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Piper APACHE PA-23-235 Service Manual

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SERVICE MANUAL

CARD 1 OF 6

PA-23-235 APACHE

PA-23-250 AZTEC

PA-23-250 (SIX PLACE) AZTEC

PIPER AIRCRAFT CORPORATION

PART NUMBER 753-564

July 15, 2006

1A1

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Page 1 SERVICE MANUAL CARD 1 OF 6 PA-23-235 APACHE PA-23-250 AZTEC PA-23-250 (SIX PLACE) AZTEC PIPER AIRCRAFT CORPORATION PART NUMBER 753-564 July 15, 2006...
Page 2 PIPER AZTEC SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Aztec Service Manual (P/N 753-564) originally published April 1, 1960 are as follows: Revisions Publication Date Aerofiche Card Effectivity CR681001 October 1, 1968 1, 2, 3, 4 and 5 CR720829...
Page 3 PIPER AZTEC SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A21 HANDLING AND SERVICING INSPECTION STRUCTURES 1F13 SURFACE CONTROLS 1I19 HYDRAULIC SYSTEM LANDING GEAR AND BRAKES VIII POWERPLANT (Normally Aspirated) VIIIA POWERPLANT (Air-Research Turbocharger) 3D17 VIIIB...
Page 4 PIPER AZTEC SERVICE MANUAL NOTE: An expanded, complete, Introduction is provided on Aerofiche Card No. 6 beginning on grid 6A7. Refer to it for the serial number effectivity of this manual. INTRODUCTION 07/15/06...
Page 5 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 2-1. Three-View of PA-23-250 and PA-23-235 ..... 2-2. Three-View of PA-23-250 (six place), S/N’s 27-2000 thru 27-2504...
Page 6 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 3-11. External Wear Patterns ........
Page 7 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 5-3. Aileron Controls ......... .
Page 8 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 6-14. Flow Diagram, Flap Selector Lever Up ......
Page 9 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 7-16. Reserved 7-17. Adjustment of Nose Gear Up Limit Switch .....
Page 10 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 8A-3. Typical Nicks and Removal Method ......
Page 11 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 9-6. Fuel System Diagram, PA-23-250 “F”, S/N’s 27-7654001 and up .......
Page 12 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 10-8. Instrument Panel, PA-23-250 (six place), S/N’s 27-7554001 thru 27-7554168 ..... . .
Page 13 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-33a. Alternator Blast Tube Routing .......
Page 14 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 13-1. Heating and Ventilating System, PA-23-235 and PA-23-250, S/N’s 27-1 thru 27-504 ....... . .
Page 15 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 13-35. Heater Fuel Filter .........
Page 16 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 14-21. Brush Block Assembly, PA-23-250 (six place), S/N’s 27-2505 and up ........
Page 18 PIPER AZTEC SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. II-I. Leading Particulars and Principle Dimensions ....1B13 II-11. Consumable Materials ........
Page 19 PIPER AZTEC SERVICE MANUAL LIST OF TABLES (cont.) Table Aerofiche Grid No. X-II. Instrument Markings - PA-23-250 (six place), S/N’s 27-2322 and up with Fuel Injected Induction System or AiResearch Turbocharger ......
Page 21 PIPER AZTEC SERVICE MANUAL SECTION I - AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS SUBJECT SECTION GRID NO. AIRWORTHINESS LIMITATIONS 1A23 Limitations 1A23 Inspections 1A23 Life Limited Parts Marking and Disposition 1A23 07/15/06 I - TABLE OF CONTENTS 1A21...
Page 22 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK I - TABLE OF CONTENTS 07/15/06 1A22...
Page 23 43.10 in a manner that does not affect part structural integrity, i.e. - no surface deformation such as vibration/etching allowed. Parts that have accumulated the life limit shall be disposed of in accordance with the applicable FARs. Piper recommends life limited parts with no time and/or cycles remaining be completely destroyed. 07/15/06...
Page 24 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK I - AIRWORTHINESS LIMITATIONS 07/15/06 1A24...
Page 25 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...
Page 26 PIPER AZTEC SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS Paragraph Grid No. 2-1. Introduction ..........
Page 45 PIPER AZTEC SERVICE MANUAL TABLE II-II. CONSUMABLE MATERIALS Material Specification Product Manufacturer Alcohol MC200 * See Note 1 Cartridge. Engine P/N AC6435683 A.C. Spark Plug Division, Oil Filter General Motors Corp. Flint, MI Cement EC-678 Minnesota Mining Co. St. Paul, MN EC-1300L Minnesota Mining Co.
Page 46 PIPER AZTEC SERVICE MANUAL TABLE II-II. CONSUMABLE MATERIALS (cont.) Material Specification Product Manufacturer Grease, Aircraft MIL-G-23827A *See Note 2 Royal Lubricants Co. MIL-G-3545 Roseland, NJ MIL-G-771 lA MIL-G-81322 MIL-G-3278A MIL-G-21164C Grease, Beacon Exxon Co., Box 2180 Houston, TX 77001 Grease, Lithium # 1925 Molytex “O”...
Page 47 PIPER AZTEC SERVICE MANUAL TABLE II-II. CONSUMABLE MATERIALS (cont.) Material Specification Product Manufacturer Sealant, Ribbon Dope Permacel 412 Avery International Corp. Thread Permacel, P.O. Box 671 New Brunswick, NJ 08903-0671 Sealer #1126 3M Center St. Paul, MN 55101 Sealer, Bead...
Page 48 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK II - HANDLING AND SERVICING 07/15/06 1B24...
Page 49 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 07/15/06 II - HANDLING AND SERVICING...
Page 53 PIPER AZTEC SERVICE MANUAL Figure 2-8a. Access Plates and Panels PA-23-250 (six place) Serial Nos. 27-4426 and 27-4574 and up 07/15/06 II - HANDLING AND SERVICING...
Page 67 PIPER AZTEC SERVICE MANUAL Figure 2-11. Jacking Arrangements 2-10. GROUND HANDLING. CAUTION: FAILURE TO FOLLOW GROUND HANDLING INSTRUCTIONS MAY RESULT IN SERIOUS DAMAGE TO THE AIRPLANE. 2-11. RESERVED. 2-12. JACKING. The airplane is provided with a jacking pad on each main spar just outboard of the engine nacelle and a support position by making use of the tail skid.
Page 69 PIPER AZTEC SERVICE MANUAL Figure 2-13. Longitudinal Leveling Figure 2-14. Lateral Leveling 2-14. LEVELING. All configurations of the airplane are provided with a means for longitudinal and lateral leveling. The airplane may be leveled while on jacks, during the weighing procedure while the wheels are on scales, or while the wheels are on the ground.
Page 72 PIPER AZTEC SERVICE MANUAL 2-21. CLEANING. 2-22. CLEANING ENGINE COMPARTMENT. Before cleaning the engine compartment, place a strip of tape on the magneto vents to prevent any solvent from entering these units. Place a large pan under the engine to catch waste.
Page 74 "Feather-Edge" the surface with fine wet or dry paper (400-600 grit). If gouges are deep, fill with polyester or epoxy filler. Sand lightly. Apply a coat of Epoxy Primer (8951/8678). Dry overnight and sand lightly. (For Piper Part No. refer to Table II-VII.) Apply a Polythane Enamel.
Page 83 PIPER AZTEC SERVICE MANUAL 2-43. SERVICING. 2-44. INTRODUCTION TO SERVICING. Servicing the airplane includes the replenishment of fuel, oil, hydraulic fluid, tire pressures, lubrication requirements and other items required to completely service the airplane. 2-45. HYDRAULIC SYSTEM. 2-46. SERVICING HYDRAULIC SYSTEM. The hydraulic system, which consists of the landing gear and flap actuating system, powerpak, and associated lines, should be checked and serviced every 100 hours.
Page 84 PIPER AZTEC SERVICE MANUAL 2-47. POWERPAK RESERVOIR. 2-48. FILLING POWERPAK RESERVOIR (GRAVITY). Open the access door or remove the left side panel on the nose to gain access to the hydraulic filler tube. (Refer to Figure 2-8.) Place the airplane on jacks. (Refer to Jacking, Paragraph 2-12.) Remove the cap of filler tube.
Page 95 PIPER AZTEC SERVICE MANUAL 2-70. FUEL SYSTEM. 2-71. SERVICING FUEL SYSTEM. At intervals of 50 hours or 90 days, whichever comes first, clean the screens and bowl in each fuel filter unit located between each bottom wing inboard gear door and fuselage.
Page 117 PIPER AZTEC SERVICE MANUAL SECTION INSPECTION - MOVED TO 1E23...
Page 118 PIPER AZTEC SERVICE MANUAL GRIDS 1E24 THRU 1F12 INTENTIONALLY BLANK 1E24...
Page 119 PIPER AZTEC SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS Paragraph Grid No. 4-1. Introduction ..........
Page 120 PIPER AZTEC SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS (CONT.) Paragraph Grid No. 4-38. Side Windows ..........
Page 121 PIPER AZTEC SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS (CONT.) Paragraph Grid No. 4-69. Fiberglass Repairs ........
Page 122 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK IV - TABLE OF CONTENTS 07/15/06 1F16...
Page 123 PIPER AZTEC SERVICE MANUAL SECTION IV STRUCTURES 4-1. INTRODUCTION. This section explains procedures for removal and installation of structural components of the airplane, for the check and balance of the stabilator and rudder and for the repair of structural surfaces on all models.
Page 124 PIPER AZTEC SERVICE MANUAL NOTE: Some airplanes are equipped with a small plate covering the top of the pin. If the cover plate is installed, loosen the screws on either side and slide the plate into the wing tip. Remove the screws attaching the wing tip to the wing.
