Piper PA-32-301 Saratoga User manual

SARATOGA
MAINTENANCE MANUAL
CARD 1 OF 3
~ a
PA-32-301/301 T SARATOGA
I
I
PIPER AIRCRAFT CORPORATION
I
I [PART NUMBER 761 7211
1Al
Courtesy of Bomar Flying Service
www.bomar.biz

PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
Thls PIPER AIRCRAFT Maintenance Manual is prepared in accordance with the GAMA (General
Ablation Manufacturers Association) format. Thismaintenance manualis divided intovariousGroups u hlch
enable a broad separation of contents (Chapters)within each group.
The various Chapters are broken down into major systems such as Electrical Power. Flight Controls.
Fuel. Landing Gear. etc. The System~Chaptersare arranged more or less alphabetically rather than by
precedence orimportance. All System~Chaptersare 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 th~s
System Chapter.
The major System/Chapters are then broken down into Sub-SystemlSections. These sections are
identified by the second element of the standardized numbering system. Thenumber"40"of the basic number
series 32-40-00 is for the "Wheels and Brakes" portion of the landing gear.
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 co\erage requirements of the publication.
Example:
CHAPTER:SYSTEM SUB-SYSTEMS
LAISDING GEAR AKD BRAKES
INDIVIDUAL UNITS
\
NOSE WHEEL REMOVAL
This manual does not contain hardware callouts for installation. Hardware callouts are only indicated
where a special application is required. Toconfirm the correct hardware used, refer to the PA-32-301 301T
'parts Catalog PI& 761 720, and FAR 43 for proper utilization.
Introduction
Page - 1
Issued: January 2, 1980

PIPER AIRCRAFT
PA-32-3011301 T
MAINTENANCE MANUAL
AEROFICHE EXPLASATIOX ASD REVlSlOV STATL'S
The \qainle,~;lncc\lanual information incorporated in this set of Aerofiche cards has been arranged in
accordance nith thc general specifications of Aerofiche adopted by the General Aircraft Manufacturer'\
.Association. (G 4X1.4). The information compiled in this Aerofiche Maintenance Manual will be kept current
by re\ isions distributed periodically. These revisions will supersede all pre\.iousrevisions and
u ill be complete
.Aerofiche card replacements and shall supersede Aerofiche cards of the same number in the set.
Con\ersion of Aerofiche alpha numeric code numbers:
First number is the Aerofiche card number.
Letter
ir the hori7ontal line reference per card.
Second number is the vertical line reference per card.
Example:
ZJ I6 = Aerofiche card number two of given set. Grid location J Ih.
Toaid in locating the \arious chapters and related seniceinformation desired. the follo~iing is pro\ idcd:
I.
A complete manual System Chapter Index Guide is for all fiche in this set.
2.
A complete list of Illustrations is for all fiche in this set following S>,stemChapter Indel.
3.
A complete list of Charts is for all fiche in this set following list of Illustrations.
4.
A complete list of paragraph titles and appropriateGrid location numbers is gi\en at the beginn~n; (11.
each Chapter relating to the information within that Chapter.
5. Identification of Revised Material:
Re\ ised text and illustrations are indicated by a black \,erticalline alongthe left-hand margin t~i
the frame. opposite revised. added or deleted material. Re\.isionlines indicate onl! current re\ ;,ion\
with changes and additions to or deletions of existing text and illu\tration,. Change, In
capitali7ation. spelling. punctuation. indexing. thephysical location of the material or complete page
additions are not identified by re\.ision lines.
A reference and record of the material revised is included in each chapter's Tahle
01'
Contents EffectiL ity.Thecodesused in theeffectkit?columns of each chapter aredefined as iollo\\ \.
TABLE OFCOSTESTS EFFECTIVITY CODES
Original Issue: None
First Revision: Revision Identification.
( 1 R Month-Year)
Second Revision: Revision Identification.
(2R Month-Year)
All subsequent revisions will follow with consecutive re\,ision numbers
such as 3R. 4R. etc.. along with the appropriate month-year.
Added Subject: Revision Identification.
(A Month-Year)
Deleted Subject: Revision Identification. (DMonth-Year)
Introduction
Page - 2
Revised: August 11. 1983

