Piper Apache Aircraft PA-23-150 Service Maintenance Manual -

AIRPLANE SERVICE MANUAL CARD 1 OF 2 APACHE PA-23-150 PA-23-160 PIPER AIRCRAFT CORPORATION 1A1 REVISED: OCT. 5, 1999 PART NUMBER 752-422

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

1A3 Revised: 10/5/99 PREFACE PIPER COMANCHE SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to this service manual 752 422, originally published (on paper only) in 1954, reissued (on paper only) March 15, 1968 and published on microfiche May 28, 1976 are as follows: Re visions Pub lica tion Da te Aer of ic he Car d Ef f ecti vity ORIGINAL (Paper only) 1954 None COMPLETE REISSUE (Paper only) October 1960 None COMPLETE REISSUE (Paper only) March 15, 1968 None 1st (Paper only) December 21, 1973 None 2nd May 28, 1976 1 and 2 3rd February 13, 1980 1 and 2 4th February 23, 1983 1 and 2 5th April 29, 1986 1 6th September 15, 1998 1 and 2 7th* October 5, 1999 1 and 2 * Revisions appear in both cards. Accordingly, discard your existing card set and replace it with these cards dated October 5, 1999. A. Consult the latest Piper Customer Service Information Catalog No. 1753-755 (Aerofiche) for current revision dates for this manual. B. 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. C. 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. D. To aid in locating information, a complete Preface containing the Section Index Guide, List of Illustrations 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.

1A4 Revised: 10/5/99 PREFACE PIPER COMANCHE SERVICE MANUAL EFFECTIVITY This service manual is effective for all PA-23-150 and PA-23-160 airplanes as follows: Model Name Model Number Ser ial Number s Model Y ear s Apache PA-23-150 23-1 thru 23-1182 1954 - 1958 PA-23-160 23-1183 thru 1870 1958 - 1959 Apache G PA-23-160 23-1871 thru 23-2012 23-2044 thru 23-2046 1960 - 1962 Apache H PA-23-160 23-2013 thru 23-2043 1962 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- 23 Apache Parts Catalog P/N 752 421, and FAR 43 for proper utilization. WARNINGS, CAUTIONS AND NOTES These are used to highlight or emphasize important information. — WARNING — 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.

1A5 Revised: 9/15/98 PREFACE PIPER APACHE SERVICE MANUAL SECTION INDEX GUIDE SECTION SUBJECT GRID NO . AEROFICHE CARD NO. 1 I INTRODUCTION 1A11 II HANDLING AND SERVICING 1A16 III INSPECTION 1D5 IV STRUCTURES 1E3 V SURFACE CONTROLS 1F10 VI HYDRAULIC SYSTEM 1G14 VII LANDING GEAR AND BRAKE SYSTEM 1I5 VIII POWER PLANT 1J7 IX FUEL SYSTEM 1K12 AEROFICHE CARD NO. 2 X INSTRUMENTS 2A10 XI ELECTRICAL SYSTEM 2B16 XII ELECTRONICS 2E11 XIII HEATING AND VENTILATING 2E12