Page 125 PIPER AZTEC SERVICE MANUAL Figure 4-1. Aileron and Flap Installation 07/15/06 IV - STRUCTURES 1F19...
Page 126 PIPER AZTEC SERVICE MANUAL Figure 4-1. Aileron and Flap Installation (cont.) IV - STRUCTURES 07/15/06 1F20...
Page 127 PIPER AZTEC SERVICE MANUAL Slide the aileron balance weight on the balance weight arm and secure with bolt and nut. Connect the aileron control tube to the hinge fitting at the center of the aileron with bushings, bolt and nut.
Page 128 PIPER AZTEC SERVICE MANUAL Remove the assemblies from the 1.50 inch O.D. tube. Center punch the two marked center line locations on the new assembly and drill .234 holes in one wall only. Place the new assembly onto the flap torque tube and align the two holes in the new assembly with the existing holes in the flap torque tube.
Page 129 PIPER AZTEC SERVICE MANUAL 4-12B. FLAP TORQUE TUBE REPLACEMENT. (See Figure 5-14.) In PA-23-250 S/N’s 27-7654001 and up (i.e. - with the Stabilator Trim / Flap Interconnect System), remove the forward interconnect cable using the applicable portion of the instructions in paragraph 5-57.
Page 130 PIPER AZTEC SERVICE MANUAL Lubricate the flap torque tube bearings per the Lubrication Chart, Section II. Make an appropriate logbook entry documenting the installation of P/N 104622-004. 4-13. WING. 4-14. REMOVAL OF WING. (Refer to Figure 4-2.) Remove wing root fairings, all wing inspection plates and panels, front fuselage side access panels and the bottom fuselage access panel.
Page 131 PIPER AZTEC SERVICE MANUAL Place a cradle under the airplane, lower and remove jacks. If necessary, retract gears slightly. Drain the hydraulic system. (Refer to Draining Hydraulic System, Section II.) Disconnect the fuel shut-off control cable at the fuel shut-off valve. Remove the cable clamp at the rib beside the valve and at the wing butt rib.
Page 132 PIPER AZTEC SERVICE MANUAL Prepare the various lines, control cables and wires for inserting into the wing or fuselage when the wing is slid into place. Slide the wing into the fuselage and butt the spar ends. (Maximum distance of .031 of an inch is permissible between spar caps.)
Page 133 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 07/15/06 IV - STRUCTURES...
Page 138 PIPER AZTEC SERVICE MANUAL m. Place the wing jacks under the wings and remove the supports. Connect the wires at the electrical wiring terminal block in the rear section of the fuselage access opening. Connect the oil pressure lines. Connect the hydraulic lines.
Page 139 PIPER AZTEC SERVICE MANUAL Disconnect the stabilator halves at the attachment fittings on the inboard end of each rear spar by removing nut, washer and bolt. Remove two bolts (close tolerance) with nuts and washers attaching the stabilator half to the torque tube.
Page 141 PIPER AZTEC SERVICE MANUAL Relieve tension from the rudder cables by loosening one turnbuckle at the rudder pedal torque tube. Disconnect the two control cables from the rudder horn by removing cotter pin, nut, washer and clevis bolt. Disconnect the rudder horn from the lower rudder hinge bracket by removing cotter pin, nut, washer and clevis bolt.
Page 142 PIPER AZTEC SERVICE MANUAL 4-30. INSTALLATION OF RUDDER TRIM TAB. CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. Align the hinge pin holes of the trim tab with the rudder and insert new pins.
Page 162 PIPER AZTEC SERVICE MANUAL Adjust the top and bottom locking pins (3 and 17) to allow adequate clearance between the fuselage door frame and the pins using appropriate tools. Operate the door several times to insure proper fit, positive locking and free movement of all parts.
Page 201 PIPER AZTEC SERVICE MANUAL TABLE V-I. CONTROL SURFACE TRAVEL AND CABLE TENSION 07/15/06 V - SURFACE CONTROLS 1I23...
Page 215 PIPER AZTEC SERVICE MANUAL 5-12. INSTALLATION OF AILERON BELLCRANK ASSEMBLY. (Refer to Figure 5-3.) Install the stop block (28) and torque bolts, if previously removed. Position the bellcrank (2S) with the adjustable stops (27) toward the outboard end of the wing.
Page 221 PIPER AZTEC SERVICE MANUAL Figure 5-5. Stabilator and Stabilator Trim Controls 07/15/06 V - SURFACE CONTROLS 1J19...
Page 222 PIPER AZTEC SERVICE MANUAL Figure 5-5. Stabilator and Stabilator Trim Controls (cont.) V - SURFACE CONTROLS 07/15/06 1J20...
Page 223 PIPER AZTEC SERVICE MANUAL Figure 5-5. Stabilator and Stabilator Trim Controls (cont.) 07/15/06 V - SURFACE CONTROLS 1J21...
Page 224 PIPER AZTEC SERVICE MANUAL Figure 5-5a. Trim Crank Pulley Inspection V - SURFACE CONTROLS 07/15/06 1J22...
Page 227 PIPER AZTEC SERVICE MANUAL 5-18. RIGGING AND ADJUSTMENT OF STABILATOR CONTROLS. Level the airplane. (Refer to Leveling, Section II.) Place the stabilator in a neutral position using a fabricated tool and bubble protractor as shown in Figure 5-7 or Figure 5-8. (The tool may be fabricated from dimensions given in Figure 5-17 or Figure 5-18.)
Page 233 PIPER AZTEC SERVICE MANUAL Position the stabilator in neutral and proceed to set tab travels. Turn the trim in each direction to screw stops. If tab travels do not agree with angles given in Table V-l, disconnect the control rod (item 33, Figure 5-5 or item 23, Figure 5-6) from the tab, loosen the jam nut on the forward end of the rod and turn the rod until the proper travels are obtained.
Page 241 PIPER AZTEC SERVICE MANUAL Attach a fabricated checking tool to the previously mentioned bolt and secure with washer and nut. (Refer to Figure 5-12.) (The tool may be fabricated from dimensions given in Figure 5-19.) Place a level on the edge of the tool, leveling the tool vertically.
Page 245 PIPER AZTEC SERVICE MANUAL Position the rudder in neutral and proceed to set tab travels. Turn the trim in each direction to screw stops. If tab travels do not agree with angles given in Table V-I, disconnect the control rod (30) from the tab, loosen the jam nut on the forward end of the rod and turn the rod until the proper travels are obtained.
Page 249 PIPER AZTEC SERVICE MANUAL 5-49. WING FLAP CONTROLS. 5-50. REMOVAL OF FLAP ACTUATOR ASSEMBLY. (Refer to Figure 5-14.) Disconnect the flap control rods allowing both flaps to hang free. Remove the two access plates from the outboard undersides of the fuselage at station 128.75.
Page 250 PIPER AZTEC SERVICE MANUAL Figure 5-14. Flap Control Installation V - SURFACE CONTROLS 07/15/06 1K24...
Page 251 PIPER AZTEC SERVICE MANUAL 5-52. RIGGING AND ADJUSTMENT OF FLAPS. Connect all the flap system linkages together, temporarily. Place the cockpit FLAP control lever in the DOWN position. Using the pedestal hand pump, lower the flaps till there is no movement. At this time the piston will be withdrawn into the flap actuating hydraulic cylinder as far as the bushing, located on it, permits it to go.
Page 252 PIPER AZTEC SERVICE MANUAL Figure 5-15. Flap Rigging Repeat all of the above procedures on the remaining flap. NOTE: Place a plain washer under the castellated nut in addition to the washer located between the control rod end bearing and the bellcrank at the left flap.
Page 253 PIPER AZTEC SERVICE MANUAL 5-53. REMOVAL OF FLAP POSITION SENDER. Remove the access plate from the outboard right underside of the fuselage just inboard of the flap. Disconnect the flap position indicator rod by removing the self-locking adjustment nut and withdraw the rod from the torque tube.
Page 257 PIPER AZTEC SERVICE MANUAL TABLE V-II. TROUBLESHOOTING - SURFACE CONTROLS Trouble Cause Remedy AILERON CONTROL SYSTEM Lost motion between Cable tension too low. Adjust cable tension, control wheel and aileron. (Refer to Para. 5-13.) Linkage loose or worn. Check linkage and tighten or replace.
Page 258 PIPER AZTEC SERVICE MANUAL TABLE V-II. TROUBLESHOOTING - SURFACE CONTROLS (cont.) Trouble Cause Remedy AILERON CONTROL SYSTEM (cont.) Correct aileron Incorrect rigging of Rig in accordance with travel cannot be aileron cables, control Para. 5-13. obtained by adjusting wheel and control tube bellcrank stops.
Page 259 PIPER AZTEC SERVICE MANUAL TABLE V-II. TROUBLESHOOTING - SURFACE CONTROLS (cont.) Trouble Cause Remedy STABILATOR CONTROL SYSTEM (cont.) Correct stabilator travel Stabilator cables Rig cables in accordance cannot be obtained by incorrectly rigged. with Para. 5-18. adjusting stabilator stops. STABILATOR TRIM CONTROL SYSTEM Lost motion between trim Cable tension too low.
Page 260 PIPER AZTEC SERVICE MANUAL TABLE V-II. TROUBLESHOOTING - SURFACE CONTROLS (cont.) Trouble Cause Remedy STABILATOR TRIM CONTROL SYSTEM (cont.) Trim control cable slippage. Worn trim crank pulley causing Inspect pulley per cable bottoming in pulley groove. Figure 5-5a. Replace pulley as required.
Page 261 PIPER AZTEC SERVICE MANUAL TABLE V-II. TROUBLESHOOTING - SURFACE CONTROLS (cont.) Trouble Cause Remedy RUDDER CONTROL SYSTEM Lost motion between Cable tension too low. Adjust cable tension rudder pedals and rudder. per Para. 5-34. Linkage loose or worn. Check linkage and tighten or replace.
