Piper CHEROKEE WARRIOR PA-28-151 1995 User manual

AIRPLANE
MAINTENANCE MANUAL
CARD 1 OF 3
PA-28-151 CHEROKEE WARRIOR
PA-28-161 WARRIOR II
PA-28-161 WARRIOR III
PIPER AIRCRAFT CORPORATION
(PART NUMBER 761 539 FEBRUARY 28, 1995
1A1
Island Enterprises

Published by
Technical Publications
Piper Aircraft Corporation
2926 Piper Drive
Vero Beach, Florida 32960
U.S.A.
Member of GAMA
General Aviation
Manufacturers Association
1A2
Island Enterprises

SERIAL NUMBER INFORMATION
PA-28-151, WARRIOR- 1974
Serial Numbers 28-7415001 to 28-7415713 inclusive
PA-28-151, WARRIOR- 1975
Serial Numbers 28-7515001 to 28-7515459 inclusive
PA-78-151, WARRIOR- 1976
Serial Numbers 28-7615001 to 28-7615445 inclusive
PA-28-151, WARRIOR- 1977
Serial Numbers 28-7715001 to 28-7715314 inclusive
PA-28-161, WARRIOR II - 1977
Serial Numbers 28-7716001 to 28-7716323 inclusive
PA-28-161, WARRIOR II - 1978
Serial Numbers 28-7816001 to 28-7816695 inclusive
PA-28-161, WARRIOR II - 1979
Serial Numbers 28-7916001 to 28-7916617 inclusive
PA-28-161, WARRIOR II - 1980
Serial Numbers 28-8016001 to 28-8016382 inclusive
PA-28-161, WARRIOR II- 1981
Serial Numbers 28-8116001 to 28-8116342 inclusive
PA-28-161, WARRIOR II- 1982
Serial Numbers 28-8216001 to 28-8216236 inclusive
PA-28-161, WARRIOR II- 1983
Serial Numbers 28-8316001 to 28-8316112 inclusive
PA-28-161, WARRIOR II - 1984
Serial Numbers 28-8416001 to 28-8416131 inclusive
PA-28-161, WARRIOR II - 1985
Serial Numbers 28-8516001 to 28-8516099 inclusive
PA-28-161, WARRIOR II - 1986
Serial Numbers 28-8616001 to 28-8616057, inclusive
2816001 thru 2816010 (less 2816002), inclusive
PA-28-161, WARRIOR II - 1987
Serial Numbers 2816002, 2816011 thru 2816036 (less 2816029
thru 2816033), inclusive
PA-28-161, WARRIOR II - 1988
Serial Numbers 2816029 thru 2816033, 2816037 thru
2816075 (less 2816066), inclusive
PA-28-161, WARRIOR II - 1989
Serial Numbers 2816076 thru 2816094, inclusive
PA-28-161, WARRIOR II - 1990
Serial Numbers 2816095 thru 2816099, inclusive
PA-28-161, WARRIOR II - 1992
Serial Numbers 2816100 thru 2816103, inclusive
PA-28-161, WARRIOR II - 1993
Serial Numbers 2816106 thru 2816109, inclusive
PA-28-161, WARRIOR II - 1994
Serial Numbers 2816104 and 2816105, inclusive
PA-28-161, WARRIOR III - 1994
Serial Numbers 2816110
PA-28-161, WARRIOR III - 1995
Serial Numbers 2816111 and up
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 1995 1A3
Island Enterprises

AEROFICHE EXPLANATION AND REVISION STATUS
The Service Manual information incorporated in this set of Aerofiche cards has been arranged in accordance with the
general specifications of Aerofiche adopted by the General Aircraft Manufacturer’s Association, (GAMA). The
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 addi-
tions 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 761 539 issued August, 1973 ORG 730 822 are as follows:
Revisions Date Aerofiche Card Effectivity
PR740806 August 6, 1974 —
PR750630 June 30, 1975 —
PR760501 May 1, 1976 1 and 2
PR760507 May 7, 1976 1 and 2
PR761201 December 1, 1976 1 and 2
PR770527 May 27, 1977 1 and 2
PR771212 December 12, 1977 1 and 2
PR780801 August 1, 1978 1 and 2
PR790616 June 16, 1979 1 and 2
PR790823 August 23, 1979 1 and 2
PR800303 March 3, 1980 1 and 2
PR800724 July 24, 1980 1 and 2
PR801013 October 13, 1980 1 and 2
PR810623 June 23, 1981 1 and 2
PR820412 April 12, 1982 1 and 2
PR821130 November 30, 1982 1 and 2
PR830609 June 9, 1983 1 and 2
PR830712 July 12, 1983 1
PR840605 June 5, 1984 1 and 2
PR950228 February 28, 1995 1 and 2
The date on Aerofiche cards should not be earlier than the date noted for the respective card effectivity. Consult the latest
card in this series for current Aerofiche card effectivity.
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 1995 1A4
Island Enterprises

