Page 1: Maintenance Manual
DAKOTA MAINTENANCE MANUAL CARD 1 OF 3 PA-28-236 DAKOTA PIPER AIRCRAFT CORPORATION (PART NUMBER, 761 681 )
Page 2 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INTRODUCTION This Piper Aircraft maintenance manual is prepared in accordance with the General Av i a t i o n Manufacturers Association format. Introduction Page - 1 Reissued: August 1, 1986...
Page 3 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL VENDOR PUBLICATIONS —WARNING— When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publication. ENGINE: Overhaul Manual = AVCO LYCOMING - OVERHAUL MANUAL DIRECT DRIVE ENGINE - P/N 60294-7 Avco Lycoming Division Williamsport, Pa.
Page 4 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PIPER PUBLICATIONS COMMUNICATIONS: Removal, Installation and Maintenance Instructions = 76l 502 AutoControl III B Service Manual 76l 48l AutoFlite II Service Manual 753 771 Pitch Trim Service Manual Radio Service and Maintenance Manual = 761 685 Avionics Wiring Diagram Service Manual...
Page 5 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS The maintenance manual information incorporated in this set of Aerofiche cards has been arranged in accordance with general specifications for Aerofiche adopted by the General Aviation Manufacturer’s Association. The information in this Aerofiche maintenance manual is kept current by revisions distributed periodically.
Page 6 The date on Aerofiche cards must not be earlier than the date noted for the respective card eff e c t i v i t y. Consult the latest Aerofiche card in this series for current Aerofiche card effectivity. SERIAL NUMBER INFORMATION PA-28-236, DAKOTA- l979 Serial Numbers 28-7911001 to 28-7911395 inclusive. PA-28-236, DAKOTA- l980 Serial Numbers 28-8011001 to 28-8011161 inclusive.
Page 7 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GAMA SYSTEM/CHAPTER INDEX GUIDE SYST SUB-SYST AEROFICHE CHAP SECTION TITLE GRID NO. AIRWORTHINESS LIMITATIONS 1A17 TIME LIMITS/MAINT CHECKS 1A21 DIMENSIONS AND AREAS 1B12 LIFTING AND SHORING 1B20 LEVELING AND WEIGHING TOWING AND TAXIING PARKING AND MOORING...
Page 8 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GAMA SYSTEM/CHAPTER INDEX GUIDE (cont) SYST SUB-SYST AEROFICHE CHAP SECTION TITLE GRID NO. STRUCTURES 2E19 DOORS 2F13 STABILIZERS 2F21 WINDOWS WINGS 2G12 PROPELLER STANDARD PRACTICES - ENGINE 2H10 POWERPLANT 2H14 ENGINE FUEL SYSTEM 2I10 IGNITION...
Page 9 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. 6-1. Three View 1B17 6-2. Station References 1B18 6-3. Access Plates and Panels 1B19 7-1. Jacking Arrangement 1B23 8-1. Weighing Airplane 8-2. Leveling Longitudinally 8-3. Leveling Laterally 11-1.
Page 10 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. 21-15. Components Installation 21-16. Overhead Vent System (Not Available with Air Conditioning) 23-1. Avionics Master and Emergency Switch Circuit 1H14 23-2. Communications Components ELT Schematic 1H16 23-3.
Page 11 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 24-34. Testing Rotor for Shorts 24-35. Installation of Bearing 24-36. Installation of Rectifier 24-37. Terminal Assembly 24-38. Slip Ring End Bearing Assembly 24-39. Testing Alternator 24-40.
Page 12 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont.) FIGURE NO. SUBJECT GRID NO. 32-7. Main Wheel Assembly 32-8. Nose Wheel Assembly 32-9. Standard Brake Assembly (Cleveland 30-55) 32-10. Heavy Duty Brake Assembly (Cleveland 30-65) 32-11. Removal and Installation of Anchor Bolts 2C10 32-12.
Page 13 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 73-2. Engine Primer 2I14 73-3. Adjustment of Engine Controls 2I16 74-1. Height of Spring in Distributor Block Tower 2I24 74-2. Contact Points 2I24 74-3. Engine Timing Marks 74-4.
Page 14 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 95-1. Tire Balancer Fixture 95-2. Control Surface Balancing Tool 95-3. Orifice Replacement Tool 95-4. Fabricated Tool for Baggage Door Lock 95-5. Retainer Ring Tool 95-6. Fabricated Aileron Bellcrank Rigging Tool 95-7.
Page 15 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CHARTS CHART NO. SUBJECT GRID NO. Leading Particulars and Principal Dimensions 1B15 1201 Thread Lubricants 1D11 1202 Type of Lubricants 1D12 2001 Thread Lubricants 1E10 2002 Maximum Distance Between Supports For Fluid Tubing...
Page 16 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CHARTS (cont) CHART NO. SUBJECT GRID NO. 7705 Troubleshooting (Exhaust Gas Temperature Gauge) (Alcor) . 7706 Troubleshooting (Cylinder Head Temperature Gauge) 800l Troubleshooting (Starter) 2K22 8002 Starting Motor Specifications 9101 Flare Fitting Torques...
Page 17 CHAPTER AIRWORTHINESS LIMITATIONS 1A17...
Page 18 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 4 - AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 4-00-00 AIRWORTHINESS LIMITATIONS 1A20 4-00-00 General 1A20 4 - Cont./Effec. 1A18 Page - 1 Reissued: August 1, 1986...
Page 19 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1A19...
Page 20 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL AIR WORTHINESS LIMITATIONS GENERAL Airworthiness limitations are FAA approved and specify inspections and maintenance required under Parts 43 and 9l of Federal Aviation Regulations. Limitations relating to fatigue life of the airplane and its components are as follows: Safe life of airframe structure will be released when information becomes available.
Page 21 CHAPTER TIME LIMITS/MAINT CHECKS 1A21...
Page 22 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 5 - TIME LIMITS/MAINTENANCE CHECKS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 5-00-00 GENERAL 1 A24 5-10-00 TIME LIMITS 1A24 5-11-00 Inspection Requirements 1A24 5-12-00 Preflight Checks 1A24 5-13-00 Overlimits Inspection 1A24...
Page 23 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1A23...
Page 24 When performing inspections, use form P/N 230 8ll furnished by Piper factory service department; available through Piper dealers or distributors. Refer to latest Piper Parts Price List Aerofiche for current revision date.
Page 25 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SCHEDULED MAINTENANCE PERIODIC INSPECTIONS —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Inspection Time (HRS) Nature of Inspection 1000 A. PROPELLER GROUP Inspect spinner and back plate.................
Page 26 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Inspection Time (HRS) Nature of Inspection 1000 B. ENGINE GROUP (cont) Inspect oil lines and fitting for leaks, security, chafing, dents, and cracks.
Page 27 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PERIODIC INSPECTIONS (cont) —NOTE— Perform oll inspections or operations at each inspection interval as indicated by a circle (O). Inspection Time (HRS) Nature of Inspection 500 1000 B. ENGlNE GROUP (cont) 30. Inspect condition of flexible fuel lines ..............
Page 28 Inspect parking brake and brake handle for operation and cylinder leaks......................... Inspect control wheels, column, pulleys, and cables..........Inspect flap control cable attachment bolt (See latest revision of Piper Service Bulletin 965)......................Inspect landing, navigation, cabin, and instrument lights ........
Page 29 19. Inspect stabilator surfaces for damage..............20. Inspect stabilator, tab hinges, horn, and attachments for damage and operation..21. Inspect stabilator attachments. (See latest revision of Piper Service Bulletin 856)......................22. Inspect stabilator and tab hinge bolts and bearings for excess wear.
Page 30 Lubricate per lubrication chart. (Refer to chapter l2.) ..........Inspect forward and aft wing attach fittings for corrosion, general condition and security. (See latest revision of Piper Service Bulletin 977.)........9a. Inspect wing attachment bolts and brackets ............10. Inspect fuel tanks and lines for leaks and water. (See Note l6.) ......
Page 31 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection intcrval as indicated by a circle (O). Inspection Time (HRS) Nature of Inspection 1000 F. LANDING GEAR GROUP (cont) Remove wheels. Clean, check, and repack bearings ..........
Page 32 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PERIODIC INSPECTIONS (cont) —NOTE— Perform all inspections or operations at each inspection interval as indicated by a circle (O). Inspection Time (HRS) Nature of Inspection 500 1000 G. OPERATIONAL INSPECTION (cont) Check vacuum gauge....................10. Check gyros for noise and roughness..............
Page 33 FAA. 2. Piper service bulletins are of special importance and must be complied with promptly. 3. Piper service letters are product improvements and service hints pertaining to servicing. Service letters should be given careful attention.
Page 34 16. Replace flexible fuel tank supply hose at time of engine overhaul. 17. Maintain cable tensions specified in chapter 27. 18. Refer to list of vendor and Piper publications in the front of the maintenance manual for appropriate subject manual part number.
Page 35 PROGRAMMED INSPECTION The programmed inspection permits best aircraft utilization by scheduling inspections through use of planned inspection schedules. This programmed inspection schedule is available in manual form from Piper service sales under Piper part number 76l 734. UNSCHEDULED MAINTENANCE CHECKS...
Page 36 CHAPTER DIMENSIONS AND AREAS 1B12...
Page 37 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 6 - DIMENSIONS AND AREAS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 6-10-00 DIMENSIONS 1B15 6-20-00 STATION REFERENCE LINES 1B18 6-30-00 ACCESS AND INSPECTION PROVISIONS 1B19 6 - Cont./Effec. 1B13 Page - 1...
Page 38 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1B14...
Page 39 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL DIMENSIONS Airplane dimensions and specifications are shown in figure 6-1 and listed in chart 601. CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS MODEL PA-28-236 ENGINE Manufacturer Avco-Lycoming Model 0-540-J3A5D Rated horsepower at propeller rpm 235 hp/2400 rpm Oil sump capacity l2 U.S.
Page 40 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (CONT) FUEL SYSTEM CAPACITY Left wing tank 38.5 gal. Right wing tank 38.5 gal. Total 77 gal. Total unusable 5 gal. LANDING GEAR Type Fixed Shock strut type...
Page 41 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 6-l. Three View 6 - 10 - 00 1B17 Page - 6 - 03 Reissued: August 1, 1986...
Page 42 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STATION REFERENCE LINES To facilitate location of various components which require maintenance and servicing, a method utilizing fuselage station (F. S.), wing station or buttock line (BL), and water line (WL) is frequently used in this manual.
Page 43 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ACCESS AND INSPECTION PROVISIONS —CAUTION— Before entering aft section of fuselage, be sure airplane is supported at tail skid. Airplane access and inspection panels are shown in figure 6-3. All access plates and panels are secured by either metal fasteners or screws.
Page 44 CHAPTER LIFTING AND SHORING 1B20...
Page 45 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 7 - LIFTING AND SHORING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 7-l0-00 JACKING lB23 7 - Cont./Effec. 1B21 Page - 1 Reissued: August 1, 1986...
Page 46 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1B22...
Page 47 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 7-l. Jacking Arrangement JACKING Jacking airplane is necessary to service landing gear and to perform other service operations. Proceed as follows: —CAUTION— Be sure to apply sufficient tail support ballast to prevent airplane from tipping forward.
Page 48 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1B24...
Page 49 CHAPTER LEVELING AND WEIGHING...
Page 50 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 8 - LEVELING AND WEIGHING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION SUBJECT SUBJECT EFFECTIVITY 8-l0-00 LEVELING 8-20-00 WEIGHING 8 - Cont./Effec. Page - 1 Reissued: August 1, 1986...
Page 51 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK...
Page 52 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LEVELING To level the airplane for purposes of weighing or rigging, proceed as follows: To longitudinally level airplane. Partially withdraw two leveling screws immediately below the left front side window. (Refer to figure 8-2.) Place level on screw heads and adjust jacks until level is centered.
Page 53 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 8-2. Leveling Longitudinally Figure 8-3. Leveling laterally THIS SPACE INTENTIONALLY LEFT BLANK 8 - 20 - 00 Page - 8 - 02 Reissued: August 1, 1986...
Page 54 CHAPTER TOWING AND TAXIING...
Page 55 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 9 - TOWING AND TAXIING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 9-10-00 TOWING 9-20-00 TAXIING 9 - Cont./Effec. Page - 1 Reissued: August 1, 1986...
Page 56 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 9 - Cont./Effec. Page - 1 Reissued: August 1, 1986...
Page 57 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL TOWING —CAUTION— Do not turn nose gear in either direction beyond its steering radius limits This will result in damage to nose gear and steering mechanism. —CAUTION— Do not tow airplane with control locks installed —CAUTION—...
Page 58 CHAPTER PARKING AND MOORING 1C10...
Page 59 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 10 - PARKING AND MOORING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 10-10-00 PARKING 1C13 10-20-00 MOORING 1C13 10 - Cont./Effec. 1C11 Page - 1 Reissued: August 1, 1986...
Page 60 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1C12...
Page 61 5. Install pitot tube cover, if available. Cover Kit 760 297 is available from Piper dealers. —END— 10 - 20 - 00...
Page 62 CHAPTER REQUIRED PLACARDS 1C14...
Page 63 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 11- REQUIRED PLACARDS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 11-20-00 EXTERIOR PLACARDS AND MARKINGS 1C17 11-30-00 INTERIOR PLACARDS AND MARKINGS 1C18 11 - Cont./Effec. 1C15 Page - 1 Reissued: August 1, 1986...
Page 64 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1C16...
Page 65 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL EXTERIOR PLACARDS AND MARKINGS Figure 11 - l. Placards and Decals 11 - 20 - 00 1C17 Page - 11 - 01 Reissued: August 1, 1986...
Page 66: Interior Placards And Markings
PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INTERIOR PLACARDS AND MARKINGS 13. PLACARD - RUDDER TRIM 43. PLACARD - WARNING 21. PLACARD - HEATER AND DEFROST 44. PLACARD - PITCH TRIM 22. PLACARD - CLIMATE CONTROL CENTER 45. PLACARD - WARNING, ELT 23.
Page 67 CHAPTER SERVICING 1C19...
Page 68 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 12 - SERVICING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 12-00-00 GENERAL 1C21 12-11-00 Fuel System 1C21 12-11-00 Filling Fuel Tanks 1C21 12-11-00 Draining Moisture From Fuel System 1C21 12-11-00 Draining Fuel System...
Page 69 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter contains routine handling and servicing procedure. Frequent reference to this chapter will provide information such as location of various components, ground handling procedures, routine service procedures, and lubrication. When any system or component requires service other than routine procedures, refer to appropriate section for that component.
Page 70 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure l2-l. Fuel Filter Bowl and Screen DRAINING FUEL SYSTEM Drain fuel from system by opening valve at inboard end of each fuel tank. Push up on arms of drain valve and turn counterclockwise to hold drain in open position. Flush type drain valves require a pin to hold the valve open.
Page 71 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL DRAINING OIL SUMP —NOTE— Engine should be warm to ensure proper oil draining. Drain oil as follows: Remove engine cowl. 2. Open oil drain valve located on underside of engine by pushing arms of drain up and turning counterclockwise.
Page 72 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL OIL FILTER (Full Flow) Replace oil filter after each 50 hours of engine operation. Remove safety wire from bolthead at end of filter housing. Loosen bolt and remove filter assembly from adapter. 2. Remove filter element for inspection before discarding filter, using a Champion cutter tool CT470, available from Champion Spark Plug Co., Toledo, OH 43601.
Page 73 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LANDING GEAR SERVICING LANDING GEAR The landing gear consists of tires, brakes, oleo strut assemblies and on some models wheel fairings. These are inspected for proper gear extension, scored piston tubes, hydraulic fluid leakage, security, condition of all connection points, and fairings for cracks.
Page 74 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure l2-2. Servicing Points 12 - 22 - 00 Page - 12 - 05 Reissued: August 1, 1986...
Page 75 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SERVICING OLEO STRUTS Air-oil struts are incorporated in each landing gear oleo to absorb shock resulting from landing. —CAUTION— Do not exceed these tube exposures. Approximately 3.25 +/- 0.25 inches of piston tube on nose gear and 4.5 +/- 0.50 inches of piston tube on main gear must be exposed to ensure proper oleo action.
Page 76 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 4. There are two methods used to fill the strut chamber. These are as follows: a. Method I. (1) Remove valve core from filler plug at top of strut housing. Allow plug to remain installed.
Page 77 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —CAUTION— With torque links disconnected, piston tube is free to slide from strut housing. 4. Remove any one of three torque link bolts. Again raise airplane until a minimum of ten inches (do not exceed twelve inches of tube exposure) of strut tube is exposed with wheel remaining on ground. Fluid will flow from middle chamber to bottom chamber of strut housing, ensuring that bottom chamber is filled with fluid.
Page 78 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 12-3. Main Gear Oleo Struts (Cut-away View) 12 - 22 - 00 Page - 12 - 10 Reissued: August 1, 1986...
Page 79 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INFLATING OLEO STRUTS Prior to engine operation, air or nitrogen pressure in each landing gear assembly must be adjusted to either applicable pressure or visible piston extension (pressure servicing method is preferred). Ensure oleo strut has sufficient fluid and torque link is properly connected.
Page 80 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL POWER PLANT SERVICING POWER PLANT Check engine compartment regularly for oil and fuel leaks, chafing of lines, loose wires, and tightness of parts. For engine compartment cleaning, refer to chapter 20. ENGINE AIR FILTER —CAUTION—...
Page 81 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SERVICING ELECTRICAL SYSTEM Electrical system servicing involves adding distilled water to battery to maintain correct electrolyte level, checking cable connections, and checking for any spilled electrolyte that could lead to corrosion. Check security of all electrical connections as well as operation of all lights, general condition of generator or alternator and starter.
Page 82 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL APPLICATION OF OIL Observe the following precautions whenever specific instructions for lubrication of mechanisms is not available: Apply oil sparingly. Do not use more than required to coat bearing surfaces. 2. Control cables are sufficiently coated by manufacturer, additional protection is unnecessary.
Page 83 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 1201. THREAD LUBRICANTS TYPE OF LINE TYPE OF LUBRICANT CAUTION— Lubricant engine fittings only with the fluid contained in the particular lines. Brakes MIL-H-5606 Freon TT-A-580 or MIL-T-5544, anti-seize compound Fuel MIL-T-5544, anti-seize, graphite petrolatum...
Page 84 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 1202. TYPE OF LUBRICANTS PREFERRED PRODUCT LUBRICANT SPECIFICATION AND VENDOR LUBRICATING OIL, GENERAL PURPOSE, LOW MIL-L-71170 TEMPERATURE LUBRICATING OIL AIRCRAFT RECIPROCATING Mil-L-6082 ENGINE (PISTON) GRADE AS SPECIFIED (MINERAL SAE 60 ABOVE 80° F AIR TEMP.
Page 85 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 1202. TYPE OF LUBRICANTS (cont.) PREFERRED PRODUCT LUBRICANT SPECIFICATION AND VENDOR GREASE, AIRCRAFT WIDE-TEMPERATURE MIL-G-81322 MOBIL GREASE 28 AEROSHELL GREASE ROYCO 22S —CAUTIONS— 1. DO NOT USE HYDRAULIC FLUID WITH A CASTOR OIL OR ESTER BASE.
