Piper Aircraft Corporation PA-28-161 CADET User manual

CADET
MAINTENANCE MANUAL
CARD 1 OF 2
PA-28-161 CADET
PIPER AIRCRAFT CORPORATION
(PART NUMBER 761 829)
1A1
Courtesy of Bomar Flying Service
www.bomar.biz

PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
SERIAL NUMBER INFORMATION
PA-28-161 Cadet - 1988 - Serial numbers 2841001 thru 2841036
Serial numbers 2841038 thru 2841040.
PA-28-161 Cadet - 1989 - Serial numbers 2841037
Serial numbers 2841041 thru 2841289
Serial numbers 2841294 thru 2841300
Serial numbers 2841304 thru 2841314.
PA-28-161 Cadet - 1990 - Serial numbers 2841290 thru 2841293
Serial numbers 2841301 thru 2841303
Serial numbers 2841315 thru 2841320
Serial numbers 2841322
Serial numbers 2841325 thru 2841330.
PA-28-161 Cadet - 1992 - Serial numbers 2841321
Serial numbers 2841323 thru 2841324
Serial numbers 2841331 thru 2841350.
PA-28-161 Cadet - 1994 - Serial numbers 2841360 thru 2841364.
1A2

PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
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.
6. Revisions to this Service Manual 761-829 issued February 28, 1989 are as follows:
Effectivity Publication Date Aerofiche Card Effectivity
ORG 890228 August 7, 1989 1 and 2
IR 950228 * February 28, 1995 1
* INTERIM CHANGE TO MAINTENANCE MANUAL 761-829
Sections III and V of Card 1 have been revised. There are no other changes
included in this interim change revision. Please discard your current card 1,
and replace it with the revised card 1. DO NOT DISCARD CARD 2.
1A3

TABLE OF CONTENTS
AEROFICHE CARD NO. 1 GRID NO.
I INTRODUCTION..........................................................................1A12
II HANDLING AND SERVICING...................................................1A16
III INSPECTION.................................................................................1D14
IV STRUCTURES...............................................................................1E6
VSURFACE CONTROLS................................................................1F21
VI HYDRAULIC SYSTEM...................................................... (Not Applicable)
VII LANDING GEAR AND BRAKE SYSTEM................................1H18
VIII POWER PLANT............................................................................1J3
AEROFICHE CARD NO. 2
IX FUEL SYSTEM .............................................................................2A9
X INSTRUMENTS ............................................................................2B6
XI ELECTRICAL SYSTEM .............................................................2C16
XII ELECTRONICS ............................................................................2F21
XIII HEATING AND VENTILATING ............................................... 2G9
XIV ACCESSORIES AND UTILITIES ............................................. 2G14
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
1A4

LIST OF ILLUSTRATIONS Aerofiche
Figure Grid No.
2-1. Three View ............................................................................................................................1A20
2-2. Station Reference Lines.........................................................................................................1A21
2-3. Access Plates and Panels....................................................................................................... 1B2
2-4. Jacking Arrangement.............................................................................................................1B8
2-5. Weighing Arrangement..........................................................................................................1B9
2-6. Leveling Longitudinally.........................................................................................................1B10
2-7. Leveling Laterally..................................................................................................................1B10
2-8. Servicing Points.....................................................................................................................1B14
2-9. Induction Air Filter................................................................................................................1B19
2-10. Fuel Strainer...........................................................................................................................1B22
2-11. Lubrication Chart...................................................................................................................1C3
2-12. Cherrylock Rivet Removal.................................................................................................... 1C17
2-13. Identification of Aircraft Fluid Lines.....................................................................................1C18
2-14. Torque Wrench Formula........................................................................................................1C19
3-1. Inspection Areas of Exhaust System......................................................................................1D17
3-2. Typical Muffler Fatigue Areas...............................................................................................1D17
4-1. Aileron and Flap Installation................................................................................................. 1E12
4-2. Wing Installation....................................................................................................................1E13
4-3. Methods of Securing Control Cables.....................................................................................1E18
4-4. Empennage Group Installation.............................................................................................. 1E20
4-5. Windshield Installation (Typical)...........................................................................................1E23
4-6. Side Window Installation (Typical).......................................................................................1E24
4-7. Door Snubber Installation......................................................................................................1F3
4-8. Seat Back Lock......................................................................................................................1F4
4-9. Skin Materials and Thickness................................................................................................1F9
4-10. Typical Access Plates.............................................................................................................1F10
4-11. Control Surface Balance Tool................................................................................................1F11
4-12. Aileron Balance..................................................................................................................... 1F12
4-13. Rudder Balance......................................................................................................................1F13
4-14. Rudder Balance Weight.........................................................................................................1F14
4-15. Stabilator Balance..................................................................................................................1F15
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
1A5