TABLE OF CONTENTS
AEROFICHE CARD NO.1GRID NO.
IINTRODUCTION.........................................................1A13
IIHANDLING AND SERVICING....................................1A16
IIIINSPECTION..............................................................1D15
IVSTRUCTURES............................................................1E5
VSURFACE CONTROLS..............................................1G10
VIHYDRAULIC SYSTEM (Not Applicable)
VIILANDING GEAR AND BRAKE SYSTEM..................1I10
VIIIPOWER PLANT..........................................................1J19
AEROFICHE CARD NO.2
IXFUEL SYSTEM...........................................................2A10
XINSTRUMENTS..........................................................2B11
XIELECTRICAL SYSTEM.............................................2D4
XIIELECTRONICS..........................................................2J11
XIIIHEATING AND VENTILATING...................................2K5
AEROFICHE CARD NO.3
XIVACCESSORIES AND UTILITIES...............................3A8
Revised: February 28, 19951A5
Island Enterprises

LIST OF ILLUSTRATIONS
Aerofiche
FigureGrid No.
2-1.Three View.......................................................................................................................................1A20
2-2.Station Reference Lines....................................................................................................................1A21
2-3.Access Plates and Panels..................................................................................................................1B2
2-4.Jacking Arrangement........................................................................................................................1B9
2-5.Weighing Arrangement....................................................................................................................1B10
2-6.Leveling Longitudinally...................................................................................................................1B11
2-7.Leveling Laterally.............................................................................................................................1B11
2-8.Servicing Points................................................................................................................................1B15
2-9.Induction Air Filter...........................................................................................................................1B20
2-10.Fuel Strainer.....................................................................................................................................1B23
2-11.Main Gear Lubrication Chart...........................................................................................................1C4
2-12.Nose Gear Lubrication Chart...........................................................................................................1C5
2-13.Aileron Control System Lubrication Chart......................................................................................1C6
2-14.Flap Control System Lubrication Chart...........................................................................................1C7
2-15.Rudder Control System Lubrication Chart.......................................................................................1C8
2-16.Rudder Trim Control System Lubrication Chart..............................................................................1C9
2-17.Cabin Door, Baggage Door and Seats Lubrication Chart................................................................1C10
2-18Power Plant Lubrication Chart.........................................................................................................1C11
2-19Optional Air Conditioning Condenser and Compressor Lubrication Chart
PA-161, S/N’s 7716002 thru 28-8616057 and 2816001 thru 2816109.....................................1C12
2-20Cherrylock Rivet Removal...............................................................................................................1D10
2-21.Identification of Aircraft Fluid Lines...............................................................................................1D11
2-22.Torque Wrench Formula...................................................................................................................1D12
3-1.Inspection Areas of Exhaust System................................................................................................1D18
3-2.Typical Muffler Fatigue Areas..........................................................................................................1D18
4-1.Aileron and Flap Installation............................................................................................................1E9
4-2.Wing Installation..............................................................................................................................1E14
4-3.Stall Strip Installation.......................................................................................................................1E18
4-4.Methods of Securing Control Cables...............................................................................................1E19
4-5.Empennage Group Installation.........................................................................................................1E20
4-6.Windshield Installation (Typical).....................................................................................................1E24
4-7.Side Window Installation (Typical)..................................................................................................1F1
4-8.Door Snubber Installation................................................................................................................1F5
4-9.Fabricated Tool for Baggage Door Lock..........................................................................................1F6
4-10a.Seat Back Lock.................................................................................................................................1F6
4-10b.Lumbar Seat Bladder Installation.....................................................................................................1F8
4-11.Skin Materials and Thickness...........................................................................................................1F10
4-12.Typical Access Plates.......................................................................................................................1F11
4-13.Baggage Compartment Inspection Holes Cutout Details.................................................................1F12
4-14.Surface Scratches, Abrasions or Ground-in-Dirt..............................................................................1F17
4-15.Deep Scratches, Shallow Nicks and Small Holes............................................................................1F17
4-16.Mixing of Epoxy Patching Compound.............................................................................................1F19
4-17.Welding Repair Method...................................................................................................................1F19
4-18.Repairing of Cracks..........................................................................................................................1F20
4-19.Various Repairs.................................................................................................................................1F21
4-20.Repair of Stress Lines.......................................................................................................................1F22
4-21.Repair of Impacted Damage.............................................................................................................1F22
5-1.Rod End Installation Method...........................................................................................................1G14
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 19951A6
Island Enterprises

