Piper PA-24 Comanche User manual

PIPER AIRCRAFT CORPORATION
•
•
•
753 516
'~ustDmer
servIces
PA+2COMANCHE
Service Manual
CARD 1 OF 3
• PA-24-180
• PA-24-400
• PA-24-260 (TURBOCHARGED)
1 Al

.:
•
•
NOTE
PLEASE INSERT THE FOLDOUT PAGES, LOCATED AT THE END OF THIS MANUAL,
IN THEIR PROPER NUMERICAL SEQUENCE PRIOR TO USING THE MANUAL .

•
•
•
WARNING
ne information contaluecl in this manual II
perlodlcaOy revised. Piper Aircraft Corpontlon
uri" an users of tbls manual to keep It current.
Contact your nearest Piper Aircraft Corporadon
distributor to arrance for a subscription to future
revisions.
NOTE
Revisionserviceis avanable inaeroftcbeformat onl,.

•
PIPER COMANCHE SERVICE MANUAL
AEROFICHE EXPLANATION AND REVISION STATUS
Service manual information incorporated in this set
of Aerofiche cards isarranged in accordance
with general specifications of Aerofiche adopted by the General Aircraft Manufacturer's Association.
Information compiled in this Aerofiehe service manual is kept current by revisionsdistributed periodically.
These revisions supersede all previous revisions, are complete Aerofiche card replacements, and supersede
Aerofiche cards of same number in set.
Identification of revised material:
Revised text and illustrations are indicated by a black vertical line along the left-hand margin of the
frame, opposite revised or added material. Revision lines indicate only current revisions with changes and
additions to existing text and illustrations. Changes in capitalization, spelling, punctuation, indexing,
physical location of material, or complete page additions are not identified by revision lines.
Revisions to Service Manual 753 516 issued August 18, 1972are as follows:
Revisions Date
AeroflChe Card Effectivity
PR76062S June 25, 1976 I, 2, 3, and 4
PR771003 October 3,
1977
I
•PR780403 April 3,
1978 I, 2, and 3
PR790910 September 10, 1979 I, 2, and 3
PR810410 April 10,
1981
I, 2, and 3
\PR821101 November I, 1982 I, 2, and 3
IR860921 September 21, 1986(Interim)· I
•
•INTERIM CHANGE
Revisions appear in Table 111·1 of card I.
There are no other changes included in
this maintenance manual. Pleasediscard
your current card 1and replace it with
this revised one. DO NOT DISCARD
CARDS 1, or 3.
The date on Aerofiche cards must not be earlier than date noted for respectivecard effectivity.Consultlatest
card in this series for current Aerofiche card effectivity.
IA1

TABLE OF CONTENTS
AEROFICHE CARD NO.1
•
GRID NO.
I INTRODUCTION 1A1S
II HANDLING AND SERVICING 1 A20
III INSPECTION 1014
IV STRUCTURES '" " 1E6
VSURFACE CONTROLS 1
F1 3
VI
LANDING GEAR AND BRAKE SYSTEM , 1H19
AEROFICHE CARD NO.2
VII POWER PLANT PA-24- 180 . . . . . . . . .. . .. . .. . . . .. . . .. 2A 10
VilA POWER PLANT PA-24-250 AND PA-24-260 2C2
vns POWER PLANT PA-24-400 2E18
VIIC POWER PLANT PA-24-260 (Turbocharged) 2G7
VIII FUEL SYSTEM " 2112 •
AEROFICHE CARD NO.3
IX ELECTRICAL SYSTEM 3AB
XHEATING AND VENTILATING ,. 3F6
XI INSTRUMENTS 3F16
XII ELECTRONICS 3H1
•
lA3

•
PIPER CO~A'CHE SER\'ICE MA't'AL
The dc-ignauon P,\-24-1 XO, PA-2-l-250, P,-\-2-l-2hO. PA-24--l00 and PA-24-2hOT in the nomenclature ,\1
thi ... manual pertains to the PA-2-l Comanche \\ ith the following. engine installations:
•
•
P-\-~~
PA-2-l-250
PA-2-l-2Nl
PA-2-l--l00
P-\-2-l-2hO t
Turbochurgcd t
O-J()O-A
0-540-A or 10-540-(
0-540-E or 10-540-D or 10-540-'
10-120-A
10-540-R IA5
lA4

