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

Figure
PIPER COMANCHE SERVICE MANUAL
LIST OF ILLUSTRATIONS (eont.) •
Aerofiche
Grid ;'1;0.
7B·6.
7B-7.
7B-8.
7B·9.
7B-IO.
7B-11.
7B-12.
78·13-
7B-14.
7B-15.
7C-t.
7C-2.
7C-l
7C-4.
7C·5.
7C-6.
7C-7.
7C-8.
7C-9.
7C-10.
7C-11.
7C·12.
7C·13.
7C-14.
7C·15.
7C·16.
7C-17.
8-1.
8-2.
8-1
8·4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
8-11.
8-12.
8-13.
8-14.
8-15.
8-16.
8-17.
Idle Speed and Mixture Adjustment (Fuel Injector) , 2F10
Fuel Air Bleed Nozzle. . . . . . . . . . . . . . •. . . . . •. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F12
Magneto Timing
Marks.................................................... 2FI4
Reworked Plain
Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . •. . . . . . . . . . 2F 14
Filed Notch on Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . •. . . . . . . . . . . . . . . . . . 2F I5
Installation of Rotor Holding Tool
and Timing Pointer. •. . . . . . . . . . . . . . . . . . . . . . . 2FI5
Alignment of Cam in Inspection
Hole........................................ 2FI6
Engine Timing Marks ....................................................
.. 2F 17
Ignition System Retard Breaker Magneto Installation 2F20
Removal of Seized Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F22
Propeller Installation.
.. .. . . .. . . .. .. . . . .. . .. . .. .. . .. .. 2G 12
Typical Nicks and Removal Methods. . .. . . ... .. ... . . .. . .. . . . ... 2G 13
Propeller Governor .................•.•...... . . . . . . . . . . •. . . . . . . . . . . . . . . . . . . 2GIS
Engine Installation (PA-24-260 Turbocharged)....... .. . .. . .. .. 2G22
Schematic Diagram of Turbocharger
System.. . .. . .. . .. 2G23
Schematic Diagram of RSA Fuel Injector System (PA·24-260
Turbocharged)...... 2H7
Fuel
Injector. ..........................................•................ .. 2H9
Fuel Air Bleed Nozzle " . . . . . . . . . . . . . . . . . . . 2H10
Contact
Points... . . . . . . . . . . . . . . . . . . 2H 12
Rotor Holding Tool Installed ,. 2H14
Timing Kit
Installed....................................................... 2H I.
Aligning Timing Marks Single Contact Assembly Magneto ,. 2H1
Forming Leads in Breaker Compartment 2H IS
Engine Timing. Marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2H16
Magneto Timing Marks '.' .
.. . .. . .. . . . . 2H16
Removing Frozen Spark Plug '" '" . . . .
.. .. 2H19
Turbo Oil Flow Check
..•..•. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H22
Fuel Cell Installation (Main Installation)
..•.................................. 2114
Fuel System Schematic PA-24-l80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . •. . . . . . . 2115
Fuel System Schematic PA-24-2S0. Serial Nos. 24-105 to 24-2298 .. .. 2116
Fuel Svstem Schematic PA-24-2S0. Serial Nos. 24-2299 and up and PA-24-260 2117
Fuel System Schematic PA-24-260 (Turbo)... . . . . . . 2118
Fuel System Schematic PA·24·400 " . . .. . 2120
Bayonent Fasteners. . . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . .. .......... ....... .. 2121
Button Fasteners 2121
Checking Sender Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124
Checking Fuel Gauge , .....................•••.•.... , , 2124
Three Position Fuel Valve PA·24·180 and PA·24-2S0. . . . . . . . . . . . . . . . . . . . . . . . . . . 2J3
Five Position Fuel Valve PA-24-2S0 and PA-24-260... . .. . .. .. . 2J5
Fuel Valve and Filter PA-24-400. ............................................ 2J5
Fuel Strainer Disassembled PA·24-400 2J7
Bendix Plunger Fuel Pump (Early). . . . . . .
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J9
Bendix Plunger Fuel Pump (Late) 2J9
Exploded View Bendix Rotary Fuel Pump
'. 2J12
lA9
REVISED: 4/1.