LIST OF ILLUSTRATIONS (cont.)
Aerofiche
FigureGrid No.
5-2.Control Cable Inspection Technique................................................................................................1G14
5-3.Cable Weat Patterns..........................................................................................................................1G15
5-4.Internal Cable Wear..........................................................................................................................1G16
5-5.Pulley Wear Patterns.........................................................................................................................1G17
5-6.Control Column Assembly...............................................................................................................1G21
5-7.Flex (Universal) Joint Assembly......................................................................................................1G22
5-8.Aileron Controls...............................................................................................................................1G24
5-9.Bellcrank RiggingTool (1974 and 1975 Models Only)...................................................................1H3
5-10.Bellcrank RiggingTool (1976 and Subsequent Models Only)........................................................1H3
5-11Stabilator Controls............................................................................................................................1H5
5-12.Stabilator Rigging Tool....................................................................................................................1H7
5-13.Stabilator Trim Controls...................................................................................................................1H9
5-14.Methods of Securing Trim Cables....................................................................................................1H11
5-15.Rudder and Steering Pedal Assembly..............................................................................................1H13
5-16.Rudder Controls...............................................................................................................................1H16
5-17.Rudder Rigging Tool........................................................................................................................1H17
5-18.Clamping Rudder Pedals..................................................................................................................1H17
5-19.Rudder and Stabilator Travel Adjustment........................................................................................1H18
5-20.Rudder Trim Control........................................................................................................................1H19
5-21.Flap Control System.........................................................................................................................1H21
5-22.Flap Stop Adjustment.......................................................................................................................1H24
5-23.Flap Rigging Tool.............................................................................................................................1H24
5-24.Fabricated Rudder Rigging Tool......................................................................................................1I6
5-25.Fabricated Stabilator Rigging Tool...................................................................................................1I6
5-26.Fabricated Flap Rigging Tool...........................................................................................................1I7
7-1.Nose Gear Oleo Strut Assembly......................................................................................................1I13
7-2.Nose Gear Installation......................................................................................................................1I16
7-3.Clamping Rudder Pedals in Neutral Position...................................................................................1I18
7-4.Rudder Pedals at Neutral Angle.......................................................................................................1I18
7-5.Main Gear Oleo Strut Assembly......................................................................................................1I20
7-5a.Main Gear Oleo Strut Assembly (cont.)...........................................................................................1I21
7-6.Main Gear Installation......................................................................................................................1I23
7-7.Nose Wheel Assembly.....................................................................................................................1J1
7-8.Main Wheel Assembly.....................................................................................................................1J3
7-9.Wheel Brake Assembly....................................................................................................................1J4
7-10.Removal of Anchor Bolt...................................................................................................................1J5
7-11.Installation of Anchor Bolt...............................................................................................................1J6
7-12.Brake System Installation.................................................................................................................1J7
7-13.Brake Master Cylinder (Hand/Parking Brake).................................................................................1J8
7-14.Brake Cylinder (Toe Brake) (10-27, 10-30, 17000).........................................................................1J11
7-15.Retainer Ring Installation Tool........................................................................................................1J16
8-1.Typical Nicks and Removal Method................................................................................................1J23
8-2.Propeller and Cowling Installation...................................................................................................1J24
8-3.Engine Installation............................................................................................................................1K3
8-4.Engine Shock Mount Installation.....................................................................................................1K5
8-5.Adjustment of Engine Controls........................................................................................................1K6
8-6.Carburetor.........................................................................................................................................1K7
8-7.Exploded View of Magneto (4200 Series).......................................................................................1K12
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 19951A7
Island Enterprises

