Piper PA-28-161 Cadet Maintenance Manual – PDF DOWNLOAD

Piper PA-28-161 Cadet Maintenance Manual – PDF DOWNLOAD

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Piper PA-28-161 Cadet Maintenance Manual – PDF DOWNLOAD

AEROFICHE EXPLANATION AND REVISlON STATUS
The Service Manual information incorporated in this set of Aerofiche cards has been arranged in accordance
with the general specifications of Aerofiche adopted by the General Aviation Manufacturers Association.(GAMA).
The information compiled in this Aerofiche Service Manual will be kept current by revisions distributed periodically.
These revisions will supersede all previous revisions and will be complete Aerofiche card replacements, and shall
supersede Aerofiche cards of the same number in the set.
Conversion of Aerofiche alpha / numeric code numbers:
First number is the Aerofiche card number.
Letter is the horizontal line reference per card.
Second number is the vertical line reference per card.
Example: 2J16 = Aerofiche card number two of given set. Grid location J16.
To aid in locating the various chapters and related service information desired. the following is provided:
1. A complete manual Table of Contents is for all fiche in this set.
2. A complete List of Illustrations is given and follows the Table of Contents.
3. A complete list of Tables is given for all fiche in this set and follows the List of Illustrations.
4. A complete list of paragraph titles and appropriate Grid location numbers is given at the beginning of
each Chapter relating to the information within that Chapter.
5. Identification of Revised Material:
Revised text and illustrations are indicated by a black vertical line along the left-hand margin of the
frame, opposite revised, added or deleted material. Revision lines indicate only current revisions with
changes and additions to or deletions of existing text and illustrations. Changes in capitalization, spelling,
punctuation, indexing, the physical location of the material or complete page additions are not identified by
revision lines.

TABLE OF CONTENTS:

Piper PA-28-161 Cadet Maintenance Manual – PDF DOWNLOAD

761-829 – CADET MAINTENANCE MANUAL – PA-28-161………………………………………………. 1
SERIAL NUMBER INFORMATION……………………………………………………………… 2
AEROFICHE EXPLANATION AND REVISION STATUS……………………………………………….. 3
TABLE OF CONTENTS…………………………………………………………………….. 4
LIST OF ILLUSTRATIONS…………………………………………………………………. 5
FIGURE 2-1. THREE VIEW…………………………………………………………….. 20
FIGURE 2-2. STATION REFERENCE LINES…………………………………………………. 21
FIGURE 2-3. ACCESS PLATES AND PANELS………………………………………………… 26
FIGURE 2-4. JACKING ARRANGEMENT…………………………………………………….. 32
FIGURE 2-5. WEIGHING ARRANGEMENT……………………………………………………. 33
FIGURE 2-6. LEVELING LONGITUDINALLY…………………………………………………. 34
FIGURE 2-7. LEVELING LATERALLY……………………………………………………… 34
FIGURE 2-8. SERVICING POINTS……………………………………………………….. 38
FIGURE 2-9. INDUCTION AIR FILTER……………………………………………………. 43
FIGURE 2-10. FUEL STRAINER…………………………………………………………. 46
FIGURE 2-11. LUBRICATION CHART……………………………………………………… 51
FIGURE 2-12. CHERRYLOCK RIVET REMOVAL……………………………………………….. 65
FIGURE 2-13. IDENTIFICATION OF AIRCRAFT FLUID LINES…………………………………… 66
FIGURE 2-14. TORQUE WRENCH FORMULA………………………………………………….. 67
FIGURE 3-1. INSPECTION AREAS OF EXHAUST SYSTEM……………………………………….. 89
FIGURE 3-2. TYPICAL MUFFLER FATIGUE AREAS……………………………………………. 89
FIGURE 4-1. AILERON AND FLAP INSTALLATION…………………………………………….108
FIGURE 4-2. WING INSTALLATION……………………………………………………….109
FIGURE 4-3. METHODS OF SECURING CONTROL CABLES………………………………………..114
FIGURE 4-4. EMPENNAGE GROUP INSTALLATION……………………………………………..116
FIGURE 4-5. WINDSHIELD INSTALLATION (TYPICAL)…………………………………………119
FIGURE 4-6. SIDE WINDOW INSTALLATION (TYPICAL)………………………………………..120
FIGURE 4-7. DOOR SNUBBER INSTALLATION………………………………………………..123
FIGURE 4-8. SEAT BACK LOCK………………………………………………………….124
FIGURE 4-9. SKIN MATERIALS AND THICKNESS……………………………………………..129
FIGURE 4-10. TYPICAL ACCESS PLATES…………………………………………………..130
FIGURE 4-11. CONTROL SURFACE BALANCE TOOL…………………………………………….131
FIGURE 4-12. AILERON BALANCE………………………………………………………..132
FIGURE 4-13. RUDDER BALANCE…………………………………………………………133
FIGURE 4-14. RUDDER BALANCE WEIGHT…………………………………………………..134
FIGURE 4-15. STABILATOR BALANCE……………………………………………………..135
FIGURE 5-1. CONTROL COLUMN ASSEMBLY………………………………………………….146
FIGURE 5-2. CORRECT METHOD OF INSTALLING ROD END BEARINGS………………………………147
FIGURE 5-3. AILERON CONTROLS………………………………………………………..149
FIGURE 5-4. BELLCRANK RIGGING TOOL…………………………………………………..153
FIGURE 5-5. STABILATOR CONTROLS……………………………………………………..156
FIGURE 5-6. STABILATOR RIGGING TOOL………………………………………………….157
FIGURE 5-7. STABILATOR TRIM CONTROLS…………………………………………………160
FIGURE 5-8. METHODS OF SECURING TRIM CABLES…………………………………………..161
FIGURE 5-9. RUDDER AND STEERING PEDAL ASSEMBLY………………………………………..164
FIGURE 5-10. RUDDER CONTROLS………………………………………………………..166
FIGURE 5-11. RUDDER RIGGING TOOL…………………………………………………….167
FIGURE 5-12. CLAMPING RUDDER PEDALS………………………………………………….167
FIGURE 5-13. RUDDER AND STABILATOR TRAVEL ADJUSTMENT…………………………………..168
FIGURE 5-14. RUDDER TRIM CONTROL…………………………………………………….170
FIGURE 5-15. FLAP CONTROL SYSTEM…………………………………………………….172
FIGURE 5-16. FLAP STOP ADJUSTMENT……………………………………………………174
FIGURE 5-17. FLAP RIGGING TOOL………………………………………………………174
FIGURE 5-18. FABRICATED RUDDER RIGGING TOOL…………………………………………..179
FIGURE 5-19. FABRICATED STABILATOR RIGGING TOOL……………………………………….180
FIGURE 5-20. FABRICATED FLAP RIGGING TOOL…………………………………………….181
FIGURE 7-1. NOSE GEAR OLEO STRUT ASSEMBLY…………………………………………….189
FIGURE 7-2. NOSE GEAR INSTALLATION…………………………………………………..192
FIGURE 7-3. CLAMPING RUDDER PEDALS IN NEUTRAL POSITION…………………………………194
FIGURE 7-4. RUDDER PEDALS AT NEUTRAL ANGLE……………………………………………194
FIGURE 7-5. MAIN GEAR OLEO STRUT ASSEMBLY…………………………………………….196
FIGURE 7-6. MAIN GEAR INSTALLATION…………………………………………………..198
FIGURE 7-7. NOSE WHEEL ASSEMBLY……………………………………………………..201
FIGURE 7-8. MAIN WHEEL ASSEMBLY……………………………………………………..202
