Navajo Chieftain Service Manual

..................... Side Window Installation ................................................... Cabin Entrance Door Installation ............................................ Nacelle Wing Locker Latch Assembly ........................................ Cargo Door Latch Assembly ....................... ........................ Pilot's Door Latch Assembly ................................................ Aileron Balancing ......................................................... Elexator Balancing ........................................................ Friction Measurement ...................................................... Rudder Balancing ...................................... ................... Rudder Balance Weight ocation ............................................ Skin Thickness and Material ................................................ IFI 1F3 IF4 1F5 IF9 1F16 1F17 1F19 1F22 1F22 1F24 1G5 1G7 IGI I 1G15 1G15 1G16 1G17 1G19 1G19 1G20 Revised:5/3/84 1A6 NAVAJO CHIEFTAINSERVICE MANUAL LIST OF ILLUSTRATIONS(cont) Figure Aerofiche Grid No. 4-22. TypicalAccess Platesand Panels ...... .......................................... G23 4-23. SurfaceScratches. Abrasionsor Ground-InDirt ........................................ H3 4-24. Deep Scratches.Shallow Nicksand SmallHoles................................................................H3 4-25. Mixingof Epoxy PatchingCompound........ ............................. ... 1.IH4 4-26. WeldingRepairMethod ...................................................................................................... IH4 4-27. Repairingof Cracks.................................... ........H5 4-28. VariousRepairs ................................................................................................................... H7 4-29. Repair of StressLines ......................................................................................................... 1H8 4-30. Repair of ImpactedDamage ............................................................................................... H8 4-31. Installationof RadomeErosionShield ........ ............................. H...1H14 5-1. ControlColumnInstallation ...... ..................................................... H24 5-2. Correct Methodof InstallingRod End Bearings .................................... 1.....12 5-3 Aileronand AileronTrimControls ....... ............................. ..............114 5-4. Installationof BellcrankRiggingTool ........ ............................ ............ 16 5-5 Installationof AileronRiggingTool....... ............................. ............ 16 5-6 Elevatorand ElevatorTrimControls .................................................................................. 1112 5-7. Installationof ElevatorR iggingTool ................................................................................ 1115 5-8 ElevatorTravelStops .......................................................................................................... 1115 5-8a. SafetyWiringControlSurfaceStops .................................................................................. 1115 5-9 Deleted 5-10. Methodsof BlockingTrim Cables...... .......................... 11................18 5-11. Cable Routingon ElevatorTim Servo ........ ........................ ........... 1120 5-12. RudderPedal Insta llation....................................................................................................1123 5-13 Rudder and Rudder TrimControls ................................. 2............... 5-14 ClampingRudder Pedals in NeutralPosition......................................................................4 5-15. Installationof RudderRiggingTool ....... ......................... 1................ 5-16 Trim Screw Assembly ................................................... J6 5-17. ControlPed estal........................................................................................................8 5-18 Flap Controls(DukesSystem)...... ......................................................... 110 5-19 Flap Circuit Schematic(DukesSystem) 5-20. Flap RiggingCheck ............................................... 5-21 Flap SystemDiagram(Calco) ................................................ 5-22 Motor AssemblyE.-ploded View(Calco).......................................................................... J18 5-23 Flap Controls(CalcoSystem) ...... ................................................. 21 5-24 Deleted 5-25. Deleted 5-26. Deleted 5-27. Deleted 5-28a. Flap RiggingAdjustments(Calco) ............................................ 1K6 5-28b. Use of Flap RiggingTool .......................... .................. 1K6 5-29a. Calco Flap System Interconnect.......................... K.....................K7 5-29b. Calco Flap System Schematic.......................... K...............K7 5-30. Amplifier- ElectricSchematic(Calco)P/N 8482 (S/N's 31-7952001to 31-8252021incl.) ...................................................................... K9 5-30a. Amplifier- ElectricSchematic(Calco)P/N 8502M1 (SN's 31-8252022 and up) .......................................................................................... 1K Revised: 3/31/94 1A7 NAVAJO CHIEFTAIN SERVICE MANUAL LIST OF ILLUSTRATIONS (cont) Aerofiche Figure Grid No. 5-31. Fabricated Bellcrank Rigging Tool ................ ........................... IL4 5-32. Fabricated Aileron and Elevator Rigging Tool ................................. L5 5-33. Fabricated Rudder Rigging Tool ............................................ IL6 6-1. Schematic of Power Pack Electrical System ................................... 2A 13 6-2. Schematic Diagram of Hydraulic System ..................................... 2A 14 6-3. Power Pack Installation .............. .................... .................. 2A23 6-4. Identification of Power Pack ................................................ 2A24 6-5. Location of Power Pack Components (Ozone) ................................ 2B1 6-6. Hydraulic Power Pack (Ozone) ................................. ............. 2B 6-7. Power Pack Manifold (Ozone) .............................................. 2B7 6-8. Power Pack Handle-Release Mechanism (Ozone) .............................. 2B12 6-9. Safetying Control Arm (Ozone) ............................................. 2B13 6-10. Timing of Selector Spool (Ozone) ............................................ B 14 6-11. Handle-Release Adjustment (Ozone) ......................................... 2B14 6-12. Location of Power Pack Components (Wiebel Tool) ........................... 2B18 6-13. Hydraulic Power Pack (Wiebel Tool) ........................................ 2B20 6-14. Power Pack Manifold (Wiebel Tool) ......................................... B23 6-15. Power Pack Handle-Release Mechanism (Wiebel Tool) ......................... 2C 6-16. Safetying Control Arm (Wiebel Tool) ........................................ C4 6-17. Indexing of Selector Spool (Wiebel Tool) ..................................... 2C5 6-18. Handle-Release Adjustment (Wiebel Tool) .................................... 'C7 6-19. Landing Gear Selector Mechanism ................ ........................... 2C10 6-20. Hand Pump (Ozone) ..................... ................................... 2C 6-21. Hand Pump (Wiebel Tool)............................................. ..... 2C 16 6-22. Hydraulic System Installation ............................................... 2C 1 6-23. Gear Actuating Cylinder (Ozone) ............................................ C 19 6-24. Gear Actuating Cylinder (Wiebel Tool) ....................................... 2C21 6-25. Gear Door Actuating Cylinder (Ozone) ....................................... 2C23 6-26. Gear Door Actuating Cylinder (Wiebel Tool) ................ .................. 2D1 6-27. Hydraulic Filter ........................................................... 2D3 6-28. Hydraulic Pump.2D6 6-28. Hydraulic Pump ........................................................... 2 6-29. Power Pack Test Harness Schematic ......................................... 2 D10 7-1. Nose Gear Oleo Strut Assembly .............................................. 2D18 7-2. Nose Gear Steering Assembly (S N 31-7852141 and up) ...................... 2D20 7-3. Nose Landing Gear Installation ................. ................. . ..... 2 D24 7-4. Clamping Rudder Pedals in Neutral Position .................................. 2E5 7-5. Rudder Pedals Neutral Angle ............................................... E5 7-6. Aligning Nose Gear ........................................................ 2E5 7-7. Correct Method of Installing Rod End Bearings ............................... 2E8 7-8. Main Gear Oleo Strut Assembly ..................................... .. . 2E9 7-9. Main Landing Gear Installation (Left) ........................................ 