•PIPER
COMA~CHE SERVICE MANl'Al
LIST OF ILLliSTRATIO,S (cont.)
Aerofiche
Grid 'no
•
Figure
~-,~.
~-'9.
9-1.
9-:!.
9-).
9-4.
9-5.
9-ft.
9- ~,
9-~.
9-9.
9-10.
9-11.
9-12.
9-D.
9- J.t.
9-15.
9-1 ft.
9-17,
9-IX,
9-19.
9-20.
9-21.
9-22.
9-:!~ ,
9-24.
9-25.
9-:!6,
9-2'1.
9-:!7a.
9-2":'b.
9-:!'7c.
9-:!7d.
9-:!7e,
9-2:1.
9-:!7g.
9-27h,
Primer Pump (Carburetor Induction System) , .
Fabricated Fuel Quantity Transmitter Checking Jig .
Generator and Starter Wiring System .
Sectional View of Generator , , , .
Wiring Circuit of Three Unit Regulator .
L'se of Rimer File to Clean Contact Points, .
V oltage Regulator Air Gap Check and Adjustment , .
Adjusting Voltage Regulator Settings .
Checking Voltage Setting. Fix-ed Resistance Method .
Checking Voltage Setting. Variable Resistance Method , .
Cutout Relay Air Gap Check and Adjustment , . ,
Cutout Relay Point Opening Check and Adjustment .
Checking Cutout Relay Closing Voltage ,
Adjustment of Cutout Relay Closing Voltage .
Checking Current Regulator Load Method .
Checking Current Lead Method. Jumper Lead Method , ..
Alternator and Starter Wiring System , , .
Cross Sectional View of Alternator .
Checking Rotor ." .
Slip Ring End Frame. , .
Checking Stator , , .
Checking Diodes .
Brush
Holder Assembly .
Exploded View of Heat Sink Assembly , .
Checking Alternator Output .
Volt-Ohmmeter Test .
Jumper Connection .
Regulator Checks .
Relay Test .
Exploded View of Alternator " .
Alternator and Starter Wiring System Schematic (Prestolite) .
Removal of Rectifier .
Removal of Slip Ring End Bearing .
Removal of Drive End Head .
Removal of End Head Bearing .
Testing Rotor for Grounds , . , .
Testing Rotor for Shorts .
2.115
:!Jll'
3AI3
~Alo
~A:!:!
~.-\:!4
~A:!4
3BI
~BI
~BI
~B~
~B~
3B.t
~B4
385
385
~B!\
~810
~BII
~BII
3BI I
~B12
3BI4
~B14
~B15
~B17
3817
381X
~819
3820
3822
3823
38D
~814
3824
3el
~CI
•lAtO Revised: 11/1
/82

Figure
PIPER COMANCHE SERVICE MA!'il'AL
LIST OF ILLl;STRATlO,S (cont.) •
Aerofiche
Grid ,\().
9-~7i,
9~ :!7j.
9-27k.
9·271.
9-27m.
9-27n,
9-270.
9·~7p.
9-171.1.
9-:nr.
9-:!7s.
9·21<.
9-19.
9-19a.
9-19b.
9-29c.
9-29d.
9-19t.:.
9-19i.
10·1,
10-~.
10-3.
10-4.
10-f,.
to·7.
II-I.
12-1.
Installation of Bearing .
Installation of Rectifier .
Terminal Assembly .
Slip Ring End Bearing Assembly .
Testing Alternator .
Brush Installation .
Internal Wiring
Diagram .
Regulator Diagram .
Testing Regulator .
Application of Overvoltage
Control .
Test ing
0\ ervoltage Control .
'o-l.oad Test .
Lock-Torque Test .
Exploded View of Gear Reduction Starting Motor .
Turning Starting Motor Commutator .
T
costing Motor Armature for Shorts .
Testing
Motor Fields for Grounds .
'o-Load Test Hookup .
Stall-Torque Hookup .
Cabin Heater. Defroster and Fresh Air System PA-24-180 and PA-24·:!50.
Serial' os. 14-1 to 24- I251 .
Cabin Heater. Defroster and Fresh Air Svstem PA-24-180 and PA·24-150.
Serial' os. 14-1152 to 24-219M : .
Cabin Heater. Defroster and Fresh Air System PA-24-180 and PA-24-250.
Serial
'os. 24-2299 and up .
Cabin Heater. Defroster and Fresh Air System PA-24-260. Serial 'os.
24-4000 to 24-4146. 24-4248 to 24-4299 .
Cabin Heater. Defroster and Fresh Air System PA-24-260. Serial 'os.
14-4247. 24-4300 to 24-4782 inclusive: 14-4784 to 24-4803 inclusive .
Cabin Heater. Defroster and Fresh Air System PA-24-400 .
Cabin Heater. Defroster and Fresh Air System PA-24-260. Serial 'os.
24-471:0. 24·4804 and up .
Instrument Panel , .
Avionics
Antenna Locations .
NOTE
Refer to Electrical System Schematics Index at 3D7
~C2
~C2
~C3
3C3
~C3
~C4
.~C 4
.~C·
.1Cl'o
3CQ
~C9
.~CII
3C 12
3CI4
3C17
3CJf
.1(1-:'
3(lloi
~C II'
3F9.
3FIO
~FII
3FI:!
3FI5
3F24
3H5
IAII
Revised: ttl.