FIGURE 7-9. WHEEL BRAKE ASSEMBLY…………………………………………………….204
FIGURE 7-10. REMOVAL OF ANCHOR BOLT………………………………………………….205
FIGURE 7-11. INSTALLATION OF ANCHOR BOLT……………………………………………..205
FIGURE 7-12. BRAKE SYSTEM INSTALLATION……………………………………………….207
FIGURE 7-13. BRAKE MASTER CYLINDER (HAND/PARKING BRAKE)………………………………..208
FIGURE 7-14. BRAKE CYLINDER (TOE BRAKE)………………………………………………213
FIGURE 7-15. RETAINER RING INSTALLATION TOOL………………………………………….216
FIGURE 8-1. TYPICAL NICKS AND REMOVAL METHOD………………………………………….223
FIGURE 8-2. PROPELLER AND COWLING INSTALLATION………………………………………..224
FIGURE 8-3. ENGINE INSTALLATION……………………………………………………..226
FIGURE 8-4. ENGINE SHOCK MOUNT INSTALLATION…………………………………………..228
FIGURE 8-5. ADJUSTMENT OF ENGINE CONTROLS…………………………………………….229
FIGURE 8-6. CARBURETOR……………………………………………………………..231
FIGURE 8-7. T-100 ASSEMBLY AND TIMING TOOL KIT………………………………………..237
FIGURE 8-8. EXPLODED VIEW OF MAGNETO…………………………………………………238
FIGURE 8-9. REMOVING COIL WEDGES…………………………………………………….238
FIGURE 8-10. INDEX PLATE AND TIMING PLUG……………………………………………..240
FIGURE 8-11. INSTALLATION OF BEARINGS AND BEARING PLATE………………………………..240
FIGURE 8-12. POSITION OF MAGNETO ON T100 TOO1 AND OIL SEAL INSTALLATION………………….241
FIGURE 8-13. TIMING MAGNETO INTERNALLY AND ASSEMBLY……………………………………242
FIGURE 8-14. STRIPPING TOOL…………………………………………………………246
FIGURE 8-15. INSERTING STRIPPING TOOL………………………………………………..246
FIGURE 8-16. CUTTING INSULATION……………………………………………………..246
FIGURE 8-17. REMOVING SILICONE RUBBER FROM WIRE……………………………………….246
FIGURE 8-18. INSTALLATION OF PLUG END NUT…………………………………………….247
FIGURE 8-19. FLARING OUT OF SHIELDING………………………………………………..247
FIGURE 8-20. INSTALLATION OF FERRULE…………………………………………………247
FIGURE 8-21. DRIVING TOOL…………………………………………………………..247
FIGURE 8-22. INSTALLATION IN HOUSING…………………………………………………248
FIGURE 8-23. SECURING WIRE IN HOUSING………………………………………………..248
FIGURE 8-24. INSTALLATION OF ELECTRICAL SCREW…………………………………………249
FIGURE 8-25. INSTALLATION OF INSULATION SLEEVE………………………………………..249
FIGURE 8-26. INSTALLATION OF SPRING………………………………………………….249
FIGURE 8-27. REMOVING SPARK PLUG FROZEN TO BUSHING…………………………………….249
FIGURE 8-28. ICE DETECTION SYSTEM……………………………………………………253
FIGURE 9-1. FUEL SYSTEM DIAGRAM……………………………………………………..273
FIGURE 9-2. TOLERANCES, UNION NUT AND TUBING NUT………………………………………275
FIGURE 9-3. FUEL QUANTITY TRANSMITTER CHECKING JIG…………………………………….278
FIGURE 9-4. FUEL QUANTITY INDICATORS…………………………………………………278
FIGURE 9-5. LOCKING FUEL CAP………………………………………………………..279
FIGURE 9-6. FUEL FILTER BOWL AND SCREEN………………………………………………280
FIGURE 9-7. PLUNGER FUEL PUMP……………………………………………………….282
FIGURE 9-8. ENGINE PRIMER…………………………………………………………..284
FIGURE 9-9. FABRICATED FUEL QUANTITY TRANSMITTER CHECKING JIG…………………………..288
FIGURE 10-1. INSTRUMENT PANEL……………………………………………………….297
FIGURE 10-2. PITOT-STATIC SYSTEM…………………………………………………….302
FIGURE 10-3. AUXILIARY VACUUM SYSTEM…………………………………………………305
FIGURE 10-4. ENGINE OIL PRESSURE GAUGE……………………………………………….314
FIGURE 10-5. FUEL PRESSURE GAUGE…………………………………………………….315
FIGURE 10-6. OIL TEMPERATURE GAUGE…………………………………………………..319
FIGURE 11-1. INSTRUMENT PANEL (CIRCUIT BREAKER PANEL)………………………………….330
FIGURE 11-2. LAMP BANK LOAD…………………………………………………………331
FIGURE 11-3. EXPLODED VIEW OF ALTERNATOR……………………………………………..333
FIGURE 11-4. REMOVAL OF RECTIFIER……………………………………………………336
FIGURE 11-5. REMOVAL OF SLIP RING END BEARING…………………………………………336
FIGURE 11-6. REMOVAL OF DRIVE END HEAD……………………………………………….336
FIGURE 11-7. REMOVAL OF END HEAD BEARING……………………………………………..336
FIGURE 11-8. TESTING ROTOR FOR GROUNDS……………………………………………….337
FIGURE 11-9. TESTING ROTOR FOR SHORTS………………………………………………..337
FIGURE 11-10. INSTALLATION OF BEARING………………………………………………..338
FIGURE 11-11. INSTALLATION OF RECTIFIER………………………………………………338
FIGURE 11-12. TERMINAL ASSEMBLY……………………………………………………..338
FIGURE 11-13. SLIP RING END BEARING ASSEMBLY………………………………………….339
FIGURE 11-14. TESTING ALTERNATOR…………………………………………………….339
FIGURE 11-15. BRUSH INSTALLATION…………………………………………………….340
FIGURE 11-16. INTERNAL WIRING DIAGRAM………………………………………………..340
FIGURE 11-17. BATTERY BOX…………………………………………………………..345
FIGURE 11-18. APPLICATION OF OVERVOLTAGE CONTROL………………………………………347
FIGURE 11-19. EXPLODED VIEW OF GEAR REDUCTION STARTER MOTOR…………………………….348
FIGURE 11-20. TURNING MOTOR COMMUTATOR……………………………………………….350
FIGURE 11-21. TESTING MOTOR ARMATURE FOR SHORTS……………………………………….350
FIGURE 11-22. TESTING MOTOR FIELDS FOR GROUNDS………………………………………..351
FIGURE 11-23. NO LOAD TEST HOOKUP……………………………………………………351
FIGURE 11-24. STALL TORQUE HOOKUP……………………………………………………352
FIGURE 11-25. STROBE LIGHT CONNECTIONS (WITH FIN STROBE)……………………………….356
FIGURE 11-26. STROBE LIGHT CONNECTIONS (WITH ROTATING BEACON)…………………………..357
FIGURE 11-27. IGNITION SWITCH……………………………………………………….361
FIGURE 11-28. ANNUNCIATOR…………………………………………………………..376
FIGURE 11-29. ANNUNCIATOR INTERNAL WIRING…………………………………………….377
FIGURE 11-30. PITOT STATIC HEAT……………………………………………………..378
FIGURE 11-31. ALTERNATOR……………………………………………………………379
FIGURE 11-32. AVIONICS MASTER SWITCH (OPTIONAL)……………………………………….380
FIGURE 11-33. STARTER………………………………………………………………381
FIGURE 11-34. BATTERY MASTER SWITCH………………………………………………….382
FIGURE 11-35. AIR BLOWER……………………………………………………………383
FIGURE 11-36. FUEL PUMP…………………………………………………………….384
FIGURE 11-37. CLOCK, ELECTRICAL AND DIGITAL (OPTIONAL)…………………………………385
FIGURE 11-38. ENGINE GAGES………………………………………………………….386
FIGURE 11-39. HOURMETER (OPTIONAL)…………………………………………………..387
FIGURE 11-40. TURN AND BANK…………………………………………………………388
FIGURE 11-41. ANTI – COLLISION, STROBE LIGHTS (WING)…………………………………..389
FIGURE 11-42. ANTI – COLLISION, STROBE LIGHTS (TAIL)…………………………………..390
FIGURE 11-43. RECOGNITION LIGHTS (OPTIONAL)…………………………………………..391
FIGURE 11-44. INSTRUMENT FLOOD LIGHTS………………………………………………..392
FIGURE 11-45. NAVIGATION LIGHTS……………………………………………………..393
FIGURE 11-46. LANDING LIGHT…………………………………………………………394
FIGURE 11-47. INSTRUMENT PANEL AND SWITCH LIGHTS………………………………………395
