Piper Cherokee Warrior PA-28-151 & PA-28-161 Service Manual 2816119 – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Piper Cherokee Warrior PA-28-151 & PA-28-161 Service Manual 2816119 – PDF DOWNLOAD
General:
This publication is prepared in PIPER proprietary format with respect to arrangement and content.
This manual generally does not contain hardware callouts for installation. Hardware callouts are only
indicated where a special application is required. To confirm the correct hardware used, refer to the
PIPER PA-28-151 (Cherokee Warrior) / PA-28-161 (Warrior II/III) Parts Catalog, P/N 761-538, and FAR
43 for proper utilization.
Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and
suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even
though identical in appearance, may not have had the required tests and inspections performed, may be
different in fabrication techniques and materials, and may be dangerous when installed in an airplane.
Additionally, reworked or salvaged parts or those parts obtained from non-PIPER approved sources, may
have service histories which are unknown or cannot be authenticated, may have been subjected to
unacceptable stresses or temperatures or may have other hidden damage not discernible through routine
visual or nondestructive testing. This may render the part, component or structural assembly, even
though originally manufactured by PIPER, unsuitable and unsafe for airplane use.
PIPER AIRCRAFT, INC. expressly disclaims any responsibility for malfunctions, failures, damage or
injury caused by use of non-PIPER approved parts.
TABLE OF CONTENTS:
Piper Cherokee Warrior PA-28-151 & PA-28-161 Service Manual 2816119 – PDF DOWNLOAD
761-539 – CHEROKEE WARRIOR MAINTENANCE MANUAL – PA-28-151 CHEROKEE WARRIOR/PA-28-161 WARRIOR II/III……………………………….. 1
REVISION STATUS………………………………………………………………………………………………………. 3
INTRODUCTION…………………………………………………………………………………………………………. 5
TABLE OF CONTENTS…………………………………………………………………………………………………. 5
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS…………………………………………………………………………….. 7
GENERAL………………………………………………………………………………………………………….. 7
EFFECTIVITY………………………………………………………………………………………………………. 8
SERIAL NUMBER EXPLANATION………………………………………………………………………………………….. 9
ASSIGNMENT OF SUBJECT MATERIAL……………………………………………………………………………………… 9
PAGINATION……………………………………………………………………………………………………….. 9
AEROFICHE GRID NUMBERING…………………………………………………………………………………………… 9
IDENTIFYING REVISED MATERIAL……………………………………………………………………………………….. 10
INDEXING…………………………………………………………………………………………………………. 10
WARNINGS, CAUTIONS AND NOTES……………………………………………………………………………………….. 10
ACCIDENT/INCIDENT REPORTING………………………………………………………………………………………… 10
SUPPLEMENTARY PUBLICATIONS…………………………………………………………………………………………. 11
PIPER PUBLICATIONS………………………………………………………………………………………………… 11
VENDOR PUBLICATIONS……………………………………………………………………………………………….. 11
SECTION INDEX GUIDE……………………………………………………………………………………………….. 17
LIST OF ILLUSTRATIONS…………………………………………………………………………………………………. 19
FIGURE 2-1. THREE VIEW…………………………………………………………………………………………….. 40
FIGURE 2-2. STATION REFERENCE LINES…………………………………………………………………………………. 41
FIGURE 2-3. ACCESS PLATES AND PANELS………………………………………………………………………………… 45
FIGURE. 2-3A. TORQUE WRENCH FORMULA…………………………………………………………………………………. 46
FIGURE 2-3B. HOSE, TUBE, AND LINE MARKINGS…………………………………………………………………………… 57
FIGURE 2-4. JACKING ARRANGEMENT…………………………………………………………………………………….. 58
FIGURE 2-5. WEIGHING ARRANGEMENT……………………………………………………………………………………. 59
FIGURE 2-6. LEVELING LONGITUDINALLY…………………………………………………………………………………. 60
FIGURE 2-7. LEVELING LATERALLY……………………………………………………………………………………… 60
FIGURE 2-8. SERVICING POINTS……………………………………………………………………………………….. 66
FIGURE 2-8A. TIRE BALANCER…………………………………………………………………………………………. 70
FIGURE 2-9. INDUCTION AIR FILTER……………………………………………………………………………………. 73
FIGURE 2-10. FUEL STRAINER…………………………………………………………………………………………. 75
FIGURE 2-11. LUBRICATION CHART (LANDING GEAR, MAIN)…………………………………………………………………… 84
FIGURE 2-12. LUBRICATION CHART (LANDING GEAR, NOSE)…………………………………………………………………… 85
FIGURE 2-13. LUBRICATION CHART (CONTROL SYSTEM, AILERON)………………………………………………………………. 86
FIGURE 2-14. LUBRICATION CHART (CONTROL SYSTEM, FLAP)…………………………………………………………………. 87
FIGURE 2-15. LUBRICATION CHART (CONTROL SYSTEM, RUDDER)……………………………………………………………….. 88
FIGURE 2-16. LUBRICATION CHART (CONTROL SYSTEM, RUDDER TRIM)…………………………………………………………… 89
FIGURE 2-17. LUBRICATION CHART (CABIN DOOR, BAGGAGE DOOR AND SEATS)…………………………………………………….. 90
FIGURE 2-18. LUBRICATION CHART (POWER PLANT AND CONTROL PIVOT POINTS)…………………………………………………… 91
FIGURE 2-19. LUBRICATION CHART (OPTIONAL AIR CONDITIONING CONDENSER AND COMPRESSOR) PA-161, S/N’S 7716002 THRU 28-8616057 AND…. 92
FIGURE 2-20. CHERRYLOCK RIVET REMOVAL………………………………………………………………………………..110
FIGURE 3-1. STABILATOR ATTACH FITTING CORROSION INSPECTION……………………………………………………………..152
FIGURE 3-2. FLAP CONTROL CABLE ATTACHMENT BOLT INSPECTION (TYPICAL)……………………………………………………..153
FIGURE 3-3. WING ATTACH FITTINGS…………………………………………………………………………………….155
FIGURE 3-4. DRAIN HOLE INSTALLATION………………………………………………………………………………….156
FIGURE 3-5. FUEL TANK AND WING SPAR CORROSION INSPECTION……………………………………………………………….158
FIGURE 3-6. MAIN GEAR STRUT CYLINDER…………………………………………………………………………………160
FIGURE 3-7. MAIN LANDING GEAR TORQUE LINK GREASER BOLT INSPECTION……………………………………………………….161
FIGURE 3-8. TYPICAL MUFFLER FATIGUE AREAS…………………………………………………………………………….163
FIGURE 3-9. EXHAUST SYSTEM INSPECTION POINTS………………………………………………………………………….163
FIGURE 4-1. AILERON AND FLAP INSTALLATION…………………………………………………………………………….189
FIGURE 4-2. WING INSTALLATION……………………………………………………………………………………….194
FIGURE 4-3. NOT USED………………………………………………………………………………………………. 19
FIGURE 4-4. METHODS OF SECURING CONTROL CABLES………………………………………………………………………..199
FIGURE 4-5. EMPENNAGE GROUP INSTALLATION……………………………………………………………………………..200
FIGURE 4-6. WINDSHIELD INSTALLATION (TYPICAL)…………………………………………………………………………205
FIGURE 4-7. SIDE WINDOW INSTALLATION (TYPICAL)………………………………………………………………………..206
FIGURE 4-8. DOOR SEAL SNUBBER INSTALLATION……………………………………………………………………………210
FIGURE 4-9. FABRICATED TOOL FOR BAGGAGE DOOR LOCK……………………………………………………………………..211
FIGURE 4-10A. SEAT BACK LOCK………………………………………………………………………………………..212
FIGURE 4-10B. LUMBAR SEAT BLADDER INSTALLATION………………………………………………………………………..214
FIGURE 4-10C. MILLIVOLT DROP TEST……………………………………………………………………………………217
FIGURE 4-11. SKIN MATERIALS AND THICKNESS…………………………………………………………………………….219
FIGURE 4-11A. SKIN BEAD REPAIR………………………………………………………………………………………220
FIGURE 4-11B. METAL WIRE STITCHING REPAIR…………………………………………………………………………….222
FIGURE 4-12. TYPICAL ACCESS PLATES…………………………………………………………………………………..224
FIGURE 4-13. BAGGAGE COMPARTMENT INSPECTION HOLES CUTOUT DETAILS………………………………………………………..225
FIGURE 4-14. SURFACE SCRATCHES, ABRASIONS OR GROUND-IN-DIRT…………………………………………………………….230
FIGURE 4-15. DEEP SCRATCHES, SHALLOW NICKS AND SMALL HOLES……………………………………………………………..230
FIGURE 4-16. MIXING OF EPOXY PATCHING COMPOUND………………………………………………………………………..232
FIGURE 4-17. WELDING REPAIR METHOD…………………………………………………………………………………..232
FIGURE 4-18. REPAIRING OF CRACKS…………………………………………………………………………………….233
FIGURE 4-19. VARIOUS REPAIRS………………………………………………………………………………………..234
FIGURE 4-20. REPAIR OF STRESS LINES………………………………………………………………………………….235
FIGURE 4-21. REPAIR OF IMPACTED DAMAGE……………………………………………………………………………….235
FIGURE 4-22. CONTROL SURFACE BALANCE TOOL…………………………………………………………………………….238
FIGURE 4-23. AILERON BALANCE………………………………………………………………………………………..240
FIGURE 4-24. FACTORY INSTALLED AILERON BALANCE WEIGHT (1974 AND 1975 MODELS ONLY)…………………………………………241
FIGURE 4-25. RUDDER BALANCE…………………………………………………………………………………………241
FIGURE 4-26. RUDDER BALANCE WEIGHT…………………………………………………………………………………..242
FIGURE 4-27. STABILATOR BALANCE……………………………………………………………………………………..242
FIGURE 5-1. CORRECT METHOD OF INSTALLING ROD END BEARINGS………………………………………………………………251
FIGURE 5-2. CONTROL CABLE INSPECTION…………………………………………………………………………………252
FIGURE 5-3. EXTERNAL CABLE PATTERNS………………………………………………………………………………….253
FIGURE 5-4. INTERNAL CABLE PATTERNS………………………………………………………………………………….254
FIGURE 5-5. PULLEY WEAR PATTERNS…………………………………………………………………………………….255
FIGURE 5-6. CONTROL COLUMN ASSEMBLY………………………………………………………………………………….261
FIGURE 5-7. UNIVERSAL, OR FLEX, JOINT INSTALLATION…………………………………………………………………….262
FIGURE 5-8. AILERON CONTROLS………………………………………………………………………………………..264
FIGURE 5-9. BELLCRANK RIGGING TOOL (1974 AND 1975 MODELS ONLY)………………………………………………………….267
FIGURE 5-10. BELLCRANK RIGGING TOOL (1976 AND SUBSEQUENT MODELS ONLY)……………………………………………………267
FIGURE 5-11. STABILATOR CONTROLS…………………………………………………………………………………….270
FIGURE 5-12. STABILATOR RIGGING TOOL…………………………………………………………………………………272
FIGURE 5-13. STABILATOR TRIM CONTROLS………………………………………………………………………………..274
FIGURE 5-14. METHODS OF SECURING TRIM CABLES………………………………………………………………………….276
FIGURE 5-15. RUDDER AND STEERING PEDAL ASSEMBLY……………………………………………………………………….279
FIGURE 5-16. RUDDER CONTROLS………………………………………………………………………………………..282
FIGURE 5-17. RUDDER RIGGING TOOL…………………………………………………………………………………….284
FIGURE 5-18. CLAMPING RUDDER PEDALS………………………………………………………………………………….284
FIGURE 5-19. RUDDER AND STABILATOR TRAVEL ADJUSTMENT…………………………………………………………………..285
FIGURE 5-20. RUDDER TRIM CONTROL…………………………………………………………………………………….287
FIGURE 5-21. FLAP CONTROL SYSTEM…………………………………………………………………………………….290
FIGURE 5-22. FLAP STOP ADJUSTMENT……………………………………………………………………………………294
FIGURE 5-23. FLAP RIGGING TOOL………………………………………………………………………………………294
FIGURE 5-24. FABRICATED RUDDER RIGGING TOOL…………………………………………………………………………..302
FIGURE 5-25. FABRICATED STABILATOR RIGGING TOOL……………………………………………………………………….302
FIGURE 5-26. FABRICATED FLAP RIGGING TOOL…………………………………………………………………………….303
FIGURE 7-1. NOSE GEAR OLEO STRUT ASSEMBLY…………………………………………………………………………….311
FIGURE 7-2. NOSE GEAR INSTALLATION…………………………………………………………………………………..314
FIGURE 7-3. CLAMPING RUDDER PEDALS IN NEUTRAL POSITION…………………………………………………………………316
FIGURE 7-4. RUDDER PEDALS AT NEUTRAL ANGLE……………………………………………………………………………316
FIGURE 7-5. MAIN GEAR OLEO STRUT ASSEMBLY…………………………………………………………………………….318
FIGURE 7-5A. MAIN GEAR OLEO STRUT ASSEMBLY (CONT.)…………………………………………………………………….319
FIGURE 7-6. MAIN GEAR INSTALLATION…………………………………………………………………………………..321
FIGURE 7-7. NOSE WHEEL ASSEMBLY……………………………………………………………………………………..323
FIGURE 7-8. MAIN WHEEL ASSEMBLY……………………………………………………………………………………..325
