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PART NUMBER 761-523 MAY 15, 2012

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AIRPLANE MAINTENANCE MANUAL
PA-42
PA-42-720
(S/NS 42-8301001, 42-8301002 AND 42-5501003 THRU 42-5501023, 42-5501025 THRU
42-5501027, 42-5501029 THRU 42-5501031, 42-5501033, AND 42-5501039)
PIPER AIRCRAFT CORPORATION
1A2
Published by
Technical Publications
1979, 1986, 1989, 1998, 2012 Piper Aircraft, Inc.
2926 Piper Drive
Vero Beach, Florida 32960
U.S.A.
Member
General Aviation
Manufacturers Association
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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May 15, 2012
REVISION STATUS
Page 1
REVISION STATUS
Revisions to this Maintenance Manual (P/N 761-523) originally issued December 1, 1979 are as follows:
Revision Publication Date Aeroche Card Effectivity
ORG791201 December 1,1979 1, 2, 3, 4 and 5
CR860401 February 28, 1987 1, 2, 3, 4, 5 and 6
CR891231 December 31, 1989 1, 2, 3, 4, 5 6 and 7
PR980109 January 9, 1998 1, 2, 3, 4, 5, 6 and 7
PR120515 May 15, 2012 N/A*
* Piper has ceased production of all Aeroche (i.e., microche) products.
This maintenance manual and other Piper publications are available as
described in the Owner Publications Catalog (part of the Customer Service
Information File, available as described below).
Consult the Customer Service Information File (a free download from the
Piper Aircraft, Inc. website at http://www.piper.com/home/pages/Publications.
cfm) to verify that you have the latest revision.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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May 15, 2012
REVISION STATUS
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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May 15, 2012
TABLE OF CONTENTS
INTRODUCTION
TABLE OF CONTENTS

Paragraph Grid No.
Page 1
1. Instructions for Continued Airworthiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A7
2. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A7
3. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A8
4. Serial Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A8
5. Assignment of Subject Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A9
6. Pagination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A9
7. Aeroche Grid Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A10
8. Identifying Revised Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A10
9. Warnings, Cautions and Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A11
10. Accident/Incident Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A11
11. Supplementary Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A11
Piper Publications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A11
Vendor Publications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A12
12. System/Chapter Index Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A17

List of Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A23
List of Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A33
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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PA-42 / PA-42-720
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INTRODUCTION
Page 1
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.
This Piper PA-42/PA-42-720 Cheyenne III/IIIA Maintenance Manual constitutes the Instructions for
Continued Airworthiness (ICA) in accordance with Federal Aviation Regulations (FAR) Part 23, Appendix
G. Chapter 4 contains the Airworthiness Limitations section (4-00-00) and the Inspection Program is in
Chapter 5 (5-20-00).
2. General
This publication is prepared in accordance with the General Aviation Manufacturers Association (GAMA)
Specification No. 2, with respect to the arrangement and content of the System/Chapters within the
designated Chapter/Section-numbering system.
WARNING: USE ONLY GENUINE PIPER AIRCRAFT PARTS OR PIPER AIRCRAFT APPROVED
PARTS OBTAINED FROM PIPER APPROVED SOURCES, IN CONNECTION WITH
THE MAINTENANCE AND REPAIR OF PIPER AIRPLANES.
This manual generally does not contain hardware callouts for installation. Hardware callouts are only
indicated where a special application is required. To confirm the correct hardware used, refer to the
PA-42/PA-42-720 Parts Catalog, P/N 761-717, and FAR 43 for proper use.
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.
Piper Aircraft, Inc. expressly disclaims any responsibility for malfunctions, failures, damage or injury
caused by use of non-PIPER approved parts.
NOTE: 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.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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INTRODUCTION
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Also, Piper Aircraft, Inc. may possess manufacturers data which defines minimum type design beyond
what may be assumed by an authorized repair entity. When a repair is proposed, it is the responsibility of
the repairer per AC 43.13-1 to determine that the proposed repair is not contrary to manufacturers data.
The repairer or aircraft owner or his agent should contact Piper directly to determine that a proposed
repair is not in conflict with minimum type design capability.
If you have any question concerning the care of your airplane, be sure to include the airplane serial
number in any correspondence to Piper.
3. Effectivity
This maintenance manual is effective for PA-42 Cheyenne III serial numbers 42-7800001, 42-7800002, and
43-7801003 thru 42-8001106; and PA-42-720 Cheyenne IIIA serial numbers 42-8301001, 42-8301002 and
42-5501003 thru 42-5501023, 42-5501025 thru 42-5501027, 42-5501029 thru 42-5501031, 42-5501033,
and 42-5501039. This encompasses the following model years:
NOTE: The following information is provided as a general reference only.
Model Serial Number Range Model Year
PA-42 42-7800001, 42-7800002, 1978
43-7801003 and 42-7801004
42-8001001 thru 42-8001004 1980
42-8001005 thru 42-8001060 1981
42-8001061 thru 42-8001081 1982
42-8001101 thru 42-8001106 1983
PA-42-720 42-8301001, 42-8301002 and 1983
42-5501003 thru 42-5501010
42-5501011 thru 42-5501023 1984
42-5501025 thru 42-5501031, 1985
less 42-5501024 and 42-5501028
42-5501033 and 42-5501039 1986
NOTE: Serial numbers 42-5501040 thru 42-5501060 are advanced trainer airplanes and are covered in a
separate maintenance manual, P/N 761-852.
NOTE: Serial numbers 42-5501024, 42-5501028, 42-5501032, 42-5501034 thru 42-5501038 are model
PA-42-720R airplanes and are covered in a separate, limited availability, maintenance manual.
4. Serial Number Explanation
This manual encompasses airplanes manufactured under three different serial numbering systems.
A. The earlier system is comprised of three sets of numbers, as shown in the following example:
42 78 00001
TYPE CERTIFICATE DESIGNATION
SEQUENCE NUMBER
MODEL YEAR
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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INTRODUCTION
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B. The later systems are comprised of four sets of numbers, with different meanings, as shown in the
following examples:
or:
5. Assignment of Subject Material
The various Chapters are broken down into major systems such as Electrical Power, Flight Controls, Fuel,
Landing Gear, etc.
A. The system/chapters are arranged more or less alphabetically rather than by precedence or importance.
All system/chapters are assigned a number, which becomes the first element of a standardized
numbering system. thus the element 32 of the number series 32-00-00 refers to the system/chapter
on landing gear. All information pertaining to the landing gear will be covered in this system/
chapter.
B. The major system/chapters are then broken down into sub-system/sections. These sections are
identified by the second element of the standardized numbering system. The number 40 of the basic
number series 32-40-00 is for the wheels and brakes portion of the landing gear.
C. The individual units within a sub-system/section may be identified by a third element of the standardized
numbering system, such as 32-40-01. This number could be assigned by the manufacturer to fit the
coverage requirements of the publication.
6. Pagination
The Chapter - Section (i.e. - 28-40-00) numbering system (explained above) forms the primary page
numbering system for this manual. Within each Section, pages are numbered consecutively beginning
with Page 1 (i.e. - 28-40-00, Page 1). Additionally, a modified legacy Aerofiche grid numbering system
(explained below) will be used to indicate location within the manual until the next complete revision.
42 80 01 001
TYPE CERTIFICATE DESIGNATION
MODEL CODE
01 = PA-42 / PA-42-720
SEQUENCE NUMBER
MODEL YEAR
(For PA-42 only, 1981, 1982, &
1983 model years repeat 80 in this
position.)
TYPE CERTIFICATE DESIGNATION
MODEL CODE
01 = PA-42 / PA-42-720
SEQUENCE NUMBER
PLANT CODE
5 = LAKELAND
(Repeated to fill two digit space.
Indicates where first of type was built.)
42 55 01 001
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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INTRODUCTION
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7. Aerofiche Grid Numbering
Piper ceased production of all Aerofiche (i.e., microfiche) products in 2008. The Aerofiche grid numbers
will be removed in the next complete revision. In the interim, as partial revisions occur, the Aerofiche grid
numbering system may be modified, as explained below, to simplify production.
Deviations from the legacy Aerofiche grid numbering system will occur when it becomes necessary to add
pages to the manual and will typically take two forms:
A. Inserting pages between two existing grids in the same row.
When inserting two pages between the existing grids 1A8 and 1A9, the two new pages will be
numbered 1A8A and 1A8B.
B. Inserting pages at the end of an Aerofiche grid row.
The legacy Aerofiche grid numbering system limited page numbers in a row to a maximum of 24 (i.e.,
row 1A would be numbered 1A11A24). That limit no longer applies. Accordingly, if two pages need
to be added between any existing grid row end and grid row start (i.e., 1A24 and 1B1), the new pages
will simply be numbered 1A25 and 1A26.
8. Identifying Revised Material
A. 1979 through 1998:
Revised text and illustrations are indicated by a black vertical line along the left-hand margin of the
frame, opposite revised, added or deleted material. Revision lines indicate only current revisions with
changes and additions to or deletions of existing text and illustrations. Changes in capitalization,
spelling, punctuation, indexing, the physical location of the material or complete page additions are
not identified by revision lines.
A reference and record of the material revised is included in each chapters Table of Contents/
Effectivity. The codes used in the effectivity columns of each chapter are defined as follows:
TABLE OF CONTENTS/EFFECTIVITY CODES
Original Issue or Complete Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None
First Revision . . . . . . . . . . . . . . . . . . . . . . . . . . Revision Identification (1R Month-Year = 1R 8-80)
Second and Subsequent Revisions . . . . . . . . . . . . . . . . . . .Revision Identification (#R Month-Year)
Added Subject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision Identification (A Month-Year)
Deleted Subject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision Identification (D Month-Year)
Change bars and effectivity codes were removed in a complete revision.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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INTRODUCTION
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B. 2012 and later:
A revision to a page is defined as a change to the text or illustrations that existed previously. Revisions,
additions and deletions are identified by a vertical line (aka change bar) along the left-hand margin of
the page opposite only the text or illustration that was changed. Reformatted, but otherwise unchanged,
text is not identified by a change bar.
Change bars in the section Tables of Contents do not indicate a change to that page, but rather that the
information in the actual paragraph has changed.
A change bar in the left-hand margin opposite the footer (i.e. - page number and date), indicates that
the text was unchanged but the material was relocated to a different page.
Example.
NOTE: Change bars are not used in the title pages, list of illustrations, or list of charts. Likewise,
when a publication is completely revised (i.e. - reissued), change bars will only appear in the
Tables of Contents.
9. 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.
10. Accident/Incident Reporting
To improve our Service and Reliability system and aid in Pipers 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.
11. Supplementary Publications
The following publications/sources provide servicing, overhaul and parts information for the PA-42/PA-42-
720 Cheyenne III/IIIA airplanes and their various components. Use them to supplement this manual.
A. Piper Publications: Piper P/N
(1) Parts Catalog 761-717
(2) Programmed Inspection Manual (50 Hour) 761-760
(3) Programmed Inspection Manual (100 Hour) 761-739
(4) Special Inspection Manual; PA-42 / PA-42-720; -720 (Advanced Trainer);
-720R; Wing and Associated Structure 767-048
(5) Special Inspection Manual; PA-42 / PA-42-720; -720 (Advanced Trainer);
-720R; PA-42-1000; PA-42-1000 (Advanced Trainer);
Cabin and Pressurized Structure 767-078
(6) Special Inspection Manual; PA-42 / PA-42-720; -720 (Advanced Trainer);
-720R; Empennage and Associated Structure 767-079
PIPER AIRCRAFT
PA-42 / PA-42-720
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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) AUTOFLIGHT:
Vendor: Rockwell Collins Services PH: - (888) 265-5467
400 Collins Road NE
MS 153-150
Cedar Rapids, Iowa 52498
http://www.rockwellcollins.com/
Collins AP106/APS-65
AP106 Instruction Book: 523-0764802-30111A
APS-65 Instruction Book: 523-0771868-00211A
EFIS 84/85
FIS-84 Instruction Book: 523-0768867-00111A
EFIS-85A
Instruction Book: 523-077337-00311A
EFIS-85B2/12
Instruction Book: 523-0773940-00111A
EFIS-85B4/14
Instruction Book: 523-
or
Vendor: Honeywell
One Technology Center
23500 W. 105th St., M/D #45
Olathe, Kansas 66061-1950
http://www.bendixking.com/
Bendix/King KNS 300
Maintenance Manual: P/N 006-5091-01
Bendix/King KNS 660
System Manual: P/N 006-5596-00
Bendix/King EFIS 10
System Manual: P/N 006-5992-03
Global Series 2 GNS 500A
Systems Manual: P/N 34-56-00
Global Series 3 GNS 500A
Systems Manual: P/N 34-56-15
or
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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Vendor: Universal Avionics Systems Corp. PH: (800) 595-5906
3260 E. Universal Way Fax: (520) 295-2384
Tucson, Arizona 85756
Flight Control: UNS1
Systems Manual: UNS-1A
(2) COCKPIT VOICE RECORDER:
Vendor: L3 Communications PH: (941) 371-0811
100 Cattlemen Road Fax: (941) 377-5591
Sarasota, Florida 34232
http://www.l-3ar.com/html/aviation_pubs.html
(3) CORROSION INHIBITING COMPOUND:
Vendor: Chemetall US, Inc. PH: (908) 508-2182
675 Central Avenue FAX: (908) 464-2377
New Providence, NJ 07974
http://www.aerospace.chemetall.com/
(4) ENGINE:
Vendor: Pratt & Whitney Canada, Inc. PH: US/CAN - (800) 268-8000
1000 Maire-Victorian Blvd. INTL - (450) 647-8000
Longueuil, Quebec
Canada J4G 1A1
http://www.pwc.ca/www/en_pwc/index2.asp
Maintenance Manual: PT6A-41 P/N 3021442
PT6A-61 P/N 3034342
Operators Manual: PT6A-41 P/N 3021441
PT6A-61 P/N 3033741
Parts Catalog: PT6A-41 P/N 3021444
PT6A-61 P/N 3034344
(5) FIRE EXTINGUISHER (PORTABLE):
Vendor: H3R Inc. PH: - (800) 249-4289
43 Magnolia Ave # 4
San Francisco, California 94123-2911
http://www.h3r.com/index.htm
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(6) FIRE EXTINGUISHER (FIXED):
Vendor: Pacific Scientific
Aviation Services Company - Miami PH: (305) 477-4711
Aftermarket Services Center Fax: (305) 477-9799
11700 NW 102nd Road, Ste.#6
Miami, FL 33178
http://www.pacificscientific.com/links_index.html
or, Pacific Scientific
HTL/Kin-Tech Division (HTL) PH: (626) 359-9317
1800 Highland Avenue Fax: (626) 357-2107
Duarte, CA 91010
http://www.pacificscientific.com/links_index.html
(7) GENERATOR CONTROL UNIT:
Vendor: Goodrich Corporation Ph: 330 487 2007
Engine Control and Electrical Fax: 330 487 1902
Power Systems
8380 Darrow Road
Twinsburg OH 44087-2329 USA
(8) KEVLAR:
Vendor: KEVLAR Special Products
E.I. DuPont De Nemours & Co. Inc.
Textile Fibers Department
Centre Road Building
Wilmington, Delaware 19898
Guide: A Guide to Cutting and Machining Kevlar Aramid
(9) OXYGEN SYSTEM:
Vendor: Avox Systems PH: (716) 683-5100
2225 Erie Street
Lancaster, New York 14086
http://www.avoxsystems.com/
(10) PROPELLER:
Vendor: Hartzell Propeller Inc. PH: (937) 778-4379
One Propeller Place FAX: (937) 778-4321
Piqua, OH 45356-2634
http://www.hartzellprop.com/index2.htm
Steel Hub Turbine
Propeller Maintenance
Manual: Manual No. 118
Aluminum Blade
Overhaul Manual: Manual No. 133
Propeller Owners
Manual and Logbook: Manual No. 139
PIPER AIRCRAFT
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(11) WHEELS AND BRAKES:
Vendor: Goodrich Corporation PH: (937) 440-2130
Aircraft Wheels and Brakes
101 Waco St
Troy, OH 45373
https://techpubs.goodrich.com/
Installation, Maintenance
and Overhaul Manual: 3-1392 Wheel
2-1435-2 Brake
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4 AIRWORTHINESS LIMITATIONS 1A37
00 General
5 TIME LIMITS/MAINTENANCE CHECKS 1B1
10 Time Limits
20 Scheduled Maintenance Checks
50 Unscheduled Maintenance Checks
6 DIMENSIONS AND AREAS 1E7
00 General
10 Dimensions and Areas
20 Station References
30 Access and Inspection Provisions
7 LIFTING AND SHORING 1E23
00 General
10 Jacking
20 Shoring
8 LEVELING AND WEIGHING 1F9
00 General
9 TOWING AND TAXIING 1F16
00 General
10 Towing
20 Taxiing
10 PARKING AND MOORING 1F22
00 General
10 Parking
20 Mooring
11 REQUIRED PLACARDS 1G3
00 General
20 Exterior Placards/Markings
30 Interior Placards/Markings
12. System/Chapter Index Guide
CHAPTER SECTION TITLE GRID NO.
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CHAPTER SECTION TITLE GRID NO.
12 SERVICING 1G18
00 General
10 Replenishing
20 Scheduled Servicing
30 Unscheduled Servicing
20 STANDARD PRACTICES - AIRFRAME 1I7
00 General
21 ENVIRONMENTAL SYSTEM 1I15
00 General
10 Compression
20 Distribution
30 Pressurization Control
40 Heating
50 Cooling
60 Temperature Control
70 Moisture/Air Contaminant Control
22 AUTO FLIGHT 1K17
00 General
10 Autopilot
23 COMMUNICATIONS 1K24
00 General
30 Passenger Address and Entertainment
50 Audio Integrating
60 Static Discharging
70 Audio & Video Monitoring
24 ELECTRICAL POWER 2B9
00 General
30 DC Generation
40 External Power
50 Electrical Load Distribution
25 EQUIPMENT/FURNISHINGS 2E5
00 General
20 Flight and Passenger Compartment
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CHAPTER SECTION TITLE GRID NO.
26 FIRE PROTECTION 2E19
00 General
10 Detection
20 Extinguishing
27 FLIGHT CONTROLS 2F7
00 General
10 Aileron and Tab
20 Rudder and Tab
30 Elevator and Tab
50 Flaps
90 Stall Warning
28 FUEL 2J5
00 General
10 Storage
20 Distribution
40 Indicating
29 HYDRAULIC POWER 3B9
00 General
10 Main Hydraulic System
30 ICE AND RAIN PROTECTION 3D22
00 General
10 Airfoil Deicing System
20 Air Intakes
40 Windows and Windshields
60 Propellers
32 LANDING GEAR 3H8
00 General
10 Main Gear and Doors
20 Nose Gear and Doors
30 Extension and Retraction
40 Wheels and Brakes
50 Steering
60 Position and Warning
33 LIGHTS 3K22
00 General
10 Flight Compartment
20 Exterior Lighting
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CHAPTER SECTION TITLE GRID NO.
34 NAVIGATION AND PITOT/STATIC 4B9
00 General
20 Pitot Static
35 OXYGEN 4C1
00 General
10 Crew and Passgnger
36 PNEUMATIC 4C19
00 Pneumatic System
10 Distribution
37 VACUUM 4D14
00 General
10 Distribution
20 Indicating
39 ELECTRICAL/ELECTRONIC PANELS &
MULTIPURPOSE PARTS 4D23
00 General
10 Instrument and Control Panels
20 Electrical & Electronic Racks
51 STRUCTURES 4F4
00 General
10 Structural Repairs
20 Sealing Procedures
52 DOORS 4I23
00 General
10 Cabin Entrance Door
20 Cargo Door
30 Service
53 FUSELAGE 4J24
00 General
10 Main Frame
20 Auxiliary Structure
40 Attached Fittings
50 Aerodynamic Fairings
54 NACELLES 4K11
00 General
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A21
May 15, 2012
INTRODUCTION
Page 15
CHAPTER SECTION TITLE GRID NO.
55 STABILIZERS 4K17
00 General
10 Horizontal Stabilizers
20 Elevator
30 Vertical Stabilizer
40 Rudder
56 WINDOWS 5B9
00 General
10 Flight Compartment
20 Cabin
57 WINGS 5B22
00 General
20 Wing Tip Tanks
40 Wing
50 Aileron
55 Aileron
60 Flap Aileron Trim Tabs
61 PROPELLERS 5C16
00 General
10 Propeller Assembly
20 Controlling
70 STANDARD PRACTICES - ENGINES 5D15
00 Standard Practices - Engines
71 POWER PLANT 5D21
00 General
10 Cowling
20 Mounts
30 Fireseals
72 ENGINE TURBO PROP 5E14
00 General
73 ENGINE FUEL SYSTEM 5E20
00 General
10 Distribution
20 Controlling
30 Indicating
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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May 15, 2012
INTRODUCTION
Page 16
CHAPTER SECTION TITLE GRID NO.
74 IGNITION 5F15
00 General
10 Electrical Power Supply
20 Distribution
75 AIR 5G4
00 General
76 ENGINE CONTROLS 5G10
00 General
10 Description and Function
77 ENGINE INDICATING 5J10
00 General
10 Power
20 Temperature
30 Analyzers
79 OIL 5K1
00 General
20 Distribution
30 Indicating
91 CHARTS AND WIRING DIAGRAMS 6B7
See 6C15 for Wiring Diagram Index
95 SPECIAL PURPOSE EQUIPMENT 7H1
00 General
10 Tools and Test Equipment
PIPER AIRCRAFT
PA-42 / PA-42-720
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May 15, 2012
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS
FIGURE
NO. SUBJECT GRID NO.
Page 1
6-1. Three View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E10
6-2. Station References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E13
6-3. Access Plates and Panels - Engine Nacelle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E16
6-5. Access Plates and Panels - Fuselage and Stabilizer. . . . . . . . . . . . . . . . . . . . . . 1E19
7-1. Use of Tail Jacking Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2
7-2. Jacking Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F2
7-3. Shoring Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F3
7-4. Fuselage and Wing Shoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F4
7-5. Sling Location F.S.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F5
8-1. Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F11
8-2. Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F12
9-1. Turning Radius and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F18
11-1. Placards and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G6
12-1. Service Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H1
12-2. Servicing Landing Gear Shock Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H8
12-3. Electrosonic Cleaning Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H13
12-4. Lubrication Chart - Landing Gear, Main. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H20
12-5. Lubrication Chart - Landing Gear, Nose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H21
12-6. Lubrication Chart - Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H22
12-7. Lubrication Chart - Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H24
12-8. Lubrication Chart - Powerplant, Propeller and Propeller Reversing Linkage . . 1I1
12-9. Lubrication Chart - Air Inlet Ice Protection Oil Cooler Doors . . . . . . . . . . . . . 1I2
12-10. Lubrication Chart - Cabin Door, Baggage Door and Seats . . . . . . . . . . . . . . . . 1I3
20-1. Installation of Conical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I11
21-1. ECS Cabin Selector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J1
21-2. Cabin Air Distribution Schematic - Conditioned Air. . . . . . . . . . . . . . . . . . . . . 1J2
21-3. Cabin Air Distribution Schematic - Heated Air . . . . . . . . . . . . . . . . . . . . . . . . . 1J3
21-4. Cabin Pressure Control System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J5
21-5. Safety and Outow Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J7
21-6. Cabin Air Pressure Outow Valve Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 1J8
21-7. Fabricated Reducer Pressure Test Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J10
21-8. Cabin Pressure Test Unit (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J10
21-9 Pressurization Test Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J11
21-10. Absolute Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J20
21-11. Environmental Control System - PA-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1K4
21-12. Environmental Control System - PA-42-720. . . . . . . . . . . . . . . . . . . . . . . . . . . 1K5
21-13. Cabin Pressurization and Bleed Air System Schematic - PA-42. . . . . . . . . . . . 1K6
21-14. Cabin Pressurization and Bleed Air System Schematic - PA-42-720 . . . . . . . . 1K7
23-1. ELT Portable Folding Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L3
23-2. ELT Using Fixed Aircraft Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L3
23-3 Emergency Locator Transmitter Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A24
May 15, 2012
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
Page 2
24-1. Overhead Switch Panel - PA-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B19
24-2. Overhead Switch Panel - PA-42-720 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B20
24-3. Main Circuit Breaker Panel - Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B21
24-4. Starter Generator Basic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C1
24-5. Power Distribution (PA-42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C5
24-6. Power Distribution (PA-42-720) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C6
24-7. Left Circuit Breaker Panels Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . 2C7
24-8. Right Circuit Breaker Panel Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . 2C8
24-9. Typical Cross-section of Starter Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C11
24-10. Illustration of Brush Wear Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C13
24-11. Instant Filming Brushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C13
24-12. Correct Position of Brushes, Leads, and Springs . . . . . . . . . . . . . . . . . . . . . . . 2C14
24-13. Starter-Generator (250 Amp Model 23048-20) . . . . . . . . . . . . . . . . . . . . . . . . . 2C19
24-14. Correct Position of Brushes and Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C21
24-15. Electrical Connections of Starter-Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C21
24-16. Paralleling Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C24
24-17. Fabricated Cell Puller Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D7
24-18. Cell Layout - Nickel-Cadmium Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D7
24-19. Charge/Discharge Schematics (Typical-Service). . . . . . . . . . . . . . . . . . . . . . . . 2D10
24-20. Closed Loop Test Diagram (Lear Siegler, Inc.) . . . . . . . . . . . . . . . . . . . . . . . . . 2D15
24-21. Voltage Regulator Test Panel Schematic (Lear Siegler, Inc.) . . . . . . . . . . . . . . 2D16
24-22. Voltage Regulator Adapter Connector (Lear Siegler, Inc.) . . . . . . . . . . . . . . . . 2D16
25-1. Crew Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E8
25-2. Passenger Seats Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E9
25-3. Optional Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E10
25-4. Seat Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E11
25-5. Forward Curtain and Sliding Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2E12
25-6. Folding Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E13
25-7. Forward Cabinetry and Divider Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E14
25-8. Aft Refreshment Cabinet, Vanity Cabinet with
Folding Door and Divider Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E15
26-1. Engine Fire Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E22
26-2. Engine Fire Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E22
26-3. Battery Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E24
26-4. Engine Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F1
27-1. Trim Screw Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G5
27-2. Methods of Blocking Trim Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G5
27-3. Aileron and Aileron Trim Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G8
27-4. Control Column Sprocket Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G12
27-5. Control Column Travels and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G15
27-6. Aileron Control Travels and Cable Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G15
27-7. Location of Bellcrank Rigging Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G16
27-8. Installation of Aileron Rigging Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G16
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PA-42 / PA-42-720
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Page 3
27-9. Aileron Friction Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G21
27-10. Rudder Control System Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G22
27-11. Rudder and Trim Tab Control Trails and Cable Tensions . . . . . . . . . . . . . . . . . 2H2
27-12. Installation of Rudder Rigging Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H2
27-13. Installation of Rudder Trim Rigging Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H2
27-14. Rudder Friction Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H4
27-15. Rudder Pedals Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H8
27-16. Elevator System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H12
27-17. Elevator and Elevator Trim - Travels and Cable Tensions. . . . . . . . . . . . . . . . . 2H16
27-18. Elevator Rigging Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H18
27-19. Elevator Rigging Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H18
27-20. Elevator System Friction Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H19
27-21. Trim Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2H24
27-22. Flap System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I2
27-23. Flap System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I3
27-24. Wing Flap Transmission Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I5
27-25. Wing Flap Transmission Actuator ScrewJack (Exploded View) . . . . . . . . . . . . 2I7
27-26. Checking for Worm Gear Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I8
27-27. Flap Transmission Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I11
27-28. Flap Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I15
27-29. Flap Rigging Work Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I19
27-30. RESERVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I21
27-31. Aileron Balancing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2I23
28-1. Standard Fuel System Installation (PA-42 Only). . . . . . . . . . . . . . . . . . . . . . . . 2J9
28-2. PA-42-720 Fuel System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J10
28-3. Fuel Feed and Crossfeed Installation (PA-42) . . . . . . . . . . . . . . . . . . . . . . . . . . 2J11
28-4. Fuel Feed and Crossfeed Installation (PA-42-720 S/Ns 42-8301001 and up) . 2J12
28-5. Tip Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J16
28-6. Inboard-Main 95 Gallon Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J18
28-7. Outboard 40 Gallon Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J20
28-8. Aft Inboard 33Gallon Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J21
28-9. Wing Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J22
28-10. Fuel Valve - Drain Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K1
28-11. Detail in Fuel Cell Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K2
28-12. Fuel Vent System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K15
28-13. Dukes Fuel Valve (Crossfeed and Shutoff) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K18
28-14. Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K19
28-15. Jet Scavenger Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K21
28-16. Jet Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K22
28-17. Submerged Fuel Boost Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K23
28-18. Fuel Flow Test Apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K24
28-19. Fuel Capacitance Probe Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L3
28-20. Fabrication of Test Fixture For Tank Unit Testing. . . . . . . . . . . . . . . . . . . . . . . 2L8
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A26
May 15, 2012
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
Page 4
28-21. Fuel Gauge Adjustment, Gull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L9
28-22. Fuel Gauge Adjustment, Ragen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L9
29-1. Hydraulic System - Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B22
29-2. Schematic of Power Pack Electronics System. . . . . . . . . . . . . . . . . . . . . . . . . . 3B24
29-3. Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C2
29-4. Power Pack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C7
29-5. Location of Power Pack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C9
29-6. Hydraulic Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C10
29-7. Power Pack Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C14
29-8. Power Pack Handle-Release Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C17
29-9. Safetying Control Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C19
29-10. Indexing of Selector Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C19
29-11. Handle release Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C21
29-12. Landing Gear Selector Mechanism Installation . . . . . . . . . . . . . . . . . . . . . . . . 3C22
29-13. Power Pack Test Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D5
29-14. Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D7
29-15. Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D9
29-16. Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D15
29-17. Gear Door Actuating Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D18
29-18. Gear Actuating Cylinder (Nose Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D18
30-1. Pneumatic Deicing System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E6
30-2. Boot Test Apparatus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E8
30-3. Pneumatic Deicer Boots Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E11
30-4. Marking and Cutting Scuff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
30-5. Routing Scuff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
30-6. Bufng Edge of Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
30-7. Hole through Surface of Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E21
30-8. Rotating to Tube Fabric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E23
30-9. Cutting Surface of tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E23
30-10. Cementing Buffed Area and Patch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E23
30-11. Applying and Stitching Fabric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E23
30-12. Pneumatic Boot and Flow Strip Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F2
30-13. Pneumatic Boot Flow Strip Locations (continued) . . . . . . . . . . . . . . . . . . . . . . 3F3
30-14. Pneumatic Boot Flow Strip Locations (continued) . . . . . . . . . . . . . . . . . . . . . . 3F3
30-15. Placing and Stitching Gum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F5
30-16. Removing Trapped Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F5
30-17. Masking Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F5
30-18. Applying Neoprene Putty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F5
30-19. Wiring Diagram, Left Propeller and Engine Air Inlet Lip Deicing System . . . 3F17
30-20. Engine Air Inlet Ice Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F19
30-20a. Generator Inlet Scoop (PA-42 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F21
30-21. Windshield Wiper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G1
30-22. Propeller and Engine Air Inlet Lip Deicer System . . . . . . . . . . . . . . . . . . . . . . 3G4
PIPER AIRCRAFT
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LIST OF ILLUSTRATIONS
Page 5
30-23. Electrical Diagram Showing Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 3G6
30-24. Electrical Diagram Showing Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 3G6
30-25. Electrical Diagram Showing Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 3G7
30-26. Electrical Diagram Showing Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 3G7
30-27. Suggested Use of Dial Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G9
30-28. Centering of Brushes on Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G9
30-29. Brush Block Assembly and Brush Wear Check. . . . . . . . . . . . . . . . . . . . . . . . . 3G11
30-30. Angle of Contact - Brushes to Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G12
30-31. Brush Module Assembly (3E2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G15
30-32. Alternate Module Stacking Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G15
30-33. Modular Brush Assembly (3E2044-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G15
30-34. Repair of Lead Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G16
30-35. Propeller Deicer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G19
30-36. Sealer Application (Prop Boot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G22
30-37. Sealer Application (Lead Strap). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G22
30-38. Wrinkled Deicer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G23
30-39. Propeller Lead Strap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3H1
30-40. Power Control Relays and Deicer Timer Installation . . . . . . . . . . . . . . . . . . . . 3H3
32-1. Simplied Typical Wiring Diagram - Landing Gear . . . . . . . . . . . . . . . . . . . . . 3H19
32-2. Main Gear Oleo Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3H22
32-3. Main Gear Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3I6
32-4. Nose Gear Oleo Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3I10
32-5. Nose Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3I13
32-6. Aligning Nose Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3I20
32-7. Rudder Pedals Neutral Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3I23
32-8. Emergency Extension System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3I24
32-9. Emergency Extension System Operational Schematic . . . . . . . . . . . . . . . . . . . 3J3
32-10. Main Gear Actuating Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3J6
32-11. Gear Door Actuating Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3J8
32-12. Nose Gear Actuating Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3J11
32-13. B.F. Goodrich 3-1392 Main Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . 3J13
32-14. B.F. Goodrich 3-1392 Wheel Repair Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 3J16
32-15. Nose Wheel Assembly (B.F. Goodrich 3-1076) . . . . . . . . . . . . . . . . . . . . . . . . 3J19
32-16. Nose Wheel Assembly (Cleveland 40-140) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3J21
32-17. B.F. Goodrich Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3J23
32-18. Master Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K4
32-19. Master Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K6
32-20. Parking Brake Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K7
32-21. Bleeding Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K9
32-22. Nose Gear Steering Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K11
32-23. Main Gear Down Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K15
32-24. Gear Warning Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K17
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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May 15, 2012
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
Page 6
33-1. Fluorescent Lighting Inverter/Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3L2
33-2. Annunciator Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3L4
33-3. Annunciator Controller Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3L5
33-4. Annunciator Controller Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3L6
33-5. Annunciator Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3L16
33-6. Landing and Taxi Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3L18
34-1. Pitot/Static Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B13
34-2. Pitot/Static Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B19
35-1. Oxygen System Installation - FAR 91 (PA-42) . . . . . . . . . . . . . . . . . . . . . . . . . 4C5
35-2. Oxygen System Installation - FAR 91 (PA-42-720) . . . . . . . . . . . . . . . . . . . . . 4C6
35-3. Oxygen System Installation - FAR 135 (PA-42) . . . . . . . . . . . . . . . . . . . . . . . . 4C7
35-4. Oxygen System Installation - 60 Cu. Ft. Capacity - (PA-42-720) . . . . . . . . . . . 4C8
35-5. Visual Indicting Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C9
35-6. Oxygen Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C13
35-7. Surge Valve (Cross Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C15
36-1. Pneumatic System Schematic (PA-42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C24
36-2. Proof Pressure and Leakage Test Setup (PA-42) . . . . . . . . . . . . . . . . . . . . . . . . 4D8
37-1. Vacuum System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D17
37-2. Vacuum System Test Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D18
37-3. Vacuum Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D19
39-1. Instrument Panel (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E3
39-2. Main Circuit Breaker Panel (PA-42 Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E4
39-3. Typical Circuit Breaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E6
39-4. Circuit Breaker Installation (Left-Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E9
39-5. Overhead Engine Control Switch Panel (PA-42). . . . . . . . . . . . . . . . . . . . . . . . 4E10
39-6. Overhead Switch and Meter Panel (PA-42-720 Model) . . . . . . . . . . . . . . . . . . 4E11
39-7. Overhead Meter and Switch Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4E13
39-8. Dimmer Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E15
39-9. Electric Outside Air Temperature Gauge (Optional) . . . . . . . . . . . . . . . . . . . . . 4E16
39-10. Optional Control Wheel Clock Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E18
39-11. Electrical Accessory and Relay Shelf Installations (PA-42) . . . . . . . . . . . . . . . 4E19
39-12. Electrical Panels and Components Locations (PA-42-720). . . . . . . . . . . . . . . . 4E21
39-13. Avionics Bay Lay Out (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E23
51-1. Material Skin Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F8
51-2. Typical Access Holes and Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F11
51-3. Band Saw Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F12
51-4. Alternating Tooth Sabre Saw Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F13
51-5. Recommended Drill Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F13
51-6. Suggested Routers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F14
51-7. Suggested Countersink Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F14
51-8. Surface Scratches, Abrasions or Ground-in-Dirt . . . . . . . . . . . . . . . . . . . . . . . . 4F21
51-9. Deep Scratches, Shallow Nicks and Small Holes Repair . . . . . . . . . . . . . . . . . 4F21
51-10. Mixing of Epoxy Patching Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F22
PIPER AIRCRAFT
PA-42 / PA-42-720
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LIST OF ILLUSTRATIONS
Page 7
51-11. Various Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F22
51-12. Welding Repair Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F23
51-13. Repairing of Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F23
51-14. Repair of Stress Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F24
51-15. Repair of Impacted Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F24
51-16. Passenger Window Skin Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G15
51-17. Wing Inspection and Repair Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G16
51-18. Empennage Inspection and Rivet Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 4G17
51-19. Lightening Hole Flange Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G20
51-20. Cowl Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G21
51-21. Crack Type Identication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G24
51-22. Typical Inspection Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4H4
51-23. Structural Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4H11
51-24. Fuselage Sealing (Forward) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I6
51-25. Fuselage Sealing (Aft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I7
51-26. Faying Surface Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I11
51-27. Joggle Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I11
51-28. Stringers, Holes and Voids Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I13
51-29. Fillet Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I13
51-30. Bolts and Rivets Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I14
51-31. Wire Harness Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I16
51-32. Avionics and ECU Bay Door Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I19
52-1. Cabin Entrance Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J3
52-2. Cabin Entrance Door Latch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J5
52-3. Door Snubber Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J8
52-4. Door Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J10
52-5. Door Ajar Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J12
52-6. Cargo Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J14
52-7. Nacelle Locker Door Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J16
52-8. Forward Baggage Door Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J18
52-9. Nose cone Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4J20
53-1. Floorboard Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K3
53-2. Skin Material - Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K4
53-3. Access Plates and Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K5
54-1. Nacelle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K13
55-1. Empennage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4K20
55-2. Elevator Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L3
55-3. Elevator and Rudder Friction Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L5
55-4. Rudder Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L7
56-1. Determining Depth of Craze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B13
56-2. Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B17
56-3. Storm Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B19
56-4. Installation of Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B20
56-5. Emergency Exit Windows - PA-42/PA-42-720 . . . . . . . . . . . . . . . . . . . . . . . . . 5B21
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A30
May 15, 2012
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
Page 8
57-1. Tip Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C1
57-2. Wing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C4
57-3. RESERVED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C8
57-4. Aileron Friction Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C9
57-5. Aileron and Tab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C10
57-6. Wing Flap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C12
61-1. Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C18
61-2. Feedback Ring Pulley Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C19
61-3. Typical Nicks and Removal Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C20
61-4 Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C24
61-5. Propeller Synchrophaser System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D5
71-1. Power Plant Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E3
71-2. Cowling Installation (PA-42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E8
71-3. Cowling Installation (PA-42-720) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E9
73-1. Fuel Control Unit Installation (PT6A-41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E23
73-2. Fuel Manifold Test Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E24
73-3. Main Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F2
73-4. Fuel Control Unit Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F3
73-5. Jet Scavenge Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F4
73-6. Fuel Control Adjustments (PT6A-41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F8
74-1. Auto Ignition Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F23
76-1. Power Lever Control Cable Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G15
76-2. Propeller Control Cam - PT6A-41, Rigging Shim in Place. . . . . . . . . . . . . . . . 5G17
76-3. Propeller Control Cam - PT6A-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G17
76-4. Power Lever Control Cable Engine Connection . . . . . . . . . . . . . . . . . . . . . . . . 5G19
76-5. Power Lever Control Cable/Power Lever Connection. . . . . . . . . . . . . . . . . . . . 5G19
76-6. Overall View - PT6A-41 Engine Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G23
76-7. Power Control Cam assembly in Track Position . . . . . . . . . . . . . . . . . . . . . . . . 5G24
76-8. Beta Rigging Template Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G24
76-9. Fuel Control Unit Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H1
76-10a. Throttle Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H2
76-10b. Throttle Arm Alignment Tool Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H2
76-11. Reverse Dead Band Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H3
76-12. Power (Throttle) Cable Pedestal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 5H3
76-13. Wire Rope Read End Clevis Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H4
76-14. Engine Propeller Governor - Right Side View. . . . . . . . . . . . . . . . . . . . . . . . . . 5H5
76-15. Beta Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H6
76-16. PT6A-41 Fuel Control Unit - Front and Right Side View. . . . . . . . . . . . . . . . . 5H8
76-17. Fuel Control Unit Condition Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H9
76-18. Control Lever Bracket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H9
76-19. Propeller Governor Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H10
76-20a. Ground Test Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H16
76-20b. Governor Adjusting Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H16
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A31
May 15, 2012
LIST OF ILLUSTRATIONS
Page 9
76-21. Propeller Dome Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H18
76-22. Propeller Governor Pneumatic Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H20
76-23. Power Lever Cross Start and Autofeather Switches . . . . . . . . . . . . . . . . . . . . . 5H21
76-24. Overall View - PT6A-61 Engine Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I2
76-25. Power (Throttle) Cable Pedestal Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 5I3
76-26. Propeller Cam Assembly - Front to Rear View . . . . . . . . . . . . . . . . . . . . . . . . . 5I3
76-27 PT6A-61 Interconnect Rod Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I4
76-28. Fuel Control Arm Serrated Spacer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 5I5
76-29. Woodward Type II Fuel Control Unit - Left Side View. . . . . . . . . . . . . . . . . . . 5I6
76-30. Woodward Type III Fuel Control Unit - Left Side View . . . . . . . . . . . . . . . . . . 5I7
76-31. Power Lever (Throttle) Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I8
76-32. PT6A-61 Engine Propeller Governor - Right Side View. . . . . . . . . . . . . . . . . . 5I9
76-33. Woodward FCU - Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I11
76-34. Cockpit Condition (Start Control) Lever - PA-42-720 . . . . . . . . . . . . . . . . . . . 5I11
76-35. Propeller Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I12
76-36. Woodward Type III Fuel Control Unit (FCU) . . . . . . . . . . . . . . . . . . . . . . . . . . 5I20
76-37. Propeller Dome Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I21
76-38. Propeller Governor - Right Side View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I22
76-39. PA-42-720 Feather Detent Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I23
76-40. Autofeather Microswitch Adjustment (PA-42-720). . . . . . . . . . . . . . . . . . . . . . 5I24
76-41. Internal Feather Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J6
77-1. Torque System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J13
77-2. Thermocouple Harness Loop Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . 5J15
77-3. T5 Harness Installation Resistance Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J15
77-4. Inter-Turbine Temperature Calibration Check. . . . . . . . . . . . . . . . . . . . . . . . . . 5J17
77-5. Bareld TT-1000 Test Set Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J19
79-1. Engine Oil System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5K8
79-2. Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5K9
79-3. Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5K11
79-4. Oil Cooler Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5K12
79-5. Diverter Valve and Fuel Heater Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5K14
NOTE: Refer to Grid 6C15 for Electrical Schematic Index.
95-1. Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H4
95-2. Fabricated Tool, Main Gear Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 7H9
95-3. Fabricated Tool, Main Gear Side Brace Link Travel . . . . . . . . . . . . . . . . . . . . . 7H10
95-4. Fabricated Tool, Nose Gear Gauge Link Travel . . . . . . . . . . . . . . . . . . . . . . . . 7H11
95-5. Fabricated Jack Stand for Piper Jack, Part No. 18338-0 . . . . . . . . . . . . . . . . . . 7H12
95-6. Fabricated Tool, Fuselage Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H13
95-7. Protective Closures Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H14
95-8. Digital Multi-Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H15
95-9. Tire Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H15
95-10 Special Socket for Calco Flap Rheostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H16
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A32
May 15, 2012
LIST OF ILLUSTRATIONS
LIST OF ILLUSTRATIONS (continued)
FIGURE
NO. SUBJECT GRID NO.
Page 10
95-11. Control Surface Balancing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H17
95-12. Fabricated Reducer Test Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H18
95-13. Cabin Pressure Test Unit (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7H18
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A33
May 15, 2012
LIST OF CHARTS
LIST OF CHARTS
CHART
NO. SUBJECT GRID NO.
401 Structural Life Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A40
402 Component Life Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A41
601 Leading Particulars and Principal Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 1E11
1201 Thread Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H14
1202 Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H19
1203 Oxygen Cylinder Filling Pressure Vs. Ambient Temperature . . . . . . . . . . . . . . 1H16
1204 Indicated Oxygen Cylinder Pressure Vs. Ambient Temperature . . . . . . . . . . . . 1H17
2001 Ball Diameters For Testing Hose Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . 1I12
2101 Troubleshooting (Pressurization System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I19
2102 Cabin Altitude Vs. Airplane Altitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1J17
2103 Troubleshooting (Environmental Control System) . . . . . . . . . . . . . . . . . . . . . . 1J24
2401 Troubleshooting (Electrical System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B14
2402 Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B18
2403 Starter-Generator Test Specications (PA-42). . . . . . . . . . . . . . . . . . . . . . . . . . 2B23
2404 Starter-Generator Test Specications (PA-42-720) . . . . . . . . . . . . . . . . . . . . . . 2B24
2405 Inspection of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C17
2406 Troubleshooting (Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D2
2407 Nickel Cadmium Battery Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D9
2408 Main Tie Bus Circuit Breaker and Crossfeed Diode Check . . . . . . . . . . . . . . . 2D22
2409 Generator Power Distribution Diode Operation Check. . . . . . . . . . . . . . . . . . . 2D23
2601 Pressure-Temperature Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E23
2701 Troubleshooting (Surface Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F12
2702 Cable Rigging Tension Vs. Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2G3
2801 Troubleshooting (Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2J13
2802 Fuel Cell repair Equipment Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2K6
2803 Test Equipment - Fuel Quantity Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L4
2804 Tank Unit Capacitance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L6
2805 Fuel Quantity Calibration Work Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2L10
2901 Troubleshooting (Hydraulic System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B15
2902 Leading Particulars - Hydraulic Power Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . 3B19
2903 Inspection and Repair - Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D12
3001 Troubleshooting (Pneumatic Airfoil Deicer System) . . . . . . . . . . . . . . . . . . . . 3E3
3002 Operating Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E10
3003 Material and Supplies for Cold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E14
3004 Material for Vulcanized Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E15
3005 Equipment for Vulcanized Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E16
3006 Troubleshooting (Engine Deicing System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F9
3007 Inlet Deicers Electrical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F18
3008 Required Materials for Repair of Deicers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G20
3009 Propeller Deicer Electrical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G23
3201 Troubleshooting (Landing Gear System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3H14
3202 Troubleshooting (Brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K1
3203 Brake Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3K2
Page 1
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A34
May 15, 2012
LIST OF CHARTS
LIST OF CHARTS (continued)
CHART
NO. SUBJECT GRID NO.
Page 2
3301 Annunciator Identication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3L8
3302 Annunciator Panel Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3L10
3303 Ground Operational Check of Annunciator Panel . . . . . . . . . . . . . . . . . . . . . . . 3L15
3401 Troubleshooting (Pitot/Static System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B11
3501 Troubleshooting (Oxygen System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C4
3502 Oxygen System Components Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C11
3701 Troubleshooting (Vacuum System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D16
5101 List of Materials (Thermoplastic Repair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F20
5102 Edge Distance and Spacing Vs. Rivet Diameter . . . . . . . . . . . . . . . . . . . . . . . . 4G5
5103 Acceptable Rivet Substitutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G5
5104 Specication for Replacement Oversize Rivets. . . . . . . . . . . . . . . . . . . . . . . . . 4G6
5105 1/64 Oversize Rivet Hole Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G6
5106 Structural Rivet Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G8
5107 Nut-Plate Rivet Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G12
5108 Stop Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G12
5109 Number and Size of AD Rivets required on Each Side of Crack . . . . . . . . . . . 4G19
5110 Inspection Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4H1
6101 Propeller Specication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C22
6102 Troubleshooting (Synchrophaser Installation). . . . . . . . . . . . . . . . . . . . . . . . . . 5D6
6103 Synchrophaser Wiring Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D8
6104 Magnetic Pickup Voltage Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D9
7101 Troubleshooting (Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D24
7301 Troubleshooting (Fuel Scavenge System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F5
7302 Fuel System Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F11
7401 Spark Igniter Erosion Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F20
7601 Engine Operating Limits (PT6A-41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H12
7602 Engine Alignment (PT6A-61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H14
7603 1900 RPM Torque Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H17
7604 PT6A-41 Power Assurance Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H24
7605 Engine Operating Limits (PT6A-61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I14
7606 Engine Alignment (PT6A-61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5I17
7607 PT6A-61 Power Assurance Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J3
7701 Torque System Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J13
7702 Basic Millivolts and Temperature Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5J17
7703 Thermoelectric Voltage in Absolute Millivolts . . . . . . . . . . . . . . . . . . . . . . . . . 5J18
7901 Oil Pressure Gauge Calibration Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5K13
7902 Oil Temperature Bulb Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5K14
9101 List of Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B11
9102 Engine Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B24
9103 Flare Fitting torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C1
9104 Recommended Nut Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C2
9105 Thread Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C4
9106 Decimal conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C5
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A35
May 15, 2012
LIST OF CHARTS
Page 3
9107 Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C6
9108 Torque Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C7
9109 Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C9
9110 Decimal/Millimeter Equivalent of Drill Size. . . . . . . . . . . . . . . . . . . . . . . . . . . 6C12
9110A Hose Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C12A
9111 Electrical Wire Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C13
9112 Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C13
LIST OF CHARTS (continued)
CHART
NO. SUBJECT GRID NO.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A36
May 15, 2012
LIST OF CHARTS
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER
4
AIRWORTHINESS
LIMITATIONS
1A37
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A38
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A39
May 15, 2012
4 - CONTENTS
CHAPTER 4 - AIRWORTHINESS LIMITATIONS
TABLE OF CONTENTS
CHAPTER
SECTION SUBJECT GRID NO.
4-00-00 AIRWORTHINESS LIMITATIONS 1A39
Approved Mandatory Replacement Times for Type Certification 1A39
Approved Mandatory Structural Inspection Intervals 1A39
7,800 Hours 1A39
10,000 Hours 1A39
11,600 Hours 1A39
12,300 Hours 1A39
13,300 Hours 1A39
13,900 Hours 1A39
Inspection Procedures for those Approved Mandatory Structural Inspection Items 1A39
Page 1
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
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4 - CONTENTS
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A41
May 15, 2012
4-00-00
Page 1
AIRWORTHINESS LIMITATIONS
NOTE: The Airworthiness Limitations section is FAA approved and species maintenance required under
43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been
FAA approved.
1. Approved Mandatory Replacement Times for Type Certification (PIR-TCDS A23SO, Rev. 20.)
The following limitations, related to fatigue life of the airplane and its components, have been established
for the PA-42 / PA-42-720 Cheyenne III / IIIA airplanes:
A. See Chart 401 for safe life of airframe structure.
B. See Chart 402 for the safe life of other components.
C. The safe life limit of the propeller blades is unlimited.
2. Approved Mandatory Structural Inspection Intervals
A. 7,800 Hours
Each 7,800 hours, inspect the Wing, Wing Carry-Through, and their Attaching Structure per Special
Inspection Manual, P/N 767-048.
B. 10,000 Hours
At 10,000 hours time-in-service, perform the initial wing leading edge rivet inspection per Special
Inspection Manual, P/N 767-048, and repeat each 1,600 hours thereafter.
C. 11,600 Hours
At 11,600 hours time-in-service, perform the initial empennage rivet inspections per Special Inspection
Manual, P/N 767-079, and repeat each 1,600 hours thereafter.
D. 12,300 Hours
At 12,300 hours time-in-service, inspect the Cabin and Pressurized Structure per Special Inspection
Manual, P/N 767-078.
E. 13,300 Hours
At 13,300 hours time-in-service, perform the empennage crack inspections per Special Inspection
Manual, P/N 767-079.
F. 13,900 Hours
At 13,900 hours time-in-service, perform the inspections specied in Special Inspection Manual, P/N
767-078.
3. Inspection Procedures for those Approved Mandatory Structural Inspection Items
A. See Special Inspection Manual, P/N 767-048 (dated May 15, 2012 or latest revision), for the Wing,
Wing Carry-Through, and their Attaching Structure inspection procedures.
B. See Special Inspection Manual, P/N 767-078 (dated September 15, 2009 or latest revision), for the
Cabin and Pressurized Structure inspection procedures.
C. See Special Inspection Manual, P/N 767-079 (dated September 15, 2009 or latest revision), for the
Empennage and Associated Structure inspection procedures.
NOTE: To verify latest revision, see the Current Revision Checklists in the Customer Service Information
File (available online at http://pubs.piper.com).
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A42
May 15, 2012
4-00-00
Page 2
Life Limit
Component (Flight Hours)
Wing, Wing Carry-Through, and their Attaching Structure 25,000
Center Beam Assembly P/N 56467-005
PA-42 Wing Panel Assembly P/Ns 56150-026 Left / 56150-27 Right
PA-42-720 Wing Panel Assembly P/Ns 56150-040 Left / 56150-041 Right
Attach Fitting P/Ns 56161-002 Left / 56161-003 Right
Splice Plate P/Ns 56917-002 Left / 56917-003 Right
Angle Assembly P/Ns 46168-006 Left / 46168-007 Right
Bushing P/N 49999-54
Plate P/N 70115-002
Clip Assembly P/Ns 58221-006 Aft / 58221-007 Forward
Aft Drag Angles P/Ns 56939-010 Left / 56939-011 Right
Forward Drag Angles P/Ns 56939-012 Left / 56939-013 Right
Fillet Bulkhead Assembly P/Ns 57926-002 Left / 57926-003 Right
Fillet Bulkhead Assembly P/Ns 57931-002 Left / 57931-003 Right
Tip Tank Assembly P/Ns 57149-012 Left / 57149-013 Right
Tip Tank Fairing Assembly, Aft P/Ns 50155-044 Left / 0155-045 Right
Tip Tank Fairing Assembly, Forward P/Ns 50155-046 Left / 0155-047 Right
Rib, Wing Tip Attachment P/Ns 40510-004 Left / 40510-005 Right
Bracket Assembly, Tip Tank Fairing Support, Left Front P/N 51622-004 or 51622-012
Bracket Assembly, Tip Tank Fairing Support, Right Front P/N 51622-005 or 51622-013
Bracket Assembly, Tip Tank Fairing Support, Left Rear P/N 51622-002 or 51622-010
Bracket Assembly, Tip Tank Fairing Support, Right Rear P/N 51622-003 or 51622-011
Bracket Assembly, Tip Tank Fairing Support, Left P/N 72347-002
Bracket Assembly, Tip Tank Fairing Support, Right P/N 72347-003
and all associated hardware.
Cabin and Pressurized Structure 15,000
PA-42 with Cargo Door, Fuselage Assembly P/N 56700-005
PA-42 without Cargo Door, Fuselage Assembly P/N 56700-006
PA-42-720 with Cargo Door, Fuselage Assembly P/N 56700-008
PA-42-720 without Cargo Door, Fuselage Assembly P/N 56700-009
and all associated hardware.
Empennage and Associated Structure 25,000
Vertical Fin Assembly P/N 70241-002
Rudder Assembly P/N 70527-002 or 70527-006
Elevator Assembly - Left P/N 70224-004
Elevator Assembly - Right P/N 70224-013
Horizontal Stabilizer Assembly P/N 70239-002
Aft Ventral Fin Assembly P/N 59376-012 or 59376-020
and all associated hardware.
CHART 401
STRUCTURAL LIFE LIMITS
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A43
May 15, 2012
4-00-00
Page 3
CHART 402
COMPONENT LIFE LIMITS
Life Limit Inspection Interval
Component (Flight Hours) (Flight Hours)
Engine:
Engine Mount Bolts (F.S. 106.0) 7,500 N/A
Landing Gear Selector:
Cable Assembly (P/N 55416-004) 4,000 N/A
(or Ten (10) Years,
whichever comes rst)
Main Landing Gear:
Top Cylinder Bolts (P/N 401-195) 3,000 N/A
Actuator Rod Ends (P/N 758-440) 3,000 N/A
Brace,
Pivot Shaft Assembly (P/N 43286-002) 3,200 N/A
Retraction Arm (P/N 42042-002) 6,000 200
(1)
Link Bolts (AN6-14 or AN6-16)
(2)
6,000 N/A
Link Assembly
(P/N 85165-002 Left / 85165-003 Right) 6,600 N/A
(1) Beginning at 1,500 hours time-in-service and each 200 hours thereafter, inspect per Piper Service Letter No. 1092B.
(2) Replace AN6-14 and AN6-16 with AN6-16 (P/N 400-211).
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1A44
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B1
CHAPTER
5
TIME LIMITS /
MAINTENANCE
CHECKS
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B2
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B3
May 15, 2012
5 - CONTENTS
CHAPTER 5 - TIME LIMITS / MAINTENANCE CHECKS
TABLE OF CONTENTS
CHAPTER
SECTION SUBJECT GRID NO.
5-00-00 GENERAL 1B7
5-10-00 TIME LIMITS 1B9
General 1B9
Life Limited Parts Marking and Disposition 1B9
5-20-00 SCHEDULED MAINTENANCE 1B11
Description 1B11
Definitions 1B11
Inspection Requirements 1B14
Progressive Inspection Program 1B14
Overlimits Inspections 1B15
Annual / 100 Hour Inspection 1B15
Progressive Inspection Procedure 1B15
Overview 1B15
Scheduled Maintenance (5-20-00) 1B15
Special Inspections (5-30-00) 1B17
Unscheduled Maintenance (5-50-00) 1B17
Away From Home Station Requirements. 1B17
Program Responsibility 1B17
Revisions 1B18
Event 1 1B19
Propellers, Detailed 1B19
Engines, Detailed 1B19
Cabin Cockpit, Detailed 1B21
Fuselage Forward, Detailed 1B22
Fuselage Main, Detailed 1B24
Fuselage Aft And Empennage, Detailed 1B25
Left Wing, Detailed 1B26
Right Wing, Routine 1B27
Landing Gear, Routine 1B27
Special Inspections, As Required 1B28
Operational Inspection 1B28
General 1B29
Inspection Completed Certification 1B31
Inspection Discrepancy Report 1B32
Page 1
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B4
May 15, 2012
5 - CONTENTS
CHAPTER 5 - TIME LIMITS / MAINTENANCE CHECKS
TABLE OF CONTENTS (continued)
CHAPTER
SECTION SUBJECT GRID NO.
5-20-00 SCHEDULED MAINTENANCE (continued)
Event 2 1C1
Propellers, Detailed 1C1
Engines, Detailed 1C1
Cabin Cockpit, Routine 1C4
Fuselage Forward, Routine 1C4
Fuselage Main, Routine 1C4
Fuselage Aft And Empennage, Routine 1C5
Left Wing, Routine 1C5
Right Wing, Detailed 1C6
Landing Gear, Detailed 1C7
Special Inspections, As Required 1C8
Operational Inspection 1C8
General 1C9
Inspection Completed Certification 1C11
Inspection Discrepancy Report 1C12
Notes 1C13
Sample Forms 1C15
Program Responsibility 1C15
Record of Revisions 1C17
Event Inspection Record 1C19
Progressive Inspection Cycle Record 1C21
Discrepancy Record 1C23
Service Publication Compliance Record 1C25
Federal Aviation Airworthiness Directives (AD) Compliance Record 1C27
Nickel-Cadmium Battery Service Record 1C29
Equipment Change and Overhaul Record 1C31
5-30-00 SPECIAL INSPECTIONS 1D1
Per Engine Cycle 1D1
Per Flight Hour 1D1
Per Calendar Year 1D6
Per Specific Operation / Operating Environment 1D8
Operation in High Dust or Industrial Pollution Environment 1D8
Operation in High Salt or High Humidity Environment 1D9
Operation in Extreme Cold 1D9
Operation from Soft or Unusual Terrain 1D10
Airplane Inactive More than Seven (7) Days 1D10
Page 2
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B5
May 15, 2012
5 - CONTENTS
5-50-00 UNSCHEDULED MAINTENANCE CHECKS 1D11
Lightning Strike 1D11
Engine Overspeed, Overtemp, Overtorque, or Sudden Stoppage 1D12
Battery Overtemperature 1D13
Engine Foreign Object or Debris (FOD) Ingestion - Hard Material 1D13
Engine Foreign Object or Debris (FOD) Ingestion - Soft Material / Bird Strikes 1D13
Severe Turbulence, Hard or Overweight Landing 1D14
Flaps Extended Above Maximum Flap Extension Speed (V
FE
) 1D15
Flood Damage, Immersion in Water 1D16
Starter-Generator Replacement 1D19
Page 3
CHAPTER 5 - TIME LIMITS / MAINTENANCE CHECKS
TABLE OF CONTENTS (continued)
CHAPTER
SECTION SUBJECT GRID NO.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B6
May 15, 2012
5 - CONTENTS
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B7
May 15, 2012
5-00-00
Page 1
GENERAL
Piper Aircraft, Inc. (Piper) takes a continuing interest in having the owner get the most efficient use from
his airplane, and keeping the airplane in the best mechanical condition. To that end, Piper publishes a
recurring maintenance schedule which is supplemented with Service Bulletins, Service Letters and Service
Spares Letters as required.
A. The recurring maintenance schedule for the PA-42 / PA-42-720 Cheyenne III / IIIA airplanes is
provided in section 5-20-00.
B. Piper Service Bulletins are of special importance and Piper considers compliance mandatory.
C. Service Letters deal with product improvements and service hints pertaining to the affected aircraft.
Owners should give careful attention to service letter information so they can ensure their airplane is
properly serviced and kept up to date with the latest changes.
D. Service Spares Letters offer improved parts, kits and optional equipment which were not originally
available. These may be of interest to the owner.
E. Service Bulletins, Service Letters and Service Spares Letters are emailed to Piper Dealers/Service
Centers. Owners are encouraged to download these service publications from http://www.piper.com/.
NOTE: Piper mails ight manual (AFM / POH) revisions to the registered owners name and address
as shown on the Aircraft Registration Certicate. If the aircraft is based and/or operated at a
different location (or locations) and/or by a person (or persons) other than those recorded on
the aircraft registration, then the registered owner(s) is responsible for forwarding these to the
operating location(s) or person(s).
Changes in aircraft registration may take a substantial amount of time to be recorded by
the Federal Aviation Administration and received by Piper to change the mailing address.
Owners and operators should make arrangements to keep abreast of flight manual revisions
and service publications during this interim period through their Piper Dealer/Service
Center.
The Federal Aviation Administration (FAA) publishes Airworthiness Directives (ADs) that apply to
specific aircraft. They are mandatory changes and are to be complied within a time limit set by the
FAA. When an AD is issued, it is sent to the latest registered owner of the affected aircraft and also
to subscribers of the service. The owner is solely responsible for being aware of and complying with
airworthiness directives.
NOTE: A searchable database of ADs is available on the FAA website. See the Airworthiness
Directives link at www1.faa.gov. Additionally, Avantext offers a free email notication
service for new ADs as well as the last six weeks worth of ADs at www.avantext.com.
Owners should periodically check with a Piper Dealer/Service Center to find out the latest information
to keep his aircraft up to date.
Service Bulletins, Service Letters, and Service Spares Letters are available by subscription. See
availability statement in Revision Status.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B8
May 15, 2012
5-00-00
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B9
May 15, 2012
5-10-00
Page 1
TIME LIMITS
1. General
A. Refer to 4-00-00 for the FAA-approved airworthiness limitations section. It sets forth each mandatory
replacement time, structural inspection interval, and related structural inspection procedure required
for type certification.
B. Refer to 5-20-00 for Pipers recommended Progressive Inspection Program. It includes the frequency
and extent of the inspections required for the continued airworthiness of the airplane.
C. Inspections required by Engine Cycle, Flight Hour, or Calendar Year are included as part of the
Progressive Inspection Event cycles, if due, and are listed individually in 5-30-00.
2. Life Limited Parts Marking and Disposition
14 CFR Part 43.10, Disposition of Life-Limited Aircraft 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 defined by Type Certificate (TC) are
listed in 4-00-00. Other parts which are replaced or rebuilt after having accumulated cycles, hours, or other
replacement limit are specified in 5-20-00 or 5-30-00.
A. Parts that are removed prior to accumulating their life limit, 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 affect part structural integrity, i.e. - no surface deformation such as
vibration/etching allowed.
B. Parts that have accumulated the life limit shall be disposed of in accordance with the applicable FARs.
Piper recommends life limited parts with no time and/or cycles remaining be completely destroyed.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B10
May 15, 2012
5-10-00
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B11
May 15, 2012
5-20-00
Page 1
SCHEDULED MAINTENANCE
1. Description
WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN
SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER
AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION
- SUPPLEMENTARY PUBLICATIONS.)
The recurring maintenance schedule for the PA-42 / PA-42-720 Cheyenne III / IIIA airplanes is provided
herein as a Progressive Inspection Program (i.e. - paragraph 4). The inspection program is also available
in a separate manual form. See availability statement in Revision Status.
Piper Progressive Inspection Programs comply with the F.A.A. Federal Aviation Regulations Parts 43,
91 and 135. The owner/operator is primarily responsible for maintaining the airplane in an airworthy
condition, including compliance with all applicable Airworthiness Directives and conformity with the
requirements in FAR 91.409, 91.411 and 91.413.
The first overhaul or replacement of components should be performed at the given periods. The condition
of various components can then be used as criteria for determining subsequent periods applicable to
the individual airplane, depending on usage, providing the owner/operator has an established Part 91
Progressive Inspection Program (see 91.409(d)) or Part 135 Approved Aircraft Inspection Program (see
135.419).
The time periods given for inspections of various components are based on average usage and environmental
conditions.
NOTE: The listed inspection, overhaul and replacement schedules do not guarantee that a particular
item or component will reach the listed time without malfunction. Unique operating conditions
encountered by individual airplanes cannot be controlled by the manufacturer.
2. Definitions:
A. Inspections - Must be performed only by persons authorized by the FAA, or appropriate National
Aviation Authority, who are qualified on this aircraft, using acceptable methods, techniques and practices
to determine physical condition and detect defects.
(1) Routine Inspection - Consists of a visual examination or check of the aircraft and its components
and systems without disassembly.
(2) Detailed Inspection - Consists of a thorough examination of the appliances, the aircraft and the
components and systems with such disassembly as is necessary to determine condition.
(3) Special Inspection - Involves those components, systems or structure which by their application
or intended use require an inspection peculiar to, more extensive in scope or at a time period
other than that which is normally accomplished during the event inspection.
B. Checks - Can be performed by pilots and/or mechanics who are qualified on this aircraft and consists of
examinations in the form of comparisons with stated standards for the purpose of verifying condition,
accuracy and tolerances.
C. Approved Inspection - Means a continuing airworthiness inspection of an airplane and its various
component and systems at scheduled interval in accordance with procedures approved by the FAA
under FAR Part 91.409(d) or Part 135.419.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B12
May 15, 2012
5-20-00
Page 2
D. Tests - Operation of aircraft components, appliances or systems to evaluate functional performance.
(1) Operational Test - A task to determine that an item, is fulfilling its intended purpose.The task
does not require quantitative tolerances. This is a fault finding task.
(2) Functional Test - A quantitative check to determine, if one or more functions of an item performs
within specified limits. This test may require the use of supplemental bench test equipment.
(3) In addition, each of the above tests must be performed by an FAA Certified Repair Station with
appropriate ratings or by a Certified Mechanic who is qualified on this aircraft. The recording of
the above function must be made in the permanent aircraft records by the authorized individual
performing the test.
E. Bench Test - Means removal of component from the aircraft to inspect for cleanliness, impending
failure, need for lubrication, repair or replacement of parts and calibration to at least the manufacturers
specifications using the manufacturers recommended test equipment or standards or the equivalent.
Each bench test will be performed by a Piper Service Center, FAA Certified Repair Station with
appropriate rating or by a certified mechanic. This test will be performed at the scheduled interval
regardless of any bench test performed on a particular component while being repaired/overhauled
before scheduled interval bench test. After the component is installed into the aircraft, an operational
test of the component and its related system should be performed to ensure proper function. Serviceable
parts that were issued to the component will be filed in the aircraft permanent records. The person
performing the test must make appropriate entries in the aircrafts permanent maintenance record.
F. Maintenance - The word maintenance as defined by FAR Part 1, means inspection, overhaul, repair,
preservation and the replacement of parts, but excludes preventive maintenance.
G. On Condition Maintenance - A primary maintenance process having repetitive inspections or tests
to determine the condition of units, systems, or portions of structure with regard to continued
serviceability (corrective action is taken when required by item condition.)
H. Time - as used in this manual.
(1) Time-in-service for aircraft components, unless otherwise specified, is a cumulative total of
flight hours or calendar time calculated from the time a new or overhauled component was first
installed in any aircraft, and including:
(a) the aircraft time that elapses from the initial installation to the first removal, if any; and,
(b) the aircraft time that elapses from each subsequent installation to each subsequent removal,
if any; or,
(c) the calendar time elapsed since the installation.
NOTE: Dates stamped on individual components at the time of manufacture are typically
applied to determine shelf life - i.e. the maximum time allowed from manufacture/
assembly/cure until actually installed in an aircraft and are not relevant.
Do not, however; ignore markings applied to life-limited parts when removed with
time and/or cycles remaining on them.
(2) Aircraft time, flight hours, or aircraft hours are the Hobbs Time shown on, or calculated from,
the installed Hour Meter.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B13
May 15, 2012
5-20-00
Page 3
(3) A complete engine cycle is defined as engine start, idle, takeoff, flight, landing, idle, and
shutdown. Many aircraft operations involve partial engine cycles (i.e. - idle, takeoff, flight,
landing, idle) that, with the application of an appropriate formula (see P&WC Service Bulletin
No. 3002 or 13002), are also factored into the calculation of service life limits.
NOTE: The owner/operator is responsible for recording and calculating life limiting cycles.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B14
May 15, 2012
5-20-00
Page 4
3. Inspection Requirements
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.
A. Progressive Inspection Program
The Piper Progressive Inspection Program complies with the F.A.A. Federal Aviation Regulations
(FAR) Parts 43, 91 and 135 for progressive inspections. The owner/operator is primarily responsible
for maintaining the airplane in an airworthy condition, including compliance with all applicable
Airworthiness Directives and conformity with the requirements in FAR 91.409, 91.411 and 91.413.
The complete cycle inspection consists of two (2) 100 hour events, which provide for a complete
aircraft inspection in 200 aircraft flying hours. The complete inspection, Events (1) and (2), must
be completed within twelve (12) calendar months. Inspections must be accomplished by persons
authorized by the FAA or appropriate National Aviation Authority.
The Progressive Inspection Program is designed to permit the best utilization of the aircraft through the
use of a planned inspection schedule. This schedule is contained herein (i.e. - paragraph 4) and is also
available in a separate manual form:
100 Hour Progressive Inspection Manual, P/N 761-739
NOTE: Another separate manual using four (4) 50 hour events is also available: 50 Hour
Progressive Inspection Manual, P/N 761-760.
See availability statement in Revision Status.
NOTE: The PA-42 / PA-42-720 Cheyenne III / IIIA Progressive Inspection Manuals referenced above
are not stand-alone documents. The Progressive Inspection Manuals constitute a snapshot
of the Airworthiness Limitations and Inspection sections of the Instructions for Continued
Airworthiness (ICA) and are current only at the time of printing. Use them as follows:
(1) Owners/operators desiring to establish a Part 91 Progressive Inspection Program (PIP)
(see 91.409(d)) or a Part 135 Approved Aircraft Inspection Program (AAIP) (see
135.419) should use the Progressive Inspection Manual as a template for submission
to the appropriate FAA office.
(2) Service centers conducting Event Cycle inspections under a FAA-approved PIP or
AAIP can use the Progressive Inspection Manual as a working check-off list/form,
provided they verify its currency against the FAA-approved PIP or AAIP.
(3) Service centers conducting Part 91 Annual / 100 Hour Inspections (see paragraph C,
below) can use the Progressive Inspection Manual as a working check-off list/form,
provided they verify its currency against an up-to-date copy of the ICA (i.e. - this
maintenance manual, Chapters 4 and 5).
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B15
May 15, 2012
5-20-00
Page 5
B. Overlimits Inspections
If the airplane has been operated so that any of its components have exceeded their maximum
operational limits, special inspections may be required by Piper and/or the component manufacturer.
See 5-50-00 and applicable vendor publications.
C. Annual / 100 Hour Inspection
Owners/operators may maintain the airplane solely under FAR 91.409 (a) and (b) inspection
requirements. The inspection checklist for such an annual/100 hour inspection consists of both Events
(1) and (2) from the 100 hour Progressive Inspection Program described above. Inspections must be
accomplished by persons authorized by the FAA or appropriate National Aviation Authority.
4. Progressive Inspection Procedure
The progressive inspection program cycle consists of two (2) 100 Hour Events, which provides for a
complete aircraft inspection in 200 aircraft flying hours. The complete inspection cycle, Events (1) and (2),
must be completed within twelve (12) calendar months.
Each Event Inspection consists of a predetermined number of location inspections, both routine and
detailed, as indicated below. The Event Inspections are conducted each 100 hours and must be done in
sequence. Each Event Inspection will be conducted using an Event Inspection Work Sheet and, when
completed, recorded in the Event Inspection Record.
Late compliance with the Event Inspection Interval of 100 hours may be extended by not more than ten
(10) flying hours (10% of Event Inspection Interval). The excess time, however, must be deducted from
the next 100 flying hours.
Early compliance can be accomplished at the owner/operators discretion for convenience of scheduling.
However, where early compliance is accomplished, the 100 flying hour interval for the next event inspection
will be maintained.
The Event Inspections are arranged so that the 200 flying hour cycle results in a complete inspection. When
both Events are complete and recorded, an entry is made in the Progressive Inspection Cycle Record and
Sign-off Sheet which is the running log or current status of the aircrafts inspections.
A. Overview
(1) Scheduled Maintenance (5-20-00)
(a) Two (2) Event Inspections at 100 Hour Intervals. Work sheets are provided as follows:
1) Event #1 (100, 300, 500, 700, and 900 flight hours, etc.)
a) Propeller, Detailed
b) Engine, Detailed
c) Cabin and Cockpit, Routine
d) Fuselage Forward, Detailed
e) Fuselage Main, Detailed
f) Fuselage Aft and Empennage, Detailed
g) Left Wing, Detailed
h) Right Wing, Routine
i) Landing Gear, Routine
j) Special Inspections
k) Operational Inspection
l) General Inspection
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B16
May 15, 2012
5-20-00
Page 6
m) Return to Service Certification
n) Inspection Discrepancy Report
2) Event #2 (200, 400, 600, 800, and 1000 flight hours, etc.)
a) Propeller, Detailed
b) Engine, Detailed
c) Cabin and Cockpit, Detailed
d) Fuselage Forward, Routine
e) Fuselage Main, Routine
f) Fuselage Aft and Empennage, Routine
g) Right Wing, Detailed
h) Left Wing, Routine
i) Landing Gear, Detailed
j) Special Inspections
k) Operational Inspection
l) General Inspection
m) Return to Service Certification
n) Inspection Discrepancy Report
3) Notes
(b) Completed Aircraft Inspection Cycle (i.e. - as part of the second Event Inspection).
(c) Sample Forms
1) Program Responsibility - is a permanent record identifying the person responsible for
scheduling the inspections under this program.
2) Record of Revisions - is a permanent record documenting any revisions to this
inspection program. Note that any such revisions must be submitted to and approved
by the FAA District Office before enactment.
3) The Event Inspection Record - is a permanent record of 100 Hour Event Inspection
completion.
4) The Progressive Inspection Cycle Record - is a permanent record of Progressive
Inspection 200 Hour Cycle completion.
5) The Discrepancy Record is a log of conditions for corrective action at the next routine
or event inspection as determined by the maintenance personnel. FAA Airworthiness
Directives and/or manufacturers service publications, not requiring immediate action
may be entered on the (DR) providing complying with the A.D. or service publication
at the next routine or event will be within the time allowance permitted. Certain FAA
or manufacturers mandatory inspections may have to be accomplished before further
flight, in which case, their compliance should be recorded on the appropriate record.
6) Service Publication Compliance Record - is a permanent record used to document
compliance with all applicable aircraft and component manufacturers service
publications.
7) The Federal Aviation Airworthiness Directives (AD) Compliance Record - is a
permanent record used to document compliance with all applicable AD Notes.
8) Nickel-Cadmium Battery Service Record - a cumulative history of the battery condition.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B17
May 15, 2012
5-20-00
Page 7
9) The Equipment Change and Overhaul Record - is a permanent record used to document
equipment changes, allowing precise control of equipment inspection, overhaul,
or replacement intervals. Use of the ECR allows review of the Out of Sequence
equipment and permits a projection of equipment due times in relation to the aircraft
Hobbs times.
(2) Special Inspections (5-30-00)
NOTE: Includes inspections which occur outside the 100 hour event cycle.
(a) Per Engine Cycle
(b) Per Flight Hour
(c) Per Calendar Year
(d) Per Special Operation / Operating Environment
(3) Unscheduled Maintenance (5-50-00)
B. Away From Home Station Requirements.
If the airplane is to be away from the home location at the time an inspection is due, the pilot-in
command of the flight will take with him all sign off sheets which will be required for the inspection,
and a copy of this manual. The inspection will be conducted or supervised by one of the following:
(1) An appropriately certified repair station.
(2) An appropriately rated certified mechanic, qualified on this type aircraft.
The results of the inspection will be noted on the proper sign off sheets which are then brought back
to the home base. The pilot will be responsible for all inspection forms and work sheet entries with
mechanics and/or inspectors signature and identification.
Discrepancies affecting the airworthiness of the airplane, when the airplane is away from the local
station, will be corrected by either 1 or 2, above. The pilot will be responsible for all work sheet
entries with mechanics and/or inspectors signature and identification.
The pilot-in-command should also ascertain that the appropriate logbook entries have been made in
the aircraft and engine logbooks.
C. Program Responsibility
The person responsible for scheduling the inspections required under this program must enter his or
her name in a copy of the Program Responsibility form included later in this section and forward the
original copy of the form to their local FAA-FSDO office. A duplicate copy should be maintained in
this manual.
Any change in personnel responsible for scheduling the inspection program requires another copy of
the Program Responsibility form to be filled out and the original copy sent to the local FAA-FSDO
office, while a duplicate copy is attached behind the previous Program Responsibility form. The
previous form should be retained and the word CHANGED should be written across the obsolete
information.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B18
May 15, 2012
5-20-00
Page 8
D. Revisions
Revisions to this Inspection Program are the direct responsibility of the manufacturer. However,
owners/operators with an F.A.A.-approved Part 91 Progressive Inspection Program or a Part 135
Approved Aircraft Inspection Program may not enact any such revisions until approval is obtained
from the responsible F.A.A. District Office. A permanent record of revisions and F.A.A. approvals
will be maintained by the owner/operator on the form provided for this purpose later in this section.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B19
May 15, 2012
5-20-00
Page 9
WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR
INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER
THE AIRCRAFT UNAIRWORTHY. (SEE MAINTENANCE MANUAL - INTRODUCTION -
SUPPLEMENTARY PUBLICATIONS.)
NOTE: Review Notes 1, 2, 3, and 4, before beginning this event.
PROPELLERS, DETAILED
Left Right
[ ] [ ] 1. Remove and inspect spinner for cracks, corrosion and damage.
[ ] [ ] 2. Inspect blades for nicks, cracks, erosion and evidence of strikes.
[ ] [ ] 3. Check for grease and oil leaks.
[ ] [ ] 4. Inspect bulkhead for cracks, security and corrosion.
[ ] [ ] 5. Inspect propeller mounting bolts for condition and proper safety. Check torque if safety is broken.
[ ] [ ] 6. Inspect hub parts for cracks, corrosion and security.
[ ] [ ] 7. Rotate blades and inspect for tightness.
[ ] [ ] 8. Inspect beta feedback ring for runout (0.010 inch max.) and no metal to metal contact with
reverse lever and carbon block holder.
[ ] [ ] 9. Inspect carbon block for wear limit and freedom of movement.
[ ] [ ] 10. Inspect low pitch stop rods, return springs and beta feedback ring for damage, corrosion and
freedom of movement.
[ ] [ ] 11. Inspect condition of propeller deicer slip ring and brush block or modular brush assembly.
[ ] [ ] 12. Inspect propeller deice boots for security of attachment and condition.
[ ] [ ] 13. Inspect propeller deice wiring and junction blocks for security, cracks, chang and damage.
[ ] [ ] 14. If installed, inspect condition and security of synchrophaser wiring.
[ ] [ ] 15. Lubricate propeller per Lubrication Charts, 12-20-00.
[ ] [ ] 16. Install spinner.
ENGINES, DETAILED
NOTE: Refer to Pratt & Whitney PT6A-41 Maintenance Manual P/N 3021442 or Pratt & Whitney PT6A-61
Maintenance Manual P/N 3034342 as required for details. (See Note 5.)
Left Right
[ ] [ ] 1. Remove engine cowling.
[ ] [ ] 2. Remove upper and lower rewall access covers.
[ ] [ ] 3. Clean and inspect cowling and covers for cracks, distortion and loose or missing fasteners.
[ ] [ ] 4. Inspect oil temperature sender unit for leaks and security.
[ ] [ ] 5. Inspect oil lines and ttings for leaks, security, chang, dents, cracks and routing.
[ ] [ ] 6. Clean and inspect oil cooler for condition and attachment.
[ ] [ ] 7. Remove and inspect oil lter for damage and contamination Clean or replace as required.
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 1 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B20
May 15, 2012
5-20-00
Page 10
ENGINES, DETAILED (continued)
CAUTION: ALL ENGINE CLEANING PROCEDURES AND CLEANING PRECAUTIONS MUST
BE OBTAINED FROM THE APPROPRIATE SECTIONS OF THE PRATT & WHITNEY
MAINTENANCE MANUAL (PT6A-61) P/N 3034342 OR (PT6A-41) P/N 3021442.
Left Right
[ ] [ ] 8. Clean exterior of engine.
[ ] [ ] 9. Inspect condition of igniter plugs.
[ ] [ ] 10. Inspect ignition harness and insulators for high tension leakage, continuity, damage and
attachment.
[ ] [ ] 11. Inspect electrical connections on ignition exciter for safety and security.
[ ] [ ] 12. Remove air inlet screen; inspect rst stage compressor blades for ingestion damage and
corrosion. Inspect screen for damage and cleanliness. Install screen.
[ ] [ ] 13. Clean and inspect fuel pump inlet screen for foreign material. Replace outlet lter.
[ ] [ ] 14. Inspect gas generator case drain valves for security and leaks. (Check after engine run.)
[ ] [ ] 15. Inspect magnetic chip detector and jump pins A & B operational check of annunciator.
[ ] [ ] 16. Inspect condition of inlet air ducts and ice protection system for operation and t. (See latest
Piper Service Letter No. 983.)
[ ] [ ] 17. Inspect condition of actuators and linkage for ice protection system and oil cooler doors.
CAUTION: WHEN ENGINE IS NOT RUNNING, ANY ATTEMPT TO MOVE POWER LEVERS INTO
REVERSE POSITION, WITHOUT DISCONNECTING PROPELLER PUSH-PULL WIRE
ROPE CLEVIS FROM PROPELLER CONTROL CAM, WILL RESULT IN BENDING OR
KINKING OF WIRE ROPE.
[ ] [ ] 18. Inspect power lever, start control, propeller governor and propeller reversing linkage for
condition, travel and operation.
[ ] [ ] 19. Inspect gas generator case for cracks, distortion and evidence of overheating.
[ ] [ ] 20. Inspect exhaust stacks and exhaust ducts for cracks, distortion and security.
[ ] [ ] 21. Inspect propeller governor for leaks and security.
[ ] [ ] 22. Inspect propeller shaft for oil leaks.
[ ] [ ] 23. Remove drain; clean and inspect fuel lter bowl and element. (Firewall mounted.)
[ ] [ ] 24. Inspect all exible lines (fuel, hydraulic, pneumatic and oil) for leaks, abrasions, cuts and secure
connections. Replace upon condition. (See latest Piper Service Bulletin No. 822.)
[ ] [ ] 25. Inspect fuel control, fuel pumps, fuel manifold, fuel ow transmitter and fuel pressure transmitter
for leaks, security and condition. Check wiring for security and condition. (See latest revision
of Piper Service Bulletin 957.)
[ ] [ ] 26. Replace hydraulic lter and inspect for contamination. If lter shows evidence of contamination,
inspect entire hydraulic system.
[ ] [ ] 27. Inspect hydraulic pump and hydraulic lines for security and leaks.
[ ] [ ] 28. Inspect engine reseals for cracks, damage and security.
[ ] [ ] 29. Inspect rewalls for cracks, stress and condition.
[ ] [ ] 30. Inspect rewall seals for condition.
[ ] [ ] 31. Inspect oil breather tube for obstruction and security.
[ ] [ ] 32. Inspect oil ller cap seal for damage and condition.
[ ] [ ] 33. Check proper locking feature of oil ller cap.
[ ] [ ] 34. Inspect oil pressure transmitter for security and leaks. Check wires for connection and damage.
[ ] [ ] 35. Inspect torque transmitter for leaks and security. Check wiring for damage and security. Check
condition of shock mounts.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 2 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B21
May 15, 2012
5-20-00
Page 11
Left Right
[ ] [ ] 36. Inspect oil manifold for leaks and security.
[ ] [ ] 37. Inspect autoignition switch, autofeather switch and manifold for security and condition. Check
wiring for damage and secure connection.
NOTE: An autofeathering system is an optional system on the PA-42 Cheyenne III aircraft.
[ ] [ ] 38. Inspect P3 air lter for contamination. Replace if evidence of contamination.
[ ] [ ] 39. Inspect re extinguisher for damage and security of wiring. Test re extinguishing system for
proper cylinder pressure.
NOTE: Engine re extinguishers are optional equipment and are not installed on all PA-42 and PA-42-720.
[ ] [ ] 40. Inspect re warning sensors and wiring for security and condition.
[ ] [ ] 41. Inspect compressor wash ring for damage and security.
[ ] [ ] 42. Inspect compressor wash valve assembly for security and operation. (if installed)
[ ] [ ] 43. Inspect engine mounts for cracks, damage and loose mounting bolts.
[ ] [ ] 44. Inspect rubber Lord mounts for deterioration and condition.
[ ] [ ] 45. Check security, wiring and operation of blade angle sensor or beta lights, if installed.
[ ] [ ] 46. Check security, wiring and operation of beta limiter system.
[ ] [ ] 47. Inspect front and rear tachometer generators for security and wiring.
[ ] [ ] 48. Inspect starter generator quick attachment device (QAD) ring and mount pad for security,
cracks and damage.
[ ] [ ] 49. Inspect condition of starter-generator cables.
[ ] [ ] 50. Inspect condition of starter-generator cooling air ducts.
[ ] [ ] 51. In PA-42-720 airplanes only, inspect starter-generator brushes and commutator for wear,
condition, and security.
[ ] [ ] 52. Clean dual drive lube lter.
[ ] [ ] 53. Inspect generator control units (GCU) for security, damage and wiring integrity.
[ ] [ ] 54. Inspect bleed air lines, exible lines and couplings for security, damage and leakage. (Also see
Piper Service Bulletin No. 914).
[ ] [ ] 55. Check bleed air shutoff valve and mixing regulator for security, damage, leakage and correct
operation. Check wiring for attachment and damage.
[ ] [ ] 56. Inspect bleed air intercooler for cleanness and blockage. Check intercooler inlet and outlet for
blockage, security and leakage of duct couplings.
[ ] [ ] 57. Inspect and check all engine wiring and ITT harness and connectors for security and condition.
[ ] [ ] 58. Lubricate power plant per Lubrication Chart, 12-20-00.
[ ] [ ] 59. Install upper and lower rewall access covers.
[ ] [ ] 60. Install engine cowling.
CABIN COCKPIT, DETAILED
NOTE: Some items included under Fuselage Main, Detailed are also required for Cabin Cockpit, Detailed.
[ ] 1. Remove inspection plates, panels and oor panels.
[ ] 2. Inspect cabin cockpit entrance sliding doors and cockpit dividers for damage and operation.
[ ] 3. Inspect upholstery for damage.
[ ] 4. Inspect pilot and copilot seats/seat belts for damage, security and operation.
[ ] 5. Inspect trim operation and indicators for full travel, binding, damage and correct control deection.
[ ] 6. Check rudder pedals for travel, binding and security. Inspect brake cylinders for leaks and operation.
[ ] 7. Inspect parking brake and parking brake cable for condition, security and operation.
[ ] 8. Inspect control wheels, column, pulleys and cables for damage operation and full travel.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 3 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B22
May 15, 2012
5-20-00
Page 12
CABIN COCKPIT, DETAILED (continued)
[ ] 9. Inspect instruments and attachments for security, damage, proper markings and placards. (Refer to
Pilots Operating Handbook.)
[ ] 10. Inspect compass correction card for correct data. Calibrate as required.
[ ] 11. Inspect avionics and electrical systems for condition and security of switches and knobs.
[ ] 12. Inspect circuit breakers for condition and security of installation.
[ ] 13. Perform main bus tie circuit breaker and distribution diode check per Testing, 39-10-00.
[ ] 14. Check cabin pressure controller lter and instrument air lter for contamination and damage.
[ ] 15. Inspect pitot and static lines for condition and security.
[ ] 16. Inspect static system, altimeter and transponder for installation/certication per latest revision of
AC43.13-1 and current test/inspection per FARs 91.411 and 91.413, respectively.
[ ] 17. Inspect and test ELT per FAR 91.207. (See Testing ELT, 23-20-00.)
[ ] 18. Check security and operation of crossfeed valve handles.
[ ] 19. Check security and operation of emergency shutoff valve handles.
[ ] 20. Check operation of recirculation blowers.
[ ] 21. Inspect condition and operation of heater ducts and air conditioning ducts and outlets.
WARNING: BE SURE SKIN AND CLOTHING ARE FREE OF GREASE, OIL OR OTHER PETROLEUM
PRODUCTS BEFORE CHECKING OR PERFORMING MAINTENANCE ON ANY
COMPONENT OF THE OXYGEN SYSTEM.
[ ] 22. Inspect oxygen outlets for defects and corrosion.
NOTE: Operation of oxygen shutoff valve on PA-42-720 aircraft will deploy all oxygen masks.
[ ] 23. Inspect and check operation of passenger oxygen shutoff valve.
[ ] 24. Inspect oxygen masks for proper attachment and condition.
[ ] 25. Lubricate per Lubrication Chart, 12-20-00.
[ ] 26. Install inspection plates, panels and oor panels. Inspect pneumatic lines, exible lines and components
for overall condition and operation. Replace on condition.
[ ] 27. Check portable re extinguishers for proper service, condition and inspection date.
[ ] 28. If equipped, check the service time and condition of each life preserver. Check that the locate light is
securely attached and operable.
[ ] 29. Turn battery master switches on. Inspect and check operation of all electrically operated instruments.
Overhaul or replace as required.
[ ] 30. Check all instrument, cockpit, navigation, strobe and recognition lighting for operation.
[ ] 31. Check pilots storm window for condition, operation and proper seal. (If installed)
[ ] 32. Perform operational test of microphones and cabin speakers.
[ ] 33. Check glareshield and eyebrow panels for condition, cracks and security.
FUSELAGE FORWARD, DETAILED
[ ] 1. Remove inspection plates and panels and open baggage door and radome.
[ ] 2. Inspect baggage door surface, door latch, hinges, air cylinders, door ajar switch, compartment light
and door seal for damage, wear, proper rigging and operation.
[ ] 3. Check brake reservoir and brake lines for leaks, security and proper uid level in reservoir.
[ ] 4. Inspect electronics installation, wire harness plugs, ground bus bar, triplexer and radios for condition,
corrosion and security.
[ ] 5. Inspect antenna mounts and electrical wiring for security and corrosion.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 4 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B23
May 15, 2012
5-20-00
Page 13
[ ] 6. Inspect radio and ECS access panels for damage, loose or missing fasteners and condition of rain
gutter on access opening.
[ ] 7. Inspect battery box and cables for security, damage and corrosion.
[ ] 8. Inspect condition of battery, battery over temperature sensors and fuse.
[ ] 9. Inspect radome lightning diverter strips for damage and security.
[ ] 10. Within the radome inspect the radar, glide slope antenna, wave guide and receiver/transmitter for
condition and security of mounting.
[ ] 11. Inspect ap amplier for damage and security.
[ ] 12. Remove access panels within the nose baggage compartment. Inspect avionics plugs, harness and
connections for security, corrosion and condition.
[ ] 13. Inspect bulkheads, stringers and skin for damage, condition and corrosion.
[ ] 14. Inspect left and right pitot mast for obstructions, damage, security and operation.
[ ] 15. Check radar, environmental control unit (ECU), battery cooling air inlets and vents for obstructions,
damage and security.
[ ] 16. Inspect ECU ram air and ground air check valves for damage and proper operation. Check ECU
ground fan for damage and operation.
[ ] 17. Inspect refrigeration unit for damage, security and exible coupling leakage. Inspect water separator
coalescer bag for dirt, clean as required. Inspect ECU overtemperature and overpressure switches
for security and leakage and wiring for damage and attachment. Inspect water asperator plumbing for
blockage, leakage and condition.
[ ] 18. PA-42: Inspect Bleed air pressure regulator for leakage and damage. Check wiring for damage and
attachment.
WARNING: DO NOT PERMIT OIL, GREASE OR OTHER PETROLEUM PRODUCTS TO COME IN
CONTACT WITH ANY LINES OR FITTINGS UTILIZED IN THE OXYGEN SYSTEM. BE
SURE SKIN AND CLOTHING ARE FREE OF OIL, GREASE OR OTHER PETROLEUM
PRODUCTS BEFORE WORKING ON ANY COMPONENT OF THE OXYGEN SYSTEM.
NOTE: Date of last hydrostatic test is stamped on cylinder.
[ ] 19. Inspect oxygen cylinder, regulator and lines for security and condition. On PA-42: check control cable
for security and condition. Check connections and lines for leaks. Check control for operation. Check
rupture disc condition and system for proper pressure.
[ ] 20. Inspect hydraulic power pack for leaks, security and proper uid level.
[ ] 21. Inspect hydraulic power pack exible control cables and line for damage, security, operation and leaks.
[ ] 22. Inspect all hydraulic lines for leaks and security.
[ ] 23. Drain and inspect static drain pumps.
[ ] 24. Inspect landing and taxi lights for broken lenses and security.
[ ] 25. If equipped, check electrical outside air temerature probe (OAT) for corrosion, damage, condition of
wiring and secure mounting.
[ ] 26. Inspect external electrical connection (GPU) and access door for damage and security.
[ ] 27. Inspect condition of outer skin; check for loose or missing rivets, damage and condition.
[ ] 28. Lubricate per Lubrication Chart, 12-20-00.
[ ] 29. Reinstall access plates, panels and close radome and baggage door.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 5 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B24
May 15, 2012
5-20-00
Page 14
FUSELAGE MAIN, DETAILED
[ ] 1. Remove inspection plates, panels and oor panels.
[ ] 2. Inspect external skins for condition, loose or missing rivets, damage and corrosion.
[ ] 3. Inspect windshield and windows for cracks, distortion, leaks and security.
[ ] 4. Check bimetallic outside air temperature probe (OAT) for corrosion, damage and condition.
[ ] 5. Remove emergency exit window; check window and seal for cracks, distortion and leaks. Install
window and check for security of latching mechanism.
[ ] 6. Inspect windshield wipers for security of mounting, condition and operation. (Do Not Operate on Dry
Windshield.)
[ ] 7. Inspect fuel, hydraulic and pressurization lines for damage, leaks, routing and security.
[ ] 8. Inspect all control cables and pulleys for damage, full travel, alignment, clearance and proper tension.
[ ] 9. Inspect antenna mounts and connections for tightness, security and corrosion.
[ ] 10. Inspect all electrical wiring for damage, routing, attachment and security.
[ ] 11. Inspect autopilot pitch and roll servos for security. Inspect condition of bridle cables and wiring.
[ ] 12. Inspect main cabin door and if installed, inspect cargo door for damage, condition of door seal, proper
rig and operation of latching mechanisms. Check door ajar switches for mechanical operation; an
audible click should be heard when switch opens or closes.
[ ] 13. Inspect door snubber for leaks and attachment.
[ ] 14. Inspect door restraint cables for condition and security of attachment.
[ ] 15. Inspect deice valves and pneumatic system regulators for security, damage and leaks; electrical
connections for security and condition.
[ ] 16. Inspect pneumatic lines, exible lines and components for leaks, cuts, abrasions and secure
connections. Replace upon condition.
[ ] 17. Check upholstery for damage.
[ ] 18. Check seats and seat belts for security of brackets and bolts.
[ ] 19. Check all lights and air vents for damage and operation.
WARNING: BE SURE SKIN AND CLOTHING ARE FREE OF GREASE, OIL OR OTHER PETROLEUM
PRODUCTS BEFORE CHECKING OR PERFORMING MAINTENANCE ON ANY
COMPONENT OF THE OXYGEN SYSTEM.
[ ] 20. Inspect oxygen outlets and masks for defects, corrosion and attachment of masks to outlets.
[ ] 21. Check operation of oxygen system. (Refer to Pilots Operating Handbook.)
[ ] 22. Check portable re extinguisher for charge and service time.
[ ] 23. If applicable, check service time and condition of each life preserver. Check that locate light is securely
attached and operative.
[ ] 24. Check outow and outow/safety cover screen for obstructions. Check outow and safety valve popit
for cleanliness. (Clean per 21-30-00.)
[ ] 25. Check all electric options for security, damage, wiring integrity and condition.
[ ] 26. Check return air lters in airbox for cleanliness. Clean or replace as required.
[ ] 27. Check recirculation doors condition and freedom of movement. Check actuator cables and solenoids
for operation.
[ ] 28. Check cabin vent fans for operation, security and attachment.
[ ] 29. Check overtemperature and recirculation switches for security and wiring attachment.
[ ] 30. Check ECU controls for proper operation. Check cabin temperature control for security, blockage,
cleanliness of air inlet and exit. Check temperature control fan for operation.
[ ] 31. Lubricate per Lubrication Chart, 12-20-00.
[ ] 32. Replace inspection plates, panels and oor panels.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 6 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B25
May 15, 2012
5-20-00
Page 15
FUSELAGE AFT AND EMPENNAGE, DETAILED
[ ] 1. Remove all inspection plates, access panels and fairings.
[ ] 2. Inspect condition of skin, interior bulkheads, formers and stringers for damage, loose or missing rivets
and corrosion.
[ ] 3. Inspect static discharge wicks for security of attachment and condition.
[ ] 4. Inspect vertical n and rudder surfaces for security of attachment, damage and corrosion.
[ ] 5. Inspect rudder and tab hinges, bolts and attachments for damage, operation, wear and security.
[ ] 6. Inspect rudder and rudder trim mechanism for operation and full travel.
[ ] 7. Inspect rudder cove seal for damage and security of attachment.
[ ] 8. Inspect horizontal stabilizer and elevator surfaces for damage, loose or missing rivets and corrosion.
[ ] 9. Inspect lightning diverter and diverter strips on bullet assembly for damage and security.
[ ] 10. Inspect tail navigation lights and strobe lights for broken lenses and security.
[ ] 11. Inspect elevator and tab hinges, horns and attachments for damage, security and operation.
[ ] 12. Inspect horizontal stabilizer attachments for security, damage, cracks and corrosion.
[ ] 13. Inspect elevator and tab hinge bolts and bearings for security of attachments, damage, wear and
corrosion.
[ ] 14. Inspect elevator trim mechanism for operation and full travel.
[ ] 15. Inspect rudder, elevator and trim mechanism cables, turnbuckles, guides, torque tubes and pulleys
for safety, cable tension, damage, corrosion, operation and condition.
[ ] 16. Inspect elevator down spring for damage, corrosion, attachment and tension.
[ ] 17. Inspect rudder and elevator balance weights for security.
[ ] 18. Inspect autopilot components for condition, security of mounting, condition of shockmounts and
evidence of moisture or corrosion in plugs.
[ ] 19. Inspect autopilot servos bridle cables for condition, security and tension.
[ ] 20. Inspect ELT battery for condition/date per FAR 91.207.
[ ] 21. Inspect ELT and antenna installation for condition and security. Replace antenna if bent or damaged.
(Refer to latest Piper Service Letter 935.)
[ ] 22. Inspect VOR antenna and connections for corrosion, security of mounting and condition.
[ ] 23. Inspect antenna mounting(s) for security, corrosion and condition.
[ ] 24. Inspect pneumatic deice boots and plumbing for condition, leaks and damage. (Replace upon
condition.)
[ ] 25. Inspect static ports and lines for obstructions, leaks and condition.
[ ] 26. Check outow and safety valve static openings for obstructions.
CAUTION: TO PREVENT WATER DAMAGE TO VENTRAL FIN KEVLAR MATERIAL, THE EDGE OF
EACH VENTRAL FIN DRAIN HOLE IS SEALED WITH EPOXY RESIN. IF NECESSARY TO
OPEN VENTRAL FIN DRAIN HOLES, CARE SHOULD BE TAKEN NOT TO BREAK SEAL. IF
SEAL IS BROKEN, REFER TO CHAPTER 51 FOR PROCEDURE USED TO APPLY EPOXY
RESIN.
[ ] 27. Check that fuselage, elevator trim drum and ventral n drain holes are open and free of foreign matter
(See latest Piper Service Bulletin No. 857.)
[ ] 28. Lubricate per Lubrication Chart, 12-20-00.
[ ] 29. Install inspection plates and access panels.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 7 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B26
May 15, 2012
5-20-00
Page 16
LEFT WING, DETAILED
CAUTION: THE FLUX DETECTOR COVER ON THE OUTBOARD WING SURFACE IS SECURED
WITH BRASS SCREWS. ONLY BRASS SCREWS WILL BE USED WHEN INSTALLING THIS
COVER.
[ ] 1. Remove inspection plates and panels.
[ ] 2. Inspect static discharge wicks for security of attachment and condition.
[ ] 3. Inspect ux detector plug connections and wiring for corrosion, security and condition.
[ ] 4. Inspect wing and control surface skins and fairings for cracks, loose or missing rivets and damage.
[ ] 5. Inspect aileron for security of attachment and freedom of movement. (See Note 7.)
[ ] 6. Inspect interior structure for cracks, loose and missing rivets or concealed damage.
[ ] 7. Inspect aileron cables, pulleys and bellcrank for damage, full travel, alignment, clearance and proper
cable tension.
[ ] 8. Inspect aileron balance weights and aileron gap seal for condition and security.
[ ] 9. Inspect aps, actuators, limit switches, wiring and pots for corrosion, damage, operation and full
travel. (See Note 8.)
NOTE: An approach ap extension of 10 will not activate the Flap/Landing Gear Warning Horn since this
ap setting is intended for extended approach use. Normal landings are made using 30 aps and
the Flap/Landing Gear Warning Horn will activate if the landing gear is not extended when the
aps are extended more than 10.
[ ] 10. Inspect ap tracks and rollers for condition. Check rollers for freedom of movement and binding.
[ ] 11. Inspect ap track bolts and aileron hinge bolts for wear, security and corrosion.
[ ] 12. Inspect all control surface bearings for attachment, wear and freedom of movement.
[ ] 13. Check operation of left fuel shutoff valve and crossfeed valve.
[ ] 14. Inspect wing attachment bolts for stripe alignment and brackets for cracks and corrosion.
[ ] 15. Inspect engine mount brackets for condition and security.
[ ] 16. Inspect bladder fuel cells for attachment, leaks and contamination.
[ ] 17. Inspect integral fuel tanks for leaks, corrosion, contamination and damage.
[ ] 18. Inspect fuel lines for attachment, chang and leaks.
[ ] 19. Check ller neck anti-siphon valves and fuel caps for damage and proper seal. Inspect quick drains
for proper operation.
[ ] 20. Check fuel tanks for correct operating fuel. Check condition of fuel type placards.
[ ] 21. Inspect fuel vents for obstructions and damage. Check valves for operation and seal.
[ ] 22. Inspect fuel capacity probes for security, corrosion and leaks.
[ ] 23. Inspect electrical wiring harness and connections for chang, damage and security.
[ ] 24. Inspect hydraulic lines for leaks, damage or chang and attachment.
[ ] 25. Inspect pneumatic lines, exible lines and components for leaks, cuts, abrasions and secure
connections. Replace upon condition.
[ ] 26. Inspect bleed air warning duct switches for leaks and security and wiring for damage and attachment.
(PA-42: (engine, intercooler, shroud aft of rewall and wing root), PA-42-720: (Engine, intercooler and
wing root).
[ ] 27. Inspect bleed air duct coupling for leakage, damage and security. Check duct insulation for condition
and security. Check ducting for security and chang.
[ ] 28. Inspect pneumatic deicer boots for condition and damage.
[ ] 29. Inspect left transducer for security of attachment, spring centering of switch blade and corrosion.
check heat element for operation.
[ ] 30. Inspect wing tip tank attachment bolts for security.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 8 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B27
May 15, 2012
5-20-00
Page 17
[ ] 31. Inspect wing tip navigation and strobe lights for broken lenses, security, wiring and attachment.
[ ] 32. Check wing inspection light for broken lens, security, wiring and attachment.
[ ] 33. Inspect wing lockers for condition, leaks and damage.
[ ] 34. Inspect wing locker door for security and damage.
[ ] 35. Check wing locker door cylinder and lock for security, damage and operation.
[ ] 36. Inspect nacelle fuel tank for condition, leaks and damage. Check condition of fuel type and capacity
placards. Replace if illegible.
[ ] 37. Lubricate per Lubrication Chart, 12-20-00.
CAUTION: ONLY BRASS SCREWS ARE TO BE USED FOR INSTALLING FLUX DETECTOR ACCESS
DOOR.
[ ] 38. Install inspection plates and panels.
RIGHT WING, ROUTINE
[ ] 1. Check surfaces, skins, tip tank and fairings for damage, condition, loose or missing rivets.
[ ] 2. Inspect aileron and trim tab attachments for security, damage and operation. (See Note 7.)
[ ] 3. Inspect aileron balance weight for damage and security.
[ ] 4. Inspect ap and ap tracks for security of attachment, damage, condition and corrosion. (See Note 8.)
[ ] 5. Check that fuel tanks contain correct type fuel. Check fuel caps and anti-syphon valves for seal,
damage and operation. Inspect condition of fuel type and fuel capacity placards. Replace if illegible.
[ ] 6. Inspect pneumatic deice boots for condition, leaks and operation.
[ ] 7. Inspect lift transducer for security of attachment, spring centering of switch blade and corrosion. Check
heat element for operation.
[ ] 8. Inspect wing tip navigation, strobe and wing inspection lights for broken lenses, wiring and security.
[ ] 9. Lubricate per Lubrication Chart, 12-20-00.
LANDING GEAR, ROUTINE (See Piper Service Bulletins 822 and 841A.)
L N R (Left, Nose, Right)
[ ] [ ] [ ] 1. Place airplane on jacks. Jack airplane per 7-10-00.
[ ] [ ] [ ] 2. Check oleo struts for leaks, scoring, damage, cleanliness, proper extension and pressure.
[ ] [ ] [ ] 3. Inspect tires for cuts, uneven or excessive wear and slippage.
[ ] [ ] [ ] 4. Remove wheels; clean, inspect and repack bearings.
[ ] [ ] [ ] 5. Clean and inspect wheels for cracks, corrosion and broken or loose bolts.
[ ] [ ] [ ] 6. Check tires for proper pressure per Chart 601.
[ ] [ ] 7. Check brakes and lines for damage, attachment, security and wear limits.
[ ] [ ] [ ] 8. Check gear legs and braces for security, damage, corrosion and condition. (Refer to latest
Piper Service Bulletin No. 841)
[ ] [ ] [ ] 9. Inspect gear doors for security of attachment, cracks, damage and corrosion. (See Note 6.)
[ ] [ ] [ ] 10. Inspect actuating cylinders, lines and ttings for attachment, leaks and damage.
[ ] [ ] [ ] 11. Inspect all hydraulic and pneumatic lines for chang.
[ ] [ ] [ ] 12. Inspect landing gear, emergency gear extension and pneumatic bottles for security of mounting
and proper pressure.
[ ] [ ] [ ] 13. Check emergency gear extension pneumatic system lines, ttings and shuttle valves for
security, leakage and damage.
[ ] [ ] [ ] 14. Inspect condition of up and down lock hooks, springs, pushrods (PA-42) and cables (PA-42-
720) for damage, binding, operation and corrosion. Inspect up and down lock actuating cables
antirotation clips (PA-42-270 Only).
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 9 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B28
May 15, 2012
5-20-00
Page 18
LANDING GEAR, ROUTINE (continued)
NOTE: Inspection items 15 and 16 apply only to PA-42 aircraft, S/Ns 42-7800001 through 42-8001105.
L N R (Left, Nose, Right)
[ ] [ ] [ ] 15. Remove nose gear lock actuator rod assembly and main gear up and down lock actuator rod
assemblies.
[ ] [ ] [ ] (a) Remove boot; inspect telescopic portion of each rod assembly for corrosion. If evident,
replace rod assembly. If no corrosion exists, lubricate per the Lubrication Chart, 12-20-00.
[ ] [ ] [ ] (b) Inspect each rod end bearing for race damage and corrosion. If either is evident, replace
bearing. If no corrosion or evidence of damage exists, lubricate per the Lubrication Chart,
12-20-00.
[ ] [ ] [ ] 16. Install rod assemblies per 32-10-00 and 32-20-00.
[ ] [ ] [ ] 17. Inspect all wiring and wiring harness for condition, security, damage, chang and corrosion.
Check switches for adjustment, security and operation.
[ ] [ ] [ ] 18. Cycle gear. Verify landing gear retracts and extends properly.
[ ] [ ] [ ] 19. Lubricate per Lubrication Chart, 12-20-00.
WARNING: DO NOT REMOVE JACKS UNTIL IT HAS BEEN DETERMINED THAT THE LANDING GEAR
IS DOWN AND LOCKED AND ANTI-RETRACTION SYSTEM HAS BEEN CHECKED.
[ ] [ ] [ ] 20. Place weight of aircraft on landing gear. (Do Not Remove Jacks.)
[ ] [ ] [ ] 21. Check anti-retraction system for proper operation.
[ ] [ ] [ ] 22. Ensure all gears are down and locked, then remove jacks.
SPECIAL INSPECTIONS, AS REQUIRED
[ ] See 5-30-00.
OPERATIONAL INSPECTION
NOTE: Perform the following steps (1)(6) and (8)(9) per the appropriate checklists in Section 4 of the
appropriate Pilots Operating Handbook (POH):
[ ] 1. Preight.
[ ] 2. Before Engine Start.
[ ] 3. Engine Start.
[ ] 4. Before Taxiing.
[ ] 5. Taxi to runup area.
[ ] 6. Engine Runup.
[ ] 7. Perform Ground Operational Check, 21-30-00.
[ ] 8. Taxi back to parking area.
[ ] 9. Shutdown.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 10 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B29
May 15, 2012
5-20-00
Page 19
GENERAL
[ ] 1. Aircraft conforms to FAA Specications.
[ ] 2. Latest revision of applicable FAA Airworthiness Directives complied with and appropriate compliance
record completed.
[ ] 3. Current and correct Pilots Operating Handbook (POH) is in the airplane.
[ ] 4. Check airplane for required placards as identied in Section 2 of the POH.
[ ] 5. Appropriate entries made in the Aircraft and Engine Log books.
[ ] 6. Airworthiness & Registration Certicates in the aircraft and properly displayed.
[ ] 7. Aircraft Equipment List, Weight and Balance and FAA Form(s) 337 (if applicable) are in the aircraft
and in proper order.
[ ] 8. Operational inspection and run-up completed.
[ ] 9. Aircraft cleaned and lubricated after wash (as required).
[ ] 10. Event Inspection Record completed.
[ ] 11. Discrepancy Record completed.
[ ] 12. Equipment Change and Overhaul Record completed.
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 11 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B30
May 15, 2012
5-20-00
Page 20
THIS SPACE INTENTIONALLY BLANK
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 12 of 14)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B31
May 15, 2012
5-20-00
Page 21
INSPECTION COMPLETED
I certify that this aircraft has been inspected in accordance
with PIPER AIRCRAFT 100 Hour Progressive Inspection Event
No. 1, and is approved for return to service. Pertinent details of
this inspection are on le at this facility under:
Repair Order No.
Total Time: Date:
Signed: Repair Station No.:
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 13 of 14)
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1B32
May 15, 2012
5-20-00
Page 22
EVENT INSPECTION WORK SHEET
EVENT #1 (Sheet 14 of 14)
Event #1 Inspection Discrepancy Report
Engine Time
Aircraft Time: Left:
Right:
Date: Work Order No.:
Item No. Discrepancy Corrective Action Mechanic Signature
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C1
May 15, 2012
5-20-00
Page 23
WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN SERVICING OR
INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER AIRCRAFT, MAY RENDER
THE AIRCRAFT UNAIRWORTHY. (SEE MAINTENANCE MANUAL - INTRODUCTION -
SUPPLEMENTARY PUBLICATIONS.)
NOTE: Review Notes 1, 2, 3, and 4, before beginning this event.
PROPELLERS, DETAILED
Left Right
[ ] [ ] 1. Remove and inspect spinner for cracks, corrosion and damage.
[ ] [ ] 2. Inspect blades for nicks, cracks, erosion and evidence of strikes.
[ ] [ ] 3. Check for grease and oil leaks.
[ ] [ ] 4. Inspect bulkhead for cracks, security and corrosion.
[ ] [ ] 5. Inspect propeller mounting bolts for condition and proper safety. Check torque if safety is broken.
[ ] [ ] 6. Inspect hub parts for cracks, corrosion and security.
[ ] [ ] 7. Rotate blades and inspect for tightness.
[ ] [ ] 8. Inspect beta feedback ring for runout (0.010 inch max.) and no metal to metal contact with
reverse lever and carbon block holder.
[ ] [ ] 9. Inspect carbon block for wear limit and freedom of movement.
[ ] [ ] 10. Inspect low pitch stop rods, return springs and beta feedback ring for damage, corrosion and
freedom of movement.
[ ] [ ] 11. Inspect condition of propeller deicer slip ring and brush block or modular brush assembly.
[ ] [ ] 12. Inspect propeller deice boots for security of attachment and condition.
[ ] [ ] 13. Inspect propeller deice wiring and junction blocks for security, cracks, chang and damage.
[ ] [ ] 14. If installed, inspect condition and security of synchrophaser wiring.
[ ] [ ] 15. Lubricate propeller per Lubrication Charts, 12-20-00.
[ ] [ ] 16. Install spinner.
ENGINES, DETAILED
NOTE: Refer to Pratt & Whitney PT6A-41 Maintenance Manual P/N 3021442 or Pratt & Whitney PT6A-61
Maintenance Manual P/N 3034342 as required for details. (See Note 5.)
Left Right
[ ] [ ] 1. Remove engine cowling.
[ ] [ ] 2. Remove upper and lower rewall access covers.
[ ] [ ] 3. Clean and inspect cowling and covers for cracks, distortion and loose or missing fasteners.
[ ] [ ] 4. Inspect oil temperature sender unit for leaks and security.
[ ] [ ] 5. Inspect oil lines and ttings for leaks, security, chang, dents, cracks and routing.
[ ] [ ] 6. Clean and inspect oil cooler for condition and attachment.
[ ] [ ] 7. Remove and inspect oil lter for damage and contamination Clean or replace as required.
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 1 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C2
May 15, 2012
5-20-00
Page 24
ENGINES, DETAILED (continued)
CAUTION: ALL ENGINE CLEANING PROCEDURES AND CLEANING PRECAUTIONS MUST
BE OBTAINED FROM THE APPROPRIATE SECTIONS OF THE PRATT & WHITNEY
MAINTENANCE MANUAL (PT6A-61) P/N 3034342 OR (PT6A-41) P/N 3021442.
Left Right
[ ] [ ] 8. Clean exterior of engine.
[ ] [ ] 9. Inspect condition of igniter plugs.
[ ] [ ] 10. Inspect ignition harness and insulators for high tension leakage, continuity, damage and
attachment.
[ ] [ ] 11. Inspect electrical connections on ignition exciter for safety and security.
[ ] [ ] 12. Remove air inlet screen; inspect rst stage compressor blades for ingestion damage and
corrosion. Inspect screen for damage and cleanliness. Install screen.
[ ] [ ] 13. Clean and inspect fuel pump inlet screen for foreign material. Replace outlet lter.
[ ] [ ] 14. Inspect gas generator case drain valves for security and leaks. (Check after engine run.)
[ ] [ ] 15. Inspect magnetic chip detector and jump pins A & B operational check of annunciator.
[ ] [ ] 16. Inspect condition of inlet air ducts and ice protection system for operation and t. (See latest
Piper Service Letter No. 983.)
[ ] [ ] 17. Inspect condition of actuators and linkage for ice protection system and oil cooler doors.
CAUTION: WHEN ENGINE IS NOT RUNNING, ANY ATTEMPT TO MOVE POWER LEVERS INTO
REVERSE POSITION, WITHOUT DISCONNECTING PROPELLER PUSH-PULL WIRE
ROPE CLEVIS FROM PROPELLER CONTROL CAM, WILL RESULT IN BENDING OR
KINKING OF WIRE ROPE.
[ ] [ ] 18. Inspect power lever, start control, propeller governor and propeller reversing linkage for
condition, travel and operation.
[ ] [ ] 19. Inspect gas generator case for cracks, distortion and evidence of overheating.
[ ] [ ] 20. Inspect exhaust stacks and exhaust ducts for cracks, distortion and security.
[ ] [ ] 21. Inspect propeller governor for leaks and security.
[ ] [ ] 22. Inspect propeller shaft for oil leaks.
[ ] [ ] 23. Remove drain; clean and inspect fuel lter bowl and element. (Firewall mounted.)
[ ] [ ] 24. Inspect all exible lines (fuel, hydraulic, pneumatic and oil) for leaks, abrasions, cuts and secure
connections. Replace upon condition. (See latest Piper Service Bulletin No. 822.)
[ ] [ ] 25. Inspect fuel control, fuel pumps, fuel manifold, fuel ow transmitter and fuel pressure transmitter
for leaks, security and condition. Check wiring for security and condition. (See latest revision
of Piper Service Bulletin 957.)
[ ] [ ] 26. Replace hydraulic lter and inspect for contamination. If lter shows evidence of contamination,
inspect entire hydraulic system.
[ ] [ ] 27. Inspect hydraulic pump and hydraulic lines for security and leaks.
[ ] [ ] 28. Inspect engine reseals for cracks, damage and security.
[ ] [ ] 29. Inspect rewalls for cracks, stress and condition.
[ ] [ ] 30. Inspect rewall seals for condition.
[ ] [ ] 31. Inspect oil breather tube for obstruction and security.
[ ] [ ] 32. Inspect oil ller cap seal for damage and condition.
[ ] [ ] 33. Check proper locking feature of oil ller cap.
[ ] [ ] 34. Inspect oil pressure transmitter for security and leaks. Check wires for connection and damage.
[ ] [ ] 35. Inspect torque transmitter for leaks and security. Check wiring for damage and security. Check
condition of shock mounts.
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 2 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C3
May 15, 2012
5-20-00
Page 25
Left Right
[ ] [ ] 36. Inspect oil manifold for leaks and security.
[ ] [ ] 37. Inspect autoignition switch, autofeather switch and manifold for security and condition. Check
wiring for damage and secure connection.
NOTE: An autofeathering system is an optional system on the PA-42 Cheyenne III aircraft.
[ ] [ ] 38. Inspect P3 air lter for contamination. Replace if evidence of contamination.
[ ] [ ] 39. Inspect re extinguisher for damage and security of wiring. Test re extinguishing system for
proper cylinder pressure.
NOTE: Engine re extinguishers are optional equipment and are not installed on all PA-42 and PA-42-720.
[ ] [ ] 40. Inspect re warning sensors and wiring for security and condition.
[ ] [ ] 41. Inspect compressor wash ring for damage and security.
[ ] [ ] 42. Inspect compressor wash valve assembly for security and operation. (if installed)
[ ] [ ] 43. Inspect engine mounts for cracks, damage and loose mounting bolts.
[ ] [ ] 44. Inspect rubber Lord mounts for deterioration and condition.
[ ] [ ] 45. Check security, wiring and operation of blade angle sensor or beta lights, if installed.
[ ] [ ] 46. Check security, wiring and operation of beta limiter system.
[ ] [ ] 47. Inspect front and rear tachometer generators for security and wiring.
[ ] [ ] 48. Inspect starter generator quick attachment device (QAD) ring and mount pad for security,
cracks and damage.
[ ] [ ] 49. Inspect condition of starter-generator cables.
[ ] [ ] 50. Inspect condition of starter-generator cooling air ducts.
[ ] [ ] 51. In PA-42-720 airplanes only, inspect starter-generator brushes and commutator for wear,
condition, and security.
[ ] [ ] 52. Clean dual drive lube lter.
[ ] [ ] 53. Inspect generator control units (GCU) for security, damage and wiring integrity.
[ ] [ ] 54. Inspect bleed air lines, exible lines and couplings for security, damage and leakage. (Also see
Piper Service Bulletin No. 914).
[ ] [ ] 55. Check bleed air shutoff valve and mixing regulator for security, damage, leakage and correct
operation. Check wiring for attachment and damage.
[ ] [ ] 56. Inspect bleed air intercooler for cleanness and blockage. Check intercooler inlet and outlet for
blockage, security and leakage of duct couplings.
[ ] [ ] 57. Inspect and check all engine wiring and ITT harness and connectors for security and condition.
[ ] [ ] 58. Lubricate power plant per Lubrication Chart, 12-20-00.
[ ] [ ] 59. Install upper and lower rewall access covers.
[ ] [ ] 60. Install engine cowling.
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 3 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C4
May 15, 2012
5-20-00
Page 26
CABIN COCKPIT, ROUTINE
[ ] 1. Inspect cockpit seats, seat belts and shoulder harness, upholstery and curtains for tears, damage
and operation.
[ ] 2. Inspect instruments, instrument panel and circuit breakers for damage, condition and operation.
[ ] 3. Inspect cockpit, navigation, strobe and recognition lighting for damage, corrosion and operation.
[ ] 4. Perform main bus tie circuit breaker and distribution diodes check per Testing, 39-10-00.
WARNING: BE SURE SKIN AND CLOTHING ARE FREE OF GREASE, OIL, GASOLINE OR OTHER
PETROLEUM PRODUCTS BEFORE CHECKING OR PERFORMING MAINTENANCE ON
ANY COMPONENT OF THE OXYGEN SYSTEM.
[ ] 5. Check oxygen masks for damage, condition and proper attachment to outlets.
NOTE: Operation of oxygen shutoff valve on PA-42-720 aircraft will deploy all oxygen masks.
[ ] 6. Check rudder pedals, control column and control wheel for damage and operation.
[ ] 7. Lubricate per Lubrication Chart, 12-20-00.
FUSELAGE FORWARD, ROUTINE
[ ] 1. Inspect baggage door surface, door latch mechanism, door ajar switches, light switches and door seal
for damage, condition and operation.
[ ] 2. Check radome for condition, security and latching mechanism for operation.
[ ] 3. Check battery and battery case for damage and corrosion. Check battery contactors, cables, fuses,
solenoids and wiring for condition, corrosion, security and damage.
[ ] 4. Check avionics installation for security and condition.
[ ] 5. If equipped, check electrical outside air temperature probe for corrosion, damage and secure mounting.
Inspect condition and security of wiring.
[ ] 6. Check brake reservoir and hydraulic power pack for leaks, condition, damage and uid level. Service
as required.
[ ] 7. Inspect surfaces, skins and panels for loose or missing rivets, condition and damage.
[ ] 8. Lubricate per Lubrication Chart, 12-20-00.
FUSELAGE MAIN, ROUTINE
[ ] 1. Inspect external skins and fairings for missing rivets, damage, condition and corrosion.
[ ] 2. Check all windows for cracks, distortion and condition.
[ ] 3. Inspect cabin entrance door and emergency exit for damage, condition and operation. If applicable,
inspect cargo door for damage, condition and operation.
[ ] 4. Check bimetallic outside air temperature probe (OAT) for corrosion, damage and secure mounting.
[ ] 5. Inspect strobe lights for broken lenses and security.
[ ] 6. Check upholstery for damage and seats for operation, condition and damage.
[ ] 7. Check seat belts for condition, security and operation.
WARNING: BE SURE SKIN AND CLOTHING ARE FREE OF GREASE, OIL, GASOLINE OR OTHER
PETROLEUM PRODUCTS BEFORE CHECKING OR PERFORMING MAINTENANCE ON
ANY COMPONENT OF THE OXYGEN SYSTEM.
[ ] 8. Check oxygen masks for condition and damage, that masks are properly connected to outlets.
[ ] 9. Check outow and safety valve screen for damage and obstruction.
[ ] 10. Check cabinetry, consoles and dividers for damage and security.
[ ] 11. Check all lights and air vents for damage and operation.
[ ] 12. Lubricate per Lubrication Chart, 12-20-00.
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 4 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C5
May 15, 2012
5-20-00
Page 27
FUSELAGE AFT AND EMPENNAGE, ROUTINE
[ ] 1. Inspect skins, fairings, vertical n, rudder, horizontal stabilizer, elevator and tabs for damage, loose or
missing rivets, corrosion and condition.
CAUTION: TO PREVENT WATER DAMAGE TO VENTRAL FIN KEVLAR MATERIAL, THE EDGE OF
EACH VENTRAL FIN DRAIN HOLE IS SEALED WITH EPOXY RESIN. IF NECESSARY TO
OPEN VENTRAL FIN DRAIN HOLES, CARE SHOULD BE TAKEN NOT TO BREAK SEAL. IF
SEAL IS BROKEN, REFER TO CHAPTER 51 FOR PROCEDURE USED TO APPLY EPOXY
RESIN.
[ ] 2. Check ventral n drain holes are open and free of foreign matter. (See latest Piper Service Bulletin
857.)
[ ] 3. Inspect rudder, rudder tab, elevator, elevator tabs, hinges, bolts and attachments for damage, wear,
security and operation.
[ ] 4. Inspect pneumatic deice boots for damage, security and condition.
[ ] 5. Check antennas for security and condition.
[ ] 6. Inspect static ports for obstructions and condition.
[ ] 7. Inspect tail navigation lights, strobe lights and logo lights for broken lenses, corrosion and security.
[ ] 8. Lubricate per Lubrication Chart, 12-20-00.
[ ] 9. Install inspection plates and access panels.
LEFT WING, ROUTINE
[ ] 1. Check surfaces, skins, tip tank and fairings for damage, condition, loose or missing rivets.
[ ] 2. Inspect aileron and trim tab attachments for security, damage and operation. (See Note 7.)
[ ] 3. Inspect aileron balance weight for damage and security.
[ ] 4. Inspect ap and ap tracks for security of attachment, damage, condition and corrosion. (See Note 8.)
[ ] 5. Check that fuel tanks contain correct type fuel. Check fuel caps and anti-syphon valves for seal,
damage and operation. Inspect condition of fuel type and fuel capacity placards. Replace if illegible.
[ ] 6. Inspect pneumatic deice boots for condition, leaks and operation.
[ ] 7. Inspect lift transducer for security of attachment, spring centering of switch blade and corrosion. Check
heat element for operation.
[ ] 8. Inspect wing tip navigation, strobe and wing inspection lights for broken lenses, wiring and security.
[ ] 9. Lubricate per Lubrication Chart, 12-20-00.
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 5 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C6
May 15, 2012
5-20-00
Page 28
RIGHT WING, DETAILED
CAUTION: THE FLUX DETECTOR COVER ON THE OUTBOARD WING SURFACE IS SECURED
WITH BRASS SCREWS. ONLY BRASS SCREWS WILL BE USED WHEN INSTALLING THIS
COVER.
[ ] 1. Remove inspection plates and panels.
[ ] 2. Inspect static discharge wicks for security of attachment and condition.
[ ] 3. Inspect ux detector plug connections and wiring for corrosion, security and condition.
[ ] 4. Inspect wing and control surface skins and fairings for cracks, loose or missing rivets and damage.
[ ] 5. Inspect aileron for security of attachment and freedom of movement. (See Note 7.)
[ ] 6. Inspect interior structure for cracks, loose and missing rivets or concealed damage.
[ ] 7. Inspect aileron cables, pulleys and bellcrank for damage, full travel, alignment, clearance and proper
cable tension.
[ ] 8. Inspect aileron balance weights and aileron gap seal for condition and security.
[ ] 9. Inspect aps, actuators, limit switches, wiring and pots for corrosion, damage, operation and full
travel. (See Note 8.)
NOTE: An approach ap extension of 10 will not activate the Flap/Landing Gear Warning Horn since this
ap setting is intended for extended approach use. Normal landings are made using 30 aps and
the Flap/Landing Gear Warning Horn will activate if the landing gear is not extended when the
aps are extended more than 10.
[ ] 10. Inspect ap tracks and rollers for condition. Check rollers for freedom of movement and binding.
[ ] 11. Inspect ap track bolts and aileron hinge bolts for wear, security and corrosion.
[ ] 12. Inspect all control surface bearings for attachment, wear and freedom of movement.
[ ] 13. Check operation of left fuel shutoff valve and crossfeed valve.
[ ] 14. Inspect wing attachment bolts for stripe alignment and brackets for cracks and corrosion.
[ ] 15. Inspect engine mount brackets for condition and security.
[ ] 16. Inspect bladder fuel cells for attachment, leaks and contamination.
[ ] 17. Inspect integral fuel tanks for leaks, corrosion, contamination and damage.
[ ] 18. Inspect fuel lines for attachment, chang and leaks.
[ ] 19. Check ller neck anti-siphon valves and fuel caps for damage and proper seal. Inspect quick drains
for proper operation.
[ ] 20. Check fuel tanks for correct operating fuel. Check condition of fuel type placards.
[ ] 21. Inspect fuel vents for obstructions and damage. Check valves for operation and seal.
[ ] 22. Inspect fuel capacity probes for security, corrosion and leaks.
[ ] 23. Inspect electrical wiring harness and connections for chang, damage and security.
[ ] 24. Inspect hydraulic lines for leaks, damage or chang and attachment.
[ ] 25. Inspect pneumatic lines, exible lines and components for leaks, cuts, abrasions and secure
connections. Replace upon condition.
[ ] 26. Inspect bleed air warning duct switches for leaks and security and wiring for damage and attachment.
(PA-42: (engine, intercooler, shroud aft of rewall and wing root), PA-42-720: (Engine, intercooler and
wing root).
[ ] 27. Inspect bleed air duct coupling for leakage, damage and security. Check duct insulation for condition
and security. Check ducting for security and chang.
[ ] 28. Inspect pneumatic deicer boots for condition and damage.
[ ] 29. Inspect left transducer for security of attachment, spring centering of switch blade and corrosion.
check heat element for operation.
[ ] 30. Inspect wing tip tank attachment bolts for security.
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 6 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C7
May 15, 2012
5-20-00
Page 29
[ ] 31. Inspect wing tip navigation and strobe lights for broken lenses, security, wiring and attachment.
[ ] 32. Check wing inspection light for broken lens, security, wiring and attachment.
[ ] 33. Inspect wing lockers for condition, leaks and damage.
[ ] 34. Inspect wing locker door for security and damage.
[ ] 35. Check wing locker door cylinder and lock for security, damage and operation.
[ ] 36. Inspect nacelle fuel tank for condition, leaks and damage. Check condition of fuel type and capacity
placards. Replace if illegible.
[ ] 37. Lubricate per Lubrication Chart, 12-20-00.
CAUTION: ONLY BRASS SCREWS ARE TO BE USED FOR INSTALLING FLUX DETECTOR ACCESS
DOOR.
[ ] 38. Install inspection plates and panels.
LANDING GEAR, DETAILED (See Piper Service Bulletins 822 and 841A.)
L N R (Left, Nose, Right)
[ ] [ ] [ ] 1. Place airplane on jacks. Jack airplane per 7-10-00.
[ ] [ ] [ ] 2. Check oleo struts for leaks, scoring, damage, cleanliness, proper extension and pressure.
[ ] [ ] [ ] 3. Inspect tires for cuts, uneven or excessive wear and slippage.
[ ] [ ] [ ] 4. Remove wheels; clean, inspect and repack bearings.
[ ] [ ] [ ] 5. Clean and inspect wheels for cracks, corrosion and broken or loose bolts.
[ ] [ ] [ ] 6. Check tires for proper pressure per Chart 601.
[ ] [ ] 7. Check brake linings and discs for cracks, uneven wear, distortion and wear limits.
[ ] [ ] [ ] 8. Clean and inspect gear legs, nose gear fork and axles for security, damage, cracks, nicks,
corrosion and condition. (Refer to latest Piper Service Bulletin No. 841)
[ ] [ ] [ ] 9. Inspect gear doors for security of attachment, cracks, damage and corrosion. (See Note 6.)
[ ] [ ] [ ] 10. Inspect actuating cylinders, lines and ttings for attachment, leaks and damage.
[ ] [ ] [ ] 11. Inspect all hydraulic and pneumatic lines for chang.
[ ] [ ] [ ] 12. Inspect emergency gear extension pneumatic bottles for security of mounting and proper
pressure.
[ ] [ ] [ ] 13. Check emergency gear extension pneumatic system lines, ttings, shuttle valves and linkage
for security, leakage, damage and proper adjustment.
WARNING: WIRES MUST BE REMOVED FROM SQUIB PRIOR TO CONTINUITY CHECK.
[ ] [ ] [ ] 14. Check emergency air bottle squib wiring for continuity.
NOTE: Inspection items 16 and 17 apply only to PA-42 aircraft, S/Ns 42-7800001 through 42-8001105.
[ ] [ ] [ ] 15. Remove nose gear lock actuator rod assembly and main gear up and down lock actuator rod
assemblies.
[ ] [ ] [ ] (a) Remove boot; inspect telescopic portion of each rod assembly for corrosion. If evident,
replace rod assembly. If no corrosion exists, lubricate per Lubrication Chart, 12-20-00.
[ ] [ ] [ ] (b) Inspect each rod end bearing for race damage and corrosion. If either is evident, replace
bearing. If no corrosion or evidence of damage exists, lubricate per Lubrication Chart,
12-20-00.
[ ] [ ] [ ] 16. Install rod assemblies per 32-10-00 and 32-20-00.
[ ] [ ] [ ] 17. Inspect condition of up and down lock hooks, springs, pushrods (PA-42) and cables (PA-42-
720) for damage, binding, operation and corrosion. Inspect up and down lock actuating cables
antirotation clips (PA-42-270 only).
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 7 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C8
May 15, 2012
5-20-00
Page 30
LANDING GEAR, DETAILED (continued)
L N R (Left, Nose, Right)
[ ] [ ] 18. Inspect brake housings for cracks, leaks, attachment and damage.
[ ] [ ] 19. Inspect brake hydraulic lines for security, chang, damage and leaks.
[ ] 20. Inspect shimmy dampener for security, damage, corrosion and leaks.
[ ] 21. Check nose gear steering and mechanism for wear, binding, freedom of operation and full
travel.
[ ] [ ] [ ] 22. Inspect gear doors and attachments for security, cracks, loose or missing rivets, condition and
damage.
[ ] [ ] [ ] 23. Inspect actuating cylinders and lines for leaks, damage, corrosion, scoring and security.
[ ] [ ] [ ] 24. Inspect all wiring and wiring harness for condition, security, damage, chang and corrosion.
Check switches for adjustment, security and operation.
[ ] [ ] [ ] 25. Cycle gear. Verify landing gear retracts and extends properly.
[ ] [ ] [ ] 26. Lubricate per Lubrication Chart, 12-20-00.
WARNING: DO NOT REMOVE JACKS UNTIL IT HAS BEEN DETERMINED THAT THE LANDING GEAR
IS DOWN AND LOCKED AND ANTI-RETRACTION SYSTEM HAS BEEN CHECKED.
[ ] [ ] [ ] 27. Place weight of aircraft on landing gear. (Do Not Remove Jacks.)
[ ] [ ] [ ] 28. Check anti-retraction system for proper operation.
[ ] [ ] [ ] 29. Ensure all gears are down and locked, then remove jacks.
SPECIAL INSPECTIONS, AS REQUIRED
[ ] See 5-30-00.
OPERATIONAL INSPECTION
NOTE: Perform the following steps (1)(6) and (8)(9) per the appropriate checklists in Section 4 of the
appropriate Pilots Operating Handbook (POH):
[ ] 1. Preight.
[ ] 2. Before Engine Start.
[ ] 3. Engine Start.
[ ] 4. Before Taxiing.
[ ] 5. Taxi to runup area.
[ ] 6. Engine Runup.
[ ] 7. Perform Ground Operational Check, 21-30-00.
[ ] 8. Taxi back to parking area.
[ ] 9. Shutdown.
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 8 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C9
May 15, 2012
5-20-00
Page 31
GENERAL
[ ] 1. Aircraft conforms to FAA Specications.
[ ] 2. Latest revision of applicable FAA Airworthiness Directives complied with and appropriate compliance
record completed.
[ ] 3. Current and correct Pilots Operating Handbook (POH) is in the airplane.
[ ] 4. Check airplane for required placards as identied in Section 2 of the POH.
[ ] 5. Appropriate entries made in the Aircraft and Engine Log books.
[ ] 6. Airworthiness & Registration Certicates in the aircraft and properly displayed.
[ ] 7. Aircraft Equipment List, Weight and Balance and FAA Form(s) 337 (if applicable) are in the aircraft
and in proper order.
[ ] 8. Operational inspection and run-up completed.
[ ] 9. Aircraft cleaned and lubricated after wash (as required).
[ ] 10. Event Inspection Record completed.
[ ] 11. Discrepancy Record completed.
[ ] 12. Equipment Change and Overhaul Record completed.
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 9 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C10
May 15, 2012
5-20-00
Page 32
THIS SPACE INTENTIONALLY BLANK
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 10 of 12)
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C11
May 15, 2012
5-20-00
Page 33
INSPECTION COMPLETED
I certify that this aircraft has been inspected in accordance
with PIPER AIRCRAFT 100 Hour Progressive Inspection Event
No. 2, and is approved for return to service. Pertinent details of
this inspection are on le at this facility under:
Repair Order No.
Total Time: Date:
Signed: Repair Station No.:
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 11 of 12)
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C12
May 15, 2012
5-20-00
Page 34
EVENT INSPECTION WORK SHEET
EVENT #2 (Sheet 12 of 12)
Event #2 Inspection Discrepancy Report
Engine Time
Aircraft Time: Left:
Right:
Date: Work Order No.:
Item No. Discrepancy Corrective Action Mechanic Signature
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C13
May 15, 2012
5-20-00
Page 35
NOTES
1. Refer to Pipers Customer Service Information File P/N 1753-755 (available online at http://pubs.piper.
com) for latest revision dates to Piper Inspection Manuals and this maintenance manual. References to
Chapter or Section are to the appropriate Chapter or Section in this manual.
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.
2. Inspections or operations are to be performed as indicated in each 100 hour inspection event. Inspections
or operations (i.e. - component overhauls/replacements, etc.) required outside the 100 hour cycle are listed
as special inspections in section 5-30-00. Inspections must be accomplished by persons authorized by the
FAA or appropriate National Aviation Authority.
A. The routine inspection accomplishes preventive maintenance, lubrication and servicing as well as
inspecting critical components.
B. The detailed inspection is a complete inspection of the indicated inspection group.
NOTE: A log book entry should be made upon completion of any inspections.
3. Piper Service Bulletins are of special importance and Piper considers compliance mandatory. In all cases,
see Service Bulletin/Service Letter Index P/N 762-332 (available online at http://pubs.piper.com) to verify
latest revision.
4. Piper Service Letters are product improvements and service hints pertaining to servicing the airplane and
should be given careful attention.
5. Inspections given for the power plants are based on the appropriate engine manufacturers maintenance
manual for these airplanes. Any changes issued to the engine manufacturers maintenance manual shall
supersede or supplement the inspections outlined in this report.
6. Inspect main landing gear inboard door hinges for cracks, with a 10X magnifying glass.
7. In airplanes which have not yet replaced original equipment aileron inboard hinge brackets (W.S. 174.5)
with the improved aileron inboard hinge brackets P/Ns 74461-002 (left) and 74461-003 (right), remove left
and right ailerons and inspect per Piper Service Bulletin No. 967. See also AD96-21-03.
8. In airplanes with flap transmissions which have accumulated 500 hours time-in-service, inspect flap
transmission per the inspections in 27-50-00.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C14
May 15, 2012
5-20-00
Page 36
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C15
May 15, 2012
5-20-00
Page 37
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PROGRAM RESPONSIBILITY
The person responsible for scheduling the inspections required under this program must enter his or her
name below and forward the original copy of this form to their local FAA-FSDO office. A duplicate copy
should be maintained in this manual.
Name:
Address:
City: State: Zip:
Telephone Number:
Any change in personnel responsible for scheduling the inspection program, will be added with the
appropriate information on a separate sheet of paper and the original copy sent to the local FAA-FSDO
office, while a duplicate copy is attached behind this page. The previous information sheet will be left in the
booklet and the word CHANGED will be written across the deleted information.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C16
May 15, 2012
5-20-00
Page 38
THIS PAGE INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C17
May 15, 2012
5-20-00
Page 39
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
REVISIONS
Revisions to this Inspection Program are the direct responsibility of the manufacturer. However, owners/
operators with an F.A.A.-approved Part 91 Progressive Inspection Program or a Part 135 Approved Aircraft
Inspection Program may not enact any such revisions until approval is obtained from the responsible F.A.A.
District Office. A permanent record of revisions and F.A.A. approvals will be maintained by the owner/
operator.
RECORD OF REVISIONS
REV. NO. FAA APPROVAL DATE PAGE NO. INSERTED BY/DATE
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C18
May 15, 2012
5-20-00
Page 40
THIS PAGE INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C19
May 15, 2012
5-20-00
Page 41
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
EVENT INSPECTION RECORD
1. Proper inspection procedures are the responsibility of the individuals performing the inspection and must
be made in accordance with all applicable current Federal Aviation Regulations and Piper Maintenance
Manuals and Publications.
2. Work order column is applicable only to FAA approved repair stations.
3. Always check for and use only current information.
4. The signatures below signify that this aircraft has been thoroughly inspected and found airworthy in
accordance with applicable and current FARs, Piper Maintenance Manual and Service Publications
(including Service Bulletins and Mandatory Service Letters). Further, the signatures verify that all
appropriate entries have been made in Aircraft and Engine Logbooks and Progressive Inspection
Program Records (i.e. - Event Inspection Record, Progressive Inspection Cycle Record, Discrepancy
Record, Service Publication Compliance Record, FAA AD Compliance Record, and Equipment Change
and Overhaul Record).
EVENT No. A/C HOURS DATE W.O. No. SIGNATURE - CERTIFICATE No.
1 100 HR
2 200 HR
1 300 HR
2 400 HR
1 500 HR
2 600 HR
1 700 HR
2 800 HR
1 900 HR
2 1000 HR
1 1100 HR
2 1200 HR
1 1300 HR
2 1400 HR
1 1500 HR
2 1600 HR
1 1700 HR
2 1800 HR
1 1900 HR
2 2000 HR
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C20
May 15, 2012
5-20-00
Page 42
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C21
May 15, 2012
5-20-00
Page 43
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PROGRESSIVE INSPECTION CYCLE RECORD
1. Current and correct FAA Pilots Operating Handbook is in the aircraft.
2. Aircraft and Engine Logbooks are in the aircraft and appropriate entries made in these logbooks.
3. Registration certificate is in the aircraft and properly displayed.
4. Airworthiness certificate in aircraft and properly displayed.
5. Aircraft Equipment List, Weight and Balance and FAA Form 337 (if applicable) are in the aircraft and in
proper order.
6. Applicable FAA Airworthiness Directives are complied with.
7. Piper Progressive Inspection Records in order and properly signed off.
8. Outstanding conditions have been corrected as listed on condition record.
CYCLE No. DATE A/C HOURS REMARKS SIGNATURE - CERTIFICATE No.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C22
May 15, 2012
5-20-00
Page 44
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AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
DISCREPANCY RECORD
DISCREPANCY A/C SIGNATURE DATE CORRECTIVE ACTION W.O.# SIGNATURE AND DATE
HOURS CERTIFICATE NO.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C24
May 15, 2012
5-20-00
Page 46
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AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
SERVICE PUBLICATION
COMPLIANCE RECORD
MANUFACTURER PUBLICATION NUMBER COMPLIANCE A/C W.O.# SIGNATURE AND CERTIFICATE NO.
DATE HOURS
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C26
May 15, 2012
5-20-00
Page 48
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M
A
N
U
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1
C
2
7
M
a
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1
5
,