LIST OF ILLUSTRATIONS (cont)
Figure Aerofiche
Grid No.
5-1. Control Column Assembly.....................................................................................................1G2
5-2. Correct Method of Installing Rod End Bearings................................................................... 1G3
5-3. Aileron Controls.....................................................................................................................1G5
5-4. Bellcrank Rigging Tool..........................................................................................................1G9
5-5. Stabilator Controls.................................................................................................................1G12
5-6. Stabilator Rigging Tool..........................................................................................................1G13
5-7. Stabilator Trim Controls........................................................................................................1G16
5-8. Methods of Securing Trim Cables.........................................................................................1G17
5-9. Rudder and Steering Pedal Assembly....................................................................................1G20
5-10. Rudder Controls.....................................................................................................................1G22
5-11. Rudder Rigging Tool..............................................................................................................1G23
5-12. Clamping Rudder Pedals........................................................................................................1G23
5-13. Rudder and Stabilator Travel Adjustment............................................................................. 1G24
5-14. Rudder Trim Control..............................................................................................................1H2
5-15. Flap Control System.............................................................................................................. 1H4
5-16. Flap Stop Adjustment............................................................................................................ 1H6
5-17. Flap Rigging Tool..................................................................................................................1H6
5-18. Fabricated Rudder Rigging Tool............................................................................................1H11
5-19. Fabricated Stabilator Rigging Tool........................................................................................1H12
5-20. Fabricated Flap Rigging Tool................................................................................................1H13
7-1. Nose Gear Oleo Strut Assembly............................................................................................1H21
7-2. Nose Gear Installation............................................................................................................1IH24
7-3. Clamping Rudder Pedals in Neutral Position........................................................................ 1I2
7-4. Rudder Pedals at Neutral Angle.............................................................................................1I2
7-5. Main Gear Oleo Strut Assembly............................................................................................1I4
7-6. Main Gear Installation...........................................................................................................1I6
7-7. Nose Wheel Assembly...........................................................................................................1I9
7-8. Main Wheel Assembly...........................................................................................................1I10
7-9. Wheel Brake Assembly..........................................................................................................1I12
7-10. Removal of Anchor Bolt........................................................................................................1I13
7-11. Installation of Anchor Bolt....................................................................................................1I13
7-12. Brake System Installation......................................................................................................1I15
7-13. Brake Master Cylinder (Hand/Parking Brake)...................................................................... 1I16
7-14. Brake Cylinder (Toe Brake)...................................................................................................1I21
7-15. Retainer Ring Installation Tool..............................................................................................1I24
8-1. Typical Nicks and Removal Method......................................................................................1J7
8-2. Propeller and Cowling Installation........................................................................................1J8
8-3. Engine Installation.................................................................................................................1J10
8-4. Engine Shock Mount Installation...........................................................................................1J12
8-5. Adjustment of Engine Controls............................................................................................. 1J13
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
1A6

