Piper PA-24-180 Comanche User manual

|
PIPER
AIRPLANE SERVICE MANUAL
CARD 10F 3
® COMANCHE
PA-24-180
PA-24-250
PA-24-260
PA-24-260 TURBO
PA-24-400
PIPER AIRCRAFT CORPORATION
PART
NUMBER
753
516
REVISED:
AUGUST
15,
1998
1A1

Member
General Aviation
Manufacturers
Association
Published
by
Technical
Publications
©
The
New
Piper
Aircraft,
Inc.
2926
Piper
Drive
Vero
Beach,
Florida
32960
US.A.
1A2

PIPER COMANCHE SERVICE MANUAL
AEROFICHE REVISION STATUS
Revisions
to
this
service
manual
753
516,
originally
published
(on
paper
only)
in
1959,
reissued
(on
paper
only)
August
18,
1972
and
published
on
microfiche
June
25,
1976
are
as
follows:
Revisi
Publication
D
fiche
Card
Effectivi
ORIGINAL
(Paper
only)
1959
None
COMPLETE
REISSUE
(Paper
only)
August
18,
1972
-
None
1st
(Paper
only)
December
18,
1973
None
2nd
June
25,
1976
1,2,3,and
4
3rd
October
3,
1977
1
4th
April
3,
1978
1,2,and
3
5th
September
10,
1979
1,2,and
3
6th
April
10,
1981
1,2,and
3
7th
November
1,
1982
1,2,and
3
8th
September
21,
1986
1
9th*
August
15,
1998
1,2,and
3
* Revisions appear in all three cards.
Accordingly, discard your existing card set
and replace it with these cards dated August
15, 1998.
Consult the latest Piper Customer Service Information Catalog No. 1753-755 (Aerofiche) for
current revision dates for this manual.
The
General
Aviation
Manufacturers
Association
(GAMA)
has
developed
specifications
for
microfiche
reproduction
of
aircraft
publications.
The
information
compiled
in
this
Aerofiche
Service
Manual
will
be
kept
current
by
revisions
distributed
periodically.
These
revisions
will
supersede
all
previous
revisions
and
will
be
complete
Aerofiche
card
replacements
and
shall
supersede
Aerofiche
cards
of the
same
number
in
the
set.
Conversion of Aerofiche alpha/numeric grid code numbers:
First number is the Aerofiche card number.
Letter is the horizontal row reference per card
Second number is the vertical column reference per card.
Example: 2J16 = Aerofiche card number two, row J, column 16.
To aid in locating information, a complete Preface containing the Section Index Guide, List of
THustrations and List of Tables for all fiche in this set is provided at the beginning of Card 1. Each
subsequent aerofiche card contains a partial Preface, displaying only those elements on that card.
IDENTIFYING REVISED MATERIAL
A
revision
to
a
page
is
defined
as
any
change
to
the
text
or
illustrations
that
existed
previously.
Such
revisions,
additions
and
deletions
are
identified
by
a
vertical
black
line
(change
bar)
along
the
left-
hand
margin
of
the
page
opposite
only
the
text
or
illustration
that
was
changed.
Changes
in
capitalization,
spelling,
punctuation,
indexing,
the
physical
location
of
the
material
or
complete
page
additions
are
not
identified
by
revision
lines.
\ Example.
Revised:
8/15/98
PREFACE
1A3

PIPER COMANCHE SERVICE MANUAL
EFFECTIVITY
This
service
manual
is
effective
for
all
PA-24
Comanche
airplanes
as
follows:
Model
Name
Model
Number
Serial
Numbers
"
Model
Years
Comanche
PA-24-180
24-1
thru
24-3687*
1958
-
1964
PA-24-250
24-1
thru24-3687*
1958
-
1964
~
PA-24-260
24-4000
thru
24-4299
1964
-
1965
Comanche
B
PA-24-260
24-4300
thru
24-4803
1965
-
1968
Comanche
C
PA-24-260
24-4804
thru
24-5028*
1969
-
1972
Turbo
Comanche
C
PA-24-260
Turbo
24-4904
thr
24-5028*
1969
-
1972
and
Comanche
400
PA-24-400
26-1
thru
26-148
1964
*
Multiple
models
assigned
serial
numbers
from
a
single
serial
number
list.
No serial numbers duplicated.
PARTS
This
manual
generally
does
not
contain
hardware
callouts
for
installation.
Hardware
callouts
are
only
indicated
where
a
special
application
is
required.
To
confirm
the
correct
hardware
used,
refer
to
the
PA-
24
Comanche
Catalog
P/N
752
464,
and
FAR
43
for
proper
utilization.
WARNINGS, CAUTIONS AND NOTES
These
are
used
to
highlight
or
emphasize
important
information.
— WARNING —
PREFACE
OPERATING
PROCEDURES,
PRACTICES,
ETC.,
WHICH
MAY
RESULT
IN
PERSONAL
INJURY
OR
LOSS
OF
LIFE
IF
NOT
CAREFULLY
FOLLOWED.
— CAUTION —
OPERATING
PROCEDURES,
PRACTICES,
ETC.,
WHICH
IF
NOT
STRICTLY
OBSERVED
MAY
RESULT
IN
DAMAGE
TO
EQUIPMENT.
— Note —
An
operating
procedure,
condition,
etc.,
which
is
essential
to
emphasize.
Revised: 8/15/98 ‘
1A4