FIGURE 11-48. PITCH TRIM……………………………………………………………396
FIGURE 11-49. STALL WARNING…………………………………………………………397
FIGURE 11-50. OPTIONAL AVIONICS……………………………………………………..398
FIGURE 12-1. ELT PORTABLE FOLDING ANTENNA…………………………………………….405
FIGURE 12-2. ELT USING FIXED AIRCRAFT ANTENNA…………………………………………405
FIGURE 12-3. ELT SCHEMATIC………………………………………………………….406
FIGURE 12-4. AVIONICS MASTER AND EMERGENCY SWITCH CIRCUIT………………………………409
FIGURE 13-1. CABIN HEATER, DEFROSTER AND FRESH AIR SYSTEM………………………………416
LIST OF TABLES……………………………………………………………………….. 10
CHART II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS………………………………. 22
CHART II-II. RECOMMENDED TORQUES……………………………………………………. 28
CHART II-IIA. FLARE FITTING TORQUES…………………………………………………. 31
CHART II-IIB. TYPE OF LUBRICANTS……………………………………………………. 49
CHART II-IIC. TYPES OF METAL CORROSION………………………………………………. 61
CHART II-III. LIST OF CONSUMABLE MATERIALS…………………………………………… 68
CHART II-IV. CONVERSION TABLES……………………………………………………… 75
CHART II-V. THREAD LUBRICANTS………………………………………………………. 79
CHART II-VI. HOSE CLAMP TIGHTENING………………………………………………….. 79
CHART II-VII. MAXIMUM DISTANCE BETWEEN SUPPORTS FOR FLUID TUBING……………………….. 80
CHART II-VIII. DECIMAL-MILLIMETER EQUIVALENTS OF DRILL SIZES…………………………… 81
CHART III-I. INSPECTION REPORT……………………………………………………… 90
CHART IV-I. BALANCING SPECIFICATIONS…………………………………………………127
CHART V-I. CONTROL SURFACE TRAVEL AND CABLE TENSION……………………………………144
CHART V-II. CABLE TENSION VS. AMBIENT TEMPERATURE……………………………………..145
CHART V-III. TROUBLESHOOTING CHART (SURFACE CONTROLS)………………………………….175
CHART VII-I. LANDING GEAR TROUBLESHOOTING…………………………………………….214
CHART VIII-I. PROPELLER TORQUE LIMITS………………………………………………..224
CHART VIII-II. ENGINE TROUBLESHOOTING………………………………………………..255
CHART IX-I. TRANSMITTER/FUEL GAUGE TOLERANCES…………………………………………277
CHART IX-II. FUEL QUANTITY TRANSMITTER CALIBRATION TOLERANCE……………………………277
CHART IX-III. FUEL SYSTEM TROUBLESHOOTING…………………………………………….286
CHART X-I. VACUUM SYSTEM……………………………………………………………298
CHART X-II. DIRECTIONAL GYRO INDICATOR……………………………………………….306
CHART X-III. GYRO HORIZON INDICATOR………………………………………………….307
CHART X-IV. RATE OF CLIMB INDICATOR………………………………………………….308
CHART X-V. ALTIMETER……………………………………………………………….309
CHART X-VI. AIRSPEED TUBES AND INDICATOR……………………………………………..311
CHART X-VII. MAGNETIC COMPASS……………………………………………………….312
CHART X-VIII. TACHOMETER……………………………………………………………313
CHART X-IX. ENGINE OIL PRESSURE GAUGE………………………………………………..314
CHART X-X. FUEL PRESSURE GAUGE………………………………………………………316
CHART X-XI. TURN AND BANK INDICATOR………………………………………………….317
CHART X-XII. FUEL QUANTITY INDICATOR…………………………………………………318
CHART X-XIII. OIL TEMPERATURE INDICATOR………………………………………………320
CHART XI-I. INDEX ELECTRICAL SYSTEM SCHEMATICS………………………………………..328
CHART XI-II. ALTERNATOR SPECIFICATIONS……………………………………………….341
CHART XI-III. ALTERNATOR BELT TENSION………………………………………………..341
CHART XI-IV. HYDROMETER READING AND BATTERY CHARGE PERCENT……………………………..343
CHART XI-V. STARTING MOTOR SPECIFICATIONS…………………………………………….353
CHART XI-VI. TROUBLESHOOTING CHART (ELECTRICAL SYSTEM)…………………………………363
CHART XI-VII. LAMP REPLACEMENT GUIDE…………………………………………………372
CHART XI-VIII. ELECTRICAL SYSTEM COMPONENT LOADS………………………………………373
CHART XI-IX. ELECTRICAL WIRE CODING………………………………………………….374
CHART XI-X. ELECTRICAL SYMBOLS………………………………………………………375
CHART XIV-I. BLOWER SYSTEM WIRE COLOR CODES…………………………………………..421
SECTION I – INTRODUCTION………………………………………………………………. 12
1-1. GENERAL……………………………………………………………………… 13
1-2. SCOPE OF MANUAL………………………………………………………………. 13
1-3. DESCRIPTION………………………………………………………………….. 13
1-4. WING……………………………………………………………………….. 13
1-5. EMPENNAGE……………………………………………………………………. 13
1-6. FUSELAGE…………………………………………………………………….. 13
1-7. LANDING GEAR…………………………………………………………………. 13
1-8. BRAKE SYSTEM…………………………………………………………………. 13
1-9. ENGINE………………………………………………………………………. 13
1-10. PROPELLER…………………………………………………………………… 13
1-11. FUEL SYSTEM…………………………………………………………………. 14
1-12. FLIGHT CONTROLS……………………………………………………………… 14
1-13. RADIO………………………………………………………………………. 14
1-14. CABIN HEATER, DEFROSTER, AND FRESH AIR SYSTEM…………………………………… 14
1-15. INSTRUMENT AND AUTOPILOT SYSTEM……………………………………………….. 14
1-16. WARNINGS, CAUTIONS, AND NOTES…………………………………………………. 14
SECTION II – HANDLING AND SERVICING…………………………………………………….. 16
2-1. INTRODUCTION…………………………………………………………………. 19
2-2. DIMENSIONS…………………………………………………………………… 19
2-3. STATION REFERENCE LINES……………………………………………………….. 19
2-4. WEIGHT AND BALANCE DATA……………………………………………………….. 19
2-5. SERIAL NUMBER PLATE…………………………………………………………… 19
2-6. ACCESS AND INSPECTION PROVISIONS……………………………………………….. 19
2-7. TOOLS AND TEST EQUIPMENT………………………………………………………. 19
2-8. TORQUE REQUIREMENTS…………………………………………………………… 27
2-9. WALKWAY, HANDHOLD AND STEP…………………………………………………….. 32
2-10. GROUND HANDLING……………………………………………………………… 32
2-11. INTRODUCTION TO GROUND HANDLING……………………………………………….. 32
2-12. JACKING…………………………………………………………………….. 32
2-13. WEIGHING……………………………………………………………………. 33
2-14. LEVELING……………………………………………………………………. 33
2-15. MOORING…………………………………………………………………….. 34
2-16. LOCKING AIRPLANE…………………………………………………………….. 35
2-17. PARKING…………………………………………………………………….. 35
2-18. TOWING……………………………………………………………………… 35
2-19. TAXIING…………………………………………………………………….. 35
2-20. EXTERNAL POWER RECEPTACLE (OPTIONAL)…………………………………………… 36
2-21. OPERATION OF EXTERNAL POWER RECEPTACLE…………………………………………. 36
2-22. CLEANING……………………………………………………………………. 36
2-23. CLEANING ENGINE COMPARTMENT…………………………………………………… 36
2-24. CLEANING LANDING GEAR………………………………………………………… 36
2-25. CLEANING EXTERIOR SURFACES……………………………………………………. 37
2-26. CLEANING WINDSHIELD AND WINDOWS……………………………………………….. 37
2-27. CLEANING HEADLINER, SIDE PANELS, AND SEATS……………………………………… 37
2-28.CLEANING CARPETS……………………………………………………………… 39
2-29. SERVICING…………………………………………………………………… 39
2-30. INTRODUCTION TO SERVICING…………………………………………………….. 39
2-31. LANDING GEAR SYSTEM………………………………………………………….. 39
