Table Of Contents - Piper PA-24 Comanche Service Manual

Table of Contents

Table Of Contents5
List Of Illustrations7
List Of Tables14
Scope Of Manual18
Handling And Servicing22
Three-View26
Access Panels And Plates31
Leading Particulars And Principle Dimensions32
Access Panels And Plates Diagram42
Torque Wrenches44
Recommended Nut Torques45
Flare Fitting Torques48
Jacking49
Weighing49
Leveling50
Mooring52
Parking52
Locking Airplane53
Towing53
Taxiing53
External Power Receptacle53
Cleaning54
Servicing55
Servicing Landing Gear56
Servicing Oleo Struts56
Filling Oleo Struts57
Servicing Brake System58
Inflating Oleo Struts58
Filling Brake System Reservoir58
Draining Brake System58
Servicing Power Plant59
Servicing Propeller60
Fuel Systems60
Filling Fuel Tanks60
Draining Fuel Valve And Strainers61
Draining Fuel System62
Electrical System Servicing62
Oxygen System62
Filling Oxygen Cylinder63
Indicated Oxygen Cylinder Pressures For Given Ambient Temperatures63
Inspection - Overhaul Time Limits65
Testing For Leaks65
Removal Of Oxygen Cylinder And Regulator66
Installation Of Oxygen Cylinder And Regulator66
Filler Valve Removal And Installation67
Pressure Gauge Removal And Installation67
Outlets Removal And Installation67
Purging Oxygen System68
Cleaning Of Face Masks68
Oxygen System Troubleshooting68
Oil System Servicing69
Draining Oil Sump69
Filling Oil Sump69
Recommended Lubricating Oils69
Oil Screen (Suction)70
Oil Screen (Pressure)70
Oil Filter (Full Flow)71
Recommendations For Changing Oil71
Lubrication Instructions71
Application Of Oil72
Application Of Grease72
Lubrication Chart72
Decimal Equivalents Table73
Control Column Lubrication78
Step Lock Mechanism Lubrication79
Flap Track Lubrication80
Nose Landing Gear Lubrication81
Stabilator Lubrication83
Rudder Control Lubrication84
Bellcrank Lubrication85
Propeller Lubrication86
Main Landing Gear Lubrication87
Inspection88
Inspection Requirements89
Preflight89
Special Inspections90
Exhaust System Inspection90
Typical Muffler Fatigue Areas View91
Exhaust System Inspection Points92
Inspection Report94
Structure104
Wing Assembly Removal106
Wing Tip Removal106
Landing Light And Housing Removal106
Landing Light Installation107
Aileron Removal107
Flap Removal107
Wing Removal108
Fin Removal109
Stabilator Removal109
Fuselage Components Removal109
Door Assembly Removal109
Wing Attachment Fittings View110
Wing Installation111
Flap Installation111
Aileron Installation112
Landing Light And Housing Installation113
Heated Pitot Tube113
Fin Installation113
Rudder Installation113
Stabilator Installation114
Tail Fairings Installation114
Windshield Replacement114
Cabin Door Installation115
Door Locking Mechanism Adjustment115
Door Locking Mechanism Installation116
Adf Loop Antenna Installation118
Marker Beacon Antenna Installation118
Fiberglas Repair118
Fiberglas Touch-Up And Surface Repairs118
Fibegrlas Fracture And Patch Repairs119
Structural Repairs120
Stabilator Repair (Horizontal Tail Surface)121
Ruddr Repair121
Balancing Stabilator121
Stabilator Balance Weight122
Stabilator Trim Tab123
Checking Stabilator Free Play124
Rudder Checking And Balancing125
Aileron Balancing126
Checking And Balancing Rudder127
Fuselage Skin Diagram128
Wing And Empennage Skin Diagram129
Typical Access Holes134
Surface Controls135
Control Surface Travel And Cable Tension137
Control Column Assembly Removal139
Control Column Assembly Installation140
Correct Method Of Installing Rod End Bearings145
Aileron Controls146
Aileron Control Cables Installation147