Page 262 PIPER AZTEC SERVICE MANUAL TABLE V-II. TROUBLESHOOTING - SURFACE CONTROLS (cont.) Trouble Cause Remedy RUDDER TRIM CONTROL SYSTEM Lost motion between Cable tension too low. Adjust in accordance trim control handle and trim tab. with Para. 5-40. Cables not in place on Install cables according pulleys.
Page 263 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 07/15/06 V - SURFACE CONTROLS 1L13...
Page 264 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK V - SURFACE CONTROLS 07/15/06 1L14...
Page 271 SERVICE MANUAL CARD 2 OF 6 PA-23-235 APACHE PA-23-250 AZTEC PA-23-250 (SIX PLACE) AZTEC PIPER AIRCRAFT CORPORATION PART NUMBER 753-564 July 15, 2006...
Page 272 PIPER AZTEC SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Aztec Service Manual (P/N 753-564) originally published April 1, 1960 are as follows: Revisions Publication Date Aerofiche Card Effectivity CR681001 October 1, 1968 1, 2, 3, 4 and 5 CR720829...
Page 273 PIPER AZTEC SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A21 HANDLING AND SERVICING INSPECTION STRUCTURES 1F13 SURFACE CONTROLS 1I19 HYDRAULIC SYSTEM LANDING GEAR AND BRAKES VIII POWERPLANT (Normally Aspirated) VIIIA POWERPLANT (Air-Research Turbocharger) 3D17 VIIIB...
Page 274 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 6-1. Hydraulic System Schematic, PA-23-250, PA-23-235 and PA-23-250 (six place), S/N’s 27-2000 thru 27-2504 ..2A19 6-2. Hydraulic System Installation, PA-23-250, PA-23-235 and PA-23-250 (six place) S/N’s 27-2000 thru 27-2504...
Page 275 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 6-33. Hydraulic Filter ........
Page 276 PIPER AZTEC SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. VI-l. Leading Particulars, Hydraulic System ..... 2A17 VI-II. Leading Particulars, Powerpak Assembly ....
Page 324 PIPER AZTEC SERVICE MANUAL Remove drive gear (19), secondary gear (18), and secondary shaft (17) by pulling from centerplate (10). Remove drive shaft by pushing out of drive side. Remove centerplate with dowels by rocking it from side to side.
Page 385 PIPER AZTEC SERVICE MANUAL Figure 6-32. Priority Valve VI - HYDRAULIC SYSTEM 07/15/06 2E22...
Page 387 PIPER AZTEC SERVICE MANUAL Figure 6-33. Hydraulic Filter 6-120. REMOVAL AND INSTALLATION OF HYDRAULIC LINES. Remove a damaged hydraulic line by disconnecting the fittings at each end and by disconnecting where secured by brackets. Refer to Figure 6-2 or 6-4 as an aid in the location of attaching brackets and bends in the lines. Provide a small container for draining the line.
Page 388 PIPER AZTEC SERVICE MANUAL Clean filter bowl with a suitable cleaning solvent and dry. Replace filter element and "O" ring on bowl. Half fill filter bowl to minimize trapped air in the hydraulic system and replace bowl. Safety filter bowl with MS20995-C20 safety wire and replace the side panel on the engine cowl.
Page 444 PIPER AZTEC SERVICE MANUAL should be made with the latch springs (15) detached and manually holding the latch (13) in the closed position. When assured that the bolt is not binding, tighten jam nut and reassemble springs. CAUTION: IF THE ACTUATOR IS OVEREXTENDED, RATHER THAN OBTAINING THE FREE FIT FOR THE BOLT AS DESCRIBED ABOVE, EXCESSIVE PRESSURE MAY BEND OR SNAP THE DRAG LINKS.
Page 456 PIPER AZTEC SERVICE MANUAL Connect the carburetor heat or alternate air knobs. Screw on the nut that secures the cable to the placard. Screw on the inside nut. Install the spring and screw on the outside nut. Install the flap and landing gear selector knobs to their respective handles.
Page 457 PIPER AZTEC SERVICE MANUAL With the warning horn operating, lower the gear to insure that the horn and light cease to operate when the gear is down and locked. Remove the aircraft from the jacks. Flight test the aircraft to insure operation of...
Page 488 SERVICE MANUAL CARD 3 OF 6 PA-23-235 APACHE PA-23-250 AZTEC PA-23-250 (SIX PLACE) AZTEC PIPER AIRCRAFT CORPORATION PART NUMBER 753-564 July 15, 2006...
Page 489 PIPER AZTEC SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Aztec Service Manual (P/N 753-564) originally published April 1, 1960 are as follows: Revisions Publication Date Aerofiche Card Effectivity CR681001 October 1, 1968 1, 2, 3, 4 and 5 CR720829...
Page 490 PIPER AZTEC SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A21 HANDLING AND SERVICING INSPECTION STRUCTURES 1F13 SURFACE CONTROLS 1I19 HYDRAULIC SYSTEM LANDING GEAR AND BRAKES VIII POWERPLANT (Normally Aspirated) VIIIA POWERPLANT (Air-Research Turbocharger) 3D17 VIIIB...
Page 491 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 8-1. Cowl Flap Installation ........
Page 492 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 8A-17. Removal of Spring From Lead Assembly ....8A-18. Assembly Tool ........
Page 493 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 9-14. Fuel Selector Valve ........
Page 494 PIPER AZTEC SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. VIII-I. Propeller Specifications - PA-23-250; PA-23-235 and PA-23-250 (six place), S/N’s 27-2000 thru 27-2504 ..3A23 VIII-II. Propeller Specifications - PA-23-250 (six place), S/N’s 27-2505 and up...
Page 498 PIPER AZTEC SERVICE MANUAL SECTION VIII POWER PLANT (NORMALLY ASPIRATED) 8-1. INTRODUCTION. This section covers non-turbocharged powerplants used in PA-23 airplanes (as listed below) and is comprised of instructions for the removal, minor repair, service and installation of the engine cowling, propeller, propeller governor, engine, engine shock mounts, induction system, carburetor, fuel injector, fuel air bleed nozzle, ignition system and lubrication system.
Page 523 PIPER AZTEC SERVICE MANUAL Figure 8-6. Engine Installation, PA-23-235 and PA-23-250 S/N’s 27-1 thru 27-2504 VIII - POWER PLANT 07/15/06 (NORMALLY ASPIRATED) 3B12...
Page 524 PIPER AZTEC SERVICE MANUAL Figure 8-6. Engine Installation, PA-23-235 and PA-23-250 S/N’s 27-1 thru 27-2504 (cont.) 07/15/06 VIII - POWER PLANT (NORMALLY ASPIRATED) 3B13...
Page 525 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VIII - POWER PLANT 07/15/06 (NORMALLY ASPIRATED) 3B14...
Page 539 PIPER AZTEC SERVICE MANUAL —CAUTION— DO NOT EXCEED AIR PRESSURE GIVEN IN STEP A, BELOW AS INTERNAL DAMAGE TO THE INJECTOR MAY RESULT. SEE ADDITIONAL CAUTION IN PARAGRAPH 8-47. Remove plugs and drain all fuel from the injector. If available, apply 10 to 15 psi air pressure to the fuel inlet until all fuel is discharged from the injector.
Page 549 PIPER AZTEC SERVICE MANUAL Figure 8-17. Timing Kit Installed Figure 8-18. Breaker Compartment With Cast Timing Marks rotating magnet back to the point of main breaker opening. Hold the magnet in this position and move pointer to the "O" mark. Now turn magnet until pointer is over the required retard degree mark.
Page 558 8-79. INSPECTION AND ADJUSTMENT OF BALL JOINT EXHAUST SYSTEM. (See Figure 8-22.) NOTE: The following incorporates the requirements of Piper Service Bulletin No. 319 as referenced in AD 72-14-05. The ball joints are not intended to take up any misalignment; that is, they should never be angled in any direction to position the tailpipe in the firewall “chute.”...
Page 559 Support Bracket Assembly is installed (i.e. - in PA-23-250’s S/N’s 27-7304959 & up, and in PA-23-250’s S/N’s 27-2505 thru 27-7304958 with Piper Kit No. 760-702 installed). In that case, do not compress or stretch isolators, putting excessive load or severe bending on cables.
Page 560 PIPER AZTEC SERVICE MANUAL Figure 8-22. Adjustment of Ball Joint Exhaust System 07/15/06 VIII - POWER PLANT (NORMALLY ASPIRATED)
Page 561 PIPER AZTEC SERVICE MANUAL Figure 8-22. Adjustment of Ball Joint Exhaust System (cont.) VIII - POWER PLANT 07/15/06 (NORMALLY ASPIRATED)
Page 562 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING Trouble Cause Remedy CARBURETOR Failure of engine to start. Lack of fuel. Check fuel system for leaks. Fill fuel cell. Clean dirty lines, strainers, or fuelcocks. Underpriming. Prime with four or five strokes of primer.
Page 563 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy CARBURETOR (cont.) Failure of engine Mixture control in idle Open mixture control. to start (cont). cut-off. Shorted ignition switch Check and replace or or loose ground. repair. Failure of engine...
Page 564 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy CARBURETOR (cont.) Low power and Defective ignition wire. Check wire with electric uneven running tester. Replace defective engine (cont). wire. Defective spark plug Replace connectors on terminal connectors.
Page 565 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy CARBURETOR (cont.) Low oil pressure. Insufficient oil. Check oil supply. Dirty oil strainers. Remove and clean oil strainers. Defective pressure gauge. Replace gauge. Air lock or dirt in relief Remove and clean oil valve.
