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Piper Comanche PA-24 Service Manual

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SERVICE MANUAL

PA-24

PA-24-250

PA-24-260

PA-24-400

PIPER AIRCRAFT CORPORATION

PART NUMBER 753-516

April 1, 2009

1A1

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Summary of Contents for Piper Comanche PA-24

Page 2 PIPER COMANCHE SERVICE MANUAL Published by Technical Publications © 1959, 2009 Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...
Page 3 April 1, 2009 * Piper has ceased production of all Aerofiche (i.e. microfiche) products. Consult the “Customer Service Information File” (a free download from the Piper Aircraft, Inc. website at Http://www.piper.com/publications.asp) to verify that you have the latest revision. 04/01/09...
Page 4 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK REVISION STATUS 04/01/09...
Page 5: Table Of Contents
1A11 PIPER Publications ........1A11 Vendor Publications .
Page 6 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION - TABLE OF CONTENTS 04/01/09...
Page 7: Instructions For Continued Airworthiness
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 8 PIPER COMANCHE SERVICE MANUAL Effectivity This service manual is effective for all PA-24 Comanche series airplanes as follows: This encompasses the following model years: NOTE: The following is provided as a general reference only. Model Sub-Model Serial Numbers Model Year...
Page 9: Serial Number Explanation
Aerofiche Grid Number Piper has ceased production of all Aerofiche (i.e.,microfiche) products. The Aerofiche grid numbers will be replaced by Section page numbers (i.e. I-1, II-3, etc.) indicating the Section and the consecutive page number from the beginning of the section in the next complete revision.
Page 10: Identifying Revised Material
PIPER COMANCHE SERVICE MANUAL Identifying Revised Material A. 1976 thru 1982: Revised text and illustrations are indicated by a vertical line along the left-hand margin of the frame, opposite revised, added or deleted material. Revision lines indicate only current revisions with changes and additions to or deletions of existing text and illustrations.
Page 11: Warnings, Cautions And Notes
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.
Page 12 PIPER COMANCHE SERVICE MANUAL BRAKES AND WHEELS: Vendor Address: Parker Hannifin Corp (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/ag/wbd ENGINE: Vendor Address: Lycoming Engines (717) 323-6181 652 Oliver Street FAX: (717) 327-7101 Williamsport, PA 17701 http://www.lycoming.com/...
Page 13 PIPER COMANCHE SERVICE MANUAL MAGNETOS: Vendor Address: Teledyne Continental Motors (251) 438-3411 P.O. Box 90 (800) 718-3411 Mobile, AL 36601 FAX: (251) 432-7352 http://www.tcmlink.com Service Support Manual: S-1200 Series High Tension Magnetos, P/N x42001 Service Support Manual: S-20 / S-200 Series High Tension Magnetos, P/N x42002...
Page 14 PIPER COMANCHE SERVICE MANUAL (10) PROPELLER GOVERNOR: Vendor Address: See listing under Propeller, Hartzell above. Governor Maintenance: Manual No. 130B Woodward Governor Company (815) 877-7441 5001 North Second Street FAX: (815) 639-6033 Rockford, IL 61125 (11) STARTER: Vendor Address: Sky-Tec (800) 476-7896 350 Howard Clemmons Rd.
Page 15 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 04/01/09 INTRODUCTION 1A15...
Page 16 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION 04/01/09 1A16...
Page 17: Section Index Guide
PIPER COMANCHE SERVICE MANUAL SECTION INDEX GUIDE SECTION SUBJECT GRID NO. AIRWORTHINESS LIMITATIONS 1Al7 HANDLING AND SERVICING 1A23 INSPECTION STRUCTURE SURFACE CONTROLS lF12A LANDING GEAR AND BRAKE SYSTEM 1H18A POWER PLANT - PA-24-180 VIIA POWER PLANT - PA-24-250 AND PA-24-260...
Page 18 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK INTRODUCTION MM/DD/YY 1A16B...
Page 19: List Of Illustrations
PIPER COMANCHE SERVICE MANUAL LIST OF ILLUSTRATIONS Figure Grid No. 2-1. Three-View of Comanche - PA-24-180 and PA-24-250 ... 1A30 2-2. Three-View of Comanche - PA-24-260 (S/N’s 24-4000 to 24-4246, 24-4248 to 24-4299) ... . .
Page 20 PIPER COMANCHE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Grid No. 3-1. Typical Muffler Fatigue Areas .......
Page 21 PIPER COMANCHE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Grid No. 6-1. Nose Gear Oleo Strut (S/N’s 24-1 to 24-214 incl.) ....1H24 6-2. Nose Gear Oleo Strut Assembly - PA-24-180, PA-24-250 (S/N’s 24-215 and up;PA-24-260 and PA-24-400 .
Page 22 PIPER COMANCHE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Grid No. 6-35. Brake Master Cylinder - PA-24-180 and PA-24-250 (S/N’s 24-1 to 24-2174 incl., 24-2176 to 24-2298 incl.) ..1K23 6-36. Parking Brake Valve ........
Page 23 PIPER COMANCHE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Grid No. 7A-12. Idle and Mixture Adjustment (Fuel Injector) ....2D16 7A-13.
Page 24 PIPER COMANCHE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Grid No. 7C-16. Removing Frozen Spark Plug .......
Page 25 PIPER COMANCHE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Grid No. 9-23. Checking Alternator Output ....... . .
Page 26 PIPER COMANCHE SERVICE MANUAL LIST OF ILLUSTRATIONS (cont.) Figure Grid No. 10-4. Cabin Heater, Defroster and Fresh Air System - PA-24-260 (S/N’s 24-4000 to 24-4246, 24-4248 to 24-4299) ... . .
Page 27 PIPER COMANCHE SERVICE MANUAL LIST OF TABLES Table Grid No. II-I. Leading Particulars and Principal Dimensions ....II-II. Flare Fitting Torques ........
Page 28 PIPER COMANCHE SERVICE MANUAL LIST OF TABLES (cont.) Table Grid No. IX-I. Alternator Checks .........
Page 29 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 04/01/09 LIST OF TABLES 1A16M...
Page 30 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK LIST OF TABLES 04/01/09 1A16N...
Page 31 PIPER COMANCHE SERVICE MANUAL SECTION AIRWORTHINESS LIMITATIONS 1A17...
Page 32 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 1A18...
Page 33 PIPER COMANCHE SERVICE MANUAL SECTION I - AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS SUBJECT GRID NO. 1-1. Airworthiness Limitations ........
Page 34 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK I - TABLE OF CONTENTS 04/01/09 1A20...
Page 35 B. Parts that have accumulated the life limit shall be dispositioned of in accordance with the applicable FARs. Piper recommends life limited parts with no time and/or cycles remaining be completely destroyed.
Page 36 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK I - AIRWORTHINESS LIMITATIONS 04/01/09 1A22...
Page 37 PIPER COMANCHE SERVICE MANUAL SECTION HANDLING SERVICING 1A23...
Page 38 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 1A24...
Page 39 PIPER COMANCHE SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS Paragraph Grid No. 2-1. Introduction ..........
Page 40 PIPER COMANCHE SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS (continued) Paragraph Grid No. 2-40. Tires ...........
Page 41 PIPER COMANCHE SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS (continued) Paragraph Grid No. 2-73. Lubrication ..........
Page 42 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK II - TABLE OF CONTENTS 04/01/09 1A28...
Page 43 PIPER COMANCHE SERVICE MANUAL SECTION II HANDLING AND SERVICING 2-1. Introduction. This section contains routine handling and servicing procedures that are most frequently encountered. Frequent reference to this section will aid the individual by providing information such as the location of various components, ground handling procedures, routine service procedures and lubrication.
Page 44 PIPER COMANCHE SERVICE MANUAL Figure 2-1. Three-View of Comanche PA-24-180 AND PA-24-250 II - HANDLING AND SERVICING 04/01/09 1A30...
Page 50 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS MODEL PA-24-180 PA-24-250 Carburetor Induction ENGINE Manufacturer Lycoming Lycoming Model 0-360-A1A or 0-360-A1D 0-540-A1A5, 0-540-A1B5, 0-540-A1C5 or 0-540-A1D5 FAA type certificate Rated horsepower, RPM: Full throttle 180 HP @ 2700 RPM...
Page 51 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-250 Fuel Injected ENGINE Manufacturer Lycoming Model I0-540-C1B5 FAA type certificate Rated horsepower, RPM: Full throttle 250 HP @ 2575 RPM Oil, SAE number See Figure 2-30 Oil sump capacity 12 qts.
Page 52 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-180 PA-24-250 Carburetor Induction PROPELLER Manufacturer McCauley or Hartzell McCauley or Hartzell Type Constant speed (two blades) Constant speed (two blades) McCauley Hub model 2D36C14 2D36C28 Blade model...
Page 53 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-250 Fuel Injected PROPELLER Manufacturer Hartzell Type Constant speed (two blades) Constant speed (two blades) Hub model HC-A2VK-I Blade model V8433N-7 Diameter, max. 77 in. Diameter, min.
Page 54 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-180 PA-24-250 FUEL SYSTEM Inboard (main) fuel cells Capacity (each) 30 U.S. gal 30 U.S. gal Unusable fuel (each) 2 U.S. gal 2 U.S. gal Outboard (auxiliary) fuel cells —...
Page 55 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-260 Carburetor Induction ENGINE Manufacturer Lycoming Model 0-540-E4A5 FAA type certificate Rated horsepower, RPM: Full throttle 260 HP @ 2700 RPM Oil, SAE number See Figure 2-30 Oil sump capacity 12 qts.
Page 56 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-260 PA-24-260 Fuel Injected - Serial Nos. Fuel Injected - Serial Nos. 24-4783, 24-4804 and up 24-4000 to 24-4782, 24-4784 to 24-4803 inclusive ENGINE Manufacturer Lycoming Lycoming...
Page 57 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-260 Turbo ENGINE Manufacturer Lycoming Model I0-540-R1A5 FAA type certificate Rated horsepower, RPM: Full throttle 260 HP @ 2700 RPM Oil, SAE number See Figure 2-30 Oil sump capacity...
Page 58 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-260 Carburetor Induction and Fuel Injected - S/N’s 24-4000 to 24-4782, 24-4784 to 24-4803 incl. PROPELLER Manufacturer Hartzell Type Constant speed (two blades) Hub model HC-C2YK-1A or...
Page 59 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-260 PA-24-260 S/N’s S/N’s 24-4783, 24-2400 thru 24-4782, 24-4804 and up 24-4784 thru 24-4803 FUEL SYSTEM Inboard (main) fuel cells Capacity (each) 30 U.S. gal 30 U.S. gal Unusable fuel (each) 2 U.S.
Page 60 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-400 ENGINE Manufacturer Lycoming Model I0-720-A1A FAA type certificate lE15 Rated horsepower, RPM: Full throttle 400 HP @ 2650 RPM Oil, SAE number See Figure 2-30 Oil sump capacity...
Page 61 PIPER COMANCHE SERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPLE DIMENSIONS (CONT.) MODEL PA-24-400 PROPELLER Manufacturer Hartzell Type Constant speed (three blades) Hub model HC-A3VK-4 Blade model V8433-7 Diameter, 77.25 in. Diameter, min., 75.25 in. Blade angle (low pitch) 14°...
Page 64 PIPER COMANCHE SERVICE MANUAL 2-7. Torque Wrenches. Torque wrenches should be checked daily and calibrated by means of weights and a measured lever arm to make sure that inaccuracies are not present. Checking one torque wrench against another is not sufficient and is not recommended.
Page 65 PIPER COMANCHE SERVICE MANUAL Torque Requirements. 2-7a. (PIR-PPS20015-1, Rev. W.) CAUTION: DO NOT OVERTORQUE FITTINGS. Table II-I lists the torque values for flared fittings of various sizes and material. NOTE: When installing flared fittings, verify that male threads are properly lubricated.
Page 66 PIPER COMANCHE SERVICE MANUAL (3) The friction drag torque can be determined as follows: Run the nut down to near contact (but not in contact) with the bearing surface and check the "friction drag torque" required to turn the nut.