2E15 7-10. Actuator Cylinder ......................................................... 2E17 7-11. Aligning Main Gear ...................................... ................. 2E19 7-12. Landing Gear Circuit Diagram ............................... . ......... 2E21 Revised: 3/5/84 1A8 NAVAJO CHIEFTAIN SERVICE MANUAL LIST OF ILLUSTRATIONS (cont) Figure Aerofiche Grid No. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7-26. 7-27. 7-28. 7-29. 7-30. 7-31. 7-32. 7-33. 7-34. 7-35. 7-36. 7-37. 7-38. 7-39. 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. Adjusting Main Gear Down Light Switch ..................................... Gear Warning Switches Installation .......................................... Nose Wheel Assembly ...................................................... Main Wheel Assembly (Cleveland) ........................................... Brake Installation (Typical) ................................................. Brake Disc Minimum Thickness ............................................. Wheel Brake Assembly (Cleveland 30-68 A and B) ............................. Wheel Brake Assembly (Cleveland 30-95 and 30-95a) ........................... Wheel Brake Assembly Cleveland 30- 123 .................................... Removal and Installation of Anchor Bolts .................................... Brake Master Cylinder Assembly ........................................... Parking Brake Valve Assembly ............................................. Bleeding Brake (Typical).................................................... Main Wheel Assembly ......... ............................................ Wheel Brake Assembly ...................................... ............... Snow Shield Modification .................................................. Rivet Head Grinding Limits ................................................ Wear Pad - Wear Limits ............................ ....................... Limits for Repadded Pressure and Back Plates ................................ Brake Disc Visual Check for Serviceable Limits ............................... Fabncated Rivet Tool (Goodyear Only ) ...................................... Fabricated Tool, Checking Nose Wheel Alignment ............................ Fabricated Tool, Checking Nose Gear Link Travel ............................ Fabricated Tool, Checking Main Gear Side Brace Link Travel .................. Fabricated Tool, Checking Main Gear Toe-in Adjustment ...................... Nose Gear Wear Limits .................................................... Main Gear Wear Limits .................................................... Engine Cowling ........................................................... Cowl Flap Transmission and Sender Assembly ................................ Propeller Installation ..................................................... Typical Nicks and Removal Method ......................................... Propeller Governor ........................................................ Engine Installation ..................................................... 2H21 Schematic Diagram of Turbocharger System .................................. Turbocharger Installation, PA-31-350 ........................................ Exhaust Waste Gate ....................................................... Fuel Injector ............................................................. Fuel-Air Bleed Nozzle ...................................................... Height of Spring in Distributor Block Tower .................................. Contact Points ............................................................ Engine Timing Marks ...................................................... Timing Light Connected to Magneto ......................................... Timing Marks on Rotating Magneto (Present)................................ Timing Marks on Magneto Rotor (Earlier). .................................. 2F1 2FI 2F3 2F3 2F5 2F7 2F8 2F8 2F9 2F10 2F11 2F13 2F13 2F20 2F21 2F23 2F24 2G5 2G5 2G6 2G15 2G16 2G17 2G18 2G19 2G20 2G23 2H8 2H8 2H12 2H14 2H16 2H21 215 216 217 219 2113 2113 2113 2114 2114 2116 2116 Revised: 10/15/82 1A9 NAVAJO CHIEFTAIN SERVICE MANUAL LIST OF ILLUSTRATIONS (cont) Aerofiche Figure Grid No. 8-18. Painted Tooth Centered in Timing Window ................................... 2117 8-19. Cam End View of Magneto ................................................. 2118 8-20. Timing Mark on Rotor Aligned with Pointer (Right-Hand Rotation) ............. 2119 8-21. Timing Light Connected to Magneto ......................................... 2119 8-22. Timing Light Connected to Magneto and Breakers........................ ... 2119 8-23. Checking Harness Lead Continuity ................................... ...... 2119 8-24. Checking Harness Lead Insulation Resistance ................................. 2124 8-25. Modified Pliers .................................................... 2124 8-26. Removing Spring From Lead Assembly ...................................... 2124 8-27. Assembly Tool ............................................................ 2J1 8-28. Using Assembly Tool ...................................................... 2J1 8-29. Ferrule Positioned Under Braid ............................................. 2J2 8-30. Ferrule Seating Tool 11-7074........................................... .. 2J2 8-31. Position of 11-8627Kit and Contact Spring at Start of Installation .............. 2J2 8-32. Position of 11-8627Kit and Contact Spring after Installation .................... 2J2 8-33. Lubricating Sleeve ................................................. 2J4 8-34. Lubricating Ferrule Shoulder ............................................... 2J4 8-35. Ignition System Schematic .................................................. 2J6 8-36. Removing Frozen Spark Plug ............................................... 2J7 9-1. Fuel System Schematic ..................................................... 2K4 9-2. Fuel Cell Installation (Main/Inboard) ................... ..................... 2K6 9-2a. Fuel Cell Installation (Nacelle Optional) ...................................... 2K7 9-3. Fuel Cell Installation (Auxiliary/Outboard) ................................... 2K10 9-4. Installation of Fuel Valve Drain Plate ........................................ 2K12 9-5. Fuel Gauge Adjustment Wires............................................... 2K12 9-6. Fuel Selector Valve (Scott) ................................................. 2K16 9-7. Crossfeed Valve ........................................................... 2K17 9-8. Fire Wall Shutoff Valve .................................................... 2K17 9-9. Fuel System Installation .................................................... 2K19 9-10. Adjustment of Crossfeed Valve .............................................. 2K24 9-11. Fuel Filter ................................................................ 2K24 9-12. Electric Fuel Pump ........................................................ 2L2 9-13. Fuel Cell Tie Detail ........................................ ................ 2 L12 9-14. Low Fuel Warning Sender Sealing .............................. ............. 2L13 10-1. Instrument Panel (Typical)................................................. 3AI I 10-2. Instrument Air System Installation (Typical) .......................... ....... 3A12 10-3. Pilot's and Copilot's Gyro Installation with Deicer(S/N 31-5001to 31-7652123incl.). 3A19 10-4. Pilot's and Copilot's Gyro Installation with Deicer(S/N 31-7652124and up) ........ 3A21 10-5. Pilot's Gyro Installation with Deicer (S/N 31-5001to 31-7652123incl.) ... ......... 3A23 10-6. Pilot's Gyro Installation with Deicer (S/N 31-7652124and up) .................... 3B1 10-7. Pilot's and Copilot's Gyro Installation (S/N 31-5001to 31-7652123incl.) . .......... 3B2 10-8. Pilot's and Copilot's Gyro Installation (S/N 31-7652124and up) .... ........ ..... 3B3 10-9. Pilot's Gyro Installation (S/N 31-5001and 31-7652123incl.) ................... 3B4 10-10. Pilot's Gyro Installation (S/N 31-7652124and up) .................. ............ 3B5 10-11. Digital Clock (Optional) .................. ................................ 3C6 lA10 Revised: 10/15/82 NAVAJO CHIEFTAIN SERVICE MANUAL LIST OF ILLUSTRATIONS(cont) Figure Aerofiche Grid No. 11-1. Overhead Switch Panel ..................................................... 3C14 11-2. Switch and Circuit Breaker Control Panel .................................... C15 11-3. Exploded View of Alternator (Prestolite) .................................... .. 9 11-4. Schematic - Alternator Paralleling System .................................... C20 11-5. Removal of Rectifier ....................................................... C22 11-6. Removal of Slip Ring End Bearing .................................... C2. 11-7. Removal of Drive End Head .................................... C.23 11-8. Removal of End Head Bearing ................. ........................ 