Piper Seneca Service Manual

Piper PA-34 Seneca III · Service Manual

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Overview

This document is the Service Manual for the Piper PA-34-200 Seneca, effective for serial numbers 34-7250001 through 34-7450220. It serves as the Instructions for Continued Airworthiness, detailing maintenance procedures, airworthiness limitations, and inspection programs necessary for the safe operation of the aircraft. The manual emphasizes the importance of using genuine Piper parts and outlines the procedures for inspections and maintenance to ensure compliance with FAA regulations. It includes sections on various aircraft systems, handling and servicing, and provides guidance on accident reporting and supplementary publications.

Effective for PA-34-200 Seneca serial numbers 34-7250001 to 34-7450220.
Emphasizes the use of genuine Piper parts for maintenance.
Includes FAA-approved airworthiness limitations and inspection requirements.
Details handling and servicing procedures for safe operation.
Provides comprehensive maintenance guidelines for the powerplant and landing gear systems.

Document

Source

Originally published by pa34owners.org. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.

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Document details

Type: Service Manual
Year: 2003
Pages: 810
File size: 11 MB
Publisher: pa34owners.org

Documentation completeness

4/7

Most owners only have the POH. Here's the essential set for the Piper PA-34 Seneca III.

Pilot's Operating Handbook / AFM
Checklist
Maintenance Manual
Parts Catalog (IPC)
Systems & Wiring
Service Bulletins
Type Certificate (TCDS)

More Piper PA-34 Seneca IIImanuals & documents

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In this document

Introduction

The introduction outlines the purpose of the manual as the Instructions for Continued Airworthiness for the PA-34-200 Seneca. It emphasizes the need for using genuine Piper parts and provides a warning regarding non-Piper approved parts. The section also details the effective serial numbers for the manual and provides a general reference for model years.

Airworthiness Limitations

This section specifies the maintenance requirements under FAA regulations, focusing on the fatigue life of the airplane and its components. It includes limitations that must be adhered to for safe operation and compliance.

Handling and Servicing

This section provides guidelines for the proper handling and servicing of the PA-34-200 Seneca, including preflight checks, fueling procedures, and maintenance practices to ensure the aircraft remains in airworthy condition.

Inspection

Details the inspection program required for the PA-34-200 Seneca, including periodic inspections and specific checks that must be performed to maintain airworthiness.

Powerplant

This section covers the maintenance and inspection procedures for the aircraft's engines, including operational checks, troubleshooting, and servicing requirements.

Landing Gear and Brakes

Outlines the maintenance procedures for the landing gear system and brakes, including inspection intervals, servicing, and troubleshooting tips.

Electrical System

Describes the electrical system components, their maintenance, and troubleshooting procedures to ensure reliable operation.

Fuel System

Covers the fuel system's components, maintenance requirements, and troubleshooting procedures to ensure proper fuel management and safety.

Safety notes

Use only genuine Piper aircraft parts or Piper-approved parts for maintenance.
Non-Piper approved STC installations must be inspected according to the ICA published by the STC owner.

Full document text

PART NUMBER 753-817 October 30, 2003 1A1 AIRPLANE SERVICE MANUAL CARD 1 OF 4 PA-34-200 (S/N’s 34-7250001 THRU 34-7450220) PIPER AIRCRAFT CORPORATION 1A2 Published by Technical Publications © The New Piper Aircraft, Inc. 2926 Piper Drive Vero Beach, Florida 32960 U.S.A. Member General Aviation Manufacturers Association PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1A3 AEROFICHE EFFECTIVITY 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 N/A CR720613 June 13, 1972 N/A CR031030 * October 30, 2003 1, 2, 3, & 4 * COMPLETE REISSUE OF SERVICE MANUAL 753-817 This is a complete reissue of this publication. Accordingly, replace your existing Aerofiche Card Set (i.e. - Cards 1 and 2) with this set (i.e. - Cards 1, 2, 3, and 4) dated 10/30/03. Consult the Customer Service Information Aerofiche (P/N 1753-755) for current revision dates for this manual. PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1A4 AEROFICHE EFFECTIVITY THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1A5 INTRO - LIST OF EFFECTIVE PAGES INTRODUCTION LIST OF EFFECTIVE PAGES SECTION PAGE DATE Intro-List of 1 Oct 30/03 Effective Pages 2 Oct 30/03 Intro-Table of Contents 1 Oct 30/03 2 Oct 30/03 Introduction 1 Oct 30/03 2 Oct 30/03 3 Oct 30/03 4 Oct 30/03 5 Oct 30/03 6 Oct 30/03 7 Oct 30/03 8 Oct 30/03 9 Oct 30/03 10 Oct 30/03 Index 1 Oct 30/03 2 Oct 30/03 3 Oct 30/03 4 Oct 30/03 5 Oct 30/03 6 Oct 30/03 SECTION PAGE DATE PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1A6 INTRO - LIST OF EFFECTIVE PAGES THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL INTRO - CONTENTS PAGE 1 Oct 30/03 1A7 TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. Introduction Instructions for Continued Airworthiness 1 1A9 General 1 1A9 Effectivity 1 1A9 Serial Number Explanation 2 1A10 Assignment of Subject Material 2 1A10 Pagination 2 1A10 Aerofiche Effectivity 2 1A10 Identifying Revised Material 2 1A10 Indexing 2 1A10 List of Effective Pages 3 1A11 Warnings, Cautions, and Notes 3 1A11 Accident / Incident Reporting 3 1A11 Supplementary Publications 3 1A11 PIPER Publications 3 1A11 Vendor Publications 3 1A11 Section Index Guide 9 1A17 Index Index 1 1B1 PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1A8 INTRO - CONTENTS THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1A9 INTRODUCTION INTRODUCTION 1. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS. WARNING: INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) FOR ALL NON-PIPER APPROVED STC INSTALLATIONS ARE NOT INCLUDED IN THIS MANUAL. WHEN A NON-PIPER APPROVED STC INSTALLATION IS INCORPORATED ON THE AIRPLANE, THOSE PORTIONS OF THE AIRPLANE AFFECTED BY THE INSTALLATION MUST BE INSPECTED IN ACCORDANCE WITH THE ICA PUBLISHED BY THE OWNER OF THE STC. SINCE NON-PIPER APPROVED STC INSTALLATIONS MAY CHANGE SYSTEMS INTERFACE, OPERATING CHARACTERISTICS AND COMPONENT LOADS OR STRESSES ON ADJACENT STRUCTURES, THE PIPER PROVIDED ICA MAY NOT BE VALID FOR AIRPLANES SO MODIFIED. The PIPER PA-34-200 Seneca Service Manual constitutes the Instructions for Continued Airworthiness. Section I contains the Airworthiness Limitations and the Inspection Program is in Section III. 2. GENERAL. WARNING: USE ONLY GENUINE PIPER AIRCRAFT PARTS OR PIPER AIRCRAFT APPROVED PARTS OBTAINED FROM PIPER APPROVED SOURCES, IN CONNECTION WITH THE MAINTENANCE AND REPAIR OF PIPER AIRPLANES. Genuine PIPER parts are produced and inspected under rigorous procedures to insure airworthiness and suitability for use in PIPER airplane applications. Parts purchased from sources other than PIPER, even though identical in appearance, may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in an airplane. Additionally, reworked or salvaged parts or those parts obtained from non-PIPER approved sources, may have service histories which are unknown or cannot be authenticated, may have been subjected to unacceptable stresses or temperatures or may have other hidden damage not discernible through routine visual or nondestructive testing. This may render the part, component or structural assembly, even though originally manufactured by PIPER, unsuitable and unsafe for airplane use. THE NEW PIPER AIRCRAFT, INC. expressly disclaims any responsibility for malfunctions, failures, damage or injury caused by use of non-PIPER approved parts. NOTE: THE NEW PIPER AIRCRAFT, INC. expressly reserves the right to supersede, cancel and/or declare obsolete any part, part numbers, kits or publication that may be referenced in this manual without prior notice. In any question concerning the care of your airplane, be sure to include the airplane serial number in any correspondence. 3. EFFECTIVITY. This maintenance manual is effective for PA-34-200 Seneca airplane serial numbers 34-7250001 thru 34-7450220. This encompasses the following model years: NOTE: The following is provided as a general reference only. Model Year Serial Numbers 1972 34-7250001 thru 34-7250360 1973 34-7350001 thru 34-7350353 1974 34-7450001 thru 34-7450220 PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1A10 INTRODUCTION 4. SERIAL NUMBER EXPLANATION. Example: 5. 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. The material is arranged in ascending numerical sequence. 6. PAGINATION. The Section (i.e. - I, II, III, etc.) numbering system forms the primary page numbering system for this manual. Within each Section, pages are numbered consecutively beginning with Page 1 (i.e. - Section