Bellcrank Checking Tool Installation150
Aileron Adjusting Points View150
Aileron Control Rigging And Adjustment151
Manually Operated Flaps151
Flap Control Installation Diagram152
Electrically Operated Flaps155
Electrically Operated Flap Controls Rigging And Adjustment157
Flap Controls Removal158
Flap Controls Installation158
Flap Control Rigging And Adjustment159
Rudder Controls Removal160
Rudder Controls Installation160
Rudder Controls Rigging And Adjustment160
Determining Neutral Rudder Position161
Checking Rudder Travel161
Rudder And Rudder Trim Control View162
Clamping Rudder Pedals In Neutral Position164
Rudder Trim Controls165
Rudder Trim Mechanism Removal, Rigging And Adjustment165
Stabilator Controls Removal165
Stabilator And Stabilator Trim Controls View167
Stabilator Control Installation171
Checking Stabilator Travel171
Stabilator Controls Rigging And Adjustment172
Stabilator Trim Controls172
Stabilator Trim Mechanism Removal172
Stabilator Trim Mechanism Installation173
Stabilator Trim Mechanism Rigging And Adjustment173
Stabilator Trim Drum Wrapping174
Stabilator Adjustment Point View174
Surface Controls Troubleshooting175
Landing Gear And Brake System , 1 H1189
Nose Landing Gear193
Nose Gear Oleo Disassembly193
Nose Gear Oleo Cleaning, Inspection And Repair193
Nose Gear Oleo Strut View194
Nose Gear Oleo Assembly195
Nose Landing Gear Removal198
Nose Landing Gear Cleaning, Inspection And Repair202
Nose Landing Gear Installation202
Nose Gear Drag Links Adjustment203
Nose Landing Gear Alignment207
Rudder Pedals At Neutral Angle207
Nose Gear Door Assembly Removal208
Nose Gear Door Assembly Cleaning, Inspection And Repair209
Nose Landing Gear Doors Installation209
Nose Landing Gear Door Adjustment209
Nose Landing Gear Door Assembly Removal, Inspection And Repair209
Nose Landing Gear Doors Adjustment210
Main Landing Gear210
Main Gear Oleo Disassembly210
Main Gear Oleo Cleaning, Inspection And Repair211
Main Gear Oleo Assembly211
Main Landing Gear Removal213
Main Landing Gear Cleaning, Inspection And Repair213
Main Gear Oleo Strut Assembly View214
Main Gear Side Brace Link Travel216
Main Gear Side Brace Bearing Tolerance216
Main Gear Side Brace Link Tolerance217
Main Gear Side Brace Links And Rod End Bearings Inspection218
Main Landing Gear Installation218
Main Gear Side Brace Links Adjustment224
Main Landing Gear Alignment224
Main Landing Gear Door Assembly Removal And Repair225
Main Landing Gear Door Assembly Installation226
Main Landing Gear Doors Adjustment226
Wiper Strip On Landing Gear Struts Replacement226
Landing Gear Retraction System227
Gear Retraction Transmission Assembly Removal227
Gear Retraction Transmission Cleaning, Inspection And Repair227
Retraction Transmission Assembly Installation229
Nose Gear Push-Pull Control Rod Removal231
Main Landing Gear Push-Pull Control Cables Removal231
Retraction Push-Pull Controls Cleaning, Inspection And Repair232
Nose Landing Gear Push-Pull Control Rod Installation232
Main Landing Gear Push-Pull Control Cable Installation232
Landing Gear Retraction System Adjustment233
Landing Gear Safety Switch Adjustment234
Gear Down Limit Switch Adjustment234
Gear Retraction Transmission Assembly Adjustment234
Landing Gear Retraction System Installation235
Nose Gear Drag Link Clevis View236
Main Gear Push-Pull Cables Adjustment236
Main Gear Push-Pull Rod Adjustment237
Landing Gear Up Limit Switch View237
Gear Up Switch Adjustment238
Landing Gear Retraction Load Check241
Torque Wrench And Adapter Installation242