2-32. SERVICING LANDING GEAR……………………………………………………….. 39
2-33. OLEO STRUTS…………………………………………………………………. 39
2-34. SERVICING OLEO STRUTS………………………………………………………… 39
2-35. FILLING NOSE GEAR OLEO STRUT………………………………………………….. 40
2-36. FILLING MAIN GEAR OLEO STRUT………………………………………………….. 40
2-37. INFLATING OLEO STRUTS………………………………………………………… 42
2-38. BRAKE SYSTEM………………………………………………………………… 42
2-39. SERVICING BRAKE SYSTEM……………………………………………………….. 42
2-40. FILLING BRAKE CYLINDER RESERVOIR………………………………………………. 42
2-41. DRAINING BRAKE SYSTEM………………………………………………………… 42
2-42. TIRES………………………………………………………………………. 42
2-43. SERVICING TIRES……………………………………………………………… 42
2-44. POWER PLANT…………………………………………………………………. 42
2-45. SERVICING POWER PLANT………………………………………………………… 42
2-46. INDUCTION AIR FILTER…………………………………………………………. 44
2-47. REMOVAL OF AIR FILTER………………………………………………………… 44
2-48. SERVICE INSTRUCTIONS (INSPECTION AND REPLACEMENT)……………………………….. 44
2-49. INSTALLATION OF AIR FILTER……………………………………………………. 44
2-50. PROPELLER…………………………………………………………………… 44
2-51. SERVICING PROPELLER………………………………………………………….. 44
2-52. FUEL SYSTEM…………………………………………………………………. 44
2-53. SERVICING FUEL SYSTEM………………………………………………………… 44
2-54. FILLING FUEL TANKS…………………………………………………………… 45
2-55. ANTI-ICING FUEL ADDITIVE……………………………………………………… 45
2-56. DRAINING FUEL VALVE AND STRAINER………………………………………………. 45
2-57. DRAINING FUEL SYSTEM…………………………………………………………. 45
2-58. ELECTRICAL SYSTEM……………………………………………………………. 46
2-59. SERVICING THE ELECTRICAL SYSTEM……………………………………………….. 46
2-60. LUBRICATION…………………………………………………………………. 46
2-61. OIL SYSTEM (ENGINE)………………………………………………………….. 46
2-62. SERVICING OIL SYSTEM…………………………………………………………. 46
2-63. FILLING OIL SUMP…………………………………………………………….. 47
2-64. DRAINING OIL SUMP……………………………………………………………. 47
2-65. OIL SCREENS (SUCTION)………………………………………………………… 47
2-66. OIL SCREEN (PRESSURE)………………………………………………………… 47
2-67. OIL FILTER (FULL FLOW)……………………………………………………….. 47
2-68. RECOMMENDATIONS FOR CHANGING OIL………………………………………………. 48
2-69. LUBRICATION INSTRUCTIONS……………………………………………………… 48
2-70. APPLICATION OF OIL…………………………………………………………… 48
2-71. APPLICATION OF GREASE………………………………………………………… 48
2-72. WINTERIZATION PLATE………………………………………………………….. 48
2-73. LUBRICATION CHART……………………………………………………………. 48
2-74. CORROSION CONTROL……………………………………………………………. 59
2-75. FORM OF CORROSION……………………………………………………………. 59
2-76. CONDITIONS AFFECTING CORROSION………………………………………………… 59
2-77. INSPECTION………………………………………………………………….. 60
2-78. CORROSION REMOVAL AND CONTROL…………………………………………………. 60
2-79. AREAS PRONE TO CORROSION……………………………………………………… 62
2-80. REPAINTING………………………………………………………………….. 63
2-81. PRODUCT LISTING FOR URETHANE ENAMEL AIRCRAFT FINISH (OPTIONAL FINISH)……………… 63
2-82. PREPARATION OF EPOXY ZINC CHROMATE PRIMER………………………………………. 63
2-83. PREPARATION AND APPLICATION OF DUPONT IMRON URETHANE ENAMEL………………………. 64
2-84. PRODUCT LISTING FOR RANDOLPH PAINT FINISH………………………………………. 64
2-85. PREPARATION AND APPLICATION OF ZINC CHROMATE PRIMER……………………………… 64
2-86. FINISH PAINTING WITH RANDOLPH PAINT (B5420/D7784)……………………………….. 64
2-87. REPAIRS…………………………………………………………………….. 65
2-88. REMOVAL OF CHERRYLOCK RIVETS………………………………………………….. 65
2-89. STANDARD PRACTICE – AIRFRAME………………………………………………….. 67
2-90. TORQUE WRENCHES……………………………………………………………… 67
SECTION III – INSPECTION………………………………………………………………. 86
3-1. INTRODUCTION…………………………………………………………………. 87
3-2. RECOMMENDED LUBRICANTS………………………………………………………… 87
3-3. INSPECTION PERIODS……………………………………………………………. 87
3-4. INSPECTION REQUIREMENTS……………………………………………………….. 87
3-5. PREFLIGHT CHECK………………………………………………………………. 87
3-6. OVERLIMITS INSPECTION…………………………………………………………. 88
3-7. SPECIAL INSPECTIONS…………………………………………………………… 88
3-8. INSPECTION OF EXHAUST SYSTEM…………………………………………………… 88
3-9. PROGRAMMED INSPECTION…………………………………………………………. 88
SECTION IV – STRUCTURES………………………………………………………………..102
4-1. INTRODUCTION………………………………………………………………….104
4-2. DESCRIPTION…………………………………………………………………..104
4-3. WING GROUP……………………………………………………………………105
4-4. WING TIP……………………………………………………………………..105
4-5. REMOVAL OF WING TIP……………………………………………………………105
4-6. INSTALLATION OF WING TIP……………………………………………………….105
4-7. AILERON………………………………………………………………………105
4-8. REMOVAL OF AILERON…………………………………………………………….105
4-9. INSTALLATION OF AILERON………………………………………………………..105
4-10. WING FLAP……………………………………………………………………106
4-11. REMOVAL OF WING FLAP………………………………………………………….106
4-12. INSTALLATION OF WING FLAP……………………………………………………..106
4-13. WING………………………………………………………………………..106
4-14. REMOVAL OF WING………………………………………………………………106
4-15. INSTALLATION OF WING………………………………………………………….107
4-16. EMPENNAGE GROUP………………………………………………………………112
4-17. STABILATOR…………………………………………………………………..112
4-18. REMOVAL OF STABILATOR…………………………………………………………112
4-19. INSTALLATION OF STABILATOR…………………………………………………….113
4-20. STABILATOR TRIM TAB…………………………………………………………..113
4-21. REMOVAL OF STABILATOR TRIM TAB…………………………………………………113
4-22. INSTALLATION OF STABILATOR TRIM TAB…………………………………………….102
4-23. RUDDER………………………………………………………………………114
4-24. REMOVAL OF RUDDER…………………………………………………………….114
4-25. INSTALLATION OF RUDDER………………………………………………………..114
4-26. VERTICAL FIN…………………………………………………………………115
4-27. REMOVAL OF VERTICAL FIN……………………………………………………….115
4-28. INSTALLATION OF VERTICAL FIN…………………………………………………..115
4-29. FUSELAGE ASSEMBLY…………………………………………………………….115
4-30. WINDSHIELD…………………………………………………………………..115
4-31. REMOVAL OF WINDSHIELD…………………………………………………………115
4-32. INSTALLATION OF WINDSHIELD…………………………………………………….118
4-33. SIDE WINDOWS…………………………………………………………………118
4-34. REMOVAL OF SIDE WINDOWS……………………………………………………….118
4-35. INSTALLATION OF SIDE WINDOWS…………………………………………………..118
4-36. DOOR………………………………………………………………………..118
4-37. REMOVAL OF DOOR………………………………………………………………118
4-38. INSTALLATION OF DOOR………………………………………………………….120
4-39. ADJUSTMENT OF DOOR……………………………………………………………120
4-40. REMOVAL OF DOOR LATCH MECHANISM………………………………………………..120
4-41. INSTALLATION OF DOOR LATCH MECHANISM……………………………………………121
