..............1A22 II-II. Recommended Torques......................II-III. Flare Fitting Torques......................II-IV. Type of Lubricants......................... II-V. Types of Metal Corrosion ...................... 1C15 II-VI. List of Consumable Materials....................
Page 12 PIPER CHEROKEE WARRIOR SERVICE MANUAL X-XI Troubleshooting PA-28-161, Warrior III Engine Oil Pressure Gauge........2C16 X-XII Troubleshooting PA-28-161, Warrior III Engine Oil Temperature Gauge ......2C16 X-XIII Troubleshooting Fuel Pressure Gauge ................... 2C17 X-XIV Warrior III Instrument Calibration Chart................2C18 X-XV Turn and Bank Indicator ......................
Page 13 SECTION I INTRODUCTION Aerofiche Paragraph Grid No. 1-1. General 1-2. Scope of Manual ....................1A13 1-3. Descriptions ..................... 1-4. Wing......................... 1A13 1-5. Empennage....................... 1A13 1-6. Fuselage ......................1A13 1-7. Landing Gear....................1A13 1-8. Brake System ....................1A13 1-9. Engines......................1A14 1-10.
Page 14 INTRODUCTION 1-1. GENERAL. This manual contains service and maintenance instructions for the Piper PA-28-151 and PA-28-161 Cherokee Warrior, designed and manufactured as a versatile airplane in the personal and business aviation field, by the Piper Aircraft Corporation, Vero Beach, Florida.
Page 15 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1-13. RADIO. Provisions are provided for the installation of various radio equipment along with microphone and headset jacks, loudspeaker and other radio navigation-equipment. 1-14. CABIN HEATER, DEFROSTER, AND FRESH AIR SYSTEM. Heated air for the cabin and defroster is obtained directly from the exhaust system muffler shroud.
Page 16 SECTION II HANDLING AND SERVICING Aerofiche Paragraph Grid No.. 2-1. Introduction...................... 1A19 2-2. Dimensions....................... 1A19 2-3. Station Reference Lines................... 1A19 2-4. Weight and Balance Data................. 1A19 2-5. Serial Number Plate..................1A19 2-6. Access and Inspection Provisions..............1A19 2-7. Tools and Test Equipment................1A19 2-8.
Page 17 Aerofiche Paragraph Grid No. 2-31. Landing Gear System ..................1B15 2-32. Servicing Landing Gear..............1B15 2-33. Oleo Struts....................1B15 2-34. Servicing Oleo Struts..............1B15 2-35. Filling Nose Gear Oleo Strut............1B17 2-36. Filling Main Gear Oleo Strut............1B17 2-37. Inflating Oleo Struts ...............1B18 2-38. Brake System..................1B19 2-39.
Page 18 Aerofiche Paragraph Grid No. 2-74. Corrosion Control..................1C13 2-75. Form of Corrosion................1C13 2-76. Conditions Affecting Corrosion .............1C13 2-77. Inspection..................1C14 2-78. Corrosion Removal and Control.............1C14 2-79. Areas Prone to Corrosion ...............1C16 2-80. Repainting....................1C17 2-81. Product Listing For Urethane Enamel Aircraft Finish ....1C17 2-82.
Page 19 PIPER CHEROKEE WARRIOR SERVICE MANUAL SECTION II HANDLING AND SERVICING 2 - 1 . INTRODUCTION: This section contains routine handling and servicing procedures that are most f r equently encountered. Frequent reference to this section will aid the individual by providing information such as the location of various components, ground handling procedures, routine service procedures and l u b r ication.
Page 20 PIPER CHEROKEE WARRIOR SERVICE MANUAL 12’ 11.75” 2’ 8” 3’ 6.2” 5’ 3” 35’ 10’ 23’ 9.6” Figure 2-1. Three View Issued: August 22, 1973 HANDLING AND SERVICING 1A20 Island Enterprises...
Page 21 PIPER CHEROKEE WARRIOR SERVICE MANUAL 53.12 6.15 77.87 256.60 14.94 71.17 53.37 19.73 106.20 22.25 106.63 THEORETICAL TIP 208.05 88.75 211.57 57.00 7.00 258.72 280.90 00.00 267.40 7.00 48.60 80.60 108.17 138.33 100.10 101.13 98.50 52.79 62.88 67.85 60.94 53.35 51.75...
Page 22: Ii-I
PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS MODEL: PA-28-151, WARRIOR PA-28-161, WARRIOR II PA-28-161, WARRIOR III ENGINE: Manufacturer Textron Lycoming Model O-320-E3D /O-320-D2A O-320-D3G 3 & 4 FAA Type Certificate Rated Horsepower /160 3 & 4...
Page 23 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (cont.) MODEL: PA-28-151, WARRIOR PA-28-161, WARRIOR II PA-28-161, WARRIOR III PROPELLER Fixed Pitch: Manufacturer Sensenich Model 74 DM6-0-58 , 74 DM6-0-60 3 &4 Diameter 74 in Diameter, Minimum...
Page 24 3. PA-28-161, Warrior II 4. PA-28-161, Warrior III 5. Standard on PA-28-151, Warrior. Optional climb propeller on PA-28-161, Warrior II 6. Refer to Piper Parts Catalog for effective serial numbers. 7. PA-28-151, Warrior, S/N’s 7515001 and up. THIS SPACE INTENTIONALLY LEFT BLANK...
Page 25 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 26 MANUFACTURED BEFORE 1979 MAY NOT HAVE THESE PANELS INSTALLED. REFER TO SECTION IV FOR PROCEDURES TO INSTALL CONTROL CABLE INSPECTION PANELS,) (REFER TO LATEST REVISION OF PIPER SERVICE BULLETIN NO, 977.) Figure 2-3. Access Plates and Panels Revised: February 28, 1995...
Page 27 Lycoming Special Service Publications No. SSP1776, and propeller torque values are found in Section VIII of this manual. Table II-IIA lists the torque values for flared fittings of various sizes and material. Important p r ocedures for torquing assemblies on Piper Aircraft are as follows: a. Frequently check and/or calibrate the torque wrench.
Page 28 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 29 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-II. RECOMMENDED NUT TORQUES T O R Q U E S : The importance of correct application can not be overemphasized. CHART B Under torque can result in unnecessary wear of nuts and bolts as well as the parts they are holding together.
Page 30 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-II. RECOMMENDED NUT TORQUES (continued) FINE THREAD SERIES BOLTS BOLTS BOLTS Steel Tension Steel Tension Aluminum AN 3 THRU AN 20 MS 20004 THRU MS 20024 AN 3DD THRU AN 20DD AN 42 THRU AN 49...
Page 31 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-III. FLARE FITTING TORQUESX TORQUE INCH-POUNDS TUBING ALUMINUM - ALLOY STEEL TUBING HOSE END FITTING TUBING FLARE - AND FLARE INCHES 10061 OR AND 10078 AND 10061 HOSE ASSEMBLIES MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM...
Page 32 A fixed handhold is located on the right side of the fuselage near the rear window. A step is available as optional equipment and is installed just aft of the trailing edge of the right flap. Refer to latest r e v i s i o n of Piper Service Kit No.763 848 (PAC Drawing 78802) 2-10.
Page 33 PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-13. WEIGHING: (Refer to Figure 2-5.) The airplane may be weighed by the following procedure: a. Position a scale and ramp in front of each of the three wheels. b. Secure the scales from rolling forward and tow the airplane up onto the scales.
Page 34 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 2-6. Leveling Longitudinally Figure 2-7. Leveling Laterally 2-15. MOORING. The airplane is moored to insure its immovability, protections and security under various weather conditions. The following procedure gives the instructions for proper mooring of the airplane: a.
Page 35 PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-16. LOCKING AIRPLANE. The cabin and baggage compartment doors are provided with a key lock on the outside. The ignition switch and cabin door require the same key while the baggage compartment door has a separate key.
Page 36 1. Turn aircraft MASTER SWITCH and all electrical equipment OFF. 2 . Ensure that the RED lead of PEP (Piper External Power) kit jumper cable goes to the POSI- TIVE (+) terminal of external 12-volt battery and the BLACK lead goes to the NEGATIVE (-) terminal.
Page 37 PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-2 1 a . O P E R ATION OF EXTERNAL 28 VDC POWER RECEPTACLE: On the PA-18-161, Warrior III, S / N ’s 2816110 and up, the 28 Vdc external power receptacle is located on the right side of the fuselage just aft of the baggage door.
Page 38 PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-24. CLEANING LANDING GEAR: Before cleaning the landing gear, place a plastic cover or similar material over the wheel and brake assembly. a. Place a pan under the gear to catch waste. b. Spray or brush the gear area with solvent or a mixture of solvent and degreaser, as desired. It may be necessary to brush areas that were sprayed where heavy grease and dirt deposits have collected in order to clean them.
Page 39: Landing Gear System
PIPER CHEROKEE WARRIOR SERVICE MANUAL b. Soiled upholstery, except leather, may be cleaned by using an approved air drying type cleaner or foam upholstery cleaner. Carefully follow the manufacturer’s instructions. Avoid soaking or harsh rubbing. c. Leather material should be cleaned with saddle soap or mild soap and water.
Page 40 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. FILLER , LEFT FUEL TANK 13. CARBURETOR, ENGINE 2. DRAIN, LEFT FUEL TANK 14. FILTER, INDUCTION AIR 3. FILTER, VACUUM REGULATOR 15. SCREEN, ENGINE OIL PRESSURE 4. RESEVOIR, BRAKE SYSTEM 16. FUEL MANIFOLD DRAINS, L AND R 5.
Page 41: Filling Nose Gear Oleo Strut
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-3 5 . FILLING NOSE GEAR OLEO STRUT: To fill the nose gear oleo strut with hydraulic fluid ( M I L-H5606), whether it be only the addition of a small amount or if the unit has been completely emptied and will require a large amount, it should be filled as follows: a.
Page 42 PIPER CHEROKEE WARRIOR SERVICE MANUAL d. Remove any one of the three torque link bolts, and again raise the airplane until a minimum of ten inches (do not exceed twelve inches of tube exposure) of strut tube is exposed with the wheel remaining on the ground.
Page 43: Inflating Oleo Struts
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-37. INFLATING OLEO STRUTS: After making certain that the oleo strut has sufficient fluid, attach a strut pump to the air valve and inflate the oleo strut. The strut should be inflated until the correct inches of p i ston is exposed with normal static load (empty weight of airplane plus full fuel and oil on the gears.
Page 44 PIPER CHEROKEE WARRIOR SERVICE MANUAL PA-28-151 WARRIOR S/N 28-7415001 THRU 28-7715314 PA-28-161,WARRIOR II S/N 28-7716001 THRU 28-8116074 1. CARBURETOR AIR INTAKE DUCT 2. AIR FILTER BOX SEAL 3. COVER PLATE 4. RETAINER 5. FILTER ELEMENT 6. RETAINER 7. HOUSING 8. AIR FILTER BOX SEAL 9.
Page 45: Service Instructions (Inspection And Replacement)
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-48. SERVICE INSTRUCTIONS (INSPECTION AND REPLACEMENT): a. The wet-type polyurethane foam air filter must be inspected 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 46: Draining Fuel System
(Refer to latest Piper Service Bulletin No. 631.) The security of all electrical connections should be checked as well as the operation of all lights, general condition of the alternator and starter.
Page 47: Lubrication
PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. BODY 2. SCREEN 3. GASKET 4. STRAINER BOWL 5. BAIL WIRE 6. BAIL ASSEMBLY 7. SAFETY WIRE 8. DRAIN VALVE Figure 2-10. Fuel Strainer 2-60. LUBRICATION. 2-61. OIL SYSTEM (ENGINE). 2-62. SERVICING OIL SYSTEM: The engine oil level should be checked before each flight and changed after each 50 hours of engine operation.
Page 48: Oil Screens (Suction)
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-64. DRAINING OIL SUM:. To drain the oil sump, provide a suitable container with a minimum capacity of that required to fill the sump. Remove the engine cowl and open the oil drain valve located on the underside of the engine by pushing the arms of the drain up and turning counterclockwise.
Page 49: Lubrication Instructions
PIPER CHEROKEE WARRIOR SERVICE MANUAL b. When changing from straight mineral oil to compounded oil, the following precautionary steps should be taken: 1. Do not add additive oil to straight mineral oil. Drain the straight mineral oil from the engine and fill with additive oil.
Page 50: Type Of Lubricants
PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-IV. TYPE OF LUBRICANTS PREFERRED PRODUCT LUBRICANT SPECIFICATION AND VENDOR LUBRICATING OIL, GENERAL PURPOSE, LOW MIL-L-7870 TEMPERATURE LUBRICATING OIL, GENERAL PURPOSE, LOW MIL-L-6082 REFER TO THE LATEST ENGINE (PISTON) GRADE AS SPECIFIED REVISION OF LYCOMING SAE 50 ABOVE 60°F AIR TEMP...
Page 51 WATER. 3. FUEL SELECTOR VALVE - LUBRICATE FUEL SELECTOR VALVE AS REQUIRED. REFER TO THE LATEST REVISION OF PIPER SERVICE LETTER NO. 351. 4. SEE THE LATEST REVISION OF LYCOMING SERVICE INSTRUCTION NO. 1014 FOR USE OF DETERGENT OIL. CAUTIONS 1.
Page 52 PIPER CHEROKEE WARRIOR SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY OLEO STRUT FILLER POINT MIL-H-5606 AS REQUIRED UPPER TORQUE LINK BEARING MIL-G-23817 100 HOURS TORQUE LINK BUSHING MIL-L-7820 (See Note 1) MIL-G-23827 (See Note 2) 100 HOURS TORQUE LINK CONNECTING BUSHING MIL-G-23827...
Page 53 PIPER CHEROKEE WARRIOR SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY OLEO STRUT FILLER POINT MIL-H-5606 AS REQUIRED STEERING BELLCRANK PIVOT POINT MIL-L-7870 100 HOURS SHIMMY DAMPENER PIVOT POINT MIL-L-7870 100 HOURS TORQUE LINK ASSEMBLY MIL-L-7870 100 HOURS NOSE WHEEL BEARING TEXACO MARFAX ALL PURPOSE...
Page 54 PIPER CHEROKEE WARRIOR SERVICE MANUAL —CAUTION— Do not lubricate control wheel shaft or bushing Clean only, using alcohol or other suitable solvent. COMPONENT LUBRICANT FREQUENCY 1. AILERON HINGE PINS MIL-L-7870 100 HOURS 2.. FLAP HINGE BEARINGS MIL-L-7870 100 HOURS 3. STABILATOR HINGE PINS...
Page 55 PIPER CHEROKEE WARRIOR SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY FLAP TORQUE TUBE BEARING BLOCKS MIL-L-7870 100 HOURS FLAP CONTROL ROD END BEARINGS MIL-L-7870 100 HOURS FLAP HANDLE PIVOT POINT, LOCK MECHANISM, AND TURNBUCKLE END AND CABLE PULLEY MIL-L-7870 100 HOURS FLAP RETURN AND TENSION CHAINS...
Page 56 PIPER CHEROKEE WARRIOR SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY RUDDER TUBE BEARING LOCKS CARBON DIOXIDE RELEASE AGENT DRY LUBRICANT MS-122N/CO 2 100 HOURS TOE BRAKE CYLINDER ATTACHMENTS MIL-L-7870 100 HOURS RUDDER TUBE CONNECTIONS MIL-L-7870 100 HOURS BRAKE ROD ENDS MIL-L-7870 100 HOURS...
Page 57 PIPER CHEROKEE WARRIOR SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY RUDDER ARM CABLE ENDS MIL-L-7870 100 HOURS STABILATOR TRIM SCREW LUBRIPLATE 907, FISKE BROS. REFINING CO. 100 HOURS STABILATOR SCREW/TAB LINKS MIL-L-7870 100 HOURS STABILATOR HINGE POINTS MIL-L-7870 100 HOURS RUDDER TRIM ASSEMBLY...
Page 58 PIPER CHEROKEE WARRIOR SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY DOOR HINGES MIL-L-7870 100 HOURS DOOR SEALS CARBON DIOXIDE RELEASE AGENT DRY LUBRICANT MS-122N/CO 2 50 HOURS DOOR LATCH MECHANISMS MIL-L-7870 500 HOURS SEAT TRACK ROLLERS, STOP PINS AND REAR LUBRIPLATE 907, FISKE BROS.
Page 59 PIPER CHEROKEE WARRIOR SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY ENGINE SUMP See the latest revision of Lycoming Service Instructions No. 1014 for appropriate gardes of both MIL-L-6082 straight mineral type, or MIL-L-22851 for ashless dispersant type oil. 50 HOURS CARTRIDGE TYPE OIL FILTERS...
Page 60 PIPER CHEROKEE WARRIOR SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY CONDENSER HINGE AND ACTUATORS MIL-L-7870 100 HOURS CONDENSER DOOR ACTUATING TRANSMISSION V MIL-G-23827 500 HOURS ALTERNATOR IDLER PULLEY BEARING MIL-G-81322 100 HOURS SPECIAL INSTRUCTIONS 1 . Transmission to be 1/2 full of grease. Apply grease during assembly and lubricate transmission ball nut and screw with M I L -G -23827 grease.
Page 61: Corrosion Control
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-74. 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 corro- sion in aircraft. The two general types of corrosion are: 1) a direct chemical attack (ex. spilled battery acid);...
Page 62: Inspection
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-77. INSPECTION: Corrosion should be inspected for at every inspection. In trouble areas, the inspection frequency should be increased. In addition to routine inspections: a. Aircraft operating around a marine environment should be given special checks on a weekly basis.
Page 63 PIPER CHEROKEE WARRIOR SERVICE MANUAL There are several methods for removing corrosion; chemical treatment; hand sanding with abrasive paper or metal wool; and, mechanical sanding or buffing with abrasive mats or grinding wheels. The method selected depends on the type and extent of the corrosion.
Page 64: Areas Prone To Corrosion
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-7 9 . AREAS PRONE TO CORROSION. Certain areas are more prone to corrosion than others. The fol- l o wing list is intended to be a general guide to areas where corrosion is frequently found: a.
Page 65: Repainting
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-80. REPAINTING: If it becomes necessary or desirable to repaint the aircraft, the following procedures will apply: NOTE Solvent resistant masking tapes are authorized for use. NOTE Masking tapes should be removed as soon as practicable after finish application.
Page 66: Preparation Of Epoxy Zinc Chromate Primer
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-82. PREPARATION OF EPOXY ZINC CHROMATE PRIMER: a. MIXING RATIO: Two parts primer 825S with one part activator 826S. Thin with approximately one part reducer 3602S, mix thoroughly, and allow to stand for one hour minimum.
Page 67: Finish Painting With Randolph Paint (B5420/D7784)
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-86. FINISH PAINTING WITH RANDOLPH PAINT (B5420/D7784). a. MIXING RATIO: When Randolph B5420 is sprayed it should be thinned for proper spraying results for either hot or cold spray. Randolph D7784 is prethinned, but may be thinned if required.
Page 68 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VI. LIST OF CONSUMABLE MATERIALS MATERIAL SPECIFICATION BRAND NAME MANUFACTURER Grease, High MIL-G-3545 High Temp. Grease, Texaco Inc., 135 East Temperature QPL-3545-15 Marfax All Purpose 42nd, New York, New York 10017 Shellaire Grease HT, Shell Oil Co., 50...
Page 69 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VI. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION BRAND NAME MANUFACTURER Lubricating Grease MIL-G-7711 Regal AFB2, Regal Texaco, Inc., 135 East QPL-7711-15 Starfak Premium 2 42nd., New York, New York 10017 Standard Oil of...
Page 70 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VI. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION BRAND NAME MANUFACTURER Grease Aircraft and MIL-G-23827 Low Temp. Grease EP Texaco, Inc., 135 East Instrument, Gear and QPL-23827-10 42nd., New York, Actuator Screw (See Note 2 at end of...
Page 71 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VI. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION BRAND NAME MANUFACTURER Grease, Aircraft MIL-G-3278 Unitemp EP Texaco, Inc., 135 East Instruments, Low and QPL-3278-24 42nd., New York, High Temperature New York 10017 Rpmavn Grease 5, Standard Oil of Supermil Grease No.
Page 72 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VI. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION BRAND NAME MANUFACTURER Grease, Ball and Roller MIL-G-18709 Regal ASB-2 Formula Texaco, Inc., 135 East Bearing QPL-18709-55 TG-10293 42nd., New York, New York 10017 Exxon Company, Andok B U.S.A., Box 2180,...
Page 73 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VI. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION BRAND NAME MANUFACTURER D r y Lubricant, C a r b o n MS-122N/CO2 MS-122N/CO2 M i l l e r- S t e p h e n s o n...
Page 74 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VI. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION BRAND NAME MANUFACTURER Epoxy Patching Solarite #400 Solar Compounds Corp. Compound 1201 W. Blancke St. P.O. Box 27, Linden, N.J. 07036 Hot Melt Adhesives Stick Form 1/2 in.dia.3 Sears Roebuck &...
Page 75 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VII. CONVERSION TABLES 1. These charts contain the various conversion data that may be useful when figuring capacities, length, temperatures, and various weights and measures from the English system values to the metric system values or back again.
Page 76 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VII. CONVERSION TABLES MULTIPLY TO OBTAIN MULTIPLY TO OBTAIN CENTIMETERS 0.3937 KILOGRAMS 2.205 0.03281 35.27 1000 GRAMS CU. CENTIMETERS 0.001 LITERS 0.06102 CU. IN LITERS 1000 CU. CM. 0.0002642 U.S. GAL. 61.03 CU. IN.
Page 77 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VII. CONVERSION TABLES (cont.) CENTIGRADE - FAHRENHEIT CONVERSION TABLE Example: To convert 20°C, to Fahrenheit, find 20 in the center column headed (°F - °C); then read 68.0°F, in the column (°F) to the right. To convert 20°F, to Centigrade;...