PIPER COMANCHE SERVICE MANUAL
SECTION
vl
VIIA
VIIB
VIIC
VIHI
IX
XI
XII
Revised: 8/15/98
SECTION INDEX GUIDE
UBJECT
AEROFICHE CARD NO. 1
INTRODUCTION
HANDLING AND SERVICING
INSPECTION
STRUCTURE
SURFACE CONTROLS
LANDING GEAR AND BRAKE SYSTEM
AEROFICHE CARD NO. 2
POWER PLANT - PA-24-180
POWER PLANT - PA-24-250 AND PA-24-260
POWER PLANT - PA-24-400
POWER PLANT - PA-24-260 Turbo
FUEL SYSTEM
AEROFICHE CARD NO. 3
ELECTRICAL SYSTEM
HEATING AND VENTILATING
INSTRUMENTS
ELECTRONICS
1A5
GRID NO.
1AI5
1A20
1D14
1E6
IF13
1H19
2A10
2C2
2E18
2G7
2112
3A8
3F6
3F16
3H1
PREFACE

PIPER COMANCHE SERVICE MANUAL
2-3.
24,
2-5.
2-6.
2-7.
2-8.
2-8a.
29.
2-10.
2-11.
2-12.
2-13.
2-14.
2-15.
2-16.
2-17.
2-18.
2-19.
2-20.
2-21.
2-22.
2-23.
2-24.
2-25.
2-26.
2-27.
2-28.
2-29.
2-30.
2-31.
2-32.
3-1.
3-2.
3-3.
4-1.
4-2.
4-3.
PREFACE
LIST OF ILLUSTRATIONS
Subject
Grid
No,
Three-View
of
Comanche
-
PA-24-180
and
PA-24-250
1A24
Three- View of Comanche - PA-24-260
(Serial
Nos.
24-4000
to
24-4246,
24-4248
to
24-4299)
1B1
Three-View of Comanche B - PA-24-260 :
(Serial
Nos.
24-4247,
24-4300
to
24-4782,
24-4784
to
24-4803
incl.)
1B2
Three-View
of
Comanche
-
PA-24-400
1B3
Three-View
of
Comanche
C
-
PA-24-260
(Serial
Nos.
24-4783,
24-4804
and
up.)
1B4
Access
Panels
and
Plates
-
PA-24-180,
250,
260
(Serial
Nos.
24-4000
to
24-4246,
24-4248
to
24-4299)
1BS
Access
Panels
and
Plates
-
PA-24-260
(Serial
Nos.
24-4247,
24-4300
and
up)
1B16
Access
Panels
and
Plates
-
PA-24-400
1B17
Torque
Wrench
Formula
1B18
Jacking
Arrangements
1B23
Weighing
1B24
Leveling Airplane - PA-24-180, 250, 260
(Serial
Nos.
24-4000
to
24-4246,
24-4248
to
24-4299)
and
PA-24-400
1C1
Leveling
Airplane
-
PA-24-260
(Serial
Nos.
24-4247,
24-4300
and
up)
1C1
Landing
Gear
Strut
Exposure
1Cé
Brake
Reservoir
-
PA-24-180,
250
(Serial
Nos.
24-1
to
24-2298
incl)
1C9
Brake Reservoir -
PA-24-180,
250
(Serial
Nos.
24-2299
and
up);
PA-24-260
and
PA-24-400
1C9
Fuel
Strainer
and
Drain
-
PA-24-180,
250
(Serial
Nos.
24-2299
and
up);
and
PA-24-260
1C11
Fuel
Selector
and
Drain
-
PA-24-400
icn
Qil
Suction
Screen
1C20
Qil
Pressure
Screen
1C20
Lubrication
Chart
-
General
-
PA-24-180
and
PA-24-250
1D1
Lubrication
Chart
-
General
-
PA-24-260
1D2
Lubrication
Chart
-
General
-
PA-24-400
iD3
Lubrication
Chart
-
Control
Column
-
PA-24-180,
250,
260
and
400
1D4
Lubrication
Chart
-
Step
Lock
Mechanism
-
PA-24-180,
250,
260
and
400
1D5
Lubrication
Chart
-
Flap
Track
-
PA-24-180,
250,
260
and
400
1D6
Lubrication
Chart
-
Nose
Landing
Gear
-
PA-24-400
1D7
Lubrication
Chart
-
Nose
Landing
Gear
-
PA-24-
180,
250
and
260
1D8
Lubrication
Chart
-
Stabilator
-
PA-24-180,
250,
260
and
400
1D9
Lubrication
Chart
-
Rudder
Control
-
PA-24-180,
250,
260
and
400
1D10
Lubrication
Chart
-
Bellcrank
-
PA-24-180,
250,
260
and
400
1D11
Lubrication
Chart
-
Propeller
-
PA-24-180,
250,
260
and
400
iD12
Lubrication
Chart
-
Main
Landing
Gear
-
PA-24-180,
250,
260
and
400
1D13
Typical
Muffler
Fatigue
Areas
1D17
Exhaust
System
Inspection
Points
-
PA-24-180,
250
and
400
1D18
Exhaust
System
Inspection
Points
-
PA-24-260
1D19
Landing
Light
Installation
1E9
Wing
Attachment
Fittings
1E12
Flap Roller
Installation
(Electrically
Operated)
1E14
Revised: 8/15/98
1A6

