ARROW III - TURBO ARROW III
ARROW
SERVICE MANUAL
CARD 1 OF 3
PA-28R-201/201T
PIPER AIRCRAFT CORPORATION
(PART NUMBER 761 639)
1A1
1A2
CHEROKEE ARROW III SERVICE MANUAL
AEROFICHE EXPLANATION AND REVISION STATUS
Service manual information incorporated in this set of Aerofiche cards is arranged in accordance with the
general specifications of Aerofiche adopted by the General Aviation Manufacturer’s Association. Information
compiled in this Aerofiche service manual is kept current by revisions distributed periodically. These revisions
supersede all previous revisions, are complete Aerofiche card replacements, and supersede Aerofiche cards of
the same number in the set.
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 or added material. Revision lines indicate only current revisions with changes and additions to
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.
Revisions to Service Manual 761-639 issued December 15, 1976 are as follows:
Effectivity Publication Date Aerofiche Card Effectivity
ORG761215 December 15, 1976 1 and 2
PR770831 August 31, 1977 1 and 2
PR781211 December 11, 1978 1 and 2
PR800501 May 1, 1980 1 and 2
PR801121 November 21, 1980 1 and 2
PR810713 July 13, 1981 1 and 2
PR831018 October 18, 1983 1 and 2
IR860730 July 30, 1986 1
IR860920 September 20, 1986 1
IR870506 July 12, 1987 1
PR890213 August 1, 1989 1, 2 and 3
IR950221 February 21, 1995 1 and 2
IR040227* February 27, 2004 1 and 2
*INTERIM CHANGE TO SERVICE MANUAL 761-639
Section VII in Card 1 and Sections VIII and VIIIA in Card 2 have been
revised. There are no other changes included in this interim change
revision. Please discard your current cards 1 and 2, and replace them with
the revised ones. DO NOT DISCARD CARD 3.
Consult the latest Customer Services Information Aerofiche for current revision dates for this manual.
TABLE OF CONTENTS
NO. AEROFICHE CARD NO. 1 GRID NO.
I INTRODUCTION 1A13
II HANDLING AND SERVICING 1A16
III INSPECTION 1D1
IV STRUCTURES 1D17
V SURFACE CONTROLS 1F6
VI HYDRAULIC SYSTEM 1H5
VII LANDING GEAR AND BRAKE SYSTEM 1I22
AEROFICHE CARD NO. 2
VIII POWER PLANT (CONTINENTAL) 2A9
VIIIA POWER PLANT (LYCOMING) 2C18
IX FUEL SYSTEM 2E8
X INSTRUMENTS 2F5
XI ELECTRICAL SYSTEM 2G15
XII ELECTRONICS 2J19
XIII HEATING AND VENTILATING 2K5
AEROFICHE CARD NO. 3
XIV ACCESSORIES AND UTILITIES 3A5
1A3
THIS PAGE INTENTIONALLY LEFT BLANK
1A4
Interim Revision: 2/21/95
1A5
LIST OF ILLUSTRATIONS
Aerofiche
Figure Grid No.