PIPER AIRCRAFT
PA-32-301/30lT
MAINTENANCE MANUAL
6. Revisions to Maintenance Manual 761 721 issued January 2, 1980 are as
follows:
Effectivity Publication Date Aerofiche Card Effectivity
January 2, 1980
May 21. 1980
August 19, 1980
September 23, 1981
February 19, 1982
August 23, 1982
August
l I, 1983
August 9, 1984
August 15, 1985
April
30, 1986
~uiy30, 1986
September 20, 1986
May 12, 1987
I, 2 and 3
I. 2 and 3
1, 2 and 3
I. 2and 3
I, 2 and 3
I, 2 and 3
1. 2and 3
1, 2and 3
3
1
1
1
1
The date on Aerofiche cards must not be earlier than the datenoted for the respective card effectivity. Consult
the latest Aerofiche card in this series for current Aerofiche card effectivity.
This publication contains material revised as of August 15, 1985
(with four interim revisions effective April 30, 1986,July
30, 1986,
September 20. 1986 and March 16. 1987).
INTERIM CHANGE
Revisions appear in chapter
5 of card 1. There are no other changes
in this maintenance manual. Please discard your current card
1 and
replace it with this revised one. DO
NOT DISCARD CARDS 2 or
3.
Introduction
Page
- 3
Interim Revision: March 16, 1987

PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANLAL
E\GI\E.
O\erhaul \lanual .4t'CO LYCOMING
- OVERH .4C'L \I \\.I AL
DIRECT DRIi'E ESGlVE - P \ 60291--
A\ co Lycoming Di\ ision
H'illiarnsport. Pa. 1770 1
Parts Catalog =
AVCO LYCOMIVG - P S PC-I02
Abco Lycorning Di\ ision
Williarnsport. Pa. 17701
Operators Handbook
= AVCO LYCOMIVG 10-540 and TIO-540
SERIES AIRCRAFT ESGISES - P
V 60297-10
A\ro Lycoming Di\.ision
Williamsport. Pa. 1770 1
PROPEL1 ER:
O\erhaul Instructions = HARTZELL COMPACT COSST.\\T SPEED
and FEATHERISG PROPELLER
- P S 11'-D
Hartzell Propeller Inc.
Piqua. Ohio 45356
\1.4GVETOS:
I nqtallation. Operation
and Maintenance
l nst ruct ions =
D-2000 and D-2200 SERIES M.4G\ETO
IGSITIOS SYSTEM - P
S L-928
Bendix Electrical Components Di~lslon
Sidne!.. S~H York 13838
.41'TO FLIGHT: CEVTURY 41 ACT0 PILOT
EDO-41RE Mitchell
P.O. Box 610
31 ineral H'ells. Texas 76067
Introduction
Page - 4
Revised: August 9. 1984

PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
PIPER PL'BLICATIOSS.
CO\I \IC\ICATIOSS:
Rrmo\ al. Installation
and Maintenance
Instructions
=
761 502 Autocontrol Ill B Senice Vanual
761 481 AutoFlite I1 Senice Manual
753 771 Pitch Trim Senice Manual
Radio Senice and
Maintenance Manual
= 761 713 Avionics Wiring Diagram Ser\ice Manual
Vol.
I and Vol. 11 ( 1979)
REPAIRS:
A.B.S. Thermoplastic
Landing Gear Wheel
and Strut Fairing
Repair Instructions
=
761 708V A.B.S. Thermoplastic Landlng Gear
Wheel and Strut Fairing Repair lnstructlon Manual
PARTS CATALOG
= 761 720
PA-32-30] 3OlT
PERIODIC ISSPECTION
REPORT FORM = 230 1046
PA-32-301 3OIT
PROGRAMMED ISSPEC-
TIOY MASUAL = 761 747
PA-32-301 3OIT
l ntroduction
Page - 5
Revised: August 9, 1984

PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
SYST
CHAP
CAMA
SYSTEMICHAPTER INDEX GUIDE
SUB-SYST
SECTIOS TITLE
AIRWORTHINESS
TIME LIMITS MAlNT CHECKS
DIMENSIONS AND AREAS
LIFTIKG AND SHORllVG
LEVELISG AND WEIGHING
TOWING AKD TAXIING
PARKISG AND MOORING
REQUIRED PLACARDS
SERVICISG - LUBRICATIOK
STASDARD PRACT - AIRFRAME
ENVIRONMENTAL SYSTEM
AUTOFLIGHT
COMMUSICATIONS
ELECTRICAL POWER
EQUIPMENT: FURKISHINGS
FLIGHT CONTROLS
FUEL
LASDING GEAR
LIGHTS
NAVIGATION
& PITOT,STATIC
OXYGEN
AEROFlCHE
GRID \O.
I A'O
lBl l
1C15
1 D'O
Introduction
Page
- 6
1A7
Revised: August 11, 1983

PIPER AIRCRAFT
PA-32-301/301 T
MAINTENANCE MANUAL
GAMA SYSTEM/CHAPTER INDEX GLIDE (cont)
SYST SUB-SYST
CHAP SECTIOS TITLE
3 7 VACUUM
39 ELECTRICAL
STRUCTURES
DOORS
STABILIZERS
WISDOWS
WlSGS
PROPELLERS
STASDARDPRACTICES
- ENGIKES
POWER PLANT
ENGIKE FUEL SYSTEM
IGSITIOS
ESGINE IKDICATISG
EXHAUST
OIL SYSTEM
STARTING
TURBINES
CHARTS AND WIRING DIAGRAMS
SPECIAL PURPOSE EQUIPMENT
AEROFICHE
GRID KO.
'I'
21 15
21 18
Introduction
Page - 7
Revised: August 9. 1984

PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
FIGURE SO
LIST OF ILLUSTRATIONS
SUBJECT GRID
\O
Three View of PA-32-301
Three View of PA-32-301T
Station Reference Lines (PA-32-30
1)
Station Reference Lines (PA-32-30IT)
Access Plates and Panels
Jacking
Lekeling Airplane
Weighing
Placards and Decals
Fuel Filter Bowl and Screen
Servicing Points
Main Gear Oleo Struts (Cut-Away View)
Lubrication Chart (Landing Gear. Main)
Lubrication Chart (Landing Gear, Nose)
Lubrication Chart (Control System)
Lubrication Chart (Air Conditioning Condenser)
Lubrication Chart (Cabin Door. Baggage ~oor
and Seat)
Lubrication Chart (Power Plant. Propeller and
Control Pivot Points)
Lubrication Chart (Back-Up Extender and Fuel Selector)
Torque Wrench Formula
Method of Installing Rod End Bearings
Cherrylock Rivet Removal
Hose Line Markings
Flareless-Tube Fittings
Maximum Distance Between Supports for Fluid Tubing
Cabin Heater. Defrosters and Fresh Air System
( PA-32-30 1)
Cabin Heater. Defroster and Fresh Air System
( PA-32-30 1 T)
Air Conditioning System lnstallation (Typical)
Service Valves
Test Gauge and Manifold Set
Manifold Set Operation
Leak Test Hookup
E\acuation Hookup
Charging Stand
Charging Hookup
Compressor and Fabricated Oil Dipstick
Compressor and Alternator Belt Installation
Magnetic Clutch
Condenser Air Scoop Installation
Expansion Valve
Components Installation
Air Conditioning Wiring Schematic (Early Models)
Air Conditioning Wiring Schematic (Later Models)
IE15
I E23
I F4
I F5
I F6
I F7
I F9
IF11
I FI?
I F17
IF18
l F2O
I F24
1GI
1G3
I G4
1G5
Introduction
Page - 8
Revised: August 11, 1983

PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
LIST OF ILLUSTRATIONS (cont)
SUBJECT
Emergency Locator Transmitter Schematic
(Narco)
E LT.Portable Folding Antenna (Narco)
ELT Using Fixed Aircraft Antenna (Sarco)
Avionics Master and Emergency Switch Circuit
Exploded View of Alternator
- Prestolite
Lamp-Bank Load
Removal of Slip Ring End Bearing
Removal of Rectifier
Removal of Drive End Head
Remo\al of End Head Bearing
Testing Rotor for Ground
Testing Rotor for Shorts
Installation of Bearing
Installation of Rectifier
Terminal Assembly
- Prestolite
Slip Ring End Bearing Assembly
Testing Alternator
Brush Installation
Internal Wiring Diagram
Alternator Exploded View
- Ford
Rear View Terminal Identification
Stator Core and Windings
Rectifier Assembly
Internal Relationship of Alternator Components
Rectifier Ground and Positive Diode Test
Stator Ground and Negative Diode Test
Field Circuit Open or Ground Test
Alternator Housing Disassembly
Rear Housing Components
Front Housing Disassembly
Front Housing Components
Rotor Continuity Test
Rotor Ground Test
Stator Continuity Test
Stator Ground Test
GRID \O
Introduction
Page
- 9
Revised: August 1 1, 1983

PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANL'AL
LIST OFILLUSTRATIONS (cont)
SUBJECT
Diode Testing
Front Housing Assembl!
Rear Housing Bearing and Brush Assembly
l nstallation
Rear Housing Components
H ousing Assembly
Alternator Installation
- Ford
Seat Back Lock
Rod End Installation Method
Control Column Assembl)
Aileron Controls
Aileron Rigging
Bellcrank Rigging Tool
Aileron Rigging Tool
Aileron Rudder Interconnect
Rudder Controls
Rudder Rigging Tool
Rudder Tratel Adjustments
Rudder Rigging
Clamping Rudder Pedals
Rudder Trim Control
Rudder Steering Pedal Assembly
Stabilator Controls
Stabilator Rigging
Stabilator Tra\el Adjustments
Methods of Securing Trim Cables
Stabilator Trim Controls
H'rapp~ngTrim Barrels
Stabilator Rigging Tool
Manually Operated Flap System
Flap Step Adjustment
Electrically Operated Flap System
Flap Rigging Tool
Fuel System (PA-32-301)
Fuel System (PA-32-f01T)
Fuel Cell Installation
1 nstallation of Locking Fuel Cap
Fuel Filter
Fuel Gauge
Main Gear Oleo Strut Assembly
Main Gear Installation
Nose Gear Oleo Strut Assembly
GRID YO
1113
i115
1115
1116
112.1
15 12
lJ 13
1.1 I6
1j20
1j20
1j21
1j23
1K2
I K1
I K1
I K1
I KJ
1k5
1 K'
I K9
IKI!
1k15
1k15
IKI'
I K2O
I K20
I K21
I K21
I L2
I LJ
2,422
2 423
2 B3
2Bl l
2812
2B16
2824
2c2
2C4
I nttoduction
Page - 10
Revised: August 9, 1984

PIPER AIRCRAFT
PA-32-3011301 T
MAINTENANCE MANLAL
FIGURE \O.
LIST OF ILLUSTRATIONS (cont)
SUBJECT
Sose Gear lnstallation
Clamping Rudder Pedals in Neutral Position
Rudder Pedals at Seutral Angle
Main Wheel Assembly
Sose Wheel Assembly
Brake Assembly
-
Removal and lnstallation of Anchor Bolts
Brake Disc Minimum Thickness
Brake System lnstallation
Brake Master Cylinder (Hand.Parking Brake)
Toe Brake lnstallation
Brake Cylinder
( 10-30) (Toe Brake)
Brake Cylinder
( 17000) (Toe Brake)
Landing Gear Fairing lnstallation
Strobe Light Connections
Pitot-Static System lnstallation
Fixed Oxygen System lnstallation
Test Apparatus for Testing Oxygen S!fstem
Oxygen Tubing Installation
lnstallation of Sn.agelock Fittings
Oxygen Cylinder and Regulator Assembly
Oxygen System Recharge Valve lnstallation
Ox!,gen Pressure Gauge lnstallation
Oxygen lnstallation (Portable)
Skin Material and Thickness
Surface Scratches. Abrasions or Ground-in-Dirt
Deep Scratches. Shallow Sicks and Small Holes
Mixing of Epoxy Patching Compound
Welding Repair Method
Repairing of Cracks
Various Repairs
Repair of Stress Lines
Repair of Impacted Damage
Snubber lnstallation
Empennage Group
Stabilator Balancing
Rudder Balancing
Windshield Installation (Typical)
GRID SO
2C8
2c10
2C lo
2Cl l
2C I?
2C15
2C16
2C16
2c11
2C18
2C20
2C2 1
2C2 1
'Dl
'Dl?
2d20
2et1
'El l
2E 13
SE 16
2E 19
2E 19
2e21
2F2
zf21
2G I
SG'
2G 2
2G3
2G3
2G 4
2G6
2G 6
2G I4
2G 23
ZH I
2H3
2H8
Introduction
Page - 11
Revised: August 1 1. 1983