PIPER COMANCHE SERVICE MANUAL
4-5.
4-6.
4-7.
4-7a.
4-Tb.
4-Tc.
4-8.
4-9.
4-10.
4-11.
4-12.
4-13.
4-14,
5-1.
5-la.
5-2.
5-3.
54.
5-5.
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
5-12.
5-13.
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-8a.
6-8b.
6-8c.
6-9.
LIST OF ILLUSTRATIONS (continued)
Subject
Aileron Bearing Installation
Door Installation
Door Locking Mechanism - PA-24-250 (Serial Nos. 24-2844 to 24-3284)
Door Locking Mechanism - PA-24-250 (Serial Nos. 24-3285 and up);
PA-24-260 and PA-24-400
Stabilator Balance Weight
Checking Stabilator Free Play
Checking and Balancing Rudder
Fuselage Skin Diagram - PA-24-180, PA-24-250 and
PA-24-260 (Serial Nos. 24-4000 to 24-4246, 24-4248 to 24-4299)
Wing and Empennage Skin Diagram - PA-24-180, PA-24-250 and
PA-24-260 (Serial Nos. 24-4000 to 24-4246, 24-42438 to 24-4299)
Fuselage Skin Diagram - PA-24-260 (Serial Nos. 24-4247, 24-4300 and up)
Wing and Empennage Skin Diagram - PA-24-260
(Serial Nos. 24-4247, 24-4300 and up)
Fuselage Skin Diagram - PA-24-400
Wing and Empennage Skin Diagram - PA-24-400
Typical Access 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 Neutral Rudder Position
Checking Rudder Travel
Rudder and Rudder Trim Controls
Clamping Rudder Pedals in Neutral Position
Stabilator and Stabilator Trim Controls
Checking Stabilator Travel in Up Position
Stabilator Adjustment Points
Special Fabricated Tools
Nose Gear Oleo Strut (Serial Nos. 24-1 to 24-214 incl.)
Grid No.
1E14
1E17
. 1E18
1E19
1E24
1F2
1F5
1F6
1F7
1F8
1F9
1F10
1F11
1F12
1F19
1F23
1G2
1G4
1G4
1G6
1G15
1G1S5
1G16
1G18
1G21
1H1
1H4
1H16
1H24
Nose Gear Oleo Strut Assembly - PA-24-180, PA-24-250 (Serial Nos. 24-215 and up;
PA-24-260 and PA-24-400
Nose Landing Gear Installation
Clamping Rudder Pedals in Neutral Position
Rudder Pedals at Neutral Angle
Installations of Plumb Bob Attachment Tool and Alignment Jig
Nose Gear Door 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
Main Landing Gear Installation (Left)
Revised: 8/15/98
1A7
115
1110
1113
1113
1114
1116
1120
1122
1122
1123
1J2
PREFACE

PIPER COMANCHE SERVICE MANUAL
Figure No.
6-10.
6-11.
612.
6-13.
6-14.
6-15.
6-16.
6-19.
6-20.
6-21.
6-22.
6-23.
6-24.
6-25.
6-26.
6-27.
6-28.
6-29.
6-30.
6-31.
6-32.
6-33.
6-34,
6-34a.
6-35.
6-36.
6-37.
6-37a.
6-38.
6-39.
6-40.
641.
6-42.
6-43.
7-1.
7-2.
7-3.
74.
PREFACE
LIST OF ILLUSTRATIONS (continued)
Subject
Adjustment of Main Landing Gear Drag Link
Aligning Main Gear
Landing Gear Retraction System
Landing
Gear
Retraction
Transmission
Assembly
Landing Gear Retraction System Instailation
Nose Gear Drag Link Clevis
Landing Gear Up Limit Switch
Torque Wrench and Adapter Installation,
(Serial
Nos.
24-1
to
24-4782
incl.;
24-4784
to
24-4803
incl.)
Torque
Wrench
and
Adapter
Installation,
(Serial
Nos.
24-4783;
24-4804
and
up)
Landing Gear Down Safety Lock Installation
Landing Gear Warning Switch Installation
Landing Gear Wamning Indicator
Nose Wheel Assembly
Main
Wheel
Assembly
(Cleveland)
-
PA-24-180
and
PA-24-250
Main
Wheel
Assembly
(Cleveland)
-
PA-24-260
and
PA-24-400
Main Wheel Assembly (Goodrich) - PA-24-400
Brake
Assembly
(Cleveland)
-
PA-24-180
and
PA-24-250
(Serial Nos. 24-1 to 24-3295)
Grid No,
1J6
137
1J10.
1J12
1317
1718
1119
1724
1K1
1K2
1K3
1K5
1K6
1K8
1K9
1K10
1K12
Brake
Assembly
(Cleveland)
-
PA-24-180
and
PA-24-250
(Serial
Nos.
24-3296
&
up);
PA-24-260
and
PA-24-400
1K14
Brake
Assembly
(Goodrich)
-
PA-24-400
1K15
Replacing
Brake
Disc
1K16
Bleeding
Brakes
1K17
Brake
System
Installation
-
PA-24-180
and
PA-24-250
(Serial
Nos.
24-1
to
24-2174
incl.,
24-2176
to
24-2298
incl.)
1K18
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
1K19
Brake
Cylinder
Instaliation
1K21
Brake
Master
Cylinder
-
PA-24-180
and
PA-24-250
(Serial
Nos.
24-1
to
24-2174
incl.,
24-2176
to
24-2298
incl.)
1K23
Parking
Brake
Valve
1L1
Brake
Master
Cylinder
-
PA-24-180
and
PA-24-250
(Serial
Nos.
24-2175,
24-2299
and
up);
PA-24-260
and
PA-24-400
1L3
Brake
Cylinder
Installation
114
Fabricated
Plumb-bob
Tool
1L7
Fabricated
Nose
Whee!
Alignment
Jig
1L8
Fabricated
Spanner
Wrench
1L9
Inspection
of
Rod
End
Bearing
1L11
Main
Gear
Wear
Limits
1L14
Nose
Gear
Wear
Limits
1L16
Propeller
Installation
(McCauley)
2A14
Typical
Nicks
and
Removal
Method
2A15
Propeller
Instatlation
(Hartzell)
2A18
Woodward
Propeller
Governor
Adjustment
Points
2A21
Revised:
8/15/98
1A8