Page 78 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VII. CONVERSION TABLES (cont.) INCHES TO MILLIMETER INCHES 0.0000 0.0001 0.0002 0.0003 0.0004 0.0005 0.0006 0.0007 0.0008 0.0009 MILLIMETER 0.000 0.0025 0.0050 0.0076 0.0101 0.0127 0.0152 0.0177 0.0203 0.0228 0.001 0.0254 0.0279 0.0304 0.0330 0.0355...
Page 79: Hose Clamp Tightening. (Initial Installation)
PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-VIII. THREAD LUBRICANTS TYPE OF LINE TYPE OF LUBRICANT Brakes MIL-5-5606 Freon TT-A-580 or MIL-T-5544, Anti-Sieze Compound Fuel MIL-T-5544 Anti-Sieze, Graphite Petrolatum Landing Gear Air Valve 6PB Parker MIL-G-6032, Lubrication Grease (Gasoline and Oil Resistant)
Page 80: Maximum Distance Between Supports For Fluid Tubing
PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-X. MAXIMUM DISTANCE BETWEEN SUPPORTS FOR FLUID TUBING TUBE. OD DISTANCE BETWEEN SUPPORTS (IN.) (IN.) ALUMINUM ALLOY STEEL 9-1/2 11-1/2 3/16 13-1/2 5/16 16-1/2 25-1/2 27-1/2 26-1/2 THIS SPACE INTENTIONALLY LEFT BLANK Added: March 3, 1980...
Page 81: Decimal/Millimeter Equivalents Of Drill Sizes
PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE II-XI. DECIMAL MILLIMETER EQUIVALENTS OF DRILL SIZES Decimal/Millimeter Equivalents of Drill Sizes From 1/2” to No. 80 Size Decimal Millimeter Size Decimal Millimeter Size Decimal Millimeter Size Decimal Millimeter Equiv. Equiv. Equiv. Equiv. Equiv.
Page 82: Removal Of Cherrylock Rivets
PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 2-20. Cherry Lock Rivet Removal 2-88. REMOVAL OF CHERRYLOCK RIVETS. To remove cherrylock rivet: a. File head flat. b. Centerpunch rivet head. c. In thick material, remove the lock by driving out the rivet stem using a tapered steel drift pin. (See View 1.)
Page 83 PIPER CHEROKEE WARRIOR SERVICE MANUAL TWO COTTON BRAIDS — IMPREGNATED WITH SYNTHETIC COMPOUND YELLOW NUMERALS, LETTERS AND STRIPES MIL-H-8794:Size-6-2/68-Mfg Symbol MIL-H-5593-6-4/68-Mfg Symbol B . N O N - S E L F - S E A L I N G A R O M A T I C...
Page 84: Standard Practice - Airframe
PIPER CHEROKEE WARRIOR SERVICE MANUAL 2-89. STANDARD PRACTICE - AIRFRAME. 2-90. TORQUE WRENCH: Torque wrenches should be checked daily and calibrated by means of weights and a measured lever arm to make sure that inaccuracies are not present. Checking one torque wrench against another is not sufficient and is not recommended.
Page 85 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1D13 Island Enterprises...
Page 86 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1D14 Island Enterprises...
Page 87 SECTION III INSPECTION Aerofiche Paragraph Grid No.. 3-1. Introduction ..................... 1D16 3-2. Recommended Lubricants ................1D16 3-3. Inspection Periods ................... 1D16 3-4.Inspection Requirements................1D16 3-5.Preflight Check..................1D16 3-6.Overlimits Inspection ................1D17 3-7.Special Inspections..................1D17 3-8.Inspection of Exhaust System ..............1D17 3-9.Progressive Inspection................
Page 88 (O). If an item is not entirely accessible or must be removed, refer to the applicable section of this manual for instructions on how to gain access to remove the item. When performing inspections, use forms P/N 230 802 furnished by the Piper Factory Service Department, available through Piper Dealers or Distributors.
Page 89: Inspection Report
PROGRESSIVE INSPECTION: The progressive inspection was designed to permit the utilization of the aircraft, by scheduling inspections through the use of a planned inspection schedule. Progressive Inspection schedules are available from Piper Service Sales P/N 761 540. Revised: February 28, 1995...
Page 90 PIPER CHEROKEE WARRIOR SERVICE MANUAL ON OUTER SURFACE ON OUTER SURFACE ALL WELDS REFER TO AC-43.23-1A AS INDICATED BY ARROWS Figure 3-1. Inspection Areas of Exhaust System FATIGUE AREAS REFER TO AC-43.13-1A INDICATED BY ARROWS Figure 3-2. Typical Muffler Fatigue Areas Revised: April 12.
Page 91 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE III-I. INSPECTION REPORT NOTE All inspections or operations must be performed at each of the inspec - tion intervals as indicated by a circle (O). (See Notes 1, 2, 3 and 4.) Inspection time (hrs)
Page 92 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE III-I. INSPECTION REPORT (cont.) Inspection time (hrs) Nature of Inspection 50 100 500 1000 B. ENGINE GROUP (cont.) 15. Inspect cylinders for cracked or broken fins (See Note 11)......... 16. Inspect rocker box covers for evidence of oil leaks. If found, replace gasket, torque cover screws 50 inch-pounds.
Page 93 8. Inspect aileron centering cable installation per latest revision of Piper Service Bulletin No. 435. (See Note 9.) ................9. Inspect flap control cable attachment bolt. (See latest revision of Piper Service Bulletin No. 965.)....................10. Check landing, navigation, cabin and instrument lights........
Page 94 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE III-I. INSPECTION REPORT (cont.) Inspection time (hrs) Nature of Inspection 50 100 500 1000 C. CABIN GROUP (cont.) 20. On Warrior II models only, inspect condition of air conditioning ducts....21. On Warrior II models only, remove and clean air conditioning evaporator filter.
Page 95 ......................34. Check emergency locator transmitter battery replacement date and transmitter for operation. (See latest revision of Piper Service Letter No. 820.) ....35. Install inspection plates and panels..............E. WING GROUP 1.
Page 96 15. Inspect oleo struts for fluid leaks and scoring............16. Inspect gear struts, attachments, torque links, and bolts for condition and secur ity. (Refer to latest revision of Piper Service Letter No. 842.) ....17. Lubricate per lubrication chart................
Page 97 TABLE III-I. INSPECTION REPORT (cont.) NOTES: 1. Refer to the last card of the Piper - Parts Price List - Aerofiche, for a checklist of current revision dates to Piper Inspection Reports and Manuals. 2. Both the annual and 100 hour inspections are complete inspections of the airplane, identical in scope, while both the 500 and 1000 hour inspections are extensions of the annual or 100 hour inspections.
Page 98 20. Refer to latest Piper Service Bulletin No. 631 for Battery Protection. 21. PA-28-151, Warrior and PA-28-161, Warrior II: refer to latest revision of Piper Aircraft Service Bulletin No. 886. PA-28-161. Warrior III: refer to latest revision of Piper Aircraft Service Bulletin No.
Page 99 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 100 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 101 SECTION IV STRUCTURES Aerofiche Paragraph Grid No.. 4-1. Introduction...................... 4-2. Description ...................... 4-3. Wing Group ..................... 4-4. ..Wing Tip ......................4-5.Removal of Wing Tip ................4-6 Installation of Wing Tip ................4-7. Aileron ......................4-8.Removal of Aileron .................. 4-9.Installation of Aileron ................4-10.
Page 102 Aerofiche Paragraph Grid No. 4-36. Door (Entrance)....................4-37. Removal of Door ................4-38. Installation of Door ................4-39. Adjustment of Door ................4-40. Removal of Door Latch Mechanism........... 4-41. Installation of Door Latch Mechanism ..........4-42. Adjustment of Door Latch Mechanism ..........4-43.
Page 103 PIPER CHEROKEE WARRIOR SERVICE MANUAL SECTION IV STRUCTURES 4-1. INTRODUCTION: This section explains the removal and installation procedures for the structural surfaces of the airplane. For the removal, installation, and rigging and adjustment procedures of the control- ling components of the various structural surfaces, refer to Section V.
Page 104 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4-4. WING TIP. 4-5. REMOVAL OF WING TIP: a. Remove the screws holding the wing tip to the wing, being careful not to damage the wing or ther- moplastic wing tip. b. Pull the wing tip off far enough to disconnect the position light wire assembly. The ground lead may be disconnected at the point of connection on the wing rib, and the positive lead may be disconnected at the wire terminal or unscrewed from the light assembly.
Page 105 PIPER CHEROKEE WARRIOR SERVICE MANUAL PA-28-151, S/N’s 28-7615001 AND UP PA-28-161, S/N’s 28-7716001 AND UP Figure 4-1. Aileron and Flap Installantion Revised: November 30, 1982 STRUCTURES Island Enterprises...
Page 106 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-1. Aileron and Flap Installantion (cont) Revised: December 1, 1976 STRUCTURES 1E10 Island Enterprises...
Page 107 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4-12. INSTALLATION OF WING FLAP. (Refer to Figure 4-1.): a. Replace the wing flap by placing the flap onto its proper position and inserting the hinge bolts, bushings, washers, and nuts. b. With the flap control in the full down position, place the bushing on the outboard side of the rod end bearing and insert and tighten the bolt.
Page 108 PIPER CHEROKEE WARRIOR SERVICE MANUAL m. If the left wing is being removed, it will be necessary to disconnect the pitot and static tubes at the elbows located within the cockpit at the wing butt line. n. Arrange a suitable fuselage cradle and supports for both wings.
Page 109 PIPER CHEROKEE WARRIOR SERVICE MANUAL m. Connect the electrical leads to the appropriate posts on the terminal strip and install the washers and nuts. (For assistance in connecting the electrical lead, refer to the Electrical Schematics in Section XI.) Place the clamps along the electrical harness to secure it in position and install the terminal strip dust cover.
Page 110 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE Figure 4-2. Wing Installation Revised: March 3, 1980 STRUCTURES 1E14 Island Enterprises...
Page 111 PIPER CHEROKEE WARRIOR SERVICE MANUAL SKETCH D SKETCH C Figure 4-2. Wing Installation (cont.) Revised: February 28, 1995 STRUCTURES 1E15 Island Enterprises...
Page 112 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-2. Wing Installation (cont.) Revised: October 13, 1980 STRUCTURES 1E16 Island Enterprises...
Page 113 28-8016363 through 28-28-8616057, 2816001 through 2816093, 2816095, and 2816096 may require that stall strips be added to the leading edge of both wings. Refer to the latest revision of Piper Service Bulletin No. 916 and kit No.765 399 for further information.
Page 114 PIPER CHEROKEE WARRIOR SERVICE MANUAL TOP OF LEADING EDGE SKIN (REF.) 10.55 ” (REF.) STALL STRIP (REF.) SECTION A-A 10.55 ± 0.125 ” 10.85 ± 0.125 ” TRUE TRUE NAS 1738B4-3 (522 883) RIVETS (2 REQD.) 0.80 ± 0.125” 117.50 106.190...
Page 115 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-4. Methods of Securing Control Cables 4-19. INSTALLATION OF STABILATOR. (Refer to Figure 4-5.) NOTE A clearance of 0.25 ± 0.06 of an inch between the stabilator and the side of the fuselage and .18 of an inch minimum between all parts of the stabilator and the tail cone assembly must be maintained throughout the stabilator travel.
Page 116 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-5. Empannage Group Installation Revised: February 28, 1995 STRUCTURES 1E20 Island Enterprises...
Page 117 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-5. Empannage Group Installation (cont.) Revised: February 28, 1995 STRUCTURES 1E21 Island Enterprises...
Page 118 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4-20. STABILATOR TRIM TAB. 4-21. REMOVAL OF STABILATOR TRIM TAB. (Refer to Figure 4-5.) a. Disconnect the stabilator trim control rod by removing the bolts that attach the control rod to the stabilator trim tab.
Page 119 PIPER CHEROKEE WARRIOR SERVICE MANUAL d. Disconnect the wire antenna (optional) if installed that attaches to the leading edge of the fin. e. Disconnect the positive lead to the rotating beacon (optional) if installed and attach a line prior to removal.
Page 120 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-6. Window Installation (Typical) Revised: February 28, 1995 STRUCTURES 1E24 Island Enterprises...
Page 121 PIPER CHEROKEE WARRIOR SERVICE MANUAL f. Lay sealant at the bottom and center (inboard) of the windshield in the hollow between the outside edge and channel. g. Lay a small amount of sealant under the center trim strip, install and secure.
Page 122 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4-36. DOOR (ENTRANCE). 4-37. REMOVAL OF DOOR. a. Remove the clevis bolt, washer and bushing from the door holder assembly. b. Remove cotter pins, clevis pins and washers from serrated door hinges. c. Remove the door from the airplane.
Page 123 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4-46. INSTALLATION OF DOOR SAFETY LATCH. a. Place the latch assembly into position for installation. b. Replace the pan and install the five screws and handles. c. Check the latch assembly for operation and be certain that it is free of rubbing on the trim panels.
Page 124 PIPER CHEROKEE WARRIOR SERVICE MANUAL 7 . Remove masking tape if used, and clean off excessive adhesive using a clean cloth and mineral spirits or Toluol. 8. Install the striker plate. 9. Reposition the windlace and secure with retainers previously removed.
Page 125 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-8. Door Seal Snubber Installation Revised: February 28, 1995 STRUCTURES Island Enterprises...
Page 126 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-9. Fabricated Tool For Baggage Door Lock 4-54b . SHOULDER-HARNESS INERTIA REEL ADJUSTMENT. a. Allow the harness to wind up on the reel as much as possible. b. On the end of the reel, pry off the plastic cap over the spring, making sure the spring does not come out of the plastic cap, and set cap aside.
Page 127 Installation Of Lumbar Bladder — NOTE — An installation kit is required for airplanes not previously equipped with a lumbar support Refer to Piper's Illustrated Parts Catalog for kit part number.. Revised: February 28, 1995 STRUCTURES...
Page 128 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. If necessary to assemble pad and bladder: A Apply a layer of 3M 847 cement to smooth side of bladder pad. B Apply a layer of 3M 847 cement to back side of bladder (side away from inflation tube nipple).
Page 129 PIPER CHEROKEE WARRIOR SERVICE MANUAL BLADDER BLADDER INFLATION AIR INLET AND VENT BLADDER BLADDER AND PAD TUBE SEAT BACK FILLER BLADDER INFLATION & DEFLATION CONTROLS Figure 4-10b. Lumbar Seat Bladder Installation Added: February 28, 1995 STRUCTURES Island Enterprises...
Page 130 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4-5 5 . STRUCTURAL REPA I R S . WARNING NO access holes are permitted in any control surfaces. WARNING The use of patch plates for repairs of all movable tail surfaces is prohibited. The use of any filler material normally used for repair of minor dents and/or materials used for filling the inside of surfaces is also prohibited on all movable tail surfaces.
Page 131 PIPER CHEROKEE WARRIOR SERVICE MANUAL NUMBER MATERIAL THICKNESS (SKIN) 2024-T3 0.016 2014-0* 0.020 2024-T3 0.020 2024-T3 0.025 2024-T3 0.032 2024-T3 0.040 2024-T3 0.051 FIBERGLASS THERMOPLASTIC 5052-H34 0.032 *HEAT TREAT TO 2024-T3 AFTER FORMING Figure 4-11. Skin Materials and Thickness Revised: February 28, 1995...
Page 132 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-12. Typical Access Plates Revised: February 28, 1995 STRUCTURES 1F12 Island Enterprises...
Page 133 PIPER CHEROKEE WARRIOR SERVICE MANUAL 21.80” FORWARD 14.99” 2.28” R 2.00” R TYP;M 0.120” HOLE THRU N0.8 X 38 CRES TRUSS RECESSED HEAD SHEET METAL SCREWS (16 REQD.) 2.50” COVER (2 REQD) 30° TYP PIPER P/N 62109-0 10.98” 8.48” 19.11”...
Page 134 (puncture, breaks, and holes that have penetrated through the structure and damaged the fiberglass cloth). A repair kit, part n u mber 766 222 gives necessary material for such repairs, and is available from Piper Aircraft dealers. CAUTION Follow resin and catalyst mixing instructions furnished with repair kit.
Page 135 PIPER CHEROKEE WARRIOR SERVICE MANUAL e. After trimming patch, immediately place small amount of gel coat on cut edge of patch and cover with cellophane. Use a squeegee or the back of a razor blade, squeegee level with area surrounding patch.
Page 136 PIPER CHEROKEE WARRIOR SERVICE MANUAL p. Cover with cellophane and squeegee smooth. Cure completely before removing cellophane. Sand the area. q. Brush or spray catalyzed resin to seal patch. Sand and finish by priming. Sand again and apply color coat.
Page 137 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE 1V-1 LIST OF MATERIALS FOR THERMOPLASTIC REPAIR ITEMS DESCRIPTIONS SUPPLIERS Buffing and Rubbing Automotive Type - DuPont #7. DuPont Company Compounds. Wilmington. Del. 19898 Ram Chemical #69 x 1. Ram Chemicals Gardena, CA 90248 Mirror Glaze #1.
Page 138 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-14. Surfaces Scratches, Abrasions or Ground-In Dirt Figure 4-15. Deep Scratches, Shallow Nicks and Small Holes Revised: February 28, 1995 STRUCTURES 1F18 Island Enterprises...
Page 139 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE Increase adhesion by roughing bonding surface with sandpaper and by using as much surface area for bond as possible. 5. Mix patching compound in equal portions on a hard flat surface (use a figure eight motion).
Page 140 PIPER CHEROKEE WARRIOR SERVICE MANUAL THOROUGHLY MIX USING FIGURE EIGHT MOTION Figure 4-16. Mixing of Epoxy Patching Compound Figure 4-17. Welding Repair Method Revised: February 28, 1995 STRUCTURES 1F20 Island Enterprises...
Page 141 Instructions covering the wheel and strut fairing are contained in a special Wheel and Strut Fairing Repair Instruction Manual P/N 761 708V. This manual is obtainable from Vero Beach Service and Sales Department, Piper, Aircraft Corporation, 2926 Piper Drive, Vero Beach, Florida 32960. Revised: February 28, 1995...
Page 142 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-19. Various Repairs Revised: February 28, 1995 STRUCTURES 1F22 Island Enterprises...
Page 143 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-20. Repair of Stress Lines Figure 4-21. Repair of Impacted Damage Revised: February 28, 1995 STRUCTURES 1F23 Island Enterprises...
Page 144 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4-59. CONTROL SURFACEs 4-59a CHECKING CONTROL SURFACE FREE PLAY: The following checks are recommended before balancing to ascertain the amount of “free play” in the stabilator, stabilator trim tab and aileron: a. Stabilator: Check the stabilator for any “free play” at its attachment points by grasping each half near the tip and gently trying to move it up and down, fore and aft, and in and out.
Page 145 PIPER CHEROKEE WARRIOR SERVICE MANUAL Before balancing any control surface, it must be complete including tip, trim/servo tabs and tab actuat- ing arms or push rods with bearings as applicable, and all optional equipment which is mounted on or in the control surface when it is flown, including paint, position lights and wiring, static wicks, scuff boots, etc.
Page 146 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-22. Control Surface Balance Tool Revised: February 28, 1995 STRUCTURES Island Enterprises...
Page 147 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-23. Aileron Balance Revised: February 28, 1995 STRUCTURES Island Enterprises...
Page 148 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-24. Factory Installed Aileron Balance Weight (1974 and 1975 Models Only) Figure 4-25. Rudder Balance Revised: February 28, 1995 STRUCTURES Island Enterprises...
Page 149 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4-62. BALANCING RUDDER. (Refer to Figure 4-25.) To balance the rudder, the assembly must be complete including the tip assembly with all attaching screws and position light wiring. Place the complete assembly horizontally on knife edge supports in a draft free area in a manner that allows unrestricted movement.
Page 150 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 4-27. Stabilator Balance 4-63. BALANCING STABILATOR. (Refer to Figure 4-27.): To balance the stabilator, the assembly must be complete including the trim tab, the tab push rod and end bearing, stabilator tips and all attaching screws. Before balancing, tape the trim tab in neutral position with a small piece of tape.
Page 151 2. Sherwin Williams Lacquer Thinner R7KC120 3. Glidden Thinner No. 207 b.Safety Walk Material: Walkway Compound and Matting Nonslip (included in Piper Part No. 179 872) 4-67. APPLICATION OF LiQUID SAFETY WALK COMPOUND. Liquid safety walk compound shall bc applied in an area free of moisture for a period of 24 hours min- imum after application.
Page 152 PIPER CHEROKEE WARRIOR SERVICE MANUAL After recoating or touch-up, allow the coating to dry for 15 minutes to one hour before removing masking. NOTE The coated surface shall not bc walked on for six hours mini - mum after application of final coating 4-69 APPLICATION OF PRESSURE SENSITIVE SAFETY WALK.
Page 153 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 154: Control Surface Travel And Cable Tension
SECTION V SURFACE CONTROLS Aerofiche Paragraph Grid No. 5-1. Introduction ........................... 1G12 5-2. Description ..........................1G12 5-3. Standard Procedures ......................1G12 5-4. Control Cable Inspection....................... 1G13 5-5. Control Surface Travel and Cable Tension................1G18 5-6. Control Column Assembly ....................1G18 5-7.
Page 155 Aerofiche Paragraph Grid No.. 5-74. Wing Flap Controls........................ 1H20 5-38. Removal of Wing Flap Controls................. 1H20 5-39. Installation of Wing Flap Controls................1H22 5-40. Rigging and Adjustment of Wing Flaps..............1H23 Table VIII. Surface Control Troubleshooting Chart ................Added: February 28, 1995 1G11 Island Enterprises...
Page 156 PIPER CHEROKEE WARRIOR SERVICE MANUAL SECTION V SURFACE CONTROLS 5-1. INTRODUCTION: This section contains the explanation for the removal, installation, rigging and adjustment procedures for the control assemblies of the various structural surfaces. The assemblies need not be removed in order of paragraphs since each paragraph describes the individual removal and installation of the component.
