1961–1971 Piper Cherokee PA-28-140, PA-28-150, PA-28-160, PA-28-180, PA-28-235, PA-28R-180 & PA-28R-200 Aircraft Service Manual (P/N 753-586)

This Piper Cherokee service manual, P/N 753-586, covers the 1961–1971 PA-28-140, PA-28-150, PA-28-160, PA-28-180, PA-28-235, PA-28R-180, and PA-28R-200. The supplied edition includes interim revisions dated February 27, 2004.

• Airframe and flight controls: Structural inspections, fiberglass and thermoplastic repair, control-surface balancing, and rigging procedures for ailerons, stabilators, rudders, and flaps.

• Landing gear and brakes: Fixed and retractable landing-gear service, oleo-strut repair, brake-master-cylinder overhaul, brake bleeding, and gear-door and switch adjustments.

• PA-28R hydraulics: Pump testing, actuating-cylinder repair, gear back-up extender checks, and the Schematic Diagram of Hydraulic System.

• Powerplant and fuel: Engine removal and installation, magneto timing, carburetor and fuel-injector servicing, propeller-governor adjustment, and fuel-quantity-transmitter calibration.

• Electrical and instruments: Charging- and starting-system troubleshooting, wiring diagrams, vacuum-system diagnosis, pitot-static layouts, and instrument removal and replacement.

• Cabin systems and ELT: Heating, ventilation, air-conditioning tests and component replacement, plus Emergency Locator Transmitter battery replacement and operational checks.

Piper specifies qualified personnel for the work described here, including the rigging, pressure-testing, and electrical procedures.

Airframe Inspection and Control Rigging

Ground handling, scheduled servicing, and structural airframe inspections are organized by system. More than 150 illustrations include access-panel layouts, Three-View drawings, and Station Reference Lines; the Lubrication Chart identifies routine service points.

Control procedures distinguish overhead and floor-mounted stabilator trim arrangements. Repair methods address fiberglass wing tips and ABS thermoplastic wheel and strut fairings. Reference tables cover control-surface travel, cable tensions, and airframe nut-and-bolt torques.

Flight-control and landing-gear work requires current, applicable service data and approved tolerances.

Landing-Gear Fault Isolation

PA-28R troubleshooting separates electrical-control faults from hydraulic-supply problems and gear-mechanism faults. This helps identify which part of the retraction or extension system needs attention before components are replaced.

The brake sections distinguish hand/parking-brake and toe-brake master cylinders, with gravity and pressure bleeding procedures. Retractable-gear instructions cover downlocks, door alignment, and limit-switch adjustment.

Lycoming Installation and Fuel-System Service

Fixed-gear models use carbureted Avco-Lycoming engines; the PA-28R section covers fuel injection, including the RSA system and fuel-air bleed nozzles. Induction-air components, lubrication, engine installation, and oil-cooler installation receive separate treatment.

Fuel System Diagrams distinguish the PA-28-235's tip-tank arrangement from the other installations. Plunger-pump and Weldon rotary-pump sections provide inspection, pressure-check, and adjustment procedures. Transmitter checks include a dimensioned checking jig and fuel-gauge tolerance tables.

Powerplant coverage centers on servicing, installation, minor repairs, and troubleshooting. Major engine and component repairs require the relevant manufacturer's publications.

Electrical Diagnosis and Autopilot Coverage

Electrical sections distinguish Delco-Remy generator equipment from Chrysler and Prestolite alternator installations, with regulator checks and starter-motor repair. Wiring diagrams are separated by model and serial-number range.

Vacuum-system and pitot-static troubleshooting accompany the instrument procedures. The ELT section includes transmitter and pilot remote-switch tests. AutoControl and other autopilot servicing requires separate equipment-specific manuals referenced in the text.

Cabin Heat and Air Conditioning

Exhaust-system inspection supports cabin-heater service. Air-conditioning coverage includes leak detection, evacuation and charging, condenser-door rigging, the Air Conditioning Wiring Schematic, and Temperature Pressure Chart.

The magnetic-clutch notes identify pulley-groove and bearing damage caused by improper puller placement. Internal compressor servicing is assigned to a suitably equipped specialist shop.

A Preview of Oleo-Strut Reference Dimensions

These two nose-strut dimensions are a small sample of the landing-gear data in the manual. Fixed-gear PA-28 models have a specified exposed piston length of 3.25 ± 0.25 inches; the PA-28R specification is 2.75 ± 0.25 inches.

Both values apply under normal static load, defined in the servicing instructions as the airplane's empty weight plus full fuel and oil.

Text Search, Bookmarks, and PDF Contents

Finding procedures and diagrams: Existing OCR supports text searches across much of the manual, with gaps in tables and drawings. Embedded bookmarks reach sections, procedures, figures, and tables. Small wiring labels require zooming.

The download is one printable 916-page PDF containing all four Aerofiche card sections. Its four section covers, four revision-status pages, and 28 intentionally blank pages are already included in that total.