2-1. Three View of PA-28R-201T............................................................................................. 1A19
2-2. Three View of PA-28R-201............................................................................................... 1A20
2-3. Station Reference Lines of PA-28R-201T......................................................................... 1A21
2-4. Station Reference Lines of PA-28R-201 ........................................................................... 1A22
2-5. Access Plates and Panels................................................................................................... 1A23
2-6. Jacking Arrangement......................................................................................................... 1B8
2-7. Weighing Arrangement...................................................................................................... 1B8
2-8. Leveling Longitudinally.................................................................................................... 1B9
2-9. Leveling Laterally ............................................................................................................. 1B9
2-10. Service Points (PA-28R-201) ............................................................................................ 1B14
2-11. Service Points (PA-28R-201T).......................................................................................... 1B15
2-12. Fuel Strainer ...................................................................................................................... 1B20
2-13. Lubrication Chart (Landing Gear, Main)........................................................................... 1C14
2-14. Lubrication Chart (Landing Gear, Nose)........................................................................... 1C15
2-15. Lubrication Chart (Control System).................................................................................. 1C16
2-16. Lubrication Chart (Control System) (cont) ....................................................................... 1C17
2-17. Lubrication Chart (Control System) (cont) ....................................................................... 1C18
2-18. Lubrication Chart (Control System) (cont) ....................................................................... 1C19
2-19. Lubrication Chart (Cabin Door, Baggage Door and Seat) ................................................ 1C20
2-20. Lubrication Chart (Lycoming Power Plant, Propeller and Control Pivot Points)............. 1C21
2-21. Lubrication Chart (Continental Power Plant, Propeller and Control Pivot Points)........... 1C22
2-22. Lubrication Chart (Back-Up Extender)............................................................................. 1C23
2-23. Lubrication Chart (Air Conditioning Condenser) ............................................................. 1C24
4-1. Aileron and Flap Installation............................................................................................. 1D21
4-2. Wing Installation ............................................................................................................... 1D22
4-3. Methods of Securing Control Cables ................................................................................ 1E2
4-4. Empennage Group Installation.......................................................................................... 1E5
4-5. Windshield Installation (Typical)...................................................................................... 1E8
4-6. Side Window Installation (Typical)................................................................................... 1E10
4-7. Skin Materials and Thickness............................................................................................ 1E11
4-7a. Door Seal Snubber Installation.......................................................................................... 1E14
4-8. Fabricated Tool for Baggage Door Lock........................................................................... 1E15
4-8a. Baggage Compartment Inspection Holes Cutout Details.................................................. 1E16
4-9. Control Surface Balance Tool............................................................................................ 1E21
4-10. Aileron Balancing.............................................................................................................. 1E22
4-11. Rudder Balancing.............................................................................................................. 1E23
4-12. Rudder Balance Weight..................................................................................................... 1E24
4-13. Stabilator Balancing .......................................................................................................... 1F1
4-14. Removal of Cherrylock Rivet............................................................................................ 1F3
4-15. Identification of Aircraft Fluid Lines ................................................................................ 1F4
4-16. Torque Wrench Formula.................................................................................................... 1F5
5-1. Control Column Assembly................................................................................................ 1F11
5-1a. Correct Method of Installing Rod End Bearings............................................................... 1F12
5-2. Aileron Controls................................................................................................................ 1F15
5-3. Bellcrank Rigging Tool ..................................................................................................... 1F18
5-4. Aileron Rigging Tool......................................................................................................... 1F20
5-5. Stabilator Rigging Tool ..................................................................................................... 1F20
5-6. Stabilator Controls............................................................................................................. 1F22
5-7. Methods of Securing Trim Cables..................................................................................... 1F24
LIST OF ILLUSTRATIONS (CONT)
Aerofiche
Fgure Grid No.
5-8. Stabilator Trim Control...................................................................................................... 1G3
5-9. Rudder and Steering Pedal Assembly ............................................................................... 1G5
5-10. Rudder Controls................................................................................................................. 1G7
5-11. Rudder Rigging Tool......................................................................................................... 1G8
5-12. Clamping Rudder Pedals................................................................................................... 1G8
5-13. Rudder and Stabilator Travel Adjustments........................................................................ 1G10
5-14. Rudder Trim Control......................................................................................................... 1G11
5-15. Flap Controls..................................................................................................................... 1G13
5-16. Flap Step Adjustment........................................................................................................ 1G14