1A6 Revised: 9/15/98 PREFACE PIPER APACHE SERVICE MANUAL LIST OF ILLUSTRATIONS F igur e No. Subject Gr id No. 2-1. Three-View of Apache PA-23-150 / l60, Serial Nos. 23-1 to 23-l870 incl. ......... 1A18 2-2. Three-View of Apache PA-23-160, Serial Nos. 23-1871 and up ......................... 1A19 2-3. Station Reference Lines........................................................................................ 1B8 2-4. Station Reference Lines........................................................................................ 1B9 2-5. Access and Inspection Provisions ....................................................................... 1B10 2-6. Access and Inspection Provisions ....................................................................... 1B11 2-6b. Torque Wrench Formula ....................................................................................... 1B17 2-7. Jacking Arrangement ............................................................................................ 1B18 2-8. Weighing............................................................................................................... 1B19 2-9. Longitudinal Leveling .......................................................................................... 1B20 2-10. Lateral Leveling.................................................................................................... 1B20 2-11. Service Points ....................................................................................................... 1C2 2-12. Servicing Landing Gear Oleo Struts..................................................................... 1C5 2-13. Fuel Screen Bowl. ................................................................................................ 1C9 2-14. Oil Pressure Screen............................................................................................... 1C13 2- l5. Oil Suction Screen ............................................................................................... 1C13 2-16. Lubrication Chart ................................................................................................. 1C17 2-17. Identification of Aircraft Fluid Lines ................................................................... 1C19 2-17. Cherrylock Rivet Removal. .................................................................................. 1D1 2-19. Flareless Tube Fittings ......................................................................................... 1D3 3-1. Fuel Selector Valve Control Cables ..................................................................... 1D11 4-1. Door Lock Installation.......................................................................................... 1E10 4-2. Landing Light Installation, Serial Nos. 23-1 to 23-1163 incl............................... 1E11 4-3. Landing Light Installation, Serial Nos. 23-1164 and up ..................................... 1E12 4-4. Front Spar Attaching Members ............................................................................ 1E17 4-5. Empennage Skin Diagram ................................................................................... 1E18 4-6. Fuselage Skin Diagram......................................................................................... 1E19 4-7. Wing Skin Diagram ............................................................................................. 1E20 4-8. Nacelle Skin Diagram........................................................................................... 1E21 4-9. Surface Scratches Abrasions or Ground in Dirt .................................................. 1F2 4-10. Deep Scratches Shallow Nicks and Small Holes.................................................. 1F3 4-11. Mixing of Epoxy Patching Compound ................................................................. 1F3 4-12. Welding Repair Method ....................................................................................... 1F4 4-13. Repairing of Cracks .............................................................................................. 1F4 4-14. Various Repairs..................................................................................................... 1F5 4-15. Repair of Stress Lines........................................................................................... 1F7 4-16. Repair of Impacted Damage ................................................................................. 1F7 5-l. Aileron Control Installation.................................................................................. 1F12 5-2. Elevator Control Installation ................................................................................ 1F15 5-3. Rudder Control Installation .................................................................................. 1F16 5-4. Tail Trim Mechanism Installation ....................................................................... 1F20 5-5. Fabricated Aileron Bellcrank Special Tool .......................................................... 1F21 5-6. Aileron Adjustment Points ................................................................................... 1F22 5-7. Checking Neutral Position of Rudder................................................................... 1F24 5-8. Nose Wheel Aligning ........................................................................................... 1G2