LIST OF ILLUSTRATIONS (cont)
Figure Aerofiche
Grid No.
8-6. Carburetor..........................................................................................................................1J15
8-7. T-100 Assembly and Timing Tool Kit...............................................................................1J21
8-8. Exploded View of Magneto...............................................................................................1J22
8-9. Removing Coil Wedges.....................................................................................................1J22
8-10. Index Plate and Timing Plug.............................................................................................1J24
8-11. Installation of Bearings and Bearing Plate........................................................................1J24
8-12. Position of Magneto on T100 Too1 and oil seal Installation.............................................1K1
8-13. Timing Magneto Internally and Assembly........................................................................1K2
8-14. Stripping Tool....................................................................................................................1K6
8-15. Inserting Stripping Tool.....................................................................................................1K6
8-16. Cutting Insulation..............................................................................................................1K6
8-17. Removing Silicone Rubber from Wire..............................................................................1K6
8-18. Installation of Plug End Nut..............................................................................................1K7
8-19. Flaring Out of Shielding....................................................................................................1K7
8-20. Installation of Ferrule........................................................................................................ 1K7
8-21. Driving Tool......................................................................................................................1K7
8-22. Installation in Housing...................................................................................................... 1K8
8-23. Securing Wire in Housing................................................................................................. 1K8
8-24. Installation of Electrical Screw..........................................................................................1K9
8-25. Installation of Insulation Sleeve........................................................................................1K9
8-26. Installation of Spring.........................................................................................................1K9
8-27. Removing Spark Plug Frozen to Bushing.........................................................................1K9
8-28. Ice Detection System.........................................................................................................1K13
9-1. Fuel System Diagram........................................................................................................2A12
9-2. Tolerances. Union Nut and Tubing Nut.............................................................................2A15
9-3. Fuel Quantity Transmitter Checking Jig............................................................................2A17
9-4. Fuel Quantity Indicators....................................................................................................2A17
9-5. Locking Fuel Cap.............................................................................................................. 2A18
9-6. Fuel Filter Bowl and Screen..............................................................................................2A19
9-7. Plunger Fuel Pump............................................................................................................2A21
9-8. Engine Primer....................................................................................................................2A23
9-9. Fabricated Fuel Quantity Transmitter Checking Jig..........................................................2B3
10-1. Instrument Panel................................................................................................................2B12
10-2. Pitot-Static System............................................................................................................ 2B16
10-3. Auxiliary Vacuum System.................................................................................................2B20
10-4. Engine Oil Pressure Gauge................................................................................................2C5
10-5. Fuel Pressure Gauge..........................................................................................................2C6
10-6. Oil Temperature Gauge.....................................................................................................2C10
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
1A7

LIST OF ILLUSTRATIONS (cont.)
Figure Aerofiche
Grid No.
11-1 Instrument Panel (Circuit Breaker Panel)..............................................................................2C21
11-2. Lamp Bank Load....................................................................................................................2C22
11-3. Exploded View of Alternator.................................................................................................2C24
11-4. Removal of Rectifier..............................................................................................................2D3
11-5. Removal of Slip Ring End Bearing....................................................................................... 2D3
11-6. Removal of Drive End Head..................................................................................................2D3
11-7. Removal of End Head Bearing..............................................................................................2D3
11-8. Testing Rotor for Grounds.....................................................................................................2D4
11-9. Testing Rotor for Shorts.........................................................................................................2D4
11-10. Installation of Bearing............................................................................................................2D5
11-11. Installation of Rectifier..........................................................................................................2D5
11-12. Terminal Assembly................................................................................................................ 2D5
11-13. Slip Ring End Bearing Assembly..........................................................................................2D6
11-14. Testing Alternator...................................................................................................................2D6
11-15. Brush Installation...................................................................................................................2D7
11-16. Internal Wiring Diagram........................................................................................................2D7
11-17. Battery Box............................................................................................................................2D12
11-18. Application of Overvoltage Control......................................................................................2D14
11-19. Exploded View of Gear Reduction Starter Motor..................................................................2D15
11-20. Turning Motor Commutator...................................................................................................2D17
11-21. Testing Motor Armature for Shorts........................................................................................2D17
11-22. Testing Motor Fields for Grounds..........................................................................................2D18
11-23. No Load Test Hookup............................................................................................................2D18
11-24. Stall Torque Hookup..............................................................................................................2D19
11-25. Strobe Light Connections (With Fin Strobe).........................................................................2D23
11-26. Strobe Light Connections (With Rotating Beacon)...............................................................2D24
11-27. Ignition Switch.......................................................................................................................2E4
11-28. Annunciator............................................................................................................................2E19
11-29. Annunciator Internal Wiring..................................................................................................2E20
11-30. Pitot Static Heat.....................................................................................................................2E21
11-31. Alteernator..............................................................................................................................2E22
11-32. Avionics Master Switch (Optional).......................................................................................2E23
11-33. Starter.....................................................................................................................................2E24
11-34. Battery Master Switch............................................................................................................2F1
11-35. Air Blower..............................................................................................................................2F2
11-36. Fuel Pump..............................................................................................................................2F3
11-37. Clock, Electrical and Digital (Optional)................................................................................2F4
11-38. Engine Gages.........................................................................................................................2F5
11-39. Hourmeter (Optiuonal).......................................................................................................... 2F6
11-40. Turn and Bank........................................................................................................................2F7
11-41. Anti - Collision, Strobe Lights (Wing)..................................................................................2F8
11-42. Anti - Collision, Strobe Lights (Tail).....................................................................................2F9
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
1A8