LIST OF ILLUSTRATIONS (cont.)Aerofiche
FigureGrid No.
8-8.T-100 Assembly and Timing Tool Kit..............................................................................................1K13
8-9.Removing Coil Wedges....................................................................................................................1K14
8-10.Index Plate and Timing Plug............................................................................................................1K15
8-11.Installation of Bearings and Bearing Plate.......................................................................................1K16
8-12Position of Magneto on T-100 Tool and Oil Seal Installation..........................................................1K16
8-13.Timing Magneto Internally and Assembly.......................................................................................1K17
8-14.Magneto Inspection (Bendix)...........................................................................................................1K21
8-15.Contact Spring Inspection................................................................................................................1K21
8-16.Impulse Coupling Inspection............................................................................................................1K21
8-17.Magneto Timing Marks....................................................................................................................1K23
8-18.Timing Pointer..................................................................................................................................1K23
8-19.Timing Kit Installed..........................................................................................................................1K23
8-20.Breaker Compartment with Cast Timing Marks..............................................................................1K23
8-21.Stripping Tool...................................................................................................................................1L3
8-22.Inserting Stripping Tool....................................................................................................................1L3
8-23.Cutting Insulation.............................................................................................................................1L3
8-24.Removing Silicone Rubber from Wire.............................................................................................1L3
8-25.Installation of Plug End Nut.............................................................................................................1L4
8-26.Flaring Out of Shielding...................................................................................................................1L4
8-27.Installation of Ferrule.......................................................................................................................1L5
8-28.Driving Tool.....................................................................................................................................1L5
8-29.Installation in Housing.....................................................................................................................1L5
8-30.Securing Wire in Housing................................................................................................................1L5
8-31.Installation of Electrical Screw........................................................................................................1L6
8-32.Installation of Insulation Sleeve.......................................................................................................1L6
8-33.Installation of Spring........................................................................................................................1L6
8-34.Removing Spark Plug Frozen to Bushing........................................................................................1L6
8-35.Warrior IIIce Detection System.......................................................................................................1L10
8-36.Warrior IIIIce Detection System......................................................................................................1L12
8-37.Static Rpm (SEA LEVEL ± 500’ PRESSURE ALTITUDE ONLY)...............................................1L16
8-38.Change in Static Rpm Vs. Engine Oil Temperature
9-1.PA-28-151 and PA-28 -161, Warrior II Fuel System Diagram.........................................................2A13
9-2.PA-28 -161, Warrior III Fuel System Diagram................................................................................2A14
9-3.Tolerances, Union Nut and Tubing Nut............................................................................................2A16
9-4.Resistance Decade Test Box Set Up.................................................................................................2A20
9-5Warrior III Fuel Quantity Needle Deviation.....................................................................................2A20
9-6.Fuel Quantity Transmitter Checking Jig..........................................................................................2A22
9-7.Fabricated Fuel Quantity Transmitter Checking Jig.........................................................................2A23
9-8.Locking Fuel Cap.............................................................................................................................2A24
9-9.Fuel Filter Bowl and Screen.............................................................................................................2B1
9-10.Plunger Fuel Pump...........................................................................................................................2B3
9-11.Engine Primer...................................................................................................................................2B5
10-1.PA-28-151, Warrior and PA-28-161, Warrior II Vacuum Pump.......................................................2B16
10-2.PA-28-161, Warrior III Vacuum Pump.............................................................................................2B16
10-3.Warrior I and II Instrument Panel (Typical).....................................................................................2B17
10-4.Warrior III VFR Instrument Panel (Typical)....................................................................................2B18
10-5.Warrior II and III Auxiliary Vacuum System Installation................................................................2C1
10-6.Warrior II and III Auxiliary Vacuum Electrical Schematic..............................................................2C2
10-7.Pitot and Static Air Systems.............................................................................................................2C6
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 19951A8
Island Enterprises

LIST OF ILLUSTRATIONS (cont.)Aerofiche
FigureGrid No.
10-8.Warrior III Instrument Cluster - Oil Temperature, Fuel Pressure, and Oil Pressure Gauge.............2C18
10-9.Warrior III Fuel Quantity Gauge......................................................................................................2C20
10-10.Exhaust Gas Probe Installation.........................................................................................................2C24
11-1.Exploded View of Prestolite and Electrosystems Alternators..........................................................2E4
11-2.Lamp Bank Load..............................................................................................................................2E5
11-3.Removal of Rectifier.........................................................................................................................2E6
11-4.Removal of Slip Ring End Bearing..................................................................................................2E6
11-5.Removal of Drive End Head.............................................................................................................2E7
11-6.Removal of End Head Bearing.........................................................................................................2E7
11-7.Testing Rotor for Grounds................................................................................................................2E7
11-8.Testing Rotor for Shorts...................................................................................................................2E7
11-9.Installation of Bearing......................................................................................................................2E9
11-10.Installation of Rectifier.....................................................................................................................2E9
11-11.Terminal Assembly...........................................................................................................................2E10
11-12.Slip Ring End Bearing Assembly.....................................................................................................2E10
11-13.Testing Alternator.............................................................................................................................2E10
11-14.Brush Installation.............................................................................................................................2E11
11-15.Internal Wiring Diagram..................................................................................................................2E11
11-16.Exploded View of Chrysler Alternator.............................................................................................2E14
11-17.Checking Chrysler Alternator Field Current Draw..........................................................................2E16
11-18.Testing Chrysler Alternator Field Circuit.........................................................................................2E17
11-19.Chrysler Alternator Rectifier End Shield and Stator Assembly.......................................................2E18
11-20.Testing Positive Rectifiers With C-3829 Tester................................................................................2E19
11-21.Testing Negative Rectifiers With C-3829 Tester..............................................................................2E19
11-22.Testing Positive Rectifiers With Test Lamp.....................................................................................2E20
11-23.Testing Negative Rectifiers With Test Lamp....................................................................................2E20
11-24.Rectifier and Heat Sink Assembly Removal....................................................................................2E21
11-25.Rectifier End Shield Assembly........................................................................................................2E21
11-26.Testing Stator....................................................................................................................................2E22
11-27.Removal of Pulley............................................................................................................................2E22
11-28.Removal of Bearing..........................................................................................................................2E22
11-29.Removal of Rectifier End Shield Bearing........................................................................................2E22
11-30.Testing Rotor for Ground.................................................................................................................2E23
11-31.Testing Rotor for Open or Shorts.....................................................................................................2E23
11-32.Installation of Grease Retainer.........................................................................................................2E24
11-33.Installation of Rectifier End Shield Bearing....................................................................................2E24
11-34.Installation of Drive End Shield Bearing.........................................................................................2F1
11-35.Installation of Pulley.........................................................................................................................2F1
11-36.Installation of Insulators Assembly..................................................................................................2F1
11-37Installation of Positive Rectifier.......................................................................................................2F1
11-38.Installation of Capacitor...................................................................................................................2F3
11-39.Installation of Battery Output Insulator...........................................................................................2F3
11-40.Installation of Negative Rectifier Assembly.....................................................................................2F3
11-41.Installation of Stator.........................................................................................................................2F3
11-42.Battery Installation - 12 Volt (Warrior/Warrior II)...........................................................................2F7
11-43.Battery Installation - 24 Volt (Warrior III S/N’s 2816110)..............................................................2F10
11-44.Lamar 14 Vdc Regulator Check.......................................................................................................2F17
11-45.Lamar 28 Vdc Regulator Check.......................................................................................................2F18
11-46.Application of Wico Overvoltage Control.......................................................................................2F20
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 19951A9
Island Enterprises