Page 566 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy CARBURETOR (cont.) High oil temperature (cont). Insufficient cooling air flow. Adjust cowl flaps, Para. 8-11. Loss of cooling air Check connection of oil through oil cooler. cooler to rear engine baffle,...
Page 567 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy CARBURETOR (cont.) Inaccurate oil Cold weather. In extremely cold weather pressure readings. oil pressure readings up to 100 pounds do not necessarily indicate malfunctioning. High or low pressure pressure...
Page 568 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy FUEL INJECTION (cont.) Failure of engine to start Air bubbles in fuel system. Check fuel vent. (cont.). Boost or auxiliary fuel pump Replace pump. failure. Fuel line restricted.
Page 569 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy FUEL INJECTION (cont.) Low power and Dirt in inlet screen. Remove screen and flush uneven running (cont). with solvent. Blow with compressed air. Dirt in “T” fitting. Remove “T” fitting at dis- tributor, clean in solvent.
Page 570 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy FUEL INJECTION (cont.) Failure of engine to develop Throttle linkage limiting Check throttle linkage and full power (cont.). travel of throttle valve. throttle valve opening. Restrictions in inlet Examine air scoop and air scoop.
Page 571 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy FUEL INJECTION (cont.) High oil temperature. Insufficient cylinder cooling. Check front, rear, and- side engine baffles for proper installation and sealing. Make sure rubberized seals at top of baffles do seal well against inside of cowling.
Page 572 PIPER AZTEC SERVICE MANUAL TABLE VIII-III. ENGINE TROUBLESHOOTING (cont.) Trouble Cause Remedy FUEL INJECTION (cont.) High oil temperature (cont). Overly lean fuel/air mixture. Flow check injector. Excessive external dirt on engine. Clean engine. Oil temperature gauge error. See Table X-III.
Page 573 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VIII - POWER PLANT 07/15/06 (NORMALLY ASPIRATED) 3D14...
Page 574 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 07/15/06 VIII - POWER PLANT (NORMALLY ASPIRATED) 3D15...
Page 575 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VIII - POWER PLANT 07/15/06 (NORMALLY ASPIRATED) 3D16...
Page 576 PIPER AZTEC SERVICE MANUAL SECTION VIIIA - POWER PLANT (TURBOCHARGED) TABLE OF CONTENTS Paragraph Grid No. 8A-1. Introduction ..........
Page 577 PIPER AZTEC SERVICE MANUAL SECTION VIIIA - POWER PLANT (TURBOCHARGED) TABLE OF CONTENTS Paragraph Grid No. 8A-38. Fuel Air Bleed Nozzle ........
Page 578 PIPER AZTEC SERVICE MANUAL SECTION VIIIA - POWER PLANT (TURBOCHARGED) TABLE OF CONTENTS Paragraph Grid No. 8A-64. Turbocharger (AiResearch) ....... . .
Page 579 PIPER AZTEC SERVICE MANUAL SECTION VIIIA POWER PLANT (TURBOCHARGED) 8A-l. INTRODUCTION. This section covers power plants used in the PA-23-250 (six place) turbo powered Aztec (S/N’s 27-2505 and up) and is comprised of instructions for the removal, minor repair, service and installation of the engine cowling, propeller, propeller governor, engine, engine shock mounts, induction system, fuel injector, fuel air bleed nozzle, turbocharger, ignition system and lubrication system.
Page 580 PIPER AZTEC SERVICE MANUAL Exhaust gas is directed onto the turbine wheel causing it to turn. The compressor wheel is fixed to the opposite end of the shaft and also turns, delivering compressed air to the engine induction system. The speed of the compressor can be varied by dumping or by passing some of the exhaust gas around the turbine and out the exhaust stack.
Page 641 PIPER AZTEC SERVICE MANUAL NOTE: It is necessary to have equal controller settings on both engines to avoid throttle stagger, errors in fuel flow indication and different part throttle critical altitudes between engines. 8A-77. CLEANING OR REPLACING TURBO OIL FILTER ELEMENT.
Page 658 PIPER AZTEC SERVICE MANUAL SECTION VIIIB - POWER PLANT (LYCOMING TURBOCHARGED) TABLE OF CONTENTS Paragraph Grid No. 8B-l. Introduction ..........
Page 659 PIPER AZTEC SERVICE MANUAL SECTION VIIIB - POWER PLANT (LYCOMING TURBOCHARGED) TABLE OF CONTENTS (CONT.) Paragraph Grid No. 8A-25. Engine ..........
Page 660 PIPER AZTEC SERVICE MANUAL SECTION VIIIB POWER PLANT (LYCOMING-TURBOCHARGED) 8B-l. INTRODUCTION. This section covers power plants used in the PA-23-250 (six place) Lycoming Turbo-powered Aztec (S/N’s 27-3944 and up) and is comprised of instructions for the removal and installation of the engine and turbocharger.
Page 661 PIPER AZTEC SERVICE MANUAL Exhaust gas is directed onto the turbine wheel causing it to turn. The compressor wheel is fixed to the opposite end of the shaft and also turns, delivering compressed air to the engine induction system. The speed of the compressor can be varied by dumping or by passing some of the exhaust gas around the turbine and out the exhaust stack.
Page 662 PIPER AZTEC SERVICE MANUAL 8B-3. TROUBLESHOOTING. Troubles related to the power plant are listed in Section VIIIA, in the front of Table VIIIA-II, Engine Troubleshooting (Fuel Injection). Trouble related to the turbocharger is listed in Table VIIIB-I in the back of this section along with the probable causes and suggested remedies.
Page 673 PIPER AZTEC SERVICE MANUAL Figure 8B-3. Turbocharger System Diagram VIIIB - POWER PLANT 07/15/06 (LYCOMING TURBOCHARGED) 3H20...
Page 675 PIPER AZTEC SERVICE MANUAL 8B-21. INSTALLATION OF TURBOCHARGER. Slide connecting hose on inlet pipe of the controller housing far enough to allow clearance to mount turbocharger unit. Position turbocharger unit on mounting brackets and attach to exhaust transition section or plenum flange with attaching bolts, nuts and washers.
Page 676 PIPER AZTEC SERVICE MANUAL Figure 8B-4. Lockwiring V-Band Coupling 8B-24. ADJUSTMENT OF TURBOCHARGER. It is recommended that adjustments of the turbocharger be conducted by an authorized overhaul facility, in accordance with the latest revision of Avco Lycoming Service Instruction No. 1187.
Page 710 PIPER AZTEC SERVICE MANUAL Soak cloth in phenolphthalein indicator solution. Wring out cloth and spread evenly and smoothly over area of cell being checked. Check all surfaces of cell. Leaks will be indicated by the appearance of pink spots on the cloth.
Page 712 PIPER AZTEC SERVICE MANUAL Figure 9-12. Checking Fuel Quantity Sender Figure 9-13. Checking FuelGauges Schematic Sender Check: Remove the fuel sender to be checked. (Refer to Paragraph 9-19.) Secure the sender in the appropriate position on the fabricated jig as shown in Figure 9-12.
Page 717 PIPER AZTEC SERVICE MANUAL Position the valve to the mounting bracket inside the aft bottom of the appropriate nacelle. Install the two machine screws and self-locking nut, securing the valve in place. Connect the fuel lines to the valve fittings.
Page 721 PIPER AZTEC SERVICE MANUAL (Refer to Paragraph 9-36.) Fill fuel cells allowing fuel to flow through the valve. Check for leaks. Install the aft bottom section of the nacelle. 9-36. ADJUSTMENT AND LUBRICATION OF FUEL SELECTOR VALVE. (Refer to Figure 9-17.) Lubrication.
Page 755 SERVICE MANUAL CARD 4 OF 6 PA-23-235 APACHE PA-23-250 AZTEC PA-23-250 (SIX PLACE) AZTEC PIPER AIRCRAFT CORPORATION PART NUMBER 753-564 July 15, 2006...
Page 756 PIPER AZTEC SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Aztec Service Manual (P/N 753-564) originally published April 1, 1960 are as follows: Revisions Publication Date Aerofiche Card Effectivity CR681001 October 1, 1968 1, 2, 3, 4 and 5 CR720829...
Page 757 PIPER AZTEC SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A21 HANDLING AND SERVICING INSPECTION STRUCTURES 1F13 SURFACE CONTROLS 1I19 HYDRAULIC SYSTEM LANDING GEAR AND BRAKES VIII POWERPLANT (Normally Aspirated) VIIIA POWERPLANT (Air-Research Turbocharger) 3D17 VIIIB...
Page 758 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 10-1. Instrument Panel, PA-23-250 and PA-23-235 ....4A11 10-2. Instrument Panel, PA-23-250 (six place), S/N’s...
Page 759 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-19. Adjusting Relay Closing Voltage ......
Page 760 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 11-58. Testing Motor Fields for Grounds ......
Page 761 PIPER AZTEC SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. X-I. Instrument Markings - PA-23-250; PA-23-235 and PA-23-250 (six place), S/N’s 27-2000 thru 27-2504 with Carburetor Induction System ......
Page 792 PIPER AZTEC SERVICE MANUAL TABLE X-III. TROUBLESHOOTING - INSTRUMENTS Trouble Cause Remedy DIRECTIONAL GYRO INDICATOR Excess drift in either Excessive vibration with Check shock mounts. direction. amplitude more than 0.006 inch. Insufficient vacuum. If vacuum below that required for model, check for the following: a.
Page 793 PIPER AZTEC SERVICE MANUAL TABLE X-III. TROUBLESHOOTING - INSTRUMENTS (CONT.) Trouble Cause Remedy ALTIMETER (CONT.) Setting knob is hard Wrong lubrication or Replace instrument. to turn. lack of lubrication. Inner reference marker Out of engagement. Replace instrument. fails to move when setting knob is rotated.