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III, Page 1). Additionally, the aerofiche grid numbering system (explained below) is also used to indicate location within the manual. 7. AEROFICHE EFFECTIVITY. A. The General Aviation Manufacturers Association (GAMA) have developed specifications for microfiche reproduction of aircraft publications. The information compiled in this Aerofiche Service Manual will be kept current by revisions distributed periodically. These revisions will supersede all previous revisions and will be complete Aerofiche card replacements and shall supersede Aerofiche cards of the same number in the set. The “Aerofiche Effectivity” page at the front of this manual lists the current revision for each card in this set. B. Conversion of Aerofiche alpha/numeric grid code numbers: First number is the Aerofiche card number. Letter is the horizontal row reference per card Second number is the vertical column reference per card. Example: 2J16 = Aerofiche card number two, row J, column 16. C. To aid in locating information, the following is provided at the beginning of each aerofiche card: (1) A complete Introduction containing the Section Index Guide for all fiche in this set. (2) A complete subject Index for all fiche in this set. 8. IDENTIFYING REVISED MATERIAL. A revision to a page is defined as any change to the printed matter that existed previously. Revisions, additions and deletions are identified by a vertical line along the left-hand margin of the page opposite only that portion of the printed matter that was changed. A vertical line in the left-hand margin opposite the footer (i.e. - chapter/section/subject, page number and date), indicates that the text was unchanged but the material was relocated to a different page. Example. 9. INDEXING. An alphabetically arranged subject Index follows this introduction to assist the user in locating desired information. In addition, each System/Chapter begins with an individual Table of Contents. 34 72 50 001 TYPE CERTIFICATE DESIGNATION MODEL CODE 50 = PA-34-200 SENECA SEQUENCE NUMBER MODEL YEAR PIPER SENECA SERVICE MANUAL PAGE 3 Oct 30/03 1A11 INTRODUCTION 10. LIST OF EFFECTIVE PAGES. Each Section has a List of Effective Pages preceding the Table of Contents to identify the effective revision date for each page in that section. 11. WARNINGS, CAUTIONS AND NOTES. These adjuncts to the text are used to highlight or emphasize important points when necessary. Warnings call attention to use of materials, processes, methods, procedures or limits which must be followed precisely to avoid injury or death to persons. Cautions call attention to methods and procedures which must be followed to avoid damage to equipment. Notes call attention to methods which make the job easier. Warnings and Cautions shall be located directly above and Notes directly beneath the text and be in line with the paragraphs to which they apply. 12. ACCIDENT/INCIDENT REPORTING. 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. This procedure is to be used by all Dealers, Service Centers and Repair Facilities. 13. SUPPLEMENTARY PUBLICATIONS. The following publications/sources provide servicing, overhaul and parts information for the PA-34-200 airplanes and their various components. Use them to supplement this manual. A. PIPER PUBLICATIONS: (1) Parts Catalog: P/N 753-816 (2) Periodic Inspection Report: P/N 230-208 (3) Progressive Inspection Manual (50 Hour): P/N 230-208 (4) Autopilot Service Manuals See Section XII B. VENDOR PUBLICATIONS: WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (1) ALTERNATOR: Vendor Address: Electro Systems, Inc. PH: - (888) 461-6077 Airport Complex P. O. Box 273 Fort Deposit, Alabama 36032 http://www.kellyaerospace.com/index.htm/ (2) AUTOPILOT: See Section XII, Autoflight. (3) BATTERY: Vendor Address: GILL Batteries PH: - (800) 456-0070 (A Division of Teledyne Continental Motors, see listing under Magnetos, below) http://www.gillbatteries.com PIPER SENECA SERVICE MANUAL PAGE 4 Oct 30/03 1A12 INTRODUCTION (4) BRAKES AND WHEELS: Vendor Address: Parker Hannifin Corp PH: - (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 PH - (717) 323-6181 652 Oliver Street FAX - (717) 327-7101 Williamsport, PA 17701 http://www.lycoming.textron.com/main.html Overhaul Manual: DIRECT DRIVE MODELS - P/N 60294-7 Parts Catalog: IO-540- ..... - K1G5, ..... ENGINES - P/N PC-615 TIO-540-AH1A ENGINES - P/N PC-615-12 Operators Handbook: O-540, IO-540 SERIES - P/N 60297-10 TIO-540 Series - P/N 60297-23 NOTE: The above Lycoming publications can be ordered as a set on CD-ROM from Avantext. See www.avantext.com or PH - (800) 998-8857. (6) FIRE EXTINGUISHER (PORTABLE): Vendor Address: H3R Inc. PH: - (800) 249-4289 43 Magnolia Ave # 4 San Francisco, California 94123-2911 http://www.h3r.com/index.htm (7) FUEL PUMP: Vendor Address: Weldon Pumps PH: - (440) 232-2282 P.O. Box 46579 FAX - (440) 232-0606 640 Golden Oak Parkway Oakwood Village, Ohio 44146 http://www.weldonpumps.com/index.html (8) COMBUSTION HEATER: Vendor Address: Electro Systems, Inc. PH: - (334)-227-0152 (See listing under Alternator, above.) (9) HI-LOK FASTENERS AND TOOLS: Vendor Address: Hi-Shear Corporation PH: - (213) 326-8110 2600 Skypark Drive Torrance, California 90509 PIPER SENECA SERVICE MANUAL PAGE 5 Oct 30/03 1A13 INTRODUCTION (10) LANDING GEAR ACTUATOR, EXTENSION AND RETRACTION: Vendor Address: Parker Hannifin Corp PH: - (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: CMSFA232-5 (011-00504) (11) LIGHTS - NAVIGATION, STROBE, AND STANDBY/MAP LIGHTS: Vendor Address: Whelen Engineering Co. Inc. PH: - (860) 526-9504 Route 145, Winthrop Rd. FAX - (860) 526-2009 Chester, Conneticut 06412 http://www.whelen.com/ (12) MAGNETOS: Vendor Address: Teledyne Continental Motors PH: - (334-438-3411, P.O. Box 90 ext. 8392) Mobile, AL 36601 FAX - (334-433-2325 http://www.tcmlink.com Service Support Manual: S1200 Series Magnetos, P/N X42001-1 or, if installed: Vendor Address: Slick Aircraft Products PH - (815) 965-4700 Unison Industries FAX - (815) 965-2457 Attn: Subscription Dept. 530 Blackhawk Park Ave. Rockford, IL 61104 http://www.unisonindustries.com/index4.html Installation, Operation F1100 MASTER SERVICE MANUAL, and Maintenance 4300/6300 SERIES MAGNETO MAINTENANCE AND Instructions: OVERHAUL MANUAL - L-1363 (13) PNEUMATIC DEICE SYSTEM: Vendor Address: De-Icing and Specialty Systems PH - (330) 374-3040 Goodrich Corporation FAX - (330) 374-2290 1555 Corporate Woods Parkway Uniontown, Ohio 44685-8799 Technical Assistance: PH - (800) 334-2377 (330) 374-3743 FAX - (330) 374-2290 Email: dssd.support@goodrich.com http://www.deicingsystems.goodrich.com/ Black Standard Pneumatic De-Icer Installation, Maintenance and Repair Manual: ATA 30-10-31 PIPER SENECA SERVICE MANUAL PAGE 6 Oct 30/03 1A14 INTRODUCTION (14) PROPELLER: Vendor Address: Hartzell Propeller Inc. PH - (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 Manual and Logbook: Manual No. 115N (15) PROPELLER DEICE SYSTEM: Vendor Address: See Pneumatic Deice System, above. Installation and Maintenance Manual for Prop De-Icing Systems: ATA 30-60-02 Removal and Installation Manual, Standard and FASTpropTM Electrothermal Propeller De-Icers: ATA 30-60-07 (16) PROPELLER GOVERNOR: Vendor Address: Hartzell Propeller Inc. PH - (937) 778-4379 One Propellor Place FAX - (937) 778-4321 Piqua, OH 45356-2634 http://www.hartzellprop.com/index2.htm Governor Maintenance: Manual No. 130B (17) VACUUM PUMPS: (For service replacement, Tempest Dry Air Pumps, only.) Vendor Address: Aero Accessories, Inc. PH - (800) 822-3200 1240 Springwood Avenue Gibsonville, NC 27249 http://www.aeroaccessories.com/index.html PIPER SENECA SERVICE MANUAL PAGE 7 Oct 30/03 1A15 INTRODUCTION (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. PIPER SENECA SERVICE MANUAL PAGE 8 Oct 30/03 1A16 INTRODUCTION THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 9 Oct 30/03 1A17 INTRODUCTION 14 SECTION INDEX GUIDE. SECTION TITLE GRID NO. I AIRWORTHINESS LIMITATIONS 1C1 II HANDLING AND SERVICING 1C9 III INSPECTION 1F5 IV STRUCTURES 1H11 V SURFACE CONTROLS 2C1 VI HYDRAULIC SYSTEM 2F7 VII LANDING GEAR AND BRAKES 2G21 VIII POWERPLANT 3C1 IX FUEL SYSTEM 3F1 X INSTRUMENTS 3G1 XI ELECTRICAL SYSTEM 3H17 XII ELECTRONICS 4C1 XIII HEATING AND VENTILATION SYSTEM 4C19 XIV ACCESSORIES AND UTILITIES 4F5 PIPER SENECA SERVICE MANUAL PAGE 10 Oct 30/03 1A18 INTRODUCTION GRIDS 1A18 THRU 1A24 INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1B1 INDEX A Access Plates and Panels: 1C22 Accident/Incident Reporting: A11 Aerofiche Effectivity: A10 Grid Code: A10 Revision Status: A3 Aileron Balancing Procedure: 1K6 Specifications: 1K3 Installation: 1H20 Ailerons Control System Bellcrank Assembly: 2D6 Control Column: 2C20 Installation: 2D4 Rigging and Adjustment: 2D6 Troubleshooting: 2D1 Air Filter: 1D9 Airworthiness Directives (AD’s): 1F11 Instructions for Continued Airworthiness: A9 Limitations: 1C7 Autopilot: 4C14 Avioniics: 4C7 B Battery Battery Box Corrosion Prevention: 3J13 Charging: 3J11 Hydrometer Reading vs. Battery Charge: 3J11 Servicing: 1D18, 3J11 Troubleshooting: 3J12 Brakes Anchor Bolts: 2J11 Bleeding: 2J20 Hand / Parking Brake Master Cylinder: 2J12 Leak Check: 2J21 Reservior: 2J21 System Draining: 1D11 Filling: 1D11 System Installation: 2J13 Toe Brake Cylinder: 2J15 Toe Brake Installation: 2J17 Wheel Brake Assembly: 2J9 C Cabin Heating, Defrost, and Ventilation: 4D2 Consumable Materials: 1E9 Conversion Tables Decimal: 1E23 Drill Sizes: 1F3 Metric: 1F2 Temperature: 1E24 Weights and Measures: 1F1 D Defrosting: 4D1 Doors Baggage: 1J1 Forward Baggage Door Latch Inspection: 1J2 Cockpit and Cabin: 1I20 Snubber Installation: 1J6 E Electrical Alternators: 3I3 Belt Tension: 3I18 Checking: 3I11 Description: 3I10 Exploded View: 3I10 Inspection and Testing: 3I12 Overhaul: 3I12 Service: 3I17 Service Test Specifications: 3I18 Troubleshooting: 3I5 Aluminum Wiring: 3J21 Ammeters: 3H10 Battery-See Battery External Power: 1D9 External Power Receptacle: 3J14 Overvoltage Relay: 3I22 Schematics Alternators: 3K7 Anti-Collision Fin-Tip Strobe Light: 3K16 Combustion Heater: 4D16 Electrical Symbols: 3K3 Engine Gauges: 3K17 Fuel Pumps: 3K18 Heater and Defroster: 3K19 Landing Gear: 3K11 Landing/Taxi Lights: 3K16 Magnetos: 3K21 Panel Lights: 3K13 Pitot Heat and Cigar Lighter: 3K18 Position Lights: 3K16 Propeller Deice: 3K18 Reading and Baggage Lights: 3K15 Stall Warning: 3K20 Starters: 3K10 Turn and Bank: 3K17 Vent Blower: 3K20 Wing Ice Inspection Light: 3K16 Starters Bench Tests: 3J8 Description: 3J1 Exploded View: 3J5 Inspection: 3J1 No-Load Test Hook-up: 3J7 Overhaul: 3J5 Service Test Specifications: 3J9 Stall-Torque Hook-up: 3J8 Troubleshooting: 3J2 Switch Panel: 3I2 System Component Loads: 3I3 Description: 3I1 Precautions: 3I1 Voltage Regulator: 3I20 Electronics: 4C7 ELT Battery: 4C7 Description: 4C7 Pilot’s Remote Switch: 4C11 Testing: 4C13 Emergency Gear Extension: 2G12 Empenage Installation: 1I8 Checking Control Surface Free Play: 1K9 PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1B2 INDEX E (cont.) Engine Alternate Air Door 100 Hour Inspection: 3D6 Cowl Flaps: 3C13 Cowling: 3C13 Description.: 3C7 Fuel Adjustment of Idle Speed and Mixture: 3D7 Fuel-Air Bleed Nozzles: 3D9 Injector: 3D6 Funtional Schematic: 3D8 Installation: 3D2 Instruments CHT Gauge: 3H13 EGT Gauge: 3H11 Fuel Pressure Gauge: 3H7 Instrument Markings: 3H14 Manifold Pressure Gauge: 3H4 Oil Pressure Gauge: 3H6 Oil Temperature Indicator: 3H10 Tachometer: 3H5 Lubrication Changing Oil: 1D21 Oil Filter: 1D21 Oil Pressure Relief Valve: 3E2 Oil Screen: 1D20 Oil Screens and Filters: 3E2 Oil Sump: 1D20 Shock Mounts: 3D5 Standard Practices: 3C7 Throttle and Mixture Controls Adjustment: 3D5 Attachments 100 Hour Inspection: 3D5 Timing Marks: 3D16 Troubleshooting: 3C9 Winterization Plate: 1D21 Environmental Systems Description and Operation: 4D1 Optional Combustion Heater: 4D7 Exploded View: 4E16 Inspections: 4D17 Fuel Nozzle Orifice: 4E22 Fuel Regulator and Shutoff Valve: 4E4 Maintenance: 4D20 Overhaul: 4E8 Testing: 4E12 Bench Tests: 4E20 Troubleshooting: 4D9 Wiring Diagram: 4D16 Optional Overhead Vent Blower: 4E23 Wire Codes: 4E24 Rigging Controls: 4D4 Exhaust System 25 Hour Inspection: 3E3 Inspection Points: 3E4 Heat Exchanger 