FIGURE 7-9. WHEEL BRAKE ASSEMBLY…………………………………………………………………………………….326
FIGURE 7-10. REMOVAL OF ANCHOR BOLT………………………………………………………………………………….327
FIGURE 7-11. INSTALLATION OF ANCHOR BOLT……………………………………………………………………………..328
FIGURE 7-12. BRAKE SYSTEM INSTALLATION……………………………………………………………………………….329
FIGURE 7-13. BRAKE MASTER CYLINDER (HAND/PARKING BRAKE)………………………………………………………………..330
FIGURE 7-14. BRAKE CYLINDER (TOE BRAKE) (10-27, 10-30, 17000)…………………………………………………………..333
FIGURE 7-15. RETAINER RING INSTALLATION TOOL………………………………………………………………………….338
FIGURE 8-1. TYPICAL NICKS AND REMOVAL METHOD………………………………………………………………………….347
FIGURE 8-2. PROPELLER AND COWLING INSTALLATION………………………………………………………………………..348
FIGURE 8-3. ENGINE INSTALLATION……………………………………………………………………………………..351
FIGURE 8-4. ENGINE SHOCK MOUNT INSTALLATION…………………………………………………………………………..353
FIGURE 8-5. ADJUSTMENT OF ENGINE CONTROLS…………………………………………………………………………….354
FIGURE 8-6. CARBURETOR……………………………………………………………………………………………..355
FIGURE 8-7. EXPLODED VIEW OF MAGNETO (4200/4300 SERIES)………………………………………………………………..360
FIGURE 8-8. T-100 ASSEMBLY AND TIMING TOOL KIT………………………………………………………………………..361
FIGURE 8-9. REMOVING COIL WEDGES…………………………………………………………………………………….362
FIGURE 8-10. INDEX PLATE AND TIMING PLUG……………………………………………………………………………..363
FIGURE 8-11. INSTALLATION OF BEARINGS AND BEARING PLATE………………………………………………………………..364
FIGURE 8-12. POSITION OF MAGNETO ON T-100 TOOL AND OIL SEAL INSTALLATION…………………………………………………364
FIGURE 8-13. TIMING MAGNETO INTERNALLY AND ASSEMBLY……………………………………………………………………365
FIGURE 8-14. MAGNETO INSPECTION (BENDIX)……………………………………………………………………………..369
FIGURE 8-15. CONTACT SPRING INSPECTION……………………………………………………………………………….369
FIGURE 8-16. IMPULSE COUPLING INSPECTION……………………………………………………………………………..369
FIGURE 8-17. MAGNETO TIMING MARKS……………………………………………………………………………………371
FIGURE 8-18. TIMING POINTER…………………………………………………………………………………………371
FIGURE 8-19. TIMING KIT INSTALLED……………………………………………………………………………………371
FIGURE 8-20. BREAKER COMPARTMENT WITH CAST TIMING MARKS………………………………………………………………..371
FIGURE 8-21. STRIPPING TOOL…………………………………………………………………………………………375
FIGURE 8-22. INSERTING STRIPPING TOOL………………………………………………………………………………..375
FIGURE 8-23. CUTTING INSULATION……………………………………………………………………………………..375
FIGURE 8-24. REMOVING SILICONE RUBBER FROM WIRE……………………………………………………………………….375
FIGURE 8-25. INSTALLATION OF PLUG END NUT…………………………………………………………………………….376
FIGURE 8-26. FLARING OUT OF SHIELDING………………………………………………………………………………..376
FIGURE 8-27. INSTALLATION OF FERRULE…………………………………………………………………………………377
FIGURE 8-28. DRIVING TOOL…………………………………………………………………………………………..377
FIGURE 8-29. INSTALLATION IN HOUSING…………………………………………………………………………………377
FIGURE 8-30. SECURING WIRE IN HOUSING………………………………………………………………………………..377
FIGURE 8-31. INSTALLATION OF ELECTRICAL SCREW…………………………………………………………………………378
FIGURE 8-32. INSTALLATION OF INSULATION SLEEVE………………………………………………………………………..378
FIGURE 8-33. INSTALLATION OF SPRING………………………………………………………………………………….378
FIGURE 8-34. REMOVING SPARK PLUG FROZEN TO BUSHING…………………………………………………………………….378
FIGURE 8-35. WARRIOR II ICE DETECTION SYSTEM………………………………………………………………………….382
FIGURE 8-36. WARRIOR III ICE DETECTION SYSTEM…………………………………………………………………………384
FIGURE 8-37. STATIC RPM (SEA LEVEL ± 500 PRESSURE ALTITUDE ONLY)………………………………………………………..388
FIGURE 8-38. CHANGE IN STATIC RPM VS. ENGINE OIL TEMPERATURE……………………………………………………………389
FIGURE 8-39 PSYCHROMETRIC CHART……………………………………………………………………………………..390
FIGURE 9-1. PA-28-151 AND PA-28 -161, WARRIOR II FUEL SYSTEM DIAGRAM…………………………………………………….406
FIGURE 9-2. PA-28 -161, WARRIOR III FUEL SYSTEM DIAGRAM………………………………………………………………..409
FIGURE 9-3. TOLERANCES, UNION NUT AND TUBING NUT………………………………………………………………………411
FIGURE 9-4. RESISTANCE DECADE TEST BOX SET UP…………………………………………………………………………415
FIGURE 9-5. WARRIOR III FUEL QUANTITY NEEDLE DEVIATION…………………………………………………………………415
FIGURE 9-6. FUEL QUANTITY TRANSMITTER CHECKING JIG…………………………………………………………………….417
FIGURE 9-7. FABRICATED FUEL QUANTITY TRANSMITTER CHECKING JIG…………………………………………………………..418
FIGURE 9-8. LOCKING FUEL CAP………………………………………………………………………………………..419
FIGURE 9-9. FUEL FILTER BOWL AND SCREEN………………………………………………………………………………420
FIGURE 9-10. PLUNGER FUEL PUMP………………………………………………………………………………………422
FIGURE 9-11. ENGINE PRIMER………………………………………………………………………………………….424
FIGURE 10-1. PA-28-151, WARRIOR AND PA-28-161, WARRIOR II VACUUM PUMP……………………………………………………438
FIGURE 10-2. PA-28-161, WARRIOR III VACUUM PUMP……………………………………………………………………….438
FIGURE 10-3. WARRIOR I AND II INSTRUMENT PANEL (TYPICAL)……………………………………………………………….439
FIGURE 10-4. WARRIOR III VFR INSTRUMENT PANEL (TYPICAL)………………………………………………………………..440
FIGURE 10-4A. VACUUM PUMP VANE WEAR INSPECTION – AERO ACCESSORIES ONLY…………………………………………………..445
FIGURE 10-5. WARRIOR II AND III AUXILIARY VACUUM SYSTEM INSTALLATION…………………………………………………….449
FIGURE 10-6. WARRIOR II AND III AUXILIARY VACUUM ELECTRICAL SCHEMATIC……………………………………………………450
FIGURE 10-7. PITOT AND STATIC AIR SYSTEMS…………………………………………………………………………….454
FIGURE 10-8. WARRIOR III INSTRUMENT CLUSTER – OIL TEMPERATURE, FUEL PRESSURE, AND OIL PRESSURE GAUGE………………………..466
FIGURE 10-9. WARRIOR III FUEL QUANTITY GAUGE………………………………………………………………………….468
FIGURE 10-10. EXHAUST GAS TEMPERATURE PROBE INSTALLATION……………………………………………………………….472
FIGURE 11-1. EXPLODED VIEW OF PRESTOLITE AND ELECTROSYSTEMS ALTERNATORS………………………………………………….502
FIGURE 11-2. LAMP BANK LOAD…………………………………………………………………………………………503
FIGURE 11-3. REMOVAL OF RECTIFIER……………………………………………………………………………………504
FIGURE 11-4. REMOVAL OF SLIP RING END BEARING…………………………………………………………………………504
FIGURE 11-5. REMOVAL OF DRIVE END HEAD……………………………………………………………………………….505
FIGURE 11-6. REMOVAL OF END HEAD BEARING……………………………………………………………………………..505
FIGURE 11-7. TESTING ROTOR FOR GROUNDS……………………………………………………………………………….505
FIGURE 11-8. TESTING ROTOR FOR SHORTS………………………………………………………………………………..505
FIGURE 11-9. INSTALLATION OF BEARING…………………………………………………………………………………507
FIGURE 11-10. INSTALLATION OF RECTIFIER………………………………………………………………………………507
FIGURE 11-11. TERMINAL ASSEMBLY……………………………………………………………………………………..508
FIGURE 11-12. SLIP RING END BEARING ASSEMBLY………………………………………………………………………….508
FIGURE 11-13. TESTING ALTERNATOR…………………………………………………………………………………….508
FIGURE 11-14. BRUSH INSTALLATION…………………………………………………………………………………….509
FIGURE 11-15. INTERNAL WIRING DIAGRAM………………………………………………………………………………..509
FIGURE 11-16. EXPLODED VIEW OF CHRYSLER ALTERNATOR…………………………………………………………………….512
FIGURE 11-17. CHECKING CHRYSLER ALTERNATOR FIELD CURRENT DRAW…………………………………………………………..514
FIGURE 11-18. TESTING CHRYSLER ALTERNATOR FIELD CIRCUIT………………………………………………………………..515
FIGURE 11-19. CHRYSLER ALTERNATOR RECTIFIER END SHIELD AND STATOR ASSEMBLY……………………………………………….516
FIGURE 11-20. TESTING POSITIVE RECTIFIERS WITH C-3829 TESTER……………………………………………………………517
FIGURE 11-21. TESTING NEGATIVE RECTIFIERS WITH C-3829 TESTER……………………………………………………………517
FIGURE 11-22. TESTING POSITIVE RECTIFIERS WITH TEST LAMP……………………………………………………………….518
FIGURE 11-23. TESTING NEGATIVE RECTIFIERS WITH TEST LAMP……………………………………………………………….518
FIGURE 11-24. RECTIFIER AND HEAT SINK ASSEMBLY REMOVAL…………………………………………………………………519
FIGURE 11-25. RECTIFIER END SHIELD ASSEMBLY…………………………………………………………………………..519
FIGURE 11-26. TESTING STATOR………………………………………………………………………………………..520
FIGURE 11-27. REMOVAL OF PULLEY……………………………………………………………………………………..520
FIGURE 11-28. REMOVAL OF BEARING…………………………………………………………………………………….520
FIGURE 11-29. REMOVAL OF RECTIFIER END SHIELD BEARING………………………………………………………………….520
FIGURE 11-30. TESTING ROTOR FOR GROUND……………………………………………………………………………….521
FIGURE 11-31. TESTING ROTOR FOR OPEN OR SHORTS………………………………………………………………………..521
FIGURE 11-32. INSTALLATION OF GREASE RETAINER…………………………………………………………………………522
FIGURE 11-33. INSTALLATION OF RECTIFIER END SHIELD BEARING……………………………………………………………..522
FIGURE 11-34. INSTALLATION OF DRIVE END SHIELD BEARING…………………………………………………………………523
FIGURE 11-35. INSTALLATION OF PULLEY…………………………………………………………………………………523
FIGURE 11-36. INSTALLATION OF INSULATORS ASSEMBLY……………………………………………………………………..523
FIGURE 11-37. INSTALLATION OF POSITIVE RECTIFIER………………………………………………………………………523
FIGURE 11-38. INSTALLATION OF CAPACITOR………………………………………………………………………………525
FIGURE 11-39. INSTALLATION OF BATTERY OUTPUT INSULATOR…………………………………………………………………525
FIGURE 11-40. INSTALLATION OF NEGATIVE RECTIFIER ASSEMBLY………………………………………………………………525
FIGURE 11-41. INSTALLATION OF STATOR…………………………………………………………………………………525
FIGURE 11-42. BATTERY INSTALLATION – 12 VOLT (WARRIOR/WARRIOR II)……………………………………………………….529
FIGURE 11-43. BATTERY INSTALLATION – 24 VOLT (WARRIOR III S/N’S 2816110 AND UP)…………………………………………..532
FIGURE 11-44. LAMAR 14 VDC REGULATOR CHECK……………………………………………………………………………539
FIGURE 11-45. LAMAR 28 VDC REGULATOR CHECK……………………………………………………………………………540
FIGURE 11-46. APPLICATION OF WICO OVERVOLTAGE CONTROL………………………………………………………………….542
FIGURE 11-47. LAMAR 14 VDC SYSTEM OVERVOLTAGE CHECK……………………………………………………………………543
FIGURE 11-48. LAMAR 28 VDC SYSTEM OVERVOLTAGE CHECK……………………………………………………………………543
FIGURE 11-49. EXPLODED VIEW OF GEAR REDUCTION STARTER MOTOR…………………………………………………………….545
FIGURE 11-50. TURNING STARTING MOTOR COMMUTATOR……………………………………………………………………….547
FIGURE 11-51. TESTING MOTOR ARMATURE FOR SHORTS……………………………………………………………………….547
FIGURE 11-52. TESTING MOTOR FIELDS FOR GROUNDS………………………………………………………………………..549
FIGURE 11-53. NO LOAD TEST HOOKUP……………………………………………………………………………………549
FIGURE 11-54. STALL TORQUE HOOKUP……………………………………………………………………………………549
FIGURE 11-55. STROBE LIGHT CONNECTIONS (WARRIOR/WARRIOR II)…………………………………………………………….555
FIGURE 11-56. STROBE LIGHT CONNECTIONS (WARRIOR II)……………………………………………………………………556
FIGURE 11-57. STROBE LIGHT CONNECTIONS (WARRIOR III)…………………………………………………………………..557
FIGURE 11-58. ANNUNCIATOR PANEL (WARRIOR/WARRIOR II)…………………………………………………………………..561
FIGURE 11-59. ANNUNCIATOR PANEL (WARRIOR III)…………………………………………………………………………562
FIGURE 11-60. IGNITION SWITCH WIRE POSITIONS………………………………………………………………………….567
FIGURE 11-60A. CIRCUIT BREAKER PANEL (WARRIOR/WARRIOR II – TYPICAL)……………………………………………………..568
FIGURE 12-1. TWO YEAR, MAGNESIUM BATTERY CONNECTIONS…………………………………………………………………..635
FIGURE 12-2. GARRETT ELT SCHEMATIC…………………………………………………………………………………..635
FIGURE 12-3. COMMUNICATIONS COMPONENTS ELT SCHEMATIC…………………………………………………………………..637