4-42. ADJUSTMENT OF DOOR LATCH MECHANISM……………………………………………..121
4-43. REMOVAL OF DOOR LOCK ASSEMBLY………………………………………………….121
4-44. INSTALLATION OF DOOR LOCK ASSEMBLY……………………………………………..121
4-45. REMOVAL OF DOOR SAFETY LATCH…………………………………………………..121
4-46. INSTALLATION OF DOOR SAFETY LATCH………………………………………………121
4-47. ADJUSTMENT OF DOOR SAFETY LATCH………………………………………………..121
4-48. REMOVAL AND INSTALLATION OF DOOR SEAL SNUBBER……………………………………121
4-49. RIGGING INSTRUCTIONS – SEAT BACK LOCK AND RELEASE………………………………..124
4-50. STRUCTURAL REPAIRS……………………………………………………………125
4-51. FIBERGLASS REPAIRS……………………………………………………………125
4-52. FIBERGLASS TOUCH-UP AND SURFACE REPAIRS…………………………………………125
4-53. FIBERGLASS FRACTURE AND PATCH REPAIRS…………………………………………..126
4-54. CHECKING CONTROL SURFACE FREE PLAY……………………………………………..127
4-55. CONTROL SURFACE BALANCING……………………………………………………..127
4-56. CHECKING CONTROL SURFACE BALANCE……………………………………………….128
4-57. BALANCING EQUIPMENT…………………………………………………………..128
4-58. BALANCING AILERONS……………………………………………………………132
4-59. BALANCING RUDDER……………………………………………………………..133
4-60. BALANCING STABILATOR………………………………………………………….135
4-61. SAFETY WALK REPAIR……………………………………………………………136
4-62. SURFACE PREPARATION FOR PRESSURE SENSITIVE SAFETY WALK……………………………136
4-63. APPLICATION OF PRESSURE SENSITIVE SAFETY WALK……………………………………136
SECTION V – SURFACE CONTROLS……………………………………………………………141
5-1. INTRODUCTION………………………………………………………………….142
5-2. DESCRIPTION…………………………………………………………………..142
5-3. STANDARD PROCEDURES……………………………………………………………142
5-4. CONTROL COLUMN ASSEMBLY………………………………………………………..143
5-5. REMOVAL OF CONTROL COLUMN ASSEMBLY………………………………………………143
5-6. INSTALLATION OF CONTROL COLUMN ASSEMBLY………………………………………….148
5-7. AILERON CONTROLS………………………………………………………………148
5-8. REMOVAL OF AILERON CONTROL CABLES……………………………………………….148
5-9. INSTALLATION OF AILERON CONTROL CABLES…………………………………………..150
5-10. REMOVAL OF AILERON BELLCRANK ASSEMBLY…………………………………………..151
5-11. INSTALLATION OF AILERON BELLCRANK ASSEMBLY………………………………………152
5-12. RIGGING AND ADJUSTMENT OF AILERON CONTROLS………………………………………152
5-13. STABILATOR CONTROLS…………………………………………………………..154
5-14. REMOVAL OF STABILATOR CONTROL CABLES……………………………………………154
5-15. INSTALLATION OF STABILATOR CONTROL CABLES……………………………………….155
5-16. RIGGING AND ADJUSTMENT OF STABILATOR CONTROLS……………………………………155
5-17. STABILATOR TRIM CONTROLS………………………………………………………158
5-18. REMOVAL OF STABILATOR TRIM ASSEMBLY…………………………………………….158
5-19. INSTALLATION OF STABILATOR TRIM ASSEMBLY (FORWARD)……………………………….159
5-20. REMOVAL OF STABILATOR TRIM ASSEMBLY (AFT)……………………………………….159
5-21. INSTALLATION OF STABILATOR TRIM ASSEMBLY (AFT)…………………………………..161
5-22. RIGGING AND ADJUSTMENT OF STABILATOR TRIM……………………………………….162
5-23. RUDDER AND STEERING PEDAL ASSEMBLY……………………………………………..162
5-24. REMOVAL OF RUDDER AND STEERING PEDAL ASSEMBLY……………………………………162
5-25. INSTALLATION OF RUDDER AND STEERING PEDAL ASSEMBLY……………………………….163
5-26. RUDDER CONTROLS………………………………………………………………165
5-27. REMOVAL OF RUDDER CONTROL CABLES……………………………………………….165
5-28. INSTALLATION OF RUDDER CONTROL CABLES…………………………………………..165
5-29. RIGGING AND ADJUSTMENT OF RUDDER CONTROLS……………………………………….167
5-30. RUDDER TRIM CONTROLS………………………………………………………….169
5-31. REMOVAL OF RUDDER TRIM CONTROLS………………………………………………..169
5-32. INSTALLATION OF RUDDER TRIM CONTROLS……………………………………………169
5-33. RIGGING AND ADJUSTMENT OF RUDDER TRIM CONTROLS…………………………………..169
5-34. WING FLAP CONTROLS……………………………………………………………169
5-35. REMOVAL OF WING FLAP CONTROLS………………………………………………….169
5-36. INSTALLATION OF FLAP CONTROLS………………………………………………….171
5-37. RIGGING AND ADJUSTMENT OF WING FLAPS……………………………………………173
SECTION VI – HYDRAULIC SYSTEM (NOT APPLICABLE)…………………………………………… 4
SECTION VII – LANDING GEAR AND BRAKE SYSTEM………………………………………………186
7-1. INTRODUCTION………………………………………………………………….188
7-2. DESCRIPTION…………………………………………………………………..188
7-3. TROUBLESHOOTING……………………………………………………………….188
7-4. LANDING GEAR SYSTEM……………………………………………………………188
7-5. NOSE LANDING GEAR……………………………………………………………..188
7-6. DISASSEMBLY OF NOSE GEAR OLEO…………………………………………………..188
7-7. CLEANLNG, INSPECTION AND REPAIR OF NOSE GEAR OLEO…………………………………190
7-8. NOSE GEAR OIL ORIFICE RETAINER RING INSTALLATION………………………………….190
7-9. ASSEMBLY OF NOSE GEAR OLEO……………………………………………………..191
7-10. REMOVAL OF NOSE LANDING GEAR…………………………………………………..191
7-11. CLEANING, INSPECTION, AND REPAIR OF NOSE LANDING GEAR…………………………….193
7-12. INSTALLATION OF NOSE LANDING GEAR………………………………………………193
7-13. ALIGNMENT OF NOSE GEAR………………………………………………………..194
7-14. MAIN LANDING GEAR…………………………………………………………….195
7-15. DISASSEMBLY OF MAIN GEAR OLEO………………………………………………….195
7-16. CLEANING, INSPECTION AND REPAIR OF MAIN GEAR OLEO………………………………..195
7-17. ASSEMBLY OF MAIN GEAR OLEO…………………………………………………….199
7-18. REMOVAL OF MAIN LANDING GEAR…………………………………………………..199
7-19. CLEANING INSPECTION AND REPAIR OF MAIN LANDING GEAR………………………………200
7-20. INSTALLATION OF MAIN LANDING GEAR………………………………………………200
7-21. WHEELS………………………………………………………………………200
7-22. REMOVAL AND DISASSEMBLY OF NOSE WHEEL…………………………………………..200
7-23. INSPECTION OF NOSE WHEEL ASSEMBLY………………………………………………200
7-24. ASSEMBLY AND INSTALLATION OF NOSE WHEEL…………………………………………201
7-25. REMOVAL AND DISASSEMBLY OF MAIN WHEEL…………………………………………..203
7-26. INSPECTION OF MAIN WHEEL ASSEMBLY………………………………………………203
7-27. ASSEMBLY AND INSTALLATION OF MAIN WHEEL…………………………………………203
7-28. BRAKE SYSTEM…………………………………………………………………203
7-29. WHEEL BRAKE ASSEMBLY………………………………………………………….203
7-30. BRAKE ADJUSTMENT AND LINING TOLERANCE…………………………………………..203
7-31. REMOVAL AND DISASSEMBLY OF WHEEL BRAKE ASSEMBLY………………………………….204
7-32. CLEANING, INSPECTION AND REPAIR OF WHEEL BRAKE ASSEMBLIES…………………………206
7-33. ASSEMBLY AND INSTALLATION OF WHEEL BRAKE ASSEMBLY………………………………..206
7-34. BRAKE MASTER CYLINDER…………………………………………………………206
7-35. REMOVAL OF BRAKE MASTER CYLINDER……………………………………………….206
7-36. DISASSEMBLY OF BRAKE MASTER CYLINDER……………………………………………208
