Piper SENECA PA-34-200 Service Manual
  1. Manuals
  2. Brands
  3. Piper Manuals
  4. Aircrafts
  5. SENECA PA-34-200
  6. Service manual
Piper SENECA PA-34-200 Service Manual

Piper SENECA PA-34-200 Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
Table of Contents

Advertisement

Quick Links

Download this manual
AIRPLANE SERVICE MANUAL
CARD 1 OF 4
PA-34-200
(S/N's 34-7250001 THRU 34-7450220)
PIPER AIRCRAFT CORPORATION
PART NUMBER 753-817
October 30, 2003
1A1

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SENECA PA-34-200 and is the answer not in the manual?

Questions and answers

Related Manuals for Piper SENECA PA-34-200

Summary of Contents for Piper SENECA PA-34-200

  • Page 1 AIRPLANE SERVICE MANUAL CARD 1 OF 4 PA-34-200 (S/N’s 34-7250001 THRU 34-7450220) PIPER AIRCRAFT CORPORATION PART NUMBER 753-817 October 30, 2003...
  • Page 2 Published by Technical Publications © The New Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...

  • Page 3: Aerofiche Effectivity

    PIPER SENECA SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to this Service Manual 753-817 originally issued April 5, 1971 are as follows: Revision Publication Date Aerofiche Card Effectivity ORG710405 April 5, 1971 CR720613 June 13, 1972 CR031030 * October 30, 2003 1, 2, 3, &...
  • Page 4 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Oct 30/03...
  • Page 5 PIPER SENECA SERVICE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE Intro-List of Oct 30/03 Effective Pages Oct 30/03 Intro-Table of Contents Oct 30/03 Oct 30/03 Introduction Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 6 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 7 PIPER SENECA SERVICE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity Serial Number Explanation 1A10 Assignment of Subject Material 1A10 Pagination 1A10 Aerofiche Effectivity 1A10 Identifying Revised Material 1A10 Indexing 1A10 List of Effective Pages...
  • Page 8 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Oct 30/03...

  • Page 9: Instructions For Continued Airworthiness

    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.
  • Page 10 PIPER SENECA SERVICE MANUAL SERIAL NUMBER EXPLANATION. Example: 34 72 50 001 SEQUENCE NUMBER TYPE CERTIFICATE DESIGNATION MODEL YEAR MODEL CODE 50 = PA-34-200 SENECA ASSIGNMENT OF SUBJECT MATERIAL. This publication is divided into logical subject groupings based on aircraft system or task function. Refer to paragraph 14, Section Index Guide, for a complete breakdown and list.
  • Page 11 To improve our Service and Reliability system and aid in our compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
  • Page 12 PIPER SENECA SERVICE MANUAL (4) BRAKES AND WHEELS: Vendor Address: Parker Hannifin Corp - (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/cleveland/Universe/book.pdf (5) ENGINE: Vendor Address: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • Page 13 PIPER SENECA SERVICE MANUAL (10) LANDING GEAR ACTUATOR, EXTENSION AND RETRACTION: Vendor Address: Parker Hannifin Corp - (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/cleveland/ Component (Effective for P/N’s 96860-002 and 96860-003 only.) Maintenance Manual:...
  • Page 14 PIPER SENECA SERVICE MANUAL (14) PROPELLER: Vendor Address: Hartzell Propeller Inc. - (937) 778-4379 One Propellor Place FAX - (937) 778-4321 Piqua, OH 45356-2634 http://www.hartzellprop.com/index2.htm Standard Practices: Manual No. 202A Overhaul and Maintenance: Manual No. 117D Aluminum Blade Overhaul: Manual No. 133C Propeller Owner’s...

  • Page 15: Voltage Regulator

    PIPER SENECA SERVICE MANUAL (18) VACUUM REGULATORS: Vendor Address: Parker Hannifin Corp. PH: - (800) 382-8422 Airborne Division 711 Taylor Street Elyria, Ohio 44035 http://www.parker.com/cleveland/Universe/book.pdf (19) VOLTAGE REGULATOR: Vendor Address: See listing under Alternator, above. INTRODUCTION PAGE 7 1A15 Oct 30/03...
  • Page 16 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Oct 30/03 1A16...
  • Page 17 PIPER SENECA SERVICE MANUAL 14 SECTION INDEX GUIDE. SECTION TITLE GRID NO. AIRWORTHINESS LIMITATIONS HANDLING AND SERVICING INSPECTION STRUCTURES 1H11 SURFACE CONTROLS HYDRAULIC SYSTEM LANDING GEAR AND BRAKES 2G21 VIII POWERPLANT FUEL SYSTEM INSTRUMENTS ELECTRICAL SYSTEM 3H17 ELECTRONICS XIII HEATING AND VENTILATION SYSTEM...
  • Page 18 PIPER SENECA SERVICE MANUAL GRIDS 1A18 THRU 1A24 INTENTIONALLY BLANK PAGE 10 INTRODUCTION Oct 30/03 1A18...
  • Page 19 PIPER SENECA SERVICE MANUAL Schematics Alternators: 3K7 Cabin Access Plates and Panels: 1C22 Anti-Collision Fin-Tip Strobe Heating, Defrost, and Accident/Incident Reporting: A11 Light: 3K16 Ventilation: 4D2 Aerofiche Combustion Heater: 4D16 Consumable Materials: 1E9 Effectivity: A10 Electrical Symbols: 3K3 Conversion Tables...
  • Page 20 PIPER SENECA SERVICE MANUAL Environmental Systems Fuel System: 1D9 E (cont.) Description and Operation: 4D1 Description: 3F7 Engine Optional Combustion Heater: Draining Alternate Air Door Entirely: 1D11 100 Hour Inspection: 3D6 Exploded View: 4E16 Moisture: 1D11 Cowl Flaps: 3C13 Inspections: 4D17...
  • Page 21 PIPER SENECA SERVICE MANUAL Per Specific Operation / Operating Environment.: Landing Gear Ice and Rain Protection: 4F11, 1G20 Cleaning: 1D19 4G15 Extreme Cold: 1G21 Description: 2H3 Ignition System High Dust: 1G20 Electrical Schematic: 2J3 Contact Points: 3D11 High Humidity: 1G21...
  • Page 22 PIPER SENECA SERVICE MANUAL Propeller Rudder L (cont.) Air Charge Pressure vs. 100 Hour Rudder Tab Freeplay Lights Temperature: 3C15 Inspection: 2E14 Exterior: 3J15 Deicing System: 4F11 Balancing Anti-Collision Strobe: 3J18 Deicers: 4G4 Procedure: 1K8 Landing and Taxi: 3J15 Electrical Check: 4G10...
  • Page 23 PIPER SENECA SERVICE MANUAL Troubleshooting Aileron Controls: 2D1 Vacuum System Taxiing: 1D7 Airspeed Indicator: 3G23 Description: 3G12 Testing Alternator: 3I5 Filter(s): 3G14 Alternator: 3I17 Altimeter: 3G22 Gauge: 3G14 Combustion Heater: 4E12 Ammeters: 3H10 Pump: 3G16 Bench Tests: 4E20 Battery: 3J12...
  • Page 24 PIPER SENECA SERVICE MANUAL GRIDS 1B6 THRU 1B24 INTENTIONALLY BLANK PAGE 6 INDEX Oct 30/03...

  • Page 25: Airworthiness Limitations

    PIPER SENECA SERVICE MANUAL SECTION AIRWORTHINESS LIMITATIONS...
  • Page 26 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...
  • Page 27 PIPER SENECA SERVICE MANUAL SECTION I LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE I-List of Oct 30/03 Effective Pages Oct 30/03 I-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 I - LIST OF EFFECTIVE PAGES...
  • Page 28 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 I - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 29 PIPER SENECA SERVICE MANUAL SECTION I - AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. AIRWORTHINESS LIMITATIONS Limitations Inspections Life Limited Parts Marking and Disposition I - CONTENTS PAGE 1 Oct 30/03...
  • Page 30 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 I - CONTENTS Oct 30/03...
  • Page 31 Parts that have accumulated the life limit shall be dispositioned of in accordance with the applicable FARs. Piper recommends life limited parts with no time and/or cycles remaining be completely destroyed.
  • Page 32 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 I - AIRWORTHINESS LIMITATIONS Oct 30/03...

  • Page 33: Handling And Servicing

    PIPER SENECA SERVICE MANUAL SECTION HANDLING AND SERVICING...
  • Page 34 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 1C10...

  • Page 35: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION II LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE II-List of Oct 30/03 II (cont.) Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 II-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 36 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 II - LIST OF EFFECTIVE PAGES Oct 30/03 1C12...
  • Page 37 PIPER SENECA SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. HANDLING AND SERVICING 1C15 Introduction 1C15 Dimensions 1C15 Station Reference Lines 1C15 Weight and Balance Data 1C15 Serial Number Plate 1C15 Access and Inspection Provisions...
  • Page 38 PIPER SENECA SERVICE MANUAL SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS (continued) SUBJECT SECTION PAGE GRID NO. Hydraulic System 1D18 Servicing Hydraulic System 1D18 Servicing Hydraulic Pump/Reservoir 1D18 Battery 1D18 Servicing Battery 1D18 Cleaning 1D18 Engine Compartments 1D18...
  • Page 39 PIPER SENECA SERVICE MANUAL HANDLING AND SERVICING WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) INTRODUCTION. This section contains routine handling and servicing procedures that are most frequently encountered.
  • Page 40 PIPER SENECA SERVICE MANUAL Three View Figure 1 PAGE 2 II - HANDLING AND SERVICING Oct 30/03 1C16...
  • Page 41 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 1 of 4) LEADING PARTICULARS MODEL PA-34-200 ENGINE Manufacturer Lycoming Model- Left IO-360-C1E6 (CW) Model - Right LIO-360-C1E6 (CCW) FAA Type Certificate TC1E10 Rated Horsepower 200 HP Rated Speed 2700 RPM Fuel Consumption, Cruise 75% Rated Power (Both Engines) 20.6 GPH...
  • Page 42 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 2 of 4) LEADING PARTICULARS MODEL PA-34-200 ENGINE (cont.) Spark Plugs (Shielded): SR-86 Champion REM-38E Spark Plug Gap Setting See Lycoming Service Instruction 1042F Firing Order 1—3—2—4 Tachometer Drive, Ratio to Crankshaft 0.500: 1...
  • Page 43 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 3 of 4) LEADING PARTICULARS MODEL PA-34-200 PROPELLER Manufacturer Hartzell Hub and Blade Model: Right Engine HC-C2YK-2( )LE/JC7666A-0 HC-C2YK-2( )LEU/JC7666A-0 (1) HC-C2YK-2( )LEF/FJC7666A-0 HC-C2YK-2( )LEFU/FJC7666A-0 (1) HC-C2YK-2CLG(F)/(F)JC7666A (2) HC-C2YK-2CLGU(F)/(F)JC7666A (1 & 2) Left Engine...
  • Page 44 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 4 of 4) LEADING PARTICULARS MODEL PA-34-200 LANDING GEAR Type Fully Retractable Shock Strut Type Air-Oil Oleo Fluid Required (Struts, Brakes & Hydraulic System) MIL-H-5606 Strut Exposure (Exposure under static load): Nose 2.60 ± .25 In.
  • Page 45 PIPER SENECA SERVICE MANUAL Station Reference Lines Figure 2 II - HANDLING AND SERVICING PAGE 7 1C21 Oct 30/03...
  • Page 46 PIPER SENECA SERVICE MANUAL Access Plates and Panels Figure 3 (Sheet 1 of 2) PAGE 8 II - HANDLING AND SERVICING Oct 30/03 1C22...
  • Page 47 PIPER SENECA SERVICE MANUAL Access Plates and Panels Figure 3 (Sheet 2 of 2) II - HANDLING AND SERVICING PAGE 9 1C23 Oct 30/03...

  • Page 48: Torque Wrenches

    PIPER SENECA SERVICE MANUAL Torque Wrench Formula Figure 4 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.
  • Page 49 PIPER SENECA SERVICE MANUAL TABLE II (Sheet 1 of 2) RECOMMENDED NUT TORQUES TORQUES: The importance of correct application can not be CHART B overemphasized. Undertorque can result in unnecessary wear of nuts and bolts as well as the parts they are holding together. When insufficient...
  • Page 50 PIPER SENECA SERVICE MANUAL TABLE II (Sheet 2 of 2) RECOMMENDED NUT TORQUES FINE THREAD SERIES BOLTS BOLTS BOLTS Steel Tension Steel Tension Aluminum AN 3 THRU AN 20 MS 20004 THRU MS 20024 AN 3DD THRU AN 20DD AN 42 THRU AN 49...
  • Page 51 PIPER SENECA SERVICE MANUAL CAUTION: DO NOT OVERTORQUE FITTINGS. TABLE III FLARE FITTING TORQUE VALUES TORQUE — INCH-POUNDS TUBING ALUMINUM - ALLOY STEEL TUBING HOSE END FITTING TUBING FLARE - AND FLARE INCHES 10061 OR AND 10078 AND 10061 HOSE ASSEMBLIES...

  • Page 52: Ground Handling

    PIPER SENECA SERVICE MANUAL Jacking Figure 5 STEP, HANDHOLD, AND WALKWAYS. A fixed handhold is located on the right side of the fuselage, above and aft of the second window. The walkway is made up of a non-skid material which is in turn bonded to the wing surface.
  • Page 53 PIPER SENECA SERVICE MANUAL Weighing Figure 6 13. WEIGHING. (Refer to Figure 6.) The airplane may be weighed by the following procedure: Position a scale and ramp in front of each of the three wheels. Secure the scales from rolling forward and tow the airplane up onto the scales. (Refer to Towing, Paragraph 18.)
  • Page 54 PIPER SENECA SERVICE MANUAL Leveling Figure 7 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...
  • Page 55 PIPER SENECA SERVICE MANUAL 16. LOCKING AIRPLANE. The right cabin door is provided with a key lock on the outside. The cabin door lock and nose baggage compartment door lock use the same key. 17. PARKING. When parking the airplane, insure that it is sufficiently protected against adverse weather conditions and presents no danger to other aircraft.
  • Page 56 PIPER SENECA SERVICE MANUAL Turning Distance Figure 8 PAGE 18 II - HANDLING AND SERVICING Oct 30/03...

  • Page 57: External Power Receptacle

    PIPER SENECA SERVICE MANUAL 20. EXTERNAL POWER RECEPTACLE. CAUTION: TURN MASTER SWITCH OFF BEFORE INSERTING OR REMOVING PLUG. 20a. OPERATION OF EXTERNAL POWER RECEPTACLE. The external power receptacle is located on the left side of the nose section. When using external power for starting or operation of any of the airplane’s equipment, the master switch must be ON.
  • Page 58 PIPER SENECA SERVICE MANUAL Service Points Figure 9 PAGE 20 II - HANDLING AND SERVICING Oct 30/03 1D10...

  • Page 59: Brake System

    PIPER SENECA SERVICE MANUAL 27. DRAINING MOISTURE FROM FUEL SYSTEM. To facilitate draining the fuel system gascolators, lines and tanks of moisture and foreign matter, drains are incorporated in the bottom of the systems lowest point (see Figure 10 for 100 Hour Inspection) and the inboard end of each fuel tank.
  • Page 60 PIPER SENECA SERVICE MANUAL Fuel Drain Valve 100 Hour Inspection Figure 10 PAGE 22 II - HANDLING AND SERVICING Oct 30/03 1D12...
  • Page 61 PIPER SENECA SERVICE MANUAL WARNING: DO NOT RELEASE AIR BY REMOVING THE STRUT VALVE CORE OR FILLER PLUG. DEPRESS THE VALVE CORE PIN UNTIL THE STRUT CHAMBER PRESSURE HAS DIMINISHED. CAUTION: DIRT AND FOREIGN PARTICLES COLLECT AROUND THE FILLER PLUGS OF THE...
  • Page 62 PIPER SENECA SERVICE MANUAL With the airplane still on jacks, compress and extend the gear piston tube several times to ascertain that the strut will operate freely. The weight of the gear. wheel and fork should allow the piston tube to extend.
  • Page 63 PIPER SENECA SERVICE MANUAL 36. INFLATING OLEO STRUTS. After making certain that an oleo strut has sufficient fluid, attach a strut pump to the air valve and inflate the oleo strut. The strut should be inflated (i.e. - Main = 250 psi;...

  • Page 64: Tire Balance

    PIPER SENECA SERVICE MANUAL 37. TIRES. The tires should be maintained at the pressure specified in Table I. When checking tire pressure, examine the tires for wear, cuts, bruises and slippage. The tire, tube, and wheel should be balanced when installed. Align the index mark on the tire with the index mark on the tube.
  • Page 65 PIPER SENECA SERVICE MANUAL Wheel Balancer Figure 11 (2) Release the tire. If it is out of balance it will rotate, coming to rest with the heaviest point on the bottom. Tape a one-half (1/2) ounce patch across top center of the tire. Rotate the tire 45° and release it again.
  • Page 66 PIPER SENECA SERVICE MANUAL 39. HYDRAULIC SYSTEM. 40. SERVICING HYDRAULIC SYSTEM. The hydraulic pump and landing gear actuating cylinders should be checked for leaks, tightness of line fittings and general condition. The cylinder rods are to be free of all dirt and grit.

  • Page 67: Cleaning Windshield And Windows

    PIPER SENECA SERVICE MANUAL 46. CLEANING LANDING GEAR. Before cleaning the landing gear, place a plastic cover or similar material over the wheel and brake assembly. Place a pan under the gear to catch waste. Spray or brush the gear area with solvent or a mixture of solvent and degreaser, as desired. It may be necessary to brush areas that were sprayed where heavy grease and dirt deposits have collected in order to clean them.

  • Page 68: Cleaning Headliner, Side Panels And Seats

    PIPER SENECA SERVICE MANUAL 49. CLEANING HEADLINER, SIDE PANELS AND SEATS. Clean headliner, side panels and seats with a stiff bristle brush and vacuum where necessary. CAUTION: SOLVENT CLEANERS REQUIRE ADEQUATE VENTILATION. Soiled upholstery, except leather, may be cleaned by using an approved air type cleaner or foam upholstery cleaner.

  • Page 69: Oil Filter. (Full Flow.)

    PIPER SENECA SERVICE MANUAL 58. OIL FILTER. (FULL FLOW.) The oil filter element should be replaced after each 50 hours of engine operation; this is accomplished by removing the lockwire from the bolt-head at the end of the filter housing, loosening the bolt, and removing the filter assembly from the adapter.
  • Page 70 PIPER SENECA SERVICE MANUAL GRIDS 1D22 THRU 1D24 INTENTIONALLY BLANK PAGE 32 II - HANDLING AND SERVICING Oct 30/03 1D22...
  • Page 71 PIPER SENECA SERVICE MANUAL 61. LUBRICATION INSTRUCTIONS. Proper lubrication procedures are of immeasurable value both as a means of prolonging the service life of the airplane and as a means of reducing the frequency of extensive and expensive repairs. The periodic application of recommended lubricants to their relevant bearing surfaces, as detailed in the following paragraphs, together with the observance of cleanliness, will insure the maximum efficiency and utmost service of all moving parts.
  • Page 72 PIPER SENECA SERVICE MANUAL 64. LUBRICATION CHART. (See Figure 12.) Each part of the airplane to be lubricated, is indicated by an item number which is keyed to the legend. Adjacent to each item number is a frequency symbol which indicates the lubrication interval.
  • Page 73 PIPER SENECA SERVICE MANUAL Lubrication Chart Figure 12 (Sheet 2 of 5) II - HANDLING AND SERVICING PAGE 35 Oct 30/03...
  • Page 74 PIPER SENECA SERVICE MANUAL Lubrication Chart Figure 12 (Sheet 3 of 5) PAGE 36 II - HANDLING AND SERVICING Oct 30/03...

  • Page 75: Specification

    PIPER SENECA SERVICE MANUAL TYPE OF LUBRICANT LUBRICANT CODE SPECIFICATION AIR TEMPERATURE LUBRICANT MIL-PRF-7870C LUBRICATING OIL, GENERAL PURPOSE, LOW TEMPERATURE MIL-L-22851 SAE 15W50 OR 20W50 (ASHLESS DISPERSANT) ABOVE 80°F (27°C) SAE 60 ABOVE 60°F (16°C) SAE 40 OR 50 30° TO 90°F (-1° TO 32°C) SAE 40 0°...
  • Page 76 PIPER SENECA SERVICE MANUAL CAUTIONS DO NOT USE HYDRAULIC FLUID WITH A CASTOR OIL OR ESTER BASE. DO NOT OVER-LUBRICATE COCKPIT CONTROLS. DO NOT APPLY LUBRICANT TO RUBBER PARTS. DO NOT OIL CONTROL CABLES. SPECIAL INSTRUCTIONS AIR FILTER - TO CLEAN FILTER, TAP GENTLY TO REMOVE DIRT PARTICLES. DO NOT BLOW OUT WITH COMPRESSED AIR OR USE OIL.

  • Page 77: Consumable Materials

    PIPER SENECA SERVICE MANUAL 65. CONSUMABLE MATERIALS. See Table V. 66. VENDOR CONTACT INFORMATION. See Table VI. 67. CONVERSION TABLES. The following charts contain various conversion data that may be useful when figuring capacities, lengths, temperatures, and various weights and measures from the English system to the metric system...
  • Page 78 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 40 II - HANDLING AND SERVICING Oct 30/03...
  • Page 79 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 1 of 8) CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR ABS-Solvent/ Solarite, #11 Series Solar Compounds Corp. Cements Adhesive EC 801 Minnesota Mining and EC 807 Manufacturing EC 1357 Adhesive Coating and Scotch Grip 210...
  • Page 80 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 2 of 8) CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR Epoxy Patching Solarite #400 Solar Compounds Corp. Compound Gasket Cement Permatex No. 2 Permatex Company, Inc. Grease, Actuator 2196-74-1 Dukes Astronautics Co. Grease, Aircraft...
  • Page 81 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 3 of 8) CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR Grease, Ball and MIL-G-18709 Regal ASB-2 Formula Texaco Incorporated Roller Bearing TG-10293 Andok B Exxon Company, U.S.A. Code 1-20481, Darina Shell Oil Company Grease 1 XSG-6213...
  • Page 82 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 4 of 8) CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR Grease, Aircraft MIL-G-7711 Regal AFB2 Regal Texaco Incorporated General Purpose Starfak Premium PED 3040 Standard Oil of Calif. Aeroshell Grease 6 Shell Oil Company...
  • Page 83 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 5 of 8) CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR Hydraulic Fluid MIL-H-5606 Brayco 756D Bray Oil Company TL-5874 Texaco Incorporated PED 3565 Standard Oil Company of California Aircraft Hydraulic Texaco Incorporated Oil AA...
  • Page 84 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 6 of 8) CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR Oil Lubricating, MIL-L-7870 Caltex Low Temp. Caltex Oil Products General Purpose, Company Low Temperature Sinclair Aircraft Sinclair Refining Orbit Lube Company 1692 Low Temp Oil...
  • Page 85 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 7 of 8) CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR Sealant, Fuel BJO-0930, Phenolic Union Carbide Plastics Tank Sealing (continued) Balloons Division ERL-2795, Epoxy Resin 22LA-0340 Polyamid Hardener Class A-2 Thiokol MC-236 Sealant, Fuselage Class A-1/2, A-2, B-2 H.S.
  • Page 86 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 8 of 8) CONSUMABLE MATERIALS MATERIAL SPECIFICATION PRODUCT VENDOR Solvents Methylethyl Ketone Local Suppliers Methylene Chloride Acetone Y2900 Union Carbide; Plastic Division Fed. Spec. PD 680 Local Supplier Type I - Stoddard Solvent...
  • Page 87 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK II - HANDLING AND SERVICING PAGE 49 1E17 Oct 30/03...
  • Page 88 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 50 II - HANDLING AND SERVICING Oct 30/03 1E18...
  • Page 89 PIPER SENECA SERVICE MANUAL TABLE VI (Sheet 1 of 2) VENDOR CONTACT INFORMATION CRC Industries Goodrich Corporation 885 Louis Drive (See listing in Introduction, American Gas and Warminster, PA 18974-0586 Supplementary Publications, Chemical Co. LTD 800-272-8963 Vendor Publications.) 220 Pegasus Avenue www.crcindustries.com/...
  • Page 90 PIPER SENECA SERVICE MANUAL TABLE VI (Sheet 2 of 2) VENDOR CONTACT INFORMATION Sun Oil Company of Penna 5 Penn Center Plaza Miller-Stephenson Radiator Specialty Co. Philadelphia, PA 19103 George Washington Hwy P.O. Box 34689 215-972-2000 Danbury, CT 06810 Charlotte, NC 28234...
  • Page 91 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK II - HANDLING AND SERVICING PAGE 53 1E21 Oct 30/03...
  • Page 92 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 54 II - HANDLING AND SERVICING Oct 30/03 1E22...
  • Page 93 PIPER SENECA SERVICE MANUAL TABLE VII DECIMAL CONVERSIONS II - HANDLING AND SERVICING PAGE 55 1E23 Oct 30/03...
  • Page 94 PIPER SENECA SERVICE MANUAL TABLE VIII TEMPERATURE CONVERSION CENTIGRADE - FAHRENHEIT Example: To convert 20°C, to Fahrenheit, find 20 in the center column headed (°F - °C); then read 68.0°F, in the column (°F) to the right. To convert 20°F, to Centigrade;...
  • Page 95 PIPER SENECA SERVICE MANUAL TABLE IX WEIGHTS AND MEASURES CONVERSION MULTIPLY TO OBTAIN MULTIPLY TO OBTAIN CENTIMETERS 0.3937 KILOGRAMS 2.205 0.03281 35.27 1000 GRAMS CU. CENTIMETERS 0.001 LITERS 0.06102 CU. IN. LITERS 1000 CU. CM. 0.0002642 U.S. GAL. 61.03 CU. IN.

  • Page 96: Metric Conversion

    PIPER SENECA SERVICE MANUAL TABLE X METRIC CONVERSION Example: Convert 1.5 inches to millimeters. (1) Read down inches column to 1. inches. (2) Read across top inch column to 0.5. (3) Read down and across to find millimeters (1.5 inches is 38.10 millimeters).
  • Page 97 PIPER SENECA SERVICE MANUAL TABLE XI DRILL SIZES Decimal/Millimeter Equivalents of Drill Sizes From 1/2" to No. 80 Size Decimal Millimeter Size Decimal Millimeter Size Decimal Millimeter Size Decimal Millimeter Equiv. Equiv. Equiv. Equiv. Equiv. Equiv. Equiv. Equiv. 0.500 12.7000 0.261...
  • Page 98 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 60 II - HANDLING AND SERVICING Oct 30/03...
  • Page 99 PIPER SENECA SERVICE MANUAL SECTION INSPECTION...
  • Page 100 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...

  • Page 101: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION III LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE III-List of Oct 30/03 IiI (cont.) Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 III-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 102 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 III - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 103 PIPER SENECA SERVICE MANUAL SECTION III - INSPECTION TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. INSPECTION 1F11 General 1F11 Time Limits 1F13 Scheduled Maintenance 1F15 Description 1F15 Definitions 1F15 Inspection Requirements 1F17 Annual / 100 Hour Inspection 1F17 Progressive Inspection...
  • Page 104 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 III - CONTENTS Oct 30/03 1F10...
  • Page 105 DIrectives” link at “www1.faa.gov”. Additionally, Avantext offers a free email notification service for new AD’s as well as the last six weeks worth of AD’s at “www.avantext.com”. An owner should periodically check with a Piper Service Center to find out the latest information to keep his aircraft up to date.
  • Page 106 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 III - INSPECTION Oct 30/03 1F12...