Page 157 PIPER CHEROKEE WARRIOR SERVICE MANUAL g. Check cable tensions with the control surface in neutral position. h. After each adjustment, check turnbuckles to verify not more than three terminal threads are visible outside barrel. Install locking clips, and check for proper installation by trying to remove clips using fingers only.
Page 158 PIPER CHEROKEE WARRIOR SERVICE MANUAL DAMAGE HERE WRONG DAMAGE HERE IMPROPER TOOL (RESULTING IN LOCKED BALL) A SPECIAL WRENCH MAY BE REQUIRED WITH A LONG THROAT ONLY CORRRECT METHOD Figure 5-1. Rod End Installation Method The absence of snags is not positive evidence that broken wires do not exist. Figure 5-2A shows a cable with broken wires that were not detected by wiping, but were found during a visual inspection.
Page 159 PIPER CHEROKEE WARRIOR SERVICE MANUAL b. 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 5-3.
Page 160 PIPER CHEROKEE WARRIOR SERVICE MANUAL CABLE WEAR CABLE WEAR Figure 5-4. Internal Cable Wear d. 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 161 PIPER CHEROKEE WARRIOR SERVICE MANUAL e. Cable Maintenance Frequent inspections and preservation measures such as rust prevention treatments for bare cable areas will help to extend cable service life. Where cables pass through fairleads, pressure seals, or over pulleys, remove accumulated heavy coatings of corrosion prevention compound. Provide corrosion protection for these cable sections by lubricating with a light coat of graphite grease or general purpose, low-temperature oil.
Page 162 PIPER CHEROKEE WARRIOR SERVICE MANUAL CONTROL SURFACE TRAVEL AND CABLE TENSION: Refer to Table V-II for specifics when rigging control surface travel and measuring or adjusting cable tension. 5-6. CONTROL COLUMN ASSEMBLY. 5-7. REMOVAL OF CONTROL COLUMN ASSEMBLY. (Refer to Figure 5-6.) a.
Page 163 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE V-II CONTROL SURFACE TRAVEL AND CABLE TENSION AILERON 1974 & 1975 MODELS A = 23° ± 2° UP (SEE NOTE 3) B = 17° ± 2° DN (SEE NOTE 3) AILERON 1976 & SUBSEQUENT MODELS A = 25°...
Page 164 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE V-II CONTROL SURFACE TRAVEL AND CABLE TENSION (Cont.) RUDDER PEDAL NEUTRAL ANGLE = 14° + 3° -1° AFT OF VERTICAL FLAP A. 10° ± 2° FIRST NOTCH TRAVEL B. 25° ± 2° SECOND NOTCH TRAVEL C.
Page 165 PIPER CHEROKEE WARRIOR SERVICE MANUAL CONTROL WHEEL CONTROL WHEEL TUBE BOLT, WASHER & NUT FLEXIBLE JOINT TEE BAR STOP SPACER RIGHT ROLLER CHAIN LEFT ROLLER CHAIN CONTROL CHAINS TURNBUCKLE 10. BOLT, BUSHING, NUT & COTTER PIN 11. STABILATOR CONTROL CABLE 12.
Page 166 PIPER CHEROKEE WARRIOR SERVICE MANUAL 5-9. INSTALLATION OF FLEX JOINT REPLACEMENT. (Refer to Figures 5-6 and 5-7.) a. Carefully lay out location for hole to be drilled in flex joint tube to match hole in control column shaft. b. Using a #5 (0.2055) drill bit, drill hole through flex joint tube at location determined in paragraph (1).
Page 167 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE To help facilitate reinstallation of control cables, mark the cable ends and attach a line where applicable before drawing them through the fuselage or wing. 3. Separate the primary control cable (14 or 15) at the turnbuckle (12 or 16) located under the floor panel aft of the main spar.
Page 168 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. CONTROL CHAINS TURNBUCKLE 2. CONTROL WHEEL SPROCKET 3. IDLER SPROCKET 4. AILERON CONTROL CHAIN 5. PULLEY BRACKET 6. AILERON BELLCRANK 7. AILERON CONTROL ROD 8. TEE BAR PULLEY 9. FORWARD CLUSTER PULLEY 10. PRIMARY CONTROL CABLE PULLEY 11.
Page 169 PIPER CHEROKEE WARRIOR SERVICE MANUAL 2. Connect the cable to the end of the control chain (4) and secure using bushing, bolt, nut and cotter pin (23). 3. Place the cable around the pulley (9) that is located in the tunnel aft of the tee bar. Install the cable guard (28) only after cables have been tensioned.
Page 170 PIPER CHEROKEE WARRIOR SERVICE MANUAL g. Remove the nut, pivot bolt (25) and washers that secure the bellcrank. The nut is visible from the underside of the wing. h. Remove the bellcrank from within the wing. 5-14. INSTALLATION OF AILERON BELLCRANK ASSEMBLY. (Refer to Figure 5-8.) a .
Page 171 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 5-9. Bellcrank Rigging Tool (1974 and 1975 Models Only) Figure 5-10. Bellcrank Rigging Tool (1976 and Subsequent Models) Revised: February 28, 1995 SURFACE CONTROLS Island Enterprises...
Page 172 PIPER CHEROKEE WARRIOR SERVICE MANUAL 5. Should the two trailing edges (aileron and flap) not align, disconnect the aileron control push rod from the bellcrank and aileron, and loosen the jam nuts at each rod end and adjust the rod ends to obtain trailing edge alignment.
Page 173 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. CONTROL COLUMN TEE BAR 2.. RIGHT FORWARD CABLE 3. LEFT FORWARD CABLE 4. AFT LOWER LEFT CABLE 5. RIGHT UPPER AFT CABLE 6. FORWARD PULLEY CLUSTER 7. AFT PULLEY 8. BOLT, WASHER, NUT, & COTTER PIN 9.
Page 174 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4. Within the access opening aft of the main spar, remove the cable rub blocks that are attached to the spar housing by removing the block attaching screws. 5. Remove the cotter pin cable guard at the pulley cluster located in the access opening aft of the main spar.
Page 175 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 5-12. Stabilator Rigging Tool 5-19. RIGGING AND ADJUSTMENT OF STABILATOR CONTROLS. a. Level the airplane. (Refer to Leveling, Section II.) b. To check and set the correct degree of stabilator travel, the following procedure may be used.
Page 176 PIPER CHEROKEE WARRIOR SERVICE MANUAL 3 . Secure the control column in the near forward position. On PA - 2 8-1 5 1 ’s, 1974 and 1975 m o dels, allow 0.25 ± 0.031 inch between the column and the stop bumper. For all other models, allow 0.25 + 0.12 -0.03 inch.
Page 177 PIPER CHEROKEE WARRIOR SERVICE MANUAL TRIM CONTROL WHEEL TRIM POSITION INDICATOR TRIM CABLE DRUM MOUNTING BRACKET CLEVIS PIN, WASHER & COTTER PIN PULLEY CLUSTER BOLT, BUSHING, WASHER & NUT RIGHT FORWARD CABLE LEFT FORWARD CABLE 10. RIGHT TURNBUCKLE 11. LEFT TURNBUCKLE 12.
Page 178 PIPER CHEROKEE WARRIOR SERVICE MANUAL 7. If installed, remove the cable pulleys (33) within the aft section of the fuselage at station 156.5 by removing nut, washer, bushing and bolt. 8. With the cables disconnected from the trim control wheel, draw the cable(s) through the floor tunnel.
Page 179 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 5-14. Methods of Securing Trim Cables c. Disconnect the cable (12) at the turnbuckles (10 and 11) in the aft section of the fuselage. d. Remove the tail cone by removing its attaching screws.
Page 180 PIPER CHEROKEE WARRIOR SERVICE MANUAL g. Attach link (25) between trim screw and trim control arm (28). Check bushing and sleeve are in place before installing bolt, washer and nut (26). h. Route cables into fuselage and attach ends to forward trim cables.
Page 181 PIPER CHEROKEE WARRIOR SERVICE MANUAL 13. CLEVIS PIN & COTTER PIN 24. BOLT & NUT L. OUTER TUBE 14. RUDDER CONTROL TUBE 25. BOLT, WASHER & NUT L. CENTER TUBE 15. CLEVIS ROD 26. BOLT, WASHER & NUT R. CENTER TUBE R.
Page 182 NOTE Prior to installation, S/N’s 28-74150001 thru 28-7415495 refer to Piper Kit No. 760 935. S/N’s 28-7716001 thru 28-8416095 refer to Piper Kit No. 764 975 . a. Assemble the torque tube assembly (1, 2, 3 and 4) as shown in Figure 5-15. Do not at this time install the two bolts (25 and 26) through the center of the tube assembly.
Page 183 PIPER CHEROKEE WARRIOR SERVICE MANUAL Connect the rudder trim to the arm of the torque tube and secure with bolt, washer, nut and cotter pin. A thin washer is installed under the nut which is tightened only finger tight. Connect the ends of the rudder control cables (19) to the arms provided on the torque tube and secure with bolts, washers, nuts and cotter pins (20).
Page 184 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. RUDDER AND STEERING PEDAL ASSY. 2. BOLT , WASHER, NUT & COTTER PIN 3. BOLT , BUSHING, WASHER & NUT 4. CABLE GUARD PIN 5. PULLEY CLUSTER 6. RU B BLOCK 7. CABLE GUARD PIN 8.
Page 185 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4. Move the cable guard (4) into position, that is located in the forward area of the tunnel, under the pulley cluster (5) and secure with cotter pin. 5. Within the area aft of the main spar, install the cable guard blocks (6) onto the spar housing and secure with screws.
Page 186 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 5-19. Rudder and Stabilator Travel Adjustments 2 . A rigging tool may be fabricated from dimensions given in Figure 5-24 to aid in rudder rigging. With the rudder against its stop, place the rigging tool against the side of the rudder and vertical stabilizer as shown in Figure 5-17.
Page 187 PIPER CHEROKEE WARRIOR SERVICE MANUAL 3. Ascertain that the rudder pedal stop (at the fire wall) has 0.060 to 0.120 of an inch clearance between the pedal stop and the rudder pedal 4. Repeat steps 2 and 3 with the copilots right rudder pedal. Do not push harder than necessary to avoid cable stretch.
Page 188 PIPER CHEROKEE WARRIOR SERVICE MANUAL b. Before attaching the assembly to the mounting channel, ascertain that the clips (11) are installed so the safety wire (12) will be on top. Also, that the threaded bushing (4) is installed on the assembly shaft (15) with the welded attachment bushing forward or toward the housing.
Page 189 PIPER CHEROKEE WARRIOR SERVICE MANUAL 18. BOLT, WASHER & NUT 1. ROD ATTACHMENT BRACKET 2. BOLT, WASHER & NUT 19. BEARING BLOCK BRACKET 3. JAM NUT 20. TENSION SPRING CHAIN 4. FLAP CONTROL ROD 21. CLEVIS BOLT, BUSHING, NUT & COTTER PIN 5.
Page 190 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4 . Disconnect the cable from the chain (20) by removing cotter pin, nut, clevis pin and bushing (21). 5. Remove the flap handle bracket and cover. 6. Lift the aft section of the tunnel carpet far enough to remove the screws securing the tunnel cover that is between the flap handle and the spar cover.
Page 191 PIPER CHEROKEE WARRIOR SERVICE MANUAL 5. Attach the cable end to the tension chain (20) and secure with bushings, clevis bolt, nut and cotter pin. If the chain is not installed because of the torque tube assembly being removed, install the assembly as given in step a, 7.
Page 192 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 5-22. Flap Stop Adjustment Figure 5-23. Flap Rigging Tool Revised: February 28, 1995 SURFACE CONTROLS 1H24 Island Enterprises...
Page 193 PIPER CHEROKEE WARRIOR SERVICE MANUAL g. Check and adjust the other flap in a like manner. NOTE In the event of wing heaviness during flight, the flap on the side of the heavy wing can be adjusted down from neutral to remedy this condition by lengthening the control rod.
Page 194 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE V-III. SURFACE CONTROLS TROUBLESHOOTING CHART (cont.) AILERON CONTROL SYSTEM (cont.) Trouble Cause Remedy Resistance to control wheel Bent aileron and/or hinge. Repair or replace aileron and/or r o t ation. (cont.) hinge. Cables crossed or routed incorr e c tly.
Page 195 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE V-III. SURFACE CONTROLS TROUBLESHOOTING CHART (cont.) STABILATOR CONTROL SYSTEM (cont.) Trouble Cause Remedy Resistance to stabilator control Binding control column. Adjust and lubricate per movement. (cont.) Paragraph 5-8. Pulleys binding or rubbing. Replace binding pulleys and/or provide clearance between pul- leys and brackets.
Page 196 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE V-III. SURFACE CONTROLS TROUBLESHOOTING CHART (cont.) STABILATOR TRIM CONTROL SYSTEM (cont.) Trouble Cause Remedy Trim control wheel moves with Cables not in place on pulleys. Refer to Paragraphs 5-22 and excessive resistance. (cont.) 5-24.
Page 197 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE V-III. SURFACE CONTROLS TROUBLESHOOTING CHART (cont.) RUDDER CONTROL SYSTEM (cont.) Trouble Cause Remedy Excessive resistance to rudder Cables not in place on pulleys. Install cables correctly. Check pedal movement. (cont.) cable guards. Cables crossed or routed Check routing of control cables.
Page 198 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 5-24. Fabricated Rudder Rigging Tool Figure 5-25. Fabricated Stabilator Rigging Tool Revised: February 28, 1995 SURFACE CONTROLS Island Enterprises...
Page 199 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 5-26. Fabricated Flap Rigging Tool Revised: February 28, 1995 SURFACE CONTROLS Island Enterprises...
Page 200 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 201 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 202 SECTION VII LANDING GEAR AND BRAKE SYSTEM Aerofiche Paragraph Grid No.. 7-1. Introduction..........................1I12 7-2. Description..........................1I12 7-3. Troubleshooting........................1I12 7-4. Landing Gear System......................1I12 7-5. Nose Landing Gear........................ 1I12 7-6.Disassembly of Nose Gear Oleo..................1I12 7-7. Cleaning, Inspection and Repair of Nose Gear Oleo..........1I14 7-7a.
Page 203 Aerofiche Paragraph Grid No. 7-28. Wheel Brake Assembly........................7-29. Brake Adjustment and Lining Tolerance..............7-30. Removal and Disassembly of Wheel Brake Assembly..........7-31. Cleaning, Inspection and Repair of Wheel Brake Assemblies ........7-32. Assembly and Installation of Wheel Brake Assembly..........7-33.
Page 204 (For turning arc of the a i rplane, refer to Table II-I.). Bungee devices, or spring assisted push rods (refer to Piper Service kit 760 934 or 764 975), are attached to the rudder pedal torque tube assemblies to aid in nose wheel and rudder centering.
Page 205 PIPER CHEROKEE WARRIOR SERVICE MANUAL RETAINER NUT WASHER TOP BEARING STRUT HOUSING BOTTOM BEARING VALVE CAP AIR VALVE FILLER PLUG WASHER 10. CYLINDER 11. METERING TUBE 12. RETAINER RING 13. BEARING 14. O-RING PACKING 15. BACKUP O-RING AND WASHER 16. WIPER STRIP 17.
Page 206 PIPER CHEROKEE WARRIOR SERVICE MANUAL f. Loosen the strut assembly retainer nut (1) that secures the strut assembly in the strut housing. At the same time, slide the strut assembly out through the bottom of the strut housing. Remove the nut (1) and washer (2) from the top of the strut housing after the assembly is removed.
Page 207 PIPER CHEROKEE WARRIOR SERVICE MANUAL e. Hold the tool tightly against the metering tube and slide the sleeve of the tool towards the metering tube. This will move the new retainer ring (12) over the end of the metering tube and position itself into the groove of the metering tube (11).
Page 208 PIPER CHEROKEE WARRIOR SERVICE MANUAL BOLT, WASHER & NUT CAPSCREW HORN ASSEMBLY RIGHT STEERING CONTROL BUNGEE OR ROD ROD END BEARING AIR VALVE CAP AIR VALVE BOLT PIN, WASHER & COTTER PIN 10. MOUNT ASSEMBLY 11. LEFT STEERING CONTROL BUNGEE OR ROD 12.
Page 209 Bungee type steering assemblies are used only on the PA - 2 8 -151, Wa r r i o r. Operators of PA-28-161, Warrior II’s , S / N ’s 28-7716001 thought 28-8416095 should refer to Piper Kit No. 764 975 for replacing bungees with steering rods, Piper P/N 87468-2.
Page 210 PIPER CHEROKEE WARRIOR SERVICE MANUAL a. Install the nose gear and engine mount assembly to the firewall with bolts, washers and nuts. 1. PA-28-151, s/n’s 28-7415001 thru 28-7715314, and PA-28-161, s/n’s 28-7716001 thru S/N’s 28-8616057 uses 1 each AN6-35A at the top center of the mount, and 4 each AN6-25A bolts.
Page 211 PIPER CHEROKEE WARRIOR SERVICE MANUAL e. Extend a chalk line from the mark on the floor below the tail skid to a point approximately three feet forward of the nose wheel. Allow the line to pass under the wheel at the centerline of the tire. Snap the chalk line.
Page 212 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. VALVE CAP 2. FILLER PLUG 3. O-RING 4. CYLINDER HEAD 5. O-RING 6. ORIFICE ASSEMBLY 7. STRUT HOUSING 8. NUT 9. TORQUE LINKS 10. O-RING OR QUAD RING 11. SCRAPER RING 12. SPACER RING 13.
Page 213 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. VALVE CAP 2. FILLER PLUG 3. O-RING 4. CYLINDER HEAD 5. O-RING 6. STRUT HOUSING 7. WASHER 8. NUT 9. WASHER 10. TORQUE LINKS Figure 7-5a . Main Gear Oleo Strut Assembly (cont) Revised: February 28, 1995...
Page 214 PIPER CHEROKEE WARRIOR SERVICE MANUAL 7-15. CLEANING, INSPECTION AND REPAIR OF MAIN GEAR OLEO. a. Clean all parts with a suitable quick drying type cleaning solvent. b. Inspect the landing gear oleo components for the following: 1. Bearing surfaces of housing for excess wear, corrosion, scratches and overall damage.
Page 215 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. SCREW 2. AIR VALVE CAP 3. BOLT 4. AIR VALVE 5. CYLINDER 6. BOLT 7. BRAKE LINE HOSE 8. BOLT, WASHER, NUT & COTTER PIN 9. OLEO ASSEMBLY 10. TORQUE LINK ASSEMBLY 11. TORQUE LINK ASSEMBLY 12.
Page 216 PIPER CHEROKEE WARRIOR SERVICE MANUAL c. If desired, remove the air from the oleo chamber by depressing the air valve core pin found in the inspection hole on top of the wing. After the pressure in the oleo chamber has diminished, remove the valve core pin and attach a small hose to the air valve and drain the fluid by slowly compressing the piston tube.
Page 217 PIPER CHEROKEE WARRIOR SERVICE MANUAL e. The wheel bearing assemblies may be removed from each wheel half by first removing the snap rings (1 or 16 that secures the grease seal retainers, and then the retainers, grease seals (4 or 13) and bearing cones (6 or 12).
Page 218 PIPER CHEROKEE WARRIOR SERVICE MANUAL 7-23. ASSEMBLY AND INSTALLATION OF NOSE WHEEL. (Refer to Figure 7-7.) a. Ascertain that the bearing cup (5 or 11) for each wheel half (7 and 10) is properly installed. Install the tire with tube on the wheel half with the valve stem hole and then join the two wheel halves. Install the through bolts (18) with the washers (9 and 17) and nuts (8) to the valve stem side.
Page 219 PIPER CHEROKEE WARRIOR SERVICE MANUAL SNAP RING GREASE RETAINER RING FELT RING GREASE SEAL RING BEARING CUP BEARING CONE OUTER WHEEL HALF INNER WHEEL HALF BEARING CUP 10. BEARING CONE 11. GREASE SEAL RING 12. FELT RING 13. GREASE RETAINER RING 14.
Page 220 PIPER CHEROKEE WARRIOR SERVICE MANUAL e. Position the brake lining back plates between the wheel and brake disc and the brake cylinder on the torque plate. Install the four bolts to secure the assembly. If the brake line was disconnected, reconnect the line and bleed the brakes.
Page 221 PIPER CHEROKEE WARRIOR SERVICE MANUAL 6 . Remove the piston by injecting low air pressure in the cylinder fluid inlet and forcing the p i ston from the housing. 7. Check Anchor Bolt for wear. b. To remove anchor bolt: 1.
Page 222 (A rivet setting kit is available through Piper Dealers under part number 754 165.) After replacing brake linings, condition them as follows: Perform a minimum of six light pedal effort braking applications from 25 to 40 mph..Allow the...
Page 223 PIPER CHEROKEE WARRIOR SERVICE MANUAL 10. MASTER CYLINDER ASSEMBLY 1. BRAKE RESERVOIR 11. BOLT ASSEMBLY 2. RIGHT BRAKE AND RUDDER PEDAL 12. TORQUE TUBE 3. LEFT BRAKE AND RUDDER PEDAL 13. COPILOT'S RIGHT BRAKE AND RUDDER PEDAL 4. RIGHT BRAKE CYLINDER 14.
Page 224 PIPER CHEROKEE WARRIOR SERVICE MANUAL c. Disconnect the end of the cylinder rod from the brake handle (6) by removing the cotter pin that safeties the connecting clevis pin (9). Remove the clevis pin and spacer washers. d. Disconnect the base of the cylinder from its mounting bracket by removing the attaching bolt assembly (11).