Page 67 Accomplish this for all fasteners common to the gapped interface. If no gap exists after accomplishing the above, finish torquing to final torque. If a gap remains consult your Piper Dealer’s Service Advisor (DSA) for further assistance.
Page 68 PIPER COMANCHE SERVICE MANUAL TABLE II-IIA. RECOMMENDED NUT TORQUES Bolts - Steel Bolts - Aluminum AN 3 thru AN 20 MS 20004 AN 3DD Series AN 42 thru AN 49 NAS 333 thru NAS 340 AN 525 NAS 464 MS 20033 thru MS 20046...
Page 69 PIPER COMANCHE SERVICE MANUAL TABLE II-IIA. RECOMMENDED NUT TORQUES (cont.) Bolts - Steel Bolts - Aluminum AN 3 thru AN 20 MS 20004 AN 3DD Series AN 42 thru AN 49 NAS 333 thru NAS 340 AN 525 NAS 464...
Page 70 PIPER COMANCHE SERVICE MANUAL Threaded Fastener Installation. 2-7b. (PIR-PPS20015-1, Rev. W.) A. Fastener Lengths Fastener lengths must be long enough to prevent bearing loads on threads. In addition, the fastener or screw must extend through the nut. The specified fastener grip length can be varied by one size (longer or shorter) to meet requirements stated above.
Page 71 PIPER COMANCHE SERVICE MANUAL Figure 2-9. Jacking Arrangements Jacking. 2-11. The airplane is provided with a jack pad on each main spar just outboard of the main landing gear and support position by making use of the tail skid. (Refer to Figure 2-9.) To jack the airplane, proceed as follows: Place the jacks under the jack pads.
Page 72 PIPER COMANCHE SERVICE MANUAL Figure 2-10. Weighing Leveling. (Refer to Figures 2-11 and 2-12.) 2-13. The aircraft may be leveled while on jacks or during the weighing procedure. (Refer to Paragraph 2-12 for weighing.) NOTE: Always level the aircraft laterally first, then longitudinally.
Page 76 PIPER COMANCHE SERVICE MANUAL Cleaning. 2-21. Cleaning Engine Compartment. 2-22. Before cleaning the engine compartment, place a strip of tape on the magneto vents to prevent any solvent from entering these units. CAUTION: DO NOT SPRAY SOLVENT INTO THE GENERATOR OR ALTERNATOR, STARTER, OR INTAKES.
Page 77 PIPER COMANCHE SERVICE MANUAL Cleaning Exterior Surfaces. 2-24. CAUTION: WHEN HOSING DOWN AIRCRAFT AVOID DIRECTING WATER IN THE FUEL TANK VENTS, DRAIN TUBES AND AROUND THE SEALED COVER PLATES AND FILLER CAP ACCESS OPENINGS. The airplane should be washed with a mild soap and water. Harsh abrasive or alkaline soaps or detergents used on painted or plastic surfaces could make scratches or cause corrosion of metal surfaces.
Page 78 PIPER COMANCHE SERVICE MANUAL Cleaning Carpets. 2-27. Use a small whisk broom or vacuum to remove dirt. For soiled spots, use a non-flammable dry-cleaning fluid. Servicing. 2-28. Introduction to Servicing. 2-29. Servicing the airplane includes the replenishment of fuel, oil, hydraulic fluid, tire pressures, lubrication requirements and other items required to completely service the airplane.
Page 79 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 04/01/09 II - HANDLING AND SERVICING...
Page 83 PIPER COMANCHE SERVICE MANUAL Figure 2-14. Brake Reservoir Figure 2-15. Brake Reservoir PA-24 and PA-24-250, S/N’s 24-1 thru 24-2298 PA-24 and PA-24-250, S/N’s 24-2299 and up; and PA-24-260 and PA-24-400 04/01/09 II - HANDLING AND SERVICING 1C8A...
Page 84 PIPER COMANCHE SERVICE MANUAL Tires. 2-40. Servicing Tires. 2-41. The tires should be maintained at the pressure specified in Table II-I. When checking tire pressure, examine the tire for wear, cuts, bruises and slippage. NOTE: At tire change, in PA-24-400 complete inspection per paragraph 6-72a.
Page 85 PIPER COMANCHE SERVICE MANUAL Figure 2-15A. Tire Balancer (c) When balance is attained, put a chalk mark on the sidewall directly below the patch. Use one mark for each half ounce of weight needed. Mark the valve stem location on the tire and the opposite wheel half to assure reassembly in the same position.
Page 87 PIPER COMANCHE SERVICE MANUAL Figure 2-16. Fuel Strainer and Drain Figure 2-17. Fuel Selector and Drain PA-24 and PA-24-250, S/N’s 24-2299 and up; PA-24-400 and PA-24-260 Draining Fuel Valve and Strainers. 2-50. On PA-24-180 and PA-24-250 aircraft bearing Serial Nos. 24-1 to 24-2298 inclusive, the fuel strainer, equipped with an easy drain valve is mounted under the right forward section of the fuselage.
Page 88 PIPER COMANCHE SERVICE MANUAL Draining Fuel System. 2-51. Drain the fuel from the system by opening the drain valve at the bottom of the fuel strainer bowl, or removing the bowl. 2-51a. Fuel System Draining Procedures - Water Contamination. (PA-24-400) Fuel cells should be kept full of fuel during storage and the aircraft refueled as soon as possible after each flight to prevent accumulation of moisture and deterioration of the cells.
Page 89 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 04/01/09 II - HANDLING AND SERVICING 1C11...
Page 90 PIPER COMANCHE SERVICE MANUAL Electrical System. 2-52. Servicing Electrical System. 2-53. Servicing the electrical system involves adding distilled water to the battery to maintain correct electrolyte level, checking cable connections and checking for any spilled electrolyte that would lead to corrosion.
Page 93 PIPER COMANCHE SERVICE MANUAL TABLE II-IV. INSPECTION - OVERHAUL TIME LIMITS Component Inspection Overhaul Weekly 1 Cylinder Each 3 Years On Condition / Each Use 2 Regulator Every 6 Years On Condition / Each Use 2 Pressure Gauge Replace on Condition...
Page 97 PIPER COMANCHE SERVICE MANUAL 2-72a. Conversion Tables. The following tables contain various conversion data that may be useful when figuring capacities, lengths, temperatures, and various weights and measurements from the English system to the metric system or back again: Table II-VI Torque Conversions...
Page 98 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK II - HANDLING AND SERVICING 04/01/09 1C20...
Page 99 PIPER COMANCHE SERVICE MANUAL TABLE II-VI. TORQUE CONVERSION INCH POUNDS (IN.-LBS.) TO CENTIMETER KILOGRAMS (CMKG.) CENTIMETER KILOGRAMS (CMKG.) TO INCH POUNDS (IN.-LBS.) FOOT POUNDS (FT.-LBS.) TO METER KILOGRAMS (MKG.) METER KILOGRAMS (MKG.) TO FOOT-POUNDS (FT.-LBS.) IN.-LBS. CMKG. FT.-LBS. MKG. FT.-LBS.
Page 100 PIPER COMANCHE SERVICE MANUAL TABLE II-VII. DECIMAL CONVERSION II - HANDLING AND SERVICING 04/01/09 1C22...
Page 101 PIPER COMANCHE SERVICE MANUAL TABLE II-VIII. TEMPERATURE CONVERSION CENTIGRADE - FAHRENHEIT Example: To convert 20°C, to Fahrenheit, find 20 in the center column headed (°F - °C); then read 68.0°F, in the column (°F) to the right. To convert 20°F, to Centigrade; find 20 in the center column and read -6.67°C, in the (°C) column to the left.
Page 102 PIPER COMANCHE SERVICE MANUAL TABLE II-IX. WEIGHTS AND MEASURES CONVERSION MULTIPLY TO OBTAIN MULTIPLY TO OBTAIN CENTIMETERS 0.3937 KILOGRAMS 2.205 0.03281 35.27 1000 GRAMS CU. CENTIMETERS 0.001 LITERS 0.06102 CU. IN. LITERS 1000 CU. CM. 0.0002642 U.S. GAL. 61.03 CU. IN.
Page 103 PIPER COMANCHE SERVICE MANUAL TABLE II-X. METRIC CONVERSIONS Example: Convert 1.5 inches to millimeters. (1) Read down inches column to 1. inches. (2) Read across top inch column to 0.5. (3) Read down and across to find millimeters (1.5 inches is 38.10 millimeters).
Page 104 PIPER COMANCHE SERVICE MANUAL TABLE II-XI. DRILL SIZES Decimal/Millimeter Equivalents of Drill Sizes From 1/2" to No. 80 Size Decimal Millimeter Size Decimal Millimeter Size Decimal Millimeter Size Decimal Millimeter Equiv. Equiv. Equiv. Equiv. Equiv. Equiv. Equiv. Equiv. 0.500 12.7000 0.261...
Page 105 PIPER COMANCHE SERVICE MANUAL TABLE II-XII. HOSE SPECIFICATIONS SINGLE WIRE BRAID FABRIC COVERED TUBE HOSE HOSE RECOMMENDE SIZE SIZE SIZE OPER. BURST PROOF BEND PART NO. O.D. I.D. O.D. PRESS PRESS PRESS RADIUS MIL-H-8794- 3-L 3/16 3,000 12,000 6,000 3.00...
Page 106 PIPER COMANCHE SERVICE MANUAL TABLE II-XIII. CONSUMABLE MATERIALS (Sheet 1 of 7) Material Specification Product Vendor ABS-Solvent/ Solarite, #11 Series Solar Compounds Corp. Cements Adhesive EC 801 Minnesota Mining and EC 807 Manufacturing EC 1357 Adhesive Coating and Scotch Grip 210...
Page 107 PIPER COMANCHE SERVICE MANUAL TABLE II-XIII. CONSUMABLE MATERIALS (Sheet 2 of 7) Material Specification Product Vendor Gasket Cement Permatex No. 2 Permatex Company, Inc. Grease, Actuator 2196-74-1 Dukes Astronautics Co. Grease, Aircraft MIL-PRF-23827C Supermil Grease Amoco Instrumentation, (See Note at end.) No.
Page 108 PIPER COMANCHE SERVICE MANUAL TABLE II-XIII. CONSUMABLE MATERIALS (Sheet 3 of 7) Material Specification Product Vendor Grease, Lubricating, MIL-G-21164 Aeroshell Grease Shell Oil Company Molybdenum No. 17 Disulfide, Low and High Temperature Royco 64C Royal Lubricants Co. Castrolease MSA (c) Burmah Castrol LTD.
Page 109 PIPER COMANCHE SERVICE MANUAL TABLE II-XIII. CONSUMABLE MATERIALS (Sheet 4 of 7) Material Specification Product Vendor Leak Detector MIL-PRF-25567 ALPHA 73 U.S. Gulf Corporation Solution for Oxygen Leak Detector Oxygen Systems Type 1 Leak Tec #16-OX American Gas and Chemical Co. LTD.
Page 110 PIPER COMANCHE SERVICE MANUAL TABLE II-XIII. CONSUMABLE MATERIALS (Sheet 5 of 7) Material Specification Product Vendor Rain Repellent FSCM 50150 Repcon Unelco Corporation Safety Walk Flextred 300 Wooster Products, Pressure Sensitive Incorporated Sealant, Adhesive, A-A-59293 PPG Aerospace Polysulfide PRC-DeSoto Sealant, Airframe...
Page 111 PIPER COMANCHE SERVICE MANUAL TABLE II-XIII. CONSUMABLE MATERIALS (Sheet 6 of 7) Material Specification Product Vendor Sealant, Fuselage Class A-1/2, A-2, B-2 H.S. Bancroft Corp.Structure B-4, B-6, B-8 EC 1239 Minnesota Mining and Manufacturing Industrial Specialties Division EC 612 (Leak Marker or Weather Stripping, etc) G.E.-SS-4004 (Primer)
Page 112 PIPER COMANCHE SERVICE MANUAL TABLE II-XIII. CONSUMABLE MATERIALS (Sheet 7 of 7) Material Specification Product Vendor Thread Sealant A-A-58092 Permacel 412 Johnson & Johnson, Inc. for High Pressure Permacel Division Oxygen System Toluol TT-M-261 Local Supplier Trichlorethylene MIL-T-7003 Perm-A-Clor Dextrex Chemical Industries, Inc.