  • Page 107: Time Limits

    Refer to paragraph 8 for Piper’s recommended Inspection Programs. They include the frequency and extent of the inspections required for the continued airworthiness of these airplanes.
  • Page 108 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 III - INSPECTION Oct 30/03 1F14...
  • Page 109 Inspection. A Progressive Inspection Program is available from Piper Dealers in a separate manual form. Piper inspection programs comply with the F.A.A. Federal Aviation Regulations Parts 43, 91 and 135. The owner/operator is primarily responsible for maintaining the airplane in an airworthy condition, including compliance with all applicable Airworthiness Directives and conformity with the requirements in FAR 91.409, 91.411 and 91.413.
  • Page 110 Each bench test will be performed by a Piper Service Center, FAA Certified Repair Station with appropriate rating or by a certified mechanic. This test will be performed at the scheduled interval regardless of any bench test performed on a particular component while being repaired/overhauled before scheduled interval bench test.

  • Page 111: Inspection Requirements

    This schedule is prepared in a manual form, which is available from Piper Dealers as P/N 761-499, 50 Hour Progressive Inspection Manual. Refer to Piper's Customer Service Information Aerofiche P/N 1761-755 for a checklist to ensure obtaining latest issue.
  • Page 112 (2) Refer to the applicable section of this manual for instructions on how to gain access to remove any item that must be removed and is not completely accessible. To help in the performance of periodic inspections, Inspection Report forms are available through Piper Dealers as P/N 230-208.
  • Page 113 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK III - INSPECTION PAGE 9 1F19 Oct 30/03...
  • Page 114 PIPER SENECA SERVICE MANUAL GRIDS 1F20 THRU 1F24 INTENTIONALLY BLANK PAGE 10 III - INSPECTION Oct 30/03 1F20...

  • Page 115: Scheduled Maintenance

    PIPER SENECA SERVICE MANUAL SCHEDULED MAINTENANCE - PA-34-200 Inspection Time (Hrs) NATURE OF INSPECTION 500 1000 PROPELLER GROUP WARNING: USE EXTREME CAUTION WHEN ROTATING PROPELLER BY HAND; PROPELLER MAY KICK BACK. PRIOR TO ROTATING PROPELLER ENSURE BOTH MAGNETO SWITCHES ARE OFF (GROUNDED).

  • Page 116: Engine Group

    PIPER SENECA SERVICE MANUAL SCHEDULED MAINTENANCE - PA-34-200 (continued) Inspection Time (Hrs) NATURE OF INSPECTION 500 1000 ENGINE GROUP WARNING: IF MAGNETOS ARE NOT GROUNDED, TURNING PROPELLER MAY START ENGINE. USE EXTREME CAUTION WHEN ROTATING PROPELLER BY HAND; PROPELLER MAY KICK BACK. PRIOR TO ROTATING PROPELLER ENSURE BOTH MAGNETO SWITCHES ARE OFF (GROUNDED).
  • Page 117 CAUTION: THE ONLY DRY AIR PUMP MOUNTING GASKET AUTHORIZED AND APPROVED FOR USE WITH THE ORIGINAL EQUIPMENT AIRBORNE DRY AIR PUMP IS THE AIRBORNE GASKET B3-1-2, PIPER P/N 751-859. USE OF ANY OTHER GASKET MAY RESULT IN OIL SEEPAGE OR LEAKAGE AT THE MOUNTING SURFACE.

  • Page 118: Cabin And Cockpit Group

    PIPER SENECA SERVICE MANUAL SCHEDULED MAINTENANCE - PA-34-200 (continued) Inspection Time (Hrs) NATURE OF INSPECTION 500 1000 ENGINE GROUP (CONT.) 43. Inspect rubber engine mount bushings for deterioration. (Replace as required.) ................44. Inspect fire wall seals ................45. Inspect condition and tension of alternator drive belt ......

  • Page 119: Fuselage And Empennage Group

    PIPER SENECA SERVICE MANUAL SCHEDULED MAINTENANCE - PA-34-200 (continued) Inspection Time (Hrs) NATURE OF INSPECTION 500 1000 CABIN AND COCKPIT GROUP (CONT.) 17. Inspect and test ELT per FAR 91.207. (See Testing, ELT, Section XII.) 18. Inspect operation of fuel selector valves ..........
  • Page 120 PIPER SENECA SERVICE MANUAL SCHEDULED MAINTENANCE - PA-34-200 (continued) Inspection Time (Hrs) NATURE OF INSPECTION 500 1000 FUSELAGE AND EMPENNAGE GROUP (CONT.) 20. Inspect rudder trim mechanism. (See Note 21.)........21. Inspect stabilator for surface damage or irregularities (i.e. - skin cracks, distortion, dents, corrosion, and excessive paint build up);...
  • Page 121 PIPER SENECA SERVICE MANUAL SCHEDULED MAINTENANCE - PA-34-200 (continued) Inspection Time (Hrs) NATURE OF INSPECTION 500 1000 WING GROUP (CONT.) 4. Inspect ailerons for surface damage or irregularities (i.e. - skin cracks, distortion, dents, corrosion, and excessive paint build up); structural defects (i.e. - loose or missing rivets); misrigging or structural imbalance;...

  • Page 122: Landing Gear Group

    NATURE OF INSPECTION 500 1000 LANDING GEAR GROUP NOTE: Verify compliance with all later revisions of Piper Service Bulletin No. 1123. This 10/30/03 revision of this manual incorporates and supercedes the original 5/7/03 issue of Piper Service Bulletin No. 1123. See also AD 93-24-14.
  • Page 123 PIPER SENECA SERVICE MANUAL SCHEDULED MAINTENANCE - PA-34-200 (continued) Inspection Time (Hrs) NATURE OF INSPECTION 500 1000 LANDING GEAR GROUP (CONT.) 20. Remove triangular shaped, nose gear strut servicing access panel located in the forward baggage compartment floor: Inspect nose tiller roller, steering arm channel and tiller track for condition ..................

  • Page 124: Operational Inspection

    PIPER SENECA SERVICE MANUAL SCHEDULED MAINTENANCE - PA-34-200 (continued) Inspection Time (Hrs) NATURE OF INSPECTION 500 1000 SPECIAL INSPECTIONS See paragraph 9..................O OPERATIONAL INSPECTION Note: Refer to Note 26 prior to starting engine or taxiing airplane. 1. Check fuel pump and fuel tank selector and crossfeed operation..O 2.
  • Page 125 SCHEDULED MAINTENANCE - PA-34-200 (continued) NOTES Refer to Piper's Customer Service Information Aerofiche P/N 1753-755 for latest revision dates to Piper Inspection Reports/Manuals and this maintenance manual. References to Section (i.e. - “See Section II.”) are to the corresponding Section in this manual.
  • Page 126 16. Verify compliance with Piper Service Bulletin No. 965. See also AD 96-10-3. 17. Verify compliance with Piper Service Bulletin No. 475. 18. Verify compliance with Piper Service Bulletin No. 977. (See also Section IV: Figure 2 and 100 Hour Aft Wing Attach Fitting Corrosion Inspection.
  • Page 127 34-7250272, 34-7250280, 34-7250284, 34-7250285, 34-7250287, 34-7250288, 34-7250291, 34-7250292, and 34-7250294 thru 347250297 only, verify installation of two (2) ten amp circuit breakers (P/N 454-707), for the left and right electric fuel pumps, per Piper Service Bulletin No. 364A. In serial numbers 34-7250001 thru 34-7250335 only, verify compliance with Piper Service Bulletin No.
  • Page 128 45. Verify compliance with Piper Service Bulletin No. 579. See also AD 80-9-4. 46. Verify compliance with Piper Service Bulletin No. 899. See also AD 92-8-4. 47. Verify compliance with Piper Service Bulletin No. 836A. For airplanes which have no record of compliance, see Section XI, Aluminum Wiring.
  • Page 129 Piper Service Bulletin No. 1134, Lycoming Service Bulletin No. 557, or Precision Airmotive Service Bulletin No. PRS-105. 63. Verify compliance with Piper Service Bulletin No. 1130 or the installation of Kit No. 767-369. III - INSPECTION PAGE 25...
  • Page 130 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 26 III - INSPECTION Oct 30/03 1G16...

  • Page 131: Special Inspections

    Inspection, Section VIII. See also AD 73-14-2. Each 50 Hours For those airplanes which have not installed either Kit No. 767-357 or 767-358 per Piper Service Bulletin No. 1123: inspect Actuator Mounting Bracket for wear, cracks, loose rivets, and elongation of the .250 dia.
  • Page 132 PIPER SENECA SERVICE MANUAL Each 400 Hours At every 400 hours of engine operation, remove the rocker box covers and check for freedom of valve rockers when valves are closed. Look for evidence of abnormal wear or broken parts in the area of the valve tips, valve keepers, springs, and spring seats.
  • Page 133 PIPER SENECA SERVICE MANUAL Per Calendar Year Each Six (6) Months If annual usage is significantly less than 100 Hours, lubricate propeller each six (6) months. See Hartzell Standard Practices Manual No. 202A. Each One (1) Year Lubricate propeller every 100 Hours or annually, whichever comes first. If annual usage is significantly less than 100 Hours, lubricate propeller each six (6) months.
  • Page 134 PIPER SENECA SERVICE MANUAL Each Ten (10) Years Each ten (10) years time-in-service, test fuselage and wing fluid hoses to system pressure. Visually inspect for leaks. Hoses that pass inspection may remain in service, but must be rechecked each five (5) years additional time-in-service.
  • Page 135 PIPER SENECA SERVICE MANUAL (2) Operation in High Salt or High Humidity Environment Item Inspection Inspection Interval Fuselage, Empennage Remove floor panels and exterior 200 Hours. and Wings. access plates; inspect for corrosion. Landing Gear. Inspect for corrosion and lubrication.
  • Page 136 PIPER SENECA SERVICE MANUAL (4) Operation from Soft or Unusual Terrain Item Inspection Inspection Interval Landing Gear. Inspect for cracks, attachment, 100 Hours. damage, cleanliness and lubrication. Wheels. Inspect for cracks, damage, chipped 100 Hours. rims; bearings for damage, corrosion and lubrication.
  • Page 137 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK III - INSPECTION PAGE 33 1G23 Oct 30/03...
  • Page 138 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 34 III - INSPECTION Oct 30/03 1G24...

  • Page 139: Unscheduled Maintenance Checks

    PIPER SENECA SERVICE MANUAL 10. UNSCHEDULED MAINTENANCE CHECKS. WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) The following inspections are required in response to specific anomalies encountered during aircraft operation.
  • Page 140 Make a preliminary inspection of checking alignment and out-of-track condition of engine, wings, tail, landing gear and doors. Follow Piper and Textron-Lycoming Maintenance Manual procedures. If there are any questions regarding repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA).
  • Page 141 PIPER SENECA SERVICE MANUAL Severe Turbulence, Hard or Overweight Landing. (continued) Item Inspection Inspection Interval Wings. Wing attach bolts for slippage, damage Each occurrence, and overstress. Upper and lower wing before further flight. skins for wrinkles, cracks, popped or loose rivets.
  • Page 142 MANUFACTURER'S MAINTENANCE MANUAL, AND FAR PART 43. PAY PARTICULAR ATTENTION TO SILT, CORROSION AND CONTAMINANTS. (2) Follow Piper and Textron-Lycoming Maintenance Manual procedures. If there are any questions regarding repairs or procedures, contact your Piper Dealer’s Service Advisor (DSA). (3) Determine the water level on the aircraft. Determine which operating and/or electrical components have been exposed to the water.
  • Page 143 PIPER SENECA SERVICE MANUAL Flood Damage, Immersion in Water. (continued) Item Inspection Inspection Interval Engine. Remove, disassemble, and inspect. If immersed, each event, Examine all parts paying particular before further flight. attention for evidence of corrosion, rust or contaminants imbedded on...
  • Page 144 PIPER SENECA SERVICE MANUAL Flood Damage, Immersion in Water. (continued) Item Inspection Inspection Interval Electrical Systems. Replace all circuit breakers and If immersed, each event, switches. before further flight. Replace all solenoids, relays and master contactors. Replace battery. Disassemble all connectors; clean and inspect for corrosion.
  • Page 145 PIPER SENECA SERVICE MANUAL Flood Damage, Immersion in Water. (continued) Item Inspection Inspection Interval Vacuum and Pitot-Static Replace gyros. If immersed, each event, Systems. before further flight. Replace filters. Clean and inspect all lines, and pitot and static vents. Clean and check all regulating valves.
  • Page 146 PIPER SENECA SERVICE MANUAL Flood Damage, Immersion in Water. (continued) Item Inspection Inspection Interval Avionics Systems. Replace avionics. If immersed, each event, before further flight. Clean and inspect antennas and connectors. Insulation and Upholstery. Remove all wet insulation and upholstery.
  • Page 147 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK III - INSPECTION PAGE 43 Oct 30/03...
  • Page 148 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 44 III - INSPECTION Oct 30/03 1H10...
  • Page 149 PIPER SENECA SERVICE MANUAL SECTION STRUCTURES 1H11...
  • Page 150 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 1H12...

  • Page 151: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION IV LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE IV-List of Oct 30/03 Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 IV-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 152 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 IV - LIST OF EFFECTIVE PAGES Oct 30/03 1H14...
  • Page 153 PIPER SENECA SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. STRUCTURES 1H19 Introduction 1H19 Description 1H19 Wing Group 1H19 Wing Tip 1H19 Removal 1H19 Repair 1H19 Installation 1H22 Aileron 1H22 Removal 1H22 Installation 1H22...
  • Page 154 PIPER SENECA SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS (cont.) SUBJECT SECTION PAGE GRID NO. Cabin (Aft) Door Window 1I18 Removal 1I18 Installation 1I18 Cockpit and Cabin Doors 1I20 Removal 1I20 Installation 1I20 Adjustment 1I20 Door Latch Mechanism - Lower...
  • Page 155 PIPER SENECA SERVICE MANUAL SECTION IV - STRUCTURES TABLE OF CONTENTS (cont.) SUBJECT SECTION PAGE GRID NO. Safety Walk Repair Liquid Safety Walk Compound Surface Preparation Product Listing Application Pressure Sensitive Safety Walk Surface Preparation Application Control Surface Balancing Checking...
  • Page 156 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 IV - CONTENTS Oct 30/03 1H18...

  • Page 157: Wing Group

    PIPER SENECA SERVICE MANUAL STRUCTURES INTRODUCTION. This section explains the removal and installation procedures for the structural surfaces of the airplane. For the removal, installation, and rigging and adjustment procedures of the flight control components of the various structural surfaces, refer to Section V.
  • Page 158 PIPER SENECA SERVICE MANUAL Aileron and Flap Installation Figure 1 (Sheet 1 of 2) PAGE 2 IV - STRUCTURES Oct 30/03 1H20...
  • Page 159 PIPER SENECA SERVICE MANUAL Aileron and Flap Installation Figure 1 (Sheet 2 of 2) IV - STRUCTURES PAGE 3 1H21 Oct 30/03...

  • Page 160: Installation

    PIPER SENECA SERVICE MANUAL INSTALLATION. Place the wing tip in a position that the navigation light leads may be connected. Connect the ground lead to the wing rib by use of a screw and nut, and the positive lead to the navigation light by connecting the wire terminals or screwing the connectors together.
  • Page 161 If sealing windows, use P/N 279-058 Sealant (Bostik 1100 FS) or equivalent. If using insulation other than Piper original material, be sure that the insulation is flame resistant and conforms to FAR Part 23.853.
  • Page 162 Assess the job before beginning to determine if additional steps or additional parts may be necessary. Consult the parts catalog for additional parts as required. Technical support is available through the nearest Piper Dealer’s Service Advisor (DSA). Remove electrical power from aircraft by disconnecting the battery.
  • Page 163 PIPER SENECA SERVICE MANUAL 15. REMOVAL OF WING. (Refer to Figure 3.) Close the fuel valve and drain the fuel from the wing to be removed. (Refer to Draining Fuel System, Section II.) Drain the brake lines and reservoir. (Refer to Draining Brake System, Section II.) Remove the engine from the wing to be removed.
  • Page 164 PIPER SENECA SERVICE MANUAL BOLT LEGEND WASHER POSITION BOLT UNDER HEAD UNDER NUT NAS464P6LA17 MS21042-6 AN960-616 AN960-616 (2 Max) NAS464P6LA16 MS21042-6 AN960-616 AN960-616 (2 Max) NAS464P6LA16 MS21042-6 AN960-616 AN960-616 (2 Max) NAS464P6LA16 MS21042-6 AN960-616 AN960-616 (2 Max) NAS464P6LA16 MS21042-6 AN960-616...
  • Page 165 PIPER SENECA SERVICE MANUAL Wing Installation Figure 3 (Sheet 2 of 2) IV - STRUCTURES PAGE 9 Oct 30/03...
  • Page 166 PIPER SENECA SERVICE MANUAL 16. INSTALLATION OF WING. (Refer to Figure 3.) Ascertain that the fuselage is positioned solidly on a support cradle. Place the wing in position for installation, with the spar end a few inches from the side of the fuselage and set on trestles.
  • Page 167 PIPER SENECA SERVICE MANUAL Service and refill the brake system with hydraulic fluid in accordance with Servicing Brake System, Section II. Bleed the system as given in Section VII and check for fluid leaks. Check the fluid level of the landing gear hydraulic system and fill in accordance with Servicing Hydraulic Pump/Reservoir, Section II.
  • Page 168 PIPER SENECA SERVICE MANUAL 17. EMPENNAGE GROUP. NOTE: Before entering the aft portion of the fuselage, attach a stand to the tail skid for support; and with the use of a heavy pad, protect the inside of the fuselage. Be certain to distribute weight on top of the bulkheads so as not to damage the fuselage skin.
  • Page 169 PIPER SENECA SERVICE MANUAL 19. REMOVAL. (Refer to Figure 5.) CAUTION: AT EACH REMOVAL OF THE STABILATOR, CONDUCT ATTACH BRACKETS CORROSION CONTROL INSPECTION, BELOW. NOTE: Should it be necessary to move the rudder to its extreme left or right for clearance, do so with the use of the rudder pedals or tow bar.
  • Page 170 PIPER SENECA SERVICE MANUAL Empenage Installation Figure 5 (Sheet 1 of 2) PAGE 14 IV - STRUCTURES Oct 30/03...
  • Page 171 PIPER SENECA SERVICE MANUAL Empenage Installation Figure 5 (Sheet 2 of 2) IV - STRUCTURES PAGE 15 Oct 30/03...
  • Page 172 PIPER SENECA SERVICE MANUAL Methods of Securing Control Cables Figure 6 20. INSTALLATION. (Refer to Figure 5.) WARNING: ALL CONTROL SURFACES THAT HAVE BEEN REPLACED OR REPAINTED MUST BE BALANCED BEFORE INSTALLATION PER INSTRUCTIONS IN BALANCING, BELOW. NOTE: A clearance of .25 ± .06 of an inch between the stabilator and the side of the fuselage and .18 of an inch minimum between all parts of the stabilator and the tail cone assembly must be maintained throughout the stabilator travel.
  • Page 173 PIPER SENECA SERVICE MANUAL 21. STABILATOR TRIM TAB. CAUTION: CONTROL SURFACE SKINS MUST BE REPLACED IF THEY SUSTAIN DAMAGE OR EXHIBIT CRACKS. 22. REMOVAL. (Refer to Figure 5.) Disconnect the stabilator trim control rod by removing the bolts that attach the control rod to the stabilator trim tab.

  • Page 174: Rudder Trim Tab

    PIPER SENECA SERVICE MANUAL Connect the tail position light electrical lead at the quick disconnect and cover me connector with an insulating sleeve. Tie both ends of the sleeve with number six electrical lacing twine. Connect me control cables to the rudder horn with bolts, washers, nuts and cotter pins.
  • Page 175 PIPER SENECA SERVICE MANUAL 32. INSTALLATION. (Refer to Figure 5.) Insert the vertical fin into position and install the bolts, washers and nuts that secure the fin spar to the aft bulkhead. Install the bolt and washer that attaches the leading edge of the fin to the fuselage.
  • Page 176 PIPER SENECA SERVICE MANUAL 33. FUSELAGE ASSEMBLY. 34. WINDSHIELD. 35. REMOVAL. (Refer to Figure 7.) Remove the collar molding from around the bottom of the windshield by removing attaching screws. Remove the trim strip from between the windshield halves by removing attaching screws.
  • Page 177 PIPER SENECA SERVICE MANUAL Windshield Installation Figure 7 IV - STRUCTURES PAGE 21 1I15 Oct 30/03...

  • Page 178: Side Windows

    PIPER SENECA SERVICE MANUAL Side Window Installation (Typical) Figure 8 37. SIDE WINDOWS. 38. REMOVAL. (Refer to Figure 8.) Remove the retainer molding from around the window by removing attachment screws. At the forward end of both the right and left window that is adjacent to the second row of seats, the window retainer is riveted in place and need not be removed.
  • Page 179 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK IV - STRUCTURES PAGE 23 1I17 Oct 30/03...
  • Page 180 NOTE: Repair Kit, part number 757-023, contains all materials necessary to replace the cabin door window and is available through Piper Aircraft Dealers or Distributors. Temporarily position new retainer. Using a 1/8-inch drill, drill 16 holes around the inner panel assembly using the holes in the retainer as pilot holes.
  • Page 181 PIPER SENECA SERVICE MANUAL Cabin (Aft) Door Window Installation Figure 9 IV - STRUCTURES PAGE 25 1I19 Oct 30/03...

  • Page 182: Installation

    PIPER SENECA SERVICE MANUAL Place new retainer into position and secure with 16 screws and washers (AN96-06). Carefully invert the door. Apply a bead of Bostik 1100FS (Urethane), P/N 279-058; or, 3M Marine Sealant 101, P/N 279-177, sealing compound to the outer perimeter of the window. Allow sealant to dry before reinstalling door.
  • Page 183 PIPER SENECA SERVICE MANUAL 48. ADJUSTMENT. To adjust the door latch, loosen the screws on the striker plate, make necessary adjustment, and retighten the screws. 48a. DOOR LATCH MECHANISM - UPPER (I.E. - AUXILIARY/SAFETY). 49. REMOVAL. Remove screw and handle from top outer surface of door.
  • Page 184 PIPER SENECA SERVICE MANUAL GRIDS 1I22 THRU 1I24 INTENTIONALLY BLANK PAGE 28 IV - STRUCTURES Oct 30/03 1I22...
  • Page 185 PIPER SENECA SERVICE MANUAL 54. BAGGAGE DOORS. 54a. FORWARD BAGGAGE DOOR LATCH. 54b. PRE/POST-FLIGHT INSPECTION. (See Figure 10.) Prior to each flight, during the preflight inspection, and after each flight: NOTE: The postflight inspection is required in order to determine the integrity of the door latch and locking mechanism after flight since the possibility exists that any discrepancy could go undetected during routine removal of any baggage by ground personnel.
  • Page 186 54c. DOOR LATCH INSPECTION AND RIGGING. Upon condition as determined by pre/post-flight inspection, above: NOTE: The following procedures assume compliance with Piper Service Bulletins 447, 633B, and 872. Examine the inside and outside of the forward baggage door along the hinge and along all inner stiffening sections for evidence of cracks or delamination of the figerglass.
  • Page 187 PIPER SENECA SERVICE MANUAL Forward Baggage Door Latch Inspection Figure 10 (Sheet 2 of 3) IV - STRUCTURES PAGE 31 Oct 30/03...
  • Page 188 NOTE: The one (1) inch minimum drawbolt extension dimension given herein supercedes the 1.5 inch dimension previously given in Piper Service Bulletin No. 633B. (a) With the door open, the latch mechanism turned to the full closed position and locked, turn the latch counter-clockwise to take up the “back lash”...
  • Page 189 PIPER SENECA SERVICE MANUAL (c) When the drawbolts are extended into the closed position, the shoulders of the bolts should not prematurely contact the guide bushing (i.e. - create pre-tensioning/springback in push rods). (d) Re-rigging the engagement of the drawbolts is facilitated by adjusting the fork end. Minimum thread engagement of the push rod is .40 inches.
  • Page 190 PIPER SENECA SERVICE MANUAL Door Snubber Installation Figure 11 (Sheet 1 of 2) PAGE 34 IV - STRUCTURES Oct 30/03...
  • Page 191 PIPER SENECA SERVICE MANUAL Door Snubber Installation Figure 11 (Sheet 2 of 2) IV - STRUCTURES PAGE 35 Oct 30/03...
  • Page 192 PIPER SENECA SERVICE MANUAL 60a. DOOR SNUBBERS. Door snubber seals have been incorporated in the three door jambs to improve on door sealing. For those aircraft equipped as such, the following procedure should be used. If snubbers are not installed, the “Field Kit For Improved Sealing” (763-993V), should be consulted for installation if so desired.
  • Page 193 PIPER SENECA SERVICE MANUAL Seat Back Lock Figure 12 Wait at least one day for the bond to cure and DO NOT allow door to close. The bond will cure more efficiently with the door left open and a maximum cure age will be effected.
  • Page 194 Figure 13 61b. REAR SEAT QUICK-DISCONNECT MECHANISM INSPECTION. (See Figure 13.) NOTE: This inspection incorporates the requirements of Piper Service Letter No. 763 as referenced in AD 75-24-3. Inspection. Each 100 hours or at each annual inspection, whichever comes first, inspect the quick- disconnect mechanism for each rear seat as follows: (1) With one hand, grasp the lower rear portion of the seat and lift up.
  • Page 195 PIPER SENECA SERVICE MANUAL 62. STRUCTURAL REPAIRS. Structural repair methods used must be in accordance with the procedures set forth in latest revision of FAA Advisory Circular 43.13-1; ACCEPTABLE METHODS, TECHNIQUES, AND PRACTICES, AIRCRAFT INSPECTION AND REPAIR. To assist in making repairs, Figure 14 identifies the type and thickness of skin structure used.
  • Page 196 PIPER SENECA SERVICE MANUAL Skin Material and Thickness Figure 14 (Sheet 1 of 2) PAGE 40 IV - STRUCTURES Oct 30/03 1J12...
  • Page 197 PIPER SENECA SERVICE MANUAL Skin Material and Thickness Figure 14 (Sheet 2 of 2) IV - STRUCTURES PAGE 41 1J13 Oct 30/03...

  • Page 198: Fiberglass Touch-Up And Surface Repairs

    Paragraph 65 describes Fracture and Patch Repairs such as puncture, breaks and holes that have penetrated through the structure and damaged the fiberglass cloth. A repair kit, part number 756-729, that will furnish the necessary material for such repairs is available through Piper Distributors.
  • Page 199 PIPER SENECA SERVICE MANUAL Metal Wire Stitching Repair Figure 15 IV - STRUCTURES PAGE 43 1J15 Oct 30/03...