100 Hour Inspection: 3E3 F Flap Installation: 1H20 Flaps Control System Flap Stop Adjustment: 2E21 Installation: 2E20 Rigging and Adjustment: 2E23 Troubleshooting: 2E19 Torque Tube/Push Rod Distortion Inspection: 2E19 Flight Controls Ailerons-See Ailerons Cable Tension: 2C8 vs. Ambient Temperature: 2C10 Control Cable Inspection: 2C12 Description and Operation: 2C7 Flaps-See Flaps Rudder-See Rudder Stabilator-See Stabilator Standard Practices and Procedures: 2C7 Travel: 2C8 Fluid Line Identification: 1K11 Fuel System: 1D9 Description: 3F7 Draining Entirely: 1D11 Moisture: 1D11 Electric Fuel Pump: 3F16 Filling: 1D9 Fuel Quantity Sender/Gauge Check: 3F13 Fuel Tanks Inspection and Repair: 3F10 Installation: 3F11 Vent Obstruction Test: 3F12 Gascolator: 3F14 Inspection: 3F12 Installation: 3F9 Instruments Fuel Flow Gauge: 3H13 Fuel Pressure Gauge: 3H7 Fuel Quantity Indicator: 3H9 Selector Valve: 3F15 Troubleshooting: 3F8 H Heating: 4D1 Hose Clamp Tightening: 1K10 Identification: 1K10 Installation of Flexible Hose Assemblies: 1K10 Hydraulic System Description: 2F13 Free-Fall Valve: 2G12 Functional Schematic: 2F20 Hydraulic Pump Oildyne: 2G9 Prestolite: 2G2 Mounting: 2G7 Test/Adjust: 2G6 Servicing: 2G17 Installation: 2F22 Leading Particulars: 2G4 Lines: 2G17 Pump Motor Characteristics: 2G4 Servicing: 1D18 Hydraulic Pump/Reservior: 1D18 Testing: 2G17 Troubleshooting: 2F14 PIPER SENECA SERVICE MANUAL PAGE 3 Oct 30/03 1B3 INDEX I Ice and Rain Protection: 4F11, 4G15 Ignition System Contact Points: 3D11 Engine Timing Marks: 3D16 Harness Assembly: 3D19 Magnetos: 3D10 Spark Plugs: 3E1 Inspections-See also System Section Aft Wing Attach Fitting: 1H23 Alternate Air Door: 3D6 Alternator: 3I12 Cable Fittings: 2C15 Combustion Heater 50-Hour: 4D17 100-Hour: 4D17 Fuel Nozzle Orifice: 4E22 Fuel Regulator and Shutoff Valve 100 Hour: 4E4 Ignition Unit: 4E2 Control Cable: 2C12 Definitions: 1F15 Exhaust Manifold: 4D1 Exhaust System: 3E3 Flap Torque Tube/Push Rod: 2E19 Forward Baggage Door Latch: 1J1 Fuel System: 3F12 Fuel Tanks: 3F10 Ignition Harness: 3D19 Per Calendar Year: 1G19 Per Event: 1H1 Engine Loss of Oil: 1H2 Engine Overspeed: 1H2 Engine Overtemp: 1H2 Flaps Extended Above Max Speed: 1H3 Flood Damage: 1H4 Hard or Overweight Landing: 1H2 Lightning Strike: 1H1 Severe Turbulence: 1H2 Sudden Engine Stoppage: 1H2 Per Flight Hour: 1G17 Per Specific Operation / Operating Environment.: 1G20 Extreme Cold: 1G21 High Dust: 1G20 High Humidity: 1G21 High Salt: 1G21 Industrial Pollution: 1G20 Soft or Unusual Terrain: 1G22 Pneumatic Deice System: 4G20 Pneumatic Deicers (Boots): 4H13 Propeller Deice System: 4F20 Rear Seat Quick-Disconnect Mechanism: 1J10 Requirements: 1F17 Annual / 100 Hour Inspection: 1F17 Procedure: 1F18 Overlimits Inspection: 1F17 Progressive Inspection: 1F17 Rudder Bar: 2E4 Rudder Tab Freeplay: 2E14 Seat Belt and Shoulder Harness: 4H17 Special: 1G17 Stabilator Attach Fittings: 1I6 Starter: 3J1 STC Installations: 1F17 Throttle and Mixture Control Attachments: 3D5 Unscheduled: 1H1 Vacuum Pump Vane Wear: 3G16 Instruments Airspeed Indicator: 3G23 Altimeter: 3G22 Directional Gyro: 3G19 Gyro Horizon: 3G20 Instrument Markings: 3H14 Instrument Panel: 3G10 Magnetic Compass: 3H2 Rate of Climb Indicator: 3G21 Removal and Installation: 3G9 Turn and Bank: 3H8 Introduction: A9 J Jacking: 1D4 L Landing Gear Cleaning: 1D19 Description: 2H3 Electrical Schematic: 2J3 Extension and Retraction Actuating Cylinders: 2G13 Troubleshooting: 2F15 Gear Up/Power Reduced Warning Switch: 2J4 Main Aligning: 2I21 Door: 2I23 Inspection Trunnion: 2I6 Trunnion Attach Fittings: 2I9 Installation: 2I10 Limit Switches: 2J2 Oleo: 2I3 Service Tolerances: 2I16 Squat Switch: 2J4 Toe-Out Correction: 2I20 Nose Door: 2I1 Inspection Drag Link Upper Attach Bolt Inspection: 2H18 Trunnion: 2H17 Installation: 2H14 Limit Switches: 2J1 Modified Components: 2H9 Oleo: 2H10 Service Tolerances: 2H20 Steering Bungees: 1D15 Oleo Struts Filling Main Gear: 1D14 Nose Gear: 1D13 Inflating: 1D15 Servicing: 1D11 Troubleshooting: 2H5 Leading Particulars: 1C17 Leveling: 1D6 Life Limited Parts: 1C7 Lift Detectors: 3J22 PIPER SENECA SERVICE MANUAL PAGE 4 Oct 30/03 1B4 INDEX L (cont.) Lights Exterior: 3J15 Anti-Collision Strobe: 3J18 Landing and Taxi: 3J15 Landing Light Adjustment: 3J15 Navigation: 3J17 Wing Ice Inspection: 4H15 Interior: 3J20 Dimmer Control Assembly: 3J20 Instrument: 3J20 Overhead Reading: 3J20 Panel: 3J20 Lamp Replacement Guide: 3J16 Lubrication Application of Grease: 1E1 Application of Oil: 1E1 Chart: 1E2 Thread Lubricants: 1E7 M Model Code: A10 Year: A9 Mooring: 1D6 P Parking: 1D7 Piper Parts: A9 Publications: A11 Autopilot: 4C14 Pitot-Static System Description: 3G14 Installation: 3G11 Pneumatic Deice System: 4G15 Deicers (Boots): 4H1 Inspection: 4H13 Maintenance: 4H6 Operation: 4G18 Repair Limits: 4H9 Required Materials: 4H2 Electrical Schematic: 4G18 Test: 4G19 Inspections: 4G20 Installation: 4G17 Operational Check: 4G15 Pressure Leakage Test: 4G19 Troubleshooting: 4G16 Propeller Air Charge Pressure vs. Temperature: 3C15 Deicing System: 4F11 Deicers: 4G4 Electrical Check: 4G10 Installation: 4G7 Required Materials: 4G6 Resistance Check: 4G4 Wrinkled Deicers: 4G9 Final Electrical Check: 4G12 Inspection 50-Hour: 4F20 100-Hour: 4F20 Installation: 4F12 Operational Check: 4F15 Timer Test: 4G10 Troubleshooting: 4F16 Governor: 3C19 Rigging and Adjustment: 3C20 Installation: 3C17 Specifications: 3C15 Typical Nicks and Removal Methods: 3C18 Publications Piper AutoPilot: 4C14 Vendor Autopilot: 4C15 R Repairs Fiberglass: 1J14 Metal Wire Stitching: 1J14 Pneumatic Deicers (Boots): 4H9 Safety Walk: 1K1 Structural: 1J11 Thermoplastic: 1J17 List of Materials: 1J18 Restraint System Inspection Lap Belt: 4H17 Shoulder Harness: 4H17 Shoulder Harness Inertia Reel Adjustment: 4H17 Rivets Removing Cherrylocks: 1K12 Rudder 100 Hour Rudder Tab Freeplay Inspection: 2E14 Balancing Procedure: 1K8 Specifications: 1K3 Control System Installation: 2E7 Rigging and Adjustment: 2E10 Trim Controls Rigging and Adjustment: 2E17 Troubleshooting: 2E13 Troubleshooting: 2E1 Installation: 1I11 Rudder Bar Inspection and Repair: 2E4 Travel Adjustments: 2E12 S Seats Retention Clip Adjustment: 1J10 Seat Back Lock: 1J9 Serial Number Explanation: A10 Service Points: 1D10 Skin Material and Thickness: 1J12 Stabilator Balancing Procedure: 1K7 Specifications: 1K3 Control System Installation: 2D16 Rigging and Adjustment: 2D13 Trim Controls Rigging and Adjustment: 2D23 Troubleshooting: 2D19 Troubleshooting: 2D11 Installation: 1I10 Travel Adjustments: 2E12 Stall Warning: 3J22 Station Reference Lines: 1C21 PIPER SENECA SERVICE MANUAL PAGE 5 Oct 30/03 1B5 INDEX T Taxiing: 1D7 Testing Alternator: 3I17 Combustion Heater: 4E12 Bench Tests: 4E20 ELT: 4C13 Fuel Quantity Indicating: 3F13 Fuel Tank Vent Obstruction Test: 3F12 Hydraulic System: 2G17 Starter: 3J8 Three View: 1C16 Tires: 1D16 Tools Aileron Bellcrank Rigging Tool: 2D7, 2F1 Aileron Rigging Tool: 2D9, 2F2 Flap Rigging Tool: 2E24, 2F2 Rudder Rigging Tool: 2E11, 2F4 Stabilator Rigging Tool: 2D18, 2F3 Torque Requirements: 1D3 Flare Fittings: 1D3 Nuts: 1D1 Wrenches: 1C24 Towing: 1D7 Troubleshooting Aileron Controls: 2D1 Airspeed Indicator: 3G23 Alternator: 3I5 Altimeter: 3G22 Ammeters: 3H10 Battery: 3J12 CHT Gauge: 3H12 Combustion Heater: 4D9 Directional Gyro: 3G19 EGT Gauge: 3H12 Flap Controls: 2E19 Fuel Flow Gauge: 3H13 Fuel Pressure Gauge: 3H7 Fuel Quantity Indicator: 3H9 Fuel System: 3F8 Gyro Horizon: 3G20 Hydraulic System: 2F15 Landing Gear: 2H5 Extension and Retraction: 2F15 Magnetic Compass: 3H3 Manifold Pressure Indicator: 3H4 Oil Pressure Gauge: 3H6 Oil Temperature Indicator: 3H10 Pneumatic Deice System: 4G16 Power Plant: 3C9 Propeller Deice System: 4F16 Rate of Climb Indicator: 3G21 Rudder Controls: 2E1 Rudder Trim Controls: 2E13 Stabilator Controls: 2D11 Stabilator Trim Controls: 2D19 Starter: 3J2 Tachometer: 3H5 Turn and Bank Indicator: 3H8 Tubing Identification: 1K10 Maximum Distance Between Supports: 1K9 Support Clamp Use: 1K9 Turning Distance: 1D8 V Vacuum System Description: 3G12 Filter(s): 3G14 Gauge: 3G14 Pump: 3G16 Inspection: 3G16 Regulators: 3G15 Service Tips: 3G12 Vendor Contact Information: 1E19 Publications: A11 Autopilot: 4C15 Ventilation: 4D1 W Weighing: 1D5 Wheels Balancer: 1D17 Main Assembly: 2J7 Nose Assembly: 2J6 Windows and Windshield Windows Cabin (Aft) Door Window Installation: 1I19 Side Window Installation: 1I16 Windshield Installation: 1I15 Wing Checking Control Surface Free Play: 1K9 Installation: 1I2 Wing Ice Light: 4H15 Winterization Plate: 1D21 PIPER SENECA SERVICE MANUAL PAGE 6 Oct 30/03 1B6 INDEX GRIDS 1B6 THRU 1B24 INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL 1C1 SECTION I AIRWORTHINESS LIMITATIONS PIPER SENECA SERVICE MANUAL 1C2 THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1C3 I - LIST OF EFFECTIVE PAGES SECTION I LIST OF EFFECTIVE PAGES SECTION PAGE DATE I-List of 1 Oct 30/03 Effective Pages 2 Oct 30/03 I-Table of Contents 1 Oct 30/03 2 Oct 30/03 I 1 Oct 30/03 2 Oct 30/03 SECTION PAGE DATE PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1C4 I - LIST OF EFFECTIVE PAGES THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1C5 I - CONTENTS SECTION I - AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. AIRWORTHINESS LIMITATIONS I 1 1C7 Limitations 1 1C7 Inspections 1 1C7 Life Limited Parts Marking and Disposition 1 1C7 PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1C6 I - CONTENTS THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1C7 I - AIRWORTHINESS LIMITATIONS AIRWORTHINESS LIMITATIONS NOTE: The Airworthiness Limitations section is FAA approved and specifies maintenance required under §§ 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. 1. LIMITATIONS. The following limitations related to fatigue life of the airplane and its components have been established with respect to the PA-34-200 Seneca airplane: The bolt and stack-up that connect the upper drag link to the nose gear trunnion are required to be replaced every 500 hours time-in-service. The part numbers are as follows: A. P/N 400-274 (AN7-35) bolt; B. P/N 407-591 (AN960-716L) washer, as applicable; C. P/N 407-568 (AN 960-716) washer, as applicable; D. P/N 404-396 (AN 320-7) nut; and E. P/N 424-085 cotter pin. NOTE: Refer to the LIMITATIONS section in the Pilot’s Operating Handbook for a detailed delineation of the flight limitations of the airplane. 2. INSPECTIONS. Refer to Section III for Piper’s recommended Inspection Program. 3. LIFE LIMITED PARTS MARKING AND DISPOSITION. 14 CFR Part 45.16, Marking of Life Limited Parts requires that proper procedures are followed when removing life limited parts with time and/or cycles remaining on them as well as the disposition of life limited parts with no time and/or cycles left. Life limited parts are defined in paragraph 1, above. A. Parts that are removed prior to attaining the required time and/or cycles in service defining the useful life , are to be marked with indelible ink or marker with the part number, serial number and accumulated life status as defined in 14 CFR Part 43.10 in a manner that does not effect part structural integrity, i.e., no surface deformation such as vibration/etching allowed. B. 