3C2 11-9. Testing Rotor for Ground .................................... .C24 11-10. Testing Rotor for Shorts .................................... 4... 1-11. Installation of Bearing.................................... D 11-12. Installation of Rectifier .................................................... 3D 1 11-12. Installation of Rectifier .D111-13. Terminal Assembly (Prestolite) ................... ................. ... .D1 11-14. Slip Ring End Bearing Assembly .................................... D... 11-15. Testing Alternator ....... ............................. D. 11-16. Brush Installation .................................... D.. 11-17. Internal Wiring Diagram .................................... D.. 11-18. Regulator Diagram (Lamar) ................................................ 4 11-19. Testing Regulator (Lamar) .................................................. D 11-20. Adjusting Regulator (Lamar) ................................................ 0D9 11-21. Application of Overvoltage Control .......................................... 3D1O 1-22. Testing Overvoltage Control ................................................ DI0 11-23. Exploded View Starting Motor ............................................... 3D12 -2. TurnExploded Starting Motor Commutator ................................................11-24. Turning Motor Commutator D1J 11-25. Testing Motor Armature for Shorts .......................... D..........14 11-26. Testing Motor Fields for Grounds ........................................... 3D15 11-2. Testing Motor Fields for Grounds...........................................5 11-27. No-Load Test Hookup .D15 I -28. Stall-Torque Hookup ...................................................... 3D17 11-29. Landing Light ............................................................. 3D 23 12-1. Two Year, Magnesium Battery Connections ................................... 4A 11 12-2. Five Year, Lithium Battery Connections (Garrett) ................ 4A 12 12-3. Emergency Locator Transmitter Schematics (Garrett) ........................ 4A 18 12-4. Communications Components ELT Schematics (Early Models) ........ 4A 19 12-5. Communications Components ELT Schematic (Later Models) ................... 4A20 12-6. Emergency Locator Transmitter Schematic (Narco) ............... 4A21 12-7. ELT Portable Folding Antenna (Narco) ...................................... 4A22 12-8. ELT Using Fixed Aircraft Antenna (Narco) ................................... 4A22 12-9. Avionics Master and Emergency Switch Circuit ............................... 4A NOTE Index for Electrical System Schematics may be found in Table XI-I, Grid 3C18. Revised: 10/5/83 NAVAJO CHIEFTAIN SERVICE MANUAL LIST OF ILLUSTRATIONS (cont) Aerofiche Figure Grid No. 13-1. Heating and Ventilating System........................................................................................... 4B10 13-2. Heater Assembly and Combination Air Blower ................................................................. 4B14 13-3. Diagrammatic Cut-a-way of Heater Showing Whirling Flame Action ...............................4B 16 13-4. Diagrammatic Cut-a-way of Heater to Show Whirling Flame Action ...............................4B 16 13-5. Left Side View - Duct Switch ............................................................................................. 4B19 13-6. Wiring Schematic ............................................................................................................. 4B19 13-7. Vent Blower Power Circuit ............................................................................................. 4B20 13-8. Heater Power Circuit ............................................................................ ............. 4B20 13-9. Spark Plug Fixture ......................................................................................................... 4B22 13-10. Wiring - Test Setup ..................................................................................................... 4B22 13-11. Spark Plug Gap Adjustment and Tool ................................................................................. 4B24 13-12. Spark Plug Gap Adjustment and Tool ................................................................................. 4C 13-13. Test Setup for Fuel Regulator and Shutoff Valve ...............................................................4C1 13-14. Suggested Design for Seal Plate. Plugs and Caps for Combustion Tube Leakage Test...................................................................................... ..................4C5 13-15. Test Setup - Combustion Air Pressure Switch ................................................................ 4C7 13-16. Deleted 13-17. Exploded View of Heater Assembly ................................................................................... 4C13 13-18. Exploded View of Combustion Air Blower and Motor Assembly ......................................4C16 13-19. Suggested Setup for Heater Operation Test ......................................................................... 4C18 13-20. Wiring Connections for Heater Operation Test .................................................................. 4C 18 14-1. Oxygen System Installation (Forward - 6 Outlets) .............................................................. 4E7 14-2. Oxygen System Installation (Forward - 8. 9 and 10 Outlets) .............................................4E7 14-3 Oxygen System Installation (Aft - 6 Outlets) ..................................................................... 4E8 11-4. Oxygen System Installation (Aft - 8. 9 and 10 Outlets) ......................................................4E8 14-5. Oxygen System Installation (S/N 31-7752001 and up) .......................................................4E9 14-5a. Oxygen Tubing Installation ......................................................................... .. ........ 4E10 14-6. Electric Propeller Deicer Installation...................................................................................4E17 14-7. Electrical Diagram Showing Cycle Sequence - Phase I ..................................................... 4E19 14-8. Electrical Diagram Showing Cycle Sequence - Phase II ....................................................4E19 14-9. Electrical Diagram Showing Cycle Sequence - Phase m ..................................................4E21 14-10. Electrical Diagram Showing Cycle Sequence - Phase IV ..................................................4E21 14-11. Typical Use of Dial Indicator ........................................................................................... 4E23 14-12. Centering of Brushes on Slip Rings ..................................................... ............................. 4E23 14-13. Wiring Schematic. Electric Propeller Deicing System ...................................................... 4F2 14-14. Propeller Deicer Brush Assemblies .................................................................... 4F3 14-15a. Angle of Contact Brushes to Slip Rings .............................................................................4F5 14-15b. Brush Alignment Template ............................................................................................... 4E5 14-16. Repair of Lead Strap ...........................................................................................................4F5 14-17. Installation of Deicer Boots ............................................................................................. 4F7 14-18. Wrinkled Deicers ................................................................................................................4F7 14-19. Sealer Application ( Boot) .................................................................................................. 4F9 14-20. Sealer Application (Lead Straps)...............................................................................4F9 4F9 14-21. Propeller Blade Low Pitch Position..................................................................................... 4F11 14-22 Propeller Blade in Feather Position ....................................................................... 4F114F11 Revised: 3/31/94 1A12 NAVAJO CHIEFTAIN SERVICE MANUAL LIST OF ILLUSTRATIONS (cont) Figure Aerofiche Grid No. 14-23. Pneumatic Deicer System Installation (Typical) (S/N 31-5001 to 31-7652123 inclusive) ................................................... 4F 19 14-24. Pneumatic Deicer System Installation (Typical) (S/N 31-7652124 to 31-7952250 inclusive) ................................................... 4F20 14-25. Pneumatic Deicer System Installation (Typical) (S/N 31-8052001 and up) ........ 4F21 14-26. Pneumatic Deicer Boots Operation .......... ....... ......................... 4F24 14-27. Pneumatic Deicer System Schematic (S/N 31-50001 to 31-7652123 inclusive) ..... 4F24 14-28. Pneumatic Deicing System Schematic (S/N 31-7652124 to 31-8052004 inclusive) .. 