Page 113 PIPER COMANCHE SERVICE MANUAL Table II-XIV. Vendor Contact Information (Sheet 1 of 3) Corrosion Reaction Consultants, Inc. American Gas and H. S. Bancroft Corp. Limekin Pike Chemical Co. LTD One Rockhill Dresher, PA 19025 220 Pegasus Avenue Industrial Park Northvale, NJ 07647...
Page 114 PIPER COMANCHE SERVICE MANUAL TABLE II-XIV. VENDOR CONTACT INFORMATION (Sheet 2 of 3) PPG Aerospace PRC-DeSoto Solar Compounds Corp. 11601 United Street 1201 W. Blancke Street Miller-Stephenson Mojave, California 93501 Linden, NJ 07036 George Washington Hwy. 661-824-4532 201-862-2813 Danbury, Ct 06810...
Page 115 PIPER COMANCHE SERVICE MANUAL TABLE II-XIV. VENDOR CONTACT INFORMATION (Sheet 3 of 3) WECHEM, INC. 5734 Susitna Drive Harahan, LA 70123 800-426-0512 504-733-2218 www.wechem.com Wooster Products, Inc. 1000 Spruce Street Wooster, OH 44691 800-321-4936 In OH 216-264-2844 04/01/09 II - HANDLING AND SERVICING...
Page 116: Lubrication
PIPER COMANCHE SERVICE MANUAL Lubrication. 2-73. Oil Systems (Engine). (Refer to latest revisions of Lycoming Service Instruction No. 1014 and 2 74. Lycoming Service Bulletin No. 480.) Servicing Oil System. 2-75. The engine oil level should be checked before each flight and the oil changed as specified in Paragraph 2-81.
Page 117: Oil Screen (Pressure)
PIPER COMANCHE SERVICE MANUAL Figure 2-18. Oil Suction Screen Figure 2-19. Oil Pressure Screen Oil Screen (Pressure). 2-79. The pressure screen located in a housing on the accessory case of the engine between the magnetos, should be cleaned at each oil change to remove any accumulation of sludge and to examine for metal filings or chips.
Page 118: Recommendations For Changing Oil
PIPER COMANCHE SERVICE MANUAL Recommendations f or Changing Oil. (Refer to latest revision of Lycoming Service Bulletin No. 2-81. 480 and Lycoming Service Instruction No. 1014.) Oil Change Intervals. For engines equipped with full-flow oil filters, change the oil and filter each 50 hours of engine operation or every four months, whichever comes first.
Page 119: Lubrication Instructions
PIPER COMANCHE SERVICE MANUAL Lubrication Instructions. 2-82. Proper lubrication procedures are valuable both as a means of prolonging the service life of the airplane and reducing the frequency of repairs. The periodic application of recommended lubricants to their relevant bearing surfaces, together with cleanliness, ensures the maximum efficiency and utmost service of all moving parts.
Page 120 PIPER COMANCHE SERVICE MANUAL Use extra care when greasing the constant speed propeller hub to avoid blowing the clamp gaskets. Remove one grease fitting and apply grease to the other fitting until fresh grease appears at the hole of the removed fitting.
Page 121 PIPER COMANCHE SERVICE MANUAL TABLE II-XVI. LUBRICANT SPECIFICATION CROSS-REFERENCE (Sheet 1 of 2) Old Spec / Product New Spec / Product Product Type superceded by MIL-C-16173 MIL-PRF-16173E Corrosion Preventative Compound, Solvent Cutback, Cold Application. MIL-G-3278 MIL-PRF-23827C Grease, Aircraft & Instrument, Gear and Actuator Screw.
Page 122 PIPER COMANCHE SERVICE MANUAL TABLE II-XVI. LUBRICANT SPECIFICATION CROSS-REFERENCE (Sheet 2 of 2) Old Spec / Product New Spec / Product Product Type superceded by MS-122 * MS-122AD * Dry-Lubricant MS-122-6075 * MS-122AD * Dry-Lubricant Parker O-Ring Lube * Parker O-LUBE *...
Page 123 PIPER COMANCHE SERVICE MANUAL TABLE II-XVII. LUBRICATION - SPECIAL INSTRUCTIONS 1. BEARINGS AND BUSHINGS - Clean exterior with a quick-drying solvent before relubricating (except sealed bearings). 2. LUBRICATION POINTS - Wipe all lubrication points clean of old grease, oil, dirt, etc. before lubricating.
Page 124 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. STABILATOR TRIM TAB AND RUDDER HINGES MIL-PRF-7870C 100 HR. 2. BAGGAGE DOOR HINGES MIL-PRF-7870C 100 HRS. 3. STABILATOR TRIM PULLEY MIL-PRF-7870C 100 HRS. 4. FLAP TRANSMISSION (See Spec. Instr. 13) MIL-PRF-23827C 500 HRS.
Page 125 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. STABILATOR TRIM TAB AND RUDDER HINGES MIL-PRF-7870C 100 HRS. 2. STABILATOR TRIM PULLEYS MIL-PRF-7870C 100 HRS. 3. BAGGAGE DOOR HINGES MIL-PRF-7870C 100 HRS. 4. FLAP TRANSMISSION (See Spec. Instr. 13) MIL-PRF-23827C 500 HRS.
Page 126 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. STABILATOR TRIM TAB AND RUDDER HINGES MIL-PRF-7870C 100 HRS. 2. RUDDER PULLEYS MIL-PRF-7870C 100 HRS. 3. STABILATOR TRIM PULLEYS MIL-PRF-7870C 100 HRS. 4. FLAP TRANSMISSION (See Spec. Instr. 13) MIL-PRF-23827C 500 HRS.
Page 127 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. ROLLER ATTACHMENT FITTING MIL-PRF-7870C 100 HRS 2. CONTROL WHEEL CHAIN, VERTICAL AND HORIZONTAL MIL-PRF-7870C 500 HRS 3. STABILATOR CONTROL TUBE BEARING AND SQUARE TUBE MOUNTING BEARING MIL-PRF-7870C 100 HRS CAUTION: DO NOT OVER LUBRICATE PEDESTAL CONTROLS AND COCKPIT CONTROLS.
Page 128 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. LOCK, PIN, STEP MIL-PRF-23827C 100 HRS. 2. STEP LOCK PULLEYS AND RELEASE ARM PIVOT BEARING MIL-PRF-7870C 100 HRS. 3. FLAP STOP MIL-PRF-23827C 100 HRS. 4. PIVOT POINT AND ROD END MIL-PRF-7870C 100 HRS.
Page 129 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. FLAP TRACK ROLLER INNER BUSHINGS (See Item #7, Figure 4-3.), (STEEL OR NYLON ROLLERS) MIL-PRF-7870C 50 HRS. 2. FLAP TRACK (STEEL ROLLERS ONLY) ALL PURPOSE SLIP SPRAY (See Spec. Instr. 14.) DUPONT NO. 6611 50 HRS.
Page 130 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. STEERING ROD END BEARING, STEERING BELLCRANK PIVOT BEARING, STEERING ARM BUSHING, GEAR ALIGNING BUSHING. MIL-PRF-7870C 100 HRS. (PA-24/PA-24-150/-260) NOSE GEAR PUSH-PULL END BEARING MIL-PRF-7870C 100 HRS. (PA-24-400 only) DRAG LINK PIVOT MIL-PRF-23827C 100 HRS.
Page 131 PIPER COMANCHE SERVICE MANUAL Figure 2-26. Lubrication Chart - Nose Landing Gear (Sheet 2 of 2) 04/01/09 II - HANDLING AND SERVICING 1C53...
Page 132 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. BALANCE WEIGHT PIVOT BOLT MIL-PRF-7870C 100 HRS. 2. RUDDER CONTROL CABLE AND TRIM TUBE END BEARINGS MIL-PRF-7870C 100 HRS. 3. STABILATOR TRIM TAB CONTROL ROD MIL-PRF-7870C 100 HRS. 4. STABILATOR TRIM SCREW (See Spec. Instr. 13) MIL-PRF-81322G 100 HRS.
Page 133 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. RUDDER PEDALS, CONTROL CABLE ENDS, STEERING ROD ENDS MIL-PRF-7870C 100 HRS. 2. BRAKE ACTUATING MECHANISM, BRAKE CYLINDER ENDS MIL-PRF-7870C 100 HRS. 3. RUDDER PEDAL TORQUE TUBES AND BLOCK BEARINGS MIL-PRF-7870C 100 HRS.
Page 134 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. AILERON PUSH-PULL ROD END BEARINGS, CONTROL CABLE ATTACHMENT POINTS MIL-PRF-7870C 100 HRS. 2 BELLCRANK PIVOT BEARINGS MIL-PRF-7870C 100 HRS Figure 2-29. Lubrication Chart - Aileron Bellcrank II - HANDLING AND SERVICING 04/01/09...
Page 135 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. PROPELLER GREASE FITTING, MIL-PRF-23827C 100 HRS. RIGHT (See Spec. Instr. 11) AEROSHELL 6 (Hartzell Props) 2. PROPELLER GREASE FITTING, MIL-PRF-23827C 100 HRS. LEFT (See Spec. Instr. 11) AEROSHELL 6 (Hartzell Props) 3. ENGINE OIL SUMP,...
Page 136 PIPER COMANCHE SERVICE MANUAL COMPONENT LUBRICANT FREQUENCY 1. STRUT ATTACHMENT BEARING MIL-PRF-23827C 100 HRS. 2. GEAR OLEO STRUT FILLER (See Spec. Instr. 3) MIL-PRF-5606H AS REQUIRED 3. RETRACTION CABLE END BEARING AND SIDE BRACE ATTACHMENT BUSHING MIL-PRF-7870C 100 HRS. 4. GEAR DOOR HINGE, RETRACTION ROD END BEARINGS,...
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Page 139 PIPER COMANCHE SERVICE MANUAL SECTION INSPECTION...
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Page 141 PIPER COMANCHE SERVICE MANUAL SECTION III - INSPECTION TABLE OF CONTENTS Paragraph Grid No. 3-1. General ..........
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Page 143 INSPECTION 3-1. General 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.
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Page 145 B. Refer to the remainder of this section for Piper’s recommended Inspection Programs. They include the frequency and extent of the inspections required for the continued airworthiness of these airplanes.
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Page 147 Avantext TechPubs Maintenance Libraries for Piper Aircraft (see www.Avantext.com). 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 148 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 149 PIPER COMANCHE 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 150 The Progressive Inspection program is designed to permit the best utilization of the aircraft through the use of a planned inspection schedule. This schedule is prepared in a manual form, which is available exclusively by subscription to the Avantext TechPubs Maintenance Libraries for Piper Aircraft (see www.Avantext.com): P/N 761-541 for the Comanche Series.
Page 151 (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 3-8.) C.
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Page 153 PIPER COMANCHE SERVICE MANUAL TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 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;...
Page 154 PIPER COMANCHE SERVICE MANUAL TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 (cont.) Inspection NATURE OF INSPECTION Interval (Hrs) B. ENGINE GROUP (CONT.) 13. Inspect cylinders for cracked or broken fins ............14. Fill engine with oil per lubrication chart and Table II-VI........
Page 155 PIPER COMANCHE SERVICE MANUAL TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 (cont.) Inspection NATURE OF INSPECTION Interval (Hrs) 40. Lubricate all controls per lubrication chart in Section II ........41. Reinstall engine cowling; except for PA-24-260 Turbo, proceed to Turbocharger Group ..........
Page 156 PIPER COMANCHE SERVICE MANUAL TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 (cont.) Inspection NATURE OF INSPECTION Interval (Hrs) D. CABIN AND COCKPIT GROUP Inspect cabin entrance door, baggage compartment door and windows for damage, operation and security..........Inspect upholstery for tears ..................
Page 157 PIPER COMANCHE SERVICE MANUAL TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 (cont.) Inspection NATURE OF INSPECTION Interval (Hrs) E. FUSELAGE AND EMPENNAGE GROUP Remove inspection panels and plates. (See Special Inspections.) ......Inspect fluid in brake reservoir. (Fill as required.)..........