Landing Gear Down Safety Lock Adjustment244
Landing Gear Warning Switch Removal245
Landing Gear Warning Switch Installation245
Landing Gear Warning Switch Adjustment246
Landing Gear Warning Indicator Removal And Installation247
Landing Gear Warning Indicator Adjustment247
Nose Wheel Removal And Disassembly248
Nose Wheel Assembly Inspection248
Nose Wheel Assembly And Installation249
Main Wheel Removal And Disassembly249
Wheel Assembly Inspection250
Main Wheel Assembly And Installation250
Main Gear Wheel Removal And Disassembly251
Brake System253
Wheel Brake Assembly Removal And Disassembly253
Wheel Brake Assembly Cleaning, Inspection And Repair253
Wheel Brake Assembly Assembly And Installation254
Brake Assembly View256
Wear Limit Check (Brake System)256
Replacement Of Wheel Brake Disc258
Brakes Bleeding259
Brake System Installation261
Brake Master Cylinder Removal262
Brake Master Cylinder Disassembly, Cleaning And Repair262
Brake Master Cylinder Assembly262
Brake Master Cylinder Installation263
Brake Master Cylinder View265
Parking Brake Valve Removal266
Parking Brake Valve Disassembly, Cleaning And Inspection266
Parking Brake Valve Assembly266
Parking Brake Valve Installation267
Brake Cylinder Removal268
Brake Cylinder Disassembly268
Brake Cylinder Cleaning, Inspection And Repair268
Brake Cylinder Assembly268
Landing Gear And Brake System Troubleshooting271
Fabricated Plumb Bob Tool273
Fabricated Nose Wheel Alignment Jig274
Fabricated Spanner Wrench View275
Rod End Bearings Inspection277
Main Gear Wear Limits279
Nose Gear Wear Limits281
Aerofiche Cards287
Engine Timing. Marks288
Engine Timing Marks289
Propeller Installation289
Typical Nicks And Removal Methods289
Engine Installation (Pa-24-260 Turbocharged)289
Schematic Diagram Of Turbocharger System289
Schematic Diagram Of Rsa Fuel Injector System (Pa-24-260 Turbocharged)289
Fuel Injector289
Fuel Air Bleed Nozzle289
Timing Kit Installed289
Removing Frozen Spark Plug289
Turbo Oil Flow Check289
Power Plant294
Engine Cowling Removal297
Engine Cowling Cleaning, Inspection And Repair297
Engine Cowling Installation297
Propeller297
Removal Of Propeller298
Propeller Cleaning, Inspection And Repair299
Propeller Specifications303
Blade Track304
Propeller Governor Removal304
Propeller Governor Installation304
Adjustment Of Propeller Governor305
Engine Installation Diagram309
Installation Of Engine311
Removal Of Air Filter311
Air Filter Installation312
Carburetor Maintenance312
Carburetor Removal312
Carburetor Installation313
Adjustment Of Carburetor Controls313
Idle Speed And Mixture Adjustment314
Inspection Of Magnetos315
Magneto Removal317
Timing Procedure (Internal Timing)317
Retard Breaker Points Adjustment318
Installation And Timing Procedure (Timing Magneto To Engine)320
Vibrator Checking Procedure322
Harness Assembly323
Removal Of Harness323
Installation Of Harness324
Spark Plugs Removal324
Spark Plug Inspection And Cleaning325
Lubrication System326
Oil Pressure Relief Valve326
Oil Screens326
Oil Cooler327
Engine Troubleshooting329
Power Plant Pa-24-250 And Pa-24-260334
Power Plant Pa-24-250 And336
Carburetor Controls Adjustment368
Idle Speed And Mixture Adjustment (Carburetor)368
Fuel Injector Maintenance369
Fuel Injector Lubrication369
Fuel Injector Removal369
Preparation Of Fuel Injector For Shipping369
Rsa Fuel Injector System Schematic Diagram370
Preparation Of Fuel Injector For Service371
Fuel Injector Installation371
Throttle And Mixture Controls Adjustment (Fuel Injector)372
Idle Speed And Mixture Adjustment (Fuel Injector)372