4G1 14-29. Pneumatic Deicer System Schematic (S/N 31-8052005 and up) .................. 4G2 14-30. Air Conditioning Schematic Diagram ........................................ 4G14 14-31. Air Conditioning System Installation ........................................ 4G18 14-32. Service Valves............................................................. 4G20 14-33. Manifold Set Operation ............ ........................................ 4G22 14-34. Test Gauge and Manifold Set ............................................... 4G24 14-35. Leak Test Hookup ......................................................... 4G24 14-36. Evacuation Hookup ........................................................ 4H2 14-37. Charging Stand ............................................................ 4H4 14-38. Charging Hookup ........................................................ 4H8 14-39. Compressor and Fabricated Oil Dipstick ..................................... 4H 10 14-40. Magnetic Clutch Installation ............................................... 4H12 14-41. Expansion Valve (Typical) .................................................. 4H14 14-42. Service Points (Air Conditioning System) ...................................... 4H16 14-43. Air Conditioning Outlets ................................................... 4H17 14-44. Positioning of Airflow Probe ............................................... 4H18 14-45. Sealing of Ducts ...................................................... . 4H19 14-46. Installation of VOI SHAN Seals ............................................. 4H20 14-47. Synchrophaser Installation .................................................. 417 14-48. Strobe Sensor ........................................................... 4112 14-49. Pulse Generator ........................................................... 4114 14-50. Computer Assembly ....................................................... 4115 14-51. Fabricated Test Box ....................................................... 4116 14-52. Electrical Schematics ....................................................... 4116 14-53. Strobe Sensor Internal Wiring Test Unit ...................................... 4117 14-54. Strobe Sensor Simulator ................................................... 4117 14-55. Patch Cable and Test Terminal ............................................. 4118 14-56. Pulse Generator Simulator .................................................. 4118 14-57. Synchrophaser Schematic (S/N 31-7852038 and up) ............................ 4119 14-58. Typical Cargo Loading ..................................................... 4121 14-59. Cargo Loading Placard ..................................................... 4122 14-60. Cargo Furnishing Installation ............................................... 4123 14-61. Location of Extrusion Holes ............................................... 4124 14-62. Commuter. Corporate and Executive Interiors ................................. 4J9 Revised:2/8/82 1A13 NAVAJO CHIEFTAINSERVICE MANUAL LIST OF TABLES Table Aerofiche Grid No. 11-1. Leading Particulars and Principal Dimensions .............................. B I 11-11. Recommended Nut Torques (Inch-Pounds) ........................ ......... 1B6 11-111. Flare Fitting Torque Chart ...................................... ..... IB II-IV. Recommended Lubricating Oils ........................................... IC2 11V. Thread Lubricants ............................................ ... . 1C5 II-VI. List of Consumable Materials ............................................ IC 14 II-VII. Indicated Oxygen Pressures for Given Ambient Temperatures ................. 1D1 II-VIII. Decimal Conversion Chart ............................................... ID2 II-IX. Decimal/Millimeter Equivalents of Drill Sizes............................... ID5 II-X. Conversion Charts....................................................... 1D II-XI. Maximum Distance Between Supports Fluid Tubing ......................... 1 III-I. Inspection Report ..... ............................................ IE6 IV-I. Balance Weights.................................................. IG 17 IV-II. List of Materials (Thermoplastic Repairs)................................... 1H2 V-I. Cable Rigging Tension Vs. Temperature .................................... I H 19 V-II. Control Surface Travel and Cable Tension .................................. I H 19 V-III. Troubleshooting Chart (Surface Controls) .................................. IK 14 VI-I. Leading Particulars, Hydraulic Power Pack (Ozone) ............... .......... 2A17 VI-II. Leading Particulars, Hydraulic Power Pack (Wiebel Tool) .................... 2A18 VI-Ill. Inspection and Repair, Hydraulic Pump .................................... 2D7 VI-IV. Troubleshooting Chart (Hydraulic System) ................................. 2DII VII-I. Inspection Limits ....................................... . .......... 2G1 VII-II. Troubleshooting Chart (Landing Gear System) .............................. 2G10 VIII-I. Propeller Specifications ............................................ 2H13 VIII-II. Turbocharger Installation Torque Values in Inch-Pounds ..................... 2H24 VIII-III. Coupling Torques ............ ........................................... 2J7 VIII-IV. Troubleshooting Chart (Engine) ........................................... 2J12 IX-I. Fuel Quantity Sender Resistance Limits .................................... 2K14 IX-II. Wear Limits for Electrical Fuel Pump ...................................... 2L4 IX-III. Fuel Cell Repair Equipment Lists ......................................... 2L10 IX-IV. Troubleshooting Chart (Fuel System) ...................................... 2L14 X-I. Pressure System ................................................ .. 3B7 X-II. Deleted ........................ ............................... 3B8 X-III. Deleted ......................................................... 3B9 X-IV. Rate of Climb Indicator .............................. ..... 3B10 X-V. Altimeter ........................................ .................... 3B12 X-VI. Airspeed Tubes and Indicator ......................................... . 3B13 X-VII. Magnetic Compass ................................. 3B15 X-VIII. Manifold Pressure Indicator ............................................. 3B16 X-IX. Tachometer ........................ .... ........................ 3B17 X-X. Engine Oil Pressure Gauge ........................... 3B18 X-XI. Fuel Pressure Gauge ............................... . ......... 3B19 X-XII. Deleted ......... .......... .. ................................ 3B20 X-XIII. Fuel Quantity Indicators ............................ 3B22 X-XIV. Oil Temperature Indicators ...................... .. 3B23 Revised: 5/3/84 1A14 1A14 NAVAJO CHIEFTAIN SERVICE MANUAL LIST OF TABLES (cont) 0 Table X-XV. X-XVI. X-XVII. X-XVIII. XI-I Xl-II. xi-m. XI-IV. XI-V. XI VI. XI-VII. XI-VIII. XI-IX. XI-X. XI-XI. XIII-I. XIV-I. XIV-II. XIV-III. XIV-IV. XIV-V. XIV-VI. XIV-VII. XIV-VIII. XIV-IX. XIV-X. XIV-XI. XIV-XII. XIV-XIII. XIV-XIV. XIV-XV. XIV-XVI. Aerofiche Grid No. ExhaustGas TemperatureGauge ...... ................................................... 3C CylinderHead TemperatureGauge ..........................................................................3C2 Fuel FlowGauge ............................................................................................... 3C3 InstrumentMarkings ...............................................................................................3C5 AlternatorTestSpecifications(Prestolite)................................................................... 3C18 AlternatorBelt Tension ................................................................................................. 3D11 StartingMotorTest Specifications....................................................................... 3D18 HydrometerPercentageGuide ...... ................................................... 3D18 TroubleshootingChart (ElectricalSystem) ......... ................................................3EII Circuit LoadChart .................................................................................................... 3E16 Lamp ReplacementGuide .............................................................................. 3E19 ComponentValuesto Obtain BalanceLight OutputIntensity ...................................... 3E20 ElectricalWireCoding ............................................................................................3E21 ElectricalSymbols......................................................... .......................... 3E22 Index - ElectricalSystemSchematics............................................................................ 3E23 TroubleshootingChart (HeatingSystem) ......... ................................................ 