‘E.Lgm.iflm
PIPER COMANCHE SERVICE MANUAL
LIST OF ILLUSTRATIONS (continued)
Subject
7-5. Hartzell Propeller Governor Adjustment Points
7-6. Engine Installation - PA-24-180
7-6a. Cockpit Control Spring Back
7-7. Carburetor
7-8. Magneto Inspection
7-9. Lead Positioning
7-10. Impulse Coupling
7-11. Magneto Timing Marks
7-12. Timing Pointer
7-13. Timing Plate Installed on Breaker Compartment
7-14. Breaker Compartment With Cast Timing Marks
7-15. Engine Timing Marks
7-16. Ignition System Retard Breaker Magneto Installation
7-17. Removing Seized Spark Plug
TA-1. Propeller Installation (McCauley) - PA-24-250
TA-2. Typical Nicks and Removal Method
TA-3. Propeller Installation (Hartzell) - PA-24-250
TA4. Propeller Installation (Hartzell) - PA-24-260
7A-5. Woodward Propeller Governor Adjustment Points
TA-6. Hartzell Propeller Governor Adjustment Points
TA-7. Engine Installation - PA-24-250
TA-8.
Engine
Installation
-
PA-24-260
(Serial
Nos.
24-4000
thru
24-4803,
less
24-4783)
7A-9.
Engine
Installation
-
PA-24-260
(Serial
Nos.
24-4783
and
24-4804
and
up)
7A-10. Carburetor
TA-11.
Schematic
Diagram
of
RSA
Fuel
Injector
System
-
PA-24-
250
&
PA-24-260
TA-12. Idle and Mixture Adjustment (Fuel Injector)
7A-13. Fuel Air Bleed Nozzle
7A-14. Magneto Inspection
7TA-15. Lead Positioning
7TA-16. Impulse Coupling
TA-17. Magneto Timing Marks
TA-18. Timing Pointer
7A-19 Timing Plate Installed on Breaker Compartment
7A-20. Breaker Compartment with Cast Timing Marks
TA-21. Engine Timing Marks
TA-22. Ignition System Retard Breaker Magneto Installation
7A-23. Removing Seized Spark Plugs
7B-1. Propeller Installation
7B-2. Typical Nicks and Removal Methods
7B-3. Propeller Governor Adjustment Points
7B-4. Engine Installation - PA-24-400
7B-5.
Schematic
Diagram
of
RSA
Fuel
Injector
System
-
PA-24-400
7B-6. 1dle Speed and Mixture Adjustment (Fuel Injector)
7B-7. Fuel Air Bleed Nozzle
7B-8. Magneto Timing Marks
Revised: 8/15/98
1A9
Grid No.
2A22
2B1
- 2BS
2B6
2B8
2B9
2B9
2B10
2B10
2B11
2B11
2B12
2B1S
2B17
2C7
2C8
2C10
2C12
2C16
2C17
2C21
2D1
2D7
2D11
2D14
2D16
2D17
2D19
2D20
2D20
2D21
2D21
2D22
2D22
2D24
2E2
2E4
2E22
2E23
2F2
2F3
2F8
2F10
2F12
2F14
PREFACE