Page 86 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY OLEO STRUT FILLER POINT MlL H 5606 2 AS REQUIRED UPPER TORQUE LINK BEARING MIL-G-23827 100 HRS TORQUE LINK BUSHING MIL-G-23827 100 HRS TORQUE LINK CONNECTING BUSHING MIL-G-23827 100 HRS TEXACO MARFAK ALL 1...
Page 87 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY MIL-H-6606 2 OLEO STRUT FILLER POINT AS REQUIRED STEERING BELLCRANK PIVOT POINT MIL-G-7711 100 HRS SHIMMY DAMPENER PIVOT POINT MIL-L-7711 100 HRS TORQUE LINK ASSEMBLY MIL-L-7870 100 HRS NOSE WHEEL BEARING TEXACO MARFAX ALL...
Page 88 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —CAUTION— Do not lubricate control wheel shaft or bushing. Clean only using alcohol or other suitable solvent. COMPONENT LUBRICANT FREQUENCY AILERON HINGE PINS MIL-L-7870 100 HRS FLAP HINGE BEARINGS MIL-L-7870 100 HRS STABILATOR HINGE PINS...
Page 89 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY FLAP TORQUE TUBE BEARING BLOCKS MIL-L-7870 100 HRS FLAP CONTROL ROD END BEARINGS MIL-L-7870 100 HRS FLAP HANDLE PIVOT POINT, LOCK MECHANISM AERO LUBRIPLATE FISKE BROS. AND TURNBUCKLE END OF AERO SHELL GREASE #7...
Page 90 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY RUDDER TUBE BEARING BLOCKS FLUOROCARBON RELEASE AGENT DRY LUBRICANT MS-122 100 HRS TOE BRAKE CYLINDER ATTACHMENTS MIL-L-7870 100 HRS RUDDER TUBE CONNECTIONS MIL-L-7870 100 HRS BRAKE ROD ENDS MIL-L-7870 100 HRS Figure 12-6. Lubrication Chart (Control System) (cont.)
Page 91 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY RUDDER ARM CABLE ENDS MIL-L-7870 100 HRS STABILATOR TRIM SCREW AERO LUBRIPLATE OR MAG #1. FISKE BROS. REFINING CO. OR AERO SHELL GREASE #7 100 HRS STABILATOR SCREW/TAB LINKS MIL-L-7870 100 HRS...
Page 92 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY DOOR HINGES MIL-L-7870 100 HRS DOOR SEALS FLUOROCARBON RELEASE AGENT DRY LUBRICANT MS-122 50 HRS DOOR LATCH MECHANISMS AERO LUBRIPLATE FISKE BROS. OR AERO SHELL GREASE #7 500 HRS SEAT TRACK ROLLERS, STOP PINS...
Page 93 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY MIL-L-6082 MINERAL 1 3 ENGINE SUMP MIL-L-22851 1 3 (ASHLESS DISPERSANT) 50 HRS CARTRIDGE TYPE OIL FILTERS 50 HRS AIR FILTERS 50 HRS MIL-G-23827 3 PROPELLER ASSEMBLY 100 HRS ENGINE CONTROL AND ENVIRONMENTAL...
Page 94 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COMPONENT LUBRICANT FREQUENCY CONDENSER HINGE AND ACTUATORS MIL-L-7870 100 HRS CONDENSER DOOR ACTUATING TRANSMISSION MIL-G-23827 500 HRS SPECIAL INSTRUCTIONS Transmission to be 1/2 full of grease. Apply grease during sssembly and lubricate transmission ball nut and screw with MIL-G-23827 grease.
Page 95 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1D23...
Page 96 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1D24...
Page 97 CHAPTER STANDARD PRACTICES/ AlR FRAME...
Page 98 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 20 - STANDARD PRACTICES - AIRFRAME TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 20-00-00 GENERAL 20-10-00 STANDARD PRACTICES - AIRFRAME 20-10-00 Torque Wrenches 20-10-00 Method of Installing Rod End Bearings 20-10-00 Cherrylock Rivets, Removal...
Page 99 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 20 - STANDARD PRACTICES - AIRFRAME (CONT.) TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 20-20-00 AIRCRAFT FINISH CARE (cont.) 20-25-00 DuPont Imron Method 1E20 20-25-00 Randolph Ranthane Method 1E21 20-25-00 Alumigrip Method...
Page 100 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter contains general information pertaining to standard aircraft hardware installation and removal practices. Information included will be very helpful if referred to on a regular basis. For standard repair practices of a minor nature, refer to AC43.l3.
Page 101 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 20-1. Torque Wrench Extension METHOD OF INSTALLING ROD END BEARINGS Figure 20-2. Correct Method of Installing Rod End Bearings 20 - 10 - 00 Page - 20 - 02 Reissued: August 1, 1986...
Page 102 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL REMOVAL CHERRYLOCK RIVETS (Refer to figure 20-3) If it is necessary to remove a cherrylock rivet proceed as follows: 1. In thick material: Drive out rivet stem with a tapered steel drift pin to remove lock. (See view 1.) —CAUTION—...
Page 103 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL IDENTIFICATION OF FLUID LINES (Refer to figure 204) Fluid lines in aircraft are often identified by markers made up of color codes, words, and geometric symbols. These markers identify each line’s function, content, and primary hazard, as well as direction of fluid flow.
Page 104 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 20-4. Hose/Line Markings 20 - 10 - 00 Page - 20 - 06 Reissued: August 1, 1986...
Page 105 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 20-5. Flareless Tube Fittings 20 - 10 - 00 Page - 20 - 06 Reissued: August 1, 1986...
Page 106 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2001. THREAD LUBRICANTS TYPE OF LINE TYPE OF LUBRICANT —CAUTION— Lubricate engine fittings only with the fluid contained in the particular lines. Brakes MIL-H-5606 Deicer (Air) TT-A-580 (JAN-A-669), Anti-Seize Compound (White Lead Base) Freon...
Page 107 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LUBRICATION OF GASKETS AND SEALS Lubricate gaskets and O-ring seals with the same type of fluid they are sealing. LUBRICATION OF THREADS All fittings on external lines, including points of attachment at engine and other components, must be lubricated with lubricant as specified in chart 2001.
Page 108 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CLEANING EXTERIOR SURFACES Wash airplane with mild soap and water. Harsh, abrasive or alkaline soaps or detergents used on painted or plastic surfaces could make scratches or cause corrosion. Cover areas where cleaning solution could cause damage.
Page 109 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 6. To improve visibility through windshield and windows during flights through rain, apply a rain repellent such as REPCON to windshield and windows. Apply in accordance with the manufacturer’s instructions. (Refer to Chart 9105. Consumable Materials for Specifications and Manufacturer’s address.)
Page 110 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. Repeat procedure for each tank. 4. When all tanks are flushed, clean all filters. CONDITIONS AFFECTING CORROSION Some conditions affecting corrosion are: Heat and humidity. 2. Different metals and their relative sizes. 3. Frequent contributing factors to corrosion: a.
Page 111 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Before beginning any rework: Position airplane in a wash rack or provide some type of washing apparatus for rapid rinsing of all surfaces. 2. Connect static ground line to airplane. 3. Remove airplane battery if required.
Page 112 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL * Red rust generally shows on bolts, nuts, and other aircraft hardware. Rust in these areas is generally not dangerous. It is indicative of a need for maintenance and also of possibility of corrosive attack in more critical areas.
Page 113 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PAINTING This section contains suggestions that will aid in good results when applying finishes to the airplane. —NOTE— The paint type is found in aircraft’s log book, parts catalog or pilot’s operating handbook. PAINTING SAFETY —WARNING—...
Page 114 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PAINT APPLICATION —WARNING— Aircraft must be grounded before painting to ensure that no static electricity charges could build up and discharge. —CAUTION— When masking aircraft, be careful to protect the windshield. Paint strippers, metal brighteners, and solvents could damage the windshield —CAUTION—...
Page 115 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 4. Paint the bottom of the airplane first including the bottom of the horizontal tail surfaces. Starting at the root and working outward, spray chordwise. Work up the fuselage and allow the spray to cover the sides.
Page 116 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL DUPONT IMRON METHOD If finishing fiberglass parts proceed to step 4, for magnesium parts proceed to step 6. —WARNING— Always wear protective goggles and rubber gloves when using a paint stripper. Wash strippers off skin immediately. If stripper comes into contact with eyes, flood repeatedly with water and CALL A PHYSICIAN.
Page 117 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —WARNING— When mixed with 192S, the mixture will have the hazards of both components. Observe all applicable label precautions. FIRST AID: In case of skin contact, flush with plenty of water, for contact with eyes, flush with plenty of water for 15 minutes and get medical attention.
Page 118 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 6. Trim and lettering may be applied within 48 hours. If later than 48 hours, sand, rinse and dry before application. 7. Rework should not be attempted before 16 hours of curing. Sand area with #400 wet sandpaper, rinse and dry.
Page 119 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5. Primer Application - Coat parts to be painted with zinc chromate wash primer solution followed by a coat of urethane primer solution. Coat fiberglass parts only with urethane primer solution. Allow zinc chromate wash primer to dry 30 minutes minimum before applying urethane primer.
Page 120 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. Mix intermediate epoxy primer to manufacturer’s directions. Thin 20-30% by volume with MX- l5 thinner. Air dry 4-6 hours at 75° F or force dry 2-3 hours at l 25° F before top coating with Jet-Glo.
Page 121 The location and size is found in Federal Aviation Regulations. PAINT SYSTEM COMPATIBILITY Before painting, determine what type of finish was used previously. Refer to Piper parts catalog for correct paint number and color.
Page 122 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 7. Old acrylic finishes may be refinished with new acrylic provided old coating is thoroughly softened using acrylic nitrocellulose thinner before paint touchup. 8. Damage to epoxy finishes can be repaired using more epoxy. Neither lacquer finish will stick to epoxy surfaces.
Page 123 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Painting facilities must conform to applicable local, state, and OSHA standards with respect to air circulation, exhaust emissions, lighting, and fire protection. When spraying, provide sufficient movement of air in painting area so there is no more than a slight odor of finishing material.
Page 124 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GRIDS 1F4 THRU 1F11 INTENTIONALLY LEFT BLANK...
Page 125 CHAPTER ENVIRONMENTAL SYSTEM 1F12...
Page 126 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 21 - ENVIRONMENTAL SYSTEM TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 21-00-00 GENERAL 1F15 21-40-00 HEATING 1F15 21-41-00 Description and Operation 1F15 21-42-00 Heater Maintenance 1F15 21-50-00 COOLING 1F17 21-51-00 Description and Operation...
Page 127 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 21 - ENVIRONMENTAL SYSTEM (cont) TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 21-50-00 COOLING (cont) 21-56-00 Expansion Valve 21-56-00 Expansion Valve Removal 21-56-00 Expansion Valve Installation 21-57-00 Evaporator 21-57-00 Evaporator Removal 21-57-00...
Page 128 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter contains instructions for operating, servicing, inspection and repair of environmental system components installed in this airplane. HEATING DESCRIPTION AND OPERATION —WARNING— When cabin heat is operated, heat duct surfaces become hot. This could result in burns if arms or legs are placed too close to heat duct outlets or surface.
Page 129 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-1. Cabin Heater. Defroster and Fresh Air System 21 - 42 - 00 1F16 Page - 21 - 02 Reissued: August 1, 1986...
Page 130 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL COOLING DESCRIPTION AND OPERATION The air conditioning system comprises a compressor and special brackets, evaporator, condenser, receiver- dehydrator, circulating fan, thermal expansion valve, and related plumbing. The evaporator is mounted in a fabricated housing along with the receiver- d e h y d r a t o r, circulating fan, thermal expansion valve and related plumbing.
Page 131 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2101, TROUBLESHOOTING (AIR CONDITIONER) Gauge Indication Probable Causes Remedy High discharge pressure. Overcharge of refrigerant. Purge excess refrigerant. Air in system. Check for leaks. Bleed charge from system. Evacuate and recharge system. Overheated condenser due to Clean bugs and dirt from con- blocking air passage.
Page 132 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2101. TROUBLESHOOTING (AIR CONDITIONER) (cont) . Gauge Indication Probable Causes Remedy Low suction pressure. (Evap- Undercharge of refrigerant. Add refrigerant. Install new orator not cold enough) Moisture freezing in expan- dryer. Evacuate and recharge.
Page 133 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2102. TROUBLESHOOTING (AIR CONDITIONING SYSTEM) Trouble Cause Remedy Condenser door will not Faulty relay K-2. Replace relay. close when air conditioner switch is in OFF position. System produces no Electrical cooling. Blown fuse in control head.
Page 134 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2102. TROUBLESHOOTING (AIR CONDITIONING SYSTEM) (cont) Trouble Cause Remedy System produces no Refrigeration cooling, (cont) Broken refrigerant line. Examine all lines for evidence of breakage by external stress or rubbing wear. Leak in system.
Page 135 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2102. TROUBLESHOOTING (AIR CONDITIONING SYSTEM) (cont.) Trouble Cause Remedy System will not produce Refrigeration sufficient cooling. (cont) Insufficient refrigerant in Recharge system until bub system. bles disappear in receiver dehydrator and gauge read- ings stabilize to specifi- cations.
Page 136 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2102. TROUBLESHOOTING (AIR CONDITIONING SYSTEM) (cont) Trouble Cause Remedy Excessively noisy system. Electrical (cont) (cont) Compressor noisy. Check mountings and repair; remove compressor for ser- vice or replacement. Compressor oil level low. Fill with correct amount of specified oil.
Page 137 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-2- Air Conditioning System Installation (Typical) 21 - 52 - 00 1F24 Page - 21 - 10 Reissued: August 1, 1986...
Page 138 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SERVICING COOLING SYSTEM MALFUNCTION DETECTION A normally operating system will have a low side gauge pressure reading corresponding with refrigerant temperature in the evaporator, allowing for a few degrees temperature rise due to loss in tube walls and fins.
Page 139 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2103. TEMPERATURE PRESSURE Evaporator Pressure Evaporator High Pressure Ambient Gauge Reading Temperature Gauge Reading Temperature p.s.i. °F. p.s.i. °F. 0-21 10,1 11-2 12,3 13.4 14,6 15,8 17,1 18,3 19,7 22,4 23,1 23,8 24,6 25,3...
Page 140 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SPECIAL SERVlCING PROCEDURES —WARNING— Only trained personnel may service the air conditioning system. All work must be done in a shop equipped for such work. —WARNING— Wear eye protection when handling R-12 (Freon). If liquid Freon contacts the eyes.
Page 141 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —WARNING— A very strong acid (HCL) is formed when Freon comes in contact with moisture. —CAUTION— Replace any receiver-dehydrator assembly which has been operated after air has leaked into system. The drying compound is damaged by moisture contained in air.
Page 142 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-3. Service Valves SERVICE VALVE REPLACEMENT —CAUTION— Whenever a r conditioning refrigerant lines or system are opened for any reason, lines and fittings must be capped and sealed immediately to prevent dirt and other contaminants from entering system.
Page 143 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-4. Test Gauge and Manifold Set TEST GAUGE AND MANIFOLD SET Proper air conditioning system testing and diagnosis requires that a manifold gauge set be attached to the system. This set consists of two gauges mounted to a manifold. One gauge is a high pressure gauge used on discharge side of system.
Page 144 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-5. Manifold Set Operation 21 - 52 - 00 Page - 21 - 17 Reissued: August 1, 1986...
Page 145 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21b. Leak Test Hookup —NOTE— Evacuate system prior to leak check. LEAK CHECK A. METHOD I. 1. Connect manifold gauge set to system and determine if there is any refrigerant in system. A minimum of 50 psi refrigerant pressure in system is needed for leak detection.
Page 146 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LEAK CHECK B. METHOD II 1. Remove access panel at rear of cabin to gain access to service valves. 2. Remove protective cap on high pressure Schrader valve fitting and connect a charging hose with a shutoff valve arrangement to fitting.
Page 147 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-7. Evacuation Hookup EVACUATING THE SYSTEM If system has been operated in a discharged condition or anytime system has been open to atmospheric pressure, replace receiver-dehydrator and evacuate system to remove any trapped air and moisture which has entered it.
Page 148 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL The following steps will help when performing this operation: 1. Remove access panel at rear of cabin to gain access to Schrader service valves. —CAUTION— Ensure that all system pressure is released before attempting evacuation. (Refer to Special Servicing Procedures.) 2.
Page 149 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-8. Charging Stand WITH A CHARGING STAND This is the preferred method for system charging. —NOTE— The following instructions apply to Kent Moore, J23500 charging stand. (Refer to figure 21-8.) 1. With system discharged and evacuated, hook-up charging stand. (Refer to figure 21-9.) 2.
Page 150 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5. Connect heating element plug (16) to 110 volt outlet. 6. Turn cylinder sight glass to match pressure reading on cylinder pressure gauge, use this scale during entire charging operation. 7. Close valve (3) (low pressure control), fully open valve (11) (refrigerant control) and allow all liquid refrigerant contained in charging cylinder to enter high side of aircraft system.
Page 151 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-9. Charging Hookup 10. Shut off air conditioning system and airplane engine. Remove charging lines from Schrader valves. Use a shop cloth to divert escaping refrigerant when disconnecting charging hose from Schrader valve. Recap valve.
Page 152 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —WARNING— Be careful when removing charging hose from Schrader valve. Hose will have refrigerant remaining in it and become very cold as the gas escapes. 11. Shut off air conditioner and engine. Remove charging hose from Schrader valve.
Page 153 5. With compressor in installed position, use chart 2106 to determine amount of oil in crankcase. 6. Never operate compressor with less than 6 ounces of oil. When oil is added, level should not be more than 10 ounces. Piper refrigerant oil PMS-L2000 or equivalent 500 viscosity refrigerant oil must be used.
Page 154 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-10. Compressor and Fabricated Oil Dipstick —WARNING— Do not remove oil plug with system under pressure. CHART 2106. COMPRESSOR OIL CHARGE Oil Charge Ounces Dipstick Reading Inches 13/ 16” 1.00 1-3/16” 1-15/16” REPLACEMENT OF COMPRESSOR DRIVE BELT (figure 21-11) Remove old belt by removing spinner, propeller, nose cowl, engine baffles, and as required, starter ring gear assembly, and drive belts.
Page 155 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21 - 11. Compressor and Alternator Belt Installation 21 - 53 - 00 1G18 Page - 21 - 28 Reissued: August 1, 1986...
Page 156 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5. Check belt and pulley alignment of compressor and alternator as follows: a. A datum line must be established for checking belt and pulley alignment. A nominal dimension must be established between forward edge of compressor belt and forward machined surface of ring gear.