4C23 OxygenSystemComponentLimits ........................................................................4E6 TroubleshootingChart (OxygenSystem) ......... ................................................ 4E14 RequiredMaterialsfor Repairof PropellerDeicer........................................................ 4F2 ElectricalResistance ................................................................... 4F8 TroubleshootingChart (PropellerDeicerSystem)........................................................4F12 OperatingPressures..................................................................... G3 Materialand Suppliesfor Cold Repair .......... ............................................... 4G5 TroubleshootingChart (PneumaticDeicer System)..................................................... 4G12 TemperaturePressureChart ............................................................................ 4G15 AluminumTubingTorque.....................................................................4G20 SystemVacuumChart ................................................................................................... 4G23 CompressorOil Charge ................................................................................................ 4H7 Belt Tensions(TIO-540-J2BD- Engine)(WithFreonCompressorInstalled ..............4H9 Air VelocityChart........................................................................ 4H17 TroubleshootingChart(Air Conditioner) ......... .................................................4H21 TroubleshootingChart(EngineSynchrophaser).......................................................4120 Revised: 331/94 1A15 SECTION I INTRODUCTION Aerofiche Grid No. Paragraph 1-1. 1-2. 1-3. General .............. Scope of Manual ......... Description ............. 1-4. Fuselage ......... 1-5. Wing .......... 1-6. Empennage ...... 1-7. Flight Controls .... 1-8. Hydraulic System . 1-9. Landing Gear ..... 1-10. Engines and Propellers 1-11. Fuel System ..... 1-12. Instruments ...... ...... 1A17 1A17 ............................. ................................ ................................. ................................. ................................. ................................. ................................. ................................. ................................ ................................. ................................. ................................. 1A17 1A17 1A17 1A17 1A17 1A17 1A17 1A18 1A18 1A18 1A18 1-13. Electronic Equipment 1-14. Heating and Ventilating System g System ...... 1Al8 Revised:3/11/81 1A16 PIPER NAVAJO SERVICE MANUAL SECTION I INTRODUCTION 1-1. GENERAL.This manual containsservice and maintenanceinstructionsfor the Piper PA31-350,designed and manufacturedas a versatileaircraftin the air taxi, air cargo,commuterand executiveaviationfields,by the Piper Aircraft Corporation,VeroBeach,Florida. 1-2. SCOPE OF MANUAL.Sections II and III comprisethe service part of this manual, whereas SectionsIV through XIV comprisethe maintenanceinstructions.The serviceinstructionsinclude groundhandling,servicing and inspection.The maintenanceinstructionsfor each systeminclude troubleshooting,removaland installation of components, and corrective maintenanceand testing; each major system of the airplane is covered in a separate section. Only qualified personnel are to perform the operations described in this manual. The descriptionof the airplaneincludedin this section is limited to general information.Section II gives leading particularsand principaldimensions,whileeach majorsystem is describedin its appropriatesection of the manual. 1-3. DESCRIPTION.The Piper PA-31-350 is a versatile, twin-engine, low-wing monoplane of all-metal construction.The followingparagraphsprovidedescriptionsof the majorcomponentsand systems. 1-4. FUSELAGE. The fuselage is a semi-monocoquestructure that consists of three basic units: the nose section, the cabin sectionand the tail cone section. 1-5. WING.The laminarflow wingis of all-metalstressed-skin,full cantilever design,consistingof two wing panels bolted together at the center of the fuselage.The wing tips are removable.The aileron are cable and push rod controlledand are staticallybalanced.Thetrailingedge wing flaps are electricallyoperated. 1-6. EMPENNAGE.The empennageconsists of the vertical stabilizer (fin), rudder with trim tab, horizontal stabilizer,and elevatorwith trim tab. The controlsurfacesare cable controlled,and are staticallybalanced. 1-7. FLIGHTCONTROLS.The flightcontrolsare conventional,consistingof dual controlwheelsthat operate the aileronsand elevator,and dual foot pedalsthat operatethe rudder.The trim tabs for eachcontrol areoperated by wheels or knobslocatedin the controlpedestal. 1-8.HYDRAULICSYSTEM.Twoseparatehydraulicsystemsare incorporatedin the airplane.The main system incorporates a hydraulic Power Pack that operates the landing gear and inboard main gear door-actuating cylinders.The secondsystem operatesthe airplane's brake system. 1-9. LANDINGGEAR.The tricycle landing gear system is hydraulicallyoperated and fully retractable with doors that completelycover the gear whenretracted.The gears are air-oiltype units. Revised: 3/31/94 INTRODUCTION 1A17 NAVAJO CHIEFTAIN SERVICEMANUAL 1-10. ENGINES AND PROPELLERS. The airplane is powered by two Avco-Lycomingsix cylinder, direct drive, wet sump, horizontally opposed, fuel injected, turbocharged engines. The left engine rotation is in the right hand direction, while the right engine rotates in the left hand direction. The propellers are Hartzell full feathering, constant speed three bladed units controlled by a governor mounted on each engine. 1-11. FUEL SYSTEM. The fuel system consists of four bladder-type cells located in the wings with a total fuel capacity of 192 U.S. gallons. Incorporated in the system are NACA type anti-icing, non-siphoning vents, fuel filters, electric auxiliary fuel pumps, boost pumps, engine driven pumps and a crossfeed system. 1-12. INSTRUMENTS.Provisions for the instrument installation includes panels for engine instruments and advance flight instruments, as well as space for an optional second set of flight instruments for the copilot. The panel is shock-mounted to minimize vibration to the instruments. 1-13. ELECTRONIC EQUIPMENT. Provision for electronic equipment includes various combinations of radio installations, AutoPilot and radar. 1-14. HEATING AND VENTILATING SYSTEM. Heated air for the cabin and defroster is obtained from a 50,000 B.T.U. Janitrol Heater installed in the nose section. Fresh air for the cabin interior is obtained from two individual sources; one from an intake in the nose section and the other from an intake located outside on the forward bottom of the fuselage. Revised: 10/15/82 INTRODUCTION IA18 1A19 INTENTIONALLY LEFT BLANK 1A20 INTENTIONALY LEFT BLANK SECTION II HANDLING AND SERVICING Aerofiche Grid No. Paragraph 2-1. Introduction .............................................................. 2-2. Dimensions................................................. 2-3. Serial Number Plates ...................................................... 2-4. Weight and Balance Data................................................... 2-5. Station Reference Lines .................................................... 2-6. Access and Inspection Provisions ............................................ 2-7. Tools and Test Equipment .................................................. 2-8. Torque Requirements ...................................................... 2-9. Torque W renches.......................................................... 2-10. Ground Handling.......................................................... 2-11. Introduction to Ground Handling .................................. 2-12. Jacking .......................................................... 2-13. W eighing ........................................................ 2-14. Leveling ......................................................... 2-15. M ooring ....................................................... 2-16. Parking.......................................................... 2-17. Towing .......................................................... 2-18. Taxiing .......................................................... 2-19. External Power Receptacle ................................................. 2-20. Operation of External Power Receptacle ............................. 2-21. Servicing ................................................................. 2-22. General......................................................... 2-23. Fuel System .............................................................. 2-24. Servicing Fuel System ............................................. 2-25. Filling Fuel Cells ................................................ 2-26. Draining Moisture from Fuel System ................................ 2-27. Draining Fuel System ............................................. 