LIST OF ILLUSTRATIONS
Figure Aerofiche
Grid No.
11-43. Recognition Lights (Optional)............................................................................................ 2F10
11-44. Instrument Flood Lights......................................................................................................2F11
11-45. Navigation Lights................................................................................................................2F12
11-46. Landing Light......................................................................................................................2F13
11-47. Instrument Panel and Switch Lights....................................................................................2F14
11-48. Pitch Trim............................................................................................................................2F15
11-49. Stall Warning.......................................................................................................................2F16
11-50. Optional Avionics................................................................................................................2F17
12-1. ELT Portable Folding Antenna............................................................................................2F24
12-2. ELT Using Fixed Aircraft Antenna.....................................................................................2F24
12-3. ELT Schematic....................................................................................................................2G1
12-4. Avionics Master and Emergency Switch Circuit.................................................................2G4
13-1. Cabin Heater, Defroster and Fresh Air System...................................................................2G11
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
1A9

LIST OF TABLES
Table Aerofiche
Grid No.
II-I Leading Particulars and Principal Dimensions................................................................... 1A22
II-II Recommended Torques.......................................................................................................1B4
II-IIA Flare Fitting Torques...........................................................................................................1B7
II-IIB Type of Lubricants...............................................................................................................1C1
II-IIC Types of Metal Corrosion....................................................................................................1C13
II-III List of Consumable Materials............................................................................................. 1C20
II-1V Conversion Tables...............................................................................................................1D3
II-V Thread Lubricants................................................................................................................1D7
II-VI Hose Clamp Tightening.......................................................................................................1D7
II-VII Maximum Distance Between Supports For Fluid Tubing...................................................1D8
II-VIII Decimal-Millimeter Equivalents of Drill Sizes.................................................................. 1D9
III-I Inspection Report................................................................................................................ 1D18
IV-I Balancing Specifications.....................................................................................................1F7
V-I Control Surface Travel and Cable Tension..........................................................................1F24
V-II Cable Tension vs. Ambient Temperature............................................................................ 1G1
V-III Troubleshooting Chart (Surface Controls)..........................................................................1H7
VII-I Landing Gear Troubleshooting............................................................................................1I22
VIII-I Propeller Torque Limits.......................................................................................................1J8
VIII-II Engine Troubleshooting......................................................................................................1K15
IX-I Transmitter/Fuel Gauge Tolerances.....................................................................................2A16
IX-II Fuel Quantity Transmitter Calibration Tolerance................................................................2A16
IX-III Fuel System Troubleshooting..............................................................................................2B1
X-I Vacuum System...................................................................................................................2B13
X-II Directional Gyro Indicator...................................................................................................2B21
X-III Gyro Horizon Indicator.......................................................................................................2B22
X-IV Rate of Climb Indicator.......................................................................................................2B23
X-V Altimeter..............................................................................................................................2B24
X-VI Airspeed Tubes and Indicator..............................................................................................2C2
X-VII Magnetic Compass .............................................................................................................2C3
X-VIII Tachometer.......................................................................................................................... 2C4
X-IX Engine Oil Pressure Gauge..................................................................................................2C5
X-X Fuel Pressure Gauge............................................................................................................2C7
X-XI Turn and Bank Indicator......................................................................................................2C8
X-XII Fuel Quantity Indicator........................................................................................................2C9
X-XIII Oil Temperature Indicator................................................................................................... 2C11
XI-I Index Electrical System Schematics....................................................................................2C19
XI-II Alternator Specifications.....................................................................................................2D8
XI-III Alternator Belt Tension.......................................................................................................2D8
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
1A10