  • Page 200: Fiberglass Fracture And Patch Repairs

    PIPER SENECA SERVICE MANUAL Allow the gel to cure 10 to 15 minutes until it feels rubbery to the touch. Remove the cellophane and trim flush with the surface, using a sharp razor blade or knife. Replace the cellophane and allow to cure completely for 30 minutes to an hour.
  • Page 201 PIPER SENECA SERVICE MANUAL Remove cardboard or aluminum sheet from outside of hole and rough-sand the patch and edge of hole. Feather edge of hole about two inches into undamaged area. Mask area around hole with tape and paper to protect surface. Cut a piece of fiberglass mat about one inch larger than the hole and one or more pieces of fiberglass cloth two inches larger than the hole.
  • Page 202 PIPER SENECA SERVICE MANUAL TABLE I LIST OF MATERIALS - THERMOPLASTIC REPAIR Buffing and Rubbing Automotive Type - DuPont #7 DuPont Company Compounds Wilmington, Del. 19898 Ram Chemical #69 x I Ram Chemicals Gardena, Cal. 90248 Mirror Glaze #l Mirror Bright Polish Co., Inc.
  • Page 203 PIPER SENECA SERVICE MANUAL Surface Scratches, Abrasions or Ground-in-Dirt Figure 16 Deep Scratches, Shallow Nicks, and Small Holes Figure 17 IV - STRUCTURES PAGE 47 1J19 Oct 30/03...
  • Page 204 PIPER SENECA SERVICE MANUAL Mixing Epoxy Patching Compound Figure 18 Retention Clip Adjustment Figure 19 PAGE 48 IV - STRUCTURES Oct 30/03 1J20...
  • Page 205 PIPER SENECA SERVICE MANUAL Repairing Cracks Figure 20 For repairs in areas involving small holes, indentations or cracks in the material where high stress is apparent or thin walled sections are used, the welding method is suggested. 10. This welding method requires a hot air gun and ASB rods, to weld, the gun should be held to direct the flow of hot air into the fusion (repair) zone, heating the damaged area and rod simultaneously.
  • Page 206 PIPER SENECA SERVICE MANUAL Repairing Major Damage: (Larger than I inch in diameter.) (Refer to Figure 21.) If possible a patch should be made of the same material and cut slightly larger than the section being repaired. When appearances are important, large holes, cracks, tears, etc. should be repaired by cutting out the damaged area and replacing it with a piece of similar material.
  • Page 207 PIPER SENECA SERVICE MANUAL Various Repairs Figure 21 IV - STRUCTURES PAGE 51 1J23 Oct 30/03...
  • Page 208 PIPER SENECA SERVICE MANUAL Repair of Stress Lines Figure 22 Repairing Impact Damage Figure 23 PAGE 52 IV - STRUCTURES Oct 30/03 1J24...

  • Page 209: Safety Walk Repair

    PIPER SENECA SERVICE MANUAL 67. SAFETY WALK REPAIR. 67a. LIQUID SAFETY WALK COMPOUND. 68. SURFACE PREPARATION. NOTE: When existing shelf stocks are depleted, see Pressure Sensitive Safety Walk, below. Clean all surfaces with a suitable cleaning solvent to remove dirt, grease and oils. Solvents may be applied by dipping, spraying or mopping.
  • Page 210 PIPER SENECA SERVICE MANUAL 70a. PRESSURE SENSITIVE SAFETY WALK. 71. SURFACE PREPARATION. The areas to which the pressure sensitive safety walk is to be installed must be free from all contaminates and no moisture present. If liquid safety walk is installed the area must be prepared as follows: Area must be masked off to protect painted surfaces.

  • Page 211: Control Surface Balancing

    PIPER SENECA SERVICE MANUAL 73. CONTROL SURFACE BALANCING. WARNING: ALL CONTROL SURFACES THAT HAVE BEEN REPLACED OR REPAINTED MUST BE BALANCED BEFORE INSTALLATION PER INSTRUCTIONS IN BALANCING, BELOW. 74. CHECKING CONTROL SURFACE BALANCE. The movable control surfaces have been statically balanced at the time of installation at the factory and normally should not require rebalancing.
  • Page 212 PIPER SENECA SERVICE MANUAL 75. BALANCING EQUIPMENT. (Refer to Figure 24.) Balancing must be done using a suitable tool capable of measuring unbalance in inch-pounds from the centerline of the control surface hinge pin. See the tool configuration in Figure 24. Other tool configurations may be used if accuracy is maintained and recalibration capability is provided.
  • Page 213 PIPER SENECA SERVICE MANUAL Control Surface Balancing Tool Figure 24 IV - STRUCTURES PAGE 57 Oct 30/03...
  • Page 214 PIPER SENECA SERVICE MANUAL 76. BALANCING AILERONS. (Refer to Figure 25.) Position the aileron on the balancing fixture in a draft free area and in a manner which allows unrestricted movement of the aileron on the hinge bearings. Place the tool on the aileron, avoid rivets and keep the beam perpendicular to the hinge centerline. Calibrate the tool as described in Paragraph 75.
  • Page 215 PIPER SENECA SERVICE MANUAL 77. BALANCING STABILATOR. (Refer to Figure 26.) To balance the stabilator, the assembly must be complete including the trim tab, the tab push rod and end bearing, stabilator tips and all attaching screws. Before balancing, tape the trim tab in neutral position with a small piece of tape. Place the complete assembly on the knife edge supports in a draft free area in a manner that allows unrestricted movement.
  • Page 216 PIPER SENECA SERVICE MANUAL 78. BALANCING RUDDER. (Refer to Figure 27.) To balance the rudder, the assembly must be complete including the tip assembly and all attaching screws, the position light wiring and trim tab and push rod. Tape the trim tab in neutral position with a small piece of tape. Place the complete assembly horizontally on knife edge support in a draft free area in a manner that allows unrestricted movement.
  • Page 217 PIPER SENECA SERVICE MANUAL 79. CHECKING CONTROL SURFACE FREE PLAY. The following checks are recommended before balancing to ascertain the amount of “freeplay” in the stabilator trim tab and aileron: Stabilator: Check the stabilator for any “free play” at its attachment points by grasping each half near the tip and gently trying to move it up and down, fore and aft, and in and out.
  • Page 218 PIPER SENECA SERVICE MANUAL 81. HOSE CLAMP TIGHTENING. The following information is for use upon initial hose installation in the absence of a hose clamp torque-limiting wrench Due to variations in hose clamp design and hose structure, the values given in Table IV are approximate. Therefore, use good judgement when tightening hose clamps by this method NOTE: Since hose connections are subject to “cold flow”...
  • Page 219 PIPER SENECA SERVICE MANUAL Fluid Line Identification Figure 28 IV - STRUCTURES PAGE 63 1K11 Oct 30/03...

  • Page 220: Removal Of Cherrylock Rivets

    PIPER SENECA SERVICE MANUAL 84. REMOVAL OF CHERRYLOCK RIVETS. (See Figure 29.) Should it be necessary to remove an installed cherrylock rivet, the following procedures are recommended: In thick material remove the lock by driving out the rivet stem, using a tapered steel drift pin (See View 1.)
  • Page 221 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK IV - STRUCTURES PAGE 65 1K13 Oct 30/03...
  • Page 222 PIPER SENECA SERVICE MANUAL GRIDS 1K14 THRU 1L24 INTENTIONALLY BLANK PAGE 66 IV - STRUCTURES Oct 30/03 1K14...
  • Page 223 AIRPLANE SERVICE MANUAL CARD 2 OF 4 PA-34-200 (S/N’s 34-7250001 THRU 34-7450220) PIPER AIRCRAFT CORPORATION PART NUMBER 753-817 October 30, 2003...
  • Page 224 Published by Technical Publications © The New Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...

  • Page 225: Aerofiche Effectivity

    PIPER SENECA SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to this Service Manual 753-817 originally issued April 5, 1971 are as follows: Revision Publication Date Aerofiche Card Effectivity ORG710405 April 5, 1971 CR720613 June 13, 1972 CR031030 * October 30, 2003 1, 2, 3, &...
  • Page 226 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Oct 30/03...
  • Page 227 PIPER SENECA SERVICE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE Intro-List of Oct 30/03 Effective Pages Oct 30/03 Intro-Table of Contents Oct 30/03 Oct 30/03 Introduction Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 228 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 229 PIPER SENECA SERVICE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity Serial Number Explanation 2A10 Assignment of Subject Material 2A10 Pagination 2A10 Aerofiche Effectivity 2A10 Identifying Revised Material 2A10 Indexing 2A10 List of Effective Pages...
  • Page 230 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Oct 30/03...

  • Page 231: Instructions For Continued Airworthiness

    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.
  • Page 232 PIPER SENECA SERVICE MANUAL SERIAL NUMBER EXPLANATION. Example: 34 72 50 001 SEQUENCE NUMBER TYPE CERTIFICATE DESIGNATION MODEL YEAR MODEL CODE 50 = PA-34-200 SENECA ASSIGNMENT OF SUBJECT MATERIAL. This publication is divided into logical subject groupings based on aircraft system or task function. Refer to paragraph 14, Section Index Guide, for a complete breakdown and list.
  • Page 233 To improve our Service and Reliability system and aid in our compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
  • Page 234 PIPER SENECA SERVICE MANUAL (4) BRAKES AND WHEELS: Vendor Address: Parker Hannifin Corp - (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/cleveland/Universe/book.pdf (5) ENGINE: Vendor Address: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • Page 235 PIPER SENECA SERVICE MANUAL (10) LANDING GEAR ACTUATOR, EXTENSION AND RETRACTION: Vendor Address: Parker Hannifin Corp - (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/cleveland/ Component (Effective for P/N’s 96860-002 and 96860-003 only.) Maintenance Manual:...
  • Page 236 PIPER SENECA SERVICE MANUAL (14) PROPELLER: Vendor Address: Hartzell Propeller Inc. - (937) 778-4379 One Propellor Place FAX - (937) 778-4321 Piqua, OH 45356-2634 http://www.hartzellprop.com/index2.htm Standard Practices: Manual No. 202A Overhaul and Maintenance: Manual No. 117D Aluminum Blade Overhaul: Manual No. 133C Propeller Owner’s...

  • Page 237: Voltage Regulator

    PIPER SENECA SERVICE MANUAL (18) VACUUM REGULATORS: Vendor Address: Parker Hannifin Corp. PH: - (800) 382-8422 Airborne Division 711 Taylor Street Elyria, Ohio 44035 http://www.parker.com/cleveland/Universe/book.pdf (19) VOLTAGE REGULATOR: Vendor Address: See listing under Alternator, above. INTRODUCTION PAGE 7 2A15 Oct 30/03...
  • Page 238 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Oct 30/03 2A16...
  • Page 239 PIPER SENECA SERVICE MANUAL 14 SECTION INDEX GUIDE. SECTION TITLE GRID NO. AIRWORTHINESS LIMITATIONS HANDLING AND SERVICING INSPECTION STRUCTURES 1H11 SURFACE CONTROLS HYDRAULIC SYSTEM LANDING GEAR AND BRAKES 2G21 VIII POWERPLANT FUEL SYSTEM INSTRUMENTS ELECTRICAL SYSTEM 3H17 ELECTRONICS XIII HEATING AND VENTILATION SYSTEM...
  • Page 240 PIPER SENECA SERVICE MANUAL GRIDS 2A18 THRU 2A24 INTENTIONALLY BLANK PAGE 10 INTRODUCTION Oct 30/03 2A18...
  • Page 241 PIPER SENECA SERVICE MANUAL Schematics Alternators: 3K7 Cabin Access Plates and Panels: 1C22 Anti-Collision Fin-Tip Strobe Heating, Defrost, and Accident/Incident Reporting: A11 Light: 3K16 Ventilation: 4D2 Aerofiche Combustion Heater: 4D16 Consumable Materials: 1E9 Effectivity: A10 Electrical Symbols: 3K3 Conversion Tables...
  • Page 242 PIPER SENECA SERVICE MANUAL Environmental Systems Fuel System: 1D9 E (cont.) Description and Operation: 4D1 Description: 3F7 Engine Optional Combustion Heater: Draining Alternate Air Door Entirely: 1D11 100 Hour Inspection: 3D6 Exploded View: 4E16 Moisture: 1D11 Cowl Flaps: 3C13 Inspections: 4D17...
  • Page 243 PIPER SENECA SERVICE MANUAL Per Specific Operation / Operating Environment.: Landing Gear Ice and Rain Protection: 4F11, 1G20 Cleaning: 1D19 4G15 Extreme Cold: 1G21 Description: 2H3 Ignition System High Dust: 1G20 Electrical Schematic: 2J3 Contact Points: 3D11 High Humidity: 1G21...
  • Page 244 PIPER SENECA SERVICE MANUAL Propeller Rudder L (cont.) Air Charge Pressure vs. 100 Hour Rudder Tab Freeplay Lights Temperature: 3C15 Inspection: 2E14 Exterior: 3J15 Deicing System: 4F11 Balancing Anti-Collision Strobe: 3J18 Deicers: 4G4 Procedure: 1K8 Landing and Taxi: 3J15 Electrical Check: 4G10...
  • Page 245 PIPER SENECA SERVICE MANUAL Troubleshooting Aileron Controls: 2D1 Vacuum System Taxiing: 1D7 Airspeed Indicator: 3G23 Description: 3G12 Testing Alternator: 3I5 Filter(s): 3G14 Alternator: 3I17 Altimeter: 3G22 Gauge: 3G14 Combustion Heater: 4E12 Ammeters: 3H10 Pump: 3G16 Bench Tests: 4E20 Battery: 3J12...
  • Page 246 PIPER SENECA SERVICE MANUAL GRIDS 2B6 THRU 2B24 INTENTIONALLY BLANK PAGE 6 INDEX Oct 30/03...

  • Page 247: Surface Controls

    PIPER SENECA SERVICE MANUAL SECTION SURFACE CONTROLS...
  • Page 248 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...
  • Page 249 PIPER SENECA SERVICE MANUAL SECTION V LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE V-List of Oct 30/03 Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 V-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...

  • Page 250: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 V - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 251 PIPER SENECA SERVICE MANUAL SECTION V - SURFACE CONTROLS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. SURFACE CONTROLS Description and Operation Standard Practices and Procedures Control Cable Inspection 2C12 Control Column Assembly 2C19 Removal 2C19 Installation 2C19 Flex Joint Replacement...
  • Page 252 PIPER SENECA SERVICE MANUAL SECTION V - SURFACE CONTROLS TABLE OF CONTENTS (continued) SUBJECT SECTION PAGE GRID NO. Rudder Trim Controls 2E13 Troubleshooting 2E13 100 Hour Rudder Tab Freeplay Inspection 2E14 Rudder Trim Controls (Forward) 2E14 Removal 2E14 Installation 2E15...

  • Page 253: Description And Operation

    PIPER SENECA SERVICE MANUAL SURFACE CONTROLS DESCRIPTION AND OPERATION. The Seneca is controlled in flight by the use of standard three-axis primary control surfaces, consisting of ailerons, stabilator and rudder. Operation of these controls is through the movement of the control column-tee bar assembly and rudder pedals.

  • Page 254: Control Surface Travel And Cable Tension

    PIPER SENECA SERVICE MANUAL TABLE I (Sheet 1 of 2) CONTROL SURFACE TRAVEL AND CABLE TENSION PAGE 2 V - SURFACE CONTROLS Oct 30/03...
  • Page 255 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 2 of 2) CONTROL SURFACE TRAVEL AND CABLE TENSION V - SURFACE CONTROLS PAGE 3 Oct 30/03...
  • Page 256 PIPER SENECA SERVICE MANUAL TABLE II CABLE TENSION VS. AMBIENT TEMPERATURE -10 -8 Subtract Rigging Load Correction, Pounds PAGE 4 V - SURFACE CONTROLS Oct 30/03 2C10...
  • Page 257 PIPER SENECA SERVICE MANUAL When pushrods or rod ends are provided with an inspection hole, the screw must be screwed in far enough to pass the inspection hole. This can be determined visually or by feel, inserting a piece of wire into the inspection hole.
  • Page 258 PIPER SENECA SERVICE MANUAL 2a. CONTROL CABLE INSPECTION. Aircraft control cable systems are subject to a variety of environmental conditions and forms of deterioration that, with time, may be easy to recognize as wire/strand breakage or the not-so-readily visible types of wear, corrosion, and/or distortion. The following data may help in detecting the presence of these conditions: Cable Damage.
  • Page 259 PIPER SENECA SERVICE MANUAL External Wear Patterns. Wear will normally extend along cable equal to the distance cable moves at that location. Wear may occur on one side of the cable only or on its entire circumference. Replace flexible and non-flexible cables when individual wires in each strand appear to blend together (outer wires worn 40-50 percent) as depicted in Figure 3.
  • Page 260 PIPER SENECA SERVICE MANUAL Internal Cable Wear. As wear is taking place on the exterior surface of a cable, the same condition is taking place internally, particularly in the sections of the cable which pass over pulleys and quadrants. This condition, shown in Figure 4, is not easily detected unless the strands of the cable are separated.
  • Page 261 PIPER SENECA SERVICE MANUAL Cable Maintenance. CAUTION: TO AVOID REMOVAL OF CORROSION-PREVENTATIVE COMPOUNDS AND CABLE INTERNAL LUBRICANT, DO NOT USE VAPOR DEGREASING, STEAM CLEANING, METHYLETHYLKETONE (MEK) OR OTHER SOLVENTS. CAUTION: DO NOT OIL CONTROL CABLES. Frequent inspections and preservation measures such as rust prevention treatments for bare cable areas will help to extend cable service life.
  • Page 262 PIPER SENECA SERVICE MANUAL Pulley Wear Patterns Figure 5 PAGE 10 V - SURFACE CONTROLS Oct 30/03 2C16...
  • Page 263 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK V - SURFACE CONTROLS PAGE 11 2C17 Oct 30/03...
  • Page 264 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 12 V - SURFACE CONTROLS Oct 30/03 2C18...

  • Page 265: Control Column Assembly

    PIPER SENECA SERVICE MANUAL CONTROL COLUMN ASSEMBLY. REMOVAL. (Refer to Figure 6.) To remove either control wheel (5) with tube (4), the following procedure may be used: Separate the control wheel tube (4) from the flexible joint (2) that is located on either side of the tee bar assembly (7) by removing the nut, washer and bolt (3).
  • Page 266 PIPER SENECA SERVICE MANUAL Control Column Installation Figure 6 PAGE 14 V - SURFACE CONTROLS Oct 30/03 2C20...
  • Page 267 PIPER SENECA SERVICE MANUAL Place the control wheels in neutral (centered) position and install the aileron control chains (14 and 16) on the control wheel sprockets (1 and 13) and idler crossover sprockets (15 and 18). The turnbuckle (6) must be centered between the two control wheel sprockets.
  • Page 268 PIPER SENECA SERVICE MANUAL TAPER PIN (P/N 480-730) WASHER (P/N 407-564 [AN960-10]) WASHER (P/N 494-093 [AN975-3]) NUT (P/N 484-835 [MS20364-1032C]) SHAFT (P/N 62716-07) 0.098 DIA. SEE SAFE HOLE TO ENSURE PROPER SHAFT INSERTION Flex (Universal) Joint Assembly Figure 7 5a. FLEX JOINT REPLACEMENT. (See Figures 6 and 7.) Install a replacement control column flex joint as follows: (1) Carefully lay out location for hole to be drilled in flex joint tube to match hole in control column shaft.
  • Page 269 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK V - SURFACE CONTROLS PAGE 17 2C23 Oct 30/03...
  • Page 270 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 18 V - SURFACE CONTROLS Oct 30/03 2C24...

  • Page 271: Aileron Controls

    PIPER SENECA SERVICE MANUAL AILERON CONTROLS. 6a. TROUBLESHOOTING. See Table III. TABLE III TROUBLESHOOTING AILERON CONTROLS Trouble Cause Remedy Lost motion between Cable tension too low. Adjust cable tension. control wheel and aileron. (Refer to Paragraph 11.) Linkage loose or worn.
  • Page 272 PIPER SENECA SERVICE MANUAL REMOVAL. (Refer to Figure 8.) For the removal of any of the control cables in the fuselage or wings, first remove the floor panel that is located directly aft of the main spar by removing the center seats, seat belt attachments and the screws securing the panel.
  • Page 273 PIPER SENECA SERVICE MANUAL INSTALLATION. (Refer to Figure 8.) The installation of either the right or left primary control cable (8 or 9) that is located in the fuselage may be accomplished as follows: Draw the cable through the fuselage floor tunnel.
  • Page 274 PIPER SENECA SERVICE MANUAL Aileron Controls Installation Figure 8 (Sheet 1 of 2) PAGE 22 V - SURFACE CONTROLS Oct 30/03...
  • Page 275 PIPER SENECA SERVICE MANUAL Aileron Controls Installation Figure 8 (Sheet 2 of 2) V - SURFACE CONTROLS PAGE 23 Oct 30/03...

  • Page 276: Rigging And Adjustment Of Aileron Controls

    PIPER SENECA SERVICE MANUAL 8a. AILERON BELLCRANK ASSEMBLY. REMOVAL. (Refer to Figure 8.) Remove the floor panel located directly aft of the main spar by removing the center seats, seat belt attachments and the screws securing the floor panel. Lift the panel and remove from the airplane.
  • Page 277 PIPER SENECA SERVICE MANUAL Aileron Bellcrank Rigging Tool Figure 9 Place the control wheel in the centered position and place the tee bar in the full forward position. Maintain the wheel and tee bar in these positions. The tee bar may be kept in this position by placing weights on the stabilator if the stabilator cables have already been tensioned.
  • Page 278 PIPER SENECA SERVICE MANUAL Adjust the turnbuckles on the primary and balance cables to obtain the proper tension as given in Table I. During adjustment obtain a little more tension on the primary cable to hold the bellcranks in neutral (against the rigging tools), finish with approximately even tension on all cables, and install all pulley guard pins.
  • Page 279 PIPER SENECA SERVICE MANUAL Aileron Rigging Tool Figure 10 Reconnect rudder-aileron interconnect springs. Check control operation, and bolts and turnbuckles for safety and connect interconnecting spring. (Refer to Figure 8, Sketch E.) Install access plates and panels. NOTE: When an out-of-trim condition persists despite all the rigging corrections that can be made, there is a possibility that the trailing edge of the aileron has been used to move the aircraft forward.
  • Page 280 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 28 V - SURFACE CONTROLS Oct 30/03 2D10...

  • Page 281: Stabilator Controls

    PIPER SENECA SERVICE MANUAL 12. STABILATOR CONTROLS. 12a. TROUBLESHOOTING. See Table IV. TABLE IV TROUBLESHOOTING STABILATOR CONTROLS Trouble Cause Remedy Lost motion between control Cable tension too low. Adjust cable tension wheel and stabilator. per Paragraph 15. Linkage loose or worn.
  • Page 282 PIPER SENECA SERVICE MANUAL 13. REMOVAL. (Refer to Figure 11.) To remove either the forward or aft stabilator cables, first remove the access panel to the aft section of the fuselage. Relieve cable tension from control system by loosening one of the cable turnbuckles in the aft section of the fuselage.
  • Page 283 PIPER SENECA SERVICE MANUAL For the right control cable (20), install the cotter pin cable guard at the pulley (1) in the forward area of the tunnel. Within the forward area of the floor opening aft of the main spar, install the cable rub blocks (see Sketch A) to the spar housing and secure the screws.
  • Page 284 PIPER SENECA SERVICE MANUAL Set on a bubble protractor the number of degree up travel as given in Table I and place it on the rigging tool. Raise the trailing edge of the stabilator and determine that when the stabilator contacts its stops, the bubble of the protractor is centered.
  • Page 285 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK V - SURFACE CONTROLS PAGE 33 2D15 Oct 30/03...
  • Page 286 PIPER SENECA SERVICE MANUAL Stabilator and Stabilator Trim Controls Installation Figure 11 (Sheet 1 of 2) PAGE 34 V - SURFACE CONTROLS Oct 30/03 2D16...
  • Page 287 PIPER SENECA SERVICE MANUAL Stabilator and Stabilator Trim Controls Installation Figure 11 (Sheet 2 of 2) V - SURFACE CONTROLS PAGE 35 2D17 Oct 30/03...
  • Page 288 PIPER SENECA SERVICE MANUAL Stabilator Rigging Tool Securing Trim Cables Figure 12 Figure 13 PAGE 36 V - SURFACE CONTROLS Oct 30/03 2D18...

  • Page 289: Stabilator Trim Controls

    PIPER SENECA SERVICE MANUAL 16. STABILATOR TRIM CONTROLS. 16a. TROUBLESHOOTING. See Table V. TABLE V TROUBLESHOOTING STABILATOR TRIM CONTROLS Trouble Cause Remedy Lost motion between trim Cable tension too low. Adjust in accordance control wheel and trim tab. with Paragraph 21.
  • Page 290 PIPER SENECA SERVICE MANUAL 16b. STABILATOR TRIM CONTROLS (FORWARD). 17. REMOVAL. (Refer to Figure 11.) To remove the trim control wheel assembly and/or the trim control cables, first remove the panel to the aft section of the airplane. If the aft trim cable (16) is not to be removed, block the cables at the pulleys (12) in the tail cone to prevent them from unwrapping from the trim drum.
  • Page 291 PIPER SENECA SERVICE MANUAL 18. INSTALLATION. (Refer to Figure 11.) The trim control wheel with drum may be installed by the following procedure: Wrap the right trim cable on the trim drum by inserting the swagged ball of the cable in the slot provided in the side (right side) of the drum that mates with the control wheel, and looking at this side, wrap the drum with three and a half wraps of the cable in a clockwise direction.
  • Page 292 PIPER SENECA SERVICE MANUAL 18a. STABILATOR TRIM CONTROLS (AFT). 19. REMOVAL. (Refer to Figure 11.) Remove the access panel to the aft section of the fuselage. Block the trim cables (19) at the first set of pulleys (5) forward of the cable turnbuckles (17) in the aft section of the fuselage by a method shown in Figure 13.
  • Page 293 PIPER SENECA SERVICE MANUAL Connect the cables (16) to the turnbuckles (17) and remove the blocking from both the forward and aft cables. Set cable tension in accordance with Table I and check rigging and adjustment per paragraph 21, then install the guard pins (22) at the pulleys (12).
  • Page 294 PIPER SENECA SERVICE MANUAL Rudder and Brake Pedal Installation Figure 14 PAGE 42 V - SURFACE CONTROLS Oct 30/03 2D24...

  • Page 295: Rudder Pedal Assembly

    PIPER SENECA SERVICE MANUAL 22. RUDDER PEDAL ASSEMBLY. 22a. TROUBLESHOOTING. See Table VI. TABLE VI TROUBLESHOOTING RUDDER CONTROLS Trouble Cause Remedy Lost motion between Cable tension too low. Adjust cable tension rudder pedals and rudder. per Paragraph 28. Linkage loose or worn.
  • Page 296 PIPER SENECA SERVICE MANUAL 23. REMOVAL. (Refer to Figure 14.) Remove the access panel to the aft section of the fuselage. Relieve rudder and stabilator cable tension by loosening one of the rudder and stabilator cable turnbuckles in the aft section of the fuselage.
  • Page 297 PIPER SENECA SERVICE MANUAL 24. INSTALLATION. (Refer to Figure 14.) Assemble the torque tube assembly as shown in Figure 14. Do not at this time install the two bolts through the center of the tube assembly. Place the upper support blocks (34) on the ends of the torque tube assembly. Note that a washer (17) is required on each end of the tube.