•Table
LIST OF TABLES
Acrotichc
Gnd \~l.
•
•
II-I
II-II
II-IIA
II-Ill
11-1\'
II- v
II- vI
11-\'11
11-\111
111-1
\'-1
\'·11
\'1-1
v I-II
\'1-111
\'1-1\'
\'11-1
\'II-II
\'II-111
\'IIA-l
\'IIA-II
\'IIA-lIl
v 11 B-1
\' 11 B-lI
\'11C-\
\'IIC-IA
\'lIC-lI
\'111-1
\'111-11
\'111-\II
\'11 I-I\'
IX-I
IX-II
\X·lIA
I\:-\II
ix-tv
I\:- v
1\.-\'1
1\.-\'11
x1-I
XI-\I
\:1-111
XI-I\'
x1-v
X\-\'\
\:\-\'11
Leading Particulars and Principal Dimensions , . , . ,
Recommended
'ut Torques (Inch Pounds) , .
Flare Fitting Torques , , .
Indicated Oxygen Cylinder Pressures for Given Ambient Temperatures , .
Inspection Report -Overhaul Time Limits (Oxygen System Components) .
Trouble hooting
Chart (Oxygen System) , .
Recommended Lubricating Oils .
Decimal Equivalents Millimeters , , , .
Lubrication (Special \nstructions) " "
.,.,
Inspection Report .. ,., , ,., .. "
Control Surface Travel And Tension , , .
Troubleshooting
Chart (Surface Controls) , , , , .
Torque
For Effective Wrench Length , , ..
Troubleshooting Chart (Landing Gear and Brake System) " .
Main Gear Wear Limits , , .
'ose Gear Wear Limits , .. , ,.
Propeller Specifications (PA-24-180) , .
Timing
Data , .. , . , , , , , , .
Troubleshooting Chart (Engine) (P A-24-180) , , , .
Propeller Specifications (PA-24-250 2(0) , , .
Timing Data " , ,. , .
Troubleshooting
Chart (Engine) (PA-24-250 2(0) , , . ' .
Propeller Specifications (PA-24-40m .
Troubleshooting
Chart (Engine) (PA-24-400) .. , , ,.,., ",.
Propeller Specifications (P A-24-160 Turbocharged) ,., .
Troubleshooting
Chart (M ixture Control Indicator) , , .
Troubleshooting
Chart (Engine -Turbocharged) , , .. , .
Specifications. Duke ModeI414Q..00-218 Electric Fuel Pump .. , ,.
Flow Versus Pressure Chart at 14 V,D.C. , , .
Pump Pressures (Fuel Injection) , , , .. , , . , .
Fuel System Troubleshooting , , .
Alternator Checks , , .
Circuit Load
Chart (Models Prior To 1970) .
Circuit Load
Chart (Models 1970 And Later) , .
Lamp Replacement Guide , . , .
Index Electrical Svstern Schematics , .
Electrical Wire Coding , .
Electrical Svrnbols , , .
Troubleshooting .
Vacuum Svsrern , , .
Directional Gyro Indicator , , ,
..
Gyro Horizon Indicator , .
Rate Of Climb Indicator
,.,.
Altimeter .
Airspeed Tubes And Indicator ,_ , .
Magnetic Compass , , , , .
IRI'
IRI9
IB~~
JCI~
ICI5
ICIX
1("19
IC~~
IC~~
ID20
lFI5
IH5
IJ~':\
115
I\. 1 ,:\
1L15
2\ 19
:8 \I
:R~I
:CI~
2D2~
2EH
:r-:l
:G2
2GII'
:H2
211
2.1 1 ~
2.1 I.;
2.1 15
2.117
~B16
~D~
~D5
~D6
,:\07
~DII
~D12
~E22
~F2~
~G6
~G7
~GX
~G9
~GIO
~GII
REVISED: 11/1/82
IAl2