PIPER COMANCHE SERVICE MANUAL
Figure No.
7B-9.
7B-10.
7B-11.
7B-12.
7B-13.
7B-14.
7TB- 15.
7C-1.
7C-2.
7C-3.
7C-4.
7C-5.
7C-5a.
7C-5b.
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.
8-3.
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.
8-18.
8-19.
PREFACE
LIST OF ILLUSTRATIONS (continued)
Subject
Grid
No,
Reworked
Plain
Washer
2F14
Filed
Notch
on
Cam
2F15
Installation
of
Rotor
Holding
Tool
and
Timing
Pointer
2F15
Alignment
of
Cam
in
Inspection
Hole
)
2F16
Engine
Timing
Marks
2F17
Ignition
System
Retard
Breaker
Magneto
Installation
2F20
Removal
of
Seized
Spark
Plug
2F22
Propeller
Installation
2G12
Typical
Nicks
and
Removal
Methods
2G13
Propeller
Govemnor
2G15
Engine
Installation
-
PA-24-260
Turbo
2G22
Schematic
Diagram
of
Turbocharger
System
2G23
Lockwiring
V-Band
Couplings
2G24
Indicator
Probe
Installation
2H3
Schematic
Diagram
of
RSA
Fuel
Injector
System
-
PA-24-260
Turbo
2H7
Fuel
Injector
2H9
Fuel
Air
Bleed
Nozzle
2H10
Contact
Points
2H12
Rotor
Holding
Tool
Installed
2H14
Timing
Kit
Installed
2H14
Aligning
Timing
Marks
Single
Contact
Assembly
Magneto
2H15
Forming
Leads
in
Breaker
Compartment
2H15
Engine
Timing
Marks
2H16
Magneto
Timing
Marks
2H16
Removing
Frozen
Spark
Plug
2H19
Turbo
Oil
Flow
Check
2H22
Fuel
Cell
Installation
(Main/Inboard)
2114
Fuel
System
Schematic
-
PA-24-180
2115
Fuel
System
Schematic
-
PA-24-250
(Serial
Nos.
24-105
to
24-2298)
2116
Fuel
System
Schematic
-
PA-24-250
(Serial
Nos.
24-2299
&
up)
and
PA-24-260
2117
Fuel
System
Schematic
-
PA-24-260
Turbo
2118
Fuel
System
Schematic
-
PA-24-400
2120
Bayonet
Fasteners
2121
Button
Fasteners
2121
Checking
Sender
Unit
2124
Checking
Fuel
Gauge
2124
Three
Position
Fuel
Valve
-
PA-24-180
and
PA-24-250
213
Five
Position
Fuel
Valve
-
PA-24250
and
PA-24-260
215
Fuel
Valve
and
Filter
-
PA-24-400
215
Fuel
Strainer
Disassembled
-
PA-24-400
2]7
Bendix
Plunger
Fuel
Pump
(Early)
2]9
Bendix
Plunger
Fuel
Pump
(Late)
2J9
Exploded
View
Bendix
Rotary
Fuel
Pump
2712
Primer
Pump
(Carburetor
Induction
System)
215
Fabricated
Fuel
Quantity
Transmitter
Checking
Jig
2J18
Revised:
8/15/98
1A10

PIPER COMANCHE SERVICE MANUAL
LIST OF ILLUSTRATIONS (continued)
Figure No. Subject
9-1. Generator and Starter Wiring System
9-2. Sectional View of Generator
9-3. Wiring Circuit of Three Unit Regulator
9-4. Use of Riffle File to Clean Contact Points
9-5. Voltage Regulator Air Gap Check and Adjustment
9-6. Adjusting Voltage Regulator Settings
9-7. Checking Voltage Setting, Fixed Resistance Method
9-8. Checking Voltage Setting, Variable Resistance Method
99. Cutout Relay Air Gap Check and Adjustment
9-10. Cutout Relay Point Opening Check and Adjustment
9-11. Checking Cutout Relay Closing Voltage
9-12. Adjustment of Cutout Relay Closing Voitage
9-13. Checking Current Regulator, Load Method
9-14. Checking Current Lead Method, Jumnper Lead Method
9-15. Alternator and Starter Wiring System
9-16. Cross Sectional View of Alternator
9-17. Checking Rotor
9-18. Slip Ring End Frame
9-19. Checking Stator
9-20. Checking Diodes
9-21. Brush Holder Assembly
9-22. Exploded View of Heat Sink Assembly
9-23. Checking Alternator Qutput
9-24. Volt-Ohmmeter Test
9-25. Jumper Connection
9-26. Regulator Checks
9-27. Relay Test
9-27a. Exploded View of Alternator
9-27b. Alternator and Starter Wiring System Schematic (Prestolite)
9-27c. Removal of Rectifier
9-27d. Removal of Slip Ring End Bearing
9-27e. Removal of Drive End Head
9-27f. Removal of End Head Bearing
9-27g. Testing Rotor for Grounds
9-27h. Testing Rotor for Shorts
9-27i. Installation of Bearing
9-27]. Installation of Rectifier
9-27k. Terminal Assembly
9-271. Slip Ring End Bearing Assembly
9-27m. Testing Alternator
9-27n. Brush Installation
9-270. Internal Wiring Diagram
9-27p. Regulator Diagram
9-27q. Testing Regulator
9-27r. Application of Overvoltage Control
Revised: 8/15/98
1A11
Grid No,
3A13
3A16
- 3A22
3A24
3A24
3B1
3B1
3B1
3B3
3B3
3B4
3B4
3BS
3BS
3B8
3B10
3BI11
3B11
3Bl
3BI12
3B14
3B14
3B15
3B17
3B17
3B18
3B19
3B20
3B22
3B23
3B23
3B24
3B24
3C1
3C1
3C2
3C2
3C3
3C3
3C3
3C4
3C4
3C7
3C8
3C9
PREFACE