  • Page 298: Rudder Controls

    PIPER SENECA SERVICE MANUAL 24a. RUDDER BAR INSPECTION AND REPAIR. (See Figure 15.) In serial numbers 34-7250001 thru 34-7350129 only, for those aircraft with original configuration rudder bar assemblies: if inspection reveals cracks in the area noted in Figure 15; the rudder bar may be repaired as shown in Figure 15.
  • Page 299 PIPER SENECA SERVICE MANUAL Rudder Bar Inspection and Repair Effectivity Figure 15 34-7250001 thru 34-7350129 V - SURFACE CONTROLS PAGE 47 Oct 30/03...
  • Page 300 PIPER SENECA SERVICE MANUAL 27. INSTALLATION. (Refer to Figure 16.) The forward rudder control cables (2) may be installed by the following procedure: Draw the control cable through the floor tunnel. Connect the end of the cable to the arm on the rudder pedal torque tube (refer to Figure 14) by installing bolt, washer, nut and cotter pin, allowing the cable end to rotate freely.
  • Page 301 PIPER SENECA SERVICE MANUAL Rudder and Rudder Trim Controls Installation Figure 16 (Sheet 1 of 3) V - SURFACE CONTROLS PAGE 49 Oct 30/03...
  • Page 302 PIPER SENECA SERVICE MANUAL Rudder and Rudder Trim Controls Installation Figure 16 (Sheet 2 of 3) PAGE 50 V - SURFACE CONTROLS Oct 30/03...
  • Page 303 PIPER SENECA SERVICE MANUAL Rudder and Rudder Trim Controls Installation Figure 16 (Sheet 3 of 3) V - SURFACE CONTROLS PAGE 51 Oct 30/03...
  • Page 304 PIPER SENECA SERVICE MANUAL 28. RIGGING AND ADJUSTMENT. CAUTION: VERIFY FREE AND CORRECT MOVEMENT OF RUDDER. WHILE IT WOULD SEEM SELF-EVIDENT, FIELD EXPERIENCE HAS SHOWN THAT THIS CHECK IS FREQUENTLY MISINTERPRETED OR NOT PERFORMED AT ALL. ACCORDINGLY, UPON COMPLETION OF RUDDER RIGGING AND ADJUSTMENT, VERIFY THAT THE RUDDER MOVES RIGHT WHEN THE RIGHT PEDAL IS DEPRESSED;...
  • Page 305 PIPER SENECA SERVICE MANUAL Rudder Rigging Tool Rudder Pedals Neutral Figure 17 Figure 18 Clamping Rudder Pedals Figure 19 V - SURFACE CONTROLS PAGE 53 2E11 Oct 30/03...
  • Page 306 PIPER SENECA SERVICE MANUAL Rudder and Stabilator Travel Adjustments Figure 20 PAGE 54 V - SURFACE CONTROLS Oct 30/03 2E12...
  • Page 307 PIPER SENECA SERVICE MANUAL 29. RUDDER TRIM CONTROLS. (Refer to Figure 16.) 29a. TROUBLESHOOTING. See Table VII. TABLE VII TROUBLESHOOTING RUDDER TRIM CONTROLS Trouble Cause Remedy Lost motion between Cable tension too low. Adjust in accordance trim control wheel with Paragraph 34.
  • Page 308 Kit No. 760-800 per Piper Service Letter No. 714, inspect as follows, each 100 hours. With the rudder in the neutral position and the rudder tab trailing edge at least 3/8 inch off center to one side, determine the rudder tab “free play”...
  • Page 309 PIPER SENECA SERVICE MANUAL If the trim control wheel and forward cables (5) are to be removed, block the aft cables (17) aft of the turnbuckles (36) and proceed with the following steps: Remove the tunnel cover in the aft area of the cabin by removing the carpet over the tunnel and the cover attachment screws.
  • Page 310 PIPER SENECA SERVICE MANUAL Install the carpet over the floor tunnel. Install the cover over the trim control wheels and flap handle and secure with screws. 10. Install the seat belts removed from the top of the floor tunnel and secure with bolt, washer and nut.
  • Page 311 PIPER SENECA SERVICE MANUAL Remove the clamp securing the forward trim cables and proceed to rig the system in accordance with paragraph 34. Install the cable guards at the pulley bracket in the fuselage, at station 279.032. Install the access panel and tail cone fairing.
  • Page 312 PIPER SENECA SERVICE MANUAL Check the trim and servo travels by positioning the trim control wheel in the cockpit in neutral and apply pressure to the left rudder pedal until the rudder stop is contacted. NOTE: Do not depress the rudder pedals more than needed to contact the stops, thus avoiding cable stretch.

  • Page 313: Flap Controls

    PIPER SENECA SERVICE MANUAL 35. FLAP CONTROLS. 35a. TROUBLESHOOTING. See Table VIII. TABLE VIII TROUBLESHOOTING FLAP CONTROLS Trouble Cause Remedy Flaps fail to extend Control cable broken Replace or reconnect or retract. or disconnected. control cable. Refer to Paragraph 37.
  • Page 314 PIPER SENECA SERVICE MANUAL Flap Controls Installation Figure 21 PAGE 62 V - SURFACE CONTROLS Oct 30/03 2E20...
  • Page 315 PIPER SENECA SERVICE MANUAL Flap Stop Adjustment Figure 22 Disconnect the flap return spring (18) at the spar or return chain (11) as desired. Disconnect the control cable from the chain (20) by removing cotter pin, nut, and clevis bolt (21).
  • Page 316 PIPER SENECA SERVICE MANUAL Remove the flap handle bracket (29) and trim control wheel cover. Remove the aft heat deflectors on each forward floor tunnel by sliding far enough to release the spring fasteners. Lift the aft section of the tunnel carpet far enough to remove the screws securing the tunnel cover that is between the flap handle and the spar cover.
  • Page 317 PIPER SENECA SERVICE MANUAL The flap control cable (24) may be installed by the following procedure: Attach the cable (24) and turnbuckle (22) to the chain (20) with clevis bolt assembly (21). Ascertain that the turnbuckle end is free to rotate on the chain. If the chain is not installed because of the torque tube assembly being removed, install the assembly in accordance with instructions given in step c.
  • Page 318 PIPER SENECA SERVICE MANUAL Flap Rigging Tool Figure 23 With the flap control rod connected between the torque tube crank arm and the flap check that the surface of the wing contacts the tool at its forward surface and at the spacer, and the aft end of the flap contacts the aft end of the tool.
  • Page 319 PIPER SENECA SERVICE MANUAL Fabricated Aileron Bellcrank Rigging Tool Figure 24 V - SURFACE CONTROLS PAGE 67 Oct 30/03...
  • Page 320 PIPER SENECA SERVICE MANUAL Fabricated Aileron and Flap Rigging Tool Figure 25 PAGE 68 V - SURFACE CONTROLS Oct 30/03...
  • Page 321 PIPER SENECA SERVICE MANUAL Fabricated Stabilator Rigging Tool Figure 26 V - SURFACE CONTROLS PAGE 69 Oct 30/03...
  • Page 322 PIPER SENECA SERVICE MANUAL Fabricated Rudder Rigging Tool Figure 27 PAGE 70 V - SURFACE CONTROLS Oct 30/03...
  • Page 323 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK V - SURFACE CONTROLS PAGE 71 Oct 30/03...
  • Page 324 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 72 V - SURFACE CONTROLS Oct 30/03...

  • Page 325: Hydraulic System

    PIPER SENECA SERVICE MANUAL SECTION HYDRAULIC SYSTEM...
  • Page 326 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...
  • Page 327 PIPER SENECA SERVICE MANUAL SECTION VI LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE VI-List of Oct 30/03 Effective Pages Oct 30/03 VI-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03...

  • Page 328: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 VI - LIST OF EFFECTIVE PAGES Oct 30/03 2F10...
  • Page 329 PIPER SENECA SERVICE MANUAL SECTION VI - HYDRAULIC SYSTEM TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. HYDRAULIC SYSTEM 2F13 Introduction 2F13 Description 2F13 Original Equipment 2F13 Service Replacement 2F13 Troubleshooting 2F14 Hydraulic Pump - Original Equipment - Prestolite Removal...
  • Page 330 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 VI - CONTENTS Oct 30/03 2F12...
  • Page 331 PIPER SENECA SERVICE MANUAL SECTION VI WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) CAUTION: PRIOR TO STARTING ANY INVESTIGATION OF THE HYDRAULIC SYSTEM, PLACE THE AIRPLANE ON JACKS.
  • Page 332 NOTE: Field service of the Oildyne hydraulic pump is limited to motor replacement and removal, cleaning, inspection, and/or replacement of the hydraulic fluid reservoir. Should pump malfunction, replace pump, or return pump to Piper Aircraft via your local Piper distributor for servicing or repairs.

  • Page 333: Troubleshooting Hydraulic System

    PIPER SENECA SERVICE MANUAL TABLE I (Sheet 1 of 4) TROUBLESHOOTING HYDRAULIC SYSTEM Trouble Cause Remedy Landing gear retraction Landing gear actuator Reset circuit breaker system fails to operate. circuit breaker open. and determine cause for open circuit breaker. Landing gear selector Reset circuit breaker circuit breaker open.
  • Page 334 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 2 of 4) TROUBLESHOOTING HYDRAULIC SYSTEM Trouble Cause Remedy Landing gear extension Pump extension solenoid Replace solenoid. system fails to operate. (cont.) inoperative (outboard solenoid). Gear selector switch Check ground. ground incomplete. Gear selector switch Replace switch.
  • Page 335 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 3 of 4) TROUBLESHOOTING HYDRAULIC SYSTEM Trouble Cause Remedy Pump fails to shut off Pressure switch inoperative. Replace switch. though gear has fully retracted. Pressure switch out of Replace switch. adjustment. Pump retraction solenoid Replace solenoid.
  • Page 336 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 4 of 4) TROUBLESHOOTING HYDRAULIC SYSTEM Trouble Cause Remedy Pump running inter- Leakage of high pressure Remove pump and remittently after gear check valve. place check valve. has retracted. Internal leakage of system.
  • Page 337 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VI - HYDRAULIC SYSTEM PAGE 7 2F19 Oct 30/03...
  • Page 338 PIPER SENECA SERVICE MANUAL Hydraulic System Schematic Figure 1 (Sheet 1 of 2) PAGE 8 VI - HYDRAULIC SYSTEM Oct 30/03 2F20...
  • Page 339 PIPER SENECA SERVICE MANUAL Hydraulic System Schematic Figure 1 (Sheet 2 of 2) VI - HYDRAULIC SYSTEM PAGE 9 2F21 Oct 30/03...
  • Page 340 PIPER SENECA SERVICE MANUAL Hydraulic System Installation Figure 2 PAGE 10 VI - HYDRAULIC SYSTEM Oct 30/03 2F22...
  • Page 341 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VI - HYDRAULIC SYSTEM PAGE 11 2F23 Oct 30/03...
  • Page 342 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 12 VI - HYDRAULIC SYSTEM Oct 30/03 2F24...
  • Page 343 HYDRAULIC PUMP - ORIGINAL EQUIPMENT - PRESTOLITE. (See Figures 3, 4, and 5.) WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) REMOVAL.
  • Page 344 PIPER SENECA SERVICE MANUAL Hydraulic Pump - Prestolite Figure 3 PAGE 14 VI - HYDRAULIC SYSTEM Oct 30/03...

  • Page 345: Cleaning, Inspection And Repair

    PIPER SENECA SERVICE MANUAL CLEANING, INSPECTION AND REPAIR. NOTE: Repair facilities must be clean to prevent contamination of pump components. Proper and careful handling should be exercised to prevent damaging pump components. Discard all O-rings. Remove caps or plugs and clean all components with a dry type cleaning solvent and dry thoroughly.
  • Page 346 PIPER SENECA SERVICE MANUAL TABLE II LEADING PARTICULARS, HYDRAULIC SYSTEM Hydraulic Pump Prestolite Oildyne High Pressure 2000 to 2500 psi 2400 ± 200 psi Low Pressure 650 ± 150 psi 600 ± 200 psi Flow Rate @ 1000 psi 45 cu. in. per min.
  • Page 347 PIPER SENECA SERVICE MANUAL Attach the pump base to the pump as follows: With pump inverted, lubricate O-ring seals and install them in recesses provided in the valve and gear case (15). Install attaching bolts with washers and torque to 70-inch pounds.
  • Page 348 PIPER SENECA SERVICE MANUAL Test/Adjust - Hydraulic Pump - Prestolite Figure 4 PAGE 18 VI - HYDRAULIC SYSTEM Oct 30/03...
  • Page 349 PIPER SENECA SERVICE MANUAL Pump Mounting - Prestolite Figure 5 10. Connect the blue lead from the pump motor to the positive terminal of the power supply. With high pressure indication within 2000 to 2500 psi range on the pressure gauge, the ammeter should read 75 amperes maximum.
  • Page 350 Field service of Oildyne hydraulic pump is limited to motor replacement and removal, inspection, cleaning, and replacement of the hydraulic fluid reservoir. Should the pump/adapter assembly malfunction, either replace pump, or return pump to Piper, via the local Piper distributor, for servicing or repairs.
  • Page 351 PIPER SENECA SERVICE MANUAL Hydraulic Pump - Oildyne Figure 6 (Sheet 1 of 2) VI - HYDRAULIC SYSTEM PAGE 21 Oct 30/03...
  • Page 352 PIPER SENECA SERVICE MANUAL Hydraulic Pump - Oildyne Figure 6 (Sheet 2 of 2) PAGE 22 VI - HYDRAULIC SYSTEM Oct 30/03 2G10...
  • Page 353 PIPER SENECA SERVICE MANUAL Installation. (a) If bracket was removed from pump mount, install bracket to Piper pump mount with four MS24693-S298 screws. (b) Position pump assembly on bracket so that tapped holes in oildyne adapter align with bolt holes on bracket.

  • Page 354: Installation

    PIPER SENECA SERVICE MANUAL 11. LANDING GEAR FREE-FALL VALVE ASSEMBLY. (Refer to Figure 7.) 12. INSPECTION AND REPAIR. This valve is located directly above the nose wheel actuating cylinder. Inspection is limited to determining if any signs of hydraulic fluid leakage are evident around the seam between the end fitting and valve body, and around the periphery of the piston assembly shaft.
  • Page 355 PIPER SENECA SERVICE MANUAL 15. GEAR ACTUATING CYLINDERS. 15a. NOSE GEAR ACTUATING CYLINDER. (Refer to Figure 8.) 16. REMOVAL. Place airplane on jacks. (Refer to Jacking, Section II.) Disconnect hydraulic lines from actuating cylinder and cover open line ends to prevent contamination.
  • Page 356 PIPER SENECA SERVICE MANUAL Gear Actuating Cylinder Figure 9 End Gland Locking Device Figure 10 PAGE 26 VI - HYDRAULIC SYSTEM Oct 30/03 2G14...
  • Page 357 PIPER SENECA SERVICE MANUAL 17a. MAIN GEAR ACTUATING CYLINDER. 18. REMOVAL. Place airplane on jacks. (Refer to Jacking, Section II.) Disconnect hydraulic lines from actuating cylinder and cover open line ends to prevent contamination. Disconnect gear downlock spring from swivel fitting at upper end of spring.

  • Page 358: Cleaning, Inspection And Repair

    PIPER SENECA SERVICE MANUAL 21. CLEANING, INSPECTION AND REPAIR. Clean cylinder components with a suitable dry type solvent and dry thoroughly. Inspect cylinder assembly for the following: Interior walls of cylinder and exterior surface of the piston for scratches, burrs, corrosion, etc.

  • Page 359: Hydraulic Lines

    PIPER SENECA SERVICE MANUAL 23. HYDRAULIC LINES. 24. REMOVAL AND INSTALLATION. Remove damaged hydraulic lines by disconnecting fittings at both ends and disconnecting where secured by brackets. Refer to Figure 2 as an aid in locating attaching brackets and bends in lines. Provide a small, clean container for draining the lines. Install a new or repaired line in reverse.
  • Page 360 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 30 VI - HYDRAULIC SYSTEM Oct 30/03 2G18...
  • Page 361 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VI - HYDRAULIC SYSTEM PAGE 31 2G19 Oct 30/03...
  • Page 362 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 32 VI - HYDRAULIC SYSTEM Oct 30/03 2G20...

  • Page 363: Landing Gear And Brakes

    PIPER SENECA SERVICE MANUAL SECTION LANDING GEAR AND BRAKES 2G21...
  • Page 364 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 2G22...

  • Page 365: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION VII LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE VII-List of Oct 30/03 Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 VII-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 366 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 VII - LIST OF EFFECTIVE PAGES Oct 30/03 2G24...
  • Page 367 PIPER SENECA SERVICE MANUAL SECTION VII - LANDING GEAR AND BRAKES TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. LANDING GEAR AND BRAKES Introduction Description Troubleshooting Landing Gear System Nose Landing Gear Modified Components Oleo 2H10 Disassembly 2H10 Cleaning, Inspection and Repair...
  • Page 368 PIPER SENECA SERVICE MANUAL SECTION VII - LANDING GEAR AND BRAKES TABLE OF CONTENTS (continued) SUBJECT SECTION PAGE GRID NO. Adjusting Landing Gear Limit Switches Nose Gear Up Limit Switch Down Limit Switch Main Gear Up Limit Switch Down Limit Switch...
  • Page 369 PIPER SENECA SERVICE MANUAL SECTION VII INTRODUCTION. This section contains instructions for overhauling, inspecting and adjusting the various components of the PA-34 landing gear and brake system. Also included are adjustments for the electrical limit, safety and warning switches. See Section VI, Hydraulic System, for information on the landing gear extension and retraction system.
  • Page 370 PIPER SENECA SERVICE MANUAL TROUBLESHOOTING. (See Table I.) Mechanical and electrical troubles peculiar to the landing gear system are listed in Table I. When troubleshooting, first eliminate potential hydraulic malfunctions as listed in Section VI, Table I. Then proceed to switch malfunctions and last to the mechanical operation of the gear itself, both of which are included in this section.
  • Page 371 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 1 of 3) TROUBLESHOOTING LANDING GEAR Trouble Cause Remedy Green gear down lights Failed instrument panel Replace switch. dim though position light control switch. light switch is off, (Lights grounding through and gear is down and dimming resistor instead locked.
  • Page 372 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 2 of 3) TROUBLESHOOTING LANDING GEAR Trouble Cause Remedy Nose landing gear Internal wear in Replace shimmy shimmies during fast centering springs. dampener. taxi, take-off, or landing. Centering springs or Replace necessary parts.
  • Page 373 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 3 of 3) TROUBLESHOOTING LANDING GEAR Trouble Cause Remedy Main landing gear Tire out of balance. Check balance and re shimmies during fast place tire if necessary. taxi, take-off, or landing. Worn or loose wheel Replace and/or adjust bearings.
  • Page 374 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 6 VII - LANDING GEAR & BRAKES Oct 30/03...
  • Page 375 NOTE: Installation of either Kit No. 767-357 or 767-358 relieves the actuator mount bracket 50 hour inspection requirement. Turn-stop boss failure on the strut upper tube assembly P/N 95720. Install Piper Kit No. 767-368 to add a Turn Limit Indicator. VII - LANDING GEAR & BRAKES PAGE 7...

  • Page 376: Cleaning, Inspection And Repair

    PIPER SENECA SERVICE MANUAL 5b. OLEO. (Refer to Figure 1.) CAUTION: PLACE THE AIRPLANE ON JACKS BEFORE PERFORMING WORK ON THE LANDING GEAR WHICH INVOLVES DISASSEMBLY OR REQUIRES RAISING OR LOWERING THE GEAR. DISASSEMBLY. The nose gear oleo assembly may be removed and disassembled from the trunnion assembly with gear removed from or installed in the airplane.
  • Page 377 PIPER SENECA SERVICE MANUAL Nose Gear Oleo Strut Assembly Figure 1 (Sheet 1 of 2) VII - LANDING GEAR & BRAKES PAGE 9 2H11 Oct 30/03...
  • Page 378 PIPER SENECA SERVICE MANUAL Nose Gear Oleo Strut Assembly Figure 1 (Sheet 2 of 2) PAGE 10 VII - LANDING GEAR & BRAKES Oct 30/03 2H12...
  • Page 379 PIPER SENECA SERVICE MANUAL Lubricate inner walls of oleo cylinder with hydraulic fluid. Carefully insert piston strut into cylinder far enough to permit positioning of washer (36) and snap ring (37). (Refer to paragraph b above.) Install torque links (33) using appropriate hardware.
  • Page 380 PIPER SENECA SERVICE MANUAL Nose Gear Installation Figure 2 (Sheet 1 of 3) PAGE 12 VII - LANDING GEAR & BRAKES Oct 30/03 2H14...
  • Page 381 PIPER SENECA SERVICE MANUAL Nose Gear Installation Figure 2 (Sheet 2 of 3) VII - LANDING GEAR & BRAKES PAGE 13 2H15 Oct 30/03...
  • Page 382 PIPER SENECA SERVICE MANUAL Nose Gear Installation Figure 2 (Sheet 3 of 3) PAGE 14 VII - LANDING GEAR & BRAKES Oct 30/03 2H16...
  • Page 383 PIPER SENECA SERVICE MANUAL Nose Gear Trunnion Inspection Figure 3 VII - LANDING GEAR & BRAKES PAGE 15 2H17 Oct 30/03...
  • Page 384 PIPER SENECA SERVICE MANUAL 10. CLEANING, INSPECTION AND REPAIR. WARNING: DO NOT ATTEMPT TO REMOVE THE SPRING FROM THE SHAFT ASSEMBLY OF THE NOSE GEAR CENTERING SPRING ASSEMBLY. THIS SPRING IS HELD UNDER COMPRESSION BY TWO BUSHINGS AND TWO PINS WITH FUSED HEADS.
  • Page 385 PIPER SENECA SERVICE MANUAL 11. INSTALLATION AND RIGGING. (Refer to Figure 2.) CAUTION: WHEN ASSEMBLING ANY UNITS OF THE LANDING GEAR; LUBRICATE BEARINGS, BUSHINGS, AND FRICTION SURFACES WITH THE PROPER LUBRICANT AS DESCRIBED IN SECTION II. Position the landing gear assembly between the mounting points, ensuring that the tiller assembly (5) roller is properly inserted into the steering arm channel (4).
  • Page 386 PIPER SENECA SERVICE MANUAL Nose Gear Service Tolerances Figure 4 (Sheet 1 of 3) PAGE 18 VII - LANDING GEAR & BRAKES Oct 30/03 2H20...
  • Page 387 PIPER SENECA SERVICE MANUAL Item Manufactured Service Service Part No. Nomenclature Dimension Dimension Tolerance Remarks (1) I.D. .312 67012-00 Torque link I.D. 312 .002 .313 .314 67012-00 Torque link I.D. .3760 I.D. .3765 .002 .3745 .3745 (3) I.D. .252 31796 Bushing, torque link I.D.
  • Page 388 PIPER SENECA SERVICE MANUAL Item Manufactured Service Service Part No. Nomenclature Dimension Dimension Tolerance Remarks (3) I.D. .441 95061-32 Bushing, drag link I.D. .442 .004 assembly, lower .438 .438 452-540 Bearing (bushing), I.D. .376 I.D. .377 .002 (FF-520-10) steering arm, .375...
  • Page 389 PIPER SENECA SERVICE MANUAL Let the gear free fall to determine that the downlock spring returns the body end of the retraction cylinder aft so the downlock link assembly is fully retracted and the drag link arms are overcenter. With the nose gear turned full left and right against the stops, check and if necessary, adjust the clearance between the steering arm channel assembly (4) and tiller track (37).
  • Page 390 PIPER SENECA SERVICE MANUAL Clamping Rudder Pedals in Neutral Rudder Pedals at Neutral Angle Figure 5 Figure 6 PAGE 22 VII - LANDING GEAR & BRAKES Oct 30/03 2H24...

  • Page 391: Installation

    PIPER SENECA SERVICE MANUAL 12a. DOOR. (Refer to Figure 2.) 13. REMOVAL. With nose gear extended, disconnect door retraction rods (18) from doors (19) by removing attaching hardware. To remove doors, straighten bent end of hinge pins and pull the pins out from the opposite end.
  • Page 392 PIPER SENECA SERVICE MANUAL 16. ADJUSTMENT. (See Figure 2.) Place airplane on jacks. With link assembly and retraction rods adjusted per paragraph 15, above, the gear should swing through the door opening with a clearance of .25 inch between the gear and door at their closest point.

  • Page 393: Main Landing Gear

    PIPER SENECA SERVICE MANUAL 17. MAIN LANDING GEAR. 17a. OLEO. (See Figure 7.) 18. DISASSEMBLY. The main gear oleo assembly may be removed and disassembled from the trunnion (i.e. - strut housing) with the gear removed from or installed in the airplane.
  • Page 394 PIPER SENECA SERVICE MANUAL Main Gear Oleo Strut Assembly Figure 7 (Sheet 1 of 2) PAGE 26 VII - LANDING GEAR & BRAKES Oct 30/03...
  • Page 395 PIPER SENECA SERVICE MANUAL Main Gear Oleo Strut Assembly Figure 7 (Sheet 2 of 2) VII - LANDING GEAR & BRAKES PAGE 27 Oct 30/03...
  • Page 396 19a. MAIN GEAR TRUNNION (I.E. - OLEO STRUT HOUSING) INSPECTION. Airplanes which have installed main landing gear trunnions P/N 67926-030 or 67926-031 (both of which can be identified by the embossed forging number 025599-2) per Piper Service Bulletin No. 787C: Required inspection is included as part of the routine 100 hour visual inspection of the gear for condition and security.
  • Page 397 PIPER SENECA SERVICE MANUAL Main Gear Trunnion Inspection Figure 8 VII - LANDING GEAR & BRAKES PAGE 29 Oct 30/03...
  • Page 398 PIPER SENECA SERVICE MANUAL 20. ASSEMBLY. (Refer to Figure 5.) Determine that all parts are cleaned and inspected. To install the piston tube plug (26), first lubricate the plug O-ring (27) with hydraulic fluid (MIL-H-5606) and install it on the plug. Lubricate the inside wall of the tube. Insert the plug into the top of the tube (25) and push it to the fork end.
  • Page 399 20b. MAIN GEAR TRUNNION ATTACH FITTINGS INSPECTION. For those airplanes which have not installed main landing gear trunnion attach fittings P/N 67040-014, 67040-015, and two (2) P/N’s 67042-013 per Piper Service Bulletin No. 956: each 100 hours inspect as follows: Using a calibrated torque wrench, verify that the torque on all four (4) attachment bolts on each of the four (4) main gear trunnion attach fittings is between 50 to 70 in.
  • Page 400 PIPER SENECA SERVICE MANUAL Main Gear Installation Figure 9 (Sheet 1 of 3) PAGE 32 VII - LANDING GEAR & BRAKES Oct 30/03 2I10...
  • Page 401 PIPER SENECA SERVICE MANUAL Main Gear Installation Figure 9 (Sheet 2 of 3) VII - LANDING GEAR & BRAKES PAGE 33 2I11 Oct 30/03...
  • Page 402 PIPER SENECA SERVICE MANUAL Main Gear Installation Figure 9 (Sheet 3 of 3) PAGE 34 VII - LANDING GEAR & BRAKES Oct 30/03 2I12...
  • Page 403 PIPER SENECA SERVICE MANUAL The aft attach fitting (1) may be removed by holding the nuts in position, reaching through the access opening, and removing the four bolts. The forward attach fitting (16) may be removed from the arm of the trunnion by removing the bolt and washer from the base side of the fitting.
  • Page 404 PIPER SENECA SERVICE MANUAL 23. INSTALLATION. (Refer to Figure 9.) NOTE: When assembling components of the landing gear, lubricate bearings, bushings and friction surfaces with proper lubricant as described in Section II. Insert a gear support bearing (53 and 54) in each attach fitting (1 or 16) and secure with snap rings (2).
  • Page 405 PIPER SENECA SERVICE MANUAL 24. ADJUSTMENT. Place the airplane on jacks. Level the airplane laterally and longitudinally. (Refer to Leveling, Section II.) Disconnect the gear door actuating rods at either the door or the trunnion, as desired, by removing the rod attachment bolt. Secure the door out of the way.
  • Page 406 PIPER SENECA SERVICE MANUAL Main Gear Service Tolerances Figure 10 (Sheet 1 of 3) PAGE 38 VII - LANDING GEAR & BRAKES Oct 30/03 2I16...
  • Page 407 PIPER SENECA SERVICE MANUAL Item Manufactured Service Service Part No. Nomenclature Dimension Dimension Tolerance Remarks 67514-0 Link, upper side brace * I.D. .3645 I.D. .3647 .004 .3625 .3623 63900-89 Bushing, * I.D. .251 I.D. .252 .004 Press fit. truss assembly .249...
  • Page 408 PIPER SENECA SERVICE MANUAL Item Manufactured Service Service Part No. Nomenclature Dimension Dimension Tolerance Remarks 67926-04/-30 Trunnion, I.D. .4410 I.D. .4410 .003 67926-05/-31 torque link attachment .4430 .4440 67026-07 (2 ea.) Bushing, trunnion * I.D. .314 I.D. .315 Press Fit. Install .313...
  • Page 409 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VII - LANDING GEAR & BRAKES PAGE 41 2I19 Oct 30/03...
  • Page 410 PIPER SENECA SERVICE MANUAL 25. ALIGNMENT. (Refer to Figure 11 and Table II.) Place a straightedge no less than twelve feet long across the front of both main landing gear wheels. Butt the straightedge against the tire at the hub level of the landing gear wheels. Jack the airplane up just high enough to obtain a six and one-half inch dimension between the center line of the strut piston and the center line of the center pivot bolt of the gear torque links.
  • Page 411 PIPER SENECA SERVICE MANUAL Aligning Main Gear Figure 11 VII - LANDING GEAR & BRAKES PAGE 43 2I21 Oct 30/03...
  • Page 412 PIPER SENECA SERVICE MANUAL If a new link on the top left main gear had to be installed or it had to be reversed during the alignment check, it will be necessary to check the gear safety switch (squat switch) bracket for engagement and locking in place.