Page 225 PIPER CHEROKEE WARRIOR SERVICE MANUAL 7-37 ASSEMBLY OF BRAKE MASTER CYLINDER. (Refer to Figure 7-13.) NOTE Use is small amount of hydraulic fluid (MIL-H-5606) on the O-rings and component parts to prevent damage and ease of handling during reassembly. a. Install new O-rings on the inside and outside of the packing gland (9) and on the outside of the pis- ton (6).
Page 226 PIPER CHEROKEE WARRIOR SERVICE MANUAL b. Cleveland cylinder number 10-30. (Refer to Figure 7-14.) 1. Remove the cylinder from its mounting bracket per Paragraph 7-40. 2. To disassemble the cylinder, first remove the piston rod assembly by removing the retaining ring from the annular slot in the cylinder housing (1).
Page 227 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE Figure 7-14. 10-27, 10-30 and 17000 Toe Brake Brake Cylinders Revised: April 12, 1982 LANDING GEAR AND BRAKE SYSTEM 1J11 Island Enterprises...
Page 228 PIPER CHEROKEE WARRIOR SERVICE MANUAL c. Gar-Kenyon cylinder number 17000. (Refer to Figure 7-14.) 1 . Install new O-rings on the inside and outside of the fitting (8) and on the outside of the piston (6). 2. To assemble the piston rod assembly, install on the rod (12), in order the roll pin (14), return spring retainer washer (13), return spring (11) fitting (8) with O-rings, seal (7), piston (6) with O-ring, spring (4) and sleeve (3).
Page 229 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE By watching the fluid pass through the plastic hose at the fluid reservoir and the bleeder fitting on the gear being bled, it can be determined whether any air is left in the system. If air bub -...
Page 230 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VII-I. TROUBLESHOOTING LANDING GEAR Trouble Cause Remedy Nose landing gear shimmies Internal wear in shimmy dampener. Replace shimmy dampener. d u ring fast taxi, take- o ff, or l a n ding. Shimmy dampener or bracket Replace necessary parts and loose at mounting.
Page 231 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VII-I. TROUBLESHOOTING LANDING GEAR (cont.) Trouble Cause Remedy Main landing gear shimmies Tire out of balance. Check balance and replace tire if d u ring fast taxi, take- o ff, or necessary. l a n ding.
Page 232 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 7-15. Retainer Ring Installation Tool THIS SPACE INTENTIONALLY LEFT BLANK Added: June 30, 1975 LANDING GEAR AND BRAKE SYSTEM 1J16 Island Enterprises...
Page 233 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1J17 Island Enterprises...
Page 234 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1J18 Island Enterprises...
Page 235 SECTION VIII POWER PLANT Aerofiche Paragraph Grid No.. 8-1. Introduction ........................... 1J21 8-2. Description..........................1J21 8-2a. Standard Practices - Engine....................1J22 8-3. Troubleshooting........................1J22 8-4. Static RPM Determination..................... Propeller ............................1J23 8-5. Removal of Propeller....................1J23 8-6. Cleaning, Inspection and Repair of Propeller............. 1J23 8-7.
Page 236 Aerofiche Paragraph Grid No. 8-29. Bendix Magnetos ........................1K20 8-30. Inspection of Bendix Magnetos.................. 1K20 8-31. Removal of Bendix Magnetos ..................1K22 8-32. Bendix -20 And -200 Series Magneto Internal Timing Procedure......1K22 8-33. Bendix Magneto Installation and Timing To Engine Procedure ........ 1K24 8-34.
Page 237 PIPER CHEROKEE WARRIOR SERVICE MANUAL SECTION VIII POWER PLANT 8-1. INTRODUCTION. This section covers the power plant used in the PA-28-151 and PA-28-161 airplanes, and is comprised of instructions for the removal and installation, minor repairs and service of the propeller, engine, induction system components, ignition system components and engine lubrication system.
Page 238 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-2a. STANDARD PRACTICES - ENGINE. The following suggestions should be applied wherever they are needed when working on the power plant. a. 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 239 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 8-1. Typical Nicks and Removed Method 8-4. PROPELLER. 8-5. REMOVAL OF PROPELLER. a. Insure master and magneto switches are off. b. Move fuel selector to off position and place mixture control in idle cut-off.
Page 240 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VIII-I. PROPELLER TORQUE LIMITS DESCRIPTION REQUIRED TORQUE Propeller Mounting Bolts McCauley 300-360 in-lbs. Sensenich 280-300 in-lbs. Spinner Backplate Attachment Screws 30-35 in-lbs. Spinner Attachment Screws 20-25 in-lbs. CAUTION G R OU N D R U N NI N G W IT H T HE C OW L IN G REMOVED.
Page 241 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-7. INSTALLATION OF PROPELLER. (Refer to Figure 8-2.) NOTE If the propeller-engine combination feels rough on initial r u n-up or flight, propeller may be rotated 180° from initial installation. a. Insure magneto switch is OFF.
Page 242 PIPER CHEROKEE WARRIOR SERVICE MANUAL a. Turn off all electrical switches in the cockpit and then disconnect the battery ground wire at the battery. b. Move the fuel selector lever in the cockpit to the OFF position. c . Remove the engine cowlings by releasing the cowl fasteners and the attachment screws. Be c e rtain that all electrical leads are disconnected prior to removal of the cowl.
Page 243 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE: A maximum of 3 AN960-616 washers can be used to permit a maximum of 2.5 threads exposed on the bolt. Torque to 240 /270 inch-pounds. 1. LEFT BAFFLE ASSEMBLY 9. OIL FILTER 17. LEFT MAGNETO 2.
Page 244 PIPER CHEROKEE WARRIOR SERVICE MANUAL c . Assemble the engine shock mounts as shown in Figure 8-4. Note the position of each mount c a r efully. The upper right and lower left mounts are installed the same. The upper left and lower right are installed the same.
Page 245 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 8-4. Engine Shock Mount Installation Issued: August 22, 1973 POWER PLANT Island Enterprises...
Page 246 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-13. INSTALLATION OF OIL COOLER. a. When installing fittings in the oil coolers, care should be used to prevent excessive torque to the c o o l e r. Where a rectangular fitting boss is provided, a backup wrench should be used employing a scissor motion, so that no load is transmitted to the cooler.
Page 247 PIPER CHEROKEE WARRIOR SERVICE MANUAL b. The mixture may be adjusted as follows: 1. At the carburetor, disconnect the rod end of the mixture control cable from the control arm. Loosen the jam nut that secures the rod end. 2. Adjust the linkage by rotating the rod end of the cable to obtain 0.010 to 0.0300 fan inch spring back on the instrument panel stop when in full rich position.
Page 248 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-17. ADJUSTMENT OF IDLE MIXTURE. (Refer to Figure 8-6.) a. After performing the standard engine starting procedure, operate the engine for at least two min- utes between 800 to 1200 RPM to insure proper engine warm-up.
Page 249 PIPER CHEROKEE WARRIOR SERVICE MANUAL c. Disconnect the ground lead at the magneto. d. Remove the nuts and washers and remove the magnetos from the engine. 8-21. INSPECTION OF SLICK 4000, 4200, AND 4300 MAGNETOS. The 4000 series magnetos require very little inspection. These units are sealed and tampering with them will void their warranty.
Page 250 PIPER CHEROKEE WARRIOR SERVICE MANUAL Check insulators for cracks, breaks or evidence of dry rot. Be sure they are clean. k. Check ventilator plugs. Ventilator has drilled holes and should be in the lowest hole in the magne- to to serve as a drain for excess water or oil.
Page 251 PIPER CHEROKEE WARRIOR SERVICE MANUAL 3. Fasten the ground wire of an electric timing light to any unpainted metallic portion of the engine, and one of the positive wires of the timing light to a suitable terminal connected to the ground terminal connection of the left magneto.
Page 252 PIPER CHEROKEE WARRIOR SERVICE MANUAL e. Using two flat blade screwdrivers or equivalent, placed under the rotor gear, gently pry the gear off the rotor shaft and discard. f. Remove and discard the breaker assembly by removing screw and washer. Remove cam by prying straight up with a screwdriver blade and discard.
Page 253 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 8-8. T-100 Assembly and Timing Tool Kit Revised: February 28, 1995 POWER PLANT Effectivity Magneto (SLICK) 1K13 Island Enterprises...
Page 254 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. WEDGE EXTRACTOR COIL WEDGE 3. COIL Figure 8-9. Removing Coil Wedges a. Inspect internal and external threads of all threaded hardware. Damaged or worn parts must be replaced. b. Inspect the bearing plate for excessive wear and damage. (Maximum bearing bore I.D. to be 1.5752 inch.)
Page 255 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 8-10. Index Plate and Timing Plug Insert the base plate (T-117) and the adapter plate bushing(T-119) into the base of the T-100 assembly and timing tool. Assemble both ball bearings on the rotor shaft, making sure the grease shield of each bearing is toward the magnet.
Page 256 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. BASE PLUG 2. BEARING ASSY. PLUG 3. BALL BEARING 4. ROTOR SHAFT 5. T-SCREW 6. BEARING PLATE 7. FRAME ASSY. PLUG 8. FRAME Figure 8-11. Installation of Bearings and Bearing Plate 1. OIL SEAL ASSY. PLUG 2.
Page 257 PIPER CHEROKEE WARRIOR SERVICE MANUAL o. Assemble the rotor gear onto the rotor, making sure the key slot of the gear fits into the cam slot of the rotor. Tap with a light hammer until the gear bottoms on the shaft.
Page 258 PIPER CHEROKEE WARRIOR SERVICE MANUAL CAUTION Do not bend coil high tension lead. u . Fit the distributor housing to the frame. Making sure the bosses of the distributor housing are seat- ed in the slots of the frame. Start by fitting the top boss (next to the vent) and assemble the distributor housing into place.
Page 259 PIPER CHEROKEE WARRIOR SERVICE MANUAL D. Rotate the complete magneto opposite normal rotation of the magneto on the engine mounting until the timing light indicates the contact breaker points are just opening. Secure the magneto in this position. Select magneto switch OFF.
Page 260 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-29. BENDIX MAGNETOS. 8-30. INSPECTION OF BENDIX MAGNETOS. CAUTION Ensure the primary (P) circuits of both engines are grounded before working on the engine. NOTE Check all appropriate Textron Lycoming, Bendix, and Teledyne Continental Service Bulletins.
Page 261 PIPER CHEROKEE WARRIOR SERVICE MANUAL 6. CAPACITOR 11. DELETED 1. CONTACT SPRING 7. BREALER ASSEMBLY 12. HIGH TENSION LEAD 2. RETAINING RING 8. BREAKER CAM 13. CONTACT SPRING 3. DISTRIBUTOR BLOCK 9. IMPULSE COUPLING 14. INSULATOR 4. BREAKER COMPARTMENT 15. VENT PLUG 10.
Page 262 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-31. REMOVAL OF BENDIX MAGNETOS. WARNING Before removing the magneto, make sure magneto switches are OFF. WARNING The magneto is not internally grounded. When the ground lead is disconnected, the magneto is hot. Removing the harness...
Page 263 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 8-17. Magneto Timing Marks Figure 8-18. Timing Pointer Figure 8-19. Timing Kit Installed Figure 8-20. Breaker Compartment with Cast Timing Marks Revised: April 12, 1982 POWER PLANT Effectivity Magneto (BENDIX) 1K23 Island Enterprises...
Page 264 PIPER CHEROKEE WARRIOR SERVICE MANUAL 3 . Using the alignment of the chamfered red or white marked gear with the white line of the distrib- utor block as a reference, adjust breaker points to open at this position A. Turn the magneto drive until the cam follower is on high point of the cam lobe.
Page 265 PIPER CHEROKEE WARRIOR SERVICE MANUAL 3. Fasten ground wire on electric timing light to any unpainted metallic portion of the engine. Attach one of the positive wires of the timing light to a suitable terminal connected to the ground terminal c o nnection of the right magneto.
Page 266 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-34. HARNESS ASSEMBLY. 8-35. INSPECTION OF HARNESS. a. Check lead assemblies for nicks, cuts, mutilated braiding, badly worn section or any other evi- dence of physical damage. Inspect spark plug sleeves for chafing or tears, and damage or stripped threads on coupling nuts.
Page 267 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-38 HARNESS ASSEMBLY INSTRUCTIONS. a. Cut a piece of harness wire to the length required. Do not stretch the wire when measuring it. b. Make a mark on the magneto from one end of new harness wire: 1.
Page 268 PIPER CHEROKEE WARRIOR SERVICE MANUAL Using M-1742 Pin Vise, insert M-1741 Drill (#72 drill). Drill out the silicone rubber from inside of coiled conductor approximately 0.375 inch deep. Refer to Figure 8-24. g. On spark plug end of wire install M-1673 Nut followed by M-1671 Female Taper Hex Ferrule.
Page 269 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-27. Installation of Ferrule Figure 8-28. Driving Tool Figure 8-29. Installation in Housing Figure 8-30. Securing wire in Housing 5. Insert the tapered pin of the electrode screw into the center of the coiled conductor by turning the pin vise counterclockwise and pushing at the same time until the screw is flush with the insulation.
Page 270 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 8-31. Installation of Electrical Screw Figure 8-32. Installation of Insulator Sleeve Figure 8-33. Installation of Spring Figure 8-34. Removing Spark Plug Frozen to Bushing Revised: April 12, 1982 POWER PLANT Island Enterprises...
Page 271 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-39. INSTALLATION OF HARNESS. a. Check mating surfaces for cleanliness before installing harness on magneto, . b. Place the harness terminal plate on the magneto. Tighten nuts around the plate alternately to seat cover squarely on magneto. Torque nuts 18 to 22 inch pounds.
Page 272 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-42. INSPECTION AND CLEANING OF SPARK PLUG. a. Visually inspect each spark plug. Replace any plug found to have one or more of the following defects. 1. Severely damaged shell or shield threads nicked up, stripped or cross threaded.
Page 273 PIPER CHEROKEE WARRIOR SERVICE MANUAL b. Adjustable Oil Pressure Relief Valve - The adjustable oil pressure relief valve enables the operator to maintain engine oil pressure within the specified limits (refer to the appropriate engine manufacturer’s m a nual). The valve is located above and to the rear of No. 3 cylinder. If the pressure under normal operat- ing conditions should consistently exceed 90 psi., or run less than 60 psi., adjust the valve as follows:...
Page 274 PIPER CHEROKEE WARRIOR SERVICE MANUAL +12V WARRIOR II GRND 2 AMP FUSE 107AP WHITE CARBURETOR BLACK KNIFE CONNECTORS PRIOBE Figure 8-35. Warrior II Ice Detection System 8-49. CARBURETOR ICE DETECTION SYSTEM TEST. a. To test Warrior II and III probes(Refer to Figure 8-35)
Page 275 PIPER CHEROKEE WARRIOR SERVICE MANUAL 2. Apply +12 Vdc to the red wire with the fuse holder. Apply -12 Vdc to the black ground wire. 3. The red carburetor ice light should illuminate. If it does not, the instrument is inoperative, and must be returned to the manufacturer for repair.
Page 276 PIPER CHEROKEE WARRIOR SERVICE MANUAL CARB ICE ANNUNCIATOR CONNECTOR J 3 CARB ICE DETECT SWITCH SENSITIVITY KNIFE CONTROL CONNECTORS TEMPERATURE PROBE 107004 BLACK CARBURETOR FIREWALL 1.5 A Figure 8-36. Warrior III Ice Detection System Added: February 28, 1995 POWER PLANT...
Page 277 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8-50. STATIC RPM TEST PROCEDURE. The maximum static rpm value for a fixed pitch propeller equipped aircraft provides an indication that the engine/propeller combination is meeting rated power output. Low static rpm indicates a low engine power or incorrect propeller (higher pitch/longer diameter) while a high rpm indicates high engine power or incorrect propeller diameter), any of which is not desirable.
Page 278 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE Relative humidity may be obtained using a psychrometric chart (Figure 8-39) if the outside air temperature, and dew point, or wet bulb are known. b. Head aircraft into the wind. c. Apply full throttle. Avoid prolonged runs at full power.
Page 279 PIPER CHEROKEE WARRIOR SERVICE 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: Rpm: (Reference Figure 71-1) Delta rpm (subtract)
Page 280 PIPER CHEROKEE WARRIOR SERVICE MANUAL PA-28-161 2480 74DM6-0-60 PROP HUMIDITY EFFECTS EXAMPLE: 0% Rel. Humidity O.A.T.: REL. HUMIDITY: 90 2440 STATIC RPM: 2347 20% Rel. Humidity 2400 40% Rel. Humidity 2360 60% Rel. Humidity 2320 80% Rel. Humidity 2280 100% Rel. Humidity 2240 O.A.T.
Page 281 PIPER CHEROKEE WARRIOR SERVICE MANUAL STATIC RPM ENGINE OIL TEMPERATURE PA-28-161 EXAMPLE: O.A.T.: ENG. OIL.TEMP.: 145 DELT RPM: ENGINE OIL TEMP - DEG. F Figure 8-38. Change in Static Rpm Vs. Engine Oil Temperature Added: February 28, 1995 POWER PLANT...
Page 282 PIPER CHEROKEE WARRIOR SERVICE MANUAL PSYCHROMETRIC CHART SEA LEVEL BAROMETRIC PRESSURE EXAMPLE: O.A.T. (Dry Bulb): 75.5 Wet Bulb: 62.5 Dew Point: Rel. Humidity: Dew Point Line Figure 8-39 Psychrometric Chart Added: February 28, 1995 POWER PLANT 1L18 Island Enterprises...
Page 283 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VIII-III. STATIC RPM PA-28-161 WITH 74DM6-0-60 PROPELLER TABLE VIII-IV. STATIC RPM PA-28-161 WITH 74DM6-0-58 PROPELLER Added: February 28, 1995 POWER PLANT 1L19 Island Enterprises...
Page 284 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VIII-V. ENGINE TROUBLESHOOTING CHART 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. Underpriming. Prime with two or three strokes of primer.
Page 285 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VIII-V. ENGINE TROUBLESHOOTING CHART (cont.) Trouble Cause Remedy Failure of engine to start (cont.). Shorted ignition switch or loose Check and replace or repair. ground. Failure of engine to idle properly. Incorrect carburetor idle Adjust throttle stop to obtain a d j u s tment.
Page 286 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VIII-V. ENGINE TROUBLESHOOTING CHART (cont.) Trouble Cause Remedy Low power and uneven running Improper engine operation. Check entire engine. engine (cont.). Improper grade of fuel. Fill tank with recommended fuel grade. Magneto not working properly.
Page 287 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VIII-V. ENGINE TROUBLESHOOTING CHART (cont.) Trouble Cause Remedy Rough running engine (cont.). Lead deposit on spark plug. Clean or replace plugs. Malfunctioning engine. Check entire engine. Low oil pressure. Insufficient oil. Check oil supply.
Page 288 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE VIII-V. ENGINE TROUBLESHOOTING CHART (cont.) Trouble Cause Remedy Excessive oil consumption. Leakage through engine fuel Replace fuel pump O-ring. pump vent. Engine breather or vacuum pump Check engine compression. If breather (blowing oil). too low, top overhaul engine.
Page 289 AIRPLANE MAINTENANCE MANUAL CARD 2 OF 3 PA-28-151 CHEROKEE WARRIOR PA-28-161 WARRIOR II PA-28-161 WARRIOR III PIPER AIRCRAFT CORPORATION (PART NUMBER 761 539 FEBRUARY 28, 1995 Island Enterprises...
Page 290 Published by Technical Publications Piper Aircraft Corporation 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member of GAMA General Aviation Manufacturers Association Island Enterprises...
Page 291 PIPER CHEROKEE WARRIOR SERVICE MANUAL SERIAL NUMBER INFORMATION PA-28-151, WARRIOR- 1974 Serial Numbers 28-7415001 to 28-7415713 inclusive PA-28-151, WARRIOR- 1975 Serial Numbers 28-7515001 to 28-7515459 inclusive PA-78-151, WARRIOR- 1976 Serial Numbers 28-7615001 to 28-7615445 inclusive PA-28-151, WARRIOR- 1977 Serial Numbers 28-7715001 to 28-7715314 inclusive...
Page 292 PIPER CHEROKEE WARRIOR SERVICE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS The Service Manual information incorporated in this set of Aerofiche cards has been arranged in accordance with the general specifications of Aerofiche adopted by the General Aircraft Manufacturer’s Association, (GAMA). The i n f o r m ation compiled in this Aerofiche Service Manual will be kept current by revisions distributed periodically.
Page 293 TABLE OF CONTENTS AEROFICHE CARD NO.1 GRID NO. INTRODUCTION ............1A13 HANDLING AND SERVICING........1A16 INSPECTION..............1D15 STRUCTURES ............1E5 SURFACE CONTROLS..........1G10 HYDRAULIC SYSTEM......(Not Applicable) LANDING GEAR AND BRAKE SYSTEM....1I10 VIII POWER PLANT ............1J19 AEROFICHE CARD NO.2 FUEL SYSTEM............2A9 INSTRUMENTS ............2B11 ELECTRICAL SYSTEM ..........2D4 ELECTRONICS ............2J11 XIII HEATING AND VENTILATING........2K5...
Page 294: Warrior Iii Instrument Cluster - Oil Temperature, Fuel Pressure, And Oil Pressure Gauge
PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF ILLUSTRATIONS Aerofiche Figure Grid No. 9-1. PA-28-151 and PA-28 -161, Warrior II Fuel System Diagram ............2A13 9-2. PA-28 -161, Warrior III Fuel System Diagram..................2A14 9-3. Tolerances, Union Nut and Tubing Nut....................
Page 295: Figure Grid No
PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Aerofiche Figure Grid No. 11-29. Removal of Rectifier End Shield Bearing.................... 2E22 11-30. Testing Rotor for Ground........................2E23 11-31. Testing Rotor for Open or Shorts......................2E23 11-32. Installation of Grease Retainer......................