2
0
1
2
5
-
2
0
-
0
0
P
a
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e

4
9
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
FAA AIRWORTHINESS
DIRECTIVE (AD)
COMPLIANCE RECORD
ONE TIME RECURRING
AD AD A/C METHOD OF DATE / TIME W.O.# SIGNATURE AND CERTIFICATE NO.
NUMBER DATE HOURS COMPLIANCE NEXT DUE
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C28
May 15, 2012
5-20-00
Page 50
THIS PAGE INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C29
May 15, 2012
5-20-00
Page 51
NICKEL-CADMIUM BATTERY SERVICE RECORD
BATTERY TYPE RATED CAPACTY (C): Ah CHARGE RATES
SERIAL NO. MINIMUM ALLOWABLE CELL
INSTALLATION DATE CAPACITY (0.85 x C): Ah C/2 AMPS
AIRCRAFT *ALLOWABLE WATER CONSUMPTION Cm
3
AMPS C/10
SERVICE IN ACCORDANCE WITH AIRFRAME SERVICE/MAINTENANCE MANUAL
Condition From Aircraft Charge and Water Consumption Data
Cell End of Distilled Water Cell Remarks
Removal Reason Hours Minimum Charge Voltage Added to Cells to
Dates for Since Visual Cell Battery Case
Removal Serviced Capacity Capacity Insul.
(CA) (CB) AVG Max./Cell Min./Cell AVG Max./Cell Min./Cell
No. No. No. No.
NOTE
Number cells by starting with the cell connected *If the quantity of water added during maintenance is greater than that indicated,
to the negative battery terminal and proceeding it is recommended that a check be made of charge voltage with reference to
sequentially as the cells are connected in series temperature. If necessary, shorten interval between maintenance.
to the positive battery terminal.
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C30
May 15, 2012
5-20-00
Page 52
THIS PAGE INTENTIONALLY BLANK
P
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P
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3
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
EQUIPMENT CHANGE
AND OVERHAUL
RECORD
DATE A/C REMOVED PART NO. SERIAL INSTALLED PART NO. SERIAL SIGNATURE AND CERTIFICATE NO.
HOURS NUMBER NUMBER
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1C32
May 15, 2012
5-20-00
Page 54
THIS PAGE INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D1
May 15, 2012
5-30-00
Page 1
WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN
SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER
AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION
- SUPPLEMENTARY PUBLICATIONS.)
The following inspections are required in addition to those listed in the Progressive Inspection Program
(i.e. - 5-20-00). These inspections are required at intervals of:
Q Engine Cycles;
Q Flight hours;
Q Calendar Year; or
Q the specific operation being conducted or the environment being operated in.
Unless otherwise indicated, these inspections are to be repeated at each occurrence of the specified interval.
Note that the items listed herein are guidelines based on past operating experience. Each operator should
closely monitor his own unique operating conditions/environment and react accordingly to keep his aircraft
airworthy.
NOTE: A log book entry should be made upon completion of any inspections.
1. Per Engine Cycle
[ ] See latest revision of Pratt & Whitney Canada Service Bulletin No. 3002 or 13002 for PT6A-41
or PT6A-61 Rotor Components Service Life Limits, respectively.
NOTE: A complete engine cycle is dened as engine start, idle, takeoff, ight, landing, idle,
and shutdown. Many aircraft operations involve partial engine cycles (i.e. - idle, takeoff,
ight, landing, idle) that, with the application of an appropriate formula (see appropriate
P&WC Service Bulletin, above), are also factored into the calculation of service life
limits.
The owner/operator is responsible for recording and calculating life limiting cycles.
2. Per Flight Hour
A. First 100 Hours
[ ] (1) At the rst 100 hour inspection after installation of a new battery, deep cycle of the battery
is recommended. At the second 100 hour inspection another deep cycle is recommended.
Subsequent intervals of battery deep cycle checks are dependent on service and operating
conditions.
NOTE: A battery log is provided for recording battery condition.
SPECIAL INSPECTIONS WORK SHEET
(Sheet 1 of 10)
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D2
May 15, 2012
5-30-00
Page 2
SPECIAL INSPECTIONS WORK SHEET
(Sheet 2 of 10)
A. First 100 Hours (cont.)
[ ] (2) At rst 100 hours after receipt of new aircraft or new or overhauled engines a ow check of
the fuel nozzles is recommended.
[ ] (3) At rst 100 hours after receipt of new aircraft or new or overhauled engines, re-torque
engine mount bolts.
B. Each 200 Hours
[ ] For airplanes equipped with main gear retraction arms (P/N 42042-002) which have
accumulated 1,500 hours time-in-service, inspect the main gear retraction arms per Piper
Service Letter No. 1192B.
C. Each 250 Hours
[ ] In PA-42 airplanes only, inspect starter-generator brushes and commutator for wear,
condition, and security.
D. Each 300 Hours
[ ] (1) Inspect and check fuel nozzles for ow, leaks, damage and condition. (Refer to Pratt &
Whitney Maintenance Manual (PT6A-61) P/N 3034342 or (PT6A-41) P/N 3021442.)
WARNING: DO NOT PERMIT OIL, GREASE OR OTHER PETROLEUM PRODUCTS TO COME
IN CONTACT WITH ANY LINES OR FITTINGS UTILIZED IN THE OXYGEN
SYSTEM. BE SURE SKIN AND CLOTHING ARE FREE OF OIL, GREASE,
GASOLINE OR OTHER PETROLEUM PRODUCTS BEFORE WORKING ON ANY
COMPONENTS OF THE OXYGEN SYSTEM.
[ ] (2) Inspect oxygen cylinder pressure regulator for condition and operation.
[ ] (3) Clean water separator coalescer.
[ ] (4) Re-torque engine mount bolts.
E. Each 500 Hours
[ ] (1) Inspect static system drain assembly for corrosion.
[ ] (2) Inspect water aspirator nozzle and hose for condition.
[ ] (3) Inspect fuel quantity indication system for proper calibration.
[ ] (4) Inspect and clean engine oil scavenge screen on reduction gear box.
[ ] (5) Replace the vacuum system inlet air lter (i.e., central air lter, gyro lter, etc.) element
each 500 hours time-in-service, annually, or at vacuum pump replacement, whichever
comes rst.
[ ] (6) In PA-42 airplanes only, replace starter-generator brushes.
[ ] (7) Repack oil cooler exhaust door transmission 75% full with Dukes actuator grease (Dukes
P/N 2196-74-1).
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D3
May 15, 2012
5-30-00
Page 3
SPECIAL INSPECTIONS WORK SHEET
(Sheet 3 of 10)
F. Each 1,000 Hours
[ ] (1) Overhaul or replace starter generators.
[ ] (2) Replace compressor P3 air lter.
[ ] (3) Replace engine main oil lter element.
[ ] (4) In airplanes which have not complied with Piper Service Bulletin No. 888, inspect rudder
pedal torque tube brackets for cracks. Replace upon condition.
[ ] (5) Replace engine compartment exible fuel and oil hoses as required; but not to exceed 1000
hours time-in-service, eight (8) years, or engine overhaul, whichever comes rst; except for
TSO-C53a - Type D hoses which are replaced on-condition.
[ ] (6) For other hoses, inspect as follows each 1,000 hours:
[ ] (a) Pressurize the exible fuel lines with the fuel boost pump operating.
NOTE: Place the condition lever in the stop position prior to using the boost pump for fuel
system pressurization.
[ ] (b) Examine the hose exterior for evidence of leakage or wetness.
[ ] (c) Inspect for discoloration of the hoses and/or color bleaching of the end ttings.
[ ] (d) Check the hoses for evidence of stiffness.
[ ] (e) Replace any exible hoses which are found leaking or which show a notable amount
of stiffness.
[ ] (f) During reinstallation of exible hose assemblies:
[ ] a) Ensure the hose is not twisted. High pressures applied to a twisted hose can
cause failure of the hose or loosening of the B-nut.
[ ] b) Do not attempt to straighten a hose having a bend in it as this could result in
damage to the hose. Rubber hoses will take a permanent set during extended
service periods. Care should also be taken during removal and reinstallation
of such hoses to assure they are not bent excessively and that they are returned
to their original position.
[ ] (7) Inspect acrylic windows per Chapter 56.
[ ] (8) Inspect main landing gear inboard door hinges for cracks, using a dye penetrant method of
inspection.
[ ] (9) For airplanes which have not yet replaced the original equipment inboard aileron hinge
bracket (P/Ns 40110-002 / -003) with the improved inboard aileron hinge bracket (P/Ns
74461-002 / -003), replace the inboard aileron hinge bracket and inspect the aileron spar per
Piper Service Bulletin No. 967.
[ ] (10) For airplanes which have installed the improved inboard aileron hinge bracket (P/Ns 74461-
002 / -003) per Piper Service Bulletin No. 967, each 1,000 hours time-in-service remove the
inboard aileron hinge bracket and inspect the aileron spar per the procedure in Piper Service
Bulletin No. 967.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D4
May 15, 2012
5-30-00
Page 4
SPECIAL INSPECTIONS WORK SHEET
(Sheet 4 of 10)
G. Each 1,200 Hours
[ ] Inspect nose and main landing gear upper bearing block retaining pins.
H. Each 1,250 Hours
[ ] In PA-42-720 airplanes, perform Hot Section Inspection (HSI) in accordance with the latest
Pratt & Whitney Service Bulletin No. 13303.
NOTE: All PT6A engines may be operated to a scheduled hot section inspection interval
or alternatively, the HSI frequency may be based on engine performance trend
monitoring. If trend monitoring is introduced part way through engine life,
compressor wash and hot section inspection must be accomplished to establish
performance base line. Refer to Pratt & Whitney Agtoil 23 for details on trend
monitoring.
I. Each 1,500 Hours
[ ] (1) In PA-42 airplanes, perform Hot Section Inspection (HSI) in accordance with the latest Pratt
& Whitney Service Bulletin No. 3003.
NOTE: PT6A-41 engine Hot Section Inspection (HSI) may be based on inspection intervals
or on engine performance trend monitoring is introduced part way through the
engine life, a compressor wash and HSI must be accomplished to establish the
performance base line. Refer to Pratt & Whitney AGTOIL 8 for details on trend
monitoring.
[ ] (2) Replace exible bleed air lines (high temp), at pneumatic pressure regulator and at pneumatic
boot deice injectors, each 1,500 hours time-in-service or 7 years, whichever occurs rst.
J. Each 1,600 Hours
[ ] (1) For airplanes whose wings have accumulated 10,000 hours time-in-service, inspect the
wing leading edge rivets per Special Inspection Manual, P/N 767-048.
[ ] (2) For airplanes whose empennage has accumulated 11,600 hours time-in-service, perform the
empennage rivet inspections in Special Inspection Manual, P/N 767-079.
K. Each 2,000 Hours
[ ] (1) Inspect interior of nacelle and tip tank for contamination, corrosion and evidence of leaks.
[ ] (2) Inspect operation of fuel cell bafes, check valves and fuel tanks per 28-10-00.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D5
May 15, 2012
5-30-00
Page 5
SPECIAL INSPECTIONS WORK SHEET
(Sheet 5 of 10)
L. Each 2,500 Hours (In PA-42-720 airplanes only.)
[ ] (1) Overhaul engines.
[ ] (2) Replace rubber engine mounts.
[ ] (3) Overhaul or replace hydraulic pumps (on condition).
[ ] (4) Overhaul or replace tachometer generators (on condition).
[ ] (5) Overhaul or replace fuel crossfeed and shutoff valves.
NOTE: Refer to the latest Pratt & Whitney Canada Service Bulletin 13303 for criterion for
escalating time between overhauls on PT6A-61 engines.
M. Each 3,000 Hours
[ ] (1) In PA-42 airplanes, overhaul engines.
[ ] (2) In PA-42 airplanes, replace rubber engine mounts.
[ ] (3) In PA-42 airplanes, overhaul or replace hydraulic pumps (on condition).
[ ] (4) In PA-42 airplanes, overhaul or replace tachometer generators (on condition).
[ ] (5) In PA-42 airplanes, overhaul or replace fuel crossfeed and shutoff valves.
NOTE: Refer to the latest Pratt & Whitney Canada Service Bulletin 3003 for criterion for
escalating time between overhauls on PT6A-41 engines.
[ ] (6) Overhaul propellers every 3,000 hours or Five (5) years, whichever comes rst. Refer to
latest Hartzell Service Letter No. HC-SL-61-61Y.
[ ] (7) Replace main landing gear top cylinder bolts, P/N 401-195.
[ ] (8) Replace main landing gear actuator rod ends, P/N 758-440.
N. Each 3,200 Hours
[ ] Replace main landing gear brace pivot shaft assembly, P/N 43286-002.
O. Each 4,000 Hours
[ ] Replace landing gear selector cable assembly, P/N 55416-004, each 4,000 hours time-in-
service or every ten (10) years, whichever comes rst.
P. Each 6,000 Hours
[ ] (1) Replace main landing gear retraction arm, P/N 42042-002.
[ ] (2) Replace main landing gear link bolts (AN6-14 or AN6-16). Replace with AN6-16 P/N
400-211.
Q. Each 6,500 Hours
[ ] Overhaul or replace overspeed governors.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D6
May 15, 2012
5-30-00
Page 6
SPECIAL INSPECTIONS WORK SHEET
(Sheet 6 of 10)
R. Each 6,600 Hours
[ ] Replace main gear link assemblies, P/N 85165-002 Left / 85165-003 Right.
S. Each 7,500 Hours
[ ] Replace engine mount bolts located at the rewall (Station 106.00).
T. Each 7,800 Hours
[ ] Each 7,800 hours, inspect the Wing, Wing Carry-Through, and their Attaching Structure per
Special Inspection Manual, P/N 767-048.
U. At 12,300 Hours
[ ] At 12,300 hours time-in-service, inspect the Cabin and Pressurized Structure per Special
Inspection Manual, P/N 767-078.
V. At 13,300 Hours
[ ] At 13,300 hours time-in-service, perform the empennage crack inspections per Special
Inspection Manual, P/N 767-079.
W. At 13,900 Hours
At 13,900 hours time-in-service, perform the inspections specied in Special Inspection Manual, P/N
767-078.
3. Per Calendar Year
A. Each Three (3) Years
WARNING: DO NOT PERMIT OIL, GREASE OR OTHER PETROLEUM PRODUCTS TO COME
IN CONTACT WITH ANY LINES OR FITTINGS USED IN OXYGEN SYSTEM.
BE SURE SKIN AND CLOTHING ARE FREE OF GREASE, OIL, GASOLINE OR
OTHER PETROLEUM PRODUCTS BEFORE PERFORMING ANY WORK ON
THE OXYGEN SYSTEM.
[ ] Hydrostatic test oxygen cylinders with 3HT designation to 5/3 their working pressure every 3
years and retire from service at 24 years or 4,380 lling cycles (partial or full pressurization)
after date of manufacture, whichever occurs rst.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D7
May 15, 2012
5-30-00
Page 7
SPECIAL INSPECTIONS WORK SHEET
(Sheet 7 of 10)
B. Each Five (5) Years
[ ] (1) Replace landing gear emergency extension nitrogen bottle squibs.
[ ] (2) Hydrostatic test engine re extinguisher bottles.
[ ] (3) Replace engine landing gear emergency extension nitrogen bottle squibs.
WARNING: DO NOT PERMIT OIL, GREASE OR OTHER PETROLEUM PRODUCTS TO COME
IN CONTACT WITH ANY LINES OR FITTINGS USED IN OXYGEN SYSTEM.
BE SURE SKIN AND CLOTHING ARE FREE OF GREASE, OIL, GASOLINE OR
OTHER PETROLEUM PRODUCTS BEFORE PERFORMING ANY WORK ON
THE OXYGEN SYSTEM.
[ ] (4) Overhaul or replace oxygen pressure regulator each 5 years time-in-service.
[ ] (5) Hydrostatic test oxygen cylinders with 3AA designation to 5/3 their working pressure every
ve (5) years.
[ ] (6) Overhaul propellers every 3,000 hours or Five (5) years, whichever comes rst. Refer to
latest Hartzell Service Letter No. HC-SL-61-61Y.
C. Each Seven (7) Years
[ ] (1) Replace exible pneumatic lines in wings and fuselage.
[ ] (2) Replace exible bleed air lines (high temp), at pneumatic pressure regulator and at pneumatic
boot deice injectors, each 1,500 hours time-in-service or 7 years, whichever occurs rst.
D. Each Eight (8) Years
[ ] Replace engine compartment exible fuel and oil hoses as required; but not to exceed 1000
hours time-in-service, eight (8) years, or engine overhaul, whichever comes rst; except for
TSO-C53a - Type D hoses which are replaced on-condition.
E. Each Ten (10) Years
[ ] (1) Replace landing gear selector cable assembly, P/N 55416-004, each 4,000 hours time-in-
service or every ten (10) years, whichever comes rst.
[ ] (2) Test all uid hoses to system pressures and visually check for leaks or a notable amount of
stiffness. If found free of leaks and still exible, return to service for an additional 5 years.
Retest every 5 years after the initial ten year inspection. No exible hose may exceed twenty
(20) years time-in-service.
NOTE: The hoses are to be check in the aircraft without disturbing the hoses.
F. Each Twelve (12) Years
[ ] Hydrostatically test rechargeable (gauged) re extinguishers each twelve (12) years time-
in-service.
G. Each Twenty (20) Years
[ ] Replace all exible hoses each twenty (20) years time-in-service.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D8
May 15, 2012
5-30-00
Page 8
SPECIAL INSPECTIONS WORK SHEET
(Sheet 8 of 10)
4. Per Specific Operation / Operating Environment
A. Operation in High Dust or Industrial Pollution Environment
CAUTION: DISCONNECT LINES FROM PITOT/STATIC SYSTEM BEFORE CONDUCTING
THIS INSPECTION.
Item Inspection Inspection Interval
P3 Air Filter. Remove, inspect and clean. 100 Hours.
Replace as required.
Air Intake Screens. Clean and inspect for damage. 100 Hours.
Engine Oil Filter. Clean and inspect condition. 100 Hours.
Engine Oil. Drain and replace. 200 Hours.
Compressor. Inspect and complete performance Weekly or more
recovery wash. (See appropriate often as required.
Pratt & Whitney Canada Maintenance
Manual, 71-00-00.)
Propeller. Refer to latest Hartzell Service Letter. 1,500 Hours or
Three (3) years.
Cowling. Snug t of reseals and ice doors. 100 Hours.
Water Separator Coalescer Remove, inspect and wash. 100 Hours or
as required.
Cabin Environmental and Inspect and replace if necessary. 100 Hours.
Instrument Air Filters.
CAUTION: VERIFY LINES DISCONNECTED FROM SYSTEM BEFORE REVERSING FLOW.
Pitot/Static system. Check for obstruction. Reverse 100 Hours or
ow to lines. as required.
Landing Gear Up and Clean, inspect, and lubricate 100 Hours.
Down Lock Assemblies. per Lubrication Chart, 12-20-00.
Landing Gear Actuators Clean. Before each ight.
and Oleos.
Inspect. 100 Hours.
Landing Gear Wheel Clean, inspect and repack. 100 Hours.
Bearings.
Windows. Inspect for cracks, erosion, crazing, Daily.
visibility, and cleanliness.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D9
May 15, 2012
5-30-00
Page 9
SPECIAL INSPECTIONS WORK SHEET
(Sheet 9 of 10)
B. Operation in High Salt or High Humidity Environment
Item Inspection Inspection Interval
Fuselage, Empennage Remove oor panels and exterior 200 Hours.
and Wings. access plates; inspect for corrosion.
Landing Gear. Inspect for corrosion and lubrication; 200 Hours.
switches and wiring for condition.
Engines. Perform desalinization and wash. Daily or
See Pratt and Whitney Canada as required.
SIL No. PT6A-144, latest revision.
Instruments and Wiring. Inspect for proper seal of cases and 100 Hours.
corrosion.
Interior. Inspect upholstery, seat belts, seats and 100 Hours.
rugs for corrosion and integrity.
NOTE: Do not use metallic tie downs (i.e. - chains, cables, etc.) in high salt or high humidity environments.
C. Operation in Extreme Cold
Item Inspection Inspection Interval
Hydraulic, Pneumatic Check all ttings and attachments for First 100 Hour, then
and Environmental. security and leaks. as required.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D10
May 15, 2012
5-30-00
Page 10
SPECIAL INSPECTIONS WORK SHEET
(Sheet 10 of 10)
D. Operation from Soft or Unusual Terrain
Item Inspection Inspection Interval
Propeller. Check for damage (i.e., nicks, gouges, Each occurrence,
and scratches) or change in vibration before further ight.
that was not previously present.
Engine Air Inlets. Check for damage and debris. Each occurrence,
before further ight.
Oil Cooler Inlet. Check for damage and debris. Each occurrence,
before further ight.
Landing Gear. Visually inspect for crack indications 25 Hours.
at gear actuator attachments, engine
mount attachments, and for damage,
lubrication and abnormal wear.
Oleo Strut. Visually inspect for proper extension Daily.
and evidence of uid leakage. See
Landing Gear, 12-10-00.
Wheels. Inspect for cracks, damage, chipped 25 Hours.
rims; bearings for damage, corrosion
and lubrication.
Tires. Inspect for cuts, wear, required ination Daily.
pressure and deterioration.
Wheel Wells. Inspect for foreign material, damage 25 Hours.
and corrosion.
Brakes. Inspect for damage, foreign material, Daily.
cracks and overheating.
Flaps, Lower Fuselage Inspect for damage, cracks and 25 Hours.
and Wing. corrosion.
Tip Tanks. Inspect for proper attachment. 25 Hours.
E. Airplane Inactive More than Seven (7) Days
Item Inspection Inspection Interval
Engine. See appropriate Pratt & Whitney Canada As required.
Maintenance Manual, 72-00-00, Engine,
Turboprop - Servicing, Preservation and
Depreservation.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D11
May 15, 2012
5-50-00
Page 1
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 1 of 9)
WARNING: FAILURE TO CONSULT APPLICABLE VENDOR PUBLICATION(S), WHEN
SERVICING OR INSPECTING VENDOR EQUIPMENT INSTALLED IN PIPER
AIRCRAFT, MAY RENDER THE AIRCRAFT UNAIRWORTHY. (SEE INTRODUCTION
- SUPPLEMENTARY PUBLICATIONS.)
CAUTION: UPON OCCURANCE OF ANY UNSCHEDULED MAINTENANCE EVENT, REVIEW
OF THE APPROPRIATE PRATT & WHITNEY CANADA, MAINTENANCE MANUAL,
72-00-00, ENGINE, TURBOPROP - INSPECTION, IS RECOMMENDED BEFORE
FURTHER FLIGHT.
The following inspections are required in response to specific anomalies encountered during aircraft
operation. Note that the items listed herein are guidelines based on past operating experience. Each operator
should closely monitor his own unique operating conditions/environment and react accordingly to keep his
aircraft airworthy.
1. Lightning Strike
Item Inspection Inspection Interval
Propeller. Refer to the inspection requirements Each occurrence,
in the latest revision of before further ight.
Hartzell Owners Manual No. 139.
Propeller Governor. Overhaul or replace. Each occurence,
before further ight.
Engine. See appropriate Pratt & Whitney Canada Each occurrence,
Maintenance Manual, 72-00-00, before further ight.
Engine, Turboprop - Inspection,
Unscheduled Inspection.
Electrical and Avionics Inspect and check harness, connections, Each occurrence,
Systems. and equipment for high voltage damage, before further ight.
burns and insulation degradation.
Replace or overhaul as required.
Consult with appropriate avionics
vendor(s) for inspections and operational
checks. Bench check starter-generator,
and voltage control panel. (See 24-30-00.)
AIRPLANE
SERIAL NUMBER
REGISTRATION
NUMBER
ENGINE SERIAL NO.
Left:
Right:
PROPELLER SERIAL NO.
Left:
Right:
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D12
May 15, 2012
5-50-00
Page 2
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 2 of 9)
1. Lightning Strike (cont.)
Item Inspection Inspection Interval
All exterior surfaces, skins, Inspect for burns, evidence of arcing, Each occurrence,
and structure. and damage on surfaces and bearings. before further ight.
Check for correct material properties in
the area of the strike path. Degauss
engine mount. Replace or repair
affected areas/parts.
System Components. Inspect instrumentation, hydraulic, Each occurrence,
vacuum, pitot/static, and fuel systems, before further ight.
for damage and correct operation.
Static Wicks. Replace. Each occurrence,
before further ight.
Bearings. Inspect all control surface hinges and Each occurrence,
bearings, and landing gear and wheel before further ight.
bearings for pitting and damage.
Replace as required.
2. Engine Overspeed, Overtemp, Overtorque, or Sudden Stoppage
Item Inspection Inspection Interval
Engine. See appropriate Pratt & Whitney Canada Each occurrence,
Maintenance Manual, 72-00-00, before further ight.
Engine, Turboprop - Inspection,
Unscheduled Inspection.
Propeller. Propeller overspeed of more than 10%. Each occurrence,
Refer to the inspection requirements before further ight.
in the latest revision of
Hartzell Owners Manual No. 139.
Propeller Governor. Overhaul or replace. Each sudden stoppage,
before further ight.
Engine Mount and Inspect for distortion and Each occurrence,
Attachments. damage. Replace or repair, before further ight.
as required.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D13
May 15, 2012
5-50-00
Page 3
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 3 of 9)
3. Battery Overtemperature
Item Inspection Inspection Interval
Battery. Deep cycle battery. Battery overtemperature
warning or indication.
Electrical. Inspect wiring and charging circuit Battery overtemperature
for damage. Check for proper warning or indication.
opens and shorts.
Check crossfeed diode for
opens and shorts.
4. Engine Foreign Object or Debris (FOD) Ingestion - Hard Material
Item Inspection Inspection Interval
First-stage compressor blades. Check for damage. Each occurrence,
See appropriate Pratt & Whitney before further ight.
Canada Maintenance Manual,
72-30-05.
Engine. Conduct engine ground power check. Each occurrence,
See appropriate Pratt & Whitney before further ight.
Canada Maintenance Manual,
71-00-00.
5. Engine Foreign Object or Debris (FOD) Ingestion - Soft Material / Bird Strikes
Item Inspection Inspection Interval
Engine. A hot section inspection is Each occurrence,
recommended. as soon as possible.
See appropriate Pratt & Whitney
Canada Maintenance Manual,
72-00-00.
First-stage compressor Check for damage, bird remains, Each occurrence,
airfoils. or other soft foreign material. before further ight.
See appropriate Pratt & Whitney
Canada Maintenance Manual,
72-30-05.
Engine. Conduct engine performance Each occurrence,
recovery wash and engine ground before further ight.
power check. See appropriate
Pratt & Whitney Canada Maintenance
Manual, 71-00-00.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D14
May 15, 2012
5-50-00
Page 4
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 4 of 9)
6. Severe Turbulence, Hard or Overweight Landing
CAUTION: MINOR OR APPARENTLY SUPERFICIAL DAMAGE MAY INDICATE A MORE
SEVERE CONDITION SOMEWHERE ELSE IN THE STRUCTURE.
A. Place aircraft in a normal level attitude.
B. Make a preliminary inspection of checking alignment and out-of-track condition of nacelles, engines,
wings, tail, tip tanks, landing gear and doors.
C. Follow Piper and Pratt & Whitney Canada Maintenance Manual procedures. If there are any questions
regarding repairs or procedures, contact your Piper Distributors Service Advisor (DSA).
D. Inspect the following items closely to determine the extent of damage:
Item Inspection Inspection Interval
Landing Gear Struts Cracks, signs of overstress Each occurrence,
and Actuators deformation, loose or damaged before further ight.
(Not required for trunnion mounts. Axles for cracks,
severe turbulence.) bending or at spots. Damaged oleos
and seals, hydraulic leaks and landing
gear alignment.
Wheels, Tires, Brakes. Cracks, chips, loose or cracked Each occurrence,
(Not required for mounting bolts, alignment of slippage before further ight.
severe turbulence.) marks, sidewall distress, hydraulic or
air leaks. Inspect the wheels (dye
penetrant method) and wheel bolts
(magnetic particle method).
Wheel Wells and Landing Buckling, cracks, overstress, wing skin Each occurrence,
Gear attach points. buckling, actuator and side brace before further ight.
(Not required for damage and condition. Inspect
severe turbulence.) landing gear attachment and drag
link bolts using a dye penetrant method.
Wings. Wing attach bolts for slippage, damage Each occurrence,
and overstress. Upper and lower wing before further ight.
skins for wrinkles, cracks, popped or
loose rivets.
Remove access plates and inspect for
internal damage to ribs, stringers and
sparwebs; and fuel cells, liners, and
tip tanks for damage, attachment,
and leaks.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D15
May 15, 2012
5-50-00
Page 5
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 5 of 9)
Item Inspection Inspection Interval
Engines. Engine mounts for distortion and Each occurrence,
damage to elastomeric parts. before further ight.
Propeller for evidence of ground strike
(i.e. - hard or overweight landing).
See appropriate Pratt & Whitney Canada
Maintenance Manual, 72-00-00,
Engine, Turboprop - Inspection,
Unscheduled Inspection.
Nacelles. Inspect for loose or missing rivets, Each occurrence,
skin buckling or fuel leaks. before further ight.
Fuselage. Loose or missing rivets, door alignment, Each occurrence,
windows and attachments for overstress, before further ight.
cracks or damage. Wing carry through
member for overstress damage.
Stringers, bulkheads, keel beams for
buckling, cracks, or damage. Forward
and aft pressure bulkheads for buckling,
cracks and damage. Avionics,
instruments and accessories installation
for security and operation.
Perform ground pressurization check
per 21-30-00.
Empennage. Skins for buckling wrinkles, loose or Each occurrence,
missing rivets. Elevator, rudder, vertical before further ight.
n and horizontal stabilizer for security
of attachment and overstress of bolts.
Ribs, stringers for buckling, cracks
and damage.
7. Flaps Extended Above Maximum Flap Extension Speed (V
FE
)
Item Inspection Inspection Interval
Flap actuators and Inspect for distortion and damage. Each occurrence,
transmissions. Replace as required. before further ight.
Flaps. Inspect for damage to the skin and Each occurrence,
attach points. Replace as required. before further ight.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D16
May 15, 2012
5-50-00
Page 6
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 6 of 9)
8. Flood Damage, Immersion in Water
A. These guidelines are general in nature and should be applied or varied to fit the individual aircraft
according to water level, length of time of exposure and other variables. Only those areas that might
not be obvious to the mechanic are addressed.
CAUTION: MAKE ALL REPAIRS AND/OR ADJUSTMENTS IN ACCORDANCE WITH
THE APPROPRIATE PIPER MAINTENANCE MANUAL, THE COMPONENT
MANUFACTURERS MAINTENANCE MANUAL, AND FAR PART 43. PAY
PARTICULAR ATTENTION TO SILT, CORROSION AND CONTAMINANTS.
B. Follow Piper and Pratt & Whitney Canada Maintenance Manual procedures. If there are any questions
regarding repairs or procedures, contact your Piper Distributors Service Advisor (DSA).
C. Determine the water level on the aircraft. Determine which operating and/or electrical components
have been exposed to the water.
D. If the following items were immersed, inspect them closely to determine the extent of damage:
Item Inspection Inspection Interval
Airframe Clean silt and contaminants from If immersed, each event,
airframe. before further ight.
Tubular Structures Check for internal corrosion. If immersed, each event,
(i.e. - Engine Mounts, etc.) Clean and represerve as required. before further ight.
Wings and Nacelles Inspect to ensure that contaminants If immersed, each event,
are cleaned from fuel cell areas. before further ight.
Landing Gear and associated Check all limit switches, replace If immersed, each event,
Bearings, Locks, Torque Links, non-sealed type. Jack airplane and before further ight.
Shimmy Dampeners, etc. cycle landing gear to ensure
proper operation.
Control Surfaces Remove surface, clean and check If immersed, each event,
all bearings - relube or replace before further ight.
as necessary.
Rebalance before installation.
Flight Control System Clean and inspect all cables, pulleys, If immersed, each event,
and bearings for evidence of corrosion. before further ight.
Replace corroded cables.
Re-preserve galvanized cable
with MIL-C-11796 Class 2 (hot).
Trim Control System Clean and inspect all trim system If immersed, each event,
cables, pulleys, drums, bearings, before further ight.
jack screws, etc. Do not apply
preservation to trim cables.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D17
May 15, 2012
5-50-00
Page 7
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 7 of 9)
Item Inspection Inspection Interval
Actuating Cables Inspect push-pull actuating cables If immersed, each event,
for powerplant, heating and before further ight.
ventilating system, fuel system, etc.
for proper operation.
Engine Remove and ship to an approved If immersed, each event,
overhaul facility for Light Overhaul before further ight.
- Immersion in Water.
Engine Accessories Inspect. Aircraft systems that supply If immersed, each event,
either fuel or oil to the engine must be before further ight.
thoroughly cleaned, including oil cooler,
lines,valves, etc. to prevent
contamination of the engine after
reinstallation.
Propellers Inspect and repair as necessary If immersed, each event,
in an authorized propeller shop. before further ight.
Hydraulic System Replace hydraulic powerpak. If immersed, each event,
before further ight.
Electrical Systems Replace all circuit breakers and If immersed, each event,
switches (except sealed landing gear before further ight.
limit switches).
Replace all solenoids, relays and
master contactors.
Replace battery.
Disassemble all connectors; clean
and inspect for corrosion. Replace all
corroded or pitted connectors. Inspect
for wire corrosion at connector.
Check all harness assemblies for
entrapped contaminants. Clean and
check for short circuits.
Remove electric motors and electric
pumps.
Remove all potted solid state electrical
equipment such as ap time delay relays,
alternator inop. switches, windshield heat
timers, low fuel warning switches, etc.
Clean, dry and bench check per
appropriate maintenance manual.
Replace de-icer timers. Clean and check
prop de-icer brush holders.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D18
May 15, 2012
5-50-00
Page 8
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 8 of 9)
8. Flood Damage, Immersion in Water (continued)
Item Inspection Inspection Interval
Electrical Systems Clean and check voltage regulators. If immersed, each event,
(cont.) Replace as necessary before further ight.
Clean and check aIl strobe light power
supplies. Refer to appropriate
maintenance manual.
Replace all fuel senders, ap
pots, ap motors, etc.
Clean, inspect and check heated
pitot systems.
Autopilot System Bench check in accordance with If immersed, each event,
appropriate maintenance manual. before further ight.
Pay particular attention to clutch settings.
Vacuum and Pitot-Static Replace gyros. If immersed, each event,
Systems before further ight.
Replace lters.
Clean and inspect all lines, and pitot
and static vents.
Clean and check all regulating valves.
Remove and inspect engine driven and
auxiliary vacuum pumps.
Induction and Bleed Air Clean and inspect for silt and If immersed, each event,
Systems corrosion. Check all ducts and gaskets. before further ight.
Replace as necessary.
Clean and inspect all heat shrouds
and ducting.
Fuel Systems Remove access panels and clean areas If immersed, each event,
around fuel cells and clean all associated before further ight.
lines and pumps.
Drain and inspect fuel cells for
contamination. Clean as required.
Clean and inspect all fuel tank vents,
cap vents and vent lines.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D19
May 15, 2012
5-50-00
Page 9
UNSCHEDULED MAINTENANCE CHECKS WORK SHEET
(Sheet 9 of 9)
Item Inspection Inspection Interval
Instruments Clean and inspect instruments. Bench If immersed, each event,
check per appropriate maintenance before further ight.
manual.
Heating and Ventilating Replace blower. If immersed, each event,
Systems before further ight.
Clean and inspect all ducting and valves.
Inspect and check system control cables.
Replace corroded or binding cables.
Clean and inspect air conditioning
evaporator, condenser, and compressor.
Pressurization Systems Remove and replace all system controls If immersed, each event,
and valves. before further ight.
Oxygen Systems Disconnect all lines from source and If immersed, each event,
outlets; clean all ttings and lines before further ight.
per MIL-D-8683.
Remove and clean regulator valve per
appropriate Scott publication.
Replace pressure gauge.
Replace oxygen generator units.
Avionics Systems Replace avionics. If immersed, each event,
before further ight.
Clean and inspect antennas
and connectors.
Insulation and Upholstery Remove all wet insulation and upholstery. If immersed, each event,
Thoroughly clean and dry (or replace) before further ight.
to ensure corrosion is not promoted in
adjacent structures.
9. Starter-Generator Replacement
Required if there is an engine starting fault or an electrical generation defect.
Item Inspection Inspection Interval
Engine. See appropriate Pratt & Whitney Canada Each occurrence,
Maintenance Manual, 72-00-00, before further ight.
Engine, Turboprop - Inspection,
Unscheduled Inspection,
Starter-Generator Replacement.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1D20
May 15, 2012
5-50-00
Page 10
GRIDS 1D20 THRU 1E6
INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER
6
DIMENSIONS AND
AREAS
1E7
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1E8
THIS PAGE INTENTIONALLY BLANK
SYSTEM
SUB-SYSTEM
6-1()-00
62()-1J()
6-30-00
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 6 - DIMENSIONS AND AREAS
TABLE OF CONTENTS/EFFECTIVITY
DIMENSIONS AND AREAS
STATION REFERENCE LINES
SUBJECT
ACCESS AND INSPECTION PROVISIONS
1E9
GRID
NO.
IElO
IEl3
IEl6
EFFECTIVITY
6 - Conti Effect.
Page 1
Reissued: December 31, 1989
DIMENSIONS AND AREAS
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
The principal airplane dimensions are shown in Figure 6-1 and the leading particulars/principal dimensions are
listed in Chart 601. The airplane serial number is located on the Manufacturers Aircraft Association (MAA)
plate, which is located below and to the right of the cabin door. The engine serial number plates are located on
the left rear side of the engine accessory case.
1+---21'-10" ---I

/
95 inches
I "'\
DIHEDRAL
I 'L
f1 ',-fr112.35" PROP
4----1 8' 8.9" --11 CLEARANCE
4---------47' - 8" --------1
,_------43' -4.7" -------,
Figure 6-1. Three View
1E10
14' - 9"
6-10-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS
MODEL
ENGINE
Manufacturer
Number of Engines
ModeJ
ModelTypc
Compressor Stages and Type
Thrbine Stages and Type
Combustion Chamber Type
Rat Rated Horsepower (Airframe Limit)
Rated RPM
Dry Weight (Lbs.)
Fuel Specification
Alternate Fuel
Approved Fuel Additives
Oil Specification
Oil Tank Capacity (each cngine)
Thtal Oil Capacity (each engine)
PROPELLER
Number of Propellers
Manufacturer
Type
Blade Model
Number of Blades
Hub Model
Propeller Diameter
Ovcrspeed Governor Model
1 Govemor Model without Synchrophaser and AutoCeather
2 Govemor Model with SyncllTophaser without aUlOflight
Governor Model with Syncliropilser with AUlOfeathcr (PA-42720)
4 Governor Model witllout synchrophascr with Autofeathcr
5 PA42.720Only
6-10-00
Page 2
Reissued: December 31, 1989
1E11
PA-42 I PA-42-720
Prau and Whitney Aircraft of canada.
2
PT6A-41 I PT6A-61 ,
Free Turbine, Reverse How, 2 Shaft
3 Axial Stages, 1 Centrifugal Stage
1 Stage Compressor, 2 Stage Power
ArumJar
720
2000
370 I 429'
Refcr to Pratt & Whitney Service
Bulletin No. 13044 (latest revision)S
(Including Jet A. Jet A-I, Jet B
t
JP4 and
JP5) Section 3026522-72-44
Aviation gasoline. all grades
Anti-icc additives per MIL-I-27686
Refcr to Pratt & Whitney Service
Bulletin No. 13001 (latest revision)s
Section 3026522-72-1
2.3 U.S. Gallons
3.25 U.S. Gallons
2
TRW Hanzcll
Hydraulically operated, constant speed,
full feathering, reversible
T10173AB-6Q
3
HC-B3TN-3B or HC-B3TN-3K
95 inches
Woodward - PIN 210617
1
Woodward - PIN 210613'
Woodward - PIN 21062()3'
Woodward - PIN 210619
4
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 601. LEADING PARTICULARS AND PRINCIPAL DIMENSIONS (continued)
FUEL SYSTEM CAPACITY
Total Useable Fuel
Total Unusable Fuel
LANDING GEAR
Type
Shock Strut Design
Wheel. Nose
Wheel, Main
Brake
Tire. Main
nre,Nose
TIre Pressures
1E12
562 U.S. Gallons
560 U.S. Gallons
2 U.S. Gallons
Tricycle Retractable - Hydraulic
Combination Air and Oil
B.F. Goodrich 3 1076
Cleveland 40-140
B.F. Goodrich 31392
B.F. Goodrich 2- 1435 2
6.50 x 10. 12 ply rating. Type 1II.
ribbed tread. tubeless
17.50 x 6.25 - 6. 10 ply rating.
tube type
Main: 100 psi
Nose: 70 psi
61000
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
STATION REFERENCE LINES (Figure 6-2.)
To locate various airplane components that require maintenance and servicing, a method using wing fuselage
slation, wing station. buuock line and waterline designations is frequently used in this manual. Fuselage stations.
buttock lines (B.L.) and waterlines (W.L.) are reference points measured by inches in the vertical or horizontal
direction from a given reference line. These point indicate slation locations of airplane structural members.
STA
-44.00
STA
13.00
STA
25.60
STA
72.25
STA
57.00
FUSELAGE STATIONS
~
~
Figure 6-2. Station References
1E13
STA
81 .00
t ..
191.70
6-2000
Page 1
Reissued: December 31, 1989
62000
Page 2
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
T
174.50