PIPER COMANCHE SERVICE MANUAL
9-27s.
9-27t.
9-27u.
9-28.
9-29.
9-29a.
9-29b.
9-29c.
9-29d.
9-29e.
9-29f.
10-1.
10-2.
10-3.
10-4.
10-5.
10-6.
10-7.
11-1.
12-1.
Wb
PREFACE
LIST OF ILLUSTRATIONS (continued)
Subject
Testing Overvoltage Control
No-Load Test
Lock-Torque Test
Not Used.
Not Used.
Exploded
View
of
Gear
Reduction
Starting
Motor
Turning Starting Motor Commutator
Testing Motor Armature for Shorts
Testing Motor Fields for Grounds
No-Load Test Hookup
Stall-Torque Hookup
Cabin
Heater,
Defroster
and
Fresh
Air
System
-
PA-24-180
and
PA-24-250
(Serial Nos. 24-1 to 24-1251)
Cabin
Heater,
Defroster
and
Fresh
Air
System
-
PA-24-180
and
PA-24-250
(Serial Nos. 24-1252 to 24-2298)
Cabin
Heater,
Defroster
and
Fresh
Air
System
-
PA-24-180
and
PA-24-250
(Serial Nos. 24-2299 and up)
-
Cabin
Heater,
Defroster
and
Fresh
Air
System
-
PA-24-260
(Serial Nos. 24-4000 to 24-4246, 24-4248 to 24-4299)
Cabin
Heater,
Defroster
and
Fresh
Air
System
-
PA-24-260
(Serial
Nos.
24-4247,
24-4300
to
24-4782
incl.;
24-4784
to
24-4803
incl.)
Cabin
Heater,
Defroster
and
Fresh
Air
System
-
PA-24-400
Cabin
Heater,
Defroster
and
Fresh
Air
System
-
PA-24-260
(Serial
Nos.
24-4783,
24-4804
and
up)
Instrument Panel
Avionics Antenna Locations
NOTE
Refer to Electrical Schematics Index at 3D7
ndi
Control Cable Inspection Technique
External Cable Wear Patterns
Internal Cable Wear
Pulley Wear Patterns
1A12
- @
3C9
3C11
3C12
3C14
3C17
3C17
3C17
3Ci8
3C18
3F9
3F10
3F11
3F12
3F13
3F14
3F15 ‘
3F24
3H5
1L18
1L18
iL19
1L20

PIPER COMANCHE SERVICE MANUAL
Table No,
LI
II-1
-
I-IA
o-1
v
o-v
I-vI
I-vin
o-vi
IH-I
V-1
v-II
VI
VI-II
VI-II
VI-IV
VI-I
VII-IT
VII-III
VHA-I
VIA-O
VIA-I
VIIB-1
VIIB-II
VHC-1
VIC-IA
VIIC-IT
VHI-I
VII-II
VII-UI
VII-IV
IX-1
IX-1I
IX-1IA
X-III
IX-1v
X-v
IX-vi
IX-VII
XI-1
XI-II
X111
XI-IV
XI-v
Revised: 8/15/98
LIST OF TABLES
Subject
Engine and Propeller
Leading Particulars and Principal Dimensions
Recornmended Nut Torques (Inch Pounds)
Flare Fitting Torques ’
Indicated Oxygen Cylinder Pressures for Given Ambient Temperatures
Inspection Report - Overhaul Time Limits (Oxygen Syst. Components)
Troubleshooting Chart (Oxygen Systemn)
Recommended Lubricating Oils
Decimal Equivalents of Drill Sizes
Lubrication (Special Instructions)
Inspection Report
Control Surface Travel and Tension
Troubleshooting Chart (Surface Controls)
Torgue For Effective Wrench Length
Troubleshooting Chart (Landing Gear and Brake System)
Main Gear Wear Limits
Nose Gear Wear Limits
Propeller Specifications - PA-24-180
Timing Data
Troubleshooting Chart (Engine) - PA-24-180
Propeller Specifications - PA-24-250/260
Timing Data
Troubleshooting Chart (Engine) - PA-24-250/260
Propeller Specifications - PA-24-400
Troubleshooting Chart (Engine) - PA-24-400
Propeller Specifications - PA-24-260 Turbo .
Troubleshooting Chart (Mixture Control Indicator)
Troubleshooting Chart (Engine) - PA-24-260 Turbo
Specifications, Duke Model 4140-00-218 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 System Schematics
Electrical Wire Coding
Electrical Symbols
Troubleshooting
Vacuum System
Directional Gyro Indicator
Gyro Horizon Indicator
Rate Of Climb Indicator
Altimeter
1A13
Grid No.
1A17
1B6
- 1B19
1B22
1C13
1C1S
1C18
1C19
1C23
1C24
1D20
1F15
1H5
1323
L5
1L13
1L15
2A19
2B11
2B21
2C14
2D23
2E8
2F1
2G2
2G16
2H2
211
2113
2j14
2J15
2J17
3B16
3D3
3D5
3D6
3D7
3D11
3D12
3E22
3F23
3G6
3G7
3G8
3G9
PREFACE

PIPER
COMANCHE
SERVICE
MANUAL
Table No.
XI-VI
XI-VII
XI-IX
XI-X
X1-XI
XI-X1I
XI-X1V
XI-XvV
PREFACE
LIST OF TABLES (continued)
Subject
Airspeed Tubes And Indicator
Magnetic Compass
Manifold Pressure Indicator
Tachometer *
Engine Oil Pressure Gauge
Fuel Pressure Gauge
Turn and Bank Indicator
Oil Temperature Indicators
Fuel Quantity Indicators
Fuel Quantity Indicator
1A14
Revised: 8/15/98 ‘