LIST OF ILLUSTRATIONS (cont.)Aerofiche
FigureGrid No.
11-47.Lamar 14 Vdc System Overvoltage Check......................................................................................2F21
11-48.Lamar 28 Vdc System Overvoltage Check......................................................................................2F21
11-49.Exploded View of Gear Reduction Starter Motor............................................................................2F23
11-50.Turning Starting Motor Commutator...............................................................................................2G1
11-51Testing Motor Armature for Shorts..................................................................................................2G1
11-52.Testing Motor Fields for Grounds....................................................................................................2G3
11-53.No Load Test Hookup......................................................................................................................2G3
11-54.Stall Torque Hookup.........................................................................................................................2G3
11-55.Strobe Light Connections (Warrior/Warrior II)................................................................................2G9
11-56.Strobe Light Connections (Warrior II).............................................................................................2G10
11-57Strobe Light Connections (Warrior III)............................................................................................2G11
11-58.Annunciator Panel (Warrior/Warrior II)...........................................................................................2G15
11-59.Annunciator Panel (Warrior III).......................................................................................................2G15
11-60.Ignition Switch Wire Position..........................................................................................................2G21
See Section XI. Electrical Charts and Wiring Diagram Index for 11-61 thru 11-128.....................2H5
12-1.Two Year, Magnesium Battery Connection......................................................................................2J15
12-2.Garrett ELT’s Schematic..................................................................................................................2J15
12-3.Communications Components ELT Schematic................................................................................2J17
12-4.Narco ELT 10 Schematic (Prior to S/N 2816053)...........................................................................2J19
12-5Narco ELT 10 Schematic (2816053 to 2816093)............................................................................2J19
12-6ELT Portable Folding Antenna (Narco)...........................................................................................2J20
12-7.ELT Using Fixed Aircraft Antenna (Narco).....................................................................................2J20
12-8.Narco ELT 910 Emergency Locator Transmitter Schematic ...........................................................2J22
12-9.ELT 910 Battery Pack.......................................................................................................................2J23
12-10.Artex 11 ELT....................................................................................................................................2J24
12-11.Artex ELT 110 Wiring Schematic....................................................................................................2K1
13-1.Cabin Heater, Defroster and Fresh Air System................................................................................2K7
14-1.Air Conditioning System Installation....................................................................................3A17
14-2.Service Valves........................................................................................................................3A22
14-3.Test Manifold and Charging Cart...........................................................................................3A23
14-4.Manifold Set Operation..........................................................................................................3A23
14-5.Manifold to Recharging/Test Stand Hookup.........................................................................3A24
14-6.Robinair 34700 Control Panel and Hose Connections..........................................................3B1
14-7.Robinair 34700 Hose Hookup...............................................................................................3B2
14-8.Compressor and Fabricated Oil Dipstick...............................................................................3B11
14-9.Compressor and Alternator Belt Installation (Sheet 1 of 2)..................................................3B13
14-9.Compressor and Alternator Belt Installation (Sheet 2 of 2)..................................................3B14
14-10.Magnetic Clutch (York Compressor).....................................................................................3B16
14-11.Condenser Air Scoop Installation..........................................................................................3B18
14-12.Expansion Valve.....................................................................................................................3B19
14-13.Components Installation........................................................................................................3B21
14-14.Typical Air Conditioning Wiring Schematic.........................................................................3B23
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 19951A10
Island Enterprises