-

, ,
."
222."
STA
176. 134
WING STATIONS
STA
312.32
FUSELAGESTAnONS
Figure 62. Station References (continued)
"'.J>
Reissued: December 31, 1989
1E14
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
HORIZONTAL STABIUZER STATIONS
BL BL
0.00 11.9
BL
19.56
NACELLE STATIONS
STA
28.17
Sf
66.1 1
Bl
33.30
Bl
32.86
STA STA
84.03 110.
Bl
58.n
o
L
100,09
BL
101.1
BL
131.
BL
+-+--{ O.OO
Figure 6-2. Station References (cominued)
1E15
62000
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ACCESS AND INSPECTION PROVISIONS
Airplane access and inspection provisions are shown in Figure's 6-3 through 6-5. Componcms to be
serviced or inspected through each opening arc identified in the illustration by an assigned index reference
number. All access plates and panels are secured by metal fasteners or screws.
-NOTE-
Before removing any access plates or panel s in the pressurized
portion of the fuselage, refer to Chapter 51 to determine the sealing
requirements.
Gain access to floor panel attachment screws by removing sealS and carpeting. To enter aft section of
fuselage, remove access panels on either side of fuselage, aft of station 332.00.
, .
2.
3.
4.
5.
6.
9
""

:ft}
10 1 6 7
\ 3"
12
.iII.
0
] Q ---=--=:JJ
0
:.-.
/
l
"
9
x-==:::::c=

/
..
6 I la 8
- NACELLE -
WASHRING FiniNG 7. FUEL FILTER DRAIN HANDLE
AFT NACELLE PANEL - INSPECTION 8. FUEL FILTER DRAIN
NACELLE PANEL - INSPECTION 9. OIL FILL AND DIPSTICK
FORWARD NACELLE PANEL INSPECTION ,a. ICE DEFLECTION DOOR CONTROL CONNECTIONS
NACEUE FUEL SENSOR 11 . ICE DEFLECTION DOOR
INTERCOOLER AIR INLET 12. OIL COOLER DOOR
Figure 6-3. Access Plates and Panels - Engine Nacelle
1E16
6-30-00
Page I
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
ACCESS AND INSPECTION PROVISIONS (continued)
23
13
15 - +tI
17
57
58
19 20 21 22 24
18
~ 5 6
55 5451 4847

~ ~ I
II
53 52 52 50
_ EXTERNAL
_ INTERNAL
25 28 30
26 27 29
46
45 4238 41 37
~ 1


I!'ICj1i
49 44 43 40 39
Figure 6-4. Access Plates and Panels - Wing
6-30-00
Page 2
Reissued: December 31, 1989
1E17
31
35
33
;
II
W
~
.l!
36 34
NOTE: CALL OUTS LOCATED
ON PAGE 3, 6-30-00.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ACCESS AND INSPECTION PROVISIONS (conti nued)
-WING-
13. FUEL QUANTITY SENSQR - AFT INBOARD CELL
14. INSPECTION AND ACCESS TO AFT CELL COVER AND MOUNTING PLATE
15. INSPECTION AND ACCESS TO MAIN CELL, COVER AND MOUNTING PLATE AND SUBMERGED
FUEL PUMP
16. FUEL QUANTITY SENSOR - MAIN FUEL CELL
17. MAIN CELL - ACCESS, INSPECTION, MOUNTING
18. MAIN CELL - ACCESS, INSPECTION, MOUNTING, AFT CELL CONNECTION
19. FUEL QUANTITY SENSOR - MAIN CELL OUTBOARD
20. MAIN CELL - ACCESS, INSPECTION, NACELLE AND OUTBOARD CELL INTERCONNECT
21 . INTERCONNECT OF MAIN AND NACELLE FUEL CELLS
22. FUEL VENT INTERCONNECT, FLOAT VALVE SYSTEM - FUEL VENT INTERCONNECT
23. FUEL QUANTITY SENSOR - OUT BOARD FUEL CELL
24. FUEL CELL
25. FUEL CELL
26. FUEL QUANTITY SENSOR
27. INSPECTION ACCESS
28. FUEL QUANTITY SENSOR
29. INSPECTION ACCESS
30. INSPECTION ACCESS
31 . FLUX DETECTOR
32. FUEL VENT LINE INTERCONNECT, TIP TANK VENT FLOAT VALVE
33. ACCESS TO FUEL LINES AND TIP TANK STRAINER SCREEN
34. STROBE LIGHT TRANSFORMER
35. FUEL LINE SUPPORT AND FUEL VENT CONNECTION
36. FLUX DETECTOR COMPENSATOR
37. FUEL LINE SUPPORT
38. FUEL LINE AND FUEL VENT LINE
39. AILERON BELLCRANK AND CONNECTIONS
40. AILERON BELLCRANK AND CONNECTIONS - RIGHT WING ONLY
41. FUEL VENT
42. FUEL VENT CAN
43. AILERON CABLES
44. FUEL CELL VENT - RIGHT WING ONLY
45. FUEL CELL VENT
46. FUEL LINE AND FUEL VENT LINE
47. QUICK DEFUEL DRAIN ACCESS
48. JACK PAD
49. INSPECTION, FLAP ACTUATOR
50. INSPECTION, FLAP ACTUATOR
51 FUEL DRAIN - OUTBOARD FUEL CELL
52. AILERON CABLES AND MAIN LANDING GEAR TRUNNION BOLT
53. AILERON CABLES AND MAIN LANDING GEAR LINK BOLT
54. FUEL LINE AND MAIN LANDING GEAR TRUNNION BOLT
55. FUEL LINE
56. BLEED AIR LINE COUPLING AND MAIN LANDING GEAR LINK BOLT
57. FUEL DRAIN - MAIN CELL (INBOARD)
58. FUEL DRAIN - AFT INBOARD CELL
lEla
6-30-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42!42-720
AIRPLANE MAINTENANCE MANUAL
ACCESS AND INSPECTION PROVISIONS (continued)
63
000
0000
73
78
~
~
/"
tt
f-
C
I
I
7.
_ EXTERNAL
_ INTERNAL
NOTE: CALL OUTS LOCATED
ON PAGE 5, 6-30-00.
Figure 6-5. Access Plates and Panels - Fuselage and Stabilizer
6-30-00
Page 4
Reissued: December 31, 1989
1E19
PIPER AIRCRAFT
PA42142 720
AIRPLANE MAINTENANCE MANUAL
ACCESS AND INSPECTION PROVISIONS (continued)
- FUSELAGE AND STABILIZER -
59. TAIL RECOGNITI ON LIGHTS, ELEVATOR CONTROLS, STABILIZER ATTACHMENT AND ELEVATOR
PUSH ROD
60. ELEVATOR SECTOR, RUDDER AND ELEVATOR CABLE
61 . PRESSURIZATION OUTFLOW VALVE
62. ELT.
63. EMERGENCY EXIT
64. ECU, HYDRAULIC RESERVOIR AND HYDRAULIC POWER PACK
65. RADAR AND BATTERY
66. ANTENNA AND CABLE
67, RUDDER TRIM
66. RUDDER SECTOR CONTROL CABLES
69. NOSE BAGGAGE COMPARTMENT, OXYGEN BOTTLES, ECU GROUND COOLING FAN AND
ELECTRIC CONTROL PANELS
70. BRAKE RESERVOIR FILL
71 . AVIONICS BAY AND NOSE GEAR STEERING CONNECTIONS
72. Q-SENSOR RELAYS
73. BELOW FLOOR ACCESS, RUDDER CABLES, ECS LINES AND MISCELLANEOUS
74. GPU RECEPTACLE
75. NOSE GEAR DOORS
76. ELEVATOR, RUDDER, ELEVATOR TRIM AND RUDDER TRIM CABLES
77. ELEVATOR, RUDDER, ELEVATOR TRIM AND RUDDER TRIM CABLES
78. ELEVATOR TRIM CABLES PULLEY
79. ELEVATOR OUTBOARD HINGE BOLT ACCESS
1E20
630-00
Page 5
Reissued: December 31, 1989
6-30-00
Page 6
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GRIDS lEU THROUGH lE22
INTENTIONALLY LEFT BLANK
1E21
CHAPTER
LIFTING AND SHORING
1E23
SYSTEM
SUB-SYSTEM SUBJECT
7-00-00 GENERAL
7-lO-00 lACKING
7-20-00 SHORING
7-20-00 Sling
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 7 - LIFTING AND SHORI NG
TABLE OF CONTENTS/EFFECTIVITY
1E24
GRID
NO. EFFECTIVITY
IFI
IFI
IF3
IF5
7 ContJ Effect.
Page t
Reissued: December 31, 1989
GENERAL
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
The airplane is lifted with the usc of conventionallripod jacks. In an emergency situation, it may be necessary
to usc slings or airbags for the initial lifting procedure.
If wing and fuselage shoring is required, be sure support is contoured to conform to lIle surface it upholds.
JACKING
- NOTE-
Jacking must be done in a wind protected area on a level surface.
The lifting arrangement for the PA-42/42-720 consists of a jacking pad on each wing. outboard of the nacells. a
nose pad forward of the nose gear and a removable tail jacking pad which attaches in from of the tail tic-down
ring (Figure 7-1.). Adjustable 25 inch tripod jacks must be used. Eight ton capacity wing jacks and two ton
capacity nose and lailjacks are recommended for the following procedure:
1. Mount tail jacking pad (shown in Figure 7-1.).
2. Temporarily align jacks under their respective jack pads.
3. Pump jacks up to pads. While jacking, realign jacks as necessary. Ensure jackheads fit properly with their
pads and jacks are nol slanted.
4. Carefully raise wing and nose jacks until all wheels clear the surface; maintain a level airplane.
-CAUTION -
CARE MUST BE USED IN APPLYING PRESSURE AT THE
TAIL JACKING PAD. EXCESSIVE LOADS CAN DAMAGE
THE AIRCRAFT STRUCTURE.
5. Raise tail jack to maintain contact with tail jacking pad.
1F1
, 1000
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
JACK PAD
ATIACH SCREWS '
(4 REQ'O)
TAIL JACK ~ : \ - I : \ - I
PIN 7224610
JACK CENTERING
......,. CONE (INTEGRAL TO
~ TAIL JACK PAD)
JACK
TAIL TIE DOWN
RING
Figure 7-1. Use of Tail Jacking Pad
DISTANCES TO JACKPOINTS (Ground to Structure)
JACKPOINT AND
DISTANCES WHEN STRUTS AT:
STRUT AFFECTED MIN. EXTENSION MAX. COLlAPSED
WINGIMAIN G. 51 IN. 32 IN.
NQSElNOSE G. 44 IN. 25 IN.
Figure 7-2. Jacking Arrangements
'-10-00
Page 2
Reissued: December 31, 1989
Interim Revision: January 9, 1998
1F2
TOOL
PIN 72246-10
SHORING
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
When supporting the aircraft at points other than jacking pads, loads must be carefully distributed to avoid
overstressing local structures. To shore fuselage and wings, use wooden contour blocks as shown in Figure 7-3.
The fuselage is supported by a single block at Fuselage Station (F.S.) 93.0. A pair of blocks at ES. 297.38 and
310.0 are mounted together on a transverse pivot at ES. 304.0 to equally distribute weight of the aft fuselage.
The wing is supponed by single blocks as Wing Station (W.S.) 30.0 and W.S. 109.5. All blocks arc made of 2 x
10's, and are lined with carpet or heavy foam rubber along contact faces.
. I

Figure 7-3. Shoring Arragements
1F3
7-20-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FUSELAGE CONTOUR - 1 INCH GRID
NOIE.: ALLOW FOR COMPRESSED
THICKNESS OF PADDING WHEN
PlOTTING CONTOUR BOARDS.
FUSELAGE
/ SKIN CONTOUR
FUSELAGE STATION 93.0
CENTERUNE
OF AIRPLANE
/
FUSELAGE
/ SKIN CONTOUR
/
FUSELAGE
SKIN OONTOUR
FUSELAGE STATION 297.38
CENTERUNE
OF AIRPLANE
/
WING CONTOUR - 1 INCH GRID
FUSELAGE STATION 310.0
CENTERLINE
OF AIRPLANE
11.11111111111111111111!pllllllllllllllllllllllllilllll11111111111111111I1111111111111
WING STATION 30.0
WING BOTTOM SKIN CONTOUR
7-20-00
Page 2
Reissued: December 31, 1989
WING STATION 109.5
Figure 7-4. Fuselage and Wing Shoring
1F4
SLING
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
The centerline locations, loads on and strap widths are shown in the table below. The forward strap can be no
less than 12 inches wide and the aft strap 15 inches wide. (See Figure 7-5)
LOCATION F.s.
Front F.S. 40.0
(1)
(2)
Aft F.S. 230
(1)
(2)
STRAP WIDTH IN
12
24
15
30
LOAD PSI
138.06
69
100.54
50.3
Guide wires will be needed on wing tips, nose, and tail. To facilitate the attachment of the guide wires the tip
tank fairings and nose radome will need to be removed. The tail guide wire can be attached to the tail tie down.
These guide wires are to be used for stability only. The guide wires will need one person per wire to guide the
lifting and moving of the aircraft.
IX - NOT TO EXCEED 45'
GUIDE WIRE
GUIDE WIRE
1
00
GUIDE WIRE
Figure 75. Sling Location F.S.
lF5
GUIDE WIRE
GUIDE WIRE
72000
Page 3
Reissued: December 31, 1989
7-20-00
Page 4
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-72D
AIRPLANE MAINTENANCE MANUAL
GRIDS IF6 THROUGH IF8
INTENTIONALLY LEFT BLANK
1F6
CHAPTER
LEVELING AND WEIGHING
1F9
SYSTEM
SUB-SYSTEM
8-00-00
8-10-00
8-20-00
GENERAL
LEVELING
WEIGHING
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 8 - LEVELING AND WEIGIDNG
TABLE OF CONTENTS/EFFECTIVITY
SUBJECT
1F10
GRID
NO_
I FI 3
IFI3
IFI4
EFFECTMTY
8 . Conti Effect.
Page 1
Reissued: December 31, 1989
GENERAL
LEVELING
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
All airplane configurations are provided with longitudinal and lateral leveling. The airplane can be leveled
while on jacks. during weighing procedure, while wheels arc on scales, or on the ground. To level airplane for
weighing or rigging. proceed as follows:
To level airplane longitudinally, withdraw tool attaclunent screws from right side of aircraft at Fuselage Station
87.5 and 66.5 (approximately). Place aircraft leveling tool (PIN 71587-3) in position against aircraft skin, secure
with screws previously removed, and place spirit level on leveling tool. Deflate nose wheel or adjust jacks until
bubble in level is centered.
, <
I ,
/ 0
,
o
u
F.S.87.S
u
"
u
o
Figure 8-1. Leveling
lFll
u
o o.
o 0
, 0
u u
u 0
o u
o 0
o 0
o ,
u 0
u .0
u 0
o 0
o 0
o 0
u u
u u
o ~
F.S. 66.5
8-00-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
WEIGHING
TIle airplane is weighed as follows:
1. Position a scale and ramp in front of all three wheels.
2. Secure scales from rolling forward and tow airplane up onto scales. (Refer to Chapter 9.)
3. Remove ramps to avoid interference wi th scales.
4. To weigh or balance airplane, level airplane using instructions given in previous sub-system section.
Figure 8 2. Weighing
1F12
8 2000
Page 1
Reissued: December 31, 1989
8-20-00
Page 2
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GRIDS IFI3 THRU IFIS
INTENTIONALLY LEFT BLANK
1F13
CHAPTER
TOWING AND TAXIING
1F16
SYSTEM
SUB-SYSTEM SUBJECT
9-00-00 GENERAL
9-1().00 TOWING
9-20-00 TAXIING
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 9 - TOWING AND TAXIING
TABLE OF CONTENTS/EFFECTIVITY
1F17
GRID
NO_
IF21
IF22
IF22
EFFECTIVITY
9 . Conti Effect.
Page 1
Reissued: December 31, 1989
GENERAL
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
Before towing or taxiing airplane. ground personnel must be infonned by a Qualified pilot or other personnel
about tow turning limits of nose gear, engine starting and shutdown procedures, and any other system functions
required to properly and safely move the airplane. (Refer to Figure 91.)
75' - O' (22.86M) TOWED
84' - O' (25.603M) STEERED
_I I
Figure 9 1. Turning Radius and Limits
lF18
9-00-00
Page 1
Reissued: December 31, 1989
TOWlNG
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
- CAUTION -
WHEN TOWING, DO NOT TURN NOSE GEAR IN EITHER
DIRECTION BEYOND ITS 40 DEGREE ARC FROM
CENTER. THIS RESULTS IN DAMAGE TO NOSE GEAR
AND STEERING MECHANISM. A PLACARD IS INSTALLED
ON NOSE GEAR STRUT TO INDICATE TURN LIMITS.
(FIGURE 9-1.)
The airplane can be moved by using power equipment which will not damage or cause excess strain to nose
gear steering assembly. Towing lugs are used as part of the nose gear fork.
To pull the airplane on a hard level sulface, approximately 100 pounds of pull is required to stan its roll and
approximately 60 pounds to maintain roll.
When towing lines are necessary, lines are attached to both main gear struts below the side brace link
attachments, Lines must be long enough to clear nose or tail by not less than 15 feet and a qualified person must
ride in the pilot's seat and use the brakes and nose wheel steering to maintain control.
A collapsible tow bar, located in the nose baggage compartment fastened to the rear bulkhead, is removed by
pulling it from friction retainers.
TAXDNG
When the propeller prop wash, exhaust blast. and taxi areas are clear, start engines. Apply power slowly to stan
taxi roll and perfonn the following checks:
1. Taxi forward a few fcet and apply brakes to determine effectiveness.
2. Taxi with propellers set in low pitch and high rpm sctting. Check fDr even prop reversing.
3. While taxiing. make slight turns to determine the effectiveness of the steering.
4. Check wing clearance when taxiing near buildings or other stationary objects. If possible. place guides at
each wing tip.
5. When taxiing on uneven ground. avoid holes and ruts.
6. Do not operate engines at high !pm when running or taxiing over ground containing loose stones, gravel, or
any other loose material that can cause damage to propeller blades.
1F19
92000
Page 1
Reissued: December 31.1989
9-20-00
Page 2
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GRIDS 1F20 TURU 1F21
INTENTIONALLY LEIT BLANK
lF20
CHAPTER
PARKING AND MOORING
1F22
SYSTEM
SUBSYSTEM
100000
IOIO.QO
102000
GENERAL
PARKING
MOORING
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 10 PARKING AND MOORING
TABLE OF CONTENTSIEFFECTIVITY
SUBJECT
1F23
GRID
NO.
IG4
IG4
IG4
EFFECTIVITY
10 . ContJ Effect.
Page 1
Reissued: December 31, 1989
GENERAL
PARKING
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
When parking the airplane, ensure 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 must be moored
according to sub-system section on mooring below.
I. When parking airplane, head it into the wind if possible.
- CAUTION -
USE CARE WHEN SETTING BRAKES THAT ARE VERY
HOT DURING COLD WEATHER. EXTREME HEAT OR
ACCUMULATED MOISTURE CAN FREEZE BRAKES.
PRIOR TO SETTING BRAKES, IF EITHER OF THE ABOVE
CONDITIONS EXIST, CHOCKS MUST BE USED TO BLOCK
WHEELS.
2. Set parking brake by applying toe pressure against top of rudder pedals while pulling out on brake handle.
To release parking brake. apply toe pressure on pedals and push in on parking brake handle.
3. Install protective covers on engines and pitot tubes; secure propellers.
MOORING
The airplane is moored for protection and security under various weather conditions. The following procedure
must be used for mooring this airplane:
1. Head airplane into the wi nd if JXlssible.
2. Block whccls with wheel chocks.
- CAUTION-
USE SQUARE OR BOWLINE KNOTS. DO NOT USE SLIP
KNOTS.
-NOTE -
Additional preparations for high winds include using tic-down ropes
from the landing gear forks and securing the rudder.
3. Secure tie-down ropes to wing tie-down rings and tail skid at approximately 45 degrees to the ground.
When using rope constructed of non-synthetic materi al, leave sufficient slack to avoid damagi ng aircraft
when ropes contract due to moisture.
4. Install pitol lube covers, engine inlet exhaust covers, generator cooling inlet, and exhaust outlet covers.
Restrain propellers to prevent windmilling. (Refer to Chapter 95 for special equipment.)
1F24
100000
Page 1
Reissued: December 31, 1989
10-00-00
Page 2
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
GRIDS lGl THRU lG2
INTENTIONALLY LEFT BLANK
lGl
CHAPTER
REQUIRED PLACARDS
1G3
SYSTEM
SUB-SYSTEM
11-00-00
11-00-00
11-20-00
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 11 - REQUIRED PLACARDS
TABLE OF CONTENTS/EFFECTIVITY
SUBJECT
EXTERIOR PLACARDS-DESCRIPTION AND
OPERATION
OENERAL
PLACARDS AND DECALS
1G4
GRID
NO_
105
105
106
EFFECTIVITY
11 - ContJ Effect.
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
EXTERIOR PLACARDSDESCRIPTION AND OPERATION
GENERAL
The airplane nameplate placard is located below entrance door of the airplane. The placard identifies the
airplane by its model number and serial number. Should a question arise concerning the care of the airplane, it is
important to include the airplane serial number in any correspondence to Piper Aircraft Corporation.
As required interior placards and markings are listed in Section II Limitations of the Pilot' s Operating
Handbook and FAA Approved Airplane flight Manual.
Exterior Maintenance placards are shown in this Chapter.
-NOTE-
Any time an airplane is repainted or touched up, inspect all placards
to ensure that they are not covered with paint, arc legible. and
securely attached.
1G5
11-00-00
Page I
Reissued: December 31, 1989
5&6
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
4
5&6
7
7
7 7
TOP VIEW
19
17 18
~ ~ ~ ~ Y 9
16 G-15a 14 15 11 10
12 & 13
SIDE VIEW
Figure 11-1. Placards and Decals
1G6
11-20-00
Page 1
Reissued: December 31, 1989
112000
Page 2
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
20
""-21

22 -_.-
23--t-.
BOTTOM VIEW
27 26
FRONT VIEW
Figure 111. Placards and Dcca1s (continued)
1G7
20
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
"'""
E?t
BRAKE
LEVEL POINT LEVEL POINT
RESERVOIR PLACARD 2
PLACARD 1
I CUT HERE IN EMERGENCY:-l
L CUT HERE IN E M E R G E N ~
PLACARD 3
ENGINE OIL SPECIFICATION
DO NOT MIX DIFFERENT BRANDS
OIL CAPACITY: 9_2 OTS_
DO NOT OVERFILL
FILL WITH APPROVED OIL TO MAXIMUM
MARK ON DIP STICK. SEE CURRENT ISSUE
OF UNITED AIRCRAFT OF CANADA LTD.
ENGINE SERVICE BULLETIN NO.1 FOR LIST
OF APPROVED LUBRICATING OILS.
PLACARD 4
JET FUEL ONLY
PLACARD 5
1G8
112000
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA 42/42720
AIRPLANE MAINTENANCE MANUAL
FUEL
USE AVIATION KEROSENE
SEE AIRCRAFT FLIGHT
MANUAL
FOR ALTERNATE FUEL
PLACARD 6
TIE DOWN ONLY
NO JACKING
PLACARD 9
TC_ PC_
MANUFACTURED BY
PIPER AIRCRAFT
CORPORATION
VERO BEACH, FLORIDA
MODEL
SERIAL NO.
PLATE NO.
PIPER PART NO. 79644-2
11-2000
Page 4
PLACARD 11
Reissued: December 31, 1989
1G9
NO STEP
PLACARD 7
DO NOT PUSH
PLACARD 8
STATIC VENTS
KEEP CLEAN
PLACARD 10
LIFT AND PULL DOWN
PLACARD 12
PUSH
PLACARD 13
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
INSTRUCTIONS FOR SERVICE
(SEE MAINTENANCE MANUAL FOR
SERVICING WITH MIL - H - 5606
(RED) HYDRAULIC FLUID). WITH
NO LOAD ON STRUT. INFLATE TO
ITIRE INFLATION - MAIN 100 PSI I
435 pSi.
PLACARD 14
PLACARD 15
ITIRE INFLATION - NosE 70 PSII INSTRUCTIONS FOR SERVICE
(SEE MAINTENANCE MANUAL FOR
PLACARD 15.
SERVICING WITH MIL - H - 5606
(RED) HYDRAULIC FLUID). WITH
NO LOAD ON STRUT. INFLATE TO
330 psi (350 psi on PA-42-720) .
PLACARD 16

1!'1enne .11T
or
1!'1enne lU:A
PLACARD 17
E. L. T. OXYGEN
LOCATED BEHIND PANEL
FILL
PLACARD 19
PLACARD 18
1G10
JACK PAD
PLACARD 20
11-20-00
Page 5
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
FILL PORT DRY NITROGEN ONLY
SEE SERVICE MANUAL
FOR INSTRUCTIONS
TEMP-PRESSURE RANGE
F -40 -20 0 +20
II PSIG 11585 11660 11735 1815
F 1+60 +70 HO +100
I L PSIG -' 1960 I 2000 12035 2110
FUEL SUMP
DRAIN
PLACARD 22
FUEL SHUTOFF
1\-20-00
Page 6
DRAIN
PLACARD 24
EXTERNAL
POWER
28 VOLTS DC
EB
PLACARD 26
Reissued: December 31, 1989
+40
1890
+120
2185
FUNCTIONAL TEST PORT
WARNING
SEE SERVICE MANUAL
FOR INS RUCTIONS
COMPRESSED GAS
PLACARD 21
OXYGEN SYSTEM
OVERPRESSURE
DISCHARGE DISC
PLACARD 23
FUEL
CROSSFEED
DRAIN
PLACARD 25
STATIC SYST. DRAINS
PLACARD 27
1G11
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1G12
May 15, 2012
11-20-00
Page 7
GRIDS 1G12 THROUGH 1G16
INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER
12
SERVICING
1G17
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1G18
THIS PAGE INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1G19
May 15, 2012
12 - CONTENTS
CHAPTER 12 - SERVICING
TABLE OF CONTENTS
CHAPTER
SECTION SUBJECT GRID NO.
12-00-00 GENERAL 1G21
Engine/Compressor Washing 1G21
Field Cleaning Engine 1G21
Aircraft Finish Care 1G22
Cleaning 1G22
Cleaning Exterior Surfaces 1G22
Cleaning Windshield and Windows 1G22
Cleaning Interior 1G23
Cleaning Carpets 1G23
Cleaning Toilet 1G24
Cleaning Surface Deicing Equipment 1G24
Cleaning Landing Gear 1G24
12-10-00 REPLENISHING 1H2
Fuel Handling Practices 1H2
Filling Fuel Cells 1H2
Jet Fuel Additives 1H2
MIL-I-27686 Jet Fuel Anti-Icing Inhibitors 1H3
Biobor JF (Biocide) 1H3
Draining Moisture From Fuel System 1H4
Draining Fuel System - Complete 1H4
Procedure For Removing Biological Fuel Contamination 1H4
Brake System 1H7
Filling Brake System Reservoir 1H7
Draining Brake System 1H7
Landing Gear Oleo Struts 1H7
Filling Oleo Struts 1H8
Inflating Oleo Struts 1H8
Tires 1H9
Hydraulic Power Pack 1H9
Propellers 1H10
Engine Lubrication 1H10
Engine Oil Level Check 1H10
Engine Oil Chip Detector 1H11
Removal Of Chip Detector 1H11
Inspection of Chip Detector 1H11
Installation of Chip Detector 1H11
Draining Engine Oil 1H11
Servicing Oil Filter Elements 1H12
Page 1
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1G20
May 15, 2012
12 - CONTENTS
CHAPTER 12 - SERVICING
TABLE OF CONTENTS (continued)
CHAPTER
SECTION SUBJECT GRID NO.
12-10-00 REPLENISHING (continued)
Engine Lubrication (continued)
Recommendations for Changing Oil 1H14
Oxygen System 1H15
Oxygen System Safety Precautions 1H15
Filling Oxygen Cylinder 1H15
12-20-00 SCHEDULED SERVICING 1H18
Airframe Lubrication 1H18
Application of Grease 1H18
Application of Oil 1H18
Lubrication Charts 1H19
12-30-00 UNSCHEDULED SERVICING 1I4
Engine Accessory Drive Shafts - Lubrication 1I4
Page 2
GENERAL
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
This chapter covers all routine servicing of airplane, scheduled and non-scheduled. including replenishment of
fuel, oil, hydraulic fluid, oxygen, tire pressure. lubrication requirements, servicing of oleo struts with air and oil,
etc. Pay special attention to all WARNINGS or CAUTIONS.
ENGINE/COMPRESSOR WASIDNG
Due to accumulated environmental airborne chlorides which cause deterioration of compressor blades by a
process Known as sulphidation. Pratt & Whitney Aircraft recommends a compressor wash be carried out weekly
regardless of apparent atmospheric conditions. Pratt & Whitney Service Manual, PIN 3021442 for PT6A-38/41
and PIN 3032842 for PT6A-61 engine. gives full, detailed instructions to wash of engine and compressor. For
specific Pipcr installations insUllctions. use following additional instructions:
-CAUTJON-
BEFORE CLEANING, CABLES MUST BE PROPERLY
SEALED TO PREVENT WATER FROM ENTERING CABLE
HOUSINGS. DO NOT DIRECT ANY WATER PRESSURE AT
THESE SEALS. WATER COULD FREEZE AND BIND
CABLES UNDER CERTAIN CONDITIONS.
DO NOT USE TAP WATER AS INHERENT CHEMICALS CAN
CAUSE DEPOSITS ON COMPRESSOR BLADES.
BE CAREFUL WHEN WASHING EXTERIOR OF FCU. DO
NOT ALLOW WASH SOLUTION TO ENTER VENT HOLES
OF FCU, WHICH COULD GIVE FALSE INDICATION OF
FUEL PUMP LEAK.
OBSERVE STARTER OPERATING UMITS OF 30 SECONDS
ON, 60 SECONDS OFF, 30 SECONDS ON, 60 SECONDS OFF,
30 SECONDS ON, AND 30 MINUTES OFF.
RUN ENGINE WITH STARTER ONLY. ENSURE IGNITION
IS OFF AND APPROPRIATE FUEL FIREWALL SHUTOFF
VALVE IS CLOSED.
1. Allow engine to cool for at least 30 minutes before performing compressor wash.
2. With top cowling removed, discofU1ect bleed air line at union below T-connection. Secure cap lines.
3. Close bleed air shutoff valve and install ground run cowl. On PA42 720, disconnect and cap HI and LO
stage bleed lines. Do not wash engine with bleed mixing valve connected to bleed lines as valve control
passageways become plugged or fouled, rendering valve inoperative and uncontrollable.
4. Open access door on side of bottom cowl; clean mechanism attached to wash ring fitling and clean
according to PraU & Whitney SelVice Manual.
5. Soak for aoou115 minutes after wash.
FIELD CLEANING ENGINE
Field cleaning consists of internal washing of engine compressor and external washing of engine. Refer to
UACL Maintenance Manual, PIN 3021442 or 3032842, Chapter 71, for approved procedures and Chapter 12 of
this manual for precautions.
lG21
120000
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
AIRCRAFT FINISH CARE
CLEANING
-WARNING-
DO NOT USE GASOLINE, KEROSENE, ALCOHOL, BENZENE,
CARBON TETRACHLORIDE, THINNER, ACETONE, OR
WINDOW CLEANING SPRAYS TO CLEAN AIRPLANE.
The entire airplane is carefully finished inside and out to assure maximum service life. All parts are alodine
treated and sprayed with zinc chromate primer on both sides. The external surfaces are coated with durable
Polyurethane enamel.
CLEANING EXTERIOR SURFACES
The airplane should be washed with a mild soap and water solution. Harsh abrasives or alkaline soaps or
detergents could scratch painted or plastic surfaces or corrode metal. Cover areas where a cleaning solution could
cause damage. To wash the airplane usc the following procedure:
1. Flush away loose dirt with water.
2, Apply cleaning solution with a soft doth. a sponge or a soft brush.
3. To remove exhaust stains, allow the solution to remain on the surface longer.
4. To remove stuboom oil and grease stains, use a soft cloth dampened with naphtha.
S. Rinse aU surfaces thoroughly.
6. Any good automotive wax may be used to protect and preserve painted surfaces. Soft cleaning cloths or a
chamois should be used to prevent scratches when cleaning or polishing. A heavier coat of wax on leading
sutfaces will reduce the abrasion problems in these areas. Refer to surface de-ice cleaning procedures.
CLEANING WINDSHIELD AND WINDOWS
-CAUTION-
USE ONLY WATER AND MILD SOAP WHEN CLEANING
THE HEATED WINDSHIELD. USE OF ANY OTHER
CLEANING AGENT OR MATERIAL MAY CAUSE
DISTORTION OR DAMAGE TO WINDSHIELD COATINGS.
1. Remove dirt, mud and other loose particles from exterior surfaces with clean water.
2. Wash interior and exterior window surfaces with mild soap and warm water. Use a soft cloth or sponge in a
straight back and forth motion. 00 not rub harshly.
3. Remove oil and grease with a cloth dampened with Plcxiglas Polish and Cleaner, PIN 403D or similar
substance conforming to Federal Specification (P-P-560) or kerosene.
4. Rinse windows thoroughly and dry with soft lint-free cloth.
-WARNING-
DO NOT USE GASOLINE, ALCOHOL, BENZENE, CARBON
TETRACHLORIDE, THINNER, ACETONE, STRONG
SOLVENTS OR WINDOW CLEANING SPRAYS. DO NOT USE
PLASTIC CLEANER ON HEATED GLASS WINDSHIELDS.
S. A superficial scratch or mar in plastic can be removed by polishing out the scratch with jeweler's rouge.
6. When windows are clean, apply a thin coat of polishing wax. Rub lightly with a soft cloth. Do not apply
wax to heated windshields with electrical heating elements.
7. Apply REPCON repellent or equivalent to windows and windshicld to improve visibility during flights
through rain. Apply only according to manufacturer's instructions. (Refer to Chapter 91, Consumable
Materials.)
1200-00
Page 2
Reissued: December 31, 1989
1G22
CLEANING INTERIOR
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
1. Vinyl interior surfaces may be cleaned with a damp cloth and mild soap and water solution.
2. Leather may be cleaned with a mild hand soap and waler solution or with a saddle soap. Follow the
precautions which apply to the cleaning of any fine leather product. Avoid saturation and never use
detergents or harsh cleaning solutions on leather.
-CAUTlON-
USE OF COMMON HOUSEHOLD CLEANERS AND
POLISHES ON WOOD LAMINATED SURFACES COULD BE
VERY HARMFUL.
4. Wood laminated surfaces should be maintained using only a high grade furniture wax.
5. All upholstery fabrics are Scotchguard treated and may be cleaned as follows:
Spilled oily and watery liquids will generally bead up on the fabric and can be blotted away leaving little or
no stain. Blot spills up as quickly as possible with an absorbent cloth, tissue or sponge. If the material is a
solid or scmi-solid, such as butter. remove the excess by gently scraping with a table knife. Often, blotting
will remove all traces of stain but if the staining agent is not completely removed by blotting, the following
techniques are suggested:
Water-based stains such s ketchup, mnk, ice cream, coffee:
Wipe the stain with a cloth wet with water containing a detergent or ammonia (4 fluid ounces of
ammonia to one gallon of water). repeat if necessary.
Oil based stains such as salad dressing. butter or mayonnaise may be removed by either of the following
procedures:
Apply "Texize K-2R Spot Remover" by spraying or rubbing into the fabric and let dry. Vacuum off the
residual powder. Repeat if necessary or wet a cloth with a solvent type spot cleaner such as "Energine"
or "Renuzit" and wipe or gently rub lhe stained area. Tum cloth and rewet with solvent often. Repeat
until stain disappears.
To remove residual detergem left on the fabric. wipe the entire fabric surface with a cloth dampened with
water. The cloth should be rinsed in clean water several times. This procedure will ensurc that the
treatment will continue to function.
-NOTE-
It is best to test the cleaner on an inconspicuous portion of the fabric
to test for discoloration. Also avoid soaking or harsh rubbing.
CLEANING CARPETS
-WARNING-
SOLVENT CLEANERS REQUIRE ADEQUATE VENTILATION.
Use a small whisk broom or vacuum cleaner to remove dirt. For soiled spots. use a nonflammable dry cleaning
fluid. Floor carpets may be removed and cleaned like any household carpet.
1G23
120000
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CLEANING TOILET
Dry Toilet
1. To dispose of the sanitary bag. pull the top of the bag from the pail and close with a wire tie. Remove it
from the airplane in the covered pail and dispose of according to field facilities. Do not attempt to flush the
bag in a toilet.
2. To clean and deodorize the airplane's toilet. mix a solution of disinfectant type cleaner. Using a soft bristle
brush, rag and solution, wash the toilet pail and seat. The toilet may be removed for cleaning by
disconnecting the two fasteners at the inside forward end of the unit. Slide it back and lift from the floor.
3. When offensive odor remains. use a stronger solution and reclean.
4. Rinse with fresh water and dry.
5. To install a new sanitary bag, place it over the top edge of the pail and push it into the bonom of the pail.
Flushing Toilet
1. To clean, disconnect the electrical plug. Unlock the toilet assembly by turning the wing head fasteners
half tum Remove the toilet assembly and clean. Service per the instructions located on
the toilet waste tank.
CLEANING SURFACE DEICING EQUIPMENT
The deice boots should be cleaned when the aircraft is washed using a mild soap and water solution.
In cold weather, wash the boots with the airplane inside a wann hangar if possible. If the cleaning is to be
done outdoors, heat the soap and water solution before taking it out to the airplane. If difficulty is encountered
with the water freezing on boots, direct a flow of wann air along the region being cleaned, using a portable type
ground heater.
As an alternate cleaning solvent, use benzol or nonleaded gasoline. Moisten the cleaning cloth in the solvent,
scrub lightly and then with a clean dry cloth. wipe dry so that the cleaner docs not have time to soak into the
rubber.
-CAUTION-
PETROLEUM PRODUCTS SUCH AS THESE ARE
INJURIOUS TO RUBBER AND THEREFORE SHOULD BE
USED SPARINGLY IF AT ALL.
When deice boots are clean, a coating of B.F. Goodrich Icex should be applied. Icex is compounded to lowcr
the strength of adhesion between ice and rubber surface of the deice boots.
CLEANING LANDING GEAR
Before cleaning landing gear, place plastic cover or similar material over wheel and brake assembly.
-NOTE-
Inboard gear doors can be lowered by actuating emergency hand
pump handle with master switch OFF.
1. Place can under gear to catch waste.
2. Spray or brush gear area. as required, with solvent or mixture of solvent and degreaser.
3. Allow solvent to remain on gear for 5 to 10 minutes. Rinse gear wilh additional solvent and allow to dry.
4. Remove cover from wheel and remove catch can.
5. Lubricate gear per lubrication chart in Chapter 12.
120000
Page 4
Reissued: December 31, 1989
1G24
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
2
3
10
29--,,L
27
2 6 ~ - ~ ~
11
18 13
3S
28
1. TIP TANK FUel Fill 20. MAIN FUEL TANK DRAIN - RIGHT & LEFT
2. DRAIN FOR TIP TANK (ON FAIRING) 21. OXYGEN PRESSURE GAUGE
3. ENGINE OIL FILTER (OUTBOARD) 22. PRESSURIZATION CONTROLLER FILTER BLEED AIR
4. OIL DRAIN (UNE FROM ENGINE) 23. OXYGEN FILL
5. HYDRAULIC FILTER 24. NOSE GEAR TIRE
6. FUEL FILTER 25. APU COUPLING
7. NACEllE FUEL FILl - RIGHT 26. BAlTERY
8. SUBMERGED FUEL PUMP - RIGHT & lEFT 27. OXYGEN BOlTLE (BEHIND ROYALITE PANEL)
9. INBOARD AFT CELL DRAIN - RIGHT & LEFT 28. NOSE GEAR SHOCK STRUT FILL VALVE
10. SHOCK STRUT VALVE AND FILL - RIGHT & LEFT 29. HYDRAULIC BRAKE RESERVOIR AND POWERPACK Fill
11 . OUTBOARD CELL DRAIN RIGHT & LEFT 30. ECU AIR WATER SEPARATOR
12. RIGHT & lEFT MAIN TIRES 31. HYDRAULIC POWERPACK
13. DUAL DAIVE Oil LINE FILTER -lEFT ENGINE (OUTBOARD 32. VACUUM SYSTEM FILTER
14. WASH RING CONNECTION AND CAP - LEFT ENGINE
15. FUEL FILTER
16. NACELLE FUEL FILL - lEFT ENGINE
17. HYDRAULIC FILTER
18. OIL DRAIN - LEFT ENGINE (INBOARD)
19. ENGINE OIL FILTER (INBOARD)
33. WASH RING CONNECTION AND CAP
RIGHT ENGINE (I NBOARD)
34. DUAL DRIVE OIL LINE FILTER
RIGHT ENGINE (INBOARD)
35. ENGINE GEARBOX OIL STRAINER
Figure 12-1. Service Points
1H1
12-10-00
Page 1
Reissued: December 31, 1989
REPLENISHING
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FUEL HANDLING PRACTICES
The handling of turbine fuel as used in this airplane requires some special attention and safety precautions
which cannot be overly stated. There are several problems which are not nonnally associated with aviation
gasoline. One is water or microscopic particles of free water suspended in the fuel, another is microbiological
contaminants or micco-<>rganisms which live and multiply in the water interfaces with turbine fuel. Due [0 these
problems, turbine fuel requires good fuel handling practices to assure that the airplane is serviced with clean fuel.
The following steps should be used to minimize the possible introduction of contaminants into the fuel system
and maintain a clean condition within the fuel ceUs:
1. Know the source (supplier) of the fuel to be used, ascertain that it is properly stored and filtered as it is
passed from the storage area to the airplane.
2. Perfonn regular fuel filter inspections to detcnninc if any sludge is present. (Microbiological contamination
is visible as a slime or sludge which may vary in color, i.e. red, brown, gray or black.) Micro-organisms
have a tendency to mat and cause interference with fuel flow. Reference to FAA Manual A.C. 65-9, Chapter
4 gives complete explanation on fuels and related problems.
3. It is very important to maintain a clean fuel system by periodically flushing the fuel cells to remove any
contaminants within.
FILLING FUEL CELLS
- WARNING -
DO NOT OPEN OPTIONAL NACELLE FUEL CELL FILLER
OR WING FILLER CAPS WITH MORE THAN 2 INCHES OF
FUEL IN TIP TANKS.
ALWAYS CONNECT STATI C GROUND CABLE FROM
REFUELER TO AIRPLANE. KEEP AI. L GROUNDING
CONNECTIONS CLEAN AND CORROSION FREE.
The fuel cells in each wing arc filled through wing filler cap. Optional nacelle fuel cells contain individual
filler necks on top of each nacelle instead of wing fillers,
After refueling airplane, allow 3 to 4 hours settling period whenever possible, then drain small amounts of fuel
from each drain. the benefits of a settling period will be lost, unless the accumulated contaminants within the fuel
cells are drained before the airplane is moved or the fuel is disturbed by the operation of the internal fuel pumps.
To reduce accumulation of condensation within the fuel cells, it is suggested thallhe cells be maintained in a full
condition as often as possible.
At intervals of 100 hours or 90 days, whichever comes first, clean the filter clements in each fuel filter unit
located on the inboard side of each engine mount. Remove and clean the filters in accordance with instruction
outlined in Cbapter 28. Inspection intervals of the various fuel system components may be found in the Piper
Progressive Inspection Manual, PIN 761 739 (100 Hour).
J ET FUEL ADDITIVES
Condensation of water in the fuel tanks increases the possibility of microbiological growth contamination of
the fuel. This contamination can damage skins, coatings and sealants in the tanks. Fuel additives confonning 10
MIL-I-27686 and/or a biocidal agent manufactured under such trade name's as Biobor JF are compounds which
contain anti-fungicidal agents. Usc of either of these additives in the fuel tanks will reduce the possibility of
conLamination of fuel and fuel ftiters/lines.
12-10-00
Page 2
Reissued: December 31, 1989
1H2
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
-NOTE-
Refer to latest Prau & Whitney Canada Service Bulletin 3044 (PT6A-
41 engine) or 13044 (PT6A-61 engine) for instructions on use of fuel
additives.
MIL-I-27686 JET FUEL ANTI-ICING INHIBITORS
The MIL-I-27686 Jet Fuel Anti-Icing Inhibitor, primarily is an anti-icing agent. however it also has excellent
microbiological sludge deterrent characteristics. It is very soluble in water, and only slightly soluble in fuel,
which mandates that the blending with fuel be accomplished in a precise maMer. Such a device permits injection
of the agent into a flowing stream of fuel to ensure even disbursement. When blending the additive. the
concentration should nOl be less than 0.10 percem or morc than 0.15 percent by volume. Except for the
information contained herein and in the Pilot's Operating Handbook, the manufacturer's mixing or blending
instructions should be carefully followed.
-CAUTION-
ASSURE THAT THE ADDITIVE IS DIRECTED INTO THE
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
PREBLENDED IN THE FUEL AT THE REFINERY, SO NO
FURTHER BLENDING SHOULD BE PERFORMED_
THIS ADDITIVE SHOULD NOT BE USED AS A
REPLACEMENT FOR PREFLIGHT DRAINING OF THE
FUEL SYSTEM DRAINS_
BIOBOR JF (BIOCIDE)
Biobor JF is not an anti-icing agent and is intended to be used specifically as a fuel biocide. The compound is
an extremely efficient biocidal agent and is soluble in the fuel as well as water. Biobor JF disperses throughout
the entire fuel system to even the most remote areas soon after introduction into the fuel system. This compound
is used as a periodic treatment in concentrations of 135 ppm when the airplane has been operated in an
environment conductive to contamination or when evidence of such contamination is found. Biobor JF may also
be used in maximum concentrations of 270 ppm as a single dose shock treatment to clean out and sterilize a very
contaminated system. Biobor JF is not volatile and may remain in the tank until the fuel is used.
The preferred method of introducing Biobor JF into the fuel is by injection through a metering device. If no
metering device is available, blending may be accomplished by batch blending or by over-the-wing blending
while filling the tanks. When one half the required quantity of fuel has been added, gradually introduce lhe
compound directly into the stream of fuel while the remaining one half of fuel is added. Complete mixing is
necessary depending on the severity of the contamination. It must be used at a high enough concentration to kill,
not control the infestation. When used only periodically. it must be used often enough to contact the entire
surface of the fuel tank interiors and remain in contact up to 72 rours to effect the kill. An airplane which has
been treated and flown, should be re-treated at consecutive fills so that a 72 hour contact lime is accomplished.
-CAUTION-
IT IS IMPERATIVE THAT ALL MANUFACTURER'S
INSTRUCTIONS BE FOLLOWED WHEN USING THESE
PRODUCTS
1H3
12-10'()O
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
DRAINING MOISTURE FROM FUEL SYSTEM
To facilitate draining fuel system filter bowls. lines. and fuel cells of moisture and foreign mauer, drains are
incorporated in bottom of each mtee bowl. wing tip tank. main outboard and inboard fuel cell. aft inboard fuel
cells. and cross feed lines. The nacelle fuel cells drain into main fuel cells and do not have individual external
drains.
- WARNING-
TO PREVENT RAMP SURFACE CONTAMI NATI ON AND
POSSIBLE FIRE DAMAGE, ANY FUEL SPILLED ON RAMP
AREA, ETC, MUST BE REMOVED IMMEDIATELY.
1. To drain cilher filler bowl, open access door on lefL rear side of each engine cowl and momentarily push
down on the drain valve ann. Allow enough fuel to flow to clear filter bowl.
-NOTE-
Ensure nacelle tank is full to drain filter bowl.
2. To drain off water in fuel cells, push up on each cell drain ann and allow fuel to flow momentarily. Five
drains; one for each tip tank, one for each main outboard cell, onc for each main inooard cell, and one in
inboard aft tank and crossfecd line drain on bottom of each wing.
-NOTE -
To ensure removal of moisture from each fuel drain, allow fuel to
settle for three to four hours if possible.
DRAINING FUEL SYSTEM COMPLETE
The bulk of fuel is drained from system by placing hose down through wing filler for standard systems or
nacelle filler neck for optional systems. The fuel is drained from fuel filter bowls by activating individual filter
drains. Each wing is drained separately, providing crossfeed valves arc in off }X>sition.
PROCEDURE FOR REMOVING BIOLOGICAL FUEL CONTAMINATION
Fuel system contamination presents a bigger potential problem in turbine fuel systems than in fuel systems
using aviation gasoline because of turbine fuels greater affinity for water. Micro-organisms thrive when water
droplets and fuel are mixed since by-products created by this fonn of contamination attack fuel cell bladders and
metal components; fuel system must be kept clean and periodically inspected to ensure it is free of water and
other foreign maller. If biological contamination exists, evidenced by presence of red, brown, gray, or black
slime in fuel tanks, lines, pumps and filters, thoroughly clean aU system components with lowest octane aviation
gasoline available.
Proceed as follows:
- WARNING -
PROPER GROUNDI NG PROCEDURES AND SAFETY
PRECAUTIONS MUST BE FOLWWED.
1. Level aircraft.
121000
Page 4
Reissued: December 31,1989
1H4
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
PROCEDURE FOR REMOVING BIOLOGICAL FUEL CONTAMINATION (continued)
2. Defuel affected wings, nacelles, and tip tanks.
-NOTE-
Only use container designed for use with contaminated fuel.
3. Remove aU sump drains on effected sides and ensure all fuel is removed.
4. Remove bottom wing root fairing.
S. Remove fuel cell and tank. access covers on wing upper surface.
6. Remove boost pump.
7. Remove cowling of affected engines.
8. Remove firewall mounted fuel fIltcr and engine driven fuel pump inlet and outlet filters. Clean or replace as
required.
9. Remove all finger screens and float or check valves.
10. Clean aU fuel filler bowls and housings with aviation gasoline and inspect components for etching. If
etching exists. replace affected component
- CAUTION-
BRUSH MUST HAVE LANYARD ATTACHED TO PREVENT
BRUSH FROM FALLING WITHIN CELL.
11. Remove access covers from fuel cells which require cleaning. Use Stoddard solvent and soft bristle brush
to scrub affected cells. Remove any panicles of contamination in fuel cell with tack rag. When fuel cell
cleaning is completed, ensure no equipment is left in fuel cells and reinstall all access covers.
-NOTE-
Nacelle tank access cover requires sealing.
12. Use lowest octane aviation gasoline available. Thoroughly flush all fuel cells. tanks. connecting fuel lines,
and boost pump.
13. Inspect all fuel cens. tanks. pumps. and lines for deterioration. The micro-organism by-products attach fuel
bladders. harm fuel tank coatings, and etch underlying metals.
14. Reinstall boost pump and safety.
15. Reinstall all sump drains.
16. Reinstall firewall mounted fuel filter bowls without filter elements.
17. Reinstall roth filter clements and bowls on engine driven fuel pumps and safety.
18. Flush system as follows:
a. Disconnect fuel line between fuel pressure snubber and fuel pwnp.
b. Add eight gallons of aviation gasoline to affected sides.
c. Pull all circuit breakers except those controlling fuel boost pump.
d. Place master switch in on position and actuate boost pwnp.
e. After pumping two gallons of aviation gasoline using pump. observe fuel coming from fuel line.
Actuate crossfeed valve; ensure crossfeed line is clean.
-NOTE-
If right wing is only contaminated ponion, ensure crossfeed valve and
line is adequately flushed by disconnecting crossfeed line at crossfccd
valve on left wing side. Drain fuel into contaminated fuel container.
19. Check allUnes and finings for leaks.
lH5
12.\0-00
Page 5
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
PROCEDURE FOR REMOVING BIOWGICAL FUEL CONTAMINATION (continued)
20. Continue to pump aviation gasoline through system until clean fuel flows into contaminated container.
21. Reinstall filler clements in firewall mounted fuel filters and safety.
22. Reconnect fuel lines between fuel flow transmitters and engine driven fuel pumps.
23. Check system for leaks.
24. Reinstall bottom wing root fairings, fuel cell, and tank access covers.
25. Reinstall engine cowlings.
26. Fill affected fuel cells with 30 gallons of lowest octane aviation gasoline availablc.(Add one quart of 120
aviation grade mineral oil to every 100 gallons of fuel) Run engines. Observe all cautions when operating
engines.
-NOTE -
Make logbook entry each time engine is run on aviation gasoline.
Refer to Prau & Whitney Service Bulletin No, 3044, Engine Fuels
and Additives.
27. Inspect firewall mounted fuel filters after operating engines. Look for evidence of microbiological
contamination. If conlamination ex.ists. repeat cleaning procedure.
28. Clcan fuel filters; reinstall and safety.
12-10-00
Page 6
Reissued: December 31, 1989
1H6
BRAKE SYSTEM
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
The brake system contains a hydraulic fluid reservoir through which the brake system is periodically serviced.
Fluid is drawn from the reservoir by the brake master cylinders to mai ntain the volume of fluid requi red for
maximum braking efficiency. Spongy brake pedal actions is often an indication that the brake fluid reservoir is
running Iowan fluid or air. When repairs to brake system components or bleeding the system are required. refer
to instructions in Chapter 32.
F1LLING BRAKE SYSTEM RESERVOIR
The brake system reservoir must be filled with hydraulic fluid to the level marked on the dipstick (MIL-H-
5606), The reservoir in the upper nose section above the power pack must be checked at every 50 hour
inspection and replenished as necessary. Access to the reservoir is lhrough the door on the upper right portion of
the nose section. If fluid level is low, it must be filled with ftltered hydraulic fluid (MILH-5606). No adjustment
to the brakes is necessary. but they must be checked periodically per instructioru; given in Chapter 32.
DRAINING BRAKE SYSTEM
To drain brake system. connect hose to bleeder filling on brake housing. Place other hose end in suitable
container. Open bleeder valve and slowly pump brake pedal until fluid stops flowing. Th clean system. flush
with denatured alcohol.
-NOTE-
If brake system is drained. pans replaced. or line connections brok.en,
pressure fill and bleed system per procedure in Chapter 32. Procedure
assures air is not trapped in system.
LANDING GEAR OLEO STRUTS (Figure 12-2)
-WARNING-
DO NOT RELEASE AIR BY REMOVING STRUT VALVE CORE
OR FILLER PLUG. DEPRESS VALVE CORE PIN OR OPEN
AIR VALVE SLOWLY TO RELEASE STRUT PRESSURE (AS
APPUCABLE).
Airoil shock. struts. incorporated in each landing gear oleo assembly, absorb shock from wheel impact on
runway during landing.
-NOTE-
Service and adjust struts per placard on strut.
1H7
121000
Page 7
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FILLING OLEO STRUTS
Fill oleo strut completely as follows:
1. Place airplane on jacks (Chapter 7).
2. Place pan under gear to catch spillage.
3. Open air valve slowly or depress valve core pin (as applicable) to release strut pressure.
4. Remove valve core pin.
5. Attach clear plastic tube to valve stem. Place opposite end of tube in hydraulic fluid filled container.
-NOTE-
An airtight connection is necessary between plastic tube and valve
stem. Without an airtight connection, a small amount of air is drawn
into oleo strut during each sequence, resulting in inordinate amount of
air bubbles and prolonged filling operation.
6. Extend oleo strut by pulling down on wheel and drawing fluid into oleo strut. Continue compressing and
extending oleo strut until it is full of fluid and air bubbles cease to appear in plastic tube.
7. Slowly compress strut to fully compressed position.
8. Remove plastic tube. Reinstall valve core (if applicable).
9. Inflate oleo struts according to information in Figure 12-2.
10. Tighten air valve (if applicable).
-NOTE-
For accurate oleo strut inflation, the aircraft must be placed on jacks
with the weight of the aircraft off of the wheels.
INFLATING OLEO STRUTS
Ensure oleo strut contains sufficient fluid (described in Landing Gear Oleo Struts). Attach strut pump to air
valve and pump up oleo strut. Before capping valve, check for valve core leakage.
NOSE GEAR STRUT
INSTRUCTIONS FOR SERVICE
(SEE MAINTENANCE MANUAL FOR
SERVICING WITH MIL - H - 5606
(RED) HYDRAULIC FLUID). WITH
NO LOAD ON STRUT, INFLATE TO
330 psi (350 psi on PA-42-720).
MAIN GEAR STRUT
INSTRUCTIONS FOR SERVICE
(SEE MAINTENANCE MANUAL FOR
SERVICING WITH MIL - H - 5606
(RED) HYDRAULIC FLUID). WITH
NO LOAD ON STRUT, INFLATE TO
435 psi.
Figure 12-2. Servicing Landing Gear Shock Struts
12-10-00
Page 8
Reissued: December 31, 1989
1H8
TIRES
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Tubeless tires are designed to pennit 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 uead, sidewall or ply separation. Discounting tire growth after initial inflation, once the tire
has been reinflated, 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 fonn. Some
vents may emit a continuous stream of bubbles. Others may produce intennittent bubbles. And some may not
bubble at all. This variety is nomal and docs not mean lhatthere is anything wrong with the lire. 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 00 covered during retreading.
check for evidence that your retreads have been revenled.
Several basic characteristics of tuooless aircraft tires may be mistaken for problems:
I. Tire growth in the first 12 to 24 hours after inflation will result in a seemingly severe pressure drop. Simply
reinflate, 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.
Maintain tires at pressure specified in Chart 601. Chapter 6. When checking tire pressure, examine tires for
wear, cuts. bruises. and slippage. Apply Age-Master Nl to tires to protcct against ozone attach 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 fool. 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. Re-apply as conditions required.
HYDRAULIC POWER PACK
Check hydraulic power pack reservoi r fluid level every 50 hours and fill as required. Special filling and
draining service hookup is installed inside right fuselage access panel of nose section. A pressure pot or
hydraulic test unit can be cormected by removing panel, opening access in hydraulic component covers and
protective cap on suclion; fill and drain fitting. Cormect fluid supply line from supply source to fitting. Raise
lever to open valve and fill reservoir. To gravity fill reservoir, support hydraulic fluid supply container higher
than fluid level in power pack reservoir. Reservoir is full when fluid reaches fuU line on transparent reservoirs.
Be sure to close suction; fill and drain valve by placing lever in down position before disconnecting supply line
from fitting. ReinstaU protective cap on fitting. reclose access in hydraulic components cover, and install access
panel.
1H9
12-10-00
Page 9
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1H10
May 15, 2012
12-10-00
Page 10
PROPELLERS
Check blades periodically for damage. Minor nicks in blade leading edges must be filed out and all edges
rounded. Daily inspection must include examination of blades and spinner for visible damage and grease
leakage. For further information on servicing propeller, refer to Chapter 61, or AC 43.13-1A, Section III
on propeller repairing.
ENGINE LUBRICATION
CAUTION: DO NOT MIX DIFFERENT BRANDS OR SPECIFICATIONS OF OIL. CHEMICAL
STRUCTURES CAN DIFFER, MAKING OILS INCOMPATIBLE.
Check engine oil level within ten minutes after engine shutdown. If engine is stationary for 12 hours or
more; start it, run at idle for minimum 2 minutes, shutdown, and check oil not more than 10 minutes later.
Regular oil changes are not necessary. Oil contamination from extraneous matter, such as hydraulic fluid,
sand, etc., will require that the oil system to be drained, flushed and refilled with oil of an approved brand.
Should a switch to another brand be made or should oils of different brand be mixed, drain and flush the
complete oil system. Refill in accordance with the appropriate Pratt & Whitney Maintenance Manual.
Any program established to monitor oil quality should be done in collaboration with the oil supplier or
manufacturer. Refer to latest Pratt & Whitney Canada Service Bulletin No. 3001 (PT6A-41) or No. 13001
(PT6A-61) for additional instructions.
ENGINE OIL LEVEL CHECK
CAUTION: IF OIL LEVEL IN TANK IS BELOW BOTTOM OF DIPSTICK, DETERMINE CAUSE
TO TROUBLESHOOT. IF NEITHER FLUCTUATING OR LOW OIL PRESSURE
READINGS ARE NOTICED, CHECK FOR EXTERNAL LEAKS AND OIL FILTER
CONTAMINATION. CLEAN OIL FILTER AND FILL OIL TANK TO RECOMMENDED
LEVEL. RECORD OIL QUANTITY ADDED, COMPLETE 15 MINUTE ENGINE RUN,
AND RECHECK OIL QUANTITY AND CONDITION OF OIL FILTER. IF BOTH ARE
SATISFACTORY, NO FURTHER ACTION IS NECESSARY. OTHERWISE, REFER TO
ENGINE MAINTENANCE MANUAL.
Within 10 minutes following engine shutdown, unlock filler cap at 11 o'clock position on accessory gearbox
housing. Check contents of tank against marks on dipstick and fill to required level.
NOTE: Normal oil level is one quart below maximum level. Do not ll oil tank more than one quart below
maximum mark.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ENGINE OIL CHIP DETECTOR
The magnetic chip detector, located in the same place as the drain plug on the reduction gearbox, is connected
electrically to the annunciator panel lights. Ulumination of chip detect light on annunciator indicates metal
contamination in oil system. If chip detect light illuminates, remove chip detector and inspect magnetic pole
pieces for contaminate. Refer to Pratt & Whittle), Maintenance Manual, PIN 3021442. Chapter 79.
-NOTE-
When chip detector is removed for inspection. also inspect oil filler.
REMOVAL OF CHIP DETECTOR
1. Remove wiring from chip detector.
2. Remove chip detector from gearbox and discard prefonned packing.
INSPECTION OF CHIP DETECTOR
1. If a single chain of magnetic particles bridges gap across detector poles and particles consists of small
slivers. clean chip detector by wiping with lint-free cloth and reinstall.
2. If marc than 10 pieces of small, nugget shaped magnetic materials exist on detector, send engine to overhaul
facility for inspection.
3. If small amount of fuzz (powered material) exists, clean detector and reinstall. Recheck for continuity after
10 hours of operation.
4. If same amount of fuzz is found again, clean detector, reinstall. and make another continuity check after
another 10 hours of operation.
5. If fuzz is found a third time with similar or greater quantities, ship engine to overhaul facility for inspection.
INSTALLATION OF CHIP DETECTOR
I. Install chip detector with new prcfonned packing in boss on reduction gearbox.
2. Tighten and torque the detector to 45 - 55 inch-pounds.
3. Connect plug and safety.
DRAINING ENGINE OIL
I. Remove engine cowling and place suitable container or drip pan under engine.
2. Remove chip detector at 6 o'clock JX)sition on front case of reduction gearbox.
3. Remove drain plug at 6 o'clock JX)sition on accessory drive gearbox.
4. Remove drain plug from oil tank drain line.
-NOTE-
When operating engine on oil which differs from that previously used,
or if oil system is contaminated by other metallic matter, proceed with
steps 5 through 18. If using same oil and no contamination exists,
proceed only with steps 7, 8, 17, and 18.
1H11
12 1000
Page 11
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
5. Remove drain plug from Oil-lo-fuel heater.
- CAUTION-
LIMIT ENGINE ROTATION TO MINIMUM TIME
REQUIRED TO ACCOMPLISH COMPLETE DRAINING. DO
NOT EXCEED STARTER TIME LIMITS (30 SECONDS ON, 1
MINUTE OFF, 30 SECONDS ON, 1 MINUTE OFF, 30
SECONDS ON, 30 MINUTES OFF).
6. With drains open and ignition and condition lever off, motor engine with starter only; allow scavenger
pumps to clear all lubricating oil.
7. Install new prefonned packings on chip detector and plugs.
8. Reinstall chip detector and drain plugs. (Sec ChapLer 91 for torque values.)
9. Refill oil tank with specified oil. (See latest revision of Pratt & Whitney SClVicc Bunetio. 3001.) Nonnal
oil lever is onc quart below maximum level (hot). Over filling causes excess oil to flow through accessory
gearbox breather.
10. Start engine and run at idle speed for minimum 2 minutes.
11. Feather propeller and shut down engine.
12. Repeat steps 1 through 6.
13. Remove and clean main oil filter.
14. Remove and clean reduction gearbox oil strainer.
15. Reinstall all engine drain plugs and chip detector, tighten, torque, and lockwire. (Sec Otapter 91 for torque
values.)
16. Repeatsteps 7 through 10.
17. Check oil level; replenish as required.
18. Install filler cap and dipstick assembly in filler lube. Ensure cap is colTCcUy installed and locked securely.
SERVICING OIL FILTER ELEMENTS
- CAUTlON -
PLUG BOTH ENDS OF FI LTER ELEMENT BEFORE
SUBMERGING I N VARSOL CLEANER. THE ELEMENT
MUST NEVER BE ULTRASONICALLY CLEANED,
PRESSURE FLUSHED, OR DRIED WITH COMPRESSED AIR
CAUSING DAMAGE TO FILTER MEDIA.
Oil filter elements must be cleaned every 100 hours. Remove and inspect for foreign material and hand flush
in petroleum solvent (AMS 3160 Varsol) bath to remove light contaminants collected on external protcctive
screening. Service life of filter element is 1000 hours.
12-10 00
Page 12
Reissued: December 31, 1989
1H12
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
If cleaning method previously described proves ineffective, clean moor element electrosonically.
1. Plug openings at each end of filter element with suitable plastic or rubber plugs.
2. Place filter element in elcctrosonic cleaner tank.
3. Add sufficient quantity of cleaning solvent to tank. (Approximately 1/4 inch below top edge of tank.)
4. Operate unit for 10 minutes.
5. Rotate element (cod-ta-cnd) 180
0
in cleaning tank and operate unit for additional 10 minutes.
-NOTE-
Adjust cleaning duration depending on condition of element. For best
results. replace cleaning solvent every 20 minutes.
6. Remove element from tank using clean, lint-free gloves; remove plugs.
7. Place element in clean location and allow to dry.
8. After element is cleaned, inspect with magnifying glass for clogged passages and broken wires. If more
than five percent of visible passages are clogged, return element to overhaul facility. If dents or broken
wires are found, replace element.
9. Install new O-rings on filter clement whether element is cleaned or new,
to, Insert filter element (perforated flange first) into filter housing in compressor inlet case.
Plug
Cleaning Tank
Filter Element
___ --Plug
-NOTE-
Electrosonic Cleaner Tank may be proeurred from:
Aerosupport International, Inc.
75 de ta Moselle
SI. l ambert, Quebec
J45 lW3 Canada
PIN Sanae S-2
Figure 12-3, Electrosonic Cleaning Tank
1H13
12-10-00
Page 13
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
11. Install new Qring on filter cover.
- NOTE-
Ensure teflon spacer is in position on filter cover studs.
12. Install filter cover and secure with four plain washers and self-locking nuts. TIghten nuts and torque to 24 -
36 inch-pounds.
13. Clean dual drive oil filter every 100 hours.
RECOMMENDATIONS FOR CHANGING OIL (Refer to Prall & Whitney SelVicc Bulletin No. 3(01)
1. Major factors concerning oil change frequency are engine mechanical condition, spectrometer analysis of
used oil. climatic conditions. dust and sand ingestion during takeoff and landing roll, engine usage, and
shelf life limitations of synthetic lubricants.
2, Whenever oil is changed, remove and check oil filter element for metal particles. Clean. reinstall, or replace
depending on time in service. (See Servicing Oil Filter Elements.)
3. Only use oils listed in UACL Service Bulletin No. 3001.
CHART 1201. THREAD LUBRICANTS
TYPE OF LINE TYPE OF LUBRICANT
Brake MIL-H-5606
Deicer (Air) IT-A-580 (JAN-A-669), Anti-Seize Compound
(White Lead Base)
Fuel MIL-T-5544, Anti-Seize, Graphite Petrolatum
Oil MIL-G-6032, Lubricating Grease (Gasoline and
Oil Resistant)
Oxygen MIL-T-5542, Thread Compound, Anti-Seize and Sealing.
Oxygen System
Pitot and Static IT-A-580 (JAN-A-669), Anti-Seize Compound
(White Lead Base)
Engine - Bleed Air C5-A High Temperature Anti-Seize Compound
- NOTE -
Lubricate engine fittings only with fluid contained in particular lines.
12-10-00
Page 14
Reissued: December 31, 1989
1H14
OXYGEN SYSTEM
PIPER AIRCRAFT
PA 42/42720
AIRPLANE MAINTENANCE MANUAL
Brealhing system oxygen is furnished from a stationary cylinder in the aft section of the forward compartment.
Service and maintenance instructions (or the oxygen system is found in Chapter 35.
OXYGEN SYSTEM SAFETY PRECAUTIONS
- WARNING-
FOREIGN MAlTER IN HIGH PRESSURE UNES CAN CAUSE
AN EXPLOSION. WHEN COMING IN CONTACT WITH
OXYGEN EQUIPMENT, KEEP HANDS, TOOLS, AND
CWTIIING CLEAN.
Use extreme caution when servicing. handling, and inspecting the oxygen system. Comply with the following
precautions:
I. Keep oxygen regulator, cylinder, gauge. valve. fittings. masks, and all other oxygen system componems free
of oil. grease, fuel , and other readily combustible substances.
2. Do not allow foreign matter to enter oxygen lines.
3. Never attempt to repair or repaint oxygen equipment.
4. Keep fire and heat away from oxygen equipment. Do not smoke when working with or near oxygen
equipment. Do not generate sparks when using tools.
5. Never allow electrical equipment 10 contact o)tygen cylinder.
6. Use only thread compound approved under MU..-T-5542 on oxygen systems. Apply only to first thread of
male fittings to prevent thread seizure.
FILLING OXYGEN CYLINDER
The oxygen system filler valve is accessible through a door on left side of nose section.
-NOTE-
If airplane oxygen pressure is below 50 psi , purge system as described
in Chapter 35.
1. To fill oxygen cylinder, open access door. remove cap from mler valve, and attach filler hose of oxygen
recharge unit to filler valve. Ensure all fittings are free of oil, grease, dirt, etc.
2. When using recharge unit containing one supply cylinder, slowly open supply unit valve and allow oxygen
to transfer until cylinder service pressure is reached. Ambient temperature must be considered when filling
oxygen cylinders. See Clan 1203, Indicated Oxygen Cylinder Pressures vs. Ambient Temperature.
3. When using recharge unit containing two or more supply cylinders (cascade storage system), proceed as
follows:
a. Before opening any valves, check remaining pressure in airplane O)tygen cylinder. If partly charged,
note pressure indicated on cylinder gauge. Opcn and close each valve on cascade storage system and
determine which cylinder has lowest pressure. If this cylinder has pressure lower than oxygen cylinder
in airplane, do not attempt to fill it. Use storage cylinder with pressure higher than airplane cylinder,
but lower than all others.
1H15
12-1000
Page 15
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FILLING OXYGEN CYLINDER (continued)
b. Open valve only on storage cylinder with lowest pressure. When indicated pressure on airplane oxygen
gauge and charging gauge is equal , close storage cylinder valve. Proceed 10 storage cylinder with next
higher pressure and repeat procedure.
c. After adjusting last storage cylinder, if oxygen system is still not fully charged then place full storage
cylinder in place of cylinder with lowest pressure.
d. Oxygen will remain in large cylinders used in cascade systems after ftIling only one cylinder. Such
remaining oxygen is at a pressure less than 1800 pounds, which is not sufficient to completely refill
another aircraft cylinder.
c. Do not recharge three or four-cylinder cascade systems with oxygen at less than 300 psi pressure in 300
cubic foot bank. of cylinders. Use 300 cubic foot cylinders to approximately 300 psi and return for
refilling. In two-cylinder systems, usc to approximately 600 psi and return for filling. (Sec Chart 1203,
indicated Oxygen Cylinder Pressures vs. Ambient Temperatures.)
-WARNING-
BLEED PRESSURE FROM FILLER HOSE BEFORE
DISCONNECTING FROM FILLER VALVE.
4. When pressure gauge on recharge unit or in airplane reaches appropriate service pressure (Chan 1204).
close pressure valve on recharge unit. Disconnect filler hose from filler valve; replace protective cap on
filler valve and close access door.
121000
Page 16
-NOTE-
This table accounts for about 25 raise in temperature due to heat of
compression and presumes cylinders are filled at maximum ratc.
CHART 1203. OXYGEN CYLINDER FILLING PRESSURES VS.
AMBIENT TEMPERATURE
Ambient Temperature _ OF
o
10
20
30
40
50
60
70
80
90
100
110
120
130
Filling Pressures Psig
1650
1700
In5
1775
1825
1875
1925
1975
2000
2050
2100
2150
2200
2250
Reissued: December 31, 1989
1H16
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
FILLING OXYGEN CYLINDER (conlinued)
-NOTE-
Pressures arc not exact, but accurate enough for working pressures
between 1800 to 2400 psig cylinders.
CHART 1204. INDICATED OXYGEN CYLINDER PRESSURES VS.
AMBIENT TEMPERATURE
Ambient Temperature _ OF
110
100
90
80
70
60
50
40
1H17
Indicated Cylinder Pressure - Psig
1980
1935
1890
1845
1800
1755
1710
1665
121000
Page 17
Reissued: December 31, 1989
SCHEDULED SERVICING
AIRFRAME LUBRICATION
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
Proper lubrication procedures are valuable for prolonging the service life of the aiTPianc and as a means of
reducing the frequency of extensive and expensive repairs. The periodic application of recommended lubricants
to relevant bearing surfaces combined with cleanliness, as detailed in the following paragraphs, ensures
maximum efficiency and utmost service of all moving parts. Lubrication instruction regarding locations. lime
intervals, and type of lubricants used are found in proper lubrication chans. To ensure the best possible results
from lubricant application, observe the following precautions:
1. Use only recommended lubricants. Where general purpose lubricating oil is specified, but unavailable.
clean reciprocating engine oil is a satisfactory substitute.
2. Check components for evidence of excessive wear and replace as necessary.
3. Removal all excess lubricants from components to prevent collecting dirt and sand in quantities capable of
causing excessive wear or damage to bearing surfaces.
APPLICATION OF GREASE
When lubricating bearings and bearing surfaces with a grease gun. ensure gun is filled with new. clean grease
specified for the panicular application before applying lubricant to grease fillings.
1. If a reservoir is not provided around a bearing. apply lubricant sparingly and wipe off excess.
2. Remove wheel bearings from wheel hub and clean thoroughly with suitable solvent. When repacking with
grease. ensure lubricant enters space between rollers in retainer ring. Do not pack grease into wheel hub.
3. Use extra care when greasing Hartzell propeller hub to avoid blowing clamp gaskets. Remove one grease
fitting while applying grease to other fitting. Uneven greasing effects propeller balance.
APPLICATION OF OIL
If specific lubrication instructions for cenain components are not available. observe the following precautions:
1. Apply oil sparingly. Never apply more than enough to coal bearing surfaces.
2. Since control cables are sufficiently coated by manufacturer. additional protection for corrosion prevention
is unnecessary.
-CAUTION-
AFTER THOROUGHLY WASHING AIRPLANE, ENSURE
LANDING GEAR, FLIGHT SURFACE WINGS, FLAP
TRACKS, ELEVATOR TRIM SCREW, AND ENGINE
COMPARTMENT ARE STILL PROPERLY LUBRICATED.
1H18
12-2000
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1H19
May 15, 2012
12-20-00
Page 2
LUBRICATION CHARTS
Lubrication charts consists of individual illustrations for various aircraft systems with components
referenced by numbers and by type of lubrication and frequency of lubrication in hours. Special instructions
are listed at the beginning of lubrication chart and are referenced on each particular chart.
WARNING: KEEP JET FUELS AND LUBRICATING OILS OFF OF SKIN.
CAUTION: DO NOT USE HYDRAULIC FLUID WITH CASTOR OIL OR ESTER BASE. DO NOT
APPLY LUBRICANT TO RUBBER PARTS.
NOTE: Lubricate pilot and passenger seats track rollers and stop pins as required using general purpose,
low temperature lubricating oil (MIL-PRF-7870).
NOTE: Wheel bearings require cleaning and repacking after exposure to excessive quantity of water.
1. Clean exterior of bearings and bushings with dry solvent before relubricating.
2. Disassemble oil cooler door, ice protection transmission, and screws. Trim screws
and wheel bearings; clean with dry solvent. When reassembling transmission,
lubricate and apply thin coating to screw.
3. Fill oleo struts, power pack reservoir, and brake reservoir per instructions on unit or
container or container or refer to Maintenance Manual, Chapter 12.
4. Remove one of two propeller grease fitting for each blade. Apply grease through
fitting until fresh grease appears at hole of removed fitting.
5. Wipe all lubrication points clean of old grease, oil, dirt, etc, before relubricating.
6. Clean and inspect oil filter element (described in Maintenance Manual, Chapter 12)
each 100 hours time-in-service. See Pratt & Whitney Canada Service Bulletin No.
3001 (PA-42) or 13001 (PA-42-720).
7. Loosen boot from gear lock assembly and grease tube. Tube must slide free to slot
limits. (Gear lock cable assembly on PA-42-720 only.)
CHART 1202. SPECIAL INSTRUCTIONS
1.
2.
3.


PIPER AIRCRAFT
PA 42/42720
AIRPLANE MAINTENANCE MANUAL
COMPONENT LUBRICANT
GEAR [)(x)R, OUTBOARD, HINGES AND CONmOl RODS, RIGHT AND lEFT MILl 7870
GEAR OLEO STRUT FILLER, RIGHT AND LEFT: COAT PISTON TUBE AS NECESSARY MIL-H-5606
GEAR CONTROL ROD ENDS AND BELlCRANK BOLTS, RIGHT AND LEFT MIL-l -7870
WHEEL BEARINGS, RIGHT AND lEFT MIL-G-81322
GEAR DOWN LOCK AND UP LOCK HOOKS, GEAR TORQUE LINK FrTIINGS,
RIGHT AND LEFT MIL-G-81322
FREQUENCY
100 HAS
ASREOUIRED
l00HRS
100 HAS
100 HRS
6. GEAR SIDE BRACE LINK BUSHING AND HOUSING BUSHING, MAIN GEAR DRAG
7.


10.
LINK ASSY, TORQUE LINE ASSY, RIGHT AND LEFT MIL-G-83122 100 HAS
GEAR CONTROL ROD ENOS, CYLINDER END HOOK, RIGHT AND LEFT Mll-L-7870 l00HRS
GEAR DOOR, INBOARD, HINGES AND CYLINDER ENOS, RIGHT AND LEFT MIL-L-7870 100 HRS
BRAKE AND POWER PACK RESERVOIR Mll-H-5606 AS REQUIRED
GEAR LOCK ASSEMBLY (SEE SPECIALINSTAUCnON 7) GEAR LOCK CABLE
ON PA.-42-720 ONLY.
SEE
NOTE
,
, .
5
~ \ 4
Mll-G-81322 100 HAS
-NOTE-
Wipe exposed slrul with clean cloth and
hydraulic fluid MIL-H-S606.
Figure 12-4. Lubrication Chan (Landing Gear. Main)
1H20
\2-20-00
Page 3
Reissued: December 31,1989
1.
2.
3.
4.
5.

7.