LIST OF TABLES (cont.)
Table Aerofiche
Grid No.
XI-IV Hydrometer Reading and Battery Charge Percent..............................................................2D10
XI-V Starting Motor Specifications..............................................................................................2D20
XI-VI Troubleshooting Chart (Electrical System).........................................................................2E6
XI-VII Lamp Replacement Guide...................................................................................................2E15
XI-VIII Electrical System Component Loads.................................................................................. 2E16
XI-IX Electrical Wire Coding........................................................................................................2E17
XI-X Electrical Symbols...............................................................................................................2E18
XIV-I Blower System Wire Color Codes...................................................................................... 2G16
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
1A11

SECTION I
INTRODUCTION
Paragraph Aerofiche
Grid No.
1-1 General................................................................................................................................. 1A13
1-2 Scope of Manual................................................................................................................... 1A13
1-3 Description........................................................................................................................... 1A13
1-4 Wing..................................................................................................................................... 1A13
1-5 Empennage........................................................................................................................... 1A13
1-6 Fuselage................................................................................................................................ 1A13
1-7 Landing Gear........................................................................................................................ 1A13
1-8 Brake System....................................................................................................................... 1A13
1-9 Engines................................................................................................................................. 1A13
1-10 Propeller............................................................................................................................... 1A13
1-11 Fuel System.......................................................................................................................... 1A14
1-12 Flight Controls..................................................................................................................... 1A14
1-13 Radio.................................................................................................................................... 1A14
1-14 Cabin heater, Defroster, and Fresh Air System.................................................................... 1A14
1-15 Instrument and Autopilot System......................................................................................... 1A14
1-16 Warnings, Cautions, and Notes............................................................................................ 1A14
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 INTRODUCTION
1A12