Page 794 PIPER AZTEC SERVICE MANUAL TABLE X-III. TROUBLESHOOTING - INSTRUMENTS (CONT.) Trouble Cause Remedy RATE OF CLIMB INDICATOR Pointer does not set Aging of diaphragm. Reset pointer to zero by on zero. means of setting screw. Tap instrument while resetting. Pointer fails to...
Page 795 PIPER AZTEC SERVICE MANUAL TABLE X-III. TROUBLESHOOTING - INSTRUMENTS (CONT.) Trouble Cause Remedy TURN AND BANK INDICATOR (CONT.) In low temperature, pointer Oil has become too Replace instrument. fails to respond or does thick. so sluggishly and with insufficient deflection.
Page 796 PIPER AZTEC SERVICE MANUAL TABLE X-III. TROUBLESHOOTING - INSTRUMENTS (CONT.) Trouble Cause Remedy OIL TEMPERATURE INDICATORS (CONT.) One gauge OK, Don’t know. Trade sender wires only, one gauge bad. between left and right gauge, temporarily, to see if malfunction stays with gauge or with sender wire and its probe.
Page 797 PIPER AZTEC SERVICE MANUAL TABLE X-III. TROUBLESHOOTING - INSTRUMENTS (CONT.) Trouble Cause Remedy FUEL PRESSURE GAUGE Low or no pressure Defective fuel pump. Replace. indication. Defective electric Replace. fuel pump switch. Defective wiring. Repair. Defective gauge. Replace. Leak in engine pump Repair.
Page 798 PIPER AZTEC SERVICE MANUAL TABLE X-III. TROUBLESHOOTING - INSTRUMENTS (CONT.) Trouble Cause Remedy TACHOMETER No reading on indicator, Broken shaft. Replace instrument. either permanent or intermittent. Springs weak. Replace instrument. Pointer oscillates excessively. Rough spot on, or Repair or replace.
Page 799 PIPER AZTEC SERVICE MANUAL TABLE X-III. TROUBLESHOOTING - INSTRUMENTS (CONT.) Trouble Cause Remedy MAGNETIC COMPASS (CONT.) Defective light. Burned out lamp or Check lamp or broken circuit. continuity of wiring. EXHAUST GAS TEMPERATURE Gauge inoperative. Defective gauge, probe, Isolate defective circuit, or wiring.
Page 800 PIPER AZTEC SERVICE MANUAL GRIDS 4B22 THRU 4B24 INTENTIONALLY BLANK X - INSTRUMENTS 07/15/06 4B22...
Page 1011 SERVICE MANUAL CARD 5 OF 6 PA-23-235 APACHE PA-23-250 AZTEC PA-23-250 (SIX PLACE) AZTEC PIPER AIRCRAFT CORPORATION PART NUMBER 753-564 July 15, 2006...
Page 1012 PIPER AZTEC SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Aztec Service Manual (P/N 753-564) originally published April 1, 1960 are as follows: Revisions Publication Date Aerofiche Card Effectivity CR681001 October 1, 1968 1, 2, 3, 4 and 5 CR720829...
Page 1013 PIPER AZTEC SERVICE MANUAL SECTION INDEX GUIDE SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A21 HANDLING AND SERVICING INSPECTION STRUCTURES 1F13 SURFACE CONTROLS 1I19 HYDRAULIC SYSTEM LANDING GEAR AND BRAKES VIII POWERPLANT (Normally Aspirated) VIIIA POWERPLANT (Air-Research Turbocharger) 3D17 VIIIB...
Page 1014 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 12-1. Two Year, Magnesium Battery Connection (Garrett) ..5A11 12-2. Emergency Locator Transmitter Schematics (Garrett) ..
Page 1015 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 13-22. Diagrammatic Cutaway of Heater to Show Whirling Flame Action ........
Page 1016 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 14-3. Oxygen System Installation, PA-23-250 (six place), S/N’s 27-2000 thru 27-3049 27-3051 thru 27-3153 ..5H21 14-4. Oxygen System Installation, PA-23-250 (six place), S/N’s...
Page 1017 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Aerofiche Grid No. 14-32. Pneumatic Deicer Installation (Dry Vacuum Pump), S/N’s 27-7304964 thru 27-7554168 ......
Page 1018 PIPER AZTEC SERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. XIII-I. Heater Troubleshooting (South Wind) ..... . 5C21 XIII-II.
Page 1019 5A19 12-13. Piper A.F.C.S. Equipment ........5A20 12-14.
Page 1030 Piper name, and the appropriate Piper AutoPilot/Flight Director Service Manual shall be used. NOTE: If a Roll Axis only AutoPilot is installed, or if no AutoPilot is installed, consult the Piper Pitch Trim Service Manual - 753-771 for manual electric pitch trim service information.
Page 1031 PIPER AZTEC SERVICE MANUAL Figure 12-2. Emergency Locater Transmitter Schematic (Garrett) 12-14. RADIO SHELF CAPACITIES. A summary of approved capacities for various shelves in Piper Aircraft listed by models below: SHELF INSTALLATION MAXIMUM APPROVED MODEL DRAWING NUMBER WEIGHT PA-23-250 and PA-23-235 16300 50 lbs.
Page 1039 PIPER AZTEC SERVICE MANUAL SECTION XIII - HEATING AND VENTILATING TABLE OF CONTENTS Paragraph Grid No. 13-1. Introduction ..........
Page 1040 PIPER AZTEC SERVICE MANUAL SECTION XIII - HEATING AND VENTILATING TABLE OF CONTENTS (CONT.) Paragraph Grid No. 13-37. External Causes of Trouble ....... . .
Page 1041 PIPER AZTEC SERVICE MANUAL SECTION XIII - HEATING AND VENTILATING TABLE OF CONTENTS (CONT.) Paragraph Grid No. 13-76. Reassembly ......... .
Page 1042 PIPER AZTEC SERVICE MANUAL SECTION XIII - HEATING AND VENTILATING TABLE OF CONTENTS (CONT.) Paragraph Grid No. 13-114. Ignition Assembly ........
Page 1043 PIPER AZTEC SERVICE MANUAL SECTION XIII - HEATING AND VENTILATING TABLE OF CONTENTS (CONT.) Paragraph Grid No. 13-154. Heater Electrical System Checks ......
Page 1110 PIPER AZTEC SERVICE MANUAL Figure 13-23. Fuel Regulator and Shutoff Valve 13-94. FUEL REGULATOR AND SHUTOFF VALVE. (Refer to Figure 13-23 ) This unit provides preset, regulated fuel pressure as well as remote shutoff to the heater, regardless of fuel inlet pressure variations. It is adjustable to 7 psi, with inlet pressures up to 50 psi. The shutoff valve is operated by a solenoid.
Page 1111 PIPER AZTEC SERVICE MANUAL 13-96. COMBUSTION AIR BLOWER. This centrifugal-type blower supplies combustion air to the combustion chamber of the heater. Performance of the combustion air blower is assisted by the use of ram air during flight. 13 -97. VENTILATING AIR BLOWER. This blower...
Page 1112 PIPER AZTEC SERVICE MANUAL Figure 13-25. Wiring Diagram 13-100. INSPECTION OF HEATER AND HEATER COMPONENTS. 13-101. PREFLIGHT AND OR DAILY INSPECTION. Inspect the ventilating air inlet scoop, combustion air inlet scoop, exhaust outlet and fuel drain for possible obstructions. Make sure that all of these openings are clear of any restrictions and that no damage has occurred to air scoop protrusions.
Page 1113 PIPER AZTEC SERVICE MANUAL 13-102. 100-HOUR INSPECTION. The mandatory 100-Hour Inspection shall be conducted on new heaters or overhauled heaters with a new combustion tube assembly upon accumulation of 500-heater operating hours or twenty-four months, which-ever occurs first, and thereafter at intervals not to exceed 100-heater operating hours or twenty-four months, whichever occurs first.
Page 1146 PIPER AZTEC SERVICE MANUAL 13-133. REPLACEMENT FUEL FILTER ELEMENT. The fuel filter element located on the aft bulkhead in the fuselage nose section may be replaced by the following procedures: Remove the access panel from the right side of the nose section.
Page 1147 PIPER AZTEC SERVICE MANUAL Figure 13-36. Heater Fuel Valve S/N’s 27-1 thru 27-7405431 07/15/06 XIII - HEATING AND VENTILATING 5F17...
Page 1148 PIPER AZTEC SERVICE MANUAL 13-136. INSTALLATION OF HEATER FUEL VALVE. (S/N’s 27-1 thru 27-7405431.) Install the pressure side of the valve to the crossfeed drain line. The pressure side is marked with a “P” stamped on the valve body. On early valves that are not stamped the pressure side can be determined by looking into the body ends, with the valve closed;...
Page 1181 PIPER AZTEC SERVICE MANUAL Energize and de-energize the solenoid several times. The spray should shut off permanently each time the solenoid is de-energized. There should be no sign of dribbling at the nozzle tip in excess of one or two drops.
Page 1195 PIPER AZTEC SERVICE MANUAL 14-2. OXYGEN SYSTEM. 14-3. DESCRIPTION AND PRINCIPLE OF OPERATION. The oxygen system for the PA-23-250 series airplanes consists of an oxygen cylinder and regulator, filler valve, pressure gauge, outlets and masks and an ON-OFF control. High pressure is routed from the cylinder and regulator to the pressure gauge.
Page 1196 PIPER AZTEC SERVICE MANUAL The high pressure gauge may be checked for accuracy by comparing its indicated pressure with that of a gauge of known accuracy. Inspection of the regulator may be effected by introducing into an outlet a mask connector to which is attached a 100 psi gauge.