5-17. Flap Rigging Tool.............................................................................................................. 1G14
5-18. Fabricated Aileron Bellcrank Rigging Tool ...................................................................... 1G16
5-19. Fabricated Aileron and Flap Rigging Tool........................................................................ 1G17
5-20. Fabricated Stabilator Rigging Tool.................................................................................... 1G18
5-21. Fabricated Rudder Rigging Tool ....................................................................................... 1G19
6-1. Schematic Diagram of Hydraulic System (Prestolite)....................................................... 1H8
6-1a. Schematic Diagram of Hydraulic System (Oildyne)......................................................... 1H9
6-2. Hydraulic System Installation ........................................................................................... 1H10
6-2a. Hydraulic System Installation (SN’s 2837001 & up, PA-28R-201) and
(SN’s 2803001 & up, PA-28R-201T and up.)................... 1H11
6-3. Hydraulic Pump/Reservior Exploded Vew (Prestolite)..................................................... 1H14
6-3a. Hydraulic Pump/Reservoir Exploded View (Oildyne)...................................................... 1H15
6-4. Tests and Adjustments of Hydraulic Pump....................................................................... 1H16
6-5. Checking Aligning Brackets of Gear Back-Up Extender Actuator................................... 1H21
6-6. Gear Back-Up Extender Actuator...................................................................................... 1H22
6-7. Nose Gear Actuating Cylinder .......................................................................................... 1I3
6-8. End Gland Locking Device............................................................................................... 1I5
6-9. Main Gear Actuating Cylinder.......................................................................................... 1I6
6-10. Gear Back-Up Extender Actuator Aligning Tool.............................................................. 1I19
7-1. Nose Gear Oleo Strut Assembly........................................................................................ 1J3
7-2. Nose Gear Installation....................................................................................................... 1J6
7-3. Nose Gear Adjustment (PA-28R-201)............................................................................... 1J9
7-4. Nose Gear Adjustment (PA-28R-201T) ............................................................................ 1J10
7-5. Clamping Rudder Pedals in Neutral Position.................................................................... 1J12
7-6. Rudder Pedals at Neutral Angle........................................................................................ 1J12
7-7. Nose Gear Door Retraction Mechanism (PA-28R-201).................................................... 1J13
7-8. Nose Gear Door Retraction Mechanism (PA-28R-201T) ................................................. 1J14
7-9. Main Gear Oleo Strut Assembly ....................................................................................... 1J15
7-10. Main Gear Installation....................................................................................................... 1J17
7-11. Aligning Main Gear........................................................................................................... 1J19
7-12. Adjustment of Nose Gear Down Limit Switch ................................................................. 1K6
7-13. Adjustment of Main Gear Down Limit Switch................................................................. 1K6
7-14. Flap Torque Tube Cam Gear Warning Switch Installation................................................ 1K8
7-15. Throttle Warning Switch ................................................................................................... 1K9
7-16. Nose Wheel Assembly ...................................................................................................... 1K11
7-17. Main Wheel Assembly...................................................................................................... 1K12
7-18. Wheel Brake Assembly..................................................................................................... 1K13
7-19. Removal of Anchor Bolt ................................................................................................... 1K15
Revised: 2/13/89
1A6
LIST OF ILLUSTRATIONS (cont)
Aerofiche
Figure Grid No.
7-20. Installation of Anchor Bolt................................................................................................ 1K16
7-21. Brake System Installation.................................................................................................. 1K18
7-22. Brake Master Cylinder (Hand/Parking Brake).................................................................. 1K19
7-23. Toe Brake Installation........................................................................................................ 1K20
7-24. Brake Cylinder (1700) (Toe Brake)................................................................................... 1K21
7-25. Brake Cylinder (10-27) (Toe Brake) ................................................................................. 1K21
7-26. Bleeding Brakes................................................................................................................. 1L1
7-27. Nose Gear Service Tolerances........................................................................................... 1L9
7-28. Main Gear Service Tolerances........................................................................................... 1L12
8-1. Engine Cowling Installation.............................................................................................. 2A13
8-3. Propeller Installation ......................................................................................................... 2A14
8-4. Propeller Blade Minor Repair ........................................................................................... 2A16
8-5. Propeller Governor............................................................................................................ 2A17
8-6. Engine Installation............................................................................................................. 2A20
8-7. Schematic Diagram of Turbocharger System.................................................................... 2A23
8-8. Induction System Installation............................................................................................ 2B5
8-8a. Magneto Assembly............................................................................................................ 2B7
8-9. Contact Spring Inspection ................................................................................................. 2B8
8-10. Contact Points.................................................................................................................... 2B9
8-11. Impulse Coupling .............................................................................................................. 2B10
8-12. Flyweight Clearance of Impulse Coupling........................................................................ 2B10
8-13. Rotor Holding Tool Installed............................................................................................. 2B11