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. PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1C8 I - AIRWORTHINESS LIMITATIONS THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL 1C9 SECTION II HANDLING AND SERVICING PIPER SENECA SERVICE MANUAL 1C10 THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1C11 II - LIST OF EFFECTIVE PAGES SECTION II LIST OF EFFECTIVE PAGES SECTION PAGE DATE SECTION PAGE DATE II-List of 1 Oct 30/03 Effective Pages 2 Oct 30/03 II-Table of Contents 1 Oct 30/03 2 Oct 30/03 II 1 Oct 30/03 2 Oct 30/03 3 Oct 30/03 4 Oct 30/03 5 Oct 30/03 6 Oct 30/03 7 Oct 30/03 8 Oct 30/03 9 Oct 30/03 10 Oct 30/03 11 Oct 30/03 12 Oct 30/03 13 Oct 30/03 14 Oct 30/03 15 Oct 30/03 16 Oct 30/03 17 Oct 30/03 18 Oct 30/03 19 Oct 30/03 20 Oct 30/03 21 Oct 30/03 22 Oct 30/03 23 Oct 30/03 24 Oct 30/03 25 Oct 30/03 26 Oct 30/03 27 Oct 30/03 28 Oct 30/03 29 Oct 30/03 30 Oct 30/03 31 Oct 30/03 32 Oct 30/03 33 Oct 30/03 34 Oct 30/03 35 Oct 30/03 II (cont.) 36 Oct 30/03 37 Oct 30/03 38 Oct 30/03 39 Oct 30/03 40 Oct 30/03 41 Oct 30/03 42 Oct 30/03 43 Oct 30/03 44 Oct 30/03 45 Oct 30/03 46 Oct 30/03 47 Oct 30/03 48 Oct 30/03 49 Oct 30/03 50 Oct 30/03 51 Oct 30/03 52 Oct 30/03 53 Oct 30/03 54 Oct 30/03 55 Oct 30/03 56 Oct 30/03 57 Oct 30/03 58 Oct 30/03 59 Oct 30/03 60 Oct 30/03 PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1C12 II - LIST OF EFFECTIVE PAGES THIS PAGE INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1C13 II - CONTENTS SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS SUBJECT SECTION PAGE GRID NO. HANDLING AND SERVICING II 1 1C15 Introduction 1 1C15 Dimensions 1 1C15 Station Reference Lines 1 1C15 Weight and Balance Data 1 1C15 Serial Number Plate 1 1C15 Access and Inspection Provisions 1 1C15 Tools and Test Equipment 1 1C15 Torque Wrenches 10 1C24 Torque Requirements 13 1D3 Step, Handhold, and Walkways 14 1D4 Ground Handling 14 1D4 Introduction to Ground Handling 14 1D4 Jacking 14 1D4 Weighing 15 1D5 Leveling 16 1D6 Mooring 16 1D6 Locking Airplane 17 1D7 Parking 17 1D7 Towing 17 1D7 Taxiing 17 1D7 External Power Receptacle 19 1D9 Operation 19 1D9 Servicing 19 1D9 Introduction 19 1D9 Induction Air Filter 19 1D9 Fuel System 19 1D9 Servicing Fuel System 19 1D9 Filling Fuel Tanks 19 1D9 Draining Moisture from Fuel System 21 1D11 Draining Fuel System 21 1D11 Brake System 21 1D11 Servicing Brake System 21 1D11 Filling Brake Cylinder Reservoir 21 1D11 Draining Brake System 21 1D11 Oleo Struts 21 1D11 Servicing Oleo Struts 21 1D11 Filling Nose Gear Oleo Strut 23 1D13 Filling Main Gear Oleo Struts 24 1D14 Inflating Oleo Struts 25 1D15 Servicing Steering Bungees 25 1D15 Tires 26 1D16 Tire Balance 26 1D16 PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1C14 II - CONTENTS SECTION II - HANDLING AND SERVICING TABLE OF CONTENTS (continued) SUBJECT SECTION PAGE GRID NO. Hydraulic System 28 1D18 Servicing Hydraulic System 28 1D18 Servicing Hydraulic Pump/Reservoir 28 1D18 Battery 28 1D18 Servicing Battery 28 1D18 Cleaning 28 1D18 Engine Compartments 28 1D18 Landing Gear 29 1D19 Exterior Surfaces 29 1D19 Windshield and Windows 29 1D19 Headliner, Side Panels and Seats 30 1D20 Carpets 30 1D20 Lubrication 30 1D20 Oil System (Engine) 30 1D20 Servicing Oil System 30 1D20 Filling Oil Sump 30 1D20 Draining Oil Sump 30 1D20 Oil Screen (Suction) 30 1D20 Oil Screen (Pressure) 30 1D20 Oil Filter (Full Flow) 31 1D21 Recommendations for Changing Oil 31 1D21 Winterization Plate 31 1D21 Lubrication Instructions 33 1E1 Application of Oil 33 1E1 Application of Grease 33 1E1 Lubrication Chart 34 1E2 Consumable Materials 39 1E7 Vendor Contact Information 39 1E7 Conversion Tables 39 1E7 PIPER SENECA SERVICE MANUAL PAGE 1 Oct 30/03 1C15 II - HANDLING AND SERVICING 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.) 1. INTRODUCTION. This section contains routine handling and servicing procedures that are most frequently encountered. Frequent reference to this section will aid the individual by providing information such as the location of various components, ground handling procedures, routine service procedures and lubrication. When any system or component requires service other than the routine procedures as outlined in this section, refer to the appropriate section for that component. 2. DIMENSIONS. The principal airplane dimensions are shown in Figure 1 and are listed in Table I. 3. STATION REFERENCE LINES. In order to facilitate the location of various components of the airplane which require maintenance and servicing, a method utilizing fuselage station, wing station or buttock line (BL), and water line (WL) designations is frequently employed in this manual. (Refer to Figure 2.) Fuselage stations, buttock lines, and water lines are reference points measured by inches in the vertical or horizontal direction from a given reference line which indicates station locations of structural members of the airplane. 4. WEIGHT AND BALANCE DATA. When figuring various weight and balance computations, the empty, static and gross weight, and center of gravity of the airplane may be found in the Weight and Balance Form of the Airplane Flight Manual. 5. SERIAL NUMBER PLATE. The serial number plate is located on the left side of the fuselage near the leading edge of the stabilator. The serial number should always be used when referring to the airplane on service or warranty matters. CAUTION: BEFORE ENTERING THE AFT SECTION OF THE FUSELAGE, BE SURE THE AIRPLANE IS SUPPORTED AT THE TAIL SKID. 6. ACCESS AND INSPECTION PROVISIONS. The access and inspection provisions for the airplane area shown in Figure 3. The component to be serviced or inspected through each opening is identified in the illustration. All access plates and panels are secured by either metal fasteners or screws. To enter the aft section of the fuselage, remove the rear baggage compartment upholstery panel by removing the attachment screws. 7. TOOLS AND TEST EQUIPMENT. Because of the simplicity and easy accessibility of components, few special tools outside normal shop tools will be required. Tools that are required may be fabricated from dimensions given in the back of the section that pertains to a particular component or are listed in the back of the PA-34 Parts Catalog, P/N 753-816. PIPER SENECA SERVICE MANUAL PAGE 2 Oct 30/03 1C16 II - HANDLING AND SERVICING Three View Figure 1 PIPER SENECA SERVICE MANUAL PAGE 3 Oct 30/03 1C17 II - HANDLING AND SERVICING 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 65% Rated Power (Both Engines) 18.3 GPH Propeller Drive Ratio 1:1 Propeller Shaft Rotation - Left Engine Clockwise (CW) Propeller Shaft Rotation - Right Engine Counterclockwise (CCW) Bore (Inches) 5.125 Stroke (Inches) 4-375 Displacement (Cu. In.) 361 Compression Ratio 8.7:1 Weight (With starter and alternator) 350 Lbs. Dimensions: Height 19.48 In. Width 34.25 In. Length 33.65 In. Oil, SAE Number See Lubrication Chart Oil Sump Capacity 8 U.S. Quarts Oil Consumption. Max. (Qt./Hr.) .21 Fuel, Aviation Grade, Minimum Octane 100/130 * Fuel Injector RSA-5AD1 Magnetos, Scintilla: Left (Left Engine) S4LN-1227 Right (Left Engine) S4LN-1209 Left (Right Engine) S4RN-1227 Right (Right Engine) S4RN-1209 or, Magnetos, Slick: Left (Left Engine) 4372 Right (Left Engine) 4370 Left (Right Engine) 4374 Right (Right Engine) 4302 Magneto Drive, Ratio to Crankshaft 1.5:1 Magneto Drive, Rotation Left Engine CW Right Engine CCW Magneto Timing 25° BTC Magneto Point Clearance, Scintilla (Main) 0.016 ± .003 Magneto Point Clearance, Scintilla (Retard) 0.016 ± .006 Magneto Point Clearance, Slick Use “E” Gap Method * See latest revision of Lycoming Service Instruction 1070M. PIPER SENECA SERVICE MANUAL PAGE 4 Oct 30/03 1C18 II - HANDLING AND SERVICING Spark Plugs (Shielded): AC 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 Tachometer Drive, Rotation Left Engine CW Right Engine CCW Starter - Prestolite (12-volt) Left Engine MZ-4206 Right Engine MZ-4216 Starter Gear Ratio 16.55:1 (CW) Starter Drive, Ratio to Crankshaft 16.556:1 Starter Drive, Rotation Left Engine CCW Right Engine CW Alternator - Prestolite (60 amp) ALY-6408 Alternator Voltage Regulator, Electro Delta Inc. VR710 Alternator Overvoltage Relay, WICO X16799B Alternator Drive, Ratio to Crankshaft 3.250:1 Alternator Drive Rotation Left Engine CW Right Engine CCW Vacuum Pump Drive, Ratio to Crankshaft 1.300:1 Vacuum Pump Drive, Rotation Left Engine CCW Right Engine CW Propeller Governor Drive, Ratio to Crankshaft 0.866:1 Propeller Governor Drive, Rotation: Left Engine CW Right Engine CCW Fuel Pump Drive, Rotation: Left Engine Plunger Right Engine Plunger TABLE I (Sheet 2 of 4) LEADING PARTICULARS MODEL PA-34-200 ENGINE (cont.) PIPER SENECA SERVICE MANUAL PAGE 5 Oct 30/03 1C19 II - HANDLING AND SERVICING 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 HC-C2YK-2( )E/C7666A-0 HC-C2YK-2( )EU/C7666A-0 (1) HC-C2YK-2( )EF/FC7666A-0 HC-C2YK-2( )EFU/FC7666A-0 (1) HC-C2YK-2CG(F)/(F)C7666A (2) HC-C2YK-2CGU(F)/(F)C7666A (1 & 2) NOTE: HC-( )2YR-( ) propeller hubs may be substituted for the HC-( )2YK-( ) propeller hubs called out above per Hartzell Standard Practices Manual No. 202A. Diameter 76 In. Diameter, Minimum 74 In. Blade Angle, Low Pitch (3) 13.5° Blade Angle, Feather (3) 79° - 81° Governor Control Hartzell Governor Model: Left Engine F-6-18A Right Engine F-6-18AL (1) Feather assist spring propellers. See also Parts Catalog, P/N 753-816. (2) Includes damper. If used, dampers must be installed on both left and right propellers. (3) Measurement taken at 30 inch station. FUEL SYSTEM Fuel Tank 49 Gal/Wing Total Capacity (Both Wings) 98 Gal. Total Usable Fuel 93 Gal. TABLE I (Sheet 3 of 4) LEADING PARTICULARS MODEL PA-34-200 PROPELLER PIPER SENECA SERVICE MANUAL PAGE 6 Oct 30/03 1C20 II - HANDLING AND SERVICING 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. Main 3.60 ± .25 In. Wheel Tread 11.1 Ft. Wheel Base 7 Ft. Nose Wheel Travel 21° left, 21° right 27° left, 27° right (1) Turning Radius (Minimum): Nose Wheel 19.5 Ft. Wing Tip 37.7 Ft. Wheel, Nose Cleveland, 6:00 x 6 (2) Wheel, Main Cleveland, 6:00 x 6 (2) Brake Type Cleveland 30-65, Double Disc Tires, Nose 6:00 x 6 (6 ply) Tires, Main 6:00 x 6 (8 ply) Tire Pressure, Nose 31 psi @ Gross Weight Tire Pressure, Main 53 psi @ Gross Weight (1) 1974 models only. (2) Refer to parts catalog for wheels and brakes part numbers and vendors. Control Surfaces and Cable Tensions - Refer to Section V, Table I. TABLE I (Sheet 4 of 4) LEADING PARTICULARS MODEL PA-34-200 LANDING GEAR PIPER SENECA SERVICE MANUAL PAGE 7 Oct 30/03 1C21 II - HANDLING AND SERVICING Station Reference Lines Figure 2 PIPER SENECA SERVICE MANUAL PAGE 8 Oct 30/03 1C22 II - HANDLING AND SERVICING Access Plates and Panels Figure 3 (Sheet 1 of 2) PIPER SENECA SERVICE MANUAL PAGE 9 Oct 30/03 1C23 II - HANDLING AND SERVICING Access Plates and Panels Figure 3 (Sheet 2 of 2) PIPER SENECA SERVICE MANUAL PAGE 10 Oct 30/03 1C24 II - HANDLING AND SERVICING 8. TORQUE WRENCHES. Torque wrenches should be checked daily and calibrated by means of weights and a measured lever arm to make sure that inaccuracies are not present. Checking one torque wrench against another is not sufficient and is not recommended. Some wrenches are quite sensitive as to the way they are supported during a tightening operation. Any instructions furnished by the manufacturer must be followed explicitly. When it is necessary to use a special extension or adapter wrench together with a torque wrench, a simple mathematical equation must be worked out to arrive at the correct torque reading. Following is the formula to be used: (Refer to Figure 4.) T = Torque desired at the part. A = Basic lever length from center of wrench shank to center of handle or stamped on wrench or listed for that model wrench. B = Length of adapter extension, center of bolt to center of shank. C = Scale reading needed to obtain desired torque (T). The formula: C = A x T A + B EXAMPLE: A bolt requires 30 foot pounds and a 3 inch adapter (one-quarter of a foot or 0.25’) is needed to get at it. You want to know what scale reading it will take on a one-foot lever arm wrench to obtain the 30 foot pounds at the bolt. C = 1 x 30 or C = 30 1 + 0.25 1.25 Remember, the 3 inch adapter must be projecting 3 inches straight along the wrench axis. In general, avoid all complex assemblages or adapters and extensions of flex joints. Torque Wrench Formula Figure 4 PIPER SENECA SERVICE MANUAL PAGE 11 Oct 30/03 1D1 II - HANDLING AND SERVICING TABLE II (Sheet 1 of 2) RECOMMENDED NUT TORQUES TORQUES: The importance of correct application can not be overemphasized. Undertorque can result in unnecessary wear of nuts and bolts as well as the parts they are holding together. When insufficient pressures are applied, uneven loads will be transmitted throughout the assembly which may result in excessive wear or premature failure due to fatigue. Overtorque can be equally damaging because of failure of a bolt or nut from overstressing the threaded areas. The following procedures should be followed to assure that the correct torque is applied: 1. Self-Locking Fasteners - Add the friction torque from Chart “A” for sizes 8 through 7/16 to the recommended torque from Chart “B” to get the final torque. This would be the actual reading on the torque wrench. To determine friction drag torque for sizes 1/2 through 1 1/4, turn the nut fully on to the bolt and determine the torque required to turn the nut. Add this friction drag torque to the torque given in Chart “B”. 