.
SECTION
1
INTRODUCTION
Paragraph
"Aerofiche
Grid No
1-1
GeneTal
...
e
e
e
IA16
1-3
Scope
Of
Manual.
..
...t
e
e
et
1Al6
1-7
DI
Pl OM
.
ottt
ittt
e
e
i
e
e
1A
L6
1-9.
2
1V
1A16
1-10.
EmMPennage
..ot
e
e
1A16
I-11.
Fuselage
..
...
e
1A16
1-12.
Landing
Gear
.......o.iiuiiiii
it
e
iitn
ettt
tAl6
1-13.
Hydraulic
Systems
...
...
..
.ottt
1A16
1-14.
Engine
And
Propellers......
..
..
i
it
tA16
1-15. Fuel System. . .ot i i e e i et 1A17
1-16.
Flight
Controls
.....
..o
i
i
i
i
1A17
1-17
Radio
...
..
i
e
e
i
e
1A17
I-18. Cabin Heater, Defroster, And Fresh Air System ...................... 1A17
1-19. Instrument And Autopilot Systems. . .........oveviiiiieiineeennnnn.s 1A17
ISSUED: 8/18/72
1A15

PIPER COMANCHE SERVICE MANUAL
SECTION 1
INTRODUCTION
.
1-1. General.
1-2.
This
manual
contains
service
and
maintenance
instructions
for the
Piper
PA-24
Comanche
(Figure
1-1),
designed
and
manufactured
as
a
versatile
aircraft
in
the
personal
and
business
aviation
field,
by
the
Piper
Aircraft
Corporation,
Lock
Haven,
Pennsylvania.
1-3. Scope of Manual.
1-4.
Sections
II
and
ITI
comprise
the
service
part
of
this
manual,
whereas
Sections
IV
through
XTI
comprise
the
maintenance
instructions.
The
service
instructions
include
ground
handling,
servicing,
and
inspection.
The
maintenance
instructions
for
each
system
include
troubleshooting,
removal
and
installation
of
components,
and
corrective
maintenance
and
testing;
each
major
system
of
the
aircraft
is
covered
in
a
separate
section
1-5.
Only
qualified
personnel
shouid
perform
the
operations
described
in
this
manual.
1-6.
The
description
of
the
aircraft
included
in
this
section
is
limited
to
general
information;
however,
Figures
1-2
through
1-4
gives
specific
external
dimensions.
Table
II-II
lists
the
leading
particulars
and
principal
dimensions.
1-7. Description.
1-8.
The
Piper
PA-24
Comanche
is
a
four
place,
(optional
5th
and
6th
seats
are
available
in
the
PA-24-260,
Serial
Nos.
24-4300
and
up)
single-engine,
low-wing
monoplane
of
all
metal
construction.
Paragraphs
1-9
through
1-19
provide
descriptions
of
the
major
components
and
systems.
1-9.
Wing.
The
laminar
flow
wing
is
of
all-metal
stressed-skin,
full-cantilever,
low-wing
design,
consisting
.
of
two
wing
panels
bolted
together
at
the
center
of
the
fuselage.
The
wing
tips
are
removable.
The
ailerons
are
cable
and
push
rod
controlled
and
are
statically
and
dynamically
balanced.
The
trailing
edge
wing
flaps
are
manually
or
electrically
operated.
.
1-10.
Empennage.
The
empennage
consists
of
the
fin,
stabilators,
and
stabilator
trim
tabs.
The
rudder
and
stabilators
are
dynamically
and
statically
balanced.
1-11.
Fuselage.
The
fuselage
consists
of
three
basic
units:
the
engine
section,
the
cabin
section,
and
the
sheet-metal
tail
cone.
1-12.
Landing
Gear.
The
landing
gear
is
an
electrically
operated
tricycle
gear.
consisting
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.
INTRODUCTION
Revised:
8/15/98
‘
1A16

PIPER COMANCHE SERVICE MANUAL
1-14. Engine and Propeller.
Table I-1. Engine and Propeller.
Model
Engines
Propellers
Horsepower
Octane
PA-24-180
0-360-A1A
Hartzell
HC-92ZK-8D,
or
180
91/96
0-360-A1D
McCauley
2D36C14
PA-24-250
0-540-A1A5
Hartzell
HC-82XK-1D
250
"91/96
0-540-A1B5
or
HC-A2VK-1,
or
0-540-A1C5
McCauley
2D36C28
0-540-A1D5
10-540-C1B5
Hartzelt
HC-A2VK-1
PA-24-260
0O-540-E4AS
Hartzell
HC-C2YK-1A
260
91/96
10-540-D4AS
or
HC-C2YK-1B
10-540-N1A5
Hartzell
HC-E2YR-1B
PA-24-260
Tutbo
10-540-R1AS5
Hartzell
HC-E2YR-1B
260
100/130
or
HC-E2YR-1BF
PA-24-400
10-720-A1A
Hartzell
HC-A3VK-4
400
100/130
1-15.
Fuel
System.
The
fuel
system
on
the
PA-24-180
consists
of
two
rubber
cells
in
the
wings,
one
engine
driven
pump,
and
one
electrical
auxiliary
pump.
On
the
PA-24-250
the
fuel
system
is
similar,
with
the
exception
that
there
are
two
electrical
auxiliary
pumps
in
addition
to
the
engine
driven
pump
and
two
auxiliary
fuel
cells
as
optional
equipment.
The
fuel
system
on
the
PA-24-260
has
two
fuel
cells
as
standard
equipment,
two
fuel
cells
as
optional
equipment,
one
engine
driven
pump
and
two
electric
auxiliary
fuel
pumps
with
carburetor
equipped
engines
or
one
electric
auxiliary
pump
with
fuel
injection
engines.
The
PA-
24-400
system
consists
of
four
fuel
cells,
one
engine
driven
pump
and
one
electric
auxiliary
pump.
1-16. Flight Controls. The flight controls are conventional equipment, consisting of a control wheel which
operates the ailerons and stabilators, and pedals which operate the rudder. Duplicate controls are provided for
the copilot.
1-17. Radio. Provisions for radio installations consist of microphone and headset jacks and mounting
brackets, a loudspeaker, necessary wiring, and panel space for at least four radios.
1-18. Cabin Heater, Defroster, and Fresh Air System. Heater air for the cabin and defroster is obtained
directly from the exhaust system muffler shroud. On the PA-24-180 and PA-24-250 fresh air is obtained
through intakes at the engine cowl, and an air intake at the top of the fuselage providing air to the individual
seats through the air line type overhead vents. On the PA-24-260 and PA-24-400 fresh air is taken from the
leading edge of each wing to the forward portion of the cabin and through an intake located on the dorsal fin
directing air through overhead vents.
1-19. Instrument and AutoPilot Systems. Provisions for instrument installation include panels for engine
instruments and advance flight instruments, as well, as for an AutoPilot system which consists of four
principal parts: a modified directional gyro, a modified gyro horizon, a motor-driven actuator, ind an
amplifier.
Revised:
8/15/98
INTRODUCTION
1A17