8-14. Timing Kit Installed........................................................................................................... 2B11
8-15. Cast-In Timing Marks........................................................................................................ 2B12
8-16. Fabricated Pointer.............................................................................................................. 2B12
8-17. Engine Timing Marks........................................................................................................ 2B13
8-18. Removing Spring From Lead Assembly........................................................................... 2B15
8-19. Assembly Tool................................................................................................................... 2B17
8-20. Assembly Tool Application............................................................................................... 2B17
8-21. Measuring Lead Assembly Length.................................................................................... 2B17
8-22. Ferrule Seating Tool .......................................................................................................... 2B19
8-23. Measuring Wire From Top of Ferrule ............................................................................... 2B19
8-24. Needle................................................................................................................................ 2B19
8-25. Installing Grommet Over Lead Assemblies...................................................................... 2B19
8-26. Lead Assembly Installed in Grommet............................................................................... 2B20
8-27. Wire Doubled Over For Installation of Eyelet .................................................................. 2B20
8-28. Ignition Schematic............................................................................................................. 2B21
8-29. Removing Frozen Spark Plug............................................................................................ 2B23
8-30. Lubrication System Maintenance Points........................................................................... 2B24
8-31. Schematic Diagram of Fuel Injection System................................................................... 2C2
8-32. Fuel Injection Nozzle Assembly ....................................................................................... 2C3
8-33. Engine Controls................................................................................................................. 2C4
8-34. Idle Speed and Mixture Adjustment Points....................................................................... 2C6
8-35. Sectional View of Altitude Compensating Fuel Pump Assembly..................................... 2C8
8-36. Exhaust Bypass Screw....................................................................................................... 2C10
8A-l. Propeller Installation (Hartzell)......................................................................................... 2C21
8A-2. Propeller Blade Minor Repair ........................................................................................... 2C22
8A-3. Propeller Governor............................................................................................................ 2C24
8A-3a. Engine Cowling Installation.............................................................................................. 2D2
8A-4. Engine Installation (PA-28R-201)..................................................................................... 2D4
8A-4a. Adjustment of Engine Controls......................................................................................... 2D7
8A-5. Fuel Injector....................................................................................................................... 2D8
8A-6. Schematic Diagram of RSA Injector System.................................................................... 2D9
Interim Revision: 2/21/95
1A7
LIST OF ILLUSTRATIONS (CONT)
Aerofiche
Figure Grid No.
8A-7. Fuel-Air Bleed Nozzle....................................................................................................... 2D11
8A-8. Contact Points.................................................................................................................... 2D13
8A-9. Rotor Holding Tool Installed............................................................................................. 2D14
8A-10. Timing Kit Installed........................................................................................................... 2D14
8A-11. Aligning Timing Marks..................................................................................................... 2D15
8A-12. Checking Flyweight Clearance of Impulse Coupling ....................................................... 2D15
8A-13. Engine Timing Marks........................................................................................................ 2D17
8A-14. Magneto Adjustment Limits.............................................................................................. 2D17
8A-15. Magneto Timing Mark....................................................................................................... 2D18
8A-16. Removing Spring From Lead Assembly........................................................................... 2D18
8A-17. Assembly Tool................................................................................................................... 2D19
8A-18. Using Assembly Tool ........................................................................................................ 2D19
8A-19. Measuring Lead Assembly Length.................................................................................... 2D19
8A-20. Cutting Metallic Braid From End of Lead ........................................................................ 2D21
8A-21. Unbraiding Metallic Shielding.......................................................................................... 2D21
8A-22. Forming Shielding Around Ferrule................................................................................... 2D21
8A-23. Ferrule Seating Tool .......................................................................................................... 2D21
8A-24. Needle................................................................................................................................ 2D21
8A-25. Measuring Wire From Top of Ferrule ............................................................................... 2D23
8A-26. Installing Grommet Over Lead Assemblies ...................................................................... 2D23
8A-27. Lead Assembly Installed in Grommet............................................................................... 2D23
8A-28. Wire Doubled Over For Installation of Eyelet .................................................................. 2D23
8A-29. Removing Spark Plug Frozen to Bushing ......................................................................... 2E1
9-1. Fuel System Diagram (PA-28R-201)................................................................................. 2E11
9-1a. Fuel System Diagram (PA-28R-201 S/N’s 37001 and up)................................................ 2E12
9-2. Fuel System Diagram (PA-28R-201T).............................................................................. 2E13
9-3. Fuel Sender Units Installation........................................................................................... 2E15