7-37. CLEANING, INSPECTION AND REPAIR OF BRAKE MASTER CYLINDER………………………….208
7-38. ASSEMBLY OF BRAKE MASTER CYLINDER………………………………………………208
7-39. INSTALLATION OF BRAKE MASTER CYLINDER…………………………………………..209
7-40. BRAKE CYLINDER……………………………………………………………….209
7-41. REMOVAL OF BRAKE CYLINDER……………………………………………………..209
7-42. DISASSEMBLY OF BRAKE CYLINDER………………………………………………….209
7-43. CLEANING, INSPECTION AND REPAIR OF BRAKE CYLINDER………………………………..210
7-44. ASSEMBLY OF BRAKE CYLINDER…………………………………………………….210
7-45. INSTALLATION OF BRAKE CYLINDER…………………………………………………211
7-46. BLEEDING BRAKES………………………………………………………………211
7-47. BRAKE BLEEDING PROCEDURE………………………………………………………211
7-48. BRAKE BLEEDING PROCEDURE………………………………………………………211
7-49. BRAKE SYSTEM LEAK CHECK……………………………………………………….212
7-50. BLEEDING OF THE BRAKES AFTER A UNIT HAS BEEN CHANGED……………………………..212
SECTION VIII – POWER PLANT……………………………………………………………..219
8-1. INTRODUCTION………………………………………………………………….221
8-2. DESCRIPTION…………………………………………………………………..221
8-3. STANDARD PRACTICES – ENGINE…………………………………………………….222
8-4. TROUBLESHOOTING……………………………………………………………….222
8-5. PROPELLER…………………………………………………………………….223
8-6. REMOVAL OF PROPELLER…………………………………………………………..223
8-7. CLEANING, INSPECTION AND REPAIR OF PROPELLER……………………………………..223
8-8. INSTALLATION OF PROPELLER………………………………………………………225
8-9. BLADE TRACK…………………………………………………………………..225
8-10. ENGINE………………………………………………………………………225
8-11. REMOVAL OF ENGINE…………………………………………………………….225
8-12. INSTALLATION OF ENGINE………………………………………………………..227
8-13. INSTALLATION OF ENGINE SHOCK MOUNTS…………………………………………….229
8-14. INSTALLATION OF OIL COOLER…………………………………………………….230
8-15. ADJUSTMENT OF THROTTLE AND MIXTURE CONTROLS……………………………………..230
8-16. INDUCTION AIR FILTER………………………………………………………….230
8-17. CARBURETOR…………………………………………………………………..230
8-18. CARBURETOR MAINTENANCE………………………………………………………..230
8-19. ADJUSTMENT OF IDLE MIXTURE…………………………………………………….231
8-20. ADJUSTMENT OF IDLE SPEED………………………………………………………232
8-21. MAGNETOS…………………………………………………………………….233
8-22. REMOVAL OF MAGNETOS…………………………………………………………..233
8-23. INSPECTION OF MAGNETOS………………………………………………………..233
8-24. INSTALLATION AND TIMING PROCEDURE………………………………………………234
8-25. OVERHAUL INSTRUCTIONS FOR MAGNETOS……………………………………………..235
8-26. DISASSEMBLY OF MAGNETOS……………………………………………………….235
8-27. CLEANING AND INSPECTION OF MAGNETOS…………………………………………….236
8-28. REASSEMBLY OF MAGNETOS………………………………………………………..239
8-29. TIMING PROCEDURE……………………………………………………………..242
8-30. INSTALLATION AND TIMING PROCEDURE………………………………………………243
8-31. HARNESS ASSEMBLY……………………………………………………………..244
8-32. INSPECTION OF HARNESS…………………………………………………………244
8-33. REMOVAL OF HARNESS……………………………………………………………245
8-34. DISASSEMBLY OF HARNESS………………………………………………………..245
8-35. HARNESS ASSEMBLY INSTRUCTIONS………………………………………………….245
8-36. INSTALLATION OF HARNESS……………………………………………………….250
8-37. SPARK PLUGS………………………………………………………………….250
8-38. REMOVAL OF SPARK PLUGS………………………………………………………..250
8-39. INSPECTION AND CLEANING OF SPARK PLUG…………………………………………..251
8-40. INSTALLATION OF SPARK PLUGS……………………………………………………251
8-41. LUBRICATION SYSTEM (ENGINE)……………………………………………………251
8-42. OIL PRESSURE RELIEF VALVE……………………………………………………..251
8-43. CARBURETOR ICE DETECTOR……………………………………………………….252
8-44. REMOVAL OF ICE DETECTOR PROBE………………………………………………….252
8-45. INSTALLATION OF ICE DETECTOR PROBE……………………………………………..252
8-46. CARBURETOR ICE DETECTION SYSTEM TEST……………………………………………253
SECTION IX – FUEL SYSTEM……………………………………………………………….270
9-1. INTRODUCTION………………………………………………………………….272
9-2. DESCRIPTION…………………………………………………………………..272
9-3. TROUBLESHOOTING……………………………………………………………….272
9-4. FUEL TANKS……………………………………………………………………272
9-5. REMOVAL OF FUEL TANKS………………………………………………………….272
9-6. INSPECTION AND REPAIR OF FUEL TANK………………………………………………272
9-7. INSTALLATION OF FUEL TANK………………………………………………………272
9-8. FUEL LINES……………………………………………………………………274
9-9. INSPECTION AND TIGHTENING OF FUEL LINE UNION FITTINGS……………………………..274
9-10. REPLACEMENT OF FITTINGS……………………………………………………….275
9-11. FUEL QUANTITY TRANSMITTER UNIT…………………………………………………276
9-12. REMOVAL OF FUEL QUANTITY TRANSMITTER UNIT……………………………………….276
9-13. INSTALLATION OF FUEL QUANTITY TRANSMITTER UNIT…………………………………..276
9-14. FUEL QUANTITY TRANSMITTER/GAUGE CHECK…………………………………………..276
9-15. FUEL QUANTITY GAUGE CALIBRATION………………………………………………..276
9-16. CHECK AND ADJUSTMENT OF FUEL QUANTITY TRANSMITTER UNIT……………………………277
9-17. LOCKING FUEL CAP……………………………………………………………..279
9-18. DISASSEMBLY OF LOCKING FUEL CAP………………………………………………..279
9-19. ASSEMBLY OF LOCKING FUEL CAP…………………………………………………..279
9-20. FUEL SHUTOFF VALVE……………………………………………………………280
9-21. REMOVAL OF FUEL SHUTOFF VALVE………………………………………………….280
9-22. INSTALLATION OF SHUTOFF VALVE………………………………………………….280
9-23. FUEL FILTER BOWL AND SCREEN……………………………………………………280
9-24. REMOVAL OF FUEL FILTER BOWL AND HOUSING…………………………………………281
9-25. INSTALLATION OF FUEL FILTER BOWL AND SCREEN……………………………………..281
9-26. CLEANING AND INSPECTION OF FILTER BOWL SCREEN……………………………………281
9-27. ELECTRIC FUEL PUMPS…………………………………………………………..281
9-28. PLUNGER FUEL PUMPS……………………………………………………………281
9-29. REMOVAL OF FUEL PUMP………………………………………………………….281
9-30. DISASSEMBLY 0F FUEL PUMP………………………………………………………281
9-31. CLEANING, INSPECTION AND REPAIR OF FUEL PUMP…………………………………….282
9-32. RESISTANCE CHECK (PLUNGER TYPE PUMP)……………………………………………282
9-33. ASSEMBLY OF FUEL PUMP…………………………………………………………283
9-34. ADJUSTMENT OF ELECTRIC FUEL PUMP (BENCH TEST)……………………………………283
9-35. ADJUSTMENT OF ELECTRIC FUEL PUMP (IN AIRPLANE)…………………………………..283
9-36. INSTALLATION OF FUEL PUMP……………………………………………………..284
9-37. ENGINE PRIMER PUMP……………………………………………………………284
9-38. REMOVAL OF ENGINE PRIMER………………………………………………………284
9-39. DISASSEMBLY, CLEANING AND ASSEMBLY OF ENGINE PRIMER………………………………284
9-40. INSTALLATION OF ENGINE PRIMER PUMP……………………………………………..285
9-41. PRIME JETS…………………………………………………………………..285
9-42. CLEANING FUEL SYSTEM………………………………………………………….285