10.
11 .
12.
10
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
COMPONENT LUBRICANT FREQUENCY
NOSE GEAR OLEO STRUT FILLER MIL-H-5606 AS REQUIRED
STEERING ARM ROLLERS BELlCRANK RETRACTION
ROD ENOS AND STEERING ROO ENDS MIL-l -7870 100 HRS
NOSE GEAR DOOR ACTUATOR, RETRACTION ROD
END AND CYLINDER ROD END MIL-L-7870 100 HRS
UP LOCK HOOK AND UP LOCK ROO Mll-L-7870 100 HRS
DOOR HINGE BOLT MIL L7870 100 HRS
DRAG LINK ASSEMBLY AND IDLER LINK MIL-G-23827,
MILG-7711A 100 HAS
WHEEL BEARINGS MIL.()-3545C,
Mll-G-7111A 100 HAS
UPPER AND LOWER TORQUE LINKS MIL-G-23827,
Mll -G-77l1A 100 HAS
UPPER AND LOWER TORQUE LINK CONNECTING MIL-G-23827,
BOLT AND SHIMMY DAMPENER Mll-G-7711A 100 HRS
GEAR HOUSING BUSHINGS MOlYKOTE NO. 33 l 00 HRS
NOSE GEAR STEERING CONTROL ROD ENDS MIL-L-7870 100 HAS
NOSE GEAR UP LOCK ASSEMBLY (SEE SPECIAL INSTRUCTION 7)
(GEAR UP LOCK CABLE ASSEMBLY ON PA-42.7200NLy) MILG-81322 100 HRS
"" .,-
2
/
/,,
..-\ \...- :
/ ,
1/ '
/ V
.. ,
:'/
'/ /'
, /
'/
5
r
-NOTE-
Wipe exposed strut with clean cloth and
hydraulic fluid MILH-5606.
REFER TO SPECIAL
INSTRUCTIONS 12-20-00, PageS.
Figure 12-5. Lubrication Chan (Landing Gear, Nose)
12-20-00
Page 4
Reissued: December 31, 1989
1H21
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
COMPONENT WBRICANT
1. AILERON TRIM SCREW MIL-G23827. MIL-G-nl1"
2. AILERON TRIM TAB HINGS AND CONTROl ROO ENOS MIll1870
3. Rl.IODER TRIM SCREW Mfl-G-23827, MIl G-7711A
. RUOOER AND RUOOER TRIM TAB HINGES AND CONTROL ROO ENOS MIL-L-7870
5. ELEVATOR AND ELEVATOR TRIM TAB HINGES AND CONTROL ROO ENDS MIL-l7870
6. AILERON HINGES, RIGHT AND LEFT M1Ll7870
7. FLAP TRANSMISSION PIVOT 8CUS AND SENDER ARM MILL7870
8. FLAP TRACKS, RIGHT AND lEFT AU PURPOSE SLIP SPRAY
(DUPONTNO. 6611j
g. FLAP TRACK ROlLERS, RIGHT AND lEFT Mlll7870
10. AILERON BfLLCRANK CABLE ENDS, PIVOT
BEARING AND CONTROL ROD ENDS RIGHT AND lEFT MILL7870
11 . TRIM SCREWS Mll-G3278 OR Mll-O 23827
12. TRANSMISSION SCREWS, RIGHT AND LEFT MILG23827
13. ELEVATOR TRIM SCREW MIL. S-866OB
FREOUENCY
500 HAS
100 HRS
SOOHRS
l00HRS
,OOHRS
l00HRS
l00HRS
50 HAS
l00HAS
l00HRS
SOOHRS
l00HRS
(DOW CORNING" COMPOUND OR 100HRS
'4. ELEVATOR DOWN SPRING MIl.c 18173D 100HRS
CCfR)aion Re\ardant
(See Cllaptet 91 for PfodlJCte reg.)
Figure 126. Lubrication Chart (Control System)
1H22
E
12-20-00
Page 5
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
SKETCH A SKETCH B
SKETCH D
SKETCH F
SKETCH C
Figure 12-6. Lubrication Chart (Control System (continued)
12-20-00
Page 6
Reissued: December 31,1989
1H23
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
COMPONEHT
I. AILERON BELlCRANK ASSEMBLY BUSHING
2. CONTROL WHEEL CHAIN, VERTICAL AND HORIZONTAl
3. RUDDER PEDALS, TORQUE TUBe BEARINGS AND BLOCK, CONTROl
CABLE ENDS, BRAKE CYLINDER ENDS, AND PULLEYS
2
SKETCH A
WBRICANT FREOUENCY
MILL7870 100 HRS
MILL7870 500HRS
MIL-t7870 l00HRS
SKETCH B
Figure 12-7. Lubrication Chan (Control System) (continued)
lH24
12.2000
Page 7
Reissued: December 31,1989
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I1
May 15, 2012
12-20-00
Page 8
Figure 12-8. Lubrication Chart (Powerplant, Propeller and Propeller Reversing Linkage)
COMPONENT LUBRICANT FREQUENCY
1. ZERK FITTINGS, BLADE HUB (2 PER BLADE) MIL-PRF-23827 100 HRS
2. FUEL CONTROL UNIT INTERCONNECT ROD ENDS MIL-PRF-23827 100 HRS
3. CONTROL CAM AND PINS LUBRIPLATE 130A 100 HRS
4. PROPELLER CONTROL ROD ENDS MIL-PRF-23827 100 HRS
5. OIL FILTER ELEMENT Clean and Inspect 100 HRS
6. OIL TANK REFER TO SPECIAL INSTRUCTION NO. 6
7. PUSH PULL CONTROL - WIRE ROPE MIL-G-21164 100 HRS
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
I. TRANSMISSION ASSEMSlY (SEE NOTE) DUKES 21967.-1
2. TRANSMISSION SCREW Mll-G-23827
3. SlEEVE AND BOLT ASSEMBI.. Y M1L-l7870
OIL COOLER EXHAUST DOOR HINGE Mll-l-7870
S. ICE DEFLECTOR DOOA HINGE MIL-l-7870
8. BYPASS DOOR HINGE MIL-l-1870
7. BEARING BLOCKS MIL-G-23827
8. TRANSMISSION SCREW MIL-G23827
9. TRANSMISSION ASSEMBLY DUKES 21.-74-1
10. TRANSMISSION MOUNTING BUSHINGS MIL-G-23827
11. CLEVIS PIN Mll-l-7870
12. ICE DEFLECTOR DOOR ROO ENDS Mll-l-1870
13. CLEVIS PINS AND BOLT ASSEMBLIES MIl-l-7870
7 12
500HRS
500 HRS
l00HRS
l00HRS
100 HRS
l00HRS
lOOt-lAS
SOOHRS
500HRS
500 HRS
l00HRS
100 HRS
l00HRS
10
Figure 12-9. Lubrication Chan (Air Inlet Ice Protection Oil Cooler Doors)
112
122000
Page 9
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
COMPONENT LUBRICANT
1. CABIN DOOR LATCH HINGES AND STep MECHANISM MIL-L-7870
2, CARGO DOOR LATCH AND HINGES MILL-7870
3. NOSE CONE AND FORWARD BAGGAGE DOOR HINGES AND LATCHES MIL-l -7870
4. NACEUE LOCKER AND ENGINE COWl DOOR LATCH AND HINGES Mlll 7870
5. SEAT TRACKS (ALL) Mlll 7870
3
Figure 1210. Lubrication Chart (Cabin Door, Baggage Door and Seats)
122000
Page 10
Reissued: December 31, 1989
113
FREQUENCY
100 HAS
100 HRS
100 HRS
100 HRS
100 HRS
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
UNSCHEDULED SERVICING
ENGINE ACCESSORY DRIVE SHAFTS - LUBRICATION
Lubricate accessory drive shafts according to Pratt & Whitney Maintenance Manual. PIN 3021442, Chapter
70. Standard Practices, General Torque Recommendations. page 204.
Specific accessories are:
1. Tach generators.
2. Hydraulic pumps, fuel pump.
00 not apply lubricant to the following accessories:
I. Fuel pumps (P&W).
2. Prop governors (CSU).
3. Fuel control units.
Install ovcrspced governor with dry shaft or lubricate with clean turbine engine oil.
114
12-30-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I5
May 15, 2012
12-30-00
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I6
May 15, 2012
12-30-00
Page 3
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PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I7
CHAPTER
20
STANDARD
PRACTICES/
AIRFRAME
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I8
THIS PAGE INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I9
May 15, 2012
20 - CONTENTS
CHAPTER 20 - STANDARD PRACTICES - AIRFRAME
TABLE OF CONTENTS
CHAPTER
SECTION SUBJECT GRID NO.
20-00-00 GENERAL 1I11
Torque Wrenches 1I11
Flareless Tube Assemblies 1I11
Inspection of Flexible Hoses 1I11
20-10-00 PAINTING 1I13
Paint Application 1I13
Page 1
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I10
May 15, 2012
20 - CONTENTS
Page 2
THIS PAGE INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I11
May 15, 2012
20-00-00
Page 1
GENERAL
This chapter contains general information pertaining to standard aircraft hardware installation and removal
practices.
The information included will be very helpful if it is referred to on a regular basis.
If non-destructive testing is needed after repair of 4130 steel, use the magnaflux method.
Testing and inspecting of aluminum castings and machined aluminum parts may be done by the dye
penetrant method.
Usually, a good visual inspection with a 10X magnifying glass will show any damage or defect in a repair
that is of a significant nature.
1. Torque Wrenches
Torque wrenches should be checked and calibrated daily with weights and, a measured lever arm to
ensure that inaccuracies are not present. Checking one torque wrench against another is not sufficient and
not recommended. Some wrenches are quite sensitive to the way they are supported during a tightening
operation. Any instructions furnished by the manufacturer must be followed.
2. Flared Tube Assemblies (Refer to Figure 20-1)
When any fitting containing conical seals is disconnected the following steps must be performed when
reconnecting the fitting.
A. Lubricate threads of nut with a substance compatible with the fluid that is to be contained in the line
B. Install new conical seals
NOTE: Conical seals are never to be reused. If a connection is broken the seals must be replaced .
NOTE: Apply torque on back portion of nut next to shoulder to minimize distortion of thread.
CAUTION: ANGULAR MISALIGNMENT BETWEEN TUBE AND FITTING WILL OVER-
STRAIN SLEEVE AND NUT DURING TORQUE -UP. APPLY TORQUE ONLY
AFTER TUBE CENTER LINE IS SQUARELY MATED TO THE FITTING CENTER
LINE.
C. Tighten fitting one (1) to one and one half (1 1/2) hex flats from position of sharp torque rise (finger
tight).
37 Deg. Flared Fitting
Conical Seal
Tube
Nut
Sleeve
Figure 20 - 1. Installation of Conical Seals
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I12
May 15, 2012
20-00-00
Page 2
Hose Size Ball Size
- 4 ................................................. 5/64
- 5 ................................................. 9/65
- 6 ................................................ 13/64
- 8 ................................................. 9/32
- 10 ................................................. 3/8
- 12 ................................................. 1/2
- 16 ............................................... 47/64
- 20 ............................................... 61/64
CHART 2001
BALL DIAMETERS FOR TESTING HOSE RESTRICTIONS
3. Inspection of Flexible Hoses
NOTE: During the manufacturing process, a condition known as rubber strike-through occasionally
occurs. This condition is such that rubber material protrudes through the wire braid cover. This
condition has no effect on hose quality.
Inspect flexible hoses every 100 hours, especially those in the engine compartments. When inspecting
hoses, look for the following conditions:
A. Check each installation to be sure the hose is not kinked, twisted, or distorted. Check for evidence of
abrasion, cuts, and broken wires. Random broken wires are acceptable since wire breaks sometimes
occur during manufacture. Discard hose if two or more broken wires are found per plait (braid) or
more than six broken wires per lineal foot. Broken wires in an area where kinking is evident is also a
cause for rejection.
CAUTION: PUNCTURING THE OUTER COVER OF THE HOSE MAY CAUSE DAMAGE TO
THE HOSE.
B. Check each assembly for deterioration, ply separation of cover or braid, cracks, weather checking,
lack of flexibility, blisters or bulging, collapse, or sharp bending. Blisters on the outer synthetic cover
do not necessarily indicate a faulty hose.
C. Remove hose from assembly if hose shows any visible wear. Inspect hose interior and check for signs
of deterioration, tube collapse, cut rubber, wire braid puncture, or restriction. To inspect hoses with
elbow fittings, use flexible inspection light and viewer, or inspection ball as described in Chart 2001
Replace hose if any deterioration exists.
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I13
May 15, 2012
20-20-00
Page 1
PAINTING
1. Paint Application
WARNING: TO TOP AND BOTTOM OF WINGS, FROM W.S. 87.50 TO 105.50 AND W.S. 221.00
TO 239.00, APPLY NON-METALLIC STANDARD POLYURETHANE EXTERIOR
PAINT TO CLEAN, ALODINED ALUMINUM SKIN. DO NOT EXCEED 2.5 MIL IN
THICKNESS. THE 2.5 MIL MAXIMUM THICKNESS CRITERIA DOES NOT APPLY
TO INSPECTION ACCESS PLATES.
CAUTION: DO NOT PAINT PITOT TUBES, GAS CAPS, OR ANTENNA COVERS THAT WERE
NOT FACTORY PAINTED. METALLIC PAINTS MUST NOT BE USED ON RADOMES
OR ANTENNA COVERS. DO NOT USE SPRAY SILICONE LUBRICANTS PRIOR
TO PAINTING AS OVERSPRAY IS EXTREMELY DIFFICULT TO REMOVE AND
RESULTS IN LOSS OF PAINT ADHESION.
CAUTION: IN AREAS WHERE A LIMITED THICKNESS OF PAINT IS REQUIRED, BE SURE
TO VERIFY CORRECT THICKNESS BY USING A DIGITAL COATING THICKNESS
GAUGE. (ONE SUCH GAUGE IS THE ZORELCO LTD. MODEL 780/747E).
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1I14
May 15, 2012
20-20-00
Page 2
THIS PAGE INTENTIONALLY BLANK
CHAPTER
ENVIRONMENTAL SYSTEM
1115
SYSTEM
SUB-SYSTEM
21-00-00
21-00-00
21-10-00
21-10-00
21-20-00
21-20-00
21-20-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-30-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 21 - ENVIRONMENTAL SYSTEM
TABLE OF CONTENTSIEFFECTIVITY
SUBJECT
GENERAL
Description of Operation
PRESSURIZATION
Troubleshooting
DISTRIBUTION
CABIN AIR DISTRIBUTION SYSTEM
Description and Operation
PRESSURIZATION CONTROL
Component Detailed Descriptions
Cabin Pressure Dump
Pressurization Check With Test Unit
Pressurization System Checkout Procedure
Ground Operational Check
Safety Precautions
Pressurization System Flight Check
Absolute Pressure Regulator Removal
Absolute Pressure Regulamr Installation
Outflow and/or Safety Valve Removal
Outflowand/or Safety Valve Installation
Outflow and Safety Valve Cleaning
Removal of Controller
Installation of Controller
Controller Filter Replacement
HEATING/COOLING
General
Troubleshooting
Component Detailed Descriptions
Removal of Pressure Regulator and Shutoff Valve
Installation of Pressure Regulator and Shutoff Valve
Removal of Hot Air Bypass Valve
Installation of Hot Air Bypass Valve
Removal of Bleed Air Supply Overpressure Switch
Installation of Bleed Air Supply Overpressure Switch
1116
GRID
NO_
1118
1118
1119
1119
1124
111
111
114
114
119
119
1Jl3
1Jl3
IllS
1116
1121
1121
1121
1121
1122
1122
1123
1123
1123
1123
1123
11<2
1K8
1K8
lK8
lK8
lK8
lK8
EFFECTIVITY
21 - Conti Effect.
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA 42/42 720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 21 - ENVIRONMENTAL SYSTEM (continued)
SYSTEM
SUBSYSTEM
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
21-40-00
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21-40-00
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21-40-00
21-40-00
21-40-00
21-40-00
21 - Cont/Errec.
Page 2
TABLE OF CONTENTs/EFFECTIVITY
SUBJECT
HEATING/COOLING (continucd)
Removal of Compressor Discharge Ovcncmperaturc
Sensing Switch
Installation of Compressor Discharge Ovenempcrature
Sensing Switch
Removal of Water Separator
Cleaning. Inspection and Repairs of Water Separators
Installation of Water Separator
Removal of DUCI Temperature Sensor
Installation of DUCl Temperature Sensor
Removal of Cabin Temperature Sensor and Controller
[ruaallation of Cabin Temperature Sensor and Controller
Removal of Ground Cooling Fan
Installation of Ground Cooling Fan
Removal of Check Valve Assembly
Installation of Check. Valve Assembly
Reissued: December 31, 1989
1117
GRID
NO_
IK9
IK9
1K9
IK9
IKIO
IKIO
IKIO
IKIO
IKIO
IKIO
IKII
IKII
IKII
EFFECTIVITY
GENERAL
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
The cabin is pressurized by engine bleed air that is conditioned by an environmental control system (ECS).
The bleed air is cooled as required for heating, air conditioning. ventilation, and pressurizing the ai r in the cabin.
DESCRIPTION OF OPERATION
-CAUTION-
PERFORM PITOT AND STATIC SYSTEM LEAK CHECKS
BEFORE PERFORMING ANY PNEUMATIC FUNCTIONAL
TESTS. CONDUCTING CABIN PRESSURE TESTS WITH
LEAKING STATIC SYSTEMS COULD DAMAGE DELICATE
INSTRUMENTS.
The environmental control unit (ECU) uses bleed are from both engines as the prime source of energy. This
bleed air system has three parts: 1) the ECU bleed air supply; 2) the auxiliary bleed air supply for deicer boots
and gyros; and, 3) the emergency bleed air cabin pressurization system. Descriptions of each part follows:
- NOTE -
To cap isobaric valve ambient lines, remove access covers in tail of
ail)'rafi and cap finings (adapte") on aft pressure bulkhead (704843).
ECU Bleed Air Supply Systems PA-42 - The compressor bleed air from each engine is supplied to the BeU
through the bleed air shutoff valve. a shrouded duct arrangement, a check valve, and insulated ducts to the inlet of
the primary bleed ai r-la-ram air heal e)(changers in the ECU. A pressure regulator and shutoff valve controls
pressure and flow of bleed air into the ECU, located in the right hand equipment compartment, forward of
Fuselage Station 57.00 pressure bulkhead. Sub-system section titled Heating and Cooling gives a more detailed
description of various components comprising the heating and cooling portion of the system.
PA42-720 - Compressor and interstage turbine bleed air is supplied through a variable ejecwr mi)(ing valve
directly to the ECU. The bleed air shutoff valve and venturi arc not required, otherwise both systems are
basically the same.
Auxiliary Bleed Air Supply System:
Bleed air is also used to operate the cabin pressure control system, inflatable cabin door seal, surface deicer
boots. and vacuum gyro system. This bleed air is taken off the cngine bleed air dueling upstream of each bleed
air shuwff valve and carmot be shut off unless that particular engine is shut down. A ram air-bleed air intercooler
is installed a1 the firewall of each engine nacelle W cool the bleed air supply lO the auxiliary system below 2500F,
prior to entering the fuel lank area aft of the firewall . A bleed air ovenemperature switch. installed in the bleed
air duct downstream of the intercooler, closes at 425 5F and illuminalCs the BLEED AIR HOT light on the
pilot annunciator panel. During normal operation, bleed air to the auxiliary system varies between 10 - 85 psi and
150F - 500F. Temperature is reduced to below 250F by the intercooler. Sub-system section titled
Pressurization covers that ponion in more detail. Reference to Chapter 30 covers the deicer system and Chapter
37 covers vacuum system.
1118
210000
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Emergency Bleed Air Cabin Pressurization System:
The emergency bleed air cabin pressurization system consists of a solenoid shutoff valve. jet pump, and
pressure switch. The emergency bleed air is supplied from the right hand auxiliary bleed air supply line and
activated by the pilot with the ECS SELEcroR switch on the comfort control panel. With the ECS SELEcroR
switch in the EMER position, the emergency pressurization valve in the right hand wing root is opened. At the
same time. the pressure regulator and shutoff valve de-encrgizcs, shutting off bleed air flow to the ECU, The
emergency pressurization air serves as motive flow to the jet pump in the right hand wing roOl, which pulls in
ambient air from a port in the wing Toot fairing. A total pressurization flow up to 9 pounds per minute is
provided into the right hand heater duct. within the cabin. depending on the right hand engine power setting and
altitude.
The emergency pressurization valve is automatically opened when the cabin altitude exceeds 12,OCXJ 12,500
feet. regardless of the position of the ECS SELECTOR switch on the cabin comfort control panel. An absolute
pressure switch in the cabin. set to activate at 12.000 - 12.500 feel. provides this control. The emergency
pressurization valve is aUlomatically opened when the ECU is automatically shut down due to overtemperalurc or
overpressure. Sub-system section titled Pressurization Control covers this in more detail.
PRESSURIZATION
Pressuri zation air for the cabin originates from each engine's bleed air pon. The bleed air is controlled by a
solenoid shutoff valve. operated by an ON-OFF switch on the overhead engine switch panel. The bleed air is
routed through shrouded annular ducts. check valves. and insulated ducts to the inlet of the ECU. (Refer to suI>-
system section titled Distribution for detailed information on special duClS.)
TROUBLESHOOTING
Problems peculiar to the pressurization system componenlS are listed in Chart 2101. along with their probable
causes and suggested remedies. After a problem is corrected, check entire system for security and component
operation.
CHART 2101. TROUBLESHOOTING (PRESSURIZATION SYSTEM)
Trouble Cause
Cabin will not pressurize. Blocked safety valve cabin
air mter or orifice.
Blocked controller cabin air
fLlter wilh orifice.
Internal malfunction in the
isobaric valve.
Internal malfunction in the
safety valve.
111 9
Remedy
Replace filter and check
orifice.
Clean filler and check
orifice on controller.
Remove and replace isobaric
valve.
Remove and replace safety
valve.
21-10-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2101. TROUBLESHOOTING (PRESSURIZATION SYSTEM) (conlinued)
Trouble
Cabin will not pressurize
(continued)
Cabin pressurizes to full
positive differential
pressure after takeoff,
21-10-00
Page 2
Reissued: December 31, 1989
Cause
Internal malfunction in the
controller.
Defective "q" switch and/or
landing gear safety switch.
Defective dump/test switch.
No pressure to door seal.
Excessive leakage in
pressurization ducts.
Excessive cabin leakage.
Solenoid valve malfunctions
in the open position.
Valve on outside air control
box won't close.
Malfunction of ECS control
switch.
Malfunction of ECU pressure
regulator and shut off valve.
Vacuum tube nol connected
to controller.
Malfunction in aircraft
vacuum supply.
Rupture in volume tank.
Internal malfunction in the
outflow isobaric valve.
Internal malfunction in the
controller.
1120
Remedy
Remove and replace
controller.
Remove and replace switch.
Replace switch.
Check and repair door
seal or door seal valve.
Locate leak and tighten
connections.
Locale and repair leak.
Replace valve.
Adjust or lubricate valve
or control linkage.
Repair or replace switch.
Repair or replace valve,
Connect vacuum tube.
Check ai rcraft vacuum
supply.
Replace tank.
Remove and replace valve.
Remove and replace
controller.
PIPER AIRCRAFT
PA-42/42-720
AI RPLANE MAINTENANCE MANUAL
CHART 2101. TROUBLESHOOTING (PRESSURIZATION SYSTEM) (continued)
1Touble Cause
Cabin altitude decreases Low aircraft vacuwn supply.
below selected altitude.
Minor leak in tube between
controller and volume tank
or in volume lank.
Minor leak in lube between
controller and isobaric valve
or in isobaric valve,
Minor leak in the controller,
Minimum rates unbalanced. Minor leak in tube between
Down rate faster than up controller and volume tank
rate.

or in volume tank.
Minor leak. in the controUer.
Pressurized operation Solenoid valve malfunction
before takeoff and in the closed position.
after landing.
"q" switch, landing gear
squat switch or test/dump
switch malfunclion in the
open position.
Broken wiring 10 the
vacuum relief solenoid.
Loose or damaged pneumatic
tube between solenoid va1ve
and safety valve.
Internal malfunction in the
safety valve.
1121
Remedy
Check aircraft vacuum
supply.
Remove and replace tube
or volume tank.
Remove and replace tube
or isobaric valve.
Remove and replace
controUer.
Remove or replace tube
or volume tank..
Remove and replace
controller.
Replace valve.
Remove and replace
switch.
Repair wiring.
Check tube connections or
replace damaged rube.
Remove and replace valve.
21-10-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2101. TROUBLESHOOTING (PRESSURIZATION SYSTEM) (cominued)
Trouble
Cabin exceeds full positive
differential calibrated
setting.
Cabin climbs and descends
at a fixed rate regardless
of rate selection.
Cabin rate exceeds selected
ratc valve during aircraft
climb to cruise altitude.
Cabin pressure rapidly
increases or decreases
with reselection of cabin
altitude.
Cabin altitude exceeds
selected value.
21-1000
Page 4
Reissued: December 31, 1989
Cause Remedy
True static atmosphere tube Securely connect or remove
blocked or not connected on blockage from the true static
isobaric valve and safety atmosphere tube on isobaric
valve. valve and safety valve.
Loose or damaged pneumatic Repair or replace tubing.
tubing from port "1" of
safety and isobaric valve to
atmosphere.
Internal malfunction in Remove and replace
comroller. comroller.
Malfunction in controller. Remove and replace
controller.
Defective cabin rate of Remove and replace
climb indicator, indicator.
Malfunction in controller. Remove and replace
controller.
Loss of airflow into cabin. Repair bleed air supply
ofECU system.
Internal malfunction in Remove and replace valve.
isobaric valve.
Internal malfunction in Remove and replace valve.
safety valve.
Internal malfunction in Remove and replace
controller. controller.
Excessive cabin leak ratc. Seal leaks.
1122
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2101. TROUBLESHOOTING (PRESSURIZATION SYSTEM) (continued)
Trouble Cause
Cabin pressure will not Dump valve paniaUy open.
maintain control setting.
Defective isobaric control
valve.
Defective safety valve.
Defective pressurized air
dump valve.
Defective cabin altitude
controller.
Pressurization duct leakage.
Cabin leakage
Defective cabin altitude
pressure gauge.
Foreign matter on isobaric
outflow control valve or
safety valve seats.
Leak in outflow isobaric
valve control line.
Cabin pressure excessively Isobaric outflow valve static
high. line clogged.
Defective cabin over pressure
switch.
Defective cabin altitude
pressure gauge.
Safety valve static vent
clogged.
Defective safety valve.
1123
Remedy
Close valve; adjust valve
control cables.
Remove and replace valve.
Remove and replace valve.
Remove or repair valve.
Remove and replace cabin
altitude controller.
Locale leak. and tighten
connection.
Locate and repair leak.
Remove and replace gauge.
Clean valve scats.
Locate leak and tighten
COMccoon.
Clean static line.
Remove and replace switch.
Remove and replace gauge.
Qean vent line.
Remove and replace valve.
21-10-00
Page 5
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2101. TROUBLESHOOTING (PRESSURIZATION SYSTEM) (continued)
Trouble Cause Remedy
Cabin door unsafe light Latching relay sticking in Lubricate the mechanical parts
will not go out. the open position. (sparingly) with "Glide Air" or
equivalent.
Switch or switches in door Adjust.
frame out of adjusbllcnt.
Defective pressure switch. Replace switch.
Short to ground. Check wiring and repair.
Cabin door unsafe light Circuit breaker open. Reset circuit breaker.
will not come on.
Broken wire or loose Check wiring and repair.
connection.
No pressure to door seal. Leak in door seal pressure Check and repair door
system. seal pressure system.
DISTRIBUTION
The PA42-720 bleed air dueling from the nacelle firewall to the ECU in the aircraft nose is similar to the PA-
42. except a duct cooling air vent in the engine compartment does not exist. The c)(isting cooling air vent in the
wing root fairing is retained and provides a flow path overboard when a bleed coupling O-ring fails. The bleed
mixing capability of the bleed air control valve assumes a lower bleed air temperature in the ducting system and
eliminates the need for bleed ducting COOling flow. The 350"F temperature switch at the nacelle end of the bleed
ducling has been eliminated. The remaining temperature switches are in the same locations as the PA-42.
After bleed air lines penetrate the fuselage on either side. they join at a V-duct dowruarearn from a check valve
installed in each leg of the Y. These check valves prevent reverse flow into a non-operating engine or non-
pressurized duct system and prevent loss of cabin pressurization. The dUCl from the V-duct forward to the
forward pressure bulkhead. Fuselage Station 57.00. is shrouded and vented overboard at the bottom of the
fuselage. with the inlet in the right hand equipment comparnnent at Fuselage Station 57.00 bulkhead.
Bleed air also operates the cabin pressurization control system. inflatable cabin door seal. pneumatic surface
deicer boots and vacuum gyro system. This bleed ai r is taken off the engine bleed air ducting upstream of each
bleed air shutoff valve and cannot be shut off unless that particular engine is shut down.
1124
212000
Page 1
Reissued: December 31, 1989
DISTRIBUTION (continued)
PIPER AIRCRAFT
PA-42!42-720
AIRPLANE MAINTENANCE MANUAL
A ram air-bleed air intercooler is installed at the firewall to cool the bleed air supply auxiliary systems below
250
o
P, prior to entering the fuel tank area aft of the firewall . When ram air inlet to the intercooler is blocked, a
bleed air ovenemperature switch is installed in the bleed air duel downstream of the intercooler. This switch is
set to close at 425
0
5F, which illuminates the BLEED AIR HOT light in the pilot annunciator panel. If this
occurs, the following steps must be taken:
1. Shut off the ECU bleed air from that engine by using the ON-OFF switch on the ovemead engine switch
panel.
2. If the light remains on after shutting off the ECU bleed air, the 425F switch could have caused the light to
come on. Since this air cannot be shut off. power to that engine must be reduced.
3. If the light remains on after completing steps I and 2. make a precautionary landing as soon as possible,
using minimum engine power on the side with the light.
4. Inspect engine bleed air duct system and make repairs as necessary.
CABIN AIR DISTRIBUTION SYSTEM
DESCRIPTION AND OPERATION
The cabin air dislribution syslCm uses bleed air from the engines and air entering the ECU from outside the
airplane to operate the ECS. The ECS in tum produces cabin heating or cooling and air to defrost the windshield
and side windows. Hot bleed air is used to supply heat. when required. through a bypass valve on the ECU. The
bypass valve controls the amount of hot air mixed with cold air prior to the air entering the cabin.
Air is distributed through out the cabin through a system of ducts, blower motors, louvers and outlets. TIle air
boxcs. located forward of the spar boxes. house blower motors which help distribute the proper volume of air to
each outlet. A diverter valve. located below the junction of the windshield and side window defroster lines. is
install to operate the distribution of defroster air for these windows.
The ECS cabin selector panel. located at the lower portion of the copilot's instrument panel, allows for
operation of cabin air distribution with the usc of electrically operatcd temperature and pressure controls.
2\ -20-00
Page 2
Reissued: December 31, 1989
n
CABIN AIR,
OUTSIDE
"'U- CABIN COMFORT
I I
COOQARM
AUTO HEAT


TEMP
OL
CONT
HI
EII ERG
OF PRESS
FAN
ECS SELECTOR
LO
Fi gu re 21-1. EeS Cabm Selcctor Panel
1J1
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CREW AND PASSENGER
/ OVERIH",\o AIR OUTLET (COlD AIR)
CREW SIDE
OUTlET
WNDSH!aD
FllETEAED AlA
INLET
COLO AIR
"AIR OIST" SELECTOR 'OVHO"
FANS'OFP
SIDE WIIINOC;W
DEFOG OUTLET
DEFROSTER MAY BE SELECTED "ON"OR "OFP
PANEL
VALVE
DEFOG COfIITROl
VALVE
Figure 21 -2. Cabin Air Distribution Schematic - Conditioned Ai r
1J2
21-20-00
Page 3
Reissued: December 31, 1989
\I
21-20-00
Page 4
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CR8NANDPASSENGER
PASSENGER
HEAT PLENUM
(HOT AIR)
FIL TEREO AIR
INLET
(COlO AIR)
FAN
CHECK
WAAMAIR
-AIR DIST" SELECTOR "FLOOR'
RECIRCUlATED AlA
- WITH FANS "to" OR "HI"
DEFROSTER MAY BE SElECTED 'ON" OR 'OFP
SIDE WINDOW
DEFOG OUTLET
Figure 21 3. Cabin Air DisLribuLion Schematic - Heated Air
Reissued: December 31,1989
1J3
FFOM
ECS
VALVE
WINDSHIELD
DEFOG CONTROl
VALVE
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
PRESSURIZATION CONTROL (Refer to Figure 21-4.)
The cabin pressure control system consists of the cabin outflow valve, cabin safety valve, cabin pressure
controller, auxiliary volume tank, absolute pressure regulator, filter, vacuum solenoid relief valve, vacuum
regulator, manual test valve, cabin pressure test/dump switch, cabin differential pressure switch, cabin absolute
pressure switches, and plumbing and wiring. These items are given a detailed operational description followed
by a general description of the cabin pressure control system.
The cabin safety valve is left open on the ground with engines operated by a vacuum applied to the control
chamber of the safety valve. The vacuum regulator of the vacuum system provides a vacuum of 4 to 6 inches
mercury, referenced to cabin pressure. Engine bleed air is supplied to the ejector to produce the required vacuum.
This vacuum holds the safety valve open while on the ground through the action of the landing gear squat switch
and "q" switch which energize and open the vacuum relief solenoid valve. The cabin pressure control switch on
the lower center instrument panel controls the vacuum relief solenoid valve. When placed in the DUMP position,
it energizes the vacuum solenoid and opens the safety valve. The TEST position bypasses the landing gear squat
switch and "q" switch to permit the cabin to pressurize on the ground for test purposes only. The normal position
is CABIN PRESS., which allows the system to pressurize after takeoff.
The cabin pressure controller is mounted on the lower center instrument panel and the auxiliary volume tank
and filter are located behind the instrument panel. The volume tank provides additional volume for the rate
pressure chamber in the controller to give greater accuracy of the cabin rate-of-change control. The air filter
eliminates entry of tobacco tar and dust particles greater than 0.3 microns into the pneumatic control elements of
the controller.
The cabin outflow and safety valves, cabin absolute pressure switches, cabin differential pressure switch
absolute pressure regulator, and vacuum relief solenoid valve are mounted on the aft pressure bulkhead. The
vacuum regulator is located behind the copilot's instrument panel (see Chapter 37).
COMPONENT DETAILED DESCRIPTIONS
1. Cabin Outflow Valve (Figure 21-5)
The outflow valve contains a head and base section. The head section contains port 2 (controller
connection) and a plugged cabin air port. Mounted on the head is the differential control, containing port 1
(true static atmosphere connection with orifice). The base assembly encloses a poppet outflow valve which
sits on a base assembly surface when in the closed position.
2. Cabin Safety Valve (Figure 21-5)
The safety valve contains a head and base section. The head section contains port 2 depressurization
connection and a cabin air filter with orifice. Mounted on the head is a differential control, containing port
I (true static atmosphere connection with orifice). The base assembly encloses a poppet outflow valve
which sits on a base assembly surface when in the closed position.
3. Cabin Pressure Controller (Figure 21-6)
The controller body consists of three elements: 1) The lower element forms a chamber open to cabin
pressure and houses the absolute bellows. It is also the face of the controller that contains cabin altitude
selector knob and cabin rate control knob. 2) The middle element, when assembled to the lower element,
completes and seals the cabin pressure chamber from the rest of the controller with a sealing diaphragm.
The opposite sides of the middle element forms a rate pressure chamber which houses the rate spring. 3)
The upper element, when assembled to the rate diaphragm and the other two elements, forms a reference
pressure chamber which houses the reference pressure metering valve and metering valve follower spring.
This element also contains the various air connections to install the controller into the cabin pressure control
system.
1J4
21-3000
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FR:lM
ECU
CABIN PRESSURE
AUXllLARV
VOLUME
TANK
CABI N PRESSURE
REFERENCE PRESSURE
I) DISCHARGE PRESSURE
& RATE PRESSURE
TANK
TEE
==U FIniNG
AIRCRAFT AIR VALVE
VACUUM PRESSURE
I) mUESTATlC
PRESSURE
CONTOOl
FILTER
WATER
SEPERATOR
---""'=l
FIL TEA CHAMBER FACE VIEW OF CONTROlleR
VESSEL BOUNDARY
PORT
"2'
TRUE STATIC
ATMOSPHERE
OUTFLOW VALVE
CABIN
DISCHARGE
Figure 21-4. Cabin Pressure Control System Schematic
21-30-00
Page 2
Reissued: December 31, 1989
1J5
-,.
CABIN RATE
CONTROL
SELECTOR
KNOB
ABSOLUTE
PRESSURE
REGULATOR
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
COMPONENT DETAILED DESCRIPTIONS (continued)
4. Auxiliary Volume Tank
The tank is a small scaled chamber next to the controller. When connected to the controller, it provides
additional volume to the rate pressure chamber in the controUer and provides greater accuracy of the cabin
rate-of-controL
5. Absolute Pressure Regulator (Figure 21-10)
The absolute pressure regulator contains a spring-loaded, closed ball metering valve and an aneroid bellows.
The bellows sense cabin pressure and override spring closing force when cabin pressure reduces to
approxi mately 13,500 1,000 feet. The unit is poned so opening the ball-metering valve allows cabin
pressure to enter the outflow valve head with sufficient flow capacity to: a) fully close the outflow valve;
and b) shut off the pneumatic control pressure from the controller,
6. Air Filter
The filler element is a cylindrical plug made of treated paper fabric. completely enclosed in a thin aluminum
case, with perforations around its circumference. The filter effectively eliminates entry of tobacco tar and
dust panicles greater than 0.3 micron in diameter into the pneumatic control clements of the outflow valve
controller.
7. Vacuum Relief Solenoid Valve
This valve, nonnally closed. is located between the vacuum regulator vacuwn pon and the control line from
the cabin pressure controller to the safety valve. When energized, the vacuum provided by the vacuum
regulator ejector is appHed to the diaphragm of the safety valve to hold it open. The vacuum relief solenoid
valve is open under either of the following conditions:
a. On the ground with the Q switch or landing gear squat switch energized.
b. In flight whenever the cabin dump switch is in the DUMP position.
8. Vacuum Regulator
Vacuwn to operate the safety valve and controller is obtained from the vacuum system. which uses its own
regulator. The regulator. set to provide 4.5 to 5.4 inches of mercury (relative to cabin pressure). is placed in
the system betwecn thc vacuum driven instruments and the ejector.
9. Ejcctor
The ejector is used by the vacuum system to provide a vacuum source. Located under the right side floor
panels near FS 151.30, it is connected to the pneumatic lines from the intercoolers. Bleed air flows through
the ejector to create the necessary vacuum. (Sec Chapter 36 and 37 for further infonnation.)
10. Manual Test Valves
The manual shutoff valve is located below the instrument panel, 10 the right of center, along the brake
support channel. When used, the valve allows for system ground checkout and is iockwired in the open
position except when the system is tested. The valve is installed in the vacuum line going to the controller
and is used during the system positive differential pressure relief check.
II. Cabin Pressure Switches
a. Cabin differential switch, located on aft pressure bulkhead, provides a warning to the pilot if cabin
differential pressure exceeds 6.45 0.05 psid, by lighting the CABIN PRESS caution light on the
master caution panel.
b. Cabin absolute switch, located on aft pressure bulkhead, provides a warning to the pilot if the cabin
altitude exceeds 10.000 feet for the PA-42 or 11,500 feet for the PA-42-720. by lighting the CABIN
PRESS caution light on the pilot annunciator panel.
c. Cabin absolute switch for emergency pressurization, located on aft pressure bulkhead. turns on the
emergency pressurization valve if cabin altitude exceeds 12,000 to 12.500 feet.
1J6
21-30-00
Page 3
Reissued: December 31,1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
HEAD
CONTROL CHAMBER
DIFFERENTIAL CONTROL CAUBRATION SPRING
DIFFERENTIAL CALIBRATION SCREW
METERING VALVE
DIFFERENTIAL CONTAOL
DIAPHRAGM ASSEMBLY
PORT "I" TRUE STATIC A TMOSPHE"'::R::E'-_ .... Ifl
CONNECTION WITH ORIFICE -
CABIN AIR FIL TEA WITH ORIFICE
ON SAFETY VALVE ONLY
I) DISCHARGE PRESSURE

HOLD THIS DIMENSION
'WT
2 SHIM (AS REO)
L
GASKET
0.075 IN
0.085 .
}3 PLACES
TYPiCAl DIMENSION AFTER
INSTALLATION Of SHIM
GASKET INSTALLATION DIMENSIONS SKETCH A
PORT ' 2' DEPRESSURIZATION CONNECnON
INNER DIAPHRAGM
BASE ASSEMBLY
POPPET VALVE RETURN
SPRING
NOISE SUPPRESSION
SCREEN
SEE
SKETCH A
[) TRUESTATIC ATMOSPHEAE
$ RefERENCE PRESSURE
SEE NOTE UPPER VALVE POPPET VALVE FOR DETAILS
CABIN PRESSURE
213000
Page 4
Reissued: December 31, 1989
"Zt-flAGM COVER
NOTE.! THIS PORT PLUGGED ON OUTFLOW VALVE ONLY.
Figure 21-5. Safety and Outflow Valves
1J7
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
AUXILIARY VOLUME
TANK CONNECTION
REFERENCE PRESSURE
METERING VALVE
METERING VALVE
FOLLOWER SPRING
RATE SPRING
CHECK VALVE
ABSOLUTE BEU.OWS
CABIN AlA SENSE PORT
ACTUATOR
AIRCRAFT VACUUM
CONNECTION
CABIN AL Tl lUDE
SELECTOA KNOB
+ CABIN PRESSURE
RATE PRESSURE
$ REFERENCE PRESSURE
OUTFlOW VALVE
CONNECTlON
AlRCRAFTVACUUMPRESSUAE
FACE VI EW OF CONTROLlER
CABIN AIR FILTER
CONNECTOR
WITH ORIFICE
RATE DIAPHRAGM
--- RATE CONTROL VALVE
--- SEALING DIAPHRAGM
___ RATE CONTROL VALVE
POSmON ACTUATOR
SELECTOR KNOB
Figure 21 -6. Cabin Air Pressure Outflow Valve Controller
1J8
21-30-00
Page S
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
CABIN PRESSURE DUMP
In case of smoke or any emergency, the cabin pressure could be dumped in flight in several ways. In addition
to placing cabin pressure switch in DUMP position. the following actions can be used to dump or decrease cabin
pressure.
I. Position ECS selector switch to OFF position.
2. Pull circuit breaker for DOOR SEAL.
PRESSURIZATION CHECK WITH TEST UNIT (Figure 21-7)
-NOTE-
The ambient lines on the isobaric valves are capped by capping their
adapter fittings on the external side of the aft pressure bulkhead.
These fittings arc reached by removing the access panel in the tail.
Use the following pressurization test procedure to dewnnine if the aircraft fuselage has an acceptable leakage
rate. A pressurization test unit (shown in Figures 21-7, 21-8, and 21 9) is required to perfonn the test.
1. Aircraft Preparation
a. Remove access panel on right side of nose section, to permit access to forward pressure bulkhead at
Fuselage Station 57.00.
b. Rcmove access panels on right and left side of fuselage tail section at Station 346.00.
c. Remove trim panel at Fuselage Station 296.00, in front ofthc outflow and safety valves. Remove cotter
pin and eap ambient lines from outflow and safety valves.
d. Place cabin air control in pressurized position. Close pressurization test valve under instrumcnt panel.
e. Position all circuit breakers except cabin pressure control, door seal. and annunciator/waming lights
circuits in the OFF position.
-NOTE-
If airplane is not on jacks, disconnect electrical power to vacuum
relief solenoid.
f. Disconnect and plug gyro inlet lines at the filter. (See Vacuum System, Chapter 37 for location.)
2. Test Unit Hookup (Figure 21-9)
a. On the right side of the forward pressure bulkhead, remove the cabin pressure tcst fitting protcctive cap.
Connect the cabin reference line from the test unit to the fining.
b. Remove air supply line from water separator inlet and install test adapter (Figure 21-7) as shown in
Figure 21-6. Connect air pressure line from cart to adapter.
-NOTE-
Ensure connections do not leak.
c. The door seal can either be set up with shop air regulated to 18 psi or through the test can. Proceed as
follows :
21-30-00
Page 6
(1) Disconnect line from inlet side of solenoid valve (located on left side of fuselage. under Door, near
Fuselage Station 203.(0).
(2) Connect line (hose) to inlet side of valve and route it back to fining on upper middle pan of rear
pressure bulkhead. Attach hose to adapter with tightened hose clamp to prevent leakage.
(3) Remove access panels on tail of aircraft and reach into tail to unscrew cap from external side of
fitting.
(4) Auach line from test cart or shop air source to external side of fitting.
Reissued: December 31, 1989
lJ9
1.
2.
3.
4.
5.
6.
2.50
OIA
/
V
0 0530
1 2

". = .....
f
......
....
\6
:,J
FRONT VIEW
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
3.75
'"
~
I
1.25 DIA
~
Figure 21-7. Fabricated Reducer Pressure Test Adapter
/
-NOTE-
1. THIS UNIT MUST BE
PURCHASED FROM PIPER.
. .
THIS UNIT IS DESIGNATED WITH
0
~
PIPER PART NUMBER 756 344.
! I :
1\

'0'
15
5
2. THE FLOW RATE VALVE MUST
16

BE SET IN FULL PUMP BYPASS
~
BEFORE STARTING OR
'"
STOPPING UNIT.
[
III ! I11II
"""
/
'89
,,0
~
.
~
!:)
BACK VIEW
.
.
.....
.-
.
~
FLOW METER PRESSURE INDICATOR 7. CIRCUIT BREAKER ,3. SIGHT GAUGE
RATE OF CLIMB INDICATOR
,.
STAAT BUrTON 14.
RATE OF FLOW INDICATOR 9. STOP BUnON 15.
CABIN DIFFERENTIAL PRESSURE INDICATOR 10. AIR REGULATOR VALVE 16.
INSTRUMENT AIR PRESSURE INDICATOR 11. ELECTRICAL CONNECTION 17.
FLOW RATE VALVE2 ,2 FILL PORT
Figure 21-8. Cabin Pressure Test Unit (Typical)
1J10
INSTRUMENT AIR
CABIN REFERENCE
PNEUMATIC AIR OR PRESS. AIR
SHOP AIR
2130-00
Page 7
Reissued: December 31, 1989
21-30-00
Page 8
PIPER AIRCRAFT
PA-42/ 42-720
AIRPLANE MAINTENANCE MANUAL
CABIN PRESSURE
TEST PORT
PNEUMATIC
HOSE
FROM
TEST
CART
ENVIRONMENTAL CONTROl
UNIT INSTAlLATION
TOTESTCAATCA IN
DIFFERENTIAL PRESSURE CAGE
,.-\\:-____
...Ii I-OSE FROM TEST CART
I '
r-l l
( 1'---1\ CABIN PRESSURE IN
\rb
i
--'"'tT' C 2l --
-
... -1 PREsSuRE TEST ADAPTER
(SEE FIGURE 21-7)

--
--
- -
Figure 21-9. Pressurization Test Hookup
PA-42/PA-42-720
Reissued: December 31, 1989
1J11
3. Test Unit Operation
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
-WARNING-
EXERCISE CAUTION DURING DEPRESSURIZATION TO
AVOID HARMING AIRPLANE, TEST UNIT, OR PERSONNEL.
THE TEST UNIT CANNOT BE TURNED OFF WHEN
PRESSURE DIFFERENTIAL EXISTS IN CABIN. IF
MACHINE IS UNPLUGGED, RAPID DEPRESSURIZATION
RESULTS CAUSING SERIOUS DISCOMFORT TO ANYONE IN
THE CABIN.
Proceed as follows:
a. Tum on electrical power to activate door seal system.
b. Close cabin door and ensure it is closed securely.
c. Engage pneumatic system pressure on test unit using regulator control knob so at least 18 psig appears
on test unit door seal pressure gauge. If shop air is hooked up, apply equal pressure.
d. Connect test unit to proper voltage source and tum flow rate valve knob to full bypass position to allow
machine to tum on.
- CAUTION-
TO PREVENT DAMAGE TO RATE OF CLIMB INDICATOR,
DO NOT EXCEED 4000 FEET PER MINUTE RATE OF
CHANGE.
e. Tum cabin pressurization flow control valve so a 2000 - 4000 feet per minute rate of descent is
maintained on rate cHmb indicator. Allow cabin differential pressure to rise to 6.0 psi on cabin
differential pressure gauge (COP).
f. When 6.0 psi is indicated on COP gauge, rotate flow control valve and decrease air flow rate until cabin
rate of climb gauge indicates zero.
g. Maintain 6.0 psi cabin differential pressure and zero rate of change.
h. Observe leak rate on test unit flow meter. The actual leakage rate must not exceed 60 CFM.
i. If allowable leakage rate is exceeded, locate leak using soap bubbles, mechanic stethoscope, or other
appropriate method; repair leak and repressurize by following above procedure.
j. After completion of leak rate test, check annunciator/warning Hght system as follows:
(I) Ensure ambient sense line from outflow and safety valves arc capped.
(2) Secure door and any other openings; slowly increase cabin pressure to a 6.45 0.05 psig reading
on cabin differential pressure gauge.
(3) Note activation of annunciator/warning light system and ensure cabin pressure does not exceed 6.5
psig. The light must come on at 6.45 0.05 psig.
-CAUTlON-
AFTER COMPLETION OF PRECEDING TESTS, ENSURE
CAPS ARE REMOVED FROM AMBIENT SENSE LINES TO
OUTFLOW AND SAFETY VALVES AND ENSURE COTTER
PINS ARE REPLACED.
1J12
213000
Page 9
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
k. Prior to any engine IUnup test, check bleed ai r. cabin pressurization system, safety, and outflow valves
as foUows:
(1) Safety valve check - Ensure ambient sense line for safety valve is open. Cap outflow valve ambient
sense line.
(2) WiUt cabin pressure stabilized. slowly increase cabin pressure to a 6.2 - 6.4 psi reading on cabin
differential pressure gauge to pennil opening of safety valve. The test unit cabin rate of climb
indicator will indicate a climb when safety valve opcm.
(3) Outflow valve check - Cap ambient sense line for safety valve and open ambient sense line for
outflow valve. Repeat preceding step for outflow valve.
1. After completing safety and outflow valve opening checks, rotate flow contralto depressurize cabin and
bring pressure to ambient. by observing cabin differential pressure gauge. Secure ambient sense lines in
open positions by removing caps and replacing cotter pins.
m. Shut down and turn off shop air to test unit. Bleed off air pressure in door seal and open cabin door.
n. De-energize airplane electrical system and disconnect test unit pneumatic lines from airplane.
Reconnect Clcclricallines to vacuum relief solenoid, if disconnected and all airplane pneumatic lines.
o. Replace access and trim panels.
PRESSURIZATION SYSTEM CHECKOUT PROCEDURE
The following procedure is established to systematically check the function of each cabin pressure control
system element so any single or combination of component malfunctions is safely detected and corrected. If a
malfunction is detected, it must be corrected immediately.
GROUND OPERATIONAL CHECK
-WARNING -
THE FOLLOWING OPERATIONAL CHECK REQUIRES
ENGINE RUNUP AND ALL SAFETY PRECAUTIONS MUST BE
STRICTLY OBSERVED. ALL PERSONNEL WORKING ON
THIS CHECK MUST HAVE COMPLETE OPERATIONAL
KNOWLEDGE OF POWER PLANTS AND BE FAMIUAR WITH
ALL EMERGENCY PROCEDURES OUTLINED IN THE
AIRPLANE FLIGHT MANUAL.
1. Ensure cabin door and pilot window are closed and locked.
2. Open manual test valve.
-NOTE-
Ensure caps are removed from outflow and safety valve ambient
sense lines.
3. Position right and left engine bleed air switches ON.
4. Ensure cabin ai r manual control is in PRESSURIZE position.
S. Rotate cabin rate control-selector knob to 9 o'clock, nonn position.
6. Rotate cabin altitude selector knob until cabin altitude indicates approximately 500 feet above field
elevation.
213000
Page 10
Reissued: December 31,1989
lJ13
PIPER AIRCRAFT
PA42142 720
AIRPLANE MAINTENANCE MANUAL
7. PA-42 only:
a, Depress toe brakes and set parking brake valve.
b. Start engine (refer to POH).
c. Place left and right bleed air switch to ON position.
d. Place EeS switch to HI position.
c. Set engine power levers to obtain 75% compressor Ng speed,
f. Establish steady cabin air inflow.
-NOTE-
Ensure BLEED AIR OFF light illuminates when each engine is
started and when bleed air switch is in off position.
7a. PA-42-720only:
a. Depress toe brakes and set parking brake valve.
h. Start engines.
c. Place left and right bleed air switches to LO position.
d. Place EeS selector to GND position.
e. Set engine power levers to GROUND IDLE position.
f. Ensure GROUND BLEED AIR annunciator lights are on.
g. Slowly advance power levers and verify that GROUND BLEED AIR lights extinguish at 70 - 75% Ng
speed.
h. Retard throttles slowly and ensure lights illuminate again at 65 - 70% Ng speed.
-NOTE-
Ensure BLEED AIR OFF light illuminates when each engine is
started and when bleed air switch and ECS switch are in the OFF
position.
8. Place cabin pressure switch in test position. Note that safety valve closes.
9. Rotate cabin altitude selector knob until either CABIN ALT indicates approximately 1,500 feet below field
altitude or to full counterclockwise stop position (below sea level), whichever is applicable. Cabin pressure
will increase during rate-of-change operation.
to. Rotate cabin rate control selector knob counterclockwise. Not reduction in cabin pressure raw-of-change.
11. Rotate cabin rate control selector knob clockwisc. Note increase in cabin rate-of-change.
12. Allow the cabin pressure to stabilize at the selected value.
13. Rotate cabin altitude selector knob until CABIN ALT indicates awroximately 500 feet aoove field altitude.
14. Rotate cabin rate control selector knob counterclockwise. Note reduction in cabin pressure rate-of-change.
15. Rotate cabin rate control selector knob clockwise. Note increase in cabin pressure rate-of-change. Allow
cabin pressure to return to field altitude.
16. Monitor cabin rate of climb, cabin differential pressure and the cabin altitude gauges during tesl. Check for
system malfunction if gauge readings arc not acceptable.
17. Place cabin pressure switch to cabin pressure position and permit cabin to depressurize. Nare safety valve
and outflow valve are fully open.
18. For positive differential pressure relief check. establish steady cabin air inflow (outlined aoove) and proceed
as follows:
a. Rotate cabin rate control selector knob fully clockwise. This allows pressure in rate chamber to remain
equal with cabin pressure during checkout procedure.
b. Rotate cabin altitude selector knob until CABIN ALT indicates approximately 500 feet above field
altitude.
c. Place cabin pressure switch in test position to simulate flight condition. Ensure safety valve closes and
outflow valve moves toward OPEN poSition.
d. Behind instrument panel, locate manual test valve in controller vacuum line and cut safely wire to
handle.
1J14
2130-00
Page 11
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
e. Slowly move test valve handle toward closed position until cabin pressure srans to increase (indicated
on cabin altimeter and rate of change indicator),
f. Adjust neutral test valve until comfortable cabin rate of change is established. Allow cabin pressure to
increase until positive differential pressure control operation is achieved (shown on cabin-to-armosphcre
differential pressure gauge).
-NOTE-
When working with manual test valve, opening valve decreases cabin
pressure rate of change and closing valve increases cabin pressure rate
of change.
g. When pressure rate-of-change decreases to zero, close manual test valve to shutoff vacuum to
controller. The cabin pressure control system must control cabin pressure during normal positive
differential pressure operation.
h. Cap outflow valve ambient line to ensure proper transfer of differential pressure control to safety valve,
The system now exhibits control at maximum positive differential pressure operation, verifying
operation of outflow and safety valves.
i. Uncap outnow valve ambient line, allowing differential pressure control to return to out1low valve.
j . Slowly open manual test valve to establish comfortable cabin pressure ratc-of-change while ascending
to field altitude.
k. When cabin pressure returns to field altitude, shut engines down.
I. Lockwire manual test valve in OPEN position and ensure adaptcr fittings are uncapped and secured
open with cotter pins.
SAFETY PRECAUTIONS
The following safety precautions must re observed:
1. Uncontrolled Pressurization:
a. During flight testing of system, continuously monitor cabin pressuri zation instruments for
overpressurization.
b. In case of uncontrolled pressurization, the pilot must stop pressurization or depressurize aircraft as
follows:
(1) Move cabin pressure mode switch to DUMP position.
(2) Pull cireuit breaker to deactivate inflation of cabin door seal.
(3) Close right and left engine bleed air valves by placing both bleed air switches in OFF position,
(4) Rotate BCU control to OFF position.
(5) Open pilot storm window.
2. Control1ed Depressurization:
a. At altitudcs above 10,000 feet, if an unpressurized condition is required for an emergency (such as
smoke in cabin), depressurize as fol1ows:
21-30-00
Page 12
(I) Apply oxygen masks (aU persons on board).
(2) Place cabin pressure mode switch in DUMP poSition.
(3) Position ECS selector switch to EMERGENCY position.
-NOTE-
If smoke persists or if cabin becomes 100 wann, position ECS selector
switch to OFF poSition and move manual cabin ai r lever to OUTSIDE
AIR.
(4) Immediately reduce aircraft altitude to less than 10,000 feet.
(5) When emergency condition is correctcd, place cabin pressure mode switch in PRESSURIZE
position, ECS selector switch in HI or LO position, manual cabin air lever to PRESS position, and
return to aircraft cruise altitude. The cabin pressure will automatical1y return to preselected sening
on rate-of-change control.
Reissued: December 31, 1989
1J15
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
PRESSURIZATION SYSTEM FLIGHT CHECK
The following instructions explain how to perfonn a pressurization system flight check:
I. Pre-Flight Procedure
a. Ensure cabin door and pilot window are closed and locked.
b. Set cabin altitude selector knob so cabin altitude indicates awroximately SOO feet above field altitude.
c. Tum cabin rate control knob to NORM position.
d. Move cabin air manual control handle to PRESSURIZE position.
- CAUTION-
CHECK FOR BROKEN OR DISCONNECTED CONTROL
CABLE IF LITTLE EFFORT IS REQUIRED TO MOVE
CONTROL HANDLE. DO NOT CONTINUE FLIGHT CHECK
UNTIL INSPECTION OR REPAIRS ARE COMPLETED.
e. Sct cabin pressure mode switch to CABIN PRESS position.
f. Stan engines, set both right and left engine bleed air switches 10 ON JX)sition, ECS selector switch to HI
or LO, as desired, and establish steady cabin air flow.
g. Ensure cabin door seal is inflated.
2. Ascem Procedure
a, After lift-off. when selected cabin altitude is attained and cockpit workload pcnnits, select aircraft
cruise altitude plug, 1,000 feet on aircraft altitude dial. Note when safety valve closes on lift-off, no
appreciable increase in cabin pressure exists. The cabin rate of descent must not exceed 500 FPM from
safety valve to outflow valve during transition of cabin altitude COnlrol.
b. Cabin altitude automatically climbs to altitude indicated on controller at rate set with cabin rate control
selector knob.
c. Monitor differential pressure gauge, cabin altitude gauge, and other pressurization controls during
climb.
3. Cruise Procedure
a. Annunciator/Waming Light Emergency Pressurization System Check.:
(1) With airplane cruising at 10,000 feet, position cabin pressure switch to DUMP position and allow
cabin pressure to stabilize.
(2) Initiate climb to 10,500 feet for PA-42 or 11,700 200 feet for PA-42-720 and ensure cabin
pressurization warning tight and annunciator have activated. Continue climb to 12,500 feet and
ensure emergcncy pressurization comes on.
(3) Repressurize cabin by positioning cabin pressure switch to CABIN PRESSURE poSition.
1J16
213000
Page 13
Reissued: December 31, 1989
213000
Page 14
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2102. CABIN ALTITUDE VS. AIRPLANE ALTITUDE
J
I
14.000 HHH-+++-+-+-+-+-+-.j/1/ 4 --+1
/
Lj--+-1f.1-l
I
r- if .;; /
H--+-+-+-+-..J+.+-H--+.....IJ'-I
12.000 HHH-++&1-I-I-I-I--A-
I
+
I/
-A-+4l--+tf-H
!:>i!/,-+-+---+++41+- /+f-,!
$
@ 10,000 f-f-f-I-
u.

ff I I / / II
II ,, '?j
.
/ f.,I

II
;!; B,OOO

II
II II I-
I 1/
1/ I / 11
I1I1
6,000 f-HH4-1--I--I--I/I-IlHI-'J'-A-
I I /1/
I II
1/ /
4,000 f-Hr-l--+-I-
Il
-.Jj....Jj.-I-J.I
I/
-I-JLfJl4-+-+-+--+-H-
II
I II
2,000 I-.Jj..- II-I I/W'I--l--+--+-+-+-+--+-H-

PA-42720
I1 I1 PA-42
II
SEA LEVEL '1 ULL.J--"';L.J..-JL.J..-JL..J....J,-U-,
o

12 16 .. .. 3233"36
AIRPLANE ALTITUDE FEET x 10 3
Reissued: December 31, 1989
1J17
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
PRESSURIZATION SYSTEM FLIGHT CHECK (continued)
4. Maximum Positive Differential Relief Test Procedure
a. Monitor cabin differential pressure gauge continuously during test so maximum outflow valve setting is
not exceeded.
b. Stabilize cabin altirude at 10.500 feet and initiate climb to 16,000 feet at climb power.
- NOTE-
Leave pressurization controls at 10.000 feet and rate full clockwise.
c. When 16,000 feet is reached, establish cruise power. The cabin altitude must Slay at 10,000 feet with
zero rate of change.
d. Perfonn the following steps while maintaining cruise power at 16,000 feet:
(1) Tum rate knob counterclockwise (decrease),
(2) Select 7.500 feet cabin altitude (outer knob).
(3) Tum rate knob slowly clockwise until comfortable rate of descent is obtained. When cabin altitude
nears 7,500, turn rate knob counterclockwise until 300 FPM descent is obtained.
(4) Wait until cabin stabilizes.
- NOTE -
Continue only if system is operating satisfactorily.
(5) Tum rate knob fully counterclockwise (decrease).
(6) Select 800 feet cabin altitude.
(7) Tum rate knob clockwise until comfortable rate of descent is obtained. When cabin altitude nears
7,500, tum rate knob counterclockwise until 300 FPM descent is obtained.
(8) Continue to monitor differential pressure gauge and test altimeter to ensure cabin altitude does not
drop below 800 feet or cabin differential pressure docs not exceed 6.4 psi.
(9) After cabin stabilizes at 800 500 feet, monitor pressurization inSUllrnents. Appl y climb power
and ensure cabin does not descent oolow 800 feet or cxceed 6.4 psi differential pressure on gauge.
Climb to 18,000 feet.
- NOTE-
If at start of climb cabin differential pressure was not a1 6.3 psi, a rise
in differential pressure will occur. It must not exceed 6.4 psi and
cabin rate of climb must be identical as aircraft rate of climb.
1J18
21-30-00
Page 15
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
PRESSURIZATION SYSTEM FLIGHT CHECK (continued)
c. At 18,000 foot altitude. sct up cruise power and record the following data:
(1) Aircraft altimeter reading in feet.
(2) Cabin test altimeter reading in feet.
-NOTE-
A calibrated. handheld test altimeter is required to check cabin
altitude gauge.
(3) Differential pressure reading in psid.
- NOTE-
Cabin differential pressure must not exceed 6.4 psi and cabin altitude
must not be less than 2,000 feet
f. If system is operating satisfactorily, proceed to next test procedure.
S. Descent and Negative ReHef Check Procedure
a. While maintaining 18,000 feet and cruise. proceed with the following steps:
(1) Set cabin rate control fully counterclockwise (decrease).
(2) Set cabin altitude control knob to 10,000 feet.
(3) Sct slowly rotate cabin rate control clockwise to maximum rate (no climb will be observed for
approximately 1 minute). When cabin stabilizes at 10,000 feeL, proceed to next step.
b. Initiate nonnal descent, maintaining sufficient power to maintain pressurization (until below 10,000
feet) and observe the following:
2\-30-00
Page 16
(1) At 18,()(X) feet, the cabin must be at 10,000 feet and remain constant until aircraft reaches 10.000
foot altitude.
(2) Below 10,000 fect. cabin rate of descent must be approximately the same as airplane.
-NOTE-
When airplanc goes through 10.000 fect, differential between cabin
altitude and aircraft altitude must not exceed 1,(0} feet.
Reissued: December 31, 1989
1J19
PIPER AI RCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
PRESSURIZATION SYSTEM FLIGHT CHECK (continued)
- NOTE -
Do not land with more than 0.3 psi cabin differential. Dump pressure
and control airplane descent to airplane altitude does not catch up
with cabin altitude during rate operation.
c, Prior to landing. pcrfonn the following steps:
(I) Reset cabin altitude selector to field elevation plus 500 feet, descent position.
(2) Adjust rate of change control 10 comfortable rate of descent.
(3) Observe cabin differential pressure indicator. When airplane reaches pattern altitude, cabin
differential pressure must be nearly equalized.
BEllOW
CHAMBER ' A'
CHAMBER ' S'
OUTFlOW
>------VALVE
PORT
Figure 21-10. Absolute Pressure Regulator
lJ20
21-30-00
Page 17
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ABSOLUTE PRESSURE REGULATOR REMOVAL
1. Remove trim panel in front of pressure regulator (located on rear pressure bulkhead).
2. Disconnect lines from regulator.
3. Remove three attaching screws from regulator.
4. Remove regulator from mounting bracket.
ABSOLUTE PRESSURE REGULATOR INSTALLATION
1. Install regulator into mounting bracket.
2. Install three attaching screws and tighten.
3. Connect lines removed from regulator.
4. Install trim panel on rear pressure bulkhead.
OUTFLOW AND SAFETY VALVE REMOVAL
1. Remove trim panel in front of safety and outflow valves (located in rear pressure bulkhead).
2. Remove access panel on left side of tail section, just aft of entrance door. jf safety valve is being removed.
or remove access panel on right side if outflow valve is being removed.
3. Disconnect lines to valve being removed.
4. Worldng through tail section access hole. remove three locknuts securing valve.
5. Remove valve from pressure bulkhead.
OUTFLOW AND SAFETY VALVE INSTALLATION
1. Place valve onto shelf in rear pressure bulkhead.
2. When reinstalling safety and outflow valve. see Sketch A. Figure 21-5, to ensure proper gasket scaling
requirements. For proper clearance between nuts and gasket face. adjust clearance as follows:
a. Remove nuts using deep socket and sufficient shims to meet dimensional requirements. A minimum of
one shim is required for installation of each nut.
b. Install nuts and tighten.
c. Apply drop of locking compound (MIL-S-22473-EV) to top of nuts, between nuts and studs.
3. Through tail section access opening, install three locknuts holding valve in place; tighten to metal contact
then back off 1/4 tum.
4. Install access plate removed from side of tail section.
5. COlUlCct lines removed from valve.
6. Install trim panel in front of valves to ensure acoustical material is in good condition.
21-30-00
Page 18
Reissued: December 31, 1989
1J21
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
OUTFLOW AND SAFETY VALVE CLEANING
Routine maintenance for cabin pressure control system components is limited to ftlicr replacement in cabin air
pressure safety valve and cleaning of seats in outflow and safety valves. Clean outflow and safety valve seals
thoroughly using detergent or isopropyl alcohol.
-WARNING-
DRY CLEANING SOLVENT MUST BE USED IN A WELL
VENTILATED AREA. AVOID BREATHING FUMES AND
KEEP AWAY FROM FLAME.
Clean safety valve filter as follows :
1. Remove retaining ring, onc screen, copper ribbon. and remaining screen from filter housing.
2. Wash both screens, copper ribbon. and filter housing in dry cleaning solvent. Ensure orifice hole in filter
housing is free of foreign material.
3. Install one screen in filler housing.
4. Install copper ribbon in filter housing.
-NOTE-
Do not over compress copper ribbon in filter housing.
5. Install remaining screen and install retaining ring.
-NOTE-
Do not clean ai r filter on controller. Remove and replace component
as required.
REMOVAL OF CONTROLLER
1. Disconnect lines from rear of cabin altitude controUer assembly. Cap open parts of lines and fittings to
prevent dust from entering system.
2. Remove screws securing electroluminescent panellO face of instrument panel.
3. Remove three screws securing selector to instrument panel.
4. Remove controller by lifting assembly from rear of instrument panel.
1J22
21-3000
Page 19
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF CONTROLLER
1. From front side of panel, JX)sition controller into instrument panel cutout.
2. Secure controller to instrument panel with three screws.
3. Position electroluminescent panel to instrument panel and secure with screws previously removed.
4. Remove protective caps from selector lines and fittings. Connect lines to fittings on rear of controller.
CONTROLLER FILTER REPLACEMENT
A disposable tobacco mtcr, installed in the pressurization system must be replaced every 500 hours of nonnal
usc. (Refer to parts catalog for replacement mter pan number.) More frequent filter change and cleaning of the
outflow and safety valve scats could be required depending on amount of smoking in cabin.
Replace controller filter as follows:
1. Remove flIler, accessible from underneath instrument panel, from behind and discard.
2. Install new filter.
HEATING/COOLING
GENERAL
The heating and cooling system uses engine bleed air 10 operate the envirorunentaI control system. which in
tum produces heating or cooling to supply the cabin. HOI bleed air is used to supply heat through a bypass valve
on the environmental control uniL TIle valve controls the amount of hol air mixed with cold air prior to entering
the cabin.
TROUBLESHOOTING
Problems, probable causes, and suggested remedies of the environmental control system components are li sted
in Chart 2103. When a problem is corrected. check entire system for security and component operation.
1J23
21-40-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42!42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2103. TROUBLESHOOTING (ENVIRONMENTAL CONTROL SYSTEM)
'frouble
Bleed air leakage in primary
or secondary heat exchanger.
Cooling turbine will nOl start.
Cooling turbine SLOps when
required to run.
Water separator blockage.
Water separator coalesccr
cloth is damaged,
Excessive moisture entering
cabin.
Conditioned air temperature
too high.
21.4000
Page 1
Reissued: December 31, 1989
Cause
Rupture or corrosion.
Excessive air leakage.
Frozen bearing due
to contamination or
improper shimming.
Excessive air leakage.
Coalesccr cloth is iced.
Dirt comamination.
Overtempcrature.
Coalescer cloth is tom
or dirty.
Ram ai r dUCI obstructed
or face of heat exchanger
clogged.
Heat exchanger leaking.
Cooling turbine rotating
torque unsatisfactory.
(See NOle.)
Bypass valve inoperative.
Malfunctioning Variable
Ejector Mixing Valve
(PA42-720 only).
1J24
Remedy
Replace heat exchanger.
Replace seals.
Replace cooling turbine.
Repair leaks.
Check anti-icc system.
Clean coalesccr cloth.
Replace coaicscer cloth.
Clean coaicscer cloth.
If tom, replace.
Remove obstruction or
debris.
Replace heat exchanger.
Replace cooling turbine.
Check valve wiring and
operation. Replace as
required.
Remove and replace valve.
PIPER AIRCRAFT
PA-42/42-72D
AIRPLANE MAINTENANCE MANUAL
CHART 2103. TROUBLESHOOTING (ENVIRONMENTAL CONTROL SYSTEM) (continued)
Trouble Cause Remedy
Insufficient conditioned airflow. Bleed air ON/OFF valve Check wiring.
not full open.
Leaks in joints or connections. Repair leaking joints and
connections.
Cooling turbine rotating Replace cooling turbine.
torque unsatisfactory.
(See Note.)
Heat exchanger leaking. Replace heat exchanger.
Malfunctioning Variable Remove and replace valve.
Ejector Mixing Valve
(PA-42-720 only).
-NOTE -
Refer to label on cooling turbine for maximum acceptable torque
value,
1K1
21-4000
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
COMPONENT DETAILED DESCRIPTIONS
This system, operated by engine bleed air, is controlled by a pressure regulator and flow limiting venturi, along
with various components which comprise the environmental control system. The following is a description of
these various components: (Figure 21-11 for PA-42 and 2 t -12 for PA-42-720.)
1. Pressure Regulating and Shutoff Valve
The pressure regulating and shutoff valve is installed in the bleed air line upstream from the refrigeration
unit This is a solenoid operated valve which regulates the bleed air supply pressure to the refrigeration unit
and includes means for shutting off all bleed air to the refrigeration unit.
2. Bleed Air Supply Overpressure Switch
This switch. located at the inlet to the refrigeration unit, monitors bleed air pressure to the unit and signals
the regulating and shutoff valve to shut off air flow if pressure exceeds 40 3 psig.
3. Variable Ejector Mixing Valve (PA-42720 only)
The PA42720 uses a variable ejector mixing valve. While the bleed air systems of both models are
essentially the same, the PT6A61 engine of the PA42720 produces a higher compressor bleed air pressurc
and a resulting higher bleed air temperature. The variable ejector mixing valve mixes this higher
prcss./temp. compressor bleed air with interstage turbine bleed air and comrols both temperature and
pressure of the bleed air supply.
4. Primary Heat Exchanger
This heat exchanger,located in the refrigeration unit, is used to lower the high bleed air temperature prior to
being routed to the compressor.
5. Compressor
The compressor in the refrigeration unit is boot strapped to the turbine and compresses the bleed ai r to a
higher pressure which raises the temperature.
6. Compressor Discharge Ovcn.emperature Sensing Switch
This switch, installed at the compressor discharge pont sel1SCs discharge temperature. The switch, nonnally
closed. must open when temperatures reach 425F 5F and must signal the pressure regulator and shutoff
valve to close and shut off the bleed air supply to the refrigeration unit.
7. Secondary Heat Exchanger
This heat exchanger. located in the refrigeration unit, is used to lower the air temperature (still high due to
now through the compressor).
8. Cooling 1Urbine
The cooling turbine, instaUed on the common shaft with the compressor, receives the precooled air from the
secondary heat exchanger. This ai r, still at high pressure when passing through the turbine, is lowcred by
expansion. The turbine absorbs energy from the high pressure bleed air and drives the compressor. The
expansion of the bleed air, plus its loss of energy, causes a temperature reduction at the turbine discharge.
9. Mixing Muff
This mixing device, located immediately downstream from the cooling turbine (I) mixes cold turbine outlet
ai r with hot bleed air from the hot air bypass valve and (2) prevents icing of the turbine rotor and discharge
ducting.
10. Hot Air Bypass Valve
This valve is installed between the turbine mi xing muff and the bleed air line to the primary heat exchanger.
Its function is to modulate the flow of hot bleed air into the mixing muff according to signals sent to the
valve from the cabin temperature sensor and controller. This valve use an electric actuator motor.
21-40-00
Page 4
Reissued: December 31, 1989
1K2
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
COMPONENT DETAILED DESCRIPTIONS (continued)
11 . Water Separator Assembly
This assembly consists of a coalescer, water coUector, and drain. The drain consists of a line. routed to the
water aspirator on the air inlet side of the refrigeration unit, ahead of the heat exchangers. A small ponion
of bleed air is extracted from the heat exchanger and is routed through the aspirator, causing high velocity
air flow through the aspirator and creating a vacuum on the drain line which removes any water from the
water separator collector. This moisture is sprayed into the ambient air ahead of the heat exchanger to
provide additional cooling capacity.
12. Duct Temperature Sensor
This sensor, located in the cabin air supply duct downstream of the water separator, senses cabin air
temperature. This unit, capable of monitoring temperatures between +30
o
P _200
o
P, supplies sensor data to
the cabin temperature sensor and controller.
13. Cabin Temperature Sensor and Controller
This unit worKs in conjunction with the duct temperature sensor and cabin temperature selector to conlrOl
the hot air bypass valve and maintains the desired cabin temperature. It is centrally mounted in the aircraft
cabin. The controller range of operation is +30F -16<rF.
The ECS must maintain the average cabin and cockpit temperatures of 75F for cooling and 800F for
heating. During ground operation, the system must maintain the cabin at an average temperature of 75F or
less. During a hal day, the system must pull the cabin temperature below SOop in 20 minutes or less from
the time the system is turned on. The cabin temperature control automatically maintains the temperature at
the sensor within 3F of the selected setting.
14. The cooling fan is energized by the landing gear SQuat switch only when the aircraft is on the ground. It
provides ram air cooling for both the primary and secondary heat exchangers through a 28-volt vaneaxial
fan.
1K3
21-40-00
Page 5
Reissued: December 31. 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-NOTE-
ll/!S UNIT IS LOCATED IN THE NOSE
SECTION, RIGHT SIDE, BETWEEN
STATIONS 57.00 AND 25.60.
REFRIGERATION
\ AIR
SECONDARY
HEAT
EXCHANGER
AIR

RAM
OVERTEMP
I SWITCH
INLET
COMPRESSOR
I OPEN ..

SENSOR &
CONTROlLER
TEMP RANGE
+3O"F TO +16O"F
I
PAESSBHD.
CHECK VALVE)
(SERVICE - SOO HA)
GROUND AIR FAN
(SERVICE - 500 HAl
TEMP
SELECTOR
@
LEGEND
------ --- --
----------.
ELECTRICAL
AIR
INLET
20-58 pslg.
PRESSURE REG &
SHUTOFF VALVE
HIGH .. 312 pslg.
lOW .. 18% 1.5 psIg
- - - - -- REFRIGERATION UNIT BOUNDARY
2140-00
Page'
Reissued: December 31, 1989
Figure 21- 11 . Environmental Control System
PA-42
1K4
OVERPRESSURE
SWITCH
OPEN .. 40 3 pslg.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
STA.
25.60
-NOTE-
REFRIGERATION UNIT
CHECK
VALVES
THIS UNIT IS LOCATED IN THE NOSE
SECTION, RIGHT SIDE, BETWEEN
STATIONS 57.00 AND 25.60.
CABIN TEMP
SENSOA&
CONTROLLER
TEMP. RANGE
SECONDARY
HEAT
EXCHANGER
"
_ 3O"F TO ... 1600F
TE..,
SELECTOR
LEGEND
-----------
----------
ELECTRICAL
TURBINE MJFF
WATERSEPARATOA
GROUND AIR FAN
(SERVICE - 500 HAl
COALESCEA
(SERVICE -500 HAl
SWITCH
OPEN _ 40 3 pslg
- - -- - -- REFRIGERATION UNIT BOUNDARY
Figure 2112. Environmental Control System
PA-42-720
1K5
21-40-00
Page 7
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ENGINE BI.E'I<;o' PORT
rENOUNE'"B"'U""EEDn'PORT \" j ,.
'-- "', 7 , "\ RO R.H. BLEED
\ ,'- I--- 1 \J -'JA7'
'\ 21 17 /liL/ ;'
3, "" I CAB,N.,A 1/
3
1-----.
\

,.
15
1,--'.
1'--<
t'-- '"
UGHT -
TO SQUAT SWITCH _
20""," f
J
CABIN PRESS I
TO EMERGENCY CABIN \
KLPRESSURIZATION BLEED \ 5 "-4
AlA SHUTOFF VALVE
_---...1----..l....... ____ _
1. BLEEDAlRSHUTOFFVAlVE 12. ABSOLUTE PRESSURE SWITCH
2. INlERCOOlER 13. VACUUM SOLENOID REUEF VALVE
3. BlEED AlROVERTEMPERATURE SWITCH 14. CHECK VALVE
4. CABIN OUTFlOW VALVE 15. CHECK VALVE
5. CABIN SAFETY VALVE 16. CHECK VALVE
6. CABIN PRESSURE CONTROLlER 17. DUCTSTATSWITCH
7. AUXILIARY VOLUME TANK 18. SHUTOFF VALVE EMERGENCY PRESSURIZATION
a ABSOlUTE PRESSURE ReGULATOR 19. JET PUMP EMERGENCY PRESSURIZATION
9. FILTER 20. PRESSURE S'NITCH - PRESSURIZATION
10. MANUAL SHUTOFF VALVE 21. CONDITIONED AlA DUCT
11 . DlFFERENTLAl PRESSUAE SWITCH 22. RESERVED
Figure 21-13. Cabin Prcssunzation and Bleed Air System Schematic (PA-42 Only)
21-40-00
Page 8
Reissued: December 31, 1989
1K6
PIPER AIRCRAFT
PA-42/42-72D
AIRPLANE MAINTENANCE MANUAL
I
ENGINE BLEED PORT
1'- TO WARNING LIGHT
TOSOUATSW1TCH ____ ;:\
/\
f--
+
\."

/
v'
7
-.
o \'---- '9
ENGINE BlEED PORT
20 ---., L I- 11
J
IHIL.tJI'i"/:::l" r--C-AB-' N-P-R-ESS--'I
TO EMERGENCY CABIN
PRESSURIZATION BLEED
AIR SHUTOFF VALVE
1. BlEED AlA SHUTOFF VAlVE
2. INTERCOOLER
3. BlEED AIR OVERTEMPERATURE SWITCH
4. CABIN OUTFLOW VALVE
5. CABIN SAFETY VALVE
6. CABIN PRESSURE CONTROlLER
7. AUXILIARY V W ~ TANK
8. ABSOlUTE PRESSURE REGULATOR
9. FILTER
10. MANUAL SHUTOFF VALVE
11 . DIFFERENTIAL PRESSURE SWITCH
5 4
-
12. ABSOLUTE PRESSURE SWITCH
13. VACUUM SOLENOID RELIEF VALVE
14. CHECK VALVE
15. CHECK VALVE
16. CHECK VALVE
17. OUCTSTATSWITCH
18. SHUTOFF VALVE EMERGENCY PRESSURIZATION
19. JET PUMP EMERGENCY PRESSURIZATION
20. PRESSURE SWITCH - EMERGENCY PRESSURIZATION
21 , CONDITIONED AIR DUCT
22. GROUND BLEED AIR BYPASS VALVE
Figure 21-14. rabin PressunzaUon and Bleed Air System Schematic (PA-42-720 Only)
1K7
21-41)-00
Page 9
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF PRESSURE REGULATOR AND SHUTOFF VALVE
I , Remove water separator according to instructions in this chapter.
2. Disengage bleed air circuit breaker.
3. Disconnect pressure regulator sensing tube from pressure regulating and shutoff valve.
4. Disconnect electrical plug from pressure regulating and shutoff valve.
5. Remove couplings securing pressure regulator and shutoff valve assembly in position.
6. Remove pressure regulator and shutoff valve from airplane.
INSTALLATION OF PRESSURE REGULATOR AND SHUTOFF VALVE
1. Ensure pressure regulator and shutoff valve are in position and sccured with couplings. Torque couplings to
35 - 45 inch-pounds.
2. Cormecl pressure regulator sensing tube to pressure regulating and shutoff valve.
3. Connect electrical plug to pressure regulating and shutoff valve.
4. Engage bleed air circuit breaker.
S. Install water separator according to insttuctions in this chapter.
REMOVAL OF HOT AIR BYPASS VALVE
1. Disengage cabin temperature circuit breaker.
2. Disconnect electrical plug from bypass valve.
3. Remove couplings securing bypass valve to duct flange.
4. Remove bypass valve and seals.
INSTALLATION OF HOT AIR BYPASS VALVE
1. Secure bypass valve and new seals to duct flange using previously removed couplings. Torque couplings to
35 3.5 inch-pounds.
2. COimect electrical connector to bypass valve.
3. Engage cabin temperature circuit breaker.
REMOVAL OF BLEED AIR SUPPLY OVERPRESSURE SWITCH
1. Gain access 10 overpressure switch. (Figures 21-11 and 21 -12.)
2. Discormecl electrical connector from switch.
3. Cut safety wire and unscrew switch from receptacle.
4. Remove switch and D-ring.
21-4000
Page 10
Reissued: December 31, 1989
1K8
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF BLEED AIR SUPPLY OVERPRESSURE SWITCH
1. Install new switch and ~ r i n g into receptacle.
-NOTE-
Ensure proper high temperature D-ring is used by referring to Pans
Catalog.
2. Secure switch with safety wire.
3. Reconnect electrical connector switch.
REMOVAL OF COMPRESSOR DISCHARGE OVERTEMPERATURE SENSING SWITCH
1. Gain access to ovcncmperature switch. (Figures 21-11 and 21-12.)
-NOTE -
Note location of each wire to facilitate reinstallation.
2. DisCOJUlcct electrical leads from switch.
3. Loosen nut and unscrew switch from receptacle.
4. Remove switch and O-ring.
INSTALLATION OF COMPRESSOR DISCHARGE OVERTEMPERATURE SENSING SWITCH
1. Install new switch and O-ring into receptacle.
-NOTE -
Ensure proper high temperature O-ring is used by referring to Pans
Catalog.
2. Screw switch into receptacle.
3. Connect wires to switch.
REMOVAL OF WATER SEPARATOR
1. Discormect water line, inlet, and outlet air connections from water separator.
2. Remove clamps securing water separator.
3. Remove water separator.
CLEANING, INSPECTION AND REPAIRS OF WATER SEPARATORS
The coalescer cloth must be cleaned or replaced at 500 flight hours or less. except when operated in
abnormally dusty or contaminating conditions.
1. Remove band and cover from water separator.
2. Remove coalescer cloth from inside water separator.
3. Wash coalcsccr cloth with warm water and mild detergent; rinse with clean water.
- CAUTION-
DO NOT WRlNG COALESCER CLOTH.
4. Replace coalescer cloth on irmer housing with nap inside against the screen and rubber bands flat and finnly
in place.
5. Install cover and band on water separator.
1K9
21-40-00
Page 11
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF WATER SEPARATOR
1. Secure water separator to hoses with clamps. Torque to 30 35 inch-pounds.
2. Cormect water line to water separator.
REMOVAL OF DUCT TEMPERATURE SENSOR
1. Gain access to duct temperature sensor under the floor on right hand side of fuselage, immediately aft of FS
57.00 forward pressure bulkhead.
2. Remove four screws securing sensor in position.
3. Remove sensor with gasket.
INSTALLATION OF DUCT TEMPERATURE SENSOR
1. Install new sensor and gasket. Secure with four screws.
REMOVAL OF CABIN TEMPERATURE SENSOR AND CONTROLLER
1. Gain access to cabin temperature sensor and controller. Remove screws and washers to secure unit in
position. Pull unit out so electrical connector can be disconnected.
2. Remove cabin temperature and controller.
INSTALLATION OF CABIN TEMPERATURE SENSOR AND CONTROLLER
1. Install new sensor and connect electrical connector.
2. Secure unit with washers and screws.
REMOVAL OF GROUND COOUNG FAN
1. Gain access to baggage compartment area and remove hardware securi ng partition between baggage
compartment and fan.
2. Remove access panel on ri ght side ofnosc section.
3. Loosen and remove clamps securing fan to flexible rubber cuffs and refrigeration unit.
4. Disconnect elecuicalleads to fan motor.
S. Slide cuffs from refrigeration unit so fan motor can be removed from refrigeration unit.
6. Remove fan.
21-40-00
Page 12
Reissued: December 31, 1989
1K10
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF GROUND COOLING FAN
1. With fan in position, slide rubber cuffs over ends of fan.
2. Connect electrical leads to fan motor.
3. TIghten clamps securing fan in position.
4. Replace access panel removed from right side of nose section.
5. Replace partition removed from baggage compartment
REMOVAL OF CHECK VALVE ASSEMBLY
1. Remove clamps securing hose between water separator and check valve assembly.
2. Remove bolts and washers that attach check valve to pressure bulkhead.
3. Remove check valve with gasket.
INSTALLATION OF CHECK VALVE ASSEMBLY
1. Install new valve and gasket to pressure bulkhead.
- NOTE-
Check valve must be installed with fl apper shaft in vertical position.
2. Secure valve in poSition with washers and bollS.
3. Install hose between water separator and check valve.
4. Secure hose with clamps.
1K11
21-40-00
Page 13
Reissued: December 31, 1989
21-40-00
Page 14
Reissued: December 31. 1989
PIPER AIRCRAFT
PA42142 720
AIRPLANE MAINTENANCE MANUAL
GRIDS lK12 THRU lK16
INTENTIONALLY LEFT BLANK
1K12
CHAPTER
AUTOFLIGHT
1K17
SYSTEM
SUBSYSTEM
22.()()OO
221Q.()()
GENERAL
PIPER AIRCRAFT
PA 42142 720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 22 AUTOFLIGHT
TABLE OF CONTENTS/EFFECTIVITY
SUBJECT
NONPIPER AFCS EQUIPMENT CONTACTS
lK18
GRID
NO.
IKI9
IKI9
EFFECTIVITY
22 Cont) Errect.
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GENERAL
Due to variety of Automated Flight Control System (AFeS) options. service literature published by the
specific manufacturer must be strictly observed. This includes mechanical servicing such as adjusting bridle
cable tension, servo removal and installation, servo clutch adjustments. etc.
NON-PIPER AFCS EQUIPMENT CONTACTS
Refer to the following list of Autopilot/Flight Director manufacturers to obtain service direction, pans sUPIX>rt.
and SCIVice literature:
Bendix Avionics Division
2100 N. W. 62nd Street
Fort LauderdaJe. Florida 33310
(305) 776-4100
TWX 5109559884
Collins General Aviation Division
Rockwell International
Cedar Rapids, Iowa 52406
(319) 395-3625
Telex: 464-421
1K19
King Radio Corporation
400 North Rodgers Road
Olathe. Kansas 60601
(913) 782-0400
Telex: 4-2299-Kingrad
22-10-00
Page I
Reissued: December 31, 1989
22-10-00
Page 2
Reissue.d: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
GRIDS lK20 THRU lK23
INTENTIONALLY LEFT BLANK
1K20
CHAPTER
COMMUNICATIONS
1K24
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1L1
May 15, 2012
23 - CONTENTS
CHAPTER 23 - COMMUNICATIONS
TABLE OF CONTENTS
CHAPTER
SECTION SUBJECT GRID NO.
23-00-00 GENERAL 1L2
23-20-00 EMERGENCY LOCATOR TRANSMITTER 1L2
Description of Emergency Locator Transmitter 1L2
Battery Removal and Installation Alkaline 1L2
Testing Emergency Locator Transmitter 1L4
Pilots Remote Switch 1L5
Testing Pilots Remote Switch 1L6
Inadvertent Activation 1L7
23-60-00 STATIC DISCHARGING 1L7
Page 1
GENERAL
PIPER AIRCRAFT
PA-42!42-720
AIRPLANE MAINTENANCE MANUAL
This chapter describes the operational checks of the emergency locator transmitter (ELT), the pilot's remote
switch used with the ELT, and includes the removal and installation instructions for battery replacement.
EMERGENCY LOCATOR TRANSMITTER
DESCRIPTION OF EMERGENCY LOCATOR TRANSMITTER
The electrical power for the ELT is supplied by a seIf--contained battery. The useable life of this battery is 19
months from the date of manufacture. The mandatory replacement date is marked on each banery. The
replacement date must be marked on the ELT when the battery is installed. According to FAA regulations, the
battery must be replaced if the transmitter has been used in an emergency situation or has morc than onc hour of
accumulated test time. It is necessary to remove the ELT from the aircraft to replace the baLtery.
BATTERY REMOVAL AND INSTALLATION ALKALINE (19 month alkaline battery)
- CAUTION -
DO NOT REMOVE THE INSIDE LIP SEALANT FROM THE
NEW BATTERY PACK. THE SEALANT SERVES AS A
WATER TIGHT SEAL AND MUST NOT BE REMOVED.
The ELT is located underneath the dorsal fin between stations 310.00 and 327.00.
1. Remove the access panel on the dorsal fin at station 321.00.
2. Disconnect the anterma cable from the transmitter. (Figure 23 1)
3. To remove the ELT, release the latch on the strap and slide the ELT off the bracket.
4. Disconnect the pilot's remove switch harness from the transmitter.
5. Extend the portable antelUla. (Figure 23-2)
6. Unscrew the four screws holding the control head to the battery casing. (The control head-battery case
slides apart. Battery connection leads are approximately 3" long.)
7. Disconnect battery by unsnapping the snap off battery pigtail tenninals from the bottom of Lhe transmiuer
printed circuit board.
8. Before installing the new banery pack, check replacement date printed on the battery. Mark date on the
outside of the ELT.
9. Connect new battery pack. tenninals to the bottom of the transmitter printed circuit board.
to. Reinsert the control head section into the battery pack; be careful not to pinch wires. Repl ace four screws.
If the four holes do nOlline up, rotate the battery pack 180
0
and reinsert.
II . Connect the pilot's remote switch harness to the transmitter.
12. Place transmitter into its mounting bracket and latch strap.
13. Connect the antenna cable to the transmitter. Emure contact separator is inserted between portable antenna
contact finger and portable antenna (see Figure 23-1).
-NOTE-
Test unit operation before installing the access panel.
14. Install access panel on the dorsal fin. Enter the new battery expiration date into the aircraft logbook.
1L2
232000
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
OOTCH PIN
PORTABLE
ANTENNA
OPERATIVE
BUTSTOREO
232000
Page 2
ANTENNA BLADE
TOUCHES
PORTABLE
FINGER OONTACT