9-4. Engine Primer System Placard.......................................................................................... 2E16
9-5. Fuel Quantity Indicator...................................................................................................... 2E19
9-6. Fuel Filter Bowl and Screen.............................................................................................. 2E20
9-7. Fuel Pump Variable Resistor............................................................................................. 2E21
9-8. Tolerance, Union Nut and Tubing..................................................................................... 2F2
10-1. Instrument Panel (Typical) ................................................................................................ 2F11
10-1a. Instrument Panel(PA-28R-201 S/N’s 2837001 and up)..................................................... 2F12
10-1b. Instrument Panel (PA-28R-201T S/N’s 2803001 and up)................................................. 2F13
10-2. Pitot Static System............................................................................................................. 2F14
10-3. Vacuum-Auxiliary Vacuum System .................................................................................. 2F16
11-2. Lamp-Bank Load............................................................................................................... 2G20
11-3. Checking Field Circuit ...................................................................................................... 2G21
11-4. Testing Field Circuit.......................................................................................................... 2G21
11-5. Testing Rectifiers (Positive).............................................................................................. 2G22
11-6. Testing Rectifiers (Negative)............................................................................................. 2G23
11-7. C-3928 Fixtures and Adapters........................................................................................... 2G24
11-8. Removing Rectifiers.......................................................................................................... 2G24
11-9. Installing Rectifiers ........................................................................................................... 2H1
11-10. Soldering Rectifiers Lead.................................................................................................. 2H2
11-11. Testing Stator Coils ........................................................................................................... 2H3
11-12. Removing End Bearing ..................................................................................................... 2H4
Revised: 2/13/89
1A8
LIST OF ILLUSTRATIONS (CONT)
Aerofiche
Figure Grid No.
11-13. Installing End Bearing....................................................................................................... 2H4
11-14. Removing Drive Pulley..................................................................................................... 2H5
11-15. Removing Drive End Bealing ........................................................................................... 2H5
11-16. Removing Slip Ring. ......................................................................................................... 2H6
11-17. Installing Slip Ring............................................................................................................ 2H6
11-18. Solder Points...................................................................................................................... 2H7
11-19. Installing Retainer ............................................................................................................. 2H7
11-20. Installing Drive End Shield and Bearing (Typical)........................................................... 2H8
11-21. Installing Pulley................................................................................................................. 2H8
11-22. Meter Connections for Alternator Performance Test ........................................................ 2H10
11-23. Exploded View of Prestolite Alternator............................................................................. 2H12
11-24. Removal of Slip Ring End Bearing................................................................................... 2H13
11-25. Removal of Rectifier ......................................................................................................... 2H13
11-26. Removal of Drive End Head (PA-28R-201 only).............................................................. 2H14
11-27. Removal of End Head Bearing (Typical).......................................................................... 2H14
11-28. Testing Rotor for Ground .................................................................................................. 2H15
11-29. Testing Rotor for Shorts .................................................................................................... 2H15
11-30. Installation of Drive End Head.......................................................................................... 2H16
11-31. Installation of Rectifier...................................................................................................... 2H16
11-32. Temminal Assembly.......................................................................................................... 2H17
11-33. Slip Ring End Bearing Assembly...................................................................................... 2H18
11-34. Testing Alternator.............................................................................................................. 2H18
11-35. Brush Installation............................................................................................................... 2H19
11-36. Internal Wiring Diagram.................................................................................................... 2H19
11-37. Exploded View of Gear Reduction Starting Motor (PA-28R-201) ................................... 2H21
11-38. Exploded View of Starting Motor (PA-28R-201T)........................................................... 2H22
11-39. Tuming Starting Motor Commutator................................................................................. 2H23
11-40. Testing Motor Armature for Shorts................................................................................... 2H23
11-41. Testing Motor Fields for Grounds..................................................................................... 2H24
11-42. No-Load Test Hook-Up..................................................................................................... 2H24
11-43. Stall-Torque Hook-Up....................................................................................................... 2I1
11-44. Strobe Light Connections (Earlier Models) ...................................................................... 2I7
11-44a. Strobe Light Connections (Later Models)......................................................................... 2I8
11-44b. Ignition Switch .................................................................................................................. 2I12
11-45. Temminal Block ................................................................................................................ 2I13
NOTE: (Electrical Schematics Figures 11-46 thru 11-67, see Table XI-VIII.)