Fuel Air Bleed Nozzles Removal373
Fuel Air Bleed Nozzles Cleaning And Inspection374
Fuel Air Bleed Nozzle Installation374
Ignition System374
Magneto Inspection374
Adjusting Retard Breaker Points -200 Series Magnetos377
Timing Magneto To Engine379
Ignition System Retard Breaker Magneto Installation382
Inspection Of Harness382
Harness Removal383
Harness Installation383
Engine/Carburetor Troubleshooting388
Power Plant Pa-24-400398
Magneto Breaker Points Adjustment417
Magneto Timing Marks View418
Installation Of Rotor Holding Tool And Timing Pointer419
Alignment Of Cam In Inspection Hole420
Transformer Assembly421
Removal Of Seized Spark Plug426
Power Plant Pa-24-260 (Turbocharged)435
Propeller Governor435
Protection Of Engine Mount447
Engine Shock Mounts447
Turbocharger Nomenclature447
Turbocharger Removal449
Turbocharger Installation449
Turbocharger System Schematic Diagram451
Turbocharger Adjustment452
Relief Valve Overboost Pressure452
Pressure Relief Valve Removal, Cleaning And Inspection452
Pressure Relief Valve Installation453
Alternate Air Door453
Indicator, Mixture Control (Egt)454
Mixture Control Indicator Troubleshooting454
Indicator Probe Installation455
Mixture Control Indicator Probe Installation456
Contact Points463
Oil Filter Element473
Engine (Turbocharged) Troubleshooting477
Fuel System488
Fuel Cells Removal489
Fuel Cell Installation490
Fuel System Schematic491
Fuel Cells Handling And Storage497
Fuel Cell Compartment498
Molded Nipple Fittings498
Fuel Quantity Indicating System Checks499
Fuel Sender Removal501
Fuel Sender Installation501
Fuel Cell Repair501
Fuel Selector Valves Removal502
Three Position Fuel Valve Servicing503
Servicing Five Position Fuel Valve (Hoof)504
Servicing Fuel Valve (Airborne Mechanisms)505
Installation Of Fuel Selector Valve505
Fuel System Cleaning506
Fuel Strainers506
Fuel Strainer, Bendix Plunger Pump507
Fuel Pump Removal And Replacement507
Fuel Pump, Bendix Plunger Type508
Late Plunger Pump510
Plunger Type Pump Resistance Check510
Servicing Of Fuel Pumps Bendix Model510
Performance Requirements For Motor Driven Fuel Pumps511
Fuel Pump Pressure Check512
Electric Fuel Pump Removal And Installation513
Pump Pressures (Fuel Injection)515
Engine Primer System (Carburetor Induction)515
Prime Pump515
Prime Jets516
Fuel Flow Gauge Damper (Fuel Injection System)516
Fuel System Troubeshooting517
Fabricated Fuel Quantity Transmitter Checking Jig518
Aerofiche Card525
Electrical System 3Ab525
Xheating And Ventilating 3F6525
Instruments 3F16525
Electronics 3H1525
Electrical System530
Generator System534
Checking Generator System536
Adjustments, Inspections, Tests And Maintenance Of Generator537
Generator Sectional View538
Unsteady Or Low Output Of The Generator540
Excessive Output Of The Generator540
Noisy Generator540
Generator Disassembly, Repair And Reassembly541
Field Coil Removal541
Armature Service541
Polarizing Generator542
Generator Service Test Specifications542
Cold Output542
Regulators543
Cutout Relay543
Voltage Regulator543
Current Regulator544
Resistances (Regulator)545
Temperature Compensation545
Regulator Polarity545
Regulator Maintenance545
Cleaning Contact Points (Regulator)546
Regulator Checks And Adjustments547
Voltage Setting547
Regulator Spring Replacement551
Radio By-Pass Condensers551
Regulator Armature Replacement551
High Points On Regulator Performace And Checks552
Generator Output Control And Relay Test Specifications552
Alternator System553
Alternator And Starter Wiring System Diagram554