EXTENSION
TAB
Reissued: December 31, 1989
STOP
lATCH
VIEW A
ANTENNA
POPS OUT
OFCKANNEL
ANTENNA
EXTENSION
TAB
SET
ON-OFF-ARM
SWrrCH
10 'ON"
r ANDCOWN
\
VIEWC
Figure 23-1. ELT Portable Folding Antenna
<XlNTACT
PiN
STOP
PORTABLE
ANTENNA
tXlNTACT
SEPARATOR,"====::;] POATABLE ANTENNA BlADE
\. NOT MAKING CONTACT
FIXED ANTENNA'S
CABLE CONNECTOR AND
CONTACT SEPARATOR
TO REMOTE SWITCH _
Figure 23-2. ELT Using Fixed Aircraft Amenna
1L3
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
TESTING EMERGENCY LOCATOR TRANSMITTER
The transmitter operates on emergency frequencies of 121 .5 and 243 mHz. Both frequencies are monitored by
various FAA installations. Before perfonning any ELT operational tests, the following precautions must be
observed:
Conduct ELT testing in a screen room or metal enclosure to ensure electromagnetic energy is not radiated. If a
shielded enclosure is not available, the following precautions must be adhered to:
-NOTE-
For detailed information concerning ELT testing. consult FAA
AdviSOry Circular, AC 20-81.
1. Do not test longer than three audio sweeps.
2. Usc a dummy load as a substitute if the antenna is removed.
3. Testing of the ELT must only be conducted during the first five minutes after any hour.
4. If the operational tests must be conducted at a time other than five minutes after the hour, the test must be
coordinated with the nearest FAA lOwer or flight service station.
To conduct test, proceed as follows:
1. Remove access panel or cover to gain transmitter access.
2. Thrn master switch ON.
3. Switch receiver ON and tune to 121.5 mHz. Deactivate squelch and Lurn up volume until slight background
noise can be heard.
-NOTE-
If the aircraft is not fitted with a communication receiver, request that
the tower lislen for your test.
4. On transmitter, set the ON/ARM/OFF switch to ON position. Kccp switch ON for a few seconds, then set
to OFF (or ARM if OFF does not exist). Return to ARM position.
-NOTE -
The test transmission should be picked up by the aircraft
communications receiver or control tower. During cold weather, there
could be a slight delay before transmission occurs.
5. A properly functioning transmitter must emit a characteristic downward swept tone.
6. When test is completed, be sure transmitter ON/ARM/OFF switch is in the ARM position.
1L4
23-20-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
TESTING EMERGENCY LOCATOR TRANSMITTER (continued)
7. Place access panel on dorsal fin at station 321.0 and secure with screws.
-NOTE-
When checking the ELT by alternating the transmi tter ON/ARMfOFF
switch from ARM to ON, the switch must be put in the OFF position
before going back to ARM. Under nonnal conditions. the transminer
switch must be set to ARM.
Inspect the external whip antenna for any damage. Avoid bending the
whip. Any sharply bent or kinked whip must be replaced. Antenna
damage may cause suuctural failure of whip in flight.
PILOT'S REMOTE SWITCH
-NOTE -
Under nonnal conditions. the remote switch must be set to ARM.
The pilot's remote switch. located on the overhead switch panel. is provided so the transmitter can be
controlled from inside the cabin. The switch is locked into each position. To move the switch, the toggle must be
pulled out and moved tD the new position. The pilot's remote switch is positioned to ON and ARM (NORMAL
POSITION). The switch is normally left in the down or ARM position. To turn the transmitter off, move the
switch to the ON position for one second and then return it to the ARM position. To actuate the transmitter for
tests or other reasons, move the switch upward to the ON position. Leave it in that position as long as
transmission is desired.
232000
Page 4
Reissued: December 31, 1989
1L5
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
TESTING PILOT'S REMOTE SWITCH
Before performing any pilot's remote switch operational test, the following precautions must be observed:
- NOTE-
The transmitter operates on the emergency frequencies of 121.5 and
243 mHz, both of which are monitored by the various FAA
installations. Pennission must be obtained from the FAA/FCC
representative (or other authorized authority) prior to testing. Keep
your test transmission to a minimal duration.
1. Switch the receiver ON and tum communications receiver to 121.5 mHz. Deactivate squelch and tum up
volume until slight background noise is heard.
~ 3 S2
~ 2
-NOTE -
If the aircraft is not fitted with a communications receiver, request
that the tower listen for your test.
" r
E.LT.
J-
L
-
,-,
WHT
--,
'"' WHT
r'
,
L
~ if
! i
,
I
REMOlE
,
,
1 I '
I
, , ,
, ,
2
2 I
WHTIBLU
' ,
T
WHTIBLU
~
'"
"_J
3 3
4 4
Er
CONN
E327
-
Figure 23 3. Emergency Locator Transmitter Schematic
1L6
23-20-00
Page 5
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1L7
May 15, 2012
23-60-00
Page 1
2. Set the pilot's remote switch to ON and hold switch in this position for a few seconds.
NOTE
The test transmission must be picked up by the aircraft
communications receiver or control tower. During cold weather,
there could be a slight delay before transmission occurs.
3. Set the pilot's remote switch to ON for one second; select ARM position.
INADVERTENT ACTIVATION
In the event the ELT is inadvertently activated, set the pilot's remote switch to ON, then return it to
ARM position.
As a routine precaution, it is recommended that the ELT be replaced at the earliest chance following
inadvertent activation. However, the problem may not be in the transmitter. Check the following:
1. Proper spacing of antennas to minimize antenna conducted RF.
2. Rigidity of the transmitter installation.
CAUTION
UNDER NORMAL CONDITIONS, THE PILOT'S REMOTE
SWITCH MUST BE SET TO ARM POSITION.
STATIC DISCHARGING
Static discharging wicks must be inspected at each annual inspection for the following:
1. General appearance and physical condition.
2. Security of attachment to airframe.
3. Discharge points visible.
4. Resistance (1.0 to 200 megohms, 500 to 1,000 volt megohmmeter).
5. Base resistance to airframe (100 milliohms maximum).
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
1L8
May 15, 2012
23-60-00
Page 2
GRIDS 1L8 THRU 2B8
INTENTIONALLY LEFT BLANK
CHAPTER
ELECTRICAL POWER
289
SYSTEM
SUB-SYSTEM
24-00-00
24-00-00
24-00-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
224-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 24 - ELECTRICAL POWER
TABLE OF CONTENTSIEFFECTIVITY
SUBJECT
General
Description
Troubleshooting
D.C. Generation
Description and Operation of
Starter-Generator System (PA-42)
Description and Operation of
Starter-Generator System (PA-42-720)
Starter-Generator Service Test Specifications
(PA-42 Models Only)
Starter-Generator Service Test Specifications
(PA-42-720 Models Only)
Checking Starter-Generator System
Adjustments of Starter-Generator
Maintenance of Starter Generator (PA-42-720 Only)
General
Description
Maintenance
Removal and Installation of Starter Generator
Generator Cleaning (Assembled)
Generator Brush Inspection
Maintenance of Starter Generator
(250 Amp -Model 23048-20 Only)
Removal of Starter-Generator From Aircraft
Disassembly of (Model 23048-20) Starter-Generator
Cleaning Procedures
Inspection
Repair and Replacement (250 Amp Model)
Reassembly of (Model 23048-20) Starter-Generator
Fits and Clearances
Inspection and Testing of Components
(pA42 Only 250 Amp)
Battery
Important Precautions
Troubleshooting
Removal of Battery
2810
GRID
NO. EFFECTIVITY
2B13
2B13
2B13
2B22
2B22
2B23
2B23
2B24
2C9
2C9
2ClO
2ClO
2ClO
2C'0
2Cll
2C12
2C13
2C15
2C15
2C15
2Cl6
2C17
2C20
2C22
2C23
2C23
2Dl
2Dl
2Dl
204
24 - Cont.lEffec.
Page 1
Reissued: December 31, 1989
SYSTEM
SUB-SYSTEM
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-30-00
24-40-00
24-40-00
24-40-00
24 - ContJEffec.
Page 2
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 24 - ELECTRICAL POWER (continued)
TABLE OF CONTENTS/EFFECTIVITY)
GRID
SUBJECT NO.
O.C. Generation (continued)
Battery Cleaning 204
Battery Inspection 204
Periodic Battery Check 205
Adjustment of Electrolyte Level 205
Battery Cell Replacement 206
Charging Battery 208
Constasnt Current Charging 208
Constant Potential Charging 2011
Cell Voltage Check 2011
Battery Oisconnect and Receptacle Inspection 2011
Installation of Battery 2012
Testing Battery Temperature Sensor 2012
Voltage Control Panel 2012
Oescription and Operation of Voltage Control Panel 2012
Checking Voltage Control Panel 2013
Removal of Voltage Control Panel(s) (A/C Serial
Numbers 42-7800001 to 42-8001037) 2013
Removal of Voltage Control Panel (A/C
Serial Numbers 42-8001038 and up) 2013
Installation of Voltage Control Panel(s) (A/C
Serial Numbers 42-7800001 to 42-8001037) 2014
Installation of Voltage Control Panel(s) (A/C
Serial Numbers 42-8001038 and up) 2014
Performance Test Lear Siegler PIN 51530-001,
Voltage Control Panel(pA42-720) 2014
Oielectric Test 2014
Final Testing 2015
Open Loop Test (Voltage Regulator) 2015
Overvoltage Test 2017
Overexcitation Protection 2D17
Automatic Line Contactor Test 2017
Closed Loop Tests 2018
Paralleling Test 2018
External Power 2019
Operation of External Power Receptacle 2019
Starting Through External Power Receptacle 2020
Reissued: December 31, 1989
2811
EFFECTIVITY
SYSTEM
SUB-SYSTEM
24-50-00
24-50-00
24-50-00
24-50-00
24-50-00
24-50-00
24-50-00
24-50-00
24-50-00
24-50-00
24-50-00
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 24 - ELECTRICAL POWER
TABLE OF CONTENTSIEFFECTIVITY
SUBJECT
Electrical Load Distribution
Description of Overhead Switches
Removal of Overhead Switches
Installation of Overhead Switches
Purpose of the Main Tie Circuit Breaker and
Crossfeed Diode Check
Description of Circuit Breaker and Switch Panel
Removal of Circuit Breakers and Toggle Switches
Installation of Circuit Breakers and Toggle Switches
Cross Start Relay(s)
Removal of Cross Start Relay(s)
Installation of Cross Start Relay(s)
-NOTE-
Electric Schematics are located in Chapter 91.
2812
GRID
NO.
2D2I
2D2I
2D2I
2D2I
2D24
2D24
2D24
2EI
2EI
2EI
2EI
EFFECTIVITY
24 - ContJEffec.
Page 3
Reissued: December 31,1989
GENERAL
DESCRIPTION
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Electrical power is supplied by a 28-volt, direct current, negative ground electrical system. A 24-volt (Nickel-
Cadmium) battery supplies power for starting and is a reserve power source in case of generator failure. An
external power receptacle in the nose of the airplane supplies external power during cold weather operation, or
whenever external power is needed to start the engines.
The electrical system is controlled by the battery master switch, right starter-generator switch, and left starter-
generator switch. The battery master switch controls a master contactor which connects the battery to the tie bus.
The five basic electrical system buses are also connected to the tie bus. The mode of operation of the DC starter-
generator is selected by using the left or right starter-generator switches. There are two and three position
switches which function as follows: UP position GEN, CENTER position OFF, and DOWN position START.
Each switch contains a placard indicating its selected function.
The model PA-42 contains two 28 Vdc - 250 amp starter-generators, and the model PA-42-720 contains two 28
V dc - 300 amp starter-generators. Also incorporated into the system are overvoltage and overload protection.
The electrical switches are located in an overhead panel just above the windshield. There are two circuit breaker
panels on the right and left side panels of the cockpit.
Lighting consists of standard navigation lights, a landing, and taxi light located on the nose gear strut housing.
Navigation lights are located on both wing tips and the tail. Strobe lights are part of the light assembly on both
wing tips. Recognition lights are optional. Lighting in the cabin consists of indirect fluorescent lights and four
reading lights. Lighting in the cockpit consists of an annunciator panel, various indicator lights, instrument panel
lighting, and two map lights. The overhead switch panel, lower switch panel, and circuit breaker panel are
electroluminescent. Courtesy lights consists of a baggage compartment light in the nose and a passenger entrance
light. There is also a 50 watt wing inspection light located outboard in the left engine nacelle.
TROUBLESHOOTING
Problems peculiar in the electrical system components covered in this chapter are listed in Chart 2401 along
with probable causes and suggested remedies. After the trouble is corrected, check the entire system for security
and operation of components. Chapter 91 provides electrical wiring schematics to use with conventional
troubleshooting methods.
2813
24-00-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (ELECTRICAL SYSTEM)
Trouble
Unit fails to operate or does
not attain nonna1 speed.
Excessive sparking
at brushes.
24-00-00
Page 2
Reissued: December 31,1989
Cause
STARTER-GENERATOR
Low voltage power source.
Defective switch in power
supply line.
Defective starter solenoid.
Damaged armature.
Short circuited or open
stator windings.
Improperly seated
brushes.
Eccentric commutator.
Short circuited or grounded
field windings.
Excessive clearance in
bearings or rough
bearing races.
Eccentric commutator.
Short circuit in annature
windings.
Brushes incorrectly installed
with top bevel reversed.
Annature out of ba1ance.
2814
Remedy
Check the power source to
make certain that full voltage
is being applied to starter
tennina1s.
Replace switch.
Replace solenoid.
Replace the annature
assembly.
Replace the stator and
housing assembly.
Check brush seats and
increase brush run-in
time.
Refinish commutator.
Replace stator and housing
assembly.
Replace bearings.
Refinish commutator.
Replace armature assembly.
Reverse and reseat
Ba1ance or replace
armature.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (ELECTRICAL SYSTEM) (continued)
Trouble Cause
STARTER-GENERATOR (continued)
Excessive sparking Insufficient brush run-in;
at brushes. (continued) improper seating.
Severe overload or short
circuit in aircraft electrical
system.
Brushes sticking in holders.
Weak brush springs.
Brushes loose in holder.
Noisy operation. Rough bearings.
Scored or worn drive splines.
Armature rubbing in stator.
Fan blades bent and
rubbing.
Unit vibrates. Unbalanced armature
assembly.
Excessive run-out of
armature bearings.
Fan damaged or out
of balance.
Generator produces full Voltmeter leads reversed.
voltage - but with
reversed polarity.
Residual magnetism in
field poles creates wrong
polarity.
2815
Remedy
Run in brushes until
seated.
Locate and correct fault.
Free-up brushes.
Replace brush holders.
Replace brushes. If still
loose. replace brush holder
assemblies.
Replace bearings.
Replace drive shaft.
Repair or replace defective
parts.
Straighten or replace
fan.
Balance or replace
annature assembly.
Replace annature bearings.
Rebalance or replace fan.
Connect voltmeter
correctly.
Flash the field.
24-00-00
Page 3
Reissued: December 31,1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (ELECTRICAL SYSTEM) (continued)
Trouble
Generator overheats.
D to E paralleling voltage
not within limits.
Starter-generator fails
starting test.
Does not operate.
24-00-00
Page 4
Reissued: December 31, 1989
Cause
STARTER-GENERATOR (continued)
Continuous overload or
restricted air inlet.
Insufficient cooling air.
Air flow obstruction; dirt
accumulation in generator
ducting.
Wrong load applied during
testing.
Short circuited or open
stator winding.
Open circuit in annature.
BATTERY-DISCONNECT SOLENOID
Open circuit.
Dirty contact on
connector plug.
Open-circuited solenoid
coil.
Plunger binding.
2816
Remedy
Check aircraft electrical
system for grounds, etc.
Make correction as
necessary.
Check for air inlet
temperature.
Check ducting and generator
air inlet.
Check testing procedure
and correct condition.
Replace stator and housing
assembly.
Replace annature.
Repair wiring.
Clean contacts.
Replace unit.
Remove and wash plunger
and housing thoroughly
with Stoddard solution.
Change spring compression
only as a last resort.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (ELECTRICAL SYSTEM) (continued)
Trouble Cause Remedy
BATTERY-DISCONNECT SOLENOID (continued)
Intermittent operation. Short-circuited coil.
Loose electrical
connection.
Plunger binding.
Badly burned points.
STROBE LIGHT
Flash tubes do not Flash tube exposed to
fire. very high temperature.
Lead around seal of the
wire to the glass.
Power supply.
Flash tubes continuously Flash tubes are self-
glow a light blue. ionized.
DOOR SEAL CIRCUIT
Cabin door unsafe light Door switch sticking in
will not go out. the open poSition.
Switch or switches in door
frame out of adjustment.
Short to ground.
Cabin door unsafe light Broken wire or loose
will not come on. connection.
2817
Replace coil. Clean and
tighten electrical connections.
See remedy pertaining to
"Plunger binding" under
"Does not operate."
If points cannot be dressed
down, replace the unit.
Replace flash tube.
Replace flash tube.
Replace power supply.
Replace flash tube.
Lubricate the mechanical
parts (sparingly with "Glide
Air") or equivalent.
Adjust switches.
Check wiring and repair.
Check and repair wiring.
24-00-00
Page 5
Reissued: December 31, 1989
24-00-00
Page 6
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2402. SWITCH LOCATIONS
SWITCH FUNCTION
RIGHT IGNITION
LEFf IGNITION
RIGHT GEN. SELECTOR
BATTERY MASTER
LEFf GEN. SELECTOR
RIGHT BLEED AIR
RIGHT OIL COOLER COWL
LEFf BLEED AIR
LEFf OIL COOLER COWL
STROBE LIGHTS
NAVIGATION LIGHTS
TAXI LIGHT
LANDING LIGHTS
ICE DETECTION LIGHT
EXIT LIGHT
RECOGNITION LIGHT
RIGHT AUTO FUEL PUMP SELECTOR
LEFf AUTO FUEL PUMP SELECTOR
RIGHT PITOT HEAT
RIGHT WINDSHIELD HEAT
LEFf PITOT HEAT
LEFf WINDSHIELD HEAT
SURFACE DE-ICE
LOCATION
EYEBROW SW PANEL
EYEBROW SW PANEL
EYEBROW SW PANEL
OVERHEAD SW PANEL
EYEBROW SW PANEL
EYEBROW SW PANEL
EYEBROW SW PANEL
EYEBROW SW PANEL
EYEBROW SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
EYEBROW SW PANEL
EYEBROW SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
OVERHEAD SW PANEL
Reissued: December 31,1989
2818
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
1 . EXTERNAL LIGHTING SWITCHES
2. DEICE SYSTEM SWITCHES
3. LEFT ENGINE SWITCHES
4. RIGHT ENGINE SWITCHES
5. BATTERY MASTER SWITCH
6. RIGHT GENERATOR AMMETER
7. LEFT GENERATOR AMMETER
8. VOLTMETER
9. CROSS-START READY LIGHTS
10. REVERSE LOCKOUT TEST SWITCH
/
11. HYDRAULIC TOPPING GOVERNOR RESET SWITCHES
12. MAP LIGHT AND SWITCH
13. INSTRUMENT LIGHT DIMMERS
14. NO SMOKING, SEAT BELT, AND DOME LIGHT SWITCH
15. DOME LIGHT
16. GENERATOR TRIP SWITCHES
17. FIXED DIMMING SWITCH
18. DOME LIGHT SWITCH
Figure 24-1. Overhead Switch Panel (PA-42)
2819
24-00-00
Page 7
Reissued: December 31, 1989
24-00-00
Page 8
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
1. EXTERNAL LIGHTING SWITCH ES
2. DEICE SYSTEM SWITCHES
3. LEFT ENGINE SWITCHES
4. RIGHT ENGINE SWITCHES
5. STARTER DISENGAGE SWITCH
6. BATTERY MASTER SWITCH
7. LEFT GENERATOR AMMETER
8. RIGHT GENERATOR AMMETER
9. VOLTMETER
10. REVERSE LOCKOUT TEST SWITCH
11. HYDRAULIC TOPPING GOVERNOR RESET SWITCHES
12. MAP LIGHT AND SWITCH
13. INSTRUMENT LIGHT DIMMERS
14. NO SMOKING, SEAT BELT, AND DOME LIGHT SWITCH
15. DOME LIGHT
16. FIXED DIMMING SWITCH
17. DOME LIGHT SWITCH
Figure 24-2. Overhead Switch Panel (PA-42-720)
Reissued: December 31,1989
2820
60AMPC.B.
ON PA-42 ONLY
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
PA-42-720
Figure 24-3. Main Circuit Breaker Panel (Typical)
2821
PA-42
24-00-00
Page 9
Reissued: December 31, 1989
DC GENERATION
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-CAUTION-
DO NOT LEAVE SELECTOR SWITCH IN THE START
POSITION ANY LONGER THAN THE TIME REQUIRED
FOR A NORMAL ENGINE START. OTHERWISE, THE UNIT
CAN BE DAMAGED BY EXCESSIVE TEMPERATURES
CAUSED BY LARGE STARTING CURRENTS IF A NORMAL
START IS NOT EFFECTED.
DESCRIPTION AND OPERATION OF STARTER-GENERATOR SYSTEM (PA-42)
The starter-generator is located on the upper part of the engine accessory section. The purpose of the unit is to
provide torque for engine starting and to generate DC electrical power. When this unit is used as a starter, it can
be energized by aircraft battery, or by using an external power source for first engine start. Also incorporated is a
cross start system providing generated power to assist the battery in starting the second engine. The cross start
relay connects the functioning generator to the battery and the start solenoid to start the second engine by-passing
the main tie bus breakers. Three conditions must be met: 1. Running engine generator switch must be on; 2.
Engine tach must be over 70% - (the engine to be started under 70%); 3. After these two conditions are met, the
cross start ready light will illuminated. Thrn on generator/start switch to start the second engine.
-CAUTION-
A POWER SPLIT BETWEEN ENGINES IN FLIGHT WILL
ILLUMINATE THE CROSS START READY LIGHT (ONE
ENGINE ABOVE 70%, THE OTHER BELOW 70%). READY
LIGHT WILL EXTINGUISH WITH POWER THE SAME,
ABOVE, OR BELOW 70%.
When the unit is used as a generator, it provides rated DC output when operated at rated speeds. This
generated electrical power is then used as required to operate various aircraft electrical systems.
This unit incorporates its own cooling system consisting of an air inlet duct, heated scoop, exhaust duct, and a
four bladed fan. Cooling is obtained by routing the outside ram air through the air inlet duct, which is then driven
through the unit by the four bladed fan and overboard through the exhaust duct.
Each unit is controlled by its own independent, three position switch: DN for start, UP for generator, center
position for off. The switches are located on the overhead switch panel. (Figure 24-1.) With the battery master
switch on, placing the right or left starter-generator switch in the start position closes the appropriate starter
solenoid for that particular engine. Power is then supplied through the master contactor to the field windings and
the armature windings of the starter unit creating a strong magnetic field. The magnetic field now existing in the
armature combines with that existing in the field windings of the starter unit ,driving the armature to start the
engine.
When the switch is placed in the GEN position, the unit provides rated DC output to the aircraft electrical
system through the voltage control panel and the overvoltage control. Placing the switch in the center or off
position disconnects the unit from the electrical system of the aircraft.
2B22
24-30-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
DESCRIPTION AND OPERATION OF STARTER GENERATOR SYSTEM (PA-42-720)
The starter generator is located on the upper part of the engine accessory section. The purpose of the unit is to
provide torque for engine starting and to generate de electrical power. When this unit is being utilized as a starter,
it may be energized by aircraft battery or through the use of an external power source for first engine start. Also
incorporated is a cross start system to provide generated power to assist the battery in starting the second engine.
The cross start relays connect the functioning generator to the battery and the start solenoid to start the second
engine, bypassing the main bus breakers. For cross starting, these conditions must be met: operating engine
generator switch on, engine at high idle, and second engine start switch to START position.
When the unit is being utilized as a generator, it will provide rated dc output when operated at rated speeds.
This generated electrical power is then utilized as required to operate the various electrical systems of the aircraft.
This unit incorporates its own cooling system which consists of an air inlet duct, exhaust duct, and a four
bladed fan which is part of the unit. Cooling is obtained by routing the outside ram air through the air inlet duct
which is then driven through the unit by the four bladed fan and overboard through the exhaust duct.
Each unit is controlled by its own independent three position switch: DN for START, UP for GENERATOR,
center position OFF. The switches are located on the overhead switch panel (refer to Figure 24-2). With the
battery master switch on, placing the right or left starter generator switch in the START position closes the
appropriate starter solenoid for the particular engine. Power is then supplied through the master contactor to the
field windings and the armature windings of the starter unit creating a strong magnetic field. The magnetic field
now existing in the armature combines with that existing in the field windings of the starter unit driving the
armature as required to start the engine.
When the switch is placed in the GEN position, the unit provides rated de output to the aircraft electrical
system through the voltage control panel and the overvoltage control. Placing the switch in the center or OFF
position disconnects the unit from the electrical system of the aircraft.
STARTER-GENERATOR SERVICE TEST SPECIFICATIONS (PA-42)
Lear Siegler specifications for the 28-volt starter-generator installed as standard equipment on PA-42 series
airplanes, are as follows: (Refer to Chart 2403.)
CHART 2403. STARTER-GENERATOR TEST SPECIFICATIONS (PA-42)
DC Starter-Generator Model......................................................................................... 23048-020
Rating (kw).................................................................................................................... 7.5
Current @ max. RPM... ...... ............... ....... ...... ......... ........... ....... ..................... ............... 250 amps
Voltage (gen. output) ..................................................................................................... 30 Vdc (nominal)
Speed range (rpm) ......................................................................................................... 6,200-12,000
Rated Continuous Speed ............................................................................................... 12,000 RPM
Direction of rotation when viewing shaft end.. ...... ................ ............................ ........... CCW
Operating altitude (max.-ft.) ......................................................................................... 35,000
Voltage (starter, max.) .............................. ...... ..... .......................... ................. ............... 28
Positive terminal designation........................................................................................ B+
Negative terminal designation....................................................................................... E-
Positive field-terminal designation .......... ...... .................... ................................. ...... .... A+
Equalizer terminal designation...................................................................................... D
Starting terminal designation ........................................................................................ C+
Weight ........................................... ........... ..................................................................... 32.llbs. (Q.D.)
Brush life....................................................................................................................... 1000 hours min.
24-30-00
Page 2
Reissued: December 31, 1989
2823
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
STARTER GENERATOR SERVICE TEST SPECIFICATIONS (PA-42-720)
Lear Siegler leading particulars for the 28-volt starter generators installed as standard equipment on PA42-720
airplanes are as follows (refer to Chart 2404):
CHART 2404. STARTER GENERATOR TEST SPECIFICATIONS (PA-42-720)
Rating (Minimum Continuous)
175 amperes, 28 volts at ground idle speed of 6,720 rpm.
300 amperes, 28 volts at 6,950 rpm.
300 amperes, 30.0 volts to maximum rated speed of 12,000 rpm.
External Starting Power Limitations:
1,700 amperes maximum, self-limiting with 30 volts maximum at start receptacle and 0.004 ohm
aircraft circuit resistance when power supply is connected to terminal B (shunt start).
Cooling ........................................................................................... Combination Self-Cooled & Blast Air
Air Inlet Opening Diameter ...................................................................................................... 3.00 inches
Overall Length (Less Spline Drive) ........................................................................................ 12.00 inches
Housing Diameter ..................................................................................................................... 5.86 inches
Weight (Including QAD Kit)'" (Approx) ............................................................................... 30.55 pounds
Overhung Moment (Approx) ............................................................................................ 153 inch-pounds
Direction of Rotation (Viewing Drive End) ................................................................... Counterclockwise
Drive Spline & Mounting Flange ............................................................................................ MS3331-1P
Number of Teeth in Drive Spline ............................................................................................................ 12
Drive Spline Pitch Diameter ...................................................................................................... 0.600 inch
Drive Shaft Shear Torque (Nom.) ................................................................................. 1 ,600 inch-pounds
Terminal Designations
Positive ........................................................................................................................................... B+
Negative ......................................................................................................................................... E-
Positive Field .................................................................................................................................. A+
Equalizer ......................................................................................................................................... D
2824
24-30-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Figure 24-4. Starter - Generator Basic Diagram
2C1 2C2
24-30-00
Page 4
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Figure 24-4. Starter - Generator Basic Diagram (Continued)
24-30-00
Page 5
Reissued: December 31, 1989
2C3 2C4
L
GEN
LEFT GENERATOR
LINE CONTACTOR
P1A 6
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
r----,
I I
I I
I I
15A
INVERTER 112
INVERTER #1

LEFT MAIN BUS P1B 6-----,
P1C 6 P1D 6
KLC-2
AVIONICS
BUS #1
CONTACTOR
AVIONICS BUS #1
I
P1L 6
100A
KLC-1
R
GEN
P7E 8 ---0 P11E 8 --------,
RIGHT GENERATOR
LINE CONTACTOR
200 A
P7L 20
I-----m-P7G 20 AUO 39B 20 ---,
POWER
SOLENOID
(KGp)
A409l309
(STA_ 57.00)
BATIERY
SOLENOID
(KBAT)
Figure 24-5. Power Distribution (PA-42)
2C5
AVIONICS
BUS 112
CONTACTOR

E456 I
P11G 20
AUO 38B 20
'OO?:ja
l
{
I 0 ___ OFF II _ I
I "1 I
L ___ l __ --l
AVIONIC #1 AVIONIC #2
BATIERY BUS
SSSS
24-30-00
Page 6
Reissued: December 31,1989
GEN
LEFT GENERATOR
LINE CONTACTOR
24-30-00
Page 7
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
r----..,
I I
I I
LINE CONTACTORS ARE CONTROLLED
BY GENERATOR VOLTAGE CONTROL PANEL.
I
I
L..9N ___ -,
INVERTERN1
INVERTER CONTROL SOLENOIDS AND AVIONICS
r-----,
I
I
I
INVERTERN2
BUS CONTACTORS CONTROLLED BY AVIONICS PANEL
15A
L.. ____ .J
P1A 6 LEFT MAIN BUS ~ i P1B 6 ----,
KLC-2
P1C 6
AVIONICS
BUS #1
CONTACTOR
RIGHT MAIN BUS 1-*1----- P1D 6
r---====-k; ~
AVIONICSACCESS rJ
NON-ESSENTIAL
i
P1L 6
100A
~
2 0 0 A ~ 2 0 0 A
200 A
AVIONICS
BUSN2
CONTACTOR
AVIONICS BUS N1
GROUND THROUGH
SQUAT SWITCH
KSC-1
TIE BUS
LEFT MAIN BYPASS
LANDING GEAR CONTACTORS
(AIRBORNE)
KCS-2
TIE BUS
BYPASS
CONTACTORS
'--_____ TOSTART
CONTROL
GROUND
POWER
SOLENOID
(KGp)
BATIERY
SOLENOID
(KBAT)
Figure 24-6. Power Distribution (PA-42-720)
KLC-1
Reissued: December 31, 1989
2C6
R
GEN
RIGHT GENERATOR
LINE CONTACTOR
BATIERY BUS
SSSS
I.
I
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
3
-NOTE-
On PA-42-720 Models Only, Left A.H. and
D.G. not standard. See Avionics Installation.
Also, No Fuel Heat or Generator Inlet Deice
Circuit Breakers on the same models.
6
7
8
1. LEFT PITOT HEAT INDICATOR
2. RIGHT PITOT HEAT INDICATOR
3. STALL WARNING HEAT INDICATOR
4. PROP INLET DEICE SWITCH (L&R)
5. AMMETER
6. LEFT MAIN BUS
7. ESSENTIAL BUS
8. AC BUS
Figure 24-7. Left Circuit Breaker Panels Installation (Typical)
2C7
24-30-00
Page 8
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
2
1. HOUR METER
2. SURFACE DEICE WARN LIGHTS
3. MAIN CIS ELECTROLUMINESCENT PANEL
3
4
5
4. NONESSENTIAL CIS ELECTROLUMINESCENT PANEL
5. AVIONICS CIS ELECTROLUMINESCENT PANEL
Figure 24-8. Right Circuit Breaker Panel Installation (Typical)
24-30-00
Page 9
Reissued: December 31, 1989
2C8
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHECKING STARTER-GENERATOR SYSTEM
The system incorporates two ammeters which provide an independent output check of each generator and a
voltmeter which monitors the electrical bus voltage. Should either ammeter fail to indicate an output from its
generator, check appropriate circuit breaker (Figures 24-7/8). If circuit breakers are in normal operating position,
a further check of the system is required: (Refer to Chart 2405 for inspection and time limits.)
1. Check that ammeters are operating properly.
2. Check that all electrical units are off and battery is fully charged.
3. Disconnect electrical lead at terminal stud B+ on starter-generator being tested. (L or R.)
4. Tum on battery master switch and tum selector switch (L or R) for unit being tested to START position.
5. Using a voltmeter, attach positive lead to electrical lead removed from tenninal stud B+ on starter-generator,
and attach the other lead to airframe ground. Voltmeter must read battery voltage of 24 volts.
6. Tum battery master switch off.
7. Disconnect voltmeter positive lead from the wire removed from starter-generator tenninal stud B+.
8. Connect electrical lead previously removed to B+ tenninal stud on starter-generator.
-NOTE-
On PA-42 series aircraft with Lear Siegler model 23048-020 starter-
generators, the positive tenninals are A+.
ADJUSTMENTS OF STARTER GENERATOR
The only adjustment necessary to maintain the proper generator output is located on the generator control unit.
A voltage of 28.5 volts must be maintained. All other control adjustments are made at time of installation and
need not be reset.
Since the starter generator and regulator units are designed for use on a single polarity type electrical system,
the following listed precautions must be observed when servicing the charging circuits.
-CAUTION-
FAILURE TO OBSERVE THESE PRECAUTIONS COULD
RESULT IN SERIOUS DAMAGE TO THE ELECTRICAL
EQUIPMENT.
1. When installing a battery, ensure that the ground polarity of the battery and the ground polarity of the starter
generator is the same.
2. When connecting a booster battery, make certain to connect the negative battery tenninals together and the
positive battery tenninals together.
3. When connecting a charger to the battery, connect the charger positive lead to the battery positive tenninal
and the charger negative lead to the battery negative tenninal.
4. Never operate the starter generator on an open circuit. Make absolutely certain all connections in the circuit
are secure.
5. Do not short across or ground any of the terminals on the starter generator or generator control unit.
2C9
24-30-00
Page 10
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ADJUSTMENTS OF STARTER GENERATOR (continued)
6. A starter generator with reversed polarity in the output voltage may be corrected by flashing the field as in
the procedure below:
-CAUTION-
DO NOT FLASH THE FIELD WHILE STARTER
GENERATOR IS IN OPERATION.
a. Disconnect the leads to the proper generator control unit.
b. Connect the negative terminal of a small battery (1.5 to 6 volts), or an equivalent dc power supply, to
terminal E of affected starter generator.
c. Connect a jumper wire from positive terminal of same battery to terminal A of same starter generator.
-NOTE-
If flashing the field fails to correct generator polarity, check for
incorrect connections or defective field circuit.
MAINTENANCE OF STARTER GENERATOR (PA-42-720 Only)
GENERAL
The instructions contained in this manual provide a guide for line maintenance, inspection, and brush
replacement only. Replacement of brushes at this level is made possible by the use of instant filming brushes.
DESCRIPTION
-CAUTION-
DO NOT EXCEED 1000 HOURS BETWEEN OVERHAULS
UNLESS OTHERWISE SPECIFIED.
The starter generator serves a dual purpose which, when energized by the proper electric source, starts the
aircraft engines and then serves as a source of continuous 30-volt nominal direct current power when driven by
the engine.
MAINTENANCE
As a precautionary measure between overhaul periods, it is recommended that the starter generators be given a
periodic inspection. (Check event schedules in Chapter 5 for inspection frequency.) Normally it will be
necessary to remove the starter generator from the engine for a thorough inspection of brushes and commutator.
Such removal also affords the opportunity to inspect for spline or dampener wear, and other details.
24-30-00
Page 11
-NOTE-
No special tools are required to accomplish line maintenance of the
starter generators.
Reissued: December 31, 1989
2C10
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL AND INSTALLATION OF STARTER GENERATOR
After engine cowling has been removed:
1. Disconnect and mark electrical wiring at terminal block.
2. Disconnect cooling air inlet and exhaust hoses or ducts.
-CAUTION-
THE STARTER GENERATOR MUST BE SUPPORTED
BEFORE LOOSENING THE HOLDING CLAMP AS DAMAGE
TO THE SPLINE MAY OCCUR. CARE SHOULD ALSO BE
EXERCISED IN THAT THE UNIT DOES NOT HIT THE
LOWER ENGINE MOUNT WHEN REMOVING IT FROM
THE ENGINE ACCESSORY COMPARTMENT.
3. Support starter generator and loosen clamp between QAD and starter generator.
4. Remove starter generator by sliding aft and lift out of engine accessory compartment.
5. Reverse procedure for installation of starter generator.
Ouick-Attach-Detach (QAD)
Mounting Kit
Torsion
Damper
Shaft "0" Ring
,

V-Band Assembly
Figure 24-9. Typical Cross-Section of Starter Generator
Fan
24-30-00
Page 12
Reissued: December 31, 1989
2C11
PIPER AIRCRAFT
PA-42142-720
AIRPLANE MAINTENANCE MANUAL
GENERATOR CLEANING (ASSEMBLED)
1. Remove generator from aircraft.
2. Remove brush inspection cover. Do not remove brushes during internal cleaning and resistance check
procedures.
3. Internal cleaning:
- WARNING-
WHILE USING COMPRESSED AIR, WEAR GOGGLES OR
FACE SHIELD TO PROTECT EYES. DO NOT AIM AIR JET AT
EXPOSED SKIN. USE A DUST FILTER RESPIRATOR.
-CAUTION-
TO PREVENT DAMAGE TO BEARING SEALS AND TO
AVOID FORCING CONTAMINANTS INTO BEARINGS, DO
NOT AIM AIR JET AT BEARINGS
a. Remove carbon and copper dust from armature and stator windings using a low pressure (40 psi) air
supply and nozzle. Start at the drive end of unit and work toward the brushes and commutator area.
- WARNING-
STODDARD SOLVENT IS TOXIC AND COMBUSTIBLE. DO
NOT BREATHE VAPORS. USE IN WELL VENTILATED AREA
FREE FROM SPARKS, FLAME, AND HOT SURFACES. WEAR
SPLASH GOGGLES, SOLVENT RESISTANT GLOVES, AND
OTHER PROTECTIVE GEAR. IN CASE OF SKIN CONTACT,
WASH WITH SOAP AND WATER; IN CASE OF EYE
CONTACT, FLUSH EYES WITH WATER AND SEEK MEDICAL
ATTENTION.
-CAUTION-
DO NOT USE LUBRICANTS OR UNAUTHORIZED
SOLVENTS, WHICH CAN REDUCE BRUSH LIFE.
b. Inspect interior of unit for oil and other contaminants. Wipe contaminants with clean cloth moistened
with Stoddard solvent (Federal Specification P-D-680, Type 1).
c. Perform an insulation check using a volt-ohmmeter or equivalent (50-volt maximum) source tester. The
dc resistance between positive terminal B and the machine frame must measure at least tO,OOO ohms. If
resistance again measures less than to,ooo ohms, return unit to an authorized overhaul center for repair.
d. Inspect air intake and exhaust screens for foreign material. Carefully remove foreign material and
check for possible internal damage to unit.
24-30-00
Page 13
Reissued: December 31, 1989
2C12
4. Exterior cleaning:
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
a. Ensure that brush inspection cover is installed to unit.
-WARNING-
REFER TO WARNING IN STEP (3A) BEFORE PERFORMING
NEXT STEP.
b. Thoroughly clean exterior of unit with soft, clean cloth moistened with Stoddard solvent (Federal
Specification P-D-680, Type 1). Wipe dry with a clean, lint-free cloth.
S. Inspect generator brushes using procedure in Generator Brush Inspection section.
GENERATOR BRUSH INSPECTION
Generator brush inspection is recommended at 100 hour intervals. By means of the diagonal wear groove on
the side of each brush, which shows 100% useful life when new, the percentage of remaining useful life is easily
estimated at each inspection. Inspect generator brushes as follows to determine continued airworthiness:
1. Remove brush cover from unit.
2. Remove screws securing brush leads to brush holders. With a stiff wire hook, lift springs from brushes and
remove brushes.
-NOTE-
If brushes will be reused, mark each brush to allow that the brush will
be installed into brush holder that it was removed from.
3. Determine remaining life of each brush (refer to Figure 24-10). If anyone brush is estimated to be worn
out before the next inspection or overhaul, replace all brushes.
4. After inspection, replace brush cover. Ensure that cover is seated in housing recess and that exhaust air
holes are located adjacent to terminal block.
S. Install generator on aircraft.
m
OJ
WEAR
1/4 LIFE
GROOVE
112 LIFE REMAINING
REMAINING
NEW BRUSH
Figure 24-10. lliustration of Brush Wear Stages
2C13
/ f$-p>
&00 "0 ()
SOLID STYLE

SPLIT STYLE
00"
CORE TYPE RANDOM PARTICLE
ALTITUDE TREATMENT ALTlnJDE TREATMENT
Figure 24-11. Instant Filming Brushes
24-30-00
Page 14
Reissued: December 31, 1989
24-30-00
Page 15
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-NOTE-
Instant filming brushes which do not have cores or visible particles
are identified by marking IIF, in addition to any grade numbers and
date code letters.
-NOTE-
If new brushes have been installed, it is not necessary to conduct
seating or run-in operations due to the ability of instant-filming
brushes to carry full starting and generating currents without such
run-in. If the specified brush is NOT one of these types, the unit must
be returned to an overhaul shop for brush replacement, run-in, and
test.
Brush must be installed with top bevel as shown for the
clockwise armature rotation indicated. (For reverse rotation
units, top bevel will be opposite to that shown.
RECONNECT NEGATIVE
FIELD LEAD
LAY BRUSH LEADS OVER
BRUSH SPRING CLIPS
Figure 24-12. Correct Position of Brushes, Leads, and Springs
Reissued: December 31, 1989
2C14
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
MAINTENANCE OF STARTER-GENERATOR (PA-42, 250 AMP MODEL 23048-20 ONLY)
REMOVAL OF STARTER-GENERATOR FROM AIRCRAFT
1. Disconnect vents from top cowl and remove cowl from engine.
2. Check oil drain from starter-generator (sg) drive housing for signs of oil leakage. If excess oil is shown,
inspect seals after removing sg end bell mount from engine to ensure they haven't failed.
3. Disconnect battery from system.
4. Note appropriate wire connections on sg buss and disconnect wires.
5. Separate necessary tubing from sg ducts.
6. Remove v-clamp retaining sg to its end bell mount and carefully slide sg back out of engine.
7. Remove bell end collector by unscrewing retaining nuts.
DISASSEMBLY OF MODEL 23048-20 STARTER-GENERATOR
1. Loosen v-clamp and remove inlet assembly from end of starter-generator (sg).
2. Twist fan cover to unlock it from stator housing; withdraw cover.
3. To remove brush cover from housing, loosen screw tightening clamp; separate clamp.
4. Remove four brushes from their holders by unscrewing brush and field leads.
5. Using a suitable spline wrench to restrain drive shaft, remove fan retaining nut and withdraw fan from shaft.
6. Tap drive shaft out of stator and housing assembly with a plastic, leather, or other soft mallet on fan end of
shaft.
7. Remove dampener plate and friction ring. Remove dampener hub only if damaged. If replacement is
necessary, use the following instructions:
a. Cover threads on far attachment end of drive shaft.
b. Use a suitable arbor press to press shaft from hub.
8. Remove drive end bell by unscrewing twelve screws attaching it to the stator housing. Only remove screen
if necessary.
9. With armature pressed in bearing and brush support assembly, remove right screws attaching assembly to
stator housing, and withdraw them from housing.
10. Place support assembly in a suitable arbor press. Press armature out of bearing.
11. Remove retaining ring and baffle disc drive end of armature shaft.
-CAUTION-
BEARING PULLER JAWS MUST BE TAPED TO PREVENT
DAMAGE TO BACK PLATE CHAMBERED FACE.
12. Remove drive end bearing from armature shaft with a suitable bearing puller.
13. Remove remaining baffle disc from shaft.
14. Remove bearing in support assembly by unscrewing four screws mounting bearing retainer to support
assembly; press out bearing.
2C15
24-30-00
Page 16
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-NOTE-
Do not remove brush holders and springs from support assembly
unless an inspection reveals replacement of the parts is necessary.
Refer to repair and replacement paragraph for procedures. Do not
disassemble stator and housing assembly.
15. To replace terminal block, proceed as follows:
a. Remove nuts and washers at studs A and D.
b. Remove nuts and washers from studs E, B, and C.
c. Remove two screws, lockwashers, and washers.
d. Remove terminal block from stator housing.
-NOTE-
Do not remove instruction decal or identification plate unless
damaged and replacement is necessary.
CLEANING PROCEDURES
Suitable solvents for cleaning starter-generator parts are found in the list of consumable materials in Chapter 91.
-WARNING-
DO NOT INHALE SOLVENT VAPOR AND USE ONLY IN A
WELL VENTILATED AREA. AVOID PHYSICAL CONTACT.
DO NOT USE CARBON TETRACHLORIDE FOR CLEANING.
t. With the starter-generator (sg) disassembled, those parts not included with the major assembly (brushes,
bearings, armature, and stator-housing) must be thoroughly cleaned in solvent, Federal Spec. P-D-680.
2. Thoroughly dry all applicable parts with dry, low pressure (5 - 10 psi), filtered compressed air.
3. Blow dust and other foreign matter from armature, commutator, inside and outside of stator-housing. Clean
commutator using a soft bristle brush of foreign material between commutator bars.
4. Wipe all assemblies mentioned in step 3 with a clean cloth moistened in cleaning solvent.
5. After cleaning armature and stator-housing assembly, dry them in a 200F (93C) oven for about 2 hours.
24-30-00
Page 17
Reissued: December 31, 1989
2C16
INSPECTION
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Chart 2405 will give the name of the parts and the type inspection reqired for that part.
INDEX NO.
(See Figure 24-13.)
5,6
8
10
12
15
14
16
CHART 2405. INSPECTION OF COMPONENTS
NOMENCLATURE
Covers (Fan
and Brush)
Brush
Fan
Drive Shaft
Plate,
Dampener
Hub,
Dampener
Ring,
Friction
INSPECTION TIME AND
REPLACEMENT
Check for dents or broken spot welds. Replace
if damaged.
Check for cracks, chips, frayed leads, and loose
rivets or shunt connections. Replace if defective.
Replace brushes if remaining allowable wear
will be exceeded before the next inspection.
(See Figure 24-10.)
Inspect every 250 hours.
Replace every 500 hours.
Inspect for looseness of blade on hub or a bent
or cracked condition. Forward edge of blade
shall not measure less than 0.100 inch from
locating shoulder of hub, and the back edge of
blade shall not measure more than 0.830 inch.
Replace if beyond repair.
Magnaflux inspect per MIL-I-6868 for cracks.
Visually inspect for broken or damaged splines
and spline wear. To measure spline wear on the
large splines, use two 0.096 inch diameter pins.
Dimension across the pins should be not less
than 0.7262 inch. Replace shaft if dimensions
are less than indicated.
Inspect for cracks and warpage. Replace if
defective, or if Belleville spring shows signs
of wear.
Magnaflux inspect per MIL-I-6868 for cracks.
Replace if defective.
Inspect for cracks and warpage. Replace ring
if thickness is not .063 minimum.
2C17
24-30-00
Page 18
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2405. INSPECTION OF COMPONENTS (continued)
INDEX NO.
(See Figure 24-13.)
24-3000
Page 19
17
22
25,29
26
38
41
42
53
Reissued: December 31, 1989
NOMENl:LATURE
Dampener
BackPlate
Drive-End
End-Bell
Ball Bearings
Annature
Brush Holder
and Spring
Support
Assembly
Tenninal
Block
Stator
Assembly
INSPEl:TION TIME AND
REPLACEMENT
Magnaflux inspect per MIL-I-6878 for cracks.
Replace if defective.
Inspect for cracks or warpage. Replace if
defective. Repair or replace if liner I.D. is
not within 1.8501/1.0504 inch.
Replace at each overhaul.
Inspect for worn, pitted, or burned commutator
bars; damage to windings, retainer band or
shaft; shaft concentricity and bar to bar
concentricity. Refinish commutator, if
necessary, and electrically test. Bar to bar
concentricity must be within 0.0001 inch and
concentricity with shaft must be within 0.005
inch total indicator reading. Minimum
commutator diameter is 2.055 inches.
Inspect for cracks, warpage, or weak
spring.
Inspect for cracks or warpage. Replace if
defective. Perfonn electrical test. Repair
or replace ifliner I.D. is not within
1.8501/1.8504 inch.
Inspect for cracks, and loose or damaged
tenninals. Check for shorts between tenni-
nals, but do not hi -pot to avoid damaging
embedded capacitors. Replace if defective.
Visually inspect for cracks, burned or damaged
insulation, loose pole shoes and damaged coils.
Replace stator assembly if defective. Perfonn
electrical test.
2C18
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
19
52
I
I
L----
~
~ ~ ~ 0-- 54 __ -
:J)
---
- 5 6 ...-----
__ 10
55 .._-- 28
i ...----
L----
7
INLET ASSEMBLY 15. PLATE (DAMPENER) 29. BEARING
CLAMP 16. RING 30. SCREW
SCREW 17. BACK PLATE 31. WASHER
WASHER 18. SCREW 32. BOLT
COVER (FAN) 19. SCREEN 33. NUT
COVER (BRUSH) 20. SCREW 34. WASHER
SCREW 21. WASHER 35. WASHER
BRUSH 22. END BELL 36. SPRING
SCREW 23. RETAINING RING 37. STUD
FAN 24. DISC 38. BRUSH HOLDER
LOCKNUT 25. BEARING 39. SLEEVE
PACKING 26. ARMATURE 40. INSULATION PLATE
DRIVE SHAFT 27. BEARING RETAINER 41. SUPPORT
HUB (DAMPENER) 28. SCREW 42. TERMINAL BLOCK
43. SCREW
44. LOCK WASHER
45. WASHER
46. NUT
47. LOCK WASHER
48. NUT
49. LOCK WASHER
50. TERMINAL LUG
51. TERMINAL LUG
52. TERMINAL LUG
53. STATOR
54. INSTRUCTION DECAL
55. IDENTIFICATION PLATE
56. SCREW
Figure 24-13. Starter-Generator (250 Amp Mode123048-20)
2C19
24-30-00
Page 20
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REPAIR AND REPLACEMENT (250 AMP MODEL 23048-20 ONLY)
1. If inspection reveals commutator is rough, pitted, or burned, refmish in an accurately set up lathe and adjust.
Remove enough material to clean and true up commutator surface. Replace armature if it needs to be turned
to less than a 2.055 inch diameter. Hold commutator diameter concentric with bearing journals to within
0.0005 inch total indicator reading.
2. To undercut the mica, tum commutator in a lathe. If depth of undercut remaining is less than 0.032 inch, re-
undercut mica between bars to 0.032 inch. Use a triangular scraper to remove all excess mica, sharp edges,
and burrs from between bars. Use a bristle brush to remove metal chips and mica particles from slots
between commutator bars. Check tolerances outlined in step 1.
3. To polish commutator, mount armature in a lathe and operate at a speed of 500 - 600 rpm. Polish
commutator by using sandpaper (5/0) positioned on an accurately cut block of wood over its entire length
and at least one-third its perimeter. Remove any dust or particles from between commutator bars with a
bristle brush.
4. After refinishing commutator, the armature must be checked for proper balance of within 5 grain-inches. If
balance correction is required, mill stainless steel retaining bands at each end of lamination stack until
proper balance is obtained. Only two 0.25 inch wide and 0.031 inch deep millings are permitted in each
band to maintain adequate strength.
5. To measure brush spring tension, use the following procedure:
a. Using a new brush, cut a groove down the center of both edges and across the bottom. The brush will
have a continuous groove around three sides.
b. Place a thin wire around brush in groove and insert brush in one of the brush holders. Tie two ends of
wire together and attach to a spring scale.
c. Raise brush with spring scale until lower end of brush is even with bottom edge of holder. The tension
must be 40 - 55 ounces. Use an average of several readings, and if tension is not within this range,
replace spring.
d. Use same procedure for remaining brush holders.
6. Although new brushes are instant filming, sand them to ensure they are properly seated on commutator
surface. Failure to properly seat brushes can affect results obtained during post overhaul tests. Seat brushed
on the motor as follows:
a. Position brush leads over brush springs to prevent hangup.
b. Raise each brush spring with a stiff wire hook and lift brush away from commutator until brush spring
can hold brush in position by resting against side of brush.
c. Place a strip of 5/0 or fmer sandpaper slightly wider than width of brush around commutator. Cut the
sandpaper strip to one inch greater than commutator circumference. Secure one end of the sandpaper
strip with masking tape so taped end will lead in the direction of rotation and the other end will remain
loose and overlap taped end.
d. Lower brushes in place against sandpaper and carefully rotate armature by hand in the normal direction
of rotation (Figure 24-5) until a full seat is obtained on each brush. Do not sand excessively.
e. Remove sandpaper and remove all carbon dust with dry, compressed air.
24-30-00
Page 21
Reissued: December 31, 1989
2C20
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
LAY BRUSH LEADS OVER
BRUSH SPRING CLIPS
SERIES
RADIO NOISE FILTER
======-=--=====::-:.:::::J
0
OF SLOT IN BRUSHES
(MAXIMUM WEAR POINT)
Figure 24-14. Correct Position of Brushes
and Springs
A+ D
Figure 24-15. Electrical Connections of
Starter-Generator
7. Correct a unit with reversed polarity in the output voltage by flashing the field as follows:
-CAUTION-
DO NOT FLASH THE FIELD WHILE UNIT IS IN
OPERATION.
a. Disconnect leads to external voltage regulator.
b. Connect negative terminal battery to terminal E.
c. Connect positive terminal of battery to terminal A through a knife switch.
d. Close switch for 5 seconds; open switch and disconnect from battery.
-NOTE-
If flashing the field fails to correct generator polarity, check for
incorrect connections or defective field circuit.
E-
24-30-00
Page 22
Reissued: December 31, 1989
2C21
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REASSEMBLY OF MODEL 23048-20 STARTER-GENERATOR (Figure 24-4)
1. If the identification plate or instruction decal was removed or is lost off the stator housing, reinstall and coat
surface lightly with a moisture and fungus resistant varnish per MIL-V-173 or PED (see consumable
materials chart), PIN 05-651260.
2. Only replace bearing and brush support assembly bearing after assembly is completely cleaned. Press
support bearing into assembly and install bearing retainer with screws coated with JAN-A-669 or PED, PIN
05-648227, anti-seize compound.
3. Install one baffle disc with recessed surface facing windings on drive end of armature shaft.
4. With armature supported in an arbor press, press a new bearing on drive end of armature shaft.
5. Position recessed surface of other baffle disc away from armature and install disc on drive end of armature
shaft.
6. Install retaining ring in groove on armature shaft drive end, being sure ring fully engages groove.
7. With armature supported in an arbor press, position assembled support assembly on commutator end of
armature shaft and at inner race of bearing; press them together.
8. Insert assembled armature and support assembly into stator-housing assembly and secure with eight screws.
9. Position drive end bell assembly on stator and housing assembly so one dowel pin hole in drive end bell is
at the 12 o'clock position with terminal block located at top of unit.
10. Thread JAN-A-669 or PED, PIN 05-648227 anti-seize compound on twelve mounting screws, and secure
drive end bell assembly to stator-housing.
-CAUTION-
DO NOT USE AN ARBOR PRESS TO FORCE DAMPENER
BACK PLATE ONTO ARMATURE SHAFT OR DAMPENER
HUB ON DRIVE SHAFT. TIGHTENING OF NUT PROPERLY
SEATS THESE COMPONENTS.
11. Wring dampener back plate onto armature shaft by hand ensuring plate taper is fully seated on shaft taper.
12. Rotate armature in its bearings and ensure back plate runout does not exceed 0.003 inch TIR.
13. If dampener hub was removed from drive shaft, align hub on shaft so hub taper seats with shaft taper, and
wring it onto shaft by hand.
14. Place new friction ring in recess of dampener back plate and position plate on hub, being sure plate splines
align with those on hub and fully bottoms out on shoulder of hub.
15. Insert drive shaft through armature and ensure splines of the two shafts engage fully.
16. Position and secure fan assembly with one-piece selflocking nut.
17. With a suitable spline wrench retaining the drive shaft, tighten fan retaining nut 100 - 120 inch pounds.
18. Install brushes and secure brush and field leads with four screws. The electrical connections must be in line
with figure 24-6. (Refer to previous paragraph and figure 24-5 for brush seating and correct positioning of
brush leads.)
19. Install brush cover on housing so clamp screw is 90 counterclockwise from center stud on terminal block.
20. Properly align fan cover in its grooves on housing and tum it clockwise or counterclockwise to lock in
position.
21. Install air inlet assembly with v-clamp and tighten nut to 25 inch pounds.
24-30-00
Page 23
Reissued: December 31,1989
2C22
FITS AND CLEARANCES
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
No special fits or clearances are required, but fan dimensions must be maintained.
INSPECTION AND TESTING OF COMPONENTS (PA-42 ONLY 250 AMP)
The following test equipment is required to inspect and test components: a variable speed test stand capable of
driving the unit 5,500 - 12,000 rpm at full load and to 14,000 rpm no load and a stand containing instruments to
measure torque, speed, voltage, current, and temperature; adequate circuitry to load unit in five steps of 0 amps
(no load), 50 amps, 100 amps, 150 amps, and 200 amps and cool air from a shop air source to inject into blast
cover.
1. Test requirements before assembly of unit:
a. Check brush holders and support for shorts to ground with a 1l0-volt AC source and a 7 1/2 watt test
light connect in series. Touch one lead to brush holder and one to support for one second. If lamp
illuminates, support must be repaired.
b. To test armature, use a 1l0-volt source and a 7 1/2 watt light connected in series. Touch one lead to
armature shaft and other lead to commutator risers and check between each of the two commutator
bands and commutator risers. If lamp illuminates, the armature is grounded and must be replaced.
c. To test stator assembly, use same circuit as before and touch one lead to frame and other to terminal A.
If lamp illuminates, stator is grounded and must be replaced. Use an ohmmeter and check for
continuity by touching one meter lead to negative field lead and other to terminal A. The terminal
block must be removed for this test.
2. Test requirements after assembly of the unit (after overhaul):
a. With regulator connected to unit, operate generator without a warmup at 13,000 rpm, 30-volts, and no
load. Calculate resistance between terminals, band A dividing B to A voltage by field current.
Resistance between band A must not be greater than 35 ohms. Record field current, commutation, and
frame temperatures. Commutation must be black and shunt field current not less then 0.81 amperes.
b. With voltage regulator connected to unit, operate at 12,000 rpm, 30-volts, 250 amps, until frame
temperature shows no more than 2F rise in five minutes. Record voltage between D and E, airblast
inlet temperature, commutation, field current, and frame temperature. Commutation can not be worse
then pinpoints along brush edges. The paralleling voltage must be within limits shown in figure 24-6.
Frame temperature must not exceed air temperature by more than 175F.
c. Operate unit at 12,000 rpm, 30-volts. Compound current at 0, 62.5, 125, 187.5, and 250 amps. Field
current must increase with load and commutation can not exceed pinpoints.
d. To ensure unit operates properly at its minimum speed for regulation, operate at 6,900 rpm and check
for 30-volts and 200 amperes. With field current not exceeding 8.0 amperes, calculate resistance
between terminals B and A by dividing B to A voltage by the attained field current. Resistance must
not be less then 1.25 ohms.
e. Reduce speed to approximately 5,800 rpm. Operate at no load and open field until frame temperature is
120F or less. Substitute 1.25 ohms resistance for field circuit regulator (between terminals A and B)
and adjust speed for 26-volts and 200 amps. Operate until stabilized as in step b. Record field current,
speed, frame temperature, voltage between A and B, and commutation. Speed can not be greater than
5,800 rpm.
2C23
24-30-00
Page 24
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
f. Reconnect voltage regulator and check commutation at 30-volts, 0, 125, and 250 amps at speeds of 6,500,
10,000, and 12,000 rpm. Record field current, frame temperature, and commutation. Commutation must
not exceed pinpoints for all conditions.
g. With the unit hot, operate for five minutes at 14,000 rpm with field circuit open. Then operate at 12,000
rpm, 30-volts, and 250 amps. Record field current, frame temperature, and commutation. Commutation
must not exceed pinpoints.
h. To conduct a dielectric test, remove unit from test stand while still hot from testing. Conduct a test using
11O-volts AC, 60 Hz. Put one lead on frame and the other to leads removed from terminal block. The
leads from terminal block must be removed from studs due to embedded capacitors connected to ground.
The unit can not be shorted or grounded in any circuit.
i. To conduct tests on unit as a starter, connect a 50 ohm resistor between terminals A and B.
j. With unit rigidly mounted in a horizontal position by use of a mounting flange, operate at no load with
IS-volts applied to terminals C and E. The no load speed must be greater than 4,800 rpm.
-CAUTION-
DO NOT ENERGIZE UNIT FOR MORE THAN FIVE
SECONDS DURING THE FOLLOWING TEST.
k. Lock rotor and apply voltage between terminals C and E. Increase voltage until output torque is 23 foot-
pounds. Do not energize unit for more than two seconds. Record current and voltage. Current can not
be greater than 500 amps and voltage can not exceed 13-volts.
l. Complete commutator run out checks while rotating armature on its own bearings. Record total indicated
run-out and maximum bar-to-bar difference. Maximum total indicated run-out must be 0.0005 inch and
bar-to-bar difference must not be more than 0.0002 inch.
24-30-00
Page 25
LL
0
.
w
a:
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....
ct
a:
w
Do
:&
w
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cc
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w
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:!5
110
100
90
80
70
60
50
40-
1.3
Reissued: December 31, 1989
.
/
V /
L
/
/ I
,
,
I


I'
/
/
L
1.5 1.7 1.9 2.2 2.3 2.5
PARALLELING VOLTAGE - VOLTS
Figure 24-16. Paralleling Voltage Check
2C24
BATTERY
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Nickel-Cadmium batteries must be kept clean and charged to remain airworthy. Service is required every 100
hours or 60 days, whichever occurs first. Water consumption is directly proportional to overcharge currents
experienced. Service frequency depends on operating condition.
IMPORTANT PRECAUTIONS
-WARNING-
SERIOUS INJURY CAN RESULT FROM CARELESSNESS OR
IGNORANCE WHEN CLEANING OR SERVICING ANI-CAD
BATTERY.
1. All metal jewelry such as rings, watch bands, bracelets, etc must be removed. Due to very high current
capabilities, the battery can quickly melt or fuse metal and cause severe bums.
2. Use only insulated tools. Never use tools previously used on lead acid batteries.
3. The potassium hydroxide and water battery electrolyte is caustic and can cause severe bums. Wear
protective clothing such as rubber gloves, apron, and eye protection while handling electrolyte. If contact
occurs, flush immediately with water and neutralize with acetic acid, vinegar, lemon juice, or a 10%
solution of boric acid. Hush eyes with water continuously; contact physician immediately.
4. Hydrogen and oxygen gases are generated and are highly explosive. Vent these gases to outside air when
charging. In case of charging indoors with central air conditioning present, these gases can be circulated via
the duck work throughout the building. Outside venting of battery service area is mandatory.
5. Ensure all electrical connections are tight and secure to prevent electrical arcs, which could trigger an
explosion.
6. Keep cell vent plugs in place at all times except when inspecting or adjusting electrolyte levels.
TROUBLESHOOTING BATTERY
Refer to Chart 2406 for troubleshooting procedures for the battery installed in this aircraft.
201
24-30-00
Page 26
Revised: August 1, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2406. TROUBLESHOOTING (BATTERY)
Trouble
Excessive electrolyte
spewage.
Excess use of water by one
or more cells.
Foaming during charge
after water addition.
Continued foaming during
charging.
No battery output.
Loss of capacity.
24-30-00
Page 27
Reissued: December 31, 1989
Cause
Electrolyte level too high.
Vent caps loose or damaged.
Damaged cell case.
Charging voltage too high.
Leaky or defective cell or
vent.
High charger voltage.
Low concentration
electrolyte.
Oil and grease contamination
in the electrolyte.
Broken or disconnectedlinks.
Loose batteryconnector.
Cell open internally.
Electrolyte level too low.
Charging rate too low in
service.
Too little usage or shallow
discharges
202
Remedy
Clean and adjust electrolyte
level.
Replace or tighten caps,
recharge and check
electrolyte level and drain.
Short out all cells to O-volts,
clean, recharge, and check
electrolyte level. Replace
defective cell.
Clean and recharge, check
electrolyte level and check
battery charge system.
Inspect for electrolyte leakage;
remove and replace defective
cells or vents.
Reset voltage regulator.
Discharge; constant-current
charge. Replace defective
cells.
Replace defective cells.
Replace or tighten links
and connector. Replace
defective cell.
Charge; adjust electrolyte
level and capacity test.
Charge and capacity test.
Discharge and Recharge
per this Chapter
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2406. TROUBLESHOOTING (BATTERY) (continued)
Trouble Cause
Below normal output Battery left on load.
voltage.
Charger not operating
properly.
Internal connecting links
loose.
External connector burned
or pitted.
Terminal links discolored Loose terminal hardware.
or burned.
Burned or pitted terminals. Foreign metallic objects in
the battery; tools dropped
into the open battery.
Burned or pitted output Improperly fitting or loose
receptacle terminals. mating output connections.
Distortion of cell case Cell with internal short.
and cover.
Charger failure.
Plugged vent caps, minor
explosion.
Overheated battery,
improper cooling.
Distortion of battery case Major explosion:
or cover. Loose links
Dry cells
High charge voltage
Charger failure
203
Remedy
Recharge and capacity test.
Recharge and capacity
test battery. Check
charger operation.
Torque to proper value;
recharge and capacity test.
Clean or replace, recharge
and capacity test.
Clean or replace links, and
torque all terminal hardware
to specified values.
Locate and remove foreign
objects and replace defective
parts.
Replace both mating
connectors.
Discharge, disassemble, and
replace defective cells.
Discharge, disassemble, and
replace defective cells.
Discharge, disassemble,
replace defective cells,
and replace vents.
Discharge, disassemble, and
replace defective parts.
Discharge, disassemble, and
replace defective cells, links,
vent caps, hardware, and case.
Replace battery case and
cover.
24-30-00
Page 28
Reissued: December 31, 1989
REMOVAL OF BATTERY
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
The battery is located behind the nose cone.
1. Open forward baggage compartment door.
2. Release nose cone latch located immediately to the left, inside the baggage compartment door.
3. Swing open nose cone, cut safety wire on large Eleon electrical connector and unplug connector.
4. Locate single wire (in line connector) to battery temperature probe and disconnect the wire ends.
5. Tum camlocks loose at bottom front of battery and remove battery support angle.
6. Slide battery forward on tracks and withdraw from hose section. Be careful, battery weight is considerable.
BATTERY CLEANING
-CAUTION-
USE EYE PROTECTION WHEN CLEANING BATTERY.
Nickel-Cadmium batteries must be kept clean to maintain an airworthy condition. Contamination can cause
conductive paths leading to self discharge. The battery must be cleaned and serviced every 100 operating hours
or 60 days, whichever occurs first. Charge rates determine water consumption and operating conditions must
determine service frequency. Ni-cad batteries must never be serviced in a lead acid battery service area. Even
small traces of sulfuric acid entering a Ni-cad battery can cause permanent damage.
1. Wipe down all surfaces with a clean, dry cloth.
2. Loosen stubborn deposits with a plastic scraper. Use filtered, dry, low pressure air with a non-metallic
nozzle to blow away contamination (dust, salts, etc) from around top of the cells and case.
-NOTE-
Do not clean battery with chemical or petroleum base liquids.
BATTERY INSPECTION
1. Inspect Eleon connector for arcing, mechanical wear, corrosion, cracks, bent terminals, and general physical
condition. Look for signs of overheating, especially around positive and negative connector pins. Defective
connectors can cause dangerous overheating due to high current capabilities of the Ni-cad battery. Using an
ohmmeter set on highest scale, verify resistance of insulation is infinite between connector pins.
24-30-00
Page 29
-NOTE-
Refer to battery disconnect and receptacle inspection in this chapter
for complete inspection procedure.
Reissued: December 31, 1989
204
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
2. Inspect battery case and cover for bends, dents, cracks, bums, and general physical condition. If metal is
exposed through plastic coating or paint, recoat or replace.
3. Within battery case, inspect connector links for bends, tarnish, loss of nickel plating, corrosion, or bums.
Polish tarnish off with fine wire brush.
4. Ensure cell wedges and case insulation are free of cracks and holes. Replace any that are found defective.
-NOTE-
Consult the latest service literature published by the battery
manufacturer for overhaul, repair, and service testing.
PERIODIC BATTERY CHECK
The condition of the battery must be determined every 50 to 100 hours initially. Periodic battery check
intervals can be varied as service experience dictates by referring to battery service record. If the temperatures
are above 100F for an extended period, or if battery problems arise, battery must be checked more frequently.
This check also equalizes cell voltages.
1. Discharge battery.
2. Recharge battery.
3. Check electrolyte level and adjust, if necessary.
4. Rest battery for 24 hours.
-NOTE-
The battery cells must be at room temperature.
5. Discharge battery at 40 amps; at one hour, battery voltage must be 20-volts.
6. If battery voltage is below 20-volts, rest battery for 4 hours and repeat steps 2 thru 5.
7. During this discharge, check individual cell Voltages. If battery voltage is again below 20-volts, replace
each cell which fell below one-volt before 1 hour. (Consult battery manufacturers service and repair
literature.)
ADJUSTMENT OF ELECTROLYTE LEVEL
-WARNING-
WEAR PROPER PROTECTIVE GEAR WHEN PERFORMING
BATTERY MAINTENANCE. ELECTROLYTE (POTASSIUM
HYDROXIDE) IS VERY CAUSTIC AND MAY CAUSE
PERSONAL INJURY OR AIRCRAFT STRUCTURAL DAMAGE.
IF INJURED, NEUTRALIZE WITH 3% BORIC ACID
SOLUTION IN WATER, AND SEEK MEDICAL ATTENTION.
The liquid level in battery varies with the state of charge. It must be visible above baffle top when battery is
fully charged.
1. Adjust level after battery is fully charged and is at rest for 2 to 4 hours disconnected from any circuit.
2. Remove vent plug from each cell, one at a time, to adjust electrolyte level.
3. Use a transparent tube open at both ends, about six inches long, and 0.025 inch in diameter. Insert it
perpendicular to baffles into filler well until end rests lightly on cell baffle. Then place index finger over
top end of tube and withdraw
205
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PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
4. Tube liquid level must be between 0.375 - 0.5 inch. If liquid level is above 0.5 inch, remove excess with a
syringe or squeeze bottle. If liquid level is below 0.375 inch, add only distilled water.
5. Recharge battery at 4 amps for I hour after adding distilled water to prevent damage from freezing during
cold weather. Remove battery from aircraft for charging.
BATTERY CELL REPLACEMENT
-WARNING-
TO AVOID PERSONAL INJURY OR BATTERY DAMAGE, DO
NOT REMOVE A CELL OR TERMINAL LUGS FROM
WEARSAFETYGOGGLESAND
PROTECTWE CLOTHING TO PROTECT EYES AND BODY
FROM ANY ELECTROLYTE SPRAY SQUEEZED FROM
REPLACEMENT CELL WHEN IT IS PUSHED INTO PLACE.
-CAUTION-
DO NOT REMOVE DEFECTIVE CELL FROM BATTERY
UNTIL A PROPER REPLACEMENT CELL IS AVAILABLE.
(SAFT CELL ASSEMBLY D17360 GULTON, PIN C13950.)
(PIPER PIN 758 025.)
1. Discharge battery at 20 amps for 2 hours.
2. With clip leads, short across each cell as voltage goes below 1(2 volt.
3. After all cells are shorted, remove connecting straps from defective cell.
4. Lift defective cell from battery by lifting at terminals using a specially fabricated tool (figure 24-8).
5. Install new cell ensuring it is discharged and polarity symbols are properly positioned.
-NOTE-
To aid insertion, be sure vents on all cells in the same row, including
replacement cell, are loosened.
6. If cell is difficult to install, apply vaseline or Shell Dorina 2 on sides of replacement cell.
7. Reassemble attaching hardware.
-NOTE-
These parts are specifically designed to provide an adequate electrical
connection. Never use homemade hardware.
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206
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
SOCKET SCREW
TERMINALS
-
-
APPROPRIATE T H R E D ~ =
(5/16)
2 REQUIRED
Figure 24-17. Fabricated Cell Puller Tool
1-----II------IvTHERMOSTAT
FUSEHOLDER
Figure 24-18. Cell Layout - Nickel-Cadmium Battery
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PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHARGING BATTERY
A battery's capacity is measured in ampere hours (AR), which is the product of the number of amps flowing
and the hours this current flows. The charge required is also measured in ampere hours and is always somewhat
larger than the discharge obtainable. The amount of recharge required at normal rates and temperatures is 140%
of the discharge obtainable.
Voltages values, currents, etc, refer to chart 2406. Charging is most efficient when performed at battery
temperatures between +40F and +80F. Do not start charging, except when necessary, if the battery temperature
is above 100F.
Do not charge a nickel cadmium battery in the proximity of lead acid batteries. Fumes or acid spillage can
exist to contaminate the nickel cadmium battery. If the same equipment is used to charge both types of batteries.
clean thoroughly with a sodium bicarbonate solution before using it on nickel cadmium batteries. There are
several methods used to charge this type of battery. The preferred method and an alternate method are presented
in the following chart.
CONSTANT CURRENT CHARGING
If battery charge is unknown, completely discharge the battery before charging.
1. Charge battery at 13.3 amps until battery voltage reaches control point (30.5 volts).
2. The finishing charge rate will be 4 amps. To determine time to fully charge battery at finishing rate, use the
following formula:
Tf=IsxTs
3 x If
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Page 33
Tf - Time, in hours required for finishing charge.
Is - Starting charge rate, in amps.
Ts - Time, in hours, of charge at the starting until "Control
Point" voltage is reached.
If - Rate, in amps, of finishing charge.
EXAMPLE
Using a charging rate of 10 amps, and assuming it takes 2. 7 hours for
the voltage to reach the control point of 31 volts, the formula is as
follows:
Is (10) x Ts (2.7 hrs)
3 x If (4A)
27
= Tf (2.25 hrs)
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208
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PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2407. NICKEL CADMIUM BATTERY SPECIFICATIONS
Battery Type: 40776
Capacity: 40 AH at the 1 hour rate
Number of series connected cells - 20 - Nominal Voltage - 24
Constant Current Charging:
Starting rate (Is) - 8.5 to 22 amperes - - Control Point 30.5 volts
Finishing Rate (It) - 4.0 to 10 amperes - - Triclde Rate 215 to 430 milliamps
Constant Potential Charging:
Voltage (Bc) (See Constant Potential Charging vrr Table) 43 amperes min.
Inrush current at above voltage: 350 amperes max.
Floating Voltages:
OF 29.0 to 31.0 volts
75F 28.0 to 30.0 volts
100F 27.4 to 29.4 volts
Discharge Rates:
Max. Short Time:
10 sec. 1720 amperes
30 sec. 860 amperes
Max. Continuous:
430 amperes
1 hour rate: 43 amperes
5 hour rate: 9 amperes
20 hour rate: 2.25 amperes
(Cell) Terminal Type: Screw - - Thread Size: 10/32 - - Torque: 113 in.lbs
Electrolyte Level:
During last 20 minutes of charge
Cutoff Voltage:
15.0
20.0
21.0
22.0
Depth in Baffle:
20mm
CONSTANT POTENTIAL CHARGING V/T TABLE
Battery Temp. (OF) Volts/Cell
0 1.565
20 1.545
40 1.525
60 1.505
80 1.485
100 1.460
120 1.440
140 1.420
209
Voltage
31.3 .5
30.9 .4
30.5 .3
30.1 .2
29.7 .2
29.2 .2
28.8 .1
28.4 .1
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Battery
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Ammeter
Shunt
Circuit Diagram No.1
Load
Resistor
Shunt
Battery
Knife Switch
Discharge Circuit (Preferred)
Discharge Circuit (Alternate)
Battery
[J
Temperature
Probe
II
II
II
II
Ammeter
I I ... ~ Recorder
Lk
Shunt
Charging Circuit (Preferred)
Circuit Diagram No.2
Temperature Probe
Ammeter
Battery
Charger
Charger
Knife Switch
Charging Circuit (Alternate)
Figure 24-19. Charge/Discharge Schematics (Typical-Service)
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Reissued: December 31, 1989
2010
Load
Resistor
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CONSTANT POTENTIAL CHARGING
1. Charge battery for 4 hours using proper voltage (refer to chart 2407). The charger must deliver a minimum
of43 amps.
2. A nearly full charge can be restored in 1 hour if charger is capable of delivering 86 amps.
3. A battery in a discharged state will accept very high currents, for a few minutes, at the beginning of the
charge (350 amps maximum inrush current). This current will not damage the battery, but the charger must
have inherent current limiting, or be otherwise protected against overload.
CELL VOLTAGE CHECK
The cell voltage check requires using a 0-50 Vdc range voltmeter with at least 2% accuracy. A digital readout
type is suggested.
1. Connect negative lead of voltmeter to negative tenninal of Elcon connector.
2. Using positive probe and starting at positive tenninal of cell number 20, measure and record voltage
readings of all cells in reverse order of numerical sequence (figure 24-9).
3. Disconnect negative lead of voltmeter from negative tenninal of Elcon connector and connect positive lead
of voltmeter to negative tenninal of Elcon connector.
4. Using negative probe and starting at negative tenninal of cell number I, measure and record voltage
readings of all cells in numeric sequence (figure 24-9).
5. The defective cell is found by monitoring voltage readings obtained between each cell terminal and the
battery case. The lowest voltages will occur at the terminal connectors on each side of the defective cell.
Replace defective cell.
BATTERY DISCONNECT AND RECEPTACLE INSPECTION
The purpose of this inspection is to detect worn or weakened battery quick disconnects, reducing the
possibility of a potentially hazardous condition.
1. Disengage battery disconnect from mating receptacle and inspect for the following:
a. Corrosion or pitting of helix.
b. Excessive free-play in handwheel-wonn assembly.
c. Evidence of arcing or burn marks on helix.
2. Insert 0.385 inch diameter end of inspection gauge (Elcon Inspection Gauge No. 029) into each helix to a
depth of 0.437 inches. The fit must be snug with a force to remove greater than one pound. This tests
resiliency of helix to an oversized pin.
3. Insert 0.370 inch diameter end of inspection gauge into each helix to a depth of 0.437 inches. The fit must
be snug with a nominal force to remove of one pound. This will ensure proper contact to a worn or
undersized contact pin.
4. With mating disconnect removed, inspect battery receptacle as follows:
a. Inspect contact pins for evidence of corrosion or pitting.
b. Inspect contact pins for evidence of arcing or bum marks.
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AIRPLANE MAINTENANCE MANUAL
c. Check for battery electrolyte leakage through receptacle body or contact pins.
-NOTE-
Electrolyte leakage is evidenced by a discoloration of receptacle body
with glass fibers exposed.
d. Using dial calipers, gauge each contact pin diameter. The diameter must be 0.375 0.005 inch.
5. If defects are found, rework or replace parts.
INSTALLATION OF BATTERY
1. Place battery on mounting bracket and reconnect vent lines previously removed.
2. Slide battery into place and secure with two camlocks on bottom front of battery.
3. Connect battery temperature probe wire from top of battery, at inline connector.
4. Put electrical connector on battery with (+) symbols on connector on top and (-) symbols on connector on
bottom. Secure by tightening knob on connector.
5. Secure knob by placing safety wire through two holes on knob to two nuts on each side of knob.
6. Close nose cone and secure with latch. Close small access door to latching mechanism and secure with
screw type fastener.
TESTING BATTERY TEMPERATURE SENSOR
Use the following information to check temperature sensor operation:
1. Set up a hot oil bath at 130
0
P and obtain an ohmmeter.
2. Remove temperature sensor unit from battery and disconnect wire at fuse holder.
3. Connect ohmmeter probes to temperature sensor. No reading should exist.
4. Submerge temperature sensor into hot oil and observe ohmmeter. A reading must be indicated. Reset
sensor when removed from hot oil after allowing to cool to 110P'
5. With test completed, reinstall temperature sensor to battery and connect fuse holder. Ensure fuse is installed
and in good condition.
VOLTAGE CONTROL PANEL
DESCRIPTION AND OPERATION OF VOLTAGE CONTROL PANEL
The control panel is designed to incorporate all normal features of a 28-volt control system in one compact unit
containing printed circuit boards. By using a comparator amplifier with a regulated reference voltage, any
difference between reference voltage and generator output, as seen by the sensing line, is amplified and supplied
to the comparator circuit, which in tum, controls the shunt field excitation of the generator.
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2012
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
The paralleling portion of the control panel incorporates the advantages provided by integrated circuitry. The
difference between the interpole voltage of the local generator and interpole of the other generator is amplified,
inverted, and filtered. Any resultant difference is then coupled to the summing junction of the voltage regulator
circuit. The equalizing circuit continuously sums the difference between the interpole voltages of both generators
to zero.
The line contactor and reverse current control circuitry consists of two integrated circuits and differential
voltage sensing operations. When the generator has attained an output voltage equal to the tie bus voltage, these
circuits allow the line contactor to close. They also monitor the difference in voltage across the interpole
terminals of each generator. When this potential reaches a positive voltage of 0.2 volts or more, the integrated
circuits, after a time delay inversely proportional to the magnitude of the voltage, cause the line contactorto open.
When this happens, the circuit automatically shifts back to differential voltage sensing.
CHECKING VOLTAGE CONTROL PANEL
1. Start engines and set gas generator to 60% rpm. Tum on all electrical equipment available in aircraft and
system voltage must remain at 28 1 volts.
-NOTE-
Voltage adjustment screw is located on connector side of voltage
control panel unit behind removable rubber plug.
2. Tum left starter-generator switch to OFF position, transferring full electrical load to right generator and dc
control panel. System voltage must remain at 28 1 volts.
3. Tum left starter-generator switch to ON position and tum the right starter-generator switch off, transferring
full electrical load to left starter-generator and dc control panel. The system voltage must remain 28 1
volts.
4. If voltage does not remain at 28 1 volts, check generator and battery. Check all circuit connections and
wiring in starter-generator system for unwanted resistance. Clean wiring connections and resolder as
necessary. Check voltmeter for accuracy and repeat test. If system voltage still is not within 28 1 volts,
refer to performance test.
REMOVAL OF VOLTAGE CONTROL PANEL (AiC serial numbers 42-7800001 to 42-8001037)
The dc control panel regulators are mounted to an electrical accessory shelf which is mounted to the forward side
of fuselage station 25.6.
REMOVAL OF VOLTAGE CONTROL PANELS (Serial numbers 42-8001038 and up)
Location of dc control panels on aft engine nacelle electrical accessory panel, aft of engine firewall station
108.5 on respective engine.
1. Open fuselage - nose baggage compartment and remove rear royalite covers.
2. Disconnect electrical plug from appropriate panel and remove securing screws and unit.
3. Remove aft upper engine panel for access to dc control panel.
4. Disconnect electrical plug and securing screws; remove unit.
2013
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PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF VOLTAGE CONTROL PANELS (A/C serial numbers 42-7800001 to 42-8001037)
1. Position dc control panel on electrical accessory shelf and secure with appropriate screws.
2. Reconnect electrical plug to dc control panel.
-NOTE-
If radio equipment from upper radio shelf was removed, reinstall
radio equipment plugs and equipment.
3. Replace accessory shelf covers; secure baggage door.
INSTALLATION OF VOLTAGE CONTROL PANELS (A/C serial numbers 42-8001038 and up)
1. Position dc control panel on aft engine nacelle panel and secure with appropriate screws.
2. Reconnect electrical plug.
3. Replace aft engine access panel and secure with appropriate screws.
-NOTE-
The replacement of voltage control panels requires a functional check
for proper operation (refer to checking voltage control panels in
chapter 24).
PERFORMANCE TESTS - LEAR SIEGLER #51530-001, VOLTAGE CONTROL PANEL (PA-42-720)
The following performance tests are comprised of both bench and systems tests. The bench tests must be
performed in a closed loop system (Figure 24-13).
DIELECTRIC TEST
Connect all J-l pins together, and apply a potential of 250 VAC (rms) at 60 Hertz for 60 seconds, or 300 VAC
(rms) at 60 Hertz for 1 second. Ensure no failure exists resulting from this test.
2430-00
Page 39
Reissued: December 31,1989
2014
FINAL TESTING
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
The final tests are always performed in sequence. Any adjustments must be performed at an approved facility
using adjustment procedures in Lear Siegler, Inc. service and overhaul literature. Connector pins referenced in
tests are those of electrical connector J -1 located on front of unit.
-CAUTION-
UNLESS OTHERWISE NOTED, ALL SYSTEMS MUST BE
STARTED WITH FIELD CONTROL RELAY (KFR) IN RESET
POSITION.
The field control relay (KFR) is a dual coil magnetic latching type which provides one set of contacts to
disconnect the line contactor and a second set to control the power relay (KFRA). The power relay is a small
vacuum relay located in the field power circuit.
OPEN LOOP TEST (VOLTAGE REGULATOR)
Perform an open loop test before any closed loop tests are applied. Open loop tests can be omitted if
calibration tests have been performed. (per the Lear Siegler, Inc. overhaul manual.)
1. Connect a variable 0-50 Vdc power supply, positive side to pins A, B, C, and J, and negative side to pins D,
G, and L. Connect 28 Vdc type 313 lamps between pins M and H, and negative side of power supply.
STARTER
GENERATOR
+28Vdc
POWER
SUPPLY
GENERATOR
CONTROL
_______ SWITCH
RESET
A
B
L...-----IC
L...------;K

L...-________ __ --__IF
I VOLTAGE REGULATOR
..... :N ..... OR_MA_L-+-____ r
ND
CONTROL PANEL
- I
KLC
V I
VARIABLE SELF-TEST I
LOW VOLTAGE t.... ________ ---1
POWER SUPPLY 1 '-TRIP SWITCH
- (MOMENTARy)
Figure 24-20. Closed Loop Test Diagram (Lear Siegler, Inc.)
2015
24-30-00
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Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
---








.+
L


r4-


r-!L


f--




..J...

51509-TE5T PANEL
CONNECTOR
AWG 16
AWOl6
AWGI6
.. ...
TRIP SWITCH
7:"
re
c
-
..g..



H
r;-



rt:I
t-p

'S"
....:.....
!lIS30-VOLT R EO
CONNECTOR
Figure 24-21. Voltage Regulator Test Panel Schematic (Lear Siegler, Inc.)
I
I
L
PS NO.2
POLARITY
REV. SW
4 PDT
19B
5W
CllINOICATES SCREW POST TERMINAL
(+)O-!lOV PS
REV CURR
PMAU.EL
REVERSE CURR
TEST 2POT
PAR"
INTERNAL
POWER SWITCH
, w 'FIELD PWR
R
oN-OFF
INT PWR
(-)O-5OV PS
BUS TIE
...L
TRIP SWITCH
Figure 24-22. Voltage Regulator Adapter Connector (Lear Siegler, Inc.)
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2016
A
B
J
0
Q
P
E
M
S
C
K
G
L
H
F
N
R
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
2. If power supply is set at 28 Vdc, field lamp must glow at approximately half brilliance. Increase input to 29
0.5 Vdc and lamp must extinguish. Decrease output to 28 Vdc and lamp must again glow at half
brilliance.
OVERVOLTAGE TEST
1. Increase voltage input from 28 to 33 Vdc KFR; relay must trip (indicated by extinguished line lamp).
2. Connect a 50-volt, 1.5 amp variable dc power supply to J-1 connector applying positive to pins A, B, C, and
J, and negative to pins D, L, and G. Install 28 Vdc, type 3131amp between pins M and G.
3. Tum on power supply and adjust input to 28 Vdc. Reduce to 4-5 Vdc; disconnect positive lead from pin C,
and connect to pin K.
4. Gradually increase input voltage until field lamp glows, indicating KFR and KFRA have reset. The KFR
relay must reset at approximately 6 Vdc. After reset, disconnect power supply lead from pin K.
OVEREXCITATION PROTECTION
1. Connect positive side of variable 0-50 Vdc power supply to pins A, B, C, and J, and negative side to pins D,
G, and L. Connect positive lead of low voltage supply to pin E and negative side to pins D, G, and L.
2. Adjust primary power supply input to 27.5 Vdc. Slowly adjust low voltage supply to 0.23 Vdc and hold for
approximately 10 seconds. KFR relay must not trip.
3. Slowly increase primary input voltage from 27.5 to 29 Vdc KFR; relay must now trip within approximately
10 seconds.
4. Disconnect low voltage supply and reset KFR by reducing input to 4-5 Vdc. Disconnect positive lead from
pin C and connect it to pin K. Again increase input voltage gradually until field lamp glows and KFR relay
resets. After reset, disconnect pin K.
AUTOMATIC LINE CONTACTOR TEST
1. Connect positive side of variable 0-5 Vdc, low voltage power supply to pins A, B, C, and J, and negative
side to pins L and G. Connect low voltage power supply to pin D, so 0.19 to 0.03 Vdc is applied to pin D
with respect to pins Land G. Connect a 28 Vdc, type 313 lamp from pin H to pin G.
2. Adjust primary to 28 Vdc, set low voltage supply at 0 Vdc. Lamp must light.
3. Adjust low voltage supply to 0.15 Vdc; lamp must remain lit. After ten seconds, adjust low voltage slowly
to a maximum of 0.22 Vdc; lamp must extinguish.
4. Adjust low voltage supply back to 0 Vdc; lamp must glow.
5. Adjust primary high voltage supply to 10.5 0.5 Vdc with low voltage supply at 0 Vdc; lamp must continue
to glow dimly. Increase low voltage supply to 0.12 Vdc maximum; lamp must extinguish.
6. Shut down and disconnect power supplies and panel.
2017
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Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CLOSED LOOP TESTS
-CAUTION-
DO NOT MAKE OR BREAK ANY CONNECTIONS TO
REGULATOR PANEL DURING TESTS WITHOUT OPENING
CIRCUIT BREAKER.
1. Connect panel (shown in figure 24-11). Stabilize generator frame temperature before each test is run.
Stabilization is reached when generator frame temperature changes 2P or less during a five minute period.
-CAUTION-
DO NOT CONNECT J-l CONNECTOR PIN E TO ANY TEST
EQUIPMENT OR INSTRUMENTS DURING REGULATOR
TEST.
2. Regulator Test-Operate generator at minimum plate rated speed. Set voltage adjustment to bring system
voltage at point-of-regulator (por) to 28 Vdc.
3. With generator operating at minimum speed for regulation, apply one-half the rated generated load. POR
voltage must be stable at 0.75 Vdc.
4. Apply and remove load several times. Voltage must recover and return to a stable 28 0.75 Vdc.
5. With generator operating at minimum rated speed for regulation, apply full rated generator load. Voltage at
por must be a stable 28 0.75 Vdc.
6. Increase generator speed to 150% of minimum rated speed for regulation. Apply one-half generator rated
load suddenly (shock load). POR voltage must recover and return to a stable 28 0.75 Vdc.
7. Repeat step 6 applying full plate rated generator load. POR voltage must recover and return to a stable 28
0.75 Vdc.
8. With generator operating at full rated generator speed for regulation, apply one-half rated load suddenly
(shock load). POR voltage must recover and return to a stable 28 0.75 Vdc.
9. Repeat step 8 applying full rated load. POR voltage must recover to a stable 28 0.75 Vdc.
-NOTE-
POR cannot drift or show instability during regulator testing.
PARALLELING TEST
1. Trip off generator by actuating trip switch. Disconnect J -1 connector and pin D; connect pin D to ground.
2. Connect variable 0-2 volt, low voltage power supply, positive side to pin E; connect negative side to ground.
3. Reset panel by placing generator control switch to ON position. With point-of-regulator (por) voltage set at
28 V dc and 0.25 V dc applied at pin E, por voltage must be reduced a minimum of 2.5 V dc.
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2D18
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
4. Reverse polarity of pin E by applying -0.25 V dc. POR voltage must increase a minimum of 2.5 V dc.
-NOTE-
At completing of paralleling effectiveness tests, adjust por voltage at
no-load to 28.8 Vdc.
5. Place test switch to ON position. Panel must trip approximately one second after switch is actuated. Place
generator control switch in RESET position to reset panel. When panel resets, place generator control
switch to ON position.
6. Hold generator control switch in reset position and simultaneously hold trip switch in trip position. Panel
must trip but not attempt to reset.
-CAUTION-
AT CONCLUSION OF TESTS, FIELD RELAY (KFR) MUST
BE AND REMAIN IN TRIPPED POSITION TO PREVENT
DAMAGE TO EQUIPMENT WHEN INSTALLED IN
AIRCRAFT.
EXTERNAL POWER
OPERATION OF EXTERNAL POWER RECEPTACLE
The external power receptacle is located on underside of nose section below forward side of baggage
compartment door. To avoid damaging electrical system, follow instructions on power receptacle access door.
-NOTE-
When using a ground power unit for external power starting, follow
instructions given below.
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PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
STARTING THROUGH EXTERNAL POWER RECEPTACLE
The external power receptacle is located on underside of nose section below forward baggage compartment
door.
1. Place battery master switch in OFF position.
2. Ensure all other electrical equipment in aircraft is turned off.
3. Insert plug from auxiliary power unit into external power receptacle located on underside of nose section
below forward baggage compartment door.
4. Monitor aircraft voltmeter, when voltage stabilizes between 28 and 30-volts, tum battery master switch on.
5. Start left engine only using normal starting procedure outlined in the Pilot's Operating Handbook.
6. With left engine operating at ground idle speed, start right engine using normal starting procedure outlined
in the Pilot's Operating Handbook.
-CAUTION-
APPROACH FROM NOSE OF AIRCRAFT AND REMAIN
CLEAR OF PROPS. REMOVE AUXILIARY POWER UNIT
PLUG.
7. With both engines running, disconnect and remove auxiliary power unit from aircraft.
-CAUTION-
244000
Page 2
IF IT BECOMES NECESSARY TO START ENGINES WITH
EXTERNAL POWER RECEPTACLE, DUE TO A LOW
BATTERY CONDITION, ENSURE AIRCRAFT BATTERY IS
ON CHARGING LINE BY MONITORING BATTERY
AMMETER (CHARGING CURRENT WILL BE HIGH). DO
NOT TAKE OFF UNTIL CHARGING CURRENT FALLS TO
20 AMPS OR LESS.
Reissued: December 31, 1989
2020
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ELECTRICAL LOAD DISTRIBUTION
DESCRIPTION OF OVERHEAD SWITCHES
These rocker type switches are located on electroluminescent panels in royalite trim panels. They are centrally
located above the windshield and on the cockpit ceiling.
REMOVAL OF OVERHEAD SWITCHES
1. Position two starter-generator switches and battery master switch in OFF position.
2. Remove screws securing electroluminescent panel containing switch.
3. With electroluminescent panel unfastened from royalite trim panel, gain access to switch mounting clip at
back of panel.
4. Working from rear of switch, insert a narrow, thin bladed screwdriver between top of switch. Mount clip
and disengage it from switch. Repeat procedure at bottom of switch and mount clip.
-CAUTION-
DO NOT DAMAGE OTHER PARTS OR WIRING WHEN
WORKING ON SWITCHES AND PANELS.
5. Remove various electrical leads from switch; remove switch.
-NOTE-
Note position of electrical leads to facilitate reinstallation.
INSTALLATION OF OVERHEAD SWITCHES
1. Install switch in back end of electroluminescent panel by inserting a narrow, thin bladed screwdriver
between top of switch and mounting clip, engaging prongs on switch body into clip. Attach bottom of
switch using same procedure.
-NOTE-
The mounting clip has two built-in positions for positioning the
switch. Be sure both upper and lower prongs in switch body are in
the same position on clip.
2. Connect various electrical leads to proper positions on switch.
3. Install switch panel into royalite trim panel; secure with appropriate screws.
4. Check operation of new switch to ensure correct installation.
2021
24-50-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2408. MAIN TIE BUS CIRCUIT BREAKER & CROSSFEED DIODE CHECK
LEFT DIODE/CIRCUIT BREAKER OPERATIONAL CHECK
R Gen Distribution Circuit Breaker Circuit Breaker Components
Circuit Breakers Pulled Activated Checked Remarks
Essential (lOOA) Yes Feeder diodes &
L Main (lOOA) Yes circuit breakers
R Main (lOOA) Yes attached to Left Observe that equip-
Gen Distribution ment operated by
bus. the appropriate bus
is still powered.
L Gen Distribution
Circuit Breakers
Essential (lOOA) Yes
L Main (lOOA) Yes
R Main (lOOA) Yes
RIGHT DIODE/CIRCUIT BREAKER OPERATIONAL CHECK
L Gen Distribution
Circuit Breakers
Essential (lOOA)
L Main (lOOA)
R Main (lOOA)
R Gen Distribution
Circuit Breakers
Essential (1 OOA)
L Main (lOOA)
R Main (lOOA)
24-50-00
Page 2
Circuit Breaker
Pulled
Yes
Yes
Yes
Reissued: December 31, 1989
Circuit Breaker Components
Activated Checked Remarks
Feeder diodes &
circuit breakers
attached to Right Observe that equip-
Gen Distribution ment operated by
bus. the appropriate bus
is still powered.
Yes
Yes
Yes
2022
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2409. GENERATOR POWER DISTRIBUTION DIODE OPERATIONAL CHECK
L Gen Distribution Circuit Breaker Circuit Breaker
Circuit Breakers Pulled Activated
Essential (tOOA) Yes
L Main (tooA) Yes
R Main (tOGA) Yes
R Gen Tie Bus (200A) Yes
Essential (lOOA) Yes
L Main (tOOA) Yes
R Main (lOOA) Yes
R Gen Tie Bus (200A) Yes
Essential (tOOA) Yes
L Main (lOOA) Yes
R Main (lOOA) Yes
R Gen Tie Bus (200A) Yes
R Gen Distribution Circuit Breaker Circuit Breaker
Circuit Breakers Pulled Activated
Essential (tOOA) Yes
L Main (lOOA) Yes
R Main (lOOA) Yes
L Gen Tie Bus (200A) Yes
Essential (lOOA) Yes
L Main (lOOA) Yes
R Main (tOOA) Yes
L Gen Tie Bus (200A) Yes
Essential (tOOA) Yes
L Main (lOOA) Yes
R Main (lOOA) Yes
L Gen Tie Bus (200A) Yes
2023
Components
Malfunction Remarks
Shorted diode on No power should be
Essential bus from observed on L & R
Right Dist. bus. Main bus.
Shorted diode on No power should be
L Main bus from observed on Essential
Right Dist. bus. and R Main bus.
Shorted diode on No power should be
R Main bus from observed on Essential
Right Dist. bus. and L Main bus.
Components
Malfunction Remarks
Shorted diode on No power should be
Essential bus from observed on L & R
Left Dist. bus.
Shorted diode on
L Main bus from
Left Dist. bus.
Shorted diode on
R Main bus from
Left Dist. bus.
Main bus.
No power should be
observed on Essential
and R Main bus.
No power should be
observed on Essential
and L Main bus.
24-50-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
PURPOSE OF THE MAIN BUS TIE CIRCUIT BREAKER AND CROSSFEED DIODE CHECK
To detennine if left and right distribution buses are crossfeeding power to right main, left main, and essential
buses, use Chart 2407 for an operational check. System isolation will aid in troubleshooting location of circuit
breakers on center main circuit breaker panel.
DESCRIPTION OF CIRCUIT BREAKER AND SWITCH PANEL
Two circuit breaker and switch panels are installed in PA-42 airplanes. The left circuit breaker and switch
panel contains circuit breakers for the left engine and electrical system. The right circuit breaker and switch
panel contain circuit breakers for the right engines, radio equipment, and various electrical systems for the right
side. The circuit breakers are manual reset type and must be pushed to reset after being tripped. The switches are
toggle type and are used for disconnecting various buses from system.
REMOVAL OF CIRCUIT BREAKERS AND TOGGLE SWITCHES
1. Ensure two starter-generator switches and battery master switch are in OFF position.
2. Remove mounting screws on face of circuit breaker panel and pull panel out slightly to gain access to screw
and nut connecting wire to electroluminescent panel in middle of mounting bracket.
-CAUTION-
ALWAYS DISCONNECT THE BATTERY WHEN WORKING
ON CIRCUIT BREAKERS AND ENSURE OTHER PARTS
AND WIRING ARE NOT DAMAGED.
3. Remove knurl nut from face plate of circuit breaker panel.
4. Disconnect electrical lead secured with a screw from circuit breaker.
-NOTE-
Note position of electrical leads to facilitate reinstallation.
5. Remove screw securing circuit breaker to bus bar and remove circuit breaker from rear of panel.
24-50-00
Page 4
Reissued: December 31, 1989
2024
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF CIRCUIT BREAKERS AND TOGGLE SWITCHES
1. Position circuit breaker in place and secure to bus bar with appropriate screw.
2. Connect electrical lead and secure with screw.
3. Insert circuit breaker into proper hole and secure breaker with knurl nut to face plate.
4. Connect wire from electroluminescent panel at middle of mounting bracket with appropriate screw. Push
panel back into place and secure with appropriate mounting screws on face of panel.
5. Check operation of new circuit breaker to ensure correct physical installation.
CROSS START RELAYS
REMOVAL OF CROSS START RELAYS
The cross start relays are located in engine nacelle, aft of engine station 108.5.
1. Ensure electrical power is disconnected (battery and exterial power).
2. Remove aft engine upper nacelle panel to gain access to relay.
3. Disconnect electrical leads at cross start relay terminals and mark terminals to facilitate reinstallation.
4. Remove electrical lead on starter relay terminal A-I and shorting bar from A-I (starter relay) to cross start
relay A-2. (Mark starter relay electrical lead to facilitate reinstallation.)
5. Remove screws of cross start relay; remove unit.
INSTALLATION OF CROSS START RELAYS
1. Position cross start relay on mounting plate; secure with appropriate screws.
2. Reconnect shorting bar and all marked electrical lead to their appropriate terminals; secure with lock
washers and nuts.
3. Reconnect battery or external power; perform operational check.
2E1
24-50-00
Page 5
Reissued: December 31, 1989
24-50-00
Page 6
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GRIDS 2E2THRU 2E4
INTENTIONALLY LEFT BLANK
2E2
CHAPTER
EQUIPMENT/FURNISHINGS
2E5
SYSTEM
SUB-SYSTEM
25-00-00
25-20-00
25-20-00
25-20-00
25-20-00
25-20-00
SUBJECT
GENERAL
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENTIFURNISHINGS
TABLE OF CONTENTS/EFFECTIVITY
FLIGHT AND PASSENGER COMPARTMENTS (SEATS)
Removal and Installation of Seats
Removal and Installation of Forward Curtain and
Sliding Door
Removal and Installation of Folding Table
Removal and Installation of Cabinetry and Divider
2E6
GRID
NO EFFECTIVITY
2E7
2E7
2E7
2E7
2E7
2E13
25 - ContJEffec.
Page -1
Reissued: December 31, 1989
GENERAL
PIPER AIRCRAFT
PA42/ 42 720
AIRPLANE MAINTENANCE MANUAL
The flight and passenger compartments are equipped with the following standard and optional equipment and
furnishings. The flight compartment contains two crew seats and a divider between the crew and passenger
compartments consisting of divider panels, curtain, sliding doors, refreshment cabinet, storage cabinet, and jepp
case cabinet. The passenger compartment can be equipped with eight seats, two folding tables, refreshment and
storage cabinet and with bi-fold door, refreshment and vanity with bi-fold door, toilet seat, oven cabinet, aft
refreshment cabinet, and cabin divider. (Refer to parts catalog for part numbers.) This chapter provides
instructions for removal and installation of equipment listed above.
FLIGHT AND PASSENGER COMPARTMENTS (seats)
REMOVAL AND INSTALLATION OF SEATS (figures 25-1, 25-2, 25-3, and 25-4)
1. To remove the crew and passenger seats, proceed as follows:
a. Remove seat track end covers and seat stops.
b. Move seat forward or aft to slots in seat tracks and lift seat off tracks.
c. To remove toilet seat, disconnect relief tube from hom and valve assembly and remove attaching
hardware and seat.
2. To install crew and passenger seats, proceed as follows:
a. Place seats into slots in seat tracks and move seats to their proper positions.
b. Replace seat track end covers and seat stops.
c. To install toilet seat, connect relief tube to hom and valve assembly and mount seat with attaching
hardware.
REMOVAL AND INSTALLATION OF FORWARD CURTAIN AND SLIDING DOOR (figure 25-5)
1. Remove curtain from curtain track by removing curtain stops.
2. Install curtain by positioning curtain on tracks and installing curtain stops.
3. Remove sliding door by pulling door open and lifting it out of tracks.
4. Install sliding door by positioning door in tracks. Ensure door opens and closes properly.
REMOVAL AND INSTALLATION OF FOLDING TABLE (figure 25-6)
1. To remove folding table, proceed as follows:
a. Disconnect cigar lighter wires.
b. Remove attaching screws and table assembly.
2. To install folding table, proceed as follows:
a. Connect cigar lighter wires.
b. Place table assembly in proper position. Insert attaching screws.
c. To install cigar lighter, place lighter into panel top. Insert and tighten attaching nut.
2E7
25-20-00
Page 1
Reissued: December 31, 1989
25-20-00
Page 2
Reissued: December 31,1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Figure 25-1. Crew Seat Installation
2E8
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
1. SEAT, FORWARD FACING (SPAR)
2. SEAT, THIRD AND FOURTH, AFT FACING
3. SEAT, FORWARD FACING
4. HANDLE, SEAT TRACK LATCH RELEASE
5. HANDLE, SEAT RECLINER RELEASE
EXECUTIVE VERSON
3
5
COMMUTER VERSION
Figure 25-2. Passenger Seats Installation
2E9
25-20-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
5
4
1. TOILET, SIDE FACING
2. TOILET, FORWARD FACING
3. TOILET, FORWARD FACING
4. PLATE, SEAT FORWARD ATIACHMENT 6
5. WEDJIT ASSEMBLY
6. PLATE, SEAT MOUNTING FORWARD
7. PLATE, SEAT MOUNTING, REAR
Figure 25-3. Optional Seat Installations
252000
Page 4
Reissued: December 31, 1989
2E10
2
3
=8:1
=8l
=8l
=8l1
=8:1 c:::::::8:J1
=:8J
c:::::::8:J
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
STANDARD SEATING ARRANGMENT