  • Page 413: Cleaning, Inspection And Repair

    PIPER SENECA SERVICE MANUAL 25a. DOOR. 26. REMOVAL. With the landing gear extended, disconnect the door retraction rod from the door by removing nut, washers and bolt. Remove the door from the wing panel by bending the door hinge pin straight and from the other end pulling out the pin.
  • Page 414 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 46 VII - LANDING GEAR & BRAKES Oct 30/03 2I24...
  • Page 415 PIPER SENECA SERVICE MANUAL 30. ADJUSTING LANDING GEAR LIMIT SWITCHES. NOTE: All adjustments of the limit switches should be made with the airplane on jacks. Do not bend actuator springs mounted on the limit switches. 30a. NOSE LANDING GEAR. 31. UP LIMIT SWITCH. (See Item 36, Figure 2.) The gear up limit switch is mounted on a bracket attached to the lower inner left tubular member of the nose gear mount, adjacent to the gear roller track assembly or mounted on the stop assembly.
  • Page 416 PIPER SENECA SERVICE MANUAL Nose Gear Down Limit Switch Main Gear Down Limit Switch Figure 12 Figure 13 32a. MAIN LANDING GEAR. 33. UP LIMIT SWITCH. A gear up limit switch is located in each wheel well above the gear door hinge. The red “GEAR UNSAFE”...
  • Page 417 PIPER SENECA SERVICE MANUAL Landing Gear Electrical Schematic Figure 14 VII - LANDING GEAR & BRAKES PAGE 49 Oct 30/03...
  • Page 418 PIPER SENECA SERVICE MANUAL Manually move the hook assembly up from the pin until the hook nearly disengages from the pin. Then with pressure against the bottom of the link assembly, move back to determine that the switch actuates within .025 to .035 inch of full lock.
  • Page 419 PIPER SENECA SERVICE MANUAL Landing Gear Up / Power Reduced Warning Switch Figure 15 41. WHEELS. 41a. NOSE WHEEL. 42. REMOVAL AND DISASSEMBLY. (Refer to Figure 16.) Jack the airplane enough to raise the nose wheel clear of the ground.
  • Page 420 PIPER SENECA SERVICE MANUAL Nose Wheel Assembly Figure 16 43. INSPECTION. Visually check all parts for cracks, distortion, defects and excess wear. Check wheel bolts for stripped or damaged threads. Check internal diameter of felt grease seals. Replace the felt grease seal if surface is hard or gritty.
  • Page 421 PIPER SENECA SERVICE MANUAL Main Wheel Assembly Figure 17 44a. MAIN WHEEL. 45. REMOVAL AND DISASSEMBLY. (Refer to Figure 17.) Place airplane on jacks. To remove main wheel, remove cap bolts joining brake cylinder housing and back plate lining assemblies. Remove back plate from between brake disc and wheel.
  • Page 422 PIPER SENECA SERVICE MANUAL 47. ASSEMBLY AND INSTALLATION. (Refer to Figure 17.) Determine that the bearing cup (10) is properly installed in each wheel half. Install the tire with tube on the outer wheel half (1) and then join two wheel halves. Position the brake disc (3) in the inner wheel half and install wheel bolts (9) with nuts on valve stem side.
  • Page 423 PIPER SENECA SERVICE MANUAL Wheel Brake Assembly Figure 18 VII - LANDING GEAR & BRAKES PAGE 55 Oct 30/03...
  • Page 424 PIPER SENECA SERVICE MANUAL Check the brake disc for wear, grooves, scratches pits or heat cracks. Ear of disc should not be less than 0.345 of an inch at its thinnest point. A single groove or isolated grooves up to 0.031 of an inch deep would not necessitate replacement, but a grooving of the entire surface would reduce lining life and should be replaced.
  • Page 425 PIPER SENECA SERVICE MANUAL Anchor Bolt Removal and Installation Figure 19 VII - LANDING GEAR & BRAKES PAGE 57 2J11 Oct 30/03...

  • Page 426: Brake Master Cylinder (Hand Parking Brake)

    PIPER SENECA SERVICE MANUAL Brake Master Cylinder (Hand / Parking Brake) Figure 20 53. BRAKE MASTER CYLINDER (HAND PARKING BRAKE). 54. REMOVAL. (Refer to Figure 21.) To remove brake master cylinder (8), first disconnect inlet supply line (13) from fitting at top of cylinder and allow fluid to drain from the reservoir and line into a suitable clean container.
  • Page 427 PIPER SENECA SERVICE MANUAL Brake System Installation Figure 21 VII - LANDING GEAR & BRAKES PAGE 59 2J13 Oct 30/03...
  • Page 428 PIPER SENECA SERVICE MANUAL 56. CLEANING, INSPECTION AND REPAIR. Clean cylinder components using a suitable solvent, then dry thoroughly. Inspect interior walls of cylinder for scratches, nicks, burrs, corrosion, etc. Inspect general condition of fitting threads. Check piston and valve for scratches, bum, and corrosion.

  • Page 429: Brake Cylinder (Toe Brake)

    PIPER SENECA SERVICE MANUAL 59. BRAKE CYLINDER (TOE BRAKE). 60. REMOVAL. (Refer to Figure 23.) Disconnect the upper and lower lines from the cylinder (14) to be removed and cap the lines to prevent fluid leakage or drain the fluid from the brake reservoir and master cylinder.
  • Page 430 PIPER SENECA SERVICE MANUAL Toe Brake Cylinder Figure 22 PAGE 62 VII - LANDING GEAR & BRAKES Oct 30/03 2J16...
  • Page 431 PIPER SENECA SERVICE MANUAL Toe Brake Installation Effectivity Figure 23 (Sheet 1 of 2) 34-7250001 thru 34-7350353 VII - LANDING GEAR & BRAKES PAGE 63 2J17 Oct 30/03...
  • Page 432 PIPER SENECA SERVICE MANUAL Effectivity Toe Brake Installation 34-7450001 thru 34-7450220 Figure 23 (Sheet 2 of 2) PAGE 64 VII - LANDING GEAR & BRAKES Oct 30/03 2J18...
  • Page 433 PIPER SENECA SERVICE MANUAL 63. ASSEMBLY. (Refer to Figure 22.) NOTE: Rub a small amount of hydraulic fluid (MIL-H-5606) on all O-rings and component parts for ease of handling during reassembly and to prevent damage. CLEVELAND CYLINDER NUMBER 10-27. (Refer to Figure 22.) Install new O-rings on the inside and outside of the packing gland (7) and on the outside of the piston (3).

  • Page 434: Brake Bleeding Procedure (Gravity)

    PIPER SENECA SERVICE MANUAL 65. BRAKE BLEEDING PROCEDURE (GRAVITY). On both main landing gear wheel brake assemblies, attach a clear plastic hose to the brake bleeders and extend into container partially filled with Hydraulic Fluid, MIL-H-5606. The ends of this hose should be submerged in the fluid.

  • Page 435: Brake System Leak Check

    PIPER SENECA SERVICE MANUAL Brake Reservior Bleeding Brake Figure 24 Figure 25 67. BRAKE SYSTEM LEAK CHECK. Pull for a good firm hand brake and lock parking brake mechanism. Allow system to stand for approximately 10 minutes, then by gripping the park brake handle it should not be able to be pulled aft further than the original set.
  • Page 436 PIPER SENECA SERVICE MANUAL GRIDS 2J22 THRU 2L24 INTENTIONALLY BLANK PAGE 68 VII - LANDING GEAR & BRAKES Oct 30/03 2J22...
  • Page 437 AIRPLANE SERVICE MANUAL CARD 3 OF 4 PA-34-200 (S/N’s 34-7250001 THRU 34-7450220) PIPER AIRCRAFT CORPORATION PART NUMBER 753-817 October 30, 2003...
  • Page 438 Published by Technical Publications © The New Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...

  • Page 439: Aerofiche Effectivity

    PIPER SENECA SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to this Service Manual 753-817 originally issued April 5, 1971 are as follows: Revision Publication Date Aerofiche Card Effectivity ORG710405 April 5, 1971 CR720613 June 13, 1972 CR031030 * October 30, 2003 1, 2, 3, &...
  • Page 440 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Oct 30/03...
  • Page 441 PIPER SENECA SERVICE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE Intro-List of Oct 30/03 Effective Pages Oct 30/03 Intro-Table of Contents Oct 30/03 Oct 30/03 Introduction Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 442 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 443 PIPER SENECA SERVICE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity Serial Number Explanation 3A10 Assignment of Subject Material 3A10 Pagination 3A10 Aerofiche Effectivity 3A10 Identifying Revised Material 3A10 Indexing 3A10 List of Effective Pages...
  • Page 444 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Oct 30/03...

  • Page 445: Instructions For Continued Airworthiness

    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.
  • Page 446 PIPER SENECA SERVICE MANUAL SERIAL NUMBER EXPLANATION. Example: 34 72 50 001 SEQUENCE NUMBER TYPE CERTIFICATE DESIGNATION MODEL YEAR MODEL CODE 50 = PA-34-200 SENECA ASSIGNMENT OF SUBJECT MATERIAL. This publication is divided into logical subject groupings based on aircraft system or task function. Refer to paragraph 14, Section Index Guide, for a complete breakdown and list.
  • Page 447 To improve our Service and Reliability system and aid in our compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
  • Page 448 PIPER SENECA SERVICE MANUAL (4) BRAKES AND WHEELS: Vendor Address: Parker Hannifin Corp - (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/cleveland/Universe/book.pdf (5) ENGINE: Vendor Address: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • Page 449 PIPER SENECA SERVICE MANUAL (10) LANDING GEAR ACTUATOR, EXTENSION AND RETRACTION: Vendor Address: Parker Hannifin Corp - (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/cleveland/ Component (Effective for P/N’s 96860-002 and 96860-003 only.) Maintenance Manual:...
  • Page 450 PIPER SENECA SERVICE MANUAL (14) PROPELLER: Vendor Address: Hartzell Propeller Inc. - (937) 778-4379 One Propellor Place FAX - (937) 778-4321 Piqua, OH 45356-2634 http://www.hartzellprop.com/index2.htm Standard Practices: Manual No. 202A Overhaul and Maintenance: Manual No. 117D Aluminum Blade Overhaul: Manual No. 133C Propeller Owner’s...

  • Page 451: Voltage Regulator

    PIPER SENECA SERVICE MANUAL (18) VACUUM REGULATORS: Vendor Address: Parker Hannifin Corp. PH: - (800) 382-8422 Airborne Division 711 Taylor Street Elyria, Ohio 44035 http://www.parker.com/cleveland/Universe/book.pdf (19) VOLTAGE REGULATOR: Vendor Address: See listing under Alternator, above. INTRODUCTION PAGE 7 3A15 Oct 30/03...
  • Page 452 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Oct 30/03 3A16...
  • Page 453 PIPER SENECA SERVICE MANUAL 14 SECTION INDEX GUIDE. SECTION TITLE GRID NO. AIRWORTHINESS LIMITATIONS HANDLING AND SERVICING INSPECTION STRUCTURES 1H11 SURFACE CONTROLS HYDRAULIC SYSTEM LANDING GEAR AND BRAKES 2G21 VIII POWERPLANT FUEL SYSTEM INSTRUMENTS ELECTRICAL SYSTEM 3H17 ELECTRONICS XIII HEATING AND VENTILATION SYSTEM...
  • Page 454 PIPER SENECA SERVICE MANUAL GRIDS 3A18 THRU 3A24 INTENTIONALLY BLANK PAGE 10 INTRODUCTION Oct 30/03 3A18...
  • Page 455 PIPER SENECA SERVICE MANUAL Schematics Alternators: 3K7 Cabin Access Plates and Panels: 1C22 Anti-Collision Fin-Tip Strobe Heating, Defrost, and Accident/Incident Reporting: A11 Light: 3K16 Ventilation: 4D2 Aerofiche Combustion Heater: 4D16 Consumable Materials: 1E9 Effectivity: A10 Electrical Symbols: 3K3 Conversion Tables...
  • Page 456 PIPER SENECA SERVICE MANUAL Environmental Systems Fuel System: 1D9 E (cont.) Description and Operation: 4D1 Description: 3F7 Engine Optional Combustion Heater: Draining Alternate Air Door Entirely: 1D11 100 Hour Inspection: 3D6 Exploded View: 4E16 Moisture: 1D11 Cowl Flaps: 3C13 Inspections: 4D17...
  • Page 457 PIPER SENECA SERVICE MANUAL Per Specific Operation / Operating Environment.: Landing Gear Ice and Rain Protection: 4F11, 1G20 Cleaning: 1D19 4G15 Extreme Cold: 1G21 Description: 2H3 Ignition System High Dust: 1G20 Electrical Schematic: 2J3 Contact Points: 3D11 High Humidity: 1G21...
  • Page 458 PIPER SENECA SERVICE MANUAL Propeller Rudder L (cont.) Air Charge Pressure vs. 100 Hour Rudder Tab Freeplay Lights Temperature: 3C15 Inspection: 2E14 Exterior: 3J15 Deicing System: 4F11 Balancing Anti-Collision Strobe: 3J18 Deicers: 4G4 Procedure: 1K8 Landing and Taxi: 3J15 Electrical Check: 4G10...
  • Page 459 PIPER SENECA SERVICE MANUAL Troubleshooting Aileron Controls: 2D1 Vacuum System Taxiing: 1D7 Airspeed Indicator: 3G23 Description: 3G12 Testing Alternator: 3I5 Filter(s): 3G14 Alternator: 3I17 Altimeter: 3G22 Gauge: 3G14 Combustion Heater: 4E12 Ammeters: 3H10 Pump: 3G16 Bench Tests: 4E20 Battery: 3J12...
  • Page 460 PIPER SENECA SERVICE MANUAL GRIDS 3B6 THRU 3B24 INTENTIONALLY BLANK PAGE 6 INDEX Oct 30/03...

  • Page 461: Power Plant

    PIPER SENECA SERVICE MANUAL SECTION VIII POWER PLANT...
  • Page 462 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...

  • Page 463: Section Viii

    PIPER SENECA SERVICE MANUAL SECTION VIII LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE VIII-List of Oct 30/03 Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 VIII-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 464 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 VIII - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 465 PIPER SENECA SERVICE MANUAL SECTION VIII - POWER PLANT TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. POWER PLANT VIII Introduction Description Troubleshooting Standard Practices - Engine Engine Cowling 3C13 Removal 3C13 Cleaning, Inspection and Repair 3C13 Installation 3C13 Engine Cowl Flaps...
  • Page 466 PIPER SENECA SERVICE MANUAL SECTION VIII - POWER PLANT TABLE OF CONTENTS (continued) SUBJECT SECTION PAGE GRID NO. Harness Assembly 3D19 Inspection 3D19 Removal 3D19 Maintenance 3D19 Installation of Harness 3D23 Spark Plugs Removal Inspection and Cleaning Installation Lubrication System...

  • Page 467: Troubleshooting

    PIPER SENECA SERVICE MANUAL POWER PLANT WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) INTRODUCTION. This section covers the power plant used in the PA-34 airplane and is comprised of instructions for the removal, service and installation of the propeller, propeller governor, engine, induction system, fuel injector, fuel air bleed nozzle, ignition system and engine lubrication system.
  • Page 468 PIPER SENECA SERVICE MANUAL Never reuse any lockwire, lockwashers, tablocks, tabwashers or cotter pins. All lockwire and cotter pins must fit snugly in holes drilled in studs and bolts for locking purposes. Cotter pins should be installed so the head fits into the castellation of the nut, and unless otherwise specified, bend one end of the pin back over the stud or bolt and the other end down flat against the nut.
  • Page 469 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 1 of 4) TROUBLESHOOTING POWER PLANT Trouble Cause Remedy Failure of engine to start. Lack of fuel. Check fuel system for leaks. Fill fuel tank. Clean dirty lines, strainers or fuel valves. Check fuel selector valve for proper tank.
  • Page 470 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 2 of 4) TROUBLESHOOTING POWER PLANT Trouble Cause Remedy Failure of engine to idle Uneven cylinder Check condition of piston properly. (cont.) compression. rings and valve seats. Faulty ignition system. Check entire ignition system.
  • Page 471 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 3 of 4) TROUBLESHOOTING POWER PLANT Trouble Cause Remedy Failure of engine to Faulty ignition. Tighten all connections. develop full power. (cont.) Check system with tester. Check ignition timing. Rough engine Cracked engine mount.
  • Page 472 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 4 of 4) TROUBLESHOOTING POWER PLANT Trouble Cause Remedy Excessive oil consumption. Low grade of oil. Fill tank with oil conforming to specifications. Failing or failed Check sump for metal bearings. particles. Worn piston rings.

  • Page 473: Installation

    PIPER SENECA SERVICE MANUAL ENGINE COWLING. REMOVAL. The procedure for removing the cowling is the same for both engines. Release the fasteners securing the two side access panels. Remove the screw fasteners that secure the top cowling and then remove the top cowling assembly.
  • Page 474 PIPER SENECA SERVICE MANUAL If the flap is not flush, disconnect the push-pull control from the arm on the inboard side of the flap. Loosen the jam nut on the clevis end and adjust the clevis to get a flush fit between the cowl flap and engine cowling.
  • Page 475 PIPER SENECA SERVICE MANUAL TABLE II PROPELLER SPECIFICATIONS Blade Angle Low Pitch (High RPM) 13.5° High Pitch (Low RPM) 79°-81° (Feathered) RPM Setting Engine Static High RPM 2700 RPM max. Torque Item Required Torque (Dry) Spinner Bulkhead (Aft) Without Damper...
  • Page 476 PIPER SENECA SERVICE MANUAL 10. PROPELLER. WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) WARNING: USE EXTREME CAUTION WHEN ROTATING PROPELLER BY HAND; PROPELLER MAY KICK BACK.
  • Page 477 PIPER SENECA SERVICE MANUAL Propeller Installation Figure 1 VIII - POWER PLANT PAGE 11 3C17 Oct 30/03...
  • Page 478 PIPER SENECA SERVICE MANUAL Typical Nicks and Removal Methods Figure 2 13. INSTALLATION. (Refer to Figure 1.) Insure master and magneto switches are off. Place fuel selector to off position. Place mixture control in idle cut-off. Observe the starter ring gear to make sure it is mounted properly on the engine crankshaft flange.
  • Page 479 PIPER SENECA SERVICE MANUAL 14. CHECKING PROPELLER BLADE TRACK. Blade track is the ability of one blade tip to follow the other, while rotating, in almost the same plane. Excessive difference in blade track - more than .0625 inch may be an indication of bent blades or improper propeller installation.
  • Page 480 PIPER SENECA SERVICE MANUAL Propeller Governor Figure 3 18. RIGGING AND ADJUSTMENT. (Refer to Figure 3.) Start engine, park 90° to wind direction and warm in normal manner. To check high RPM, low pitch setting, move the propeller control all the way forward. At this position the governor speed control arm (1) should be against the high RPM fine adjusting screw (2).
  • Page 481 PIPER SENECA SERVICE MANUAL With the high RPM adjustment complete, the control system should be adjusted so that the governor control arm will contact the high RPM stop when the cockpit control knob is .032 to .047 of an inch from its full forward stop. To adjust the control knob travel, disconnect the control cable end from the control arm, loosen the cable end jam nut and rotate the end to obtain the desired level clearance.
  • Page 482 PIPER SENECA SERVICE MANUAL GRIDS 3C22 THRU 3C24 INTENTIONALLY BLANK PAGE 16 VIII - POWER PLANT Oct 30/03 3C22...
  • Page 483 PIPER SENECA SERVICE MANUAL 19. ENGINE. WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) WARNING: GROUND THE MAGNETO PRIMARY CIRCUIT BEFORE WORKING ON THE ENGINE.
  • Page 484 PIPER SENECA SERVICE MANUAL Engine Installation Figure 4 (Sheet 1 of 2) PAGE 18 VIII - POWER PLANT Oct 30/03...
  • Page 485 PIPER SENECA SERVICE MANUAL Engine Installation Figure 4 (Sheet 2 of 2) VIII - POWER PLANT PAGE 19 Oct 30/03...
  • Page 486 PIPER SENECA SERVICE MANUAL Drain the engine oil and then close drain. Remove the four engine mount assemblies and swing the engine free, being careful not to damage any attaching parts. 21. INSTALLATION. (Refer to Figure 4.) Attach a one-half ton (minimum) hoist to the engine hoisting straps and swing the engine into alignment with its attaching points.
  • Page 487 PIPER SENECA SERVICE MANUAL Install the proper grade and amount of engine oil. Pre-oil the engine prior to initial start. aa. Turn on the fuel valve; open the throttle full and turn on the electric fuel pump. Check the fuel lines for leaks.

  • Page 488: Alternate Air Door

    PIPER SENECA SERVICE MANUAL 26. ALTERNATE AIR DOOR. The alternate air door is located in the induction airbox to provide a source of air to the engine should there be an air stoppage through the filter system. The following should be checked during any inspection: Check that air door seals are tight and hinge is secure.
  • Page 489 PIPER SENECA SERVICE MANUAL Fuel Injector Figure 6 29. ADJUSTMENT OF IDLE SPEED AND MIXTURE. (Refer to Figure 6.) Start the engine and warm up in the usual manner until oil and cylinder head temperatures are normal. Check magnetos. If the “mag-drop” is normal, proceed with idle adjustment.
  • Page 490 PIPER SENECA SERVICE MANUAL RSA Fuel Injector System Funtional Schematic Figure 7 PAGE 24 VIII - POWER PLANT Oct 30/03...

  • Page 491: Cleaning And Inspection

    PIPER SENECA SERVICE MANUAL 30. FUEL-AIR BLEED NOZZLES. 31. REMOVAL. The nozzles must be carefully removed as they or the cylinders may be damaged. Remove the lower engine cowl. Disconnect the fuel line from the nozzle. Carefully remove the nozzle, using the correct size deep socket.
  • Page 492 WARNING: GROUND THE MAGNETO PRIMARY CIRCUIT BEFORE WORKING ON THE ENGINE. WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE NOTES, BELOW.) NOTE: Magneto service information provided in this manual applies solely to Bendix Series 1200 Magnetos and is based on Bendix’s original “Installation, Operation, and Maintenance Manual,...
  • Page 493 PIPER SENECA SERVICE MANUAL Contact Points Figure 8 Minor irregularities or roughness of point surfaces are not harmful (refer to Figure 8, center), neither are small pits or mounds, if not too pronounced. If there is a possibility of pit becoming deep enough to penetrate pad, Figure 8, right, reject contact assembly.
  • Page 494 PIPER SENECA SERVICE MANUAL 37. REMOVAL. Before removing the magneto, make sure magneto switches are off. WARNING: THE MAGNETO IS NOT INTERNALLY GROUNDED; WHEN THE GROUND LEAD IS DISCONNECTED, THE MAGNETO IS HOT. WHEN THE “P” LEAD IS REMOVED THE MAGNETO IS GROUNDED INTERNALLY.
  • Page 495 PIPER SENECA SERVICE MANUAL Rotor Holding Tool Installed Timing Kit Installed Figure 9 Figure 10 Aligning Timing Marks (Single Contact Assembly Magneto) Figure 11 VIII - POWER PLANT PAGE 29 3D13 Oct 30/03...
  • Page 496 PIPER SENECA SERVICE MANUAL If the distributor block was not removed from the housing, the internal timing may be checked by turning the magneto in the normal rotation to number one firing position (keyway up and points just opening). At this position, the reference line on the distributor block should line up with the L mark on the gear.
  • Page 497 PIPER SENECA SERVICE MANUAL Checking Flyweight Clearance on Impulse Coupling Figure 12 VIII - POWER PLANT PAGE 31 3D15 Oct 30/03...
  • Page 498 PIPER SENECA SERVICE MANUAL Engine Timing Marks Figure 13 39. INSTALLATION AND TIMING PROCEDURE (Timing Magneto to Engine.) Although only the left magneto is equipped with an impulse coupling, the timing procedure, in the following paragraphs, is the same for both magnetos.
  • Page 499 PIPER SENECA SERVICE MANUAL Magneto Timing Marks Magneto Timing Marks Figure 14 Figure 15 Using a battery powered timing light attach the positive lead to a suitable terminal connected to the ground terminal of the magneto and the negative lead to any unpainted portion of the engine.
  • Page 500 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 34 VIII - POWER PLANT Oct 30/03 3D18...

  • Page 501: Maintenance

    PIPER SENECA SERVICE MANUAL 40. HARNESS ASSEMBLY. 41. INSPECTION. Check lead assemblies for nicks, cuts, mutilated braiding, badly worn section or any other evidence of physical damage. Inspect spark plug sleeves for chafing or tears and damaged or stripped threads on coupling nuts. Check compression spring to see if it is broken or distorted. Inspect grommet for tears.
  • Page 502 PIPER SENECA SERVICE MANUAL Slide insulating sleeve and spring retainer assembly off end of lead assembly. Replace defective component and reassemble as follows: (a) Fabricate a tool as shown in Figure 17 for installing the insulating sleeves over cable terminals.
  • Page 503 PIPER SENECA SERVICE MANUAL Assembly Tool Figure 17 Using Assembly Tool Figure 18 Measuring Lead Assembly Length Figure 19 VIII - POWER PLANT PAGE 37 3D21 Oct 30/03...
  • Page 504 PIPER SENECA SERVICE MANUAL Cutting Metallic Braid Unbraiding Metallic Shielding Figure 20 Figure 21 Forming Shielding Around Ferrule Figure 22 PAGE 38 VIII - POWER PLANT Oct 30/03 3D22...
  • Page 505 PIPER SENECA SERVICE MANUAL Ferrule Seating Tool Measuring Wire From Top of Ferrule Figure 23 Figure 24 12. Measure .500 inch from tapered ferrule and strip remaining insulation from wire. (Refer to Figure 24.) 13. Insert Scintilla 11-7073 Needle (Figure 25) thru small hole of grommet and over stripped end of wire.
  • Page 506 PIPER SENECA SERVICE MANUAL Needle Installing Grommet Over Lead Assemblies Figure 25 Figure 26 Lead Assembly Installed in Grommet Wire Doubled Over For Installation of Eyelet Figure 27 Figure 28 PAGE 40 VIII - POWER PLANT Oct 30/03 3D24...
  • Page 507 PIPER SENECA SERVICE MANUAL 45. SPARK PLUGS. 46. REMOVAL. CAUTION: WHEN WITHDRAWING THE IGNITION CABLE LEAD CONNECTION FROM THE PLUG, CARE MUST BE TAKEN TO PULL THE LEAD STRAIGHT OUT AND IN LINE WITH THE CENTER LINE OF THE PLUG BARREL; OTHERWISE A SIDE LOAD WILL BE APPLIED, WHICH FREQUENTLY RESULTS IN DAMAGE TO THE BARREL INSULATOR AND CONNECTOR.