FIGURE 12-4. NARCO ELT 10 SCHEMATIC (PRIOR TO S/N 2816053)……………………………………………………………..639
FIGURE 12-5. NARCO ELT 10 SCHEMATIC (2816053 TO 2816093)……………………………………………………………….639
FIGURE 12-6. ELT PORTABLE FOLDING ANTENNA (NARCO)……………………………………………………………………..640
FIGURE 12-7. ELT USING FIXED AIRCRAFT ANTENNA (NARCO)………………………………………………………………….640
FIGURE 12-8. NARCO ELT 910 WIRING SCHEMATIC…………………………………………………………………………..642
FIGURE 12-9. ELT 910 BATTERY PACK……………………………………………………………………………………643
FIGURE 12-10. ARTEX 110 ELT…………………………………………………………………………………………644
FIGURE 12-11. ARTEX ELT 110 WIRING SCHEMATIC………………………………………………………………………….645
FIGURE 13-1. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM………………………………………………………………654
FIGURE 14-1. AIR CONDITIONING SYSTEM INSTALLATION……………………………………………………………………..669
FIGURE 14-2. SERVICE VALVES…………………………………………………………………………………………674
FIGURE 14-3. TEST MANIFOLD AND CHARGING CART………………………………………………………………………….675
FIGURE 14-4. MANIFOLD SET OPERATION………………………………………………………………………………….675
FIGURE 14-5. MANIFOLD TO RECHARGING/TEST STAND HOOKUP………………………………………………………………….676
FIGURE 14-6. ROBINAIR 34700 CONTROL PANEL AND HOSE CONNECTIONS………………………………………………………….677
FIGURE 14-7. ROBINAIR 34700 HOSE HOOKUP………………………………………………………………………………678
FIGURE 14-8. COMPRESSOR AND FABRICATED OIL DIPSTICK……………………………………………………………………687
FIGURE 14-9. COMPRESSOR AND ALTERNATOR BELT INSTALLATION (SHEET 1 OF 2)………………………………………………….689
FIGURE 14-9. COMPRESSOR AND ALTERNATOR BELT INSTALLATION (SHEET 2 OF 2)………………………………………………….690
FIGURE 14-10. MAGNETIC CLUTCH……………………………………………………………………………………….692
FIGURE 14-11. CONDENSER AIR SCOOP INSTALLATION………………………………………………………………………..694
FIGURE 14-12. EXPANSION VALVE……………………………………………………………………………………….695
FIGURE 14-13. COMPONENTS INSTALLATION………………………………………………………………………………..697
FIGURE 14-14. TYPICAL AIR CONDITIONING WIRING SCHEMATIC………………………………………………………………..699
LIST OF TABLES……………………………………………………………………………………………………….. 25
TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS………………………………………………………………. 42
TABLE II-II. FLARE FITTING TORQUE VALUES…………………………………………………………………………….. 48
TABLE II-III. RECOMMENDED NUT TORQUES……………………………………………………………………………….. 50
TABLE II-IV. CONVERSION TABLES……………………………………………………………………………………… 52
TABLE II-V. DECIMAL/MILLIMETER EQUIVALENTS OF DRILL SIZES……………………………………………………………… 55
TABLE II-VI. MAXIMUM DISTANCE BETWEEN SUPPORTS FOR FLUID TUBING………………………………………………………… 56
TABLE II-VII. HOSE CLAMP TIGHTENING. (INITIAL INSTALLATION)……………………………………………………………. 56
TABLE II-VIII. LUBRICANT SPECIFICATION CROSS-REFERENCE………………………………………………………………… 80
TABLE II-IX. THREAD LUBRICANTS……………………………………………………………………………………… 82
TABLE II-X. SPECIAL INSTRUCTIONS……………………………………………………………………………………. 83
TABLE II-XI. LIST OF CONSUMABLE MATERIALS……………………………………………………………………………. 93
TABLE II-XII. VENDOR CONTACT INFORMATION……………………………………………………………………………..100
TABLE II-XIII. TYPES OF METAL CORROSION………………………………………………………………………………105
TABLE III-I. INSPECTION REPORT………………………………………………………………………………………127
TABLE IV-I. LIST OF MATERIALS – THERMOPLASTIC REPAIR…………………………………………………………………..229
TABLE IV-II. BALANCE SPECIFICATIONS………………………………………………………………………………….237
TABLE IV-III. ELECTRICAL BONDING RESISTANCE INDEX……………………………………………………………………..217
TABLE V-I. CABLE TENSION VS. AMBIENT TEMPERATURE………………………………………………………………………250
TABLE V-II. FLIGHT CONTROL SURFACES RIGGING LIMITS…………………………………………………………………….259
TABLE V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS)………………………………………………………………….297
TABLE VII-I. LANDING GEAR TROUBLESHOOTING…………………………………………………………………………….336
TABLE VIII-I. PROPELLER TORQUE LIMITS………………………………………………………………………………..348
TABLE VIII-II. PROPELLER APPLICABILITY……………………………………………………………………………….386
TABLE VIII-III. STATIC RPM PA-280-161 WITH 74DM6-0-60 PROPELLER…………………………………………………………391
TABLE VIII-IV. STATIC RPM PA-280-161 WITH 74DM6-0-58 PROPELLER………………………………………………………….391
TABLE VIII-V. ENGINE TROUBLESHOOTING…………………………………………………………………………………392
TABLE IX-I. TRANSMITTER/FUEL GAUGE TOLERANCES…………………………………………………………………………412
TABLE IX-II. FUEL QUANTITY GAUGE RESISTANCE/TOLERANCE VALUES……………………………………………………………413
TABLE IX-III. 14 VDC FUEL QUANTITY GAUGE TOLERANCE VALUES………………………………………………………………413
TABLE IX-IV. 28 VDC FUEL QUANTITY GAUGE RESISTANCE/TOLERANCE VALUE………………………………………………………414
TABLE IX-V. 28 VDC FUEL QUANTITY GAUGE TOLERANCE VALUES………………………………………………………………..416
TABLE IX-VI. FUEL QUANTITY TRANSMITTER CALIBRATION TOLERANCE……………………………………………………………416
TABLE IX-VII. FUEL SYSTEM TROUBLESHOOTING…………………………………………………………………………….426
TABLE X-I. TROUBLESHOOTING VACUUM SYSTEM……………………………………………………………………………..441
TABLE X-II. TROUBLESHOOTING (DIRECTIONAL GYRO) INDICATOR……………………………………………………………….451
TABLE X-III. TROUBLESHOOTING ATTITUDE DEVIATION INDICATOR………………………………………………………………453
TABLE X-IV. TROUBLESHOOTING VERTICAL SPEED INDICATOR…………………………………………………………………..455
TABLE X-V. TROUBLESHOOTING ALTIMETER…………………………………………………………………………………456
TABLE X-VI. TROUBLESHOOTING PITOT/STATIC TUBES AND AIRSPEED INDICATOR……………………………………………………458
TABLE X-VII. TROUBLESHOOTING MAGNETIC COMPASS…………………………………………………………………………459
TABLE X-VIII. TROUBLESHOOTING TACHOMETER……………………………………………………………………………..460
TABLE X-IX. TROUBLESHOOTING PA-28-151, WARRIOR AND PA-28-161, WARRIOR II ENGINE OIL PRESSURE GAUGE………………………….463
TABLE X-X. TROUBLESHOOTING PA-28-151, WARRIOR AND PA-28-161, WARRIOR II ENGINE OIL TEMPERATURE GAUGE………………………..463
TABLE X-XI. TROUBLESHOOTING PA-28-161, WARRIOR III ENGINE OIL PRESSURE GAUGE……………………………………………..464
TABLE X-XII. TROUBLESHOOTING PA-28-161, WARRIOR III ENGINE OIL TEMPERATURE GAUGE………………………………………….464
TABLE X-XIII. TROUBLESHOOTING FUEL PRESSURE GAUGE……………………………………………………………………..465
TABLE X-XIV. WARRIOR III INSTRUMENT CALIBRATION CHART………………………………………………………………….466
TABLE X-XV. TURN AND BANK INDICATOR………………………………………………………………………………….467
TABLE X-XVI. TROUBLESHOOTING FUEL QUANTITY INDICATOR…………………………………………………………………..468
TABLE X-XVII. TROUBLESHOOTING CYLINDER HEAD TEMPERATURE GAUGE…………………………………………………………..471
TABLE X-XVIII. TROUBLESHOOTING EXHAUST GAS TEMPERATURE GAUGE……………………………………………………………473
TABLE XI-I. TROBLESHOOTING ELECTRICAL SYSTEM………………………………………………………………………….484
TABLE XI-II. PRESTOLITE AND ELECTROSYSTEMS ALTERNATOR SPECIFICATIONS…………………………………………………….510
TABLE XI-III. CHRYSLER ALTERNATOR SPECIFICATIONS………………………………………………………………………526
TABLE XI-IV. ALTERNATOR BELT TENSION…………………………………………………………………………………526
TABLE XI-V. HYDROMETER READING AND BATTERY CHARGE PERCENT WARRIOR/WARRIOR II 12 VOLT BATTERY……………………………….528
TABLE XI-VI. HYDROMETER READING AND BATTERY CHARGE PERCENT WARRIOR III 24 VOLT BATTERY…………………………………….535
TABLE XI-VII. ELECTROLYTE TEMPERATURE CORRECTIONS……………………………………………………………………..535
TABLE XI-VIII. SPECIFIC GRAVITY TEMPERATURE CORRECTION…………………………………………………………………535
TABLE XI-IX. DISCHARGE RATE…………………………………………………………………………………………536
TABLE XI-X. ELECTROLYTE FREEZING POINT……………………………………………………………………………….536
TABLE XI-XI. STARTING MOTOR SPECIFICATIONS……………………………………………………………………………550
TABLE XI-XII. ANNUNCIATOR LIGHTS DESCRIPTION AND FUNCTION (WARRIOR III)………………………………………………….560
TABLE XI-XIII. LAMP REPLACEMENT GUIDE………………………………………………………………………………..569
TABLE XI-XIV. WARRIOR/WARRIOR II ELECTRICAL SYSTEM COMPONENT LOADS………………………………………………………570
TABLE XI-XV. WARRIOR III ELECTRICAL SYSTEM COMPONENT LOADS……………………………………………………………..571
TABLE XI-XVI. ELECTRICAL WIRE CODING…………………………………………………………………………………579
TABLE XI-XVII. ELECTRICAL SYMBOLS (OLD STYLE)…………………………………………………………………………580
TABLE XI-XVIII. ELECTRICAL SYMBOLS (NEW STYLE)………………………………………………………………………..581
TABLE XIV-I. TROUBLESHOOTING AIR CONDITIONER………………………………………………………………………….663
TABLE XIV-II. TROUBLESHOOTING AIR CONDITIONER SYSTEM…………………………………………………………………..665
TABLE XIV-III. REFRIGERANT TEMPERATURE PRESSURE……………………………………………………………………….671
TABLE XIV-IV. ALUMINUM TUBING TORQUE…………………………………………………………………………………673
TABLE XIV-V. SYSTEM VACUUM………………………………………………………………………………………….676
TABLE XIV-VI. COMPRESSOR OIL CHARGE………………………………………………………………………………….687
TABLE XIV-VII. COMPRESSOR MISALIGNMENT AND IDLER PULLEY NOMINAL LOCATION…………………………………………………688
TABLE XIV-VIII. BLOWER SYSTEM WIRE COLOR CODES………………………………………………………………………..701
SECTION I – AIRWORTHINESS LIMITATIONS…………………………………………………………………………………… 27
TABLE OF CONTENTS…………………………………………………………………………………………………. 29
LIMITATIONS………………………………………………………………………………………………………. 31
INSPECTIONS………………………………………………………………………………………………………. 31
MAJOR REPAIRS TO LIFE LIMITED COMPONENTS…………………………………………………………………………….. 31
LIFE LIMITED PARTS MARKING AND DISPOSITION…………………………………………………………………………… 31
SECTION II – HANDLING AND SERVICING…………………………………………………………………………………….. 33
TABLE OF CONTENTS…………………………………………………………………………………………………. 35
2-1. INTRODUCTION…………………………………………………………………………………………………. 39
2-2. DIMENSIONS…………………………………………………………………………………………………… 39
2-3. STATION REFERENCE LINES……………………………………………………………………………………….. 39
2-4. WEIGHT AND BALANCE DATA……………………………………………………………………………………….. 39
2-5. SERIAL NUMBER PLATE…………………………………………………………………………………………… 39
2-6. ACCESS AND INSPECTION PROVISIONS……………………………………………………………………………….. 39
2-7. TOOLS AND TEST EQUIPMENT………………………………………………………………………………………. 39
2-8. THREADED FASTENER INSTALLATION…………………………………………………………………………………. 46
2-8A. TORQUE WRENCHES……………………………………………………………………………………………… 47
2-8B. TORQUE REQUIREMENTS………………………………………………………………………………………….. 47
2-8C. METRIC CONVERSION……………………………………………………………………………………………. 51
2-9. WALKWAY, HANDHOLD AND STEP…………………………………………………………………………………….. 58
2-10. GROUND HANDLING……………………………………………………………………………………………… 58
2-11. INTRODUCTION TO GROUND HANDLING……………………………………………………………………………. 58
2-12. JACKING…………………………………………………………………………………………………. 58
2-13. WEIGHING………………………………………………………………………………………………… 59
2-14. LEVELING………………………………………………………………………………………………… 59
2-15. MOORING…………………………………………………………………………………………………. 60
2-16. LOCKING AIRPLANE…………………………………………………………………………………………. 60
2-17. PARKING…………………………………………………………………………………………………. 60
2-18. TOWING………………………………………………………………………………………………….. 61
2-19. TAXIING…………………………………………………………………………………………………. 61
2-20. 14 VDC EXTERNAL POWER RECEPTACLE………………………………………………………………………………. 61
2-20A. 28 VDC EXTERNAL POWER RECEPTACLE……………………………………………………………………………… 61
2-21. OPERATION OF EXTERNAL 14 VDC POWER RECEPTACLE……………………………………………………………….. 61