PIPER AIRCRAFT
PA-32-301 130 1 T
MAINTENANCE MANUAL
FIGURE SO.
LIST OF ILLUSTRATIONS (cont)
SUBJECT
Side Windou Installation. Single Pane (Typical)
Wing lnstallation
Aileron and Flap Installation
Aileron Balance Configuration
Typical Nicks and Removal Method
Propeller lnstallation (PA-32-301)
Three Blade Propeller lnstallation (PA-32-301)
Propeller Installation (PA-32-30IT)
Three Blade Propeller lnstallation (PA-32-30
1 T)
Propeller Governor
Engine Installation (PA-32-30
1)
E ngine Mount lnstallation (PA-32-301 T) (Dynafocal)
Engine Mount Installation (PA-32-30 1 T) (Lord Mounts)
Fuel injector
Schematic Diagram of RSA Fuel Injection System
Fuel-Air Bleed Sozzle
Adjustment of Engine Controls
Height of Spring in Distributor Block Tower
Contact Points
Engine Timing Marks
Timing Light Connected to Magneto
Timing Marks on Magneto Rotor
Painted Tooth Centered in Timing Window
Timing Mark on Rotor Aligned with Pointer
Timing Light Connected to Magento and Breakers
Cam End View of Magneto
Removing Impulse Coupling
Checking Flyweight to Stop Pin Clearance
Stop Pin lnstallation Dimension
Checking Flyweight Axial Wear with Drill Shank
Checking Flyweight Radial Wear with Gauge
Points of Coupling Body Wear
Acceptable and Deformed Coupling Springs
Checking impulse Coupling for Magnetization
Orientation of Spring in Coupling Body
Lifting Inner End of Spring
Checking Harness Lead Continuity
Checking Harness Lead Insulation Resistance
Modified Pliers
Removing Spring From Lead Assembly
Assembly Tool
Using Assembly Tool
Ferrule Postioned Under Braid
Ferrule Seating Tool
Position of 11-8627 Kit and Contact Spring at
Start of lnstallation
GRID \O.
Introduction
Page - 12
Revised: August 11, 1983

PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
LIST OF ILLCSTRATIONS (cont)
FIGURE KO. SUBJECT
Position of 11-8627
Kit and Contact Spring
After Installation
Lubricating Sleeve
Lubricating Ferrule Shoulder
Removing Spark Plug Frozen to Bushing
Ignition Switch Wire Positions
Exhaust System Inspection Points
Exploded View of Gear Reduction Starting Motor
Turning Starting Motor Commutator
Testing Motor Armature for Shorts
Testing Motor Fields for Grounds
So-Load Test Hook-Up
Stall-Torque Hook-Up
Turbocharger Installation
Tire Balancer Fixture
Orifice Replacement Tool
Fabricated Tool for Baggage Door Lock
Retainer Ring Tool
Fabricated Aileron Bellcrank Rigging Tool
Fabricated Rudder Rigging Tool
Fabricated Aileron and Flap Rigging Tool
Fabricated Stabilator Rigging Tool
Control Surface Balancing Tool
GRID 50
Refer to Card 3, GridNo. 3011 for Electrical Schemaric Index.
lntroduction
Page
- 13
Revised: August 9. 1984