Page 296: Fuel Quantity Gauge Resistance/Tolerance Values
PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. IX-I. Transmitter/Fuel Gauge Tolerances..................2A17 IX-II. Fuel Quantity Gauge Resistance/Tolerance Values............. 2A18 IX-III 14 Vdc Fuel Quantity Gauge Tolerance Values..............2A18 IX-IV 28 Vdc Fuel Quantity Gauge Resistance/Tolerance Value..........
Page 297: Electrical Symbols (Old Style)
PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF TABLES (cont.) Table Aerofiche Grid No. XI-XVII. Electrical Symbols (Old Style)..................... 2H10 XI-XVIII. Electrical Symbols (New Style)................... 2H11 XIV-I. Troubleshooting Air Conditioner..................3A11 XIV-II. Troubleshooting Air Conditioner System................3A13 XIV-III. Refrigerant Temperature Pressure ..................
Page 298 SECTION IX FUEL SYSTEM Aerofiche Paragraph Grid No.. 9-1. Introduction..........................2A12 9-2. Description..........................2A12 9-3. Troubleshooting........................2A13 9-4. Fuel Tanks..........................2A13 9-5. Removal of Fuel Tanks....................2A13 9-6. Inspection and Repair of Fuel Tank................2A13 9-7. Installation of Fuel Tank....................2A13 9-8.
Page 299 Aerofiche Paragraph Grid No. 9-36. Engine Primer Pump......................9-37. Removal of Engine Primer..................9-38. Disassembly, Cleaning and Assembly of Engine Primer..........9-39. Installation of Engine Primer Pump................9-40. Primer Jets..........................9-41. Cleaning Fuel System......................Revised: February 28, 1995 2A11 Island Enterprises...
Page 300 PIPER CHEROKEE WARRIOR SERVICE MANUAL SECTION IX FUEL SYSTEM 9-1. INTRODUCTION. The fuel system components covered in this section consist of the fuel tanks, selector valves, filter screens and fuel pump. Instructions are given for remedying difficulties which may arise in the normal o p e r ation of the fuel system.
Page 301 The seams of fuel tanks in early PA-28-151 / -161 models were sealed by sloshing. Piper Aircraft Corporation no longer uses, nor approves the use of, sloshing compound to seal fuel tank seams. Piper now uses Thiokol MC-236, Class A2 sealant to seal fuel tank seams.
Page 302 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 9-l. PA-28-151 and PA-28-161, Warrior II Fuel Systems Diagram Revised: February 28, 1995 FUEL SYSTEM 2A14 Island Enterprises...
Page 303 PIPER CHEROKEE WARRIOR SERVICE MANUAL CARBURETOR THROTTLE MIXTURE FUEL FUEL PRESSURE PRIMER GAUGE SOLENOID ENGINE FUEL PUMP ELECTRIC FUEL PUMP RELAY PRIMER SWITCH ELECTRIC FUEL PUMP FUEL STRAINER FUEL TANK LEFT MAIN TANK RIGHT MAIN TANK SELECTOR VALVE FUEL QUANTITY GAUGE Figure 9-2.
Page 304 2. Cut off the swaged ferrule and add a short length of tubing. 3. Replace union using a standard AN fitting as outlined in AC43.13-1A paragraph 392. c. Fabricated replacement tubes and unions purchased from Piper have the ferrule pre-swaged onto the tube. Install as follows: 1 .
Page 305 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 9-3. Tolerances, Union Nut and Tubing Nut 5. Insert the tubes into the unions, being careful to insure proper straight alignment of the tubing and union. 6. Using a tubing wrench tighten the nut one and one-quarter (1-1/4) turns.
Page 306: Transmitter/Fuel Gauge Tolerances
PIPER CHEROKEE WARRIOR SERVICE MANUAL 5. Connect external power supply unit. Connect the red (positive) lead to the starter solenoid heavy terminal which is not connected to the starter. Adjust power supply unit to provide 13.5 to 14.5 Vdc. Allow gauges to warm-up for a m i n imum of three minutes.
Page 307 PIPER CHEROKEE WARRIOR SERVICE MANUAL Apply 14 Vdc to the terminals at the rear of the gauge through a resistor network comprised of the resistive values specified in the Table IX-II. Verify that, for each resistive value, the gauge indication is as specified in Table IX-II.
Page 308 PIPER CHEROKEE WARRIOR SERVICE MANUAL c. PA-28-161 Warrior III 28 Vdc Fuel Gauges The Wa r r i o r III fuel gauges consist of individual indicators for the left and right fuel tanks c o ntained in a common instrument.
Page 309 PIPER CHEROKEE WARRIOR SERVICE MANUAL FUEL QUANTITY INDICATOR 45 OHMS 5 OHM DUMMY RESISTOR RIGHT SEND LEFT SEND 33 OHMS 23 OHMS SWITCH 28 VDC 14 OHMS 3 OHMS LEFT NULL RIGHT NULL AND GAIN AND GAIN ADJUSTMENTS ADJUSTMENTS Figure 9-4. Resistance Decade Test Box Set Up...
Page 310 PIPER CHEROKEE WARRIOR SERVICE MANUAL Post installation functional check: (1) Level airplane, ± 1°, longitudinally and laterally. (2) Place battery-alternator switch in OFF position. (3) Completely drain fuel tank that relates to the gauge to be checked. (Refer to draining fuel system, chapter 12.)
Page 311 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 9-6. Fuel Quantity Transmitter Checking Jig b. Warrior II and III Rochester Fuel Quantity Transmitter Check. 1. Remove transmitter unit to be checked from the fuel tank. 2. Check and adjust transmitter unit float position as follows: (A) Fasten unit to a fabricated checking jig with washer and nuts as shown in Figure 9-6.
Page 312 PIPER CHEROKEE WARRIOR SERVICE MANUAL 0.219” 0.875”R 0.188” HOLE 3 REQ. (T.M.M.P.) 0.344” 1.625” 0.75” 4.219” 9.938” 0.75” 1” 2 WOOD SCREWS EVENLY SPACED MATERIAL LIST 2-8.75 x 9.938 x 0.125 2024-T3 ALUM 1-9.75 x 6 x 0.75 RICHLITE, MASONITE, OR HARDWOOD 1-8.75 x 6 x 1RICHLITE, MASONITE, OR...
Page 313 PIPER CHEROKEE WARRIOR SERVICE MANUAL 9-16. LOCKING FUEL CAP NOTE The vent groove on the cover is filled with sealant PR 1422. 9-17. DISASSEMBLY OF LOCKING FUEL CAP. (Refer to Figure 9-8.) a. Remove two screws on the back of the fuel cap.
Page 314 PIPER CHEROKEE WARRIOR SERVICE MANUAL 9-19. FUEL SHUTOFF VALVE. 9-20. REMOVAL OF FUEL SHUTOFF VALVE. a. Remove two screws holding the fuel valve placard plate. b. Remove the screw holding the fuel shutoff valve handle. c. Remove fuel shutoff valve handle and placard plate.
Page 315 PIPER CHEROKEE WARRIOR SERVICE MANUAL 9-24. INSTALLATION OF FUEL FILTER BOWL AND SCREEN. a. Position top of the filter bowl to the bracket and connect the fuel lines. b. Spread bail wire ends and insert them through the holes in the side of the mounting bracket and the top of the filter bowl.
Page 316 PIPER CHEROKEE WARRIOR SERVICE MANUAL CAUTION Do not remove the buffer spring and valve from the plunger assembly. CAUTION Do not tamper with seal at center of mounting bracket at side of pump. It retains the dry gas which surrounds the electric system in the upper portion of the pump.
Page 317 PIPER CHEROKEE WARRIOR SERVICE MANUAL 9-31. RESISTANCE CHECK OF PLUNGER TYPE ELECTRIC FUEL PUMP. To check the resistance of the motor of a completely assembled pump, connect an ohmmeter to the lead wire of the pump and the pump body.
Page 318 PIPER CHEROKEE WARRIOR SERVICE MANUAL e. Place a container below the open end of the test line to catch any fuel during the adjustment of the pump. Turn the fuel selector ON, open the by-pass valve on the test line, and turn the FUEL PUMP switch ON.
Page 319 PIPER CHEROKEE WARRIOR SERVICE MANUAL 9 - 3 8 . D I S A S S E M B LY, CLEANING AND ASSEMBLY OF ENGINE PRIMER. (Refer to Figure 9-11.) a. To disassemble primer 1. Remove the retainer screw (3) from the end of the cylinder housing.
Page 320 PIPER CHEROKEE WARRIOR SERVICE MANUAL 2 . Select a fuel tank. N O T E During flushing operation, agitate fuel within the tank to help pick up and remove any dirt. 3 . Turn electric fuel pump ON. Flush fuel through the system until it is determined there is no dirt and foreign matter in the fuel valve or tank.
Page 321 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE IX-VII. FUEL SYSTEM TROUBLESHOOTING (cont.) Trouble Cause Remedy No fuel pressure indication. Fuel valve stuck. Check valve. No fuel in tanks. Check fuel level. Add fuel as required. Defective engine driven fuel Check engine driven pump for pump.
Page 322 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2B10 Island Enterprises...
Page 323 SECTION X INSTRUMENTS Aerofiche Paragraph Grid No.. 10-1. General........................... 2B14 10-2. Non-electrical Instruments ....................2B14 10-3. Vacuum System........................2B14 10-4 Vacuum System and Gyro Pressure Service Tips............. 2B14 10-5 Troubleshooting......................2B19 10-6. Vacuum Gauge ........................2B20 10-7 General ........................2B20 10-8 Troubleshooting......................
Page 324 Aerofiche Paragraph Grid No. 10-37. Airspeed Indicator ......................... 10-38. Troubleshooting Airspeed Indicator ................. 10-39. Removal and Replacement ..................2C10 10-40. Magnetic Compass......................... 2C10 10-41. General........................2C10 10-42. Troubleshooting ......................2C11 10-43 Adjustment of Compass ..................... 2C11 10-44. Tachometer Indicator ......................2C12 10-45.
Page 325 Aerofiche Paragraph Grid No. 10-83. Piper AutoControl System..................... Interim Revision: 10/12/94 2B13 Island Enterprises...
Page 326 PIPER CHEROKEE WARRIOR SERVICE MANUAL SECTION X INSTRUMENTS 10-1. GENERAL WARNING It is the user’s responsibility to refer to the applicable vendor publication when servicing or inspecting vendor equipment installed in Piper aircraft. The instrumentation is designed to give a quick and actual indication of the attitude, performance and condition of the airplane.
Page 327 PIPER CHEROKEE WARRIOR SERVICE MANUAL a. Hoses and Clamps: 1. Examine periodically and inspect carefully when engine maintenance requires disconnecting hose at the pump, regulating valve, gyros and/or vacuum gauge. CAUTION Slivers of rubber from the hoses can become detached and sucked into the pump, causing damage to the pump.
Page 328 PIPER CHEROKEE WARRIOR SERVICE MANUAL CAUTION The vacuum gauge will indicate a decrease in suction when the filter is clogged and vacuum decreases below the r e c o mmended value. Replace filter when gauge reading decrease below the recommended value. DO NOT ADJUST REGULATOR.
Page 329 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. CLOCK 19. MAGNETO/STARTER SWITCH 2. TURN INDICATOR 20. PITCH CONTROL 3. AIRSPEED INDICATOR 21. RPM CRUISE CHART 4. HEADING INDICATOR 22. INSTRUMENT CLUSTER 23. TACHOMETER 5. ATTITUDE DEVIATION INDICATOR 24. PRIMER 6. VERTICAL SPEED INDICATOR 25.
Page 330 PIPER CHEROKEE WARRIOR SERVICE MANUAL 11 12 13 1. VACUUM GAUGE 13. IFR NAV/COMM PACKAGE 2. CLOCK 14. AMMETER 3. TURN INDICATOR 15. HOUR METER 4. AIRSPEED INDICATOR 16. CIRCUIT BREAKER PANEL 5. HEADING INDICATOR 17. SWITCH PANEL 6. ATTITUDE DEVIATION INDICATOR 18.
Page 331: Troubleshooting Vacuum System
PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-5. TROUBLESHOOTING. TABLE X-I. TROUBLESHOOTING VACUUM SYSTEM Trouble Cause Remedy No vacuum gauge indication at Filter clogged or dirty. Clean or replace filter. instrument. Line from gyro to filter restricted. Check line. No vacuum gauge indication at Faulty gauge or malfunctioning Replace gauge or pump.
Page 332 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-I. TROUBLESHOOTING VACUUM SYSTEM (cont.) Trouble Cause Remedy Pressure can only be maintained Leak in system. Check all lines and fittings. at full throttle on ground. Replace or tighten as necessary. Worn pump. Replace pump.
Page 333 CAUTION The only pump mounting gasket authorized and approved for use on Airborne vacuum pumps is Piper p/n 751 859 (Warrior II), or 461 907 (Warrior III). Any other gaskets can result in oil seepage or leakage at the mounting surface.
Page 334 Do not apply vise pressure to the outside diameter or overall length of pump. NOTE Vacuum pumps purchased from Piper will have fittings installed. If required, install fittings into pump ports. Hand tighten firmly. Then, using a wrench, tighten each fitting 1/2 to 2 turns.
Page 335 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. Select battery master switch ON. Check that VAC OFF annunciator illuminates. 2. Press VAC OFF/AUX ON annunciator switch. Check that AUX ON annunciator lights, and VAC OFF annunciator extinguishes. Check that the vacuum gauge reads between 4.8 and 5.2 in. hg.
Page 336 PIPER CHEROKEE WARRIOR SERVICE MANUAL CAUTION The elapsed time indicator is matched to the pump/motor assembly and must be removed and replaced with the pump/motor assembly. 1. Connect elapsed time indicator to two-pin connector on the leads coming from the back of the switch.
Page 337 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. Install fittings into ports. Hand tighten firmly. 2. Use a wrench and tighten each fitting no more than 1/2 to 2 turns to align properly. Figure 10-5. Warrior II and III Auxiliary Vacuum System Installation...
Page 338 PIPER CHEROKEE WARRIOR SERVICE MANUAL MOTOR V7A14 RELAY FILTER 373 17 373 19 373 15 373 13 V6A20 PUMP (FRONT VIEW) VAC OFF AUX ON (REAR VIEW) SWITCH V5A20 V4A20 MANIFOLD ETI ASSEMBLY V3C20 V3B20 V1A20 V2A20 V3A20 REGULATOR Figure 10-6. Warrior II and III Auxiliary Vacuum Electrical Schematic...
Page 339 PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-20. HEADING INDICATOR. 10-21. GENERAL. The 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 340 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-II TROUBLESHOOTING HEADING (DIRECTIONAL GYRO) INDICATOR (cont.) Trouble Cause Remedy Dial spins during turn. Limits (55 ° bank or pitch) of Recage gyro in level fflight. gimbal exceeded. Blockage or leak in line between Check hose bertween regulator r e g u l ator and instrument.
Page 341 PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-26. TROUBLESHOOTING. TABLE X-III. TROUBLESHOOTING ATTITUDE DEVIATION INDICATOR Trouble Cause Remedy Bar fails to respond. Observe vacuum gauge for If insufficient vacuum exists, insufficient vacuum. check pump and tubing. Filter dirty. Clean or replace filter.
Page 342 PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-28 PITOT AND STATIC AIR SYSTEMS. (Refer to Figure 10-7.) 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 hoseing and tubing routed through the wing to the airspeed indicator on the instrument panel.
Page 343: Troubleshooting Vertical Speed Indicator
PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-29. VERTICAL SPEED INDICATOR. 10-30. GENERAL. The vertical speed indicator measures r a t e of change in static pressure when the airplane is e s t a blished in a climb or descent. A pointer and dial will show the airplane’s rate of climb or descent in feet per minute.
Page 344 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-IV. TROUBLESHOOTING VERTICAL SPEED INDICATOR (cont.) TROUBLE CAUSE REMEDY Instrument reads excessively less Instrument case broken or Replace instrument. than actual rate during climb or l e a king. descent. 10-32. REMOVAL AND REPLACEMENT. Refer to Paragraph 10-71 of this section.
Page 345 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-V. TROUBLESHOOTING ALTIMETER (cont.) TROUBLE CAUSE REMEDY Setting knob is hard to turn. Wrong lubrication or lack of Replace instrument. lubrication. Inner reference marker fails to Out of engagement. Replace instrument. move when setting knob is rotated.
Page 346: Troubleshooting Pitot/Static Tubes And Airspeed Indicator
PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-VI. TROUBLESHOOTING PITOT/STATIC TUBES AND AIRSPEED INDICATOR TROUBLE CAUSE REMEDY Pointers of static instruments do Leak in instrument case or in Check for leak and seal. not indicate property. pitot lines. Pointer of instrument oscillates.
Page 347 PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-42 TROUBLESHOOTING TABLE X-VII. TROUBLESHOOTING MAGNETIC COMPASS TROUBLE CAUSE REMEDY Excessive card error. Compass not properly compensated. Compensate instrument. (Refer to Paragraph 10-42) External magnetic interference. Locate magnetic interference and eliminate if possible. Replace instrument.
Page 348 PIPER CHEROKEE WARRIOR SERVICE MANUAL Place airplane on a magnetic compass rose designed and intended for adjusting magnetic compasses. Set adjustment screws of compensator on zero. Zero position of adjusting screws is when the dot of the screw is lined up with the dot of the frame.
Page 349 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-VIII. TROUBLESHOOTING TACHOMETER TROUBLE CAUSE REMEDY Pointer goes all the way to stop; Excessive lubricant in instrument. Replace instrument. more noticeable in cold weather. Pointer jumps at idle. Speed cup hitting rotating magnet. Replace instrument.
Page 350 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. Removal of Oil Pressure Sender A. Gain access to the sender from under the pilot’s (left) instrument panel. B. Disconnect the single wire by removing the nut and washer securing it to the sender.
Page 351: Troubleshooting Pa-28-151, Warrior And Pa-28-161, Warrior
PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-IX. TROUBLESHOOTING PA-28-151, WARRIOR AND PA-28-161, WARRIOR II ENGINE OIL PRESSURE GAUGE TROUBLE CAUSE REMEDY Excessive error at zero. Pointer loose on shaft. Replace instrument. Over pressure or seasoning of Replace instrument. Bourdon tube.
Page 352 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-XI. TROUBLESHOOTING WARRIOR III ENGINE OIL PRESSURE GAUGE TROUBLE CAUSE REMEDY Excessive error at zero. Pointer loose on shaft. Replace instrument. Excessive scale error. Improper calibration adjustment. Replace instrument. Excessive pointer oscillation. Air in line or rough engine relief.
Page 353 PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-52. FUEL PRESSURE GAUGE. The fuel pressure gauge instrument is mounted in the cluster on instrument panel. On the PA-28-151, Warrior and PA-28-161, Warrior II, the gauge is connected to the fuel system at the carburetor fuel inlet fitting.
Page 354 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-XIV. WARRIOR III INSTRUMENT CALIBRATION CHART CALIBRATION CHART CALIBRATION CHART CALIBRATION CHART OIL PRESSURE TOL ± 2% FUEL PRESSURE OIL TEMP. TOL ± 2% OHMS D E G R E E S P S I...
Page 355 PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-54 ELECTRIC INSTRUMENTS 10-55 TURN INDICATOR 10-56. GENERAL PA-28-151, Warrior airplanes are equipped with a turn and slip (turn and bank) indicator. PA-28-161, Warrior II and Warrior III airplanes are equipped with a turn c o o r d i n a t o r. The conventional turn and slip i n d i c ator(s) are available as an option on both models.
Page 356: Warrior Iii Fuel Quantity Gauge
PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-59. FUEL QUANTITY INDICATORS. 10-60. GENERAL The PA-28-151, Wa r r i o r, and PA-28-161, Warrior II, have two fuel quantity gauges mounted in the cluster on the instrument panel. These instruments are calibrated in fractional divisions of one fourth, one half, three fourths and full.
Page 357 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE X-XVI. FUEL QUANTITY INDICATORS (cont.) TROUBLE CAUSE REMEDY Fuel gauge indicates incorrectly. Intermittent ground. Check ground at transmitter and instrument. Float arm sticky. Replace fuel transmitter. 10-62. REMOVAL AND REPLACEMENT. Refer to Paragraph 10-72 of this section.
Page 358 PIPER CHEROKEE WARRIOR SERVICE MANUAL 2. With face panel removed, mounting screws for individual instruments will be exposed. Remove the connections to the instrument before removing instrument mounting screws. 3. Install instruments by reversing removal instructions. After installation and before replacing instrument face panel, check all components for security and control column clearance.
Page 359 PIPER CHEROKEE WARRIOR SERVICE MANUAL 10-75. TROUBLESHOOTING. TABLE X-XVII. TROUBLESHOOTING CYLINDER HEAD TEMPERATURE GAUGE TROUBLE CAUSE REMEDY Instrument shows no indication. Power supply wire. Repair wire broken. Defective instrument. Replace instrument. Master (BAT) switch OFF. Select master (BAT) switch O N .
Page 360 PIPER CHEROKEE WARRIOR SERVICE MANUAL b. Disconnect lead wires at instrument and measure. Resistance with lead wires connected to probe must be 3.3 ohms. Clean connections with steel wool before assembly. c. With leads connected to instrument, heat probe with propane torch to dull red. Meter must read up to fourth graduation or approximately 1500°F.
Page 361 Install new gauge in reverse sequence. Check that tapered face on inner and outer bushings are positioned properly against windshield. Check gauge position before hand tightening sunshield 10-83. PIPER AUTOCONTROL SYSTEM. (See AutoControl Service Manual) THIS SPACE INTENTIONALLY LEFT BLANK...
Page 362 PIPER CHEROKEE WARRIOR SERVICE MANUAL GRIDS 2D2 AND 2D3 INTENTIONALLY LEFT BLANK Island Enterprises...