Page 157 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL c. Run engine for 15 minutes at 1200 rpm. —WARNING— If air conditioner is to be operated on ground f or servicing, test area must be clean and free of any loose objects lying on ramp.
Page 158 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-12. Magnetic Clutch 3. Connect electrical lead from field assembly. —NOTE— The compressor shaft must be clean and free from burrs. 4. Slide pulley assembly over field assembly and onto crankshaft, now tighten the field assembly to a torque of 85 to 120 inch-pounds.
Page 159 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL RECEIVER-DEHYDRATOR RECEIVER-DEHYDRATOR REMOVAL —CAUTION— This part is not serviceable, it must be replaced. The receiver- dehydrator should be replaced when system has been operated without a charge or is left open. The receiver-dehydrator is mounted on inboard side of evaporator assembly housing.
Page 160 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CONDENSER INSTALLATION 1. Install condenser core to frame assembly with hose fittings forward and up. 2. Place condenser and frame assembly to fuselage frame mounting bracket and insert 8 screws into piano hinge. 3. Attach side hinges and actuating rod and rig per Condenser Assembly Rigging Instructions.
Page 161 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-13. Condenser Air Scoop Installation 21 - 55 - 00 1G24 Page - 21 - 34 Reissued: August 1, 1986...
Page 162 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-14. Expansion Valve EXPANSION VALVE EXPANSION VALVE REMOVAL (figure 21-14) —CAUTION— This part is not serviceable and must be replaced. The expansion valve is located in evaporator assembly between receiver dehydrator and evaporator inlet.
Page 163 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL EVAPORATOR EVAPORATOR REMOVAL The evaporator assembly consists of evaporator core, receiver-dehydrator, expansion valve, circulating fan, pressure switch, housing, and associated plumbing. The housing is fabricated of thermoplastic. Condensed moisture is dumped overboard through a hose clamped to a fitting on bottom of evaporator housing.
Page 164 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-15. Components Installation PRESSURE RELIEF SWITCH (Ranco) The pressure relief switch automatically prevents system over pressurization by breaking electrical circuit to magnetic clutch. This stops the compressor until pressure is reduced. The switch is located in line between receiver and expansion valve.
Page 165 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ADJUSTMENT OF THROTTLE SWITCH A throttle switch is mounted forward and below throttle arm. Adjust switch so it will actuate at last quarter inch of full open throttle travel. The switch should be positioned so throttle arm contacts center of switch actuator button.
Page 166 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 21-16. Overhead Vent System (Not Available With Air Conditioning) 21 - 81 - 00 Page - 21 - 39 Reissued: August 1, 1986...
Page 167 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL REASSEMBLY OF BLOWER ASSEMBLY 1. Mount motor on plate and secure it with bolts, washers, and nuts. Be sure that motor nuts are snug and the shaft spins freely. 2. Position cover over motor plate with motor wires protruding through cover grommet.
Page 168 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK...
Page 169 CHAPTER AUTO FLIGHT...
Page 170 CHAPTER 22 - AUTOFLIGHT TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 22-00-00 GENERAL 1H10 22-10-00 AUTOPILOT 1H10 22-11-00 Non-Piper AFCS Equipment Contacts 1H10 22-12-00 Piper AFCS Equipment 1H11 22 - Cont./Effec. Page - 1 Reissued: August 1, 1986...
Page 171 This includes mechanical service such as; adjusting bridle cable tension. servo removal and installation, servo clutch adjustments, etc. AUTOPILOT NON-PIPER AFCS EQUIPMENT CONTACTS Refer to the following list of Autopilot/ Flight Director manufacturers to obtain service direction. parts support, and service literature.
Page 172 Piper Pitch Trim Service Manual - 753 771 for manual electric pitch trim service information. The following is a complete listing of Piper AFCS equipment service literature. It is imperative to correctly identify Autopilot system by faceplate model name, in order to consult the appropriate service manual.
Page 173 CHAPTER COMMUNICATIONS 1H12...
Page 174 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 23 - COMMUNICATIONS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 23-00-00 GENERAL 1H14 23-10-00 AVIONICS MASTER AND EMERGENCY SWITCH CIRCUIT 1H14 23-11-00 Description and Operation 1H14 23-20-00 DATA TRANSMISSION AND AUTOMATIC CALLING...
Page 175 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter contains information necessary to perform operational checks of the emergency locator transmitter (elt). Included are appropriate removal and installation instructions to facilitate battery replacement. AVIONICS MASTER AND EMERGENCY SWITCH CIRCUIT (figure 23-1)
Page 176 (Refer to Battery Removal and Installation.) BATTERY REMOVAL AND INSTALLATION (COMMUNICATIONS COMPONENTS CORP.) (Refer to latest revision of Piper Service Letter No. 820.) The elt is located on right side of airplane tail section. ahead of stabilator.
Page 177 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 23-2. Communications Components ELT Schematic Figure 23-3. Emergency Locator Transmitter Schematic (Narco) 23 - 21 - 00 1H16 Page - 23 - 03 Reissued: August 1, 1986...
Page 178 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL BATTERY REMOVAL AND INSTALLATION (NARCO) (Figures 23-4 and 23-5) Set ON/OFF/ARM switch on transmitter to OFF. 2. Disconnect antenna coaxial cable from elt. 3. Remove elt from its mounting bracket by releasing latch on strap and sliding elt off bracket.
Page 179 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Fig. 23-4. ELT Portable Folding Antenna (Narco) Fig. 23-5. ELT Using Fixed Aircrat Antenna (Narco) 23 - 21 - 00 - 00 1H18 Page - 05 Reissued: August 1, 1986...
Page 180 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL TESTING EMERGENCY LOCATOR TRANSMITTER The transmitter operates on the emergency frequencies of 121.5 and 243 MHz. Both of these frequencies are monitored by FAA installations. Before performing any operational test of an elt, the following precautions must be observed.
Page 181 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAE INTENTIONALLY LEFT BLANK 1H20...
Page 182 CHAPTER ELECTRICAL POWER 1H21...
Page 183 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 24 - ELECTRICAL POWER TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 24-00-00 GENERAL 1H24 24-01-00 Description and Operation 1H24 24 02-00 Troubleshooting 1H24 24-30-00 DC GENERATION 24-31-00 Description of Alternator System 24-31-00...
Page 184 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 24 - ELECTRICAL POWER (cont) TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 24-30-00 DC GENERATION (cont) 24-34-00 Battery 1J12 24-34-00 Servicing Battery 1J12 24-34-00 Removal of Battery 1J12 24-34-00 Installation of Battery...
Page 185 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter contains instructions for correcting problems in the electrical system. It includes a general description and function of each system part along with test and adjustments of various components. DESCRIPTION AND OPERATION The electrical system is a l4-volt, direct current, single wire, negative ground system. All electrical equipment is grounded to metal airplane structure.
Page 186 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2401. TROUBLESHOOTING (ALTERNATOR) Trouble Cause Remedy Zero output indicated on Open field circuit. With master switch turned on, ammeter regardless of rpm check for battery voltage from (refer to alternator system airplane’s main buss through test procedure).
Page 187 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2401. TROUBLESHOOTING (ALTERNATOR) (cont) Trouble Cause Remedy Zcro output indicated on Open field winding in al- Disconnect field terminal of ammeter regardless of rpm ternator. alternator from field wiring (refer to alternator system and check for continuity test procedure).
Page 188 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2401. TROUBLESHOOTING (ALTERNATOR) (cont) Trouble Cause Remedy Output indicated on am- High resistance connec- Check visually for loose bind- meter does not meet mini- tions in field or output cir- ing posts at the various junc mum values specified in al- cuit.
Page 189 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2401. TROUBLESHOOTING (ALTERNATOR) (cont) Trouble Cause Remedy Field circuit breaker trips. Short circuit in field winding Disconnect field wiring at (cont.) of alternator. terminal of alternator. Turn on master switch. Reset breaker and if breaker fails...
Page 190 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2401. TROUBLESHOOTING (ALTERNATOR) (cont) Trouble Cause Remedy Battery installed with re- Battery charged backwards. Remove battery. Connect versed polarity. (cont) load such as landing light lamp or similar load and dis charge battery. Recharge...
Page 191 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2402. TROUBLESHOOTING (BATTERY) Trouble Cause Remedy Discharged battery. Battery worn out. Replace battery. Charging rate not set right. Reset. Standing too long. Remove and recharge bat- tery if left in unused airplane three weeks or more.
Page 192 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2402. TROUBLESHOOTING (BATTERY) (cont) Trouble Cause Remedy Excessive corrosion inside Spillage from overfilling. Use care in adding water. container. Vent lines leaking or clog- Repair or clean. ged. Charging rate too high. Adjust voltage regulator.
Page 193 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL DC GENERATION DESCRIPTION OF ALTERNATOR SYSTEM On engines without air conditioning, the alternator is located on front lower right side; front lower left side with air conditioning. It uses a belt drive from engine crankshaft. Full electrical power output is available regardless of engine rpm.
Page 194 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHECKING ALTERNATOR SYSTEM With all electrical equipment off (except master switch) ammeter will indicate amount of charging current demanded by battery. This amount will vary, depending on percentage of charge in battery. As the battery becomes charged, the amount of current displayed on ammeter will reduce to approximately two amperes.
Page 195 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-1. Lamp-Bank Load SERVICE PRECAUTIONS —CAUTION— Be very careful when connecting or disconnecting test equipment (except voltmeter) or before removing or replacing any unit. Accidental grounding at the regulator, alternator, ammeter, or accessories will cause severe damage to the units and wiring.
Page 196 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL OVERHAUL OF ALTERNATOR When repairing alternator, complete disassembly may not be required. In some cases it will only be necessary to perform those operations which are required to effect repair. However, in this section, complete overhaul is covered to provide detailed information on each operation.
Page 197 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24 2. Exploded View of Alternator (Chrysler) Figure 24-3. Checking Field Coil Figure 24-4. Testing Field Circuit Current Draw 24 - 32 - 00 1I12 Page - 24 - 13 Reissued: August 1, 1986...
Page 198 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL c. Touch one test lamp probe to one of the slip rings and remaining test probe to rotor shaft. Lamp should not light. A lighted test lamp indicates a grounded rotor assembly and requires rotor replacement.
Page 199 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-5. Testing Positive Rectifiers Figure 24-6. Testing Negative Rectifiers with C-3829 Tester with C-3829 Tester Figure 24-7. Rectifier End Shield and Stator Assembly 24 - 32 - 00 1I14 Page - 24 - 15...
Page 200 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 4. Touch metal strap of each of positive rectifiers with test probe. a. A reading on tester of 1.75 amps or more indicates a satisfactory rectifier. Readings and direction of needle movement must be same for all three rectifiers.
Page 201 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-8. Testing Positive Rectifiers Figure 24-9. Testing Negative Rectifiers With Test Lamp With Test Lamp 5. Reverse test probes (move probe from rectifier heatsink to rectifier strap and move probe from rectifier strap to rectifier heatsink), and repeat test for each rectifier.
Page 202 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-l0. Rectifier and Heatsink Figure 24-11. Rectifier End Shield Assembly Assembly Removal REMOVAL OF RECTIFIER AND HEATSINK ASSEMBLY (figure 24-l0) —NOTE— If negative heatsink rectifier straps are under positive heatsink straps, proceed to step 2.
Page 203 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-12. Testing Stator Figure 24-l3. Removal of Pulley TESTING OF STATOR Remove varnish from a spot on stator frame. 2. Press a test probe firmly onto bare spot. 3. Press other test probe firmly to each of three stator lead terminals one at a time. If lamp lights, individual stator lead is grounded.
Page 204 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 1. Remove pulley with tool C 4068. (Refer to figure 24-l3.) 2. Rcmove three bearing retainer screws. 3. Pry drive end bearing retainer from end shield with a screwdriver. 4. Support end shield and tap rotor shaft with a plastic hammer to separate rotor from end shield.
Page 205 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-l6. Testing Rotor for Ground Figure 24-17. Testing Rotor for Opens or Shorts 2. To check for an open field coil, connect an ohmmeter to slip rings. a. Ohmmeter should read between 1.5 and 2.0 ohms on rotor coils at room ambient conditions.
Page 206 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-l8. Installation of Grease Retainer Figure 24-19. Installation of Rectifier End Shield Bearing Figure 24-20. Installation of Drive End Figure 24-2l. Installation of Pulley Shield Bearing 24 - 32 - 00 1I21 Page - 24 - 22...
Page 207 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. Position rectifier end shield bearing on the base of tool C-420l. Place alternator end shield on top of bearing so that it is properly aligned. With top part of tool C-4201 placed on end shield, press into place until it bottoms against it.
Page 208 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-22. Installation of Insulators Figure 24-23. Installation of Positive Rectified Assembly Figure 24-24.Installation of Capacitor Figure 24-25. Installation of Battery Output Insulator 24 - 32 - 00 1I23 Page - 24 - 24 Reissued: August 1, 1986...
Page 209 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL l2. Turn end shield over and install round plastic insulator over battery terminal with flat side up. Install nut and washer and tighten to a torque of 30 to 50 inch-pounds. (Refer to figure 24-25.) l3.
Page 210 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-26. Installation of Negative Figure 24-27. Installation of Stator Rectifier Assembly THIS SPACE INTENTIONALLY LEFT BLANK 24 - 32 - 00 Page - 24 - 26 Reissued: August 1, 1986...
Page 211 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ALTERNATOR SYSTEM (PRESTOLITE) DESCRIPTION OF ALTERNATOR (figure 2~28) Principal alternator components are brush holder assembly, slip ring end head, rectifiers, stator, rotor, and drive end head. 1. The brush and holder assembly contains two brushes, two brush springs, brush holder, and insulator.
Page 212 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-28. Exploded View of Alternator (Prestolite) 24 - 33 - 00 Page - 24 - 28 Reissued: August 1, 1986...
Page 213 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-29. Removal of Slip Ring End Bearing Figure 24-30. Removal of Rectifier Figure 24-3l. Removal of Drive End Head Figure 24-32. Removal of End Head Bearing 24 - 33 - 00 Page - 24 - 29...
Page 214 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-33. Testing Rotor for Ground Figure 24-34. Testing Rotor for Shorts 6. To remove drive end head from rotor shaft, use a puller that grips on bearing retainer plate as shown in figure 24-31. Do not attempt to remove by supporting end head and pressing on shaft, as this may result in distortion of end head or stripping of retainer plate screws.
Page 215 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. Rectifiers: A diode rectifier tester detects and pinpoints open or shorted rectifiers without disconnecting stator leads. However, if a tester is not available, test probes and a number 57 bulb, connected in series with a 12-volt battery, can be used. Touch one test probe to a rectifier heat sink and other test probe to a lead from one of the rectifiers in that heat sink.
Page 216 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-35. Installation of Bearing Figure 24-36. Installation of Rectifier Figure 24-37. Terminal Assembly (Prestolite) 24 - 33 - 00 Page - 24 - 32 Reissued: August 1, 1986...
Page 217 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 24-38. Slip Ring End Bearing Assembly Figure 24-39. Testing Alternator 6. Assemble alternator and install through bolts. Spin rotor to make sure there is no mechanical interference. Tighten bolts to a torque of 30 to 35 inch-pounds. Install safety wire after unit has been bench tested for output.
Page 218 (See schematics for your airplane.) If, during inspection, a fault in the aluminum cable is found, Piper considers it mandatory that the complete cable assembly be replaced with copper wire and suitable terminals.
Page 219 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ALTERNATOR SERVICE TIPS Bearings: These units have a sealed ball bearing at the drive end and a two-piece roller bearing at slip ring end. Press inner race onto rotor shaft. The rest of bearing is in slip ring end head. When unit is assembled, inner race aligns with bearing.
Page 220 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHECKING ALTERNATOR BELT TENSION An improperly tensioned belt may wear rapidly or slip, reducing alternator output. Check belt for proper tension when installed, at 25 hours of operation, and every l00 hours thereafter. —NOTE— For aircraft with air conditioning installed, refer to chapter 21, for replacement and adjustment of compressor drive belt.
Page 221 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. V-Belt Tensiometer: a. Position alternator to obtain an initial belt tension of 75 lbs. b. Operate engine for a minimum of l5 minutes. c. Recheck alternator belt tension. The meter should indicate 46 to 58 lbs. If tension does not fall within this range, readjust alternator as necessary.
Page 222 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF BATTERY —CAUTION— Check battery vent tubes for obstructions. Remove obstructions to ensure positive airflow through battery box. Ensure that battery and battery box have been cleaned and are free of acid. 2. Install battery in box.
Page 223 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —CAUTION— Aircraft serial numbers 8611005 and up have an uncapped center vent. Verify angled face of center vent is facing aft to ensure positive airflow through battery box. 1. Remove box drain cap from under side of fuselage and drain off any electrolyte that may have overflowed into box.
Page 224 1. Turn aircraft MASTER SWITCH to OFF position and turn off all electrical equipment. 2. Ensure that red lead of Piper External Power (PEP) kit jumper cable is connected to positive (+) terminal of external l2-volt battery and that black lead is connected to negative (-) terminal...
Page 225 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. Insert plug of jumper cable into socket located on aircraft fuselage. 4. Proceed with normal engine starting procedure. 5. Remove jumper cable plug from aircraft. 6. Turn aircraft MASTER SWITCH to ON and check alternator ammeter for indication of output.
Page 226 CHAPTER EQUIPMENT/FURNISHINGS 1J17...
Page 227 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 25 - EQUIPMENT/FURNISHINGS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 25-10-00 FLIGHT COMPARTMENT 1J19 25-11-00 Rigging Instructions - Seat Back Lock and Release 1J19 25-12-00 Shoulder Harness Inertia Reel Adjustment 1J20 25 - Cont./Effec.
Page 228 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 25-1. Seat Back Lock FLIGHT COMPARTMENT RIGGING INSTRUCTIONS - SEAT BACK LOCK AND RELEASE (figure 25-1) 1. Loosen screws and clamps. (Push-pull cable is able to move within the clamps.) 2. Place a straightedge along lower surface of seat back release bushing.