1A7 Revised: 9/15/98 PREFACE PIPER APACHE SERVICE MANUAL 5-9. Installing Elevator Trim Drum Cable Locking Pin .............................................. 1G3 5-10. Wrapping Elevator Trim Drum Cable .................................................................. 1G4 5-11. Wrapping Rudder Trim Drum Cable .................................................................... 1G5 5-12. Wrapped Rudder Trim Drum Cable ..................................................................... 1G6 5-13. Installing the Forward Rudder Trim Tab Screw Collar Cotter Pin ....................... 1G8 5-14. Flap Alignment ..................................................................................................... 1G10 5-15. Adjusting Flap Control Rod End Bearing ............................................................ 1G11 5-16. Correct Method of Installing Rod End Bearings .................................................. 1G13 6-1. Schematic Diagram, Hydraulic System................................................................ 1G17 6-2. Flow Diagram Landing Gear Selector Lever “UP” .............................................. 1G20 6-3. Flow Diagram Landing Gear Selector Lever “DOWN” ....................................... 1G21 6-4. Flow Diagram Wing Flap Selector Lever “DOWN” ............................................ 1G22 6-5. Flow Diagram Wing Flap Selector Lever “UP” ................................................... 1G2 6-6. Flow Diagram Both Selector Levers Neutral ....................................................... 1H4 6-7. Hydraulic Powerpak, Exploded View................................................................... 1H11 6-7. Hydraulic Powerpak, Exploded View (cont.) ....................................................... 1H12 6-8. Hydraulic System ................................................................................................. 1I1 7-1. Landing Gear Installation, Serial Nos. 23-1 to 23-1837 incl ............................... 1I7 7-2. Landing Gear Installation, Serial Nos. 23-l838 and up ........................................ 1I8 7-3. Landing Gear Drag Link (Fabricated Type) ......................................................... 1I10 7-4. Landing Gear Drag Link (Forged Type) .............................................................. 1I11 7-5. Oleo Strut, Exploded View of Internal Parts ........................................................ 1I12 7-6. Main Gear Attaching Detail ................................................................................. 1I14 7-7. Checking Wheel Alignment ................................................................................. 1I15 7-8. Adjusting Landing Gear Limit Switches .............................................................. 1I19 7-9. Anti-Retraction Valve ........................................................................................... 1I21 7-10. Inspection and Replacement of Cleveland Brake Linings.................................... 1I24 7-11. Bleeding the Brake ............................................................................................... 1J2 7-12. Replacing Cleveland Brake Disc When Installed With Rivets ............................. 1J3 7-13. Cleveland Brake Disc Minimum Thickness ......................................................... 1J4 7-14. Adjusting the Goodrich Brake .............................................................................. 1J5 8-1. Hartzell Propeller.................................................................................................. 1J20 8-2. Rear View of Engine Prior to Installation ............................................................ 1J21 8-3. Bottom Right View of Engine .............................................................................. 1J22 8-4. Lord Mount, Exploded View ................................................................................ 1J23 8-5. Installing the Engine ............................................................................................ 1J24 8-6. Engine Lord Mount Locating Pin Diagram.......................................................... 1K1 8-7. Woodward Propeller Governor Adjustment Points .............................................. 1K7 8-8. Removing Spark Plug Frozen to Bushing ............................................................ 1K11 9-1. Main Fuel System................................................................................................. 1K15 9-2. Auxiliary Fuel System .......................................................................................... 1K18 9-3. Parallel Relation of the Fuel Valve Control and Auxiliary Fuel Valve Arm Assemblies in the “OFF” Position .............................................. 1K23 9-4. Checking Recommended Clearance Between Valve Arm and Valve in the”ON” Position.............................................................................. 1K24 LIST OF ILLUSTRATIONS (cont.) F igur e No. Subject Gr id No.