Page 158 PIPER COMANCHE SERVICE MANUAL TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 (cont.) Inspection NATURE OF INSPECTION Interval (Hrs) E. FUSELAGE AND EMPENNAGE GROUP (CONT.) 21. Inspect rudder, stabilator, and stabilator trim cables; and cable terminals, turnbuckles, guides, fittings, and pulleys for safety, condition, and operation.
Page 159 PIPER COMANCHE SERVICE MANUAL TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 (cont.) Inspection NATURE OF INSPECTION Interval (Hrs) 18. Inspect switches to indicators registering fuel tank quantity ......... 19. Inspect fuel cell vents..................... 20. Reinstall inspection plates and fairings..............
Page 160 PIPER COMANCHE SERVICE MANUAL TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 (cont.) Inspection NATURE OF INSPECTION Interval (Hrs) H. SPECIAL INSPECTIONS See Special Inspections, Requirements, below. OPERATIONAL INSPECTION Check fuel pump and fuel tank selector operation..........Check indication of fuel quantity and pressure or flow gauges ......
Page 161 TABLE III-I. INSPECTION REPORT - PA-24 / PA-24-250/260/400 (cont.) K. NOTES Refer to Piper's Customer Service Information File P/N 1753-755 for latest revision dates to Piper Inspection Reports/Manuals and this service manual. References to section, paragraph, figure, or table are to the appropriate section, paragraph, figure, or table in this manual.
Page 162 P/N 10-391586 with molded batch codes 0000 thru 8601: inspect in accordance with Bendix Service Bulletin No. 629 per Piper Vendor Service Publication No. 69. 14. Examine cables for broken strands by wiping the cable with a cloth along the entire length of the cable.
Page 163 If noticeable gasket extrusion or fuel leakage is evident, see latest revisions of Crane/Lear Romec Service Bulletin No. 101SB020, Rev. 3, per Lycoming Service Bulletin No. 529B and Piper Service Bulletin No. 1035A.
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Page 167 Lycoming Service Table of Limits SSP1776. For airplanes equipped with fuel selector valves P/N’s 11383-000/-002/-003/- 004 or with Piper Kit No. 764-295 installed (i.e., service replacement fuel selector valve P/N 77413-002), each 400 hours time-in-service, annually, or whenever valve is difficult to rotate, whichever comes first, service the fuel selector valve per paragraph 8-14a.
Page 168 PIPER COMANCHE SERVICE MANUAL (c) Each 500 Hours Remove and flush oil radiator. Clean and lubricate stabilator trim drum screw. Remove propeller; remove sludge from crankshaft. Clean any residual sludge clinging to the exterior of propeller / crankshaft mating surfaces.
Page 169 TSO-C53a - Type D hoses which are replaced on condition. Muffler replacement is recommended at or near 1000 hours time-in-service. Replace outboard aileron hinges. Order and use Piper Kit No. 760-914, one per aileron. In PA-24-260 Turbos, remove all Turbocharger components from the engine.
Page 170 PIPER COMANCHE SERVICE MANUAL Each 2000 Hours Each 2000 hours or seven (7) years, whichever occurs first, remove interior 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 171 PIPER COMANCHE SERVICE MANUAL (c) Each Ninety (90) Days Remove, drain and clean fuel filter bowl and screen per paragraph 8-20, 8-21, or 8-22, as applicable. (d) Each Four (4) Months Change the engine oil and full-flow cartridge-type oil filter each four (4) months or every 50 hours time-in-service, whichever comes first.
Page 172 PIPER COMANCHE SERVICE MANUAL (j) Each Five (5) Years In PA-24s and PA-24-250s equipped with McCauley propellers, overhaul or replace propeller each five years or each 1000 or 1200 hours. (Verify TBO in McCauley Service Bulletin No. 137AD, or later.)
Page 173 PIPER COMANCHE SERVICE MANUAL (m) Each Eight (8) Years 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 except for TSO-C53a - Type D hoses which are replaced on-condition.
Page 174 (a) Each Flight In PA-24-400 S/N’s 26-1 thru 26-148, for airplanes which installed Kit No. 756- 922 and have not subsequently installed Piper Kit No. 756-994, inspect fuel purge valve hose assembly P/N 17766-88 for signs of deterioration before each flight.
Page 175 PIPER COMANCHE SERVICE MANUAL (c) Operation in High Salt or High Humidity Environment Item Inspection Inspection Interval Fuselage, Empennage, Remove floor panels and exterior 200 Hours. and Wings. access plates; inspect for corrosion. Landing Gear. Inspect for corrosion and lubrication.
Page 176 PIPER COMANCHE SERVICE MANUAL (e) 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 177 100 hour period. The system should also be checked carefully before winter operation when the cabin heat will be in use. NOTE: Piper recommends that all PA-24 airplanes be fitted with a new muffler at or near the 1000 hour period of which the muffler has been used.
Page 178 PIPER COMANCHE SERVICE MANUAL Removal of the tail pipe and stacks is required for inspection of the muffler baffle. Remove or loosen all exhaust shields, carburetor and cabin heat muffs, shrouds, heat blankets, etc., as required to permit inspection of the complete system. Perform the necessary cleaning operations and inspect all external surfaces for dents, cracks and missing parts.
Page 179 PIPER COMANCHE SERVICE MANUAL Figure 3-2. Exhaust System Inspection Points (Sheet 1 of 2) 04/01/09 III - INSPECTION 1D41...
Page 180 PIPER COMANCHE SERVICE MANUAL Figure 3-2. Exhaust System Inspection Points (Sheet 2 of 2) III - INSPECTION 04/01/09 1D42...
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Page 183 PIPER COMANCHE SERVICE MANUAL 3-9. 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 184 PIPER COMANCHE SERVICE MANUAL A. Lightning Strike (continued) Item Inspection Inspection Interval Static Wicks. Replace. Each occurrence, before further flight. Bearings. Inspect all control surface hinges and Each occurrence, bearings, and landing gear and wheel before further flight. bearings for pitting and damage.
Page 185 (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 Lycoming Maintenance Manual procedures. If there are any questions regarding repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA).
Page 186 PIPER COMANCHE SERVICE MANUAL C. Severe Turbulence, Hard or Overweight Landing (continued) Item Inspection Inspection Interval Fuselage. Loose or missing rivets, door alignment, Each occurrence, windows and attachments for overstress, before further flight. cracks or damage. Wing carry through member for overstress damage.
Page 187 MANUFACTURER'S MAINTENANCE MANUAL, AND FAR PART 43. PAY PARTICULAR ATTENTION TO SILT, CORROSION AND CONTAMINANTS. B. Follow Piper and 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 188 PIPER COMANCHE SERVICE MANUAL Flood Damage, Immersion in Water (continued) 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 189 PIPER COMANCHE SERVICE MANUAL Flood Damage, Immersion in Water (continued) 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 190 PIPER COMANCHE SERVICE MANUAL Flood Damage, Immersion in Water (continued) 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 191 PIPER COMANCHE SERVICE MANUAL Flood Damage, Immersion in Water (continued) 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 193 PIPER COMANCHE SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST This table is a cumulative list of Piper service publications (i.e. - Service Bulletins, Service Letters, and Vendor Service Publications) applicable to the airplane models covered by this manual, with the following exceptions: A.
Page 194 SB 751 Spar Cap Chafing Inspection SB 771 Parking Brake Application SB 836A Aluminum Wire Inspection/Replacement SB 855 Use of Automobile Gasoline in Piper Aircraft SB 980 Shoulder Harness Installation SB 1041 Distribution of Airborne SL No. 56 SL 317 754-230...
Page 195 PIPER COMANCHE SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-24 1958-1964 SL 682B Lycoming SB No. 367D Required Inspection of (cont.) (cont.) Piston Pin SL 687 760-747 Stabilator Modification SL 695 Edo-Aire Mitchell SL No. ML-38,...
Page 196 PIPER COMANCHE SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-24-250 1958-1959 SB 180 Fuel Cell Vent Tubes Modification (cont.) (cont.) SB 187 754-221 or 754-217 Landing Gear Safety Switches SB 191 Aileron Hinge Bracket...
Page 197 (cont.) (cont.) SB 771 Parking Brake Application SB 836A Aluminum Wire Inspection/Replacement SB 855 Use of Automobile Gasoline in Piper Aircraft SB 980 Shoulder Harness Installation SB 1041 Distribution of Airborne SL No. 56 SL 317 754-230 50 Ampere Generator Installation...
Page 198 PIPER COMANCHE SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-24-250 1959-1963 SB 216 756-756 Fuel Cell Drain Modification 1959-1964 SB 1022 460-632 Distribution of Purolator SB 090298.01 1960 SL 347 754-358 Installation of Dry Vacuum Pump Exhaust Tube...
Page 199 (O-ring Deterioration) 1965-1972 SB 677 Publications for Aircraft Operation SB 855 Use of Automobile Gasoline in Piper Aircraft SL 636 Prestolite SB No ASM-8, Alternator Fan Replacement VSP 148 Lycoming SB No. 554 and SB No. 554 Supplement 1 VSP 152 Lycoming SB No.
Page 200 Spar Cap Chafing Inspection SB 771 Parking Brake Application SB 836A Aluminum Wire Inspection/Replacement SB 855 Use of Automobile Gasoline in Piper Aircraft SB 980 Shoulder Harness Installation SB 1026 753-910 Distribution of Parker Hannifin Airbourne SL No. 48 SB 1041 Distribution of Airborne SL No.
Page 201 PIPER COMANCHE SERVICE MANUAL TABLE III-II. SERVICE PUBLICATIONS LIST (cont.) Model Year Pub No. Kit No. Subject PA-24-400 1964 SL 453 756-306 Engine Mount Refinishing (cont.) (cont.) SL 459 Mixture Control Cable Shield SL 470 492-671 Starter Vibrating SL 546A...
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Page 203 PIPER COMANCHE SERVICE MANUAL SECTION STRUCTURES...
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Page 205 PIPER COMANCHE SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS Paragraph Grid No. 4-1. Introduction ..........
Page 206 PIPER COMANCHE SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS (continued) Paragraph Grid No. 4-40. Adjustment Of Door Locking Mechanism. (PA-24-250. Serial Nos. 24-2844 to 24-3284) ......
Page 207 PIPER COMANCHE SERVICE MANUAL SECTION IV STRUCTURE 4-1. Introduction. This section covers the removal and installation procedures for the main structural components, for checking and balancing the control surfaces and minor repairs. No major structural repairs are recommended. Minor replacement of skins may be made providing there is no internal damage. Minor repairs such as patching the skin, welding, etc., may be made in accordance with the methods,...
Page 208 PIPER COMANCHE SERVICE MANUAL Figure 4-1. Landing Light Installation 4-6. Removal Of Landing Light And Housing. (Refer to Figure 4-1.) A. Remove wing tip. B. Remove the sheet metal screws from the landing light window assembly (1). C. Remove the machine screws and clamps (2) holding the lamp (3).
Page 209 Inspect both right and left ailerons as follows: NOTE: If the aileron spar and aileron reinforcement plates show no evidence of cracks, and if Piper Kit No 763-893 is installed, this recurring inspection requirement is relieved.
Page 210 PIPER COMANCHE SERVICE MANUAL 4-10. Removal Of Flap. (PA-24-400) A. Remove the access plate to the flap bellcrank located on the rear-under side of the wing. Remove the main gear wheel well splash pan. B. A flap step lock unit is located at the rear-inboard portion of the right wing. Enter through the wheel well and release the spring tension and disengage the step lock.
Page 211 PIPER COMANCHE SERVICE MANUAL 4-13. Removal Of Rudder. A. Remove the tail cone fairing B. Disconnect the navigation lights at the wire quick-disconnect C. Disconnect the control cables from the rudder horn. D. Disconnect the rudder horn from the lower rudder hinge bracket.
Page 212 If corrosion or wear is found other than on the torque tube itself, order replacement parts through your Piper Aircraft Inc. authorized dealer, or repair per the corrosion removal procedures in the latest revision of AC 43.13-1. If surface corrosion is found on the stabilator torque tube, removal of corrosion is permitted only to the extent noted in Table IV-I.