PIPER COMANCHE SERVICE MANUAL
LIST OF TABLES (eont.) •
Table Aerofiche
Grid 1'0.
XI-VIlI
Xl-IX
XI-X
XI-XI
XI-XII
Xl-XIII
XI-IV
XI-V
XlI-I
Manifold Pressure Indicator .
Tachometer .
Engine Oil Pressure Gauge .
Fuel Pressure Gauge .
Turn And Bank Indicator .............•..................................
Oil Temperature Indicators .
Fuel Quantity Indicators
..........•........••.•..........................
Fuel Quantity Indicator .
Index -Electronic Installation Schematics
...............•..................
3GI2
3GI3
3G13
3GI4
3GI5
3G17
3GI8
3GI9
3D7
•
REVISED: 4/10/81
tAt3
•

•
•
•
lA14
INTENTIONALLY LEFT BLANK

•
SECTION I
INTRODUCTION
Paragraph Aeroficbe
Grid \0.
I-I. General......... A 16
1-3. Scope Of Manual Alb
1-7. Description............................................................... A 16
1-9. Wing.................... A 16
1-10. Empennage...................................................... AI6
I-I I. Fuselage.................................................... A 16
I-I~. Landing Gear AI6
1-13. Hydraulic Systems.... . A 16
1-14. Engine And Propellers............................................. AI6
1-15. Fuel System ~ · All
1-16. Flight Controls................................................... A 17
1-17. Radio........................................................... AI7
I-IS. Cabin Heater. Defroster. And Fresh Air System. .... . .. . . . . . . .. . . . . . . A 1'7
1-19. Instrument And Autopilot Systems.................................. A 1'7
•
•
ISSl'ED: 8/18/72
tAl5

•
•
•
PIPER COMANCHE SERVICE MANUAL
SECTION I
INTRODUCTION
1-1. Gala.
1·2. This manual conains sct'Iice and maintenance irlsuue:t:ions for the Piper PA·24 Comanche (Figure
1-1).
dcsiped and manufaCtUred u a venatile aircnft in the penonal and businas aviation field. by the
Piper AimVt Cotporation. Lock Haven. PClUllYIVUlia.
1-3. Scope OfMaaual.
14. Sections II and 111 comprise the servicepan: of this manual. wbereas Seet:ions IV throuah XII comprise
the maintenance instructions. The service iDscructions include p'0llDd handlint. servicm,. and inspection.
The maintenance instrUctions for each system include troublahooan" ranoval and iDsullation of
components. and COlTC'Ctive mamteMJlce and tcstinl; each major system of the aircn.ft is covered in I
separate section
1·5. Only qualified personnel should perform
the operations described in this manual.
1~. The description of the airc:rait included in this section is limited to ICDera1 infomation: however.
FiBures 1·2 throulh
1-10 lives specific extcma1 dUnCftlions. Table IHI lisa the IClldm, particulan and
principal dimensions.
1·7. Dacription.
1-8. The Piper PA-24 Comanche is I four place. (optional 5th and 6th seats arc available in the P.'o·2....260.
Serial Sos. 24-4300 and up) sinllC'"CDIine. loW"Wi"l monoplane of all metal construction. Paragraphs 1-9
through 1-19 provide descriptions of the major components and systems.
1·9. Wm,. The laminar flow win, is of all·meta1 stresICd1k.in. tilU-eantilcvcr. low·wing desip. consisting of
two willi panels bolted tOiether at the ccntCf of the fusclqe. The winJ tip areremovable. The ailerons an:
cable and push rod controlled and are statically and dynamically balaaccd. The trailin, edp wing flaps are
manually or electrically operated.
HO. Empamap. The CtnpeftDqe consists of the f1l1. stabilators. and stabilator trim tabs. The rudder and
stabilators ate dynamically and statically balanced.
1·11. Fuselap. The tilse1ate consists of three baic units: the eftlinc section. the cabin section. Uld the
sheet-metal tail cone.
1-12.
Landini Gar. The landinggcu is an electrically operated tricycle IQI'. consiRinr of a nose wheel
and
two main wheels.
1·13. Hydraulic Systems.
The brake system is operated by a hand lever or by toe brakes.
1·14. EnJinc And Propellers.
INTRODUCTION
ISSUED: 8118n2
lA16