PIPER COMANCHE SERVICE MANrAL
LIST OF ILLLJSTRATIO'S
•
Figure Aerofiche
Grid '0.
1:\24
18\
182
IR~
IR4
IA5
I AIIi
1817
IBII'
1 B2~
I B~~
1('1
1('1
I('ti
1(9
IC9 •
1(11
1(11
IC:!O
IC10
101
102
103
104
105
lOti
107
lOX
109
1010
1011
lDI2
10lJ
1017
10lH
1019
IE9
1E 12
IA5
2-1. Three-View of Comanche PA-24-1~0 and PA-2~-250 .
2-2. Three-View of Comanche PA-24-260. Serial Xos. 24-4000 to 24-42411.
2~-424~ to 24-4199 .
2-). Three-View of Comanche PA-24-260 Serial 'os. 24-4247.24-4)00 to
24-4782. 24-47~~ to 24-4~()~ incl. .
2-4. Three-View of Comanche PA-24-400 .
2-5. Three-View of Comanche PA-24-260 Serial 'os. 24-47~D. 24-4R04 and up .
2-t.. Acce- Panels and Plates PA-24-1 ~O. 250. 211O. Serial' os. 24-4000
to 24-424ti. 24-4241' to 24-4299 .
2-7. Access Panels and Plates PA-24-260 Serial 'os. 24-4247.24-4)00 and up .
2-1\. Access Panels and Plates PA-24-400 .
2-~a. Torque Wrench Formula .
2-9. Jacking Arrangements .
2-10. Weighing .
2-11. Leveling Airplane PA-24-180. 250. 260 Serial Nos. 244000 to
24-424ti. 24-424~ to 24-4299 and PA-24-400 .
2-12. Leveling Airplane PA-24-2tiO Serial 'os. 24-4247. 24-4)00 and up .
2-13. Landing
Gear Strut Exposure .
2-14. Brake Reservoir PA-24-180. 250 Serial 'os. 24-1 to 24-2298 incl. .
2-15. Brake Reservoir PA-24-180. 250 Serial Nos. 24-2299 and up. PA-24-260
and PA-24-400 .
2-16. Fuel Strainer and Drain PA-24-180. 250. Serial ~os. 24-2299 and up.
and PA-24-260 .
2-17. Fuel Selector and Drain PA-24-400 .
2-18. Oil Suction Screen .
2-19. Oil Pressure Screen .
2-20. Lubrication Chart PA-24-180 and PA-24-250 .
2-2\. Lubrication Chart PA-24-260 .
2-22. Lubrication
Chart PA-24-400 .
2-23, Control Column Lubrication (PA-24-180. 250. 260 &400) ; .
2-24.
Step Lock Mechanism Lubrication (PA-24-180. 250. 260 and 400) .
2-25. Flap Track Lubrication (PA-24-180. 250. 260 and 400) .
2-26. Nose Landing
Gear Lubrication (PA-24-400) .
2-27. Nose Landing
Gear Lubrication (PA-24-180. 250 and 260) .
2-28.
Stabilaror Lubrication (PA-24-180. 250. 260 and 400) .
2-29. Rudder Control Lubrication (PA-24-180. 250. 260 and 4(0) .
2-30. Bellcrank Lubrication (PA-24-180. 250. 260 and 400) .
2-31. Propeller Lubrication (PA-24-180. 250. 260 and 400) .
2-32. Main Landing
Gear Lubrication (PAf-24-180. 250. 260 and 400) .
3-1. Typical Muffler Fatigue Areas '.' .
3-2. Exhaust System Inspection Points CPA-24-180. 250 and 400) .
3-3. Exhaust System Inspection Points (PA-24-260) .
4-1. Landing Light Installation .
4-2. Wing Attachment Fittings .
Revised: 11/1.