Page 213 PIPER COMANCHE SERVICE MANUAL TABLE IV-I. TOLERANCE Tube Tube Torque Tube Minimum Minimum Part Number Model Effectivity Outside Dia. Wall Thickness 20203-00 PA-24 24-1 to 24-102 2.3113 .105 PA-24-250 24-1 to 24-102 20203-03 PA-24 24-103 to 24-3687 2.3113 .105 PA-24-250...
Page 215 4-23. Installation Of Wing. (Refer to Figure 4-2.) NOTE: When installing a “replacement” wing, a Stall Warning Flight Test is required upon completion of wing installation. Contact Piper factory Technical Support through your Piper Dealer for further instruction. A. Slide the wing panels into the fuselage until the main wing spars butt against each other at the spar center attachment fitting.
Page 216 PIPER COMANCHE SERVICE MANUAL Figure 4-3. Flap Roller Installation Figure 4-4. Aileron Bearing Installation (Electrically Operated) 4-25. Installation Of Flap. (PA-24-250 Electrically Operated And PA-24-260.) CAUTION: FLAP SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. A. Ascertain that the flap control rod is installed to the flap.
Page 217 PIPER COMANCHE SERVICE MANUAL 4-26. Installation Of Flap. (PA-24-400) CAUTION: FLAP SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. A. Ascertain that the flap control rod is installed on the flap. B. Position the flap in place, lubricate the flap rollers and tracks (refer to Lubrication Chart, Section II) and install the lower roller assemblies.
Page 218 PIPER COMANCHE SERVICE MANUAL 4-31. Heated Pitot Tube. A. Connect the quick-disconnect fitting on the wire for the heated pitot tube to the associated wing wires. Attach the heated pitot tube assembly to the pitot tube mounting mast on the bottom skin of the left wing panel.
Page 219 PIPER COMANCHE SERVICE MANUAL C. Install the right stabilator in a similar manner as the left stabilator. D. Connect inboard trailing edges of the left and right stabilator and install the bolt. Attach the stabilator trim rod to the stabilator trim tabs and install the bolt.
Page 220 PIPER COMANCHE SERVICE MANUAL Figure 4-5. Door Installation 4-39. Installation of Cabin Door. The entrance door on the Comanche is made of formed aluminum assemblies spot welded together. This type of construction gives a ridged assembly, but still retains the flexibility needed for proper fitting of the door.
Page 221 PIPER SENECA SERVICE MANUAL Figure 4-6. Door Locking Mechanism PA-24-250, Serial Nos. 24-2844 to 24-3284 4-40. Adjustment Of Door Locking Mechanism. (PA-24-250, Serial Nos. 24-2844 to 24-3284) The following is the procedure for adjusting the door latching mechanism on the Comanche. (Refer to Figure 4-6.)
Page 222 PIPER SENECA SERVICE MANUAL Figure 4-7. Door Locking Mechanism PA-24-250, Serial Nos. 24-2844 to 24-3284 4-41. Installation And Adjustment Of Door Locking Mechanism. (PA-24-250 Serial Nos. 24-3285 and up, PA-24-260 and PA-24-400) (Refer to Figure 4-7.) A. Install the upper (1) and lower (2) latch assemblies.
Page 223 PIPER SENECA SERVICE MANUAL H. Install door lock release tube (12) and spring (13). Adjust to allow the forward portion of the outside handle to move out finger width when the rearward portion is depressed. Check the operation of the latch handle and ascertain that the upper and lower latches (1 and 2) are...
Page 224 PIPER SENECA SERVICE MANUAL 4-43a. Electrical Bonding A. General (PIR-PPS55006, Rev. Z) All electrical and electronic equipment and specified components shall be installed in such a manner as to provide a continuous low resistance path (bonds) from the equipment enclosure/component to the airplane structure. Bonds must be installed to ensure that the structure and equipment are electrically stable and free from the hazards of lightning, static discharge, electrical shock, etc.
Page 225 PIPER SENECA SERVICE MANUAL TABLE IV-III. ELECTRICAL BONDING RESISTANCE INDEX Maximum Allowable Component Resistance Value in Ohms Engine Mount(s) .003 Generator(s) .010 Ailerons .003 Elevator / Stabilator .003 Rudder .003 Alternator(s) .010 Trim Tab(s) Conventional Hinge .003 Piano Hinge .010 Instrument Panel Inserts .010...
Page 226 PIPER SENECA SERVICE MANUAL 4-43b. Metal Wire Stitching Repair. (See Figure 4-7b.) (PIR-PPS20024, Rev. A.) CAUTION: METAL/WIRE STITCHING (AND THE ALTERNATE METHOD OF JOINING DESCRIBED BELOW) SHALL ONLY BE USED FOR NON-STRUCTURAL, NON- LOAD CARRYING APPLICATIONS. A metal/wire stitching process is used to staple fabric and rubber seal materials to engine baffles and some composite materials.
Page 227 PIPER COMANCHE SERVICE MANUAL Figure 4-7b. Metal Wire Stitching Repair 04/01/09 IV - STRUCTURES 1E19...
Page 228 Paragraph 4-46 describes Fracture and Patch Repairs such as puncture, breaks and holes that have penetrated through the structure and damaged the fiberglas cloth. A repair kit, part number 756- 729, that will furnish the necessary material for such repairs is available through Piper Aircraft Distributors.
Page 229 PIPER COMANCHE SERVICE MANUAL After repair has cured for 24 hours, sand patched area, using a sanding block with fine wet sandpaper. Finish by priming, again sanding and applying color coat. 4-46. Fiberglas Fracture And Patch Repairs. A. Remove wax, oil and dirt from around the damaged area with acetone, methylethylketone or equivalent.
Page 230 PIPER COMANCHE SERVICE MANUAL N. Using dry 80 grit sandpaper on a power sander or sanding block, smooth patch and blend with surrounding surface. Should air pockets appear while sanding, puncture and fill with catalyzed resin. A hypodermic needle may be used to fill cavities. Let cure and resand.
Page 231 PIPER COMANCHE SERVICE MANUAL 4-49. Repair of Rudder. WARNING: NO REPAIRS TO THE RUDDER ARE ALLOWED, OTHER THAN THOSE STATED HEREIN. THE STRUCTURAL INTEGRITY OF THE ASSEMBLY MUST BE MAINTAINED. Repairs are limited to replacement of complete skin sections, ribs, hinges, spars, etc. and paint.
Page 233 PIPER COMANCHE SERVICE MANUAL (PA-24-180, 230 and 260) After complying with steps (1) (2) and both the NOTE and CAUTION proceed as follows: Level the aircraft and set the trim tab in neutral position. The control arm must be connected between the stabilator trim tab horns and the trim tab adjustment mechanism.
Page 234 PIPER COMANCHE SERVICE MANUAL Figure 4-7d. Checking Stabilator Free Play IV - STRUCTURES 04/01/09...
Page 235 PIPER COMANCHE SERVICE MANUAL 4-51. Checking And Balancing Rudder. (Refer to Figure 4-7e.) The rudder must be checked to assure it is properly balanced whenever it has been repaired, repainted, or altered in any manner. The balancing requirement of the rudder must be checked with the complete assembly removed from the airplane NOTE: The PA-24-400 rudder is properly balanced as long as head weight is installed.
Page 236 PIPER COMANCHE SERVICE MANUAL 4-52. Aileron Balancing. NOTE: The ailerons are properly balanced as long as the lead weight and steel arm are installed. No further balancing is required. Should repainting be required it will be necessary to remove all the old paint prior to applying the new paint to insure staying within the balance limits.
Page 237 PIPER COMANCHE SERVICE MANUAL Figure 4-7e. Checking and Balancing Rudder 04/01/09 IV - STRUCTURES...
Page 245 PIPER COMANCHE SERVICE MANUAL SECTION SURFACE CONTROLS 1F12A...
Page 246 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 1F12B...
Page 247 PIPER COMANCHE SERVICE MANUAL SECTION V - SURFACE CONTROLS TABLE OF CONTENTS Paragraph Grid No. 5-1. Introduction ..........
Page 248 PIPER COMANCHE SERVICE MANUAL SECTION V - SURFACE CONTROLS TABLE OF CONTENTS (continued) Paragraph Grid No. 5-38. Installation of Stabilator Trim Mechanism .....
Page 249 PIPER COMANCHE SERVICE MANUAL SECTION V SURFACE CONTROLS 5-1. Introduction This section is comprised of information for removal installation, rigging and adjustment of surface controls and their related component throughout the PA-24 series aircraft. For the removal and installation of structural surfaces refer to Section IV.
Page 250 PIPER COMANCHE SERVICE MANUAL 5-3a. Flight Control Surface Travel. See Table V-I for specifications, see appropriate section for rigging instructions. 5-3b. Flight Control Cable Tension. CAUTION: CABLE TENSIONS GIVEN IN TABLE V-I APPLY ONLY TO AIRPLANES WITHOUT AUTOPILOT BRIDLE CABLE INSTALLATIONS. IF AN AUTOPILOT USING BRIDLE...
Page 251 PIPER COMANCHE SERVICE MANUAL Figure 5-1. Correct Method of Installing Rod End Bearings 04/01/09 V - SURFACE CONTROLS 1F17...
Page 252 PIPER COMANCHE SERVICE MANUAL TABLE V-I. FLIGHT CONTROL SURFACES RIGGING LIMITS V - SURFACE CONTROLS 04/01/09 1F18...
Page 253 PIPER SENECA SERVICE MANUAL TABLE V-I. FLIGHT CONTROL SURFACES RIGGING LIMITS (cont.) 04/01/09 V - SURFACE CONTROLS 1F18A...
Page 254 PIPER SENECA SERVICE MANUAL 5-4a. 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. The following data may help in detecting the presence of these conditions: A.
Page 255 PIPER COMANCHE SERVICE MANUAL Figure 5-3. External Cable Wear Patterns C. Internal Cable 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. This condition, shown in Figure 5-4, is not easily detected unless the strands of the cable are separated.
Page 256 PIPER COMANCHE SERVICE MANUAL Figure 5-4. Internal Cable Wear 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.
Page 257 PIPER COMANCHE SERVICE MANUAL Cable Fittings 100 Hour Standard Inspection Check swaged terminal reference marks for any indication of cable slippage within fitting. Inspect fitting assembly for distortion and/or broken strands at the terminal. Check that all bearings and swivel fittings (bolted or pinned) pivot freely to prevent binding and subsequent failure.
Page 258 PIPER COMANCHE SERVICE MANUAL G. Pulleys Inspect pulleys for roughness, sharp edges, and presence of foreign material embedded in the grooves. Examine pulley bearings to assure proper lubrication, smooth rotation, freedom from flat spots, dirt, and paint spray. Periodically rotate pulleys, which turn through a small arc, to provide a new bearing surface for the cable.
Page 259 PIPER COMANCHE SERVICE MANUAL 5-7. Installation Of Control Column Assembly. (Refer to Figure 5-5.) A. When installing the control column assembly, first install the components of the square tube assembly. If the nylon rub blocks (23) have been removed, install and tighten them on their attaching screws and secure in place with safety wire.
Page 260 PIPER COMANCHE SERVICE MANUAL D. To install the square tube with sprocket assembly, proceed as follows: Position sprocket (26 or 27) in sprocket brackets (4 or 8) and place washer (38) on square tube shaft (3). Slide square tube shaft into sprocket bracket and sprocket. Attach sprocket with bolt, washer and hex nut (12) using Kaynar wrench (P/N W10-3).
Page 261 PIPER COMANCHE SERVICE MANUAL Figure 5-5. Control Column Installation 04/01/09 V - SURFACE CONTROLS...
Page 262 PIPER COMANCHE SERVICE MANUAL Figure 5-5. Control Column Installation (cont.) V - SURFACE CONTROLS 04/01/09...
Page 263 PIPER COMANCHE SERVICE MANUAL Figure 5-5. Control Column Installation (cont.) 04/01/09 V - SURFACE CONTROLS...
Page 264 PIPER COMANCHE SERVICE MANUAL 5-8. Aileron Control. 5-9. Removal Of Aileron Control Cables. (Refer to Figure 5-6.) A. Remove the rear seats, and seat rails, carpet and floor panel from the left side of the fuselage aft of the main spar.