PIPER COMANCHE SERVICE MANUAL
I
EqiDa
PropcUm
Honepower Ocaae
I
I
iPA·24-180 O·3600A
Huaell HC·92ZX-8D 180 91196
McCaulry ZD36C14
PA·2 ... Z50
0·540-A
HaraeU HC-8ZXX·ID
250
91/96
[Q.54O-C
or HC·AZXX-l
McCauley
2DJ6C28
IPA·24-260
0-540-E
HC-c2YX·IA or
260
91/96
1Q.540-D. NHC-cZYX-lB I
IPA-Z4-400 1Q.72o-A HC·A3VX-4
400
100/130
I
PA·Z4-Z60 "C"
1<r5040-N
He·EZVR-lB
260 91/96
[Q.S40-R HC·E2YR·1BF
260
100/130
•
1·15. Puel System. The fuel system on the PA-Z4-11O consilb of nro rubber cells in the winp. one engine
driven pump. and one electrical auxiliary pump. On the PA-2....Z$O the fuel system is similar. with the
exception that there are two electrical auxiliary PwbPS in addition to the CJIIiDc driven pump and two
auxiliary fuel ceUs as optional equipment. The fuel system on the PA-24-260 has two fuel cd1s ustandard •
equipment. twO fuel cells as optional equipment. one eDJine dtiYCft pump and two eleetric auxiliary fuel
pumps with carburetor equipped e.a or one electric auxiliary plUllp with fuel injection enpnes. The
PA.Z"-400 syRem consistS of four fuel cells. one CftpC dri¥cn pump and one elecaic auxiliary pump.
1·16.
PU ....t Conaoll. The fllsht controls arc conventional equipment. consisrinl of a control wheel which
operates the ailerons and stabiJatOl'S. and pcdais which operate the rudder. Duplicate contrOls areprovided
for the copilot.
1-11. Radio. Provisions for radio installations consist of microphone and headset jacks and mounting
bracken. Iloudspeaker. necessary winn" andpanel spacefor It last four radios.
1-18. tabiD Heater. Detro'Uf. ADd
Frail Air SyRnl. Heater air for the cabin and defrostct is obtained
directly from the exhauSt system muffler shroud. On the PA-Z4-180 and PA·Z4-250 fresh air is obtained
through intakes It the ~e cowl, and an air intake at the top of the fuxJace providinl air to the
individual scats through the air line
type overhead vena. On the PA·24-Z60 and PA-204-400 fresh air is taken
from the lcacling edge of each wing to the forwud portion of the cabin and throulh 1ft intake located on
the dorsal fin directing air throuth overhead ventS.
1-19. InstrUment .-\bd AutoPilot Systeml. Provisions for inltnUnent installation include panels for engine
instruments and ldvance flight instrUments. :u
wdl u for 1ft AutoPilot system .which consists of four
principal pam: amodified directional gyro. amodified JYfO horizon. Ii motor-driven actuator, and an
amplifier.
INTRODUCTION
ISSUED: 8/18n2
tAl7
•

•
•
•
THIS PAGE INTENTIONALLY LEFT BLANK
tAt8