Page 363 SECTION XI ELECTRICAL SYSTEM Aerofiche Paragraph Grid No.. 11-1. Introduction..........................11-2. Description..........................11-3. Troubleshooting........................2D10 11-4. Precautions..........................11-5. Prestolite and Electrosystem Alternator and Components............. 11-6. General........................11-7. Description of Prestolite and Electrosystem Alternators.......... 11-8. Checking Prestolite and Electrosystem Alternator System ........11-9.
Page 364 Aerofiche Paragraph Grid No. 11-34 Battery............................ 11-35. Battery Description (Warrior and Warrior II)............11-36. Servicing Battery (Warrior and Warrior II)............... 11-37. Removal of Battery (Warrior and Warrior II)............11-38. Installation of Battery (Warrior and Warrior II)............11-39. Charging Battery (Warrior and Warrior II)............... 11-40.
Page 365 Aerofiche Paragraph Grid No. 11-79. Field Coils......................... 2F25 11-80. Brush Holders......................2F26 11-81. Gear and Pinion Housing..................2F26 11-82. Bendix Drive......................2F26 11-83. Assembly of Starting Motor ..................2F26 11-84. Bench Tests....................... 2F26 11-85. Starting Motor Control Circuit ................. 2F26 11-86.
Page 366 Aerofiche Paragraph Grid No. 11-125. Annunciator Panel........................2G14 11-126. Annunciator Panel Description (Warrior/Warrior II)..........2G14 11-127.Annunciator Panel Description (Warrior III)............. 2G14 11-128. Troubleshooting Annunciator Panel (Warrior/Warrior II/Warrior III)...... 2G14 11-129 Replacement of Annunciator Panel Bulbs (Warrior/Warrior II)....... 2G15 11-130. Replacement of Annunciator Panel Bulbs (Warrior/Warrior II)....... 2G16 11-131.
Page 367 Aerofiche Paragraph Grid No. THIS PAGE INTENTIONALLY LEFT BLANK Revised: February 28, 1995 Island Enterprises...
Page 368 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L SECTION XI ELECTRICAL SYSTEM 11-1. INTRODUCTION. This section contains instructions and schematics for correcting difficulties which may arise in the operation of the electrical system in the aircraft.
Page 369 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L The airplane is equipped with standard navigation lights and wing tip strobe type anti-collision lights, which are controlled by rocker type switches (NAV LIGHT and STROB LIGHT) located on the instrument panel.
Page 370 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy ALTERNATOR (cont.) Zero output indicated on ammeter Open output circuit. (cont.) Open circuit in alternator output regardless of rpm (refer to will usually burn out ALT a l t e rnator system test procedure).
Page 371 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy ALTERNATOR (cont.) Output indicated on ammeter High resistance connections in Check visually for loose binding does not meet minimum values field or output circuit.
Page 372 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy ALTERNATOR (cont.) Field circuit breaker trips. Short circuit in field winding of WARNING (cont.) alternator. (cont.) Before turning propeller by hand, turn magneto switch OFF, and ensure magneto is g r o u n ded.
Page 373 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy ALTERNATOR (cont.) Output circuit breaker trips. Battery charged backwards. Remove battery. Connect load, (cont.) such as landing light lamp or s i m i l a r l o a d , a n d d i s c h a r g e b a tt e r y.
Page 374 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy STARTER (cont.) Starter fails to operate. (cont.) Binding, worn, or improperly CAUTION seated brush, or brushes with excessive side play.
Page 375 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy STARTER (cont.) Low motor and cranking speed. Worn, rough, or improperly lubri- Disassemble, clean, inspect, and cated motor or starter gearing.
Page 376 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy BATTERY Battery life is short. O v e r c h a rge due to level of Maintain proper electrolyte level.
Page 377 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy BATTERY Battery consumes excessive Charging rate too high, if loss is Correct charging rate. water. in all cells.
Page 378 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy WARRIOR/WARRIOR II ANNUNCIATOR PANEL (cont.) V A C w a r n i n g l i g h t f a i l s t o Bulb burned out.
Page 379 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy WARRIOR III ANNUNCIATOR PANEL A l l w a r n i n g l i g h t s f a i l to 5 amp ANNUNCIATOR PANEL Reset (push in) circuit breaker.
Page 380 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy WARRIOR III ANNUNCIATOR PANEL (cont) P I TOT HEAT OFF/INOP fails to Blown bulb(s). Replace bulb(s). i l l u m i n a t e .
Page 381 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy WARRIOR III ANNUNCIATOR PANEL (cont) VACUUM INOP light does not Sensor activates at too high of a Replace sensor.
Page 382 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. TROUBLESHOOTING ELECTRICAL SYSTEM (cont.) Trouble Cause Remedy WARRIOR III ANNUNCIATOR PANEL (cont) PRESSURE fails Blown bulb(s). Replace bulb(s). i l l u m in a t e .
Page 383 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L THIS PAGE INTENTIONALLY LEFT BLANK 2D24 Island Enterprises...
Page 384 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-4. 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.
Page 385 PIPER CHEROKEE WARRIOR SERVICE MANUAL CAUTION If booster battery or fast charger is used, its polarity must be connected correctly to prevent damage to electrical system components. CAUTION Refer to wiring diagram and Figure 11-13 when installing or testing alternator.
Page 386 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-5. P R E S TOLITE AND ELECTROSYSTEMS ALTERNATOR AND COMPONENTS 11-6. GENERAL The PA-28-151, Warrior and PA-28-161, Warrior II were equipped with either a 14 Vdc, 60 amp Prestolite or Chrysler alternator.
Page 387: Exploded View Of Prestolite And Electrosystems Alternators
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-1. Exploded View of Prestolite and Electrosystems Alternators NOTE Current reading on ammeter is the load in amperes demanded by the electrical system from alternator. Check, for example, a condition where battery is demanding 10 amperes charging current, then switch on landing light.
Page 388: Lamp Bank Load
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L CAUTION On air-conditioned aircraft, full alternator output on ground must be limited to not more than 10 minutes. Refer to Pilot’s Operating Handbook. a. Check airplane is positioned so prop blast will not interfere with other operations going on near by.
Page 389 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L d. Remove nuts, lock washers, flat washers, and insulators from output and auxiliary terminal studs. (Note carefully the correct assembly of insulator washers and bushings.) Using special tools shown in Figure 11-3, support end head and press out the three negative rectifiers.
Page 390: Removal Of End Head Bearing
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-5. Removal of Drive End Head Figure 11-6. Removal of End Head Bearing RHEOSTAT AMMETER ROTOR BATTERY VOLTMETER Figure 11-7. Testing Rotor for Ground Figure 11-8. Testing Rotor for Shorts...
Page 391 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L b . Rectifiers: A diode rectifier tester will detect and pinpoint open or shorted rectifiers without d i sconnecting stator leads. On both the 12 Vdc and 24 Vdc alternators, if a tester is not available, test probes and a no.
Page 392: Installation Of Bearing
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-12. ASSEMBLY OF PRESTOLITE AND ELECTROSYSTEMS ALTERNATOR a. Press ball bearing into drive end head using a flat block approximately two inch square, so pres- sure is exerted on outer race of bearing. Install retainer plate. With snap ring and retainer cup in place on rotor shaft, use a tool that fits over shaft and against inner bearing race, and press until inner bearing race is against snap ring retainer cup.
Page 393: Terminal Assembly
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L LOCK WASHER FLAT WASHER FIBER WASHER END HEAD INSULATOR RECTIFIER MOUNTING PLATE TERMINAL STUD OUTPUT (+) TERMINAL AUXILLARY TERMINAL Figure 11-11. Terminal Assembly SEAL - INSTALL SEAL WITH...
Page 394: Brush Installation
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-13. TESTING OF PRESTOLITE AND ELECTROSYSTEMS A LT E R N ATO R S CAUTION Alternator should not be run more than 2 minutes for each test point.
Page 395 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L c. Brushes: These units have a separate brush holder assembly that is installed after the alternator has been assembled. The brush holder has a small hole that intersects the brush cavities. Use a pin or wire, as in figure 11-14 to hold brushes in holder during assembly.
Page 396 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-16. CHRYSLER ALTERNATOR AND COMPONENTS 11-17. DESCRIPTION OF CHRYSLER ALTERNATOR Chrysler alternators were installed only on the PA-28-151, Warrior. The alternator is located on the front lower right side of the engine and utilizes a belt drive from the engine crankshaft.
Page 397: Exploded View Of Chrysler Alternator
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 1. RECTIFIER END SHIELD ASSEMBLY 2. DRIVE END SHIELD ASSEMBLY 3. DRIVE END BEARING 4. BEARING RETAINER PLATE 5. STATOR ASSEMBLY 6. ROTOR ASSEMBLY 7. BATTERY TERMINAL PACKAGE 8.
Page 398 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L NOTE Current shown on ammeter is the load in amperes demanded by electrical system from alternator. For example, consider a condition where battery is demanding 10 amperes charging current;...
Page 399: Checking Chrysler Alternator Field Current Draw
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L CAUTION A low rotor coil draw indicates high resistance in the field coil circuit (brushes, slip rings or rotor coils). A higher rotor coil draw indicates possible shorted rotor coil or grounded rotor.
Page 400 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Touch one test lamp probe to one slip ring and remaining test probe to rotor shaft. Lamp should not light. Lighted test lamp indicates a grounded rotor assembly and requires rotor replacement. If test lamp does not light, a ground condition exists in insulated brush assembly.
Page 401: Chrysler Alternator Rectifier End Shield And Stator Assembly
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L ATTACHING STATOR LEADS (3) NUTS TERMINAL BLOCK STUDS STATOR Figure 11-19. Chrysler Alternator Rectifier End Shield and Stator Assembly 11-24. TESTING OF CHRYSLER ALT E R N ATOR POSITIVE RECTIFIERS USING C-3829 TESTER (Refer to Figure 11-20.)
Page 402: Testing Positive Rectifiers With C-3829 Tester
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L NOTE If negative rectifier shows shorted, isolate stator from rectifier end shield and retest. Stator winding could be grounded to s t ator lamination or rectifier end shield which would indicate a shorted negative rectifier.
Page 403: Testing Positive Rectifiers With Test Lamp
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L NOTE Lamp must light in the same direction for all rectifiers on each assembly. — NOTE — Replace rectifier and heat sink assemblies which have shorted or open rectifiers.
Page 404: Rectifier End Shield Assembly
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L NUT AND HEAT SINK ASSEMBLY NUT AND WASHER WASHER OUTPUT TERMINAL ASSEMBLY NEGATIVE RECTIFIER ATTACHMENT ASSEMBLY ATTACHMENT PLASTIC MICA SCREW CAPACITOR SCREWS INSULATOR INSULATOR Figure 11-24. Rectifier and Heat Sink Figure 11-25.
Page 405: Removal Of Rectifier
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TEST LAMP TOOL C-4068 C-4333 BEARING PULLEY RETAINER SCREW Figure 11-26. Testing Stator Figure 11-27. Removal of Pulley TOOL C-4068 PRESS C-3770A C-4333 C-3925 BEARING RETAINER Figure 11-28. Removal of Bearing Figure 11-29.
Page 406: Testing Rotor For Ground
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-30. TESTING OF CHRYSLER ALTERNATOR ROTOR (Refer to Figures 11-30 and 11-31.) a. Check for a grounded field coil by connecting an ohmmeter from each slip ring to rotor shaft.
Page 407: Installation Of Rectifier
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L c. Insert drive end bearing in drive end shield and install bearing retainer plate to hold bearing in place. Install all three bearing retainer screws. Tighten to torque of 25 to 45 inch-pounds.
Page 408: Installation Of Drive End Shield Bearing
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TOOL C-3858 BEARING RETAINER PRESS DRIVE END SHIELD PULLEY ROTOR DRIVE END SHIELD BEARING RETAINER SCREWS Figure 11-34. Installation of Drive End Shield Figure 11-35. Installation of Pulley...
Page 409 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L NOTE PA-28-151 S/N 28-7415001 thru 28-7715314, and PA - 2 8 - 1 6 1 S/N 28-7716001 thru 28-8216162, capacitor is on aft alternator bracket per SPL366A and Kit 764 347. Installed kit will pro - vide improved service life of alternator bracket and filter capacitor.
Page 410: Installation Of Capacitor
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L NUT AND WASHER TORQUE MICA HEAT SINK 30 TO 40 IN. - LB INSULATOR ASSEMBLY BATERY OUTPUT STUD TERMINAL ROUND CAPACITOR NEGATIVE RECTIFIER PLASTIC TORQUE ASSEMBLY ATTACHING...
Page 411: Alternator Belt Tension
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-III. CHRYSLER ALTERNATOR SPECIFICATIONS ALTERNATOR MODEL CHRYSLER 3656624 or 4111810 Rated Output 60 amperes Ground Polarity Negative Rotation Clockwise at Drive End Rotor: Current Draw 4.5 to 6.5 amps 12-volts Resistance 1.5 to 2.0 ohms...
Page 412 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L NOTE The higher tension specified for a new belt is to compensate for the initial stretch that takes place as soon as it is operated. These higher tension values should not be applied to belts which have previously been used.
Page 413: Hydrometer Reading And Battery Charge Percent Warrior/Warrior Ii 12 Volt Battery
Connect the ground cable to the negative battery terminal and secure. e. Replace battery box lid and secure with four cam locks. If not already accomplished, refer to latest revision of Piper Service Bulletin No. 631 for battery protection and correct rear seat installation.
Page 414: Battery Installation - 12 Volt (Warrior/Warrior Ii)
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-42. Battery Installation - 12 volt (Warrior / Warrior II) Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 415 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11 - 4 0 . S TA RTING THROUGH EXTERNAL POWER RECEPTACLE WITH AIRPLANE’S BATTERY NEARLY DEPLETED. 11-41. WARRIOR/WARRIOR II Use the following procedure for starting with a 12 volt battery for external power when the airplane’s battery is nearly depleted: a.
Page 416 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-46. REMOVAL OF BATTERY BOX. (WARRIOR and WARRIOR II) (Refer to Figure 11-42.) a. Remove battery according to instructions in Paragraph 11-21. b. Remove the two bolts and nuts securing the Master Contactor to the side of the battery box. Lay master contactor aside.
Page 417: Battery Installation - 24 Volt (Warrior Iii S/N's 2816110)
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 1. BATTERY 2. COVER 3. MOUNTING BOLT, WASHER, INSULATOR 4. VENT TUBE 5. CONTACTOR 6. DIODE ASSEMBLY 7. FUSE ASSEMBLY Figure 11-43. Battery Installation - 24 volt (Warrior III S/N’s 2816110 and up)
Page 418 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-51. CLEANING BATTERY. (WARRIOR III) a. Remove all accumulated contamination from the battery exterior with a stiff bristle brush. (Do not use a metal brush or abrasive materials.) Wipe exterior of battery and interior of manifold, including manifold top cover, with a cloth saturated with a solution of bicarbonate of soda mixed - one part soda to twenty parts of water.
Page 419 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L d. It is recommended that vent caps be left on the battery while charging. In addition a wet cloth should be placed over the vent caps within the manifold.
Page 420 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-VI. HYDROMETER READING AND BATTERY CHARGE PERCENT WARRIOR III, 24 VOLT BATTERY Hydrometer Reading Percent of Charge 1.285 to 1.295 1.250 1.217 1.184 1.150 Discharged TABLE XI-VII. ELECTROLYTE TEMPERATURE CORRECTIONS...
Page 421: Electrolyte Freezing Point
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-55. BATTERY DISCHARGE (WARRIOR III) 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 422 The PA-28-151, Warrior, s/n’s 28-7415001 and up, and the PA-278-16, s/n’ 28-7716001 through s/n’s 28-8416028, were originally equipped with Wico voltage regulators. These regulators are no longer available, and have been replaced by Lamar voltage regulators. Refer to Piper’s Alternator Control Service Replacement Kit No. 764 928.
Page 423 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L f. With the alternator turning at sufficient rpm to produce a half load condition or approximately 25 amperes output, the voltmeter should read between 13.6 and 14.3 volts. The ambient temperature around the voltage regulator should be between 50°...
Page 424: Lamar 14 Vdc Regulator Check
PIPER CHEROKEE WARRIOR SERVICE MANUAL VOLTAGE REGULATOR 1000 OHM 1/2 W BLUE 11-18 VDC VARIABLE POWER SUPPLY Figure 11-44. Lamar 14 Vdc Regulator Check 1. V1 Connections. A. Connect positive voltmeter lead to red wire (supply) at regulator harness connector or ter- minal block.
Page 425: Lamar 28 Vdc Regulator Check
PIPER CHEROKEE WARRIOR SERVICE MANUAL 3. Voltage continues to rise. a. Regulator housing not grounded. b. Regulator shorted, must be replaced. In case of failure check for: 1. Poor or loose connections. 2. Poor ground on regulator housing. 3. Shorted alternator windings.
Page 426 The PA-28-151, Warrior, s/n’s 28-7415001 and up, and the PA-278-16, s/n’ 28-7716001 through s/n’s 28-8416028, were originally equipped with Wico overvoltage relays. These relays are no longer available, and have been replaced by Lamar overvoltage relays. Refer to Piper’s Alternator Control Service Replacement Kit No. 764 928.
Page 427: Application Of Wico Overvoltage Control
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L c. Remove the two bolts securing the overvoltage relay in place and remove the relay for testing. (See Paragraph 11-60.) Figure 11-46. Application of Wico Overvoltage Control 11-66.
Page 428: Lamar 14 Vdc System Overvoltage Check
PIPER CHEROKEE WARRIOR SERVICE MANUAL Overvoltage control is set to operate between 16.2-volts and 17.3-volts. By adjusting the voltage, click will be heard when relay operates. If overvoltage control does not operate between 16.2 and 17.3-volts, it must be replaced.
Page 429 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-69 LAMAR 28 V0LT REGULATOR OVERVOLTAGE CHECK The Lamar regulator has an incorporated overvoltage relay. To check relay operation use the same test connections as testing the regulator, except connect the bulb across the RED and BLUE wires. (Refer to figure 11-48.) Test as follows:...
Page 430: Exploded View Of Gear Reduction Starter Motor
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-49. Exploded View of Gear Reduction Starter Motor 11-73. STARTER MOTOR MAINTENANCE The starting system installation requires inspection each 50 hour inspection interval or every 30 days whichever occurs first.
Page 431 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L c. No lubrication is required on starting motor except at overhaul. Then lubricate entire shaft under Bendix drive, fill grooves in armature shaft at drive end, and pack gear box with l.3 to 2.0 ounces of lithium soap base grease Texaco #1925 Molytex O or equivalent.
Page 432: Turning Starting Motor Commutator
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-77. BRUSHES Check brushes slide freely in their holders and make full contact on commutator. If worn one quarter inch or less, they must be replaced. 11-78. ARMATURE a.
Page 433: Brush Holders
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-80. BRUSH HOLDERS. a. To test brush holders, touch one test probe to the brush plate and the other to each brush holder. b. The test lamp should light when the grounded brush holders are touched and should not light when the insulated brush holders are touched.
Page 434: Testing Motor Fields For Grounds
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-52. Testing Motor Fields for Grounds Figure 11-53. No Load Test Hookup Figure 11-54. Stall Torque Hookup Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 435: Starting Motor Specifications
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-86. STARTING MOTOR SERVICE TEST SPECIFICATIONS. Prestolite specifications for 12 or 24 volt starting motors installed as standard equipment on the PA - 2 8 -151, Warrior, and the PA-28-161, Warier II/Warrior III series aircraft are as follows: TABLE XI-XI.
Page 436: Installation Of Wing Navigation Lights (Warrior/Warrior Ii)
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L a. Be sure electrical power is removed from aircraft and/or applicable system. b. Remove screw securing the lens retainer. c. Remove the lens and bulb. 11-94. INSTALLATION OF WING NAVIGATION LIGHTS. (WARRIOR/WARRIOR II) a.
Page 437: Anti-Collision Lights (Warrior/Warrior Ii)
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L c. Set (push in) NAV LIGHTS circuit breaker. d. Verify that bulb(s) is/are working by selecting BATT MASTR and NAV LIGHT switches ON and checking that all navigation light bulbs are lit. Select BATT MASTR and NAV LIGHT switches OFF.
Page 438: Removal
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L c. Secure lens to mounting plate by the clamp previously removed. d. Reconnect electrical plugs underneath fin tip. e. Replace fin tip and secure with appropriate screws.
Page 439: Strobe Power Supply
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-112. STROBE POWER SUPPLY The strobe power supply is in the aft section of the fuselage. 11-113. REMOVAL OF STROBE POWER SUPPLY. (WARRIOR/WARRIOR II/WARRIOR III) a. Be sure electrical power is removed from aircraft and/or applicable system.
Page 440 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-55. Strobe Light Connections (Warrior/Warrior II) Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 441 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-56. Strobe Light Connections (Warrior II) Revised: February 28, 1995 ELECTRICAL SYSTEM 2G10 Island Enterprises...
Page 442 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TO LIGHT WHITE DIMMER CONTROL BLACK AVG #22 BUS WIRE #20 VINYL GLASS TUBING GROUND STROBE LIGHT SWITCH L4A 20 WIRE SWITCH CONNECTIONS FACE L4B 20 BLACK (WITH SHIELD)
Page 443: Instrument And Panel Lights
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L b. Check for malfunction in interconnecting cables. 1. Check Pins 1 and 3 of interconnecting cable are not reversed. 2 . Using an ohmmeter, check continuity between Pin 1 and 3 of interconnecting cable. If a reading is obtained on the meter, the cable is shorted and should be replaced.
Page 444: Instrument And Panel Lights Description (Warrior Iii)
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-120. INSTRUMENT AND PANEL LIGHTS DESCRIPTION (WARRIOR III). Instrument post lights, switch lights, and avionics lights are controlled by individual electronic dimmer control assemblies, located on the right side on the back of the firewall. They are operated by HI-LOW adjust- ment potentiometers located on the instrument panel below the pilot’s control wheel,.