2-28. Landing Gear............................................................1B20 IA23 1A23 IA23 I A23 IA23 IA23 IA23 1B8 1B9 I B14 1B14 1B14 1B15 I B 17 IB17 1B191B19 1B19 1B19 I B19 1B19 1B19 1B19 1B19 1B19 IB20 I B20 1B20 1B20 1B21 2-29. 2-30. Oleo 2-31. 2-32. 2-33. 2-34. 2-35. Tires 2-36. 2-37. 2-38. Servicing Landing Gear............... Struts ................... .......... Servicing Oleo Struts................. Adding Fluid to Struts ............... Filling Oleo Struts ................... Inflating Oleo Struts ................. .... .... ........... ...................... Servicing Tires ...................... Tire Balancing....................... Construction of Tire Balancer ......... ...... ..... ...... ....................... 1 ....................... 1 ....................... 1 ....................... 1B21 ....................... 1B21 ....................... 1 ....................... IB22 ....................... B22 ....................... B23 2-38a Application of Tire Rubber Protective Agent ......................... IB24 Revised: 10/5/83 1A21 Aerofiche Paragraph Grid No. 2-39. Brake System ...................... I B23 2-40. Servicing Brake System ............................................ 1B24 2-41. Filling Brake Cylinder Reservoir.................................... IB24 2-42. Draining Brake System ............................................ 1B24 2-43. Hydraulic System .......................................................... I B24 2-44. Servicing Hydraulic System ........................................ 1B24 2-45. Filling Hydraulic System Reservoir ................................. 1C1 2-46. Propeller ................... 1C1 2-47. Servicing Propeller ............................................... 1C1 2-48. Electrical System .......................................................... 1 2-49. Servicing Electrical System ........................................ 1C1 2-50. Lubrication System (Engine) ................................................ 1C2 2-51. Servicing System ................................................. IC2 2-52. Filling Oil Sump .................................... 1C2 2-53. Draining Oil Sump ................................................ C2 2-54. Changing Oil Filter (Full Flow) ..................................... C3 2-55. Recommendations for Changing Oil................................. 1C3 2-56. Oil Screens (Suction) .............................................. 1C3 2-57. Lubrication (Airframe) ..................................................... 1C3 2-58. Lubrication Procedures .............................. 1C3 2-59. Application of Grease . ....................................... IC4 2-60. Application of Oil ..................................... ..... IC4 2-61. Lubrication of Threads ........................................... 1C4 2-62. Lubrication of Gaskets and Seals ................................... 1C4 2-63. Lubrication Chart......................................... ...... 1C5 2-64. Cleaning . .. ................... ......... .................. IC5 2-65. Cleaning Engine Compartment ..................................... 1C5 2-66. Cleaning Landing Gear .................................... . IC21 2-67. Cleaning Exterior Surfaces ........................................ IC21 2-68. Cleaning Windshield and Windows ................................ IC21 2-69. Cleaning Headliner. Side Panels and Seats ........................... IC22 2-70. Cleaning Wood Surfaces........................................... IC22 2-71. Cleaning Carpets 1C22....................................... C22 2-72. Cleaning Toilet ................................ 1C22 2-73. Airplane Finish Care .............................................. IC23 2-74. Oxygen System ............................................................ IC23 2-75. Servicing Oxygen System .................................. IC23 2-76. Oxygen System Safety Precautions .................................. 1C23 2-77. Filling Oxygen Cylinder ........................................... 1C24 2-78. Air Conditioning System .............. ... ...................... 1C24 Revised:5/3/84 1A22 NAVAJO CHIEFTAIN SERVICEMANUAL SECTIONII HANDLINGAND SERVICING 2-1. INTRODUCTION.This section contains routine handling and servicing procedures that are most frequently encountered. Frequent reference to this section will aid the individual by providinginformation such as the location of various components, ground handling procedures, routine service procedures and lubrication. When any system or component requires service other than the routine procedures as outlined in this section, refer to the appropriate section for that component. 2-2. DIMENSIONS.The principal airplane dimensions are shown in Figure 2-1 and are listed in Table II-I. 2-3. SERIAL NUMBERPLATES. The serial number plate for the airplane is located near the tail skid. The MAA plate is located under the lower front corner of the entrance door. The engine number plates are located on the right side of the oil sump. 2-4. WEIGHTAND BALANCEDATA. When figuringvarious weight and balance computations the weight and empty weight center of gravity of the airplane may be found in the Weightand Balancesection of the Airplane Flight Manual. 2-5. STATION REFERENCE LINES. In order to facilitate the location of various components of the airplane which require maintenance and servicing, a method utilizing fuselage station, wing station or buttock line (BL), and water line (WL)designations is frequently employed in this manual. (Refer to Figure 2-2.) Fuselage stations, buttock lines, and water lines are reference points measured by inches in the vertical or horizontal direction from a given reference line which indicates station locations of structural members of the airplane. Station 0 of the fuselageis 18 inches aft of the nose. Station 0 (BL) of the wing, horizontal stabilizer and elevator is the center line of the airplane; and station 0 (WL) of the vertical stabilizer and rudder is 15.82 inches above the cabin floor with the airplane level. The reference datum line is located at the main spar, fuselagestation 137. 2-6. ACCESS AND INSPECTION PROVISIONS. The access and inspection provisions for the airplane are shown in Figure 2-4.The components to be servicedor inspected through each opening is assignedan index number to identify it in the illustration. All access plates and panels are secured by either metal fasteners or screws. The floor panels may be removed by first removing the desired seats, then removing the carpet, thus exposing the floor panel attachment screws. Carefully remove the floor panels so as not to damage them. To enter the aft section of the fuselage, remove the rear baggage compartment upholstery panel by removing the attachment screws. CAUTION Before entering the aft section of the fuselage,be sure the airplane is supported at the tail skid. 2-7. TOOLS AND TEST EQUIPMENT. Because of the simplicity and easy accessibility of components, few special tools outside normal shop tools will be required. Tools that are required may be fabricated from dimensions given in the back of the section that pertains to a particular component or are listed in the back of the PA-31-350 Parts Catalog, Part No. 761 487. Reissued:9/23/80 HANDLINGAND SERVICING 1A23 NAVAJO CHEIFTAIN-SERVICEMANUAL 1125 Figure 2-1. Three-Viewof PA-31-350 Reissued:9/23/80 1A24 HANDLING AND SERVICING NAVAJO CHIEFTAINSERVICE MANUAL TABLE II-I. LEADING PARTICULARS DIMENSIONS PA-31-350 MODEL ENGINE Manufacturer Model Avco Lycoming TIO-540-J2BD and LTIO-540-J2BD Rated Horsepower, RPM, Altitude: Performance Cruise (75% Rated) Economy Cruise (60% Rated) Fuel Consumption, Cruise: Oil, SAE Number Oil Sump Capacity Turbocharger, AiResearch Fuel, Aviation Grade, Minimum Octane Fuel Injector, Bendix Magnetos, Bendix Left Engine Right Engine Magneto Timing (Spark Advance) Magneto Point Clearance Main Left Right Retard and Tach Retard Angle Spark Plugs (Shielded): AC Champion Spark Plug Gap Setting Firing Order Starter, Presolite, 24 Volt Alternator, Presolite, 24 Volt, 70 Amp Voltage Regulator, Lamar Over Voltage Relay, Lamar Fuel Pump: Lear Siegler 350 - @ 2575 - 13,000 ft. 260 - @ 2400 - 20,000 ft. 210 - @ 2200 Refer to Pilot's Operating Manual See Lubrication Chart 12 qts. THO8A6Q 100/130 RSA-10ED1 D6LN-2230 D6RN-2230 20° BTC .016 .002 .016+ .004 .016 ± .004 11 HSR-87L1 RHB-36W Refer to latest Issue of Lycoming Service Instruction 1042 1-4-5-2-3-6 MHB-4001 ALU 8403 or ALU 8421 B-00286-1 B-00266- RG9080-J4A or J7A PROPELLER Manufacturer Type Hub Blade Diameter Governor Model Hartzell 3 Blade, Constant Speed, Feathering HC-E3YR-2A, HC-E3YR-2AL C8468-6R, JC8468-6R 80 in. Refer to Parts Cataloge HANDLING AND SERVICING Revised:2/8/82 lB1 NAVAJO CHIEFTAINSERVICE MANUAL TABLE II-I. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS MODEL PA-31-350 FUEL CELL CAPACITIES Inboard (Main) Fuel Cells Capacity (each) Unusable Fuel (each) Outboard (Auxiliary) Fuel Cells Capacity (each) Unusable Fuel (each) Two 56 U.S. gal. 3 U.S. gal. Two 40 U.S. gal. 2 U.S. gal. LANDING GEAR Type Shock Strut Type Fluid Required (Struts & Brakes) Strut Extension (Static Load) Nose Wheel Travel Main Wheel Toe-In Turning Radius (Min.) (Nose Wheel) Turning Radius (Min.) (Wing Tip) Wheel, Nose Wheel, Main Brake Type Tire, Nose Tire, Main Tire Pressure, Nose Tire Pressure, Main Hydraulically retractable Combination air and oil MIL-H-5606 3.25 in. 20° + 1° Right 20° + 1° Left .5 degrees 25 ft. 3 in. 44.0 ft. Cleveland 40-76B or 40-140 Cleveland 40-102, 40-130 or 40-141 Cleveland 30-68A, 30-68B, 30-95, 6:00 x 6 ply rating 6:50 x 10, 8 ply rating 42 psi 66 psi CONTROL SURFACE TRAVELS: Refer to Section V, Table V-I. CABLE TENSIONS: Refer to Section V, Table V-I. Revised:3/11/81 1B2 HANDLING AND SERVICING 1124 BAGGAGE FLOOR W.L.-13.00, FRONT SPAR ATTACH. FACE Figure 2-2. Station Reference Lines Revised: 10/15/82 NAVAJO CHIEFTAIN SERVICE MANUAL REAR SPARATTACH. FACE HANDLING AND SERVICING 1B3. 217.75 NAVAJO CHIEFTAIN SERVICE MANUAL 1126 296.00 REAR SPARATTACH. FACE Figure 2-2. Station Reference Lines (cont.) I Revised: 10/15/82 HANDLING AND SERVICING 1B4 1002 NAVAJO CHIEFTAIN SERVICE MANUAL 104.50 137.0 17359 FLAP SPAR Figure 2-2. Station Reference Lines (cont.) HANDLING AND SERVICING I Revised: 10/15/82 1B5 NOTE If the bolt is stationary and the nut is torqued. use the lower side of the torque range If the nut is stationary and the bolt is torque, use the higher side of the torque range 5. When torquing castellated nuts. begin with minimum torque plus friction drag torque. but do not exceed maximum torque plus friction drag torque when trying to align slot on nut with the hole in the bolt shank. If they do not align. change washers and try again. When using castellated nuts on moveable joints. do not torque asdescribed above. Tighten nuts only to remove looseness in the joint and then install the cotter pin. 6. After the final torque has been applied the nut or bolt or screws if no nut is used) should be permanently marked red and should not be further tightened or disturbed. NOTE SEE NOTE 8 -32 10 -24 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8- 9 1 -8 1-1/8-8 1 1/4-8 NAVAJOCHIEFTAINSERVICEMANUAL TABLE II-II. RECOMMENDED NUT TORQUES (Inch-Pounds) TORQUES: The importnce of correct application cannot be overemphasized. Undertorque can result in unnecessary wear of nuts and bolts as well as the partsthey are holding together. When insufficient pressure are applied. uneven loads will be transmitted throughout the assembly which may result in excessive wear or premature failure due to fatigue. Overtorque can be equally damaging because of failure of a bolt or nut from overstressing the threaded areas. There are a few simple. but very important, procedures that should be followed to assure that the correct torque is applied: 1. Calibrate the torque wrench periodically to assure accuracy: and recheck frequently. 2. Unless otherwise specified. torque all nuts to the applicable torque in the Recommended Nut Chart. Ifthe nut (or the bolt) is listed but not its mating fastener, use the lower torque specified for the listed nut (or bolt). NOTE If normal operation requires movement between any of the components being clamped together. tighten the nut Ior bolt) without regard to the nut torque chart, to insure intended operation of the assembly 3. Bolt and nut threads should be clean and dry unless otherwise specified. If the threads are to be lubricated and no torque is specified. reduce the recommended nut torque (plus the friction drag torque) by 50%. 4 For other bolt sizes. determine the friction drag torque by turning the nut to near contact with the bearing surface. Attach a scale type torque wrench to the nut and determine the torque required to turn the nut on the bolt (before the nut makes contact with the bearing surface) Add this. the friction drag torque. to the specified torque to get the final torque COARSE THREAD SERIES BOLTS Steel Tension AN 3 thru AN 20 AN 42 thru AN 49 AN 73 thru AN 81 AN 173 thru AN 186 MS 20033 thru MS 20046 MS 20073 MS 20074 AN 509 NK9 MS 24694 AN 525 NK525 MS 27039 NUTS Steel Tension Steel Shear AN 310 AN 320 AN 315 AN 364 AN 363 NAS 1022 AN 365 MS 17826 NAS 1021 MS 20364 MS 17825 MS 21045 MS 20365 MS 20500 NAS 679 Men. Max. Nut and bolt sizes 8 through 7/16 include friction drag torque values. Revised:2/8/82 1B6 HANDLING AND SERVICING NAVAJO CHIEFTAIN SERVICEMANUAL TABLE II-II. RECOMMENDED NUT TORQUES (Inch-Pounds)(cont.) FINE THREAD SERIES BOLTS Steel Tension BOLTS Steel Tension BOLTS Aluminum AN 3 thru AN 20 AN 42 thru AN 49 AN 73 thru AN 81 AN 173 thru AN 186 MS 20033 thru MS 20046 MS 20073 MS 20074 AN 509 NK9 MS 24694 AN 525 NK525 MS 27039 NUTS Steel Tension Steel Shear MS 20004 thru MS 20024 NAS 144 thru NAS 158 NAS 333 thru NAS 340 NAS 583 thru NAS 590 NAS 624 thru NAS 644 NAS 1303 thru NAS 1320 NAS 172 NAS 174 NAS 517 Steel shear bolt NAS 464 NUTS AN 3DD thru AN 20DD AN 173DD thru AN 186DD AN 509DD AN 525D MS 27039D MS 24694DD NUTS AN 310 AN 315 AN 363 AN 365 NAS 1021 MS 17825 MS 21045 MS 20365 MS 20500 NAS 679 AN 320 AN 364 NAS 1022 MS 17826 MS 20364 Steel Tension AN 310 AN 315 AN 363 AN 365 MS 17825 MS 20365 MS 21045 NAS 1021 NAS 679 NAS 1291 Steel Shear AN 320 AN 364 NAS 1022 MS 17826 MS 20364 Alum. Tension AN 3650 AN 3100 NAS 1021D Alum Shear AN 320D AN 364D NAS 1022D Nut-bolt size Torque Limits Torque Limits Torque Limits in-lbs in-lbs in-lbs Torque Limits in-lbs Torque Limits Torque Limits in.lbs in-lbs Min Max 8 36 10 -32 1 4-28 5/16-24 3/8- 24 7/16-20 1/2-20 9/16-18 5/8-18 3/4 16 7/8-14 1 -14 NOTE Min. Max. Min Max Min. Max BOLT AND NUT SIZES 10 THROUGH 7 16 INCLUDE Min Max Min Max 6 28 60 100 150 270 260 360 420 880 1,200 1.500 2,000 3.650 660 1.300 1.500 2.200 3.000 5.400 780 1.500 1.800 3.300 4.200 6,600 1,250 2.650 3.550 4 500 6000 11,000 1,550 3.200 4,350 5.500 7.300 13,400 750 1,600 2,100 2,700 3,600 6,600 950 1,900 2.600 3,300 4.400 8,000 HANDLING AND SERVICINGRevised:2/8/82 1B7 1B7 NAVAJOCHIEFTAINSERVICEMANUAL TABLE II-III. FLARE FITTING TORQUE CHART TORQUE - INCH POUND TUBING OD INCHES ALUMINUM- ALLOY TUBING FLARE-AND 10061 OR AND 10078 STEEL TUBING FLARE AND 10061 HOSE END FITTING AND HOSE ASSEMBLIES MINIMUMMAXIMUMMINIMUMMAXIMUMMINIMUMMAXIMUM 1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 1-1/4 1-1/2 1-3/4 2 40 60 75 150 200 300 500 600 600 65 80 125 250 350 500 700 900 900 90 135 180 270 450 650 900 1200 100 70 150 70 200 85 300 100 500 210 700 300 1000 500 1400 700 100 120 180 250 420 480 850 1150 2-8. TORQUE REQUIREMENTS.The torque values given in Table II-II are derived from oil free cadmium-plated threads and are recommended for all airframe installation procedures where torquing is required, unless otherwise noted in sections where other values are stipulated. Engine torque values are found in the latest revision of Avco Lycoming Service Bulletin No. 268, and propeller torque values are found in Section VIII of this manual. Table II-III list the torque values for flared fittings of various sizes and material. NOTE When flared fittings are being installed, ascertain that the male threads are properly lubricated. Torque the fittings in accordance with Table II-III. CAUTION Do not over torque fittings. a. Unless otherwisespecified, torque all nuts to the applicable torque in the Recommended Nut Chart. If the nut (or the bolt) is listed but not its mating fastener, use the lower torque specifiedfor the listed nut (or bolt). Reissued:9/23/80 HANDLINGAND SERVICING 1B8 A933 NAVAJO CHIEFTAIN SERVICE MANUAL 2-9. TORQUE WRENCHES. Torque wrenches should be checked daily and calibrated by means of weights and a measured lever arm to make sure that inaccuracies are not present. Checking one torque wrench against another is not sufficient and is not recommended. Some wrenches are quite sensitive as to the way they are supported during a tightening operation. Any instructions furnished by the manufacturer must be followed explicitly. When it is necessary to use a special extension or adapter wrench together with a torque wrench. a simple mathematical equation must be worked out to arrive at the correct torque reading. Following is the formula to be used: (Refer to Figure 2-3.) T = Torque desired at the part. A = Basic lever length from center of wrench shank to center of handle or stamped on wrench or listed for that model wrench. B = Length of adapter extension. center of bolt to center of shank. C = Scale reading needed to obtain desired torque (T). The formula: C = A xT A+B EXAMPLE A bolt requires 30 foot-pounds and a 3 inch adapter (one-quarter of a foot or .25) is needed to get at it. You want to know what scale reading it will take on a one-foot lever arm wrench to obtain the 30 foot-pounds at the bolt. Remember. the 3 inch adapter must