Page 229 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL SHOULDER HARNESS INERTIA REEL ADJUSTMENT A shoulder harness with an inertia reel is provided for each front seat occupant and is available (optional) for all rear seats. Check the inertia reel mechanism by pulling sharply on the strap and checking that reel will lock in place under sudden stress.
Page 230 CHAPTER FLIGHT CONTROLS 1J21...
Page 231 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 27 - FLIGHT CONTROLS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 27-00-00 GENERAL 1J24 27-02-00 Troubleshooting 1J24 27-03-00 Standard Procedures 27-04-00 Control Column Assembly 27-04-00 Removal of Control Column Assembly 27-04-00 Installation of Control Column Assembly...
Page 232 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 27 - FLIGHT CONTROLS (cont) TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 27-50-00 FLAPS 1L12 27-51-00 Wing Flap Controls 1L12 27-51-00 Removal of Wing Flap Controls 1L12 27-51-00 Installation of Wing Flap Controls...
Page 233 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter contains procedures for removal, installation, rigging, and adjustment of the control surface assemblies. TROUBLESHOOTING Troubles peculiar to Flight Controls are listed in chart 2701, along with their probable causes and suggested remedies.
Page 234 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 270l. TROUBLESHOOTING (SURFACE CONTROLS) Trouble Cause Remedy AILERON CONTROL SYSTEM Lost motion between control Cable tension too low. Adjust cable tension. wheel and aileron. Linkage loose or worn. Check linkage and tighten or replace.
Page 235 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (CONT) Trouble Cause Remedy AILERON CONTROL SYSTEM (CONT) Incorrect aileron travel. Aileron control rods not ad- Adjust control rods. justed properly. Aileron bellcrank stops not Adjust bellcrank Stops. adjusted properly.
Page 236 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont.) Trouble Cause Remedy RUDDER CONTROL SYSTEM (CONT.) Excessive resistance to rudder Cables not in place on Install cables correctly. Check pedal movement. (cont) pulleys cable guards. Cables crossed or routed Check routing of control incorrectly.
Page 237 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (cont) Trouble Cause Remedy STABILATOR CONTROL SYSTEM (cont) Resistance to Stabilator Pulleys binding or rubbing. Replace binding pulleys control movement (cont.) or provide clearance between pulleys and brackets. Cables not in place on Install cables correctly.
Page 238 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (CONT.) Trouble Cause Remedy STABILATOR CONTROL SYSTEM (cont) Trim control wheel moves Cables not in place on Install cables properly. with excessive resistance. pulleys. (cont.) Trim tab hinge binding. Lubricate hinge. If necessary, replace.
Page 239 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2701. CABLE TENSION VS. AMBIENT TEMPERATURE RIGGING LOAD CORRECTION, POUNDS 27- 02 - 00 Page 27 - 07 Reissued: August 1, 1986...
Page 240 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-l. Rod End Installation Method 27- 02 - 00 Page 27 - 08 Reissued: August 1, 1986...
Page 241 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STANDARD PROCEDURES The following tips will help in removal, installation and rigging of various assemblies: 1. It is recommended, though not always necessary to level and place airplane on jacks during rigging and adjustment. 2. Remove turnbuckle barrels from cable ends before withdrawing cables through structures.
Page 242 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-2. Control Column Assembly 27- 04 - 00 Page 27 - 10 Reissued: August 1, 1986...
Page 243 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. Remove tee bar with assembled parts from airplane as follows: a. Remove access panel or door to the aft section of fuselage. b. Relieve cable tension from stabilator control cables at one of the stabilator cable turnbuckles in the aft section of fuselage.
Page 244 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Set stabilator cable tension with turnbuckle in aft section of fuselage. Refer to instructions in Rigging and Adjustment of Stabilator Controls. Check safety of all turnbuckles upon completion of adjustments. Tighten connecting bolts of idler sprockets.
Page 245 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-3. Aileron Controls (Typical) 27- 11 - 00 1K12 Page 27 - 13 Reissued: August 1, 1986...
Page 246 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Remove cotter pins used as cable guards at pulley in forward area of floor opening aft of main spar. g. Disconnect cable from control chain at control column tee bar assembly by removing cotter pin, nut, bolt, and bushing that connect the two together.
Page 247 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. Install the primary control cable in either wing as follows: a. Draw control cable into wing. b. Connect cable to forward end of aileron bellcrank using a bolt, washer, nut, and cotter pin. Allow cable end to rotate freely on bellcrank.
Page 248 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5. Connect ends of primary and balance control cables to bellcrank using bolts, washers, nuts, and cotter pins. Allow cable ends to rotate freely on bellcrank. 6. Tighten control cables at balance cable turnbuckle in floor opening aft of main spar. Check cable tension per Rigging and Adjustment of Aileron Controls.
Page 249 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-4. Aileron Rigging Figure 27-5. Bellcrank Rigging Tool 27- 13 - 00 1K16 Page 27 - 17 Reissued: August 1, 1986...
Page 250 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL d. Adjust turnbuckles, located in access opening just aft of main spar, of primary and balance cables to their proper cable tension and maintain neutral-center position of control wheels. To obtain neutral position of both control wheels, it may also be necessary to adjust roller chain turnbuckle located between control wheel sprockets.
Page 251 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 6. Check bellcrank stops to ensure that bellcrank contact is made simultaneously, but still have cushion before contacting control wheel stops. Maintain 0.030 to 0.040 clearance between sprocket pin and adjustable stop bolts on models having adjustable tee bar stops.
Page 252 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-7. Rudder and Steering Pedal Assembly 27- 21 - 00 1K19 Page 27 - 20 Reissued: August 1, 1986...
Page 253 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 14. Remove trim side panels, if desired. 15. Rotate rudder pedal bar assembly toward cabin door far enough to pull right pedal bar out. Rotate remaining assembly to left and remove assembly from aircraft. Note spacers and washers on each end and between support blocks.
Page 254 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-8. Rudder Controls 27- 21 - 00 1K21 Page 27 - 22 Reissued: August 1, 1986...
Page 255 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-9. Rudder Rigging Tool Figure 27-10. Clamping Rudder Pedals Figure 27-11. Rudder Rigging 27- 21 - 00 1K22 Page 27 - 23 Reissued: August 1, 1986...
Page 256 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL RUDDER CONTROL CABLES REMOVAL OF RUDDER CONTROL CABLES (figure 27-8) Remove access panel to aft section of fuselage. 2. Disconnect desired cable at turnbuckle in aft section of fuselage. 3. Remove either forward rudder cable as follows: a.
Page 257 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. Install aft rudder control cables as follows: a. Position control cable in fuselage. b. Connect end of cable to rudder horn with bolt, washer, nut, and cotter pin. Allow cable end to rotate freely.
Page 258 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 4. Disconnect housing lug from arm on rudder pedal torque tube by removing cotter pin, nut, washer, and bolt. 5. Remove threaded bushing from aft end of mounting channel by removing cotter pin and clevis pin.
Page 259 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-l2. Rudder Travel Adjustments Figure 27- l 3 . Rudder Trim Control 27- 31 - 00 Page 27 - 27 Reissued: August 1, 1986...
Page 260 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. Remove either forward stabilator cable as follows: a. Remove tunnel carpet and cover plate as follows: (l) Remove rudder trim covers by removing knobs and attaching screws. (2) Remove tunnel plate located just aft of tee bar by laying back enough tunnel carpet to remove plate attaching screws.
Page 261 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-l4. Stabilator Controls 27- 31 - 00 Page 27 - 29 Reissued: August 1, 1986...
Page 262 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-l5. Stabilator and stabilator Trim Travel Adjustments Figure 27-l6. Stabilator Rigging Tool 27- 31 - 00 Page 27 - 30 Reissued: August 1, 1986...
Page 263 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Install floor tunnel plate and trim covers as follows: (l) Install floor tunnel plate and secure with attachment screws. (2) Fasten tunnel carpet into place. (3) Replace rudder trim covers and rudder trim knob. Install front seats and rear seat bottom on floor panel.
Page 264 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL f. Check safety of all turnbuckles and bolts. g. With tension of upper cable correct and control wheel still forward, adjust turnbuckle of lower cable to obtain correct tension. h. Check full travel of control wheel with relation to full travel of stabilator to determine that stabilator contacts its stops before control wheel contacts its stops.
Page 265 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-l7. Methods of Securing Trim Cables g. If installed, remove cable pulleys within aft section of fuselage at station l56.5 by removing nut, washer, bushing, and bolt. h. With cables disconnected from trim control wheel, draw cable(s) through floor tunnel.
Page 266 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-18. Stabilator Trim Control 27- 33 - 00 Page 27 - 35 Reissued: August 1, 1986...
Page 267 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL e. Align control cables and position control wheel assembly between its mounting brackets. Ensure that end of trim indicator wire is positioned in spiraled slot of the drum with no bind on the end. Install retainer bolt from left side and install washer and nut.
Page 268 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF STABILATOR TRIM ASSEMBLY (AFT) (figure 27-l8) 1. Wrap trim barrel as follows: a. Lay center (as measured equally from each end to center of cable) of trim cable in slot of barrel. b. Bring upper cable through diagonal slot in flange at upper end of barrel and wrap down in a counterclockwise direction.
Page 269 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 12. Turn trim wheel to full travel and check for turnbuckle clearance, interference between turn- buckles and pulleys, and location of tab indicator. FLAPS WING FLAP CONTROLS REMOVAL OF WING FLAP CONTROLS (figure 27-l9) 1. Remove flap torque tube assembly as follows: a.
Page 270 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-l9. Flap Controls 27- 51 - 00 1L13 Page 27 - 38 Interim Revision: February 15, 1995...
Page 271 3. Install flap control cable as follows: a. Attach cable and turnbuckle to flap handle arm and secure with clevis bolt, bushing*, washer, nut and cotter pin. Ensure that turnbuckle end is free to rotate on arm. *(See latest revision of Piper Service Bulletin 965.) b.
Page 272 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-20. Flap Step Adjustment Figure 27-2l. Flap Rigging Tool 27- 51 - 00 1L15 Page 27 - 40 Reissued: August 1, 1986...
Page 273 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL RIGGING AND ADJUSTMENT OF WING FLAPS Place flap handle in full forward position. 2. If not done previously, remove rear seats. 3. To adjust flap up stop and step lock, loosen jam nut of right torque tube stop screw, located in floor opening along outer end of flap torque tube, and turn stop screw to obtain approximately 0.60 of an...
Page 274 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STALL WARNING STALL WARNING HORN, INDICATOR, AND DETECTOR The stall warning system consists of a lift detector electrically connected to a stall warning horn. As stalling conditions are approached, lift detector will activate stall warning horn.
Page 275 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 27-22. Flap Rigging 27- 91 - 00 1L18 Page 27 - 43 Reissued: August 1, 1986...
Page 276 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GRIDS 1L19 THRU 1L24 INTENTIONALLY LEFT BLANK 1L19...
Page 277 DAKOTA MAINTENANCE MANUAL CARD 2 OF 3 PA-28-236 DAKOTA PIPER AIRCRAFT CORPORATION (PART NUMBER 761 681 )
Page 278 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INTRODUCTION This Piper Aircraft maintenance manual is prepared in accordance with the General Aviation Manufacturers Association format, Introduction Page - 1 Reissued: August 1, 1986...
Page 279 PA-28-236 MAINTENANCE MANUAL VENDOR PUBLICATIONS —WARNING— When servicing or inspecting vendor equipment- installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publication. ENGINE: Overhaul Manual = AVCO LYCOMING - OVERHAUL MANUAL DIRECT DRIVE ENGINE - P/N 60294-7 Avco Lycoming Division Williamsport, Pa.
Page 280 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PIPER PUBLICATIONS COMMUNICATIONS: Removal, Installation and Maintenance Instructions = 761 502 AutoControl III B Service Manual 761 481 AutoFlite II Service Manual 753 771 Pitch Trim Service Manual Radio Service and Maintenance Manual = 761 685 Avionics Wiring Diagram Service Manual...
Page 281 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS The maintenance manual information incorporated in this set of Aerofiche cards has been arranged in accordance with general specifications for Aerofiche adopted by the General Aviation Manufacturer’s Association, The information in this Aerofiche maintenance manual is kept current by revisions distributed...
Page 282 The date on Aerofiche cards must not be earlier than the date noted for the respective card eff e c t i v i t y. Consult the latest Aerofiche card in this series for current Aerofiche card effectivity. SERIAL NUMBER INFORMATION PA-28-236, DAKOTA- l979 Serial Numbers 28-7911001 to 28-7911395 inclusive. PA-28-236, DAKOTA- l980 Serial Numbers 28-8011001 to 28-8011161 inclusive.
Page 283 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GAMA SYSTEM/CHAPTER INDEX GUIDE SYST SUB-SYST AEROFICHE CHAP SECTION TITLE GRID NO AIRWORTHINESS LIMITATIONS lA17 TIME LIMITS/MAINT CHECKS 1A21 DIMENSIONS AND AREAS 1B12 LIFTING AND SHORING 1B20 LEVELING AND WEIGHING TOWING AND TAXIING PARKING AND MOORING...
Page 284 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GAMA SYSTEM/CHAPTER INDEX GUIDE (cont) SYST SUB-SYST AEROFICHE CHAP SECTION TITLE GRID NO STRUCTURES 2E19 DOORS 2F13 STABILIZERS 2F21 WINDOWS WINGS 2G12 PROPELLER STANDARD PRACTICES - ENGINE 2H10 POWERPLANT 2H14 ENGINE FUEL SYSTEM 2I10 IGNITION...
Page 285 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. 6-1. Three View 1B17 6-2. Station References 1B18 6-3. Access Plates and Panels 1B19 7-1. Jacking Arrangement 1B23 8-1. Weighing Airplane 8-2. Leveling Longitudinally 8-3. Leveling Laterally 11-1.
Page 286 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. 21-15. Components Installation 21-16. Overhead Vent System (Not Available with Air Conditioning) 23-1. Avionics Master and Emergency Switch Circuit 1H14 23-2. Communications Components ELT Schematic 1H16 23-3.
Page 287 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 24-34. Testing Rotor for Shorts 24-35. Installation of Bearing 24-36. Installation of Rectifier 24-37. Terminal Assembly 24-38. Slip Ring End Bearing Assembly 24-39. Testing Alternator 24-40.
Page 288 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont.) FIGURE NO. SUBJECT GRID NO. 32-7. Main Wheel Assembly 32-8. Nose Wheel Assembly 32-9. Standard Brake Assembly (Cleveland 30-55) 32-10. Heavy Duty Brake Assembly (Cleveland 30-65) 32-11. Removal and Installation of Anchor Bolts 2C10 32-12.
Page 289 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 73-2. Engine Primer 2I14 73-3. Adjustment of Engine Controls 2I16 74-1. Height of Spring in Distributor Block Tower 2I24 74-2. Contact Points 2I24 74-3. Engine Timing Marks 74-4.
Page 290 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 95-1. Tire Balancer Fixture 95-2. Control Surface Balancing Tool 95-3. Orifice Replacement Tool 95-4. Fabricated Tool for Baggage Door Lock 95-5. Retainer Ring Tool 95-6. Fabricated Aileron Bellcrank Rigging Tool 95-7.
Page 291 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CHARTS CHART NO. SUBJECT GRID NO. Leading Particulars and Principal Dimensions 1B15 1201 Thread Lubricants 1D11 1202 Type of Lubricants 1D12 2001 Thread Lubricants 1E10 2002 Maximum Distance Between Supports For Fluid Tubing...
Page 292 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CHARTS (cont) FIGURE NO. SUBJECT GRID NO. 7705 Troubleshooting (Exhaust Gas Temperature Gauge) (Alcor) 7706 Troubleshooting (Cylinder Head Temperature Gauge) 8001 Troubleshooting (Starter) 2K22 8002 Starting Motor Specifications 9101 Flare Fitting Torques 3A19...
Page 293 CHAPTER FUEL 2A17...
Page 294 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 28 - FUEL TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 28-00-00 GENERAL 2A19 28-01-00 Description 2A19 28-02-00 Troubleshooting 2A19 28-10-00 STORAGE 2A23 28-11-00 Fuel Tank 2A23 28-11-00 Removal of Fuel Tank 2A23...
Page 295 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL The fuel system components covered in this chapter consist of the fuel tanks, selector valve, filter screens, fuel pump, and quantity transmitter units. Instructions are given for fixing problems which may arise in the normal operation of the fuel system.
Page 296 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 28-1. Fuel System Diagram 28 - 02 - 00 2A20 Page - 28-02 Reissued: August 1, 1986...
Page 297 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2801. TROUBLESHOOTING (FUEL SYSTEM) TROUBLE CAUSE REMEDY Failure of fuel to flow. Blockage in fuel line. Flush fuel system. Blockage of cap vent. Check and clean vent hole in cap. Failure of mechanical or Check and replace if nec- electrical fuel pump.
Page 298 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2801. TROUBLESHOOTING (FUEL SYSTEM) (cont) TROUBLE CAUSE REMEDY No fuel pressure indication. Defective gauge. Replace gauge. (cont) Failure of fuel selector to be Check position of selector and in proper position. adjust if required.
Page 299 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STORAGE FUEL TANK REMOVAL OF FUEL TANK 1. Drain fuel from fuel tank. (Refer to chapter 12.) 2. Remove screws from around perimeter of tank assembly. 3. Disconnect fuel line attached to tank. 4. Pull tank away from wing assembly far enough to gain access to sender wire.
Page 300 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 28-2. Locking Fuel Cap Assembly 3. Reinstall nut securing key lock to cover. 4. Attach pawl to back of lock assembly with screw previously removed. Use Loctite 271 on screw. 5. Reinstall two screws on back of fuel cap. Use Loctite 271 on threads.
Page 301 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF FUEL SELECTOR VALVE —CAUTION— Seal all threads with PST-5674-7 Loctite thread sealant to prevent loosening. 1. Secure valve to bulkhead with screws. 2. Connect fuel lines to valve. 3. Install side panel. 4. Install selector cover with attaching screws.
Page 302 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 28-3. Fuel Filter Bowl and Screen Figure 28-4. Plunger Fuel Pump 28 - 00 - 00 Page - 28-08 Reissued: August 1, 1986...
Page 303 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. Ensure that fuel shutoff valve is in OFF position. 3. Disconnect fuel lines from inlet and outlet sides of pump. 4. Remove nuts and bolts securing pump to forewall and remove fuel pump. DISASSEMBLY OF ELECTRIC FUEL PUMP Repair of the pump is limited to the fuel reservoir area only, as the electrical system is sealed.
Page 304 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ASSEMBLY OF FUEL PUMP (figure 28-4) 1. Insert plunger assembly (10) in tube with buffer spring end first. Check fit by slowly raising and lowering plunger to see if it sticks. If a click cannot be heard, interrupter assembly is not functioning properly and pump must be replaced.