2. Castellated and Non-Self Locking Nuts - Use only the torque given in Chart “B”. Unless otherwise specified, when castellated nuts are used with a cotter pin on moving joints, do not torque the nut. Turn the nut onto the bolt until proper grip is established and alignment with the cotter pin hole is achieved. Then install the cotter pin. GENERAL REQUIREMENTS. 1. Calibrate the torque wrench periodically to assure accuracy. Recheck frequently. 2. Ascertain that the bolt and nut threads are clean and dry (unless otherwise specified by the manufacturers.) If the bolt or nut is required to be lubricated prior to tightening, the torque range should be reduced 50 percent. 3. Use a bolt long enough to prevent bearing loads on the threads. The complete chamfer or end radius of the bolt or screw must extend through the nut. 4. Unique torques specified in the text of this manual supercede the torques given in Charts “A” and “B”. 5. Refer o the latest revision of Lycoming Service Table Limits, SSP1776, for torques on parts used on Lycoming engines. 6. A maximum of two AN960 washers may be added under bolt heads or nuts to correct for variations in material thickness within the tolerances permitted. 7. Self-Locking Fasteners - Limitations of the use of self-locking nuts, bolts and screws including fasteners with non-metallic inserts are as follows: A. Fasteners incorporating self-locking devices shall not be reused if they can be run-up using only fingers. They may be reused if hand tools are required to required to run them up providing there is no obvious damage to the self-locking device prior to installation. B. Bolts 5/16 inch diameter and over with cotter pin holes may be used with self-locking nuts. Nuts with non-metallic locking devices may be used in this application only if the bolts are free from burrs around the cotter pin hole. C. Do not use self-locking nuts at joints which subject either the nut or bolt to rotate. D. Never tap or rethread self-locking fasteners. Do not use nuts, bolts or screws with damaged threads or rough ends. CHART A BOLT FRICTION DRAG SIZE TORQUE (IN. -LB.) 8 (course thread) 15 10 18 1/4 30 5/16 60 3/8 80 7/16 100 CHART B COARSE THREAD SERIES BOLTS Steel Tension AN 3 THROUGH AN 20 AN 42 THROUGH AN 49 AN 73 THROUGH AN 81 AN 173 THROUGH AN 186 MS 20033 THROUGH MS 20046 MS 20073 MS 20074 AN 509 NK9 MS 24694 AN 525 NK525 MS 27039 NUTS Steel Tension Steel Shear AN 310 AN 320 AN 315 AN 364 AN 363 NAS 1022 AN 365 MS 17826 NAS 1021 MS 20364 MS 17825 MS 21045 MS 20365 MS 20500 NAS 679 Nut-bolt Torque Limits Torque Limits size in-lbs. in-lbs. Min. Max. Min. Max. 8-32 12 15 7 9 10-24 20 25 12 15 1/4-20 40 50 25 30 5/16-18 80 90 48 55 3/8-16 160 185 95 110 7/16-14 235 255 140 155 1/2-13 400 480 240 290 9/16-12 500 700 300 420 5/8-11 700 900 420 540 3/4-10 1,150 1,600 700 950 7/8-9 2,200 3,000 1,300 1,800 1-8 3,700 5,000 2,200 3,000 1-1/8-8 5,500 6,500 3,300 4,000 1-1/4-8 6,500 8,000 4,000 5,000 PIPER SENECA SERVICE MANUAL PAGE 12 Oct 30/03 1D2 II - HANDLING AND SERVICING 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 NAS 144 THRU NAS 158 AN 173DD THRU AN 186DD AN 73 THRU AN 81 NAS 333 THRU NAS 340 AN 509DD AN 173 THRU AN 186 NAS 583 THRU NAS 590 AN 525D MS 20033 THRU MS 20046 NAS 624 THRU NAS 644 MS 27039D MS 20073 NAS 1303 THRU NAS 1320 MS 24694DD MS 20074 NAS 172 AN 509 NK9 NAS 174 MS 24694 NAS 517 AN 525 NK525 MS 27039 NUTS NUTS NUTS Steel Tension Steel Shear Steel Tension Steel Shear Alum. Tension Alum. Shear AN 310 AN 320 AN 310 AN 320 AN 365D AN 320D AN 315 AN 364 AN 315 AN 364 AN 310D AN 364D AN 363 NAS 1022 AN 363 NAS 1022 NAS 1021D NAS 1022D AN 365 MS 17826 AN 365 MS 17826 NAS 1021 MS 20364 MS 17825 MS 20364 MS 17825 MS 20365 MS 21045 MS 21045 MS 20365 NAS 1021 MS 20500 NAS 679 NAS 679 NAS 1291 Nut-bolt Torque Limits Torque Limits Torque Limits Torque Limits Torque Limits Torque Limits size in-lbs. in-lbs. in-lbs. in-lbs. in-lbs. in-lbs. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. 8-36 12 15 7 9 5 10 3 6 10-32 20 25 12 15 25 30 15 20 10 15 5 10 1/4-28 50 70 30 40 80 100 50 60 30 45 15 30 5/16-24 100 140 60 85 120 145 70 90 40 65 25 40 3/8-24 160 190 95 110 200 250 120 150 75 110 45 70 7/16-20 450 500 270 300 520 630 300 400 180 280 110 170 1/2-20 480 690 290 410 770 950 450 550 280 410 160 260 9/16-18 800 1,000 480 600 1,100 1,300 650 800 380 580 230 360 5/8-18 1,100 1,300 660 780 1,250 1,550 750 950 550 670 270 420 3/4-16 2,300 2,500 1,300 1,500 2,650 3,200 1,600 1,900 950 1,250 560 880 7/8-14 2,500 3,000 1,500 1,800 3,550 4,350 2,100 2,690 1,250 1,900 750 1,200 1-14 3,700 4,500 2,200 3,300 4,500 5,500 2,700 3,300 1,600 2,400 950 1,500 1-1/8-12 5,000 7,000 3,000 4,200 6,000 7,300 3,600 4,400 2,100 3,200 1,250 2,000 1-1/4-12 9,000 11,000 5,400 6,600 11,000 13,400 6,600 8,000 3,900 5,600 2,300 3,650 Steel shear bolt NAS 464 PIPER SENECA SERVICE MANUAL PAGE 13 Oct 30/03 1D3 II - HANDLING AND SERVICING NOTE: When flared fittings are being installed, ascertain that the male threads are properly lubricated. Torque the fittings in accordance with Table III. TORQUE — INCH-POUNDS TUBING ALUMINUM - ALLOY STEEL TUBING HOSE END FITTING OD TUBING FLARE - AND FLARE AND INCHES 10061 OR AND 10078 AND 10061 HOSE ASSEMBLIES MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM 1/8 ——— ——— ——— ——— ——— ——— 3/16 ——— ——— 90 100 70 100 1/4 40 65 135 150 70 120 5/16 60 80 180 200 85 180 3/8 75 125 270 300 100 250 1/2 150 250 450 500 210 420 5/8 200 350 650 700 300 480 3/4 300 500 900 1000 500 850 1 500 700 1200 1400 500 1150 1-1/4 600 900 ——— ——— ——— ——— 1-1/2 600 900 ——— ——— ——— ——— 1-3/4 ——— ——— ——— ——— ——— ——— 2 ——— ——— ——— ——— ——— ——— TABLE III FLARE FITTING TORQUE VALUES CAUTION: DO NOT OVERTORQUE FITTINGS. 8a. TORQUE REQUIREMENTS. The torque values given in Table II are derived from oil-free cadmium-plated threads and are recommended for all airframe installation procedures where torqueing is; required, unless otherwise noted in sections where other values are stipulated. Engine torque values are found in the latest revision of Lycoming Special Service Publication No. 1776 (i.e. - SSP-1776), and propeller torque values are found in Section VIII. PIPER SENECA SERVICE MANUAL PAGE 14 Oct 30/03 1D4 II - HANDLING AND SERVICING 9. 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. CAUTION: IN ORDER TO AVOID DAMAGE TO THE WING SURFACE WALK ONLY ON THE WALKWAY. 10. GROUND HANDLING. 11. INTRODUCTION TO GROUND HANDLING. Ground handling covers all essential information governing the handling of the airplane while on the ground. This includes jacking, weighing, leveling, mooring, parking, towing and taxiing. When the airplane is handled in the manner described in the following paragraphs, damage to the airplane and its equipment will be prevented. 12. JACKING. Jack the airplane as specified to perform various service operations. Proceed as follows: a. Place the jacks under the jack pads on the wing front spar. CAUTION: BE SURE TO APPLY SUFFICIENT SUPPORT BALLAST; OTHERWISE THE AIRPLANE WILL TIP FORWARD AND FALL ON THE FUSELAGE NOSE SECTION. b. Attach a tail support to the tail skid. Place approximately 500 pounds of ballast on the support to hold the tail down. (Refer to Figure 5.) CAUTION: IF THE PURPOSE FOR PLACING THE AIRPLANE ON JACKS IS TO SERVICE THE HYDRAULIC SYSTEM, THE FREE-FALL VALVE KNOB SHOULD BE PULLED FULL OUT FROM THE INSTRUMENT PANEL. (REFER TO SECTION VI, PARAGRAPH 1.) c. Carefully raise jacks until all three wheels are clear of the surface. Jacking Figure 5 PIPER SENECA SERVICE MANUAL PAGE 15 Oct 30/03 1D5 II - HANDLING AND SERVICING 13. WEIGHING. (Refer to Figure 6.) The airplane may be weighed by the following procedure: a. Position a scale and ramp in front of each of the three wheels. b. Secure the scales from rolling forward and tow the airplane up onto the scales. (Refer to Towing, Paragraph 18.) c. Remove the ramp so as not to interfere with the scales. d. If the airplane is to be weighed for weight and balance computations, level the airplane per instructions given in paragraph 14. Weighing Figure 6 PIPER SENECA SERVICE MANUAL PAGE 16 Oct 30/03 1D6 II - HANDLING AND SERVICING 14. LEVELING. All configurations of the airplane are provided with a means for longitudinal and lateral leveling. The airplane may be leveled while on jacks; during the weighing procedure while the wheels are on scales; or while the wheels are on the ground. To level the airplane for purposes of weighing or rigging, the following procedures may be used: a. To longitudinally level the airplane, partially withdraw the two leveling screws located immediately below the left front side window. (Refer to Figure 7.) Place a spirit level on these screw heads and deflate the nose wheel tire or adjust the jacks until the bubble of the level is centered. b. To laterally level the airplane, place a spirit level across the baggage compartment floor along the rear bulkhead (refer to Figure 7) and deflate the tire on the high side of the airplane or adjust either jack until the bubble of the level is centered. 15. MOORING. The airplane is moored to insure its immovability, protection and security under various weather conditions. The following procedure gives the instructions for proper mooring of the airplane. a. Head the airplane into the wind, if possible. b. Block the wheels. c. Lock the aileron and stabilator controls using the control lock pin provided. CAUTION: USE SQUARE OR BOWLINE KNOTS. DO NOT USE SLIP KNOTS. d. Secure tie-down ropes to the wing tie-down rings and the tail skid at approximately 45 degree angles to the ground. When using rope constructed of non-synthetic material, leave sufficient slack to avoid damage to the airplane when the ropes contract due to moisture. NOTE: Additional preparations for high winds include using tie-down ropes from the landing gear forks, and securing the rudder. Leveling Figure 7 PIPER SENECA SERVICE MANUAL PAGE 17 Oct 30/03 1D7 II - HANDLING AND SERVICING 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. When parking the airplane for any length of time or overnight, it is recommended that it be moored as in paragraph 15. a. To park the airplane, head it into the wind, if possible. b. Set the parking brake by pulling back the brake lever and depressing the knob attached to the left side of the handle. Then release the handle. To release the parking brakes, pull back on the brake lever to disengage the catch mechanism. Then allow the handle to swing forward. NOTE: Care should be taken when setting brakes that are overheated or during cold weather when accumulated moisture may freeze the brakes. c. The aileron and stabilator controls may be locked by using the control wheel lock. CAUTION: DO NOT TURN THE NOSE GEAR BEYOND ITS TRAVEL LIMITS (SEE TABLE 1). ESPECIALLY WHEN TOWING WITH POWER EQUIPMENT, THIS WILL EASILY DAMAGE THE NOSE GEAR RETRACTION, EXTENSION, AND STEERING MECHANISMS. CAUTION: DO NOT PUSH ON THE TRAILING EDGE OF THE AILERON, WHEN MOVING THE AIRCRAFT FORWARD BY HAND. THIS WILL CAUSE THE AILERON CONTOUR TO CHANGE RESULTING IN AN OUT-OF-TRIM CONDITION. 18. TOWING. The airplane may be moved by using the nose wheel steering bar that is stowed below the forward ledge of the rear baggage compartment or power equipment that will not damage or cause excess strain to the nose gear steering assembly. Tow bar engages front axle inside fork. In the event towing lines are necessary, lines (rope) should be attached to both main gear struts as high up on the tubes as possible. Lines should be long enough to clear the nose and/or tail by not less than 15 feet, and a qualified person to ride in the pilot’s seat to maintain control by use of the brakes. 