LIST OF TABLES
Table Aerofiche
Grid No.
II-I. Leading Particulars and Principal Dimensions...................................................................... 1A22
II-II. Recommended Torques.......................................................................................................... 1B5
II-III. Flare Fitting Torques.............................................................................................................. 1B7
II-IV. Type of Lubricants................................................................................................................. 1C2
II-V. Types of Metal Corrosion...................................................................................................... 1C15
II-VI. List of Consumable Materials................................................................................................ 1C20
II-VII. Conversion Tables.................................................................................................................. 1D4
II-VIII. Thread Lubricants.................................................................................................................. 1D7
II-IX. Hose Clamp Tightening. (Initial Installation)....................................................................... 1D7
II-X. Maximum Distance Between Supports For Fluid Tubing..................................................... 1D8
II-XI. Decimal/Millimeter Equivalents of Drill Sizes...................................................................... 1D9
III-I. Inspection Report................................................................................................................... 1D19
IV-I. List of Materials (Thermoplastic Repair) .............................................................................. 1F16
IV-II. Balancing Specifications........................................................................................................ 1F23
V-I. Cable Tension vs. Ambient Temperature............................................................................... 1G13
V-II. Control Surface Travel and Cable Tension............................................................................ 1G19
V-III. Troubleshooting Chart (Surface Controls)............................................................................. 1I1
VII-I. Landing Gear Troubleshooting.............................................................................................. 1J14
VIII-I. Propeller Torque Limits......................................................................................................... 1J24
VIII-II. Propeller Applicability........................................................................................................... 1L14
VIII-III. Static Rpm PA-280-161 With 74DM6-0-60 Propeller........................................................... 1L19
VIII-IV. Static Rpm PA-280-161 With 74DM6-0-58 Propeller........................................................... 1L19
VIII-V. Engine Troubleshooting......................................................................................................... 1L20
IX-I. Transmitter/Fuel Gauge Tolerances....................................................................................... 2A17
IX-II. Fuel Quantity Gauge Resistance/Tolerance Values ............................................................... 2A18
IX-III 14 Vdc Fuel Quantity Gauge Tolerance Values..................................................................... 2A18
IX-IV 28 Vdc Fuel Quantity Gauge Resistance/Tolerance Value .................................................... 2A19
IX-V 28 Vdc Fuel Quantity Gauge Tolerance Values..................................................................... 2A21
IX-VI Fuel Quantity Transmitter Calibration Tolerance.................................................................. 2A21
IX-VII. Fuel System Troubleshooting................................................................................................ 2B7
X-I. Troubleshooting Vacuum System .......................................................................................... 2B19
X-II. Troubleshooting (Directional Gyro) Indicator....................................................................... 2C3
X-III. Troubleshooting Attitude Deviation Indicator....................................................................... 2C5
X-IV. Troubleshooting Vertical Speed Indicator.............................................................................. 2C7
X-V. Troubleshooting Altimeter..................................................................................................... 2C8
X-VI. Troubleshooting Pitot/Static Tubes and Airspeed Indicator.................................................. 2C10
X-VII. Troubleshooting Magnetic Compass ..................................................................................... 2C11
X-VIII Troubleshooting Tachometer ................................................................................................. 2C12
X-IX. Troubleshooting PA-28-151, Warrior and PA-28-161, Warrior II
Engine Oil Pressure Gauge.................................................................................................... 2C15
X-X. Troubleshooting PA-28-151, Warrior and PA-28-161, Warrior II
Engine Oil Temperature Gauge............................................................................................. 2C15
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 1995 1A11
Island Enterprises