SECTION X – INSTRUMENTS………………………………………………………………..291
10-1. GENERAL……………………………………………………………………..294
10-2. NON-ELECTRICAL INSTRUMENTS…………………………………………………….294
10-3. VACUUM SYSTEM………………………………………………………………..294
10-4. VACUUM SYSTEM AND GYRO PRESSURE SERVICE TIPS…………………………………….294
10-5. TROUBLESHOOTING………………………………………………………………296
10-6. SUCTION GAUGE………………………………………………………………..296
10-7. GENERAL……………………………………………………………………..296
10-8. TROUBLESHOOTING………………………………………………………………296
10-9. VACUUM REGULATOR VALVE………………………………………………………..296
10-10. GENERAL…………………………………………………………………….296
10-11. TROUBLESHOOTING……………………………………………………………..296
10-12. ADJUSTMENTS OF VACUUM REGULATOR VALVE………………………………………….296
10-13. VACUUM PUMP…………………………………………………………………299
10-14. GENERAL…………………………………………………………………….299
10-15. TROUBLESHOOTING……………………………………………………………..299
10-16. REMOVAL OF VACUUM PUMP……………………………………………………….299
10-17. REPLACING PUMP FITTINGS………………………………………………………299
10-18. INSTALLATION OF VACUUM PUMP…………………………………………………..300
10-19. AUXILIARY VACUUM PUMP………………………………………………………..300
10-20. GENERAL…………………………………………………………………….300
10-21. SYSTEM ADJUSTMENT AND FUNCTIONAL CHECKS………………………………………..300
10-22. VACUUM REGULATOR SETTING – AUXILIARY PUMP OFF…………………………………..301
10-23. AUXILIARY AIR PUMP FUNCTIONAL CHECK – ENGINE SHUT DOWN…………………………..301
10-24. AUXILIARY SYSTEM FUNCTIONAL CHECK – ENGINE RUNNING………………………………303
10-25. MAINTENANCE AND SERVICE………………………………………………………303
10-26. REMOVAL/REPLACEMENT OF MOTOR/PUMP ASSEMBLY……………………………………..303
10-27. INFREQUENT AIRCRAFT OR AUXILIARY PUMP USAGE…………………………………….304
10-28. ANNUNCIATOR LIGHT REPLACEMENT…………………………………………………304
10-29. ENGINE CLEANING PRECAUTIONS…………………………………………………..304
10-30. INSTRUMENT AIR SYSTEM………………………………………………………..305
10-31. DIRECTIONAL GYRO…………………………………………………………….306
10-32. GENERAL…………………………………………………………………….306
10-33. TROUBLESHOOTING……………………………………………………………..306
10-34. REMOVAL AND REPLACEMENT………………………………………………………307
10-35. GYRO HORIZON………………………………………………………………..307
10-36. GENERAL…………………………………………………………………….307
10-37. TROUBLESHOOTING……………………………………………………………..307
10-38. REMOVAL AND REPLACEMENT………………………………………………………308
10-39. RATE OF CLIMB INDICATOR………………………………………………………308
10-40. GENERAL…………………………………………………………………….308
10-41. TROUBLESHOOTING……………………………………………………………..308
10-42. REMOVAL AND REPLACEMENT………………………………………………………309
10-43. SENSITIVE ALTIMETER………………………………………………………….309
10-44. GENERAL…………………………………………………………………….309
10-45. TROUBLESHOOTING……………………………………………………………..309
10-46. REMOVAL AND REPLACEMENT………………………………………………………310
10-47. AIRSPEED INDICATOR…………………………………………………………..310
10-48. GENERAL…………………………………………………………………….310
10-49. TROUBLESHOOTING……………………………………………………………..311
10-50. REMOVAL AND REPLACEMENT………………………………………………………311
10-51. MAGNETIC COMPASS…………………………………………………………….311
10-52. GENERAL…………………………………………………………………….311
10-53. ADJUSTMENT OF COMPASS………………………………………………………..311
10-54. TROUBLESHOOTING……………………………………………………………..312
10-55. TACHOMETER INDICATOR…………………………………………………………313
10-56. GENERAL…………………………………………………………………….313
10-57. TROUBLESHOOTING……………………………………………………………..313
10-58. REMOVAL AND REPLACEMENT………………………………………………………313
10-59. ENGINE OIL PRESSURE GAUGE…………………………………………………….313
10-60. GENERAL…………………………………………………………………….313
10-61. ENGINE OIL PRESSURE GAUGE CALIBRATION………………………………………….313
10-62. TROUBLESHOOTING……………………………………………………………..314
10-63. REMOVAL AND REPLACEMENT………………………………………………………314
10-64. FUEL PRESSURE GAUGE………………………………………………………….315
10-65. GENERAL…………………………………………………………………….315
10-66. FUEL PRESSURE GAUGE CALIBRATION……………………………………………….315
10-67. TROUBLESHOOTING……………………………………………………………..316
10-68. REMOVAL AND REPLACEMENT………………………………………………………316
10-69. ELECTRICAL INSTRUMENTS……………………………………………………….317
10-70. TURN AND BANK INDICATOR………………………………………………………317
10-71. GENERAL…………………………………………………………………….317
10-72. TROUBLESHOOTING……………………………………………………………..317
10-73. REMOVAL AND REPLACEMENT………………………………………………………317
10-74. FUEL QUANTITY INDICATOR………………………………………………………317
10-75. GENERAL…………………………………………………………………….317
10-76. TROUBLESHOOTING……………………………………………………………..318
10-77. REMOVAL AND REPLACEMENT………………………………………………………318
10-78. OIL TEMPERATURE INDICATOR…………………………………………………….319
10-79. GENERAL…………………………………………………………………….319
10-80. ENGINE OIL TEMPERATURE GAUGE CALIBRATION……………………………………….319
10-81. TROUBLESHOOTING……………………………………………………………..320
10-82. REMOVAL AND REPLACEMENT………………………………………………………320
10-83. AMMETER…………………………………………………………………….320
10-84. GENERAL…………………………………………………………………….320
10-85. TROUBLESHOOTING……………………………………………………………..320
10-86. REMOVAL AND REPLACEMENT………………………………………………………320
10-87. REMOVAL AND REPLACEMENT OF FACE MOUNTED INSTRUMENTS……………………………..320
10-88. GENERAL…………………………………………………………………….320
10-89. REMOVAL AND REPLACEMENT OF CLUSTER MOUNTED INSTRUMENTS…………………………..321
10-90. GENERAL…………………………………………………………………….321
10-91. PIPER AUTO CONTROL SYSTEM…………………………………………………….322
10-92. ANNUNCIATOR PANEL……………………………………………………………322
10-93. GENERAL…………………………………………………………………….322
10-94. TROUBLESHOOTING……………………………………………………………..322
10-95. REMOVAL AND REPLACEMENT………………………………………………………322
SECTION XI – ELECTRICAL SYSTEM………………………………………………………….325
11-1. INTRODUCTION…………………………………………………………………329
11-2. DESCRIPTION………………………………………………………………….329
11-3. TROUBLESHOOTING………………………………………………………………329
11-4. ALTERNATOR SYSTEM…………………………………………………………….329
11-5. ALTERNATOR AND COMPONENTS……………………………………………………..333
11-6. DESCRIPTION OF ALTERNATOR……………………………………………………..333
11-7. CHECKING ALTERNATOR SYSTEM…………………………………………………….334
11-8. SERVICE PROCEDURES……………………………………………………………334
11-9. OVERHAUL OF ALTERNATORS……………………………………………………….334
11-10. DISASSEMBLY OF ALTERNATORS……………………………………………………334
11-11. INSPECTION AND TESTING OF COMPONENTS…………………………………………..335
11-12. ASSEMBLY OF ALTERNATOR……………………………………………………….337
11-13. TESTING OF ALTERNATORS……………………………………………………….339
11-14. PRECAUTIONS…………………………………………………………………339