  • Page 508: Inspection And Cleaning

    PIPER SENECA SERVICE MANUAL 47. INSPECTION AND CLEANING. Visually inspect each spark plug for the following non-repairable defects: Severely damaged shell or shield threads nicked up, stripped or cross-threaded. Badly battered or rounded shell hexagons. Out-of-round or damaged shielding barrel.
  • Page 509 NOTE: Installation of Kit No. 760-764v relieves this requirement, as well as the requirements of AD 73-14-2. NOTE: In serial numbers 34-7250001 thru 34-7250214 only, either Kit No. 760-607 or 760-611 (see Piper Service Spares Letter No. SP-318) must be installed before Kit No. 760-764v, above, can be installed.
  • Page 510 PIPER SENECA SERVICE MANUAL Effectivity Exhaust System 25 Hour Inspection See Paragraph 52 Figure 30 PAGE 44 VIII - POWER PLANT Oct 30/03...
  • Page 511 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK VIII - POWER PLANT PAGE 45 Oct 30/03...
  • Page 512 PIPER SENECA SERVICE MANUAL GRIDS 3E6 THRU 3E24 INTENTIONALLY BLANK PAGE 46 VIII - POWER PLANT Oct 30/03...

  • Page 513: Fuel System

    PIPER SENECA SERVICE MANUAL SECTION FUEL SYSTEM...
  • Page 514 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...

  • Page 515: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION IX LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE IX-List of Oct 30/03 Effective Pages Oct 30/03 IX-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 516 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 IX - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 517 PIPER SENECA SERVICE MANUAL SECTION IX - FUEL SYSTEM TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. FUEL SYSTEM Introduction Description Troubleshooting Fuel Tanks 3F10 Inspection and Repair 3F10 Inboard Fuel Tank 3F10 Removal 3F10 Installation 3F10 Outboard Fuel Tank...
  • Page 518 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 IX - CONTENTS Oct 30/03...
  • Page 519 PIPER SENECA SERVICE MANUAL FUEL SYSTEM INTRODUCTION. The fuel system components covered in this section consist of fuel tanks, fuel selector valves, gascolator and electric fuel pumps. Each wing contains interconnected aluminum inboard and outboard fuel tanks, having a combined capacity of 49 U.S. gallons, for a total capacity of 98 U.S.
  • Page 520 PIPER SENECA SERVICE MANUAL TABLE I TROUBLESHOOTING FUEL SYSTEM Trouble Cause Remedy Failure of fuel to flow. Fuel line blocked. Flush fuel system. Fuel vent cap blocked. Check and clean vent hole in cap. Mechanical or electrical Check and replace fuel pump failure.

  • Page 522: Fuel Tanks

    PIPER SENECA SERVICE MANUAL FUEL TANKS. INSPECTION AND REPAIR. Fuel tanks should be completely drained before inspection. (Refer to Draining Fuel System, Section II.) Each tank should be carefully inspected for signs of leaks as indicated by telltale stains. In the event a fuel leak is detected, the fuel tank must be removed as explained below, and repaired as follows.
  • Page 523 PIPER SENECA SERVICE MANUAL Fuel Tank Installation Figure 2 IX - FUEL SYSTEM PAGE 5 3F11 Oct 30/03...
  • Page 524 PIPER SENECA SERVICE MANUAL OUTBOARD FUEL TANK. 8a. REMOVAL. Using the same access hole described in Inboard Fuel Tank - Removal, above, and with fuel completely drained from the tank, loosen clamps on hose connections on fuel line and fuel vent line.
  • Page 525 PIPER SENECA SERVICE MANUAL 11. FUEL QUANTITY SENDER UNIT. NOTE: Inboard and outboard fuel tanks in each wing are interconnected and have a total capacity of 49.00 gallons. Fuel quantity sender units mounted in each fuel tank transmit electrically the cumulative quantity of fuel in each set of tanks, to fuel quantity gauges mounted in the instrument panel.
  • Page 526 PIPER SENECA SERVICE MANUAL 13. GASCOLATOR. (Refer to Figure 4.) NOTE: The gascolator should be inspected at periodic intervals as explained in Section II, Servicing Fuel System. 14. REMOVAL. Determine that fuel selector valve lever is in the off position. Remove cowling necessary to gain access to the gascolator.
  • Page 527 PIPER SENECA SERVICE MANUAL 17. FUEL Selector Valve. CAUTION: NO FIELD DISASSEMBLY OR REPAIR OF FUEL SELECTOR VALVES IS AUTHORIZED. MAINTENANCE IS LIMITED TO REMOVAL AND REPLACEMENT OF THE WHOLE UNIT. 18. REMOVAL. The fuel selector valve need not be removed unless any of the following conditions exist: Failure of selector lever to seat in detent.

  • Page 528: Electric Fuel Pump

    PIPER SENECA SERVICE MANUAL 22. ELECTRIC FUEL PUMP. 23. REMOVAL AND INSTALLATION. There is one electric rotary vane type fuel pump for each engine. The pump is mounted in a bracket on the aft side of the firewall. To remove pump, proceed as follows: Remove rectangular hatch assembly located on the top of the nacelle, aft of the firewall.
  • Page 529 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK IX - FUEL SYSTEM PAGE 11 3F17 Oct 30/03...
  • Page 530 PIPER SENECA SERVICE MANUAL GRIDS 3F18 THRU 3F24 INTENTIONALLY BLANK PAGE 12 IX - FUEL SYSTEM Oct 30/03 3F18...
  • Page 531 PIPER SENECA SERVICE MANUAL SECTION INSTRUMENTS...
  • Page 532 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...
  • Page 533 PIPER SENECA SERVICE MANUAL SECTION X LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE X-List of Oct 30/03 Effective Pages Oct 30/03 X-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03...

  • Page 534: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 X - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 535 PIPER SENECA SERVICE MANUAL SECTION X - INSTRUMENTS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. INSTRUMENTS General Removal and Installation of Face Mounted Instruments Removal and Installation of Cluster Mounted Instruments Non-Electrical Instruments 3G12 Vacuum System 3G12 General 3G12...
  • Page 536 PIPER SENECA SERVICE MANUAL SECTION X - INSTRUMENTS TABLE OF CONTENTS (cont.) SUBJECT SECTION PAGE GRID NO. Magnetic Compass General Adjusting Troubleshooting Manifold Pressure Gauge General Troubleshooting Removal and Installation Tachometer Indicator General Troubleshooting Removal and Installation Engine Oil Pressure Gauge...
  • Page 537 PIPER SENECA SERVICE MANUAL SECTION X - INSTRUMENTS TABLE OF CONTENTS (cont.) SUBJECT SECTION PAGE GRID NO. Cylinder Head Temperature (CHT) Gauge 3H13 General 3H13 Troubleshooting 3H13 Removal and Installation 3H13 Fuel Flow Gauge 3H13 General 3H13 Troubleshooting 3H13 Removal and Installation...
  • Page 538 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 X - CONTENTS Oct 30/03...
  • Page 539 PIPER SENECA SERVICE MANUAL INSTRUMENTS GENERAL. The instrumentation in the Seneca is designed to give a quick and actual indication of the attitude, performance and condition of the airplane. Maintenance, other than described herein shall be done by the instrument manufacturer or an authorized repair station.
  • Page 540 PIPER SENECA SERVICE MANUAL Instrument Panel Figure 1 PAGE 2 X - INSTRUMENTS Oct 30/03 3G10...
  • Page 541 PIPER SENECA SERVICE MANUAL Pitot-Static System Installation Figure 2 X - INSTRUMENTS PAGE 3 3G11 Oct 30/03...
  • Page 542 PIPER SENECA SERVICE MANUAL NON-ELECTRICAL INSTRUMENTS. VACUUM SYSTEM. GENERAL. The vacuum system employed to operate the gyro instruments is comprised of two engine driven dry vacuum pumps, two vacuum regulator valves, two check valves, and the necessary tubing on each engine. When the dry type vacuum pumps are installed, the need for oil-air separators and the hardware necessary for their installation is eliminated.
  • Page 543 PIPER SENECA SERVICE MANUAL Vacuum Gauges: NOTE: Vacuum gauge failure in a properly operating vacuum system does not impair safety of flight. Vacuum gauges seldom require service and usually are replaced when malfunctions occur. If the vacuum gauge malfunctions in a manner to cause an incorrect reading in normal cruise conditions, the gauge must be checked by comparing the reading with a gauge of known accuracy.
  • Page 544 PIPER SENECA SERVICE MANUAL VACUUM (SUCTION) GAUGE. GENERAL. The suction gauge is mounted to the left of the right control column. This gauge is calibrated in inches of mercury and indicates the differential pressure across the pilot’s attitude gyro. As the system becomes clogged or lines obstructed, the gauge will show a decrease in pressure.

  • Page 545: Removal And Installation

    PIPER SENECA SERVICE MANUAL VACUUM REGULATORS. 10. GENERAL. Two vacuum regulator valves are incorporated in the system to control vacuum pressure to the gyro instruments. A manifold check valve assembly assures vacuum if one engine or pump should fail. 11. ADJUSTING. (See Figure 3.) NOTE: Do not reset the regulator until the filter and lines have been checked Remove nacelle cover(s), remove safety from adjustment check nut and loosen check nut.

  • Page 546: Vacuum Pump

    PIPER SENECA SERVICE MANUAL 13. VACUUM PUMP. 14. GENERAL. The vacuum pump is of the rotary vane, positive displacement dry type. This unit consists essentially of an aluminum housing containing a tempered sleeve in which an offset rotor, with moving blades incorporated.

  • Page 547: Replacing Pump Fittings

    CAUTION: ONLY PUMP MOUNTING GASKET AUTHORIZED AND APPROVED FOR USE WITH ORIGINAL EQUIPMENT AIRBORNE VACUUM PUMP IS AIRBORNE GASKET B3-1-2, PIPER P/N 751-859. USE OF ANY OTHER GASKET MAY RESULT IN OIL SEEPAGE OR LEAKAGE AT MOUNTING SURFACE. Place pump gasket in its proper place and align spline on pump drive with spline on engine drive assembly.
  • Page 548 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 10 X - INSTRUMENTS Oct 30/03 3G18...
  • Page 549 PIPER SENECA SERVICE MANUAL 17. Directional Gyro. 18. GENERAL. Both air and electric Directional Gyros are used, depending on the option package installed. Both types are displacement type gyros with “FREE” rotors mounted in Gimbal Assemblies. It is important that if a Magnetic Slaving System, Flight Director, or AutoPilot is coupled to the D.G., the A.F.C.S.

  • Page 550: Gyro Horizon

    PIPER SENECA SERVICE MANUAL 21. GYRO HORIZON. 22. GENERAL. Both air and electric Attitude Horizons are used, depending on the option package installed. Both types are displacement type gyros with “FREE” rotors mounted in Gimbal Assemblies. It is important to consult the A.F.C.S. Manufacturer’s Service Manual if a, Flight Director, or AutoPilot is coupled to the Attitude Horizon.

  • Page 551: Rate Of Climb Indicator

    PIPER SENECA SERVICE MANUAL 27. RATE OF CLIMB INDICATOR. 28. GENERAL. The rate of climb indicator measures the rate of change in static pressure when the airplane is climbing or descending. By means of a pointer and dial, this instrument will indicate the rate of ascent or descent of the airplane in feet per minute.

  • Page 552: Sensitive Altimeter

    PIPER SENECA SERVICE MANUAL 31. SENSITIVE ALTIMETER. 32. GENERAL. The altimeter indicates altitude in feet above sea level. The indicator has three pointers and a dial scale, the long pointer is read in hundreds of feet, the middle pointer in thousandths of feet and the short pointer in ten thousandths of feet.

  • Page 553: Airspeed Indicator

    PIPER SENECA SERVICE MANUAL 34. REMOVAL AND INSTALLATION. Refer to Removal and Installation of Face Mounted Instruments, above. NOTE: When any connections in the static system are opened for check, system must be rechecked per Part FAR 23.1325. 35. AIRSPEED INDICATOR.
  • Page 554 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 16 X - INSTRUMENTS Oct 30/03 3G24...
  • Page 555 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK X - INSTRUMENTS PAGE 17 Oct 30/03...

  • Page 556: Magnetic Compass

    PIPER SENECA SERVICE MANUAL 39. MAGNETIC COMPASS. 40. GENERAL. The magnetic compass is a self-contained instrument. This instrument has an individual light which is connected to the instrument lighting circuit. The compass correction card is located in the card holder mounted on the instrument. The compass should be swung whenever instruments or radios are changed and at least once a year.
  • Page 557 PIPER SENECA SERVICE MANUAL TABLE IV TROUBLESHOOTING MAGNETIC COMPASS Trouble Cause Remedy Excessive card error. Compass not properly Compensate instrument. compensated. (See Magnetic Compass, Adjusting, above.) External magnetic Locate magnetic interference. interference and eliminate, if possible. Excessive card oscillation. Insufficient liquid.

  • Page 558: Manifold Pressure Gauge

    On later aircraft or aircraft which have had Piper Kit No. 760-765V installed, there are two in line filters which are located in the lines ahead of the instrument panel at both sides of the fuselage. They are accessible from within the cockpit and should be checked for moisture and/or replaced at each 100 or annual inspection.

  • Page 559: Tachometer Indicator

    PIPER SENECA SERVICE MANUAL 47. TACHOMETER INDICATOR. 48. GENERAL. Each tachometer is connected to the engine accessory cover by a flexible cable and provides an indication of crankshaft speed in revolutions per minute. The instrument has a recording mechanism for recording the time that the engine is in actual operation. The right hand tachometer has a reversing drive to correct for the counter rotation of the right hand engine.

  • Page 560: Engine Oil Pressure Gauge

    PIPER SENECA SERVICE MANUAL 51. ENGINE OIL PRESSURE GAUGE. 52. GENERAL. The oil pressure gauge is mounted in the cluster on the instrument panel. This gauge will indicate the amount of oil pressure available at the pressurized engine oil passage in psi.

  • Page 561: Fuel Pressure Gauge

    PIPER SENECA SERVICE MANUAL 55. FUEL PRESSURE GAUGE. 56. GENERAL. The fuel pressure gauge instrument is mounted in the cluster on the instrument panel. This gauge is connected to the fuel system at the injector fuel inlet fitting. 57. TROUBLESHOOTING. See Table VIII.
  • Page 562 PIPER SENECA SERVICE MANUAL 59. ELECTRICAL INSTRUMENTS. 60. TURN AND BANK/PICTORIAL RATE INSTRUMENTS. 61. GENERAL Unlike the familiar “FREE” gyro rotor found in the Directional and Attitude gyros both the Turn and Bank, and Pictorial Rate Indicator have captive gyro rotors, the axis of which are attached to the instrument housings.

  • Page 563: Fuel Quantity Indicator

    PIPER SENECA SERVICE MANUAL 64. FUEL QUANTITY INDICATOR. 65. GENERAL. The two fuel quantity gauges are mounted in the clusters on the instrument panel. These instruments are calibrated in U.S. gallons. Two transmitter units are installed in each fuel tank. Each unit contains a resistance strip and a movable control arm.

  • Page 564: Oil Temperature Indicator

    PIPER SENECA SERVICE MANUAL 68. OIL TEMPERATURE INDICATOR. 69. GENERAL. The oil temperature indicator is mounted in the instrument cluster on the instrument panel. This instrument will provide a temperature indication of the engine oil in degrees Fahrenheit. The instrument has a temperature bulb located in the oil screen assembly, on the engine accessory section.
  • Page 565 PIPER SENECA SERVICE MANUAL 80. EXHAUST GAS TEMPERATURE (EGT) GAUGE. 81. GENERAL. This dual instrument, which is commonly referred to as EGT, is used to aid the pilot in setting the economical fuel-air mixture for cruising flight at a power setting of 75% or less. It is a sensing device to monitor the temperature of exhaust gases leaving the engine cylinders.
  • Page 566 PIPER SENECA SERVICE MANUAL TABLE XII TROUBLESHOOTING EGT GAUGE Trouble Cause Remedy Gauge inoperative. Master Switch OFF. Turn switch ON. Circuit Breaker OUT. Push breaker IN. Defective gauge, probe Check probe and lead or wiring. wires for chafing, breaks or shorting between wires between wires and/or metal structure.

  • Page 567: Fuel Flow Gauge

    PIPER SENECA SERVICE MANUAL 85. CYLINDER HEAD TEMPERATURE (CHT) GAUGE. 86. GENERAL. The cylinder head temperature gauge is in the instrument cluster, located on the instrument panel. This instrument measures the cylinder head temperature using a sender located in a cylinder head.
  • Page 568 PIPER SENECA SERVICE MANUAL TABLE XV INSTRUMENT MARKINGS Fuel Flow Green Arc (Normal Operating Range) 0 to 19.7 GPH Red Line 19.7 GPH Tachometer Green Arc (Normal Operating Range) 500 to 2200 RPM and 2400 to 2700 RPM Radial Red Line (Maximum)
  • Page 569 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK X - INSTRUMENTS PAGE 31 3H15 Oct 30/03...
  • Page 570 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 32 X - INSTRUMENTS Oct 30/03 3H16...

  • Page 571: Electrical System

    PIPER SENECA SERVICE MANUAL SECTION ELECTRICAL SYSTEM 3H17...
  • Page 572 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 3H18...

  • Page 573: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION XI LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE XI-List of Oct 30/03 Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 XI-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 574 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 XI - LIST OF EFFECTIVE PAGES Oct 30/03 3H20...
  • Page 575 PIPER SENECA SERVICE MANUAL SECTION XI - ELECTRICAL SYSTEM TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. ELECTRICAL SYSTEM Introduction Description Precautions Troubleshooting Alternator System Troubleshooting Alternator and Components 3I10 Description 3I10 Checking Alternator System 3I11 Service Procedures 3I11 Overhaul of Alternator...
  • Page 576 PIPER SENECA SERVICE MANUAL SECTION XI - ELECTRICAL SYSTEM TABLE OF CONTENTS (cont.) SUBJECT SECTION PAGE GRID NO. Battery 3J11 Troubleshooting 3J11 Servicing 3J11 Removal 3J11 Installation 3J11 Charging 3J11 Battery Box Corrosion Prevention 3J13 Extemal Power Receptacle 3J14 Exterior Lights...
  • Page 577 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XI - CONTENTS PAGE 3 3H23 Oct 30/03...
  • Page 578 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 4 XI - CONTENTS Oct 30/03 3H24...
  • Page 579 PIPER SENECA SERVICE MANUAL ELECTRICAL SYSTEM WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) INTRODUCTION. This section contains instructions and schematics for correcting difficulties which may arise in the operation of the electrical system.
  • Page 580 PIPER SENECA SERVICE MANUAL Switch Panel Figure 1 PAGE 2 XI - ELECTRICAL SYSTEM Oct 30/03...
  • Page 581 PIPER SENECA SERVICE MANUAL TABLE I ELECTRICAL SYSTEM COMPONENT LOADS Duty Cycle Circuit Load Continuous Intermitant Equipment Breaker (Amps) Optional Alternator Field (2) Anti-Collision (Strobe) Cabin Lights (4) Cigar Lighter Combustion Heater 13.0 Defroster Blower Electric Pitch Trim Fuel Pump (2) 10.0...
  • Page 582 PIPER SENECA SERVICE MANUAL Located on the instrument panel are four circuit breakers which control both generating systems. Two are marked “alternator output” and the others “alternator field.” The “output” circuit breakers are 60- ampere, and protect the alternators and electrical system from overloads. The ‘’field’’ circuit breakers for the voltage regulators and field wiring of each alternator are 5-amperes each.
  • Page 583 PIPER SENECA SERVICE MANUAL TABLE II (Sheet 1 of 5) TROUBLESHOOTING ALTERNATOR Trouble Cause Remedy Zero output indicated on Open field circuit. With master switch turned ammeter regardless of RPM on check for battery (refer to alternator system voltage (12V) from ship’s test procedure).
  • Page 584 PIPER SENECA SERVICE MANUAL TABLE II (Sheet 2 of 5) TROUBLESHOOTING ALTERNATOR Trouble Cause Remedy CAUTION: TURN MAGNETO SWITCH TO OFF BEFORE TURNING PROP. Zero output indicated on Open field winding in Disconnect field terminal of ammeter regardless of RPM alternator.
  • Page 585 PIPER SENECA SERVICE MANUAL TABLE II (Sheet 3 of 5) TROUBLESHOOTING ALTERNATOR Trouble Cause Remedy Output indicated on ammeter Open rectifier. If any of the six rectifiers does not meet minimum pressed into the rear bell values specified in alternator housing of the alternator system test procedure.
  • Page 586 PIPER SENECA SERVICE MANUAL TABLE II (Sheet 4 of 5) TROUBLESHOOTING ALTERNATOR Trouble Cause Remedy CAUTION: TURN MAGNETO SWITCH TO OFF BEFORE TURNING PROP. Field circuit breaker trips. (cont.) Short circuit in field winding Internal short circuiting of of alternator.
  • Page 587 PIPER SENECA SERVICE MANUAL TABLE II (Sheet 5 of 5) TROUBLESHOOTING ALTERNATOR Trouble Cause Remedy Output circuit breaker trips. Battery charged backwards. Remove battery. Connect (cont.) load such as landing light lamp or similar load and discharge battery. Recharge with correct...
  • Page 588 PIPER SENECA SERVICE MANUAL ALTERNATOR AND COMPONENTS. WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) DESCRIPTION. (Refer to Figure 2.) The principal components of the alternator are the brush holder assembly (a), the slip ring end head (b), the rectifiers (c), the stator (d), the rotor (e) and the drive end head (f).
  • Page 589 PIPER SENECA SERVICE MANUAL CHECKING ALTERNATOR SYSTEM. Two ammeters are used which enable an independent output check of each alternator, as well as the electrical output-input of the battery. Should either alternator show no output on its ammeter, check the appropriate circuit breakers. If a further check of the ammeters show no output from both alternators, switch to the auxiliary voltage regulator and overvoltage relay.
  • Page 590 PIPER SENECA SERVICE MANUAL OVERHAUL OF ALTERNATOR. When repairing the alternator, complete disassembly may not be required. In some cases it will only be necessary to perform those operations which are required to effect the repair. However, in this section, the complete overhaul is covered step-by-step to provide detailed information on each operation.
  • Page 591 PIPER SENECA SERVICE MANUAL Removing Slip Ring End Bearing Removing Rectifier Figure 3 Figure 4 Removing Drive End Head Removing End Head Bearing Figure 5 Figure 6 XI - ELECTRICAL SYSTEM PAGE 13 3I13 Oct 30/03...
  • Page 592 PIPER SENECA SERVICE MANUAL Stator: The stator can be tested for open or grounded windings with a 12 volt test bulb, described in the rectifier section, or an ohmmeter, in the following manner. Separate the stator from the slip ring end head just far enough to insert a fold of rags or blocks of wood.
  • Page 593 PIPER SENECA SERVICE MANUAL Testing Rotor for Ground Testing Rotor for Shorts Figure 7 Figure 8 Installing Bearing Installing Rectifier Figure 9 Figure 10 XI - ELECTRICAL SYSTEM PAGE 15 3I15 Oct 30/03...
  • Page 594 PIPER SENECA SERVICE MANUAL Terminal Assembly Figure 11 Slip Ring End Bearing Assembly Testing Alternator Figure 12 Figure 13 PAGE 16 XI - ELECTRICAL SYSTEM Oct 30/03 3I16...

  • Page 595: Alternator Service

    PIPER SENECA SERVICE MANUAL 13. TESTING. Wiring connections for bench testing the alternator are shown in Figure 13. Refer to the Alternator Service Test Specifications paragraph for output test figures. Adjust the carbon pile if necessary, to obtain the specified voltage.
  • Page 596 PIPER SENECA SERVICE MANUAL 16. ALTERNATOR SERVICE TEST SPECIFICATIONS. Specifications for the 14-volt Prestolite alternators installed as original equipment on PA-34-200 airplanes are as shown in Table III, below. TABLE III ALTERNATOR SERVICE TEST SPECIFICATIONS Alternator Model Prestolite ALY 6408...

  • Page 597: Checking Alternator Belt Tension

    PIPER SENECA SERVICE MANUAL 17. CHECKING ALTERNATOR BELT TENSION. If properly installed, tensioned and checked periodically, the alternator drive belt will give very satisfactory service. However, an improperly tensioned belt will wear rapidly and may slip and reduce alternator output Consequently, a belt should be checked for proper tension at the time it is installed, again after 25 hours operation and at each 100 hour inspection thereafter.

  • Page 598: Voltage Regulator

    PIPER SENECA SERVICE MANUAL Overvoltage Control Installation Figure 16 18. VOLTAGE REGULATOR. 19. CHECKING VOLTAGE REGULATOR. The regulator is a fully transistorized unit in which all of the components are encapsulated in epoxy, which makes field repair of the unit impractical, and if it does not meet the specifications, it must be replaced.
  • Page 599 PIPER SENECA SERVICE MANUAL Regulator Circuit Schematic - Typical Figure 17 The voltage regulator heat sink, or case, is the ground connection for the electronic circuit. Therefore, if this unit is tested on the bench, it is most important that a wire, No. 8 or larger, be connected between the regulator case and the alternator.

  • Page 600: Overvoltage Relay

    PIPER SENECA SERVICE MANUAL Testing Overvoltage Control Figure 18 20. OVERVOLTAGE RELAY. 21. CHECKING OVERVOLTAGE RELAY. The relay may be tested with the use of a good quality, accurate voltmeter, with a scale of at least 20 volts and a suitable power supply, with an output of at least 20 volts, or sufficient batteries with a voltage divider to regulate voltage.
  • Page 601 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XI - ELECTRICAL SYSTEM PAGE 23 3I23 Oct 30/03...
  • Page 602 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 24 XI - ELECTRICAL SYSTEM Oct 30/03 3I24...
  • Page 603 PIPER SENECA SERVICE MANUAL 22. STARTERS. WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) 23. DESCRIPTION. The gear reduction starting motor consists of six major components: the Commutator End Head Assembly, the Armature, the Frame and Field Assembly, the Gear Housing, the Pinion Housing, and the Bendix Drive Assembly.
  • Page 604 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 1 of 2) TROUBLESHOOTING STARTER Trouble Cause Remedy Starter fails to operate. Low battery charge. Check and recharge if necessary. Defective or improper Refer to electrical wiring wiring or loose connections. wiring diagram and check all wiring.
  • Page 605 PIPER SENECA SERVICE MANUAL TABLE V (Sheet 2 of 2) TROUBLESHOOTING STARTER Trouble Cause Remedy Low motor and cranking Worn, rough, or improperly Disassemble, clean, inspect speed. lubricated motor or starter and relubricate, replacing gearing. ball bearings, if worn. Same electrical causes Same remedies listed for as listed under “Starter...
  • Page 606 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 28 XI - ELECTRICAL SYSTEM Oct 30/03...
  • Page 607 PIPER SENECA SERVICE MANUAL Starter - Exploded View Figure 19 26. OVERHAUL. If during the above inspection any indication of starting motor difficulty is noted, the starting motor should be removed from the engine for cleaning and repair. 27. REMOVAL. To remove the starting motor from the engine, first disconnect the ground cable from the battery post to prevent short circuiting.
  • Page 608 PIPER SENECA SERVICE MANUAL Turning Motor Commutator Testing Motor Armature for Shorts Figure 20 Figure 21 Turn the Bendix pinion until it locks in the extended position. Locate “spirol” pin and use a punch to remove. Slide drive assembly off the shaft. Do not attempt to disassemble the drive and do not dip it in cleaning solvent.