2-21A. OPERATION OF EXTERNAL 28 VDC POWER RECEPTACLE………………………………………………………………. 63
2-22. CLEANING……………………………………………………………………………………………………. 63
2-23. CLEANING ENGINE COMPARTMENT……………………………………………………………………………….. 63
2-24. CLEANING LANDING GEAR…………………………………………………………………………………….. 64
2-25. CLEANING EXTERIOR SURFACES………………………………………………………………………………… 64
2-26. CLEANING WINDSHIELD AND WINDOWS……………………………………………………………………………. 64
2-27. CLEANING HEADLINER, SIDE PANELS AND SEATS…………………………………………………………………… 65
2-28. CLEANING CARPETS…………………………………………………………………………………………. 65
2-29. SERVICING…………………………………………………………………………………………………… 65
2-30. INTRODUCTION TO SERVICING…………………………………………………………………………………. 65
2-31. LANDING GEAR SYSTEM………………………………………………………………………………………….. 65
2-32. SERVICING LANDING GEAR……………………………………………………………………………………. 65
2-33. OLEO STRUTS…………………………………………………………………………………………………. 65
2-34. SERVICING OLEO STRUTS…………………………………………………………………………………….. 65
2-35. FILLING NOSE GEAR OLEO STRUT………………………………………………………………………………. 67
2-36. FILLING MAIN GEAR OLEO STRUT………………………………………………………………………………. 68
2-37. INFLATING OLEO STRUTS…………………………………………………………………………………….. 69
2-38. BRAKE SYSTEM………………………………………………………………………………………………… 69
2-39. SERVICING BRAKE SYSTEM……………………………………………………………………………………. 69
2-40. FILLING BRAKE CYLINDER RESERVOIR…………………………………………………………………………… 69
2-41. DRAINING BRAKE SYSTEM…………………………………………………………………………………….. 69
2-42. TIRES………………………………………………………………………………………………………. 70
2-43. SERVICING TIRES………………………………………………………………………………………….. 70
2-43A. TIRE BALANCER…………………………………………………………………………………………… 70
2-44. POWER PLANT…………………………………………………………………………………………………. 72
2-45. SERVICING POWER PLANT…………………………………………………………………………………….. 72
2-46. INDUCTION AIR FILTER…………………………………………………………………………………………. 72
2-47. REMOVAL OF AIR FILTER…………………………………………………………………………………….. 72
2-48. SERVICE INSTRUCTIONS (INSPECTION AND REPLACEMENT)……………………………………………………………. 72
2-49. INSTALLATION OF AIR FILTER………………………………………………………………………………… 72
2-50. PROPELLER…………………………………………………………………………………………………… 72
2-51. SERVICING PROPELLER………………………………………………………………………………………. 72
2-52. FUEL SYSTEM…………………………………………………………………………………………………. 72
2-53. SERVICING FUEL SYSTEM…………………………………………………………………………………….. 72
2-54. FILLING FUEL TANKS……………………………………………………………………………………….. 74
2-55. ANTI-ICING FUEL ADDITIVE………………………………………………………………………………….. 74
2-56. FUEL DRAIN VALVE AND STRAINER……………………………………………………………………………… 74
2-57. DRAINING FUEL SYSTEM……………………………………………………………………………………… 74
2-58. ELECTRICAL SYSTEM……………………………………………………………………………………………. 75
2-59. SERVICING ELECTRICAL SYSTEM……………………………………………………………………………….. 75
2-60. LUBRICATION…………………………………………………………………………………………………. 76
2-61. OIL SYSTEM (ENGINE)………………………………………………………………………………………….. 76
2-62. SERVICING OIL SYSTEM……………………………………………………………………………………… 76
2-63. FILLING OIL SUMP…………………………………………………………………………………………. 76
2-64. DRAINING OIL SUM…………………………………………………………………………………………. 76
2-65. OIL SCREENS (SUCTION)…………………………………………………………………………………….. 76
2-66. OIL SCREEN (PRESSURE)…………………………………………………………………………………….. 76
2-67. OIL FILTER (FULL FLOW)……………………………………………………………………………………. 77
2-68. RECOMMENDATIONS FOR CHANGING OIL…………………………………………………………………………… 77
2-69. LUBRICATION INSTRUCTIONS………………………………………………………………………………….. 78
2-69A. PRECAUTIONS…………………………………………………………………………………………….. 78
2-70. APPLICATION OF GREASE…………………………………………………………………………………….. 78
2-71. APPLICATION OF OIL……………………………………………………………………………………….. 78
2-71A. LUBRICATION OF THREADS…………………………………………………………………………………… 79
2-72. WINTERIZATION PLATE………………………………………………………………………………………. 79
2-73. LUBRICATION CHART………………………………………………………………………………………… 79
2-74. CORROSION CONTROL…………………………………………………………………………………………….103
2-75. FORM OF CORROSION…………………………………………………………………………………………103
2-76. CONDITIONS AFFECTING CORROSION……………………………………………………………………………..103
2-77. INSPECTION……………………………………………………………………………………………….104
2-78. CORROSION REMOVAL AND CONTROL………………………………………………………………………………104
2-79. AREAS PRONE TO CORROSION…………………………………………………………………………………..106
2-80. REPAINTING…………………………………………………………………………………………………..107
2-81. PRODUCT LISTING FOR URETHANE ENAMEL AIRCRAFT FINISH…………………………………………………………..107
2-82. NOT USED…………………………………………………………………………………………………108
2-83. PREPARATION AND APPLICATION OF DUPONT IMRON URETHANE ENAMEL……………………………………………………108
2-84. PRODUCT LISTING FOR RANDOLPH PAINT FINISH……………………………………………………………………108
2-85. NOT USED…………………………………………………………………………………………………108
2-86. FINISH PAINTING WITH RANDOLPH PAINT (B5420/D7784)…………………………………………………………….109
2-87. REPAIRS………………………………………………………………………………………………….109
2-88. REMOVAL OF CHERRYLOCK RIVETS…………………………………………………………………………………..110
SECTION III – INSPECTION……………………………………………………………………………………………….113
TABLE OF CONTENTS………………………………………………………………………………………………….115
GENERAL…………………………………………………………………………………………………………..117
TIME LIMITS……………………………………………………………………………………………………….119
SCHEDULED MAINTENANCE………………………………………………………………………………………………121
DESCRIPTION……………………………………………………………………………………………………….121
DEFINITIONS……………………………………………………………………………………………………….121
INSPECTION REQUIREMENTS…………………………………………………………………………………………….124
ANNUAL / 100 HOUR INSPECTION…………………………………………………………………………………….124
PROGRESSIVE INSPECTION………………………………………………………………………………………….124
OVERLIMITS INSPECTION…………………………………………………………………………………………..124
ANNUAL / 100 HOUR INSPECTION PROCEDURE……………………………………………………………………………….125
SPECIAL INSPECTIONS………………………………………………………………………………………………..139
REQUIREMENTS…………………………………………………………………………………………………..139
PER FLIGHT HOUR………………………………………………………………………………………………..139
PER CALENDAR YEAR………………………………………………………………………………………………142
PER SPECIFIC OPERATION / OPERATING ENVIRONMENT…………………………………………………………………….144
HIGH DUST OR INDUSTRIAL POLLUTION………………………………………………………………………………..144
HIGH SALT OR HIGH HUMIDITY………………………………………………………………………………………144
EXTREME COLD…………………………………………………………………………………………………..145
SOFT OR UNUSUAL TERRAIN…………………………………………………………………………………………145
PROCEDURES………………………………………………………………………………………………………..147
ENGINE MOUNT CORROSION INSPECTION, IMMERSION IN WATER………………………………………………………………147
WING SPAR INSPECTION……………………………………………………………………………………………148
WING AFT SPAR-TO-FUSELAGE ATTACHMENT HARDWARE 100 HOUR INSPECTION……………………………………………………151
STABILATOR ATTACH FITTINGS CORROSION INSPECTION……………………………………………………………………152
FLAP CONTROL CABLE ATTACHMENT BOLT INSPECTION……………………………………………………………………..153
AFT WING ATTACH FITTINGS 100 HOUR INSPECTION………………………………………………………………………154
FUEL TANK/WING SPAR CORROSION INSPECTION………………………………………………………………………….159
CAST MAIN LANDING GEAR STRUT CYLINDER 100 HOUR INSPECTION…………………………………………………………..160
MAIN LANDING GEAR TORQUE LINK GREASER BOLT INSPECTION………………………………………………………………161
EXHAUST SYSTEM INSPECTION……………………………………………………………………………………….162
AILERON CENTERING CABLE INSPECTION……………………………………………………………………………….164
UNSCHEDULED MAINTENANCE CHECKS………………………………………………………………………………………167
LIGHTNING STRIKE……………………………………………………………………………………………….167
ENGINE OVERTEMP, LOSS OF OIL, OR SUDDEN STOPPAGE…………………………………………………………………..168
SEVERE TURBULENCE, HARD OR OVERWEIGHT LANDING……………………………………………………………………..168
FLAPS EXTENDED ABOVE MAXIMUM FLAP EXTENSION SPEED (V FE )…………………………………………………………..169
FLOOD DAMAGE, IMMERSION IN WATER…………………………………………………………………………………170
SECTION IV – STRUCTURES………………………………………………………………………………………………..181
TABLE OF CONTENTS………………………………………………………………………………………………….183
4-1. INTRODUCTION………………………………………………………………………………………………….187
4-2. DESCRIPTION…………………………………………………………………………………………………..187
4-3. WING GROUP……………………………………………………………………………………………………187
4-4. WING TIP……………………………………………………………………………………………………..187
4-5. REMOVAL OF WING TIP………………………………………………………………………………………..187
4-6. INSTALLATION OF WING TIP……………………………………………………………………………………188
4-7. AILERON………………………………………………………………………………………………………188
4-8. REMOVAL OF AILERON…………………………………………………………………………………………188
4-9. INSTALLATION OF AILERON…………………………………………………………………………………….188
4-10. WING FLAP……………………………………………………………………………………………………188
4-11. REMOVAL OF WING FLAP………………………………………………………………………………………188
4-12. INSTALLATION OF WING FLAP………………………………………………………………………………….191
4-13. WING………………………………………………………………………………………………………..191
4-14. REMOVAL OF WING…………………………………………………………………………………………..191
4-15. INSTALLATION OF WING………………………………………………………………………………………192
4-15A. INSTALLATION OF STALL STRIPS………………………………………………………………………………197
4-16. EMPENNAGE GROUP………………………………………………………………………………………………197
4-17. STABILATOR…………………………………………………………………………………………………..197
4-18. REMOVAL OF STABILATOR……………………………………………………………………………………..197
4-19. INSTALLATION OF STABILATOR…………………………………………………………………………………199
4-20. STABILATOR TRIM TAB…………………………………………………………………………………………..202
4-21. REMOVAL OF STABILATOR TRIM TAB……………………………………………………………………………..202
4-22. INSTALLATION OF STABILATOR TRIM TAB…………………………………………………………………………202
4-23. RUDDER………………………………………………………………………………………………………202
4-24. REMOVAL OF RUDDER…………………………………………………………………………………………202
4-25. INSTALLATION OF RUDDER…………………………………………………………………………………….203
4-26. VERTICAL FIN…………………………………………………………………………………………………203
4-27. REMOVAL OF VERTICAL FIN……………………………………………………………………………………203
4-28. INSTALLATION OF VERTICAL FIN……………………………………………………………………………….203
4-29. FUSELAGE ASSEMBLY…………………………………………………………………………………………….204
4-30. WINDSHIELD…………………………………………………………………………………………………..204
4-31. REMOVAL OF WINDSHIELD……………………………………………………………………………………..204
4-32. INSTALLATION OF WINDSHIELD…………………………………………………………………………………204
4-33. SIDE WINDOWS…………………………………………………………………………………………………206
4-34. REMOVAL OF SIDE WINDOWS……………………………………………………………………………………206
4-35. INSTALLATION OF SIDE WINDOWS……………………………………………………………………………….206
4-36. DOOR (ENTRANCE)………………………………………………………………………………………………207
4-37. REMOVAL OF DOOR…………………………………………………………………………………………..207
4-38. INSTALLATION OF DOOR………………………………………………………………………………………207
4-39. ADJUSTMENT OF DOOR………………………………………………………………………………………..207
4-40. REMOVAL OF DOOR LATCH MECHANISM…………………………………………………………………………….207
4-41. INSTALLATION OF DOOR LATCH MECHANISM………………………………………………………………………..207
4-42. ADJUSTMENT OF DOOR LATCH MECHANISM………………………………………………………………………….207
4-43. REMOVAL OF DOOR LOCK ASSEMBLY………………………………………………………………………………208
4-44. INSTALLATION OF DOOR LOCK ASSEMBLY………………………………………………………………………….208
4-45. REMOVAL OF DOOR SAFETY LATCH……………………………………………………………………………….208
4-46. INSTALLATION OF DOOR SAFETY LATCH…………………………………………………………………………..208
4-47. ADJUSTMENT OF DOOR SAFETY LATCH…………………………………………………………………………….208