SECTION I
INTRODUCTION
1-1. GENERAL. This manual contains service and maintenance instructions for the PA-28-161 Cadet. This
aircraft is designed and manufactured as a versatile airplane in the personal and business aviation field by the
Piper Aircraft Corporation, Vero Beach, Florida.
1-2. SCOPE OF MANUAL. Sections II and III comprise the service part of this manual, whereas Sections IV
thru XIV comprise the maintenance instructions. The service instructions include ground handling, servicing
and inspection. The maintenance instructions for each system include description, removal, inspection,
installation,corrective maintenance and testing of components along with troubleshooting. Each major system of
the airplane is covered in a separate section. Only qualified personnel should perform the operations described
in this manual.
The description of the airplane included in this section is limited to general information. Section II gives
leading particulars and principal dimensions, while each major system is described in its appropriate section of
the manual. For a more detailed description of the airplane operation, refer to the Pilot's Operating Manual or
Information Manual.
1-3. DESCRIPTION. The Cadet is a single-engine, low wing monoplane, of all-metal construction, with a
seating capacity of four. Paragraphs 1-4 through 1-12 provide descriptions of the major components and
systems.
1-4. WING. The laminar flow wing is of all-metal stressed-skin, full cantilever, tapered, low-wing design.
Each tapered wing panel is bolted to a spar box assembly in the fuselage. The wing tips are made of tough
resilient fiberglass and are easily removed. The ailerons are statically balanced and cable and push rod
controlled. The trailing edge wing flaps are manually operated.
1-5. EMPENNAGE. The empennage consists of the fin, rudder, stabilator and stabilator trim tabs. The
stabilator and rudder are statically balanced and cable operated.
1-6. FUSELAGE. The fuselage consists of three basic units: the engine section, the cabin section, and sheet-
metal tail cone.
1-7. LANDING GEAR. The tricycle landing gear is of the fixed type, consisting of shock absorbing air-oil
type oleo struts.
1-8. BRAKE SYSTEM. The brake system is hydraulically operated and controlled by a hand lever connected
to a single brake cylinder that operates both wheel brakes, plus individually operated toe brakes.
1-9. ENGINE. The engine installed in the airplane is a Avco-Lycoming direct drive, wet sump, horizontally
opposed, air cooled model. The four cylinder engine is carburetor equipped. The engine model, rated
horsepower and other related information may be found in Table II-I of Section II.
1-10. PROPELLER. The airplane is equipped with an all-metal fixed pitch propeller. Propeller specifications
may be found in Table II-I of Section II.
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 INTRODUCTION
1A13

1-11. FUEL SYSTEM. The fuel system consists of two aluminum tanks in the leading edge of the wings, a fuel
strainer bowl with filter screen, one electric auxiliary pump and one engine driven pump. Fuel drains are
provided throughout the system to remove any fuel contamination.
1-12. FLIGHT CONTROLS. The flight controls are conventional, consisting of dual control wheels which
operate the ailerons and stabilator, and dual pedals which operate the rudder.
1-13. RADIO. Provisions are provided for the installation of various radio equipment along with microphone
and headset jacks, loudspeaker and other radio navigation equipment.
1-14. CABIN HEATER, DEFROSTER, AND FRESH AIR SYSTEM. Heated air for the cabin and defroster is
obtained directly from the exhaust system muffler shroud. Fresh air is picked up from air inlets in the leading
edge of each wing. The air passes through the wings to individually controlled outlets located just forward of
each front seat. Rear seat vents are available as optional equipment.
1-15. INSTRUMENT AND AUTOPILOT SYSTEM. Provisions for instrument installation include panels for
engine instruments and advanced instruments, as well as for an Autopilot System.
1-16. WARNINGS, CAUTIONS, and NOTES are used throughout this manual to emphasize important
operating information.
— WARNINGS —
Operating procedures, practices, etc., which may result in personal injury or loss of
life if not carefully followed.
— CAUTION —
Operating procedures, practices, etc., which if not strictly observed may result in
damage to equipment.
— Notes —
An operating procedure, condition, etc., which is essential to emphasize.
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 INTRODUCTION
1A14