19. TAXIING. Before attempting to taxi the airplane, ground personnel should be checked out by a qualified pilot or other responsible person. Engine starting and shut-down procedures should be covered as well. When it is ascertained that the propeller back blast and taxi areas are clear, apply power to start the taxi roll and perform the following checks. a. Taxi forward a few feet and apply brakes to determine their effectiveness. b. Taxi with propellers set in low pitch, high RPM setting. c. While taxiing, make slight turns to ascertain the effectiveness of steering. d. Observe wing clearances when taxiing near buildings or other stationary objects. If possible, station a guide outside the airplane to observe. e. When taxiing on uneven ground, look for holes and ruts. f. Do not operate the engines at high RPM when running up or taxiing over ground containing loose stones, gravel or any loose material that may cause damage to the propeller blades. PIPER SENECA SERVICE MANUAL PAGE 18 Oct 30/03 1D8 II - HANDLING AND SERVICING Turning Distance Figure 8 PIPER SENECA SERVICE MANUAL PAGE 19 Oct 30/03 1D9 II - HANDLING AND SERVICING 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. NOTE: When using a 12-volt battery for external power starting and the airplane’s battery is nearly depleted, the instructions given in Section XI must be followed. 21. SERVICING. 22. INTRODUCTION TO SERVICING. Servicing the airplane includes the replenishment of fuel, oil, hydraulic fluid, tire pressures, lubrication requirements and other items required to completely service the airplane. 23. INDUCTION AIR FILTER. a. The filter should be cleaned daily when operating in dusty conditions. If any holes or tears are noticed, the filter must be replaced immediately. CAUTION: NEVER WASH THE FILTER ELEMENT IN ANY LIQUID OR SOAK IT IN OIL. NEVER ATTEMPT TO BLOW OFF DIRT WITH COMPRESSED AIR. b. Remove the filter element and shake off loose dirt by rapping on a hard flat surface, being careful not to damage or crease the sealing ends. c. The filter housing can be cleaned by wiping with a clean cloth soaked in a suitable dry type solvent. When the housing is dry reinstall and seal the filter element. 24. FUEL SYSTEM. 25. SERVICING FUEL SYSTEM. At intervals of 50 hours or 90 days, whichever comes first, clean the screens and bowls of the gascolators. Remove and clean the filters in accordance with the instructions outlined in Section VIII. Additional service information may also be found in Section VIII. Inspection intervals of the various fuel system components may be found in Section III. 26. FILLING FUEL TANKS. The fuel tanks of each wing are filled through a single filler located on the forward slope of the wing. at the outboard tank. Each wing tank has a capacity of 24.5 U.S. gallons. The two 24.5 gallon tanks of each wing are interconnected, therefore giving a total capacity of 49 U.S. gallons of fuel per wing. a. Observe all required safety precautions for handling gasoline. b. Fill tanks with fuel as specified on the placard adjacent to the filler neck (see Table I). CAUTION: ASSURE THAT THE ADDITIVE IS DIRECTED INTO FLOWING FUEL STREAM. THE ADDITIVE FLOW SHOULD START AFTER AND STOP BEFORE THE FUEL FLOW. DO NOT PERMIT THE CONCENTRATED ADDITIVE TO COME IN CONTACT WITH THE AIRCRAFT PAINTED SURFACES OR THE INTERIOR SURFACES OF THE FUEL TANKS. SOME FUELS HAVE ANTI-ICING ADDITIVES PRE-BLENDED IN THE FUEL AT THE REFINERY, SO NO FURTHER BLENDING SHOULD BE PERFORMED. FUEL ADDITIVE CANNOT BE USED AS A SUBSTITUTE FOR A PREFLIGHT DRAINING OF THE FUEL SYSTEM DRAINS. NOTE: The PA-34-200 aircraft is approved for operation with an anti-icing additive in the fuel. When an anti-icing additive is used it must meet the specification MIL-1-27686, must be uniformly blended with the fuel while refueling, must not exceed 15% by volumn of the refueled quantity, and to ensure its effectiveness should be blended at not less than 10% by volume (one and one hay liquid ozs. per ten gallon of fuel would be within the range). A blender supplied by the additive manufacturer should be used Except for the information contained in this section, the manufacturer’s mixing or blending instructions should be carefully followed. PIPER SENECA SERVICE MANUAL PAGE 20 Oct 30/03 1D10 II - HANDLING AND SERVICING Service Points Figure 9 PIPER SENECA SERVICE MANUAL PAGE 21 Oct 30/03 1D11 II - HANDLING AND SERVICING 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. 28. DRAINING FUEL SYSTEM. The bulk of the fuel may be drained from the system by opening the valve at the inboard end of each fuel tank. Push up on the arms of the drain valve and turn counter-clockwise to hold the drain in the open position. The remaining fuel in the system may be drained through the gascolators and the two drains located on the lower right side of the fuselage inboard to the flaps. 29. BRAKE SYSTEM. 30. SERVICING BRAKE SYSTEM. The brake system incorporates a hydraulic fluid reservoir through which the brake system is periodically serviced. Fluid is drawn from the reservoir by the brake cylinders to maintain the volume of fluid required for maximum braking efficiency. Spongy brake pedal action is often an indication that the brake fluid reservoir is running low on fluid. Instructions for filling the reservoir are given in paragraph 31. When found necessary to accomplish repairs to any of the brake system components, or to bleed the system, these instructions may be found in Section VII. 31. FILLING BRAKE CYLINDER RESERVOIR. The brake cylinder reservoir should be filled to the level marked on reservoir, with the fluid specified in Table I. The reservoir, located on the center of the bulkhead in the nose baggage compartment, should be checked at every 50-hour inspection and replenished as necessary. No adjustment of the brakes is necessary, though they should be checked periodically per instructions given in Section VII. 32. DRAINING BRAKE SYSTEM. To drain the brake system, connect a hose to the bleeder fitting on the bottom of the cylinder and place the other end of the line in a suitable container. Open the bleeder and slowly pump the hand brake lever and the desired brake pedal until fluid ceases to flow. To drain the wheel brake unit, disconnect the line at the bottom of the unit and allow fluid to flow into a suitable container. To clean the brake system, flush with denatured alcohol. 33. OLEO STRUTS. CAUTION: DO NOT EXCEED THESE TUBE EXPOSURES. 34. Servicing OLEO STRUTS. The air-oil type oleo strut should be maintained at proper strut piston tube exposures for best oleo action. The nose gear strut must have approximately 2.60 ±.25 inches of piston tube exposed, while the main gear strut requires approximately 3.60 ± .25 inches of tube exposure. These measurements are taken with the airplane sitting on a level surface under normal static load. NOTE: Normal static load is the empty weight of the airplane plus full fuel and oil. If the strut has less tube exposure than prescribed, determine whether it needs air or oil by rocking the airplane. If the oleo strut oscillated with short strokes (approximately one inch) and the airplane settles to its normal position within one or two cycles after the rocking force is removed, the oleo strut requires inflating. Check the valve core and filler plug for air leaks, correct if required, and add air as described in Paragraph 36. If the oleo strut oscillates with long strokes (approximately three inches) and the airplane continues to oscillate after the rocking force is removed, the oleo struts require fluid. Check the oleo for indications of oil leaks, correct if required and add fluid as described in Paragraph 35 or 35a. For repair procedures of the landing gear and/or oleo struts, refer to Section VII of this manual. PIPER SENECA SERVICE MANUAL PAGE 22 Oct 30/03 1D12 II - HANDLING AND SERVICING Fuel Drain Valve 100 Hour Inspection Figure 10 PIPER SENECA SERVICE MANUAL PAGE 23 Oct 30/03 1D13 II - HANDLING AND SERVICING 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 LANDING GEAR STRUTS, THEREFORE, BEFORE ATTEMPTING TO REMOVE THESE PLUGS, THE AREA AROUND THE FILLER PLUGS SHOULD BE CLEANED WITH COMPRESSED AIR AND/OR WITH A QUICK DRYING SOLVENT. 35. FILLING NOSE GEAR OLEO STRUT. To fill the nose gear oleo strut with hydraulic fluid (MIL-H-5606) whether it be only the addition of a small amount or if the unit has been completely emptied and will require a large amount, it should be filled as follows: a. Raise the airplane on jacks. (Refer to Paragraph 12.) b. Place a pan under the gear to catch spillage. c. Relieve air pressure from the strut housing chamber by removing the cap from the air valve and depressing the valve core. d. There are two methods by which the strut chamber may be filled, and these are as follows: Method I: 1. Remove the valve core from the filler plug at the top of the nose gear strut housing. Allow the filler plug to remain installed. 2. With the piston tube extended, fill the strut with approved type fluid. 3. Attach one end of a clean plastic hose to the valve stem of the filler plug and submerge the other end of the hose in a container of clean hydraulic fluid, make sure the end of the hose is below the surface of the fluid. NOTE: An air tight connection is necessary between the plastic tube and the valve stem. Without such a connection, a small amount of air will be sucked into the oleo strut during each sequence, resulting in an inordinate amount of air bubbles and prolonged filling operations. 4. Fully compress and extend the piston tube, thus expelling any air trapped within the strut chamber. By watching the fluid pass through the plastic hose, it can be determined when the strut is full and no air is present in the chamber. 5. When air bubbles cease to flow through the hose, compress the piston fully and remove the hose from the valve stem. Remove the filler plug to determine that fluid level is visible up to the bottom of the filler plug hole. 6. Reinstall the core in the filler plug and the plug in the strut housing and torque to 45 foot- pounds. Method II: 1. Remove the filler plug from the top of the nose gear strut housing. 2. Raise the strut piston tube until it is fully compressed. 3. Pour hydraulic fluid from a clean container through the filler opening until it reaches the bottom of the filler plug hole. (Air pressure type oil container may be helpful.) 4. Install the filler plug finger tight and extend and compress the strut two or three times to remove air from the housing. 5. Remove the filler plug; raise the strut to full compression and fill with fluid if needed. 6. Reinstall filler plug and torque to 45 foot-pounds. PIPER SENECA SERVICE MANUAL PAGE 24 Oct 30/03 1D14 II - HANDLING AND SERVICING e. 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. f. Clean off any overflow of fluid and inflate the strut as described in Paragraph 36. g. Check that fluid is not leaking around the strut piston at the bottom of the housing. 35a. FILLING MAIN GEAR OLEO STRUTS. To fill the main gear oleo struts with hydraulic fluid (MIL-H-5606) one of the following methods should be used, depending on the type of service performed on the strut assembly. Method I. Addition of small amount of fluid: 1. Raise the airplane on jacks. (Refer to Paragraph 12.) 2. Place a pan under the gear to catch any spillage. 3. Relieve the air pressure from the strut housing chamber by removing the cap from the air valve and depressing the valve core. 4. Remove the valve core from the filler plug and allow the filler plug to remain installed. 5. With the piston tube extended, fill the strut with the approved type hydraulic fluid. 6. Attach one end of a clear plastic hose to the valve stem of the filler plug and submerge the other end of the hose in a container of clean hydraulic fluid, make sure the end of the hose is below the surface of the fluid. NOTE: An air tight connection is necessary between the plastic tube and the valve stem. Without such a connection, a small amount of air will be sucked into the oleo strut during each sequence, resulting in an inordinate amount of air bubbles and prolonged filling operations. 7. Fully compress and extend the piston tube, thus expelling any air trapped within the strut chamber. By watching the fluid pass through the plastic hose it can be determined when the strut is full and no air is present in the chamber. 8. When air bubbles cease to flow through the hose, fully compress the piston and remove the hose from the valve stem. Remove the filler plug to determine that fluid is visible up to the bottom of the filler plug hole. 9. Reinstall the air valve core in the filler plug and the plug in the strut housing and torque to 45 foot-pounds. 