1A8 Revised: 9/15/98 PREFACE PIPER APACHE SERVICE MANUAL 9-5. Fuel Selector Control Box .................................................................................... 1L3 9-6. Fuel Strainer Bowl ................................................................................................ 1L4 10-1. Instrument Panel ................................................................................................... 2A15 10-2. Instrument Panel ................................................................................................... 2A18 10-3. Dual Vacuum System ........................................................................................... 2A19 11-1. Generator Wiring System Schematic (Single)...................................................... 2B19 11-2. Generator Wiring System Schematic (Dual) ........................................................ 2B20 11-3. Sectional View of Generator................................................................................. 2B24 11-4. Wiring Circuit, Single Regulator .......................................................................... 2C2 11-5. Wiring Circuit, Dual Regulators ........................................................................... 2C2 11-6. Current-Voltage Regulator .................................................................................... 2C9 11-7. Use of Riffler File to Clean Contact Points .......................................................... 2C12 11-8. Voltage Regulator Air Gap ................................................................................... 2C12 11-9. Checking Voltage Setting Fixed Resistance Method............................................ 2C13 11-10. Checking Voltage Setting Variable Resistance Method ....................................... 2C13 11-11. Adjusting Voltage Regulator Setting .................................................................... 2C14 11-12. Cutout Relay Air Gap Check and Adjustment ..................................................... 2C16 11-13. Cutout Relay Point Opening Check and Adjustment ........................................... 2C16 11-14. Checking Cutout Relay Closing Voltage .............................................................. 2C17 11-15. Adjustment of Cutout Relay Closing Voltage ...................................................... 2C17 11-16. Checking Current Regulator, Load Method ......................................................... 2C18 11-17. Checking Current Regulator, Jumper Lead Method ............................................. 2C18 11-18. Checking and Adjusting Relay Air Gap ............................................................... 2C21 11-19. Checking and Adjusting Relay Point Opening..................................................... 2C21 11-20. Checking Relay Closiing Voltage ......................................................................... 2C22 11-21. Adjusting Relay Closing Voltage ......................................................................... 2C22 11-22. No-Load Test Hookup .......................................................................................... 2D1 11-23. Lock-Torque Test Hookup .................................................................................... 2D2 11-24. Resistance Test Hookup ....................................................................................... 2D2 11-25. Electrical System Schematic (Basic), Serial Nos. 23-1 to 23-746 incl. .............. 2D21 11-26. Electrical System Schematic (Complete), Serial Nos. 23-1 to 23-746 incl. ........ 2D23 11-27. Electrical System Schematic (Basic), Serial Nos. 23-747 to 23-1688 incl. ........ 2E1 11-28. Electrical System Schematic (Complete), Serial Nos. 23-747 to 23-l683 incl. .. 2E3 11-29. Electrical System Schematic (Basic), Serial Nos. 23-1684 and up ..................... 2E5 11-30. Electrical System Schematic (Complete), Early Models .................................... 2E7 11-31. Electrical System Schematic (Complete), Late Models ...................................... 2E9 13-1. Heating and Ventilating System, Serial Nos. 23-1 to 23-170 incl. ...................... 2E17 13-2. Heating and Ventilating System, Serial Nos. 23-171 to 23-375 incl.................... 2E18 13-3. Heating and Ventilating System, Serial Nos 23-376 to 23-746 incl. ................... 2E19 13-4. Heating and Ventilating System, Serial Nos. 23-747 to 23-1501 incl. ................ 2E20 13-5. Heating and Ventilating System, Serial Nos. 23-1502 and up ............................. 2E21 13-6. South Wind Heater - Model 979-B1..................................................................... 2E23 13-7. Safety Valve ......................................................................................................... 2E24 13-8. Fuel Control Valve ................................................................................................ 2E24 13-9. Combustion Air Blower........................................................................................ 2F2 LIST OF ILLUSTRATIONS (cont.) F igur e No. Subject Gr id No.

1A9 Revised: 9/15/98 PREFACE PIPER APACHE SERVICE MANUAL 13-10. Ventilating Air Fan. .............................................................................................. 2F2 13-11. Heater Wiring Diagram - Model 979-B1 ............................................................. 2F3 13-12. Circuit Analyzer ................................................................................................... 2F6 13-13. Circuit Analyzer Electrical Circuit ...................................................................... 2F6 13-14. Heater Test Stand.................................................................................................. 2F7 13-15. Test Stand Accessories ........................................................................................ 2F7 13-l6. Test Stand Conversion Kit .................................................................................... 2F8 13-17. Circuit Analyzer Installation ............................................................................... 2F8 13-18. Test Stand Installation ......................................................................................... 2F13 13-19. Test Stand Electrical Circuit ................................................................................. 2F15 13-20. High Heat Fuel Flow Check ................................................................................. 2F18 13-21. Combustion Air Blower Check ............................................................................ 2F20 13-22. Ventilating Air Blower Check ............................................................................. 2F20 13-23. Exploded Parts View, Model 979-B1 Heater ....................................................... 2F24 13-24. Service Tools (South Wind).................................................................................. 2G7 13-25. Fuel Control Valve (Cutaway View)..................................................................... 2G9 13-26. Flow System (South Wind Heater) ....................................................................... 2G10 13-27. Fuel Safety Valve (Cutaway View)....................................................................... 2G11 13-28. Heater Wiring Diagram - Models 940-B and 940-B12 ........................................ 2G15 13-29. Heater Wiring Diagram - Models 940-D, 940-DA, and 940-D12 ........................ 2G16 13-30. Flame Detector Switch (Cutaway View) ............................................................. 2G23 13-31. Exploded Parts View, Heater Assembly .............................................................. 2H6 13-32. Exploded Parts View, Ventilating Air Blower Assembly .................................... 2H8 13-33. Ventilating Air Blower Motor ............................................................................. 2H11 13-34. Combustion Air Blower Motor............................................................................. 2H12 13-35. Detail of Exhaust Extensions Installation............................................................. 2H17 13-36. Fuel Flow Test Set-Up .......................................................................................... 2H19 13-37. Heater Fuel Filter ................................................................................................. 2H21 13-38. Heater Fuel Valve ................................................................................................. 2H22 LIST OF ILLUSTRATIONS (cont.) F igur e No. Subject Gr id No.