Page 265 PIPER COMANCHE SERVICE MANUAL D. Removal of the aileron balance cable (4) may be accomplished by the following procedure: Ascertain that the access plates are removed from the aft underside of each wing at stations 72.0, 115.5 and 139.50. Also, the fairing from between the underside of the fuselage and each wing.
Page 266 PIPER COMANCHE SERVICE MANUAL Through the access hole in the wing at station 115.5, position the cable on the lower pulley of the cluster and install the cotter pin cable guard. Attach the cable to the aft end of the cable bellcrank by assembling turnbuckle and/or securing with clevis bolt, washer, nut and cotter pin.
Page 267 PIPER COMANCHE SERVICE MANUAL Figure 5-6. Aileron Control Installation 04/01/09 V - SURFACE CONTROLS...
Page 268 PIPER COMANCHE SERVICE MANUAL Figure 5-6. Aileron Control Installation (cont.) V - SURFACE CONTROLS 04/01/09...
Page 269 PIPER COMANCHE SERVICE MANUAL Figure 5-7. Installation of Bellcrank Checking Tool Figure 5-8. Aileron Adjusting Points 5-11. Rigging And Adjustment Of Aileron Control. CAUTION: VERIFY FREE AND CORRECT MOVEMENT OF AILERONS. WHILE IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL.
Page 270 PIPER COMANCHE SERVICE MANUAL On PA-24-260 Serial No. 24-4783, 24-4804 and up, and PA-24-400 aircraft set the rudder-aileron interconnect cable turnbuckle (17) (Refer to Figure 5-6), so that the large spring (18) has .062 inch extension when the rudder and ailerons are neutral. On the PA-24-260 system the length of the left interconnect spring (19) may be increased up to a maximum extension of .38 to allow the aileron...
Page 271 PIPER COMANCHE SERVICE MANUAL 5-13a. Flap Bellcrank Distortion Inspection. If flaps have been extended at or above V , inspect the flap bellcranks for evidence of distortion. A. If the paint is cracked or peeling anywhere along the bellcrank, torsional movement has occurred.
Page 272 PIPER COMANCHE SERVICE MANUAL Figure 5-9. Flap Control Installation V - SURFACE CONTROLS 04/01/09 1G12...
Page 273 PIPER COMANCHE SERVICE MANUAL Figure 5-9. Flap Control Installation (cont.) 04/01/09 V - SURFACE CONTROLS 1G13...
Page 274 PIPER COMANCHE SERVICE MANUAL Figure 5-9. Flap Control Installation (cont.) V - SURFACE CONTROLS 04/01/09 1G14...
Page 275 PIPER COMANCHE SERVICE MANUAL 5-16. Electrically Operated Flaps. 5-17. Removal Of Electrically Operated Flap Controls. (PA-24-250 and PA-24-260.) (Refer to Figure 5-9.) A. Access for the removal of the flap actuating mechanism and flap control cable within the fuselage may be reached by removing the rear seat. Access to the controls in the wing may be reached by removing the wheel well splash pan and access plate to the flap bellcrank.
Page 276 PIPER COMANCHE SERVICE MANUAL The control cable (5) that is within the fuselage should be connected to the wing cable and flap transmission actuating arm (15). Install cable pulley(s). On Serial Nos. 24-4000 to 24-4246, 24- 4248 to 24-4299 connect tension spring (42) to the cable end of the left turnbuckle To install the flap return cable (27) in the left wing, enter through the wheel well and place the return cable through the trailing edge of the wing.
Page 277 PIPER COMANCHE SERVICE MANUAL NOTE: When determining the deflection angle of the flap use a bubble protractor. The angle between the aircraft leveling lugs and the flaps when they are fully retracted should be 13°, when the flaps are fully extended to 32° the angle should be 45°. Tolerances are 2°.
Page 278 PIPER COMANCHE SERVICE MANUAL D. The flap push-pull control cable may be installed by drawing the cable from the fuselage into the wing. Place the cable end through the support tube, locknut and to the flap bellcrank. Install the cable end and connect to the bellcrank. Secure and safety the locknut at the support tube. Within the fuselage, insert the cable through the support tube and locknut, secure and safety.
Page 279 PIPER COMANCHE SERVICE MANUAL 5-24. Rudder Control. 5-25. Removal Of Rudder Control. (Refer to Figure 5-12.) A. Rotate the two vertical turnbuckle barrels (21) to relieve tension from the rudder control cables and disconnect the fork end of the turnbuckles from the pedal assembly.
Page 280 PIPER COMANCHE SERVICE MANUAL Figure 5-10. Determining Neutral Rudder Position Figure 5-11. Checking Rudder Travel B. Check, and if required, adjust rudder for neutral alignment with relation to the neutral position of the rudder pedals, and cables for correct tension as required in Table V-I. The following procedure may be used: Place airplane on jacks (refer to Jacking, Section II) to clear the nose wheel.
Page 281 PIPER COMANCHE SERVICE MANUAL Figure 5-12. Rudder and Rudder Trim Control 04/01/09 V - SURFACE CONTROLS 1G21...
Page 282 PIPER COMANCHE SERVICE MANUAL Figure 5-12. Rudder and Rudder Trim Control (Cont.) V - SURFACE CONTROLS 04/01/09 1G22...
Page 283 PIPER COMANCHE SERVICE MANUAL Figure 5-13. Clamping Rudder Pedals in Neutral Position C. To check and adjust rudder travel, proceed as follows: At a distance of 6.125 outboard of the aircraft centerline, (stabilator trim control rod), make two small dots approximately six inches apart fore and aft, with a pencil, on the top surface of the stabilator, both sides of the rudder and parallel to the aircraft's centerline.
Page 284 PIPER COMANCHE SERVICE MANUAL D. Check safety of turnbuckle and bolts. WARNING: MAKE SURE POINTER ROD IS REMOVED TO AVOID RESTRICTION OF RUDDER MOVEMENT. Remove pointer rod and install access panels and plates and tail cone fairings. 5-28. Rudder Trim Controls 5-29.
Page 285 PIPER COMANCHE SERVICE MANUAL B. For the removal of the forward control cable, relieve cable tension and disconnect the two turnbuckles (5) located to the rear of the fuselage near the radio rack. The upper turnbuckle ends should be marked to facilitate reinstallation. Remove the control cable guards or pulleys (1) along the bottom of the fuselage.
Page 286 PIPER COMANCHE SERVICE MANUAL 5-35. Rigging and Adjustment of Stabilator Controls. CAUTION: VERIFY FREE AND CORRECT MOVEMENT OF STABILATOR. WHILE IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY,...
Page 287 PIPER COMANCHE SERVICE MANUAL Figure 5-14. Stabilator and Stabilator Trim Controls 04/01/09 V - SURFACE CONTROLS...
Page 288 PIPER COMANCHE SERVICE MANUAL Figure 5-14. Stabilator and Stabilator Trim Controls (cont.) V - SURFACE CONTROLS 04/01/09...
Page 289 PIPER COMANCHE SERVICE MANUAL Figure 5-14. Stabilator and Stabilator Trim Controls (cont.) 04/01/09 V - SURFACE CONTROLS 1H4A...
Page 290 PIPER COMANCHE SERVICE MANUAL Figure 5-14. Stabilator and Stabilator Trim Controls (cont.) V - SURFACE CONTROLS 04/01/09 1H4B...
Page 291 PIPER COMANCHE SERVICE MANUAL Figure 5-15. Checking Stabilator Travel. 5-38. Installation of Stabilator Trim Mechanism. (Refer to Figure 5-14.) A. To install the stabilator trim mechanism, assemble the drum assembly (10) onto its support brackets. Attach the bellcrank (34) to the bearing blocks and safety. Draw the rim cables (2) into the fuselage, allowing them not to cross, and install the cable pulleys.
Page 292 PIPER COMANCHE SERVICE MANUAL B. Within the fuselage, draw the forward trim cable fore or aft and connect the turnbuckles. Should it be necessary to swage a cable end before connecting the remaining turnbuckle, assemble the eye, thimble and sleeve. Connect the ends to the barrel with three or four threads. Draw the free cable end until it is tight, clamp the cable so that it will not damage the cable or slip back.
Page 293 PIPER COMANCHE SERVICE MANUAL Figure 5-16. Stabilator Adjustment Point 5-40. Wrapping Stabilator Trim Drum. (Refer to Figure 5-14, Sketch D or G.) A. To wrap the trim drum, ascertain that the screw and drum assembly is removed from the aircraft.
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Page 306 PIPER COMANCHE SERVICE MANUAL Figure 5-17. Special Fabricated Tools (Sheet 1 of 3) V - SURFACE CONTROLS 04/01/09 1H16...
Page 307 PIPER SENECA SERVICE MANUAL Figure 5-17. Special Fabricated Tools (Sheet 2 of 3) Figure 5-17. Special Fabricated Tools (Sheet 3 of 3) 04/01/09 V - SURFACE CONTROLS 1H17...
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Page 309 PIPER COMANCHE SERVICE MANUAL SECTION LANDING GEAR BRAKE SYSTEM 1H18A...
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Page 311 PIPER COMANCHE SERVICE MANUAL SECTION VI - LANDING GEAR AND BRAKE SYSTEM TABLE OF CONTENTS Paragraph Grid No. 6-1. Introduction ..........
Page 312 PIPER COMANCHE SERVICE MANUAL SECTION VI - LANDING GEAR AND BRAKE SYSTEM TABLE OF CONTENTS (continued) Paragraph Grid No. 6-38. Installation of Main Landing Gear Door Assembly ... 6-39. Adjustment of Main Landing Gear Doors ....
Page 313 PIPER COMANCHE SERVICE MANUAL SECTION VI - LANDING GEAR AND BRAKE SYSTEM TABLE OF CONTENTS (continued) Paragraph Grid No. 6-77. Brake System ..........
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Page 315: Introduction
PIPER COMANCHE SERVICE MANUAL SECTION VI LANDING GEAR AND BRAKE SYSTEM 6-1. Introduction. Contained in this section are instructions for troubleshooting, overhaul, inspection and adjustment of the PA-24, PA-24-250, PA-24-260, and PA-24-400 landing gear, landing gear retraction system, and brake system.
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Page 356 PIPER COMANCHE SERVICE MANUAL Disconnect cables from the support brackets (36) by removing nuts (34) and washers. m. Remove the end bearings from the cables at the drag links by backing off the jam nuts and unscrewing end bearings. Slide the cable support nut (34) and washer off the cable and remove the cable by sliding it through the support bracket and out through the access holes in the floor.
Page 377 PIPER COMANCHE SERVICE MANUAL 6-76. Assembly and Installation of Main Wheel. (Goodrich) PA-24-400 (Refer to Figure 6-27 ) To assemble the main wheel, mount the tire and tube on the wheel and inflate the tube slightly to prevent pinching Install the tie bolts (7). instruction plate washers and nuts and torque the bolts to the specification given on the instruction plate.
Page 378 PIPER COMANCHE SERVICE MANUAL Figure 6-28. Brake Assembly (Cleveland 3000-250 (30-12)) PA-24-180 and PA-24-250, Serial Nos. 24-1 thru 24-3295 6-80. Assembly and Installation of Wheel Brake Assembly. (Cleveland 3000-250 (30-12)) PA-24-180 and PA-24-250, S/N’s 24-1 thru 24-3295. (Refer to Figure 6-28.) Lubricate the piston "O"...
Page 379 PIPER COMANCHE SERVICE MANUAL Figure 6-29. Brake Assembly (Cleveland 30-23 or 30-41) PA-24-180 and PA-24-250, Serial Nos. 24-3296 and up; and PA-24-260 and PA-24-400 6-81. Removal and Disassembly of Wheel Brak e Assembly. (Cleveland 30-23 or 30-41) PA-24-180 and PA-24-250, S/N’s 24-3296 and up; and PA-24-260 and PA-24-400. (Refer to Figure 6-29.) To remove the brake assembly, first disconnect the brake line from the brake cylinder and cap it to prevent contamination.
Page 380 PIPER COMANCHE SERVICE MANUAL The old lining can be removed by prying it from the back plate and pressure plate and a new lining snapped into place. NOTE: Linings should be replaced when the thickness of any one segment is 3/32 inch or less, or the lining is worn uneven.