•
Figure
PIPER COMANCHE SERVICE MANt'AL
LIST OF ILLlJSTRATIO~S (cont.)
Aerofiche
Grid xo.
Revised: 11/1/82
•
•
4-1
4-4.
4-5.
4-6.
4-7.
4_7a.
4-"b.
4-"c.
4-X.
4-9.
4-10.
4-11.
4·12.
4-1 :.
4-14.
5-1.
5-la.
5-2.
5-3.
5-4.
5-5.
5-6.
5-1.
5-~.
5-9.
5·10.
5-11.
5-12.
5-13.
0-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-8a.
6-8b.
6-8c.
Flap Roller Installation (Electrically Operated) .
Aileron Bearing Installation .
Door Installation .
Door l.ockins Mechanism PA-24-250. Serial 'os. 24-2844 to 24-3284 .
Door Locking Mechanism PA-24-250. Serial 'os. 24-3285 and up. PA-24-200
and PA-24-400 .
Stabilator Balance Weight .
Checking Stabilator Free Play .
Checking and Balancing Rudder .
Fuselage Skin Diagram PA-24-IXO. PA-24-250 and PA-24-260. Serial '0".
24-4000 to 24-4246. 24424X to 24-4299 .
Wing and Empennage Skin Diagram PA-24-180. PA-24-250 and PA-24-260.
Serial '0.,. 24-4000 to 24-4246. 24-424~ to 24-4299 .
Fuselage Skin Diagram PA-24-260. Serial ~os. 24-4247. 24-4300 and up .
Wing. and Empennage Skin Diagram PA-24-260. Serial Nos. 24-4247.24.4300
and ur .
Fuselage Skin Diagram PA-::~4-400 .
\\ ing and rmpennage Skill Diagram PA-24400 .
Typical Acce Holes .
Control Column Installation .
Correct Method of Installing Rod End Bearings .
Aileron Control Installation .
Installation of Bellcrank Checking Tool .
Aileron Adjusting Points .
Flap Control Installation .
Determining ~eutral Rudder Position .
Checking Rudder Travel .
Rudder and Rudder Trim Controls .
Clamping Rudder Pedals in Neutral Position .
Stabilaror and Stabilator Trim Controls .
Checking Stabilator Travel in Up Position .
Stabilator Adjustment Points .
Special Fabricated Tools .
~ose Gear Oleo Strut. Serial 'os. 24-1 to 24-214 incl. .
Xose Gear Oleo Strut Assembly PA-24-180. PA-24-250. Serial 'os. 24-215 and up.
PA-24-260 and PA-24-400 .
~ose Landing Gear Installation .
Clamping Rudder Pedals in ~eutral Position .
Rudder Pedals at 'eutral Angle .
Installations of Plumb Bob Attachment Tool and Alignment Jig .
Nose Gear Installation PA-24-260 and PA-24-400 ..........•...................
Main Gear Oleo Strut Assembly : .
Main Gear Side Brace Link Travel .
Main Gear Side Brace Bearing Tolerance " .
Main Gear Side Brace Link Tolerance .
lA6
IEI4
IE 14
IE 17
If IX
I EI9
IE::;4
IF2
IF5
IFfl
I Fi
IF!'
IF9
IFIO
IFII
I FI2
IFI9
IF::!)
IG2
IG4
IG4
IG6
IGI5
IGI5
IG If'
IGI~
IG21
IHI
IH4
IHI6
IH24
115
1110
1113
1113
1114
1116
1120
1122
1121
\123

PIPER COMANCHE SERVICE MANl~AL
LIST OF IlLUSTRATlO~S (com.) •
Figure Aerofiche
Grid \0.
1./2
Uti
Ir
1.1 I()
1.11 ~
1.1('7
1.l1!'
IJ 19
1.114
IKI
IK1
IK3
IK5
IKti
IKX
IK9
IK 10
IKI~.
IKI4
I KI5
IKI6
IKli
IA7
\lain Landing Gear Installation (left) .
Adjustment of Main Landing Gear Drag Link .
Aligning Main Gear .
Landing Gear Retraction System .
Landing Gear Retraction Transmission Assembly .
Landing Gear Retraction System Installation .
'ose Gear Drag Link Clevis .
Landing Gear L'p limit Switch. , .
Torque Wrench and Adapter Installation. Serial Xos. 24-1 to 24.4781 incl.
14-471'4 to 24-480J incl. .
Torque Wrench and Adapter Installation. Serial Nos, 24-478J. 244804 and up .
Landing Gear Down Safety Lock Installation .
Landing Gear Warning Switch Installation .
Landing Gear Warning Indicator .
\osc "'heel Assernblv " .
Main Wheel Assernblv (Cleveland] PA-24-180 and PA-24-250 .
Main Wheel Assembl;' (Cleveland) PA-24-260
and PA·24-400 .
Main Wheel Assemblv (Goodrich) PA-24400 .
Brake Assembly (Cleveland) PA-24-180
and PA-24-250. Serial ~os.
14-\ to 14-3295 .
Brake Assemble (Cleveland] PA-24-180 and PA-24-250. Serial ~os.
14-3196 and up. PA-14-260 and PA-24400 .
Brake Assembly
(Goodrich) PA-24-400 .
Replacing Brake Disc .
Bleeding Brakes .
Brake System InstalIation PA-24-180
and PA-24-250. Serial"!';as. 24-1 to
14·2174 incl.. 24-2176 to 24.:2298 incl. IK IH
Brake System Installation PA-24-180 and PA-24-250. Serial '0S. 24-2175.
24-2298 and up. PA-24-260 and PA-24-400 IKI9
Brake Cvlinderlnstallation ; . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . IK21
Brake
Master Cylinder PA-24-180 and PA-24-250. Serial 1\05. 24-1 to
14-2174 incl.. 24-2176 to 24-2298 inc.......................................... IK23
Parking Brake Valve. ..................... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
Brake Master Cylinder PA-24-180 and PA-24-250. Serial Nos. 24-2175
14-1299 and up:PA-24-260 and PA-24-400.................................... I U
Brake Cylinder Installation IL4
Fabricated Plumb Bob Tool 11.7
Fabricated \ose Wheel Alignment Jig. . . . . . . .. ... .. .. . . . .. . .. . . . . .. ....... I1.X
Fabricated Spanner Wrench......................................... .... . ... 11.9
Inspection of Rod End Bearing....... . . . . . . . . . .. .. ... . .. . .. .. . . .. . .. . . . . . . . . I 1 II
Main Gear Wear Limits.................................................... IL14
\ose Gear Wear Limits :. . . . .. . . . . . . . . ILito
Propeller Installation (McCauley) . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . 2A 14
Typical Nicks
and Removal Method 2A 15
Propeller Installation (Hanlell).............................................. 2AI~
Revised: 1111.
6-9.
6-10.
6-11.
6-11.
6-L~.
6-14.
6-15.
6-16.
6-19.
6-10.
6-11.
6-11.
6-13.
6-14.
6-15.
6-10.
6-27.
6-1~.
6-~7a.
o-JX.
6-:~9 .
6-40.
6-41.
ti-41.
ti-43.
7-1.
7·1.
7-J.
6-:~0.
6-J I.
h-:~1.
to-JJ.