Page 305 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF ELECTRIC FUEL PUMP 1. Position fuel pump to firewall and secure with bolts, washers, and nuts. 2. Connect fuel lines to pump. 3. Connect electrical leads to pump. 4. Turn fuel shutoff ON and operate fuel pump. Check all fuel line fittings for leakage.
Page 306 AC 43.13-lA, paragraph 392. This will require cutting off the swaged ferrule and adding a short length of tubing. 3. If a Piper replacement tube and union is being used, the ferrule is pre-swaged onto the tube. Install the pre-fabricated tube as follows: a.
Page 307 —CAUTION— The inboard and outboard senders are different units in that one unit (Piper P/N 550 504) requires fiber insulating washers. When removing bolts and washers from this unit, be careful not to damage fiber insulating washers. Make sure when reinstalling sender to use correct bolts and washers.
Page 308 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. Apply Lubon No. 404 sealant to male threads of five bolts, and secure sender unit to tank. Remove any excess sealant from bolts before and after installation. —NOTE— Ensure that correct arrangement of washers and insulators are used upon installation of sender units.
Page 309 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 2802. TRANSMITTER/FUEL GAGUE TOLERANCES Tolerance Actual Fuel in Gauge Reading (Plus or Minus) Tank (U.S. Gal.) (U.S. Gal.) (Needle-Widths) Full 32.5 22.5 12.5 ±1/2 Zero Plus 0 - Minus 1/2 0 Empty Empty Dot ±1/2...
Page 310 CHAPTER LANDING GEAR 2B10...
Page 311 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 32 - LANDING GEAR TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 32-00-00 GENERAL 2B13 32-01-00 Description 2B13 32-02-00 Troubleshooting 2B13 32-10-00 MAIN GEAR 2B16 32-11-00 Main Gear Oleo 2B16 32-11-00 Disassembly of Main Gear Oleo...
Page 312 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 32 - LANDING GEAR (CONT) TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 32-40-00 WHEELS AND BRAKES (cont) 32-44-00 Master Cylinder (Hand Brake) 2C12 32-44-00 Removal of Brake Master Cylinder (Hand Brake) 2C12...
Page 313 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter contains instructions for removal, disassembly, inspection, overhaul, installation and alignment of landing gear and brake system components. DESCRIPTION The landing gear is a fixed tricycle type, fitted with three 6.00 x 6 wheels. The landing gear struts are the air-oil type.
Page 314 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3201. TROUBLESHOOTING (LANDING GEAR) TROUBLE CAUSE REMEDY Nose landing gear shimmies Internal wear in shimmy Replace shimmy dampener. during fast taxi, take-off, or dampener. landing. Worn steering horn bolt Replace horn assembly. holes. Excessive free play in Rework or replace.
Page 315 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3201. TROUBLESHOOTING (LANDING GEAR) (cont) TROUBLE CAUSE REMEDY Nose gear fails to steer Steering bungee broken Replace. properly. (cont) internal spring. Binding in either rudder Grease. trim or steering bungee. Main landing gear shimmies Tire out of balance.
Page 316 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL MAIN GEAR MAIN GEAR OLEO DISASSEMBLY OF MAIN GEAR OLEO (figure 32-1) The main gear axle and piston tube assembly can be removed from the cylinder housing with either the gear removed from or installed on the airplane. On some airplanes the metering components of the gear that are located in the top of the housing may be removed, but only with the gear removed from the airplane.
Page 317 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-1. Main Gear Oleo Strut Assembly 32 - 11 - 00 2B17 Page - 32-05 Reissued: August 1, 1986...
Page 318 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ASSEMBLY OF MAIN GEAR OLEO (figure 32-1) 1. Install orifice assembly, if removed, as follows: a. Lubricate an O-ring with hydraulic fluid (MIL-H-5606) and install in annular slot in metering orifice. b. Insert orifice through opening in top of gear housing and turn it into threaded hole web. Tighten orfice with use of a stud type spanner wrench.
Page 319 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-2. Main Gear Installation 32 - 12 - 00 2B19 Page 32 - 07 Reissued: August 1, 1986...
Page 320 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. If desired, remove air from oleo chamber by depressing air valve core in inspection hole on top of wing. After pressure in oleo chamber has diminished, remove valve core pin. Attach a small hose to air valve and drain fluid by slowly compressing piston tube.
Page 321 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-3. Nose Gear Oleo Strut Assembly 32 - 21 - 00 2B21 Page - 32-09 Reissued: August 1, 1986...
Page 322 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5. Remove strut assembly from strut housing as follows: a. Cut safety wire at top of housing that secures steering horn attaching bolt to tube retainer nut. b. Remove steering horn attaching bolts thus relieving steering horn from top of strut housing.
Page 323 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL NOSE GEAR OIL ORIFICE RETAINER RING INSTALLATION (figures 32-3 and 32-4) 1. With piston tube and fork removed from cylinder, ensure all traces of old retainer ring are removed from metering tube. 2. A tool may be fabricated to simplify installation of new retainer ring. (Refer to chapter 95.) 3.
Page 324 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL NOSE LANDING GEAR ASSEMBLY REMOVAL OF NOSE LANDING GEAR (figure 32-4) 1. Remove engine cowling. (Refer to chapter 71.) 2. Remove propeller. (Refer to chapter 61.) 3. Place airplane on jacks. (Refer to chapter 7.) 4.
Page 325 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-4. Nose Gear Installation 32 - 22 - 00 Page - 32-13 Reissued: August 1, 1986...
Page 326 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ALIGNMENT OF NOSE GEAR 1. Place airplane on a smooth level floor that will accommodate striking of a chalk 1ine. 2. Place airplane on jacks. (Refer to chapter 7.) 3. Level airplane laterally and longitudinally. (Refer to chapter 8.) 4.
Page 327 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-5. Clamping Rudder Pedals Figure 32-6. Rudder Pedals at Neutral Angle in Neutral Position WHEELS AND BRAKES MAIN WHEEL ASSEMBLY REMOVAL AND DISASSEMBLY OF MAIN WHEEL ASSEMBLY (figure 32-7) 1. Place airplane on jacks. (Refer to chapter 7.) 2.
Page 328 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-7. Main Wheel Assembly 32 - 41 - 00 Page - 32-16 Reissued: August 1, 1986...
Page 329 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSPECTION OF MAIN WHEEL ASSEMBLY 1. Visually check all parts for cracks, distortion, defects, and excess wear. 2. Check tie bolts for looseness or failure. 3. Check internal diameter of felt grease seals. Replace felt grease seal if surface is hard or gritty.
Page 330 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-8. Nose Wheel Assembly 32 - 42 - 00 Page - 32-18 Reissued: August 1, 1986...
Page 331 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSPECTION OF NOSE WHEEL ASSEMBLY 1. Visually check all parts for cracks, distortion, defects, and excess wear. 2. Check tie bolts for looseness or failure. 3. Check internal diameter of felt grease seals. Replace felt grease seal if surface is hard or gritty.
Page 332 5. Remove lining from backing plates by drilling or punching out the old rivets, and installing a new set using proper rivets and a rivet set that will properly stake lining and form a correct flare of rivet. A rivet setting kit is available through Piper dealers under Part Number 754 165. 32 - 43 - 00...
Page 333 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-10. Heavy Duty Wheel Brake Assembly (Cleveland 30-65) 32 - 43 - 00 Page - 32-21 Reissued: August 1, 1986...
Page 334 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-11. Removal and Installation of Anchor Bolts 32 - 43 - 00 2C10 Page - 32-22 Reissued: August 1, 1986...
Page 335 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-12. Brake Disc Minimum Thickness Figure 32-13. Brake System Installation 32 - 43 - 00 2C11 Page - 32-23 Reissued: August 1, 1986...
Page 336 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —NOTE— New brake linings must be properly conditioned in order to provide optimum servicing life. Conditioning linings is accomplished by performing a minimum of six light pedal effort braking applications from 25 to 40 mph. Allow the brake discs to partially cool between stops.
Page 337 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-14. Brake Master Cylinder (Hand/Parking Brake) CLEANING, INSPECTION, AND REPAIR OF MASTER CYLINDER (HAND BRAKE) 1. Clean cylinder pans with a suitable solvent and dry thoroughly. 2. Inspect interior walls of cylinder for scratches, burrs, corrosion, etc.
Page 338 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. Insert piston rod assembly in housing and secure packing gland with snap ring. 4. Install cylinder. (Refer to Installation of Brake Master Cylinder.) INSTALLATION OF MASTER CYLINDER (HAND BRAKE) (figure 32-12) 1. Install brake handle assembly in its mounting bracket and secure with bolt, washers, nut, and cotter pin.
Page 339 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-15. Toe Brake Installation 32 - 45 - 00 2C15 Page - 32-27 Reissued: August 1, 1986...
Page 340 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 32-16. Brake Cylinder (10-30) (Toe Brake) Figure 32-17. Brake Cylinder (17000) (Toe Brake) 32 - 45 - 00 2C16 Page - 32-28 Reissued: August 1, 1986...
Page 341 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CLEANING, INSPECTION, AND REPAIR OF BRAKE CYLINDER 1. Clean cylinder parts with a suitable solvent and dry thoroughly. 2. Inspect interior walls of cylinder for scratches, burrs, corrosion, etc. 3. Inspect general condition of cylinder fitting threads.
Page 342 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. Ensure that right toe brake pedals have been pulled full aft. 4. Pull hand brake handle and slowly pump master cylinder approximately 50 times or until hydraulic fluid is observed passing through plastic tube at brake bleeder.
Page 343 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL BRAKE SYSTEM LEAK CHECK 1. Pull brake handle and lock parking brake. 2. Allow system to stand for approximately 10 minutes, then pull brake handle. It should not be able to be pulled further than originally set.
Page 344 CHAPTER LIGHTS 2C20...
Page 345 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 33 - LIGHTS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 33-00-00 GENERAL 2C22 33-01-00 Description and Operation 2C22 33-02-00 Troubleshooting 2C22 33-10-00 FLIGHT COMPARTMENT 33-11-00 Instrument Panel Lights 33-12-00 Dimmer Control Assembly...
Page 346 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter provides instructions for maintenance of the lighting equipment on this aircraft. DESCRIPTION AND OPERATION Electrical switches are located on the right center instrument panel, and the circuit breakers are located on the lower right instrument panel. A rheostat switch on the left side of the switch panel controls the navigational lights and radio lights.
Page 347 PIPER AIRCRAFT PA-28-181 MAINTENANCE MANUAL CHART 3301. TROUBLESHOOTING (ELECTRICAL SYSTEM) Trouble Cause Remedy ANNUNCIATOR PANEL All warning lights fail to Blown fuse. Replace 5 amp fuse behind operate. instrument panel. No current from bus. Check all wire segments, connections, and recep- tacle at left side of annunciator panel.
Page 348 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3301. TROUBLESHOOTING (ELECTRICAL SYSTEM) (cont) Trouble Cause Remedy ANNUNCIATOR PANEL (cont) VAC warning light fails to Sensor activates at a too Replace. extinguish. high setting. Sensor terminals bridged. Remove material between terminals. Defective sensor.
Page 349 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL FLIGHT COMPARTMENT INSTRUMENT PANEL LIGHTS The instrument panel lights are controlled by transistorized dimmer control unit and protected by a 5 amp circuit breaker located on the right center instrument panel. There are two control knobs. One is for panel lights and the other for radio lights.
Page 350 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL The OIL warning light is controlled by an oil pressure sensor switch incorporated in the oil line and is located at the firewall. The sensor switch activates when oil pressure is below 35 psi. The ALT warning light is illuminated by current flowing from the bus bar to the alternator circuit. This condition exists when the alternator is not operating properly and output is zero.
Page 351 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ROTATING BEACON REMOVAL OF ROTATING BEACON 1. Loosen screw securing clamp around rotating beacon lens. Remove clamp and lens. 2. Remove light bulb from bayonet socket. 3. To remove complete rotating beacon assembly, proceed as follows: a.
Page 352 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 33-l. Strobe Light Connections 33 - 44 - 00 Page 33 - 07 Reissued: August 1, 1986...
Page 353 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STROBE POWER SUPPLY REMOVAL OF STROBE POWER SUPPLY —WARNING— Disconnect battery before removal of power supply to prevent electrical shock. The strobe power supply is in the fuselage aft section. Remove access panel to the aft section of fuselage in rear baggage compartment.
Page 354 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 1. Ensure power supply input voltage is 14-volts. 2. Check for malfunction in interconnecting cables. a. Ensure pins 1 and 3 of interconnecting cable are not reversed. b. With an ohmmeter, checlc continuity between pins l and 3 of interconnecting cable. If a reading is obtained on the meter, cable is shorted and must be replaced.
Page 355 CHAPTER NAVIGATION AND PITOT/ STATIC...
Page 356 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 34 - NAVIGATION AND PITOT/STATIC TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 34-00-00 GENERAL 34-01-00 Description and Operation 34-02-00 Removal and Installation of Face Mounted Instruments 34-03-00 Gyro Fitting Installation Procedure (Edo Aire)
Page 357 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL The instrument air system consists of pitot air and static air sources. The system supplies both pitot and static air pressurc for the airspeed indicator, altimeter and rate of climb indicator. These instruments are face mounted.
Page 358 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GYRO FITTING INSTALLATION PROCEDURE (EDO-AIRE) The use of Teflon tape on fitting threads is recommended. Install Teflon tape as follows: —CAUTION— Permit no oil, grease, pipe compound, or any foreign material to enter ports prior to installation of fittings. Make sure that all air lines are clean and free of foreign particles or residue before connecting lines to gyro.
Page 359 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 34 1. Pitot/Static System 34 - 03 - 00 2D11 Page 34 - 03 Reissued: August 1, 1986...
Page 360 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL REMOVAL AND REPLACEMENT OF CLUSTER MOUNTED INSTRUMENTS A cluster, located on the instrument panel, contains five individual instruments. Remove these instruments as follows: 1. Remove face panel by pulling panel free from retainers. 2. With face panel removed, clear plastic cover on cluster assembly is exposed. Remove cover and cluster by removing two mounting screws.
Page 361 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3401. TROUBLESHOOTING (RATE OF CLIMB INDICATOR) (cont) Trouble Cause Remedy Pointer oscillates. Leaks in static lines. Disconnect all instruments connected to the static line. Check individual instru- ments for leaks. Reconnect instruments to static line and test installation for leaks.
Page 362 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3402. TROUBLESHOOTING (ALTIMETER) Trouble Cause Remedy Excessive scale error Improper calibration ad- Calibrate or replace justment. instrument. Excessive pointer oscil- Defective mechanism. Replace instrument. lation. High or low reading. Improper venting. Eliminate leak in static pressure system and check alignment of airspeed tube.
Page 363 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3402. TROUBLESHOOTING (ALTIMETER) (CONT) Trouble Cause Remedy Altimeter changes reading Water in static line. Remove static lines from all as aircraft is banked. instruments, and blow line clear from cockpit to pitot head. Altimeter requires re- Temperature compensator Change instrument.
Page 364 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3403. TROUBLESHOOTING (AIRSPEED TUBES AND INDICATOR) (cont) Trouble Cause Remedy Instrument reads low. Internal fault. Replace instrument. Leaking static system. Find leak and correct. Pitot head not aligncd Realign pitot head. correctly. Airspeed changes as aircraft Watcr in pitot line.
Page 365 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL TROUBLESHOOTING Unless an obvious malfunction (such as inability to erect, spinning, or great horizon bar displacement none of which can be corrected by manually caging the instrument) requires repair or replacement of the gyro, service is restricted to instrument installation and power source. Typical installation examples of artificial...
Page 366 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL AIR DRIVEN DIRECTIONAL GYRO The air driven D.G. is driven by the engine driven dry-pneumatic pumps either on pressure or vacuum. Air volume, and not air pressure, spins the gyro rotor. The air filter can become contaminated and restrict airflow, reducing gyro rotor speed, while the pressure regulator will automatically adjust air pressure within proper limits.
Page 367 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL MAGNETIC COMPASS The magnetic compass is a self-contained instrument. This instrument has a light connected to the instrument lighting circuit. The compass correction card is located in the card holder mounted on the instrument. The compass should be swung whenever instruments or radios are changed or once a year whichever comes first.
Page 368 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3404. TROUBLESHOOTING (MAGNETIC COMPASS) (cont.) Trouble Cause Remedy Liquid leakage. Loose bezel screws. Replace instrument. Broken cover glass. Replace instrument. Defective sealing gaskets. Replace instrument. Discolored markings. Age. Replace instrument. Defective light. Burned out lamp or broken Check lamp or continuity circuit.
Page 369 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 34 - 17 - 00 2D21 Page 34 - 13 Reissued: August 1, 1986...
Page 370 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2D22...
Page 371 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2D23...
Page 372 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2D24...
Page 373 CHAPTER VACUUM...
Page 374 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 37 - VACUUM TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 37-00-00 GENERAL 37-01-00 Desription and Operation 37-02-00 Troubleshooting 37-10-00 DISTRIBUTION 37-11-00 Vacuum System Service Tips 37-l2-00 Vacuum Pump 37-l2-00 Removal of Vacuum Pump...
Page 375 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL The instrumentation in this airplane gives a quick and accurate indication of airplane attitude, performance, and condition. Maintenance, other than described, should be done by the instrument manufacturer or an authorized repair station. DESCRIPTION AND OPERATION The vacuum system employed to operate the gyro instruments comprises an engine driven dry vacuum pump, vacuum regulator and filter, and necessary tubing.
Page 376 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 3701. TROUBLESHOOTING (VACUUM SYSTEM) (contd) TROUBLE CAUSE REMEDY Normal pressure indication Faulty instrument. Replace instrument. but sluggish operation of instruments. High system pressure. Incorrectly adjusted Adjust regulator. vacuum regulator. Sticking vacuum regulator Clean and check operation or dirty screen.
Page 377 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 370L. TROUBLESHOOTING (VACUUM SYSTEM) (CONT,D) AIRCRAFT WITH AUXILIARY VACUUM PUMP SYSTEMS TROUBLE CAUSE REMEDY AUX ON selected on Circuit breaker open. Push circuit breaker(s) ground check and auxiliary vacuum pump will not run Faulty electrical motor.
Page 378 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL DISTRIBUTION VACUUM SYSTEM SERVICE TIPS —CAUTION— When replacing any threaded fittings, DO NOT USE PIPE DOPE or any other anti-seize tape or compound. The AIRBORNE fittings are all cadmium plated to avoid the need for any other anti-seize materials.