4-47A. REMOVAL AND INSTALLATION OF DOOR SEAL SNUBBERS………………………………………………………………208
4-48. BAGGAGE DOOR…………………………………………………………………………………………………211
4-49. REMOVAL OF BAGGAGE DOOR……………………………………………………………………………………211
4-50. INSTALLATION OF BAGGAGE DOOR……………………………………………………………………………….211
4-51. REMOVAL OF BAGGAGE DOOR LOCK ASSEMBLY……………………………………………………………………….211
4-52. INSTALLATION OF BAGGAGE DOOR LOCK ASSEMBLY…………………………………………………………………..211
4-53. REMOVAL OF BAGGAGE DOOR HINGE………………………………………………………………………………211
4-54. INSTALLATION OF BAGGAGE DOOR HINGE………………………………………………………………………….212
4-54A. RIGGING INSTRUCTIONS – SEAT BACK LOCK AND RELEASE……………………………………………………………….212
4-54B. NOT USED……………………………………………………………………………………………………213
4-54C. LUMBAR SEATS………………………………………………………………………………………………..213
4-54D. ELECTRICAL BONDING…………………………………………………………………………………………..216
4-55. STRUCTURAL REPAIRS……………………………………………………………………………………………218
4-55A. SKIN BEAD REPAIR…………………………………………………………………………………………220
4-55B. METAL WIRE STITCHING REPAIR……………………………………………………………………………….221
4-56. BAGGAGE COMPARTMENT INSPECTION HOLES FABRICATION PROCEDURE………………………………………………………..223
4-56A. FABRICATING INSPECTION HOLES………………………………………………………………………………223
4-57. FIBERGLAS REPAIRS…………………………………………………………………………………………….226
4-57A. MINOR SCRATCH AND CRACK REPAIR…………………………………………………………………………….226
4-57B. HOLE REPAIR……………………………………………………………………………………………..226
4-57C. FIBERGLASS FRACTURE AND PATCH REPAIRS………………………………………………………………………227
4-57D. ADDING LAYERS TO UNDAMAGED AREAS…………………………………………………………………………..228
4-58. GENERAL THERMOPLASTIC REPAIRS………………………………………………………………………………….228
4-59. CONTROL SURFACES……………………………………………………………………………………………..236
4-59A. CHECKING CONTROL SURFACE FREE PLAY…………………………………………………………………………236
4-59B. CONTROL SURFACE BALANCING…………………………………………………………………………………236
4-59C. CHECKING CONTROL SURFACE BALANCE…………………………………………………………………………..236
4-60. BALANCING EQUIPMENT…………………………………………………………………………………………..237
4-61. BALANCING AILERONS………………………………………………………………………………………..239
4-62. BALANCING RUDDER………………………………………………………………………………………….239
4-63. BALANCING STABILATOR………………………………………………………………………………………239
4-64. SAFETY WALK REPAIR/REPLACEMENT…………………………………………………………………………………243
4-65. LIQUID SAFETY WALK COMPOUND – SURFACE PREPARATION…………………………………………………………….243
4-66. LIQUID SAFETY WALK COMPOUND – PRODUCT LISTING………………………………………………………………..243
4-67. LIQUID SAFETY WALK COMPOUND – APPLICATION……………………………………………………………………243
4-68. PRESSURE SENSITIVE SAFETY WALK – SURFACE PREPARATION………………………………………………………….244
4-69. PRESSURE SENSITIVE SAFETY WALK – APPLICATION…………………………………………………………………244
SECTION V – SURFACE CONTROLS……………………………………………………………………………………………245
TABLE OF CONTENTS………………………………………………………………………………………………….247
5-1. INTRODUCTION………………………………………………………………………………………………….249
5-2. DESCRIPTION…………………………………………………………………………………………………..249
5-2A. TROUBLESHOOTING………………………………………………………………………………………………249
5-3. STANDARD PROCEDURES……………………………………………………………………………………………249
5-4. CONTROL CABLE INSPECTION……………………………………………………………………………………….252
5-5A. FLIGHT CONTROL SURFACE TRAVEL………………………………………………………………………………….257
5-5B. FLIGHT CONTROL CABLE TENSION…………………………………………………………………………………..257
5-6. CONTROL COLUMN ASSEMBLY………………………………………………………………………………………..257
5-7. REMOVAL OF CONTROL COLUMN ASSEMBLY…………………………………………………………………………..257
5-8. INSTALLATION OF CONTROL COLUMN ASSEMBLY………………………………………………………………………258
5-9. INSTALLATION OF UNIVERSAL JOINT……………………………………………………………………………..262
5-10. AILERON CONTROLS……………………………………………………………………………………………..262
5-11. REMOVAL OF AILERON CONTROL CABLES…………………………………………………………………………..262
5-12. INSTALLATION OF AILERON CONTROL CABLES………………………………………………………………………263
5-13. REMOVAL OF AILERON BELLCRANK ASSEMBLY……………………………………………………………………….265
5-14. INSTALLATION OF AILERON BELLCRANK ASSEMBLY…………………………………………………………………..266
5-15. RIGGING AND ADJUSTMENT OF AILERON CONTROLS…………………………………………………………………..266
5-16. STABILATOR CONTROLS…………………………………………………………………………………………..269
5-17. REMOVAL OF STABILATOR CONTROL CABLES………………………………………………………………………..269
5-18. INSTALLATION OF STABILATOR CONTROL CABLES……………………………………………………………………269
5-19. RIGGING AND ADJUSTMENT OF STABILATOR CONTROLS………………………………………………………………..271
5-20. STABILATOR TRIM CONTROLS………………………………………………………………………………………273
5-21. REMOVAL OF STABILATOR TRIM ASSEMBLY (FORWARD)………………………………………………………………..273
5-22. INSTALLATION OF STABILATOR TRIM ASSEMBLY (FORWARD)……………………………………………………………275
5-23. REMOVAL OF STABILATOR TRIM CONTROLS (AFT)……………………………………………………………………276
5-24. INSTALLATION OF STABILATOR TRIM CONTROLS (AFT)……………………………………………………………….276
5-25. RIGGING AND ADJUSTMENT OF STABILATOR TRIM……………………………………………………………………277
5-26. RUDDER AND STEERING PEDAL ASSEMBLY……………………………………………………………………………..278
5-27. REMOVAL OF RUDDER AND STEERING PEDAL ASSEMBLY………………………………………………………………..278
5-28. INSTALLATION OF RUDDER AND STEERING PEDAL ASSEMBLY……………………………………………………………280
5-29. RUDDER CONTROLS………………………………………………………………………………………………281
5-30. REMOVAL OF RUDDER CONTROL CABLES……………………………………………………………………………281
5-31. INSTALLATION OF RUDDER CONTROL CABLES……………………………………………………………………….281
5-32. RIGGING AND ADJUSTMENT OF RUDDER CONTROLS……………………………………………………………………283
5-33. RUDDER TRIM CONTROLS………………………………………………………………………………………….285
5-34. REMOVAL OF RUDDER TRIM CONTROLS…………………………………………………………………………….285
5-35. INSTALLATION OF RUDDER TRIM CONTROLS………………………………………………………………………..286
5-36. RIGGING AND ADJUSTMENT OF RUDDER TRIM CONTROLS……………………………………………………………….289
5-37. WING FLAP CONTROLS……………………………………………………………………………………………289
5-38. REMOVAL OF WING FLAP CONTROLS………………………………………………………………………………289
5-39. INSTALLATION OF WING FLAP CONTROLS………………………………………………………………………….291
5-39A. TORQUE TUBE/PUSH ROD DISTORTION INSPECTION………………………………………………………………….292
5-40. RIGGING AND ADJUSTMENT OF WING FLAPS………………………………………………………………………..293
SECTION VII – LANDING GEAR AND BRAKE SYSTEM………………………………………………………………………………305
TABLE OF CONTENTS………………………………………………………………………………………………….307
7-1. INTRODUCTION………………………………………………………………………………………………….309
7-2. DESCRIPTION…………………………………………………………………………………………………..309
7-3. TROUBLESHOOTING……………………………………………………………………………………………….309
7-4. LANDING GEAR SYSTEM……………………………………………………………………………………………309
7-5. NOSE LANDING GEAR……………………………………………………………………………………………..309
7-6. DISASSEMBLY OF NOSE GEAR OLEO……………………………………………………………………………….309
7-7. CLEANING, INSPECTION AND REPAIR OF NOSE GEAR OLEO……………………………………………………………..312
7-7A. NOSE GEAR OIL ORIFICE RETAINER RING INSTALLATION……………………………………………………………..312
7-8. ASSEMBLY OF NOSE GEAR OLEO………………………………………………………………………………….313
7-9. REMOVAL OF NOSE LANDING GEAR………………………………………………………………………………..313
7-10. CLEANING, INSPECTION AND REPAIR OF NOSE LANDING GEAR………………………………………………………….315
7-11. INSTALLATION OF NOSE LANDING GEAR…………………………………………………………………………..315
7-12. ALIGNMENT OF NOSE GEAR…………………………………………………………………………………….316
7-13.MAIN LANDING GEAR……………………………………………………………………………………………..317
7-14. DISASSEMBLY OF MAIN GEAR OLEO………………………………………………………………………………317
7-15. CLEANING, INSPECTION AND REPAIR OF MAIN GEAR OLEO…………………………………………………………….320
7-16. ASSEMBLY OF MAIN GEAR OLEO…………………………………………………………………………………320
7-17. REMOVAL OF MAIN LANDING GEAR……………………………………………………………………………….320
7-18. CLEANING, INSPECTION AND REPAIR OF MAIN LANDING GEAR………………………………………………………….322
7-19. INSTALLATION OF MAIN LANDING GEAR…………………………………………………………………………..322
7-20. WHEELS………………………………………………………………………………………………………322
7-21. REMOVAL AND DISASSEMBLY OF NOSE WHEEL……………………………………………………………………….322
7-22. INSPECTION OF NOSE WHEEL ASSEMBLY…………………………………………………………………………..323
7-23. ASSEMBLY AND INSTALLATION OF NOSE WHEEL……………………………………………………………………..324
7-24. REMOVAL AND DISASSEMBLY OF MAIN WHEEL……………………………………………………………………….324
7-25. INSPECTION OF MAIN WHEEL ASSEMBLY…………………………………………………………………………..324
7-26. ASSEMBLY AND INSTALLATION OF MAIN WHEEL……………………………………………………………………..325
7-27. BRAKE SYSTEM…………………………………………………………………………………………………326
7-28. WHEEL BRAKE ASSEMBLY………………………………………………………………………………………….326
7-29. BRAKE ADJUSTMENT AND LINING TOLERANCE……………………………………………………………………….326
7-30. REMOVAL AND DISASSEMBLY OF WHEEL BRAKE ASSEMBLY………………………………………………………………326
7-31. CLEANING, INSPECTION AND REPAIR OF WHEEL BRAKE ASSEMBLIES……………………………………………………..327
7-32. ASSEMBLY AND INSTALLATION OF WHEEL BRAKE ASSEMBLY…………………………………………………………….328
7-33. BRAKE MASTER CYLINDER (HAND PARKING BRAKE)………………………………………………………………………328
7-34. REMOVAL OF BRAKE MASTER CYLINDER (HAND BRAKE)………………………………………………………………..328
7-35. DISASSEMBLY OF BRAKE MASTER CYLINDER………………………………………………………………………..330
7-36. CLEANING, INSPECTION AND REPAIR OF BRAKE MASTER CYLINDER………………………………………………………330
7-37. ASSEMBLY OF BRAKE MASTER CYLINDER…………………………………………………………………………..331
7-38. INSTALLATION OF BRAKE MASTER CYLINDER (HAND BRAKE)……………………………………………………………331
7-39. TOE BRAKE CYLINDER……………………………………………………………………………………………331
7-40. REMOVAL OF TOE BRAKE CYLINDER………………………………………………………………………………331
7-41. DISASSEMBLY OF TOE BRAKE CYLINDER…………………………………………………………………………..331
7-42. CLEANING, INSPECTION AND REPAIR OF TOE BRAKE CYLINDER…………………………………………………………332
7-43. ASSEMBLY OF TOE BRAKE CYLINDER……………………………………………………………………………..332
7-44. INSTALLATION OF BRAKE CYLINDER……………………………………………………………………………..334
7-45. BLEEDING BRAKES………………………………………………………………………………………………334
7-46. BRAKE BLEEDING PROCEDURE (GRAVITY)………………………………………………………………………….334
7-47. BRAKE BLEEDING PROCEDURE (PRESSURE)…………………………………………………………………………334
7-48. BRAKE SYSTEM LEAK CHECK……………………………………………………………………………………335
7-49. BLEEDING OF THE BRAKES AFTER A UNIT HAS BEEN CHANGED………………………………………………………….335
SECTION VIII – POWER PLANT……………………………………………………………………………………………..341
TABLE OF CONTENTS………………………………………………………………………………………………….343
8-1. INTRODUCTION………………………………………………………………………………………………….345
8-2. DESCRIPTION…………………………………………………………………………………………………..345
8-2A. STANDARD PRACTICES – ENGINE……………………………………………………………………………………346
8-3. TROUBLESHOOTING……………………………………………………………………………………………….346
8-4. PROPELLER…………………………………………………………………………………………………….347
8-5. REMOVAL OF PROPELLER……………………………………………………………………………………….347
8-6. CLEANING, INSPECTION AND REPAIR OF PROPELLER………………………………………………………………….347
8-7. INSTALLATION OF PROPELLER…………………………………………………………………………………..349
8-8. BLADE TRACK……………………………………………………………………………………………….349
8-9. ENGINE……………………………………………………………………………………………………….349