THIS PAGE INTENTIONALLY LEFT BLANK
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 INTRODUCTION
1A15

SECTION II
HANDLING AND SERVICING
Paragraph Aerofiche
Grid No.
2-1. Introduction..............................................................................................................................1A19
2-2. Dimensions.............................................................................................................................. 1A19
2-3. Station Reference Lines............................................................................................................1A19
2-4. Weight and Balance Data.........................................................................................................1A19
2-5. Serial Number Plate..................................................................................................................1A19
2-6. Access and Inspection Provisions............................................................................................ 1A19
2-7. Tools and Test Equipment........................................................................................................ 1A19
2-8. Torque Requirements................................................................................................................1B3
2-9. Walkway, Handhold and Step...................................................................................................1B8
2-10. Ground Handling......................................................................................................................1B8
2-11. Introduction to Ground Handling.............................................................................................1B8
2-12. Jacking......................................................................................................................................1B8
2-13. Weighing...................................................................................................................................1B9
2-14. Leveling....................................................................................................................................1B9
2-15. Mooring....................................................................................................................................1B10
2-16. Locking Airplane......................................................................................................................1B11
2-17. Parking......................................................................................................................................1B11
2-18. Towing......................................................................................................................................1B11
2-19. Taxiing......................................................................................................................................1B11
2-20. External Power Receptacle (Optional).....................................................................................1B12
2-21. Operation of External Power Receptacle................................................................................. 1B12
2-22. Cleaning....................................................................................................................................1B12
2-23. Cleaning Engine Compartment................................................................................................ 1B12
2-24. Cleaning Landing Gear.............................................................................................................1B12
2-25. Cleaning Exterior Surfaces.......................................................................................................1B13
2-26. Cleaning Windshield and Windows.........................................................................................1B13
2-27. Cleaning Headliner, Side Panels and Seats..............................................................................1B13
2-28. Cleaning Carpets...................................................................................................................... 1B15
2-29. Servicing...................................................................................................................................1B15
2-30. Introduction to Servicing..........................................................................................................1B15
2-31. Landing Gear System...............................................................................................................1B15
2-32. Servicing Landing Gear............................................................................................................1B15
2-33. Oleo Struts................................................................................................................................1B15
2-34. Servicing Oleo Struts................................................................................................................1B15
2-35. Filling Nose Gear Oleo Strut....................................................................................................1B16
2-36. Filling Main Gear Oleo Strut....................................................................................................1B16
2-37. Inflating Oleo Struts.................................................................................................................1B18
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING
1A16

Paragraph Aerofiche
Grid No.
2-38. Brake System....................................................................................................................... 1B18
2-39. Servicing Brake System.......................................................................................................1B18
2-40. Filling Brake Cylinder Reservoir.........................................................................................1B18
2-41. Draining Brake System........................................................................................................1B18
2-42. Tires......................................................................................................................................1B18
2-43. Servicing Tires.....................................................................................................................1B18
2-44. Power Plant..........................................................................................................................1B18
2-45. Servicing Power Plant..........................................................................................................1B18
2-46. Induction Air Filter...............................................................................................................1B20
2-47. Removal of Air Filter...........................................................................................................1B20
2-48. Service Instructions (Inspection and Replacement).............................................................1B20
2-49. Installation of Air Filter........................................................................................................1B20
2-50. Propeller...............................................................................................................................1B20
2-51. Servicing Propeller...............................................................................................................1B20
2-52. Fuel System..........................................................................................................................1B20
2-53. Servicing Fuel System......................................................................................................... 1B20
2-54. Filling Fuel Tanks................................................................................................................1B21
2-55. Anti-Icing Fuel Additive......................................................................................................1B21
2-56. Fuel Drain Valve and Strainer..............................................................................................1B21
2-57. Draining Fuel System...........................................................................................................1B21
2-58. Electrical System..................................................................................................................1B22
2-59. Servicing Electrical System.................................................................................................1B22
2-60. Lubrication...........................................................................................................................1B22
2-61. Oil System (Engine).............................................................................................................1B22
2-62. Servicing Oil System........................................................................................................... 1B22
2-63. Filling Oil Sump...................................................................................................................1B23
2-64. Draining Oil Sump...............................................................................................................1B23
2-65. Oil Screens (Suction)...........................................................................................................1B23
2-66. Oil Screens (Pressure)..........................................................................................................1B23
2-67. Oil Filter (Full Flow)............................................................................................................1B23
2-68. Recommendations for Changing Oil....................................................................................1B24
2-69. Lubrication Instructions.......................................................................................................1B24
2-70. Application of Oil................................................................................................................ 1B24
2-71. Application of Grease..........................................................................................................1B24
2-72. Winterization Plate...............................................................................................................1B24
2-73. Lubrication Chart.................................................................................................................1B24
2-74. Corrosion Control................................................................................................................ 1C11
2-75. Form of Corrosion................................................................................................................1C11
2-76. Conditions Affecting Corrosion...........................................................................................1C11
2-77. Inspection.............................................................................................................................1C12
2-78. Corrosion Removal and Control..........................................................................................1C12
2-79. Areas Prone to Corrosion.....................................................................................................1C14
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING
1A17