10. 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. 11. Clean off any overflow of fluid and inflate the strut as described in Paragraph 36. 12. Remove the aircraft from jacks and check strut exposure per Paragraph 34. Method II. Filling completely empty struts: 1. Proceed with Steps I through 3 of Method I. 2. Remove the filler plug at the top inboard side of the main gear housing and fully extend the piston. 3. Pour 17 ± 1 ounces of MIL-H-5606 hydraulic fluid through the plug hole, using a syringe or pump oil can. 4. Proceed with Steps 9 through 12 of Method I. PIPER SENECA SERVICE MANUAL PAGE 25 Oct 30/03 1D15 II - HANDLING AND SERVICING 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; Nose = 150 psi; ± 10%) until the correct inches of piston is exposed with normal static load (empty weight of the airplane plus full fuel and oil) on the gear. (Refer to Paragraph 34.) Rock the airplane several times to ascertain that the gear settles back to the correct strut position. (If a strut pump is not available, the airplane may be raised and line pressure from a high pressure air system used. Lower the airplane and while rocking it, let air from the valve to bring the strut down to the proper extension. (Before capping the valve, check for valve core leakage.) 36a. SERVICING STEERING BUNGEES. At the specified frequency, according to the Lubrication Chart, the steering bungees must be serviced as follows: a. Remove the access panels located in the forward baggage compartment. b. Clamp the rudder pedals in the neutral position as shown in Figure 11, Section V. c. Remove the nut, washers and bolt that secures the steering bungee and the steering arm. d. Remove the clamp that secures the boot, on the frame at station 49.50, to the bungee. e. Within the fuselage, disconnect the bungee from the rudder pedal arm by removing the nut, washer and bolt. f. Remove the steering bungee from the aircraft. g. Cut the safety wire from the bungee retainer. h. Carefully remove the retainer and release the spring. i. Apply Aero Lubriplate to the spring and mounting hardware. j. Compress the spring into the bungee tube and install the retainer securing with MIL-W-6713 Type 316 safety wire. k. Ascertain that the measurement taken between the facing sides of the washers at the rod end is 13.71 inches. l. With the nose gear in the neutral position, install the steering bungee into position. The web must be in the vertical position. (Refer to Figure 2, Section VII.) m. Install the bolt, washers and nut that secures the bungee to the steering arm. n. Install the bolt, washer and nut that secures the bungee to the rudder pedal arm. o. Install the boot clamp. p. Repeat this procedure for the other steering bungee. q. Align the nose gear per Alignment of Nose Landing Gear, Section VII. r. Remove the rudder pedal clamps and check the operation of the steering bungees. s. Install the access panels in the forward baggage compartment with the attachment hardware. PIPER SENECA SERVICE MANUAL PAGE 26 Oct 30/03 1D16 II - HANDLING AND SERVICING 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. The airplane may be equipped with either tubed or tubeless tires. Tubeless tires are designed to permit any air or nitrogen that is trapped in the cords or that diffuses through the liner to escape through special sidewall vents. This venting prevents pressure build-up within the cord body which might cause tread, sidewall or ply separation. Discounting tire growth after initial inflation, once the tire has been inflated, the maximum permissible pressure drop due to diffusion is 5% in any 24 hour period. Vent holes penetrate the sidewall rubber to, or into, the cord body and may vary in size, depth and angle. Therefore, the amount of diffusion through these holes will vary. When water or a soap solution is brushed over the outside of an inflated tubeless tire, bubbles form. Some vents may emit a continuous stream of bubbles. Others may produce intermittent bubbles. And some may not bubble at all. This variety is normal and does not mean that there is anything wrong with the tire. In fact, as long as a tubeless tire is inflated, there will be some diffusion from the vents. When the loss rate exceeds 5% in 24 hours, recheck for possible injuries. Vents should remain open, so check periodically to make sure they have not been covered over or closed by tire paint or spilled solvent. And since vents may be covered during retreading, check for evidence that your retreads have been revented. A. Several basic characteristics of tubeless aircraft tires may be mistaken for problems: (1) Tire growth in the first 12 to 24 hours after inflation will result in a seemingly severe pressure drop. Simply inflate, wait for another 24 hours, then check pressure. It will probably be within specs. (2) Make sure that initial inflation is to recommended operating pressure to ensure full tire growth. (3) It is normal for tubeless tires to show a small amount of pressure leakage throughout the life of the tires. B. Maintain tires at pressure specified in Table 1. When checking tire pressure, examine tires for wear, cuts, bruises and slippage on the wheel. Check that index mark on tire is aligned with index mark on wheel. Apply Age-Master #1 to tires to protect against ozone attack and weathering as follows: (1) Clean oil and grease from all tire surfaces. (2) Apply single heavy coat using brush at 0.4 - 0.5 fluid ounces per square foot. Cover surface completely and evenly; allow to dry for 5 - 10 minutes. (3) Apply second coat per step 2; allow to dry for 20 - 30 minutes before handling. (4) Remove agent on wheel assembly with cleaning solvent. (5) Apply as conditions dictate. 38. TIRE BALANCE. Proper balancing is critical for the life of aircraft tires. If a new tire is balanced upon installation it will usually remain balanced for the life of the tire without having any shimmy or flat spots. An inexpensive balancer can be made that will balance almost any tire for light aircraft. See Figure 11 for balancer details. Balance the tire as follows: (1) Mount tire and tube (if one is used) on wheel, but do not install the securing bolts. Install wheel bearings in wheel; then, using the -7 bushings, -6 spacers, and -5 nuts, (refer to Figure 11) install the wheel-tire assembly on the pipe. Secure the nuts finger-tight so that the wheel halves touch each other. Be sure the bolt holes are aligned. Insert the axle through the pipe and place the wheel in the center of the balancer. Make sure the axle is only on the chamfered edges of the balancer and that it is at 90° to the sides of the balancer. PIPER SENECA SERVICE MANUAL PAGE 27 Oct 30/03 1D17 II - HANDLING AND SERVICING (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. If the tire returns to the same position, add a one (1) ounce patch and again rotate the tire and release it. Continue this procedure until the tire is balanced. (3) When balance is attained, put a chalk mark on the sidewall directly below the patch. Use one mark for each half ounce of weight needed. Mark the valve stem location on the tire and the opposite wheel half to assure reassembly in the same position. Remove the wheel from the balance stand, break it down and clean the inside of the tire with toluol. Apply a coat of patch cement to both the patch and the inside center of the tire in line with the chalk marks. When the cement has dried, install the patches making certain they are on the center line of the tire and aligned with the chalk marks on the sidewall. Burnish the patches to remove trapped air, etc. (4) When reassembling the wheel, powder the inside of the tire. Mount the tire on the valve side of the wheel in the same position it was in when it was balanced. Install the other wheel half, aligning the chalk marks. Install the bolts and tighten to required torque, then air the tire and recheck the balance. The wheel should not be more than one-half (1/2) ounce out of balance. Wheel Balancer Figure 11 PIPER SENECA SERVICE MANUAL PAGE 28 Oct 30/03 1D18 II - HANDLING AND SERVICING 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. To clean the rods use an oil soaked rag and carefully wipe them. All the hydraulic lines should also be checked for leaks, kinks, corrosion and attachment fittings for tightness and security. Repair and check procedures for the hydraulic pump, cylinders and various components may be found in Section VI of this manual. 41. SERVICING HYDRAULIC PUMP/RESERVIOR. The fluid level of the reservoir of the combination pump and reservoir should be checked every 50 hours by viewing the fluid through the filler plug hole in the hydraulic pump. Access to the pump is through the panel at the right forward side of the nose baggage compartment. To check fluid level, remove the filler plug located on the forward side of the pump and ascertain that fluid is visible up to the bottom of the filler plug hole. Should fluid be below the hole, loosen the vent screw and add fluid, MIL-H-5606, through the filler hole until full. Reinstall the filler plug and position the vent screw. NOTE: A small vent hole is located under the vent screw head. Retain 1/64 inch clearance between the screw head and the small vent hole. 42. BATTERY. 43. SERVICING BATTERY Servicing of the battery, which is located under the floor panel of the forward baggage compartment, involves adding distilled water to maintain electrolyte even with the horizontal baffles, checking cable connections, and checking for any spilled electrolyte that would lead to corrosion. A check for proper fluid level and presence of corrosion should be conducted at intervals of 50 hours or 30 days, whichever comes first. When corrosion is found, at each 100 hour inspection or every 90 days, the battery should be removed from the box, and the battery and box should be cleaned. Removal, cleaning and charging instructions may be found in Section XI. 44. CLEANING. 45. CLEANING ENGINE COMPARTMENTS. Before cleaning the engine compartments, place a strip of tape on the magneto vents to prevent any solvent from entering these units. a. Place a pan under the engines to catch waste. CAUTION: DO NOT SPRAY SOLVENT INTO THE ALTERNATOR, STARTER, AIR INTAKE, ALTERNATE AIR INLETS OR VACUUM PUMP DRIVE AREA. b. With the engine cowlings removed, spray or brush the engines 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. c. Allow the solvent to remain on the engine from five to 10 minutes, then rinse the engine clean with additional solvent and allow to dry. CAUTION: DO NOT OPERATE ENGINES UNTIL EXCESS SOLVENT HAS EVAPORATED OR OTHERWISE BEEN REMOVED. d. Remove the protective covers from the filter and magnetos. e. Lubricate controls, bearing surfaces, etc., per Figure 12, Lubrication Chart. PIPER SENECA SERVICE MANUAL PAGE 29 Oct 30/03 1D19 II - HANDLING AND SERVICING 46. CLEANING LANDING GEAR. Before cleaning the landing gear, place a plastic cover or similar material over the wheel and brake assembly. a. Place a pan under the gear to catch waste. b. 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. Do not brush micro switches. c. Allow the solvent to remain on the gear from 5 to 10 minutes, then rinse the gear with additional solvent and allow to dry. d. Remove the cover from the wheel and remove the catch pan. e. Lubricate the gear per Lubrication Chart. 47. CLEANING EXTERIOR SURFACES. The airplane should be washed with a mild soap and water. Harsh abrasive or alkaline soaps or detergents used on painted or plastic surfaces could make scratches or cause corrosion of metal surfaces. Cover areas where cleaning solution could cause damage. To wash the airplane, the following procedure may be used: a. Flush away loose dirt with water. b. Apply cleaning solution with a rag, sponge or soft bristle brush. c. To remove stubborn oil and grease, use a cloth dampened with naptha. d. Where exhaust stains exist, allow solution to remain on the surface longer. e. Any good automotive wax may be used to preserve the painted surfaces. Soft cleaning cloths or a chamois should be used to prevent scratches when cleaning or polishing. A heavier coating of wax on the leading surfaces will reduce the abrasion problems in these areas. 