12-1. ELT Schematic Typical...................................................................................................... 2K3
12-2. ELT Portable Folding Antenna (Narco) ............................................................................ 2K4
12-3. ELT Using Fixed Aircraft Antenna (Narco)...................................................................... 2K4
13-1. Cabin Heater and Defroster (PA-28R-201) ....................................................................... 2K7
13-2. Cabin Heater and Defroster (PA-28R-201T)..................................................................... 2K8
13-3. Ovemead Vent System and Fresh Air System................................................................... 2K9
Revised: 2/13/89
1A9
LIST OF ILLUSTRATIONS (CONT)
Aerofiche
Flgure Grid No.
14-1. Air Conditioning System Installation................................................................................ 3A8
14-2. Service Valves ................................................................................................................... 3A12
14-3. Test Gauge and Manifold Set ............................................................................................ 3A13
14-4. Manifold Set Operation..................................................................................................... 3A14
14-5. Leak Test Hook-Up ........................................................................................................... 3A15
14-6. Evacuation Hook-Up......................................................................................................... 3A17
14-7. Charging Stand.................................................................................................................. 3A19
14-8. Charging Hook-Up............................................................................................................ 3A20
14-8a. Top Dead Center Casting Mark (Sankyo Compressor)..................................................... 3B1
14-8b. Rotation of Clutch Front Plate (Sankyo Compressor Oil Check) ..................................... 3B1
14-9. York Compressor and Fabricated Oil Dipstick (PA-28R-201).......................................... 3B2
14-9a. Compressor and Altemator Belt Installation..................................................................... 3B3
14-10. Magnetic Clutch (York Compressor)................................................................................. 3B6
14-11. Condenser Air Scoop Installation...................................................................................... 3B9
14-12. Expansion Valve................................................................................................................ 3B10
14-13. Components Installation.................................................................................................... 3B11
14-14. Adjustment of Air Conditioning Throttle Switch (PA-28R-201)...................................... 3B13
14-15. Air Conditioning Wiring Schematic.................................................................................. 3B14
14-16. Oxygen Installation ........................................................................................................... 3C2
14-17. Test Apparatus for Testing Oxygen System...................................................................... 3C3
14-18. Oxygen Tubing Installations.............................................................................................. 3C4
14-19. Installation of Swageloc Fittings....................................................................................... 3C7
14-20. Portable Oxygen Installation............................................................................................. 3C14
LIST OF TABLES
Aerofiche
Table Grid No.
II-I. Leading Particulars and Principal Dimensions.................................................................. 1A24
II-II. Recommended Torques ..................................................................................................... 1B3
II-III Recommended Engine Lubrication Oils ........................................................................... 1C2
II-IV Thread Lubricant............................................................................................................... 1C3
II-V ConversionTables .............................................................................................................. 1C4
II-VI Lubrication Specification .................................................................................................. 1C10
III-I Inspection Report............................................................................................................... 1D5
IV-I Balance Specifications....................................................................................................... 1E24
IV-II Maximum Distance Between Supports For Fluid Tubing................................................. 1F2
IV-III Hose Clamps Tightening (Initial Installation)................................................................... 1F2
V-I Control Surface Travel and Cable Tension........................................................................ 1F8
V-II Cable TensionVs. Ambient Temperature........................................................................... 1F10
V-III Troubleshooting Chart (Surface Controls) ........................................................................ 1G20
VI-I Leading Particulars, Hydraulic System............................................................................. 1H12
VI-II Characteristics, Hydraulic Pump Motor............................................................................ 1H18
VI-III Hydraulic System Troubleshooting................................................................................... 1I10
VII-I Toe-In-Toe-Out Correction Chart...................................................................................... 1K4
VII-II Troubleshooting Chart (Landing Gear)............................................................................. 1L2
VII-III Nose Gear Service Tolerances........................................................................................... 1L10
VII-IV Main Gear Service Tolerances........................................................................................... 1L13
Revised: 2/13/89
1A10
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Piper PA-28R Arrow, Arrow III, Turbo Arrow III Aircraft Full Service & Repair Manual
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