8-10. REMOVAL OF ENGINE…………………………………………………………………………………………349
8-11. INSTALLATION OF ENGINE…………………………………………………………………………………….350
8-12. INSTALLATION OF ENGINE SHOCK MOUNTS…………………………………………………………………………352
8-13. INSTALLATION OF OIL COOLER…………………………………………………………………………………….354
8-14. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLS……………………………………………………………………..354
8-14A. INDUCTION AIR FILTER…………………………………………………………………………………………355
8-15. CARBURETOR…………………………………………………………………………………………………..355
8-16. CARBURETOR MAINTENANCE…………………………………………………………………………………….355
8-17. ADJUSTMENT OF IDLE MIXTURE…………………………………………………………………………………356
8-18. ADJUSTMENT OF IDLE SPEED…………………………………………………………………………………..356
8-19. SLICK 4000, 4200, AND 4300 SERIES MAGNETOS………………………………………………………………………356
8-20. REMOVAL OF SLICK 4000, 4200, AND 4300 SERIES MAGNETOS…………………………………………………………356
8-21. INSPECTION OF SLICK 4000, 4200, AND 4300 MAGNETOS…………………………………………………………….357
8-22. 4000 SERIES MAGNETOS INSTALLATION AND TIMING PROCEDURE………………………………………………………..358
8-23. OVERHAUL INSTRUCTIONS FOR SLICK 4200/4300 SERIES MAGNETOS……………………………………………………..359
8-24. DISASSEMBLY OF SLICK 4200/4300 SERIES MAGNETOS……………………………………………………………….359
8-25. CLEANING AND INSPECTION OF 4200/4300 SERIES MAGNETOS………………………………………………………….360
8-26. ASSEMBLY OF 4200/4300 SERIES MAGNETOS……………………………………………………………………….362
8-27. INTERNAL TIMING OF 4200/4300 SERIES MAGNETOS…………………………………………………………………366
8-28. 4200/4300 SERIES MAGNETOS INSTALLATION AND TIMING MAGNETO TO ENGINE PROCEDURE……………………………………366
8-29. BENDIX MAGNETOS………………………………………………………………………………………………368
8-30. INSPECTION OF BENDIX MAGNETOS………………………………………………………………………………368
8-31. REMOVAL OF BENDIX MAGNETOS…………………………………………………………………………………370
8-32. INTERNAL TIMING OF BENDIX -20 AND -200 SERIES MAGNETOS………………………………………………………..370
8-33. BENDIX MAGNETO INSTALLATION AND TIMING TO ENGINE PROCEDURE…………………………………………………….372
8-34. HARNESS ASSEMBLY……………………………………………………………………………………………..374
8-35. INSPECTION OF HARNESS……………………………………………………………………………………..374
8-36. REMOVAL OF HARNESS………………………………………………………………………………………..374
8-37. DISASSEMBLY OF HARNESS…………………………………………………………………………………….374
8-38. HARNESS ASSEMBLY INSTRUCTIONS………………………………………………………………………………375
8-39. INSTALLATION OF HARNESS……………………………………………………………………………………379
8-40. SPARK PLUGS………………………………………………………………………………………………….379
8-41. REMOVAL OF SPARK PLUGS…………………………………………………………………………………….379
8-42. INSPECTION AND CLEANING OF SPARK PLUG……………………………………………………………………….380
8-43. INSTALLATION OF SPARK PLUGS………………………………………………………………………………..380
8-44. LUBRICATION SYSTEM (ENGINE)……………………………………………………………………………………380
8-45. OIL PRESSURE RELIEF VALVE………………………………………………………………………………….380
8-46. CARBURETOR ICE DETECTOR……………………………………………………………………………………….381
8-47. REMOVAL OF ICE DETECTOR PROBE………………………………………………………………………………381
8-48. INSTALLATION OF ICE DETECTOR PROBE…………………………………………………………………………381
8-49. CARBURETOR ICE DETECTION SYSTEM TEST………………………………………………………………………..382
8-50. STATIC RPM TEST PROCEDURE……………………………………………………………………………………..385
8-51. SCOPE……………………………………………………………………………………………………385
8-52. EQUIPMENT………………………………………………………………………………………………..385
8-53. TEST PROCEDURE……………………………………………………………………………………………385
8-54. SIMPLIFIED TEST PROCEDURE………………………………………………………………………………….385
8-55. EXPANDED TEST PROCEDURE……………………………………………………………………………………385
8-56. TEST RESULTS……………………………………………………………………………………………..386
SECTION IX – FUEL SYSTEM……………………………………………………………………………………………….399
TABLE OF CONTENTS………………………………………………………………………………………………….401
9-1. INTRODUCTION………………………………………………………………………………………………….403
9-2. DESCRIPTION…………………………………………………………………………………………………..403
9-3. TROUBLESHOOTING……………………………………………………………………………………………….405
9-4. FUEL TANKS……………………………………………………………………………………………………405
9-5. REMOVAL OF FUEL TANKS………………………………………………………………………………………405
9-6. INSPECTION AND REPAIR OF FUEL TANK…………………………………………………………………………..405
9-6A. SLOSHED FUEL TANK 100 HOUR INSPECTION……………………………………………………………………….407
9-7. INSTALLATION OF FUEL TANK…………………………………………………………………………………..407
9-8. FUEL LINES……………………………………………………………………………………………………407
9-9. INSPECTION AND TIGHTENING OF FUEL LINE UNION FITTINGS………………………………………………………….409
9-10. REPLACEMENT OF FITTINGS……………………………………………………………………………………410
9-11. FUEL QUANTITY TRANSMITTER UNIT…………………………………………………………………………………411
9-12. REMOVAL OF FUEL QUANTITY TRANSMITTER UNIT……………………………………………………………………411
9-13. INSTALLATION OF FUEL QUANTITY TRANSMITTER UNIT……………………………………………………………….411
9-14. FUEL QUANTITY TRANSMITTER/GAUGE CHECK……………………………………………………………………….411
9-15. CHECK AND ADJUSTMENT OF FUEL QUANTITY TRANSMITTER UNIT………………………………………………………..416
9-16. LOCKING FUEL CAP……………………………………………………………………………………………..419
9-17. DISASSEMBLY OF LOCKING FUEL CAP…………………………………………………………………………….419
9-18. ASSEMBLY OF LOCKING FUEL CAP……………………………………………………………………………….419
9-19. FUEL SHUTOFF VALVE……………………………………………………………………………………………420
9-20. REMOVAL OF FUEL SHUTOFF VALVE………………………………………………………………………………420
9-21. INSTALLATION OF SHUTOFF VALVE………………………………………………………………………………420
9-22. FUEL FILTER BOWL AND SCREEN……………………………………………………………………………………420
9-23. REMOVAL OF FUEL FILTER BOWL AND HOUSING……………………………………………………………………..420
9-24. INSTALLATION OF FUEL FILTER BOWL AND SCREEN………………………………………………………………….421
9-25. CLEANING AND INSPECTION OF FILTER BOWL SCREEN………………………………………………………………..421
9-26. ELECTRIC FUEL PUMPS…………………………………………………………………………………………..421
9-27. PLUNGER TYPE ELECTRIC FUEL PUMPS……………………………………………………………………………….421
9-28. REMOVAL OF ELECTRIC FUEL PUMP………………………………………………………………………………421
9-29. DISASSEMBLY OF ELECTRIC FUEL PUMP…………………………………………………………………………..421
9-30. CLEANING, INSPECTION AND REPAIR OF ELECTRIC FUEL PUMP…………………………………………………………422
9-31. RESISTANCE CHECK OF PLUNGER TYPE ELECTRIC FUEL PUMP…………………………………………………………..423
9-32. ASSEMBLY OF FUEL PUMP……………………………………………………………………………………..423
9-33. BENCH TEST ADJUSTMENT OF ELECTRIC FUEL PUMP………………………………………………………………….423
9-34. IN AIRPLANE ADJUSTMENT OF ELECTRIC FUEL PUMP…………………………………………………………………423
9-35. INSTALLATION OF FUEL PUMP………………………………………………………………………………….424
9-36. ENGINE PRIMER PUMP……………………………………………………………………………………………424
9-37. REMOVAL OF ENGINE PRIMER…………………………………………………………………………………..424
9-38. DISASSEMBLY, CLEANING AND ASSEMBLY OF ENGINE PRIMER…………………………………………………………..425
9-39. INSTALLATION OF ENGINE PRIMER PUMP………………………………………………………………………….425
9-40. PRIME JETS…………………………………………………………………………………………………..425
9-41. CLEANING FUEL SYSTEM………………………………………………………………………………………….425
SECTION X – INSTRUMENTS………………………………………………………………………………………………..429
TABLE OF CONTENTS………………………………………………………………………………………………….431
10-1. GENERAL……………………………………………………………………………………………………..435
10-2. NON-ELECTRICAL INSTRUMENTS…………………………………………………………………………………….435
10-3. VACUUM SYSTEM………………………………………………………………………………………………..435
10-4. VACUUM SYSTEM SERVICE TIPS…………………………………………………………………………………435
10-5. TROUBLESHOOTING…………………………………………………………………………………………..441
10-6. VACUUM GAUGE…………………………………………………………………………………………………442
10-7. GENERAL………………………………………………………………………………………………….442
10-8. TROUBLESHOOTING…………………………………………………………………………………………..442
10-9. VACUUM REGULATOR VALVE………………………………………………………………………………………..442
10-10. GENERAL…………………………………………………………………………………………………442
10-11. TROUBLESHOOTING………………………………………………………………………………………….442
10-12. ADJUSTMENT OF VACUUM REGULATOR VALVE……………………………………………………………………….442
10-13. REMOVAL AND INSTALLATION OF VACUUM REGULATOR VALVE…………………………………………………………..443
10-14. ENGINE DRIVEN VACUUM PUMP…………………………………………………………………………………….444
10-15. GENERAL…………………………………………………………………………………………………444
10-16. TROUBLESHOOTING………………………………………………………………………………………….444
10-17A. REMOVAL OF ENGINE-DRIVEN VACUUM PUMP………………………………………………………………………444
10-17B. INSTALLATION OF ENGINE-DRIVEN VACUUM PUMP………………………………………………………………….444
10-17C. INSPECTION – AERO ACCESSORIES TEMPEST PUMPS ONLY……………………………………………………………445
10-18. WARRIOR II AND WARRIOR III AUXILIARY VACUUM PUMP………………………………………………………………..446
10-19. REPLACING PUMP FITTINGS………………………………………………………………………………………448
10-20. HEADING INDICATOR……………………………………………………………………………………………451
10-21. GENERAL…………………………………………………………………………………………………451
10-22. TROUBLESHOOTING HEADING INDICATOR………………………………………………………………………….451
10-23. REMOVAL AND REPLACEMENT…………………………………………………………………………………..452
10-24. ATTITUDE DEVIATION INDICATOR (ADI)…………………………………………………………………………….452
10-25. GENERAL…………………………………………………………………………………………………452
10-26. TROUBLESHOOTING………………………………………………………………………………………….453
10-27. REMOVAL AND REPLACEMENT…………………………………………………………………………………..453
10-28. PITOT AND STATIC AIR SYSTEMS………………………………………………………………………………….454
10-29. VERTICAL SPEED INDICATOR……………………………………………………………………………………..455
10-30. GENERAL…………………………………………………………………………………………………455
10-31. TROUBLESHOOTING………………………………………………………………………………………….455
10-32. REMOVAL AND REPLACEMENT…………………………………………………………………………………..456
10-33. SENSITIVE ALTIMETER………………………………………………………………………………………….456
10-34. GENERAL…………………………………………………………………………………………………456
10-35. TROUBLESHOOTING………………………………………………………………………………………….456
10-36. REMOVAL AND REPLACEMENT…………………………………………………………………………………..457
10-37. AIRSPEED INDICATOR…………………………………………………………………………………………..457
10-38. TROUBLESHOOTING AIRSPEED INDICATOR…………………………………………………………………………457
10-39. REMOVAL AND REPLACEMENT…………………………………………………………………………………..458
10-40. MAGNETIC COMPASS…………………………………………………………………………………………….458
10-41. GENERAL…………………………………………………………………………………………………458
10-42. TROUBLESHOOTING………………………………………………………………………………………….459
10-43. ADJUSTMENT OF MAGNETIC COMPASS…………………………………………………………………………….459
10-44. TACHOMETER INDICATOR…………………………………………………………………………………………460
10-45. GENERAL…………………………………………………………………………………………………460
10-46. TROUBLESHOOTING………………………………………………………………………………………….460
10-47. REMOVAL AND REPLACEMENT…………………………………………………………………………………..461
10-48. ENGINE OIL PRESSURE AND TEMPERATURE……………………………………………………………………………461
10-49. GENERAL…………………………………………………………………………………………………461
10-50. TROUBLESHOOTING………………………………………………………………………………………….462
10-51. REMOVAL AND REPLACEMENT…………………………………………………………………………………..464
10-52. FUEL PRESSURE GAUGE………………………………………………………………………………………….465
10-53. TROUBLESHOOTING………………………………………………………………………………………….465
10-54. ELECTRIC INSTRUMENTS…………………………………………………………………………………………467
10-55. TURN INDICATOR………………………………………………………………………………………………467
10-56. GENERAL…………………………………………………………………………………………………467