  • Page 609: Field Coils

    PIPER SENECA SERVICE MANUAL Testing Motor Fields for Ground No-Load Test Hook-up Figure 22 Figure 23 31. FIELD COILS. Check the field coils for grounds (refer to Figure 22) by placing one test probe on the frame and the other on the starter terminal. Be sure the brushes are not accidentally touching the frame. If the lamp lights, the fields are grounded.

  • Page 610: Bench Tests

    PIPER SENECA SERVICE MANUAL Stall-Torque Hook-up Figure 24 35. ASSEMBLY. When assembling the starting motor, always use an arbor press and the proper bearing arbor for installing graphitized bronze and roller bearings. The Bendix shaft should have a thin film of Lubriplate #777 or equivalent on the Bendix portion of the shaft.

  • Page 611: Starting Motor Control Circuit

    PIPER SENECA SERVICE MANUAL 37. STARTING MOTOR CONTROL CIRCUIT. Inspect the control circuit wiring between the battery, solenoid and manual starting switches for breaks, poor connections and faulty insulation. Tighten all connections and make sure solenoid is firmly mounted and makes a good ground connection.
  • Page 612 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 34 XI - ELECTRICAL SYSTEM Oct 30/03 3J10...

  • Page 613: Installation

    PIPER SENECA SERVICE MANUAL 39. BATTERY. 39a. TROUBLESHOOTING. See Table VIII, below. 40. SERVICING. The battery is located in the left forward portion of the nose section. It is enclosed in a fiberglass box with a vent system and a drain. The vents allow fresh air to enter the box and draw off fumes that may accumulate due to the charging process of the battery.
  • Page 614 PIPER SENECA SERVICE MANUAL TABLE VIII (Sheet 1 of 2) TROUBLESHOOTING BATTERY Trouble Cause Remedy Discharged battery. Battery worn out. Replace battery. Low electrical system Check voltage regulator voltage. voltage. Standing too long. Remove and recharge battery if left in unused airplane three (3) weeks or more.
  • Page 615 PIPER SENECA SERVICE MANUAL TABLE VIII (Sheet 2 of 2) TROUBLESHOOTING BATTERY Trouble Cause Remedy Leaking battery jar. Frozen. Replace. Battery polarity reversed. Connected backwards on Battery should be slowly airplane or charger. discharged completely and then charged correctly and tested.
  • Page 616 PIPER SENECA SERVICE MANUAL 44a. EXTERNAL POWER RECEPTACLE. The external power receptacle is located on the left side of the nose section. CAUTION: IF AIRCRAFT BATTERY IS WEAK, CHARGING CURRENT WILL BE HIGH. DO NOT TAKE OFF UNTIL CHARGING CURRENT FALLS BELOW 20 AMPS. NEVER USE A 12 OR 24 VOLT BATTERY IN PLACE OF A SIX VOLT BATTERY SINCE ELECTRICAL DAMAGE MAY RESULT.
  • Page 617 PIPER SENECA SERVICE MANUAL 44b. EXTERIOR LIGHTS. See Table IX, below, for replacement lamps. 45. LANDING AND TAXI LIGHTS. These lights consist of two 250 watt lamps which are located on a mounting fixture secured to the nose gear oleo strut housing. Both lamps are used for landing and one lamp is used while taxiing.
  • Page 618 PIPER SENECA SERVICE MANUAL TABLE IX LAMP REPLACEMENT GUIDE Location Piper Part No. Lamp No. Exterior Wing Tips 751-381 # 1512 Tail Light 753-431 # 1073 Anti-Collision 757-635 # A406 Landing Light 472-661 # 4509 Interior Reading Light # 93 Instrument—Glar-Ban...
  • Page 619 PIPER SENECA SERVICE MANUAL To install the landing light assembly to the strut, position the assembly against the strut housing with the bottom of the mounting fixture 2.9 in. up from the bottom of the strut housing. (See Figure 25.) Align the bracket longitudinally and secure in place with clamps.
  • Page 620 PIPER SENECA SERVICE MANUAL 55a. ANTI-COLLISION STROBE LIGHTS. 55b. TROUBLESHOOTING. The strobe light assembly functions as a condenser discharge system. A condenser in the power supply is charged to approximately 450 volts D.C., then discharged across the Xenon flash tube at intervals approximately 45 flashes per minute. The condenser is parallel across the Xenon flash tube which is designed to hold off the 450 volts D.C.
  • Page 621 PIPER SENECA SERVICE MANUAL Check the tube socket assembly for shorts. Disconnect the tube socket assembly of the anti-collision light from the interconnecting cable. The following continuity checks can be made with an ohmmeter. Check for continuity between pin 1 of AMP connector to pin 1 of tube socket, pin 2 of AMP connector to pins 6 and 7 of tube socket and pin 3 of AMP connector to pin 4 of tube socket.
  • Page 622 PIPER SENECA SERVICE MANUAL 60a. INTERIOR LIGHTS. See Table IX, above, for replacement lamps. 60b. OVERHEAD READING LIGHT LAMP. 61. REMOVAL. The lights are located in the center and rear overhead panels. Grasp the protruding section of the light assembly and turn to remove from its socket.
  • Page 623 PIPER SENECA SERVICE MANUAL 66. ALUMINUM WIRING. For airplanes which have not complied with Piper Service Bulletin No. 836A: Locate and identify the following cables: (1) Battery to ground. (2) Battery to master relay. (3) Master relay to starter solenoid.
  • Page 624 PIPER SENECA SERVICE MANUAL 67. STALL WARNING INDICATOR, HORN AND LIFT DETECTORS. This system consists of an inboard and outboard lift detector, both of which are electrically connected to a stall warning light located in the instrument panel in front of the pilot and a stall warning horn located behind the instrument panel.
  • Page 625 PIPER SENECA SERVICE MANUAL Adjusting Lift Detector Microswitch Figure 26 XI - ELECTRICAL SYSTEM PAGE 47 3J23 Oct 30/03...
  • Page 626 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 48 XI - ELECTRICAL SYSTEM Oct 30/03 3J24...
  • Page 627 PIPER SENECA SERVICE MANUAL 71. ELECTRICAL SCHEMATICS (I.E. - WIRING DIAGRAMS) INDEX. Subject Grid Number Alternators Anti-Collision Fin-Tip Strobe Light 3K16 Electrical Symbols Engine Gauges 3K17 Fuel Pumps 3K18 Heater and Defroster 3K19 Landing Gear 3K11 Landing/Taxi Lights 3K16 Magnetos...
  • Page 628 PIPER SENECA SERVICE MANUAL TABLE X ELECTRICAL WIRE CODING CIRCUIT FUNCTION LETTER CIRCUITS AUTOPILOT CONTROL SURFACE FLIGHT INSTRUMENT LANDING GEAR HEATER - VENTILATING & DEICING LIGHTING POWER FUEL, OIL & ENGINE INSTRUMENT RADIO POWER RADIO AUDIO IGNITION PAGE 50 XI - ELECTRICAL SYSTEM...
  • Page 629 PIPER SENECA SERVICE MANUAL TABLE XI (Sheet 1 of 3 ELECTRICAL SYMBOLS (Old Style) XI - ELECTRICAL SYSTEM PAGE 51 Oct 30/03...
  • Page 630 PIPER SENECA SERVICE MANUAL TABLE XI (Sheet 2 of 3 ELECTRICAL SYMBOLS (New Style) AIRCRAFT LOCATION SYMBOLS BATTERIES ADJUSTABILITY GENERAL GENERAL MULTICELL FUSELAGE STATION WATER LINE BUTT LINE CABLES AND CONDUCTORS SHIELDED SHIELDED TWO COAXIAL SHIELDED SINGLE TWISTED TWISTED CONDUCTOR...
  • Page 631 PIPER SENECA SERVICE MANUAL TABLE XI (Sheet 3 of 3 ELECTRICAL SYMBOLS (New Style) MOMENTARY OR PUSH BUTTON CONTACT SWITCH ASSEMBLIES SPRING RETURN BASIC (MAKE) (BREAK) CLOSED OPEN TRANSFER CIRCUIT CIRCUIT CONTACT CONTACT CLOSING OPENING CIRCUIT LOCKING AND NON-LOCKING MOMENTARY OR...
  • Page 632 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 54 XI - ELECTRICAL SYSTEM Oct 30/03...
  • Page 633 PIPER SENECA SERVICE MANUAL Alternators Effectivity Figure 27 34-7250001 thru 34-7350135 XI - ELECTRICAL SYSTEM PAGE 55 Oct 30/03...
  • Page 634 PIPER SENECA SERVICE MANUAL Effectivity Alternators 34-7350136 thru 34-7350363 Figure 28 PAGE 56 XI - ELECTRICAL SYSTEM Oct 30/03...
  • Page 635 PIPER SENECA SERVICE MANUAL Alternators Effectivity Figure 29 34-7450001 thru 34-7450220 XI - ELECTRICAL SYSTEM PAGE 57 Oct 30/03...
  • Page 636 PIPER SENECA SERVICE MANUAL Starters Figure 30 PAGE 58 XI - ELECTRICAL SYSTEM Oct 30/03 3K10...
  • Page 637 PIPER SENECA SERVICE MANUAL Landing Gear Effectivity Figure 31 34-7250001 thru 34-7350135 XI - ELECTRICAL SYSTEM PAGE 59 3K11 Oct 30/03...
  • Page 638 PIPER SENECA SERVICE MANUAL Effectivity Landing Gear 34-7350136 thru 34-7450220 Figure 32 PAGE 60 XI - ELECTRICAL SYSTEM Oct 30/03 3K12...
  • Page 639 PIPER SENECA SERVICE MANUAL Panel Lights Effectivity Figure 33 34-7250001 thru 34-7350363 XI - ELECTRICAL SYSTEM PAGE 61 3K13 Oct 30/03...
  • Page 640 PIPER SENECA SERVICE MANUAL Effectivity Panel Lights 34-7450001 thru 34-7450220 Figure 34 PAGE 62 XI - ELECTRICAL SYSTEM Oct 30/03 3K14...
  • Page 641 PIPER SENECA SERVICE MANUAL Reading and Baggage Lights Effectivity Figure 35 34-7250001 thru 34-7350363 Reading and Baggage Lights Effectivity Figure 36 34-7450001 thru 34-7450220 XI - ELECTRICAL SYSTEM PAGE 63 3K15 Oct 30/03...
  • Page 642 PIPER SENECA SERVICE MANUAL Position Lights Landing/Taxi Lights Figure 37 Figure 38 Anti-Collision Fin-Tip Strobe Light Wing Ice Inspection Light Figure 39 Figure 40 PAGE 64 XI - ELECTRICAL SYSTEM Oct 30/03 3K16...
  • Page 643 PIPER SENECA SERVICE MANUAL Turn and Bank Figure 41 Engine Gauges Figure 42 XI - ELECTRICAL SYSTEM PAGE 65 3K17 Oct 30/03...
  • Page 644 PIPER SENECA SERVICE MANUAL Pitot Heat and Cigar Lighter Fuel Pumps Figure 43 Figure 44 Propeller Deice Figure 45 PAGE 66 XI - ELECTRICAL SYSTEM Oct 30/03 3K18...
  • Page 646 PIPER SENECA SERVICE MANUAL Stall Warning Figure 47 Vent Blower Figure 48 PAGE 68 XI - ELECTRICAL SYSTEM Oct 30/03 3K20...
  • Page 647 PIPER SENECA SERVICE MANUAL Magnetos Figure 49 XI - ELECTRICAL SYSTEM PAGE 69 3K21 Oct 30/03...
  • Page 648 PIPER SENECA SERVICE MANUAL GRIDS 3K22 THRU 3L24 INTENTIONALLY BLANK PAGE 70 XI - ELECTRICAL SYSTEM Oct 30/03 3K22...
  • Page 649 AIRPLANE SERVICE MANUAL CARD 4 OF 4 PA-34-200 (S/N’s 34-7250001 THRU 34-7450220) PIPER AIRCRAFT CORPORATION PART NUMBER 753-817 October 30, 2003...
  • Page 650 Published by Technical Publications © The New Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association...

  • Page 651: Aerofiche Effectivity

    PIPER SENECA SERVICE MANUAL AEROFICHE REVISION STATUS Revisions to this Service Manual 753-817 originally issued April 5, 1971 are as follows: Revision Publication Date Aerofiche Card Effectivity ORG710405 April 5, 1971 CR720613 June 13, 1972 CR031030 * October 30, 2003 1, 2, 3, &...
  • Page 652 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 AEROFICHE EFFECTIVITY Oct 30/03...
  • Page 653 PIPER SENECA SERVICE MANUAL INTRODUCTION LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE Intro-List of Oct 30/03 Effective Pages Oct 30/03 Intro-Table of Contents Oct 30/03 Oct 30/03 Introduction Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 654 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 655 PIPER SENECA SERVICE MANUAL TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness General Effectivity Serial Number Explanation 4A10 Assignment of Subject Material 4A10 Pagination 4A10 Aerofiche Effectivity 4A10 Identifying Revised Material 4A10 Indexing 4A10 List of Effective Pages...
  • Page 656 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 INTRO - CONTENTS Oct 30/03...
  • Page 657 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.
  • Page 658 PIPER SENECA SERVICE MANUAL SERIAL NUMBER EXPLANATION. Example: 34 72 50 001 SEQUENCE NUMBER TYPE CERTIFICATE DESIGNATION MODEL YEAR MODEL CODE 50 = PA-34-200 SENECA ASSIGNMENT OF SUBJECT MATERIAL. This publication is divided into logical subject groupings based on aircraft system or task function. Refer to paragraph 14, Section Index Guide, for a complete breakdown and list.
  • Page 659 To improve our Service and Reliability system and aid in our compliance with FAR 21.3, knowledge of all incidents and/or accidents must be reported to Piper immediately. To expedite and assist in reporting all incidents and accidents, Piper Form 420-01 has been created. See Service Letter 1041 for latest revision.
  • Page 660 PIPER SENECA SERVICE MANUAL (4) BRAKES AND WHEELS: Vendor Address: Parker Hannifin Corp - (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/cleveland/Universe/book.pdf (5) ENGINE: Vendor Address: Textron Lycoming - (717) 323-6181 652 Oliver Street...
  • Page 661 PIPER SENECA SERVICE MANUAL (10) LANDING GEAR ACTUATOR, EXTENSION AND RETRACTION: Vendor Address: Parker Hannifin Corp - (800) 272-5464 Aircraft Wheel and Brake Division 1160 Center Road Avon, Ohio 44011 http://www.parker.com/cleveland/ Component (Effective for P/N’s 96860-002 and 96860-003 only.) Maintenance Manual:...
  • Page 662 PIPER SENECA SERVICE MANUAL (14) PROPELLER: Vendor Address: Hartzell Propeller Inc. - (937) 778-4379 One Propellor Place FAX - (937) 778-4321 Piqua, OH 45356-2634 http://www.hartzellprop.com/index2.htm Standard Practices: Manual No. 202A Overhaul and Maintenance: Manual No. 117D Aluminum Blade Overhaul: Manual No. 133C Propeller Owner’s...
  • Page 663 PIPER SENECA SERVICE MANUAL (18) VACUUM REGULATORS: Vendor Address: Parker Hannifin Corp. PH: - (800) 382-8422 Airborne Division 711 Taylor Street Elyria, Ohio 44035 http://www.parker.com/cleveland/Universe/book.pdf (19) VOLTAGE REGULATOR: Vendor Address: See listing under Alternator, above. INTRODUCTION PAGE 7 4A15 Oct 30/03...
  • Page 664 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 8 INTRODUCTION Oct 30/03 4A16...
  • Page 665 PIPER SENECA SERVICE MANUAL 14 SECTION INDEX GUIDE. SECTION TITLE GRID NO. AIRWORTHINESS LIMITATIONS HANDLING AND SERVICING INSPECTION STRUCTURES 1H11 SURFACE CONTROLS HYDRAULIC SYSTEM LANDING GEAR AND BRAKES 2G21 VIII POWERPLANT FUEL SYSTEM INSTRUMENTS ELECTRICAL SYSTEM 3H17 ELECTRONICS XIII HEATING AND VENTILATION SYSTEM...
  • Page 666 PIPER SENECA SERVICE MANUAL GRIDS 4A18 THRU 4A24 INTENTIONALLY BLANK PAGE 10 INTRODUCTION Oct 30/03 4A18...
  • Page 667 PIPER SENECA SERVICE MANUAL Schematics Alternators: 3K7 Cabin Access Plates and Panels: 1C22 Anti-Collision Fin-Tip Strobe Heating, Defrost, and Accident/Incident Reporting: A11 Light: 3K16 Ventilation: 4D2 Aerofiche Combustion Heater: 4D16 Consumable Materials: 1E9 Effectivity: A10 Electrical Symbols: 3K3 Conversion Tables...
  • Page 668 PIPER SENECA SERVICE MANUAL Environmental Systems Fuel System: 1D9 E (cont.) Description and Operation: 4D1 Description: 3F7 Engine Optional Combustion Heater: Draining Alternate Air Door Entirely: 1D11 100 Hour Inspection: 3D6 Exploded View: 4E16 Moisture: 1D11 Cowl Flaps: 3C13 Inspections: 4D17...
  • Page 669 PIPER SENECA SERVICE MANUAL Per Specific Operation / Operating Environment.: Landing Gear Ice and Rain Protection: 4F11, 1G20 Cleaning: 1D19 4G15 Extreme Cold: 1G21 Description: 2H3 Ignition System High Dust: 1G20 Electrical Schematic: 2J3 Contact Points: 3D11 High Humidity: 1G21...
  • Page 670 PIPER SENECA SERVICE MANUAL Propeller Rudder L (cont.) Air Charge Pressure vs. 100 Hour Rudder Tab Freeplay Lights Temperature: 3C15 Inspection: 2E14 Exterior: 3J15 Deicing System: 4F11 Balancing Anti-Collision Strobe: 3J18 Deicers: 4G4 Procedure: 1K8 Landing and Taxi: 3J15 Electrical Check: 4G10...
  • Page 671 PIPER SENECA SERVICE MANUAL Troubleshooting Aileron Controls: 2D1 Vacuum System Taxiing: 1D7 Airspeed Indicator: 3G23 Description: 3G12 Testing Alternator: 3I5 Filter(s): 3G14 Alternator: 3I17 Altimeter: 3G22 Gauge: 3G14 Combustion Heater: 4E12 Ammeters: 3H10 Pump: 3G16 Bench Tests: 4E20 Battery: 3J12...
  • Page 672 PIPER SENECA SERVICE MANUAL GRIDS 4B6 THRU 4B24 INTENTIONALLY BLANK PAGE 6 INDEX Oct 30/03...
  • Page 673 PIPER SENECA SERVICE MANUAL SECTION ELECTRONICS...
  • Page 674 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...

  • Page 675: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION XII LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE XII-List of Oct 30/03 Effective Pages Oct 30/03 XII-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 676 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 XII - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 677 Narco Alkaline Battery 4C11 Pilot’s Remote Switch - Description, Operation and Testing 4C11 Testing 4C13 Autoflight 4C14 Piper Automated Flight Control System Equipment 4C14 Non-Piper Automated Flight Control System (AFCS) Equipment Contacts 4C15 XII - CONTENTS PAGE 1 Oct 30/03...
  • Page 678 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 XII - CONTENTS Oct 30/03...

  • Page 679: Emergency Locator Transmitter (Elt)

    NOTE: One or more of the following batteries may no longer be available. See parts catalog and consult your local Piper Service Center for available replacement options, if any. As of the 2003 revision, Artex Aircraft Supplies, 14405 Keil Rd NE, Aurora, OR 97022 (www.artex.net) offered a line of replacement batteries.
  • Page 680 PIPER SENECA SERVICE MANUAL Garrett Magnesium Battery Connections Figure 1 Disconnect the battery connector from the board terminals. Withdraw the battery pack from the transmitter case. Before installing the new battery pack, check the replacement date printed on the battery. Transfer this date onto the ELT label.
  • Page 681 PIPER SENECA SERVICE MANUAL Connect the antenna coax to the transmitter. CAUTION: ANTENNA DAMAGE MAY CAUSE STRUCTURAL FAILURE OF WHIP IN FLIGHT. Inspect the external whip antenna for any damage. Avoid bending the whip. Any sharply bent or kinked whip should be replaced.
  • Page 682 PIPER SENECA SERVICE MANUAL Narco ELT 10 Figure 2 PAGE 4 XII - ELECTRONICS Oct 30/03 4C10...
  • Page 683 PIPER SENECA SERVICE MANUAL NARCO ALKALINE BATTERY. (Refer to Figure 2.) The ELT is located on the right side of the airplane tail section, ahead of the stabilator. Remove the access plate on the right side of fuselage aft of sta. 257.678.
  • Page 684 PIPER SENECA SERVICE MANUAL Pilot’s Remote Switch Figure 3 PAGE 6 XII - ELECTRONICS Oct 30/03 4C12...
  • Page 685 PIPER SENECA SERVICE MANUAL Testing. The transmitter operates on the emergency frequencies of 121.5 and 243 MHz; both of these frequencies are monitored by the various FAA installations. Before performing any operational test of the ELT, the following precautions should be observed:...
  • Page 686 Piper AutoPilot/Flight Director Service Manual shall be used. NOTE: If a Roll Axis-only AutoPilot is installed, or if no AutoPilot is installed, consult the Piper Pitch Trim Service Manual - 753 771 for manual electric pitch trim service information.
  • Page 687 PIPER SENECA SERVICE MANUAL 11. NON-PIPER A.F.C.S. EQUIPMENT CONTACTS: Refer the following list of AutoPilot/Flight Director manufacturers to obtain service direction, parts support, and service literature. WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY.
  • Page 688 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 10 XII - ELECTRONICS Oct 30/03 4C16...
  • Page 689 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XII - ELECTRONICS PAGE 11 4C17 Oct 30/03...
  • Page 690 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 12 XII - ELECTRONICS Oct 30/03 4C18...

  • Page 691: Heating And Ventilation System

    PIPER SENECA SERVICE MANUAL SECTION XIII HEATING AND VENTILATION SYSTEM 4C19...
  • Page 692 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK 4C20...

  • Page 693: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION XIII LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE XIII-List of Oct 30/03 Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 XIII-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 694 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 XIII - LIST OF EFFECTIVE PAGES Oct 30/03 4C22...
  • Page 695 PIPER SENECA SERVICE MANUAL SECTION XIII - HEATING AND VENTILATION SYSTEM TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. HEATING AND VENTILATION SYSTEM XIII Introduction Description and Operation Inspection Rigging Cabin Heat and Defrost Controls Control Interconnect to Firewall Heat Valve...
  • Page 696 PIPER SENECA SERVICE MANUAL SECTION XIII - HEATING AND VENTILATION SYSTEM TABLE OF CONTENTS (cont.) SUBJECT SECTION PAGE GRID NO. Cycling Switch and Limit (Overheat Switch) Removal Installation Combustion Air Pressure Switch Removal Installation Fuel Regulator and Shutoff Valve Removal...
  • Page 697 PIPER SENECA SERVICE MANUAL HEATING AND VENTILATION SYSTEM INTRODUCTION. This section contains instructions for operating, servicing, and inspecting the heating, defrosting and ventilating systems installed in the PA-34-200. DESCRIPTION AND OPERATION. Cabin and defrost heat is provided by means of a heat exchanger mounted on the exhaust manifold of each engine (outboard side).
  • Page 698 PIPER SENECA SERVICE MANUAL Cabin Heating, Defrost, and Ventilation Effectivity (1972 - 1973 Models) 34-7250001 thru 34-7350363 Figure 1 PAGE 2 XIII - HEATING & VENTILATION Oct 30/03...
  • Page 699 PIPER SENECA SERVICE MANUAL Cabin Heating, Defrost, and Ventilation (1974 Models) Effectivity Figure 2 34-7450001 thru 34-7450220 XIII - HEATING & VENTILATION PAGE 3 Oct 30/03...
  • Page 700 PIPER SENECA SERVICE MANUAL RIGGING CABIN HEAT AND DEFROST CONTROLS. (The following paragraphs keyed to Figure 3.) CONTROL INTERCONNECT TO FIREWALL HEAT VALVE. Position the control arm actuating end (2) so that its centerline is perpendicular to the centerline of the sliding link (3), and install the cable (10) in the fitting on the control arm (1).
  • Page 701 PIPER SENECA SERVICE MANUAL Effectivity 34-7250246 thru 34-7450220 34-7250001 thru 34-7250245 Rigging Cabin Heat / Defrost Controls with Kit No. 760-692 or Figure 3 (Sheet 1 of 2) 760-693 installed XIII - HEATING & VENTILATION PAGE 5 Oct 30/03...
  • Page 702 PIPER SENECA SERVICE MANUAL Effectivity Rigging Cabin Heat / Defrost Controls 34-7250001 thru 34-7250245 Figure 3 (Sheet 2 of 2) as originally delivered PAGE 6 XIII - HEATING & VENTILATION Oct 30/03...
  • Page 703 8 and 9. 10. OPTIONAL COMBUSTION HEATER (JANITROL). (See Figures 2 and 4.) WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) 11.
  • Page 704 PIPER SENECA SERVICE MANUAL Regulating the heater and airflow is accomplished by adjusting the levers on the heater control console. The right-hand lever regulates the air intake valve, while the left-hand lever regulates cabin temperature. Cabin temperature and air circulation can be varied to suit individual requirements by various combinations of lever settings.
  • Page 705 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 1 of 5) TROUBLESHOOTING COMBUSTION HEATER (JANITROL) Trouble Cause Remedy Heater fails to light. Heater switch or circuit Turn on heater switch or breaker off. close circuit breaker. Low voltage supply. Apply external power supply.
  • Page 706 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 2 of 5) TROUBLESHOOTING COMBUSTION HEATER (JANITROL) Trouble Cause Remedy Heater fails to light. (cont.) Combustion air pressure Check for low blower switch open. (Defective output due to low voltage switch or low combustion and correct it.
  • Page 707 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 3 of 5) TROUBLESHOOTING COMBUSTION HEATER (JANITROL) Trouble Cause Remedy Combustion air blower Blower wheel jammed. Overhaul the combustion fails to run. (Cont.) (Usually indicated by air blower. (Refer to hot motor housing.) Ventilating Air Blower, below;...
  • Page 708 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 4 of 5) TROUBLESHOOTING COMBUSTION HEATER (JANITROL) Trouble Cause Remedy Heater fires but burns High voltage leak in Replace ignition assembly. unsteadily (cont). lead between ignition (Refer to Ignition Unit: assembly and spark plug.
  • Page 709 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 5 of 5) TROUBLESHOOTING COMBUSTION HEATER (JANITROL) Trouble Cause Remedy Heater fails to shut off. Fuel solenoid valve in Remove and replace heater stuck open. solenoid assembly. (Refer to Overhaul: Disassembly, below; and, Overhaul: Inspection of Remaining Components, below;...
  • Page 710 PIPER SENECA SERVICE MANUAL Optional Combustion Heater (Janitrol) Figure 4 PAGE 14 XIII - HEATING & VENTILATION Oct 30/03 4D14...
  • Page 711 PIPER SENECA SERVICE MANUAL Heater Cutaway Showing Whirling Flame Action Figure 5 14. OPERATING CONTROLS. (Refer to Figure 6.) NOTE: The schematic diagram (Figure 6) shows the heater circuit, including the electrical wiring in the airplane. The HEATER SWITCH is connected in the line that supplies electrical power to all heater equipment and controls.
  • Page 712 PIPER SENECA SERVICE MANUAL Heater Wiring Diagram Figure 6 PAGE 16 XIII - HEATING & VENTILATION Oct 30/03 4D16...