Page 1291 PIPER AZTEC SERVICE MANUAL Figure 14-46. Fabricated Test Box Figure 14-47. Electrical Schematic 07/15/06 XIV - ACCESSORIES AND UTILITIES 5L17...
Page 1297 SERVICE MANUAL CARD 6 OF 6 PA-23-235 APACHE PA-23-250 AZTEC PA-23-250 (SIX PLACE) AZTEC PIPER AIRCRAFT CORPORATION PART NUMBER 753-564 July 15, 2006...
Page 1298 Published by Technical Publications © The New Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...
Page 1299 PIPER AZTEC SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to the Aztec Service Manual (P/N 753-564) originally published April 1, 1960 are as follows: Revisions Publication Date Aerofiche Card Effectivity CR681001 October 1, 1968 1, 2, 3, 4 and 5 CR720829...
Page 1300 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK AEROFICHE EFFECTIVITY 07/15/06...
Page 1301 PIPER AZTEC SERVICE MANUAL TABLE OF CONTENTS SUBJECT SECTION GRID NO. Introduction Instructions for Continued Airworthiness ................... General ............................... Effectivity............................Serial Number Explanation......................... Assignment of Subject Material......................Pagination............................Aerofiche Effectivity........................... Identifying Revised Material ......................6A10 Indexing .............................. 6A10 Warnings, Cautions, and Notes ......................
Page 1302 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION - TABLE OF CONTENTS 07/15/06...
Page 1303 Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even though identical in appearance, may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane.
Page 1304 PIPER AZTEC SERVICE MANUAL Effectivity This service manual is effective for PA-23-235, PA-23-250, and PA-E23-250 airplane serial numbers 27-1 thru 27-8154030. This encompasses the following model years: NOTE: The designation PA-23-250 (6) or PA-23-250 (six place) is not used below. Such references should be considered to mean PA-23-250 S/N’s 27-2000 and up, unless otherwise indicated.
Page 1305 PIPER AZTEC SERVICE MANUAL Serial Number Explanation Example - (1960 thru 1972): 27 671 TYPE CERTIFICATE DESIGNATION SEQUENCE NUMBER (1 to 4 digits) (No Model Year Designation) (No Model Code) Example - (1973 and 1974): 27 73 00001 SEQUENCE NUMBER (5 digits)
Page 1306 11. Accident/Incident Reporting To improve our Service and Reliability system and aid in Piper’s compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
Page 1307 (3) Progressive Inspection Manual (25 Hour) (PA-23-250 only): 761-498 (4) Progressive Inspection Manual (50 Hour) (PA-23-250 only): 761-738 B. Vendor Publications: WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (1) ALTERNATOR: Vendor Address:...
Page 1308 PIPER AZTEC SERVICE MANUAL (5) EMERGENCY LOCATOR TRANSMITTER: Vendor Address: Artex Airccraft Supplies (800) 547-8901 14405 Keil Road NE Aurora, Oregon 97002 http://www.artex.net/ (6) ENGINE: Vendor Address: Textron Lycoming (717) 323-6181 652 Oliver Street FAX: (717) 327-7101 Williamsport, PA 17701 http://www.lycoming.textron.com/main.html...
Page 1309 PIPER AZTEC SERVICE MANUAL (11) LIGHTS - NAVIGATION, STROBE, AND STANDBY/MAP LIGHTS: Vendor Address: Whelen Engineering Co. Inc. (860) 526-9504 Route 145, Winthrop Rd. FAX: (860) 526-2009 Chester, Conneticut 06412 http://www.whelen.com/ (12) MAGNETOS: Vendor Address: Teledyne Continental Motors (334-438-3411, P.O. Box 90 ext.
Page 1310 PIPER AZTEC SERVICE MANUAL (14) PROPELLER GOVERNOR: Vendor Address: Hartzell Propeller Inc. (937) 778-4379 One Propellor Place FAX: (937) 778-4321 Piqua, OH 45356-2634 http://www.hartzellprop.com/index2.htm Governor Maintenance: Manual No. 130B (16) VACUUM PUMPS: Vendor Address: Aero Accessories, Inc. (800) 822-3200 1240 Springwood Avenue Gibsonville, NC 27249 http://www.aeroaccessories.com/index.html...
Page 1311 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 07/15/06 INTRODUCTION 6A15...
Page 1312 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION 07/15/06 6A16...
Page 1313 PIPER AZTEC SERVICE MANUAL 13. Section Index Guide SECTION TITLE GRID NO. INTRODUCTION AIRWORTHINESS LIMITATIONS 1A21 HANDLING AND SERVICING INSPECTION STRUCTURES 1F13 SURFACE CONTROLS 1I19 HYDRAULIC SYSTEM LANDING GEAR AND BRAKES 1I21 VIII POWERPLANT (Normally Aspirated) VIIIA POWERPLANT (Air-Research Turbocharger)
Page 1314 PIPER AZTEC SERVICE MANUAL GRIDS 6A18 THRU 6A24 INTENTIONALLY BLANK INTRODUCTION 07/15/06 6A18...
Page 1315 PIPER AZTEC SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Aerofiche Grid No. 3-1. Outboard Flap Hinge Inspection, S/N’s 27-3050, 27-3154 thru 27-7405330 ....
Page 1316 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK LIST OF ILLUSTRATIONS 07/15/06...
Page 1317 PIPER AZTEC SERVICE MANUAL LIST OF TABLES Figure Aerofiche Grid No. III-I. INSPECTION REPORT ........
Page 1318 PIPER AZTEC SERVICE MANUAL GRIDS 6B4 THRU 6B24 INTENTIONALLY BLANK LIST OF TABLES 07/15/06...
Page 1319 PIPER AZTEC SERVICE MANUAL SECTION INSPECTION...
Page 1320 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...
Page 1321 PIPER AZTEC SERVICE MANUAL SECTION III - INSPECTION TABLE OF CONTENTS PARAGRAPH GRID NO. General ............................Time Limits............................Scheduled Maintenance ........................Description ............................Definitions............................Inspection Requirements........................6C12 Annual / 100 Hour Inspection ......................6C12 Progressive Inspection ........................6C12 Overlimits Inspection........................
Page 1322 PIPER AZTEC SERVICE MANUAL SECTION III - INSPECTION TABLE OF CONTENTS (CONT.) PARAGRAPH GRID NO. Unscheduled Maintenance Checks ..................... 6F11 Lightning Strike ..........................6F11 Engine Overspeed, Overtemp, Overtorque, or Sudden Stoppage........... 6F12 Severe Turbulence, Hard or Overweight Landing ................6F12 Flaps Extended Above Maximum Flap Extension Speed (V ).............
Page 1323 PIPER AZTEC SERVICE MANUAL General The New Piper Aircraft, Inc. (Piper) takes a continuing interest in having the owner get the most efficient use from his airplane, and keeping the airplane in the best mechanical condition. To that end, Piper publishes a recurring maintenance schedule which is supplemented with Service Bulletins, Service Letters and Service Spares Letters as required.
Page 1324 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK III - Inspection 07/15/06...
Page 1325 B. Refer to paragraph 6 for Piper’s recommended Inspection Programs. They include the frequency and extent of the inspections required for the continued airworthiness of these airplanes.
Page 1326 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK III - Inspection 07/15/06...
Page 1327 Annual / 100 Hour Inspection. Progressive Inspection Programs (25 and 50 Hour) for the PA-23-250 Aztec only are available from Piper Dealers in separate manual form. Piper inspection programs comply with the F.A.A. Federal Aviation Regulations Parts 43, 91 and 135. The owner/operator is primarily responsible for maintaining the airplane in an airworthy condition, including compliance with all applicable Airworthiness Directives and conformity with the requirements in FAR 91.409, 91.411 and 91.413.
Page 1328 Each bench test will be performed by a Piper Service Center, FAA Certified Repair Station with appropriate rating or by a certified mechanic. This test will be performed at the scheduled interval regardless of any bench test performed on a particular component while being repaired/overhauled before scheduled interval bench test.
Page 1329 PIPER AZTEC SERVICE MANUAL H. Time - as used in this manual. (1) Time-in-service for aircraft components, unless otherwise specified, is a cumulative total of flight hours or calendar time calculated from the time a new or overhauled component was first installed in any aircraft, and including: (a) the aircraft time that elapses from the initial installation to the first removal, if any;...
Page 1330 P/N 761-498 for the PA-23-250 Aztec (25 Hour), and P/N 761-738 for the PA-23-250 Aztec (50 Hour). Refer to Piper's Customer Service Information Aerofiche P/N 1753-755 for a checklist to ensure obtaining latest issue. NOTE: The Progressive Inspection Manuals (P/N’s 761-498 and 761-738) referenced above are not stand-alone documents.
Page 1331 (4) In addition to inspection intervals required in scheduled maintenance (i.e. - Table III-I), preflight inspection must also be performed. (5) References to service manual applicable areas are per the Piper proprietary system defined by the Section Index Guide. B. Special Inspections (see paragraph 8.) C.
Page 1332 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK III - Inspection 07/15/06 6C14...
Page 1333 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Refer to Notes 1, 2, 3, and 4 before performing the following inspections. Inspection NATURE OF INSPECTION Interval (Hrs) A. PROPELLER GROUP WARNING: USE EXTREME CAUTION WHEN ROTATING PROPELLER BY HAND; PROPELLER MAY KICK BACK.
Page 1334 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) B. ENGINE GROUP (CONT.) 5. Clean pressure oil strainer or change full flow, cartridge type, oil filter element; inspect strainer or element for foreign particles....... O 6.
Page 1335 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) B. ENGINE GROUP (CONT.) 25. Inspect air induction system for leaks, security and damage. Repair or replace as required..............O 26. Inspect condition and operation of carburetor heat or alternate air door and box................