Page 379 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. Service gyro filters on a scheduled basis, not to exceed 100 hours, or as conditions indicate. The system comprises a large central filter and differential vacuum gauge that continuously monitors filter condition while indicating vacuum readings.
Page 380 INSTALLATION OF VACUUM PUMP —CAUTION— The only pump mounting gasket approved for use on Airborne vacuum pumps is the Airborne gasket B3-1-2, Piper part number 751 859. Any other gasket may allow oil seepage or leakage at mounting surface. Place pump gasket in place and align spline on pump drive with spline on engine drive assembly.
Page 381 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL VACUUM REGULATOR VALVE A vacuum regulator valve is incorporated in the system to control vacuum pressure to gyro instruments. The regulator valve is located under the instrument panel. ADJUSTMENT OF VACUUM REGULATOR VALVE 1. Loosen locking nut or remove protective cap from valve, depending on which type is installed.
Page 382 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INDICATING VACUUM GAUGE A suction gauge is mounted on the right side of the instrument panel. This gauge is calibrated in inches of mercury and indicates the amount of vacuum in the system. The suction gauge has a direct pressure line and a vent line.
Page 383 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL AUXILIARY VACUUM PUMP (SERIAL NUMBERS 8611001 AND UP) (figure 37-1) —CAUTION— Replace auxiliary vacuum pump/motor assembly with a new, working unit, or send unit to vendor for repair. It is important that pump/motor assembly be repaired by trained personnel, to ensure proper operation.
Page 384 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 37-1. Auxiliary Vacuum Pump Installation 37 - 22 - 00 2E12 Page 37 - 10 Reissued: August 1, 1986...
Page 385 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL REMOVAL OF AUXILIARY PUMP —WARNING— Be sure that battery master is OFF before beginning any work on electrical components to prevent electrical shock. —WARNING— Cover auxiliary pump switch on instrument panel with an INOP placard, if a replacement auxiliary pump/motor assembly is not installed before the next flight.
Page 386 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF AUXILIARY VACUUM PUMP —WARNING— Be sure that battery master switch is OFF before working with electrical components to prevent electrical shock. —CAUTION— The elapsed time indicator is matched to pump/motor assembly and must be removed and replaced with pump/motor assembly.
Page 387 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2E15...
Page 388 CHAPTER ELECTRIC/ELECTRONIC PANELS AND MULTIPURPOSE PARTS 2E16...
Page 389 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 39 - ELECTRIC/ELECTRONIC PANELS AND MULTIPURPOSE PARTS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 39-40-00 MULTIPURPOSE ELECTRICAL AND ELECTRONIC PARTS 2E18 39-41-00 Electrical Switches and Circuit Breakers 2E18 39-41-00 Removal of Electrical Switches 2E18 —NOTE—...
Page 390 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL MULTIPURPOSE ELECTRICAL AND ELECTRONIC PARTS ELECTRICAL SWITCHES AND CIRCUIT BREAKERS The switches are of the rocker type. The switches are mounted in the middle of the instrument panel. The circuit breakers are single hole mounting, pushbutton type with manual reset; they must be reset when tripped.
Page 391 CHAPTER STRUCTURES 2E19...
Page 392 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 51 - STRUCTURES TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 51-00-00 GENERAL 2E21 51-01-00 Description 2E21 51-10-00 STRUCTURAL REPAIRS 2E21 51-11-00 Baggage Compartment Inspection Hole and Cover Plate 2E21 51-11-00 Fiberglass Repairs...
Page 393 BAGGAGE COMPARTMENT INSPECTION HOLE AND COVER PLATE. (See latest revision of Piper Service Bulletin 977.) a. General. Airplanes manufactured before 1979 may not have had control cable inspection access holes in the baggage compartment floor.
Page 394 Repair kit, part number 756 729 furnishes materials necessary for such repairs, and is available through Piper Aircraft Dealers. —CAUTION—...
Page 395 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 51-1. Skin Materials and Thickness 51 - 11 - 00 2E23 Page 51 - 03 Reissued: August 1, 1986...
Page 396 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 51-1. Skin Materials and Thickness (cont.) 51 - 11 - 00 2E24 Page 51 - 04 Reissued: August 1, 1986...
Page 397 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 51-1a. Baggage Compartment Inspection Holes Cutout Details 51 - 11 - 00 Page 51 - 05 Interim Revision: February 15, 1995...
Page 398 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL FIBERGLASS TOUCH-UP AND SURFACE REPAIRS 1. Remove wax, oil, and dirt from around damaged area with acetone, methylethylketone, or equivalent and remove paint to gel coat. 2. Scrape damaged area with a fine blade knife or a power drill and burr attachment to roughen bottom and sides of damaged area.
Page 399 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 6. Prepare a patch of fiberglass mat and cloth to cover area two inches larger than hole. 7. Mix small amount of resin and catalyst according to kit instructions. 8. Thoroughly wet mat and cloth with catalyzed resin. Apply mat to structures surface with cloth on top.
Page 400 PIPER AIRCRAFT PA-28-181 MAINTENANCE MANUAL CHART 5101. LIST OF MATERIALS (THERMOPLASTIC REPAIR) ITEMS DESCRIPTIONS SUPPLIERS Buffing and rubbing Automotive Type - DuPont DuPont Company compounds Wilmington, Del. 19898 Ram Chemical #69 x 1 Ram Chemicals Gardena, Cal. 90248 Mirror Glaze #l Mirror Bright Polish Co., Inc.
Page 401 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 51-2. Surface Scratches, Abrasions or Ground-in-Dirt 1. Surface preparation: a. Surface dirt and paint if applied must be removed from item being repaired. b. Preliminary cleaning of damaged area with perchlorethylene or VM-P Naphtha will ensure a good bond between epoxy compounds and thermoplastic.
Page 402 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 51-3. Deep Scratches, Shallow Nicks and Small Holes Figure 51 4. Mixing of Epoxy Patching Compound 51 - 12 - 00 Page 51 - 10 Reissued: August 1, 1986...
Page 403 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL d. For larger damages, an epoxy patching compound is recommended. This type material is a two part, fast curing, easy sanding commercially available compound. —NOTE— Increase adhesion by roughing bonding surface with sandpaper and by using as much surface area for bond as possible.
Page 404 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 51-5. Welding Repair Method Figure 51-6. Repairing of Cracks 51 - 12 - 03 Page 51 - 12 Reissued: August 1, 1986...
Page 405 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 51-7. Various Repairs 51 - 12 - 00 Page 51 - 13 Reissued: August 1, 1986...
Page 406 Safety Solvent per MIL-S-18718 Sherwin William’s Lacquer Thinner R7KC120 Glidden Thinner No. 207 Safety Walk Material: Walkway Compound and Nonslip Matting (included in Piper part no. 179872) 51 - 13 - 00 2F10 Page 51 - 14 Reissued: August 1, 1986...
Page 407 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 51-8. Repair of Stress Lines Figure 51-9. Repair of Impacted Damage 51 - 12 - 02 2F11 Page 51 - 15 Reissued: August 1, 1986...
Page 408 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL APPLICATION OF LIQUID SAFETY WALK COMPOUND Liquid safety walk compound must be applied and remain in an area, free of moisture for a period of 24 hours minimum after application. Do not apply when surface to be coated is below 50° F. Apply liquid safety walk compound as follows: 1.
Page 409 CHAPTER DOORS 2F13...
Page 410 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 52 - DOORS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 52-00-00 GENERAL 2F15 52-10-00 PASSENGER/CREW 2F15 52-11-00 Cabin Door 2F15 52-11-00 Removal of Door 2F15 52-11-00 Installation of Door 2F15 52-11-00 Adjustment of Door...
Page 411 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This airplane has one entrance door and one baggage door. Both are located on the right side of the fuselage. The baggage door is located aft of the cabin door above the wing trailing edge.
Page 412 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF DOOR LATCH MECHANISM 1. Place latch assembly into position on door. 2. Connect latch pull rod to inside door handle. 3. Replace screws that attach latch plate and mechanism to door. 4. Install door trim upholstery and secure with screws.
Page 413 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ADJUSTMENT OF DOOR SAFETY LATCH 1. To adjust safety latch, remove two screws from latch plate at top of door opening. 2. Remove plate. Turn loop assembly in or out to make necessary adjustments. 3. Replace latch plate and secure with two attachment screws.
Page 414 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL —CAUTION— Do not pre-stretch snubber as this can induce cracks. —CAUTION— Make certain leg of snubber goes under striker plate for side latch and over striker plate for upper latch. (figure 52-1) —NOTE— Normal tack time for Carboline F-1 is 30 - 45 minutes (less in a warm area).
Page 415 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 52-1. Door Snubber Installation 52 - 15 - 00 2F19 Page 52-05 Reissued: August 1, 1986...
Page 416 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL BAGGAGE DOOR REMOVAL OF BAGGAGE DOOR With door open, remove hinge pin from hinge and remove door. INSTALLATION OF BAGGAGE DOOR Place door in position so that hinge halves are properly matched and install hinge pin.
Page 417 CHAPTER STABILIZERS 2F21...
Page 418 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 55 - STABILIZERS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 55-20-00 STABILATOR AND TAB 2F23 55-21-00 Stabilator 2F23 55-21-00 Removal of Stabilator 2F23 55-21-00 Installation of Stabilator 2F23 55-22-00 Stabilator Trim Tab...
Page 419 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STABILATOR AND TAB STABILATOR REMOVAL OF STABILATOR (figure 55-1) —CAUTION— Before entering aft portion of fuselage, attach a stand to tail skid for support. Use a heavy pad to protect inside of fuselage. Be certain to distribute weight on top of bulkheads to prevent damage to fuselage skin.
Page 420 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 1. Insert stabilator in position and install attaching hinge bolts, washers, and nuts. 2. Move trim assembly through cutout in stabilator and attach brackets of assembly to aft bulkhead with bolts, washers, and nuts. Insert trim cable ends into fuselage.
Page 421 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 55-1. Empennage Group Installation 55 - 23 - 00 Page - 55-03 Reissued: August 1, 1986...
Page 422 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 55-2. Methods of Securing Control Cables Figure 55-3. Stabilator Balance 55 - 23 - 00 Page - 55-04 Reissued: August 1, 1986...
Page 423 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL BALANCING BALANCING EQUIPMENT (chapter 95) Balancing must be done with tool capable of measuring unbalance in inch-pounds from centerline of control surface hinge pin. A suggested tool configuration is shown in chapter 95. Other tool configurations may be used, provided accuracy is maintained and recalibration capability is provided.
Page 424 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 6. Remove stabilator trim assembly and aft trim cable in accordance with Removal of Stabilator Trim Assembly (aft), chapter 27. 7. Remove bolt and washer that attaches leading edge of fin to fuselage. 8. Remove nuts, washers, and bolts that secure fin spar to aft bulkhead and remove vertical fin.
Page 425 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 55-4. Rudder Balance 2. Connect tail position light electrical lead at quick disconnect and cover connector with an insulating sleeve. Tie both ends of sleeve with number six electrical lacing twine. 3. Connect control cables to rudder horn with bolts, washers, nuts, and cotter pins.
Page 426 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL a. Nose Heavy: This condition is highly improbable; recheck calculations and measurements. b. Nose Light: Mass balance weight is too light or rudder is too heavy because of painting; it is necessary to strip and repaint. If rudder is too heavy as a result of repairs, repair must be removed and damaged parts replaced.
Page 427 CHAPTER WINDOWS...
Page 428 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 56- WINDOWS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 56-10-00 FLIGHT COMPARTMENT 56-11-00 Windshield 56-11-00 Removal of Windshield 56-11-00 Installation of Windshield 56-20-00 CABIN 56-21-00 Side Windows 56-21-00 Removal of Side Windows...
Page 429 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL FLIGHT COMPARTMENT WINDSHIELD REMOVAL OF WINDSHIELD 1. Remove collar molding from around bottom of windshield and trim strip from between windshield halves by removing attaching screws. 2. Remove windshield by raising lower portion of windshield and carefully pulling it out and downward to release top and side edges.
Page 430 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 56-1. Windshield Installation (Typical) 56 - 21 - 00 2G10 Page - 56-02 Reissued: August 1, 1986...
Page 431 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 56-2. Side Window Installation, Single Pane (Typical) 1. Remove retainer molding from around window by removing attachment screws. 2. Carefully remove window from frame. —NOTE— A damaged window should be saved to provide a pattern for shaping the new window.
Page 432 CHAPTER WINGS 2G12...
Page 433 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 57 - WINGS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 57-00-00 GENERAL 2G14 57-01-00 Description 2G14 57-20-00 AUXILIARY STRUCTURE 2G14 57-21-00 Wing Tip 2G14 57-21-00 Removal of Wing Tip 2G14 57-21-00 Installation of Wing Tip...
Page 434 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter explains removal and installation procedures for wings and related components. DESCRIPTION Each wing is an all metal, full cantilever, semi-monocoque type structure with removable tips and access panels. Attached to each wing are ailerons, flaps, main landing gear, and fuel tanks. The wings are attached to each side of the fuselage by inserting the butt ends of the main spars into a spar box carry through.
Page 435 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 57-1. Wing Installation 57 - 21 - 00 2G15 Page - 57-02 Reissued: August 1, 1986...
Page 436 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 57-1. Wing Installation (cont) 57 - 21 - 00 2G16 Page - 57-03 Reissued: August 1, 1986...
Page 437 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 57-1. Wing Installation (cont) THIS SPACE INTENTIONALLY LEFT BLANK 57 - 21 - 00 2G17 Page - 57-04 Reissued: August 1, 1986...
Page 438 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ATTACH FITTINGS WING TO FUSELAGE ATTACH FITTINGS REMOVAL OF WING (figure 57-1) —CAUTION— To prevent damage or contamination of fuel, hydraulic and miscellaneous lines, place a protective cover over line fittings and ends. 1. Close fuel valve and drain fuel from wing to be removed. (Refer to Draining Fuel System, chapter 12.) 2.
Page 439 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF WING (figure 57-1) 1. Ensure that fuselage is positioned solidly on a support cradle. 2. Place wing in position for installation, with spar end a few inches from side of fuselage and set on trestles.
Page 440 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 57-2. Aileron and Flap Installation 57 - 41 - 00 2G20 Page - 57-07 Reissued: August 1, 1986...
Page 441 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 57-2. Aileron and Flap Installation (cont) 57 - 41 - 00 2G21 Page - 57-08 Reissued: August 1, 1986...
Page 442 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 8. Tighten bolt heads on upper spar cap and nuts on lower spar cap from 360 to 390 inch-pounds. Be certain that bolts, nuts, and washers are installed in accordance with bolt legend. Tighten forward spar attachment nut from 50 to 60 inch-pounds.
Page 443 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF AILERON (figure 57-2) 1. Install balance arm into opening in outboard rib by moving inboard end of aileron forward to allow arm to be inserted through opening. Move aileron into place and install attaching screws and nuts.
Page 444 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Balance control surface as follows: 1. Ensure that control surface is in its final flight configuration with static wicks, trim tabs, trim tab push pull rod, and control surface tip (as applicable) installed. The surface should be painted and trim/servo tabs placed in neutral position.
Page 445 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 10. If static balance is not within limits specified, proceed as follows: a. Leading Edge Heavy: This condition is highly improbable; recheck measurements and calcu- lations. b. Trailing Edge Heavy: (1) There are no provisions for adding weight to balance weight to counteract a trailing edge heavy condition;...
Page 446 CHAPTER PROPELLER...
Page 447 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 61 - PROPELLER TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 61-00-00 GENERAL 61-10-00 PROPELLER ASSEMBLY 61-11-00 Maintenance of Propeller 61-11-00 Removal of Propeller 61-11-00 Cleaning, Inspection and Repair of Propeller 61-11-00 Installation of Propeller...
Page 448 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 61-1. Typical Nicks and Removal Method GENERAL PROPELLER ASSEMBLY MAINTENANCE OF PROPELLER REMOVAL OF PROPELLER (figure 61-2) —WARNING— Master and magneto switches must be OFF before any work is done on the propeller assembly.
Page 449 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CLEANING, INSPECTION, AND REPAIR OF PROPELLER (figure 61-1) 1. Check for oil and grease leaks. 2. Clean spinner, propeller hub interior and exterior, and blades with a non-corrosive solvent. 3. Inspect hub parts for cracks.
Page 450 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 61-2. Propeller Installation 61 - 11 - 00 Page - 61-03 Reissued: August 1, 1986...
Page 451 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 6101. PROPELLER TORQUE LIMITS DESCRIPTION REQUIRED TORQUE Propeller Mounting Nuts 60-70 Foot-Pounds Spinner Attachment Screws 35-40 Inch-Pounds Spinner Bulkhead (Aft) 20-22 Inch-Pounds CHECKING PROPELLER BLADE TRACK Blade track is the ability of one blade tip to follow the other, while rotating, in almost the same plane.
Page 452 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 61-3. Propeller Governor Figure 61-4. Adjustment of Propeller Control 3. Align splines on governor shaft with engine drive and slide governor into position. 4. With governor in position, raise governor enough to install washers and start mounting bolts. Tighten nuts from 140 to 160 inch-pounds.
Page 453 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL b. Adjust governor by means of the fine adjustment screw for 2400 rpm. To do this, loosen high rpm fine adjustment screw locknut. Turn screw in a clockwise direction to decrease engine speed or in a counterclock wise direction to increase engine speed.
Page 454 CHAPTER STANDARD PRACTICES ENGINES 2H10...
Page 455 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 70 - STANDARD PRACTICES - ENGINE TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 70-00-00 STANDARD PRACTICES - ENGINE 2H12 70 - Cont./Effec. 2H11 Page - 1 Reissued: August 1, 1986...
Page 456 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STANDARD PRACTICES - ENGINE —CAUTION— To ensure proper installation or assembly, tag or mark all parts as to location before removal or disassembly. —CAUTION— All parts removed from engine must be inspected for burning or scoring before installation.
Page 457 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2H13...
Page 458 CHAPTER POWER PLANT 2H14...
Page 459 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 71 - POWER PLANT TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 71-00-00 GENERAL 2H16 71-01-00 Description 2H16 71-02-00 Troubleshooting 2H16 71-03-00 Engine 2H23 71-03-00 Removal of Engine 2H23 71-03-00 Pre-Oiling Engine 2H23...
Page 460 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL This chapter covers the power plant used in PA-28-236 airplanes, and is compnsed of instructions for removal and installation. For further instructions and for major repairs, consult appropriate publication of engine or component manufacturer.