  • Page 713: Hour Inspection

    PIPER SENECA SERVICE MANUAL 16. INSPECTIONS. 17. 50-HOUR INSPECTION. Inspect the ventilating air inlet scoop, combustion air inlet scoop, exhaust outlet and fuel drains for possible obstructions. Make sure that all of these openings are clear of any restrictions and that no damage has occurred to the exhaust, cold or hot fuel drains, water drain or fuel line drain.
  • Page 714 PIPER SENECA SERVICE MANUAL Heater Primary Power Circuit Figure 7 21. VENT BLOWER POWER CIRCUIT CHECK. This blower is attached to the inlet end of the heater assembly and provides a source of ventilating air through the heater. Ram air from the ventilating air intake scoop is used during flight.
  • Page 715 PIPER SENECA SERVICE MANUAL Heater Starting Power Circuit Figure 8 Terminal No. 1 of the heater terminal strip, if the air valve is not closed. From terminal No. 1 of the heater terminal strip through the radio noise filter to the combustion air motor, and to terminal No.
  • Page 716 PIPER SENECA SERVICE MANUAL 23. MAINTENANCE. Instructions below pertain to maintenance of the basic heater and components while the heater is installed in the airplane. Instructions for removal of components are included provided the installation permits accessibility. NOTE: No special service tools are required for normal periodic maintenance.

  • Page 717: Combustion Air Blower

    PIPER SENECA SERVICE MANUAL Check the operation of the heater per Heater System - Operational Test, above. Install the access panel to the aft section of the fuselage. 27. COMBUSTION AIR BLOWER. This centrifugal-type blower supplies combustion air to the combustion chamber of the heater.

  • Page 718: Spark Plug

    PIPER SENECA SERVICE MANUAL 28. SPARK PLUG. Removal: (Refer to Figure 18.) Remove the necessary access panels to expose the spark plug area of the heater assembly. NOTE: Insure that heater electrical circuits are de-energized. Unscrew and remove the high-voltage lead connector at the spark plug. Exercise care to avoid fouling or damaging the connector.

  • Page 719: Operational Test

    PIPER SENECA SERVICE MANUAL Spark Plug Gap Adjustment Figure 9 29. IGNITION UNIT. This unit converts 14-volt DC to high voltage, oscillating current capable of producing a continuous spark in the combustion chamber of the heater. This unit remains energized and produces a continuous spark during heater operation.
  • Page 720 PIPER SENECA SERVICE MANUAL Spark Plug Fixture Test Setup Wiring Figure 10 Figure 11 Connect the primary lead to the primary terminal on the ignition unit (2) and tighten the nut securely. Check for proper heater operation. 32. TESTING. The ignition unit does not require complete overhaul. The following test will indicate whether or not the unit is operational and whether the vibrator should be replaced before reinstallation in the aircraft.
  • Page 721 PIPER SENECA SERVICE MANUAL 33. DISASSEMBLY. (Refer to Figure 12.) Remove cover assembly (1) by carefully drilling out the “pop” rivets (2). Remove ignition cable terminal from ignition coil (8). All replaceable items are accessible for checking without further disassembly from the ignition box (12).
  • Page 722 PIPER SENECA SERVICE MANUAL TABLE II IGNITION UNIT INSPECTION Index No. Nomenclature Inspection Cover Assembly Inspect for security of lead assembly to cover. Ignition cable, grommet, terminal and connector for carbon tracks, cracks or distortion. Repair or replace for any of above conditions.
  • Page 723 PIPER SENECA SERVICE MANUAL 38. CYCLING SWITCH AND LIMIT (OVERHEAT) SWITCH. (Refer to Figure 18.) Removal: If the limit switch (25) is damaged or defective, disconnect the three electrical leads from the switch terminals. Be sure to mark the leads for proper reassembly. (The switch terminals are identified by numbers “1,”...
  • Page 724 PIPER SENECA SERVICE MANUAL 40. FUEL REGULATOR AND SHUTOFF VALVE. (Refer to Figure 13 and 19.) This unit provides preset, regulated fuel pressure as well as remote shutoff to the heater, regardless of fuel inlet pressure variations. It is set for 7.0 psi. The shutoff valve is operated by a solenoid.
  • Page 725 PIPER SENECA SERVICE MANUAL Fuel Regulator and Shutoff Valve Figure 13 Fuel Regulator and Shutoff Valve Test Setup Figure 14 XIII - HEATING & VENTILATION PAGE 29 Oct 30/03...

  • Page 726: Fuel Filter

    PIPER SENECA SERVICE MANUAL 42. FUEL FILTER. At the end of each 500 hours of operation, the fuel filter should be removed from the aircraft and overhauled according to the following procedure: Remove the tube from the “IN” side of the filter assembly.
  • Page 727 PIPER SENECA SERVICE MANUAL Position the filter assembly on the mount and secure with the two bolts. Screw the hex shoulder nipple in the “OUT” side of the filter assembly. Install the tube on the “IN” side of the filter assembly.
  • Page 728 WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) 45.
  • Page 729 PIPER SENECA SERVICE MANUAL m. Reach inside the inlet end of the jacket assembly (5) with a 3/4 inch open-end wrench and, while holding the fuel-tube fitting at the jacket, use a 3/4 inch deep socket to remove the nut (38), washer and gasket (29).
  • Page 730 PIPER SENECA SERVICE MANUAL 47. CLEANING. (Refer to Figure 18.) Clean individual metal parts (except those parts containing switches and electrical wiring) and the combustion tube assembly, by immersing them in dry-cleaning solvent, such as Stoddard solvent (Federal Specification P-D-680). A bristle brush should be used to assist the cleaning process if foreign accumulations are stubborn to remove.
  • Page 731 PIPER SENECA SERVICE MANUAL 49. INSPECTION OF REMAINING COMPONENTS. (Refer to Figure 18.) Discard all rubber parts such as grommets, gaskets, etc. These items should always be replaced at overhaul. Also discard the rope gasket (31). Inspect all wires and wiring harnesses for damage to insulation, damaged terminals, chafed or cracked insulation and broken plastic bands.
  • Page 732 PIPER SENECA SERVICE MANUAL Remove the brushes, one at a time, from the ventilating air blower motor (13) by removing the brush cap and carefully withdrawing the brush from its guide. Remove foreign material from the brush guide and commutator with a stream of filtered compressed air. Check for brush wear (refer to Maintenance - Combustion Air Blower - Replacing Motor Brushes, above).
  • Page 733 PIPER SENECA SERVICE MANUAL Seal Plate, Plugs, and Caps for Combustion Tube Leak Test Figure 16 Combustion Air Pressure Switch Test Setup Figure 17 XIII - HEATING & VENTILATION PAGE 37 4E13 Oct 30/03...
  • Page 734 PIPER SENECA SERVICE MANUAL Apply air pressure allowing it to build up very slowly from zero. The switch contacts should close at 0.5 ± 0.1 inches of water which will be indicated on the manometer. NOTE: The switch cover has a differential pressure tap and this opening must be left open to atmosphere during test.
  • Page 735 PIPER SENECA SERVICE MANUAL Insert this assembly into the blower housing (12) and position it so the long screw is in alignment with the gap on the inner ring of the motor bracket assembly (19). This is the screw used to secure and align the motor in the bracket.
  • Page 736 PIPER SENECA SERVICE MANUAL Heater (Janitrol) Assembly - Exploded View Figure 18 (Sheet 1 of 2) PAGE 40 XIII - HEATING & VENTILATION Oct 30/03 4E16...
  • Page 737 PIPER SENECA SERVICE MANUAL Heater (Janitrol) Assembly - Exploded View Figure 18 (Sheet 2 of 2) XIII - HEATING & VENTILATION PAGE 41 4E17 Oct 30/03...
  • Page 738 PIPER SENECA SERVICE MANUAL Place the terminal strip insulation (36) in position on the jacket (5), followed by the terminal strip (35). Secure both parts by installing the two screws and lock washers. The two screws are located at two diagonal corners of the terminal strip.
  • Page 739 PIPER SENECA SERVICE MANUAL Combustion Air Blower and Motor Assembly - Exploded View Figure 19 XIII - HEATING & VENTILATION PAGE 43 4E19 Oct 30/03...

  • Page 740: Bench Test

    PIPER SENECA SERVICE MANUAL 54. BENCH TEST. A test of all components should have been made after overhaul to insure proper operation. Some shops may not have complete testing facilities for measuring airflows, pressure drops, and other factors which would be accomplished in a laboratory-type test. If such a test cannot be made, install the heater and check operation on the ground and in the air to determine if operation is normal.
  • Page 741 PIPER SENECA SERVICE MANUAL Heater Operation Bench Test - Setup Figure 20 Heater Operation Bench Test - Wiring Figure 21 XIII - HEATING & VENTILATION PAGE 45 4E21 Oct 30/03...
  • Page 742 PIPER SENECA SERVICE MANUAL Observe the manometer connected to the combustion air tube tap, which should show a reading of 1.5 inches of water (minimum) at rated voltage. Open the power supply switch and reconnect the terminal lead disconnected in preceding Step e.
  • Page 743 PIPER SENECA SERVICE MANUAL 58. OPTIONAL OVERHEAD VENT BLOWER. (See Figure 2.) 59. DESCRIPTION. If installed, the blower is mounted in the aft section of the fuselage and is connected to the overhead vent system. The blower draws air in from the dorsal fin and forces it through the ducting whenever desired.

  • Page 744: Installation

    PIPER SENECA SERVICE MANUAL 63. INSTALLATION. Position the blower assembly in the hangers and retainer and install the washers and screws. Install the nuts, washers and screws securing the blower assembly to the hanger braces. Seal all hose joints with Arno No. C-520 gray tape, then install the inlet and outlet hoses securing them with the clamps.
  • Page 745 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XIII - HEATING & VENTILATION PAGE 49 Oct 30/03...
  • Page 746 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 50 XIII - HEATING & VENTILATION Oct 30/03...
  • Page 747 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XIII - HEATING & VENTILATION PAGE 51 Oct 30/03...
  • Page 748 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 52 XIII - HEATING & VENTILATION Oct 30/03...

  • Page 749: Accessories And Utilities

    PIPER SENECA SERVICE MANUAL SECTION ACCESSORIES AND UTILITIES...
  • Page 750 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK...

  • Page 751: List Of Effective Pages

    PIPER SENECA SERVICE MANUAL SECTION XIV LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE XIV-List of Oct 30/03 Oct 30/03 Effective Pages Oct 30/03 Oct 30/03 Oct 30/03 Oct 30/03 XIV-Table of Contents Oct 30/03 Oct 30/03 Oct 30/03...
  • Page 752 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 2 XIV - LIST OF EFFECTIVE PAGES Oct 30/03...
  • Page 753 PIPER SENECA SERVICE MANUAL SECTION XIV - ACCESSORIES AND UTILITES TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. ACCESSORIES AND UTILITIES 4F11 Introduction 4F11 Troubleshooting 4F11 Propeller Deicing System 4F11 Description and Operation 4F11 Operational Check 4F15 Troubleshooting 4F15 Using the Ammeter...
  • Page 754 PIPER SENECA SERVICE MANUAL SECTION XIV - ACCESSORIES AND UTILITIES TABLE OF CONTENTS (cont.) SUBJECT SECTION PAGE GRID NO. Pneumatic Deicing System 4G15 Introduction 4G15 Description and Operation 4G15 Troubleshooting 4G15 Operational Check 4G15 Electrical Test 4G19 Pressure Leakage Test...
  • Page 755 PROPELLER DEICING SYSTEM. (See also Goodrich ATA Report No. 30-60-02, dtd 3/20/02.) WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) DESCRIPTION AND OPERATION.
  • Page 756 PIPER SENECA SERVICE MANUAL Propeller Deice Installation Figure 1 PAGE 2 XIV - ACCESSORIES & UTILITIES Oct 30/03 4F12...
  • Page 757 PIPER SENECA SERVICE MANUAL Cycle Sequence - Phase 1 Figure 2 Cycle Sequence - Phase 2 Figure 3 XIV - ACCESSORIES & UTILITIES PAGE 3 4F13 Oct 30/03...
  • Page 758 PIPER SENECA SERVICE MANUAL Cycle Sequence - Phase 3 Figure 4 Cycle Sequence - Phase 4 Figure 5 PAGE 4 XIV - ACCESSORIES & UTILITIES Oct 30/03 4F14...

  • Page 759: Operational Check

    PIPER SENECA SERVICE MANUAL Ammeter: The ammeter is designed for each particular system and it is therefore important that the correct replacement part number be used if replacement should be required. In the event of low aircraft battery voltage (very possible in ground checks), the ammeter readings will be lower than at full voltage.
  • Page 760 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 1 of 4) TROUBLESHOOTING PROPELLER DEICE SYSTEM Trouble Cause Remedy Ammeter shows zero Tripped circuit Locate and correct short current. (All 4 phases of breaker switch. before setting circuit the 2 minute cycle.) breaker.
  • Page 761 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 2 of 4) TROUBLESHOOTING PROPELLER DEICE SYSTEM Trouble Cause Remedy Ammeter shows normal Inner and outer deicers Locate and repair current part of cycle, low heating same phase. incorrect connections. current rest of cycle.
  • Page 762 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 3 of 4) TROUBLESHOOTING PROPELLER DEICE SYSTEM Trouble Cause Remedy Ammeter shows normal Ground between timer and Disconnect leads at brush current part of cycle, brush block. block and, with ohmmeter, excess current rest of cycle.
  • Page 763 PIPER SENECA SERVICE MANUAL TABLE I (Sheet 4 of 4) TROUBLESHOOTING PROPELLER DEICE SYSTEM Trouble Cause Remedy Ammeter flicks between Timer cycles erratically. Perform Timer Test, below. 34 second phase periods. (cont.) Radio noise or interference Brushes “arcing”. Check brush alignment per with deicers ON.
  • Page 764 PIPER SENECA SERVICE MANUAL INSPECTION (PROPELLER DEICE SYSTEM). WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) 10. 50-HOUR INSPECTION. Lock brakes and operate engines at near takeoff power. Turn deicer system switch ON and observe deicer ammeter for at least two minutes.
  • Page 765 PIPER SENECA SERVICE MANUAL Using a Dial Indicator (Typical) Figure 6 Centering Brushes on Slip Rings Figure 7 XIV - ACCESSORIES & UTILITIES PAGE 11 4F21 Oct 30/03...
  • Page 766 PIPER SENECA SERVICE MANUAL Brush Block - Brushes: Examine mounting brackets and housing for cracks, deformation or other physical damage. Test that each brush rides fully on its slip ring over 360°. Figure 7 shows wear pattern if this condition is not corrected. If alignment is off, shim where brush block bracket attached to engine back bone or pivot at support arm which is attached to generator idler pulley bracket.
  • Page 767 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XIV - ACCESSORIES & UTILITIES PAGE 13 4F23 Oct 30/03...
  • Page 768 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 14 XIV - ACCESSORIES & UTILITIES Oct 30/03 4F24...
  • Page 769 PIPER SENECA SERVICE MANUAL Propeller DeiceSystem - Electrical Schematic Figure 9 12. INDIVIDUAL COMPONENTS. 13. BRUSHES. 14. REPLACEMENT. Brushes are replaceable when the “B” barrel rests entirely within the block; for example, when the aft end of the .187 inch barrel is flush with the aft surface of the block. The brushes must be replaced when the aft end of the “B”...
  • Page 770 PIPER SENECA SERVICE MANUAL Brush Block Assembly Figure 10 PAGE 16 XIV - ACCESSORIES & UTILITIES Oct 30/03...
  • Page 771 PIPER SENECA SERVICE MANUAL 15. REPAIRING BRUSH BLOCK ASSEMBLY. Discard the old brush retainer assembly. Assemble the new brush retainer assembly to the other block by slipping the block from the front of the retainer assembly over the brushes and then over the springs. Replace the two screws removed in Brushes, Replacement, step b, above.

  • Page 772: Slip Rings

    PIPER SENECA SERVICE MANUAL Check for free movement of brushes by pushing the brushes back into the block and allowing the spring pressure to return them. DO NOT SNAP. If free movement is impaired, correct the restriction and recheck. In particular, check the concentricity requirement in paragraph i, above.

  • Page 773: Blade Preparation

    PIPER SENECA SERVICE MANUAL 24. REMOVAL. Disconnect terminals of propeller deicer from studs on the spinner bulkhead. Use MEK or Toluene to soften the adhesion line between the deicer and the propeller blade. Starting at one corner of the deicer, loosen enough of the deicer to grasp in the jaws of a vise grip pliers or similar tool.
  • Page 774 PIPER SENECA SERVICE MANUAL TABLE II REQUIRED MATERIALS - PROPELLER DEICER - INSTALLATION / REMOVAL / REPAIR Adhesive - Choose One System Bostik 1096M System EC776 (if required) and 1007 or 1007M Bostik Primer and 1096M Bostik Cement and #9R Boscodur Accelerator...
  • Page 775 PIPER SENECA SERVICE MANUAL Propeller Deicer Installation Figure 11 Propeller Deicer Installation Procedure Figure 12 XIV - ACCESSORIES & UTILITIES PAGE 21 Oct 30/03...
  • Page 776 PIPER SENECA SERVICE MANUAL Thoroughly mix the 1300L cement. Apply one even brush coat of cement on the unglazed back surface of the deicer. Cement one inch of the deicer lead strap. Allow to air dry for a minimum of one hour at 40°...
  • Page 777 PIPER SENECA SERVICE MANUAL Sealer Application - Deicer Sealer Application - Lead Strap Figure 13 Figure 14 Locate masking tape approximately .125 inch beyond cemented area around deicer to allow application of filler directly to metal. Apply one even brush coat of filler (or sealer) over .125 inch of bare metal, cemented area and about .125 of an inch of deicer.

  • Page 778: Electrical Check

    PIPER SENECA SERVICE MANUAL 31. ELECTRICAL CHECK. Check the electrical resistance of each of the two elements within the deicer. Refer to Schematic, Figure 8, and Resistance Readings. Refer to Table III. Check for intermittent open circuits by tensioning the deicer strap slightly while measuring the resistance.
  • Page 779 PIPER SENECA SERVICE MANUAL Propeller Blade in Low Pitch Figure 15 Propeller Blade in Full Feather Figure 16 XIV - ACCESSORIES & UTILITIES PAGE 25 4G11 Oct 30/03...

  • Page 780: Final Electrical Check

    PIPER SENECA SERVICE MANUAL 35. BALANCING. To assure balance of the propeller assembly, the original balancing weights or their equivalents must be reinstalled. The weights must be left in their original position on the propeller hub. The restrainer and weights should not interfere with any part of the propeller assembly under any condition.
  • Page 781 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XIV - ACCESSORIES & UTILITIES PAGE 27 4G13 Oct 30/03...
  • Page 782 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 28 XIV - ACCESSORIES & UTILITIES Oct 30/03 4G14...
  • Page 783 PIPER SENECA SERVICE MANUAL 37. PNEUMATIC DEICE SYSTEM. WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION - SUPPLEMENTARY PUBLICATIONS.) 38. INTRODUCTION. The following provides service and maintenance procedures for the pneumatic deicing system.
  • Page 784 PIPER SENECA SERVICE MANUAL TABLE IV TROUBLESHOOTING PNEUMATIC DEICE SYSTEM Trouble Cause Remedy Deicers do not inflate. Open circuit breaker. Push circuit breaker to Both engines operating reset. at minimum cruise RPM or either engine at 2575 RPM. System connection loose Tighten or repair as or wire broken.
  • Page 785 PIPER SENECA SERVICE MANUAL Pneumatic Deice System Installation Figure 17 XIV - ACCESSORIES & UTILITIES PAGE 31 4G17 Oct 30/03...
  • Page 786 PIPER SENECA SERVICE MANUAL Pneumatic Deicer (Boot) Operation Figure 18 Pneumatic Deice System Schematic Figure 19 PAGE 32 XIV - ACCESSORIES & UTILITIES Oct 30/03 4G18...
  • Page 787 PIPER SENECA SERVICE MANUAL 42. ELECTRICAL TEST. With engines off, turn airplane battery switch to ON position. Timer: Activate the deicer system switch. The timer should begin to operate immediately and complete one full cycle of the system. If the timer does not function: Reset circuit breaker and recheck.
  • Page 788 PIPER SENECA SERVICE MANUAL 45. INSPECTIONS (PNEUMATIC DEICE SYSTEM). A ground check of the entire deicer system should be made at least every 100 hours or whenever damage is suspected or repairs have been completed. To permit ground checking the system without engine operation, a test plug is designed into all systems, usually between the pressure check valve and the combination unit.
  • Page 789 PIPER SENECA SERVICE MANUAL TABLE V OPERATING PRESSURES Recommended Operating Pressure Test Pressure PSIG in PSIG 48. COMPONENT MAINTENANCE AND REPLACEMENT. 49. AIR FILTER(S). The air filter(s) in the vacuum system can affect pneumatic deice system performance if they are clogged. See Section X, Non-Electrical Instruments, Vacuum Filter(s) for inspection and replacement instructions.
  • Page 790 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 36 XIV - ACCESSORIES & UTILITIES Oct 30/03 4G22...
  • Page 791 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK XIV - ACCESSORIES & UTILITIES PAGE 37 4G23 Oct 30/03...
  • Page 792 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 38 XIV - ACCESSORIES & UTILITIES Oct 30/03 4G24...
  • Page 793 PIPER SENECA SERVICE MANUAL 52. DEICERS (BOOTS) (PNEUMATIC DEICE SYSTEM). (See also Goodrich ATA Report No. 30-10-31, dtd 7/21/03.) See Table VI, below, for required materials. WARNING: CEMENTS AND SOLVENTS USED TO REMOVE AND INSTALL DEICERS ARE EXTREMELY FLAMMABLE AND TOXIC. EXTINGUISH OPEN FLAMES. AVOID SPARKS.
  • Page 794 REQUIRED MATERIALS - PNEUMATIC DEICER - INSTALLATION / REMOVAL / REPAIR Adhesive * - Choose One System (Goodrich Part Number) 3M 1300L System (preferred adhesive) and, A-851-B Fuel Barrier Adhesive 1300L Cement [Piper P/N 179-929 = 1 qt.] (74-451-99) = 1 qt. Bostik 1096M System British Bostick 2402 System...
  • Page 795 PIPER SENECA SERVICE MANUAL TABLE VI (Sheet 2 of 2) REQUIRED MATERIALS - PNEUMATIC DEICER - INSTALLATION / REMOVAL / REPAIR Goodrich Kits Goodrich Part No. Quantity Description 74-451-AA Universal FASTpatch Repair Kit 74-451-206 Primer Pen (2 oz.) 74-451-187 Small Oval Patch (1-1/4 x 2-1/2 in.)
  • Page 796 PIPER SENECA SERVICE MANUAL Apply fuel barrier cement over fuel tank rivets and edges of fuel tanks which will lie under the installed deicer. Proceed as follows: (1) Stir cement thoroughly to blend solids. (2) Apply one even brush coat and let dry one (1) hour.
  • Page 797 PIPER SENECA SERVICE MANUAL Continue installation by reactivating the cement along the centerline leading edge surface and boot in spanwise strips approximately six (6) inches wide. Use a clean lint free cloth dampened with Toulene. Wring and shake cloth to remove excess solvent.
  • Page 798 PIPER SENECA SERVICE MANUAL 58. ADHESION TEST. Using excess boot material trimmed from the ends of any wing and empennage deicers, prepare one test specimen for each deicer installed. This specimen should be a 1 x 8 inch full thickness strip of boot material cemented to the wing skin adjacent to installed boot following the identical procedure used for installation.
  • Page 799 PIPER SENECA SERVICE MANUAL 59a. AGEMASTER ® NO. 1 APPLICATION. AgeMaster ® No. 1 is a rubber preservative for neoprene deicers only that protects against weathering, ozone and ultraviolet rays. Apply AgeMaster ® No. 1 initially 6 months after a new deicer is installed.
  • Page 800 PIPER SENECA SERVICE MANUAL 59b. SHINEMASTER ® APPLICATION. ShineMaster ® treatment is a cosmetic coating that provides high luster shine. ShineMaster ® Prep cleaner is used to clean deicer for ShineMaster ® application, and remove residual ShineMaster ® before reapplication. Application interval for ShineMaster ® depends on operating environment (2 or 3 times per year is typical).
  • Page 801 PIPER SENECA SERVICE MANUAL 60a. APPLICATION IN COMBINATION. AgeMaster ® No. 1, ShineMaster ® and Icex ® II are specifically designed to use together to provide maximum deicer care, appearance and performance. Clean deicer surface to remove previous coatings, dirt, grease, oil and other contamination.
  • Page 802 PIPER SENECA SERVICE MANUAL 62. REPAIR PROCEDURE. See Table VI for materials and supplies. Kits and part numbers referenced below are Goodrich Corporation, unless otherwise noted. NOTE: Repair of damage that does not leak air is not mandatory. Scuff (Surface) Damage. This type of damage will be most commonly encountered and, fortunately, it is not necessary in most cases to make a repair.
  • Page 803 PIPER SENECA SERVICE MANUAL Tube Area Damage. Use Kit No. 74-451-AA (see application instructions, above) to repair cuts, tears or ruptures that leak air but do not cut inflatable tube fabric, and do not exceed 4” X 9”. Use Kit No. 74-451-AE to repair pinholes that leak air, but do not exceed 1/16 inch in diameter.
  • Page 804 PIPER SENECA SERVICE MANUAL 63. RESURFACING. P/N 74-451-L resurfacing kit provides an oil resistant urethane coating. The ”L” Kit can be used to refurbish weathered deicers to extend service life, or to provide oil resistance to newly installed deicers. CAUTION: AFTER KIT NO. 74-451-L IS APPLIED TO A NEOPRENE DEICER, THE DEICER SHOULD BE TREATED AS AN ESTANE ®...
  • Page 805 PIPER SENECA SERVICE MANUAL 64. INSPECTION (PNEUMATIC DEICERS (BOOTS)). Perform the following inspection when: For an uninstalled deicer: (1) The deicer has been stored for more than 84 months. (2) There is evidence of damage to original packaging. (3) The deicer is not in original packaging.
  • Page 806 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 52 XIV - ACCESSORIES & UTILITIES Oct 30/03 4H14...
  • Page 807 PIPER SENECA SERVICE MANUAL 65. WING ICE INSPECTION LIGHT. 66. INTRODUCTION. This light is installed as part of the pneumatic deicing installation and aids the pilot in detecting ice formation on the left wing leading edge during night flying operations.
  • Page 808 PIPER SENECA SERVICE MANUAL THIS PAGE INTENTIONALLY BLANK PAGE 54 XIV - ACCESSORIES & UTILITIES Oct 30/03 4H16...
  • Page 809 PIPER SENECA SERVICE MANUAL 71. RESTRAINT SYSTEM. 72. SHOULDER HARNESS INERTIA REEL ADJUSTMENT. Allow the harness to wind up on the reel as much as possible. On the end of the reel, pry off the plastic cap over the spring, making sure the spring does not come out of the plastic cap, and set cap aside.
  • Page 810 PIPER SENECA SERVICE MANUAL GRIDS 4H18 THRU 4L24 INTENTIONALLY BLANK PAGE 56 XIV - ACCESSORIES & UTILITIES Oct 30/03 4H18...

Table of Contents