11-15. ALTERNATOR NOMENCLATURE………………………………………………………340
11-16. ALTERNATOR SERVICE TEST SPECIFICATIONS…………………………………………341
11-17. CHECKING ALTERNATOR BELT TENSION………………………………………………341
11-18. BATTERY…………………………………………………………………….343
11-19. BATTERY DESCRIPTION………………………………………………………….343
11-20. SERVICING BATTERY……………………………………………………………343
11-21. REMOVAL OF BATTERY…………………………………………………………..343
11-22. INSTALLATION OF BATTERY………………………………………………………344
11-23. CHARGING BATTERY…………………………………………………………….344
11-24. STARTING THROUGH EXTERNAL POWER RECEPTACLE WITH AIRPLANE’S BATTERY NEARLY DEPLETED….344
11-25. TESTING THE BATTERY………………………………………………………….344
11-26. BATTERY BOX…………………………………………………………………344
11-27. DESCRIPTION…………………………………………………………………344
11-28. REMOVAL OF BATTERY BOX……………………………………………………….346
11-29. INSTALLATION OF BATTERY BOX…………………………………………………..346
11-30. BATTERY BOX CORROSION PREVENTION………………………………………………346
11-31. ALTERNATOR CONTROL…………………………………………………………..346
11-32. CHECKING ALTERNATOR CONTROL…………………………………………………..346
11-33. REMOVAL OF ALTERNATOR CONTROL…………………………………………………346
11-34. INSTALLATION OF ALTERNATOR CONTROL…………………………………………….347
11-35. STARTING MOTORS……………………………………………………………..348
11-36. DESCRIPTION…………………………………………………………………348
11-37. OPERATION…………………………………………………………………..348
11-38. MAINTENANCE…………………………………………………………………349
11-39. OVERHAUL……………………………………………………………………349
11-40. REMOVAL…………………………………………………………………….349
11-41. DISASSEMBLY…………………………………………………………………349
11-42. BRUSHES…………………………………………………………………….350
11-43. ARMATURE……………………………………………………………………350
11-44. FIELD COILS…………………………………………………………………350
11-45. BRUSH HOLDERS……………………………………………………………….351
11-46. GEAR AND PINION HOUSING………………………………………………………351
11-47. BENDIX DRIVE………………………………………………………………..351
11-48. ASSEMBLY……………………………………………………………………351
11-49. BENCH TESTS…………………………………………………………………352
11-50. STARTING MOTOR CONTROL CIRCUIT………………………………………………..353
11-51. STARTING MOTOR SERVICE TEST SPECIFICATIONS……………………………………..353
11-52. LANDING AND TAXI LIGHT……………………………………………………….354
11-53. DESCRIPTION…………………………………………………………………354
11-54. REMOVAL…………………………………………………………………….354
11-55. INSTALLATION………………………………………………………………..354
11-56. NAVIGATION LIGHTS……………………………………………………………354
11-57. DESCRIPTION…………………………………………………………………354
11-58. REMOVAL OF WING NAVIGATION LIGHTS……………………………………………..354
11-59. INSTALLATION OF WING NAVIGATION LIGHT………………………………………….354
11-60. REMOVAL OF TAIL NAVIGATION LIGHT………………………………………………354
11-61. INSTALLATION OF TAIL NAVIGATION LIGHT………………………………………….355
11-62. ANTI-COLLISION LIGHT (ROTATING BEACON)…………………………………………355
11-63. REMOVAL…………………………………………………………………….355
11-64. INSTALLATION………………………………………………………………..355
11-65. ANTI-COLLISION (STROBE)………………………………………………………355
11-66. DESCRIPTION…………………………………………………………………355
11-67. REMOVAL OF WING TIP STROBE LIGHT………………………………………………355
11-68. INSTALLATION OF WING TIP STROBE LIGHT………………………………………….355
11-69. REMOVAL OF FIN TIP STROBE LIGHT……………………………………………….355
11-70. INSTALLATION OF FIN TIP STROBE LIGHT…………………………………………..358
11-71. REMOVAL OF STROBE POWER SUPPLY………………………………………………..358
11-72. INSTALLATION OF STROBE POWER SUPPLY……………………………………………358
11-73. TROUBLESHOOTING PROCEDURE…………………………………………………….358
11-74. INSTRUMENT AND PANEL LIGHTS…………………………………………………..359
11-75. REMOVAL OF DIMMER CONTROL ASSEMBLY…………………………………………….359
11-76. INSTALLATION OF DIMMER CONTROL ASSEMBLY………………………………………..359
11-77. STALL WARNING HORN AND LIFT DETECTOR…………………………………………..360
11-78. REMOVAL OF LIFT DETECTOR……………………………………………………..360
11-79. INSTALLATION OF LIFT DETECTOR…………………………………………………360
11-80. ELECTRICAL SWITCHES AND CIRCUIT BREAKERS……………………………………….360
11-81. DESCRIPTION…………………………………………………………………360
11-82. REMOVAL OF ELECTRICAL SWITCHES………………………………………………..360
11-83. INSTALLATION OF ELECTRICAL SWITCHES……………………………………………360
11-84. REMOVAL OF CIRCUIT BREAKERS…………………………………………………..361
11-85. INSTALLATION OF CIRCUIT BREAKERS………………………………………………361
11-86. SWITCHING…………………………………………………………………..361
11-87. REMOVAL OF IGNITION SWITCH……………………………………………………361
11-88. INSTALLATION OF IGNITION SWITCH……………………………………………….361
11-89. ANNUNCIATOR PANEL……………………………………………………………362
11-90. DESCRIPTION…………………………………………………………………362
11-91. REMOVAL OF OIL PRESSURE SENSOR………………………………………………..362
11-92. INSTALLATION OF OIL PRESSURE SENSOR……………………………………………362
11-93. REMOVAL OF VACUUM SENSOR……………………………………………………..362
11-94. INSTALLATION OF VACUUM SENSOR…………………………………………………362
SECTION XII – ELECTRONICS………………………………………………………………402
12-1. INTRODUCTION…………………………………………………………………403
12-2. EMERGENCY LOCATOR TRANSMITTER (NARCO)…………………………………………..404
12-3. DESCRIPTION………………………………………………………………….404
12-4. BATTERY REMOVAL AND INSTALLATION (NARCO)………………………………………..404
12-5. TESTING EMERGENCY LOCATOR TRANSMITTER…………………………………………..407
12-6. DESCRIPTION, OPERATION AND TESTING OF PILOT’S REMOTE SWITCH……………………….408
12-7. AVIONICS MASTER AND EMERGENCY SWITCH CIRCUIT…………………………………….408
12-8. DESCRIPTION AND OPERATION……………………………………………………..408
12-9. AUTOPILOT……………………………………………………………………409
12-10. GENERAL…………………………………………………………………….409
12-11. A.F.C.S. EQUIPMENT MANUFACTURERS………………………………………………409
SECTION XIII – HEATING AND VENTILATING…………………………………………………..414
13-1. INTRODUCTION…………………………………………………………………415
13-2. DESCRIPTION………………………………………………………………….415
13-3. HEATER MAINTENANCE……………………………………………………………415
13-4. OVERHEAD VENT SYSTEM………………………………………………………….415
SECTION XIV – ACCESSORIES AND UTILITIES………………………………………………….419
14-1. SHOULDER-HARNESS INERTIA REEL ADJUSTMENT………………………………………..420
14-2. OVERHEAD VENT BLOWER………………………………………………………….420
14-3. DESCRIPTION………………………………………………………………….420
14-4. REMOVAL OF BLOWER ASSEMBLY…………………………………………………….420
14-5. DISASSEMBLY OF BLOWER ASSEMBLY…………………………………………………420
14-6. REASSEMBLY OF BLOWER ASSEMBLY………………………………………………….420
14-7. INSTALLATION OF BLOWER ASSEMBLY………………………………………………..421

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