Page 384 PIPER COMANCHE SERVICE MANUAL 6-88a. Hand Brake / Master Cylinder Control Cable Inspection. (See Figure 6-33.) (PA-24, PA-24-250, S/N’s 24-1 thru 24-2298, less 24-2175.) The hand brake / master cylinder control cable idler bushing (P/N 80022-096) may wear and/or cause the master cylinder control cable (P/N 21077-000) (6) to wear.
Page 385 PIPER COMANCHE SERVICE MANUAL Figure 6-33. Brake System Installation - PA-24 and PA-24-250 S/N’s 24-1 thru 24-2298, less 24-2175 04/01/09 VI - LANDING GEAR AND BRAKE SYSTEM 1K19...
Page 386 PIPER COMANCHE SERVICE MANUAL Figure 6-34. Brake System Installation PA-24-180 and PA-24-250, Serial Nos. 24-2175, 24-2298 and up, PA-24-260 and PA-24-400. VI - LANDING GEAR AND BRAKE SYSTEM 04/01/09 1K20...
Page 402 Check the thru center travel of each main gear side brace link (Refer to paragraph 6-32 and Figure 6-8a.) Install the downlock springs on the nose gear. If only one spring is used, obtain Piper Service Kit 761-082 for additional spring installation. (Refer to paragraph 6-14 for installation instructions.) Disconnect and inspect main gear push-pull cable prior to installation (Refer to paragraph 6-48.)
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Page 408 PIPER COMANCHE SERVICE MANUAL GRIDS 1L18 THRU 2A6 INTENTIONALLY BLANK VI - LANDING GEAR AND BRAKE SYSTEM 04/01/09 1L18...
Page 409 PIPER SENECA SERVICE MANUAL SECTION POWER PLANT PA-24-180...
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Page 411 PIPER COMANCHE SERVICE MANUAL SECTION VII - POWER PLANT PA-24-180 TABLE OF CONTENTS Paragraph Grid No. 7-1. Introduction ..........
Page 412 PIPER COMANCHE SERVICE MANUAL SECTION VII - POWER PLANT PA-24-180 TABLE OF CONTENTS (continued) Paragraph Grid No. 7-38. Ignition System ......... .
Page 413 PIPER COMANCHE SERVICE MANUAL SECTION VII POWER PLANT PA-24-180 7-1. Introduction. This section covers power plants used in the PA-24-180 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, ignition system and lubrication system.
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Page 425 PIPER COMANCHE SERVICE MANUAL 7-21. Engine. 7-22. Removal Of Engine. 7-22a. 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 438 PIPER COMANCHE SERVICE MANUAL Figure 7-15. Engine Timing Marks. 7-44. Installation and Timing Procedure. (Timing Magneto to Engine.) The magnetos can be installed and timed to the engine by the following procedure: NOTE: Ascertain that the breakers are correct for proper internal timing of magnetos.
Page 451 PIPER COMANCHE SERVICE MANUAL SECTION VIIA POWER PLANT PA-24-250/260...
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Page 453 PIPER COMANCHE SERVICE MANUAL SECTION VIIA - POWER PLANT PA-24-250/260 TABLE OF CONTENTS Paragraph Grid No. 7A-1. Introduction ..........
Page 454 PIPER COMANCHE SERVICE MANUAL SECTION VIIA - POWER PLANT PA-24-250/260 TABLE OF CONTENTS (continued) Paragraph Grid No. 7A-39. Induction System Air Filter (PA-24-250 and PA-24-260, Serial Nos. 24-2477 to 24-4782 and 24-4784 to 24-4803 incl.) . . 7A-40. Removal Of Air Filter ........
Page 455 PIPER COMANCHE SERVICE MANUAL SECTION VIIA - POWER PLANT PA-24-250/260 TABLE OF CONTENTS (continued) Paragraph Grid No. 7A-75. Harness Assembly ........
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Page 457: 1. Introduction
PIPER COMANCHE SERVICE MANUAL SECTION VIIA POWER PLANT PA-24-250 AND PA-24-260 7A-1. Introduction. This section covers power plants used in the PA-24-250 and PA-24-260 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, ignition system and lubrication system 7A-2.
Page 458 PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VIIA - POWER PLANT 04/01/09 (PA-24-250/260)
Page 501 PIPER COMANCHE SERVICE MANUAL Table VIIA-II. Timing Data Magneto Magneto Type Part No. Degree Retard S6LN-200 10-163010-2, -4, -5, -9, -11 10-163010-3, -6 10-163010-10 37 1/2 7A-73. Installation And Timing Procedure. (Timing Magneto to Engine.) The magnetos can be installed and timed to the engine by the following procedure: NOTE: Ascertain that the breakers are correct for proper internal timing of magnetos NOTE: Verify correct engine timing for the airplane being worked on by checking the engine dataplate.
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Page 521 PIPER COMANCHE SERVICE MANUAL SECTION VIIB POWER PLANT PA-24-400 2E18A...
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Page 523: Removal Of Propeller Governor
PIPER COMANCHE SERVICE MANUAL SECTION VIIB - POWER PLANT PA-24-400 TABLE OF CONTENTS Paragraph Grid No. 7B-l. Introduction ..........
Page 524 PIPER COMANCHE SERVICE MANUAL SECTION VIIB - POWER PLANT PA-24-400 TABLE OF CONTENTS (continued) Paragraph Grid No. 7B-37. Ignition System Maintenance .......
Page 525 PIPER COMANCHE SERVICE MANUAL SECTION VIIB POWER PLANT PA-24-400 7B-1. Introduction. This section covers power plants used in the PA-24-400 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, ignition system and lubrication system.
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Page 548 PIPER COMANCHE SERVICE MANUAL Turn the engine crankshaft to number one cylinder full advance firing position. (Refer to Figure 7B-13.) Install the magneto on the engine and tighten the mounting clamps sufficiently to hold magneto position and yet allow it to be rotated.
Page 561 PIPER COMANCHE SERVICE MANUAL SECTION VIIC POWER PLANT PA-24-260 (TURBOCHARGED)
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Page 563: Removal Of Engine
PIPER COMANCHE SERVICE MANUAL SECTION VIIC - POWER PLANT PA-24-260 TURBO TABLE OF CONTENTS Paragraph Grid No. 7C-1. Introduction ..........
Page 564 PIPER COMANCHE SERVICE MANUAL SECTION VIIC - POWER PLANT PA-24-260 TURBO TABLE OF CONTENTS (continued) Paragraph Grid No. 7C-35. Fuel Injector ..........
Page 568 PIPER COMANCHE SERVICE MANUAL Figure 7C-1. Propeller Installation 7C-10. Cleaning, Inspection And Repair Of Propeller. (Refer to Figure 7C-2.) Check for oil and grese leaks. Clean the spinner, propeller hub and blades with a non-corrosive solvent. Inspect the hub parts for cracks.
Page 569 PIPER COMANCHE SERVICE MANUAL Figure 7C-2. Typical Nicks and Removal Methods 7C-11. Installation of Propeller. (Refer to Figure 7C-1.) Clean propeller and engine flanges. Install spinner bulkhead (10) on srcrer ring gear, and torque bolts to specficacions given in Table VIIC-I.
Page 580 PIPER COMANCHE SERVICE MANUAL K. Connect turbocharger outlet stack brace. Connect waste gate control cable and clamp to turbocharger outlet stack. Adjust control cable rod so swaged area is recessed into cable attachment clamp with waste gate in the closed position.
Page 581 PIPER COMANCHE SERVICE MANUAL Figure 7C-5a. Lockwiring V-Band Coupling. 7C-28. Cleaning and Inspection of Pressure Relief Valve. A. Clean valve and seat areas with solvent or air. B. Inspect valve action by pushing on pressure side, to determine that bellows or spring are not restricted.
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Page 597 PIPER COMANCHE SERVICE MANUAL Figure 7C-12. Aligning Timing Marks Figure 7C-13. Forming Leads In Single Contact Assembly Magneto. Breaker Compartment Secure distributor block to housing with studs and washers. Tighten studs finger tight. Loosen the 11-8465 Rotor Holding Tool and turn rotating magnet in reverse direction of rotation until timing light indicates main contact assembly has just opened and check to make certain timing marks align within tolerance indicated above.
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Page 619 PIPER COMANCHE SERVICE MANUAL SECTION VIII FUEL SYSTEM 2I12A...
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Page 621 PIPER COMANCHE SERVICE MANUAL SECTION VIII - FUEL SYSTEM TABLE OF CONTENTS Paragraph Grid No. 8-1. General ..........
Page 622 PIPER COMANCHE SERVICE MANUAL SECTION VIII - FUEL SYSTEM TABLE OF CONTENTS (continued) Paragraph Grid No. 8-30. Electric Fuel Pump, Dukes (PA-24-250 and PA-24-260 with Fuel Injected Engines) ......
Page 637 PIPER COMANCHE SERVICE MANUAL and disconnect the wiring. Remove the floor carpet and floor panel covering the selector. Disconnect the fuel lines. Remove the screws securing the valve mounting plate. The forward screws are secured by nuts while the aft screws are secured by plate nuts. Remove the valve from the aircraft.
Page 638 PIPER COMANCHE SERVICE MANUAL Figure 8-11. Three Position Fuel Selector Valve - PA-24-180 AND PA-24-250 VIII - FUEL SYSTEM 04/01/09...
Page 639: Servicing Five Position Fuel Valve (Pa-24-250 & Pa-24-260)
Clean valve of all foreign material, lubricate plug sparingly with Dow Corning Molykote No. FS-3452 lubricant (Piper P/N 761-281). Turn the plug several times in its seat, and wipe off any excess lubricant in the plug and valve ports. Lubricate the position washer (7) and “O”-rings with a light film of the above lubricant.
Page 640: Servicing Fuel Valve (Airborne Mechanisms) (Pa-24-400)
PIPER COMANCHE SERVICE MANUAL Figure 8-12. Five-Position Fuel Valve Figure 8-13. Fuel Valve and Filter PA-24-250 and PA-24-260 PA-24-400 Servicing Fuel Valve (Airborne Mechanisms). (PA-24-400) 8-16. CAUTION: NO FIELD DISASSEMBLY OR REPAIR OF FUEL THESE SELECTOR VALVES IS AUTHORIZED. MAINTENANCE IS LIMITED TO REMOVAL AND REPLACEMENT OF THE WHOLE UNIT.
Page 641: Installation Of Fuel Selector Valve
PIPER COMANCHE SERVICE MANUAL 8-16a. Fuel Valve Internal Leak Inspection. (PA-24-400) Each 50 hours time-in-service inspect as follows: Position aircraft on relatively level ground with a minimum of one (1) gallon in each tank. Drain fuel selector sump using normal preflight procedures.
Page 642: Cleaning The Fuel System
PIPER COMANCHE SERVICE MANUAL 8-18. Cleaning The Fuel System. To flush fuel tanks and selector valve, disconnect fuel line at the carburetor or injector Select a fuel tank, turn on the electric fuel pump(s) and flush fuel through the system until it is determined that there is no dirt and foreign matter in the fuel valve, lines or tank.
Page 643: Fuel Strainer. (Pa-24-400)
PIPER COMANCHE SERVICE MANUAL 8-22. Fuel Strainer. (PA-24-400) The fuel strainer and fuel selector are one unit, with the strainer assembly making up the lower portion of the unit. Close the fuel selector valve. To clean and inspect the filter, remove the access panel located at the bottom of the fuselage.
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Page 657 PIPER SENECA SERVICE MANUAL SECTION ELECTRICAL SYSTEM...
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Page 659 PIPER SENECA SERVICE MANUAL SECTION IX - ELECTRICAL SYSTEM TABLE OF CONTENTS Paragraph Grid No. 9-1. General ..........
Page 660 PIPER SENECA SERVICE MANUAL SECTION IX - ELECTRICAL SYSTEM TABLE OF CONTENTS (continued) Paragraph Grid No. 9-42. Alternator System .........
Page 661 PIPER SENECA SERVICE MANUAL SECTION IX - ELECTRICAL SYSTEM TABLE OF CONTENTS (continued) Paragraph Grid No. 9-62. Cranking Motors. (Delco-Remy) ......