THIS
PAGE
INTENTIONALLY
LEFT
BLANK
1A18

THIS PAGE INTENTIONALLY LEFT BLANK
1A19

SECTION
II
‘
HANDLING
AND
SERVICING
Paragraph
Acrofiche
Grid
No
2-1
TR
e
10
L
4T
1
1A22
2-2.
DIMNEISTONS
& &
v
vt
eeeae
e
ettt
i
et
et
ite
e
et
s
aa
e
aasanean
e
rsanaas
1A22
2-3.
Weight
and
Balance
Data
.
...
...t
1A22
2-4.
Serial
Number
Plate
.
...ooooriiin
i
it
1A22
2-5
Access
and
Inspection Provisions
1A22
2-6.
Tools
and
Test
EQuipment
.......ooov
i
iiiineeens
1A22
2-7
Torque
REQUITEMENIES
...ttt
ean
ettt
e
een
e
reacnaens
1A23
2-Ta
Torque
WIenCRES
...
.v
i\ttt
ettt
a
e
e
1A23
2-8
Handhold
and
WalkWays
..
.co.eenerontr
et
eninteaanearanecaneanerannss
1A23
2-9
Ground
Handling.
...
cooirini
i
e
e
1A23
2-10
Introduction
to
Ground
Handling
............
...
i,
1A23
2-10a.
Torque
Wrenches
1BI18
2-1
JACKINE
1 e e
ettt
i
e
1B23
2-12.
Weighing
.
1823
2-13
Leveling
............ooooit
...
1B24
2-14.
MOOTING
.«
ettt
ittt
i e
Lo
Q2
2-15.
S
)
1C2
2-16
Locking
Airplane
1C3
2-17
T
OWITIE
£
o
o
vttt
et
et
e
et
vt
e
e
1C3
2-18.
TAKIIIZ
.+
oot
e
et
eee
it
et
et
e
1C3
2-19.
External
Power
Receptacle
1C3
2-20
Operation
of
External
Power
Receptacle
...t
1C3
2-21
L1
11T
PR
RS
1C4
2-22.
Cleaning
Engine
Compartment
1C4
2-23.
Cleaning
Landing
Gear
.....................
1C4
2-24
Cleaning
Exterior
Surfaces
.
.......oo
i
1C4
2-25.
Cleaning
Windshield
and
Windows
...,
1C5
2-26.
Cleaning
Headliner.
Side
Panels
and Seats
......................0tn
1C5
2-27
Cleaning
Carpets
........ovueerieeaneeerireaanrnesnsconnaeinannnas
1C5
2-28.
Y
o111
R
EE
1CS
2-29
INtroduction
tO
SEMVICING
« . v v
v
v
iiii
it
aaaiicecen
e
eas
1CS
2-30.
Landing
Gear
SYSIEM
...
ovtntnt
it
e
ittt
1C6
2-31
Servicing
Landing Gear...
1C6
2-32.
Oleo
SIrUts
oo
ovvevvveiennannenns
1Cé
2-23.
Servicing
Oleo
Struts
...
vv
i
1CA
2-34.
FUing
Oleo
SITULS
...ttt
es
105
2-35
Inflating
Oleo
SITULS
...
.iut
it
e
inans
1C8
2-36
Brake
SyStem
...
.e..iniieinee
ettt
1C8
2-37
Servicing
Brake
SyStem
...
...uoiiut
i
1C8
2-38.
Filling
Brake
System
Reservoir
........
..ot
1C8
2-39
Draining
Brake
System
..
...
...
viiiiet
i
1C8
2-40
THEES
o
v
et
eeeecieri
i
1C9
2-41.
Servicing
Tires
....
..
1C9
2-42,
Power
Plant
.
...
..ottt
1C9
2-43.
Servicing
Power
Plant
1C9
2-44
PrOPeller
.ottt
e
IC10
REVISED: 11/1/82