1A1 AIRPLANE MAINTENANCE MANUAL CARD 1 OF 2 PA-38-112 TOMAHAWK PIPER AIRCRAFT CORPORATION PART NUMBER 761-660 REVISED: FEBRUARY 28, 2002 Island Enterprises
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 Island Enterprises
PIPER AIRCRAFT PA-38-112 AIRPLANE MAINTENANCE MANUAL AEROFICHE REVISION STATUS Revisions to this maintenance manual 761 660 published November 5, 1977 and reissued September 4, 1979 are as follows: Re visions Pub lica tion Da te Aer of ic he Car d Ef f ecti vity ORIGINAL November 5, 1977 1 and 2 1R 6-78 June 1, 1978 1 and 2 2R 12-78 December 1, 1978 1 and 2 3R 8-78 August 1, 1979 1 and 2 COMPLETE REISSUE September 4, 1979 1 and 2 1R 2-80 February 21, 1980 1 and 2 2R 1-81 January 5, 1981 1 and 2 3R 6-81 June 23, 1981 1 and 2 4R 2-82 February 26, 1982 1 and 2 5R 12-82 November 12, 1982 1 and 2 6R 3-84 March 23, 1984 1 and 2 7R 7-86 July 30, 1986 1 and 2 8R 1-88 June 15, 1988 1 and 2 9R 9-93 September 1, 1993 1 and 2 10R 7-98 July 15, 1998 1 and 2 11R 2-00 February 25, 2000 1 12R 2-02 * February 28, 2002 1 * Revisions appear in aerofiche card 1 only. Accordingly, discard your existing card 1 and replace it with this card 1 dated 2/28/02. Consult the latest Piper Customer Service Information Aerofiche (P/N 1753-755) for current revision dates for this manual. 1A3 Introduction Page - 1 Revised: February 28, 2002 Island Enterprises
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS The PIPER PA-38-112 Tomahawk Maintenance Manual constitutes the Instructions for Continued Airworthiness as required by Federal Aviation Regulations (FAR) Part 23, Appendix G. Chapter 4 contains the Airworthiness Limitations section (4-00-00) and the Inspection Program is in Chapter 5 (5-20-00). GENERAL This manual is prepared in accordance with the General Aviation Manufacturers Association (GAMA) Specification No. 2, with respect to the arrangement and content of the System/Chapters within the designated Chapter/Section-numbering system. — WARNING — USE ONLY GENUINE PIPER AIRCRAFT PARTS OR PIPER AIRCRAFT APPROVED PARTS OBTAINED FROM PIPER APPROVED SOURCES,IN CONNECTION WITH THE MAINTENANCE AND REPAIR OF PIPER AIRPLANES. Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even though identical in appearance, may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane. Reworked, salvaged or those parts obtained from non-PIPER approved sources, which the service history is unknown or cannot be authenticated, may have been subjected to unacceptable stresses or temperatures or have other hidden damage, not discernible through routine visual or usual nondestructive testing. This may render the part, component or structural assembly, even though originally manufactured by PIPER AIRCRAFT unsuitable and unsafe for airplane use. PIPER expressly disclaims any responsibility for malfunctions, failures, damage or injury caused by use of non-PIPER approved parts. — Note — PIPER expressly reserves the right to supersede, cancel and/or declare obsolete any part, part numbers, kits or publication that may be referenced in this manual without prior notice. Any question concerning the care of your airplane, be sure to include the airplane serial number in any correspondence. EFFECTIVITY This maintenance manual is effective for PA-38-112, Tomahawk, Serial Numbers: 38-78A0001 thru 38-82A0122 SERIAL NUMBER EXPLANATION Example: Introduction Page - 1 Revised: February 28, 2002 1A4 PIPER AIRCRAFT PA-38-112 AIRPLANE MAINTENANCE MANUAL 38 84 A 0001 TYPE CERTIFICATE DESIGNATION MODEL CODE A = PA-38-112 TOMAHAWK MODEL SEQUENCE NUMBER MODEL YEAR Island Enterprises