Page 1336 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) B. ENGINE GROUP (CONT.) 47. Inspect condition of generator or alternator and starter ......O 48. Inspect security of generator or alternator and starter mounting .... O 49.
Page 1337 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) D. CABIN AND COCKPIT GROUP 1. Inspect cabin door, latches, and hinges, and windows, and baggage compartment doors, latches, and hinges for damage, operation, and security ......................
Page 1338 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) D. CABIN AND COCKPIT GROUP (CONT.) 25. Check operation of cowl flaps ................26. Inspect condition of heater controls and ducts............27. Inspect condition and operation of air vents ............
Page 1339 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) E. FUSELAGE AND EMPENNAGE GROUP (CONT.) 20. Inspect rudder and tab for surface damage or irregularities (i.e. - skin cracks, distortion, dents, corrosion, and excessive paint build up);...
Page 1340 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) E. FUSELAGE AND EMPENNAGE GROUP (CONT.) 36. If installed, inspect condition and security of Autopilot bridle cable clamps. (See Notes 10 and 17.) ................... 37. If installed, inspect condition of pneumatic deicers..........
Page 1341 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) WING GROUP (CONT.) 14. Lubricate per Lubrication Chart, Section II ............15. Inspect wing attachment bolts and brackets............16. Inspect engine mount attaching structure .............. 17. Inspect fuel cells and lines for leaks and water............
Page 1342 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT Inspection NATURE OF INSPECTION Interval (Hrs) G. LANDING GEAR GROUP (CONT) 19. Retract gear - Inspect doors for clearance and operation........20. Inspect anti-retraction system ................21. Inspect actuating cylinders for leaking and security..........
Page 1343 In all cases, see Service Bulletin/Service Letter Index P/N 762-332 or Service Bulletin/Service Letter Aerofiche Set P/N 1762-331 to verify latest revision. 4. Piper Service Letters are product improvements and service hints pertaining to servicing the airplane and should be given careful attention.
Page 1344 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT K. NOTES (CONT.) 5. Inspections given for the power plant are based on the engine manufacturer’s operator’s manual ( Lycoming Part No. 60927-10 or 60297-23, as appropriate ) for these airplanes. Any changes issued to the engine manufacturer’s operator’s manual shall supersede or supplement...
Page 1345 “sag” or permanent deflection resulting in internal bottoming with spacer, engine and cowl interference, unusual vibration. In PA-23-250 S/N’s 27-3457 and up, if installed, inspect Piper AutoControl III, AltiMatic III, AltiMatic IIIB, and AltiMatic IIIB-1 autopilot servo and bridle cable installations per 100 Hour AutoControl III/AltiMatic III Autopilot Inspection (see Special Inspections, Procedures).
Page 1346 PIPER AZTEC SERVICE MANUAL TABLE III-I. INSPECTION REPORT K. NOTES (CONT.) For airplanes equipped with Aero Accessories Inc., Tempest Dry Air Pumps only, for pumps which have accumulated 500 hours time-in-service or more, inspect vacuum pump vane wear per Vacuum Pump Vane Wear Inspection (see Special Inspections, Procedures).
Page 1347 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 07/15/06 III - Inspection...
Page 1348 PIPER AZTEC SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK III - Inspection 07/15/06...
Page 1349 PIPER AZTEC SERVICE MANUAL Special Inspections WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) A. Requirements The following inspections are required in addition to those listed in Tables III-I and III-II. These inspections are required at intervals of: Flight hours;...
Page 1350 PIPER AZTEC SERVICE MANUAL Each 1000 Hours Replace pins and bolts used as flap and aileron hinge. Inspect drag link bolts (Replace as required). Replace engine compartment flexible hoses (fuel, oil, etc.) as required; but not to exceed 1000 hours time-in-service, eight (8) years, or engine overhaul, whichever comes first.
Page 1351 PIPER AZTEC SERVICE MANUAL Each 2000 Hours Each 2000 hours or seven (7) years, whichever occurs first, remove interior cabinets, panels, and headliner and conduct detailed inspection of aircraft structure (skin, bulkheads, stringers, etc.) for condition and security. Inspection of structure concealed by headliner may be accomplished by alternate means (i.e.
Page 1352 PIPER AZTEC SERVICE MANUAL Each Two (2) Years Test and inspect the static pressure system and altimeters. Ensure compliance with the requirements of FAR 43, Appendix E. (See FAR 91.411.) Test and inspect the transponder. Ensure compliance with the requirements of FAR 43, Appendix F.
Page 1353 PIPER AZTEC SERVICE MANUAL Each Ten (10) Years Each ten (10) years time-in-service, test fuselage and wing fluid hoses to system pressure. Visually inspect for leaks. Hoses that pass inspection may remain in service, but must be rechecked each five (5) years additional time-in-service.
Page 1354 PIPER AZTEC SERVICE MANUAL (b) Operation in High Salt or High Humidity Environment Item Inspection Inspection Interval Fuselage, Empennage, and Remove floor panels and exterior 200 Hours. Wings. access plates; inspect for corrosion. Landing Gear. Inspect for corrosion and lubrication.
Page 1355 PIPER AZTEC SERVICE MANUAL (d) Operation from Soft or Unusual Terrain Item Inspection Inspection Interval Landing Gear. Inspect for cracks, attachment, 100 Hours. damage, cleanliness and lubrication. Wheels. Inspect for cracks, damage, chipped 100 Hours. rims; bearings for damage, corrosion and lubrication.
Page 1356 PIPER AZTEC SERVICE MANUAL GRIDS 6D14 THRU 6D24 INTENTIONALLY BLANK III - Inspection 07/15/06 6D14...
Page 1357 (2) 100 HOUR AUTOCONTROL III / ALTIMATIC III AUTOPILOT INSPECTION. In PA-23-250’s S/N’s 27-3457 and up, for airplanes equipped with Piper AutoControl III, AltiMatic III, AltiMatic IIIB, or AltiMatic IIIB-1 autopilots,...
Page 1358 100 hours time-in-service or annually, whichever comes first, inspect the outboard flap hinge for cracks as follows: NOTE: Piper Kits No. 760-861 and 760-817 are no longer available (circa 2006). (a) Using the hydraulic hand pump, lower the flaps to the full down position.
Page 1359 PIPER AZTEC SERVICE MANUAL Figure 3-1. Outboard Flap Hinge Inspection S/N’s 27-3050, 27-3154 thru 27-7405330 07/15/06 III - Inspection...
Page 1360 PIPER AZTEC SERVICE MANUAL Figure 3-2. Fuel Selector Valve Control Cables III - Inspection 07/15/06...
Page 1361 PIPER AZTEC SERVICE MANUAL Figure 3-2. Fuel Selector Valve Control Cables (cont.) 07/15/06 III - Inspection...
Page 1362 NOTE: Round steel tube (10 x 0.625 (5/8) x .058 inch Type 4130 Cond. N) should be procured locally, if possible. If necessary, tube may be ordered from Piper as P/N 15589-005. Weld shut the area around the hole in the attachment plate and the tubes.
Page 1363 PIPER AZTEC SERVICE MANUAL Figure 3-3. Stabilator Tip Tube And Weight Assembly 07/15/06 III - Inspection...
Page 1364 PIPER AZTEC SERVICE MANUAL In S/N’s 27-7654001 thru 27-7954035 with modified P/N 15658-020 tube and weight assemblies (see above), or with P/N 15658-029 tube and weight assemblies, or with Piper Kit No. 763-987 installed: NOTE: Piper Kit No. 763-987 is no longer available (circa 2001).
Page 1365 PIPER AZTEC SERVICE MANUAL Figure 3-4. Engine Controls Support Bracket Inspection 07/15/06 III - Inspection...
Page 1366 PIPER AZTEC SERVICE MANUAL (7) LANDING GEAR SELECTOR LEVER 100 HOUR INSPECTION. In all PA-23-235’s and PA-23-250 S/N’s 27-1 thru 27-7854139 only, for airplanes which have not installed the heavy duty landing gear selector lever P/N 761-213 (i.e. - 28468-002),...
Page 1367 PIPER AZTEC SERVICE MANUAL Figure 3-5. Landing Gear Selector Lever 07/15/06 III - Inspection 6E11...
Page 1368 PIPER AZTEC SERVICE MANUAL (8) STABILATOR LOWER SURFACE RIVETS AND RIB ATTACHMENT 100 HOUR INSPECTION. In PA-23-250 Aztec “F” S/N’s 27-7654001 thru 27-7954044 with unmodified stabilator serial numbers 0336-L thru 0340-L and 0401-L thru 0607-L and 0337-R thru 0341-R and 0402-R thru 0609-R only,...
Page 1369 PIPER AZTEC SERVICE MANUAL Figure 3-6. Stabilator Lower Surface Rivets And Rib Attachment 07/15/06 III - Inspection 6E13...
Page 1370 In all PA-23-235’s and PA-23-250 S/N’s 27- 1 thru 27-8054059 only, for airplanes which have accumulated at least 1000 hours total time- in-service, have initially completed Piper Service Bulletin No. 671, and have not installed the improved flap bellcrank P/N 16423-006;...
Page 1371 PIPER AZTEC SERVICE MANUAL Figure 3-7. Flap Bellcrank Inspection 07/15/06 III - Inspection 6E15...
Page 1372 Sta. 153/171 canted bulkhead for cracks as follows: NOTE: Installation of Footstep Reinforcement Brackets per Piper Service Bulletin No. 672A relieves this repetitive inspection requirement. (a) Gain access to the rear baggage compartment thru the rear baggage compartment door.
Page 1373 PIPER AZTEC SERVICE MANUAL Figure 3-8. Fuselage Frame Inspection 07/15/06 III - Inspection 6E17...
Page 1374 PIPER AZTEC SERVICE MANUAL Figure 3-8. Fuselage Frame Inspection (cont.) III - Inspection 07/15/06 6E18...