1A10 Revised: 9/15/98 PREFACE PIPER APACHE SERVICE MANUAL LIST OF TABLES F igur e No. Subject Gr id No. II-I. Leading Particulars and Principal Dimensions (PA-23-150)................................ 1A20 II-Ia. Leading Particulars and Principal Dimensions (PA-23-160)................................ 1B2 II-II. Recommended Nut Torques (Inch-Pounds) ......................................................... 1B14 II-III. Flare Fitting Torques ............................................................................................ 1B16 II-IIIa. Recommended Lubricating Oils ........................................................................... 1C16 II-IV. Thread Lubricants................................................................................................. 1C18 II-V. Maximum Distance Between Supports for Fluid Tubing ..................................... 1C18 II-VI Conversion Tables ................................................................................................ 1C21 II-VII. Decimal/ Millimeter Equivalents of Drill Sizes ................................................... 1C24 II-VIII. Hose Clamp Tightening ........................................................................................ ID2 III-I. Inspection Report ................................................................................................. 1D13 IV-I. List of Materials (Thermoplastic Repair) ............................................................. 1Fl VI-I. Leading Particulars - Hydraulic Powerpak........................................................... 1G16 VI-III. Hydraulic System Troubleshooting ...................................................................... 1G24 VI-III. Powerpak Troubleshooting ................................................................................... 1H7 VI-IV. Special Tools and Test Equipment........................................................................ 1H24 VIII-I. Engine Troubleshooting ....................................................................................... 1J12 IX-I. Fuel System Troubleshooting ............................................................................... 1L1 X-I. Vacuum System .................................................................................................... 2A16 X-II. Directional Gyro Indicator ................................................................................... 2A22 X-III. Gyro Horizon Indicator ........................................................................................ 2A23 X-IV. Rate of Climb Indicator ........................................................................................ 2A24 X-V. Altimeter ............................................................................................................... 2B1 X-VI. Airspeed Tubes and Indicator ............................................................................... 2B3 X-VII. Magnetic Compass ............................................................................................... 2B4 X-VIII. Manifold Pressure Indicator ................................................................................. 2B5 X-IX. Tachometer ........................................................................................................... 2B6 X-X. Engine Oil Pressure Gauge................................................................................... 2B7 X-XI. Fuel Pressure Gauge ............................................................................................. 2B8 X-XII. Turn and Bank Indicator ....................................................................................... 2B9 X-XIII. Fuel Quantity Indicators ....................................................................................... 2B10 X-XIV. Oil Temperature Indicators ................................................................................... 2B11 X-XV. Carburetor Air Temperature Indicator .................................................................. 2B12 X-XVI. Flap Position Indicator ......................................................................................... 2B13 XI-I. Electrical System Troubleshooting....................................................................... 2D8 XI-II. Electrical Wire Coding ......................................................................................... 2D19 XIII-I. Troubleshooting Analysis Chart, Model 979-B1 ................................................. 2D19 XIII-II. Troubleshooting Chart (Heater, 940 Series) ......................................................... 2H24

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Piper Apache Aircraft PA-23-150 Service Maintenance Manual -

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