Page 461 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7101. TROUBLESHOOTING (ENGINE) Trouble Cause Remedy Failure of engine to start. Lack of fuel. Check fuel system for leaks. Fill fuel tank. Clean dirty lines, strainers, or fuel valves. Underpriming. Prime with two or three strokes of primer.
Page 462 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7101. TROUBLESHOOTING (ENGINE) (CONT) Trouble Cause Remedy Failure of engine to start. Defective battery. Replace or charge battery. (cont.) Mixture control in IDLE Open mixture control. CUT-OFF. Shorted ignition switch or Check and replace or repair.
Page 463 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7101. TROUBLESHOOTING (ENGINE) (CONT.) Trouble Cause Remedy Low power and uneven run- Leaks in induction system. Tighten all connections. ning engine. (cont.) Replace defective parts. Defective spark plugs. Clean or replace spark plug. Improper grade of fuel.
Page 464 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7101. TROUBLESHOOTING (ENGINE) (CONT) Trouble Cause Remedy Rough running engine. Cracked engine mounts. Repair or replace engine mount. Unbalanced propeller. Remove propeller and have it checked for balance. Bend propeller blades. Check propeller for track.
Page 465 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7101. TROUBLESHOOTING (ENGINE) (CONT.) Trouble Cause Remedy High oil temperature (cont.) Low grade of oil. Replace with oil conforming to specifications. Clogged oil lines or screens. Remove and clean oil screens. Failing or failed bearing.
Page 466 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7101. TROUBLESHOOTING (ENGINE) (CONT) Trouble Cause Remedy Excessive oil consumption Low grade of oil. Fill with oil conforming (cont.) to specifications. Failure of rings to seat Use mineral base oil. Climb (new nitrided cylinders).
Page 467 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ENGINE REMOVAL OF ENGINE (figure 7l-1) 1. Turn off all electrical switches in cockpit and disconnect the battery ground wire at battery 2. Move fuel selector lever in cockpit to OFF. 3. Remove engine cowling. (Refer to Removal of Cowling.) 4.
Page 468 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 5. Energize starter for two or more one minute periods. —CAUTION— Do not energize for periods of over one minute. Allow starter to cool after each energizing. 6. Turn engine with starter for approximately 45 seconds to check for continued oil pressure.
Page 469 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 71-1. Engine Installation (PA-28-236) 71 - 03 - 00 Page - 71-10 Reissued: August 1, 1986...
Page 470 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 71-2. Engine Mount Assembly 71 - 03 - 00 Page - 71-11 Reissued: August 1, 1986...
Page 471 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL l6. Connect primer line at tee connection. 17. Connect cabin heat line tube at heat muff. 18. Be certain that magneto switches are OFF and install propeller. (Refer to chapter 61.) 19. Install proper grade and amount of engine oil. (Refer to Lubrication Chart, chapter 12.) 20.
Page 472 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CLEANING, INSPECTION, AND REPAIR OF COWLING 1. Clean cowling with a suitable cleaning solvent and wipe dry with a clean cloth. 2. Inspect cowling for dents, cracks, loose rivets, elongated holes, and damaged or missing fasteners.
Page 473 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 71-4. Carburetor Ice Detection System 71 - 61 - 00 Page - 71-14 Reissued: August 1, 1986...
Page 474 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL REMOVAL OF ICE DETECTOR PROBE (figure 71-5) 1. Remove engine cowl. 2. Probe is mounted in carburetor just below throttle valve. Remove safety wire and unscrew probe carburetor. Measure and note how far probe extends into carburetor.
Page 475 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 71-5. Carburetor Ice Detector Probe Installation 71 - 60 - 00 Page - 71-16 Reissued: August 1, 1986...
Page 476 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CARBURETOR ICE DETECTION SYSTEM TEST —CAUTION— Do not attempt to test probe or instrument by applying a voltage to each. Any voltage over 2-volts will burn out probe lamp, sensor, and instrument red light switching transistor.
Page 477 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CARBURETOR AIRBOX REMOVAL OF CARBURETOR AIRBOX 1. Remove lower engine cowling. 2. Disconnect air inlet hose from front of airbox. 3. Disconnect alternate air hose from left side of airbox. 4. Disconnect alternate air control cable from right side of airbox.
Page 478 CHAPTER ENGINE FUEL SYSTEM 2I10...
Page 479 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 73 - ENGINE FUEL SYSTEM TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 73-00-00 GENERAL 2I12 73-10-00 DISTRIBUTION 2I12 73-11-00 Carburetor Maintenance 2I12 73-11-00 Throttle Arm 2I12 73-11-00 Adjustment of Idle Mixture 2I12...
Page 480 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL DISTRIBUTION CARBURETOR MAINTENANCE Check the following items during recommended engine inspection periods: 1. Check tightness and safety of all nuts and screws securing carburetor to engine. 2. Check all fuel lines for tightness and evidence of leakage.
Page 481 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 73- 1. Carburetor 4. Turn screw counterclockwise until engine runs smoothly again. Continue to turn screw in same direction until engine begins to run rough again. At this point, fuel mixture will be too rich and engine speed will decrease.
Page 482 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 73-2. Engine Primer ENGINE PRIMER (Optionl) REMOVAL OF ENGINE PRIMER (figure 73-2) Disconnect fuel lines from primer behind instrument panel. 2. Loosen locknut from behind panel. 3. Unscrew knurled face nut, and withdraw pump handle and piston from cylinder.
Page 483 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF ENGINE PRIMER (figure 73-2) 1. Remove pump handle and piston by unscrewing knurled face nut, if previously installed. 2. Insert cylinder assembly through back side of panel. 3. Insert piston into cylinder and tighten knurled face nut.
Page 484 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 73-3. Adjustment of Engine Controls c. On aircraft equipped with air conditioning systems, a micro switch is located below the throttle control which is set to actuate in full open position. With throttle control adjusted to obtain a clearance of 0.010 to 0.030, adjust micro switch to actuate at this point also.
Page 485 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7301. TROUBLESHOOTING (FUEL PRESSURE GAUGE) TROUBLE CAUSE REMEDY No fuel pressure indica- Fuel valve stuck. Check valve. tion. No fuel in tanks. Check fuel, fill. Defective fuel pump. Check pump for pressure build-up. Check diaphragm and relief valves in engine pump.
Page 486 CHAPTER IGNITION 2I18...
Page 487 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 74- IGNITION TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 74-00-00 GENERAL 2I21 74-01-00 Description and Operation 2I21 74-02-00 Troubleshooting 2I21 74-10-00 ELECTRICAL POWER SUPPLY 2I23 74-11-00 Magneto 2I23 74-11-00 Inspection of Magneto...
Page 488 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2I20...
Page 489 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL DESCRIPTION AND OPERATION The D-2031, D-3031 and D-3000 magnetos feature two electrically independent ignition circuits in one housing. This magneto uses an impulse coupling to provide reliable ignition to engine cranking speed. A single cam operates the main breakers for both magneto circuits.
Page 490 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7401. TROUBLESHOOTING (MAGNETO) TROUBLE CAUSE REMEDY Failure of engine to start. Defective spark plugs. Clean and adjust or replace spark plugs. Defective ignition wire. Check with electric tester and replace defective wires. Defective battery.
Page 491 ELECTRICAL POWER SUPPLY MAGNETO INSPECTION OF MAGNETO (Refer to Piper Vendor Service Publication 61.) After first 50 hour period and every 100 hours thereafter, check the magneto ignition system. If engine develops operating troubles which appear to be caused by the ignition system, check the spark plugs and wiring first before working on the magneto.
Page 492 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-1. Height of Spring in Distributor Block Tower Figure 74-2. Contact Points 74 - 11 - 00 2I24 Page - 74-04 Reissued: August 1, 1986...
Page 493 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 8. Check capacitors for looseness in magneto cover and for any physical damage. Use a Bendix 11-1767- 1, -2, or -3 condenser tester or equivalent to check for capacitance, series resistance, and leakage. Capacitance must be 0.34 to 0.4l microfarads.
Page 494 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-3. Engine Timing Marks Figure 74-4. Timing Light Connected to Magneto 74 - 11 - 00 Page - 74-06 Reissued: August 1, 1986...
Page 495 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 7. Remove magneto drive gear backlash by turning propeller opposite to normal rotation approximately 40° past No. 1 firing position. Turn propeller in direction of normal rotation up to No. 1 firing position of 23° BTC.
Page 496 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-5. Timing Marks on Magneto Rotor Figure 74-6. Painted Tooth Centered Figure 74-7. Timing Mark on Rotor in Timing Window Aligned with Pointer 74 - 11 - 00 Page - 74-08 Reissued: August 1, 1986...
Page 497 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-8. Timing Light Connected to Magneto and Breakers INTERNAL TIMING OF MAGNETO 1. Remove magneto cover. 2. Loosen flange clamps and remove magneto from engine. 3. Check condition of points; replace if necessary. 4. Rotate magneto drive shaft until a main cam lobe touches follower of left main breaker assembly and adjust breaker points to an initial opening of 0.016 inch.
Page 498 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 9. Loosen rotor holding tool and turn magnet in direction of rotation until adjacent R (E gap) mark is aligned with pointer and lock in position. Both red painted teeth should be approximately centered in timing windows.
Page 499 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-9. Cam End View of Magneto 74 - 11 - 00 Page - 74-11 Reissued: August 1, 1986...
Page 500 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 19. Check capacitors for looseness in magneto cover of harness assembly and for any physical damage. Check capacitors for capacitance, series resistance, and leakage. Capacitance should be 0.34 to 0.41 microfarads. The use of a Bendix condenser tester, part number 11-1767-1, -2, or-3 or equivalent will simplify this test.
Page 501 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-10. Removing Impulse Coupling Figure 74-11. Checking Flyweight to Stop Pin Clearance Figure 74-12. Stop Pin Installation Dimension 74 - 12 - 00 Page - 74-13 Reissued: August 1, 1986...
Page 502 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-13. Checking Flyweight Axial Figure 74-14. Checking Flyweight Radial Wear with Drill Shank Wear with Gauge b. Hold magneto as shown in figure 74-11. Pull heel of flyweight outward with fabricated hooked wire and make certain that a feeler gauge of 0.015 of an inch minimum thickness will pass between stop pin and highest point of flyweight.
Page 503 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-15. Points of Coupling Body Wear Figure 74-16. Acceptable and Deformed Coupling Springs 74 - 12 - 00 2J11 Page - 74-15 Reissued: August 1, 1986...
Page 504 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 4. Inspect for axial wear between flyweight and axle using shank of a new No. 35 drill as a gauge. Hold flyweight so outer radius is in alignment with rim of cam flange and try to insert drill shank between flange and flyweight as shown in figure 74-14.
Page 505 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-17. Checking Impulse Coupling Figure 74-18. Orientation of Spring for Magnetization in Coupling Body Figure 74-19. Lifting Inner End of Spring 74 - 12 - 00 2J13 Page - 74-17 Reissued: August 1, 1986...
Page 506 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 7. Engage recess in hub on cam assembly with eye at inner end of spring. With eye engaged, rotate cam assembly slightly in direction to unwind spring to permit hub of cam to slip into inner turn of spring.
Page 507 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-20. Checking Harness Lead Figure 74-21. Checking Harness Lead Continuity lnsulation Resistance Figure 74-22. Modified Pliers Figure 74-23. Removing Spring From Lead Assembly 74 - 21 - 00 2J15 Page - 74-19 Reissued: August 1, 1986...
Page 508 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL MAINTENANCE OF HARNESS Minor repairs of the harness assembly, such as replacement of contact springs, sleeves, compression springs, eyelets, or grommets is accomplished with the harness mounted on the engine. Lead assemblies are also replaced with harness mounted on the engine unless inaccessibility of installation or number of leads to be replaced makes it unreasonable.
Page 509 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-24. Assembly Tool Figure 74-25. Using Assembly Tool 74 - 12 - 00 2J17 Page - 74-21 Reissued: August 1, 1986...
Page 510 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-26. Ferrule Positioned Under Braid Figure 74-27. Ferrule Seating Tool 74 - 12 - 00 2J18 Page - 74-22 Reissued: August 1, 1986...
Page 511 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-28. Position of l 1-8627 Kit and Figure 74-29. Position of 11-8627 Kit and Contact Spring at Start of Installation Contact Spring After Installation Figure 74-30. Lubricating Sleeve Figure 74-31. Lubricating Ferrule Shoulder 74 - 21 - 00...
Page 512 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Scrape blue coating being careful not to cut braid one-half of an inch from end of lead. —CAUTION— New ferrules must be used and inserted under braid exactly as stated in step f. f. Push back braid and thread a new ferrule over wire and under braid until braid just covers knurling.
Page 513 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-32. Removing Spark Plug Frozen to Bushing SPARK PLUGS Refer to latest revision of Avco-Lycoming Service Instruction 1042 for a list of approved spark plugs. REMOVAL OF SPARK PLUGS —CAUTION— When withdrawing ignition cable lead connection from plug, be careful to pull lead straight out and in line with centerline of plug barrel;...
Page 514 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 2. Remove spark plug from engine. In course of engine operation, carbon and other combustion products will be deposited on end of spark plug and will penetrate lower threads to some degree. As a result, greater effort is frequently required for removing a plug than for its installation.
Page 515 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF SPARK PLUGS Before installing spark plugs, ensure that threads within cylinder are clean and undamaged. —CAUTION— Make certain the deep socket is properly seated on spark plug hexagon as damage to plug could result if wrench is cocked to one side when pressure is applied.
Page 516 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 74-33. Ignition Switch Wire Positions —END— 74 - 31 - 00 2J24 Page - 74-28 Reissued: August 1, 1986...
Page 517 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIOALLY LEFT BLANK...
Page 518 CHAPTER ENGINE INDICATING...
Page 519 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 77 - ENGINE INDICATING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 77-00-00 GENERAL 77-10-00 POWER 77-11-00 Manifold Pressure Gauge 77-12-00 Tachometer Indicator 77-13-00 Engine Oil Pressure Gauge 77-20-00 TEMPERATURE 77-21-00 Oil Temperature Indicator...
Page 520 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL POWER MANIFOLD PRESSURE GAUGE The manifold pressure gauge is a vapor proof, absolute pressure instrument. Pressure from the intake manifold is transmitted to the instrument through a line. A pointer indicates manifold pressure available at the engine in inches of mercury.
Page 521 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL TACHOMETER INDICATOR The tachometer is connected to the engine accessory by a flexible cable and provides an indication of crankshaft speed in revolutions per minute. The instrument has a recording mechanism for recording time that engine is in actual operation.
Page 522 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ENGINE OIL PRESSURE GAUGE The oil pressure gauge is mounted in the instrument panel cluster. This gauge will indicate the amount of oil pressure available at the pressurized engine oil passage. CHART 7703. TROUBLESHOOTING (ENGINE OIL PRESSURE GAUGE)
Page 523 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7704. TROUBLESHOOTING (OIL TEMPERATURE INDICATORS) TROUBLE CAUSE REMEDY Instrument fails to show Broken or damaged bulb. Check engine unit and any reading. Wiring open. wiring to instrument. Excessive scale error. Improper calibration ad- Repair or replace.
Page 524 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 1. Remove probe from exhaust stack and check for a broken weld (at tip end) or a burnt off end. The measured resistance of probe should be 0.8 ohms. Clean connections with steel wool before reassembly.
Page 525 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 7706. TROUBLESHOOTING (CYLINDER HEAD TEMPERATURE GAUGE) TROUBLE CAUSE REMEDY Instrument shows no indi- Power supply wire broken. Repair wire. cation. Defective instrument. Replace instrument. Master switch off. Instrument goes all the Wire broken between Repair wire.
Page 526 CHAPTER EXHAUST 2K10...
Page 527 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 78- EXHAUST TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 78-00-00 GENERAL 2K12 78-01-00 Inspection of Exhaust System 2K12 78 - Cont./Effec. 2K11 Page - 1 Reissued: August 1, 1986...
Page 528 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 78-1. Exhaust System Inspection Points GENERAL INSPECTION OF EXHAUST SYSTEM (figure 78-1) —CAUTION— All airplanes should be fitted with a new muffler at or near 1000 hours of muffler use. The entire exhaust system, including heat exchange shroud, muff l e r, muffler baffles, stacks, and all exhaust connections must be rigidly inspected at each annual or 100 hour inspection.
Page 529 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Removal of tail pipe and stacks is required for inspection of the muffler baffle. Remove or loosen all exhaust shields, carburetor, and cabin heat muffs, shrouds, heat blankets, etc., as required to permit inspection of the system. Clean and inspect all external surfaces for dents, cracks, and missing parts.
Page 530 CHAPTER OIL SYSTEM 2K14...
Page 531 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 79 - OIL SYSTEM TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 79-00-00 GENERAL 2K16 79-20-00 DISTRIBUTION 2K16 79-21-00 Oil Cooler 2K16 79-21-00 Removal of Oil Cooler 2K16 79-21-00 Installation of Oil Cooler...
Page 532 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL DISTRIBUTION OIL COOLER REMOVAL OF OIL COOLER The oil cooler is located on the right rear baffle assembly. Remove oil cooler as follows: 1. Disconnect two oil lines at fittings. 2. Cap lines to prevent leaking or contamination of oil.
Page 533 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INSTALLATION OF OIL PRESSURE SENSOR 1. Seal sensor unit pipe threads with thread sealant tape (3M-Teflon No.48 x 1/4”). 2. Screw sensor unit into bulkhead fitting. 3. Connect two electrical leads. 4. Perform operational check.
Page 534 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2K18...
Page 535 CHAPTER STARTING 2K19...
Page 536 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 80 - STARTING TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 80-00-00 GENERAL 2K21 80-01-00 Description and Operation 2K21 80-02-00 Troubleshooting 2K21 80-10-00 CRANKING 2K24 80-11-00 Maintenance of Starting System 2K24 80-12-00 Overhaul of Starting Motor...
Page 537 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL DESCRIPTION AND OPERATION (figure 80-1) The gear reduction starting motor comprises commutator end head assembly, armature, frame and field a s s e m b l y, gear housing, pinion housing, and Bendix drive asembly. When the starting circuit is energ i z e d , battery current is applied to the starting motor terminal.