0
HIGH DENSITY SEATING ARRANGMENT
Figure 25-4. Seat Stops
2E11
25-20-00
PageS
Reissued: December 31, 1989
8 ------,..
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
8
8
Figure 25-5. Forward Curtain and Sliding Door Installation
25-20-00
Page 6
Reissued: December 31, 1989
2E12
8
2
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Figure 25-6. Folding Table
REMOVAL AND INSTALLATION OF CABINETRY AND DIVIDER (figures 25-7 and 25-8)
1. To remove cabinetry and divider, proceed as follows:
a. Tum off electrical power.
b. Slide crew seat full forward and slide passenger seat full aft to remove forward dividers or cabinetry.
c. Tag and disconnect electrical wiring.
d. Remove attaching hardware securing divider panels and cabinetry. Remove divider panels and
cabinetry.
e. Remove heating elements by disconnecting wires and screwing them out of unit.
f. Remove razor invertor, razor outlet, and razor or heating unit switches by disconnecting electrical wires
and removing attaching hardware.
g. Remove armrest by removing two nuts securing it to oven cabinet.
2. To install cabinetry and divider, proceed as follows:
a. Mount armrest to oven cabinet with two nuts.
b. Mount razor invertor, razor outlet, and razor or heating unit switches with attaching hardware, and
connect electrical wires.
c. Mount heating elements into unit with screws and connect appropriate wires.
d. Secure divider panels and cabinetry with attaching hardware.
e. Connect all electrical wiring.
f. Install forward dividers and cabinetry.
g. Tum on electrical power.
2E13
25-20-00
Page 7
Reissued: December 31, 1989
25-20-00
Page 8
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
5
1. DIVIDER
2. RIGHT JEPP CABINET
3. LEFT REFRESHMENT CABINET
4. LEFT STORAGE CABINET
5. ATTACHMENTS
6. HEATING ELEMENT - LIQUID
7. ELEMENT SWITCH - LIQUID
Figure 25-7. Forward Cabinetry and Divider Panel
Reissued: December 31, 1989
2E14
5
4
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
6
PA42-720 ONLY
16
18
PA42-720 ONLY
2
3
1. VANITY AND REFRESHMENT CABINET
2. RAZOR OUTLET SWITCH
3. FOLDING DOOR
4. THERMOS STORAGE CABINET
5. REFRESHMENT CABINET WITH DIVIDER
6. HEATING UNIT AND ELEMENT
7. HEATING UNIT SWITCH
8. REFRESHMENT CABINET
9. INVERTER - RAZOR OUTLET
15. LIGHT
10. OVEN CABINET
16. ATTACHMENTS
16
4
6
16
3 15
16
16
11. ARMREST 17. REFRESHMENT CABINET WITH POP UP DIVIDER
12. CUP HOLDER
18. DOOR CABINET
13. ASH HOLDER
14. PANEL DIVIDER
Figure 25-8. Aft Refreshment Cabinet, Vanity Cabinet with Folding Door and Divider Panels
2E15
25-20-00
Page 9
Reissued: December 31, 1989
25-20-00
Page 10
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GRIDS 2Et6 THRU 2EtS
INTENTIONALLY LEFT BLANK
2E16
CHAPTER
FIRE PROTECTION
2E19
SYSTEM
SUB-SYSTEM
26-00-00
26-10-00
26-20-00
26-20-00
26-20-00
26-20-00
26-20-00
26-20-00
26-20-00
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER CHAPTER 26 - FIRE PROTECTION
TABLE OF CONTENTSIEFFECTIVITY
SUBJECT
GENERAL
DETECTION DESCRIPfION AND OPERATION
EXTINGUISHING DESCRIPfION AND OPERATION
Testing Extinguishing System
Removal of Fire Extinguisher Bottle
Servicing Fire Extinguisher Bottle
Replacing Fire Extinguisher Squib Assembly
Installation of Fire Extinguisher
PORTABLE FIRE EXTINGUISHER
2E20
GRID
NO. EFFECTIVITY
2E2l
2E2l
2E2l
2E23
2Fl
2F2
2F2
2F2
2F3
26 - ContJEffec.
Page -1
Reissued December 31, 1989
GENERAL
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
A fire detection and extinguishing system is provided for each engine; both completely independent from the
other. During an engine compartment fire, thermal detectors installed in the engine compartment actuate and
complete an electrical circuit that illuminates the master caution warning light, sounds a warning hom, and
illuminates the appropriate engine fire warning light on the annunciator display. Each system has a switch
located on the lower left side of the instrument panel which electrically discharges the fire extinguishing agent
through tubes into appropriate engine compartment areas.
DETECTION DESCRIPTION AND OPERATION
Each engine fire detection system consists of three fire detecting thermal units and interconnecting harness.
Two of these units are located on each side of the front fire seal in the hot section. One is located at the bottom of
the rear fire seal in the accessory section. The thermal units actuate at a temperature of 450F. Whenever
contacts in one of the thermal units is actuated (due to a fire condition), the circuit is completed and causes a
master caution light to blink, a hom to blow, and the engine fire warning light to illuminate on the annunciator
display. The hom and flashing light can be deactivated by pressing the master caution light.
When test switch is pressed, it connects interconnecting harnesses of each engine system in series, and it
completes a circuit from annunciator display to ground which checks continuity of system and operation of left
and right engine fire warning lights on annunciator.
EXTINGUISIDNG DESCRIPTION AND OPERATION
Each engine fire extinguishing system consists of a spherical container (bottle) storing a fire extinguishing
agent (Halon 1301) charged to 360 +25 -0 psig at 70
0
P with dry nitrogen. A pressure gauge mounted on the side
of the bottle indicates the internal (charged) pressure. Each bottle is mounted on the right side of each rear fire
seal in the accessory section of the engine nacelles. A main discharge pipe extends from a valve on the bottom of
the bottle forward through rear and front fire seals to the hot section of the engine. An additional tube extends
from the main discharge pipe, passes aft through the rear fire seal, and terminates at the top of the engine
accessory section.
An electrically operated cartridge (firing squib), screwed into the discharge valve at the base of the bottle,
provides a release for the extinguishing agent. When the switch in the cockpit is actuated, the firing squib in the
discharge valve is detonated and punctures the seal in the discharge valve that allows the release of extinguishing
agent through pipes. The container (bottle) also has a combination fill fitting and safety relief valve assembly. If
ambient temperature rises abnormally (215P to 226P), a fusible check valve within the fill fitting melts,
relieving contents of container (bottle) and avoiding possible bursting of container.
2E21
26-20-00
Page 1
Reissued December 31, 1989
1. SENSOR
2. FIRESEAL
1. SWITCH PANEL
2. LEFT FIRE EXTINGUISHER
3. RIGHT FIRE EXTINGUISHER
4. ANNUNCIATOR DISPLAY
26-20-00
Page 2
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Figure 26-1. Engine Fire Detectors
Figure 26-2. Engine Fire Control System
2E22
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
TESTING EXTINGUISIDNG SYSTEM
1. A quick check of the system electrical circuit is accomplished by turning aircraft master switch on, pressing
annunciator display test switch, and verifying that left and right engine fire extinguisher inoperative
indicator lights are operating. A more thorough check is as follows:
a. Assure all aircraft electrical power is off and all circuit breakers are disengaged.
b. Disconnect electrical wiring harness from fire extinguisher squib in one engine compartment and
connect a test lamp across disconnected wires of harness.
c. eset circuit breakers and tum master switch on.
d. Engage appropriate engine fire extinguisher switch in cockpit and verify that test lamp illuminates.
e. Reset fire extinguisher switch, tum master switch off, disengage circuit breakers, and disconnect test
lamp.
-WARNING-
DO NOT USE A VOLT-OHMMETER, BATTERY POWERED
CONTINUITY LIGHT, OR SIMILAR DEVICE WHEN TESTING
SQUIB ASSEMBLY. USE OF TEST DEVICES WHICH PASS
MORE THAN 30 MA CAN DETONATE SQUIB.
f. Connect squib tester (Model 115 squib test, American Standard, Monrovia, California) to squib
tenninals and check for nominal resistance of 1.15 0.25 ohms. Disconnect squib tester.
g. Ensure aircraft electrical system is deactivated; reconnect system wiring to squib assembly tenninals,
assuring ground wire is connected to ground tenninal.
h. Repeat steps a through g for opposite engine.
i. Pressure check fire extinguisher containers periodically to ensure pressure is between minimum and
maximum limits prescribed by manufacturer. (Refer to pressure temperature correction table on
container (bottle) or refer to chart 2601.)
Temperature
Farenheit
Ind. Pressure
-NOTE-
Pressure changes with ambient pressure must fall within prescribed
limits. If pressures do not fall within prescribed limits, replace
extinguisher container.
CHART 2601. PRESSURE-TEMPERATURE CORRECTION
-60
110
134
-40
127
155
-20 0
148 174
180 212
+20 +40
207 249
251 299
2E23
+60 +80 + 100 + 120
304 367 442 532
354 417 492 582
26-20-00
Page 3
Reissued December 31, 1989
26-20-00
Page 4
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
Figure 26-3. Battery Bus
2E24
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF FIRE EXTINGUISHER BOTTLE
1. Ensure aircraft master switch is off and fire extinguisher circuit breaker is disengaged.
2. Remove upper and lower engine cowling.
-WARNING-
FROSTBITE OR LOW TEMPERATURE BURNS WILL
RESULT IF HAWN 1301 (BAROMOTRIFLUOROMETHANE
CBRF3) COMES IN CONTACT WITH SKIN.
3. Disconnect three wires connecting squib unit with aircraft harness.
-WARNING-
CHARGED BOTTLES MUST BE HANDLED WITH CARE TO
AVOID DAMAGING THE SEAL. DO NOT BRING
ELECTRICAL CURRENT IN CONTACT WITH TERMINALS
ON SQUIB ASSEMBLY OF A LOADED UNIT OR
ACCIDENTAL DETONATION COUW RESULT.
4. Disconnect discharge pipe at fire seal fitting and remove nut and washer from fitting on forward side of fire
seal.
5. Support bottle; loosen mounting clamp and remove bottle. Remove fitting from discharge port of squib
housing.
UPPER COWLING SKIN
3
4
Figure 26-4. Engine Fire Extinguisher
2F1
1. DISCHARGE TUBE
2. FIRE EXTINGUISHER
3. PRESSURE GAUGE
4. CLAMP
5. SQUIB ASSEMBLY
6. DISCHARGE TUBE
7. SENSOR
,I!! /
II"I
1
1
11)
I II \
II,J
'I
I 2.50
26-20-00
PageS
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
SERVICING FIRE EXTINGUISHER BOTTLE
1. Check for leakage or damage to container.
2. If bottle is not being replaced, weigh it to be sure it is within 0.25 pounds of total weight stamped on data
plate.
3. If bottle is underweight or damaged, replace with serviceable unit.
4. Ensure indicated pressure reading on fire extinguisher bottle is within specification given in chart 2601.
REPLACING FIRE EXTINGUISHER SQUIB ASSEMBLY
The squib assembly has a total life of 10 years (Five years shelf life and five years time - in - service). The
squib assembly must be replaced after five years time - in - service. To determine service life, check the date the
squib assembly was installed in the aircraft, not the date which the squib assembly began its shelf life. Do not
install any squib assembly that has exceeded its five year life onto any aircraft.
-WARNING-
DISPOSE OF REMOVED SQUIB ASSEMBLY IN A SAFE
MANNER AS WITH ANY OTHER EXPLOSIVE DEVISE.
INSTALLATION OF FIRE EXTINGUISHER
1. Install connector fitting into squib housing and tighten.
2. Position bottle into proper position with discharge tube connector fitting protruding through hole in fire seal.
3. Secure bottle by tightening clamp and installing nut and washer on fitting protruding through fire seal.
4. Connect and secure discharge pipe to fire seal fitting.
5. Check placement of discharge nozzles (shown in figure 26-3). Nozzles must be positioned as shown to
obtain proper dispersal of extinguishing agent.
6. Ensure all aircraft electrical power is off; connect wires to proper terminals on squib assembly.
7. Install engine cowling.
8. Tum aircraft electrical system on, press annunciator test switch, and verify left and right engine fire
extinguisher inoperative indicator lights are operating.
26-2000
Page 6
Reissued December 31, 1989
2F2
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
PORTABLE FIRE EXTINGUISHER
The portable fire extinguisher unit General Fire Extinguisher COlporation (Model No. GH - 2 - 1/2), contains 2
1/2 pounds of Halon 1211. It has a discharge rate of no less than 9.5 seconds. The original weight of the
extinguisher is 4 pounds 12 ounces
-NOTE-
There are no field recharge facilities. The manufacturer will recharge
and return for a service charge. (See list of vendors)
To operate the extinguisher, remove it from the quick - release bracket, hold it upright in either hand by the
handgrip, with the spray nozzle pointing forward. Remove the safety pin, direct the nozzle towards the base of
the fire source, squeeze the lever with the palm of the hand. Maximum extinguishing effect is obtained if the fire
- fighter uses side to side motion and keeps moving in towards the base of the fire source as it is extinguished.
Releasing the lever closes a secondary seal inside the operating head. This interrupts the flow of extinguishant,
thus retaining part of the charge, for dealing with a flash back or re-ignition should they occur, without waste or
leakage. Ejection of the indicator disc provides a visual indication of partial or total discharge. A partly or totally
discharged extinguisher assembly should be replaced immediately after use.
The extinguisher shall be inspected monthly or unless otherwise specified. The nozzle shall be examined to
ascertain that they are unobstructed. The tamper tag or tamper indicator shall be intact. The extinguisher shall be
pressurized as indicated and the weight shall be within the tolerance on the label
-WARNING-
AFTER DISCHARGE OF EXTINGUISHER AVOID EXPOSURE
TO SMOKE, VAPORS AND OTHER BY - PRODUCTS OF FIRE.
DO NOT INCINERATE EXTINGUISHER.
-CAUTION-
EXTINGUISHER IS A PRESSURE VESSEL. PROTECT
FROM CORROSIVE CONDITIONS. IF THERE IS ANY
CORROSION OR DAMAGE, EXTINGUISHER SHOULD BE
CAREFULLY EMPTIED AND DISCARDED. USE ONLY AS
DIRECTED.
The required service checks are as follows:
1. 12 year hydro - static test.
2F3
26-20-00
Page 7
Reissued December 31, 1989
26-20-00
PageS
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GRIDS 2F4 THRU 2F6
INTENTIONALLY LEFT BLANK
2F4
CHAPTER
FLIGHT CONTROLS
2F7
SYSTEM
SUB-SYSTEM
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 27 - FLIGHT CONTROLS
TABLE OF CONTENTS/EFFECTIVITY
SUBJECT
27-00-00 OENERAL
27-00-00 Description and Operation
27 -00-00 Troubleshooting
27-00-00 Standard Procedures
27-00-00 Wrapping of Trim Drums
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
27-10-00
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27-10-00
27-10-00
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27-20-00
27-20-00
27-20-00
27-20-00
27-20-00
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27-20-00
27-20-00
27-20-00
27-20-00
27-20-00
27-20-00
27-20-00
27-20-00
27-20-00
AILERON AND TAB
Removal of Aileron Control Cables
Installation of Aileron Control Cables
Removal of Control Column Sprockets
Installation of Control Column Sprockets
Removal of Aileron Control Sector
Installation of Aileron Control Sector
Rigging of Aileron Controls
Removal of Aileron Bellcrank
Installation of Aileron Bellcrank
Removal of Aileron Trim (Fuselage)
Installation of Aileron Trim (Fuselage)
Removal of Aileron Trim (Wing)
Installation of Aileron Trim (Wing)
Rigging of Aileron Trim
Aileron Control System Friction Check
Aileron Trim Tab Free Play
Aileron Balancing Procedure
RUDDER AND TAB CONTROLS
Removal of Forward Rudder Cables
Removal and Installation of Forward Rudder
Control Sector
Installation of Forward Rudder Cables
Removal of Aft Rudder Cables
Removal and Installation of Aft Rudder Control Sector
Installation of Aft Rudder Cables
Rigging of the Rudder and Its Controls
Rudder Control System Friction Check
Removal of Forward Rudder Trim System
Installation of Forward Rudder Trim System
Removal of Aft Rudder Trim System
Installation of Aft Rudder Trim System
Removal and Installation of Trim Tab
Rigging of Rudder Trim
2F8
GRID
NO.
2F11
2F11
2F11
202
204
206
206
207
207
2011
2013
2013
2013
2014
2017
2017
2018
2019
2019
2020
2020
2020
2020
2021
2021
2021
2024
2024
2024
2H1
2H1
2H3
2H3
2H4
2H5
2H5
2H5
2H6
EFFECTIVITY
27 - Cont.lEffec.
Page -1
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 27 - FLIGHT CONTROLS (continued)
TABLE OF CONTENTS/EFFECTIVITY
SYSTEM GRID
SUB-SYSTEM SUBJECT NO.
27-20-00 RUDDER AND TAB CONTROLS (cont)
27-20-00 Removal of Rudder Pedal Assembly 2H6
27-20-00 Installation of Rudder Pedal Assemblies 2H9
27-30-00 ELEVATOR AND TAB 2HlO
27-30-00 Removal of Forward Elevator Control Sector 2HlO
27-30-00 Installation of Forward Elevator Control Sector 2HlO
27-30-00 Removal of Aft Elevator Control Sector 2Hll
27-30-00 Installation of Aft Elevator Control Sector 2Hll
27-30-00 Removal of Elevator Control Cables 2H14
27-30-00 Installation of Elevator Control Cables 2H15
27-30-00 Removal and Installation of Elevator Push Tube 2H15
27-30-00 Rigging the Elevator Control System 2H17
27-30-00 Elevator Control System Friction Check 2H19
27-30-00 ELEVATOR TRIM SYSTEM 2H20
27-30-00 Removal of Forward Elevator Trim System 2H20
27-30-00 Installation of Forward Elevator Trim 2H20
27-30-00 Removal of Aft Elevator Trim Actuator 2H21
27-30-00 Inspection of Aft Elevator Trim Actuator 2H21
27-30-00 Installation of Aft Elevator Trim Actuator 2H21
27-30-00 Rigging of Elevator Trim 2H22
27-30-00 Elevator Trim System Friction Check 2H22
27-30-00 Free Play Check of Elevator Tabs 2H23
27-30-00 TRIM SYSTEMS' CONTROLS AND INDICATORS 2H23
27-30-00 Removal and Installation of Trim Controls 2H23
27-30-00 Adjustment of Trim Indicators 2H23
27-50-00 FLAPS 211
27-50-00 Description and Operation 211
27-50-00 Removal of Flap Actuator Motor 211
27-50-00 Installation of Flap Actuator Motor 211
27-50-00 Removal of Flexible Actuator Motor 212
27-50-00 Installation of Flexible Actuator Shaft 214
27-50-00 Inspection of Outboard Wing Flap Transmission 214
27-50-00 Inspection of Inboard Wing Flap Transmission 214
27-50-00 Removal of Flap Transmission 215
27-50-00 Disassembly of Flap Transmission 216
27-50-00 Service and Inspection of Flap Transmission
Internal components (CAL eO) 218
27-50-00 Assembly of Flap Transmission (CALCO) 219
27 - ContJEffec.
Page - 2
Reissued December 31, 1989
2F9
EFFECTIVITY
SYSTEM
SUB-SYSTEM
27-50-00
27-50-00
27-50-00
27-50-00
27-50-00
27-50-00
27-50-00
27-50-00
27-50-00
27-50-00
27-50-00
27-90-00
27-90-00
27-90-00
27-90-00
27-90-00
27-90-00
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 27 - FLIGHT CONTROLS (continued)
TABLE OF CONTENTS/EFFECTIVITY
SUBJECT
FLAPS (cont)
Installation of Flap Transmission
Removal of Flap Control Box (Selector)
Installation of Flap Control Box
Removal of Flap Control Amplifier
Installation of Flap Control Amplifier
Rigging and Adjustment of Flaps
Preparation for Rigging
Mechanical Rigging Procedure
Electrical Rigging Procedure
Electrical System Functional Test Procedure
STALL WARNING
Stall Warning/Recognition System
FUNCTIONAL TESTS OF SYSTEM
Stall Warning Functional Test
Stall Warning System Self Test
Force Applicator Kit Test
2F10
GRID
NO.
2112
2113
2113
2113
2113
2113
2114
2116
2116
2120
2124
2124
2124
2124
2124
2J1
EFFECTIVITY
27 - Cont.lEffec.
Page - 3
Reissued December 31,1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GENERAL
DESCRIPTION AND OPERATION
The primary flight controls are conventional type operated by dual control columns and rudder pedals.
The control columns in the PA-42 function on a lever arm principle attached to a crossover shaft (torque tube)
mounted under the cockpit floor. The crossover shaft acts as the axis of rotation for the two columns and houses
the roller chain that interconnects the two control wheels. The control columns contain hardware for adjustment
of control wheels and aileron primary drive mechanism. The linkages to the aileron and elevator control sectors
are contained under the left side of the floor.
The ailerons are actuated by the pilot and copilot control wheels through the roller chain which drives a lever
located in the pilot's control column. This lever transmits the control wheels travel to the aileron control sector
through the link, bell crank, and another link. Cables run from the sector to aileron bellcranks in the wings.
The elevators are controlled by control columns through the crossover shaft. An arm, extending from the pivot
fitting located on the left side of the crossover shaft, transmits control column travel through a link to the forward
elevator control sector. The control cables for the elevator control system run from the forward control sector at
Fuselage Station 93.30 to the aft control sector at Station 373.10. The aft control sector is connected to a long
push-pull tube which reaches up through to the top of the vertical stabilizer where it bolts to the elevator control
hom.
Attached to the left set of rudder pedal arms are tubes connected to a bellcrank which is attached to the
pressure bulkhead at Station 57.0. The rudder control sector at W.L. 18.00 is driven by a tube running from the
bellcrank. Control cables run from the control sector to the rudder sector, which is attached directly to the rudder.
The aileron, elevator, and rudder trim controls are mounted on the pedestal along with position indicators for
each system. As each control is moved, cable wrapped drums rotate, and in tum they actuate the particular trim
system being operated.
The Calco type flap mechanism used in the PA-42 is described in detail in the flaps section of this chapter.
TROUBLESHOOTING
Problems peculiar to this aircraft's control systems are listed in chart 2701 along with probable causes and
suggested remedies.
2F11
27-00-00
Page 1
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS)
Trouble
Lost motion between
control wheel and
aileron.
Resistance to control
wheel rotation.
27-00-00
Page 2
Reissued December 31, 1989
Cause
AILERON CONTROL SYSTEM
Cable tension too low.
Linkage loose or worn.
Broken pulley.
Cables not in place on
pulleys.
Improper rigging.
System not lubricated
properly.
Cable tension too high.
Control column chain
improperly adjusted.
Pulleys binding or
rubbing.
Cables not in place on
pulleys.
Bent aileron and/or
hinge.
Cables crossed or
routed incorrectly.
2F12
Remedy
Adjust cable tension.
Check linkage and tighten
or replace.
Replace pulley.
Install cables correctly.
Check cable guards.
Check rigging in the control
column and crossover (torque
tube) shaft, and at the bell-
cranks in the fuselage and the
wings.
Lubricate system.
Adjust cable tension.
Adjust chain tension.
Replace binding pulleys
and/or provide clearance
between pulleys and
brackets.
Install cables correctly.
Check cable guards.
Repair or replace aileron
and/or hinge.
Check routing of control
cables.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble
Resistance to control
wheel rotation. (cont)
Control wheels not
synchronized.
Control wheels not
horizontal when
ailerons are neutral.
Incorrect aileron traveL
Correct aileron travel
cannot be obtained by
adjusting bellcrank stops.
Control wheel stops
before control surfaces
reach full traveL
Lost motion between
trim control wheel
and trim tab.
Cause Remedy
AILERON CONTROL SYSTEM (continued)
Interference between
fittings.
Incorrect control
column rigging.
Incorrect rigging of
aileron system.
Aileron control rods not
adjusted properly.
Aileron bellcrank stops
not adjusted properly.
Incorrect rigging of
aileron cables, control
wheel and control rod.
Incorrect rigging between
control wheel and control
cables.
AILERON TRIM CONTROL SYSTEM
Cable tension too low.
Cables not in place on
pulleys.
Broken pulley.
Linkage loose or worn.
2F13
Check control column fittings
in pilot's control column.
Linkages to bellcrank from
control column.
Rig and check roller chain
firmness between the two
control wheels.
Rig.
Adjust.
Adjust and check all
bellcranks in the fuselage
and wings.
Rig.
Rig.
Adjust.
Install cables correctly.
Check cable guards.
Replace pulley.
Check linkage and
tighten or replace.
27-00-00
Page 3
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble
Trim control wheel moves
with excessive resistance.
Trim tab fails to reach
full travel.
Trim indicator fails to
indicate correct trim
position.
27-00-00
Page 4
Reissued December 31, 1989
Cause Remedy
AILERON CONTROL SYSTEM (continued)
System not lubricated Lubricate system.
properly.
Cable tension too high. Adjust.
Pulleys binding or Replace binding pulleys.
rubbing. Provide clearance between
pulleys and brackets.
Cables not in place on Install cables correctly.
pulleys. Check cable guards.
Trim tab hinge binding. Lubricate hinge. If
necessary, replace.
Cables crossed or Check routing of control
routed incorrectly. cables.
System incorrectly Check and/or adjust
rigged. rigging.
Either or both trim drums Check and/or adjust
incorrectly wrapped. rigging.
Trim indicator unit not Adjust.
adjusted properly.
2F14
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble Cause
ELEVATOR CONTROL SYSTEM
Lost motion between Cable tension too low.
control column and
elevator. Linkage loose or worn.
Broken pulley.
Cables not in place on
pulleys.
Improper rigging.
Resistance to elevator System not lubricated
control movement. properly.
Cable tension too high.
Binding control column.
Pulleys binding or
rubbing.
Cables not in place on
pulleys.
Bent elevator or hinge.
Cables crossed or
routed incorrectly.
Damaged bellcrank(s)
(bellcranks binding).
2F15
Remedy
Adjust cable tension.
Check linkage and tighten
or replace.
Replace pulley.
Install cables correctly.
Check rigging and
dimensions.
Lubricate system.
Adjust cable tension.
Adjust and lubricate.
Replace binding pulleys
and/or provide clearance
between pulleys and
brackets.
Install cables correctly.
Repair or replace elevator
or hinge.
Check routing of control
cables.
Check fuselage and wing
mounted bellcranks and
adjust.
27-00-00
Page 5
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble
Incorrect elevator
traveL
Correct elevator travel
cannot be obtained by
adjusting elevator stops.
Lost motion between
trim control wheel
and trim tab.
Trim control wheel
moves with excessive
resistance.
27-00-00
Page 6
Reissued December 31, 1989
Cause Remedy
ELEVATOR CONTROL SYSTEM (continued)
Elevator stops incorrectly
adjusted.
Elevator control rods
incorrectly adjusted.
Improper rigging at
fuselage bellcrank.
Elevator cables
incorrectly rigged.
ELEVATOR TRIM CONTROL SYSTEM
Cable tension too low.
Cables not in place on
pulleys.
Broken pulley.
Linkage loose or worn.
System not lubricated
properly.
Cable tension too high.
Pulleys binding or
rubbing.
Cables not in place on
pulleys.
Trim tab hinge binding.
2F16
Adjust stop screws.
Adjust control rod(s).
Check fuselage, control
bell crank rigging.
Rig cables and check elevator
control bellcrank in forward
part of fuselage.
Adjust.
Install cables correctly.
Check cable guards.
Replace pulley.
Check linkage and tighten
or replace.
Lubricate system.
Adjust.
Replace binding pulleys.
Provide clearance between
pulleys and brackets.
Install cables correctly.
Check cable guards.
Lubricate hinge. If
necessary, replace.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble
Trim control wheel
moves with excessive
resistance. (cont)
Trim tab fails to reach
full travel.
Trim indicator fails to
indicate correct trim
position.
Lost motion between
rudder pedals and
rudder.
Cause Remedy
ELEVATOR TRIM CONTROL SYSTEM (continued)
Cables crossed or routed
incorrectly.
Misadjustment of tab
actuator rods.
System incorrectly
rigged.
Either or both trim drums
incorrectly wrapped.
Trim indicator unit not
adjusted properly.
RUDDER CONTROL SYSTEM
Cable tension too low.
Linkage loose or worn.
Loose bellcrank on pressure
bulkhead station 57.0.
Broken pulley.
Bolts attaching rudder
to bellcrank are loose.
2F17
Check routing of control
cables.
Adjust.
Check and/or adjust
rigging.
Check and/or adjust
rigging.
Adjust.
Adjust cable tension.
Check linkage and tighten
or replace.
Repair belle rank.
Replace pulley.
Tighten bellcrank bolts.
27-00-00
Page 7
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble
Excessive resistance to
rudder pedal movement.
Rudder pedals not
neutral when rudder
is streamlined.
Incorrect rudder
travel.
Excessive right or left
rudder noticed in flight
WHEN PRESSURIZED.
27-00-00
Page 8
Reissued December 31, 1989
Cause Remedy
RUDDER CONTROL SYSTEM (continued)
System not lubricated Lubricate system.
properly.
Rudder pedal torque tube Lubricate torque tube
bearing(s) in need of bearings.
lubrication.
Cable tension too high. Adjust cable tension.
Pulleys binding or Replace binding pulleys
rubbing. and/or provide clearance
between pulleys and
brackets.
Cables not in place on Install cables correctly.
pulleys. Check cable guards.
Cables crossed or routed Check routing of control
incorrectly. cables.
Interference of torque Adjust tube(s) for proper
tubes. operation.
Rudder cables or torque Rig.
tubes incorrectly rigged.
Rudder bellcrank stop Rig.
incorrectly adjusted.
Nose wheel contacts Rig.
stops before rudder.
Tab actuator rod hitting Rerig tab.
stops.
Compensating bellows Replace the required
punctured or collapsed. bellows.
2F18
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) innued
Trouble Cause
RUDDER TRIM CONTROL SYSTEM
Lost motion between trim Cable tension too low.
control wheel and trim tab.
Cables not in place on
pulleys.
Broken pulley.
Linkage loose or worn.
Trim control wheel moves System not lubricated
with excessive resistance. properly.
Pulleys binding or
rubbing.
Cables not in place on
pulleys.
Trim tab hinge binding.
Cables crossed or routed
incorrectly.
Trim tab fails to reach System incorrectly
full travel. rigged.
Either or both trim drums
incorrectly wrapped.
Trim indicator fails to Trim indicator unit not
indicate correct trim adjusted properly.
position.
2F19
Remedy
Adjust.
Install cables correctly.
Check cable guards.
Replace pulley.
Check linkage and tighten
or replace.
Lubricate system.
Replace binding pulleys.
Provide clearance between
pulleys and brackets.
Install cables correctly.
Check cable guards.
Lubricate hinge. Replace
if necessary.
Check routing of control
cables.
Check and/or adjust
rigging.
Check and/or adjust
rigging.
Adjust.
27-00-00
Page 9
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
'frouble
Flaps fail to extend or
retract though flap
solenoid actuates.
(Motor circuit.)
Flaps fail to extend or
retract. Flap solenoid
does not actuate.
(Solenoid circuit.)
27-00-00
Page 10
Reissued December 31, 1989
Cause
FLAP CONTROL SYSTEM
Flap motor circuit breaker
open.
Defective flap selector
switch.
Defective flap motor
circuit relay.
Ground open from flap
motor circuit relay.
Ground open from flap
selector switch.
Defective flap motor.
Defective circuit wiring.
Battery switch off.
Flap solenoid circuit
breaker open.
Defective flap selector
switch.
Defective up or down
limit switch.
Defective flap solenoid.
Ground open from flap
solenoid.
Defective circuit wiring.
2F20
Remedy
Reset circuit breaker.
Replace flap control box.
Replace relay.
Check ground connection.
Check ground connection.
Replace motor.
Isolate cause and repair.
Tum switch on.
Reset circuit breaker.
Replace selector switch.
Replace defective switch.
Replace flap solenoid.
Check ground connection.
Isolate cause and repair.
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble Cause
FLAP CONTROL SYSTEM (continued)
Flaps fail to retract Up limit switch
completely. incorrectly adjusted.
Flaps do not extend Down limit switch
completely. incorrectly adjusted.
Flaps not synchronized Incorrect adjustment of
or fail to fit evenly the transmission tube.
when retracted.
Flaps have erratic Binding between flexible
operation during shaft and motor.
extension and
retraction. Binding between track
and rollers.
Slipping or stripped
transmission.
Loose electrical
connection.
Transmission needs
lubrication.
Flap on one side fails Broken flexible actuator
to operate. shaft.
Defective transmission.
Faulty time delay switch.
2F21
Remedy
Adjust flap.
Adjust.
Rig.
Isolate cause and lubricate
cable if required.
Refer to Rigging and
Adjustment.
Replace transmission.
Check and repair
electrical connections.
Lubricate transmission.
Replace flexible shaft.
Determine cause and
replace or repair.
Check operation.
27-00-00
Page 11
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble
System won't turn on.
Frozen flap lever.
No flap movement.
Slow system cycle.
Motor stall.
27-00-00
Page12
Reissued December 31, 1989
Cause
FLAP CONTROL SYSTEM (continued)
Bad flap control.
Malfunctioning amplifier.
Disconnect flap control
potentiometer in flap
control box.
Shaft failure.
Gearing failure.
Flap control box:
Lever shaft failure,
Locking pin failure,
Gearing failure.
Flexshaft or coupling
failure.
Open circuit.
Excessive motor brush
wear.
Motor open circuit.
Malfunctioning screwjack.
2F22
Remedy
Check flap control box
for proper operation and
continuity in flap control
box; repair or replace as
necessary.
Replace amplifier.
Locking pin failure -
service the control box.
Service the control box.
Service the control box.
Service the control box.
Replace worn part.
Check circuitry (refer to
schematic in this chapter).
Remove and service flap
motor.
Check circuit per rigging
and test procedures.
Check circuit continuity.
Inspect all screwjacks for
excessive wear and free
travel. If inspection does
not uncover problem,
disconnect screwjacks from
flaps and flex shaft and
check for free travel. Remove
and service damaged screwjack.
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble Cause
FLAP CONTROL SYSTEM (continued)
Motor stall. (cont) Excessive brush wear.
Motor open circuit.
Motor power circuit Outboard flex shaft or
breaker tripped. connection failure.
Screwjack actuator
failure.
Motor bearing failure.
Motor short circuit.
System shutdown. Improper system
hookup.
Malfunctioning amplifier.
Open ground to amplifier.
System stall in position. Power or ground circuit
open.
Bearing seize - motor stall,
circuit breaker tripped.
Synchronization
shutdown.
Excessive brush wear
in motor.
Motor open circuit
Malfunctioning flap
amplifier.
2F23
Remedy
Remove and selVice motor.
Check circuit for proper
installation.
Replace worn part.
Remove and selVice
actuator.
Repair motor.
Repair motor.
Perfonn rigging electrical
tests.
Replace amplifier.
Check electrical system and
repair.
Check circuit for open line
and repair.
Replace bearings affected.
Check inboard flexshafts
and coupling.
Replace brushes.
SelVice motor and check
circuit.
Replace amplifier.
27-00-00
Page 13
Reissued December 31,1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble
Synchronization shutdown.
Wracked flap.
Frozen screwjack
Heavy wear on worm
gear.
System will not hold in
preset position.
Fault lamp indicating a
failure during no demand
periods.
Flap position indicator
wrong.
27-00-00
Page 14
Reissued December 31, 1989
Cause Remedy
FLAP CONTROL SYSTEM (continued)
Flexshaft or coupling Replace worn part.
failure.
Failure of screwjack Remove and service
actuator. actuator.
Improper adjustment of Perform rigging test and
flap potentiometers. procedure.
Screwjack housing failure. Remove applicable screwjack
and repair.
Ball screw fracture. Remove applicable screwjack
and repair.
Flap connection failure. Replace shaft or connection.
Outboard flexshaft and/or Replace the required item.
coupling failure.
Worm bearing failure, Remove and service
compression bearing actuator.
failure on screw, tension
bearing failure on screw,
ball nut failure or seize.
Worm bearing failure. Remove and service
actuator.
Flap control box: Repair flap control.
Detent Failure
Drag Brake Failure
Malfunctioning amplifier. Replace amplifier.
Malfunctioning amplifier. Replace amplifier.
2F24
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2701. TROUBLESHOOTING (SURFACE CONTROLS) (continued)
Trouble Cause
FLAP CONTROL SYSTEM (continued)
Annunciator light on, but Malfunctioning amplifier.
flaps operate.
Annunciator light on Flap motor circuit breaker
with flaps inoperative. pulled or tripped.
Flaps asymmetric.
Potentiometer failure.
Motor and/or relay
failure.
Flaps inoperative Power loss to amplifier.
annunciator light
off and flap indicator
pointing off.
No indication of flap Battery switch off.
position on indicator.
Circuit breaker open.
Sender unit ground
open.
Defective indicator unit.
Defective sender unit.
Sender unit not adjusted
properly.
Defective wiring.
2G1
Remedy
Replace amplifier.
Reset circuit breaker.
Check and rerig flaps.
Replace potentiometer.
Replace component.
Probably flap amplifier
circuit breaker. Reset
breaker if applicable and/or
check system.
Tum switch on.
Reset circuit breaker.
Check ground connection.
Replace indicator unit.
Replace sender unit.
Adjust sender unit.
Check and repair wiring.
27-00-00
PagelS
Reissued December 31,1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
STANDARD PROCEDURES
-NOTE-
Refer to chapter 95 for description and information on special tools
used in this chapter.
The following tips are helpful when removing and installing various assemblies:
1. Level and place airplane on jacks during rigging and adjustment of controls.
2. Remove turnbuckle barrels from cable ends before withdrawing cables through structures.
3. Tie a cord to cable end before drawing cable through structures to facilitate reinstallation of cable.
4. Turnbuckle stations are given at neutral position.
5. Before disconnecting, use a felt marker to mark cable ends, etc.
6. Assemble and adjust turnbuckles to ensure each tenninal is screwed in approximately equal distance into
barrel. During adjustment, do not tum terminals so a pennanent twist is put in cables.
7. When turnbuckles are set to correct cable tension, no more than three threads must be exposed from either
end of turnbuckle barrel. Check locking clips for proper installation by removing clips using fingers only.
Both locking clips can be inserted in the same turnbuckle barrel hole or installed in opposite holes. Locking
clips installed and removed must be scrapped.
8. When push rods or rod ends are provided with an inspection hole, the screw must be screwed in enough to
pass the inspection hole. This is detennined visually or by inserting a piece of wire into the inspection hole.
Where no inspection hole is provided, a minimum 3/8 inch thread must be engaged.
9. Cable tension must be measured with appropriate surface control in neutral position.
-NOTE-
Perform a friction check of the system whenever elevator, rudder, or
aileron control system is serviced.
-NOTE-
Cable rigging tensions specified in the following paragraphs must be
corrected to ambient temperature in area where tension is being
checked (use chart 2702).
10. Ensure all cable guard pins are installed properly and are not interfering with control cable travel.
-CAUTION-
WITH RIGGING PINS INSTALLED, CLAMP THE
BELLCRANK, SECTOR, OR ASSEMBLY SO WHEN CABLES
ARE TIGHTENED THE LOAD IS NOT TAKEN UP BY THE
PIN. ENSURE PIN IS FREE AT ALL TIMES. IT IS
RECOMMENDED THAT CABLES ARE CLAMPED NEAR
SECTOR, INSTEAD OF CLAMPING THE SECTOR.
11. After adjusting trim tab travels, check cable wraps on trim drums at each end of travel. Minimum allowable
is 1 1/4 wraps. Install fairleads so they do not cause a change in direction of more than 3.
12. Install pulleys so they do not cause a change in cable direction of more than 1 laterally (primary controls)
or 2 laterally (trim system).
27-00-00
Page 16
Reissued December 31, 1989
2G2
I-
iIi
J:
Z
UJ
a:
J:

u.
C/)
UJ
UJ
a:
(!)
UJ
Cl
UJ
a:
::>
l-

UJ
a..
::E
UJ
I-
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2702. CABLE RIGGING TENSION VS. TEMPERATURE
200 ___ _
170
150
100
SO
0
-50 ttlttittttlllittttlllitttlttitjITtlli:tJtttijjj:t:l:tt:tt1:t:t:i
-20 -10 o 10
RIGGING LOAD CORRECTION, POUNDS
SUBTRACT
2G3
20
ADD
27-00-00
Page 17
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
WRAPPING OF TRIM DRUMS (figure 27-1)
-NOTE-
The following instructions provide generalized instructions. For
specific requirements as to number and position of cable wraps on
drum, refer to appropriate trim rigging procedure.
All trim drums, wrapped basically the same, must be removed from the airplane as follows:
1. For reference, mark end of drum toward base of housing bracket when later installing and wrapping cable
on drum.
2. With drum housing bracket held firmly, remove one of the cable guard bolts from housing bracket.
3. Remove drum screw or drum shaft from trim screw assembly. Remove screw by removing stop located on
end of screw opposite base of housing bracket. Tum screw from drum. Remove shaft by driving roll pin
from center of drum. Press shaft from drum.
4. Remove drum from housing.
5. Unwrap trim cable and remove cable and lockpin from drum. (If one end of cable is marked to facilitate
hookup of cable ends, note location in relation to drum when installing new cable on drum.)
6. Check condition of bushing in housing bracket for excess wear.
7. To install and wrap trim cable, locate center of cable, measuring from end to end.
8. Insert center of cable into cable slot in drum; installiockpin.
9. Hold drum with previously marked or base end of drum down.
10. Looking down on drum, wrap cable leading from base end up in a counterclockwise direction. Wrap cable
from upper end down in a clockwise direction.
11. Insert drum in housing bracket, position drum, and route cables from assembly (shown in figure 27-1).
12. Install screw and screw stop or drum shaft. Secure with roll pin.
13. Block trim cables in center position using method shown in figure 27-2.
14. Center drum between stops on screw by rotating screw.
27-00-00
Page 18
Reissued December 31, 1989
THIS SPACE INTENTIONALLY LEFT BLANK
2G4
10
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
_ ~ ~
It-9
7 11
==++--7
+t--
13
1. CABLE
2. DRUM
3. HOUSING BRACKET
4. DRUM SCREW
5. SCREW STOP
6. SCREW STOP
7. BUSHING
8. BOLT GUARD
9. DRUM SHAFT
6---+
10. ROLL PIN
11. HOUSING BRACKET BASE
12. ATTACHMENT NUTS
13. LOCK PIN
Figure 27-1. Trim Screw Assembly
Figure 27-2. Methods of Blocking Trim Cables
2G5
27-00-00
Page 19
Reissued December 31, 1989
AILERON AND TAB
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF AILERON CONTROL CABLES (figure 27-3)
1. Remove pilot and left passenger seats behind main spar carry through.
2. Remove left floor panels from behind control column back to Station 174.0 or approximately 34 inches
behind main spar carry through. If necessary, move the affected passenger seat so right floor panel and
center panels can be removed at same station.
3. Remove fairleads from wings at Station 121.5 and 58.5, and remove fairleads from where aileron cables go
through fuselage at fairlead pan, Station 173.0.
4. Remove access plates under wing along front of rear spar at Wing Stations 92.5, 121.0, and 183.0. Also
remove three plates at rear of wheel well and on underside of wing fillet.
5. To remove left balance cable, proceed as follows:
a. In left wing at bellcrank, remove safety wire or clip from aft turnbuckle; disconnect cable.
b. Remove fairleads at Wing Stations 58.5 and 121.5 and remove cable guard pins at Wing Stations 0.5,
30.9, and 147.5.
c. In fuselage, remove safety wire or clip from aft turnbuckle at Station 172.0; disconnect cables.
d. Mark cable end to facilitate installation.
e. Pull cable end to facilitate installation.
6. Remove the right balance cable as follows:
a. In right wing at bellcrank, remove safety wire from aft turnbuckle and disconnect cable.
b. Disconnect turnbuckle at Fuselage Station 172.0.
c. Remove fairleads and cable guard pins as described for left wing.
d. Mark cable to facilitate installation.
e. Carefully pull cable from aircraft.
7. Remove left primary cable as follows:
-NOTE-
When removing inboard section which leads from control sector to
turnbuckle at Station 142.0 or outboard section which leads to the
bellcrank from turnbuckles only use directions leading to or from
Station 142.0.
a. In left wing at bellcrank, remove safety wire or clip from turnbuckle and disconnect cable.
b. Remove primary control cable fairleads at Wing Stations 121.5 and 58.5, cable guard pins at Wing
Stations 0.5, 30.0, 147.5, and at Fuselage Stations 164.51 and 112.48.
c. Remove safety wire and screw securing retainer plate and cable end to sector; disconnect cable from
sector.
d. At Station 155.0, draw cables from wing and inside fuselage.
8. To remove right aileron cable, use basically the same procedure as the left. The only difference for the right
cable system is that pulley locations aft of sector are different. The right system's first pulley from sector is
at Station 101.07. One is at Station 164.51 where cable turns toward wing and goes under another pulley at
Station 168.0. The inboard and outboard sections are still divided by a turnbuckle at Station 142.0.
2G6
27-10-00
Page 1
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF AILERON CONTROL CABLES (figure 27-3)
-NOTE-
When all fairleads and cable guard pins are removed, and only the
inboard or outboard section of cable is to be installed, follow
instructions for the specific section from either side of turnbuckles at
Station 142.0 and on.
1. Install left primary cable as follows:
a. At bellcrank in left wing, fasten turnbuckle fork to forward arm of bellcrank.
b. Carefully feed cable through pulleys in wiring at Stations 147.5, 30.0, and 0.5 and around pulley at
wing root (Fuselage Station 170.03, Buttock Line 28.58). Angle slightly forward through forward hole
in fairlead pan assembly and around port pulley at Fuselage Station 164.51.
c. If full cable is being rigged, feed cable forward around pulley at Fuselage Station 112.48 and to left side
of upper control sector.
d. Fasten cable end to aileron control sector by screwing on retainer and safety wiring.
2. Install right primary cable as follows:
a. Connect turnbuckle fork to forward arm of bellcrank in right wing.
b. Route cable through pulleys in right wing as previously described for left wing.
c. Again feed cable through forward hole in fairlead pan assembly, Waterline 16.81.
d. At a slight angle forward, route cable from pan inboard to a pulley at Fuselage Station 168.0. Feed
cable under and around pulley to rear pulley at Station 164.51 and around it.
e. If both sections are being installed, route cable forward to pulley at Station 101.07, around its left side,
through bulkhead at Station 100 and onto right side of aileron control sector.
f. Fasten cable end to control sector by screwing on cable retainer plate and safety wiring them to sector.
3. Install left and right balance cables as follows:
a. Connect cables to aft arm of individual bellcranks. Verify, if applicable, that red painted cable terminals
on aileron balance cables are installed to red painted lugs on aileron bellcranks in wings.
b. Route cables through pulleys installing cable guard pins at Wing Stations 147.5, 30.0, and 0.5 and
fairleads at Stations 121.5 and 58.5.
c. Check proper angle of ailerons; connect and tighten cables at turnbuckle accordingly. Verify trailing
edge of left aileron moves up and trailing edge of right aileron moves down when control wheel is
turned counterclockwise and vice-versa when control wheel is turned clockwise.
REMOVAL OF CONTROL COLUMN SPROCKETS
1. Remove access panels located on forward side of control column approximately 6.00 inches below control
wheels on pilot and copilot control columns.
2. Remove cover assembly from top of both control columns.
3. Install rigging pins in lower portion of pilot control column ensuring bellcrank is captured between two
pins.
4. Insert two pieces of 0.032 inch safety wire down copilot control column and one piece down pilot control
column. Wrap one end of each wire to a link in chain below turnbuckles. Tie opposite ends of wires to
holes which forward access panels are mounted to columns.
27-10-00
Page 2
-NOTE-
Keep the wires tight so chain does not fall off sprockets under
floorboards (figure 27-3a).
Reissued December 31, 1989
2G7
W.S. W.S.
174.5 147.5
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
F.S.
78.76
F.S.
101.10
F.S.
F.S.
F.S. 171.00
163.38
F.S.
142.0
101.23 F.S.
F.S. 164.51 F.S.
112.49 170.03
Figure 27-3. Aileron and Aileron Trim Controls
2G8
27-10-00
Page 3
Reissued December 31, 1989
27-10-00
Page 4
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FUSELAGE STATION 93.30
AILERON TRIM PULLEY
FUSELAGE STATION 101.23
FUSELAGE STATION 101.10
FUSELAGE STATION 142.0
FUSELAGE STATION 164.51
FUSELAGE STATION 170.03
Figure 27-3. Aileron and Aileron Trim Controls (continued)
Reissued December 31, 1989
2G9
AILERON BALANCE CABLE
FUSELAGE STATION 171.0
AILERON TRIM TAB CABLE
WING STATION 30.0
AILERON TRIM
TAB CABLE
WING STATION 147.5
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
AILERON TRIM TAB CABLE
WING STATION .5
WING STATION 174.5
WING STATION 174.5 (RIGHT WING ONLY)
Figure 27-3. Aileron and Aileron Trim Controls (continued)
2G10
27-10-00
PageS
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
5. With control wheels in neutral, tie a ty-rap to top link in pilot and copilot chains as they pass over sprockets.
Place marks on sprockets to align with ty-raps.
6. Remove safety pins from turnbuckles, identify each turnbuckle for location, and disconnect turnbuckles
from chains.
7. Life chains off sprockets.
8. Remove ten AN3-3A bolts (five on forward side of column and five on aft side of each column) securing
sprocket and wheel assembly to column. Lift and remove sprocket and wheel assembly from column.
9. Slide bearing support off shaft.
10. Remove collar from hi-shear bolt through sprocket hub by splitting collar with a chisel. Drive bolt out with
a pin punch; remove sprocket.
11. Ensure control shaft hole diameter is 0.163 inch or less. If hole diameter is greater than 0.163 inch, replace
shaft.
INSTALLATION OF CONTROL COLUMN SPROCKETS
1. Place alignment mark on new sprocket in same place as old sprocket.
2. Mount new sprocket on shaft with sprocket hub facing away from control wheel (figure 27-3a). Line ream
hole in sprocket and shaft assembly to 0.1635 - 0.1640 inch diameter. Install Hy-Lok HL 18-5-16 pin in
hole for drive fit. Install Hy-Lok HL-70-5 collar on pin and tighten it until hex position shears off. Hold
pin head with an Allen wrench if necessary.
3. Reassembly control wheel assemblies into control columns by securing bearing blocks to each column with
ten AN3-3A bolts previously removed.
4. Install chains on sprockets so previously installed ty-raps align with sprocket alignment marks.
5. Reconnect turnbuckles ensuring proper placement. Remove safety wire used to retain chains. Level pilot
control wheel by adjusting turnbuckles A and B and taking up slack with turnbuckle C (figure 27-3a).
Level copilot control wheel by adjusting turnbuckles B and C. Tension chain enough to remove slack, but
not enough to increase friction. Through access hole in copilot column, deflect chain with finger applying
approximately 5 pounds of pressure. Deflection must be between 1/4 - 1/2 inch.
6. Remove rigging pins and ty-raps. Check aileron system friction per maintenance manual, chapter 27, Flight
Controls. Move controls through full travel range and check for free movement.
7. Install turnbuckle safety pins and access covers.
27-10-00
Page 6
Reissued December 31, 1989
2G11
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL

BEARING SUPPORT
DRILL AND REAM .16351.1640
BEARING SUPPORT SPROCKET
ACCESS PANEL

-{J .. / l'
A
BEARING SUPPORT I
I
I
AN3-3A BOLTS
CONTROL WHEEL
CO-PILOTS CONTROL COLUMN
PILOTS CONTROL COLUMN
AN3-3A BOLTS
T SAFE1YWIRE
SAFETY WIRE
TURNBUCKLE "B"
SAFE1Y WIRE
JL..-I.....--' TURN BUCKLE "A"
TURNBUCKL
VIEW A-A
(LOOKING AFT)
I
Jc
VIEWB-B
(LOOKING AFT)
c
Figure 27-4. Control Column Sprocket Installation
2G12
VIEWC-C
27-10-00
Page 7
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF AILERON CONTROL SECTION (figure 27-3)
-NOTE-
Both aileron and elevator sectors are located at Station 93.3. Though
not integrally connected, a hinge bolt maintains their axial position. If
is necessary, therefore, to remove aileron cables from their sector and
loosen elevator cables so hinge bolt can be pulled out. The forward
elevator sector will not be unhinged due to removal of aileron sector.
1. Disconnect cables and aileron control pushrod from sector.
2. Remove AN6-60A pivot bolt.
3. Rotate sector so grooves are facing fore and aft. Slide sector to left of aircraft and out from between bracket
supports.
INSTALLATION OF AILERON CONTROL SECTOR (figure 27-3)
1. Hold sector on end with grooved ends fore and aft, and rotate it down and between top two supports.
2. With sector between its supports, connect control rod to mounting flange.
3. Ensure flange is to left side of aircraft. Position sector between its support.
4. Ensure elevator control sector is in position. Drive AN6-60A pivot bolt down through two sectors and their
supports. Screw bolt into nut plate.
5. Connect and tighten aileron control cables.
6. Tighten elevator control cables.
RIGGING OF AILERON CONTROLS (figures 27-3 thru 27-8)
-NOTE-
The following procedure assumes system to be far enough in rig to
allow all rigging pins to fit in their individual holes at same time.
1. Remove access plate to each aileron bellcrank at Wmg Station 178.
2. Position bellcranks in neutral positions using rigging pins. (AN-3-20 bolts with ribbons attached.) (figure
27-7)
3. Remove access plates under pilot seat and insert rigging pin through the sectors. If pins will not line up in
both bellcranks and sectors under pilot seat, proceed as follows:
a. Align sectors and install rigging pin.
b. Clamp cables near sectors to prevent any load on rigging pin.
c. Adjust cables with turnbuckles at Fuselage Station 142 until both aileron bellcrank pinholes align.
d. Insert rigging pins and unc1amp cables.
4. Install rigging pins in bottom of pilot control column. Adjust pushrod to sector if necessary. Adjust length
of vertical pushrod in column as follows (shown in figure 27-5):
27-10-00
Page 8
Reissued December 31, 1989
2G13
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
a. Level pilot control wheel by adjusting turnbuckle A in pilot control column and turnbuckle B in copilot
control column. Use turnbuckle C in copilot column to take up slack (figure 27-5).
b. Level copilot control wheel by adjusting turnbuckles B and C.
-NOTE-
When tensioning chain to remove slack, do not increase system
friction. To check for proper tension, reach through copilot column
access opening and deflect chain with finger pressure of
approximately 5 pounds. Deflection must be between 1/4 - 1/2 inch.
5. Install rigging tool (PIN 72025) on top surface of left wing and tool (PIN 72159) on top surface of ring wing
at station 174.50 (figure 27-8).
6. Adjust pushrod between wing bellcrank and aileron to bring aileron to neutral 1 position (shown on the
rigging tool). This neutral position is 2 down relative to wing chord line.
7. Ensure control wheels are in neutral position, cables are routed properly on pulleys, and guard pins are
properly replaced. Rig control cables according to specifications in figure 27-6 or the following procedure
if autopilot is installed.
8. On aircraft equipped with autopilot, adjust aileron cable tension as follows:
a. Tension aileron primary cables to 50 pounds 5 pounds.
b. Connect and tension autopilot bridle cables in accordance with autopilot service manual.
c. Check aileron primary cable tension (in wing) and adjust (if required) tension to 55 pounds 5 pounds
downstream of autopilot bridle cables.
9. Remove all rigging pins and rotate control wheel to position aileron at indicated down and up positions on
rigging tool (figures 27-6 and 27-8). Adjust stops on wing bellcranks to be the same.
10. Adjust stops in control column to pennit 5 wheel rotation after wing bellcrank has stopped.
REMOVAL OF AILERON BELLCRANK (figure 27-3)
1. Remove access plate to bellcrank assembly.
2. Relieve cable tension of control system by rotating one turnbuckle attached to bellcrank.
3. Disconnect turnbuckle ends from forward and aft bellcrank ends.
4. Disconnect aileron control rod at bellcrank.
5. Remove pivot bolt securing bellcrank. Remove bellcrank from wing.
6. Unbolt stop block and remove from wing.
2G14
27-10-00
Page 9
Reissued December 31,1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
1. CONTROL WHEEL RT.
2. CONTROL WHEEL LT.
3. COVER ASSEMBLY CO-PILOTS CONTROL
RIGGING POSITION
OF CONTROL COLUMN BELLCRANK 4. CONTROL COLUMN RT.
TURNBUCKLE C
6
CONTROL WHEEL ADJUSTMENTS
~
5. CONTROL COLUMN LT.
l
! 6. ACCESS COVER
~ 7. CHAIN ASSEMBLY
SEE NOT \ 8. TORQUE TUBE
~
~ 15 9. AILERON INTERCONNECT
0-
. TUBE
10. ROD END BEARING
VIEW A 11. AILERON SECTOR
1.50 .12 --I r:-
INST y
PANEL
FWD LIMIT OF
COLUMN TRAVEL
12. ELEVATOR SECTOR
13. AILERON PUSH PULL ROD
14. ELEVATOR PUSH PULL ROD
15. BELLCRANK
-NOTE-
ADJUST PUSH - PULL ROD
INSIDE PILOTS CONTROL
COLUMN TO POSITION ROD END
(AND BELLCRANK) AT W.L. -18.00
Figure 27-5. Control Column Travels and Limits
AILERON AND AILERON TRIM TAB
-CAUTION-
MAKE SURE TO SECURELY CLAMP
BELLCRANKS AT QUADRANT BEFORE
TIGHTENING CABLES
A. 18.5 + 1 - 0
B. 18.5 + 1 - 0
C. 29 + 1 - 0
0.15+_0
CHORD LINE LEVEL
CABLE TENSION
AILERON = 55 LBS. 5 LBS.
AILERON TRIM TAB = 14 LBS . 2 LBS.
-NOTE-
TRIM TAB TRAVEL WITH AILERON IN
NEUTRAL POSITION 2 BELOW CHORD LINE
Figure 27-6. Aileron Control Travels and Cable Tension
271000
Page 10
Reissued December 31, 1989
2G15
2
o
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
3 RIGGING PIN HOLE
1. STOP BOLT
o 2. STOP BLOCK
3. RIGGING HOLE
4. BELLCRANK
Figure 27-7. Location of Bellcrank Rigging Hole
@--
.S.
174.50
---

Figure 27-8. Installation of Aileron Riggint Tool
2G16
- TOOL PIN 72025
27-10-00
Page 11
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF AILERON BELLCRANK (figure 27-3)
1. Place bellcrank in mounting bracket with adjustable stops toward outboard end of wing.
2. Install pivot bolt and torque.
3. Install aileron control rod; secure bolt assembly and safety.
4. Connect turnbuckle ends to bellcrank; secure and safety.
-NOTE-
The bellcrank aft end and balance cable end is painted red to facilitate
proper hookup. Do not tighten turnbuckle fork ends on bellcrank so
ends cannot rotate.
5. Install stop block and torque bolts.
6. Check aileron controls rigging and adjustment.
7. Install access plate and secure.
REMOVAL OF AILERON TRIM (FUSELAGE) (figure 27-3)
1. To gain access to trim control actuator, cables, pulleys, and control pedestal, remove right and left pilot
seats, floorboards, and access panels in and around pedestal.
-NOTE-
The fuselage aileron trim cables are routed down right side of
fuselage from pedestal into right wing. After entering wing, cables go
through two sets of pulleys to Wing Station 92.5 where they attach to
wing aileron trim cable with turnbuckles.
2. To release tension on the aileron cable system, loosen balance cable turnbuckle at Fuselage Station 171.3.
Access to turnbuckle is accomplished by removing necessary seats and floor panels.
3. Cables and pulleys in fuselage are reached by removing right hand and central floorboards in cockpit
through cabin at Fuselage Station 99.0 to 163.0. Remove seats from Station 135.0 to 163.0 as necessary.
4. Block trim cables at screw drum assembly in wing at Wing Station 171.0 and in fuselage at pulleys under
pedestal.
5. Under wing at Wing Station 92.5, remove access panel, mark cables to ensure proper reinstallation;
disengage fuselage trim cables from turnbuckles.
271000
Page 12
-NOTE-
Be sure to note specific routing and hookup of each cable to ensure
trim tab operates properly after reinstallation.
Reissued December 31, 1989
2G17
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
6. Remove two small snap bushings securing trim cables to rib flange at Wing Station 58.5 by reaching
through outboard access hole in aft wheel well bulkhead and under wing at Wing Station 65.0.
7. On aft wheel well bulkhead, remove inboard access panel. Reach through access hole, remove nut from
pulley bearing bolt. and carefully slide bolt up through pulleys far enough to remove tab pulleys.
8. At Wing Station 0.5. reach through bottom. aft access hole in wing fillet. and remove tab pulleys.
9. Tab cables are routed from last wing pulley group. through a doubler assembly. and into fuselage.
10. Remove required pulley guide pins from specific pulleys in fuselage. Carefully draw cables from wing into
fuselage.
11. From pedestal in cockpit. carefully draw cables through fuselage.
12. Remove access covers on control pedestal.
13. With tab cables still blocked at pulleys below pedestal. block cables at pedestal trim screw and remove
clevis pin fastening universal joint to screw shaft.
14. Unblock cables at pulleys; remove pulleys.
15. Remove four bolts retaining screw assembly to support bracket.
16. Slide screw assembly forward from support bracket until shaft clears support bracket.
17. Carefully remove screw assembly from pedestal. Pull cables out through pedestal.
18. Refer to appropriate section on trim controls and iIidicators for removal of aileron tab control.
INSTALLATION OF AILERON TRIM (FUSELAGE) (figure 27-3)
-NOTE-
Before installing cable. note which cable is routed to which
turnbuckle in wing.
1. Ensure appropriate cable is centered and evenly wrapped and blocked on trim drum to prevent unwrapping.
2. Remove all access panels. pulleys. and pins (explained in previous paragraph).
3. Carefully feed cables through bottom access hole on left side of pedestal under torque tube for control
column and back toward right side of fuselage where cables go thru pulleys at Fuselage Station 101.23 and
Right Buttline 7.9.
4. From copilot side of pedestal, carefully pull and lay cable so screw drum assembly can be installed with as
little cable slack in pedestal assembly as possible.
5. Carefully position screw drum assembly through access hole. Position assembly on mounting brackets so
universal joint, attached to trim control drive shaft, can be attached to drum drive shaft.
6. Fasten universal to drum drive shaft. Attach screw drum assembly to support bracket.
2G18
27-10-00
Page 13
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
7. Align cables handing from screw drum in first set of pulleys under pedestal. Allow cable to go through
pulleys on same sides as they leave drums.
8. Reinstall pulleys in pulley bracket under pedestal.
9. Route cables through pulleys at Station 101.23 and back through right side of fuselage to Station 163.38.
Turn cables through doubler assembly on fuselage and out through wing by pulleys at Wing Station 31.0.
From pulley at Station 31.0, cables go through holes for snap bushings in rib at Station 58.5, and top cable
from fuselage goes in aft hole. Finally, cables travel out wing to Station 90.0 where they attach to wing
aileron tab cables.
10. Be sure to connect proper trim cables and tighten to tension described in figure 27-6.
REMOVAL OF AILERON TRIM (WING) (figure 27-3)
1. Remove access plates located under bottom trailing edge of wing at Stations 92.5, 117.5, 128.0, 151.5,
171.0, and 176.0.
2. Disconnect trim control link located between trim screw and tab push-pull tube.
3. Block both sets of trim cables to prevent unwrapping from their drums and ease removal. Block fuselage
cable system at pedestal drum and wing system at tab screw assembly Wing Station 171.0 (shown in figure
27-3).
4. Mark one set of cable ends at Wing Station 90.0 to facilitate installation and disconnect cables at
turnbuckles.
-NOTE-
Note specific routing and hookup of each cable to ensure proper
operation after installation.
5. Remove fairleads in rib at Station 121.5 by reaching through access openings at Wing Stations 117.5 and
128.0.
6. Through access opening at Wing Station 150.0, remove appropriate guide pin.
7. With screw drum disconnect from tab link assembly, remove bolts securing drum assembly to rear spar.
8. Carefully pull screw drum assembly and cables from wing.
INSTALLATION OF AILERON TRIM (WING) (figure 27-3)
1. Ensure appropriate cable assembly is centered and evenly wrapped on drum (see paragraph titled Wrapping
of Trim Drums). Center drum between stops on trim screw and block cables to prevent unwrapping.
2. Feed cables back through wing so screw drum is fed up into wing as cable slack becomes less.
3. Position screw drum assembly inside wing, install attachment bolts, and torque.
4. Finish drawing cables through wing. Connect to appropriate turnbuckles at Wing Station 90.0. If fuselage
cable system is not installed, block cables at rib Wing Station 121.5 by reaching through access opening at
Station 117.5.
5. With cables retained, remove cable blocks.
6. Connect trim link to screw drum shaft.
7. Install cable guard pin at Wing Station 150.0.
8. Install snap bushings at Station 121.5
9. If both fuselage and wing cable system are installed and engaged, set cable tension with turnbuckles at
Wing Station 90 (figure 27-6). Check rigging and adjustment.
10. Install all access plates.
27-10-00
Page 14
Reissued December 31, 1989
2G19
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
RIGGING OF AILERON TRIM (figure 27-2)
1. To adjust aileron trim, ensure the following is accomplished either during installation or as a preadjustment
check:
a. Trim cables are evenly wrapped (centered) on drums both below control pedestal and in wing and both
cable turnbuckles are located approximately at Wing Station 90.
b. Trim drum in wing is centered between stops of trim screw.
c. The cable tension is set according to specifications in figure 27-6.
2. Remove access plates on underside of right wing at Stations 171.0 and 176.0.
3. With trim screw held from rotating, tum trim drum until 0.560 inch exists between forward screw stop and
drum housing measured along screw. (This is neutral position of screw.)
4. With right wing rigging tool (PIN 72159-2) installed and ailerons in neutral position, rotate trim wheel in
cockpit to specifications in figure 27-6 as indicated on rigging tool. Ensure cable tension meets
specifications in figure 27-6.
5. Ensure rotation of wheel from stop to stop is smooth and free with no binding or chafing.
6. Using tool (L73035) and a dial type torque wrench, check trim system friction at pedestal by removing trim
wheel and attaching tool and torque wrench to splined shaft. Friction must not exceed 9 inch-pounds when
tested in either direction at any point between limits.
AILERON CONTROL SYSTEM FRICTION CHECK (figure 27-9)
Using a spring scale and pulling from point on aileron shown in figure 27-9, take readings in both up and down
directions as aileron passes through neutral position. Record readings, add them, and ensure total does not
exceed 9 pounds without autopilot bridle cables connected, or 10 pounds with autopilot bridle cables connected.
AILERON TRIM TAB FREE PLAY
1. Position trim tab in neutral position. Trailing edge of tab in neutral position must be in line with trailing
edge of main surface.
2. Total free play must not exceed 0.04 inch measured from one extreme to other between outboard end of tab
trailing edge and trailing edge of main surface.
3. If excessive play exists, inspect aileron trim screw and hinge assemblies to determine location of excessive
play. Repair or replace worn parts as required.
AILERON BALANCING PROCEDURE
1. Position the aileron upside down in the aileron balance jig. Ensure surface rotates freely with no binding at
knife edges.
2. Establish horizontal reference mark which aligns with trailing edge of aileron when held in horizontal
position (chord line level).
3. Hang the master weight (2.74 pounds) in the aft most tool hole in the outboard rib (6.21 inches aft of the
aileron hinge).
4. If the surface is trailing edge heavy, determine the reason for the unbalance and static balance to -17 +0 -2
inch-pounds.
5. If the surface is leading edge heavy, add from 1 to 3 .10 pound test weights to the master weight. If the
unbalance still exists, remove material from the outboard balance lead weight until the surface is balanced
(see figure 27-31).
2G20
27-10-00
Page 15
Reissued December 31, 1989
Interim Revision: January 9, 1998
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
AILERON _--+:r-
Figure 27-9. Aileron Friction Check
RUDDER AND TAB CONTROLS
REMOVAL OF FORWARD RUDDER CABLES (figure 27-10)
1.. Remove pilot seat and floor panels under and in front of pressure bulkhead at Fuselage Station (FS) 57.0.
2. Rudder cable pulleys for forward system are located at Fuselage Station 77.2 (in front of control column),
161.35,212.96,248.96, and 281.5. Remove left seats and floorboards in these areas, only where necessary.
Remove left side floor panels around FS 303.5 to make access to rudder cable turnbuckles.
3. Before disconnecting forward cables, block rear cables in front of bulkhead FS 310.0, keeping cables
tensioned and preventing Slippage from pulleys and sector.
4. Mark one cable and turnbuckle to facilitate installation and disconnect turnbuckles at FS 303.5.
5. Remove cable guard pins from pulley clusters, disengage cable ends from forward control sector, and
remove top pulley at FS 77.2.
6. Slowly and carefully pull cables from between FS 110.37 and FS 117.88 bulkheads.
REMOVAL AND INSTALLATION OF FORWARD RUDDER CONTROL SECTOR
1. Disengage control tubes from left pedal arms. Tape tubes to pressure bulkhead FS 57.0.
2. Rotate pedals and tie them out of way.
3. With floorboards under pedals removed, disconnect cables.
4. Reach down through access hole in floor and disconnect control tubes on sector and tube, connecting sector
bellcrank to rudder pedal control bellcrank.
5. Remove bolt retaining sector assembly to two mounts.
6. Carefully remove assembly from under floor.
7. Install sector in reverse order of removal.
2G21
27-20-00
Page 1
Reissued December 31, 1989
FUSELAGE STATION 279.38
27-20-00
Page 2
Reissued December 31, 1989
PIPER AIRCRAFT
PA .. 42/42-720
AIRPLANE MAINTENANCE MANUAL
F.S.
279.38
F.S.
333.43
F.S.
281.50
FUSELAGE STATION 333.43
Figure 27-10. Rudder Control System Installation
2G22
F.S
387.00
F.S.
380.66
PIPER AIRCRAFT
PA .. 42/42 .. 720
AIRPLANE MAINTENANCE MANUAL
Ni
-~ - - : : : ~ - - -
-. W.L.
i < f - - , - ~
: I - .-' L2.041N
-, -- ----
NEUTRAL
POSITION
OF
FWD.
SECTOR
FUSELAGE STATION 62.75
RUDDER TRIM ACTUATOR ASSEMBLY
FUSELAGE STATION 380.61
FUSELAGE STATION 101.23
FUSELAGE STATION 387.00
FUSELAGE STATION 402.40
Figure 27-10. Rudder Control System Installation (continued)
2G23
27-20-00
Page 3
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF FORWARD RUDDER CABLES (figure 27-10)
1. With floorboards, pulleys, and guide pins removed, install cable ball ends to forward sector underneath
rudder pedals. (Remove sector, if necessary.)
2. Feed cables back through pulleys to FS 303.5.
3. If aft cables are not installed, ensure cables are aligned on pulleys and sector, and put tension on cables
while blocking them aft of bulkhead FS 310.0.
4. If aft cables are installed, attach cables to turnbuckles at FS 303.5.
5. Rig rudder and set cable tension (shown in figure 27-11). Ensure cables are aligned on pulleys and sector.
REMOVAL OF AFT RUDDER CABLES (figure 27-10)
1. Remove left side floor panels on back two cargo decks from FS 280.0 to FS 332.0 and tail cone (stinger).
2. Remove fairleads in bulkhead FS 332.0.
3. If forward cable system has not been removed, block it at FS 281.5 pulleys to prevent cables from slipping
pulleys and sector.
4. Disengage aft cables from turnbuckles at FS 303.5 and tie a 10 foot leader line to each cable terminals end.
5. Remove access panels on left side of tail.
6. Remove cable guide pins at FS 334.00, 354.67, and 379.5 (those on aft canted bulkhead) pulleys.
7. Disconnect cable ends from aft sector and carefully pull cables out through back of aircraft ensuring enough
leader line extends from each end.
REMOVAL AND INSTALLATION OF AFT RUDDER CONTROL SECTOR (figure 27-10)
1. Remove tail cone (stinger) and after loosening cables at FS 303.51, disconnect control cables from rudder
sector.
2. Disconnect rudder trim actuator rod end from trim shaft arm and remove trim shaft (explained in section
covering the rudder trim system).
3. Remove safety wire and four bolts fastening rudder torque tube mounting plate (stud weldment plate) to
rudder sector.
4. Remove five countersunk machine screws by rotating sector for access.
-NOTE-
It could be necessary to rotate sector 180
0
to gain access to two
forward screws.
5. Slide sector assembly off support bracket.
6. To disassemble sector assembly, remove snap ring where adapter extends through sector and carefully pull
pieces apart noting where each component is installed.
7. Install sector assembly in reverse order of removal.
27-20-00
Page 4
Reissued December 31, 1989
2G24
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF AFT RUDDER CABLES (figure 27-10)
1. Tie each cable tenninal end to leader line and from cargo area inside cabin at FS 303.5 pull each cable
through fuselage tail.
2. Attach cable ball ends to sector and lock rudder in neutral position.
-NOTE-
If forward cable system is not installed, ensure cables are centered in
pulleys and block them to bulkhead FS 310.0.
3. At FS 303.5 in cargo section of cabin, remove leader lines. After ensuring all cables are properly positioned
on their pulleys, engage cable tenninal ends with proper turnbuckles and tighten to specifications in figure
27-11.
4. Install cabin fairleads into FS bulkhead 332.0.
RIGGING OF THE RUDDER AND ITS CONTROLS (figure 27-11) PPSSOO43F
1. Remove pilot seat and floor panels on forward side of pressure bulkhead (Fuselage Station 57.0).
2. In back of cabin between FS bulkheads 298.38 and 310.00, remove left side floor panels to access pulleys at
FS 303.5. Remove tail cone (stinger) to access rudder sector.
3. Adjust rudder pedal and rudder for neutral position as follows:
a. Install rudder rigging tool (PIN 72260) on right side of vertical fin with markings on tool facing down.
Attach tool to fin with No. 10-32 screws and 3 rivnuts at WL 84.57.
b. Install rudder trim tab rigging tool (PIN 72266-2) on right side of rudder. Attach tool to rudder,
markings facing down, using 3 No. 8-32 screws and 3 rivnuts at WL 35.42.
c. Since different installations of rudder pedal pushrod assemblies exist, reference point for rudder pedals
is detennined as follows:
(1) For pedal pushrods PIN 70752-19 and PIN 70752-20, aircraft up to serial number 42-801038,
position and secure rudder pedals 10.51 0.25 inches aft of pressure bulkhead to pedal hinge tube.
Measurement to center after tube is 10.85 0.25 inches.
(2) For wing pedal pushrods PIN 70752-23 and PIN 70752-24, aircraft serial numbers 42-8010038 and
up, install rudder pedal rigging tool PIN 72233 on pilot left and right pedals as follows:
d. Adjust length of pedal pushrods to level bellcrank on pressure bulkhead and adjust bellcrank to section
pushrod so forward rudder sector is vertical.
e. Position rudder in neutral ( 1).
f. Ensure rudder cables are properly routed around pulleys and are secured with cable guards. Rig cables
according to specifications in figure 27-11, or proceed with following step if autopilot is installed.
-CAUTION-
CABLE TENSION MUST BE ADJUSTED EVENLY SO AS
NOT TO DAMAGE CLAMPED RUDDER.
2H1
27-20-00
Page 5
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
RUDDER AND RUDDER TRIM TAB
-CAUTION-
BEFORE TENSIONING CABLES MAKE
SURE TO CLAMP THE SECTOR OR
CABLES TO PREVENT LOAD ON
CLAMPED RUDDER
A. 20 + 1 - 0
B. 10 + 1 - 0
C. 30 + 1 - 0
D. 20 + 1 - 0
RUDDER = 55 LBS. 5 LBS.
RUDDER TRIM TAB = 14 LBS 2 LBS.
CHORD LINE (NEUTRAL POSITION)
-NOTE-
1. TRIM TAB TRAVEL WITH RUDDER IN NEUTRAL POSITION
2. FIN, RUDDER AND TRIM TAB VIEWED AS SEEN FROM ABOVE.
Figure 27-11. Rudder and Trim Tab Control Travels and Cable Tensions
Figure 27-12. Installation of Rudder
Rigging Tool
27-20-00
Page 6
Reissued December 31, 1989
2H2
TRIM TAB TOOL PIN 72266-
Figure 27-13. Installation of Rudder
Trim Riggint Tool
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
g. Since autopilot bridles affect primary cable tension, do not readjust primary rudder cable tensions.
Proceed as follows:
(1) Set tension to 55 pounds 5 pounds and hook up bridle.
(2) Tension autopilot bridle cables using proper manufacturers service manual. Primary rudder cable
tension increases downstream of bridle and decreases upstream.
(3) Record tensions upstream and downstream of autopilot bridle cable hookup for later verification.
(4) During verification, ensure tension upstream of autopilot bridle cable hookup is within 5 pounds
of previously recorded values.
h. Remove rudder clamp and pedal tools. Smoothly rotate rudder 30 right and 20 left.
i. Adjust rudder stops at rudder sector for 30 right and 20 left.
j. With rudder in neutral, rotate trim wheel in cockpit so tab travel is 10 right and 20 left. Trim cable
tension to match specifications in figure 27-11.
k. Remove rigging tools and reinstall access covers.
RUDDER CONTROL SYSTEM FRICTION CHECK (figure 27-14)
-NOTE-
When measuring rudder control system friction, nose gear must be
retracted or bungee disconnected in nose landing gear wheel well.
Using a spring scale placed on rudder (figure 27-14), move rudder from two inches trailing edge left to two
inches trailing edge right and back. Measure force needed to move rudder each time trailing edge passes through
neutral. Both readings must not exceed 6 pounds.
-NOTE-
Friction measurements are taken without autopilot bridle cables
connected. If bridle cables are connected, friction reading must not
exceed seven (7) pounds.
REMOVAL OF FORWARD RUDDER TRIM SYSTEM (figure 27-10)
1. Remove copilot seat and floor panels on same side, from spar carry through to pressure bulkhead FS 57.0.
2. Pulleys aft of forward screw drum are located on right side of aircraft under floor at FS 101.23, 280.0,
332.0, and 376.0. Rub blocks are located at FS 162.3, 181.0, 174.0, and 251.0. To gain access to this cable
hardware, remove required seats and floor panels. If fairleads for aft cable system in pressure bulkhead FS
332.0 must be removed, remove right side floor panels. Approach turnbuckles around FS 312 through right
side floor panels between bulkheads at FS 310.0 and 321.0.
2H3
27-20-00
Page 7
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
3. Block forward cable system at trim screw underneath control pedestal and aft cable system (if not removed)
at pressure bulkhead FS 332.0. If also removing aft rudder trim system, block cables at aft screw drum on
aft canted bulkhead at FS 380.35.
4. Mark one set of turnbuckle cable ends to facilitate installation of FS 312.0. Remove cable guide pins and
rub blocks to ease removal of cables.
5. Disconnect cables from turnbuckles and attach two 23 foot leader lines to each cable terminal end.
6. From cockpit at FS 78.0, carefully pull cables through aircraft.
7. Remove four bolts attaching screw drum assembly to channel plate. Remove pin linking drive shaft to
drum.
8. Pull cables up to drum and disconnect leader lines.
9. Remove drum and cable assembly from aircraft.
-NOTE-
Note cable routing and which cables (respective to screw drum) are
attached to which leader lines.
Figure 27-14. Rudder Friction Check
INSTALLATION OF FORWARD RUDDER TRIM SYSTEM (figure 27-10)
1. Ensure cable is centered and evenly wrapped on trim drum (see paragraph on Wrapping of Trim Drums).
Block cables to prevent drum from unwrapping.
2. Lay trim drum on floor in front of pedestal and attach leader lines to proper cables.
3. From rear of cabin, carefully pull cables through fuselage ensuring cables are aligned on pulleys.
4. Install cable guide pins and rub blocks.
5. Install drive shaft from control and mount the drum assembly on channel plate.
6. Follow cable back down fuselage and align in pulley and rub blocks.
7. If aft trim system is not installed, pull cables tight and block them on aft side ofFS 310.0 bulkhead.
8. If aft trim system is installed, engage cables with proper turnbuckles and rig and tighten cables to
specifications in figure 27-11.
9. Conduct a final check of all cable routing, pulleys, and rub blocks.
10. Install all access plates, carpeting, and seats.
272000
Page 8
Reissued December 31, 1989
2H4
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF AFT RUDDER TRIM SYSTEM (figure 27-10)
1. Remove right side floor panels between bulkheads FS 310.0 to 332.0, two access plates on right side of tail
and tail cone (stinger).
2. Block aft trim cables (using one method in figure 27-2) on front side of bulkhead FS 332.0 to prevent
unwrapping from screw drum assembly on aft canted bulkhead.
3. Block forward cables to rear ofFS 310.0 bulkhead.
4. Mark one set ofturnbuckle cable ends and remove fairleads in pressure bulkhead FS 332.0.
5. Disconnect cables at turnbuckles and attach 10 foot leader line to two cable terminal ends.
6. At pulleys on bottom of pressure bulkhead and on aft canted bulkhead, remove cable guide pins and block
cables on aft screw drum.
7. Remove cable blocks at FS 332.0 and bolts retaining screw drum to canted bulkhead. Carefully remove
drum.
8. Carefully pull cables out tail and disconnect leader lines, noting which lines are attached to which cables,
respective to trim drum in its mounted position.
INSTALLATION OF AFT RUDDER TRIM SYSTEM (figure 27-10)
1. Ensure appropriate cable is centered, evenly wrapped on drum (explained on paragraph entitled Wrapping of
Trim Drums), and blocked to prevent unraveling.
2. Position screw drum assembly on canted bulkhead. Mount with two bolts and required washers.
3. Attach cable terminal ends to leader lines and from inside cockpit at FS 313.0. Carefully and slowly pull
cables through fuselage. Remove leader lines from cables when cables are in fuselage.
4. Ensure cables are properly centered on pulleys.
5. Attache cable to proper turnbuckles. Tighten and rig system to speCifications in figure 27-11.
REMOVAL AND INSTALLATION OF TRIM TAB
1. Remove fairing/access covers where cables come through rudder.
2. Loosen cable turnbuckles and remove cable securing fixtures on trim tab sectors.
3. Remove hinge bolts and tab.
4. Install trim tab in reverse order of removal. Ensure cables are rerigged before reinstalling fairing/access
covers.
2H5
27-20-00
Page 9
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
RIGGING OF RUDDER TRIM (figure 27-11)
1. Before adjusting rudder trim, proceed as follows:
a. Ensure cables are centered and evenly wrapped on trim drums.
b. Remove right side floor panels between FS 310.0 and 321.0. Ensure cable turnbuckles are near FS
312.3.
c. Check cable tension (figure 27-11).
2. Remove tail cone (stinger) and access plate on rudder near Water Line 45.0.
3. Disconnect rod end from trim tube arm so trim screw is free to rotate.
4. In cockpit, center control at neutral and ensure trim drum under floor is in neutral position. Forward drum
cable capacity is 18 1/2 turns, and when set with system in neutral, 2 1/4 turns of each side of cable must be
wrapped on drum.
5. With system in neutral, ensure aft screw drum in tail also has 9 1/4 turns of cable wrapped on each side of
drum.
6. On aft trim drum, measure distance from machined surface of drum assembly to stop washer on screw. (End
of screw with rod end attached.) Distance must measure 0.625 inches. Screw rod assembly in or out for
proper measurement.
7. With trim screw and system in neutral, align rod end with trim tube arm, and insert bolt to set and hold tab
position. Trailing edges of tab and rudder must align. If control surfaces do not align, pull bolt out of arm
and rod end and turn screw shaft in or out until tab aligns. For fine adjustments, use turnbuckles.
8. Install and secure attachment bolt in rod end; trim tube arm.
9. In cockpit, tum control to each stop and measure angles of deflection from centerline of rudder.
Measurements must compare to those in figure 27-11. Use rigging tool (figure 27-13) to check tab angles.
10. After adjusting system, turn control to its stops and ensure no less than 1 1/4 turns of cable is left on either
drum.
11. Using tool (L 73035) and dial type torque wrench, check trim system friction at pedestal by removing trim
wheel and attaching tool and torque wrench to splined shaft. Friction must not exceed 9 inch-pounds when
tested in either direction at any point between limits.
REMOVAL OF RUDDER PEDAL ASSEMBLY (figure 27-15)
1. Remove pilot and copilot seats for easier access to pedals.
-NOTE-
If bearing support housing and bearings on end of tubes are only
required serviceable items, proceed to step 6.
2. Disconnect brake cylinders from rudder pedal clevis arms and support brackets so brake cylinder assemblies
(brake cylinder and extension) remain assembled. If removing either of copilot pedals, disconnect brake
cylinder for left pedal at rudder pedal clevis arm and extension. Remove extension with right rudder pedal
or forward tube assembly.
27-20-00
Page 10
Reissued December 31, 1989
2H6
PIPER AIRCRAFT
PA42142720
AIRPLANE MAINTENANCE MANUAL
3. Use the following procedure to remove left pedals (aft tube assembly) on pilot and copilot side:
a. Remove bolts attaching pillow block caps to housings and remove two bolts on right side of block
mounting bracket. After removing caps, reinstall bolts in left block.
b. Remove two bolts, attaching tube support assembly on pilot side to bracket, mounted on pressure
bulkhead.
c. Remove bolts securing left pedal assemblies to torque tube.
d. Supporting aft tube with your hand, remove clevis pin in left end of tube, fastening it to bearing support
housing.
e. With bolts removed from right pillow block, ensure its free movement. Carefully slide rear tube right,
sliding pillow block with it until tube is free of bearing; lay block on floor.
f. When tube is clear of bearing support housing, slide subassemblies off tube. If tube needs to be
replaced, jockey it out from underneath.
4. To remove pilot and copilot right pedals or forward torque tube, proceed as follows:
a. Remove both pillow block caps. Reinstall attachment bolts in right side block housing. Remove bolts
in left side of block housing mounting bracket.
b. Disconnect brake cylinder assemblies (brake cylinder and extension) from forward tube support and
remove bolts securing two tube supports to brackets mounted on pressure bulkhead.
c. Remove bolts mounting rudder pedal assemblies to forward torque tube.
d. On pilot side, disconnect aft tube support from bracket and rotate out of way. After removing bolts
connecting pilot left rudder pedal to pushrod and torque tube, slide pedal assembly as far to left as
possible.
e. Remove clevis pin in bearing support housing and disconnect copilot left brake cylinder from its
extension.
f. While holding left pillow block housing, carefully slide forward tube left, moving assemblies out of
way until tube clears bearing support housing.
g. Remove necessary assemblies from tube. If rudder pedal torque tube need to be replaced, remove as
many assemblies as possible from tube before jockeying it out from underneath panel.
5. Sleeves and bearings support tubes on rub blocks constitute a pressed fit. To disconnect, remove rivets, heat
tube, cool sleeve, and bearing; slide sleeve and bearing from tube.
6. Remove bearing support housings and bearings as follows:
-NOTE-
If previous instructions have been followed, proceed to step e.
a. Remove clevis pin mounting specific bearing support housing to tube.
b. With reference to aft tube assembly (that closest to pilot and copilot), remove bolts retaining pedals to
torque tube and bolts in right pillow block.
c. With reference to forward tube assembly, remove bolts retaining pedals to torque tube and bolts in left
pillow block. After disconnecting pilot left brake cylinder assembly (brake cylinder and extension)
from forward tube support, disconnect support from bracket on pressure bulkhead and swing it out of
way so forward tube can slide to left.
d. While supporting unconnected pillow block housing, slide affected torque tube and block housing so
they clear bearing support sleeve. A socket wrench can be used to remove bolt mounting bearing
support sleeve to fuselage support skin. When pilot block clears mounting pad, lay it on floor.
e. With torque tube removed away from bearing support housing, remove bearing and housing by
ratcheting bolt out of sleeve. Note placement of hardware.
f. After removing housing, remove bearing pressed into housing.
2H7
27-20-00
Page 11
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
VIEW A- A
1. TORQUE TUBE END BEARING ASSEMBLY
2. BEARING
3. BOLT
4. TORQUE TUBE
5. SUPPORT ASSEMBLY
6. TORQUE TUBE
7. TORQUE TUBE CENTER BEARING ASSEMBLY
8. RUDDER PEDAL ARM ASSEMBLY
9. BEARING
10. RUDDER PEDALS
11. conER PIN
12. MASTER CYLINDER ASSEMBLY
Figure 27-15. Rudder Pedals Installation
27-20-00
Page 12
Reissued December 31, 1989
2H8
11
6
I
- - - ~ . --
VIEWS S
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF THE RUDDER PEDAL ASSEMBLIES (figure 27-15)
1. If rudder pedal torque tube and pillow block bearing support sleeve from tube is to be removed, proceed as
follows:
a. Fill bucket with ice cubes and place end of tube so it accepts sleeve in ice.
b. Heat support sleeve in oven at 350
0
for 15 minutes.
c. Remove torque tube from ice and immediately slide heated sleeve over tube. Be sure to align holes in
two assemblies so longer sleeve end, relative to rivet holes, faces toward tube end to be supported in
bearing support housing on fuselage side.
d. With sleeve properly positioned on tube, install two NAS 1738B blind rivets.
e. If bearing support housing on side of fuselage is removed, replace in reverse order of removal.
f. With bearing support housing installed, properly insert and align tube in support housing and align
pillow block in proper position.
g. Mark support sleeve where KP21B pillow block bearing is to be positioned.
h. Remove torque tube from underneath panel. Install bearing on sleeve.
2. With torque tube positioned under panel, proceed as follows:
a Position tube in bearing support housing so it is properly placed in right pillow block, forward opening.
b With right pedal and forward tube support on pilot side slide on torque tube, loosely mount tube support
to bracket on pressure bulkhead.
c Complete same procedure on copilot side.
d With tube loosely mounted on support brackets, slide it left until bearing on bearing support sleeve is
hanging over floor. Push bearing into proper pillow block housing by aligning housing bearing slot with
bearing and pushing housing up onto bearing. If fit is too tight, ensure bearing is properly aligned and
appropriate bearing is used. Finally, rotate housing around tube and carefully push housing on with soft
mallet.
-NOTE-
For RUDDER BALANCING PROCEDURE, refer to chapter 55.
e With bearing positioned in pillow block housing, place housing under tube and align aft tube with
opening in pillow block. Slide forward tube right and into bearing support housing, ensuring the pillow
block also slides into proper position on mounting bracket. To ensure proper alignment of pillow block
housing, install cap bolts without block cap.
f Install clevis pin, washer, and cotter pin through bearing support housing and torque tube.
g Bolt on rudder pedals and brake cylinders where required.
h Install and connect all hardware and assemblies.
3. Slide removed assemblies to aft rudder torque tube in proper sequence.
a Position tube in bearing support housing on left side of fuselage so it is properly placed in left pillow
block, aft opening.
b Connect aft tube support on pilot side to bracket on pressure bulkhead.
c With tube supported by support bracket and left pillow block, reinstall bearing in pillow block housing.
d Reinstall tube and reconnect all hardware.
4. Check rigging.
2H9
27-20-00
Page 13
Reissued December 31, 1989
ELEVATOR AND TAB
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-NOTE-
Anytime elevator control system is serviced, conduct a friction check
to ensure system friction is within limits.
REMOVAL OF FORWARD ELEVATOR CONTROL SECTOR (figure 27-16)
1. Remove pilot seat and all central floor panels at FS 270.0 and 322.5, and those in front and behind them.
2. Remove safety clip from proper elevator cable turnbuckle (FS 270.0 or 322.5) and decrease cable tension by
partially unscrewing one of turnbuckle eyes.
3. Move or remove appropriate seats on left side of cabin so floor panel behind spar carry through section can
be removed.
4. Remove safety clip on one of aileron cable turnbuckles at FS 142.0 and decrease cable tension on aileron
sector.
5. Disconnect control column elevator pushrod and control cables from forward elevator sector.
6. Remove tension from two cable systems, unscrew pivot bolt, and carefully slide out bolt until elevator
sector can be removed from under aileron sector. If control column pushrod of aileron control sector
impedes removal, disconnect pushrod from aileron sector.
INSTALLATION OF FORWARD ELEVATOR CONTROL SECTOR (figure 27-16)
1. Position sector, under aileron sector containing pushrod mounting flange, to right and on bottom.
2. Align sector to fit pivot bolt and push bolt through sectors.
3. Screw AN6-60A pivot bolt into nut plate using standard torque designated in AC43-13.
-NOTE-
To facilitate rigging, ensure torque tube driving forward sector
measures 12.31 inches between defined centers of two rod end
bearings (figure 27-16).
4. Attach pushrod to mounting flange extending from bottom of sector.
5. Install right elevator cable in starboard groove of sector, retaining plate with retaining screw, and safety
wire.
6. Install left elevator cable in groove.
7. Tighten aileron cables (figure 27-6) and rig elevator cables (figure 27-17).
2H10
27-30-00
Pagel
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF AFT ELEVATOR CONTROL SECTOR (figure 27-16)
1. Remove rearward most access plates on both side of fuselage tail and bullet assembly extending from tail.
-NOTE-
When removing aft push-pull tube from sector, gain access to
tube/sector linkage with elevator in up position. Maintain a firm grip
or clamp support on elevator to prevent release.
2. Rotate elevator to pull up position.
3. With two people reaching through each tail section access hole, remove locknut and bolt and carefully
release tube.
4. Remove first three access plates in center of raised floor and disconnect elevator cables at FS 270.0 and FS
322.5 to relieve tension in system.
5. With one person reaching through access and lightening holes and holding bolt, and another holding nut,
unscrew and remove pivot bolt.
6. Pull sector forward through slotted bulkhead and disconnect cables by removing safety wire and retaining
screws.
7. Remove sector from fuselage.
INSTALLATION OF AFT ELEVATOR CONTROL SECTOR (figure 27-16)
1. With aft cable system disconnected at one turnbuckle, either at FS 270.0 or 322.5, connect cables as
follows:
a. Insert up cable in groove between arm and sector, fasten cable to sector by screwing on retaining place,
and safety wire plate and screw to sector.
b. Repeat procedure to fasten other cable.
2. With an assistant reaching through aft control bulkhead, slide sector (tube arm forward) through slot in
bulkhead FS 368.0 until it can be held in aligned position. While holding sector in position, insert AN5-25
pivot bolt.
3. With an assistant reaching through starboard access and lightening holes holding nut, reach through on other
side and tighten pivot bolt.
4. Reconnect turnbuckles and push tube to sector arm.
27-30-00
Page 2
Reissued December 31, 1989
2H11
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
FUSELAGE STATION 102.72
SEE
NOTE
2
FUSELAGE STATION 93.90
ELEVATOR
UP CABLE
F.S.
431.45
F.S.
417.76
F.S.
-NOTES-
SEE ",,-. 435.614
NOTE 1. ""-,, F.S.
1. APPLY CORROSION RETARDANT COMPOUND
PIPER PIN 197 - 508 OR 197 - 509, WITH SPRING
IN EXTENDED CONDITION. REFER TO CHAPTER
91 FOR VENDORS (CONSUMABLE MATERIALS).
2. SHADED AREAS REPRESENT THE CORNERS
OF THE SECTORS PAINTED RED.
F.S.
F.S. 279.38
162.80 F.S.
251.00
FS
F.S. ---
---;>""' 160 20
-- '
F.S. "-
93.30 \ r-,
\
Figure 27-16. Elevator System Installation
2H12
'" - 432.84
"
F.S.
365.96
27-30-00
Page 3
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ELEVATOR TRIM CABLES
FUSELAGE STATIONS 162.60 AND 251.00
SEE NOTE 2
FUSELAGE STATION 373.37
ELEVATOR TRIM PULLEYS
FUSELAGE STATION 279.38
FUSELAGE STATION 332.50
FUSELAGE STATION 431.45
Figure 27-16. Elevator System Installation (continued)
27-30-00
Page 4
Reissued December 31, 1989
2H13
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF ELEVATOR CONTROL CABLES (figure 27-16)
The cable system for elevator primary controls runs from the forward control sector at FS 93.3, under pilot seat,
to aft sector at FS 373.10. The forward up cable, attached to right side of sector, is routed to left side of aircraft
and around pulley at FS 101.07. The cable is then routed through left side of fuselage and spar carry through to a
second pulley at FS 153.35, where it turns toward pulley at FS 193.72 at center of aircraft. From third pulley, it
travels straight through fuselage center to fourth pulley at FS 278.0, where it angles up to turnbuckle at FS 322.5.
The aft up cable is routed through fairlead in aft pressure bulkhead through pulleys at FS 355.75 and 366.0 and to
aft control sector. The forward down cable, attached to left side of forward control sector, is mounted similar to
up cable with pulleys at FS 112.47, 160.2, and 200.98, and turnbuckle at FS 270.0. The aft down cable travels
from turnbuckle through pulley at FS 278.0, fairlead in aft pressure bulkhead, and pulley on bulkhead ahead of
aft control sector. To remove cables, proceed as follows:
1. The following procedure must be used to remove forward elevator cables:
a. Remove pilot seat and left passenger seats from FS 135. to 203.0 and floor panels necessary to gain
access to pulleys and turnbuckles.
b. Mark end of cable to be removed to facilitate installation. Disconnect cable from turnbuckle.
c. After detaching cable from turnbuckle, attach 20 foot leader line to cable end.
d. Remove cable guard pins from required pulleys. Disconnect cables from forward sector.
e. From behind pulleys at FS 101.07, carefully pull cables inside aircraft so enough leader line exists for
reinstallation.
2. To remove aft elevator control cables, proceed as follows:
a. Remove center floor access panels from FS 265.0 back to aft pressure bulkhead. Access panels on tail
and tail cone (stinger).
b. Follow steps lb, Ic, and Id to remove cables from aft sector.
c. Reach through aft access opening on fuselage, work cables forward through slotted bulkhead, and pull
cables from aircraft ensuring leader line lays in path of removed cable.
d. Disconnect leader lines.
2H14
27-30-00
PageS
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF ELEVATOR CONTROL CABLES (figure 27-16)
-NOTE-
Later model aircraft use cables and sectors marked with red paint to
facilitate and assure proper installation of elevator up cables. On
these aircraft, ensure red ball end of cable is attached to appropriate
red comer of sector and red terminal end of cable is attached to
turnbuckle with adjoining up cable also having red terminal end.
1. Forward control cables, running from forward control sector to turnbuckles at Fuselage Station 270.0 and
322.5, are installed as follows:
a. Behind forward sector, tie leader line onto cable swaged terminal end, an from (aft cable) turnbuckle
position or end of leader line, pull leader and cable through aircraft ensuring the cable is routed
correctly.
b. Refer to section on elevator rigging control and tighten elevator control cables at turnbuckles.
c. Reinstall all cable guard pins, rub blocks, and other hardware.
2. Aft cables, running from turnbuckle positions to aft sector, are installed as follows:
a. Connect cables to aft control sector by reaching through lightening hole in aft canted bulkhead and aft
access opening in tail, or by removing aft sector.
b. Feed cables through pulleys on FS 368.0 bulkhead (where aft sector is attached). Attach cable terminal
ends to leader lines.
c. With leader lines tied to cable ends, have assistant feed cables through pulleys at turnbuckle station, or
where leader lines end.
d. After cables are pulled through, ensure cables are properly routed with respect to sector and seated in
pulleys.
e. Check rigging instructions in this section. TIghten cables in turnbuckles.
f. Reinstall all cable guard pins, fairleads access panels, and other hardware.
3. Check proper operation of elevator after cable rigging is completed.
REMOVAL AND INSTALLATION OF ELEVATOR PUSH TUBE (figure 27-16)
1. Remove bullet, aft access plates on tail and vertical stabilizer, and bullet assembly on top of vertical
stabilizer.
2. After removing bullet assembly from top of vertical stabilizer, block or tie control hom so elevator remains
in most upward position when tube is released from sector.
3. With elevator in most upward position, tube and connecting arm on aft sector must protrude through slot on
bulkhead to which the sector is attached. Reach through aft access hole in tail and disconnect tube from
sector by removing AN4-l3A bolt.
4. Remove restraint from control hom. Allow elevator to move to down stop.
5. With elevator in down position, tube connection to control arm is now accessible. Disconnect tube from
elevator hom and pull out of tail.
6. Disconnect elevator down spring and apply retardant with spring in extended position. (Refer to lubrication
chart in chapter 12 for corrosion retardants used on elevator down spring.)
27-30-00
Page 6
-NOTE-
Fir rigging, ensure control tube measures 120.5 inches from center of
end fitting bearing to center of rod end bearing.
Reissued December 31, 1989
2H15
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ELEVATOR AND ELEVATOR TRIM TAB
A. 7+ 1_2
B. 30 + 1 - 0
C. 12 + 1/2 -1
D. 20 + 1 - 1
CABLE TENSIONS
ELEVATOR = 55 LBS 5 LBS.
ELEVATOR TRIM = 14 LBS. 2 LBS.
-NOTES-
1. TRIM TAB NEUTRAL POSITION IS TAB
TRAILING EDGE EVEN WITH THE
TRAILING EDGE OF THE ELEVATOR, OR
ITS NEUTRAL POSITION.
2. TRIM TAB FREE PLAY MUST NOT EXCEED
0.126 MAX. AT THE TRAILING EDGE OF
THE TAB.
3. RIG ELEVATORS WITH ELEVATORS IN
NEUTRAL POSITION (PINNED AT AFT
SECTOR) VERIFY THAT RIGHT HAND
ELEVATOR IS ALIGNED WITH LEFT HAND
ELEVATOR TRAILING EDGE ADJUST
LENGTH OF ANTI - SERVO RODS TO
OBTAIN 0.12" 0.12" TRAILING EDGE UP
OF THE RIGHT HAND TAB AS MEASURED
ON THE INBOARD TRAILING EDGE OF THE
TAB.
PPS 50043N
-NOTE-
TRIM TAB TRAVEL WITH ELEVATOR IN
NEUTRAL POSITION
CHORD LINE LEVEL (NEUTRAL POSITION)
Figure 27-17. Elevator and Elevator Trim - Travels and Cable Tensions
27-30-00
2H16
Page 7
Reissued December 31, 1989
PIPER AIRCRAFT
PA .. 42/42 .. 720
AIRPLANE MAINTENANCE MANUAL
RIGGING THE ELEVATOR CONTROL SYSTEM (figure 27-17)
-NOTE-
Most adjustments to system are made with cable turnbuckles.
Pushrods and tube are a specified length from rod end to rod end
bearing center, and can only be used for minor small adjustments. If
whole system must be rigged, follow instructions as given.
Otherwise, follow instructions for specific areas only, using other
instructions as a check.
1. To gain access to existing systems, proceed as follows:
a. To gain access to forward control sectors, remove pilot seat and surrounding access panels.
b. To gain access to aft elevator controls consisting of hardware controlling elevator from aft sector,
remove last large access panels on either side of fuselage, tail cone, and bullet as sembi y.
2. Before rigging any part of elevator control system, set elevator in neutral position ( 1
0
) and install rigging
tool (pIN 72046) and rigging pins in aft fuselage sector, below fin and sector, under pilot seat (figure 27-18).
Install rigging too on left hand stabilizer.
3. Rig control cables to specifications in figure 27-17, or following step, if autopilot is installed. Ensure both
rigging pins are in place without carrying a load and clamp sectors or block cables.
4. Since autopilot bridles affect primary cable tension, do not readjust primary elevator cable tensions.
Proceed as follows:
a. Set tension to 55 5 pounds. Hookup bridle.
b. Tension autopilot bridle cables using manufacturer selVice manuals. Primary elevator cable tension
increases downstream of bridle and decreases upstream.
c. Record tension upstream and downstream of autopilot bridle cable hookup for later verification.
d. During verification, ensure tension upstream and downstream of autopilot bridle cable hookups are
within 5 pounds of previously recorded values.
5. Adjust pushrod in fin to bring elevator to neutral 10.
6. Remove rigging pins from sectors and adjust stops (figure 27-19) at elevator to obtain values specified in
figure 27-17.
-NOTE-
All travels are taken from tailing edge of control surface.
7. Adjust pushrod going from front sector to control column for 1.50 0.12 inch clearance between column
and instrument panel when column is full forward.
8. Check system travel for smooth operation.
9. Adjust trim wheel in cockpit for neutral with elevator tab in neutral.
to. With elevator in neutral, rotate trim control wheel in cockpit to obtain up and down tab travels and
minimum trim cable tension specified in figure 27-17.
11. Remove rigging tool. Install access covers.
27-30-00
Page 8
Reissued December 31, 1989
2H17
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
___ n . - ~ r
TOOL PIN 72046 --_
Figure 27-18. Elevator Rigging Tool
1. REAR FIN SPAR
2. ELEVATOR TORQUE TUBE COLLAR
3. ELEVATOR HORN ASSEMBLY
4. UP STOP
5. PUSH ROD
6. DOWN STOP BRACKETS
7. DOWN STOP LOCK NUT
8. DOWN STOP
5 - __ "
6
Figure 27-19. Elevator Rigging Stops
2H18
---
.L.
_ 33.30
2
o
27-3000
Page 9
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
ELEVATOR CONTROL SYSTEM FRICTION CHECK
-CAUTION-
DO NOT EXCEED 60 POUNDS DURING THE FOLLOWING
PROCESS. IF SCALE READING APPROACHES THIS
VALUE, STOP AND CHECK SYSTEM FOR BINDING.
ENSURE ALL RIGGING PINS ARE REMOVED.
1. Attach spring scale to inboard trailing edge of elevator (figure 27-20).
2. With spring scale attached, position elevator trailing edge 2 inches down from neutral position.
-NOTE-
To obtain effective reading on spring scale, rotate elevator with firm
and steady movement, recording force reading as elevator passes thru
neutral position. Do not stop rotation while taking reading or exceed
60 pounds of force for any measurement.
3. Raise elevator with attached scale from its down position to 2 inches above neutral and record force
required to raise elevator.
4. Lower elevator with attached scale from 2 inch up position to 2 inch down position and record force.
5. Repeat steps 3 and 4 until average force is attained.
6. Subtract two average forces to verify total friction in system. Total friction in elevator control system must
not exceed 10 pounds without autopilot system installed or 11 pounds with autopilot system installed.
ELEVATOR-_",,-
TAB
MEASURE FROM HERE
Figure 27-20. Elevator System Friction Check
27-30-00
Page 10
Reissued December 31, 1989
2H19
ELEVATOR TRIM SYSTEM
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
The elevator trim system consists of an adjustable trim tab mounted on the left elevator, a trim tab actuator
mounted to the stabilizer rear spar, a control wheel and drum mounted in the cockpit control pedestal, and
accompanying trim control cable and pulleys.
-NOTE-
Kit No. 764411L is available for modification of the trim actuator to
reduce friction and for installation of an environmental enclosure
around trim actuator preventing water entry.
REMOVAL OF FORWARD ELEVATOR TRIM SYSTEM (figure 27-16)
1. Remove pilot and copilot seats and right side passenger seats as necessary.
2. Remove floor panel aft of pedestal, those under and left of copilot seat, right side passenger seats, floor
panels necessary to reach required cables and hardware, and right side floor panels on two aft cargo decks.
3. Block forward trim cables at left set of pulleys and under pedestal. Block aft cables at aft drum on stabilator
(see figure 27-2).
4. Mark one set of cable ends at FS 65.0 to facilitate installation and disconnect cables at turnbuckles.
5. Remove cable guard pins at FS 125.0 and 243.5.
6. Remove one screw from each set of rub blocks at FS 140.0, 162.0, 174.0, and 215.0. Open them enough to
allow cable ends to pass through.
7. Slide bushing up shaft to separate two halves of trim screw assembly.
8. Remove bolts attaching screw assembly to mounting bracket. Draw assembly with cables from fuselage.
INSTALLATION OF FORWARD ELEVATOR TRIM (figure 27-16)
1. Ensure cable is evenly wrapped on trim drum (centered) and blocked to prevent unwrapping. (Refer to
Wrapping the Trim Drum.)
2. Position forward trim screw on left side of mounting bracket below pedestal at FS 100.0.
3. Draw cables aft through fuselage, back to FS 65.0.
4. If trim cables from elevator are installed, connect cable ends. (If cables from elevator are not installed, pull
cables tight and block them in fuselage at bulkhead 274.0.)
5. With cables installed and connected, install cable guard pins at FS 125.0 and FS 243.5. Close and secure
rub blocks at FS 140.0, 162.0, 174.0, and 215.0.
6. Remove cable blocks.
7. Set cable tension with turnbuckles at approximately FS 220.0 (figure 27-16). (Check rigging of elevator
trim for rigging and adjustments.)
8. Install and seal access plates and panels. Install bullet assembly on vertical stabilizer and install seats.
2H20
27-30-00
Page 11
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF AFT ELEVATOR TRIM ACTUATOR
1. Remove top and bottom cover assemblies from stabilizer to gain access to actuator assembly.
2. Remove cotter pins, nuts, washers, and bolts securing two trim tab rod assemblies to trim actuator.
3. Remove elevator (described in chapter 55, Removal of Elevator). Block trim cables to actuator (figure 27-
21).
4. Remove seats, cabinets, and carpet at F.S. 215.00 to F.S. 251.00. Remove floorboard to gain access to right
side floorboard.
5. Block trim cables at aft side of bulkhead located at F.S. 235.35 (figure 27-2).
6. Mark one set of cable ends to facilitate installation and disconnect cables at turnbuckles. Attach leader lines
to cable ends.
7. Remove bullet assembly from top of vertical stabilizer and elevator trim cable pulley access panels on top
and bottom of horizontal stabilizer (B.L. 36.10).
8. Remove tail cone assembly to gain access to elevator trim cable pulley, located on aft side of bulkhead at FS
368.00.
9. Remove access panel on right side of rear fuselage at F.S. 339.50.
10. Remove cable guide pins from pulleys at F.S. 280.00, 332.00, 344.31, 368.94,418.00, and two pulleys in
horizontal stabilizer at B.L. 34.40 and 36.98. Remove rub blocks at F.S. 251.00.
11. Draw cables aft through fuselage, tail, and horizontal stabilizer.
12. Mark leader lines to facilitate installation. Disconnect from trim cables.
13. Remove six bolts securing trim actuator to horizontal stabilizer rear spar; remove actuator.
INSPECTION OF AFT ELEVATOR TRIM ACTUATOR
Complete the following before reinstalling aft elevator trim actuator:
1. Ensure bearings installed in trim drum move freely.
2. Ensure end play on trim drum is 0.001 to 0.003 mch. Use one of the following methods to ensure proper
end play:
a. Place washer 49981-9, or washer 59486-2, -3, or -4, as required, between bearing and drum.
b. Place laminated shim 70153-2, as required, between trim drum and trim drum bracket.
3. Ensure 0.01 inch minimum looseness between actuator frame. Trim drum bracket guide assembly.
4. Ensure force required to actuate unit at room temperature (60F to 85F) does not exceed 1.5 pounds break-
out force or 1 pound pull on either cable throughout stroke. At -40F, these forces must not exceed 4.5
pounds and 3 pounds, respectively.
INSTALLATION OF AFT ELEVATOR TRIM ACTUATOR
1. Ensure cable is properly wrapped on drum (explained in Wrapping of Trim Drums). Block cables to
prevent unraveling.
2. Position trim actuator on mounting bracket (L.B.L. 42.84). Secure with 6 bolts and washers.
3. Attach leader lines to cable ends. In fuselage at FS 215.00, draw cables through horizontal stabilizer,
vertical fin, and fuselage. Remove leader lines and connect cable ends to appropriate turnbuckle.
4. Install cable guide pins at pulleys in horizontal stabilizer, vertical fin, and fuselage. Install rub blocks at ES.
251.00.
5. Remove cable blocks from cable at trim actuator and aft side of bulkhead at ES. 235.35.
6. Install elevator (explained in chapter 55, Installation of Elevator).
7. Attach trim tab rod assemblies to trim actuator with appropriate bolts, washers, nuts, and cotter pins.
8. Adjust cable tension and trim tab travel using specification in figure 27-17.
27-30-00
Page 12
Reissued December 31, 1989
2H21
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
9. Check trim system friction as described in elevator trim system friction check.
to. Install access panels, cover plates, tail cone, and bullet assembly.
11. Reinstall floorboard, carpet, seats, or cabinetry.
RIGGING OF ELEVATOR TRIM
1. Complete the following steps during installation or as a preadjustment check to adjust elevator trim:
a. Remove access panels on left and right side of fuselage aft of pressure bulkhead at ES. 339.50, access
panels on vertical fin, and bullet assembly on vertical stabilizer. Carefully remove access panel in
control pedestal floor.
b. Ensure trim cables are properly wrapped.
c. Ensure trim cable tension is set according to specifications in figure 27-17.
d. Ensure actuating screws are positioned to anti-rotation bushings are at midpoint of slots.
2. Rotate trim control wheel in cockpit to full nose up position. Ensure turnbuckle tenninal does not strike
pulley.
-NOTE-
If turnbuckle terminal does strike center pulley before actuating
screws are at their stops, disconnect trim tab rods and rotate screws in
drums until screws are at stops before tenninal of turnbuckle strikes
center pulley. It may be necessary to back off trim wheel to reinstall
trim tab rods and anti-rotation bushings.
3. Adjust trim tab rods so tabs are properly positioned with elevators in neutral.
-NOTE-
Rig elevators with elevators in neutral (pinned at aft sector) and
ensure RH elevator trailing edge is aligned with LH elevator trailing
edge. Adjust length of trim tab for 0.12 0.12 inch trailing edge up
from RH tab, as measured on inboard trailing edge of tab.
4. Check rod ends for proper thread engagement.
5. With elevator rigging tool (pIN 72046) installed on left stabilizer and elevator in neutral, rotate trim wheel
in cockpit for tab travels specified in figure 27-17.
6. Coordinate trim wheel indicator with tab position.
7. Use tool L 73035 and a dial torque wrench to check trim system friction at pedestal by removing trim wheel
and attaching tool and torque wrench to splined shaft. Friction must not exceed 9 inch-pounds when tested
in either direction, at any point between limits.
ELEVATOR TRIM SYSTEM FRICTION CHECK
1. Remove elevator trim control wheel from elevator trim actuator shaft in control pedestal (figure 27-20).
2. Attach PAC tool number 73035 and a dial torque wrench to splined shaft of elevator trim actuator.
3. Move elevator trim actuator to its travel limits, in both up and the down directions, using torque wrench.
Friction must not exceed 9 inch-pounds when tested in either direction, at any point between limits.
4. Locate problem area. Repair or replace defective parts if friction exceeds 9 inch-pounds at any point.
2H22
27-30-00
Page 13
Reissued December 31,1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
FREE PLAY CHECK OF ELEVATOR TABS
1. Ensure trim tab is in neutral.
2. Ensure total tab free play, with tab neutral, does not exceed 0.126 inch maximum measured at tab trailing
edge.
TRIM SYSTEMS' CONTROLS AND INDICATORS
The trim controls for aileron, rudder, and elevator trim systems are mounted in the control pedestal. The aileron
and rudder trim controls are connected to cable drums by shafts with aileron trim drum mounted in pedestal, and
rudder trim drum on a channel plate mounted under pedestal. The elevator trim control drum is mounted directly
to elevator control assembly and must be removed along with the assembly.
REMOVAL AND INSTALLATION OF TRIM CONTROLS (figure 27-21)
1. Remove flush head set screw retaining control knob or wheel to splined shaft. Carefully pull wheel/knob
from shaft.
2. Remove and install elevator trim control as follows:
a. Remove control wheel and remove six retaining screws holding indicator plate to the control hub
assembly.
b. Block, disconnect, and pull forward cable system through aircraft (described in paragraph on Removal
of the Forward Elevator Trim System). Remove four mounting screws and pull control assembly from
control pedestal.
c. Reinstall, in reverse order, ensuring indicator is aligned properly.
3. Remove and install the aileron and rudder trim control mechanism as follows:
a. Remove pilot seat and two access plates on side of pedestal.
b. Remove clevis pin connecting control mechanism shaft to universal joint.
c. With control wheel removed, unscrew three indicator retaining screws. Remove indicator.
d. Remove mounting screws and pull assembly from pedestal.
e. Reinstall removed assembly in reverse order, ensuring indicator is aligned in neutral.
ADJUSTMENT OF TRIM INDICATORS
1. Ensure indicator mechanism moves freely and is properly lubricated according to lubrication charts in
chapter 12.
2. Maintain trim tabs at control surfaces in neutral.
3. Ensure trim drums are at neutral positions.
4. Proceed as follows if trim indicators are not aligned with neutral marker on pedestal:
a. Remove trim control wheel from shaft.
b. Loosen three screws holding indicator discs to indicator mechanism.
c. Rotate discs right or left to align neutral position of discs with marker on pedestal.
d. Tighten three screws. Replace trim control wheel.
-NOTE-
For ELEVATOR BALANCING PROCEDURE, see chapter 55.
27-30-00
Page 14
Reissued December 31, 1989
2H23
1. CONTROL PEDESTAL
2. ELEVATOR TRIM CONTROL
3. TRIM POSITION INDICATOR
4. TRIM DRUM( ELEVATOR)
5. RUDDER TRIM CONTROL
6. SHAFT
7. TRIM POSITION INDICATOR
8. AILERON TRIM CONTROLS
9. TRIM DRUM (RUDDER)
10. TRIM CABLES (AILERON)
11. TRIM CABLES (ELEVATOR)
12. MOUNTING BRACKET
13. SAFETY WIRE
14. GEAR
VIEW A-A
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
2
Figure 27-21. Trim Controls Installation
2H24
27-30-00
Page 15
Reissued December 31, 1989
FLAPS
PIPER AIRCRAFT
PA-42/42720
AIRPLANE MAINTENANCE MANUAL
DESCRIPTION AND OPERATION (figures 27-22 and 27-23)
The wing flap control system provides continuous control and monitoring of flap position and condition over its
full range. In addition to limiting both up and down overtravel, the system will shut off the driving mechanism in
the event of a 5 differential between right and left flap position, and will self-monitor and react appropriately
during a critical component failure in the control circuitry.
Preselection of any desired flap position from full up (0) to full down (30) is possible by positioning the
selector control. The selector incorporates a friction type drag brake to hold the lever at any desired intermediate
position, as well as ball lock detents at 0, 10, and 30 of flap extension. Flaps are deployed mechanically by a
single motor drive thru flexible shafts connected to individual ball screw actuators.
Selection of flap position moves the control rheostat relative to the left wing flap rheostat, with a resultant
amplifier output which operates flap motor through contactors Kl and K2, and moves the left and right flaps to
the desired position. If at any time, the amplifier senses a differential voltage in excess of 0.5 V dc between left
wing rheostat and right wing rheostat, the amplifier will shut the system off. This condition corresponds to a
maximum differential of 5 of flap position.
A flap fault test switch is provided to check control circuitry for asymmetrical flap protection, as well as
operation of the fault lamp switching transistor. Activation of this switch, while flaps are in motion, gives a false
signal to the right side follower potentiometer, simulating an out-of-sync condition and causing the amplifier to
shut the system off and illuminate the fault light. Release of the switch clears the simulated fault and allows the
system to respond normally to selector position command.
REMOVAL OF FLAP ACTUATOR MOTOR (figure 27-23)
1. Remove center floor panel in main cabin area. The flap actuator motor is located on forward side of
Bulkhead Station 174.00.
2. Disconnect electrical leads from motor.
3. Cut safety wire and disconnect flexible drive shaft ends from motor.
4. Remove clamp holding motor units mounting bracket. Remove motor.
5. Replace shock grommets from bulkhead by removing motor with mounting bracket from bulkhead.
INSTALLATION OF FLAP ACTUATOR MOTOR (figure 27-23)
1. Install shock grommets in bulkhead at F.S. 174.00.
2. Install flap actuator motor and bracket, if previously removed, on forward side of bulkhead. Ensure anti-
rotation pin on motor fits in mounting bracket pinhole. Secure holding clamp.
3. Connect flexible drive shaft ends to motor, attach nut finger tight, and secure with MS20995-C4l safety
wire.
4. Connect electrical leads.
5. Check flap rigging and adjustments (figure 27-28).
6. Install access plates and panels.
211
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Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
If ..... CIR. BKR.
MOTOR CIA. BKA.
FLAP TEST SWITCH
POSITION INDICATOR
/
I
'\
RIGHT /
:rRANSMISSIO /' $
POWER CONTACTOR
UP LIMIT SWITCH
LEFT CONTROL POTENTIOMETER
PPS 50035
......
"
..............
RT2
o