10-57. TROUBLESHOOTING………………………………………………………………………………………….467
10-58. REMOVAL AND REPLACEMENT…………………………………………………………………………………..467
10-59. FUEL QUANTITY INDICATORS……………………………………………………………………………………..468
10-60. GENERAL…………………………………………………………………………………………………468
10-61. TROUBLESHOOTING………………………………………………………………………………………….468
10-62. REMOVAL AND REPLACEMENT…………………………………………………………………………………..469
10-63. OIL TEMPERATURE INDICATORS……………………………………………………………………………………469
10-64. GENERAL…………………………………………………………………………………………………469
10-65. TROUBLESHOOTING………………………………………………………………………………………….469
10-66. REMOVAL AND REPLACEMENT…………………………………………………………………………………..469
10-67. AMMETER…………………………………………………………………………………………………….469
10-68. GENERAL…………………………………………………………………………………………………469
10-69. TROUBLESHOOTING………………………………………………………………………………………….469
10-70. REMOVAL AND REPLACEMENT…………………………………………………………………………………..469
10-71. REMOVAL AND REPLACEMENT OF FACE MOUNTED INSTRUMENTS……………………………………………………………..469
10-72. REMOVAL AND REPLACEMENT OF CLUSTER MOUNTED INSTRUMENTS…………………………………………………………..470
10-73. CYLINDER HEAD TEMPERATURE GAUGE……………………………………………………………………………….470
10-74. GENERAL…………………………………………………………………………………………………470
10-75. TROUBLESHOOTING………………………………………………………………………………………….471
10-76. EXHAUST GAS TEMPERATURE GAUGE (ALCOR)………………………………………………………………………….471
10-77. GENERAL…………………………………………………………………………………………………471
10-78. REMOVAL AND INSTALLATION OF EGT PROBE AND GAUGE……………………………………………………………..471
10-79. CLEANING AND INSPECTION OF EGT…………………………………………………………………………….471
10-80. TROUBLESHOOTING EFT GAUGE…………………………………………………………………………………473
10-81. OUTSIDE AIR TEMPERATURE GAUGE (OAT)……………………………………………………………………………473
10-82. REMOVING AND INSTALLING OUTSIDE TEMPERATURE GAUGE……………………………………………………………473
10-83. PIPER AUTOCONTROL SYSTEM……………………………………………………………………………………..473
SECTION XI – ELECTRICAL SYSTEM………………………………………………………………………………………….475
TABLE OF CONTENTS………………………………………………………………………………………………….477
11-1. INTRODUCTION…………………………………………………………………………………………………483
11-2. DESCRIPTION………………………………………………………………………………………………….483
11-3. TROUBLESHOOTING………………………………………………………………………………………………484
11-4. PRECAUTIONS………………………………………………………………………………………………….499
11-5. PRESTOLITE AND ELECTROSYSTEMS ALTERNATOR AND COMPONENTS…………………………………………………………..501
11-6. GENERAL………………………………………………………………………………………………….501
11-7. DESCRIPTION OF PRESTOLITE AND ELECTROSYSTEMS ALTERNATORS………………………………………………………501
11-8. CHECKING PRESTOLITE AND ELECTROSYSTEMS ALTERNATOR SYSTEM………………………………………………………501
11-9. OVERHAUL OF PRESTOLITE AND ELECTROSYSTEMS ALTERNATORS…………………………………………………………503
11-10. DISASSEMBLY OF PRESTOLITE AND ELECTROSYSTEMS ALTERNATORS……………………………………………………..503
11-11. INSPECTION AND TESTING OF PRESTOLITE AND ELECTROSYSTEMS ALTERNATOR COMPONENTS…………………………………..504
11-12. ASSEMBLY OF PRESTOLITE AND ELECTROSYSTEMS ALTERNATOR…………………………………………………………507
11-13. TESTING OF PRESTOLITE AND ELECTROSYSTEMS ALTERNATORS…………………………………………………………509
11-14. PRESTOLITE AND ELECTROSYSTEMS ALTERNATOR SERVICE TIPS………………………………………………………..509
11-15. PRESTOLITE AND ELECTROSYSTEMS ALTERNATOR SERVICE TEST SPECIFICATIONS…………………………………………..510
11-16. CHRYSLER ALTERNATOR AND COMPONENTS…………………………………………………………………………….511
11-17. DESCRIPTION OF CHRYSLER ALTERNATOR…………………………………………………………………………511
11-18. CHECKING THE CHRYSLER ALTERNATOR SYSTEM…………………………………………………………………….511
11-19. OVERHAUL OF CHRYSLER ALTERNATOR……………………………………………………………………………513
11-20. CHRYSLER ALTERNATOR ROTOR FIELD COIL CURRENT DRAW……………………………………………………………513
11-21. TESTING CHRYSLER ALTERNATOR INTERNAL FIELD CIRCUIT…………………………………………………………..514
11-22. INSPECTION OF CHRYSLER ALTERNATOR………………………………………………………………………….515
11-23. TESTING RECTIFIER ASSEMBLIES OF CHRYSLER ALTERNATOR………………………………………………………….515
11-24. TESTING OF CHRYSLER ALTERNATOR POSITIVE RECTIFIERS USING C-3829 TESTER…………………………………………516
11-25. TESTING OF CHRYSLER ALTERNATOR NEGATIVE RECTIFIERS USING C-3829 TESTER…………………………………………516
11-26. TESTING OF CHRYSLER ALTERNATOR RECTIFIER ASSEMBLIES USING TEST LAMP……………………………………………517
11-27. REMOVAL OF CHRYSLER ALTERNATOR RECTIFIER AND HEAT SINK ASSEMBLY……………………………………………….518
11-28. TESTING OF CHRYSLER ALTERNATOR STATOR………………………………………………………………………518
11-29. REMOVAL OF CHRYSLER ALTERNATOR PULLEY AND BEARING……………………………………………………………519
11-30. TESTING OF CHRYSLER ALTERNATOR ROTOR……………………………………………………………………….521
11-31. CHRYSLER ALTERNATOR SLIP RINGS…………………………………………………………………………….521
11-32. ASSEMBLY OF CHRYSLER ALTERNATOR……………………………………………………………………………521
11-33. CHECKING ALTERNATOR BELT TENSION………………………………………………………………………………526
11-34. BATTERY…………………………………………………………………………………………………….527
11-35. BATTERY DESCRIPTION (WARRIOR AND WARRIOR II)………………………………………………………………..527
11-36. SERVICING BATTERY (WARRIOR AND WARRIOR II)………………………………………………………………….528
11-37. REMOVAL OF BATTERY (WARRIOR AND WARRIOR II)…………………………………………………………………528
11-38. INSTALLATION OF BATTERY (WARRIOR AND WARRIOR II)…………………………………………………………….528
11-39. CHARGING BATTERY (WARRIOR AND WARRIOR II)…………………………………………………………………..528
11-40. STARTING THROUGH EXTERNAL POWER RECEPTACLE WITH AIRPLANE’S BATTERY NEARLY DEPLETED………………………………530
11-41. WARRIOR/WARRIOR II……………………………………………………………………………………530
11-42. WARRIOR III………………………………………………………………………………………….530
11-43. TESTING THE BATTERY (WARRIOR AND WARRIOR II)………………………………………………………………..530
11-44. BATTERY BOX (WARRIOR AND WARRIOR II)…………………………………………………………………………..530
11-45. DESCRIPTION (WARRIOR AND WARRIOR II)……………………………………………………………………….530
11-46. REMOVAL OF BATTERY BOX (WARRIOR AND WARRIOR II)……………………………………………………………..531
11-47. INSTALLATION OF BATTERY BOX (WARRIOR AND WARRIOR II)…………………………………………………………531
11-48. BATTERY BOX CORROSION PREVENTION (WARRIOR AND WARRIOR II)…………………………………………………….531
11-49. BATTERY DESCRIPTION (WARRIOR III)………………………………………………………………………….531
11-50. BATTERY REMOVAL (WARRIOR III)……………………………………………………………………………..531
11-51. CLEANING BATTERY (WARRIOR III)…………………………………………………………………………….533
11-52. BATTERY INSTALLATION (WARRIOR III)…………………………………………………………………………….533
11-53. BATTERY CHARGING (GILL MODEL G-243) (WARRIOR III)……………………………………………………………….533
11-54. HYDROMETER READING AND BATTERY CHARGE (WARRIOR III)………………………………………………………….534
11-55. BATTERY DISCHARGE (WARRIOR III)……………………………………………………………………………536
11-56. BATTERY TEMPERATURE CONSIDERATIONS (WARRIOR III)…………………………………………………………….536
11-57. BATTERY REPAIRS, STORAGE, AND SERVICE TIPS (WARRIOR III)……………………………………………………..537
11-58. PREPARING NEW DRY CHARGED BATTERY FOR INSTALLATION (WARRIOR III…………………………………………………..537
11-59. VOLTAGE REGULATOR……………………………………………………………………………………………537
11-60. TESTING WICO 14 VOLT SYSTEM REGULATOR………………………………………………………………………537
11-61. TESTING LAMAR 14 VOLT SYSTEM REGULATOR……………………………………………………………………..538
11-62. TESTING LAMAR 28 VOLT REGULATOR……………………………………………………………………………540
11-63. OVERVOLTAGE RELAY……………………………………………………………………………………………541
11-64. CHECKING WICO 14 VOLT OVERVOLTAGE RELAY…………………………………………………………………….541
11-65. REMOVAL OF WICO 14 VOLT OVERVOLTAGE RELAY…………………………………………………………………..541
11-66. INSTALLATION OF WICO 14 VOLT OVERVOLTAGE RELAY………………………………………………………………542
11-67. LAMAR 14 VOLT REGULATOR OVERVOLTAGE CHECK…………………………………………………………………..542
11-68. CHECKING LAMAR 14 VOLT OVERVOLTAGE RELAY……………………………………………………………………542
11-69. LAMAR 28 VOLT REGULATOR OVERVOLTAGE CHECK…………………………………………………………………..544
11-70. STARTING MOTORS (PRESTOLITE AND ELECTROSYSTEMS)…………………………………………………………………544
11-71. DESCRIPTION……………………………………………………………………………………………..544
11-72. OPERATION……………………………………………………………………………………………….544
11-73. STARTER MOTOR MAINTENANCE…………………………………………………………………………………545
11-74. OVERHAUL OF STARTING MOTOR………………………………………………………………………………..546
11-75. REMOVAL OF STARTING MOTOR…………………………………………………………………………………546
11-76. DISASSEMBLY OF STARTING MOTOR……………………………………………………………………………..546
11-77. BRUSHES…………………………………………………………………………………………………547
11-78. ARMATURE………………………………………………………………………………………………..547
11-79. FIELD COILS……………………………………………………………………………………………..547
11-80. BRUSH HOLDERS……………………………………………………………………………………………548
11-81. GEAR AND PINION HOUSING…………………………………………………………………………………..548
11-82. BENDIX DRIVE…………………………………………………………………………………………….548
11-83. ASSEMBLY OF STARTING MOTOR………………………………………………………………………………..548
11-84. BENCH TEST………………………………………………………………………………………………548
11-85. STARTING MOTOR CONTROL CIRCUIT…………………………………………………………………………….548
11-86. STARTING MOTOR SERVICE TEST SPECIFICATIONS………………………………………………………………….550
11-87. LANDING AND TAXI LIGHT……………………………………………………………………………………….550
11-88. DESCRIPTION (WARRIOR/WARRIOR II/WARRIOR III)………………………………………………………………..550
11-89. REMOVAL (WARRIOR/WWARRIOR II/WARRIOR III)…………………………………………………………………..550
11-90. INSTALLATION (WARRIOR/WARRIOR II/WARRIOR III)……………………………………………………………….550
11-91. NAVIGATION LIGHTS……………………………………………………………………………………………550
11-92. NAVIGATION LIGHTS DESCRIPTION (WARRIOR/WARRIOR II)…………………………………………………………..550
11-93. REMOVAL OF WING NAVIGATION LIGHTS (WARRIOR/WARRIOR II)……………………………………………………….550
11-94. INSTALLATION OF WING NAVIGATION LIGHTS (WARRIOR/WARRIOR II)…………………………………………………..551
11-95. REMOVAL OF TAIL NAVIGATION LIGHT (WARRIOR/WARRIOR II)………………………………………………………..551
11-96. INSTALLATION OF TAIL NAVIGATION LIGHT (WARRIOR/WARRIOR II)……………………………………………………551
11-97. NAVIGATION LIGHTS DESCRIPTION (WARRIOR III)…………………………………………………………………551
11-98. REMOVING NAVIGATION LIGHT BULB(S) (WARRIOR III)……………………………………………………………..551
11-99. INSTALLING NAVIGATION LIGHT BULB(S) (WARRIOR III)……………………………………………………………551
11-100. ANTI-COLLISION LIGHTS (WARRIOR/WARRIOR II)…………………………………………………………………….552
11-101. ANTI-COLLISION LIGHTS DESCRIPTION (WARRIOR/WARRIOR II)………………………………………………………552
11-102. REMOVAL OF WING TIP STROBE LIGHT (WARRIOR/WARRIOR II)……………………………………………………….552
11-103. INSTALLATION OF WING TIP STROBE LIGHT (WARRIOR/WARRIOR II)…………………………………………………..552
11-104. REMOVAL OF FIN TIP STROBE LIGHT (WARRIOR/WARRIOR II)………………………………………………………..552
11-105. INSTALLATION OF FIN TIP STROBE LIGHT (WARRIOR/WARRIOR II)……………………………………………………552
11-106. ROTATING BEACON TYPE ANTI-COLLISION LIGHT (WARRIOR/WARRIOR II)…………………………………………………..553
11-107. REMOVAL………………………………………………………………………………………………..553
11-108. INSTALLATION……………………………………………………………………………………………553
11-109. STROBE ANTI-COLLISION LIGHTS DESCRIPTION (WARRIOR III)………………………………………………………….553