48. CLEANING WINDSHIELD AND WINDOWS. a. Remove dirt, mud. etc., from exterior surfaces with clean water. b. Wash with mild soap and warm water or an aircraft plastic cleaner. Use a soft cloth or sponge using a straight rubbing motion. Do not harshly rub surfaces. c. Remove oil and grease with a cloth moistened with kerosene. NOTE: Do not use gasoline, alcohol, benzene, carbon tetrachloride, thinner, acetone, or window cleaning sprays. d. After cleaning plastic surfaces, apply a thin coat of hard polishing wax. Rub lightly with a soft cloth. Do not use a circular motion. e. A severe scratch or mar in plastic can be removed by using jeweler’s rouge to rub out the scratch. Smooth both sides and apply wax. f. To improve visibility through windshield and windows during flight through rain, a rain repellent such as REPCON should be applied to the windshield and windows. The surface of the windshield and windows treated becomes so smooth that water beads up and readily flows off the surface. Apply this product in accordance with the manufacturer’s instructions. (Refer to Table V.) PIPER SENECA SERVICE MANUAL PAGE 30 Oct 30/03 1D20 II - HANDLING AND SERVICING 49. CLEANING HEADLINER, SIDE PANELS AND SEATS. a. Clean headliner, side panels and seats with a stiff bristle brush and vacuum where necessary. CAUTION: SOLVENT CLEANERS REQUIRE ADEQUATE VENTILATION. b. Soiled upholstery, except leather, may be cleaned by using an approved air type cleaner or foam upholstery cleaner. Carefully follow the manufacture’s instructions. Avoid soaking or harsh rubbing. c. Leather material should be cleaned with saddle soap or mild soap and water. 50. CLEANING CARPETS. Use a small whisk broom or vacuum to remove dirt. For soiled spots, use a non-inflammable dry cleaning fluid. Floor carpets may be removed and cleaned like any household carpet. 51. LUBRICATION. 52. OIL SYSTEM. (ENGINE.) 53. SERVICING OIL SYSTEM. The engine oil level should be checked before each flight and changed after each 50 hours of engine operation. During oil change, the oil screen(s) should be removed and cleaned, and when installed, the oil filter cartridge replaced. Intervals between oil changes can be increased as much as 100% on engines equipped with full flow (cartridge type) oil filters provided the element is replaced each 50 hours of operation. The engine manufacturer does not recommend oils by brand names. Use a quality brand Aviation Grade Oil of the proper season viscosity. For information on the use of detergent oil, refer to paragraph 59. CAUTION: DO NOT INTRODUCE ANY TRADE ADDITIVE TO THE BASIC LUBRICANT UNLESS RECOMMENDED BY THE MANUFACTURER. 54. FILLING OIL SUMP. The oil sump should normally be filled with oil to the mark on the engine dipstick. The quantity of oil required for the engines may be found in Table I. The specified grade of oil may be found in the Lubrication Chart or on the right cowl panel access door of each engine. To service the engine with oil, open the access door of the cowl and remove the oil filler cap with dipstick. 55. DRAINING OIL SUMP. To drain the oil sump, provide a suitable container with a minimum capacity of that required to fill the sump. Remove the engine cowl and open the oil drain valve located on the underside of the engine by pushing the arms of the drain up and turning counterclockwise. This will hold the drain in the open position. It is recommended the engine be warmed to operating temperature to insure complete draining of the old oil. 56. OIL SCREEN. (SUCTION.) The oil suction screen is located on the bottom aft end of the engine sump, installed horizontally. To remove, cut the safety wire and remove the hex head plug. The screen should be cleaned at each oil change to remove any accumulation of sludge and to examine for metal filings or chips. If metal particles are found in the screen, the engine should be examined for internal damage. After cleaning and inspection, place the screen inside the recess in the hex head plug to eliminate possible damage to the screen. Insert the screen into the housing and when certain that the screen is properly seated, tighten and safety the plug with MS-20995-C41 safety wire. 57. OIL SCREEN. (PRESSURE.) The oil pressure screen, located in a housing on the accessory case of the engine, between the magnetos, should be cleaned at each oil change to remove any accumulation of sludge and to examine for metal filings or chips. If metal particles are found in the screen, the engine should be examined for internal damage. When reinstalling the screen, it is recommended that a new gasket be used. Ascertain that the screen fits flush with the base surface of the screen housing. Position housing on mounting pad and install attachment bolts. Torque bolts within 50 to 70 inch pounds. NOTE: The oil screen (pressure), above, and the oil filter (full flow), below, installations are mutually exclusive. I.E. - if a full flow cartridge-type oil filter is installed, there is no oil screen (pressure). PIPER SENECA SERVICE MANUAL PAGE 31 Oct 30/03 1D21 II - HANDLING AND SERVICING 58. OIL FILTER. (FULL FLOW.) a. 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. b. Before discarding the filter element, remove the outer perforated paper cover, and using a sharp knife, cut through the folds of the element at both ends, close to the metal caps. Then, carefully unfold the pleated element and examine the material trapped in the filter for evidence of internal engine damage such as chips or particles from bearings. In new or newly overhauled engines, some small particle or metallic shavings might be found; these are generally of no consequence and should not be confused with particles produced by impacting, abrasion or pressure. Evidence of internal engine damage found in the oil filter justifies further examination to determine the cause. c. After the element has been replaced, tighten the attaching bolt within 20 to 25 foot pounds of torque. Lockwire the bolt through the loops on the side of the housing to the drilled head of the thermostatic valve. Be sure the lockwire is replaced at both the attaching bolt head and the thermostatic oil cooler bypass valve. 59. RECOMMENDATIONS FOR CHANGING OIL. (Refer to latest revision of Lycoming Service Instruction No. 1014 and Service Bulletin No. 480.) a. In engines that have been operating on straight mineral oil for several hundred hours, a change to additive oil should be made with a degree of caution, since the cleaning action of some additive oils will tend to loosen sludge deposits and cause plugged oil passages. When an engine has been operating on straight mineral oil and is known to be in excessively dirty condition, the switch to additive or compounded oil should be deferred until after the engine is overhauled. b. When changing from straight mineral oil to compounded oil, the following precautionary steps should be taken: 1. Do not add additive oil to straight mineral oil. Drain the straight mineral oil from the engine and fill with additive oil. 2. Do not operate the engine longer than five hours before the first oil change. 3. Check all oil screens for evidence of sludge or plugging and change oil every ten hours if sludge conditions are evident. Resume normal oil drain periods after sludge conditions improve. 60. WINTERIZATION PLATE. For winter operations there is a Winterization Plate Kit available. When the ambient temperature is 50°F or less, the plate is installed on the inlet opening of the oil cooler plenum chamber. When the plate is not being used it can be stored in the nose baggage compartment. PIPER SENECA SERVICE MANUAL PAGE 32 Oct 30/03 1D22 II - HANDLING AND SERVICING GRIDS 1D22 THRU 1D24 INTENTIONALLY BLANK PIPER SENECA SERVICE MANUAL PAGE 33 Oct 30/03 1E1 II - HANDLING AND SERVICING 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. Lubrication instructions regarding the locations, time intervals, and type of lubricants used may be found in Figure 12, Lubrication Chart. To insure the best possible results from the application of lubricants, the following precautions should be observed: a. Use recommended lubricants. Where general purpose lubricating oil is specified, but unavailable, clean engine oil may be used as a satisfactory substitute. b. Check the components to be lubricated for evidence of excessive wear and replace them as necessary. c. Remove all excess lubricants from components in order to prevent the collection of dirt and sand in abrasive quantities capable of causing excessive wear or damage to bearing surfaces. NOTE: If the airplane is inactive for long periods of time, it should be lubricated in accordance with Lubrication Chart every 90 days. 62. APPLICATION OF OIL. Whenever specific instructions for lubrication of mechanisms requiring lubrication are not available, observe the following precautions: a. Apply oil sparingly, never more than enough to coat the bearing surfaces. b. Do not oil control cables. CAUTION: BE CAREFUL NOT TO ADD TOO MUCH OIL, BECAUSE THE EXCESS WILL BE THROWN OFF DURING OPERATION AND WILL CAUSE PITTING AND BURNING OF THE MAGNETO POINTS. c. Squeeze the magneto cam follower felts at regular inspection periods. If oil appears on fingers, do not add oil. If the felt is dry, moisten with light oil. 63. APPLICATION OF GREASE. Care must be taken when lubricating bearings and bearing surfaces with a grease gun, to insure that gun is filled with new, clean grease of the grade specified for the particular application before applying lubricant to the grease fittings. a. Where a reservoir is not provided around a bearing, apply the lubricant sparingly and wipe off any excess. b. Remove wheel bearings from the wheel hub and clean thoroughly with a suitable solvent. When repacking with grease, be sure the lubricant enters the space between the rollers in the retainer ring. Do not pack the grease into the wheel hub. c. Use extra care when greasing the constant speed propeller hub to avoid blowing the clamp gaskets. Remove one grease fitting and apply grease to the other fitting until fresh grease appears at the hole of the removed fitting. PIPER SENECA SERVICE MANUAL PAGE 34 Oct 30/03 1E2 II - HANDLING AND SERVICING 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. Application symbols within the frequency symbols show how the lubrication is applied. Also within the frequency symbol is a type of lubricant code letter and a special instructions code number which indicate the specific lubricant and application instructions for each individual component. CAUTION: DO NOT LUBRICATE CONTROL WHEEL SHAFT OR BUSHING. CLEAN ONLY USING ALCOHOL OR OTHER SUITABLE SOLVENT. Lubrication Chart Figure 12 (Sheet 1 of 5) 1. CONTROL COLUMN FLEX JOINT, SPROCKET AND O-RING 2. AILERON AND STABILATOR CONTROL CHAIN 3. O-RING CONTROL SHAFT BUSHING 4. TEE BAR PIVOT POINTS, AILERON AND STABILATOR CONTROL PULLEYS 5. STABILATOR CONTROL ROD AND IDLER PULLEY 6. NOSE GEAR STRUT HOUSING 7. NOSE GEAR PIVOT POINT AND HYDRAULIC CYLINDER ROD END 8. NOSE GEAR DOOR RETRACTION MECHANISM 9. NOSE GEAR DOOR HINGES 10. EXPOSED OLEO STRUT (NOSE) 11. NOSE WHEEL BEARINGS 12. NOSE GEAR TORQUE LINK ASSEMBLY 13. NOSE GEAR TORQUE LINK ASSEMBLY AND STRUT HOUSING 14. NOSE GEAR PIVOT POINT, DRAG LINK ASSEMBLY, DOWNLOCK AND CYLINDER ASSEMBLY, STEERING ROLLER AND CENTERING SPRING PIVOT POINTS 15. STEERING BELLCRANK PIVOT POINTS AND ROD ENDS 16. NOSE GEAR ROLLER TRACK AND BUNGEE 17. NOSE GEAR OLEO STRUT FILLER POINT 18. PROPELLER ASSEMBLY 19. FLAP CONTROL ROD END BEARINGS 20. FLAP RETURN AND TENSION CHAIN 21. FLAP TORQUE TUBE BEARING BLOCK 22. FLAP HANDLE PIVOT POINT LOCK MECHANISM AND CABLE PULLEY 23. RUDDER SECTOR AND STABILATOR TRIM PIVOT POINTS 24. STABILATOR TRIM SCREW 25. MAIN GEAR PIVOT POINTS 26. MAIN GEAR DOOR HINGE 27. MAIN GEAR TORQUE LINKS 28. MAIN GEAR TORQUE LINKS (SEE NOTE 5) 29. EXPOSED OLEO STRUT (MAIN) 30. MAIN GEAR WHEEL BEARINGS 31. MAIN GEAR DOOR CONTROL ROD ENDS 32 MAIN GEAR SIDE BRACE LINK ASSEMBLY 33. UPPER SIDE BRACE SWIVEL FITTING 34. MAIN GEAR DOWNLOCK ASSEMBLY RETRACTION FITTING AND CYLINDER ATTACHMENT POINTS 35. OLEO STRUT FILLER POINT (MAIN GEAR) 36. RUDDER TUBE CONNECTIONS, TUBE CABLE ENDS AND STEERING ROD ENDS 37. BRAKE ROD ENDS 38. TOE BRAKE AT

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