RT3
(JJ
AMPLIFIER ADJUSTMENT AND TEST PIONTS
-NOTE-
SHOULD CONTROL POTENTIOMETERS WITHIN THE WINGS NEED
REPLACEMENT A SPECIAL TOOL CAN BE FABRICATED LOCALLY TO
FACILATE REMOVAL AND INSTALLATION. REFER TO CHAPTER 95
FOR SPECIFICS ON THIS TOOL.
Figure 27-22. Flap System Diagram
REMOVAL OF FLEXIBLE ACTUATOR SHAFT (figure 27-23)
1. Remove center floor panel in main cabin area.
2. Remove right and left row of seats and floor panels aft of main spar.
3. Remove aft access plate on fairing on underside between fuselage and wing.
4. Remove access plates at aft side of wheel well at Wing Stations 40, 47, and 56, on underside of wing at
Stations 34.50, 42.50,82.75, and 92.50 and on false spar at Stations 42.5,53.00,92.5, and 101.0.
S. Cut safety wire. Disconnect shaft from actuator motor and flap transmission.
6. Remove support clamp on fuselage bulkhead and support grommets in wing and fuselage.
7. Remove actuator shaft.
27-50-00
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Reissued December 31, 1989
212
1. INDICATOR, FLAP POSITION
2. SELECTOR SWITCH
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
10. NUT 20. SENDER SHAFT
11 . SHAFT ASSY. 21. SENDER ARM
3. RIGHT TRANSMISSION ASSEMBLY 12. SAFETY WIRE .040 22. FLAP POSITION SENDER
4. RIGHT SHAFT ASSEMBLY 13. MOTOR MOUNTING BRACKET 23. UP LIMIT SWITCH
5. MOTOR 14. LIN KAGE ROD 24. UP LIMIT ADJUSTMENT BOLT
6. LEFT SHAFT ASSEMBLY 15. BUSHING AND SCREW ASSY. 25. DOWN LIMIT ADJUSTMENT BOLT
7. LEFT TRANSMISSION ASSEMBLY 16. FLAP HORN 26. ATIACHMENT BOLT ASSY.
8. FLAP POSITION SENDER ASSY. 17. BOLT ASSY.
9. LEFT SHAFT ASSEMBLY
5
12
10
SKETCH A
18. TRANSMISSION TUBE
19. DOWN LIMIT SWITCH
BOLT AN3-4A
WASHER AN960-10L
GROMMET MS35489-33
NUT MS20365-1 032C
7
26--+u:eJ
11
27. GROMMET
28. SENDER ARM BOLT ASSY.
19
22
28

20 27
10 6
SKETCH B
15
17 16

I
Figure 27-23. Flap System Installation
213
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Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF FLEXIBLE ACTUATOR SHAFT (figure 27-23)
1. Draw shaft through wing into fuselage.
2. Connect flexible drive shafts to transmissions. Ensure splines are properly engaged and install shaft
attaching nuts on finger tight. Safety nuts with MS20995-C41 safety wire.
3. Check flap rigging and adjustments.
4. Install access plates, panels, clamps, grommets, and seats.
INSPECTION OF OUTBOARD WING FLAP TRANSMISSION (figure 27-24)
The flap transmissions are inspected at the first 500 hour inspection cycle of the aircraft and each 100 hours
thereafter. This is accomplished without removal of the transmissions of the following procedures:
1. Position the flaps in the extended position (DOWN).
2. Remove the access covers on the lower wing surface to gain access to the flap transmissions.
3. With the use of vise grip pliers and exerting light pressure, grasp the exposed portion of the screw close to
the transmission as shown (refer to views A and B).
-NOTE-
With the pliers secured to the screw, a light pressure will move the
pliers and screw as free play in the transmission gear set is taken up
in either direction. Do not force the pliers.
4. Place a six-inch ruler along the skin surface as shown in view B and measure the overall distance the pliers
move.
5. Should the dimension exceed 0.300 of an inch, replace the transmission assembly.
6. Reinstall the access panels and make appropriate logbook entry.
7. Continue inspection at 100 hour intervals.
INSPECTION OF INBOARD WING FLAP TRANSMISSION
This inspection is performed at the same time the outboard wing flap transmission inspection is performed. To
perform inboard wing flap transmission inspection, proceed as follows:
1. Using appropriate tools, check and record flap position at full up and full down positions.
2. Extend flaps to full down position.
a. Pull flap motor control circuit breaker. Remove power (APU, etc) from aircraft.
b. Remove access panels to flap transmissions.
c. Remove nut, washer, and bolt from both inboard and outboard flap transmissions at flap attach hom on
right flap.
d. Remove nut retaining the potentiometer arm and free arm from flap on the left flap. Remove nut,
washer, and bolt from inboard and outboard flap transmission.
3. Gently lower flaps by hand to their fully extended position. Ensure that the right flap potentiometer arm
straightens out smoothly.
4. Mark outboard flap transmissions and take care that housing is not moved in or out from original position.
5. Tum inboard flap transmission housing out to its full extension. Keep track of the number of turns to
ensure turning housing back to original position.
6. Attach locking pliers to inboard transmission screwjack. Do not force pliers.
a. Place a six-inch ruler perpendicular to bottom wing skin.
b. Measure freeplay from center of flap transmission down (approximately 3 inches). Freeplay must not
exceed 0.180 inches.
27-50-00
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Reissued December 31, 1989
214
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
~ T .30 MAX
t
FWD

.
r.
c
'I
FIGURE A FIGURE B
Figure 27-24. Wing Flap Transmission Inspection
7. Tum inboard flap transmission housing in to number of turns previously counted.
a. Raise right flap until bolt holes in inboard and outboard flap transmission align with bolt holes in flap
hom. Ensure that flap potentiometer ann retracts properly.
b. Grease transmission bolts with small amount of general grease. Install transmission' bolt, washer, and
nut, and safety with cotter pin.
c. Perfonn steps a and b for the left flap. When transmissions are connected, connect potentiometer ann
to flap and tighten nut.
8. Using the flap rigging tool, check value in full down position. Value should match value detennined in step
1.
9. Lubricate screw jacks per chapter 12 in maintenance manual.
10. Install access covers on wings.
11. Check that flap handle is in full down position.
12. Reset flap control circuit breaker and tum master switch on. Flaps should remain stationary.
-NOTE-
Flap motor may surge for one second if down limit switch was moved
or not completely contacted.
13. While having someone outside the aircraft to watch, raise the flaps in small increments until the flaps are
fully retracted. Ensure that both flaps raise in a consistent manner.
14. Check degree of flaps in full position. Ensure that measurement matches measurement in step 1.
REMOVAL OF FLAP TRANSMISSIONS (figure 27-23)
1. Lower the flap and remove the access plate on the aft underside of the wing and the false spar area, both of
which are at W.S. 92.50 and 42.50.
2. Disconnect the transmission tube from the flap hom bracket.
215
27-5000
PageS
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PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
3. Remove the safety wire and disconnect the flexible actuator shaft.
4. Remove the spreader bushing and washers from between the transmission attachment brackets.
5. Remove the transmission from its mounting brackets and draw the unit through the access opening in the
wing false spar.
DISASSEMBLY OF FLAP TRANSMISSION (Refer to Figure 27-25.)
-CAUTION-
CALCO FLAP TRANSMISSION DISASSEMBLY AND
ASSEMBLY PROCEDURE ARE INCLUDED IN THIS
MAINTENANCE MANUAL FOR INSPECTION PURPOSES
ONLY. CALCO DOES NOT RECOMMEND OVERHAUL IN
THE FIELD.
1. Remove safety wire, bolts (2) and rear housing (1).
2. Remove O-ring (3).
3. Straighten tang on lockwasher (5) so that locknut (4) and lockwire (5) can be removed.
4. Remove ball screw and tube assembly (S).
5. Remove bearing assembly (6) and shim (7).
6. Remove worm gear (120, key (13) and shim (7).
7. Remove front bearing assembly (14) from housing.
S. Remove protective cap (15) ifused.
9. Remove screws (17) and both output flanges (16).
10. Push worm shaft (20) and bearings (19) out of housing.
11. Remove O-ring (22) from housing.
12. Bumper washer (25) is attached to the housing with Locktite adhesive. Use Locktite solvent, if necessary to
remove washer.
13 Remove safety wire, screws (10), and wiper block (9) and wiper (11) from ball screw and tube assembly (8).
14. Place a container or tray under the ball screw and tube assembly and remove the two screws securing the
ball return tube to the ball nut.
-CAUTION-
DO NOT ATTEMPT TO REMOVE THE OUTPUT TUBE
FROM THE BALL NUT. THE OUTPUT TUBE IS FORM
ROLLED TO THE BALL NUT DURING MANUFACTURE
AND MUST BE SERVICED AS AN ASSEMBLY.
15. Carefully remove the ball return tube and separate the two halfs allowing the steel balls to drop into a
container. Turn the ball nut over and rotate the ball screw until all steel balls (67 - 69 total) have dropped
out, allowing the ball screw to be removed from the ball nut.
27-50-00
Page 6
Reissued December 31, 1989
216
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
16
18
19
20 21
I
/.!2 24 26222325'-
5
1. HOUSING, REAR
2. BOLT, MACHINE
3. O-RING
4. NUT, LOCK
5. WASHER, LOCK
6. BEARING ASSY, REAR
7. SHIM
8. BALL SCREW AND TUBE ASSY
9. BLOCK, WIPER
10. SCREW, MACHINE
11. WIPER
12. WORMGEAR
13. KEY
14. BEARING ASSY, FRONT
15. CAP, PROTECTOR
16. FLANGE, OUTPUT
17. SCREW, MACHINE
18. SHIM
19. BEARING, BALL
20. SHAFT, WORM
21. HOUSING ASSY, FRONT
22. O-RING
23. INSERT, HEll-COIL
24. INSERT, HEll-COIL
25. WASHER, RUBBER BUMPER
26. HOUSING, FRONT
SEE SKETCH
A
.... ----SCREWS
CLAMP
STEEL
"""'---BALLS
OUTPUT
TUBE
SKETCH A
(67 - 69)
Figure 27-25. Wing Flap Transmission Actuator Screw Jack.(Exploded View)
217
27-50-00
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Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
SERVICE AND INSPECTION OF FLAP TRANSMISSION INTERNAL COMPONENTS (CALCO)
-CAUTION-
ALL DEFECTIVE OR WORN PARTS MUST BE REPLACED
WITH NEW PARTS. DO NOT ATTEMPT TO REPAIR
DEFECTIVE PARTS.
1. Wash all disassembled parts in a suitable dry cleaning solvent.
2. Thoroughly clean off old sealant and adhesive.
3. Dry parts thoroughly using low pressure compressed air, or wipe dry with a clean, lint-free cloth.
4. Examine all parts for cracks, burrs and corrosion
5. Visually inspect balls and grooves in ball screw for pitting, scoring, corrosion and flat spots.
-NOTE-
If anyone part of the ball screw and/or tube assembly appear
defective, the entire ball screw and tube assembly must be replaced.
6. Discard and replace all bearings, O-rings, wipers and bumper washer.
7. Inspect worm shaft and worm gear and wonn shaft for excessive wear. If wonn gear is worn more than
0.015 inch the wonn gear and wonn shaft must be replaced as a set. (Refer to Figure 27-26)
27-50-00
Page 8
Reissued December 31, 1989
MEASURE STEP
IN TOOTH FORM
Figure 27-26. Checking for Wonn Gear Wear.
218
PIPER AIRCRAFT
PA42/ 42 720
AIRPLANE MAINTENANCE MANUAL
ASSEMBLY OF FLAP TRANSMISSION (CALCO) (Refer to Figure 27-25.)
1. Assemble ball screw and tube assembly (8) as follows:
a. Apply a thin coat of Aeroshell NO.7 grease, or equivalent to entire thread of ball screw.
b. Insert ball screw part way into ball nut and output tube assembly.
c. Lay one half of ball return tube flat on a table and fill groove with steel balls. Place the other half of the
ball return tube on the assembled balls.
-NOTE-
A light coat of Aeroshell No 7 or equivalent may be used to hold the
balls in place.
-CAUTION-
DO NOT ALLOW THE BALLS TO ROLL OUT EITHER END
OF THE BALL NUT.
d. Insert the remaining steel balls into the ball nut by placing them in one of the hales and turning the ball
shaft until all the balls are in place.
e. Carefully install the ball return tube onto the ball nut and secure wit clamp and two screws. Apply a coat
of Dow Corning 732 RTV adhesive, or equivalent to the ball return tube to seal external openings.
f. Apply a lubricant consisting of 20% Aeroshell No. 7 grease and 80% Mobile Jet II Oil or an equivalent
mixture, to the wiper (11). Install wiper and wiper block (9) onto the ball nut and secure with screws
(10).
g. Safety wire (MS20995-C20) the screws on the ball nut.
2. Clean bumper washer (25) with chlorothane, or equivalent and attach to housing (26) with a thin film of
Locktite 495 adhesive, or equivalent.
-NOTE-
Special tools, Pin 7801-Tl, 7801-T2 and 7801-T3 can be purchased
from C.E.P. Industries, 423 Interstate Road, Addison, illinois
3. Insert tool fixture 77801-Tl and 7801-T2 into wonn shaft bearing bores. Insert pin through tool fixtures
and bearing bores (refer to Figure 27-27). Take measurement with depth gauge from milled surface of
housing to outside diameter (O.D.) of pin, add 1/2 diameter of pin and record this dimension (Z dimension).
Remove tool fixtures.
4. Install new O-rings (22) in wonn shaft bore of housing. Apply a thin film or 20% Aeroshell No.7 grease
and 80% Mobil Jet II OHlubricant, or equivalent to O-rings.
5. Insert wonn shaft (20) into housing.
6. Insert both ball bearings (19) into housing, making sure bearings are seated.
7. Attach one output flange (16) and secure with four screws (17). On opposite side attach output flange with
two screws. Using a dial indicator, check end play of wonn shaft and add shim (18) as required to obtain
0.004 to 0.010 inch end play. Secure with four screws (17).
8. Insert tool 7801-T3 onto spline of wonn shaft and check that shaft torque does not exceed 12 in. oz.
9. Insert front bearing assembly (14) into front housing assembly (21).
-NOTE-
Shoulder of bearing is to be pressed into bumper washer (25).
219
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PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
10. Take measurement from milled surface of housing to inner race (14) Y dimension. Subtract Z dimension
taken in first measurement from Y dimension (refer to Figure 27-36).
11. Measure width of worm gear (12) face. Take hale the thickness and subtract this from A dimension
obtained in second measurement. Subtract 0.001/0.002 inch from results. This is the shim (7) thickness
required (refer to Figure 27-36).
12. Place shim (7) over top of front bearing (14). Place worm gear (12) over shim, shoulder end up.
13. Take measurement from milled surface of housing to shoulder of worm gear (12) W dimension (refer to
Figure 27-36). Measure width of rear bearing (6) K dimension. Subtract the two measurements. Subtract
0.001/0.002 from results. This is the shim (7) required.
-NOTE-
Do not install the shim at this time.
14. Apply approximately 1/8 oz. of lubrication consisting of 20% Aeroshell No.7 grease and 80% Mobil Jet II
Oil, or equivalent mixture, to worm shaft and wonn gear. Rotate wonn shaft while applying.
15. Install ball screw and tube assembly (8) through bearing and worm gear in front housing and line up
keyways.
-NOTE-
Keep worm gear and wonn shaft in mesh while inserting.
16. Insert key (13) in keyway.
17. Place shim (7), previously detennined on top of worm gear.
18. Place rear bearing (6), flange side up, in housing.
19. Place lockwasher (5) over ball screw. Thread locknut (4) (chamfered side down) onto screw.
-CAUTION-
MAKE SURE BALL NUT AND TUBE ASSEMBLY (8) IS
POSITIONED AWAY FROM HOUSING BEFORE
TIGHTENING LOCKNUT.
20. Tighten locknut (4) to a torque of 80 in.lbs. minimum to align lockwasher tang with slot in nut. Bend tang
into slot.
-CAUTION-
MAKE SURE THAT NO CHIPS ARE FORMED DURING
TIGHTENING OF NUT.
21. After tightening nut, measure distance from milled surface of housing to outer race of rear bearing. Reading
should be between 0.001/0.004 inch.
22. Place O-ring (3) into O-ring groove in housing. Install rear housing (1) and attach with bolts (2). Tighten
bolts to a torque of 35-40 in. lbs.
27-50-00
Page 10
Reissued December 31, 1989
2110
r-
I)
\0:_
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
X
+0.164"
T
PIN DIA.+ 2 = 0.164"
(0.328" REF)
(t) FiRST READING
NOTE: SHOULD READ 0.750" (REF.)
Y

(A) SECOND READING
FIRST MEASURMENT
MEASURE GEAR
FACE (0.282" REF.)
DIVIDE BY 2 = "L"
A
-L
ANS
SUBTRACT 0.001/0.002"
FOR SHIM REQUIREMENT
WORM GEAR
SECOND MEASUREMENT
SHIM
THIRD MEASURMENT
Figure 27-27. Flap Transmission Measurements
2111
27-50-00
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Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
MEASURE REAR BEARING
"K" WIDTH, SUBTRACT
FROM DIMENSION "W"
W

A\
SUBTRACT 0.001/0.002"
FOR SHIM REQUIREMENT
"W'
_-+-----. FRONT BEARING
WORM GEAR
SHIM
FOURTH MEASURMENT
Figure 27-27. Flap Transmission Measurement (continued)
INSTALLATION OF FLAP TRANSMISSION (figure 27-23)
Determine that the correct flap transmission assemblies are being installed by checking the part numbers on the
assemblies with information in the latest PA-42/42-720 Parts Catalog.
1. Lubricate the flap transmission assembly in accordance with lubrication chart.
2. Insert the transmission through the access opening in the wing false spar and attach to its mounting brackets.
To allow the transmission to rotate, tighten the attachment bolts (only finger tight) and safety.
3. Install the spreader bushing with one washer between each mounting bracket and bushing. Install the
through bolt and secure.
4. If working with the left transmission, connect the flexible actuator shaft and safety with MS20995C4l
safety wire. Attach the right flexible shaft during rigging and adjustment.
5. Safety wire (MS20995-C20) protective cap (figure 27-23) on outboard transmission.
6. Check the flap rigging and adjustment.
7. Install access plates.
27-5000
Page 12
Reissued December 31, 1989
2112
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF FLAP CONTROL BOX (SELECTOR)
1. Remove knob from control box.
2. Remove electrical connector from rear side of control box.
3. Remove two screws securing control box to instrument panel.
4. Remove control box from instrument panel.
INSTALLATION OF FLAP CONTROL BOX
1. Install flap control box in instrument panel.
2. Install two screws securing control box.
3. Connect electrical leads.
REMOVAL OF FLAP CONTROL AMPLIFIER
1. Open access door in nose of airplane to gain access to amplifier at Station 25.60.
2. Disconnect electrical plug from amplifier.
3. Remove attaching screws. Remove amplifier from airplane.
INSTALLATION OF FLAP CONTROL AMPLIFIER
1. Install control amplifier in airplane. Secure with attaching screws.
2. Connect electrical plug to amplifier.
3. Check rigging and adjustment of flaps.
4. Close and secure access door.
RIGGING AND ADJUSTMENT OF FLAPS PPS-SOO3S-M
The rigging procedure for this wing flap system is both mechanical and electrical and requires that the landing
gear be raised or squat switches in the left main gear be made to the in-flight position. The control system, in
addition to providing proportional preselect, also incorporates circuitry for system shut-down in the event of any
asymmetrical flap condition of five degrees, and control of flap transmission stroke length in both extend and
retract positions. The main components of the control system are: a control amplifier that supplies voltage for
and receives signals from three separate reostats used in the system. Two of three reostats are linked (one to the
left and one to the right) wing flap assemblies in such a manor as to sense flap position. The third rheostat is
located in the wing flap position selector and is the control for flap positioning. The following abbreviations are
used in description and service information presented in the following paragraphs:
RC- Control Potentiometer Wiper at Selector.
RL- Left Wing Flap Potentiometer Wiper.
RR- Right Wing Flap Potentiometer Wiper.
A VCL- Voltage difference from (RL to RC - .10).X 2 in the up position.
A VCR- Voltage difference from (RC to RR - .10) x 2 in the up position.
REQUIRED EQIDPMENT
Digital Voltmeter (10 Miliamp Scale)
Rig Board flap tools (PIN 71505-16 and 71505-17)
Work Sheet (figure 27-29)
2113
27-50-00
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PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
-WARNING-
ALL ADJUSTMENTS MUST BE MADE WITH MOTOR POWER
OFF.
All adjustments are made with motor circuit breaker pulled OFF and flaps in DOWN position. Adjusnnent
procedures require special equipment such as a digital voltmeter and flap rigging tool (PIN 71505-16 and -17).
(See chapter 95 for fabrication instructions of rigging tools.)
-CAUTION-
ELECTRICAL POWER TO SYSTEM MUST BE OFF. PULL
FLAP CONTROL AND MOTOR CIRCUIT BREAKERS, SET
BATTERY MASTER SWITCH OFF, AND DISCONNECT
EXTERNAL POWER.
The control potentiometer operated by the flap selector is referred to throughout the rigging procedure as RC
(potentiometer control). The wing flap potentiometers are designated as RL (potentiometer left) and RR
(potentiometer right). The voltages at the center taps are referred to as VC, VL, and VR respectively.
Proper operation after rigging requires potentiometer RL on the left flap must respond to changes in flap
position selector potentiometer RC in VL and VC. Amount of stroke travel and how it is centered with respect to
ends is determined by how RL is adjusted relative to RC. Since VC is fixed and cannot be changed, trimmer pot
RT2, provided in the control amplifier, allows adjustment of VL to agree with VC.
Throughout adjustment procedures, whatever changes are made to RL and RT2 must also be made to RR and
RT3. RR tracks RL over entire stroke range and shuts system off if VL and VR outputs deviate by more than 0.5
volts. This voltage differential corresponds to a five-degree asymmetrical flap condition. RR also provides a
voltage input to the control amplifier to give an output to the flap position indicator.
-NOTE-
Adjustments of RL, RR, RT2, and RT3 are always made with flaps
down. The magnitude of these adjustments, based on values of VC,
VL, and VR, are measured with flaps up.
PREPARATION FOR RIGGING
-CAUTION-
ELECTRICAL POWER TO FLAP CONTROL SYSTEM MUST
BE OFF. PULL FLAP CONTROL AND MOTOR CIRCUIT
BREAKERS, SET BATTERY MASTER SWITCH OFF, AND
DISCONNECT EXTERNAL POWER.
1. Remove access plates in false spar at Wing Stations 42.50, 53.00, 92.50, and 101.0 for both right and left
wings.
2. Remove access plates on bottom side of wings at Wing Stations 34.50,42.50, 82.75, and 92.50.
3. Ensure flap position sender arms rotate freely on potentiometer shafts, with linkage rods set at proper length
(figure 27-28, Sketch B).
4. With transmission assemblies NOT attached to flap and turned into ball nut seat, ensure flaps are free to roll
full travel (0 to 30) on flap tracks.
5. Attach flap rigging tools to Wing Station 147.50 to measure flap deflection angles.
27-50-00
Page 14
Reissued December 31,1989
2114
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
SKETCH A
a.6S
t
Oa
CRtitcAL L
l;;. GiH
SKETCH B
Figure 27-28. Flap Rigging
2115
ACTUATOR ARM
ROD LINKAGE
--TOOL PIN 71505 -16
TOOL PIN 71505 - 17
-NOTE-
REFER TO CHAPTER 95 FOR
FABRICATION OF RIGGING TOOLS.
27-50-00
Page 15
Reissued December 31,1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
MECHANICAL RIGGING PROCEDURE
1. Adjust UP limit actuating bolt by manually moving left flap so switch is actuated with flap trailing edge at
0 on rigging tools.
2. Manually move left flap to full down (30 + 1 - 0) position on rigging tool. Thrn transmission sleeves out
from forward stops, record number of turns, align attachment hole in sleeves, with holes in respective flap
horns, and temporarily install attachment bolt. Adjust DOWN limit actuating bolt to actuate switch.
-NOTE-
Difference in number of turns between inboard and outboard
transmissions must not exceed 112 tum.
3. Thrn right flap transmission sleeves out from forward stops (using equal number of turns used for left flap
transmission sleeves), align attachment hole in sleeves with holes in respective flap horns, and temporarily
install attachment bolt.
4. Ensure proper alignment of sleeve and flap hom. If sleeve and hom do not align, loosen bolts attaching
hom to flap, and tap hom to achieve proper alignment. Retorque hom attachment bolts.
5. With sleeve and hom properly aligned, connect sleeve to hom with bolt and castellated nut. Tighten nut to
allow 0.03 inch bolt thrust play. Install cotter pin.
6. Connect flexible drive shafts to transmissions. Ensure splines are properly engaged and install shaft
attaching nut finger tight. Safety with MS20995-C32 wire.
ELECTRICAL RIGGING PROCEDURE
1. Remove covers from RT2 and RT3 on flap control amplifier. Ensure both trimmers are positioned fully
clockwise. Insert 30 amp fuse (for test purposes only) in flap motor electrical power connection.
2. Apply external power to aircraft and establish bus voltage of 28 0.5 volts.
3. Place flap selector in DOWN position.
4. Engage flap control circuit breaker, but DO NOT engage flap motor circuit breaker. Allow five minute
warm-up time.(Flap should still be down from mechanical rigging)
5. Insert "PLUS" test lead from digital voltmeter, into RC test point on controller and ":MINUS" test lead into
RL. Adjust shaft of left wing potentiometer for a reading of +O.lOv. and lock actuator arm to pot shaft. Be
sure that voltage has not changed while locking actuator arm. (Record voltage on work sheet.)
6. Move "MINUS" test lead to RR test point and adjust right wing pot. to +0.10v. Lock actuator arm to pot.
shaft. Check that voltage does not change while locking actuator arm. ( Record voltage on work sheet)
-NOTE-
All measurements must be taken at control amplifier.
7 Depress (but do not engage) motor circuit breaker and move flap selector to UP; ensure flap motor is wired
correctly (flaps move up). If not, reverse wiring; if correct, engage breaker.
-NOTE-
If flaps will not move to full up position, hook a jumper between RL
and RR. When flaps are up remove jumper.
8. With flaps in full up position, ensure .010 minimum clearance between actuator sleeves and rubber seals.
27-50-00
Page 16
Reissued December 31, 1989
Interim Revision: January 9, 1998
2116
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
9. With DVM "PLUS" lead in RC and "MINUS" lead in RL, measure RC/RL voltage. This voltage must be
negative; if not, trimmers RT2 and Rt3 were not fully adjusted CW in step 1.
10. Using the work sheet, perform the following calculation: Change the magnitude of RC/RL by O.lOV and
multiply the remainder be 2. The result is defined as d VCL.
11. Move "MINUS" lead to RR and repeat step 10 for d VCR.
12. Move flap selector down and disengage motor breaker.
13. With DVM "PLUS" lead in RC and "MINUS" in RL, check that voltage has not changed from that in step 5
(If voltage has changed by more than 0.03Y, repeat the entire procedure tasking special care when locking
actuator arm to pot. shaft.)
14. Adjust RT2 so that RC/RL voltage changes by the amount of the d VCL Calculated in step 9 - then, adjust
RL pot. shaft so that RC/RL changes in the opposite direction by d VCL. RC/RL voltage will now be the
same as measured in step 13.
15. Move "MINUS" lead to RR and check that RCIRR voltage has not changed from that in step 6.
16. Adjust RT3 so that RCIRR voltage changes by the amount of d VCR calculated in step 10 - then, adjust RR
pot. shaft so that RC/RR changes in the opposite direction by d VCR. RCIRR voltage will now be the same
as measured in step 15.
17. Engage flap motor breaker and move flaps to UP.
18. Measure RC/RL as in step 8. Voltage must be -0.05V minimum and -0.15V maximum.
19. Measure RC/RR. Voltage must be -0.05V minimum and -0.15V maximum.
20. Move flaps to the DOWN position.
21. Measure RC/RL. Voltage must be +0.05V minimum and +0.30V maximum.
22. Measure RC/RR. Voltage must be +0.05V minimum and +0.30V maximum.
-NOTE-
If the requirements of steps 17 and 20 are not met, repeat the
procedure from step 7 without pre-setting RT2 and RT3. The
calculated d VCL and d VCR will be smaller and the entire rigging
procedure will be easier with each repetition.
23. Insert DVM test leads into RL and RR. Move flaps UP and DOWN While obseIving voltage reading on
DVM. The reading must not exceed 0.10V
24. Run flaps through full cycle three times to ensure proper operation.
25. Measure flap deflection at full down (30 1) and approach (10 + 1) position on both left and right hand
side.
26 Check position indicator readings against flap selector and flap deflection as follows:
a. When measuring flap deflection angles, lift flap trailing edge to eliminate play between rollers and track
slot. If indicator does not correspond to flap position, place flaps in APPROACH position.
b. Adjust flap indicator trimmer, located on inboard end of flap amplifier box (opposite connector end), so
flap indicator needle falls in center of approach graduation.
c. Check location of flap indicator needle in UP and DOWN positions and adjust trimmer so needle
centerline falls within or tangent to upper and lower edge of graduation in UP, APPROACH, and
DOWN positions.
-NOTE-
If trimmer is rotated to raise needle, needle must rise an equal amount
in all three positions.
2117
27-50-00
Page 17
Reissued December 31, 1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
d. If unable to adjust indicator needle for proper indication (as in example below), proceed with steps 1
thru 5 below:
EXAMPLE
Flap Position Needle Indicator
UP Center of Graduation
APPROACH Center of Graduation
DOWN Below DOWN Graduation
(1) Adjust indicator trimmer so flap indicator needle is at upper tangent of graduation at UP and
APPROACH positions.
(2) Adjust RT3 so needle falls with down graduation.
(3) Recheck indicator at UP, APPROACH, and DOWN positions. Readjust trimmer as required.
(4) Recheck VLR and readjust as necessary. RT2 could require readjustment.
(5) Ensure VL and VR are still within limits of VC specified and ensure position indicator agrees
with flap position in UP, APPROACH, and DOWN positions.
27. Locate flap system test switch on lower instrument panel. Move flap selector handle to approach position,
activate test switch, and ensure wing flap caution light, located in annunciator panel, illuminates and flap
travel stops. Release test switch and check flaps for proper opperation.
28. Remove 30 amp fuse installed in step 1. Install all access plates and panels.
27-50-00
Page 18
Reissued December 31,1989
2118
FLAPS DOWN
FLAPS UP
FLAPS DOWN
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
FLAP RIGGING WORK SHEET
STEP 1. RC ( + ) to RL ( - )
STEP 2. RC ( + ) to RR ( - )
STEP 3. RC ( + ) to RL ( - ) VOLTAGE
(CHANGEBY)
(MULTIPLY) X2
L\ VCL=
STEP 4. RC ( + ) to RR ( - ) VOLTAGE
(CHANGEBY)
(MULTIPLY) X2
L\ VCR =
STEPS. ( SAME AS STEP 1. O.03)V
STEP 6.
ADD L\ VCL (STEP 2. )
ADJUST RT2 POT. TO
CHECK ADJUST RL SHAFT
STEP 7. RC/RL VOLTAGE
STEP 8.
ADD L\ VCR ( STEP 4. )
ADJUST RT3 POT. TO
CHECK ADJUST RR SHAFT
RR/RC VOLTAGE
Figure 27-29. Flap Rigging Work Sheet.
2119
+
V
+
V
V
V
V
V
V
V
V





27-500-00
Page 19
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
ELECTRICAL SYSTEM FUNCTIONAL TEST PROCEDURE
-NOTE-
All n connections are airframe conn E410 and KI and K2 relays are
airframe supplied reversing relays.
1. Place left engine bus tie switch, right engine bus tie switch, and non-essential bus tie switch in OFF position.
Pull all essential bus circuit breakers to OUT position.
2. Actuate flap motor and flap control circuit breakers.
3. Tum on battery master switch or connect external power to aircraft.
4. Operate flap selector handle in control box. Observe up and down operation of wing flaps.
5. Check fault light if wing flaps fail to operate. If fault light is on, proceed to step 13. If fault light is off,
proceed to step 6.
6. Ensure 27.5 volts exist at motor contactor and pin 1 of connector n (airframe conn E41O) to verify circuit
breakers and wiring are installed properly.
7. Check for 27.5 volts across power terminals of both Kl and K2 (reversing) relays.
8. Disconnect flex shafts from motor assembly.
9. Remove electrical harness plug from connector n and ground relay KI at pin 6 of connector or relay K2 at
pin 4 of connector. Apply 27.5 volts to drive motor be energizing up and down relays Kl and K2 locally.
10. If drive motor fails to operate, check up and down limit switches in 27.5 volt leg of coils for relays Kl and
K2 for 27.5 volts at NC contacts on limit switches.
11. Check 27.5 volt power at drive motors while an assistant energizes relays Kl and K2. If 27.5 volts does not
exist at drive motor, contacts of relays KI or K2 are defective. Replace defective relays. If drive motor
operates when energizing relays Kl and K2 locally, problem exists in either control box, left wing
potentiometer RL, right wing potentiometer RR, or in flap control amplifier.
12. Reconnect flex shafts to motor assembly. Connect electrical harness plug to connector n.
13. Pull flap motor circuit breaker to prevent flap motor from running remainder of test procedure.
14. Using precision voltmeter (10 volt range), connect negative lead to amplifier, and test jack amplifier and
positive lead to RC test jack. Slowly operate flap selector handle in control box through entire range.
Voltage readings must be approximately 9-volts in DOWN position and approximately 4-volts in UP
position.
15. If RC voltage readings are too high or too low, problem exists in either harness wiring or control box.
Wring out harness wiring and repair or replace, if defective. Replace control box only if harness wiring is
functional.
16. Connect voltmeter between test jacks RR and RL on amplifier. If voltage exceeds 0.5 volts, shut down is
due to flap asymmetry. Correct cause of asymmetry and rerig flap system.
17. Connect voltmeter between test jacks RR and GND on amplifier. Voltage must be within 0.3 volts of RC
voltage.
18. Connect voltmeter between test jacks RL and GND on amplifier. Voltage must be within 0.3 volts of RC
voltage.
19. If voltage readings in either step 17 or 18 exceeds 0.3 volts, shut down is still due to flap asymmetry.
Correct cause of asymmetry and rerig flap system.
20. If problem is not found, replace amplifier.
21. Tum battery master switch OFF or remove external power from aircraft.
27-50-00
Page 20
Reissued December 31, 1989
Interim Revision: January 9, 1998
2120
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INTENTIONALLY LEFT BLANK
Figure 27-30.
2121
27-50-00
Page 21
Reissued December 31,1989
Interim Revision: January 9,1998
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
27-50-00
Page 22
Reissued December 31, 1989
Interim Revision: January 9, 1998
INTENTIONALLY LEFT BLANK
Figure 27-30.
2122
JIG KNIFE EDGE
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
BALANCE LINE
AILERON BALANCE JIG
OUTBOARD BALANCE WEIGHT
NOTE
AILERON PLACED UPSIDE DOWN IN JIG.
Figure 27-31. Aileron Balancing Procedure
2123
TOOL HOLE
27-50-00
Page 23
Reissued December 31, 1989
Interim Revision: January 9,1998
STALL WARNING
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
STALL WARNING/RECOGNITION SYSTEM
The stall indicating system in the PA-42 contains two, identical safe flight SC-200 stall recognition systems,
independent of each other, power, or aircraft configuration. Each system, one for the pilot the other for the
copilot, uses a heated wing mounted lift transducer, a remote lift computer, a stall warning hom, a stall
recognition hom, a lighted placard, and a test switch.
The electro-mechanical lift transducer, mounted to the lower leading edge of the wing, senses the existing
position of the leading edge stagnation point through the spring loaded vane. The appropriate signal is sent to the
computer so when the vane is forced aft, the stall warning hom is activated, and when the vane is forced forward,
the stall recognition hom and lighted placard are activated.
The lift computer is located in the avionics bay, forward of Fuselage Station 57.0 pressure bulkhead. Signals
from the transducer are conditioned by the computer which activates the stall warning or recognition system
through a two-level output. A self monitoring circuit in the computer activates a warning light if any essential
internal or external power is lost.
The stall warning system contains a separate hom and a lighted placard. The stall recognition hom, also
mounted in the headliner, emits a loud, pulsating tone different than the stall or gear warning horns. The lighted
placard (STALL), mounted in the edge of the glareshield, is keyed simultaneously with the recognition hom.
A single test switch is mounted on the instrument panel below the fire warning light/switches. On the ground,
activation of the switch bypasses the right gear squat switch, turns on the computer, and slews the transducer vane
upward. This provides the necessary signals to activate the horns and lighted placard. If the switch is activated in
flight, the computer senses the inability of the low control voltage to move the vane against the relative wind, and
it generates a simulated signal activating the systems.
FUNCTIONAL TEST OF SYSTEMS
STALL WARNING FUNCTIONAL TEST PPS60089M
Establish 28 Vdc on essential buss. Ensure stall warning, stall warning heat, "q" sensor, annunciator, and
annunciator malfunction circuit breakers are pushed in.
STALL WARNING SYSTEM SELF TEST
1. Activate stall warning test switch on lower left instrument panel.
2. Ensure lift transducer vane, located in leading edge of outboard lift wing, moves forward and stall warning
and stall recognition (stall warning annunciator) activate. Release test switch.
-CAUTION-
STALL WARN HEAT MUST BE OFF.
2124
27-90-00
Page 1
Reissued December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
3. Manually move lift transducer forward (up). Ensure hom and light do not operate.
a. With lift transducer held forward, place left main gear squat switch to IN-FLIGHT position. Ensure
stall warning and stall recognition activate.
b. Release left main gear squat switch and lift transducer vane.
4. Perform same test for right wing installation.
5. Activate left and right pitot/stall heat switches located on overhead switch paneL
a. Ensure lift transducer vane and mounting plate on both wings become warm and ensure stall heat indicator
(blue) located on upper portion of the left circuit protection panel illuminates.
-CAUTION-
DO NOT ACTIVATE Q OVERRIDE SWITCH.
b. Tum off both pitot and stall heat switches.
FORCE APPLICATOR KIT TEST
The lift computer adjustment potentiometers are factory set to nominal values for activating the pre-stall hom,
and the stall recognition light and hom. Actual values for these settings have been determined during flight test
of the aircraft and are recorded in the aircraft flight logbook at the time of certification.
Upon replacement of the lift computer or lift transducer, the computer settings must be adjusted, if different, to
the logbook values. To make these adjustments, use Safe Flight Instruments Corporation Force Application Kit
(PIN 1952-3) as follows;
1. Attach position bracket to lift transducer cavity (shown in figure 2-1 of kit operation handbook).
2. Attach proper gauge to positioner for each of the next two setups.
3. Check tip gram setting at which the pre-stall warning occurs. If different than the logbook valve, adjust
screw #1 (under top cover of lift computer) for proper value of tip grams.
4. Check tip gram setting at which the pre-stall recognition light and hom activates. If different than the
logbook value, adjust screw #2 (under top cover of lift computer) for proper value of tip grams.
5. Remove force application kit.
6. Reinstall all panels removed for this test.
27-90-00
Page 2
Reissued December 31, 1989
2J1
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
GRIDS 2J2 THRU 2J4
INTENTIONALLY LEFT BLANK
2J2
27-90-00
Page 3
Reissued December 31, 1989
CHAPTER
FUEL
2J5
SYSTEM
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 28 - FUEL
TABLE OF CONTENTS/EFFECTIVITY
SUB-SYSTEM SUBJECT
28-00-00
28-00-00
28-00-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-10-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
GENERAL
Description and Operation
Troubleshooting
STORAGE
Removal of Wing Tip Tanks
Installation of Wing Tip Tanks
Removal of Wing Fuel Cells
Cleaning and Inspection of Fuel Cells
Fuel Cell Compartment
Molded Nipple Fittings
Installation ofInboard, Aft-Inboard, and Outboard
Fuel Cells
Handling and Storage of Fuel Cells
Repair of Fuel Cells
Handling of Repair Materials
Repair Limitations of Fuel Cells
Repair Patch (Heat Cure Method)
Repair Patch (Air Cure Method)
Metal Fitting - Sealing Surfaces
Fuel Cell Accessory Replacement
REPAIR OF FUEL CELL DEFECTS
Testing Fuel Cells
Fuel Vent System
DISTRIBUTION
FUEL VALVES
Removal of Fuel Valves
Overhaul of Fuel Shutoff Valves
Adjustment of Fuel Shutoff and Crossfeed Valve
Leakage Test of Fuel Shutoff and Crossfeed Valve
Installation of Fuel Valves
FUEL FILTER
Removal and Cleaning of Fuel Filter Screen
Installation of Fuel Filter Screen
Installation of Fuel Filter
2J6
GRID
NO.
2J8
2J8
2J8
2Jl5
2J15
2Jl5
2Jl5
2J23
2J23
2J24
2J24
2K3
2K4
2K4
2K5
2K8
2KlO
2Kl2
2K12
2K13
2K13
2K15
2K16
2K16
2K16
2K16
2K17
2K17
2K17
2K19
2K19
2K20
2K20
EFFECTIVITY
28 - Cont.lEffec.
Page - 1
Reissued: December 31, 1989
SYSTEM
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 28 - FUEL (continued)
TABLE OF CONTENTS/EFFECTIVITY
SUB-SYSTEM SUBJECT
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-20-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28-40-00
28 - ContJEffec.
Page - 2
DISTRIBUTION (continued)
FUEL JET PUMPS
Servicing Jet Scavenger Pump
Removal and Installation of the Jet Transfer Pump
Jet Pump Flow Check
Removal and Installation of Submerged Fuel Pump
Fuel Flow and Pressure Tests
INDICATING
Description and Operation
Removal and Installation of Sensor Units
Nacelle Tank Sensor
Aft Inboard and Main Fuel Cell
Main Inboard Fuel Cell Sensor
Wing Tip Tank Sensor
Fuel Quantity Indicator
Tank Sensor Units
Cleaning of Tank Units
Fuel Quantity Capacitance
CHECKS AND ADJUSTMENTS OF
FUEL QUANTITY SYSTEM
Bench Testing of Tank Units
Fuel Quantity System Calibration Tests
Dry Calibration Procedure
Wet Calibration Procedure
Automatic Fuel Pump System
Test of Automatic Fuel Pump System
Reissued: December 31, 1989
2J7
GRID
NO.
2K20
2K21
2K22
2K22
2K23
2Ll
2L2
2L2
2L2
2L2
2L2
2L2
2L4
2L5
2L5
2L5
2L6
2L7
2L7
2L7
2L7
2Lll
2Lll
2L12
EFFECTIVITY
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
GENERAL
DESCRIPTION AND OPERATION
The PA-42 contains individual fuel systems (shown in figures 28-1 and 28-2) in each wing for each engine.
Each standard fuel system consists of a wing tip tank and three bladder type tanks providing 200 gallons of fuel
for each engine. The 85 gallon integral nacelle tank, standard equipment in the PA-42-720, is optional in the PA-
42 models.
The fuel vessels within each wing are interconnected by feed and vent lines, and incorporate capacitance type
probes in each cell. The fuel probes are interconnected on each side to an individual indicator on a common dual
display gauge and give a linear response for each indicator's combined system. To vent the fuel systems, two
NACA non-siphoning and non-icing vents, incorporating flame arrestors are installed under each wing.
The controls regulating fuel flow, other than engine controls (start control lever and power control lever), are
used to control the crossfeed and fuel shutoff valves, both of which are manually controlled from the fuel control
panel within the cockpit. The crossfeed valve is located on the left side of the aircraft attached to the crossfeed
and left engine main feed lines (shown in figure 28-3). The fuel shutoff valves are in both main feed lines and
mounted to front spar reinforcement plates.
Fuel is delivered to each engine from wing main 95 gallon fuel tank, through a submerged fuel pump, main
feed line, fuel shutoff valve, fuel filter, the main engine driven fuel supply pump, and fuel control unit containing
another engine driven pump. The submerged fuel pump, located in the main inboard fuel cell of each wing,
functions as a primer pump, an emergency backup to the engine driven pump, and transfers and crossfeeds fuel.
A fuel filter, mounted on the left hand side (facing forward) of each firewall, consists of a filter assembly and a
pressure switch which determines when the filter is partially clogged and will soon bypass. This is a required
impending bypass warning. The main engine driven fuel supply pump is an engine driven pump mounted on the
accessory section of the engine on a dual drive pad which also drives a hydraulic pump.
A jet type scavenger pump, incorporated in each fuel system, controls venting of fuel into the atmosphere
during an engine shutdown. A jet pump is activated whenever fuel pressure exists and the condition lever is
positioned in idle cutoff. During start, fuel is returned to the tank by the jet pump to purge any vapor from the
fuel control unit fuel pump.
Fuel tank drains are provided at fuel cell or tank low points. Fuel filters, mounted on the forward side of each
firewall, also contain drain valves.
TROUBLESHOOTING
Troubles peculiar to the fuel system are listed in chart 2801 along with possible causes and suggested
remedies. When troubleshooting, check fuel supply to items affected. If problem is not found, check individual
components and remove, overhaul, or replace defective units. Electrical diagram for this system may be found in
Chapter 91, Electrical Wiring Section.
2J8
280000
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
DRAIN VALVE
FUEL VENT LINE
CONDITION LEVER
FUEL

.----""'- DRAIN VALVE
FLOW METER
I FUEL DUMP
FUEL DRAIN VALVE
FUEL HEATER
FUEL PUMP
FILTER
-NOTES-
1. ENGINE DRIVEN BOOST
PUMP OPERATES ANY TIME
ENGINE GAS GENERATOR
(N1) IS TURNING AND
SUPPLIES FUEL TO THE
FUEL CONTROL UNIT.
2. SUBMERGED FUEL PUMP IS
USED TO OPERATE THE
JET TRANSFER PUMP, AN
EMERGENCY BACKUP AND
FOR CROSSFEED
OPERATION.
FIREWALL SHUTOFF VALVE
CHECK VALVE
FUEL FLOW "'" :
DUAL FUEL QUANTITY GAUGE __ . _J
CROSSFEED VALVE
VENT LINE
FUEL RETURN LINE
SENDER
UNIT
INBD
FUEL CELL
28-00-00
Page 2
CHECK VALVE-- I
---=========::=:.J SOLENOID PUMP
JET
- VALVES
SUBMERGED
FUEL PUMP
SENDER UNIT
TIP RELIEF VALVE
SUMP DRAIN VALVE
VENT FLOAT VALVE
(NACA) NON-ICIN
SUMP DRAIN VALVE
ANTI - SIPHON
FILLER CAP
NACELLE FUEL TANK
SENDER UNIT
TIP FUEL CELL
Figure 28-1. Standard Fuel System Installtion (PA-42 only)
Reissued: December 31, 1989
2J9
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FLOW DIVIDER
FUEL NOZZLE
DRAIN VALVE
DRAIN VALVE
GAS GENERATOR CASE
FUEL VENT LINE

FLOW METER
FUEL DUMP
-NOTES-
CONDITION LEVER
CHECK VALVE- :
1. ENGINE DRIVEN BOOST PUMP OPERATES
ANY TIME ENGINE GAS GENERATOR (N1)
IS TURNING AND SUPPLIES FUEL TO THE
FUEL CONTROL UNIT.
2. SUBMERGED FUEL PUMP IS USED TO
OPERATE THE JET TRANSFER PUMP, AN
EMERGENCY BACKUP AND FOR
CROSSFEED OPERATION.
FILTER DRAIN VALVE
FUEL HEATER
FUEL PUMP
FILTER
FIREWALL SHUTOFF VALVE
VENT LINE
FUEL RETURN LINE
CROSSFEED VALVE JET
SOLENOID PUMP
VALVES
SENDER
UNIT
INBD
SUBMERGED
FUEL PUMP
, CHECK SENDER UNIT
TIP RELIEF LINE
SUMP DRAIN VALVE
VENT FLOAT VALVE
ALVE
NON-ICING
__ ____ __ ANTI-SIPHON FILLER CAP
'" SENDER UNIT
"'-SUMP DRAIN VALVE SENDER UNIT
ANTI-SIPHON FILLER CAP
NACELLE FUEL TANK = OPTIONAL PART OF SYSTEM ON PA-42 ONLY
Figure 28-2. PA-42-720 Fuel System Installation
2J10
28-00-00
Page 3
Reissued: December 31,1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
FUEL MANIFOLD
FLOW DIVIDER FLOW DIVIDER
FUEL NOZZLE
DRAIN VALVE -"""r-----.
FILTER DRAIN VALVE
FUEL HEATER ---tr ............ -0.,
FUEL PUMP
FILTER
FIREWALL SHUTOFF VALVE
CHECK VALVE
VENT LINE
VAPOR
BLEED
LINE
DRAIN VALVE
CROSS FEED VALVE
r---____ DRAIN VALVE
FLOW METER
.. FUEL DUMP
FILTER DRAIN VALVE
FUEL HEATER

FILTER
FIREWALL SHUTOFF VALVE
':>+-!Ht---tt--- SENDER UNIT+-----it---+-Itt-.. :.
I
DUAL FUEL
QUANTITY GAUGE
INBD AFT
FUEL CELL
Figure 28-3. Fuel Feed and Crossfeed Installation (PA-42)
28-00-00
Page 4
Reissued: December 31, 1989
2J11
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FUEL MANIFOLD
FUEL NOZZLE
DRAIN VALVE
FLOW DIVIDER FLOW DIVIDER
FUEL DUMP
FUEL DRAIN VALVE
FUEL HEATER
FUEL FLOW METER ---jM1lL" dL
FUEL PUMP
FILTER ----.IL
FIREWALL SHUTOFF VALVE
CHECK VALVE
VENT LINE
VAPOR
BLEED LINE
DRAIN VALVE
VALVE
\
DUAL FUEL QUANITY GAUGE
SUBMERGED FUEL PUMP
?=H:=C::w...
FUEL NOZZLE
DRAIN VALVE
FUEL DUMP
FUEL DRAIN VALVE
FUEL HEATER
1Ir1t""_ FUEL FLOW METER
FUEL PUMP
FILTER
REWALL SHUTOFF VALVE
VENT LINE
FUEL
RETURN
LINE
SENDER UNIT
,,-SUMP
DRAIN
VALVE
Figure 28-4. Fuel Feed and Crossfeed Installation (PA-42-720, SIN's 42-8301001 and up)
2J12
28-00-00
Page 5
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2801. TROUBLESHOOTING (FUEL SYSTEM)
Trouble
Fuel gauge fails to indicate
proper tank level.
Fuel valves leak, pressure
low or pressure surges.
Low fuel pressure.
Unidentified leak.
Fuel leaking from
NACA vents.
28-00-00
Page 6
Reissued: December 31, 1989
Cause
Circuit breaker out.
Broken wire.
Gauge inoperative.
Incomplete ground.
Vent holes in fuel
transmitter clogged.
Obstruction in inlet
side of pump.
Faulty pump.
Fuel valve stuck.
No fuel in tanks.
Filters dirty.
Faulty fuel pressure
gauge or transducer.
Fuel lines damaged or
improperly installed.
O-rings improperly
installed.
Tank leak.
Full fuel tanks and fuel
expansion due
exposure to heat.
Float valve in nacelle tank,
aft inboard tank or float
valve in tip tank sticking
open or leaking.
2J13
Remedy
Check and reset.
Check and repair.
Replace.
Check ground connection at
gauge and at fuel transmitter
in the wings.
Clear vent holes.
Trace lines and locate
obstruction.
Replace pump.
Check valve.
Check and fill.
Clean filters.
Replace gauge or
transducer.
Locate and repair.
Locate and repair or
tighten.
Repair leak.
Defuel aircraft or park in a
shaded or cooler location.
Defuel aircraft and
inspect valves for
condition.
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2801. TROUBLESHOOTING (FUEL SYSTEM) (continued)
Trouble Cause
Fuel leaking from Filler caps improperly
filler caps. adjusted and not
sealing properly.
Engine stops with more than Motive Port in Jet Transfer
10 gallons (67Ibs.) of fuel pump clogged.
remaining and/or a significant
amount of fuel still remains in Inlet Port screen clogged.
aft inboard (aux) tank.
Erratic movement of meter Friction in meter movement
in Fuel Quantity Indicator. caused by dirt or improper
alignment of meter pointer.
Fuel Quantity Indicator Meter movement coil is
inoperative. open.
Defective component on
printed circuit boards.
Aircraft connector not
connected properly to
indicator.
Aircraft wiring defective.
Zero indication of Fuel Meter pointer out of
Quantity Indicator is balance.
out of tolerance.
Internal mechanical
adjusnnent of meter
not set properly.
External adjusnnent
incorrect.
2J14
Remedy
Adjust filler caps to
obtain tight seal.
Service Jet Transfer Pump.
Remove and clean affected
item.
Replace Fuel Quantity
Indicator.
Replace Fuel Quantity
Indicator.
Replace indicator.
Check connector installation
at indicator.
Check wiring, repair as
required.
Replace indicator.
Replace indicator.
Adjust.
28-00-00
Page 7
Reissued: December 31, 1989
STORAGE
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF WING TIP TANKS (figure 28-4)
1. Drain tarue
2. Remove fairing between wing tip and tip tank.
3. Remove sender unit.
4. Disconnect electrical wires to navigation lights and strobes.
5. Disconnect all plumbing from tip tank. Cover ends to prevent fuel contamination.
6. Support tank, remove six bolts holding tank to the wing and remove tank.
INSTALLATION OF WING TIP TANKS (figure 28-4)
1. Connect tank to wing by installing six bolts.
2. Connect all plumbing to tank.
3. Install sender unit and connect electrical leads to navigation lights and strobes.
4. Install fairing between wing tip and tip tank.
-NOTE-
Model serial numbers 42-7800001 thru 42-8001012 require
installation of MIL-I-63I clear plastic tubing (Piper PIN 189-534)
between clamp and tubing and bonding strap of fuel system tip tank
installation. (See figure 28-4, sketch A and B.)
REMOVAL OF WING FUEL CELLS (figures 28-5, 28-6, and 28-7)
1. Drain both systems when removing cells on both sides. If only one side is affected, or when replacing or
servicing main inboard fuel cell, close crossfeed valve and drain appropriate tank or system.
2. Remove necessary access plates on wing to gain access to fuel cell and senders. When removing inboard
main fuel cell, remove forward bottom wing root and fuel cell drain panels and plates.
3. Inboard and outboard main fuel cells interconnect, where applicable, with nacelle tank, wing, and vent
system through fittings mounted in wing skin located under nacelle. When removing tanks, remove top
center panel on nacelle to make access to fittings. Remove bolts attaching fittings to wing and all hardware
from affected tank.
4. Disconnect wires from appropriate senders, remove screws securing each sender to fitting, and carefully
withdraw sender with its gasket from cell. Note position of each gasket relative to sender unit when
removing, to facilitate reinstallation.
5. Reach through appropriate access hole. Loosen and disconnect clamps from nipples and interconnecting
tubes. If replacement of tubes is necessary, remove from wing by disconnecting each tube ground strap
from spar and from other tank.
2J15
28-10-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
1. TIP TANK ASSEMBLY
2. VENT WELL COVER
3. FUEL FILLER CAP ASSEMBLY (ANTI- SIPHON)
4. QUICK DISCONNECT
5. ATTACHMENT PLATE (WING FRONT SPAR)
6. BOLT ASSEMBLY (6 REQ.)
7. ATTACHMENT PLATE ( WING MAIN SPAR)
8. SENDER.
9. ATTACHMENT PLATE (WING REAR SPAR) 3
2

I " B
I \

\ \ \
\ \ \
\..
10. FITTING
11. WASHER
'- 12. BOSS
13. STRAINER ASSEMBLY
14. LINE ASSEMBLY
15. BOSS
16. FITTING
17. GASKET
18. PLASTIC TUBING
5
19. CLAMP
20. BONDING STRAP
TORQUE
""f.''''-'''' .... _____ 150 TO 250
IN. LBS.
20
/ /.,-"--- 18
SKETCH A
16
18
17
20
SKETCH B
Figure 28-5. Tip Tank Installation
281000
Page 2
Reissued: December 31, 1989
2J16
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
.060 MIN. CLEARANCE
BETWEEN SKIN AND
ADAPTER
SEALANT (PR1422 - A 2) FOR
DOME NUT SEALING AND
LIGHTNING PROTECTION
GASKET
SECTIONAL VIEW A - A
---
SECTIONAL VIEW B - B
-NOTE-
COVER PLATE
SEALANT (PR1422 - A 2) FOR
DOME NUT SEALING AND
LIGHTNING PROTECTION
IF NECESSARY, THE TIP TANK DOME NUTS MAY BE SEALED BY COATING
THE ENTIRE SURFACE OF THE NUTS WITH PR 1422 - A 2 SEALANT. THE
DOME NUTS MUST BE COATED WITH SEALANT ON THE FUEL SIDE AS
SHOWN ABOVE. THIS WILL ASSURE OPTIMUM LIGHTNING PROTECTION
FOR THE TANK AS WELL AS A FUEL SEAL FOR THE NUTS
Figure 28-5. Tip Tank Installation (continued)
2J17
28-10-00
Page 3
Reissued: December 31, 1989
16
1. ATIACHMENT PLATE
2. COVER
3. GASKET
4. FUEL QUANTITY SENSOR
5. GASKET
6. ATIACHMENT LOOP
7. CORD
8. TIE KNOT
9. FUEL CELL
10. GASKET
11. CAP ASSEMBLY
12. ADAPTER
13. GASKET
14. BUSHING
15. WASHER
16. LINER
281000
Page 4
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
8
g
1 ~
-NOTE-
LACING IN THIS AREA TO BE PULLED "TIGHT" AND "TIED OFF"
AFTER SENDER UNIT INSTALLATION HAS BEEN COMPLETED
Figure 28-6. Inboard-Main 95 Gallon Fuel Cell
2J18
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
6. On underside of wing, remove screws mounting quick drain plates to wing. Carefully draw two fuel cell
drains out of wing. (Enough to allow screwdriver to release clamps.)
-CAUTION-
TO PREVENT NYLON FITTING FROM TURNING WHEN
DISCONNECTING ELECTRICAL CONNECTION ON FUEL
PUMPS, A WRENCH MUST BE USED TO BACK UP EACH
CONNECTION ON TANK. IF FITTING TURNS, INTERNAL
WIRE CONNECTIONS WILL BREAK AND PUMP MUST BE
REPLACED.
7. When removing inboard main fuel cell, remove electrical connections from fuel pump in cell and
disconnect and cap fuel lines.
a. Withdraw pump from tank by removing four bolts mounting pump to tank and wing rib. Lift pump
through access hole in wing.
-CAUTION-
DO NOT DAMAGE SMALL FLAPPER VALVE IN INTERIOR
BAFFLE, NEXT TO FUEL PUMP MOUNTING LOCATIONS,
WHEN REMOVING MAIN INBOARD FUEL CELLS.
8. Reach through proper access hole for each fuel cell. Untie nylon cord securing each cell.
9. Remove all cap bolts at access holes attaching cells to skin brackets. Push cell down and work nylon cord
back through cell hangers and rib bushings to ends of cell compartment.
10. Remove screws attaching mounting brackets to wing skin in each elongated access hole. Remove brackets
from holes.
11. Place tape or other protective material around cell access opening, preventing damage to cell during
removal.
12. Fold cell neatly in wing; tape or tie. Remove cell gently through elongated opening on top of wing.
THIS SPACE INTENTIONALLY LEFT BLANK
2J19
28-10-00
PageS
Reissued: December 31,1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
1. FUEL CELL ASSEMBLY
2. FUEL CELL LINERS
3. WASHER
4. SNAP BUSHING
5. FUEL FILLER ADAPTER
6. NYLON CORDS
7. FUEL CELL ATTACHMENT CORDS
8. FUEL CELL GASKET
9. FUEL CELL ATTACHMENT PLATE
10 .CAP ASSEMBLY
11. FUEL SENSOR SUPPORT PLATE
12. FUEL QUANTITY SENSOR ASSEMBLY
13. FUEL SENSOR GASKET
14. COVER PLATE
Figure 28-7. Outboard 40 Gallon Fuel Cell
281000
Page 6
Reissued: December 31,1989
2J20
~ 0
0-,
I
~ - - 3
1. FUEL CELL LINERS
2. CLAMP
3. FLOAT VALVE
4. FUEL CELL ASSEMBLY
5. WASHER
6. SNAP BUSH ING
7. NYLON CORDS
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
8
'Q::;. -
10. FUEL CELL COVER
11. FUEL CELL ATIACHMENT PLATE
12. WASHER AND BOLT
13. FUEL CELL STRAP
7 6
5
8. FUEL QUANTITY SENSOR ASSEMBLY
9. FUEL CELL GASKET
Figure 28-8. Aft Inboard 33 Gallon Fuel Cell
2J21
28-10-00
Page 7
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
5. CHECK VALVE AND FINGER STRAINER
6. FUEL FILLER CAP ASSEMBLY
7. FUEL FILTER ASSEMBLY
8. FUEL PRESSURE TRANSMITTER
9. FUEL FLOW TRANSMITTER
10 .FUEL PUMP ASSEMBLY
11. SUBMERGED FUEL PUMP ASSEMBLY
12. FUEL CROSSFEED VALVE
13. FUEL JET PUMP
14. FUEL DRAIN VALVE ASSEMBLY
15. FUEL SHUTOFF VALVE
16. FUEL RETURN LINE
UP
~ F W
VIEWB
4
15
8
VIEW A
Figure 28-9. Wing Fuel System
28-10-00
Page 8
Reissued: December 31, 1989
2J22
13
16
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CLEANING AND INSPECTION OF FUEL CELLS
1. Cleaning procedure:
a. New Cells: New cells need not be cleaned after removal from containers, if promptly installed in
airframe cavities. If cells are not installed immediately and become dirty, clean with soap and wann
water prior to installation in clean cavity.
b. Used Cells: Prior to removal, drain fuel from cells, purge with fresh air, and swab out to remove all
traces of fuel. Following removal, clean cells inside and out with soap and water.
-WARNING-
A VAPOR-PROOF LIGHT MUST BE USED DURING
INSPECTION.
2. Inspection procedure:
a. New Cells: Inspect cell surface inside and out for cuts, abraded (scuffed) areas, and accessory damage.
Also inspect fitting seals for nicks, scratches, and foreign material.
b. Used Cells: Inspect cells removed from airframe cavity for repair, or being returned to service for cuts,
abraded (scuffed) areas, and accessory damage on inside and outside of cell surface. Reach through
fuel cell access plate and take section of cell between thumb and forefinger. Wipe ridge with cloth
soaked with Methylethylketone. If fine cracks are found, fuel cell is not repairable and must be
replaced.
c. Baffled Fuel Cells: Conduct the following inspection every 2 years or after 2000 hours in service,
whichever comes first:
(1) Defuel both main cells.
(2) Remove access plates located inboard of nacelle. Remove both wing and fuel cell access plates.
(3) Inspect fuel cell fittings for rubber deterioration by using fingernail to attempt scraping rubber off
metal or nipple fitting. If rubber is not deteriorated, fingernail will glide across rubber. If
deterioration, fingernail will dig into rubber. Deteriorated rubber usually changes from light
yellowish tan to dark, reddish brown color.
(4) Check tension and knots of two nylon support cords.
(5) Inspect interior of cell for baffle security and proper operation of flapper valve. Inspect both sides
of baffle.
(6) Inspect exterior of cells to ensure Velcro tape has not separated from cell or liner surfaces.
(7) Install all access plates on fuel cells and wings. Fill cells and check for leaks.
3. Fuel cell repair procedures are found in paragraph titled Repair of Fuel Cells.
FUEL CELL COMPARTMENT
1. Clear cell compartment of all foreign material such as trimmings, loose washers, bolts, or nuts.
2. Round off any sharp edges in fuel cell compartment.
3. Inspect fuel cell compartment prior to fuel cell installation.
4. Tape over all sharp edges and rough rivets.
2J23
28-10-00
Page 9
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
MOLDED NIPPLE FITTINGS
For best service from this type fitting, exercise the following precautions at time of installation.
1. Apply thin film of Simonize Wax. to metal tubes to facilitate installation and removal.
2. Insert fuel lines into each nipple until end is flush with inside edge of cell.
3. Ensure hose clamps clear end of fitting by 0.25 inch, where possible.
4. Torque hose clamps once. Do not retighten unless hose clamp is loosened completely and allowed to set for
15 minutes before retightening.
5. Do not use sealing paste or gasket compound.
INSTALLATION OF INBOARD, AFT-INBOARD, AND OUTBOARD FUEL CELLS (figure 28-5 and
28-6)
1. Inspect cell compartment.
2. Do not remove cell from shipping container until ready for installation.
3. Ensure cell is wann enough to flex. Do not use sharp tools such as screwdrivers, files, etc, for installation
purposes.
4. Place tape or protective material over edges of elongated access opening to prevent damage to cell.
5. Roll cell into proper shape and size to insert through access opening cell.
6. After fitting cell into wing, unroll cell and establish proper sizing of cell to fit compartment.
7. From each end of cell compartment, feed cord through cell hangers and rib bushings until cords can be
joined at access openings. Do not tie cord but route as shown in figures 28-5 and 28-6.
-NOTE-
The nylon cord holding fuel cells has a 0.125 inch diameter with a
minimum breaking strength of 550 pounds and confonns to MIL-T-
5040C, Type III specifications.
8. Connect fuel drain plate by inserting threaded end of bolt or rod (not under three inches long) up through
plate and nipple fitting of fuel cell (figure 28-9). Reach through fuel cell opening and install 2 or 2 1/2 inch
diameter washer on bolt or rod; secure with nut. Pull nipple down through opening in wing panel enough to
clamp nipple fitting to plate.
9. Remove bolt or rod. Secure plate to wing panel and install drain valve.
10. On inboard main cell, install submerged fuel pump through access opening in wing top. Secure to inboard
rib with four bolts attaching pump.
11. Connect electrical wires to inboard cell, check valve on submerged fuel pump, and connect fuel lines to
check valve.
12. Install fuel cell flange mounting brackets in elongated access holes with screws.
28-10-00
Page 10
Reissued: December 31, 1989
2J24
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL

Figure 28-10. Fuel Valve - Drain Plate Installation
13. Wipe inside of cell clean with clean, soft, lint-free tack cloth; inspect cleanliness.
14. To attach fittings in nacelle wing skins, proceed as follows:
a. If fitting can be reached through nearby access hole, hold cell and gasket up against attachment bracket
and insert several bolts.
b. If fitting cannot be installed as above, reach down through removed access plate on nacelle, insert
threaded rod or bolt through hole in wing bracket, down into corresponding hole in cell nut flange
fitting, and pull cell up against bracket. Install several cap bolts to hold fuel cell until rod is removed,
install remaining bolts, and torque to 35 5 inch-pounds.
15. Connect fuel lines attached to outboard ends of fuel cells and drain line running from inboard end of main
outboard fuel cell to inboard end of main inboard cell.
16. Connect two crossover tubes between main inboard and outboard fuel cells by inserting tubes into nipples in
each cell and installing clamps from inside cell. Torque clamps to 60 - 65 inch-pounds. Ensure ground
strap on crossover tubes is attached to spar.
17. Install senders, gaskets (one on each side of bracket), and screws. Tighten nylon screws to 5 +2/-0 inch-
pounds.
18. Connect sender wires. Ensure insulator sleeve insulates so wires attach to sender. Install sender access
plates.
19. Draw nylon tie cords tight and hold. (See figure 28-5 for positioning of tie cords on outboard fuel sender on
main fuel cell.) Ensure cell is positioned correctly in cell compartment, draw cord tight, hold with clamp or
pliers, and tie. (See figure 28-10.)
20. Install remaining cell cover access plates on top of wing. Torque cell cover cap bolts to 25 5 inch-pounds.
21. Check for fitting leaks in cell by inserting fuel.
22. Install remaining access plates, lower wing root fairing, and nacelle top panel.
2K1
28-10-00
Page 11
Reissued: December 31, 1989
28-10-00
Page 12
STEP 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
1
STEP 2 STEP 3 STEP 4
STEP 5
STEP 6 STEP?
Figure 28-11. Detail in Fuel Cell Threading
2K2
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
HANDLING AND STORAGE OF FUEL CELLS
1. To prevent needless damage to fuel cells, exercise the following precautions when handling cells:
a. Fold or collapse cells for storage, transport, or installation into airframe cavities.
b. Use protective covers over fitting seal to protect seal surface from contact with cavities during removal
or installation.
c. Protect cells from tools, hot lights, etc.
d. Avoid stepping on folds or creases.
e. Do not carry cells by fittings.
f. Maintain original cell contours or folds when refolding.
g. When repairing, maintain natural contours of cells, place on well-lit and well-ventilated surfaces, and
prevent contact with sharp edges, comers, and dirty floors.
h. Inspect cavities and ensure cleanliness prior to cell installation.
i. Do not stack cells.
-WARNING-
NO SMOKING OR OPEN FLAME IS ALLOWED WHEN
REPAIRING CELLS.
2. Observe the following rule when storing cells:
a. Clean used cells with soap and wann water prior to storage; dry and place in container.
b. Fold cells smoothly and lightly as possible with minimum number of folds. Place protective wadding
between folds.
c. Wrap cell in moisture-proof paper and place in suitable container. Do not crowd cell in container. Use
wadding to prevent movement.
d. Stack boxed cells to allow access to oldest cells first. Do not allow stacks to crush bottom boxes.
Leave cells in boxes until used.
e. Storage area must be approximately 70 and free of exposure to sunlight, dirt, and damage.
2K3
28-10-00
Page 13
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
REPAIR OF FUEL CELLS
-CAUTION-
THE REPAIR OF LORAL VITHANE FUEL CELLS SHOULD
BE RESTRICTED TO AUTHORIZED PERSONNEL WHO
HAVE BEEN CERTIFIED AND TRAINED BY LORAL
REPRESENTATIVES, OR WHO HAVE RECEIVED THEIR
TRAINING FROM PERSONS WHO HAVE BEEN CERTIFIED
AND TRAINED BY LORAL REPRESENTATIVES.
-NOTE-
The following repair procedures are in accordance with the cell
manufacturers repair procedure.
The following are recommended field repair procedures for fuel cells constructed of Loral BTC - 85 material.
Any of three methods may be used for repairs: heat cure, air cure, or quick cure. All repairs are neat and
permanent. Heat cure repairing allows cells to be cured and ready for installation in two hours. Air cure
repairing requires that the cell not be moved for 72 hours or longer. Quick cure repairing can be used on cells
that have minor damage and can be repaired in six hours.
HANDLING OF REPAIR MATERIALS
-CAUTION-
REPAIR CEMENT FOR HEAT AND AIR CURE REPAIRS
(5923C) AND QUICK CURE REPAIRS (82C32) REQUIRES
THOROUGH MIXING TO OBTAIN FULL ADHESIVE
VALUES.
ALL CONTAINERS FOR CEMENTS AND SOLVENTS
SHOULD BE PROPERLY IDENTIFIED.
1. Protect repair materials from dirt, contamination, sunlight. and excessive heat or cold during storage.
Containers are to be tightly capped and stored between 30F and 85F temperature.
2. Mix repair cements immediately before application.
3. Refer to each curing method for pot life of mixed cement.
28-10-00
Page 14
-NOTE-
Unmixed repair cements have a shelf life designated by Loral on the
storage containers.
Reissued: December 31, 1989
2K4
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REPAIR LIMITATIONS OF FUEL CELLS
-NOTE-
Ff - 227 fabric is used to repair simple contours only. All patches
referred to in repair procedures are of this type
1. Lap inside patches over defective edges 1.0 inch minimum in each direction.
2. Cut outside patches approximately 0.25 to 0.50 inch larger than inside patches.
3. Apply outside patches and allow to cure before applying inside patches
4. Apply both outside and inside patches for blisters between inner liner and fabric larger than 0.25 inch in
diameter.
5. Apply both outside and inside patches to rerair holes and punctures. Apply both outside and inside patches
to repair seperations between outer plies larger than 1.0 inches in diameter.
-NOTE-
Slits or tears are limited to 6.0 inches maximum in length.
6. Apply outside patch only to external abraded or scuffed areas without fabric damage.
7. Trim loose laps as necessary provided a 5.0 inch effective band remains.
-CAUTION-
FOR EACH 10 DROP IN TEMPERATURE FROM 70F, ADD
20 HOURS CURE TIME. DO NOT AIR CURE REPAIRS
BELOW 60F.
8. Clamp repair patches when performing air cure repair. Cure at room temperature of 70F undisturbed for 72
hours.
9. Limit fitting repairs to loose flange edges, seal surface rework, and coat stock.
10. Do not exceed four heat cure repairs in the same area.
-NOTE-
Any damage not covered by the above the cell should be returned for
repair to: Loral Engineered Fabrics, 669 Goodyear Street, Rockmart,
Georga. 30153 - 0548.
2K5
28-10-00
Page 15
Reissued: December 31, 1989
ITEM/DESCRIPfION
*5923C Cement
FT - 227 Repair fabric
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2802
FUEL CELL REPAIR EQUIPMENT LISTS
Repair Kit, Loral Part No. 2F1-3-37813
GROUP I MINIMUM MATERIALS
(3 component, 1/2 pint set.)
(Sheet, 12 in X12 in min.)
Methylethylketone (MEK) solvent (Quart can)
AP -368 manual (latest issue)
*Shelflife limited to one year from date on container.
GROUP II MINIMUM EQUIPMENT
ITEM/DESCRIPfION
Measuring cup (250 ml.)
Release film (cellophane) (Sheet 6in X 24 in. min.)
Foam rubber, cloth backed (Sheet 12/4 in X 12 in. X 12in min.)
Cement application brush (lin wide)
Aluminum pressure plate (1/4 in X6 in X6 in min.)
GROUP m. MINIMUM LEAK TEST EQUIPMENT
ITEM/DESCRIPfION
Phenolphthalein (analytical grade)
Ammonia (27% concentrate)
Ethyl alcohol
Balloon or broad cloth
2Fl - 3 - 35721 - 1 heat cure iron
C - clamps
Vaperproof light
Sheers
Electric motor
Abrasive armor
Sanding sleeve
Abrasive cloth
Abrasive cloth
Scale
Manometer
Closure plates
28-10-00
Page 16
Reissued: December 31, 1989
(40 g in 20z bottle)
(commercial grade)
(commercial grade)
(white)
(240 temperature setting)
(6 inch)
(with 25 foot cord)
(8 to 10 inch long)
(Black and Decker PIN 725,2250 rpm,
1.9 amp, 115 VAC or equivalent)
(Dunemore R421003, 1/4 in. drive,
1 in long X 1 in. dia.,or equivalent.)
(80 grit)
(120 grit in sheets)
(320 grit in sheets)
(12 inch straight edge)
(Fisher Scientific Co.PIN 11 - 286,
water or mercury, 12 in. long, or equivalent.)
(fabricated locally)
2K6
QUANTITY REQUIRED
8
2
1
1
QUANTITY REQUIRED
1
2
2
2
4
QUANTITY REQUIRED
4 btl.
Ipt.
8 qt.
2 yd.
1
6
1
1
1
1
6
2
2
1
1
AIR
lTEM/DESCRIPfION
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2802 (continued)
FUEL CELL REPAIR EQUIPMENT LISTS
Repair Kit, Loral Part No. 2Fl-3-4221S
GROUP I MATERIALS
3604N nylon fabric (NSN 8135-01-242-3515) 3.5 oz
*82C32 Cement NSN 8040-01-243-6624 ( 2 comonent set)
AP - 472 Manual (latest issue)
* Shelf life limit 12 months.
lTEM/DESCRIPfION
Cement application brush
Scotch Brite pad
Tounge depressor
CUlved sissors(4inch long)
China marker
GROUP II MATERIALS
(l inch wide)
(6 inch X 9 inch)
(wooden)
1pr.
(white #l64T)
-NOTES-
QUANTITY REQUIRED
2 sq. yds.
9 ea. 1/2 pt.
1 ea.
QUANTITY REQUIRED
4 ea.
2 ea.
9 ea.
1 ea.
1. All materials required to perform autorized repairs are included in the group I and group II repair kits except
for clean cloths and methylethyketone.Accessories -To be ordered per individual cell requirements.
2. Order material and equipment from Aero Hardware and Parts Co. if not avaialble order from Loral
Engineered Fabrics.
Aero Hardware& Parts Co. Loral Engineered Fabrics
1037 Boston Post Road 669 Goodyear Street
Rye, N.Y10580. Rockmart Georga, 30153 - 0548
3. Repair fabric and cement can be purchased seperaUy by specifying the code number or national stock
number (NSN) listed above
4. Solvent and Clean cloth can be purchased from Aero Hardware or a local supplier.
2K7
28-10-00
Page 17
Reissued: December 31, 1989
PIPER AIRCRAFT
PA .. 42/42 .. 720
AIRPLANE MAINTENANCE MANUAL
REPAIR PATCH (HEAT CURE METHOD)
-CAUTION-
DO NOT APPLY AN OUTSIDE AND INSIDE PATCH
SIMULTANEOUSLY. APPLY OUTSIDE PATCH FIRST.
1. Cut a patch from Ff - 227 repair fabric to the size required to ensure a proper lap over the injury in all
directions.
a. Hold shears at an angle to produce a beveled edge (feather) on the patch.
b. Round comers of patch. Ensure dull side or gum contact face of repair patch is the largest surface after
beveling.
2. Wash one square foot of cell wall beyond damaged area in all directions.
3. Wash contact side of patch using a clean cloth dampened with Methylethylketone solvent.
4. Center repair patch over damaged area. Mark cell .50 beyond patch in all directions
-CAUTION-
BUFF CELL SURFACE WITH CARE TO AVOID FURTHER
DAMAGE.
5. Buff cell surface surrounding damaged area as marked and contact side of patch with fine emery cloth to
remove gloss.
6. Wash cell and patch surfaces two more times using a cloth dampened with MEK.
-CAUTION-
TO PREVENT CEMENT FROM STICKING CELL WALLS
TOGETHER, ENSURE CELLOPHANE PLACED INSIDE
CELL REMAINS IN PLACE.
7. Tape a piece of cellophane inside the cell over the injury.
8. Fold cell so repair can be completed without repositioning cell.
-WARNING-
CEMENTS AND SOLVENTS ARE FLAMMABLE. MIX AND
APPLY CEMENT IN WELL VENTILATED AREA.
REPAIR CEMENT 5923C SHELF LIFE IS ONE YEAR FROM
DATE ON CONTAINER. DO NOT USE OUT DATED CEMENT.
-NOTE-
Mix and apply cement at minimum temperature of 700E Pot life of
mixed cement is 20 minutes to one hour.
9. Mix repair cement 5923C as follows:
a. Shake contents of part 2.
b. Pour contents of part 2 into part 1. Stir thoroughly, making sure entire contents of both containers are
are blended completely.
28-10-00
Page 18
Reissued: December 31, 1989
2K8
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-NOTE-
Rapid stirring or shaking will cause air bubbles to form. Air bubbles
in cement can result in repair voids. pits. blisters. and leak paths.
10. Apply one even coat of 5923C cement on buffed area of cell to within 1/4 inch of edge and on buffed side of
patch. Allow to dry for 15 minutes.
-CAUTION-
COVER CEMENT CONTAINER BETWEEN APPLICATIONS
TO MAXIMIZE POT LIFE.
11. Apply second coat of 5923C repair cement to cell and patch. If cement has become too thick to brush. mix
new batch of cement. (Refer to step 9.)
12. Allow cement to dry for 5 minutes.
13. Center repair patch over damaged area. Lay patch carefully by rolling action from center of patch to edges
to prevent trapping air. While surface is wet, slide repair patch by hand to improve lap
-CAUTION-
BE SURE PIECE OF CELLOPHANE IS LARGER THAN
CEMENTED AREA AND REMAINS IN PLACE. ENSURE
FILM OBTAINS COMPLETE COVERAGE.
14. Tape piece of cellophane over patch.
-NOTE-
Aluminum plates must be larger than patch.
15. Cover one side of aluminum plate with 0.25 inch fabric-backed airfoam (fabric side out). Tape airfoam into
place. Ensure airfoam covers edges of plate for protection.
16. Cut two backup boards larger than cemented area and smooth all edges.
-CAUTION-
ENSURE CELL IS NOT FOLDED BETWEEN PRESSURE
PLATE AND BOARDS TO PREVENT PERMANENT CREASE.
ENSURE PATCH DOES NOT MOVE WHEN TIGHTENING
CLAMP.
17. Fold cell next to patch. Place plate with airfoam over patch.
18. Place 2Fl-3-2572 repair iron on center of plate. Cover iron with other backup board. Secure assembly in
place with C clamp. Wipe off any excess cement that flows from pressure plates.
19. Connect repair iron to 110/120 Vac. Set iron to 240F and allow to cure for two hours.
20. Unplug iron and allow assembly to cool to the touch.
21. Dissemble cure iron, plate, and boards from cell. Dampen cellophane and remove from cell.
22. Check for complete seal of patch edges.
a. Trim loose edges ifless than 1/8 inch.
b. Bond loose edges with cement and cure if more than 1/8/ inch.
23. Repeat steps 1 thru 22 for inside patch. except cut patch 1/4 inch to lf2 inch smaller than outside patch.
2K9
28-10-00
Page 19
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
REPAIR PATCH (AIR CURE METHOD)
-NOTE-
A minimum of 72 hours curing time at 70F is required per patch. A
minimum of 144 hours is required to install an outside and inside
patch. Add 20 hours cure time for each 10F drop in temperature.
Never attempt to air cure at temperatures below 60F.
1. Follow the procedure for the heat cure method, except omit the following:
a. Omit cure iron from steps 18 and21.
b. Omit steps 19 and 21.
2. Refer to fuel cell repair limitations for curing time.
REPAIR PATCH - QUICK CURE METHOD
-WARNING-
REMOVE FUEL CELL FROM AIRCRAFT BEFORE
PERFORMING QUICK CURE METHOD.
-CAUTION-
USE EITHER HEAT CURE OR AIR CURE METHOD IF
DAMAGE IS WITHIN 5/8 INCH FROM OUTSIDE DIAMETER
OF METAL FITTINGS
1. Cut repair patch from 3604N fabric material to size that extends 1.0 inch beyond injury in all directions
-NOTE-
It is recommended that a round patch 3 inches in diameter be used.
-WARNING-
MEK IS FLAMMABLE. TAKE ALL NECESSARY PRE-
CAUTIONS TO PREVENT SERIOUS INJURY TO YOURSELF
AND/OR FELLOW WORKERS.
2. Wash fuel cell approximately 12 inches beyond injury in all directions using a cloth dampened with MEK.
3. Center fabric patch over injury. Mark cell 0.50 inch beyond patch in all directions.
28-10-00
Page 20
Reissued: December 31, 1989
2K10
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-CAUTION-
BUFF FUEL CELL WITH CARE TO PREVENT DAMAGE
BEYOND INJURY AND TO PROTECT CELL FABRIC
REINFORCEMENT.
4. Buff fuel cell inside marked area with a Scotch Brie pad or fine emery cloth to remove glosslshine from
cell.
5. Wash buffed area using a clean, lint free cloth dampened with MEK. Repeat with a second clean cloth.
-CAUTION-
DO NOT MIX CEMENT BATCHES SMALLER THAN AS
SUPPLIED AS UNRELIABLE CURE CONDITIONS CAN
RESULT.
6. Mix 82C32 cement as follows:
a. Pour contents of part 2 into container of part 1.
b. Thoroughly stir contents with a tongue depressor for about 5 minutes.
-NOTE-
Pot life of mixed 82C32 cement is about 20 to 30 minutes in and open
container. Pot life can be extended up to 1 hour by recapping
container between applications.
7. Apply one brush coat of 82C32 cement to clean buffed area of cell. Do not not apply beyond buffed area.
Allow to dry from 10 to 15 minutes.
8. Repeat step 7 with second coat.
9. Repeat step 7 with third coat.
to. While third coat of cement is wet, apply fabric patch to damaged area as follows:
a. Dip patch in clean MEK and shake off excess solvent.
b. Lay patch into wet cement. Make sure patch is centered over damaged area.
c. Smooth out patch using a relatively dry brush. Work from the center of the patch to the edges to
remove all trapped air.
11. Apply final coat of 82C32 cement over patch. Spread cement at least 1/8 inch beyond fabric patch. but not
beyond buffed area.
-CAUTION-
NEVER APPLY A HEAT CURE TO 82C32 CEMENT.
12. Allow repair to air cure for a minimum of 6 hours at a minimum temperature of 70
0
P before moving cell or
exposing the cell to fuel.
13. Check repair after cure time to ensure cement is cured. If sticky proceed as follows:
a. Remove repair patch and all cement.
b. Repeat steps 1 thm 12. Make sure cement is not out of date.
14. Check edges of repair for looseness:
a. Trim loose edges if less than 1/8 inch radially.
b. Bond loose edges if more than 1/8 radially.
2K11
28-10-00
Page 21
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-NOTE-
Channels or voids running from center of patch to edges are
unacceptable.
15. Perform fuel cell leak test (refer to testing fuel cells).
SEALING METAL FITTING SURFACES
-WARNING-
DO NOT ALLOW ALODINE SOLUTION TO COME IN
CONTACT WITH HANDS, EYES, OR CLOTHING.
1. Rub roughness off the affected area with a fine file or fine emery cloth.
2. Oean metal surface using a clean cloth dipped in Methyiethylketone.
3. Moisten the cleaned surface with a clean cloth dipped in water.
4. Apply undiluted alodine 1200 solution to the affected area with a small nylon brush.
5. Allow the solution to dry until a light golden color appears.
6. After a coating has been formed. remove the excess solution by wiping the surface with a clean water
moistened cloth.
7 Wipe dry.
FUEL CELL ACCESSORY REPLACEMENT
1. Obtain a cured repair accessory from the cell manufacturer.
2. Mark location of old accessory and preserve markings for guide lines to locate the new part.
3. Remove the old accessory as follows:
a. Gradually loosening an edge with a blunt probe-like instrument.
b. Grasp the accessory by the loose edge with pliers and gently peel the accessory off the cell wall from
the blind side of a cell lap toward the exposed edge. Be careful not to pull the cell lap open while
peeling accessory, off.
-NOTE-
Removal of the old accessory will probably leave an uneven cavity
and surface.
4. Buff the cell surface under the accessory with emery cloth to smooth roughness and prepare for cement.
5. Buff and wash the contact surface of new accessory. Wash the cell surface (see repair patch heat cure
method steps 2 thru 4).
6. Apply mixed 5923C repair cement to both surfaces. Level the cavity left by the removal of the old
accessory.
7. Roll the new accessory into place. Place padded plates in position to ensure adequate pressure when
clamped. Use a cellophane separator to prevent the cement from sticking in the wrong place.
8. Cure accessory with either air cure or heat cure method.
28-10-00
Page 22
Reissued: December 31, 1989
2K12
PIPER AIRCRAFT
PA42/ 42 720
AIRPLANE MAINTENANCE MANUAL
REPAIR OF FUEL CELL DEFECTS
1. Repair blisters as follows:
a. Trim loose or ragged material from affected area.
b. Apply an outside and inside repair patch.
2. Repair holes, punctures, cuts, tears and deep abraded areas as follows:
a. Trim loose or ragged material from affected area.
b. Apply an outside and inside repair patch.
3. Repair Loose edges as follows:
a. Buff loose edges and contact surfaces with emery cloth.
b. Wash buffed area three times with Methylethylketone.
c. Apply two coats of 5923C mixed cement to each surface.
d. Clamp and cure. Either method may be used. (See repair patch.).
e. Trim loose edges if less than 1/8 inch remains.
4 Repair inside loose fitting flange as follows:
a. Buff the edge of the flange and the contact surface under the flange.
b. Apply 5923C mixed repair cement, cellophane, padded plates and clamp. (Refer to repair patch heat
cure method.)
5. Repair looseness against metal as follows:
a. Prepare metal (refer to sealing metal fitting surfaces).
b. Apply 5923C mixed repair cement and cure by either method.
6. If patched area of fuel cell lacks repair cement proceed as follows:
a. Buff surface next to missing sealant with emery cloth.
b. Wash surface three times with MEK.
c. Apply four coats of 5923C mixed repair cement.
d. Clamp and cure using either method.
TESTING FUEL CELLS
-NOTE-
Either of the following leak tests may be used to detect leaks in the
bladder cells. The chemical leak test is the more sensitive and
preferred test.
1. Perform the soap suds leak test as follows:
a. Attach test plates to all fittings.
-WARNING-
DO NOT EXCEED 0.25 PSI WHEN INFLATING FUEL CELLS.
b. Inflate the cell with air to a pressure of 0.25 psi maximum.
c. Apply a soap and water solution to all repaired areas suspected of leakage. Check for bubbles to appear
at any point where leakage occurs.
d. After testing, remove all plates and wipe soap residue from the exterior of the cell.
2. Perform chemical test as follows:
a. Attach test plates to all but one fitting opening.
b. Mix 40 grams of Phenolphthalein crystals in 1/2 gallon of ethyl alcohol. Add 1/2 gallon of water after
the crystals have dissolved.
2K13
28-10-00
Page 23
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
-WARNING-
AMMONIA GAS IS GIVEN OFF BY AMMONIUM
HYDROXIDE. USE CAUTION WHEN OPENING THE
CONTAINER AND WHEN USING AMMONIUM HYDROXIDE.
PROVIDE ADEQUATE VENTILATION TO MAINTAIN THE
CONCENTRATION OF AMMONIA BELOW ACCEPTABLE
LEVELS. (REFER TO CHART 2803).
c. Pour ammonia as supplied on an absorbent cloth in the ratio of 3cc (l teaspoon) per cubic foot of cell
capacity. Place a saturated cloth inside the cell and install the remaining test plate.
-WARNING-
DO NOT EXCEED 0.25 PSI WHEN INFLATING CELL.
d. Inflate the cell with air to a pressure of 0.25 psi maximum. Maintain pressure for a minimum of 15
minutes.
e. Soak a large clean white cloth in the phenolphthalein solution, wring it out thoroughly, and spread it
smoothly on the outer surface of the cell. Press the cloth down to ensure detection of minute leaks.
-NOTE-
Red spots on the cloth will indicate leakage.
f. Check the cloth for red spots which will indicate leak. Mark any leaks found.
g. Repeat steps e. and f. for remaining outer surface of fuel cell.
-NOTE-
Phenolphthalein solution and test cloth can be reused only if they
remain clean. Store solution not in immediate use in a closed rust
proof container to prevent evaporation and deterioration
h. Repair fuel cell as necessary.
i. Remove all plates and test equipment. Purge cell with fresh air.
28-10-00
Page 24
Reissued: December 31, 1989
2K14
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
FUEL VENT SYSTEM (figure 28-12)
The main fuel vent line extends from the upper portion of the nacelle fuel tank, down through the wing, out to
the tip tank. A float valve is installed on the end of the vent line in the nacelle tank. to prevent fuel from escaping
through the vent system. The two NACA non-icing type vent assemblies, installed along the vent line, are non-
siphoning and incorporate flame arrestors. The tip tank has a vent well assembly containing a float valve, tip
relief tube, and the main vent line connected to it. This vent well is sealed from the fuel storage area in the tip
tank, except for the float valve and relief tube, which extends to the forward top portion of the tank. The float
valve installed in the tip tank vent well prevents fuel from escaping through the vent line. The relief tube allows
the fuel system to vent during climb to altitude with full fuel aboard and also allows fuel to escape when tanks are
full and fuel expansion occurs due to heat (such as aircraft being parked on ramp and exposed to high ramp
temperatures).
2
1. VENT LINE
2. NACELLE VENT RELIEF VALVE
3. VENT ASSEMBLIES
4. VENT WELL ASSEMBLY
5. TIP TANK VENT RELIEF LINE
6. VENT LINE FITTING ASSEMBLY
7. TIP TANK VENT LINE
3
Figure 28-12. Fuel Vent System
2K15
281000
Page 25
Reissued: December 31, 1989
DISTRIBUTION
FUEL VALVES (figure 28-13)
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
REMOVAL OF FUEL VALVES
The PA-42 contains three major fuel control valves consisting of two primary fuel shutoff valves and a
crossfeed valve. Each fuel shutoff valve is mounted to a wing forward spar reinforcement plate within the wing
root cavity. The crossfeed valve is mounted to a tee fitting on the left wing rib in the left root cavity and is
connected in line with the left fuel feed line.
1. Ensure crossfeed valve is off when removing either of the two shutoff valves. Proceed as follows:
a. Drain all fuel from side of system affected.
b. Remove bottom wing root panel to gain access to valve on forward spar reinforcement plate.
c. Disconnect lines from valve. Cap lines and remove valve by unscrewing screws from self locking nuts.
Disconnect control cable from actuating ann.
2. To remove crossfeed valve, drain fuel from both systems. In left root cavity in front of fuel pump,
disconnect valve from its bracket, tee fitting, and crossfeed line.
OVERHAUL OF FUEL SHUTOFF VALVES
A kit (pIN 763-995) containing valve for replacement parts can be obtained from Piper.
Disassemble valve and rebuild as follows:
1. Firmly secure valve in vise between two slabs of wood or thick sheets of soft aluminum.
2. With screwdriver that fits securely in screw heads, apply small amount of down pressure on screws and
remove screws from body. Screws are secured with Loctite Grade A thread lock.
3. Remove safety wire and screw in valve shaft. The screw is also secured with Loctite.
4. Ensure valve is closed position and remove handle on valve shaft. Note position of valve shaft and roll
pins.
5. With pliers, remove roll pins.
6. Pull fitting from valve body and remove O-ring.
7. Clean fitting and apply Dow Corning Lubricant (FS3451) or equivalent to O-ring flange.
S. Install new MS29513-019 O-ring. Set fitting in clean area and cover with clear plastic. (Saran wrap, etc.)
9. Remove and throwaway valve (spring, washer, and spacer.
to. Remove and dispose seal (2555-05, Dukes) and O-ring.
11. Remove valve from vise. With soft, wood dowel, push out ball from other end of valve body. Be careful
not to nick or damage ball. Clean as necessary.
12. With roll pin removed from shaft, push control shaft into valve body and remove.
13. Remove O-ring from shaft and clean O-ring.
14. Remove other seal, O-ring, wave washer, and spacer.
15. Thoroughly clean inside of valve and dry.
16. Install new valve washer and spacer.
17. Using Dow Corning Lubricant (FS3451) or equivalent, lubricate one 2559-05 seal and install MS29513-016
0-ring on seal.
IS. Carefully insert seal in body until it meets spacer.
19. With control shaft clean and corrosion free, lubricate with Dow Corning Lubricant (FS3451) or equivalent.
Install MS29513-00S O-ring.
2K16
28-20-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
20. Apply large amount of lubricant on bottom of shaft (figure 28-13) and install shaft in valve body.
21. Replace roll pins so shaft pin is positioned on side with open designation. Install grooved pins in body with
grooved ends down.
22. With shaft in closed position, install handle.
23. Coat AN500AD6-3 screw threads with threadlock from kit. Install two AN960C6L washers and screw on
shaft. Safety wire handle and screw.
24. Install ball valve, ensuring ball slides into body with openings toward side of body. Also ensure shaft flange
is snug against body flange (figure 28-13).
25. Install second seal per steps 17 and 18 above.
26. Install other new spacer and washer.
27. With fitting prepared per steps 7 and 8, install it on valve body with attaching screws, ensuring threads are
coated with Loctite.
ADJUSTMENT OF FUEL SHUTOFF AND CROSSFEED VALVE (figure 28-13)
1. Remove lower wing root fairing on side requiring valve adjustment.
2. Place fuel shutoff control lever to full ON position. Confirm valve actuator is against stop on valve body.
3. Gap between control lever and stop must be 0.10 - 0.20 inch. If not, proceed to step 4.
4. Disconnect control cable at actuator arm. Loosen jam nut at clevis fitting.
5. Place shutoff valve actuator arm firmly against OPEN position stop pin. Place cockpit lever against stop
position.
6. Carefully move lever 0.10 - 0.20 inch off stop.
7. Align clevis hole with mating hole in valve actuator arm. Secure with attaching hardware.
8. Operate control lever several times, to ensure actuator arm on valve contacts stop pin, before control lever in
cockpit contacts stop.
9. Reinstall lower wing root fairing.
LEAKAGE TEST OF FUEL SHUTOFF AND CROSSFEED VALVE
1. Connect valve inlet port to 50 psi air source.
2. Close valve, apply 50 psi air pressure, and submerge valve in kerosene or similar petroleum base fluid for 2
minutes.
3. Ensure no evidence of leakage through valve port or around seat.
4. Disconnect air source. Wipe fluid from valve exterior.
INSTALLATION OF FUEL VALVES
1. Place valve in proper position. Secure to mounting bracket or with attachment clamps, depending on valve
being installed.
2. Connect proper fuel lines to valve. Connect control cable to actuator arm with attaching hardware.
3. Check valve and end fittings for leaks by filling tank with fuel.
4. Install lower wing root fairing.
28-20-00
Page 2
Reissued: December 31, 1989
2K17
1. LEVER RETAINING ARM
2. VALVE CONTROL SHAFT
3. LEVER ARM
4. SHAFT ROLL PIN
5. O-RING MS29513-00P
6. VALVE BODY
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
10. SEAL
11. O-RING MS29513-016
12. FiniNG RETAINING SCREWS
13. FiniNG
14. O-RING MS29513-019
15. LUBRICANT,DOW CORNING FS3451
7. WAVE (SPRING) WASHER 16. ROLL PIN
8. SPACER 17. ARM RETAINING WASHERS AN960C6L
9. BALL VALVE
13
"ON" POSITION
FUEL CONTROL QUAD RENT
.10 TO .20 GAP
WITH LEVER I N ~ ~ f
FULL FORWARD9
POSITION
!
",/
"..-"OFF" POSITION
SHUTOFF
VALVE (SEE NOTE)
-NOTE-
VIEW SHOWING LEFT SIDE SHUT - OFF VALVE
(RIGHT SIDE OPPOSITE WITH ARM ON TOP)
Figure 28-13. Dukes Fuel Valve (Crossfeed and Shutoff)
2K18
"CLOSED"
POSITION
ACTUATOR
ARM
28-20-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FUEL FILTER (figure 28-14)
Fuel filters on the PA-42, located on the left side of the engine firewall, are reached by removing the top engine
cowling. Maintenance to filter assembly is limited to removal and cleaning of filter screen, repair of minor
damage or corrosion, or total replacement of filter assembly.
REMOVAL AND CLEANING OF FUEL FILTER SCREEN
1. Close fuel shutoff valve.
2. Drain fuel from filter assembly. Remove drain valve lever from fuel filter assembly by removing clamp
attached to filter bowl.
3. Unscrew drain valve from filter bowl.
4. Unscrew filter bowl from body.
5. Remove screen and inspect seals on retainer and body assembly. If seals are deteriorated or damaged,
replace by scraping them off their fixture (or replace retainer) and gluing on new ones.
6. Remove old O-ring in body assembly.
7. Clean bowl and body with oil solvent and check for damage. Replace if necessary.
8. Clean filter electrosonically and inspect damage. Replace if necessary.
28-20-00
Page 4
Reissued: December 31, 1989
6
5
Figure 28-14. Fuel Filter Assembly
2K19
4
3
1. BYPASS VALVE ASSEMBLY
2. DRAIN
3. FILTER ELEMENT
4. a-RING
5. PACKING
6. OUTLET FiniNG
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF FUEL FILTER SCREEN
1. Ensure screen seals on body assembly and retainer are in good condition and solidly mounted.
2. Install new D-ring in body.
3. Insert screen in bowl and install bowl on body.
4. Attach drain fitting and drain lever.
INSTALLATION OF FUEL FILTER
1. Position filter housing in proper location; secure to mounting bracket with three cap bolts and safety.
2. Connect two fuel lines to proper fittings.
3. Attach fuel bowl quick drain actuator handle removed to mounting clamp on filter bowl with screw, washer,
and nut.
4. Connect filter bowl drain hose to fitting on bottom of bowl.
-NDTE-
Fuel cells must be 90% full to get fuel flow from filter.
5. Tum fuel shutoff valve on and depress fuel filter bowl drain valve until steady flow of fuel exists. Release
handle and check for leaks where filter bowl assembly screws into head assembly, and where two fuel lines
and filter bowl drain line attach to filter housing.
6. Install top engine cowl.
FUEL JET PUMPS (figures 28-15 and 28-16)
The PA-42 is equipped with a jet scavenger fuel pump which returns unused fuel at start and shut down and a
jet transfer fuel pump which transfers fuel from the inboard aft auxiliary tank to the inboard main tank.
The jet scavenger pump (figure 28-15) is mounted to the inlet air duct on the right rear side of each engine.
The jet transfer pump (figure 28-16) is located in the wing root cavity 8.5 inches in front of the aft spar and
clamped to the aft inboard (auxiliary) tank nipple. Though the auxiliary tank is interconnected with the inboard
main tank, the auxiliary tank is the lowest part of the system and requires a means of transferring fuel to an
engine feed area once the fuel level has decreased below the interconnecting tube level. The jet transfer pump
draws all fuel from the aft inboard fuel tank to the feed area in the inboard main tank. High pressure filtered fuel
is delivered to the pump, which uses a venturi affect to pull unused fuel from the auxiliary tank and delivers it to
the inboard main tank.
2K20
28-20-00
Page 5
Reissued: December 31,1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
SERVICING JET SCAVENGER PUMP (figure 28-15)
1. This jet pump canister is basically a replaceable, not a repairable item. However, if the jet, elbow, or check
valve become clogged or fouled, remove and replace as follows:
a. Disconnect inlet line from elbow.
b. Release locknut securing elbow in position.
c. Carefully remove elbow, check valve, and replace O-ring if necessary.
d. Slide a piece of 0.02 inch safety wire through elbow end of canister to other side and put a 1/16 inch or
less bend at end of wire.
e. Carefully slide wire back through and pull out jet and spring washer. Replace washer, if necessary.
f. Replace parts in reverse order.
1. FUEL OVERFLOW DRAIN
2. CHECK VALVE
3. O-RING SEAL
4. OVERFLOW DRAIN LINE
5. FUEL SCAVENGE CAN
6. SPRING CLAMP
7. HOSE TO FUEL DIVIDER
8. SPRING CLAMP
9. JET NOZZLE
10. SPRING WASHER
11. AN92-4 NUT
12. O-RING
13. MODIFIED ELBOW
14. LINE CONNECTOR TO SOLENOID VALVE
Figure 28-15. Jet Scavenger Pump
28-20-00
Page 6
Reissued: December 31, 1989
2K21
14
13
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL AND INSTALLATION OF THE JET TRANSFER PUMP (figure 28-16)
1. With crossfeed valve off, drain system. If both systems must be drained, leave crossfeed on.
2. Remove necessary wing root fairings.
3. Disconnect fuel lines from pump.
4. Remove retaining clamps and slide pump inlet port out of tank nipple.
5. Install pump in reverse order.
JET PUMP FLOW CHECK
-WARNING-
AREA SURROUNDING AND INSIDE OF AIRCRAFT MUST BE
WELL VENTILATED AND CLEAR OF ANY SOURCE OF
FLAME OR SPARK.
1. Drain affected fuel system (if not already drained).
2. Disconnect and plug jet pump return line from pump.
3. When accumulating any fuel, ensure it is done outside or as close as possible to outside of aircraft. Obtain
an eight foot or longer piece of 1/2-inch hose or tubing. Connect line to jet pump, and while keeping free
end 24 inches above jet pump outlet, route line out or near door. Connect control on/off valve to free end of
line.
4. With firewall shutoff valve closed (off), add at least 20 gallons of fuel to system.
5. Open firewall shutoff valve, operate boost pump until fuel flow clears, and close control valve to check for
leaks. With control valve open, it must take maximum 4.3 minutes to accumulate 5 gallons (466 PPH
minimum).
4.50
INLET PORT 4 X 4 MESH SCREEN
Figure 28-16. Jet Transfer Pump
2K22
MOTIVE FiniNG PORT
28-20-00
Page 7
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
REMOVAL AND INSTALLATION OF SUBMERGED FUEL PUMP (figure 28-17)
1. Drain entire system or ensure crossfeed valve is off so either wing can be drained separately without
draining fuel from opposite side.
2. Remove lower wing root fairing from under side of wing where pump is to be removed.
3. Remove access plate on top of wing, ahead of main spar, next to fuselage. Remove fuel cell cover plate to
gain access to fuel pumps (figure 28-17).
-CAUTION-
WHEN DISCONNECTING ANY ELECTRICAL
CONNECTION ON FUEL PUMPS, A WRENCH MUST BE
USED TO BACK UP EACH TANK CONNECTION TO
PREVENT NYLON FITTING FROM TURNING. IF FITTING
TURNS, INTERNAL WIRE CONNECTION WILL BREAK,
NECESSITATING PUMP REPLACEMENT.
4. In wing root cavity, back up and disconnect electrical connections, fuel, and drain lines from pump.
5. While holding pump through cell access opening in top of wing, an assistance must remove four pump
mounting bolts in wing root cavity and pull pump up and out of fuel cell.
6. Install new gasket on fuel pump mounting boss, insert pump into cell, and hold in place while assistant
attaches it to wing but rib with four mounting bolts.
7. Reconnect electrical connections, fuel, and drain lines and ensure valves are positioned properly.
8. Install fuel cell cover plate and access plate on top of wing. Fill fuel cell through nacelle filler and check all
connections in the wing root cavity for leaks.
9. Install lower wing root fairing.
1. SUBMERGED FUEL PUMP
2. FUEL CELL
3. NYLON CONNECTOR ASSEMBLY
4. CHECK VALVE
4
___ 2
Figure 28-17. Submerged Fuel Boost Pump
28-20-00
Page 8
Reissued: December 31, 1989
2K23
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
1400 SERIES GAUGE 6" DIA. 0-60 PSI
1/4 OF 1% ACCURACY OR EQUIV.
REGULATING VALVE ----,
DISCONNECT LINE AT
ENGINE PUMP INLET
AND CONNECT TO
TEST RIG.
.,..,.,
00
-
HOSE RETURN
TO TANK BEING
USED
FISHER AND PORTER
FLOWMETER
o MAX. FLOW RATE 800 PPH
ACCURACY + 1% OF READING
OR EQUIVALENT CALIBRATED
FOR JET A-1
FLOWMETER SHOULD BE MOUNTED IN A VERTICAL POSITION.
THE ELEVATION SHOULD BE NO HIGHER THAN INJECTOR INLET
AND THE SAME FOR ALL TESTS.
Figure 28-18. Fuel Flow Test Apparatus
2K24
28-20-00
Page 9
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FUEL FLOW AND PRESSURE TEST (figure 28-18)
1. At flow divider/dump valve, disconnect fuel line from flow meter and connect it to test rig inlet.
2. Place return line end onto nacelle or tip tank filler opening. Ensure resulting fuel pressure doesn't push it
out of opening.
3. Connect electric power supply at APU connector. Maintain 28 volts for all tests.
4. Ensure all shutoff valves have full travel and wing tanks contain enough fuel to allow fuel to flow freely to
main inboard tank. At least 10 gallons of fuel must exist in each main inboard tank.
5. For zero fuel flow check, proceed as follows:
a. Tum crossfeed valve and right firewall shutoff valve off. Tum left firewall shutoff valve and right
submerged fuel pump on.
b. Ensure both aircraft fuel pressure gauges read 0 psi.
c. Tum crossfeed valve off, and left and right firewall shutoff valves on. Close test rig regulating valve
and tum right submerged fuel pump on.
d. Ensure fuel pressure gauge reads 0 psi for left engine and maximum 35 psi for right engine.
e. Compare readings on aircraft gauge with reading on test rig gauge.
f. Tum crossfeed valve off, and left and right firewall shutoff valves on. Close test rig regulator valve and
tum left submerged fuel pump on.
g. Ensure both fuel pressure gauges read 0 psi.
h. Tum crossfeed valve off, and left and right firewall shutoff valves on. Close test rig regulator valve and
tum left submerged fuel pump on.
i. Ensure left fuel pressure gauge reads maximum 35 psi and right fuel pressure reads 0 psi.
j. Compare readings on aircraft gauges with those on test rig.
6. For positive pressure fuel flow test, proceed as follows:
a. For left engine:
(1) Tum crossfeed valve off, and tum left firewall shutoff valve and left submerged fuel pump on.
(2) Adjust flow meter reading to 500 pph. Fuel pressure must read minimum 17 psig.
(3) Ensure aircraft fuel gauge reads minimum 17 psig.
(4) Tum crossfeed valve on and right firewall shutoff valve off. Tum left firewall shutoff valve and
right submerged fuel pump on.
(5) Adjust flow meter reading to 500 pph and fuel pressure gauge reading must read minimum 17 psig.
b. For right engine flow test, use previous procedure reversing all references to shutoff valves and pumps.
(Ex: right fuel pump in previous procedure becomes left fuel pump in this procedure.)
28-20-00
Page 10
-NOTE-
If flow meter is not available and positive pressure fuel flow test
cannot be perfonned use fuel weight per time method. In this test,
500 pph equals 8.33 pound/minute or 1.24 gallon/minute. Perform
test for approximately 2-3 minutes with stop watch.
Reissued: December 31, 1989
2L1
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INDICATING
DESCRIPTION AND OPERATION
The fuel quantity indicating system in the PA-42 contains two separate capacitance systems using dual display
indicators. Each identical probe system measures its fuel capacity with two probes in each inboard main cell (95
gal cap.) and one probe in all other cells and tanks (figure 28-19). The probe units have fixed tabular capacitor
elements to match the contour of the respective cell or tank position. This system displays very accurate
indications due to the linear response of probes. With fixed electrodes, sensor capacitance if about 2:1, or
approximately twice as great with a full system. Any change in fuel quantity between full and empty produces
corresponding changes in capacitance. These changes are amplified within the dual indicator and continuously
displayed on the indicator face. The dual indicator readout is a direct indication of fuel weight on board the
aircraft.
The dual-needle fuel quantity indicator, mounted on the copilot side above the control wheel, has its own AC
inverter to power the capacitance probe systems. Electrical power for the entire system is supplied from the 28
VDC aircraft power supply.
REMOVAL AND INSTALLATION OF SENSOR UNITS
Except for inboard main cell (which has two), one fuel sensor unit is located in each fuel cell and tank. Handle
units very carefully, as damaging tubes destroys accuracy of units. Each installation is covered separately.
NACELLE TANK SENSOR REMOVAL
Remove sensor mounted in upper portion of nacelle tank, inboard of filler cap, as follows:
1. Ensure enough fuel is drained from system to prevent spillover.
2. Remove access cover next to filler cap.
3. Disconnect and tag or mark leads to facilitate reconnection.
4. Remove screws attaching sensor to nacelle. Carefully remove unit and gasket.
AFT INBOARD AND MAIN FUEL CELL
Fuel sensors for aft inboard and main outboard cells are mounted at Wing Stations 15.0 and 102.0.
1. Remove access cover at WS 15.0 and repeat steps 2 and 4 under Nacelle Tank Sensor Removal.
MAIN INBOARD FUEL CELL SENSOR
The main inboard cell has two fuel senders at WS 13.3 and 36.0. To remove, repeat steps 1 and 4 under Nacelle
Tank Sensor Removal.
2L2
28-40-00
Page 1
Reissued: December 31, 1989
WING TIP TANK SENSOR
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
1. Remove bottom tank-wing fairing. Disconnect electric lines.
2. Ensure enough fuel is drained from system. Remove probe sensor.
CHART 2803. TEST EQIDPMENT FUEL QUANTITY INDICATOR
Nomenclature Model No.
Test Set 2548-G
Cheyenne III Adapter
(for Ragen) 101-00450
Lead Package 101-00431
or
2 coax/BNC jumper
cables.
Test Set 89-109-Z
Cheyenne III System
Harness
Probe Harness
Test Set GTF-12
Test Harness (for Gull
system) 083-047-001
Manufacturer
Barfield Instrument
Corp.
4101 N.W. 29th Street
Miami, FL 33142
Phone: 305-871-3900
Telex: 51-8808
or
Ragen Data Systems
3 Oval Drive
P.O. Box417
Central Islip, NY 11722
Phone: 516-234-3800
Telex: 685-2305
or
Gull Airborne
395 Oser Avenue
P.O. Box 9400
Smithtown, NY 11787
Phone: 516-213-3737
Telex: 685-2305
2L4
Use
Test Sensor Units or
Gauge in aircraft or on
bench for electrical
leakage, or capacitance,
and calibration.
284000
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
FUEL QUANTITY INDICATOR
Do not overhaul indicator. Replace, if necessary.
TANK SENSOR UNITS (ALL)
Do not overhaul tank units. If unit is found defective, replace it.
CLEANING OF TANK UNITS
All tank sensor units in this system are cleaned with trichlorethylene or any similar degreasing agent. Handle
sensor units carefully, as damaging tubes destroys accuracy of unit. After cleaning sensor units, allow to air dry.
284000
Page 4
-WARNING-
TRICHLORETHYLENE OR OTHER DRY CLEANING
SOLVENTS MUST BE USED IN WELL VENTILATED AREAS.
SOLVENTS CAN PRODUCE TOXIC FUMES AND REPEATED
CONTACT WITH SKIN CAN BE HARMFUL. ALSO, USE
RUBBER GLOVES WHEN HANDLING SOLVENTS.
THIS SPACE INTENTIONALLY LEFT BLANK
Reissued: December 31, 1989
2L5
PIPER AIRCRAFT
PA .. 42/42 .. 720
AIRPLANE MAINTENANCE MANUAL
FUEL QUANTITY CAPACITANCE
Unit Location
Tip
Main (Inbd.)
Main (Outbd.)
Main (Outbd.)
Nacelle
Aft (Inbd.)
Unit Location
Tip
Main (Iubd.)
Main (Outbd.)
Main (Outbd.)
Nacelle
Aft (Inbd.)
CHART 2804. TANK UNIT CAPACITANCE (DRY) - RAGEN
Piper Part No. Tank Unit Model Capacitance (pF) Tolerance (+pF)
56937-7 peA 1949 10.86 .5
56937-2 PBA 1944 13.75 .5
56937-03 PBA 1945 11.72 .5
56937-8 PBA 1946-1 23.89 .5
56937-6 PBA 1948 31.03 .5
56937-5 PBA 1947 11.62 .5
CHART 2804. TANK UNIT CAPACITANCE (DRY) CONT. - GULL
Piper Part No. Tank Umt Model
56937-13 GUAOI4-943-006
56937-14 GUA014-943-002
56937-10 GAU014-943-003
56937-11 GUAOI4-943-005
56937-12 GUAOI4-943-004
56937-9 GUA014-943-001
2L6
Capacitance (pF) Tolerance (+pF)
11.20
14.00
12.40
24.00
31.20
11.80
.5
.5
.5
.5
.5
.5
28-40-00
PageS
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHECKS AND ADJUSTMENT OF FUEL QUANTITY SYSTEM (figure 28-21 or 28-22)
BENCH TESTING TANK UNITS
Use appropriate test equipment when perfonning following test:
1. Tank Unit Dry Capacitance Bench Test:
PPS60095J
Using capacitance tester, measure dry capacitance of tank units. Capacitance readings must be within limits
shown on chart 2804 and electrical leakage must be greater than 10 megohms.
FUEL QUANTITY SYSTEM CALIBRATION TESTS
The complete calibration check requires that the aircraft be level both longitudinally and laterally, and that
both the dry and wet checks be accomplished.
DRY CALIBRATION PROCEDURE
1. Drain fuel system completely.
2. Ensure fuel quantity circuit breaker on essential buss is activated.
3. Ensure all distribution circuit breakers forward of crossfeed shutoffs are activated.
4. Ensure battery master switch is off and connect external power unit to aircraft. Increase voltage on external
power source until 28 V dc shows on overhead panel voltmeter.
5. Using a Barfield #2548-G, or other approved capacitance fuel system test set (see chart 2803), check total
left and right side probes and system capacitance as follows:
a. On the barfield test set disconnect the indicator for testing Ragen systems
b. On the Barfield test set disconnect the signal conditioners for the Gull system.
c. Obtain a capacitance reading per wing of 71.84 pF to 79.84 pF for standard fuel system, 102.87 pF to
111.87 pF for the Ragen system (includes 75 gallon nacelle tank), or 104.43 pF to 113.43 pF for the
Gull system (includes 75 gallon nacelle tank).
d. Recheck and correct probes and systems if capacitance values do not fall within specified limits.
-CAUTION-
DO NOT CHANGE ADJUSTMENTS OF SENDER UNITS, BUT
ADJUST QUANTITY GAUGES INSTEAD.
6. Ensure that the fuel lines from the electric fuel pump to the engine and from the engine to the jet pump are
full of fuel. If fuel lines have been drained, add enough fuel to fuel tank to prime the pump (approximately
one gallon).
a. Maintain fuel pressure for two minutes.
b. Tum off fuel pump and drain fuel tanks.
c. Add three gallons of fuel to each wing tip tank.
d. Tum on fuel pump, wait ten minutes, and record system capacitance. (The capacitance obtained will
correspond to a fuel quantity indication of zero).
e. With fuel quantity gauge connected to aircraft wiring, set low adjustment until gauge reads zero. (Tap
gauge lightly during all adjustments).
f. Add 110.0 pF to the aircraft gauging system using the Barfield #2548-G test set and set the high
adjustment on the gauge to read 1870 lbs.
7. Repeat steps 6. e. and 6. f. checking and adjusting the zero and 1870 lb. quantity until minimal adjustment is
required.
284000
Page 6
Reissued: December 31, 1989
2L7
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
SENSOR FLANGE GROUND LEAD
GROUND POST
j-------.
-'----+t-- SENSOR UNDER TEST
\_. --6'''--' -_I I
CONVENIENT GAUGE
METAL
INSULATED SURFACE
1.70" DIA.
36"
1-' --6"L...' --'I
Figure 28-20, Fabrication of Test Fixture For Tank Unit Testing
2L8
28-40-00
Page 7
Reissued: December 31, 1989
28-40-00
PageS
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CONNECTOR
E244A (R)
E144A (L)
MS51958 - 63 (4 REO.)
CASE SEAL
7 WIRE HARNESS

SIGNAL CONDo INSTALLATION ( GULL FUEL
OUANTITY SYSTEM) ON REAR OF FIREWALL
3650 - 968 - 001 SIGNAL CONDo
(WHEN SIGNAL CONDo IS NOT
INSTALLED INSTALL THE (4)
MS51958 - 63 SCREWS TO SEAL
THE FIREWALL.)
Figure 28-21. Fuel Gauge Adjustment, Gull
FULL RIGHT ""' _____
EMPTY LEFT
EMPTY RIGHT
Figure 28-22. Fuel Gauge Adjustment, Ragen
Reissued: December 31, 1989
2L9
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2805 FUEL QUANTITY CALIBRATION WORK SHEET
FUEL QUANTITY CALIBRATION DATA
DATE __________ _
AffiPLANESIN __________________ __
TECHNICIAN(S) ____________________________________ _
TEST SET BARFIELD 2548 - G 1- GA SIN __________ _
PROCEDURE L. SIDE R. SIDE
DRY pf.
--------
pf.
--------
(WAIT 15 MINUTES FOR SETTLING) 3 GAL/SIDE
ADJLOW FOR ZERO LB. FOR ZERO LB.
SYSTEM CAPACITANCE
SIMULATE 1870 LBS. 110.0
ADJUST HIGH FOR 1870
500 LB OF FUEL
1000 LB OF FUEL
1500 LB OF FUEL
FULL OR 2000 LB OF FUEL
2L10
pf.
pf.
LB. FOR
LB.
LB.
LB.
LB.
pf.
--------
110.0 = = ~ _____ pf.
1870 LB.
LB.
--------
________ LB.
LB.
--------
________ LB.
28-40-00
Page 9
Reissued: December 31, 1989
'-d
\1'
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
WET CALIBRATION PROCEDURE
-CAUTION-
ENSURE THAT THE WEIGHT OF THE FUEL IS ACCURATE
BEFORE ADJUSTING THE FUEL QUANTITY GAUGE.
(EXAMPLE: A PARTICULAR BATCH OF JET A WEIGHING
2000 LBS. PER 300 U.S. GALLONS AT +75F WILL TAKE
APPROXIMATELY 305 U.S. GALLONS AT +100F.
-CAUTION-
VERIFY EMPTY SETTING AND REPLACE GAUGE IF FULL
SETTING MUST BE ADJUSTED MORE THAN 50 LBS.
1. Add fuel to each wing in 500 lb. increments until all tanks are full. Record fuel quantity gauge readings for
each increment (500, 1000, 1500, and full).
2. Full scale indication may be adjusted 50 Ibs. max. to agree with the amount of fuel added. If a difference
greater than 5% of full scale indication occurs at any calibration point, repeat the wet calibration
procedure.
3. If a difference greater than or equal to 5% of full scale indication occurs after the second calibration and
all probes have been checked per step 5 of the dry calibration procedure, replace the indicator and
recalibrate the system.
AUTOMATIC FUEL PUMP SYSTEM (See Chapter 91 for Electrical Schematic)
The automatic fuel pump system supplies the appropriate system with proper fuel if fuel pressure falls below an
acceptable level. If fuel pressure starts to fall, the fuel pressure gauge mechanism senses the drop, and at 15 psi,
completes a circuit to activate the low fuel pressure annunciator and the fuel pump relay. The relay completes a
circuit between the auto position of the fuel pump switch and the fuel pump.
This system only works with the switch in auto, which in tum prevents the submerged fuel pump from running
continuously. The annunciator light will still come on at 15 psi. With both the pump and light controlled, in this
case by the gauge, the gauge also shuts them off when pressure rises above 33 psi.
The fuel pump relays are located on a shelf mounted to bulkhead at Fuselage Station 25.6. Access to the shelf
is made by removing the royalite cover at the rear of the nose baggage compartment.
28-40-00
Page 10
Reissued: December 31, 1989
2L11
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
TEST OF AUTOMATIC FUEL PUMP SYSTEM
-NOTE-
Refer to chapter 73 for further information on test and adjustment of
fuel pressure transmitter and gauge.
1. Check gauge and its pressure transmitter for accuracy with a Barfield tester before continuing. If gauge is
defective, replace with selViceable unit.
2. Two procedures exist to check this system. The crossfeed procedures is as follows:
a. Close firewall shutoff valve of system not being tested. Open crossfeed valve.
b. Tum on battery master switch. Place pump switch of system being tested in auto position.
c. Tum on opposite fuel pump until fuel pressure rises above 20 psi and shut pump off. As fuel pressure
decreases below 15 2 psi, annunciator light and submerged fuel pump must come on. If they come on
before or after 15 2 psi, replace gauge.
d. Tum all switches off.
3. Another check procedure is to start appropriate engine and proceed as follows:
a. Position pump switch in auto and shut engine down. As fuel pressure decreases, submerged fuel pump
and annunciator light must come on at 15 2 psi. If they come on before or after 15 2 psi, replace
instrument.
2L12
28-40-00
Page 11
Revised: August 1, 1989
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
2L13
May 15, 2012
28-40-00
Page 12
THIS PAGE INTENTIONALLY BLANK
PIPER AIRCRAFT
PA-42 / PA-42-720
AIRPLANE MAINTENANCE MANUAL
2L14
May 15, 2012
28-40-00
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GRIDS 2L14 THRU 3B8
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CHAPTER
HYDRAULIC POWER
389
SYSTEM
SUB-SYSTEM
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PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 29 - HYDRAULIC POWER
TABLE OF CONTENTS/EFFECTIVITY
SUBJECT
GENERAL DESCRIPTION AND OPERATION
Hydraulic System Failure
Troubleshooting
MAIN HYDRAULIC SYSTEM
Flushing Hydraulic System
Hydraulic System Operational Checks Using Piper
Test Unit
Hydraulic Test Unit (Optional)
Connecting Test Unit
Cycling Landing Gear
Checking Landing Gear Cycle Time
Checking Time Delay Valve
Checking Handle Release to Neutral
Checking Priority Valve
Checking Main Relief Valve
Checking Hand Pump Relief Valve
Checking for Suction Air Leakage
Disconnecting Test Unit
Hydraulic Power Pack
Removal of Power Pack
Installation of Power Pack
Disassembly of Power Pack
Cleaning, Inspection and Repair of Power Pack
Assembly of Power Pack
Assembly of Reservoir
Testing Reservoir for Leakage
Disassembly of Manifold
Assembly of Manifold
Installation of Manifold
Disassembly of Power Pack Handle Release Mechanism
Assembly of Power Pack Handle Release Mechanism
Adjustment of Power Pack Handle Release Mechanism
Operation of Gear Selector Handle Mechanism
Inspection of Gear Selector Handle
Adjustment of Gear Selector Handle Mechanism
Disassembly of Spring Cartridge Assembly
Disassembly of Main Relief Valve
Assembly of Main Relief Valve
3810
GRID
NO.
3B13
3B13
3B14
3B20
3B20
3B20
3B21
3B21
3B2l
3Cl
3C3
3C3
3C4
3C4
3C5
3C5
3C6
3C6
3C6
3C8
3C8
3C12
3C12
3C13
3C13
3C13
3C15
3C16
3C17
3C17
3C18
3C18
3C20
3C20
3C23
3C23
3C23
EFFECTIVITY
29 - Cont.lEffect.
Page 1
Reissued: December 31, 1989
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SUB-SYSTEM
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29 - ContJEffec.
Page 2
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 29 - HYDRAULIC POWER (continued)
TABLE OF CONTENTS/EFFECTIVITY
SUBJECT
MAIN HYDRAULIC SYSTEM (continued)
Adjustment of Main Relief Valve
. Disassembly of Priority Valve
Assembly of Priority Valve
Adjustment of Priority Valve
Disassembly of Time Delay Check Valve
Assembly of Time Delay Check Valve
Disassembly of Door Vent Valve
Assembly of Door Vent Valve
Adjustment of Door Vent Valve
Disassembly of Vent Filter
Assembly of Vent Filter
Disassembly of Standpipe Filter
Assembly of Standpipe Filter
Disassembly of Hand Pump Check Valve
Assembly of Hand Pump Check Valve
Disassembly of Hand Pump Relief Valve
Assembly of Hand Pump Relief Valve
Adjustment of Hand Pump Relief Valve
Disassembly of Hand Pump Suction Screen
Assembly of Hand Pump Suction Screen
Adjustment of Door Solenoid Valve
Disassembly of Time Delay Check Valve
Assembly of Time Delay Check Valve
Installation and Adjustment of Inboard Gear
Doors Switch
Power Pack Bench Test Adjustment
Bleeding the Hydraulic System
Removal and Installation of Hydraulic Lines
Removal and Installation of Hydraulic Filters
Replacement of Filter Elements
Hydraulic Pump Operational Check
Procedure After Hydraulic Pump Failure
Removal of Hydraulic Pump
Disassembly of Hydraulic Pump
Cleaning, Inspection, Repair of Hydraulic Pump
Assembly of Hydraulic Pump
Installation of Hydraulic Pump
Priming Hydraulic Pump
GRID
NO.
3C23
3C24
3C24
3C24
3C24
301
301
301
301
3D2
302
302
302
302
3D2
3D3
3D3
303
3D4
3D4
3D4
3D4
3D4
3D5
306
3D6
3D7
3D7
3D8
3D8
3D8
3D8
3010
3D1O
3Dll
3013
3D13
Reissued: December 31, 1989
3811
EFFECTIVITY
SYSTEM
SUB-SYSTEM
29-10-00
29-10-00
29-10-00
29-10-00
29-10-00
29-10-00
29-10-00
29-10-00
29-10-00
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHAPTER 29 - HYDRAULIC POWER (continued)
TABLE OF CONTENTS/EFFECTIVITY
SUBJECT
MAIN HYDRAULIC SYSTEM (continued)
Hand Pump (Emergency)
Removal of Hand Pump
Disassembly of Hand Pump
Cleaning, Inspection and Repair of Hand Pump
Assembly of Hand Pump
Installation of Hand Pump
Bleeding Hand Pump
Hand Pump Test
3812
GRID
NO.
3D14
3D14
3D14
3D16
3D16
3D16
3D17
3D17
EFFECTIVITY
29 - Cont./Effec.
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
GENERAL DESCRIPTION AND OPERATION
The hydraulic power pack provides the hydraulic power required to operate the landing gear. The power pack
is located in the right side of the fuselage nose section at Bulkhead Station 57.00 in front of the forward pressure
bulkhead. The power pack is operated by a flexible shaft with a selector lever fashioned like a wheel mounted on
the instrument panel left of the engine control quadrant. The power pack contains the system reservoir and
assorted valves which control the system operation. The power pack works in conjunction with the engine driven
pumps, solenoid valves, and hydraulic cylinders to perform the desired operation sequence selected with the
control lever in the cockpit.
-WARNING-
TO ENSURE LANDING GEAR DOES NOT MOVE TO THE UP
(RETRACTED) POSITION WHILE AIRCRAFT IS ON GROUND,
THE FOLWWING CHECK MUST BE PERFORMED PRIOR TO
APPLYING HYDRAULIC PRESSURE TO SYSTEM. ATTEMPT
TO MOVE SELECTOR LEVER TO UP POSITION. IF LEVER
CAN BE MOVED TO UP POSITION, AN IMPROPERLY
ADJUSTED SELECTOR MECHANISM EXISTS OR ANTI-
RETRACTION SYSTEM IS INOPERATIVE. BE SURE TO
SELECT GEAR DOWN PRIOR TO APPLYING SYSTEM
PRESSURE OR STARTING ENGINE.
During an electrical failure, the door solenoid valve in the power pack moves (spring pressure) to OPEN door
position and remains in that position. Doors will not open until selector lever is moved to gear down position and
gear extension cycle is started.
-WARNING-
PRIOR TO ANY CHECK OF HYDRAULIC SYSTEM, PLACE
AIRPLANE ON JACKS ACCORDING TO INSTRUCTIONS IN
CHAPTER 7 OF THIS MANUAL.
HYDRAULIC SYSTEM FAILURE
Emergency use of hand pump to extend gears indicates engine driven pumps are operating without sufficient
fluid. This condition causes additional wear on engine driven pumps. Remove and check filter elements even if
pump failure is not apparent.
1. Remove filter elements. Check for metal particles.
2. If no metal particles exist, replace filter element and replenish fluid.
3. If metal particles are evident in either filter, proceed as follows:
a. Inspect, replace, or repair both hydraulic pumps.
b. Prime pumps and do not connect pumps to rest of hydraulic system until system is flushed.
c. Proceed to flush system.
3813
29-00-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
TROUBLESHOOTING
Chart 2901 lists possible problems which could be encountered with the hydraulic system, probable causes, and
suggested remedies. To troubleshoot, place airplane on jacks (see Chapter 7) and perform a system operational
check.
29-00-00
Page 2
-NOTE-
If hydraulic system is serviced properly, hydraulic components used
in this airplane manufactured by the Wieble Tool Company do not
require overhaul until tO,OOO hours of service or to year, whichever
comes first. If any problems arise during inspection, corrective action
must be taken regardless of time in selVice.
Reissued: December 31,1989
3814
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2901. TROUBLESHOOTING (HYDRAULIC SYSTEM)
Trouble
Landing Gear system
fails to operate.
Cause
Selector lever disconnected.
Select lever out of
adjustment.
-CAUTION-
Remedy
Connect lever.
Adjust lever.
PULL CIRCUIT BREAKERS OF THE ICE PROTECTION
CIRCUIT AND THE STALL WARN HEAT CIRCUIT BEFORE
DEPRESSING THE Q SENSOR OVERRIDE SWITCH TO
AVOID DAMAGING THE HEATING ELEMENTS.
-NOTE-
A solenoid operated lock, located behind the instrument panel as part
of the selector assembly, prevents lever from being inadvertently
moved to the up position while the airplane is on the ground or in
flight below 100 4 KlAS. To cycle the gear with the airplape on
jacks, depress the q sensor override switch unlocking the gear selector
handle. The gear can now be operated as required.
Hydraulic fluid reselVoir
below operating level.
Leak or obstruction in
hydraulic lines.
Internal leakage in main
relief valve.
Internal leakage in hand
pump relief valve.
3815
Fill the power pack with
hydraulic fluid.
Check the system with
hydraulic test unit or
hand pump.
Check system operation.
Check system operation.
29-00-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHART 2901. TROUBLESHOOTING (HYDRAULIC SYSTEM) (continued)
Trouble
Gear operates abnonnally
slow or partially.
29-00-00
Page 4
Reissued: December 31, 1989
Cause
Low fluid level.
Leaking or kinked line.
Internal leak in cylinder.
Priority valve out of
adjustment or leaking.
Slow leak in main relief
valve. (Engine pump)
Slow leak in hand pump
relief valve.
External leakage at
selector valve.
One engine pump
inoperative.
Low pump pressure.
3816
Remedy
Fill power pack with
hydraulic fluid.
Replace line.
Repair or replace cylinder.
Check valve operation.
Check system operation.
Check system operation.
Replace damaged O-rings.
Replace pump.
Replace pump.
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
CHART 2901. TROUBLESHOOTING (HYDRAULIC SYSTEM) (continued)
Trouble Cause
Selector handle returns Cable, line or obstruction
to neutral before cycle restricting the travel
is complete. required to fully select
gear up or down.
Selector lever out of
adjustment.
If gear completes cycle
(red light out) doors do
not close, battery output
may be low.
Time relay valve and/or
piston release lock out
of adjustment.
Time delay valve air
locked.
3817
Remedy
Check and remove
obstruction.
Adjust control.
Check voltage.
Check operation.
Bleed air out by holding
selector down for 30
seconds, then make three
or four rapid movements
to neutral and back to
down.
29-00-00
Page 5
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHART 2901. TROUBLESHOOTING (HYDRAULIC SYSTEM) (continued)
Trouble
Gear retracts or extends
before doors open.
Doors come open in
flight. (Note: Refer
to Landing Gear
Troubleshooting
Chart 3201.)
Doors fail to close.
29-00-00
Page 6
Reissued: December 31, 1989
Cause
Priority valve leaks in
power pack.
Solenoid valve stuck
in closed position.
Micro switch on power
pack out of adjustment.
Micro switch on power
pack out of adjustment.
Doors adjusted too tight,
actuator not locking.
Faulty limit switch.
Low electric power
supply.
Cannon plug on power
pack loose.
Solenoid valve stuck in
door open position.
Circuit breaker out.
3818
Remedy
Check valve cracking
pressure.
Tum off power and hand
pump doors open. (Note:
With power off solenoid
valve shuttles to door open
and the doors may be opened
without selecting gear up or
down.)
Check for loose wire or
mounting, or bent bracket.
Adjust micro switch. (Door
solenoid should remain in
door close position when
handle returns to neutral.)
Loosen adjustment on
actuator rod end.
Check all indicator lights.
Check battery.
Tighten.
Check wiring to solenoid
valve.
Check breaker. (Note:
Without electric power,
the gear doors will open
but not close.)
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
CHART 2902. LEADING PARTICULARS, HYDRAULIC POWER PACK
NOMENCLATURE
Operating Pressure
Main Relief Valve Pressure (Primary)
Hand Pump Relief Valve Pressure (Secondary)
Hand Pump Relief Valve Reseat Pressure
Low Pressure Thermal Relief Vent Valve "Open"
Low Pressure Thermal Relief Vent Valve "Closed"
Priority Valve Cracking Pressure
Hand Pump Check Valve Cracking Pressure
Landing Gear Position Release
Time Delay Valve
Hydraulic Fluid Required
Weight Dry - Power Pack
Hydraulic Fluid Flow Rate (Both Pumps Operating)
Reservoir Operating Fluid Level (Engine Pump)
(Minimum - Maximum)
Reservoir Fluid Level (Emergency)
(Stand Pipe Level)
-NOTE-
WTC 2135-1
(See Note Below)
1900 PSI
1900 - 1950 PSI
2025 - 2100 PSI
1900 - 1950 PSI
o to 100 PSI
150 PSI Max.
600 - 650 PSI
1 to 3 PSI
1220 - 1250 PSI
3 to 9 seconds
MIL-H-5606
10.00 pounds
1.6 a.p.M.
1. 82 - 2.1 pints
1.22 pints
Should the values in the text differ from the chart values, the chart
values take precedence.
3819
29-00-00
Page 7
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
MAIN HYDRAULIC SYSTEM
FLUSHING HYDRAULIC SYSTEM
When hydraulic system is contaminated, drain and flush entire system to remove contaminated fluid.
Determine cause and type of contamination and proceed as follows:
1. Remove engine cowlings (Chapter 71).
2. Disconnect hydraulic lines at engine driven pumps.
3. Drain hydraulic fluid from power pack reservoir using suction, fill, and drain fitting on bracket located at
lower aft corner of nose access panel opening behind hydraulics components cover.
4. Disconnect hydraulic lines at actuating cylinders and drain fluid from all hydraulic lines.
5. Remove and replace filter elements located on engine firewall. Flush out filter bowls.
6. Flush hydraulic system with clean hydraulic fluid (MIL-H-5606). Examine several seals and cylinder bores
for damage.
7. When hydraulic system is completely flushed and no indication of contamination exists, reconnect
previously disconnected fittings and replenish system with clean hydraulic fluid.
8. Bleed hydraulic system (described in Bleeding the Hydraulic System) and check for leaks.
9. Replace engine cowlings (Chapter 71).
HYDRAULIC SYSTEM OPERATIONAL CHECKS USING PIPER TEST UNIT
The test unit (PIN 753 080) can be used to check hydraulic systems, the hydraulic power pack landing gear
cycling operation, power pack operating pressure checks and adjustments etc, all performed without operating
engines.
The unit consists of an electric, motor driven hydraulic pump, bypass valve, fluid reservoir, filter, pressure
gauge, hoses, and adapter fittings housed in a metal cabinet and mounted on casters.
3820
29-10-00
Page 1
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
HYDRAULIC TEST UNIT (OPTIONAL)
Multi-purpose hydraulic test units can also be used to provide the same functions as the Piper unit. The test unit
must be capable of duplicating and monitoring the operating pressures and the flow rate given in Chart 2902.
-NOTE-
The following procedures are written for Piper or optional hydraulic
test units. Use proper operating manual for specific unit being used.
CONNECTING TEST UNIT
1. Remove access panel on right side of nose section. Open access in hydraulics components cover.
2. If system requires filling only, remove protective cap from suction; fill and drain valve mounted on bracket
on lower aft comer of nose access panel opening. Connect pressure hose from test unit. Open valve on
suction port, place control lever in up position, and proceed to fill system per instructions with test unit.
Observe fill lines so not to overfill reservoir.
3. If system is to be operated during various ground checks, overhaul, or inspection of components, remove
protective caps from suction and pressure ports, connect test unit pressure hose to pressure port and test unit
suction hose to suction port. Open valve on suction port and operate test unit according to supplied
instructions.
CYCLING LANDING GEAR
1. Connect hydraulic test unit (described in Connecting Test Unit) and jack airplane (outlines in Chapter 7).
2. Set hydraulic test unit bypass valve open.
3. Start test unit pump motor.
4. Place gear selector handle in UP or DOWN position. Slowly close bypass valve until system pressure has
reached that specified in Chart 2902.
5. Operate gear using landing gear control handle.
291000
Page 2
Reissued: December 31, 1989
3821
14
10
PIPER AIRCRAFT
PA .. 42/42 .. 720
AIRPLANE MAINTENANCE MANUAL
I
L____ __ _____ _s_
16
9 9
BULKHEAD TEE & CAP (TEST PORT)
Figure 29-1. Hydraulic System - Schematic Diagram
3822
15
14
29-10-00
Page 3
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
1. PUMP - ENGINE DRIVEN
2. FILTER
3. CHECK VALVES
4. HAND PUMP
5. SELECTOR HANDLE
6. RESTRICTOR VALVE
7. ACTUATOR, NOSE GEAR
8. ACTUATOR, MAIN GEAR
9. ACTUATOR, MAIN GEAR DOOR
10. POWER PACK ASSEMBLY
A. MAIN RELIEF VALVE
B. ENGINE PUMP CHECK VALVE
C. PRIORITY VALVE
D. DOOR SOLENOID VALVE
E. VENT VALVE
F. TIME DELAY CHECK VALVE
G. TIME DELAY VALVE
H. HAND PUMP RELIEVE VALVE
J, K, M, FILTER
N. RESERVOIR
P. LANDING GEAR SELECTOR VALVE
Q. SELECTOR VALVE DETENT
R. SELECTOR VALVE SPRING RETURN
S. ELECTRICAL SWITCH
T. ELECTRICAL CONNECTOR
11. PRESSURE PORT VALVE
12. SUCTION PORT TOGGLE VALVE
13. HAND PUMP CHECK VALVE
14. CYLINDER ASSEMBLY
AA. CYLINDER
BB. EXPLOSIVE VALVE
CC. FILL VALVE
DD. BURST DISC
EE. GAUGE
15. UN-LOCK ACTUATOR
16. SHUTTLE VALVE, MAIN GEAR
17. SHUTTLE VALVE, NOSE GEAR
Figure 29-1. Hydraulic System - Schematic Diagram (continued)
29-10-00
Page 4
Reissued: December 31,1989
3823
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
ANTI-RETRACTION
GROUND GEAR WARNING HORN SOLENOID

DOOR
SOLENOID
GROUND GEAR
WARNING HORN RELAY
ANTI-RETRACTION
SWITCH
DOWN 0
NOSE GEAR
LIMIT SWITCH
MAIN GEAR
LIMIT SWITCH (LEFT)
'-----; A
.--------i B

NOTES:
D 1------'
DOOR SOLENOID
SWITCH
UP
DOWN
o
MAIN GEAR
LIMIT SWITCH (RIGHT)
1. GEAR IS SHOWN DOWN AND LOCKED, DOORS
CLOSED AND SELECTOR HANDLE IN DOWN
NEUTRAL, POWER ON.
2. POWER ON - DOORS CLOSED
POWER OFF - DOORS OPEN
Figure 29-2. Schematic of Power Pack Electronics System
3824
29-10-00
Page 5
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
-NOTE-
If retraction malfunction due to air in system is expected, follow
procedure for Checking Landing Gear Cycle Time. Gear cycling time
can be prolonged by slowly opening the test unit bypass valve part
way and bleeding off part of pump flow.
6. After completion of cycling, ensure landing gear selector handle is in DOWN, neutral position, and landing
gear is down and locked.
7. Disconnect hydraulic test unit.
8. Remove airplane from jacks (Chapter 7).
CHECKING LANDING GEAR CYCLE TIME
-NOTE-
The following times, taken using a single test unit, can be
considerably reduced by using two test units, one hooked to each
firewall fitting. If times are within limits when operated by test unit,
but exceed limits when operated by engine driven pump, either
internal leakage in pump or suction air leak through suction plumbing
system to either of the engine driven pumps could exist. (Refer to
paragraph entitled Checking For Suction Air Leakage.) If tests
indicate a defective pump, repair or replace defective pump. If time
exceeds limit when operated by either test unit or engine driven
pump, internal leakage exists in hydraulic system. Check actuators
for internal leakage and repair or replace actuators as required. If
actuators are not defective, power pack internal leakage exists, and
repair or replace power pack.
When malfunction in hydraulic system is suspected, due to slow gear cycle time, it could be caused by low fluid
in airplane reservoir causing system to be full of air. The following procedure will purge air from system and fill
reservoir:
1. Place airplane on jacks (see Jacking, Chapter 7).
2. Cycle landing gear through two complete cycles.
3. Excessive foam in reservoir indicates a possible leak in suction plumbing where air is drawn into system.
Check all ground service suction connections for leaks.
4. With landing gear extended, place gear handle in full UP position, and record time required for gear to
retract and doors to close. TIme must not exceed 9 0.5 seconds, plus time required for time delay valve to
operate.
5. With landing gear retracted, place gear handle in full DOWN position, and record time required for gear to
extend and doors to close. Time must not exceed 8 0.5 seconds, plus time required for time delay valve to
operate.
291000
Page 6
Reissued: December 31, 1989
3C1
PIPER AIRCRAFT
PA42/42 720
AIRPLANE MAINTENANCE MANUAL
2 5
6
7
9
1. FILTER, RIGHT PUMP 7. HYDRAULIC PUMP, RIGHT
2. GEAR ACTUATING CYLINDER, RIGHT 8. EMERGENCY HAND PUMP
3. DOOR ACTUATING CYLINDER, RIGHT 9. HYDRAULIC PUMP, LEFT
4. DOOR ACTUATING CYLINDER, LEFT 10. POWER PACK ASSEMBLY
5. GEAR ACTUATING CYLINDER, LEFT 11. GEAR ACTUATING CYLINDER, NOSE
6. FILTER, LEFT PUMP
Figure 29-3. Hydraulic System Installation
3C2
29-10-00
Page 7
Reissued: December 31, 1989
PIPER AIRCRAFT
PA42/42720
AIRPLANE MAINTENANCE MANUAL
CHECKING TIME DELAY VALVE
1. Connect hydraulic test unit (described in Connecting Test Unit).
2. With test unit operational and airplane master switch ON, move landing gear selector handle to DOWN
position. Note delay of handle returning to NEUTRAL position.
-NOTE-
Time delay between moving selector handle to down position (with
master switch on) and automatic releasing of selector handle to
neutral, must be 3 to 9 seconds at room temperature. Colder
temperature causes a longer delay.
3. If time delay is not 3 to 9 seconds, ensure valve is not air locked. Bleed air out by holding selector down for
30 seconds and complete three or four rapid movements from neutral to down.
4. Replace time delay valve, if defective.
5. Disconnect hydraulic test unit.
CHECKING HANDLE RELEASE TO NEUTRAL
-NOTE-
One release valve releases handle from both gear down and gear up
positions. If handle return springs are adjusted properly, release valve
must release handle from both positions at same pressure. The
following procedures check release pressure from gear down position
and release pressure from gear up position. This is done to assure
satisfactory operation of other equipment relative to handle release
operations.
1. Place airplane onjacks (see Jacking, Chapter 7).
2. Connect hydraulic test unit (described in Connecting Test Unit).
3. Run landing gear through two complete cycles, ending with gear down and locked and doors closed.
4. Set hydraulic test unit bypass valve fully open.
5. Place landing gear selector handle fully down.
6. Close bypass valve very slowly until handle trips back to neutral. Ensure gauge pressure readings comply
with those in Chart 2902 when handle trips to neutral. Allow time for time delay valve to open.
291000
Page 8
Reissued: December 31, 1989
3C3
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
7. Set hydraulic test unit bypass valve fully open.
8. Place landing gear selector handle in full up position.
9. Close bypass valve very slowly until handle trips back to neutral. Ensure gauge pressure readings comply
with those in Chart 2902 when handle is tripped to neutral. Allow time for time delay valve to open.
10. Adjust handle release, if required.
11. Ensure landing gear selector handle is in down neutral position and landing gear is down and locked.
12. Disconnect test unit and remove airplane from jacks.
CHECKING PRIORITY VALVE
1. Connect hydraulic test unit and place airplane on jacks (see Jacking, Chapter 7).
2. Run landing gear through two complete cycles.
3. With gear down and locked and test unit operational, tum master switch off and move gear handle to down
position causing doors to open and handle to return to neutral position. Keep switch off, leaving doors
open, facilitating completion of check.
4. Open hydraulic test unit bypass valve.
-NOTE-
As priority valve opens, nose gear downIock starts releasing. Read
pressure gauge at that point.
5. Place landing gear selector handle fully up. Close bypass valve very slowly, observe pressure gauge of test
unit, and note at which pressure reading priority valve opens. Priority valve must open at 600 - 650 psi, as
indicated in Chart 2902.
6. Make required priority valve adjustments.
7. Ensure landing gear selector handle is in down, neutral position, and landing gear is down and locked.
8. Disconnect test unit and remove airplane from jacks.
CHECKING MAIN RELIEF VALVE
1. Connecttest unit.
2. Open test unit bypass valve.
3. Hold landing gear selector handle in full down position.
4. Close bypass valve slowly and note pressure build-up and point where pressure stabilizes on test unit gauge.
Stabilization indicates relief valve setting as listed in Chart 2902.
5. Adjustment of power pack main relief valve is completed with power pack installed in airplane. Remove
top cover and drain fluid to gain access to adjusting screw.
6. Disconnect hydraulic test unit.
3C4
29-10-00
Page 9
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
CHECK HAND PUMP RELIEF VALVE
1. Place landing gear selector handle, located right of pilot seat under floor, in full down position. With master
switch off, extend handle and operate emergency hand pump to open landing gear doors.
2. Disconnect door open line (upper fitting) from main gear door cylinder. Connect hydraulic test unit
pressure hose to door open line. Cap actuator fitting.
3. Close bypass valve on hydraulic test unit.
4. Operate emergency hand pump and note at which reading on hydraulic test unit pressure gauge hand pump
relief valve open. Pressure must be between 2025 - 2100 psi (indicated in Chart 2902).
5. Adjustment of power pack hand pump relief valve is completed with power pack installed in airplane.
Remove cover and drain fluid to gain access to adjusting screw.
6. Open bypass valve on test unit to release pressure. Disconnect test unit pressure hose from door open line.
Remove cap from actuator fitting and reconnect door open line to main door actuator.
7. Replenish required hydraulic reservoir fluid.
CHECKING FOR SUCTION AIR LEAKAGE
1. Remove engine cowling for access.
2. Disconnect hydraulic pump suction hose from pump. Connect test unit suction hose to airplane suction
hose with suitable fitting.
3. Disconnect hydraulic pump pressure hose from pump. Connect test unit pressure hose to airplane pressure
hose with suitable fitting.
4. Connect test unit electrical cable to electrical power source.
5. Jack airplane and cycle landing gear through five complete cycles.
6. Check test unit reservoir for air bubbles indicating leakage in suction line, hose, or fittings. Replace
defective parts.
-NOTE-
If replacement parts eliminate visible air in test unit reservoir, but air
still enters hydraulic system, engine driven pump may contain suction
leak.
7. Ensure landing gear selector handle is in down, neutral position, and landing gear is down and locked.
8. Remove airplane from jacks. Disconnect test unit.
29-10-00
Page 10
Reissued: December 31, 1989
3C5
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
DISCONNECTING TEST UNIT
1. Ensure landing gear selector is in the down, neutral position, and the landing gear is down and locked.
2. Shut off test unit per instruction supplied with unit.
3. Close suction-fill-drain valve in airplane by placing control lever in down position and disconnecting test
unit hose from fitting. Install protective cap over fitting. Disconnect and remove test unit pressure hose
from pressure fitting in airplane (if previously connected). Install the protective cap on the fitting.
4. Check fluid level in power pack reservoir. Check system for leaks.
5. Close access in hydraulic components cover. Install access panel on right side of nose section.
HYDRAULIC POWER PACK
REMOVAL OF POWER PACK (Figure 29-4)
1. Remove right access panel at nose section between Stations 25.60 and 57.00. Completely remove hydraulic
components cover by removing retaining strips from outer edges of cover.
2. Drain power pack by removing both drain caps from end of suction; fill and drain plug installed inside
access opening behind hydraulic components cover. Connect fluid line from fitting to container; raise lever
to open valve and drain reservoir.
3. Disconnect electrical connector at forward end of power pack.
4. Disconnect vent line from power pack.
S. Disconnect gear selector control cable from power pack control arm on outboard side of power pack.
6. Disconnect various hydraulic lines from power pack. Cap open lines to prevent contamination.
7. Cut safety wire and remove attachment bolts securing power pack to mounting brackets.
8. Move power pack forward and out access opening.
3C6
29-10-00
Page 11
Reissued: December 31, 1989
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
8 6
5
7
1. POWER PACK
2. LINE, VENT
3. LINE, ENGINE PUMP SUCTION
4. LINE, ENGINR PUMP PRESSURE
5. LINE, SUCTION FILL
6. SUCTION FILL PORT
7. DRAIN PORT
8. VALVE
9. LINE, DRAIN
10. LINE, HAND PUMP PRESSURE
11. LINE, HAND PUMP SUCTION
12. LINE, GEAR UP
13. LINE, GEAR DOWN
14. LINE, GEAR UP
15. LINE, DOOR OPEN
16. LINE, GEAR DOWN
17. LINE, DOOR CLOSE
29-10-00 -
Page 12
Reissued: December 31, 1989
3
16
17
Figure 29-4. Power Pack Installation
3C7
PIPER AIRCRAFT
PA-42/42-720
AIRPLANE MAINTENANCE MANUAL
INSTALLATION OF POWER PACK (Figure 29-4)
1. Position power pack in mounting brackets. Ensure power pack control arm is facing outboard; secure
power pack and bracket supports to mounting brackets with bolts and safety.
2. Uncap and connect various hydraulic lines to power pack.
3. Connect electrical connector to forward end of power pack and connect landing gear selector cable to
selector arm.
4. Fill power pack (see Chapter 12).
5. Bleed hydraulic system per instructions in this chapter.
6. Close hydraulic components cover. Replace access panel on side of airplane nose section.
-NOTE-
Readjust gear selector cable removed from support.
DISASSEMBLY OF POWER PACK (Figure 29-6)
After power pack is removed from airplane and all ports are capped or plugged, spray with cleaning solvent
(Federal Specifications P-S-661, or equivalent) to remove all accumulated dust or dirt. Dry with filtered
compressed air. To disassemble unit, proceed as follows:
1. Remove wire, nut, reservoir cover, and D-ring. Since cover is a snug fit on reservoir, use soft mallet and tap
cover lightly to remove.
2. Remove snap ring from center stud. Remove baffle plate from reservoir. Drain remaining hydraulic fluid
from reservoir.
3. Remove reservoir and D-ring. Reservoir is a snug fit in body and requires hard pull to disengage.
4. Remove center stud and O-ring.
-NOTE-
All electrical wires are color coded. Ensure colored wires match
when wires are reinstalled.
5. Remove screws, washers, switch assembly, and insulating plate. Switch will remain hanging from electrical
wires (Figure 29-7).
6. Remove plastic strap attaching electrical wires to door sole