PIPER AIRCRAFT
PA-32-30] /301T
MAINTENANCE MANUAL
LIST OF CHARTS
SUBJECT
Leading Particulars and Principal Dimensions
Thread Lubricants
Type of Lubricants
Hose Clamp Tightening (Initial Installation)
Blower System Wire Color Codes
Troubleshooting (Air Conditioner)
Troubleshooting (Air Conditioning System)
Temperature Pressure
Aluminum Tubing Torque
System Vacuum Chart
Compressor Oil Charge
Troubleshooting (Alternator)
Troubleshooting (Battery)
Alternator Specifications (Prestolite)
Alternator Belt Tension (Prestolite)
Hydrometer Reading and Battery Charge Percent
Electrical System Component Loads
Troubleshooting (Surface Controls)
Cable Tension Vs. Ambient Temperature
Troubleshooting Chart (Fuel System)
Fuel Cell Repair Equipment Lists
Sender,Fuel Quantity Gauge Tolerances
Troubleshooting Chart (Landing Gear)
Sose Gear Alignment Tolerances
Electrical System Troubleshooting
Troubleshooting (Rate of Climb Indicator)
Troubleshooting (Altimeter)
Troubleshooting (Airspeed Tubes and Indicator)
Troubleshooting (Gyro Horizon Indicator)
Troubleshooting (Directional Gyro Indicator)
Troubleshooting (Magnetic Compass)
Troubleshooting (Turn and Bank Indicator)
Troubleshooting (Oxygen System)
Oxygen System Component Limits (Fixed)
Filling Pressures for Certain Ambient Temperatures
Oxygen System Component Limits (Portable)
Troubleshooting (Vacuum System)
List of Materials (Thermoplastic Repair)
Propeller Specifications (PA-32-301)
Propeller Specifications (PA-32-301T)
Engine Troubleshooting Chart
Troubleshooting (Magneto)
Coupling Torques
GRID SO.
introduction
Page - 14
Revised: August 11, 1983

PIPER AIRCRAFT
PA-32-301/301T
MAINTENANCE MANUAL
CHART YO.
LIST OF CHARTS (cont)
SUBJECT
Troubleshooting (Manifold Pressure Indicator)
Troubleshooting (Tachometer)
Troubleshooting (Engine Oil Pressure Gauge)
Troubleshooting (Oil Temperature Indicators)
Troubleshooting (Exhaust Gas Temperature
Gauge) (Alcor)
Troubleshooting (Cylinder Head Temperature Gauge)
Troubleshooting (Starter)
Starting Motor Specifications
Troubleshooting (Turbocharger)
Tube and Hose Assembly Torque
Recommended Nut Torques
Decimal Conversions
Conversion Charts
List of Consumable Materials
Electrical Wire Coding
Electrical Symbols
GRID \O
Introduction
Page - IS
Revised: August 9, 1984

CHAPTER
AIRWORTHINESS
LIMITATIONS

PIPER AIRCRAFT
PA-32-301 /3@ I T
MAINTENANCE MANUAL
CHAPTER
SECTIOL
StBJECT
SL BJECT
GRID
10. EFFECTIi IT)
4-00-00 .AlR\I'ORTHISESS LIM ITATIO\S
4-01-00 General
4 - Cont./Effec.
!
Page - 1
Revised: August 11. 1983 i
I

PIPER AIRCRAFT
PA-32-301/301T
SIAINTENANCE MANUAL
The airworthiness limitations are FAA approved and specif!. inspections and maintenance req~ilrcd
under Part 91.163 of the Federal A\iation Regulations.
The following limitationsrelated to fatigue life of the airplane and its components hale been c\tahl~.hr.J
with respect to the PA-32-301 3OIT airplane:
I. The safe life of the airframe structure will be released when the information become\ a\allahle
2. The safe life limit of the propeller blades is unlimited.
Rejer to the LIMITATIONS in the Pilot's Operating Handbook
and FAA Approved Airplane Flight Manual for a detailed
delineation of theflight limitations oftheairplane. Themandatory
replacement time and or inspection intervalsof life Iimitedparts are
contained in Chapter
5 of this manual.
- END -
4-0 1-00
Page 4-01
Revised: August 11. 1982

CHAPTER
TIME LIMITS/MAlNT CHECKS