ASSIGNMENT OF SUBJECT MATERIAL This publication is divided into industry standard, three element, numeric subject groupings as follows: A. System/Chapter - The various groups are broken down into major systems such as Environmental Systems, Electrical Power, Landing Gear, etc. They are assigned a number, which becomes the first element of the standardized numbering system. Thus, the element “28” of the number 28-40-01 refers to the chapter “Fuel”. Everything concerning the fuel system will be covered in this chapter. B. Sub-System/Section - The major systems/chapters of an airplane are broken down into subsystems. These sub-systems are identified by the second element of the standard numbering system. The element “40” of the number 28-40-01 concerns itself with the indicating section of the fuel system. C. Unit/Subject - The individual units within a sub-system/section may be identified by the third element of the standard numbering system. The element “01” of the number 28-40-01 is a subject designator. This element is assigned at the option of the manufacturer and is normally zeroed out by PIPER. Refer to Chapter/Section Index Guide, for a complete breakdown and list. The material is arranged in ascending numerical sequence. PAGINATION Within each Chapter (i.e. - 28), explained above, pages are numbered consecutively beginning with Page 1 (i.e. - Page 28-1). AEROFICHE EFFECTIVITY A. The General Aviation Manufacturers Association (GAMA) have developed specifications for microfiche reproduction of aircraft publications. The information compiled in this Aerofiche Maintenance 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. The “Aerofiche Effectivity” page at the front of this manual lists the current revision for each card in this set. B. 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. C. To aid in locating information, a complete Introduction containing the Chapter/Section Index Guide for all fiche in this set, is provided at the beginning of each aerofiche card. IDENTIFYING REVISED MATERIAL A revision to a page is defined as any change to the printed matter that existed previously. Revisions, additions and deletions are identified by a vertical line along the left-hand margin of the page opposite only that portion of the printed matter that was changed. A vertical line in the left-hand margin opposite the footer (i.e. - chapter/section/subject, page number and date), indicates that the text was unchanged but the material was relocated to a different page. Example. 1A5 PIPER AIRCRAFT PA-38-112 AIRPLANE MAINTENANCE MANUAL Introduction Page - 2 Revised: February 28, 2002 Island Enterprises
PIPER AIRCRAFT PA-38-112 AIRPLANE MAINTENANCE MANUAL Introduction Page - 3 Revised: February 28, 2002 1A6 IDENTIFYING REVISED MATERIAL (continued) A reference and record of the material revised is included in each chapter’s table of contents. The codes used in the effectivity columns of each chapter are defined as follows: TABLE OF CONTENTS / EFFECTIVITY CODES Issue / Re vision Code Original Issue/Reissue: None First Revision: 1R Month-Year Second Revision: 2R Month-Year All subsequent revisions will follow with consecutive revision numbers such as 3R, 4R, etc., along with the appropriate month-year. Added Subject: A Month-Year Deleted Subject: D Month-Year VENDOR PUBLICATIONS. ENGINE: Vendor: Textron Lycoming PH - (717) 323-6181 652 Oliver Street FAX - (717) 327-7101 Williamsport, PA 17701 http://www.lycoming.textron.com/main.html Overhaul Manual = DIRECT DRIVE ENGINES - P/N 60294-7 Parts Catalog = O-235-C1, ......, -N2C - P/N PC-302 Operators Handbook = O-235; O-290-D and -D2 SERIES ENGINES - P/N 60297-9 PROPELLER: Vendor: Sensenich Corporation PH - (717) 569-0435 14 Citation Lane FAX - (717) 560-3725 Lititz, PA 17543 http://www.sensenich.com/ Repair Manual = METAL PROPELLER REPAIR MANUAL - SPRM 590 MAGNETOS: Vendor: Slick Aircraft Products PH - (815) 965-4700 Unison Industries FAX - (815) 965-2457 Attn: Subscription Dept. 530 Blackhawk Park Ave. Rockford, IL 61104 http://www.unisonindustries.com/index4.html Installation, Operation and Maintenance Instructions = F1100 MASTER SERVICE MANUAL Vendor: Teledyne Continental Motors P.O. Box 90 Mobile, AL 36601 Service Support Manual = S-20 & S-200 SERIES MAGNETO MANUAL - P/N X42002-1 Island Enterprises
CHAPTER SECTION INDEX GUIDE SYST SUB-SYST AEROFICHE CHAP SECTION TITLE GRID NO. 4 AIRWORTHINESS 1A13 5 TIME LIMITS/MAINT CHECKS 1A16 6 DIMENSIONS AND AREAS 1B6 7 LIFTING AND SHORING 1B13 8 LEVELING AND WEIGHING 1B16 9 TOWING AND TAXIING 1B20 10 PARKING AND MOORING 1B23 11 REQUIRED PLACARDS 1C2 12 SERVICING 1C6 20 STANDARD PRACT - AIRFRAME 1D3 21 ENVIRONMENTAL SYSTEM 1D12 23 COMMUNICATIONS 1D17 24 ELECTRICAL POWER 1E1 25 EQUIPMENT/FURNISHINGS 1F9 27 FLIGHT CONTROLS 1F13 28 FUEL 1G20 32 LANDING GEAR 1H17 33 LIGHTS 1I22 34 NAVIGATION & PITOT/STATIC 1J7 37 VACUUM SYSTEM 1J20 39 ELECTRICAL 1K5 51 STRUCTURES - GENERAL 1K8 52 DOORS 1L1 55 STABILIZERS 1L9 56 WINDOWS 1L20 57 WINGS 2A13 61 PROPELLER 2B1 71 POWER PLANT 2B7 73 ENGINE FUEL SYSTEM 2B23 74 IGNITION 2C6 76 ENGINE CONTROLS 2D21 77 ENGINE INDICATING 2E1 79 OIL SYSTEM 2E6 80 STARTING 2E11 91 CHARTS AND WIRING DIAGRAMS 2E23 Introduction Page - 4 Revised: July 15, 1998 1A7 PIPER AIRCRAFT PA-38-112 AIRPLANE MAINTENANCE MANUAL Island Enterprises
LIST OF ILLUSTRATIONS FIGURE NO. SUBJECT GRID NO. Introduction Page - 5 Revised: February 28, 2002 1A8 PIPER AIRCRAFT PA-38-112 AIRPLANE MAINTENANCE MANUAL 6-1. Three View 1B10 6-2. Station Reference Lines 1B11 6-3. Access Plates and Panels 1B12 7-1. Jacking Arrangement 1B15 8-1. Weighing Arrangement 1B18 8-2. Leveling Longitudinally 1B19 8-3. Leveling Laterally 1B19 11-1. Placards and Decals 1C4 12-1. Servicing Points 1C9 12-2. Lubrication Chart - Landing Gear and Power Plant 1C18 12-3. Lubrication Chart - Control System 1C20 12-4. Lubrication Chart - Control System (cont) 1C21 12-5. Lubrication Chart - Control System (cont) 1C22 12-6. Lubrication Chart - Cabin Door and Seats 1C23 20-1. Torque Wrench Extension 1D6 20-2. Method of Installing Rod End Bearings 1D7 21-1. Cabin Heater, Defroster and Fresh Air System 1D15 23-1. ELT Portable Folding Antenna (Narco) 1D21 23-2. ELT Using Fixed Aircraft Antenna (Narco) 1D21 24-1. Instrument Panel Circuit Breakers 1E5 24-2. Lamp Bank Load 1E14 24-3. Exploded View of Alternator 1E14 24-4. Removal of Rectifier 1E17 24-5. Removal of Slip Ring End Bearing 1E17 24-6. Removal of Drive End Head 1E17 24-7. Removal of End Head Bearing 1E17 24-8. Testing Rotor for Grounds 1E19 24-9. Testing Rotor for Shorts 1E19 24-10. Installation of Bearing 1E19 24-11. Installation of Rectifier 1E19 24-12. Slip Ring End Bearing Assembly 1E20 24-13. Testing Alternator 1E20 24-14. Brush Installation 1E20 24-15. Internal Wiring Diagram 1E20 24-16. Battery Box 1F2 24-17. Electrical Component Location 1F5 24-18. Application of Overvoltage Control 1F6 24-19. Ammeter Gauge and Calibration 1F8 25-1. Seat Installation 1F11 27-1. Control Column Assembly 1F21 27-2. Aileron Controls 1F23 27-3. Aileron Bellcrank with Rigging Tool 1G1 27-4. Aileron Rigging 1G1 Island Enterprises