Page 538 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 8001. TROUBLESHOOTING (STARTER) TROUBLE CAUSE REMEDY Motor fails to operate. Low battery charge. Check and recharge if necessary. Defective or improper Refer to electrical wiring wiring or loose connec- diagram and check all tions.
Page 539 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 8001. TROUBLESHOOTING (STARTER) (cont.) TROUBLE CAUSE REMEDY Motor fails to operate. Dirty commutator. If commutator is rough or (cont.) dirty, smooth and polish with number 000 sand- paper. If too rough and pitted, remove and turn down.
Page 540 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 80-1. Exploded View of Gear Reduction Starting Motor CRANKING MAINTENANCE OF STARTING SYSTEM Inspect starting circuit at regular intervals, the frequency of which is determined by the amount of service and the conditions under which the airplane is operated. It is recommended that such inspection be made twice a year and include the following: —CAUTION—...
Page 541 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL 3. No lubrication is required on starting motor except at time of overhaul. Then lubricate entire shaft under Bendix Drive, fill grooves in armature shaft at drive end and pack gear box with 1.3 to 2.0 ounces of Lithium Soap Base Grease #1925 Molytex O or equivalent.
Page 542 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 80-2. Turning Starting Figure 80-3. Testing Motor Armature Motor Commutator for Shorts Figure 80-4. Testing Motor Fields for Grounds 80 - 12 - 00 Page 80 - 06 Reissued: August 1, 1986...
Page 543 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ARMATURE 1. Check commutator for uneven wear, excessive glazing, or evidence of excessive arcing. If only slightly dirty, glazed, or discolored, the commutator can be cleaned with 00 or 000 sandpaper. If commutator is rough or worn, it should be turned in a lathe. (Refer to figure 80-2.) Inspect armature shaft for rough bearing surfaces and rough or damaged splines.
Page 544 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 80-5. No-Load Test Hook-up Figure 80-6. Stall-Torque Hook-up ASSEMBLY OF STARTING MOTOR 1. When assembling starting motor, always use an arbor press and proper bearing arbor for installing graphitized bronze and roller bearings. The Bendix shaft should have a thin film of Lubriplate #777 or equivalent on Bendix portion of shaft.
Page 545 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL BENCH TEST 1. After starting motor is reassembled, test it to see that no-load current at a certain voltage is within specifications given in Starting Motor Service Test Specifications. To make this test, connect as shown in figure 80-5.
Page 546 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL STARTING MOTOR SERVICE TEST SPECIFICATION Prestolite specifications for 12-volt starting motors installed as standard equipment on this airplane are as follows: Motor Model MZ4222 Min. Brush Tension 32 oz. Max. Brush Tension 40 oz. No Load Test (75 0 F) Volt Max.
Page 547 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GRIDS 2L7 THRU 2L24 INTENTIONALLY LEFT BLANK...
Page 548 DAKOTA MAINTENANCE MANUAL CARD 3 OF 3 PA-28-236 DAKOTA PIPER AIRCRAFT CORPORATION (PART NUMBER 761 681)
Page 549 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL INTRODUCTION This Piper Aircraft maintenance manual is prepared in accordance with the General Av i a t i o n Manufacturers Association format. Introduction Page - 1 Reissued: August 1, 1986...
Page 550 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL VENDOR PUBLICATIONS —WARNING— When servicing or inspecting vendor equipment installed in Piper aircraft, it is the user’s responsibility to refer to the applicable vendor publication. ENGINE: Overhaul Manual = AVCO LYCOMING - OVERHAUL MANUAL DIRECT DRIVE ENGINE - P/N 60294-7 Avco Lycoming Division Williamsport, Pa.
Page 551 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL PIPER PUBLICATIONS COMMUNICATIONS: Removal, Installation and Maintenance Instructions = 76l 502 AutoControl III B Service Manual 761 481 AutoFlite II Service Manual 753 771 Pitch Trim Service Manual Radio Service and Maintenance Manual = 761 685 Avionics wiring Diagram Service Manual...
Page 552 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL AEROFICHE EXPLANATION AND REVISION STATUS The maintenance manual information incorporated in this set of Aerofiche cards has been arranged in accordance with general specifications for Aerofiche adopted by the General Aviation Manufacturer’s Association. The information in this Aerofiche maintenance manual is kept current by revisions distributed periodically.
Page 553 The date on Aerofiche cards must not be earlier than the date noted for the respective card eff e c t i v i t y. Consult the latest Aerofiche card in this series for current Aerofiche card effectivity. SERIAL NUMBER INFORMATION PA-28-236, DAKOTA- l979 Serial Numbers 28-7911001 to 28-7911395 inclusive. PA-28-236, DAKOTA- l980 Serial Numbers 28-8011001 to 28-8011161 inclusive.
Page 554 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GAMA SYSTEM/CHAPTER INDEX GUIDE SYST SUB-SYST AEROFICHE CHAP SECTION TITLE GRID NO. AIRWORTHINESS LIMITATIONS 1A17 TIME LIMITS/MAINT CHECKS 1A21 DIMENSIONS AND AREAS 1B12 LIFTING AND SHORING 1B20 LEVELING AND WEIGHING TOWING AND TAXIING PARKING AND MOORING...
Page 555 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GAMA SYSTEM/CHAPTER INDEX GUIDE (cont) SYST SUB-SYST AEROFICHE CHAP SECTION TITLE GRID NO. STRUCTURES 2E19 DOORS 2F11 STABILIZERS 2F21 WINDOWS WINGS 2Gl2 PROPELLER STANDARD PRACTICES - ENGINE 2H10 POWERPLANT 2H14 ENGINE FUEL SYSTEM 2I10 IGNITION...
Page 556 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. Three View 1B17 6-2. Station References 1B18 6-3. Access Plates and Panels 1B19 7-1. Jacking Arrangement 1B23 8-1. Weighing Airplane 8-2. Leveling Longitudinally 8-3. Leveling Laterally 11-1...
Page 557 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. 21-15. Components Installation 21-16. Overhead Vent System (Not Available with Air Conditioning) 23-1. Avionics Master and Emergency Switch Circuit 1H14 23-2. Communications Components ELT Schematic 1H16 23-3.
Page 558 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 24-34. Testing Rotor for Shorts 24-35. Installation of Bearing 24-36. Installation of Rectifier 24-37. Terminal Assembly 24-38. Slip Ring End Bearing Assembly 24-39. Testing Alternator 24-40.
Page 559 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont.) FIGURE NO. SUBJECT GRID NO. 32-7. Main Wheel Assembly 32-8. Nose Wheel Assembly 32-9. Standard Brake Assembly (Cleveland 30-55) 32-10. Heavy Duty Brake Assembly (Cleveland 30-65) 32-11. Removal and Installation of Anchor Bolts 2C10 32-12.
Page 560 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 73-2. Engine Primer 2I14 73-3. Adjustment of Engine Controls 2I16 74-1. Height of Spring in Distributor Block Tower 2I24 74-2. Contact Points 2I24 74-3. Engine Timing Marks 74-4.
Page 561 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF ILLUSTRATIONS (cont) FIGURE NO. SUBJECT GRID NO. 95-1 Tire Balancer Fixture 95-2. Control Surface Balancing Tool 95-3. Onfice Replacement Tool 95-4. Fabricated Tool for Baggage Door Lock 95-5. Retainer Ring Tool 95-6. Fabricated Aileron Bellcrank Rigging Tool 95-7.
Page 562 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CHARTS CHART NO. SUBJECT GRID NO. Leading Particulars and Principal Dimensions 1B15 1201 Thread Lubricants 1D11 1202 Type of Lubricants 1D12 2001 Thread Lubricants 1E10 2002 Maximum Distance Between Supports For Fluid Tubing...
Page 563 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CHARTS (cont) CHART NO. SUBJECT GRID NO. 7705 Troubleshooting (Exhaust Gas Temperature Gauge) (Alcor) 7706 Troubleshooting (Cylinder Head Temperature Gauge) 8001 Troubleshooting (Starter) 2K22 8002 Starting Motor Specifications 9101 Flare Fitting Torques 3A19...
Page 564 CHAPTER CHARTS/WIRING DIAGRAMS 3A17...
Page 565 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 91 - CHARTS AND WIRING DIAGRAMS TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 91-00-00 GENERAL 3A19 91-01-00 Torque Requirements 3A19 91-01-00 Flare Fitting Torques 3A19 91-01-00 Recommended Nut Torques 3A20 91-02-00 Conversion Tables...
Page 566 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GENERAL TORQUE REQUIREMENTS The torque values in chart 9102 are derived from oil-free cadmium-plated threads and are recommended for all airframe installation procedures where torquing is required, unless otherwise noted in sections where other values are stipulated. Engine torque values are found in the latest revision of Lycoming Overhaul Manual, and propeller torque values are found in chapter 6l of this manual.
Page 567 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9102. RECOMMENDED NUT TORQUES The proper application of torque is very important. Undertorque can result in excessive wear of nuts and bolts as well as the parts they are holding together. When insufficient pressures are applied, uneven loads are transmitted throughout the assembly which can result in excessive wear or premature failure due to fatigue.
Page 568 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9102. RECOMMENDED NUT TORQUES (CONT.) 91 - 01 - 00 3A21 Page 91 - 03 Reissued: August 1, 1986...
Page 569 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9102. RECOMMENDED NUT TORQUES (cont.) 91 - 01 - 00 3A22 Page 91 - 04 Reissued: August 1, 1986...
Page 570 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9103. CONVERSION TABLES The procedure for converting inches to millimeters is as follows. (Refer to chart 9103.) To convert l.5 inches to millimeters. a. Read down inches column to 1. inches. b. Read across top inch column to 0.5.
Page 571 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9103. CONVERSION TABLES (cont) DECIMAL CONVERSIONS 91 - 02 - 00 3A24 Page 91 - 06 Reissued: August 1, 1986...
Page 572 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9103. CONVERSION TABLES (cont) INCHES TO MILLIMETER 0.0000 0.0001 0.0002 0.0003 0.0004 0.0005 0.0006 0.0007 0.0008 0.0009 INCHES 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 573 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9103. 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; find 20 in the center column and read -6 67°C in the (C) column to the left...
Page 574 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9103. CONVERSION TABLES (cont) 91 - 02 - 00 Page 91 - 09 Reissued: August 1, 1986...
Page 575 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9104. DECIMAL EQUIVALENTS OF DRILL SIZES Decimal Equivalents of Drill Sizes From 1/2” to No. 80 Size Decimal Size Decimal Size Decimal Size Decimal Equiv. Equiv. Equiv. Equiv. 1 /2 0.500 0.261 5/32 0.1562 0.067...
Page 576 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL LIST OF CONSUMABLE MATERIALS CHART 9105. LIST OF CONSUMABLE MATERIALS —NOTE— Refer to the end of this chart for manufacturers’ addresses. MATERIAL SPECIFICATION PRODUCT VENDOR ABS-Solvent/ Solarite, #ll Series Solar Compounds Corp. Cements Carboline F-l Carboline Co.
Page 577 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9105. LIST OF CONSUMABLE MATERIALS (cont) MATERIAL SPECIFICATION PRODUCT VENDOR Epoxy Patching Solarite #400 Solar Compounds Corp. Compound Grease, Aircraft and MIL-G-23827A Supermil Grease Amoco Instrument Gear OPL-23827-l0 No. A72832 and Actuator Screw (See Note 2) Royco 27A Royal Lubricants Co.
Page 578 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9l05. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION PRODUCT VENDOR Grease Ball and MIL-G-l8709 Regal ASB-2 Formula Texaco Incorporated Roller Bearing QPL- l8709-S5 TG-10293 Andok B Exxon Company, U.S.A. Code 1-20481, Darina Shell Oil Company...
Page 579 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL MATERIAL SPECIFICATION PRODUCT VENDOR CHART 9105. LIST OF CONSUMABLE MATERIALS (cont.) Grease, Lubricating, MIL-L-21164 Aeroshell Grease Shell Oil Company Molybdenum QPL-21164-15 No. 17 Disulfide Royco 64C Royal Lubricants Co. Castrolease MSA (c) Burmah Castrol LTD...
Page 580 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9105. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION PRODUCT VENDOR Methylethylketone Fed. Spec. TT-M-26l Local Supplier Molykote - Type 2 (Powder) Oil, Lubricating, MIL-L-7870 Caltex Low Temp. Caltex Oil Products General Purpose, QPL-7870-9 Company...
Page 581 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9105. LIST OF CONSUMABLE MATERIALS (cont.) MATERIAL SPECIFICATION PRODUCT VENDOR Solvents Methylethyl Ketone Local Suppliers Methylene Chloride Acetone PD -680 Dry Cleaning Solvent Toluol TT-T-548 Local Supplier Teflon Tape .003” x.5” wide/-l 7638l Minnesota Mining and Manufactunng Company .003”...
Page 582 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9105. LIST OF CONSUMABLE MATERIAL (cont) VENDOR INFORMATION Mirror Bright Polish Co., Inc. Amoco Exxon Oil Co. Irvine Industrial Complex 200 E. Randolph Drive l25l Ave of the Americas P.O Box l7l77 Chicago, IL 60601 New York, N.Y.
Page 583 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHART 9105. LIST OF CONSUMABLE MATERIALS (cont) VENDOR INFORMATION Shamban W.S. and Co. Texaco Inc. l857 Centinela Ave. 2000 Westchester Ave. Santa Monica, CA 90404 White Plains, NY l0650 213-397-2195 914-253-4000 Shell Oil Company Unelko Corp.
Page 584 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ELECTRICAL SCHEMATICS ELECTRICAL WIRE CODING CHART 9106. ELECTRICAL WIRE CODING CIRCUIT FUNCTION LETTER CIRCUITS AUTOPILOT CONTROL SURFACE ENGINE INSTRUMENT FLIGHT INSTRUMENT LANDING GEAR HEATER - VENTILATING &DEICING LIGHTING POWER FUEL & OIL RADIO POWER RADIO GROUND RADIO AUDIO &...
Page 585 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ELECTRICAL SYMBOLS CHART 9107. ELECTRICAL SYMBOLS 91 - 32 - 00 3B14 Page 91 - 20 Reissued: August 1, 1986...
Page 586 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ELECTRICAL SCHEMATIC INDEX FIGURE NO. SCHEMATIC GRID NO. ANNUNCIATOR SYSTEMS Annunciator 9l-l. Early Models 3B18 91-2. Later Models 3B19 COMFORT SYSTEMS 91-22. Cigar Lighter DEICE SYSTEMS 91-9. Pitot Heat 3B24 ELECTRICAL POWER Alternator 91-3. Early Models...
Page 587 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL ELECTRICAL SCHEMATIC INDEX (cont.) FIGURE NO. SCHEMATIC GRID NO. LIGHTING EXTERNAL Anti-Collision 91-18. Beacon 91-16. Wing Strobes 91-17. Beacon and Wing Strobes 91-20. Landing 91-21. Position 91-19. Recognition LIGHTING INTERNAL 91-22. Cabin - Dome Panel Lighting 91-23.
Page 588 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3B17...
Page 589 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-1. Annunciator (Early Models) 91 - 33 - 00 3B18 Page 91 - 21 Reissued: August 1, 1986...
Page 590 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-2. Annunciator (Later Models) 91 - 33 - 00 3B19 Page 91 - 22 Reissued: August 1, 1986...
Page 591 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-3. Alternator (Early Models) 91 - 33 - 00 3B20 Page 91 - 23 Reissued: August 1, 1986...
Page 592 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-4. Alternator (Later Models) 91 - 33 - 00 3B21 Page 91 - 24 Reissued: August 1, 1986...
Page 593 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-5. Starters (Early Models) Figure 91-6. Starters (Late Models) 91 - 33 - 00 3B22 Page 91 - 25 Reissued: August 1, 1986...
Page 594 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-7. Air Conditioning/Air Blower 91 - 33 - 00 3B23 Page 91 - 26 Reissued: August 1, 1986...
Page 595 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-8. Avionics Bus (With Master, Emergency Switches) (Optional) Figure 91-9. Pitot Heat Figure 91-l0. Fuel Pump 91 - 33 - 00 3B24 Page 91 - 27 Reissued: August 1, 1986...
Page 596 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-11. Digital and Electrical Clock and Hourmeter (Optional) Figure 91-l2. Engine Gauges 91 - 33 - 00 Page 91 - 28 Reissued: August 1, 1986...
Page 597 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 9l-13. Alternate Turn and Bank Figure 91-14. Alternate Turn and Bank (Early Models) (Later Models) THIS SPACE INTENTIONALLY LEFT BLANK Figure 9l-l5. Turn and Bank 91 - 33 - 00 Page 91 - 29...
Page 598 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-16. Anti-Collision - Wing Strobes Figure 91-17. Anti-Collision Beacon and Wing Strobes 91 - 33 - 00 Page 91 - 30 Reissued: August 1, 1986...
Page 599 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 9l-18. Anti-Collision - Beacon Figure 91-19. Recognition Light Figure 91-20. Landing Light Figure 9l-21. Position 91 - 33 - 00 Page 91 - 31 Reissued: August 1, 1986...
Page 600 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 91-22. Cabin, Dome and Cigar Lighter Figure 91-23. Panel Lighting (Early Models) 91 - 33 - 00 Page 91 - 32 Reissued: August 1, 1986...
Page 601 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 9l-24. Panel Lighting (Later Models) 91 - 33 - 00 Page 91 - 33 Reissued: August 1, 1986...
Page 602 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 9l-25. Radio Panel Lighting Figure 9l-26. Stall Warning THIS SPACE INTENTIONALLY LEFT BLANX 91 - 33 - 00 Page 91 - 34 Reissued: August 1, 1986...
Page 603 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GRIDS 3C8 THRU 3C24 INTENTIONALLY LEFT BLANK...
Page 604 CHAPTER SPECIAL PURPOSE EQUIPMENT...
Page 605 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL CHAPTER 95 - SPECIAL PURPOSE EQUIPMENT TABLE OF CONTENTS/EFFECTIVITY CHAPTER SECTION GRID SUBJECT SUBJECT EFFECTIVITY 95-00-00 GENERAL 95-10-00 TOOLS AND TEST EQUIPMENT 95-10 00 Tire Ba1ancer Building Instructions 95 - Cont./Effec. Page - 1 Reissued: August 1, 1986...
Page 606 Some special tools other than normal shop tools are required to service the aircraft. —NOTE— Tools with part numbers given are available through the Piper Service Department. Specifications for fabricated tools is found referring to the appropriate illustration figure number in the maintenance manual following the list of tools.
Page 607 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-1. Tire Balancer Fixture TIRE BALANCER BUILDING INSTRUCTIONS 1. Chamfer top edges of -3 sides, heaving 1/16 inch flat on top inboard edge. Rivet -2 tee’s to -3 sides using AN470-AD5 rivets 2” spacing. Use AN426-AD5 rivets 2” center to center to secure -2 tee’s to - 1 base.
Page 608 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-2. Control Surface Balancing Tool 95 - 10 - 00 Page 95 - 03 Reissued: August 1, 1986...
Page 609 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-3. Orifice Replacement Tool 95 - 10 - 00 Page 95 - 04 Reissued: August 1, 1986...
Page 610 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-4. Fabricated tool for Baggage Door Lock Figure 95-5. Retainer Ring Tool 95 - 10 - 00 Page 95 - 05 Reissued: August 1, 1986...
Page 611 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-6. Fabricated Aileron Bellcrank Rigging Tool Figure 95-7. Fabricated Rudder Rigging Tool 95 - 10 - 00 Page 95 - 06 Reissued: August 1, 1986...
Page 612 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-8. Fabricated Aileron and Flap Rigging Tool 95 - 10 - 00 Page 95 - 07 Reissued: August 1, 1986...
Page 613 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-9. Fabricated Stabilator Rigging Tool 95 - 10 - 00 3D10 Page 95 - 08 Reissued: August 1, 1986...
Page 614 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-10. Charging Stand Figure 95-11. Compressor and Fabricated Oil Dipstick 95 - 10 - 00 3D11 Page 95 - 09 Reissued: August 1, 1986...
Page 615 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL Figure 95-12. Ferrule Seating Tool Figure 95-13. Assembly Tool 95 - 10 - 00 3D12 Page 95 - 10 Reissued: August 1, 1986...
Page 616 PIPER AIRCRAFT PA-28-236 MAINTENANCE MANUAL GRIDS 3D13 THRU 3124 INTENTIONALLY LEFT BLANK 3D13...

This manual is also suitable for:

Pa-28-236 dakota

Piper Dakota Maintenance Manual

Chapter 5 - Time Limits/Maintenance Checks

Chapter 12 - Servicing

Quick Links

MAINTENANCE MANUAL

Troubleshooting

Summary of Contents for Piper Dakota

Page 1: Maintenance Manual

Page 66: Interior Placards And Markings

This manual is also suitable for:

Piper Dakota Maintenance Manual

Chapter 5 - Time Limits/Maintenance Checks

Chapter 12 - Servicing

Quick Links

MAINTENANCE MANUAL

Troubleshooting

Related Manuals for Piper Dakota

Summary of Contents for Piper Dakota

Page 1: Maintenance Manual

Page 66: Interior Placards And Markings

This manual is also suitable for:

Table of Contents