Paragraph Aerofiche
Grid No.
2-80. Repainting............................................................................................................................1C15
2-81. Product Listing For Urethane Enamel Aircraft Finish.........................................................1C15
2-82. Preparation of Epoxy Zinc Chromate Primer.......................................................................1C15
2-83. Preparation and Application of Du Pont Imron Urethane Enamel...................................... 1C16
2-84. Product Listing For Randolph Paint Finish..........................................................................1C16
2-85. Preparation and Application of Zinc Chromate Primer.......................................................1C16
2-86. Finish Painting With Randolph Paint (B5420/D7784)........................................................1C16
2-87. Repairs................................................................................................................................. 1C17
2-88. Removal of Cherrylock Rivets.............................................................................................1C17
2-89. Standard Practice - Airframe................................................................................................1C19
2-90. Torque Wrenches..................................................................................................................1C19
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING
1A18

SECTION II
HANDLING AND SERVICING
2-1. INTRODUCTION. This section contains routine handling and servicing procedures that are most
frequently encountered. Frequent reference to this section will aid the individual by providing information such
as the location of various components, ground handling procedures, routine service procedures and lubrication.
When any system or component requires service other than the routine procedures as outlined in this section,
refer to the appropriate section for that component.
2-2. DIMENSIONS. The principal airplane dimensions are shown in Figure 2-1 and are listed in Table II-I.
2-3. STATION REFERENCE LINES. In order to facilitate the location of various components of the airplane
which require maintenance and servicing, a method utilizing fuselage station (Sta.), wing station or buttock line
(BL), and waterline (WL) designations is frequently employed in this manual. (Refer to Figure 2-2.) Fuselage
stations, buttock lines, and waterlines are reference points measured by inches in the vertical or horizontal
direction from a given reference line which indicates station locations of structural members of the airplane.
Station 0 of the fuselage is 44.5 inches ahead of the lower edge of the firewall; station 0 (BL) of the wing and
stabilator is the centerline of the airplane; and station 0 (WL) of the fuselage vertical stabilizer and rudder is 20.5
inches below the cabin floor as measured at the rear wing spar with the airplane level. The reference datum line
is located 78.4 inches ahead of the wing leading edge at the intersection of the straight and tapered section.
2-4. WEIGHT AND BALANCE DATA. When figuring various weight and balance computations, the empty,
static and gross weight, and center of gravity of the airplane may be found in the Weight and Balance Form of
the Airplane Flight Manual.
2-5. SERIAL NUMBER PLATE. The serial number plate is located on the left side of the fuselage near the
leading edge of the stabilator. The serial number should always be used when referring to the airplane on service
or warranty matters.
2-6. ACCESS AND INSPECTION PROVISIONS. The access and inspection provisions for the airplane are
shown in Figure 2-3. The component to be serviced or inspected through each opening is identified in the
illustration. All access plates and panels are secured by either metal fasteners or screws. To enter the aft section
of the fuselage, remove the upholstery panel.
— Caution —
before entering the aft section of the fuselage, be sure the airplane is supported at
the tail skid.
2-7. TOOLS AND TEST EQUIPMENT. Because of the simplicity and easy accessibility of components, few
special tools outside normal shop tools will be required. Tools that are required may be fabricated from
dimensions given in the section that pertains to a particular component.
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING
1A19

12' 11.75"
2' 6"
5' 3"
4
35'
10'
23' 9.6''
7'3.6"
STATIC GROUND LINE
6' 8"
Figure 2-1. Three View
PIPER AIRCRAFT
PA-28-161 CADET
AIRPLANE MAINTENANCE MANUAL
Issued: FEBRUARY. 28, 1989 HANDLING AND SERVICING
1A20