X-XITroubleshooting PA-28-161, Warrior III Engine Oil Pressure Gauge...................................2C16
X-XIITroubleshooting PA-28-161, Warrior III Engine Oil Temperature Gauge............................2C16
X-XIIITroubleshooting Fuel Pressure Gauge...................................................................................2C17
X-XIVWarrior III Instrument Calibration Chart...............................................................................2C18
X-XVTurn and Bank Indicator........................................................................................................2C19
X-XVITroubleshooting Fuel Quantity Indicator...............................................................................2C20
X-XVIITroubleshooting Cylinder Head Temperature Gauge............................................................2C23
X-XVIIITroubleshooting Exhaust Gas Temperature Gauge................................................................2D1
XI-ITrobleshooting Electrical System..........................................................................................2D10
XI-IIPrestolite and Electrosystems Alternator Specifications ......................................................2E12
XI-IIIChrysler Alternator Specifications ........................................................................................2F4
XI-IVAlternator Belt Tension..........................................................................................................2F4
XI-VHydrometer Reading and Battery Charge Percent Warrior/Warrior II 12 Volt Battery.........2F6
XI-VIHydrometer Reading and Battery Charge Percent Warrior III 24 Volt Battery.....................2F13
XI-VIIElectrolyte Temperature Corrections.....................................................................................2F13
XI-VIIISpecific Gravity Temperature Correction..............................................................................2F13
XI-IXDischarge Rate.......................................................................................................................2F15
XI-XElectrolyte Freezing Point......................................................................................................2F15
XI-XIStarting Motor Specifications................................................................................................2G4
XI-XIIAnnunciator Lights Description and Function (Warrior III)..................................................2G14
XI-XIIILamp Replacement Guide......................................................................................................2G23
XI-XIVWarrior/Warrior II Electrical System Component Loads.......................................................2G24
XI-XVWarrior III Electrical System Component Loads...................................................................2H1
XI-XVIElectrical Wire Coding...........................................................................................................2H9
XI-XVIIElectrical Symbols (Old Style)..............................................................................................2H10
XI-XVIIIElectrical Symbols (New Style)...........................................................................................2H11
XIV-ITroubleshooting Air Conditioner...........................................................................................3A11
XIV-IITroubleshooting Air Conditioner System..............................................................................3A13
XIV-IIIRefrigerant Temperature Pressure..........................................................................................3A19
XIV-IVAluminum Tubing Torque......................................................................................................3A21
XIV-VSystem Vacuum......................................................................................................................3A24
XIV-VICompressor Oil Charge..........................................................................................................3B11
XIV-VIICompressor Misalignment and Idler Pulley Nominal Location............................................3B12
XIV-VIIIBlower System Wire Color Codes.........................................................................................3C1
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 19951A12
Island Enterprises

SECTION I
INTRODUCTION
Aerofiche
Paragraph Grid No.
1-1. General
1-2. Scope of Manual .............................................................................................. 1A13
1-3. Descriptions ..................................................................................................... A13
1-4. Wing................................................................................................................. 1A13
1-5. Empennage....................................................................................................... 1A13
1-6. Fuselage ........................................................................................................... 1A13
1-7. Landing Gear.................................................................................................... 1A13
1-8. Brake System ................................................................................................... 1A13
1-9. Engines............................................................................................................. 1A14
1-10. Propeller........................................................................................................... 1A14
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
Revised: June 5, 1984 1A13
Island Enterprises

SECTION I
INTRODUCTION
1-1.GENERAL. This manual contains service and maintenance instructions for the Piper PA-28-151 and
PA-28-161 Cherokee Warrior, designed and manufactured as a versatile airplane in the personal and business
aviation field, by the Piper Aircraft Corporation, Vero Beach, Florida.
1-2.SCOPE OF MANUAL. Section II and III comprise the service part of this manual, whereas Sections IV
through XIV comprise the maintenance instructions. The service instructions include ground handling, ser-
vicing and inspection. The maintenance instructions for each system include description, removal, inspection,
installation and 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 Cherokee Warrior is a single-engine, low wing monoplane, of all metal con-
struction, with a seating capacity of four. Paragraphs 1-4 through 1-12 provide descriptions of the major com-
ponents 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 thermoplastic 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. Thc
stabilator and rudder are statically balanced and cable operated.
1-6.FUSELAGE. The fuselage consists of three basic units: the engine seetion, 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 Textron-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. Some Warrior II’s may be equipped with an optional climb propreller.
1-11.FUEL SYSTEM. The fuel system consists of two aluminum tanks in the leading edge of the wings, a
fuel manifold in each wing root, 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.
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: February 28, 1995INTRODUCTION
1A14
Island Enterprises

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.
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Revised: December 1, 1976INTRODUCTION
1A15
Island Enterprises

SECTION II
HANDLING AND SERVICING
Aerofiche
Paragraph Grid No..
2-1. Introduction...................................................................................................... 1A19
2-2. Dimensions....................................................................................................... 1A19
2-3. Station Reference Lines................................................................................... 1A19
2-4. Weight and Balance Data................................................................................. 1A19
2-5. Serial Number Plate......................................................................................... 1A19
2-6. Access and Inspection Provisions.................................................................... 1A19
2-7. Tools and Test Equipment................................................................................ 1A19
2-8. 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. 14 Vdc External Power Receptacle (Optional)................................... 1B12
2-20a. 28 Vdc External Power Receptacle..................................................... 1B12
2-21. Operation of 14 Vdc External Power Receptacle. .............................. 1B12
2-21a. Operation of 28 Vdc External Power Receptacle. .............................. 1B13
2-22. Cleaning........................................................................................................... 1B13
2-23. Cleaning Engine Compartment........................................................... 1B13
2-24. Cleaning Landing Gear....................................................................... 1B14
2-25. Cleaning Exterior Surfaces................................................................. 1B14
2-26. Cleaning Windshield and Windows.................................................... 1B14
2-27. Cleaning Headliner, Side Panels and Seats......................................... 1B14
2-28. Cleaning Carpets................................................................................. 1B15
2-29. Servicing .......................................................................................................... 1B15
2-30. Introduction to Servicing .................................................................... 1B15
Revised: July 24, 1980 1A16
Island Enterprises