Alternator Test And Maintenance555
Stator Checks557
Diode Checks557
Diode Replacement558
Slip Ring Servicing559
Drive End Frame Bearing Replacement And Lubrication559
Brush Replacement559
Heat Sink Replacement560
Alternator Service Test Specifications561
Alternator Checks Summary562
Checking Regulator Circuit563
Checking Relay565
Alternator Description566
Alternator System Checking567
Alternator Adjustments567
Alternator And Starter Wiring System Schematic568
Alternator Overhaul569
Alternator Disassembly569
Alternator Assembly572
Alternator Testing573
Alternator Nomenclature574
Regulator Components576
Regulator Overhaul576
Preparation For Testing Regulator577
Testing Regulator578
Regulator Adjustment578
Overvoltage Control579
Cranking Motor Check580
Cranking Motor Test And Maintenance580
Lock-Torque Test Check581
Cranking Motor Disassembly581
Cranking Motor Inspection And Repair582
Cranking Motor Reassembly583
Cranking Motor Service Test Specifications583
Gear Reduction Starting Motor Exploded View584
Starting Motor Removal And Disassembly586
Brushes Check586
Armature Check586
Field Coils Check587
Brush Holders Check587
Bendix Drive587
Starting Motor Assembly587
Starting Motor Bench Tests588
Starting Motor Central Circuit589
Starting Motor Service Test Specifications589
Methods Of Checking Generator Or Alternator Belt Tension590
Battery Servicing591
Hydrometer Reading And Battery Charge Percent591
Battery Charging591
Starting Through External Power Receptacble With Battery Depleted591
Battery Removal And Installation592
Battery Box Corrosion Prevention593
Checking Electrical Switches And Circuit Breakers593
Navigation Lights594
Lamp In Anti-Collistion Wing Tip Strobe Light Removal594
Lamp In Anti-Collistion Wing Tip Strobe Light Installation595
Anti-Collision And Wing Tip Strobe Light Systems Troubleshooting595
Anti-Collision Light Installation596
Circuit Load Charts597
Index Electrical System Schematic601
Electrical Wire Coding605
Electrical Symbols606
Electrical System Diagrams607
Electrical System Troubleshooting637
Cabin Heater And Ventilator System647
Heater Maintenance647
Cabin Heater, Defroster And Fresh Air System Diagram648
Instruments655
Vacuum-Gyro Instruments657
Pitot-Static Instruments657
Electrical Instruments658
Miscellaneous Instruments658
Instruments Removal And Installation659
Gyro Service659
Gyro Installation Inspection659
Gyro Handling And Shipping660
Vacuum System660
Vacuum Regulator Valve Removal, Installation And Adjustment660
Vacuum Pump Removal661
Vacuum Pump Installation662
Vacuum System Troubleshooting662
Instrument Panel View663
Face Mounted Instruments Removal And Replacement665
Cluster Mounted Instruments Removal And Replacement665
Directional Gyro665
Directional Gyro Indicator Troubleshooting666
Gyro Horizon666
Gyro Horizon Indicator Troubleshooting667
Rate Of Climb Indicator Troubleshooting668
Sensitive Altimeter668
Altimeter Troubleshooting669
Airspeed Indicator670
Airspeed Tubes And Indicator Troubleshooting670
Magnetic Compass Troubleshooting671
Manifold Pressure Gauge672
Manifold Pressure Indicator Troubleshooting672
Tachometer Indicator Troubleshooting672
Engine Oil Pressure Gauge Troubleshooting673
Fuel Pressure Gauge Troubleshooting674
Turn And Bank Indicator675
Oil Temperature Indicator Troubleshooting677
Fuel Quantity Indicators Troubleshooting678
Electronics682
Piper Automatic Locator Transmitter683
Avionic Antenna Locations684
Testing Locator Transmitter686
Automatic Locator Transmitter Inadvertent Activation687