Page 445 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L f . Engage (push in) BAT T E RY FEEDER circuit breaker and place BATT MAST switch in ON p o s ition. g. Check that lights associated with replaced potentiometer control operate properly.
Page 446 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Power is supplied from the bus through a 5 amp circuit breaker and the annunciator box assembly. The DAY-NIGHT toggle switch, located to the left of the annunciator panel, is placed in the NIGHT position to dim the annunciator lights for night flight.
Page 447 PIPER CHEROKEE WARRIOR SERVICE MANUAL 11-130. REPLACEMENT OF ANNUNCIATOR PANEL LIGHT BULBS (WARRIOR III) It is not necessary to remove the annunciator panel assembly to replace lamp bulbs. Simply “PUSH- IN” on the function light until it “clicks”, and release pressure. The cover assembly will be partially ejected from the lamp base assembly.
Page 448 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-131. OIL PRESSURE SENSOR 11-132. REMOVAL OF OIL PRESSURE SENSOR (WARRIOR/WARRIOR II) a. Gain access to sensor unit by reaching up under the instrument panel. b. Disconnect the two electrical leads.
Page 449 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-138. OIL TEMPERATURE SENSOR 11-139. REMOVAL OF OIL TEMPERATURE SENSOR (WARRIOR/WARRIOR II) a. Gain access to engine accessory section. b. Disconnect wire from sender by removing nut and washer securing wire to sender.
Page 450 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L a. Remove four screws holding plate around tab. Lift detector is fastened to the plate; remove unit from wing. b. Mark electrical wires and terminals to aid installation. Remove electrical wires from lift detector;...
Page 451 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 11-154. REMOVAL OF ELECTRICAL SWITCHES (WARRIOR III) a. Disconnect positive battery cable. b. Reach behind instrument panel and, while squeezing on the upper and lower clips, push switch out through front of panel.
Page 452: Ignition Switch Wire Position
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L e. Fasten and tighten knurled nut to circuit breaker face plate on front of instrument panel. f. Connect positive battery cable. g. Activate circuit protected by replaced breaker. Check appropriate electrical items are functioning.
Page 453 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L THIS PAGE INTENTIONALLY LEFT BLANK 2G22 Island Enterprises...
Page 454 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-XIII. LAMP REPLACEMENT GUIDE WARRIOR/WARRIOR II Location Piper Part No. Lamp No. Annunciator Panel 453 695 472 054 Cabin Light 472 036 Flood Light 472 034...
Page 455 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-XIV. WARRIOR/WARRIOR II ELECTRICAL SYSTEM COMPONENT LOADS Duty Cycle Circuit Load Cont. Inter. Equipment Breaker (Amps) Optional Alternator Field Anti-Collision (Strobe) Cabin Dome Light Cigar Lighter...
Page 456: Warrior Iii Electrical System Component Loads
PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-XV. WARRIOR III ELECTRICAL SYSTEM COMPONENT LOADS Duty Cycle Circuit Load Cont. Inter. Equipment Breaker (Amps) Optional Alternator Field Anti-Collision (Strobe) Auxiliary Vacuum Pump Cabin Dome Light...
Page 457 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 458 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L SECTION XI - ELECTRICAL CHARTS AND WIRING DIAGRAM INDEX FIGURE NO SCHEMATIC GRID NO. TABLES Table XI-XVI. Electrical Wiring Code Table XI-XVII. Electrical Symbols (Old Style) 2H10 Table XI-XVIII.
Page 459 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L SECTION XI - ELECTRICAL CHARTS AND WIRING DIAGRAM INDEX (Cont.) FIGURE NO SCHEMATIC GRID NO. ELECTRICAL SYSTEMS Alternator and Optional External Power Receptacle (Cont.) PA-28-161: 11-73 S/N’s: 28-7716001 to 28-8216059...
Page 460 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L SECTION XI - ELECTRICAL CHARTS AND WIRING DIAGRAM INDEX (Cont.) FIGURE NO SCHEMATIC GRID NO. FUEL SYSTEM Electric Fuel Pump PA-28-151 11-88 S/N’s: 28-7415001 thru 28-7515004 2I11 11-89 S/N’s: 28-7515005 and up...
Page 461 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-I. ELECTRICAL SCHEMATIC INDEX (Cont.) FIGURE NO SCHEMATIC GRID NO. INDICATORS (cont.) Turn Indicators PA-28-151: 11-100 S/N’s: 28-7415001 and up 2I16 PA-28-161: 11-100 S/N’s: 28-7716001 to 28-8216008...
Page 462 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L SECTION XI - ELECTRICAL CHARTS AND WIRING DIAGRAM INDEX (Cont.) FIGURE NO SCHEMATIC GRID NO. LIGHTING - EXTERIOR (cont.) Landing Light PA-28-151 11-113 S/N’s 28-7415001 thru 28-7715314...
Page 463 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L SECTION XI - ELECTRICAL CHARTS AND WIRING DIAGRAM INDEX (Cont.) FIGURE NO SCHEMATIC GRID NO. LIGHTING - INTERIOR (cont.) Dimmer Panel Wiring PA-28- 161: 11-123 Later Models...
Page 464 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-XVI. ELECTRICAL WIRE CODING CIRCUIT FUNCTION LETTER WIRE NUMBER WIRE SEGMENT LETTER WIRE GAUGE CIRCUIT FUNCTION CIRCUITS LETTER AUTOPILOT CONTROL SURFACE FLIGHT INSTRUMENT LANDING GEAR HEATER - VENTILATING & DEICING...
Page 465 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-XVII. ELECTRICAL SYMBOLS (Old Style) BATTERY KNIFE CONNECTORS BUS BAR PUSH-PULL PUSH SWITCH TYPE TYPE TYPE CIGAR LIGHTER ALTERNATOR SOCKET BEACON THERMAL SWITCH ELECTRICAL CLUTCH THERMAL...
Page 466 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-XVIII. ELECTRICAL SYMBOLS (New Style) AIRCRAFT LOCATION SYMBOLS BATTERIES ADJUSTABILITY GENERAL GENERAL MULTICELL FUSELAGE STATION WATER LINE BUTT LINE CABLES AND CONDUCTORS SHIELDED COAXIAL SHIELDED TWO...
Page 467 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L TABLE XI-XVIII. ELECTRICAL SYMBOLS (New Style) (Cont,) MOMENTARY OR PUSH BUTTON CONTACT SWITCH ASSEMBLIES SPRING RETURN BASIC (MAKE) (BREAK) CLOSED OPEN TRANSFER CIRCUIT CIRCUIT CONTACT CONTACT CIRCUIT...
Page 468 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-61. Annunciators (PA-28-151, S/N’s 28-7515001 thru 28-7615435) Revised: February 28, 1995 ELECTRICAL SYSTEM 2H13 Island Enterprises...
Page 469 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L 5Ω 6.5W Figure 11-62. Annunciators (PA-28-151, S/N’s 28-7715001 thru 28-7715314; PA28-161, S/N’s 28-7716001 to 28-8216059) Revised: February 28, 1995 ELECTRICAL SYSTEM 2H14 Island Enterprises...
Page 470 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L ANNUNCIATOR BOX INTERNAL WIRING Figure 11-63. Annunciator (PA-28-161, S/N’s 28-8216060 thru 28-8216226) Revised: February 28, 1995 ELECTRICAL SYSTEM 2H15 Island Enterprises...
Page 471 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L ANNUNCIATOR BOX INTERNAL WIRING Figure 11-64. Annunciator (PA28-161, S/N’s 28-831601 thru 28-8616057 & 2816001 thru 2816109 Revised: February 28, 1995 ELECTRICAL SYSTEM 2H16 Island Enterprises...
Page 472 DN10A 22 TO DIM RELAY DN18A 22 DN4A 22 TO PITOT DN19A 22 *PITOT HEAT HEAT SENSOR TO PITOT DN20A 22 OFF/INOP HEAT SWITCH DN9A 22 STE1 20 STARTER ENG DN21A 22 TO ALTERNATOR OUT SWITCH TO LOW VOLTAGE MONITOR TO STARTER CONTACTOR 5 AMP FUSE...
Page 473 PIPER CHEROKEE WARRIOR SERVICE MANUAL ANNUNCIATOR LIGHT ASSEMBLY (OPT) (OPT) 6 1 2 10 5 3 4 9 7 8 14 16 11 12 13 14 13 12 11 4 5 6 10 7 8 9 1 2 3 IN2071A DIODES LIGHT SOLDER SLEEVE - 9 REQ’D...
Page 474 PIPER CHEROKEE WARRIOR SERVICE MANUAL ANNUNCIATOR BOX ASSEMBLY PIN X2 PIN X2 Figure 11-65. Annunciator Box Assembly (S/N’s 2816110 and up) (Sheet 3 of 3) Added: February 28, 1995 ELECTRICAL SYSTEM 2H19 Island Enterprises...
Page 475 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-66. Cigar Lighter Figure 11-67. Pitot Heat (PA-28-151 and (Warrior/Warrior II) Early PA-28-161 Models) THIS SPACE INTENTIONALLY LEFT BLANK Figure 11-68 Pitot and Static Heat (Optional, Figure 11-69.
Page 476 PIPER CHEROKEE WARRIOR SERVICE MANUAL PITOT HEAT ANNUNCIATOR PANEL (REF.) 7 1/2 A PITOT HEAT OFF/INOP PITOT HEAT SWITCH DN20A 20 D19B 20 TO P1- H3A 18 H3B 18 CONT-7 H2D 18 H2E 18 P302 J302 P303 J303 PITOT 100W HEAD PITOT SENSOR ASSY.
Page 477 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 11-71. Alternator ad Optional External Power Receptacle (PA-28-151, S/N’s 28-7415001 thru 28-7415703) Revised: February 28, 1995 ELECTRICAL SYSTEM 2H22 Island Enterprises...
Page 478 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-72. Alternator ad Optional External Power Receptacle (PA-28-151, S/N’s 28-7515001 thru 28-7615435) Revised: February 28, 1995 ELECTRICAL SYSTEM 2H23 Island Enterprises...
Page 479 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-73. Alternator ad Optional External Power Receptacle (PA-28-151, S/N’s 28-7715001 thru 28-7715314; PA-1-28-161, S/Ns 28-7716001 thru 28-8216059) Revised: February 28, 1995 ELECTRICAL SYSTEM 2H24 Island Enterprises...
Page 480 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-74. Alternator ad Optional External Power Receptacle (PA-1-28-161, S/Ns 28-8216060 thru 28-8216226) Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 481 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-75. Alternator ad Optional External Power Receptacle (PA-1-28-161, S/Ns 28-8316001 thru 28-8616057 and 2816001 thru 2816093) Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 482 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-76. Alternator ad Optional External Power Receptacle (PA-28-161, S/Ns 2816094 thru 2816109) Added: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 483 PIPER CHEROKEE WARRIOR SERVICE MANUAL ALTERNATOR FIELD ELECTRICAL BUS 50 mv 100A SHUNT SWITCH FUSE ASSEMBLY ANNUN ALTERNATOR P2 R2 W2B 20 W2A 20 AMMETER P3D 4 5 9 B 1 1/4 A P AMM 1 4 3 5 W2C 20...
Page 484 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 11-78. Avionics Master (Optional) Figure 11-79. Avionics Master (Optional) (PA28-161, S/N’s 28-8016001 thru 28-8216216) (PA28-161, S/N’s 28-8216217 thru 2816109) AVIONICS BUS ELECTRICAL BUS PR1B 10 PR1A 10 PR2A 20 AVIONICS MASTER CONTACTOR PR2B 20...
Page 485 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-81. Starter (PA-28-151, S/N’s 28-7415001 thru 28-7415703) Figure 11-82. Starter (PA-28-151, S/N’s 28-7515001 thru 28-7715314; (PA-28-161, S/N’s 28-7716001 thru 28-8216059) Revised: February 28, 1995 ELECTRICAL SYSTEM...
Page 486 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-83. Starter ((PA-28-161, S/N’s 28-8216060 thru 28-8616057, and 2816001 thru 2816109) THIS SPACE INTENTIONALLY LEFT BLANK Figure 11-84. Unassigned Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 487 PIPER CHEROKEE WARRIOR SERVICE MANUAL BATTERY STARTER FEEDER & ACC. ELECTRICAL BUS 70 A 10 A STARTER SWITCH K1A 18 GND B20 STARTER TO ENGINE MAGNETOS ANNUNCIATOR STE1 20 PANEL R1 P1 BATTERY CONTACTOR P1D 4 P1C 4 STARTER EXTERNAL POWER...
Page 488 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-86. Air Conditioning/Air Blower (PA-28-161, Warrior II only) Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 489 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 11-87. Stall Warning (PA-28-151, Warrior and PA-28-161, Warrior II) Sheet 1 of 2 LIFT DETECTOR F1D 20 F1C 20 STALL WARNING HORN P1 R1 13 13 F1A 20 F1B 20 F1E 20 Figure 11-87. Stall Warning (PA-28-161, S/N’s 2816110 and up)
Page 490 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 11-88. Electric Fuel Pump (PA-28-151 Figure 11-89. Electric Fuel Pump (PA-28-151 S/N’s S/N’ 28-7415001 thru 28-7515004) 28-7515005 & Up; PA-28-161, S/N’s 28-7716001 thru 28-8616057, and 2816001 thru 2816109 ) PRIMER SWITCH PRIMER SOLENOID P1 R1...
Page 491 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-91. Electric Clock and Optional Digital Figure 11-92. Electric Clock and Optional Digital Clock (PA-28-161, S/N’s 28-8216060 thru 28-8216226) Clock (PA-28-161, S/N’s 28-8216001 thru 2816109) Figure 11-93. Optional Hour Meter Figure 11-94.
Page 492 PIPER CHEROKEE WARRIOR SERVICE MANUAL BATTERY FEEDER ELECTRICAL BUS 70 A P1A 4 BATTERY CONTACTOR P1C 4 P1D 4 STARTER CONTACTOR HOUR METER P2 R2 M1B 20 M3A 20 0 0 0 0 P2 R2 M2C 20 M2A 20 CLOCK (OPT.)
Page 493 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-96. Engine Gauges (PA28-151, S/N’s 28-7415001 and up; PA-28-161, Warrior II, Early Models) Figure 11-97. Engine Gauges (PA-28-161, Warrior II, Later Models) Revised: February 28, 1995...
Page 494 PIPER CHEROKEE WARRIOR SERVICE MANUAL ENGINE GAUGE Q6C 20 ELECTRICAL BUS PRESS Q6A 20 SENDER FUEL Q8A 20N PRESS SENDER Q6D 20N PRESS Q5B 20N FUEL TEMP PRESS TEMP Q6B 20 SENSOR Q5A 20 Q7A 20 P1 R1 Q5B 20 Figure 11-98.
Page 495 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 11-100. Turn Indicator (PA-28-151 S/N’s: Figure 11-101. Turn Indicator (PA-28-161) 28-7415001 and up, and PA-28-161, Alternate Vendor S/N’s 28-7716001 thru 28-8216008) TURN & BANK F2A 20N Figure 11-102. Turn Indicator (PA-28-161, S/N’s Figure 11-103. Turn Indicator 28-8216009 thru 28-8616057 and 2816001 thru 2816109 (PA-28-161, S/N’s 2816110 and up)
Page 496 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-104. Wing and Fin Anti-Collision Strobes (PA28-151 S/N’s: 28-7415001 thru 28-7716314, and PA-28-161, Early Models) Figure 11-105. Anti-Collision Rotating Beacon Figure 11-106. Anti-Collision Rotating Beacon (PA-28-151, S/N’s 28-7415001 thru 28-7716314 (PA-28-161, S/N’s 28-7916025 thru 28-8616057,...
Page 497 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-107. Wing Strobe Anti-Collision and Rotating Beacon PA28-161, Early Models) Revised: February 28, 1995 ELECTRICAL SYSTEM 2I18 Island Enterprises...
Page 498 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-108. Fin Strobe Anti-Collision Figures 11-109. Wing Strobe Anti-Collision and (PA-28-161, S/N’s 28-7916205 thru 28-8616057, Rotating Beacon (PA-28-161, S/N’s 28-7916205 thru and 2816001 thru 2816109) 28-8616057, and 2816001 thru 2816109) Figure 11-110.
Page 499 PIPER CHEROKEE WARRIOR SERVICE MANUAL ANTI-COLLISION LIGHTS LIGHTS ELECTRICAL BUS L1A 20 WHITE WHITE POSITION POSITION LIGHT LIGHT LEFT RIGHT STROBE STROBE LIGHT LIGHT GREEN LIGHT LIGHT LEFT RIGHT WING WING L4A 20 L1G 20 L1C 20 NAV LIGHTS POWER...
Page 500 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 11-113. Optional Landing Light (PA-28-151, S/N’s 28-7415001 thru 28-7715314 and PA-161, S/N’s 28-7716001 thru 28-8616057 and 2816001 thru 2816109) LANDING LIGHT SWITCH P1 R1 L3A 20 L3B 20 L3D 20 L3C 20 LANDING LIGHT Figure 11-114.
Page 501 PIPER CHEROKEE WARRIOR SERVICE MANUAL RIGHT WING L13B 20 R2 P2 L14A 20 RECOGNITION L14B 20 L14C 20 LIGHTS RECOGNITION LIGHTS SWITCH L14D 20 LEFT WING Figure 11-115. Recognition Lights (PA28-161, S/N’s 2816110 and up) Figure 11-116. Optional Cabin Light (PA-28-151 Figure 11-117.
Page 502 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-118. Optional Instrument Panel Lights ( PA-28-151,S/N’s 28-7415001 thru 28-7715314, and Early Models of PA-28-161, Warrior II) Figure 11-119. Optional Navigation and Radio Lights (PA-28-151,S/N’s 28-7415001 thru 28-7715314,...
Page 503 PIPER CHEROKEE WARRIOR SERV I C E M A N U A L Figure 11-120. Optional Instrument Flood Lights Figure 11-121. Optional Instrument Flood and Cabin (Later Models of PA-28 -161, Warrior II) Lights (Later Models of PA-28 -161, Warrior II) Figure 11-122.
Page 504 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure11-123. Dimmer Panel Wiring (Later Models of PA-28 -161, Warrior II) FLOOD LIGHT L2B 20 L2A 20 L2D 20 FLOOD LIGHT CONTROL Figure 11-124. Overhead Flood Light (PA-18-161, Warrior III, S/N’s 2816110 and up) Revised: February 28, 1995...
Page 505 PIPER CHEROKEE WARRIOR SERVICE MANUAL DOME LIGHT L6A 20 L6C 20 Figure 11-125. Cabin Dome Light (PA-18-161, Warrior III, S/N’s 2816110 and up) RADIO LIGHTS ELECTRICAL BUS L8A 20 AVIONICS DIMMING LIGHTS L8C 20N RADIO L8D 20 LIGHTS DIMMER ASSY...
Page 506 PIPER CHEROKEE WARRIOR SERVICE MANUAL PANEL/SWITCH LIGHTS ELECTRICAL BUS 7 1/2A L5A 20 L5C 20N INSTRUMENT PANEL L5D 20 POST LIGHTS L5E 20 DIMMER ASSY L5B 20 FUEL GAUGE CLOCK (OPT) TACH L5E 20 L3G 20 COMPASS Figure 11-127. Instrument Lights ((PA-18-161, Warrior III, S/N’s 2816110 and up)
Page 507 PIPER CHEROKEE WARRIOR SERVICE MANUAL PANEL/SWITCH LIGHTS ELECTRICAL BUS 7 1/2A L7A 20 FUEL STROBE LANDING PITOT BATT RECOG PUMP LIGHT LIGHT HEAT (OPT) MASTER LIGHTS LIGHTS PRIMER L7B 20N SWITCH L7C 20 LIGHTS DIMMER ASSY L7D 20 L7E 20...
Page 508 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 509 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 510 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 511 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 512 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Revised: February 28, 1995 ELECTRICAL SYSTEM Island Enterprises...
Page 513 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Revised: February 28, 1995 ELECTRICAL SYSTEM 2J10 Island Enterprises...
Page 514 2J24 12-19. Testing Artex 110 ELT Emergency Locator Transmitter.......... 12-20. Avionics Master and Emergency Switch Circuit..............12-21. Description and Operation..................12-22. Autoflight..........................12-23 General........................12-24 Non-Piper A.F.C.S. Equipment Manufacturers............12-25 Piper A.F.C.S. Equipment..................Revised: June 5, 1984 2J11 Island Enterprises...
Page 515 Aerofiche Paragraph Grid No. THIS PAGE INTENTIONALLY LEFT BLANK 2J12 Island Enterprises...
Page 516 PIPER CHEROKEE WARRIOR SERVICE MANUAL SECTION XII ELECTRONICS WARNING It is the user’s responsibility to refer to the applicable vendor publication when servicing or inspecting vendor equipment installed in Piper aircraft . 12-1. INTRODUCTION This section of the manual contains the information necessary to perform operational checks of the Emergency Locator Transmitter (ELT) installed in the Warrior, Warrior II, or Warrior III, with and without a pilot’s remote switch.
Page 517 PIPER CHEROKEE WARRIOR SERVICE MANUAL 12-2. GARRETT EMERGENCY LOCATOR TRANSMITTER. 12-3. DESCRIPTION Electrical power for the ELT is supplied by its own self-contained battery. FAA regulations require the b a ttery be replaced at the expiration date printed on battery, or if transmitter has been used in an e m e rgency situation, or has more than one hour accumulated test time.
Page 518: Two Year, Magnesium Battery Connection
PIPER CHEROKEE WARRIOR SERVICE MANUAL BATTERY LONG CONNECTOR SCREWS VERIFY BATTERY LEADS ARE LOCATED PLAIN BATTERY IN VEE OF O-RING TRANSMITTER PACK BOARD Figure 12-1. Two Year, Magnesium Battery Connections Figure 12-2. Garrett ELT Schematic Revised: February 28, 1995 ELECTRONICS...