be projecting 3 inches straight along the wrench axis. In general. avoid all complex assemblages or adapters and extensions of flex joints. A Figure 2-3. Torque Wrench Formula Reissued: 9/23/80 lB9 HANDLING AND SERVICING NAVAJOCHIEFTAIN SERVICEMANUAL 1127A 1. BATTERY DRAIN AND VENTS 2. PITOT ATTACHMENT LINES 3. CABIN AIR CONTROL 4. HEATER AIR INLET LINE 5. NOSE GEAR STEERING BELLCRANK 6. HYDRAULIC LINES 7. TRIM CONTROL CABLES AND PULLEYS - FUEL SELECTOR VALVE AND LINES 8. TRIM CABLES AND PULLEYS - ENGINE CONTROL LINES, WIRES, AND CABLES 9. ROLL SERVO, IF INSTALLED 10. TRIM CABLES AND PULLEYS 11. FLAP MOTOR - AILERON BALANCE CABLE 12. CONTROL AND TRIM CABLES 13. BAGGAGE COMPARTMENT COVER PLATE 14. EXTERNAL POWER RECEPTACLE ATTACHMENTS IS. OXYGEN CYLINDER HEAD 16. CONTROL CABLES, PULLEYS, AND TURNBUCKLES 17. CONTROL CABLES, PULLEYS, AND TURNBUCKLES - ENGINE CONTROL LINES, WIRES, AND CABLES 18. HYDRAULIC HAND PUMP 19. CONTROL CABLES AND PULLEYS 20. TRIM WARNING SYSTEM, IF INSTALLED 21. AUTOPILOT UNITS; ROLL PITCH AND PITCH TRIM SERVOS, VOLTAGE DIVIDER, AND GYRO AMPLIFIER - CONTROL CABLES - WING FLAP MOTOR 22. PITCH SERVO, IF INSTALLED 23. CABIN EXHAUST DOOR MECHANISM 24. CONTROL AND TRIM CABLES AND PULLEYS SEAT ATTACHMENTS 25. PITCH TRIM SENSOR, IF INSTALLED 26. GROUND VENT FAN Figure 2-4. Access Plates and Panels Reissued: 9/23/80 HANDLINGAND SERVICING 1B10 NOTE ON AIRCRAFT EQUIPPED WITH REMOTE COMPASS SYSTEMS, ACCESS PLATE (1) MUST HAVE BRASS SCREWS ONLY WHEN REPLACING ANY OF THESE SCREWS. STEEL SCREWS CAUSE ERRATIC COMPASS READINGS. 1. FLUX DETECTOR 2. FUEL FILLER 3. FUEL SENDER UNIT 4. FUEL CELL 5. PRESSURE SYSTEM AIR FILTER - INSPECTION LIGHT - PULSE GENERATOR (IF PROP SYNCHROPHASER IS INSTALLED) 6. ENGINE 7. NACELLE INTERIOR - PRESSURE SYSTEM INLINE FILTER 8. OILFILLER 9. PROPELLER 10. PROPELLER RECHARGE 11. LINES WIRES-CABLES 12. NACELLE INTERIOR - CONDENSER AIR OUTLET PLATE (IF AIR CONDITIONING IS INSTALLED) 13. COWL FLAP TRANSMISSION - PRESSURE SYSTEM RELIEF VALVE 14. CONDENSER AIR OUTLET - PRESSURE SYSTEM AIR FILTER - STROBE SENSOR (IF PROP SYNCHROPHASER IS INSTALLED) 15. WING TIP 16. FREON CONDENSER, IF INSTALLED 17. COWL FLAP TRANSMISSION - PRESSURE SYSTEM RELIEF VALVE - PRESSURE SYSTEM INLINE FILTER - FREON CONDENSER (IF AIR CONDITIONING IS INSTALLED) NAVAJO CHIEFTAIN SERVICE MANUAL 18. AILERON CABLE PULLEYS 19. AILERON BELLCRANK 20. FUEL CELL CHECK VALVE 21. AILERON CABLE FAIRLEADS 22. AILERON TRIM CABLES AND RUB BLOCKS - FLAP TRANSMISSION 23. LANDING GEAR ATTACHMENTS 24. MAIN LANDING GEAR 25. GEAR DOOR ACTIVATING CYLINDER 26. FUEL CELL DRAIN 27. LANDING GEAR SIDE BRACE ATTACHMENTS 28. AILERON TRIM SCREW AND SENDER 29. ELEVATOR TRIM SCREW AND SENDER Figure 2-4. Access Plates and Panels (cont) Reissued: 9/23/80 lB11 HANDLING AND SERVICING 1129 NAVAJO CHIEFTAIN SERVICE MANUAL 4 25 1. RUDDER TIP 2. VERTICAL STABILIZER TIP 3. RUDDER TRIM SCREW AND SENDER 4. AIR INTAKE ELT 5. RUDDER PEDAL TORQUE TUBE 6. HEATER -CENTER PRESSURE REGULATOR. POWER PACK 7. ELEVATOR CONTROL ARM 8. RUDDER CONTROL HORN 9. ELEVATOR BUNGEE 10. ELEVATOR BELLCRANK 11. BATTERY. POWER PACK 12. OXYGEN CYLINDER - VOLTAGE REGULATORS FUSES - ELECTRONICS EQUIPMENT 13. EXTERNAL POWER RECEPTABLE 14. NOSE LANDING GEAR 15. HYDRAULIC LINES- ELECTRICAL LEADS 16. ELECTRICAL CONNECTORS - LINE CONNECTORS FRONT SPAR ATTACHMENT 17. ELECTRICAL CONNECTORS - LINES 18. FUEL PUMP - FUEL FILTER - SELECTOR VALVE - CROSSFEED VALVE - EMERGENCY SHUTOFF VALVE 19. FUEL FILTER BOWL 20. SPAR SPLICE - DEICER PRESSURE SWITCH 21. MAIN SPAR ATTACHMENT 22. REAR SPAR ATTACHMENT 23. CABIN EXHAUST 24. SPAR SPLICE 25. BRAKE RESERVOIR 26. ALTIMATIC SERIAL NOS. 74-05 2 0 3 & UP 27. PULLEY AND CABLE INSPECTION 28. CIRCUIT BREAKERS Figure 2-4. Access Plates and Panels (cont.) Reissued: 9/23/80 1B12 HANDLING AND SERVICING 1130 REFERTO NOTE NOTE ENSURESUFFICIENTBALLAST ON TAIL SUPPORT TO OFFSET WEIGHT OF AIRCRAFT Figure 2-5. Jacking Arrangement NOTE If normal operation requires movement between any of the components being clamped together, tighten the nut (or bolt) without regard to the nut torque chart, to insure intended operation of the assembly. b. Bolt and nut threads should be clean and dry unless otherwise specified. If the threads are to be lubricated and no torque is specified, reduce the recommended nut torque (plus the friction drag torque) by 50%. c. For thread sizes 10through 7/16, add the friction drag torque for all self-locking fasteners specified in the friction drag torque table. For non self-locking fasteners, assume the friction drag torque to be zero. d. For other bolt sizes, determine the friction drag torque by turning the nut to near contact with the bearing surface. Attach a scale type torque wrench to the nut and determine the torque required to turn the nut on the bolt (before the nut makes contact with the bearing surface). Add this friction drag torque to the specified torque to get the final torque. NOTE If the bolt is stationary and the nut is torqued, use the lower side of the torque range. If the nut is stationary and the bolt is torqued, use the higher side of the torque range. Revised: 10/15/82 HANDLING AND SERVICING NAVAJOCHIEFTAINSERVICEMANUAL 1B13 NAVAJO CHIEFTAINSERVICEMANUAL 1131 TO NOTE NOTE BLOCK WHEELS TO ENSURE AIRCRAFT DOES NOT ROLL OFF SCALES Figure 2-6. Weighing Arrangement e. When torquing castellated nuts, begin with minimum torque plus friction drag torque. but do not exceed maximum torque plus friction drag torque when trying to align slot on nut with the hole in the bolt shank. If they do not align, change washers and try again. When using castellated nuts on movable joints. do not torque as described above. Tighten nuts only to remove looseness in the joint and then install the cotter pin. f. Unless otherwise specified, when parts are used on Lycoming engines, using Piper furnished or existing Lycoming threaded fasteners, use the torques specified in the latest applicable Lycoming specifications. g. After the final torque has been applied, the nut (or bolts or screw if no nut is used) should be permanently marked red and should not be further tightened or disturbed. 2-10. GROUND HANDLING. 2-11. INTRODUCTION TO GROUND HANDLING. Ground handling covers all essential information governing the handling of the airplane while on the ground. This includesjacking, weighing, leveling, mooring. parking. towing and taxiing. When the airplane is handled in the manner described in the following paragraphs. damage to the airplane and its equipment will be prevented. 2-12. JACKING. The airplane is provided with a jacking pad on each main spar just outboard of the engine nacelle and a support position by making use of the tail skid. (Refer to Figure 2-5.) To jack the airplane. proceed as follows: a. Place the jacks under the jack pads. b. Attach the tail support to the tail skid. Place approximately 500 pounds of ballast on the support to hold the tail down. Revised:10/15/82 HANDLINGAND SERVICING 1B14 NAVAJO CHIEFTAINSERVICEMANUAL 1132 104 SEAT RAILS LATERAL / (LONGITUDINAL) \ Figure 2-7. Leveling - Longitudinal and Lateral CAUTION Be sure to apply sufficient tail support ballast; otherwise the airplane will tip forward and fall on the fuselage nose section. c. Raise the jacks evenly until all three wheels clear the surface. 2-13. WEIGHING. (Refer to Figure 2-6.) The airplane may be weighed by the following procedure: a. Position a scale and ramp in front of each of the three wheels. b. Secure the scales from rolling forward and tow the airplane up onto the scales. (Refer to Towing. paragraph 2-17.) c. Remove the ramp so as not to interfere with the scales. d. If the airplane is to be weighed for weight and balance computations. level the airplane per instructions given in paragraph 2-14. 2-14. LEVELING. All configurations of the airplane are provided with a means for longitudinal and lateral leveling. The airplane may be leveled while on jacks during the weighing procedure. while the wheels are on scales. or while the wheels are on the ground. To level the airplane for purposes of weighing or rigging. the following procedures may be used: a. To longitudinally level the airplane. partially withdraw the two leveling screws located on the right side of the fuselage nose section at station 57.00 and 35.00 (Refer to Figure 2-7.) Place a spirit level on these screw heads and deflate the nose wheel tire or adjust the jacks until the bubble of the level is centered. b. To laterally level the airplane. place a spirit level across the two center seat rails of the cabin (Refer to Figure 2-7) and deflate the tire on the high side of the airplane or adjust eitherjack until the bubble of the level is centered. Revised: 10/15/82 HANDLINGAND SERVICING lB15 NAVAJOCHIEFTAINSERVICEMANUAL I WHEELBASE-10 FT. 8 IN. NOSEWHEELTRAVEL- 20° LEFTAND20° RIGHT Figure 2-8. Tow Turn Limits and Indicator Revised:2/8/82 HANDLING AND SERVICING 1B16