Page 1375 PIPER AZTEC SERVICE MANUAL Figure 3-8. Fuselage Frame Inspection (cont.) 07/15/06 III - Inspection 6E19...
Page 1376 PIPER AZTEC SERVICE MANUAL (11) FLAP TORQUE TUBE 100 HOUR INSPECTION. For airplanes which have accumulated at least 2500 hours total time-in-service and have not installed a steel flap torque tube (P/N 17634-002, 104622-002, or 104622-004); each 100 hour time-in-service or annually,...
Page 1377 NOTE: The initial ten year inspection interval should date from the logbook entry documenting completion of Piper Service Bulletin No. 1160. If no such logbook entry can be found, perform the initial inspection as part of the next 100 hour or annual inspection.
Page 1378 PIPER AZTEC SERVICE MANUAL (13) CONTROL CABLE INSPECTION. Aircraft control cable systems are subject to a variety of environmental conditions and forms of deterioration that, with time, may be easy to recognize as wire/strand breakage or the not-so-readily visible types of wear, corrosion, and/or distortion.
Page 1379 PIPER AZTEC SERVICE MANUAL Figure 3-11. External Wear Patterns Figure 3-12. Internal Cable Wear 07/15/06 III - Inspection 6E23...
Page 1380 PIPER AZTEC SERVICE MANUAL Figure 3-13. Cable Pulley Wear As wear is taking place on the exterior surface of a cable, the same condition is taking place internally, particularly in the sections of the cable which pass over pulleys and quadrants.
Page 1381 PIPER AZTEC SERVICE MANUAL (e) Cable Maintenance CAUTION: TO AVOID REMOVAL OF CORROSION-PREVENTATIVE COMPOUNDS AND CABLE INTERNAL LUBRICANT, DO NOT USE VAPOR DEGREASING, STEAM CLEANING, METHYLETHYLKETONE (MEK) OR OTHER SOLVENTS. CAUTION: DO NOT OIL CONTROL CABLES. Frequent inspections and preservation measures such as rust prevention treatments for bare cable areas will help to extend cable service life.
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Page 1383 PIPER AZTEC SERVICE MANUAL (14) EXHAUST SYSTEM 100 HOUR INSPECTION. Each 100 hours, or annually, whichever comes first, a thorough and detailed inspection of all components of the exhaust system for condition, correct installation, and leakage is critical. NOTE: In the interest of safety and proper maintenance, a daily visual line inspection of the exhaust stack gaskets, exhaust stack muffler assembly and muffler tail pipe joints should be made to assure tightness;...
Page 1384 PIPER AZTEC SERVICE MANUAL (c) As with any other system, age (number of hours) must be considered. Even though the best materials and techniques are incorporated in these systems, inspections for instance, at the 700-800 hour period, should be more critical than at the 100 hour mark. Possible replacement of parts should be considered after the 1000 hour mark.
Page 1385 PIPER AZTEC SERVICE MANUAL (15) ENGINE MOUNT CORROSION INSPECTION, IMMERSION IN WATER. The following guidance is general in nature and should be applied or varied to fit the individual situation based on water level during immersion, length of time immersed, length of time since exposure, etc.
Page 1386 PIPER AZTEC SERVICE MANUAL (16) VACUUM PUMP VANE WEAR INSPECTION. For airplanes equipped with Aero Accessories, Inc., Tempest Dry Air Pumps only, which have accumulated 500 hours time-in- service; each 100 hours thereafter inspect vacuum pump vane wear as follows: (a) Remove the inspection port plug and observe vane wear as shown in Figure 3-15.
Page 1387 PIPER AZTEC SERVICE MANUAL (17) TORQUE TUBE/PUSH ROD DISTORTION INSPECTION. If flaps have been extended at or above V , inspect the flap torque tube arm, bellcrank, and pushrods for evidence of distortion. (a) If the paint is cracked or peeling anywhere along the torque tube arm or pushrod, torsional movement has occurred.
Page 1388 PIPER AZTEC SERVICE MANUAL (19) FLAP SPAR 100 HOUR INSPECTION. In PA-23-235’s and PA-23-250 S/N’s 27-1 thru 27- 7405300, for airplanes which have accumulated at least 2000 hours total time-in-service and have not installed improved flap assemblies (P/N’s 17104-071 right and 17104-072 left;...
Page 1389 PIPER AZTEC SERVICE MANUAL Figure 3-16. Stabilator and Rudder Control Cable Attachment Inspection 07/15/06 III - Inspection...
Page 1390 NOTE: See Section IX, paragraphs 9-29 through 9-36, when accomplishing the following. (a) Remove and disassemble the Scott fuel selector valves. (b) Remove the existing valve spool "O" rings and install new ones contained in Piper Kit No. 760-504. (c) Reassemble the fuel selector valves and inspect for leaks.
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Page 1393 PIPER AZTEC SERVICE MANUAL Unscheduled Maintenance Checks WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) The following inspections are required in response to specific anomalies encountered during aircraft operation.
Page 1394 (2) Make a preliminary inspection of checking alignment and out-of-track condition of engine, wings, tail, landing gear and doors. (3) Follow Piper and Textron-Lycoming Maintenance Manual procedures. If there are any questions regarding repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA).
Page 1395 PIPER AZTEC SERVICE MANUAL C. Severe Turbulence, Hard or Overweight Landing (cont.) Item Inspection Inspection Interval Wings. Wing attach bolts for slippage, damage Each occurrence, and overstress. Upper and lower wing before further flight. skins for wrinkles, cracks, popped or loose rivets.
Page 1396 MANUFACTURER'S MAINTENANCE MANUAL, AND FAR PART 43. PAY PARTICULAR ATTENTION TO SILT, CORROSION AND CONTAMINANTS. B. Follow Piper and Textron-Lycoming Maintenance Manual procedures. If there are any questions regarding repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA). C. Determine the water level on the aircraft. Determine which operating and/or electrical components have been exposed to the water.
Page 1397 PIPER AZTEC SERVICE MANUAL Flood Damage, Immersion in Water (cont.) Item Inspection Inspection Interval Engine. Remove, disassemble, and inspect. If immersed, each event, Examine all parts paying particular before further flight. attention for evidence of corrosion, rust or contaminants imbedded on...
Page 1398 PIPER AZTEC SERVICE MANUAL Flood Damage, Immersion in Water (cont.) Item Inspection Inspection Interval Electrical Systems. Replace all circuit breakers and If immersed, each event, switches. before further flight. Replace all solenoids, relays and master contactors. Replace battery. Disassemble all connectors; clean and inspect for corrosion.
Page 1399 PIPER AZTEC SERVICE MANUAL Flood Damage, Immersion in Water (cont.) Item Inspection Inspection Interval Vacuum and Pitot-Static Replace gyros. If immersed, each event, Systems. before further flight. Replace filters. Clean and inspect all lines, and pitot and static vents. Clean and check all regulating valves.
Page 1400 PIPER AZTEC SERVICE MANUAL Flood Damage, Immersion in Water (cont.) Item Inspection Inspection Interval Avionics Systems. Replace avionics. If immersed, each event, before further flight. Clean and inspect antennas and connectors. Insulation and Upholstery. Remove all wet insulation and upholstery.
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Page 1402 PIPER AZTEC SERVICE MANUAL GRIDS 6F22 THRU 6F24 INTENTIONALLY BLANK III - Inspection 07/15/06 6F22...
Page 1403 PIPER AZTEC SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST This table is a cumulative list of Piper service publications (i.e. - Service Bulletins and Service Letters) applicable to the airplane models covered by this manual, with the following exceptions: A. Service publications which have been fully incorporated into this manual are not listed, B.
Page 1404 SL 591 Wing Front Spar Inspection and Reinforcement SL 606A Fuel System Inspection and Modification SL 619 Inspection of Piper P/N 83302-13 Retainer Spring SL 629 Fuselage Frame Tube Corrosion Inspection SL 653 Throttle Lever And Shaft, Serrated SL 667A...
Page 1405 Wing Front Spar Inspection and Reinforcement SL 667A Stabilator Attachment Bolts 1960-1972 SL 606A Fuel System Inspection and Modification SL 619 Inspection of Piper P/N 83302-13 Retainer Spring SL 629 Fuselage Frame Tube Corrosion Inspection 1960-1973 SL 696 Control Surface Balancing Recommendation 1960-1974...
Page 1406 PIPER AZTEC SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-23-250 1963-1964 SB 218 Vacuum Pump Splined Coupling Replacement (cont.) SL 432 Inspection of Auxiliary Power Plug Solenoid 1963-1975 SB 456A Warning Placard Replacement...
Page 1407 Whelen Wing Tip Strobe Lights Reference FAA 1970-1978 SL 820 Replacement/(LiS02) ELT Batteries/Transmitters 1971-1973 SL 617B Piper Automatic Locator Transmitter Replacement 1971-1977 SB 558 Altimatic V and V F/D Series; M-4D F/D Series SB 559 Rudder Tail Light Inspection 1972...
Page 1408 PIPER AZTEC SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-23-250 1974-1975 SB 461 760-971 Encoding Altimeter Harness Rewiring (cont.) 1975 SB 452 760-932 Instrument Glare Shield Panel Replacement 1975-1977 SB 566 Horizontal Situation Indicator, Modification...
Page 1409 PIPER AZTEC SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-E23-250 1964-1981 SB 1035 Textron Lycoming S / B 529A (cont.) SB 1041 Distribution of Airborne S/L No. 56 1966-1968 SL 676 Weight and Balance Equipment List Correction...
Page 1410 PIPER AZTEC SERVICE MANUAL GRIDS 6G8 THRU 6L24 INTENTIONALLY BLANK III - Inspection 07/15/06...

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