Page 519 PIPER CHEROKEE WARRIOR SERVICE MANUAL 1 2 - 5 . C O M M U N I C ATIONS COMPONENTS CORPORATION EMERGENCY LOCAT O R T R A N SMITTER. 12-6. DESCRIPTION. The electrical power for the ELT transmitter is totally supplied by its own self-contained battery.
Page 520: Communications Components Elt Schematic
PIPER CHEROKEE WARRIOR SERVICE MANUAL COMMUNICATIONS COMPONENTS CORP. SWITCH POSITIONS OFF / RESET NORMAL AUTO / ARM REMOTE FLIGHT RESET POSITION SHIELD WHITE SW-79762-2 REMOTE KEYWAY + 14 VOLT DC (TEST) TO OVERHEAD FLOOD LIGHT SHLD TRANSMITTER NO. CIR-11-2 CIRCUIT...
Page 521 PIPER CHEROKEE WARRIOR SERVICE MANUAL 4. Set the ON/ARM/OFF switch on the transmitter to the ON position. Keep the switch in this position for only a few seconds; then set to the OFF position. Return to the ARM position. 5. If transmitter is only labeled ON/ARM, set to ON position for a few seconds, then return to...
Page 522 PIPER CHEROKEE WARRIOR SERVICE MANUAL CAUTION The battery pack is shipped with a sealant on the inside lip so that a water tight seal will be retained. DO NOT REMOVE THIS SEALANT. Connect new battery pack terminals to the bottom of the circuit board.
Page 523: Elt Portable Folding Antenna (Narco)
PIPER CHEROKEE WARRIOR SERVICE MANUAL PORTABLE NOTCH STOP ANTENNA OPERATIVE ANTENNA BLADE BUT STORED ANTENNA TOUCHES EXTENSION PORTABLE FINGER CONTACT VIEW ANTENNA ON-OFF-ARM EXTENSION SWITCH ANTENNA TO “ON” LATCH POPS OUT CHANNEL AND DOWN VIEW STOP PULL TAB VIEW T O E X T E N D F U L L L E N G T H Figure 12-6.
Page 524 PIPER CHEROKEE WARRIOR SERVICE MANUAL 12-12. TESTING NARCO 10 EMERGENCY LOCATOR TRANSMITTERS Conduct ELT tests in a screen room or metal enclosure to ensure that electromagnetic energy is not radiated during testing. If a shielded enclosure is not available, perform tests in accordance with the following...
Page 525: Narco Elt 910 Emergency Locator Transmitter Schematic
PIPER CHEROKEE WARRIOR SERVICE MANUAL 12-13. NARCO 910 ELT BATTERY REMOVAL AND INSTALLATION (S/N’S 2890140 THRU 2890205) (REFER TO FIGURES 12-8 AND 12-9.) a. Remove access panel located at fuselage station 228.30. b. Set ON/OFF/ARM switch on transmitter to OFF.
Page 526: Elt 910 Battery Pack
PIPER CHEROKEE WARRIOR SERVICE MANUAL b. If operational test must be made at any time other than the first five minutes after the hour, notify the nearest FAA traffic Control Tower or Flight Service Station prior to the test. c. Test should be no longer than three audio sweeps.
Page 527 PIPER CHEROKEE WARRIOR SERVICE MANUAL M OL EX CONNECTOR S IDE VI EW MOUNTING BATTERY HOLES COVER SCREWS F RO NT V I E W E ND BOT TOM VI EW CA P Figure 12-10. Artex 110 ELT The Artex 110 cannot be accidentally activated by dropping the unit, handling it roughly, or during shipping.
Page 528 PIPER CHEROKEE WARRIOR SERVICE MANUAL Replace the four screws. Dress wires away from standoffs to avoid pinching wires between stand- offs and the battery pack. Install unit into mounting tray: 1. Connect molex and coax cables to ELT unit. 2. Install mounting tray cap and secure to front of mounting tray with the two screws.
Page 529 12.22. AUTO FLIGHT 12-23. GENERAL WARNING It is the user’s responsibility, when servicing or inspecting v e ndor equipment installed in Piper aircraft, to refer to the applicable vendor publication. WARNING Do not use a substitute trim system component part for an original design part.
Page 530 The following is a complete list of Piper AFCS equipment service literature. Correctly identify the AutoPilot system by faceplate model name. Each manual identifies revision level and revision status in the Master Parts Price List - Aerofiche published monthly by Piper. Consult aircraft parts catalog for replacement parts.
Page 531 PIPER CHEROKEE WARRIOR SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Island Enterprises...
Page 532 SECTION XIII HEATING AND VENTILATING Aerofiche Paragraph Grid No.. 13-1. Introduction ...................... 13-2. Cabin Heat and Defroster Description ............. 13-3. Overhead Vent System Description ..............13-4. Heater Maintenance ..................Revised: June 5, 1984 Island Enterprises...
Page 533 PIPER CHEROKEE WARRIOR SERVICE MANUAL SECTION XIII HEATING AND VENTILATING SYSTEM 13-1. INTRODUCTION. The operation and maintenance instructions for the heating and ventilating system components installed on the PA-28-151 and -161 are contained in Paragraph 13-3. Refer to Figure 13-1 for a pictorial description of these systems.
Page 534: Cabin Heater, Defroster And Fresh Air System
PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. FRESH AIR INLET 2. DRAIN TUBE 3. FRESH AIR BLOWER 4. BULKHEAD ASSEMBLY 5. FRESH AIR DUCT 6. CABIN EXHAUST OUTLET 7. DEFROSTER OUTLET 8. BLOWER SWITCH PANEL 9. DEFROSTER OUTLET 10. HEATER CONTROL 11.
Page 535 PIPER CHEROKEE WARRIOR SERVICE MANUAL GRIDS 2K8 AND 2L24 INTENTIONALLY LEFT BLANK Island Enterprises...
Page 536 AIRPLANE MAINTENANCE MANUAL CARD 3 OF 3 PA-28-151 CHEROKEE WARRIOR PA-28-161 WARRIOR II PA-28-161 WARRIOR III PIPER AIRCRAFT CORPORATION (PART NUMBER 761 539 FEBRUARY 28, 1995 Island Enterprises...
Page 537 Published by Technical Publications Piper Aircraft Corporation 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member of GAMA General Aviation Manufacturers Association Island Enterprises...
Page 538 PIPER CHEROKEE WARRIOR SERVICE MANUAL SERIAL NUMBER INFORMATION PA-28-151, WARRIOR- 1974 Serial Numbers 28-7415001 to 28-7415713 inclusive PA-28-151, WARRIOR- 1975 Serial Numbers 28-7515001 to 28-7515459 inclusive PA-78-151, WARRIOR- 1976 Serial Numbers 28-7615001 to 28-7615445 inclusive PA-28-151, WARRIOR- 1977 Serial Numbers 28-7715001 to 28-7715314 inclusive...
Page 539 PIPER CHEROKEE WARRIOR SERVICE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS The Service Manual information incorporated in this set of Aerofiche cards has been arranged in accordance with the general specifications of Aerofiche adopted by the General Aircraft Manufacturer’s Association, (GAMA). The i n f o r m ation compiled in this Aerofiche Service Manual will be kept current by revisions distributed periodically.
Page 540 TABLE OF CONTENTS AEROFICHE CARD NO.1 GRID NO. INTRODUCTION ............1A13 HANDLING AND SERVICING........1A16 INSPECTION..............1D15 STRUCTURES ............1E5 SURFACE CONTROLS..........1G10 HYDRAULIC SYSTEM......(Not Applicable) LANDING GEAR AND BRAKE SYSTEM....1I10 VIII POWER PLANT ............1J19 AEROFICHE CARD NO.2 FUEL SYSTEM............2A10 INSTRUMENTS ............2B11 ELECTRICAL SYSTEM ..........2D4 ELECTRONICS ............2J11 XIII HEATING AND VENTILATING........2K5...
Page 541 PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF ILLUSTRATIONS Aerofiche Figure Grid No. 14-1. Air Conditioning System Installation..................2H16 14-2. Service Valves ...........................2H20 14-3. Test Gauge and Manifold Set ....................2H21 14-4. Manifold Set Operation......................2H22 14-5. Leak Test Hookup........................2H23 14-6. Evacuation Hookup........................2I1 14-7.
Page 542 PIPER CHEROKEE WARRIOR SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. XIV-I. Temperature Pressure Chart......................2H17 XIV-II. Aluminum Tubing Torque ......................2H20 XIV-IIA. Moisture Removal Temperature....................2I1 XIV-III. Compressor Oil Charge........................2I7 XIV-IV. Troubleshooting Chart (Air Conditioner) ..................2I22 XIV-V. Blower System Wire Color Codes....................2J5...
Page 543 Island Enterprises...
Page 544: Paragraph Grid No
Island Enterprises...
Page 545: Air Conditioning Installation
PIPER CHEROKEE WARRIOR SERVICE MANUAL 14-1. AIR CONDITIONING INSTALLATION. Air conditioning is installed as an option only in the PA-28-161, Warrior II, S/N’s 28-7716001 thru 2 8 -8616057, and 2816001 through 28-16109. 14-2. DESCRIPTION. CAUTION Operate air conditioning system at least once a month to keep system lubricated and prevent sticking valves.
Page 546 PIPER CHEROKEE WARRIOR SERVICE MANUAL The following definitions apply: a. High Side: Consists of all lines and components between the compressor outlet and the expansion valve. It includes the condenser and receiver sight gauge. b. Low Side: Consists of all lines and components between the expansion valve and the compressor inlet.
Page 547 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE United States environmental regulations require use of a c o llection system when necessary to evacuate refrigerant from air conditioner. NOTE Check all environmental regulations for your local area before servicing air conditioning system TABLE XIV-I.
Page 548 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE United States environmental regulations require use of a c o llection system when necessary to evacuate refrigerant from air conditioner. NOTE Check all environmental regulations for your local area before servicing air conditioning system TABLE XIV-II.
Page 549 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE United States environmental regulations require use of a c o llection system when necessary to evacuate refrigerant from air conditioner. NOTE Check all environmental regulations for your local area before servicing air conditioning system TABLE XIV-II.
Page 550 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE United States environmental regulations require use of a c o llection system when necessary to evacuate refrigerant from air conditioner. NOTE Check all environmental regulations for your local area before servicing air conditioning system TABLE XIV-II.
Page 551 PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE United States environmental regulations require use of a c o llection system when necessary to evacuate refrigerant from air conditioner. NOTE Check all environmental regulations for your local area before servicing air conditioning system TABLE XIV-II.
Page 552: Air Conditioning System Installation
PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. COMPRESSOR 2. FREON LINES 3. ALTERNATOR 4. PULLY POSITIONS 5. DUCT ASSEMBLY 6. EVAPORATOR FILTER AND COVER 7. EXPANSION VALVE 8. PRESSURE SWITCH 9. RECEIVER/DEHYDRATOR 10. EVAPORATOR 11. BLOWER MOTOR 12. CONDENSOR 13. COVER ASSEMBLY 14.
Page 553: Malfunction Detection
PIPER CHEROKEE WARRIOR SERVICE MANUAL 14-5. MALFUNCTION DETECTION. Detection of system malfunctions largely depends on the mechanic’s ability to interpret gauge pressure readings into system problems. A system operating normally will have low side gauge pressure reading that will correspond with the temperature of the refrigerant evaporating, allowing for a few degrees temperature rise due to loss in tube walls and fins.
Page 554 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE XIV-III. REFRIGERANT TEMPERATURE PRESSURE Refigerant R12 Refigerant R12 Refigerant R12 Refigerant R12 Evaporator Pressure Evaporator Temperature Evaporator Pressure Evaporator Temperature Gauge Reading psi °F Gauge Reading psi °F 29.2 30.9 10.1 31.7 11.2 32.5 12.3...
Page 555 PIPER CHEROKEE WARRIOR SERVICE MANUAL WARNING Liquid refrigerant on the skin will cause frostbite. Treat with cool water and protect with petroleum jelly. Seek medical attention. WARNING Use care not to discharge refrigerant into a closed room. Refrigerant displaces air in the room and causes oxygen s t a rvation.
Page 556: Service Valves
PIPER CHEROKEE WARRIOR SERVICE MANUAL WARNING Do not reuse oil removed from the system. Properly dispose of WARNING Heat joint to 400°F before disassembly if Loctite Refrigerant Sealant was used. Use Loctite to seal any system line pipe threads. WARNING When R-12 Refrigerant comes in contact with moisture it forms a very strong acid (HCl).
Page 557: Service Valves
Robinair 34700 and should be augmented by reference to the instructions supplied by R o b i n a i r. This does not imply that Piper Aircraft specifically recommends the use of the Robinair 34700.
Page 558: Manifold Set Operation
PIPER CHEROKEE WARRIOR SERVICE MANUAL Proper testing and diagnosis of air conditioning system requires a manifold gauge set and/or an appropriate test stand be attached to system. The manifold gauge set comprises a high pressure gauge in the discharge side of the the system and a low pressure gauge in the suction side of the system.
Page 559 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 14-5. Manifold to Recharging/Test Stand Hookup If system is operated in a discharged condition, or has been open to atmospheric pressure, the r e c e i ver/dehydrator must be replaced, and the system evacuated to remove non-condensible gases and any trapped moisture from within the system.
Page 560 PIPER CHEROKEE WARRIOR SERVICE MANUAL a. Using the Robinair 34700 (Refer to Figures 14-6 and 14-7) 1. Remove access panel at rear of cabin to gain access to service valves. 2. Remove protective caps from the high and low side service ports on the evaporator unit.
Page 561 PIPER CHEROKEE WARRIOR SERVICE MANUAL INLET EVAPORATOR COIL COMPRESSOR OUTLET CONDENSER EXPANSION VALVE LOW SIDE RECEIVER — DRYER — SIGHT GLASS SERVICE PORT HIGH SIDE SERVICE PORT GAUGE 2 RED HIGH PRESSURE CHARGING LINE GAUGE 1 HIGH SIDE SIDE MICROPRESSOR...
Page 562 PIPER CHEROKEE WARRIOR SERVICE MANUAL 12. When RED gauge indicated a little below zero, open red (high side) valve (2), and continue evacuation. 13. Operate vacuum pump for 0:15 minutes, or until low side gauge (GAUGE 1) indicates 24 to 26 inches of mercury (in.
Page 563: Leak Detection
PIPER CHEROKEE WARRIOR SERVICE MANUAL 1 3 . When High side manifold hand set gauge indicates a little below zero, open High s i d e m a n ifold hand set valve and continue evacuation. 14. Operate vacuum pump for 0:15 minutes, or until manifold hand set low side gauge indicates 24 to 26 inches of mercury (in.
Page 564: Discharging (Bleeding Or Purging) System
PIPER CHEROKEE WARRIOR SERVICE MANUAL 5. Locate leak(s) using an electronic leak detector designed to detect R12. Or, use soap and water in a thick solution. 6. Repair leak(s) 7. Check that the both high side and low side valves on the manifold hand set are closed.
Page 565: Charging The System
PIPER CHEROKEE WARRIOR SERVICE MANUAL Press the RECOVER key on charging station keypad. m. To assure complete recovery of refrigerant: 1. Wait 5 minutes. Observe pressure gauges for a rise above zero (0), 2. If a rise occurs, press the HOLD/CONT keys.
Page 566: Post Charging Charging Operational Check
PIPER CHEROKEE WARRIOR SERVICE MANUAL NOTE The amount of refrigerant required must be determined for each airplane. It is the amount that will result in bubble-free operation at the system sight gauge specified in paragraph 1 4 -14, Post Charging Operational Check.
Page 567 PIPER CHEROKEE WARRIOR SERVICE MANUAL 8. Operate engine at 1000 rpm to 1500 rpm. The low and high side gauges on the control panel shall indicate as follows: AMBIENT GAUGE GAUGE TEMPERATURE INDICATION Low Side (Pressure) 10 to 35 psig High Side (Pressure) Up thru 75°...
Page 568: Compressor Service
PIPER CHEROKEE WARRIOR SERVICE MANUAL 11. When charge is properly established: A. Stop engine. B. Close valve on refrigerant tank. C. Close low side valve on manifold set. (12) Disconnect manifold set hoses from service valves. (13) Install protective caps on service valve.
Page 569: Compressor Installation
PIPER CHEROKEE WARRIOR SERVICE MANUAL 14-17. COMPRESSOR INSTALLATION. WARNING If air conditioner is operated on ground for servicing, clear test area of loose objects. Ensure that a qualified person is at the airplane controls. Use service valves on evaporator a s s e mbly for testing.
Page 570 (6) Do not operate compressor with less than 6 ounces oil. Oil level must not exceed 10 ounces total oil. Use Piper refrigerant oil PMS-L2000 or equivalent 500 viscosity refrigerant oil. (7) Evacuate and charge system. (Refer to Paragraphs 14-10 and 14-13.) TABLE XIV-VI.
Page 571: Adjustment Of Drive Belt Tension
Belt alignment must be made as close to nominal as shims will allow. g. Alternator Belt Alignment: (Refer to Figure 14-9, Sheet 2 of 2.) Align idler pulley in the belt plane by adding or removing Piper P/N 62833-82 shims, with alternator belt installed. 14-20. ADJUSTMENT OF DRIVE BELT TENSION.
Page 572: Compressor And Alternator Belt Installation (Sheet 1 Of 2)
PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 14-9. Compressor and Alternator Belt Installation (Sheet 1 of 2) Revised: February 28, 1995 ACCESSORIES AND UTILITIES 3B13 Island Enterprises...
Page 573: Compressor And Alternator Belt Installation (Sheet 2 Of 2)
PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 14-9. Compressor and Alternator Belt Installation (Sheet 2 of 2) Revised: February 28, 1995 ACCESSORIES AND UTILITIES 3B14 Island Enterprises...
Page 574: Magnetic Clutch
PIPER CHEROKEE WARRIOR SERVICE MANUAL CAUTION If air conditioner is operated on the ground for servicing, clear test area of any loose objects lying on ramp. Ensure that a qualified person is at the airplane controls. 4. Run engine 15 minutes at 1200 rpm.
Page 575: Refrigerant Lines And Routing
PIPER CHEROKEE WARRIOR SERVICE MANUAL 1. CAPSCREW 2. ROTOR PULLLEY ASSY. 3. CAPSCREW AND LOCK WASHERS 4. FIELD ASSY. 5. COMPRESSOR Figure 14-10. Magnetic Clutch b. Secure field assembly with four cap screws and lock washers. Do not torque at this time.
Page 576: Receiver-Dehydrator
PIPER CHEROKEE WARRIOR SERVICE MANUAL Handle refrigerant lines carefully. Refrigerant lines are flexible high pressure hoses. Hoses in power plant area are routed for maximum protection from heat and abrasion. They couple at firewall to hoses routed through the two inboard, external hat sections on bottom of fuselage, up through floor to condenser and evapo- rator in tail cone.
Page 577: Condenser Air Scoop Installation
PIPER CHEROKEE WARRIOR SERVICE MANUAL d. Seal and couple hose fittings (seal with Loctite refrigerant sealant applied to flares only). e. Adjust condenser per condenser assembly rigging instructions. WARNING Cabin rear panel must be replaced and sealed in the original m a n n e r.
Page 578: Expansion Valve
PIPER CHEROKEE WARRIOR SERVICE MANUAL 14-31. CONDENSER DOOR ACTUATOR. The actuator is on a bracket mounted between two bulkheads in tail cone. It is coupled to the c o ndenser assembly through a bellcrank mounted to a bracket on bulkhead aft of condenser. Actuator travel is controlled by two limit switches.
Page 579: Expansion Valve Installation
PIPER CHEROKEE WARRIOR SERVICE MANUAL The expansion valve is in evaporator assembly between receiver dehydrator and evaporator inlet. The capillary coil is attached to evaporator outlet line. a. Remove access panels, and discharge system. Refer to paragraph D, 5. b. Remove capillary coil from outlet line. (Do not kink capillary tube.) c.
Page 580: Components Installation
PIPER CHEROKEE WARRIOR SERVICE MANUAL c. Line mounting bracket with mating holes in mounting panel, insert screws and tighten. Tighten screws in flange. Check gasket is in place. Flange seal must be air tight. d. Couple suction and discharge lines to their proper fittings (apply Loctite refrigerant sealant to tube flares only).
Page 581: Pressure Relief Switch
PIPER CHEROKEE WARRIOR SERVICE MANUAL 14.39. PRESSURE RELIEF SWITCH. (Refer to Figure 14-13.) 14-40. REMOVAL AND INSTALLATION OF PRESSURE RELIEF SWITCH. — CAUTION — Before relief switch removal, air conditioning system must be discharged. (Refer to paragraph D, 5, Discharging.) —...
Page 582 PIPER CHEROKEE WARRIOR SERVICE MANUAL Figure 14-14. Typical Air Conditioning Wiring Schematic Revised: February 28, 1995 ACCESSORIES AND UTILITIES 3B23 Island Enterprises...
Page 583: Removal Of Blower Assembly
PIPER CHEROKEE WARRIOR SERVICE MANUAL 14-46. REMOVAL OF BLOWER ASSEMBLY a. Remove access door from aft wall of baggage area. b. With master switch off, disconnect plug assemblies at blower assembly. c. Remove inlet and outlet hoses from blower assembly by removing clamps.
Page 584 PIPER CHEROKEE WARRIOR SERVICE MANUAL TABLE XIV-VIII. BLOWER SYSTEM WIRE COLOR CODES S/N’s 28-7716001 thru 28-7816171 when kit No’s 763 814 or 763 815 NOT installed AIRCRAFT MOTOR WIRES WIRES E362Q µ Singer Controls YY7S062 ESB - 15920-01 Universal F0018075FA General Elect.
Page 585 PIPER CHEROKEE WARRIOR SERVICE MANUAL GRIDS 3C2 THRU 3L24 INTENTIONALLY LEFT BLANK Revised: February 28, 1995 ACCESSORIES AND UTILITIES Island Enterprises...

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