LIST OF ILLUSTRATIONS (cont.) FIGURE NO. SUBJECT GRID NO. Introduction Page - 6 Revised: February 28, 2002 1A9 PIPER AIRCRAFT PA-38-112 AIRPLANE MAINTENANCE MANUAL 27-5. Rudder System Installation 1G4 27-6. Clamping Rudder Pedals 1G6 27-7. Rudder Rigging 1G6 27-8. Elevator Controls 1G8 27-9. Elevator Rigging 1G10 27-10. Elevator Trim Controls 1G11 27-11. Trim Wheel Installation 1G15 27-12. Flap Control System 1G17 27-13. Flap Rigging 1G17 28-1. Fuel System Installation 1G23 28-1A. Fuel Selector Valve 1H5 28-2. Fuel Filter Bowl 1H7 28-3. Plunger Fuel Pump 1H9 28-4. Fuel Sender Units Installation 1H13 25-5. Fuel Quantity Gauge and Maximum Deviation of Fuel Quantity Gauge 1H14 28-6. Resistor Set Up Test For Fuel Quantity Gauge 1H15 28-7. Fuel Pressure Gauge and Calibration 1H16 32-1. Main Landing Gear and Axle Installation 1H23 32-2. Main Wheel Alignment 1H24 32-3. Nose Gear Oleo Strut Assembly and Installation (Without Internal Stop Assembly Installed) 1I2 32-4. Nose Gear Oleo Strut Assembly (Internal Stop Assembly Installed) 1I3 32-5. 500 Hour Special Inspection - Nose Gear Oleo Cylinder Housing 1I4 32-6. Main Wheel Assembly 1I8 32-7. Nose Wheel Assembly (Typical) 1I10 32-8. Wheel Brake Assembly 1I13 32-9. Removal and Installation of Anchor Bolts 1I14 32-10. Toe Brake System Installation 1I16 32-11. Brake Master Cylinder (Hand/Parking Brake) 1I17 32-12. Brake Cylinder (Toe Brake) 1I17 33-1. Dimmer Control Assembly 1J1 33-2. Strobe Light Connections 1J5 34-1. Pitot Static System Installation 1J11 37-1. Vacuum System Installation 1J24 51-1. Skin Material and Thickness 1K12 51-2. Surface Scratches, Abrasions or Ground-In Dirt 1K16 51-3. Deep Scratches, Shallow Nicks and Small Holes 1K17 51-4. Mixing of Epoxy Patching Compound 1K17 51-5. Welding Repair Method 1K18 51-6. Repair of Cracks 1K18 Island Enterprises
LIST OF ILLUSTRATIONS (cont.) FIGURE NO. SUBJECT GRID NO. Introduction Page - 7 Revised: February 28, 2002 1A10 PIPER AIRCRAFT PA-38-112 AIRPLANE MAINTENANCE MANUAL 51-7. Various Repairs 1K19 51-8. Repair of Stress Lines 1K21 51-9. Repair of Impacted Damage 1K21 51-10. Vertical Fin Forward Attachment Plate 1K24 52-1. Door Latch Mechanism - Upper 1L4 52-2. Door Latch Mechanism and Hinges 1L6 52-3. Door Seal Installation 1L8 55-1. Horizontal Stabilizer Installation 1L12 55-2. Elevator Installation 1L12 55-3. Elevator Balancing 1L14 55-4. Vertical Fin Installation 1L14 55-5. Rudder Installation 1L16 55-6. Rudder Balancing 1L17 56-1. Window Installation 1L23 57-1. Wing Installation 2A17 57-2. Aileron Installation 2A18 57-3. Aileron Balancing 2A19 57-4. Flap Installation 2A20 61-1. Typical Nicks and Repair Methods 2B4 71-1. Engine and Shock Mount Installations 2B10 71-2. Proper Heat Hose Connections 2B18 71-3. Engine Cowling 2B20 73-1. Carburetor 2C2 73-2. Engine Primer 2C4 74-1. T-100 Assembly and Timing Tool Kit 2C10 74-2. Exploded View of Magneto (4200 Series) 2C14 74-3. Removing Coil Wedges 2C14 74-4. Index Plate and Timing Plug 2C16 74-5. Installation of Bearings and Bearing Plate 2C16 74-6. Magneto on T-100 (Oil Seal Installation) 2C18 74-7. Magneto Internal Timing 2C18 74-8. Stripping Tool 2C21 74-9. Inserting Stripping Tool 2C21 74-10. Cutting Insulation 2C21 74-11. Removing Silicone Rubber From Wire 2C21 74-12. Installation of Plug End Nut 2C22 74-13. Flaring Out the Shielding 2C22 74-14. Installation of Ferrule 2C22 74-15. Driving Tool 2C22 74-16. Installation in Housing 2C24 74-17. Securing Wire in Housing 2C24 74 18. Installation of Electrical Screw 2D1 74-19. Installation of Insulator Sleeve 2D1 Island Enterprises