11-110. REMOVAL OF WING TIP STROBE LIGHT (WARRIOR III)……………………………………………………………..553
11-111. INSTALLATION OF WING TIP STROBE LIGHT (WARRIOR III)…………………………………………………………553
11-112. STROBE POWER SUPPLY…………………………………………………………………………………………554
11-113. REMOVAL OF STROBE POWER SUPPLY (WARRIOR/WARRIOR II/WARRIOR III)………………………………………………554
11-114. INSTALLATION OF STROBE POWER SUPPLY (WARRIOR/WARRIOR II/WARRIOR III)………………………………………….554
11-115. TROUBLESHOOTING STROBE LIGHTS (WARRIOR/WARRIOR II/WARRIOR III)……………………………………………….554
11-116. INSTRUMENT AND PANEL LIGHTS………………………………………………………………………………….558
11-117. INSTRUMENT AND PANEL LIGHTS DESCRIPTION (WARRIOR/WARRIOR II)…………………………………………………558
11-118. REMOVAL OF DIMMER CONTROL ASSEMBLY (WARRIOR/WARRIOR II)……………………………………………………..558
11-119. INSTALLATION OF DIMMER CONTROL ASSEMBLY (WARRIOR/WARRIOR II)…………………………………………………558
11-120. INSTRUMENT AND PANEL LIGHTS DESCRIPTION (WARRIOR III)……………………………………………………….559
11-121. REMOVAL OF DIMMER CONTROL (WARRIOR III)……………………………………………………………………559
11-122. REMOVAL OF DIMMER CONTROL POTENTIOMETER (WARRIOR III)……………………………………………………….559
11-123. INSTALLATION OF DIMMER CONTROL (WARRIOR III)……………………………………………………………….559
11-124. INSTALLATION OF DIMMER CONTROL POTENTIOMETER (WARRIOR III)…………………………………………………..559
11-125. ANNUNCIATOR PANEL…………………………………………………………………………………………..560
11-126. ANNUNCIATOR PANEL DESCRIPTION (WARRIOR/WARRIOR II)………………………………………………………….560
11-127. ANNUNCIATOR PANEL DESCRIPTION (WARRIOR III)………………………………………………………………..560
11-128. TROUBLESHOOTING ANNUNCIATOR PANEL (WARRIOR/WARRIOR II/WARRIOR III)……………………………………………561
11-129. REPLACEMENT OF ANNUNCIATOR PANEL LIGHT BULBS (WARRIOR/WARRIOR II)…………………………………………….561
11-130. REPLACEMENT OF ANNUNCIATOR PANEL LIGHT BULBS (WARRIOR III)…………………………………………………..562
11-131. OIL PRESSURE SENSOR…………………………………………………………………………………………563
11-132. REMOVAL OF OIL PRESSURE SENSOR (WARRIOR/WARRIOR II)…………………………………………………………563
11-133. INSTALLATION OF OIL PRESSURE SENSOR (WARRIOR/WARRIOR II)…………………………………………………….563
11-134. REMOVAL OF OIL PRESSURE SENDER (WARRIOR III)……………………………………………………………….563
11-135. INSTALLATION OF OIL PRESSURE SENDER (WARRIOR III)…………………………………………………………..563
11-136. REMOVAL OF OIL PRESSURE SWITCH (WARRIOR III)……………………………………………………………….563
11-137. INSTALLATION OF OIL PRESSURE SWITCH (WARRIOR III)…………………………………………………………..563
11-138. OIL TEMPERATURE SENSOR………………………………………………………………………………………564
11-139. REMOVAL OF OIL TEMPERATURE SENSOR (WARRIOR/WARRIOR II)………………………………………………………564
11-140. INSTALLATION OF OIL TEMPERATURE SENSOR (WARRIOR/WARRIOR II)………………………………………………….564
11-141. REMOVAL OF OIL TEMPERATURE SENSOR (WARRIOR III)…………………………………………………………….564
11-142. INSTALLATION OF OIL TEMPERATURE SENSOR (WARRIOR III)………………………………………………………..564
11-143. VACUUM SENSOR………………………………………………………………………………………………564
11-144. REMOVAL OF VACUUM SENSOR (WARRIOR/WARRIOR II/WARRIOR III)……………………………………………………564
11-145. INSTALLATION OF VACUUM SENSOR (WARRIOR/WARRIOR II/WARRIOR III)……………………………………………….564
11-146. STALL WARNING………………………………………………………………………………………………564
11-147. REMOVAL OF LIFT DETECTOR…………………………………………………………………………………564
11-148. INSTALLATION OF LIFT DETECTOR…………………………………………………………………………….565
11-149. ADJUSTMENT OF LIFT DETECTOR………………………………………………………………………………565
11-150. ELECTRICAL SWITCHES…………………………………………………………………………………………565
11-151. DESCRIPTION…………………………………………………………………………………………….565
11-152. REMOVAL OF ELECTRICAL SWITCHES (WARRIOR/WARRIOR II)…………………………………………………………565
11-153. INSTALLATION OF ELECTRICAL SWITCHES (WARRIOR/WARRIOR II)…………………………………………………….565
11-154. REMOVAL OF ELECTRICAL SWITCHES (WARRIOR III)……………………………………………………………….566
11-155. INSTALLATION OF ELECTRICAL SWITCHES (WARRIOR III)…………………………………………………………..566
11-156. CIRCUIT BREAKERS……………………………………………………………………………………………566
11-157. REMOVAL OF CIRCUIT BREAKERS………………………………………………………………………………566
11-158. INSTALLATION OF CIRCUIT BREAKERS………………………………………………………………………….566
11-159. IGNITION SWITCH…………………………………………………………………………………………….567
11-160. REMOVAL OF IGNITION SWITCH……………………………………………………………………………….567
11-161. INSTALLATION OF IGNITION SWITCH…………………………………………………………………………..567
ELECTRICAL CHARTS AND WIRING DIAGRAM INDEX……………………………………………………………………………573
SECTION XII – ELECTRONICS………………………………………………………………………………………………629
TABLE OF CONTENTS………………………………………………………………………………………………….631
12-1. INTRODUCTION…………………………………………………………………………………………………633
12-2. GARRETT EMERGENCY LOCATOR TRANSMITTER…………………………………………………………………………..634
12-3. DESCRIPTION………………………………………………………………………………………………634
12-4. GARRETT ELT BATTERY REMOVAL AND INSTALLATION (2 YEAR MAGNESIUM BATTERY)…………………………………………634
12-5. COMMUNICATIONS COMPONENTS CORPORATION EMERGENCY LOCATOR TRANSMITTER………………………………………………..636
12-6. DESCRIPTION………………………………………………………………………………………………636
12-7. BATTERY REMOVAL AND INSTALLATION……………………………………………………………………………636
12-8. TESTING GARRETT OR COMMUNICATIONS COMPONENT EMERGENCY LOCATOR TRANSMITTERS………………………………………….637
12-9. NARCO 10 AND 910 EMERGENCY LOCATOR TRANSMITTER…………………………………………………………………..638
12-10. DESCRIPTION……………………………………………………………………………………………..638
12-11. NARCO ELT 10 BATTERY REMOVAL AND INSTALLATION……………………………………………………………….638
12-12. TESTING NARCO 10 EMERGENCY LOCATOR TRANSMITTER………………………………………………………………641
12-13. NARCO ELT 910 BATTERY REMOVAL AND INSTALLATION………………………………………………………………642
12-14. TESTING NARCO 910 EMERGENCY LOCATOR TRANSMITTER……………………………………………………………..642
12-15. DESCRIPTION, OPERATION AND TESTING OF ELT 10 AND ELT 910 PILOT’S REMOTE SWITCH………………………………….643
12-16. ARTEX 110 ELT……………………………………………………………………………………………….643
12-17. GENERAL INFORMATION………………………………………………………………………………………643
12-18. ARTEX ELT 110 BATTERY REMOVAL AND INSTALLATION………………………………………………………………644
12-19. TESTING ARTEX 110 EMERGENCY LOCATOR TRANSMITTER……………………………………………………………..645
12-20. AVIONICS MASTER AND EMERGENCY SWITCH CIRCUIT……………………………………………………………………646
12-21. DESCRIPTION AND OPERATION…………………………………………………………………………………646
12-22. AUTOFLIGHT………………………………………………………………………………………………….646
12-23. GENERAL…………………………………………………………………………………………………646
12-24. NON-PIPER A.F.C.S. EQUIPMENT CONTACTS………………………………………………………………………646
12-25. PIPER A.F.C.S. EQUIPMENT………………………………………………………………………………….646
12-26. RACK-MOUNTED AVIONICS………………………………………………………………………………………..647
SECTION XIII – HEATING AND VENTILATING…………………………………………………………………………………..649
TABLE OF CONTENTS………………………………………………………………………………………………….651
13-1. INTRODUCTION…………………………………………………………………………………………………653
13-2. CABIN HEAT AND DEFROSTER SYSTEM DESCRIPTION……………………………………………………………………..653
13-3. OVERHEAD VENT SYSTEM DESCRIPTION……………………………………………………………………………….653
13-4. HEATER MAINTENANCE……………………………………………………………………………………………653
SECTION XIV – ACCESSORIES AND UTILITIES………………………………………………………………………………….657
TABLE OF CONTENTS………………………………………………………………………………………………….659
14-1. AIR CONDITIONING INSTALLATION………………………………………………………………………………….661
14-2. DESCRIPTION………………………………………………………………………………………………….661
14-3. AIR CONDITIONING SYSTEM OPERATION………………………………………………………………………………662
14-4. TROUBLESHOOTING………………………………………………………………………………………………662
14-5. MALFUNCTION DETECTION…………………………………………………………………………………………670
14-6. SPECIAL SERVICING PROCEDURES…………………………………………………………………………………..670
14-7. SERVICE VALVES……………………………………………………………………………………………….673
14-8. SERVICE VALVE REPLACEMENT………………………………………………………………………………….674
14-9. CHARGING STATION AND HAND MANIFOLD SET………………………………………………………………………….674
14-10. EVACUATING THE SYSTEM…………………………………………………………………………………….675
14-11. LEAK DETECTION…………………………………………………………………………………………..680
14-12. DISCHARGING (BLEEDING OR PURGING) SYSTEM……………………………………………………………………681
14-13. CHARGING THE SYSTEM………………………………………………………………………………………682
14-14. POST CHARGING OPERATIONAL CHECK……………………………………………………………………………683
14-15. COMPRESSOR SERVICE…………………………………………………………………………………………..685
14-16. COMPRESSOR REMOVAL……………………………………………………………………………………….685
14-17. COMPRESSOR INSTALLATION…………………………………………………………………………………..686
14-18. CHECKING COMPRESSOR OIL…………………………………………………………………………………..686
14-19. REPLACEMENT OF COMPRESSOR AND/OR ALTERNATOR DRIVE BELTS………………………………………………………….687
14-20. ADJUSTMENT OF DRIVE BELT TENSION…………………………………………………………………………..688
14-21. MAGNETIC CLUTCH……………………………………………………………………………………………..691
14-22. MAGNETIC CLUTCH REMOVAL…………………………………………………………………………………..691
14-23. MAGNETIC CLUTCH INSTALLATION………………………………………………………………………………691
14-24. REFRIGERANT LINES AND ROUTING…………………………………………………………………………………692
14-25. RECEIVER-DEHYDRATOR………………………………………………………………………………………….693
14-26. RECEIVER-DEHYDRATOR REMOVAL……………………………………………………………………………….693
14-27. RECEIVER-DEHYDRATOR INSTALLATION…………………………………………………………………………..693
14-28. CONDENSER…………………………………………………………………………………………………..693
14-29. CONDENSER ASSEMBLY REMOVAL………………………………………………………………………………..693
14-30. CONDENSER INSTALLATION……………………………………………………………………………………693
14-31. CONDENSER DOOR ACTUATOR…………………………………………………………………………………..695
14-32. CONDENSER DOOR ASSEMBLY RIGGING INSTRUCTIONS………………………………………………………………..695
14-33. EXPANSION VALVE……………………………………………………………………………………………..695
14-34. EXPANSION VALVE REMOVAL…………………………………………………………………………………..695
14-35.EXPANSION VALVE INSTALLATION……………………………………………………………………………….696
14-36. EVAPORATOR ASSEMBLY………………………………………………………………………………………….696
14-37. EVAPORATOR ASSEMBLY REMOVAL……………………………………………………………………………….696
14-38. EVAPORATOR ASSEMBLY INSTALLATION…………………………………………………………………………..696
14-39. PRESSURE RELIEF SWITCH……………………………………………………………………………………….698
14-40. REMOVAL AND INSTALLATION OF PRESSURE RELIEF SWITCH…………………………………………………………..698
14-41. ELECTRICAL INSTALLATION………………………………………………………………………………………698
14-42. FUSE REPLACEMENT…………………………………………………………………………………………….698
14-43. ADJUSTMENT OF AIR CONDITIONING THROTTLE SWITCH………………………………………………………………….698
14-44. OVERHEAD VENT BLOWER…………………………………………………………………………………………698
14-45. OVERHEAD VENT BLOWER DESCRIPTION…………………………………………………………………………..698
14-46. REMOVAL OF BLOWER ASSEMBLY………………………………………………………………………………..700
14-47. DISASSEMBLY OF BLOWER ASSEMBLY…………………………………………………………………………….700
14-48. ASSEMBLY OF BLOWER ASSEMBLY……………………………………………………………………………….700
14-49. INSTALLATION OF BLOWER ASSEMBLY……………………………………………………………………………700
14-50. RESTRAINT SYSTEM…………………………………………………………………………………………….702
14-51. PORTABLE FIRE EXTINGUISHER……………………………………………………………………………………703
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V