Aerofiche
Paragraph Grid No.
Revised: February 28, 1995 1A17
2-31. Landing Gear System ..................................................................................1B15
2-32. Servicing Landing Gear..................................................................1B15
2-33. Oleo Struts...................................................................................................1B15
2-34. Servicing Oleo Struts......................................................................1B15
2-35. Filling Nose Gear Oleo Strut..........................................................1B17
2-36. Filling Main Gear Oleo Strut..........................................................1B17
2-37. Inflating Oleo Struts .......................................................................1B18
2-38. Brake System..................................................................................1B19
2-39. Servicing Brake System..................................................................1B19
2-40. Filling Brake Cylinder Reservoir ...................................................1B19
2-41. Draining Brake System...................................................................1B19
2-42. Tires.............................................................................................................1B19
2-43. Servicing Tires................................................................................1B19
2-44. Power Plant..................................................................................................1B19
2-45. Servicing Power Plant ....................................................................1B19
2-46. Induction Air Filter......................................................................................1B19
2-47. Removal of Air Filter .....................................................................1B19
2-48. Service Instructions (Inspection and Replacement) .......................1B21
2-49. Installation of Air Filter..................................................................1B21
2-50. Propeller.......................................................................................................1B21
2-51. Servicing Propeller.........................................................................1B21
2-52. Fuel System .................................................................................................1B21
2-53. Servicing Fuel System....................................................................1B21
2-54. Filling Fuel Tanks...........................................................................1B21
2-55. Anti-lcing Fuel Additive.................................................................1B21
2-56. Fuel Drain Valve and Strainer.........................................................1B22
2-57. Draining Fuel System.....................................................................1B22
2-58. Electrical System.........................................................................................1B22
2-59. Servicing Electrical System............................................................1B22
2-60. Lubrication...................................................................................................1B23
2-61. Oil System (Engine) ....................................................................................1B23
2-62. Servicing Oil System......................................................................1B23
2-63. Filling Oil Sump.............................................................................1B23
2-64. Draining Oil Sump..........................................................................1B24
2-65. Oil Screens (Suction)......................................................................1B24
2-66. Oil Screens (Pressure).....................................................................1B24
2-67. Oil Filter (Full Flow)......................................................................1B24
2-68. Recommendations for Changing Oil..............................................1B24
2-69. Lubrication Instructions...................................................................1C1
2-70. Application of Oil............................................................................1C1
2-71. Application of Grease......................................................................1C1
2-72. Winterization Plate..........................................................................1C1
2-73. Lubrication Chart.............................................................................1C1
Island Enterprises

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Paragraph Grid No.
Added: April 12, 1982 1A18
2-74. Corrosion Control........................................................................................1C13
2-75. Form of Corrosion..........................................................................1C13
2-76. Conditions Affecting Corrosion .....................................................1C13
2-77. Inspection........................................................................................1C14
2-78. Corrosion Removal and Control.....................................................1C14
2-79. Areas Prone to Corrosion ...............................................................1C16
2-80. Repainting....................................................................................................1C17
2-81. Product Listing For Urethane Enamel Aircraft Finish ...................1C17
2-82. Preparation of Epoxy Zinc Chromate Primer.................................1C18
2-83. Preparation and Application of DuPont Imron Urethane Enamel..1C18
2-84. Product Listing For Randolph Paint Finish....................................1C18
2-85. Preparation and Application of Zinc Chromate Primer..................1C18
2-86. Finish Painting With Randolph Paint (B5420/D7784)...................1C19
2-87. Repairs............................................................................................1C19
2-88. Removal of Cherrylock Rivets ....................................................................1D10
2-89. Standard Practice - Airframe.......................................................................1D12
2-90. Torque Wrenches............................................................................1D12
Island Enterprises

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 (LB), 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 fire wall; 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 ser-
vice 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 sec-
tion of the fuselage, open the baggage compartment door and 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 CHEROKEE WARRIOR SERVICE MANUAL
Issued: August 22, 1973 HANDLING AND SERVICING
1A19
Island Enterprises

Figure 2-1. Three View
PIPER CHEROKEE WARRIOR SERVICE MANUAL
Issued: August 22, 1973 HANDLING AND SERVICING
1A20
12’ 11.75”
2’ 8”
3’ 6.2”
5’ 3”
35’
23’ 9.6”
10’
6’ 8”
STATIC GROUND LINE
7’ 3.6”
Island Enterprises