Page 662 PIPER SENECA SERVICE MANUAL SECTION IX - ELECTRICAL SYSTEM TABLE OF CONTENTS (continued) Paragraph Grid No. 9-102. Navigation Lights .........
Page 663 PIPER SENECA SERVICE MANUAL SECTION IX ELECTRICAL SYSTEM 9-1. General. 9-2. Electrical power for the Comanche is supplied by a 12-volt, direct current, single wire, negative ground electrical system. A 12-volt battery is incorporated in the system to furnish power for starting and a reserve power source in case of generator or alternator failure.
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Page 731 PIPER SENECA SERVICE MANUAL Table IX-IV. Electrical Schematic Index Figure No. Grid No. COMFORT SYSTEM - Cigar Lighter (PA-24 All Models, EXCEPT PA-24-260 S/N 24-4783, 24-4804 & Up) 9-30 3D13 COMFORT SYSTEM - Cigar Lighter (PA-24-260 S/N 24-4783, 24-4804 & Up)
Page 732 PIPER SENECA SERVICE MANUAL TABLE IX-IV. ELECTRICAL SCHEMATIC INDEX (cont.) Figure No. Grid No. INDICATORS - Flap Position (PA-24-250 S/N 24-2844 & Up; PA-24-260 S/N 24-4000 & Up) 9-67 INDICATORS - Flap Position (PA-24-400, S/N 26-2 & Up) 9-68 INDICATORS - Fuel Gauge, Oil Temperature Gauge (PA-24-180 &...
Page 733 PIPER SENECA SERVICE MANUAL TABLE IX-IV. ELECTRICAL SCHEMATIC INDEX (cont.) Figure No. Grid No. LIGHTING SYSTEM - Dome (PA-24-180 & PA-24-250 S/N 24-2202 To 24-2298) 9-38 3D15 LIGHTING SYSTEM - Dome (PA-24-180 & PA-24-250 S/N 24-2299 To 24-2843) 9-39 3D16 LIGHTING SYSTEM - Dome (PA-24-180 S/N 2844 &...
Page 734 PIPER SENECA SERVICE MANUAL TABLE IX-IV. ELECTRICAL SCHEMATIC INDEX (cont.) Figure No. Grid No. WARNING SYSTEM - Stall (PA-24-250 S/N 24-103 To 24-655, 24-2202 & Up; PA-24-260 S/N 24-4000 To 24-4782, 24-4784 To 24-4803; PA-24-400 S/N 26-2 & Up) 9-32 3D14 WARNING SYSTEM - Stall (PA-24-260 S/N 24-4783.
Page 742 PIPER SENECA SERVICE MANUAL FUEL GAUGES, 25744 E OIL TEMP., CHT, EXHAUST GAS TEMPERATURE (EGT) AMPLIFIER AND EGT GAUGES, AND DOME LIGHTS INDICATOR PROBE DOME LIGHT SWITCHES DOME LIGHTS REAR FRONT FUEL QUANTITY GAUGE CYLINDER HEAD TEMP GAUGE OIL TEMP GAUGE OIL TEMPERATURE ENGINE UNIT ENGINE CYL.
Page 743 PIPER SENECA SERVICE MANUAL Figure 9-43. Fuel, Oil Temp. Gauge, Dome Light, CHT Gauge, and EGT Indicator 04/01/09 IX - ELECTRICAL SYSTEM 3D18A...
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Page 765 PIPER COMANCHE SERVICE MANUAL Figure 9-85. Gear Motor, Solenoid, and Indicator Lights (PA-24-180 and PA-24-250 S/N’s 24-2202 & Up) Revised: 8/15/98 ELECTRICAL SYSTEM 3E15 3E16...
Page 766 PIPER COMANCHE SERVICE MANUAL Figure 9-86. Gear Motor, Solenoid, and Indicator Lights (PA-24-260 S/N’s 24-4783 and 24-4804 & Up) Revised: 8/15/98 ELECTRICAL SYSTEM 3E17 3E18...
Page 767 PIPER COMANCHE SERVICE MANUAL Figure 9-87. Gear Motor, Solenoid, and Indicator Lights (PA-24-400 (All) and PA-24-260 (S/N’s 24-4000 thru 24-4803, less 24-4783)) Revised: 8/15/98 ELECTRICAL SYSTEM 3E19 3E20...
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Page 788 PIPER COMANCHE SERVICE MANUAL SECTION INSTRUMENTS 3F16A...
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Page 790 PIPER COMANCHE SERVICE MANUAL SECTION XI - INSTRUMENTS TABLE OF CONTENTS Paragraph Grid No. 11-1. Description ..........
Page 791 PIPER COMANCHE SERVICE MANUAL SECTION XI - INSTRUMENTS TABLE OF CONTENTS Paragraph Grid No. 11-38. Airspeed Indicator ........
Page 792: General
PIPER COMANCHE SERVICE MANUAL SECTION XI - INSTRUMENTS TABLE OF CONTENTS Paragraph Grid No. 11-78. Fuel Quantity Indicator ........
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Page 794 PIPER COMANCHE SERVICE MANUAL SECTION XI INSTRUMENTS Description. 11-1. The instrumentation in the Comanche is designed to give a quick and actual indication of the attitude, performance and condition of the airplane. The instrument panel has been arranged to accommodate all the advanced flight instruments on the left side in front of the pilot and required engine and miscellaneous instruments on the right side.
Page 795 PIPER COMANCHE SERVICE MANUAL The altimeter indicates pressure altitude in feet above sea level. The indicator has three pointers and a dial scale. The long pointer is read in hundreds of feet. The middle pointer is read in thousands of feet and the short pointer in ten thousand feet.
Page 796: Troubleshooting
NOTE: These airplanes were originally equipped with A.C. Sparkplug or Stewart Warner engine gauges and sending unit systems which are no longer available. For replacement engine gauges and sending units, see the current Comanche Parts Catalog (P/N 752 464) or Piper Service Spares Letter No. 406.
Page 797 These forms and the special containers should be available at any Piper Dealer and/or Distributor. Should any gyro instrument be received by the factory in an unapproved container or if the ports are not sealed, the warranty will be immediately voided and the instrument returned to the sender.
Page 798 PIPER COMANCHE SERVICE MANUAL 11-11a. Hoses and Clamps A. These items should be examined periodically and inspected carefully whenever maintenance activities cause hose disconnections. B. Ends of hoses should be examined for rubber separation and slivers of rubber on inside diameter of hoses.
Page 799 PIPER COMANCHE SERVICE MANUAL 11-15. Vacuum Pump Removal. The vacuum pump is removed by the following procedure: A. Remove the top portion of the engine cowling. B. Loosen the two hose clamps and remove the two hoses from the vacuum pump fittings. Identify the hoses to aid in reinstallation.
Page 800 CAUTION: ONLY PUMP MOUNTING GASKET AUTHORIZED AND APPROVED FOR USE ON AIRBORNE VACUUM PUMP IS AIRBORNE GASKET B3-1-2, PIPER PART NUMBER 751-859. USE OF ANY OTHER GASKET MAY RESULT IN OIL SEEPAGE OR LEAKAGE AT MOUNTING SURFACE. Place pump gasket in its proper place and align spline on pump drive with spline on engine drive assembly.
Page 801 PIPER COMANCHE SERVICE MANUAL Figure 11-1. Vacuum Pump Vane Wear Inspection XI - INSTRUMENTS 04/01/09 3F24...
Page 802: Troubleshooting
PIPER COMANCHE SERVICE MANUAL 11-17. Troubleshooting. Table XI-I. Troubleshooting Vacuum System Trouble Cause Remedy No vacuum pressure gauge Pump inoperative. Dis- Replace pump. Locate indication. connected. Broken or trouble and correct. restricted lines. No vacuum pressure gauge Hose from instrument to Check all lines and indication at instrument.
Page 803 PIPER COMANCHE SERVICE MANUAL Figure 11-2. Instrument Panel XI - INSTRUMENTS 04/01/09...
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Page 813: Manifold Pressure Gauge
PIPER COMANCHE SERVICE MANUAL 11-45. Manifold Pressure Gauge. 11-46. General. The manifold pressure gauge is a vapor proof. absolute pressure type instrument Pressure from the intake manifold of the engine is transmitted to the instrument through a line. A pointer indicates the manifold pressure available at the engine in inches of mercury.
Page 814: General
PIPER COMANCHE SERVICE MANUAL 11-48a. Cylinder Head Temperature (CHT) Gauge. When installed, the cylinder head temperature readings for the CHT Gauge are provided by a CHT probe installed in the engine cylinder indicated below. Model Cylinder No. PA-24 PA-24-250 (Carb.) PA-24-250 (F.I.)
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Page 826 PIPER COMANCHE SERVICE MANUAL SECTION ELECTRONICS 3G23...
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Page 828 Non-Piper A.F.C.S. Equipment Contacts ..... . 12-7. Piper A.F.C.S. Equipment ........12-7a.
Page 829: Table Of Contents
PIPER COMANCHE SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XII - TABLE OF CONTENTS 04/01/09...
Page 830 This section of the manual is divided into two parts. The first part consists of the information necessary to perform an operational check of the Piper Automatic Locator Transmitter along with the appropriate removal and installation instruction to facilitate battery replacement. The second part consists of wiring diagrams of the various configurations of avionics equipment installations.
Page 831 PIPER COMANCHE SERVICE MANUAL 12-3. Testing Locator Transmitter. CAUTION: THE TRANSMITTER OPERATES ON THE EMERGENCY FREQUENCIES OF 121.5 AND 243 MHZ, BOTH THESE FREQUENCIES ARE MONITORED BY THE VARIOUS FAA INSTALLATIONS. PERMISSION MUST BE OBTAINED FROM THE FAA/FCC REPRESENTATIVE (OR OTHER APPLICABLE AUTHORITY) PRIOR TO TESTING.
Page 833 This includes mechanical service such as; adjusting bridle cable tension, servo removal and installation, servo clutch adjustment,. etc. 12-6. Non-Piper A.F.C.S. Equipment Contacts. Refer to the following list of AutoPilot Flight Director manufacturers to obtain service direction, parts...
Page 834 Piper AutoPilot / Flight Director Service Manual for service information. NOTE: If a Roll Axis-only AutoPilot is installed, or if no AutoPilot is installed, consult the Piper Pitch Trim Service Manual, P/N 753-771, for manual electric pitch trim service information The following is a complete listing of Piper A.F.C.S.
Page 835 PIPER COMANCHE SERVICE MANUAL 12-8. Rack-Mounted Avionics For airplanes with modern updgraded instrument / avionics panels, some avionics may be rack mounted. Rack Mounted Avionics are rack-mounted front-removable units generally secured to the instrument panel tray/rack by a single jackscrew located in the center of their faceplate.
Page 836 PIPER COMANCHE SERVICE MANUAL 12-10. EMI and RFI Check. (PIR-PPS65119, Rev A.) A. Background ElectroMagnetic Interference (EMI) and Radio Frequency Interference (RFI) are a growing concern with the installation of advanced digital avionics. The following test procedure is recommended before return-to-service each time any electrical / avionics work is performed.
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Page 838 PIPER COMANCHE SERVICE MANUAL SECTION XIII ACCESSORIES UTILITIES 3H11...
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Page 840 PIPER COMANCHE SERVICE MANUAL SECTION XIII - ACCESSORIES AND UTILITIES TABLE OF CONTENTS Paragraph Grid No. 13-1. Restraint System .........
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Page 842 PIPER COMANCHE SERVICE MANUAL SECTION XIII ACCESSORIES AND UTILITIES Restraint System 13-1. A. Inspections. Shoulder Harness: (a) Inspect ends and attachment points for condition and security. (b) Inspect harness web material for condition and wear over its entire length. Particularly look for wear and fraying where harness web passes in and out of inertial reel.
Page 843 PIPER COMANCHE SERVICE MANUAL Portable Fire Extinguisher 13-2. Inspections. (1) Disposable-type (non-gauged) Fire Extinguishers Disposable-type fire extinguishers should be maintained and inspected in accordance with the nameplate instructions. (a) Monthly Check monthly or more frequently. Ensure nozzle is not obstructed and safety seal is intact.
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Comanche pa-24-250 Comanche pa-24-260 Comanche pa-24-400

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