1995–2004 Piper PA-32R-301 Saratoga II HP & PA-32R-301T Saratoga II TC Airplane Maintenance Manual (P/N 761-879)

Piper Airplane Maintenance Manual P/N 761-879 covers the 1995–2004 PA-32R-301 Saratoga II HP and PA-32R-301T Saratoga II TC, the 46- and 57-series airframes. First published in 1996, this edition incorporates revisions through February 16, 2004.

Text search, navigation and diagrams: Body text is searchable, with PDF bookmarks for chapters, procedures and appendices. Some early-airframe wiring labels are not searchable. Small wire codes and connector numbers in dense diagrams require zooming.

• Power plant and propeller: Engine removal and installation, fuel-injection adjustments, Slick 6300-series magneto inspection and timing, and Hartzell propeller service and governor rigging.

• Flight controls and structures: Aileron, rudder and stabilator rigging, control-surface balancing, cable inspection, and fiberglass and thermoplastic repair procedures.

• Landing gear and brakes: Oleo strut disassembly, extension/retraction troubleshooting, emergency free-fall valve service, and Parker Hannifin wheel-brake and master-cylinder repair.

• Fuel system: Inboard tank and outboard bladder-cell inspection, fuel-cell repair limits, sender testing, and Digital Display Monitoring Panel (DDMP) fuel-quantity calibration.

• Electrical systems: Alternator and starter troubleshooting, bench testing and overhaul, with electrical schematics selected by aircraft configuration and serial number.

• Autopilot and displays: S-TEC 55/55X servo replacement, clutch adjustment and operational checks, plus Piper-specific Avidyne Entegra installation and maintenance information.

• Air conditioning: Leak detection, evacuation, charging and operational testing, with separate York and Sanden compressor, belt and magnetic-clutch procedures.

This manual is suited to aircraft maintenance technicians familiar with rigging, electrical diagnosis and bench testing; its inspection program specifies certified mechanics qualified on the aircraft.

Inspections, Airframe Repair and Rigging

Organized to GAMA Specification No. 2, the manual separates scheduled maintenance from special inspections after lightning strikes, engine events, severe turbulence and hard or overweight landings. It also addresses high-dust, salt, humidity and extreme-cold operating environments, with additional turbocharger inspection items for the TC.

Structural coverage includes fuselage skin-material references, fiberglass patching, thermoplastic damage repair and wing-attachment work. Cable-tension charts account for ambient temperature, while Chapter 95 provides drawings for fabricated aileron, rudder and stabilator rigging tools.

Power Plant and Ignition

The Lycoming sections distinguish the naturally aspirated IO-540-K1G5 from the turbocharged TIO-540-AH1A. TC coverage adds turbocharger removal, lubrication-system priming, exhaust-wastegate adjustment and pressurized-magneto testing.

Magneto internal timing is illustrated, with the Slick T-100 assembly and timing tool kit and T-150 E-gap gauge identified. Full engine and magneto overhaul requires the separate Lycoming and Slick publications referenced in the manual; Hartzell overhaul data is also supplied through separate vendor manuals.

Fuel, Hydraulics and Landing Gear

The fuel chapter distinguishes aluminum inboard tanks from Goodyear Vithane outboard cells, including leak tests and repair limitations. Vithane cell repair is restricted to personnel with the manufacturer-specified training.

DDMP fuel-quantity calibration applies to HP S/Ns 3246088 and up and TC S/Ns 3257001 and up. Earlier HP aircraft have separate analog-gauge testing and adjustment procedures.

Hydraulic pressure checks and landing-gear functional tests help distinguish pump or circuit faults from actuator, lock and switch problems. The pump section warns that separating the pump from its adapter can damage valves and alter nonadjustable pressure settings. Brake coverage includes gravity and pressure bleeding, lining tolerances and leak checks.

Electrical Variants and Avionics

HP S/Ns 3246001–3246017 use the 14-volt system; later HP aircraft and all covered TC aircraft use 28 volts. Serial-specific wiring sheets help technicians select the correct circuit before tracing a fault.

S-TEC systems: System 55 applies to HP 3246126–3246181 and TC 3257076–3257198; System 55X starts at HP 3246182 and TC 3257199. The appendix distinguishes pitch-servo cable routing and trim-clutch requirements. Detailed troubleshooting is referred to appropriately equipped, authorized S-TEC dealers.

Avidyne Entegra: Optional equipment coverage starts at HP 3246218 and TC 3257339. The appendix supplies component and harness locations, magnetometer/OAT removal and installation, and Piper-specific amendments to the separate Avidyne instructions, including PFD replacement calibration requirements.

Air-Conditioning Configurations

York compressors apply to HP 3246001–3246087; Sanden compressors apply to later HP aircraft and all covered TC aircraft. R12/mineral-oil systems are limited to HP 3246001–3246017; the remaining installations use HFC-134a/PAG.

The procedures distinguish compatible service equipment and lubricants, with Robinair 34700 charging/test station instructions for HFC-134a systems. Compressor field work is limited, with internal service assigned to a qualified specialist shop. For HP 3246001–3246087, incorrect alternator-idler orientation can damage the cowling and pulley and cause drive-belt failure.

Diagrams, Specifications and Coverage Limits

References include the Hydraulic System Schematic, DDMP Fuel Quantity Calibration Menu Flow Chart, Magneto Internal Timing view, Landing Gear electrical schematic and Avidyne Wiring Harness Installation drawings. Lubrication charts, exploded views and three-view drawings accompany oil-pressure limits, spark-plug gap and ignition-timing data, fluid capacities, and standard nut and ignition-harness coupling torques.

Instructions for non-Piper-approved STC installations are excluded. General installation hardware identification requires the separate parts catalog. Consult current OEM bulletins and applicable vendor instructions, and have aircraft maintenance performed by appropriately certified personnel before return to service.

PDF Contents and Included Appendices

One printable 1,236-page PDF: 1,194 pages of main-manual material, 26 pages in Appendix 1 - Autoflight, and 16 pages in Appendix 2 - Electronic Flight Display System. These totals already include the cover sheets, repeated introductory/index material, contents and revision pages, and intentionally blank pages.