PIPER COMANCHE SERVICE MASt" AL
LIST OF ILLl1STRA TlO'S (cont.)
Aerofichc
Grid
'0,
Revised: It /1/82
•
figure
7-~.
7-5.
7-fl.
7-fla.
7-7.
7-H.
7-9.
7-10.
7-11,
7-1 ~.
7-13.
7-14,
7-15.
7-1 ft.
7-17.
7A-I,
7A-~.
•7A-4.
7A-5.
7/,\-(,.
7A- -:.
7A-~.
7A-9,
7A-IO.
7A-II.
7A-I~.
7A-I~.
7.'\-14.
7A-15.
7A-lh.
7A-li.
7A-IX,
7A-19
1A-20.
7 A-~ I.
7 A-~2.
7 A-~).
7B-1.
7B-1.
7B-J.
78-4.
7B-5.
•
Woodward Propeller Governor Adjustment Points .
Hartzell Propeller Governor Adjustment Points .
Engine Installation (PA-24-IXO) .
Cockpit Control Spring Back .
Carburetor .
Magneto Inspection .
Lead Positioning .
Impulse Coupling .
Magneto Timing Marks .
Timing Pointer .
Timing Plate Installed on Breaker Compartment .
Breaker Compartment With Cast Timing Marks .
Engine Timing Marks .
Ignition System Retard Breaker Magneto Installation .
Removing Seized Spark Plug .
Propeller Installation (McCauley) PA-24-250 .
Typical
'ick~ and Removal Method .
Propeller Installation (Hartzell] PA-24-250 .
Propeller Installation (Hartzell] PA-24-260 .
Woodward Propeller Governor Adjustment Points .
Hartzell Propeller Governor Adjustment Points .
Engine Installation PA-24-250 .
Engine Installation PA-14-160. Serial
'as. 24-4000 to 244782 inel. and
2~-~7x~ to 24-~I<OJ incl. .
Engine Installation PA-24-2flO. Serial
'os. 24-4783 and 24-4804 and up .
Carburetor .
Schematic Diagram of RSA Fuel Injector System (PA-24-250 &PA-24-260) .
Idle
and Mixture Adjustment (Fuel Injector) .
Fuel Air Bleed
'OllIe .
Magneto Inspection _ .
Lead Positioning .
Impulse Coupling .
Magneto Timing Marks .
Timing Pointer .
Timing Plate Installed on Breaker Compartment ' .
Breaker Compartment with Cast Timing Marks .
Engine Timing Marks ,
Ignition System Retard Breaker Magneto Installation .
Removing Seized Spark Plugs .
Propeller Installation .
Typical
'icks and Removal Methods .
Propeller
Governor Adjustment Points .
Engine Installation (PAp:24-400l .
Schematic Diagram of
RSA Fuel Injector System (PA-14-400l .
lAS
:2A~'
2A2~
2BI
2B5
~Bf,
:2 Bl'
2B9
~B9
28 In
2810
2811
2B\I
2B 12
2B 15
281'"
2C7
2el<
2CIO
2('12
2CIf,
:2CI7
2C21
~DI
20
7
2DII
2014
2016
2DI7
1DI9
2020
2020
~011
2D21
2D2~
~D22
2D24
2E2
2E4
1E22
1E2J
2F1
1FJ
'~FX